FANUC ROBOT MANUAL

After Power on
S1- PUT FLASH CARD IN ROBOT CONTROLLER
1.First Step is to put Flash card in in robot controller.
2. The slot for flash card is shown in figure, First there is screw their we first
lossen the screw and out the flash card holder and put the flash card in it
and then put it back in controller and tighten the screw.
USB
Slot

S2- ROBOT BACK UP

There are two types of Back-up
1: Image Back-up
2: System Back-up

In genral we Store the back up in memory card and USB device.First we store the IMAGE back up and
then SYSTEM back up.
First back up is stored in MEMORY CARD, In case of USB device first we have to select Set Device in
UTILITY and select USB1
IN CASE OF STORE BACK-UP IN MEMORY CARD
Step I. Procedure for Image Back-up
Load a Flash Card with Adaptor in the PCMCIA Slot in the Robot Controller
MENUS
FILES
SELECT "MEMORY CARD" i.e. Exp: MC\*.*
F5: UTILITIES
SELECT: "4. MAKE DIRECTORY (Make DIR)" First we make Date directory using words option i.e.
Exp- MC\090412\*.*
Select WORDS and type DATE (Exp- 090412) using number keypad and ENTER
F5: UTILITIES
SELECT: "4. MAKE DIRECTORY (Make DIR)" now In Date directory we make Robot Number Sub
directory using WORDS &UPPER CASE option
i.e. Exp- MC\090412\ R301J\*.*
F5: UTILITIES
SELECT: "4. MAKE DIRECTORY (Make DIR)" now In directory MC\090412\ R301J\*.*we make
IMAGE Sub directory using UPPER CASE option
we type IMAGE just like we type in mobile, the alphabates are shown in bottom of the the screen. i.e.
Exp: MC\090412\ R301J \ IMAGE\*.* and ENTER
Here for up one level we press again ENTER to move in above directory on up one level
F4: BACK-UP
 go in NEXT (0) page & ENTER
Select "2. IMAGE Back-up & ENTER
Select "1. CURRENT DIRECTORIES & ENTER
CYCLE POWER ON
the Image back up will start & precessed and message will be prompted completing the Back up
Step II. Procedure fors System Back-up
MENUS
FILES
F5: UTILITIES
SELECT: "4. MAKE DIRECTORY (Make DIR)" now In directory MC\090412\ R301J\*.*we make
SYSTEM Sub directory using UPPER CASE option as we did in case of IMAGE Back up i.e. Exp
MC\090412\ R301J \ SYSTEM\*.* and ENTER
F4: BACK-UP
SELECT: "7. ALL OF THE ABOVE" & ENTER
the System back up will start & precessed and message will be prompted completing the Back up
IN CASE OF STORE BACK-UP IN USB DEVICE
Step I. Procedure for Image Back-up
Load a Flash Card with Adaptor in the PCMCIA Slot in the Robot Controller or insert an USB Disk on
the door
Use USB card to take back-up of system files as number of directories can be made inside the USB
Drive
MENUS
FILES
F5:UTILITIES
SELECT: "1. SET DEVICE"
SELECT: "7. USB1"
Following the same steps as we follow for back up for Memory Card we make Directires after setting
the USB device
i.e. Exp: USB1\090412\ R301J \ IMAGE\*.* and ENTER
Here for up one level we press again ENTER to move in above directory on up one level
F4: BACK-UP
go in NEXT (0) page & ENTER
Select "2. IMAGE Back-up & ENTER
Select "1. CURRENT DIRECTORIES & ENTER
CYCLE POWER ON
the Image back up will start & precessed and message will be prompted completing the Back up.
Step II. Procedure fors System Back-up
MENUS
FILES
F5:UTILITIES
SELECT: "1. SET DEVICE"
SELECT: "7. USB1"
F5: UTILITIES
SELECT: "4. MAKE DIRECTORY (Make DIR)" now In directory USB1\090412\ R301J\*.*we make
SYSTEM Sub directory using UPPER CASE option as we did in case of IMAGE Back up i.e. Exp
USB1\090412\ R301J \ SYSTEM\*.* and ENTER
F4: BACK-UP
SELECT: 7. ALL OF THE ABOVE" & ENTER
the System back up will start & precessed and message will be prompted completing the Back up
S3- TO CHECK ENCODER VALUE
MENUS
go in NEXT (0) page & ENTER
Select "6. SYSTEM & ENTER
 TYPE F1
Select "2. VARIABLE & ENTER
Press ITEM key & enter 116 Which define the $ DMR_GRP & ENTER
Select "4. MASTER COUNT & ENTER
Check Encoder value which is given in that Robot data sheet to counter check the value
shown in teach pendent, both value should be samel.
S4- SERVOGUN SETUP
1 Press FCTN key & go in NEXT (0) page
SELECT: "8 CYCLE POWER & ENTER
2 Hold the PREV & the NEXT Key simultaneously while powering on & hold it
continuously till you see a controlled start menus screen
3 Release the Prev & next key
4 SELECT: 3" CONTROLLED START
5 The TP will take several minutes (1-2 Minutes) for loading
6 After the completion of the loading Select MENU
7 Select MAINTENANCE
8 You will see a screen Similar to the following

