robot manual os-ope-10okura.pro.tok2.com/manuals/ul/os-(2)ope-10(2010-02-12).pdf · os(10)...

Okura Yusoki Co., Ltd.

Robot Manual

Operation

OS-OPE-10

OS(10)

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Introduction Thank you for purchasing a model from the Okura Robot Palletizer A series. This manual is a guidebook to help you safely and correctly use your A Series Robot

Palletizer. It should be useful not only to beginners who are using an Okura Palletizer for the first time, but also to experienced users, who can use this Manual to reconfirm their knowledge. Please read this Manual carefully and use the Palletizer with a clear understanding of its content.

Definition of Operator

Important! Definition of operator: Only AUTHORIZED PERSONNEL can operate the robot. The definition of “AUTHORIZED PERSON” is described below: The only personnel that can operate the robot and/or robot system, are those who have enough knowledge or experience of robot operation and have also been trained to operate the robot. They must also have been authorized by the employer.

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Table of Contents

1. DAILY OPERATION PROCEDURE...............................................................1-1 1.1. Main Power ON ...................................................................................1-2 1.2. Program Allocation .............................................................................1-2 1.3. Motor Power ON .................................................................................1-3 1.4. Start Operation...................................................................................1-3 1.5. Stop Operation ...................................................................................1-4 1.6. Finish daily work (shut down) ............................................................1-4

2. FREQUENTLY OPERATED PROCEDURES ....................................................2-1 2.1. Initialize Counter................................................................................2-2 2.2. Change counter value .........................................................................2-3 2.3. Robot Manual Operation .....................................................................2-4 2.4. Conveyor Manual Operation................................................................2-5 2.5. Conveyor Reset (System Reset) .........................................................2-6 2.6. Conveyor Zero Reset (Line Reset) ......................................................2-6 2.7. Robot Sequence Reset ........................................................................2-7

3. INTRODUCTION .......................................................................................3-1 3.1. Explanation of Display Screens...........................................................3-2 3.2. Data Input ..........................................................................................3-7 3.3. Coordinate System .............................................................................3-9 3.4. Manual Operation ............................................................................. 3-12 3.5. Operation Panel................................................................................ 3-13 3.6. Teaching Pendant (For Installation Only)......................................... 3-15

4. TROUBLESHOOTING .................................................................................4-1 4.1. Error Message.....................................................................................4-2 4.2. Diagnostic Menus ............................................................................. 4-14

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1.Daily Operation Procedure This section gives an easy to understand explanation of the daily operation procedure for an A series robot palletizer.

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1.1. Main Power ON

1. Turn on the main breaker switch on the front of the robot controller by turning the handle to the right.

2. Press the abnormal reset button Display will turn to Auto mode.

1.2. Program Allocation If there is no need to change the program, skip this item

1. Press the pallet No. key to select the desired pallet.

2. Press the program allocation key. The screen will change to Program

Allocation.

3. Confirm the program No. on the list and press [Select Program] button.

The screen will switch to a ten key pad.

4. Input the program No. to select.

5. Press [back] key and return to the Auto menu.

Note Whenever new product is set up, Program No.0 is to be firstly executed to

return to the standard posture in any case. Please remove products in hand before proceeding to the new ones,

starting with program No.0 execution, and also verify if the stacking counter is correct.

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1.3. Motor Power ON

Importance

Before turning on the motor power switch, check that there are no people inside the guarding, and that there are no obstacles on the conveyor or pallet.

1. Turn on the Motor power switch. Motor power indicator lamp will be ON

1.4. Start Operation

1. Press the start switch (momentary with a 6 second delay)

Operation indicator lamp will be ON and the robot will move to the standby position above station conveyor. Product will convey to the station conveyor and the robot will begin stacking. (If the infeed conveyors are not on or the robot does not pick from the infeed, perform the follwing.)

2. Press station switch to start. The handling articles will be loaded to

the station conveyor and robot starts stacking operation.

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1.5. Stop Operation

1.5.1.Stop operation This procedure is used when daily procedures such as pallet hopper filling are to be performed.

1. Press the station switch to prevent product from being loaded to the station conveyor.

2. Press the stop switch.

3. Turn off the motor power switch.

1.6. Finish daily work (shut down) This procedure is used when the days work is finished. This procedure will permit movement around the machine to perform maintenance or repair.

Note Pallet discharge can be performed only when operation indicator lamp is on.

1.6.1.In case of one pallet system

1. Press the Discharge Key Input (yes) .

●The robot will perform one more stacking cycle before starting pallet discharge when “arm movement at discharge” is selected in the program parameter.

2. (After confirming the pallet discharge is finished) press Stop key.

1

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1.6.2.In case of multiple pallets system

1. Press the station No. key to select the pallet.

The product will stop on the station conveyor and the robot will stop at a stanby position.

2. Press the pallet No. to be discharged. Input (yes) to confirm.

●The robot will perform one stacking cycle before starting pallet discharge when “arm movement at discharge” is selected on program parameter.

3. (After confirming the pallet discharge is finished) press the Stop key.

4. (After confirming pallet discharging is completely finished) press the stop push button.

