I&J Fisnar I&J4000-LF Series User manual

I&J4000-LF Series Operating Manual
Part # 562187
Rev. E - Jan. 08
© 2008 I&J Fisnar Inc.
I&J4000-LF
SERIES ROBOTS
OPERATING MANUAL

I&J4000-LF Series Operating Manual
Part # 562187
Rev. E - Jan. 08
- Page 2 - © 2008 I&J Fisnar Inc.
THIS PAGE INTENTIONALLYLEFTBLANK

I&J4000-LF Series Operating Manual
Part # 562187
Rev. E - Jan. 08
- Page 3 - © 2008 I&J Fisnar Inc.
TABLE OF CONTENTS
SECTION 1: INTRODUCTION....................................................................................6
1. SAFETY PRECAUTIONS ........................................................................................................7
2. PACKAGE CONTENTS...........................................................................................................8
3. CONNECTOR AND SWITCH LOCATIONS................................................................................9
3.1 I&J4100-LF.........................................................................................................................................9
3.2 I&J4300/4400-LF................................................................................................................................10
SECTION 2: SETUP....................................................................................................11
1. UNPACKING THE ROBOT......................................................................................................12
2. SETUP..................................................................................................................................12
SECTION 3: TEACHING OVERVIEW.........................................................................14
1. TEACHING OVERVIEW.........................................................................................................15
2. USING THE TEACH PENDANT...............................................................................................17
2.1 Key Selection .......................................................................................................................................17
2.2 Key Assignments..................................................................................................................................18
2.3 Navigation Menu .................................................................................................................................19
2.4 Jogging ................................................................................................................................................19
2.5 Data Entry ...........................................................................................................................................19
2.6 Running a Program .............................................................................................................................19
3. TEACH BOX KEY ASSIGNMENTS .........................................................................................20
4. POINT TYPE &FUNCTION SUMMARY ..................................................................................23
4.1 Point Menu...........................................................................................................................................23
4.2 Setup Menu ..........................................................................................................................................25
4.3 Menu 1.................................................................................................................................................27
4.4 Utility Menu.........................................................................................................................................28
4.5 Menu 2.................................................................................................................................................29
SECTION 4: PROGRAMMING EXAMPLE .................................................................30
1. PROGRAMMING EXAMPLE ...................................................................................................31
2. GOOD PROGRAMMING PRACTICES ......................................................................................34
3. EDITING A PROGRAM...........................................................................................................34
3.1 Changing a Point’s XYZ location........................................................................................................35
3.2 Insert / Delete an Instruction...............................................................................................................35
4. CHANGING THE PROGRAM NUMBER....................................................................................35
5. CHANGING FROM TEACH MODE TO RUN MODE ..................................................................36
SECTION 5: POINT TYPE & FUNCTION REFERENCE ............................................37
1. POINT MENU .......................................................................................................................38
1.1 Dispense Dot........................................................................................................................................38
1.2 Line Start .............................................................................................................................................38
1.3 Line Passing.........................................................................................................................................39
1.4 Circle...................................................................................................................................................39
1.5 Arc Point..............................................................................................................................................40
1.6 Line End...............................................................................................................................................40
1.7 End Program .......................................................................................................................................40
1.8 Dispense ON / OFF.............................................................................................................................41
1.9 Goto Address .......................................................................................................................................41
1.10 Step & Repeat X...................................................................................................................................42
1.11 Step & Repeat Y...................................................................................................................................46
1.12 Brush Area...........................................................................................................................................47
1.13 Call Subroutine....................................................................................................................................53
1.14 Call Program.......................................................................................................................................54

