Kaaa WSK: C Series Controller I/O Interface Mpeiccon28E

Kawasak
C SERIES CONTROLLER
I/O INTERFACE
MPEICCON28E
Kawasak
Kawasaki Robotics (USA), Inc.
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and
is furnished solely for customer use only. No other uses are authorized or permitted
without the express written permission of Kawasaki Robotics (USA), Inc. The contents
of this manual cannot be reproduced, nor transmitted by any means, e.g., mechanical,
electrical, photocopy, facsimile, or electronic data media, without the express written per-
mission of Kawasaki Robotics (USA), Inc.
All Rights Reserved.
Copyright © 1999, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393
The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discon-
tinue specific robot models and associated hardware and software, designs, descrip-
tions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.
This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming procedures,
all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc.
training course.
KAWASAKI ROBOTICS (USA), INC. TRAINING
Training is available from Kawasaki Robotics (USA), Inc. on courses covering operation,
programming, electrical maintenance and mechanical maintenance. These courses are
conducted both on-site at the customer’s location, or at our training facility in Wixom,
Michigan.
For additional information contact:
Kawasaki Robotics (USA), Inc.

Training and Documentation Dept.
28059 Center Oaks Court
Wixom, Michigan 48393
C SERIES CONTROLLER
Kawasak I/O INTERFACE
REVISION HISTORY
Revision Release
Description of Change Initials
Number Date
0 7/6/99 Initial PDF release, based on rev. 3 of print copy KR

Kawasak C SERIES CONTROLLER
I/O INTERFACE
INTRODUCTION
I.0 INTRODUCTION .................................................................................................. I-2

I.1 Hardware Dedicated Signal .................................................................................. I-2
I.2 Software Dedicated Signal ................................................................................... I-2
I.3 General Purpose Signal........................................................................................ I-2
February 20, 1998 I-1

I/O INTERFACE
INTRODUCTION
I.0 INTRODUCTION
When using a robot for various applications, an interlock system with peripheral equip-
ment, a central control of RUN/HOLD, or a safety interlock may be required. To provide
control of these functions, external I/O (input/output) signals are used to send or receive
information to, or from, these external devices. External I/O signals can be classified
into the following three types.
I.1 HARDWARE DEDICATED SIGNAL
Hardware dedicated signals are hard-wired. They are optional and are selectable by the
user. These signals differ from software dedicated signals because they cannot be used
as general purpose signals.
I.2 SOFTWARE DEDICATED SIGNAL
A software dedicated signal can be selected with the multi function panel from the
auxiliary function screens [111 (dedicated input signal) and 112 (dedicated output sig-
nal)] and defined as a dedicated signal.
I.3 GENERAL PURPOSE SIGNAL
General purpose signals are I/O signals which can be selected by the user during pro-
gramming and teaching. They are similar to software dedicated signals, but may be
used for purposes other than those defined by software dedicated signals.
NOTE
The number of system I/O signals is the sum of soft-

ware dedicated signals and general purpose signals.
I-2 February 20, 1998

I/O INTERFACE
SAFETY
1.0 SAFETY ......................................................................................................... 1-2

1.1 Introduction .................................................................................................... 1-2
1.2 Safety Conventions and Symbology .............................................................. 1-3
1.2.1 Warning/Caution Symbols ............................................................................. 1-3
1.3 Personal Safety .............................................................................................. 1-4
1.3.1 Personnel Safety Categories ......................................................................... 1-4
1.3.1.1 Personal Safety .............................................................................................. 1-4
1.3.1.2 Safety During Operation ................................................................................ 1-6
1.3.1.3 Safety During Programming ........................................................................... 1-6
1.3.1.4 Safety During Inspection and Maintenance ................................................... 1-7
1.3.2 Safety Features .............................................................................................. 1-8
February 20, 1998 1-1

I/O INTERFACE
SAFETY
1.0 SAFETY
1.1 INTRODUCTION
Safety is an important consideration in the use of automated and robotic equipment in

the industrial environment. All operators, maintenance personnel, and programmers
must be aware of all automated equipment, peripheral and robotic equipment that occu-
pies the work cell, and their associated operational and maintenance procedures. For
this reason it is recommended that all personnel who operate, maintain, and program
Kawasaki robots, attend a Kawasaki approved training course that would be pertinent to
each employee’s specific job responsibilities.
The following safety sections in this text are designed to support and augment existing
safety guidelines that may be in use in your plant, and/or are provided by municipal,
state, or federal governments, but are NOT designed to supplant or supersede any
existing rules, regulations, or guidelines that may be in use. Because safety is the
primary responsibility of the user, owner, and/or employer, Kawasaki recommends that
specific safety guidelines and recommendations be adopted from groups or individuals
that are professionals in safety design and implementation.
Two recommended sources for national and federal safety laws and regulations include:
1. OCCUPATIONAL SAFETY AND HEALTH STANDARDS, available from: DEPART-

MENT OF LABOR, WASHINGTON, D.C.
2. AMERICAN NATIONAL STANDARD FOR INDUSTRIAL ROBOTS AND ROBOT

SYSTEMS-SAFETY REQUIREMENTS (ANSI/RIA R15.06-1992), available from:
AMERICAN NATIONAL STANDARDS INSTITUTE, INC., 1430 Broadway, New York,
New York 10018
All safety related issues and descriptions, either presented in written or oral form from
any representative of Kawasaki Robotics (USA), Inc., are intended to provide general
safety precautions and procedures and, therefore, are not intended to provide all safety
measures necessary for the protection of all personnel in the work environment.
Kawasaki robots are considered safe for use in industrial environments when all safety
guidelines are adhered to. Adherence to the safety guidelines for safe robot operation
and the protection of personnel and equipment is the responsibility of the end user.
1-2 February 20, 1998

I/O INTERFACE
SAFETY
1.2 SAFETY CONVENTIONS AND SYMBOLOGY
1.2.1 WARNING/CAUTION SYMBOLS
The following symbol is present in all Kawasaki Robotics (USA), Inc. documentation to
signify to the user that proper guidelines, as set forth in the text, are designed to provide
pertinent information for the protection of personnel:
! WARNING
This warning symbology is used in all Kawasaki Robot-
ics (USA), Inc. documentation to identify processes or
procedures, that if not followed properly, may result in
serious injury or death to personnel.
The following symbol is present in all Kawasaki Robotics (USA), Inc. documentation to
signify to the user that proper guidelines as set forth, are designed to provide pertinent
information for the protection of robotic related equipment:
! CAUTION
This caution symbology is used in all Kawasaki Robot-
ics (USA), Inc. documentation to identify processes or
procedures, that if not followed properly, may result in
damage to robotic or peripheral equipment.
February 20, 1998 1-3

I/O INTERFACE
SAFETY
1.3 PERSONAL SAFETY
1.3.1 PERSONNEL SAFETY CATEGORIES
Personnel safety can be described in one of four categories:
• Personal safety.
• Safety during operation.
• Safety during programming.
• Safety during inspection and maintenance.
A description of each follows in this section.
1.3.1.1 PERSONAL SAFETY
Safety procedures must be an integral part of operational procedures for the operator,
programmer, and maintenance person. These procedures must be followed explicitly
and on a regular basis. If consistent safety procedures are followed on a daily basis,
they should become a regular part of everyday operational procedures which are de-
signed to protect the user. Some guidelines are presented in brief in the following sec-
tion:
• Before operating or maintaining the robot or robot controller, be sure you fully un-
derstand and comprehend all maintenance, operating and programming proce-
dures, and ensure that all safety related precautions are taken and complied with
before these procedures are attempted.
• Avoid wearing loose clothing, scarves, wrist watches, rings, and jewelry when work-
ing on the controller and robot. It is also recommended that if ties must be worn in
your shop environment, that they be the clip-on variety, rather than tied ties.
• Always wear safety glasses or goggles and approved safety shoes for your shop
conditions. Follow all applicable OSHA, NIOSHA, MHSA, local, state, federal, and
plant safety specifications and procedures.
• Know the entire work cell or area that the robot occupies.
• Be aware of the entire work envelope of the robot and any peripheral devices.
• Locate all emergency stop buttons or switches.
1-4 February 20, 1998

I/O INTERFACE
SAFETY
• Avoid trap points in which personnel could become trapped between a moving
device and any stationary devices.
• Personnel should never enter the work envelope during automatic operations.
• Ensure that all personnel are clear of the work envelope before initiating any motion
commands for the robot.
• Before initiating any motion commands, KNOW beforehand how the robot will per-
form when that command is given.
• Be sure that the entire work area is free of any debris, tools, fixturing, lubricants,
and cleaning equipment before operation of the robot is attempted.
• If any personnel observe unsafe working conditions, report them immediately to

your supervisor or plant safety coordinator.
• All personnel should identify by name and function all switches, indicators, and
control signals that could initiate robot motion.
• Never defeat, render useless, jumper out, or bypass any safety related device,
whether mechanical or electrical in design.
• All safety devices approved for use in your plant must be properly installed and
maintained to ensure personnel safety.
• NEVER attempt to stop or brake the robot during operation with your body or per-
son. In case of an emergency, utilize E-stops to stop robot motion.
February 20, 1998 1-5

I/O INTERFACE
SAFETY
1.3.1.2 SAFETY DURING OPERATION
• During operation of the robot, identify the maximum reach of the robot in all direc-
tions, which is referred to as the work envelope.
• Always keep your work area clean and free of any debris which includes, but is not
limited to, oil, water, tool, fixturing, electronic test equipment, etc.
• During operations that involve the multi function panel (MFP) or small teach pen-
dant, the only person allowed in the work envelope is the teacher, or the person
operating the multi function panel or small teach pendant. The MFP and small
teach pendant have safety provisions to protect the operator; including E-Stop,
trigger, and deadman switches.
• Never block the operator’s path of retreat.
• During the teach operation of the robot always have a path of retreat planned.
• AVOID pinch points.
1.3.1.3 SAFETY DURING PROGRAMMING
• During operation of the robot, be sure you are able to identify the maximum reach of
the robot in all directions, which is referred to as the work envelope.
• During teach operations the only person allowed in the work envelope is the
teacher, or the person operating the MFP or small teach pendant. The MFP and
small teach pendant have safety provisions to protect the operator; including E-
Stop, trigger, and deadman switches.
• AVOID pinch points.
• During point-to-point playback operations, be aware that the robot is only cognizant
of its present location and the next point it is requested to move to. It will execute
this move with total disregard to what may lie in its path when the move is executed.
• Playback accuracy and speed can affect the geometry of the path coordinates.
Therefore, when changing accuracy or speed, always test run the program at a slow
speed, or point-to-point mode before attempting the continuous path operation in
the repeat mode.
• ALWAYS test run a new path program at a reduced speed, or in point-to-point mode
prior to attempting a high-speed playback operation in the repeat mode.
1-6 June 25, 1999

I/O INTERFACE
SAFETY
1.3.1.4 SAFETY DURING INSPECTION AND MAINTENANCE
Before entering the work envelope to perform either inspection or maintenance proce-
dures, turn off three-phase power on the disconnect and tag and lock-out the disconnect
switch.
! WARNING
The input side (top) of the controller disconnect may still
be live when the controller disconnect is turned OFF. If
work is to be performed at the controller disconnect
switch, turn OFF the three phase power at the source,
and tag and lock-out the source disconnect.
• When removing an axis motor, be aware that the axis will fall if left unsupported.
The brake assembly is in the servo drive motor, therefore, the axis of the robot will
be unsupported if removed.
• When using the axis brake release switches in the controller, be aware that the axis
may fall if left unsupported.
• Before working on pneumatic or high pressure water supplies, turn off supply pres-
sure and purge all lines to remove any residual pressure.
• Assign only qualified personnel to perform all maintenance procedures.
• Consult all available documentation before attempting any repair or service proce-
dures.
• Use only replacement parts approved by Kawasaki Robotics (USA), Inc.
• Before attempting to adjust or repair a device in the robot controller that may have
yellow interlock control circuit wires attached, locate the source of the power and
remove it by disconnecting the appropriate disconnect at its source.
• During inspection and maintenance procedures, if your installation is equipped with

safety fences and safety plugs, remove and hold the safety plug while performing
these operations. In addition, the safety procedures outlined above should be
adhered to.
February 20, 1998 1-7

I/O INTERFACE
SAFETY
1.3.2 SAFETY FEATURES
To safeguard the user, the Kawasaki robot system is equipped with many safety fea-
tures. Some of these safety items include:
• All E-stops are hardwired.
• The MFP, small teach pendant, and operation panel are equipped with red mush-
room-type detented E-stop push buttons. If an optional interface panel is installed,
the E-stop from the operation panel is relocated to the optional interface panel.
• Robot velocities are constantly monitored by software. Should an overvelocity

condition be detected, the robot will fault in a velocity error condition.
• Teach velocities and check mode velocities are limited to a maximum of 250 mm/
sec (9.84 in/sec).
• The JT1 (R-axis) is equipped with overtravel limit switches (U series mechanical
units only).
• All robot axes have software limits.
• All U and F-series mechanical units have overtravel hardstops on the JT1, JT2, JT3,
and JT5 axes.
• All robot axes are monitored by the robot controller for velocity and deviation errors.
• All robot axes are equipped with 24 VDC electromechanical brakes. Should the
robot lose line power, the robot arm will not drop because the brakes are engaged
when power is off at the robot controller.
1-8 June 25, 1999

I/O INTERFACE
I/O SIGNALS
2.0 I/O SIGNALS ................................................................................................. 2-2

2.1 Hardware Dedicated Signals ......................................................................... 2-2
2.2 Software Dedicated Signals ........................................................................... 2-5
2.2.1 Software Dedicated Input Signals .................................................................. 2-6
2.2.2 Software Dedicated Output Signals ............................................................... 2-7
2.3 General Purpose I/O Signals ......................................................................... 2-9
2.3.1 Types of General Purpose Signals............................................................... 2-10
2.3.2 I/O Timing of General Purpose Signals........................................................ 2-10
2.3.2.1 I/O Timing for Block Step Programs ............................................................. 2-10
2.3.2.2 I/O Timing Using AS Language.................................................................... 2-13
February 20, 1999 2-1

I/O INTERFACE
I/O SIGNALS
2.0 I/O SIGNALS
2.1 HARDWARE DEDICATED SIGNALS
The primary purpose of hardware dedicated signals is to function as external remote

control signals. These signals can be selected by making connections to the 1HP board
via terminal block number two (TB2) (refer to section 3.1).
The following hardware dedicated signals are available:
Input
1) External Control Power ON/OFF

2) External Motor Power ON
3) External Motor Power OFF
4) External HOLD
Output
1) TEACH/REPEAT Switch Output

2) Emergency Stop Switch Output
! WARNING
The external control power ON/OFF signal, switches
control power only. Prior to performing control panel
maintenance, ensure the main breaker is OFF.
2-2 February 20, 1998

I/O INTERFACE
I/O SIGNALS
or Leading edge trigger
or Trailing edge trigger
Level trigger (active high)
Level trigger (active low)
Pulse trigger (specified duration)
Figure 2-1 Signal Types
! WARNING
External motor power ON must be precisely set for a
duration of 0.3 ~ 0.5 seconds. If the duration is too
short, the signal may not be recognized. Ensure exter-
nal motor power ON is not applied continuously. In this
case, if an emergency stop is applied, motor power is
reapplied as soon as the emergency stop switch is re-
leased.
February 20, 1999 2-3

I/O INTERFACE
I/O SIGNALS
Table 2-1 Hardware Dedicated Signals
Signal Name Signal Type Description
External Control This +24 VDC signal sets control power ON.
Power ON/OFF When removed, control power is set to OFF.
There is a wait time of 2~3 seconds before the
next ON signal can be effectively applied.
External Motor When applied for 0.3~0.5 seconds, motor

Power ON power is set to ON.
External Motor When applied, control power is set to OFF.

Power OFF
NOTE
This signal should not be used as an external
emergency stop. It is recommended that a
safety door with a safety plug be used for
emergency stops.
External HOLD This signal temporarily stops repeat operation
of the robot (when in the repeat mode), and
maintains the "cycle start" state. When this
signal is applied, the robot continues its motion
from the point where it stopped.
TEACH/REPEAT This signal originates at the TEACH/REPEAT

Switch Output switch on the operation panel. The signal is
active (high) when the switch is set to the
TEACH position.
EMERGENCY This signal originates at the EMERGENCY

STOP Switch STOP switch on the operation panel, multi-
Output function panel, or small teach pendant. This
signal is active (low) when the EMERGENCY
STOP switch is pushed.
2-4 February 20, 1998

I/O INTERFACE
I/O SIGNALS
2.2 SOFTWARE DEDICATED SIGNALS
! WARNING
Software dedicated signals are defined and operated on
via AS system software. Safety interlocks must not be
accomplished using only software. Other hardware
methods must be used (e.g., using a limit switch).
Software dedicated signals can be used for external remote control and interlock con-
figuration. Once defined by the operator, software dedicated signals use a portion of the
total system I/O signals, which includes hardware and general purpose signals. There
are 32 input and 32 output channels per 1GW board. Up to four 1GW boards can be
used, for a total of 128 input and 128 output channels. The number of available general
purpose signals decreases as additional software dedicated signals are defined. Soft-
ware dedicated signals and general purpose signals function in the same way.
NOTE
Ensure that defined software dedicated signals do not

conflict with hardware dedicated signals. Refer to unit 3,
“Connection of External I/O Signals”.
Software dedicated signals can be assigned by:
1) Using auxiliary functions 111 (dedicated input signal) or 112 (dedicated output
signal), refer to the C Series Controller Operations and Programming manual.
or
2) Using the DEFSIG command, refer to the C Series Controller AS Language Refer-
ence Manual.
June 25, 1999 2-5

I/O INTERFACE
I/O SIGNALS
2.2.1 SOFTWARE DEDICATED INPUT SIGNALS
Table 2-2 Software Dedicated Input Signals
Signal Name Signal Type Description of Function
External Motor Externally switches motor power to ON.