5. Turn motor power switch OFF.

6. Turn off the breaker switch on the front of the robot controller by turning the handle to the left.

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2.Frequently Operated Procedures Here are summarized the Frequently operated procedure in daily operation.

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2.1. Initialize Counter

Important Perform this operation only when palletizing begins from the 1st work on the 1st layer. Do not perform this operation when product is on the pallet. Pallet initialization cannot be performed during operation.

2.1.1.Single pallet systems

1. Press the Reset Counter key on the Automatic mode screen.

2. Input (yes) to confirm.

2.1.2.Multiple pallet systems

1. Select the pallet to initialize counters on.

2. Press the Reset Counter key on the Automatic mode screen.

3. Input (yes) to confirm.

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2.2. Change counter value

Important The product counter can be changed with following the procedure. Change counter value cannot be performed during operation

2.2.1.Single pallet systems

1. Press the change key on the Automatic mode screen. (layer counter value and work counter value can be changed separately)

2. Input the new counter value.

2.2.2.Multiple pallet systems

1. Select the pallet No. .

2. Press the change key on the Automatic mode screen. (layer counter value and work counter value can be changed separately)

3. Input the new counter value.

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2.3. Robot Manual Operation

Note Manual operation allows you to move the robot for troubleshooting,

maintenance, and manual teaching.

1. Select the [MANU] with the MODE Key. Switch to manual operation mode

screen.

2. Turn on the motor power switch. Motor power indicator lamp will be lit

3. Press start push button switch. Operation indicator lamp will turn on

4. The following explains operation if each key at the manual operation screen. [F1] While this key is pressed, the R-axis of the robot

moves to the right. [F2] While this key is pressed, the D-axis of the

robot moves to the upward. [F3] While this key is pressed, the O-axis of the

robot moves to the outward. [F4] While this key is pressed, the T-axis of the robot

moves to the right. [F6] While this key is pressed, the R-axis of the robot

moves to the left. [F7] While this key is pressed, the D-axis of the

robot moves to the downward. [F8] While this key is pressed, the O-axis of the

robot moves to the inward.

[F9] While this key is pressed, the T-axis of the robot moves to the left. 1~9: Current condition, 1~9, of hand are reversed respectively.

5. Press stop push button. Operation indicator lamp will be off.

6. Select [AUTO] with MODE key. Back to the previous screen

Note

The difference among CP and PTP in terms of respective movements ; CP - - - movement is as per arm coordinate (linear) PTP - - movement is as per coordinates for each axis (arc) PM - - -movement is as per hand coordinates (linear) When a teaching pendant (option) is connected, the system can be operated only by the teaching pendant.

Manual speed(high speed) R AXIS 5°/sec

D AXIS 80 mm/sec O AXIS 80 mm/sec T AXIS 10°/sec

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Note The difference between continuous and inching, continuous- - - movement is kept while button is pressed intermittent drive - - ovement is kept for a certain time at one press of the button (longer time press of button will not work after a movement started)

2.4. Conveyor Manual Operation Note

Conveyor manual operation allows you to operate conveyors and other functions for troubleshooting, and maintenance.

1. Press the Conveyor manual key in the robot manual operation screen.

Switch to conveyor manual mode screen.

2. Turn on the motor power switch. Motor power indicator lamp will be lit.

3. Press start switch (momentary with 5 seconds delay)

Switch to On Operation screen.

4. Select the conveyor No. key to operate

5. Press “forward-up-open”direction” key or “ reverse-down-close” direction to operate conveyer.

6. Press stop switch to finish manual operation.

switch to On stop screen..

7. Press Back key.

4

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2.5. Conveyor Reset (System Reset) Note - After troubleshooting, perform a conveyor reset if necessary. - This operation clears all the latched data for peripheral conveyor motion controlled the robot controller and the PLC.

- Conveyor Reset cannot be executed during operation.

1. Select [Manual] with MODE Key. Switch to manual operation mode

screen..

2. Press Conveyer manual key in the robot manual operation screen.

Switch to conveyor manual mode screen

3. Press System Reset key Confirming message will appear.

4. Press yes key. ”processing completed” message will

appear.

5. Select [Auto] with MODE Key.

2.6. Conveyor Zero Reset (Line Reset)

Notes - After troubleshooting on an individual station conveyor, perform conveyor

zero reset. - This operation clears the latched data for the designated station conveyor

only. - Conveyor zero reset cannot be executed during operation.

1. Select [Manual] with MODE Key. Switch to manual operation mode

screen.

2. Press Conveyor manual key in the robot manual operation screen.

Switch to conveyor manual mode screen

3. Press Line Reset key Switch to pallet No input screen.

4. Input pallet No. ”processing completed” message will

appear.

5. Select [Auto] with MODE Key.

3

3

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2.7. Robot Sequence Reset

Note - After creating a new program, execute robot sequence reset and operate a

new program. - After stopping robot in a troubleshooting, execute robot sequence reset and operate the present stacking program from the first step of the program. - Counter value has no change in this robot sequence reset. – If the robot is holding product, release the articles first and execute robot sequence reset. – Robot sequence reset cannot be executed during operation

1. Press Reset Sequence key. Switch to confirming screen

2. Press Yes key. .

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3.Introduction

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3.1. Explanation of Display Screens The controller has four basic modes: (1) Automatic operation mode, (2) Teaching mode, (3) System storage mode, and (4) Maintenance mode Press the RETURN or MAIN MENU key to return again to the basic menu from each mode. Each screen has its own display.

