Fanuc S-420W + RH controller - some software issues...

[bidzej]

Hi.

I've got a problem with an old, 1992 Fanuc S-420W robot. It's equipped with RH controller, which had some software issues (unmaskable interrupts occuring randomly), so I tried to update it. Here is the story: I only got software which seemed to fit R-J2 (information from SSD.txt file), but my supervisor told me that my company has no other software and this one should be working ok. well, I've tried a few different versions and finally found one that started without problems - or at least it looked so... one thing that confuses me is that there were no prompts during the update (user's manual tells me that there should be a few). I've launched KFLOPPY, started emulation, then powered on the controller using UserPB1+Hold+On buttons and after some standard information and READING AUTO line on the CRT, all started normally. What is more, robot model is set to S-420R and I have no idea how to change it. There are some problems with axis 3 limit error (it occurs even when axis 3 is far from its limits) and moving in TOOL coordinate system (it seems that in some arm positions the TCP is defined about 20cm from a mounting plate, while in others it looks like it's directly on the plate). Guess this could be caused by invalid robot model defined in the controller and/or bad software version. any suggestions how to fix it?

cheers.

PS. The robot is old and quite worn - so used for rather educational purposes, that's why we're experimenting on it :)

[fanuc_insider]

You have the wrong library loaded. S-420 R is a press mount robot which has 45degree base allowing it to reach into presses and remove part. That is why it won't jog properly. I'm not for certain how to change the robot library on an RH. I will look into it for you. I do believe the software will have to be loaded again with the proper library. I think the RH software came specific to robot model.

[bidzej]

would be grateful for looking into the problem :) meantime, we've found some more appropriate software buried among other stuff. I will try to upload it tomorrow, hope it helps a bit...

EDIT:

here is the story of my struggle with the other software... I looked into AUTO.CF file and it contains commands and syntax different to those specified in "KCL Command Alphabetical Description" manual BUT the very beginning of the file look like this:

type Karel system software load procedure
type Copyright (c) 1987,1988,1989,1990,1991,1992 FANUC Robotics North Amercia Inc.
type
type Robot Model:        S-420
type Software Version:   2.23P Enhanced Karel

so it seems it should suit our S-420, as I've also found something like a library for S-420W in the same directory (filename: S420W_B.DT). Launching the controller in BootROM (with KFLOPPY working on a pc connected to the controller) goes like this:
1. the controller shows some standard startup info
2. KFLOPPY sends AUTO.CF to the controller, which displays READING AUTO and then Clearing DRAM memories... - this looks like a continuation of a normal startup procedure, but:
3. KFLOPPY starts sending files from its directory to the controller (it just waits for KFLOPPY to finish) - I've traced the transfer and it seems that all files (AUTO.CF, SYS1E.CF, SYS2.CF, SYS3.CF, SYS4.CF, SYSDEF.CF) are executed and all files are sent. None of them contains information on which robot will be used, at least not a notepad-readable one 
4. after receiving all files, the controller displays a message that the system has been saved:
Saving MAIN processor/module (numbers)
Saving PATH processor/module (numbers)
Saving SRV0 processor/module(numbers)
Controller System save complete
and a BMON> prompt

what's strange is that no messages are displayed on the CRT - guess type command doesn't work (as far as I know, WRITE ('message') command should be used to display text). anyway, the controller loads all specified files and at least that's good...

another strange thing is that "KAREL R-H System Software Installation Kit" manual mentions a need to press Enter at prompts, and there aren't any, except that final BMON>...

entering START or AUTO ends in initializing Karel and starting to work, but nothing seems to be changed. No possibility of choosing robot model during the upload, although there are some different library files. That makes me think it should be possible to change the model with current controller software, using CRT/KB...

[bidzej]

searching Karel Reference Manual for any hints, I found this:

UTIL> SINITIALIZE command

Syntax: SINITIALIZE

Purpose: Loads the deafult values for robot-specific system variables. The command prompts for the robot type (number of axes, standard or high speed, floor or wall mount, wrist type, extended arm and so forth). Next, the command initializes system variable values based on your responses to the prompts.

