Basic operation

CONTENTS
Page

1 Introduction ..................................................................................................................... 3
2 Safety ................................................................................................................................ 5
3 System Overview ............................................................................................................. 7
3.1 General.................................................................................................................... 7
3.2 The manipulator...................................................................................................... 8
3.3 The controller ......................................................................................................... 8
3.4 Operator’s panel ..................................................................................................... 9
3.5 Teach pendant......................................................................................................... 10
4 Starting the System ......................................................................................................... 15
5 Working with Windows.................................................................................................. 17
6 Jogging the Robot Using the Joystick............................................................................ 21
6.1 Linear jogging......................................................................................................... 21
6.2 Fine positioning ...................................................................................................... 23
7 Selecting a Program ........................................................................................................ 25
7.1 Using the training program..................................................................................... 25
8 Starting the Program ...................................................................................................... 31
9 Stopping the Program..................................................................................................... 35
10 Automatic Mode ............................................................................................................ 37
11 Errors ............................................................................................................................. 39
12 Switching the System off............................................................................................... 41
13 Changing a Program..................................................................................................... 43
13.1 Modifying positions.............................................................................................. 43
13.2 Changing arguments ............................................................................................. 45
13.3 Adding instructions............................................................................................... 46
13.4 Programming a delay............................................................................................ 48
14 Storing the Program on Diskette ................................................................................. 51
14.1 Formatting a diskette ............................................................................................ 51
14.2 Storing on diskette ................................................................................................ 53
15 Printing Programs......................................................................................................... 57
15.1 Using a PC ............................................................................................................ 57
16 I/O Signals...................................................................................................................... 59
16.1 Programming an I/O instruction........................................................................... 59

Basic operation 1
Basic operation
CONTENTS
Page

2 Basic operation
Basic Operation Introduction

1 Introduction

This manual explains the basics of handling and operating an ABB robot. You do not
need any previous experience of robots to understand its contents.

The manual is divided into chapters, each of which describes a particular work task and
how to go about performing it. The chapters complement one another and should,
therefore, be read in the order they appear in the book.

It is an advantage if you have access to a robot (or the PC-program Quick Teach) when
you use this manual, but just reading it should help you understand the basic operation
of a robot.

The manual is written to suit a standard installation. Differences can therefore occur,
depending on the configuration of the system.

There are two versions of the controller: a small one and a large one. The large version
is shown in this manual. The cabinet of the small controller has the same operator’s
panel as the large one, but is located in another position.

Please note that this manual describes only one method of carrying out any of the
normal work tasks and, if you are an experienced user, there may be other methods. For
other methods and more detailed information, see the following manuals.

User’s Guide provides a description of all robot functions and describes the program-
ming language in detail. This manual is primarily intended as a reference manual for
operators and programmers.

Product Manual provides a description of the installation, how to locate errors in the
robot; etc.

If you just wish to be able to start programs, run the robot with the joystick, load pro-
grams from diskette, etc., it is not necessary to read Chapters 14-16.

Basic Operation 3
Introduction Basic Operation

4 Basic Operation
Basic Operation Safety

2 Safety

Operational procedures, during training or at any other time, must be carried out safely.

Entering the safeguarded space around the robot may cause severe injury and should
be avoided whenever possible. However, if this is necessary, then only authorised
personnel may enter the area. The existing safety regulations must always be taken into
consideration.

The safety regulations are specified in the chapters on safety in the User’s Guide and
in relevant plant documentation (if any).

Basic Operation 5
Safety Basic Operation

6 Basic Operation
Basic Operation System Overview

3 System Overview

3.1 General
A robot is made up of two principal parts:

Controller
Manipulator

Figure 1 The controller and manipulator are connected by two cables.

You can communicate with the robot using a teach pendant and/or an operator’s panel,
located on the controller (see Figure 2).

250 mm/s

100%

M 789
~ 456
123
1
2
0
P1 P2
P3

Figure 2 Operator’s panel and teach pendant.

Basic Operation 7
System Overview Basic Operation

3.2 The manipulator

Figure 3 shows the directions in which the various axes of the manipulator can move
and what these are called.

Axis 3
Axis 4

Axis 6

Axis 5

Axis 2

Axis 1

Figure 3 Manipulator, IRB 2400.

3.3 The controller

Figure 4 illustrates the principal parts of the controller.

Mains switch
Connection for teach pendant
Operator’s panel Holder for teach
pendant
Disk drive
Cable holder

Duty time counter

Socket for printer

Figure 4 The S4 control system.

8 Basic Operation
Basic Operation System Overview

3.4 Operator’s panel

Figure 5 below shows a close-up of the operator’s panel. A short explanation of the
push buttons follows.

Operating mode selector

<250 mm/s
AUTO ( -----)
MANUAL REDUCED SPEED(< 250 mm/s)
100%
MANUAL FULL SPEED (100%)

MOTORS ON
M
~
MOTORS OFF

Emergency stop

Figure 5 The operator’s panel.

Operating mode AUTO (Production mode)

Used when running ready-made programs in production. It is not possible to move the
manipulator with the joystick in this mode. The MOTORS OFF button is continuously lit.

Operating mode MANUAL REDUCED SPEED (Programming mode)

Used when working inside the robot’s working area and when programming the robot.

Operating mode MANUAL FULL SPEED (Testing mode)

Used to test run the robot program at full programming speed.

MOTORS ON

In the MOTORS ON state, the motors of the robot are activated and the MOTORS
ON button is continuously lit.

MOTORS OFF

In the MOTORS OFF state, the motors are switched off and brakes are applied. When
in manual mode, the button flashes.

Emergency stop

The robot stops – regardless of which state or mode the system is in – immediately the
emergency stop button is pressed. The button remains pressed in and, to turn to
MOTORS ON again, must be returned to its original position.
Basic Operation 9
System Overview Basic Operation

3.5 Teach pendant

The teach pendant is described briefly below; see Figure 6 and Figure 7.

