CR1/CR1B Controller setup, basic operation, and

MITSUBISHI
Mitsubishi Industrial Robot
CR1/CR1B Controller
INSTRUCTION MANUAL
Controller setup, basic operation, and maintenance
BFP-A8054-J
The operation-lock of the power switch
The power switch has operation-lock function. It is the mechanism in which the mistaken power supply ON is prevented
with the padlock etc. at the time of the maintenance of the robot system. Prepare lock devices, such as the padlock, by the
customer.
The usage of lock function is shown in the following.
CR1-500/CR1B-500 series
*The figure is the example of CR1-500 series.
Also "CR1B-500" series is the same. The difference is the direction of the power switch.
<Operation method>
(1) The lock method (power supply OFF)
1) Turn OFF the power switch.
2) Loosen the fixing screw and remove the
lock plate.
3) Cover the power switch with lock plate
and fix it by fixing screw securely.
4)Install the padlock (customer preparation)
in the hole of the lock plate.
The lock is completed.
Power switch
Lock plate
fixing screw
Power switch
(2) The release method (power supply ON)
1) Remove the padlock.
2) Loosen the fixing screw and remove the
lock plate.
3) Fix the lock plate securely with the fixing
screw in the position separated from the
power switch.
The lock release is completed.
Lock plate
Padlock
(customer preparation)
The recommended dimension of the padlock
dimension of the padlock
Dimension(mm)
A
B
C
25
14
4mm or less
Safety Precautions
Always read the following precautions and the separate
"Safety Manual" before starting use of the robot to learn the
required measures to be taken.
CAUTION
CAUTION
WARNING
CAUTION
WARNING
CAUTION
CAUTION
CAUTION
All teaching work must be carried out by an operator who has received special
training. (This also applies to maintenance work with the power source turned ON.)
Enforcement of safety training
For teaching work, prepare a work plan related to the methods and procedures of
operating the robot, and to the measures to be taken when an error occurs or when
restarting. Carry out work following this plan. (This also applies to maintenance
work with the power source turned ON.)
Preparation of work plan
Prepare a device that allows operation to be stopped immediately during teaching
work. (This also applies to maintenance work with the power source turned ON.)
Setting of emergency stop switch
During teaching work, place a sign indicating that teaching work is in progress on
the start switch, etc. (This also applies to maintenance work with the power source
turned ON.)
Indication of teaching work in progress
Provide a fence or enclosure during operation to prevent contact of the operator
and robot.
Installation of safety fence
Establish a set signaling method to the related operators for starting work, and follow this method.
Signaling of operation start
As a principle turn the power OFF during maintenance work. Place a sign indicating that maintenance work is in progress on the start switch, etc.
Indication of maintenance work in progress
Before starting work, inspect the robot, emergency stop switch and other related
devices, etc., and confirm that there are no errors.
Inspection before starting work
The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
WARNING
WARNING
CAUTION
WARNING
CAUTION
CAUTION
CAUTION
CAUTION
WARNING
Use the robot within the environment given in the specifications. Failure to do so
could lead to a drop or reliability or faults. (Temperature, humidity, atmosphere,
noise environment, etc.)
Transport the robot with the designated transportation posture. Transporting the
robot in a non-designated posture could lead to personal injuries or faults from
dropping.
Always use the robot installed on a secure table. Use in an instable posture could
lead to positional deviation and vibration.
Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.
Do not apply excessive force on the connector or excessively bend the cable. Failure to observe this could lead to contact defects or wire breakage.
Make sure that the workpiece weight, including the hand, does not exceed the
rated load or tolerable torque. Exceeding these values could lead to alarms or
faults.
Securely install the hand and tool, and securely grasp the workpiece. Failure to
observe this could lead to personal injuries or damage if the object comes off or
flies off during operation.
Securely ground the robot and controller. Failure to observe this could lead to malfunctioning by noise or to electric shock accidents.
Indicate the operation state during robot operation. Failure to indicate the state
could lead to operators approaching the robot or to incorrect operation.
When carrying out teaching work in the robot's movement range, always secure the
priority right for the robot control. Failure to observe this could lead to personal injuries or damage if the robot is started with external commands.
Keep the jog speed as low as possible, and always watch the robot. Failure to do
so could lead to interference with the workpiece or peripheral devices.
After editing the program, always confirm the operation with step operation before
starting automatic operation. Failure to do so could lead to interference with peripheral devices because of programming mistakes, etc.
Make sure that if the safety fence entrance door is opened during automatic operation, the door is locked or that the robot will automatically stop. Failure to do so
could lead to personal injuries.
Never carry out modifications based on personal judgments, or use non-designated
maintenance parts.
Failure to observe this could lead to faults or failures.
When the robot arm has to be moved by hand from an external area, do not place
hands or fingers in the openings. Failure to observe this could lead to hands or fingers catching depending on the posture.
CAUTION
CAUTION
Do not stop the robot or apply emergency stop by turning the robot controller's main power OFF. If the robot controller main power is turned OFF during automatic operation, the robot accuracy could be adversely
affected.Moreover, it may interfere with the peripheral device by drop or
move by inertia of the arm.
Do not turn off the main power to the robot controller while rewriting the
internal information of the robot controller such as the program or parameters.
If the main power to the robot controller is turned off while in automatic
operation or rewriting the program or parameters, the internal information of
the robot controller may be damaged.
Precautions for the basic configuration are shown below.(When CR1-571 is used for the controller.)
CAUTION
Provide an earth leakage breaker that packed together on the primary
power supply of the controller as protection against electric leakage. Confirm the setting connector of the input power supply voltage of the controller,
if the type
which more than one power supply voltage can be used. Then connect the
power supply.
Failure to do so could lead to electric shock accidents.
Power supply *RV-1A/2AJ series and RP-1AH/3AH/5AH series: Single phase 90-132VAC, 180-253VAC.
*Except the above: Single phase 180-253VAC.
Rear side of controller
Earth leakage
breaker
(NV)
Cover
Terminal
Cover
Terminal cover
Protective earth
terminal
(PE)
Revision history
Date of print
Specifications No.
Details of revisions
2000-02-17
BFP-A8054Z-*
・ First print
2000-03-24
BFP-A8054
・ The earth leakage breaker packaged is added.
・ Writing error correction.
2000-04-11
BFP-A8054-A
・ RP-1AH/3AH/5AH series was added.
2000-06-09
BFP-A8054-B
・ The power supply voltage of CR1 controller was corrected.
2000-12-18
BFP-A8054-C
・ Writing error correction.
2001-03-21
BFP-A8054-D
・ Writing error correction.
2001-09-06
BFP-A8054-E
・ RV-2A/3AJ series was added.
・ The power supply voltage of CR1 controller was corrected.
・ Writing error correction.
2002-03-18
BFP-A8054-F
・ CR1-MB (controller protection box) was added.
・ Writing error correction.
2002-12-11
BFP-A8054-G
・ How to inspect, clean and replace the filter was added.
・ "The procedures for installing the pneumatic hand interface" is added.
・ Writing error correction.
2005-02-23
BFP-A8054-H
・ CR1B-571controller was added.
・ Change title.
・ Changed the filter cleaning and replacement procedures.
・ Changed the filter model name.
・ Writing error correction.
2009-09-30
BFP-A8054-J
・ The EC Declaration of Conformity was changed.
(Correspond to the EMC directive; 2006/42/EC)
■ Introduction
Thank you for purchasing the Mitsubishi industrial robot.
This instruction manual explains the unpacking methods, installation, basic operation, maintenance and
inspection of the controller.
The optional equipments and power supply voltage are different according to connecting robot type.
Refer to separate "Standard Specifications Manual" for detail.
Always read through this manual before starting use to ensure correct usage of the robot.
The information contained in this document has been written to be accurate as much as possible. Please
interpret that items not described in this document "cannot be performed."
・ No part of this manual may be reproduced by any means or in any form, without prior consent from
Mitsubishi.
・ The details of this manual are subject to change without notice.
・ An effort has been made to make full descriptions in this manual. However, if any discrepancies or
unclear points are found, please contact your dealer.
・ The information contained in this document has been written to be accurate as much as possible.
Please interpret that items not described in this document "cannot be performed." or "alarm may
occur".
Please contact your nearest dealer if you find any doubtful, wrong or skipped point.
・ This Instruction Manual is original.
Copyright(C) 2002-2009 MITSUBISHI ELECTRIC CORPORATION
Contents
Page
1 Before starting use ..........................................................................................................................
1.1 Using the instruction manuals ...................................................................................................
1.1.1 The details of each instruction manuals .............................................................................
1.1.2 Symbols used in instruction manual ...................................................................................
1.2 Safety Precautions ....................................................................................................................
1.2.1 Precautions given in the separate Safety Manual ..............................................................
1-1
1-1
1-1
1-2
1-3
1-4
2 Unpacking to installation .............................................................................................................................................................. 2-5
2.1 Confirming the products ...................................................................................................................................................... 2-5
2.2 Installation ................................................................................................................................................................................. 2-6
2.2.1 Unpacking procedures .................................................................................................................................................. 2-6
2.2.2 Transportation procedures ......................................................................................................................................... 2-6
2.2.3 Installation procedures ................................................................................................................................................. 2-7
2.2.4 Connecting the power cable and grounding cable ............................................................................................ 2-8
(1) Setting the power specifications (CR1-571 controller only) .................................................................... 2-8
(2) Connecting the power and grounding cable ..................................................................................................... 2-9
2.2.5 Connecting the external emergency stop .......................................................................................................... 2-10
2.2.6 Connecting to the robot arm ................................................................................................................................... 2-11
2.3 Setting the origin .................................................................................................................................................................. 2-11
2.4 Confirming the operation ................................................................................................................................................... 2-11
3 Installing the option devices .....................................................................................................................................................
3.1 Installing the pneumatic hand interface and motorized hand interface .........................................................
3.2 Installing the expansion option box ...............................................................................................................................
3.3 Installation of the controller protection box (CR1B-MB) ....................................................................................
3.3.1 Name of each part .......................................................................................................................................................
3.3.2 Confirmation before installation .............................................................................................................................
3.3.3 Unpacking procedures ................................................................................................................................................
3.3.4 Transportation procedures .......................................................................................................................................
3.3.5 Installation procedures ...............................................................................................................................................
3.3.6 Handling the protection box .....................................................................................................................................
3-12
3-12
3-15
3-17
3-17
3-18
3-18
3-18
3-19
3-25
4 Basic operations ............................................................................................................................................................................
4.1 Handling the controller .......................................................................................................................................................
4.1.1 Functions of each key ................................................................................................................................................
4.2 Handling the T/B ..................................................................................................................................................................
4.2.1 Installing and removing the T/B .............................................................................................................................
(1) Installing with the control power OFF ..............................................................................................................
(2) Removing with the control power ON ..............................................................................................................
(3) Installing with the control power ON ................................................................................................................
4.2.2 Functions of each key ................................................................................................................................................
4.3 Turning the power ON and OFF .....................................................................................................................................
4.3.1 Turning the control power ON ................................................................................................................................
4.3.2 Shutting OFF the control power ............................................................................................................................
4.4 Turning the servo power ON/OFF ................................................................................................................................
4.4.1 Turning the servo power ON (servo ON) ...........................................................................................................
4.4.2 Shutting OFF the servo power (servo OFF) .....................................................................................................
4.5 Jog operation .........................................................................................................................................................................
4.6 Opening and closing the hand .........................................................................................................................................
4.7 Programming ...........................................................................................................................................................................
(1) Creation procedures ................................................................................................................................................
(2) Robot work ..................................................................................................................................................................
4.7.1 Creating the program ..................................................................................................................................................
(1) Deciding the operation order ...............................................................................................................................
(2) Deciding the operation position name ..............................................................................................................
4-26
4-27
4-27
4-29
4-29
4-29
4-29
4-29
4-30
4-32
4-32
4-32
4-33
4-33
4-33
4-34
4-34
4-35
4-35
4-35
4-36
4-36
4-37
i
Page
(3) Describing and creating the program ................................................................................................................
(4) Confirming the program ..........................................................................................................................................
(5) Correcting the program ..........................................................................................................................................
(6) Start automatic operation. ....................................................................................................................................
4-38
4-43
4-44
4-48
5 Maintenance and Inspection .....................................................................................................................................................
