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WARNING
The SCORBOT-ER VII is dangerous
and can cause severe injury.
USE WITH EXTREME CAUTION.
Set up a protective screen or guard rail
around the robot to
KEEP PEOPLE AWAY
from its working range.
Copyright 1996, 1998 by Eshed Robotec (1982) Limited.
February 1996, reprinted December 1998 (PDF)
Catalog # 100017 Rev.C
ISBN 965-291-033-3
All rights reserved.
This book is designed to provide inIormation about the 6&25%27(59,,.
Every eIIort has been made to make this book as complete and accurate as
possible. However, no warranty oI suitability, purpose, or Iitness is made or
implied. Eshed Robotec (1982) Ltd. is not liable or responsible to any person or
entity Ior loss or damage in connection with or stemming Irom the use oI
&RQWUROOHU$, $&/, $76, the 6&25%27(59,, robot, and/or the inIormation
contained in this publication.
Eshed Robotec (1982) Ltd. bears no responsibility Ior errors which may appear in
this publication and retains the right to make changes to the hardware, soItware
and manual without prior notice.
SCORBOT is a registered trademark, and $&/ is a trademark, oI Eshed Robotec
(1982) Ltd.
Read this manual thoroughly beIore attempting to install or operate the robot. II
you have any problems during installation or operation, call your agent Ior
assistance.
Save the original carton and all packing material. You may need them later Ior
shipment.
Table of Contents
CHAPTER 1 General Information 1-1
Unpacking Instructions . . . . . . . . . . . . . . . . . . . . 1-1
Handling Instructions . . . . . . . . . . . . . . . . . . . . . 1-2
Repacking for Shipment . . . . . . . . . . . . . . . . . . . 1-2
Acceptance Inspection . . . . . . . . . . . . . . . . . . . . 1-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 1-4
Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Controller . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Controller . . . . . . . . . . . . . . . . . . . . . . . . 1-6
CHAPTER 2 The Robot Arm 2-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Work Envelope . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Position and Limit Devices . . . . . . . . . . . . . . . . . . 2-6
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Microswitches . . . . . . . . . . . . . . . . . . . . . . 2-7
Limit Switches . . . . . . . . . . . . . . . . . . . . 2-7
Home Switches . . . . . . . . . . . . . . . . . . . 2-8
Hard Stops . . . . . . . . . . . . . . . . . . . . . 2-8
Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Cables and Pin Assignments . . . . . . . . . . . . . . . . 2-9
CHAPTER 3 The Controller 3-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Controller Functions . . . . . . . . . . . . . . . . . . . . . 3-4
Power On/Off Switch and LED . . . . . . . . . . . . . 3-4
Motors and User Power Supply Switch and LED . . . . 3-4
Emergency Switch and Lamp . . . . . . . . . . . . . . 3-5
User Power Supply Terminals . . . . . . . . . . . . . . 3-5
Input and Output Terminals and LEDs . . . . . . . . . 3-6
Inputs . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Outputs . . . . . . . . . . . . . . . . . . . . . . . 3-7
Relay Outputs 1-4 . . . . . . . . . . . . . . . . 3-7
Open Collector Outputs 5-16 . . . . . . . . . . 3-7
Input and Output LEDs . . . . . . . . . . . . . . . 3-8
Controller Components . . . . . . . . . . . . . . . . . . . 3-9
Controller-Computer RS232 Cable . . . . . . . . . . . . . 3-10
Users Manual SCORBOT-ER VII vii
9602
CHAPTER 4 Installation 4-1
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cable Connections . . . . . . . . . . . . . . . . . . . . . . 4-2
Peripheral Axes . . . . . . . . . . . . . . . . . . . . . . . 4-4
Power On . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Controller Configuration . . . . . . . . . . . . . . . . . . . 4-5
Homing the Robot . . . . . . . . . . . . . . . . . . . . . . 4-7
Gripper Installation . . . . . . . . . . . . . . . . . . . . . . 4-8
DC Servo Electric Gripper . . . . . . . . . . . . . . . . 4-8
Pneumatic Gripper . . . . . . . . . . . . . . . . . . . . 4-10
CHAPTER 5 Operating Methods 5-1
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ACL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ACLoff-line . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SCORBASE . . . . . . . . . . . . . . . . . . . . . . . 5-2
Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Keypad Functions . . . . . . . . . . . . . . . . . . . . 5-3
The Display Panel . . . . . . . . . . . . . . . . . . . . 5-7
CHAPTER 6 Operating the Robot 6-1
DIRECT Mode . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Using this Manual . . . . . . . . . . . . . . . . . . . . . . 6-2
Activating the Sytem . . . . . . . . . . . . . . . . . . . . . 6-2
Homing the Robot and Peripheral Axes . . . . . . . . . . . 6-3
Coordinate Systems . . . . . . . . . . . . . . . . . . . . . 6-5
Cartesian (XYZ) Coordinates . . . . . . . . . . . . . . 6-5
Joint Coordinates . . . . . . . . . . . . . . . . . . . . 6-5
Servo Control . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Axis Control Groups . . . . . . . . . . . . . . . . . . . . . 6-8
Moving the Axes . . . . . . . . . . . . . . . . . . . . . . . 6-9
XYZ and Joint Movements . . . . . . . . . . . . . . . . 6-9
Activating the Gripper . . . . . . . . . . . . . . . . . . 6-11
Setting the Speed . . . . . . . . . . . . . . . . . . . . . . 6-12
Defining and Recording Positions . . . . . . . . . . . . . . 6-13
Relative Positions . . . . . . . . . . . . . . . . . . . . 6-15
Listing Positions . . . . . . . . . . . . . . . . . . . . . 6-16
Deleting Positions . . . . . . . . . . . . . . . . . . . . 6-16
Moving to Recorded Position . . . . . . . . . . . . . . . . 6-17
Linear Movement . . . . . . . . . . . . . . . . . . . . 6-18
Circular Movement . . . . . . . . . . . . . . . . . . . . 6-18
viii SCORBOT-ER VII Users Manual
9602
CHAPTER 7 Programming with ACL 7-1
EDIT Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Creating a Program . . . . . . . . . . . . . . . . . . . . . 7-2
Writing a Program . . . . . . . . . . . . . . . . . . . . . . 7-2
Running a Program . . . . . . . . . . . . . . . . . . . . . 7-3
Program Loop . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Displaying Program Lines . . . . . . . . . . . . . . . . . . 7-4
Halting Program Execution . . . . . . . . . . . . . . . . . . 7-4
Suspend the Program . . . . . . . . . . . . . . . . . . 7-4
Abort the Program . . . . . . . . . . . . . . . . . . . . 7-5
Stop the Program . . . . . . . . . . . . . . . . . . . . 7-5
Delaying Program Execution . . . . . . . . . . . . . . . . . 7-6
Variable Programming . . . . . . . . . . . . . . . . . . . . 7-6
Mathematical and Logical Functions . . . . . . . . . . 7-7
Iteration Functions . . . . . . . . . . . . . . . . . . . . 7-8
Conditional Functions . . . . . . . . . . . . . . . . . . 7-9
Input and Output Programming . . . . . . . . . . . . . . . 7-10
Displaying Input/Output Status . . . . . . . . . . . . . 7-10
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Activating Output-Driven Devices . . . . . . . . . . 7-11
Pneumatic End Effectors or Devices . . . . . . 7-11
Warning Light . . . . . . . . . . . . . . . . . . 7-11
Sample Program: INOUT . . . . . . . . . . . . . . . . . . 7-12
Program Directory . . . . . . . . . . . . . . . . . . . . . . 7-14
Multi-Tasking . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Displaying Program Status . . . . . . . . . . . . . . . 7-15
Activating a Program from Another Program . . . . . . . . 7-15
Simultaneous Execution . . . . . . . . . . . . . . . . . 7-15
Program Interrupt . . . . . . . . . . . . . . . . . . . . 7-16
Saving a Program (Backup) to Disk . . . . . . . . . . . . . 7-16
Downloading a Program (Restore) to Controller . . . . . . . 7-17
CHAPTER 8 Maintenance 8-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 8-2
Robot Arm Calibration Parameters . . . . . . . . . . . 8-2
General System Check . . . . . . . . . . . . . . . . . 8-3
Diagnostic Procedures . . . . . . . . . . . . . . . . . . 8-3
Error Messages . . . . . . . . . . . . . . . . . . . . . 8-13
Adjustments and Repairs . . . . . . . . . . . . . . . . . . 8-15
Opening the Controller Cover . . . . . . . . . . . . . . 8-15
Changing the Voltage Setting . . . . . . . . . . . . . . 8-15
Replacing Fuses . . . . . . . . . . . . . . . . . . . . . 8-16
Logic Power Supply Fuse . . . . . . . . . . . . . . 8-16
Power Transformer Fuse . . . . . . . . . . . . . . 8-16
User Power Supply Fuse . . . . . . . . . . . . . . 8-17
Driver Card Fuses . . . . . . . . . . . . . . . . . . 8-17
Users Manual SCORBOT-ER VII ix
9602
Changing the I/O Logic Mode . . . . . . . . . . . . . . 8-18
Replacing or Adding a Driver Card . . . . . . . . . . . 8-19
Adjusting Driver Card Current Limit . . . . . . . . . . . 8-20
Driver Card Jumper Configuration . . . . . . . . . . . . 8-20
Installing the Auxiliary RS232 Communication Card . . 8-21
APPENDIX A Theory of Control A-1
Servo Control . . . . . . . . . . . . . . . . . . . . . . . . A-1
Open Loop Control . . . . . . . . . . . . . . . . . . . A-1
Closed-Loop Control . . . . . . . . . . . . . . . . . . . A-1
Digital Control . . . . . . . . . . . . . . . . . . . . . . . . A-2
Transient and Steady State Responses . . . . . . . . . . . A-4
Controller-A Control Process . . . . . . . . . . . . . . . . . A-6
Trajectory Control . . . . . . . . . . . . . . . . . . . . . . A-7
Paraboloid . . . . . . . . . . . . . . . . . . . . . . . . A-7
Trapezoid . . . . . . . . . . . . . . . . . . . . . . . . A-7
Path Control . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Point-to-Point Control . . . . . . . . . . . . . . . . . . A-7
Continuous Path Control . . . . . . . . . . . . . . . . . A-8
The Control Parameters . . . . . . . . . . . . . . . . . . . A-9
Proportional Control . . . . . . . . . . . . . . . . . . . A-9
Differential Control . . . . . . . . . . . . . . . . . . . A-10
Integral Control . . . . . . . . . . . . . . . . . . . . A-10
ProportionalIntegralDifferential Control . . . . . . . A-11
Offset . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Changing Parameter Values . . . . . . . . . . . . . . A-12
x SCORBOT-ER VII Users Manual
9602
CHAPTER 1
General Information
Read this chapter carefully before you unpack the robot and controller.
This chapter contains instructions for unpacking and handling the
SCORBOT-ER VII and Controller-A.
This chapter also includes important safety guidelines and warnings.
Unpacking Instructions
The robot arm and the controller are packed in two separate cartons. Save the
original packing materials and shipping carton. You may need them later for
shipment or storage.
To protect the robot during shipment, a metal plate holds the gripper-mounting
flange to the robot base. The plate is fixed to the flange with three bolts and to the
base with two bolts. See Figure 1-1. Use the hex wrench supplied with the robot
to detach these bolts.
Save these bolts and the
plate. You will need
them should you repack
the robot for shipment.
More important, you
will need three of these
bolts to attach the
gripper to the flange.
Figure 1-1: SCORBOT-ER VII Packing
Users Manual SCORBOT-ER VII 1 - 1
9602
The controller package contains two ATS diskettes. Each diskette includes a
parameter file named PAR7.CBU which is uniquely associated with the robot you
have received. One diskette is write-protected.
Store the protected disk together with the computer print-out of the robots
parameter file.
Handling Instructions
Lift and carry the robot arm only by
grasping the body or the base.
See Figure 1-2.
Do not lift and/or carry the robot arm
by its upper arm or forearm.
Lift and carry the controller by
grasping it on and under the left and
right side panels.
Do not grasp the controller on either
its front or back panel, and avoid
handling near the power switch.
Repacking for Shipment
Be sure all parts are back in place before packing the robot/controller.
When repacking the robot for shipment, bolt the flange and base to the metal
plate. Failure to do so may cause irreversible damage to the arm, particularly to
the harmonic drive transmissions. Also be sure to secure the cables around the
foam spool.
The robot and controller should be repacked in their original packaging for
transport.
If the original carton is not available, wrap the robot/controller in plastic or heavy
paper. Put the wrapped robot/controller in a strong cardboard box at least 15 cm
(about 6 inches) longer in all three dimensions than the robot. Fill the box equally
around the unit with resilient packing material (shredded paper, bubble pack,
expanded foam chunks).
Seal the carton with sealing or strapping tape. Do not use cellophane or masking
tape.
Figure 1-2: Robot Arm Parts
1 - 2 SCORBOT-ER VII Users Manual
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Acceptance Inspection
After removing the robot arm and controller from their shipping cartons, examine
them for signs of shipping damage. If any damage is evident, do not install or
operate the system. Notify your freight carrier and begin appropriate claims
procedures.
The following is a list of the standard components in the SCORBOT-ER VII
package. Make sure you have received all the items listed on the shipments
packing list. If anything is missing, contact your supplier.
SCORBOT-ER VII Standard Package (Catalog # 404)
Item Description
SCORBOT-ER VII Robot Arm
Includes: power cable 100/110/220VAC; RS232 cable;
4 driver cards (for 8 axes); bolts for mounting robot;
set of hex wrenches.
ACL Controller-A
Gripper Options: Pneumatic or Electric DC Servo
Software
ATS (Advanced Terminal Software): 2 diskettes; one
is write-protected; includes ACLoff-line software.
SCORBASE Level 5 Software: 1 diskette
Documentation
SCORBOT-ER VII Users Manual
ACL Reference Guide
ATS Reference Guide
SCORBASE Level 5 (ACL Version) Reference Guide
ACLoff-line Users Manual
The following table is a sampling of the optional accessories which are
compatible for use with the SCORBOT-ER VII system.
For a complete list of the accessories, devices, software and documentation for
integration and use with the SCORBOT-ER VII sytem, contact your agent.
Optional Components for SCORBOT-ER VII System
Item Cat. # Notes
Teach Pendant for Controller-A 1703
Driver Card for Peripheral Axes:
Card with two 2A fuses
Card with one 2A fuse and one 4A fuse
Card with two 4A fuses
45018
45019
45020
Each card drives 2 axes;
If ordered with controller,
card is factory-installed.
Auxiliary RS232 Communication Card
Cable with 8 connectors for auxiliary card
45012
40024
If ordered with controller,
card is factory-installed.
SCORBASE Levels 1-3 software 9004
Users Manual SCORBOT-ER VII 1 - 3
9602
Optional Components for SCORBOT-ER VII System
Item Cat. # Notes
DC Motor Kits:
Motor with 5.9:1gear ratio
Motor with 19.5:1 gear ratio
Motor with 65.5:1 gear ratio
Motor with 127:1 gear ratio
1210
1212
1211
1206
12VDC, Includes encoder and
connector cable.
Rotary Table (black) 1005 12VDC, 350mm plate
Proximity Sensor for Rotary Table 1209
Conveyor Belt (gray) 1006 12VDC, 20-slot encoder
Proximity Sensor for Conveyor 1203
Experiment Table 1201
48" Linear Slidebase
72" Linear Slidebase
1001
1002
12VDC
1.0M Linear Slidebase
1.5M Linear Slidebase
1008
1007
24VDC
Gripper attachment for round/square parts 616 For #613
DC Servo Gripper
Pneumatic Gripper
613
614
Vacuum Gripper (1 suction cup)
Vacuum Gripper (3 suction cups)
601
602
Requires #1204 and #1208
Air Brush Paint Gun 603
Syringe Dispenser 604
Utilities Control Box 1204
Includes solenoid value, air
regulator, fittings, power
supply.
Air Supply Adapter Kit 1208
Includes 2 quick connectors
and air hose.
I/O Interface Box for Controller-A 1215
Safety Precautions
This manual provides complete details for proper installation and operation of the
SCORBOT-ER VII and Controller-A. Do not install or operate the robot or
controller until you have thoroughly studied this Users Manual. Be sure you
fheed the safety guidelines for both the robot and the controller.
Robot
1. Make sure the robot base is properly and securely bolted in place.
2. Make sure the robot arm has ample space in which to operate freely.
1 - 4 SCORBOT-ER VII Users Manual
9602
3. Make sure a guardrail, rope or safety screen has been set up around the
SCORBOT-ER VII operating area to protect both the operator and bystanders.
4. Do not enter the robots safety range or touch the robot when the system is in
operation. Before approaching the robot, make sure the motor switch on the
controller front panel has been shut off.
5. Make sure loose hair and clothing is tied back when you work with the robot.
Controller
1. The power cable must have a ground connection. If your power outlet does not
have a safety ground, do not connect the controller. Failure to connect the power
cable to a grounded outlet could result in electrical shock.
1. Turn off the controllers motor switch before you enter the robots operating area.
2. Turn off the controllers power switch before you connect any inputs or outputs
to the controller.
3. Turn off the controllers power switch and disconnect the controller power cable
from the AC power outlet before you open the controller cover or remove any
fuses. The power cable must be disconnected to remove possible shock hazard.
4. Never open the controller cover during robot operation.
Be sure you know how to immediately abort all running programs and stop all
axes of motion:

press the Abort key on the teach pendant, or

use the ACL command A <Enter>, or

press the controllers red EMERGENCY button.