I&J4000-LF Series Operating Manual
Part # 562187
Rev. E - Jan. 08
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1.15 Set I/O..................................................................................................................................................54
1.16 Wait Point............................................................................................................................................54
1.17 Stop Point ............................................................................................................................................55
1.18 Home Point..........................................................................................................................................55
1.19 Loop Address.......................................................................................................................................55
1.20 Dummy Point.......................................................................................................................................55
1.21 Initialize...............................................................................................................................................56
1.22 Label....................................................................................................................................................56
1.23 Display Counter...................................................................................................................................56
2. SETUP MENU.......................................................................................................................56
2.1 Line Speed............................................................................................................................................56
2.2 Line Dispense Setup.............................................................................................................................56
2.3 Point Dispense Setup...........................................................................................................................58
2.4 Dispense End Setup .............................................................................................................................58
2.5 Z Clearance .........................................................................................................................................59
2.6 X/Y Move Speed...................................................................................................................................61
2.7 Z Move Speed.......................................................................................................................................61
2.8 Home Position Setup............................................................................................................................61
2.9 Adjust Position Setup...........................................................................................................................61
2.10 Retract Setup........................................................................................................................................63
2.11 Quickstep .............................................................................................................................................65
2.12 Auto Purge Setup.................................................................................................................................66
2.13 ESTOP Output Status...........................................................................................................................66
2.14 Acceleration.........................................................................................................................................66
2.15 Pause Status.........................................................................................................................................67
3. MENU 1...............................................................................................................................67
3.1 Group Edit...........................................................................................................................................67
3.2 Expand Step & Repeat.........................................................................................................................73
3.3 Program Name.....................................................................................................................................74
3.4 Z-axis Limit (mm) ................................................................................................................................74
3.5 Initial Output Port ...............................................................................................................................75
3.6 Debug Speed (mm/s)............................................................................................................................75
3.7 Utility Menu.........................................................................................................................................75
3.8 Jog Speed.............................................................................................................................................75
3.9 Adjust Origin .......................................................................................................................................76
3.10 Control by RS232.................................................................................................................................76
4. UTILITY MENU....................................................................................................................76
4.1 Program...............................................................................................................................................76
4.2 Memory................................................................................................................................................76
4.3 Teach Pendant.....................................................................................................................................77
4.4 Relocate Data ......................................................................................................................................77
4.5 Lock or Unlock Program.....................................................................................................................78
4.6 Password Setup....................................................................................................................................78
4.7 Cycle Counter......................................................................................................................................79
5. MENU 2...............................................................................................................................79
5.1 Numerical Move...................................................................................................................................79
5.2 Save Temp Point..................................................................................................................................79
5.3 Move To Temp Point............................................................................................................................80
5.4 Undo Program.....................................................................................................................................80
5.5 Redo Program......................................................................................................................................80
5.6 Debug Program ...................................................................................................................................80
5.7 Move To Home Position ......................................................................................................................80
5.8 System Information..............................................................................................................................80
5.9 Execute Point.......................................................................................................................................80
SECTION 6: SAMPLE PROGRAMS...........................................................................81
1. DOTS,LINES AND ARCS –SAMPLE PROGRAM.....................................................................82
2. BRUSH AREA –SAMPLE PROGRAM .....................................................................................83
3. STEP &REPEAT –SAMPLE PROGRAM.................................................................................84
4. INPUT /OUTPUT SIGNAL PROCESSING –SAMPLE PROGRAM................................................85
SECTION 7: ERROR MESSAGES AND SPECIFICATIONS......................................88
1. ERROR MESSAGES...............................................................................................................89

I&J4000-LF Series Operating Manual
Part # 562187
Rev. E - Jan. 08
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1.1 Point Closed Error ..............................................................................................................................89
1.2 Need Line Start Point...........................................................................................................................89
1.3 Need Step & Repeat.............................................................................................................................89
1.4 Unlock Program ..................................................................................................................................89
1.5 Address Over Memory.........................................................................................................................89
1.6 Move Over Memory.............................................................................................................................90
1.7 System Error........................................................................................................................................90
2. I/O SPECIFICATIONS ............................................................................................................90
2.1 Dispenser Connector:..........................................................................................................................90
2.2 Ext. Control Connector: ......................................................................................................................91
2.3 Output Signals .....................................................................................................................................92
2.4 Input Signals........................................................................................................................................94
2.5 Input / Output Schematic .....................................................................................................................95
2.6 Input / Output Power Specifications....................................................................................................96
3. SYSTEM SPECIFICATIONS.....................................................................................................97
4. MACHINE DIMENSIONS .......................................................................................................98
4.1 I&J4100-LF Dimensions .....................................................................................................................98
4.2 I&J4300-LF Dimensions .....................................................................................................................99
4.3 I&J4400-LF Dimensions .....................................................................................................................100
4.4 Work Table Dimensions.......................................................................................................................101
4.5 Work Table Dimensions.......................................................................................................................102
SECTION 8: MECHANICAL AND ELECTRICAL PARTS LISTS...............................103
1. I&J4100-LF PARTS LISTS...................................................................................................104
1.1 I&J4100-LF – X-axis Mechanical Parts List.......................................................................................104
1.2 I&J4100-LF – Y-axis Mechanical Parts List.......................................................................................105
1.3 I&J4100-LF – Z-axis Mechanical Parts List.......................................................................................106
1.4 I&J4100-LF – Electronic Parts List....................................................................................................107
1.5 I&J4100-LF – Electronic Parts List – Connectors / Wires ................................................................108
2. I&J4300/4400-LF –PARTS LISTS.......................................................................................110
2.1 I&J4300-LF –– Body Mechanical Parts List.......................................................................................110
2.2 I&J4400-LF –– Body Mechanical Parts List.......................................................................................111
2.3 I&J4300/4400-LF ––Z-axis Mechanical Parts List.............................................................................112
2.4 I&J4300/4400-LF ––Electronic Parts List..........................................................................................113
2.5 I&J4300/4400-LF ––Electronic Parts List – Connectors / Wires ......................................................114
SECTION 9: MAINTENANCE AND PERIODIC INSPECTION ...................................116
1. CHECK CYCLES AND METHODS...........................................................................................117
1.1 General Consideration ........................................................................................................................117
1.2 Check Cycles and Points......................................................................................................................117
1.3 Check Methods.....................................................................................................................................118
2. GREASING PROCEDURE .......................................................................................................119
2.1 Grease Type and Greasing Interval.....................................................................................................119
2.2 Accessing Parts to be Greased ............................................................................................................119
3. PARTS THAT COULD REQUIRE FREQUENT REPLACEMENT ..................................................129

