AXstandardRev7+SafetyRev4 Combined

7th edition
(1)
(2)
AX standard course “First time to use robot”
Robot School
AX standard course
First time to use robot
Section#1: Industrial Robot

Section#2: Bases of NACHI ROBOT
Section#3: Caution for tool design
Section#1
Industrial Robot
page 2
(3)
Industrial robot history
Diffusion of industrial robot

In 1960s, industrial robot was presented in the industrial news
paper in USA. Diffused to industrial market.
In Japan...
Imported from USA 1967, and quickly diffused in Japanese
industrial market because
- Master dangerous task instead of worker
- Compensate the lack of worker
- Prevent from high wages in 1973 and 1979 oil shock
- Accelerated by the advanced control technology
page 3
NACHI ROBOT history

1969 1980 1987 1994 1998 2001 2007
UNIMAN 8600 series 8608 series SA series SF series SH series ST-F series
Manufacture Electric Concept: Concept: Concept: Concept: Concept:
industrial industrial robot high production Compact and fast & fine Module concept Built in
robot first in Japan high reliability save space Easy maintenance application cable
AK AM AP AR AW AX AX20
‘80 ‘84 ‘88 ‘92 ‘98 ‘02 ‘07
Digital control Personal computer
Robot language
Controller Open architecture
CPU is used
Programming
thru CRT Easy operation
Color touch panel
page 4
(4)
What is “Industrial robot”
Definition of “Industrial robot”
Machine with manipulating utility that is automatically controlled,

enabling to re-programming and having more than 3 dimension
freedom.
or
Having the similar movable utility with human being arm or hand,
or having sensing ability or recognition ability.
page 5
Articulated robot
Characteristics of articulated robot

Big operating area compared with
narrow small space
(effective usage of area)
page 6
(5)
Section#2
Bases of NACHI ROBOT
page 7
How to read the type (1)
S T 1 6 6 T - 0 2 - A X 2 0 - 0000
Robot (manipulator) series name
MC series MR series SC series ST series
page 8
(6)
S T 1 6 6 T - 0 2 - A X 2 0 - 0000
Rated payload of robot
unit：KG
Bigger size for heavier payload

page 9
S T 1 6 6 T - 0 2 - A X 2 0 - 0000
Robot supplement type
T: table mount type
L: Long arm type and or so
ST166-02 ST166T-02
floor mount table mount
page 10
(7)
S T 1 6 6 T - 0 2 - A X 2 0 - 0000
Robot version
(Sample)
SH166-03：Inline wrist type SH166-04：Offset wrist type
Motor type and wrist specification differs depending on this

version number. Basically, program is not compatible.
page 11
S T 1 6 6 T - 0 2 - A X 2 0 - 0000
＊１＊２＊３＊４
Controller series name
＊１ Compatible standards ＊４ Language specification
0：Japanese domestic (JIS) 0：Japanese
1：North America (ANSI, NFPA79) 1：English
2：CE specification 2：French
3：－
4：Czech
＊２ Supply voltage specification 5：Chinese
0：200 V (without transformer) 6：Taiwanese
1：400 V system (with transformer) 7：German
2：200 V system (with transformer) 8：Korean
3：600 V system (with transformer) 9：Italian
A：Spanish
(Languages except for Japanese and
＊３ 0：fixed English are option. )
page 12
(8)
How to read basic specification (1)
項目仕様 Robot type
ロボット型式 ST166-02 ST166L-02 ST200-02
構造関節形
自由度 6 Basic construction
駆動方式 ACｻｰﾎﾞ方式
J1 旋回 ±3.14 rad
最腕 J2 前後＋1.40 ～－1.05 rad
大
動 J3 上下＋2.62 ～－2.38 rad
作 J4 回転２ ±6.28 rad
範
囲
手
J5 曲げ ±2.36 rad ±2.27 rad Operating area
首
J6 回転１ ±6.28 rad
J1 旋回 1.75 rad/s
腕 J2 前後 1.57 rad/s 1.22 rad/s 1.57 rad/s
最
大 J3 上下 1.66 rad/s 1.31 rad/s 1.66 rad/s
速 J4 回転２ 2.62 rad/s 2.27 rad/s 2.09 rad/s
度手
首
J5 曲げ 2.62 rad/s 2.27 rad/s 2.09 rad/s Speed
J6 回転１ 3.67 rad/s 3.14 rad/s 3.32 rad/s
page 13
How to read basic specification (2)
最大可搬手首部 166 kg 200 kg

質量
Payload
第１アーム上負荷最大 90 kg
J4 回転２ 951 N･m 1274 N･m
手首許容
静負荷 J5 曲げ 951 N･m 1274 N･m
トルク
J6 回転１ 490 N･m 686 N･m Wrist torque and inertia
手首許容 J4 回転２ 88.9 kg･m２ 117.3 kg･m２
最大慣性
J5 曲げ 88.9 kg･m２ 117.3 kg･m２
モーメ
ント *) J6 回転１ 44.1 kg･m２ 65.9 kg･m２
Repeatability
位置繰り返し精度 ±0.3 mm
設置
周囲温度 0 ～ 45 ℃ Ambient temperature
周囲湿度 20 ～ 85 %RH （結露無きこと）
条件
振動値 0.5 G 以下
ロボットタイプ床置 Robot weight
本体質量 1170 kg 1200 kg 1215 kg
！！！CAUTION！！！
Carry the robot in proper method referring the
maintenance manual. Otherwise, serious trouble including
death may happen.
page 14
(9)
Operating area
Operating area written in

basic specification sheet
indicates the locus of
this position called “point A”.
When tool is attached,
the area becomes much wider.
Operating area of ST166-02
page 15
Name of parts (SH series)
№ 各部の名称
Name of parts № 各部の名称
Name of parts
１旋回ベース
Swing axis motor ９軸モータ
J3axis
J3 motor
２本体フレーム
Body frame １０ J4 軸モータ
J4axis motor
３バランサー
Balance unit １１ J5 軸モータ
J5axis motor
４第２アーム
2nd arm １２ J6 軸モータ
J6axis motor
５第１アーム
1st arm １３ J1 軸オーバーランリミットスイッチ
J1 axis over-run limit switch
６手首
Wrist １４ J2 軸オーバーランリミットスイッチ
J2axis over-run limit switch
７軸モータ
J1 axis
J1 motor １５ Arm
アーム干渉リミットスイッチ
interference limit switch
８軸モータ
J2 axis
J2 motor
page 16
( 10 )
Axis name and its movement
J4 : Wrist rotating 2
J5 : Wrist bending
J3 : Up and down
J6 : Wrist rotating 1
Wrist axes J2 : Forward and backward
J1 : Swinging
Press
Press axis
axis
operating
operating key
key Main axes
page 17
Limitation of operating range

3 ways to limit the operating range
1. Software limit
Software defines the operating range by encoder data.
2. Electrical limit switch

Limit switch is installed end to shut down the power
circuit when hit this. (J1,J2,J3 axis)
Some robot does not equip limit switches
3. Mechanical stopper
Limit the operating range by mechanical stopper.
(J1,J2,J3 axis)
When robot system has some trouble, “software limit” can not limit
the operating range. So real range must be limited by the electrical
CAUTION (hardware) limit switch and mechanical stopper.
Please refer to the “Installation manual” section 2 for detail.
page 18
( 11 )
Section#3
Cautions for tool design
page 19
Limitation of tool payload
Tool payload is limited by 3 specifications those are weight, torque and

inertia.
Please comply these specifications when designing the tool.
Permitted torque map of tool Permitted inertia map of tool

payload payload
page 20
( 12 )
Rated payload weight
Tool payload weight must not be over the rated weight.

examples
Robot type Rated weight of payload
ST166-02, ST166L-02, ST166T-02 166 kg or less
ST200-02, ST200T-02 200 kg or less
complement
For material handling application, tool weight is
gripper weight + work piece weight.
If work piece shape and weight varies much,
register tool constant for each. But when they
are similar, plural tool constants may not be
necessary.
page 21
Payload torque
Tool payload torque must not be over the rated torque. Torque is determined
by the weight and COG of payload.
examples
Robot type Rated torque of payload
Rotating on J4 axis Rotating on J5 axis Rotating on J6 axis
ST166-02, ST166L-02,
951 N･m or less 951 N･m or less 490 N･m or less
ST166T-02
ST200-02, ST200T-02 1274 N･m or less 1274 N･m or less 686 N･m or less
[calculation example]
Try to calculate the distance how far the 100Kg payload COG can exist from the J6 axis rotating
center.
(Rated torque of rotating on J6 axis [Nm]) / (weight [kg] * 9.8[m/s2])
= 490/ (100×9.8) = 0.5[m]
Therefore, COG of 100Kg payload must exist within 0.5m distance from the center of J6
rotating center.
page 22
( 13 )
Payload torque map
The limitation of tool payload torque is represented by the visible graph here, so
called “torque map”. When tool weight and its COG is fixed, try to plot on this
map at first. If it is closed to the limited line, then calculate in detail.
Wider range
for lighter payload.
Example of ST166-02
page 23
Payload inertia
Tool payload inertia must not be over the rated inertia. Inertia is determined by
the weight and COG of payload.
examples
Robot type Rated inertia of payload
Rotating on J4 axis Rotating on J5 axis Rotating on J6 axis
ST166-02, ST166L-02,
88.9 kg･m2 or less 88.9 kg･m2 or less 44.1 kg･m2 or less
ST166T-02
ST200-02, ST200T-02 117.3 kg･m2 or less 117.3 kg･m2 or less 65.9 kg･m2 or less
[calculation example]
Try to calculate the inertia when 100Kg payload COG is 0.5 m far from the J6 axis rotating center.
(Inertia) = (weight[kg]) * (distance from the rotating center [m])2
= 100 * 0.52 = 25 [kg・m2]
Referring above map, this value is under the limit. So OK.
page 24
( 14 )
Payload inertia map
The limitation of tool payload inertia is represented by the visible graph here, so
called “inertia map”. Inertia differs depending on the torque. When tool weight
and its COG is fixed, try to plot on this map at first. If it is closed to the limited
line, then calculate in detail.
Example of ST166-02
page 25
( 15 )
AX standard course “Operation”
Robot School
AX standard course
Operation
Section#1: Operating Panel
and Teach Pendant
Section#2: Controller power ON
and Mode selection
Section#3: Motor power ON
and Manual operation
Section#4: Teach
Section#5: Various operations for Teach
Section#6: Playback
Section#1
Operating Panel
Teach Pendant
page 2
( 16 )
Teach and Playback
“Teach” (teaching) is programming (recording) the task

to robot. Move command, signal ON/OFF, call, jump
and welding command are recorded in program.
“Playback” (playing) is executing the recorded

program automatically. Robot does its task according to
the recorded program.
Program sample Program playback

page 3
Operating Panel
E S E
R T
T R
E S E
E S E T
POWER R
R
E S E T
(A) (B) (C) (D) (E)
(A) Motor power ON push button

AXcontroller
AX 制御装置
(B) Start push button
(C) Stop push button
(D) Mode selector switch
(E) Emergency stop push button push lock, turn reset
page 4
( 17 )
PB and SW of Operating Panel
Motor power This is to turn the motor power ON.