Warnings
Do not install or operate the SCORBOT-ER VII or Controller-A under any of the
following conditions:

Where the ambient temperature or humidity drops below or exceeds the

specified limits.

Where exposed to large amounts of dust, dirt, salt, iron powder, or similar
substances.

Where subject to vibrations or shocks.

Where exposed to direct sunlight.

Where subject to chemical, oil or water splashes.

Users Manual SCORBOT-ER VII 1 - 5
9602

Where corrosive or flammable gas is present.

Where the power line contains voltage spikes, or near any equipment which
generates large electrical noises.
Robot

Do not overload the robot arm. The combined weight of the workload and
gripper may not exceed 2kg (4.4 lb). It is recommended that the workload be
grasped at its center of gravity.

Do not use physical force to move or stop any part of the robot arm.

Do not drive the robot arm into any object or physical obstacle.

Do not leave a loaded arm extended for more than a few minutes.

Do not leave any of the axes under mechanical strain for any length of time.
Especially, do not leave the gripper grasping an object indefinitely.

Since the SCORBOT-ER VII motors are rated 12VDC nominal, while the
controller motor drivers supply 24VDC, do not drive axes continuously in one
direction at maximum speeds. Specifically, when using the ACL command:
SET ANOUT[n]=DAC, make sure the DAC value is in the range 2500.
Controller

Before you plug the controller into the AC outlet, make sure its voltage
requirement (as seen on the tag at the back of the controller) matches your
voltage supply.
If the voltage setting does not match your supply, do not connect the
controller; contact your agent.

Do not connect accessories to the driver cards for axes 1 through 6 (cards
with black brackets). Irreversible damage will occur.

Do not connect any voltage in excess of 24 VDC to the input terminals.

Do not connect any voltage in excess of 24VDC to the output terminals.

Never connect voltage from a power supply directly to any open collector
outputs (terminals 516). The open collector ouputs must always be
connected to a load. Never connect a load to voltage exceeding 24VDC.

Never drive a current of more than 4A through the relay outputs

(terminals 1-4).

Never drive a current of more than 0.5A through the open collector outputs
(terminals 516).
1 - 6 SCORBOT-ER VII Users Manual
9602
CHAPTER 2
The Robot Arm
This chapter details the specifications and components of the
SCORBOT-ER VII robot arm.
Figure 2-1: SCORBOT-ER VII Robot Arm
Users Manual SCORBOT-ER VII 2 - 1
9602
Specifications
The following table details the robot arm specifications.
SCORBOT-ER VII Specifications
Mechanical Structure Vertical articulated
Number of Axes 5 axes plus gripper
Axis Movement
Axis 1: Base rotation
Axis 2: Shoulder rotation
Axis 3: Elbow rotation
Axis 4: Wrist pitch
Axis 5: Wrist roll
250; 310 user programmable
170
225
180
360
Maximum Operating Radius 690 (27.2") at flange
End Effector options Pneumatic and DCServo
Hard Home
Fixed position on each axis,
found by means of microswitches
Feedback
Optical incremental encoder on each axis;
96-slot disk
Actuators 12VDC servo motors
Transmission Harmonic drives; timing belts and pulleys
Maximum Payload 2 kg (4.4 lb.), including gripper
Position Repeatability 0.2 mm (0.008")
Weight 30 kg (66 lbs)
Maximum Path Velocity 1000 mm/sec (39.4"/sec)
Ambient Operating Temperature 240C (36104F)
2 - 2 SCORBOT-ER VII Users Manual
9602
Structure
The SCORBOT-ER VII is a vertical articulated robot, with five revolute joints.
With gripper attached, the robot has six degrees of freedom. This design permits
the end effector to be positioned and oriented arbitrarily within a large work space.
Figures 2-2 and 2-3 identify the joints and links of the mechanical arm.
The movements of the joints are described in the following table:
Axis No. Joint Name Motion Motor No.
1 Base Rotates the body. 1
2 Shoulder Raises and lowers the upper arm. 2
3 Elbow Raises and lowers the forearm. 3
4 Wrist Pitch Raises and lowers the end effector 4
5 Wrist Roll Rotates the end effector 5
Figure 2-2: Robot Arm Links
Figure 2-3: Robot Arm Joints
Users Manual SCORBOT-ER VII 2 - 3
9602
Work Envelope
The length of the links and the degree of rotation of the joints determine the
robots work envelope. Figure 2-4 shows the dimensions and reach of the
SCORBOT-ER VII.
The base of the robot is normally fixed to a stationary work surface. It may,
however, be attached to a slidebase, resulting in an extended working range.
Figure 2-4: Operating Range With Gripper Attached
2 - 4 SCORBOT-ER VII Users Manual
9602
Drive System
The main elements of the SCORBOT-ER VII drive system are motors,
Harmonic drive gears, and
pulleys and timing belts, as
shown in Figures 2-5 and 2-6.
Brush-commutated, DC
permanent magnet motors drive
the five axes. Figure 2-7 shows
the location of the motors. The
direction of motor revolution is
determined by the polarity of the
operating voltage: positive DC
voltage turns the motor in one
direction, while negative DC
voltage turns it in the opposite
direction. Each motor is fitted with an encoder for closed-loop control.
Motor Specifications
Motor Axes 1, 2, 3 Motor Axes 4, 5
Motor Constant 3.01 ozin / W 1.94 ozin / W
Peak Torque (Stall) 41.3 ozin 15.6 ozin
No Load Speed 6151 rpm 5592 rpm
Motor Friction Torque 0.60 ozin 0.50 ozin
Motor Weight 10.1 oz 8.98 oz
Axes 1 through 4 are driven by a two-stage transmission, as shown in Figure 2-5. The
roll axis (axis 5) is driven directly by a Harmonic drive gear.
Figure 2-5: Drive System
Figure 2-6: Transmissions Figure 2-7: Motor Locations
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Position and Limit Devices
The SCORBOT-ER VII uses encoders, microswitches and hard stops to position
the robot arm and limit its motion.
Encoders
The location and movement of each SCORBOT-ER VII axis is measured by an
electro-optical incremental encoder which is attached to the shaft of the motor
which drives the axis, as shown in Figure 2-8.
When the robot axis moves, the encoder
generates a series of alternating high and low
electrical digital signals, which can be
understood by the controller. The controller reads
these signals and determines the extent and
direction of axis movement.
The encoder used on the SCORBOT-ER VII
contains a single light emitting diode (LED) as
its light source. Opposite the LED is a light
detector integrated circuit. This IC contains
several sets of photodetectors and the circuitry
for producing a digital signal.
A perforated, rotating disk is located between the
emitter and detector IC. The SCORBOT-ER VII
encoders have 96 slots, as shown in Figure 2-9. As
the encoder disk rotates between the emitter and detectors, the light beam is
interrupted by the pattern of bars and windows on the disk, resulting in a
series of pulses received by the detectors.
The photodetectors are arranged so that, alternately, some detect light while
others do not. The photodiode outputs are then fed through the signal processing
Figure 2-8: Encoder
Figure 2-9: Encoder Disk Figure 2-10: Encoder Output Signals
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circuitry, resulting in the signals A, A, B and B. Comparators receive these
signals and produce the final digital outputs for channels A and B. The output of
channel A is in quadrature with that of channel B (90 out of phase), as shown in
Figure 2-10.
When the disk rotation is counterclockwise (as viewed from the encoder end of
the motor), channel A will lead channel B. When the disk rotation is clockwise,
channel B will lead channel A.
Microswitches
Microswitches, shown in Figure 2-11, are used in the
SCORBOT-ER VII to limit robot motion (limit
switches) and to home the robot (home switches).
Limit Switches
Limit switches prevent the joints from moving
beyond their functional limits. When the robot
control software fails to stop the axis at the end of
its working range, the limit switch serves to halt its
movement.
Each of axes 1 through 4 has two limit switches
one at each end of the axis working range. These
switches are mounted on a disk which is attached to
the robots frame and are normally depressed. Figure 2-12 shows the
microswitches on axis 3.
The Harmonic drive output shaft moves relative to the microswitch disk. As the
joint moves, the limit switch reaches a notch on the Harmonic drive output shaft,
which releases the activating button and thus activates the switch.
When the limit switch is activated, it causes a control error, resulting in the
activation of COFF, and an impact
protection message. CON must be
activated and the robot arm must be
manually moved (using keyboard or
teach pendant) away from the impact
condition.
Axis 5 (roll) has no limit switches; it
can rotate endlessly. When a gripper is
attached to axis 5, its movements are
controlled and limited by means of
software (encoder) only.
Figure 2-11: Microswitch
Figure 2-12: Microswitches on Axis
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Home Switches
The SCORBOT-ER VII also has a microswitch on each axis to identify the fixed
reference, or home, position. The home switch is mounted on the same disk as the
limit switches, and is activated by the stopping screw on the Harmonic drive
output shaft.
During the homing procedure, the robot joints are moved one at a time. Each axis
is moved until its home switch is activated. The axis is then moved slightly until
the switch shuts offat that point the joint is at home.
When all joints are at home, the robot is at home. This is the point of reference
for robot operation. Whenever the system is turned on, the robot should be sent to
this position, by means of a software homing routine.
Hard Stops
When the software limits and/or the limit switches fail to halt the movement of
the robot arm, it is possible that the momentum of the robot arm will drive it until
it reaches its mechanical limit. The SCORBOT-ER VII has a stopping screw on
the Harmonic drive output shaft for this purpose.
If the stopping screw hits the microswitch disk, the impact protection processes
detect an error, thus activating COFF.
CON must be activated and the robot arm must be manually moved away from
the impact condition.
Gripper
The SCORBOT-ER VII can be equipped
with either a pneumatic gripper driven by
output signals, or by an electric servo gripper
driven by a DC motor and controlled as axis
number 6, shown in Figure 2-13.
These grippers have parallel finger motion.
The non-servo DC gripper (cat.#608) is no
longer available for the SCORBOT-ER VII.
Figure 2-13: DC Servo Gripper
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Cables and Pin Assignments
The robot cable contains six cables with D9 connectors, for connecting to axis
driver card ports at the back of the controller. Each cable is labeled for a specific
axis. The robot cable wiring and pin assignments are given in the table below.
Refer also to Figure 2-14.
SCORBOT-ER VII Cables and Connector Pin Assignments
Axis #
(Robot Cable #)
D9 Connector
Pin #
Wire
Color
Connector
to Robot
PCB
Function
1
3 Red
Telephone
+5V
4 Blue Home switch
5 Black Common
6 Green Encoder channel B
8 White Encoder channel B
9 Red
Molex
Motor 1 +
1 Black Motor 1
2
3 Red
Telephone
+5V
4 Blue Home switch
5 Black Common
6 Green Encoder channel B
8 White Encoder channel B
9 Orange
Molex
Motor 2 +
1 Brown Motor 2
3
3 Red
Telephone
+5V
4 Blue Home switch
5 Black Common
6 Green Encoder channel B
8 White Encoder channel B
9 Violet
Molex
Motor 3 +
1 Yellow Motor 3
4
3 Red
Telephone
+5V
4 Blue Home switch
5 Black Common
6 Green Encoder channel B
8 White Encoder channel B
9 Blue
Molex
Motor 4 +
1 Light Blue Motor 4
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SCORBOT-ER VII Cables and Connector Pin Assignments
Axis #
(Robot Cable #)
D9 Connector
Pin #
Wire
Color
Connector
to Robot
PCB
Function
5
3 Red
Telephone
+5V
4 Blue Home switch
5 Black Common
6 Green Encoder channel B
8 White Encoder channel B
9 Pink
Molex
Motor 5 +
1 Gray Motor 5
6
3 Red
Telephone
+5V
4 Blue Home switch
5 Black Common
6 Green Encoder channel B
8 White Encoder channel B
9 Green
Molex
Motor 6 +
1 White Motor 6
Figure 2-14: Robot Wiring
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CHAPTER 3
The Controller
This chapter details the specifications and functions of Controller-A, which controls
the SCORBOT-ER VII robotic system.
Figure 3-1: Controller-A
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Specifications
Item Controller-A Specification Notes
Type of Control
Stand-alone
Real-time
Multi-tasking
PID (proportional, integral, differential)
PWM (pulse width modulation)
Terminal or PC required
only for programming
stage.
Number of
Servo Axes
Standard: 8
Maximum: 11
Groups of Control
11 axes can be divided into 3 groups:
Group A
Group B
Group C (independent axes)
Each group has
independent control.
Axis interpolation in
groups A and B.
Axis Drivers
PWM (pulse width modulation)
20 KHz
Path Control
PTP (point to point), CP (continuous path)
Joint
Linear
Circular
User-defined path
10 ms control cycle.
Software controlled
acceleration/deceleration.
PID parameters.
Trajectory Control
Paraboloid
Trapezoid
Open Loop (not for user)
Speed Control
Speed
Travel time
Speed programmed as a
percentage of range.
Control Parameters
Servo control
Speed, velocity profile, smoothing
Axis position error
Gripper operation
Thermic, impact, limit protection
Homing
Encoder interface
Cartesian calculations
Power Requirements 100/110/220V AC, 50/60Hz, 500W max. 5%
Internal Power
Supplies
Motors: +24VDC, 18A
User: +12VDC, 2A
Weight 19 kg (42 lbs)
Dimensions
490mm (19.3") L
445mm (17.5") W
150mm (5.9") H
Ambient Operating
Temperature
240C (36104F)
CPU Motorola 68020
EPROM 384KB
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Item Controller-A Specification Notes
RAM
System: 64KB
User: 128KB
Communication RS232 serial port
Inputs
16 inputs (with indicator LEDs);
NPN (default) and PNP logic modes.
TTL, 12V or 24V logic
Outputs
12 open collector outputs (with indicator LEDs);
NPN (default) and PNP logic modes.
4 relay outputs (with indicator LEDs)
Programming
Languages
ACL: Advanced Control Language
Using any terminal
Using PC with ATS
SCORBASE Level 5 Software Using PC
Position Recording
Absolute
Relative
Cartesian
Joint
Using: ACL,
SCORBASE,
Teach Pendant
No. of program
lines/positions
12800 lines or 6375 positions (or any combination)
No. of programs in
user RAM
Hundreds; depends on length of programs.
Multi-tasking Maximum simultaneous execution: 20 user tasks
Positioning System Incremental optical encoders
Coordinate System
XYZ coordinates
Joint coordinates
LED Indicators
Main power
Inputs/Outputs
Servo Power
Emergency
On front panel
Axis power On rear panel
Safety Features
Emergency switch
Motor power switch
On front panel
Adjustable current limit
Automatic fuse
On all axes
Thermic, impact and limit software protection
Connectors
Inputs/Outputs
User power supply
Terminals on front panel
Axis drivers
RS232 channel
Teach Pendant
Robot
Auxiliary RS232 channels (optional)
On rear panel:
D9 connectors
D25 connector
D25 connector
D50 connector
D37 connector
Teach Pendant
30 multi-function keys
2 line LCD display; 16 characters per line
Full control features
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Controller Functions
The front panel of the controller contains switches, LEDs and connection
terminals for operator use. Refer to Figure 3-2.
Power On/Off Switch and LED
The controllers power switch, which is located on the side of the controller,
connects and disconnects AC power to the controller.
The yellow power LED on the controllers front panel lights up when the power
switch is turned on. It indicates that power is being supplied to the controller.
Motors and User Power Supply Switch and LED
This switch connects and and disconnects DC voltage to all the connected motors
and to the user power supply. A green LED embedded in the switch lights up
when the switch is on.
The motors switch is turned off in the following circumstances:

To disconnect power to the motors, user power supply, and inputs without
turning off the controller.

To prevent possible motion of axes.

Figure 3-2: Controller Front Panel
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When the motors switch is turned off, the robot motors and all connected axes are
unable to move. In addition, it disconnects the user power supply, making the
controller inputs and open collector outputs inoperative.
Emergency Switch and Lamp
This switch halts all controller operations. A red lamp embedded in the switch
lights up with the switch is on. When the switch is depressed, the following
occurs:

The red emergency lamp lights up.

All running programs are aborted.

Motor power is disconnected; all motor movement stops; the green motors
LED shuts off. All the green LEDs on the rear panel shut off.

The user power supply is shut off.

The inputs and outputs are shut off.

When the switch is pressed again, the following occurs:

The red emergency lamp shuts off.

The green LED on the motors switch lights up.

The green LEDs on the rear panel light up again.

