ZDT-DP 1.

1 SETUP PROCEDURE

Robot Controller Setup – Start

SET CLOCK - START
· Correct Robot Controller date and time if needed – To arrive at the SYSTEM > Clock Menu - select
[MENU] à “0”, Next à “6”, System à [TYPE] à “1”, Clock
o From here press the [ADJUST] button à then cursor over the values that need to be adjusted
o Once Completed press the [FINISH] button

SET CLOCK – END

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BACKUP CONTROLLER - START

· Backup controllers, before making any changes
o Get Image Backup of Robot Controller
o Get “Backup All” of Robot Controller
· Get Screenshot of STATUS > Memory Screen
· Before proceeding make sure that the media device you are using to store this screen shot
on is selected
· STATUS > [TYPE] à Memory

Press [FCTN] Button and select “Print Screen”

· Copy Image files and MD files to Laptop

BACKUP CONTROLLER – END

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PERFORM AUTO-UPDATE– START

· Perform Auto-Update (15-30min)

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 ZDT-DP 1.1 SETUP PROCEDURE

Check that the variable $SHELL_WRK.$CUST_NAME found in:

MENU à SETUP à TYPE à PROG SELECT, highlight “Program select mode: OTHER” à DETAIL
is still set to MAIN. If variable is blank, set to MAIN.

PERFORM AUTO-UPDATE – END

LOADING ZDT SYSTEM CUSTOMIZATION – START

· Verify Version of System Custo you will be loading, by looking at the currently loaded version of core
from the MENU > UTILITIES >Hints Screen
o Currently FAC Supports Only – Handling Tool V7.70/P46
o If software version on your robot DOES NOT MATCH a version from above or you do not
have that version on your load media DO NOT LOAD – Make a note of the F# and Station
Number for that unit and report that back to FAC or load the correct version on your load media
and begin loading.

· Install customization (ZDT) (2-3 minutes)

o Insert media with customization software into controller
o Go to CTRL START. How to go to CONTROLLED START:
· While CYCLING POWER on the Robot press and hold [PREV] and [NEXT]
simultaneously.
· Once the “Configuration Menu” appears (below)

· Select “3” – Controlled Start - and then [ENTER]

· Once Boot-up has completed proceed to the next steps.
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 ZDT-DP 1.1 SETUP PROCEDURE

o Press [MENU] > S/W INSTALL

o Select Load Media source
o Select <Customization> and [ENTER]

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 ZDT-DP
ZDT
ZD T DP 1.1
1.1 SETUP
SET
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UP PROCEDURE
PRO
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HandlingTool

· Check messages on TP screen for install problems

· Check alarm log for error messages

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 ZDT-DP 1.1 SETUP PROCEDURE

· Go to cold start – From Controlled Start press [FCTN] key and select “1” Start (Cold)

LOADING ZDT SYSTEM CUSTOMIZATION – END

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 ZDT-DP 1.1 SETUP PROCEDURE

SETUP ZDT – START

Additional Custo files – START

1. Insert Custo media

2. Go to the [FILE] menu
3. DIR *.*
4. Cursor to and select custom_fin.cm (under cust_support_files folder)
5. Press [ENTER] and Confirm execution of the CM file.
6. Load MAIN_TEMPLATE.TP
7. Load STYLE25.TP

Additional Custo files – END

MAIN.TP Modification – START

Inserting ZDT Diagnostic Program calls in loop

o In MAIN.TP or equivalent main program, insert the following highlighted lines to Main .tp:

The lines to be inserted can be copied from the program main_template.tp

Example1
47: !------------------------------- ;
48: LBL[20:Exec Style] ;
49: !------------------------------- ;
50: ;
51: DO[211:In Cycle]=ON ; Insert
52: ;
53: ! Start ZDT Program ;
54: CALL START_ZDT ;
55: ;
56: ;
57: !Add all style programs required ;
58: !by application here. ;
59: SELECT R[50:Style No]=1,CALL STYLE001 ;
60: =2,CALL STYLE002 ;
61: =3,CALL STYLE003 ;
62: =22,CALL STYLE022 ;
62: =25,CALL STYLE025 ;
63: =42,CALL STYLE042 ;
64: =181,CALL STYLE181 ;
65: =182,CALL STYLE182 ;
66: =185,CALL STYLE185 ;
67: =186,CALL STYLE186 ;
68: =199,CALL STYLE199 ;
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69: =242,CALL STYLE242 ;
70: ELSE,JMP LBL[900] ;
71: ;
72: DO[211:In Cycle]=OFF ;
73: ; Insert
74: ! Stop ZDT Program ;
75: CALL STOP_ZDT ;