ON push button In playback mode, motor servo power is turned
ON and brake released immediately.
Start push
This is to start (playback) the program.
button
Stop push This is to stop the program.

button
Mode selector
This is to select the mode (Teach / Playback).
switch
page 5
Teach Pendant
TP
TP enabling
enabling Emergency
Emergency
switch
switch Stop
Stop button
button
FF keys
keys FF keys
keys
(F1
(F1 to
to F6)
F6) (F7
(F7 to
to F12)
F12)
TFT
TFT color
color
LCD
LCD display
display
Deadman
Deadman switch
switch
is
is mounted
mounted backside
backside
Operating
Operating keys
keys
(axis
(axis operation,
operation,
numeric
numeric keys
keys etc.)
etc.)
page 6
( 18 )
Teach Pendant
“TP enabling switch” for safety operation

This determines the operating mode with the combination of
“Mode selector switch” of operating panel.
“Emergency stop button”

Robot stops immediately and motor power OFF.
“3 position Deadman switch” called “enabling device”

BACK Grip to release brake, then manual operation is possible.
In emergency, just release or compress this switch to lock
brake again. (3 position)
Deadman switch is disabled in Playback mode.
page 7
Teach Pendant
Key samples
Keys to move
To
To enable
enable green
green colored
colored
keys,
keys, press
press this
this key
key
the robot
at the same time
at the same time
Operate these
keys while
(1) Avoid mis-operation gripping the
(2) Second function in one key deadman SW
and watching
robot carefully
To
To input
input parameters
parameters According to the applications, also
[Clamp/Arc] key can move gun and
gripper
Select menu by [cursor] key

↓
Input number by [ten key]
↓
To
To cancel
cancel input
input operation
operation
Finish by ［Enter］ key
This can designate the shortcut
operation at the top screen
page 8
( 19 )
Section#2
Controller power ON
Mode selection
For reference;
“Basic Operating” manual
section 3
page 9
Controller power ON
1. Turn the controller main
power ON.
OFF
ON
2. After self check completed,

starting screen comes up as 電源スイッチ
Main power switch
followed.
制御装置
AX controller
page 10
( 20 )
How to select Teach/Playback mode
Teach pendant
TP enabling switch
Manual operation No manual operation

available No Playback
Mode
Both switches must be Operations without robot
turned to Teach movement are available
Select
No manual operation Playback operation
Switch No Playback available
Operations without robot Both switches must be
movement are available turned to Playback
page 11
Basic screen (Teach mode)

Mode
Mode Current
Current Current
Current
(Teach) Date
Date &
& time
time
(Teach) Program
Program No.
No. Step
Step No.
No.
Current
Current
Mechanism
Mechanism
Manual
Manual speed/
speed/
Check
Check speed
speed
Coordinate
Coordinate
Spot
Spot welding
welding system
system
FF keys
keys area
area
located
located on
on right
right
gun
gun status
status
and
and left
left side
side
Constant
Constant menu
menu
“Monitor
“Monitor area”
area”
Service
Service menu
menu such
such as
as program
program monitor
monitor
and
and axis
axis position
position monitor
monitor
page 12
( 21 )
Qualification of operators
Operations and setting items are limited by the operator’s

qualification.
Beginner : Elementary level (only startup the robot in factory)

User : Regular level (teach and playback)
Expert : Expert level (maintenance of robot)
Specialist : Senior Expert (highest class maintenance)
Example) Beginner can not open constant setting screen (But Expert is
free to open it.)
To change the operator’s qualification, shortcut code R314 and password is
necessary. Useful to avoid important setting by mistake operation.
At the moment of power on, operator’s qualification is Beginner or User.
So many constant setting items are prohibited to edit.
page 13
Section#3
Motor power ON
Manual operation
For reference;
section 3
page 14
( 22 )
Motor power ON
(Servo power ON)
1. Select TEACH TEACH mode icon is
mode of “mode displayed on left top.
selector switch” on
operating panel.
2. Select TEACH Now manual operation is
side of “TP enabling permitted.
switch” on teach
pendant.
3. Press “Motor ON” Servo power is ON, now ready

button on operating to motor power ON. In Teach
panel. mode, brakes are still locked.
page 15
Axis manual operation
Condition
Condition
setting
setting keys
keys
Axis
Axis operating
operating
keys
keys
page 16
( 23 )
Select coordinate system

and manual speed
Before moving the robot, [coordinate] and [speed] must be selected.
Press [coordinate] key Press [Teach speed] key to

to select the coordinate select the speed in manual
system in manual operation. (5 levels)
operation.
[joint]->[XYZ]->[tool]
Beginner operators had better do practice to confirm the

robot movement according to the coordinate system and
speed selection.
page 17
Joint manual operation (1)
Press [X+/-] to rotate J1 axis (swing base).
Press [Y+/-] to rotate J2 axis (2nd arm).
Press [Z+/-] to rotate J3 axis (1st arm).
page 18
( 24 )
Joint manual operation (2)
Press [RX+/-] to rotate J4 axis (1st axis of wrist).
Press [RY+/-] to rotate J5 axis (2nd axis of wrist).
Press [RZ+/-] to rotate J6 axis (3rd axis of wrist).
page 19
XYZ manual operation (1)

XYZ coordinate system is fixed on the robot base.
When pressing main axes key, TCP (Tool top position) moves parallel along
this XYZ coordinate direction.
+Z
TCP
TCP
+X
+Y
XYZ coordinate
system
page 20
( 25 )
XYZ manual operation (2)

When pressing wrist axes key (RX, RY and RZ), robot twists its tool while
keeping TCP position stationary. Rotating direction is based on the
XYZ coordinate system. This is convenient to change wrist attitude after
fixing TCP position.
TCP
TCP
page 21
More than 6 axes robot
In case of the robot that has more than 6 axes, choose the operating axis by key.
J7 : Servo gun
J7 : Swinging 2
page 22
( 26 )
Let’s move the robot

Let’s move the robot. Pay much attention.
Touch the emergency push button.

Always operator has to be in the
ready position to press emergency.
Grip deadman switch. You can hear the slight sound then all
axes motor is energized and brake is released.
Do not compress or release deadman switch. Motor power is
turned OFF.
Motor power lamp is

illuminated in green.
Press axis operating key to
move robot.
page 23
Caution in operating robot
Every time pay much attention to the robot destination area.
Also tool and cables on the robot arm must be cared.
Every time pay much attention while

operating the robot to protect not only
yourself but also the robot, work piece
and peripheral equipment.
page 24
( 27 )
Caution in operating robot
Releasing deadman switch can stop the

robot immediately, but careless
operation causes unnecessary brake pad
consumption.
Normally to stop the robot,

release the axis operating key.
After that, release deadman switch.
page 25
When not operating the robot
When you do not operate the robot, turn the motor power OFF for safety.
If while playback, press STOP button to stop the robot.

If while manual operation, just release the axis operating key.
After confirming robot stops, press emergency stop

button.
Motor power is turned OFF.
page 26
( 28 )
Practice
1. Confirm the real robot speed by changing the manual speed level 1 to 5.
2. Confirm the real robot movement by changing the coordinate system.

[Joint] mode [XYZ] mode [Tool] mode
3. Confirm the real robot movement (fixing TCP movement) when pressing
RX, RY and RZ key in [XYZ] mode.
4. Put the tool attitude in slant position, an confirm the real robot movement
when pressing [Tool] mode. Confirm the difference from [XYZ] mode.
5. Stop the robot and press emergency stop button, and confirm the motor on
lump goes out. Next, confirm that robot can never be moved by gripping
deadman switch and pressing axis operating key.
page 27
Section#4
Teach
For reference;
section 4 and 5
page 28
( 29 )
Top window of Teach mode
Following picture shows the top window in teach mode.
Here
Here is
is current
current mode.
mode. Confirm “Teach” is displayed.
Here
Here is
is current program No. When empty, [none] is displayed.
Here
Here is
is current step No.
Here
Here is
is comment of current program. (If recorded)
Recording
Recording status.
status.
This
This indicates
indicates the
the
information
information those
those are
are
recorded
recorded in
in next
next step.
step.
page 29
Program construction
Program
Program Step
Step (command)
(command) Move
Move command
command
0 to 9999 0 to 9999 Move the robot to the recorded position.
(sample ) 100 mm/s LIN A1 T1
Function
Function command
command
Select the desired Move command can This can execute signal ON/OFF,
call other program, delay, welding
number, and record move the robot. and or so.
steps in it.
And function command (sample )
can execute variable END FN92 ; End
things. SPOT FN119 : Spot welding
CALLP FN80 ; Program Call
DELAY FN50 ; Delay
SETM FN105 ; Signal ON/OFF
page 30
( 30 )
Select program number
ENABLE
ENABLE key
key
Program
Program (step)
(step)
selection
selection
page 31
Select program number
Current (=selected) program content is displayed on the screen. How to change

current program, please operate as followed.
1. Press [STEP/PRO] key while pressing [ENABLE] key.
[ENABLE] key enables the green colored
function. So it is “PROGRAM”.
2. Following dialog is displayed, then key in the requested program number (0

to 9999) and finally press [ENTER]. Requested program content is loaded and
screen is refreshed.
page 32
( 31 )
Select step number

Current (=selected) step is displayed on the screen. This is the target step of
Check go/back, editing and or so. How to change current step, please operate as
followed.
1. Press [STEP/PRO] key.
2. Following dialog is displayed, then key in the requested step number (0 to

9999) and finally press [ENTER]. Requested step is selected and colored green.
page 33
Record “MOVE” command
［REC］
［REC］ key
key
to
to record
record
Move
Move command
command
移動命令を
移動命令を
To
To edit
edit
編集する
編集する
Move
Move command
command
・MODify Position
・INSert Sample of Move command
・DELete
・Over Write
Modify
Modify easily
easily
Speed
Speed and
and accuracy
accuracy
page 34
( 32 )
Record “MOVE” command

Come
Command to move robot is called “MOVE” command. Here
One line (one step) has one destination position. By this way
Step
Step No.
No.
Speed
Speed Interpolation
Interpolation Accuracy
Accuracy Tool
Tool No.
No.
Move the robot to the desired position and press [REC]. New move command
step is generated which content is same as “Recording status”.
Recording status
New generated step

page 35
Speed dimension
How to designate the robot speed?
mm/s : Designating by the line speed of TCP.

% : Designating by the robot ability ratio.
sec : Designating by the time to reach.
deg/s : Designating by the tool changing speed.
By utilizing “Screen editor” , speed dimension is free to be

changed after recoding step.
page 36
( 33 )
Interpolation
How to designate the trajectory of robot?

LIN : TCP trajectory is linear.
JOINT: TCP trajectory is never linear. (each axis is driven separately.)
CIR1 : TCP trajectory is circle. (mid point)
CIR2 : TCP trajectory is circle. (final point)
By utilizing “Screen editor” , interpolation designation is free to be changed after
recoding step. CIR1
JOINT
CIR2 CIR2
CIR2
LIN
LIN CIR1
LIN CIR2
page 37
Accuracy (1)
“Accuracy” is designating the shortcut level when passing through the recorded
point. Bigger number makes bigger shortcut (away from the recorded point).
Factory setting [mm]
A1 A1 0
A4 A2 5
A3 10
A4 25
Shortcut starting A5 50
point A6 100
A7 200
A8 500
Shortcut level for each accuracy is set

in Constant menu. The distance between
shortcut starting point and recorded point
is registered.
A1 Redundant axis robot such as MR20, shortcut level is

needed to be designated by velocity not distance.
page 38
( 34 )
Accuracy (2)
Whether “In position” is checked or not can be designated.

“In position” is checked : P = making a brief stop （Ex; A1P)
“In position” is not checked : (no P) = pass through （Ex; A1)
100[mm/s] 80[mm/s]
100[mm/s] 80[mm/s] A2
A2P
speed making a brief speed

pass through
stop
time time
page 39
Tool number
This number is designating the tool number (T1 to 32) to select which tool
(which TCP) is mounted on the robot.
TCP TCP
defined as Tool number 1 defined as Tool number 2
page 40
( 35 )
Edit of “MOVE” command
“MOVE” command can be deleted, modified, inserted and overwritten

by the following operation. After selecting the target step, then proceed
to each operation.
The selected step is deleted. Step number

Press with after the deleted step is renumbered
automatically.
Only the position of the selected step is

Press with modified. Other information is never
changed.
New step is inserted before (after) the

Press with selected step. Step number after the
inserted step is renumbered automatically.
page 41
Record “Function” command
Sample of Function command
Shortcut
Shortcut keys
keys for
for [FN]
[FN] key
key
frequently
frequently used
used functions
functions
to
to record
record
OUT ; FN105 Function
Function command
command
IN ; FN525
TIMER ; FN50
page 42
( 36 )
Record “Function” command

Command without move command is called “Function” command.
This is displayed with command code and its number (FN***) .
Step
Step No.
No. Command
Command code
code Function
Function No.
No.
Some function has plural parameters.

(Sample)
FN119 spot welding function has 4 parameters
Operation is as followed. Number of parameters differs for each.