Power ON Performs the same function as the MOTOR
(EXT_MOTOR_ON) POWER switch on the operation panel.
External Error Reset Externally resets an error condition.
(EXT_ERR_RESET) Performs the same function as the ERROR
switch on the operation panel.
External Cycle Start Externally selects cycle start. Performs the
(EXT-C/S) same function as the CYCLE START switch
on the operation panel.
RPS-ON At an auxiliary data "END" taught point, this
signal is used to select execution of a
program changeover, according to an
external program number.
(refer to Appendix A.2)
JUMP-ON At an auxiliary data "JUMP" taught point,
this signal is used to select execution of a
program changeover, according to an
external program number.
JUMP-OFF At an auxiliary data "JUMP" taught point,
this signal disables selecting execution of a
program changeover. The current program
continues.
External Program This signal selects an external program
Number number. Up to 99 programs can be
(RPSxx) selected. (refer to Appendix A.2)
External Program This external signal causes a cycle stop and
Reset resets the main program to the first step.
(EXT_PGM_RESET) When this signal is input, with RPS (random
program selection) mode enabled, the
external program number is read and reset
to the first step.
(Refer to appendix A.2)
2-6 February 20, 1998

I/O INTERFACE
I/O SIGNALS
2.2.2 SOFTWARE DEDICATED OUTPUT SIGNALS
Table 2-3 Software Dedicated Output Signals

Motor Power ON Indicates that motor power is set to ON, and
(MOTOR_ON) performs the same function as the signal that
indicates motor power on via the control panel.
Error Occurrence Indicates an error condition, and performs the

(ERROR) same function as the signal that indicates an
error via the control panel.
AUTOMATIC Indicates the operating state of the robot (with the

(AUTOMATIC) HOLD/RUN switch set to RUN). The following
status information is transmitted:
1) external HOLD
2) input signal OFF
3) repeat mode
4) cycle auto mode
5) step auto mode
6) TEACH LOCK OFF
7) cycle start
8) RGSO ON
9) dryrun OFF
In Repeat (C/S) Indicates that the controller is in the repeat mode

(during cycle start), and performs the same
function as the signal that indicates cycle start on
the control panel.
Teach mode Indicates that the controller is in the teach mode,
(TEACH) when the TEACH/REPEAT switch on the
operation panel is set to TEACH.
Home Position 1 Indicates that the robot is in the first home

(HOME_POS1) position.
February 20, 1999 2-7

I/O INTERFACE
I/O SIGNALS
Table 2-3 Software Dedicated Output Signals (continued)

Home Position 2 Indicates that the robot is in the second home
(HOME_POS2) position.
(refer to Appendix 3)
Power ON Indicates that control power is set to ON, and
(POWER_ON) performs the same function as the signal that
indicates that control power is on via the control
panel.
RGSO Indicates that the servo motor brake is released.
External Indicates that the program selection mode is valid

Program (RPS valid).
Selection valid (refer to Appendix A.2)
(RPS)
RPS-ST Indicates that the robot is at the auxiliary data END
taught point of the external program.
JUMP-ST Indicates that the robot is at the auxiliary data
JUMP taught point of the external program.
2-8 February 20, 1998

I/O INTERFACE
I/O SIGNALS
2.3 GENERAL PURPOSE I/O SIGNALS
General purpose I/O signals are assigned during teaching or programming. In repeat
mode, when executing a program, these signals are sent to, or received from, external
devices. General purpose signals function similarly to software dedicated signals. Soft-
ware dedicated signals are assigned prior to program creation and are used for specific,
commonly used functions. General purpose signals can be assigned for any desired
external function.
! WARNING
When using general purpose signals for safety inter-
locks, ensure additional physical safety procedures are
also used.
! CAUTION
When assigning general purpose signal numbers and
functions, ensure they are not duplicates of those previ-
ously assigned as hardware or software dedicated sig-
nals, or other general purpose signals. If duplicate as-
signments are made, the conflict may cause the control-
ler to function unpredictably.
February 20, 1999 2-9

I/O INTERFACE
I/O SIGNALS
2.3.1 TYPES OF GENERAL PURPOSE SIGNALS
There are two types of general purpose I/O signals, external and internal. This section
addresses external I/O signals only. For information about internal I/O signals, refer to
unit five of this manual and the C Series Controller AS Language Reference Manual.
External I/O signals include both software dedicated signals and general purpose sig-
nals. When determining general purpose signal requirements, remember that the total
number of assignments includes software dedicated signals.
NOTE
Expansion of external I/O signals is made in increments

of 32 input and output channels, based on the physical
configuration of the 1GW board.
2.3.2 I/O TIMING OF GENERAL PURPOSE SIGNALS
The I/O timing of general purpose signals is dependent on the method of robot opera-
tion (teaching or programming). It is important to understand the differences in I/O
timing between these two methods.
2.3.2.1 I/O TIMING FOR BLOCK STEP PROGRAMS
When teaching the robot, using the MFP or small teach pendant, the following informa-
tion is recorded for each step:
1) robot joint angle

2) motion auxiliary data (interpolation mode, speed, accuracy, and tool)
3) clamp data
4) general purpose I/O signals
This method of programming is called “block step” programming. When performing

block step programming, taught general purpose signals are designated OX (output)
and WX (input). The I/O timing to execute OX and WX signals when the taught program
is executed is shown in figure 2-2.
2-10 June 25, 1999

I/O INTERFACE
I/O SIGNALS
NOTE
Timing of advancement to the next step occurs when

the robot arrives at the taught step. This does not nec-
essarily coincide with the taught point. This variation
depends on the accuracy data taught at the step. The
finer the accuracy, the closer to the taught point that ad-
vancement occurs.
Step 7 8 9 10
Robot Motion
wait
OX5
OX6
WX3
WX3
Figure 2-2 System Switch OX.PREOUT ON
OX5: Taught in step 8.
1) When the robot reaches the accuracy range of step 7 and moves toward the point
taught in step 8, OX5 is set to ON.
taught in step 9, OX5 is set to OFF because OX5 is not taught in step 9.
February 20, 1999 2-11

I/O INTERFACE
I/O SIGNALS
OX6: Taught in step 8 and 9.
taught in step 8, OX6 is set to ON.
taught in step 9, OX6 stays ON because it is also taught in step 9.
NOTE
Normally, upon arriving at the accuracy range of step 9,

the robot would move toward the point taught in step 10,
and OX6 would immediately be set to OFF (because it
is not taught in step 10); however, in this example, the
controller is waiting to receive WX3 (taught in step 9).
Step 9 is not completed until WX3 is received.
3) When WX3 is received OX6 is set to OFF.
WX3: Taught in Step 9.
1) Upon arriving at the accuracy range of the point taught in step 9, the robot waits
until WX3 is received.
2) When WX3 is received, the robot moves toward the point taught in step 10.
NOTE
When the robot is stopped by setting MOTOR POWER

to OFF, setting CYCLE START to OFF, or setting HOLD/
RUN to HOLD, currently active OX signals are tempo-
rarily set to OFF. When the robot is restarted, these OX
signals are restored to the ON state.
2-12 February 20, 1998

I/O INTERFACE
I/O SIGNALS
2.3.2.2 I/O TIMING USING AS LANGUAGE
In addition to the block step teaching method for assigning general purpose I/O signals
(OX and WX), I/O signals can also be assigned using AS language commands. Using
this programming method, various instructions are available to control input and output
signals (see table 2-4). Refer to the C Series Controller AS Language Reference
Manual for a more detailed explanation of these program instructions.
Table 2-4 AS Language Instructions
Input/Output Instruction Function

Signal Control
Output SIGNAL Sets specified external output signals to ON/OFF.
BITS Arranges signals in a binary pattern and sets signal
states according to the binary equivalent of the
decimal value specified.
RESET Sets all external output signals to OFF.
RUNMASK Allows signals to be ON only while the program is
executing.
PULSE Sets signal to ON for a specified duration.
DLYSIG Sets signal to ON/OFF after a specified delay time.
Input SWAIT Causes program execution to wait until the specified
external I/O signals are set to a given state.
SIG Returns the logical AND of the specified binary signal
states.
BITS Reads consecutive binary signals,and returns the
decimal value corresponding to the binary bit pattern
of the specified signals.
ON/ONI Starts monitoring the specified external input signal,
and when the signal is set to the desired state, calls
the specified subroutine (or jumps to the given label).
June 25, 1999 2-13

I/O INTERFACE
I/O SIGNALS
Timing of general purpose I/O signals using AS Language programming is shown in

figure 2-3.
Example Program:
11 JMOVE #lc1
12 SIGNAL 5,6
13 JMOVE #lc2
14 SIGNAL -5
15 JMOVE #lc3
16 SWAIT 1003
17 SIGNAL -6
18 JMOVE #lc4
#lc1 #lc2 #lc3 #lc4
Robot Motion
wait
OUT5
OUT 6
IN3
(waiting for input)
IN3
Figure 2-3 System Switch PREFETCH.SIGINS OFF
NOTE
For the timing diagram shown in figure 2-3, positioning

accuracy (ACCURACY) is assumed to be fine. When
the accuracy is coarse, transitions occur sooner than
when the robot reaches the actual taught point.
2-14 February 20, 1998

I/O INTERFACE
I/O SIGNALS
OUT5 :
1) When the robot moves toward #1c2, general purpose output signal (OUT5) is set to
ON.
2) After reaching #1c2, the robot moves toward #1c3. and OUT5 is set to OFF.
OUT6:
1) When the robot moves toward #1c2, general purpose output signal (OUT6) is set to
ON.
2) After reaching #1c2, the robot moves toward #1c3, OUT6 remains ON.
3) When the robot moves toward #1c4, OUT6 is set to OFF.
IN3:
1) When the robot moves toward #lc3, the controller begins to monitor universal input
signal IN3.
2) Upon reaching #1c3, IN3 stays OFF and the controller waits for the input.
3) When signal 1003 is received, IN3 is set to ON, the robot moves toward #1c4, and
OUT6 is set to OFF.
NOTE
Normally, if the robot is stopped, OUT signals are not

turned OFF (OX signals are temporarily set to OFF);
however, if a signal is defined with a RUNMASK instruc-
tion, the OUT signal is temporarily set to OFF when the
robot is stopped.
February 20, 1999 2-15

I/O INTERFACE
EXTERNAL I/O SIGNAL CONFIGURATIONS
3.0 EXTERNAL I/O SIGNAL CONFIGURATIONS ................................................. 3-2

3.1 Hardware Dedicated Signals ............................................................................. 3-2
3.1.1 External Control Power...................................................................................... 3-2
3.1.2 External Motor Power ON .................................................................................. 3-4
3.1.3 External EMERGENCY STOP .......................................................................... 3-6
3.1.4 External HOLD .................................................................................................. 3-8
3.1.5 External TEACH/REPEAT Output ................................................................... 3-10
3.1.6 Safety Fence Input .......................................................................................... 3-11
3.1.7 External Trigger Input ...................................................................................... 3-13
3.2 General Purpose I/O Signals .......................................................................... 3-17
3.2.1 External Input Signals ..................................................................................... 3-17
3.2.2 External Output Signals .................................................................................. 3-19
February 20, 1998 3-1

I/O INTERFACE
3.0 EXTERNAL I/O SIGNAL CONFIGURATIONS
This section describes external I/O hardware, general purpose, and software dedicated
signal configurations.
3.1 HARDWARE DEDICATED SIGNALS
When using hardware dedicated signals, ensure connections are made according to the
information provided in the following sections.
3.1.1 EXTERNAL CONTROL POWER
! CAUTION
Ensure that connection to CN1 pins 1 and 2 is not re-
versed; damage to diode D28 can occur.
CONTROLLER EXTERNAL DEVICE
Switch
or
CN1 TB2 relay contact +24V
CN3-23
1 1
RY5 RY5 D28
2 2
3 3
Do not connect
Contact Position/
4 4
Control Power ON/OFF
closed: ON
1HP board open: OFF
Figure 3-1 External Control Power
3-2 February 20, 1998

I/O INTERFACE
NOTE
The external relay must meet the following specifica-

tions:
Contact Power Capacity: 24 VDC > 0.1 A

Coil: 24 VDC , 10mA +/- 20%
Power Supply: 24 VDC ±10%
Wiring: AWG 22~24
There is a cycle wait time of 2~3 seconds from OFF to

ON for relay RY2 on the 1HP board.
CN1 TB2
CN3-23
1 1
RY5 RY5 D28 Do not connect
2 2
3 3
Jumper
4 4
1HP board
Figure 3-2 External Control Power Disabled
NOTE
The controller is shipped with TB2-3/4 jumpered (exter-

nal control power not used). To use the external control
power capability, ensure the jumper is removed and
connection of the external device to TB2 is configured
as shown in figure 3-1.
February 20, 1998 3-3

I/O INTERFACE
3.1.2 EXTERNAL MOTOR POWER ON
External motor power ON is an external signal used to set the controller motor power to
ON, and performs the same function as the MOTOR POWER ON switch on the opera-
tion panel.
! WARNING
If external motor power ON (contact closed) is applied
when the controller EMERGENCY STOP switch is
pressed, robot motion will resume when the switch is re-
leased.
switch
CN1 TB2 or
relay contact
F2
+24VDC 1A 29 29
R66
PC7 30 30
2.4K
R40
680 D13
Motor Power ON
when switch or relay
1HP board contact is closed
for 0.3~0.5 seconds.
Figure 3-3 External Motor Power ON
3-4 February 20, 1998

I/O INTERFACE
NOTE
The external switch or relay must meet the following

specifications:

Wiring: AWG 22~24
Photo Coupler PC22 is rated at 24 VDC, 10 mA +/-20%.
February 20, 1998 3-5

I/O INTERFACE
3.1.3 EXTERNAL EMERGENCY STOP
External emergency stop is an input signal from an external device that interrupts motor
power. It performs the same function as the EMERGENCY STOP switch on the opera-
tion panel.
CONTROLLER EXTERNAL
Emergency
DEVICE
Stop Emergency
Switch Stop Emergency
(multi function Switch Stop
panel) (control panel) CN1 TB2 Switch
CN2-5
5 5
F1 RY2
0.3A 5 4
+24 VDC 9 6
6 7
CN4-12 R73
PC14 10 8
2.4K
R47 7 9
680 D20
11 10
8 11
CN2-7
12 12
SW1
CN2-12
6 5
+24V
CN4-14
RY2
9 8
1HP Board
Figure 3-4 External Emergency Stop (E-Stop)
NOTE
External switches must meet the following specifica-

tions:

Wiring: AWG 22~24
3-6 September 30, 1998

I/O INTERFACE
Emergency
Stop Emergency
Switch Stop
(multi function Switch
panel) (control panel) CN1 TB2
CN2-5
5 5
F1 RY2 jumper
0.3A 5 4
+24 VDC 9 6
6 7
CN4-12 R73
PC14 10 8
2.4K
R47 7 9
680 D20 jumper
11 10
8 11
CN2-7
12 12
SW1
CN2-12
6 5
+24V
CN4-14
RY2
9 8
1HP Board
Figure 3-5 External Emergency Stop (E-Stop) Disabled
NOTE
When the controller is shipped, motor power cannot be

turned on because TB2-5/6 and TB2-9/10 are not
jumpered. These jumpers must be installed before op-
erating the robot.
June 25, 1999 3-7

I/O INTERFACE
3.1.4 EXTERNAL HOLD
External hold is an external input signal that stops the robot temporarily, and is effective
only when the controller is in the repeat mode.
CN1 TB2 switch

or
relay contact
+24 VDC 17 19
R72
PC13 18 20
2.4K
R46
680 D19
When the switch or relay

contact (between TB2-19/20)
opens, the robot is in the
1HP Board hold mode.
Figure 3-6 External Hold
NOTE
The external switch or relay contact must meet the fol-

lowing specifications:

Coil: 24 VDC , 10mA ±20%
Wiring: AWG 22~24
3-8 June 25, 1999

I/O INTERFACE
CN1 TB2
+24 VDC 17 19
jumper
R72
PC13 18 20
2.4K
R46
680 D19
1HP Board
Figure 3-7 External Hold Not Used
NOTE
When the controller is shipped, the robot is in the HOLD

mode because pins CN3-7/8 are not jumpered. Prior to
operating the robot, the jumper must be installed.
June 25, 1999 3-9

I/O INTERFACE
3.1.5 EXTERNAL TEACH/REPEAT OUTPUT
The external teach/repeat output is provided via TB2-31/32.
repeat teach
CN1 TB2
CN2
19 35 31
Teach: closed
Repeat: open
20 36 32
1HP Board
Figure 3-8 External Teach/Repeat Output
NOTE
The load should not exceed the switch contact specifi-

cation.
Contact specification: 24 VDC, < 0.1A.
3-10 February 20, 1998

I/O INTERFACE
3.1.6 SAFETY FENCE INPUT
The safety fence input signal interrupts motor power and performs the same function as
the external emergency stop (E-stop) signal.
! WARNING
Functional operation of the safety fence switch is ex-
tremely important for the safety of personnel. Ensure
that a mechanical switch is used; semiconductor type
switches should not be used, because they are less reli-
able.
CONTROLLER EXTERNAL
DEVICE
CN1 TB2
CN2-14 safety fence
13 15
R75
PC17 14 16
+24 VDC
2.4K
R50 safety fence
680 D23 15 17
16 18
CN1-24
CN2-17
1HP Board
Figure 3-9 Safety Fence Switches
February 20, 1998 3-11

I/O INTERFACE
CN1 TB2
CN2-14
13 15
jumper
R75
PC17 14 16
+24 VDC
2.4K
R50
680 D23 15 17
jumper
16 18
CN1-24
CN2-17
1HP Board
Figure 3-10 Safety Fence Switches Not Used
NOTE
When the controller is shipped, the jumpers for TB2-15/

16 and TB2-17/18 are not installed; motor power cannot
be set to ON. These jumpers must be installed prior to
operating the controller.
3-12 February 20, 1998

I/O INTERFACE
3.1.7 EXTERNAL TRIGGER INPUT
The external trigger input signal interrupts motor power, and performs the same function
as the EMERGENCY STOP (E-stop) switch on the operation panel.
! WARNING
Functional operation of the external trigger switch is ex-
tremely important for the safety of personnel. Ensure
that a mechanical switch is used; semiconductor type
switches should not be used, because they are less reli-
able.
February 20, 1998 3-13

3-14
CONTROLLER EXTERNAL
DEVICE
TB2
CN1
CN4-16
25 25
Kawasak
R79
PC20
2.4K
+24 VDC R53
680 D26

CN3-5 D6 RY4
5 4 26 26
R57 R80
2.4K P21
2.4K
PC8 R54
680 D27
R41
680 D14
CN3-7 RY4
9 8 27 27
+24 VDC
R69
PC10
2.4K
R43
680 D16
C SERIES CONTROLLER
February 20, 1998
I/O INTERFACE
CN4-17
28 28
1HP Board
Figure 3-11 External Trigger Input

I/O INTERFACE
NOTE
The external switch or relay contact must meet the fol-

lowing specifications:

Coil: 24 VDC , 10mA ±20%
Wiring: AWG 22~24
February 20, 1998 3-15

3-16
TB2
CN1
CN4-16
25 25
R79
Kawasak
PC20
2.4K
+24 VDC R53
680 D26
jumper

CN3-5 D6 RY4
5 4 26 26
R57 R80
2.4K P21
2.4K
PC8 R54
680 D27
R41
680 D14
CN3-7 RY4
9 8 27 27
+24 VDC
R69
PC10
2.4K
R43
680 D16
jumper
C SERIES CONTROLLER
February 20, 1998
CN4-17
I/O INTERFACE
28 28
1HP Board
Figure 3-12 External Trigger Input Not Used

I/O INTERFACE
NOTE
When the controller is shipped, the jumpers for TB2-25/

26 and TB2-27/28 are not installed; motor power cannot
be set to ON. These jumpers must be installed prior to
operating the controller.
3.2 GENERAL PURPOSE I/O SIGNALS
All general purpose I/O signals (including software dedicated signals) are processed by
the 1GW board. For connector CN4 pin assignments, refer to Appendix A.7.
3.2.1 EXTERNAL INPUT SIGNALS
The 1GW board provides the capability to connect 32 input signals. There are two
common connections [IC-1 and IC-2 (CN4 pins 18 and 19 respectively)], each is con-
nected to an external +24 VDC power supply. Each of these +24 VDC inputs provides
power for 16 input circuits. External input signals are connected to pins 1~16 and 20~35
of CN4.
Input Specifications:
Number of Circuits: 32
Input Device: relay contact or photo coupler
Voltage: +24 VDC ±10%
Current: 10mA ±20%
Connector Type: 37 pin D-type
June 25, 1999 3-17

