CONTENTS SAFETY

THE CONTROLS

MOVEMENT PRINCIPLES

OPERATION

LOGICAL INSTRUCTION MENU

POSITION INSTRUCTION MENU

AUTOMATIC MENU

EDITING MENU

MANUAL MENU

ADAPTIVITY

10

PROGRAMMING

11

ARC WELDING

12

GLUING

13

SPOT WELDING

14

ERROR LIST

INDEX

SHAB ooos-2/Rev I

15

16

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for any
errors that may appear in this document.
In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from
use of this document or of the software and hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB Robotics Products AB's
written permission, and the contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Robotics Products AB at its then current
charge.

ABB Robotics Products AB 1994

Article number: 3HAB 0002-2/Rev 1

Issued: M93
ABB Robotics Products AB
S-721 68 Vasteras
Sweden

1 Safety

1
SAFETY
Before operating, servicing or in any other way handling the robot system, the Safety Manual in
the Product Manual must be thoroughly studied.

S3

1 Safety

Programming

S3

Contents

Contents
Section
1
2

Page

Safety
1.1 General

1:1

The
2.1
2.2
2.3

2:3
2:7
2:8

Controls
The Control cabinet
Mains switch
Control panel
2.3.1 AUTO mode
2.3.2 MANUAL REDUCED SPEED mode
2.3.3 MANUAL FULL SPEED mode
2.3.4 Change of operation mode
2.4 Programming unit
2.4.1 Dialog via programming unit
2.5 Joystick
2.6 Enabling device
2.7 Monitor (option)
2.8 Program printout (option)
2.9 Computer Link (option)
2.10 Remote control

Movement Principles
3.1 The Manipulator
3.2 Coordinate Systems
3.2.1 Coordinate systems for defining positions
3.2.2 Coordinate systems in program execution
3.2.3 Coordinate systems for manual movements
3.2.4 Moving the robot with the joystick
3.2.4.1 Rectangular base coordinate system
3.2.4.2 Robot main axes coordinate system
3.2.4.3 Robot wrist axes coordinate system
3.2.4.4 Tool coordinate system, no basepoint active
3.2.4.5 Tool coordinate system, basepoint active
3.2.4.6 Reorientation around TCP
3.3 TCP
3.3.1 Normal TCP
3.3.1.1 Basepoint
3.3.2 Room fixed TCP
3.3.2.1 General
3.3.2.2 Moving the robot with the joystick
3.3.2.3 Program execution with fixed TCP
3.3.2.4 Limitations
3.4 Position programming
3.4.1 Robot configuration
3.5 Movement velocity

Programming

2:12
2:14
2:15
2:15
2:15
2:16
2:16
3:3
3:5

3:18

3:22
3:23

S3

Contents

Section

Page

3.6

Movement characteristics
3.6.1 Path optimization
3.6.1.1 Path following principles
3.6.1.2 Zones
3.6.1.3 Velocity in corners
3.6.1.4 Corner deviation
3.6.1.5 Exceptions
3.6.2 Speed optimization
3.6.2.1 Guide text
3.6.2.2 Programming
3.7 Circles
3.7.1 Orientation interpolation
3.7.2 Velocity in circle
3.8 Soft Servo
3.8.1 Introduction
3.8.2 Definition of softness
3.8.3 Use of Soft Servo
3.9 Program displacement
3.9.1 Parallel displacement with reference point (REFP)
3.9.2 Program displacement with reference frame (FRAME)
3.10 Singular points
4

OPERATION
4.1 Start
4.1.1 Power on, power off, synchronization
4.1.2 Program Execution
4.1.3 Stop
4.2
Restart after power failure
4.2.1 General
4.2.2 Automatic restart
4.2.3 Manual restart
4.2.4 Restart from PLC
4.3 Languge selection
4.4
Software configuration
4.5
Program information
4.6
Error buffer
4.7
Disk handling
4.7.1 Initialize disk
4.8 Computer link
4.8.1 General
4.8.2 Commands to robot
4.8.3 Commands from robot
4.8.4 Spontaneous status messages
4.8.5 Request for superior control
4.8.6 Operation status
4.9 Register
4.9.1 Register
, 4.9.2 Position registers, location
4.10 Inputs and outputs
4.11 Ports
4.11.1 Digital ports
4.11.2 Analog ports

Programming

3:25

3:36
3:38

3:40
3:46
4:3

4:5

4:8
4:8
4:9
4:10
4:11
4:13

4:15
4:17
4:17

S3

Contents

Section

Page

4.12 SYSTEM-I/0
4.12.1 Standard SYSTEM-I/0, inputs
4.12.2 Standard SYSTEM-I/0, outputs
4.12.3 Additional SYSTEM-I/O at I/O MAP
4.12.3.1 Summary of HOLD, HOLD RESET and AUTO INPUT
4.12.3.2 Inputs
4.12.3.3 Outputs
4.13 Remote control panel signals, panel- I/O
5

Logical instructions menu

5.1 GRIPPER
5.2 WAIT
5.2.1 WAIT (TIME)
5.2.2 WAIT (INPUT)
5.3 OUTPUT
5.4 JUMP
5.4.1 JUMP (unconditional)
5.4.2 JUMP (conditional)
5.4.3 JUMP (SEARCH)
5.4.4 JUMP (NINPOS)
5.5 VELOC
5.6 CALL
5.7 RETURN
5.8 REG
5.8.1 REG (FETCH)
5.8.2 REG (SET)
5.8.3 REG (TRANSFER)
5.8.4 REG (LOC)
5.9 TCP
5.10 INTER
5.11 COORD
5.12 GET B/ADD BLOCK
5.13 COM
5.14 SUCTRL

4:22

4:28
5:5
5:7
5:9
5:9

5:12
5:13
5:15
5:15

5:18
5:19
551
5:21
5:22
5:23

5.15 FRAME/FRAME DEFINE

5.16 SOFTS
5.17 EXTAX
5.18 EXTFRAME
5.19 GLUE SCA

5:24
5:25
5:26
5:27
5:27

5.20 LOAD (IRB 6000 only)

5.21 TRIM (IRB 6000 only)
5.22 LOCATE and VISCTRL

5:27
5.27
5:28

Programming

S3

Contents

Section
6

Page

Positioning instructions m e n u
6.1 V%
6.2 SAME
6.3 ZONE
6.4 SEARCH
6.4.1
SEARCH (dist)
6.4.2
SEARCH (dir)
6.4.3
SEARCH (auto)
6.5 WEAVING
6.6 REFP
6.7 VCTRL
6.8 CONTOUR
6.9 CORVEC
6.10 POSPOS
6.11 STOPOS
6.12 POSLOC
6.13 CIRCLE
6.14 FRAME
6.15 TIME
6.16 PALLET
6.17 RELTOOL
6.17.1 RELTOOL (X, Y, Z)
6.17.2
RELTOOL (via REG)
6.18 EXTFRAME

6:5
6:5
6:5
66

6:8
6:12
612
6:13
6:14
6:14
6:16
6:17
6:18
6:18
6:19
6:19
6:21
6:23

Automatic menu
7.1-4 PROGST., INS ST., BWD., SIM
7.5 DISPL
7.6 CORV ST
7.7 ALIGN
7.7.1 Tool direction
7.7.2 External axes
7.7.3 Homeposition
7.8 AW REST
7.9 RESYNC
7.10 MOV REST

Programming

7:5
7:5
7:6
7:6

7.8
7:8
7:9

S3

Contents

Section
8

Page

Editing menu
8.1 V%
8.2 INSTNO
8.3 STEP
8.4 MODPOS
8.5 MODIFY
8.5.1
HANDCHK
8.5.2
MODIF and MODARG
8.5.3
DISPL
8.5.4
MODEXT
8.6 DELETE
8.7 INSERT
8.8 PROGRAM
8.9 RESEQ
8.10 COPY
8.11 ERASE
8.12 PROG NO
8.13 MIRROR
8.14 TIME
8.15 COPY INS

8:5
8:5
8-5
8:5
86

8:8
8:8
89
8:9
8:10
8-11
811
8:12
8:14
8:15

Manual Menu
9.1
CLEAR
9.2
DISK
9.2.1 DISK (FROM DISK)
9.2.2 DISK (TO DISK)
9.2.3
DISK(INIT)
9.2.4 DISK (DELETE)
9.3 WINSCHESTER MEMORY
9.3.1 WINCH (FR WINCH)
9.3.2 WINCH (TO WINCH)
9.3.3 WINCH (INIT)
9.3.4 WINCH (DELETE)
9.4
IN/OUT (INPUT, OUTPUT, REG)
9.5
TOOL (TCP, SENSOR, WRIST LOAD, SOFT S)
9.6
FRAME
9.7 LIST (prog, errors)
9.7.1 PROG
9.7.2 ERRORS
9.7.3 SYS PAR
9.7.4 USER PAR
9.8
FRSC
9.9 TO SC
9.10 RBMODE
9.11 *LANG
9.12 ERRORS
9.12.1 Software Configuration
9.13 TEACH
9.14 WDATA (arc weld function)
9.15 PALLET
9.16 EXTFRAME
9.17 HOMEPOS (from M93/5)
9.18 REFP

Programming

9:5
9:6

9:8

9:9
9:10
9:26
9:28

9:28
9:29
9:30
9:30
9:30
9:32
9:34
9:34
9:35
9:35
9:36

S3

Contents

Section
10

11

Page

Adaptivity
10.1 Adaptivity sensor interface
10.2 Connection and definition of sensors
10.3 Searching
10:4
10.3.1 Distance searching
10.3.2 Direction searching
10.3.3 Autosearch (AW)
10.4 Speed control
10.5 Contour tracing
10.6 Correction vector
10.7 FRAME
Programming
11.1 OVERVIEW OF FIVE PROGRAMMING MENUS
11.2 Initialization sequence for the main program
11.3 PROGRAM STRUCTURE
11.4 PATTERN PROGRAM
11.5 PROGRAMMING ROBOT PATHS
11.5.1 Smooth wrist reorientation
11.5.2 Recommendation for Arc Welding
11.5.3 Recommendation for Glueing and Sealing
11.5.4 Process application type plastic cutting, metal cleaning,
deburring and polishing
11.5.5 Recommendation for Assembly, Machine, Tending and
Material Handling
11.5.6 Closely spaced positions
11.6 PROGRAMMING EXAMPLES
11.6.1 Arc welding of rear axis member
11.6.2 Glueing of a car door
11.6.3 Cutting and deburring of plastic, forming of holes using
the CIRCLE function
11.6.4 Cutting and deburring of plastic lining for a car door
11.6.5 Material handling applications
11.7 HIGH PERFORMANCE PROGRAMMING
11.7.1 General
11.7.2 Recommendations for best performance
11.7.3 Movement principle choice
11.7.3.1 Coordinate system
11.7.3.2 Movement principle
11.8 LOAD, PROGRAMMABLE
11.8.1 General function
11.8.2 Wrist operations (A and P).
11.8.2.1 Acceleration index calculation.
11.8.2.2 Trimming of position gain index.
11.8.2.3 Preset values
11.8.2.4 Measures to deal with overshoots.
11.9 TRIM, PROGRAMMABLE

Programming

10:3
10:3

10:7
10:8
10:10
10:11
11:3
11:5
11:5
11:7
11:9

11:16

11:23

11:27

11:38

S3

Contents

Section

Page

12

12:3
12:3
12:3
12:12
12:15
12:61

13

14

Arc welding
12.1 Introduction
12.2 System principles
12.3 Program structure
12.4 Description and programming of welding data
12.5 Description of robot instructions
12.5.1 Instructions for the welding process
12.5.2 Instructions for manipulator
12.6 Programming of robot instructions
12.6.1 Define a position with a PATH zone
12.6.2 Instructions for the weld process
12.6.3 Instructions for manipulator movements
12.6.4 Common functions
12.6.5 EXTFRAME
12.6.5.1 Alignment of External axes
12.7 Program execution
12.7.1 Program test
12.7.2 Override function
12.7.3 Supervision of welding process
12.7 .4 Execution of welding instructions
12.8 Program example
Gluing
13.1 Introduction
13.1.1 General
13.1.2 Signals
13.2 Programming
13.2.1 Gluing instruction
13.2.2 Scaling instruction
13.3 Overrides
13.3.2 Override on the scaling instruction
13.4 Error handling
Spot weld
14.1 Introduction
14.2 The standard function
14.2.1 General
14.2.2 Welding gun, manual operation
14.2.3 Function parameters
14.2.4 The spot weld instruction
14.2.5 Programming the first spot weld instruction
14.2.6 Subsequent instructions
14.2.7 Editing of spot weld in structions
14.2.8 Execution of instruction without current

Programming

12:64

12:83

12:88
13:3

13:7
13:15
13:20

14.3
14.3

S3

Contents

Section

Page

14.3 The SWI-function

14.3.1 General
14.3.2 Function parameters
14.3.3 I/O signals
14.3.4 The spot weld instruction
14.3.5 Programming the spot weld instruction
14.3.6 Execution of instruction
14.3.7 Repeat weld after interrupt
14.3.8 Execution of instruction without weld current
14.3.9 Reset of the weld controller
14.3.10 Weld Controller programming.

14.11

15

Error List
15.1 General
15.2 Error buffer
15.3 Operational errors
15.4 System faults
15.5 Diagnotic messages

15:1
15:2
15:3
15:5
15:10
15:35

16

Index

16:1

Programming

S3

2 The Controls

Thej Controls

Section

Paj

2.1
2.2

2:3
2:7
2:8

The Control cabinet

Mains switch
2.3 Control panel
2.3.1
AUTO mode
2.3.2
MANUAL REDUCED SPEED mode
2.3.3
MANUAL FULL SPEED mode
2.3.4
Change of operation mode
2.4 Programming unit
2.4.1
Dialog via programming unit
2.5 Joystick
2.6 Enabling device
2.7 Monitor (option)
2.8 Program printout (option)
2.9 Computer Link (option)
2.10 Remote control

Programming

2:12
2:14
2:15
2:15
2:15
2:16
2:16

S3

2 The Controls

Programming

S3

2 The Controls

2 THE CONTROLS
2.1
The Control cabinet
External features
Control panel

Prograi

Main functions for robot operation

Programming unit

All functions for robot operation and programming.

Built-in system test.

Disk drive

Storing/loading of data on diskette.

Winchester memory
(Option)

Storing/loading of data on hard disk.

Monitor
(Option)

Additional display of user program and process

messages.

Customer connections

Connectors for process communication.

S3

2 The Controls
Main components
Unit

Functions

Computer board

System board

Digital I/O boards

(option)

Digital process communication (parallel or serial).

Analogue I/O boards

(option)

Analogue process communication.

Power unit

Distributes voltages in the control cabinet to drive system

and robot brakes

Power supply

Stabilized voltage supply to all electronics, for the

I/O-units and robot brakes.

Drive units

Current amplification and control of motor

current with a common rectifier. (Up to 7 units incl.
one external axis.)

Control board for external

axes (option)

Reference signals for speed and connection of

resolvers for 1-6 external axes (axes 7-12).

Mains transformer

Provides:
* galvanic isolation of the control system from the mains
supply;
* adapts the system to mains voltages between 200 V and
600 V.
Two versions:

Software

Contains four microprocessors:

Main computer - for overall control.
Servo computer - for control of servo functions and robot
movements.
Axis computer - for individual control of robot axes
I/O computer - for control of communication with
operators unit, periferal equipment, host computer
(option), floppy disc unit and Winchester memory.
Contains all robot primary memory.
Contains circuits for the personal safety functions
emergency stop;
work hold;
etc.
* Controls, via the safety functions, power supply and
brakes for the robot motors.

Arcweld
Material handling, glue, spotweld
(Shortening MH/GL/SW)
How to find out which version is present is described
in 9.12.1.

Programming

S3

2 The Controls
Process connections (option)
The system can handle the following input and output signals from the peripheral
equipment:
Digital I/O
- up to 128 in and 128 out.
Analogue I/O
up to 4 in and 4 out.
Computer communication via RS 232 interface.
Control signals for 1-6 external axes.

The AC drive system, for the robot motors and one integrated axis 7 (option), consists of the
following units.
Computer board
for overall control.
Rectifier unit
for power supply to the drive units.
Drive unit
receives current references from the computer
board.
Serial measurement board
monitors resolver signals

Position

Speed

Torque

Speed

Drive Unit
Current'
!
Rotor angte

XCurrert

Serial measurement board

(on manipulator)

AC drive system, robot axes and integrated axis 7

Programming

S3

2 The Controls
Drive units for optional external axes, other than the integrated axis 7, are located outside
the cabinet.
These drive units are provided with a speed reference by the control system.
Separate drive unit
outside control cabinet

Control cabinet
Position
Control
board
for ext.
axes

Speed

-(

Position

Di agnostics

The control system is provided with its own built-in diagnostics with the following
characteristics:
* Test on start-up:
computer board
programming unit
monitor (option)
power supply
power unit
rectifier unit
location control of I/O board and drive unit
* During test running, a red LED on the computer board is flashing.
*

Successful test running is indicated by:

the absence of red LEDs on all units
a green LED lights up on the computer board

Unsuccessful test running is indicated by:

a red LED lighting up on the faulty board
if it is possible, a fault message on the programming unit, (and on an optional monitor)

* Running of the control system in a special test mode during servicing, with the
following functions:
start-up test:
full test of the I/O boards, jumpers included
test running of the drive units at full voltage
program for cleaning heads on floppy disk unit

Prograi

S3

2 The Controls

2.2
Mains switch

The mains switch is used for connection and disconnection of the mains voltage.
If the robot is provided with the optional flange disconnect, the door will be mechanical
interlocked. To open the door the flange disconnectet must be in OFF position.

Progrju

S3

2 The Controls

2.3
Control panel

(1) Operation mode selector dockable)

Three different operation modes may be selected:
AUTO (production mode) is used in production and program execution.
MANUAL REDUCED SPEED (programming mode) is used when working in the robot
working range, when programming the robot and testing of programs.
MANUAL FULL SPEED (test mode for 100% speed) is used for testing the robot programs
at full program speed.
(2) MOTOR ON
The MOTOR ON button is used in AUTO mode to put the robot to MOTOR ON mode .
power is connected to the robot motors.
The MOTOR ON lamp is normally steadily lit. When a restart after a power failure is
possible or when external axes are not synchronized, the MOTOR ON lamp flashes.
(3) MOTOR OFF
The MOTOR OFF button is used to put the robot in the MOTOR OFF mode regardless of
the operation mode. Brakes are applied and power is disconnected from the motors.
The MOTOR OFF lamp is normally steadily lit, but flashes when an error is detected.
The error indication is reset by depress of the button.
(4) EMERGENCY STOP
An emergency stop immediately stops the robot regardless of previous state and operation
mode. The robot will enter MOTOR OFF mode with MOTOR OFF flashing. Emergency stop
mode is reset by depress of MOTOR OFF button.
Programming

S3

2 The Controls

2.3.1
AUTO mode
AUTO (production mode) is used to run previously entered programs in production.
The following applies to AUTO mode:
general mode stop is possible
auto-mode stop is possible
enabling device not in operation
control via computer link/remote control is enabled
programming/editing is disabled
manual running (using the joystick) is disabled
no robot speed limitation
corrections during programexecution are disabled
Some of these features can be changed by system parameters, see Installation S3

2.3.2
MANUAL REDUCED SPEED mode
MANUAL REDUCED SPEED mode (programming mode) is used when working inside the
robot working range and when programming the robot and testing of programs at limited
speed.
The following applies to the MANUAL REDUCED SPEED mode:
general mode stop is possible
auto mode stop is not possible
enabling device in operation
control via computer link/remote control is disabled
programming/editing is enabled
manual running (using the joystick) is allowed
robot speed is limited to 250 mm/s
HOLD TO RUN is active but can be disabled by a system parameter

233
MANUAL FULL SPEED mode
MANUAL FULL SPEED mode (test mode for 100% robot speed) is used for programming
and testing the robot programs at full program speed.
The following applies to the MANUAL FULL SPEED mode:
general mode stop is possible
auto mode stop is not possible
enabling device in operation
control via computer link/remote control is disabled
programming/editing is allowed
manual running (using the joystick) is allowed
no robot speed limitation
HOLD TO RUN is active

S3

2 The Controls

2.3.4
Change of operation mode
The function "Software Key" means that the operator has to confirm the change in
operation mode to AUTO mode or to MANUAL FULL SPEED mode before the new
operation mode is acknowledged.
The confirmation is done by answering a check question given on the programming unit
when changing the operation mode.

Changing from MANUAL REDUCED SPEED to AUTO

The operator wants to change mode, YES was selected.

PLEASE:
CHANGE TO MANUAL REDUCED SPEED

The operator does not want to change mode; NO was selected.

MANUAL FULL SPEED OK?

YES

NO

Change from MANUAL REDUCED SPEED to MANUAL FULL SPEED

MANUAL FULL SPEED

The operator wants to change mode, YES was selected.

Programming

10

S3

2 The Controls

i PLEASE:
CHANGE TO MANUAL REDUCED SPEED

|p mm

tSSRffllSSk

1L

I
1

The operator does not want to change mode; NO was selected.

MANUAL REDUCED SPEED

Change from AUTO/MANUAL FULL SPEED to MANUAL REDUCED SPEED: no

question is asked.
The buttons on the programming unit are disabled until the question is answered, or until
the operation mode selector is turned to the MANUAL REDUCED SPEED position.

Programming

11

S3

2 The Controls
24

o
12
[^ If

.2 i ?.;

I
-Jo I
SHIFT

DECIMAL POINT

Shift of part of message on upper display bie

CanceOation of error message

Decimal point
Shift of error message in plain language

MENUS

SPEED CORRECTION

LOGICAL INSTRUCTION

Overriding programmed basic speed

Accuracy 5 % of programmed basic speed

Selection of program control instructions

Current correction value shown on upper display Brie

POSITION
Selection of position instruction

Active only in MANUAL modes (can be changed by a

parameter to be active also in AUTO mode)

AUTOMATIC
Automatic program execution
(continuous or siep-by-step)
Simulation of input signals
Displacement of positions, programmed

Rectangular base coordinates

previously
Robot coordinates

fff

EDITING
Selection of program correction functions

Tool coordinates
MANUAL
Selection of manual functions
VISION
Image handling functions

INCREMENTAL POSITIONING (toggle function)

Fine trimming of robot position using the joystick
(1 step 0,1 mm)

PROCESS
Selection of appication-speciftc instructions

ft ft

PROGRAM STOP

ft ft

Immediate stop of automatic program execution

Programming

12

GRIPPER1 OPEN, CLOSED

GRIPPER 2 OPEN, CLOSED

S3

2 The Controls
2.4.1
Dialog via programming unit
Programming and other work with the robot system via the programming unit is performed
as a dialogue between the operator and the robot system. The dialogue is based on a set of
menus from which different alternatives can be chosen.
The menus are presented on the programming unit display. The operator selects a menu by
pressing the button under the alternative required.
The robot system responds by presenting consequential questions, by presenting an
information or error text or by presenting a program instruction on the display. If
necessary, the menu which the operator needs to continue the dialogue is also presented.
The main menus are obtained by pressing the buttons LOGICAL INSTRUCTION,
POSITION, AUTOMATIC, EDITING, MANUAL, VISION and PROCESS on the
programming unit.
The five buttons located immediately below the display are designated multi-function
buttons as their function depends on the current menu alternatives, displayed above.
SCAN is used to page new alternatives forward on the display. SCAN is always at the
extreme right in the menus.
When an alternative has been selected either a sub-menu or a question with response
alternatives is presented. If a value is requested this is supplied by means of the numerical
buttons. Complete program instructions are presented on the upper line of the display
when the dialogue is finished.
An incorrect choice of main menu or menu alternative can most often be corrected by a
reselection of menu or alternative. If the selection has resulted in the creation of a complete
program instruction, this must be erased before any further work is performed.
10 different dialogue languages can be selected.

Programming

13

S3

2 The Controls

2.5
Joystick
Emergency stop

0m

Enabling
device

12

Toggle
buttons

Joystick

The joystick on the programming unit is used for positioning of the robot, when
programming. The joystick can also be used to change the positions of external axes
which may be connected to the system. The joystick can also be used for override of
the current and voltage when arc welding.
The joystick can be moved forward, backward, up and down and turned clockwise and
counterclockwise or combinations of these. The speed of the corresponding robot movement
is proportional to the deflection of the joystick.

The robot moves immediately when the joystick is operated. Make sure nobody is
inside the robot working area before running the robot.
Two toggle buttons are associated with the joystick.
Either control of robot axes or control of external axes is selected by pressing the upper
button. The functions of the lower button depend on the status of the upper button as
follows:
* If control of robot axes has been selected, selection of function 1 results in linear
movement of the TCP if rectangular coordinates are active, or movement of axes 1-3, if
robot coordinates are active. If function 2 is selected, wrist orientation can be performed
around TCP, if rectangular coordinates are active, or, if robot coordinates, axis 4-6 can be
moved.
If control of external axes has been selected with the upper button, axes 7, 8 and 9
can be controlled with function 1. When function 2 is selected, the axes 10, 11 and 12 can be
controlled.
Each time a toggle button is pressed, the selection changes. The LEDs in the buttons
illuminate to indicate activation of the corresponding selection.
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2.6
Enabling device
The enabling device is in operation when the operation mode selector is in either the
MANUAL REDUCED SPEED or the MANUAL FULL SPEED mode.
When the enabling device is kept in the middle position, the robot is brought to the
MOTOR ON mode.
When released or fully depressed, the robot returns to the MOTOR OFF mode.

2.7
Monitor (option)
A monitor, is used for display of:
program section in the active program when program execution is stopped. The
current instruction is pointed out by the cursor
any comments in the program during program execution.
error messages.
During program execution, the most recently executed comment will be presented on the
screen until the next comment in the program is executed. (This assumes the presence of
comments in the program.)
An example of a program section with comments is given below:
120 POSV=100%
130 ("WAITING FOR OBJECT*)
140 WAIT UNTIL INPUT 6=1
150 POS V = 100 %
160 ("COMPONENT 1 MOUNTED*)

2.8
Program printout (option)
This option makes it possible to connect a printer for printout of:
Individual programs.
The contents of the error buffer.
Parameters
The communication with the printer is serial asynchronous at a speed of 300/1200 baud.
The interface is RS 232C/V24. The printer connected must have an internal memory buffer.

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2.9

Computer link (option)

Computer link makes it possible to connect a superior computer (S.C.).
The communication link, is serial asynchronous at 9600 baud. The interface is RS 232
C/V.24.
The S.C. can be of any type provided that it is equipped with the same interface and
contains software to handle the same communication protocol as the robot.
Computer link with all of its functions provides added possibilities for flexible automatic
production.
Simplified coordination and production supervision of complex processes is obtained with
the help of functions for program transmission, remote control and status supervision.
Detailed documentation with respect to communication and applications functions is
included in the document Computer Link.

2.10
Remote control
Remote control makes it possible to operate the robot from an external panel
or from a PLC.
Digital I/O signals are used with a parallel or serial interface. The signals accessible are
described further in chapter 4.12 and 4.13.

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Movement Principles
Section

Page

3.1
3.2

The Manipulator
3:3
Coordinate Systems
3:5
3.2.1 Coordinate systems for defining positions
3.2.2 Coordinate systems in program execution
3.2.3 Coordinate systems for manual movements
3.2.4 Moving the robot with the joystick
3.2.4.1 Rectangular base coordinate system
3.2.4.2 Robot main axes coordinate system
3.2.4.3 Robot wrist axes coordinate system
3.2.4.4 Tool coordinate system, no basepoint active
3.2.4.5 Tool coordinate system, basepoint active
3.2.4.6 Reorientation around TCP
3.3 TCP
3:18
3.3.1 Normal TCP
3.3.1.1 Base point
3.3.2 Room fixed TCP
3.3.2.1 General
3.3.2.2 Moving the robot with the joystick
3.3.2.3 Program execution with fixed TCP
3.3.2.4 Limitations
3.4 Position programming
322
3.4.1 Robot configuration
3.5 Movement velocity
3:23
3.6 Movement characteristics
3:25
3.6.1 Path optimization
3.6.1.1 Path following principles
3.6.1.2 Zones
3.6.1.3 Velocity in corners
3.6.1.4 Corner deviation
3.6.1.5 Exceptions
3.6.2 Speed optimization
3.6.2.1 Guide text
3.6.2.2 Programming
3.7 Circles
3:36
3.7.1 Orientation interpolation
3.7.2 Velocity in circle
3.8 Soft Servo
3:38
3.8.1 Introduction
3.8.2 Definition of softness
3.8.3 Use of Soft Servo
3.9 Program displacement
3:40
3.9.1 Parallel displacement with reference point (REFP)
3.9.2 Program displacement with reference frame (FRAME)
3.10 Singular points
3:46

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3 MOVEMENT PRINCIPLES
3.1
The Manipulator
The robot's movement pattern can be briefly described as follows (see also the figure below
showing the IRB 2000).
Axis 1 (C) Turning of the complete mechanical robot arm system.
Axis 2 (B) Forward and reverse movement of the lower arm.
Axis 3 (A) Up and down movement of the upper arm.
Axis 4 (D) Turning of the complete wrist centre.
Axis 5 (E) Bending of wrist around the wrist centre.
Axis 6 (P) Turning of mounting flange.
Motor unit 5th and
6th axes
3rd (A) axis
Motor unit 4th axis

5th (E) axis

6th (P) axis
Wrist

Motor unit and

gear box 2nd axis

Motor unit and

gear box 3rd axis

1st (C) axis

Base
Gear box 1st axis

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Drive system
All motors are servo controlled, brushless AC motors, specially adapted for each axis.
Feedback system:

one resolver per axis for position and speed indication

a circuit board reading the resolver feedback from all axes

Brakes
The robot is supplied with brakes on all axes. The robot is automatically braked at
emergency stops, power failure, or when taken to MOTORS OFF mode. Brakes are
also activated after still-stand for 30 seconds (automatic operation) or 5 min (manual
operation).

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3.2
Coordinate systems
3.2.1
Coordinate systems for defining positions
All positions of the robot are expressed with the help of coordinate values. These values
describe the positions of the robot in space. To know how to interpret the coordinates, i.e. to
know from what reference and in what direction to measure the position, a reference frame
or coordinate system must be defined.

FIG.1

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The internal calculations in the robot controller will be expressed in the Base Coordinate
System (BCS), see the figure above. BCS is always fixed to the robot base with the x-y plane
in the floor and the z-axis pointing upwards and concentric with the first rotation axis.
However, it is not always a good idea to express the programmed positions in the BCS,
because then it will be hard to change the positions if the robot installation changes. Often,
when an installation changes, the relative movements are the same but the positions
should be some what displaced. Then it is not necessary to reprogram all the positions but
just to redefine the used coordinate system. For this purpose, a World Coordinate System
(WCS) is used for defining the stored positions, see the figure above. The dislocation of the
WCS from the BCS is defined with a FRAME-value, holding an x, y, z value defining the
displacement, and an orientation quaternion (a four value vector) defining the
reorientation.
In some cases a temporary displacement search will be needed, e.g, if an object is located at
different positions from time to time and localized with a search function. In this case the
position is expressed in the Object Coordinate System (OCS) and the displacement is
defined with a REFERENCE POINT. Please note that REF. POINT displacement will only
give a parallell displacement, i.e. no reorientation.
The outermost coordinate system of the figure above is the Goal Coordinate System (GCS).
This defines the goal position (with an x, y, z value for the origin) and orientation (defined
by a quaternion) which the robot should reach with its tool. The GCS is stored in every
position instruction.
To summarize, the goal position and orientation is always stored in a position instruction
relative to the OCS. The location of OCS is defined relative to the WCS, with REF. POINT.
If REF. POINT is not active OCS and WCS will coincide. The location of WCS is defined
relative to BCS with FRAME. If no FRAME is active WCS and BCS will coincide.

3.2.2
Coordinate system in program execution
While the final position or goal of a movement always is expressed in rectangular
coordinates as have been described above, the path between positions can be executed in
three different coordinate systems. These are Rectangular Coordinates, Robot Coordinates
and Modifed Rectangular Coordinates which can all be activated through instructions in a
robot program. Each of these coordinate systems will give a slightly different path and
should be used depending on priority of speed, accuracy or orientation.
Rectangular Coordinates
These coordinates are default and should be used in most movements. The path, which the
TCP follows, will be linear or circular depending on the used position instruction. The
speed will be controlled to the programmed value, but the path accuracy will be given
priority. The speed will therefore be reduced when necessary. The orientation will be
changed regularly from start orientation to end orientation. If start and end orientations
are the same, the orientation will be held constant. A reduction in TCP velocity may occur
during passage near a singular point (see section 3.9 and below), or during wrist
reorientation.
Robot Coordinates
When running the robot in Robot Coordinates (Joint Coordinates) all axes are moved with
constant motor speed from start position to end position. All axes will reach their goal
position at the same time. The path will be curved in space. Robot Coordinates are used
when a fast motion is given higher priority than the linear path accuracy.
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Modified Rectangular Coordinates (MODRECT)
All six axis robots will have so called "singular points" in their working area. A singular
point is a point where two or more of the robot axes are parallell. Very big robot axes
movements or movement stop (with error message) can arise in or near singular points
when running the robot in rectangular coordinates. In such cases it is advisable to use
Modified Rectangular Coordinates to avoid the singular point.
When running the robot in MODRECT the TCP is moved along a linear path, as in
rectangular coordinates. The wrist axes (axes 4, 5 and 6) however, are moved with constant
speed in Joint coordinates from the start orientation to the end orientation. This means
that the orientation will not be held constant during the movement, but will change slightly
along the path.
Note: When changing from robot to rectangular coordinates the robot movement makes a
short stop, while coordinating the axes. This stop does not occur when changing from
rectangular to robot coordinates.

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3.2.3
Coordinate systems for manual movements
Three coordinate systems are used to define manual (joystick controlled) movements of the
robot These are Base Coordinate System, Tool Coordinate System and Robot Coordinate
System (see figure 2).
I

WRIST COORDINATE SYSTEM

Flg-2 Coordinate system used for manual movemens.

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The Base Coordinate System is always fixed to the robot base with the x-y plane in the floor
and the z-axis pointing upwards and concentric to the first axis. When using the Base
Coordinate System, joystick movements will correspond to TCP movements parallell to
Base axes.
The Wrist Coordinate System, (see figure 2) is used to define the tool and the Tool
Coordinate System. The Hand Coordinate System is always fixed to the mounting flange of
the robot, with the origin in the center of the flange, the x-axis pointing outwards and the
z-axis pointing through the pinhole.
The Tool Coordinate System has its origin in the Tool Center Point (TCP) and is defined
relative to the Wrist Coordinate System of the robot. The Tool Coordinate System is used to
define the goal positions of the robot, i.e. the Tool Coordinate System is moved to coincide
with the Goal Coordinate System (see 3.2.1).
Normally the orientation of the Tool Coordinate System is the same as for the
Wrist Coordinate System. In this case only the TCP-values (x,y,z), defining the are origin,
are defined (see figure 3).

TCP

II

TOOL COORDINATE SYSTEM

WRIST COORDINATE SYSTEM

MOUNTING FLANGE
Fig. 3 Toed coordinate system with no base point

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The Tool Coordinate System can, however, also be given another orientation according to the
mounted tool. In this case also a Base point has to be defined (see figure 4). The orientation of the
Tool Coordinate System will be determined in the following way:

The x"-axis will point through the TCP and the Basepoint.
The y"-axis is perpendicular to the x-axis and points through the TCP and on a line through
the Basepoint, which is parallell to the x'-axis of the Wrist Coordinate System. If the x"-axis
is perpendicular to the x'-axis of the hand coordinate system, the y"-axis will point in the
negative x'-direction.
The z"-axis will be perpendicular to the x"-axis and the y"-axis.

\
\
LINE THROUGH BASE POINT
PARALLELLTOX -A[S
WRIST COORDINATE SYSTEM

MOUNTING FLANGE

Fig 4 Tool coordinate system with base point

When using Tool Coordinate System, joystick movements will correspond to TCP movements
parallell to Tool axes. In both Base Coordinates and Tool Coordinates, reorientation around TCP
will be performed so that joystick movements will correspond to rotations around the Tool axes.
Robot Coordinates are used to control each individual axis of the robot. Joystick movements will
correspond to movements of particular axis, as will be described later. Note that the use of
different coordinate systems when manually moving the robot, will in no way affect the behaviour
of the robot in automatic mode.

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3.2.4
Moving the robot with the joystick
Select the coordinate system which is most convenient to run the robot to the required position
with the joystick. (When programming positions, how the robot has reached a position is
immaterial, it is the position itself that is registered).

Rectangular base coordinates

Robot coordinates

Tool coordinates

The robot system has to be synchronized before coordinate system can be selected. How the
movements of the joystick affect the movements of the robot in the different coordinate systems is
described in the following sections.

The robot moves immediately when the joystick is moved. Make sure nobody remains

inside the robot working area before running the robot.

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3.2.4.1
Rectangular base coordinate system
Obtained with button combination

The coordinate system is permanently located at the origin in the robot base in accordance with
the figures above. When the joystick is moved in the directions of the arrows, the robot TCP
currently active moves in straight lines in the X, Y-and Z-directions respectively.
Note!
When the robot is mounted in an inverted position (function parameter M0UNTING=2), the
movement directions of y and z are reversed relative to the robot base.

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3.2.4.2
Robot main axes coordinatesystem
Obtained with button combination

When the robot coordinate system is selected, joystick deflections in accordance with the
arrows correspond to movements of the robot axes 1,2 and 3 respectively in accordance with the
robot sketches. The TCP does not move in straight lines.
The robot reacts to joystick deflection as described above also when the robot is not synchronized.

The working range of the axes is not supervised when the robot is manoeuvred
unsynchronized. The movements are only interrupted by the mechanical stop if the
robot attempts to move outside the working range.
Note!
When the robot is mounted in an inverted position (function parameter M0UNTING=2), the
movement directions of axes 1 and 3 are reversed relative to the robot base.

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3.2.4.3
Robot wrist axes coordinatesystem
Obtained with button combination

When the robot coordinate system is selected, joystick deflections in accordance with the arrows
correspond to movements of the robot axes 4, 5 and 6 respectively in accordance with the robot
sketch. The TCP does not move in straight lines.
An unsynchronized robot also reacts to joystick deflections as described above.

The working range of the robot axes is not supervised when an unsynchronized robot
is maneuvred. Attempted movements outside the working range are only interrupted
by the mechanical stop.
Note!
When the robot is mounted in an inverted position (function parameter M0UNTING=2), the
movement direction of axis 5 is reversed.

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3.2.4.4
Tool coordinate system, no basepoint active
Obtained with button combination
Z"

The tool coordinate system gives movements of the active TCP in straight lines, parallell to the
axes of the tool coordinate system. If no basepoint is active the movement will be parallell to the
wrist coordinate system, as shown above.

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3.2.4.5
Tool coordinate system, basepoint active
Y"

Obtained with button combination

BASEP1

The tool coordinate system gives movements of the active TCP in straight lines, parallell to the
axes of the tool coordinate system.

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3.2.4.6
Reorientation around TCP
Obtained with button combination

The joystick deflections will rotate the tool around the axes of the tool coordinate system as
shown above. The robot axes interact to keep the TCP stationary, despite the movements of
the robot.

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3.3
TCP
TCP is an abbreviation of Tool Center Point. Normally the TCP refers to the point moved
by the robot (see 3.3.1). It can also refer to a room fixed point, around which the robot
moves an object (see 3.3.2).

3.3.1
Normal TCP
The active TCP is the point moved by the robot when positioning and it is the position of
the TCP which is registered when programming positions.
As many different types of tool with different forms and sizes can be mounted on the robot,
the work point for each tool must be determined individually e.g. the nozzle of a glue
dispenser, the centre point of a gripper, the tip of a drill or a deburring tool etc.
19 different normal TCFs can be stored simultaneously in addition to TCP 0 which is
predefined as the centre of the mounting flange of the robot.

Only one TCP can be active at a time. TCP 0 becomes active immediately on start up and
remains active until a change is made.
A TCP can be defined either manually or automatically. With manual definition, the
operator states the measures in x-, y-, and z- directions from the center of the tool fixing
(TCP 0) to the working point of the tool via the programming unit.
An example of automatic definition is the utilization of a fixed point in space to which first
the TCP 0 and then the TCP to be defined are positioned. The robot system then calculates
the difference between the TCP 0 and the new TCP, thus defining the new TCP.
When a TCP is redefined the original TCP-values are erased and the new measures are
entered instead.

3.3.1.1
Base point
The BASE POINT is used in combination with TCP to define the 'Tool Coordinate System",
see section 3.2.3. This coordinate system is used to define not only the TCP of a tool but also
its orientation, which is necessary if tool relative motions should be programmed or
performed.
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3.3.2

Room Fixed TCP

3.3.2.1
General
This section describes the function room fixed TCP. The function facilitates jogging of the
robot, when the work piece is held by the robot and the tool is fixed. When reorienting the
work piece, the movement is carried out in relation to the room fixed tool point (TCP),
independent of the position of the robot.
When running the program, the work piece is going to move, either in a straight line or in a
circle, when passing the room fixed tool point. The velocity of the work piece, relative to the
room fixed point, is the programmed velocity.
10 differet room fixed TCP's can be stored.
The function is not available in the arc weld software.

3.3.2.2
Moving the robot with the joystick
The robot will move normally in the base, wrist and robot coordinates, when jogging the
robot. The difference, compared to a normal TCP, is when reorientation of the wrist is
performed. Then the work piece will twist and move in relation to the room fixed work
point, independent of the position of the robot. See figure next page.

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3.3.2.3
Program execution with room fixed TCP
When running the program the work piece is going to move either in a straight line or in a
circle while passing the fixed tool point. The path and veloicity are not affected by
reorientation of the work piece during the movement. See figure below.
Linear interpolation with room fixed TCP.

Room fixed TCP

Base coordinate system

The movement in relation

to the work piece.

H.%

Circular interpolation with roomfixed TCP

Room fixed TCP

The movement in relation

to the work piece

Base coordinate system

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3.3.2.4
Limitations
BASE POINT
Definition of base points is not possible for a room fixed TCP. An error message is
displayed if an attempt is made.
REFERENCE POINT
The reference point does not move the room fixed TCP. Instead the work point on the work
piece is moved. The reference point must be deactivated before changing between an
ordinary and a room fixed TCP.
FRAME
Manual and automatic definition of frame can not be done with an active room fixed TCP.
An earlier defined frame can be used. The frame moves the room fixed TCP and changes
the orientation of the work piece in the same way as for an ordinary position.
MIRROR
The function is interrupted with an error message if a position is programmed with a room
fixed TCP.
WEAVING
Weaving is blocked for programming and program execution when a fixed TCP is active.
MODPOS
The function MODPOS is working normally when a room fixed TCP is active, but if the
position instruction in question was created with an ordinary TCP, the function is blocked.
RELTOOL
The function is blocked for programming and program execution if a room fixed TCP is
active.
VISION
If a room fixed TCP is active all the vision functions are blocked for programming and
program running.

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3.4
Position programming
The following principles apply to position programming.
The robot, i.e. the TCP, is moved by deflecting the joystick, to the position it is to pass
when the program is executed.
The position, i.e. TCP position and wrist/tool orientation (see below) expressed in the world
coordinate system (see 3.2.1), is programmed and stored in memory by pressing the POSbutton.
When a position is programmed:
The wrist orientation is stored, if no basepoint is defined for the active TCP.
The tool orientation is stored if a base point for the active TCP is defined.
It diouldte noted, that a poationcouW be pix^rammed with one TCP active and
later a movement to that position could be performed with another TCP active.
Generally this should be avoided, since it could result in dangerous and
unexpected movements.
Sometimes this could be useful, however, giving a possibility to use different tools in the
same position, which has to be programmed only once. In most cases the different tools
have different mounting orientations relative to the mounting flange, and in these cases
base points must be used to define the tool orientations.
When a position is programmed, a number of optional arguments describing the movement,
may also be defined. Such arguments are for instance corner zones (see 3.6) and speed (see
3.5). For a complete description of the position instruction, see chapter 6.

3.4.1
Robot configuration
Many combinations of tool position and orientation can be reached with more than one
robot configuration. The controller therefore has to make a choise of configuration, before
going to the position in question.
Information on the configuration at programming time is stored in each position
instruction.
Rectangular coordinates
The configuration in the next position that gives the smallest wrist axes movements is
chosen.
The configuration is supervised so that execution stops and an error message is issued
if either
the configuration obtained as the next position is reached is not the same
as the one at programming time if the position is a FINE-position.
on the way towards the next position, the axis 4 deviates more than 45 degrees,
or axis 6 deviates more than 90 degrees from the start position in direction away from
the stored configuration of the next position.
This supervision can be deactivated (see 8.5) so as to allow the configuration to be different
at programming and execution time.
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Robot coordinates and modified rectangular coordinates
The configuration which is closest (normally identical) to that at programming time
will be chosen.
Displacement
If some kind of position displacement is made (reference point or frame active, pallett
instruction, stored position with offset or mirrored program), the configuration information
in the position is no longer used (as it is not valid for the displaced position).
This means that, regardless of coordinate system, the configuration in the next position
that gives the smallest wrist axes movements will be chosen. There will be no supervision
of the configuration.
Note! When mirroring a program the operator is given the option of retaining the
configruration information.
From software version M93/7 and on, the configuration handling for displaced programs
(except for mirrored programs) can be changed by the parameter DHANDCHK. If set to 1
the following apply:
Displaced and undisplaced programs are handled in the same way. This change will lead to
some positions causing the supervision to trip in rectangular coordinates. To avoid this, the
supervisions can be deactivated for such positions (see section 8.5).
The advantages of the changed handling in displaced programs are:
1.

The user can chose whether configuration supervision should be active or not (always
deactivate previously).

2.

The user can choose between the programmed and the closest configuration in
modified rectangular coordinates and in robot coordinates (by chosing DHANDCHK
active or not). Previously the closest configuration was always chosen.

3.5
Movement velocity
The speed of robot movement during program execution depends on the basic and
maximum speeds, programmed in a velocity instruction, and the speed percentage specified
in each positioning instruction. The speed is also affected by the speed correction (the plus
and minus buttons on the programming unit). The preprogrammed basic speed is 1000
mm/s and the preprogrammed maximum speed is 2500 mm/s.
The positioning speed is specified in each instruction as a percentage of the basic speed.
There is however a check that this never exceeds the maximum speed. If an attempt is
made to program an impossible maximum speed, an error message is obtained and the
value is rejected.
Note that speed correction, with the plus (+%) and minus (-%) buttons, is only to be used
for testing of different speeds. The percentage should always be set to 100% when the
finished program is run in production. Otherwise unnecessary speed reduction and jerks
can result in corners.

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Rectangular coordinate system
The programmed velocity refers to the velocity of the TCP. The robot will always try to
reach the programmed velocity, but due to physical limitations, this might not always be
possible for high speeds.
If minimum cycle time is strived for (and robot coordinates cannot be used), it is advisable
to program a realistic velocity. If a velocity which cannot be reached is programmed,
unnecessary delays will be introduced in corners, which will lead to a longer cycle time
than would have been the case with a lower programmed speed.
Wrist reorientation and external axes movements are synchronized with the TCP so
that they are spread evenly over the available path length and all conclude the
movement simultaneously. For large wrist reorientation, the reorientation can set a limit
to the TCP velocity to enable the programmed orientation to be reached at the programmed
position. At low percentage speeds (V% below 10%) the rate of reorientation is reduced
proportionally to the percentage speed value. Note that the rate of reorientation is also
affected by the % buttons.
The external axes velocities are limited by the instruction velocity.
V=100% corresponds to maximum external axes velocity.
Influence of programming functions on the robot velocity:
Programming functions
Programmed
Programmed
Speed correcvelocity V
POS-speed V% tion + %-%
TCP velocity
Reorientation velocity
External axes velocity
Velocity dependent
zone

below 10%
x

x
x

Robot coordinate system

When robot coordinates are active, the robot moves at approximately the speed
programmed.
To guarantee the shortest possible cycle time, the maximum (2500 mm/s) speed should be
programmed. All axes concerned begin and conclude their movements simutaneously and
they all run at constant speed.
The speed of external axes and the robot speed when running in robot
coordinates may supersede the programmed speed!

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3.6
Movement characteristics
Two different modes of path planning can be chosen with the system parameter PATH
(see "Installation S3"). These are path and speed optimization.

3.6.1
Path, optimization
To ensure accurate path performance with the high speed and agility of ABB robots, the S3
controller uses the so called SPF (servo path following) concept
SPF results in optimum path accuracy in rectangular and modified rectangular
coordinates.

Zone
(see section 3.6.2)

500 mm/s PATH

Scale 1:4

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3.6.1.1
Path following principles
SPF keeps the TCP close to the straight line between two programmed positions while
compensating for changing moment of inertia, gravity and robot dynamics without
overshoot.
Path following in rectangular coordinates is carried out by continuously coordinating the
movements of each individual axis to the speed of the axis which limits the performance for
the moment. When a change of direction in TCP movement is programmed, a parabolic
corner path is automatically generated.
The corner path starts at a defined distance from the programmed position. This distance is
called the corner zone or just zone.
Zone
B

automatically generated
corner path

If the robot TCP velocity is too high to take the corner, the incoming velocity is reduced to a
suitable value. A certain speed reduction will also take place within the corner zone.
Because of servo lag logical instructions are executed just before the robot TCP enters into
the zone.
Servo
A

robot TCP is here when

logical instructions
are executed

Programming

lag

logical instructions
are
processed
here by the
controller

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3.6.1.2
Zones
The zone is the distance from the programmed position to the point at which the robot TCP
leaves the straight-line path. The different zone sizes are defined in the system parameters
(S3 Installation) and a suitable zone is selected when programming a position (see 6.3).
The size of the zone is defined in mm or inch, however the value is applicable only when
using rectangular coordinates. When using robot coordinates the zone size might differ
somewhat from that programmed.
The zone can have a fixed size or a velocity dependent size.
The zone has fixed size if the zone size is entered as a positive value. If the value is
entered as a negative value, the zone will be treated as a velocity dependent one.
A velocity dependent zone size corresponds to the defined value (in mm or inches) at a TCP
velocity of 1000 mm/sec and is directly proportional to the velocity. For example in
rectangular coordinates and defined zone value of-25 mm, the zone size at 100 mm/sec is
2,5 mm.
Zone

The figure shows zone size variation due to either:

change in zone definition for position B
change in programmed TCP velocity (if velocity dependent zone is used for B)
The size of a velocity dependent zone is proportional to the programmed velocity VELOC
(section 5.5) and the programmed percentage velocity V % (section 6.1). It is not affected by
the speed correction (-%) (+%) buttons on the programming unit thus, retaining an
unchanged path when testing a program at different speeds.

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If the velocities before and after a programmed position differ, the zone entry and exit sizes
of a velocity dependent zone will differ, and will be directly proportional to the velocity
ratios. The path is automatically generated accordingly.
50 mm

25 mm
Zone

Example: the zone = 50 mm for position B.

Velocity to position B = 500 mm/sec
Velocity to position C = 250 mm/sec
The exit size of the zone is for B

250 mm/s

250
=

x 50 = 25 mm
500

Using zones when programming positions

One of four different corner zones can be selected in a position instruction with the
argument Fine, Path or Comer 1/2. The different zone types will be briefly described in the
following:
1. Position Fine
With argument FINE, the robot TCP moves towards the programmed position, pauses
until all axes have entered, and then goes on to the next instruction. Logical instructions
are carried out within the defined zone.
2. Position Path, Cl or C2
With argument PATH, Cl or C2, a parabolic path is automatically generated at corners.
The TCP moves through the corner without halting. Logical instructions are carried out
before entering the zone as described in 3.6.1.1. With default settings PATH signifies a
normal and C2 a big speed dependent zone wheras Cl signifies a small fixed size (see 6.3
for default values).
A corner can also be programmed with a CIRCLE instruction. In this case three positions
have to be programmed to construct the corner. The result will be a circular arc instead of a
parabola. The deviation from the corner will be bigger than when using zones. The speed
through the corner will be constant in contrast to the zone case (see 3.6.1.3).

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3.6.1.3
Velocity in corners
Highest incoming velocity
If necessary, the velocity when entering the zone is reduced automatically to the maximum
velocity allowed to perform the programmed path without overshoot. The maximum
velocity is a function of the zone size and the corner angle. It can also be limited by large
wrist reorientation.
VELOCITIES

Variation in TCP velocity when passing

through a position zone at high speed.

PROGRAMMED
MAXIMUM INCOMING
MINIMUM

ZONE

TIME

Approximate maximum incoming velocity mm/sec (without large wrist reorientation)

Zone size
(mm)

Corner angle

1
2
5
15
25
50
100

45

90

135

180

40
80
200
600

40
80
200
600

1000
2100
2500

1000
1000
2100

20
40
100
300
500
700
800

15
30
70
200
350
500
700

15
30
70
200
350
400
600

Velocity through the curve

The optimum acceleration and deceleration performance of the axes is used through the
corner. This results in a smooth reduction of velocity along the curved path to a minimum
value, and an increase again to the exit value.
The minimum velocity is proportional to the incoming velocity and is a function of the
corner angle. It can also be limited by large wrist reorientation.
Corner
angle

minimum velocity in % of
incoming velocity

100%
90%
70%
40%
0%

45
90
135

180

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3 Movement principles
Velocity between overlapping zones.
If two postions lie so close that their programmed zones overlap, there will be an automatic
reduction of zone sizes, so as to avoid overlap. The TCP velocity between the two positions will
then also be reduced. The reduction is directly proportional to the reduction of zone size, see the
figure below.
V

I ZONE

I
Entry zone to position

I 2

A = ZONE1

EXIT zone from position A = ZONE2

The X = Vo

ZONE2
ZONE1

Example: The original zone is 15 mm, the positions are 15 mm apart so that the exit zone size for
position A is 7.5 mm. The velocity at X will then be 7.5/15 = 0.5 times the programmed velocity.
The speed correction buttons -% and +%
As mentioned earlier, the speed correction buttons do not affect the size of zones, and the TCP
path is therefore unchanged.
However, the TCP velocity and the velocity of external axes are affected by these buttons, as well
as the rate of reorientation. This will give the possibility to check the path with a lower speed.
This possibility should only be used at testing. The speed correction should be set to 100% in
production.

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3.6.1.4
Corner deviation
The deviation from the corner point is a function of the zone size and the corner angle.
Zone |

V
\

deviation = d

corner angle

Deviation in nun
Zone size
(nun)

Corner angle
45
0

90

135

180

0,2

0,4

0,5

0,5

0,4

0,7

0,9

1,8

2^

2,5

15

5,5

7,5

25

11,5

12,5

50

10

18

23

25

100

19

36

46

50

Note that for velocity dependent zones, the current velocity must of course be taken into
account to calculate the actual zone size.

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3.6.1.5
Exceptions
No corner path is generated after the following instructions and functions:
after a TCP instruction
(section 5.9)
at a FINE position
(section 6.3)
after a SEARCH STOP
(section 6.4)
between two circle segments
on PROGRAM START after
a PROGRAM STOP in a zone
on INSTRUCTION START
on BACKWARD instruction
on WEAVE
on LASERTRAK operations
on manual control with the joystick

(section 6.13)
(section 7.1)
(section 7.2)
(section 7.3)
(section 6.5, 12.4)
(separate document)
(section 2.5)

Zone

POS A FINE
POS B PATH
TCP
POS C FINE

TCP instruction

The TCP is activated at the entry

point to the zone and moves
directly to the next position (argument
FINE recommended)

Program stop

Program stop within the zone of position B.

Forward movement
to C after star

Backward movement
tto B after start

INSTRUCTION START

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Observe that if the velocity is high and/or the programmed points are close, the
instruction execution can be serveral steps ahead of the physical position of the TCP.
This can result man unexpected path at Program Start after emergency stop or similar.

This position instruction

has been executed by the
system before the
emergency stop

Position of TCP when

the emergency stop occurs

TCP position when the

robot stops after the
emergency stop

TCP path after

program start

To avoid collision risk in these situations, the Move Restart function (see 7.10) should be
used instead of Program Start.
Note: Emergency stop or similar connected as" Category 1 safety stop" (controlled stop),
see Installation S3 chapter 3.5, does not cause this phenomenon.

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3.6.2
Speed optimization
Speed optimization is advantagous in applications where problems
are caused by speed reductions. Using speed optimization, the movement
characteristics will be similar to that of ABB robots of M87 model or earlier. This
means, for instance, that there will be no speed reductions due to overlapping corner
zones and that the cycle time will be shorter than for path optimization. Speed
optimization is only described in 3.6.2. In the rest of this manual the default value,
path optimization is presupposed.
The zones used at corners have different meaning and values, depending on which
optimization pridple is used. Path optimization uses a corner zone, showing how far
ahead of a point the control system will begin to generate a parabolic path. Speed
optimization uses a zero zone, showing the servo system how close to the point the
axes should be before driving towards the next point Both type of zones are installed
with MANUAL/PARAM/CHANGE/AUTO/ZONE. If path optimization is chosen,
comer zones will automatically be installed and if speed optimizing is chosen, zero
zones will be installed.

3.6.2.1 Guide text

The below tables show the guide texts used for zero and corner zones respectively.
Instruction texts:
Speed optimization

Path optimization

POS FINE
POS FINE L
POS FINE XL
POS

POS FINE
POS Cl
POSC2
POS PATH

Zone installation texts:

Speed optimization

Path optimization

FINE
SMALL
LARGE
XLARGE

Programming

ZONE
FINE
CORNER 1
CORNER 2

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3.6.2.2

Programming
When speed optimization has been chosen, three different types of fine points and
coarse points can be chosen.
Fine point with SMALL, LARGE or EXLARGE zero zone. The zero zone is
defined with the installation parameter PARAM/CHANGE/AUTO/ZONE.

Coarse point without defined zero zone. You can however define a zero zone also
for coarse points. The coarse point will then work as a fine point.

The accuracy of a programmed point is always the same, independent of whether it is

a coarse point or a fine point, and independeant of the size of the zero zone. The
difference is that with coarse points the next instruction will start when the robot
begins to decelerate towards the point. If the next instruction is a WAFT, the robot
will continue to the point as if it was a fine point For fine points the next instruction
will begin when the robot is within the zero zone for the point.
If you want to use speed optimization for programs programmed for path
optimization, it might be necessary to adjust some points in the program. Also extra
points and wait instructions could be used to obtain the requested path.
Use of coarse points without defined zero zone can cause the same problem as
emergency stop in connection with path optimization. See 3&1.5 for more
information.

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3.7
Circles
Circles are programmed by putting in a circle point between two ordinary positions.
The circle point is used only to define a position on the circle, i.e speed and
orientation are not influenced by the circle point.

3.7.1
Orientation interpolation
There are three different ways to interpolate the wrist orientation in a circular
movement:
Interpolation with CIRCLE = 0
The wrist orientation will be interpolated as during a linear movement. All
reorientation calculations are handled as orientations relative to the base coordinate
system. This means, that the wrist orientation will change from start pos A to end
pos B, without respect to the TCP's circular movement. As in linear interpolation, the
wrist reorientation will always be done in the shortest possible way, i.e. reorientation
during path will always be less than 180 degrees.
Example:

Interpolation with CIRCLE = 1

The wrist orientation will be interpolated as orientations relative to the circle
coordinate system (CCS). This means, that the wrist orientation will change from
start pos A to end pos B, with respect to the TCP's circular movement.
The CCS is a coordinate system which moves along the circle line during
interpolation.
As in linear interpolation the wrist reorientation will always be done in the shortest
possible way, i.e. reorientation during path will always be less than 180 degrees (in
the CCS).

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3 Movement principles
Observe: Only CIRCLE = 1 should be used when running circles in a rotational
EXTFRAME.
Example with small reorientation relative to the CCS:
I

Example with big reorintation relative to the CCS:

Interpolation with CIRCLE = 2

This mode is intended only for special needs and is normally not used. For small
reorientatdons, it is identical to CIRCLE = 1. For big reorientations, the reorientation
will normally be made in the opposite direction, i.e. the longer way.

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3.7.2 Velocity in circle.

The maximum avaiable velocity in a circle is a function of the circle diameter. It can also
be limited by large wrist reorientation.
Variation in TCP velocity
when passing through a
circular path at high speed
VELOCITIES
/

PROGRAMMED
MAXIMUM
IN CIRCLE

1
1
1
1

1
1
1
1

CIRCLE

TIME

Maximum attainable velocity in a circular path (without large wrist reorientation)

2,5 mm
5mm
12 mm
25 mm
50 mm
100 mm
200 mm
400 mm

limited by robot
90 mm/s
130 mm/s
220 mm/s
300 mm/s
450 mm/s
650 mm/s
900 mm/s
1200 mm/s

w ouuimmi (2iH5UUUL TPHMI

10 mm/s
20 mm/s
50 mm/s
100 mm/s
200 mm/s
400 mm/s
800 mm/s
1200 mm/s

3.8
Soft servo
3.8.1
Introduction
The SOFT SERVO function only exists in the MH/GI/SW software.
The SOFT SERVO function enables the operator to:
define 9 sets of "softness percentages"; each set containing a softness value for each
axis
manually activate any of the 9 sets, or normal axis control
program an instruction in the robot program for activation of any of these sets, or
normal control
check the number of the active "softness percentage" set.
When SOFT SERVO for any axis (1-7) is active, a force applied on this axis will cause a
positional deviation from the programmed position. The deviation is directly proportional to
the force (except for frictional effects which are significant for small forces).

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3.8.2
Definition of softness
When the "softness" for an axis has the value 0%, the axis is controlled normally and no
deviation is allowed. If a force is large enough to cause deviation from the programmed
position, an error message is displayed and program execution is stopped.
When the axis is "soft" with percentage value between 1-100, an outer force will cause axis
deviation.
Static loads are automatically compensated, thus the robot will not move at
activation or deactivation of SOFT SERVO, if the load remains the same.
For a specific face, the deviation will increase for increased softness, see fig below

Deviation

1%

Programming

100%

39

Softness

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3 Movement principles

3.8.3
Use of SOFT SERVO
SOFT SERVO is a software alternative to mechanical compliance in
grippers in applications where imperfections in processed objects can be assumed.
Assembly, grinding and polishing are such applications.
SOFT SERVO can also be used to limit the forces caused by the robot on the processed
objects, e.g. assembly of fragile parts such as glass.
"Trial and error" methods in assembly applications can be performed with SOFT SERVO
together with the function "JUMP IF NOT INPOS". This function controls the program
depending on whether the robot has reached close enough to the programmed position or
not.
Different characteristics of SOFT SERVO compliance can be used in the same robot
program.
Soft servo is defined for each axis individually. The purpose is often to obtain "softness" in
a specific rectangular direction and therefore the softness should be defined on those axes
that mainlly are working in that direction. Because of the robots non-rectangular structure
some softness is also obtained in other directions.
Often, an application for soft servo requires a robot TCP movement in one direction while a
force is applied at the TCP in another direction. A robot configuration should be chosen so
that the main movement is carried out by one or two axes and these should be given a
rather "stiff' softness value (for example 10%), while the force is taken up by one axis (with
movement in the direction of the force) and with a "soft" value of soft servo
(e.g. 70% to 90 %). In other words, softness in the axes contributing the most to the TCP
movement should be avoided.
The brakes are activated 30 seconds after the robot has stopped during program execution.
Activated brakes disable softness. If a long period with force on an axis without movement
is required, activate softness immediately after movement has ceased. In this case, SOFT
SERVO will be active for 9 hours until brakes are activated.
Some notes regarding the SOFT SERVO function:
* if SOFT SERVO is active for any axis from 1 to 7 the dynamic performance of all
axes is decreased
* the static load compensation is the same as was valid in the position, when SOFT
SERVO was activated. When the "soft" axes are moved from this position, they will
deviate from the nominal path. This will result in axis movement when the
function is deactivated as the nominal part in resumed.
* Motion speed affects the path strongly when SOFT SERVO is active. Using delays (for
example "WATT 0.5 S") helps keeping the path close to nominal.

When using the Soft Servo function, speed and path are affected!

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3.9
Program displacement
Two different functions are available for program displacement:
Parallel displacement by means of a reference point.
Program displacement by change of reference frame, i.e. displacement of the world
coordinate system.
Both functions mean that all positions in a program are displaced in relation to their
original locations. Both functions should be activated at a FINE position.

3.9.1
Parallel displacement with a reference point (REFP)
Parallell displacement is used for temporary displacement which will change for every new
operation cycle of the robot. A typical application is when the exact location of an object is
being searched for with a sensor, and the following sequence of positions should all be
displaced equally.
Only one reference point can be defined at a time and it is always defined and activated in
the same instruction, POS KEFPOINT. When programming the instruction POS
REFPOINT the position POS1 (see the figure below) is stored in the instruction. When
executing the instruction the robot is in position POS1' after a search operation. The REF
POINT vector (d) defines the displacement of the Object Coordinate System (figure in
section 3.2.1) relative to the World Coordinate System. If no FRAME is active the World
Coordinate System will be the same as the Base Coordinate System.

POS1'

POS1
The reference point vector

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Example
Subprogram 5 includes a movement pattern which must be capable of parallel
displacement For practical reasons, the movement pattern is placed in a separate
subprogram 100.
Program 5:
200 POSV = 50% FINE

The position for the reference point is

defined here. This position would typically
(but not necessarily) be a search position.

210 CALL PROG 100

Execution of program 100 then continues

from this position.

Program 100:
10 POSV REFPOINT ON

20

The reference point is activated in the

position of the robot when instruction 200
in program 5 was executed
The movement pattern (including other
instructions) is performed parallel but
displaced

POS V = 100 %

150 POS V = 100 % FINE

Movement to the final point in the pattern

160 POS V = 0 % REFPOINT OFF

The reference point is deactivated.

170 RETURN

Program execution returns to

subprogram 5.

When the instruction REFPOINT is executed a displacement vector is calculated which is

equal to the difference in position between the point where REFPOINT is executed and the
point where it was originally programmed. All points after REFPOINT will be displaced in
accordance with this displacement vector. See the figure below.
Instruction 10 is executed

Displacement vector
Instruction 10 was
programmed here

Instruction 20 was
programmed here

Instruction 20 is
executed here

Note!
The instructions 10 and 160 are not positioning instructions. Their only purpose
is to activate and deactivate parallel displacement of the program section
between them.

