FANUC ROBOT MANUAL

INDEX

1. INTRODUCTION
2. BACKUP
3. RESTART ROBOT
4. HOME DEFINE
5. GUN ADDITION
6. GUN MASTERING
7. AUTO TUNNING
8. FORCE CALIBRATION
9. CURRENT CALIBARTION
10. PAYLOAD CALIBARTION
11. PROGRAM SHIFT
12. ENABLE UI SIGNAL
13. PULSE MISMATCH ERROR
14. SET U-TOOL AND U-FRAME VALUE
15. GROUP ENABLE DISABLE
16. ROBOT FAULTS
 1. INTRODUCTION

1. THE ROBOT IS THE MECHANICAL UNIT THAT, ALONG WITH THE

END-OF-ARM TOOLING(E.O.A.T.) OR GRIPPER, ACTUALLY
PERFORMS THE TASK TO BE COMPLETED.
2. A ROBOT IS A SERIES OF MECHANICAL LINKS DRIVEN BY
SERVOMOTORS.
3. THE AREA AT EACH JUNCTION BETWEEN THE LINKS IS A JOINT,
OR AXIS.
4. THE FIRST THREE AXES MAKE UP THE MAJOR AXES . A ROBOT IS
CLASSIFIED BYTHE NUMBER OF LINEAR AND ROTATIONAL
MAJOR AXES.
1.1. ROBOT WITH CONTROLLER
ON/OFF SWITCH FAULT INDICATE LED POWER ON LED EMERGENCY STOP

FAULT RESET

CYCLE
START

A ROBOT
TEACH PENDANT

B CONTROLLER
 1.2 TEACH PENDANT
TP ENABLE DISABLE EMERGENCY STOP

DEADMAN:-DEADMAN SWITCH
IS USED TO ENABLE THE TP
IF RELEASE THE SWITCH THE
THE ROBOT STOP IMMEDIATELY.
1.3 TEACH PENDANT
 2. ROBOT BACKUP

SYSTEM BACKUP
IMAGE BACKUP
ASCII(LS) BACKUP
 2.1 SYSTEM BACKUP
1. MENU
2. FILE
3. UTILITIES(F5)
3.1 SET DEVICE
3.2 MAKE DIRECTORY(MAKE DIR)
3.3 FORMAT
4. FIRST SELECT DEVICE
4.1 MEMORY CARD(MC)
4.2 MEMORY DEVICE(MF)
4.3 REMOVABLE DEVICE(USB)
5. AFTER SELECTING DEVICE MAKE DIRECTORY (OPTION 2 IN UTILITY).
(e.g. Date-robot name- backup type (system,LS,Image)).
6. PRESS BACKUP(f4).
7. SELECT ALL THE ABOVE (no.7).
8. PRESS OK.
9. THE SYSTEM BACKUP WILL STORE INTO PARTICULAR DEVICE.
10. FINESH.
 2.2 IMAGE BACKUP
1. MENU
2. FILE
3. UTILITIES(F5)
3.1 SET DEVICE
3.2 MAKE DIRECTORY(MAKE DIR)
3.3 FORMAT
4. FIRST SELECT DEVICE
4.1 MEMORY CARD(MC)
4.2 MEMORY DEVICE(MF)
4.3 REMOVABLE DEVICE(USB)
5. AFTER SELECTING DEVICE MAKE DIRECTORY (OPTION 2 IN UTILITY).
(e.g. Date-robot name- backup type (system,LS,Image)).
6. PRESS BACKUP(f4).
7. SELECT IMAGE BACKUP .
NOTE:- MAKE SURE THAT TEACH PENDENT IS DISABLE