Key in function
Key in
number, or select
parameters
from the dialog box
page 43
Frequently used Function
■ Waiting for input signal Exclusive key on teach pendant
■ Output signal ON/OFF Exclusive key on teach pendant
■ Stopping in a while Exclusive key on teach pendant
■ Comment (name, mark) FN 9 9
OFF
■ End (of program) FN 9 2
page 44
( 37 )
Frequently used Function
Very useful FN99 (Comment Function) recorded at

FN99(Comment Function) step 1 is displayed on the top of screen
as the title of this program.
page 45
Check the recorded program
“Check
“Check go”
go”
“Check
“Check back“
back“
page 46
( 38 )

Recorded program must be checked before playback.
[Check GO] and [Check Back] keys are used.
Robot moves forward along the recorded

step (MOVE step) in slow speed. When
switch is released, robot stops immediately.
Robot moves backward along the recorded
grip deadman switch step (MOVE step) in slow speed. When
switch is released, robot stops immediately.
2 3
1
Not only the MOVE steps but also the function steps can
be executed in this operation.
Setting is needed beforehand. 4
page 47
To determine whether to stop robot at very To determine the speed of check

step or move GO and BACK
continuously
with
Separated setting with

MANUAL SPEED
(green bar)
No display Robot stops at every step. Step display changes to yellow after coincidence.
Release switch and press again for proceeding to the next step.
［CONT］ Robot does not stop at the step and keep going continuously.
Robot stops after achieving to END (FN92) step.
page 48
( 39 )
Screen editor
[EDIT]
[EDIT] key
key
to
to open
open
Editor
Editor screen
screen
Editor screen will appear

to edit each items.
page 49
Screen editor
To
To find
find function
function
Cursor
Cursor
position
position Cut
Cut and
and paste
paste
with
with plural
plural step
step
Designating
Designating
step
step copy
copy until
until pressing
pressing F12,
F12,
direction
direction program
program isis never
never
overwritten.
overwritten.
Separation
Separation F11
F11 can
can abort.
abort.
of
of edit
edit screen
screen
page 50
( 40 )
Screen editor
Also information of “MOVE” command can be edited, referring the guide

message displayed at the bottom of screen.
Cursor position
Speed value
Speed dimension
Interpolation
Accuracy No.
In position check
Tool No.
page 51
Section#5
Various operations for Teach
For reference;
section 4 and 5
page 52
( 41 )
Manual output signal ON/OFF
→ 8. User Outputs
Put cursor to the output signal to be operated
ON
＋ 1 ＯＮ
OFF
＋ 2 ＯＦＦ
Reference This key can also drive the signal ON/OFF manually.
Two output signals can be operated alternatively at the same time.
Beforehand, setting is needed in constant setting mode.
page 53
HELP message
Put cursor to the unknown Detail explanations will

function appear
List box and contents box can be switched by
Press to close help screen.
Reference If key is press at the top menu screen, whole of

help menu will appear. Not only the function help but
also many other explanations can be referenced.
page 54
( 42 )
Useful shortcut (R code)
At the top menu, try to press key and 3 digit number・・
ON
1 7 Program list display
ON ON
1 1 7 Program deletion
ON ON
1 1 5 Program copy and so on・・・
You can achieve to the needed operation Very useful if you

faster than normal menu operation remember this number
page 55
Section#6
Playback
For reference;
section 4 and 5
page 56
( 43 )
Playback program
Check All the trajectory checking is really done by

check GO/BACK operation?
Didn’t you forget to check

trajectory from the last
step to the start step?
Step 1 Last step and

start step had
better be the
Step 2 same position.
Last step
page 57
Playback program
1 Change to playback mode.
In playback mode, deadman SW is disabled.

(Motor power is ON)
2 Select one playing mode.
For the first confirmation, “Step” mode or

”Cycle” mode is to be selected.
page 58
( 44 )
Playback program
3 Reduce the playback speed by “Velocity override”.
Playback speed can be temporary reduced without

program modification.
＋ Recorded speed Velocity O/R Playback speed

Ex) 1200mm/sec × 50% = 600mm/sec
Ex) 90% × 20% = 18%
Sudden playback with top speed is very dangerous.

Unexpected interference with the peripheral equipments, big
vibration of application wires and dropping off the work-
CAUTION
piece may happen. New program must be checked with
sufficient low speed (ex: 20% to 30%) using velocity override.
page 59
Playback program
4 Confirm the current step No. and current robot position.
Current step No.

Robot moves
from current position
to this step.
● Intermediate step is not set?

● Robot position is correct?
● Conditions of peripheral equipment such as gripper is correct?
● For the playback from start step, select step 0.
When immediately after the END step playback is completed, this is same. When playback
is started, robot jumps to the top of this program (= step 0) after END step.
page 60
( 45 )
Playback program
Put your finger on emergency stop button,

5
check the peripherals around the robot, and
press START.
● If robot moves to the different position or with the different speed

with your expectation, immediately press emergency stop button
without hesitating.
Teaching mistake? Wrong program No.? Wrong step No.? And or so.
● After checking finished, increase the speed gradually and try again.
● After 100% O/W is finished, checking is completed at this moment.

Velocity override can be set larger than 100% value. Please use this utility to try the
tact up.
page 61
Playback program
Off course, it’s possible to playback from the intermediate step.
Enter
Select the start step by ＃ then press
From the position where

START button was pressed, This is the safety countermeasure
to step # position. Robot assuming the mistaken selection
moves with slow safety speed. by the operator.
Step 1 After passing through step #,
robot speed is raised up to the
original speed.
Step 2 Current position (where
START button was pressed)
Last step
Step #
Caution Function step can not been selected. Because it’s very dangerous if function is executed at the incorrect position.
page 62
( 46 )
Finish the programming
6 Finish the programming by removing the useless

motion, by checking the following items and or so, to
make robot faster.
● NO place to hit the peripheral equipment? (Be sure to perform the

continuous check go/back.)
● All move command is smoothly connected? (no sudden acceleration.)
● No useless motion? (Unnecessary point, unnecessary delay, and or so)
● Unnecessary big motion to make overload? (This is very important to
make robot lifetime longer.)
page 63
( 47 )
AX standard course “Setup”
Robot School
AX standard course
Setup
Section#1: Connection
Section#2: I/O signals
Section#3: Constant Setting
Section#1
Connection
For reference;
“Installation” manual
section 3
page 2
( 48 )
Connect robot and controller
Connect robot and controller with wire harness.
IMPORTANT
Before connecting harness to
the receptacle of robot joint
box, please confirm their
wire harness
ワイヤーハーネス
labels.
Although its key direction is
designed to prevent from miss-
matching, forcible insertion
will break connector pins .
page 3
Connect teach pendant
Connect teach pendant to controller.
ティーチペンダント
Teach pendant
Connector of controller for T/P
※ Connector position may differs

depending on the controller type.
page 4
( 49 )
Primary power (1)
Before connection
1. Turn OFF the power supply unit and main circuit breaker of AX controller.
OFF
ON
ON
OFFOFF
CAUTION
〔handle type〕
If connected keeping power ON,
operator may be seriously injured.
Power
Power
supply
supply unit
unit
OFF Never forget to check
main power supply unit is also OFF.
page 5
Primary power (2)
Before connection
2. Please check the primary power voltage. Controller specification is
labeled near the main circuit breaker as followed.
CAUTION
AC200V Wrong voltage may break the
controller power circuit.
5.5mm22 (grounding wire）
3.5mm22 (each phase for power wire)

page 6
( 50 )
Primary power (3)
3. Connect power wire.

Remove the clothing of wire and connect
Power cable
電源ケーブル to the circuit breaker with compressed
terminals.
圧着端子を使用し After that, attach the ceiling panel again.
て接続
ブレーカ
Circuit breaker
CAUTION
パネル
panel
Be sure to attach the panel,
breaker cover and cable clump.
If not, water or dust may cause a
serious accident or trouble.
ブレーカ
Circuit breaker
page 7
Grounding (1)
POINT of grounding
1. Grounding of controller is absolutely necessary to prevent from the
receiving an electric shock and noise.
More than 5.5 mm2 wire must be used for grounding wire,
and wire length had better be as short as possible. (D earth)
2. Also peripheral equipment must be grounded to make same voltage level.
gripper
ハンド
gripper 制御装置
ハンド controller
制御装置
controller Work piece
ワーク
Work piece
ワーク
配電盤
ロボット本体
ロボット本体
Ｄ種接地 D Ｄ種接地
earth
D earth
page 8
( 51 )
Safety signals connection
For safe operation, safety related signals such as emergency

stop signal and safety plug signal are absolutely necessary to
be connected to robot controller.
Safety fence
Safety plug
page 9
Section#2
I/O signals
For reference;
“Installation” manual
section 3
page 10
( 52 )
I/O signals
Communication between controller and peripheral equipment

AX controller
Output signals
Peripheral
equipment
Weld
Weld signal,
signal, home
home position
position
signal,
signal,error
errorsignal,
signal,etc.
etc. sensor,
sensor,
switch,
switch,
Input signals PLC,
PLC,
Weld
Weld controller,
controller,
Program
Program selection
selection signal,
signal, and
and or
or so
so
start
startcommand,
command,weld weld complete
complete
interlock
interlock signal,
signal,etc.
etc. including
including other
other
robot
robot controller
controller
page 11
Sample of I/O signal usage (1)
Communication with robot each other.
I’ll
I’ll wait
wait for
for the
the input
input signal
signal
Mr.
Mr. Robot-B,
Robot-B, from Robot-A.
from Robot-A.
please
please wait for
wait for my
my “task
“task complete”
complete”
when
when you start next
you start next job.
job.
A B
Waiting
Waiting for
for
Task
Task complete
complete “Task
“Task complete
complete of
of A”
A”
output
output signal
signal ON
ON input
input signal
signal
Output signal Input signal
page 12
( 53 )
Sample of I/O signal usage (2)
Changing the playback program depending on the work type.

Changing the “Program selection” input
signal depending on the work type.
Next
Next work
work is
is type
type “A”
“A”
so
so program No. is
program No. is 100
100
I’m
I’m ready!
ready! program
program selection
selection
It’s
It’s time
time to
to start!
start!
AX controller
B
Input
Input program
program selection
selection
signal
signal “100”
A “100”
Prg.#100
START “start”
“start” input
input signal
signal
page 13
DC24V I/O (UM212 board)
In case of DC24V I/O specification,

input and output signals are connected to I/O board UM212 (connector
CNIN and CNOUT).
CNIN
Connector for outputs
DC24V I/O spec. CNOUT
I/O board
CNOUT
Connector for inputs
UM212 CNIN
(in PCB rack)
I/O board itself is selectable option in AX20 controller.

Not only DC24V I/O, but also field bus such as DeviceNet, PROFIBUS is available.
page 14
( 54 )
DC24V I/O (UM212 board)
I1
I1 32
Input signal (I1～I2048) “I signal”
:: DC24V inputs
AX controller supports 32 DC24V input signals
::
as standard (I1 to I21).
::
Please use these signals as start/stop command
:: input and or so from peripheral equipment.
I2048
I2048
32
O1
O1
DC24V outputs
Output signal (O1～O2048) “O signal”
::
AX controller supports 32 DC24V output
::
signals as standard (O1 to O21).
:: Please use these signals as weld start command
:: output and or so to peripheral equipment.
O2048
O2048
Please refer to the “installation manual” section 3 and 4.

page 15
Input signals connector CNIN
Connector CNIN view from solder pot side.

Type : MR-50LM (Honta Tsushin)
18pin
1pin
19pin
33pin
32pin
50pin
key
Input signals are free to be assigned to general usage signals and status
signals. Please refer to the “Installation manual” section 3 for default
allocation.
page 16
( 55 )
Output signals connector CNOUT
Connector CNOUT view from solder pot side.

