sankyo_robotics_3000spwin_software_maintenace_manual

sankyo_robotics_3000spwin_software_maintenace_manual Maintenance Tool for the SC3000 Robot Systems (For Maintenance Work Users) AMO-NP-03017-34 SC3000 Robot Systems 3000SPWin Operation Manual For Maintenance Work Users This English version manual has been prepared according to the descriptions of the latest issue of the corresponding Japanese version (7th issue dated March 1, 2005) listed below: dated March 1, 2005 ?? 7th issue Notices for Safety CAUTION This notice advises of a condition that could present a potential hazard where personal injury or damage of material are possible unless care is exercised and correct operations are performed ? No part of this manual may be used or reproduced in any manner whatsoever without the written permission of Sankyo Seiki Mfg. Co., Ltd. All descriptions included in this manual are subject to change without notice. ? ? This publication may contain technical inaccuracies or typographical errors. Any of your questions and comments on the contents of this document should be directed to Sankyo Seiki Mfg. Co., Ltd. Sankyo Seiki Mfg. Co., Ltd. is exempt from any responsibilities, for damages ? caused directly and/or indirectly by the contents of this manual. March 2005 Edition Sankyo Seiki Mfg. Co., Ltd. Ina Plant 6100 Uenohara, Ina-shi Nagano-Pref., Japan (Postal Code 396-8511) TEL 0265 (78) 5111 FAX 0265 (78) 5116 Copyright ? 2002, Sankyo Seiki Mfg. Co., Ltd. AMO-NP-03017-34 Contents ? Related Documents ? For Safety Work 1. Generals.......................................................................................................................................1 2. Operation Environment.................................................................................................................1 3. Installing and Uninstalling of 3000SPWin......................................................................................3 3.1 Installing...................................................................................................................................3 3.2 Uninstalling..............................................................................................................................4 4. Basic Operations...........................................................................................................................5 4.1 Online Operation......................................................................................................................5 4.2 Offline Operation......................................................................................................................5 4.3 Main Screen.............................................................................................................................6 4.4 Setup of 3000SPWin................................................................................................................8 4.5 User levels...............................................................................................................................9 4.5.1 How to Control the User Levels......................................................................................9 4.5.2 How to Change the User level......................................................................................10 5. Various Maintenance Functions..................................................................................................11 5.1 Controller status monitor........................................................................................................11 5.1.1 Controller error..............................................................................................................11 5.1.2 Task status monitor.......................................................................................................12 5.1.3 DI/DO monitor...............................................................................................................15 5.1.4 Robot current position monitor......................................................................................16 5.1.5 Version check...............................................................................................................17 5.2 Maintenance work..................................................................................................................18 5.2.1 Change operation range...............................................................................................18 5.2.2 Motor replacement........................................................................................................19 5.2.3 Change home position..................................................................................................23 5.3 Servo monitoring....................................................................................................................24 5.3.1 Buffering.......................................................................................................................24 5.3.2 Monitor the thermal value and implementation value....................................................27 5.4 ROM communication.............................................................................................................29 5.4.1 Outline of ROM communication....................................................................................29 5.4.2 Erase all in flash...........................................................................................................29 5.4.3 Upload Controller System Software..............................................................................29 5.4.4 Download System Software to Flash............................................................................29 