The controllers CPU is reset and the following appears on the screen:
---- RAM TEST COMPLETE.
---- ROM TEST COMPLETE.
SYSTEM READY!
>_
The robot must be homed before work can resume following an Emergency.
User Power Supply Terminals
The user power supply allows external devices in the users applications to
receive power from the controller. The controller user power supply has four
terminals:

Two +12VDC, 2A regulated power supply

Two safety ground

When the motors switch is turned off, it also disconnects the user power supply.
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Input and Output Terminals and LEDs
Controller-A is equipped with an I/O board which allows you to individually
configure the inputs and open collector outputs to operate in either negative
(NPN) or positive (PNP) logic. The controller is factory-configured for operation
in NPN mode.
Refer to the section, Adjustments and Repairs, in Chapter 8 for instructions on
altering the I/O logic mode.
Inputs
The controllers inputs allow the robotic system to receive signals from external
devices in the robots environment. The controller has 16 input terminals and four
ground connection points, as shown in Figure 3-3.
All inputs are coupled to the controller system with opto-couplers.
Inputs can be operated in either of two modes:

Negative logic mode (NPN) ; default mode:

ON is defined as low voltage (less than 1.5VDC or ground).
OFF is defined as high voltage (+5VDC to +24VDC).

Positive logic mode (PNP):

ON is defined as high voltage (+5VDC to +24VDC),
OFF is defined as low voltage (less than 1.5VDC or ground).
When the motors switch is turned off, it disconnects the user power supply,
making the controller inputs and open collector outputs inoperative.
To simulate the operation of an input when no device is connected, short the input
manually; use a wire or an unraveled paper clip, for example.

When the input is operating in NPN mode, short the input by connecting it to
a ground connector.

When the input is operating in PNP mode, short the input by connecting it to
the user power supply.
Figure 3-3: Input Terminals
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Outputs
The controllers outputs allow the robotic system to transmit signals to external
devices in the robots environment. The controller has 4 relay outputs and 12
open collector outputs.
Relay Outputs 1-4
Outputs 1 to 4, shown in Figure 3-4,
include relays in their final stage. Each
relay includes three contact points:
Common Tab (COM)
Normally Closed Tab (NC)
Normally Open Tab (NO)
Maximum voltage allowed: 24VDC
Maximum current allowed: 4A
Figure 3-5 shows the ON and OFF states
of a relay output.
Open Collector Outputs 5-16
Outputs 5 to 16, shown in Figure 3-6,
include a transistor with an open collector
in their final stage. These outputs must be
connected to a load.
Never connect open collector outputs
directly to a power supply or ground.
When using an inductive load, such as a
solenoid or relay, connect a protection diode across the load. You may connect an
open collector output directly to an input.
Open collector outputs can be operated in either of two modes:

Negative logic mode (NPN); default mode:

ON is defined as low voltage (0.3VDC or less)
OFF is defined as V (refer to Figure 3-7)

Positive logic mode (PNP):

ON is defined as +12VDC
OFF is defined as 0 volts (refer to Figure 3-8)
Maximum voltage allowed: 24VDC
Maximum current allowed: 0.5A
Figure 3-4: Relay Output Terminals
Figure 3-5: Relay Output States
Figure 3-6: Open Collector Output
Terminals
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Input and Output LEDs
16 yellow LEDs, corresponding to outputs 116, light up when the outputs are ON.
16 orange LEDs, corresponding to inputs 116, light up when the inputs are ON.
Figure 9-7: Controller-A Components
Figure 3-8: Open Collector Output: PNP Mode Figure 3-9: Open Collector Output: NPN Mode
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Controller Components
Controller Parts List
Dwg # Cat # Description
110715 Metal case - lower part
110717 Metal case - upper part
113002 Controller front panel
110719 Metal case - rear panel
110723 Coil fastener
102501 Lexan tags for front panel
110725 Long bracket - driver card support
107204 Blank brackets
12 110721 Transformer cover
13 35008 Logic power supply (220/110VAC)
9 35006 24V/12V Transformer (100VAC)
10 35003 Gripper coil assembly
2 35001 Fan plus cabling and connector
19 450541 Main board
15-17 45018 Driver cards for robot
18 45019 Driver cards for accessories
3 45011 Display card
4 45013 I/O card
11 45023 User power supply card
14 45009 Communication card
5-6 45003 Power LED card plus motors switch plus cabling
1 40004 Emergency switch plus cabling
40018 +24VDC feed cable (from J12 to capacitor J12)
40007 Diode bridge cabling
40005 Switching cable (from J20 to user power supply.)
411807 Flat cable (from J10 to I/O card)
411806 Flat cable (from J13 to communicationcard)
411808 Flat cable (from J11 to display card)
411805 Flat cable (from J8 to communication card)
40017 Gripper cable (jumper)
40010 Grounding cable for capacitor
40009 Grounding cable for transformer metal cover
40006 Resistors cable for capacitor
7 408102 Diode bridge
8 404501 10,000 F/63V capacitor
45024 Teach pendant card [inside teach pendant]
20 45012 (optional) Auxiliary RS232 multiport card
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Controller-Computer RS232 Cable
The computer and controller communicate on the RS232 channel at 9600 baud,
with 8 data bits, 1 stop bit, no parity and XON/XOFF protocol.
The RS232 cable connections between the computer and controller are as
follows:
Computer
D25 female connector
Controller
D25 male connector
Pin 2 (Transmit) Pin 3 (Receive)
Pin 3 (Receive) Pin 2 (Transmit)
Pin 7 (Logic GND) Pin 7 (Logic GND)
Pin 4 to Pin 5
Pin 6 to Pin 8 and 20
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CHAPTER 4
Installation
Before installing the SCORBOT-ER VII, be sure you have read and understood
the safety instructions and warnings detailed in Chapter 1.
Preparations
Be sure you have ample space to set up the robotic system, as shown in
Figure 4-1.
1. Set up the SCORBOT-ER VII on a sturdy surface with a minimum 900mm of
free space all around the robot.
2. Fasten the base of the robot arm to the work surface with at least 3 bolts 120
apart, as shown in Figure 4-2.
Robot Base 330 mm
Pitch Circle 226 mm
Hole (6 off) 8 mm
Make sure the robot is securely bolted in place. Otherwise the robot could
become unbalanced and topple over while in motion.
Figure 4-1: SCORBOT-ER VII Installation
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3. Set up a guardrail, rope or safety
screen around the robots operating
area to protect both the operator and
bystanders.
4. Place the controller and computer on
a sturdy surface at a safe distance
from the robotwell outside the
robots safety range.
Do not yet mount the robot gripper.
First complete the installation
procedures according to the
instructions in this chapter, in the
following order:

Cable connections

Peripheral axis connections

Activate and configure the controller

Home the robot

Mount the gripper

The robot must be homed before the gripper is mounted.
Cable Connections
Be sure to verify that the controllers voltage setting matches your voltage supply
before you connect the controller to the AC power outlet.
1. Install and configure your computer/terminal and monitor according to the
manufacturers instructions.
2. Connect the computer power cable to an AC power source.
It is recommended, though not imperative, that you connect the computer to an
AC power source other than the one used by the controller.
Make sure the controllers power switch and computers power switch are in the
off position before you continue to the next step.
For the following steps, refer to Figure 4-3.
3. Connect each of the D9 connectors on the robot cable to driver ports 1 through 6.
Note the number labeled on each cable, and connect each cable to its proper port.
Figure 4-2: Robot Base Plate Layout
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Connect the axis 6 (reserved for electric gripper) cable to port 6, even if you will
be not be using an electric gripper.
4. Connect the RS232 cable (D25 connector) to the RS232 port on the controller and
to the RS232 port on the computer. You may use either COM1 or COM2 on the
computer.
If your computers COM port requires a D9 connector, use a standard D25-D9
adapter to connect the RS232 cable to your computer.
5. If an auxiliary RS232 communication card is installed in the controller, make the
following cable connections:

Connect the cables D37 connector to the auxiliary RS232 port on the
controller.

The auxiliary card may have a cable with either two or eight D25 connectors.
Connect the cables D25 connectors to the corresponding COM ports on the
other controllers or computers. (If any of these COM ports requires a D9
connector, use a standard D25-D9 adapter to connect the RS232 cable).
To install an auxiliary RS232 communication card in your controller, follow the
instructions described in the section, Adjustments and Repairs, in Chapter 8.
6. If you will be using a teach pendant, connect it to the Teach Pendant port (D25
connector) on the controller.
7. If you will be operating additional axes by means of the controller, connect them
at this time. Refer to the following section, Peripheral Axes.
8. When you have completed all cable connections, tighten all retaining screws on
all the connectors.
Figure 4-3: Controller Rear Panel
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9. Make sure the controllers power switch is off. Then plug the controllers power
cable into AC power supply outlet.
10. You may now perform the Power On, Configuration and Homing
procedures according to the instructions which appear later in this chapter.
Peripheral Axes
Do not connect peripheral devices to the axis driver connectors labeled 1, 2, 3,
4, 5 and 6, which are reserved for the SCORBOT-ER VII robot axes and electric
gripper. Doing so will cause irreversible damage.
Use only axis driver connectors 7 and 8 (and 9 through 11 where available) for
connecting peripheral devices.
For information on installing additional driver cards, refer to the section,
Adjustments and Repairs, in Chapter 8.
For instructions on configuring Controller-A for use with peripheral devices,
refer to the ATS Reference Guide.
Do not connect accessories which require high current to axis 8 or 10.
Accessories which require high current (such as the linear slidebase) must be
connected to axis 7, 9 or 11.
Power On
1. Once you have made all the required hardware connections, you can power on the
controller.

Turn on the controllers power switch.

Turn on the controllers motors power switch.

The green (power and motor) LEDs light up.
2. Turn on your computer, and boot using your own DOS.
If your computer does not wake up, disconnect the RS232 cable, then power
on the computer, and then reconnect the RS232 cable
3. If your computer has a hard drive, make a directory for ATS, and copy the files
from the ATS distribution disk to that directory.
If your computer does not have a hard drive, make a backup copy of the ATS
disk. Keep the original disk in a safe place, and use the copy for operation.
4. Make the ATS directory or disk drive the default.
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At the DOS prompt, activate ATS.
If the controller is connected to computer port COM1 (default), type:
ats <Enter>
If the controller is connected to computer port COM2, type:
ats /c2 <Enter>
5. Once the software has loaded, the ATS main screen will appear on your monitor:
Press <Enter> to receive the > prompt, if it is not already displayed.
If you have connected a teach pendant, the TP display will show:
_
A JOINTS
6. You can now communicate directly with the controller.
Perform the controller configuration, as described in the following section.
Controller Configuration
This section describes the short-form controller configuration which loads default
parameter settings according to your responses to the prompts. The procedure
described below should be sufficient for you to begin operating the system.
If the controller has already been in operation, be sure to back-up all data before
initiating this configuration procedure.
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The configuration procedure is initiated from the ATS main screen by pressing
the hot-key combination:
<Ctrl> + <F1>
You are prompted:
Controller Configuration
ARE YOU SURE (Y/N)? N
Press Y to proceed with the configuration, or
Press N or <Enter> to cancel the configuration.
You are prompted by a short series of Controller Configuration options.
) Make sure you select the proper options for your installation.
Incorrect selections may result in damage to your equipment.
Robot type: ER V / ER-Vplus / ER-VII / OTHER
This defines the robot which is connected to the controller.
Use the left and right arrow keys to highlight ER-VII, which is the robot
connected to the controller. Then press <Enter> to accept.
When a robot (not OTHER) is selected, the controller reserves axis 6 (the
first available axis after the robot axes) for an electrical servo gripper.
How many axes are installed (8)? ..
This defines the number of axes which can be driven by the controller.
Press <Enter> to accept 8 axes (default), or
Type any other valid number and press <Enter>.
Is expanded memory installed (Y/N) Y
Press Y or <Enter> if controller has 128K RAM (default), or
Press N if controller has 32K RAM .
Does the controller have an auxiliary RS232 board?(Y/N)? N
Press Y if the auxiliary multiport RS232 board is installed in your controller,
or
Press N or <Enter> if the board is not installed (default).
Working directory is: c:\ATS
Is this correct (Y/N)?Y
The first time this prompt appears, it shows the DOS directory from which the
ATS software was activated.
The Working directory must be the directory which contains the parameter files
and the SCORBASE program file (.CBU files).
If you change the directory definition, it is written to a file named SETUP.DIR.
Thereafter, whenever ATS is loaded, the Working directory is set according to
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the definition in the SETUP.DIR file. Similarly, the SETUP.DIR file determines
the definition of the Backup directory shown in the Backup Manager screen.
SETUP.DIR is updated when either the Working directory or Backup directory
definition is changed.
Press N if you want to change the directory. The cursor moves to the directory
line, prompting you to type and <Enter> a different directory.
Press Y if the directory is correct.
Press <Esc> if you are not sure whether the displayed directory is correct.
This will cancel the configuration procedure. Press F10 to access the ATS
Backup Manager menu to verify the proper directory definition. Or exit to
DOS to verify the location of the .CBU files.
WARNING ! USER RAM WILL BE ERASED !!
ARE YOU SURE(Y/N)? N
Press Y to proceed with the configuration.
Press N or <Enter> to cancel the configuration.
After you confirm, ATS compares your selections with the controllers current
configuration. You are warned of any differences, and again prompted to confirm
the configuration.
After you again confirm, ATS performs the configuration and loads the proper
parameter files in accordance with your selections.
For complete instructions on the short-form controller configuration, including
configuration for use with the SCORBASE software, refer to the ATS Reference
Guide.
For definitions not included in the short-form configuration proceduresuch as axes
in control group C, a robot of another make, and memory allocation you will need
to use the ACL command CONFIG. Refer to the ACL Reference Guide.
Homing the Robot
The robot is homed from the ATS main screen.
At the > prompt, enter the ACL command HOME.
Type: home <Enter>
WAIT!! HOMING...
If all axes reach their home postion, a message is displayed:
HOMING COMPLETE (ROBOT)
If the homing process is not completed, an error message identifying the failure is
displayed:
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*** HOME FAILURE AXIS 4
To stop the homing while the operation is in progress, use the abort commands:
Type: A <Enter>
or press: <Ctrl>+A
For instructions on homing the robot by means of the teach pendant, and homing
the peripheral axes, refer to Chapter 6.
Gripper Installation
The gripper is attached to the flange at the
end of the robot arm whose layout is
shown in Figure 4-4.
DC Servo Electric Gripper
The controller supplied with the
SCORBOT-ER VII robot is equipped
with a piggy-back board with 68020 CPU
and 68881 FPU (floating point unit) and
ACL EPROM version F.44 or later.
The controller must be be properly
equipped and/or upgraded if you intend to
mount a DC servo electric gripper on an
older model of Controller-A (or one which was supplied with a
SCORBOT-ER V or SCORBOT-ER Vplus robots).
To install the DC servo electric gripper, do the following:
1. Make sure the D9 connector for the gripper is connected to the axis 6 driver port
at the rear of the controller.
2. Make sure the robot has been succesfully homed.
3. Using a hex wrench and six M3 socket screws, attach the gripper to the gripper
mounting flange at the end of the robot arm.
4. Connect the gripper cable to the electrical connector on the robot arm.
Make sure the connector is oriented as shown in Figure 4-5.
5. Make sure the gripper cable is positioned as shown in Figure 4-6.
6. Again execute the ACL HOME command.
Stay close to the teach pendant or controller. If the gripper cable becomes
entangled or excessively stretched during the homing, abort the procedure
immediately.
Figure 4-4: Gripper Mounting Flange
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The gripper has a rotation of 270. Do not attempt to move the gripper beyond
this limit.
7. Open and close the gripper to verify that it is functioning.
At the > prompt in the ATS main screen, enter the ACL commands:
Type:
open <Enter>
The gripper opens.
Figure 4-5: Connecting DC Servo Gripper - top view
Figure 4-6: Connecting DC Servo Gripper - side view
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Type:
close <Enter>
The gripper closes.
Or, from the teach pendant, key in:
Open/Close
The Open/Close key toggles the gripper between its open and closed states.
At the end of each work session (before turning off the controller), or before
homing the robot, make sure the grippers position is as shown in Figures 4-5
and 4-6.
Pneumatic Gripper
The pneumatic gripper, shown in Figure 4-7, is controlled by a 5/2 solenoid
pneumatic valve which is activated by one of the controllers relay outputs. The
valve may be 12VDC or 24VDC and can draw its power from the controllers
User Power Supply.
To install the pneumatic gripper, do the following:
1. Make sure the robot has been succesfully homed.
2. Using a hex wrench and six M3 socket screws, attach the gripper to the robot arm
flange.
3. Connect the coiled double hose from the gripper to the quick coupling on the
robots forearm, as indicated in Figure 4-8.
4. Refer to Figure 4-9.

Connect the two transparent 1/4" O.D.

hoses from the robot cable to the CYL
ports on the pneumatic valve.

Connect a 5 bar/90 PSI air supply to the

IN port on the valve.
5. Connect the valve to the controllers User
Power Supply as follows:

Connect one wire to a ground terminal.

Connect the other wire to the normally

open (NO) terminal of any relay output.
6. Connect 12VDC to the common (C) terminal
of the same relay output.
Figure 4-7: Pneumatic Gripper
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7. Attach the valve to the controller or
any other metalic surface by means of
the valves magnetic base.
8. Open and close the gripper to verify
that it is functioning. Refer to the
section Activating Output-Driven
Devices in Chapter 7 for instructions
on how to program and operate the
pneumatic gripper.
Figure 4-8: Gripper Connectors Figure 4-9: Pneumatic Solenoid Valve
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CHAPTER 5
Operating Methods
SCORBOT-ER VII can be programmed and operated in a number of ways. This
chapter introduces the robotic software and the teach pendant functions. Software
and teach pendant operation is described in other chapters of this manual, and in
the other manuals supplied with the system.
Software
ACL
ACL, Advanced Control Language, is an advanced, multi-tasking robotic
programming language developed by Eshed Robotec. ACL is programmed onto a
set of EPROMs within Controller-A, and can be accessed from any standard
terminal or PC computer by means of an RS232 communication channel.
ACL features include the following:

Direct user control of robotic axes.