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3.9.2
Program displacement with reference frame (FRAME)
With a FRAME instruction it is possible to displace and reorient all positions in a program
with the same amount. FRAME is used if a more permanent change has occured in the
station, (e.g. the robot has been displaced or a fixture has been moved). The FRAME
function can, however, also be used in combination with search functions to adapt to
temporary displacements of the object, like REF.POINT. The FRAME function is more
powerful than the REF.POINT, as it also allows for rotations, but it is more complicated to
define.
All stored positions in position instructions are expressed relative to the World Coordinate
System WCS (let us suppose that REF.POINT is zero) (see the figure in section 3.2.1). If
there is no FRAME active the WCS will coincide with the Base Coordinate System BCS.
A FRAME instruction however will displace the WCS relative to the BCS with an x, y, z
value and a quaternion value for reorientation (both symbolised by vector FRAME) i.e. the
WCS will be displaced and rotated relative to the BCS. Rotation may be performed around
any axis.
Up to five FRAME-vectors may be stored in frame registers in memory, i.e. FRAME 1 FRAME 5. A FRAME-vector can be defined by dislocation of three positions (see figure
below). This can be done either manually by moving the robot with the joystick or
automatically during program execution. A FRAME vector is stored in the frame register
until it is overwritten by a new definition of the frame with the same number.
If possible, the orientation of the tool should be kept unchanged, to get the highest
accuracy.
POS3'

POS2'

POST
POS1

POS2

DEFINING A FRAME

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When defining a frame in automatic mode, the dislocations are measured with POS FRAME
POS instructions. Suppose that the robot is in position POS1 when programming the POS
FRAME POS 1 instruction (see figure above). The coordinates for this position will be stored
in the instruction. When executing the instruction the robot will be in position POSl',
perhaps after a search operation, and the dislocation vector d will be calculated. The same
operations are performed for POS2 and POS3. After this the execution of a FRAME 1
DEFINE instruction will calculate the FRAME vector from the three dislocation vectors and
store the result in FRAME 1 (the same will go for FRAME 2-5). Please observe that no real
dislocation of the following stored positions is performed yet. This will not happen until
FRAME 1 is activated with a FRAME 1 instruction.
A new FRAME may be activated while a former one is still active. This will give an
accumulated displacement. This should however be avoided since the accuracy will be
suffering. Thus an active FRAME should be deactivated a FRAME 0 instruction before a
new FRAME is activated. Also observe that through both FRAME instructions and POS
REFPOINT instructions can be active at the same time.
Three positions are included in the definition of a program displacement. In order to
succeed with the definition, the three positions must be located as below:

In a triangle.
> 100 mm from each other.

Position 1 must be defined with the high accuracy.

Position 2 defines the direction of the line between POSl and P0S2 and can be
positioned anywhere on the line.
Position 3 defines the orientation of the plane through POSl, POS2 and POS3
and can be positioned anywhere in the plane. See figures below.
Position 1 defines the new location for position (1):

(1)

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Position 2 defines the new direction, for the line (1) - (2), as 1 - 2:

Displacement
in relation to 1

Position 3 defines the new position of the plane (1) - (2) - (3), as 1 - 2 - 3:

(D&(2)

Displacement
in relation to 1 and 2

(3)

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3 Movement principles
As the direction only is important, position 2 can be placed as in the figure below:

2 can be
placed here

As the position of the plane only is important, position 3 can be placed according
to the figure below:

3 can be
placed here

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3.10
Singular points
Singular points are points in the robot working range where the axis of rotation of two
robot axes coincide. Sometimes, when driving the robot in rectangular coordinates, this will
cause very big robot axes movements or movement stop (with error message). To overcome
this problem when jogging with the joystick, the robot coordinate system should be chosen
when the point is to be passed.
In the case of program execution, singular point problems can be handled by the following
instructions:
MODRECT COORD

enter the modified rectangular coordinate system before the

positioning instruction at which the problem occured. This means
that linearity and speed are preserved but the wrist orientation
may change.

RECT COORD

return to the rectangular coordinate system after the problem

area.

Of course MODRECT COORD can be used throughout the program if the orientation is of
minor inportance.
Another type of singularity occurs when the wrist rotates around the z-axis of the Base
Coordinate System. To meet this, the following limitations are introduced:
The wrist center can not move through a prohibited zone with the radius 2 cm in
rectangular coordinates. A pass-through can be performed in robot coordinates.
When running in MODRECT coordinates, the TCP as well must not be located inside a
corresponding prohibited zone around the z-axis. The radius of the zone in question
varies and can as a maximum reach a size equal to the TCP vector, depending on the
TCP orientation at the pass-through.
It is not possible to program a point with the wrist center inside the prohibited zone.

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Programming

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4 Operation

Operation
Section

Page

4.1 Start
4:3
4.1.1
Power on, power off, synchronization
4.1.2
Program Execution
4.1.3
Stop
4.2 Restart after power failure
4:5
4.2.1
General
4.2.2
Automatic restart
4.2.3
Manual restart
4.2.4 Restart from PLC
4.3 Languge selection
4:8
4.4 Software configuration
4:8
4.5 Program information
4:9
4.6 Error buffer
4:10
4.7 Disk handling
4:11
4.7.1
Initialize disk
4.8 Computer link
4:13
4.8.1
General
4.8.2
Commands to robot
4.8.3
Commands from robot
4.8.4
Spontaneous status messages
4.8.5
Request for superior control
4.8.6
Operation status
4.9 Register
4:15
4.9.1
Register
4.9.2
Position registers, location
4.10 Inputs and outputs
4:17
4.11 Ports
4:17
4.11.1 Digital ports
4.11.2 Analog ports
4.12SYSTEM-I/O
4:22
4.12.1 Standard SYSTEM-I/O, inputs
4.12.2 Standard SYSTEM-I/O, outputs
4.12.3 Additional SYSTEM-I/O at I/O MAP
4.12.3.1 Summary of HOLD, HOLD RESET and AUTO INPUT
4.12.3.2 Inputs
4.12.3.3 Outputs
4.13 Remote control panel signals, panel- I/O
4:28

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4 Operation

Programming

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4 Operation
4.1

Start
4.1.1 Power on, power off, synchronization
Power on
Before the robot is started, ensure that the working range ofthe robot is
unobstructed and that no person is in any dangerous zone.
The robot must be 'left alone" during the initiation.
The initiation is ended by displaying the text shown below at the same time as all the panel
and programming unit lights are lit for 3 seconds.
"ABB ROBOT SYSTEM AT YOUR SERVICE"
SOFTWARE FOR IRB XXXX
After the initiation followed by MOTOR ON command a safety test is performed. This will
cause the robot movement, initiated by a program start or by the joystick, to be delayed
about 10 sec.
Power off
First, stop any program execution. Then bring the robot to the MOTOR OFF mode.
Turn off the mains switch.
When the robot is switched a&, all outputs are reset This may affect the
peripheral equipment and grippers which in turn might cause damage.
The memory utilizes battery backup, and is not affected by mains switched off.
Synchronization
If optional external axes are not equipped with absolute measurement system, the MOTOR
ON lamp will start flashing when the robot is taken to the MOTOR ON mode for the first
time after initiating. This is to indicate that the robot has not been synchronized.
Press the programming unit SYNC button to synchronize the external axes. The MOTOR
ON lamp will be on steadily when the synchronization is completed.
When SYNC is selected, the external axes immediately start moving.
Make sure nobody is inside any dangerous zone.

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4 Operation

4.1.2 Program Execution

Programs can be executed only in the MOTOR ON mode.
Position instructions can be executed
Instruction by instruction forward
Continuously forward
Instruction by instruction backwards
Other instructions can only be executed forwards, instruction by instruction or
continuously. When executing backwards, other instructions have to be skipped, using the
SKIP BW button.
When a programmed movement is executed, the robot always moves towards the
programmed position irrespective of where the movement began.
When the operating mode selector is in any of the positions MANUAL REDUCED SPEED
or MANUAL FULL SPEED, built-in safety functions ensure that:
The robot can not be controlled via the remote control or computer link.
The enabeling device must be operated to switch to the MOTOR ON mode.
The button starting the execution must be kept depressed (HOLD TO RUN)
When the operating mode selector is in the MANUAL REDUCED SPEED position,
the following also applies:
The robot programs are executed at max. 250 mm/s.
The HOLD TO RUN-function can be deactivated by a system parameter

4.1.3 Stop
Program execution may be stopped in several ways:
manually, by releasing HOLD TO RUN
manually, using the programming unit STOP button.
manually, using the remote control STOP button.
automatically, using the program stop digital input (system I/O)
automatically, using programmed stop in the robot program
automatically, due to a system fault
Note!
Program execution stop performed in one of the above mentioned ways results in
a shortest possible smooth stop on the path. Release of the enabling device in
MANUAL mode or use of any switch in the MOTOR ON chains will activate the
brakes immediately causing the robot to stop without path control.
Note!
Stopping program execution in the MANUAL REDUCED SPEED and MANUAL
FULL SPEED modes should be done by pressing the PROG STOP button on the
programming unit before releasing the safety pad. Otherwise the braking is done
more harshly since hardware is performing the braking (safely demand).
NandR
On program stop, an R (ready) is shown at the right hand side of the second line of the
display if the current instruction is completed. An in completed instruction is shown by the
letter N (not ready). (An instruction can be executed twice by entering the Editing menu
between the two executions).

Programming

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4.2
Restart after power failure
4.2.1 General
By using the automatic restart function program execution can be resumed at the
instruction interrupted by a power failure. Automatic restart can be performed at:
the programming unit
a remote control panel
a superior computer
A robot system provided with absolute measurement need not be synchronized before
restart, as the measurement system automatically registers the robot position anywhere
inside the working area. Calibration of the measurement system is performed during
installation. See the Installation S3.

4.2.2 Automatic restart

When automatic restart is possible, the following apply:
The MOTOR ON lamp is flashing
The text RESTART POSSIBLE is shown on the display of the programming unit,
together with soft key texts CH OUT (check outputs) and NO RSTRT (no automatic
restart).
One of the following four alternatives is selected:
1. MOTOR ON command is issued
2. Press CH OUT on the programming unit
3. Press NO RSTRT on the programming unit.
4. Restart from PLC i.e. by remote panel, see chapter 4.2.4.
1. This commences a procedure for a simple automatic restart without output checks:
1A MOTOR ON command
IB RESTART command
1C START PROGRAM or MOVE RESTART or AW RESTART commmand. The robot
will then continue the program where the interruption occurred.
2. This allows checking output values before the automatic start is activated:
2A press CH OUT (check outputs) on the prog. unit.
2B enter the logical number of the output to be checked.
2C
CHANGE the ouput value, or check the next output
2D when outputs are checked press BREAK and the MOTOR ON button.
2E Press RESTART on the programming unit. The start can be aborted by
pressing NO RSTRT (no restart) on the prog unit.
2F Press the START PROGRAM button or MOVE RESTART or AW RESTART
button on the programming unit.
The robot will then continue the program where the interruption occured.
3. This allows a manual restart as described in the next section.
On pressing RESTART the first line of the Automatic Menu is displayed on the
programming unit The robot prepares automatic restart of the program. This means that
the following functions will be set as before the power failure:
Digital outputs. (As an alternative, outputs can be set to a status as explained above)
All registers.
Programming

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4 Operation

TCP and FRAME.

Reference point.
The calling sequence between the different subprograms.
The speed correction.

Note!
Analog outputs are cleared.

4.2.3 Manual restart

Manual restart is performed when:
The system parameter for automatic restart has been deactivated.
The operator selected NO RSTRT, i e manual restart on the programming unit.
The robot is too far from the programmed path (error message displayed).
Any of the buttons EDIT or MAN was pressed after program execution or the robot was
moved manually by means of the joystick before the power failure occurred.
The robot, or an external axis, is outside the working area (error message displayed).
An instruction, which cannot be restarted was performed at the power failure (error
message displayed).
The internal close-down of program execution failed (error message
displayed).
Manual restart means that:
The first instruction in program 0 is presented.
All outputs are reset.
TCP 0 and FRAME 0 are activated.
REFPOINT is deactivated.
The absolute speed is set to 1000 mm/s and the speed correction to 100%.
Manual restart is performed as follows:
1. Go to MOTOR ON status.
2. Restart the program running from a suitable instruction in the main program.
All calling sequences has disappeared, caused by the power failure. Run the robot
manually to a suitable position.
3. Check the status for digital outputs, and values in registers, and change if required.
When everything is ready, start program running.
Program start (PROG ST, INS ST, EXEC BW, AW REST) means that the robot will move
at high speed.
Make sure nobody remains inside the robot working range and tiiat all safety
equipment is functioning correctly.
Before program execution is started make sure the robot is in a suitabe position.

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4.2.4
Restart from PLC
After a power failure the logic for a pic can be like the following:
Read output SYNC.
When SYNC is high (after lamptest which is approx 3 seconds) then set input MOTOR
ON with a pulse.
Read the output MOTOR ON.
When MOTOR ON is high, set input SYNC with a pulse.
When output SYNC is low, start program execution by either PROG START or MOVE
RESTART.
See chapter 4.12 and 4.13 for definition of the signals. (If MOVE RESTART is desired, I/Omap has to be used.)

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Programming Unit

Control Panel
gync lamp lit on
remote control panel

RESTART POSSIBLE

MOTOR ON via
control panel/remote
control panel

RESTART (sync
input) via remote
control (sync lamp
goes out).

START PROGRAM
via remote control

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4.3
Language selection
The dialog with the robot system can be performed in ten different languages: English,
German, French, Dutch, Spanish, Italian, Portuguese, Finish, Japanese (katakana) or
Swedish.
The language used can be changed, at any time during the course of the dialog. Not only
the menus, guide questions and messages presented on the display are changed, but all of
the robot programs are presented in the new language.
Language is changed according to the following:
1.
2.
3.
4.
5.

Put the robot system in the MOTOR OFF mode.

Press the MANUAL button.
Press the SCAN button until a menu containing an asterisk (*) is shown.
Press the button directly under the asterisk.
Select the language from the menu.

The asterisk is there to simplify finding the language function, no matter if the langauge
presently on the display is not understood by the operator.

4.4
Software configuration
The code for the software supplied in the controller can be read on the programming unit
display or on the Monitor. When the programming unit display shows ERRORS, these
should be scanned through by pressing the SHIFT button until finally details of the
software configuration are shown.
Robot type

Program
version

Program
revision

Year

Week

Model

.*-:.>:M.-:*:~^-.^^W.^.V.-.W.^W.^-.W.^^

IRB 60002,4-120

"Programming

NB/6 9412 M93/6

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4.5
Program information
Program information is available by using the SHIFT button. The following example shows
what information is displayed:
100 POS V = 100% FINE

X= 143.3 Y = 311.4 Z = 861MM

A = 32.4 B = 13 C =-36.3 DEGREES

Euler angles for the

programmed position.

PROG 10 TCPO FRAME 0 REFP

ROBOT COORD

V=1000MM/S 100%

100 POS V = 100% FINE

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4.6
Error buffer
The system contains an internal error buffer, which can store 9 error messages. In the
buffer the system stores:
All kinds of error messages (both system errors and operator errors), occurred at the
latest error occasion.
Earlier messages about system errors.
The system can, on request, present the contents of the error buffer via:
The programming unit. (Just error messages from the latest error occasion.)
A printer, if the optional function Program printout is provided.
A monitor, if this optional function is provided.
Display on the programming unit of error messages.
The programming unit displays one error message at a time, according to the following:
When the system stops running due to an error, the operator will see the first
error message. An arrow on the display indicates if there are any consequent errors. In
this case the operator can display these messages also, one by one.
During manual operation the operator can, on request, display stored messages from
the latest error occasion, one by one. The error messages are chronologically displayed.
For most error messages, it is possible to get text in plain language by pressing "" on
the programming unit.
Display on the monitor of error messages.
The monitor displays all the messages within the error buffer, according to the following:
When the system stops running due to an error, the operator will see all messages
in plain language, occurred during that error occasion. The error messages are
chronologically displayed.
During manual operation the operator can, on request, display all stored messages. The
error messages are chronologically displayed. The oldest message on top of the list.
Printout of error messages.
During manual operation the operator can, on request, display all stored messages.
The error messages are chronologically displayed, the oldest one on top of the list.
EIrasure of the contents in the error buffer and display of text in plain language.
During manual operation the operator can, on request, erase all messages stored in
the error buffer.
On request, the operator can get text in plain language for most error messages.
On request, the operator can load the texts in plain language from disk
(See Installation S3).

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4.7
Disk handling
The disk drive is used for storage and loading of robot programs, system parameters and
program parameters. 3.5"-2DD (two side, double density) IMbytes disk are used.
A block corresponds to the whole contents of theuser memory, including main program, all
subprograms and program data.
Up to 7 program blocks with different numbers can be stored on each disk, in addition to
system parameters, and program parameters (See Installation S3 for system parameter
information).
Program blocks can have numbers from 0 to 9999. Program blocks stored previously are
written over if a new block with the same number is entered for storage.

4.7.1
Initialize disk
Anew disk must be initialized before being used. The contents of a disk used previously
will be erased by initializing the disk again.
A disk can only be initialized when the robot is in MOTOR OFF mode.
The procedure is described in section 9.2.3.

S3

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4.8
Computer link
4.8.1
General
Connections to the Superior Computer are point-to-point as shown below.

SC
.

IRB1

IRB5 1
IRB4

IRB2
1KB 3
4.8.2
Commands to robot

A large number of commands can be given to a robot from the superior computer (SC). Each
command must be acknowledged by the robot. The different types of commands are
described below:
Loading of program blocks or individual programs from the SC.
Start or stop of program execution.
Reading and writing of
robot data
process data
Reading of the current status of the robot
Position of active TCP, wrist and external axes
Change of robot mode (MOTOR OFF, MOTOR ON etc)
Control of IRB from S.C. by means of X, Y, Z and wrist position and orientation
coordinates.
Note: While the robot program is executing logical (i.e. non-position) instructions,
commands from SC can not be received. Therfore if a long sequence (approximately 15) of
logical instructions is executed, e.g. in a loop waiting for an input, occational WAIT 0.1s
instructions should be entered so as to allow receptions of SC commands.

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4.8.3
Commands from robot
A few commands can be initiated manually from a robot to the SC via the programming
unit:
Storage or loading from the SC of program blocks or an individual program (for arc
welding robots even weld data, see chapter 12).
Storage or loading from the SC of system data.

4.8.4
Spontaneous status messages
When certain events occur in the robot, a message is automatically transmitted to the
superior computer. The message contains information regarding the current robot status
with respect to:
Robot mode (MOTOR OFF, MOTOR ON, PROGRAM EXECUTING or EMERGENCY
STOP).
The operating mode selector in position AUTO or MANUAL REDUCED
SPEED/MANUAL FULL SPEED.
Interrupt via direct acting inputs (permitted or not permitted).
Active program and instruction number
Position of active TCP, wrist and any external axes.
A spontaneous status message is transmitted each time:

The instruction SUCTRL is executed. See section 4.8.5

Emergency stop is tripped.
Search stop is given.
Program execution is stopped manually.
The operating mode selector is switched between MANUAL REDUCED SPEED and
AUTO (not between MANUAL REDUCED SPEED and MANUAL FULL SPEED).
Faults which activate error codes occur.
The robot is powered on.

4.8.5
Request for superior control
The robot will send a request for superior control to the SC by executing the instruction
SUCTRL. The instruction can have a combination of functions for program stop and
register information.

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4.8.6
Operation status
A robot can be run in two different operation modes:
Local operation mode, when the robot control system does not accept commands from an
SC.
Remote operation mode, when commands from an SC are processed by the robot control
system.
The different operation modes can be selected manually using the Programming Unit.
After power on, the remote operation mode is obtained automatically if the robot is
configurated for a computer link.
The robot can be programmed in either operation mode. It is however necessary for the
local operation mode to be selected when programs are transferred to and from disk and
when function parameters are changed. The remote operation mode must be selected when
the above operations are to be performed with the SC.
All functions are allowed in the AUTO mode, but the following are not allowed in the
MANUAL REDUCED SPEED and MANUAL FULL SPEED modes when issued from a
S.C.
Write to frame register
Write to program/block
Order MOTOR ON and SYNC
Start of robot program
Write arc weld data
Write to sensor register
Write parameters
Write to TCP register *
Write to location register *
Write to register *
Write to digital output *
E

Erase program
Load program/block from disk
Write positioning data
Write to analog outputs

Allowed from control program M93/2.

4.9
Registers
4.9.1
Register
Control of program or peripheral equipment is performed on the basis of a value in a
numerical register.
The system contains 120 numerical registers, number 0 -119, where one integer value at a
time can be stored. When a new value is stored, the previous value is written over.
Permitted values range from - 32 768 to +32 767.
During program execution, a numerical value can:

Be stored directly.
Be stored indirect from a digital or an analog input port.
Be sent to the peripheral equipment via a digital or on anlogue output port.
Compared with another value in a jump instruction.

Be added, subtracted, multiplied or divided with another register value.

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Be a:
- Program number at an indirect call of a program.
- Position register number when running to a stored position.
- Block number at indirect read of a block from diskette.
Define a value for a robot position
Specify which module in a pattern program is to be called.
Define displacement or rotation of a location, or a position, defined by one of the
instructions POS LOC, POS POS or RELTOOL (not on ARCW software).
Define the current position in a pallet (not on ARCW software).
It is possible to manually check and change the value in one register at a time.
The register instruction is used for:
Storing a value into a numerical register directly or via other registers.
Fetching a value from a port.
Transferring a value from a register to a port.
Arithmetic handling of the register value.
Entry of location coordinate values.
The manual function is used in checking and editing the program.
The robot reacts immediately as soon as a manual or a programmed command, as described
above, is concluded.

4.9.2
Position register, location
Means:
Storage and reuse of a position in a position register during program execution as an
argument in positioning instructions.
Facts:
When using a position register there is a difference between location and position.
A robot location is only three coordinates in the memory, i.e. the TCP location.
Positions of external axes are also saved.
A robot position is, besides of the TCP coordinates, also the tool orientation and the
positions of external axes (provided that any one of the position registers 0 - 95 is used).
(Arc welding robots only)
By activating/deactivating a parameter (REF POINT MODE) it is possible to
compensate/not compensate for the influence by an active reference point.
Used:
When the same position is to be used for the tool several times during a work cycle.
When a programmed position is to be displaced step by step each time the tool moves to
the position.
Executed:
By the STO POS-instruction, the TCP location, the tool orientation and the positions
for the external axes are stored in a position register.
By the POS POS-instuction a position is programmed in such a way that the robot, during
program execution, will move to a stored position with the tool orientation stored.
The position can be provided with an offset if required.

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4 Operation
The offset can be given in three different ways:
1. Entered from the programming unit as x, y and z values when programming the POS
POS instruction.
2. Entered by moving the robot with the joystick the distance wanted, when programming
the POS POS instruction.
3. The x, y and z values are read from three numerical registers when the instruction is
executed. When the POS POS instruction is programmed the number of the referred
numerical registers are given. In this way the offsets can be changed dynamically while
the program is running.
By the POS LOC-instruction a position is programmed in such a way that the robot, during
program running, will move to a stored location with the current tool orientation. The
location can also be provided with an offset if required.

4.10
Inputs and outputs
Means:
The robot and peripheral equipment communicate via inputs and outputs of both digital
and analog types. The analog version is described under "Ports".
Facts:
A digital input or output can have one of two different statuses, "1" (voltage) and "0" (no
voltage). Via the outputs, the robot transmits information and commands to the peripheral
equipment and the corresponding information from this is received at the inputs. The
setting of outputs to 1 or 0 is managed by special instructions during program execution
and such an instruction applies until a similar but contradictory instruction is encountered
during the execution.
A manual function permits:
checking of the status of individual digital inputs.
checking of digital outputs individually. It is also possible to make, an immediate
correction when the status of an output is found out to be faulty.
It is also possible to invert an output and to send a negative or positive pulse of 200 ms
duration via an output (short change of the current status of the output).

4.11
Ports
A port is a group configuration of digital inputs/outputs or a single analog input/output. It
is possible, in a user program, by using REGISTER instructions (section 5.8) to connect
register 0-119 to ports. The connection is temporary and is only active in connection with
execution of REGISTER instructions. The normal functions of the digital inputs/outputs in
other program sections is not affected.
The function permits:
The accessing of the status of a group of digital inputs for storage in a numerical
register. The status of each of the inputs is given by a binary digit, "1" (closed input) or
"0" (open input), and the binary value formed is stored in the register.
Transmission of the binary value in a register to a group of digital outputs for setting
these to one or zero. The value is coded in binary form, "V (active output) or "0"
(inactive output).

Programming

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4.11.1
Digital ports
In this context a group is either 4 inputs/outputs (ports 1,2,11 or 12) or 8 inputs/outputs
(port 3, 4, 13 or 14). There are two 16 bit ports, 70 and 80, which embrace both inputs and
outputs. Two analog outputs, port 21 and 22, are used in arcwelding and glueing software,
see chapter 12 and 13.
The group configuration of inputs/outputs for ports 1-4 and ports 11-14 are shown in the
table below. (LSB means Least Significant Bit and MSB means Most Significant Bit".)
Port no.

Output no.

Logical output

First bit (LSB)

3
4
13
2

14
15
16

17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

Last bit (MSB)

First bit (LSB)
>
>
Last bit (MSB)

*
'
1.astbit (MSB)

0-15

0-15

0-255

0-255

No. of bits

Value in register

0-15

0-15

0-255

1Last bit (MSB)

Logical input

1First bit (LSB)

11

2
4

]Last bit (MSB)

13
14
15
16

]First bit (LSB)

]Last bit (MSB)

17
18
19
20

]First bit (LSB)

13

1^rst bit (LSB)

Input no.

12

Value in register

First bit (LSB)

Port no.

No. of bits

Programming

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4 Operation
21

22
23
24

>

Last bit (MSB)

25

First bit (LSB)

26

27

28
29
30
31

14

32

0-255

1^astbitCMSB)

The use of port 70 and port 80

The ports number 70 and 80 are used to transmit 16 bits binary values. The transmission
is sequential and divided into four sections with four bits each time. The robot system and
the peripheral equipment "shake hands" between each section.
Before the start of the transmission of the 16 bits, a control word of four bits is sent to the
peripheral equipment. The value of this word, between 0 and 15, is determined by the
register number. If a higher register number is used, the value will be Reg. no MOD 16, i.e
the remainder of an integer division by 16. E.g. Reg.no. 16= Control word 0, Reg.no 17=
Control word 1, and so on.
In the user program it is only necessary to specify transferring or fetching of data to or
from the different ports. The robot system then automatically manages all signal handling
until the transmission is complete.
The table below shows the configuration of inputs/outputs for ports 70 and 80. The number
of bits is 4 x 4, and the value in the register can be between -32.768 and +32.767.
Port no.

70

Output no.
1
2
3
4
5
6

Logical in/output
First bit (LSB)

80

Outputs 1-4 used for control word and data

Last bit (MSB)

Outputs 5-6 used for handshaking during
data transmission

Input no.
5
Input no.
1
2
3
4
5

Note

Input 5 is used for handshaking during data

transmission
First bit (LSB)

Inputs 1-4 used for data

Last bit (MSB)

Input 5 is used for handshaking during data
transmission

Prograi

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4 Operation
Output no.
1
2
3
4
5
6

First bit (LSB)

Outputs 1-4 used for control word

Last bit (MSB)

Outputs 5-6 are used for handshaking during

data transmission

There is a time supervision in the robot. If input 5 is not inverted within 400 ms after
output 6 is inverted the program execution will be stopped.
When transmitting via Port 70 it is never checked that data bit 0-3 has been read input 5
inverted.Therefore a waiting time in the program will secure that data has been
transmitted correctly before output 1-4 is changed.
Activity sequence at data transfer to port 70
Robot

External equipment

Set output 6
Transmit control data to outputs 1-4
Invert output 5

Wait 2 ms
Read the control word
Invert input 5

Transmit bits 12-15 to outputs 1-4

Invert output 6
Wait 2 ms
Read data
Invert input 5
Transmit bits 8-11 to outputs 1-4
Invert output 6
Wait 2 ms
Read data
Invert input 5
Transmit bits 4-7 to outputs 1-4
Invert output 6
Wait 2 ms
Read data
Invert input 5
Transmit bits 0-3 to outputs 1-4
Invert output 6
Wait 2 ms
Read data
(Invert input 5)

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4 Operation
Activity sequence at data fetching from port 80
Reset output 6
Transmit control data to outputs 1-4
Invert output 5
Wait 2 ms
Read control word
Transmit data, bit 12-15 to inputs 1-4
Invert input 5
Read data from input 1-4
Invert output 6

Wait 2 ms
Transmit data, bit 8-11 to inputs 1-4
Invert input 5

Read data from inputs 1-4

Invert output 6

Wait 2 ms
Transmit data, bit 4-7 to inputs 1-4
Invert input 5

Read data from inputs 1-4

Invert output 6

Wait 2 ms
Transmit data, bit 0-3 to inputs 1-4
Invert input 5

Read data from inputs 1-4

Invert output 6
Reset outputs 1-4

4.11.2
Analog ports
For analog input/output signals there are four ports , numbered according to the table
below. The same REGISTER instructions as for digital ports apply.
Corresponding
Port no.
21
22
23
24

Output no.
1
2
3
4

Limit values
0- 10 V
0- 10 V
0- 10 V
0- 20 mA

Port no.
31
32
33
34

Input no.
1
2
3
4

Limit values
0- 10 V
0- 10 V
0- 10 V
0- 10 V

Programming

Register values
0- 1024
0- 1024
0- 1024
0- 1024
0- 1024
0- 1024
0-+ 1024
0- 1024

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4.12
SYSTEM-I/O
System-I/O is a group of functions which can be selected in two ways, either as a standard
set according to the list below, or as a flexible set decided by the user (see Installation S3).
The selection is done by defining the I/O USE - SYS parameter in PREDEFINED
(standard) mode or in I/O MAP (flexible) mode. In the standard mode only the I/O-board
position, preferrably the last one, has to be selected. The input and output channels no. 9-.,
16 will then be occupied. In the flexible mode the functions desired can be selected on any
board and any channel.

4.12.1
Standard SYSTEM-I/O, inputs
There are 8 inputs which can control the execution of the user program from outside. The
robot to reacts on an input signal if:
the instruction ENABLE INTERRUPT is executed in the user program before any of
INTERRUPT INSTRUCTION, INTERRUPT PROGRAM, JUMP TO PROGRAM is
used.
the input signal is changed from "0" to "1* (the input is closed)
Combined input signals must be delayed in relation to each other by at least 10 ms and
activated in the correct sequence to make sure that they are processed in the correct order
and interpreted correctly by the robot.
Input channel on
board selected

Function

INPUT CH 9

Interrupt instruction
When the signal is activated, the robot interrupts the execution of
the current instruction. Execution of the next instruction in the
program then begins.
Interrupt program
When the signal is activated, the robot completes the execution of
the current instruction. The program execution is then stopped.
Interrupt instruction before Interrupt program.
When the signal combination is activated, the robot interrupts the
execution of the current instruction in the program. Execution of
the next instruction in the program is then begun. The robot
completes this and program execution is then stopped.
Interrupt program before Interrupt instruction.
When the signal combination is activated, program execution is
stopped immediately.
Jump to program
Each one of the inputs is connected to a fixed subprogram:
Input channel 11 to subprogram 1.
Input channel 12 to subprogram 2.
Input channel 13 to subprogram 3.
Input channel 14 to subprogram 4.
Input channel 15 to subprogram 5.

INPUT CH 10
INPUT CH 9 and 10

INPUT CH 11-15

When one of these signals is activated, the robot first completes

execution of the current instruction. The associated subprogram is
then called and executed. Then execution continues in the program
that was interrupted. Only one signal at a time may be activated.
Programming

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4 Operation
INPUT 16

Arc weld restart (AW only)

When this signal is activated, the program execution is restarted
with a correct set of arc weld data.

INPUT CH 9 and one of INPUT CH11-15

Jump to program before Interrupt instruction
When the signal combination is activated, the associated subprogram is called immediately
and executed. Then the program that was interrupted is contiuned by repeating the
interrupted instruction.
Interrupt instruction before Jump to program
When the signal combination is activated, the robot interrupts the execution of the current
instruction and execution of the next instruction in the program is completed. The
associated subprogram is then called and executed.When the sub program is finished, the
interrupted program is resumed at the next instruction after the last completed.
Jump to program only
The current instruction is executed before the subprogram is called. When the subprogram
is finished, the interrupted program is resumed at the next instruction after the last
completed.

4.12.2
Standard SYSTEM-I/O, outputs
There are 7 outputs for indication of the status of the robot:
Output channel on
board selected

OUTPUT CH 9

Function

Gripl
Grip/release - activation of gripper no. 1

OUPUT CH 10

Grip 2
Grip/release - activation of gripper no. 2

OUTPUT CH 11

MOTOR ON
An active signal indicates that the robot is in the MOTOR ON
mode, i. e. that voltage is applied to the motors.

OUTPUT CH 12

Cycle on
An active signal indicates that program execution of the robot is
in progress. When execution instruction by instruction, the signal
is deactivated when the instruction is completed.

OUTPUT CH 13

Cycle Error
An active signal indicates a malfunction in the robot during
program execution. Error code is displayed.

OUTPUT CH 14

MANUAL mode
An active signal indicates mode MANUAL REDUCED SPEED or
MANUAL FULL SPEED.

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OUTPUT CH 15

4 Operation
Search stop
An active signal indicates that searching function has been
stopped by a sensor signal.

4.12.3
Additional System I/O at I/O MAP
4.12.3.1
Summary of HOLD, HOLD RESET and AUTO INPUT
Stoping of program exection followed by MOTOR OFF mode is possible by to active HOLD
command. If the operating mode selector is in AUTO it is possible to resume program
execution with one commend by either AUTO INPUT or HOLD RESET.
Presumption: Robot in AUTO mode and a program is executing. An (EXT) HOLD stops
program execution, sets HOLD-ACK and sets MOTOR OFF. If the operating mode selector
remains in AUTO, it is possible to resume program execution again by AUTO INPUT (or if
SYSTEM AUTO is set by (EXT) HOLD RESET).
HOLD-ACK indicates that the robot has been stopped by HOLD and has to be started by
AUTO INPUT or (EXT) HOLD RESET. HOLD-ACK can be reset by MOTOR OFF.
See time chart.
The following signals are involved in this functionality:
Inputs
HOLD
EXTERNAL HOLD
HOLD RESET

EXTERNAL HOLD RESET

AUTO INPUT

Outputs
HOLD-ACKnowledge

SYSTEM AUTO

Each of the signals covered in this chapter have to be defined in the I/O-MAP before they
can be used. The exception is HOLD which is not always part of the SYSTEM I/O but is
involved in the functionality. HOLD is inputs to the System board DSQC 256A in robots
from M93.
EXTERNAL HOLD is nearly indentical to HOLD.
EXTERNAL HOLD RESET is indentical to HOLD RESET.
In the following text the term "(EXT) HOLD" symbolized any of HOLD and EXTERNAL
HOLD. (EXT) HOLD RESET is equals to any of EXTERNAL HOLD RESET and HOLD
RESET.
The (EXT) HOLD is an inverted signal i.e. it is activated when it goes from 1 to 0 and
passive when it is high.
Examples of some simple ways to utilze this functionality.
A. If no signals are defined in a robot equipped with DSQC 256A:

- A program execution can be stopped followed by a delayed MOTOR OFF in one step
by HOLD on the System board. When the signals become passive it is possible to
resume program execution by commending MOTOR ON and Program Start.
(If the robot doesn't have DSQC 256A, (EXT) HOLD has to be defined to get the
same functionality).

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4 Operation
B. If AUTO INPUT is defined. After commanding (EXT) HOLD, the program execution
can be resumed by AUTO INPUTafler that (EXT) HOLD has been set passive. AUTO
INPUT carries out MOTOR ON , reset HOLD-ACK, executes Program Start and sets
SYSTEM OUTPUT, if it is defined.
Note the following columns in the time chart.
Column 4 (EXT) HOLD RESET when SYSTEM AUTO is reset. (Compare column no 7.)
Column 5 AUTO INPUT starts program execution instead of (EXT) HOLD RESET.

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MOTOR ON

n_

MOTOR OFF
PROG START

(EXT) HOLD
(EXT) HOLD RESET

AUTO INPUT

n
n

EMERGENCY STOP
O

MOTOR ON

CJ

MOTOR OFF

>

CQ

CYCLE ON

2)

SYSTEM AUTO
HOLD ACKNOWLEDGE
ERROR
1) Aprox 1 sec. after cycle on -0
2) 0.5 sec. after motor on
3) ERROR lamp
4) ERROR IN AUTO. Cycle error and ERROR lamp

3)

4 Operation
4.12.3.2
Inputs
HOLD and EXTERNAL HOLD
HOLD (HOLDl and HOLD2) carries out a program stop by the software. Connected in the
MOTOR ON chains, the hardware on system the board delays MOTOR OFF by approx. 1.5
sec.

EXTERNAL HOLD executes both program stop and sets MOTOR OFF by software.
(If the robot is not equipped with the system board DSQC 256A, HOLD can be defined by
I/O MAP and consequently only executes a program stop.)
AUTO INPUT
1) If program is executing, AUTO INPUT, will set the output SYSTEM AUTO.
2) If program execution is stopped by (EXT) HOLD, AUTO INPUT will start program
execution. (HOLD ACK must be set and HOLD passive.) HOLD ACK is then reset
and SYSTEM AUTO is set
Note. Neither of the outputs HOLD ACK and SYSTEM AUTO have to be defined to get
this functionality.

HOLD BESET and EXTERNAL HOLD RESET

If HOLD_ACK and SYSTEM AUTO are set and (EXT) HOLD is passive, program
execution is resumed by any of these two signals. This means that AUTO INPUT, which
sets SYSTEM AUTO, is a "master" for (EXT) HOLD RESET. It determines when (EXT)
HOLD RESET is allowed to be used.
MOV REST
The purpose of this input is to avoid collisions at a start after an abrupt stop. For detailed
information see section 7.10.

4.12.4.3
Outputs
HOLD ACKNOWLEDGE (HOLD ACK)
This output is set by (EXT) HOLD, and is reset by either MOTOR OFF, AUTO INPUT or
(EXT) HOLD RESET if (EXT) HOLD is passive.
HOLD ACK informs the operator or a PLC that the robot is stopped by an (EXT) HOLD
signal. As long as the output is active, program execution can only be resumed by AUTO
INPUT or (EXT) HOLD RESET, if (EXT) HOLD is passive.
When (EXT) HOLD becomes passive it is also possible to reset HOLD ACK by MOTOR
OFF. Thus program execution has to be started by MOTOR ON and Program Start.
ERROR in AUTO
This output is set at errors stopping program execution provided that SYSTEM AUTO is
set.
SYSTEM AUTO
The purpose of this output is only to inform the operator of the status for the AUTO
INPUT. See above.

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4.13
Remote control panel signals, Panel-I/O
The following section is valid if PANEL I/O is defined under PARAM/CHANGE/I/OUSE/PREDEF. If I/O MAP is used board, place and in- and outputs can be freely selected.
A central control panel or a PLC for remote control can be used by one or more robots. The
remote control panel may be used in paralell with the cabinet control panel. The inputs are
called buttons and outputs are called lamps, since this is intended for a remote panel.
Input channel on
board selected

Function

INPUT CHI

MOTOR ON button
Brings the robot to MOTOR ON in AUTO mode.
Voltage is applied to the robot motors.

INPUT CH2

MOTOR OFF button

Puts the robot to MOTOR OFF. Removes voltage to
the robot motors. Reset of emergency stop mode.

INPUT CH3

FROM DISK button

Loads program from disk in AUTO mode. The disk
program block 0 is loaded into the robot memory when
the button is pressed twice. The loaded program block
replaces the old contents in the user memory.

INPUT CH4

Disabling edit
When set, editing of programs from programming unit
is prevented.

INPUT CH5

LAMP TEST button

Is used to check the function of the control system and
remote control panel lamps. All lamps are lit when the
button is pressed. (Except Robot/Ext, axes and 1-2
key functions.

INPUT CH6

PROG STOP button

Interrupts progam execution and synchronization
procedure.

INPUT CH7

PROG START button

Starts program execution in AUTO mode. In special
circumstances the AUTO button on the programming
unit has to be pressed before starting the program
execution.

INPUT CH8

SYNCHRONIZATION button
This button is used to restart the robot after a power
failure during program execution . The
synchronization of external axes is started when the
button is pressed.

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4 Operation

4.13
Remote control panel signals, Panel-I/O
The following section is valid if PANEL I/O is defined under PARAM/CHANGE/I/OUSE/PREDEF. If I/O MAP is used board, place and in- and outputs can be freely selected.
A central control panel or a PLC for remote control can be used by one or more robots. The
remote control panel may be used in paralell with the cabinet control panel. The inputs are
called buttons and outputs are called lamps, since this is intended for a remote panel.
Input channel on
board selected

Function

INPUT CHI

MOTOR ON button
Brings the robot to MOTOR ON in AUTO mode.
Voltage is applied to the robot motors.

INPUT CH2

MOTOR OFF button

Puts the robot to MOTOR OFF. Removes voltage to
the robot motors. Reset of emergency stop mode.

INPUT CH 3

FROM DISK button

Loads program from disk in AUTO mode. The disk
program block 0 is loaded into the robot memory when
the button is pressed twice. The loaded program block
replaces the old contents in the user memory.

INPUT CH4

Disabling edit
When set, editing of programs from programming unit
is prevented.

INPUT CH5

LAMP TEST button

Is used to check the function of the control system and
remote control panel lamps. All lamps are lit when the
button is pressed. (Except Robot/Ext, axes and 1 - 2
key functions.

INPUT CH 6

PROG STOP button

Interrupts progam execution and synchronization
procedure.

INPUT CH 7

PROG START button

Starts program execution in AUTO mode. In special
circumstances the AUTO button on the programming
unit has to be pressed before starting the program
execution.

INPUT CH 8

SYNCHRONIZATION button
This button is used to restart the robot after a power
failure during program execution . The
synchronization of external axes is started when the
button is pressed.

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4 Operation

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5 Logical instruction menu

Logical instructions menu

Section

Page

5.1
5.2

5:5
5:7

GRIPPER
WAIT
5.2.1
WAIT (TIME)
5.2.2
WAIT (INPUT)
5.3
OUTPUT
5.4
JUMP
5.4.1
JUMP (unconditional)
5.4.2
JUMP (conditional)
5.4.3
JUMP (SEARCH)
5.4.4
JUMP (NINPOS)
5.5
VELOC
5.6
CALL
5.7
RETURN
5.8 REG
5.8.1
REG (FETCH)
5.8.2 REG (SET)
5.8.3
REG (TRANSFER)
5.8.4 REG (LOC)
5.9 TCP
5.10 INTER
5.11 COORD
5.12 GET B/ADD BLOCK
5.13 COM
5.14 SUCTRL
5.15 FRAME/FRAME DEFINE
5.16 SOFTS
5.17 EXTAX
5.18 EXTFRAME
5.19 GLUE SCA
5.20 LOAD (IRB 6000 only)
5.21 TRIM (IRB 6000 only)
5.22 LOCATE and VISCTRL

Programming

5:9
5:9

5:12
5:13
5:15
5:15

5:18
5:19
5:21
5:21
5:22
5:23
554
5:25
5:26
5:27
5:27
5:27
5.27
5:28

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LOGICAL INSTRUCTION

GRIPPER

Grippercontrol

Time/Input
status

VELOC

speed

Jump to
subprog.

Enable/
disable

Prog end

Request for
superior
control

Set/reset
register

COORD
Selection
of coord.
syst.

SUCTRL

Entry of
itary

UncondV
cond-jump

RETURN

INTER
Activate
TCP

Control of
digital output

Load prog,
block from
disk/Winchester

FRAME
External
FRAME

Activation
of displayed
system

*
EXTAX

SOFTS

Independent
rotating
external axes

SOFT SERVO

*
LOAD

GLUESCA

VISCTRL

Glue scaling

TRIM
MH/GL/SW
* If Vision is defined
AW only
* IRB 6000 only

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Programming

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5.1
GRIPPER
Gripper function
Menu: INSTRUCTION

Function: GRIPPER

Means:
A gripper, a welding gun or corresponding tool is operated during program execution.
Facts:
The gripper can assume two positions, GRIP or RELEASE. With gripper operations the robot
must remain still until the movement is completed. For this reason, a waiting time is given in
the instruction.
The gripper instruction is implemented in two versions; one for MH/GL/SW robots and one for
AW robots.
In the MH/GL/SW case, up to eight tools can be controlled and the release/grip movement for
the chosen gripper is explicitely programmed in the instruction. Only one gripper can be
controlled by one instruction. In this case the actual positions of the grippers does not matter
when programming. The connection of the grippers is described briefly below (see Outputs for
gripper) and in detail in the Installation S3.
In the AW case, only grippers can be controlled. The release/grip function is implicitely defined
by the actual positions of the grippers when programming,i.e the grippers must be positioned
manually befor the instruction is programmed. Both of the grippers can be controlled in one
instruction.
Executed:
During program execution, the gripper is positioned to the position decided when
programming. The robot then stands still until the waiting time has expired.
Procedure:
Instruction for gripper operation MH/GL/SW
Menu: INSTRUCTION

Function: GRIPPER

1. Select GRIPPER under the INSTRUCTION menu.

2. Specify gripper number 1-8.
The gripper number last used will be taken if ENTER is pressed without giving any
gripper number.
3. Select GRIP or RELEASE.
4. Specify if the waiting time for gripper operation is to be entered with the numerical button
set (YES) or have its pre- programmed value 0.3 s (NO).
If NO is selected, the instruction is now completed. Otherwise continue with point 5 below.
5. Specify the waiting time in the range 0.1 - 9.9 in seconds with one decimal.
The instruction is thereby completed.

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Manual control of gripper MH/GL/SW
Menu:

RELEASE or

GRIP

Manual operation of the "GRIPPER" via the programming unit is done as shown below:
The function is divided in two cases:
Two grippers defined (default value)
The button for gripper 1 (grip, release) handles gripper one
The button for gripper 2 (grip, release) handles gripper two

More than two grippers defined (n pcs)

The button for gripper 1 (grip, release) handles gripper one
The button for gripper 2 (grip, release) gives the question which gripper you want to
control.Valid answers rabge from 2-8.
The last gripper number is used as a default value, and only ENTER is needed.
Hie gripper is usually opened directly when the the gripper button is pressed.
Make sure no detail is dropped causing damage or injury.

Procedure:
Instruction for gripper operation (AW)
1

Set the gripper or the welding gun in the position required with gripper buttons on the
operators panel.

Select GRIPPER under the INSTRUCTION menu.

3 Specify if the waiting time for gripper opertaion is to be enterd with the numerical button
set (YES) or have its pre- programmed value 0.5 s (NO).
If NO is selected, the isntruction is now completed. Otherwise continue with point 4 below.
4

Specify the waiting time in the range 0.1 - 9.9 in seconds with one decimal.
The instruction is thereby completed.

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Outputs for gripper (MH/GL/SW)
It is possible to connect grippers (in a multi-gripper) to the robot via digital outputs.
The robot will automatically reserve a group of logical outputs. The reservation will only affect
the number of ligical outputs necessary for the specified number of grippers
Example: Five grippers are to be connected to the robot system.
Gripper 1 and 2 are connected to their respective outputs in system I/O.
The following gripper data is entered in the system parameter:
1. Five grippers
2. Logical output 14 (output for gripper 3)
When connecting the grippers 3-5:
Gripper 3 is connected to the logical output 14
Gripper 4 is connected to the logical output 15
Gripper 5 is connected to the logical output 16
The logical outputs 17-19 are not reserved for gripper 6-8, because five grippers has been
specified under 1 above.

5.2
WAIT
Pause in program running
Menu: INSTRUCTION

Function: WAIT

Means:
The running of the program is interruped:
A predetermined time.
Until 1-8 digital inputs have assumed the required status.
Until 1-8 digital inputs have assumed the required status, or the supervision time has
expired.
Facts:
A waiting time can be determined in seconds with two decimals in the range 0 - 99.99 s.
The correct status before restart of program execution at each of the inputs included in the
condition can be 1 or 0.
If required, a maximum permitted time before restart can be set in complete seconds in the
range 0 - 320 s. A time of 60 s is preprogrammed. See Installation S3.
Used:
When program execution must be interrupted at a particular position in the program while
another machine, or the operator, performes some other operation.

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Executed:
During program execution, the program remains inactive:
Until the time selected has expired.
Until all 1 - 8 inputs in the condition have assumed their correct status or, if supervision is
selected, the time has expired.
If CLINK is defined, a WAIT-instruction should be used if there are more than 15
instructions between two POS-instructions, two WAIT-instructions or one POS and
one WAIT-instruction. Then the delay time should be at least 0.01 seconds.

5.2.1
WAIT (TIME)
Procedure:
Instruction with waiting time
1. Select WATT under the INSTRUCTION menu.
2. Select TIME.
3. Specify the time 0.01 - 99.99 s.
The instruction is now complete.

5.2.2
WAIT (INPUT)
Instruction with input conditions
1. Select WAIT under the INSTRUCTION menu.
2. Select INPUT.
3. State the number of the first input in the condition.
4. Give the correct status for the first input.
5. Repeat the points 3 - 4 above for a new input (YES) or go to point 6 (NO).
6. Specify (with YES) if there is to be supervision of the maximum permitted waiting time
before restart of program execution. Continue in this case to point 7.
The instruction is otherwise now complete.
7. Specify the time 0 - 320 seconds. Press ENTER directly if the preprogrammed value
(normally 60 s) is to apply.
The instruction is now complete.

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A program example is shown below:
160 POS V=100 %
170 WATT UNTIL INP 6 =1 MAX = 60 S
180 JUMP TO 200 IF INP 6 = 1
190 CALL PROG 1000
200 POS V=100 %

5.3
OUTPUT
Change of the status of an output during program execution
Menu: INSTRUCTION

Function: OUTPUT

1. Select OUTPUT under the INSTRUCTION menu.

2. State the number of the output concerned.
3. Select one of the following alternatives:
Set the output to 1 irrespective of its current status.
Set the output to 0 irrespective of its current status.
Change the status.
Send a 200 ms pulse (negative if the output is a 1, positive if the output is at 0 when
the command is executed).
The instruction is now completed.

5.4
JUMP
Jump within the program
Menu: INSTRUCTION

Function: JUMP

Means:
A program execution can jump to another instruction uncondionaly or when one or more
conditions are fullfilled.
Facts:
Jumps can be made both forwards and backwards in the program
* Unconditionally.
Under 1-8 conditions each of which can be one of the following:
- One digital input is to be 1 or 0.
- One digital output is to be 1 or 0.
- The value in a number register 0 - 99 is to be either
- greater than (> )
- less then ( < )
- equal to (= )
or
- not equal to < - >
a reference value. ( <>)

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5 Logical instruction menu

Used:
Generally, when program execution is to be controlled by internal or external conditions.
Executed:
After the jump instruction has been executed, a jump will be performed to the instruction with
the number given in the jump instruction. If the jump instruction is conditional, the jump will
be performed only if the condition is fulfilled, otherwise the execution will go on with the
instruction following the jump instruction.

5.4.1
JUMP (unconditional)
Executed:
An unconditional jump is performed as followed:
1. Select JUMP under the INSTRUCTION menu.
2. Specify which instruction in the program is to be executed instead of that immediately
following.
3. Specify that there are no conditions for the jump with NO.
The instruction is complete.

5.4.2
JUMP (conditional)
Procedure:
Jump instruction with 1-8 conditions
1. Select JUMP under the INSTRUCTION menu.
2. Specify which instruction in the program is to be executed instead of that immediately
following when all conditions are satisfied.
3. Specify that conditions for the jump is to be set with YES.
4. Specify if the condition is to apply to either:
- A register, with REG.
- An input, with INPUT.
- An output, with OUTPUT.
- Search condition
Continue through the conditions selected (see "Facts", above) until the question CONTINUE? is
presented on the display.
5. Specify if several conditions are to be set for the jump (YES). Repeat in this case
points 3 and 4 for the next conditions.
If NO, the instruction is now concluded.

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5.4.3
JUMP (SEARCH)
Jump with search stop conditions
Search stop can be used as a jump condition. A jump can be programmed to take place when
the search stop is either active (one) or inactive (0). Through these the following program
execution can be controlled by the search result. See the example below.
Example: Main program
80 POS SEARCH
90 JUMP TO 110 IF
SEARCH = 0
100 CALL PROG 5
110 POS
In the program above, the robot searches for an object when instruction so is executed. If the
object is encountered SEARCH becomes = 1 and subprogram 5 is called. If however no object is
encountered during the search, SEARCH remains = 0 and the program call in the instruction
100 is omitted.
Further information about jump in program, see "Jump within the program".
If the robot contains extra digital outputs, the output SEARCH STOP can control
peripheral equipment. See Installation S3.
The instruction is now programmed and no further arguments can be added.
4. Press ENTER
5. Press YES
6. Press SEARCH
7. If the search stop is to be a jump condition press =1 otherwise press =0.

5.4.4
JUMP (N INPOS)
Jump if not in position
Means:
A conditional jump instruction which causes a jump in the program if the robot does not
reach the programmed position. No other conditions are permitted together with N INPOS.
Facts:
To use the function, soft servo must be and activated. See section 9.5.
The allowed position error can be chosen by specifying different zones. When using this
instruction the position of the robot must not be programmed with a FINE zone.

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Program example:
100 SOFTSERVO 1
110 POS V = 100 % PATH
130 JUMP TO 300 IF N INPOS
FINE
140 SOFT SERVO 0
150...
300 POS V = 100 % PATH

Jump

if

Activate soft servo

Position
the
position
is

incorrect

Deactivate soft servo

Assembly is correct. Continue.
Assembly is not correct. Move the tool to
free space and make error handling.

310 SOFT SERVO 0

320...
Used:
The instruction can be used to check if the robot has reached the desired position or not. If the
position is not reached, a jump is made in the program and corrections of the error can be done.
Executed:
As the normal conditional JUMP instruction.
Procedure:
Menu: INSTRUCTION

Function: JUMP

1. Select JUMP under the INSTRUCTION menu.

2. Specify which instruction in the program is to be executed instead of that immediately
following when the condition is satisfied.
3. Specify that conditions for the jump are to be set with YES.
4. Select N INPOS.
5. Specify zone by selecting CORNERl, CORNER2 or PATH.
The instruction is now completed.
5.5
VELOC
Change of basic and maximum speeds
Menu: INSTRUCTION

Function: VELOC

Means:
Definition of basic and maximum speeds for a number of instructions.

Facts:
The speed with which a movement is to be performed to a programmed position is built by
three different components:
An absolute basic speed with pre-programmed value 1000 mm/s.
A relative percentages speed specified for each individual instruction as a percentage of
the basic speed with pre-programmed value 0 %.
An absolute max. speed with pre-programmed value 2500 mm/s.

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The relationship between these is shown in the following example:
110 V = 1000 MM/S MAX = 2000 MM/S

Basic and max. speeds are specified for

the succeeding instructions.
Movement with 100 % x 1000 mm/s =
1000 mm/s
A new maximum speed is specified for the
succeeding instructions.
Motion with 200 mm/s. The maximum
speed is less than the programmed speed.

120 POS V = 100 %

130 V = 1000 MM/S MAX = 200 MM/S
140 POS V = 25 %

Used:
When basic and maximum speeds are to be redefined (from their pre-programmed values).
Performed:
After definition of the speeds during program execution these apply until a new definition is
encountered in some program, irrespective of the number of program changes which have
occurred before.
Procedures:
1. Select VELCO under INSTRUCTION menu
2. Specify both basic and maximum speeds, even if only one of these is to be redefined.
/ | \ The speed of the external axes and robot may, when running in robot
/ \ coordinates, exceed the programmed speed.

5.6
CALL
Program exchange
Menu: INSTRUCTION

Function: CALL

Means:
The program execution continues in a subprogram, performed completely or module by module
before execution of the program interrupted is continued.
Facts:
Program change is performed via call. The program called can be performed when called an
optional number of times from 1 - 99 before return to the calling program is executed.
The number of the program to be called can be specified in the instruction, either:
Directly.
Indirectly via the value in a numberical register 0 - 119.
Used:
Generally, when program exchange is necessary during program execution.

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Executed:
1. The call instruction is issued.
2. The execution of the calling program is interrupted.
3. The program called (or the module within the program) is executed 1-99 times.
4. The program called continues with the instruction after the call instruction.
Procedure:
1. Select CALL under the INSTRUCTION menu.
2. Specify if the number of the programmed called is to be selected via a register (YES) or
directly (NO).
3. Specify the program number or the register number depending on the selection in point 2
above (0 - 9999 or 0 -119).
4. Specify if the program called is a pattern program (YES) or not (NO).
If YES, continue with point 5 below. If NO, go directly to point 6.
5. Specify the number register 0-119 which is to control the call of the modules within the
program.
6. Specify if the program called is to be performed 2-99 times (YES) or once only (NO) at
the time of the call.
When the repetition is to be performed, continue to point 7. The instruction is otherwise now
complete.
7. Specify how many times the program is to be performed (2 -119).
The instruction is now completed.

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5.7
RETURN
End of instruction sequence
Menu: INSTRUCTION

Function: RETURN

Means:
The last instruction in a program.
In a pattern program it is also the last instruction within a program module, see section 11.4.
Facts:
The instruction returns the program running to:

The first instruction in the same program.

The calling program where the running continues with the first instruction after the
call when the program called is executed the number of times required.
Procedure:
Instruction for program end (or end of program module)
1. Select RETURN under the INSTRUCTION menu.
The instruction is then completed.

5.8
REG
Arithmetic handling
The values stored in the registers can be handled with arithmetics, i e be added, subtracted,
multiplied or divided, with each other or with constant values. The values can be positive as
well as negative.
Example:
Rl =
R2 + 5
(Rl, R2 and R3 are data registers)
R2 =
R3 + Rl
Rl =
R3 + 1
Division with 0 or overflow causes PROGRAM RUN ERROR 27.
Division is performed without respect to decimals, i e 8/5 = 2.7/1 = 1, and the decimal part is
adjusted. If the decimal part is 0.5 or greater it is adjusted upwards to the next unit value.
Range: -32 768
to
32 767

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5.8.1
REG (FETCH)
Accessing of register value
A robot register is given a value from an external source.
Menu: INSTRUCTION

Function: REG

1 Select REG under the INSTRUCTION menu.

2 Select FETCH.
3 Specify register number 0 - 119.
4. Specify:
- Digital port 11-14
- Analog port 31-34
The instruction is hereby concluded.
Port
Digital
Analog

11
12
13
14
31
32
33
34

Input
1-4

13-16
17-24
25-32
1
2
3
4

See Installation manual.

Digital ports 11 and 12 can access four bits, i.e values between 0-15, ports 13-14 can access
eight bits, i.e values between 0-255. The analog ports have a scale factor of 10 mV and 0.02 mA
respectively corresponding to value 1 in the register.

5.8.2
REG (LET)
Procedures:
Arithmetic handling of register values
Menu: INSTRUCTION

Function: REG

1. Select REG under the INSTRUCTION menu.

2. Select LET.
3. Specify register number.
4. Select VALUE, REG eller REG- depending on if a constant value, a positive or a negative
value is to be entered.
5. Define the register number or the constant value.
6. Define whether the earlier value is to be added, subtracted, multiplied or divided with the
following specified values.

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5 Logical instruction menu

7. Define VALUE or REG depending on if a constant value or a register number is to be
entered.
8. Define the register number or the constant value.
9. Check the final formula on the upper line of the programming unit's display.
Finally, leave the menu by, for example, pressing MANUAL

5.8.3
REG (TRANSFER)
Transmission of register value during program execution
A robot register value is transmitted to an external.
Menu: INSTRUCTION

Function: REG

1. Select REG under the INSTRUCTION menu.

2. Select TRANSFER.
3.

Specify register number 0-119.

4. State port number in accordance with the following:

Digital port 1 - 4
Analog port 21-24
Input
Port
Digital

Analog

1
2
3
4
21
22
23
24

1-4

13-16
17-24
25-32
1
2
3
4

See Installation manual.

The instruction is hereby concluded.
Digital ports 1 and 2 can transmit volues of 0-15 units, ports 3 and 4 can transmit 0-255 units.
The analog ports have a scale factor of 10 mV = one register unit and 0,02 mA = one register
unit.

5.8.4
REG (LOC)
Robot positions
The different positions of the robot can be stored in the data registers (REG NO 0-119). The
three coordinate values (x, y and z) are stored in three consecutive registers. With the help of
register arithmetics (see above), displaced positions can be calculated for example.
The stored position is the location for the active TCP when the instruction is executed. The
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5 Logical instruction menu

location is expressed with a resolution of 0.1 mm or 0.01 inches and is defined relative the
object coordinate system.
A specific position in space will cause different values depending on the FRAME or REFPOINT
ACTIVE. This means that when the displacement between the two points is to be calculated,
the same FRAME (REFPOINT) must be active for both points during storage in registers.
During entry to registers, the first register number only is specified and the two remaining
values will be stored in the two consecutively numbered registers.
Entry of robot position
1. Select REG under the INSTRUCTION menu.
2. Select LOC.
3. Specify register number 0-119.
The instruction is hereby complete.

5.9
TCP
Activation of TCP during program execution
Menu: INSTRUCTION
Function: TCP
Previous definition of the TCP-selected is assumed
1. Select TCP under the INSTRUCTION menu.
2. Specify TCP number 0-19 for ordinary TCP. MH/GL/SW only: 20 - 29 are reserved for
room fixed TCP.
Note!
When the instruction is programmed the TCP selected is also activated.
Activation of an incorrect TCP wQl cause Hie robot to perform unintended motions.
When the TCP instruction is executed during program execution, the internal representation of
the TCP position will change but the TCP instruction itself will cause any robot motion. The
first position instruction after the TCP instruction, however, will move the robot using the new
TCP to the programmed position.
Please note, that if a path is programmed with zones, no comerpath will be generated after the
TCP instruction but the robot will move directly to the following position with the new TCP
activated. See section 3.6. To avoid problems, the TCP instruction should be executed after a
POS FINE instruction, i.e. in a well defined position.
Warning text for TCP
In certain circumstances when editing and interchanging programs, there is an increased risk
that an incorrect TCP is active. A warning text is presented on the programming unit to
indicate that an incorrect TCP may be active.
The warning text is obtained with execution of the program after the following operations if a
TCP instruction has not been executed before the first POS instruction.
* Exchange of active instruction during editing.
* Exchange of active TCP during manual operation.
* Exchange of active program during editing.
* Exchange of active program during system intialization.
* Exchange of active program during CLEAR.
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Exchange of active program during downloading from a disk.
Exchange of active program during synchronization.
The warning text on the programming unit has the following appearance:
TCP xx IS ACTIVE!
An error code as follows is presented in the error buffer and on the monitor:
504 PROGRAM RUN ERROR 72
The TCP must be checked when the warning is presented. Continue execution by pressing
again program start or instruction start.
For Room Fixed TCP see chapter 3.3.2.

5.10
INTER
Interrupt in the program execution via direct-acting inputs
Menu: INSTRUCTION

Function: INTER

Means:
Program execution can be interrupted with the help of digital signals from peripheral
equipment via direct-acting inputs. These interrupts can be controlled to affect or not affect the
program running during different stages of the work cycle.
Facts:
Interrupt can be performed in one of the following ways:
Current instruction interrupted and the next instruction is begun.
Program stop when the current instruction is performed.
Immediate program stop.
Jump to one of the subprograms 1-5 when the current instruction is executed.
Immediate jump to one of the subprograms 1-5.
A small program example is shown below:
60 DISABLE INTERRUPT

Interrupt caused by direct-acting inputs are not

permitted to affect program execution from and
including instruction number 70.

Assume that input JUMP TO PROGRAM 5 is connected to the peripheral equipment. If the
input is then set to 1, the program execution is not affected as the interrupt request is not
registered by the robot.
250 ENABLE INTERRUPT

From this instruction, interrupt in program

execution is permitted from direct-acting inputs.

When the signal is set to 1 before instruction 250 is entered, the robot is again
unaffected by the signal because the signal must be set to 1 after instruction 250 is
executed.
The following happens however when JUMP TO PROGRAM 5 is set to 1 after instruction 250
has been executed:
1. The instruction under execution, e.g. instruction 340, is completed.
2. Subprogram 5 is called and executed.
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3. Program execution returns to the program interrupted, i.e. execution continues with
instruction 350.
An instruction in the program which enables or disables interruptions in the execution applies
until a new instruction of the same type is encountered.
The direct-acting functions according to the above are connected, as hardware, during the
installation of the robot. See Installation S3.
Used:
When the peripheral equipment may enable the program execution during the work cycle. The
instruction determines when this is allowed.
Executed:
If interruption of program execution is currently allowed, the robot immediately reacts to
signals from the direct-acting inputs. Note that there are certain limitations which are
described in the Installation S3.
Procedures:
1. Select INTER under the INSTRUCTION menu.
2. State whether interruptions are to be allowed, ENABLE, or not allowed, DISABLE, for the
following instructions.

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5.11
COORD
Change of coordinate system for programmed execution
Menu: INSTRUCTION

Function: COORD

1. Select COORD under the INSTRUCTION menu.

2. Select RECT(angular) MODRECT or ROBOT.

5.12
GETS
An instruction for program loading in a robot program is prepared as follows:
Programmed loading of program block
Menu: INSTRUCTION

Function: GET B

1. Select GET B in the menu INSTRUCTION.

2. Specify whether the block number is to be selected via registers (YES) or directly (NO).
3. Specify the block number or the register number depending on the selction made in point 2
above (0-9999 or 0-119).
4. Select either of:
- FR DISK The program block is loaded from the diskette.
- FR WIN The program is loaded from Winchester memory (if such is connected)
5. Select either of:
- REPLACE The contents of the program memory are replaced by the block to be loaded.
The instruction GET BLOCK is completed when REPLACE is pressed.
- ADD ALL The contents of the user memory are supplemented by the block to be loaded.
However, any duplicates in the program memory are replaced by the programs loaded.
6. When ADD ALL has been selected, a question is displayed whether any program in the
program memory is to be erased before the loading is executed. Press ENTER if erasure is
not required. The instruction ADD BLOCK is completed.
7. Specify the number of a single program to be erased and press ENTER if a program is to be
erased. If a series of programs are to be erased, specify the number of the first and last
programs in the series and press ENTER. The instruction ADD BLOCK.. ERASE... is now
completed.
Note! When a GET BLOCK instruction has been executed, program execution
continues from the first instruction in the main program of the newly loaded
program block.
When an ADD BLOCK instruction has been executed, program execution
con tinues from the next instruction in the program which called for program
loading. ADD BLOCK can be executed from main program level only, not from a
subprogram.
Program blocks containing the same program number as the program requesting
the loading, can not be loaded. An error message will be displayed and program
execution is stopped.
Avoid program printout and displacement of positions when mass storage is used.
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5.13
COM
Program stop with comments
Menu: INSTRUCTION

Function: COM

Means:
Comments can be entered in the program using the programming unit. When the optional
function "Program Printout" is provided , a comment can be inserted in the program from the
printer.
Facts:
The comments in the program, with associated program stop can consist of up to 72 ASCII code
characters, including spaces, read in from a keyboard or 24 characters read in from the
programming unit.
Used:
The commentary in the program with associated program stop is used in program sequences in
which it is necessary to be able, simultaneously, to:
Stop program execution.
Receive a readout on a monitor or on the programming unit, or a printout on a printer
indicating why the robot is at standstill. Even without program stop, the comment
takes time to present. Comments may therefor not be suitable in all situations.
Executed:
When a commentary instruction with associated program stop is performed, the robot stops
and the commentary is presented. If the program stop is not used, comments are presented on
the display and monitor when the instruction with comment is executed, and remains untill
the next comment is presented.
Procedure:
Instruction with comments and associated program stop (from keyboard)
1. Select COM under the INSTRUCTION menu.
2. Select YES on the question "FROM TERMINAL?' if an external keyboard is to be used.
3. Specify whether program stop is to be associated with the commentary, or not.
4. Enter the comments from the keyboard, with up to 72 characters including spaces.
5. Make a carriage return on the keyboard.
10 STOP (*COMMENT*)
ABCDEF

CHIJKL

MNOPQR STUVWX

Instruction with comments and associated program stop (from programming unit)
1. Select COM under the INSTRUCTION menu.
2. Select NO on the question "FROM TERMINAL?" if the programming unit is to be used.
3. Specify whether program stop is to be associated with the commentary, or not.
4. Enter the comments from the programming unit, according to the figure below.
5. Enter "." when the comment is completed. The text string is otherwise concluded
automatically after 24 characters "-" for erasure.
Entry is performed with the help of the multi-function buttons and numbers. To enter, for
example, a P, first press the button F3 and then "4".
* # is available but does not appear.
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5.14
SUCTRL
SUCTRL, request for superior computer control
The function SUCTRL is used when a programmed request for superior computer control is to
be sent to the SC. When the instruction is executed during programmed execution, the robot
system concerned will send a spontaneous status message to the S.C. The robot is then
prepared to react immediately on order from the S.C.
If stop is programmed, a stop-command must be given from the S.C. before a start of program
execution can be requested again. When the robot is in the instruction SUCTRL before a STOP
command is given from the S.C. the programming unit is blocked. It is possible to execute
commands from the S.C.
If required, the request for superior control can be cancelled manually by means of a program
stop via the programming unit. In addition a request for superior control can also be cancelled
by a program stop via an digital input.
Program the function in accordance with the following:
1. Press the function control button INSTR
2. Press the function button SCAN three times.
3. Press the function button SUCTRL.
4. If the robot is to continue to execute without halting, press YES. If it is to stop and await a
STOP command from the S.C, press NO.
5. If a register value is to be sent to the S.C, press REG NO and enter the required register
number (0-119)
The instruction SUCTRL is now completely programmed and no further arguments can be
added.