System storage mode

Teaching mode

Maintenance mode

Basic menu

Automatic operation mode

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3.1.1.Automatic operation mode The composition of display screens in the automatic operation mode is as follows:

Any displays, peculiar to system, should be added here.

Automatic operation mode

Amplifier side

Conditions for operation

Peripheral equipment

Past performance Performance display

Error display

Data display Details display

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3.1.2.Teaching mode The composition of display screen in teaching mode is as follows:

Program parameter editing (4/5)

Teaching mode

Program new creation (1/7)







Program editing menu


Sequence program




Step parameter

Automatic height calculation

C-axis position storage

Step auxiliary data

Step location data

Pallet coordinate origin shift

Pallet coordinate origin copy

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3.1.3.System storage mode The composition of display screen in system storage mode is as follows:

Soft limit

Input of peripheral equipment name

Hour meter

C-communication setting

Parameter for Qm II

Memory switch

Coordinate origin storage

Servo parameter

Equipment name input for hand’s manual operation

External PLC C-communication setting

Accordance precision of axis

Password setting

System storage mode

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3.1.4.Maintenance Mode Screen display of maintenance mode is as follows ;

By a hidden key at upper-left corner in the screen.

Deviation trace name

Positioning, accelerating/decelerating

Display of conditions for “Operation

Stacking count change

I/O display

Coordinate origin storage

Conveyor setting

Allocation of ID No.・Prg. No.

Executing sequence

Measuring for timer value

Maintenance 2

Overlapping

RISC output data

SMOV calculation

Key trace

PLC data exchange

Task counter

Servo amperage setting

Servo torque display

Motor rotation test

Damaged file list

Contents display for data memory

Maintenance mode

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3.2. Data Input There are four methods of inputting data from the controller screen: 1.) Numerical value input using numerical input keys 2.) Selection and input pressing item keys directly 3.) Character input using the character input screen 4.) Parameter selection and input using function keys

3.2.1.Numerical data input using numerical input keys Numerical value data input program numbers and various conditions is to be done by using numerical keys. The input procedure is as follows:

Move the cursor to the numerical data to be Input (or revised) by the cursor movement keys, then press the INPUT key (or item key required to revise)

Input the numerical value using the numerical input keys

Store the numerical value of above 2 by pressing the ENT key

3.2.2.Selection and input pressing item keys directly When selecting from a list, press an item directly key required to revise.

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3.2.3.Character input using the character input screen Character input can be done using the character input screen at the following menu screen. Conveyor information Equipment name input for hand’s manual operation Program new creation (1/7) Program parameter editing(1/5)

The input procedure is as follows:

1. Press an item key required to input (or revise)

2. Move the cursor to a character required to select using the cursor movement key (or press the character directly)

3. Upon pressing INSERT key, a character selected by a character input screen is to be input just one character

4. Repeat step 2 to 3 for the necessary characters.

5. Upon pressing the ENT key after input is finished, the character input is finalized, and the system returns from character input mode to menu screen.

Note Input screen turns one by one, “English-Numeral”― “Japanese Hirakana” ―

“Japanese Katakana” ― “Character row” ―“Chinese Character” ,at each press of NEXT key

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3.3. Coordinate System With an Okura A series robot palletizer, there are 5 ways of expressing robot position.

1.Coordinates for each axis 2.Pulse coordinates 3.Arm coordinates 4.Hand coordinates 5.Pallet coordinates

Coordinates for each axis

Coordinates for each axis are of angles which denote the rotating angle of robot’s each axis (Each axis corresponds to the motor shaft of robot) (See diagram below) When PTP is selected during manual operation, the robot moves in accordance with these coordinates. Pulse coordinates

Pulse coordinate are of pulse number of the motor encoder which denote the rotating angle of robot’s each axis. These coordinates are not used for programming.

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Arm coordinates

Arm coordinates are similar to cylindrical coordinates.(See diagram below) The X-axis and Z-axis express the position of the point A at the tip of the robot arm, in terms of the distance from point O, running parallel to the X-axis and Z-axis respectively. If CP is selected during manual operation, the robot moves in accordance with these coordinates. Hand coordinates

Hand coordinates employ a 3-dimentional coordinate system based on the three axis (X,Y and Z) indicated in the diagram below. The X, Y, and Z axes indicate the position of point B at hand center (T-axis output shaft), in terms of the distance from point O, running parallel to the X, Y, and Z axes respectively.

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Pallet coordinates

These coordinates are on the pallet where stacking occurs. (See diagram below). The origin position for pallet coordinates can be set (or revised) for each program. (As a rule, the other 4 types of coordinates cannot be changed). Pallet coordinates are the same as hand coordinates (See above), with point O shifted to the stacking position on the pallet for the 1st article on the 1st layer (point C). In teaching operation, the position of the handled article on the pallet is expressed using pallet coordinates.