5.1 Maintenance and inspection interval ............................................................................................................................
5.2 Inspection items ....................................................................................................................................................................
5.2.1 Daily inspection items ................................................................................................................................................
5.2.2 Periodic inspections ....................................................................................................................................................
5.3 Maintenance and inspection procedures ....................................................................................................................
5.3.1 Cleaning and replacing the filter ............................................................................................................................
5.3.2 Replacing the battery .................................................................................................................................................
5.4 Maintenance parts ................................................................................................................................................................
5-50
5-50
5-51
5-51
5-51
5-52
5-52
5-53
5-54
ii
1Before starting use
1 Before starting use
This chapter explains the details and usage methods of the instruction manuals, the basic terminology and
the safety precautions.
1.1 Using the instruction manuals
1.1.1 The details of each instruction manuals
The contents and purposes of the documents enclosed with this product are shown below. Use these documents according to the application.
For special specifications, a separate instruction manual describing the special section may be enclosed.
Safety Manual
Standard
Specifications
Robot Arm
Setup &
Maintenance
Controller
Setup, Basic
Operation and
Maintenance
Explains the common precautions and safety measures to be taken for robot handling, system design and manufacture to ensure safety of the operators involved
with the robot.
Explains the product's standard specifications, factory-set special specifications,
option configuration and maintenance parts, etc. Precautions for safety and technology, when incorporating the robot, are also explained.
Explains the procedures required to operate the robot arm (unpacking, transportation, installation, confirmation of operation), and the maintenance and inspection
procedures.
Explains the procedures required to operate the controller (unpacking, transportation, installation, confirmation of operation), basic operation from creating the program to automatic operation, and the maintenance and inspection procedures.
Detailed
Explanation of
Functions and
Operations
Explains details on the functions and operations such as each function and operation, commands used in the program, connection with the external input/output
device, and parameters, etc.
Explanations
of MOVEMASTER
COMMANDS
Explains details on the MOVEMASTER commands used in the program.
(For RV-1A/2AJ, RV-2A/3AJ and RV-3S/3SJ/3SB/3SJB series)
Troubleshooting
Explains the causes and remedies to be taken when an error occurs. Explanations
are given for each error No.
Using the instruction manuals 1-1
1Before starting use
1.1.2 Symbols used in instruction manual
The symbols and expressions shown in Table 1-1 are used throughout this instruction manual. Learn the
meaning of these symbols before reading this instruction manual.
Table 1-1:Symbols in instruction manual
Symbol
Meaning
DANGER
Precaution indicating cases where there is a risk of operator fatality or
serious injury if handling is mistaken. Always observe these precautions
to safely use the robot.
WARNING
Precaution indicating cases where the operator could be subject to fatalities or serious injuries if handling is mistaken. Always observe these precautions to safely use the robot.
CAUTION
Precaution indicating cases where operator could be subject to injury or
physical damage could occur if handling is mistaken. Always observe
these precautions to safely use the robot.
[JOINT]
[+/FORWD]+[+X]
(A)
(B)
[STEP/MOVE]+([COND]-[RPL])
(A)
(B)
(C)
T/B
1-2 Using the instruction manuals
If a word is enclosed in brackets or a box in the text, this refers to a key on
the teaching pendant.
This indicates to press the (B) key while holding down the (A) key.
In this example, the [+/Forward] key is pressed while holding down the
[+X/+Y] key.
This indicates to hold down the (A) key, press and release the (B) key, and
then press the (C) key. In this example, the [Step/Move] key is held down,
the [Condition] key is pressed and released, and the [Replace] key is
pressed.
This indicates the teaching pendant.
1Before starting use
1.2 Safety Precautions
Always read the following precautions and the separate "Safety Manual" before starting use of the robot to
learn the required measures to be taken.
CAUTION
CAUTION
WARNING
CAUTION
DANGER
CAUTION
CAUTION
CAUTION
All teaching work must be carried out by an operator who has received special
training. (This also applies to maintenance work with the power source turned ON.)
Enforcement of safety training
For teaching work, prepare a work plan related to the methods and procedures of
operating the robot, and to the measures to be taken when an error occurs or when
restarting. Carry out work following this plan. (This also applies to maintenance
work with the power source turned ON.)
Preparation of work plan
Prepare a device that allows operation to be stopped immediately during teaching
work. (This also applies to maintenance work with the power source turned ON.)
Setting of emergency stop switch
During teaching work, place a sign indicating that teaching work is in progress on
the start switch, etc. (This also applies to maintenance work with the power source
turned ON.)
Indication of teaching work in progress
Provide a fence or enclosure during operation to prevent contact of the operator
and robot.
Installation of safety fence
Establish a set signaling method to the related operators for starting work, and follow this method.
Signaling of operation start
As a principle turn the power OFF during maintenance work. Place a sign indicating that maintenance work is in progress on the start switch, etc.
Indication of maintenance work in progress
Before starting work, inspect the robot, emergency stop switch and other related
devices, etc., and confirm that there are no errors.
Inspection before starting work
Safety Precautions 1-3
1Before starting use
1.2.1 Precautions given in the separate Safety Manual
The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.
CAUTION
Use the robot within the environment given in the specifications. Failure to do so
could lead to a drop or reliability or faults. (Temperature, humidity, atmosphere,
noise environment, etc.)
CAUTION
Transport the robot with the designated transportation posture. Transporting the
robot in a non-designated posture could lead to personal injuries or faults from
dropping.
CAUTION
Always use the robot installed on a secure table. Use in an instable posture could
lead to positional deviation and vibration.
CAUTION
Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.
CAUTION
Do not apply excessive force on the connector or excessively bend the cable.
Failure to observe this could lead to contact defects or wire breakage.
CAUTION
Make sure that the workpiece weight, including the hand, does not exceed the
rated load or tolerable torque. Exceeding these values could lead to alarms or
faults.
WARNING
Securely install the hand and tool, and securely grasp the workpiece. Failure to
observe this could lead to personal injuries or damage if the object comes off or
flies off during operation.
WARNING
Securely ground the robot and controller. Failure to observe this could lead to
malfunctioning by noise or to electric shock accidents.
CAUTION
Indicate the operation state during robot operation. Failure to indicate the state
could lead to operators approaching the robot or to incorrect operation.
WARNING
When carrying out teaching work in the robot's movement range, always secure
the priority right for the robot control. Failure to observe this could lead to personal
injuries or damage if the robot is started with external commands.
CAUTION
Keep the jog speed as low as possible, and always watch the robot. Failure to do
so could lead to interference with the workpiece or peripheral devices.
CAUTION
After editing the program, always confirm the operation with step operation before
starting automatic operation. Failure to do so could lead to interference with
peripheral devices because of programming mistakes, etc.
CAUTION
Make sure that if the safety fence entrance door is opened during automatic operation, the door is locked or that the robot will automatically stop. Failure to do so
could lead to personal injuries.
CAUTION
Never carry out modifications based on personal judgments, or use non-designated maintenance parts.
Failure to observe this could lead to faults or failures.
WARNING
When the robot arm has to be moved by hand from an external area, do not place
hands or fingers in the openings. Failure to observe this could lead to hands or fingers catching depending on the posture.
CAUTION
Do not stop the robot or apply emergency stop by turning the robot controller's
main power OFF.
If the robot controller main power is turned OFF during automatic operation, the
robot accuracy could be adversely affected.
CAUTION
Do not turn off the main power to the robot controller while rewriting the internal
information of the robot controller such as the program or parameters. If the main
power to the robot controller is turned off while in automatic operation or rewriting
the program or parameters , the internal information of the robot controller may be
damaged.
1-4 Safety Precautions
2Unpacking to installation
2 Unpacking to installation
2.1 Confirming the products
Confirm that the parts shown in the standard configuration of the controller shown in Table 2-1 are enclosed with
the purchased product.
Users who have purchased options should refer to the separate "Standard Specifications". The primary power
supply cable and grounding cable must be prepared by the customer.
Table 2-1 : Standard configuration
No.
Part name
Type
Qty.
Remarks
CR1B-571
1 unit
With machine cable.
1 pc.
Cover and installation screw(2 pc) is
attached.
For the RV-3S/RV-3SJ series
1
Controller
2
Earth leakage breaker(NV)
3
Safety Manual
BFP-A8006
1 copy
4
CD-ROM (Instruction manual)
BFP-A8317
1 disk
Standard Specifications
BFP-A8387
(1 copy)
Found on CD-ROM
Instruction Manual
(Robot arm setup and maintenance)
BFP-A8388
(1 copy)
Found on CD-ROM
Instruction Manual
(Controller setup, basic operation and maintenance)
BFP-A8054
(1 copy)
This book
Found on CD-ROM
Instruction Manual
(Detailed explanations of functions and operations)
BFP-A5992
(1 copy)
Found on CD-ROM
Instruction Manual
(Explanations of MOVEMASTER COMMANDS)
BFP-A8056
(1 copy)
Found on CD-ROM
Instruction Manual
(Troubleshooting)
BFP-A5993
(1 copy)
Found on CD-ROM
5
Guarantee Card
1 copy
For other models
1
Controller
CR1-571
2
Earth leakage breaker(NV)
3
Safety Manual
BFP-A8006
4
Standard Specifications
BFP-A8050
1 unit
1 pc.
With machine cable
Cover and installation screw(2 pc) is
attached.
1 copy
RV-1A/2AJ series type.
5
BFP-A8182
6
BFP-A8104
7
BFP-A8176
RH-15UHC series type.
BFP-A8052
RV-1A/2AJ series type.
8
9
Instruction Manual
(Robot arm setup and maintenance)
BFP-A8183
10
BFP-A8111
11
BFP-A8177
1 of
these
copy
1 of
these
copy
RV-2A/3AJ series type.
RP-1AH/3AH/5AH series type.
RV-2A/3AJ series type.
RP-1AH/3AH/5AH series type.
RH-15UHC series type.
12
Instruction Manual
(Controller setup, basic operation and maintenance)
BFP-A8054
1 copy
13
Instruction Manual
(Detailed explanations of functions and operations)
BFP-A5992
1 copy
14
Instruction Manual
(Explanations of MOVEMASTER COMMANDS)
BFP-A8056
1 copy
15
Instruction Manual
(Troubleshooting)
BFP-A5993
1 copy
16
Guarantee Card
This book
For RV-1A/2AJ and RV-2A/3AJ series
type.
1 copy
Confirming the products 2-5
2Unpacking to installation
2.2 Installation
2.2.1 Unpacking procedures
1. Open the top of the cardboard box,
and remove the instruction manual.
Manuals, etc
Packaging
material
2. Remove the inner case-1, and
remove the machine cable.
3. Remove the inner case-2,
and remove the controller.
Controller
Inner case-2
Machine cable
Inner case-1
Note)The packaging material is required when transporting the controller again, so keep it in safekeeping.
Fig.2-1 : Unpacking the controller
2.2.2 Transportation procedures Mass: Approx. 8kg
!!
Fig.2-2 : Transporting the controller
(1) Transport the controller by placing hands between the lower clearance created with the rubber foot on the
front and back sides, and lifting up the controller. Do not hold the switches or connectors.
2-6 Installation
2Unpacking to installation
2.2.3 Installation procedures
50
EMG.STOP
STATUS NUMBER
50
CHANG DISP
UP
DOWN
MODE
SVO ON
START
RESET
SVO OFF
STOP
END
TEACH
AUTO
(Op.)
AUTO
(Ext.)
REMOVE T/B
170 or more
Fig.2-3 : Installation dimensions
[Caution] A suction port is installed on the bottom of the controller, so do not remove the rubber foot and install
the controller flat on a surface.
Installation 2-7
2Unpacking to installation
2.2.4 Connecting the power cable and grounding cable
The power supply voltage is classified as follows by the use robot type. The connection of the cable is to proceed
in each explanation clause, and do it.
*RV-1A/2AJ series
Power supply voltage : Choose 1-phase 100VAC or 1-phase 200VAC. (Default setting is 1-phase 100VAC.)
Explanation clause
: Do it from the following "(1)Setting the power specifications (CR1-571 controller only)".
*RP-1AH/3AH/5AH series
Power supply voltage : Choose 1-phase 100VAC or 1-phase 200VAC. (Default setting is 1-phase 200VAC.)