I/O INTERFACE
! CAUTION
Ensure that the polarity of the external +24 VDC power
supply is correct (i.e., +24 VDC connected to pins 18/19
of the 1GW board). If incorrectly connected, damage to
the 1GW board, power supply, and contacts may occur.
CONTROLLER EXTERNAL
DEVICE
CN4 TB
1W ID1 1 1
PC
2.4K
16 16
680
ID16 16 16
NC 17 17 +24 VDC
IC-1 18 18
IC-2 19 19
32
ID17 20 20
1W
PC
16 16
2.4K
680
ID32 35 35
NC 36
NC 37
1GW Board
Figure 3-13 General Purpose Input Signals
NOTE
The terminal block (TB) in figure 3-13 is located on the

controller cabinet door.
3-18 June 25, 1999

I/O INTERFACE
3.2.2 EXTERNAL OUTPUT SIGNALS
There are 32 available output signals from the 1GW board. The +24 VDC external
power supply provides power to the output circuitry via VIN1 (for output signals
OD1~OD16) and VIN2 (for output signals OD17~32). The two commons (OC-1 and OC-
2) provide a ground for the output circuitry for OD1~OD16 and OD17~OD32 respec-
tively.
! CAUTION
Ensure that the correct polarity of the external
+24 VDC power supply is observed when connecting it
to CN2 of the 1GW board. If connected incorrectly,
damage to components on the 1GW board may occur.
Output Specification:
Number of Circuits: 32
Output Type: transistor
Voltage: +24 VDC ±10%
Maximum Load Current: < 0.1A
Connector Type: 37 pin D-type
June 25, 1999 3-19

I/O INTERFACE
! CAUTION
Ensure that surge protection is provided for all inductive
loads (i.e., relay coils, solenoids, etc.).
! CAUTION
It is recommended that the diode installed in parallel
with the load be a Hitachi V06C, or equivalent. Ensure
that proper polarity of this diode is observed. If installed
incorrectly, damage to components on the 1GW board
may occur.
3-20 June 25, 1999

I/O INTERFACE
NOTE
Figure 3-14 represents the portion of the general pur-

pose output circuitry of the 1GW board for outputs OD-
1~OD4. There is identical circuitry for the remaining 28
outputs (OD5~OD32).
CONTROLLER EXTERNAL
DEVICE
+24 VDC
TB
CN2
VIN-1
4700 pf 18 18
U3
ZD4
C3
PC4
1
R52
3 2 OD-1
1 1 load
PC6 12K 1/4W
4
R54
6 7 OD-2
2 2 load
PC9 12K 1/4W
5
R55
11 9 OD-3 3 load
3
PC12 12K 1/4W
12
R53
14 16 OD-4
4 4 load
8 13
12K 1/4W
ZD19
ZD17
ZD20
ZD18
OC-1 36 36
1GW Board
Figure 3-14 External Outputs
NOTE
The terminal block (TB) in figure 3-14 is located on the

controller cabinet door.
June 25, 1999 3-21

I/O INTERFACE
CONNECTION OF EXTERNAL I/O SIGNALS
4.0 CONNECTION OF EXTERNAL I/O SIGNALS .................................................... 4-2

4.1 Connection of Hardware Dedicated Signals ........................................................ 4-3
4.2 Connection of General Purpose Signals .............................................................. 4-7
February 20, 1998 4-1

I/O INTERFACE
4.0 CONNECTION OF EXTERNAL I/O SIGNALS
This section desribes the procedures for connecting external I/O signals. Hardware
dedicated signals are connected to CN1 on the 1HP board via terminal board No. 2
(TB2), located on the lower left side of the controller cabinet. General purpose I/O
signals are connected to CN2 (output signals) and CN4 (input signals) of the 1GW
board via a terminal block (TB) that is mounted to the controller cabinet door.
NOTE
It is recommended that AWG 20 wire be used when

connecting external I/O devices to the controller. En-
sure that the wire is securely fastened to the cabinet us-
ing tie wraps, to prevent stress on the connection to the
terminal block and chafing of the insulation at the point
of entry into the cabinet (access hole on the right side of
the cabinet).
NOTE
Refer to sections 3.1 and 3.2, and Appendix A.7 for a

description of I/O signal pin assignments.
4-2 June 25, 1999

I/O INTERFACE
4.1 CONNECTION OF HARDWARE DEDICATED SIGNALS
! WARNING
There is a risk of electric shock and the possibility of
damage to controller components when connecting ex-
ternal I/O devices. Turn off and tag out the controller
and peripheral equipment main circuit breakers before
making external I/O connections. Do not remove safety
tags and reapply power until connections are com-
pleted.
1) Set primary power to OFF at the controller and external device main circuit break-
ers, and attach safety tags.
2) Remove access hole cover from the right side of the controller (see figure 4-1).
3) Open the controller front door.
4) Strip 8-9 mm of insulation from the end of the wires from the external device.
5) Feed the wires into the controller cabinet through the access hole.
6) Connect the wires to the appropriate connector numbers on the top side of TB2
(see figures 4-2 and 4-3).
7) Secure the wires to the cabinet using tie wraps at its entry into the cabinet, near
TB2, and at intermediate points as required.
8) Close controller cabinet door.
9) Remove safety tags from the controller and external device.
10) Apply power to the controller and external device.
February 20, 1998 4-3

I/O INTERFACE
Access Hole Cover
Figure 4-1 Controller Cabinet (Right Side)
4-4 February 20, 1998

I/O INTERFACE
Card Rack AVR

Power
Grounding Bar Supply
(G1)
F1
1HZ
Power Block
K1 (1GC/1GD)
Servo CPU
C1 (1GB)
F2
Relay
Chassis
K3
1HY
TB2
Figure 4-2 Controller Cabinet (Front View, Door Removed)
June 25,1999 4-5

I/O INTERFACE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Figure 4-3 Terminal Block No. 2 (TB2)
4-6 February 20, 1998

I/O INTERFACE
4.2 CONNECTION OF GENERAL PURPOSE SIGNALS
! WARNING
There is a risk of electric shock and the possibility of
damage to controller components when connecting ex-
ternal I/O devices. Turn off and tag out the controller
and peripheral equipment main circuit breakers before
making external I/O connections. Do not remove safety
tags and reapply power until connections are com-
pleted.
1) Turn off primary power at the controller and external device main circuit breakers,
and attach safety tags.
2) Remove access hole cover from the right side of the controller (see figure 4-1).
3) Open the controller front door.
5) Feed the wires from the external device into the controller cabinet through the
access hole.
6) Connect the wires to the appropriate connector numbers on the TB, located on the
interface relay panel of the controller cabinet door (see figure 4-4).
NOTE
Various components (e.g., TBs, relays, etc.) installed on

the interface relay plate are not included with the stan-
dard controller. These are user supplied components.
The TB configuration shown in figure 4-4 is a Ford
specification. TB configurations may vary, but terminal
number assignments must be made according to sec-
tion 3.2 of this manual.
7) Secure the wire to the cabinet using tie wraps at its entry into the cabinet, near the
TB, and at intermediate points as required. Leave adequate slack to allow full
opening of the door.
February 20, 1998 4-7

I/O INTERFACE
8) Close the controller cabinet door.
9) Remove safety tags from the controller and external device.
10) Apply power to the controller and external device.
SW1
SW2
L1
SW4 SW3
SW6 SW5
Host
115 VAC/3A
MFP
To CR21
External CR22
Devices
Brake From
Release
JT1 3719 1FR
JT2 CN2
Switches
JT3
JT4
W1 To
JT5 1FR
JT6 GND 1 CN4
37 19
JT7
CR31
W2
From CR32
External GND 1
CR33
Devices
Figure 4-4 Controller Cabinet Door (Interior)
4-8 February 20, 1998

I/O INTERFACE
REMOTE I/O AND CONTROLNET
5.0 REMOTE I/O AND CONTROLNET ................................................................... 5-2

5.1 Slogic ................................................................................................................ 5-2
5.2 Remote I/O ........................................................................................................ 5-5
5.2.1 Remote I/O and Slogic Specifications ............................................................... 5-7
5.2.2 Monitor Screens .............................................................................................. 5-13
5.2.3 PLC (NAC) Setting .......................................................................................... 5-22
5.2.4 Weld Control Setting ....................................................................................... 5-23
5.2.4 Slogic Control .................................................................................................. 5-24
5.2.6 Slogic Forced Output ....................................................................................... 5-30
5.2.7 Status Screen .................................................................................................. 5-31
5.3 ControlNet ....................................................................................................... 5-32
5.3.1 ControlNet Specifications ................................................................................ 5-35
June 25, 1999 5-1

I/O INTERFACE
5.0 REMOTE I/O AND CONTROLNET
The C-series controller provides the capability to control remote input/output functions
using Slogic programming with two configurations of the 1FS circuit board. These con-
figurations are the remote input/output (R I/O) and RS-485, and ControlNet.
5.1 SLOGIC
Relay circuitry for the robot interface is reduced by replacing it with the Slogic software
function. Slogic is similar to ladder logic, used with programmable controllers (Table 5-
1). Making signal assignments using Slogic is much easier than making changes on
hardwired systems. For hardwired systems, changes are made by physically making
connections. Using Slogic, changes are made by simply making changes to programs.
Slogic program instructions can be used to specify outputs, timers, and counters. Slogic
program instructions are edited on the 1GA board (main CPU) via the multi function
panel (MFP), and then transferred to the 1FS (R I/O) board, which executes the Slogic
program.
5-2 June 25, 1999

I/O INTERFACE
Table 5-1 Sample Slogic Program Instructions
Ladder Logic Slogic Program Instruction
June 25, 1999 5-3

I/O INTERFACE
The following is an example of the process used to edit the Slogic program using the
user display screen (refer to section 5.2.4).
User Display
>SS “Slogic Stop”
>SU “S Upload” - Upload Slogic from the 1FS board to the 1GA board
to edit the program SPG.
>ED SPG Program SPG can now be edited.
>1 SOUT 301 = 101

>?
>2 SOUT 302 = 101 and 102
>?
>3 SOUT 303 = 101 or 102
>?
>4 SOUT 304 = (-101 and -102) or -103
>?
>5 SOUT 305 = (101 or 103) and (102 or -104)
>?
>6 STIM 2601 = 101, 5.0
>?
>7 SOUT 306 = 2601
>?
>8 SCNT 2701 = 101, 102, 10
>?
>9 SOUT 307 = 2701
>?
>10?E Exit
>SD “S Download” - Download the program from the 1GA to the 1FS to
execute the program.
Password Enter the password
>SR Slogic Run
Editing Slogic
S-STEP# The step number to be edited

I Insert lines before the current step.
D Delete the program step.
O Places the cursor on the current step for editing.
E Exits from the editor to the monitor mode.
5-4 June 25, 1999

I/O INTERFACE
5.2 REMOTE I/O
The remote input/output (R I/O) function is performed by the optional 1FS board (figure
5-1). The RI/O sytem provides Allen-Bradley (A-B) programmable logic controller (PLC)
serial communication, weld control serial communication, and Slogic execution.
The R I/O function provides the status of all signals, including A-B PLC and weld control
serial signals. Internal Slogic signals can be displayed via the MFP.
The R I/O system performs the following functions:
• A-B PLC serial communication is performed by the A-B node adapter chip (NAC).
Robot controllers are daisy chained through the NAC, enabling communication with
the line PLC system. A maximum of 128 I/O channels are available.
• Weld control serial communication is performed by the 1FS board serial I/O func-
tion, which is capable of controlling a maximum of four weld controllers. A maximum
of 16 I/O channels are available for each weld controller.
• The Slogic function is similar to a PLC instruction which uses Slogic instructions for
outputs, timers, and counters. The Slogic instructions are edited on the robot con-
troller through the 1GA board (main CPU), and then transferred to the 1FS board for
execution of Slogic programs.
June 25, 1999 5-5

I/O INTERFACE
G RIO Run
R ControlNet Error
LEDs G ControlNet Run FLASH EPROM
R System Error
G System Run 2 MB 128 KB
DRAM VME Bus

DIP
1 MB Interface
SW P1
SRAM
MPU
4 KB
8
SIO Interrupt
pin µPD72001 Controller
Timer
NAC &
PIO
BNC
C-Net
Controller P2
BNC
FLASH
64 KB
Figure 5-1 1FS Board Functional Block Diagram
5-6 February 20, 1998

I/O INTERFACE
5.2.1 REMOTE I/O AND SLOGIC SPECIFICATIONS
The following are specifications for remote I/O and Slogic functions:
Control method: stored progam (Slogic)
Program size: Approximately 1500 steps (maximum of 72,000 characters).
1. The following example Slogic instruction is considered two steps:
SOUT XXXX=YYYY + 80 comment characters = 96 total characters
2. The following example Slogic instruction is considered three steps:
SOUT XXXX=YYYY AND ZZZZ + 119 comment characters = 144 total characters
Execution cycle time:
1-300 steps 5ms

301-900 steps 10ms
901-1500 steps 15ms
Number of parallel signals:
Standard signals (one 1GW board)
32 I/O channels
24 VDC, 100mA
Optional signals
64 I/O channels (one additional 1GW board)

96 I/O channels (two additional 1GW boards)
128 I/O channels (three additional 1GW boards)
Number of internal signals:
Non-retentive relay 128

Retentive relay 16
Timer 16 (range: 0.1 to 999.9 seconds)
Counter 16 (range: 1 to 9999 counts)
Message display 64
Slogic status 16
June 25, 1999 5-7

I/O INTERFACE
Robot CPU (1GA)

Robot Output 1 ~ 256 OX signals = Robot Output signals 1-256
Robot Input 1001 ~ 1256 WX signals = Robot Input signals 1001-1256
Robot Internal 2001 ~ 2256
1001 ~ 1256 1 ~ 256

PLC Weld
Serial Serial
Input Input
1501 ~ 1564 1601 ~ 1632
1FS Board
Allen-Bradley Weld
PLC *Slogic Functions Controllers
(Internal Signals) (maximum 8)
501 ~ 564 601 ~ 632

PLC Weld
Serial Serial
Output 1301~1428 301~428 901~902 Output
Magnetic relay output

(e.g., Motor Power OFF,
I/O Boards External Hold, etc.)*
(1GW, maximum 4,
optional)
*Slogic Functions (Internal Signals)
Relays: Non-Retentive 2301 ~ 2428

Relays: Retentive 2501 ~ 2516 * In addition to 901 and 902,
Relays: Timers 2601 ~ 2616 an additional magnetic
Relays: Counters 2701 ~ 2716 relay output "SRUN" signal
Slogic Status Signals 2801 ~ 2816 is available. This signal
W/C #1 Not Connected 2801 indicates that Slogic is
W/C #2 Communication Error 2802 running. It does not have
NAC Communication Error 2803 a signal number.
Battery Error 2804
W/C #2 Not Connected 2805
W/C #2 Communication Error 2806
Spare 2807 ~ 2816
Message Display 2901 ~ 2964
Slogic messages must be named $w2901 ~ $w2964.

Refer to the C Series Controller AS Language Reference Manual for
steps to create string variables (e.g., $w2901 = "message").
Signal for Last Weld Current 2965
Figure 5-2 Remote Input/Output and Robot Signal Numbers
5-8 June 25, 1999

CN1 CN2 CN3 S1
June 25, 1999

C-Net BNC Connector C-Net BNC Connector R-I/O and RS485 Connector DIP Switch LD101 LD1 LD2 LD3 LD4 LD5
1 2
S1
CN4
8 CN3
CN1 CN2
ZD1 T1 ZD2 T2
C6
C5 75C140GNS
R10 R11
1FS-71 U102
1 U1 17
C-Net Hybrid-IC
Kawasaki
53 U9 33
9904 HYBO 54 U12
U11
Kawasak
M8M
M8M
X1
FLASH
FLASH
Memory
Memory
29F400TA
29F400TA
System SW
System SW
ALS08 1 CN101 5
CPU
N80960SA
U18
6 U14 40
U19
0SC1
U13 51 7 39
M8M
M8M
FLASH
FLASH
Memory
Program
Memory
Program
RI/O ASIC
29F400TA
29F400TA
50
User S-Logic
User S-Logic
(NAC)
75 1 11
C-Net ASIC 94317761 TP102
9904-CNA10M 17 29
31 18 28
CP33
28 U24 18 TP101
Mount for
13 U23 5 29 17 U26
Reverse Side
14 C-Net 4 HN27C1024 TP104
OSC2
FLASH ROM
AM29F010 39 7
30 U104
20
21 29 40 6
EXO-3C TP103
OSC3
P2 9 1
P1
10 CN5 2
1FS-71 L1 SM BUHIN < 9710074 >
Figure 5-3 1FS Board Layout

I/O INTERFACE
C SERIES CONTROLLER
5-9
I/O INTERFACE
Table 5-2 1FS Board Specifications
MPU 32-bit RISC CPU i960 series working memory

80960SA20(Intel) no backup
20Mhz
DRAM 1 MB (pc 256k 16) debug only
MB814260-70LPJ-G(FUJITSU) 2pc not used after download
EPROM 128 KB (64K 16) system memory
HN27C1024HCC-10(Hitachi) 1pc sequence source object
SRAM 4 KB (2k 16) CPU
common shared CPU VME bus main communication
memory HM62256BLFP-7T 2pc
Serial ControlNet or R I/O
I/F installed
Communication ControlNet 64KB FLASH memory
Line
I/F RS485 1 channel ControlNet
Serial R I/O, not installed when using
Communication for ControlNet
Weld Interface 19,200 bps, half duplex
PD72001(NEC) 1pc
System Bus VME bus interface VME Master
Interface Master/Slave 1FR board
no system control
A:16, D:16
Hardware Interrupt ACFAIL
Watch Dog Error
VME Bus Error
H/W Timer Interrupt
NAC or ControlNet Interrupt
SIO Interrupt
Watch Dog Timer 100ms
DIP Switch Software start condition
FLASH memory write mask
BOOT (FLASH or EPROM) boot from
setting
LED CPU RUN, ERROR, NAC or ControlNet
STATUS, WDT
Board VME double height
Configuration
Current 1.5A < engineering target
Working temperature 0 ~ 70 C
5-10 February 20, 1998

I/O INTERFACE
Table 5-3 1FS Board S1 Settings
Condition
Location Color Function Normal Error
LD1 Green RI/O Status ON
LD2 Red CNet Error OFF ON
LD3 Green CNet Status ON
LD4 Red Error OFF ON
LD5 Green CPU Run Blinks approx. 1.2sec/cycle
LD101 Red Watch Dog Timer OFF ON
Table 5-4 1FS Board LED Conditions
LED Color Function Condition

Normal Error
LD5 Green CPU Run Blinks approx. 1.2sec/cycle
LD4 Red Error OFF ON
LD3 Green CNet Status ON
LD2 Red CNet Error OFF ON
LD1 Green RI/O Status ON
LD101 Red Watch Dog Timer OFF ON
June 25, 1999 5-11

I/O INTERFACE
Table 5-5 1FS Board CN3 Connector Pin Assignments
BIT Signal
1 R I/O blue wire
2 R I/O clear wire
3 R I/O shield
4 chassis ground (FG)
5 not connected
6 RS485 signal ground
7 RS485 SD+
8 RS485 SD-
5-12 February 20, 1998

I/O INTERFACE
5.2.2 MONITOR SCREENS
The remote I/O monitor function (auxiliary function 180) provides information about
remote I/O signals, including signal status, timer and counter status, Slogic signals and
status, and last weld data. To access the RI/O MONITOR menu, follow the procedure
shown in figure 5-4.
ƒXƒe [ƒ^ƒX
Figure 5-4 RI/O Monitor, Auxiliary Function 180
June 25, 1999 5-13