Example 2

44: !**************************** ;
45: !ROBOT STYLE SELECT ;
46: !**************************** ;
47: ;
48: !Start ZDT Program; ;
49: CALL START_ZDT ;
50: ;
51: SELECT R[50:Style No]=0,JMP LBL[1003] ;
52: ;
53: !STYLE01 ;
54: !PICK AUTO CONV, PROCESS, ;
55: !WASH, DRY AND PLACE AUTO CONVER ;
56: =1,CALL STYLE01 ;
57: ;
58: !STYLE25 ;
59: !Robot Condition ;
60: =25,CALL STYLE25 ;
61: ;
62: !STYLE181 ;
63: !HOME TO MAINT ;
64: =181,CALL STYLE181 ;
65: ;
66: !STYLE182 ;
67: !MAINT TO HOME ;
68: =182,CALL STYLE182 ;
69: ;
70: !**************************** ;
71: !MAKE SURE PLC REQUESTS A ;
72: !VALID STYLE ;
73: !**************************** ;
74: !If Else then Style Invalid ;
75: ELSE,JMP LBL[1003] ;
76: ;
77: !Stop ZDT Program; ;
78: CALL STOP_ZDT ;
79: ;
80: !RETURN TO STYLE SELECT ;
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 ZDT-DP 1.1 SETUP PROCEDURE

If MAIN does not look like any of the above examples, you will have to read through the
program and put the relevant code in the equivalent places.
Just prior to going into the STYLE selection place the
!Start ZDT Program; CALL_START_ZDT
Amongst the STYLE list place the
!STYLE25; Robot Condition; =25,CALL STYLE25 ;
And right after any STYLE has been called and completed, make sure that
!Stop ZDT Program; CALL STOP_ZDT ;
is called.

Once all edits have been completed, DELETE the program MAIN_TEMPLATE.TP

MAIN.TP Modification – END

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 ZDT-DP 1.1 SETUP PROCEDURE

· Create Condition Monitoring Program:

Base location (and program) must be confirmed at each robot. Motion during this program must be
collision-free and not damage robot, tooling, or dress. Base location can be Home or maintenance position,
if they meet the criteria.
o MENUS à 1 UTILITIES à Robot Condition
o move robot to a safe position that facilitates collision free motion (within a limited range)
o record position
o setup range of motion at this position (typically +/- 10 degrees,
but can be be shifted, ex. -5 to 15 degrees)
o Switch to AUTO or T2, Set OVERRIDE = 100%, reset faults
o Robot must be in Local control: SYSTEM à CONFIG à
Remote/Local setup: Local
o press CREATE [F2] to create program

Note : For systems with two groups, you must disable motion or machinelock both group 1 and group 2
in order to create the DIAG program:
MENU à TEST CYCLE à Group Motion: Disable
GROUP à 2
Group Motion: Disable

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 ZDT-DP 1.1 SETUP PROCEDURE
o Run Condition Monitoring Program (DIAG1) at 100% T2 or in Auto
o Once the program is created, remove machinelock and re-enable Group 1 and 2 if disabled
o Jog DIAG1 and make sure that the unit clears all obstruction
o If robot path needs to be adjusted, adjust limits and recreate program again. Reasons that
program may need to be adjusted:
· If DCS I/O Connect is the only thing used please BLOCK THE LIGHT SCREEN
WHILE TESTING THE PATH.
· Path Interferes with DCS Zones: If the robot is loaded with DCS Pos Speed
Check – Verify that the DIAG1 path can run without posting an “Unsafe”
condition (also break light curtain while running) as seen on the left screen shot
below.
o If an “Unsafe” condition is realized make appropriate adjustments on the
affected axis – re-teach base position, limit amount of motion to one
direction or the other (example: Min = -20 / Max = +0) based on where
the violation occurs.

· If the DIAG1 path causes collisions or disturbance excess warnings – due to

aggressive motion - adjust the following to relieve condition – DO NOT LEAVE
THE PATH RUNNING AT THIS STATE.

Re-teach Base Position to relieve affected axis (example: J3 is ~90

degrees from floor – then adjust angle lower when teaching the Base
Position)
o Adjust speeds in the path as a LAST RESORT (example: Below – DO
NOT ADJUST THE “PREMOVE” or “MIN” move at all) please make
note of that unit and report to FAC.

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o Once the program has been verified run the program in Auto or T2 at 100% override speed.
· Run program 5 times at 100% prior to setting baseline
o Master / Record Baseline after running DIAG1 as directed above (this should be completed
only after running the robot at 100% Override Speed in auto or from T2).
· This is done at the MENU > “0”, “4” - STATUS à[TYPE] à Robot Condition
· After pressing the [MASTER] F-key
· If all axis need to be Mastered / Baseline Set then you will be prompted to type in
(-1) [ENTER]
· If only one axis needs to be Mastered / Baseline Set then only select the axis to be
set “#”, [ENTER] (# = 1 – 6)

o Once baseline is set the robot runs an analysis each time the Condition Monitor program runs.
o Return Robot to Remote control:
SYSTEM à CONFIG à Remote/Local setup: Local

SETUP ZDT – END

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FLIGHT RECORDER DATA ON MC: AT CONTROLLER – START

· To collect servo off event data please install a Memory Card (provided by FAC)

FLIGHT RECORDER DATA ON MC: AT CONTROLLER – END

ROBOT SETUP - END

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