Enabling
device
7 8 9
4 5 6
1 2 3 Joystick
Display 1 0
2

P1 P2
P3 Emergency
stop button

Figure 6 The teach pendant.

Emergency stop

The robot stops – regardless of which state or mode the system is in – immediately the
emergency stop button is pressed. The button remains pressed in and, to turn to
MOTORS ON again, must be returned to its original position.

Enabling device (for safe operation)

A push button on the teach pendant which, when pressed halfway in, takes the system
to MOTORS ON (if the operating mode selector is switched to one of the two manual
modes). When the enabling device is released or pushed all the way in, the robot is
taken to the MOTORS OFF state.

If the enabling device is released and pressed in halfway again within half a second, the
robot will not return to the MOTORS ON state.
If this happens, the enabling device must first be released and then pushed halfway in
again.

The enabling device should only be activated when the robot is to be moved –
either with the joystick or during program execution.

Joystick

The joystick is used to jog (move) the robot manually; e.g. when programming the
robot.

Display

Used to display all information during programming, to change programs, etc. It can
accommodate 16 lines; each line can accommodate 40 characters.

10 Basic Operation
Basic Operation System Overview

Figure 7 shows the names of the various keys on the teach pendant.

Menu keys Contrast

Display
7 8 9
Jogging 4 5 6 Numeric
Program 1 2 3 keyboard
Window Inputs/ Motion keys
0
keys Outputs
1
2
Delete
Misc. Incremental
P1 P2
Enter
User defined key P3

Stop key
Function keys User defined Navigation keys
keys

Figure 7 An overview of the various keys on the teach pendant, Version 2.

Window keys (to select a window to work with on the display):

Jogging: Used to jog the robot.

Program: Used to program and test.

Inputs/Outputs: Used to manually operate the input and output

signals connected to the robot.

Misc.: Miscellaneous; other windows, i.e. the System Parameters,

Service, Production and File Manager windows.

Basic Operation 11
System Overview Basic Operation

Navigation keys (to move the cursor within a window on the display):

List: Press to move the cursor from one part of the window to
another (normally separated by a double line).

Previous/Next page: Press to see the next/previous page.

Up and Down arrows: Press to move the cursor up or down.

Left and Right arrows: Press to move the cursor to the left or right.

Motion keys: (to select how the robot or other peripheral equipment should move when
using the joystick – during manual operation):

Motion Unit: Press to jog the robot or other mechanical units.

Motion Type: Press to select how the robot should be jogged,

reorientation or linear.

1
Motion Type: Axis by axis movement. 1 = axis 1-3, 2 = axis 4-6
2

Incremental: Incremental jogging on/off

12 Basic Operation
Basic Operation System Overview

Other keys:

Stop: Stops program execution.

Contrast: Adjusts contrast of the display

Menu keys: Press to display menus containing various commands.

Function keys: Press to select the various commands directly.

Delete: Deletes the data selected on the display.

Enter: Press to input data.

Programmable keys:

P1 P2 P3 Functions to be defined by the user.

(P4)
(P5)

Basic Operation 13
System Overview Basic Operation

14 Basic Operation
Basic Operation Starting the System

4 Starting the System

You are now going to turn the system on, i.e. get it ready for programming, running
programs, etc.

Before you switch the system on, make sure that no-one is inside the safeguarded
space around the robot.

1. Switch the mains switch on (see Figure 8). The robot is then automatically checked.

Figure 8 Mains switch

After the system has been checked and no errors are located, the following message
(see Figure 9 below) appears on the display.

Welcome to IRB x400 M94A

3HAB XXXX- 1

ABB Robotics Products AB

Figure 9 The “welcome” window may vary slightly depending on the type and version of your
robot.

Basic Operation 15
Starting the System Basic Operation

16 Basic Operation
Basic Operation Working with Windows

5 Working with Windows

In this chapter, you will find out about the basics of working with windows. The fol-
lowing example shows the window for Inputs/Outputs (manual handling of in- and
outputs).

1. Press the Inputs/Outputs window key (see Figure 10.)

Figure 10 The Inputs/Outputs application key, both versions.

2. The window for manual I/O is now shown on the display, as in Figure 11. The
appearance of the I/O list may vary depending on how the signals have been defined
and how many I/O boards there are in the system.

Menu keys
File Edit View
Window title Inputs / Outputs
All signals
I/O list name Name Value Type Line number
1(40)
di1 0 DI
di2 0 DI
di3 0 DI
di4 0 DI
I/O list di5 0 DI
di6 0 DI
di7 0 DI
di8 0 DI Cursor

Function keys

Figure 11 Window for manual I/O handling.

When a digital output is selected, its status can be changed using the function keys.
If you press a function key with an arrow to the right of its name, e.g. Test->, this will
call up a new window to the display.

Basic Operation 17
Working with Windows Basic Operation

3. You can select a signal in the list (move the cursor) in several ways:

Movement Select

One line up ArrowUp

One line down ArrowDown

To the first line in the list Goto top from the Edit menu

To the last line in the list Goto bottom from the Edit menu

To the next page NextPage

To the previous page PreviousPage

To select a specific line in the list Goto from the Edit menu; enter
the desired line number and press OK

4. Windows are sometimes divided in two by a double line (see Figure 12).

5. Press the NextPage key until an output is shown on the first line, two function keys
will be displayed (see Figure 12).

File Edit View

Inputs/Outputs double line

All signals
Name Value Type
17(40
do1 0 DO
do2 0 DO
do3 0 DO
do4 0 DO
do5 0 DO
do6 0 DO
do7 0 DO
do8 0 DO

0 1 Function keys

Figure 12 A window with two parts.

