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Chapter 01

1)Basic of robot manipulator and attached


units
Contains:
Robot controller unit.
No of group.
No of axis.
Location of each axis.

Fanuc Robot units

Standard Number Of Robot Axes,


Group 01 Axes 06

Extended Axes and Sub-Groups

Extended axes are the available axes


controlled by the controller beyond the
standard number of robot axes. There is a
limit of three extended axes per motion
group.

Chapter 02
2) Overview of teach pendent
Contains:
Teach pendent keys.
Functions of each keys.

Chapter 03
3)Jogging of robot in different mode
Contains:
Jogging in joint mode.
Jogging in world frame.
Jogging in tool frame.
Jogging in user frame.

MODE SELECT Switch


The MODE SELECT switch is a key-switch installed on the controller operator
panel. You use the MODE SELECT switch to select the most appropriate way
to operate the robot, depending on the conditions and situation. The operation
modes are AUTO, T1, and T2

You can lock the key switch in the AUTO or T1 modes by removing the key from
the switch. You cannot remove the key from the key switch when the key is in
the T2 position.
.

Jog speed selection

Jog Speed Values


Press the +% or -% jog speed key to
change the jog speed values

Speed value

Joint

Cartesian

100, 95,90,85, ... 20,


15, 10, 5,4,3, 2, 1

% of jog speed

% of jog speed

FINE (incremental
steps)

Approximately 0.001
degrees

Approximately 0.023
mm

VFINE (incremental
steps)

Approximately 0.0001
degrees

Approximately 0.002
mm

COORD Display

You change the coordinate system by


pressing the COORD key on the teach
pendant,
1)Joint
2)User
3)World
4)Tool
5)JGFRM

Jogging procedure

1)Select a coordinate system by pressing the COORD key on the teach pendant until the coordinate
system you want is displayed in the upper right hand corner of the teach pendant screen, and on the
teach pendant LEDs. You will see a screen similar to the following.

2)Hold the teach pendant and continuously press the DEADMAN switch on the back of the teach
pendant.

3)Turn the teach pendant ON/OFF switch to the ON position

4)If you release the DEADMAN switch while the teach pendant is ON, an error will occur. To clear
the error, continuously press the DEADMAN switch and then press the RESET key on the teach
pendant.

To jog, press and hold the SHIFT key and continuously press the jog key that corresponds to the
direction in which you want to move the robot. To stop jogging, release the jog key.

Robot movement in joint mode


COORDINATE SYSTEM
AND LED OR LCD
DISPLAY

DESCRIPTION

Moves the individual


axes of the robot.

ILLUSTRATION

Robot movement in XYZ


(USER.JGFRM mode
COORDINATE
SYSTEM AND LED
OR LCD DISPLAY

DESCRIPTION

Moves the robot TCP in


the x, y, or z directions
and rotates about x (w),
y (p), or z (r).

ILLUSTRATION

Robot movement in Tool mode


COORDINATE
SYSTEM AND LED
OR LCD DISPLAY

DESCRIPTION

Moves the robot


TCP in the x, y, or
z direction and
rotates x(w), y(p),
and z(r) in the
selected tool
frame.

ILLUSTRATION

Chapter 04
2)Kinds of I/O
Contains:
Analog.
Digital.
Group.
Standard Operator Panel (SOP)
User Operator Panel (UOP)
Robot

Kinds of I/O
1)Analog: An analog I/O signal (AI or AO) is an input or output voltage that has a
value within the range of the I/O board or module used.
Analog input devices convert external analog signals into numeric signals for use
by the controller. Analog output devices allow analog signals to be send out to
external devices. Typical values of analog inputs and outputs are from -10
volts to 0 volts, or from 0 volts to +10 volts. These values depend on the
particular device used in your controller.
2)Digital:A digital I/O signal (DI or DO) is a control signal sent to or from the
controller. Digital signals can have only one of two possible states: ON or OFF.
Digital signals provide access to data on a single input or output signal line.
3) Group:Group I/O signals (GI or GO) are made up of a sequence of digital I/O
signals. These are interpreted as a binary integer.
A group signal is a group of up to 16 ones (1) and zeros (0), indicated ON or OFF.
Each bit in group input or output is a single digital input or output line. Unused
bits are assigned a "0."
If you group your digital I/O signals, you can control or monitor the sequence of I/O
signals within your program by setting or reading a single group using the
group I/O instructions.