I/O INTERFACE
NOTE
Menu items can be directly selected by typing the item

number and pressing the return key.
Figure 5-4 RI/O Monitor, Auxiliary Function 180 (continued)
5-14 February 20, 1998

I/O INTERFACE
Figure 5-5 Auxiliary Function 180 RI/O Monitor, Signal Status
February 20, 1998 5-15

I/O INTERFACE
Figure 5-5 Auxiliary Function 180 RI/O Monitor, Signal Status (continued)
5-16 February 20, 1998

I/O INTERFACE
Figure 5-6 Timer and Counter Status
February 20, 1998 5-17

I/O INTERFACE
Figure 5-7 Slogic Monitor
5-18 June 25, 1999

I/O INTERFACE
Figure 5-8 Last Weld Data
February 20, 1998 5-19

I/O INTERFACE
Figure 5-8 Last Weld Data (continued)
5-20 February 20, 1998

I/O INTERFACE
Figure 5-9 Slogic Status
June 25, 1999 5-21

I/O INTERFACE
5.2.3 PLC (NAC) SETTING
The RI/O PLC (NAC) SETTING function provides information about the 1FS board,
including baud rate and information about the PLC rack. To select the RI/O PLC (NAC)
SETTING screen, follow the procedure shown in figure 5-10.
Figure 5-10 RI/O PLC(NAC) Setting
5-22 February 20, 1998

I/O INTERFACE
5.2.4 WELD CONTROL SETTING
The RI/O WELD CONTROL SETTING function provides information about the weld
controller(s). To select the RI/O WELD CONTROL SETTING screen, following the
procedure shown in figure 5-11.
Figure 5-11 RI/O Weld Control Setting
February 20, 1998 5-23

I/O INTERFACE
5.2.4 SLOGIC CONTROL
The RI/O SLOGIC CONTROL function allows the operator to edit the Slogic program.
To edit the program, the program is stopped (SSTOP), uploaded from the 1FS board to
the 1GA board for editing (SUPLOAD), downloaded back to the 1FS board
(SDOWNLOAD), and then started (SRUN). To select the RI/O SLOGIC CONTROL
function, follow the procedure shown in figure 5-12. Once uploaded to the 1GA board,
Slogic programs are edited using the user display screen (figure 5-13).
Figure 5-12 RI/O Slogic Control
5-24 June 25, 1999

I/O INTERFACE
ƒXƒe [ƒ^ƒX
>SS
>SU
>ED SPG
>1 SOUT 301 = 101
>?
>10?E
>SD
PASSWORD
>SR
Figure 5-13 User Display Screen
June 25, 1999 5-25

I/O INTERFACE
Figure 5-14 Slogic Run (SRUN)
5-26 June 25, 1999

I/O INTERFACE
Figure 5-15 Slogic Stop (SSTOP)
June 25, 1999 5-27

I/O INTERFACE
Figure 5-16 Slogic Download (SDOWNLOAD)
5-28 June 25, 1999

I/O INTERFACE
Figure 5-17 Slogic Upload (SUPLOAD)
June 25, 1999 5-29

I/O INTERFACE
5.2.6 SLOGIC FORCED OUTPUT
The SLOGIC FORCED OUTPUT function (figure 5-18) provides a means to verify the
proper functioning of selected Slogic signal outputs.
Figure 5-18 Slogic Forced Output
5-30 June 25, 1999

I/O INTERFACE
5.2.7 STATUS SCREEN
The STATUS screen (figure 5-19) indicates the current execution status of the Slogic
program and the primary weld current of the welder.
1 3
1) Slogic execution status

Slogic RUN: executing
Slogic STOP: hold
2) When a welder is connected, the number of the welder and the weld current of the
last weld are displayed.
3) FLOWGAIN data
Figure 5-19 Status Screen
June 25, 1999 5-31

I/O INTERFACE
5.3 CONTROLNET
The ControlNet network (figure 5-20) is an open control network that provides real-time,
high-throughput applications by linking PLC processors, I/O, computers, operator inter-
faces, and other intelligent devices. The ControlNet network combines the functionality
of an I/O network and a peer-to-peer network, while providing high-speed performance
for both functions.
Windows NT/95 ON OFF

C Series Controller
with 1FS board
TEACH LOCK
computer running
RSView software EMERGENCY STOP
with RSLinx PanelView 1200e

ERROR MOTOR POWER
ERROR RESET CYCLE START
TEACH REPEAT HOLD RUN

Windows NT/95
MFP
HOST
AC115V 1A Operator Terminal computer running

RSI PLC-5 A.I.
programming software
with RSLinx
1770-KFC
serial/parallel 1784-KTCX
interface module
PLC-5/20C
processor
ControlNet Network
DeviceNet PLC-5/40C
Windows NT/95 FLEX I/O adapter
scanner processor
computer with 1794-ACN PLC-5/40C
1771-SDN processor
1786-CP cable
1784-KTC
ControlNet I/O adapter

1771-ACNR
DeviceNet Network
Figure 5-20 ControlNet Network
The ControlNet network transfers data at 5M bit/s, and provides deterministic, repeat-
able transfers of mission critical control data (e.g., I/O updates and processor interlock-
ing).
Due to its fast update times, the network can support highly distributed systems, espe-
cially those with high-speed digital I/O or heavy analog I/O content. I/O chassis and
other devices can be located hundreds of meters from PLC processors; or for distributed
processing, a processor can be located at the I/O chassis where it can monitor its own
resident I/O, while communicating via the network to a supervisory controller.
5-32 February 20, 1998

I/O INTERFACE
The ControlNet network can process the following automation and control data on a
single coaxial cable: peer-to-peer messaging, remote programming, troubleshooting,
and I/O updates and PLC processor interlocking.
I/O and PLC processor interlocking update times that match application requirements
can be selected. The network’s media access method places a higher priority on I/O
updates and processor interlocking; these messages always take precedence over
transfers of non-time-critical data (e.g., program uploads/ downloads and messaging).
The network simplifies PLC programming by eliminating the need to program block
transfers.
A ControlNet network is simple and cost-effective to install, and offers flexible installation
options. Allen-Bradley offers PLC processors with built-in ControlNet communication,
ControlNet adapters for I/O chassis, and ControlNet interface cards for personal com-
puters. Although the Control-Net network is based on bus technology, repeaters can be
used to implement tree and star topologies. For added reliability, a redundant set of
cables may be added between nodes. The additional cables provide a backup path if a
primary cable fails. Each node compares the quality of the signals from each cable and
uses the cable with the better signal. The 1FS board provides a redundant connection
to the network via two BNC connectors (channel A and B).
Windows NT/95/98 computers can access real-time data over the network using RSLinx
software. This software functions as a communications engine for software products
such as Rockwell Software’s man machine interface software RSView, and program-
ming software such as PLC-5 A.I. series programming software. RSLinx can also pro-
vide plant floor data to commercially available applications (e.g., Microsoft Excel and
Access) for display, logging, or trending.
The ControlNet network provides real-time communication between PLC processors, I/

O chassis, personal computers, third-party hardware and software, and related I/O
devices. The network also allows the user to perform other functions such as program-
ming the processors on the network and configuring network devices from a single
terminal.
The network uses standard RG-6 coaxial cable and BNC connectors. ControlNet also
supports fiber-optic media. Fiber-optic repeaters allow increased network distances,
and accommodate changes in topology.
The network uses taps with integrated drop cables for node connections. Up to 99
addressable nodes (with taps) can be installed anywhere along the network’s trunk
cable, with a maximum length per segment ranging from 250 meters (820 ft) to 1,000
meters (3,280 ft), depending on how many taps are used. There is no minimum tap
separation. The network can be accessed from every node, including ControlNet I/O
adapters, using the network access port.
June 25, 1999 5-33

I/O INTERFACE
The ControlNet network is compatible with a range of products, and can be added to
existing systems. The PLC-5 processor includes standard ports for communication with
devices on Universal Remote I/O and Data Highway Plus networks.
The ControlNet network provides a time-critical link between PLC processors and I/O
devices, and the architectural link between information and device layers of a communi-
cation architecture.
5-34 February 20, 1998

I/O INTERFACE
5.3.1 CONTROLNET SPECIFICATIONS
Type of Bus
• Control
• I/O data, programming data on same wire
Bus Topologies
• Linear Trunk
• Tree
• Star
• Mix of any of above
Bus Speed
• 5.0 Mb/sec (maximum)
Length, single segment

• 1,000 m (coax) @ 5 Mb/s
• 1,000 m with two nodes
• 250 m with 48 nodes
• 3,000 m (fiber) @ 5 Mb/s
Number of Repeaters
• 5 (maximum) in series
• 6 segments (5 repeaters) in series
• 48 segments in parallel
Maximum Length with Repeaters

• 5,000 m (coax) @ 5 Mb/s
• 30+ km (fiber)
Types of Repeaters
• high voltage AC and DC
• low voltage DC
Device Power
• Devices powered externally
Connectors (Standard Coax BNC)

• barrel (plug-to-plug)
• bullet (jack-to-jack)
• extender (plug-to-jack)
• isolated bulkhead (jack-to-jack)
• right angle (plug-to-jack)
February 20, 1998 5-35

I/O INTERFACE
Communication Model
• Producer/Consumer
Number of Nodes
• 99 Maximum Addressable Nodes
• 48 taps (nodes) without a repeater
Size of Data Packet

• Variable, 0-510 bytes
Number of I/O Data Points

• No limit
Network Update Time (Scan Time)

• 2-100 msec (user selectable)
Communication Modes (Bus-Addressing)

• Master/Slave
• Multi-Master
• Peer-to-Peer
I/O Data Triggers

• Polling
• Cyclic
• Change-of-State
Cyclic Redundancy Check

• Modified CCITT using 16-bit, polynomial
Application Layer
• Object-Oriented: Class/Instance/Attribute
• Device Object Model using Device Profiles
Physical Media
• coax - R6/U
• fiber
Network and System Features

• Remove/Insert Devices Under Power
• Deterministic, Repeatable
• Intrinsic Safety Option
• Duplicate Node ID Detection
• Message Fragmentation (block transfers)
5-36 February 20, 1998

I/O INTERFACE
APPENDIX
A.1 STOPPING THE ROBOT WITH EXTERNAL I/O SIGNALS .......................... A-2
A.1.1 External Hold/Run.......................................................................................... A-2
A.1.2 External Motor Power OFF ............................................................................ A-4
A.2 External Program Selection Function ............................................................ A-6
A.2.1 Program Selection Using AS Language “IF” Instruction................................. A-8
A.2.2 Program Selection Using RPS Function ........................................................ A-9
A.2.3 Signal Timing ............................................................................................... A-11
A.2.4 Program Selection Using the Jump Function ............................................... A-13
A.2.4.1 Signal Timing ............................................................................................... A-15
A.3 Home Position Signal Output Function ........................................................ A-17
A.4 Mutual Interlock............................................................................................ A-19
A.5 Clamp Signal Output Timing ........................................................................ A-21
A.6 Dedicated Signals Classified by Application ................................................ A-24
A.6.1 Handling Specification ................................................................................. A-24
A.6.2 Spot Welding Specification .......................................................................... A-30
A.6.2.1 Spot Welding Control ................................................................................... A-33
A.7 External I/O Signal Pin Assignments ........................................................... A-40
A.7.1 1GW Board Pin Assignments ...................................................................... A-40
A.7.2 TB2 Dedicated Signal Pin Assignments ...................................................... A-42
A.8 External I/O Connection Examples .............................................................. A-43
A.8.1 Output Signal Connections .......................................................................... A-43
A.8.2 Input Signal (IN) Connections ...................................................................... A-45
A.9 Controller Internal Arrangement................................................................... A-46
A.10 General Purpose Signal Assignments ......................................................... A-47
June 25, 1999 A-1

I/O INTERFACE
APPENDIX
A.1 STOPPING THE ROBOT WITH EXTERNAL I/O SIGNALS
The controller allows the operator to stop the mechanical unit using two primary meth-
ods; setting the RUN/HOLD switch to HOLD, or the MOTOR POWER switch to OFF. In
case of an emergency, the mechanical unit can be immediately stopped, using the
EMERGENCY STOP (E-Stop) switch. When control power is switched off and then on,
motion of the mechanical unit resumes from the point where it was stopped.
A.1.1 EXTERNAL HOLD/RUN
! WARNING
When external hold is applied, the mechanical unit is
stopped by means of brakes; motor power is still ener-
gized. Before entering the work cell, ensure motor
power is off at the control panel (figure A-1 and A-2).
When the mechanical unit is stopped using an external hold signal, the position is main-
tained with the brakes. External hold is valid only when the controller is in the repeat
mode; in teach mode, manual operation is still available.
NOTE
When external hold is applied, the state of the following

output signals is:
Auxiliary data OX signals - all temporarily set to off.
Clamp signals - (HANDLING TYPE and OUT; not desig-

nated in the RUNMASK instruction) maintain the same
state.
When external hold is released, the mechanical unit continues operation immediately;
however, if cycle start has been set to OFF (e.g., controller was set to TEACH), the
TEACH/REPEAT switch must be set to REPEAT and the CYCLE START switch set to
ON, before motion resumes.
A-2 February 20, 1998

I/O INTERFACE
APPENDIX
TEACH LOCK
Control Panel
EMERGENCY STOP
ERROR MOTOR POWER
Figure A-1 Controller Cabinet (Front View)

EMERGENCY STOP
ERROR MOTOR POWER
Figure A-2 Control Panel
February 20, 1998 A-3

I/O INTERFACE
APPENDIX
A.1.2 EXTERNAL MOTOR POWER OFF
! WARNING
When entering the work cell, ensure motor power is
OFF, unless the controller is in the teach mode.
The motor power OFF signal is input from a variety of locations (e.g., emergency stop
push button, safety fence plug, etc.). This signal sets motor power to OFF, and cycle
start to OFF (cycle stop); the mechanical unit stops immediately. This method of stop-
ping should only be used in emergency situations; when the mechanical unit stops
quickly, excessive stress is applied to its components. For stopping the robot in normal
situations (non-emergency), use of the hold signal is preferred.

I/O INTERFACE
APPENDIX
Figure A-3 is an example circuit. In an actual work cell configuration, there may be more
safety related circuits.
+24 VDC Operation 0V

E-Stop E-Stop
Start
SP
Operation Enabled - When the
CR-X CR-X relay is off, the robot
motor power is switched off.
Safety Safety
Plug Plug
SP Safety Plug ON
TE
External Teach
Repeat Teach
TE Robot Teach
Operation Start
HOLD Release CR-X Weld
Fault HOLD Release - When the
HOLD HOLD relay is ON, the HOLD
state is released.
HOLD
HOLD
External Hold
COM
CR-X
External
Motor Power OFF
Figure A-3 Stop Circuitry
! WARNING
When teaching the robot, a second person should be
present for safety purposes. In the teach mode, cell
door safety plugs are not functional.

I/O INTERFACE
APPENDIX
A.2 EXTERNAL PROGRAM SELECTION FUNCTION
To select programs externally, the following methods are available:
1) AS program “IF” instruction.

2) RPS (Random Program Selection) function (software dedicated signal).
3) JUMP function (software dedicated signal).
Main
Program
pg00
pg01
pg02
pg08
pg10
Figure A-4 Program Selection Using AS Language IF instruction
Main Program
pg1
pg0
END
END
Main Program
pg3 pg1 pg3 pg5
END
END END END

Main Program
pg5
END
At completion of a program (taught Upon completion of a program, if the

step “END”), the next program is external program number (RPSXX) is set
selected (RPS function is not used). to 0, pg0 is selected.
Figure A-5 Program Selection Using RPS Function

I/O INTERFACE
APPENDIX
Main Program
pg2
During the execution of a program, when a

jump ON
JUMP taught step is encountered, a selec-
OFF tion is made to continue with the current
program (JUMP OFF), or select another
Main Program
pg5 program (JUMP ON).
END
Figure A-6 Program Selection Using the JUMP Function

I/O INTERFACE
APPENDIX
A.2.1 PROGRAM SELECTION USING AS LANGUAGE “IF” INSTRUCTION
By using the following AS instructions, selection of signal codes is obtained by means of

the BIT function. By determining the value using the “IF” instruction, the applicable
program is selected and executed.
Example program:
.PROGRAM pg0( )
100 HOME ; Moves toward the home position.
WAIT SIG(1009) ; Program selection OK signal from external device (wait for
input signal IN9).
TWAIT 0.1 ; Wait for program selection signal (Set up time of input signals
IN10~13 ).
pg.no = BITS(1010,4) ; Get the program selection signal (IN10~13).
IF pg.no = = 1 THEN ;
CALL pg1 ;
END ;
IF pg.no = = 2 THEN ; Call the sub-program according to the program selection.
CALL pg2 ;
END ;
CALL pg8 ;
END ;
CALL pg10 ;
END ;
GOTO 100 ;
END ;
NOTE
In the previous program example, AS Language instruc-

tions BITS and IF~THEN~END are used. AS Language
instructions BITS, CASE~VALUE~END, or EXTCALL
can also be used. Refer to the C Series Controller AS
Language Reference Manual for a complete description
of instructions.
A-8 June 25, 1999

I/O INTERFACE
APPENDIX
A.2.2 PROGRAM SELECTION USING RPS FUNCTION
To select programs externally using the RPS function, the following dedicated signals
can be used. These are software dedicated signals and are defined using the DEFSIG
command.
OUTPUT
External program selection mode is valid “RPS”:

Output occurs when the external program selection mode is valid (RPS ON).
RPS-ST:
This indicates that external program selection is ready. Output occurs when the
RPS mode is valid and during the execution of a step where “END” is taught.
INPUT
RPS-ON:
This signal enables program selection using an external program number. The
external program number (RPSxx) is selected when the RPS mode is valid, and if
this signal is set to ON at a step where “END” is taught.
External Program Number “RPSxx”:

This external signal (binary code) indicates a program number. The number of
signal bits can be set by the user.
Program Reset “EXT_PGM_RESET”:

This signal causes a program reset to the first step of a main program. In automatic
operation, a cycle stop is executed, and a reset to the first step of the program
occurs. Also, when the RPS mode is valid (in external program selection mode), if
this signal is selected, external program number (RPSxx) is fetched and reset to the
first step.

I/O INTERFACE
APPENDIX
Table A-1 Example of RPS Codes (7-bits)
SIGNAL
PROGRAM RPS1 RPS2 RPS4 RPS8 RPS16 RPS32 RPS64
PG0 X X X X X X X
PG1 O X X X X X X
PG2 X O X X X X X
PG3 O O X X X X X
PG15 O O O X X X X
PG16 X X X O X X X
PG99 O O X X X O O
O = ON
X = OFF
In table A-1, seven bits are used for the binary code. BCD (binary-coded decimal nota-
tion) codes can also be selected via software.
NOTE
Ensure that external program numbers (RPSxx) do not

conflict with other program numbers (e.g., for the first 10
external program numbers, use PG0 ~ PG9, vice
PG00 ~ PG09).