In some windows, you can move the cursor between the different parts of the window.

In these windows, move the cursor using the List key .

18 Basic Operation
Basic Operation Working with Windows

6. There are four window keys on the teach pendant (see Figure 13 below and
Chapter 3).

7 8 9
4 5 6
1 2 3
Window keys
1 0
2

P1 P2
P3

Figure 13 The four window keys.

When you press a window key, the active window will be hidden under the new one.
Each time you select a window, it will look the same as it did the last time you worked
with it.

Basic Operation 19
Working with Windows Basic Operation

20 Basic Operation
Basic Operation Jogging the Robot Using the Joystick

6 Jogging the Robot Using the Joystick

You can move (jog) the robot using the joystick on the teach pendant. This chapter
describes how to jog the robot linearly (i.e. in a straight line) and step by step, to make
it easier to position the robot exactly (known as incremental jogging).

6.1 Linear jogging

1. Make sure that the operating mode selector is in the < 250 mm/s position, as shown
in Figure 14.

<250 mm/s

100%

Figure 14 The maximum speed during manual operation is 250 mm/s.

2. Check that the Robot motion unit and the Linear motion type are selected
(see Figure 15).

Motion unit

Motion type
1
2

Figure 15 Motion keys, LEDs shows the current settings.

With the Motion unit key, you can choose between operating the robot, or some other
unit connected to the controller, using the joystick. Select the robot for this exercise.

With the Motion type key, you can choose the way you want the robot to move when
you use the joystick during manual operation.

You can choose:

- linear movement
- reorientation of a particular end-effector
- axis-by-axis movement (group 1: axes 1-3; group 2: axes 4-6)

We will use linear motion for the purposes of this exercise.

Basic Operation 21
Jogging the Robot Using the Joystick Basic Operation

When linear type motion is selected, the robot will move as shown in Figure 16.
Z+
Y+

X+

X+
Figure 16 X, Y, Z form the robot’s coordinate system.

The point that will move linearly, along the axes of the coordinate system above, is
called the Tool Centre Point (TCP) 0. It is located at the front of the upper arm, in the
centre of the robot’s face plate (see Figure 17).

Tool Centre Point 0

Figure 17 The centre of the face plate is called TCP 0.

3. Push the enabling device halfway in to switch the MOTORS ON.

4. Now, jog the robot using the joystick.

Standing in front of the robot, the TCP 0 will, depending on how you move the
joystick, move linearly along the X-, Y- and Z-axes (see Figure 18).

X-

Y- Y+
Z+ Z-

X+

Figure 18 Robot movements with different joystick deflections.

Try jogging the robot in the directions corresponding to X, Y and Z above.

You can also combine the various movements of the joystick and move in several
directions simultaneously. Note that the speed of the robot depends on how much you
move the joystick. The larger deflection, the faster the robot moves.

22 Basic Operation
Basic Operation Jogging the Robot Using the Joystick

6.2 Fine positioning

1. Press the Jogging window key (see Figure 19).

Figure 19 The Jogging window key.

A window like the one in Figure 20 will appear.

Window Special
Title
Jogging Robot Pos:
Unit: Robot x: 1234.5 mm
Motion: Linear y: -244.9 mm
z: 12.8 mm
AA AA
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
Field AA
AA Coord: AA
AA q1: 0.7071
AA Base AA
AA
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
AA q2: 0.0000
Tool: tool0...
q3: 0.0000
Wobj: wobj0... q4: -0.7071

Incremental: No Joystick direction

x y z
World Base Tool WObj

Figure 20 The Jogging window.

The appearance of the window changes depending on the type of window selected (i.e.
depending on what you want to do).

The Menu keys perform different commands. The list of commands available is dis-
played in a pull-down menu when you press any of the menu keys.

The area enclosed by a dashed line is called a Field. The highlighted (shaded, grey)
area is known as an input field and can be changed by selecting a different function
using one of the Function keys (or, in some cases, using the Motion keys on the teach
pendant).

The highlighted input field in Figure 20 is marked with a “ ” after it which means
that:

- Selection is done using a Function key

Basic Operation 23
Jogging the Robot Using the Joystick Basic Operation

2. Move the cursor (the shaded field) to the Incremental field using the
Down arrow key on the teach pendant (see Figure 21).

Figure 21 The Down arrow navigation key.

3. If you move the cursor to the Incremental field, as in Figure 22, you can choose
incremental jogging by pressing one the function keys.

Special
Jogging Robot Pos:
x: 1234.5 mm
Unit: Robot y:
Motion: Linear -244.9 mm
z: 12.8 mm
q1: 0.7071
Coord:= Base q2: 0.0000
Tool:= tool0... q3: 0.0000
Wobj:= wobj0... q4: -0.7071

Incremental:= No x y z
No Small Medium Large

Figure 22 Selection of incremental jogging.

If you press the Small, Medium or Large function key, the No in the Incremental field
will be immediately replaced.

The robot will then move one step at a time each time you move the joystick; the size
of the steps (Small, Medium or Large) will depend on your choice.

You can also use the key to turn incremental movement on and off.

Try operating the robot using the joystick and note how the robot moves.

More information on manual operation, the various coordinate systems, etc., can be
found in the chapter on jogging in the User’s Guide.

If you do not wish to continue this exercise, switch off the system as explained in
Chapter 12 “Switching the System off”.

24 Basic Operation
Basic Operation Selecting a Program

7 Selecting a Program

This chapter explains how to open (choose) a program. A program is usually made up
of three different parts, one main routine (always present), a number of subroutines
and program data. Only one main routine is permitted per program (see Figure 23).

RAPID-program
Robot positions
Program data Counters
etc.
main routine

subroutine 1
MoveL.....
MoveL.....
subroutine 2

subroutine 3
WaitTime 3;
MoveL....

Figure 23 Program structure.