Type : MR-50LF (Honta Tsushin)
50pin
33pin
19pin
1pin
32pin
18pin
key
Output signals are free to be assigned to general usage signals and status
signals. Please refer to the “Installation manual” section 3 for default
allocation.
page 17
Status I/O assignment
Status input (output) signals are allocable in I1 to I2048 (O1 to O2048)

signals.
Minimum I/O status

signals are already
assigned in default. But
all signals are free to be
re-allocated.
(Sample in above figure)

External start input signal is assigned to I30. Robot starts playback when I30
is inputted from external controller.
page 18
( 56 )
I/O signals connection
Connection Solder necessary cables to I/O connector of UM212,

and connect necessary cables to terminal blocks with
compressed terminal. Finally attach the panel.
ＵＭ２１２
付属コネクタ
connectors
出力コネクタ
CNIN
ＣＮＯＵＴ
ハンダ付け
soldering
入力コネクタ
CNOUT
信号線ケーブル
Signal cable
ＣＮＩＮ
端子台
Terminal blocks
ＴＢＥＸ１、２へ
TBEX1, TBEX2
page 19
Section#3
Constant Setting
For reference;
“Installation” manual Before proceeding to this section,
section 4 basic operation acknowledgement
is necessary.
page 20
( 57 )
What is “constant setting”?
Constant setting = Set up procedure before beginning teach

Constant setting is to fix variable setting that must be done before beginning
teach.
Sample: Tool constant

tool top position?
tool direction?
tool weight? +Z
COG of tool?
(others constant setting)
+X
Press F5 “Constant Setting”.
- Home position registration (User or upper operator class
- Soft limit definition is needed for this operation.)
- and or so
page 21
Tool constant
[constant setting] -> [3 machine constant] -> [1 Tool constant]
[constant setting] F6 key in teach mode

Tool
Tool name
name
Tool
Tool length
length
Tool
Tool angle
angle
Weight
Weight &
& COG
COG
Tool
Tool inertia
inertia
Tool
Tool rotating
rotating radius
radius
page 22
( 58 )
Tool constant
Tool length
This is to define where the tool top position is. It’s length (X,Y and Z value) is
measured from the tool attaching plate.
Tool angle
This is to define the tool direction. It’s angle is measured as rotating angle on
X,Y and Z axis.
Tool weight & COG （Expert or upper operator level is necessary to set this.)
This is to define where the tool COG position is. Also its weight is set.
These parameters are necessary to make an adequate acceleration control.
Tool inertia
This is to define the tool inertia.
These parameters are necessary to make an adequate acceleration control.
page 23
Tool length (TCP position)
+X
Wrist
Wrist coordinate
coordinate
Tool
Tool top
top position
position +Y
(like
(like welding
welding gun
gun
contact
contact point)
point)
Z length
Wrist
Wrist coordinate
coordinate (0,0,0)
(0,0,0)
+Z is
is aa center
center position
position of
of
X length tool
tool attachment
attachment plate
plate
Y length Before start teaching, check X,Y and Z length of

tool and input these values in TP screen. Tool
drawing had better be prepared.
page 24
( 59 )
Sample of TCP position
In the case of spot welding

Tool top position gun, settled tip top position
should be defined as tool
top position. This position
moves in linear when
interpolation (LIN).
X length
LIN
Z length LIN
Interpolation movement is controlled

based on the tool top position.
page 25
Tool angle (tool coordinate)

+X
Wrist
Wrist coordinate
coordinate
+Xt
+Y
Tool
Tool coordinate
coordinate
+Zt
+Yt +Z
Tool
Tool coordinate
coordinate
(0,0,0)
(0,0,0) Tool coordinate system determines the tool moving
== tool
tool top
top position
position direction.
This can make teaching much easier even when the
shape of work piece is so complicated.
page 26
( 60 )
Necessity of Tool angle
Tool angle
This can make teaching much easier even when the shape of work piece is so
complicated because X,Y and Z direction from tool never changes.
ワーク
Work piece
Work
ワーク piece
Press
Press [X+]
[X+] inin tool
tool
coordinate,
coordinate, then
then tool
tool moves
moves
toward
toward the
the work
work piece
piece in
in
any
any attitude
attitude..
For servo gun system, tool angle setting is absolutely necessary for the correct
bending compensation.
page 27
Tool weight and COG

Center of gravity
Tool weight and COG Correct tool weight and COG

position is necessary to make an
Tool top position
adequate acceleration control.
COG of tool Automatic

Automatic tooltool weight
weight and
and COG
COG
Point A setting is
setting is convenient
convenient to
to get
get aa correct
correct
value. Expert
value. Expert oror upper
upper operator
operator
level
level is
is necessary
necessary to
to do
do this.
this.
CAUTION
If tool weight, COG and inertia are beyond the rated capacity, this
may cause to shorten the lifetime of robot so early.
page 28
( 61 )
Easy setting of Tool constant
There is a convenient utility to get

- tool length (X,Y and Z)[mm] and tool angle [deg]
- tool inertia [kg・m2]
by easy setting procedure.
When these values are not clear, please use this utility.
In “tool constant”
screen
“Easy setting” screen
appears
Press “Easy setting”

key
page 29
Tool length easy setting (1)
Preparation of program
At first, install the sharp edge thing on the fixed ground.
Then make a program where tool top position is touched the edge in variable
tool attitude. Record more than 10 steps (preferred).
Record more than

10 steps in variable
tool attitude.
sharp edge needle on
the fixed ground
POINT
- All steps have big different tool angle.
- All steps are recorded in interpolation ON (LIN).
- Record TCP position as correct as possible. (needle is preferred.)
page 30
( 62 )
“Tool length” in
Choose “only tool length”
Input the program number already

created.
After inputting above, just press F12

(execute). Tool length is
automatically calculated.
Finally Press F12

(overwrite)
page 31
Confirm the tool length

Let’s confirm the calculated tool length value. Select the same program (10
steps program) and execute Check GO.
If tool top position

does not move
between the step,
In teach mode, grip automatically
deadman switch and press setting was
[Check GO] key. successfully done.
page 32
( 63 )
Tool angle easy setting (1)
“Tool angle” in Z
“Easy setting” screen Required tool
coordinate system
X Y
Move the robot manually so

that two coordinate systems
seem to be parallel.
Z
Robot base
coordinate system
X Y
Finally Press F12 execute

and overwrite.
page 33
Tool angle easy setting (2)
Confirm the tool angle

Let’s confirm the calculated tool angle value. Select [tool coordinate] in
manual operation, and try to press X,Y,Z keys and RX,RY,RZ keys and check
the moving direction of tool.
[Z+]
[RY]+/-
Press [coordinate] key to select the

coordinate system in manual
[X+]
operation.
[joint]->[XYZ]->[tool] XYZ key Tool rotate key
page 34
( 64 )
Automatic tool weight & COG

setting (1)
Preparation of program
[Service] -> [19 auto COG setting] -> [2 Program creation]
In Teach mode f6 key
Input
Input the
the empty
empty program
program No.
No. This
This
program
program number
number is
is created
created as
as the
the
auto
auto COG
COG setting
setting program.
program.
page 35

setting (2)
Record steps as shown below. Torque of J3, J5 and J6 axis had better be high.
Watch torque monitor in same screen.
J3 torque
J5 torque
Torque monitor
Angle Torque monitor
J6 torque
※ J1,J2,J4 torque does not matter to this Higher

Higher torque
torque is
is better
better
function. These axes does not have to be moved.
page 36
( 65 )

setting (3)
Set cursor in “Pose 1” and press.

Then its position is displayed and recorded.
Record “Pose 2” in same way. But change position much.
Sample of two poses Finally Press F12(execute) to create

the new program.
page 37

setting (4)
Measurement of COG
Change mode to Playback, and set “1 cycle mode”.
If above icon does not appear, press and f5 and f4 at the

same time.
[Service] -> [19 auto COG setting] -> [1 Measurement]
page 38
( 66 )

setting (5)
Following screen is displayed. Input necessary parameters.
Input
Input the
the created
created program
program No.
No.
Input
Input the
the tool
tool No
No which
which length
length is
is
required.
required.
Select
Select “automatic”
“automatic” when
when tool
tool weight
weight
is unknown.
is unknown.
Input
Input the
the weight
weight andand COG
COG on
on the
the 1st
1st
arm.
arm. If
If those
those are
are unknown,
unknown, leave
leave
these
these values
values to
to 0.
0.
page 39

setting (6)
Press f12 (execute), then robot is in standby.
Turn the motor power ON and press start PB to start playback.

Robot moves slowly and tool weight and COG is calculated. After that, robot
stops and result is displayed on the screen.
Tool weight and COG automatic setting is completed.

page 40
( 67 )
Tool inertia easy setting (1)
“Tool inertia” in
Select
Select the
the tool
tool gripping
gripping style.
style.
Select
Select the
the tool
tool shape.
shape.
Input
Input the
the tool
tool size.
size.
Finally Press F12

execute and
overwrite.
page 41
Tool inertia easy setting (2)
Guide picture changes according to the setting.
EDGE・BOX
EDGE・BOX EDGE ・FRAME
EDGE ・FRAME PLATE・
PLATE・ BOX
BOX PLATE ・
PLATE ・ FRAME
FRAME
Input width(a),depth(b),height (c) and , then tool inertia is calculated.
Check the value and press , then registered in file. (If not pressed, this
value is not registered.)
page 42
( 68 )
AX standard course “Maintenance”
保守編
Robot School
AX standard course
Maintenance
Section#1: Principle of robot structure
Section#2: Operation in emergency
Section#3: Controller
Section#4: Data backup and restoring
Section#5: Manipulator
Section#6: Motor/encoder replacement
and encoder correction
Section#1 Principle of robot structure
Section #1
Principle of robot structure
page 2
( 69 )
Main axis mechanical structure
Bigger torque J3 axis

Reduction gear
Small torque
Reduction gear
Servo motor
Encoder
J2 axis
Reduction gear
Small torque generated by the motor
is converted to bigger torque
by the reduction gear, J1 axis
to move robot arm. Reduction gear
page 3
Wrist axis mechanical structure
Servo motor Servo motor

J4 axis
J4 axis
Reduction gear
Reduction gear
J5 axis J5 axis
Reduction gear Reduction gear
Shaft
J6 axis
J6 axis
Reduction gear
Reduction gear
Bevel gear Spur gear
Drive mechanism is basically same as main axes,

but power train parts such as shafts and bevel gears are inserted.
page 4
( 70 )
Controller structure
Especially important parts
CPU Board
Main control tower that consists
of not only CPU but also the Control section
memories where system software
and program data is stored Center of control
Plural print circuit boards are inserted
to the slots
Drive Unit
Drive section
Circuit to generate the big ampere Circuit to generate the big ampere to
to drive the robot and interface drive the robot
circuit to read position data
-This type depends on the manipulator type
-Sometimes this is called “Amplifier”
AX20 Controller
page 5
Servo control
Reduction gear
CPU board
Encoder Working program
(= Position detecting device)
CPU
Command
position
Drive unit
Current POWER
position Position feedback

Encoder I/F
Motor
ampere Current amplifier
etc.
Controller
Motor ampere is controlled in order that command position
and current position is coincident. (servo control)
page 6
( 71 )
Arm is held by brake
Motor
Brake
Encoder
Brake power OFF → LOCK ARM

Motor power OFF Brake lock
Brake power ON → RELEASE ARM

Motor power ON Servo lock
Arm is held by servo control
page 7
Arm is held by brake
When a motor is removed without supporting the arm properly, the

arm may drop or move forward or backward. PROPERLY
SUPPROT THE ARM BEFORE REMOVING THE MOTOR.
DANGER
page 8
( 72 )
Section #2
Operation in emergency
For reference;
Controller maintenance manual
page 9
“Brake release switch” （option)
TYPE 2 : Portable type
BRAKE RELEASE SWITCH UM217A
J1 J2 J3 J4 J5 J6 J7 J8 J9
CNSW CNSW1
(J8) AX10-OP90-B-*
CNSWJ CNSW1J
J7 CNSWJ CNSW1J
AX20-OP90-B
J6
J5
J4
J3
J2
CNSW
J1
DRIVE UNIT CNSWA

8軸仕様の場合
TYPE 1 :
Built in type
Example of AX20 controller

page 10
( 73 )
“Brake release switch” （option)
The arm drops or moves forward or

backward under the force of its own
DANGER
gravity. Release the brake after taking
steps to hold or support the arm and
any other parts. At first switch back
quickly to see the behavior of arm.
Death or serious injury may result if

you make contact with the robot or are
squeezed between the robot and
another part.
page 11
“Over travel LS release switch”
Over travel LS release

switch
On UM310 board
Over travel LS release

switch
On UM213 board
AX10 controller AX20 controller
page 12
( 74 )
Section#3 Controller
Section #3
Controller
For reference;
Controller maintenance manual
page 13
Function of each parts
CPU board Main control tower that consists of not only CPU but also the
memories where system software and program data is stored
I/O board I/O signals are connected here
Drive unit Circuit to generate the big ampere to

drive the robot and interface circuit
to read position data
Power unit
・・・・・
Refer to the controller maintenance manual for

the detail of parts name and function
page 14
( 75 )
Periodical inspection and parts

replacement (example)
■ Daily Inspection
・Check the functions of pushbutton switches and other operating switches
・Clean up whole of controller (Dirt and dust), and or so
■ Inspection every 3 months
・Check the Clearance and deformation of packing, lock keys
・Check the functions if tech pendant keys, and or so
・Check the unfastened connectors and grounding terminals
・Measure the voltage of primary power supply and P1-M1, and or so
■ Periodical replaced parts

・Battery (on CPU board)・・・every 3 years irrelevant to operating time of robot
・Fan motors to cool down the controller・・・every 4 years irrelevant to operating time of robot
page 15
Replacement of CPU board

Copy (backup) the Backup of data
important data to CF card
CPU board is
replaced
Photo indicates AX20 controller
All data is restored to the

new CPU board from Restoring of data
backup CF card
page 16
( 76 )
Replacement of drive unit

AX10 Controller AX20 Controller
(bigger controller) (smaller controller)
4 big screws to install it
2 big screws to install it
Pay attention to the

compatibility of drive unit
Photo indicates AX20 controller
page 17
Section#4 Data backup and restoring
Section #4
Data backup and restoring
For reference;
“Basic operations”
Chapter 6 File operations
page 18
( 77 )
File manager
To select file and copy.