7. PRESS OK.
8. THE IMAGE BACKUP WILL STORE INTO PARTICULAR DEVICE.
9. FINESH.
 2.3 ASCII(LS) BACKUP
1. MENU
2. FILE
3. UTILITIES(F5)
3.1 SET DEVICE
3.2 MAKE DIRECTORY(MAKE DIR)
3.3 FORMAT
4. FIRST SELECT DEVICE
4.1 MEMORY CARD(MC)
4.2 MEMORY DEVICE(MF)
4.3 REMOVABLE DEVICE(USB)
5. AFTER SELECTING DEVICE MAKE DIRECTORY (OPTION 2 IN UTILITY).
(e.g. Date-robot name- backup type (system,LS,Image)).
6. PRESS BACKUP(f4).
7. SELECT ASCII BACKUP .
8. PRESS OK.
9. THE ASCII BACKUP WILL STORE INTO PARTICULAR DEVICE.
10. FINESH.
 2.4 LOAD IO FILES,TP FILES FORM
1. MENU
USB
2. FILE
3. UTILITIES(F5)
3.1 SET DEVICE
3.2 MAKE DIRECTORY(MAKE DIR)
3.3 FORMAT
4. FIRST SELECT DEVICE
4.1 MEMORY CARD(MC)
4.2 MEMORY DEVICE(MF)
4.3 REMOVABLE DEVICE(USB)
5. AFTER SELECTING DEVICE OPEN DIRECTORY OF THAT DEVICE
AND SELECT TP FILE WHICH YOU WANT TO LOAD INTO THE RB.
6. PRESS LOAD(f3).
7. PRESS YES.
8. THE TP,IO FILES WILL LOAD INTO CONTROLLER.
9. FINESH.
 3. RESTART ROBOT
 ROBOT IS RESTART BY TWO WAYS
I. COLD START.
II. RESTART FROM CONTROLLER.
 COLD START : -
I.FUNCTION
II.NEXT(0)
III.CYCLE POWER
IV. YES
ROBOT WILL RESTART.
 OFF THE CONTROLLER AND TURNS ON THE ROBOT WILL RESTART.
 4. HOME DEFINE
1. MENU
2. DATA
3. TYPE
4. POSITION REGISTER
5. PR1(HOME POS)
6. POSITION(F3)
IF VALUES ARE IN CORDINSATES (X,Y,Z) THEN PRESS F5 TO SELECT
IN JOINTS.
7. PUT VALUES OF J1 TO J7.
8. DONE.
 5. NEW GUN ADDITION
1. BEFORE GUN ADDITATION CHECK DETAILS OF GUN
I. GUN MOTOR NO.
II. AMPERE OF MOTOR.
III. TORQUE.
IV. GUN ELECTRODE FORCE.
V. MAXIMUM GUN OPENING.
VI. MINIMUM GUN OPENINIG.
VII. TIP DISPLACEMENT.
 GUN ADDITION
1. CYCLE POWER
I. FUNCTION
II. NEXT(0)
III. CYCLE POWER YES.
2. FOR CONTRELLED START FUNCTION PRESS NEXT & PREV BUTTON AT
SAME TIME.
3. GO TO MENU.
4. MAINTENANCE
I. ROBOT
II.SERVO GUN AXIS
5. MOVE CURSOR TO SERVO GUN AXIS.
5. PRESS MANUAL (NOTE. DO NOT PRESS ENTER AFTER SELECTING SERVO GUN AXIS).