Explanation clause
: Do it from the following "(1)Setting the power specifications (CR1-571 controller only)".
*Except the above
Power supply voltage : 1-phase 200VAC fixation. (Default setting is 1-phase 200VAC.)
Explanation clause
: Proceed to "(2) Connecting the power and grounding cable" on page 9.
CAUTION
Use an earth leakage breaker in the package on the primary power
supply of the controller to protect against leakage currents.
Failure to observe this could lead to electric shock accidents.
Input power voltage setting connector
200VAC
100VAC
Power card(RZ802A)
Earth leakage
breaker
(NV)
Power supply connection terminal
L1
L2
Protective earth
terminal
(PE)
FG
Power and grounding cable
(Prepared by customer)
Power supply connection
terminal(M4)
(With cover)
Fig.2-4 : Connecting the power cable and grounding cable
(1) Setting the power specifications (CR1-571 controller only)
1) Remove the controller cabinet cover.
2) Set the input power voltage setting connector on the power card (RZ802A: refer to Fig. 2-4) in the controller
as follows.
<When using as single-phase 200VAC>
Insert the "input power voltage setting connector" into the connector indicated as 200VAC (CON200V:
refer to Fig. 2-4) on the power card (RZ802A).
<When using as single-phase 100VAC>
Insert the "input power voltage setting connector" into the connector indicated as 100VAC (CON100V:
refer to Fig. 2-4) on the power card (RZ802A).
3) Install the controller cabinet cover.
CAUTION
2-8 Installation
(To the user of the CR1-571 controller)
If the voltage set with "input power voltage setting connector" and the actual input
voltage differ (ex. When input voltage is 200VAC even though 100VAC is set), the
error "input Power Voltage Setting Incorrect" (error No.850) will occur.
Error No. 850 will also occur if the robot arm designed for 200 VAC is set to 100
VAC.
2Unpacking to installation
(2) Connecting the power and grounding cable
1) Prepare the 2 power cables and 1 grounding cable (both AWG#14(2mm2) or more).
2) Remove the two M4 screws for the power supply terminal block cover on the rear of the controller.
3) Confirm that the primary power is set to the power specifications set in "(1)Setting the power specifications
(CR1-571 controller only)" above.
4) Confirm that the primary power is OFF, and that the power switch on the front of the controller is OFF.
5) Connect the 1 power cable to the power supply terminal on the back of the controller. (L1 and L2 from the
top.) Connect the opposition side to the secondary terminal of the earth leakage breaker packaged. (Terminal
of the bottom side.)
6) Connect the grounding cable to the grounding terminal on the power supply terminal block. (Lowest terminal.)
7) Connect the one rest of the power cable with the primary terminal of the earth leakage breaker. (Terminal of
the upside)
8) Install the power supply terminal block cover removed in step "2)".
This completes the connection of the power and grounding cables.
Note) Do the installation of the earth leakage breaker packaged by the customer. The length of the power cable
varies according to the distance between the installation place and the controller.
Installation 2-9
2Unpacking to installation
2.2.5 Connecting the external emergency stop
24V
Short piece 1
1
2
Short piece 2
Emergency stop input
RA1
3
4
6
Door switch input
RA2
5
RA3
RG (24G)
Note1)
Emergency stop output
(Customer-prepared wiring) (Controller side)
Composition of external emergency stop and door switch
DOOR
Switch
EMG.
STOP
1
2
3
4
24V
System emergency
stop line
(Prepared by customer)
Wire insert
Controller rear side
5
6
RA5
RG (24G)
Example of wiring for external emergency stop and door switch
(customer-prepared wiring)
1)
2)
3)
4)
5)
6)
Wire fixing screw
Maker:Phoenix Contact
Type:FRONT-MSTB2.5/6-ST-5.08
Terminal block array of
external emergency stop
Note 1) Emergency stop output opens when either one of the
emergency stop switches shown below or an input signal turns on.
・Emergency stop switch of the controller.
・Emergency stop switch or deadman switch of the T/B (option).
・External emergency stop input.
・External door input.
・The T/B mount/dismount switch is OFF
when the T/B is unconnected.
Fig.2-5 : Connecting the external emergency stop
For safety purposes, install the External emergency stop switch at an easy-to-operate place. The external
emergency stop input and door switch input terminal block are short-circuited with a short bar (short piece) as
shown in Fig. 2-5.
Connect the external emergency stop switch and door switch with the following procedures.
Refer to the standard specifications for details on the door switch functions.
1) Prepare the emergency stop switch and door switch.
2) Loosen the wire fixing screw on the terminal block, and remove the short bars 1 and 2.
3) Securely connect the external emergency stop contact across "1)-2)" on the terminal block, and connect
the door switch contact across "3)-4)" on the terminal block. The connection method is indicated below.
a) Loosen the wire fixing screw on the terminal block, and open the wire insertion port.
b) Peel 5 to 7mm of the sheath off the wire (AWG#24 to 16 recommended).
c) Insert the wire into the wire insertion port.
d) Securely tighten the wire fixing screw to fix the wire.
2-10 Installation
2Unpacking to installation
2.2.6 Connecting to the robot arm
Refer to the separate manual "Robot arm setup and maintenance", and connect the controller and robot arm with
machine cables.
2.3 Setting the origin
Refer to the separate manual "Robot arm setup and maintenance", and set the origin.
2.4 Confirming the operation
Refer to the separate manual "Robot arm setup and maintenance", and confirm the robot operation with jog
operation.
Setting the origin 2-11
3Installing the option devices
3 Installing the option devices
The T/B can be installed in the power OFF state as described in the separate manual "Robot arm setup and maintenance", or can be installed/removed in the power ON state as described in "4.2.1 Installing and removing the T/
B" on page 29 of this manual. Refer to the respective explanations.
Refer to the separate "Standard Specifications" for the optional devices other than those described in this manual.
3.1 Installing the pneumatic hand interface and motorized hand interface
The method for installing the pneumatic hand interface and motorized hand interface is explained below.
CAUTION
Always turn the controller supply base power and controller power switch OFF
before starting this work.
(1) Removing the controller cover
1) Remove the cabinet cover installation screws from the side of the controller, and remove the cabinet cover.
2) Remove the operation panel installation screws from the side of the controller, and remove the operation panel.
Cabinet cover
One cabinet cover
installation screw
(Rear side)
Four operation panel
installation screws
(Two each on left/right)
Operation panel
CAUTION
Wait at least three minutes
after turning OFF the supply
base power before removing
the cabinet cover (top plate).
Do not supply the power until
the top plate is installed.
Failure to observe this could
lead to electric shocks.
RZ386 or RZ387 card
Connection cable A
CAUTION
The operation panel is connected with cables. Take care
not to pull the cables with
force.
Fig.3-1 : Removing the controller cover
3-12 Installing the pneumatic hand interface and motorized hand interface
3Installing the option devices
(2) Removing the RZ386 or RZ387 card
1) Remove the connection cable A connector.
RZ386 or RZ387 card
Spread the connector
fixing latches outward
Connection cable A connector
Fig.3-2 : Removing the connection cable A
2) Remove the three installation screws from the RZ386 or RZ387 card, and pull out the card to a height where
the hand interface can be installed.
Two RZ386 or RZ387 card installation screws
RZ386 or RZ387 card
Battery cable
Push up the bottom of the
connector and pull out.
[Caution]Pull out while taking
care to the connector
fixing fittings.
One RZ386 or RZ387 card installation screw
Fig.3-3 : Pulling out the RZ386 or RZ387 card
Installing the pneumatic hand interface and motorized hand interface 3-13
3Installing the option devices
(3) Installing the pneumatic hand interface or motorized hand interface
Install the pneumatic hand interface or motorized hand interface.
RZ386 or RZ387 card
CNHNDOUT connector
CNHND connector
Connect both connectors
together. Push in securely.
Pneumatic hand interface
or motorized hand interface
Fig.3-4 : Installing the hand interface
(4) Assembling the controller
1) Install the RZ386 or RZ387 card at the original position, removed in step "(2)" "2)", and securely fix with the
three installation screws. Return the battery cable to the original position.
2) Install the connection cable A connector, removed in step "(2)" "1)" on the original position of the RZ386 or
RZ387 card. Fix by pressing the connector fixing latches inward until a "click" is heard.
3) Install the operation panel, removed in step "(1)" "2)" at the original position. Take care not to catch the cable
at this time. The cable could be damaged if forcibly bent and pressed in.
4) Install the cabinet cover, removed in step "(1)" "1)" at the original position.
Take care not to catch the battery cable at this time.
This completes the installation of the pneumatic hand interface or motorized hand interface.
3-14 Installing the pneumatic hand interface and motorized hand interface
3Installing the option devices
3.2 Installing the expansion option box
The procedures for installing the expansion option box are indicated below.
Installation screw
(Four positions)
1) Loosen the four screws from the side of
the controller, and remove the side
plate.
Side plate
2) Remove the four screws from the
expansion option box and remove the
upper cover.
Upper cover
Installation screw
(Four positions)
Expansion option
box
3) Connect the connectors from the side
of the controller with the connectors
from the expansion option box.
At this time, insert and position the
positioning latches on the expansion
option box into the groove on the side
of the controller.
Connector
Groove
(Two positions)
Installation screw
(Four positions)
Positioning latches
(Two positions)
4) Securely fix both pieces with the
screws removed in step 1).
Installing the expansion option box 3-15
3Installing the option devices
Installation screw
(Four positions)
Rail plate
(2 pcs.)
5) Insert the option card to be mounted
into the corresponding slot, and fix with
the rail plate. Lead any required cables
from the cable lead-out port on the rear
side.
Option card
Cable lead-out port
Option slot 1(OPT1)
・Ethernet interface
・Extended serial interface
・Additional axis interface
・PROFIBUS interface
Option slot 2(OPT2)
・Extended serial interface
・CC-Link interface
・Additional axis interface
・PROFIBUS interface
Option slot 3(OPT3)
・Additional axis interface
・PROFIBUS interface
Installation screw
(Four positions)
Note) The No. of the slot for inserting
each option is determined. Refer to
the instruction manual provided with
each option for the corresponding
slot Nos.
6) Install the upper cover removed in step
"2)".
Upper cover
7) This completes the installation of the
expansion option box.
3-16 Installing the expansion option box
3Installing the option devices
3.3 Installation of the controller protection box (CR1B-MB)
Shows the installation method of using the controller protection box (hereinafter referred to as the protection box)
to protect the controller from using environment such as oil-mist in the following.
For outside dimensions, refer to separate manual "Standard specifications manual".
3.3.1 Name of each part
Fig. 3-5 shows the names of each part of the protection box. Put the controller in this box, and use it.
<Rear>
<Front>
Cable cover
Chassis cover (Top board)
Rear panel
(Machine cable for power)
Heat exchanger
Window
Front panel
Corner type catch clip
Cable cover
(Machine cable for signal)
Name of each part of CR1B-MB
Controller
CR1B-MB
Teaching pendant(option)
The installation state of the controller
Fig.3-5 : Name of each part of protection box (CR1B-MB)
Installation of the controller protection box (CR1B-MB) 3-17
3Installing the option devices
3.3.2 Confirmation before installation
(1) Confirming the products
The configuration part of the protection box is shown in Table 3-1. Confirm the parts.
Table 3-1 : Configuration device
Part name
Controller protection box
Type
Qty.
CR1B-MB
1 unit
Remarks
Serial number posting label
1
Protection seal transparent
1
Cable tie
2
Power supply wiring cable
1
For connecting the power relay terminal and the controller inside the box.
Grounding cable
1
For connecting the FG terminal and the controller inside the box.
External emergency stop box
(Controll box)
HW1X-BV401R
1 unit
Protection for the serial number posting label
Single emergency line. Install at a location outside the protection box where
operation can be performed easily. The outside dimensions is shown in Fig.
3-10.
(2) Customer preparation parts
Prepare the cable etc. which show in the following by the customer.
・ Power cable(AWG#14(2mm2)) ................................................................................. 2 cables
・ Grounding cable(AWG#14(2mm2)).......................................................................... 1 cable
・ External emergency stop box cables(AWG#24 ~ 16 recommendation) 2 cables
・ External emergency stop box cable clamp ........................................................ 1 piece
Fit the size to the use external emergency stop box cable, and make preparation.
