Kawasak

C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES
MPOCCONTSW78E

Kawasak
Kawasaki Robotics (USA), Inc.
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and
is furnished solely for customer use only. No other uses are authorized or permitted
without the express written permission of Kawasaki Robotics (USA), Inc. The contents
of this manual cannot be reproduced, nor transmitted by any means, e.g., mechanical,
electrical, photocopy, facsimile, or electronic data media, without the express written per-
mission of Kawasaki Robotics (USA), Inc.

All Rights Reserved.

Copyright © 1999, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393

The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discon-
tinue specific robot models and associated hardware and software, designs, descrip-
tions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.

This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming procedures,
all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc.
training course.

KAWASAKI ROBOTICS (USA), INC. TRAINING

Training is available from Kawasaki Robotics (USA), Inc. on courses covering operation,
programming, electrical maintenance and mechanical maintenance. These courses are
conducted both on-site at the customer’s location, or at our training facility in Wixom,
Michigan.

For additional information contact:

Kawasaki Robotics (USA), Inc.

Training and Documentation Dept.
28059 Center Oaks Court
Wixom, Michigan 48393
 C SERIES CONTROLLER
Kawasak SOFTWARE DOWNLOAD PROCEDURES

REVISION HISTORY

Revision Release
Description of Change Initials
Number Date

0 7/1/99 Initial PDF release, based on rev. 3 of print copy KR

 Kawasak C SERIES CONTROLLER
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1.0 SOFTWARE DOWNLOAD PROCEDURES

This unit describes the procedures for downloading TP (multi function panel) software to
the multi function panel (MFP) 1FT board, AS (controller operating system) and Servo
(servo system) software to the 1GA board, and FS (I/O system) software to the 1FS
board using a personal computer (PC) and a static random access memory (SRAM) PC
card (Figure 1-1). Because the C controller is shipped with all software installed, this
unit describes the procedure for upgrading existing software or installing software for a
different application or I/O type (remote I/O or ControlNet). This unit also describes
procedures for configuring ControlNet software and loading data from a PC floppy or
hard disk.

Figure 1-1 SRAM PC Card (Actual Size)

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When loading all software types, load the software in the following order:

1. TP — MFP software
2. AS — C controller operating system
3. Servo — servo system software
4. FS — I/O system software

It is important to note that each type of software can be loaded separately. For example,
when an upgraded version of the AS software becomes available, it may be loaded
without also loading TP, FS, and Servo software; however, TP, AS, and FS software,
must be compatible (Table 1-1). It is also important to note that AS and Servo software
can be loaded at the same time, by modifying the “as_load.cmd” file (refer to section
1.4.1.1). Servo software must be matched with the robot model (e.g., UX120, UX150,
etc.) and application (e.g., spot welding, sealing, or arc welding).

NOTE

Due to the variety of software types (i.e., TP, AS, Servo,

and FS) and versions that are available for the C con-
troller, it is very important that these files be carefully
managed by the user.

Ensure that copies of all types and versions of the C controller software that are used
throughout the facility are saved to a PC hard disk, and that these files are well orga-
nized and documented. It is also important to document the current software that is
loaded on each C controller in the facility. The PC must have an SRAM PCMCIA slot, so
that software from the hard disk can be transferred to SRAM PC cards for subsequent
downloading to the C controllers. By maintaining a well organized directory of C control-
ler software, SRAM PC cards can be quickly loaded with the necessary files to perform
a software download to any C controller desired. Ensure that several 4MB SRAM PC
cards are available for this purpose. The 4MB card is required because the total file size
for a complete software download is 3-4MB.

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Table 1-1 AS, MFP, and FS Command and Executable Files Example

Application and I/O Type

(Directory Name)
Spot Spot
Welding & Welding &
Material Sealing & Material Sealing &
Handling Dispensing Handling Dispensing
RI/O RI/O ControlNet ControlNet
Software Type (Swrio) (Sdrio) (Swcnet) (Sdcnet)
AS Version 03010E00E 03020E00E 06010E10E 06020E10E
AS File Name 03010E.00E 03020E.00E 06010E.10E 06020E.10E
AS Cmd File Name as_load.cmd as_load.cmd as_load.cmd as_load.cmd

MFP Version T3010E00E T3010E00E T6010E00E T6010E00E

MFP File Name T3010E.00E T3010E.00E T6010E.00E T6010E.00E
MFP Cmd File Name tp_load.cmd tp_load.cmd tp_load.cmd tp_load.cmd

FS Version NAC040 NAC040 CNA005 CNA005

FS File Name NAC040.bin NAC040.bin CNA005.bin CNA005.bin
FS Cmd File Name fs_load.cmd fs_load.cmd fs_load.cmd fs_load.cmd

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1.1 SRAM PC CARD PREPARATION

To download TP, AS, and Servo software to the C controller, the software must first be
downloaded to an SRAM PC card, using a PC with a Personal Computer Memory Card
International Association (PCMCIA) slot. To set up a PC with Windows 95 for SRAM PC
card support and copy the C controller software to the SRAM PC card, perform the
following:

1. Select “Start” from the windows taskbar and the “Run...” option.

2. Enter C:\WINDOWS\SYSTEM\Sysedit.exe (Figure 1-2), select “OK” to open the

system editor.

Figure 1-2 Run Dialog Box

3. Add the following lines, in the order shown, to the end of the “config.sys” file:

NOTE

Ensure that these lines are typed exactly as shown be-

low. For n, enter the number of PC card slots; for most
PCs, n = 2. Ensure that the files “Csmapper.sys” and
“Carddrv.exe” have been installed in the
“windows\system” directory.

device=c:\windows\system\csmapper.sys
device=c:\windows\system\carddrv.exe/slot=n

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4. Save the changes.

