Denso Robot Training PDF

DENSO ROBOT TRAINING MANUAL
TRAINING
MANUAL
ROBOT
M. LEE 24/03/07 1
Contents
PAGE PAGE
Introduction 3 Inputs and Outputs 29
 Robot  Monitoring
 Controller  Simulating
 Teach Pendant  IO Macro names
Moving the robot 10 Variables 31

 Joint mode  Variable Macro
 XY Mode names
 Tool mode  Types of variables
 Touchscreen 33
Motion space
Teach pendant screens 16  Software limits
 Arm screen  Interference areas
 Program screen 36
 IO screen Calibration
 Error log  Rang data
 Maintenance screen  Calset
39
Robot positions 19 Errors
 Teaching positions  Error level recording
 Moving to a position  Error code 2AF1
40
Programming 21 Maintenance
 Connecting a PC  Robot maintenance
 Writing a program  Controller
 Basic programming maintenance 45
 Basic programming
commands EMZY 0097 Fault histories
 Running a program
M. LEE 24/03/07 2
Introduction
Throughout this manual, I will be referring machine EMZK 0097 which is installed
on ZR Head Sub Assembly line. This is the first machine to be installed in the
factory which uses a Denso robot. Other machines using the robot will vary and
some sections of this training manual may not be relevant to another machine. You
will have to use your own knowledge and notes to adapt this training manual to
your particular machine.
Denso robot
The robot installed on EMZK 0097 is a six axis robot. Each axis is knows as J. (So
J1 is axis one. J2 is axis 2, etc)
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The specification of the robot installed on EMZK 0097 is;
V S 6 5 5 6 G – B
Description
(a) Brake on all axis
(b) Robot series RC7
(c) Max reach of 650mm
(d) Maximum payload
(e) Number of axis
(f) Medium size robot
(g) Vertically aligned
Notes
(a) Every robot has brakes installed on axis J2, J3 and J4. –B in the spec means
there are also brakes on axis J5 and J6.
(b) Robot used with RC7M Controller (Older robots used RC5 controllers)
(c) Do not assume that this number is the length, for example the next robot up
has 77 here which means a reach of 850mm.
(d) This is the maximum payload the robot can lift in kg. This also includes the
weight of the tool or clamp installed.
(e) Number of axis (Denso have 4 or 6)
(f) Relates to size of robot (P – small, S – medium, M – large)
(g) Vertically articulated (H is horizontally articulated)
There is also a code on the robot label. On EMZK 0097, the code is 12G 102R.
This is a unique code related to the robot. Denso will keep information on this
robot on a database, so if you ever have any problems with the robot and need to
contact Denso, make sure you inform them of this code.
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Robots are also available in different IP protections – so 2 robots with the same
spec may look different due to the casing. Standard IP rating is IP40.
There are 4 connections on the robot base, 2 electrical and 2 pneumatic.
The larger electrical connector (CN22) is used to control the motors and brakes
and for feedback from encoders. This connects to the robot controller.
The other electrical connector (CN20) is used for the tooling. There is an
electrical connector (CN21) on top of the 4th axis which is wired direct to CN20.
There are also 3 2-position double solenoid valves inside the 4th axis. These are
also wired to CN20.
The pneumatic connectors supply the solenoids with an air feed.
Motors Encoders
CN22
Brakes
CN20 CN21
Solenoids
Air
See wiring diagrams in Robot manual for further details.
The tooling connector (CN20) can be wired to the controller or to another device
to be controlled independently (such as a PLC) On EMZK 0097, it is wired to the
controller.
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Robot controller
The robot controller isn’t one standard item. There are optional extras for the
controller so if you ordered a controller to replace an old one, ensure you also
order or swap the optional extra components for the new controller. For example;
EMZK 0097 controller has optional device-net card for PLC communication. If you
ordered a new controller, this item is not supplied.
Controller specification.
RC7M–VSG6BA–CP
Description
Robot model (a)
Number of axis (b)
Encoder type (c)
Brake type (d)
Safety type (e)
I/O type (f)
Notes
(a) Relates to robot type connected to (See EMZK 0097 is VS xxxG)
(b) Number of controllable axis
(c) Encoder type B (or C is type C)
(d) Brake type (A is 24V brake)
(e) Safety type (C is with safety box and card, B is just safety card)
(f) Input and output is PNP (or N is NPN)
The controller is supplied by 200Vac power to CN6.

CN5 and CN9 are connections for inputs and outputs.
CN7 is connected to CN22 on the robot (for motor, encoder and brakes)
CN3 is where the teach pendant is connected.
CN1, CN2 and CN4 are the communication ports.
The controller has an IP rating of IP20 as standard but there is an optional

enclosure to give IP53
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General layout
PLC Controller
(Device net board)
Power Cable (5m) Pendant
Personal
computer
Blue – Items provided by user

Red – Optional Extra items
Green – Standard supplied items
Standard components include

Robot unit 1
Robot Controller 1
Power Cable (5m) 1
Motor and encoder cable (6m, 6m or 12m, and standard or splashproof) 1
Manual pack (manuals, manuals CD and Safety precautions) 1 set
Networc CD (Includes WincapsII software) 1
Spare fuses for controller 3
Initialization floppy disk (Contains critical arm data specifically for your robot) 1
Pendantless connector (dummy connector) 1
Connector set for CN20 and CN21 1 set
Direction indicator labels 1
Warning labels 1
Spare output IC for controller 1
Dowel pins 1 set
Short sockets for controller 2
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Teach Pendant
The teach pendant is used to manually move the robot, teach the robot positions,
write or edit programs, view error messages and logs and set options and
parameters.
If the pendant is not connected to the controller, the dummy connector must be
connected.
If you repeatedly press cancel key, you will see a blank green background with no
windows open. This is known as the TOP SCREEN. When referring to button
selections during the manual, they will be from the top screen.
If you obtain a pendant, it is likely to be set to Japanesse language. To set to