5.5 Axis move..............................................................................................................................30 5.6 File manager..........................................................................................................................31 5.7 HWDEF editor........................................................................................................................33 AMO-NP-03017-34 Notices for Robot System Users This manual has been prepared on the premise, for safety reasons, that the personnel who read and use this manual have already acquired sufficient knowledge on operation of automated equipment and devices. Before any operation or maintenance work begins on the robot system(s), be sure to read and understand the section titled, “For Safety Work”, which soon appears in this manual. AMO-NP-03017-34 Related Documents For the robot system(s), there are various instruction manuals listed below and you are requested to refer to those documents as you require. Listed below are the documents related only to the SC3100 robot systems. System Instructions Rev. 3 provides the comprehensive information on the SC3150/SC3400 Robot Systems. Installation Manual Rev. 3 describes how to install the Controller, the way of cabling work, how to perform the ABS homing, etc. SC3150 Controller Hardware Manual SC3400 Controller Hardware Manual describes electrical specifications on the corresponding Controller. Instructions on AD1309 Expansion I/O Card (Option) Instructions on AD1319 Expansion I/O Card (Option) Instructions on AD1339 HS Card (Option) describes electrical specifications and other information on each expansion card. Instructions on AD1316 Safety Connector (Option) describes electrical specifications and other information on the AD1316 Safty Connector. Instructions on AD1340 Remote Switch Box describes electrical specifications and other information on the AD1340 Remote Switch Box. Instructions on AB4301 CC-Link Card (Option) describes electrical specifications and other information on the AB4301CC-Link Card. Buzz2 User’s Guide describes the operation of Buzz2, which has been developed as “ADS” (*). Pendant Operation Manual (Option) Rev. 3 describes the operation of the Pendant to be used, being connected to the Controller. 3000SPWin Operation Manual (For General Users) describes the operation of the maintenance work software, 3000SPWin, for the SC3000 series robot systems. 3000SPWin Operation Manual (For Maintenance Work Users) This manual. SC3150 Controller Maintenance Manual SC3400 Controller Maintenance Manual describes the checks and parts replacement work, spare parts, etc. for the corresponding Controller. SSL/E Language Reference Manual Rev. 2 SSL/E means “Sankyo Structured Language / Enhanced”, a robot language to be used for the SC3000 Series Robot Systems. Discussed in this manual are; how to create programs in SSL/E, syntax of SSL/E and detailed information on each language command. Manipulator Hardware Manual describes the installation, maintenance and inspection work for the Manipulator. Specifications depending on the Manipulator are given in this manual. (*) “ADS” stands for the Application Development System and it is the name of the software development environment, which is used to create Robot programs in SSL/E on a PC and download them to the Controller to enable testing of source program level. AMO-NP-03017-34 For Safety Work 1. Introduction Industrial robots usually have wide workspace and their manipulators move in high speed. Since they require special working procedures, such as teaching operation, any industrial robots is accompanied by some critical operating condition that other industrial systems do not have. Furthermore, erroneous motion may potentially be caused in the robot systems by wrong operation or electromagnetic noise effect. The Sankyo SC3000 Robot Systems are supplied with various safety operation functions, and descriptions on safety operations are included in the manuals and their related publications. All the Sankyo Robot users are highly recommended to read the entire “For Safety Operation” publication and the other related manuals to become familiar with safety operations and instructions for the SC3000 Robot Systems. 1.1 General Notice Ensure compliance with all local, state and national safety and electrical codes for the installation and operation of the Sankyo Robot System. For example, if you used the Sankyo robot in the USA, you need to be very familiar with the American National Standards Institute / Robotic Industries Association (ANSI/RIA) safety standard R15.06-1992. In other countries, the equivalent codes and/or standards shall be observed. 1.2 Training Course In the codes and standards regarding industrial robots, it is described that the operators who perform teaching, inspection and tuning, and repair work for industrial robots are obligated to receive special training for their work. All the operators for such work of the Sankyo Robot Systems and their safety administrators need to receive instruction through the special training course organized by Sankyo. 1.3 Scheme for Safety Operation Administration For using the Sankyo Robot Systems, you shall designate the persons in charge of the Robot operation and its safety operation respectively. Furthermore, organize the scheme for safety operation administration, such as emergent norm and reporting network, in preparation for emergencies. 