5. Restart the PC.

6. Access Windows Explorer and confirm that there are two new drive letters, E: and F:
for most PCs. Each drive letter represents a PCMCIA slot.

NOTE

If the PC is connected to a network, there may be a

conflict between the network drives (E: or F:) and the
PCMCIA slots. The load files may have to be copied to
the PC hard drive and the PC disconnected from the
network before accessing the PCMCIA slot and saving
the load files to the SRAM PC card.

NOTE

Ensure that a battery is installed in the SRAM PC card;

data cannot be stored on the card if a battery is not in-
stalled.

7. Insert a blank SRAM PC card into the PCMCIA slot of the PC.

8. Copy the contents of the appropriate directory from the network or local drive to the
SRAM PC card. The example H:\Ford\C-Controller\Software directory and file
structure, shown in figure 1-3, is arranged according to the controller application
and I/O type. For example, the directory “Sdcnet” contains all of the necessary files
needed to download sealing/dispensing software for ControlNet I/O. Table 1-1 lists
examples of command and executable files needed to download AS, TP, and FS
software.

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Figure 1-3 C Controller Software Directory Example

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1.1.1 COMMAND FILE

The command files (i.e., as_load.cmd, fs_load.cmd, and tp_load.cmd) contain a group
of commands that control the download process for TP, AS, and FS software. Figures 1-
4 through 1-7 show the contents of the these command files. If modifications to these
command files are necessary, they can be edited using a text editor (e.g., Notepad).
The following is a description of the commands that are contained in the load files.

Command Description

test Communication test.

open xxxxxxxx.xxx Open file. xxxxxxxx.xxx is a user defined executable file.

There are files for each controller application (e.g., spot
welding/material handling and sealing/dispensing).

mfera xxxxxxxx xxxxxxxx Erase 1GA flash memory location xxxxxxxx xxxxxxxx.

fload -b Load the binary file to 1GA flash memory location

xxxxxxxx xxxxxxxx.

fchk xxxxxxxx xxxxxxxx Perform a check sum of 1GA flash memory location
xxxxxxxx xxxxxxxx. This confirms that the binary file has
been accurately copied from the SRAM PC card to 1GA
flash memory location xxxxxxxx xxxxxxxx.

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Figure 1-4 Sdcnet Directory Contents Example

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Figure 1-5 Sdrio Directory Contents Example

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Figure 1-6 Swcnet Directory Contents Example

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Figure 1-7 Swrio Directory Contents Example

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1.2 MULTI FUNCTION PANEL SOFTWARE DOWNLOAD

1.2.1 PREPARATION

Copy the TP software and the command file “tp_load.cmd” from the PC to the SRAM PC
card.

1.2.1.1 COMMAND FILE

The command file “tp_load.cmd” defines the MFP software download parameters.

“mfera xxxx xxxx” Flash memory erase instruction

“fpcload xxxxxxxx.xxx -b” Binary file Ioad instruction (downloaded file)
“fera XXXX” Flash memory erase instruction
“fchk Check sum instruction

Example

The following is the content description of a “tp_load.cmd” file, for downloading TP

software to the MFP. The binary file t00003.203 is the TP software file name; this file
name is unique for each application.

mfera a0000 3d0000

fpcload t00003.203 -b
fera 3e0000
Fchk 03e0000

1.2.2 EXECUTION

1. Set the controller power to OFF.

2. Ensure that 1GA board DIP switch S2 (Figure 1-8) is set to its default postion, as
shown below.
1 2 3 4 5 6 7 8
DSP

OFF

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VCC, +5V(±0.05V)
LD3
green
+12V(±0.1V)
LD2
green
-12V(±0.1V)
S2 LD1
red

1 2 3 4 5 6 7 8
GND

DSP
OFF

SW1

System Reset

CN2

CN1

Figure 1-8 1GA Board

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3. Insert the SRAM PC card containing the TP software and the command file
“tp_load.cmd” into the PC card slot of the MFP (Figure 1-9).

4. On the MFP, set DIP switch SW1, located next to the PC card slot as follows:

To download
MFP
Default software
12 12
xx ox (o:ON, x:OFF)

5. On the MFP set the TEACH LOCK switch to ON. On the control panel set the
TEACH REPEAT switch to TEACH.

6. Set the controller power to ON and press all four corners of the MFP touch panel at
the same time, as indicated by the Xs in figure 1-9. When the download executes,
the user display screen shown in figure 1-10 is displayed. When the user display
screen is displayed, the operator may release fingers from the touch panel.

Teach Lock Switch

Emergency Stop Switch

ON OFF
Trigger Switch Trigger Switch
TEACH LOCK

X X

LCD Display

X X

Touch Panel Pen

Contrast Adjustment
PC Card Slot

Figure 1-9 Multi Function Panel

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! “ # $ % & ‘ ( ) =
BS
1 2 3 4 5 6 7 8 9 0 -
~ NEXT MENU
Q W E R T Y U I O P @
CTL+L
A S D F G H J K L ; :
< > ? |
Z X C V B N M , . /
*
{ } SHIFT
[ ] ^ -
ENTER

Figure 1-10 MFP User Display Screen

NOTE

If the LCD display screen does not display the back

light, set the controller power to OFF and repeat this
procedure starting with step 6. If the screen is back lit,
but the download does not execute after pressing the
touch screen, set the controller power to OFF and re-
peat this procedure starting with step 2. If the download
is unsuccessful after several attempts, replace the MFP
and repeat this procedure.