1 R2000iB / 165F 0
2 Servo Gun Axes 0

TYPE ORD NO AUTO Manual

F1 F2 F3 F4 F5
Prev NEXT

8 Select F4 Manual
9 The following options are displayed on the TP screen

10 Select 2 Add servo gun axis & press enter

The following are prompted on the TP

1 Partial Setup
2 Complete Setup

11 Select Complete Setup

First Define the Axis movement type value 1 & ENTER , which define gun movement through + X & -X
& ENTER then Select the axis number type 7 & ENTER, which define the 7th axies which is given to
the GUN.
The motor selection screen is displayed on the TP
12 Carryout the setup as below
1 Motor Type ais8/4000/80A
2 Amplifier No 2
this is the mm/rev of the motor
3 Tip Displacement/gear Ratio 6.74
the gun tip moves
4 Motion sign FALSE
5 Gun close Direction Negative
 Refer to the Gun data sheet for
6 Enter Open Limit 155mm
this value
Enter a positive value (for the
7 Enter Close limit 30mm
lower limit)
Refer to the Gun data sheet for
8 Maximum Gun Pressure 400Kgf
this value (400 is OK)

9 Brake No 2
10 Servo Off Disable
13 the setup is now complete. Exit the screen
14 Press FCTN Key & select Cold start
Note:
1. For setting up of Item No. 3 & 6 refer to the Gun Data Sheet
2. For setting up of item no 2, refer to the motor mounted on the gun
3. Motion sign false means, In case of gun movement is done from zero to positive direction & vice
versa. but in case of Turn table Motion sign will be true because table move in both positive in negative
direction about zero.
S5- ALARM RESET
MENUS
go in NEXT (0) page & ENTER
Select "6. SYSTEM & ENTER
TYPE F1
Select "3. GUN MASTER & ENTER
Select F3" BZAL (shown if fig.)
Select BZAL alarn ON & ENTER

EQ. NO. GROUP 2

1. GUN 1 (J1, COMP) ZERO MASTER

TYPE EQUIP BZAL EXEC

F1 F2 F3 F4 F5
Prev NEXT

S6- GUN MASTERING

MENUS
go in NEXT (0) page & ENTER
Select "6. SYSTEM & ENTER
TYPE F1
Select "3. GUN MASTER & ENTER
Select F4" EXEC (shown if fig.)
 Select OK