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5.15
FRAME/FRAME DEFINE
Activation of program displacement
Function: FRAME
Menu: INSTRUCTION
1. Select FRAME under the INSTRUCTION menu.
2. Specify which of the program displacements 1 - 5 is to be activated.
3. Select SET.
Note that the frame displacement and a reference point displacement can be active
simultaneously. In such a case, the frame displacement is always calculated first, and
consequently, the reference point displacement will be calculated and superpositioned upon the
frame displacement, according to the figure below.

The pattern is
^ X programmed h iere!

The program is
executed here after
instruction 100!

This displacement
is activated in
INSTRUCTION 50
10
"50 REFP

100 FRAME

See section 3.9.2 for a more detailed description of the FRAME function.
See section 6.14 for programmed actovation of desireed FRAME.
See section 2.6 for manual definition of FRAME.
See section 10.7 for automatic definition of FRAME.

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5.16
SOFTS (MH/GL/SW only)
Instruction programming
Any set of defined softness or normal speed control, can be activated manually or during
program execution. An attempt to execute a SOFT SERVO instruction with an undefined
number will cause the program execution to stop and disply an error message C'504 PROGRAM
RUN ERROR 70").
A SOFT SERVO instruction is programmed as follows:
1. Select SOFTS under the INSTRUCTION menu.
2. Specify desired set of soft servo. Number 0 provides normal speed control on all axes.
Position instructions executed while SOFT SERVO is activated should not be FINE.
All nine sets of softness percentages form a part of the system parameters, possible to store on
a disk for later use.
for detailed information, see section 3.8.
See section 9.5 for definition of softness percentage.
| \ When usmg the function Soft Servo, the robot speed and path are changedNote. In order to prevent abrupt motions when activating and deactivating SOFT SERVO,
a WAIT instruction can be programmed before and after the SOFT SERVO sequence.

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5.17
EXTAX Independant External Axes
EXTAX is a function which allows the external axes of a robot to be moved independently of the
normal positioning. Independent mode or normal mode may be selected dynamically during the
robot program execution by using instructions "AXIS x START" or "AXIS x STOP" respectively.
During independent mode, an axis may be rotated in one direction for long periods, and
because of this, it is necessary to allow it to have an undefined working area, so that it does not
become limited. The working area can be selected as undefined or defined during definition of
the system parameters (See Installation S3). As axes may have a defined or undefined working
area in both independent and normal movement modes, there is no restriction.
In some cases, an external axis may be a rotational device (e.g a rotating table), in some cases
it may be linear device (e.g. track motion). As a consequence of this, it is possible to specify the
axis type as rotational or linear during definition of the system parameters.
When EXTAX is used, the parameter ROTAX should be set to 1. This means that, for example,
a rotating table will only ever rotate up to one revolution to reach a position. For such a device
it is important to define the external axis gear ratios correctly.
Programming of external axes to start independent movement will be done by the following
programming unit interaction:
Menu: INSTRUCTION
Function: EXTAX
1. Select EXTAX under the INSTRUCTION menu.
2. Specify the number of the axis in question.
The valid range of "AXIS NO=" is 7-12.
There will be NO check to ensure that the programmed axis is defined because it is possible to
modify the parameters and undefine an axis at some later time. Instead, operations on
undefined axes will be ignored at execution time as is already the case with normal external
axes programming.
3. Select START.
4. Specify the velocity of the external axis in question (RPM if rotational, UNITS/S if linear).
The valid range for "VELOCITY (RPM)=" is -5000...+5000 rpm.
There will be NO check to ensure that the programmed speed does not exceed the maximum
speed because it is possible to modify the parameters and change the maximum speed at some
later time. Instead, the speed will be limited at execution time if necessary.
Programming of external axes to stop independent movement and return to normal movement
mode will be done by the following programming unit interaction:
Menu: INSTRUCTION
Function: EXTAX
Step 1 and 2 are the same as for the start instruction above.
3. Select STOP.

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5.18
EXTFRAM (AW only)
The instruction makes it possible to program interpolated movement between the robot and one
external axis.
Ses section 12.6.5 for detailed description and how to program.

5.19
GLUE SCA (MH/GL/SW only)
Used for gluing only. See chapter 13.

5.20
LOAD (1KB 6000 only)
The instruction makes it possible to program differernt wrist loads. Thus the prefrmance of the
robot can be optimized to the actual load in order to reduce cycle time. See 11.8 for detailed
information. 20 different loads can be programmed.
1. Selected LOAD under the instruction menue.
2. Specify LOAD number 0-19.
LOAD 0 is defined as a system parameter, see Installation S3.
LOAD 1-19 is denned according to section 9.5.
The defined LOAD 0 values are stored as systemparameters and LOAD 1-19 values as user
parameters like TCP.

5.21
TRIM (1KB 6000 only)
To be able to optimize the robot's 'movement into FINE points in a movement, a function
TRIM is available. The TRIM function makes it possible to adjust the movement between
two FINE points, according to mod. A described in Chapter 4, in the optimum manner. As well
as mode A, it is only available for 1KB 6000.
The function is programmed as an ordinary instruction and can change the servo position
control with 100 scale divisions.
Preselected value is 0, the same as when disconnected. The TRIM factor is a part of the robot
program and will be saved on a disk or superiorur computer together with the robot program.
All fine points programmed according to a TRIM instruction will be using the programmed
factor until a new TRIM instruction is programmed.
The current TRIM factor is displayed out on the topline on an optional monitor when the
program stops.
The same information is displayed on the programming unit by pressing the SHIFT key.

5.22
LOCATE andVISCTKL
The instructions makes it possible to program image processing instructions. For detailed
information of the function and how to program, see OptiMaster User's manual.
Programming

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!i

GRIPPER WAIT OUTPUT

AW ONLY

=!

fl

|;'J"

JUMP

SCAN |

1^

WAITING TIME 0.8 S

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5 Logical instruction menu

GRIPPER WAIT OUTPUT JUMP SCAN

CE

ENTER

CE

ENTER

WAITING TIME 3.5 S

140 WATT 3.5 S

140 WATT UNTIL INP 1=0

CONTINUE?

NO, PAGE 30
YES, PAGE 30

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5 Logical instruction menu

NO, PAGE 29
140 WATT UNTIL INP 1=0
MAX WATT TIME?

140 WAIT UNTIL INP 1=0

140 WATT UNTIL INP 1=0

CE

ENTER

r~ir~Kr~i
WATTING TIME 30 SEK

140 WATT UNTIL INP 1= MAX 30 S

YES, PAGE 29

140 WATT UNTIL INP 1-0

140 WATT UNTIL INP 1=0

140 WAIT UNTIL INP 1=P*P3 = 1

Max 8 inputs

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5 Logical instruction menu

140

GRIPPER WAIT OUTPUT JUMP SCAN

=2

INVERT PULSE

l
140 INVERT OUTP 5

i 140 PULSE OUTP 5

II 1

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5 Logical instruction menu

GRIPPER WAIT OUTPUT JUMP SCAN

CE

ENTER

INSTRUCTION NO 710

CONDITION?

YES

140 JUMP TO 710

NO

140 JUMP TO 710

SEARCH INPUT OUTPUT REG

SCAN

REG, PAGE 35
OUTPUT, PAGE 34
INPUT, PAGE 33

140JUMPTO710

IFSEARCH

140JUMPTO710

IFSEARCH=1
YES

Programming

140JUMPTO710

IFSEARCH

NO

32

S3

5 Logical instruction menu

INPUT, PAGE 32

i
i

1 140 JUMP TO 710 IF INP 13= L

YES

| CONTINUE?

rr

Programming

NO

MM

ITJH LJ

140 JUMP TO 710 IF INP 13 = 0

CONTINUE?

YES

|
NO

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5 Logical instruction menu

OUTPUT, PAGE 32

SEARCH INPUT OUTPUT

ni

14OJUMPTO710 IF OUTP 9 = 1
YES

1 CONTINUE?

9 ^

pi

NO

|%

140JUMPTO710 IFOUTP9 = 0

i mmmmm
H

CONTINUE?

YES

II

NO

i|

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5 Logical instruction menu

REG, PAGE 32

140 JUMP TO 710

REGISTER NO 3

140 JUMP TO 710

NOT EQUAL TO
GREATER THAN

140 JUMP TO 710

140 JUMP TO 710

140 JUMP TO 710 IF R3 > 20

140 JUMP TO 710 IF R3 > 20

140 JUMP TO 710

140 JUMP TO 710

140 JUMP TO 710 IF R3 < 20

140 JUMP TO 710 IF R3 < 20

Progrn-mmi-ng

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SCAN, PAGE 32

FINE

CONER1 CONER2

140 JUMP TO 710 IF NOT INPOS FINE

Prograi

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5 Logical instruction menu

140
GRIPPER WATT OUTPUT JUMP

VELOC CALL RETURN REG

VELOCITY ( M M / S )

SCAN

SCAN

CE

ENTER

CE

ENTER

VELOCITY 300 M M / S

MAXVEL.CMM/S)

MAX VELOCITYIOOO MM / S

140V = 300MM/S MAX =1000MM/S

Programming

140 RETURN

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5 Logical instruction menu

140
GRIPPER WATT OUTPUT JUMP SCAN

140
VELOC CALL RETURN REG SCAN

Programming

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5 Logical instruction menu

NO, PAGE 38

140 CALL PROG 7 . . . KEP3

140 CALL PROG... R5 REP 4

Programming

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5 Logical instruction menu

I 140

I GRIPPER WATT OUTPUT JUMP SCAN

8888888888!

140
VELOC CALL RETURN

FETCH

14

CE

3 J 140

4 b

8
- 0

LOC

ENTERj

11

1
|

11 PORT NO =

CE

gSw:<w:*:<iSSS-:'C;M;>:*:*:i.1':'

~m'""' 11

PORT* lla
12

TRANSF

j REG NO =

LET

REG SCAN

i ffl

i1

ENTER

11

140 FETCH R5 FROM PORT NO 12

140 TRANSFER RS TO PORT NO 3

REGISTER NO 5

Programming

40

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5 Logical instruction menu

SET, PAGE 40
10
VALUE

REG

-REG

VALUE=1

10SETR5=l

10 SET R5 = -R2

ADD

10

SUB

MUL

DIV

10SETR5 = -R2
CE

REG NO =

ENTER

VALUE

DIV

10
REG NO:

REG

REG NO = 2

10SETR5
ADD

SUB

MUL

CE

ENTER

REG NO = 3

10SETR5 = -R2-R3

ADD, PAGE 42
DIV, PAGE 42

MUL, PAGE 42

VALUE=3

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S3

42

5 Logical instruction menu

POS, PAGE 40

1
140
CE

REG NO =

ENTER

REG NO = 5

140 CURRENT LOCATION TO R5 - R7

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5 Logical instruction menu

i

| 140

JGRIPPER

WATT OUTPUT .JUMP SCAN

it:

IN

II

i
140

VELOC CALL

RETURN REG SCAN

140
TCP

INTER

Programming
44

COORD GETB

SCAN

S3

5 Logical instruction menu

INTER, PAGE 44

140 JUMP TO 710 IP R3 = 20

ENABLE INTERRUPT?

140 ENABLE INTERRUPT

Programming

YES

NO

140 DISABLE INTERRUPT

S3

45

5 Logical instruction menu

COORD, PAGE 44

ROBOT MODRECT RECT

Programming

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5 Logical instruction menu

140 GET BLOCK (R5) FROM WIN

IF NO VALUE IS ENTERED,
ONLY PROGRAM 2 WILL
BE ERASED

S3

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47

5 Logical instruction menu

GRIPPER WATT OUTPUT JUMP SCAN

1 140
\ VELOC CALL RETURN REG

1 IH

SCAN

I 140

1 TCP

INTER

i i

COORD

GETB

SCAN

140
COM

Programming

SUCTRL

FRAME

SCAN

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48

5 Logical instruction menu

Programming

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5 Logical instruction menu

FRAME, PAGE 48

140 FRAME 3

irTTTl

Programming

140 FRAME 3 DEFINE

1
%

S3

50

5 Logical instruction menu

SCAN 4 TIMES

EXTAX

SOFTS GLUESCAL

30 AXIS 8 START V=1700 RFM

S3

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5 Logical instruction menu

SCAN 5 TIMES

I 29LOAlDNOTi)Iimi:S
! LOADNO=

CE ENTER

Q 1 m,I

Programming

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5 Logical instruction menu

FUNCTION + SCAN 5 TIMES

Programming

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Programming

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6 Position instruction menu

6.

Position instruction menu

Section

Page

6.1
6.2
6.3
6.4

6:5
6:5
6:5
6:6

6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18

Programming

V%
SAME
ZONE
SEARCH
6.4.1 SEARCH (dist)
6.4.2 SEARCH (dir)
6.4.3 SEARCH (auto)
WEAVING
REFP
VCTRL
CONTOUR
CORVEC
POSPOS
STOPOS
POSLOC
CIRCLE
FRAME
TIME
PALLET
RELTOOL
6.17.1RELTOOL (X, Y, Z)
6.17.2RELTOOL (via REG)
EXTFRAME

6:8
6:12
6:12
6:13
6:14
6:14
6:16
6:17
6:18
6:18
6:19
6:19
6:21
6:23

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Programming

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i
1

1
SAME

Pos.-speed

Arg. ace. to

WEAVE

Weaving

I
CORVEC

REFP

Ref. point
ON/OFF

POS POS

CIRCLE

Circle
movement

ZONE

SEARCH

Fine point

Searching

VCTRL

CONTOUR

Speed
control

I
STO POS

SCAN

Pos. to
stored loc.

TIME

SCAN

Pos.-time

Pallet pos.
MH/GL/SW

POS LOC

PALLET

SCAN

Contour
tracing

Automatic
correction of
FRAME

SCAN

Store location

FRAME

POSITIONING

Correction
movement

1
RELTOOL

SCAN

Pos. relative
actual pos.

MH/GL/SW not IRB 6000

Programming

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Programming

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6 Position instruction menu

6. POSITIONING
Programming of position
The Menu button gives the instruction
1. Position the tool to the required position with the joy stick
2. Press the POSITION menu button. The position is programmed and the percentage
speed which applies is shown.
If the percentage speed is not to be changed omit the next procedure. If the position is only
to be a PATH point, the programming of the position is now complete.
Note
When 10 -12 axes are present the system generates two instructions, according to the
following examle:
240 AXES 10 -12 POS
Extra instruction
250 POS V = 100% PATH
Normal instruction

6.1
V%
Change of percentage velocity
1. Select V % in the menu
2. Specify the percentage speed 0-799.9 %.

6.2
SAME
If the complete instruction is to be repeated in a new position, select SAME in the menu
and conclude in this way the programming of the position.
In other cases, the definition of the zero zone is described in the next procedure whereas
other arguments described briefly under "Otherwise".

6.3
ZONES
There are four alternatives for programming a zone. The values for the alternatives are
defined as system parameters. The default zone alternative for an instruction is PATH. The
other alternatives are programmed by using the ZONE button:
Three alternatives will appear:
ZONE

FINE
CORNER 1 CORNER2
The text on the display shows which alternative is active:
100 POS V = 100 % PATH
100 POS V = 100 % FINE
100 POS V = 100 % Cl
100 POS V = 100 % C2
Programming

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6 Position instruction menu

The default values of the system parameters have been chosen to provide a useful choice of
zone sizes. Particular applications may require other values to be defined, see chapter 11.
ZONE
PATH
CORNER1
CORNER2
FINE

Default value
-2
Note! ("-") indicates velocity dependent zone size
15
-100
2

Use of zones
PATH
CORNER1
CORNER2
FINE

for normal path

for corners with small deviation, regardless of speed
for big corner rounding and thus high speed
for precise positioning and when logical instruction must
be carried out at the position.

See section 3.6.1 for a more detailed description of corner handling.

6.4 SEARCH
See section 10.3 for more detailed description.

6.4.1 SEARCH (DIST)

Program a distance searching as follows:
1. Program a FINE position instruction
2. Press SEARCH
3. Press DISTANCE
4. Specify the number of the sensor (1-16) with the numerical button set.
5. Press ENTER. If the question "STOP CONDITIONS=" is shown on the lower line of the
display, continue with point 6. Otherwise continue directly to point 8.
6. Specify the search stop condition as a percentage (0-100) of the maximum signal range
of the sensor with the numerical button set. If the current signal level is to be a stop
value, run the robot with the joy stick to the position where the sensor gives the
required signal.
7. Press ENTER.
8

If several sensors are to be used press YES and repeat the points 4-6 for the new
sensor. Otherwise press NO and continue with point 9.

9. If a delayed search stop is required, press the function button YES. Otherwise press
NO.
The argument SEARCH is now programmed. If required, more arguments can be added to
the instruction.

Programming

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6 Position instruction menu

6.4.2 SEARCH (DIR)

Program a direction searching as follows:
1

Program FINE position instruction.

2 Press SEARCH
3 Press DIR
4 Enter the number of the sensor (1-16) with the numerical button set
5 Press ENTER. If the question "STOP CONDITIONS=" is shown on the lower line of the
display, continue with point 6. Otherwise proceed to point 8.
6 Specify the search stop condition, as a percentage (0-100) of the maximum signal range
with the numerical button set. If the current signal level is to be a stop value, run the
robot with the joy stick to the position where the sensor gives the required signal.
7 Press ENTER.
8 If more sensors are to be used, press YES and repeat the points 4-6 for the new sensor.
Otherwise press NO and continue with point 9.
9 If a detailed search stop is required, press function button YES. Otherwise press NO.
The SEARCH argument is now programmed completely. If required, more arguments can
be added to the instruction.

6.4.3 SEARCH (AUTO) AW only

Program automatic distance searching AUTO SEARCH as follows:
Program the start position in accordance with " Distance search". Then jog the robot to the
position close to the intended search stop position:
1

Program a FINE position instruction.

2 Press SEARCH.
3 Press AUTO.
4 Specify the number of the sensor (1-16) with the numerical keyboard.
5 Press ENTER.
6 Answer the question "MORE SENSORS?". If YES, return to point 4. Otherwise,
continue as below.
7 Answer the question "DELAY?". The instruction is now complete.
The resulting instruction looks as the example below:
140 POS V = 100% AUTOSEARCH SI
where "SI" is the sensor used.
Programming

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6 Position instruction menu

6.5 Weaving MH/GL/SW not IRB 6000

In AW robot the function is replaced by the integrated weaving function which is part of
the welding instruction.
Menu: POSITIONING

Function: WEAVE

Means:
A periodic recalling transverse movement (weaving), stored in a separate sub-program, the
weaving program is superimposed on a movement to a programmed position, the main
movement.
Facts:
The weaving movement is a combination of:
The main movement between the start point and the end point, in the ordinary
program.
A superimposed periodic weaving movement, in a separate weaving subprogram.
The example below shows how each of the programs contributes with one part of the
resulting weaving movement.
Example
The movement below is performed during running of subprogram 10, with the help of
weaving subprogram 200, where the periodic weaving movement is programmed.
20,30

10

40,50

Subprogram 10
90 POS V = 10% WEAVING PROG 200 H = 100%

Subprogram 200 (weaving program)

10 POS V = 100%
(Movement sideways to the left end position)
20 WAIT 1S
(Paus in the left end position)
30 POS V = 100%
(Movement sideways to the right end position)
40 WAIT 1 S
(Paus in the right end position)
50 RETURN
(Program end)

Programming

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The resulting weaving movement will look as below:
20 30
Start position

10-^

20 30

\-
-f

\- - # - End position

40 50

40 50

Subprogram 10

90 POS V = 10% WEAVING PROG 200 V = !

vc

Subprogram 200
10 POS V = 1
V

30POSV =

Vm = The percentage speed for the main movement in subprogram 10, instruction 90. (An
increase of the percent value results in a smaller number of weavings on a specified
distance. The weaving pattern is "streched out" in the direction of the main movement and
keeps it's proportions.)
Before increase of Vm

After increase of Vm

Vp = The percentage speed in the weaving program 200 for all movements. (An increase of
the percent value results in faster movements sideways. On the other hand, the tool will
remain in the end positions during the same time as before. The weaving pattern is
"shortened" in the direction of the main movement, but will not keep it's proportions.)
Before increase of V

After increase of V

Programming

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6 Position instruction menu

Vc = The correction factor, expressed in percent, for how fast the weaving pattern is to be
performed relative to it's own programmed speed. (An increase of the percent value gives a
greater number of weavings on a specified distance. The weaving pattern is "shortened" in
the direction of the main movement and will keep it's proportions.)
Before increase of V

After increase of V,

Weaving is performed in basic coordinates, i.e. the tool does not change orientation. It
means also that the same movement pattern, performed in a new direction, requires a
special weaving program. See the example below:
1

10

10
20

^ ^

30

20

20

Main movement

Result

20,30

10

Movement

20

3-*"

30

AA

20 < ^
l b ^ 30
20 < ^

30

30

w
10

20

10,40

10

10

40

20

30

40

go

Weaving program
10POSV =
100%

10POSV =
100%

10POSV =
100%

10POSV =
100%

20POSV =
100%

20POSV =
100%

20POSV =
100%

20 WATT 1 S

30 RETURN

30 RETURN
100%

30POSV =
100%

30POSV =

40 RETURN

40 WATT 1 S
50 RETURN

Prngra-nmtiiTi |

10

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6 Position instruction menu

Executed:
The main movement and the weaving program start at the same time to the programmed
position. The resulting motion is concluded:
Within the zone for the main movement

Note.
Weaving can not be combined with movements of an external axis.
External axis can not be used in the weaving pattern.
Procedure:
The procedure is a direct continuation of positioning programming. Proceed in accordance
with the following:
1. Select the WEAVE function.
2. State which weaving program 1 -9999 is to be used.
3. State the adjustment factor 0.1 -100% for the basic speed of the weaving program.

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6.6 REFP
See section 3.9.1 for more detailed description.
and 3.4.1 for parameter DHANDCK.
Program the REFP (reference point) instruction, as follows:
1. Check that the reference point is not active.
2. Program the position (program segment) parallel to desired positions.
3. Program the REFPOINT ON instruction immediately before the first position to be
displaced.
4. Program the REFPOINT OFF instruction immediately after the last position to be
displaced.
Note
The reference point is not activated/deactivated until the REFPOINT ON/OFF instruction
is executed. Use a FINE position before REFPOINT is activated.
Reference point can be used alsot with an external axis. In this case you do not achieve a
parallel displacement but:
a rotating external axis moves a number of degrees from it's current starting position.
a linear external axis moves a number of millimeters from it's starting position.

6.7VELCTRL
See section 10.4 for more detailed description.
Speed control is programmed as follows:
1 Program a FINE position instruction.
2 Press VELCTRL
3 Enter the number of the sensor (1-16) with the numerical button set
4 Press the function button ENTER. If the question THRESHOLD VALUE=" is
presented on the lower line of the display, go directly to point 7. Otherwise go to point 5.
5 Specifiy the speed as a percentage (0-100) of the programmed speed with the
numerical button set.
6 Press ENTER.
7 Specifiy with the numerical button set the required threshold value as a percentage (0100) of the maximum signal range of the sensor. If the current signal level is to be a
threshold or maximum value, run the robot with the joy stick to the position where the
sensor gives the required signal.
8 Press ENTER.
The argument is now programmed. If required, further arguments can be added to the
instruction.
Programming

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6.8 CONTOUR
See section 10.5 for more detailed description.
Contour tracing is programmed as follows.
1 Program a FINE position instruction.
2 Press SCAN
3 Press CONTOUR
4 Enter the number of the sensor (1-16) with the numerical button set
5 Press ENTER. If the question "BIAS = "is shown on the lower line of the display,
continue to point 6. Otherwise go to point 8 directly
6 Specify with the numerical button set the required bias as a percentage (0-100) of the
maximum signal range of the sensor. If the current signal level is to be the bias, run the
robot with the joy stick to the position at which the sensor gives the required signal
before the value is programmed.
7 Press ENTER
8 If further sensors are to be used press YES and repeat points 4-6 for the new
sensor. Otherwise press NO.
The argument CONTOUR is now programmed. If required, further arguments can be
added to the instruction.
Note
This instruction is affected by the use of the speed correction buttons +%, -%

Programming

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6.9CORVEC
See section 10.6 for more detailed description.
A correction movement is programmed as follows.
1 Check that the relevant sensor is defined.
2 Press SCAN twice
3 Press COR VEC
4 Specify the number of the sensor (1-16) for which the correction movement is to be
programmed with the numerical button set
5 Press ENTER
6 Run the robot with the joystick a short distance in the direction required
7 Press END POS
Note
If the operator should release the enabeling device during running with the joy
stick before finishing the sequence the programming of this function has to be
started from the beginning.
If the current percent value V = .... % on the upper line of the display is to be changed for
the correction separately, execute the points 7 and 8 below. Otherwise omit these.
8 Specify with the numerical button set the required percentage value for the correction
(0.1-799.9)
9 Press ENTER.

6.10 POS POS

Position argument for movement
With POS POS a positioning instruction is programmed in such a way that the robot,
during program execution, will move to a stored position i. e. with the tool orientation
stored. The position can be provided with an offset if required.
1. Select POS POS under the POSITION menu.
2. The system now asks: VIA REG? Answer YES if you wish to specify a register which
contains the position regist number. Answer NO if you wish to give the position register
number directly.
3. Specify a required register number (0 - 199)
4. Specify if a displacement (OFFSET) is to be added. If the answer is NO, the argument
is entered and ready.

Programming

14

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6 Position instruction menu

5. If the answer is YES, the offset, it can be given in one of the ways described here:
A. Enter the x-, y- and z-values in basic coordinates in mm with one decimal and with the
correct sign. If any of the values is to be 0, press ENTER directly. See figure below.
B Run the tool the distance required in the direction required and then press END POS.
C
Select VIA REG
Define the scale factor (0.1 - 20, scale factor 1.0 means 1 mm or 0.1 inch).
Define the data register which contains the required x- displacement.
Define the data register which contains the required y- displacement.
Define the data register which contains the required z- displacement.
The latter procedure thus allows entry of displacements from data registers is possible.
In this way the offsets can be changed dynamically during program execution.
See section 3.4.1for more information about, parameter DHANDCK.

From above

"

Programming

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6 Position instruction menu

6.11 STO POS

Storage of position
Menu: POSITIONING

Function: STO POS

1. Select STO POS under the POSITIONING menu.

2. Specify a position register 0-199 in which the position is to be stored.
3. (Valid if position register 0-49). Specify if the current position of the robot is to be stored
at occasion of programming (Answer YES on the question PROGRAMMED POSITION?)
or if current position shall be stored during program running (answer NO).
Note that only register 0-95 stores external axes. Register 96-199 does not store external
axes.
The instruction is now complete.
Note STO POS is intended for FINE positions. If the instruction is used on other types of
position zone, the starting point of the zone (the zone entry point) will be stored.
For more detailed information see section 4.9.2.
If Programmed point is selected,the position will be fixed and can not be changed during
execution. I.e. execution of the position does not store the current position of the robot.
(Valid for AW)
|\ Check if reference point shall have influence over stored coordinate values or not. If the
reference point shall be counted must the parameter REF POINT MOD be activated.

Programming

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6 Position instruction menu

6.12 POS LOC

Location argument for movement
Menu: POSITIONING

Function: POS LOC

With POS LOC a positioning instruction is programmed in such a way that the robot,
during program execution, will move to a stored location i e with the current tool
orientation. The location can be provided with an offset if required.
1. Select POS LOC under the POSITIONING menu.
2. The system now asks: VIA REG? Answer with YES if you wish to name the register
which contains the number of the position register you wish to use. Answer NO if you
wish to give the number of the position register directly.
3. Specify the required register number (0-99)
4. Specify if a displacement (OFFSET) is to be added. If the answer is NO, the argument is
entered and ready.
5. The offset, can be given in one of the ways described here:
A. Enter the x-, y- and z-values in basic coordinates in mm with one decimal and with the
correct sign. If any of the values is to be 0, press ENTER directly.
B Run the tool the distance required in the direction required and then press END POS.
C
Select VIA REG
Define the scale factor (0.1 - 20, scale factor 1.0 means 1 mm or 0.1 inch).
Define the data register which contains the required x- displacement.
Define the data register which contains the required y- displacement.
Define the data register which contains the required z- displacement.
The latter procedure thus allows entry of displacements from data registers.

Programming

17

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6.13 CIRCLE
Circular movement
Menu: POSITIONING

Function: CIRCLE

Means:
The tool moves in a circular arc if the program is executing in RECT or MODRECT
coordinates.

2 = CIRCLE POINT

Facts:
A circular arc < 180 degrees is built up of two standard points and an intermediate circle
point. For circular arcs, equal to or greater than 180 degrees, two circular arcs with the
same radius must be used in succession (the end point for the first becomes the starting
point of the second).

6.14 FRAME
Activation of program displacement
Menu: INSTRUCTION

Function: FRAME

1. Select FRAME under the POSITION menu.

2. Position (1-3) that should be stored.
The new frame will be calculated, when the instruction FRAME (1-5) DEFINE is executed.
It will be activated when FRAME (1 - 5) is executed.
For more information, see section 3.9.2, 5.15, 9.6 and 10.7.
See section 3.4.1 for more information about, parameter DHANDCK.

Programming

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6.15 TIME
Definition of positioning time
Menu: POSITIONING

Function: TIME

1. Select TIME in the menu

2. Specify the positioning time for movement from the preceding position in the program
forward to the current position in seconds with one decimal. Max time is 650 seconds.
Note
The TIME-argument can occur together with the following arguments:
SEARCH
POS LOC
FINE Cl, C2
RELTOOL (MH/GL/SW)
POS POS
All other arguments:
Disappear when the TIME function is selected
Are impermissible when the TIME function has been selected.

6.16 PALLET
(MH/ASM and GLUE)
Means:
A pallet (matrix) is defined by specifying three of the corner points. The robot is then
automatically positioned to the different points in the pallet. Every time the PALLETinstruction is executed the positioning will be made to the next element in the pallet.
Facts:
The pallet is defined by specifying the size, number of rows and columns, and by manually
moving the robot to three corner points. A position above the pallet can also be defined by
giving the fourth position. This position specifies a displacement from the first point. This
displacement can then be used for all points to define a fetch position above the pallet. 10
pallets can be defined with a size of up to 99x99 elements in each. Also single columns can
be defined.
The pallets can be stored on floppy disc together with the other system data.
The pallets can be placed anywhere in the working area and they need not be rectangular.
Actual position in the pallet is pointed out by two ordinary registers. These are
automatically updated when a PALLET- instruction is executed but can also be set by the
REGister- instructioin.
The positioning can be done both to a position above the pallet and to the real pallet
position.
When the pallet is defined the orientation of the tool (not the wrist) is stored. This has the
effect that a multigrip with different TCPs can be used if the BASEPoints are defined.
Used:
When any type of pallet or matrix-pattern is used.

Programming

19

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6 Position instruction menu

Executed:
The robot is positioned to the next position in the pallet. If the last position in the pallet
has been passed or if the registers are pointing out a nonexistent position in the pallet an
error message is given.
Meny: POSITIONING

Funktion: PALLET

1 Select PALLET under the POSITIONING menu.

2 Specify pallet number 0-9
3 Specify the register which contains actual column.
4 Specify the register which contains actual row.
5 If positioning shall be done above the pallet select YES, if it shall be done in the
palletlevel select NO.
The instruction is now ready.
Note!
The registers must be set to correct values before the PALLET instruction is performed.
See section 3.4.1 for more information about, parameter DHANDCK.
Example:
The robot shall fetch details from a pallet and assemble these somewhere. The pallet has
been defined as Pallet no. 1. Two points contain no details because they are check holes for
the fixture. See figure.

|x|

Programming

Pallet 1:7 rows - 6 colums

[x\
a
a

Check hole

20

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'PROGRAM 10
i
i

100SETRl=l
110SETR2=l
120SETR3=l
130 SET R4 = 1
140 JUMP TO 300 IF Rl=l * R2=4
150 JUMP TO 300 IF Rl=6 * R2=4
160 POS V=100% PALLET 1 Rl R2 OFFSET
170 POS V=50% FIN PALLET 1R3 R4
180 GRIP 1 WATT 0.3 S
190 POS V=50% RELTOOL DX= - 50
200 CALL PROG11
210 JUMP TO 140 IF R2<8
220 !

Initiate
Initiate
Initiate
Initiate
Jump if hole 1
Jump if hole 2
Above pallet
In pallet
Grip
50 mm above pallet
Assemble
Continue until all details are used.
Change pallet....

250 JUMP TO 100

i

300 SET Rl = R 1+1

310SETR3 = R3+l
320 JUMP TO 140 IF R 1 < 7
330 SET R 1 = 1
340SETR2 = R2+l
350SETR3 = l
360 SET R4 = R 4+1
370 JUMP TO 140

Control hole
New column
Jump if not end of row
New row

6.17 RELTOOL
Tool-relative displacement (MH/GL/SW)
Means:
The next goal position is calculated relative to the present position and orientation of the
tool and based on the arguments given in the instruction or in the referred registers.
Facts:
The arguments are given as elementary translations and rotations in the rectangular hand
or tool coordinate system defined in the chapter 3.2 'Coordinate systems'. If the active TCP
does not have a corresponding basepoint (BASEP) the movement is calculated in the hand
coordinate system.
The movements (arguments) resemble the joystick movements. No more than six
arguments can be given in one instruction.
The translations (DX, DY, DZ) and rotations (RX, RY, RZ using the 'right hand rule') are
combined based on the initial orientation of the tool. (For example RX is a rotation about
x"-axis.) The resulting position is the result of this combination and the initial position.
Additional POSITIONING arguments (V(%), FINE, TIME, SEARCH, CONTOUR and
VELCTRL) can be given with RELTOOL.
The translational arguments are given in mm or inches and the rotational in degrees.

Programming

21

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6 Position instruction menu

When the arguments are given in registers, they can be scaled with a scale factor, that can
have values from 0.1 to 20 with 0.1 increments. Then the real argument value is the integer
in the referred register multiplied with the scale factor. The resolution of the values in the
registers is 1 mm, 0.1 inch and 1 degree with scale factor of 1.
For safety reasons limit values for the arguments can not be exceeded. They are 400 mm for
translations and 180 degrees for rotations.
The arguments can be modified by the DISPL-function.
Used:
When a movement relative to the present position and orientation of tool is desired. The
arguments can be also calculated outside robot and transferred to robot via a port as
described in the section 5.8.
Executed:
As a special variant of POSITIONING. The movement is performed if the arguments are
within the safety limits.
The movements are always performed in the rectangular coordinates (RECT).

6.17.1 REL TOOL (X.Y.Z)

Procedure:
POS RELTOOL with immediate arguments
Menu: POSITIONING

Function: RELTOOL

1.

Select RELTOOL under the POSITIONING menu.

2.

Specify that the arguments are given in the instruction by pressing NO.

3.

Enter translational arguments (DX, DY, DZ) as required

4.

Enter rotational arguments (RX, RY, RZ) as required.

5.

Push 'BREAK.

6.

Enter other POSITIONING arguments.

The instruction is now complete.

Recommendation:
The instruction should be programmed with FINE point.

Programming

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6.17.2 REL TOOL (via REG)

Procedure:
POS RELTOOL with pointers to registers containing arguments
Menu: POSITIONING

FunctionrRELTOOL

1. Select RELTOOL under the POSITIONING menu.

2. Specify that the arguments are given in registers by pressing YES.
3. Enter the scaling factor for the arguments.
4. Enter register numbers containing translational arguments (DX, DY, DZ) as required.
5. Enter registers numbers containing rotational arguments (RX, RY, RZ) as required
6. Push'BREAK.
7. Enter other POSITIONING arguments.
The instruction is now complete.

6.18EXTFRAME (AW only)

Programming of EXTFRAME, see section 12.6.5.

Programming

23

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V(%)

SAME

ZONE SEARCH SCAN

100 POS V = 100% PATH

VELOCITY 20%

100 POS V = 20% PATH

V(%)

SAME

ZONE SEARCH

SCAN

f
PREVIOUS
INSTRUCTION:
90 POS
V=100% FINE

100 POS V= 100% PATH

100POS V=100%FINE

FINE

! 100POS

CORNER1

CORNER2

v= 100% FINE

1 V(%)

ZONE SEARCH SCAN i

|n

msss&
MM*

i 100 POS

v =100% C l

100 POS

ZONE SEARCH SCAN i

V(%)

V(%)

ZONE

v= 100% C2
SEARCH

SCAN

1 i i

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6 Position instruction menu

100 P O S V - 100 % F1WJE
V(%J

SAME ZONE

SEARCH SCATS

100 POS V m 100 % FINE

DIST

AUTO

D1K

AUTO button, Only Arc Welding

SEE PAGE 26

SEE PAGE 27

3g 100 POS V = 100 % FINE

100POS V=.100%FINE
MORE SENSORS?

YES

100POS V- 100%FINE

100 POS V . 1 0 0 % FINE SEARCH S6

ZONE

ZONE SEARCH SCAN

SEARCH SCAN

If an anlog or digital multibitsensor is used, the system asks for a stop condition before this is
shown on the display. The answer is to be entered in percent of the maximum sensor voltage.
** The stop condition for the current multibitsensor is displayed when the instruction is
completed (e.g. S6/45%).

Programming

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6 Position instruction menu

SEARCH/DIR

100FOS V=100% FINE

SENSOR NO 6

100 POS V = 100% FINE

MORE SENSORS?

100 POS V = 100% FINE

100 POS Vs 100* FINE

**

DIBSEARCH DELAY SG
ZONE

SEARCH

100 POS V * 1 0 0 * FINE

DIRSEARCH DELAY S6

ZONE

SCAN

SEARCH

SCAN

If an analog or digital multibitsensor is used, the system asks for a stop condition
before this is shown on the display. The answer is to be enterde in percent of the
sensor voltage.
** The stop condition for the current multibitsensor is displayed when the instruction is
completed (e.g. S6/45%)

Programming

26

S3

6 Position instiruction menu

SEARCH/AUTO
100 POS V= 100% FINE

100 POS V = 100% FINE

100 POS V = 100% FINE

Programming

27

S3

6 Position instruction menu

SCAN

100POS V = 20%FINE
REFP

VELCTRL CONTOUR

SCAN

100POS V = 20%FINE

\ 100POS V = 20%

REFPOINTON

100 POS V = 20 %

Programming

28

REFPOINT OFF

S3

6 Position instruction menu

SCAN

100POS V = 100%FINE
WEAVE

4
A

3
b

REFP

VELCTRL

CONTOUR

SCAN

100 POS V = 1001FINE

SENSOK MO =

UK

1tmmm

SENSOR N O - 2

KNTKK

Up

100 POS V m WO% FINE

** For multibit sensors these texts are replaced according to following:

The threshold value, before the speed is to decrease, is specified in % of the maximum
sensorvoltage.
* The argument to the positioning instruction is presented without
"VCORR = 20%" instead threshold and maximum values are displayed (e.g. S2/20% max = 75%)

Programming

29

S3

6 Position instruction menu

SCAN

100POS V = 100%FINE
REFP

VELCTRL CONTOUR

SCAN

an

100POS V = 100%FINE

100 POS V = 100 % FINE

100 POS V = 100 % FINE CONTOUR S9

V%

ZONE

SEARCH

SCAN

If analog or digital multibitsensor is used, the system asks for a bias before this is
shown on the display. The answer is to be entered in percent of the maximum sensor
voltage.lt is displayed when the instruction is completed (e.g. S9/40%)

Programming

30

S3

6 Position instruction menu

SCAN 2 TIMES

100POS V= 100%PATH
COR.VEC

POSPOS

STOPOS

POSLOC

SCAN

100 POS V= 1 0 0 * FINE

100POS V = 100%PATH
4
7
-

6
9

POSITION NO=

|
CE ENTER

ft&gN8&Siffi8SPDfl&tSf!i

POSITION NO = 7

SENSOR NO =9

100 POS V = 10 % STORE POSITION 7

PROGRAMMED POSITION? YES NO

100POS V= 100%PATH

100 POS V=100* STORE

100POS V=100%PATH

POSmON7

VELOCITY (%)=

100POS V= 10%

Programming

VECTORS9

31

S3

6 Position instruction menu

FROM PAGE 31

100POS V = 60%FINE
COR.VEC POSPOS STOPOS POSLOC

SCAN

100POS V = 60%FINE

100POS V = 60%FINE

100POS V = 60%FINE
POSITION NO

POSITION NO= 5

100POS V=60% FINE POSITION5

100POS V = 60% FINE POSITION(R2)

100POS V=60%

100 POS V=60% FINE POSITION (R2)

ZONE SEARCH SCAN

FINEPOS1TION5

ZONE SEARCH SCAN

32

S3

6 Position instruction menu

FROM PAGE 31

100 POS V = 60 % POSTION 5

VALUE VIA REG AUTO

_JS'^

SEE PAGE 36

100 POS V = 60 % POSTION 5

100 POS V = 60 % POSTION 5

100 POS V = 60 % POSTION 5

CE

ENTER

| 100 POS V = 60% POSTION 5

100 POS V = 60 % POSTION 5

ZONE

SEARCH

n II

^SCAN

100 POS V = 60 % POSTION 5

ZONE

Programming

SEARCH

SCAN

33

S3

6 Position instruction menu

FROM PAGE 31

100POSV = 60%FINE
VECTOR POSPOS

1 2
4

7
-

8
0

STOPOS

POSLOC

SCAN

3
LOCATION NO =

CE

pal mmmm

LOCATION NO =5

ENTER ;

i|

REG NO = 10

100POSV = 60%FINE LOCATION (RIO)

100POSV = 60%FINE LOCATION 5

YES

OFFSET?

NO

SEEPAGE 33

SEE PAGE 33

100POSV = 60%FINE LOCATION (R10)

V%

ZONE

SEARCH

SCAN

100POSV = 60%FINE LOCATION 5

V%

Programming

ZONE

SEARCH SCAN

34

S3

6 Position instruction menu

PROM PAGE 31

100 POS V = 60 % LOCATION 5

SEE PAGE 36

100 POS V = 60 % LOCATION 5

X=5

100 POS V = 60% LOCATION 5

100POSV = 60% FINELOCATION5

Y=4

100 POS V = 60% FINE LOCATIONS

CE

ENTER

Z=3

100 POS V =6 0 % LOCATION 5

v%

ZONE SJSAKCH

- > SCAN

I
i OFFSET X=5 Y=4 Z=3
Ij V%

ZONE SEARCH

SCAN

BffHSB55388SHB5i

1 P
Programming

35

S3

6 Position instruction menu

FROM PAGE 33 and 35

=100 % POSITION 1
VALUE

VIA KEG

AUTO

10 POS V =100 % POSITION 1

10 POS V =100 % POSITION 1

10 POS V =100 % POSITION 1

10 POS V =100 % POSITION 1

ZREG NO = 3

10 POS V =100 % POSITION 1

SEARCH SCAM

OFFSET SC = 1.5 X = (R2) Y =0 Z= (R3)

FINE

Prograi

36

SEARCH SCAN

S3

6 Position instruction menu

SCAN 3 TIMES

100 POS V =100 % CIRCLE

100 POS V =100 % PATH

100 POS V =100 % FRAME POS1

Pmgr

37

S3

6 Position instruction menu

SCAN 4 TIMES

140POSV=100 %PATH
PALLET REL TOOL SCAN

140POSV=100 %PATH

PALLET NO=1

140POSV=100 %PATH

140POSV=100 %PATH

140POSV =100 % PALLETTl Rl R2

140POSV =100 % PALLETTl Rl R2 OFFSET

Programming

140POSV =100 % PALLETTl Rl R2

38

S3

7 Automatic menu

Automatic menu
Section

Page

7.1-4
7.5
7.6
7.7

7:5
7:5
7:6
7:6

PROGST., INS ST., BWD., SIM

DISPL
CORV ST
ALIGN
7.7.1 Tool direction
7.7.2 External axes
7.7.3 Homeposition
7.8 AW REST
7.9 RESYNC
7.10 MOV REST

Programming

7.8
7:8
7:9

S3

7 Automatic menu

Programming

S3

7 Automatic menu

PROGST
ConEprogr
execution

instruction
wiseprogr.
execution

CORVST
Displacement of progr.
pos

Check of
correction
movem

RESYNC

MOVREST

Resynchronization of
sync, axes

Restart after
interrupt

Exec, of pos.
instr. backwards

Simulation
ofWATT
condition

ALIGN
Alignment
of tool or home
position

* Possible to block by parameter setting,

(see Installation S3 chapter 5)

PROGST
Cont progr.
execution

INSST
Instruction
wise progr.
execution

CORVST
Displacement of progr.
pos

(Jheck ot
correction
movem

RESYNC

MOVREST

Resynchronization of
sync, axes

Restart after
interrupt

Programming

Exec, of pos.
instr. backwards

Simulation
ofWAIT
condition

AW REST
Arcweld
Restart

Alignment
of external axes or
homeposition

S3

7 Automatic menu

Pri>grnTTrmiTig

S3

7 Automatic menu

7.1-4
PROG ST., INS ST., BWD., SIM
Menu: AUTOMATIC

Functions: see below

PROGST

Continuous execution forward.

INSST

Execution instruction by instruction forward.

BWD

Execution of tool movements only, instruction by

instruction backwards, logical instructions must be skipped over
using the SKIP BW button. Position instructions can be skipped if
desired.
The PROG ST, INS ST resp. EXEC BW keys must be pressed
during program running in manual full speed mode.
When execution in MANUAL REDUCED SPEED mode it is
possible to disconnect this function with the parameter HOLD RC.

SIM

Simulation of input conditions for WAIT instruction. If the button

is depressed when a WAIT instruction is executed, all conditions
are assumed to be satisfied.

Program start (PROG ST, INS ST, EXEC BW, AW REST) means that the robot
will start moving at high speed.
Make sure nobody remains inside the robot working range before starting the
robot and make sure all safety equipment is functioning correctly.

7.5
DISPL
Definition of position by reading in during program execution.
Menu: AUTOMATIC

Function: DISPL

1.
2.
3.
4.

Select DISPL during programming program execution.

Specify the program 0- 9999 within which the position to be changed is located.
Specify the instruction number for the position within the program 10 - 65 535.
Specify the displacement from the present position in mm, with one decimal,
for the X- ,Y- and Z-coordinates in the base coordinate system. If any of the
displacements are zero press ENTER directly when the coordinate value concerned is
requested by the system. Permitted maximum value for the different coordinate
displacement is 10 mm.
Interrupt the procedure completely by selecting the AUTOMATIC menu again.
Informationabout the active program etc. is then presented again.

Select the AUTOMATIC menu again if the displacement is to be executed again with this
function by:
A position which is before the newly adjusted position in the same program.
A position within another program.

Programming

S3

7 Automatic menu

7.6
CORVST
Execution of correction movement
Menu: AUTOMATIC

Function: CORV ST

The CORV ST function is used when the correction movement for a specific sensor is to be
checked. The check is performed according to the following:
1. Call the vector instruction required, see program selection and searching within the
program.
2. Press AUTO
3. Press SCAN
4. Press CORVST
When point 4 as above is performed, the robot will move in the direction programmed for
the activated sensor (Activation takes place when the desired instruction is executed).
Note. If the sensor concerned is mounted on the robot in accordance with the sensor data entered
(see chapter 9.5), the direction of the robot orientation is affected when the button CORV
ST is pressed.
To enable the function the robot must be in AUTO with no program execution.

7.7
ALIGN
7.7.1
Tool direction (MH/GL/SW only)
Menu: AUTOMATIC

Function: ALIGN

Means:
The tool is rotated to desired orientation while TCP stand still. With BASE mode the x"axis of tool (see chapter 3.2.3) is aligned with one axis of the rectangular basic coordinate
system.
Facts:
Ten different orientations of (0-9) can be stored and used afterwards. For practical reasons
the tool should be rotated at first with a joystick close to the desired orientation. If the
overall rotation will be wider than 20 degrees in the BASE mode and 45 degrees in the
FETCH mode, an error message is displayed.
Because ALIGN depends excessively on the definition of the TCP, it should be checked
before ALIGN is used at first time with a TCP.
The TCP can be changed between storing and reusing an orientation.
Stored orientations are transferred to and from diskette with other system parameters.
Used:
When a specific, or repeated orientation is used in a robot program. Thus it is used during
teaching of positions.

Programming

S3

7 Automatic menu
Executed:
Only if the desired rotation is not wider than the limits above and the operator starts the
movement.
Procedures:
Storing an orientation (STORE)
1. Select ALIGN under the AUTOMATIC menu.
2. Select STORE.
3. Enter the number of the orientation.
Reusing a stored orientation (FETCH)
1. Select ALIGN under the AUTOMATIC menu.
2. Select FETCH.
3. Enter the number of the orientation.
4. Start align movement.
The robot will move with slow speed and "ROBOT ALIGNED" will be displayed.
Aligning the tool to a base coordinate system axis. (BASE)
1. Select ALIGN under the AUTOMATIC menu.
2. Select BASE.
3. Start align movement.
The robot will move with slow speed and "ROBOT ALIGNED" will be displayed.

7.7.2
External axes, (AW only)
Menu: AUTOMATIC

Function: ALIGN

Alignment of external axes together with the EXTFRAME function.

See description of EXTFRAME in section 12.6.5.
1. Select ALIGN under the AUTOMATIC menu.
2. Enter the EXTFRAME number
3. Start align movement
The external axes will move with slow speed and "EXTERNAL AXES ALIGNED" will be
displayed.

Programming

S3

7 Automatic menu

7.7.3
HOMEPOS
Menu: AUTOMATIC

Function: ALIGN

Alignment of robot axes towards a defined home position.

See description of HOMEPOS in section 9.17
1. Select ALIGN under the AUTOMATIC menu.
2. Select HOMEPO under ALIGN.
3. Select homepos number and start align.
The robot will move in robot coordinates with slow speed to the specified home position.

7.8
AW REST (AW only)
Arcweld restart
The function AW REST facilitates restarting of the welding process after an interruption.
To make the welding seam as good as possible, the robot is moved to an optional position
which it had 0 - 0.45 seconds before the interruption.
(See Installation S3 for parameter setting). Then the welding process is restarted with the
same welding parameters as were used before the interruption. AW restart is performed as
follows:
1. Press AUTO.
2. Press SCAN.
3. Press AW REST.

Note.
A restart attempt when it is not allowed will result in an error message: "NOT ALLOWED
COMMAND".
Program start (PROG ST, INS ST, EXEC BW, AW BEST) means that the robot will
start moving at highspeed.
Make sure nobody remains inside the robot working range before starting the robot
and make sure all safety equipment is functioning correctly.

7.9
RESYNC
Using the function RESYNC it is possible to make synchronized axes unsynchronized
without reinitiating the entire system. This is done in accordance with the following:
1. Press AUTO.
2. Press SCAN twice.
3. Press RESYNC.
4. If the robot includes syncronized external axes then press SYNC white will commence
the synchronization movement.
5. Calibrate the robot. (See Service manual IRB XXXX.)

Programming

S3

7 Automatic menu

7.10
MOV REST
The function Move Restart is used for restarting the robot when there is a risk for
collisions, e.g. after an emergency stop (see 3.6.1.5).
The robot starts from standing still (2) by moving back (3) to the path, to approximately
where the interrupt occured (1).
This movement is made at about 125 mm/s.
The robot then moves forward (4) on the path at a speed of 25% of program speed.
When the TCP has reached the position (5) of the path planner at the interrupt, normal
program execution is resumed (6).
All positioning instructions except WEAVE, PALLET and RELTOOL can be restarted.
Note that a continous process, like gluing and arc welding is not resumed until the next
process instruction is executed (for AW; use AW restart).
forward path at
25% of program speed

TCP position at E-stop

path planner position

at E-stop

reverse path
at 125 mm/s
TCP position
at stand still

forward path at
program speed

Programming

S3

7 Automatic menu

1 100POS V =100% PATH

!PROGST INSST BWD SIM
I i t hi in

100% |
SCAN |

!imp
100POS V = 100% PATH
PROGST INSST
?

BWD

SIM

SCANR

S^^^^SS8S5^ffi^88S5SS8SS5SSKK8 ffi SS8SSS?KW5S

100%POS V = 100% PINE

PROGST

INSST BWD

SIM

SCANR

90POS V = 10% FINE

90POS V = 10% FINE

SKIP POSITION BACKWARDS? YES NO

START P. PAGE 11
START P. PAGE 11

Programming

10

S3

7 Automatic menu
START P. PAGE 10

60 POS V =100% FINE

40 POS V =100% FINE

60 POS V =100% FINE

Programming

11

S3

7 Automatic menu
100 POS V=100 % PATH

PUSHED "SIM" GIVES FULFILLED

CONDITION WHEN WAIT-INSTRUCTION
IS EXECUTED

100%

100 POS V=100% PATH

DISPL

CORVSTAWREST*

ALIGN* SCA

ALIGN PAGE 15
AW RESTART PAGE 16
USED FOR AN INSTRUCTION IF
CORRECTION FOR A SENSOR IS
DISPLAYED.WHEN YOU PRESS
THE BUTTON THE ROBOT WILL
MOVE 50 MM IN THE CORRECTION
DIRECTION LATEST ACTIVATED
FOR THE RELEVANT SENSOR

100 POS V=100% PATH

INSTRUCTION 30

DISPL. PAGE 13
DISPL. PAGE 13

Programming

12

S3

7 Automatic menu
DISPL. PAGE
DISPL. PAGE 12

INSTRNO =
ENTER

40 POS V= 100%

FINE

and so on

Programming

13

S3

7 Automatic menu
50

P O S V = 100% PATH

PROGST INSST

50

BWD

SIM

SCAN

POS V= 100% PATH

DISPL

CORVST ALIGN*

MH/GL/SW
50

POS V= 100% PATH

STORE

FETCH

BASE

HOMEPO PAGE 15

50

50

POS V= 100% PATH

ORIENTATION NO

POS V= 100% PATH

START ALIGNMENT?

ROBOT ALIGNED

50

POS V= 100% PATH

ORIENTATION NO

50

CE

ENTEE

POS V= 100% PATH

START ALIGNMENT?

ROBOT ALIGNED

Programming

14

S3

7 Automatic menu
ALIGN PAGE 12

100 P O S V = 100% PATH

j 100

POS V= 100% PATH

- j j l | EXTFRAMENO*

100%
CE

ENTER

mmmmm

100 POS V= 100% PATH

HOME POS 1: A!=20 A2=-4 A3=-ll

START ALIGN?

EXTERNAL

AXES ALIGNED

100 POS V=100% PATH

DISPL

CORVST AW REST

100%
ALIGN SCAN

100 POS V=100 % PATH

CORVSTAWREST AUGN

Programming

SCAN

15

S3

7 Automatic menu

Scan 2 times

50POSV=100%PATH
RESYNC MOVREST

SCAN

ROBOT NOT SYNCHRONIZED

SYNC

DE3PL ORIDE

100%
SIM

Synchronizing

Programming

16

S3

8 Editing menu

Editing menu
Section

Page

8.1
8.2
8.3
8.4
8.5

8:5
8:5
8:5
8:5
8.6

V%

INSTNO
STEP
MODPOS
MODIFY
8.5.1 HANDCHK
8.5.2 MODIF and MODARG
8.5.3 DISPL
8.5.4 MODEXT
8.6
DELETE
8.7
INSERT
8.8
PROGRAM
8.9
RESEQ
8.10
COPY
8.11
ERASE
8.12
PROG NO
8.13
MIRROR
8.14
TIME
8.15
COPY INS

Programming

8:8
8:8
8:9
8:9
8:10
8:11
8:11
8:13
8:14
8:15

S3

8 Editing menu

Programming

S3

8 Editing menu

f-*f
1
V(%)

Change of
speed

1
MODIFY

Change of
aninstr.

1
RESEQ

Resequencing
of instr. no.

INSTNO

STEP

Calling of
aninstr.

MODPOS

Stepinstr.
byinstr.

DELETE

INSERT

Erasure of
aninstr.

PROGRAM

Addition of
aninstr.

SCAN

Calling sequence
Calling of progr.

COPY

Copying of
a program

SCAN

Change of
progr. pos.

PROG NO

ERASE

Erasure of
program

used

SCAN

listing of
progr. no.

MIRROR

TIME

Mirroring of
program

Change of
pos. time

Programming

= Editing

COPY INS

SCAN

Copying of
instruction

S3

8 Editing menu

Programming

S3

8 Editing menu

8.1

V (%)
Change of speed
Menu: EDITING
Function: V%
Means:
The percentage speed in an instruction is changed. For changing of the basic or maximum
speed, see 8.5.
Used:
When editing a program.
Executed:
After the conclusion of the procedure, the robot reacts immediately.
Procedure:
Change of percentage speed
1. Ensure that the instruction required is presented on the display.
2. Select V% under the EDITING menu.
3. Specify the new percentage speed 0 - 799.9% as a percentage with one decimal.
The new percentage speed is shown in the instruction.

8.2 INSTNO
Instead of stepping forward to a certain instruction, it is possible to call it up directly by
pressing INST NO. The robot then asks which instruction number is required and when
this is given, the instruction line is shown on the display.

8.3 STEP
The STEP function is used when, for example, the program is to be presented instruction by
instruction. When STEP is pressed, it is possible to press INST NO FORW or BWD as
required. For each pressing of these buttons, a new instruction line is presented on the
display.

8.4 MODPOS
Procedures:
Redefinition of location by running the tool
Menu: EDITING
Function: MODPOS
1. Ensure that:

The tool moves as programmed to the position to be changed.

The correct instruction is shown on the display after the positioning.

2. Run the tool to the correct position.
3. Select MODPOS under the EDITING menu.
4. If the parameter MODPOS is defined (see Installation S3). Answer YES to verify the
change.
If the axes 10 - 12 are present in the system "MODPOS" will affect both instructions, if
"MODPOS" is selected when the POS-instructions are displayed on the programming unit.
The procedure is now completed.

Programming

S3

8 Editing menu

8.5

MODIFY
Change of instruction
Menu: EDITING

Function: MODIFY

Means:
An instruction is changed, partly or completely.
Facts:
Different subfunctions are available:
HANDCHK
MODINST, the complete instruction is reprogrammed.
MODARG, a motion instruction argument except position and speed is reprogrammed.
DISPL, the position for a motion instruction is changed.
MODEXT, modification of external axes.
With AW software a subfunction CLE LO (clear local override) is also available. See
Override, section 12.7.2.
Note

Change only absolute positions in the program, i.e. deactivated reference point and
reference frame 0 active. Otherwise, the expected change of position does not
correspond to the actual.

8.5.1

HANDCHK
There is an implicit argument to the POS-instruction, HANDPOS, which stores information
of the configuration of the robot arm as it was when the POS-instruction was programmed.
This information is used when running the robot in Robot Coordinates or Modrect
Coordinates to ensure a specific configuration (see chapter 3.4) of the arm. When running in
rectangular coordinates the robot will choose the configuration corresponding to the
smallest movement from start to end position. In rectangular coordinates a supervision is
available, which will stop the robot if anything of the following occurs:
1. The fourth axis is more than 45 degrees in direction from its position at programming
time.
2. The sixth axis is more than 90 degrees from its position at programming time.
3. The programmed axis configuration is not achieved.
This supervision is normally active, but can be deactivated and then reactivated with the
function HANDCHK
If the inspection is not to be performed, "*" will be displayed in the instruction.
Change of HANDCHK argument
1.
2.
3.
4.

Programming

Call up the positioning instruction which is to be changed.

Select CHANGE under the EDITING menu.
Select HANDCHK
Answer YES or NO to the question WRIST CONFIGURATION CHECK?

S3

8 Editing menu

8.5.2

MODINST and MODARG

Procedure:
Change of instruction
1.
2.
3.
4.

Call up the instruction to be changed.

Select MODIFY under EDITING menu.
Select either MODINST or MODARG.
Reprogram the instruction in the usual way.

The procedure is now complete.

8.5.3

DISPL
Definition of position by entry without moving the tool
1.
2.
3.
4.

Call up the correct program and instruction on the display.

Select MODIFY under the EDITING menu.
Select DISPL.
Specify the displacement from the present location in mm max 10 mm with one decimal
for X-, Y- and Z-coordinates in the base coordinate system. If any of the displacements
are to be 0, press ENTER directly when the coordinate value is requested by the system.

When the menu, shown before point 3 above is performed, is presented again, the
procedure is complete.

Programming

S3

8 Editing menu

8.5.4

MODEXT
Modification of external axes
Means:
MODEXT is a function with which it is possible to copy the position of an external axis to
another, within one and the same POS-instruction. It is possible to execute the copying
within a sequence of instructions.
The system copies the position from the required external axis to another external axis
immediately after the procedure is concluded. The possibility of displacement is available.
Procedure:
Copying of external axes
1. Call the program and the first instruction (of several) which is to be modified.
2. Select MODEXT under the EDIT/MODIFY menu.
3. Specify the axis from which the position is to be copied.
4. Specify the axis to which the position is to be copied.
5. State the number of instructions up to and including the last to be modified.
6. State the displacement in increment. (Max = working range).
When the modification is completed the instruction most recently changed is the current
instruction.
Any intermediate logical instructions and POS-instructions which do not include the
external axes concerned are not affected.

Programming

S3
8

8 Editing menu

8.6 DELETE
Erasure of an instruction
Menu: EDITING
Function: DELETE
Means:
An instruction, or several, in a sequence in the program is erased.
Executed:
The system reacts immediately after the procedure is concluded.
Procedure:
Erase of instruction
1. Call the program required and the first instruction (of several) which is to be erased.
2. Select DELETE under the EDITING menu.
3. Specify the number of instructions which is to be erased, from and including the
instruction displayed.
The first remaining instruction in the program (or the message PROGRAM END) is
presented, thereby concluding the procedure.
Note.
In order to regain memory space you must clear the program block, see Clearing of program
block, (see section 9.1) or make a program selection.

8.7 INSERT
Addition of an instruction
Menu: EDITING

Function: INSERT

Means:
Addition of instructions at an optional place in an existing program.
Facts:
When instructions are added, the new instructions will be numbered in accordance with the
following system.
If the next multiple often is vacant, the instruction will receive this number.
If the next multiple often is occupied, the next following vacant number will be used.
See example next page:
Existing
program

Instructions
to be inserted

Program after
insertion

^^fos

110

POS

120 POS

POS

130 POS
131 POS

Programming

S3
9

8 Editing menu
Procedure:
Addition of instruction
1. Call the instruction after which the addition is to be made, in the required program.
2. Select INSERT under the EDITING menu.
3. Specify the number of the new instruction.
Programming in the normal way of the instructions which are to be added can now begin.

8.8 PROGRAM
To write a robot program, begin by selecting a program number by pressing PROGRAM in
the editing menu after which the robot system asks for the required program number.
When the number is specified, line 10 without an instruction is shown if a new program is
created. If the program already contains instructions, the first program line is presented.

8.9 RESEQ
Numbering in even tenths of instructions
Menu: EDITING

Function: RESEQ

Means:
Renumbering of the instructions within a corrected program so that all instructions again
have numbering in consequitive multiples of 10.
Used:
After editing of a program
Executed:
The system reacts immediately after the conclusion of the procedure.

Programming

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8 Editing menu
Procedure:
Numbering of instructions in multiples of 10
1. Call the program required.
2. Select RESEQ under the EDITING menu.
The procedure is now concluded.
Otherwise:
When the function RESEQ is executed, the jump addresses within the program are also
changed.
An error message is presented when a jump is to be made to an erased instruction.
The renumbering function RESEQ is associated with a function parameter with the same
name. Renumbering is not permitted when the parameter is set to the value 0.

8.10

COPY
Copying of a program
Menu: EDITING

Function: COPY

Means:
A program existing in the user memory is copied under another number.
Used:
For example, when two or several similar programs are to be created.
Procedure:
Copying of a program

'

1. Call the program to be copied.

2. Select COPY under the EDITING menu (used program number is shown with the active
program marked-up with "*" beside the number. Empty memory space, in percent of the
total memory area, is also displayed.).
3. Specify the program number 0- 9999 under which the copy of the program is to be
stored in the user memory. (Attempts to copy a program under an already occupied
program will cause an error message.)
The procedure is now completed.

Programming

S3
11

8 Editing menu

8.11

ERASE
Erasure of a program
Menu: EDITING

Function: ERASE

Means:
One or several programs are to be erased from the user memory.
Facts:
When the function is selected, the size of the remaining user memory can be presented as a
readout by pressing the SHIFT button.
Executed:
The system reacts immediately after the procedure is concluded by specifying which
program is to be erased.
Procedure:
Erasure of a program
1. Select ERASE under the EDITING menu (the numbers of program used are presented
with the active program marked with an asterisk. Empty memory space, in percent of
the total memory area, is also displayed.).
2. Give the program (or the first program in a continuous number series) to be erased with
the number 0 - 9999.
If only this program is to be erased, press ENTER. Thereby concluding the procedure.
Otherwise continue with point 3 below.
3. Specify the last program number, 0 - 9999, in the number series of the program to be
erased.
The procedure is now concluded and the system erases the programs specified, regains the
space after the erased programs in the memory and responds with information about which
programs that have been erased.

8.12

PROG NO
All numbers of programs stored in memory can be displayed by pressing PROG NO. All
program numbers in use are then presented on the display. An active program is marked
with an asterisk after the program number. Empty memory space is also displayed.