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NOTE

For a description of download display messages, refer

to section 1.2.3, Download Display Messages.

7. The download is completed in approximately two minutes. When the download is

completed, “Finished successfully” is displayed on the MFP LCD display screen.

8. Set the controller power to OFF.

9. Set MFP DIP switch SW1 back to its default setting (see step 4).

10. Set the controller power to ON.

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1.2.3 DOWNLOAD DISPLAY MESSAGES

1.2.3.1 NORMAL DOWNLOAD

Display Message Description

“Now processing command file “TP-LOAD.CMD” Start message

“>> xxxxx xxxxxx” Execution command of the command

file description.

“erased bank xx-xxx(xxxxxx-xxxxxx)” Execution state display.

“erase check ...PASSED”
“read xxxx lines”
“Loaded 000a0000-xxxxxx”
“Start addr=000a0000”
“check sum bank 0-31”

“0—10—20—30//—90—100%” Bar display.

“………….” Advances under the bar display as

the file is downloaded.

“Finished successfully.” Download complete.

1.2.3.2 ERROR MESSAGES

The download process stops immediately when any of the following errors occur:

Error Message Description

“Can’t read this PC card (XX)” Displayed when there is a PC card communication
error, ensure PC card is properly inserted.

“Flash ROM write protected!!” Cannot write to flash area. The DIP switch setting is
incorrect, or the switch is defective.

“Aborted!!” Download terminated.

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1.3 AS SOFTWARE DOWNLOAD

This section describes the procedure for downloading AS software to the 1GA board
flash memory.

NOTE

Ensure that the AS and TP software versions are com-

patible (Table 1-1). AS and Servo software can be
downloaded at the same time; refer to section 1.4.1.1
for the procedure for setting up the command file to
download AS and Servo software at the same time, and
then return to this section to complete the download.
When downloading AS software only, follow the proce-
dure described here. When downloading Servo soft-
ware only, refer to section 1.4.

NOTE

When the spinning function is used, ZEROING and ex-

ecution of the ZENDLESS command is required upon
completion of the AS software download.

Prior to performing an AS software download, save the user program(s) and robot data
to an SRAM PC card, as described in steps 1-3 below.

1. Insert a blank SRAM PC card into the MFP PC card slot (Figure 1-9).

2. Set the controller power to ON.

3. Save the user program(s) and robot data to an SRAM PC card using:

• AUX 10 MEMORY->PC CARD(SAVE) option 1, ALL DATA (Figure 1-11).

or

• The AS Language SAVE command.

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NOTE

As a precaution, manually record the following data:

• Zeroing (AUX 41), setting only

• System switch (AUX 75)
• Dedicated signal (AUX 111 and 112)

If the memory capacity of the 1GA board is not indi-

cated on the robot data sheet (located in the pocket on
the interior of the controller door), determine the
memory capacity using AUX 70 or the AS Language
FREE command.

PROGRAM STEP PC SPEED 10% '97-03-18

17:30
TEACH
TEACHING FUNCTION NEXT MENU

8 9
AUX 10 MEMORY PC CARD(SAVE)
1 ALL DATA
2 PROGRAM
3 AUXILIARY DATA 6 7
4 ALL DATA(selected program only)
10 ROBOT DATA
11 ERROR LOGGING

4 5 - EXIT

2 3 . BS
FUNCTION NUMBER:
F1 F2 F3 F4
0 1 CLEAR
RETURN

Figure 1-11 AUX 10 Memory to PC Card (Save)

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4. Set the controller power to OFF.

5. Insert the SRAM card containing the AS software and the command file
“as_load.cmd” (see section 1.1, step 8) into the MFP PC card slot.

6. On the 1GA board, set DIP switch S2 to download AS software as follows:

Default Setting for Download

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

DSP
DSP

OFF OFF

7. Set the controller power to ON.

8. When the MFP LCD display screen is back lit (all white), press the touch panel
areas shown in figure 1-12 at the same time, until the download starts. The execu-
tion status is displayed on the MFP screen.

ON OFF ON OFF

TEACH LOCK TEACH LOCK

x x
or
x x

Figure 1-12 MFP Touch Panel

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NOTE

If the LCD display screen does not display the back

light, set the controller power to OFF and repeat this
procedure starting with step 7. If the screen is back lit,
but the download does not execute after pressing the
touch screen, set the controller power to OFF. Repeat
this procedure starting with step 7, and in step 8 use the
opposite corners from those used previously. If the
download is unsuccessful after several attempts, re-
place the MFP and repeat this procedure.

When the download starts, the execution status is displayed on the MFP screen.
For a description of normal download display messages, refer to section 1.3.1.1.
The AS software load takes approximately four minutes. When “OK! OK! OK!” is
displayed, the download is complete.

9. If the download is unsuccessful, observe the display message and refer to section
1.3.1.2, Error Messages. These messages can help the operator determine if the
problem is related to the SRAM card/MFP, download files, 1GA board, or connec-
tions.

NOTE

If the download is unsuccessful, repeat the procedure

starting with step 5. Ensure that the software version
and the command file are correct. Ensure that the
SRAM card is properly inserted. If the download is un-
successful after several attempts, replace the 1GA
board and repeat the procedure.

10. Set the controller power to OFF.

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11. After downloading the AS software, the system must be initialized.

a. Set 1GA board DIP switch S2, shown in figure 1-8, as follows:
1 2 3 4 5 6 7 8
DSP

OFF

b. Set the controller power to ON.

c. OK to initialize?… <1> <ENTER>

d. Are you sure?... <9894> <ENTER>

Entering 9894 clears programs from SRAM and resets the system variables to
their defaults.