EQ. NO. GROUP 2

1. GUN 1 (J1, COMP) ZERO MASTER

TYPE EQUIP BZAL EXEC
F1 F2 F3 F4 F5
Prev NEXT

S7- VARIABLE UNIT CHANGE

MENUS
go in NEXT (0) page & ENTER
Select "6. SYSTEM & ENTER
TYPE F1
Select "2. VARIABLE & ENTER
Press ITEM key & enter 539 Which define the $ SGSYSCFG & ENTER
Press ITEM key & enter 26 Which define the $ PRS UNIT (pressure unit) & ENTER
then replace the value of pressure unit from 2 to 0, which defines that unit is changed from N/m to Kg.
Afer change the value first off the power then on.
S8- TOOL CENTER POINT (TCP) ENTRY
1. FOR GUN
MENUS
Select 6". SETUP & ENTER
TYPE F1
go in NEXT (0) page & ENTER
Select "2. FRAMES & ENTER
goto DETAILS & write the TCP value given in gun data sheet using arrow and numerical keys
Select ". METHODS & choose 3" DIRECT ENTRY & ENTER
2. FOR GRIPPER
MENUS
Select 6". SETUP & ENTER
TYPE F1
go in NEXT (0) page & ENTER
Select "2. FRAMES & ENTER
after enter the screen will shown, move down the cursor in number 2 which is standard( in case of
maruti) to define gripper
then ENTER "F2: DETAILS
put the x,y,z,w,p,r, coordinate which is given in gripper data sheet
after putting value click on "F2: METHOD:select DIRECT ENTRY
3. FOR REMOTE TCP/ SSW
MENUS
Select 6". SETUP & ENTER
TYPE F1
go in NEXT (0) page & ENTER
Select "2. FRAMES & ENTER
Select "3. OTHERS & select FRAME/RTCP
then ENTER "F2: DETAILS
put the x,y,z,w,p,r, coordinate which is given in gripper data sheet
after putting value click on "F2: METHOD:select DIRECT ENTRY
 S9- AUTO-TUNNING
M1: BY USING PROGRAM
1 Move the Robot to a Safe Position
2 Press SELECT Key
3 Press F1 TYPE
4 Select ALL
5 Move the cursor to "AUTOTUNE.MR" Macro program
6 Press Enter
7 After Entering the program, set the over ride to 100%
8 Remove the Step mode
9 Hold SHIFT key + FWD key & execute the program
10 Do not release the SHIFT key till the autotuning is completed
NOTE:
The gun moves several times during this procedure at high & low speeds. Be alert & prepared to hit
EMG if necessary
Gun Auto tuning is completed after this procedure
M2: BY GUN-SET UP
1. MENUS
2. FILES
3. F5:UTILITIES
4. TYPE F1
5. Select "2. GUN SETUP & ENTER
6. The following options are displayed on the TP screen
1. Set gun motion fig. INCOMP
2. Set gun , speed, mass gun INCOMP
TIP displacement = 10.400 mm/rev
Open stroke limit = 100
Close stroke limit = 20
3. Auto tuning INCOMP
4. ….
5……
7. goto first option & ENTER
open the gun tip through jogging and select F4 OPEN & ENTER
8. similarly goto option 2 and do YES,YES to all option, complete four step first close the
gripper , put tip distance, open limit & close limit & ENTER
9. goto Autotuning thired option complete the option which are ask then SHIFT + EXECUTE
for processing of gun..
S10- FORCE CALIBRATION
1 Press MENUS
2 Select 6 SETUP
3 Press F1 TYPE
4 Select 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 The following screen is seen
 Set this to 5 sec

Measure the total Thickness of

the gage & Enter here in mm

If the Gage thickness is 15 mm

keep the opening as 30mm

F1 F2 F3 F4 F5
Prev NEXT

10 Enter the value of Pressuring time, gauge thickness and gun open value.
11 Set the Speed & the Pressure colums as shown below
Torque Speed (mm/sec) Pressure (kgf)
5 4.60% 20mm/sec 100
6 11.30% 200mm/sec 200
7 14.20% 200mm/sec 250
8 16.10% 200mm/sec 300
9 19.70% 200mm/sec 350
10 22.60% 200mm/sec 400

12 Start with a approximately small torque value (4.6%, for example) in row 5
13 Hold the pressure guage firmly on to the fixed tip
14 Press SHIFT + F3 together for the gun to actuate & apply pressure on the gage
Execute care. Do not keep your hands in the gun movement area.
15 Vary the override upto 100% to get proper values
Note the reading on the gage, write it on teach pendant pressure value according to their
percentage torque. Alter the torque value to get the gage pressure to 100kgf, The Torque &
16
the Pressure are directly proportional. An increased torque value will result in higher
pressure & vice versa
16 Similarly carryout the procedure for 200,250, 300,350 & 400kgf
17 After the completion of the above, move the cursor down till to move at Calibration Status,
and press F4 COMP to finish the Pressure Calibration. The resulting calibration table is
displayed after the calculation.
Please refer to the following pictures for more details
 Pressure Gage

Thickness
S11- TURN-TABLE AXIS SETUP
1 Press FCTN key & go in NEXT (0) page
SELECT: "8 CYCLE POWER & ENTER
2 Hold the PREV & the NEXT Key simultaneously while powering on & hold it
continuously till you see a controlled start menus screen
3 Release the Prev & next key
4 SELECT: 3" CONTROLLED START
5 The TP will take several minutes (1-2 Minutes) for loading
6 After the completion of the loading Select MENU
7 Select MAINTENANCE
8 You will see a screen Similar to the following

1 R2000iB / 165F 0
2 Servo Gun Axes 0
3 Basic positioner 0

TYPE ORD NO AUTO Manual

F1 F2 F3 F4 F5
Prev NEXT

9 Move cursor to 3" Basic positioner and Select F4 Manual

10 Total axis Installed =
1. Display/ modify Axis 1-4
2. Add axis
3. Delete axis
4. Exit
 write 2 & ENTER to add the axis to turn-table
11 Motion sys = TRUE
12 Upper limit = 180.00
13 Lower limit = -180.00
14 Master position = 0 degree
15 ACC time 1 = 384
16 ACC time 2 = 192
17 Exp filter valid = FALSE
18 Min. acc. Time = 384
19 Load ratio = 3
20 Brake number = 2
21 Servo off valid = FALSE
22 EXIT
S12- PAY-LOAD CALIBRATION
Payload Identification:
Robot payload is the weight of the end of arm tool and work piece. You need to change robot payload
when ever you change End of arm tool or work piece.
Procedure for setting up of Payload:
1. First move all axis to Zero position. ( J1 is optional and ensure that tool or dressout
should not collide )
2. Follow the procedure below:
Steps:
1. Press MENUS.
2. Select SYSTEM.
3. Press F1, [TYPE].
4. Select Motion. You will see a screen similar to the following.