1.4 Working Norm For safety operation administration, prepare the working norm and ensure to observe the norm. i AMO-NP-03017-34 2. Precautions for Installation and Operations 2.1 Installing a Safety Barrier Consider installing a safety barrier to avoid any person from stepping into the Manipulator workspace. ? It must be possible to see the Manipulator movement through the barrier from its outside. ? The barrier shall have enough rigidity with which the barrier would neither easily get moved, broken nor damaged. ? The barrier shall have an entrance only through which the operator can enter the barrier inside. ? A safety plug shall be placed at the entrance, which the operator pulls out before entering the Manipulator workspace to disable the Manipulator from moving. 2.2 Installation Environment If your installation site is relevant to any of the following items, consider improving the installation environment or taking countermeasures required. ? The temperature at the installation site is out of the range of 0, 40?. ? The humidity at the installation site is out of the range of 30,90% RH, or the temperature changes so quickly that moisture condensing is caused. ? Some noise generator(s), (such as high-voltage equipment, electric driving systems, etc.) is located near to the installation site. ? Oil mist and/or dust is generated at or around the installation site. ? Corrosive gas is generated at or around the installation site. ? The installation site is in explosive or inflammable atmosphere. ? Excessive vibration and/or mechanical shock is generated at or around the installation site. ? The installation site is ill-ventilated because of bad ventilation condition. 2.3 Installation When installing the robot system, pay attention to the following notes: ? In order to perform teaching operation and maintenance/inspection work safely, provide the robot system and its peripheral equipment with sufficient working area for the operator. ? The robot system and its peripheral equipment shall be so installed as that the operator can always see them. Wire emergency stop button(s) from more than 1 of I/O-1, I/O-2 or AUX connector of the Controller to make operator(s) push the emergency stop button easily and stop the Manipulator. ? The Pendant shall be so placed that the operator can use it outside the Manipulator workspace while watching the Manipulator movement. ? Refer to the “Installation Manual” as well for the other notices regarding installation work. ii AMO-NP-03017-34 2.5 Connecting Peripheral Equipment CAUTION - Before connecting any peripheral equipment, check the rated voltage and current of the equipment. Connecting peripheral equipment having its rated voltage and/or current outside the specified allowable range may cause the Controller to get damaged. - Do not keep the “/STBY” input always being turned on. Keeping it always turned on, a realtime error occurs. iii AMO-NP-03017-34 3. Preparation of Working Norm Referring to the descriptions below and the manuals on the SC3000 Robot Systems, make up your working norm and ensure to observe it. For the communication to the observing personnel and the operator(s) of the other related equipment, prepare the safety care sheets and perform communication according to the descriptions on them. On such an occasion, oral communication may have some problem because of noisy working locations and using body language may be recommended. 3.1 Checks Before Robot Operations Before placing the SC3000 Series Robot System into operation, perform the following checks. If you find any problem, repair the broken part or take actions required for the problem. You are recommended to make your own checklist, referring to the following descriptions: ? Check on the safety plug Check that removing the safety plug of the safety barrier entrance surely causes an emergency stop. ? Check on the cables a. Make sure that the interface cables are free from any damage on their outer cover. b. Make sure that the EMS cable is free from any damage on its outer cover. c. Check that there exists no damage such as a dent with the Controller, Pendant and/or Manipulator outside section. ? Check on the Manipulator movement After making sure of no person inside the Manipulator workspace, try to move every axis by using the Pendant to check if the Manipulator moves smoothly without any unusual noise. ? Check on the emergency stop button function Check that pressing each of the emergency stop buttons (of the Pendant and the external emergency stop button if any) surely stops operation. ? Making sure of no obstacle Make sure that there exists no obstacle inside the Manipulator workspace. iv AMO-NP-03017-34 3.2 Precautions for Teaching Operation ? Whenever possible, teaching operation shall be done while the operators being outside the Manipulator workspace. If it is impossible to perform teaching operation in that way, extreme attention shall be paid in preparation for unpredictable erroneous motion and operation because the Manipulator moves at high speed. ? All personnel for teaching operation including observing personnel shall have received special instruction for their work, and only the personnel appointed by the responsible chief person can perform teaching operation. ? Be sure to wear safety helmets, safety shoes and safety glasses. ? For teaching work, two men are required. One does teaching operation while the other is observing the teaching at the control panel. ? The observing personnel is to do the following: a. Devote himself to observing while standing at the position where all the robot motion can be seen. b. Press the emergency stop button immediately in an emergency. c. Make no body other than the teaching personnel penetrate the work area. ? The personnel carrying out teaching operation shall always be ready to press the emergency stop button. ? Before teaching work, perform pre-work checking with the check list which you make according to item “3.1 Checks Before Robot Operations” of this manual. In case