Kinds of I/O
4)Robot:: Robot I/O signals (RI or RO) consist of the input and output signals
between the controller and the robot. These signals are sent to the EE (End
Effector) connector located on the robot. The number of robot input and output
signals varies depending on the number of axes in your system.

CONTROLLING I/O

OVERVIEW::Controlling I/O allows you to test the I/O in your system for
proper function during testing operations. Controlling I/O includes:
1)Forcing outputs
2)Simulating inputs and outputs
Forcing Outputs: Steps
1)Press MENUS.
2)Select I/O.
3)Press F1, [TYPE].
4)Select the kind of output you want to force: digital, analog, group, robot.
For digital outputs for example
I/O Digital Out
# SIM STATUS
DO[ 1] U OFF [
]
DO[ 2] U ON
[
]
DO[ 3] U OFF [
]
DO[ 4] U OFF [
]
DO[ 5] U OFF [
]
DO[ 6] U ON
[
]
DO[ 7] U OFF [
]
DO[ 8] U OFF [
]
DO[ 9] U OFF [
]

CONTROLLING I/O

5)Move the cursor to the STATUS of the output you want to force.
6)Press the function key that corresponds to the value you want.
Press
F4 for ON
F5 for OFF
Simulating Inputs and Outputs:Simulating inputs and outputs is forcing
inputs and outputs without signals entering or leaving the controller.
This can be used to test program logic.
1)Press MENUS.
2)Select I/O.
3)Press F1, [TYPE].
4)Select the kind of output you want to force: digital, analog, group, robot.

CONTROLLING I/O

For digital inputs for example, you will see a screen similar to the following.
I/O Digital Input
# SIM STATUS
DI[ 1] U OFF
[
]
DI[ 2] U ON
[
]
DI[ 3] U OFF
[
]
DI[ 4] U OFF
[
]
DI[ 5] U OFF
[
]
DI[ 6] U ON
[
]
DI[ 7] U OFF
[
]
DI[ 8] S OFF
[
]
DI[ 9] U OFF
[
]
DI[ 10] U OFF
[
]
5)If you simulate a signal, you can force the status by setting it to a value.
When the signal is unsimulated, its actual status is displayed.
6)Move the cursor to the SIM column of the signal you want to simulate.
U means the signal is not simulated or unsimulated.
S means the signal is simulated.
7)Simulate or unsimulate the signal.
To simulate, press F4, SIMULATE.
To unsimulate , press F5, UNSIM

Chapter 04
4)Part Programming
Contains:
Creating,Deleting,Copying programs .
Adding instruction in program .
Use of different instructions .

Program
Example

BRANCHING INSTRUCTIONS
Branching instructions cause the program to branch, or jump,
from one place in a program to another. There are three
kinds of branching instructions:
1) Label definition instruction
2)Unconditional branching instructions
3)Conditional branching instructions

1)Label definition instruction :


A label marks the location in a program that is the
destination of a program branch. A label is defined using a
label definition instruction .

BRANCHING INSTRUCTIONS
Branching instructions cause the program to branch, or jump,
from one place in a program to another. There are three
kinds of branching instructions:
1) Label definition instruction
2)Unconditional branching instructions
3)Conditional branching instructions

1)Label definition instruction :


A label marks the location in a program that is the
destination of a program branch. A label is defined using a
label definition instruction .