English, follow the following steps;
[top screen] – [F6 set] – [F7 options] – [F6 language]

then select the language required and press the OK button on the touch screen.
If the ESTOP button is pressed, this will estop the whole machine (via the
controller and machine safety circuits)
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The buttons on the touch screen above the function keys have the same function
as the function key it is above. They also describe the function that the button
will do. If the shift key is pressed once, the function keys F1 to F6 now become
F7 to F12.
Speed key sets the robot operating speed (as a percentage of it’s maximum
speed) ENSURE IT IS ALWAYS SELECTED TO A LOW SPEED BEFORE
MOVING THE ROBOT MANUALLY!!
M-Mod key selects the co-ordination method for moving manually.
R-Select key will select which robot is required to be moved (only one robot is
fitted to EMZK 0097 so only one in the list)
Lock key ‘isolates’ the pendant from the controller so any keys pressed will not
have any effect on the robot.
Keyswitch is used to select running mode.
Cursors and Jog keys used for scrolling/selecting.
Arm traverse keys are used for moving individual axis manually.
OK key used to confirm selections.
Stop key used to stop a running function.
Motor key will turn the motor power supply on and release the brakes. It will only
turn on if the deadmans switch is enabled (see below)
The deadmans switch has 3 positions; Not pressed (disabled), Pressed in one click
(enabled) and pressed in 2 clicks (disabled). This is a safety switch and also used
to confirm some selections.
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Moving the robot
The first step is to put the robot into manual mode. Turn the machine to manual
and enable master on. Put the Keyswitch into manual mode. An error may appear
on the screen ‘Enable auto on/off’. This is because the PLC has 3 ways of
operating the robot, Auto mode, Jog mode or Teach mode. You must select Teach
mode to operate via the pendant. On EMZK 0097, this is done by selecting page
2/4 on the machine touchscreen and selecting robot operate page. Then select
Robot Teach mode on the screen.
You are now able to use the pendant to move the robot. Ensure you have a good
view of the robot at all times. If you think you might collide with an object,
release the deadmans switch and the robot will stop.
First, ENSURE YOU SELECT A LOW SPEED!! Press the Speed button on the
pendant. You will see on the bottom that the function keys will select 1%, 10%,
50% or 100%. Select 10% or you can use the Jog dial to adjust the speed. When
selected a low speed, press OK on the screen to confirm it.
Next, hold in the deadmans switch (remember only one click)
Press the motor button once. There is a short delay then you see the green LED
illuminate in the top left corner of the motor button. You may also here the
contactor kick in in the controller.
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Joint Mode
Press the M-Mod button to select the movement mode. Select Joint and press OK
on the screen.
You can now use the arm traverse keys to manually move the robot arm. J1 + and –
will move axis 1, J2 for axis 2, etc. Use the diagram below to assist you to move
the axis in the correct direction.
Have some practice at moving the robot and getting comfortable with the teach
pendant. REMEMBER TO KEEP THE SPEED LOW AND RELEASE DEADMANS
SWITCH IF YOU ARE CLOSE TO COLLIDING WITH AN OBJECT.
This is the simplest way of moving the robot. There are also 2 other methods of
movement modes, X-Y and TOOL. These methods are not as easy as Joint mode.
X-Y Mode
First, we need to understand the right hand rule.
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Hold your hand as shown above. Now imagine the back of your hand was flat on
the base where the robot is mounted, and the robot connections are grabbed by
the 3rd and 4th fingers. You now have the directions which your robot will move.
The point of movement is calculated from a particular point on the tool (or the
centre of axis 6 flange if no tool fitted)
On the pendant, press M-Mod. Now select X-Y and press OK.
Now the arm traverse keys indicated X, Y and Z will move in the directions
calculated by the right hand rule. (X+/- moves tool away/towards robot
connections, Y+/- moves tool in a line 90° from X, and Z+/- moves tool up/down.)
The keys indicated RX, RY and RZ will rotate the tool around the plane of X, Y or
Z.
Use the next diagram as an aid to moving the robot in the X-Y mode.
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Ensure you have selected a low speed and have a go at moving the robot in the X-
Y mode.
Tool mode
This also uses the right hand rule. This time, imagine there is no tool fitted to the
robot, but the back of your hand is mounted there instead with your 1st finger
pointing from the centre of the flange to the dowel hole.
Dowel hole
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You now can work out which way the robot will move when you use the arm
traverse X, Y and Z buttons. Again the RX, RY and RZ will rotate around the axis.
Use the diagram above to aid you and have a go at moving in tool mode. Don’t
forget to ensure you have selected a low speed.
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Moving using the machine touchscreen
If there was no pendant available, or it was broken, it is possible on EMZK 0097