Programming

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12

8 Editing menu

8.13

MIRROR
Mirroring of program
Menu: EDITING

Function: MIRROR

Means:
All the positions of the active program are reflected in relation to a mirroring plane.
Facts:
The program is reflected in base coordinates. Three different planes are available:

YZ-plane
A

XY-plane

In addition, a displacement in base coordinates can be added to each of the planes.

Note.
The robot tool must be designed so that it can also be used, in the same way as before, in a
mirrored program i.e. it should be symmetric around the selected plane.
Used:
When a (copied) program is to be mirrored (in relation to the original program).
Executed:
A mirroring of a program is performed immediately after the conclusion of the procedure.
Two examples of mirroring are shown below:
Example 1: Mirroring in XZ-plane
1Y

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Programming
13

8 Editing menu
Example 2: Mirroring in parallel displaced XZ-plane
,Y

MIRRORING PLANE

Procedure:
1. Select the program to be mirrored.
2. Select MIRROR under the EDITING menu.
3. CLEAR CONFIG YES NO. (from M93/5, otherwise continue with 4)
Answer Yes and the robot will take the shortest way to get the right orientation of the tool.
This meams that axis 1,4 and 6 can be rotated 180 degrees compared to the original
program (performance as in control programs up to and including M93/4).
Answer No, and it will try to have axes 1,4 and 6 in approximately the same position as
they had when the program was not mirrored. Depending on the orientation it is not
always possible to not clear the configuration.
When you once have answered YES, you can not restore the configuration.
Hint: Try to mirror the program by answer NO.If you the later on want to clear the
configuration, mirror the program twice and clear the configuration when you mirror the
program.
4. Select mirroring plane according to the figures below:
5. Press YES if a parallel offset is wanted.
YZ-plane

XY-plane

SAME
Which means the
same mirroring
plane that was
selected the last
time the MIRRORfunction was used.

6. Press NO if no parallell displacement is wanted.

In this case the mirror plane is defined by the base coordinate system like in example 1
above. The mirroring will be executed immediately.
A displacement can be defined in two ways, A, by entering a value from the teachpendant,
S3

Programming
14

8 Editing menu
or B, by moving the robot a corresponding distance.
A Enter the displacement concerned along the relevant axis in the basic coordinate
system. Use the correct sign for the value which is to be expressed in mm.
In example 2 above a negative value should be entered, corresponding to the distance
from origo to the mirroring plane in negative y-direction.
B Position the robot to a position in the original program with the joystick and press
ST POS. Run then to the corresponding position in the "mirror image" of the program
and press ENDPOS.
In example 2 above the robot is first positioned, for instance, in the point 3 in the
original program and STPOS is pressed. After that the robot is manually moved to the
point 3 where it should be located in the reflected program and ENDPOS is pressed.
Then the mirrorplane will be automatically calculated and all positions in the program
will be mirrored.
Note, when placing the robot in the mirrored point, only the distance perpendiular to
the mirror plane will be used in the calculation.

Before mirroring

8.14

After mirroring

TIME
Change of positioning time
Menu: EDITING

Function: TIME

Means:
The positioning time in an instruction is changed.
Used:
When editing a program.
Executed:
After the conclusion of the procedure, the system reacts immediately.

S3

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15

8 Editing menu
Procedure:
Change of positioning time
1. Ensure that the instruction required is presented on the display.
2. Select TIME under the EDITING menu.
3. Specify the new positioning time in seconds with two decimals (0.00 - 650.00 s).
The new positioning time is shown in the instruction.

8.15

COPY INS
Copying of instruction
Means:
One instruction, or more, are copied.
Facts:
The copied instructions are placed after the current instruction.
Copying to a place between two instructions can be performed if enough spare instruction
numbers are available.
Instructions can be copied from another program.
Performed:
The system reacts immediately after concluded procedure.
Procedures:
Menu: EDITING
Function: COPYINS
1. Call the instruction, after which the copied instructions are to be placed.
2. Select COPYINS under the EDITING menu.
3. Specify from which program the instructions are to be copied. If they are to be copied
from the
current program, press
ENTER directly.
4. Specify the instruction number for the first instruction to be copied.
5. Specify the number of instructions that is to be copied. If one instruction only is to be
copied, press ENTER directly.
The last copied instruction is now shown and the procedure is thereby concluded.

Programming

S3
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8 Editing menu

100POSV = 100% FINE

V(%) INSTNO STEP MODPOS SCAK

100 POSV = 100% FINE

VELOCITY (%)=
CE

100POSV=100% FINE
CE ENTER

ENTER

VELOCITY 60%

INSTRUCTION NR 350

100POSV=60% FINE

350POSV = 100% FINE

INSTNO STEP MODPOS SCAN

V(%) INSTNO STEP MODPOS SCAN

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8 Editing menu

1 0 0 P O S V = 1 0 0 % FINE
V(%) INSTNO STEP MODPOS SCAN
JOG THE ROBOT WITH THE
JOYSTICK TO REQUIRED
POSITION BEFORE
"MODPOS" IS PRESSED.

1 0 0 P O S V = 1 0 0 % FINE

1 0 0 P O S V = 1 0 0 % FINE

INSTNO FORWDBWD BREAK

3 100POSV= 100% FINE

150 POS V=100 % PATH

INSTNO FORWD BWD BREAK

INSTRUCTION NR 350

350 ROBOT COORD

350 ROBOT COORD

INSTNO FORWD BWD BREAK

INSTNO FORWD BWD BREAK

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8 Editing menu
100 POS V = 100% FINE
V(%) INSTNO STEP MGDPOS SCAN

100 POS V = 100 % FINE

MODIFY

DELETE

INSERT PROGRAM

SCAN

100POSV=100% FINE
DISPL CLE.LO MODABG MODINS SCAN

Arc Weld
software only
100POSV = 100% FINE
CE

100POSV=100% PATH
ZONE SEARCH SCAN

ENTER

(MAX 10 mm)

1 2 31100 POS V= 100% FINE

CE
< 5
7 8
(

ENTER

1 1 1

mm

(MAX 10 mm)

1 2 J|jlOOPOSV = l 00% FINE

5
CE ENTER
7 g
(1 > pi
^
1
\
\
(MAX 10 mm)

MM

MB

I| 1

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Progranuning
19

8 Editing menu
PAGE 19
100POSV = 100% FINE

100POSV=100% FINE
HANDCONFIGUKATION CHECK? YES

NO

100POSV = 100% FINE

1 0 0 P O S V = 1 0 0 % *FINE

V(%) INSTNO STEP MODPOS SCAN

/(%) INSTNO STEP MODPOS SCAN

30POSV=100%
TROMAXISNO =

CE

ENTER

30POSV=100%

30POSV=100%

30POSV=100%
DISPLACEMENT

CE

ENTER

80POSV=55%
V(%) INSTNO STEP MODPOS SCAN

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20

8 Editing menu
100POSV=100% FINE
V (%) INSTNO STEP MODPOS SCAN

100POSV=100% FINE
MODIFY DELETE INSERT PROG SCA>

5 HOW MANY?

CE

Gil PROGRAM NO

ENTER

CE

ENTER

PROGRAM NO 7

0 V= 1000MM/5 MAX = 1500MM/S

SET OUTPUT 5
INSTNO STEP MODPOS

SCAN

I (%) INSTNO STEP MODPOS SCAN

100POSV=100% FINE

INSTRUCTION NO 355

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8 Editing menu
100POSV=100% FINE
V(%)

INSTNO

STEP MODPOS SCAN

100POSV = 100% FINE

MODIFY DELETE INSERT PROG SCAN I!

100POSV=100% FINE
RESEQ COPY ERASE PROG NO SCAN

100POSV=100%

RENUMBERING OF INSTRUCTIONS
IN THE PROGRAM TO THE NEAREST
NUMBER OF TEN

100POSV=100% FINE
TIME COPYINS SCAN

COPYINS, PAGE ^5
TIME, PAGE 23
MIRROR, PAGE 24

V(%)

V(ft)

INSTNO

INSTNO STEP

MODPOS SCAN

STEP MODPOS SCAN

ERASE, PAGE 23^

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22

8 Editing menu
ERASE, PAGE 22

ERUSED PROG: 0 2 10

EMPTY AREA 98 ft

ERASE PROGRAM

CE

ENTER

ERUSED PROG: 0 2 10 EMPTY AREA 98%

TOPROGRAM

PROGRAM

CE

ENTER

ERASED PROG: 0 2
V(ft)

INSTNO

STEP

MODPOS SCAN

TIME, PAGE 22

1 2

A 5
7 8
- (

a \ POS T
< | TIME(S)

=25SPATH
CE

ENTER

ITTTTi

1 SEC

POS T =1BANA

j V(%)

INSTNO

II 1 _l

STEP

MODPOS SCAN

111

mmmmmz

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Programming
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8 Editing menu
MIRROR, PAGE 22

100POSV=100% FINE
XZ
YZ
XY
SAME

100 POSV= 100% FINE

100POSV = 100% FINE

mssmsmmmmm

| !

100POSV=100% FINE

100POSV=100% FINE

100POSV = 100% FINE

CE

ENTER

100POSV=100% FINE

100POSV = 100% FINE

100 POS V = 100 % FINE

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Programming
24

8 Editing menu
COPYINS, PAGE 22

100POSV = 100% PINE

PROGRAM NO

PROGRAM NO Y

100POSV=100% PINE
CE

ENTER

INST. NO 120

100POSV=100% PINE
NUMBER OP INST

CE

ENTER

NUMBER OF INST. X

120POSV = 100% PATH

V()

INSTNO

STEP

MODPOS SCAN

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25

8 Editing menu

Programming

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9 Manual menu

Manual menu
Section

Page

9.1
9.2

9:5
9:6

CLEAR
DISK
9.2.1 DISK (FROM DISK)
9.2.2 DISK (TO DISK)
9.2.3 DISK(INIT)
9.2.4 DISK (DELETE)
9.3 WINCHESTER MEMORY
9.3.1 WINCH (FR WINCH)
9.3.2 WINCH (TO WINCH)
9.3.3 WINCH (INIT)
9.3.4 WINCH (DELETE)
9.4
IN/OUT (INPUT, OUTPUT, REG)
9.5 TOOL (TCP, SENSOR, WRIST LOAD, SOFT S)
9.6
FRAME
9.7
LIST (prog, errors)
9.7.1 PROG
9.7.2 ERRORS
9.7.3 SYS PAR
9.7.4 USER PAR
9.8
FRSC
9.9 TOSC
9.10 RBMODE
9.11 LANG
9.12 ERRORS
9.12.1 Software Configuration
9.13 TEACH
9.14 WDATA (arc weld function)
9.15 PALLET
9.16 EXTFRAME
9.17 HOMEPOS (from M93/5)
9.18 REFP

Programming

9:8

9:9
9:10
9:26
9:28

9:28
9:29
9:30
9:30
9:30
9:32
9:34
9:34
9:35
9:35
9:36

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Programming

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9 Manual menu

= ]MANUAL

1
CLEAR

DISK

Clearance
Handling of
of
outputs
diskettes
(floppy disks)
|

TOOL

PARAM

Def.of
TCP/Sensor

WINCH
Handling of
Winchester
memory (option)

Prog, listing
with printer
on paper

PALLET

SYSTEM
Pallet
PARAMETERS definition
Installation
Manual. Ch 5

Status check
of input,
output, reg

FRAME

SCAN

Definition of
displaced
coord.

FRSC

TOSC

Loading of
Storing of
progr ./block progr. in
from superior superior
computer
computer

LANG

SCAN

LIST

IN/OUT

RB
MODE
Running mode
relative
superior
computer

ERRORS

TEACH

SCAN

**

WDATA

** AW
* MH/GL/SW
SCAN

Change of Listing of error Offline

language
message
programming

TRIM
External axes
functions. See
Installation S3

**

EXTFRA
Funct. ext.
axes. See
chapter 12.

Programming

READSYN

TSIG

HOMEPOS

SCAN

See S3
Service
Manual

1
I REFP

1
SCAN

Reference
pointer
OS/On

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9 Manual menu

Programming

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9 Manual menu

9.1

CLEAR
Clearing of a program block
Menu: MANUAL

Function: CLEAR

Means:
The program block is reset so that:
The first instruction in the program 0 is presented.
All outputs and register are cleared.
All stored positions (with STO POS function) in position registers are cleared.
Correction movements for all sensors are cleared, see Adaptivity.
The system regains memory space after erased instructions.
Program displacement by means of reference point is deactivated.
The velocity override is set to 100%.
Used:
When a program block is to be restarted from the beginning.
When it is necessary to regain blocked memory space after manual erasure.
Executed:
The system reacts immediately after the procedure is completed.
Procedure:
Clearing of a program (Regaining of memory space).
Select CLEAR under the MANUAL menu, thereby concluding the procedure.
Otherwise:
The function should be used with discretion during manual work with a program after a
program stop. The contents of the register and outputs can control the complete working
process which has been stopped.
If a program assumes certain value at the output and register, this must be set manually
before the program is started after a resetting to 0.

Programming

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9 Manual menu

9.2

DISK

9.2.1

DISK (FR DISK)

The transfer of information (data) from a diskette to the robot system user memory is
designated loading. A complete program block or an individual program can be loaded with
the help of the programming unit.
Loading of a program block or program with the same number as one already in the user
memory results in the previous program/block being written over.
Manual loading from diskette
Menu: MANUAL

Function: DISK

1. Place the required diskette in the disk drive.

2. Select DISK from the MANUAL menu.
3. Select FR DISK
4. Specify the number of the BLOCK to be loaded.
5. Select either:
- REPLACE The complete user memory is erased and the block is entered.
- ADD ALL The user memory contents remain intact and are supplemented with the
block which is entered. The program loaded however writes over any duplicates in the
user memory.
- ADD ONLY The user memory is supplemented with one of the programs in the block
specified in Point 4 after the program to be loaded has been specified. The loading is
started when ENTER is pressed.
6. If ADD ALL is used, state whether arc weld data is to be loaded or not.

9.2.2

DISK (TO DISK)

A complete program block can be stored on a diskette.
Manual storing on a diskette
Menu: MANUAL

Function: DISK

1. Place the required diskette in the disk drive.

2. Select DISK from the MANUAL menu.
3. Select TO DISK
4. Specify the number of the BLOCK to be stored.
An error message is presented on the display if there is no diskette in the disk drive.
Up to 7 program blocks with different numbers can be stored on each diskette, in addition
to system data. Program blocks can have numbers from 0 to 9999. Program blocks stored
previously are written over if a new block with the same number is entered for storage.
The entry of the block into storage is completed when "READY" is presented on the display.
When storing a block on diskette the welding data, if any, are also stored in the same block.
For a description of welding data, see chapter 10.2.3. No other data are stored in the block.
However TCP-registers and FRAME-registers will be stored on diskette together with
systemparameters under function PARAM. See Installation Manual.

Programming

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9 Manual menu

9.2.3

DISK (INIT)
A new diskette must be initialized before being used. The contents of a diskette used
previously can be erased b y initializing the diskette again.
Diskettes can only be initialized when the robot system is at Standby.
Initializing of a diskette
Menu: MANUAL

Function: DISK

1. Place the required diskette in the disk drive.

2. Select DISK from the MANUAL menu.
3. Select INIT.
4. The question INITIATE DISK? is presented. Start the intializing by pressing YES.
The initialization is completed when "READY" is presented.

9.2.4

DISK (DELETE)
A complete program block can be deleted from the diskette.
Manual deleting from diskette
Menu: MANUAL

Function: DISK

1. Place the required diskette in the disk drive.

2. Select DISK from the MANUAL menu.
3. Select DELETE.
4. Specify the number of the BLOCK to be deleted.
5. The question DELETE BLOCK? is presented start deletion by pressing YES.

PragraTwmrng

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9 Manual menu

9.3

WINCHESTER

9.3.1

WINCH (FR WIN)

The transfer of information (data) from Winchester to the robot system user memory is
designated loading. A complete program block can be loaded with the help of the
programming unit.
Loading of a program block or program with the same number as one already in the user
memory results in the previous program/block being written over.
Manual loading from Winchester
Menu: MANUAL

Function: WINCH

1. Select WINCH from the MANUAL menu.

2. Select FR WIN.
3. Specify the number of the BLOCK to be loaded.
4. Select either:
- REPLACE The complete user memory is erased and the block is entered
- ADD ALL The user memory contents remain intact and is supplemented with the
block which is entered. The program loaded is however written over any duplcates in
the user memory.
- ADD ONLY The user memory is supplemented with one of the programs in the
block specified in point 3 above after the program to be loaded has been specified.
The loading is started when ENTER is pressed.

9.3.2

WINCH (TO WINCH)

A complete program block can be stored on the Winchester memory.
Manual storing on Winchester
Menu: MANUAL

Function: WINCH

1. Select WINCH from the MANUAL menu.

2. Select TO WIN.
3. Specify the number of the BLOCK to be stored.
Up to 250 program blocks with different numbers, 0-9999, can be stored. Program blocks
previously stored is written over if a new block with the same number is entered for
storage.
The entry of the block into storage is completed when "READY1 is shown on the display.

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9 Manual menu

9.3.3

WINCH (INIT)
The Winchester memory must be initialized before being used, which can only be performed
when the robot system is in the STANDBY mode.
Initializing the Winchester
Menu: MANUAL

Function: WINCH

1. Select WINCH from the MANUAL menu.

2. Select INIT.
3. The question INITIATE WINCHESTER? is presented. Start the initialization by
pressing YES.
The initialization is completed when "READY' is presented.

9.3.4

WINCH (DELETE)
A complete program block can be deleted from the Winchester.
Manual deleting from Winchester
Menu: MANUAL

Function: WINCH

1. Select WINCH from the MANUAL menu.

2. Select DELETE.
3. Specify the number of the BLOCK to be deleted.
4. Verify the deletion by pressing YES.

9.4

IN/OUT
IN/OUT (INPUT)
Check of the status of an input
Menu: MANUAL

Function: IN/OUT

1. Select IN/OUT under the MANUAL menu.

2. Select INPUT.
3. Give input number.
The current status of the input is read once and displayed. It is possible to:
Read the status of the input once more with SAME.
Present the status of the next input with NEXT.
Exit finally from this menu by selecting any other menu except POSITION.

Programming

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9 Manual menu
IN/OUT (OUTPUT)
Check and possible changing of status of an output
Menu: MANUAL

Function: IN/OUT

1. Select IN/OUT under the MANUAL menu.

2. Select OUTPUT.
3. State the output number.
The current status of the output is now displayed. It is possible to:
Set the output to 1 with 1.
Set the output to 0 with 0.
Present the status of the next output with NEXT.
Exit finally from this menu by selecting any other menu than POSITION, because
POSITIONING means programming of a position.
Changing the status of an output may affect the peripheral equipment which in
turn might cause damage or injuries.
IN/OUT (REG)
Manual check and possible change of the value in the number register.
Menu: MANUAL

Function: IN/OUT

1. Select IN/OUT under the MANUAL menu.

2. Select REG.
3. Specify register number 0-119.
The value in the register selected is now shown. It is possible to:
Change the value with CHANGE.
Present the value in the next register with NEXT.

9.5

TOOL
TOOL (TCP, CHANGE, MAN DEF)
Manual definition of TCP or BASEP
Menu: MANUAL

Function: TOOL

1. Select TOOL under the MANUAL menu.

2. Select TCP.
3. Specify TCP number 1 -19 for normal TCP. (MH/GL/SW only 20 - 29 are for
Room fixed TCP.)
4. Select CHANGE.
5. Select MAN DEF.
6. Normal TCP: Specify x-, y- and z-values in hand coordinates, relative to the turn disc of
the robot. If no value is to be changed, press ENTER directly.
Room fixed TCP: x, y and z-values are in the base coordinate system.

Prograi

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9 Manual menu
Note! Allowed range for x-, y- z- coordinates is 1500mm, and for the vector
V X2 + Y2 + Z2 for 1KB 2000. 1500 mm, far 1KB 3000 1290 mm and for
IRB 6000 2500 mm. If these values are exceeded the error message TDATA ERROR" is
displayed on the programming unit.
7. Activate (see Manual activation of TCP, below) and test run the TCP by manually
changing the tool orientation. If necessary, correct the TCP by a new definition, manually
or automatically.
TOOL (TCP, CHANGE, AUTO DEF)
Automatic definition of a normal TCP
Facts:
** ^ With the automatic definition it is possible to use an already known TCP value of one tool
to measure, with the help of the robot, the TCP coordinates for a new tool. The known "tool"
could be the center of the mounting flange, defined by TCP 0.
^^

Procedure:
The known tool is mounted and the corresponding TCP value is activated. Then the robot is
positioned with the tool-tip (TCP) in a defined position. This position is stored in the robot
memory as the start position.
After the new tool, which should be measured, is mounted and the robot is repositioned so
that the TCP of the new tool is in the defined position. This position will be used as the end
position, and the system will automatically calculate the new TCP value and store it in the
specified register.
If the center of the mounting flange is used as the known TCP, no tool should be mounted
when defining the start position, and TCP 0 should be activated.

v-s,

When the start position has once been defined and stored in the robot memory, it can be
reused when measuring new tools, without the need to remounting the old tool and
reposition the robot. However, the old TCP must be active when measuring and defining
the new TCP.
Menu: MANUAL
Function: TOOL
1. Activate TCP 0 (see Manual activation of TCP, below).
2. Select TOOL under the MANUAL mode.
3. Select TCP.
4. Specify TCP number 1 -19.
5. If a basepoint is to be defined, press BASEP.
6. Select CHANGE.
7. Select AUTO DEF.
8. If a new starting position for TCP measuring is to be defined, select YES. Otherwise,
select NO and go directly to point 9.
9. Dismount the tool, jog the robot manually to a known position, press ST POS and
finally, mount the tool again.
10. Jog the robot manually to the known point where the tool is located, and then press
ENDPOS.
11. Activate the TCP and test run by orientation of the tool. If necessary, correct the TCP
by a new definition automatically or manually.

Programming

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9 Manual menu
Automatic definition of a Room fixed TCP.
Move the active normal TCP to the desired position where the Room fixed TCP should be
defined.
Press TCP
Enter a value in the range 20 - 29
Press AUTO DEF
Press END POS Use the BREAK function (under point 8 - 9) to, if required, break:
The entire procedure if the function was selected erronously.
Definition of a TCP if the intention is to define a starting position for the TCP definition
by running.
For IRB 1500, 2000 and 6000 systems, there is a set of TCP aids which simplifies the
handling and increases the accuracy when determining the TCP with the function AUTO
DEF. The following is a brief description of the operation:
1. The tool, can remain mounted on the mounting flange during the complete procedure.
2. Mount the guide pin in the outer hole of the mounting flange .
3. Define a suitable TCP number for the guide pin at TCP position given according to the
table below.
4. Follow the procedure for AUTODEF of TCP in accordance with the programming
manual with the following exception:
*) On IRB 1500 it is
possible to use the
TCP-pin on robots
delivered from
autumn 1993.

IRB 1500
IRB 2000
IRB 6000

Art.no. for kit

-6.5
-8
-15

-100
100
0

3HAA 2246-1
3HAA 2246-1
3HAA 0001-UA

0
-150

I
a Activate the previously selected TCP (see point 3 above) instead of TCP 0.
b When defining the starting point for the TCP measurement the tip of the guide pin (and
not the TCP 0) is run to the starting point with ST POS.

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Programming
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9 Manual menu
TOOL (TCP, ACTIVE)
Manual activation of TCP
Menu: MANUAL

Function: TOOL

Previous definition of the TCP selected is assumed

1.
2.
3.
4.

Select TOOL under the MANUAL menu.

Select TCP.
Specify TCP number 0 - 29.
Select ACTIVE.

The TCP selected is now activated immediately.

Activation of an incorrect TCP might result in unintentional robot movements.

TOOL (TCP, NEXT)
Control of TCP-position
Menu: MANUAL

Function: TOOL

1. Select TOOL under the MANUAL menu.

2. Select TCP.
3. Specify the TCP with which the check is to begin.
The x-, y- and z-values, in hand coordinates, of the TCP are now presented.
Room fixed TCP:
The x-, y- and z-values are measured in the base coordinate system.
If the next TCP is to be checked, page with the NEXT function. Finally, when coordinates
for a TCP are not available, the TCP concerned has not been defined.
TOOL (TCP, DELETE)
TCP definition canceled
It is assumed that the TCP concerned is not active.
1. Select TOOL under the MANUAL menu.
2. Select TCP.
3. Specify TCP number 1 - 29.
4. Select DELETE.
5. DELETE TCP? YES, NO.
(The coordinates of the TCP selected are now erased immediately.)

Programming

3
13

9 Manual menu
TOOL (TCP,BASEP)
Normal TCP only.
It is described below how the tool coordinate system can be defined with a TCP and a
Basepoint. First the Startpoint is defined to a reference point in the work piece, for instance
with the help of a guide pin as described above, see figure below. After that the tool is
mounted and the TCP is defined, see figure below. The Basepoint should now be located on
the symmetrical axis of the tool to define the orientation of the tool coordinate system.
REFERENCE POINT
TCP

r/\

REFERENCE POINT

MOUNTING FLANGE
FIG. 7

SYMMETRICAL AXIS OF TOOL

DEFINING START POSITION

FIG. 8

DEFINING TCP

The base point can be defined manually or by Automatic definition. Below three ways of
using the automatic definition are described.
When defining the Basepoint the robot should first be
moved to a position where the symmetrical axis or its
extension points through the referencepoint, see the
figure below. In this figure, the Basepoint will be defined
in point B, i.e. outside the TCP.
Note.This means that the z-axis of the tool-coordinate system will point in the
opposite tool direction, but this is generally of less importance.
REFERENCE POINT
B-BASE POINT
TCP

X-AXIS
FIG. 9
DEFINING BASEPOINT
Alternative 1:
1. Direct the tool to the orientation required, relative the work piece.
2. Define the TCP with the AUTO DEF method.
3. When ENDPOS is entered the TCP is defined. Move the TCP a couple of centimeters
backwards from the work piece by moving the robot manually with the joystick.
4. Define the BASEPoint with the AUTO method without moving the robot, i. e. answer
thequestion "NEW START POS" with NO, and then press ENDPOS.
5. Activate the recently defined TCP.

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Programming
14

9 Manual menu
Alternative 2:
If the tool orientation is to be changed during the program execution, a new pair of
basepoint/TCP must be defined.
1. Activate the old TCP.
2. Direct the tool to the orientation required (by manual running).
3. Copy the old TCP-location under the new TCP-number with the AUTO method,
i e answer the question "NEW START POS" with YES, press START POS and then
press ENDPOS, without moving the robot in between.
4. Move the TCP a couple of centimeters backwards from the work piece by moving the
robot manually.
5. Define the new basepoint with the AUTO method without moving the robot, i e answer
the question "NEW START POS" with NO, and then press ENDPOS.
Alternative 3:
Define the TCP (Manually or already defined).
Press BASEP, CHANGE and AUTO DEF.
NEW START POS: answer YES.
Press ST POS
Move the robot in the desired x-direction, showed in the fig. 9.
TOOL (SENSOR)
The following menu for selection of sensor numbers is avaiable under TOOL + SENSOR in
the MANUAL menu on the programming unit.
S246
SENSOR NO =

CE

ENTER

1. The numbers of the sensors which are already defined in the system are presented in
theupper display line.
2. Select the number of the sensor which is to be checked, changed or defined.
3 The system then presents a succession of questions for all parameters which are
availablefor the sensor concerned.
4. With ENTER without specification of data, a value already defined for the parameter
concerned is not changed. This is used if parameter values are only to be checked.
5. When the sensor definition is completed, the following menu is presented:

YES: Return to the basic menu for definition of further sensors. NO: Conclusion.

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Programming
15

9 Manual menu
Sensor data upper display line
Parameter values previously defined for the sensor concerned is shown on the upper
display line. The display line is updated after each new entry of parameter values. The
following figure shows an example of a completely defined sensor.
(1)

(4) (2)

(3)

(5)

(6 ) (7 )

1 1 1 ) J II
S2

0.2 -500/500 ;

INP1

YES

MORE SENSORS?

NO

;! 1

i , 11 ,.

For the numbering (1) - (7) ace. to the figure above, refer to parameter I to VII ace. to the
following:
1 S2
SENSOR NO = 2
2 A
Analog sensor
2 B
NO OF BITS = 2
3 INP1
INPUT NO = 1
4 R
INSTALLED ON ROBOT
NOT INSTALLED ON ROBOT
5 0,2
SCALE = 0,2
6 -500
MINVALUE = -500
7 500
MAXVALUE = 500
Parameter definitions
Parameter I

The parameter refers to the logical number

when programming adaptive instructions.

Menu

Basic menu for sensor definition.

Guide text

SENSOR NO =

Def.range

1-16

Parameter II

The parameter specifies whether an install

analog or digital type. For digital sensors, the parameter
also defines the number of digital bits for the sensor concerned.

Menu Consequential question above.

Guide text

NO OF BITS=

Def.range

0 = Analog sensor.
1 = Digital one bit sensor of ON/OFF type
2 = Digital two bit sensor.
The two bit sensor can be interpreted as a one bit sensor with a
sign bit (MSB).

Note

It is possible to define a digital multi bit sensor with 3-8 bits, but
the performance is unspecified.

Programming

S3
16

9 Manual menu
Parameter III

The parameter specifies, for an analog or digital sensor, to which

physical inputs or outputs the sensor is connected.

Menu

Consequential question above

Guide text

INPUT NO=

Def.range

1-4
= Analog inputs
1-96
= Normal digital inputs
237 - 239 = Fast digital inputs

Type of inputs

1. Analog inputs:
The parameter value 1-4 corresponds to the connection of the
sensor to a physical input 1-4 on analog I/O board DSQC 209.
E.g. Parameter value 2 = Physical input 2.
2. Normal digital inputs:
The parameter value 1-96 corresponds to the connection of the
least significant bit (LSB) of the sensor to logical inputs 1-96 on
up to 6 digital I/O board DSQC 223 . For definitions, see section
7.5.3.1. E.g. Parameter value 17 = Logical input 17 i.e. first
physical input on the second digital I/O board.
3. Fast digital inputs:
The parameter values 237-239 correspond to connection of the
sensor to sensor input 1-3 on the system board DSQC 256 A.
E.g. Parameter value 238 = Sensor input 2.

Note

1. Normal digital inputs:

a Intended for digital sensors with 1-2 bits.
b The figure below shows how the other bits of the sensor are
connected:
c A sensor must be connected within the same input group of
8 inputs (SCAN group).

DSQC 223

INPUT

Input
group -v

1
2
3
4
5
6
7
8

LSB

9
10
11
12
13
14
15
16

MSB Digital 3-bit sensor

2. Fast digital inputs:

a Intended for digital one bit sensors for which high speed is
required e.g. for searching
Programming

17

S3

9 Manual menu

DSQC 256A

SENSOR

1
2
3

Digital
1-bit sensor

Parameter IV

When tracing contours and with free searching, the

adaptive procedure is affected by an active correction
vector for the sensor concerned. The parameter below
defines whether an active correction vector is defined or
follows the orientation of the robot wrist.

Menu

Consequential question above "INSTALLED ON ROBOT ?"

Def. range

NO = Active correction vector is fixed in the basic coordinate

system of the robot. Corresponding normally to the sensor not
being mounted on the robot.
YES = Active correction vector is fixed in the robot wrist
coordinate system. Means that the correction vector follows any
reorientation of the wrist between the prgramming of the
correction vector and the adaptive procedure. Corresponds
normally to the sensor being mounted in the hand of the robot.

Parameter V

1. The parameter defines the position gain (correction in mm per

bit change of sensor signal) which affects the magnitude of the
reference issued by the control system of correction movement
with contour tracking.
2. The parameter defineds in addition a scale factor which affects
the reference issued by the control system for:
a The speed of the correction movement with contour tracking,
b The search speed with free searching.

Menu

Consequential question above. Final question for digital one

bit and two bit sensors.

Guide text

SCALE=

Def.range

0.00 - 99.99

Note

Practically usable values 0,01 When using contour tracking with weld guard, too high values can
result in instabile weaving direction.

S3
18

Parameter VI

9 Manual menu
The parameter defines te least permissible digital value of the
sensor signal i.e. the control system, before use, filters out sensor
signals less than a certain value.

Menu

Consequential question above concerning analog sensor or digital

(3-8) bit sensor.

Guide text

MINVALUE =

Def.range

For an analog sensor the permissible definition range is +/- 1023.

The permissble range corresponds to +/- (2(n-l)-l), where n = the
number of bits.

Note

An analog sensor reading of +/-10 V is converted to a digital value

of+/-1023. This corresponds to a sensor with 11 bits of which one
is a sign bit.

Parameter VII

The parameter defines the greatest permissible digital value of the

sensor signal, i.e the control signal before use, filters out the sensor
signals greater than a certain value.

Menu

Consequential question above. Final question analog sensor or

digital (3-8) bit sensor.

Guide text

MAXVALUE =

Def.range

See parameter VI above.

Note

1. See parameter VI above.

2. MAX VALUE and MIN VALUE are to be defined so that the
sensor signal receives a suitably large working range.

TOOL (WRIST LOAD)

Manual definition of programmable wrist load (only IRB 6000)
19 sets of wrist loads can be defined (No. 1-19).
Each contains wrist weight, distance in X direction to the centre of gravity of the wrist load
from rotary plate of the axis 6, acceleration and position gain indeces for axes 4-6. (See
chapter 11.9 for detailed description). Wrist load No. 0 can only be changed under the
parameter meny as it contains values for normal wrist load.
Any sets of values can be activated manually or during program execution displayed as
follows:
SSSKSSKKSttKS^^

The values in the upper row displays the defined sets of wrist loads, the digit with a star
displays the set currently activ.
Menu

Programming

The following menue will be displayed when WRIST LOAD= 0 -19

is selected.

S3
19

9 Manual menu
*
Active LOAD
**
Not for LOAD 0
*** Not for undedfined LOAD
**** Not for active LOAD

LOAD 3 M=50 KG X=200 MM

CHANGE**ACTIVE***NEXT DELETE

When the shift key on the programming unit is pressed the acceleration and position gain
indeces are displayed.

CHANGE

LOAD 3 M=50 KG X=200 MM

LOAD 3 M=30 KG X=200 MM

A4=10 A5=10 A6=ll P4=10 P5=ll P6=12

12
Cont.

Programming

S3
20

9 Manual menu

A4=12 A5=10 A6=ll P4=10 P 5 = l l P6=12

ACCS (-) =

CE

ENTER

12

A4=12 A5=12 A 6 = l l P4=10 P 5 = l l P6=12

A4=12 A5=12 A6=10 P4=10 P5=ll P6=12

CE

ENTER

A4=12 A5=12 A6=10 P4=8 P5=ll P6=12

CE

ENTER

CE

ENTER

LOAD 3 M=30KG X=120MM

CHANGE ACTIVE

Programming

NEXT

DELETE

S3
21

9 Manual menu
ACTIVE

LOAD 4 M=75 KG X =250 MM

CHANGE ACTIVE NEXT DELETE

Current set of WRIST LOAD values is activated.

NEXT
LOAD 4 M=75 KG X =250 MM
CHANGE ACTIVE NEXT DELETE

LOAD 5

M=-KGX=-MM

CHANGE NEXT

I
If the WRIST LOAD number is undefined, the values for the acceleration and position gain
indeces will be uppdated with predefined values.

Programming

S3
22

9 Manual menu
DELETE
^>..:.>-.X.-------.--.-..............v.

^...w.r...-.-.v.-.v.-.v^..^rvv..w.v.-.-.v^w...-.-.-.-.-.-.-.-.-.-.-.-..-..v-

LOAD 3 M=75 KG X =200 MM

CHANGE ACTIVE NEXT DELETE

LOAD3 M= 50 KG X=200 MM

TOOL (SOFT S, MH/GL/SW only)

Use of soft servo function
Nine sets of "softness percentages" can be defined (1-9). Each set contains softness values
for each axis. Number 0 can not be changed as it contains values for normal servo control.
Number 1- 9 are undefined as default. Any set of values, or normal control, can be activated
manually or during program execution displayed as follows:

SOFTSERVO 0 1 2 * 4 9
SOFT SERVO

CE

ENTER

The values in the upper row displays the defined sets of softness percentages. The digit
with a star displays the set currently active.

Note!

If HUB 6000, the current wrist load should be trimmed before defining
SOFT SERVO.

S3

Programming
23

9 Manual menu
MENU
The following menu will be displayed when SOFT SERVO=l-9 is selected and the selected
number is active:
SOFT SERVO Al=10 A2=20 A3=30
CHANGE ACTIVE NEXT

When the shift key on the programming unit is pressed, axes A4-A7 are displayed. Should
the 7th axis be undefined it will not be displayed and can not be changed.
A4=15 A5=25 A6=35 A7=45
CHANGE ACTIVE NEXT

CHANGE
|

SOFT SERVO Al=10 A2=20 A3=30 >

1 A1=
|

CE

ENTER 1

i
15

SHE
{ SOFTSERVOA1=10 A2 =20 A3=30 > i
A2=

CE

ENTER
J

\ U 11|

!i. . ?.^\ s i...r. ...!"' S i

SOFT SERVO Al=10 A2=20 A3=30 |

I A7=

CE

1 1
Programming

>

ENTER

S3
24

9 Manual menu
If he SOFT SERVO number was undefined, the values for all axes will be updated with
the values for normal servo (0).
All values entered with the ENTER key will be displayed in the upper row. ENTER
without a value will leave the old value displayed.
When the SOFT SERVO number is ACTIVE, all changes will immediatly be transferred to
the SERVO COMPUTER. Accordingly, no activiation of the SOFT SERVO number is
necessary after a change if the number was already active.
When the desired value has been entered for axis A7 the display will return to the SOFT
SERVO menu.
The values for axes A1-A7 are defined in percent (0-100%). 0% corresponds to normal servo.
1-100% activates SOFT SERVO. Maximum SOFT SERVO is obtained at 100%.
ACTIVE
CHANGE ACTIVE NEXT

SOFT SERVO 0 2 3 * 5

Current set of SOFT SERVO values is activated.

When using the Soft Servo function, the robot speed and path is changed.
NEXT

SOFT SERVO 4 Al=10 A2=20 A3=30

CHANGE ACTIVE NEXT

SOFT SERVO 5A1=15A2=25A3=35

CHANGE ACTIVE NEXT

DELETE

The next set of SOFT SERVO values is displayed. If NEXT is pressed at

SOFT SERVO 9 the display returns to SOFT SERVO 0.

Prograi

S3
25

9 Manual menu
DELETE
| SOFT SERVO 4 Al=10 A2=20 A3=30 > ]
I CHANGE ACTIVE NEXT

DELETE
'is

....:?

I
J

"S

DELETE SOFT SERVO?

YES

NO

?<??..

YES: Current set of SOFT SERVO values are deleted. The SOFT SERVO number becomes
undefined. Return to the SOFT SERVO menu.
NO: Nothing will happen and the SOFT SERVO menu will be displayed.

9.6

FRAME
Menu: MANUAL

Function: FRAME

1. Check that program displacement 0 is active using the SHIFT button, see section 4.5.
stored displacements give an uncertain result
2. Select FRAME under the MANUAL menu.
3. Select DEFINE (RESET resets program displacement to its original place.)
4. Type in FRAME number 1 - 5.
5. Run the tool to the original position 1, select FRAME under the MANUAL menu and
then press ST POS 1.
6. Position the tool with the joystick to the new position 1 and then press END POS 1.
7. Repeat points 5-6 above for position 2 (ST POS 2 and ENDPOS 2 are presented on the
display).
8. Repeat points 5 - 6 for position 3 (ST POS 3 and ENDPOS 3 are presented on the
display).
Note!
If the operator happens to release the safety pad during jogging, the system exits
from the function selected. In that case, start from the beginning once again with
function selection.
Automatic definition
The entire procedure is described in detail in section 10.7.

Programming

S3
26

9 Manual menu

9.7

LIST

9.7.

PROGRAM,
Program printout
Menu: MANUAL

Function: LIST

Means:
Readout of program on a display or printout on a printer (option).
Facts:
A printout queue of up to five programs can be requested and the printouts are performed
in the order in which they are commanded. The printout of a program can be commanded
while another program is under execution.
The printout is in groups of 60 lines each to suit A4 format paper.
Executed:
The system reacts immediately after the conclusion of the procedure (one program at a
time, if there is no queue of printouts to be processed).
Procedure:
1. Ensure that the printer or screen is switched on.
2. Select LIST under the MANUAL menu.
3. Select PROGRAM.
4. Specify the number 0 - 9999 of the program to be printed out.
The procedure is now completed.
Note!

Avoid the following operations during program printout:

Clearing of program block
Floppy disk operations
Manual program selection
Erasure of programs
The reason is that you can indirectly interfere the program which the system prints out,
with the consequence that the printout is faulty.

9.7.2

LIST (ERRORS)
Printout of all error messages in the buffer
Menu: MANUAL
Function: LIST
1. Select LIST under the MANUAL menu
2. Select ERRORS
The system responds by printing out a list of the messages int the buffer. The version of the
control program is also printed out.

9.7.3

SYSPARl.
Select LIST under the MANUAL menu
2. Select SYSPAR
The function prints the system parameters i.e. parameters under PARMICHANGE.

9.7.4

USEPARl.
Select LIST under the MANUAL menu
2. Select USEPAR
The function prints user parameters i.e. TCP, SENSOR, EXTFRAME, FRAME, LANG.

Programming

S3
27

9 Manual menu

9.8

FR SC
Loading of program from SC
The function FROM SC is used to load program blocks or individual programs from the SC.
The different procedures are described below.
Note that the remote operation mode must be selected before FROM SC can be used.
Procedure A
Loading of a program block is performed as follows:
1. Select the menu MANUAL.
2. Press function button SCAN twice.
3. Press function button FROM SC.
4. Press function button BLOCK
5. Enter the number (storage identity) of the system data block required (0-9999) with the
numerical button set.
6. Press the function button ENTER.
The loading begins immediately after this. The upper line of the display presents the text:
"COMMAND IN PROGRESS" (during the loading phase itself)
"READY" (when the loading is complete)
Procedure B
The loading of an individual program is performed as described in the following:
1. Select the menu MANUAL.
2. Press function button SCAN twice.
3. Press function button FROM SC.
4. Press function button PROGRAM.
5. Enter the number (0-9999) of the program block required (in which the program sought
is located) with the numerical button set.
6. Press the function button ENTER
7. Enter the number of the program required (storage identity)in the block (0-9999) with
the numerical button set.
8. Press function button ENTER.
The entry begins immediately after this. The following text is then presented on the upper
line of the programming unit:
"COMMAND IN PROGRESS" (during the loading phase itself)
"READY" (when the loading is complete)

Programming

S3
28

9 Manual menu
9.9

TO SC
Storage of program in SC
The function TO SC is used to store program blocks or individual programs in the SC. The
different procedures are described below.
Note that the remote operation mode must be selected before TO SC can be used.
Procedure A
Storage of a program block is performed in accordance with the following:
1. Select the menu MANUAL.
2. Press function button SCAN twice.
3. Press function button TO SC.
4. Press function button BLOCK
5. Enter the number (storage identity) of the program block required (0-9999) with the
numerical button set.
6. Press function button ENTER
The storage then begins immediately and when this is completed, the text "READY" is
presented on the upper line of the display on the programming unit.
Procedure B
Storage of an individual program is performed in accordance with the following:
1. Select the menu MANUAL.
2. Press function button SCAN twice.
3. Press function button TO SC.
4. Press function button PROGRAM.
5. Enter the number (0-9999) of the program block in which the program sought is to be
stored by means of the numerical button set.
6. Press function button ENTER.
7. Enter the number (storage identity) of the program required (0-9999) with the
numerical button set.
8. Press the function button ENTER.
The storage then begins immediately and when this is completed, the text "READY" is
presented on the upper line of the programming unit display.

Programming

S3
29

9 Manual menu

9.10

RB MODE
Change of operational mode in relation to SC
The function RB MODE is used when the operational mode of the robot system in relation
to the SC is to be changed.
The change is performed in accordance with the following:
1. Select the menu MANUAL.
2. Press function button SCAN twice.
3. Press function button RBMODE.
4. Check which operational mode is currently selected on the upper line of the
programming unit display. If a change is to be performed, continue with point 5.
Otherwise return to the manual menu by pressing the Manual button.
5. If the remote operation mode is to be selected, press function button REMOTE. If local
operation is to be selected, press function button LOCAL.
When the status changes to REMOTE, the robot may be started by an superior
computer. Before switching to REMOTE, make sure nobody remains inside
the robot working area.

9.11

*LANG
Selection of language
A change of language is obtained in the following manner:
1.
2.
3.
4.
5.

Set the robot system in the MOTOR OFF mode.

Press the MANUAL button.
Scan forward the menu to the text marked with an asterisk at the extreme left.
Press the button with the asterisk.i.e the language button.
Select a language from those sHown in the menu now presented.

This asterisk is intended to simplify location of the language button in the menus when the
language currently in use in te programming unit is not understood by the operator.

9.12

Errors
Display on the programming unit of error messages (after production stop)
Read the error message. For most messages it is possible to get text in plain language by
pressing "" on the programming unit. Use the SHIFT button to display more error
messages, if required. If you want to read messages about system errors once again, select
errors under the MANUAL meny as below:
Display on the programming unit of error messages from the latest error
occasion
Menu: MANUAL
Function: ERRORS
1. Select ERRORS under the MANUAL menu and read the error message.
2. Press "" to show text in plain language.
3. Use the SHIFT button to display more error messages if required.

Programming

S3
30

9 Manual menu
Display of error messages on the monitor after production stop
Read the error message displayed on the monitor.
Display of all error messages in the buffer on the monitor
Manu: MANUAL
Function: ERRORS
Select ERRORS under the MANUAL menu and read the error messages tat are displayed
on the monitor.
Erasure of all messages in the error buffer
Menu: MANUAL
Function: ERRORS
1 Select ERRORS under the MANUAL menu.
2 Select ERASE.
3 Answer with YES. (If the answer is NO the system will not erase any message).
Optional Error message in plain language (to be selected)
Menu: MANUAL
1. Select ERRORS under the MANUAL menu.
2. Select TEXT.
3. Answer with message number and code.

Function: ERRORS

Load texts in plain language into memory

Menu: MANUAL
1. Select ERRORS under the MANUAL menu.
2. Select FR DISK
3. Answer with block number (see Installation Manual).

9.12.1

Function: ERRORS

Software Configuration
The controller software configuration can be read by pressing the ERROR button, and then
scanning through any errors in the buffer by pressing the SHIFT button until finally the
software configuration is shown on the display.
Menu: MANUAL
Robot type

Function: ERRORS
Program
version

Program
revision

Year

Week

Model

IRB 60002,4-120 NB/6 9412 M93/6

Display error messages with the SHIFT button until the display shows the following
information:
The control program version is also displayed on the monitor.

Programming

S3
31

9 Manual menu
9.13

TEACH
Position definition for Off-line
Means
Definition of robot positions for use with Off-line programming.
Facts
The TEACH function can only be used when the Off-line Programming Package is
connected via a computer link to the robot.
Positioning instructions in programs developed Off-line can refer to robot positions stored
on a coordinate file in the development computer.
When TEACH is utilized, the name, position and wrist orientation of each robot position is
registered on a coordinate file. When external axes are used, the positions of these are also
stored if they are defined in the robot system.
A position is defined by placing the robot in the required position with the joystick and
pressing the POS button of the TEACH function.
Used
To be able to use TEACH, the function must start from the Off- line package and be
selected under the MANUAL menu on the programming unit.
When TEACH is used in the development computer, all of the TEACH messages and
spontaneous messages from the robot system are presented on the development computer
display screen. In addition the messages are saved in accordance with the above on the
TEACH LOG file in the development computer.
The parameters "Communication board", "Robot identity" and "Computer Link" are to be
set correctly in the robot system and the REMOTE mode is to be selected (See Installation
S3) for the control system. The parameters "Robot identity" and "Computer link" in the
development computer are to have the same values as the corresponding parameters in the
robot system.
The robot system is to be in the MOTOR ON mode when TEACH is used.
To check that the connections between the development computer and the robot system
function, some action can be taken in the robot system which results in the presentation of
a spontaneous message on the computer display. For example, the programming unit can
be extracted from the robot system control cabinet and then returned.
Procedure Menu: MANUAL

Function: TEACH

When names on coordinate files and positions are to be specified, the write function on the
programming unit is to be used in accordance with the following.
Six letters are shown at each multifunction-button on the lower display line on the
programming unit. If for example an "N" is required, the third button from the left is
pressed followed by the figure 2 ("N" is the second letter in the group of letters at the third
multifunction button). The letter "NT is then presented on the display. Numbers are typed
in at the numerical key set of the programming unit. Characters are erased with the minus
sign "-". Each name is concluded with a period sign (.).

Programming

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9 Manual menu
Sequence definition of positions means that positions are named in sequence when
defining. A basic named is given and each new position defined is given the basic name
followed by a sequence number. If, for example, the basic name "BOX 1" is selected, the
first position defined will be given the designation "BOX 1", the second "BOX 2" etc. The
alternative to sequence naming of positions is manual entry of each name.
1 Select TEACH under the menu MANUAL. Then start TEACH from the Off-line package
in the development computer.
2 The question "NEW COORDINATE FILE?" is asked.
Answer YES if a new file is to be created and give the name of the new coordinate file.
Answer NO if the coordinate file shown on the upper line of the display is to be used (the
coordinate most recently edited.
3 The alternatives DEF, CHANGE, ERASE and EXIT are shown on the lower line of the
display.
DEF
4 The system asks if a sequential definition is required.
If YES, give the base name for the position sequence to be defined (e.g. BOX 1). If NO, give
the name of the position to be defined (conclude the name with a point).
5 Run the robot to the required position with the joystick and then press the button to
define the position.
6A Sequence-definition
The name of the next position (e.g. BOX 2) is shown on the display.
Define the next position in accordance with the point 5 above and repeat the procedure
until all positions are defined within the sequence.
Pressing "BREAK" breaks the definition of positions within the sequence and results in the
repetition of the presentation on the display of the menu in accordance with point 3 above.
6B Manual entry of each name
The robot system asks if more positions are to be defined.
With YES, give the name of the position and then define the position in accordance with
point 5 above. Repeat until all positions have been entered. With NO, the menu in
accordance with point 3 above is presented again.
CHANGE
4 The system asks which position is to be changed. Give the name of the position,
concluded with a point.
5 Run the robot to the position required with the joystick. Then press the menu button
POS to redefine the position.
ERASE
4 The system asks which position is to be erased.
Give the name of the position and conclude with a point. The point named is then erased
EXIT
4 Conclude TEACH.
Programming

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9 Manual menu

9.14

WDATA
Weld data (W DATA) contains instructions for definding the different parts of the arcweld
process:
START DATA
MAIN DATA
END DATA
WEAVE DATA
SENSOR DATA
These are described in chapter 10 under the Arc Welding Process. The instructions are
available in the IRB 2000 AW software only.

9.15

PALLET
Definition of a pallet. Available on MH/ASM and GLUE software.
Menu: MANUAL

Function:PALLET

1
2
3
4

Check that correct TPC is active.

Select PALLET under the MANUAL menu.
Specify pallet number 0-9.
Run the tool with the joystick to the first point in the pallet. Check that the orientation
is correct.
5 Press END POS1.
6 Run the tool to desired position above the pallet.
7 Press ST POS
8 Run the tool to the last point in the first row.
9 Press END POS2
10 Specify no of points in every row 1-99.
11 Run the tool to the first point in the last row.
12 Press END POS3.
13 Specify no of rows 1-99

The pallet is now defined. The definition can be interrupted by pressing BREAK. The pallet
will then be undefined.
ST POS

END POS 2

END POS 1

END POS 3

Programming

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9 Manual menu

9.16

EXTFRAM (AW only)

Defoliation of EXTFRA (external frame), see section 10.2.5.5

9.17

HOMEPOS (From M93/5)

HOMEPOS
This function makes it possible to indicate if the robot is in a certain position, the so called
HOMEPOS, via setting/resetting of a digital output. Up to three homepositions can be used
at the same time.
See also section 7.7 ALIGN/HOMEPOS
The HOMEPOS supervision is done in robot axes coordinates, which means that the
HOMEPOS is not a TCP-position, but always refers to a certain mechanical position of all
robot axes. As soon as the homeposition is defined, a (selectable) digital output will be set
as long as the robot is in (resp. close to) this position.
The zone around the HOMEPOS is +/- 60 increments for each axis. This is the value which
corresponds to a zone of 10 mm radius around TCP 0 whan the IRB 6000/S3.0 -100 is in it's
most extendend position.
The HOMEPOS supervision is done as soon as any home position is defined by the user.
The supervision is active during program execution as well as during manual moving via
the joystick.
Any defined homepos is internally handled as user parameters like TCP-data and can be
stored and loaded to/from disk.

NOTE 1

External axes positions are not included in the HOMEPOS, i.e. it is only the 6 robot axes
which are supervised.

NOTE 2 As there is a sampling time of 200 ms and because servo-lags are not observed, the output
will - especially at high speeds - not be set at the exact point of time when the robot is in
the home position. When using the HOMEPOS-output during program execution especially at high speeds - special care has to be taken about the timing.
DEFINITION OF THE HOMEPOS AND THE CORRESPONDING OUTPUT
The homepos definition is done under the manual menu.
For a complete homepos definition, the position and a corresponding output have to be
defined. The position is defined by moving the robot into the desired position and then
enter this position to the HOMEPOS memory. Any free accessable output may be used as
homepos indicator.
The HOMEPOS definition is done by selecting the HAND menu and then depressing SCAN
4 times.

Programming

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35

9 Manual menu

9.18

REFP
Reference point can be turned off by answering YES.

Programming

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36

9 Manual menu
100 POS V= 100% PATH
CLEAR DISK WINCH IN/OUT

SCAN

10 V= 1000 MM/S MAX= 1000 MM/S

CLEAR DISK WINCH IN/OUT

SCAN

100 POSV= 100% PATH

i DISK TO DISK INITDELETE BREAK

FRWIN TO WIN INTT DELETE BREAK

DELETE, PAGE 38
INIT.PAGE38
INIT.PAGE38

JLJi USED BLOCKS 1,5

BLOCK NO*

CE

ENTER

USED BLOCKS: 1,5

REPLACE ADDALL ADDONLY

1 2

USED BLOCKS: 1, 5
PROGRAM N O :

CE

ENTER

READY

Programming

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37

9 Manual menu
DELETE, PAGE 37

DELETE BLOCK?

YES

NO

Block deleted

INIT, PAGE 37

INITIATE WINCHESTER?

YES

NO

CLEAR

Programming

DISK

WINCH IN/OUT

SCAN

S3
38

9 Manual m e n u

CLEAR DISK

WINCH IN/OUT SCAN

INPUT OUTPUT REG

Programming

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39

9 Manual menu
REG, PAGE 39
OUTPUT, PAGE 39

=1

HI j n

II

\MMIm

K 11 = 23
CHANGE

Programming

NEXT

S3

40

9 Manual menu

100 POS

V=100%PATH

TOOL PARAM PALLET FRAME SCAN

100 POS
Only IRB 6000
(see section 11.8)

TCP

V=100%PATH

SENSOR WRIST SOFTS

SOFTS (MH/GL/SW only)
PAGE 45
SENSOR, PAGE 44

CE

ENTER

IFTCPO-19
ex. TCP 5

CHANGE ACTIVE

IF TCP 2 0 - 2 9 PAGE 59

NEXT BASEP DELETE

BASER PAGE 43

CLEAR

DISK

IN/OUT

NEXT BASEP

SCAN

TCP, PAGE 42

Programming

S3

41

9 Manual menu
TCP, PAGE 41

TCP5 X-250

Y=0

AUTODEF

Z=0
MANDEF

1 2 3

TCP5
NEW START POS?

YES

4 5 b
7 8 9
0

NO

t
TCP5 X=250 Y = 0
X=

CE

X-1iTALUE = 100 mm

4OVE
REMC
THE TOOL

z=o

TCP5 X=250 Y = 0

ENTER

Hi

Z=0
CE

ENTER

VALUE = 50 mm

f
TCP5 X=250 Y = 0

Z=0
CE

ENTER

Z-VALUE =50 mm

REINSTATE
THE TOOL

f
TCP5 X=100 Y = 50

75

CHANGE ACTIVE NEXT BASEP DELETE

5 X=100 Y = 50 Z = 75

TCP5 X=100 Y = 50

Z = 75

CHANGE ACTIVE NEXT

BASEP DELETE

Programming

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9 Manual menu
BASEP.PAGE41

TCP5 X=250 Y = 0 Z = OMM

CHANGE ACTIV NEXT BASEP DELETE

|BASEP5X=_. Y = _ Z = ... MM
AUTODEF

MANDEF

8ASEP5
NEW START POS?

YES

NO
BASEP6 X=... Y=... Z = ...MM

REMOVE
THE TOOL

EASEP5
STPOS

\
BREAK

1 ill 1

BASEP5 X = 5 Y=70 Z = 100

|BASEP5X=5 Y = 70 Z=100
CHANGE

NEXT TCP DELETE

Programming

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43

9 Manual menu
SENSOR, PAGE 41

See also
SENSOR
INTERFACE
Chapter 10.

Programming

44

S3

9 Manual menu
SOFT SERVO, PAGE 41

SOFT SERVO 0 1 2 * 4 9
SOFT

SERVO

CE

ENTER

SOFT SERVO 4A1=1O A2=20 A3=50

CHANGE ACTIVE NEXT

DELETE

SHIFT

A4=15 A5=45 A6=35 A7=50

CHANGE ACTIVE NEXT

I SOFT SERVO 4 Al=10 A2=20 A3=50

ACTIVATE
CURRENT
VALUES

CE ENTER

DELETE

SOFT SERVO 9 Al=15% A3=40%~

CHANGE ACTIVE NEXT

DELETE

1 2
DELETE SOFT SERVO? YES

15

SOFT SERVO 4 Al=15 A2=20 A3=50

A2=

NO

SOFT SERVO 0 12 * 4

CE ENTER

S3

Programming
45

9 Manual menu
100 POS
CLEAR

V = 100% PATH

DISK

100 POS

WINCH IN/OUT SCAN

V = 100% PATH

TOOL PARAM PALLET FRAME SCAN

PALLET, PAGE 57

INSTALLATION S3

S3

Programming
46

9 Manual menu
100 POS

100%PATH

CLEAR DISK WINCH

100 POS

IN/OUT SCAN

V=100%PATH

FOOL PARAM PALLET FRAME* SCAN

t i iob pos v=iob %

100 POS

= 100%PATH

DEFINE

RESET

| 100 POS

PATH

V=100%PATH

1 \p
lOOPOS

V-lOOttPATH

FRAME, PAGE 48
RUN THE ROBOT INSTRUCTIONWISE TO POINT 2.

Programming

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47

9 Manual menu
140 POS V=100%PATH
CLEAR DISK WINCH IN/OUT

TOOL PARAM PALLET FRAME

SCAN

SCAN

RUN THE ROBOT INSTRUCTIONWISE TO POINT 3.

170 POS V=100%PATH

STPOS3

CLEAR

DISK WINCH IN/OUT

BREAK

SCAN

170 POS V=100%PATH

TOOL PARAM PALLET FRAME

SCAN

170 POS V = 100%PATH

STPOS3

Programming

BREAK

S3
48

9 Manual menu
CLEAR DISK

WINCH IN/OUT SCAN

POOL PARAM PALLET FRAME SC

*)AVAILABLE ONLY IF THE

ROBOT IS PROVIDED WITH
PROGRAM PRINTOUT.

100 POS
LIST

kVAILABLE ONLY IF THE ROBOT

IS PROVIDED WITH COMPUTER
LINK.

V=100%PATH

FRSC TOSC RBMODE SCAN

FROM SC / TO SC. PAGE 50

100 POS

V=100%PATH

PROGRAM ERRORS LTDATAWDATA

AW SOFTWARE ONLY
AW SOFTWARE
WITH LASERTRAK OPTION
ONLY
PRINTOUT OF
ERROR BUFFER.
100 POS

V=100%PATH

PROGRAM NO=

100 POS
CLEAR

Programming

V=100%PATH

DISK

WINCH IN/OUT SCAN

S3
49

9 Manual menu
FROM SC / TO SC. PAGE 49
100 POS V = 100 % PATH
BLOCK PROGRAM

100 POS V=100%PATH

100 POS V=100%PATH

100 POS V = 100%PATH

PROGRAM NO=

Programming

S3
50

9 Manual menu
100 POS

V=100%PATH

CLEAR DISK WINCH IN/OUT

100 POS

SCAN

V=100%PATH

TOOL PARAM PALLET FRAME SCAN

100 POS
LIST

V = 100%PATH

FRSC TOSC RBMODE SCAN

LOCAL MODE

REMOTE MODE
LOCAL REMOTE

LOCAL REMOTE

LOCAL MODE

REMOTE MODE

CLEAR DISK WINCH IN/OUT SCAN

CLEAR DISK WINCH IN/OUT SCAN

Programming

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51

9 Manual menu
100 POS

V=100%PATH

CLEAR DISK

WINCH IN/OUT SCAN

\?\

100 POS
TOOL

V=100%PATH
PARAM PALLET FRAME SCAN

| 100 POS

V=100%PATH

| LIST FRSC TOSC

RBMODE SCAN

1 p

\ 100 POS
| *LANG ERR<

4 f

V=100%PATH
5 TEACH WDATA* SCAN

1n

TEACH, PAGE 53
ERRORS, PAGE 56

ENGLISH DEXTTSCH FRANC SVENSKA SCAN

PORTUG ITALIA DUTCH SUOMI

**(AW0NLY)
DESCRIBED IN CHAPTER 12,

SCAN

SELECTED LANGUAGE
APPEARS AT ONCE

Programming

S3
52

9 Manual menu
TEACH, PAGE 52
If no file has been
edited previously,
the menu below is
shown directly.

COORDINATE FILE = AFILE

NEW COORDINATE FILE?

YES

NO

The file edited most

recently is shown on
the upper line.

COORDINATE FILE = AFILE

COORDINATE FILE * AFILE

ABCDEP GHUKL MNOFQK STUVWX YZDEF

DEF

CHANGE ERASE

LETTER NO. 2
CONCLUDE
TEACH
COORDINATE FILE = T

ERASE, PAGE 55

ABCDEF GHUKL MNOPQR STUVWX

CHANGE, PAGE 55
DEF, PAGE 54

LETTER NO. 5

COORDINATE FILE - TECHANGE,

ABCDEF GHUKL MNOPQR STUVWX

LETTER NO. 1

COORDINATE FILE = TEST

COORDINATE FILE = TES

ABCDEF GHUKL MNOPQR STUVWX

DEF

CHANGE ERASE

LETTER NO. 2
CONCLUDE
TEACH
COORDINATE FILE = TEST

ERASE, PAGE 55

ABCDEF GHUKL MNOPQR STUVWX

CHANGE, PAGE 55
DEF, PAGE 54

Programming

S3
53

9 Manual menu
DEF, PAGE 53
If no file has been
edited previously,
the menu below is
shown directly.

....-.

...........i..

COORDINATE FILE >

SEQUENCE?

. . . . .

YES

NO

The file edited most

recently is shown on
the upper line.

.......^^....J:-..>....::C.>1M

NAME;
ABCDEF GHIJKL MNOPQR STUVWX YZ

Enter the first name in the sequence

with the function and numerical
buttons as on the previous page.
Conclude with a point

2 3

4
7

b
8 9

NAME =
ABCDEF GHIJKL MNOPQR STUVWX YZ

_JI_1

1 111 1

Enter the first name in the sequence

with the function and numerical
buttons as on the previous page.
Conclude with a point.
NAME = SQUARE
POS

Run the robot to the required position

for "Box 1" with the joy stick.

Run the robot to the required position

for "SQUARE" with the joystick.

NAME = BOX 2

BOX: X = 30.0 Y = 10.0 Z= 150.5

BREAK

POS

Run the robot to the required position

for "Box 2" with the joy stick.

NAME = BOX 3

BOX: X = 30.0 Y - 10.0 Z= 150.5

POS

BREAK

SEE THIS
PAGE

NAME=BOX3
DEF CHANGE ERASE

SEE THIS PAGE

CONCLUDE
TEACH

BREAK

CONCLUDE TEACH

ERASE, PAGE 55
CHANGE, PAGE 55 ,

Programming

S3
54

9 Manual menu
CHANGE, PAGE 53

ABCDEP GHUKL MNOPQR STUVWX YZ

Enter the name of the

position to be changed.
Conclude with a point.

Run the robot to the required

position for "BOX 2" with
the joystick.
BOX2: X = 100.2 Y = 25.5 Z = 943.2

ERASE, PAGE 53

3!

7
-

i NAME=B0X2

9 1I ABCDEF GHUKL MNOPQR STUVWX YZ

ij

III

NAME = B 0 X 2
Enter the name of the position
which is to be erased. Conclude
with a point.

NAME = BOX 2
DEP CHANGE ERASE

-..........re"v.yw=v.

Programming

BREAK

,-w.:::>:

.-.v.-.-.-.w:

-\

.;;[;;;

^r-

S3
55

9 Manual menu
ERRORS, PAGE 52

503 EMERGENCY STOP

ERASE TEXT FRDISK

503 EMERGENCY STOP

ERASE ERROR BUFFER? YES

n times

IRB2000AW DOl

NO

9104 1991

ERASE TEXT FRDISK

NO ERROR MESSAGE
LANG ERRORS TEACH

SCAN

was

503 EMERGENCY STOP

ERASE TEXT FRDISK

503 EMERGENCY STOP

503 EMERGENCY STOP

READY

S3

Programming
56

9 Manual menu
SCAN 1 TIME
PALLET, PAGE 46

PALLET, PAGE 58

Programming

57

S3

9 Manual menu
PALLET, PAGE 57
FROMSTPOS

4
7

5
8

6
9

PAT.TJ!T
,

NOOFPOS =
!|

CE

ENTER

PALLET 1/4:5
PALLET

Progranmiing

SCAN

S3
58

9 Manual menu
TCP, PAGE 41

CHANGE

NEXT BASEP

AUTODEF

MANDEF

TCP 22 X=1500 Y=200 Z=1650MM

TCP22 X=1500 Y=0 Z=OMM

aiANGE ACTIVE NEXT BASEP DELETE

CE

ENTER

Y-VALUE = 200MM

TCP22 X=1500 Y=200 Z=0MM

Z=

CE

ENTER

Z-VALUE=1650MM

w.v.w.s_...w..~M.y.w^^^

TCP 22 X=1500 Y=200 Z=1650 MM

CHANGE ACTIVE NEXT BASEP DELETE

S3

Programming

59

9 Manual menu

SCAN 4 TIMES
TRIM READSYN TSIG HOMEPOS

HOMEPOS 1:=A1:-9O A2:60 A3:-20 >

SCAN

A4:-0 A5:15 A6:-200 OUTPUT=10

I HOMEPOS 1: = A1:-9O A 2 0 A3:-20 >

HOMEPOS 1:=A1:-9O A 2 0 A3:-20 ->

IMODPOS MODOUIT

DELETE HOMEPOS

Programming

BREAK

60

YES

S3

10 Adaptivity

10

Adaptivity
Section

Page

10.1 Adaptivity sensor interface

10.2 Connection and definition of sensors
10.3 Searching
10.3.1 Distance searching
10.3.2 Direction searching
10.3.3 Autosearch (AW)
10.4 Speed control
10.5 Contour tracing
10.6 Correction vector
10.7 FRAME

10:3
10:3
10:4

Programming

10:7
10:8
10:10
10:11

S3

10 Adaptivity

Programming

S3

10 Adaptivity

10.1

Adaptivity sensor interface

Introduction
The adaptivity functions are utilized when it is advantageous to use the same robot
program for a task, despite it being possible that the work situation may be changed during
the program execution. For example, the task can be to pick up work pieces from a conveyor
at standstill, irrespective of the placing of individual units on the conveyor, to apply
adhesive to the contour of work pieces each with its individual shape or to grind objects
with varying dimensions to a specified dimension.
The adaptivity functions utilize indications from sensors which are connected to the robot
system to permit adaption of the robot movements to the position and form of the work
piece.