If you open a program, that program replaces the program in the robot’s memory.
When a program is opened, the main routine will be shown on the display with the first
instruction in the main routine selected (highlighted).

7.1 Using the training program

The training program is stored on the IRB 2 system diskette, under the directory
DEMO, and is called “EXERCISE”.

1. Turn the operating mode selector on the operator’s panel to < 250 mm/s.

2. Press the Program window key (see Figure 24).

Figure 24 The Program window key.

Basic Operation 25
Selecting a Program Basic Operation

If there is no program in the robot’s memory, the following window will appear (Figure
25), otherwise you will see the program that is stored in the memory of the robot.

File
Program Instr

No Program to show.

Use the menu File to

open or to create a new
Program

Figure 25 The Program window.

3. Insert the Setup diskette into the disk drive at the front of the cabinet. The diskette
should be inserted as in Figure 26.

Figure 26 Inserting the diskette.

4. Press the File menu key (see Figure 25 above). The window in Figure 27 will appear.

1 Open... File
2 New...
1 Open
(Save Program Program Instr
2 New...
(Save Program as)
No Program to show.
(Print...)
(Preferences...) Use the menu File to
(Check Program) open or to create a new
(Close Program) Program

Figure 27 The File menu when there is no program in the robot’s internal memory.

26 Basic Operation
Basic Operation Selecting a Program

The menu that now appears on your display is called a “pull-down menu”. All com-
mands that can be chosen from the File menu are listed here (commands that cannot be
chosen are indicated by parentheses). The other menu keys work in the same way.

From now on we will write File: Open..., File: Save, etc. The name on the left of the
colon is the name of the menu and the name on the right stands for the command you
should choose.

The first function in the pull-down menu is always highlighted when you press the
menu key. You can move the cursor within the menu using the arrow keys on the teach
pendant (see Figure 24). When you have selected the command you want to choose,
press Enter.

You can also use the numeric keyboard to choose a command; to do this enter the
number in front of the command.

Up arrow

Down arrow

Figure 28 Navigation keys: Up arrow and Down arrow.

Three dots “...” following the command means that a dialog box will appear when that
command is chosen.

To remove a pull-down menu, press the menu key with which you opened it.

5. After selecting Open..., press Enter (see Figure 29).

This means that the “Open...” command will be carried out. However, as it has three
dots “...” after it, the command will not be performed directly since more information
is required. You must now, in this case, choose the particular program you wish to
open.
Enter

Figure 29 The Enter key on the teach pendant.

Basic Operation 27
Selecting a Program Basic Operation

Using the Unit function key, you can switch between the robot’s internal memory
(ram1disk), the diskette unit (flp1:) or some other type of mass storage device.

6. Press Unit. Check that “flp1:” appears after Massmemory unit:=. A dialog box will
appear and the contents of the diskette will be shown, as in Figure 30.

Open...
Select a Program or a Module
Massmemory
The training Massmemory unit:= flp1: name
program is /
1(5)
stored here
DEMO Directory
The appear-
MOVEPROG Directory
ance of the
README Program
list can
SERVICE Directory
vary
SYSPAR Directory

Unit Cancel OK

Figure 30 The Open dialog box.

If a dialog box (does not have any menus) is closed by pressing Cancel, the command
requested will not be carried out. If you press OK, the command requested will be car-
ried out and the dialog box will close.

7. Select DEMO. Move the cursor with the Up and Down arrow keys.

8. Press Enter.

9. Select EXERCISE.

10.Press OK and a window like the one in Figure 31 will appear.

File Edit View Routine Special

Program Routines EXERCISE

Routines In Module
Name Type
1(1)
main

New.. Decl.. Dupl.. Data-> Test

Figure 31 Opening the main file of the training program.

28 Basic Operation
Basic Operation Selecting a Program

11. Then press Enter . The window in Figure 32 appears.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main

1(4)
MoveL *,v300,fine,tool0;
MoveL *,v300,fine,tool0;
MoveL *,v300,fine,tool0;
MoveL *,v300,fine,tool0:

Copy Paste OptArg... ModPos Test->

Figure 32 The training program appears on the display.

This is the main routine in the training program. It consists of four “move” instructions.

The routines consist of different types of instructions, such as move instructions, wait
instructions, etc. Each instruction is followed by different arguments. Arguments can,
depending on their type, be changed or omitted altogether. Figure 33 indicates an
example of an instruction.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main

1(4)
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
The name of the
instruction which
moves the
robot linearly.

Copy Paste OptArg... ModPos Test->

Hides the values of

the instruction’s Determines the Determines the Specifies which
position. velocity of the precision of the tool is active.
robot. robot’s position.

Figure 33 Example of a motion instruction.

Basic Operation 29
Selecting a Program Basic Operation

30 Basic Operation
Basic Operation Starting the Program

8 Starting the Program

You are now going to start the program you just opened. It should first be run step by
step using reduced velocity, then continuously.

The program consists of four motion instructions and includes positions near the
robot’s “calibration position” (see Figure 34).

1 4

TCP 0
(TOOL0)
2 3

Figure 34 The robot’s calibration position

Before starting the program move axis 5, manually with the joystick, downwards
about 45°. (For information on the various robot axes, see Chapter 3.2 on page 8.)

1. Press the Program window key and a window, like the one in Figure 35,
will appear (you have already reached this stage if you have come directly from
Chapter 7).

File Edit View IPL1 IPL2

Program Instr EXERCISE/main

1(4)
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Copy Paste OptArg... ModPos Test->

Figure 35 The Program window.

Basic Operation 31
Starting the Program Basic Operation

2. Press the Test function key. The window in Figure 36 appears.

File Edit View Special

Program Test EXERCISE/main
Speed:= 100%
Execution:= Continuous
» Program pointer = PP 1(4)
» MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Start FWD BWD Modpos Instr->

Figure 36 The Program Test window.