to move the robot in all 3 modes by the machine touchscreen.
Turn the pendant Keyswitch to auto. On Robot Operate page, (on page 2/4) select
robot jog mode.
You can see on the screen – Each axis jog select. This is the same as Joint mode.
X, Y, Z coordinate jog select is the same as X-Y mode. And Tool coordinate
jog select is the same as Tool mode.
When in each axis mode, you can select your axis to move by the 6 selections in
the bottom left corner of the screen, then select high or low speed and jog + or
jog – then press the execute button.
When in XYZ or Tool mode, you can select the X, Y or Z coordinate to move and
use jog high or low speed and + or – and execute as above. You cannot use the
Rotation around the coordinate as you can with the teach pendant.
There is also a Robot home pos return button, but will only operate if the pos to
home pos return light is on.
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Teach Pendant Screens
From top screen, press [F2 Arm] This displays current robot position window.
You can see the angles of each axis is indicated in degrees, when J is selected. This is
known as the Joint variable.
If you select P, it will show the current arm position in measurements (from centre of
robot base) and description of arm position. This is known as the position variable.
You can also see a slider bar for each axis. This indicates the maximum allowable
movement of each axis (until software limit).
From the top screen, press [F1 Program] This displays the program list window.
The screen shows a list of all programs stored in the controller and its status (compiled
and enabled/disabled)
From this screen, the program can be edited or a new program written.
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From the top screen, press [F4 I/O] This displays the I/O Monitor screen.
This screen shows the status of inputs and outputs. A black square indicates an
input/output is off and a green square indicates an input/output is on.
From the top screen, press [F6 set]-[F2 log]-[F1 errlog] This displays the error log
This screen displays the error codes received and is in time and date order, most recent
first. The number next to the error code is the seriousness of the error, 0 being least
serious and 5 being most serious. There is further detail of the error selected near the
bottom of the screen.
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From top screen [F2 arm]-[F12 maint] This displays maintenance functions screen
This screen displays the option used for maintenance purposes. Here we can perform
calibrations, software limits, encoder resets. These areas will be covered later in the
manual.
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Robot positions
Teaching a position
The robot programming tells the robot to move to certain positions stored in it’s
memory. But first you have to teach the robot where these positions are.
You already know how to move the robot. Move the robot to the position you wish
to teach it (you would probably start with the robot home position). When you are
happy with the position of the robot, press (from top screen) [F2 arm]. Ensure
you have the Position variable button selected (P). You will see the measurements
and description of the robot current position.
To store this position, press [F4 var]-[F4 pos] a new window will appear which
displays a list of position variables.
Select any box next to the position variable you wish to store (in yellow area) and
turn on the motor power. Now press [F6 getpos] and select OK to the
confirmation box which appears. You will now see the new position variable data in
the six boxes next to the position you selected (in this case you stored it as
position P0). On EMZK 0097, the home position variable data is stored as P900.
Repeat this process for all positions required for the cycle (ie pick up and put
down points, etc) and ensure you store them all as different positions. Make a
note of where each position is.
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Moving to a stored position
On the position variables screen, select any of the 6 boxes relating to the
position you wish to move the robot to.
TIP: Use the jog dial or cursor up/down to scroll up or down. If you hold cursor
down and scroll down with the jog dial, it will scroll by 10 lines (so quicker to
scroll) and vice versa for up. If you wanted to select P900, you can press [F3
Jump to] and type in 900 then press OK.
Now you have selected the position you want to move to, press [F4 Move]. You will
see a window where you can select movement by PTP or CP. Select the movement
type required (see explanation below) then press and hold the OK button on the
pendant. You will see a bar appear displaying 0% to 100%. This is the amount of
movement from current position to the target position. If you release the OK
button, the movement will stop and the screen will revert back to the position
variables screen.
PTP – Point to point

This is a movement from current position to target position whereby the robot
will move in its easiest path. It can carry out this movement quicker than a CP
movement.
CP – Continuous Path
This is a movement from current position to target position whereby the robot
will move in a linear motion (a direct line). The robot has to do more calculations
to move each axis to keep this linear motion and so is slower to carry out the
movement.
If you were to put a pen onto the robot flange and carry out PTP or CP movement,
the line would be draw as:
PTP CP
Current pos Target pos Current pos Target pos
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In an open area it wouldn’t matter if you selected PTP or CP for the movement but
it would be quicker and more time efficient in a cycle to use PTP movement where
possible. On EMZK 0097, the robot places tubes onto a press fit machine. For this
movement it wouldn’t be possible to use PTP.
Press Fit Required movement
Tube
Programming
Now you have taught the robot its required positions, we can now create a
program to make the machine run to these programs. We can do this in 2 ways, on
the tech pendant or with a PC running Wincaps II.
We will first look at Wincaps II software and connecting the pc to the controller
then will create a simple program using Wincaps II and the teach pendant.
You will need an Ethernet cross over cable. You can see if an Ethernet cable is a
crossover type or not by putting the 2 ends together and looking at the order of
the internal cables.
Standard Ethernet cable Crossover Ethernet cable
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Connecting the computer to the controller
Connect the Ethernet crossover cable to the LAN port on the controller and the LAN
port on the computer.
On the teach pendant, press [F6 set]-[F5 set com]-[F4 address]

This displays the network address of the controller.
On the computer, open the control panel. Open the network connections. Right click the
Local Area Connection icon and select properties. Select internet protocol and click
properties button. Under section IP Address, insert the number displayed on the teach
pendant, but change the last number to one greater than the pendant. (ie If pendant IP
is 192.168.0.1, set computer IP to 192.168.0.2)
Under Subnet mask, insert the same number as displayed on pendant.
Now the computer is set up to connect to the controller. Open the WincapsII program
(it is called system manager).
We will first create a backup of the controller before making any modifications or
changes. Follow the work standard for creating a backup of the controller.
Writing a program
To write a new program on pendant To write a new program with WincapsII