BRANCHING INSTRUCTIONS
Branching instructions cause the program to branch, or jump,
from one place in a program to another. There are three
kinds of branching instructions:
1) Label definition instruction
2)Unconditional branching instructions
3)Conditional branching instructions

1)Label definition instruction :


A label marks the location in a program that is the
destination of a program branch. A label is defined using a
label definition instruction .

BRANCHING INSTRUCTIONS

2)Unconditional branching instruction:


Unconditional branching instructions branch from one place in a
program to another any time they are executed. There are two kinds
of unconditional branching instructions:
Jump instructions - Cause the program to branch to a named label.
Sub program call instructions - Cause the program to branch to
another program.

BRANCHING INSTRUCTIONS

3)conditional branching instruction:


Conditional branching instructions branch from one place to another in
a program, depending on whether certain conditions are true. There
are two kinds of conditional branching instructions:
IF instructions - Branch to a specified label or program if certain
conditions are true. There are register IF instructions and input/output
IF instructions.

INSTRUCTIONS
WAIT INSTRUCTIONS:
1)WAIT time - delays program execution for a specified time.
2)WAIT condition - delay program execution until specified condition
are true.

INSTRUCTIONS
Timer Instruction:
Timer instructions allow you to start, stop, and reset up to ten different
timers in a program. Timers allow you to determine how long a routine
takes to execute, or how long your entire production program takes to
execute. Timers can be started in one program and then stopped in
another. The status of each timer is displayed in the $TIMER[n] system
variable.

OVERRIDE Instruction:The OVERRIDE instruction sets the speed


override to a percentage value of the programmed speed

INSTRUCTIONS
Timer Instruction:
Timer instructions allow you to start, stop, and reset up to ten different
timers in a program. Timers allow you to determine how long a routine
takes to execute, or how long your entire production program takes to
execute. Timers can be started in one program and then stopped in
another. The status of each timer is displayed in the $TIMER[n] system
variable.

OVERRIDE Instruction:The OVERRIDE instruction sets the speed


override to a percentage value of the programmed speed

Chapter 05
5)Robot movement path teaching
Contains:

Motion type.
Adding new teach point.
Touch up for existing point.
Teaching of robot in different motion
instruction(Linear,circular etc)

Motion Type
Motion type defines how the robot will move to the
destination position. There are three motion types:
1)Joint.
2)Linear.
3)Circular.

Motion instruction:

Joint motion type


Causes the robot to move all required axes to the destination
position simultaneously. The motion of each axis starts
and stops at the same time.

Linear motion type


Causes the robot to move the tool center point in a straight
line from the start position to the destination position.

Circular motion type


Causes the robot to move the tool center point in an arc from
the start position through an intermediate to the
destination position.

Chapter 06
6)Battery Replacement.
Contains:
Locations of battery.
Replacement procedure.

Battery Location

Battery Replacement
The positional data of each axis is preserved by the backup battery.
The battery needs to be periodically replaced at every one year
and six months. Also use the following procedure to replace
the battery when the backup battery voltage drop alarm occurs.
1) Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.
Replacing the battery with the power supply turned off causes all current position data to
be lost. Therefore, mastering will be required again.
2)Remove the battery case cap.
3)Take out the old batteries from the battery case.
4)Insert new batteries into the battery case.
Pay attention to the direction of batteries.
5)Close the battery case cap.

Chapter 07
7)Robot axis zeroing/mastering
Contains:
Different method for zeroing
Procedure for axis zeroing.

RESETTING ALARMS AND PREPARING FOR


MASTERING
When you turn on the robot after pulse coder backup battery
power has been interrupted you will see a SRVO-062
BZAL alarm. You might also see a SRVO-038 Pulse
Mismatch alarm. Before mastering the robot you must
reset these alarms and rotate the motor of each axis that
lost battery power to prepare the robot for mastering.

Condition:
You see a SRVO-062 BZAL
You see a SRVO-038 Servo pulse
mismatch alarm.