Function keys displayed:

- Start: continuous running of the program.

- FWD: one instruction forward.
- BWD: one instruction backward.
- Instr->: select the Program instruction window again.

The program point (PP) indicates the instruction with which the program will start
when you press one of the options Start, FWD or BWD.

3. Select the upper part of the window by pressing the List key.

4. Reduce the velocity to 75% by pressing the -% function key (see Figure 37).
Correction is carried out in increments of 5%.

File Edit View Special

Program Test EXERCISE/main
Speed:= 75%
Running:= Continuous
1(4)
» MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

- % +% 25% 100%

Figure 37 Correction of velocity.

32 Basic Operation
Basic Operation Starting the Program

5. Move (using the same key as in point 3) the cursor back to the first line of the
program (see Figure 38).

File Edit View Special

Program Test EXERCISE/main
Speed:= 75%
Running:= Continuous
1(4)
» MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Start FWD BWD Modpos Instr->

Figure 38 Window for starting the program.

The program can now be started. Make sure that no-one is inside the
safeguarded space around the robot.

6. Start the program by pushing in the enabling device and pressing the FWD function
key (see Figure 38).

When the program has started, the robot will carry out one instruction, then it will stop.
Press FWD to initiate the next instruction, press again for the next one, and so on.

Basic Operation 33
Starting the Program Basic Operation

The window in Figure 39 is displayed during the execution of the program.

Exec Test
Program Run EXERCISE/main
Speed:= 75%
Running:= Continuous
Event Log
1(1)
Executing

Figure 39 Window during program execution.

9. Go through all the program instructions step by step. Press FWD repeatedly after
the robot is in position.

10. If you press FWD when the program comes to the final instruction, the program
will start from the beginning again.

11. Let the robot move to position number 4 (see Figure 34).

12. Move, in the same way as before, the cursor to the Running field and change to
Cycle execution.

13. Move the cursor back to the program.

14. Start the program by pressing Start.

When Cycle is selected the program will be executed once, and then will stop in
position 4 (one cycle).

15. Select Continuous execution again.

34 Basic Operation
Basic Operation Stopping the Program

9 Stopping the Program

Stop the program by pressing the Stop key on the teach pendant (see Figure 40).

7 8 9
4 5 6
1 2 3
1 0
2

P1 P2
P3

Figure 40 Stop key on the teach pendant.

Basic Operation 35
Stopping the Program Basic Operation

36 Basic Operation
Basic Operation Automatic Mode

10 Automatic Mode

Automatic mode is used to execute ready-made programs.

1. Turn the operating mode selector on the operator’s panel to the Auto position.
The window in Figure 41 appears.

Change of Operating Mode

Operating Mode has been changed
from MANUAL to AUTO.

Please acknowledge this by pressing OK.

(If Cancel, the Operating Mode Selector must

be switched back to MANUAL.)

Cancel OK

Figure 41 Dialog box used to confirm a change from manual to automatic mode.

2. Press OK. You have now changed to automatic mode and the Production
window appears on the display (see Figure 42).

File Edit View

Window title Production Program

Program name : EXERCISE Program name
Status : Ready Program status
Robot Speed : * mm/s % :100 Adjusted velocity
velocity Running mode : Continuous Running mode
Routine : main Routine name
Program 1(4)
» MoveL *, v300, fine, tool0;
pointer MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
Program list MoveL *, v300, fine, tool0;
Start FWD BWD

Figure 42 The Production window in auto mode.

3. Press the MOTORS ON button on the operators panel.

4. Start the program with the Start function key.

5. Stop the program with the STOP button on the teach pendant.

6. Then press MOTORS OFF on the operator’s panel.

7. Switch back to < 250 mm/s.

For further information, see Chapter 8, Running Production in the User’s Guide.

Basic Operation 37
Automatic Mode Basic Operation

38 Basic Operation
Basic Operation Errors

11 Errors

A window displaying an error message appears whenever there is any type of error (see
Figure 43).

Category of
Error code number Error:6005 Operator errors
error
Reason..............................
Reason for error ....................................
....................................

x(y)
<no> <Message header> <time stamp>
Message log <xx> <......> <time stamp>
<yy> <Operational status> <time stamp>

Check OK

Figure 43 Example of a window displaying an error message.

Error code number

A number unique to each error.

Category of error

Assigns errors to groups relating to the type of error. Each category has its own code
number series; e.g. Operator errors (6001-6999).

Reason

Describes the reason for the error in plain language. For more information regarding
hardware faults, see the Product Manual.

Message log

Indicates the most recent errors. The error indicated on the first line is displayed in the
window. The log shows the error code number, a brief description of the error, and the
time the error was registered. If you highlight one of the errors in the log, the window
will then be updated with the appropriate error code number, reason and category.

The Check function key can be used to get help on how handle a specific error.

If you press OK, the error-message window will disappear.

Using the joystick, try to manually operate the robot outside its operating area. You
will then see an example of an error message.

Basic Operation 39
Errors Basic Operation

40 Basic Operation
Basic Operation Switching the System off

12 Switching the System off

If you are going to continue with the rest of the exercises, you can skip this chapter.

All output signals will be set to zero when the robot is switched off. This may affect
the gripper and peripheral equipment.
So, before switching the system off, check first that the equipment, and any people
in the area, will not come to any harm.

1. If the program is running, stop it by pressing the Stop push button on the teach pen-
dant.

2. Then press the MOTORS OFF push button on the operator’s panel.

3. After you have done this, switch off the mains switch.

The robot’s memory is battery-backed and is thus not affected when the system is
switched off.

Basic Operation 41
Switching the System off Basic Operation

42 Basic Operation
Basic Operation Changing a Program

13 Changing a Program

The following chapters are intended to be read by people who will create programs, edit
programs, etc.