Press [F1 prog]-[F1 newprog] OK to confirm writing a Select the left icon called PAC Manager
new program Click the top left icon for New program
Type in a name for the program using the keypad which Enter your program title and name where stated (delete
appears on the screen the < and >)
Insert your programming lines after Takearm and Simply type in the program lines in order as required (no
before End. need to put in line numbers)
To insert a new line, scroll down to highlight line 0003 When complete, click on the top right X to close the
and press [F1 newline] window
Type in the program line and press OK when done (no Select Yes to confirm saving the program. Save it to
need to put in line number) the directory created in the WSS
The program lines will automatically renumber If there are errors, a warning will appear and red error
themselves accordingly message informs of line with error
To edit a line of programming, scroll to highlight the line When complete, click on the transfer icon. Select yes to
and press [F5 editline] saving the project.
When all done, press [F6 save] and confirm by pressing Select Yes to creating execution program
OK A message appears showing any errors
Select your program from the list and press Config to Click Select all then transmit on the window that
compile it. appears
Select Make the specified program active and press A bar appears on the pendant showing uploading status
OK
Your program is now ready to run When complete, your program is ready to run
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Basic Programming
The basic layout of the program is as follows;
0001 ‘!TITLE “PRO01” This is the program title EG Pick up part

0002 PROGRAM PRO01 This is the program name EG Pickpart
0003 ‘TAKEARM This is the first command
0004 END This indicates the end of the program
This apostrophe is an indication of a comment. Whatever is after this comment is

ignored by the robot and is used to describe what the command does. Look at this
example from a program on EMZK 0097;
WAIT IO[50]=ON ‘[ToolB Unclamped Complete]
Command Comment
Program name
You may name your program anything you wish, but if the PLC output is to execute
a program, the name must be PROxx. EG PRO01, PRO02, PRO13.
Basic Program commands
TAKEARM
This command gives the program authority to take control of the robot arm and
enable movements. If this command is not entered, the robot will not move when
commanded to.
GIVEARM
This gives the authority back to the program which the TAKEARM took the
authority from.
END
This signifies the end of the program and also automatically executes the
GIVEARM command.
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MOVE
Commands the robot to move from the current position to a position variable.
MOVE <move method>,@<target type> < position variable>, S=<internal speed>

Examples; MOVE P, P1 MOVE P,@O P1 MOVE L,@P P2 MOVE P,@E P3,S=20
The move method <P> selects movement method PTP, <L> selects CP method.
The target type <@O> means it reaches the target point. If no target point type is
entered, this type is used. (The first and second examples above are the same). <@P>
means it doesn’t reach the target position. As the robot arm starts to decelerate, the
next move command is executed. <@E> means the robot will move to the target position
more precisely and will take longer to move to this position as it continuously takes
encoder values. <S=X> will execute the move command at internal speed of X%. See
SPEED command for internal speed description.
0001 ‘!TITLE “Move eg 1”
0002 PROGRAM MOVE@O
0003 TAKEARM Current Pos
P1
0004 MOVE L, P1
0005 MOVE L, P2
0006 END
(MOVE L,@O P1 can also be used)

P2

0002 PROGRAM MOVE@P
0003 TAKEARM Current Pos P1
0004 MOVE L,@P P1
0005 MOVE L,@P P2 Obstacle
0006 END
It isn’t possible to move to the target position
via the red line.
Target Pos P2
0002 PROGRAM MOVE@E P1
0003 TAKEARM Current Pos
0004 MOVE L,@E P1
0005 MOVE L,@E P2
0006 END
The positions tolerance is a lot smaller using
P2
the @E command.
EMZY doesn’t use the @E method, but a robot on a machining line may well do due
to tighter tolerances. The tolerance has to be within 20 encoder pulses.
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APPROACH
This command is similar to the MOVE command and will command the arm to move
to a certain distance away from a position variable. The line is written the same
way as the MOVE command with an extra input for the distance away from the
position variable. The distance is measured in millimetres along the –Z direction of
the tool coordinates.
APPROACH <move method>,< position variable> @<target type>,<distance>, S=<internal speed>
APPROACH P,P1,50 APPROACH L,P3 @P,30 APPROACH L,P2 @E,100,S=20
The same target type options are available as with the MOVE command (@O, @P
and @E) If none is specified, @O is automatically used.
Look at these examples below if we were using a pen as the robot tool.
Position variable P1 Approach P,P1,50

-Z
Robot Pen
-Z
+Z
50mm
+Z
Position variable P2 Approach P,P2,30

-Z
-Z
+Z
30mm
+Z
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DEPART
This is the opposite to APPROACH. It will move in the –Z direction of the tool
coordinates at a distance specified. Again, the movement can be PTP (P) or CP (L)
as with MOVE and APPROACH.
DEPART <move method>,<distance>,S=<internal speed>

DEPART P,30 DEPART L,50,S=50 DEPART L,70,S=I5
NEXT
If this is written after a command, it instructs the program to execute the next
line of programming while still performing its current line.
EG 0003 MOVE P,P4,S=40 NEXT

0004 CALL opengate
While the robot is still moving to position P4, it will run line 0004. If the NEXT
command is not written in, line 0004 will not run until position P4 has been
reached.
DELAY
This is a pause command.
DELAY <delay time> EG DELAY 2000
The delay time is entered in milliseconds. So the example is a 2 second delay.
CALL
This calls another program to run. The current program will stop until the called
program is complete. See example on the next page.
RUN
This is like call. It commands another program to run, but will not stop the
current program from running. Both programs will run together. See example on
next page.
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CALL command RUN command