TYPE GROUP DETAIL ARM LOAD SETIND >

F1 F2 F3 F4 F5
Prev NEXT

The following function menus are displayed when the next key is pressed
TYPE IDENT >
F1 F2 F3 F4 F5
Prev NEXT
 Prev NEXT

5. Press F2, IDENT you will find the screen similar to the following

TYPE GROUP NUMBER EXEC APPLY >

F1 F2 F3 F4 F5
Prev NEXT

The following function menus are displayed whan the next key is pressed
GROUP DETAIL >
F1 F2 F3 F4 F5
Prev NEXT

Carryout the settings as follows:

MOTION/PAYLOAD ID
Group 1
Schedule No[ 1]: [****************]
1. PAYLOAD ESTIMATION **********
Previous Estimated value (Maximum)
Payload [Kg] : 0.00 ( 165.00)****
Axis Moment [Nm]
J4: 0.00E+00 ( 9.02E+02)
J5: 0.00E+00 ( 9.02E+02)
J6: 0.00E+00 ( 4.41E+02)
Axis Inertia [Kgf cm^2]
J4: 0.00E+00 ( 8.82E+05)
J5: 0.00E+00 ( 8.82E+05)
J6: 0.00E+00 ( 4.41E+05)
2. MASS IS KNOWN [yes ] 120.000 [Kg]
3. CALIBRATION MODE [ON]
4. CALIBRATION STATUS [OK]
5. Press NEXT, >, and then press F4, DETAIL. You will see a screen similar to the following
 TYPE POS2 DEFAULT MOVE TO RECORD >
F1 F2 F3 F4 F5
Prev NEXT

6. then adjust the speed percentage of gun through + %, - % age keys.

7. Select SHIFT + "F4: MOVE TO, for to see the motion of the gun
8. Press F2, POS2. You will see a screen similar to the following

TYPE POS1 DEFAULT MOVE TO RECORD >

F1 F2 F3 F4 F5
Prev NEXT

9. Select SHIFT + "F4: MOVE TO, for to see the motion of the gun
10. Press F2 and Move to POS 1 & POS 2 by shuffling (run at 5%,10%, 25%,50%, 75%
and 100%)
 a. We can restrict J5 & J6 axis rotation if there is any fouling with Dressout espicially for
handling robots
11. Move robot arm to down position
12. Switch off the TP to execute, leave deadman switch and keep it in Auto mode
a. Press F4 to execute you will find similar screen

b. Press F4 to run calibration

13. A good estimation needs the following conditions:
a. The range of J5 between POS1 and POS2 is 180 degrees.
b. The range of J6 between POS1 and POS2 is 180 degrees
14.First Robot will run at 1% moving both J5 & J6 axis by 180 degrees up and down then it
will run at 100%
15. After running with 100% the moment and Inertia values will be displayed on the screen
16. Apply settings
17. Path & cycle time will change. You want to apply
18. Confirm
S13- PUT .I/O FILE AND .TP FILE FROM USB DEVICE
1 MENUS
2 FILES
3 F5:UTILITIES
4 SELECT: "1. SET DEVICE"
5 SELECT: "7. USB1"
After setting USB device we click on *.* file which shows the list of all the folder
6 on that USB device.
i.e. Exp: USB1\*.* and ENTER
7 now select the folder in which programme files is kept.
i.e. Exp: USB1\ 711A\*.* and ENTER
now goto DIRECTORY and select the .I/O file through NEXT (0) and select .I/O
8 and ENTER
LOAD the given .I/O file and for .TP file again goto DIRECTORY and select the
9
.TP file through NEXT (0) and select .TP and ENTER
10 LOAD the given .TP file exp: R301ia, others different program
11 Now run the R301ia program , make sure the final value change from 0 to 2.5
S14- TURN-TABLE MASTERING
1 Set GROUP-3 for Turn-Table
2 MENUS
3 go in NEXT (0) page & ENTER
4 Select "6. SYSTEM & ENTER
5 TYPE F1
6 Select "2. VARIABLE & ENTER
Press ITEM key & enter 284 Which define the $ MASTER_ENB and change its
7
value to 1 & ENTER now press TYPE F1 and select MASTER/CAL & ENTER
9 In MASTER/CAL select ZERO POSITION MASTER & ENTER
10 then CALIBRATE ,OK & ENTER
11 Now check position value of turn-table axis and it will show ZERO value
 S15- DEVICE-NET SETTING
DEFINING SLAVE:
1. Press MENUS.
2. Select I/O.
3. Press F1, [TYPE].
4. Select DeviceNet. You will see a screen similar to the following.
(You might have to swith to the next screen to see the devicenet option)