any unusual condition is found, take an appropriate action to solve the problem. ? The Manipulator speed in teaching shall be 250 mm/sec or less. ? Place a "NOW TEACHING" sign plate onto the control panel. ? If you must enter the safety barrier inside section, pull out the safety plug at the entrance of the barrier and carry it with you. ? For the communication to the observing personnel and the operator(s) of the other related equipment, the descriptions of the safety care sheets shall be observed. ? Neither operate nor allow to operate any equipment, which may act as a noise generator, at the teaching operation area or its surrounding area. ? Do not use the Teaching Pendant by groping it while paying attention to only the teaching points. ? Do not perform your work while turning your back to the Manipulator. ? Before teaching work, make sure that there is no obstacle near your feet. Be careful to perform teaching work while standing on any high step (2 m or higher). ? When a failure comes up during your teaching operation, take actions as described below: a. Press the Emergency Stop button immediately when any erroneous motion is observed. b. Communicate with the observing personnel to turn off the main power and place a "DO NOT TURN ON" sign plate at the main power switch. c. When you check the failure after causing an emergency stop, first make sure that the other related equipment is also stopping. d. Pull out the safety plug at the entrance of the barrier and carry it with you during your work. e. If the robot automatically stops due to power failure, ensure to stop the robot, then check the problem cause to take actions required. f. If any emergency stop device does not work, immediately turn off the main power, then check the problem cause to take actions required. g. Only the appointed personnel can do the work of problem solving. v AMO-NP-03017-34 ? To boot up the robot again after causing an emergency stop because of some problem, first make the problem cause(s) clear and take the actions required. Then carry out the re-booting operation according to the procedures described in item “3.3 Operation Procedures“. 3.3 Operation Procedures ? Powering up a. Turn on the main power (a) Make sure that the switch you are now going to turn on is the main power switch of the control panel. (b) Make sure that nobody is in the Manipulator workspace. (c) Make sure that no sign plate of "DO NOT TURN ON" is placed at the main power switch. (d) After making sure of the points described above, turn on the main power switch of the control panel. (e) At the time, check that the manipulator does not move at all. b. Turn on the servo power (a) According to what operation you want to do, turn the mode of the Controller (*1) to the “Local” or “Teach”. (b) Turn the Key Switch of the Pendant to the same position as the mode of the Controller is turned to. (c) Press the Manip. Power Switch (servo power switch = Green button) of the Pendant. (d) Make sure that the Servo power LED (Manip. Power) gets lighted. (e) If the Manipulator shows any motion (even slightly) at this time, press the Emergency Stop button to turn off the servo power. (f) If any error happens in the procedures up to here, consult your maintenance team to ask for taking actions. Note *1: The mode of the Controller The mode of the Controller means the mode setup of the Controller side. It is different between the Controller models. <In the case of the SC3150 & SC3400> The mode setting input has prepared at the AUX connector in the rear section of the Controller. It is set by equipment that users wired or the mode change switch of the Remote Switch Box, AD1340 (Option). <In the case of the SC3100 & SC3300> It is set by the mode change switch in front of the Controller. <In the case of the SC3000 & SC3200> The mode change switch of the Controller do not exist, therefore only the mode change switch of the Pendant decide the operation mode. vi AMO-NP-03017-34 ? Initial operation check Perform initial operation check, usually at the beginning of the robot operation, to make sure that not only the robot system but also the other related equipment work properly. a. Selecting the operation mode. Turn the Key Switch of the Pendant and the mode of the Controller to the “Local”. b. Verifying the robot motion by the "Step" operation (a) Press the “Step” key on the Pendant LCD screen. (b) Make sure that there is neither unusual motion nor any teaching point displacement. c. Verifying the robot motion by continuous operation (a) Press the "Start" key on the Pendant LCD screen to perform the continuous operation from the top of the program. On this occasion, by using the “Speed Override” function, first perform the continuous operation at low speed, and then at the specified speed if there exists no problem. (b) Make sure that there is neither unusual motion nor any teaching point displacement. (c) In this operation, you shall always be ready to press the Emergency Stop button. ? Teaching operation a. Selecting the “Teach” mode Turn the Key Switch of the Pendant and the mode of the Controller to the “Teach”. b. Using the Pendant, operate each axis to perform teaching and save the teaching data. The following precautions shall be observed through the teaching operation. (a) Make sure that nobody is in the Manipulator workspace. (b) Avoid any sudden motion of the Manipulator. (c) Operate the Manipulator as slow as possible. (d) Make sure that there is no obstacle near your feet. (e) Do not deal with the Pendant roughly. (f) Always be ready to press the Emergency Stop button. (g) While holding the Pendant with your left hand, operate it with your right hand. ? Debugging Debug the program created by using Buzz. On this occasion, with the “