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3.4. Manual Operation Robot Manual Operation ⇒ Refer 2.3. Robot Manual Operation Conveyor Manual Operation ⇒ Refer 2.4. Conveyor Manual Operation

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3.5. Operation Panel The operation panel is roughly divided into two parts.

1. Manual Pushbuttons This section includes switches and lamps relating to the robot operation.

2. Touch panel 7.7 inch color LCD touch panel

3.5.1.Manual Pushbutton Section

[1] Emergency stop push button [2] Abnormality reset push button [3] Abnormal buzzer [4] Start push button [5] Stop push button [6] Main power indicator lamp [7] Motor power indicator lamp [8] Motor power switch [9] Mode select switch [10] Connector for OXPA [11] Outlet for power supply [12] Operation lamp

9

1

3

7

2

6

8 4

5

[ CE type ]

11

1

2

8

9

3

7

6 10 [ JIS type ]

2

1

3

4 6 7

5 9 8

[ UL type ]

12

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• Switches and lamps relating to abnormalities and emergency stopping: ①Emergency stop push-button (Red) This turns off motor power and turns ON the motor brake. Safety Category 3 (ISO13849-1). Note:

This button switch is the locking type. Turn the button in the arrow direction to reset.

②Abnormality reset button (CE:Blue, JIS,UL:Yellow) This resets the abnormality state when an abnormality occurs.

Note When an abnormality occurs, this switch must be pressed to reset the abnormality, even if the cause of the problem has been eliminated.

③Alarm buzzer This sounds when an abnormality occurs in order to notify to operator.

•Switches and lamps related to starting and stopping ④Start push-button (CE:White, UL:Green) This starts operation. When this is pressed, the operation indicator lamp lights up simultaneously. ⑤Stop push-button (CE:Black, UL:Red) This stops operation. When this is pressed, the operation indicator lamp goes out simultaneously.

Note

This stops operation, but does not turn off motor power.

⑥Main power indicator lamp (White) This lights up when the breaker switch is turned ON. ⑦Motor power indicator lamp (White) This lights up when motor power is turned ON. ⑧Motor power switch Setting this switch to [ON] position turns motor power ON, setting this switch to [OFF] position turns motor power OFF.

Note If the key is released while in the [ON] position, it will return to the center due to spring return, but motor power will remain ON.

⑨Mode select switch This key selects mode [Manu] or [Auto]. When this key is selected in [Manu] mode, the system will turn to manual operation mode. ⑩Connector for OXPA When use offline teaching program OXPA-QmⅡ, connect PC with this connector. ⑪Outlet for power supply Outlet for AC 100V (0.5 A Max)

3.5.2.Touch panel Information necessary for operating the robot is displayed on a 7.7 inch LCD.

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3.6. Teaching Pendant (For Installation Only) Note：Teaching pendant is not permitted by user operation.

3.6.1.Outline When Mode select switch is selected in [Manu] mode, the system will turn to manual operation mode. When teaching pendant is connected to the controller in [Manu] mode, robot operation can be done only by using teaching pendant. When to operate robot manually by controller panel, disconnect teaching pendant and connect “teach connector” instead.

Note: If the teaching pendant is connected, manual operation using the controller sheet keys is impossible.

The table below shows the differences between disconnecting and connecting teaching pendant in [Manu] mode. Disconnecting teaching

pendant Connecting teaching pendant

Robot Manual operation By controller panel By teaching pendant Motor power ON/OFF By motor power switch on

controller panel By enable switch on teaching pendant.

Door switch on safety fence If OFF, system will be emergency stop.

System can be ON, not depending on the switch situation.

3.6.2.Switches Identification of each parts of the teaching pendant

[4]

[2]

[1]

[3]

[1]

[4]

[6]

[5]

[1] Emergency stop push-button switch

[2] Data display

[3] Motor power ON-OFF switch

[4] Lamps and operation keys

[5] Motor power ON-OFF switch

[6] Enable switch

[CE,UL type] [JIS type]

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①Emergency stop push-button

This turns off motor power and turns ON the motor brake. Safety Category 3 (ISO13849-1).

Note: This button switch is the lock type. press the button again to reset.

②Data display Current robot position data or other necessary data are displayed.

③Motor power ON-OFF switch (CE,UL type) Hold this switch rightly will set motor power ON. ⑤Motor power ON-OFF switch (JIS type) ⑥Enable switch (JIS type) Hold this switch rightly will make it enable to set motor power ON.

3.6.3.Teaching Connector [CE,UL type only] When to operate robot manually by controller panel, disconnect teaching pendant and connect “teaching connector” instead. <outlook of teaching connector>

3.6.4.Connect and disconnect Teaching pendant [CE,UL type only] Follow the instruction below when to connect or disconnect teaching pendant. 1.Connection Turn off the main power supply. Then disconnect the teching pendant and connect the pendant. 2.Disconnection Turn off the main power supply. Then disconnect the teaching pendant and connect the teaching connector.