(*)
To see the directory of memory and CF card.
To delete unnecessary file.
To protect important file.
To verify (compare) two files.

(*)
To initialize CF card.
To make backup of whole program and setting

parameters.
(*) Refer to the manual “Basic Operation” Chapter 6. File Operation for the
specification of guaranteed CF card.
page 19
File manager
Basic menu construction of “File Manager”
Device Program No. File type

selection field input field selection field
File directory
Folder
selection field
Upon
completion of
the necessary
settings, press
f12 <Execute>
page 20
( 78 )
Insert and pullout CF card

When inserting CF card, turn of the controller power
and be careful with its direction.
AX10 Controller CPU board AX20 Controller CPU board

(bigger controller) (smaller controller)
IC mounting surface
CF card
projection
IC mounting surface
CF card
projection When pulling out CF card, push the black button near
the card slot.
page 21
Initialize CF card
User is enough to perform this operation
Select this menu to

initialize CF card
page 22
( 79 )
Making backup
Select this menu to

make backup CF
page 23
Making backup
(1) Select CF card (card 1) as

destination device.
(2) Select destination folder and

press <Enter>.
(3) If necessary, make folder for it

in advance.
(4) Press f12<execute>.
(Notes) - Some time is needed to finish this work. Please wait for a moment.
- New folder such as “NRA2001-2004-12-01-0800” is automatically created.
page 24
( 80 )
Conformation of restored data

Select this menu o

confirm restored data
In order to display the too long characters such

as “NRA2001-2004-12-01-0800”,
＋
Push this way then characters will be shifted
and appear on the screen.
page 25
Restoring of backup data

Operator level must be upgraded to Expert or higher.
Select this menu to

restore data
page 26
( 81 )
Restoring of backup data
(1) Select CF card (card 1) where

backup data is stored as source
device.
(2) Select folder where backup data

is stored and press <Enter>.
(4) Upon completion of restoring

data, power off and on controller.
(Notes) - Some time is needed to finish this work. Please wait for a moment.
page 27
Performing automatic backup

Data backup operation can be executed automatically.
(1) Set the number of backuping data.
(2) Select the verification.
(3) Select the retry execution.
(4) Select when to do.
page 28
( 82 )
Section#5 Manipulator
Section #5
Manipulator
For reference;
Maintenance manual
For each robot
page 29
Carrying
Referring the robot maintenance manual,
carry and install robot by proper method.
(notes) Robot COG should be located in center before carrying the robot.
Check Point
1. After installation, remove the J2
axis fixing bracket.
2. Protect arm where the wire
contacts arm directly. (rubber cover
and or so)
3. Refer the robot maintenance
manual for the proper wire quantity,
length and thickness.
page 30
( 83 )
Carrying
Check Point
1. After installation, remove the
standing bracket and wiring bracket.
2. Protect arm where the wire
contacts arm directly. (rubber cover
and or so)
3. Refer the robot maintenance
manual for the proper wire quantity,
length and thickness.
page 31
Installation
Dimensions for installation

（ST166-02）
page 32
( 84 )
Cautions for installation
Check Point
(1) Flatness of four mounting plates should be within 1.0 mm.
(2) Clearance of four mounting plates should be within 1.0 mm

+/- 0.5 mm.
page 33
Cautions for installation
Check Point
(3) If pre-described two specifications were difficult, use the
following jack bolt to contact four point equally.
！！！CAUTION！！！
If four mounting points do not contact to the floor equally, tool position may
be unstable while playback and lifetime of swing base may be shortened.
Please refer to the “Installation manual” section 2 for detail.
page 34
( 85 )
Periodical inspection (example)
■ Daily Inspection
・Clean up the body (remove dust and oil dirt)
・Check for abnormal heat and sound on motor
・Check for abnormal heat and sound on reduction gear (J1 to J3 axis)
・Visual check for cable damage
・Refasten the fixing major bolts (including tool attaching bolts)
・Check for abnormal heat and sound on reduction gear (J4 to J6 axis)
・Check for any backlash and play
■ Inspection every 1 year

・Check correct functioning of brakes and limit switches
・Refasten the fixing bolts
page 35
Inspection of bolts (example)
By referring the maintenance manual, check and refasten the major bolts. Be sure
to use a torque wrench to fasten the bolts to proper torque.
page 36
( 86 )
Inspection of wires (example)
By referring the maintenance manual, visually check for wiring damage and
loosening of cable clamps.
page 37
Inspection of limit switches (example)
While motor power ON, push

Over travel limit switch with long stick to
be activated, and check motor
limit switch power OFF.
DANGER
Never put fingers closing to

the robot carelessly.
Unexpected robot moving
will cause the serious injury.
page 38
( 87 )
Grease supplement (example)
By referring the maintenance manual, supply the grease. Be sure to follow the
instructions such as grease kind, supplying place, supplying period, supplying
amount of grease, and or so.
page 39
Grease replacement (example)
Discharge the Charge the

Old grease New grease
By referring the maintenance manual, discharge the old grease from the outlet
(DRAIN port) and charge the new grease from the inlet (LUB.PORT) to replace the
whole grease in the gear box.
page 40
( 88 )
Battery replacement (example)
By referring the maintenance manual, replace the battery used for encoder data
backup. If not replaced periodically, robot can not been driven correctly because
correct position is never detected.
page 41
Section#6 Encoder correction
Section #6
Motor/Encoder replacement
and Encoder correction
For reference;
Maintenance manual
For each robot
page 42
( 89 )
From replacement to restoration
(= driving power source) Replacing of

Motor
Motor with Encoder
Restoration of position
・Encoder ID Registration （※）
・Encoder Reset
・Encoder Correction
Encoder
(= Position detecting device)
Correct position can be detected
（※） Only necessary to the robot adapting bass line

communication type encoder (MR20, MC20 and others)
page 43
Restoration of position
（※）
Encoder ID Registration To write encoder ID number (axis
No.) to encoder itself.
Operation to
the encoder
itself To initial reset of encoder itself by
Encoder Reset clearing all data such as multi-
rotating amount.
Zeroing adjustment
Data stored
in controller
Encoder Correction To renew the encoder correction
value.
（※） Only necessary to the robot adapting bass line communication type encoder (MR20, MC20
and others). Encoder ID number (axis No.) is never cleared by encoder reset procedure.
page 44
( 90 )
What is encoder correction?
Recover the position data as it was
Pre-determined pose = Pre-determined data

(position) (position data)
（＊1）
Reference position = 0 degree

（＊2）
Encoder data 80000H

In other words
Zeroing pose (*1) Reference position of J2 axis is 90 degree in case of

Zeroing position floor mounting type robot.
Reference pose
(not home position) (*2) Encoder data of reference postion varies depending
on the robot type. See maintenance manual for detail.
page 45
Move the desired axis to the “reference position”

J2 axis reference position
(where zeroing pin can be
Zeroing pin inserted)
J2 axis zeroing pin
Refer to the robot maintenance manual for detail.
page 46
( 91 )
Put the encoder in order that position data is just 0 degree,

But this is impossible.
Remember the discrepancy amount

and subtract it from original data, in
order that position data becomes just
0 degree (encoder data 80000H)
Encoder AX controller
（＊）
Encoder original
data -Discrepancy 80000H
CPU
amount
Encoder 0 degree
Reference position
correction value
(*) Encoder data of reference position varies depending
page 47
Encoder ID registration
Only necessary to the robot adapting bass line communication type encoder
(MR20, MC20 and others)
Change the operator level

→ [3 Machine Constants] → [4 Encoder Correction]
to Expert
Refer to the robot maintenance manual for detail.
page 48
( 92 )
Encoder reset
to Expert
Encoder
correction menu
is here
Encode reset
menu is here
This
screen
This operation indicated the way for the robot adopting the software reset type encoder. Operation
varies according to the robot type. Pleaser refer to the robot maintenance manual for detail.
page 49
Encoder reset
ON
＋ 1
Move the cursor to the line of
the desired axis
OFF
＋ 2
This operation indicated the way for the robot adopting the software reset type encoder. Operation
varies according to the robot type. Pleaser refer to the robot maintenance manual for detail.
page 50
( 93 )
Encoder correction (zeroing adjustment)

to Expert
Encoder
correction menu
is here
This
screen
Encode reset
menu is here
page 51
Encoder correction (zeroing adjustment)
Move the cursor to the line of Enter

the desired axis
page 52
( 94 )
Conformation of Encoder correction
In order to confirm whether encoder correction is successfully completed

or not, open the monitor screen of “Axis Position” and check the encoder
position data.
(*) Encoder data of reference position varies depending

page 53
Mechanical interference
■ For J6 axis encoder correction,

Unavoidable mechanical J4 and J5 axis must be in the
interference in the wrist reference position.
■ For J5 axis encoder correction,
J6 axis J4 axis must be in the reference
Interference position. Sample of ST-02 series
J5 axis
Interference
J4 axis
Interference relationship varies depending on the robot

type. Refer to the robot maintenance manual for detail.
page 54
( 95 )
AX standard course “Auto Operation”
保守編
Robot School
AX standard course
Auto Operation
Section#1: Useful functions to check and edit

Section#2: File protection
Section#3: Designating how to start the robot
Section#4: Registration of home position
Useful functions to check program
Section #1
Useful functions to check and
edit programs
page 2
( 96 )
Useful functions to check/edit

programs
This can be set in
■ Function playback during check operations
No playback :
None of the functions are executed during the Check GO or BACK
operations.
All :
All the functions are executed Check GO operations. Only the input
wait functions are executed during Check BACK operations.
I only :
Only the input wait functions are executed during Check GO or
BACK operations.
page 3

programs
This can be set in
■ Machine Lock
This function enables the playback of program without
operating the robot.
Since the functions are still executed while the machine is
locked, it is useful for I/O checks.
Never be approached during a playback operation even in

the machine lock status. Operators may suffer death or
serious injury because the robot moves in an unintended
DANGER
way.
page 4
( 97 )

programs
■ I/O simulation mode
This function enables the logical I/O to be set to ON or OFF as
desired without changing the physical I/O. It is convenient for
checking the playback of a robot program when the connection
of the peripheral devices has not been completed, for instance.
Although some of the output signals are designed to be output to the external
source such as the "trouble" and "emergency stop underway", during I/O
simulation no output signals are set to ON even if trouble or emergency stop
CAUTION occurs. This should be borne in mind.
The enabled or disabled status of I/O simulation is stored in the memory even
after the power is turned off.
Before auto operation is initiated, I/O simulation must be returned to the
disabled status without fail. Performing auto operations with I/O simulation still
CAUTION in the enabled status is extremely dangerous since proper control will not be
exercised over the I/O signals.
page 5

programs
■ Program conversion
This function enables to create the new program through some
conversion rule from the already taught program. Original program
itself can be over-written.
page 6
( 98 )

programs
■ Program conversion (sample of “XYZ shift”)
Original program itself can be
over-written by designating
“Source = Destination” program
Designate the Converted steps can

conversion be designated
rule here
Finally press
“Execute”
page 7
File protection
Section #2
File protection
For reference;
“Basic operations”
Chapter 6 File operations
page 8
( 99 )
File protection
File Protect
This function enables to protect the important
files (programs) not to be modified and deleted
by mis-operation.
This sign indicates “now protected”
(Shortcut R269 can also perform this operation)
page 9
Designating how to start the robot
Section #3
Designating how to start the
robot
For reference;
Installation manual
Chapter 7 Preparation for
auto operation
page 10
( 100 )
Selection of start source and program source (internal or external)

