Kawasaki Robot

E Series Controller

Fast Check
Function Manual

Kawasaki Heavy Industries, Ltd.

90210－1256DEA
E Series Controller
Kawasaki Robot Fast Check Function Manual

PREFACE

This manual describes the fast check function for Kawasaki Robot E series controller. This
manual should be read with careful review of the separate basic manuals (including Safety
Manual) delivered with the robot. Once the contents of all the manuals are thoroughly read and
understood the robot can be used.

The manual provides as much detailed information as possible. However, not every possible
operation, condition or situation that should be avoided can be described in full. Therefore,
should any unexplained questions or problems arise during robot operation, please contact
Kawasaki Machine Systems.

1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different site or sold off to a different user, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2009 Kawasaki Heavy Industries Ltd. All rights reserved.

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E Series Controller
Kawasaki Robot Fast Check Function Manual

SAFETY

The items that require special attention in this manual are designated with the following symbols.

Ensure proper and safe operation of the robot and prevent physical injury or property damages by
complying with the safety matters given in the boxes with these symbols.

！ DANGER

Failure to comply with indicated matters can result in

imminent injury or death.

！ WARNING

Failure to comply with indicated matters may possibly

lead to injury or death.

！ CAUTION

Failure to comply with indicated matters may lead to

physical injury and/or mechanical damage.

[ NOTE ]
Denotes precautions regarding robot specification,
handling, teaching, operation, and maintenance.

！ WARNING

1. The accuracy and effectiveness of the diagrams, procedures, and detail

explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give one’s fullest attention when
using this manual to perform any work.
2. Safety related contents described in this manual apply to each individual
work and not to all robot work. In order to perform every work in safety,
read and fully understand the safety manual, all pertinent laws, regulations
and related materials as well as all the safety explanations described in each
chapter, and prepare safety measures suitable for actual work.

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E Series Controller
Kawasaki Robot Fast Check Function Manual

INTRODUCTORY NOTES

1. HARDWARE KEYS AND SWITCHES (BUTTON)

E series controller provides hardware keys and switches on the operation panel and the teach
pendant for various kinds of operations. In this manual the names of the hardware keys and
switches are enclosed with a square as follows. The terms “key” or “switch” which should
follow the relevant names are sometimes omitted for simpler expression. When pressing two or
more keys at the same time, the keys are indicated by “+” as shown in the example below.

EXAMPLES

ENTER: expresses the hardware key “ENTER”.

TEACH/REPEAT: indicates the mode switch “TEACH/REPEAT” on the operation panel.
A+MENU: indicates pressing and holding down A then pressing MENU.

2. SOFTWARE KEYS AND SWITCHES

E series controller provides software keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this
manual, the names of software keys and switches are enclosed by “< >” parentheses. The terms
“key” or “switch” which should follow the relevant names are sometimes omitted for simpler
expression.

EXAMPLES

<ENTER>: expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE>: expresses a “NEXT PAGE” key on the teach pendant screen.

3. SELECTION ITEMS

Very often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items are enclosed in brackets [XXX].

EXAMPLES

[Auxiliary Function]: Expresses the item “Auxiliary Function” in a menu. To select it, move the
cursor to the relevant item by the arrow keys, and press the ↵ key. For
detailed description, this procedure should be described every time, but
“select [XXX] item” will be used instead for simpler expression.
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E Series Controller
Kawasaki Robot Fast Check Function Manual

CONTENTS

1.0 Explanation of the Function ·······························································································5

1.1 Before Conducting the Check Operation with Fast Check Mode·······································5
1.2 Deference between Fast Check Mode and Teach/Repeat Mode·········································6
1.3 100%/TEACH/REPEAT Switch ·······················································································7

2.0 Operating Procedure for Check Operation in Fast Check Mode·········································8

2.1 Comparison of Procedures between Check Operation and Fast Check Operation ·············8
2.2 First Step: Fast Check Call ·································································································9
2.3 Speed Selection in Fast Check Mode ···············································································10
2.3.1 Speed Display···················································································································10
2.4 Second Step: Fast Check Ready ·······················································································11
2.5 Execution of Fast Check Motion ······················································································12

3.0 Auxiliary Function ···········································································································13

3.1 Auxiliary Function 814 Fast Check Mode········································································13

4.0 Dedicated Signal ··············································································································14

5.0 Errors Specific to Fast Check Function ············································································15

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E Series Controller 1. Explanation of the Function
Kawasaki Robot Fast Check Function Manual

1.0 EXPLANATION OF THE FUNCTION

Fast check function enables check operations at the speed of more than 250 mm/s by setting the
fast check mode.

！ DANGER
The following measures are taken for the danger that the robot in motion and
personnel collide while using the fast check function.
・ Mode is selected via a key switch on the operation panel.
・ Default speed in fast check mode is set to 250 mm/s or less.
・ Dedicated key necessary for fast check operation is provided on TP.
・ Fast check speed can be changed via TP.
・ Current fast check speed is displayed on TP.
・ Awareness of staying away from robot’s motion range is promoted.
However, none of the above measures restricts or disables fast check
operations when personnel are inside the safety fence. Use the fast check
function after considering the robot use environment and taking enough
measures for risk control/risk assessment so that robot does not collide with
personnel during its motion.