This chapter explains some of the ways in which you can change the program you
opened and started in the preceding chapters. You will:

- run the program step by step until you get to the position you want to modify
- modify this position
- change an argument in an instruction
- enter a new instruction (position)
- program a time delay (WaitTime)

13.1 Modifying positions

1. If you have exited the previous exercises, choose the Program window
(see Figure 44).

Figure 44 The Program window key.

The window in Figure 45 appears on the display.

File Edit View Special

Program Test EXERCISE/main
Speed:= 75%
Running:= Continuous
1(4)
» MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Start FWD BWD Modpos Instr->

Figure 45 The Program Instr window.

Basic Operation 43
Changing a Program Basic Operation

2. Push in the enabling device and press FWD. Move the robot to the first position in
the program (the first instruction should be highlighted).

File Edit View Special

Program Test EXERCISE/main
Speed:= 100%
Running:= Continuous
1(4)
>< MoveL *, v300, fine, tool0;
» MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Start FWD BWD Modpos Instr->

Figure 46 The first instruction is selected.

3. Then move the robot to a new position with the joystick.

4. Press the ModPos function key. The original position specified will now change to
the current position of the robot.

5. Activate the enabling device and press FWD again to move the robot to the next
position.

Repeat points 3 to 5 and go through all the positions in the training program.

6. Test run the program step by step without reducing the velocity.
Stop the program in any position and press the Instr function key (to terminate the
Program Test). The window in Figure 47 will then appear on the display.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main

1(4)
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Copy Paste OptArg.. ModPos Test->

Figure 47 The Program Instr window.

44 Basic Operation
Basic Operation Changing a Program

13.2 Changing arguments

You are now going to change one of the arguments of the first move instruction
(MoveL), which should be highlighted. You are going to change the precision of the
position.

1. Select the “fine” argument (see Figure 48). Move the cursor using the right arrow
key.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main

1(4)
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Copy Paste OptArg.. (ModPos) Test->

Figure 48 The “fine” argument is selected.

2. Press Enter. The window in Figure 49 appears.

Instruction arguments
MoveL *, v300, ?fine, tool0

Zone: fine
1(5)
New... fine z1
z5 z10 z15
z20 z30 z40
z50 z60 z80

Next Func More.. Cancel OK

Figure 49 Dialog box for programming instruction arguments.

3. Move the cursor to z10.

4. Press Enter and the fine argument will change to z10.

5. Then press OK. The instruction has now changed to z10.

6. Move the cursor so as to select the complete instruction (see Figure 50).

Basic Operation 45
Changing a Program Basic Operation

13.3 Adding instructions

You are now going to add a movement instruction to the program after the first instruc-
tion. The Program Instr window in Figure 50 should now appear on the display.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main

1(4)
MoveL *, v300, z10, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Copy Paste OptArg.. (ModPos) Test->

Figure 50 Program window.

1. Press the Copy function key to copy the first instruction (highlighted) in Figure 50.

2. Then press Paste. The window in Figure 51 appears. As it is the first instruction in
the program that is highlighted, you will be asked where you want the new instruc-
tion to be inserted.

MoveL *, v300, z10, tool0;

Insert before: No

Yes No Cancel OK

Figure 51 Dialog box used to insert new instructions when the first instruction is highlighted.

3. Select No. Press OK.

46 Basic Operation
Basic Operation Changing a Program

4. The new instruction will be inserted directly under the instruction that was
highlighted, and will be highlighted itself.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main

2(5)
MoveL *, v300, z10, tool0
MoveL *, v300, z10, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0;
MoveL *, v300, fine, tool0:

Copy Paste OptArg.. ModPos Test->

Figure 52 An extra position (the same as the one copied) is added to the program.

5. Using the joystick, move the robot to the position to which you want it moved.

6. Press Modpos (see Figure 52).

7. Test run the program using continuous execution.

8. Select Test->.

9. Push the enabling device.

10. Press Start.

Basic Operation 47
Changing a Program Basic Operation

13.4 Programming a delay

You are now going to program a delay, i.e. make the robot wait a specified amount of
time. The new instruction will be inserted after the fourth instruction.

1. When the program test-run is completed, press the Instr function key.
The window in Figure 53 appears.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main

1(5)
MoveL *, v300, z10, tool0
MoveL *, v300, z10, tool0
MoveL *, v300, fine, tool0
MoveL *, v300, fine, tool0
MoveL *, v300, fine, tool0

Copy Paste OptArg.. ModPos Test->

Figure 53 The Program Instruction window.

2. Using the arrow keys (up and down), move the cursor to the fourth instruction in the
program. The new instruction will be inserted under the highlighted one.

3. Select IPL1: Various (see Figure 54). The window in Figure 54 appears.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main
Various
4(5)
MoveL *, v300, z10, tool0 1 :=
MoveL *, v300, z10, tool0 2 Comment
MoveL *, v300, fine, tool0 3 WaitDI
MoveL *, v300, fine, tool0
MoveL *, v300, fine, tool0 4 WaitTime
5 WaitUntil

Copy Paste OptArg.. ModPos Test->

Figure 54 The pick list including the waitTime instruction.

48 Basic Operation
Basic Operation Changing a Program

4. Select the desired instruction from the pick list, in one of the following ways:

- Using the numeric keyboard, enter the number (4) shown in front of WaitTime
(see Figure 54). (The numeric keyboard is illustrated in chapter 3.)

- Select the pick list by pressing the List key . Then select the desired instruc-
tion and press Enter. See Figure 55.

File Edit View IPL1 IPL2

Program Instr EXERCISE/main
Various
5(6)
MoveL *, v300, z10, tool0 1 :=
MoveL *, v300, z10, tool0 2 WaitTime
MoveL *, v300, fine, tool0
3 WaitUntil
MoveL *, v300, fine, tool0
WaitTime 1;
MoveL *, v300, fine, tool0

Copy Paste OPtArg.. (ModPos) Test->

Figure 55 The window after selection of the WaitTime instruction.