Host controller or
Teach Pendant
Operating console, etc
Start input
Program No.
input
Internal External
AX
controller
This can be also set in
page 11
By referring the time chart of “Installation” manual,

input the start signal and program selection signal.
Time chart example of start selection and program selection both EXTERNAL
(I) : 入力（外部装置 → AX） / (O):出力（AX → 外部装置）

page 12
( 101 )
Registration of home position
Section #4
For reference;
Installation manual
Chapter 7 Preparation for
auto operation
page 13
Whether or not robot is in the pre-determined home position

can be checked by output signal. one condition of external start
Home Position
While the robot is in this range,

the home position output signal is set to ON;
when it is outside this range,
it signal is automatically set to OFF.
page 14
( 102 )
→ [9 Range] → [1 Home Position]
Already created program and

step number can be used to
designate position.
Output signal is needed

to be allocated.
(No.1 is allocated from shipped)
Refer to “Instillation” manual and each application manuals for the detail of
another basic I/O signal allocations and setup procedures for each application.
page 15
( 103 )
Frequently used terms Air cylinder
Moving side arm
Moving side
electrode
Numeric
0 (zero) degree position Standard
This refers to 0 (zero) degrees of the registration position of each Settled side
axis. electrode
The robot coordinates are defined using this position of each axis Settled side arm Welding
as a reference. transformer
Air gun (X gun)
(The gun shape differs from one manufacturer to another.)
See "Servo gun."
Posture at 0 (zero) degree Air-cut Standard

position set at the factory This refers to an operation where the robot moves through the air
prior to shipment
(floor-installed robot) only. Since there is normally no need for exact positioning, the cycle
time is reduced by specifying a rough accuracy.
Alarm Standard
This is a relatively minor form of trouble, and it is indicated by a
code starting with "A." When an alarm has been detected during
A playback, the robot stops operating but the motor power is not
( 104 )
turned off.
See “Error” and “Information.”
Accuracy Standard
Although the robot plays back the taught position precisely,
Application Standard
accurate positioning is at times not required in some locations.
With what degree of accuracy the robot is to operate is Robots can be used for multi-purpose uses. An "application" refers
specified by a number which is referred to as the accuracy (or to the way in which a robot is used, and examples of applications
accuracy level). The higher the number used, the coarser the include spot welding, arc welding, sealing, painting/coating and
positioning accuracy. materials handling. The functions for supporting each of the
See “Air cut.” applications are provided in advance so that the necessary
functions can be chosen from the selection provided and used.
Air Gun Spot weld
This refers to the kind of gun which is driven pneumatically. ASCII file Standard
This is a general term used to refer to the files in which characters
are stored in the text format. If a software program available on the
market called a text editor is available, the contents of these files
can be read easily.
"ASCII" is a standard character code consisting of alphanumerics,
symbols and line feeds established by the American National
Standards Institute (ANSI).
Automatic tool center of gravity and weight setting Standard

This function automatically calculates the tool "center of gravity and
weight".
The exact tool center of gravity and weight are required in order to
maintain the service life of the robot and exercise correct C
acceleration/deceleration control.
Automatic tool length setting Standard Call Standard

This function automatically calculates the tool "length". When the same movements or commands are to be repeatedly
The exact tool length is required in order for correct linear played back, this function enables the parts concerned (multiple
interpolation to be performed. number of steps or a program) to be called as subroutines.
Operation is returned to the step following the step called originally
Auxiliary axis (auxiliary mechanism) Standard using the return command when a step is called or using the end
All types of mechanisms (such as positioners, sliders and servo command when a program is called.
guns) with the exception of manipulators are generally referred to Program 1
as auxiliary axes, auxiliary mechanisms or external axes. Program 30
See “Manipulator.”
Program call 30
Axis Standard
The robot is controlled by a multiple number of motors. The parts
controlled by these motors are called axes. A robot which is End
controlled by six motors is called a 6-axis robot.
End
Axis constant Standard See “End” and “Return.”
( 105 )
→ 0 (zero) degree position
Cancel WI Spot weld
This refers to the operation which forcibly releases the status in
which the robot is waiting for the WI signal.
B It is useful, for instance, during teaching work where the peripheral
devices have not yet been set up.
Basic input/output signal Standard ＋
These are those signals among the status signals which are for
standard uses regardless of the application at hand. Some of the
basic input/output signals were already assigned at the factory prior CHECK GO/CHECK BACK Standard
to shipment. This function slowly runs the programs which have been created on
See “Status signal.” a step by step basis, and checks the teach positions. It operates in
two directions, step forward (CHECK GO) and step backward
Bending compensation Spot weld (CHECK BACK).
This is a technical term used with servo guns.
The gun arm bends as the welding force is increased. It may Circular interpolation Standard
bend not only in the welding force direction (Z direction) but also This is one of the interpolation modes and, in this system, the robot
on the plane (XY direction) perpendicular to the welding force is operated in such a way that the tool tip draws an arc. The
direction depending on the shape of the gun arm. interpolation mode is specified in a move command.
This function compensates for bending to achieve the proper See “Indirect interpolation” and “Line interpolation.”
welding position by measuring these characteristics in advance.
See “Gun search.”
Client Standard
This refers to the role played in a network by the computer at the Continue Standard
end where the resources and functions provided by the server are This refers to a position control system that does not check the
utilized. arrival of the machine at the recorded points.
See “Server.” The extent of the pass is specified by the accuracy level.
The machine takes a short-cut between the recorded points in
Command position Standard accordance with the command position as defined by the accuracy
This refers to the target position which is specified for the robot by setting.
See “In position.”
the software.
See “Current position.”
Continuous mode Standard
Constant Standard This is one of the operation modes.
This is a general term used to refer to the groups of parameters Programs are executed repeatedly when the [Start button] is
required to perform the robot movements and operations pressed.
The constants are divided into a multiple number of files each for a
particular application, and stored in the memory. In the teach mode,
the editing screen can be displayed by pressing the f key shown
See “Cycle mode” and “Step mode.”
below.
Coordinate System Standard

This is an decalt coordinate system in which, using the front of the
robot as the reference, the X coordinate represents the
backward/forward direction, the Y coordinate the left/right direction
( 106 )
Consumption compensation Spot weld
and the Z coordinate the up/down direction. More specifically, these
This is a technical term used with servo guns.
are called the robot coordinates or machine coordinates.
As welding is performed over and over again, the electrodes
gradually start to wear down, and their length shortens. An Ｚ＋
equalizing function is not generally provided with servo guns. For
this reason, when the electrodes start to wear down, the settled side
electrode is no longer pressed against the work, resulting in a Ｙ－Ｘ－
deficient welding force on the settled side and extra stress on the
work, resulting also in a deterioration of the simultaneous arrival of
the top and bottom electrodes and an increase in the cycle time.
Ｙ＋
In order to maintain the correct welding position, the tip Ｘ＋
consumption compensation function serves to shift the respective Ｚ－
target points on the settled side and moving side at the welding
points by an amount equivalent to the wear.
These coordinates serve as a reference for calculating the linear
Pressurizing interpolation, shift and other operations.
See “Tool coordinates.”
Coordinate transform Standard

This function compensates for the positions in the programs which
New tip Worn tip Worn tip have already been conducted in cases where the relative positions
(Without compensation) (With compensation)
of the robot and work piece have shifted, rotated or tilted or
undergone any other changes in such instances as when programs
created by off-line teaching have been downloaded to the actual Directory Standard
robot. → Folder
It is one of the program conversion functions.
Current position Standard

This is the actual position of the robot which is read from the E
encoder.
See “Command position.”
Emergency stop Standard
Cycle mode Standard "Emergency stop" refers to stopping down the robot (or system) in
This is one of the operation modes. an emergency. Generally, a multiple number of buttons for initiating
When the [Start button] is pressed once, the program is executed emergency stop are provided in the system, and emergency stop
once from start to end. When the last step is reached, the robot can be applied to the system immediately by pressing one of these
stops. buttons.
Encoder Standard
This device detects the robot position, and one such device is
See “Continuous mode”, “Step mode.”
incorporated inside each axis motor.
Cycle time Standard

Encoder correction Standard
This is the time needed for the robot to execute one job.
After adjustment is made in such a way that the encoder value
is set to exactly 80000H (HEX) when the robot is in the posture
( 107 )
where the reference pin is inserted, the positions of the robot
axes are controlled by using this as a reference. However, since
D the encoder value cannot be set exactly to 80000H in the
posture where the reference pin is inserted (posture in which
the motors are mounted), the compensation value contained in
Deadman switch Standard the raw encoder value is factored in to provide compensation so
This is a safety device for ensuring that the robot will not operate that the encoder value is set to 80000H by all appearances.
unexpectedly due to incorrect operations, etc. The deadman switch This compensation value is known as the encoder
is located on the rear panel of the teach pendant. By design, it is not compensation value.
possible to perform manual robot operations, CHECK GO/BACK,
The encoder data
etc. unless the deadman switch is held down. values when the robot
is in the basic posture
vary depending on the
model.
Basic posture (posture in
which the values after
encoder compensation are
set to 80000H for all the
axes)
Deadman Switch
The posture in which the reference pin is inserted for all the axes is
called the basic posture.
Depalletize Materials handling
The encoder compensation value changes each time a motor is
→ Palletize
changed or the encoder is reset. See “Robot language.”
Encoder reset Standard

This refers to resetting the stored information of the encoder
internal circuitry. F
For a new encoder, it must be implemented without fail. Depending
on the encoder model used, it may be implemented by hard wiring
or using software. Fault Standard
When fault has occurred in the robot, the fault monitor starts,
and the details of the fault (name of its category, date/time of its
END Standard
occurrence, description and remedial action) are displayed on
This is the command which is recorded at the end of a program.
the teach pendant. Depending on how serious it is, trouble is
It uses a function command (END: FN92).
classified into one of three types: error, alarm or information.
See “Error,” “Alarm” and “Information.”
End effector Standard
→ Tool File Manager Standard
The programs and groups of parameters are managed in the
End Relay Standard controller as files.
→ Program ended The term "file operations" refers to such actions as copying and
deleting files. They are initiated from the service menu.
Equalizing Spot weld
This is the mechanism through which the impact that results when Folder Standard
the gun makes contact with the work piece is absorbed. In the case Folders are like drawers that are used to contain multiple numbers
of an air gun, the gun itself normally comes with a mechanical of files.
( 108 )
equalizing device. In the case of a servo gun, equalizing is achieved By creating folders under folders, it is possible to control files
by controlling the position of the robot. hierarchically. The folder (or directory) at the very top of the
hierarchy is called the root directory.
Error Standard Folder structure of AX controller
This is the most serious of the three forms of trouble, and it is Memory
indicated by a code starting with "E." When it is detected during
playback the robot's operation is immediately suspended, and INI
the motor power is turned off.
WORK
See “Alarm” and “Information.”
UNIT
Ethernet Standard
LOG
This bus-type network LAN (local area network) access method
was jointly developed by Xerox, Intel and Digital Equipment PROGRAM
Corporation of the United States, and it has been defined by the
IEEE as the 802.3 standard. It is widely used in manufacturing
plants, offices and homes. Formatting (initializing) Standard
In this process, all the data written in the memory or other storage
Execution type Standard media is deleted so that fresh data can be stored.
The programs taught using the [O.WRITE/REC] key on the teach
pendant are recorded using an execution format that enables them Full open/Half open Spot weld
to be played back in their original form. These are stroke statuses for an air gun with a 2-step stroke. In the
full open status, the gun is open widely. The stroke status is Gun Search Spot weld
established by the output signals also named full open or half open. This is a technical term used with servo guns.
In order for the tip consumption to be compensated, this amount
Function Standard has to be detected. A predetermined operation pattern is played
→ Function Command back for this, and the wear amount is calculated on the basis of the
position of the gun at this time. This action is known as the “gun
search,” and three different detection methods are provided. (Gun
Function Command Standard
This is a high-level command which cannot be expressed by a Search 1, 2, 3)
See “Consumption compensation.”
move command in a step. Many different kinds of function
commands such as I/O commands and welding commands are
provided.
See "Step" and "Move command."
H
Hand Materials handling
G This device is attached to the end of the wrist to enable the robot to
grip the work piece. It is also known as a gripper. Most hands are
usually driven by air, but servo-controlled hands are treated as
General-purpose signals Standard
These signals can be set to ON or OFF without restriction in the auxiliary axes (auxiliary mechanisms).
programs.
The job of deciding what signals as identified by their numbers are Home position Standard
to serve as the general-purpose signals and what signals as When a multiple number of robots are to be started up together from
the host controller unless start is instructed after it has been verified
( 109 )
identified by their numbers are to serve as the status signals is
called "signal assignment." that the robots are at their prescribed positions (home positions),
they may, in a worst case scenario, interfere with one another. To
solve this problem, whether the robots are at their prescribed
positions can be verified by means of an output signal by registering
the home positions of the robots.
Home
position
range
While the robot is in this range, the

home position output signal is set
to ON; when it is outside this range,
it is automatically set to OFF.
Output signals are recorded using such function commands as
SETM (FN105) while the input signal wait commands are recorded
using such function commands as WAITI (FN525). Hot edit Standard
See “Status signal.” The job of program conversion which is performed while the robot is
conducting a playback operation is called hot editing as distinct
Gun lock Spot weld from program editing which is performed at other times.
→ Mechanism locked It enables changes to be made even in the program which is now
the target of the playback operation.
"I." The robot does not stop operating when information is detected
during playback.
See “Error” and “Alarm.”
I
Input/output signal assignment Standard
→ Status signal
I release Standard
This refers to the operation which forcibly releases the status in Install Standard
which the robot is waiting for the I signal. "Installation" refers to copying the software program into the
This operation comes in handy at times such as during teaching memory and setting it up so that it can be used. An alternative term
work where the peripheral devices have not yet been set up. is "setup."
＋
Interlock Standard
The placing of the robot in the wait status until the jigs, etc are set to
a status in which it is permissible for the robot to start operating is
I signal Standard
This is the general term used to refer to the input signals which are called "interlock wait." An I signal is used for this.
supplied to the robot. (The "I" stands for "input.")
There are 2,048 logical input signals which are assigned either as Interlock alarm Standard
status signals or general-purpose signals for use. When interlock wait continues for an abnormally long period of time,
See “Interlock,” “O signal,” “General-purpose signals” and “Status signal.” this can be conveyed as an alarm to an external source.
I/O simulation Standard Internal memory Standard