10.2 Connection and definition of sensors

The following sensor types can be connected:
SENSOR TYPE

SIGNAL LEVEL

Digital one bit sensors

High
Low

Digital two bit sensors

High
"01"
No signal "00"
Low
"10"
Error status "11" (stop of programmed
running)

Analog senors

-lOVto

"1"
"0"

+10V

The sensors can be used for the following functions and are connected in accordance with
the table:
SENSOR

FUNCTION

CONNECTED VIA

Digital one bit sensor

Distance searching
Speed control

System board
System board

Digital two bit sensor

Distance searching
Direction searching
Speed control
Contour tracking

Digital I/O board

Digital I/O board
Digital I/O board
Digital I/O board

Analog sensor

Distance searching
Direction searching
Speed control
Contour tracking

Analog I/O board

Analog I/O board
Analog I/O board
Analog I/O board

A digital sensor can be connected to any digital input on any digital I/O board. Both bits in
a two bit sensor are to be connected to input channels within the same supply group. The
connections is to be made input channels next to each other, with the lowest bit connection
to the input channel with the lower number.
Up to three one-bit sensors for distance searching can also be connected to the direct action
inputs of the system board. These inputs have a response time of 12 5 msec,
i.e. 7 to 17 msec. The response time for inputs on the digital I/O board 12 (- 5 + 15) msec,
Programming

S3

10 Adaptivity
i.e. 7 to 27 msec.
Connection of one bit sensors via the system board is described in Installation S3,
chapter 3.
Analog sensors can be connected to arbitrary analog input.
Except the physical connection according to above, must the sensors be logically definined
before the adaptive functions can be used. This is described in chapter 9.

10.3

Searching
The search function is usable for example when the position of the work piece which the
robot is to process is not completely known or if it can vary from cycle to cycle.
The robot searches for the part and uses its location as a starting point for the processing.
Two variants of searching can be programmed, distance searching and direction searching.
In both cases a search distance is defined during the programming which determines the
direction of the searching to be performed.
Up to three sensors can be used simultaneously when searching. When distance searching
all sensor types can be used (one bit and two bit digital and analog) and when using
direction searching all except digital one bit sensors.
When a sensor "finds" an object in the search distance, its signal level changes. During
distance searching, this causes a so-called search stop i.e. the searching movement is
interrupted.
During direction searching such a signal change results instead in the start of free
searching.
When two-bit sensor are used, a search stop is given when the sensor signal changes level
from "01" to "10" (or from "10" to "01"). During free searching under direction searching, a
search stop is given when level "00" is searched.
For analog sensors, a signal level is programmed at which a search stop is to be given. The
search stop is given irrespective of whether the signal was previously at a level higher or
lower than that programmed.
With free searching under direction searching, a search stop is also given when a certain
level programmed previously is reached.
As the search stop status is presented at the robot outputs, this can be utilized to control
peripherals or as jump conditions etc.
The length of the search movements are determined by the positioning tolerances of the
workpiece. To ensure constant search speed the start and stop positions of the searches
should be placed approx. 5 mm outside the tolerance range of the workpiece.

Programming

S3

10 Adaptivity
If the position of the workpiece varies within very wide limits, the long search movements
necessary become excessively time-consuming. An introductory quick search with reduced
accuracy can then be used to advantage to give a start point for a search with normal speed
and accuracy. To secure that the whole distance of the programmed search movement is
executed, the start and end position of the search must be fine points.
Reference point
Reference point instructions are used to refer the search and TCP movements to the
preceding search stop. This procedure permits transposition of the TCP movements to the
correct position. Reference point instruction REFP should be programmed at a FINE
position.
When a reference point is programmed, the current position of the robot TCP is stored in
the robot memory. When the reference point instruction is executed, the difference between
the stored position when programming and the current position is calculated. This
difference is added, with further programming or program execution, to the position of all
position instructions until a new reference point is activated or the instruction "REFP OFF
is executed. A new reference point can be activated without deactivation of the preceding
reference point.
/""*

Conditional jumps
When executing a search movement, the register "Search" is activated to indicate that the
search has resulted in a search stop. The search register is one of the arguments with
conditional jumps. This permits repetition of unsuccessful searches or jump to an error,
control program. If also a jump, conditional with respect to the contents of a register is
used, unsuccessful searches can be repeated a programmed number of times before the
error control program is called.

10.3.1

Distance searching
If a sensor detects that which is required during a distance searching the searching is
interrupted and a search stop is activated. The next instruction in the program is then
executed. The search stop applies until a new search begins.
If no search stop is activated, the robot continues to the end of the search distance and then
begins execution of the next instruction.
It is also possible to program a delay so that the search stop is not actuated until 0.5
seconds after the sensor detection.

10.3.

Direction searching
Direction searching can be used when the robot is to locate the corner of a sheet or a box.
When such a corner is located in the search distance, searching continues in a new
direction (free searching) without a search stop.
The direction of the free searching is determined by correction vectors, the magnitude and
direction of which are programmed with the help of the VECTOR function. (See section
10.6 Correction vector for a more detailed description of how the function is utilized).

Programming

S3
5

10 Adaptivity
The free searching continues until all of the sensors used give signals that no more
correction is necessary, (i.e. level "00" for two bit sensors. For analog sensors, the level to
apply is selected at programming). The position of the corner is determined and a search
stop becomes effective. The search stop can also be delayed until 0.5 seconds after location
of the corner.
The stop position is adjusted with respect to the zero zone after which execution of the next
instruction is begun.
If no sensor reacts during the first search distance free searching begins at the end of the
search distance.
Free searching is stopped if it reaches outside a radius of 5 cm from where it began.

10.3.3

Autosearch (AW only)

The function AUTOSEARCH is a further development of distance searching. Some
differences are described below:
During programming of the search distance, there are sometimes problems to define the
end position for the search, depending on difficulties to reach the position physically, or
other obstacles. Then it is possible to define a calculated end position, as follows:
Program the start position of the search in the same way as for distance search.
* Then program an end position close to the expected position for search stop.
With the instruction AUTO (under the SEARCH menu) it is possible to simulate an end
position. It is placed as follows:
1. The operator runs the robot tool to a position, where a search stop is likely to occur.
That position is situated on the distance A from the start position for the search.
Simulated end position

Start position

Expected position
for search stop

2. The operator performes the procedure as below.

3. The system will, as an answer, an end position situated at a distance 2 * A from the
start position for the search.
When the search stop occurs the search is interruppted and the robot position stored. The
reference point is also activated (REFP ON). This will simplify complicated searching
sequences with many consequent searches.

Programming

S3

10 Adaptivity

10.4

Speed control
In some robot applications, the possibility of controlling the working speed of the robot is to
advantage, particularly when different parts may require different processing.
A sensor is utilized for speed control so that the sensor signal controls the reduction of the
programmed speed. The reduction (X % below) is specified when programming digital
sensors. In the case of analog sensors a threshold value and a maximum value are specified
(see below)
One bit sensors:
Two bit sensor:

Analog sensor:

O=Unreduced speed
l=Speed reduced by X %
01=Unreduced speed
OO=Speed reduced by X %
10=Speed reduced by 2 x X %
ll=Stop
When the signal is lower than the
threshold value, the speed is not reduced.
For signals equal to or greater than the
threshold value but less than the
maximum value, the speed is reduced in
proportion to the signal with signals equal
to or greater than the maximum value,
the robot movement is halted.

Only one sensor is used with speed control. All types of sensor can be used.
The present velocity correction is saved when the program is stopped (irrespective of how).
It is still active when the program restarts (even at backwards execution). The correction is
erased first when a POS-instruction without a VCTRL-argument is executed.

Programming

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10 Adaptivity

10.5

Contour tracing
When the robot is to follow a contour between two points the contour tracing function can
be utilized. The function is activated with the argument CONTOUR.
Start and stop points for the tracing distance are specified during the program as FINE
positions. During movement between the two points, the sensors signal states where the
robot is, in relation to the followed contour.
The position of the robot is corrected if it departs from its path. The direction in which the
correction is to be made is given with the help of correction vectors (see section 10.6).
Up to three sensors can be used at the same time when tracing contours. Analog sensors,
digital two bit sensors but not one bit sensors can be used.
When programming, the signal level to be adopted by the analog sensors when the contour
is followed correctly i.e. when no correction is necessary (a so- called BIAS level). For two
bit sensors the level "00" is the BIAS level.
For contour tracing, the following applies:
Up to three sensors can be used
Digital one-bit sensors cannot be used
Correction vectors for each sensor used must have been programmed previously.
Principle
The contouring function is designed to enable small path corrections to be made when the
robot moves between two pre-programmed points. Correction are performed by each
interpolated interval (each 48 ms) that are proportional to value of the sensor and the
programmed speed of the correction vector.
The actual formula for calculating the correction is as follows:

CORR = (SENSOR VALUE) * SCALE FACTOR * (CORR. VEC. VELOCITY) * K

where K is a internal constant.
The sensor value is read every 10 ms and a correction value calculated which is
accumulated in a register and is used for calculation of the next interpolated step.
To obtain a more stable movement there is a 0.1 mm zero zone from desired location
within which no correction is done.
The actual deviation from the nominal path is saved when the program is stopped(no
matter how). It is in effect when the program is restarted(even at backwards execution).
The correction is cleared first when a POS-instruction without contour argument is
executed.
Limitations
The contouring function is designed for welding applications where low robot speeds are
used. It is not intended for cases where large deviations from the programmed path are
expected.
In general the contour function should be used at robot speeds of less than 20 mm/s and
deviations of less than 10 degrees. The function has a time constant of around 210 ms (of
which the mechanical time constant of the robot is around 120 ms).

Programming

S3
8

10 Adaptivity
The algorithm for calculating the position corrections is located in the robot system and
therefore the function is not designed to receive pre-calculated position corrections from
"smart" sensors such as seam trackers.
ABB Robotics seam tracking system - LaserTrak - operates on a different principle which
means that the limitations in the speed and deviations given above do not apply.
Complementary programming notes
Normally is an analog sensor used for contouring. As can be seen from the formula given
above, the scale factor and correction vector speed together determine the size of the
correction.
The recommended procedure for obtaining smooth contouring is to define a small scale
factor and then to adjust the correction vector speed.
A recommended scale factor value is between 0.01-0.1 and a suggested starting value for
the correction vector speed is four times the robot speed.
Note that the direction on the correction vector normally should be perpendicular to the
programmed robot path and that if the speed of the correction vector is less than that of the
programmed points no correction to the pre-programmed path will be noticed.
The BIAS defined in the contour instruction is given as a percentage of the working range
of the sensor which in turn is defined as the max-/min values provided in the list of sensor
parameters. If the sensor operates from 0-10 V the min-/max values should be given as 0
and 1023 (since, an analog sensor is converted to an ten bit digital value). A BIAS of 50%,
therefore, means that corrections will be calculated when the sensor value deviates from 5
V. If the sensor voltage lies outside the defined MinTMax range ADAPTrvTTY ERROR 1
will be displayed.
The correction vector operates in hand coordinates or base coordinates depending on
whether the sensor is defined as being ON or OFF the robot in the sensor parameter
definition. "ON the robot" means that the correction vector follows the orientation of the
robot hand. "OFF the robot" means that the correction vector is fixed relative the robot's
base coordinates.
Note!
A correction vector cannot be defined as a pure rotation: a correction vector must be defined
between two separate TCP points.
Speed
Since the contouring function is intended to be used when small deviations from the
programmed path are expected, the robot speed with contouring is approx. the same as the
programmed speed of the robot without contouring.
Where control of the speed of the robot is important, the VELOCITY CONTROL function
should be used.

Programming

S3
9

10 Adaptivity

10.6

Correction vector
During free searching (direction search and counter search) the correction is given as a
vector with speed and direction. When programming a correction vector, the speed is
specified as a percentage of the basic speed. The direction is defined by running the robot
from a start point to a final point in the direction specified for the vector.
For analog sensors, a signal level at which no correction is required is defined. (For two bit
sensors, the zero level applies).
All signals lower than this level give a correction in the direction of the correction vector
and all signals higher than the level give corrections in the opposite direction of the vector.
The speed value, V, in an instruction in which a correction vector is defined, has different
meanings for free searching and for contour tracing as follows:
V specifies the maximum search speed with free searching (as a percentage of the basic
speed).
V specifies a gain factor for position correction when contour tracing.
The formula for calculation of the correction, at counter tracing is given in section 10.5.
The formula for the speed of a correction during free searching is as follows:
Search speed (mm/s) = 20 x scale factor x the difference between required and actual sensor
signal.
If the current sensor signal deviates less than 3 % from the required sensor signal no
correction movement is performed (zero zone).
The max. value for the search speed is determined by the programmed speed, in mm/s.
When two or three sensors with associated correction vectors together control a free
search or contour tracing, the different directions and speeds will be stored as shown in the
example below.
Vector 1

Resulting vector
Vector 2

The robot can locate an object in a plane or follow an optional contour with two correction
movements. An object in space can be localized by the robot with three correction
movements.
When a sensor, in accordance with sensor data entered (see section 9.5) is mounted on
the robot, the associated correction movement follows the robot orientation. If the robot
wrist is rotated around the TCP, the direction is affected. When a sensor, according to
sensor data entered, is installed elsewhere, the above does not apply.

Programming

S3
10

10 Adaptivity
A correction movement for a specific sensor can be programmed in a program at any time.
It applies until:
A new movement for the same sensor is programmed and activated.
The contents of the program memory are lost.
The VECTOR function is used when the direction and the speed of a correction movement
are to be determined.
When the instruction is executed, the new correction vector will replace any previous
vector for the sensor concerned.
The following applies for a correction vector:
A correction vector for a sensor is programmed. If several vectors for several sensors
are to be program, one instruction is required for each sensor.
The correction vector for a sensor applies until a new movement for one and the same
sensor is programmed and activated
A program correction vector follows the orientation of the robot if the sensor concerned
is mounted on the robot in accordance with the sensor data read in.
If the memory content in the program memory is lost, all vectors disappear
At start-up, no correction vectors are programmed.
At Testart the correction vectors remain active.

10.7

FRAME
The procedure for programming automatic definition of FRAME is described in detail in the
following pages. Note that the method for searching for objects must always be adapted
from case to case. The basic definition of the FRAME function is found under section 3.9.2.
A simple example of the appearance of a program section with automatic definition of
program displacement is given below. It is assumed that the program is to be twisted in a
plane.
1. Ensure that program displacement 0 is active. Displacements stored on each other give
an inaccurate result.
2. Place the object to be located in a suitable place.
3. Program the start point for searching for the actual location of position 1, (FINE
position)
4. Program the end point for the seraching so that the searching is always successful if an
object is available, (FINE position).
5. Program an instruction with the FRAME function under the POSITIONING menu for
position 1.
6. Perform points 3-5 above for position 2.
7. Perform points 3-5 above for position 3.
The program is now to have the following appearance. Note that all instruction numbers
and numerical values in the instructions are examples only.
90

SET FRAME 0

Normal position for program

displacement, i.e. no displacement is
activated.
Start point for searching for the true
location of position 1.
Searching for the position 1 true location.

100 POS V=100% FINE

110 POS V=10% FINE
SEARCH SI

Programming

S3
11

120 POS V=10% FRAME

POS1
130 POS V=100% FINE

Definition

of

displacement

of

10 Adaptivity
position
1.*

Start point for searching for the true

location of position 2.
Searching for the position 2 true location.

140 POS V=10% FINE

SEARCH S2
150 POS V=10% FRAME
POS 2
160 POS V= 100% FINE

Definition

170 POS V=10% FINE

SEARCH S3
180 POS V=10% FRAME
POS 3

Definition

of

displacement

of

position

2.*

Start point for searching for the true

location of position 3.
Searching for the position 3 true location.
of

displacement

of

position

3.*

8. Enter instruction 190 with the help of the FRAME instruction under the LOGICAL
INSTRUCTION menu. Select the sub-instruction DEF. The result is to become as
follows:
190

DEFINE FRAME 1

*)Note
When these positions are programmed, the robot is to stand in the positions which
correspond to the search points on a non-displaced object. Each FRAME-POS instruction
has to be executed once were the non-displaced positions are. The execution of these
instructions will give information for the instruction DEFINE FRAME later on were the
non-displaced object were placed.
For a successful search for the true location of the positions 2 and 3, the complete program
must be parallel displaced when the searching for the true location of position 1 is
performed. When the definition of FRAME 1 is performed in accordance with the example,
the parallel displacement is cancelled. The program displacement according to FRAME 1
is to be activated instead. This is to be continued as follows:
9. Add an instruction with number 125 to the program. This instruction is to activate a
reference point. Use:
INSERT under the EDITING menu to create the new instruction number.
REFPunder the POSITIONING menu for activation of the reference point.
10. Program deactivation of a reference point as an instruction 200. Use the REFP under
the POSITIONING menu.
11. Activate the program displacement FRAME 1 with the help of instruction 210. Use SET
under the FRAME function in the INSTRUCTION menu.

Programming

S3
12

10 Adaptivity
12.The program should now continue with a further searching which determines how the
object is parallel-displaced in relation to the established program displacement. The
instructions 220 - 240 are used for this is accordance with the following:
220

POS V=50% FINE

The start point is placed well within the

area occupied by the object.

230

POS V=10% FINE DIST

SEARCH SI

Searching transversely along

the position of one long side.

240 POS V=10% REFPOINT ON

Continued program running is performed

parallel displaced and adapted to the true
position of the object.

The program is now to have the following appearance:

90

FRAME 0

Any program displacement is cleared.

95

POS V=0% REFPOINT OFF

REFPOINT off

100

POS V=100% FINE

The start point for searching for the true

location of position 1.

110 POS V=10% FINE

SEARCH SI

Height tracing downward of the true

location of position 1.

120 POS V=10% FRAME POS 1

Definition of displacement of position 1.

125 POS V=0% REFPOINT ON

Parallel displacement of the program

before searching for the positions 2 and 3
is activated.

130

POS V=100 %FINE

Start point for searching for the true

location of position 2.

140

POSV=10%
SEARCH S2

Transverse searching for the true

location of position 2.

150 POS V=10% FRAME POS 2

Definition of displacement of position 2.

160 POS V=100% FINE

Start point for searching for the true

location of position 3.

170

Transverse searching for the true

location of position 3.

POS V=10% FINE

SEARCH S3

180 POS V= 10% FRAME POS 3

Definition of displacement of position 3.

190 FRAME 1 DEFINE

Position of FRAME 1 is calculated on the

basis of the three searches above.

200

POS V=0% REFPOINT OFF

Parallel displacement of the program is

deactivated.

210

FRAME 1

The program displacement is activated.

Programming

S3
13

220

POS V=50% FINE

10 Adaptivity
The start point is placed well within the
area occupied by the object.

230

POS V=10% FINE

SEARCH SI

Transverse searching along the

position of one long side.

240

POS V=0% REFPOINT ON

Continued program running is performed

parallel displaced, adapted to the true
location of the object.

400

REFPOINT OFF

410

RETURN

Programming

S3
14

11 Programming

11

Programming
Section

Page

11.1 OVERVIEW OF FIVE PROGRAMMING MENUS

11:3
11.2 Initialization sequence for the main program
11:5
11.3 PROGRAM STRUCTURE
11:5
11.4 PATTERN PROGRAM
11:7
11.5 PROGRAMMING ROBOT PATHS
11:11
11.5.1 Smooth wrist reorientation
11.5.2 Recommendation for Arc Welding
11.5.3 Recommendation for Glueing and Sealing
11.5.4 Process application type plastic cutting, metal cleaning,
deburring and polishing
11.5.5 Recommendation for Assembly, Machine, Tending and
Material Handling
11.5.6 Closely spaced positions
11.6 PROGRAMMING EXAMPLES
11:15
11.6.1 Arc welding of rear axis member
11.6.2 Glueing of a car door
11.6.3 Cutting and deburring of plastic, forming of holes using
the CIRCLE function
11.6.4 Cutting and deburring of plastic lining for a car door
11.6.5 Material handling applications
11.7 HIGH PERFORMANCE PROGRAMMING
11:22
11.7.1 General
11.7.2 Recommendations for best performance
11.7.3 Movement principle choice
11.7.3.1
Coordinate system
11.7.3.2
Movement principle
11.8 LOAD, PROGRAMMABLE
11:26
11.8.1 General function
11.8.2 Wrist operations (A and P).
11.8.2.1
Acceleration index calculation.
11.8.2.2 Trimming of position gain index.
11.8.2.3
Preset values
11.8.2.4
Measures to deal with overshoots.
11.9 TRIM, PROGRAMMABLE
11:31

Programming

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11 Programming

Programming

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11 Programming
11 Programming
11.1 Overview of five programming menus:
Descriptions of the instructions are found under respective chapter and section, The
section corresponds
to the position on the menu. Example: TIME is described in chapter 6 section 15. etc.

= Positioning
Instruction

= Logical Instruction
Menu chapter 5

GBIPPEB

WATT

OUTPUT

JUMP

S.1

S3

SJ

5*

VELOC

CALL

RETURN

BEG

5.7

54

55
TCP
&9

INTER
5.10

COM

SUCTKL

COORD
SJ1
.,

GETB
5.12

BtmAME
(LOCATE)

5.13

5J4

EXTAX

SOFTS

;LUESCA

5.17

5.16

10.1

LOAD
530

TRIM
531

FBAIIE

SCAN

SCAN

SCAN

WEAVE

6.1
BEFP
6.6

COB
VEC

POSPOS

CIRCLE
8.13

5.15 S32)

SAME

S.18

ta
SCAN

5.16

VISCTBL

V()
63

6.10
FSAMZ
6.14

SCAN

ZONE

SEARCH

6J

6-4

VCTRL

SCAN

6.7

CONTOUB
6*

STOPOS

POSLOC

SCAN

6.11

.li
SCAN

TIME
6.15
HELTO-

PALLET

522

SCAN

SCAN

6.17

6.16
SCAN

Automatic Menu
chapter 7 AW

1
PROG SI

DSST

BWD

7J

72

73

DISPL
75

COB VST
7.6

HESYNC

MOVE
RESTART
7J0

IS

= Automatic Menu
chapter 7
MH/GL/SW
SIM

SCAN

7.4

ALIGN*
7.7

PBOGST
7.1

DISPL
7S

SCAN

RESYNC
73

BWD
73

SDC
7A

COBVST

ALIGN*

AW BEST

7.6

7.7

7.8

INSST
73

MOVE
JESTABT
7.10

SCAN

SCAN

SCAN

SCAN

3"
= Editing Menu
chapter 8
vow

INSTNO

8.1

82

MODIFY

DELETE

85

1 STEP

1"

PKOGRA

PEOGNO

copy

1 EBASE

&

8.10

1 8.11

8.12

1 TIME

copy

1 8.14

INS
8.15

8J3

SCAN

84

RES8Q

MIRBOR

SCAN

84

&?

1 INSERT

MODPOS

SCAN

SCAN

CLEAR
9.1
TOOL
A
LIST
9.7

DISK

rase

Manual Menu
chapter 9
DOUT

PALLET
9.15

FRAME
9

SCAN

rose

BBMOD
9.10

SCAN

SCAN

9.8

LANG

ERRORS

TEACH

WDATA

9.11

9.12

9.13

9.14

TBM

sxrnuME
9J6

READ
SYN

REPP
9.18

SCAN

93

93
PARAM
InatMan.

TSIG

HOME
PCS
9.17

SCAN

SCAN

Programming

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11 Programming

Programming

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11 Programming

11.2

Initialization sequence for the main program

It is recommended that programmers make a habit of entering the following instruction
sequence with the required initialization values at the beginning of each main program
when programming the robot. This ensures that programmed operations begin with correct
values from the beginning.

10 V = (value) M A X = (value)
20 TCP (number)
30 RECT COORD or ROBOT COORD
40 FRAME (No)
50 REFP OFF

Basic and max. speeds

Required TCP number
Selection of coordinate system
Required reference frame
Any previously activated ref. point is
removed

If these values are not specified the robot system utilizes instead the values most recently
used.
The SHIFT button on the programming unit can be used to check the values currently
activated program information is then presented on the display.

11.3

Program structure
Each robot program has its own program number and consists of a series of instructions
which are numbered within the program. Programs can include positioning instructions,
logical instructions such as jump, allocation statements tests and comparisons, call of
subprogram etc.
Programs can be numbered optionally between 0 and 9999. Instructions within a program
can be numbered optionally from 1 to 65535.
The types of instructions determine how many can be accommodated in the memory at any
one time. Positioning instructions occupy considerable space - more than logical
instructions. The primary memory accommodates 64 kbytes which corresponds to 2500
coarse points.
An appropriate program construction includes an administrative main program which
controls the work of the robot and calls subprogram for different sub-processes which are
often repeated during a work cycle.
A main program with all associated subprograms is designated a program block. Program
number 0 should be used for the main program if possible.

Programming

S3

11 Programming
MAIN PROGRAM

Call of a subprogram
Subprogram can be called with repetition so that they are executed the number of times
required before a return is made to the main program. (Max 99 repetitions)
Call of subprogram with repetition
MAIN PROGRAM 0

SUB-PROGRAMS

EXECUTE
3 TIMES

Call of a subprogram with repetition

A subprogram can also call a further subprogram (maximum 12 levels down). If a
subprogram on level 12 attempts to call a further subprogram, program execution is
stopped and an error message is presented.

Programming

S3

11 Programming
MAIN PROGRAM 0

10 mmmmmmmm
20

LEVEL 1

CALLS

30
mmmmm
40 seemssmmmsmmmz

SUB-PROGRAM 3

50 ****

LEVEL2

SUB-PROGRAM7

"To

'

20 CALLS
30
40
50
60
70
80
90 RETURN

11.4

Pattern program
A pattern program is a sub-program and is treated in a special way as follows:
The program is divided into a number of modules separated by RETURN-instructions.
PATTERN PROGRAM

> module 0

module 1

370 POS
380
390
400
410
420 REGISTER - 0

module 6

430 RETURN

Each module can, for example, contain:

Prograi

S3

11 Programming
A number of positions for a repetitive task where the task itself is stored within another
sub-program which is called from each program module, see example below:
PATTERN PROGRAM
10 POS
20
30
40
50
60
70
80
90

790
800
810
820

SUB-PROGRAM
FOR PATTERN

CALL
RETURN
POS
CALL
RETURN
POS
CALL
RETURN

10 REFPON
20 POS
30 POS
40
50
60
70

GRIPPER
POS
REFPOFF
RETURN

POS
CALL
REGISTER = 0
RETURN

* Variations of a task.
Different tasks which are executed during different stages of the main program's work
cycle.
When calling such a program a number register is defined for control of which module that
is to be called.
The register is normally set to 0. When the content of the register is 0, the first module is
called. When the content is 1, the second module is called etc. The register is incremented
with 1 each time the patternprogram is called. At the first call, the content thus becomes 1,
at the second, 2 etc.
Only a register defined in such a way should be used for this purpose.

Programming

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8

11 Programming
Below is shown an example on how the calling instruction co- operates with the number
register when executing the different modules within a sub-program.
VALUE
MAIN PROGRAM

PATTERN PROGRAM
10
20
-30
40
50
60
70
80
90

190
200
210
220

POS
CALL
RETURN
POS
CALL
RETURN
POS
CALL
RETURN

SUB-PROGRAM
FOR MOVEMENTS
10 REFPON
20 POS

30 POS
40 GRIPPER

50 POS
60 REFPOFF
70 RETURN

POS
CALL
REGISTER = 0
RETURN

VALUE
MAIN PROGRAM

PATTERN PROGRAM
10
20
30
-40
50
60
70
80

POS
CALL
RETURN
POS
CALL
RETURN
POS
CALL

190
200
210
220

POS
CALL
REGISTER = 0
RETURN

Programming

SUB-PROGRAM
FOR MOVEMENTS
-10
20
30
40
50
60
70

REFPON
POS
POS
GRIPPER
POS
REFPOFF
RETURN

S3
9

11 Programming
When programming the last module an instruction, before the RETURN-instruction,
should reset the number register which controls the module execution, see figure below:
VALUE
MAIN PROGRAM

PATTERN PROGRAM
' 10
20
30
40
50
60
70
80
90

-190
200
210
20

POS
CALL
RETURN
POS
CALL
RETURN
POS
CALL
RETURN

SUB-PROGRAM
FOR MOVEMENTS
JO
20
30
40
50
60
70

REFPON
POS
POS
GRIPPER
POS
REFPOFF
RETURN

POS
CALL
REGISTER = 0
RETURN

When executing a pattern program the modules can be executed in any desired order. It
isnot necessary to reset the register in the last module if appropriate values are inserted
into the register from somehwere else within the program block.
Values can also be entered into a number register, see "Registers".

Programming

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11 Programming

11.5

Programming robot paths

Earlier sections of the manual describe how path following and other robot instructions are
affected by zone instructions (section 3.6, 6.3 etc). This section contains recommendations
for programming various robot applications with respect to path following.

11.5.1

Smooth wrist reorientation

Reorientation of the wrist should be spread out over as long a path as possible to ensure
fast and smooth movemement. Reorientations of the wrist within a short path can limit the
robot TCP velocity and lenghten the cycle time.
The example below is a case where the TCP positions P5, P6, P7 are programmed, and the
reorientation of the wrist between position P6 and P7 has resulted in undesirable reduction
in velocity. The reorientation will now be reprogrammed to take place between P5 and P7.
(see figure)

c
original programmed
positions

c
programmed positions
after adjustment

P7

To obtain a smooth reorientation between positions P5 and P7 the following method can be
used: Depending on the profile of the path, either remove P6 temporarly or change P6 to a
circle point. Run the program slowly from P5 towards P7 in rectangular coordinates. When
the TCP passes P6 stop the robot. Correct the X, Y, Z location of the TCP to position P6
without changing the orientation. Program position 6 and change vack from a circle point
to a position.
The wrist reorientation is now spread out smoothly from P5 to P7. It is possible to spread
out the reorientation even more by means of more positions, in order to achieve a smooth
reorientation over a longer path.
At some TCP velocities a circular arc can give best smoothness for reorientation. This
assumes that the position zones do not overlap, and that the circle radius is more than
twice the zone size (to avoid overlap at entry and exit from the circle).

Programming

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11

11 Programming

11.5.2

Recommendation for Arc Welding

Recommended system parameter values

FINE
CORNER1
CORNER2
PATH

2 mm
5 mm
-100 mm
-25 mm

(=default)
(=default)
(=default)

The value 5 mm for CORNER1 is chosen to give a small corner radius while still allowing
sufficient path length for smooth reorientation.
Position Zones
FINE
Used for weld start and finish positions
CORNER1
Used during the weld process. Note that the robot starts the corner path
about 5 mm before the programmed position. Logical instructions and for
example, change of weld data, are executed just before entry to the zone.
CORNER2
Used for fast movements between weld paths.
PATH Used during the weld process. Note that because of the low velocity the
zone is very small. The robot TCP will therefor enter the position and
logical instructions will execute at the programmed position.
Program structure
Rectangular coordinates should be used during the weld process.
Robot coordinates are used for movement between process runs as this gives the highest
velocity.
FINE
positions are used at weld start and finish.
CIRCLE
is used when possible on curved weld runs. Reorientation is spread out
over as long a path as possible.
CORNER 1 is used on sharp turns on a weld run. Note that the distance between
programmed positions should be over 10 mm to avoid velocity reduction due
to zone interference.

11.5.3
Recommendation for Glueing and Sealing

Recommended system parameter values

FINE
2 mm
(=default)
CORNER1
15 mm
(=default)
CORNER2
-100 mm
(=default)
PATH
-25 mm
(=default)
Position Zones
PATH Used in glue/seal process for start of flow, change in flow etc. PATH is the
only argument to the GLUE instruction. The size of the PATH zone at a TCP
velocity of 150 mm/sec is 3,75 mm and at 500 mm/sec is 12,5 mm.
CORNER 1 Used in the glue/seal process.
CORNER2
Used for fast movement to and from the process.
Program Structure
Rectangular coordinates are used in the process.
Robot coordinates together with CORNER2 are used for movements to and from the
process. This gives the fastest possible movement.

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11 Programming
Circle is used for curved glueing paths.
Reorientation of the wrist is spread out over the greatest available space to give smooth
reorientation. The distance between positions should be greater than two times the zone
size to avoid velocity reduction at interfering zones.

11.5.4

Process application type plastic cutting, metal cleaning, deburring

and polishing
Recommended parameter values
FINE
2 mm
(=default)
CORNER1 15 mm
(=default)
CORNER2 -100 mm
(=default)
PATH
-25 mm
(=default)
Use of ZONES
FINE Use at the start and end of a program as "Start" and "end" positions. Avoid
in the process program because of loss of cycle time.
CORNER1
Used during the process for reorientation with large angles.
CORNER2
Used with robot coordinates for movements to and from workpiece for
example between deburring operations.
PATH Used to form a path to follow the curve of a workpiece.
PATH and CIRCLE are very useful in corners with a circular radius, or when working on
round holes. At the working speeds of 80-200 mm/sec used for cutting and deburring a good
zone is obtained with PATH. Example: at 150 mm/sec the PATH zone is 3,8 mm.
Program structure
Movements in space, for example between two process machines are programmed using
ROBOT COORD and CORNER2 for fastest movements.
In a process program, for example a cutting process, straights or uneven curves
RECT COORD and PATH
in circular paths or even curves
RECT COORD and PATH and CIRCLE
Workpiece reorientation is done over as long a distance as possible, or, if this is not possible
use a TIME instruction to allow smooth reorientation.
FINE positions should be avoided in the process as the TCP pause can cause an uneven
finish on the work piece.
It is important to avoid overlapping zones to obtain as even a process speed as possible.
That is to say, the distance between positions must be at least double the relevant zone
size.
Do not change from ROB COORD to RECT COORD during the process because of the
resulting pause in TCP movement.

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11 Programming

11.5.5

Recommendation for Assembly, Machine Tending and Material

Handling
Recommended system parameter values
FINE
2 mm
(=default)
CORNER1 15 mm
(=default)
CORNER2 -100 mm
(=default)
PATH
-25 mm
(=default)
Position Zones
FINE Used in connection with fetching or hand-over of work components, I/Ohandling, activation of reference points, store positions etc.
CORNER1 Used in connection with change of direction of a robot TCP in a small space,
deceleration of robot velocity before a fetch or hand-over position and such
cases.
PATH
Used for TCP movements in movement sub-programs for the first and last
positions in fetch and assembly sub-programs etc.
Program structure
The main program is used for movement of the robot, blocks of logical instructions and calls
to subprograms. This program section should not require very accurate path following. The
accuracy of the path can be allowed to vary with the robot TCP velocity.
Generally robot coordinates are used for this program section and PATH is used for
movement between different work-centers. If positions are at a distance from each other a
faster result can be obtained using CORNER2, but if positions lie close to each other PATH
gives higher velocity. Where possible, logical instructions should be collected in blocks in
connection with calling a sub-program or with a return from a sub-program.
Sub-programs are used where there is a requirement for accurate path following at all
speeds. Rectangular coordinates are used. The choice of zone depends on the required path
accuracy.

11.5.6

Closely spaced positions

To avoid problems with closely spaced positions, the distance between two positions is to be
two steps at the speed currently programmed, e.g. 10 mm at lOOmm/s, 50 mm at 500 mm/s.
In applications with critical cycle times and closely spaced positions, programming without
call of sub-programs is recommended to minimize the number of logic instructions.

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11 Programming
11.6

Programming examples
General
A number of functions often used when examples are to be programmed are summarized
below.
A subprogram is called up as follows:
1. Press EDITING.
2. Press the function button SCAN.
3. Press the function button PROG.
4. Enter the number of the required subprogram with the numerical keyboard.
5. Press the function button ENTER.
Searching of an instruction within the program is executed as follows:
1. Press EDITING.
2. Press the function button STEP.
Now three subfunctions are displayed, which can be used, namely:
FORW, step forward to next instruction number.
BWD, step backwards to the subsequent instruction number.
INST NO, jump directly to an instruction number, which is entered with the numerical
keyboard.
Functions for program execution are located under the AUTO menue, see chapter 7.
Continuous program execution is commanded with the function button START P.
Program execution forward, instruction by instruction, is commanded with the function
button START I.
Positioning backward, instruction by instruction, is commanded with the function button
BWD.
"Satisfied conditions" for WAIT instructions are simulated with the function button SIM.

Programming

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11 Programming

11.6.1 Arc welding of rear axis member

The example shows a program for

arc welding one side of a car rear
axis member. Three sides will be
welded.
section A-A

Main program 0
10 V=2500 mm/s. Max 2500 mm/s
20 TCP = 1
30 ROB COORD
40 FRAME 0
50 POS V = 100% C2
60 WAIT until INPUT 5=1
70 CALL PROG 100
80 RETURN

(home position)
(wait for start signal)
(call weld program)

Weld program 100

10 POS V = 100% C2
20 POS V = 100% C2
30 RECT COORD
40 POS V= 10% FINE AWELD 1100
50 POS V= 10% CIRCLE
60 POS V= 10% PATH
70 POS V= 10% PATH
80 POS V= 10% CIRCLE
90 POS V = 10% PATH
100 POS V = 10% Cl
120 POS V = 10% FINE WEND 1100
130 POS V = 50% PATH CALL PROG 300
140 POS V = 50% PATH
etc.
Cleaning program 300
10 Set output 4
20 Wait 0,5 s
30 Reset output 4
40 Wait 0,2 s
50 Set output 4
60 Wait 0,5 s
70 Reset output 4
80 Return

Programming

(move to work piece)

(move to work piece)
(start first weld)
(circle point)
(circle point)
(small radius and reorientation, use Cl)
(end of first weld)
(cleaning program)

(first cleaning)

(second cleaning)

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11 Programming

11.6.2

Glueing of a car door

r:

P9

P3

^ *

P12

I I I I I I I I I I I I I I I I
i i i i i i i i i i i i i i i i

PO.PIU
Car door

Profile

Main Program 0
10
20
30
40
50
60
70
80
90
100

V = 2500 mm/s Max 2500 mm/s

TCP1
ROB COORD
FRAME 0
POS V = 100% C2
WAIT until INPUTX=1
POS V = 100% C2
POS V = 100% Cl
CALL Prog 1
RETURN

Glue: Process program 1

10
V = 500 mm/s Max 1000 mm/s
Pos V = 100% PATH
20
RECT COORD
30
POS V = 100% FINE
40
50
POS V = 100% GLUE FLOW = 100%
POS V = 100% PATH
60
POS V = 100% CIRCLE
70
POS V = 100% PATH
80
POS V = 100% PATH
90
100 POS V = 100% CIRCLE
110 POS V = 100% PATH
120 POS V = 100% PATH
130 POS V = 100% Cl
140 POS V = 60% GLUE FLOW = 30%
150 POS V = 100% GLUE FLOW = 100%
160 POS V = 100% Cl
170 POS V = 60% GLUE FLOW = 30%
180 POS V = 100% GLUE FLOW = 100%
190 POS V = 100% PATH
200 POS V = 100% PATH
210 POS V = 100% GLUE FLOW = 0%

(home position)
(wait for start signal)
(positions close to the start pos)

(P0, above start pos)

(PI, glue start position)
(P2)
(P3)
(P4)
(P5)
(P6)
(P7)
(P8)
(P9, note 1)
(P10 reduced flow)
(Pll increased flow)
(P12)
(P13 reduced flow)
(P14 increased flow)
(P15)
(P16)
(P17, glue end position above P16)

P9

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11 Programming

11.6.3 Cutting and deburring of plastic, forming of holes using the

CIRCLE function

In this example it is not necessary to reorient the work-tool.

Program 10
10
20
30
40
50
60
70
80
90
100
110
120
130
140

V = 1000 mm/s max 2500 mm/s

TCP=1
RECT COORD
PosV= 100% PATH
WAIT till INPUT 10=1
Pos V = 50% PATH
Pos V = 5% PATH
Pos V = 10% CIRCLE
Pos V = 5% PATH
Pos V = 5% CIRCLE
Pos V = 5% PATH
Pos V = 10% CIRCLE
Pos V = 5% PATH
Pos V = 5% CIRCLE

230
240
250

Pos V = 5% PATH
Pos V= 10% PATH
Pos V = 100% PATH

Programming

(start position)
(in front of work piece)
(movement to work piece)
(cutting large circle)
(cutting small circle)

(as pos 70, cutting finished)

(movement from work piece)
(return to start position)

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11 Programming

11.6.4

Cutting and deburring of plastic lining for a car door

- 800 mm
Pos 210

700 mm

Pos 310

POS 90,400, Start and Stop positions

In this example the work-tool is reoriented.

Program 100
10 V = 1000 mm/s max 2500 mm/s
20 TCP = 1
30 Robot Coord
40 Pos V= 100% PATH
50 WAIT till INPUT 1 = 1
60 Pos V = 100% PATH
70 Rect Coord
80 Pos V = 50% PATH
90 Pos V = 5% PATH
100 Pos V = 5% PATH
180 Robot Coord
190 Pos V= 100% PATH
200 RECT COORD
210 Pos V = 50% PATH
220 Pos V = 5% PATH

(to start position)

(in front of work piece)
(movement to workpiece)
(tool to work piece)
(cutting starts)

(reorientation of workpiece in free space)

(movement to work piece)
(tool to work piece)

310
320
330

PosV = 5%C2
Pos V = 5% CIRCLE
Pos V = 5% C2

(cutting in a circular shape)

400
410
420
430
440

Pos V = 5% PATH
Robot Coord
Pos V = 100% PATH
Pos V = 100% PATH
WAIT until INPUT 2 = 1

(cutting finished)

Programming

(tool from work piece)

(to start position)

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11 Programming

11.6.5

Material handling applications

When logical instructions must be executed at the programmed position a FINE zone is
used. Define and activate a suitable TCP in the sub-program. This will help to ensure that
the robot will move to the correct programmed position during program testing, editing etc.
Define and activate a suitable TCP and Basepoint for assembly applications which include
twisting around a fixed center point. This simplifies programming. When positions with
displacement in the X, Y, Z axes relative to a reference point are used, a FINE zone is
programmed where the reference point is activated. When positions with displacement in
the X, Y, Z-axes relative to a stored position are used, a FINE zone is programmed where
the position is to red (STO POS). A program layout can be as follows:
Program 10
10 TCPO
20
ROBOT COORD
30 POS V=100% PATH
40 POS V= 100% PATH
50 POS V= 100% PATH
60
CALL PROG 110
70
TCPO
80
ROBOT COORD
90
OUTPUT 10=0
100 REG1=REG1 + 1
110 POS V= 100% PATH
120 POS V= 100% PATH
130 POS V=100% PATH
140 POS V=100% PATH
150 WAIT TILL IN 8=1
160 OUTPUT 11=1
170 CALL PROG 120
180 TCP 0
190 ROBOT COORD
etc

40

POS

Program 110
10 TCP 1
20 RECT COORD
30 GRIPPER 1 OPEN WAIT =,5 S
V=
100%
PATH
50 POSV=100%C1
60 POSV=100%C1
70 POS V=5% FINE
80 GRIPPER 1 CLOSE WAIT 0,3 S
90 POSV=10%C1
100 POS V=25% PATH
110 RETURN

When first programming these applications the robot may enter a fault condition. If and
when this may happen depends on possibilities which are then shown on the display. To
handle these situations it is important that the programmer structures the program in an
operator-friendly way.

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11 Programming
Therefore:
1. Follow the recommended program structure.
2. After a return to the main or transport program from a sub- program use the following
three- instruction sequence:
TCPX
ROBOT COORD
POS V=100% PATH
The position should lie about 200 mm above or in front of the fetch or hand-over
position. This position results in controlled path following even if the operator by
mistake makes a restart from the end of the sub-program. Instruction TCP X is also a
safety measure if something has happend in the sub-program. ROBOT COORD gives
the fastest cycle times.
3. The first position in a sub-program should be the same as the last position in the main
program. This will result in a controlled path following even if the operator by mistake
restarts from the sub-programs first instruction.
These recommendations will allow the operator to proceed with the operations after a fault
condition without needing to restart from the beginning of the program, and without
needing to know exactly at which robot position the stop occured. The operator can read-in
the first or last instruction in the sub-program depending on whether it is desired to repeat
or hop over the operation which failed.

Programming

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11 Programming

11.7

HIGH PERFORMANCE PROGRAMMING

11.7.1

General
Two servo concepts (mode A and B) ensure high performance of IRB 6000. In mode A
advanced algorithms are used to handle flexible mechanical arm structures. Thereby, it
will be possible to allow very rapid motor torque changes, resulting in very fast
movements.
One of the two servo modes is automatically chosen:
Mode A for short movements for axis 1, < 120 mm, with high programmed speed.
Mode B is for longer movements or short movements at low speed.
The difference in cycle time between mode A and mode B is especially large for short axis 1
motions.
The maximum TCP motion distance for mode A varies between approx. 60 mm and
120 mm, depending on the TCP position in the workspace. Mode A will not be activated
for the main axes if any of the wrist axes performs a too long motion.
Mode A is never activated during motions within corner zone (path, corner 1 or corner 2)
or immediately before or after the corner zone.

11.7.2

Recommendation for best performance

Use robot coordinates the whole time, which results in smooth and fast movements.
At spot weld programming it is suitable to set the parameter ZONE to PATH=-25, Cl=15
and C2=-100. (Minus before the number means that this zero zone is dependent of the
velocity, directly proportional against the programmed velocity.)
Value -25 means one computer step through the zero zone irrespective of the
programmed velocity (see fig. 1).
Value 15 means a fixed zero zone irrespective of the programmed velocity, suitable when
one want's to program high velocity without increasing zero zones. This results in a
dynamical velocity reduction through the zero zone.
Value -100 means 4 or more steps through the zero zone, which reduces the speed
(rarely used in spot weld programs).
This means that the smallest velocity reduction is obtained when PATH= (-25) is used.
For each extra computer step inside the zero zone the cycle time is increased by 0.05 sec.
Overlapping zero zones also results in speed reduction. The speed reduction increases
more than described above, if the overlapping is larger, see fig. 2.
This is not valid when zero zone -25 is used.
In this case big path faults can appear, if the zero zones are overlapping, see fig. 3.

Programming

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11 Programming

Fig. 2

Fig.l
PATH= - 25

C2 = (-100)
zone
overlap

reduction of
velocity

PATH= - 25

Fig. 3

PATH= (-25)

PATH= (-25)

overlap less steps,

worse path,
faster

4 (step)

3 (step)

Above mentioned recomendations can be summarized according to the rules of thumbon

the next page:

Programming

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11 Programming
Example around obstacles:

distance between points

corner zone

40
Programming example, distance between points = 80 mm:
10
20

V=1000 mm/s Max= 2500 mm/s

ROBOT COORD

40
50
60
70
80
90

POS V=250 % FINE W(WELD)

POS V=250 % FINE W(WELD)
POS V=100% PATH
POS V=100 % PATH
POS V=100% FINE WCWELD)
POS V=250 % FINE W(WELD)

Rules of thumb

distance between
points (mm)

type of corner
(parameter)

20-50

path (-25)

500

50-125

path (-25)

1000

>125

path (-50)

2500

Programming

velocity (mm/s)

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11 Programming

11.7.3

Movement principle choice

11.7.3.1

Coordinate system
When very short cycle time is required as e.g. in spot welding, ROBOT coordinates
should be used. In applications where path following is more important than short cycle
time, RECT-coordinates is the best choice.
Using RECT-coordinates, servo path following (SPF) is carried out, see section 3.6.1.

11.7.3.2 Movement principle

Principle 0: (param. AUTO/PATH=)
Coner paths are generated according to section 4.2.
When changing from ROBOT - to RECT-coordinates, the movement is stopped.
Principle 1: (param. AUTO/PATH=)
The problem with overlapping zero zones can be avoided, because no corner paths are
generated.
The movement is not stopped when changing between ROBOT- and RECT-coordinates.
Worse path following in RECT-coordinates.

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11 Programming

11.8

LOAD, PROGRAMMABLE

11.8.1

General function
This function is only accessible for IRB 6000 and means that the robot's load can be
selected and altered manually or direct in the robot program, in the same way as TCP.
This means that the robot can operate optimally even when great weight differences are
involved in the same program. This avoids cycle time losses.
The compensation is performed for the wrist load. Any equipment mounted on robot arm
may also be defined as an additional load. This load is part of the parameters and cannot be
altered during program execution.
Wrist load definition involves the following parameters:
Wrist weight.
Distance in X direction to the centre of gravity of the wrist load, in mm from mounting
flange.
Acceleration index (A4.. A6) for axis 4..6.
Position adjustment index (P4..P6) for axis 4..6.
20 different loads can be defined under the MANUAL button.
Load no. 0 is defined under the PARAMmenu. Load no. 1-19 are defined under menue
TOOL (see chapter 9.5).
The relevant load is activated when a special load instruction, LOAD, is executed, or
manually under menu TOOL.
The weight for any equipment on the robot arm is defined, under PARAM, (see Installation
S3) in the same way as the wrist load, but cannot be activated by a program instruction.
The weight and distance values control the main axis's operations and should precisely
correspond to the load concerned. Values that are too low may lead to overload in the
mechanical structure and severe arm deflections. Values that are too high cause
unnecessary cycle time loss and somewhat oscillative performance.

11.8.2

Wrist operations (A and P).

The wrist's preset acceleration and position adjustment correspond to a load with
maximum permitted weight and a moment of inertia within the load diagram, although
these may be altered by the user.
In applications where wrist loads with higher moments of inertia (Jo) than the load
diagram permits, the acceleration and controller gain can be reduced by the user.
For loads with low moment of inertia and a positive margin to the load diagram it is also
possible to increase wrist operations to further optimize cycle time.

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11 Programming

11.8.2.1 Acceleration index calculation.

The A value is controlled by two different calculations depending on the load's moment of
inertia.
Procedure:
- Calculate K
- Read A in diagram next page.

11.8.2.1.1PT- loads
Press tending operation involves using large sheets extending out some distance and with a
high moment of inertia. This may result in greater forces and torque loadings than
permitted on the wrist.
At high loadings the robot reaches the current limit, which may result in oscillative
behaviour and unpermitted mechanical loadings, especially in gears and structures in the
wrist.
To reduce such loadings, the acceleration performance has to be reduced.
K has to be defined so as to utilise available torque without exceeding the permitted
transverse force loading.
E is the smaller value out of Kl and K2.
Axis 4 and 5
Other variants

2.4-150 kg variant

K1=(950-Ms)/Jxx

K1 =(1350-Ms)/Jxx

* 0.5
K 2= 47 / (A x * m )

K 2= 70 / (Ax * m' 5 )

where:
Jxx = Ja5, Jb4 or Jb5 according to Description 1KB 6000
Ms is the static moment on axis 4 or 5. Ms = Ax * m * 9.81
Ax in metres as per definition in diagram in section 11.8.2.1.2
m is the total handling weight.
Axis 6:
In the case of axis 6 there will be a distinction depending on what the robot cycle looks like
but the same formulae apply to all variants.
Kl = 750/J6
K2 = 47/(Ay*m 0 - 5 )
Robot cycle according to case B in Description IRB 6000
Kl = (550-Ms)/J6
K2 = 25/(Ay*m> 5 )
Programming

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11 Programming
where:
Ms is the static moment on axis 6, Ms = Ay * m * 9.81
J6 is the moment of inertia on axis 6,
m is the handling weight
Ay is in meter
see diagram in section 11.8.2.1.2
150 kg

Other
variants
A = acceleration index
10
-8
7
6
5

4
3
-2
1
1 2 3 4 5 6 7 8 9

1 0

K= smaller value
out of K1 and K2

11.8.2.1.2Low loads, Jo<10 kgm^ and weight within the load diagram
In the case of loads with moment of inertia lower than 10 kgm2 and handling weight within
the load diagram, the torque margin is regarded as utilised for increased acceleration of
the wrist axis.
The following applies to all IRB 6000 variants.
A parameter K which is proportional to the margin to the load diagram's limitation for the
relevant handling weight is created.
Axis 4 o5
Axis 6

K=Lx/Ax
K=Ly/Ay

Lx is the X load diagram for relevant handling weight +0.2 m for axis 4 and
Ly is the Y load diagram for the relevant handling weight for axis 6
Ax is the relevant distance of the centre of gravity for the total handling weight in the X
direction from the mounting flange + 0.2 m for axis 4 and 5
Ay is the relevant distanse of the centre of gravity for the total handling weight in the Y
direction from the mounting flange.

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11 Programming

Centre of gravity for

relevant handling
weight
Centre of
rotation
axis 5
Load diagram for relevant
handling weight

Robot variants

2.4-150

2.4-120

11
10
9
8
7
6
5
4

15
14
13
12
11
10
9
8

A acc. index.
Others

14
13
12
11

10

I
1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

(L/A)

K
Note: Because of stability limitations the actual acceleration may remain at a limited level despite the
index rising.

Programming

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11 Programming

11.8.2.2 Trimming of position gain index.

"P" denotes the index for position gain. It controls stability and settling and should be
trimmed after the correct acceleration has been calculated and activated. "1" denotes very
slow and stable settling, "15" denotes rapid and unstable behaviour.
Position gain depends on the load's moment of inertia and structural flexibility.
When it is desired to alter the value, it should be trimmed as follows:
- Place the robot in a position corresponding to the greatest moment of inertia (in the
program that is to use the load) for the axis that is to be trimmed.

Note!

Write a program that only concerns the axis that is to be trimmed in a long
movement at maximum speed.

Alter the position gain index until a distinct performance without overshoot is achieved.

SOFT SERVO activated.

As the position gain affects controller stiffness, it should be trimmed before the softness
parameter is determined.

11.8.2.3 Preset values.

Index

Robot type
A4

A5

A6

P4

P5

P6

IRB 6000/2.4-100

10

10

11

10

11

12

IRB 6000/2.4-150

13

IRB 6000/2.8-100

10

10

11

10

11

12

IRB 6000/3.0-75

10

10

11

10

11

12

IRB 6000/S3.0-100

10

10

11

10

11

12

10

10

11

10

11

12

IRB 6000 .4-120

IRB 6000 .25 PE-75

The acceleration and position gain are set automatically to these predefined values when
the weight and offset are undefined (LOAD 1..19) even if they are altered for the
installation load (LOAD 0).

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11 Programming

11.8.2.4 Measures to deal with overshoots.

Wrist overshoot may occur during trimming work if the acceleration and/or the position
gain are too high.
Too high acceleration value: the motor torque reaches its maximum limit and overshoot
occurs because there is not sufficient torque to stop the movement.
Too high position gain: the controller becomes too quick for the load's inertia and structual
flexibility, therby leading to oscillations.

11.9

TRIM, PROGRAMMABLE
See section 5.21.

Programming

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Programming

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12 Arc welding

12

Arc welding
Section

Page

12.1 Introduction
12.2 System principles
12.3 Program structure
12.4 Description and programming of welding data
12.5 Description of robot instructions
12.5.1 Instructions for the welding process
12.5.2 Instructions for manipulator
12.6 Programming of robot instructions
12.6.1 Define a position with a PATH zone
12.6.2 Instructions for the weld process
12.6.3 Instructions for positioner movements
12.6.4 Common functions
12.6.5 EXTFRAME
12.6.5.1 Alignment of External axes
12.7 Program execution
12.7.1 Program test
12.7.2 Override function
12.7.3 Supervision of welding process
12.7.4 Execution of welding instructions
12.8 Program example

12:3
12:3
12:12
12:15
12:61

Programming

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12 Arc welding

Programming

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12 Arc welding

12
Arc welding
12.1 Introduction
The contents in this chapter are only valid for arc welding robots.
This chapter describes operation of the robot for arc welding and the special function
developed for this application.
The design of a robot welding station is described first and then how the robot interacts
with the welding equipment and other peripheral equipment. The general principles and
methods of preparing a program for robotized arc welding are discussed.
After this broad description of the arc welding system and program structure, detailed
instructions for how the welding data (parameter values for the welding process) is
programmed and used and how the robot instructions specific to arc welding applications
are given.
A special section contains a description of program execution, how a program is tested and
optimized, how the override function is used and how the welding process is monitored. In
conclusion, an example of a robot program for welding of a simple workpiece is given.

12.2
System principles
Example of station design
A robot station for arc welding can consist of the following main parts:
Robot
- manipulator
- control system
Welding equipment
- current source
- wire feed
- welding gun with hose package
- spatter cleaning equipment
Positioning equipment
- mechanical unit
- drive equipment
- fixtur
Sundries
- operators's panel
- adaption unit
- smoke extractor
- cooling unit
- safety equipment

Programming

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12 Arc welding
The requirement for exchange of signals between the robot and the other equipment
depends on the configuration concerned but the basic requirement is in accordance with the
following list:
Analog signals
- reference voltage for control of the current source
- reference voltage for control of the current wire feed unit
Digital output signals
- current source, on/off
- wire feed unit, on/off
- protective gas, on/off
- spatter cleaning, on/off
- contour following active (Applies only under certain conditions.)
- right edge of joint (Applies only under certain conditions.)
- left edge of joint (Applies only under certain conditions.)
Digital input signals
- current indication
- supervision gas/coolant
- ready signal (workpiece fixed)
- command, block welding process
- command, block weaving
- command, manual wire feed
The signal exchange with the positioning equipment can vary considerably depending on
the type of positioner (servo powered or indexing) and should be determined for each
individual case.
All programming and testing of robot programs is performed from the programming unit.
Normal production execution in the station is controlled from the station operator's panel
which should be easily accessible to the operator.
The stations operator's panel can normally contain controls for:
Program start
Ready signal (workpiece fixed)
Program stop
Blocking of welding process and weaving
Manual wire feed
Emergency stop

Programming

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12 Arc welding
HANDLING
UNIT
FIXTURE
PROGRAMMING
UNIT

OPERATING
UNIT

CONTROL
CABINET

RELAY
UNIT

NOZZLE
CLEANING

DIGITAL SIGNALS
POWER SUPPLY

Programming

ANALOG SIGNALS

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12 Arc welding
REGISTER (AW)
Means:
Control of program or peripheral equipment is performed on the basis of a value in a
number register.
Facts:
The system contains 120 numerical registers, number 0 -119, where one value at a time can
be stored. When a new value is stored, the previous value is written over. Permitted values
are from -32 768 to +23 767.
During program execution, a numerical value can:
Be stored directly.
Be accessed from a digital or an analog input.
Be sent to the peripheral equipment on digital or an analog output.
Be compared with another value in a jump instruction, see "Jump within the program".
Added or subtracted.
Be a:
- Program number at call of a program, see "Program change".
- Number in a position register when moving to a stored position, see "Position
register".
Specify which module in a pattern program is to be called, see "Program structure".
It is also possible to check manually and if necessary, to change the value in one register at
a time.
Used:
The register instruction itself is used for:
Reading the value into a number register directly or with the help of the contents in
other registers.
Accessing a value from a port.
Transmitting a value from a register to a port.
The manual function is used in checking and editing the program.
Executed:
The robot reacts immediately as soon as a manual or a programmed command, as described
above, is concluded.

Programming

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6

12 Arc welding
Interface to welding equipment
The robot is provided with an interface for communication with the welding equipment. A
survey of the signals concerned is given below. More detailed instructions with respect to
connection, function parameters, etc., are given in the Installation S3.
Analog outputs
The system is provided with two analog outputs for control of the power source (Port 21)
and the wire feed unit (Port 22). The parameter output to the source -voltage- is expressed
in volts. The parameter output to the wire feed unit is selected using a function parameter
(see Installation S3) and can be either current (expressed in amperes) or wire speed
(expressed in meter/minute or inch/minute). These outputs are normally dedicated to the
functions specified above (via the integrated welding process control) but they can also be
programmed freely (via I/O instructions).
The relation between the parameter value, programmed via the programming unit and the
reference voltage obtained from the analog outputs is determined by function parameters.
See also figure below.
Ref. voltage
from analog
output

Ref. max

10 V

Ref. min
2

Param. max

Param. min
I

50 A

100 A

200 A

300 A

400 A

500 A

Weld
current

Example of relation between programmed value (current in A) and reference

voltage from analog output.
Programming

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12 Arc welding

The function can be specified via function parameter definition of:

Min/max values for reference
Min/max values for parameter value
Note!

The functions described below are completely integrated in the robot system and no
programming of these is necessary.
Digital inputs
The robot is provided with five special digital inputs for the arc welding application.
Current indication
(INPUT 7)
The input is used for supervision of the ignition sequence and the continuous welding and
is connected to the current relay in the power source.
The signal is to be active for at least 50ms during the ignition procedure for the arc to be
considered to be struck. If the arc has not struck within the weld start max time specified
in the start data, an error indication is presented.
If during continuous welding the signal is absent for longer than 150 ms, the arc is
considered to have extinguished and an error is presented.
In the event of malfunction the execution of the program is halted and an error printout is
presented.
Gas/coolant
(INPUT 6)
The input is used for supervision of protective gas and/or liquid cooling and is connected to
the flow monitors in the welding equipment.
The input is monitored at weld-start and continously during the welding process.
If the signal is absent, execution of the program is halted and an error is presented.
Manual wire feed
(INPUT 8)
The input is used when the wire is fed forward manually, e.g. when a new wire is
introduced.
The following takes place when the input is set:
- Output 8 (wire feed unit on) is set
- 30 % of max reference voltage is issued to the wire feed unit
The command is only accepted when the program is not execution.
Blocking of welding process
(INPUT 9)
The input is used to block the welding process manually during, for example, testing of the
robot movements.
- If the input is set during program execution, any welding in progress will be halted
as from the next WELD instruction.
Blocking of weaving
(INPUT 10)
The input is used to block a superimposed weaving motion manually during, for example,
testing of the robot movements.

Programming

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12 Arc welding
Digital outputs
The robot is provided with three special digital outputs for the arc welding application.
Switch-on of power source
(OUTPUT 7)
The output is set when the gas pre-flow time has expired. The signal then remains active
during welding until the weld end procedure has started. During the conclusion procedure,
the output is reset during the cooling time and set again during the crater-fill time and the
burn-back time.
Switch-on, wire feed unit
(OUTPUT 8)
This output has the same function as "Switch-on, power source" except for during the burnback time when it is cleared.
Switch-on, protective gas
(OUTPUT 9)
The output is set approximately 250 ms before the robot is in position for weld-start. It
remains active until the gas post-flow time has expired.
Contour following active
(OUTPUT 19)
The output is set to logical "1" when the welding arc is energized. The output setting will
remain until just before the welding is interrupted. The output is valid when the WELDinstruction is executed with automatic contour following.
Right edge joint
(OUTPUT 17)
The output will be set to logical "1" to indicate the right limit of the weaving during contour
following.
Left edge joint (OUTPUT 18)
The output will be set to logical "1" to indicate the left limit of the weaving during contour
following.

Programming

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12 Arc welding
Arc welding-I/O is primarily used with ESAB welding equipment and positioner controlled
with external axes and common drive unit.
A description of the principles of three arc welding functions is given below:
Welding cycle during three instructions
Weld start

Weld end

Logical
output 9
Gas on
Logical
output 7
Voltage on
Logical
output 8
Wire feed on

Port 2
Welding
voltage

Port 22
Welding
current

Robot
movement

Programming

Inactive signal
or activity

Hot start

Cooling time

Gas pre-flow

Welding

Filling time

Ignition (incl.
possible strike)

Burn-back time

Gas post flow time

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10

12 Arc welding
Servo controlled positioner with common drive unit
The external axis can be distributed to different stations with the help of the function
STATION so that it becomes possible to activate these in suitable groups.
The stations can be activated/deactivated independently, except when axes share a common
drive unit. An input and an output are connected to each station to permit activation of the
station and to check the status of the station respectively.
Example:
STATION A
STATION B*
STATION C*

STATION D

OUTPUT 1
OUTPUT 2

INPUT 11
INPUT 12
INPUT 13
INPUT 14

and
and
and
and

OUTPUT 12
OUTPUT 13

AXES 7
AXES 8, 9
AXES 10,11
AXES 12

Axes 8 and 10 respectively 9 and 11 share two drive units, which means that the stations B
and C cannot be active simultaneously. This is marked with a "*".
In this case the synchronization order would be the following:
1. C +robot
2. B + A + D +robot
3. B + D is being deactivated so that only A is activated after the synchronization.
A switchover from station B to station C is illustrated by the following time diagram:
Output
Input
Servo

11

Output
Input

0
1
0
- 1
active
0

1
12

Servo

- o1

deactivated
Output
Input

13

0
1

Servo

Programming

12

0
1

activated

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12 Arc welding
Signals, servo controlled positioner with common drive unit
Logical
input/output

Function

Outputs 1-128 An output used to activate/deactivate the drive unit of a

station. The servo-control is disconnected before the output
is reset to zero to deactivate the drive unit.
Inputs 11-16

The acknowledgement that a station is activated. The servo

control is connected when the signal has been received.

Only one input and one output is used in each station in accordance with the function
parameter STATION.
Non-servo-controlled positioner
A non-servo-controlled positioner can be run with the help of ports 70 and 80. A description
is given in section 12.5.2.

12.3
Program structure
Robot program construction
A robot program for a robot welding station has in principle, the following construction
elements
Welding data, special data fields containing parameter values for control of the
welding procedure. Welding data is programmed under the control button MANUAL, for
preference, separately from the programming instructions themselves.
Main program, includes basic data such as basic speed, TCP and coordinate type,
welding and positioning instructions and other instructions of a general nature as
required. The system welding instructions are of a combination type, i.e. they command
positioning of the welding gun and call of the appropriaten welding data selected. The
welding instructions are programmed under the control button PROCESS (P) and may
be conveniently entered into a subprogram, a welding program.
A series of subprograms, as required, for control of spatter cleaning equipment,
positions, weaving, etc. The system has special instructions for checking and control of
external equipment and spatter cleaning. These instructions are programmed under the
control button PROCESS (P).
A good structure is of great importance in a robot program. It permits easier tracing of
faults, amendments and additions.

Programming

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12

12 Arc welding
Even if subprograms may be numbered optionally (except interrupt programs) it is
recommended that subprogram groups be organized so that a certain type is always within
the same number series as shown in the following table.
Program number

Program type

Main program
Interrupt programs
5
100
Welding programs
199
200
External check program
299
300

Spatter cleaning program

<
399
400

Weaving program

t
t
C

499
Other subprograms
500

Building the robot program of these elements

WELDING DATA
MAIN PROGRAM
SUBPROGRAMS
provides a good structure, and changes and additions are easily performed.
WELDING DATA is further divided into five different groups to further simplify
programming and to increase the possibilities of flexible program construction.