5. A window like the one in Figure 56 appears.

Instruction Argument
WaitTime:? <EXP>
Time
1(2)
New... reg1 reg2
reg3 reg4 reg5

Next Func More.. Cancel OK

Figure 56 Dialog box for entering arguments.

6. Type 3 on the numeric keyboard to get a wait time of 3 seconds.

Basic Operation 49
Changing a Program Basic Operation

7. Press OK. The window like the one in Figure 57 appears.

File Edit View IPL1 IPL2
Program Instr EXERCISE/main
Various
5(6)
MoveL *, v300, z10, tool0; 1 :=
MoveL *, v300, z10, tool0; 2 Comment
MoveL *, v300, fine, tool0;
3 WaitDI
MoveL *, v300, fine, tool0;
WaitTime 3; 4 WaitTime
MoveL *, v300, fine, tool0; 5 WaitUntil

Copy Paste OPtArg.. (ModPos) Test->

Figure 57 The Program Instr appears on the display.

8. Press Edit: IPlhide to remove the pick list.

9. Now test run the program again using the Program Test window. Choose continuous
execution.

INFORMATION

The Edit menu includes a number of functions which can be used to edit the program
(see Figure 58).

1 Cut File Edit View IPL1 IPL2

2 Copy Program Instr
1 Cut EXERCISE/main
3 Paste 2 Copy
4 Goto Top 5(6)
5 Goto Bottom MoveL *, v300, z10, tool0;
6 Mark MoveL *, v300, z10, tool0;
MoveL *, v300, fine, tool0;
7 Change Selected MoveL *, v300, fine, tool0;
8 Value WaitTime 3;
9 ModPos MoveL *, v300, fine, tool0;
0 Search....
Show/Hide IPL

Figure 58 The Edit pull-down menu.

Press the Edit menu key again to remove the menu.

See the User’s Guide for more detailed information.

50 Basic Operation
Basic Operation Storing the Program on Diskette

14 Storing the Program on Diskette

You are now going to copy the program to a diskette.

Use 3.5” HD (High Density) diskettes.
Do not use the Setup diskette to store the exercise program.
If your diskette is new, you will have to format it first. This is done under the File Man-
ager, which you can access using the Miscellaneous key.

14.1 Formatting a diskette

Note: If you format a diskette which contains information, all information will be
deleted.

1. Insert the diskette into the disk drive on the front of the controller cabinet.

2. Choose the Miscellaneous window (see Figure 59).

Figure 59 The Miscellaneous window key.

A list of available windows will appear on the display (see Figure 60).

Other windows
1(5)
System parameters
Service
Production
FileManager
Operator & Input

Figure 60 Available windows under Miscellaneous.

Basic Operation 51
Storing the Program on Diskette Basic Operation

3. Select FileManager from the list.

4. Press Enter. The window in Figure 61 appears.

File Edit View Options

FileManager
flp1: /

Name Type Date

1(1)
Unknown

Up

Figure 61 The window displays a list of files if there are any on the diskette.

5. Select Options: Format. The dialog box in Figure 62 appears.

Format

New name of volume : ...

Format volume in unit

ramdisk:
flp1:

Cancel OK

Figure 62 Dialog box for confirming the formatting of the diskette.

6. If you want to name the file, move the cursor to the upper part of the window.

7. Press Enter .

8. Write the name. See section 14.2, Storing on diskette.

9. Move the cursor back to the lower part of the window.

10.Select flp1.

11.Start formatting the diskette by pressing OK.

12.Wait until the dialog box disappears from the teach pendant.

52 Basic Operation
Basic Operation Storing the Program on Diskette

14.2 Storing on diskette

1. Choose the Program Instr application (see Figure 63), if you are not already in it.

Figure 63 The Program window appears on the display.

2. Press the File menu key. The window in Figure 64 appears.

1 Open File Edit View IPL1 IPL2

2 New... 1 Open
2 New...
ARL Prog
Program Instr
3 Save Program... EXERCISE/main
3 Save Program... 4 Save Program as...
1(6)
4 Save Program as... MoveL *, v300, z10, tool0;
MoveL *, v300, z10, tool0;
MoveL *, v300, fine, tool0;
(Print...) MoveL *, v300, fine, tool0;
6 Preferences... WaitTime,3;
7 Check Program MoveL *, v300, fine, tool0:

8 Close Program

Copy Paste OptArg.. ModPos Test->

Figure 64 Commands in the File menu.

3. Select File: Save Program as and press Enter. (You could, alternatively, use the
numeric keyboard to enter the number shown in front of the function name.) The
dialog box in Figure 65 appears on the display.

Massmemory
Save Program as: name
Name: EXERCISE...
Massmemory Unit:= flp1:
/DEMO
1(1)
. . Go up one level

Unit Cancel OK

Figure 65 Dialog box for Save Program as.

4. Press Unit to choose the type of mass storage, if it is not already chosen;
“flp1” should appear on the third line of the window (see Figure 65).

Basic Operation 53
Storing the Program on Diskette Basic Operation

5. Press the Enter key to enter an optional name. The text-input dialog box in
Figure 66 then appears.

7 8 9
Enter Name
EXERCISE
4 5 6

789 ABC MNO YZ_ 1 2 3

456 DEF PQR
GHI STU - 0 .
123
_0_ JKL VWX
Some of the characters
obtained by pressing
<- -> Cancel OK
different numbers.

Figure 66 Window for entering text.

You can now see five groups of characters. Each group is represented on the numeric
keyboard: the layout of the keyboard corresponds to the layout of the characters. You
can move between the various groups using the <- and -> function keys (the selected
group is indicated with squares both above and below it, see Figure 66).