User programming of robotic system.

Input/output data control.

Simultaneous, synchronized and interactive program execution;

full multi-tasking support.

Simple file management.

ACL is described fully in the ACL Reference Guide.
ATS
ATS, Advanced Terminal Software, is the user interface to the ACL controller.
ATS is supplied on diskette and operates on any PC host computer. The software
is a terminal emulator which enables access to ACL from a PC computer.
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ATS features include the following:

Short-form controller configuration.

Definition of peripheral devices.

Short-cut keys for command entry.

Program editor.

Backup manager.

Print manager.
ATS is described fully in the ATS Reference Guide.
ACLoff-line
ACLoff-line is a preprocessor software utility, which lets you access and use
your own text editor to create and edit ACL programs even when the controller is
not connected or not communicating with your computer.
After communication is established, the Downloader utility lets you transfer your
program to the controller. The Downloader detects the preprocessor directives,
and replaces them with a string or block of ACL program code.
ACLoff-line also enables activation of ATS, Advanced Terminal Software, for
on-line programming and system operation.
ACLoff-line is described fully in the ACLoff-line Users Manual.
SCORBASE
SCORBASE is a robotic control software package which can be used with
Controller-A. Its menu-driven structure and off-line capabilities facilitate robotic
programming and operation.
SCORBASE is supplied on diskette and operates on any PC system.
SCORBASE communicates with ACL, the controllers internal language, by
means of an RS232 channel.
Levels 1, 2 and 3 of the SCORBASE software can be ordered separately, and are
recommended for those who wish to learn robotic programming from the most
basic stages.
SCORBASE is described fully in the SCORBASE Level 5 Reference Guide.
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Teach Pendant
The teach pendant is an optional device.
The teach pendant (TP) is a hand-held terminal, used for controlling the robot and
axis connected to Controller-A. The teach pendant is most practical for moving
the axes, recording positions, sending the axes to recorded positions, and
activating programs. Other
functions can also be executed from
the teach pendant.
The teach pendants display panel is
a 2-line, 32 character liquid crystal
display (LCD). It shows the current
status of the controller, the current
user command, and system
messages.
The teach pendant has 30 function
keys. These functions are described
in this chapter. Many of the
command keys on the teach pendant
are ACL commands; these
commands are described fully in the
ACL Reference Guide.
Keypad Functions
The teach pendants keypad has 30
color-coded keys. Most of the keys
are multi-functional; for example,
some keys include both an axis
drive command and a numeric
function. The controller recognizes
the keys from the order in which they are pressed. Thus, the numeric function will
be active only if a function such as SPEED, RUN, or MOVE has been keyed in
first; otherwise, the axis drive command will be active.
Following are descriptions of the teach pendants keys and instructions for
activating them. Bulleted items indicate the different functions of multi-functional
keys.
Figure 5-1: Teach Pendant
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Accepts and/or executes the command which has been entered.
Starts execution of a program following a Run command.
A toggle key. Switches the command mode between Joints and Cartesian (XYZ).
When used following a numeric function, this key acts as a backspace function; it
cancels the last numeric entry and moves the cursor one position to the left.

Enables TP control of a specific axis group.

Successively press for group A, group B, group C, and again for group A, and
so on. When group C is displayed, enter the axis number on the numerical
keys. Then press Enter.
The Record Position and Speed functions apply only to the currently selected
group.
A toggle key. Enables (CON) and disables (COFF) control of the selected group.

The Axis keys move axes 7 through 11 in two directions.

The numeric keys are operative if one of the following functions has been
activated: Speed, Run, Record Position, Go Position, Group Select.
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In Joint mode: the Base/X keys move the base axis in two directions.
In XYZ mode: the Base/X keys move the TCP (tip of gripper) along the X-axis;
Y and Z coordinates do not change.
In Joint mode: the Shoulder/Y keys move the shoulder axis in two directions.
In XYZ mode: the Shoulder/Y keys move the the TCP (tip of gripper) along the
Y-axis; X and Z coordinates do not change.
In Joint mode: the Elbow/Z keys move the elbow axis in two directions.
In XYZ mode, the Elbow/Z keys move the TCP (tip of gripper) along the Z-axis;
X and Y coordinates do not change.
In Joint mode: the Pitch keys move the TCP (tip of gripper) up or down, without
moving the other axes.
In XYZ mode: the Pitch keys move three axes (shoulder, elbow and pitch) in
order to change the pitch angle without changing the position of the TCP (tip of
gripper).
In both Joint and XYZ modes: the Roll keys move the roll axis in two directions.
A toggle key. Opens and closes the electrical gripper.
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Sets the speed of manual axis movement of the current axis control group; that is,
group A, B, or C. The speed is defined as a percentage (1-100) of maximum
speed.
Press Speed. The current speed is displayed.
Press Enter to accept the displayed default speed. Or use the numerical keys
to enter a different speed, and press Enter.
Defines and records a position.
Only numerical position names, of up to five digits, can be entered from the TP.
The position is defined for the currently active group, and receives the current
values of the axes in that group.
Press Record Position. Then press up to five digits for the position name.
Then press Enter to record the position coordinates.
If you use a position name which has already been defined, the new coordinates
will overwrite the existing ones.
This command is also used to record positions in a vector. The vector must first be
attached to the teach pendant by means of the ACL command ATTACH.
Moves the axes to a target position.
Press Go Position. Then use the numeric keys to enter the position name.
Then press Enter to execute the move.
In Joint mode: robot movement is by joints.
In XYZ mode: robot movement is linear.
To send the axes to their home position, enter the following commands:
Go Position 0 sends all the axes of group A to their HOME position.
Go Position 00 sends all the axes of group B to their HOME position.
number
number
number
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Executes a program.
Press Run. Then press the programs identity number on the numerical keys. The
program name will be displayed in brackets. Then press Enter to begin program
execution.
The controller automatically assigns an ID number to each user program. The
ACL command DIR lists the programs and their assigned (IDENTITY) number.
Aborts execution of all running programs. Stops movement of the robot and all
peripheral axes.
The Display Panel
The LCD panel shows the current status of the controller, the current user
command, and system messages.
A resident note shows the coordinates system currently active: JOINTS or XYZ.
Another resident note shows the currently active group: A, B, or the number of
one of the independent axes in control group C.
number
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CHAPTER 6
Operating the Robot
This chapter introduces you to the basic commands for operating the
SCORBOT-ER VII robot by means of both the ACL software and the teach
pendant.
DIRECT Mode
This chapter describes the operation of the robotic system when it is functioning
in the DIRECT mode. When the system is in DIRECT mode, the user has direct
control of the axes, and the controller executes commands as soon as they are
entered by the user.
When in DIRECT mode, the screen prompt appears like this: >_
When the system is operating in EDIT mode, commands are entered into a user
program, which can be saved and executed at a later time. Program editing
procedures are described in Chapter 7.
Manual Mode
Manual mode is available when the system is in DIRECT mode. The Manual
mode enables direct control of the robot axes when a teach pendant is not
connected.
When using the keyboard to perform some of the procedures described in this
chapter, the system must be in Manual mode.
To activate Manual mode, hold the <Alt> key and press the character M:
<Alt> + m
The system will respond in one of the following ways:
MANUAL MODE! MANUAL MODE!
>_ >_
JOINT MODE XYZ MODE
The systems response indicates the currently active coordinate system.
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To exit Manual mode, the same command is used.
Press: <Alt> + m
EXIT MANUAL MODE...
>_
Using this Manual
To familiarize yourself with the system, you should read through this chapter
(and the following ones) and practice entering the commands described in each
section.
All operations described in this chapter can be performed from the keyboard. The
steps for using the keyboard are indicated by the heading PC. The teach pendant
is optional. The operations which can also be performed from the teach pendant
are indicated by the heading TP.
This manual uses the following typographical conventions:
Descriptions of PC operation show user entries in bold, lowercase text. System
responses are shown in capital letters. (The actual screen display may be
different.) For example:
home <Enter>
WAIT!! HOMING...
The system is not case-sensitive. You may use either uppercase and lowercase
characters to enter commands and data.
Descriptions of TP operation show the teach pendant keys which the user must
press. System responses are shown in boxed capital letters. For example:
CONTROL ENABLED
A JOINTS
Activating the Sytem
Activate the system and load the ATS software, as described in the section,
Power On, in Chapter 4.
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Homing the Robot and Peripheral Axes
The location of the robot axes is monitored by encoders which track the amount
of movement relative to an initialhomeposition. To obtain repeatable robot
performance, this reference position must be identical each time the robot is used.
Thus, whenever the system is activated, the homing program, which is internally
programmed into the controller, must be executed.
During the homing procedure, the robot joints move and search for their home
positions, one at a time. Each axis is moved until the microswitch which is
mounted on the joint sends a specific signal to the controller, indicating the axis is
at home.
Before you begin the homing procedure, make sure the robot has ample space in
which to move freely and extend its arm.
TP
Press:
This instructs the controller to execute Program 0, the robot homing routine. The
display panel on the teach pendant will show:
HOMING. . .
When the Home search is successfully completed, the display panel will show:
HOMING COMPLETE
If the robot is unable to find a home position in one or more of the axes, you will
see a message such as:
HOME FAIL [4]
To stop the homing while the operation is in progress, press the Abort key.
The peripheral axes are homed by means of the TP command Run 00.
PC
To home the robot axes (Group A), use the ACL command HOME.
Type: home <Enter>
WAIT!! HOMING...
If all axes reach their home postion, a message is displayed:
HOMING COMPLETE (ROBOT)
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If the homing process is not completed, an error message identifying the failure is
displayed:
*** HOME FAILURE AXIS 4
To stop the homing while the operation is in progress, use the abort commands:
Type: A <Enter>
or press: <Ctrl>+A
To home peripheral axes, each axis must be homed individually; for example:
Type: home 7 <Enter>
home 8 <Enter>
home 9 <Enter>
To home an axis, such as a slidebase, which uses a hard stop rather than a
microswitch, use the ACL command HHOME.
Type: hhome 8 <Enter>
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Coordinate Systems
The SCORBOT-ER VII can be operated and programmed in two different
coordinate systems: Joint and Cartesian (XYZ) coordinates.
Cartesian (XYZ) Coordinates
The Cartesian, or XYZ,
coordinate system is a geometric
system used to specify the
position of the robots TCP (tool
center point=tip of gripper) by
defining its distance, in linear
units, from the point of origin
(the center bottom of its base)
along three linear axes, as shown
in Figure 6-1.
To complete the position
definition, the pitch and roll are
specified in angular units.
When robot motion is executed
in XYZ mode, all or some of the
axes move in order to move the
TCP along an X, Y or Z axis.
Joint Coordinates
Joint coordinates specify the location of each axis in encoder counts. When the
axes move, the optical encoders generate a series of alternating high and low
electrical signals. The number of signals is proportional to the amount of axis
motion; the controller counts the signals and determines how far an axis has
moved. Similarly, a robot movement or position can be defined as a specific
number of encoder counts for each axis, relative to the home position, or another
coordinate.
When robot motion is executed in Joint mode, individual axes move according to
the command.
If any peripheral devices are connected to the robotic system, the position of their
axes is always stated in encoder counts.
Figure 6-1: Cartesian Coordinates
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TP
To toggle between the two coordinate systems:
Press:
A JOINTS
Press
again:
A XYZ
The display reflects the currently active coordinate system. Manual movement of
the axes will be executed according to the currently active coordinate system.
PC
To select a coordinate system from the keyboard, you must first activate Manual
mode.
To activate the Joint coordinate system:
Press: j
JOINT MODE
To activate the XYZ coordinate system:
Press: x
XYZ MODE
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Servo Control
The controller must be in the servo control (CON) state for the axes to execute
movement commands.
Activating the Home routine will activate CON.
Certain events, such as impact, overheating (thermic error), or activation of the
Emergency switch, will automatically switch off the servo control state (COFF).
CON must be activated to resume motion and servo control.
While the controller is in the COFF state, you cannot operate the axes.
TP
To toggle servo control on and off:
Press:
CONTROL ENABLED
Press
again:
CONTROL DISABLED
When Control On/Off is activated from the teach pendant, the CONTROL
ENABLED/CONTROL DISABLED message also appears on the computer
screen.
PC
If Manual mode is active you can enable and disable control from the keyboard.
Press: c
CONTROL ENABLED
Press: f
CONTROL DISABLED
The commands C and F enable and disable control of all axes which are
connected to the controller.
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If Manual mode is not active, you can use the ACL commands CON and COFF.
Type: con <Enter> Enables control of all axes.
Type: coff <Enter> Disables control of all axes.
The format can be altered to enable and disable control of specific groups of axes;
for example:
cona Enables control of robot axes (Group A).
coffb Disables control of peripheral axes (Group B).
con 9 Enables control of axis 9 (Group C).
Axis Control Groups
By default, the controller assumes the five robot axes (Group A) are under servo
control. The Group Select key allows you to switch control to peripheral axes
(Group B), or to an independent axis (Group C).
TP
To select the axis control group:
Press:
_
B JOINTS
Press
again:
AXIS . .
When selecting an independent (Group C) axis, you must also key in the axis
number followed by Enter.
Continue pressing this key until the desired axis group is displayed.
PC
ACL does not have a command for selecting the axis control group. The specific
format of each command indicates the axis control group.
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Moving the Axes
XYZ and Joint Movements
When the coordinate system is set to the XYZ mode:

Movement commands to the X, Y or Z axis result in a linear motion of the

TCP (tip of gripper) along the respective axis, while maintaining a constant
orientation (of the gripper or tool).

Movement commands to the pitch or roll axis will change the orientation (of
the gripper or tool) while maintaining a constant TCP position.
When the coordinate system is set to the Joint mode, movement commands cause
the robot to move one joint. Peripheral axes always move according to Joint
coordinates.
TP
When in XYZ mode, the controller recognizes the Cartesian functions of the
teach pendant keys.
When in Joint mode, the controller recognizes the joint functions (shaded in
diagram) of the teach pendant keys.
The teach pendant offers the easiest method for
moving the robot arm. You simply press an axis
movement key, and the robot moves. When you
release the key, movement stops.
Before you press the keys shown below, make
sure JOINTS, Group A, and Control On are
active. Move the axes of the robot, in both
directions.
Press:
Press:
Press:
Press:
Press:
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Before you press the keys shown below, make sure XYZ appears on the teach
pendant display. Watch how the keys now affect the movement of the TCP.
Press:
Press:
Press:
PC
To directly control movement of the robot axes from the keyboard, Manual mode
and Control On must first be activated. The keys listed below are then used to
move the robot.
The axes will move as long as the activating key is depressed, until a fixed stop is
reached. The gripper will either open completely or close completely.
In Joint mode, the keys produce the following movements:
Press: 1, Q
2, W
3, E
4, R
5, T
6, Y
Move axis 1 (base)
Move axis 2 (shoulder)
Move axis 3 (elbow)
Move axis 4 (wrist pitch)
Move axis 5 (wrist roll)
Closes/Opens electrical gripper (axis 6)
In XYZ mode the following changes in manual movement occur:
Press: 1, Q
2, W
3, E
4, R
TCP moves along X+ and X axes.
TCP moves along Y+ and Y axes.
TCP moves along Z+ and Z axes.
Pitch moves; TCP maintains position.
All other movements are the same as in Joint mode.
In XYZ mode, moving the robot to positions at the maximum range of reach may
result in jerky movements. Use Joint mode to reach these positions.
While moving the arm, you may alternate between XYZ and Joint modes as often
as required.
If peripheral axes are connected, the following keys are also used:
Press: 7, U
8, I
9, O
0, P
, [
Move axis 7
Move axis 8
Move axis 9
Move axis 10
Move axis 11
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Activating the Gripper
In response to the commands to open and close, the electrical gripper goes
completely from one state to the other.
TP:
Press:
The Open/Close key toggles the gripper between its open and closed states.
If the gripper was open it will now close, and vice versa. Repeat the command.
PC:
When Manual mode is active, the following keys activate the gripper.
Press: Y Opens the gripper.
Press: 6 Closes the gripper.
When Manual mode is not active, the ACL commands OPEN and CLOSE are
used.
Type: open <Enter>
Type: close <Enter>
Pneumatic grippers or devices are controlled by means of ACL output commands.
To activate a pneumatic gripper or end effector from the teach pendant, ACL
output commands must be written to two program (one for opening the gripper
and one for closing it). Each program can then be called from the teach pendant,
resulting in activation of the pneumatic gripper or device.
For more information, refer to the section on I/O programming in Chapter 7.
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Setting the Speed
TP
The speed of the robot during Go Position movements controlled from the teach
pendant is defined as a percentage of maximum speed. Speed defined as 100
gives the robot maximum speed, while a speed of 1 is the minimum. When the
system is first turned on, the default speed is set at 50, approximately half the
robots maximum speed.
The speed of the robot during manual movements controlled from the teach
pendant is relative to the speed setting, and much slower than Go Position
movements.
Use the teach pendant to set the robots speed to a speed of 30%, for example:
Press:
All Go Position movement commands will be executed at a speed of 30, until a
different speed is entered.
PC
When Manual mode is active, use the key S to set the speed of manual movement.
Press: s
SPEED.._
You are prompted for a speed valuea percentage of the maximum speed.
Type a number between 1100, and press <Enter>.
When Manual mode is not active, the ACL command SPEED is used to define
the speed at which movements are executed. For example:
speed 50 Sets speed movements of Group A axes to 50% of
maximum speed.
speedb 20 Sets speed of movements of peripheral axes (Group B) to
20% of maximum speed.
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Defining and Recording Positions
Defining a position reserves space in controller memory, and assigns it a name.
Recording a position writes coordinate values to the allocated space in controller
memory.
Two types of position names are possible:

Numerical names (such as 3, 22, 101) of up to five digits.