0001 ‘!TITLE “calleg1” 0001 ‘!TITLE “runeg1”
0002 PROGRAM call1 0002 PROGRAM run1
0003 TAKEARM 0003 TAKEARM
0004 MOVE P, P1 0004 MOVE P, P5,S=25
0005 DELAY 2000 0005 DELAY 1000
0006 CALL call2 0006 RUN run2 0001 ‘!TITLE “runeg2”
0007 DELAY 1000 0002 PROGRAM run2
0008 MOVE P,P3,S=75 0003 DELAY 1000
0001 ‘!TITLE “calleg2” 0009 END 0004 RESET IO 765
0002 PROGRAM call2 0005 SET IO 455
0003 TAKEARM 0006 WAIT IO[875]=on
TIME
0004 APPROACH P,P5,20 0007 DELAY 1000

0005 MOVE P, P5,S=25 0008 RESET IO 455
0006 SET IO 892 0009 SET IO 765
0007 WAIT IO[893]=on 0010 WAIT IO[885]=on
0008 DELAY 1000 0011 DELAY 1000
0009 MOVE P,P3,S=75 0012 END
0010 END
0007 DELAY 2000

0008 MOVE L, P2
0009 END
WAIT
The program pauses until the WAIT command condition is true.
EG WAIT IO [865] = ON
The program will not continue until Input/Output port number 865 is ON
SET
The program will command an Input or Output to be ON.
EG SET IO [720] Input/Output port 720 is now ON
RESET
The program will command an Input or Output to be OFF
EG RESET IO [720] Input/Output port 720 is now OFF
SPEED
This sets the internal speed for the program to operate. The internal speed is a
percentage of the external speed (shown on bar in top right of pendant screen)
So if the internal speed is 20% and the external speed is 100%, the robot will run
at 20% of maximum speed. If internal speed stays at 20% and external speed is
reduced to 50%, the robot will run at 10% of maximum speed.
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Running a program
Once you have written a program, you will want to run it to check it is ok.
On pendant, turn Keyswitch to TEACH CHECK mode.

FIRST, ENSURE YOU HAVE REDUCED THE SPEED!!
Press [F1 Program]
You will see the list of all programs stored in the robot controller.
Select the program you wish to run/check using the cursor keys or jog dial.
Press [F6 StpStart]
You will see a message asking if you want to run the program forward by a single
step?
You will need motor power on (don’t forget the deadmans switch)
Press and hold the OK button on pendant
One line of the program will be run. You can now press [F6 StpStart] again and
continue to run the next line. Keep doing this for the whole program to see if you
have made any programming errors.
If you are satisfied that your program operates correctly, you can now run it for
one complete cycle.
Select the program you wish to run.

Press [F4 CycStart]
You will see a message asking if you want to run the program forward by a single
cycle?
You will need motor power on
Press and hold the OK button on pendant
The program will run for one complete cycle as long as the OK button is pressed.
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Inputs and Outputs
Monitoring
You can monitor the status of Inputs and Outputs on the teach pendant as seen
earlier (on page 17).
You can also monitor through WINCAPSII.
On the system manager, click on the light bulb icon. This is the DIO monitor.
Monitor type
(a)This is the input/output port number

(b)This indicates the status of the input/output
(c)This indicates whether or not the input/output is being monitored
(d)This button indicates if the controller is being monitored or not
(e)This button connects/disconnects to the controller
M. LEE 24/03/07 29
To monitor, click buttons (d) and (e) and double click box (c) to change it to ON.
You will now see the state (b) change when the input/output changes.
This is the TABLE type monitoring. In the drop down box (monitor type), you can
also select 1 – oscilloscope and 2 – panel.
The oscilloscope type is a time line type which will monitor IO’s selected
previously in table type.
Panel type is the same as the IO monitoring screen on the teach pendant.
Simulating IO
If you were running a single cycle of a program, you may have a WAIT command
which it won’t proceed past until the IO criteria is met. You may never get the
criteria met if you are not running the machine in continuous. For example, the
WAIT IO command may be waiting for a part to be present at a pick up point.
That part may not be there as the machine parts feeding is not running.
To get around this, you can simulate the IO as being on (or off) and so carry on
running the program.
In the DIO manager, deselect the continuous monitoring button (d). For the
input/output port you wish to simulate, ensure ON is selected under MONITOR
column (c). Double click the box under DUMMY column to select it to ON. Now
click the dummy IO button ( ). Now you are able to double click the box under
the STATE column to turn the input/output on or off as required. Deselecting the
dummy IO button will revert all IO’s to their natural condition.
IO Macro Names
Inputs and outputs can be assigned a name known as a MACRO name.
The example above shows Input port 34 is assigned a macro name as IOPARTS.
When programming, we can now write:
WAIT IO[34] = on or WAIT IO[ioparts] = on

M. LEE 24/03/07 30
To assign a macro name, double click the box under macro column for the IO port.
You can now enter the name you wish to assign to the IO. When you have
completed this for all IO’s required, click FILE then MAKE MACRO DEFINITION
FILE.
Variables
Variable Macro Names
It is also possible to assign macro names to variables too (like position variables.)
Variable
manager
Select the variable manager from the system manager (above).
As you can see above, position variable P10 is home position and has been assigned
the macro name pHome.
To name the variables macro’s is the same as previously done for naming IO
macro’s.
So you could now write in a program:
MOVE P,pHome
M. LEE 24/03/07 31
Types of variables
I Integer These are whole number variables. To view them,

[F2 Arm]-[F4 Var]-[F1 Integer]
You may see in a program something like;