Table 3-2 shows the recommendation cable clamp as a reference.
Table 3-2 : Cable clamp for external emergency stop box (recommendation)
Type
JIS wiring tube
OA-W1606
Manufacturer
φ4 ~ 6
OA-W1608
OA-W1609
Adaptation cable outside diameter
φ6 ~ 8
G1/2
φ7 ~ 9
OA-W1611
φ9 ~ 11
OA-W1613
φ11 ~ 13
OHM electric Corp
(3) Copy of the manufacture number of the controller.
Write the manufacture number (serial number) printed on the rear of controller to the attached serial number copy
seal by immortality ink.
3.3.3 Unpacking procedures
The protection box is shipped from the factory packaged in cardboard.
Unpack the cardboard packing, and take out the protection box and accessories.
3.3.4 Transportation procedures
Transport the protection box by placing hands between the lower clearance created with the rubber foot on the
front and back sides, and lifting up. (Mass of the protection box: 10kg.)
3-18 Installation of the controller protection box (CR1B-MB)
3Installing the option devices
3.3.5 Installation procedures
(1) Installation dimensions
Secure and install the space shown in the Fig. 3-6.
150mm or more
150mm or more
Note)
Note)
Note)
Keep the space of
150mm or more for
opening and closing
the corner type catch clip.
150mm or more
Fig.3-6 : Installation dimensions
CAUTION
The fan installed at the back inside of the protection box for heat exchange.
Take care to not obstruct the rotation of air.
Installation of the controller protection box (CR1B-MB) 3-19
3Installing the option devices
(2) Installation of controller
Controller
Chassis cover (Top board)
CR1B-MB
Corner type catch ckip
*Set the rubber foot of controller on
he positioning groove (two places).
Front cover
Fig.3-7 : Installation of controller
1) Remove the catch clip (two places of the right and left.) fixing the front cover of protection box, and remove
the front cover.
2) Remove the top cover of protection box by removing the ten installation screws.
3) Install the controller into the protection box. Turn the front of the controller into front of the protection box,
set the rubber foot on the positioning groove to fix the controller.
If you use the expansion option box (CR1-EB3), install it first. (Refer to "3.2 Installing the expansion option
box" on page 15.)
CAUTION
If the protection box is carried with controller installed, lift it horizontally surely.
Lifting the protection box obliquely or vertically could lead to personal injuries or damage
from dropping the controller inside the box.
3-20 Installation of the controller protection box (CR1B-MB)
3Installing the option devices
(3) Installation of earth leakage breaker
Fig. 3-8 shows the installation method of earth leakage breaker.
M4 x 50 screw (2pcs.)
*Attachments of
controller
Earth leakage breaker
*Attachments of
controller
CR1B-MB
Controller
Front view
Fig.3-8 : Installation of earth leakage breaker
1) Install the earth leakage breaker securely with attached installation screw (2-M4x50) as shown in the Fig.
3-8. The upside is ON in the installation direction.
Installation of the controller protection box (CR1B-MB) 3-21
3Installing the option devices
(4) Connecting the power cable, grounding cable, fan power cable
Fig. 3-9 shows wiring configuration and wiring system diagram of power, grounding, fan power cable.
Cable outlet
Power supply wiring cable
(for controller)
Grounding cable
(for controller)
Earth leakage breaker
Grounding terminal (PE)
(for grounding)
Grounding terminal (PE)
(Grounding for primary power supply)
Fan grounding cable
Grounding terminal (PE)
Grounding for fan
Primary terminal (upside)
Secondary terminal (downside)
Primary power supply cable/grounding cable
(Prepared by customer)
Fan power cable
Appearance diagram
Controller protection box
Power supply wiring cable
(Attachment)
Earth leakage
breaker
Primary power supply cable/
grounding cable
(Prepared by customer)
(L1)
(L1)
(L2)
(L2)
(L2)
AC fan
(L1)
(FG)
Grounding cable
(for controller)
(FG)
(FG)
Rear side of controller
(Power supply
terminal)
ACIN
FG
Grounding terminal of
protection box
(FG) Grounding terminal
(PE)
(FG)
External emergency stop box
(Attachment)
Connecton of external
emergency stop
(Prepared by customer)
(The customer needs the preparation and wiring)
Rear side of controller
(External emergency
stop terminal block)
Wiring system diagram
Fig.3-9 : Connecting the power cable, grounding cable
1) Confirm the setting of input power voltage setting connector of controller. The power supply voltage is different by the use robot type. Refer to the separate "Manual/Standard Specifications" for confirm the power
voltage which can be used. Set the input power voltage referring to "2.2.4 Connecting the power cable and
grounding cable" on page 8.
2) Connecting the power cable and grounding cable
Prepare the 2 primary power cables and 1 grounding cable (both AWG#14(2mm2 ) or more).
At inside of the protection box, use the attached power supply wiring cable for the connection of earth leakage breaker and controller, and use the attached grounding cable for the grounding of controller.
Connect the both power cable and grounding cable referring to Fig. 3-9 and "2.2.4 Connecting the power
cable and grounding cable" on page 8.
Connect the grounding cable prepared by customer to grounding terminal (PE), connect the attached
grounding cable for controller grounding to another grounding terminal (PE).
Pull out the primary power supply cable and grounding cable from the cable outlet of the protection box, and
then fix them with a cable tie together with the machine cable.
3) Connect the power cable of fan on the protection box to secondary terminal of earth leakage breaker, and
connect the grounding cable of fan to the grounding terminal on the protection box.
3-22 Installation of the controller protection box (CR1B-MB)
3Installing the option devices
(5) Connection of the external emergency stop
CAUTION
Install the attached external emergency stop box to the place easy to operate for
safety surely.
Because the controller is enclosed in the protection box, the emergency stop switch
located on the front side of the controller cannot be operated.
Install the attached external emergency stop box to the place easy to operate.
The outside and installation dimensions of the external emergency stop box are shown in Fig. 3-10 for your
reference.
For the cable connection method, refer to "2.2.5 Connecting the external emergency stop" on page 10.
Please prepare a cable clamp that is fit for the external emergency stop box cable.
For details of the external emergency stop box, refer to the Instruction Manual attached to the product.
Also, pull out the external emergency stop cable from the cable outlet of the protection box, and then fix them
with a cable tie together with the machine cable.
BOX cover
BOX base
□ 70.0
Operation switch
TOP
32.0
BOX cover installation screw
58.0
φ23.0 conduit
(Knockout)
2-φ4.6
(Two M4 installation
screw holes)
42.4
TOP
*The M4 screw prepared by customer
58.0
Panel installation dimension
Fig.3-10 : The outside dimensions and installation dimensions of emergency stop box
(6) Connecting to the robot arm
Refer to the separate manual "Robot arm setup and maintenance", and connect the controller and robot arm with
machine cables.
Lead the machine cable from the cable outlet on the rear of the protection box.
Installation of the controller protection box (CR1B-MB) 3-23
3Installing the option devices
(7) Block the cable outlet
Cable cover
Cable tie
CR1B-MB
Fig.3-11 : Block the cable outlet
The cable cover is attached to the cable outlet.(two places of top and bottom.)
Fix the cable taken out from cable outlet by using the cable tie from the top of the cable cover, and block the
cable outlet so that the oil-mist etc. not come in.
(8) Sticking the serial number posting label
Stick the serial number posting label written down in "3.3.2 Confirmation before installation" on page 18 to front
panel as shown in Fig. 3-12. And stick the protection seal transparent last.
Front panel
Serial number posting label
Protection seal transparent
Fig.3-12 : Sticking the serial number posting label
3-24 Installation of the controller protection box (CR1B-MB)
3Installing the option devices
(9) Installation of top board and front panel
Remove the sheet on the surface of packing stuck on the top board contact part at the up side of the protection
box. Reinstall the top board and securely fix with tentwelve screws. Reinstall the front panel, and close the catch
clip (two places of the right and left) for fixing the panel.
Packing
Remove the seet
CR1B-MB
Fig.3-13 : Installation of top board, front panel
This completes the installation of the protection box.
3.3.6 Handling the protection box
(1) Operation with removing the panel
The power supply ON/OFF of the controller, the operation of the front panel, the operation under the condition
that T/B is connected are carried out under the condition that the front panel of protection box is removed.
(2) Installation of the expansion option box(CR1-EB3) later
When the expansion option box installed later, take out the controller once. The method of installation of the
expansion option box is shown in the "3.2 Installing the expansion option box" on page 15.
(3) Installation of optional equipment
Any other equipments aren't installed inside the protection box except for the expansion option box.
Install the necessary equipment such as parallel I/O unit to outside of the protection box.
Installation of the controller protection box (CR1B-MB) 3-25
4Basic operations
4 Basic operations
In this chapter, the following items will be explained regarding the basic operations for handling the robot.
4-26
Handling the controller
The functions of the various keys on the controller are
explained.
Handling the teaching pendant
The methods of installing/removing the T/B, and the
functions of the various keys are explained.
Turning the power ON/OFF
The items to confirm before turning on the controller
power, and the methods of turning the power ON and
OFF are explained.
Operating the robot with jog operation
The methods for manually operating the robot arm using
the teaching pendant are explained. This is mainly used
for teaching work.
Opening and closing the hand
The methods of opening and closing the hand using the
teaching pendant are explained.
Program creation to automatic operation
The procedures of creating the program are explained in
order.
4Basic operations
4.1 Handling the controller
4.1.1 Functions of each key
<Front>
<Front side of operation panel>
9)
2)
7) 4)
15)
5)
EMG.STOP
STATUS NUMBER
CHANG DISP
UP
11)
DOWN
MODE
SVO ON
START
RESET
SVO OFF
STOP
END
TEACH
AUTO
(Op.)
AUTO
(Ext.)
14)
REMOVE T/B
6)
1)
Front operation panel
12)
10)
13) 3)
8)
Fig.4-1 : Names of controller parts
1)
2)
3)
4)
5)
6)
POWER switch ..................................... This turns the control power ON/OFF.
START button...................................... This executes the program and operates the robot. The program is run continuously.
STOP button......................................... This stops the robot immediately. The servo does not turn OFF.
RESET button ...................................... This resets the error. This also resets the program's halted state and resets the program.
Emergency stop switch .................... This stops the robot in an emergency state. The servo turns OFF.
T/B remove switch ............................ This is used to connect/disconnect the T/B without turning OFF the controller's control
power.
7) CHNGDISP button.............................. This changes the details displayed on the display panel in the order of "Override" → "Program No." → "Line No.".
8) END button............................................ This stops the program being executed at the last line or END statement.
9) SVO.ON button.................................... This turns ON the servo power. (The servo turns ON.)
10) SVO.OFF button............................... This turns OFF the servo power. (The servo turns OFF.)
11) STATUS NUMBER
(display panel)...................................... The alarm No., program No., override value (%), etc., are displayed.
12) T/B connection connector ......... This is a dedicated connector for connecting the T/B.
13) Personal computer
connection connector...................... This is an RS-232C specification connector for connecting the personal computer.
14) MODE changeover switch ............ This changes the robot's operation mode. Note1)
AUTO (Op.).................................. Only operations from the controller are valid. Operations for which the operation mode
must be at the external device or T/B are not possible.
TEACH .......................................... When the T/B is valid, only operations from the T/B are valid. Operations for which the
operation mode must be at the external device or controller are not possible.
AUTO (Ext.)................................. Only operations from the external device are valid. Operations for which the operation
mode must be at the T/B or controller are not possible.
15) UP/DOWN button ............................ This scrolls up or down the details displayed on the "STATUS. NUMBER" display panel.
Handling the controller 4-27
4Basic operations
CAUTION
Note1) The servo will turn OFF when the controller's [MODE] switch is changed. Note
that axes not provided with brakes could drop with their own weight. Carry out
the following operations to prevent the servo from turning OFF whenthe
[MODE] switch is changed.
The servo on status can be maintained by changing the mode with keeping pressing
lightly the deadman switch of T/B. The operating method is shown below.
■ When the mode is changed from TEACH to AUTO.
1) While holding down the deadman switch on the T/B, set the [ENABLE/DISABLE]
switch to "DISABLE".
2) While holding down the deadman switch on the T/B, set the controller [MODE]
switch to "AUTO".
3) Release the T/B deadman switch.