Positions with this type of name do not need to be defined before they are
recorded by means of the teach pendant; the position recording command
automatically defines and records positions with numerical names.

Alphanumeric names (such as P, POS10, A2). The name may be a

combination of up to five characters, and should begin with a letter. These
positions cannot be accessed from the teach pendant.
Positions may belong to a vector; that is an array of positions identified by a
specific name and an index; for example, PVEC[1] and PVEC[5] are positions in
a vector named PVEC. When a vector is attached to the teach pendant (by means
of the ACL command ATTACH), vector positions can be accessed from the teach
pendant by means of their index number.
If you accidently record coordinates for position 0, execute the Home program.
The homing routine records the proper coordinates for position 0.
TP
The teach pendant allows you to simultaneously define and record a position.
To record a robot position, first be sure the Group A is selected. Then use the axis
movement keys to bring the robot to any location. Record this as position 12.
Press:
DONE
Move the robot to another location and record it as position 13.
The Record Position key records the position of the currently active axis control
group (A, B or an independent axis) in joint coordinates.
If you want to define the location of both the robot and the peripheral axes, you
must record two positions, one for each group.
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PC
To define and record positions from the keyboard, you must first exit Manual
mode.
Use the ACL command DEFP to define a robot position. For example:
Type: defp A1 <Enter> Defines position A1 for the robot.
When a position is defined, it is assigned to a specific axis control group. By
default, it is assigned to the robot (Group A) axes. To define a position for Group
B, or an independent axis, the command format determines the group to which
the position is dedicated.
Type: defpb B24 <Enter> Defines position B24 for Group B.
defpc C3 10 <Enter> Defines position C3 for axis 10.
Define three robot positions:
Type: defp A31
defp A32
defp A33
The ACL command HERE records a positionin joint coordinatesaccording
to the current location of the axes.
Remember to activate Manual mode before starting motion, and to exit Manual
mode when the motion is completed. Also be sure the position is defined before
you attempt to record it.
Move the robot to any location, and record its coordinates for position A31.
Type: here A31 <Enter>
Move the robot two more times, and record coordinates for positions A32 and
A33.
If you attempt to record a position which has not been defined (for example HERE
A34), the system will display an error message.
If you specify a name of a position which has already been recorded (for
example, HERE A31), the HERE command will will overwrite the existing
coordinates with new coordinates.
The ACL command TEACH records a robot positionin Cartesian
coordinates according to user defined settings; it does not record the
coordinates of the robots current location.
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Relative Positions
TP
Relative positions cannot be recorded by means of the teach pendant.
PC
The ACL commands HERER and TEACHR allow you to record a position as
relative to another position, or as relative to the current position of the robot.
To record a position which is relative to another position by joint coordinates,
move the robot to the relative location and record the position. For example:
Type: herer A99 A33 <Enter>
The coordinates of position A99 are actually offset values; that is, the difference
in the encoder count at position A31 and at position A99. If the coordinates of
position A31 change, position A99 will remain relative to position A31 by the
same number of encoder counts.
To record a position relative to the current location of the robot by joint
coordinates, you are prompted to enter values (encoder counts) for each of the
axes. If offset values have already been recorded for this position they will appear
in the brackets; otherwise the brackets are empty. For example:
Type: here A99 <Enter>
1--[.]>0 <Enter>
2--[.]>500 <Enter>
3--[.]>250 <Enter>
4--[.]>0 <Enter>
5--[.]>0 <Enter>
Base = no offset
Shoulder = 500 counts offset
Elbow = 250 counts offset
Pitch = no offset
Roll = no offset
The command TEACHR allows you to record a position which is relative to
another position, or relative to the current position of the robot, in Cartesian
coordinates. TEACHR can be easily used to maintain a vertical offset (along the
Z-axis) between two positions; for example:
Type: >teachr over
X [.] > 0
Y [.] > 0
Z [.] > 500
P [.] > 0
R [.] > 0
Relative position OVER will always
be 50mm above the current position
of the robot.
ACL has a number of commands for recording position coordinates; they are
detailed in the ACL Reference Guide, and will not be discussed in this manual.
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Listing Positions
PC
To see a list of the defined positions, use the ACL command LISTP.
Type: listp <Enter>
The list of defined positions is displayed on the screen. Positions 12, 13, A31,
A32, A33 and A99 should now appear in the list.
To view the coordinates of position A31, use the ACL command LISTPV.
Type: listpv A31 <Enter>
Position coordinates are displayed on the screen in the following manner.
1:0 2:1791 3:2746 4:0 5:-1
X:1690 Y:0 Z:6011 P:-636 R:-1
Two sets of values are displayed for robot positions:

The first line shows the joint coordinates; defined in encoder counts.

The second line shows the Cartesian (XYZ) coordinates. X, Y and Z are
defined in tenths of millimeters; P (Pitch) and R (Roll) are defined in tenths of
degrees. For example:
Z: 6011 Z = 601.1mm
P:-636 P =63.6
Deleting Positions
PC
To delete positions, use the ACL command DELP.
Type: delp A99 <Enter>
DO YOU REALLY WANT TO DELETE THAT POINT? (YES/NO)>_
Type: yes <Enter>.
A99 DELETED.
To prevent accidental deletion of a position, you are required to respond by
entering the entire word yes, followed by <Enter>. Entering any other other
character, including Y, is regarded as no.
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Moving to Recorded Position
Once a position has been recorded, you can easily send the robot (or other devices
connected to the controller) to that position. Depending on the currently active
coordinate system, the movement of the robot (Group A) will be either point to
point (in Joint mode) or along a linear or curved path (in XYZ mode).
TP
Assuming the robot is at position 13, send the robot back to position 12.
Press:
DONE
Use the command Go Position 0 to send all the axes of group A to the home
position.
PC
Use the ACL command MOVE to send the robot to a position.
Assuming the robot is at home, send the robot to position A31.
Type: move A31 <Enter>
In this command the robot moves at the current speed setting.
The MOVE command may contain a duration parameter, which is defined in
hundredths of a second. To send the robot to position A32 in 10 seconds:
Type: move A32 1000 <Enter>
You can use the PC to move to positions recorded by the TP.
Alternately, you can use the TP to move to positions recorded by means of the
PC, providing the positions are defined by numerical names. For example:
Type move 13 <Enter>
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Linear Movement
To move the TCP in a straight path, use the ACL command MOVEL.
For example, send the robot from the home position to position A33.
Type: move 0 <Enter>
Type: movel A33 <Enter>
Circular Movement
To move the TCP along a curved path, use the ACL command MOVEC, use the
ACL command MOVEC.
You must specify two positions for MOVEC. Otherwise there are infinite
possibilities for defining the curve. For example, send the robot from the home
position to position A31, via position A32.
Be careful when using this command. For the first attempt, set the speed to a low
setting, such as 20.
Type: move 0 <Enter>
Type: speed 20 <Enter>
Type: movec A31 A32 <Enter>
Reset the speed to 50 when you have completed the movement.
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CHAPTER 7
Programming with ACL
This chapter serves as a tutorial to help you become familiar with program
editing. To learn how to write and edit a program, you should follow, in
sequence, the procedures described in this chapter.
This chapter introduces you to the basic commands for programming the
SCORBOT-ER VII. Many more commands and formats are available in the
ACL language. Refer to the ACL Reference Guide for complete lists and
descriptions of editing functions and ACL commands.
For additional instruction in the procedures introduced in this chapter, the ACL
Laboratory Manual (catalog #100039) is recommended.
EDIT Mode
So far you have learned to operate the robot in the DIRECT mode, in which all
commands are executed the moment you press <Enter>.
To write programs which will be executed by the robotic system, you will use the
EDIT mode.
Whenever the EDIT mode is active, the screen shows the current program line
number and a prompt, such as this: 143:?_
The controller assigns the line numbers; they are not user definable.
Help
Quick, on-line help is available while you are working with ACL.
Simply enter the command HELP.
A list of DIRECT mode commands are displayed when in DIRECT mode;
a list of EDIT mode commands are displayed when in EDIT.
Enter the command DO HELP when in DIRECT mode in order to display the
EDIT mode commands.
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Creating a Program
To create a program, activate the EDIT mode by using the command EDIT,
followed by the name you want to call the program. Program names are limited to
five characters; for example:
Type: edit aaa <Enter>
AAA NEW PROGRAM
DO YOU WANT TO CREATE THAT PROGRAM (Y/N)>
Type: y <Enter>
PROGRAM AAA
*********************
25:?_
At the ?_ prompt, you can begin entering program command lines.
Writing a Program
To write a program which will send the robot to each of the positions recorded
earlier, enter the following command lines:
Type: moved A31 <Enter>
moved A32 <Enter>
moved A33 <Enter>
exit
AAA IS VALID
Although the command MOVE may be used in EDIT mode, the command
MOVED is preferable. MOVED ensures that the robot will accurately reach the
target position before continuing to the next command.
The commands MOVEL and MOVEC are also available in EDIT mode. As with
the MOVE command, it is preferable to use the command format with the D
suffix; that is, MOVELD and MOVECD.
The EXIT command is used to end the current editing session and return the
system to DIRECT mode.
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Running a Program
When the > prompt is displayed, it indicates the system is in DIRECT mode. To
check the program you have just created, do the following:
Make sure control is enabled (CON) and the robot is at its home position.
Type: run aaa <Enter>
DONE
The robot moves to positions A31, A32 and A33, and then stops.
Program Loop
You will now edit the program and add command lines which will cause the
program to run in a loop.
Program loops are created by using the companion commands, LABEL and
GOTO.

LABEL n marks the beginning of a routine.

GOTO n sends program execution to the line which follows the

corresponding LABEL.
Type: edit aaa <Enter>
WELCOME TO ACL EDITOR, TYPE HELP WHEN IN TROUBLE.
PROGRAM AAA
*******************
25:?_
The prompt shows the first line of the program. Entering a new command inserts
a command line at this point.
Pressing <Enter> without entering a new command simply displays and accepts
the line as is, and moves the editor to the next line.
Type:
Press:
Press:
Press:
Type:
Type:
label 1 <Enter>
<Enter>
<Enter>
<Enter>
goto 1 <Enter>
exit <Enter>
AAA IS VALID
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Displaying Program Lines
To view the program you have edited, use the command LIST, followed by the
name of the program.
Type: list aaa <Enter>
PROGRAM AAA
*********************
25: LABEL 1
26: MOVED 31
27: MOVED 32
28: MOVED 33
29: GOTO 1
30: END
(END)
END marks the end of a program; (END) marks the end of a listing. They are
written by the controller; they are not entered by the user.
Halting Program Execution
Bring the robot to its home position, and then run program AAA. The robot
moves to positions A31, A32 and A33 in a continuous loop, without stopping.
Since you have now created and executed a program which will run in an endless
loop, this section describes the ACL commands which are used to halt a program
during its execution.
Suspend the Program
The companion commands SUSPEND and CONTINUE, respectively, suspend
execution of a program, and then restart it from the point of interruption by
executing the next program command line.
Type: suspend aaa <Enter>
The robot completes the current movement command and then stops. Program
AAA is now suspended.
Type: continue aaa <Enter>
The CONTINUE command causes the robot to continue moving from the point
where it was halted by a SUSPEND command.
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Abort the Program
To immediately abort running programs and stop all axis movement, enter the
abort command in either one of the following ways:
Type: a <Enter>
Press: <Ctrl>+A
PROGRAM AAA ABORTED
Program AAA can now be reactivated only by means of the RUN command,
which will start the program from the beginning.
If several programs are running, and you want to abort only one of them,
following the command by the name of the specific program; for example:
a aaa <Enter>
This format aborts the specified program only after the command currently being
executed has been completed.
Stop the Program
To include an abort command in a program you are editing, use the command
STOP.
The STOP command will abort a program only after all axis movement
commands which have already been sent to the controller (movement buffer)
have completed execution.
Use the STOP command in one of the following ways:
Type: stop aaa <Enter> Aborts only program AAA.
Type: stop <Enter> Aborts all running programs.
STOP is available in EDIT mode only.
STOP cannot be used to abort a running program when in DIRECT mode.
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Delaying Program Execution
The DELAY command causes program execution to pause for a specified amount
of time.
The DELAY command ensures that preceding commands have been properly
executed before the next command is executed.
The command format includes a time parameter, n, which is expressed in
hundreths of a second; for example, if n = 200, the delay is 2 seconds.
Edit program AAA. Insert delay commands following each MOVED command
line.
Press:
Press:
Type:
Press:
Type:
Press:
Type:
Press:
Type:
<Enter>
<Enter>
delay 200 <Enter>
<Enter>
delay 200 <Enter>
<Enter>
delay 200 <Enter>
<Enter>
exit <Enter>
Another ACL command, WAIT, command causes program execution to pause
until a certain condition is met.
Variable Programming
Variables are locations in controller memory which are defined by name and hold
values. Variables simplify programming by allowing instructions to be executed
conditionally and repeatedly.
ACL has a number of system defined variables whose values indicate the status
of inputs, outputs, encoders and other control system elements. Some of these
variables can accept user defined values. None of these variables can be deleted
from the system.
User variables are defined and manipulated by the user, and can be created or
deleted as needed. User variables may be either private (local) or global.

Private variables are defined and manipulated in the EDIT mode and
recognized only by the specific program in which they are defined.