Connector

Connector

[CE type] [UL type]

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4.Troubleshooting With Okura A series robot palletizers, an error message is displayed when any abnormality is detected by the self-diagnosis function. This section explains the meaning of error messages, and discusses diagnostic menus- which are useful for checking the cause of a problem.

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4.1. Error Message When an error message is displayed, an abnormal situation has arisen in which robot operation cannot continue. Error messages are displayed at the bottom of the CRT screen. As shown in the diagram at right, an error message is composed of an error no. and an error message. To stop buzzer sounding, press Silence Alarm. Upon pressing the abnormal reset button, after remedial action was taken, the error message shall be turned off. Even in an abnormal condition, screen can be aborted by pressing QUIT key, and the screen shall be returned to the one before error, lighting the ABNORMAL lamp at right- bottom of screen in red. The error message screen comes out again upon pressing this lamp. The following explains the meaning and handling method for each error message.

Error

No. Error message Cause Remedy

71 Memory's battery low (warning)

Warning at CPU substrate (RC101) memory backup battery exchange time

Please exchange CPU substrate (RC101) memory backup battery.

231 Encoder's battery low(warning)

Warning at encoder backup battery exchange time for

Please exchange encoder backup battery.

Note Operation can be continued even an error message regarding battery low

comes out, but please be aware of possible data vanishing unless due action, the sooner , the better, is to be taken against this message.

Error


70 Battery voltage drop Voltage decrease of CPU substrate (RC101) memory backup battery

Please exchange CPU substrate (RC101) memory backup battery.

221 Encoder battery voltage drop

Voltage decrease of encoder backup battery

Please exchange encoder backup battery.

Important

Please do not turn off the main power until the battery is exchanged, when an either battery voltage drop or encoder battery voltage drop error occur.

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Error


1-10 UNUSED - -

11 I-axis out of processing range

D.O-axis interfering angle are out of range.

Previous "Origin Storing" position is wrong.

12 R-axis out of processing range


13 T-axis out of processing range


To be stored "Origin Storing" on current position. With manual operation, move the robot to basic point. To be stored "Origin Storing" again.

14 UNUSED - -

15 AY out of operation range

Robot has moved out of the operating range

16 C-axis out of operation range

Robot moved to out of operation range

17 I-axis out of soft limit range

D.O-axis interfering angle are out of range.

18 R- axis out of operation range

19 AX- axis out of operation range

20 AZ axis out of operation range

21 T- axis out of operation range

Robot moved to out of operation range

While pressing the error reset switch,

1. Turn on motor power.

2. Move the robot into the move-area by manual operation.

22 R-area processing error R-area angles defined in system parameter have logical mistake

Check R area data in system parameter. Too narrow interval is not accepted.When not using R-area, input minus value of soft-limit.

23 Height revision data Error on height revision process

Check the height data from PLC.

24 R-axis, out of soft limit range

25 D-axis, out of soft limit range

26 O-axis, out of soft limit range

27 T-axis, out of soft limit range

Out of the soft limit While pressing the error reset switch,

1. Turn on motor power.

2. Move the robot into the move-area by manual operation.

28 Receiving unexpected command

Received an invalid command by the centronics

Check the program of PLC.

29 SMOVE execute twice During executing SMOV, SMOV executed again

Check the Stacking sequence program .

30 Stacking counter processing error

Gripped works is abnormal

Check the stacking program.

33 Panel internal temperature abnormality

Temperature inside the control panel is too high (60degree or more)

Check cooling fan operation and clean filters.

34 Trap occurrence Control unit abnormality Turn off power and restart.

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Error


35 DSP Tele-communication error

Data communication abnormality

If error occurs only once, do reset.

If occurs frequently replace CPU board.

36 S - I/O Initialize error S-I/O port initialization abnormlity

If error occurs only once, do reset.

If occurs frequently replace CPU board.

37 TouchPanel communication error

Communication abnormality

Check the comm cable or comm target.

38 Received data abnorm Received data is out of operation range.

Palletizing CALC command execute error

Check the Stacking sequence program.

39-44 UNUSED - -

45 PLC communication error



46 No response from PLC There is no response from PLC

Check the program of PLC

47 UNUSED - -

48 No step Specified step does not exist

Check the stacking program

49 Half finish discharge abnormal

Discharging the unoperating program


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Error


50 Program selection mistake

Any other PGS type than the current one was selected before completion of current stacking

When work on the pallet, Discharge the pallet by conveyor manual mode. Using auto mode menu set PGS type to every work and start. After starting restore the original PGS type.

Explanation In an occasion of program change, please be aware of the PGS type as an important function.

What is the PGS type ?

Changing any program no. is to be done by sequence command PGSEL.

It is possible to make such change impossible by setting up a certain condition in order for a fail-safe against a trial of sudden change.

PGS will be in 3 types to be based on the conditions.

1. Single pallet

2. Multiple pallet

3. Workpiece

No. PGS Type

Descriptions Conditions for switch-possible

1 Single

Pallet

Pallet station is just 1, and resulting as “Program Select Error”, under the judgement of which following conditions are not set up simultaneously.

1 Stacking is completed under currently executing program

2 Stacking begins from starting point of newly set program.

Either number of layer and work

of the stacking counter of a program, currently executing, is “1” , and at the same time, either number of layer and work of the stacking counter of a program, newly selected, is “1”, too.