MOVE P,P5,S=I3 The movement will be at whatever I3 is set at (%)
DELAY I14 The delay will be whatever Integer14 is set at (ms)
I2=I2+1 If Integer2 was set at 3, it is now set at 4.
I5=30 This sets Integer5 as 30.
P Position You have already learned about position variables
J Joint Joint variables are similar to position variables. The Joint variable
stores the angle of each joint. The robot can be moved to a Joint
variable in the same way you can move the robot to a position
variable. You can only store 100 joint variables. To view them,
[F2 Arm]-[F4 Var]-[F5 Joint]
F Floating point variable
}
These variables are
D Double position variable available but not
widely used. They
V Vector variable are not used on
EMZK 0097. Refer
T Transform matrix variable to Denso manuals
for further details.
S String variable
M. LEE 24/03/07 32
Motion Space
Software limits
The software limits are set points that the controller will not allow the robot to
move past. These are set before the deadstop position so the robot won’t drive
into the deadstop during operation. They are set by;
[F2 Arm]-[F12 Maint]-[F1 MSpace]
You will see a positive and negative limit setting for each axis. This is the
maximum and minimum angle the controller will allow the robot to move. You can
change the values using [F5 Change] and entering the new value using the on
screen keypad.
Interference areas
You may have an area inside the machine and wish for the controller to prevent
the robot entering the area or to warn about entering the area.
For example. You may have a supporting post inside the machine which the robot
could strike during a movement. You will setup an interference area around this
post so the robot will stop when it enters this area.
On EMZK 0097, there is an interference area around the press fitting section of
the machine. The robot can enter this area but we don’t want it to stop. When the
robot is in the area, it gives an output to the PLC. So the press fit line of logic in
the PLC will not allow the press fit cylinders to lower when the robot is in the
area.
To set up the areas, [F2 Arm]-[F6 Aux]-[F6 Area]

You can set up 8 interference areas. You will see green/black squares next to the
numbers 0 to 7. If the square is black, it is inactive and has not been setup. If it
is green, the area has been setup and is active.
M. LEE 24/03/07 33
(a)
(b)
(c)
(d)
Displays which areas are active/inactive

Data for Area0
(a) These are the coordinates for the centre location of the interference area
(b) This line is to set the rotation around the axis for the area
(c) This sets the distance from point (a) to the edge of the box in each plane
(d) This line determines what action you want the robot and controller to do.
(c)
(a)
M. LEE 24/03/07 34
(d)
(1) (2) (3)
(1) Enter the IO port number in this box. When the robot enters the
interference area, this output will come on. (On EMZY 0097, this output is
used in the PLC logic to prevent press fit cylinders lowering when robot is in
the area). If 0 is entered, no output will be switched.
(2) Enter a variable position number in this box. When the robot enters the area,
it will store the position data at the entry point as a position variable. If 0 is
entered, no position variable data will be stored.
(3) This setting will interpret the moving into/out of the area as an error or not.
If it is set to interpret as an error, it will cut off the motor power and so the
robot will not move. The list below shows the options available for this box.
M. LEE 24/03/07 35
Calibration
The robot arm must be calibrated, much like other pieces of equipment. Each axis
can be calibrated individually (except 5th and 6th axis must be calibrated
together) or all axis can be calibrated together.
The calibration data is stored in the controller and this data will be on your
backup. You may have to create a new backup if you carry out a calibration.
The calibration procedure is known as CALSET. If you look at WSS-ZR-K-COM-

DR-04 (uploading data to Denso controller) step 9, you will see you have the option
to transfer calset data from the backup to the controller.
When restoring a backup, Send calset Do new Create new