S3

PragraTn-miTig

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12 Arc welding

40

START DATA which contains parameter values for the weld start procedure.
MAIN DATA which contains parameter values for the welding operation itself.
END DATA which contains parameter values for the conclusion of the welding.
WEAVE DATA, containg parameter values for automatic weaving.
SENSOR DATA, containing parameter values for contour following.
The different types of DATA are called by the weaving instructions when executing the
program.
The instruction AWELD calls START DATA, MAIN DATA, WEAVE DATA and
SENSOR DATA
The instruction WEND calls END DATA.
Main principles for programming
Preparation of a robot program for arc welding should follow a predetermined plan, for
example, as follows:
Examine the workpiece concerned and determine the order in which the different welds
are to be run. Determine also in which positions of the positioner the different joints are
to be welded.
Make an estimate of the parameter values for the different welding runs and program
the necessary welding data.
Program the necessary basic data in the main program.
Program suitable sub-programs for, for example, spatter cleaning and control of the
positioner.
Program the robot motion with POS / AWELD / WEND instructions. The principle on
whicharc welding programming is based is:
- Position the robot to the start or end point required.
- Press the P-button.
- Select the function required (AWELD or WEND)
At suitable places, CLEAN and EXTERNAL CONTROL (EXTC) instructions are
programmed in accordance with the same principle .
When the first version of the program is complete, a test run can be executed to permit
correction of any errors. Test the robot motion first with the welding and any weaving
function blocked.Trimming to obtain optimum welding data is performed with the help
of the override function available by means of the programming unit joystick. (See
further section 12.7.2)

Programming

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12 Arc welding

12.4
Description and programming of welding data
Welding data; description
WELD DATA consists of special collections of data in which all parameter values necessary
to control the welding process are assembled.
WELD DATA is of five different types:

START DATA
MAIN DATA
END DATA
WEAVE DATA
SENSOR DATA
WELD DATA is programmed under the control button MANUAL by means of a dialogue
procedure in a manner similar to that used for other programming. Parameter values are
expressed in technical terms (V, A, mm/s, etc.) and it is easy to check and amend values
programmed.
Restrike is defined under START DATA. It removes coating from the point of the weld
wire by performing a zig-zag weaving at one point. The weaving movement is perpendicular
to the welding direction in all cases except when the following point is a circle point. The
weaving movement will then be perpendiculer to the vector from the start point to the
circle point. The weaving motion will continue until the arc is lit, then the movement will
terminate and return to the middle line.
Restrike is defined by defining the amplitude and weaving time. If these are not given, the
weld start will be performed without restrike.
WEAVE DATA is a data group which contains all data necessary for the weaving
movement of the welding gun. They are:
Weave-type:

Amplitude:

Total

width

Zigzag
Triangular
V-shape
Wristweave

of weaving movement. The weaving amplitude

for the original zig-zag pattern is, as before, the peak to
peak amplitude. With triangular and V-shaped weaving, the
weaving amplitude is defined as the base of the isosceles
triangle formed by the lines joining the weaving points, i.e.
the distance between points 2 and 3 and between points 2
and 5 with triangular and V-shaped weaving respectively.

Cross time:

The cross time is the time required for the movement, by the
shortest path in the weaving pattern, between the points
which limit the weaving. A specified cross time gives
different weaving frequencies determined by the weaving
pattern.

Dwell time Left:

During the dwell time, the TCP is moved parallel with the
direction vector from point 1 to point 2 with triangular and
V-shaped weaving in accordance with the description below.

Programming

S3
15

Dwell time Right:

12 Arc welding
During the dwell time, the TCP is moved parallel to the
direction vector from point 3 to point 4 with triangular
weaving and from point 5 to point 6 with V-shaped weaving
in accordance with the description below.

Dwell time Middle:

During the dwell time, the TCP is moved parallel with the
direction vector from point 5 to point 6 with triangular
weaving. With V-shaped weaving, there is corresponding
movement with both passages of the mean point, i.e. from
point 3 to point 4 and from point 7 to point 8 in accordance
with the description below.

Seam angle:

The seam angle is the opening angle of the triangular and Vshaped weaving. When the forward bias is not zero, the
seam angle is defined as the opening angle of the weaving
triangle projected on a plane at right angles to the direction
vector.

Forward bias:

Forward bias is the component of the movement, parallel

with the direction vector, which is subtracted from pos 1,2,3
and 4 with triangular weaving, and pos 1,2, 5 and 6 with Vshaped weaving in accordance with the description below.

Weaving angle:

The weaving angle is the angle between the TCP vector in

the tool plane and the weaving vector, according to the
weaving-coordinate system below.

Perpendicular weaving:

Determines whether the weaving direction is to be

calculated at every step order (every 48:th milliseconds) or
only for each AWELD instruction.

Note!
Dwell time left and right (and middle at V-shaped and triangular weaving) should not be
chosen less than 0.05 s, besides when weaving with maximum weaving frequency. This
dwell time is needed to obtain full amplitude at weaving.
Zig-zag, triangular and V-shaped weaving
The weaving points which are superimposed on the process movement are described below
in a coordinate system which is given by the direction vector, the weaving vector and the
TCP vector.

Programming

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12 Arc welding
The weave-coordinate system will adapt to the path so that the weaving will be carried out
perpendicular to the path for velocities down to 2,7 mm/s. Below this velocity, the operator
must himself check that the weaving is oriented correctly in relation to the path of the
ordinary movement.

Weaving vector

Direction vector

TCP

\
\
x

Base point

TCP vector

Programming

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12 Arc welding
WEAVE PATTERN

Zig-zag

V-shape

Triangular

Programming

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18

12 Arc welding
The tool direction defined by the TCP and base point, is always in the plane formed by the
TCP vector and the direction vector in the weaving-coordinate system. The weaving vector
is normally orientated perpendicular (90) to this plane, which we call the tool-plane.
The direction of the weaving vector to the tool plane can be varied by help of the weaving
angle parameter according to the following figures.
Zig-zag weaving, seen from the front.

w
Weaving vector

Weaving angle 90

TCP vector
Zig-zag weaving, seen from the front.

w
Weaving vector

Weaving angle
- 100 Weaving

TCP vector

S3

Programming
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12 Arc welding
The three dimensional patterns, V-shaped and triangular weaving, are always performed
symmetric to the normal of the weaving vector, as shown below.
V-shaped weaving, seen from the front.

Weaving Vector

Weaving angle

TCP vector
Triangular weaving, seen from the front.
Weaving Vector

Weaving angle

TCP vector

S3

Programming
20

12 Arc welding
Weaving points
Definitions:
V :
Vv :
Vh :
Am:
L :
H :
F :
Pn (m):

Dwell time Left

Dwell time Right
Dwell time Middle
Amplitude
Forward bias
Process velocity
Seam angle
Weaving point number n component m
m=l: direction vector
m=2: weaving vector
m=3: TCP vector

Triangular weaving

POO) = o

Pl(l) = -L
Pl(2) = A/2
Pl(3) = A/ (2*tan(F/2))

P2(l) = Pl(l) + W * H
P2(2) = Pl(2)
P2(3) = Pl(3)

P3(l)= P2(l)
P3(2) = -A/2
P3(3)= P2(3)

P4(l)= P3(l) + Vh*H

P4(2)= P3(2)
P4(3)= P3(3)

P5(l) = P4(l) + L
P5(2) = 0
P5(3)= 0

P(X1) = 0
P(K2) = 0

P6(l)= P5(l) + Vm*H

P6(2)= P5(2)
P6(3)= P5(3)
Output signals:
Weaving points

PO

PI

P2

P3 P4 P5 P6

Output signals
Left
Output signals
Right
The output signals are valid at least 15 ms.

Programming

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12 Arc welding
V-shaped weaving (also Zig-zag weaving, but then with a seam angle of 180)
P0(l) = 0
P0(2) = 0
POO) = 0

Pl(l) = -L
Pl(2) = A/2
Pl(3) = A/ (2*tan(F/2))

P2(1) = P1(1) + W * H
P2(2) = Pl(2)
P2(3) = Pl(3)

P3(l) = P2(l) + L
P3(2)= 0
P3(3)= 0

P4(l)= P3(l) + Vm*H

P4(2)= P3(2)
P4(3) = P3(3)

P5U) = P4(l) - L
P5(2) = -A/2
P5(3) = A/(2*tan(F/2))

P6(l) = P5(l) + Vh* H

P6(2)= P5(2)
P6(3)= P5(3)

P7(l) = P6(l) + L
P7(2)= 0
P7(3)= 0

P8(l) = P7(l) + Vm*H

P8(2)= P7(2)
P8(3)= P7(3)
Output signals:
Weaving points

P0

PI

P2

P3

P4

P5

P6

P7

P8

Output signals
Left
Output signals
Right
The output signals are valid at least 15 ms.

Programming

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12 Arc welding
Wrist weaving
Wrist weaving is a special type of weaving for axis 6. It enables weaving in confined spaces
where weaving with axes 1-3 is impossible. Wrist weaving can also be used when a higher
weaving frequency is required as the dynamic mass is smaller.
Designations
Weaving arm is an arm which extends from the TCP to the weaving axis. The arm is
perpendicular to the weaving axis.
Weaving plane
Weaving plane is the plane in which the weaving arm moves.
The wrist weaving is superimposed on the ordinary movement, but there is no vertical
error compensation. See the figure below. To reduce the vertical error, the weaving arm
should be relatively large and the amplitude small.
The robot operator must check that the weaving plane is oriented correctly in relation to
the ordinary movement. The rules which apply otherwise to the other types of weaving
apply also to the wrist weaving.
weaving arm

vertical error

A corner path (parabolic path) is generated at a corner for normal movements, but not for
WEAVE data movement. Weaving starts when entering the zone of the start position and
ends when entering the zone of the finish position.
If the weld data is changed at an intermediate position a fine point is automatically
defined. To avoid a temporary halt in robot movement at the fine point the programmer
should change the position definition to a PATH or CORNER1.
Weaving at maximum weaving frequency
The parameters shold be chosen as below when weaving at maximum weaving frequency is
used.
Zig-zag, V-shaped and triangular weaving (maximum weaving frequency 5 Hz)
Cross time = 0.1 s
Dwell time right = 0 s
Dwell time left = 0 s
Dwell time middle = 0 s
Programming

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12 Arc welding
Wrist weaving (maximum weaving frequency 10 Hz)
Cross time = 0.05 s
Dwell time right = 0 s
Dwell time left = 0 s
Note! Dwell time left and right (and middle at V-shaped and triangular weaving) should
not be chosen less than 0.05 s, besides when weaving with maximum weaving frequency.
This dwell time is needed to obtain full amplitude at weaving.
The handling of weaving outputs for contour following (output 17 and 18) are also affected
when the dwell times are set to 0 s for weaving with maximum weaving frequency. These
outputs are therefor set 0.05 s earlier than normal to be able to be set and cleared in pace
with the maximum weaving frequency (see figures below).
AMPLITUDE

OUTPUT LEFT SEX =1

1

_
i

5
\a20f
1i*.

0.05
.05 0.10 0.15 ^ V

OUTPUT RIGHT CLEARED = 0

OUTPUT RIGHT SEX = 1
0.05 s

Weaving at 5 Hz (zig-zag, V-shaped and triangular weaving)

AMPLITUDE

OUTPUT LEFT SEE = 1

//\0.10
0.05

O.j

\0.

t[s]
\

OUTPUT RIGHT CLEARED = 0

OUTPUT RIGHT SET = 1

Weaving at 10 Hz (wrist weaving)

AMPLITUDE

OUTPUT LEFT SET = 1

OUTPUT RIGHT CLEARED = 0

L05W 0 . 1 5 W 0 J 5 W
0.05

A/. .
W

t[s]

OUTPUT RIGHT SEX = 1

Programming

24

S3

12 Arc welding
Sensor data
Sensor data is a collection of data containing necessary data for definition of contour
following during AWELD. They are:
Side corr. sensor no.:

The number of the sensor used for side correction.

Side corr. sensor bias:

BIAS in percent of the sensor's total working range. 50 %

indicates sensor in the centre of its working range.

Heightcorr. sensor no.:

The number of the sensor used for height correction.

Heightcorr. sensor bias:

BIAS in percent of the sensor's total working range. 50%

indicates sensor in the centre of its working range.

Side corr. angle:

The angle between the weaving vector and the side

correction vector at simultaneous contour following and
weaving.

Normally the weaving vector corresponds to the side correction vector, which means that
the side correction angle normally is 0. The direction can however be adjusted according to
the figures below.
The height correction vector corresponds to the TCP vector in both figures.
Zig-zag weaving, seen from the front

\J
Side correction vector
Side correction
angle - +10

_^ Weaving vector
Weaving angle
-100
TCP vector

Zig-zag weaving, seen from the front correction angle normally is 0. The
direction can however be adjusted according to the figures below.

Side correction
angle - -30

, Weaving vector

Side correction vector

Weaving angle
-100
TCP vector

Programming

25

S3

12 Arc welding
Fifty different collections of each MAIN DATA type can be defined.
Twenty different collections of each WEAVE DATA type can be defined.
Ten different data collections of each of the other WELD DATA types can be defined.
The table below shows the parameter values which can be programmed.
Current is replaced by wire speed if wire speed is selected in the system parameters, (see
Installation S3).
Type Parameter
Ignition voltage
Ignition current
Ign. wire speed
Gas pre-flow
Start Hot start voltage
data Hot start current
Hot st. wire speed
Hot start time
Restrike amplitude
Restrike weave time
Weld st. max time
Weld voltage
Main Weld current
data Weld wire speed
Weld speed

End

End voltage
End current
End wire speed

Given in
Volt
Ampere
m/min
inch/min
seconds
Volt
Ampere
m/min
inch/min
seconds
millimeter
seconds
seconds
Volt
Ampere
m/min
inch/min
mm/s
inch/min
Volt
Ampere
m/min
inch/min
seconds
seconds
seconds
seconds

Basic
value
0.0
0.0
0.0
0
0.00
0.0
0.0
0.0
0
0.00
0.0
0.00
2.00
0.0
0.0
0.0
0
0.0
0
0
0
0
0
1
0.05
0
0
zig-zag
1.0
1.00

Min.
Max.
value value
-40.0
40.0
-400.0 400.0
-20.0
20.0
-787
787
0.00
99.99
-40.0
40.0
-400.0 400.0
-20.0
20.0
-787
787
0.00
99.99
0.0
99.99
0.00
99.9
0.50
99.99
-30.0
0
0.0
0
0
0
-40.0
-400.0
-20.0
-787
0
0
0
0

100.0
1000.C
50.0
1968
200.0
476
40.0
400.0
20.0
787
99.99
99.99
99.99
99.99

Resolution
0.1
0.1
0.1
1
0.01
0.1
0.1
0.1
1
0.01
0.1
0.01
0.01
0.1
0.1
0.1
1
0.1
1
0.1
0.1
0.1
1
0.01
0.01
0.01
0.01

Gas post-flow time

Burn back time
Cooling time
Fill time
Type
Amplitude
mm
0.0 *) 99.99 0.01
Wea- Cross time
99.99 0.01
seconds
0.00
ving Dwell times:
Hgfq
0.05
left, right, center
0
seconds
99.99
90
Seam angle
10
1
degrees
170
0.0
Forward bias
0.0
mm
99.9
0.1
90
Weave angle
0
degrees
180
1
Yes
Perpendicular
Yes/No
1
0
16
Side, corr. sensor no.
0
Sen- Height, corr. sensor no.
0
16
1
0
sor
0
100
50
1
Side, corr. sensor bias
%
data Height, corr. sensor bias %
0
100
50
1
-90
90
0
1
Side corr. angle
degrees
Note! Ignition, hot start and end values for voltage and current/wire speed are given as
differences relative to corresponding Main data.
*) IRB 1500: ZIG-ZAG, Triangular, V-shape maximum 16 mm, Wrist maximum 7 mm.

Programming

S3
26

12 Arc welding
The following diagram shows the relation between different signals, times, etc.
START
DATA

END
DATA

MAIN
DATA

Y/////////A
Y///Y//Y//////Ayyyyyyyyyyyyyy Gas

vyyyyyyy/.

YA

-Weld voltage on

yyyyyyyyy,yyyyyyyyyyyyyyy

"Weld current on
Contour
follower on

i/////////.
V/////////////A

_Ref. voltage
current source

Y///////////////A

Ref. voltage
wire feed unit

xzz&yy,Y/////////////A

-Robot movement
Weaving
-movement
Restrike

Y7L
TO

Tl
T2

T3

T4

I _. l _. I I
T5

T6

T4 T7

TO = Gas pre-flow time

Tl = Ignition time (< 50 ms)
T2 = Maximum restrike time
T3 = Hot start time
T4 = Burn-back time
T5 = Cool time
T6 = Filling time
T7 = Gas post-flow time

Programming

S3
27

12 Arc welding
Programming of weld data
Welding data is programmed under the control button MANUAL. Begins with:
1.
2.
3.
4.

Press SCAN.
Press SCAN.
Press SCAN.
Press WDATA
10 POS V = 60% PATH
CLEAR

DISK

WINCH IN/OUT

SCAN

10 POS V = 60% PATH

10 POS V = 60% PATH

*LANG ERRORS TEACH WDATA

SCAN

10 POS V = 60% PATH

110 POS V = 60% PATH

i WEAVE
*

SENSOR

SCAN I

f :
<

Si

Programming

S3
28

12 Arc welding
After the above sequence, START DATA, MAIN DATA, END DATA, WEAVE DATA or
SENSOR DATA can be programmed.

Programming START DATA

1. Press function button START.
2. Select the required START DATA number (1-10) with the numerical button set. Data
numbers not used are marked on the display with -.
3. Press ENTER.
4. Write the ignition voltage difference value with the numerical button
5. Press ENTER. (* The value programmed is now shown on the upper line of the
display. New values can be programmed directly if required.)
6. Press ENTER.
7. Write the ignition current/wire speed difference value required with the numerical
button set.
8. Press ENTER. (* See point 5 above)
9. Press ENTER.
10. Write the gas pre-flow time value required with the numerical button set.
11. Press ENTER. (* See point 5)
12. Press ENTER.
13. Write the hot start voltage difference value required with the numerical button set.
14. Press ENTER. (* See point 5)
15. Press ENTER.
16. Write the hot start current/wire speed difference value required with the numerical
button set.
17. Press ENTER. (* See point 5)
18. Press ENTER.
19. Write the hot start time required with the numerical button set.
20. Press ENTER. (* See point 5)
21. Press ENTER.
22. Write the restrike weaving amplitude required with the numerical button set.
23. Press ENTER. (* See point 5)
24. Press ENTER
Programming

S3
29

12 Arc welding
25. Write the restrike weaving cross time required with the numerical button set.
26. Press ENTER. (* See point 5)
27. Press ENTER.
28. Write the weld start max time required with the numerical button set.
29. Press ENTER. (* See point 5)
30. Press ENTER.
N3!
If it is decided to retain the basic value for a parameter, the sequence can be
continued by pressing ENTER directly, instead of writing another numerical
value.

Programming

S3
30

12 Arc welding
1.

1
1 START

MAIN

END

SCAN

...

*$

< j

* i
y ;

3.

4.

START DATA 1 IGNI VOLT DIFF (V) = 0.0

CE

VOLTAGE (V) =

4|| 5|| 61

ENTER

15

QUO

ran
5.

| START DATA 1 IGNI VOLT DIFF (V) = 0.0

CE

1 VOLTAGE(V) = 15

Programming

mI

ENTER!

S3
31

12 Arc welding
6.

START DATA 1 IGNI VOLT DIFF (V) = 15

VOLTAGE (V) =

7.

CE

ENTER

START DATA 1 IGNI CURR DIFF (A) = 0.0

CURRENT (A) =

*) If wire speed was

selected, the text
replaces
"CURR DIFF 1

START DATA 1 IGNI CURR DIFF (A) = 0.0

ENTER

CURRENT (A) = -200

9.

START DATA 1 IGNI CURR DIFF (A) = 0.0

CURRENT (A) =

CE

ENTER

I
START DATA 1 GAS PREFLOW TIME (S) = 0.0

Programming

S3
32

12 Arc welding
10.

11.

START DATA 1 GAS PREFLOW TIME (S) = 0.00

TIME (S) = 1.5

12.

CE

ENTER

I
START DATA 1 GAS PREFLOW TIME (S) = 1.5 0

START DATA 1 HOT VOLT DIFF (V) = 0.0

VOLTAGE (V) =

CE

13.
-10

14.

START DATA 1 HOT VOLT DIFF (V) = 0.0

CE

VOLTAGE (V) = -10

15.

ENTER

START DATA 1 HOT VOLT DIFF (V)=-10.0

CE

VOLTAGE (V) =

Programming
33

ENTER

S3

12 Arc welding
1 STARTDATA 1 HOT CURR DIFF (A) = 0.0

CE

, CURRENT (A) =
>> --

f.-ii '

- -'- '

ENTERI

" ?

ri
16.

17.

*)If wire speed was

selected the text
"WIRE DIFF'
replaces
"CURR DIFF"

START DATA 1 HOT CURR DIFF (A) = 0.0

CURRENT (A) = -150

18.

START DATA 1 HOT CURR DIFF (A) = -150.0

CURRENT (A) =

START DATA 1 HOTSTART TIME (S) = 0.00

CE

TTME(S) =

ENTER

19.

20.

START DATA 1 HOTSTART TIME (S) = 0.0 0

TIME(S) = 3

Programming

S3
34

21.

12 Arc welding

START DATA 1 HOTSTART TIME (S) = 3.00

TIME (S) =

CE

ENTER

ODO
START DATA 1 RESTREKE AMPL (MM) = 0.0
AMPLITUDE (MM) =

CE

-T J L-r
22.

23.

START DATA 1 RESTRKE AMPL (MM) = 0.0

AMPLITUDE (MM) = 50

CE

ENTER

, > > S v ** vw v

24.

START DATA 1 RESTRKE AMPL (MM) = 50.0

AMPLITUDE (MM) =
5""'1

"i-- ^

"""^yr-

START DATA 1 RESTR. CROSSTIME (S) = 0.00

CE

ENTER

25.

26.

START DATA 1 RESTR. CROSS TIME (S) = 0.00

CE

TIME(S)=10

ENTER

S3

Programming
35

12 Arc welding
27.

START DATA 1 RESTR. CROSSTIME (S) = 10.00

CE

ENTER

START DATA 1 AW START MAX. TIME = 2.00

28.

29.

START DATA AW START MAX. TIME = 2.00

TIME (S) = 1.5

30.

CE

ENTER

I
START DATA AW START MAX. TIME = 1.50
CE

TIME(S)=

ENTER

S3

Programming
36

12 Arc welding
Programming MAIN DATA
1. Press function button MAIN.
2. Select the MAIN DATA number required (1-50) with the numerical button set. Data
numbers not used are indicated on the display with -.
3. Press ENTER.
4. Write the weld voltage value required with the numerical button set.
5. Press ENTER (* The value programmed is now shown on the display. New values can
be programmed directly if so required.)
6. Press ENTER.
7. Write the weld current/wire speed value required with the numerical button set.
8. Press ENTER. (* See point 5)
9. Press ENTER.
10. Write the weld speed required with the numerical button set.
11. Press ENTER. (* See point 5)
12. Press ENTER.
NJ3!
If it is decided to retain the basic value for a parameter, it is possible to proceed
with the sequence by pressing ENTER directly instead of writing another
numerical value.

Programming

S3
37

12 Arc welding
1.

use the SHIFT

button for further
data fields.
2.

3.
MAIN DATA NO =
* *s

4.

CE
*

ENTER

"iJ

| MAIN DATA 1 VOLTAGE (V) = 0.0

CE
>

] VOLTAGE(V) =

ENTER^
s

_s

AS!

27

5.

MAIN DATA 1 VOLTAGE (V) = 0.0

CE

VOLTAGE(V) = 27

Programming

ENTER

S3
38

12 Arc welding
6.

MAIN DATA 1 VOLTAGE (V) = 27.0

MAIN DATA 1 CURRENT (A) = 0.0

CURRENT (A) =

*) If wire speed was

selected the text
"WIRE SPEED"
replaces
"CURRENT-

7.

MAIN DATA 1 CURRENT (A) = 0.0

CURRENT(A)=

9.

150

CE

ENTER

MAIN DATA 1 CURRENT (A) = 150.0

CE

CURRENT (A) =

ENTER

MAIN DATA 1 WELD VELOCITY (MM/S) = 0.0

Programming

S3
39

12 Arc welding
10.

11.

MAIN DATA 1 WELD VELOCITY (MM/S) = 0.0

VELOCITY (MM/S)= 10

12.

MAIN DATA 1 WELD VELOCITY (MM/S) =10.0

VELOCITY (MM/S) =

Programming

CE

ENTER

S3
40

12 Arc welding
Programming END DATA
1. Press the function button END.
2. Select the END DATA number required (1-10) with the numerical button set. Data
numbers not used are indicated on the display with -.
3. Press ENTER.
4. Write the end voltage difference value required with the numerical button set.
5. Press ENTER. (* The value programmed is now shown on the display. A new value can,
if required, be programmed directly.)
6. Press ENTER.
7. Write the end current/wire speed difference value required with the numerical button
set.
8. Press ENTER (* See point 5)
9. Press ENTER.
10. Write the gas post-flow time required with the numerical button set.
11. Press ENTER. (* See point 5)
12. Press ENTER.
13. Write the burn-back time required with the numerical button set.
14. Press ENTER (* See point 5)
15. Press ENTER
16. Write the cooling time required with the numerical button set.
17. Press ENTER (* See point 5)
18. Press ENTER
19. Write the fill time with the numerical button set.
20. Press ENTER (* See point 5)
21. Press ENTER
NJB!. If it is decided to retain the basic value of a parameter, the sequence can be
continued by pressing ENTER directly instead of entering another numerical
value.

Programming

S3
41

12 Arc welding
1.

1
i

1
START

MAIN

END

|
?

'

ENDDATANO =

CE

ENTER

CE

ENTER

***.!

2.

3.
END DATA NO =

END DATA 1 END VOLTAGE DIFF (V) = 0.0 |

txfflmmm&

ENTER8

CE

VOLTAGE (V) =

hi

-15

5.

END DATA 1 END VOLTAGE DIFF (V) = 0.0

CE

VOLTAGE (V) = -15

i

;-'-f

ENTER::

'

T
Programming

S3
42

12 Arc welding
6.

END DATA 1 END VOLTAGE DIFF

VOLTAGE(V) =

END DATA 1 END CURRENT DIFF (V) = 0.0

CURRENT (A) =

CE

ENTER

;--s"g>

3|

7.

-180

*) If wire speed was

selected the text
"WIRE DIFF"
replaces

"CURRENT DIFF1
END DATA 1 END CURRENT DIFF (A) = 0.0
ENTER

9.

END DATA 1 END CURRENT DIFF (A) = -180.0

CURRENT (A) =

ENTER

CE

OrO

'?:

END DATA 1 GASPOSTFLOW TIME (S) = 1.00

TIME(S) =
f r.>y/'S v. * , '

Programming

CE
. .

: V s

/ w~

ENTER
* r'-A 5 S S B ^ . . . <

S3
43

12 Arc welding
10.

11.
END DATA 1 GASPOSTFLOWTIME (S) = 1.00
TIME (S) = 1.5

CE

ENTER

12.
END DATA 1 GAS POSTFLOW TIME (S) = 1.50
CE

ENTER

j END DATA 1 BURN BACK TIME (S) = 0.05

s

ENTEES

CE

TTME(S) =

':

13.

14.

15.

END DATA 1 BURN BACK TIME (S) = 0.05

END DATA 1 BURN BACK TIME (S) = 0.20

CE

TIME(S) =

VI H IProgramming

ENTER

S3
44

12 Arc w e l d i n g

END DATA 1 COOL TIME (S) = 0.00

16.

17.

j END DATA 1 COOL TIME (S) = 0.00

CE

jTIME(S) = 2.0
*

'

*%

s!

18.

*
1

ENTER 1

43883888$$$

1i

.*

END DATA 1 COOL TIME (S) = 2.00

ENTER

TTMEG3) =

1
| END DATA 1 FILL TIME (S) == 0.00

CE

| TEME(S) =
' s *. r. "" *

' :;

ENTER
If

'>

$v

19.
2.0

20.

END DATA 1 FILL TIME (S) = 0.00

TIME (S) = 0.2

Programming

S3
45

12 Arc welding
21.

i
1 END DATA 1 FILL TIME (S) = 2.00
TIME(S) =

CE

START
*

18888

-ils

i
MAIN

ENTER!

END

?S4-

S3

Programming
46

12 Arc welding
Programming WEAVE DATA
The different parameters are described in Chapter 12.4.
1.

Press the function button WEAVE.

2.

Select required WEAVE DATA number (1-20) with the numerical button set. Not used
data numbers are marked with " -" on the display.

3.

Press ENTER

4.

Choose some weaving pattern (ZIG-ZAG, TRIANGLE or V-SHAPED) or wrist weaving

(WRIST) and then press ENTER

5.

Specify required amplitude (mm) with the numerical button set.

6.

Press ENTER (Now the programmed value is displayed. A new value can be entered if
required).

7.

Press ENTER

8.

Specify required cross time (s) with the numerical button set.

9.

Press ENTER (see point 6).

10. Press ENTER.

11. Specify required dwell time, Left (s), with the numerical button set.
12. Press ENTER (see point 6).
13. Press ENTER
14. Specify required dwell time, Right (s), with the numerical button set.
15. Press ENTER (see point 6).
16. Press ENTER
17. If wrist weaving is chosen, jump to point 31. Otherwise specify required dwell
time, Middle (s), with the numerical button set.
18. Press ENTER (see point 6).
19. Press ENTER
20. If zig-zag weaving is chosen, jump to point 23. Otherwise specify required seam angle
(deg) with the numerical button set.
21. Press ENTER (see point 6).
22. Press ENTER.
23. Specify required forward bias (mm) with the numerical button set.
24. Press ENTER (see point 6).
Programming

S3
47

12 Arc welding
25. Press ENTER.
26. Specify required weave angle (deg) with the numerical button set.
27. Press ENTER (see point 6).
28. Press ENTER.
29. State whether the weaving motion always is to be perpedicular to the programmed
robot path or not (YES/NO).
30

Press ENTER

31. Specify if reset is required. Then the starting menu will return.
10 POS V = 60% PATH

1.

WEAVE SENSOR

SCAN

$r

2.

3.
WEAVE DATA NO = 1

Programming

S3
48

12 Arc welding
WEAVE DATA 1 TYPE ZIG-ZAG
ZIG-ZAG TRIANGLE V-SHAPE

WRIST

ENTER

WRIST

ENTER

WEAVE DATA 1 TYPE WRIST

ZIG-ZAG TRIANGLE V-SHAPE
.... *.\

.*v . .*..;

"

...>.'.-.:....^..r
' > '

WEAVE DATA 1 AMPLITUDE (MM) = 1.0

QL1Q "
QLllH

Programming

S3
49

12 Arc welding
WEAVE DATA 1 AMPUTUDECMM) = 1.0

WEAVE DATA 1 AMPLITUDE (MM) = 5.5

AMPLITUDE =

CE

ENTER

WEAVE DATA 1 CROSS TIME (S )= 1.00

CROSS TIME

CE
-i>-;-#<,

ENTER

-?';-,yj

JJL3L3J

8.

ran
WEAVE DATA 1 CROSS TIME (S) = 1.00

9.

i CROSS TIME = 5.5

CE

ENTER
~ - ' s' r \
4

WEAVE DATA 1 CROSS TIME (S) = 5.5

10.

S3

Programming
50

12 Arc welding
WEAVE DATA 1 DWELL TIME L( S) = 0.05

11.

I WEAVE DATA 1 ]DWELL TIMI: L ( S ) =-- 0.05

12.

| DWELLTIMEL = 0.55

il

ENTER \

CE
wsssenssM

WEAVE DATA 1 DWELL TIME L( S) = 0.55

13.

1
| WEAVE DATA 1 DWELL TIME R (S) = 0.05
| DWELLTIMER =

CE

ENTER

|
i!

53 & $ $ $ & * '

P
0.01

14.

WEAVE DATA lDWELL TIME R (S) = 0.05

15.

Programming

I DWELL TIME R=0.01

S3
51

12 Arc welding
WEAVE DATA 1 DWELL TIME R( S) = 0.01

16.

DWELL TIME R=

CE

ENTER

WEAVE DATA 1 DWELL TIME M (S )= 0.05

DWELL TIME M =

11

CE

ENTER

M
ill 2|| 31

0<01

QQIQ

17.

1 WEAVE DATA 1 DWELL TIME M( S) = 0.05

18.

1 DWELLTIMEL =

CE

1
ill

19.

sr

IF WRIST
WEAVING,
PAGE 54

ENTER 1

v !

5''

WEAVE DATA 1 DWELL TIME R( S) = 0.05

DWELL TIME M =

WEAVE DATA 1 SEAM ANGLE (DEG) = 90

IF ZIG-ZAG
WEAVING,
PAGE 53

SEAM ANGLE =

20.

S3

Programming
52

12 Arc welding

WEAVE DATA 1 SEAM ANGEL (DEG) = 90

21.

SEAMANGEL=80

IF ZIG ZAG
WEAVING
WEAVE DATA 1 SEAM ANGLE (DEG) = 80
SEAM ANGEL =

22.

WEAVE DATA 1 FORWARD BIAS (MM) = 0.0

FORWARD BIAS

IF WRIST
WEAVING

23.

WEAVE DATA 1 FORWARD BIAS (MM) = 0.0

FORWARD BIAS = 1

24.

WEAVE DATA 1 FORWARD BIAS (MM) = 1.0

25.

FORWARD BIAS =

(Continue next page)

Programming

S3
53

12 Arc welding

WEAVE DATA 1 WEAVE ANGEL (DEG) = 90

WEAVE ANGEL = 80

CE

ENTER

26.

27.

WEAVE DATA 1 WEAVE ANGLE (DEG) = 90

VE ANGEL = 45
CE
ENTER

WEAVE DATA 1 WEAVE ANGEL (DEG) = 45

IF WRIST
WEAVING

28.

WEAVE DATA PERPENDICULAR = YES

29.

WEAVE DATA PERPENDICULAR = NO

30.

YES

ENTER

NO

31.

10 POS V = 60% PATH

Programming

S3
54

12 Arc welding
Programming SENSOR DATA
The various parameters are described in chapter 12.4.
1. Press the function key SENSOR.
2. Select the desired SENSOR DATA -number (1-10) on the numerical keyboard. Data
numbers not in use are displayed as"-".
3. Press ENTER.
4. Type the desired sensor number for side correction on the numerical keyboard.
5. Press ENTER. (The programmed value is now displayed. A new value can be entered
immediately if desired.
6. Press ENTER.
7. Type the desired BIAS value on the numerical keyboard.
8. Press ENTER.
9. Press ENTER. (See point 5).
10. Type the desired sensor number for height correction on the numerical keyboard.
11. Press ENTER. (See point 5).
12. Press ENTER.
13. Type the desired sensor BIAS on the numerical keyboard.
14. Press ENTER. (See point 5).
15. Press ENTER.
16. Type the desired side correction angle on the numerical keyboard.
17. Press ENTER. (See point 5).
18. Press ENTER.

Programming

S3
55

12 Arc welding

SENSOR DATA NO =

SENSOR DATA NO =

CE

ENTER

7
| SENSOR DATA 1 SIDE = 0 BIAS = 50

CE

; SIDE=

ENTER

it,

's s

4.

| SENSOR DATA 1 SIDE = 0 BIAS = 50

5.

CE

SEDE= 1

|
ENTER

OS

*l in in i in in II '

s v;

S3

Programming

56

12 Arc welding
SENSOR DATA 1 SIDE = 1 BIAS = 50
SIDE =

6.

SENSOR DATA 1 SIDE = 1 BIAS = 50

7.

| SENSOR DATA 1 SIDE = 1 BIAS = 50

8.

1 BIAS = 55

CE
V.,

fe.
v'

j
ENTERi

^ '

SENSOR DATA 1 SIDE = 1 BIAS = 55

9.

10.

S3

Programming
57

12 Arc welding
SENSOR DATA 1 HEIGHT = 0 BIAS = 50

11.

HEIGHT=2

CE

ENTER

SENSOR DATA 1 HEIGHT = 2 BIAS = 50

12.

HEIGHT=2

CE

I
ENTEP

SENSOR DATA 1 HEIGHT = 2 BIAS = 50

CE

BIAS=

ENTER

LJJUJG
13.

0
SENSOR DATA 1 HEIGHT = 2 BIAS = 50

14.

BIAS = 45

CE

ENTER

I
SENSOR DATA 1 HEIGHT = 2 BIAS = 45

15.

CE

BIAS=

ENTER

SENSOR DATA 1S CORR ANGLE (DEG) = 0

SIDE CORRECTION ANGLE =

16.

Programming

000

000
EEQ

CE

ENTER

S3
58

12 Arc welding
SENSOR DATA 1 S CORR ANGLE (DEG) = 0

17.

SIDE CORRECTION ANGLE = -45

CE

ENTEP

SENSOR DATA 1 S CORR ANGLE (DEG) = -45

18.

SIDE CORRECTION ANGLE = CE

ENTER

i
10POSV=10%
SCAN

WEAVE SENSOR

Check and editing of weld data

When the programming of the weld data is complete or previously programmed weld data
is to be used, it may be necessary to check and/or make amendments. This is performed
simply in accordance with the following:
1. Press the control button MANUAL once and SCAN three times.
2. Press function button WDATA.
3. Select the data type required (START/MAIN/END/WEAVE/SENSOR).
4. Select the data number required.
5. Press ENTER a number of times. Each pressing steps the parameter sequence one step.
If a value is to be changed, the new value is written in with the numerical button set
and the button ENTER is pressed.

Storage of welding data

Disk
With storage of a robot program on a disk (TO DISK) the weld data is stored automatically
in the same block as the robot program. The weld data area consists of the 10 START
DATA, 50 MAIN DATA, 10 END DATA 20 WEAVE DATA and 10 SENSOR DATA.
The transfer of the weld data from the disk (FR DISK) can be performed in three different
ways.
1. With REPLACE, the weld data in the robot is replaced with that from the disk
(according to the block number selected).
2. With ADD ALL, the operator determines whether arc weld data is to be entered or not.
3. With ADD ONLY, it is possible to select the transfer of robot program (PROG) or weld
data (WDATA) from the disk (according to the block number selected).
With all transfers from the disk the override register is cleared.

Programming

S3
59

12 Arc welding
Computer link
In systems equipped with a computer link function, the weld data area can be stored on or
accessed from the superior computer. The transfer is performed in accordance with the
following:
1.
2.
3.
4.

Select the function TO SC or FROM SC under the control button MANUAL.

Select the function WDATA.
Specify under which block identity the weld data is to be stored.
The data is transferred to/from the SC.

Programming

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12 Arc welding

12.5

Description of robot instructions

12.5.1

Instructions for the welding process

There are three instructions for the welding process under the control button P.
AWELD
WEND
CLEAN (spatter cleaning)
These instructions are of the combination type. The first contains a positioning and call for:
START DATA, MAIN DATA and WEAVE DATA and SENSOR DATA. The second contains
a positioning and call of END DATA. The third contains a positioning and a call of a robot
sub-program. The instructions are programmed by positioning the robot to the required
point with the joystick and then pressing the P button. The robot position is then stored
automatically in the memory after which one of the above instruction alternatives is
selected. The rules which apply to POS instructions also apply to coordinate systems, TCPs,
basic and maximum speed, positioning accuracy, editing, etc.
AWELD instruction
This instruction is used to program positioning forward to a point for welding start or weld
data amendment and call for data for the weld start procedure, the weld procedure, the
weaving movement of the welding gun and the sensor's method of operation. The
instruction is given automatically the speed percentage which applies for the P- and POSinstruction most recently programmed and fine point. The instruction is also given the
START DATA number, the MAIN DATA number, the WEAVE DATA and SENSOR DATA
number which applies for the AWELD instruction most recently programmed. If required,
it is possible to enter a new speed percentage, new data number and/or change the
positioning accuracy to PATH or CORNER1.
The following is the procedure when the instruction is executed:
The robot is positioned to the specified location at the speed defined in the instruction. This
applies if the positioning is forward to a point for weld start. If the positioning is forward to
a point for weld data change (welding in progress) the weld speed specified in
the
instruction (included in the MAIN DATA called) applies.
When in the location specified (positioning accuracy reached) the weld start procedure is
started in accordance with the START DATA given in the instruction. If SENSOR DATA
are programmed the function SPS (Servo Parameter Scheduling) is disconnected to achieve
constant servo log during contour following. The weld parameters VOLTAGE,
CURRENT/WIRE SPEED and WELD VELOCITY (but not WEAVE DATA or SENSOR
DATA) can be corrected during welding in progress with the direct action override function
(see section 12.7.2). During welding, weaving is performed (if specified) and if WEAVE
DATA is not 0. A correction is performed according to the data entered in the SENSOR
DATA- field (sensor data *K) and > 1 sensor * 0). If two or more successive AWELD
instructions are programmed, the first results in a weld start whereas the following only
result in change of MAIN DATA and/or SENSOR DATA.

Programming

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12 Arc welding
WEND instruction
This instruction is used to program positioning forward to a point for weld end and call of
data for the weld end procedure. The instruction is given automatically the speed
percentage (this is significant only when executing instruction by instruction, see section
12.7.4) which applies for the P- or POS-instruction most recently programmed and also fine
point The instruction is also given the END DATA number which applies for the WENDinstruction most recently programmed. If required, a new speed percentage and new data
number can be entered and/or the positioning accuracy can be adjusted to PATH or
COENER1.
When the instruction is executed the following takes place:
The robot is positioned to the location specified with the welding speed programmed in the
MAIN DATA called by the preceding AWELD-instruction.
When in position (or at zone) the weld end procedure is executed in accordance with the
END DATA specified in the instruction.
If SPS has been disconnected (contour following), it is automatically reconnected.
CLEAN instruction
Positioning of the robot to a point for spatter cleaning and call of a robot sub-program is
programmed with this instruction.
The positioning is given automatically the speed percentage which applies for the P- or
POS-instruction most recently programmed and PATH. The instruction is also given
automatically the sub-program number which applies for the CLEAN instruction most
recently programmed. If required it is also possible to enter a new speed percentage or a
new subprogram number and/or to change the positioning to fine point or CORNER1.
When this instruction is executed, the subprogram is called when the positioning is
completed (reached zone).
The subprogram called is to contain instructions for control of the spatter cleaning
procedure.

12.5.2

Instructions for positioner

There are two instructions under the control button P for controlling external equipment
such as a positioner for handling the workpiece.
EXTC (external control)
EXTPOS (external positioning)
These instructions are of the combination type. The first contains a positioning and call of a
robot subprogram and the other contains a positioning and a transfer of position
information to external equipment and acknowledgment that the transfer is concluded.
EXTC instruction
This instruction is used to program positioning of the robot to a suitable point and call of a
robot subprogram. The positioning is automatically allocated the speed percentage which
applies for the P- or POS-instruction most recently programmed and PATH. The
instruction is also given automatically the subprogram which applies for the EXTC
instruction most recently programmed. If required, a new speed percentage and a new
subprogram number can be entered and/or the positioning can be changed to fine point or
CORNER1.

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12 Arc welding
When the instruction is executed, the subprogram is called after the positioning is
complete. The subprogram called is to contain instructions to control the external
equipment concerned.
EXTPOS instruction
This instruction permits positioning of external equipment without servo control.
This instruction is used to program positioning of the robot forward to a point and
transmission of position information to external equipment.
The position of the external equipment is read and stored in the instruction when
programming. (Position information is accessed via port 70 and transmitted via port 80.
Compare with the instructions GET and TRANSFER.) The positioning is given
automatically the speed percentage which applies for the P- or POS-instruction most
recently programmed.
If required, a new speed percentage can be entered and/or the positioning can be changed to
fine point or CORNERl.
When the instruction is executed, the position information is transferred after the
positioning is completed and an acknowledgment is received.

Programming

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12 Arc welding

12.6 Programming of robot instructions

General
The following functions are discussed in this section:
12.6.1 Define a position with a PATH zone
12.6.2 Instructions for the weld process
AWELD Program a weld instruction
WEND
Program an end instruction
CLEAN
Program a spatter cleaning instruction
12.6.3 Instructions for manipulator movements
EXTC Program an external control instruction
EXTPOS Program an external positioning instruction
12.6.4 Common functions for the instructions.

12.6.1

Define a position with a PATH zone

When the P button is pressed, the robot position is defined as a PATH. The instruction
stored is identical with that obtained by pressing the POS- button.
The following function buttons are accessible after the P-button has been pressed:
AWELD

WEND

CLEAN

EXTC

EXTPOS
There are thus three types of arc weld instructions and two types of positioner instructions
available. The following sections describe in detail how these are programmed.
Note!

All instruction numbers and parameter values are examples only.

12.6.2

Instructions for the weld process

Program a AWELD instruction
The AWELD function is used to program simultaneously:
Positioning to a fine point.
Call of START DATA and MAIN DATA and performance of a weld start.
Call of WEAVE DATA and SENSOR DATA
When the AWELD instruction is performed, the robot will:
1. Position to the programmed position with the accuracy most recently specified.
2. aWhen positioning forward to a weld start point, the weld start procedure is executed in
accordance with the instruction START DATA, at the same time as weaving and welding
supervision via sensors starts if required. MAIN DATA is then called for.
b) When positioning forward to a point changing weld data, welding in accordance with
the previous MAIN DATA is performed during the positioning. New MAIN DATA is then
called for.
Only then is the next instruction executed. Programming of the AWELD function is
described under procedure 0 below. Selection of new speed, new positioning accuracy and/or
new weld data is described under the procedures A, C and D respectively in section 12.6.4.

Programming

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12 Arc welding
The relevant START, MAIN DATA,WEAVE and SENSOR DATA numbers are presented
on the display (at the end of the instruction).
PROCEDURE 0
Program positioning with subsequent weld start and/or welding according to the following:
1. Press control button P.
2. Press function button AWELD

100 POSV= 100% PATH

AWELD

WEND

CLEAN

EXTC

SCAN

100 POSV= 100% FINE AWELD 1 / 2 / 3 / 4

V(%)

PATH

ZONE

WDATA

100 POSV= 100% FINE AWELD

SCAN

1/2/3/4

The AWELD instruction is now completely programmed. If a new speed, new positioning
accuracy and/or new weld data are to be selected, continue with the corresponding
procedures (section 12.6.4).

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12 Arc welding
A. The POS POS instruction gives the position argument for the movement in accordance
with chapter 6.10.
B. The POS LOC instruction gives the location argument for the movement, in accordance
with chapter 6.12.
C. Definition of positioning time is done with the instruction TIME as in chapter 6.15.
Note!

When the instruction TIME is given, the specified positioning time will override
the given process speed.
Program a WEND instruction
The WEND instruction is used to program:
Positioning to a fine point.
Call of END DATA and execution of the END procedure.
When the WEND instruction is executed the robot will:
1. Position to the programmed position with the appropriate accuracy or zone most
recently specified.
2. Perform a weld end in accordance with the END DATA specified in the instruction.
Only then is the next instruction executed.
The programming of the WEND instruction is described under procedure 0 below.
The selection of new speed, new positioning accuracy and/or new DATA are described
under the procedures A, C and D respectively in section 12.6.4.
PROCEDURE 0
Program positioning with the subsequent weld end in accordance with the following:
1. Press control button P.
2. Press function button WEND
The WEND-instruction programming is now complete. If a new speed, new positioning
accuracy and/or new weld data is to be selected, continue with the corresponding procedure
(section 12.6.4).

Programming

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12 Arc welding

100 POS V = 100 % PATH

WELD

WEND

CLEAN

EXTC

SCAN

Weave data no
100 POS V= 100% FINE WELD 5
V%

PATH

ZONE

WDATA

100 POS V= 100% FINE WELD

POSPOS POSLOC

SCAN

TIME
f

Programming

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12 Arc welding
A. The POS POS instruction gives the position argument for the movement according to
chapter 6.10.
B. The POS LOC instruction gives the location argument for the movement according to
chapter 6.12.
C. Definition of positioning time is done with the instruction TIME as in chapter 6.15.
Note!
When the instruction TIME is given, the specified positioning time will override
the given process speed.
Programming of a CLEAN instruction
The CLEAN function is used for simultaneous programming of:
Positioning to a PATH
Call and execution of a special subprogram for spatter cleaning
When the CLEAN instruction is executed, the robot will:
1. Position to the zone.
2. Execute the subprogram.
Only then is the next instruction executed. The programming of the CLEAN instruction is
described under procedure 0 below.
Selection of new speed and new positioning accuracy and/or new subprogram number is
described under the procedures A, C and B respectively in section 12.6.4.
PROCEDURE 0
Program positions with subsequent call of subprogram for spatter cleaning according to the
following:
1. Press control button P.
2. Press function button CLEAN.

100 POS V = 100 % PATH

AWELD

WEND

CLEAN

EXTC

SCAN

j 100POSV=100 953 CLEAN 300

|v%

PATH

ZONE

PROGRAM SCAN

The CLEAN instruction is now programmed completely. If a new speed or a new

positioning accuracy is to be selected, continue with the corresponding procedures (section
12.6.4).
Programming

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12 Arc welding

12.6.3

Instructions for positioner movements

Program an EXTC instruction
The EXTC function is used to program at the same time:
* Positioning to a fine point.
Call and execution of a special subprogram for control of external equipment.
When the EXTC instruction is executed, the robot will:
1. Position to the programmed position at the zone currently specified.
2. Execute the subprogram.
Only then is the next instruction executed.
Programming of the EXTC instruction is described under procedure 0 below.
Selection of new speed, new positioning accuracy and/or new subprogram number are
described under the procedures A, C and B respectively in section 12.6.4 below.
PROCEDURE 0
Program positioning with accompanying call of subprogram for external control according
to the following:
1. Press start button P.
2. Press function button EXTC.

100 POS V = 100 % PATH

AWELD

WEND

CLEAN
*/'

EXTC
^

^ s

^ ' ^

SCAN
^

'

'

%%

V
s

100 POS V = 100 % EXTC 400

PATH

ZONE

PROGRAM SCAN

The EXTC instruction is now completely programmed. If a new speed, new positioning
accuracy and/or new subprogram are to be selected, continue with the corresponding
procedures (section 12.6.4).

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12 Arc welding
Program an EXTPOS instruction
The EXTPOS function is used to program at the same time:
Positioning to a PATH point
Transfer of position information to external equipment. This position information has
been accessed and stored in the instruction when programming.
When the EXTPOS instruction is executed, the robot will:
1. Position to the programmed position at the zone currently specified.
2. Transmit the position information.
3. Await acknowledgment.
Only then is the next instruction executed. The programming of EXTPOS instructions is
described under procedure 0 below.
Selection of new speed and new positioning accuracy described under the procedures A and
C respectively in section 12.6.4 below.
PROCEDURE 0
Program positioning with associated transmission of position information according to the
following:
1. Press control button P.
2. Press SCAN.
3. Press function button EXTPOS.

1.

100 POS V = 100 % PATH

AWELD

2.

WEND

CLEAN EXTC

I 100 POS V = 100 % PATH

i EXTPOS

1
3.

SCAN

/>:
'{
_, <

100 POS V = 100 % EXTPOS

v%

PATH

ZONE

The EXTPOS instruction is now completely programmed. If a new speed and/or new
positioning accuracy are to be selected, continue with the corresponding procedures (section
12.6.4).

Programming

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12 Arc welding

12.6.4

Common functions
PROCEDURE A
Select a new speed percentage in accordance with the following:
1. Press function button V(%).
2. Write the speed percentage required (0.1 - 799.9 %) with the numerical button set.
3. Press function button ENTER.

1.

100 POSV= 100% FINE AWELD 1/2/3/4

V%

2.

PATH

ZONE

WDATA

SCAN

100 POS V = 100 -

CE

VELOCITY (%) =

ENTER

3.

V%

Programming

PATH

ZONE

WDATA

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12 Arc welding
PROCEDURE B
Select a new subprogram number in accordance with the following:
1. Press function button PROGRAM.
2. Write the subprogram number required (1-9999) with the numerical button set.
3. Press function button ENTER.

1.

| 100 POSV= 1003

| V%

IL

PATH

-1

100
ZONE

PROGRAM

SCAN j

2.

3.

V%

Programming

PATH

ZONE

PROGRAM

SCAN

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12 Arc welding
PROCEDURE C
Select a new positioning accuracy in accordance with the following:
PATH POINT
1. Press function button PATH.

1.

100 POSV= 100% FINE

PATH

ZONE

WDATA

SCAN

ZONE

WDATA

SCAN

ZONE

WDATA

SCAN

100 POS V = 100 % PATH

PATH

FINE POINT
1. Press function button ZONE.
2. Press function button FINE.

1.

100 POS V= 100%

V%

2.

PATH

I 100 POS V= 100%

1 FINE

CORNER1 CORNER2
-;.

|
;>-;

mm

CORNER POINT
1. Press function button ZONE.
2. Press function button CORNER 1 or CORNER 2.

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12 Arc welding
PROCEDURE D
Select a new data number in accordance with the following:
START, MAIN DATA, WEAVE or SENSOR DATA number
1. Press function button WDATA.
2. Press either function button START, MAIN,WEAVE or SENSOR depending on which
data type is to be changed.
3. Write the new data number with the numerical button set.
4. Press ENTER

1.

100 POSV= 100% FINE AWELD 1 / 1 / 1 / 1

PATH

ZONE

WDATA

SCAN

I
100POSV=100% FINEAWELDl/1/1/1
START

MAIN

WEAVE

SENSOR
":

l)
100POSV=100% FINE A W E L D l / 1 / 1 / 1
CE

START DATA NO =
StS.

3.

4.

| 100 POSV= 100% FINE AWELD 1/ 1 / ] L

I STARTDATANO= 52

CE

/l I

ENTER |

I't 5s * } >

5.

100POSV=100% FINE AWELD 1 / 1 / 1 / 1

PATH

V%

"

N.

ZONE

WDATA

SCAN

\-V

* :

*l)The same sequence applies to MAIN and WEAVE.

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12 Arc welding
END DATA number
1. Press function button WDATA.
2. Write the new data number with the numerical button set.
3. Press ENTER.
1.

| 100POSV=100 3h FINE WEND 1

1

V%

PATH

ZONE
!\..?

3E '""""

SCAN 1

WDATA
#s .'

.!?.. sit

"'

.(.

100POSV=100% FINE WEND 1

3.

1 100 POSV= 100% FINE WEND 1

IENDDATANO=2

CE

ENTER 1

' ^1

100POSV=100% FINEWEND2
ZONE

Programming

WDATA

SCAN

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12 Arc welding

12.6.5

EXTFRAME
External axes are used for moving workpieces or the whole robot unit The position and
direction of these axes are not known for the robot control system and therefore
interpolation between internal and external axes is not possible.
With help of the function EXTFRAME a geometric relation of an external axis and the
robot coordinate system can be described. The EXTFRAME brings by that one interpolated
external axis to the robot system. This means that it is possible to perform linear and
circular paths with the robot and the interpolated axis at the same time. The programming
is as simple as for a stillstanding external axis. Joining of tubes can, for example, be
programmed with a few points even if the tube has been mounted excentric or not even
parallel with a rotating interpolated axis.
The real relative velocity between the edge of the tool and the workpiece is the programmed
velocity. This means that the weld parameters incl. the process velocity easily can be
adjusted afterwards, without path interfering.
Programmed weaving will be carried out relative to the moving workpiece without more
programming work then with a stillstanding workpiece.

Note! To avoid path following faults because of different dynamic quality of the external and
internal robot axes must, in certain cases, the weld velocity be limited. To get a good result
in respect of path following is it important that the KP-value for the external axis is
optimizied.
FUNCTION OVERWEEV
- Gear ratio for the external axis is defined under the function parameters.
- A rotating or linear external axis is defined in the EXTFRAME refering to location and
direction related to the robot coordinate system.
- 20 different EXTFRAMES can be defined. 1-10 for rotating external axes, 11-20 for
linear external axes.
- As standard the movement of all external axes is blocked when the EXTFRAME, for
certain axis is active.
- It is possible to exclude axes, that don't influence the geometric determination of the
interpolated axis, from blocking.
- Before EXTFRAME (n) is activated, external axes that have becomes blocked at
activation, can be run to positions valid at the time of definition of the EXTFRAME (n)
with the help of the function EXALIGN.
- Activation of earlier defined EXTFRAMES is done either manually, through
programming or execution of the EXTFRAME instruction. EXTFRAME 0 deactivates
the EXTFRAME function.
An active EXTFRAME will have the following effects on the system:
- during program execution interpolation will be carried out with the EXTFRAME
active.
- all external axes except the ORBIT axes and those axes not specified as blocked axes
(BLOCKAX) are blocked.
Programming

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12 Arc welding
At activation several checks are conducted concerning the possibility of proper activation
with respect to active REFPOINT, active STATIONS and the positions of those external
axes wich must have a fix position when the EXTFRAME is active (i.e. which were defined
as BLOCKAXes for that specific EXTFRAME). If any of these checks fails, the system will
not activate the EXTFRAME, but respond with an error message.
Before activating an EXTFRAME it is necessary to move all interfering external axes to a
position where the EXTFRAME data set is valid. For this purpose it is possible to align the
interfering external axes according to each defined EXTFRAME. Alignment towards an
EXTFRAME means, that all external axes, which are supposed to be at a fixed position for
that same EXTFRAME, are moved to the positions they had at EXTFRAME definition
time. This is done under AUTO menu; EXALIGN.
To be able to work on different external axes or to handle indexed tilting of an external axis
by another external device it is possible to switch between these data sets within the robot
program.
EXTFRAME definition is carried out by positioning the robot's TCP to a special calibration
point on the ORBIT (or on the mounted workpiece), then two times turning the axis about
90 degrees and positioning the robot's TCP to the same point on the ORBIT each time the
ORBIT has been moved. From these three positions the system will calculate the movement
of the external axis.
Only two points are necessary for a linear axis. There are two cases:
- When the robot stands in front of the external axis the calibration position should be
fixed on the moving object (as for the rotating axis in the case above). The TCP of the
robot is placed on the calibration position, there after the object is moved at least 1
meter. Finally is the robots TCP placed on the same calibration point again.
-

When the robot is mounted on the trackmotion the calibration position is a position on
the fix object. The robot is once moved to the calibrationpos on that object. Then the
external axis (with the robot mounted) is to be moved for an optional distance (dist.
should not be less than 1 mtr for accuracy reasons). Finally the robot's TCP has to be
repositioned to the fix calibrationpos. Observe, that the robot don't need to have a
certain relation toward the external axis it is mounted on, i.e. it is not necessary to take
care of parallelity of (e.g.) extax movement direction and y-axis of the robot system.

Note that the zero (origo) position of the new coordinate system for these linear cases is in
the middle, between the two calibration locations. Transport from origo can be done
4096 mm.
For improved accuracy a special tool with well defined TCP can be used. It is recommended
not to reorientate the TCP during the calibration procedure.
During EXTFRAME definition the movements of all other external axes, except the ORBIT
axis, are blocked to avoid unwanted movements of external axes which might interfere with
the calibration.
In the end of the EXTFRAME definition it is possible to define those external axes, which
shall not be blocked when the EXTFRAME is active.
After the EXTFRAME definition is completed it is possible to activate the defined
EXTFRAME via the pushbutton ACTIVE.

Programming

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12 Arc welding

SCANx5

EXTFRAME REFP

HOMEPOS SCAN

EXTFR 1 EXTAX=7 BLOCKAX=8.9

DELETE

CHANGE ACTIVE NEXT

NotforEXTFRAMEO

** Not for active or

undefined
EXTFRAME
*** Not for undefined
EXTFRAME

EXTERNAL AXIS NO=

Programming

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12 Arc welding

| EXTFR 2 NO

| ROBOT ON EXTERNAL AXIS YES

ONLY FOR
LINEAR CASES
(EXTFRAME > 10

I
EXTFR2POS1

BREAK

POSITION ROBOT AND ORBIT!

EXTFR 2-

POSl

BREAK

j EXTFR 21 POS2

BREAK
j

"A

POSITION ROBOT AND ORBIT!

EXTFR 2POS3

BREAK

NOT FOR
LINEAR CASE

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12 Arc welding
| EXTFR 2-

1 P0S3

BREAK I
MA

1
EXTFR (R) 2 EXTAX=7 BLOCKAX=8-12

UNBLOCK EXTERNAL AXIS=

CE

ENTER

(R) only for linear

case with robot on
external axis

+ '

EXTFR 2 EXTAX=7 BL0CKAX=9.10,11,12

CE

ENTER

EXTFR 2 EXTAX=7 BLOCKAX=9.10,H,12

CHANGE ACTIVE

NEXT

<

EXTFR01*
EXTFRAME REFP

HOMEPOS

SCAN

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12 Arc welding

12.6.5.1 Alignment of External axes

Description
One specific EXTFRAME set is valid only for a defined position of the robot relative to the
external axis. There might be installations where movements of other external axes may
interfere with this relation thus making the EXTFRAME data unusable. Such interfering
external axes may be a bending axis of the ORBIT or a track motion of the robot.
If for some reason those "interfering" external axes have been moved before a specific
EXTFRAME is to be activated, the system will react with an error message.
It will then be necessary to regain the positions of these interfering external axes to make
the desired EXTFRAME data valid again. For this purpose the EXALIGN function for
external axes should be used. The interfering axes (defined as BLOCKAXes in the
EXTFRAME data field) will be aligned with sync-speed. No robot axis or any other external
axis will be moved during alignment.

Programming

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12 Arc welding
Press AUTO + SCAN
50 POS V = 100 % PATH
DISPL

CORVST AW REST ALIGN

SCAN

50 POS V= 100% PATH

50 POS V = 100% PATH

50 POS V= 100% PATH

1
| EXTERNAL AXES ALIGN

1:1

| 50 POS V = 100 % PATH

1

DISPL

CORVST AW REST ALIGN

SCAN t
v1*

r
>-

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12 Arc welding

12.7

Program execution

12.7.1

Program test
The first version of a robot program for an arc welding application must be tested before
use.
The robot system has several functions for testing and editing programs:
Override function which permits individual or collective adjustment of the weld
parameters CURRENT/WIRE SPEED, VOLTAGE and WELD VELOCITY during
welding (see section 12.4). WEAVE and SENSOR DATA can not be adjusted in this
way.
+% and -% buttons, for adjustment of the positioning speed between the weld runs.
DISPLACEMENT, which permits displacement of a certain position during program
running (see programming manual).
The possibility of blocking the welding process during program execution.
The possibility of blocking weaving during program execution.
The possibility of simulating input signals during program execution.

12.7.2

Override function
The robot system is provided with a direct action override function for the welding
parameters speed, current/wire speed and voltage. This function is managed with the
programming unit joystick which permits individual or collective adjustment of the
parameters named above, during welding. The parameter values tested can be
permanently stored in the program.
The three degrees of freedom of the joystick can be utilized in correcting welding data as
shown in the figure below.

Increased
-current (A) /
wire speed (m/min)

Reduced speed
(mm/s)

Increased speed
(mm/s)

Increased
voltage (V)

Reduced
voltage (V)
-Reduced
current (A)/
wire speed (m/min)
/

The change in data obtained is proportional to the deflection of the joystick.

Increasing/decreasing is limited according to the table below. (Greater changes can be made
by repeated use of the function.)
Programming

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12 Arc welding
Parameter

Given in

Min. value

Max. value

Voltage

Volt

-40.0

40.0

Current

Apere

- 400.0

400.0

Wire speed

m/min
inch/min

-20.0
-787

20.0
787

Velocity

mm/s
inch/min

-40.0
-94

40.0
94

The changes of welding data obtained in this way are stored in a special register. The
correction is direct-acting, i.e. the welding is performed with the parameters stored in the
program (current MAIN DATA) plus the correction stored in the register. The correction
can be entered permanently into the program by means of the programming unit function
buttons.
Corrections can be made permanent in two different ways:
GLOBAL
LOCAL
Global storage means that corrected parameter values are added to the current MAIN
DATA. This means that the data is changed in all weld instructions in which just this
MAIN DATA is called.
Local storage means that the correction is only associated with the weld concerned (the
correction is stored in the instruction). Welding with the same MAIN DATA in other parts
of the program is thus not affected by local storage. Values twice the values in the table
above can be stored.
These two correction storage possibilities provide almost unlimited possibilities of trimming
the weld process.
The correction register mentioned above and the corrections stored locally can be cleared
via the programming unit.
To maintain control over the corrections etc., the current welding data concerned can be
presented during the welding in progress.
The joystick is activated for the override function by depressing a function button (ORIDE).
The enabling device must be held depressed to permit use of the override function.
Notel

Override should be performed in MANUAL REDUCED SPEED mode. The safety function
Hold-to-run can be deactivated in that mode to simplify the use of override.

S3

Programming
84

12 Arc welding
The exact sequence in which buttons are pressed for the override function and welding data
presentation is as follows:
1. After program start, the function button ORIDE is presented on the display. Pressing of
ORIDE gives the function buttons STO.LO, CLE.LO, CLE.O, STO.GLO and
presentation of the welding data concerned. In addition, two status indications are
shown at the right in the display:
O = Override-register containing correction value.
L = Instruction under execution contains the correction stored.
The active MAIN DATA number is also specified.
2. STO. GLO = Global storage of correction values.
STO. LO = Local storage of correction values.
CLE.LO = Clearing of correction values
CLE.O = Clearing of override.

1.

10POSV=10%
DISPL

ORIDE

100 20.2 V 135.0 A

STO.LO

SIM

7.0 MM/S

OL

CLE.LO CLE.0

SCAN
<

100 20.0 V 135.0 A 7.0 MMB

*LANG

ERRORS TEACH WDATA

-> ^y. ^s

OL

SCAN

^>^...>..?g

S3

Programming
85

12 Arc welding

12.7.3 Supervision of welding process

To ensure the quality of the welding performed, the robot is provided with supervision of
WELD CURRENT, GAS and COOLANT. These functions are integrated in the robort
control program on delivery.
The welding equipment must be provided with sensors which provide the robot with status
information via reserved inputs, connected as shown in Installation S3.
Current supervision:
When the wire-feed is activated during the welding start procedure, current supervision
also begins. The robot interrupts the start procedure if no indication that the weld has
struck is received within the weld start max time specified in the start data.An error
message is then presented on the display.
If the start sequence proceeds normally, the supervision remains during the complete
welding operation and if the current indication disappears, the welding is interrupted,
following a fixed sequence and an error message is presented on the display. (Very short
interruptions and disturbances are not registered.)
The current supervision is deactivated when the current source is disconnected during the
weld end sequence.
Gas and coolant supervision:
The supervision is initiated when the weld start procedure begins and is deactivated when
the weld end procedure is concluded. If during this time the indication disappears the
welding is interrupted and an error message is presented on the display.
The figure below shows when the supervision is activated and concluded.
Start
i data
Gas on
Weld voltage on
Wire feed unit on
Current
supervision
Vffla

Supervision,
gas and coolant

Supervision of welding process

Programming

S3

86

12 Arc welding

12.7 .4 Execution of welding instructions

Special rules apply to the execution of AWELD/WEND instructions as illustrated in the
following example.