2 Multiple

Pallet

It is possible to switch over to a program memorized with each pallet in multiple stations.

When switch over to a different program, same conditions as above 1, single pallet, are subjected.

It is possible to switch over a program to the program No. executed at the latest at every pallet No.

When switch over to a different program, it shall be necessary that either number of layer and work of the stacking counter of a program, currently executing, is “initialized value”, and at the same time, either number of layer and work of the stacking counter of a program, newly selected, is “initialized value ”, too.

3 Every

Work

piece

It is possible to switch over without conditions.

OS(10)

4-6

Error


51 Program check sum error

The content of the pertinent program has been destroyed at program selection


52

No program stored The pertinent program is not in memory at program selection

Creation of the stacking program.

53 No program ENDP

At program execution, the program contains no ENDP

Insert ENDP on the pertinent program.

54

Layer/work number out of range

Due to a counter correction error, the layer or work counter value exceeded the setting in the program during program execution

Input the correct value.

55

Position data processing error

A specific step necessary for position data calculation is missing or the position data is outside of the moving area

Add the step or height is to be checked in case of “drop from top” or “pallet floor placement” setting.

56 Undefined instruction error

57 IF/ELS nesting error

58 IF/LP nesting too deep

There is a logical error in the program which makes execution impossible Correct the pertinent program.

59 Designated step not stored

A step designated by, for instance, MOV instruction does not exist


60-61 UNUSED - -

62 PLC P-I/O error



63 UNUSED - -

Initial pulse mismatch

The pulse when power was last turned off differs greatly from the initial pulse when turning on power

See the explanation about this item in the manual.

What has clear causes, such as power OFF under arm-operation, is reset in manual mode. If cause is not clear, check orientation and present position of robot. If present position is right, reset on manual mode. If present position is not right, encoder reset or standard position storage is necessary.

Note The A series robot employs absolute encoders, and the pulse when power is turned OFF is stored in the controller, and this is compared with the initial pulse when power is turned on, If the difference is not within a pulse range, - (minus) 10 - 65550, which is equivalent to one rotation of the encoder, this is regarded as an initial pulse mismatch error. This occurs when there is something wrong with the encoder or servo amp, but it may also happen when a power failure or similar situation occurs during arm movement.

64

OS(10)

4-7

Error


65 Program selection out of operation range

A step which is out of operation range has been included

To correct the position data parameter of stacking program

66 Pallet No. is abnormal Pallet No. of the selected program is abnormal.


67 UNUSED - -

68 Data memory No. error Data memory No. data received form PLC is abnormal


69 Turn-information error There was a turn information creation demand of not existing program ID


72 UNUSED - -

Break in position data Data calculation for arm movement at the main CPU is not completed in time

If the error occurs only once, it can be corrected by resetting.

Make speed quick when automatic operation speed is not 10.

If 10, shorten acc-dec time of a generating step.

Note If the error of “Break in position data” occurs in specified step, acc-dec time for that step might have been set too long.

73

External hold

An input setting for external hold is at ON

Set the input setting for external hold at OFF

Note When external hold input is on, the robot stops at the current step. It does note move to the next step.)

74

75 Photocell sensor

abnormal Temp at regenerative resistor is too high

Check cooling fan operation.

76 SMOV processing error Abnormality occurred during SMOV processing

Check the position data of SMOV step and next two step

77 SMOV parameter error Processing parameter of SMOV is abnormal

Check the SMOV-parameter (in of sys-para)

78 Wrong ID No. ID No. data received form PLC is abnormal


79 Wrong count value Counter value received form PLC is abnormal


80 Pallet No. selection error

Counter value received form PLC is abnormal


81 UNUSED - -

82 Program No. is out of range

Program no. of OSFT, sequence command, is out of range

Check the sequence command.

OS(10)

4-8

Error


83 Servo board not connect

servo board not found. Check servo boad connection.

84 Servo boot failure Program sending for

DSP cannot be done

The DSP program may not be installed.

Please install two DSP programs.

Turn off the power, then turn on again.

85 RAMDISK broken

Partial damage in memory

86 RAMDISK is crashed Auto repair

Auto repaired because RAMDISK area is unreadable

Initialize the RAMDISK.

87 Execute RAMDISK initialization

Memory was initialized.

Initialization is to be executed by turning on the power after setting a dip switch 8 in RC-101 PC board to ON

-

88 RAMDISK initialization failure

Failure in initialization

89 Task stack over-flow Shortage of memory during process

Replace the RC101.

90 Abnormal operation at Motor ON

Unsupposed operation at Motor power is ON

91 Internal-PLC comm error

No reply of Internal PLC notice


92 Remote-box communication error


Check the comm cable or comm target

93 Reference Bit device is abnorm

94 Obtaining Bit device is abnorm

95 Setting Bit device is abnormal

Internal processing error Replace the RC101.

96 DMOVE T-axis uncontinuously

If operation is continued,

T-axis will move out of the operating range.

It may occur also during operation in manual

PM mode.

Check the Stacking sequence program.