What have you changed data? calset? backup?
Controller and arm NO YES YES
Controller YES NO NO
Arm NO YES YES
Nothing YES NO NO
As you can see from the table, if you do a new calset where the data will be
different (ie new robot arm) you will have to create a new backup so the correct
data is saved.
Rang data
Rang data is unique to the robot arm. If you get a new robot arm, you must input
the rang data supplied into the controller. You can view/change the rang data by
[F2 Arm]-[F12 Aux]-[F2 Rang]
M. LEE 24/03/07 36
You can see a value in degrees for each axis. This angle is the difference between
the joint at 0° and the deadstop position.
EG (top view of robot base)
Rang data
Angle X
J1 = X
0°
Deadstop Robot base Robot arm
Rang data is very precise (to 5 decimal places) and is measured by the
manufacturer when the robot is made. It will never be the same as another robot
arm. If the data is entered wrong, the robot will not accurately be able to move to
the correct position required.
Calset
When you carry out a calset, you move the robot axis to the deadstop position and
are basically telling the controller that the axis is at the angle stored in the rang
data. This is why rang data must be correct. You have to move the robot past it’s
software limits to rest each axis on it’s deadstop. This is done by releasing the
brakes on the arm and moving the arm by hand to it’s deadstop position.
NOTE
Axis 4 and 6 do not have deadstops. It is possible to rotate them over 360°. For
this we use jigs. Axis 4 jig is a screw which is fitted for the arm to sit against and
is stored behind axis 3 motor cover. A jig is supplied for axis 6. It is fitted to the
flange (so need to remove tooling) and a bolt fits to the jig and to a fixed position
on the arm. See the calset WSS for fitting the jig.
M. LEE 24/03/07 37
WARNING
Axis 4 has the internal wiring and pneumatic pipework running through the centre.
The motor that drives the axis has a crank which will tangle with the wiring and
pipework when rotated over 360°.
Axis 4
Motor and
Encoder
Axis 3 Wiring Crank Axis 4 Robot arm
Over rotated 4th axis (on VM series robot)
Ensure that when arrows are lined up at axis 4 rotation point, the wiring isn’t
twisted. If it is twisted, release the brake and turn axis by hand 360° to untwist
wiring and line up arrows.
Follow the WSS-ZR-K-COM-DR-01 to carry out calset. Notice you will need 2
people to carry out the operation. One person to operate pendant and cover
Emergency stop and one person to move robot and fit jigs (unfenced).
M. LEE 24/03/07 38
Errors
To view the error log [F6 Set]-[F2 log]-[F1 Errlog]
You will see a list of errors which have occurred. They are listed in time/date
order, with the latest error first. You will see the Date and time which the error
occurred, the error code and an error level. Error level [0] being the least critical
and [5] being most critical. There is a description of the error on the lower half
of the screen. The error codes are listed in the machine manuals.
Selecting error level recording
You can select the error level to be recorded. If you set the level to 1 (minimum
level) you will record most errors which occur. You may select the recording level
from 1 to 5. To do this from the error log screen, press [F6 Aux]-[F1 Errlvl]
You will see on the log error code 600c [0] will always be recorded on the log. This
is Emergency Stop On.
Error code 2AF1
This is an error code which you will possibly come across. Imagine the machine was
powered down at the end of a shift. The encoder values will be stored in the
memory. If someone opens the gates to the machines and goes in to clean it, they
may possibly lean on the robot arm and overcome the brake force so will move the
arm. When the machine is next powered up, error 2AF1 will be shown on the
pendant. This is Encoder Reference Position Error. It means the encoder value is
different to what the controller expects it to be. (This can also happen when an
encoder has been changed and calset not carried out). You will be able to move the
robot manually in Joint mode, but not XY or Tool mode.
M. LEE 24/03/07 39
To reset error 2AF1,
Press OK
Press [F2 Arm]
Press Shift button
Press cursor keys  and  and [F6 Maint] together
Press [F8 EncRef] This displays the encoder reference positions. You will see
the difference in the encoder stored and the encoder actual values.
Press [F5 ChgRef] Message “do you want to change?”
Press OK. The encoder readings will change to the actual encoder value.
Press OK
Press [F1 PosConf] Message “do you confirm?”
Press OK Message “it is normal.”
Press OK
Move the robot to home position.
Maintenance
We will look into maintaining the robot and the controller. The manuals have easy
to follow step by step guides to replacing components.
Robot maintenance
The 5th and 6th axis have timing belts fitted.
6th axis
timing belt
motor/encoder
5th axis
motor/encoder
timing belt
M. LEE 24/03/07 40
The manual recommends checking the timing belt every year based on 2 shift
operation (or approx 4000 hours of use). You must visually inspect the wear on
the teeth and the deflection of the timing belt. If you have to change a timing
belt, you will have to carry out calset on 5th and 6th axis together. (When 5th axis
moves, 6th axis motor must also move to keep the 6th axis in the same position due
to the gear mechanism in the flange.)
Extract from manual
Also the manual recommends that the internal wiring through the 4th axis is
inspected for damage on an annual basis. The wiring diagrams can be found in the
robot manual.
There are 3 batteries in the robot for encoder memory when the machine is
powered down. It is recommended these batteries are changed with the power on,
or it is possible to remove one and fit a new one. The other 2 batteries will be
enough to store the memory. Always change all 3 batteries together.
M. LEE 24/03/07 41
The batteries are connected to a power conversion board. This converts 24vDC
from the controller to 5vDC for the encoders. A simple way to check the board is
working is to check the supply to one of the encoders. With power on you should
read 5vDC and power off 3.6vDC (from batteries). If you read 3.6vDC with power
on, the board is not operating correctly.
Encoder
memory
batteries Power supply
conversion board
The motors, encoders and brakes are all one unit. Step by step instructions are in
the manual for changing each motor/encoder unit. When the unit has been
replaced, you may get error code 2AF1. You will have to follow the procedure for
clearing the error then perform calset on the relevant axis. If you change 5th or
6th axis motor/encoder unit, you will have to perform calset on 5th and 6th axis
together.
Controller Maintenance
The controller is made up of many components which can be changed individually.

You do not have to change the whole controller. If the controller goes down
during production, it may be better to change the whole controller to get the
machine running as quick as possible. But there are some components fitted which
don’t come as standard (eg Device-net card).
There are cooling fans fitted to the controller. If one of these fans stops
operating, the controller will not run. You can change a setting to allow the
controller to run without the cooling fans and so allow the machine to run during
production. But the fans must be fixed at the earliest opportunity. To allow
controller to run without fans, press;
[F6 Set]-[F6 Maint]-[F10 FanStop] set to ENABLE
M. LEE 24/03/07 42
There is a battery fitted for the controller backup memory. When replacing this
battery, the manual states to turn power off and change within 3 minutes.
Controller Memory Battery
The controller will keep a record of when the battery is due for change. You must
update this when you have changed the battery. Press;
[F6 Set]-[F6 Maint]-[F4 Battery]-[F5 Change]
It automatically sets a date 2 years from the current date. Ensure the date is set
correctly and press OK.
Below is a general layout diagram of the controller.
FRONT
Robot arm connector Power switch Power supply connector
CPU Board Noise filtering

board
Motor cards
2 1
4 3
Power supply board
6 5
M. LEE 24/03/07 43
The external power supply is filtered through the noise filter board and the
supplies the power supply board. This will transform the power to the supplies
needed for the controller boards and robot arm.
The CPU board has slots for expansion cards. This is where the safety card and
device-net card is mounted.
The motor cards enable the power supply to the robot arm motors when the
motor power is switched on with the pendant.
All robots (except VM series) VM series