Global variables can be defined and manipulated in both the EDIT and
DIRECT modes, and can be used in any program.
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The command DEFINE is used to define a private variable. Up to twelve
variables can be defined in one command. For example:
Type: define pv <Enter> Defines PV as a private variable.
define va vb vc <Enter> Defines VA, VB and VC as private
variables.
The command GLOBAL is used to define a global variable. Up to twelve
variables can be defined in one command. For example:
global gv <Enter> Defines GV as a global variable.
global gva gvb gvc <Enter> Defines GVA, GVB and GVC as
global variables.
Variable names must begin with an alphabetical character and may have up to 5
characters.
The commands DIM[n] and DIMG[n] are used to define arrays of private and
global variable arrays, respectively; n defines the dimension (number of elements)
in the array.
Mathematical and Logical Functions
The SET command performs mathematical and logical operations on variables.
The command format may be one of the following:
set var1=var2
set var1=oper var2
set var1=var2 oper var3
Where: var1 is a variable;
var2 and var3 can be either a variable or a constant.
oper is: Arithmetic operator: + * /
Algebraic operator: ABS, EXP, LOG, MOD
Trigonometrical operator: COS, SIN, TAN, ATAN
Logical (Boolean) operator: AND, OR, NOT
The simplest format assigns a variable the value of a constant or another variable.
For example:
set var = 1
set var1 = var2
The value of a variable can be the result of an operation performed on another
variable. For example:
set var1 = abs var2 If the value of var2 is -1, var1 is set
to 1.
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The value of a variable can be the result of a mathematical operation performed
on either two other variables or another variable and a constant. For example:
set var1 = var2 + 1 The value of var1 is greater by 1
than the value of var2.
set vara = varb * varc The value of vara is the result of
varb multiplied by varc.
set var = var + 100 The result of an operation can equal
the same variable, thereby changing
its value. The value of var now
equals the previous value of var plus
1000.
Iteration Functions
Many applications require task iteration, or repetition. Variables can be used to
produce program loops which repeat a command or commands, thereby avoiding
the need for redundant command lines within a program
The command format FOR var1 = var2 TO var3 enables a program routine
to be executed repeatedly. Var1 must be a variable; var2 and var3 may be either
variables or constants. For example, enter the following commands to create
program LOOP:
edit loop
for var=1 to 10
println "LOOP"
endfor
exit
The variable is a counter, which is set initially to 1 and increased by one each
time the loop is performed. When the counter value reaches the final value (10 in
this example), the loop is performed for the last time.
The ENDFOR command is required to mark the end of the loop.
The PRINTLN command causes comments (text within quotation marks) to be
displayed on the screen during program execution. Thus, when you run program
LOOP, the word LOOP will be displayed 10 times.
By altering the PRINTLN command line you can cause the system to report
which loop has been completed. Bring the cursor to the ENDFOR command line.
Enter the command DEL; this will delete the preceding command line. Then enter
a new command line:
println "LOOP " var
Make sure you have included a space following the text LOOP.
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The PRINTLN command causes the current value of a variable to be displayed on
the screen during program execution. Thus, when you run program LOOP, the
following will now appear on the screen.
LOOP 1
LOOP 2
LOOP 3
. . . and so on, until LOOP 10 is displayed.
In the section on input/output programming later in this chapter, you will see
additional examples of program loops which enable the system to check and
respond to the state of the controllers 16 inputs.
Conditional Functions
Many applications require the program to flow according to certain conditions.
The command format IF var1 oper var2 checks the relation between var1 and
var2. Var1 must be a variable; var2 may be either a variable or a constant. Oper is
one of the following comparison operators: > < + >= <= <>
When the IF statement is true, the program executes the next line(s), until it
reaches an ENDIF command, which marks the end of the conditional routine.
if var1=var2
goto 1
endif
The IF statement may, however, be followed by another conditional statement.
The next line may be an alternative condition (ORIF) or an additional condition
(ANDIF).
if var1=var2
orif var3>10
goto 2
endif
At least one of the two conditions
must be true in order for the
program to jump to label 2
if var1=var2
andif var3>10
goto 2
endif
Both conditions must be true in
order for the program to jump to
label 2.
The conditional routine may also contain a routine to be executed when the IF
condition is false. The beginning of such a routine begins with the command
ELSE.
if var1=var2
goto 2
else
goto 1
endif
If the condition is not true, the
program will jump to label 1.
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Input and Output Programming
The state of the controllers 16 inputs and 16 outputs is determined by means of two
system variables, IN[n] and OUT[n]; n specifies the I/O index; that is, 116.
The value of the variable indicates whether the input or output is on or off; when
the value of the variable is 1, the input or output is ON; when the value is 0, the
input or output is OFF.
Displaying Input/Output Status
The I/O LEDs on the front panel of the controller turn on and off to reflect the
status of the inputs and outputs. If you are not close enough to see the controller
panel, you may want another means to check the I/O status.
In DIRECT mode, use the following commands to display the status of all 16
inputs and outputs, respectively:
Type: show din <Enter> Shows status of the inputs.
Type: show dout <Enter> Shows status of the outputs.
The display will indicate the I/O status in the following manner:
1>16: 0 1 0 1 0 0 0 0 0 1 0 0 1 1 0 0
O.K.
When editing a program, use the command PRINTLN to display the status of a
specific input or output during program execution. For example:
println in[5] When this command is encountered during program
execution, either 1 or 0 will be displayed (that is, the
value of variable IN[5]), depending on the state of input
5;
Inputs
Conditional commands, such as IF and WAIT, are used to read and respond to the
state of the inputs. For example, you can use the following routine in a program:
if in[3]=1
move A31
else
move A32
endif
If input 3 is ON, then
Move to position A31.
If input 3 is NOT ON (off), then
Move to position A32.
End of conditional routine.
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Outputs
As with inputs, conditional commands can read and respond to the state of the
outputs. Commands can also be used to alter the state of outputs.
To change the state of an outputin both DIRECT and EDIT modesuse the
SET command. For example:
set out[6]=1 <Enter> Turns ON input 6.
set out[8]=0 <Enter> Turns OFF input 8.
Activating Output-Driven Devices
Pneumatic End Effectors or Devices
As mentioned in Chapter 6, pneumatic end effectors or devices are connected to
controller outputs and controlled by means of ACL output commands.
Assuming a pneumatic gripper is connected to controller (relay) output 2, use the
following command format
set out[2]=1 <Enter> Turn on output 2 to open the gripper.
set out[2]=0 <Enter> Turn off output 2 to close the gripper.
In order to activate the pneumatic gripper from the teach pendant, you need to
create two programs (named OGRIP and CGRIP, for example) which can be called
from the teach pendant by means of the Run key. Each program contains one of the
commands shown above.

Program OGRIP contains the command to turn on output 2.

Program CGRIP contains the command to turn off output 2.

Using the ACL command DIR note the identity number of programs OGRIP and
CGRIP. (The command DIR is explained more fully later in this chapter.)
Lets assume programs OGRIP and CGRIP are identified as program 8 and
program 9, respectively. Now, whenever you want to open the pneumatic gripper
by means of the teach pendant:
Press: Run 9 Enter
Warning Light
A flashing warning light can be integrated into the SCORBOT-ER VII system.
A program named ONOFF is included in the ONOFF.CBU file on the ATS
diskette supplied with the system. When the ONOFF program is activated, it will
automatically turn on the warning light whenever the robot is in motion.
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The light is normally connected to (relay) output 1. Therefore, the following
commands are used in program ONOFF.
set out[1]=1 When output 1 turns on, the light turns on.
set out[1]=0 When output 1 turns off, the light turns off.
(In order to download this program file for use, refer to the downloading procedure
described later in this chapter. )
Sample Program: INOUT
A program named INOUT can be found in the file DEMO.CBU which is
factory-loaded into the controller, and included in the ATS diskette supplied with
the system.
The program contains two loops; one loop has instructions for checking the status
and responding to the state of all the inputs; the other loop has instructions for
responding when input 16 is on.
This sample program demonstrates program loops and conditional routines. In
addition, it shows how to include user comments within a program.
Use the LIST command to view the program shown below. Explanatory notes are
provided below.
Type: list inout <Enter>
PROGRAM INOUT
*********************
PRINTLN "this program tests inputs & sets outputs"
PRINTLN
LABEL 1
FOR I = 1 TO 16
IF IN[I] = 1
* TEST IF INPUT I IS ON
SET OUT[I] = 1
* SET OUTPUT I ON
ELSE
SET OUT[I] = 0
* SET OUTPUT I OFF
ENDIF
DELAY 3
ENDFOR
IF IN[16] = 1
* IF INPUT 16 IS ON EXIT FROM PROGRAM
SET OUT[16] = 0
PRINTLN " program inout stopped "
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PRINTLN
GOTO 2
ENDIF
GOTO 1
LABEL 2
END

PRINTLN comments will be displayed on the screen during program

execution.

PRINTLN without a comment or argument simply enters a carriage return,

and brings the screen cursor to the beginning of the next line.

The variable I is used as the counter for 16 loops.

FOR starts a program loop which checks state of all 16 inputs.

The first IF command starts a conditional routine with instructions for

responding to the state of an input: if an input is turned on, the output of the
same index is also turned on; if the input is turned off; the output is turned off.

The asterisk * precedes a user comment within a program; the comment is not
displayed during program execution.

ENDIF ends the IF conditional routine.

ENDFOR ends the FOR loop.

The second IF command starts a routine which checks and responds to the the
state of input 16. If input 16 is on, output 16 will not light; the program will
go to label 2 and terminate.

If input 16 is off, the program will go to label 1 and repeat.

When running this program you can simulate an external input by shorting the
input terminals. Be sure you do so according the instructions for shorting inputs
detailed in Chapter 3.
Run the program, and prepare to short the inputs.
When you short any of inputs 1 through 15, the output with the same index
(115) will turn on. When you short input 16, the program will stop. Note the
messages on the screen during program execution.
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Program Directory
The ATS diskette supplied with the system contains a number of files with the
extension CBU. These files contain programs, positions, variables and
parameters. Some of these CBU files are factory-loaded into the controller and
stored in battery backed-up RAM. These files are not erased when the controller
is turned off, but their contents may be totally or partially erased during certain
configuration and restore procedures.
To view the list of programs which are found in the controllers BBRAM, use the
DIR command in DIRECT mode. For example:
Type: dir <Enter>
name : validity : identity : priority
AA : : 1 : 5
LOOP : : 2 : 5
DEMO : : 3 : 5
IO : : 4 : 5
IOA : : 5 : 5
. . . and so on.

Validity: If the program is valid no message appears. Not valid will appear
if the program contains a logic error, such as a FOR command without an
ENDFOR command.

Identity: This is the controller-assigned program identity number, which is

needed for executing a program from the teach pendant. (Since certain
controller operations can cause program identity numbers to change, use the
DIR command at the beginning of each working session to verify the identity
of program which you may want to call from the teach pendant.)

Priority: By default the controller assigns each program a run-time priority of

5, on a scale of 110. The user can define a programs priority by means of
the PRIORITY or RUN command.
Multi-Tasking
Controller-A is a multi-tasking real-time controller; it can simultaneously
execute and control 20 independent programs.
Use the DIR command, and note the programs: PICP, IO, IOA.
To run these three programs concurrently, use three RUN commands to start
executionin both DIRECT and EDIT mode.
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Type: run picp <Enter>
run io <Enter>
run ioa <Enter>
Program PICP takes the robot through a series of pick and place movements.
Programs IO and IOA both turn controller outputs on and off; watch the LED
display on the controller while these programs are being executed.
To abort all three programs, use the Abort command.
Displaying Program Status
While programs are running, use the command STAT to view their status.
Type: stat <Enter>
JOB_NAME PRIORITY STATUS
PICP 000005 PEND
IO 000005 DELAY
IOA 000005 SUSPEND

PEND: program is executing a movement command.

DELAY: program execution is currently being delayed.

SUSPEND: execution has been halted by SUSPEND command.

Activating a Program from Another Program
As indicated throughout this chapter, Controller-A enables interaction and
synchronization of programs.
Simultaneous Execution
The RUN command can be included in a program in order to start execution of
another program. When a running program encounters a RUN prog command,
both program are executed concurrently.
When several programs are running, those with a higher priority have precedence;
those with the same priority share controller CPU time by means of an equal
distribution algorithm.
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Program Interrupt
Since two programs may conflict with one other, it may be preferable to use the
GOSUB command rather than RUN.
Like RUN, the GOSUB command is used to start execution of another program.
Unlike RUN, however, when a program encounters a GOSUB prog command,
the program is suspended until the called program has completed execution. At
that point, the first program resumes execution from the line which follows the
GOSUB command.
The TRIGGER command can be used to execute another program when a specified
input or output is turned off or on. However, it will activate the program only once,
regardless of subsequent changes in the I/O state.
Saving a Program (Backup) to Disk
The programs, positions and variables used in programs will remain stored in the
controllers BBRAM. However, the controllers battery-backed RAM is limited
(and can be accidently erased). Program files should be saved to disk. They can
be downloaded to the controller as needed. ATS has a Backup Manager which
serves this purpose.
In order to save program files to disk, perform the following steps.
1. From the DIRECT mode, press <Alt>+10. The Backup Manager menu will
appear on your screen.
2. Use the arrow keys to highlight Backup PROGRAMS and press <Enter>.
Backup directory: type and <Enter> the name of the drive where you want the
file to be saved (it may be a floppy drive disk, or a subdirectory on your hard
disk).
File name: type filename (or any name of up to 8 characters) and press <Enter>.
The CBU extension will automatically be written.
3. Press F2 to save the file to disk.
When DONEappears, press <Esc> to return to the main ATS screen.
Note that this procedure saves all programs, positions and variables which are
currently in the controllers BBRAM to the file filename.CBU.
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Downloading a Program (Restore) to Controller
The following steps will download the contents of a file to the controller BBRAM.
1. From the DIRECT mode, press <Alt>+10. The Backup Manager menu will
appear on your screen.
2. Backup directory: Type and <Enter> the name of the drive where the backup
files are located; it may be a floppy disk drive, or a subdirectory on your hard
disk. (You can press F9 (CATALOG) to make sure filename appears in the
directory.)
Use the arrow keys to highlight Restore PROGRAMS and ADD TO
Controller Contents. Press <Enter> to accept these options.
File name: Type filename and press <Enter>. The CBU extension is not needed.
3. Press F5 to load (RESTORE) the file from disk to the controller BBRAM.
When DONE appears, press <Esc> to return to the main ATS screen.
ACLoff-line software, which is included on the ATS diskette, also provides a
downloading utility. Refer to the ACLoff-line Users Manual for complete details.
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CHAPTER 8
Maintenance
Maintenance
The maintenance and inspection procedures detailed below will ensure continued
optimum performance of the SCORBOT-ER VII system.
At the start of each working session, check the robot and controller, in the
following order:
1. Before you power on the system, check the following items:

The installation meets all safety standards.

The robot is properly bolted to the work surface.

All cables are properly and securely connected.

Cable connector screws are fastened.

The teach pendant, and any peripheral devices or accesssories which will be
used, are properly connected to the controller.

None of the open collector outputs is connected directly to a power supply.

No people are within the robots working range.

2. After you have powered on the system, check the following items:

The power and motors LEDs on the controller light up.

The fan in the front panel rotates and draws air into the controller.

The fan in the rear panel, within the supply unit, extracts air from the
controller.

All green LEDs on the controller rear panel light up.

No unusual noises are heard.

No unusual vibrations are observed in any of the robot axes.

There are no obstacles in the robots working range.

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3. Bring the robot to a position near home, and activate the homing procedure.
Check the following items:

Robot movement is normal.

No unusual noise is heard when robot arm moves.

Robot reaches home position in every axis.

Troubleshooting
The procedures in the section are intended only for technicians who have
received proper training and certification from the manufacturer.
Do not attempt to perform procedures for which you are not qualified.
Whenever you encounter a malfunction, try to pinpoint its source by exchanging
the suspected faulty componentfor example, robot, controller, teach pendant,
cablewith an identical component from a working system.
In general, when trying to determine the source of a malfunction, first check the
power source and external hardware, such as controller switches, LEDs and cable
connections. Fuses should also be checked.
In addition, make sure the controller is properly configured for the robot and
gripper, the software commands have been correctly issued, and system
parameters are properly set.
Make sure the controllers power switch is turned off before you open the
controller cover. Make sure the power cable is disconnected from the AC power
source before you remove fuses.
Complete instructions for removing and replacing controller components are
given in the section, Adjustments and Repairs, later in this chapter.
Robot Arm Calibration Parameters
To obtain maximum accuracy in the movement of the robot XYZ axes, each
SCORBOT-ER VII undergoes a calibration procedure during the manufacturing
process (and after it has been dismantled for repairs).
During the calibration, the robot arm is sent to a position in which it is completely
extended and parallel to a horizontal surface. The axes are adjusted (by teach
pendant) until they are all at the same height. At this point the axes encoders are read
and their values are assigned to parameters 52-56.
The working range of each axis is also calibrated, and the results are assigned to
parameters 101-105 and 121-125.
These specific parameters are stored in a file named PAR7.CBU on the two ATS
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diskettes supplied with the robot system. The contents of this file cannot be
transferred from one robot to another. Keep the diskettes together with the
print-out of the parameters and labeled for the specific robot.
General System Check
When a problem occurs, use the ACL command TEST as a first step in
diagnosing the problem. TEST activates an internal system procedure which
checks the movement of the robot axes and the input/output functions of the
controller. During the test the following occurs:

In sequence, each configured axis is moved briefly in both directions; a

message will display an axis failure.

All outputs are turned on, and then off.

All inputs are scanned. If an input is on, the corresponding output is also
turned on.
To simulate the activation of an input when no device is connected, short the
input manually by means of a wire or an unraveled paper clip.
When the input is operating in NPN mode, short the input by connecting it
to a ground connector.
When the input is operating in PNP mode, short the input by connecting it
to the user power supply.
If you want to check the homing microswitches, use the command LSON before
entering the TEST command. Use command SHOW DIN to see the results.
Diagnostic Procedures
1. Controller does not turn on. The yellow power LED does not light up. Fans do
not rotate.

Make sure the AC power supply matches the controllers voltage requirement,
as seen on the tag at the back of the controller. If the voltage supply and
controller voltage setting do not match, change the voltage setting, as
described later in this chapter.

Make sure AC power is being supplied to the power outlet.

Make sure the power cable is connected to both the proper power source and
the controller.

If RS232 cable is connected, disconnect it and and retry power on.

If successful, reconnect the RS232 cable.

Check for a blown logic power supply fuse. Using an ohmeter, measure the
resistance of the fuses. If resistance is close to 0, the fuse is functioning.
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2. Controllers motors switch does not turn on. Motors green LED does not light up.

Check for a blown power transformer fuse. Using an ohmeter, measure the
resistance of the fuses. If resistance is close to 0, the fuse is functioning.
3. No communication between the controller and the computer/terminal.
Message appears on screen "Controller Not Responding".

Make sure the controllers power switch is turned on.

Make sure the RS232 cable between the controller RS232 port and the
computer COM port is properly connected.

Make sure you have loaded ATS with the proper /C switch.

If teach pendant also does not function, make sure the flat cable is properly
connected between the communication card (PC700) and connector J8 on the
main board. Refer to Figure 8-5.

Make sure there is no break in the wires.

If problem persists, continue to Item 4.

4. Controller is totally inoperative although all power supplies are working.

Make sure the Emergency switch is not pressed.

Turn the controller power switch off and on again.

If switching off and on does not solve

problem, turn off the controller again
and open up the cover.
Turn on the controller. Check the red
LED on the main board, as shown in
Figure 8-1. If it remains lit, the CPU is
in the HALT state. Turn off the
controller and remove all the driver
cards. (For instructions on removing
driver cards, refer to the section,
Adjustments and Repairs, later in this
chapter.) Then turn the controller on
again.
If the red LED shuts off, the problem
is one of the driver cards. Return the
driver cards to the controller one at a
time, until you determine which one is
faulty. Replace the faulty driver card.
Figure 8-1: Main Board - Memory
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Make sure the hardware and software configuration are compatible with the
user RAM ICs:
Hardware: Refer to Figure 8-1. Make sure all four jumpers for configuring
user RAM (W1, W1A, W2, W2A) are set for 128K RAM. The two lower
pins must be shorted.
Software: Make sure the controller is configured for 128K memory by
entering the command: CONFIG ?