97 Word device is abnorm Internal processing error Replace the RC101.

98-99 UNUSED - -

100 Compact Flash broken Partial damage in Compact Flash

Initialise the Compact Flash.

101 CF is crashed Auto repair

Compact-Flash is crashed Auto repair.

Auto repaired because RAMDISK area is unreadable.

Possibly some files are erased

102 Execute CF initialization Compact Flash was initialized.

-

OS(10)

4-9

Error


103 CF initialization failure Failure in initialization of Compact Flash.

Replace the Compact Flash.

Replace the RC101 if you do not recover.

104 Unable to recognize the CF

Compact flash card does not insert

Please insert the Compact flash card if you use.

Or Turn OFF the this function memory switch.

105 Limitswitch ON Out of the hard limit After it returns to the state before the limit switch is turned on with motor brake release, reset the limit switch.

106 Maintenance and Inspection

The term has been passed. (example) The message pops up every 5000 hours at 5000hr-maintenace period.

It is just message so that operation can be continued. Press Abnormal reset to reset it.

107 Bar-code Reader comm error



108 FieldBus comm error Communication abnormality


Check the FieldBus unit inside control panel.

109 R axis fan abnormality The fan for motor cooling is unusual.

Please exchange fans.

110

Program check sum error in mov

When the MOV command was executed, the program was destroyed.

Cycle main power after turning off

the Motor Power switch.

111 POD program version mismatched

The version of POD program is mis-matched with

SH program.

DATA1: Correct version No.

DATA2: version sub-No.

POD program of the version shown on this screen needs to be installed though it is possible for you to continue by pressing error reset switch.

112 Pallet Count Changed [Sub code: 0-3] # of pallets from PLC is changed during stacking at pallet direct placement. [Sub code: 10] # of pallets is instructed by PLC in spite of pallet direct placement. DURING STACKING means From Pallet To Pallet. # Of Pallet means Though D5001 or X08-X0A from PLC.

[Sub code: 0-3] Remove whole things out of pallet and pickup station. Check out the pallet location and the photo eyes around. Do conveyor reset and counter reset. [Sub code: 10] Check out the PLC logic.

113-

114

UNUSED - -

OS(10)

4-10

Error


115 FieldBus initialization error

1.Abnormality occurred on the Master unit of PLC.

2."Remote device" value is abnormal.

3.Fieldbus-Board is abnormal.(see:LED)

1.Remove an abnormal factor on the Master unit.

2.Review the "Remote Device" value.

3.Fieldbus-Board are exchanged.

4.Check the Fieldbus Cable.

116 FieldBus link error 1.Abnormality occurred on the Master unit of PLC.

2.FieldBus-Board is abnormal.(see:LED)

3.Fieldbus cable disconnection.

1.Remove an abnormal factor on the Master unit.

2.Fieldbus-Board are exchanged.

3.Check the Fieldbus Cable.

117-

200

UNUSED - -

201

Servo power voltage low

DC(300V line)

Insufficient voltage

Check power voltage

Check the following

CE,JIS: circuit protector CP-1

UL: fuse F1, F2

Replace servo power board RC105)

202 Servo power voltage too high

DC(300V line)

Abnormally high voltage

Check power voltage

Check the following

CE,JIS: circuit protector CP-1

UL: fuse F1, F2

Replace servo power board RC105)

203 Primary power voltage too low

The primary power supply voltage fell in motor-

power supply ON.

Primary power has been power failured.

Check power voltage

Cycle main power.

204 Primary power voltage too high

Abnormally high AC voltage

Check power voltage

Deviation abnormal

Deviation exceed limit Check mechanical operation.

Change program so that

robot operates with

smooth movement.

Note Deviation limits are as follows

Model A1800/A1600 III / A1200 III A700 III / A400 III

R 24 degree 17 degree

D 24 degree 17 degree

O 24 degree 17 degree

T 61 degree 71 degree

205

OS(10)

4-11

Error


206

Overload Robot was operated for a while with exceeded rating torque

Check for wiring, contact.

Review a speed and acc-dec time

207 Over Speed Exceeding a value for abnormal speed detection was recorded

Review the set value

Check conductivity of wiring and harness (shield, FG)

Emergency stop Emergency stop switch has been pressed (On the operation panel teaching pendant, external switch

Reset the emergency stop switch

Note 1. External emergency stop

There are 2 points of terminal for the external emergency stop. In case the external emergency stop is not employed, connect P24 to the terminal no. PES1 and PES2 on the TBR1.

2. Teaching pendant In case the teaching pendant is not used,

JIS type: make jumper pins, JP1,JP2, JP7, JP8 and JP9, on RC106 (Safety relay PC), short circuit, and open JP10.

CE, UL type: confirm whether the teaching connector is disconnected.

208

209

Regenerative temperature abnormal

Regenerative temperature is too high

Check cooling fan for functioning

Check the contact of fasten terminal for connecting sensor on controller back side

Check regenerative transistor

210 IPM abnormal Protection circuit inside IPM energized in the following cases.

- OC to the motor

- Decrease in control voltage

- High temperature

Turn off power, then turn on again.

IPM replacement

211 Robot type not register The version of a DSP program is old.

The newest DSP program is used.