SLAVE
MASTER

TYPE DEV-LST DEF-DEV DETAIL HELP >

F1 F2 F3 F4 F5
Prev NEXT

5. move to comment & enter use upper case to write SLAVE & ENTER,similary write MASTER
6. Move the cursor to Slave & Press F4, DETAIL
You will see a screen similar to the following.

SLAVE ONLY
FANUC SLAVE

TYPE DEV-LST DEF-DEV DETAIL HELP >

F1 F2 F3 F4 F5
Prev NEXT

Set the details as per the following

This is provided by the linebuilder, Robot
controller node number, This must be a value
1 MAC-ID: 15
from 0 to 63 and must be different from the
MAC-Id of any other device in the network.

2 Baud-rate: 250KB This is provided by the linebuilder

3 Board auto-restart: ON
4 Input resume state (rack 81): ZERO
Slave Operation:
Slave Status: OFFLINE
5 SLAVE Error Severity: WARN
6 Size of output from master: 16 bytes This is provided by the linebuilder
7 Size of input to master: 16 bytes This is provided by the linebuilder
For a handling robot The Board -2 also needs to be set.
Set the Board - 2 MASTER as follows
Board: 2
Scanner Type: SST 5136-DN3-104
Motherboard: Wide-mini
1 MAC-ID: 0
2 Baud-rate: 250KB This is provided by the linebuilder
3 Board auto-restart: ON
4 Input resume state (rack 82): ZERO
Slave Operation:
Slave Status: OFFLINE
5 SLAVE Error Severity: WARN
6 Size of output from master: 10 bytes This is provided by the linebuilder exp:8 bytes/16 bytes
7 Size of input to master: 10 bytes This is provided by the linebuilder
7. After putting the value first off the power than on, after that change the SLAVE from OFFLINE to
ONLINE mode.
DEFINING MASTER:
1. Select "5: I/O and "2:TYPE then :0:NEXT & select "5:DEVICENET SETTING
2. add BOARD: SLAVE "81" and MASTER "82" (remenber all changing will be done when
slave & master in OFFLINE mode,after changes first Power Off & then change them in
3. Click on MASTER & then click NEXT, we will see DIAG click on it, then BROWSE, then
QUERY & select PULL , & select ADD_DEF, then power off & change MASTER in ONLINE
mode.
Procedure to add a user defined device (Kuroda)
1. In the devicnet screen select DEF-DEV (F3)
The following screen

TYPE BD-LST DEV-LST DETAIL HELP >

F1 F2 F3 F4 F5
Prev NEXT

2. The following function menus are displayed whan the next key is pressed
DELETE ADD-DEF STD-DEV DEL-ALL >
F1 F2 F3 F4 F5
Prev NEXT
 3. Select ADD-DEF (F2)
The screen similar to the following is seen

TYPE VERIFY LIST HELP >

F1 F2 F3 F4 F5
Prev NEXT

4. Carryout the settings as follows

Defined Device Detail 1/13
Status: IN USE
1 Device\name: KURODA AG42-D1K
2 Comment:
3 Vendor ID: 368
4 Device type: 0
5 Product code: 1
6 I/O Mode: POLL
7 Digital inputs: 80
8 Digital outputs: 80
9 Analog inputs: 0
10 Analog outputs: 0
11 COS/CYC Ack: YES
12 Analog First: NO
13 Input Data Offset (bytes): 0
Defined Device Detail Screen Items
ITEM DESCRIPTION

This item is the name of the device. It appears on the Device List screen when
Device this DeviceNet device is configured on a DeviceNet Interface daughterboard.
Name
This item is an area in which you can provide additional information to describe
Comment the DeviceNet device.
This item is the vendor ID value expected from the device. This value is
compared with the corresponding data sent by the devices. If the value is zero,
Vendor Id any value received from a device can be accepted. If the value of the received
data does not match the value on the screen, the device is put in an ERR state.
default:
Any device with an undefined (***) Vendor-Id value is not available for use.
***
This item is the device type value expected from the device. This value is
Device compared with the corresponding data sent by the devices. If the value is zero,
Type any value received from a device can be accepted. If the value of the received
default:
data does not match the value on the screen, the device is put in an ERR state.
***
Any device with an undefined (***) Device Type value is not available for use.
This item is the product code value expected from the device. This value is
Product
compared with the corresponding data sent by the devices. If the value is zero,
Code
any value received from a device can be accepted. If the value of the received
data does not match the value on the screen, the device is put in an ERR state.
default: Any device with an undefined (***) Product Code value is not available for use.
***
This item indicates which mode to use for the I/O connection that is supported
I/O Mode by the slave device.
Digital
Inputs
default: 0 This item is the number of digital input points (rounded up to the nearest
min: 0 multiple of 8).
max: 1024
Digital This item is the number of digital output points (rounded up to the nearest
Outputs multiple of 8).