Remove the user RAM ICs (U4, U10, U16, U21) and reinsert them.

If problem persists, replace the main board.

5. Controller is inoperative. Message on PC screen reads: "bus error trap",
"exception trap", etc. and data on PC screen reads:
Address error trap
D0->D7 00000000.....
A0->A7 00000C10, 000AO3FC....
PC=EB942404, SR==0008, SSP=0008796C, USP=0

Turn the controller off and on.

If problem persists, remove the driver cards and again turn the controller
power switch off and on again.

If these messages continually appear, or even occasionally reoccur, replace

the main board.
6. Controller functioning, but the robot cannot be activated.

Make sure an obstacle is not blocking the robot.

Make sure the controllers motors switch is on and the

green LED is lit.

Make sure the controller is in the control off (COFF)

state. Then activate the control on (CON) state from
PC or TP.

Make sure the robot cable is properly connected to the

controller.

Check whether all driver card LEDs on the controller

rear panel are lit. (See Figure 8-2.) Each driver card has a pair of LEDs: the
upper LED corresponds to the axis number at the top of the card; the lower
LED correspond to the axis number at the bottom of the card.
Both LEDs on each card in use should be lit, indicating that power is being
supplied to the axis driver. If one of the LEDs is not lit, proceed to Item 8.
Figure 8-2: Driver
Card LEDs
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7. Robot does not find Home position in one or all of the axes.

Make sure the homing command was properly issued.

Make sure the robot cable is properly connected to the controller.

Make sure system homing parameters are properly set.

Make sure system homing parameters have not been erased.

Check the microswitch for this axis.

Manually move the faulty axis (from teach pendant or keyboard) and use
the LSON and SHOW DIN commands to check the microswitch. The
value will change to either 1 or 0 when the microswitch is detected.
Use the commands LSON and TEST. Or prepare and continuously run a
simple ACL program to test the microswitches, as follows:
LSON
LABEL 1
PRINTLN IN[n]
DELAY 200
GOTO 1
If values do not change, check the microswitch itself.
Use a small screwdriver to press down on the microswitch. You should
hear it click and see it pop back up. If this does not happen, the
microswitch should be fixed or replaced.
If the microswitch has clicked, depress it again and, with an ohmeter,
check whether the microswitch shorts its two poles.
If there is a short, depress the switch again and check the wires between
the microswitch and D50 connector.
If there is a short, depress the switch and check the two microswitch pins
in the D50 connector. (Refer to Chapter 10 for wiring and pin
information).
If there is a short, replace the driver card for that specific axis.

If the problem persists, replace the main board.

(Alternately check ICs U88, U93, U98, U82 and U87.)
8. One of the axes does not function.

Make sure you have performed all steps in Item 5 and Item 6.

If the driver card LED for this axis is not lit, check the corresponding fuse on
the axis driver card. (Refer to Figure 8-3.)
Turn off the controller and open the cover.
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Check the fuse on the top of
the driver card for the faulty
axis. If the fuse has blown,
replace it.
(Earlier models of Controller-A
have semi-automatic fuses on
the driver cards; simply press
the switch on those fuses to
reset.)

Check the motor drive circuitry.

Drive the motor in open loop for a few seconds only.
Use the command: SET ANOUT[n]=DAC
n is the axis number
DAC is the drive level: 5000 DAC 5000
Note the following DAC values and their effect:
DAC value Motor Speed
+5000 + full speed
+2500 + half speed
0 motor stops
2500 - half speed
5000 - full speed
DAC values of 15002000 are recommended for this test.
Use extreme caution when applying the SET ANOUT command to robot axes or
accessories whose movements are mechanically restricted. High DAC values may
cause unwanted mechanical impact and can damage the robot or accessory.
To cancel the SET ANOUT command, use an Abort command, or enter
the command: SET ANOUT[n]=0.
To help you perform the motor test, you can also prepare and run a simple
ACL program which contains the following routine:
SET ANOUT[n]=1500
DELAY 200
SET ANOUT[n]=0
If the axis does not rotate, the problem can be either in the arm (motor,
transmission, cabling) or in the controller (driver card, main board,
communication card, or flat cable connections).
If the axis rotates as expected in both directions, proceed to check the
encoder feedback readings.
Figure 8-3: Driver Card Fuse
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Check the encoder.

Enter the command SHOW ENCO to display the encoder readings.
Enter the command COFF (to disable servo control) and then physically
move the axis in question in both directions.
The encoder reading should rise for rotation in one direction and fall for
rotation in the opposite direction.
If the encoder readings do not change, the problem is caused by a faulty
encoder, a break in the encoder wiring, or a faulty connection on a PCB
within the robot. Follow the procedures in Item 9 and Item 10.
9. Errors in the accuracy of the robot.
Controller does not read the encoder (fails to respond to command SHOW ENCO).

Using an oscilloscope, check the signals (P

0
and P
1
) received from the
encoders two phototransistors. Figure 8-4 shows the wave diagrams which
emanate from the two channels of the
encoder (P
0
and P
1
) with respect to the
time axis. The top two signals should be
clean square waves:
V
L
(low) value should be 0.4V or less.
V
H
(high) value should exceed 4 V.
In addition, check the third wave, which
shows the sum of the two waves. The
diagram reflects a time shift of a quarter
cycle between the two waves.
If the waves are distorted with an
incorrect shift between them, the
encoder is faulty and should be adjusted
or replaced.
10. Errors in the repeatability of the robot.

Try to identify the faulty axis. If many or all axes are faulty, look for an
electrical noise source in your environment.

Check the encoder. Follow the procedures in Item 8 and Item 9.

If no problem found by means of Items 8 and 9, do the following:

Bring the robot to a starting position. Using a pencil, draw a fine,
continuous line on the robot which crosses from one link to the adjacent
link at the joint in question.
Figure 8-4: Encoder Signals
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Enter the command SHOW ENCO to display the encoder readings.
Enter the command COFF to disable servo control.
Physically move the axis to another position. Then return to the starting
position marked by the line you drew. Check the encoder reading for the
axis again. It should be within several counts of the first reading. Repeat
this step a number of times. If the error in the encoder reading
accumulates, the encoder needs to be replaced.
11. One axis turns constantly in one direction.

Reset the controller by pressing and releasing the Emergency button.

Then give the command to home the robot.

If problem persists, replace the driver card.

12. Axis/axes vibrating, too weak to carry load, motion not smooth, or jerks during or
at end of motion.

System parameters are not properly adjusted.

Refer to the ACL Reference Guide.

If problem persists, replace the driver card.

13. Electric gripper does not respond at all.

Make sure the gripper cable is securtely connected to the axis 6 port at the
rear of the controller.

Check whether the gripper is defined as axis 6 by typing the ACL

command: CONFIG ?

Check the value of PAR 75. It should be 4000.

If problem persists, proceed with corrective actions recommended for other

axes.

Discconnect gripper cable from the robot forearm and check for voltage
(1.5V-2.0V) by connecting pins 1 and 6 while entering CLOSE/OPEN
commands. (Pins 1 and 6 are, respectively, the pins immediately to the right
and left of the notch on the connector). If voltage exists, the problem is in the
gripper. Check the cable and the motor.

Check for excessive friction. Try raising the value of the current limit of the
gripper driver axis, as explained later in this chapter. If raising the current
limit above 0.5A enables gripper motion, make adjustments to reduce friction.
Be sure to reset the current limit for the gripper axis to 0.5A.
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14. Electric servo gripper opens and closes but does not react properly to JAW
command.

The problem is probably in the feedback. Check the encoder, the wiring, and
the driver card. Follow the procedures in Item 8 and Item 9.
15. Gripper opens and closes too freely; weak gripping force; or the gripper motor
rotates endlessly.

Check the value of PAR 275. It should be 1000.

16. Unusual noise.

Loose screws.

Poor lubrication.

Worn motor brushes.

Worn timing belt.

17. Controller does not receive an input signal.

Make sure motors switch is on and make sure user power supply is +12VDC.
If not, none of the inputs will be operative.

To determine whether the problem is in the controller or a user application, enter

the command: SHOW DIN. Zeros and ones appear on the screen,
corresponding to the status of the 16 inputs (0=OFF and 1=ON).
Short the specific input:
If the input is configured as NPN (default): Short the specific input to a
ground connection.
If the input is configured as PNP: Short the specific input to the 12V user
power supply.
Again enter the command SHOW DIN Look for a status change. If the status
of the input changes, the problem is in the user application.

If the status of the input does not change, check the flat cable connections
between:
Display card and main board (J11).
I/O card and main board (J10).

If the input LED also does not light up, refer to Item 18.

If, when checking the homeswitches (LSON) , the input LED lights up and
home is found (only the input is not functioning), replace the main board.
(Alternately, check U99, U100, U101, U102, U88, U93, U98.)
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18. I/O display LEDs do not light up.

Refer to Figure 8-5. Check the flat cable connection between:

Display card and main board (J11).
I/O card and main board (J10).

If the input or output functions, but not the LED, replace the LED or the
display card PC7300.

Replace the I/O card PC7400A.

(Alternately, check U1, U2, U3, U4, U5, U6, U7.)

Replace the main board.

(Alternatively check: for inputs: U99, U100, U101, U102, U88, U93, U98;
for outputs: U76, U77, U78, U79, U80, U81, U103, U108.)
Figure 8-5: Main Board - Connectors
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19. Controller does not give output signal.
Relay Outputs

For Outputs 1-4, check whether the relays have been switched (LED is lit):
In output OFF, NC is shorted to COM, NO is disconnected from COM.
In output ON, NO is shorted to COM, NC is disconnected from COM.

Refer to Figure 8-6. If outputs have not been switched, check the flat cable
connection between the I/O card and the main board (J10).
Open Collector Outputs

For Outputs 5-16, check whether the load and voltage source have been properly
connected. (If the supply has been connected directly to the output terminal,
the output transistor will blow out immediately).

Refer to Figure 8-5. Check the flat cable connection between the I/O card and
the main board (J10).
(Alternately check the ICs which drive the open collector outputs signals:
U76, U77, U78.)
20. Pneumatic gripper or end effector does not respond.

Make sure all air hoses are connected properly.

Make sure the gripper/device is connected to the proper controller output.

Check the relay output to which the gripper is connected according to the
instructions in Item 19.
21. User programs are not saved in the BBAM. Response to ACL command DIR is
Directory is Empty.

Check the voltage level of the backup battery on the main board. (See
Figure 8-1.) A good battery produces 3.4V--3.7V. Battery should backup
RAM as long as the Vcc supply to U4, U10, U16 and U21 is 2V or higher.
Replace battery if necessary.

Make sure the battery is properly and securely set in its socket.

If battery is all right, replace the main board.

When battery is low, backup the controller frequently to avoid loss of data.
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Error Messages
Following is a alphabetical listing of system messages which indicate a problem
or error in the operation of the robot arm. Refer to the ACL Reference Guide for
additional error messages.
Axis disabled.
(1) A movement command could not be executed because servo control of
the arm has been disabled (COFF).
(2) A previous movement of the arm resulted in an Impact or Trajectory
error, thereby activating COFF and disabling the arm.
Check the movements of the robot, and correct the command(s).
CONTROL DISABLED.
Motors have been disconnected from servo control. Possible causes:
(1) COFF (control off) command was issued.
(2) CON (control on) has not been issued; motors have not been activated.
(3) A previous error (such as Impact Protection, Thermic Overload or
Trajectory Error) activated COFF, thereby disabling the arm.
*** HOME FAILURE AXIS n.
The homing procedure failed for the specified axis. Possible causes:
(1) The home microswitch was not found.
(2) The motor power supply is switched off.
(3) Hardware fault on this axis.
*** IMPACT PROTECTION axis n
The controller has detected a position error which is too large. The system
aborted all movements of that axis group, and disabled all axes of that
group. Possible causes:
(1) An obstacle prevented the movement of the arm.
(2) An axis driver fuse has shut off.
(3) An encoder fault.
(4) A mechanical fault.
(5) The axis is not connected.
Determine and correct the cause of the position error. Then reenable servo
control of the motors (CON), and restart the program.
*** LOWER LIMIT AXIS n.
During keyboard or TP manual movement of the specified axis, its
encoder attained its minimum allowed value.
Move the axis in the opposite direction.
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*** THERMIC OVERLOAD axis n
Through a software simulation of motor temperature, the system has
detected a dangerous condition for that motor. The system aborted all
movements of that axis group, and disabled all axes of that group.
Possible causes:
(1) The arm attempted to reach a position, which could not be reached due
to an obstacle (for example, a position defined as being above a table, but
actually slightly below the tables surface). The impact protection is not
activated because the obstacle is close to the target position. However,
integral feedback will increase the motor current and the motor will
overheat, subsequently causing the Thermic Protection to be activated.
(2) An axis driver is faulty or its fuse has shut off.
(3) The robot arm is near to the target position, but does not succeed in
reaching it, due to a driver fault. The software will then detect an
abnormal situation.
(4) The Thermic Protection parameters are improperly set, or have been
corrupted by improper loading of parameters.
Check the positions, the axis driver card and parameters. Reenable servo
control of the motors ( CON ).
*** TRAJECTORY ERROR !
During movement, the robot arm reached its envelope limits, and the
system aborted the movement. Since the trajectory is not computed prior to
motion, the movement may exceed the limits of the working envelope.
Modify the coordinate values of the positions which define the trajectory.
*** UPPER LIMIT AXIS n
During keyboard or TP manual movement of the specified axis, its
encoder attained its maximum allowed value.
Move the axis in the opposite direction.
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Adjustments and Repairs
These procedures are to be performed only by a qualified technician who has
received proper training and certification from the manufacturer.
Opening the Controller Cover
1. Turn off the controllers power switch.
2. Unscrew the 4 Phillips screws which hold the cover.
Unscrewing just the two screws at the front of the controller and lifting up the
cover is possible, but not recommended, as it prevents access to the rear
(connector) panel of the controller.
3. Carefully lift off the cover and set it aside.
Changing the Voltage Setting
To change the controllers voltage setting, you must change the controllers
power transformer fuse and the voltage switches. Refer to Figure 8-6.
1. Open the controller cover and replace the power transformer fuse (1).
100/110V requires 4A (SB) fuse.
220V requires 2.5A (SB) fuse.
This fuse is accessed from the side of the transformer housing. Using a
screwdriver, push down on the fuse holder cover while turning it
counterclockwise. Remove the fuse holder and replace the fuse. Reinsert the fuse
holder, and retighten it clockwise, until it is securely in place.
Figure 8-6: Controller Voltage Setting
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2. Change the two switches inside the controller:

Using a small tool, push the red switch (2) on the transformer housing to the
opposite side.

Manually push the switch (3) on the logic power supply to the proper setting.
Replacing Fuses
Warning! Before you begin to check or remove fuses, turn off the controllers
power switch, and disconnect the power cable from the AC power source.
Logic Power Supply Fuse
One 4A (220/110V) fuse inside the logic power supply.
The logic power supply is an IBM/PC type power supply. It will not wake up if
it is not loaded, and it is protected against short load. Therefore, when searching
for a blown fuse, be sure you are trying to operate the logic power supply under
loaded conditions.
To replace this fuse:

Disconnect the cable from the logic power supply to the main board (J9).

Remove the power supply from the controller by unscrewing the four screws
on the rear panel of the controller.

Open the power supply and change the fuse, which is mounted in a standard
fuse holder.
Power Transformer Fuse
One 2.5A (SB) fuse (220V) or 4A (SB) fuse (110V), on the side of the
transformer housing. Feeds AC power to the transformer, from which the motors
and users power supplies are produced.
To replace this fuse:

Using a screwdriver, push down on the fuse holder cover while turning it
counterclockwise.

Remove the fuse holder and replace the fuse.

Reinsert the fuse holder, and retighten it clockwise, until it is securely in place.
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User Power Supply Fuse
One 2A (12VDC) fuse on the power supply card PC7500 inside the transformer
housing. Protects the users power supply.
To replace this fuse you must open the transformer housing.
Warning! The large motors capacitor may be loaded with an electrical charge
even after you have disconnected power. Be careful not to touch or short it.
Driver Card Fuses
Each driver card has two slow blow (SB) fuses (one fuse per axis). See
Figures 8-3 and 8-8.

The first three driver cards, for axes 1 through 6, have a 4A fuse for each axis.

The fourth driver card, for peripheral axes 7 and 8, has a 4A fuse for the top
axis (axes 7) and a 2A fuse for the lower axis (axis 8).

Additional driver cards, for axes 9 through 11, are the same as the fourth
driver card, with a 4A fuse for the top axis and a 2A fuse for the lower axis.
Remove the driver card from the controller before you replace any of its fuses. To
replace a driver card fuse, simply grasp it and extract it from its holder. You may
need to use a tweezers. Insert the new fuse into the holder, and make sure it is
firmly in place.
(Driver cards in earlier models of Controller-A have two semi-automatic fuses
(one fuse per axis). These fuses should not need to be replaced, only reset.
However, if you do replace such a fuse, solder it only when in the open state.)
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Changing the I/O Logic Mode
The I/O logic mode can be set individually for each input and open collector
output terminal by means of jumpers on the I/O card PC7400A, as shown in
Figure 8-7.
The jumpers are marked I1 to I16 and O5 to O16. Note that the relay outputs do
not require jumpers.
Use tweezers or a fine-tip pliers to lift off the jumpers and reset them. You do not
need to remove the I/O card from the controller.