12. Following initialization, enter the appropriate value (0 or 1) for the 1GA memory
size, indicated on the robot data sheet or recorded prior to performing the down-
load. If the memory capacity exceeds 1MB, 4MB must be selected.

1GA memory size. Enter 1Mbyte:0 4Mbyte:1. <0> or <1>

NOTE

“Error (-1019) CHECKSUM ERROR in system data” is

displayed. This error can be ignored at this time; it is
cleared in step 17.

13. Set the controller power to OFF.

14. Insert the SRAM PC card containing the user program and robot data into the PC
card slot.

15. Set 1GA board DIP switch S2 to its default setting, refer to step 6.

16. Set the controller power to ON.

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NOTE

“Error (-1019) CHECKSUM ERROR in system data” is

indicated when performing a software download or in-
stalling a new 1GA board. To clear this error, perform
step 17.

17. Clear the check sum error using the AS Language CHSUM command or AUX 78.

18. Load the user program(s) and robot data from the SRAM PC card or PC floppy/hard
drive using the AS Language LOAD command or AUX 11, 1-ALL DATA.

NOTE

If the robot data cannot be loaded from the SRAM PC

card or PC, all data in step 19 must be manually en-
tered. The default machine type is JS005.

19. Confirm that the robot data matches the Robot Data Sheet.

a. ROBOT TYPE (ZROBOT command or AUX 900)

b. EXTERNAL AXIS CONFIGURATION (ZAXCONFIG command or AUX 909)

c. EXTERNAL AXIS (ZAXIS command or AUX 901)

d. ZEROING DATA DISPLAY SET (ZZERO command or AUX 44)

e. SOFTWARE LIMIT (ULIMIT/LLIMIT command or AUX 51)

f. SYSTEM SWITCH (SWITCH command or AUX 75)

g. ENVIRONMENT DATA (ENV-DATA command or AUX 91)

h. ENVIRONMENT DATA 2 (ENV2-DATA command or AUX 95)

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NOTE

For step 19.i., set PANEL ENVIRONMENT DATA (AUX

96) according to the following:

If the previous version is older than AS:000007**7,

set AS INSTRUCTION TEACHING to OFF.

If the previous version is newer than AS:000007**7,

set AS INSTRUCTION TEACHING to ON (default).

i. PANEL ENVIRONMENT DATA (AUX 96)

j. NUMBER OF I/O SIGNALS (ZSIG command or AUX 905)

k. APPLICATION (ZSETAPPLI command or AUX 907)

l. SPEC1 (ZSPEC1 command or AUX 920)

m. OPTION SET1 (ZOPTION1 command or AUX 921)

n. OPTION SET2 (ZOPTION2 command or AUX 922)

o. OPTION SET4 (ZOPTION4 command or AUX 924)

p. OPTION SET5 (ZOPTION5 command or AUX 925)

q. OPTION SET6 (ZOPTION6 command or AUX 926)

NOTE

For step 19.r., if the previous version is older than

000008C08, set OPTION SET7 (AUX 927) SIGNAL UP-
DATE CYCLE 2ms to OFF.

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r. OPTION SET7 (ZOPTION7 command or AUX 927)

s. SPEC2 (ZSPEC2 command or AUX 930)

t. MECHANICAL SOFTWARE LIMIT (ZLIMIT command or AUX 971)

u. ACCEL/DECEL PARAMETER (ZSETACCEL/ZSETDECEL command or

AUX 972)

v. DEDICATED INPUT SIGNALS (DEFSIG I command or AUX 111)

w. DEDICATED OUTPUT SIGNALS (DEFSIG O command or AUX 112)

x. CLAMP SPECIFICATIONS (HSETCLAMP command or AUX 114)

20. Set the time data using the TIME command or AUX 110.

21. Confirm the movement of all axes in the TEACH mode.

22. Set up CHECK SPECIFICATION (AUX 99) according to the following:

If the previous version is older than AS:000007**7,

set STEP CONTINUOUS to <EFFECT>

set VELOCITY PRIORITY to <INEFFECT>

If the previous version is newer than AS:000007**7,

set STEP CONTINUOUS to <INEFFECT>

set VELOCITY PRIORITY to <EFFECT>

23. Using block step programming, record several points and confirm robot movement
in the CHECK mode. Save this test program.

24. Select the test program that was created in step 23. Run the program in repeat
mode to verify proper operation.

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1.3.1 DOWNLOAD DISPLAY MESSAGES

1.3.1.1 NORMAL DOWNLOAD

Display Message Description

“AS Down Loader Start!!!” Start message.

“File Open OK[xxx] size = 999 bytes” Displayed when a file is open.

“Command [xxxxx]” Indicates the command which is currently ex-

ecuting.

“|------+------|” Bar display, indicates the progress of the down-

load.

“*****” Advances under the bar display as the file is

downloaded.

“OK! OK! OK!” Download complete.

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1.3.1.2 ERROR MESSAGES

The download process stops immediately when any of the following errors occur:

Error Message Description

“CardCheck Error = 99” Displayed when the state of the PC card

input is confirmed.

“File Open Error [xxxx.xxx]” Error when opening a file.

“File Gets Error = 99 [xxxx.xxx]” Error when the contents of the file is ac-
cessed.

“Error [File OPEN before Write]” The “open” instruction is not executed
before the “fload” instruction.

“File Close Error = 99 [xxxx.xxx]” Error when closing the file.

“File Read Error = 99 [xxxx.xxx]” Error when reading the file.