6. SELECT FSSB LINE 1.

7. SELECT AXIS 7.
8. SELECT ADD SERVO GUN.
 GUN ADDITION
10. MOTOR TYPE : -
I. MOTOR TYPE IS STARTED WITH (ALPHA).e.g. is…..
II. CHOOSE MOTOR TYPE FROM SELECTED LIST
III. IF NOT AVABLE THEN SELECT NEXT(0) ,
IV. SELECT 1.STANDARD AND SELECT MOTOR TYPE.
11. MOTOR AMPERE : -
I. CHECK ON MOTOR (normally it should be 80A).
12. AMPLIFIER NO : - PUT 2 ALWAYS.
13. TIP DISPLACEMENT : -
I. CHECK ON GUN DATA SHEET “DISTANCE OF TIP TRAVELLED FOR
L ONE ROTATION OF MOTOR i.e. tip displacement.
14. MAXIMUM GUN STROKE : -
I. GUN OPENING (CHECK ON DATA SHEET).
 GUN ADDITION
15. BREAK NO : - ALWAYS SELECT 2. (1ST ONE IS ROBOT ,2ND IS FOR GUN AND 3RD IS FOR TT).
16. ELECTRODE FORCE : -
I. IT IS THE MAXIMUM GUN PRESSURE.
II. CHECK ON GUN DATA SHEET WRITTEN IN NEWTON(NW)
III. CONVERT IT FROM NEWTON TO KGF.
17. SERVO OFF : - ENABLE.
18. TIME OFF : - ENABLE
I. TIME OFF : - 20sec.
19. EXIT (4TH OPTION ).
20. CONTINUE ENTER.
21. COLD START.
I. FUNCTION.
II. COLD START.
III. OK.
 GUN ADDITION
22. AFTER COLD START BZAL ALARM POP UP ,
RESET THAT ALARM .
23. RESET BZAL ALARM : -
I. MENU
II. SYSTEM
III. TYPE
IV. GUN MASTER
V. RESET BZAL ERROR (F3)
VI. YES OK.
24. FINESH.
 6. GUN MASTERING
1. MENU
2. SYSTEM
3. TYPE
4. GUN MASTER
5. CLOSE THE GUN UPTO A SMALL PAPER GAP
6. EXECUTE
7. OK
8. CHECK MAXIMUM GUN OPENING
I. DIGITAL :- DISPLAYED IN POSITION.
II. MANUAL :- CHECK WITH MEASURING TAPE.
* BOTH SHOULD BE SAME.
9. FINISH.
 7. AUTO TUNNING
1. MENU
2. UTILITIES
3. TYPE
4. GUN SETUP
5. FIRST COMPLETE
I.GUN MOTION SIGN
II. GUN SPECES , MASTER GUN
6. SELECT AUTO TUNE (OPTION 3).
7. EXECUTE(F4).
8. FINESH.
9. AFTER COMPLETING AUTO TUNE COMPLETE THICKNESS CHECK
PROCEDURE ALSO.
10. FINESH.
 8. FORCE CALIBARATION
1. MENUS
2. 6 SETUP
3. F1 TYPE
4. 7 SERVO GUN
5. Move the cursor to GENERAL SETUP <*DETAILS*>
6. Press Enter key
7. Scroll down to 9 PRESSURE CALIBRATION <*DETAILS*>
8. Press Enter key
9. SET
I. PRESURRING TIME :- 1sec.
II. THICKNESS OF GUAGE(mm):- (measure thickness of gauge & enter in mm).
III. GUN OPENINIG VALUE(mm) :- ( if gauge thickness is 15mm then keep gun
d opening as 30mm ).
10. PUT VALUES OF PRESSURE WITH DISTANCE OF 50(50-100-150 up to 300).
11. MAKE SPEED CONSTANT.
12. ACCORDING TO PRESSURE CHANGE THICKNESS.
 FORCE CALIBARATION
13. START WITH A APPROXIMATELY SMALL TORQUE VALUE (3%, FOR
EXAMPLE).
14. HOLD THE PRESSURE GUAGE FIRMLY ON TO THE FIXED TIP.
15. PRESS SHIFT + F3 TOGETHER FOR THE GUN TO ACTUATE & APPLY
PRESSURE ON THE GAUGE.
16. VARY THE OVERRIDE(SPEED) UP TO 100% TO GET PROPER VALUES.
17. SIMILARLY CARRYOUT THE PROCEDURE FOR 200,250, 300,350KGF.
18. AFTER THE COMPLETION OF THE ABOVE, MOVE THE CURSOR DOWN TO
CALIBRATION STATUS,AND PRESS F4 COMP TO FINISH THE PRESSURE
CALIBRATION.