100

140

110

130

100 POS V = 100% PATH

110 POS V = 25% PATH AWELD 1/1/4/1
120 POS V = 25% PATH AWELD 1/2/4/1
130 POS V = 25% PATH WEND 1
The welding is considered to start at point 110, to be changed at point 120 and is
concluded at point 130.
The robot is positioned to the point concerned and then stopped with a start instruction
at the instructions 100-130. There is no welding performed with execution, instruction
by instruction. The movements of the robot will be performed at the speed percentage
specified in the instruction.
With a start program at the instructions 100 or 110, the weld start will be performed at
point 110. If the start program begins at instruction 120, the robot will position to this
point and begin welding there.
When executing a series of weld instructions in reverse, only the positioning will be
performed, at the speed percentage specified in the instruction.
With a start program at instruction 130, only positioning will be performed. No weld
end sequence will be executed.
If the input "Block weld process" is set, the positioning program will be executed in
accordance with the above but the weld process will not be started.
While the welding is in progress (instructions 120 and 130 above) the welding speed in
the MAIN DATA is the basic speed. This has certain effects on the programming of
weaving (see section 12.4).

Programming

S3

87

12 Arc welding

12.8

Program example
Introduction
This section describes how a robot program for arc welding can be written.
The program is assumed to be used in welding a workpiece as shown in the figure below.
The different welds are numbered in the figure.
The program example is based on an installation as shown in the figure below. The
positioner is assumed to be servo-powered (external axes of the robot system)
5

A-A

The program is to perform the following:

Set the positioner in the start position - weld 1
Reorient the object - weld 2, 3,4, 5, 6, 7, 8.
All of the welds are started and concluded with the same START-data and END- data.
Three different sets of MAIN data are necessary:
SENSOR DATA 4
WEAVE DATA 1
WELD1
MAIN-data 1
SENSOR DATA 2
WEAVE DATA 3
WELD 2
MAIN-data 1 and 2
SENSOR DATA 4
WEAVE DATA 4
WELD 3
MAIN-data 1 and 2
SENSOR DATA 1
WELD 4
MAIN-data 2,1 and 2 WEAVE DATA 1
SENSOR DATA 1
WELD5-8
WEAVE DATA 2
MAIN-data 3
Welding data for the welds 2, 3,4, is exchanged during the welding.
The following program numbering has been used:
Program 0
Main program
Program 100
Weld program
Program 300
Spatter cleaning program

Programming

S3
88

12 Arc welding
The following data fields numbers have been used:
START-data
No. 1
MAIN-data
No. 1 - 3
WEAVE-data
No. 1 - 3
SENSOR-data
No. 1 - 2, 4
END-data
No. 1
The working range of the power source concerned is 17 V to 50 V (parameter values
selected).
The power source generates 17 V with a reference voltage of+3 V and 50 V with a reference
voltage of + 10V.
Reference
value
10

8 -

6 _

4 -

2 -

10

20

30

60

Parameter value

In this case, the parameters are to be defined in accordance with the following:
PARAM MIN (V)
=17
PARAMMAXCV)
=50
REFMIN(V)
= 3
REF MAX (V)
=10
The max. and min. values of the parameters and reference values for current, and
wire-feed unit are calculated and entered in a corresponding way.

Programming

S3

12 Arc welding
PROGRAM 0; MAIN PROGRAM
Basic data
Wait for ready signal
Call weld program
PROGRAM 100; WELD PROGRAM
Instruction:
POS
Positioning

Speed, TCP Coordinate system

From pushbutton on operator's panel

Control of positioner
to initial position

Instruction:
AWELD

Pos +call of
start data, main
data, weave data,
and sensor data.

The robot moves to the start point

point for the first weld and
begins welding.

Instruction:
WEND

Pos+ call of
end data

Conclusion of first weld.

Instruction:
POS

Positioning

Control of
positioning unit

Instruction:
CLEAN

Pos+ call of
spatter cleaning
program

Positioning of robot
and spatter cleaning
program.

Instruction:
AWELD

Pos+ call of
start data, main
data, weave data,
and sensor data.

The robot goes forward to the start

point for second weld and begins
the welding.

RETURN
PROGRAM 300; SPATTER CLEANING PROGRAM
Instruction:
Switch on
SET OUTPUT...
compressed air
Instruction:
WATT... S

Wait

Instruction:
RESET OUTPUT...

Switch off
compressed air

Instruction:
WATT... S

Wait

Instruction:
SET OUTPUT...

Switch on compressed air

Instruction:
WATT... S

Wait

Instruction:
RESET OUTPUT...

1st cleaning

Interval between 1st and 2nd cleaning.

2nd cleaning

Switch off compressed air

RETURN
Programming

S3
90

12 Arc welding
Program list
START DATA 1
Ignition voltage
Ignition current
Gas pre-flow time
Hot start voltage
Hot start current
Hot start time

4
-30
1

V
A
s

MAIN DATA 1
Weld voltage
Weld current
Weld velocity
MAIN DATA 2
Weld voltage
Weld current
Weld velocity

22
160
10

V
A

21.5

V
A

150
8

mm/s

mm/s

MAIN DATA 3
Weld voltage
Weld current
Weld velocity

21
145
6

END DATA1
End voltage- 2
End current
Gas post-flow time
Burn-back time
Cooling time
Fill time 0.8

V
-15
1
0.2
0.5
s

WEAVE DATA 1-10

Type zig-zag
Amplitude 1.0
Cross time 2
Dwell time L
Dwell time R
Dwell time M
Seam angle 90
Forward bias
Weaving angle
Perpendicular

mm
s
3
4
5
deg
6
90
Yes

SENSOR DATA 1
Side corr. sensor no.
Height corr. sensor no.
Side corr. sensor prestress
Height corr. sensor prestress

1
2
50
50

%
%

SENSOR DATA 2
Side corr. sensor no.
Height corr. sensor no.
Side corr. sensor prestress
Height corr. sensor prestress

1
2
45
52

%
%

Programming

V
A

mm/s

A
s
s
s

s
s
s
mm
deg

S3
91

12 Arc welding
SENSOR DATA 3
Side corr. sensor no.
Height corr. sensor no.
Side corr. sensor prestress
Height corr. sensor prestress

1
2
49
50

Programming

S3
92

S3 Robot Programming
Spot Welding

ABB Flexible Automation

13 Gluing

13

Gluing
Section

Page

13.1

13:3

13.2
13.3
13.4

Programming

Introduction
13.1.1 General
13.1.2 Signals
Programming
13.2.1 Gluing instruction
13.2.2 Scaling instruction
Overrides
13.3.2 Override on the scaling instruction
Error handling

13:7
13:15
13:20

S3

13 Gluing

Programming

S3

13 Gluing

13

13.1

Gluing
Introduction

13.1.1

General
The following chapter contains certain abbreviations describing the various functions and
signals. Explanations of these are given below:
GLFL
AIRFL

= GLUE FLOW
= AIR FLOW

GLVP
AIRVP

= GLUE FLOW SPEED VELOCITY PROPORTIONAL

= AIR FLOW SPEED VELOCITY PROPORTIONAL

GLSP
AIRSP

= GLUE SPEED (scaling speed for the glue flow)

= AIR SPEED (scaling speed for the air flow)

GDELAY = GLUE DELAY

ADELAY = AIR DELAY
FLADJ

= FLOW ADJUSTMENT

ORIDE

= OVERRIDE

GLUE REF = GLUE REFERENCE

AIR REF

= AIR REFERENCE The gluing function is a process function by means of

which external gluing and sealing equipment can be controlled.
Two instructions are intended for these applications:

(1) One is a positioning instruction, which, in addition to functioning as an ordinary

positioning instruction, also offers the possibility of programming GLUE- and AIR FLOWs.
It is possible to select if the GLUE and AIR FLOW is to be proportional to the TCP-speed or
not (the parameters GLVP and AIRVP active or inactive respectively). The following figure
shows the appearance of the instructions:

9999 POSV=100% PATH

Programming

S3

13 Gluing
(2) The second is a scaling instruction for calibrating the robot at different speeds and
different gluing/sealing equipment. See the following figure:
9999 GLSP: 10V= 500 mm/s

GDELAY= 0.1 s ->

AIRSP:10V=500mm/s

Adjustment of the gluing parameters GLUE- and AIR FLOW during the gluing process is
made possible with an override function (ORIDE).
An ordinary OUTPUT-instruction is used to open and close the glue gun (SET/RESET
OUTPUT).

13.1.2

Signals
The gluing/sealing function uses the following input and output signals:
Analog output 1, Port 21, (0-10V):
This is the reference signal for the glue flow to the gluing equipment (GLUE FLOW).
Analog output 2, Port 22, (0-10V):
This is the reference signal for the air flow to the gluing equipment (AIR FLOW).
Digital output 7, (0/1):
This is the signal for glue reference error. It is set to 1 when the calculated value of GLUE
FLOW or AIR FLOW exceeds 10V. It is only set/reset when the parameter GLUE = 1.
Digital input 6, (0/1):
The input is used to block the gluing operation. When external equipment sets the signal to
1, the reference signals GLUE FLOW and AIR FLOW are reset to zero as soon as the
current execution of an instruction is concluded.
In addition, a digital output must be used to open and close the glue gun. This output and
the analog outputs 1 and 2 also have a delaying function which permits compensation,
during the execution of the program, for lag in the robot movement and for delay in the
gluing equipment.

Programming

S3

13 Gluing
The following figure shows the connections described:
Glue equipment connections

Digital input 6
Digital output 7
Analog ouput 1
Analog output 2
Digital output x
NOTE!

Glue equipment

Glue inhibit
Glue reference error
Glue flow reference

Gluing gun
Glue and
air supply

Ait flow reference

Gluing gun on/off

Digital input 6 and digital output 7 are dedicated for process control. The user is
to ensure that the input and the output are not used for other instructions.
If an error situation occurs, it is also possible for external equipment to close off the GLUE
FLOW and the AIR FLOW by setting digital input 6 to 1. The input then resets the
reference signals as soon as the current instruction execution is completed and before
execution of the next instruction. This input is mainly intended for testing of robot
programs. The analog outputs are however limited to 10V. When any of the reference
signals exceed 10V, the calculation are changed somewhat. See the following section.

10.1.1.3 Calculation of the reference signals

(1) If GLUE FLOW or AIR FLOW are proportional to the TCP speed (GLVP or AIRVP are
active), the calculation is performed in accordance with the following general equation:
new GLUE/AIR-REF := FLADJ * FLOW * TCPSP / SCALESP * 10V
where Flow Adjustment (FLADJ) is a master override function which affects all flow
instructions. This and the GLUE/AIR flow (FLOW) are given as percentages. The TCP
speed (TCPSP) and the scaling speed for the GLUE/AIR flow (SCALESP) programmed, are
normally given in mm/s or inch/min. 10V is a correction factor.
(2) If however the GLUE FLOW or the AIR FLOW are not proportional to the TCP speed
(GLVP or AIRVP is inactive), the calculation is performed in accordance with the following
equation:
new GLUE/AIR-REF := FLADJ * FLOW * 10V
Note that all of the factors affect the new output reference. Even if the TCP speed and the
GLUE/AIR speed are equal, the new reference need not be 10V. This also depends on any
flow adjustment and the GLUE/AIR flow.

Programming

S3

13 Gluing
Example 1:
The glue reference is thus calculated in accordance with the following:
GLUE REF := FLADJ * GLFL * TCPSP / GLSP * 10V
Programmed FLADJ
Programmed GLFL
Programmed GLSP

: 90%
: 10V = 500 mm/s

Calculated TCPSP

: 400 mm/s

If GLVP is active, then GLUE REF := 0,8 * 0,9 * 400 / 500 * 10V = 5,76V
Otherwise GLUE REF := 0,8 * 0,9 * 10V = 7,2V
Example 2:
The air reference is calculated in a corresponding way in accordance with the following:
AIR REF := FLADJ * AIRFL * TCPSP / AIRSP * 10V
Programmed FLADJ
Programmed AIRFL
Programmed AIRSP

: 120%
: 75%
: 10V = 650 mm/s

Calculated TCPSP

: 400 mm/s

If AIRVP is active, then AIR REF := 1,2 * 0,75 * 400 / 650 * 10V = 5,54V
Otherwise AIR REF := 1,2 * 0,75 * 10V = 9,0V
The analog outputs are however limited to 10V. There is an exception from the normal
calculations when one of the reference signals (GLUE/AIR REF) exceeds 10V.
When both signals are proportional to the TCP speed, the higher value is limited to 10V
and the lower is reduced proportionally to maintain the relation between the two reference
signals (see the formula above). This applies even when both signals are not proportional to
the TCP speed, i.e. when GLVP and AIRVP not active.
If only one of the signals is proportional to the TCP speed, the values are only limited to a
maximum of 10V without retaining the relation.
Example:
Calculated GLUE REF
: 15V
Calculated AIR REF
: 12V
(a) Both signals proportional to the TCP speed.
As GLUE REF > AIR REF, the outputs are set to:
GLUE REF
:= 10V
AIRREF
:=12/15*10V=8V
(b) Only GLUE REF is proportional to the TCP speed.
The outputs are then set to:
GLUE REF
:= 10V
AIRREF
:=10V
Digital output 7 is set to 1 (Digital output 7 := 1) at the same time and remains so while
the reference signals are limited.
Programming

S3
6

13 Gluing

13.2

Programming

13.2.1

Gluing instruction
The gluing instruction functions as a normal positioning instruction with the added
capability of setting reference signals for the glue and air flows. When a gluing instruction
is executed, the robot positions to the zone of the position programmed and sets the glue
and air signals to the voltages which correspond to the percentages for GLUE- and AIR
FLOW. These are retained until a new gluing instruction is performed.
Note that the two percentages programmed in the gluing instruction apply to different
robot movements.
# The percentage for the speed (V=x%) applies to the robot track before the programmed
position, i.e. the speed at which the robot positions to the point programmed.
# The percentages for the glue/air flows (GLFL=x% and AIRFL=x%) apply to the the robot
track after the programmed position, i.e. the magnitude of the glue flow when the robot
leaves the point concerned. See the following figure:

GLFL/AIRFL
With respect to the coordinate system, TCP, basic and maximum speed, positioning
accuracy, editing etc. the same rules apply as for normal positioning instructions.
The instruction is programmed by positioning the robot to the point required and then
pressing the P-button. The menu for the instruction parameters appears as follows:
9999 POSV=100% PATH

Four different position types are available: PATH, Cl, C2, FINE.
GLFL (Glue Flow), Range 0-100%, Resolution 1%:
Analog output 1 is set to a value corresponding to the percentage specified, 10V corresponds
to 100%. Remember that the glue flow signal is also affected by the global override
parameter FLADJ (Flow Adjustment), and by the TCP speed if the parameter GLVP is
active.
AIRFL (Air Flow):
As for GLFL except for air flow and for analog output 2.

Programming

S3

13 Gluing
GLVP (Glue Flow Speed Velocity Proportional), Value: activeAnactive:
If the parameter is active, the glue flow is scaled proportional to the TCP speed. An
activated GLVP parameter is indicated with the letter (V) after the glue flow in the
programming menu. The parameter is activated/deactivated by pressing the button GLVP
as shown in the example below.
ABRVP (Air Flow Speed Velocity Proportional):
As for GLVP except for air flow.
Default values:
POSTYPE
GLFL
AIRFL
GLVP
AIRVP

:PATH
:0%
:0%

: inactive
: inactive

Programming

S3
8

13 Gluing
Example:
Gluing instructions are programmed via the P-button. See the following figure:

9999 POSV=100% PATH

GLUEFLOW=0%

9999 POS V=100% PATH

GLUEFLOW= 0%

AIRFLOW: 0%
GLFL

GLVP

AIRFL

9999 POSV=100% PATH

AIRVP

GLUEFLOW=0%

SCAN

->

Specify the glue flow on the numeric display panel 80

9999 POSV=100% PATH

GLUEFLOW= 0%

->

AIRFLOW: 0%
GLUEFLOW (%) = 80

9999 POSV=100% PATH

GLUEFLOW=80% >

AIRFLOW: 0%
GLFL

GLVP

AIRFL

AIRVP

Programming

SCAN

S3
9

13 Gluing
9999 POSV=100% PATH

50

Specify the air flow on the panel

9999 POSv=100% PATH

GLUEFLOWs 80%

9999 POSV=100% PATH

GLUEFLOWs 80%

->

AIRFLOW= 50%
GLFL

GLVP

AIRFL

9999 POSV=100% PATH

AIRVP

SCAN

GLUEFLOW= 80% (V) ->

The parameter is deactivated

and (V) disappears when
GLVP is pressed once again:
9999 POSV=100% PATH

GLUEFLOW=80%

9999 POSV=100% PATH

GLUEFLOWs 80%

Programming

->

S3
10

13 Gluing

13.2.2

Scaling instruction
The scaling instruction enables the user to program the relation between the calculated
TCP speed and the output voltage on the two analog channels. The instruction also includes
a global override (FLADJ) which functions as a type of scale factor in all subsequent
GLUE/AIR instructions until a new scaling instruction is executed.
The scaling instruction is normally located at the beginning of the program, as nominal
speed, reference frame etc. However, the instruction can be used anywhere in the program
if the scaling values are to be changed. If no scaling instruction is given, the preset values
apply as default values. The menu for the instruction parameters has the following
appearance:

9999 GLSP: 10V= 500 mm/s

GDELAYs 0.1

s->

ADELAY= 0.1 s ->

AIRSP:10V=500mm/s

I
B

FLADJ= 100%
GLSP

AIRSP

GDELAY

ADELAY

FLADJ

GLSP (Glue Speed):

If the robot controls the gluing equipment by using the TCP speed as a reference, a
reference speed must be defined for the maximum voltage 10V at the analog output. This is
done by setting a value for the glue speed (mm/s or inch/min) which corresponds to 10V.
AIRSP (Air Speed):
As for GLSP except for air.
GDELAY (Glue Delay):
The updated analog output signal is set a certain time before the TCP reaches the position
where the new value of the output signal is programmed. The signal thus arrives before the
TCP. It is therefore possible to delay the new reference signal to permit compensation
during program execution.
The robot reaches the position concerned a certain time, depending on the TCP speed, after
the analog signal is set. In addition, the lag varies in different gluing equipment and the
delay must be adjusted in each particular case. The following figure shows the delay times:
The analog signals
programmed are set

The flow
is changed

The TCP reaches

the position

(12)

(13)
time

(10
(te)

Programming

S3
11

13 Gluing
The analog reference signals GLUE FLOW and AIR FLOW are set at the same time (tl).
This occurs the time (tf) before the time at which the TCP reaches the position. The gluing
equipment changes the flow the time (te) after the change in the reference signals if no
extra delay is introduced. To force the change in flow to the time (t3) when the TCP has
reached the position, the delay time (td) must be programmed in the scaling instruction. If
the delay is set to zero, the flow will change somewhat before the TCP reaches the position
programmed (provided that the gluing equipment is faster than the robot).
ADELAY (Air Delay):
As for GDELAY except for air.
FLADJ (Flow Adjust):
The flow adjustment factor functions as a general override in all of the subsequent flow
instructions until the next scaling instruction is reached or program execution concludes.
This applies to both GLUE FLOW and AIR FLOW.
Argument range:
GLSP : 100 - 2000 mm/s
(236 - 4724 inch/min
AIRSP: 100 - 2000 mm/s
(236 - 4724 inch/min
GDELAY : 0 - 0,5 s
ADELAY : 0 - 0,5 s
FLADJ
: 50 - 200%

resolution 1 mm/s
resolution 1 inch/min)
resolution 1 mm/s
resolution 1 inch/min)
resolution 0,01 s
resolution 0,01 s
resolution 1%

Default values:
GLSP : 500 mm/s
AIRSP: 500 mm/s
GDELAY : 0,1 s
ADELAY : 0,1 s
FLADJ
: 100%

Programming

S3
12

13 Gluing
The scaling is located under the F-button. See the following figure:

Press SCAN 4 times

9999 POSV=100% PATH

9999 GLSP: 10V= 500 mm/s

AIRSP: 10V= 500 mm/s

GDELAY

AIRSP

9999 GLSP: 10V= 500 mm/s

AIRSP: 10V= 500 mm/s

ADELAY=0.1 s ->

FLADJ=100%
GLSP

GDELAY=0.1 s >

ADELAY

FLADJ

GDELAY= 0.1 s ->

ADELAY=0.1 s ->

FLADJs100%
CE

GLUESP 10V (mm/s) =

Specify the glue speed on the panel

ENTER

650

9999 GLSP: 10V= 500 mm/s

GDELAY= 0.1 s ->

AIRSP: 10V= 500 mm/s

ADELAY=0.1 s ->

1
1

FLADJ=100%
GLUESP 10V (mm/s) = 650

9999 GLSP: 10V= 650 mm/s

CE

ENTER

GDELAY= 0.1 s ->

S3

Programming
13

13 Gluing
1

9999 GLSP: 10V= 650 mm/s

AIRSP: 10V= 500 mm/s

FLADJs 100%

AIRDELAY (s) =

GDELAY= 0.1 s ->

ADELAY= 0.1 s ->

CE

Specify the air delay on the panel

|

9999 GLSP: 10V= 650 mm/s

AIRSP: 10V= 500 mm/s

ENTER

0.25
GDELAY= 0.1 s ->
ADELAY= 0.1 s ->

FLADJ=100%

CE

AIRDELAY (s) = 0.25

9999 GLSP: 10V= 650 mm/s

ENTER

GDELAYs 0.1 S ->

AIRSP:10V= 500 mm/s

9999 GLSP: 10Vr 650 mm/s

GDELAY= 0.1 s ->

AIRSP: 10V= 500 mm/s

Specify the flow adjustment on the panel

9999 GLSP: 10V= 650 mm/s

50

GDELAY= 0.1 s ->

AIRSP: 10V= 500 mm/s

FLOW ADJUST (%) = 50

S3

Programming
14

13 Gluing

13.3
Overrides
It is possible, with the override function ORIDE, to control the GLUE/AIR flow for
individual gluing instructions Gocal override), or via the scaling instruction FLADJ (global
override).
Changing the reference signals with ORIDE during automatic program execution affects
the reference signals the next time a gluing instruction is executed.
There are thus two principally different overrides:
(1) One which affects the GLUE/AIR flow.
(2) One which affects the scaling instruction FLADJ.
The instruction number is requested when the ORIDE button is pressed during program
execution. The instruction number specified determines which type of override function is
applied. If the instruction number is that of a GLUE/AIR function, it becomes a local
override, but if the number is that of a scaling instruction, it becomes a global override.

Programming

S3
15

13 Gluing

13.3.1

Override on the GLUE/AIR instruction

The following figure shows how this ORIDE function is used:

Specify the program number on the panel

Specify the instruction number on the panel

9999

S3

Programming
16

13 Gluing
9999 POSV=100% PATH

GLUEFLOWr 80% (V)->

Specify the glue flow on the panel

100

9999 POSV=100% PATH

GLUEFLOWs 80% (V)

9999 POSV=100% PATH

GLUEFLOW= 100%(V)->

Specify the air flow on the panel

60

9999 POSV=100% PATH

GLUEFLOWr 100% (V)->

9999 POSV=100% PATH

GLUEFLOWr 100% (V)->

It is possible to continue in the program with the NEXT or BWD buttons. When an
instruction is affected which is neither a scaling instruction nor a GLUE/AIR instruction,
the system will not go to the submenu for entry of new values for Flow Adjustment
(FLADJ) or GLUE/AIR flow. The robot then shows only the current instruction on the top
line of the display of the programming unit. It is however possible to step farther through
the program by pressing the NEXT button until a scaling instruction or a GLUE/AIR
instruction is encountered.
S3

Programming
17

13 Gluing

13.3.2

Override on the scaling instruction

This override function is used in a way similar to that described above. See the following
figure:

Specify the program number on the panel

Specify the instruction number on the panel

9999

S3

Programming'
18

13 Gluing
i

9999 GLSP: 10V= 650 mm/s

AIRSP: 10V= 500 mm/s

GDELAY= 0.1s ->

ADELAY::0.25 s ->

FLADJ=100%

CE

FLOW ADJUST (%) =

Specify the flow adjust on the panel

9999 GLSP: 10V= 650 mm/s
AIRSP: 10V= 500 mm/s

ENTER

120

GDELAY= 0.1 s
ADELAYr 0.25 s

FLADJ=100%
FLOW ADJUST (%) = 120

ENTER

9999 GLSP: 10V= 650 mm/s

AIRSP: 10V= 500 mm/s

GDELAY= 0.1 s ->

ADELAY= 0.25 s ->

FLADJ=120%
DISPL

ORIDE

NEXT

BWD

It is also possible here to continue in the program with the NEXT or BWD buttons. When
an instruction is affected which is neither a scaling instruction nor a GLUE/AIR
instruction, the robot will not go to the submenu for entry of new values for Flow
Adjustment (FLADJ) or GLUE/AIR flow. The robot then shows only the current instruction
on the top line of the display of the programming unit. It is however possible to step further
through the program by pressing the NEXT button until a scaling instruction or a
GLUE/AIR instruction is encountered.

S3

Programming
19

13 Gluing

13.4

Error handling
As described in section 13.1.2, the calculation of reference signals can result in values
which exceed 10V, the maximum permitted value. In such a case, the higher value is
limited to 10V and the lower is scaled down proportionally to maintain the relation between
the signals GLUE REF and AIR REF.
At the same time, digital output 7 is set to 1 while the references are limited. Program
execution continues however.
The reference signals are reset to zero when execution of the program stops or with an
emergency stop (GLUE REF and AIR REF := OV).

Programming

S3
20

14

14

Spot welding

Spot welding
Section

Page

14.1 Introduction
14.2 The standard function
14.2.1 General
14.2.2 Welding gun, manual operation
14.2.3 Function parameters
14.2.4 The spot weld instruction
14.2.5 Programming the first spot weld instruction
14.2.6 Subsequent instructions
14.2.7 Editing of spot weld instructions
14.2.8 Execution of instruction without current
14.3 The SWI-function
14.3.1 General
14.3.2 Function parameters
14.3.3 I/O signals
14.3.4 The spot weld instruction
14.3.5 Programming the spot weld instruction
14.3.6 Execution of instruction
14.3.7 Repeat weld after interrupt
14.3.8 Execution of instruction without weld current
14.3.9 Reset of the weld controller
14.3.10 Weld Controller programming.

14.3
14.3

Programming

14.1

S3

14

Programming

Spot welding

S3
2

14

14.1

Spot welding

INTRODUCTION
For spot welding, a weld controller is necessary to control the weld sequence. The weld
controller consists mainly of a timer unit and a power unit. This chapter describes how
to program a weld instruction, both with a standard function, and with SWI (= Spot
Weld Interface) function.
To simplify the programming of a spot weld instruction special, a control button P
(Process) on the programming unit is used. An instruction which is a combination of a
position instruction and a weld sequence instruction is obtained when this button is
pressed.

14.2

THE STANDARD FUNCTION

14.2.1

General
The spot weld function controls an external welding controller with an instruction that
contains a call for a sub-program. The physical communication between the robot and
the weld controller is effected via a digital I/O board (DSQC 223). The signal sequence is
defined in the sub program mentioned above, where ordinary logical instructions are
used to set the outputs and to control the inputs that are necessary.
The programming of a spot weld instruction requires only one push on the
programming unit P button. The number of the sub- program that is to be used is given
in the instruction, and also any register that is intended for the step function.

14.2.2

Welding gun, manual operation

The GRIPPER function works, in the programmed instruction, by stating the number
of the gripper and "grip" or "release" and the waiting time.
The spot weld function deals with two different cases of the GRIPPER function:
1 Only two welding guns.
The buttons for grippers 1 and 2 (grip, release) on the programming unit will open and
close respectively the gun without any change in the display on the p-unit.
2 More than two guns.
GRIPPER 1 will open and close gun 1 without changes in the p-unit.
GRIPPER 2 will put the question GRIPPER NO = .

14.2.3

Function parameters
To get the welding function under the P-button, a special function parameter, SWELD,
must be activated (SWELD = 1).
The function parameter SWELD is found in the MANUAL meny
See S3 Installation section 5.2.4.26.

Programming

S3

14 Spot welding
The parameter ZONE is used to chose the zero zone size for the different types o
fine points in the spot weld instruction.
The valid sizes are:
Type

Def. range

default value

SMALL

2- 100 mm

2 mm

LARGE

2- 100 mm

10 mm

XLARGE

2-100 mm

20 mm

Note that the actual size of the zero zone will be vary throughout the working range.
The size will correspond to the value stated in the parameters for movements in axis 1
with the arm fully stretched out. For other cases the size will be smaller.
(The figure describes how to set the parameter ZONE if SWELD = 1.)
MAN + SCAN + PARAM + CHANGE + SCAN + SCAN + SCAN + ZONE

CORNER1 CORNER2

PATH BREAK |1

O n l y if

PATH =0

SMALL

Programming

LARGE XLARGE

Only if
SWELD =1

S3

14

14.2.4

Spot welding

The spot weld instruction

Here follows an example of what a standard instruction looks like:
100 POS V=100% FINE L WELDPR120 R5
Valid parameter values:
Zero zone size:

FINE, FINE L, FINE XL

Program numbers:

100 - 9999

Register numbers:

0-119

Note.
In spot weld instructions, it is possible to program three different types of FINE
arguments. This is necessary to allow the programmer to adjust the zero zone to the
closing time of the gun.
Note.
Program numbers 0-99 are not allowed as subprogram numbers in the instruction.
This is in order to avoid confusion with welding programs in the welding controller.

Programming

S3

14

14.2.5

Spot welding

Programming of the first instruction.

The spot weld instruction is used for simultaneous programming of:
* A fine point with optimal speed and accuracy.
* A call of a subprogram which contains instructions for activation of the weld
controller.
The spot weld instruction is programmed with the menu control button P. When the
function is programmed it is possible to change the zero zone type and speed with the
help of the corresponding function button O- ZONE and V(%). For the function O-ZONE
the argument is changed from large (FINE L) to extra large (FINE XL) and then to small
(FINE) zero zone after each time the button is depressed.
See the figure on the next page.
The positioning speed is expressed in % (0.1-799.9 % ) of the programmed basic speed.
Procedure
1 Position the robot to the required weld point.
2 Press the P-button.
3 Press the PROGRAM button and select sub-program number (100-9999) and
ENTER.
4 If a register is to be used for any step function press the button REG NO and select a
number (0-119) and press ENTER. If the welding program is written as a pattern
program with several returns, the register is used to ensure that the right sequence
in the pattern program is executed.*)
5 The first spot weld instruction is now programmed.
*) The register is not a compensation register and the register is not incremented
automatically ( see pattern program in the section 11.4).

Programming

S3
6

14

1 2 3

100POSV=100%C1

4 6 6
7 8 9
- 0

PROGRAM NO =

ill

Spot welding

CE ENTER

DO

PROGRAM NO = 120

V(%)

0-ZONE

PROGRAM

<

1 2 3

100 POS V=100% FINEL WELDPR 120

4 5 6
7 8 9
- 0

REG NO =

REG NO = 5

Programming

CE ENTER

1 i

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14

14.2.6

Spot welding

Subsequent spot weld instructions

The same argument which applied for the preceding spot weld instruction is repeated for
the subsequent spot weld instruction in the program (i.e. each time the P -button is
depressed). If required, it is always possible to change an argument through pressing the
corresponding function button V(%), O-ZONE or PROGRAM.
Procedure
1

Run the robot to the next weld point.

Press the P- button.

The instruction number and the same sub-program number and argument as in the
preceeding spot weld instruction are presented on the upper line of the programming
unit display. If no further changes are necessary, the instruction is now completely
programmed.
Otherwise change the arguments by pressing (V%), 0-ZONE or PROGRAM.

14.2.7

Editing of spot weld instructions

A spot weld program often contains a large number of spot weld instructions with the
same argument. To save editing time when the same argument is to be changed at the
same time in a number of such instructions, the function button MODARG under the
control button f- g has the following function:
When the button is used for a spot weld instruction, the same argument which applies
for the preceeding edited instruction is obtained. After the first spot weld instruction has
been modified, only the function button MODARG needs to be used for the following
spot weld instructions to obtain the same argument as in that first edited. Change spot
weld instructions as follows:
Procedure
1 Press f- g.
2 Call the first spot weld instruction to be changed with the function button INST NO
or STEP.
3 Press SCAN.
4 Press MODIFY.
5 Press MODARG.
Change the argument(s) to be modified V(%), O-ZONE or PROGRAM by pressing the
corresponding function button.
NOTE! When MODARG is depressed, the same argument is obtained as for the
previous edited spot weld instruction.

14.2.8

Execution of instruction

Programming

S3
8

14
During the execution of a spot weld instruction the following happens:

Spot welding

1 The robot is positioned to the programmed weld point.

2 When the robot TCP is within the zero zone selected, the selected subprogram is
executed in the same way as an ordinary sub-program.
3 If a register number is programmed in the instruction, the selected part of the
subprogram is executed in the same way as a pattern program. The register is not
automatically incremented. This function gives the opportunity to successively
change the welding parameters depending on the number of spots ( step function).
When executing a spot weld instruction backwards, only the movement of the robot is
performed.

Programming

S3
9

14

14.3

THE SWI FUNCTION

14.3.1

General

Spot welding

SWI ( Spot Welding Interface) is a software function in the robot system that controls
the communication with the external weld controller. Programming is similar to that for
the standard function. The instruction states which weld program is to be used and
which register is to be used for control of the opening time of the gun. Subprograms for
control af the weld controller are not necessary.
The concept also presents the possibility of using a double gun. In that case it is necessary
to specifiy in the instruction which of the guns is to be activated (gun 1, gun 2, or both).
When a spot weld instruction is executed, the signal communication between weld
controller and gun is performed automatically in a predetermined order.
The physical communication between the robot and weld controller is accomplished via a
digital I/O board, (DSQC 223). Supervision and control of the gun is also performed through
this board.
The function is developed to suit weld controllers that can use the same signal interface,
like BOSCH PSS 208 IB, SATTWELD 1000 and others. It is also prepared for adaptation
to weld controllers with a different signal interface. It is possible to read and edit a
subset of the BOSCH weld controller parameters by use of serial communication.

14.3.2

Function parameters
To obtain access to the SWI function a special function parameter must be activated. The
parameter SWELD, which gives access to the spot weld function under the button P on the
programming unit, also has to be activated.
The function parameter SWELD is found in the MANUAL menu.
See Installation S3 section 5.2.4.26 - 27.
SWELD = 1 or 2 gives access to the parameters SWI, SERIAL COMM BOSCH and 64
PROGRAMS.
The digital I/O board DSQC 223 can be located in any slot and receives I/O numbers in
the ordinary way. When the function parameter SWI is activated, a question appears
regarding which board position (1- 6) is to be used.
The standard function with subprograms for control of the weld controller can also be
used when the parameter SWI is activated.
Note.
If the SWELD parameter is reset, the parameter SWI is also reset.

Programming

S3
10

14

14.3.3

Spot welding

I/O signals
See also Installation S3, section 3.13, for description on how to use I/O signals!
Output signals:
START 1

Start signal to the weld controller.

The signal is automatically activated at execution of the SWI
instruction. If a double gun is used, the signal is activated when
welding is ordered for gun 1.

START2

Start signal to the weld controller if a double gun is used and

welding with gun 2 is ordered.

CURRENT ENABLE

This signal is set low by the manual command INHIB, for

testing of the robot program without weld current. The input
signals FLOW OK, TEMP OK and CURRENT OK will not be
supervised. The output signal WELD POWER will also be set
low.

WELD POWER

High signal when the robot is in the MOTOR ON provided the

signal CURRENT ENABLE is high. Low signal in all other
cases. The signal can be used to control the weld power
supply.

RESET

A pulse with a length of 50 ms is obtainedwhen switching from

MOTOR of to MOTOR ON and at PROG ST. It can be used to
reset certain weld controllers after errors.
Reset can also be activated manually.

GRIP1

Controls the work stroke of the gun. Equivalent to the

corresponding system I/O signal.

GRIP 2

Controls the opening stroke of the gun. Equivalent to the

corresponding system I/O signal

PARITY

Parity bit for program number (uneven parity). The signal is

activated automatically when an SWI instruction is executed.

WELD PROGRAM

5 or 6 outputs to choose the weld program to be activated in

the weld controller, depending on the definition of the
parameter "64 programs".
Programs 0-31 or 0-63 are permitted.
For example, at execution of a SWI instruction with weld
program 26, the outputs 10,12 and 13 ("2" +"8"+"16") will be
set (Board in slot 1).

Programming

S3
11

14

Spot welding

Input signals:
WELD READY

High signal from the weld controller when the weld is ready.
The signal need to be low before START 1 or START 2 is set for
the next spot weld. If not, error message 550 WELD ERROR 1
is displayed and program execution stops. If WELD READY is
not recived within 20 sec. after START 1 or START 2, error
message 550 WELD ERROR 2 is displayed and program
execution stops (if SWI=1, MOTOR OFF is also received).

TIMER OK

High signals to indicate that weld controller is OK. As low

signal, error message 551 WELD ERROR TIMER is displayed.
SWI=1 Supervised during MOTOR ON. Low signal disables
program execution and gives MOTOR OFF.
SWI=2 Supervised when WELD READY is high. Low signal
stops program execution. At PROG ST, the SWI
instruction is repeated.

CURRENT OK

High signal to indicate that the weld current is within

permissible tolerances. At low signal, error message 552 WELD
ERROR CURRENT is displayed.
SWI=1 Supervised during WELD POWER high. Low signal
disables program execution, and gives MOTOR OFF.
SWI=2 Supervised when WELD READY is high. Low signal
stops program execution. REPEAT of weld is possible.

FLOW OK

High signal to indicate that the water supply is OK If the

signal is low for more than 5 sec. error message 553 WELD
ERROR FLOW is displayed.
SWI=1 Supervised during WELD POWER high. Low signal
for more then 5 sec.stops program execution and gives
MOTOR OFF.
SWI=2 Supervised when WELD READY is high. Low signal
for more than 5 sec. stops program execution. At
PROG ST next instruction is executed.

TEMP OK

High signal to indicate that the temperaure is OK At low

signal, error message 554 WELD ERROR TEMP is displayed.
SWI=1 Supervised during WELD POWER high. Low signal
stops program execution and gives MOTOR OFF.
SWI=2 Supervised when WELD READY is high Low signal
for stops program execution. At PROG ST next
instruction is executed.

Programming

S3
12

14
ENABLE MOVE

Spot welding

High signal indicates that the gun(s) is(are) open. Low signal is
used to prevent robot movements when the gun is closed. The
signal is checked after the programmed opening time has
expired. If low after programmed opening time, register 98 is
incremented by 1. If the signal is low more than 5 sec, error
message 555 WELD ERROR ENABLE MOVE is displayed and
robot movement is blocke (If SWI=1, MOTOR OFF is received).

Note!

Reserved input signals that are not used must be strapped to 24 V. This does not apply to
WELD READY which has to be supplied from the weld controller (see above) to make it
possible to execute the SWI -instruction.

14.3.4

The spot weld instruction

Example of a spot weld instruction:
100 POS V = 100% FINE L WELDPR 20 R5 G12
Permitted parameter values:
Zero zone sizes:

FINE, FINE L, FINE XL

predefined in the function parameters

Program numbers:

0-31 (0-63) give the SWI function

100 - 9999 give the standard function

Register numbers:

0-119

Gun arguments:

(Gl), G2 or G12

The instruction corresponds to the standard spot weld instruction with external weld
controller. It is the programmed weld program number that determines whether the
instruction should be executed as a standard or a SWI instruction.
The register in the SWI instruction contains the opening time for the gun in ms. If no
register is programmed the opening time is set to 0. If the signal WELD READY is not
given until the gun has been opened, it is not necessary to program any opening time in
the instruction.
The reason why the opening time is set in a register and not directly in the instruction
is that when trimming the opening time of the gun it is only necessary to edit one
instruction.
When double gun is used, the last argument (GUN) states which of the guns is to be
activated. If only gun 1 is to be activated, the argument is left out. If only gun 2 is to be
activated, the argument G2 is displayed, and if both guns are to be activated, G12 is
displayed.
Note!

If the SWI parameter 1 or 2 is not activated, only standard function program numbers are
possible. Gun argument is not possible to program.

Programming

S3
13

14

14.3.5

Spot welding

Programming the spot weld instruction

The spot weld instruction is programmed via the P button on the programming unit.
When programming the very first spot weld all necessary arguments have to be
specified. The subsequent spot weld instructions will get the same arguments
automatically when pressing the P button.

100 POSV=100% Cl
V(%)

0-ZONE

PROGRAM

GUN 1
pi

1 2 3
! 100 POSV=100% Cl
4 5 6
j PROGRAM NO =
7 8 q
0

1!

CE

ENTER

I!

PROGRAMNO == 26

100 POS V=100% FINEL WELDPR 26

0-ZONE

PROGRAM

GUN

100 POS V=100% FINEL WELDPR 120 R 5

Note!
If only one gun is used no
argument is displayed.

V(%)

0-ZONE

PROGRAM

GUN
See next
page.

00 POS V=100% FINE XL WELDPR 120 R 5

V(%)

0-ZONE

PROGRAM

GUN

100 POS V=100% FINE WELDPR 120 R 5

V(%)

Programming

0-ZONE

PROGRAM

GUN

S3
14

14

Spot welding

The choice of gun when a double gun is used is effected as follows:

One press on the button gives the argument G12 (both guns activated), one more press
on the button gives the argument G2 (gun 2 is activated). See fig. below.

100POSV-100%FINELWELDPR20RS
V(%)

0-ZONE

PROGRAM

GUN

First pressure on GUN

gives the argument G12

Second pressure on GUN

gives the argument G2

S3

Programming
15

14

14.3.6

Spot welding

Execution of instruction
When executing the spot weld instruction, the robot will perform the following actions:
1. Outputs for program number and parity bit are set.
2. The robot moves to the programmed point.
3. Outputs for START 1 and GRIP 1 are set.when the zerozone is reacted.
4. The robot waits for input WELD READY. If the waiting time exceeds 20 sec,
START 1 and GRIP 1 are reset and program excution is stopped.
If not, continues with 5.
5. START 1 and GRIP 1 are reset.
6. The internal timer for the opening time starts and spot counter (register 99) is
incremented.
7. The instruction is now completed and execution of the next instruction is started.
Any logical instruction will be executed directly. Another spot weld instruction will
perform the following actions.
8. Outputs for program number and parity bit are set.
9. If input ENABLE MOVE is high, the robot moves to the next point.
If ENABLE MOVE is low for more than 5 sec, the program excution stops.
A timetable of the signal sequences is shown below (principle):
Robot in weld position
Change of PROGNO:

START 1 (START 2)
GRIP 1 (GRIP 2)

CURRENT

NEXT

_T
J

WELD READY
ENABLE MOVE

Prog, opening time

Programming

S3
16

14

Spot welding

Observe that there is a certain gain of cycle time if the WELD READY signal is received
before the gun's opening phase is concluded. In such a case the opening time is used to
perform the calculations for the next position. This is why the gun's opening time has to
be specified in the instruction via the register number.
If the weld controller does not set the WELD READY signal before the gun has opened
completely, the opening time is to be set to zero in the program. In such a case the
register number can be omitted in the instruction.
Register 99 is used for counting the welded spots. Its content is incremented
automatically after each spot. Resetting must be carried out through the user's
program.
Register 98 is used for counting at how many spots the robot has been waiting for the
signal ENABLE MOVE after the programmed opening time has expired. The register is
therefore suitable for checking why the opening time of the gun has started to increase.
Resetting of the register is performed in the user program.
When executing a spot weld instruction backwards, only the robot movements are
performed.

14.3.7

Repeat weld after interrupt

If 550 WELD ERROR 1, 550 WELD ERROR 2 or 552 WELD ERROR CURRENT is
recieved during weld process the question REPEAT? is displayed.
YES (or no answer) means that the interrupted instruction is executed again at PROG
ST.
NO means that the next instruction is executed at PROG ST.
If 551 WELD ERROR TIMER the interrupted instruction is executed again at PROG
ST.
If 553 WELD ERROR FLOW and 554 WELD ERROR TEMP, the program will start
with the instruction that comes after the interrupted one at PROG ST.
At Restart after power failure, the instruction is repeated if WELD READY was not
received before the power failure.

Programming

S3
17

14

Spot welding

14.3.8 Execution of instruction without weld current

In order to simplify the test procedure for a robot program with spot weld instructions,
the program can be run without welding current. When this inhibit function is activated
there is no supervision of FLOW OK, TEMP OK and CURRENT OK. The signals
CURRENT ENABLE and WELD POWER will be set low.
When the INHIBIT function is deactivated CURRENT ENABLE is set high. WELD
POWER will then be set high when the robot is in MOTOR ON mode.
The inhibit function is activated/ deactivated via a special SWI button under the AUTO
menu. This button is only accessible if the SWI parameter is set
(SWI = 1 or 2). The function is automatically deactivated if an INIT is performed. See
figure below:
AUTO + SCAN

DISPL CORV ST ALIGN

14.3.9

SWI SCAN

Reset of the weld controller

Manual reset of the weld controller can be done via the button RESET under the
pushbutton SWI under the AUTO menu, (see figure above).

Programming

S3
18

14

14.3.10

Spot welding

Weld Controller programming.

The serial interface to the weld controller Bosch PSS 2081 B is a RS232/V24 standard
interface. The communication protocol is fixed to the controllers design. The parameters
which can be programmed from the robot are a selection of the whole range of the timer
parameters needed to control the weld process. The whole parameter set can be
programmed from an external device supplied by the weld controller manufacturer.
The parameters which can be changed from the robot are as follow.
Operating mode
Force
Squeeze time
1st Weld time
1st Heat
1st Current
1st Pause time
Pulsation
Weld time
Heat
Current
Pause time
Hold time

0,1 or 2 PHA/SSU/KSR
0,0 - 9,9 kN
01-99 cycles
01 - 30 cycles
00 - 99 scale values
in kA
00 - 99 cycles
01-09 pulses
00 - 30 cycles
00 - 99 scale values
in kA
00 - 99 cycles
01-99 cycles

With this interface it is possible to read the data block described above, to change the
data and to send it back to the weld controller. Additionally, the actual current values of
the last weld can be received by the robot control system and displayed together with the
programmed values and in case of a weld controller error code can be received from the
weld timer.

Programming

S3
19

14
AUTO + SCAN + SWI

* PARAM reads programs/parameters

in weld controller and displays them
for editing on the S3 teach pendent.
** RDCURR reads and displays the
actual weld current of the last weld
together with the programmed
values enclosed in parenthesis.

LAST CURRENT 0.0 C2.6) 0.0 (3.0)

Spot welding

INHIB RESET RDCURR PARAM

26

BREAK

WELD PROG N O . BREAK CE

ENTER

WELD PROG NO = 26

OPERATING M O D E - 2
OP MODE.

BREAK

26
CE

ENTER

FORCE and other parameters*

Parameters are also shown on the optional LCD of the S3 control system.
If there is no answer within 30 sec, an error message NO SERIAL CONTACT TIMER
will be diplayed.

Programming

S3
20

15

Error list

ERROR LIST
3HAB 0008-2/Rev 1

Error List

S3

15

Error list

1
General
When an error is detected, the ERROR lamp on the control panel illuminates. If a P-unit is
connected to the robot system, an error message is presented at the same time in plain
language on the upper line of the display. This applies also when a P- unit is connected
after the error has developed and the ERROR lamp has illuminated.
Errors which can occur are divided into:
Operational errors; the error messages beginning with a number 001-499.
System errors; the error messages beginning with a number 501-999.
The appropriate corrective actions for the different errors are described below.
OPERATIONAL ERRORS
1 Check the error type on the upper line of the P-unit display.
2 If further information is necessary, go directly to point 6. Otherwise continue with point 3.
3 Press the control button SHIFT - the error message is then cleared.
4 Perform the control operation correctly so that the error status is not repeated.
5 Continue with point 8.
6 Seek the error message displayed in section 3.
7 Perform the appropriate actions stipulated in section 3.
8 If the same error message returns or persists, despite the incorrect operation not being
repeated, contact service personnel.

SYSTEM FAULTS
1 Seek the error message presented in section 4.
2 Perform the appropriate corrective actions as described in section 4.
3 If the same error message persists or returns, call service personnel.
Note!

Some error messages described in the sections 2 - 4 can occur for certain types of
robots only.

Error List

S3

15

Error list

2
Error buffer
Means: The system contains an internal error buffer, which can store 9 error messages. In the
buffer the system stores:
All kinds of error messages (both system errors and operator errors), occurred at the
latest error occasion.
Earlier messages about system errors.
The system can, on request, present the contents of the error buffer via:
The programming unit. (Just error messages from the latest error occasion.)
A printer, if the optional function Program printout is provided.
A monitor, if this optional function is provided.
Facts: Display on the programming unit of error messages
The programming unit displays one error message at a time, according to the following:
When the system stops running due to an error, the operator will see the first error
message. An arrow on the display indicates if there are any consequent errors. In this
case the operator can display these messages also, one by one.
During manual operation the operator can, on request, display stored messages from the
latest error occasion, one by one. The error messages are chronologically displayed.
For most error messages, it's possible to get text in plain language by pressing "" on the
programming unit.
Display on the programming unit of error messages
The monitor displays all the messages within the error buffer, according to the following:
When the system stops running due to an error, the operator will see all messages,
occurred during that error occasion. The error messages are chronologically displayed.
During manual operation the operator can, on request, display all stored messages. The
error messages are in plain language and chronologically displayed.
Printout of error messages
During manual operation the operator can, on request, display stored messages from the
latest error occasion, one by one.The error messages are chronologically displayed.
Erasure of the contents in the error buffer and show text in plain language
During manual operation the operator can, on request, erase all messages stored in
the error buffer.
On request, the operator can get text in plain language for most error messages.
On request, the operator can load the texts in plain language from disk. (See Installation
manual, S3.)

Error List

S3

15

Error list

Example of a list of error messages

ERROR MESSAGE

CODE

* * * * * : M c * * * * * * * * * * * * * * * * * * * * * * * * * * * *

506 SERVO ERROR 2

1405->
506 SERVO ERROR 2
1605
536 ENABLE CHAIN FAULT 21
506 SERVO ERROR 2
1805
506 ENABLE CHAIN FAULT 21
504 PROGRAM RUN ERROR

Used:

For fault tracing and for production follow-up.

Executed:

The system reacts immediately after the procedure is concluded.

Procedures: Display on the programming unit of error messages (after production stop)
Read the error message. Use the SHIFT button to display more error messages, if
required.
If you want to read messages about system errors once again, select ERRORS under
the MANUAL menu.

Error List

S3

15

Error list

Operational errors
The following tables describe the errors which the operator can cause when programming or
operating the robot system.
These are numbered from 001-499. The table gives.
Error message
Causes
Recommended corrective action

ERROR MESSAGE

CAUSES

RECOMMENDED CORRECTIVE ACTION

1.NOT ALLOWED
COMMAND

The button concerned is

temporarily blocked by
the system.HOLD can
be active.

Select another button.

1.NOT ALLOWED
COMMAND 10

Closed due to that input

PROG STOP is active.

Deactivate input PROG STOP.

3J)ATA ERROR

Attempted entry of
incorrect numerical
value.

Depress ERASE and enter new

numerical value.

4JNSTRNOT
FOUND

After resequencing a
program the system has
detected jumps to nonexisting instructions.

Check the program and correct the

faulty jump addresses.

5.PROGRAM
MISSING

Attempt to use a program

number where instructions
are missing with:
programming running
editing of complete
program

Program the instruction

under the program number
concerned.
Select another program number.

6.MEMORY
FILLED UP

Attempt to:
enter further
instructions
copy program when the
robot memory is full

Error List

1 Clear the program block.

2 Erase superfluous instructions
and programs.
3 Clear program block once again.
If the system includes a floppy disk
unit, it is possible to:
1. Divide the existing program
and store each section on a
floppy disk under a separate
program number.
2. Utilize the mass memory function
for automatic exchange of the
different program parts in the user
memory.
S3

15
Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

7.PROGRAMEND

Attempt to step past

the last instruction

Call the first instruction number in

the program concerned.

8.PROGRAM NUMBER
OCCUPD2D

Attempt to copy a program under a program

number where instructions are already stored.

Select another program number for

the program copy.

9. INSTRUCTION
NUMBER
OVERFLOW

A.Attempt to program instruction with higher

number than 65530.
B. Attempt to resequence
a program containing
more than 6553
instructions.

A. Divide the existing program into a

main program and subprograms.
Copy the program and erase superfluos parts. Resequence and insert
CALL-instructions. If available
memory space is too small, use
floppy disc.
B. Avoid resequencing, or split the
program according to point A above.

10. ADAPTlVJLTY
ERROR1

A digital multi-bit
sensors or analog
sensor gives a
signal outside its
working area.

Change one of the min. or max.

-limits (or both) for the signal from
the sensor concerned.
Correct current positions in
the program.

10. ADAPT1V1TY
ERROR 2

A digital 2-bit sensor

gives an illegal
signal.

Check the sensor.

10. ADAPTTVITY
ERROR3

A 1-bit sensor is used

for direction searching or
contour following.

Select another sensor

Replace the sensor

10.ADAPTTVrrY
ERROR 4

A digital sensor with

2-8 bits is completely connected to the same group
of digital inputs.

Change the connection according

to the Installation manual.

lCADAPnVITY
ERROR6

The correction movement has no direction

or speed.

Determine direction and speed

for the correction movement:
In a new instruction
* By editing an existing instruction.

10.ADAPnVITY
ERROR 7

Sensor data for

a sensor used
missing.

Enter sensor data according

to the Programming manual,
chapter 9.

S3

Error List
6

ERROR MESSAGE

CAUSES

15 Error list
RECOMMENDED CORRECTIVE ACTION

lO.ADAPnVITY
ERROR 8

The signal level programmed for search stop

is outside the working
range of at least one
of the sensor.

Edit the instruction concerned

so that the signal level for
search stop is within the
working range of the sensor.

11. OUTSIDE
WORKING
AREA 1-12

The robot axis 1 to 12 has

been run outside its
working area with the
joystick.

Run the robot in the opposite

direction with the joystick.

11. OUTSIDE
WORKING
AREA 20

Too large movement with

axis 1,4 or 6 using the
joystick.

Switch-off and start-up the

robot system again.

11. OUTSIDE
WORKING
AREA 23

The angle between the

lower and upper arms at
axis 3 is too small or too
large.

Leave this area using the joystick

11. OUTSD3E
WORKING AREA 99

The main processor is in a

temporary fault condition.

Re-initiate the system.

13 ROBOT NOT
SYNCHRONIZED

A Some axis is NOT

positioned if it is a
robot with absolute
measurement system.
B Some axis is not synchronized.

A Re-start the system.

Remedy possible fault.
B Synchronize the system.

14AUTO MODE/
KEYLOCK

A The key-switch is in
A Choose position MANUAL REDUCED
position AUTO and/or the
SPEED or MANUAL FULL SPEED
key input on the remote
and/or deactivate the key input
control is activated.
on the remote control.
B
Change to MANUAL REDUCED
B Corresponding parameter
is ACTIVE under AUTO C. SPEED or MANUAL FULL SPEED
mode or deactivate the parameter.

15. SENSOR NOT

DEFINED

No sensor defined for

sensor number entered.

Press ERASE and enter

new sensor number.

16. SENSOR TYPE

NOT ALLOWED

Incorrect sensor type for

the adaptive function defined for the sensor
number entered.

sensor number.

Error List

Press ERASE and enter new

S3

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

17. WRONG
INSTRUCTION TYPE

Attempt to change:
Argument
Position
Speed
for an instruction which
does not contain positioning.

Change the complete

instruction.
Select another instruction
number.

18. INSTRUCTION
NUMBER OCCUPIED

Attempt to program instruction with occupied

instruction number.

Enter another instruction number.

Renumber the program and then
enter an instruction number.

19.PROGRAM START

Attempt to step backwards

and pass-by the first
instruction in the
program.

Erase the message and continue with

the next action.

20 SELECT ROBOT
COORDINATES

Within this area the robot

cannot be run in rectangular coordinates.

Select the robot coordinate system

21. TCP NOT

DEFINED

Attempt to program
activation of an
undefined TCP.

Program another TCP.

Define the TCP that is to be activated
via the instruction and try again.

23. ALIGN ERROR

Attempt to execute ALIGN

with a too large angle deviation between the current
tool orientation and the required one.

Turn the tool closer to the required

orientation and try again.

24.NOT DEFINED

(MH/ASM and GLUE)

Attempt to execute ALIGNFETCH on an undefined
orientation register not
containing a tool orientation.

25. INCOMPATIBLE
OPTION

The required option can

not be activated
- because to that:
A Another parameter
under OPTION is
already activated.
B Required OPTION parameter can not be activated
for the current robot type.
SWI: System I/O or panel I/O are
defined on current board.

Select another orientation register.

Define the orientation by means
ofALIGN-STORE.

S3

Error List
8

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

26 NOT ALLOWED
COMMAND/ROOM
FIXED TCP 1-8

1 Can not change

Deactivate reference point
coordinate-system, when
reference point is active.
2 Can not define a frame
Activate an ordinary TCP(0-19)
or pallet in wrist coordinate-system.
3 The function mirror is
Use the function MODPOS
interrupted if the posion required positions.
tion is programmed with
fixed TCP. Observe
that reflection has been
carried out on earlier positions with ordinary TCP.
4 MODPOS can not be carErase the instruction and
ried out if a fixed TCP
program it again, to convert
TCP is active and the pos- to the wrist coordinateinstruction is made with an system.
ordinary TCP and without
external axes.
5 The instruction is blocked Program in some other way.
when fixed TCP is active.
6 It is not possible to define
a base point with a room
fixed TCP.
7 Not allowed to define a TCP Activate an ordinary TCP.
automatic when a fixed
TCP is active.
8 After programming an
Program in the ordinary way.
earlier pos-instruction a new
TCP has been activated, so
that the coordinate-system
have been changed. The
instructions are not of the
same size, so it is not
allowed to use SAME.

27 NO MORE
INFORMATION

Required text in plain

language not with the
loaded texts

Load the texts

28 LOAD TEXT FROM DISK Required text in plain
language can not be disMenu: MANUAL + ERRORS
played. The texts have not
been loaded from the
system disk.
32 CALIBRATION
ERROR 2

Error List

Fault during defination

of EXTFRAME. Pos 1-3
does not describe a circle in
space.

Choose 3 new positions and try again

S3
9

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

32 CALIBRATION
ERROR3

A Fault during defination

A Check the gear ratio.
of EXTFRAME. Calculated
gear ratio for the ORBIT does
not correspond with the ratio
entered in the parameter
memory.
B The Radius is too small
B Make it bigger.

33 NOT ALLOWED
EXTFRAME 1

Align "interfering" external axes

When activating
an EXTFRAME the
system descovered that
some "interfering" external
axis is in an not allowed position
for the specific EXTFRAME.

33 NOT ALLOWED
EXTFRAME 2

Attempt to activate an
Use only defined EXTFRAMErs
undefined EXTFRAME have
been made or the robot system
is trying to align with an
undefined EXTFRAME.

33 NOT ALLOWED
EXTFRAME 4

Attempt to activate an
EXTFRAME have been
made while REFPOINT
is active.

33 NOT ALLOWED
EXTFRAME 5

Attempt to activate an
Activate the STATION which the
EXTFRAME without activated axis belongs to.
ORBIT axis. The axis belongs
to an inactive STATION or
Attempt to define an EXTFRAME
in the ratine for calibration, that
can't be activated because it belongs
to an inactive STATION.

33 NOT ALLOWED
EXTFRAME 7

Attempt to deactivate a
STATION while an
EXTFRAMEis active, where
the EXTFRAME is an axis to
the specific STATION.

33 NOT ALLOWED
EXTFRAME 8

Attempt to align "interfacing" Activate necessary STATIONS to

axes to a specific EXTFRAME activate blocked axes or deactivate
have been made while these EXTFRAME.
"interfacing" axes are not
allowed to move (became they
belong to inactive station or are
blocked because the EXTFRAME
in question is active).

Error l i s t

Deactivate the REFPOINT or don't

activate the EXTFRAME

Deactivate EXTFRAME first

S3
10

15

Error list

System faults
The errors which can occur in the robot system itself are described in the following table.
These are numbered from 501 to 999.
The table gives.
Error message
Causes
Recommended corrective measures.
ERROR MESSAGE

CAUSES

501 MEMORY FAULT

RECORD

A The system has discovered 1 Insert the installation diskette, with

a summary check fault in the the right system parameters, into
system parameter memory, the floppy disk unit.
Then the system has made 2 Choose the functionsbutton FR DISK
a restart with the para3 The system starts-up.
meter basic values from
4 Press MAN/PARAM/RESOLV and
PROM.
check that the system has the
B The system has discovered correct RESOLV data.
that the systemparameters (Choose the function button PROM
loaded has revision and
when restarting the system for
version number separated the first time. Then define the
from the ones in PROM.
installation systemparameters
Then the system has reincluding RESOLV data.) **)
started with the parameter
basic values from PROM.

502 PROGRAM
MEMORY FAULT

When restarting the

Load the program block in
system has discovered a
question from DISK **)
check summary fault in
the robot program memory.*)

503 EMERGENCY STOP

The robot has been

stopped in an
emergency.

RECOMMENDED CORRECTIVE MEASURES

*) Causes to the discovery of check summary fault in

system parameter memory or program memory:
Too low battery voltage.
Uncorrected or damaged battery.
Damaged robot computer board.

Error List

1. Correct the cause of the

emergency stop.
2. Press RESET on the control panel so
that the emergency stop is cancelled.
If the emergency stop cannot be
cancelled:
Check the safely board.
Start fault tracing, ace. to Chapter 4 in
the Service Manual.

**) Check the robot computer board

incl. the memory battery back-up
according to the Service Manual.

S3
11

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

503 WORKING RANGE

STOP 2

One axis has been driven

against a limit switch.

Correct the cause of the stop.

Place the key-switch in position
MAN.
Put the system back in operation
by pressing the operation button
and keeping that way and then
depressing the dead man's handle.
Then drive the axis away from
the limit switch with the joystick.
If the stop can not be restored:
Check on not used safety circuits
clamps.
Check the safety board.
Start fault tracing, acc.to Chapter 4
in the Service Manual.

504 PROGRAM RUN

ERROR3

Attempt to start program

execution when program
is missing.

Enter a robot program from floppy

disk or from programming unit.

504 PROGRAM RUN

ERROR4

Attempt to execute a correction vector for another

kind of instruction.

Call the correct instruction

and try again.

504 PROGRAM RUN

ERROR5

Last instruction was not

RETURN nor JUMP in an
executed program.
Current program has been
erased by the instruction
ADD BLOCK

Insert the correct instruction.

504 PROGRAM RUN

ERROR7

A Attempt to execute a
movement path outside
the robot's working area.
B The wrist centre of the
robot or the TCP is in
20 mm range of the
base Z-axis.

A Edit the movement path.

Check the TCP location.
B Use robot coordinates or
modify the TCP track.

504 PROGRAM RUN

ERROR8

Attempt to call a subprogram or robot program

without instructions.

Error List

Edit the program number in

the instruction.
Create a subprogram or robot program
with this number

S3
12

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

504 PROGRAM RUN

ERROR9

(MH/ASM AND GLUE)

A Attempt to execute a
Edit weave program.
weave movement with
a weave subprogram
where the first instruction is not a positioning instruction.
B (AW) Attempt to execute
a weave movement
with either:
No positioning intruction after weave start.
The distance between
weave start and next
positioning instruction
is zero. (AW).

Edit the program.

504 PROGRAM RUN

ERROR 10

A Attempt has been done to A Check the program.

execute an impermisseble
instruction.
B (AW) Undefined welddata B "Define present welddata.
number.

Exchange
welddata
nr.
C (not AW) Attempt has been C Correct the sub weaving
made to execute a weave
program.
movement when instruction
in sub weaving program is
faulty.

504 PROGRAM RUN

ERROR 12

Attempt to execute a
jump to a non-existent
instruction.

504 PROGRAM RUN

ERROR 13

Attempt to execute a
pattern subprogram, when
the register concerned
contains an incorrect
value.

Check and change the value

in the register concerned.

504 PROGRAM RUN

ERROR 14

Attempt to execute a
nested call to a 11th
subprogram level (or a
12th level of interrupt
program).

Edit the robot program.

504 PROGRAM RUN

ERROR 15

The main processor is in

Switch-off and start-up
a temporary fault condition. the robot once again.
Check electrical disturbance
on inputs.
Check that input 6 and output 7
is not used as general I/O when
glue is activated.

Error List

Edit the jump address.

Enter an instruction with this
number.

S3
13

15
Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

504 PROGRAM RUN

ERROR 16

A Main program
A, B Enter a main program.
(program 0) is missing.
B The active program replaced by the corresponding one on floppy disk
at program loading with
the subfunctional APPALL
under the GET B-function
C Another mass memory
C Try to perform the corresponding
error
GET B-function manually.

504 PROGRAM RUN

ERROR 17

A. A positioning instruction after a circle

point contains an
illegal argument.
B. Attempt to back to
the start point after
program stop in the
middle of a circular arc.

A. Edit the instruction and repeat

the attempt.
B. Run if possible to the end point
of the circle and back from
this point instead.

504 PROGRAM RUN

ERROR 18

The positions of the circle

points are selected incorrectly so that either:
The radius becomes
too large.
Two or several points
in the circular arc
coincide.

Remove the circle point and run

in straight lines instead.
* Change the position of the
points concerned so that a
circular arc is obtained.

504 PROGRAM RUN

ERROR 19

The circular interpolation has been interrupted so that it cannot

continue.

1. Erase the error message with

the SHIFT key.
2. Check that there is no obstacle in
the direct path of the robot
forward to the next point.
3. Run instruction by instruction to the
next point.

504 PROGRAM RUN

ERROR 20

The acknowledgment
of transferred data is
omitted when executing
the arc welding instruction EXTPOS.

Check the peripheral

equipment concerned.

(only for arc welding

robot)

Error List

S3
14

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

504 PROGRAM RUN

ERROR 24

A The robot is trying t

Modifiy the orientation in the current
reach a position with
or preceeding position
another configuration
or
than it had when that
Chose Modified Rectangular
position was programmed.
Coordinates
This can only occur in
or
rectangular coordinates.
Deactivate the configuration
supervision (see 8.5, HANDCHK).
B The axis 4 position differs
Modifiy the orientation in the
more than 45 degrees or
current or preceeding position
the axis 6 position differ
or
more than 90 degrees from
Chose Modified Rectangular
the positions they had in
Coordinates
the next position
Deactivate the configuration
instruction at
supervision (see 8.5 HANDCK)
programming time.

504 PROGRAM RUN

ERROR 26

A The robot is trying to

Modify the orientation in the current
reach a position with
or preceeding position
another configuration
r
or
than it had when that
Chose Modified Rectangular
position was programmed.
Coordinates
This can only occur in
r
or
rectangular coordinates
Deactivate the configuration
together with
supervision (see 8.5, HANDCHK)
FINE-positions.
B On the way towards the
position, axis 4 deviates
more than 45 degrees,
or axis 6 deviates more
than 90 degrees from
the start position, in
direction away from
the stored configuration
of the next position.
This can only occur in
rectangular coordinates.
C The time, programmed
for the time positioning,
is to short.