■ When the mode is changed from AUTO to TEACH.
1) While the [ENABLE/DISABLE] switch on the T/B is "DISABLE", hold down the
deadman switch.
2) While holding down the deadman switch on the T/B, set the controller [MODE]
switch to "TEACH".
3) While holding down the deadman switch on the T/B, set the [ENABLE/DISABLE]
switch to "ENABLE", then do the operation of T/B that you wish.
◇◆◇ What are the operation rights? ◇◆◇
Even when multiple devices, such as a T/B and personal computer, are connected to the controller, the
operation at one time is limited to one device. This limited device (has the operation rights)
◇◆◇ What operations require the operation rights? ◇◆◇
Operations that start the robot, such as program start and alarm reset, and operations that can cause starting
require the operation rights.
Conversely, operation that stop the robot, such as stopping and servo OFF, can be used without the operation
rights for safety purposes.
Refer to the separate manual "Explanation of functions and operations" for details on the functions related to
operation rights.
4-28 Handling the controller
4Basic operations
4.2 Handling the T/B
4.2.1 Installing and removing the T/B
By using the "REMOVE T/B" switch, the T/B can be installed and removed while the controller's control power is
ON.
(1) Installing with the control power OFF
Refer to the separate manual "From robot arm setup to maintenance" for details on installing the T/B with the
power OFF.
(2) Removing with the control power ON
DISABLE
ENABLE
1) Set the T/B [ENABLE/DISABLE] switch to "DISABLE".
DISABL E ENABLE
P8TB -TE
EMG.STOP
Connector
REMOVE T/B switch
2) Press the [REMOVE T/B] switch on the controller. (Indented
state) The switch's LED will start flickering.
3) Securely hold the T/B connector, and turn it to the left to
remove it.
4) Remove the T/B connector within 5 seconds after the LED
starts flickering. The switch's LED will turn OFF when the
work is completed.
Teaching pendant
(T/B)
(3) Installing with the control power ON
DISABLE
ENABLE
1) Set the T/B [ENABLE/DISABLE] switch to "DISABLE".
DISABL E ENABLE
P8TB -TE
EMG.STOP
Connector
REMOVE T/B switch
2) Connect the T/B connector. The switch's LED will start
flickering.
3) Press the [REMOVE T/B] switch on the side of the controller
within 5 seconds after installing the T/B. (Projected state)
The switch's LED will light when the work is completed.
Teaching pendant
(T/B)
WARNING
The T/B emergency stop is invalid while the [REMOVE T/B] switch is pressed
(indented state) even after the T/B is connected. This state will cause an emergency
stop within 5 seconds, but as the T/B is invalid, starting operations from devices
other than the T/B will be valid.
◇◆◇ When an emergency stop state occurs ◇◆◇
If the emergency stop state occurs during the above operations, cancel it with the following procedures.
(1) Press the [REMOVE T/B] switch on the side of the controller, and light the switch's LED.
(Projected state)
(2) Set the T/B [ENABLE/DISABLE] switch to "ENABLE".
(3) Press the T/B [ERROR RESET] key.
Handling the T/B 4-29
4Basic operations
4.2.2 Functions of each key
DISABLE
3)
ENABLE
R28TB
2)
5)
4)
19)
1)
6)
TOOL
JOINT
=*/
( )?
Back
XYZ
$" :
MENU
#%!
STOP
SVO ON
7)
STEP
-X
+X
MOVE
(J1)
(J1)
+
-Y
+Y
FORWD
(J2)
(J2)
-
-Z
+Z
BACKWD
(J3)
(J3)
-A
+A
(J4)
(J4)
-B
+B
8)
9)
10)
ADD
↑
RPL
COND
CHAR
ERROR
RESET
(J5)
(J5)
-C
+C
(J6)
(J6)
14)
15)
←
HAND
POS
13)
↓
DEL
18)
11)
EMG.STOP
16)
→
INP
EXE
12)
17)
1) [EMG. STOP] switch
This is a push-button switch with
lock function for emergency stop.
When this switch is pressed, the
servo will turn OFF and the robot
will stop immediately regardless of
the T/B enable/disable state. To
cancel this state, turn the switch
clockwise.
2) [ENABLE/DISABLE] switch
This changeover switch is used to
enable or disable the T/B key
operations. To carry out operations
using the T/B, always set this
switch to "ENABLE" (valid).
Operations with the T/B will be
enabled, and operations from the
controller and external sources will
be disabled. The T/B will have the
operation rights. To operate with
the controller or external source,
set this switch to "DISABLE"
(invalid).
3) Display LCD
The program contents and robot
state are displayed with the T/B
key operations.
Fig.4-2 : Teaching pendant (Front side of R28TB)
4) [TOOL] key
This selects the TOOL JOG mode.
4) [JOINT] key
This selects the JOINT JOG mode.
4) [XYZ] key
This selects the XYZ JOG, 3-AXIS XYZ or CYLINDER JOG mode.
5) [MENU] key
This returns the display screen to the "menu screen"
6) [STOP] key
This stops the program and decelerates the robot to a stop. This is the same function as the [STOP] switch on
the front of the controller, and can be used even when the T/B [ENABLE/DISABLE] switch is set to DISABLE.
7) [STEP/MOVE] key
Jog operations are possible when this key is pressed simultaneously with the 12) jog operation key. Step jump
is carried out when pressed simultaneously with the [INP/EXE] key. This also turns the servo ON.
8) [+/FORWD] key
Step feed is carried out when this key is pressed simultaneously with the [INP/EXE] key. On the edit screen,
the next program line is displayed. When pressed simultaneously with the [STEP/MOVE] key, the override will
increase.
9) [-/BACKWD] key
On the edit screen, the previous program line is displayed. When pressed simultaneously with the [INP/EXE]
key, the axis will return along the robot's operation path. When pressed simultaneously with the [STEP/MOVE]
key, the override (speed) will decrease.
10) [COND] key
This is used to edit the program.
11) [ERROR RESET] key
This key resets an error state that has occurred. When pressed simultaneously with the [INP/EXE] key, the
program will be reset.
4-30 Handling the T/B
4Basic operations
20)
19)
12) [Jog operation] key (12 keys from [-X
(J1)] to [+C (J6)]
In this manual, these keys are generically
called the "jog operation" keys. When
JOINT JOG is selected, each axis will
rotate, and when XYZ JOG is selected, the
robot will move along each coordinate
system. These keys are also used to input
numeric values such as when selecting a
menu or inputting a step No.
13) [ADD/ ↑ ] key
This additionally registers the position
data. It also moves the cursor upward.
14) [RPL/ ↓ ] key
It also moves the cursor downward .
15) [DEL/ ← ] key
This deletes the position data. It also
moves the cursor to the left .
16) [HAND/ → ] key
When pressed simultaneously with the [+C
(J6)] or [-C (J6)] key, hand 1 will open or
close. In the same manner, hand 2 will
open/close when pressed simultaneously
with the [+B (J5)] or [-B (J5)] key, hand 3
with the [+A (J4)] or [-A (J4)] key, and
hand 4 with the [+Z (J3)] or [-Z (J3)] key.
This key also moves the cursor to the
right .
Fig.4-3 : Teaching pendant (Rear and side of R28TB)
17) [INP/EXE] key
This inputs the program, and carries out step feed/return.
18) [POS CHAR] key This changes between numbers and alphabetic characters when editing the position data,
etc.
19) Deadman switch
When the [ENABLE/DISABLE] switch 2) is set to "ENABLE", and this key is released or pressed with force,
the servo will turn OFF. Press this switch lightly when carrying out functions with the servo ON, such as jog
operations. If emergency stop or servo OFF operation have been applied, and the servo is OFF, the servo will
not turn ON even when this switch is pressed. In this case, carry out the servo ON operation again.
20) Contrast setting switch (Top: Dark, bottom: light)
This sets the display LCD brightness.
◇◆◇ Remove the protection seal of the teaching pendant before using ◇◆◇
Installed the protection seal on the teaching pendant to prevent the damage of the display LCD and the key seat
when shipping. Remove the protection seal when using. The operation of the key and the confirmation of the display is possible without removing the protection seal, however the adhesive may be left on the teaching pendant
as the time passes.
Handling the T/B 4-31
4Basic operations
4.3 Turning the power ON and OFF
4.3.1 Turning the control power ON
CAUTION
Always confirm the following items before turning the controller power ON.
1) Make sure that there are no operators in the robot operation range.
2) Make sure that the controller and robot arm are securely connected with the
machine cable.
3) Make sure that the external emergency stop switch is connected to the controller.
4) Make sure that the controller's power cable and grounding cable are correctly
connected.
5) Make sure that the grounding cable is connected to the robot arm.
6) Make sure that there are no obstacles, such as tools, in the robot operation range.
STATUS NUMBER
POWER
OFF
ON
Turn the controller [POWER] switch ON.
" □ . 100" will appear on the STATUS NUMBER display.
This completes the turning ON of the control power.
◇◆◇ What is the main power, control power and servo power? ◇◆◇
Main power ------This supplies power to the controller. (Primary power)
Control power --- This supplies power to the control sections (PCB, etc.) in the controller.
Servo power -----This supplies power to the motor that drives the robot.
When energized, this is called servo ON, and when shut off, this is called servo OFF.
4.3.2 Shutting OFF the control power
STOP
1) If the robot is operating, press the controller [STOP] switch, and stop
the robot.
Stop the program
SVO OFF
2) After the robot has stopped, press the controller [SVO OFF] switch,
and turn the servo OFF.
Shut OFF the motor powe
3) Turn the controller [POWER] switch OFF.
The control power will be shut OFF.
4-32 Turning the power ON and OFF
4Basic operations
4.4 Turning the servo power ON/OFF
4.4.1 Turning the servo power ON (servo ON)
DISABLE
ENABLE
1) Confirm that the T/B [ENABLE/DISABLE] switch is
set to "DISABLE".
T/B disable
MODE
TEACH
AUTO
(Ext.)
AUTO
(Op.)
2) Confirm that the [MODE] switch on the front of the
controller is set to "Auto (Op.)".
Controller enable
SVO ON
Turn ON the servo power
CAUTION
3) Press the [SVO ON] switch on the front of the
controller.
The switch's lamp will light indicating that the servo is
ON.
Make sure that there are not operators in the robot operation range before turning ON
the servo.
4.4.2 Shutting OFF the servo power (servo OFF)
STOP
1) If the robot is operating, press the controller [STOP]
switch on the front of the controller, and stop the
robot.
Stop the program
SVO OFF
Shut OFF the servo
2) After the robot has stopped, press the controller
[SVO OFF] switch on the front of the controller, and
turn the servo OFF. The switch's lamp will light
indicating that the servo is OFF.
◇◆◇ Operation rights not required ◇◆◇
This operation does not require the operation rights, so the servo can be turned OFF at any time by pressing
the [SVO OFF] switch.
Turning the servo power ON/OFF 4-33
4Basic operations
4.5 Jog operation
Refer to the separate manual "Robot arm setup and maintenance" when carrying out jog operation.
The following jog operation modes are available. Use these according to the purpose.
Table 4-1 : Jog modes
Jog mode
Main application
JOINT JOG
・ Moves each joint.
・ Moves the robot arm largely.
・ Changes the robot posture.
XYZ JOG
・ Accurately sets the teaching position.
・ Moves the axis straight along the XYZ coordinate system.
・ Moves the axis straight while maintaining the robot posture.
・ Changes the posture while maintaining the hand position.
TOOL JOG
・ Accurately sets the teaching position.
・ Moves the axis straight along the hand direction.
・ Changes the posture while maintaining the hand position.
・ Rotates the hand while maintaining the hand position.
3-AXIS XYZ JOG
・ When the axis cannot be moved with XYZ JOG that maintains the posture.
・ When the tip is to be moved linearly but the posture is to be changed.
CYLINDER JOG
・ Moves in a cylindrical shape centering on the Z axis while maintaining the posture.
・ Moves linearly in a radial shape centering on the Z axis while maintaining the posture.
Explanation
Separate manual "Robot arm
setup and maintenance"
4.6 Opening and closing the hand
Hands 1 to 4 can be opened and closed with the T/B.