I/O INTERFACE
APPENDIX
A.2.3 SIGNAL TIMING
This section describes signal timing for program selection using RPS.
Step in which “END” is taught First Step

(example: PG1) (example: PG3)
Robot
“RPS-ST”
(Output)
External
“RPSxx”
(Input)
“RPS-ON”
(Input)
100 ms Min.
Figure A-7 Signal Timing Using RPS
When the RPS mode is valid, and a step in which auxiliary data END is executed, the
program input OK RPS-ST signal is sent. When this occurs, the required external pro-
gram number “RPSxx must be set at the external device (including the interface panel).
After being set, a wait time of 100ms is required before the program input OK RPS-ON
signal is sent. When the position of the mechanical unit coincides with the END taught
point, the controller confirms the RPS-ON signal. The controller then fetches RPSxx,
sets the next executing program internally, and sets RPS-ST to OFF. For external de-
vices, RPS-ON and RPSxx signals must be maintained until the RPS-ST signal is set to
OFF.

I/O INTERFACE
APPENDIX
! CAUTION
If the RPS-ON signal is input when the RPSxx signal is
not set, the controller could fail to fetch RPSxx and the
wrong program could be selected.
"RPS-ST"
ON
"RPS-ON"
"RPSxx"
FETCHING
PROGRAM
CHANGEOVER
"RPS-ST"
OFF
Figure A-8 RPS Program Selection Flow Diagram

I/O INTERFACE
APPENDIX
A.2.4 PROGRAM SELECTION USING THE JUMP FUNCTION
To select programs externally using the JUMP function, the following dedicated signals
can be used. These are software dedicated signals and are defined using the
DEFSIG command.
OUTPUT
JUMP-ST:
This indicates that external program number selection is ready. Output occurs when
the RPS mode is valid and during the execution of a step where the JUMP or
EXTCALL instruction is taught.
INPUT
JUMP-ON:
This signal enables program selection using an external program number. The
external program (RPSxx) is selected when the RPS mode is valid and if this signal
is set to ON at a step where JUMP is taught.
JUMP-OFF:
This signal disables program selection using an external program number. When
the RPS mode is valid, if the signal is externally set to ON at a step where JUMP is
taught, the program change is not performed and the current program advances to
the next step.
External Program Number “RPSxx”:

This external signal (binary code) indicates a program number. The number of
signal bits can be set by the user.

I/O INTERFACE
APPENDIX
"JUMP-ST"
ON
JUMP-ON?
JUMP-OFF? OFF
"RPSxx"
FETCHING ON
CURRENT REQUESTED
=
SAME *
PROGRAM PROGRAM
PROGRAM
CHANGEOVER
"JUMP-ST"
OFF
Current program: currently executing program.

Requested program: program number fetched by RPSxx.
* When the EXTCALL instruction is used, the following error message is displayed:
Error(-314) Cannot execute because the program is already used.
Figure A-9 JUMP Function Flow Diagram
When JUMP-ON and JUMP-OFF are both entered, JUMP-ON takes precedence. Even
when JUMP-ON is entered, if the currently executing program number is the same as
the requested program number, the program change is not performed.

I/O INTERFACE
APPENDIX
A.2.4.1 SIGNAL TIMING
This section describes signal timing for program selection using the JUMP function.
Step in which “JUMP” is taught First step

(example: PG2) (example: PG5)
robot
JUMP-ST
(output)
(external)
JUMP-CODE
(input)
JUMP-ON
(input)
100 ms Min
(ON)
JUMP-OFF (input)
(OFF)
Figure A-10 Program Selection Using the JUMP Function
When the RPS mode is valid and a step in which auxiliary data JUMP is executed, the
Program input OK JUMP-ST signal is sent.
When this occurs, the external program number (RPSxx) must be set at the external
device (including the interface panel).
After being set, a wait time of 100ms or more is required before the Program input OK
JUMP-ON signal is sent.
When the mechanical unit’s position coincides with the JUMP taught point, the controller
confirms the JUMP-ON signal.
The controller fetches RPSxx, sets the next executing program internally, and sets
JUMP-ST to OFF; however, if the program number is the same as the current program
number, a program change is not made and the robot continues to the next step.
For external devices, the JUMP-ON and RPSxx signals must be maintained until the
JUMP-ST signal is set to OFF.

I/O INTERFACE
APPENDIX
Step in which “JUMP” is taught Next step

(Example: PG2) (Example: PG2)
(robot)
“JUMP-ST”
(output)
(external)
“RPSxx”
(input)
(ON)
“JUMP-ON” (Input)
(OFF)
“JUMP-OFF”
(Input)
Figure A-11 JUMP Function When Continuous Motion is Required

I/O INTERFACE
APPENDIX
A.3 HOME POSITION SIGNAL OUTPUT FUNCTION
! WARNING
The home position signal is generated by the encoder,
provided on each joint of the mechanical unit. This soft-
ware signal is different from hardware controlled signals
(e.g., limit switches, etc.). This signal must not be the
only safety interlock used; additional hardware type in-
terlocks (e.g., limit switches, etc.) must be used for
safety purposes.
Output of the home position signal occurs when the mechanical unit is positioned within
the range of the predesignated home position. Two home position signals (first and
second) can be set (see figure A-12); the location, range, and signal number of the
home position can be programmed.

I/O INTERFACE
APPENDIX
Home Position
Range of
Location of Home Position: Joint angle values.
Range of Home Position: The range in millimeters from the home position.
Ensure that the range value is not less than 1mm.
Figure A-12 Home Position Range
The output channel number for the home position signal is selected using the DEFSIG
command. The home position location and range is selected using the SETHOME and
SET2HOME commands respectively.

I/O INTERFACE
APPENDIX
A.4 MUTUAL INTERLOCK
When robots are installed in close proximity to each other, their work envelopes may
overlap. In this situation, interlocking (mutual interlocking) between the robots is re-
quired. For example, the area of interference between robots A and B in figure A-13 is
represented by the shaded area.
Mutual Interference Zone
OXa OXb Positions WXa and WXb represent locations

WXa WXb where the robots monitor for the OX signals
output from the other robot to determine
whether or not the other robot is in the
mutual interference zone. If the zone is not
clear, the robot waits at this location until
Robot A Robot B
the zone is clear, before continuing its
motion into the zone. The dashed line
indicates an interval for which OXa and OXb
signals are continuously output, allowing
movement of the other robot into the inter-
ference zone.
OXa OXb
Figure A-13 Mutual Interference Zone
When referenced from robot A:
1) Before entering the interference zone, robot A confirms, by means of WXa (OXb
output from robot B), that robot B is located outside the zone.
2) When robot A is located outside the interference zone, the OXa signal is output,
allowing robot B to enter the zone.

I/O INTERFACE
APPENDIX
ROBOT A +24 ROBOT B

VDC
+24 VDC
OXa WXb
RUN/STOP
+24 +24 VDC

VDC
WXa OXb
RUN/STOP
Figure A-14 Example of a Mutual Interlock Circuit

I/O INTERFACE
APPENDIX
A.5 CLAMP SIGNAL OUTPUT TIMING
! WARNING
Do not set controller power to OFF during a material
handling operation; damage to materials, equipment,
and personnel may occur. When controller power is set
to OFF, all output signals (including clamp signals) are
set to OFF. If the controller is set to OFF during a mate-
rial handling process, the clamp signal is lost and the
gripper releases the object being held.
Clamp signals are used for many purposes, depending upon the application. They are
commonly used for spot welding applications and control of grippers for material han-
dling operations. To use a clamp signal for an application, the optional solenoid valve
must be installed on the arm of the mechanical unit. To configure the controller for using
a clamp signal to control the solenoid valve, jumper selection on the 1GW board and
software selection (clamp setting or HSETCLAMP command) is required.
June 25, 1999 A-21

I/O INTERFACE
APPENDIX
CLAMP key
LED Illuminated
CLAMP
Single solenoid, normally closed specification.
CLAMP key
Illuminated
LED
CLAMP
Single solenoid, normally open specification.
CLAMP key
LED Illuminated
CLAMP A
CLAMP B
Double solenoid specification.
Figure A-15 Selection of the CLAMP Signal During Teach Operation
During teaching operations, the CLAMP signal is selected using the multi function panel
(MFP), by selecting the TEACHING screen and pressing the CLAMP SIGNAL key.

I/O INTERFACE
APPENDIX
CLAMP CLAMP
ON OFF
TEACH DATA
CLAMP CLAMP
OFF ON
ON
CLAMP A
OFF
ON
CLAMP B
OFF
Figure A-16 Clamp Signal Outputs (Double Solenoid Specification)
Figure A-16 shows two clamp signal outputs (CLAMP A and CLAMP B) during repeat or
check modes. A maximum of eight clamp signals can be assigned in the teach mode.

I/O INTERFACE
APPENDIX
A.6 DEDICATED SIGNALS CLASSIFIED BY APPLICATION
This section summarizes dedicated signals for material handling and spot welding
applications.
A.6.1 HANDLING SPECIFICATION
Table A-2 Material Handling Dedicated Input Signals
Signal Name Description of Function Signal Type

CONTROL Refer to section 2.1.
H
POWER ON/OFF
MOTOR POWER
H
ON
MOTOR POWER
H
OFF
HOLD H
EXTERNAL Refer to section 2.2. Not required
MOTOR POWER S when hardware dedicated signal is
ON used.
EXTERNAL Refer to section 2.2.
S
ERROR RESET
EXTERNAL
S
CYCLE START
EXTERNAL
PROGRAM S
RESET
RPS_ON S
JUMP_ON S
JUMP_OFF S
RPSxx S
H: hardware dedicated signal

S: software dedicated signal
A-24 June 25, 1999

I/O INTERFACE
APPENDIX
C1
B1
A1
UNI
1 2 34
±10
SW2 0-15
ON
0-10
1 DA2 U14
UNI
1 2 34
2
3
CN1 SW1 ±10
0-15
ON
0-10
4 DA1
1
20
P1
CN2
C32
B32
A32
37
19
A B C A12 B12
1 24V
1 B1 A1 2 OX9
9 3 OX10
4 OX11
5
6
OX12
24G J7 U29
CN3 CN2 DA OPT I/O
NO.1 NO.2
J3 ADDRESS
A B C
SIGOUT
CN3 1
A B C
24V
CN5 2 OX13 CN6
3 OX14
4 OX15
J2
1-32
-128
-64
-96
5 OX16
ADDR
ESS
6
A B
15 24G
CN3 CN2
8 SIGOUT J4
1
2
3
4
19 B8 A8
17-24
25-32
9-16
37 J1
1-8
A1 B1 ON OFF
A B C
RESET
WX13
WX14
WX15
WX16
J5
24V
1
2
3
4
CN4 CN3
A B C
ON OFF OPT
J6
SIGIN
DA
RESET I/O
A B C
1
2
3
4
5
CN4
20
1
Figure A-17 1GW Board Jumper Locations
June 25, 1999 A-25

I/O INTERFACE
APPENDIX
Table A-3 1GW Board J5 Jumper Settings
Signal
No. Name Setting, 1GW Connector, Function Std. Note
B-C CN3 Sensor Because all
1 24V A-B signals share a
A-B CN4 General purpose I/O
common +24V,
B-C CN3 SIGIN1
2 WX13 A-B ins 1-5 must be
p
A-B CN4 General purpose I/O set the same
B-C CN3 SIGIN2 (i.e., A-B or B-C).
3 WX14 A-B
B-C CN3 SIGIN3
4 WX15 A-B
B-C CN3 SIGIN4
5 WX16 A-B
A-26 June 25, 1999

I/O INTERFACE
APPENDIX
Table A-4 Material Handling Dedicated Output Signals

TEACH/REPEAT Refer to section 2.1.
SWITCH H
OUTPUT
EMERGENCY
STOP SWITCH H
OUTPUT
MOTOR Refer to section 2.2.
S
POWER ON
IN REPEAT S
ERROR
S
OCCURRED
AUTOMATIC S
TEACH MODE Refer to section 2.2. Not required when
S
hardware dedicated signal is used
FIRST HOME Refer to section 2.2.
S
POSITION
SECOND HOME
S
POSITION
RGSO S
RPS MODE S
RPS_ST S
JUMP_ST S
CLAMP S This signal is used for material handling
(maximum of applications. A maximum of 7 system
eight channels) outputs are available. Both single and
double solenoids can be used (refer to
section A.5 for clamp signal output
timing).
H: Hardware DedicatedSignal
S : Software Dedicated Signal
June 25, 1999 A-27

I/O INTERFACE
APPENDIX
For the location of jumpers J3 and J4, refer to figure A-17.
NOTE
Clamp signals are not available by setting jumpers only;

in addition to setting the jumpers, ensure that software
dedicated signal assignments are also made.
No. Signal Name Setting, 1GW Connector, Function Std. Note

I/O24V (for SOL1-SOL4) A-B CN3 Solenoid Because all signals share
1 B-C a common VIN or I/O24V
VIN (for outputs 9-12) B-C CN2 General purpose I/O
and COM or I/O24G, pins
A-B CN3 SOL1 1-6 must be set the same
2 OUT9 B-C
B-C CN2 General purpose I/O (i.e., A-B or B-C).
A-B CN3 SOL2
3 OUT10 B-C
B-C CN2 General purpose I/O
A-B CN3 SOL3
4 OUT11 B-C
A-B CN3 SOL4
5 OUT12 B-C
I/O24G (for SOL1-SOL4) A-B CN3 Solenoid
6 B-C
COM (for outputs 9-12) B-C CN2 General purpose I/O
No. Signal Name Setting, 1GW Connector, Function Std. Note

I/O24V (for SOL5-SOL8) A-B CN3 Solenoid Because all signals share
1 B-C a common VIN or I/O24V
VIN (for outputs 13-16) B-C CN2 General purpose I/O
and COM or I/O24G, pins
A-B CN3 SOL5 1-6 must be set the same
2 OUT13 B-C
B-C CN2 General purpose I/O (i.e., A-B or B-C).
A-B CN3 SOL6
3 OUT14 B-C
A-B CN3 SOL7
4 OUT15 B-C
A-B CN3 SOL8
5 OUT16 B-C
I/O24G (for SOL5-SOL8) A-B CN3 Solenoid
6 B-C
COM (for outputs 13-16) B-C CN2 General purpose I/O
A-28 June 25, 1999

I/O INTERFACE
APPENDIX
Table A-7 Material Handling Software Dedicated Signals (Standard Shipment Settings)
Output Signal Input Signal

Signal Signal
Dedicated Signal Name Number Dedicated Signal Name Number
DURING MOTOR POWER OUT1 1 IN1 1001
ON
IN REPEAT OUT2 2 IN2 1002
ERROR OCCURRED OUT3 3 IN3 1003
OUT4 4 IN4 1004
OUT5 5 IN5 1005
OUT6 6 IN6 1006
OUT7 7 IN7 1007
OUT8 8 IN8 1008
CLAMP1 OFF* OUT9 9 IN9 1009
CLAMP1 ON* OUT10 10 IN10 1010
OUT11 11 IN11 1011
OUT12 12 IN12 1012
OUT13 13 IN13 1013
OUT14 14 IN14 1014
OUT15 15 IN15 1015
OUT16 16 IN16 1016
* May vary from specification.

I/O INTERFACE
APPENDIX
A.6.2 SPOT WELDING SPECIFICATION
Table A-8 Spot Welding Dedicated Input Signals

CONTROL H Refer to section 2.1.
POWER ON/OFF
MOTOR POWER H
ON
MOTOR POWER H
OFF
HOLD H
EXTERNAL S Refer to section 2.2. Not required when
MOTOR POWER hardware dedicated signal is used.
ON
EXTERNAL S Refer to section 2.2.
ERROR RESET
EXTERNAL S
CYCLE START
EXTERNAL S
PROGRAM
RESET
RPS-ON S
JUMP-ON S
JUMP-OFF S
RPSxx S Refer to section 2.2.
WELD S Received from up to two weld controllers
COMPLETED (timer contactors). After the weld initiate
command is sent, the robot waits for this
signal before moving to next location.
WELD FAULT S Received from up to eight weld
controllers (timer contactors). When this
signal is received, the robot stops
automatically.
RETRACTABLE S Used to detect the gun stroke retract
GUN RETRACT state. An individual detection for each
DETECTION clamp (maximum eight channels) can be
made.
RETRACTABLE S Used to detect a retractable welding gun
GUN EXTEND with a short stroke. An individual
DETECTION detection for each clamp (maximum eight
channels) can be made.
H: Hardware Dedicated Signal
S : Software Dedicated Signal

I/O INTERFACE
APPENDIX
Table A-9 Spot Welding Dedicated Output Signals

TEACH/REPEAT H Refer to section 2.1.
Switch Output
EMERGENCY H
STOP Switch
Output
MOTOR S Refer to section 2.2.
POWER ON
IN REPEAT S
ERROR S
OCCURRED
AUTOMATIC S
TEACH MODE S Refer to section 2.2. Not required when
hardware dedicated signal is used.
FIRST HOME S Refer to section 2.2.
POSITION
SECOND HOME S
POSITION
RGSO S
RPS MODE S
RPS_ST S
JUMP_ST S
WELD S Transmitted to weld controller (up to eight).
COMMAND Signal type is selectable; level or pulse
or
(maximum eight (pulse duration is adjustable).
channels)
WELD S Weld schedule number (maximum of six
SCHEDULE bits) transmitted to weld controller. May be
(maximum six either binary or individual, and is
channels) selectable.
H: Hardware DedicatedSignal
S: Software Dedicated Signal

I/O INTERFACE
APPENDIX
Table A-9 Spot Welding Dedicated Output Signals (continued)
WELD FAULT S Resets the weld control (timer

RESET contactor) weld fault condition.
(maximum eight
channels)
GUN CLAMP S Weld gun clamp command signal.
COMMAND Clamp commands can be output
(maximum eight individually, using the clamp setting.
channels)
STROKE S Stroke selection (extend or retract) for
CHANGE retractable weld guns. Separate signals
(maximum eight may be used for extend and retract.
channels, twice) Stroke selection can be output
individually, using the clamp setting.
CLAMP S Provides manual control for material
(maximum eight handling applications. The ON/OFF
channels) state for each clamp can be controlled or
separately. Control of both single and
double solenoids is available.
H: Hardware Dedicated Signal

S: Software Dedicated Signal
NOTE
Both WELD COMMAND and CLAMP (for material han-

dling) signals are controlled by the system’s clamp func-
tion (i.e., the maximum total number of WELD COM-
MAND and CLAMP signals is eight).

I/O INTERFACE
APPENDIX
A.6.2.1 SPOT WELDING CONTROL
Table A-10 Spot Welding Specifications
Single stroke
Type Cylinder-type, retractable
Stopper-type, retractable
Weld Gun Maximum number of simultaneous guns is two.
Quantity
Multiple guns can be controlled by a single weld
controller.
Weld Controller (Timer Contactor) Maximum of two, controlled individually.
Maximum of six bits.

Weld Schedule
Maximum of 63 for binary output.

I/O INTERFACE
APPENDIX
Gun Clamp Valve

One Gun Gun
(Standard Type)
Weld Controller
Gun Clamp Valve 1 Gun 1

Two Guns
without
simultaneous Gun Clamp Valve 2
welding
Weld Controller Gun 2
Gun Clamp Valve 1

Gun 1
Two Guns Weld Controller 1
with
simultaneous
welding Gun Clamp Valve 2
Gun 2
Weld Controller 2
Gun 1
Gun Clamp Valve
Gun Change
Weld Controller
Gun 2
Gun N
Figure A-18 Weld Controller/Valve/Gun Connections

I/O INTERFACE
APPENDIX
Weld Schedule (maximum 6-bits)

Weld Command Weld Controller
Weld Complete Timer Contactor
Weld Fault
Robot Controller Weld Fault Reset
Gun Clamp
Stroke Change (single/double solenoid)
Retractable Gun Retract Detection Gun
Retractalbe Gun Extend Detection
Figure A-19 Welding I/O Signals
NOTE
Some weld controllers may not have a separate input for

weld command and weld schedule (see figure A-22).