default: 0
min: 0

max: 1024
 Analog
Inputs
This item is the number of analog input points supported by the device, if any.
default: 0
min: 0
max: 32
Analog This item is the number of analog output points supported by the device, if any.
Outputs

default: 0
min: 0
max: 32
COS/CYC
Ack This item indicates whether the COS/CYCLIC mode of operation is set to
default: acknowledge or not (default is YES, most devices typically acknowledge).
YES
Analog This item indicates if the analog points appear before the digital points.
First
This item specifies how many bytes of digital input to skip before copying the
Input Data data from the remote device. This can be used to skip status bytes in the
Offset beginning of a message so that data starts with a "start point" of 1. This value
cannot be greater than the total number of digital inputs and should be
selected so that it leaves at least 8 digital input points (1 byte) to be copied.
default: 0 The value will be automatically adjusted if it is greater than the bounds
min: 0 described.
5. AFTER THE ABOVE SCREEN IS DISPLAYED, PRESS DEF-DEV F3 KEY, PRESS DEV-
LST F3 KEY
THE FOLLOWING SCREEN IS SEEN

TYPE BD-LST DEF-DEV [CHOICE] HELP >

F1 F2 F3 F4 F5
Prev NEXT

The following function menus are displayed whan the next key is pressed
DELETE ADD-DEV MOD-LST [CHOICE] CHG-DSP >
F1 F2 F3 F4 F5
Prev NEXT
 6. Select ADD-DEV F2
7. you will be prompted to enter the MAC ID for the new device, input the nuber 1& Press
ENTER key
"Device has been added " message will be displayed on the TP
Go back to the following screen

SLAVE
MASTER

TYPE DEV-LST DEF-DEV DETAIL HELP >

F1 F2 F3 F4 F5
Prev NEXT

Select DEV-LST F2 Key

The following screen is seen

******* OFF 1

TYPE BD-LST DEF-DEV [CHOICE] HELP >

F1 F2 F3 F4 F5
Prev NEXT

Select CHOICE F4 Key

Select Kuroda ( or whatever was set in the previous procedure)
The following similar screen will be dispalyed on the TP

KURODA AG-42 D1K POLL 0 N N OFF 1

CYCLE POWER FOR THE CHANGES TO TAKE EFFECT

After power is cycled the & when the robot is connected to the line the Hand related I/O's
will function & the solenid LED's will glow.
I/O Setting of a Spot Welding Robot
1. Press MENUS.
2. Select I/O.
3. Press F1, [TYPE].
4. Select the kind of I/O you want to set up: UOP, digital, or group.
You will see either an input or output screen. Go to the appropriate step:
 I/O Configuration of UOP

TYPE CONFIG IN/OUT ON OFF >

F1 F2 F3 F4 F5
Prev NEXT

The following function menus are displayed whan the next key is pressed
TYPE NUM-SRT CMT-SRT ON OFF >
F1 F2 F3 F4 F5
Prev NEXT
Press Config F2
You will see a screen similar to he following

TYPE MONITOR IN/OUT DELETE HELP

F1 F2 F3 F4 F5
Prev NEXT
 Carry out the Output settings as below
# RANGE RACK SLOT START STATUS
1 UO [1-20] 81 8 1 ACTIV
Press IN/OUT F3 to toggle between Input & Output
Carryout the Input Setting as below
# RANGE RACK SLOT START STATUS
1 UI [1-18] 81 8 1 ACTIV
Note:
Slot No is the devicenet Node no assigned by the line builder
Status changes automatically. Needs Cycle power.
I/O Configuration of Digital Input & Output for SPOT Welding Robot
Go to the following screen
Menu --> I/O --> F1 Type --> Digital --> F2 Config
Carry out the Output settings as below
# RANGE RACK SLOT START STATUS
1 DO [1-64] 81 8 65 ACTIV
2 DO [65-192] 0 0 0 UNASG
3 DO [193-236] 81 8 21 ACTIV
4 DO [237-512] 0 0 0 UNASG
Press IN/OUT F3 to toggle between Input & Output
Carryout the Input Setting as below
# RANGE RACK SLOT START STATUS
1 DI [1-64] 81 8 65 ACTIV
2 DI [65-66] 81 8 63 ACTIV
2 DI [67-192] 0 0 0 UNASG
3 DO [193-236] 81 8 19 ACTIV
4 DO [237-512] 0 0 0 UNASG