Card Axis Card Axis
1 1 1 2
2 2 2 1
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
There are different sizes of motor card available. The size relates to the size of
the motor the will control.
SS Super small
S Small
M Medium
L Large
The Motor Card has a fuse on. If this fuse has blown, motor power will not be
supplied to the relevant axis. You will get fault code 614X JX Power module
failure. (X relates to the axis at fault). When investigating you find the fuse on
the motor card has blown, you must replace the whole card, you cannot replace
the fuse.
The power supply board has 6 large capacitors. These capacitors will give enough
power to stop the robot safely and write all parameters and encoder positions to
memory in the event of a power loss. When you turn power off, always allow at
least 3 minutes for the capacitors to discharge.
M. LEE 24/03/07 44
The IO card is mounted on the CPU card. It has jumper settings for PNP or NPN
use. There are 3 replaceable IC chips fitted. They are NPN or PNP specific.
There are also 7 fuses (F2 to F8). If a fuse has blown, there is also a possibility
one of the IC chips has blown.
The safety board is also mounted on the CPU board. This has 4 fuses, but only one
is used. This fuse (F2) is used for the emergency stop circuit. If this fuse has
blown, error message 6008 will appear on the pendant when you try to put motor
power on.
The CPU board has 3 fuses fitted. One for the pendant power, one for the brake
release power and one for the 24vDC power supply to the power conversion board
on the robot. There will be fault codes indicating possibility of fuses blown.
M. LEE 24/03/07 45
EMZK 0097 Fault history
There have been a few faults with the machine but none have been robot related
faults.
There was one incident where the machine stopped mid cycle due to a tube not
sat on the 3bond wheel properly. We removed all the tubes from the table and
returned the robot to home position. We reset the PLC parts taken memory on
the touchscreen and turned back to continuous, but the machine would not run.
The robot program wouldn’t run and kept bringing up a message “Parts Mismatch”.
Eventually, we found that there is an Integer variable that counts up every time a
tube is placed on the temp table by the robot. Integer I21 is normally 0 at the
beginning of the cycle. When one tube is placed, the program runs a line I21=1.
When it places the second tube, I21=2, etc. When I21=4 it will pick all 4 tubes
from the temp table to fit to the press fit section. The value of I21 was 2 when
we were trying to run cycle from start. We reset the value of I21 to 0 and then
the machine ran OK.
To set values of Integer variables,
Teach pendant to manual

[F2 arm]-[F4 var]-[F1 Integer]-[F3 JumpTo]
Type in the Integer number you wish to change
Press OK
[F5 Change]
Type in the value for the integer
Press OK
Teach pendant to auto
M. LEE 24/03/07 46

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DENSO ROBOT TRAINING MANUAL

Moving the robot 10 Variables 31

The specification of the robot installed on EMZK 0097 is;

There are 4 connections on the robot base, 2 electrical and 2 pneumatic.

The pneumatic connectors supply the solenoids with an air feed.

See wiring diagrams in Robot manual for further details.

The controller is supplied by 200Vac power to CN6.

The controller has an IP rating of IP20 as standard but there is an optional

(Device net board)

Power Cable (5m) Pendant

Blue – Items provided by user

Standard components include

If you obtain a pendant, it is likely to be set to Japanesse language. To set to

[top screen] – [F6 set] – [F7 options] – [F6 language]

Moving the robot

Next, hold in the deadmans switch (remember only one click)

First, we need to understand the right hand rule.

Moving using the machine touchscreen

If there was no pendant available, or it was broken, it is possible on EMZK 0097

Teach Pendant Screens

Moving to a stored position

PTP – Point to point

Press Fit Required movement

Standard Ethernet cable Crossover Ethernet cable

Connecting the computer to the controller

On the teach pendant, press [F6 set]-[F5 set com]-[F4 address]

To write a new program on pendant To write a new program with WincapsII

The basic layout of the program is as follows;

0001 ‘!TITLE “PRO01” This is the program title EG Pick up part

This apostrophe is an indication of a comment. Whatever is after this comment is

WAIT IO[50]=ON ‘[ToolB Unclamped Complete]

Basic Program commands

MOVE <move method>,@<target type> < position variable>, S=<internal speed>

(MOVE L,@O P1 can also be used)

0001 ‘!TITLE “Move eg 2”

APPROACH <move method>,< position variable> @<target type>,<distance>, S=<internal speed>

APPROACH P,P1,50 APPROACH L,P3 @P,30 APPROACH L,P2 @E,100,S=20

Position variable P1 Approach P,P1,50

Position variable P2 Approach P,P2,30

DEPART <move method>,<distance>,S=<internal speed>

EG 0003 MOVE P,P4,S=40 NEXT

DELAY <delay time> EG DELAY 2000

The delay time is entered in milliseconds. So the example is a 2 second delay.

CALL command RUN command

0004 APPROACH P,P5,20 0007 DELAY 1000

0007 DELAY 2000

On pendant, turn Keyswitch to TEACH CHECK mode.

Select the program you wish to run.

Inputs and Outputs

(a)This is the input/output port number

Inputs and outputs can be assigned a name known as a MACRO name.

WAIT IO[34] = on or WAIT IO[ioparts] = on

Variable Macro Names

Select the variable manager from the system manager (above).

So you could now write in a program:

I Integer These are whole number variables. To view them,

You may see in a program something like;

P Position You have already learned about position variables

F Floating point variable