HAND
→
HAND
→
Open
4-34 Jog operation
+
-C
(J6)
0
+
+C
(J6)
5
Close
Opening and closing hand 1
Open: Press [HAND] + [+C (J6)] key
Close: Press [HAND] + [-C (J6)] key
Opening and closing hand 2
Open: Press [HAND] + [+B (J5)] key
Close: Press [HAND] + [-B (J5)] key
Opening and closing hand 3
Open: Press [HAND] + [+A (J4)] key
Close: Press [HAND] + [-A (J4)] key
Opening and closing hand 4
Open: Press [HAND] + [+Z (J3)] key
Close: Press [HAND] + [-Z (J3)] key
4Basic operations
4.7 Programming
The procedures from creating the program to automatic operation are explained in order using a simple procedure
as an example.
(1) Creation procedures
Start
Decide the robot operation order, operation path
(necessity of linear movement), and the work at each
operation position (hand open/close, etc).
Deciding the operation order
Teach the robot operation position in the position
variables.
Decide the position variable name.
Deciding the operation position name
Based on the decided operation order and operation
position name, convert the robot operations and work
into commands. Describe the commands in the program
and save in the controller.
Describing and creating the program
Move the robot to each operation position with jog
operation, and teach each position in the position
variables.
Teaching the operation position
Confirmation of program and operation position
Execute the program saved in the controller line by line,
and confirm that the program and operation positions
are correctly saved.
Yes
Judgment: OK?
No
If any mistakes were found in the robot operation or
work during the program confirmation, correct the
program.
Correcting the program
If any mistakes were found in the robot operation
position during the program confirmation, correct the
taught position.
Correcting the position
Automatically execute the completed program.
Automatic operation
End
Fig.4-4 : Program creation procedures
(2) Robot work
Assume that the robot is going to carry the workpiece from the left to the right.
Workpiece
Carry the workpiece
Fig.4-5 : Example of work
Programming 4-35
4Basic operations
4.7.1 Creating the program
(1) Deciding the operation order
(10
)
(2)
20mm
Upward position to
grasping workpiece
:Joint movement
:Linear movement
:Teaching position
(1)
Wait position
Upward position to
release workpiece
(6)
(3)
(5)
(4) Hand close
Position to grasp workpiece
(7)
(9)
(8) Hand open
Position to release workpiece
Start
(1)
(2)
(3)
(4)
(5)
(6)
Move to wait position (joint movement).
Move to 20mm upward workpiece (joint movement).
Move to position to grasp workpiece (linear movement).
Grasp workpiece (hand close).
Move 20mm upward (linear movement).
Move to 20mm upward position to release workpiece
(joint movement).
(7) Move to position to release workpiece (linear movement).
(8) Release workpiece (hand open).
(9) Move 20mm upward (linear movement).
(10) Move to wait position (joint movement).
End
Fig.4-6 : Deciding the operation order
◇◆◇ Joint movement and linear movement ◇◆◇
The operation for which the robot movement path is not designated in particular is the "joint movement". The
operation for which the movement path is designated as linear is "linear movement".
If the robot could interfere with the peripheral devices, such as the workpiece, when moving to grasp or release
the workpiece, designate "linear movement" to prevent any interference.
4-36 Programming
4Basic operations
(2) Deciding the operation position name
Wait position
(PWAIT)
Upward position to
grasping workpiece
20mm
Upward position to
release workpiece
Position to release
workpiece
(PPUT)
Position to grasp workpiece
(PGET)
Position
variable name
Teaching
PWAIT
Required
Upward position to grasping
workpiece
-
Not required
Position to grasp workpiece
PGET
Required
-
Not required
PPUT
Required
Name
Wait position
Upward position to release workpiece
Position to release workpiece
Remarks
Designate with commands.
Designate with commands.
Position variable name ・・・・ Designate a random character string starting with "P".
Up to eight characters can be designated.
Fig.4-7 : Deciding the operation position name
◇◆◇ Teaching the operation position ◇◆◇
The operation position does not necessarily need to be taught.
The positions shown with white circles in Fig. 4-7 can be designated with commands as "position 20mm away
from target position". Refer to "(3) Describing and creating the program" on page 38.
CAUTION
The designation of the direction separated from the target position differs according to the
robot type.
The position is along the Z axis of the TOOL coordinate system, and the direction is
designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Instruction Manual/
Robot arm setup and maintenance", and confirm the Z axis direction of the TOOL
coordinate system. Then, designate the correct sign (direction) that matches the robot
being used.
Designating the reverse direction could lead to interference with the peripheral devices and
damage.
Generally (in the default state), the hand retract direction is the "-" sign with the vertical
articulate type robot, and the "+" sign is the robot's upward direction with the other robots.
Programming 4-37
4Basic operations
(3) Describing and creating the program
■ Convert the target robot operations and work into commands.
Refer to the separate manual "Instruction Manual: Detailed explanations of functions and operations" for details
on the commands.
Table 4-2 : Commands used
Target operation and work
Command
Joint movement
MOV
Example of designation
Move to position variable PWAIT
MOV PWAIT
Move to 20mm upward position variable PGET
MOV PGET,+20
Move to position variable PGET
MVS PGET
Linear movement
MVS
Move to 20mm upward position variable PGET
MVS PGET,+20
Hand open
HOPEN
Open hand 1
HOPEN 1
Hand close
HCLOSE
Close hand 1
HCLOSE 1
Wait
DLY
Wait 1 second
DLY 1.0
End
END
End the program
END
Note)
Note)
■ Program the converted commands
Wait position
(PWAIT)
20mm
Upward position to
grasping workpiece
Upward position to
release workpiece
Position to grasp workpiece
(PGET)
Position to release
workpiece
(PPUT)
Start
(1) Move to wait position (joint movement) ...................................................................10 MOV PWAIT
(2) Move to 20mm upward workpiece (joint movement) ...........................................20 MOV PGET,+20
(3) Move to position to grasp workpiece (linear movement)...................................30 MVS PGET
(4) Grasp workpiece (hand close).......................................................................................40 HCLOSE 1
(5) Waits for 1 seconds...........................................................................................................50 DLY 1.0
(6) Move 20mm upward (linear movement).....................................................................60 MVS PGET,+20
(7) Move to 20mm upward position to release workpiece (joint movement) ...70 MOV PPUT,+20
(8) Move to position to place workpiece (linear movement) ...................................80 MVS PPUT
(9) Release workpiece (hand open)....................................................................................90 HOPEN 1
(10) Waits for 1 seconds ........................................................................................................100 DLY 1.0
(11) Move 20mm upward (linear movement) ..................................................................110 MVS PPUT,+20
(12) Move to wait position (joint movement) .................................................................120 MOV PWAIT
End...................................................................................................................................................130 END
Note)
Note)
Note)
Note)
Hand ・・・・ Up to four hands can be installed. However, in the above program, the 1st hand connected to
hand 1 is the target.
Fig.4-8 : Describing the program
CAUTION
4-38 Programming
Note) Upward movement is designated at a position along the Z axis of the TOOL coordinate system, and the direction is designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Installation
Manual/ Robot arm setup and maintenance", and confirm the Z axis direction of
the TOOL coordinate system. Then, designate the correct sign (direction) that
matches the robot being used.
Designating the reverse direction could lead to interference with the peripheral
devices and damage.
Generally (in the default state), the hand retract direction is the "-" sign with the
vertical articulate type robot, and the "+" sign is the robot's upward direction with
the other robots.
4Basic operations
◇◆◇ Program format ◇◆◇
The program format is configured of the "line No. command parameter affixed to command" as shown in Fig. 4-8.
Example) 1 0 M O V
PWA I T
Line No. Command Parameter affixed to command
The program is executed in order from the line No. with the smallest number.
■ Input the described program into the controller.
The T/B is used for this operation.
Preparing the T/B
MODE
AUTO
(Op.)
ENABLE
DISABLE
TEACH
AUTO
(Ext.)
Opening the program editing screen
3) In the <MENU> screen, press the arrow keys
(" ↑ ", " ↓ ", " ← ", " → ") and move the
cursor to "1. TEACH", and then press the
[INP] key. The <TEACH> screen will appear.
<TEACH>
(
)
<MENU>
1.TEACH 2.RUN
3.FILE
4.MONI
5.MAINT 6.SET
1) Set the controller [MODE] switch to
"TEACH".
2) Set the T/B [ENABLE/DISABLE] switch to
"ENABLE".
SELECT PROGRAM
ADD
RPL
DEL
HAND
↑
↓
←
→
INP
→
EXE
Move the cursor → set
4) Press the [1] → [INP] keys.
The program No. 1 editing screen will appear.
PR:1
<TEACH>
(1
)
--NO DATA-SELECT PROGRAM
-B
(J5)
Set the program number 1
INP
→
1 DEF
POS
CHAR
EXE
+
DEL
←
Delete an input character
◇◆◇ Using the T/B ◇◆◇
Set the controller [MODE] switch to "TEACH" and the T/B [ENABLE/DISABLE] switch to "ENABLE".
Operations from the T/B are not possible unless the controller [MODE] switch is set to "TEACH".
◇◆◇ Inputting numbers and spaces ◇◆◇
To input a number, press the key having a number on the lower left.
To input a space, press the key having "SPACE" on the lower left.
◇◆◇ Correcting incorrect numbers ◇◆◇
Press the [DEL] key while holding down the [CHAR] key to delete the character, and then input it again.
If the cursor is returned by pressing the [ ← ] key, and a character is input, it will be inserted.
Programming 4-39
4Basic operations
Input the program 10 MOV PWAIT
PR:1
PR:1
ST:1
LN:0
--NO DATA--
ST:1
LN:0
5) Press the [ ↓ ] key three times.
The cursor will move to the command editing
line.
CODE EDIT
RPL
↓
Using the cursor
PR:1
ST:1
LN:0
PR:1
10
CODE EDIT
CODE EDIT
-B
(J5)
1 DEF
Input "1","0"
PR:1
→
-C
(J6)
0 ABC
ST:1
LN:0
CHAR
+
6) Press the [1], [0] and [SPACE] keys.
The line No. "10" will be input.
-X
(J1)
SPACE PQR
ST:1
LN:0
10 M
CODE EDIT
POS
PR:1
→
PR:1
10
CODE EDIT
Input "M"
ST:1
LN:0
7) Press the [M] key while holding down the
[POS CHAR] key. "M" will appear.
-Y
(J2)
4 MNO
ST:1
LN:0
1.MOV 2.MVS
3.MVC 4.MVR
10 M
CODE EDIT
10 M
CODE EDIT
8) Hold down the [CHAR] key. The four
commands assigned to "M" will appear.
POS
Input "M"
CHAR
1.MOV 2.MVS
3.MVC 4.MVR
10 M
CODE EDIT
PR:1
10 MOV
CODE EDIT
POS
Input "MOV"
ST:1
LN:0
CHAR
+
9) Press the [1] key while holding down the
[CHAR] key.
The "MOV" command will be input.
-B
(J5)
1 DEF
◇◆◇ Inputting characters ◇◆◇
The characters that can be input are indicated, three in a group, on the lower right of each key.
To input a character, hold down the [CHAR] key and press the key having the character to be input. Each time
the corresponding character key is pressed while the [CHAR] key is pressed, the three characters will appear
alternately.
Release the [CHAR] key when the target character appears, and set the character.
◇◆◇ Inputting commands ◇◆◇
The commands can be input one character at a time (ex., for "M" → "O" → "V" for the MOV command), but if
the head character of the command is input, the command can be selected as a number from the list of
commands that appears.
After inputting the head character of the command, press the [CHAR] key. The list of commands will appear.
While holding down the [CHAR] key, press the numeral key for the target command No., and select the command
If the target command is not found in the list, press the [CHAR] key again to update the list.
4-40 Programming
4Basic operations
PR:1
PR:1
ST:1
LN:0
POS
PR:1
10) Press the [P] key while holding down the
[CHAR] key, and then release the [CHAR]
key.
"P" will be input.
10 MOV P
CODE EDIT
10 MOV
CODE EDIT
CHAR
Input "P"
ST:1
LN:0
+
-X
(J1)
SPACE PQR
ST:1
LN:0
PR:1
10 MOV P
CODE EDIT
11) Press the [W] key twice while holding down
the [CHAR] key, and then release the
[CHAR] key.
"W" will be input.