1.1 BEFORE CONDUCTING THE CHECK OPERATION IN FAST CHECK MODE

Conduct the following without fail before operating robot in fast check mode because the robot
moves at high speed during fast check operations.

！ DANGER

1. In fast check mode, check operations are possible at the repeat speed of
100 %. However, the danger increases compared with the normal check
operation. Accordingly, understand the contents of this manual
thoroughly before proceeding with any operation.
2. Ensure that no one is inside/around safety fence other than the operator
who operates teach pendant before operation without fail.
3. The operator who operates teach pendant must also stay away from robot’s
motion range before operating robot.
4. Limit operations in fast check mode to operators/supervisors who have
completed the special education/training.

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E Series Controller 1. Explanation of the Function
Kawasaki Robot Fast Check Function Manual

Ensure the following without fail before fast check operations as well as repeat operation.

！ DANGER

1. All EMERGENCY STOP work properly.

2. No abnormality is found on installation conditions of robot, mounted
tools and peripheral equipment such as controller.
3. Robot does not interfere with safety fence and peripheral equipment.

1.2 DEFERENCE BETWEEN FAST CHECK MODE AND TEACH/REPEAT MODE

The table below shows the difference between fast check mode and teach/repeat mode.

Manual operation Check operation Repeat operation

Repeat mode Impossible Impossible Possible
Teach mode Possible Possible Impossible
(250 mm/s or less) (250 mm/s or less)
Fast check mode Impossible Possible Impossible
(Possible at the speed of
250 mm/s or more)

[ NOTE ]
Robot cannot be operated manually in fast check mode.

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E Series Controller 1. Explanation of the Function
Kawasaki Robot Fast Check Function Manual

1.3 100%/TEACH/REPEAT SWITCH

Instead of TEACH/REPEAT switch, 100%/TEACH/REPEAT is provided on the operation panel

of the controller with which fast check function can be used.

This function cannot be used via TEACH/REPEAT switch.

Fast check mode

TEACH/REPEAT switch 100%/TEACH/REPEAT switch for

for normal specifications fast check specifications

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E Series Controller 2. Operating Procedure for Check Operation
Kawasaki Robot Fast Check Function Manual in Fast Check Mode

2.0 OPERATING PROCEDURE FOR CHECK OPERATION IN FAST CHECK MODE

This chapter describes the procedure for check operation in fast check mode via operation panel
on the controller and teach pendant.

2.1 COMPARISON OF PROCEDURES BETWEEN CHECK OPERATION AND FAST

CHECK OPERATION

This section describes the difference of procedures between check operation and fast check
operation. Different points are explained in the sections shown in the table below.

Advance preparation
Auxiliary function numbers which set check speeds differ.

Check operation Fast check operation

Setting of check speed (Aux. 401) Setting of fast check speed (Aux. 814)
(see 3.1)

Operating procedure
Operating procedures differ. Procedures for each operation are shown below.

Check operation (Refer to 7.1 in

Operation Manual for details.) Fast check operation

Teach mode Fast check mode

↓ (Fast check call) (see 2.2)
↓ ↓
Program selection Program selection
↓ ↓
Step selection Step selection
↓ ↓
Check speed selection DEADMAN＋Check speed selection (see 2.3)
↓ ↓
↓ DEADMAN＋Fast check ready (see 2.4)
↓ ↓
DEADMAN＋CHECK GO/CHECK BACK DEADMAN＋CHECK GO/CHECK BACK
(see 2.5)

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E Series Controller 2. Operating Procedure for Check Operation
Kawasaki Robot Fast Check Function Manual in Fast Check Mode

2.2 FIRST STEP: FAST CHECK CALL

Turn 100%/TEACH/REPEAT switch to “100 %” (fast check mode). This operation is referred
to as the fast check call.

Fast check mode

In fast check call, <TEACH/REPEAT> area on the upper left of the teach pendant screen
becomes orange. Element instructions display area remains in blue.

In addition, check speed is set to 1 when the mode changes to fast check mode.

Fast check call

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E Series Controller 2. Operating Procedure for Check Operation
Kawasaki Robot Fast Check Function Manual in Fast Check Mode

2.3 SPEED SELECTION IN FAST CHECK MODE

Speed for fast check mode is selected via TEACH SPEED of the teach pendant. (Refer to 2.6.1
in “Operation Manual” if the speed cannot be changed by this operation.) Pressing
TEACH SPEED key toggles the check speed between 1→2→3→4→5→1. Speeds 1-5
correspond to [Speed 1] – [Speed 5] set by “Aux. 814 Fast Check”. The speed can be changed
when motor power is ON and DEADMAN on the rear of the teach pendant is pressed.