“Error [Main CPU Non Response]” Response from the 1GA CPU did not come
within 20 seconds.

“Error [Main CPU Too many Responses]” Excessive responses from the 1GA CPU.

“Main CPU Response Error = xx” Error code reception from 1GA CPU.

01 The command communication reception

data is abnormal.

02 The specified command is incorrect.

03 The address specified by the flash

access instruction is not a flash area.

04 Flash memory erase error.

05 Checksum error when file is received.

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1.4 SERVO SOFTWARE DOWNLOAD

1.4.1 PREPARATION

Copy the Servo software, including the “as_load.cmd” file (Figure 1-13), from the PC to
the SRAM PC card. Ensure that the software version is correct for the robot model
(Table 1-2).

Figure 1-13 Servo Software Directory Example

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Table 1-2 Servo Software Examples

Robot Model Application Servo Software

spot welding
UX70
sealing
spot welding B04YC21.BIN
UX120
sealing A0RYC09.BIN
spot welding
UX120 LA
sealing
spot welding B04YG22.BIN
UX150
sealing A0RYG08.BIN
spot welding
UX150 LA
sealing
spot welding A0RYM03.BIN
UX200
sealing A0RYM03.BIN
spot welding A0RUC02.BIN
UT120
sealing A0RUC02.BIN
spot welding A0RUG05.BIN
UT150
sealing A0RUG05.BIN
UZ100 spot welding
UZ120 spot welding
UZ150 spot welding
JA15 arc welding
spot welding A0RJD03.BIN
JS30
sealing A0RJD03.BIN
spot welding A0RJD03.BIN
JS40
sealing A0RJD03.BIN

April 1, 1999 1-29

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

1.4.1.1 COMMAND FILE

The command file name is “as_load.cmd”, which is the same as for AS software. AS
and Servo software can be downloaded at the same time if the load procedure in the file
is described continuously without line breaks, refer to example 2 below.

NOTE

Ensure that the file name following the “open” instruction

is the same as the file name of the Servo software be-
ing loaded. If it is not, the command file must be edited
using a text editor (e.g., Notepad).

Example 1:

Contents of the “as_load.cmd” file when Servo software is downloaded to the1GA

board.
test
open a0jjc08.bin Open Servo software. This file is unique for
mfera e03e0000 e03e8000 each application.
mfera e03e0000 e03e8000fload -b
fchk e03e000 e03e8000

Example 2:

Contents of the “as_load.cmd” file when both AS and Servo software are downloaded to
the 1GA board at the same time.

test
open 000003.303
mfera e0200000 e0380000
AS
fload -b
fchk e0200000 e0380000
open a0jjc08.bin
mfera e03e0000 e03e8000
Servo
fload -b
fchk e03e0000 e03e8000

1-30 December 22, 1998

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

1.4.2 EXECUTION

The following procedure describes the download of Servo software only.

1. Insert the SRAM PC card containing the Servo software and the command file into
the PC card slot of the MFP. Figure 1-13 shows an example of a command file and
the binary Servo software files (*.bin). Table 1-2 shows examples of the Servo
software that is used for particular robot models and applications.

2. On the 1GA board (Figure 1-8), set DIP switch S2 as follows:

Default Setting for Download

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8
DSP

DSP

OFF OFF

3. Set the controller power to ON.

4. When the MFP LCD display screen is back lit (all white), press the touch panel
areas, as indicated by the Xs shown in figure 1-14, at the same time until the down-
load starts. The execution status is displayed on the MFP screen.

ON OFF ON OFF

TEACH LOCK TEACH LOCK

x x
or
x x

Figure 1-14 MFP Touch Panel

May 10, 1999 1-31

 Kawasak C SERIES CONTROLLER
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SOFTWARE DOWNLOAD PROCEDURES

NOTE

If the LCD display screen does not display the back

light, set the controller power to OFF and repeat this
procedure starting with step 3. If the screen is back lit,
but the download does not execute after pressing the
touch screen, set the controller power to OFF, repeat
this procedure starting with step 3, and in step 4 use the
opposite corners from those used previously. If the
download is unsuccessful after several attempts, re-
place the MFP and repeat this procedure.

When the download starts, the execution status is displayed on the MFP screen.
When “OK! OK! OK!” is displayed, the download is complete.

5. Set the controller power to OFF.

6. Set 1GA board DIP switch S2 to its default setting (see step 2).

1-32 April 1, 1999

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SOFTWARE DOWNLOAD PROCEDURES

1.5 1FS SYSTEM SOFTWARE DOWNLOAD

This section describes the procedure for downloading FS software to the 1FS board
flash memory using a PC. If the 1FS board is a remote I/O type, the Slogic program
must be uploaded to the 1GA board prior to performing the FS software download, and
then downloaded to the 1FS board upon completion of the FS software download.

NOTE

For information about downloading FS software using

an SRAM PC card and the MFP, contact Kawasaki cus-
tomer service.