This function enables the logical I/O to be set to ON or OFF as This is located on the CPU circuit board inside the controller, and it
( 110 )
desired without changing the physical I/O. It is convenient for is used to store the robot's constants and programs.
checking the playback of a robot program when the connection
of the peripheral devices has not been completed, for instance. Interpolation Standard
This is a format for moving between recorded points.
In Position Standard This is recorded in the move commands.
This refers to a position control system which accurately checks the See “Indirect interpolation,” “Linear interpolation” and “cirucular
arrival of the machine at the recorded points. interpolation.”
The roughness of the positioning is specified by the accuracy level.
The machine reaches the recorded point representing the
command position without fail regardless of the accuracy setting.
See “Continue.” J
Indirect interpolation Standard
This is a system which causes the robot to be operated on the basis Jump Standard
of its axes. It is sometimes referred to as "interpolation OFF." The This transfers operation to any step or program. Unlike the call or
interpolation mode is specified in a move command. return command, it does not return to the original operation.
See “Circular interpolation” and “Linear interpolation.”
Information Standard
This is the least serious of the three forms of trouble or just a
message to be passed on, and it is indicated by a code starting with
Program 1 multi-mechanism is to be used with manual operation, it is first
necessary to declare which mechanism is to be operated.
Program 30
Mechanism2 Mechanism1
Program jump 30
End Manipul Program

Servo-gun ator
End
See “Call” and “Return.”

Unit
Up to nine mechanisms can be controlled per unit.

L See “Unit.”
Line Interpolation Standard Mechanism lock Standard

This is one of the interpolation modes in which the robot is operated In the case of mechanisms with the exception of manipulators, this
in such a way that the tool tip draws a straight line. The interpolation function can be set to ensure that none of the axes will operate
mode is specified in a move command. even when axis operations, manual open/close operations or
See “Indirect interpolation” and “circular interpolation.” manual pressurizing operations are performed. Since errors in axes
are not checked either, it enables the robot to be moved even if the
servo gun is not ready or cannot be operated.
( 111 )
M Mirror conversion Standard
This converts postures just as if they were reflected in a mirror.
When teaching two robots installed symmetrically at the two sides
Machine lock Standard
of an automobile body for welding work, for instance, once the
This runs the programs without operating the robot. Since the program for one robot has been taught, the program for the other
functions are still executed while the machine is locked, it is useful robot is created very easily.
for I/O checks. It is one of the program conversion functions.
Manipulator Standard Moment of inertia Standard

This is the name of a mechanism that enables linear interpolation
This corresponds to the "weight in the rotating movement of an
operations to be performed by the tool tip with the greater degree of
object." In the figure below, a high rotational force is required
freedom which is provided by 5 or 6 axes. The word "robot"
generally refers to a manipulator. because (b) has a higher moment of inertia than (a).
See “Auxiliary axis (auxiliary mechanism)”
Mechanism Standard
A mechanism refers to a unit such as a manipulator, positioner,
servo gun or servo travel device that configures a control group
and cannot be broken down any further.
A "multi-mechanism" refers to a configuration where, for
instance, a servo gun has been added to a manipulator. If a
Rotary Same Rotary
axis Rotational speed axis Move Command Standard
Same
Rotational weight
In a step, this command moves the robot arm. A function command
is also present in a step.
Load Load See “Step” and “Function Command (Function).”
(a) (b) Moving side electrode Spot weld

When a servo gun is used, this refers to the one of the two tips
Moment of Moment of which is operated when the gun axis is driven. The tip on the other
inertia is low inertia is high side is the settled side electrode.
See “Servo gun” and “Settled side electrode.”
Monitors Standard Multi-mechanism Standard

This function displays the current statuses in real time. → Mechanism
A number of monitors such as ones for the programs, axis positions
and input/output signals are provided.
Up to four monitors can be displayed at the same time. Multi-unit Standard
→ Unit
Motor Power Standard
This refers to the status in which the power is supplied to the robot.
Motor power ON means that power is supplied or, in other words,
that the motor power ON status is established. Motor power OFF
N
means that the power has been turned off or, in other words, that
( 112 )
the motor power OFF status is established. Network Standard
This refers to the communications network that interconnects a
MotorsON/START sel.source Standard number of computers.
This specifies the input source of motor power ON and the start Depending on its scale and type, it may be referred to in various
command. ways by such terms as the Internet or LAN.
Controller: Teach pendant (pushbutton and key operations)
External: Input signals supplied from an external source
O
O signal Standard
This is the general term used to refer to the output signals which are
supplied from the robot to an external destination (The "O" stands
for "output.") There are 2,048 logical output signals which are
assigned either as status signals or general-purpose signals for
use.
See “I signal,” “General-purpose signal” and “Status signal.”
Off-line Teaching Standard

This is a form of teaching that, rather than using an actual robot,
See “Program selection.” uses instead the virtual robot that is displayed on the computer
screen in an office or other such environment. Rather than a gun which is held by the robot as a tool, this is a spot
welding device which is installed on the floor for use.
Operator qualifications Standard
There are four qualification classes: Beginner, User、Expert
and Specialist. The higher the qualifications class, the greater the
number of menus which are displayed on the constant setting
screens, etc., enabling the important parameters that constitute the
very basis of control to be edited.
The class is set to Beginner or User when the robot's power is
turned on.
Original Position Return Standard

Playback mode Standard
This function stores the posture adopted when the motor power was
1. This refers to the mode of playback operation, and it is
turned off, and it automatically moves the robot toward resuming
classified into three main modes (and 5 modes if step feed is
this posture when the motor power is turned back on. It enables
selected).
exactly the same path as the usual one to be traced with restart.
See “Continuous mode,” “Cycle mode” and “Step mode”
Over travel limit switch Standard 2. The programs created are run automatically in this mode.
This limit switch is mounted on the robot arm to detect robot arm See “Teach mode.”
overrun and turn off the motor power immediately.
Normally, these switches are mounted on the three spindle axes (J1,
Pose Standard
J2 and J3 axes).
This refers to the posture of the robot.
( 113 )
In robot language, there is a method of describing move commands
by teaching "pose files" in which poses alone have been recorded
and referencing these files.
P
Positioner Standard
Palletize Materials handling This consists of a rotary table and/or other device, and it is used to
This refers to the job of placing the work piece in its proper change the posture of the work to facilitate the work done by the
sequence. robot. It is treated as an auxiliary axis (auxiliary mechanism) when it
The "palletizing function" enables all the operations for all the work is servo-controlled.
piece to be taught easily only by teaching the loading (or lowering)
operation for one work piece and specifying the number of work Power save Standard
pieces, their loading (or lowering) method, distance and other data. When a status with no changes in position is sustained in the
In some cases, the unloading operation which is the reverse of playback mode for a settled period of time, the motor power is
loading is referred to as "de-palletizing." automatically turned off to conserve the power consumed.
Pause Standard Preload Standard

This refers to a state in which playback is temporarily suspended. In the case of the preload type of encoder, the resolution
Unlike "stop," the playback operation is resumed straight away temporarily deteriorates after the power of the controller is turned
simply by releasing the pause-input signal. on, causing a shift in the data equivalent up to ±32 pulses. The
preload operation is performed to restore the proper resolution.
Pedestal Gun Spot weld The preload operation is executed automatically when the motor
power is first turned on after the power of the controller has been changed unintentionally or by mistake.
turned on. No special operations need be performed by the user. There are three kinds of protection: complete protection, partial
During the preload operation, the tool tip may move several protection and playback protection.
millimeters (although this depends on the model and posture). For
this reason, ensure that nothing around the robot will interfere with
the tool tip.
R
Program Standard
This is a file in which the robot movements, welding work and other
execution procedures are recorded. R code Standard
It consists of a multiple number of steps. → Short-cuts
Up to ten thousand programs numbered from 0 to 9999 can be
stored in the memory. Recording status Standard
See “Step.” This refers to the step data which is recorded when the
[O.WRITE/REC] button is pressed during teaching. It is displayed at
Program ended Standard all times at the top of the program monitor screen.
When the function command (END: FN92) is played back, a signal
is output to an external device to advise the operator that the work Restore controller status Standard
has been completed. This signal is known as the program end When the power fails, this function stores the current statuses in the
signal. It is also referred to as the end relay, and any time can be set memory and enables operation to be resumed after the power is
as its ON time. restored.
Program selection Standard Return Standard
( 114 )
This specifies the source from which the program numbers are This command is used in tandem with the step call command.
input. When it is played back, operation returns to the next step called.
Controller: Teach pendant (pushbutton and key operations) See “Call.”
External: Input signals supplied from an external source
Robot language Standard
Programs are created using text in the language based on SLIM.
This language makes it possible to record high-level commands
such as the loop command which cannot be recorded using the
regular recording operations performed from the teach pendant.
Programs in the robot language format are first compiled and
converted into an execution format before they are played back.
Program
Robot
Execution
language Compile Playback
format
format
(ASCII file) (Binary file)

See “Execution format.”
See “Start select.”
Protect Standard
This refers to protecting the data in files so that it will not be
This is a general term used to refer to the monitor displays and
S other useful functions and to the groups of setting menus which
must be changed while the robot is operating due to the intrinsic
nature of the parameters.
Safety (protective) fence, safety plug Standard In the teach or playback mode, the editing screen is opened by
This is an enclosure (a metal fence) designed to prevent personnel pressing the f key shown below.
from gaining easy access within the operating ranges of the robot.
The safety plug is a device which is installed on the access door in
the safety fence. When the door is opened while the robot is
operating, the robot's power is forcibly turned off, and the robot is
placed in the emergency stop status. Servo Gun Spot weld
This refers to the kind of gun which is powered by a servo drive.
Safety protection fence
It utilizes the servo control of the robot controller. With the robot
Manipulator controller, the gun is treated as a mechanism as is the case with
a positioner or travel device, and highly accurate position
control is exercised in coordination with the manipulator.
Limit switch for turning off the servo power
when the door in the safety protection Motor
fence is opened
Ball screw
Robot controller
Welding power supply
Moving side arm
Moving side
electrode
Screen Editor Standard
The positions, speeds, interpolation and other data of the programs
already created as well as the parameters of the function
commands, etc., can be edited on the teach pendant screen exactly Settled side
( 115 )
electrode
as desired. Welding
Settled side arm
The display is switched to the screen-editing screen simply by transformer
pressing the [EDIT] key. Servo gun (X gun)
Edit
(The gun shape differs from one manufacturer to another.)
See “Air gun.”
Servo lock Standard

This refers to the status in which the motor power is ON and the
robot stands still because the command position and current
position have coincided.
See “Current position” and “Command position.”
Server Standard
This refers to the role played in a network by the computer at the
end where the resources and functions are provided. One example Servo tuning Standard
of a server is a printer. This refers to the job of adjusting the servo parameters, etc. so that
See “Client.” the servo-driven machine will move as it is designed to move.
Service Standard Settled input/output signal Standard

Term in general use These input/output signals are used for the sequences inside the
This refers to the resources and functions provided by the server in controller.
a network to the client. Unlike the general-purpose input/output signals, they cannot be
AX controller assigned freely.
See “Basic input/output signal.” Software PLC Standard
The "software PLC" is the software of the robot controller that
Settled side electrode (or tip) Spot weld incorporates the PLC (programmable logic controller) which was
This refers to the one of the two tips which is not driven by the gun used to play the role of intermediary with the conventional robot
axis of a servo gun. The tip on the other side is the moving side controller and peripheral devices, and it can be programmed
electrode. using the teach pendant. In this way, the need to provide a special
See “Servo gun” and “Moving side electrode” PLC externally is obviated, thereby helping to reduce costs.
Shift Material handling