For the default setting, releasing DEADMAN resets the speed to 1 (see 3.1). Moreover, the
speed returns to 1 regardless of the setting of Aux. 814 when motor power turns OFF.

2.3.1 SPEED DISPLAY

Current speed, which corresponds to the speed displayed in the check speed display area, is
displayed on the <TEACH/REPEAT> area on the upper left of teach pendant screen.

Check speed display area

<TEACH/REPEAT> area

Figures differ depending on the

setting of Aux. 814.

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E Series Controller 2. Operating Procedure for Check Operation
Kawasaki Robot Fast Check Function Manual in Fast Check Mode

2.4 SECOND STEP: FAST CHECK READY

Press Fast Check key on the teach pendant with the fast check call condition.

The color of the Element instructions display area changes to orange. This condition is called
the fast check ready.

Releasing Fast Check key returns to the fast check call condition.

Fast Check key

Fast check ready

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E Series Controller 2. Operating Procedure for Check Operation
Kawasaki Robot Fast Check Function Manual in Fast Check Mode

2.5 EXECUTION OF FAST CHECK MOTION

With the motor power ON and the fast check ready, pressing CHECK GO/CHECK BACK
together with DEADMAN on the rear of teach pendant enables check operations at the set speed.

！ WARNING

Before pressing CHECK GO/CHECK BACK and executing fast check

motion, confirm safe conditions thoroughly such as the following: no one
is inside the motion range, there is no object which interferes with robot
motion, no backlash is found on tool mounting, etc.

！ WARNING

If abnormal circumstances occur on robot during the fast check motion,

release CHECK GO/CHECK BACK immediately, release DEADMAN
or press EMERGENCY STOP.

[ NOTE ]
Pressing CHECK GO or CHECK BACK in the fast check call
condition displays the message “Press First Check key.” and the fast
check motion cannot be executed.

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E Series Controller 3. Auxiliary Function
Kawasaki Robot Fast Check Function Manual

3.0 AUXILIARY FUNCTION

This chapter describes the auxiliary function used for the setting of fast check operation.

3.1 AUXILIARY FUNCTION 814 FAST CHECK MODE

Here, speeds corresponding to check motion speeds 1 to 5 in fast check mode are set as [Speed 1]
to [Speed 5], respectively. It is possible to set the percentage of repeat speed when executing
check operations.

[Speed 1] cannot exceed 250 mm/s, which cannot be changed. [Speed 2] can be set within 1 to
30 % and [Speed 3] to [Speed 5] within 1 to 100 %. However, the set speeds must be [Speed 2]
≦[Speed 3]≦[Speed 4]≦[Speed 5]. The initial values of each check speed are shown in the
above screen.

The speed is set to Speed 1 when DEADMAN is released.

The check speed is reset to Speed 1 when DEADMAN is released by default. The check speed
is kept without resetting to Speed 1 even if DEADMAN is released if [Set speed 1 on deadman
switch off.] is set to [Disable].

！ WARNING

When [Set speed 1 on deadman switch off.] is set to [Disable], robot’s check
motion speed is kept unless motor power turns OFF or mode changes even if
DEADMAN is released. Check the check speed before executing fast check
motion. Furthermore, first change this setting to [Enable] before getting
away from the robot.

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E Series Controller 4. Dedicated Signal
Kawasaki Robot Fast Check Function Manual

4.0 DEDICATED SIGNAL

Fast check function enables to output the signal which shows the robot is in fast check mode to
the outside. Allocate the software dedicated signal to the general-purpose signal. (Refer to
“External I/O Manual” for details.)

Dedicated output signal

Signal name Function Signal type
FAST CHECKING Informs outside that the robot is in fast check mode
(100%/TEACH/REPEAT switch is set to “100 %”.).

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E Series Controller 5. Errors Specific to Fast Check Function
Kawasaki Robot Fast Check Function Manual

5.0 ERRORS SPECIFIC TO FAST CHECK FUNCTION

The following errors are specific to the fast check function.

E1368 “Mode was changed from Teach to Fast Check during robot operation.”

Content
Robot stopped because the mode was changed from teach mode to fast check mode during
teach/check motion.

Cause
Mode was changed from teach mode to fast check mode during teach/check motion.

Countermeasures
Robot is operable by resetting the error, changing to the desired mode and turning ON the motor
power. Do not change the mode while robot is moving.

E1376 “Mode was changed from Fast Check to Teach during robot operation.”

Content
Robot stopped because the mode was changed from fast check mode to teach mode during fast
check motion.

Cause
Mode was changed from fast check mode to teach mode during fast check motion.

Countermeasures
Robot is operable by resetting the error, changing to the desired mode and turning ON the motor
power. Do not change the mode while robot is moving.

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E Series Controller
Kawasaki Robot Fast Check Function Manual

MEMO

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 KAWASAKI ROBOT E Series Controller
Fast Check Function Manual

June 2009 : 1st Edition

Publication : KAWASAKI HEAVY INDUSTRIES, LTD.

90210-1256DEA

Copyright © 2009 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.