212-

213

UNUSED - -

214 Break in position data from SH

Data calculation at the main CPU is not completed

in time.

Makes speed quick when automatic operation speed

is not 10. In 10, it shortens accl-dcl time of a

generating step.

215

Tele-com. Between

DSP is abnormal

Data exchange between main DSP and sub DSP is abnormal

Only resetting will do, if error occur not frequently

Replacing of servo CPU pc board (RC103) shall be needed when error occur frequently

See ”Safety” Manual 1.5.1 Emergency stop

OS(10)

4-12

Error


216 Servo parameter abnormal

Sub No.0 :The version of a servo parameter is old.

Sub No.1 :Robot type difference.

Sub No.2 :Extended parameter is abnormal.

Sub No.3 :Check sum err Sub No.4 :Update in MotorPower ON

Sub No.0: Change into the newest servo parameter.

Sub No.1: Robot type is checked and it changes into the

right servo parameter.

Sub No.2: Check of memory switch

Sub No.3,4: Turn on power again

217 Encoder model disagreement

The encoder of a servo motor and the form of ROM for encoders of RC103 are not in agreement

Exchange of ROM for encoders of RC103.

218 No Response of RC101 Processing delay of RC101(40ms)

Turn off power, then turn on again. Replace the RC101 when relapsing.

219 Encoder Skip The encoder value was skipped

Damage Recovery ・Harness（Shield/FG） Check

・Servo Motor Check

・ RC103 Check ・

220 encoder tele-com. is abnormal

Tele-com. between encoder and servo

CPU pc board (RC103) is not possible

Check conductivity of harness (shield, FG)

Replacing servo motor

Replacing servo CPU pc board (RC103)

222 Encoder over speed Encoder rotated higher speed than rated

Storing origin point

223 Encoder excess rotation error

Information of excess rotation might be wrong


Replacing motor

224 Encoder counter over flow

An excess rotation counter over flow


225 Encoder counter error Information of one rotation might be wrong


Replacing motor

226 Encoder full absolute status

Encoder was rotating higher than rated when powered on


227 Encoder over heat Encoder’s inner temperature is too hot

When an error occurred during operation, set the temperature lower than 40 cent-grade around the servo motor

When an error occurred upon power ON, replace the servo motor

Replace servo CPU pc board

228 Encoder absolute position information error

Position information might be wrong

Turn off power then turn on again

Check current position of robot

OS(10)

4-13

Error


Encoder abnormal Some abnormal condition occurred in the encoder


Replacing motor

Note [Method for storing origin point]

Firstly, store the origin point where the trouble occurred. Then, change over to manual mode with storing origin point screen, and move the robot to the basic position after turning on the power. After moving. execute again the procedure of storing origin point. Each axis angle should be R=0, D=0, O=90 and T=0 at storing origin point. Upon completion of storing origin point, turn off power, then turn it on.

229

230 UNUSED - -

232 Position data changed suddenly

The position data which SH generated is

inaccurate.

Replace the RC101.

233 Collision Detection Because a collision was detected,

the robot stopped.

Restore the robot. In case of mis detection,

Review values of collision detection parameter.

Take note and clear the "max val" of the trace

screen.

300 and up

Abnormal signal is emitting from the sequencer

- Take due remedial action by checking the sequencer

Refer to the sequencer manual for article of error

OS(10)

4-14

4.2. Diagnostic Menus When an error occurs or the machine does not move correctly, it is necessary to check data using the controller monitor function. Automatic mode menu

4.2.1.Error content display On the error content display screen, up to 100 of the error messages can be displayed. During operation, it is not allowed to access this screen. As the maximum displaying line is 10 lines in the screen, use scroll key to display error message behind the screen. Press DETAIL DISPLAY key to see the cause and remedy of each error. [Screen explanation] ①Error o ccurrence No. The error messages displayed on the touch panel are numbered in beginning with the most recent. ②Error occurrence data and time This shows the data and time at which the error message was displayed on the touch panel. ③Error No. No. of the error which occurred. ④Sub No Detailed No. of the error which occurred. ⑤Error content Message of the error which occurred.

It is possible to display an error contents of servo amp. side by pressing Servo Amp Errors key. Displaying data shall be recent 10 only. Displaying contents and detail display are same as the error contents display.

4.2.2.I/O Display The relay actuation situation display screen enables checking and modification of the status of each relay. For details, please refer to the maintenance menu section of a separate volume "maintenance".

4.2.3.Executed sequence command display On the executed sequence command display screen, up to 40 of the sequence commands (instructions) executed recently can be displayed. For details, please refer to the maintenance menu section of a separate volume "maintenance".

1 2 3 4 5

OS(10)

Robot manual

Operation

10 Version: 2010.02.12

Robot Palletizer described in this manual is under production since Feb 2006.

<caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice.

Okura Yusoki Co., Ltd. 900 Furuouchi, Noguchi-cho, Kakogawa,

Hyogo 675-8675 Japan

robot manual os-ope-10okura.pro.tok2.com/manuals/ul/os-(2)ope-10(2010-02-12).pdf · os(10)...

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