Modifiy the orientation in the current

or preceeding position
or

Chose Modified Rectangular

Coordinates
or
Deactivate the configuration
supervision (see 8.5, HANDCHK)

C Increase the programmed time.

D Change to program running in robot

or modrect coordinates, or move the
motion a little away from the singular
point.
E Weaving: the crosstime is E Increase crosstime or decrease
to short compared to the
amplitude.
amplitude.

D Program running in
rectangular coordinates
is not possible.

Error List

S3
15

ERROR MESSAGE

CAUSES

15 Error list
RECOMMENDED CORRECTIVE ACTION

504 PROGRAM RUN

ERROR 27

The value in a number

register is not valid.

Check the program and edit the

register handling.

504 PROGRAM RUN

ERROR 50

Automatic definition
of a program displacement is in progress.
During the process, at
least two positions
approach each other
too closely:
When the positions
are selected.
* In the resulting
program displacement.

Select three new positions

and try again.

504 PROGRAM RUN

ERROR 51

Attempt to activate
an undefined TCP

Activate another TCP.

Define required TCP and try
again.

504 PROGRAM RUN

ERROR 53

(MH/ASM and GLUE)

Attempt to use:
A An undefined gripper.
B An output which is reserved for a gripper.

A Change the number of grippers

in the function parameters.
B Use another gripper/output.

504 PROGRAM RUN

ERROR 54

(MH/ASM and GLUE)

Attempt to execute a
PALLET-instruction with
an undefined pallet.

A Define the pallet.

B Use an already defined pallet.

504 PROGRAM RUN

ERROR 55

(MH/ASM and GLUE)

Attempt to execute
a PALLET-instruction
with the register values
pointing out a position
outside the pallet.

504 PROGRAM RUN

ERROR 57

(MH/ASM and GLUE)

Attempt to execute
Change the register values.
a TOOLREL-instruction
with displacements/rotations
outside permitted limits.

504 PROGRAM RUN

ERROR 58

Attempt to execute a
gluing instruction with
the parameter GLUE not
activated.

Change the register values.

Activate the GLUE function parameter

GLUE under OPTION - provided that
the robot system is a gluing system.

S3

Error List
16

ERROR MESSAGE

CAUSES

15 Error list
RECOMMENDED CORRECTIVE ACTION

504 PROGRAM RUN

ERROR 62

(AW)
Weaving data not defined for the current weaving data field.

* Select another weaving data

field.
Define weaving data.

504 PROGRAM RUN

ERROR 63

(AW)
CROSSTIM is 0.

Define CROSSTIM.

504 PROGRAM RUN

ERROR 64

(AW)
BASEPoint not defined.

Define BASEPoint and try again.

504 PROGRAM RUN

ERROR 65

(AW)
Sensor data undefined for
current sensor data field

Select another sensor data field.

Define sensor data.

504 PROGRAM RUN

ERROR 66

(AW)
Internal error in calculation
of end position for AUTOSEARCH.

504 PROGRAM RUN

ERROR 67

(AW)
The robot velocity is to high
at connection or disconnection of SPS.

Edit the program. Reduce the zero

zone or the velocity.

504 PROGRAM RUN

ERROR 68

No position stored in the

current position register.

* Select another position register.

Store a position.

504 PROGRAM RUN

ERROR 69

Internal system fault.

Re-initiate the system.

504 PROGRAM RUN

ERROR 70

Active another set of softness, or

The soft-servo number or
softness vector is undefined. define the relevant softness set under
the manual menu.

504 PROGRAM RUN

ERROR 71

The wrist centre point or

the TCP has entered within 20 mm of the base
Z-axis. This is not allowed
in rect. or modrect.
coordinates.

504 PROGRAM RUN

ERROR 72

Check that the correct TCP is active

Incorrect TCP may be
at the programmingunit. Continue
active.
Indical to TCP x IS ACTIVE. program execution by pressing
instruction start or program start
once more.

Error List

Edit the start position for AUTOSEARCH and try again. If the error
persists after several trials, check the
computer board.

Use robot coordinates

or modify the robot pass.

S3
17

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

504 PROGRAM RUN

ERROR 73

The weaving amplitude

cannot be reached because
the TCP is too close to the
x-axis (weaving axis) of
the wrist.

Change TCP
Reduce the amplitude.

504 PROGRAM RUN

ERROR 74

The robot moved when

the activation/deactivation
of a station was requested.

Stop the robot and repeat

the attempt.

504 PROGRAM RUN

ERROR 75

Timeout in supervision of a
spot weld. WELD READY
not received within 5 s after
START 1/2.

Check welding controller.

504 PROGRAM RUN

ERROR 76

Output used in SWI function Define the function parameter

not defined.
forGRIPPER3.

504 PROGRAM RUN

ERROR 77

Execution of an SWI function Define the SWI parameter or

without activated SWI
change the instruction,
parameter.

504 PROGRAM RUN

ERROR 78

The program number in the Change the program number

instruction is not permitted. in the instruction.

504 PROGRAM RUN

ERROR 80

Attempt to reach a position Check the program and active

with a wrong TCP active
TCP.
have been made. Pos-instructions and stored positions can
not be used between fixed TCP
and ordinary TCP.

504 PROGRAM RUN

ERROR 81

Attempt to switch coordinate-system with a TCPinstruction have been

made, when the reference
point is active.

The reference point has to be deactivated before change of

coordinate-system is possible.

504 PROGRAM RUN

ERROR 82

Attempt to execute an
instruction have been
made,who don't function
together with a fixed
TCP.

The instruction in question can

only be executed with a ordinary
TCP active.

504 PROGRAM RUN

ERROR 84

Attempt to activate an undefined LOAD.

Activate another LOAD. Define

required LOAD and try again.

504 PROGRAM RUN

ERROR 85

Incorrect LOAD may be

active. Indentical to
"LOAD x IS ACTIVE"

Check on teach pendant, that the

correct LOAD is active. Continue
program execution.

S3

Error List
18

ERROR MESSAGE

CAUSES

15 Error list
RECOMMENDED CORRECTIVE ACTION

504 PROGRAM RUN

ERROR 86

Robot coordinates are not

allowed during arc welding.

Change coordinate system

504 PROGRAM RUN

ERROR 87

Max. allowed velocity for an

external axis limits the
velocity of the robot during
the arc weld process.

Reprogram so that no external axes

limits the velocity of the robot.

504 PROGRAM RUN

ERROR 88

The instruction can not

be restarted.

Make ordinary restart or move the robot.

504 WRONGLY PLACED

I/O BOARD

No digital I/O-board defined

in place stated by the parameter BOARD POSITION.

Check the function parameters

for the I/O and SWI.

505 SERVO
ERROR 1

The servo computer does

not accept an order from
the main computer, because
of a serious system fault.

Check the computer board.

505 SERVO ERROR

8001

The axes computer has

not accepted an order
from the main computer,
due to a serious error in
the main computer.

Re-initiate the system. If the fault

persists.replace the main processor
board.

506 SERVO ERROR 2

1101-1124

Resolver fault, channel x.

Fine resolver,
axis 1(1101)-12(1112)
Coarse resolver,
axes 7(1119)-12(1124)

A Check for any fault by measuring

resistance in wiring and resolver.
(resolver~20ohm)
B Replace the serial measurement
board or the axis board.

506 SERVO ERROR 2

1201-1224

Resolver error, channel y.

Fine resolver,
axis 1(1201)-12(1212)
Coarse resolver,
axis 7(1219)-12(1224)

See error type 1101 - 1124

Error List

S3
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15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

506 SERVO ERROR 2

1301 1312

Speed error.
A Lower the programmed speed locally
The motor for axis 1 (1301)in the program where the error occurs
and/or change the positioning pattern
12 (1312) runs considerably
so that the axis which trips because
faster than is commanded
of the incorrect speed is not so active
from the control system.
in this part of the program.
Cause, internal axes:
A Considerable interference B Check that the correct commutator
offset is entered for the axis. If the
between the axes at
axis has been repaired, remeasured
high speeds results in
and enter a new offset
incorrect speed at certain
points in the user's
C 1. Check all fuses.
program.
2. Check the motor current using the
B Incorrectly commutated
test outlets. Check the wiring, the
motor
drive unit and the robot computer
C Axis stops (the motor
board.
receives no current)
D Incorrect acceleration of
D Replace the robot computer or drive
the motor.
unit.
F 1. Check external controller, drive
Cause, external axes:
E See point A above.
stage and external wiring.
F Incorrect acceleration of the 2. Replace robot computer or external
axis board.
motor.

506 SERVO ERROR 2

1401-1412

Jam error, internal axes

The motor for axis 1 (1401)
7(1407) remains stationary despite the robot
computer commanding
current to the motor.
Cause.
A The robot has run
against an obstacle.
B. Overload.
C.The motor receives
current but is incorrectly commutated.
D.The motor does not
receive current.
E. Resolver fault.
F. Motor fault.
G. Mechanical fault.

Error List

A 1. Select operation mode RUN and

run away from the obstacle.
2. Remove the obstacle or edit the
program.
B. Check that the load and its lever
arm do not exceed the specified
maximum limits.
C. Check that the correct commutator offset is entered for the
axis. If the axis has been repaired
measure and enter the correct
offset.
D 1. Check all fuses.
2. Check the wiring, the drive unit
and the robot computer board.

E. Turn the axis with the system in

the MOTOR OFF mode and check if
resolver fault is indicated.
F. Measure motor data.
G. Check, with the system in the
MOTOR OFF mode that axis
movement is free in its complete
working range.

S3

20

ERROR MESSAGE

15 Error list
RECOMMENDED CORRECTIVE ACTION

CAUSES
Jam error, external axes.

A 1. Select operation mode MOTOR ON

and run the axes away from the
obstacle.
2. Remove the obstacle or edit the
The motor for external axis
7 (1407) -12 (1412) runs slower
program.
than 2 % despite the robot
B 1. Check that any brake is released.
computer commanding a
higher speed.
Cause:
2. Check that a speed reference
A The axis has run
is received from the axis board.
against an obstacle.
If unrepairable, replace the axis
B The axis receives no
board.
torque.
3. Check the external controller,
C Axis not correctly adjusted.
driver, wiring and motor.
C Increase the KP-value for the axis.
The KP-values are defined in the
system parameters.
506 SERVO ERROR 2
1500

Resolver fault, supply

506 SERVO ERROR 2

1601-1612

Too high speed in TESTposition for axis 1 (1601) axis 12 (1612).

The speed protection is
tripped when the programming unit is connected and
out and the key switch not
in position 100 %.
Cause:
A Chain fault related to
an emergency stop.
B External interference on
the robot or the external
axes.
C Low motor torque.
D Incorrectly adjusted
external axes 7-12.

506 SERVO ERROR 2

1701-1707
(Concerns only robots
with tachometer).

Resolver/tacho signal
differs for axis 1 (1701)
- axis 7 (1707).
Cause:
Tachometer signal indicates
another speed than that
calculated from the resolver
signal.

1. Check for any fault by measuring

resistance in wiring and resolver.
(resolver-20ohm)
2. Replace the serial measurement
board or the axis board.

A Correct the primary fault.

B Reduce the effect of external forces
C See "506, SERVO ERROR 2 14011407", item C and D.
D Check that the adjustment of the external axes does not cause any heavy
speed overshoots.

1. If new tachometer has been

installed, check that positive
voltage is obtained if the axis is
turned in a positive direction.
2. Check that the voltage reaches
the axis board.
3. Replace the axis board.

S3

Error List
21

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

506 SERVO ERROR 2

1801-1812

Position error with brake

A,B Check that all axes are in safe
activated for axis 1(1801)
positions for program start or
-12(1812).
synchronizing. If not, run the robot to
One of axes 1-12 moved
a safe position using the programthough the system has
ming unit.
ordered the brakes to be
C Change the brake.
applied.
Cause:
A Manual release of the
brakes and movement
of the axis.
B Abrupt braking, with
the brake, from high
speed, by the Dead
Man's Handle or
a switch-over to MOTER OFFC
Poor brake.

506 SERVO ERROR 2

2001-2024

Resolver error channel x or y A Check for fault by measuring

axes 1(2001)-12(2012)
resistance in wiring and resolver
Coarse resolver,
(resolver-20 ohm)
axes 7(2013)-12(2024)
B Replace the serial measurement
board or the axis board.

506 SERVO ERROR 2

2101-2112

Racing protection at start-up. A 1. Check that the correct commutator offset is entered.
The racing protection for axis 2. If the commutation has been
1(2101)- axis 7(2107) has
changed because of repairs,
tripped as the axis has not
make new measurements.
remained stationary when the
See Installation manual.
RUN status was activated the B 1. If the tachometer is newly infirst time after initialization.
stalled, check that positive
Cause:
voltage is obtained when the
A Incorrect commutation
axis is turned in a positive
direction.
offset
B Faulting tachometer
2. Check that the voltage is
(B concerns only robots
received at the axis board.
with tachometer).
C If the resolver is newly installed,
check turning the axis very slowly
C Faulty resolver
in a positive direction and reading
D Low motor torque
with the help of the programming unit
that the resolver value increases
(when reaching 8191, the value
restarts from 0).
D 1. Check the drive unit.
2. Check the resistances of the
motor windings.

Error List

S3

22

ERROR MESSAGE

15 Error list
RECOMMENDED CORRECTIVE ACTION

CAUSES

Servo lag error for axes 1

(See "error code 1401-1421")
(2101) -12 (2112) when run- (See "error code 1301-1312")
ning in the TEST mode.
Cause:
Major positioning error
because the axis has not
rotated in accordance with
the received position references.
506 SERVO ERROR
2201-2224

Resolver error, channels x

and y. Pine resolver
axes 1(2201) -12(2212)
Coarse resolver,
axes 7(2213) - 12(2224)

A Check for fault by measuring the

resistance of the wiring and the
resolver (resolver~20 ohm).
B Replace the serial or the serial
measurement board or the axis board.

506 SERVO ERROR 2

23XX

Error in the revolution

counter of axis XX. Axes 1-6
are supervised by measurement board 1 and axis 7 by
board 2. All revolution
counters on the measurement
boards are uncalibrated.

Check the measurement system,

especially all resolver and measurement
board connections. Recalibrate the robot
revolution counter. Check the robot
calibration position. If the problem persists, replace the serialmeasurement
board

506 SERVO ERROR 2

240X

To high speed on axis X.

Reduce the speed.

506 SERVO ERROR 2

5104

Check that all parameters

Incorrect input data.
entered are within the
Cause:
Parameters entered are out- limits specified.
side specified limits.

506 SERVO ERROR 2

5105-5111
5120-5123
5130-5136
5137-5138
(The numbers shows where
in the software the stop
occured.)

A External electrical
equipment has jammed
the robot computer or
serial measurement
board.
B Faulty computer board
or serial measurement
board.
C Faulty wiring between
the robot computer
board and the serial
measurement board.

Error List

Re-initiate the system and start-up

again. If the error persists, check
the wiring or replace the computer board
and/or the serial measurement board.

S3

23

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

506 SERVO ERROR 2

5150

Voltage drop from rectifier

506 SERVO ERROR 2

7001

The maximum permissible

Find and correct the earlier error
waiting time for answer to
then re-initialize the system.
the main computer from the If the error persists, change the
axis computer has expired,
robot computer board.
depending on:
An earlier error has caused
the servo computer to halt.
Fault in the robot computer.

506 SERVO ERROR 2

7002

Non-valid channel index.

Communication fault between the diagnostic software and the main computer, caused by a fault in
the control program.

Internal error.
Re-initiate the system.

506 SERVO ERROR 2

7004

Erroneous sync position.

The sync position of the
robot is not correct,
because there are no values
for the sync position in the
robot control program.

Internal error.
Re-initiate the system.

506 SERVO ERROR 2

7005

Fault in internal
calculation routine
in the control program.

Exchange the control program.

506 SERVO ERROR 2

7006

Execution of a program
module in the main
computer starts, before a
valid acknowledge signal
has occurred.

Check the computer board.

If no error is found, change
the control program.

506 SERVO ERROR 2

7007

STALL ALARM.
The main computer has detected that messages from
the axis computer are not
transmitted fast enough.

Check the computer board.

If no error is found, perform a
common error tracing, according
to Chapter 4 in the Service
Manual.

506 SERVO ERROR 2

7008

The servo computer has

detected an undefined
error in:
It's own program.
The main computer
program.

Check the computer board.

Error List

A Check fuses
8 Check that voltage to rectifier

S3
24

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

506 SERVO ERROR 2

7009

Maximal waiting time for

Re-initialize the system,
answer to the main computer
from the servo computer, for
respond on a movement
segment, has been exceeded.

506 SERVO ERROR 2

7010

The servo computer has given Re-initialize the system.

an unallowable error code to the
main computer.

506 SERVO ERROR 2

8001

The servo computer has not

approved an order from the
main computer due to a
serious error in the main
computer.

Re-initiate the system.

If the fault remains, replace
the control program.

506 SERVO ERROR 2

9000

Transmission fault
between the serial
measurement board
and the robot
computer board.
Causes:
A External disturbances
B Wiring fault
C Electronic fault

A Check the installation

B Check and measure the wiring
C Change the serial measurement
board or the robot computer
board.

507 JOYSTICK
ERROR

1 Indicates a fault in the

joystick function.
2 Erroneous coordinate
system button.

If the fault persists, check the

joystick according to the Service Manual.

508 DISK MEMORY

FAULT 1

Error in the floppy

disk memory.

Repeat attempt
Change disk

508 DISK MEMORY

FAULT2

Data stored has disappeared.

Repeat attempt
Change disk

508 DISK MEMORY

FAULT3

Data stored incorrect

Repeat attempt
Change disk

508 DISK MEMORY

FAULT4

A. Floppy disk faulty

B. Floppy disk not
formatted.

A. Repeat attempt
B. Change disk

508 DISK MEMORY

FAULT6

Floppy disk with storage

protection.

Remove storage protection

Change disk

508 DISK MEMORY

FAULT7

Floppy disk unit not

ready.

Insert disk correctly

Close hatch
Change disk

Error List

S3
25

ERROR MESSAGE

CAUSES

15 Error list
RECOMMENDED CORRECTIVE ACTION

508 DISK MEMORY

FAULT8

Erroneous data at
attempt of storing
data on floppy disk.

Try again
Change disk

508 DISK MEMORY

FAULT10

Internal Winchester
fault

Re-initiate the system

508 ERROR IN TEXT

PROGRAM 18

Not possible to load the block

into the reserved memory
area. The block contains
other instructions than
comment instructions or is
corrupt.

Load the block into the user memory and

check the contents. Edit the block or
select a block from the system disk and
try again.

508 TEXT PROGRAM

TOO BIG 18

Not possible to load the block Load the block into the user memory and
into the reserved memory
check the contents. Edit the block or
area. More than 25% of the select a block from the system disk and
block is used.
try again.

508 DISK MEMORY

FAULT20

Attempted loading of
function parameters from
wrong disk.

Change disk

508 DISK MEMORY

FAULT 21

Attempt to program
storage when the
whole floppy disk
is occupied.

Change disk

508 DISK MEMORY

FAULT22

Attempt to load program from an empty

floppy disk.

Replace disk

508 DISK MEMORY

FAULT24

Attempt to load a program block not available

on the floppy disk.

Select another program block

number.
Change disk.

508 DISK MEMORY

FAULT 25

Attempt to add a program

block that is larger than
the user memory.

1. Erase all programs in the user

memory (program numbers 0- 9999).
2. Load required program block, with the
function ADDALL under the
MANUAL menu.
If this does not work, split the program
block into two parts at the robot, where
the block was originally programmed.

Error List

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26

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

508 DISK MEMORY

FAULT26

An attempt has been made

to add a program block
as the space available
in the user memory is
insufficient.

1. Erase any superfluous programs

in the user memory.
2. Store the remaining part of the
program block as block X.
3. Load the program block containing the
required program.
4. Erase all unwanted programs.
5. Add block X with the function
ADDALL.
If this is not successful, use the
instruction GET B in the program for
alternate running of program blocks X
andN.

508 DISK MEMORY

FAULT 27

Error in the stored

program block.

Select another block number.

Change disk.

508 DISK MEMORY

FAULT 28

Fault when formatting

floppy disk.

Change disk
Try again

508 DISK MEMORY

FAULT29

Attempt to load a nonexisting subprogram from

floppy disk.

Select another block number.

* Select another program number.

508 DISK MEMORY

FAULT30

Floppy disk function is

faulty.

Re-initiate the system.

508 DISK MEMORY

FAULT31
(for arc welding
robots only)

Weld data missing for

the program block
concerned.

Select another block number

Change disc.

508 DISK MEMORY

FAULT 32
(for arc welding
robots only)

Incorrect version of
weld data.

Select disc with right weld data

version.

509 SYNC ERROR

Error when the robot

system is to be
synchronized.

If repeated attempts are not

successful, perform a commo
error tracing, according to
Chapter 4 in the Service Manual.

Error List

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27

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

509 SYNCHRONIZATION ERROR 10XX

Robot axis XX is outside its

outside the working range
Error has occurred in the
control system, axis XX.

Move the axis manuell or with the

joystick after pressing RESYNK
(AUTO+SCAN+SCAN) into the
work, range. Switch power off
and the on.
If the problem persists, it might be
caused by DSQC 234, see the Service
Manual.
Check the robot calibration position before returning the robot to production!

509 SYNCHRONIZATION ERROR 11XX

Working range defined for

external axis no. XX is too
great with the gear ratio
in use.

509 SYNCHRONIZATION ERROR 14XX

Resolver on axis no. XX

not calibrated.

509
SYNCHRONIZATION ERROR 15XX

Resolver error.
Check the measurement system.
Axis no. XX has obtained an
impermissible resolver
value with absolute measurement.

509 SYNCHRONIZATION ERROR 16

System fault in absolute

measurement system.

See instructions in Service

Manual for checking the
robot system.

509 SYNCHRONIZATION ERROR 17

The robot is too far

away to restart.
The robot program running
can not be restarted directly.

Start-up the system the conventional

way. Check the robot calibration
position before returning the robot to
production!

509 SYNCHRONIZATION ERROR 20xx

(concerns only robots in
the 8000-serie).

Robot axis xx is outside

the working area.

Manoeuvre the axis into the

workingarea and switch off
the system. Try once more.

509 SYNCHRONIZATION ERROR 21XX

The revolution counter

for axis XX not calibrated.

Check measurements system, battery.

Battery voltage should exceed 7.0V.

509 SYNCHRONIZATION ERROR 22XX

Error on the revolution

counter on axis XX. The
revolution counter has lost
its value.

Check the measurement

system. The robot remains
unsynchronized. Operation
mode is blocked until the
error is remedied.

Error List

Redefine the working range under

PARAM or check that the correct
resolver configuration has been
selected.

S3
28

ERROR MESSAGE

CAUSES

15 Error list
RECOMMENDED CORRECTIVE ACTION

509 SYNCHRONIZATION ERROR 23XX

Error on the revolution

counter on axis XX. The
expected revolution counter
value does NOT correspond
to that of the serialmeasurementboard revolution.
counter.

Check the measurement system,

especially all resolver and measurement
board connections. Recalibrate the robot
revolution counter. Check the robot
calibration position. If the problem
persists, replace the serialmeasurement
board.

510 SYSTEM
FAULT3

Internal fault in the

control program module
in programmed robot
running.

Switch-off and start-up

the robot system once again.
If the fault persists exchange
the control program.

510 SYSTEM
FAULT4

A. The internal restart

was interrupted
undefined.
B. Power failure in an
instruction that can't
be restarted.

A,B Switch off the system and start

in the conventional way.

510 SYSTEM
FAULT5

Restart data in
memory is wrong.

Re-initiate the system.

510 SYSTEM
FAULTS

An error has occurred in the

error buffer. All old messages
have been erased.

510 SYSTEM
FAULT7

An unwanted jump in the

program may have occured.

Internal error.
Check active instruction before
resume program execution.

S3

Error List
29

15
Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

513 WRONGLY PLACED

I/O BOARD X
(X=subcode which
defines the board
position concerned)

A Board missing on
position X.
B The board on position X does not correspond to the boardtype specified in the
system parameters
(specified manually
for subcode 1-6).
C The board on position
X erroneous.

A Place a board on position X (or

change the system parameter
for subcode 1-6).
B Place the correct type of board (or
change the system parameter for
subcode 1-6).
C Check the board.

The board positions in question

are coded for the board type,
that is specified in the system
parameters (manual specifications for the 6 I/O positions).
The board positions are coded
in accordance with the following:
Subcode
0
1
2
3
4
5
6

Type ace to param

Safety board
I/O board, position 1
I/O board, position 2
I/O board, position 3
I/O board, position 4
I/O board, position 5
I/O board, position 6

514 COMMUNICATION
ERROR 1
(apply only to robots
equipped with computer
link)

Insufficient space in the

robot buffer memory for
data from superior computer.

Restart the robot system.

514 COMMUNICATION
ERROR 2
(apply only to robots
equipped with
computer link)

Data fault in message

received from superior
computer.

Check superior computer.

514 COMMUNICATION
Transmission error on
the data link.
ERROR 3
(apply only to robots equipped
with computer link)

Repeat the attempt.

514 COMMUNICATION
ERROR4
(apply only to robots
equipped with
computer link)

Erase any superfluous program

in the robot memory.

Insufficient space in
the robot memory when
attempting to load a
program from a superior
computer

S3

Error List
30

ERROR MESSAGE

15 Error list
RECOMMENDED CORRECTIVE ACTION

CAUSES

514 COMMUNICATION
Program with program
number selected not in
ERRORS
(apply only to robots equipped the robot memory.
with computer link)

Select a program with

another program number.

514 COMMUNICATION
ERROR 6
(apply only to robots
equipped with
computer link)

Maximum waiting time

before acknowledgment
from superior computer
exceeded.

Check superior computer.

514 COMMUNICATION
ERROR8
(For robots with
computer link only)

Computer link not

implemented.

Check that function parameter

C LINK is set (See Inst. manual).

514 COMMUNICATION
ERROR 9
(For robots with
computer link only)

Fault in vision system.

Restart the vision system. If the fault

persists, check the connection or
contact service personnel.

514 COMMUNICATION
ERROR 10
(For robots with
computer link only)

Vision timeout.

Restart the vision system. If the error

persists, check the connection or
contact service personnel.

514 COMMUNICATION
ERROR 11
(For robots with
computer link only)

Incorrect robot mode.

Turn MOTORS OFF.

514 COMMUNICATION
ERROR 12
(For robots with
computer link only)

Insufficient space in robot

memory when an attempt is
made to load configuration
data.

Check that the block to be loaded is

intended for the robot in question.

514 COMMUNICATION
ERROR 13
(For robots with
computer link only)

Incorrect check sum in configuration data loaded.

Robot system initialized
with configuration data
from PROM.

Make another attempt to load the

configuration data.

514 COMMUNICATION
ERROR 14
(For robots with
computer link only)

Incorrect weld data version.

Configurate to right weld data

version on superior computer.

Error List

S3
31

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

515 TIMEOUT ERROR

(only arc welding robots)

When programming the arc- Check the external equipment,

welding instruction EXTPOS,
the response from the external equipment is not received before the maximum
permissible waiting time has
been exceeded.

516 OVERRIDE ERROR 1

(only arc welding
robots)

Override has been deA.

Wait until welding is performed.
fined as:
B.Try again.
A. Welding is not performed.
B.The welding data
number has been changed.

516 OVERRIDE ERROR 2

(only arc welding
robots)

The limit values for

override definition has
been exceeded.

Store the values and keep

defining override values.

517 WELD ERROR 1010

(only arc welding
robots)

The current supervision

has detected that current
has disappeared for longer
then 500 ms.

Check the thread feeder and

current supply.

517 WELD ERROR 1020

(only arc welding
robots)

The gas/coolant supervision Check the gas flow and

has detected that gas/coolant coolant flow.
is missing.

517 WELD ERROR 2010

(only arc welding
robots)

The welding arc has not

been lighted before the
indicated time from
welding start order.

517 WELD ERROR 2020

(only arc welding
robots)

Gas and coolant flow received Check gas flow and coolant flow,
has not been started before
2 seconds after the robot
has moved to the position
for welding start

518 RIO COMMUNICATION ERROR 1

No communication with
host processor (PLC).

Check hardware.

518 RIO COMMUNICATION ERROR 2

Bad communication with

host processor.

Check hardware.

518 RIO COMMUNICATION ERROR 3

Na-chip on RIO board is out

of function.

Check hardware.

523 ERROR STATION

DRIVE UNIT 1
(only arc welding
robots)

At power-on the activation

of manipulator 1 failed
(max. allowed waiting time
for acknowledgment signal from manipulator
3 seconds exceeded).

Try again. If repeated attempts

are not successful, see
Service Manual.

Error List

Check thread feeder and

current supply.
Change the maximum time
in the start data.

S3

32

15

Error list

ERROR MESSAGE

CAUSES

RECOMMENDED CORRECTIVE ACTION

523 ERROR STATION

DRIVE UNIT 2
(only arc welding robots)

The robot moved when

activation/deactivation
of a station was requested.

Stop the robot and repeat

the attempt.

523 ERROR STATION

DRIVE UNIT 3
(only arc welding
robots)

An input indicates that the Check that the station connection

drive units of a station have is in accordance with the function
been activated, in spite of the parameter STATION. In that case
fact that no such order has
check the external equipment,
been given on the output.

523 ERROR STATION

DRIVE UNIT 4
(only arc welding
robots)

An input indicates that the

drive units of a station have
been deactivated, in spite of
the fact that no such order
has been given on the output.

Check the cables and that

the station connection is in
accordance with the function parameter STATION. In
that case check the external
equipment.

523 ERROR STATION

DRIVE UNITS
(only arc welding
robots)

An output for activating a

STATION is set, but no
answer from corresponding
input has been given within
5 sec.

Check the the connections from

ORBIT to the robot control
system.

523 ERROR STATION

DRIVE UNIT 6
(only arc welding
robots)

Signals for activation to

STATIONS have been reset
at an earlier stop. These
signals have automatically
been set high again.

Check that the connected stations

are relevantJf that is the case,
restart the program again,
otherwise connect the STATIONS
in question.

524 OUTSIDE WORKING

AREA7-12

External axis is outside

working area.

Modify the program.

536 ENABLING DEVICE

FAULT 1
536 DMH FAULT 1 (only
IRB 1500)

A The enabeling device

has been held in an
intermediate position
B A fault in the contacts of
the enabeling device.

Press the enabeling device

again. If the fault remains,
check the contacts under the
enabeling device.

536 SPEED SUPERVISION FAULT 5

The key switches position

and reported status of the
servo computer's SPEED
signal do not coincide.

Examine the SPEED signal status

on the back panel between the
safety board and the robot
computer board.

536 RUN RELAY FAULT

13

Control signal and check

signal to/from the operation
contactor do not coincide.

Check the operation contactor

and the cabling.

Error List

S3

33

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

536 ENABLE CHAIN

FAULT 21

The ENABLE chain has

been broken as a result of
one of the following fault:
A Drive unit/fatal fault
B Rectifier/fatal fault
C Measurement system/
fatal or nonfatal fault

Check the LED on the front

of the safety board.
A The LED is lit:(nonfatal fault)
The occurred fault is automaticly reset. The enable
chain is closed after a few
seconds. The system can be
in operation mode again.
B The LED is put out:(fatal fault)
The occurred fault has to be
manually reset. The enable
can only be reset by an
system initiation.Search for
the cause to the fault and
remedy it. Do a system initiation.

536 SAFETY HAZARD

33

Fault in the safety board

Replace the safety board.
indicated via the supervision for the ENABLE loop.

536 SAFETY HAZARD

34

An attempt has been made

to start-up the system with
undefined commutating
offset.

Define the commutating offset.

536 RUN BUTTON

FAULT35

The run button has been

pressed for 30 seconds.

Check and if needed remedy

the run button or the cabling.

536 KEY STATUS

FAULT36

The position/status of the

key is incorrect updated e.i.
because of two key turns
in a raw, when the system
was in operation or the run
chain was broken.

Change the position of the key

or re-initiate the system

536 MOTOR OVERLOAD FAULT 101-107

Overload in motor 1-7.

Certain models: No axes
number is stated.

Re-start the system.

Check wiring
Reduce duty cycle

538 AUTO MODE STOP

538 WORK STOP 1

One or several work stop

switchers connected to the
system have been activated.

Check for the cause to the

stop and remedy any possible
problem in the system.
Then reset the activated
switchers.

S3

Error List
34

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

538 GENERAL MODE

STOP 2
538 SAFETY STOP 2

One or several safety stop

switchers connected to the
system have been activated.

Check for the cause to the

stop and remedy any possible
problem in the system.
Then reset the activated switchers.
If the stop can not be reset:
Check the clamps that are
not used by the safely circuits.
Check the safety board.
Perform a common error tracing
according to the Service manual.

539 INTERNAL RECTIFIER POWER FAULT

1

No power from the internal

rectifier.

Check if possible clamps on

not used internal rectifier.
Check and if needed remedy
rectifier and cabling.

539 EXTERNAL RECTIFIER POWER FAULT

2

The signal POWER OK

is missing.

Check connection for POWER OK

Check and if needed remedy
rectifier and cabling.

Check and if needed remedy

539 WARNING/ RECAt least one phase in the
T1F1ER PHASE MISSING 3 power supply to the rectifier. fuses and cabling.
540 BRAKES RELAY
FAULT

System error which means

that the brakes are not
released normally.

542 MOTORTYPE
NOT DEFINED

Define motortype according to the

Attempt has been made to
take the system in operation Installation manual S3.
without that the motortype
has been defined.

544 WARNING NEW

RESOLVER DATA
LOADED

The system has discovered

a difference between the new
new resolver values, and
the resolver values already in
the parameter memory.

547 HYDRAULIC
PRESSURE ERROR 1
(ROBOTS IN THE
8000 SERIES)

Faulty pressure in the Z axis Check the pressure unit.

pressure unit.

548 ERROR IN
RUN CHAIN 2

Run chain 1 is correct but

Check the run chains.
run chain 2 indicates a fault

Error List

Examine the connections to the

robot brakes and locate the break
in the connection.

Choose if the system is to be started

on the new or old resolver data.
(Remaining system parameters
according to earlier executed
operation). Check that the robot
has the right system parameters
after re-start.

S3

35

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

550 WELD ERROR 1

WELD READY not reset

when START 1 or START 2
is activated.

550 WELD ERROR 2

WELD READY not received Check the welding controller,

within 20 s after START 1 or
START 2 has been activated.

Check the welding controller,

551 WELD ERROR TIMER Signal TIMER OK is missing. Check the welding controller.

552 W E L D E R R O R
CURRENT

Signal CURRENT OK is
missing.

553 W E L D ERROR FLOW

Signal FLOW OK is missing Check the cooling water

for more than 5 sec.
supply.

554 WELD ERROR TEMP

Signal TEMP OK is missing. Check the welding controller.

555 WELD ERROR

ENABLE MOVE

The system has been waiting Check the welding gun and
for signal ENABLE MOVE sensors,
more than 5 sec. upon gun
opening.

560 ERROR/ROBOT
COMPUTER BOARD

A robot computer board com- See subcode in chapter 5.

ponent is malfunctioning. See
chapter 5 for further information.

562 ERROR/ROBOT
DRIVE UNIT:

Erroneous signals from drive See subcode in chapter 5.

unit after start-up. See
chapter 5 for further information.

563 ERROR/DRIVE
UNTTOFFSx

Drive unit exceeds limit

values when compensating
for offset. See chapter 5 for
further information.
Subcode x:
1
2
3
4
5
6
7

567 ERROR/SYSTEM
BOARD:

Error List

Check the welding controller.

Check the drive unit connection.

If all connections are correct, replace
the drive unit.
If this doesn't work, change the
robot computer board.

Unit:
Drive unit 1
Drive unit 2
Drive unit 3
Drive unit 4
Drive unit 5
Drive unit 6
Drive unit 7

Data from the safety board

See subcode in chapter 5.
is incorrect See chapter 5 for
further information.

S3

36

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

570 ERROR/MEASURE
SYSTEM, AXES 1-6:

The measurement system

diagnostics has discovered
an error. See chapter 5 for
further information.

See subcode in chapter 5.

571 ERROR/MEASURE
SYSTEM, AXES 7:

The measurement system

diagnostics has discovered
an error. See chapter 5 for
further information.

See subcode in chapter 5.

572 ERROR/MEASURE
SYSTEM, AXES 8-12 xxxx

The measurement system

diagnostics has discovered
an error. See chapter 5 for
further information.

See subcode in chapter 5.

573 ERROR/MEASURE
SYSTEM, AXES 7-12 xxxx

The measurement system

diagnostics has discovered
an error. See chapter 5 for
further information.

See subcode in chapter 5.

580 WARNING DISK

Error when starting disk.

See chapter 5 for further
information.

See subcode in chapter 5.

581 WARNING COMPUTER Error when starting comLJNE zxzz

puter link. See chapter 5
for further information.

See subcode in chapter 5.

582 WARNING PRINTER

Error when starting printer. See subcode in chapter 5.

See chapter 5 for further
information.

583 WARNING SENSOR

xxzx

Error when testing the main See subcode in chapter 5.

computer serial links. See
chapter 5 for further
information.

585 WARNING PROG

UNTTxxxx

Error when starting the

programming unit. See
chapter 5 for further
information.

586 WARNING MONITOR

Error when starting monitor. See subcode in chapter 5.

See chapter 5 for further
information.
Error when starting the
See subcode in chapter 5.
Winchester memory. See
chapter 5 for further
information.

588 WARNING
WINCHESTER

See subcode in chapter 5.

S3

Error List
37

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

589 RECTIFIER
MISSING

The configuration check of

Check that:
the rectifier indicates type
rectifier is connected correctly
code 0, that means no rectifier
connected.

590 RECTIFIER WRONG

TYPE

Wrong type of rectifier.

591 DRIVE SYSTEM

ERROR

The drive system has

Re-initiate the system.
indicated error, but no
error status is placed in
either rectifier or drive unit.

592 RECTIFIER OUTPUT VOLTAGE HIGH

The voltage from the rectifier Change rectifier,

is too high.

593 RECTIFIER TEMP.

HIGH

The rectifier unit is is

overloaded.

Check if the surrounding

temperature is too high.
Reduce the intermittence
during the run mode.

594 SHUNT RESISTANCE

TEMP. HIGH

The return supply power

from the robot motors is
too high. Too high surroundings temperature and too
high input voltage to the
rectifier can also cause
too high temperature.

Check the input voltage

to the rectifier.
Check the surroundings
temperature around the
control cabinet.
Reduce the intermittence
during run mode.

595 DRIVE UNIT

MISSING 1-7

The configuration check

of the drive unit for the axis
in question, indicates type
0, that means no dive
unit connected.

Check if t he drive unit on

the axis in question is in the
right position. Check the flat
cable between drive unit and
computer.

596 DRIVE UNIT WRONG

TYPEX

The drive units on the axis Check the type of drive units on
X in question are of the wrong the axis in question, and change
type.
to the right type.

597 DRIVE UNIT

CURRENT HIGH X

The drive unit for the axis

X in question has gone into
the over current limit.

Error List

Check the rectifier with respect

to robot type and change to the
right type.

Check that the cabling out of

the drive units or the motor
winding is short-circuit.
Check that the out-put on
the drive unit isn't shortcircuit.

S3

38

15 Error list
RECOMMENDED CORRECTIVE ACTION

ERROR MESSAGE

CAUSES

598 DRIVE UNIT

CURRENT ERROR X

The current out from

the drive unit for the axis
X in question do not correspond to the ordered value.

599 DRIVE UNIT TEMP.

HIGHX

The temperature on the

Check:
out-put level on the drive* if the robotaxis for the axis in
unit in question for the axis
question do not work slowly
X in question has exceeded. * the commutation offset
* that the surroundings temp,
The axis number can in some around the control cabinet
systems not be displayed.
is below the max. allowed
Reduce the intermittence
during run mode.

602 VISION
SYSTEM ERROR

The hardware for VISION

is not available.

Otherwise see separate

documentation for VISION.

700 WARNING NEW

RESOLVER DATA
LOADED

The system has detected a

difference between down
loaded resolver data and
data that earlier was in the
parameter memory.

Choose if the system shall start

with new or old resolver data.
(Other systemparam. ace. to
previous operation).
After start check that the robot
has correct system parameters.

Error list

Check that the cables out from

the drive unit in question are
unbroken. Probable error cause
is interruption in one of the cables
or the motor winding.

S3
39

15

Error list

5
Diagnostic messages
Diagnostic error concerns the fault- and warning message the system discovers when testing
the hard ware during the start-up sequence.
Depending on the type of malfunction, two types of message may be displayed: error message
or warning message.
Error message:
When this type of message is displayed on the programming unit, the system is always
interrupted and put in an error mode. If the malfunction occurs during start-up, this is
interrupted.
Warning message:
The printout is given after a malfunction has been detected in any of the units, but the
malfunction is not serious enough to interrupt the system.
Normally, all message printouts are displayed on the programming unit display, but during
the diagnostic test at start-up, no text can be displayed during certain periods of time. The
error codes may then be displayed by the error LED on the computer board front. See chapter
6 for a detailed description.
Error and warning messages using a subcode:
560 ERROR/ROBOT COMPUTER BOARD xxxx
562 ERROR/DRIVE UNIT xxxx
567 ERROR/SAFETY BOARD xxxx
570 ERROR/MEASUREMENT SYSTEM, AXES 1-6 xxxx
571 ERROR/MEASUREMENT SYSTEM, AXIS 7 xxxx
572 ERROR/MEASUREMENT SYSTEM, AXES 8-12 xxxx
573 ERROR/MEASUREMENT SYSTEM, AXES 7-12 xxxx
580 WARNING DISK xxxx
581 WARNING COMPUTER LINK xxxx
582 WARNING PRINTER xxxx
583 WARNING SENSOR xxxx
585 WARNING PROGRAMMING UNIT xxxx
586 WARNING MONITOR xxxx
588 WARNING WINCHESTER xxxx
for which xxxx represents one of the following subcodes, more thoroughly describing the cause
of the message.
The following is the list of the subcodes which may be displayed along with an error or
warning message.

Error List

S3
40

SUBCODE

CAUSE

15
Error list
RECOMMENDED CORRECTIVE
ACTION

0001

Error at main computer

instruction test

Replace the robot computer board

0002

PROM checksum error

a Replace the EPROM

b Replace the robot computer board

0003

RWM error

0004

Code downloading error

0008

Main computer error when

handling not allowed command

Replace the robot computer board

0009

Error in test 1 of communication

between I/O and main computers

Replace the robot computer board

0010

Error in test 2 of communication

between I/O and main computers

Replace the robot computer board

0011

Error at ending of I/O computer first test sections

Replace the robot computer board

0013

Error when testing the main

computer sensors, serial channels

Replace the robot computer board

0014

Error when testing the

enable chain

0017

Error when starting the I/O

computer later test sections

0018

Error in test 1 of communication

between servo and main computei

0019

Error in test 2 of communication between servo and

main computers

Replace the robot computer board

Replace the robot computer board

a Replace the robot computer board

b Replace voltage supply unit DSQC 241
c Replace the computer rack rear plane
Replace the robot computer board
Replace the robot computer board
Replace the robot computer board

0039

Servo computer communication ei

0040

Error when starting the servo

computer later test sections

Replace the robot computer board

0070

Error when testing the main computer serial channel. Out = low,
In = high

Is used at manufacturing check of

robot computer board

0071

Error when testing the main computer serial channel. Out = low,
In = high

Is used at manufacturing check of

robot computer board

S3

Error List
41

15
ERROR MESSAGE

Error list

RECOMMENDED CORRECTIVE ACTION

CAUSES

0072

Error when testing the main com

puter serial channel A

Is used at manufacturing check of

robot computer board

0075

Error when testing the I/O computer serial channel A, computer

link

Is used at manufacturing check of

robot computer board

0076

Error when testing the I/O computer serial channel B, printer

Is used at manufacturing check of

robot computer board

0080

Error when testing the I/O bus

Is used at manufacturing check of

robot computer board

0081

Erroneous data from the I/O bus

Is used at manufacturing check of

robot computer board

0101

Error at I/O computer

instruction test

Replace the robot computer board

0102

PROM checksum error, I/O computer

a Replace the EPROM

b Replace the robot computer board

0105

Erroneous I/O computer "stall timer" Replace the robot computer board

0106

Erroneous I/O computer" time out

timer"

Replace the robot computer board

0107

Erroneous I/O computer" interval

timer"

Replace the robot computer board

0108

I/O computer error when

handling not allowed command

Replace the robot computer board

0109

Error in communication between

I/O and main computers

Replace the robot computer board

0112

Internal diagnostics error in

I/O computer

Replace the robot computer board

0114

Error when testing the

enable chain

a Replace the robot computer board

b Replace voltage supply unit DSQC 241
c Replace the computer rack rear plane

0116

Error when initiating the

I/O computer

Replace the robot computer board

0120

Error when testing printer output

Replace the robot computer board if

printer is to be used

0121

Error when testing computer link

Replace the robot computer board if

computer link is to be used

Error List

S3
42

0122

Error when testing disk

15 Error list
RECOMMENDED CORRECTIVE ACTION
a Check main cabling
b Replace mass memory
c Replace the robot computer board

0124

Error when testing the

safety board

a Check that 24 V I/O is there.

b Replace the safety board DSQC 228

0125

Error when testing the

Winchester memory

a Check main cabling

b Check that the massmemory gets
12 V.
c Replace the massmemory.
d Replace the robot computer board

0130

Robot computer board pd bus error

Replace the robot computer board

0131

Error when testing the programming a Perform a restart

unit
b Check main cabling especially
the 24 V supply.
c Replace the programming unit

0133

Error when testing the monitor

a Check main cabling

b Replace monitor
c Check system parameters

0134

Non standard programming unit

a Perform a restart
b Check main cabling
c Replace the programming unit

0138

Not allowed I/O computer interruption

Replace the robot computer board

0139

I/O computer not responding

Replace the robot computer board

0140

Computer bus error, I/O computer

Replace the robot computer board

0201

Error at servo computer

instruction tes t

Replace the robot computer board

0202

PROM checksum error, servo computer

a Replace the EPROM

b Replace the robot computer board

0205

Erroneous servo computer "stall

timer"

Replace the robot computer board

0206

Erroneous servo computer " time out Replace the robot computer board
timer"

0207

Erroneous I/O computer" interval

timer"

Replace the robot computer board

0208

I/O computer error when

handling not allowed command

Replace the robot computer board

ERROR MESSAGE

CAUSES

S3

Error List
43

ERROR MESSAGE

15 Error list
RECOMMENDED CORRECTIVE ACTION

CAUSES

0209

Error in communication between

servo and main computers

Replace the robot computer board

0210

Error at ending of servo computer first test sections

Replace the robot computer board

0211

Error at ending of servo computer last test sections

Replace the robot computer board

0216

Servo computer initiation error

Replace the robot computer board

0239

Servo computer not responding

Replace the robot computer board

0240

Data bus error, servo computer

Replace the robot computer board

0302

Checksum error, axis computer

sin-arctan table

Replace the robot computer board

0315

Error when loading test program

to the axis computer

Replace the robot computer board

0358

Start-up error, axis computer

Replace the robot computer board

0701

Status bit error, FAULTRES-N,

of the drive system

Replace the robot computer board

0702

Address bit error, SA0-SA5,

of the drive system

Replace the robot computer board

0722

Status POWER UP-N erroneous

from drive system after reset.

a Replace rectifier
b Check flat cable between robot
computer board and drive system,
c Replace the robot computer,
d Replace drive unit rack

0723

Signal RUNNING erroneous

from drive system after reset.

a Replace rectifier
b Check flat cable between robot
computer board and drive system,
c Replace the robot computer
d Replace drive unit rack

0724

Status AC-N erroneous

from drive system after reset.

a Replace rectifier
b Check flat cable between robot
computer board and drive system,
c Replace the robot computer,
d Replace drive unit rack

0731

Signal FAULT-N erroneous

Is used at manufacturing check of

robot computer board

Error List

S3
44

ERROR MESSAGE

15 Error list
RECOMMENDED CORRECTIVE ACTION

CAUSES

0732

Signal RUNNING erroneous

Is used at manufacturing check of

robot computer board

0733

Read data error, R3 SDO

Is used at manufacturing check of

robot computer board

0734

Read data error, R3 SD1

Is used at manufacturing check of

robot computer board

0741

Axis computer does not respond at

drive unit test

Replace the robot computer board

0742

Too large AD converter offset error

a Replace the robot computer board

0743

Too large AD converter offset error

a Replace the robot computer board

0744

Too large offset error on any drive

unit channel

a Replace the robot computer board

b Replace the drive unit

0751

The axis computer does respond at

offset compensation, drive units

Replace the robot computer board

0900

The axis computer does respond at

first contact to the measurement
system of the specified axes

a Perform a restart
b Install the missing equipment
c Check cabling between measurement
system and robot couputer.
d Replace measurement board DSQC 234
or axis board DSQC 233.
e Replace the robot computer board

0902

Communication error to
measurement system.

a Replace serialmeasurement board.

b Replace the robot computer board

0903

Not allowed offset error on the Xchannel of measurement system.

Replace serialmeasurement board.

0904

Not allowed offset error on the Xchannel of measurement system.

Replace serialmeasurement board.

0905

Too large difference between X and Replace serialmeasurement board.

Y channels of measurement system.

0906

Disruption in cabling, the loop is

closed without passing measurement
board no 2.
Linearity error on the X channel
of measurement system.
(X ramp does not increase)

A Do a restart.
B Install missing equipment
C Check the cabling between
the measurement board and
the robot computer.
D Exchange the identified
serialmeasurement board.
E Exchange robotcomputer board.

S3

Error List
45

ERROR MESSAGE

15 Error list
RECOMMENDED CORRECTIVE ACTION

CAUSES

0907

Linearity error on the Y channel

of measurement system.
(Y ramp does not increase)

Replace serialmeasurement board.

0920

Communication error to
measurement system DSQC 233

a Replace measurement board DSQC 233

b Replace the robot computer board

0921

Offset error on AD converter to

measurement system DSQC 233

Replace measurement board DSQC 233

0922

Offset error on DA converter, ch. 1

to measurement system DSQC 233

Replace measurement board DSQC 233

0923

Offset error on DA converter, ch. 2

to measurement system DSQC 233

Replace measurement board DSQC 233

0924

Offset error on DA converter, ch. 3

to measurement system DSQC 233

Replace measurement board DSQC 233

0925

Offset error on DA converter, ch. 4

to measurement system DSQC 233

Replace measurement board DSQC 233

0926

Offset error on DA converter, ch. 5

to measurement system DSQC 233

Replace measurement board DSQC 233

0927

Offset error on DA converter, ch. 6

to measurement system DSQC 233

Replace measurement board DSQC 233

0928

Linearity error, ch. 1 of

measurement system DSQC 233

Replace measurement board DSQC 233

0929

Linearity error, ch. 2,4, 6 of

measurement system DSQC 233

Replace measurement board DSQC 233

0930

Linearity error, ch. 3 and 5 of

measurement system DSQC 233

Replace measurement board DSQC 233

0960

Error at "local ring controller

loopback"

Replace the robot computer board

0961

Error at "ring controller

loopback"

Is used at manufacturing check of

robot computer board

0962

Error at "ring controller

loopback"

Is used at manufacturing check of

robot computer board

Error List

S3
46

15

Error list

6
Test mode errors
To enable performing tests in the test mode, the key switch must be set in either position
TEACH or position TEST V=100% when the robot is in its normal initiated mode.
Then, the robot is to be initiated in the test mode by pressing both push buttons on the
computer board front, and then letting the initiation button up a couple of seconds before
letting up the test button.
If an error is discovered during start-up diagnostics in the test mode, the subcode of the error
message will not only be displayed on the programming unit but also on the robot computer
board error lamp.
This enables obtaining an error code in cases where the error message is not displayed on the
programming unit. The displayed subcode is one of the subcodes explained in section 5.
To obtain an subcode from a faulty system, the operator must perform an initiation to enter
the test mode which. This is described above. During this restart, the diagnostic system will
perform the same tests once more, and the error will be rediscovered.
The error lamp on the robot computer board front will blink repeatedly to indicate the error
subcode in accordance with the following description. The blinking of the error lamp will be
repeated until the system is reinitiated.
E.g. error code
560 ERROR/ROBOT COMPUTER BOARD
302
Robot
computer
board front
DSQC230

0... ..9 blinks

FAULT lamp

IS LIT

O
o
O

ENABLE

f^*
FAULT
TEST

IS NOT LIT
INIT
1

10

I2H11112
1 II 1II 1

2.2.

2AU2
11 I I

time, seconds

S3

Error List
47

15

Error list

Test of board DSQC 233, axis board:

The error printouts available are the same as for a normal start-up according to sections 4 and
5.
570 ERROR/MEASUREMENT SYSTEM AXES 1-6 xxxx
571 ERROR/MEASUREMENT SYSTEM AXIS 7 xxxx
572 ERROR/MEASUREMENT SYSTEM AXES 8-12 xxxx
573 ERROR/MEASUREMENT SYSTEM AXES 7-12 xxxx
(xxxx = sub codes)

Test of board DSQC 236, drive unit:

The error code parameter XX indicates output/input in accordance with the table below:
XX

Function

XX

Function

01
03

Enable loop error

Test sequence error

02
04

Type code error

Axis computer does not respond

05

Drive unit missing

Test of board DSQC 209, analog in/output board:

The error printout parameter XX indicates the output/input in accordance to the table below:
XX
0
2
4

Function
Board absent
CH2
CH4

XX
1
3

Function
CHI
CH3

Test of board DSQC 223 , digital in/output board:

The error printout parameter XX indicates the output/input in accordance to the table below:
XX

Function

XX

Function

0
2
4
6
8
10
12
14
16

Board absent
CH2
CH4
CH6
CH8
CH10
CH12
CH14
CH16

1
3
5
7
9
11
13
15

CHI
CH3
CH5
CH7
CH9
CH11
CH13
CH15

Error List

S3
48

15
Test of board DSQC 224, combined digital and analog in/output board:

Error list

The error printout parameter XX indicates the output/input in accordance to the table below:
XX

Function

XX

Function

0
2
4
6
8
10
12
14
16

Board absent
CH2
CH4
CH6
CH8
CH10
CH12
CH14
CH16

1
3
5
7
9
11
13
15

CHI
CH3
CH5
CH7
CH9
CH11
CH13
CH15

21

Analog CHI

22

Analog CH 2

Error List

S3
49

15

Error List

Error list

S3
50

16 Index

Keyword

Chapter, section

Absolute measurement
Acceleration index calculation
Adaptivity
Adaptivity sensor interface
Additional system I/O at I/O MAP
ALIGN Fool, externel axis, home pos)
Analog ports
Arc welding
ARG, modify an argument
AUTO DEF, manual tool
AUTO mode
AUTO, automatic search
Automatic (menu)
Automatic restart
Autosearch (AW)
Arc weldning
Arc weldning,system principles
Arc weldning, program structure
Arc weldning of rear axis member
AW REST, Arcweld Restart

4.2
11.8.3.1
10
10.1
4.12.3
7.7
4.11.2
12
8.5
9.4
2.3
6.4.3, 10.3.3
7
4.2.3
6.4.3,10.3.3.3
12
12.2
12.3
11.6.1
7.8

BASE, aligne base

Base point
BASEP, Basepoint active
BASEP, definition
BLOCK, from/to RAM
BWD, backward execution

7.7
3.3.1.1
3.2.4.5
9.5
9.2.2
7.1-4

CALL a sub-program
Change of operation mode
CHANGE, manual tool
CIRCEL
Circuit breaker
CLEAN, welding
CLEAR
Close-down
Closely spaced positions
COM
Commands from robot
Commands to robot
Common functions
Compability with earlier programs
Computer link
CONTOUR, contour tracing
Connection and definition of sensors
Control cabinet
Control panel
Coordinate systems

5.6
2.3.4
9.4
3.7,6.13
2.2
10.2.4.1, 10.2.5.2
9.1
4.1.1,4.1.3
11.5.7
5.13
4.8.3
4.8.2
12.6.4
11.5.2
2.9, 4.8
6.8, 10.5
10.2
2.1
2.3
3.2, 5.11. 11.7.3.1

Programming

S3

16 Index

Keyword

Chapter, section

Coordinate systems for defining positions

Coordinate systems in program execution
Coordinate systems for manual movements
COPY INS
COPY, external axes
COPY, program
COORD
CORNER 1, 2 (ZONE)
COR VEC, adaptive function
Corner talking
Cornering devitations
Correction vector
CORV ST, adaptive correction
Cutting and debuning of plastic, forming of
holes using the CIRCLE function
Cutting and debuning of plastic lining
for a car door

3.2.1
3.2.2
3.2.3
8.16
8.5.4
8.10
5.11
6.3
6.9, 10.6
3.6, 11.5.6
3.6.1.4
6.9, 10.5
7.6

Delay of outputs
Definition of ARM load parameters
Define a position with PATH zone
Defining of WRIST load.
Devitations
DHANDCHK
Diagnostic messages
Dialog via prog.unit
Digital ports
DIR. direction search
DISK
DISK (DELETE)
DISK (FROM DISK)
DISKdNTT)
DISK (TO DISK)
Diskette handling
Distance searching
DISPL, displacement of position
DISPL, modify a position
DIST, distance search

5.3
8.6
9.2.4
11.8.4
12.6.1
11.8.5
3.6.4
3.4.1,6.6,6.10,6.14.6.16
15.5
2.4.1
4.11.1
6.4.2,10.3.2
9.2
9.2.4
9.2.1
9.2.3
9.2.2
4.7
10.3.1
7.5
8.5.3
6.4.1,10.3.1

Editing MENU
Editing
Emergency stop
END DATA, welding
Enabling device
ERASE, TCP, tool
Error buffer
ERASE
ERRORS
Error buffer
Error hanling
Execution of instruction
Execution of instruction without current

8
8.1
1.2.1,2.3,2.5
12.5
2.6
9.4
4.6
8.11
9.7, 9.12
15.2
13.4
14.3.6
14.3.7

DELETE
DELETE (DISK)

Programming

11.6.3
11.6.4

S3

16 Index
Keyword

Chapter, section

Exceptions
External axes, homeposition
EXTAX, Independent External Axes
EXTC, welding
EXTPOS, welding
EXTFRAME

3.6.1.5
7.7.2
5.17
10.2.4.2
10.2.4.2
5.18, 6.18, 9.16, 12.6.5

FETCH, align fetch

FETCH, fetch from register
FINE, zone
FLOW, gluing
FRDISK
FRSC
FRAME, reference frame
Function parameters

7.7
5.8.1
3.6.1.2, 6.3
13.1.1
9.2.1
9.8
3.9.2,5.15,6.14,
9.6, 10.7
14.2.3, 14.3.2

GET B/ADD BLOCK

GLU SCA
GLUING
Gluing instruction
Gluing of a car door
GRIPPERS

5.12
5.19
13.1
13.2.1
11.6.2
5.1

HANDCHK
High performance programming
HOLD, HOLD RESET and AUTO INPUT
Hold-to-run
Home position
Host computer

8.5.1
11.7
4.12.3.1
1.2.5
7.7.3,9.17
2.8,4.8, 5.14

I/O signals
IN/OUT
Information(program)
INIT (DISK)
Initialize diskette
Initialization sequence
INPUT, manual
INPUT, wait-input
Input, jump-input
Inputs and outputs
INS, instruction start
INSERT
INST NO, call up instruction
INST, modify instruction
INTER, interrupt
Intialization sequence for the main program

14.3.3
9.4
4.5
9.2.3
4.7.1
11.2
9.4
5.2.2
5.4.2
4.12, 9.4
7.1-4
8.7
8.2
8.5
4.12, 5.10
11.2

Programming

S3

16 Index
Keyword

Chapter, section

Joystick
JUMP
JUMP (SEARCH)
JUMP(NINPOS)

2.5
5.4
5.4.3
5.4.4

LANG, language
Language section
Limitations
LIST
LIST, program printout
LOAD
LOAD, programmable
LOAD definition
Local (operation)
Location (Registers)
LOCATE
Logical Instruction menu

9.11
4.3
3.3.2.4
9.7
9.7
9.5
11.8
9.5
4.8.6

MAIN DATA, welding

Main Switch
MAN.DEF, manual tool
Manual menu
MANUAL REDUCED SPEED mode
MANUAL FULL SPEED mode
Manual restart
MAX, velocity
Manipulator
Manipulator, instructions
Material handling applications
Measures to deal with overshoots
Menu overview
MIRROR
MODEXT
MODIFY
MODIFandMODARG
MODPOS
MODRECT COORD, modifiedrectangular
coordinates
Monitor
Moving the robot with the joystick
MOV REST
Movement characteristics
Movement principle
Movement velocity

12.4
2.2
9:5
9.1
2.3.2
2.3.3
4.2.2
5.5
3.1
12.5.2,12.6.3
11.6.5
11.8.3.4
11.1
8.13
8.5.4
8.5
8.5.2

N (not ready)
NINPOS, jump-not in position
NEXT, TCP, tool

4.1.3
5.4.4
9.5

Programming

4:9.2
5.22
5

8.4

3.9, 5.11
2.7
3.2.4
7.10, 4.12, 3.2
3.6
11.7.3.2
3.5

S3

16 Index

Keyword

Chapter, section

Off-line
Off-line, teach
OPERATION
Operation status, computer link
Operation status, error list
OUTPUT
Override, (Gluing)
Override on the scaling instruction
Override, function (Arc welding)
Overviewe of five programming menus

2.8
9.13
4
4.8.6
15.3
4.10, 5.3, 9.4
13.3
13.3.2
12.7.2
11.3

PALETT
Pattern program
Path following (principles)
Path optimization
Parallel displacement
Ports
POSPOS
Positioning instruction menu
Position programming
Position registers, location
POSLOC
Positioning
Power on. power off synchronization
PROG NO
PROGST.INS ST., BWD., SIM
PROG, printout
PROG.

6.16, 9.15
11.4
3.6.1.1
3.6.1
3.9
4.11
6.10
6
3.4
4.9.2
6.12
6
4.1.1
8.12
7.1-4
2.8
8.8

Parallel displacement with reference

point (REFP)
Preset values
Process application type plastic cutting,
metal cleaning, deburring and polishing.

3.9.1
11.8.3.3

Program displacement with reference

frame (FRAME)
Programming the first spot weld instruction
Programing robot path
Programing the spot weld instruction
Programing examples
Program information
Programming unit
Program execution
Program execution with fixed TCP
Program information
Program printout

Programming

11.5.5
3.9.2

14.2.5
11.5
14.3.5
11.6,12.8
4.5
2.4
4.1.2
3.3.2.2
4.5
2.8

S3

16 Index
Keyword

Chapter, section

Program structure
Program test
Program robot paths
Programming unit
Position programming

11.3
12.7.1
11.5
2.4
3.4

RB MODE
Recommendations (for programming)
Recommended paths, zones
RECT COORD Rectangular base Coordinates
system

9.10
11.5.1-6
11.5.3-6
3.2.4,3.2.4.1,
3.2.4.4, 3.2.4.5

Recommendation for Arc Welding

Recommendation for Assembly, Machining,
Tending and Material Handling.
Recommendation fo best performance
Recommendation for Glueing and Sealing
Request for superior control
REFP
REG, registers
REG (FETCH)
REG (LOC)
REG (SET)
REG (TRANSFER)
RELTOOL
Remote control
Remote controlpanel signals, panel- I/O
RESEQ
RESYNK
Restart from PLC
Restart, after power failure
RETURN, from a program
ROBOT COORD, robot coordinates
Robot configuration
Room fixed TCP

11.5.3

Safety
SAME, repeat instruction
Save on disk
SC
Scaling instruction

SEARCH
SEARCH (auto)
SEARCH (dist)
SEARCH (dir)
SEARCH AUTO
Sensor definition
SIM, simulation of input
Signals
Singular Points
Smooth wrist reorintation
Softness definition
SOFTS
Programming

11.5.6
11.7.2
11.5.4
4.8.5
3.9.1,6.6
4.9, 5.8, 10.2.1
5.8.1
5.8.4
5.8.2
5.8.3
6.17
2.10
4.13
8.9
7.9
4.2.4
4.2
5.7
3.2.4, 3.2.4.2, 3.2.4.3
3.4.1
3.3.2
1
6.2
11.8.6
2.9, 4.8, 5.14, 9.8,
9.9,9.10
13.2.2
6.4, 10.3
6.4.3
6.4.1
6.4.2
6.4.3
9.5
7.4
13.1.2
3.10
11.5.1
9.5
5.16
S3

16

Keyword

Chapter, section

Soft servo
Software configuration
Speed control
Speed optimization
Spontaneous status messages
Spot welding
Spot welding instruction
Spot welding instruction, editing
Standard SYSTEM I/O, inputs
Standard SYSTEM I/O, outputs
START DATA, welding
START
STEP
STO POS, storage of position
Stop
STORE, align store
SUCTRL, superior computer
SWI-function
SYS PAR
System-I/O
System faults

3.8
4.4, 9.12.1
10.4
3.6.2
4.8.4
14
14.2.4, 14.3.4
14.2.7
4.12.1
4.12.2
12.4
4.1
8.3
6.11
4.1.3
7.7
5.14
14.3
9.7.3
4.12
15.4

TCP
TCP, activate
TCP, fixed
TCP, definition
TEACH, offline
Trimming of position gain index
TIME
TIME, wait-time
TO SC program to SC
TO DISK
TOOL, (TCP, sensor, softs)
Tool direction
TRANSFER, register value to port
TRIM, progammable

3.3
5.9
3.2.4.6, 3.10
9.5
9.13
11.8.3.2
6.15,8.15
5.2.1
9.9
9.2.2
9.5
7.7.1
5.8.3
11.9

USER PAR

9.7.4

V (%), percentage velocity

VCTRL, speed adaptivity
VELOC
Velocity in circl
Velocity in corners
Velocity of reorient
Velocity in a zone
VISCTRL
WATT
WATT (TIME)
WAIT(INPUT)
WDATA, weld data
WEAVING
WEAWE DATA, welding
Weight (M) and distance (X)

6.1, 8.1
6.7
5.5
3.7.2
3.6.1.3
3.6.2
3.6.3
5.22
5.2
5.2.1
5.2.2
9.14,10.2.3
6.5
12.4
11.8.2

Programming

Index

S3

16 Index
Keyword

Chapter, section

WELD
Welding data, desceription and programming
Welding gun, manual operation
Welding process, instructions
Welding process, supervision
WEND, welding
WINCH (DELETE)
WINCH (FR WINCH)
WINCH (ESTIT)
WINCH (TO WINCH)
WINSCHESTER MEMORY
WRIST/LOAD

10.2.4.1
12.4
14.2.2
12.5.1, 12.6.2
12.7.3
10.2.4.1
9.3.4
9.3.1
9.3.3
9.3.2
9.3
5.20, 9.5, 11.8

Zones

3.6.1.2,6.3

S3

Programming
8