I/O INTERFACE
APPENDIX
Robot
t1 t2
Gun Clamp Output
Weld Command Output
Weld Complete Input
Weld Schedule Output
t1: Gun clamp and weld command signals can be output before reaching the actual
taught point (variable 0 ~0.99 second).
t2: Upon receiving the weld complete signal from the weld controller, movement to the
next taught point can be delayed (variable 0 ~0.99 second).
Figure A-20 Weld Timing Diagram
NOTE
The weld command signal shown in figure A-20 is a

level output (a pulsed output is also available). This ex-
ample shows a gun clamp that is controlled by the robot
controller, not a weld controller. The weld complete sig-
nal duration must be greater than 100 msec; an alterna-
tive is to keep the signal ON until the weld command is
set to OFF (if the weld command is a level output).

June 25, 1999
1 Spot Welding 2 Spot Welding 3 Spot Welding 4 Spot Welding

Retract Extend Extend Extend Retract Retract
Moving Moving Moving Moving Moving

Teach Teach Teach Teach
Robot Motion Data Data Data Data
Extend Extend Retract Retract
t1 t1 t1
Kawasak
t2 t2 t6 t1 t6
Gun Clamp Output
Retractable Gun
Cylinder Type
Stroke Select t4 t5
Retractable Gun
Stopper Type
Weld Initiate Command t3 t3

OUTPUT
APPENDIX
Weld Complete
INPUT
Weld Schedule
OUTPUT
t1: Anticipation time for the gun clamp output signal (0 ~0.99 sec., t4: Delay time of the stroke select output from the gun clamp output
variable). (retract to extend), for a stopper type retract change (00 ~9.9 sec.,
variable).
t2: Delay time from receipt of the weld complete input signal until gun
is open and motion can begin (retract to extend); for extend to t5: Delay time of the output (retract to extend) for a stopper type
C SERIES CONTROLLER
retract, delay time is T6 (0 ~0.99 sec., variable). retract change (00 ~9.9 sec., variable).
t3: Delay time of the weld initiate command output from the gun clamp t6: Delay time from receipt of the weld complete input signal until
output (retract to extend). Used for a retractable gun only (00 ~9.9 motion can begin (time until gun is open, extend to retract)(00 ~9.9
I/O INTERFACE
sec. variable). sec., variable).
A-37
Figure A-21 Timing Diagram (Retractable Gun)

I/O INTERFACE
APPENDIX
Controller Weld Controller +24VDC

(Timer Contactor)
- +
OUT17 relay WELD1
- +
OUT18 relay WELD2
- +
OUT19 relay WELD3
- +
OUT20 relay
Weld
Start
- + Weld
OUT21 relay Fault
Reset
relay Welding/
Test
+24VDC
+
Weld
IN29 Complete
-
+
Weld
IN28 Fault
-
Gun Clamp Solenoid

+24VDC
1A max.
- +
OUT22
Figure A-22 Connection to Weld Controller (Timer Contactor)

I/O INTERFACE
APPENDIX
Table A-11 Spot Welding Software Dedicated Signals (Standard Shipment)

Signal Signal
Dedicated Signal Name Number Dedicated Signal Name Number
DURING MOTOR POWER OUT32 32 EXTERNAL MOTOR IN32 1032
ON POWER ON
ERROR OCCURRED OUT31 31 EXTERNAL ERROR RESET IN31 1031
AUTOMATIC OUT30 30 EXTERNAL CYCLE START IN30 1030
IN REPEAT OUT29 29 #1 WELD COMPLETE IN29 1029
TEACH MODE OUT28 28 IN28 1028
FIRST HOME POSITION OUT27 27 IN27 1027
OUT26 26 IN26 1026
OUT25 25 IN25 1025
CLAMP2 ON (HANDLING) OUT24 24 IN24 1024
#1 WELD COMMAND OUT23 23 IN23 1023
CLAMP1 (WELD GUN OUT22 22 IN22 1022
CLAMP)
OUT21 21 IN21 1021
#1 WELD SCHEDULE WS8 OUT20 20 IN20 1020
#1 denotes weld controller number 1.

I/O INTERFACE
APPENDIX
A.7 EXTERNAL I/O SIGNAL PIN ASSIGNMENTS
A.7.1 1GW BOARD PIN ASSIGNMENTS
1
20 O UT 1
O U T 17 2
21 O UT 2
O U T 18 3
22 O UT 3
O U T 19 4
23 O UT 4
O U T 20 5
24 O UT 5
O U T 21 6
25 O UT 6
O U T 22 7
26 O UT 7
O U T 23 8
27 O UT 8
O U T 24 9
28 O UT 9
O U T 25 10
CN2 29 O U T 10
O U T 26 11
30 O U T 11
O U T 27 12
31 O U T 12
O U T 28 13
32 O U T 13
O U T 29 14
33 O U T 14
O U T 30 15
34 O U T 15
O U T 31 16
35 O U T 16
O U T 32 17
36 C O M 1 NC
(O U T 1 ∼16) 18 V IN 1
37 C O M 2 (O U T 1 ∼16)
(O U T 17 ∼32) 19 V IN 2
(O U T 17 ∼32)
Figure A-23 1GW Board Connector CN2 Pin Assignments
NOTE
The mating plug for CN2 is a JAE (Japan Aviation Elec-

tronics) model DC-37SF-N or equivalent. For channel
numbers of additional 1GW boards, add 32 to the chan-
nel numbers shown above for each additional board (up
to three additional boards).
A-40 June 25, 1999

I/O INTERFACE
APPENDIX
19 C O M 2
37 (IN 17∼32)
NC 18 C O M 1
36 (IN 1∼16)
NC 17
35 NC
IN 32 16
34 IN 16
IN 31 15
33 IN 15
IN 30 14
32 IN 14
IN 29 13
31 IN 13
IN 28 12
30 IN 12
IN 27 11
29 IN 11
IN 26 10
CN4 28 IN 10
IN 25 9
27 IN 9
IN 24 8
26 IN 8
IN 23 7
25 IN 7
IN 22 6
24 IN 6
IN 21 5
23 IN 5
IN 20 4
22 IN 4
IN 19 3
21 IN 3
IN 18 2
20 IN 2
IN 17 1
IN 1
Figure A-24 1GW Board Connector CN4 Pin Assignments
NOTE
The mating plug for CN4 is a JAE (Japan Aviation Elec-

tronics) model DC-37PF-N or equivalent. For channel
numbers of additional 1GW boards, add 32 to the chan-
nel numbers shown above for each additional board (up
to three additional boards).
June 25, 1999 A-41

I/O INTERFACE
APPENDIX
A.7.2 TB2 DEDICATED SIGNAL PIN ASSIGNMENTS
1HP-CN1 TB2
EXT CONTROL POWER-P
1 1 +24 VDC (EXT) EXTERNAL CONTROL
POWER ON/OFF
EXT CONTROL POWER-N
2 2 +24 VDC G (EXT) (+24 VDC INPUT)
REMOTE-P SHORT (STANDARD)

3 3
REMOTE-N
4 4
INTERNAL-ENG1-P
5 5
ENG1-P
6 6
INTERNAL ENG1-N
7 7 EXTERNAL
EMG-STOP
+24 VDC ENG1-N CONNECTION
8 8
INTERNAL ENG2-P
relay 9 9
ENG2-P
10 10
INTERNAL ENG2-N
relay 11 11
ENG2-N
12 12
SAFETY FENCE1-P
13 15
SAFETY FENCE1-N
14 16 SAFETY FENCE
INPUT (REPEAT MODE)
SAFETY FENCE2-P
15 17 (STOP WHEN OPEN)
SAFETY FENCE2-N
16 18
EXTERNAL HOLD-P
17 19 EXTERNAL HOLD
INPUT (REPEAT MODE)
EXT HOLD-N
21 21
22 22 (NOT USED)
23 23
24 24
EXT TRG1-P
25 25
EXT TRG1-N
26 26 EXTERNAL
TRIGGER INPUT
EXT TRG2-P (REPEAT MODE)
EXT TRG2-N
28 28
EXT MOTOR POWER -P
29 29 EXTERNAL
MOTOR POWER ON
EXT MOTOR POWER -N
30 30 (WHEN CLOSED)
TEACH SW-P
35 31 INTERNAL TEACH
SW OUTPUT
TEACH SW-N (CLOSED IN TEACH
36 32 MODE)
INTERNAL +24 VDC INTERNAL
37 33 +24 VDC OUTPUT
I/O 24 VDC INTERNAL
38 INTERNAL
34 +24 VDC G OUTPUT
+24 VDC G
39 35 I/O +24 VDC INPUT
I/O 24 VDC G
40 36 I/O +24 VDC G INPUT
Figure A-25 1HP to TB2 Connections

I/O INTERFACE
APPENDIX
A.8 EXTERNAL I/O CONNECTION EXAMPLES
A.8.1 OUTPUT SIGNAL CONNECTIONS
NOTE
Figure A-26 represents the portion of the general pur-

pose output circuitry of the 1GW board for outputs OD-
1~OD4. There is identical circuitry for the remaining 28
outputs (OD5~OD32).
! CAUTION
It is recommended that a diode be connected in parallel
with the load for surge suppression. Ensure that the po-
larity is correct.
June 25, 1999 A-43

I/O INTERFACE
APPENDIX
CONTROLLER EXTERNAL
DEVICE
+24 VDC
TB
CN2
VIN-1
18 18
4700 pf
U3
ZD4
C3
PC4
1
R52
3 2 OD-1
1 1 load
PC6 12K 1/4W
4
R54
6 7 OD-2
2 2 load
PC9 12K 1/4W
5
R55
11 9 OD-3 3 load
3
PC12 12K 1/4W
12
R53
14 16 OD-4
4 4 load
8 13
12K 1/4W
ZD19
ZD17
ZD20
ZD18
OC-1 36 36
1GW Board
Figure A-26 Connection of External Output Signals
A-44 June 25, 1999

I/O INTERFACE
APPENDIX
A.8.2 INPUT SIGNAL (IN) CONNECTIONS
CONTROLLER EXTERNAL
DEVICE
CN4 TB
1W ID1 1 1
PC
2.4K
16 16
680
ID16 16 16
NC 17 17 +24 VDC
IC-1 18 18
IC-2 19 19
32
ID17 20 20
1W
PC
16 16
2.4K
680
ID32 35 35
NC 36
NC 37
1GW Board
Figure A-27 Connection of General Purpose Input Signals
June 25, 1999 A-45

I/O INTERFACE
APPENDIX
A.9 CONTROLLER INTERNAL ARRANGEMENT
Card Rack AVR

Power
Grounding Bar Supply
(G1)
F1
1HZ
Power Block
K1 (1GC/1GD)
Servo CPU
C1 (1GB)
F2
Relay
Chassis
K3
1HY
TB2
Figure A-28 Controller Internal Arrangement
A-46 June 25, 1999

I/O INTERFACE
APPENDIX
A.10 GENERAL PURPOSE SIGNAL ASSIGNMENTS
Table A-12 General Purpose Signals

Signal Name Dedicated Signal Signal Name Dedicated Signal
Name Name
OUT1 1 IN1 1001
OUT2 2 IN2 1002
OUT3 3 IN3 1003
OUT4 4 IN4 1004
OUT5 5 IN5 1005
OUT6 6 IN6 1006
OUT7 7 IN7 1007
OUT8 8 IN8 1008
OUT9 9 IN9 1009
OUT10 10 IN10 1010
OUT11 11 IN11 1011
OUT12 12 IN12 1012
OUT13 13 IN13 1013
OUT14 14 IN14 1014
OUT15 15 IN15 1015
OUT16 16 IN16 1016

I/O INTERFACE
APPENDIX
Table A-12 General Purpose Signals (continued)

Signal Dedicated Signal Name Signal Dedicated Signal Name
Name Name
OUT17 17 IN17 1017
OUT18 18 IN18 1018
OUT19 19 IN19 1019
OUT20 20 IN20 1020
OUT21 21 IN21 1021
OUT22 22 IN22 1022
OUT23 23 IN23 1023
OUT24 24 IN24 1024
OUT25 25 IN25 1025
OUT26 26 IN26 1026
OUT27 27 IN27 1027
OUT28 28 IN28 1028
OUT29 29 IN29 1029
OUT30 30 IN30 1030
OUT31 31 IN31 1031
OUT32 32 IN32 1032

I/O INTERFACE
GLOSSARY
GLOSSARY ................................................................................................................ 1-2
June 25, 1999 G-1

I/O INTERFACE
GLOSSARY
This glossary contains definitions of terms used by operators, programmers, and main-
tenance personnel who work with Kawasaki robots. The definitions are listed in alpha-
betical order.
A
• ACCELERATE
To speed up a process.
• ACCURACY
A measure of the difference between the commanded robot arm position and the
actual position. Also identifies how well an indicated value conforms to a true value
(i.e., an actual or accepted standard value).
• ACRONYM
A word formed from the initial letters of words in a name or phrase. For example,
ASCII is an acronym for American Standard Code for Information Interchange.
• ADDRESS
A number that identifies a specific location in the computer’s or processor’s memory.
Means of identifying a location or data in a control system.
• ADDRESSING
Computer operations store data in specific memory locations or addresses. The
largest memory location determines the amount of data that can be stored. The
larger the number, the larger the possible program.
• AIR CUT
Moving a weld gun into position but without generating an arc.
• ALGORITHM
A finite set of well-defined rules or procedures for solving a problem step-by-step.
• ALPHANUMERIC
Pertaining to a set of symbols that contain both letters and numbers, either individu-
ally or in combination.
• AMBIENT TEMPERATURE
The temperature of air or liquid that surrounds a device.
• AMPERE (AMP)
A unit of electrical current flow that is equivalent to one (1) coulomb per second.
One (1) volt across one (1) ohm of resistance causes a current flow that is equiva-
lent to one (1) amp.
G-2 June 25, 1999

I/O INTERFACE
GLOSSARY
• ANALOG
A continuously changing electrical voltage signal. In robot systems, the magnitude
or value of the signal represents commanded robot axis motion.
• ANALOG DATA
Information that is represented by a characteristic of the value or magnitude of an
electrical signal, such as the amplitude, phase, or frequency of the voltage, the
amplitude or duration of a pulse, the angular position of a shaft, or the pressure of a
fluid number.
• ANTI-FRICTION BEARING
A rolling element which is used to support a rotating shaft.
• ARC SENSOR
A sensor that detects weld lines utilizing arc characteristics.
• ARGUMENT
A value applied to a procedure; data used by a function or other command. For
instance, in the AS command JMOVE flange, 2. The variable, flange, and the clamp
number 2 are the arguments of the function JMOVE.
• ARRAY
An ordered set of addresses or their values. Elements of an array can be refer-
enced individually or collectively. Array elements all have the same type of data, for
instance, integer or character, and are usually presented in rows and columns.
• ARTICULATED
To join together permanently or semi-permanently by means of a pivot connection
for operating separate segments as a unit.
• ARTICULATED ROBOT
A robot arm which contains at least two consecutive revolute joints, acting around
parallel axes, resembling human arm motion. The work envelope is formed by
partial cylinders or spheres. The two basic types of articulated robots, vertical and
horizontal, are sometimes called anthropomorphic because of the resemblance to
the motions of the human arm.
• ASCII
An acronym for American Standard Code for Information Interchange. This stan-
dard 8-bit code is used by many devices, such as keyboards and printers.
• AS LANGUAGE
Kawasaki robot language used to communicate commands and instructions from a
keyboard to the CPU.
June 25, 1999 G-3

I/O INTERFACE
GLOSSARY
• ASSIGNMENT
An instruction used to express a sequence of operations, or used to assign oper-
ands to specified variables, or symbols, or both.
• ASYNCHRONOUS
A means of data communication where the data is sent a character at a time pre-
ceded by a start bit and followed by a stop bit. No direct timing signal links the
transmitter and receiver.
• AUXILIARY DATA
Information about a point, other than the positional data, such as speed, accuracy,
weld schedule and clamp condition.
• AXIS
A straight line about which sections of the mechanical unit rotate (e.g., joints JT1,
JT2, JT3 etc.).
B
• BACKLASH
The clearance, slack, or play between adjacent gears, or the jar or reaction often
caused by such clearance when the parts are suddenly put in action or are in ir-
regular action.
• BASE COORDINATE
A fixed coordinate system having an origin at the intersection of the X, Y, and Z
axes.
• BAUD RATE
Determines the number of bits per second (bps) or characters transmitted between
devices.
• BCD
An abbreviation for binary coded decimal. The BCD 8-4-2-1 code expresses each
decimal digit by its own 4-bit binary equivalent. The 8-4-2-1 code is identical to
binary through the decimal number 9. Above the decimal number 9 each decimal
digit is represented by its own 4-bit binary equivalent. For example, using the 8-4-2-
1 binary-coded system, the number 10 is interpreted as 0001 0000.
• BINARY CODE
A system in which characters are represented by a group of binary digits, that have
the value of either 0 or 1, true or false, on or off.
G-4 June 25, 1999

I/O INTERFACE
GLOSSARY
• BIT
Acronym for binary digit, having one of two values: 0 or 1.
• BOOT
The method by which computers are brought from a non-operating to an operating
state. During this sequence, the computer memory is usually reset. This is often
performed to restart the computer after a crash, to bring it on-line.
• BUFFER
A temporary memory storage area in a computer or electronic device.
• BUG
A problem in a software or hardware element of a system.
• BUS
The primary communication path in the controller along which internal signals are
sent among processors and memories.
C
• CABLE CARRIER
A device which carries cables and hoses (including power sources) from a station-
ary location to a linear moving device.
• CARTESIAN COORDINATE
A location in space defined by three axes at right angles to each other, commonly
labeled X, Y, Z.
• cc
cubic centimeter
• CELL
A manufacturing unit consisting of two or more work stations or machines, and the
material transport mechanisms and storage buffers that interconnect them.
• CENTER OF GRAVITY
The point at which the entire weight of a body may be considered as concentrated,
so that if supported at this point the body would remain in equilibrium in any posi-
tion.
• CHARACTER
A term that describes all numbers, letters, and other symbols typically found on a
computer keyboard.
June 25, 1999 G-5

I/O INTERFACE
GLOSSARY
• CHECK MODE
A procedure that allows the user to check positional data and auxiliary data while in
the teach mode with the Kawasaki robot . This procedure is in many ways analo-
gous to reverse point and forward point operations in other robot models.
• CHECKSUM
A method by which the contents of data or a transmission are verified to be accu-
rate. This method ‘sums’ all the characters and translates them into a number which
is appended to the data.
• CHEMICAL ANCHOR
A threaded rod installed in a structure (e.g., a concrete floor) and secured by epoxy,
for the purpose of securing hardware.
• CIRCULAR INTERPOLATION
A path taken by the robot that connects at least three points with an arching motion.
The CPU will calculate a path that places the taught points on a section of a circle.
• CLOSED-LOOP SYSTEM
A system in which a command value is output and a feedback value is returned.
The resulting error, the difference between the command and the feedback, is used
to correct the signal. In a robot system, the command signal is output by the con-
troller, causing the robot arm to move, and the feedback signal is produced by the
encoder, which reads the current position of the arm.
• CODE
A set of rules for expressing information in a language that is understood and pro-
cessed by a control system.
Also, a term for instructions in a computer program. Code performs a process, and
data is the information that is processed.
• COMMAND
An analog signal, or group of signals or pulses, which cause a specified function to
be performed. An instruction or request in a computer program that performs a
particular action. Commands that are needed to run the operating system are
called a command language.
• COMMENT
Optional, non-executing remarks added to a program to explain various aspects of
the program.
G-6 June 25, 1999