ST:1
LN:0
10 MOV PW
CODE EDIT
POS
CHAR
+
Input "W"
+B
(J5)
6 VWX
PR:1
ST:1
LN:0
10 MOV PW
CODE EDIT
PR:1
ST:1
LN:0
10 MOV PWAIT
CODE EDIT
POS
CHAR
Input "A","I","T"
PR:1
ST:1
LN:0
10 MOV PWAIT
CODE EDIT
+
-C
(J6)
0 ABC
・
-A
(J4)
2
・
GHI
PR:1
12) Input "A", "I" and "T" in the same manner.
+C
(J6)
5 STU
ST:2
LN:0
13) Press the [INP] key.
"10 MOV PWAIT" will be set.
CODE EDIT
INP
Set
PR:1
EXE
ST:2
LN:0
20 MOV PGET,+2
CODE EDIT
PR:1
ST:13
LN:0
130 END
CODE EDIT
14) Input the program from line 20 to line 130 in
the same manner.
This completes the inputting of the program.
◇◆◇ Displaying the previous and next command line ◇◆◇
To display the previous line, press the [BACKWD] key, and to display the next line, press the [FORWD] key.
◇◆◇ Displaying a specific line ◇◆◇
Press the [ ↑ ] and move the cursor to LN:. Input the No. of the line to be displayed in the parentheses, and then
press the [INP] key. The designated line will appear.
Programming 4-41
4Basic operations
■ Teach the robot operation position.
Set the position with jog operation (Teaching PGET)
1) Move the robot with jog operation, and set
the end of the hand to the position for
grasping the workpiece. When the position
has been set, open and close the hand to
confirm that the workpiece can be grasped.
Refer to "4.5 Jog operation" on page 34 for
details on the jog operation, and section "4.6
Opening and closing the hand" on page 34 for
detains on opening and closing the hand.
Hand
Work
◇◆◇ Effective use of jog mode ◇◆◇
When the robot's current position is greatly separate from the target position, move the robot in axis units with
the "JOINT JOG mode", to approach the position.
If the target position is nearby, move linearly with the "XYZ JOG mode", and finely adjust the position. The
position can be set accurately by delaying the override (operation speed) at this time.
Registering the position (Teaching PGET)
PR:1
ST:13
LN:130
MO.POS(
)
X: +0.00
Y: +0.00
Z: +0.00
130 END
CODE EDIT
ADD
POS
Change to the position screen
2) On the command editing screen, press the
[ADD] key while holding down the [POS] key.
The position editing screen will appear.
CHAR
MO.POS(PGET )
X: +0.00
Y: +0.00
Z: +0.00
+
↑
3) Input "PGET" in the parentheses at
MO.POS, and then press the [INP] key.
The position variable name PGET will be
called, and the currently registered
coordinate value will appear.
MO.POS(PGET )
X: +0.00
Y: +0.00
Z: +0.00
POS
CHAR
Input "P","G","E","T"
+
-X
(J1)
SPACE PQR
・
-A
(J4)
2
GHI
・
INP
-B
(J5)
1 DEF
・
+C
(J6)
5 STU
Refer to " ◇◆◇ Inputting characters ◇◆
◇ " on page 40 for details on inputting
characters.
EXE
MO.POS(PGET )
X: +0.00
Y: +0.00
Z: +0.00
MO.POS(PGET )
MO.POS(PGET )
X: +0.00
Y: +0.00
ADDITION ?
MO.POS(PGET )
X: +132.30
Y: +254.10
Z: +32.00
ADDITION ?
4) Press the [ADD] key while holding down the
[STEP] key, and release only the [ADD] key.
The buzzer will sound a "beep", and a
confirmation message will appear.
While holding down the [STEP] key, press the
[ADD] key again.
The buzzer will sound a "beep", and the
message "ADDING" will appear. Then, the
current position will be registered.
◇◆◇ Changing between the command editing screen and position editing screen. ◇◆◇
The commands are edited on the command editing screen, and the positions are edited on the position editing
screen.
To change from the command editing screen to the position editing screen, press the [POS] + [ADD] keys.
To change from the position editing screen to the command editing screen, press the [COND] key.
4-42 Programming
4Basic operations
MO.POS(PPUT )
X: +0.00
Y: +0.00
Z: +0.00
MO.POS(PPUT )
X: +132.30
Y: +554.10
Z: +32.00
MO.POS(PWAIT )
X: +0.00
Y: +0.00
Z: +0.00
MO.POS(PWAIT )
X: +132.30
Y: +354.10
Z: +132.00
5) Teach PPUT (position to place workpiece)
and PWAIT (wait position) in the same
manner.
This completes teaching of the robot operation positions.
(4) Confirming the program
Using the T/B execute the program line by line (step operation), and confirm the operation.
The following operations are carried out while lightly pressing the deadman switch on the T/B.
MO.POS(PWAIT )
X: +132.30
Y: +354.10
Z: +132.00
PR:1
ST:1
LN:10
10 MOV PWAIT
CODE EDIT
1) Press the [COND] key, and display the
command editing screen.
COND
Change to the command screen
PR:1
ST:1
LN:10
10 MOV PWAIT
CODE EDIT
PR:1
ST:2
LN:20
20 MOV PGET
CODE EDIT
+
Start of step execution
FORWD
CAUTION
+
INP
EXE
2) While holding down the [FORWD] key, hold
down the [EXE] key.
The robot will start moving.
When the execution of one line is completed,
the robot will stop, and the next line will
appear on the screen.
If [EXE] is released during this step, the
robot will stop.
Take special care to the robot movements during operation. If any abnormality occurs,
such as interference with the peripheral devices, release the [EXE] key and stop the
robot.
◇◆◇ Step operation ◇◆◇
"Step operation" executes the program line by line. The operation speed is slow, and the robot stops after each
line, so the program and operation position can be confirmed.
During execution, the lamp on the controller's [START] switch will light.
◇◆◇ Immediately stopping the robot during operation ◇◆◇
・ Press the [EMG. STOP] (emergency stop) switch.
The servo will turn OFF, and the moving robot will immediately stop.
To resume operation, reset the alarm, turn the servo ON, and start step operation.
・ Release or forcibly press the "deadman" switch.
The servo will turn OFF, and the moving robot will immediately stop.
To resume operation, lightly press the "deadman" switch, and start step operation.
・ Release the [EXE] key.
The step execution will be stopped. The servo will not turn OFF.
To resume operation, press the [EXE] key.
Programming 4-43
4Basic operations
PR:1
ST:2
LN:20
20 MOV PGET
CODE EDIT
PR:1
ST:13
LN:130
130 END
CODE EDIT
+
FORWD
+
INP
EXE
3) Carry out step operation up to the END
command at line No. 130, and confirm the
operation in the same manner.
If the robot operation or position is incorrect,
refer to the following operations and make
corrections.
Start of step execution
(5) Correcting the program
■ Correcting the commands
As an example, the joint movement at line No. 70 will be changed to linear movement.
(Change 70 MOV PPUT, +20 to 70 MVS PPUT, +20) Note)
Call the line No.
PR:1
ST:1
LN:10
10 MOV PWAIT
CODE EDIT
PR:1
1) Press the [ ↑ ] key to move the cursor to
LN: ( ).
PR:1
2) Press the [7], [0] and [INP] keys. Line No. 70
will appear.
ST:1
LN:(10)
10 MOV PWAIT
LINE NUMBER
ADD
↑
Using the cursor
PR:1
ST:1
LN:(70)
10 MOV PWAIT
CODE EDIT
ST:7
LN:70
70 MOV PPUT,+20
CODE EDIT
+A
(J4)
Input the line number
7
YZ_
CAUTION
-C
(J6)
0 ABC
INP
EXE
Note) Upward movement is designated at a position along the Z axis of the TOOL coordinate system, and the direction is designated with the + and - signs.
Refer to the section on the TOOL JOG operation in the separate "Installation
Manual/ Robot arm setup and maintenance", and confirm the Z axis direction of
the TOOL coordinate system. Then, designate the correct sign (direction) that
matches the robot being used.
Designating the reverse direction could lead to interference with the peripheral
devices and damage.
Generally (in the default state), the hand retract direction is the "-" sign with the
vertical articulate type robot, and the "+" sign is the robot's upward direction
with the other robots.
◇◆◇ Cursor movement ◇◆◇
When the cursor is at a command line display, the command can be edited. When at a line No. display (LN:), the
line No. is designated.
The cursor is moved with the [ ↑ ], [ ↓ ], [ ← ] and [ → ] keys.
◇◆◇ Calling out a line No. ◇◆◇
When designating and calling out a line No., move the cursor to the line No. display (LN:), input the line No., and
then press the [INP] key.
The displayed line can be scrolled up or down by pressing the [FORWD] or [BACKWD] key.
4-44 Programming
4Basic operations
Change to the command
PR:1
ST:7
LN:(70 )
70 MOV PPUT,+20
LINE NUMBER
PR:1
ST:7
LN:70
70 MOV PPUT,+20
CODE EDIT
RPL
HAND
↓
→
3) Press the [ ↓ ] key and move the cursor to
the command line.
Press the [ → ] key six times, and move the
cursor to the right of "V".
Using the cursor
PR:1
ST:7
LN:70
70 MOV PPUT,+20
CODE EDIT
PR:1
ST:7
LN:70
70 M PPUT,+20
CODE EDIT
4) Press the [DEL] key, and delete "OV". "M"
will remain displayed.
DEL
←
Deleting a character
PR:1
ST:7
LN:70
70 M PPUT,+20
CODE EDIT
1.MOV 2.MVS
3.MVC 4.MVR
70 M PPUT,+20
CODE EDIT
5) Hold down the [CHAR] key.
The four commands assigned to "M" will
appear.
POS
CHAR
Display the command list
1.MOV 2.MVS
3.MVC 4.MVR
70 M PPUT,+20
CODE EDIT
1.MOV 2.MVS
3.MVC 4.MVR
70 MVS PPUT,+20
CODE EDIT
POS
Select the "MVS" command
PR:1
ST:7
LN:70
70 MVS PPUT,+20
CODE EDIT
CHAR
+
-A
(J4)
2
GHI
6) Press the [2] key while holding down the
[CHAR] key, and select "MVS".
7) Press the [INP] key, and set line No. 70. The
next line will appear on the screen.
PR:1
ST:8
LN:80
80 MVS PPUT
CODE EDIT
INP
Set line 70
EXE
Line No. 70 has been changed to linear movement with the above operation.
◇◆◇ Correcting a character ◇◆◇
Move the cursor to the right of the incorrect character, and press the [DEL] key to delete in the left direction.
Then, input the correct character. The input character will be inserted at the cursor position.
If the cursor is returned by pressing the [ ← ] key, and a character is input, it will be inserted.
◇◆◇ After correcting a program ◇◆◇
After correcting the program, carry out step operation, and confirm that the program has been corrected.
Programming 4-45
4Basic operations
■ Correcting the taught position
As an example, the wait position (PWAIT) will be corrected.
New wait position
(PWAIT)
Change
Change the movement position
PR:1
ST:8
LN:(80 )
80 MVS PPUT
CODE EDIT
MO.POS(
)
X: +0.00
Y: +0.00
Z: +0.00
POS
CHAR
+
1) On the command editing screen, press the
[ADD] key while holding down the [CHAR]
key.
The position editing screen will appear.
ADD
↑
Change to the position screen
MO.POS(PWAIT )
X: +0.00
Y: +0.00
Z: +0.00
MO.POS(PWAIT )
X: +132.30
Y: +354.10
Z: +132.00
POS
CHAR
+
-X
(J1)
SPACE PQR
・
Input "P","W","A","I","T"
-A
(J4)
2
GHI
・
+B
(J5)
6 VWX
+C
(J6)
5 STU
・
-C
(J6)
0 ABC
2) Input "PWAIT" in the parentheses at
MO.POS, and then press the [INP] key.
The position variable name PWAIT will be
called out, and the currently registered
coordinate value will appear.
・
INP
EXE
◇◆◇ Calling out a position variable ◇◆◇
Input the name of the variable to be called out in the parentheses at MO. POS on the position editing screen.
Then, press the [INP] key.
The displayed position variable can be scrolled up or down by pressing the [FORWD] or [BACKWD] key.
4-46 Programming
4Basic operations
3) Move the robot to the new wait position with
jog operation.