1. Stop the Slogic program using AUX 183-2, Slogic Stop (Figure 1-15).

PROGRAM STEP PC SPEED 10% '97-03-18

17:30
TEACH
TEACHING FUNCTION NEXT MENU

8 9
AUX 183 RI/O SLOGIC CONTROL
1 SLOGIC RUN (SRUN)
2 SLOGIC STOP (SSTOP)
3 SLOGIC DOWNLOAD (SDOWNLOAD) 6 7
4 SLOGIC UPLOAD (SUPLOAD)

4 5 - EXIT

2 3 . BS

F1 F2 F3 F4
0 1 CLEAR
RETURN

Figure 1-15 Stopping the Slogic Program

April 1, 1999 1-33

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

2. Upload the Slogic program to the 1GA board using AUX 183-4, Slogic Upload
(Figure 1-16).

PROGRAM STEP PC SPEED 10% '97-03-18

17:30
TEACH
TEACHING FUNCTION NEXT MENU

8 9
AUX 183 RI/O SLOGIC CONTROL
1 SLOGIC RUN (SRUN)
2 SLOGIC STOP (SSTOP)
3 SLOGIC DOWNLOAD (SDOWNLOAD) 6 7
4 SLOGIC UPLOAD (SUPLOAD)

4 5 - EXIT

2 3 . BS

F1 F2 F3 F4
0 1 CLEAR
RETURN

Figure 1-16 Uploading the Slogic Program

1-34 April 1, 1999

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

Before downloading the FS software from the PC to the C controller, AS monitor soft-
ware must first be installed on the hard drive of the PC. The AS Monitor software
[KCMON (DOS) and KCWIN (Windows)] provides the capability to control the robot
system using AS Language commands from the PC.

1.5.1 INSTALLING AS MONITOR SOFTWARE

1. Connect the PC to the C controller host communication port (Figure 1-17) using an
RS-232C 9-pin female-to-female null modem cable (Figure 1-18).

ON OFF

TEACH LOCK

EMERGENCY STOP

ERROR MOTOR POWER

ERROR RESET CYCLE START

Host Communication Port

TEACH REPEAT HOLD RUN

X2

MFP
AC115V 1A

Figure 1-17 C Controller Cabinet (Front View)

2 2
Personal
C Controller 3 3
Computer
5 5

Figure 1-18 RS-232C Null Modem Cable

April 1, 1999 1-35

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

2. Set the controller power to ON.

3. Set TEACH LOCK switches to TEACH and HOLD RUN switches to HOLD.

4. Set the PC power to ON.

5. Ensure that the disk containing the KCMON or KCWIN software is write protected.

6. Insert the disk into the PC floppy drive.

The following procedure describes installation of KCMON files to the PC hard drive:

1. From the C:\WINDOWS\START MENU\PROGRAMS directory select “MS-DOS

Prompt”.

2. Verify that the disk contains the following files in the KCMON\DOSV directory:

• KCMON_.EXE
• KCMON.BAT
• EDT.BAT
• FUTL.BAT
• KCMONENV.DAT
• FORMAT.EXE

3. Select the A: drive.

4. Type “INST C:\ KCMON” <ENTER>.

The KCMON directory and its contents are copied from the diskette to the root
directory of C:.

5. Confirm that the directory and its contents have been successfully copied.

6. Using the Windows system editor add the following line to the config.sys file:
DEVICE = C:\ DOS\ANSI.SYS

7. From the KCMON\DOSV directory type “KCMON” <ENTER>, to open the AS Moni-
tor program.

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SOFTWARE DOWNLOAD PROCEDURES

The following procedure describes installation of KCWIN files to the PC hard drive:

1. Confirm that the KCWIN disk contains the following files:

• KCWIN.EXE
• KCWINE.EXE
• KCWIN.INI

2. From the Windows Start menu, select “Run...”.

3. Enter “A: install”, select “OK”.

4. Confirm that files KCWIN.EXE and KCWINE.EXE have been successfully installed
at the root of C:, and KCWIN.INI is installed in the WINDOWS directory.

5. From the KCWIN directory select KCWIN.EXE to open the AS Monitor program.

1.5.2 ENABLING TERMINAL OPERATION

Select AUX 95 ENVIRONMENT DATA 2 and set TERMINAL to CONN. (connected).

When the PC is connected to the C controller host communication port and the AS
Monitor program is running, all functions that are normally available from the MFP user
display screen can be performed at the PC.

April 1, 1999 1-37

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

1.5.3 DOWNLOAD PROCEDURE

1. Copy the FS software to the C:\KCMON\DOSV directory when using KCMON, or

the C:\Windows directory when using KCWIN.

2. Connect the PC to the C controller host communication port (Figure 1-17) using an
RS-232C 9-pin female-to-female null modem cable (Figure 1-18).

3. At the PC, open the AS Monitor program (KCMON or KCWIN).

NOTE

The following special function keys are available:

Key Function
F5 END
F9 Change Baudrate
F10 Load File

4. Press the “F9” key.

The following message is displayed:

Input Baudrate =

Type “9600” <Enter>.

5. Set the 1FS board DIP switch S1 as follows:

Setting
Default for Download
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

DSP
DSP

OFF OFF

1-38 April 1, 1999

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SOFTWARE DOWNLOAD PROCEDURES

6. Set the controller power to ON.

7. At the PC, enter the following:

a. To change the ODT mode:

Type “ZODT” <ENTER>

b. To change the 1FS monitor mode:

At the ODT prompt, type “1FS” <ENTER>

c. To erase the existing 1FS system software:

At the 1FS type prompt, type “mfera 40000 a0000” <ENTER>

d. To download the new 1FS system software:

At the 1FS prompt, type “fload -b” <ENTER>
Type “FIO” <ENTER>

At the Input file name = prompt, type “test.bill” <ENTER>

When the download is completed, the following is displayed:

start address...

8. Set the controller power to OFF.

9. Set 1FS board DIP switch S1 to its default setting (see step 5).

10. Set the controller power to ON.

If the following message is not displayed, the software download is successful:

“1FS Board initialize error”

NOTE

If the download is unsuccessful, repeat the procedure

starting with step 1. Ensure that the software version is
correct and is located in the proper directory. Ensure
that the RS-232C cable connections are secure. If the
download is unsuccessful after several attempts, re-
place the 1FS board and repeat the procedure.