I/O INTERFACE
GLOSSARY
• COMPILER
A system task that translates a program written in source code, into binary code
that can be understood by the processor.
• COMPOUND TRANSFORMATION
A location in the Cartesian coordinate system that is defined relative to another
Cartesian coordinate location.
• CONTIGUOUS FILE
A file that is stored in continuously adjacent areas of memory, in contrast to a file
which is scattered to make more efficient use of disk space.
• CONTINUOUS PATH CONTROL

A type of robot control in which the robot moves according to a replay of closely
spaced points programmed on a constant time base during teaching.
• CONTROL ERROR CODE

A code which identifies system problems whenever an alarm condition occurs.
• CONTROLLED AXIS
A robot axis that is operated by electrical or hydraulic power.
• CONTROLLER
An electronic device, with processing capabilities and software, which controls the
robot actions and functions.
• CONVEYER TRACKING
Used to make the robot follow a part on a conveyor, without the use of a traverse
axis.
• COORDINATE
A set of numbers that locate a point in space.
• CPU
Abbreviation for central processing unit. A collection of hardware in a computer
which performs all calculations, handles I/O, and executes programmed tasks.
• CRASH
A situation where the computer fails to operate, due to a software or hardware
problem.
• CRT
Abbreviation for cathode ray tube. A CRT is a charge storage tube in which the
information is written by means of the cathode ray beam.
June 25, 1999 G-7

I/O INTERFACE
GLOSSARY
• CURRENT LOOP
A circuit in which a portion of the output is returned to modify the control circuit
output. This circuit may be used as a limiting device, for safety protection.
• CURSOR
A pointer or indicator on a computer screen, that identifies the current position on
the screen.
• CYCLE
A complete path of projectory performed by the robot for a specific application.
• CYCLOIDAL DRIVE
A mechanical gear reduction unit that reduces the speed of the input and increases
the torque capacity. The cycloidal unit consists of an internal arrangement of discs
and pins that are driven by an eccentric drive cam. This type of gear reduction
offers low gear train backlash and the capability to achieve high reduction ratios
from a single contained unit.
D
• DATA
A term given to information, instructions, words or symbols that are usually transmit-
ted, processed, or stored as a group.
• DETENT
A part of a mechanism that locks or unlocks a movement.
• DISCONNECT
A switch that isolates a circuit or one or more pieces of electrical apparatus after the
current has been interrupted by other means.
• DEVIATION ERROR
In all mechanical devices, the actual position of the mechanical unit will lag behind
the electrical command of the controller. An allowable limit is assigned for this
difference. However, if the controller detects a condition where the difference be-
tween this mechanical value and the desired electrical position is larger than the
established value limit, the robot controller will generate a deviation error. This error
is sometimes referred to as a FOLLOWING ERROR in the robot industry.
• DEBUG
The process by which an operator’s program is checked for mistakes and then
corrected.
G-8 June 25, 1999

I/O INTERFACE
GLOSSARY
• DECIMAL NUMBER
Numbers in the base-10 numbering system, which uses the numerals 0 - 9.
• DEDICATED
A term used to describe a system resource, such as an I/O device or terminal,
which is used for only one purpose, or assigned a single function.
• DEDICATED SIGNAL
A term used to describe a signal which is used for only one purpose, or assigned a
single function. Both inputs and outputs can be dedicated.
• DEFAULT
A value or operation that is automatically entered by the system, if the operator
does not specify one. Typically, the default is the standard or expected response.
• DELETE
A command which will eliminate unwanted data.
• DELIMITER
A character which separates a group of items or a character string, from other
groups, or which terminates a task.
• DEVICE
Any peripheral hardware connected to the processor and capable of receiving,
sorting, or transmitting data.
• DIAGNOSTICS
Function performed by the processor to identify and check for error conditions in the
robot arm and peripheral devices.
• DIP SWITCH
DIP is an acronym for dual in-line package. A set of small switches on circuit boards
that can be set for different configurations.
• DIRECTORY
A logical structure that organizes a group of similar files.
• DISK
A high-speed, random-access memory device.
• DISK-BASED SYSTEM
System in which programs and files are stored on the hard disk and are read into
memory when requested by the user.
June 25, 1999 G-9

I/O INTERFACE
GLOSSARY
• DISK PACK
A device which is used to store additional data in a computer system, and is usually
removable.
E
• ECHO
Process in which characters that are typed on a keyboard are also displayed on the
screen or are sent to the printer.
• EDITOR
An aid for entering information into the computer system and modifying existing text.
• EMERGENCY STOP (E-Stop)

An immediate stop of robot motion, selected by the operator with a switch.
• ENCODER
An electromechanical device that is connected to a shaft to produce a series of
pulses that indicate the position of the shaft.
• EPROM
Acronym for erasable programmable read-only memory. The contents of this
memory (computer chip) are retained, even when power to the system is turned off.
Usually stores executive programs and critical system variables.
• ERROR LOG
A report which contains a sequential list of system error messages.
• ERROR MESSAGE
Messages displayed on the plasma screen of the robot controller, when the action
requested by the operator could not be completed. Error messages can occur
when components malfunction or if an incorrect command is typed by the operator.
• EXPRESSION
A combination of real-valued variables and functions, and mathematical and logical
operators. When evaluated, this combination yields a numeric value.
F
• FEEDBACK
The transmission of a signal from a measuring device (e.g., encoder, transducer) to
the device which issued the command signal within a closed-loop system. See
CLOSED-LOOP SYSTEM.
G-10 June 25, 1999

I/O INTERFACE
GLOSSARY
• FIELD SIGNALS
All electrical signals that exit or enter an electrical panel.
• FILE
A set of related records or data elements, which are stored using one name and are
arranged in a structure that can be used by a program.
• FILESPEC
Includes the name, creation date and size of the specified file.
• FIXED DISK
An electromagnetic mass storage device which is not removable. Hard disks have
much higher storage capacity than floppy disks.
• FLOPPY DISK
An electromagnetic mass storage device which can be removed and exchanged.
• FORM FEED
Process which causes a printer to advance the paper to the top of the next page.
• FUNCTION
A formula or routine for evaluating an expression.
G
• GAIN
A proportional increase in power or signal value relative to a control signal. The
ratios of voltage, power, or current as related to a reference or control signal input.
• GLOBAL
Refers to a function or process that affects the entire system or file.
• GRAY CODE
A positional binary number notation in which any two numbers whose difference is
one are represented by expressions that are the same except in one place or col-
umn and differ by only one unit in that place or column.
H
• HALF-DUPLEX COMMUNICATION
Data transmission between two devices, where the signal is sent in only one direc-
tion at a time.
June 25, 1999 G-11

I/O INTERFACE
GLOSSARY
• HANDSHAKING PROTOCOL
Communication rules used for data transmissions between devices. Each device
must recognize the same protocol in order to communicate.
• HANG
A term which refers to the state of a computer system that seems to be inoperative
when processing should be taking place.
• HARDSTOP
A mechanical constraint or limit on motion.
• HARDWARE
Physical equipment and devices such as computer hard disk, cables, printer, etc.
• HAZARDOUS SIDE
The unsafe side of a component or panel, such as the inside of the control panel
when power is applied and functions are being performed.
• HOLD
When an external or an internal input is available for a hold condition, the robot will
stop its motion and servo drive power will be removed from the robot. When an
external hold reset is performed, the servo drive power will be energized.
• HOME POSITION
Refers to the starting or resting position of the robot.
• HYBRID ENCODER
On the Kawasaki robot a hybrid encoder is used to generate positional data, and is
composed of an incremental encoder that generates incremental pulses, and an
absolute encoder that generates gray code binary data.
I
• ID
Abbreviation for Identification.
• INCHING
A value that is used during the jogging process that allows the user to position the
robot in small minute increments.
G-12 June 25, 1999

I/O INTERFACE
GLOSSARY
• INCREMENTAL CODE
A digital closed loop feedback code that provides digital feedback pulses to the
robot controller for the purpose of providing positional information. These incremen-
tal pulses are generated by an encoder through the use of an optical disk with
alternating opaque and transparent bars or lines around the periphery of the disk.
On one side of the disk a light source is mounted, and on the opposite side a
phototransistor When the disk rotates, the phototransistor is alternately forced into
saturation and cutoff, producing the digital signal.
• INPUT
Transmission of an external signal into a control system.
• INTEGRATED CIRCUIT (IC)

A combination of interconnected circuit elements which are within a continuous
substrate.
• INTERACTIVE SYSTEM
System where the user and the operating system communicate directly; the user
through the keyboard, and the operating system via the display screen.
• INTERLOCK
An arrangement whereby the operation of one part or mechanism automatically
brings about or prevents the operation of another.
• INTERPRETER
A program that changes English-like commands into machine language. An inter-
preter translates and executes one command at a time.
• INSTRUCTIONS
Discrete steps in a computer program that are commands or statements that tell a
computer to do something or identify data.
• INTEGER
A whole number, a number without a fractional part such as 7, -318, or 19.
• INTERFACE
The circuitry that fits between a system and a peripheral device to provide compat-
ible coupling between the two pieces of equipment.
• INTERPOLATION
The mathematical process that the CPU utilizes to plot a path for the robot to travel
from one position to another. A mathematical process that evaluates a number of
dependent and independent variables for the purpose of comparison and prediction.
June 25, 1999 G-13

I/O INTERFACE
GLOSSARY
• INTERRUPT
An external signal that halts program execution so that the computer can service
the needs of some peripheral device or subsystem.
• INTRINSIC SAFETY BARRIER (ISB)

An electronic device used in robot controllers to restrict current and voltage to a
safe level.
• INVERTER
A circuit which switches a positive signal to a negative signal, and vice versa.
• I/O
Abbreviation for Input/Output. The interconnections through which the computer
and its peripheral devices communicate.
• IPM
Abbreviation for Intelligent Power Module
J
• JOG
A term used to describe the process in which the user moves the mechanical unit
through interaction with the robot controller and the teach pendant. Sometimes
referred to as slewing.
• JOINT
1. A term used to describe the individual axes of a robot.
2. A term used to describe the jogging process in which the robot is jogged one
axis at a time.
• JOINT MOVE
A mode of operation in which the robot moves from one point to the next with an
arching path. All axes motors (required for the move) begin and end their rotation at
the same time. The tool center point does not follow a linear path to reach the
taught position.
L
• LABEL
An identifier for a program command line. To identify an instruction, memory loca-
tion, or part of a program.
G-14 June 25, 1999

I/O INTERFACE
GLOSSARY
• LAN
An acronym for local area network. A group of computer terminals interconnected
by cables, allowing communication of information via the network.
• LCD
Abbreviation for liquid crystal display. This type of display is made of material whose
reflectance or transmittance of light changes when an electric field is applied.
• LIMIT SWITCH
An electrical switch positioned to be switched when a motion limit occurs, thereby
deactivating the actuator that caused the motion.
• LINEAR MOVE
An operation where the rate and direction of relative movement of the robot arm are
continuously under computer control.
• LINE PRINTER
A high-speed output device that prints a line at a time.
• LINE TURN-AROUND
Changing the source of transmission in half-duplex communications.
• LOGICAL OPERATION
Any of several operations that manipulate information according to the rules of logic
(e.g., AND, OR, NOT, and exclusive OR).
• LM
Abbreviation for linear motion.
• LOAD
The weight applied to the end of the robot arm.
• LOCKOUT
Serving to prevent operation of a device or part of it.
• LSB
Abbreviation for least significant bit.
M
• MANIPULATOR
Another term for the mechanical portion of the robot system.
• MACHINE LANGUAGE
June 25, 1999 G-15

I/O INTERFACE
GLOSSARY
A low-level computer language, usually written in binary code.
• MASS-STORAGE DEVICE
An input/output device that retains data input to it. Examples include: hard disk
drives, magnetic tapes, floppy diskettes, and disk packs.
• MECHANICAL UNIT
robot (excluding controller)
• MEMORY
An area of the computer which stores data, either permanently or temporarily.
When a program is requested, it is first loaded into memory so it can be accessed
quickly by the processor.
• MHz
Abbreviation for megahertz. One million cycles per second.
• MIRROR IMAGE
A process which converts the positive and negative values of a taught path from a
right-handed robot to a left-handed robot, or vice versa. The actions of the oppos-
ing robots are then coordinated and synchronized.
• mm
Abbreviation for millimeter.
• MNEMONIC
A term used to help the operator remember a large string of words or commands.
• MODEM
A signal conversion device that modulates and demodulates data into an audio
signal for transmission.
• MOMENT OF INERTIA
Used to calculate end of arm tooling and handling weights. The sum of the products
formed by multiplying the mass of the load by the square of the distance from the
tool mounting flange.
• MONITOR PROGRAM
An administrative computer program that oversees operation of a system. The AS
monitor accepts user input and initiates the appropriate response, follows instruc-
tions from user programs to direct the robot, and performs the computations neces-
sary to control the robot.
• MSB
G-16 June 25, 1999

I/O INTERFACE
GLOSSARY
Abbreviation for most significant bit.
• MSEC
Abbreviation for millisecond (0.001 seconds).
N
• NOISE
Any unwanted disturbance within a dynamic, mechanical, or electrical system.
• NULLED
An electrical zero state.
O
• OCTAL NUMBER
A numeral in the base-8 numbering system, which uses the numerals 0 - 7.
• OFF LINE
A state in which communications between two devices cannot occur (e.g., between
a printer and a computer, if the printer is off line).
• ON LINE
A state in which communication between two devices can occur.
• OPERATING SYSTEM
A set of system tasks and commands that are entered by the operator and inter-
preted and performed by the system.
• OPEN LOOP
A control which does not use feedback to determine its output.
• OPERATOR
Any mathematical action or function. The arithmetic operators are: add, subtract,
multiply, divide, modulo, and exponentiate. The relational operators are: greater
than, less than, equal to, and their combinations. The logical operators are: AND,
OR, exclusive OR, negate. The binary logical operators are AND, OR, exclusive
OR, ones complement.
• OPTO
An optical isolator or level converter.
• OVERFLOW
June 25, 1999 G-17

I/O INTERFACE
GLOSSARY
When a value or buffer exceeds a predefined limit.
• OVERTRAVEL
An error condition that exists when the robot exceeds its normal software limit
values, and then actuates an overtravel limit switch.
• OVERVELOCITY
When an axis exceeds a preset value for velocity.
• OX (OUTPUT EXTERNAL)
Information transferred from the robot controller through output modules to control
output devices.
P
• PARITY
Method by which errors are detected. In this method the combined binary values of
a byte are flagged as 1 or 0.
• PARSE
To break a command string into individual elements, so it can be interpreted.
• PASSWORD
A code, entered by the user, to permit access to protected information.
• PAYLOAD
The maximum weight that a robot can handle satisfactorily during its normal opera-
tions and extensions.
• PC PROGRAM
PC is an abbreviation for process control. A PC program cannot contain any step
that causes robot motion. PC programs are used to evaluate logic and variables
and execute program CALL and GOTO commands
• PERIPHERAL DEVICE
Hardware equipment which is external to the CPU, but that transmits and/or re-
ceives I/O from the processor. Examples include: printer, CRT screen, or disk.
• PHASE
The angular relationship between current and voltage in alternating current circuits.
In a waveform or period function, the fraction of the period that has elapsed, as
measured from a reference point. Phase angle is determined by multiplying the
phase by 360 degrees.
• PINCH POINT
G-18 June 25, 1999
I/O INTERFACE
GLOSSARY
Any point where it is possible for a part of the body to be injured between the mov-
ing or stationary parts of a robot and the moving or stationary parts of associated
equipment, or between the material and moving parts of the robot or associated
equipment.
• PLA
Abbreviation for programmable logic array. Used in many servo drive circuits.
• PLAYBACK
An operation where a taught path is run for evaluation purposes.
• PLC
Abbreviation for programmable logic controller. Usually referred to as the cell mod-
ule controller.
• POINT-TO-POINT
A robot motion control in which the robot can be programmed by a user to move
from one position to the next. The intermediate paths between these points cannot
be specified.
• POLARITY KEYS
These teach pendant or multi function panel keys allow the user to jog or slew the
robot in the Joint, Base (XYZ), or Tool coordinates system.
• PORT
The connection point of an opening or passage that is usually located outside the
housing of a device.
• POSITIONAL DATA
The location in space of the robot manipulator.
• POUNCE POSITION
A positional location at a point near the workpiece, clear of the transfer mechanism
and part, from which the robot is ready to begin production.
• PRINTED CIRCUIT
An assembly of electronic elements that provide a complete path of electrical cur-
rent through conductive material deposited between terminals on an insulated
surface.
• PRECISION POINT
The play back of robot location based on the angular position of the six axes, joint
angles
• PRINTING
June 25, 1999 G-19

I/O INTERFACE
GLOSSARY
A process in which characters are stamped on a surface, usually paper.
• PROGRAM
A predefined, step-by-step set of instructions that are entered into a computer so a
specific process can be performed repeatedly without reentering all the steps.
Robot paths are stored and run as part of programs.
• PROGRAM EDIT
Modification of an existing program.
• PROCESSOR
Generally, any hardware or software system for carrying out programs and acting on
data.
• PULSE WIDTH MODULATION (PWM)

A modulation process in which the instantaneous sampling of the modulating wave
is caused to modulate the duration of the pulse. This type of modulation is also
referred to as pulse duration modulation (PDM), or pulse length modulation (PLM).
R
• RAM
Acronym for random access memory. An area used by the CPU for processing and
temporarily loading programs so they can be accessed quickly. The contents of
RAM are lost when the computer is powered down, unless battery backup is pro-
vided.
• REAL NUMBER
A number with a fractional part, such as 1.75, -31.89, .5, -4.00, etc.
• REAL-TIME
The actual time during which the computer analyzes and processes data: informa-
tion is usually processed as it is received.
• REAL VARIABLE
AS language term for a variable that has had a real value assigned to it.
• REPEAT MODE
A mode of operation that allows the user to check positional and auxiliary informa-
tion at a selected speed value, in a continuous or a step by step type of movement
of the mechanical unit.
• REPEATABILITY
G-20 June 25, 1999

I/O INTERFACE
GLOSSARY
The measurement of the closeness of agreement among repeated measurements

of the same variable under the same conditions.
• REWRITE MODE
A mode of operation which allows the user to rewrite positional, or auxiliary data,
and to insert or delete step address locations.
• RISC
Acronym for reduced instruction set computer.
• ROM (read-only memory)
A memory device which is programmed at the factory and whose contents thereaf-
ter cannot be altered.
• RS-232C
An ASCII specification for connections and communication between serial devices.
• RUN
A mode of operation that allows the user to select servo motor power to provide
drive energy to the robot, allowing it to perform such modes of operation as teach,
check, repeat, and rewrite.
S
• SAFETY PLUG
A device used with safety fencing to interlock the opening of the fence with the
removal of power to the robot.
• SCROLL
When more information exists than can be displayed on one screen, the operator
can move up and down through the data to view it. When data is scrolled to the
screen, the information previously viewed moves up off the screen, and new infor-
mation enters the screen from the bottom.
• SENSOR
A device used to detect various conditions: proximity, heat, pressure, etc. An electri-
cal signal from the sensor can be used to communicate information to a robot
program.
• SERIAL
A method of transmitting data by which only one bit is sent or received at any one
point in time.
• SEQUENTIAL ACCESS
June 25, 1999 G-21