JOINT
LOW
J1 +34.50
J2 +20.00
J3 +80.00
MO.POS(PWAIT )
X: +132.30
Y: +354.10
Z: +132.00
MO.POS(PWAIT )
X: +132.30
Y: -284.10
Z: +132.00
STEP
Correct the position
+
MOVE
RPL
↓
・
RPL
↓
4) Press the [RPL] key while holding down the
[STEP] key, and release only the [RPL] key.
The buzzer will sound a "beep", and a
confirmation message will appear.
While holding down the [STEP] key, press the
[RPL] key again.
The buzzer will sound a "beep", and the
message "Replacing" will appear. Then, the
current position will be registered.
This completes correction of the wait position.
◇◆◇ After correcting a program ◇◆◇
After correcting the program, carry out step operation, and confirm that the program has been corrected.
Programming 4-47
4Basic operations
(6) Start automatic operation.
CAUTION
Before starting automatic operation, always confirm the following item. Starting
automatic operation without confirming these items could lead to property damage or
physical injury.
・ Make sure that there are no operators near the robot.
・ Make sure that the safety fence is locked, and operators cannot enter
unintentionally.
・ Make sure that there are no unnecessary items, such as tools, inside the robot
operation range.
・ Make sure that the workpiece is correctly placed at the designated position.
・ Confirm that the program operates correctly with step operation.
In the following explanation, automatic operation will be carried out with the controller.
Prepare the controller
1) Set the T/B [ENABLE/DISABLE] switch to
DISABLE
ENABLE
"DISABLE".
T/B disable
MODE
2) Set the controller [MODE] switch to "AUTO
(Op.)".
TEACH
AUTO
(Ext.)
AUTO
(Op.)
Controller enable
Set the operation speed
CHNG DISP
STATUS NUMBER
Display the override
UP
STATUS NUMBER
3) Press the controller [CHNG DISP] switch
twice, and display the "OVERRIDE" on the
STATUS NUMBER display panel. (A "(" will
appear at the lower left.)
Press the [DOWN] key several times, and
display "10".
The operation speed will be set to 10%.
DOWN
Set the override
CAUTION
The servo will turn OFF when the controller's [MODE] switch is changed.
Note that axes not provided with brakes could drop with their own weight.
Carry out the following operations to prevent the servo from turning OFF when the
[MODE] switch is changed.
◇◆◇ Operations to change [MODE] switch without turning servo OFF ◇◆◇
(1) While holding down the deadman switch on the T/B, set the [ENABLE/DISABLE] switch to "DISABLE".
(2) While holding down the deadman switch on the T/B, set the controller [MODE] switch to "AUTO (Op.)".
(3) Release the T/B deadman switch.
4-48 Programming
4Basic operations
Select the program number
CHNG DISP
STATUS NUMBER
Display the program number
UP
STATUS NUMBER
4) Press the [CHNG DISP] switch, and display
the "program No." on the STATUS NUMBER
display panel. (A "P" will appear at the head.)
Confirm that the program No. targeted for
automatic operation is displayed.
With the previous operation, the program was
created in program No. 1, so "P. 0001" will
appear.
DOWN
If the correct program No. is not displayed,
press the [UP] and [DOWN] keys to display
the correct program No.
Select the program number
Start automatic operation
START
Start
END
End with one cycle
CAUTION
CAUTION
CAUTION
5) After pressing the controller [START] switch,
press the [END] switch.
The robot operation will start and will stop
after one cycle.
When executing the work example given in "Fig. 4-5Example of work" on page 35,
always press the [END] switch and end the program after one cycle. If the [END]
switch is not pressed, the hand will interfere with the existing workpiece when it goes
to pale the workpiece in the second cycle.
Before starting automatic operation, always confirm that the target program No. is
selected.
Take special care to the robot movements during automatic operation. If any
abnormality occurs, press the [EMG. STOP] switch and immediately stop the robot.
◇◆◇ Operating from the controller ◇◆◇
Set the T/B [ENABLE/DISABLE] switch to "DISABLE" and the controller [MODE] switch to "AUTO (Op.)".
Operations from the controller are not possible unless the controller [MODE] switch is set to "AUTO (Op.)".
◇◆◇ Operation speed ◇◆◇
The operation speed for automatic operation with the controller can be set.
When the override is displayed on the STATUS NUMBER display panel (with a " □ " displayed on the lower left)
the override display will increment or decrement each time the [UP] or [DOWN] key is pressed. The max. speed
is 100%.
Initially set a low speed, and gradually increase it.
Programming 4-49
5Maintenance and Inspection
5 Maintenance and Inspection
The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are
described in this chapter. The types and replacement methods of consumable parts are also explained.
5.1 Maintenance and inspection interval
Maintenance and inspection are divided into the inspections carried out daily, and the periodic inspections carry
out at set intervals. Always carry these out to prevent unforeseen trouble, to maintain the product for a long time,
and to secure safety.
(1) Inspection schedule
0 Hr
Monthly inspection
Monthly inspection
5 0 0 Hr
Monthly inspection
1 0 0 0 Hr
Daily inspection
Monthly inspection
Monthly inspection
Monthly inspection
Monthly inspection
Monthly inspection
1 5 0 0 Hr
Monthly inspection
Monthly inspection
Monthly inspection
2 0 0 0 Hr
Monthly inspection
Yearly inspection
Operating time
<Guideline for inspection period>
For one shift
8 Hr/day x 20 days/month x 12 months = approx. 1800 Hr
10 Hr/day x 20 days/month x 12 months = approx. 2400 Hr
For two shifts
15 Hr/day x 20 days/month x 12 months = approx. 3600 Hr
[Caution] According to the schedule on the above, when using the double shift, you should
make the inspections at half the regular intervals.
Fig.5-1 : Inspection schedule
5-50 Maintenance and inspection interval
5Maintenance and Inspection
5.2 Inspection items
The controller inspection items are shown below.
Refer to section "Maintenance and Inspection" in the separate manual "Robot arm setup and maintenance", and
inspect the robot arm at the same time.
5.2.1 Daily inspection items
Carry out daily inspections following the procedures given in Table 5-1.
Table 5-1 : Daily inspection items (details)
Procedure
Inspection items (details)
Remedies
Before turning the power ON (Check the following inspection items before turning the power ON.)
1
Is the power cable securely connected?
Securely connect.
(Visual)
2
Are the machine cables between the robot arm and controller securely
connected?
(Visual)
Securely connect.
3
Is the controller cover cracked, has any foreign matter adhered, or is
there any interference?
Replace with a new part, or take remedial measures.
After turning the power ON (Turn the power ON while monitoring the robot.)
1
Is there any abnormal movement or noise when the power was turned
ON?
Refer to the Troubleshooting section and remedy.
During operation (Try moving with an original program.)
1
Check that the operation point is not deviated. If deviated, check the
following items.
1) Are any of the installation bolts loose?
2) Are the bolts at the hand installation section loose?
3) Is the position of the jigs, other than the robot, deviated?
4) If the positional deviation cannot be eliminated, refer to
"Troubleshooting", and remedy.
Refer to the Troubleshooting section and remedy.
2
Is there any abnormal movement or noise?
Refer to the Troubleshooting section and remedy.
(Visual)
5.2.2 Periodic inspections
Carry out periodic inspections following the procedures given in Table 5-2.
Table 5-2 : Periodic inspection items (details)
Procedure
Inspection items (details)
Remedies
Monthly inspection items
1
Are any of the connector fixing screws or terminal block terminal
screws loose?
Securely tighten the screws.
2
Is the controller filter (bottom side) dirty?
Clean or replace with a new part.
Inspect, clean and replace the filter by refer to
"5.3.1 Cleaning and replacing the filter" on page 52.
(Visual)
Yearly inspection items
1
Replace the backup battery in the controller.
Exchange it referring to "5.3.2 Replacing the
battery" on page 53.
Inspection items 5-51
5Maintenance and Inspection
5.3 Maintenance and inspection procedures
The procedures for carrying out periodic maintenance and inspection are described below. Thoroughly comprehend
the procedures, and follow the instructions. This work can be commissioned to the Mitsubishi Service Dept. for a
fee. (Never disassemble, etc., any of the parts not described in this section.)
The maintenance parts required for the maintenance and inspection are shown in section "5.4 Maintenance parts"
on page 40. Contact your dealer for these parts when required.
5.3.1 Cleaning and replacing the filter
A filter has been installed in the front part of the controller's bottom surface.
The following shows the procedure for inspecting, cleaning and replacing the filter:
Controller
Filter
Filter stopper
Filter plate
M4 screw (two pieces)
Fig.5-2 : How to remove the filter
1) Remove the filter plate in the bottom side of the controller by unscrewing the M4 screws (2 pcs.).
2) Remove the filter from the filter plate, and then remove dust and particles accumulated on the filter.
If the filter is heavily soiled, wash it using neutral a detergent diluted with water, dry it completely, and then
mount it to the filter plate. Also, if the surface of the cleaned filter is forming nap, replace with a new filter.
3) Attach the cleaned or new filter to the filter plate, and install it to the controller with the M4 screws (2 pcs.).
This completes the inspection, cleaning and replace of the filter for the controller.
5-52 Maintenance and inspection procedures
5Maintenance and Inspection
5.3.2 Replacing the battery
CAUTION
CAUTION
The procedures for replacing the battery are described below.
If the system is used after the battery cumulative time over error (Error No. 7520)
occurs, the backup fault alarm will occur. If the backup fault alarm occurs, the contents of the memory cannot be guaranteed, so save important program and position
data on a floppy disk using personal computer support software, etc.
Replace the batteries for the controller and robot arm at the same time. Replace the
controller battery within 15 minutes after removing the old battery.
Screw-A
Cabinet cover
1) Turn the controller power ON once. (For approx. one minute.)
2) Turn the controller power and base power OFF, and wait for
at least three minutes. Then, loosen the cabinet cover fixing
screw A, and remove the cover.
Battery
3) Remove the old battery installed in the battery holder on the
battery fixing plate. (Hold the connector and pull the battery
upward.)
4) Fix the new battery into the battery holder.
5) Hold both ends of the new battery's cable connector and
insert into the connectors on the relay card. Complete the
work within 15 minutes after removing the old battery.
Battery fixing plate
Battery
Battery holder
Connector
6) Refer to the separate manual "Detailed Explanation of Functions and Operations", and reset the battery cumulative time
over alarm.
Relay card
Details of battery section
[Caution]
If the old battery is replaced because it has been used up, it is
necessary to set the origin again. Refer to the separate
"Standard Specifications Manual" and reset the origin.
This completes the replacement of the controller battery.
Maintenance and inspection procedures 5-53
5Maintenance and Inspection
5.4 Maintenance parts
The consumable parts that must be replaced periodically are shown in Table 5-3, and spare parts that may be
required during repairs are shown in Table 5-4. Purchase these parts from the dealer when required. Some Mitsubishi-designated parts differ from the maker's standard parts. Thus, confirm the part name, robot arm and controller serial No. and purchase the parts from the dealer.
Table 5-3 : Controller consumable part list
No.
Part name
Type
Qty.
Usage section
1
Lithium battery
ER6 BKO-NC2157H01
1
Control unit
2
Filter
BKO-FA0773H01
1
Bottom of the controller
Type
Qty.
Usage section
LM16
1
2
LM32
1
3
LM32
1
4
HM32
1
CR1-571 : RZ802x board
CR1B-571 : RZ808x board
5
MF60NR5A05
2
Rear side of the controller
Maker
Mitsubishi Electric System
& Service;Co.,Ltd.
Table 5-4 : Controller spare part list
No.
1
Part name
Fuse
5-54 Maintenance parts
Maker
RZ386 or RZ387 board
Mitsubishi Electric System
& Service;Co.,Ltd.
HEAD OFFICE: TOKYO BUILDING, 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
NAGOYA WORKS: 5-1-14, YADA-MINAMI, HIGASHI-KU, NAGOYA 461-8670, JAPAN
Authorised representative:
MITSUBISHI ELECTRIC EUROPE B.V. GERMANY
Gothaer Str. 8, 40880 Ratingen / P.O. Box 1548, 40835 Ratingen, Germany
Oct..2009 MEE Printed in Japan on recycled paper.
Specifications are subject to change without notice.