19. THE RESULTING CALIBRATION TABLE IS DISPLAYED AFTER THE
CALCULATION.
20. FINESH.
 9. CURRENT CALIBARATION
1. CURRENT CALIBARATION PROCEDURE IS CARRIED OUT THROUGH
CURRENT CALIBRATION GAUGE & TEACH BOX.
2. IT HAS TWO MAIN FACTORS
I. TURNS RATIO
II. CURRENT(KVA)
BOTH ARE DIRECTLY PROPRTIONAL WITH EACH OTHER.
IF YOU WANT TO DECREASE TURNS RATIO INCREASE CURRENET.
PROCEDURE:-
1. PUT CURRENT CALIBRATION GAUGE IN GUN.
2. CONNECT TEACHBOX TO WELDING CONTROLLER AND CHECK TURNS
J RATION AND CURRENT.
3. CHANGE THE TURNS RATION TO SMALL VALUE AND MONITOR THE
H CURRENT ON CURRENT CALIBRATION GAUGE
4. BOTH THE CURRENT (i.e. CURRENT ON GAUGE & CURRENT SHOWS ON
U TEACHBOX BOTH SHOULD BE MATCHED).
5.IF CURRENT ON GAUGE IS MORE THAN REQUIRED CURRENT THEN
J DECREASE TURNS RATIO & IF LESS THEN INCREASE TURNS RATIO.
6. SET THE TURNS RATIO AND CHECK IT BY CHANGING CURRENT FROM
J TEACHBOX.
 10. PAYLOAD CALIBARATION
NOTE: - FIRST MOVE ALL AXIS TO ZERO POSITION (J1 IS OPTIONAL).
1. MENU
2. SYSTEM
3. MOTION
4. IDENT
5. MASS IS KNOWN : - IF WEIGHT KNOWN –PRESS YES OW SELECT NO
6. CALIBRATION MODE : - ON
7. CALIBRATION STATUS : - OK
8. PRESS NEXT AND THEN PRESS F4 (DETAIL)
9. ADJUST THE SPEED PERCENTAGE OF GUN THRUGH +% -% KEY.
10. PRESS SHIFT+F4 (MOVE TO) TO CHECK J5=+90 AND J6= -90.
11. DO SAME FOR -90 AND CHECK SAFE POSITION FOR PAYLOAD
12. PUT THE CONTROLLER IN AUTO MODE AND PRESS EXECUTE(F4).
13. APPLY SETTINGS
14. PATH & CYCLE TIME WILL CHANGE. YOU WANT TO APPLY
15. CONFIRM
 11. PROGRAM SHIFT
1. MENU
2. UTILITY
3. TYPE
4. PROGRAM SHIFT
I.ORIGINAL PROG.:-SELECT THE PROG. WHICH YOU WANT TO SHIFT.
II. RANGE: - WHOL
III. NEW PROGRAM: - GIVE NEW PROGRAM NAME.
IV. SOURCE POSITION: - SELECT 1ST SPOT POINT FROM PROGRAM
V. DESTINATION POSITION: - JOG ROBOT TO SPOT POINT WHERE YOU
J WANT.
5. RECORD.
6. DONE
7. CHECK THE SHIFTED PROGRAM IN PROGRAM FILE.
 12. ENABLE UI SIGNAL
1. MENU
2. SYSTEM
3. CONFIGURATION
4. SELECT OPT. 7 (ENABLE UI SIGNAL)=FALSE.
5. OK.
( UI SIGNAL IS DESABLE IF THERE IS NO SIGNAL FROAM PLC
(PLC PANEL OFF)).
 13.PULSE MISMATCH ERROR
NOTE:- PULSE MISMATCH ERROR OCCURE WHEN GUN IS REMOVED WITHOUT
G CONTROLLER OFF BECAUSE OF THAT POSITION IS MISMATCH &
H MASTERING LOOSE.
PROCEDURE:-
1. MENU
2. SYSTEM
3. VARIALBLE
4. MASTER ENABLE (OPT.299)
5. CHANGE FROM 0 TO 1.
6. TYPE MASTER CAL.
7. SHIFT + RES_PCA(F3)
8. DONE.
 14.SET UTOOL & UFRAME VALUES
1. MENU
2. SETUP
3. TYPE NEXT
4. FRAME OTHER
5. OTHER
I. put the x,y,z,w,p,r, coordinate which is given in gripper data sheetTOOL
FRAME
II. USER/RTCP (FOR SSW).
6. PUT THE X,Y,Z,W,P,R, COORDINATE WHICH IS GIVEN IN DATA SHEET.
 15.GROUP ENABLE DISABLE
1. MENU
2. NEXT
3. SYSTEM
4. VARIABLE
5. SCR_GROUP2
6. AXIS ORDER
I.DISABLE (PUT 0 )
II.ENABLE(PUT 1 )
 13.ROBOT FAULTS
SITUATION:- IN CASE ANY ERROR OCCURRED IN ROBOT.