NPN Logic
Shorting the two pins on the left sets the corresponding terminal to negative
(NPN) logic. All inputs and outputs area factory configured for operation in
negative (NPN) logic mode.
ON = low voltage or ground
OFF = high voltage

PNP Logic
Shorting the two pins on the right sets the corresponding terminal to positive
(PNP) logic.
ON = high voltage
OFF = low voltage or ground
Figure 8-7: I/O Card - Logic Jumpers
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Replacing or Adding a Driver Card
Refer to Figure 8-8.
(Skip Steps 4 and 5 when adding a driver card.)
1. Turn off the controller and disconnect the power cable from the power outlet.
2. Remove the cover of the controller.
3. Remove the long bracket which extends across the driver cards:

Remove the screw which holds the long bracket to the transformer cover (see
Figure 8-6).

Using pliers to grip the self-locking washer from inside the controller frame,
remove the screw that fastens the bracket to the side of the controller.

Remove the screws and washers which hold the long bracket to each driver
card.
4. Note the location of each driver cards (you will replace them later in these same
positions). Remove the screw at the top of each driver card bracket to detach the
driver card from the connector slot.
5. Holding the card with two hands, lift it out very carefully.
Figure 8-8: Axis Driver Card
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6. Before inserting the new driver card, make sure none of the 64 pins in the male
DIN connector is bent. Then, make sure the driver card is directly above the
female DIN connector on the main board, and that the metal bracket fits the rear
panel. Firmly but gently press the driver card into the driver card slot.
7. Reattach the long bracket to the transformer housing and the controller frame.
Reattach each driver card to the long bracket and its connector slot. Retighten all
the screws.
8. Check and adjust the current limit, according to the instructions in the following
section.
Adjusting Driver Card Current Limit
Refer to Figure 8-8.
1. Turn off the controller.
2. Connect the common probe of the voltmeter to the middle point in TP (marked
GND in Figure 8-8).
3. Turn on the controller.
4. Using a small screwdriver, rotate POT 1 (for upper axis) or POT 2 (for lower axis).
Rotating clockwise reduces the level of the current limit;
Rotating counterclockwise increases the level of the current limit.
Watch the voltmeter reading; the voltmeter reading reflects the amperage of the
current limit level. Adjust the current limit as follows:
Robot Axes Driver Cards
Current
Limit
SCORBOT-ER VII Upper Axis (Axes 1, 2, 3)
SCORBOT-ER VII Lower Axis (Axes 4, 5, 6)
-6.3 V
-4.0 V
Peripheral Axes Driver Cards
Peripheral Device Upper Axis (Axes 7, 9, 11)
Peripheral Device Lower Axis (Axes 8, 10)
-4.0 V
-2.25 V
Driver Card Jumper Configuration
Note the configuration of the two jumpers, W2 and W3, on the driver card, shown
in Figure 8-8.
The jumpers must be mounted in the upper position when connecting the
SCORBOT-ER VII.
(Conversely, the jumpers must be in the lower position when connecting a
SCORBOT-ER Vplus robot and peripheral axes to the controller.)
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Installing the Auxiliary RS232 Communication Card
An auxiliary (multiport) RS232 communication card may be installed in the
controller to provide additional RS232 communication channels. The cable
leading from the card may have either two or eight D25 connectors. Refer to Figures
4-3 and 8-9.
1. First, make sure Pins 1 and 2 are shorted on the cards Jumper JP1 (1).
Jumper JP1 allows the software to determine whether or not the communication
card has been installed in the controller.
Default factory setting: Pin 1 and pin 2 shorted.
2. Turn off the controller.
3. Remove the cover of the controller.
4. Remove the blank bracket at the back of the controller on the slot (J7) for the
auxiliary RS232 card.
5. Before inserting the auxiliary RS232 card, first check that none of the 64 pins in
the male DIN connector is bent. Then, make sure the card is directly above the
female DIN connector (J7) on the main board, and that the metal bracket fits the
rear panel. Firmly but gently press the card into the slot.
6. Tighten the bracket screw.
7. Make the cable connections:

Connect the D37 connector from the multiport connector cable to the
auxiliary RS232 port on the controller.

Connect the D25 connectors on the multiport connector cable to the

corresponding COM ports on the other controllers or computers.
8. The controller must be reconfigured for the auxiliary RS232 card.
Figure 8-9: Auxiliary RS232 Communication Card
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Before you perform the configuration, you must backup to disk the entire
contents of the controller, including all parameters.
Power on the system. From the ATS Backup Manager menu, select the options
Backup ALL and BACKUP to disk (F3).
9. Perform the configuration, using either of the following methods.

Use the command <Ctrl>+F1, as described in the section, Controller

Configuration, in Chapter 4; or

Use the ACL command CONFIG, as described in the ACL Reference Manual.
10. Reload the contents of the controller, including all parameters, which you backed
up to disk. From the ATS Backup Manager menu, select the options Restore
ALL and RESTORE from disk (F5).
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APPENDIX A
Theory of Control
The function of the controller is to instruct the movements of the robot arm or
other devices in the robotic system, to monitor these movements, and to make
adjustments automatically in order to correct any errors.
Servo Control
Open Loop Control
In open-loop (non-servo) control, the system does not check whether the actual
output (position or velocity) equals the desired output.
In open-loop control systems the controller output signal (U
r
) is determined only
by the input signal (r). If the system response is incorrectly predicted, or if the
output signal is affected by other factors, deviations from the desired state will
occur. Since no feedback exists, the system is unable to correct output errors.
In open loop robotic control, power is applied to the motors according to a
predefined program. The path and speed cannot be precisely predicted, since they
are determined by the torque and load on the motors, and other environmental
factors.
Closed-Loop Control
In closed-loop control, the control system measures the output signal (C),
compares it with the input (desired) signal (r), and corrects any errors.
Figure A-1 compares schematic diagrams of open-loop and closed-loop control
systems.
In servo control systems, a feedback device, commonly an optical encoder,
measures the output (C) (the amount, speed and direction of motor rotation),
converts it to an output signal (U
b
), and transmits it to the comparator.
A comparator () connects the input and feedback signals, produces an error
signal equal to the algebraic difference of its two input signals. The comparator
outputthe error signalis generally denoted as U
e
.
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The error signal is the most important value in the closed-loop system. The
system aims to reduce U
e
to the smallest possible value. When U
e
= 0, the output
signal (the actual state) is equal to the input signal (the desired state).
Digital Control
Unlike analog control systems, in which all signals within the controller are
continous analog signals, digital control systems are those in which some of the
signals within the controller are discrete digital signals, due to the presence of
microprocessors.
In digital control systems, the controller must be capable of converting between
analog and digital signals. For the microprocessor to read an analog signal, the
signal must first pass through an Analog to Digital Converter. The ADC
samplesthat is, readsthe signal at periodic intervals and stores the value for
the processor to read. For the microprocessor to transmit an analog signal, it must
send the discrete values of the signal to a Digital to Analog Converter. The DAC
holds the output continuously until given a new value.
Controllers use microprocessors to calculate the state (position, velocity, etc.)
error (e) for each motor and the control signal (U
c
) which is sent to the motors to
correct the error. The control signal is converted to an analog signal by a DAC
and then amplified before driving the motor.
Figure A-1: Open-Loop and Closed-Loop Control
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The feedback device measures the actual state and produces an analog signal. The
feedback signal is converted by a ADC so that the processor can read it to
compute e.
A digital control system can be programmed to compute any number of control
equations. The processors control program is a continuous loop whose basic steps
are as follows:
1. Read desired state from memory.
2. Read actual state from feedback device.
3. Calculate the state error (e).
4. Calculate control signal from control equation.
5. Go back to step 1.
The main difference between digital and analog controllers is the time delay
caused by the processors computations. This time delay is, in effect, the
sampling time of the DAC and of the output control signal it produces. If the
processor can complete a loop within a few milliseconds, the sampling time will
be rapid, and the digital controller will produce an output similar to the equivalent
analog controller.
On the other hand, if the processor is slow to make the computations, the
controller will be unaware of fast changes in the feedback signal and the control
signal will be based on old measurements. The greater the delay, the more the
response will oscillate, eventually becoming unstable.
Figure A-2: Analog and Digital Signals
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Transient and Steady State Responses
When the desired input signal (r) changes suddenly, the system will react in two
phases, as shown in Figure A-3. The initial reaction to a change in the input
signal is called the transient response. The second part of the reaction is known as
the steady state response. Once the input signal (r) has remained constant for
some time, and the error between the input and output signals has stabilized, the
system is said to be in steady state. The transition from transient to steady state is
not a cleanly defined break.
This constant error, known as the steady state error, should be reduced as much as
possible by the control system.
Increasing the amplitude of the controller output signal (that is, increasing the
controller gain) can reduce the steady state error and enable a more rapid
approach to the steady state value. The greater the controller gain, the faster the
system reacts.
However, excessive gain may lead to a phenomenon called overshoota rise in
the controlled value to a point above the desired value, followed by a drop below
the desired value, repeated several times before stabilization. This, in effect,
causes the actual value to oscillate around the desired value. Further increase of
the controller gain may lead to instability of the entire system that is,
uncontrollable oscillation.
A control system is damped when it reaches steady state without overshoot. A
critically damped response is the fastest approach to steady state without
overshooting; an overdamped response is a slow approach to steady state.
Figure A-4 shows different transient responses.
Figure A-3: Transient and Steady States
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Figure A-4: Transient State Responses
Figure A-5: Controller-A Control Loop
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Controller-A Control Process
The basic steps of the Controller-A control loop are described below. Refer to
Figure A-5. The entire control cycle takes 10ms.
The processor calculates the command position and speed once per cycle. It
outputs a digital value to the DAC unit in the range of 5000.
The analog unit creates a series of pulses, resulting in an average voltage value
proportional to the DAC input.
The power unit drives the motor by switching 24V to it at 20KHz , according to
the input pulse. The motor cannot react to this high frequency of switching and is
therefore affected by only the average value of the voltage.
This method of controlling the time during which current flows through the
motor, rather than controlling the value of the current, is known as PWM (Pulse
Width Modulation) control. Refer to Figure A-6.
Once per cycle the processor reads the encoders count and calculates the motors
position and speed (rate of encoder counts). The processor then compares the
actual (output) position and speed values with the desired (input) ones,
determines the error values and takes the necessary action to cancel them.
Figure A-6: Controller-A Control Signals
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Trajectory Control
For better path performance (that is, to accurately reach the desired state and
avoid overshoots), trajectory control profiles, may be programmed into the
control system. Controller-A offers two profiles: paraboloid and trapezoid. Refer
to Figure A-7.
Paraboloid
The paraboloid profile causes the motors to accelerate slowly until maximum
speed is reached, then decelerate at the same rate.
Trapezoid
The trapezoid profile causes the motors to accelerate and decelerate quickly at the
start and end of movement, with a constant speed along the path.
Path Control
It is desirable that the path and speed of a robot between taught points be
predictable. Ideally, the path between consecutive points is traversed at a constant
velocity with defined acceleration and deceleration segments.
Along the path, motion of all joints should be proportional, so that all the joints
start and finish moving at the same time. The method of coordinating the
movement of the joints so that all joints reach the desired location simultaneously
is termed joint interpolation.
Point-to-Point Control
Point-to-point control (PTP) involves the positioning of the robots end effector at
given points, without defining the exact path of the end effector between any two
points.
Figure A-7: Trajectory Control Profiles
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Point-to-point control is suitable for applications which require an exact and static
position of the end effector at the points where operations will be performed.
In principle, point-to-point control can be used to guide the robot through a large
array of positions, thus resulting in a complex path. In order to obtain such a path,
points must be defined and recorded in a very close sequence. The number of
positions will be limited, however, by the capacity of the control system to
maintain positions in memory.
Continuous Path Control
Continuous path control (CP) involves the movement of the end effector between
two points along a path defined by a mathematical formula. This method of
control is suitable for applications in which the end effector executes operations
along a precise trajectory.
During program execution, the control system calculates and plans the path, and
instructs the robot motors to move accordingly.
When continuous path control is required, the processor divides the path into
short segments, and interpolates the motion of the joints as frequently as possible.
Three type of CP control are possible.

Joint Control: Each axis moves according to the trajectory profile. The
gripper path is not defined; only the start and end points are defined.
All axes start and stop movement at same time.

Linear Path Control: The axes are coordinated in order to move the TCP
(tool center point; tip of the gripper) in a straight line according to the
trajectory profile.

Circular Path Control: The axes are coordinated in order to move the TCP
along a circular path according to the trajectory profile.
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The Control Parameters
In the robotic system controller by Controller-A, as in common in closed-loop
systems, the controlled value (C) is measured by an optical encoder. The encoder
signals serve as feedback to the controller, enabling it to correct any deviations
from the desired value.
Since control systems cannot react immediately to the input signal, there will
always be a lag between the generation of an error signal and the actual correction
of the controlled value.
The PID (proportional, integral, differential) control parameters allow the
controller to adapt to various conditions of operation, such as overcoming
nonlinear functions in the system.
Proportional Control
The proportional parameter is the gain of the control system. Its value determines
the reaction time to position errors.
When a position error exists (that is, the actual motor position is off by a certain
amount of encoder counts), the processor multiplies the error by the proportional
parameter and adds the product to the DAC value, thereby reducing the error.
The proportional parameter is the parameter in the PID control system which acts
most quickly in reducing the position error, especially during motion. It is also
the first parameter to respond to position errors when the robot has stopped at a
target position.
The greater the proportional parameter, the faster the sytem responds and reduces
the error. But, using too great a value for the proportional parameter will cause
the axis to oscillate.
The main disadvantage of proportional control is that it cannot completely cancel
the error, because once it has reduced the error it cannot generate enough power
to overcome friction in the system and propel the axis to its target position.
Even in steady state, under load, the controlled value (output signal) will always
be different from the desired value (input signal). The steady state error can be
reduced by increasing the gain, but this will increase the oscillation and reduce
stability.
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Differential Control
In differential control, the controller output (C) is a function of the rate at which
the error (U
e
) changes. The faster the rate of change of the error, the greater the
controller output (C). In other words, the controller is sensitive to the slope of the
error signal.
The differential parameter is responsible for reducing the speed error. The control
system calculates the actual speed once per cycle and compares it to the desired
value. While the robot is accelerating (during the first part of path) the differential
acts as a driving factor.
While the robot is decelerating (during the second, and last, part of path), the
differential acts as a braking factor. A good differential setting will result in a
clean and smooth motion along the entire path. Lack of the differential will cause
overshoot at the end of path. High differential values will cause small vibrations
along the path.
In this control method, the controller predicts the value of the error in accordance
with the error signal slope, and causes the correction to take place in advance.
However, if the error is constant and unchanging, differential control will not be
able to reduce the error to zero.
Integral Control
In integral control, all the state errors which have been recorded each cycle are
totalled and their sum is multiplied by the integral parameter value.
In integral control, the controller output (C) reduces the error signal (U
e
) to zero
at a rate proportional to the size and duration of the error. In other words, the
greater the error, the greater the controller output; and, the longer the duration of
the error, the greater the controller output.
The main advantage of integral control is that the steady state error is always
reduced to zero since its value increases each cycle, thus strengthening the control
systems ability to react and reduce the error. However, using too great a value
for the integral parameter may cause overshoots, while too small a value may
prevent the cancellation of a steady state error.
Unlike the proportional parameter, the integral parameter takes effect more
slowly and is less noticeable during motion. However, when the axis comes to a
complete stop and the proportional parameter can no longer reduce the steady
state error, the integral parameter takes over and can cancel the error completely.
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ProportionalIntegralDifferential Control
The PID control method enables optimal exploitation of all three types of
controlproportion, integral and differential. In this manner, it creates an output
response which follows the input signal closely, without gaps or lags, in both
slow and rapid processes, including those in which the load is in a constant state
of change. In summary, the PID control parameters serve the following functions:

Proportional Parameter: Enables fast and powerful reactions of the arm to

movement commands. Responsible for the repeatability of the motion.

Integral Parameter: Assists the proportional parameter in eliminating steady

state errors.

Differential Parameter: Provides the required damping.

Offset
Control theories often assume complete linearity; that is, the speed is proportional
to the power supplied to the motor.
However, at low levels of power, the motor will not move, mainly due to friction;
that is, the static friction is higher than the dynamic friction. This is a
non-linearity. Figure A-8 shows linearity and non-linearity.
The offset is a threshold level of the DAC. Above this DAC value the control
system acts as a linear system. Below this value, the control system acts as an
on/off system. Figure A-9 shows the offset.
Figure A-9:
Control System Offset
Figure A-8:
Linearity and Non-Linearity
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Changing Parameter Values
The control system parameters of Controller-A are factory-set, and are suitable
for most robotic applications.
Although parameter values can be manipulated by user commands, only
experienced users should attempt to do so.
For more details refer to the ACL Reference Guide.
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