April 1, 1999 1-39

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

11. a. If ControlNet I/O is used, perform the procedure described in section 1.6,
ControlNet Setup.

b. If remote I/O is used, download the Slogic program from the 1GA board to the
1FS board (Figure 1-19) and run the Slogic program (Figure 1-20).

PROGRAM STEP PC SPEED 10% '97-03-18

17:30
TEACH
TEACHING FUNCTION NEXT MENU

8 9
AUX 183 RI/O SLOGIC CONTROL
1 SLOGIC RUN (SRUN)
2 SLOGIC STOP (SSTOP)
3 SLOGIC DOWNLOAD (SDOWNLOAD) 6 7
4 SLOGIC UPLOAD (SUPLOAD)

4 5 - EXIT

2 3 . BS

F1 F2 F3 F4
0 1 CLEAR
RETURN

Figure 1-19 Slogic Download

1-40 April 1, 1999

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SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

PROGRAM STEP PC SPEED 10% '97-03-18

17:30
TEACH
TEACHING FUNCTION NEXT MENU

8 9
AUX 183 RI/O SLOGIC CONTROL
1 SLOGIC RUN (SRUN)
2 SLOGIC STOP (SSTOP)
3 SLOGIC DOWNLOAD (SDOWNLOAD) 6 7
4 SLOGIC UPLOAD (SUPLOAD)

4 5 - EXIT

2 3 . BS

F1 F2 F3 F4
0 1 CLEAR
RETURN

Figure 1-20 Running the Slogic Program

April 1, 1999 1-41

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

1.6 CONTROLNET SETUP

1. Ensure that the AS and TP software versions that are installed on the 1GA board
and MFP are for ControlNet and the desired application (i.e., spot welding/material
handling or sealing/dispensing), refer to Table 1-1.

2. Cycle the controller power.

3. Ensure that the FS software version is correct by typing ID at the PC prompt or

using the MFP function AUX 90 SOFTWARE VERSION. The display should indi-
cate “Seq. Board: version CNA00X” (the value of X depends on the revision level).

4. Verify proper operation of the 1FS board, shown in Figure 1-21; ensure that LED
LD5 is flashing. If LED LD5 is not flashing and LED LD4 is illuminated, the board is
functioning incorrectly and must be replaced.

LD5 green
LD4 red
LD3 green
LD2 red
LD1 green
LD101 red
S1
1 2 3 4 5 6 7 8
DSP

OFF

CN3

CN4

CN2

CN1

Figure 1-21 1FS Board LEDs

1-42 April 1, 1999

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

5. Set the node address of the controller. At the terminal prompt type:
“ZCNETADDR X ” <ENTER> (X is the node address).

6. Ensure proper connection to the ControlNet network. For a non-redundant network,

ensure that connection to the 1FS board is to the same channel (A or B) as the rest
of the network. For a redundant system, ensure that connections to the 1FS board
are not reversed.

7. Download the Slogic program to the 1FS board by selecting AUX 183-3, refer to
figure 1-19.

8. Run the Slogic program by selecting AUX 183-1, refer to figure 1-20.

April 1, 1999 1-43

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

1.7 DATA LOAD FROM A PERSONAL COMPUTER

1.7.1 DATA LOAD FROM A FLOPPY DISK

This section describes the procedure used to load robot, system, auxiliary and interface
panel data from a PC floppy drive to the C controller 1GA board flash memory.

! CAUTION
Do not load robot or system data from one controller to
another. This data is unique to each controller/mechani-
cal unit, and if copied from one controller to another
may cause unpredictable mechanical unit motion or sys-
tem errors when operated.

1. Connect the PC to the C controller host communication port (Figure 1-17) using an
RS-232C 9-pin female-to-female null modem cable (Figure 1-18).

2. Set the power for the controller and the PC to ON.

3. From the PC, open the AS Monitor program (KCMON or KCWIN).

4. Insert the disk, containing the files to be loaded, into the floppy drive.

NOTE

For the following steps refer to figure 1-22.

5. Enter the AS Language command LOAD/Q, source drive (a:), and file name (e.g.,
kaw.as).

6. Respond to the prompts.

1-44 April 1, 1999

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

Figure 1-22 Personal Computer Display

1.7.2 DATA LOAD FROM A HARD DRIVE

1. Connect the PC to the C controller host communication port (Figure 1-17) using an
RS-232C 9-pin female-to-female null modem cable (Figure 1-18).

2. Set the power for the controller and the PC to ON.

3. Copy the data file (user defined up to eight characters; e.g., XXXXXXXX.as) to the
KCWIN directory.

4. Execute KCWIN.exe.

5. At the command prompt, type:

“load XXXXXXXX.as” <Enter>

6. Respond to the prompts.

April 1, 1999 1-45

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

INDEX

1FS Board 1-42

1FS Board DIP Switch SW1 1-39
1FS Monitor Mode 1-39
1FS System Software 1-33
1GA Board 1-20, 1-31
1GA Board DIP Switch SW2 1-12