SINITIALIZE is used most often for a cold start - when a SYSVARS.SV file does not exist on bubble memory and the default system variable values that are loaded at power up do not match the robot type. SINITIALIZE cannot be issued from the CRT/KB while memory protection is on.

Use the KCL> SSAVE command and specify the SYSVARS.SV file to save these initial values so that they are loaded automatically at power up.

Example: UTIL> SINITIALIZE

happy to find such an info, I started to work. according to what I got to know, a cold start is made just by powering off, then on and that's what I've done first. seeing this:

1: Floor Mount Type
2: Angle Mount Type
3: S420S, Stud Robot
4: S420W

after entering UTIL> SINITIALIZE in KCL made me even happier. I chose 4, then got back to KCL by pressing Enter at UTIL> and entered SAVE SYSVARS.SV. Then, I restarted the controller and... it still shows S-420R robot model, and there are still the same jogging problems no idea what to do I've even tried to delete SYSVARS.SV from bubble memory prior to using SINITIALIZE, but no effect. anyone?

[fanuc_insider]

could you post a copy of the auto.cf file found in the software disks you loaded. It Should be the first disk.

[bidzej]

that's the whole file:

type Karel system software load procedure
type Copyright (c) 1987,1988,1989,1990,1991,1992 FANUC Robotics North Amercia Inc.
type
type Robot Model:        S-420
type Software Version:   2.23P Enhanced Karel
type
  if $BM0 goto skip1
    type Bubble Memory board is not installed or operational.
    goto quitall
:skip1
  if $path goto skip2
    type Path CPU board is not installed or operational.
    goto quitall
:skip2
  clear
 if $servo2 then
  load sv_code2
 else
  load sv_code
 endif
  load m_S420e
  load p_S420
  load m_edite
  load m_karle
  load m_lrtbe
 look mnS420e.lda
 if $diskerr goto nonatv
 load mnS420e
:nonatv
 look sys1e.cf
 if $diskerr goto ask3
 run sys1e
:ask3
  type
 prompt Insert R-H Standard System Disk #1 in the floppy drive and press RETURN
 look sys1e.cf
  if $diskerr goto ask3
    look v223P.ver
    if $diskerr goto quit
 run sys1e
  if $diskerr goto ask3
  exit
:quit
  type Software Version Mismatch
:quitall
  type Procedure abandoned!

other .CF files I've mentioned above look similar to this one.

[fanuc_insider]

you should send me an email I have something that should work.

[bidzej]

fanuc-insider, I've sent you my adress via PM but got no response...

anyway,I've finally managed to deal with that piece of junk... the controller still shows Hardware Model: S-420R, but after updating the software (just as described earlier), changing the robot model through UTIL> SINIT command and saving both SYSVARS.SV and SYS_STANDARD.SV files afterwards (maybe it was enough to save just SYS_STANDARD?), then commencing mastering and calibration, everything started to work fine. Here's a short movie of how the robot moves (everything in auto mode, which was impossible before I started working on it)... Polish subtitles only

<a href="http://www.youtube.com/v/WMXWkyX6M4M&rel=0" target="_blank">http://www.youtube.com/v/WMXWkyX6M4M&rel=0</a>

[fanuc_insider]

I sent you email with files attached maybe your server tagged it as spamm. I also just sent them again.

[bidzej]

now I got it - although it's exactly the same as what I uploaded to the controller 2 days ago :) thanks a lot for your help anyway!

[fanuc_insider]

maybe not as when I loaded it to my robot it loaded the s420if floor mount not the 420R

[bidzej]

everything seems to bo ok (except that Hardware model information), but i'll give it a try next week :)

[paminachristoph]

Hello from germany, is it right? Do you have manual for RH control and S420F ?
I would like to have tham. Is there a chance to get it?  camline@web.de

Thanks