STEPS:- I. DETERMINE CAUSE OF THE ERROR

II. FIND THE PROBLEM WHICH CAUSE THE ERROR
III. RELEASE(CORRECT) THE ERROR.
ROBOT ALARMS:- THE ROBOT ALARMS ARE SAVES IN ALARM LOG (HISTORY)
IN ALARM HISTORY PREVIOUS OCCURRED ALARMS ARE
SAVES.
STEPS TO DISPLAY ALARM LOG:-
I. MENU
II. ALARM
III. HIST(F3)

ROBOT FAULT’S: -

1.FILE OPEN ERROR:-

CAUSE: - THE FILE CANNOT BE OPEN.
REMEDY: - I. CHECK PATH AND FILE NAME BOTH SHOULD BE
CORRECT.
 13.ROBOT FAULTS
1.:-PRESSURE SHORTAGE;-
CAUSE: - I.PUSHING DEPTH PARAMETER IS NOT OK.
II.PART THICKNESS PARAMETER IS LARGE THAN ACTUAL
A PART PARAMETER.
III.GUN ZERO MASTERING IS INCORRECT.
REMEDY: -I.INCREASE THE PUSHING DEPTH IN PRESSURE SCHEDUDE
II.TO DO GUN MASTERING.
III.PART THICHNESS PARAMETER IN PRESSURE IS CLOSER
TO ACTUAL PART THICKNESS.

1.:-E82-DETECT WIRE BRECK

CAUSE: - I.TIP DETECT WIRE BRECK.
REMEDY:- I.TO CHECK TIP WIRE.
 13.ROBOT FAULTS
2.:-E78-RESISTANCE FAULT
CAUSE: - I.RESISTANCE WIRE BRECK.
II. TCI OFFSET MODE NOT CLARE.

REMEDY: -I. TO CHECK RESISTANCE WIRE.

II. TO CLARE OFFSET MODE.

3.:-E60-EXTREMELY LOW CURRENT

CAUSE: - I.IF GUN TIP IS NOT CLARE(DUST AND MOISTURE).
II. TIP DRESS NOT PROPER.
REMEDY: -I.TO CLANE GUN TIP PROPER.
II.PROPER TIP DRESS.
 13.ROBOT FAULTS
4.:-E98-COMMUNICATION FAULT
CAUSE: - I.COMMUNICATION BETWEEN ROBOT CONTROLLER AND
WELD CONTROLLER IS NOT PROPER.
II. COMMUNICATION WIRE BRECK .

REMEDY: -I.CKECK THE 4th LED (DEVICE NET) SHOULD BE BLINKING

II.TO CKECK COMMUNICATION BETWEEN ROBOT
CONTROLLER AND WELD TIMERIS PROPER .
III.TO CHECK WIRE BRECK.

5.:-E83-COUNT COMPLETE ERROR

CAUSE: - I.SPOT COUNT IS NOT RESET.

REMEDY: -I.RESET THESPOT COUNT.

 13.ROBOT FAULTS
6.:-AUTO BACKUP ERROR
CAUSE: - I.MC NOT INSERTED.
II.BACKUP FAULT IF A PERTICULAR IS CORRUPTED.

REMEDY: -I.INSER MC CARD.

7.:-POINT ARE TOO CLOSE

CAUSE: - I.THE RECORDED POSITIONS ARE TOO CLOSE TO EACH
OTHER.
REMEDY: -I.POINT SHOULD BE 10mm APART RETEACH THE
POSIITION.
 13.ROBOT FAULTS
8.:-INVALIED MOOTION GROUP
CAUSE: - I.THE MOTION GROUP NO IS INVALIED.
REMEDY: -I.USE ONLY ONE GROUP IN PROGRAM .

9.:-MOTION LIMIT ERROR

CAUSE: - I.RB MOTION FAILED DUE TO MAXIMUM LIMIT REACHED.
REMEDY: -I.MOVE THE ROBOT AWAY FROM JOINT LIMIT.

10:-INVALIED GROUP SPECIFIED

CAUSE: - I.THE GROUP SPECIFIED TO GET HOME DOES NOT EXIST.
REMEDY: -I.VARIFY THE SPECIFIC GROUP NO EXIST AND RETRY THE
OPERATION.