Use the Delete key to delete the name that is displayed or any errors you may
type.

6. Now give the program a new name. When you have entered this, press OK.
The window in Figure 67 appears.

Save Program as
Name: XXXXX...
Massmemory Unit:= flp1:
/DEMO
1(1)
. . Go up one level

Unit Cancel OK

Figure 67 The Save Program as window.

54 Basic Operation
Basic Operation Storing the Program on Diskette

7. Press OK. A window like the one in Figure 68 appears.

Save Program as
Name: XXXXX...
Massmemory Unit:= flp1:
Disk Changed!
/DEMO
1(1)
The contents of the disk has
. . Go up one level
been changed since last read.

Reread the contents?

Reread Cancel

Unit Cancel OK

Figure 68 An alert box.

8. Press Enter. The window in Figure 69 appears.

Save Program as
Name: XXXXX...
Massmemory Unit:= flp1:

1(1)
Empty volume

Unit Cancel OK

Figure 69 Window for storing the program on diskette.

9. The program is saved onto diskette when you press OK (see Figure 69).

10.Close the dialog box.

Basic Operation 55
Storing the Program on Diskette Basic Operation

56 Basic Operation
Basic Operation Printing Programs

15 Printing Programs

15.1 Using a PC
It is also possible to print programs from a PC. Almost all word-processing programs
can be used. The only requirement is that the computer can handle DOS-formatted dis-
kettes.

1. Store the program on diskette.

2. Enter the program into the PC.

3. Print.

Basic Operation 57
Printing Programs Basic Operation

58 Basic Operation
Basic Operation I/O Signals

16 I/O Signals

This chapter describes how you can program an instruction which activates a digital
output signal. After you have test run the program, you will manually open the I/O list
and look at the signal in question.

16.1 Programming an I/O instruction

1. Select the Program window (see Figure 70).

Figure 70 The Program window key.

The window in Figure 71 appears on the display.

File Edit View IPL1 IPL2

Program Instr XXXXX/main

1(6) XXXXX= the
MoveL *, v300, z10, tool0; name you gave
MoveL *, v300, z10, tool0;
MoveL *, v300, fine, tool0; the program in
MoveL *, v300, fine, tool0; Chapter 14.
WaitTime 3;
MoveL *, v300, fine, tool0;

Copy Paste OptArg.. ModPos Test->

Figure 71 The Program Instruction window.

Basic Operation 59
I/O Signals Basic Operation

The new instruction (set an output) will be entered directly under the highlighted
instruction. Select the third instruction in the program.

2. Select IPL1: I/O. The window in Figure 72 appears.

File Edit View IPL1 IPL2

Program Instr EXERCISE//main
I/O
3(7)
MoveL *, v300, z10, tool0; 1 InvertDO
MoveL *, v300, z10, tool0; 2 PulseDO
MoveL *, v300, fine, tool0; 3 Reset
MoveL *, v300, fine, tool0;
4 Set
WaitTime 3;
5 SetAO
MoveL *, v300, fine, tool0;
6 SetDO
7 SetGO
8 WaitDI
Copy Paste OptArg.. ModPos Test->

Figure 72 The pick list including the set instruction.

Select the function Set in the same way as you selected the WaitTime instruction in
Chapter 13.

3. After you have selected the function Set, the dialog box in Figure 73 appears.

Instruction Argument
Set ? <EXP>

Signal
1(11)
New... d01 d02
d03 d04 d05
d06 d07 d08
d09 d010 do11

Next Func More... Cancel OK

Figure 73 Dialog box for selecting a digital output signal.

60 Basic Operation
Basic Operation I/O Signals

4. Select “do4” in the list. Press OK. The window in Figure 74 appears.

File Edit View IPL1 IPL2

Program Instr XXXXX/main
I/O
4(7)
MoveL *, v300, z10, tool0; 1 InvertDO
MoveL *, v300, z10, tool0; 2 PulseDO
MoveL *, v300, fine, tool0; 3 Reset
Set do4; 4 Set
MoveL *, v300, fine, tool0;
5 SetAO
WaitTime 3;
MoveL *, v300, fine, tool0: 6 SetDO
7 SetGO
8 WaitDI
Copy Paste OptArg.. ModPos Test->

Figure 74 The “Set do4” instruction has been entered into the program.

5. Remove the pick list of instructions by pressing Edit: IPLhide.

The window in Figure 75 will then appear.

File Edit View IPL1 IPL2

Program Instr XXXXX/main

4(8)
MoveL *, v300, z10, tool0;
MoveL *, v300, z10, tool0;
MoveL *, v300, fine, tool0;
Set do4;
MoveL *, v300, fine, tool0;
WaitTime 3;
MoveL *, v300, fine, tool0;

Copy Paste OptArg.. (ModPos) Test->

Figure 75 The Program Instruction window.

6. Test run the program using the Test function, one instruction at a time, so that the
“Set do4” instruction can be read by the program.

7. You are now going to manually check the state of the signal.
8.Press the Inputs/Outputs window key (see Figure 76).

Previous page

Inputs/Outputs window key

Next page

Figure 76 The Manual I/O application.

Basic Operation 61
I/O Signals Basic Operation

Browse through the list displayed in the window with the keys as shown in Figure 76.

9. Find (using the up and down arrow keys) the “do4” signal in the IO list and highlight
it.

10.Check its value.

You can change the value using the function keys (0 / 1) that appear on the display each
time an output signal is highlighted.

11.Change the value of the signal and then press the Prog application key.

12. Test run the program once more (Test) and check the value of the signal again.

INFORMATION

When you use lists from the View menu in the Manual I/O window, you can choose to
have only input signals, only output signals, etc., shown on the display.

62 Basic Operation