Note:
Slot No is the devicenet Node no assigned by the line builder
Status changes automatically. Needs Cycle power.
I/O Configuration of Group Input & Output for SPOT Welding Robot
Go to the following screen
Menu --> I/O --> F1 Type --> Group --> F2 Config
Carry out the Output settings as below
GO # RACK SLOT START PT NUM PTS
1 81 8 81 8
The above is used for Schedule Sign
Press IN/OUT F3 to toggle between Input & Output
Carryout the Input Setting as below
GI # RACK SLOT START PT NUM PTS
1 81 8 73 8
The above is used for O Style no
Note:
Slot No is the devicenet Node no assigned by the line builder
Status changes automatically. Needs Cycle power.
 I/O Configuration of Digital Input & Output for SPOT Welding Robot
Go to the following screen
Menu --> I/O --> F1 Type --> Digital --> F2 Config
Carry out the Output settings as below
# RANGE RACK SLOT START STATUS
1 DO [1-64] 81 8 65 ACTIV
2 DO [65-192] 0 0 0 UNASG
3 DO [193-236] 81 8 21 ACTIV
4 DO [237-512] 0 0 0 UNASG
Press IN/OUT F3 to toggle between Input & Output
Carryout the Input Setting as below
# RANGE RACK SLOT START STATUS
1 DI [1-64] 81 8 65 ACTIV
2 DI [65-66] 81 8 63 ACTIV
2 DI [67-192] 0 0 0 UNASG
3 DO [193-236] 81 8 19 ACTIV
4 DO [237-512] 0 0 0 UNASG
Note:
Slot No is the devicenet Node no assigned by the line builder
Status changes automatically. Needs Cycle power.
I/O Configuration of Group Input & Output for SPOT Welding Robot
Go to the following screen
Menu --> I/O --> F1 Type --> Group --> F2 Config
Carry out the Output settings as below
GO # RACK SLOT START PT NUM PTS
1 81 8 81 8
The above is used for Schedule Sign
Press IN/OUT F3 to toggle between Input & Output
Carryout the Input Setting as below
GI # RACK SLOT START PT NUM PTS
1 81 8 73 8
The above is used for O Style no
Note:
Slot No is the devicenet Node no assigned by the line builder
Status changes automatically. Needs Cycle power.
I/O Setting of a Material Handling Robot
1. Press MENUS.
2. Select I/O.
3. Press F1, [TYPE].
4. Select the kind of I/O you want to set up: UOP, digital, or group.
You will see either an input or output screen. Go to the appropriate step:
 I/O Configuration of UOP

TYPE CONFIG IN/OUT ON OFF >

F1 F2 F3 F4 F5
Prev NEXT
The following function menus are displayed whan the next key is pressed
TYPE NUM-SRT CMT-SRT ON OFF >
F1 F2 F3 F4 F5
Prev NEXT
Press Config F2 You will see a screen similar to he following