SRVO-038 Servo pulse mismatch alarm.

STEP:

1) Press MENUS.
2) Select SYSTEM.
3)Press F1, [TYPE].
4)If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to
Step 5 .
a)Move the cursor to VARIABLE and press ENTER.
b)Move the cursor to $MASTER_ENB.
c) Press the numeric key "1" and then press ENTER on the teach pendant.
d)Press F1, [TYPE].
5)Select Master/Cal. You will see a screen similar to the following
6)Press F3, RES_PCA. You will see a screen similar to the following.
SYSTEM Master/Cal
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press ENTER or number key to select.
Reset pulse coder alarm? [NO]

SRVO-038 Servo pulse mismatch alarm.

STEP:

7)Press F4, YES. You will see a screen similar to the following.
SYSTEM Master/Cal
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Pulse coder alarm reset!

8)Turn off the controller


9)Wait a few seconds, then press the ON button on the operator panel to turn the
controller on again.
10)Rotate each axis that lost battery power by at least one motor revolution in either
direction. Failure to do so will result in the SRVO-075 Pulse Not Established alarm
recurring and mastering will not be possible.

SRVO-062 BZAL alarm.

STEP:

1) Press MENUS.
2) Select SYSTEM.
3)Press F1, [TYPE].
4)Move the cursor to VARIABLE and press ENTER.
5)Move the cursor to $MCR.
6)Set system variable $SPC_RESET to TRUE
7)Turn off the controller
8)Wait a few seconds, then press the ON button on the operator panel to turn the
controller on again.
9)Rotate each axis that lost battery power by at least one motor revolution in either
direction. Failure to do so will result in the SRVO-075 Pulse Not Established alarm
recurring and mastering will not be possible.

DIFFERENT METHOD OF MASTERING

1)MASTERING TO A FIXTURE. (FIXTURE POSITION


MASTER)

2)ZERO POSITION MASTER.

3)SINGLE AXIS MASTER.

4)MASTERING DATA ENTRY.

1)MASTERING TO A FIXTURE. (FIXTURE POSITION


MASTER)
Fixture mastering is performed using a mastering jig. This mastering is carried out in the
predetermined jig position. Fixture mastering is accurate because a dedicated
mastering jig is used. Fixture mastering is factory performed. It is unnecessary to
perform it in
daily operations.

2)ZERO POSITION MASTER

3)SINGLE AXIS MASTER

3)SINGLE AXIS MASTER

4)MASTERING DATA ENTRY


Fixture mastering is performed using a mastering jig. This mastering is carried out in the
predetermined jig position. Fixture mastering is accurate because a dedicated
mastering jig is used. Fixture mastering is factory performed. It is unnecessary to
perform it in
daily operations.

4)MASTERING DATA ENTRY

Chapter 08
8)Taking Backup of Robot Programs
Contains:
TP Program backup.
All of above back-up.
IMAGE back-up.

Device set-up for backup


Memory card:Insert a Flash ATA memory card or

Compact Flash memory card in to the PCMCIA slot of


the controller.
OR
USB DISC:Inset USB Disc in to the slot of the controller.
Device set-up required only one time (first time) when
you using the particular device.
Not required if using same device for next time.

Device set-up for backup


Memory card:DEVICE SET-UP PROCEDURE
1)Press MENU key
2) Select 7 FILE
3)Press F4 UTILITY
4)Select set device.
5)Set to Memory card MC.
USB disc:DEVICE SET-UP PROCEDURE
1)Press MENU key
2) Select 7 FILE
3)Press F4 UTILITY
4)Select set device.
5)Set to USB Disc UD1..

Procedure for backup


1)Insert a Flash ATA memory card or Compact Flash
memory card in to the PCMCIA slot of the controller.
2)Press MENU key
3)Select 7 FILE
4)Press F4 BACKUP
5)Select 7 ALL OF ABOVE for taking a full backup or
select required item.
6)Press YES