I/O INTERFACE
GLOSSARY
A method used by many computers whereby data is read in the order in which it is
physically stored.
• SINGULARITY POSITION
When the robot is processing a linear or circular move and two or more joints are in
alignment. The CPU can not process the ambiguity of a singularity configuration
and an error is generated.
• SOFTWARE LIMITS
Programmed values that are included in a program at the point before a mechanical
device hits an overtravel limit switch or a hard limit.
• SOFTWARE
A set of written programs and instructions that are executed by a computer system.
• SOURCE CODE
A program that contains the actual software instructions entered by the user, in
contrast to object code which is source code that has been translated into a lan-
guage which can be interpreted by the computer.
• STRING
A series of characters that have been entered in a distinct sequence that can be
interpreted as a valid statement or command.
• STROKE
The movement in either direction of a mechanical part having a reciprocating mo-
tion. The entire distance passed through in such a movement.
• SUBSCRIPT
A set of numbers that identifies an element of an array.
• SUBROUTINE
A set of instructions that is run by another routine.
• SYMBOL
A character or design that has a distinct meaning and/or is associated with some-
thing.
• SYNTAX
The proper way in which commands and phrases should be typed in order to be
understood by the control system. If the operator incorrectly types a command (i.e.,
misspelled or invalid characters), a syntax error message will be displayed.
• SYSTEM DATA
G-22 June 25, 1999

I/O INTERFACE
GLOSSARY
Data that is specific to a individual robot. Zeroing data, upper and lower software
limits, and software switch settings are all examples of system data.
• SYSTEM SWITCH
Software switches that are set to determine various configurations and characteris-
tics of the robot system performance.
T
• TEACH MODE
A mode selected on the operator panel, during which robot arm axes positions can
be taught by the operator and are recorded by the robot.
• TEACH PENDANT
A hand-held, portable device used by the operator during teach and jogging opera-
tions.
• TOOL COORDINATES
A Cartesian coordinate system in which the origin point is at the face plate of the
robot and the orientation of the tool can be expressed in terms of a 3-dimensional
space representation of X, Y, and Z projections.
• TOOL MODE
A mode of operation in which all motions are calculated to maintain the orientation
of the tool in space.
• TORQUE
Something which produces or tends to produce rotation or torsion and whose effec-
tiveness is measured by the product of the force and the perpendicular distance
from the line of action of the force to the axis of rotation.
• TRANSFORMER
A device to convert the current of a primary circuit into variations of voltage and
current used in secondary circuits.
• TRANSFORMATION
A mathematical description of a location that defines the position and orientation of
the location without regard for the configuration of the robot when it is at that loca-
tion.
• TRAP POINT
see pinch point
• TTL
June 25, 1999 G-23

I/O INTERFACE
GLOSSARY
Abbreviation for transistor-transistor logic.
• TWO’S COMPLEMENT
A means of representing a negative number as one more than the binary comple-
ment of the absolute value of the number.
• TRIANGULAR WAVEFORM
A waveform that has the shape of a triangle and is used in determining sampling
values for servo drive circuits that utilize pulse width modulation.
U
• UHF
Abbreviation for ultra-high frequency.
V
• VARIABLE
The name of a memory location or stored value. A variable can refer to a scalar or
an array.
• VELOCITY COMMAND
This analog signal is directly proportional to motor speed, and provides the initial
signal that is processed by the servo drive system to drive a servo motor.
• VELOCITY ERROR
When the robot controller detects an axis that has exceeded a preset value for
velocity, the robot controller will E-stop the robot.
• VOLT
A unit of electrical potential difference and electromotive force. One volt is equiva-
lent to the force required to produce one amp of current through one ohm of resis-
tance.
W
• WORK ENVELOPE
The effective range or reach of a robot’s axes.
• WORLD COORDINATES
G-24 June 25, 1999

I/O INTERFACE
GLOSSARY
A Cartesian coordinate system in which the origin point is near the base of the
robot, and robot movement can be expressed in terms of a 3-dimensional space
representation of X, Y, and Z projections.
• WRITE
In computer systems, a process in which information is output to and stored by a
device or area in memory.
• WS (WELD SCHEDULE)
Data that is stored in the weld controller and provides the specific current, clamp
pressures, etc. for spot welding applications.
• WX (WAIT EXTERNAL)
The wait external signal is one of many inputs that are processed by the robot
controller. When the robot encounters a wait external condition, the robot will cease
motion and the servo power will be removed.
Z
• ZEROING
This procedure provides the robot controller with encoder data that is referenced
from a known mechanical position (zeroing witness marks, in simple zeroing, or
inclinometer values in precision zeroing) and then establishes an encoder value for
this known position. Two methods can be used, simple and precision zeroing.
Some robot manufacturers call this procedure mastering or calibration.
June 25, 1999 G-25

I/O INTERFACE
INDEX
INDEX .......................................................................................................................... 1-2
June 25, 1999 IN-1

I/O INTERFACE
INDEX
Symbols
1FS Board, 5-2, 5-4, 5-5, 5-6, 5-9, 5-10, 5-11, 5-12, 5-22, 5-24, 5-33
1GA Board, 5-2, 5-4, 5-5, 5-24
1GW Board, 2-5, 3-17, 3-18, 3-19, 3-21, 4-2, 5-7, A-21, A-25, A-26, A-28, A-40, A-41, A-42
1HP Board, 2-2, 4-2, A-42
A
Access, 5-33
Accuracy, 1-6, 2-10, 2-11, 2-15
Allen-Bradley, 5-5, 5-33
ANSI/RIA, 1-2
Application Layer, 5-36
AS Language, 2-13
AS Language Instructions, 2-13
AS Language, Timing, 2-13, 2-14
AUX 180, 5-13, 5-15
Auxiliary Data, 2-10
Auxiliary Function, 2-5
B
Baud Rate, 5-22
Binary-Coded Decimal (BCD), A-10
BIT, A-8
Block Step Programming, 2-10
BNC Connectors, 5-33
Brake, Electromechanical, 1-8
Bus Speed, 5-35
Bus Topologies, 5-35
Bus-Addressing, 5-36
C
CALL, A-8
CASE~VALUE~END, A-8
Check Mode, A-23
CLAMP, A-22, A-32
Clamp Data, 2-10
Clamp Signal, A-21
CLAMP SIGNAL Key, A-22
Clamp Signal Outputs, A-23
CN1, 3-3, 4-2
CN2, 4-2, A-40
CN3, 3-9
CN4, 3-17, 4-2, A-41
Communication Mode, 5-36
Components, Controller, A-46
Continuous Motion, A-16
Control Panel, A-3
Controller, A-46
Controller Cabinet, 4-4, 4-5, 4-8, A-3
Controller, Internal Arrangement, A-46
ControlNet, 5-2, 5-32, 5-34
IN-2 June 25, 1999

I/O INTERFACE
INDEX
ControlNet Specifications, 5-35

Counter, 5-2, 5-5, 5-7
Counter Status, 5-13, 5-17
Cycle Start, A-4
Cycle Stop, A-9
Cycle Time, 5-7
Cyclic Redundancy Check, 5-36
D
Data Highway Plus, 5-34
Data Packet, 5-36
Deadman Switch, 1-6
Dedicated Input Signal, 2-5, A-24, A-30
Dedicated Output Signal, 2-5, A-27, A-31
Dedicated Signal, A-9, A-13, A-24, A-42
DEFSIG, 2-5, A-9, A-13, A-18
Device Layer, 5-34
E
Electromechanical Brake, 1-8
Emergency Stop (E-Stop) Switch, 1-4, 1-5, 1-6, 1-8, 2-2, 3-4, A-2, A-4
Encoder, A-17
END, A-6, A-8, A-9, A-11
Excel, 5-33
Execution Status, 5-31
EXT_PGM_RESET, A-9
EXTCALL, A-8, A-14
External Control Power, 2-2, 3-2, 3-3
External Emergency Stop, 3-6, 3-7
External Hold, 2-2, 3-8, 3-9, A-2
External Hold/Run, A-2
External I/O, A-40, A-43
External I/O Signal, 2-10, 3-2, 4-2
External Input Signal, 3-17
External Motor Power OFF, 2-2, A-4
External Motor Power ON, 2-2, 3-4
External Output, 3-21
External Output Signal, 3-19, A-44
External Program Number, A-13
External Program Selection, A-6
External Program Selection Mode, A-9
External TEACH/REPEAT, 3-10
External Trigger Input, 3-13
External Trigger Switch, 3-12
F
Fiber-Optic, 5-33
FLOWGAIN, 5-31
G
General Purpose I/O Signal, 2-9, 3-17, 4-2
June 25, 1999 IN-3

I/O INTERFACE
INDEX
General Purpose Input Signal, 3-18, A-45

General Purpose Signal, I-2, 2-10, 4-7, A-47
General Purpose Signal, Timing, 2-10
GOTO, A-8
Gripper, A-21
Gun Clamp, A-36
H
Hardstop, Overtravel, 1-8
Hardware Dedicated Signal, I-2, 2-2, 2-4, 3-2, 4-2, 4-3
HOME, A-8
Home Position, A-17, A-18
Home Position, Range, A-18
Home Position Signal Output, A-17
HSETCLAMP, A-21
I
I/O Adapters, 5-33
I/O Data Point, 5-36
I/O Data Trigger, 5-36
I/O Signal, 2-2
I/O Signal, Welding, A-35
I/O Update, 5-33
IC-1, 3-17
IC-2, 3-17
IF, A-6, A-8
Information Layer, 5-34
Input Signal Connection, A-45
Input/Output (I/O), I-2
Interface Panel, Optional, 1-8
Interference, A-19
Interference Zone, A-19
Interlock, I-2, 2-8
Interpolation Mode, 2-10
J
Joint Angle, 2-10
JUMP, A-6, A-7, A-13, A-14, A-15, A-16
JUMP OFF, A-7, A-13, A-14
JUMP ON, A-7, A-13, A-14, A-15
JUMP ST, A-13, A-15
L
Ladder Logic, 5-2
Last Weld Data, 5-13
Limit, Software, 1-8
Limit Switch, A-17
Limit Switch, Overtravel, 1-8
M
Material Handling, A-21, A-24, A-27, A-29
IN-4 June 25, 1999

I/O INTERFACE
INDEX
MHSA, 1-4
MOTOR POWER Switch, A-2
Multi Function Panel (MFP), 1-6, 1-8, 5-2, 5-5, A-22
Mutual Interference Zone, A-19
Mutual Interlock, A-19
Mutual Interlock Circuit, A-20
N
NAC, 5-22
Network Access Port, 5-33
Network Update Time, 5-36
NIOSHA, 1-4
Node, 5-33, 5-36
Node Adapter Chip (NAC), 5-5
Non-Retentive Relay, 5-7
O
OC-1, 3-19
OC-2, 3-19
Occupational Safety and Health Standards, 1-2
OK JUMP-ON, A-15
OK JUMP-ST, A-15
OK RPS-ON, A-11
OK RPS-ST, A-11
Operation Panel, 1-8, 3-4
OSHA, 1-4
OUT, A-2
Output Timing, A-21
Overtravel Hardstop, 1-8
Overtravel Limit Switch, 1-8
Overvelocity, 1-8
OX, 2-10, A-2, A-19
OX.PREOUT, 2-11
P
Peer-To-Peer Messaging, 5-33
Personal Computer, 5-33
Personal Safety, 1-4
Personnel Safety Categories, 1-4
Pg0, A-6
Pinch Point, 1-6
PLC, 5-22, 5-32, 5-33
PLC-5 A.I. Series, 5-33
PLC-5 Processor, 5-34
Power Supply, External +24 VDC, 3-17, 3-18, 3-19
Processor Interlocking, 5-32, 5-33
Program Selection, A-6, A-8, A-9, A-13, A-15
Programmable Logic Controller (PLC), 5-5
R
R I/O Monitor, 5-13
June 25, 1999 IN-5

I/O INTERFACE
INDEX
Random Program Selection (RPS), A-6, A-11

Range, Home Position, A-18
Remote I/O Monitor, 5-13
Remote Input/Output (R I/O), 5-2, 5-5, 5-7, 5-8
Remote Programming, 5-33
Repeat Mode, 3-8, A-2, A-23
Repeater, 5-33, 5-35
Retentive Relay, 5-7
Retractable Gun, Timing Diagram, A-37
RG-6 Coaxial Cable, 5-33
RI/O PLC (NAC) Setting, 5-22
RI/O Slogic Control, 5-24
RI/O Weld Control Setting, 5-23
RPS Code, A-10
RPS Function, A-6, A-9
RPS Mode, A-15
RPS ON, A-9
RPS Program Selection, A-12
RPS-ON, A-9, A-11, A-12
RPS-ST, A-9, A-11
RS-485, 5-2
RSLinx, 5-33
RSView, 5-33
RUN/HOLD Switch, A-2
RUNMASK, A-2
S
Safety, 1-2
Safety Features, 1-8
Safety Fence, 1-7, 3-11
Safety Fence Plug, A-4
Safety Fence Switch, 3-10, 3-12
Safety Interlock, A-17
Safety Plug, 1-7, A-5
Safety Tag, 4-3, 4-7
Scan Time, 5-36
SDOWNLOAD, 5-24, 5-28
SET2HOME, A-18
SETHOME, A-18
Signal Assignment, 2-5
Signal Numbers, Robot, 5-8
Signal Status, 5-13
Signal Timing, A-11, A-15
Signal Types, 2-3
Slogic, 5-2, 5-3, 5-4, 5-5, 5-7, 5-13, 5-24, 5-30
Slogic Execution Cycle Time, 5-7
Slogic Forced Output, 5-30
Slogic Monitor, 5-18
Slogic, Number Of Internal Signals, 5-7
Slogic Status, 5-21
Small Teach Pendant, 1-6, 1-8
Software Dedicated Input Signal, 2-6
IN-6 June 25, 1999

I/O INTERFACE
INDEX
Software Dedicated Output Signal, 2-7

Software Dedicated Signal, I-2, 2-5, 2-10, 3-17, A-9, A-29, A-39
Software Limit, 1-8
Solenoid Valve, A-21
Speed, 1-6, 2-10
Spot Welding, A-21, A-24, A-30, A-31, A-32, A-33, A-39
SRUN, 5-24, 5-26
SSTOP, 5-24, 5-27
Star Topology, 5-33
Status Screen, 5-31
Stop Circuitry, A-5
Stopping the Robot, A-2
SUPLOAD, 5-24, 5-29
Surge Protection, 3-21
T
Taps, 5-33
TB2, 2-2, 3-2, 3-6, 3-13, 3-16, 4-2, 4-3, 4-6, A-42
Teach, A-22
Teach Mode, A-2, A-4, A-5, A-23
TEACH/REPEAT Switch Output, 2-2
TEACHING Screen, A-22
Terminal Block (TB), 3-18, 3-20, 4-2, 4-7
Timer, 5-2, 5-5, 5-7
Timer Status, 5-13, 5-17
Timing Diagram, Retractable Gun, A-37
Tool, 2-10
Topology, 5-33
Trap Point, 1-5
Tree Topology, 5-33
Trigger Switch, 1-6
Trunk Cable, 5-33
TWAIT, A-8
U
Universal Remote I/O, 5-34
User Display Screen, 5-4, 5-24, 5-25
V
Valve, A-34
VIN1, 3-19
VIN2, 3-19
W
WAIT SIG, A-8
Warning/Caution Symbols, 1-3
Weld Command, A-32, A-35, A-36
Weld Complete, A-36
Weld Controller, A-34, A-35, A-36, A-38
Weld Current, 5-31
Weld Data, 5-19
June 25, 1999 IN-7

I/O INTERFACE
INDEX
Weld Schedule, A-35

Weld Timing, A-36
Welder Number, 5-31
Welding, I/O Signals, A-35
Windows NT/95/98, 5-33
Work Cell, 1-4, A-2, A-4, A-5
Work Envelope, 1-4, 1-5, 1-6, 1-7, A-19
WX, 2-10, A-19
IN-8 June 25, 1999

Kaaa WSK: C Series Controller I/O Interface Mpeiccon28E

Uploaded by

Document Information

Original Title

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

Kaaa WSK: C Series Controller I/O Interface Mpeiccon28E

Uploaded by

Copyright:

Available Formats

Kawasak

All Rights Reserved.

Copyright © 1999, Kawasaki Robotics (USA), Inc.

KAWASAKI ROBOTICS (USA), INC. TRAINING

For additional information contact:

Kawasaki Robotics (USA), Inc.

0 7/6/99 Initial PDF release, based on rev. 3 of print copy KR

I.0 INTRODUCTION .................................................................................................. I-2

February 20, 1998 I-1

I.1 HARDWARE DEDICATED SIGNAL

I.2 SOFTWARE DEDICATED SIGNAL

I.3 GENERAL PURPOSE SIGNAL

The number of system I/O signals is the sum of soft-

I-2 February 20, 1998

1.0 SAFETY ......................................................................................................... 1-2

February 20, 1998 1-1

Safety is an important consideration in the use of automated and robotic equipment in

1. OCCUPATIONAL SAFETY AND HEALTH STANDARDS, available from: DEPART-

2. AMERICAN NATIONAL STANDARD FOR INDUSTRIAL ROBOTS AND ROBOT

1-2 February 20, 1998

1.2 SAFETY CONVENTIONS AND SYMBOLOGY

1.2.1 WARNING/CAUTION SYMBOLS

February 20, 1998 1-3

1.3 PERSONAL SAFETY

1.3.1 PERSONNEL SAFETY CATEGORIES

Personnel safety can be described in one of four categories:

• Safety during operation.

• Safety during programming.

• Safety during inspection and maintenance.

A description of each follows in this section.

1.3.1.1 PERSONAL SAFETY

• Locate all emergency stop buttons or switches.

1-4 February 20, 1998

• If any personnel observe unsafe working conditions, report them immediately to

February 20, 1998 1-5

1.3.1.2 SAFETY DURING OPERATION

• Never block the operator’s path of retreat.

• AVOID pinch points.

1.3.1.3 SAFETY DURING PROGRAMMING

• AVOID pinch points.

1-6 June 25, 1999

1.3.1.4 SAFETY DURING INSPECTION AND MAINTENANCE

• Assign only qualified personnel to perform all maintenance procedures.

• Use only replacement parts approved by Kawasaki Robotics (USA), Inc.

• During inspection and maintenance procedures, if your installation is equipped with

February 20, 1998 1-7

1.3.2 SAFETY FEATURES

• All E-stops are hardwired.

• Robot velocities are constantly monitored by software. Should an overvelocity

• All robot axes have software limits.

1-8 June 25, 1999

2.0 I/O SIGNALS ................................................................................................. 2-2

February 20, 1999 2-1

2.0 I/O SIGNALS

2.1 HARDWARE DEDICATED SIGNALS

The primary purpose of hardware dedicated signals is to function as external remote

The following hardware dedicated signals are available:

1) External Control Power ON/OFF

1) TEACH/REPEAT Switch Output

2-2 February 20, 1998

or Leading edge trigger

or Trailing edge trigger

Level trigger (active high)