A
ACCEL/DECEL PARAMETER 1-25
ANSI.SYS 1-36
APPLICATION 1-24
AS Language 1-35
AS Monitor software 1-35
AS Software 1-18
AS_load.cmd 1-28, 1-30
AUX 11 1-23
AUX 110 1-25
AUX 111 1-20, 1-25
AUX 112 1-20, 1-25
AUX 114 1-25
AUX 44 1-23
AUX 51 1-23
AUX 75 1-23
AUX 78 1-23
AUX 90 SOFTWARE VERSION 1-42
AUX 900 1-23
AUX 901 1-23
AUX 905 1-24
AUX 907 1-24
AUX 909 1-23
AUX 91 1-23
AUX 920 1-24
AUX 927 1-23
AUX 930 1-25
AUX 95 Environment DATA 2 1-37
AUX 96 1-24
AUX 971 1-25
AUX 972 1-25
AUX921 1-24
AUX922 1-24
AUX924 1-24
AUX925 1-24
AUX926 1-24
AUX927 1-25
AUX95 1-23
AUX99 1-25

B
Baudrate 1-38
Block Step Programming 1-25

1-46 April 1, 1999

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SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

C
CHECK Mode 1-25
CHECK SPECIFICATION 1-25
CHECKSUM ERROR 1-21, 1-24
CHSUM 1-23
CLAMP SPECIFICATIONS 1-25
Command and Executable Files 1-3
Command File 1-30
Config.sys 1-36
ControlNet 1-40, 1-43

D
DEDICATED INPUT SIGNALS 1-25
DEDICATED OUTPUT SIGNALS 1-25
DEFSIG I 1-25
DEFSIG O 1-25

E
EDT.BAT 1-36
ENV-DATA 1-23
ENV2-DATA 1-23
ENVIRONMENT DATA 1-23
ENVIRONMENT DATA 2 1-23
Error, 1FS Board Initialize Error 1-39
Error Messages 1-17, 1-27
EXTERNAL AXIS 1-23
EXTERNAL AXIS CONFIGURATION 1-23

F
Floppy Disk 1-44
Floppy Disk, Software Load 1-44
FORMAT.EXE 1-36
FS Software 1-38
FUTL.BAT 1-36

H
Hard Drive 1-45
HOLD/RUN (switch) 1-36
Host Communication Port 1-35, 1-38, 1-44, 1-45
HSETCLAMP 1-25

I
Initializing the System 1-22

K
KCMON 1-35
KCMON, Installing 1-36
KCMON.BAT 1-36
KCMON_.EXE 1-36
KCMONENV.DAT 1-36

April 1, 1999 1-47

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

KCWIN 1-35
KCWIN, Installing 1-37
KCWIN.EXE 1-37
KCWIN.INI 1-37
KCWINE.EXE 1-37

L
LCD Display Screen 1-20, 1-31
LOAD 1-23
LOAD/Q 1-44

M
MECHANICAL SOFTWARE LIMIT 1-25
MS-DOS Prompt 1-36
Multi Function Panel 1-19
Multi Function Panel, DIP Switch SW1 1-14
Multi Function Panel Software 1-12

N
Node Address 1-43
Non-Redundant Network 1-43
Null Modem Cable 1-38, 1-44, 1-45
NUMBER OF I/O SIGNALS 1-24

O
ODT 1-39
ODT Mode 1-39
OPTION SET1 1-24
OPTION SET2 1-24
OPTION SET4 1-24
OPTION SET5 1-24
OPTION SET6 1-24
OPTION SET7 1-23, 1-25

P
PANEL ENVIRONMENT DATA 1-23, 1-24
PC 1-35
PC Card Slot 1-20
PCMCIA (Personal Computer Memory Card Internationa 1-4
Personal Computer, Display 1-45

R
Redundant Network 1-43
Remote I/O 1-33
Robot Data 1-18, 1-23
Robot Data Sheet 1-20, 1-23
ROBOT TYPE 1-23
RS-232C Null Modem Cable 1-35

1-48 April 1, 1999

 Kawasak C SERIES CONTROLLER
SOFTWARE DOWNLOAD PROCEDURES

SOFTWARE DOWNLOAD PROCEDURES

S
SAVE Command 1-18
Servo Software 1-28, 1-29, 1-30
SIGNAL UPDATE CYCLE 2ms 1-23
SLOGIC 1-33, 1-40, 1-43
Software Directory 1-6
SOFTWARE LIMIT 1-23
SPEC1 1-24
SPEC2 1-25
Special Function Keys 1-37
Spinning Function 1-17
SRAM PC Card 1-1
SRAM PC Card, Battery 1-6
SRAM PC Card Preparation 1-4
STEP CONTINUOUS 1-25
SW2 1-20, 1-31
SWITCH 1-23
SYSTEM SWITCH 1-23

T
TEACH (switch) 1-36
TEACH LOCK 1-14, 1-36
TEACH Mode 1-25
Test.bill 1-39
TIME 1-25
Time Data 1-25
TP Software 1-12
Tp_load.cmd 1-12

U
ULIMIT/LLIMIT 1-23
User Display Screen 1-14, 1-15
User Program 1-18

V
VELOCITY PRIORITY 1-25

W
Windows 95 1-4

Z
ZAXCONFIG 1-23
ZAXIS 1-23
ZCNETADDR 1-43
ZENDLESS 1-17
ZEROING 1-17
ZEROING DATA DISPLAY SET 1-23
ZLIMIT 1-25
ZODT 1-39
ZOPTION1 1-24

April 1, 1999 1-49

 Kawasak C SERIES CONTROLLER
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SOFTWARE DOWNLOAD PROCEDURES

ZOPTION2 1-24
ZOPTION4 1-24
ZOPTION5 1-24
ZOPTION6 1-24
ZOPTION7 1-25
ZROBOT 1-23
ZSETACCEL/ZSETDECEL 1-25
ZSETAPPLI 1-24
ZSIG 1-24
ZSPEC1 1-24
ZSPEC2 1-25
ZZERO 1-23

1-50 April 1, 1999