This refers to the operation where, using the recorded position as
the reference, the tool tip is moved in parallel (or in parallel and
rotated).
With the materials handling application, the deviation in the work
piece position is detected using a visual sensor or other such
means, and the robot's tool tip is shifted by an amount equivalent to
this deviation.
Short-cuts Standard Software PLC ladder editor

This refers to performing a series of operations by a single action. See “Logical I/O”, “Physical I/O”,“I signal” and “O signal”
The f keys and R codes are used for this purpose.
Example: R17 ... Memory directory shortcut Speed Standard
This is recorded in the move commands.
Signal attributes Standard The speed can be specified in one of the following four ways.
( 116 )
These signals are transmitted to and from the AX controller and the Speed Units Explanation
external equipment. specification
See “I signal” and “O signal.” Tool tip speed mm/sec The speed is specified as the linear speed of the
tool tip.
Slider Standard This can also be specified in increments of
The robot is placed on this device so that the robot can be moved [cm/min].
and used in a larger work area. It is called a travel device. It is Movement time sec The speed is specified as the time required to
treated as an auxiliary axis (auxiliary mechanism) when it is move between the recorded points.
servo-controlled.
Capacity ratio % The speed is specified as a percentage of the
maximum capacity.
SLIM language Standard
Posture change deg/sec The speed is specified as the speed at which the
→ Robot language
speed tool angle changes.
Slow safety speed Standard

This refers to the tool tip speed which does not exceed 250 Speed override Standard
mm/sec. Without changing the contents of the program, this short-cut is used
All operations in the teach mode are performed at this speed. In the to specify the percentage of the recorded speed at which the
playback mode, the robot is moved at this speed for the first step in program is to be played back. Any percentage from 1% to 150%
cases where the robot is started after steps have been selected can be set.
using the teach pendant so as to ensure safety. Speed override is used to check the operation of a program, and it
is increased in small increments starting from a slow speed.
If 100% is selected, the playback speed is as per the recorded
speed.
Status signal Standard
Spot welding controller Spot weld These are signals which have predetermined applications such as
This is the controller that controls the spot welding directly. A the "starting" output signal and "external start" input signal. The
controller made by a specialist manufacturer must be provided in process of assigning some signals to serve as general-purpose
addition to the robot controller. It is also known as a welder, welder signals and other signals to serve as status signals is called
timer or timer contactor. "input/output signal assignment."
Up to six units can be connected.
See “General-purpose signal.”
Step Standard
This is the unit in which the commands recorded in the programs
Spot welding tool Spot weld come, and it can be classified into move commands and function
( 117 )
This is a tool which comes into contact with the work piece and commands. Running numbers are given to the steps with the first
supplies the power. It is also known simply as a "gun." one coming at the beginning of the program.
See “Air gun” and “Servo gun.” See “Move command” and “Function command.”
Start Standard Step data Standard

This refers to playing back a program that has been created. This refers to the group of data recorded in each step.
For a move command, the data consists of the position, speed, type
Stationary tool interpolation Standard of interpolation, tool number and accuracy number. For a function
This refers to interpolation (linear and circular interpolation) command, the data consists of the function command number and
operations that use the tip of the tool anchored to the floor as the the group of parameters attached to this command.
reference.
Step feed Standard
Stationary tool tip position
Stationary tool nozzle When “Cycle” or “Continue” has been selected as the operation
(Defined by user mode, one of two ways to advance through the steps can be
P１
coordinates) selected.
Continue: Operation advances through the steps continuously.
(This setting is the one which is normally selected.)
P0 Single: Operation moves through each step at a time. The step can
be advanced to the next one by pressing [ENABLE] and F8 <Step
by Step>. This is useful for checking programs.
Robot hand
Step mode Standard
This is one of the operation modes. Tip Dressing Spot weld
In this mode, one step of the program is executed while the This refers to the job of grinding and reshaping the electrodes when
[Start button] is held down. Execution is suspended when the their tip consumption has become noticeable before the welding
[Start button] is released. To advance to the next step, press the quality deteriorates.
[Start button] again.
Tool Standard
This is a general term used to refer to the spot welding guns, arc
See “Cycle mode” and “Continuous mode.”
welding torches, grippers and other such devices which are
mounted at the end of the robot's arm. They are also referred as
end effectors. The tool suited to the type of robot work to be
Stop Standard performed is mounted.
"Stop" refers to stopping the robot in the start status (playback). Up to 32 tools can be registered.
Strobe Standard Tool change Standard

This signal determines the read timing so that read errors will be This refers to removing one set of tools from the robot's hand and
avoided when numerical values are read by a multiple number of replacing them with another set.
signal lines. The robot comes with a tool changer to enable tools to be removed
It is required for the external program selection. and installed.
Tool constants Standard

This is a general term used to refer to the group of constants which
T are related to the tools such as length, angle, weight, center of
( 118 )
gravity and moment of inertia.
TCP Standard
Tool Control Point Tool coordinates Standard
This refers to the tool tip. This is the coordinate system that uses the tool as its reference. In
this system, the coordinates must be set in accordance with the
TCP/IP Standard
shape and direction of the tool which has actually been installed. It
Transmission Control Protocol/Internet Protocol is defined by the length from the tool-mounting surface (flange
This is the standard communications protocol used by the Internet. surface) to the tool tip and by the tool angle.
Tool coordinate setting
example
Teach mode Standard
Ｚ＋
Tool
This is the mode which is mainly used to create the programs, etc. mounting
See “Playback mode.” Ｙ－ surface
Ｘ－ (flange
Coordinate f )
Teach pendant Standard system
This is used to perform the manual robot operations, teaching, etc. determined by
"tool length" Ｙ＋
and "tool Ｘ＋
angle"
Teaching Standard Ｚ－
This refers to teaching the robot how to move and how to do
welding work. What is taught is successively recorded in the See “Coordinates.”
programs.
Transform existing program Standard
This function changes all the recorded speed values together or it Variables Standard
creates left/right symmetrical programs by mirror conversion without Variables can be used exactly as desired in programs, etc., for
having to duplicate the commands. A number of different kinds of arithmetic calculations, etc. There are four kinds of variables:
conversion are provided. integer variables, real number variables, character string variables
This function is accessed from the service function menu. and timer variables. For instance, the count condition jump
See “Hot edit.” command uses integer variables.
The variables are also classified as global variables common to all
units, and local variables used in each respective unit.
Integer Global (V% variable)
U variables Local (L% variable)
Real number Global (V! variable)
Unit Standard variables Local (L! variable)
This refers to the increments in which a program is created. Variables
Character Global (V$ variable)
On some occasions, only one mechanism configures the unit; on
string variables Local (L$ variable)
other occasions, multiple mechanisms (multi-mechanism) are
involved. Timer For measuring command
Normally, only one unit is used for the entire controller so there is no variables For direct specification
need to be aware of it. With the multi-unit specifications (or Nachi's
conventional "multi-robots"), a multiple number of units can be
operated at the same time. Verify Standard
Up to nine units can be controlled. This refers to checking the contents of one file against the contents
of another file.
( 119 )
Mechanism2 Mechanism1
Manipul Program
W
Servo-gun ator
Weld sequences Spot weld

This is a general term used to refer to the data items that define the
Unit
I/O sequences between the robot controller and welder (timer
contactor).
See “Mechanism.” The conditions are edited using the teach pendant.
A total of 64 items of the weld sequence data can be registered per
User coordinate Standard welder.
These are not the coordinates inherent to the robot but the
coordinate system which is set to match the installation status of the Welding conditions Spot weld
peripheral devices. Teaching is facilitated when these coordinates This is a general term used to refer to the data such as the welding
are also set. current and welding force that determine the welding conditions.
The conditions are edited using the teach pendant.
A total of 255 items of the welding conditions data can be registered
per welder.
V
WI signal Spot weld
This is the welding finish (weld interlock) signal.
It is input to the robot controller from the timer contactor as proof
that spot welding has been completed normally.
X
XYZ shift Materials handling
→ Shift
( 120 )
4th edition
Robot School (Safety)
Installation of safety fence (sample)
Safety fence (robot surrounding fence) must be installed to protect operators.

Otherwise robot may hit the operator and serious injuring may happen.
Safety fence Brushing

Brushing pass
pass and
and
climb
climb over is
over is never
never
Signboard
Signboard such
such as
as
manipu permitted.
permitted. Removable
Removable
Teaching
Teaching -- keep
keep out
out
lator type
type is
is NG
NG also.
also.
Playbacking
Playbacking -- keep
keep out
out
Equip safety
Equip safety plug
plug on
on the
the
Welding controller door.
door.
AX controller Limit switch
page 1
Point
(1) Make the safety fence preventing from brushing pass or climbing over
by operator. Removable type fence is NG also.
(2) Install the door to get in the safety fence and equip the safety plug. By
pulling out this plug can only permit person to open the door.
Sequence
シーケンス基板 board
Safety
安全プラグ plug
TBEX1
5
SFP1
6 Safety plug connection to AX
7 controller (redundant circuit)
SFP2
8
page 2
1
For safe operation, safety related signals such as emergency

stop signal and safety plug signal are absolutely necessary to
be connected to robot controller.
Terminal block
I/O sequence board TBEX2
UM301
（in PCB rack） Terminal block
TBEX1
This page explains about AX20 controller. (As for another controllers, please refer to the adequate maintenance manual.)
page 3
I/O sequence board

UM301
page 4
2
CAUTION
AX controller equips redundant circuit in safety logic.
Independent two input signals must act completely same.
Ext. Emergency Stop Ext. Emergency Stop
page 5
CAUTION
AX controller equips redundant circuit in safety logic.
Independent two input signals must act completely same.
Safety plug Safety plug
page 6
3
For stand alone robot
External emergency stop and teach enable switch are used when
necessary.
If robot is used in stand alone style, these signals must be
connected as right figure.
Teach enable switch input 2

Teach enable switch input 1
Safety plug input 2

Safety plug input 1
Ext. emergency stop input 2
Ext. emergency stop input 1
page 7

AXstandardRev7+SafetyRev4 Combined

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AXstandardRev7+SafetyRev4 Combined

Uploaded by

Copyright:

Available Formats

7th edition

Section#1: Industrial Robot

Industrial robot history

Diffusion of industrial robot

NACHI ROBOT history

What is “Industrial robot”

Definition of “Industrial robot”

Machine with manipulating utility that is automatically controlled,

Characteristics of articulated robot

How to read the type (1)

MC series MR series SC series ST series

How to read the type (2)

Bigger size for heavier payload

How to read the type (3)

How to read the type (4)

SH166-03：Inline wrist type SH166-04：Offset wrist type

Motor type and wrist specification differs depending on this

How to read the type (5)

How to read basic specification (1)

How to read basic specification (2)

最大可搬 手首部 166 kg 200 kg

Operating area written in

Name of parts (SH series)

Axis name and its movement

Wrist axes J2 : Forward and backward

Limitation of operating range

2. Electrical limit switch

Limitation of tool payload

Tool payload is limited by 3 specifications those are weight, torque and

Please comply these specifications when designing the tool.

Permitted torque map of tool Permitted inertia map of tool

Rated payload weight

Tool payload weight must not be over the rated weight.

Payload torque map

Payload inertia map

Teach and Playback

“Teach” (teaching) is programming (recording) the task

“Playback” (playing) is executing the recorded

Program sample Program playback

(A) (B) (C) (D) (E)

(A) Motor power ON push button

PB and SW of Operating Panel

Motor power This is to turn the motor power ON.

Stop push This is to stop the program.

“TP enabling switch” for safety operation

“Emergency stop button”

“3 position Deadman switch” called “enabling device”

Select menu by [cursor] key

2. After self check completed,

How to select Teach/Playback mode

Manual operation No manual operation

Basic screen (Teach mode)

Operations and setting items are limited by the operator’s

Beginner : Elementary level (only startup the robot in factory)

3. Press “Motor ON” Servo power is ON, now ready

Axis manual operation

Select coordinate system

Press [coordinate] key Press [Teach speed] key to

Beginner operators had better do practice to confirm the

Joint manual operation (1)

Press [X+/-] to rotate J1 axis (swing base).

Press [Y+/-] to rotate J2 axis (2nd arm).

Press [Z+/-] to rotate J3 axis (1st arm).

最大可搬手首部 166 kg 200 kg