TYPE MONITOR IN/OUT DELETE HELP

F1 F2 F3 F4 F5 NEXT
Prev

Carry out the Output settings as below

# RANGE RACK SLOT START STATUS
1 UO [1-20] 81 43 1 ACTIV
Press IN/OUT F3 to toggle between Input & Output
Carryout the Input Setting as below
# RANGE RACK SLOT START STATUS
1 UI [1-18] 81 43 1 ACTIV
Note:
Slot No is the devicenet Node no assigned by the line builder
Status changes automatically. Needs Cycle power.
 I/O Configuration of Digital Input & Output for Material Handling Robot
Go to the following screen
Menu --> I/O --> F1 Type --> Digital --> F2 Config
Carry out the Output settings as below
# RANGE RACK SLOT START STATUS
1 DO [1-64] 81 43 65 ACTIV Devicenet Node No (SLAVE)
2 DO [65-144] 82 1 1 ACTIV Devicenet MASTER
3 DO [145-192 0 0 0 UNASG
4 DO [193-236] 81 43 21 ACTIV
5 DO [237-512] 0 0 0 UNASG
Press IN/OUT F3 to toggle between Input & Output
Carryout the Input Setting as below
# RANGE RACK SLOT START STATUS
1 DI [1-64] 81 43 65 ACTIV
2 DI [65-144] 82 1 1 ACTIV
3 DI [145-192 0 0 0 UNASG
4 DI [193-236] 81 43 19 ACTIV
5 DI [237-512] 0 0 0 UNASG
Note: Handling Robot has Two Devicenet cards
Slot No is the devicenet Node no assigned by the line builder
Status changes automatically. Needs Cycle power.
I/O Configuration of Group Input & Output for MH Robot
Go to the following screen
Menu --> I/O --> F1 Type --> Group --> F2 Config
Carry out the Output settings as below
GO # RACK SLOT START PT NUM PTS
1 81 43 81 8
The above is used for Schedule Sign
Press IN/OUT F3 to toggle between Input & Output
Carryout the Input Setting as below
GI # RACK SLOT START PT NUM PTS
1 81 43 73 8
The above is used for O Style no
Note: Slot No is the devicenet Node no assigned by the line builder
Status changes automatically. Needs Cycle power.
S16- WELD PARAMETER ENTRY
These data are put into the timer through its pendant. First attached its cable to Timer box &
switch it ON.
Then a windoe will show.
1. click FCN (function key) and goto DEVICENET & ENTER
2.First click on 2:" DATA RATE & select 0 for 125KB or 2 for 500KB.
3.back and enter on NODE ADDRESS and put DEVICE NET ADDRESS (TIMER
CONTROL ADDRESS) from data from control deptt.
4. now come to the main initial screen, use UP-DOWN & LEFT-RIGHT arrow key to put
weld parameters
5. LEFT-RIGHT key shows the different SCHEDUAL which inturn according to define the
SPOT point. Exp. 13 spot define 13 schedule.

6. UP-DOWN key shows different weld parameter, foe schedule 1 which shows spot 1 put
all weld parameter value given in sheet.
 7.Now put the PRESSURE & THICKNESS value through <TEACH PENDANT>
1. select DATA and F1:" TYPE and select PRESSURE
2. put the value of PRESSURE ( according to unit of pressure KN /kgf) and THICKNESS (mm)
8. Now put the value of P & S in PROGRAM according to the value of the scheduling.
S17- CURRENT CALIBRATION
For current calibration we need: 1. Teach pendent 2. Teaching box 3. Force gauge
1. First make a test program containg SPOT point, for the movement of gun tip.
2. Setting is done in TEACH PENDENT:
goto MENUES & select "2: TEST CYCLE then TYPE"2: & select "2:SPOT WELD & ENTER
3. Then in given window changed some entry: as given below

1. Gun operation :
2. Weld controller mode : WELD
3. Tryout-mode : disable
4. Weld I/O sign : disable
5. Weld duration : 500 m/s
6. Inform output to PLC : DO[0]

4. goto MENUES & select "5: INPUT/OUTPUT then TYPE"2: & select "2:WELD INTERFACE & ENTER

5. then change value according to put in device net setting for I/O weld output & I/O weld input
6. Then in given window changed some entry: as given below
OUT POINT
1. Weld Schedule : G[O] 1
2. Weld parity : D[O] 0
3. Schedule strobe : D[O] 3
4. Weld I/O interface : D[O] 4
7. then click input/output for I/O WELD IN
IN
1. Weld in process : DI[O] U OFF
2. Weld complete : DI[3] U OFF
3. Weld/ No weld status : DI[O] U OFF
4. Major alarm : DI[O] U OFF
8. NOTE: 1.In case of CURRENT CALIBRATION we select that SCHEDULE which
contain ONLY PRESSURE NO THICKNESS, and put that schedule number in SPOT
PROGRAM : remember only P value will be mentioned not S value because we are
considering only PRESSURE.
2.Weld should be in ON position
3.OFFSET RESISTANCE should be ZERO in TEACHING BOX
4. ALARM & RESISTANCE value shoud be OFF in TEACHING BOX
9. Now put Circular wire connect to the force gauge n gun TIP, then move gun tip & check
WELD CURRENT in force gauge by selecting left-right key to KA screen which shows
current.
10. In case WELD CURRENT is mentioned in Teaching box for EXP: 7.5KA & when we
check through force gauge it comes less or more for EXP: 7.1 or 8.2 then we maintain that
weld current near or exact 7.5 KA as per put in teaching box by DATA Sheet through
TURNS RATIO. turns ratio increses weld current decreses and vice versa.
S18- NUGGET TEST
1. Nugget test is used to get the spot diameter using two different metal sheet of different
thickness, as per given the off line data sheet.
2. First make a test program containg SPOT point, for the movement of gun tip.
3.. Select any of program schedule for EXP:5 and put the value of P & S value 5 in SPOT
point program.
4. WELD ON, and take a spot by attaching those metal sheet, and remenber there will be a
sound when tip touch.
5. then mention the schedule number and thickness on that test weld metal.