I&J4000-LF Series Operating Manual
Section 1: Introduction
Part # 562187
Rev. E - Jan. 08
- Page 6 - © 2008 I&J Fisnar Inc.
SECTION 1: Introduction

I&J4000-LF Series Operating Manual
Section 1: Introduction
Part # 562187
Rev. E - Jan. 08
- Page 7 - © 2008 I&J Fisnar Inc.
1. Safety Precautions
1.1 In order to meet the requirements of the European Community (CE) safety
directives, the robot must be placed in an enclosure supplied by I&J Fisnar Inc.
distributors. The enclosure will prevent the operator from entering the robot’s work
area and will generate an emergency stop signal if the enclosure’s door switch is
opened while the robot is running.
1.2 Make sure the robot and accessories are connected to a properly grounded power
source.
1.3 Do not drop or spill foreign objects or material such as screws or liquids into the robot.
1.4 Do not touch any moving parts while the robot is running.
1.5 Loading and unloading of parts and material must be done when the robot is not
running.
1.6 Changing of fixtures or tooling must be done with the power source disconnected.
1.7 The I&J4100, I&J4300 and I&J4400 robots should only be operated in an
environmental of 0 to 40 degrees centigrade and humidity of 20 to 95 percent with no
condensation.
1.8 Do not store or install the robot in an area where it is exposed to direct sunlight.
1.9 Do not operate the robot where electrical noise is present.
1.10 Only use a neutral detergent for cleaning. Do not use alcohol, benzene or thinner.

I&J4000-LF Series Operating Manual
Section 1: Introduction
Part # 562187
Rev. E - Jan. 08
- Page 8 - © 2008 I&J Fisnar Inc.
2. Package Contents
In addition to this operating manual, the following items should be included with the robot:
Main Unit
(I&J4100/4300/4400-LF) Enclosure (CE Units Only – Not Included)
Teach Pendant Barrel Holder
Spare Screws and Hex Key Teach Pendant Cable
Power Cord Dispenser Cable
RS232 Cable and Null Modem Adapter
(optional) I/O Port Connector (optional)
Start / Stop Box
(optional)
- External Control Connector
- Spare Control Connector
- Barrel and Air Line
- Cable Supporter (for I&J4100-LF)
Your system may also include other optional accessories.
If any of the above items are missing, please contact the supplier.

I&J4000-LF Series Operating Manual
Section 1: Introduction
Part # 562187
Rev. E - Jan. 08
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3. Connector and Switch Locations
3.1 I&J4100-LF
Left side View
Right side View
RS232 Port
Input / Output Port
Teach Pendant Connector
Monitor Port
Power Switch
Dispenser Purge
Keyboard Port
Power Inlet
Program No. Switch
RUN /TEACH Mode Switch
Dispenser Cable Connector
External Control (Start Box) Connector
Start Button Emergency Stop

I&J4000-LF Series Operating Manual
Section 1: Introduction
Part # 562187
Rev. E - Jan. 08
- Page 10 - © 2008 I&J Fisnar Inc.
3.2 I&J4300/4400-LF
Front side view
Rear side view
RS232 Port Keyboard Port
Teach Pendant Connector
Dis
p
enser Pur
g
e
Power Led
Program No. Switch
RU
N
/TEACH Mode Switch
Emer
g
enc
y
Sto
p
Start Button
Monitor Port Power Switch
Power InletCF CARD Port
Dis
p
enser Cable Connector
Input / Output Port
External Control (Start Box) Connector

I&J4000-LF Series Operating Manual
Section 2: Setup
Part # 562187
Rev. E - Jan. 08
- Page 11 - © 2008 I&J Fisnar Inc.
SECTION 2: Setup

I&J4000-LF Series Operating Manual
Section 2: Setup
Part # 562187
Rev. E - Jan. 08
- Page 12 - © 2008 I&J Fisnar Inc.
1. Unpacking the Robot
•Always lift the robot from the base. Never lift the robot from the cross member.
•Remove all accessories from the shipping package before attempting to remove the
robot.
•Place the robot on a stable workbench.
•Do not discard the packing material, as these items may be needed if the robot is
shipped or moved in the future.
2. Setup
The I&J4000 robots are available in many different configurations. The configuration of
each machine and the accessories used with each system will depend on the customer’s
application.
The steps required to setup a system using a 30 cc or a 55 cc barrel and a DSP501A
dispensing controller are described below.
2.1. If the system is being used in the European Community, the robot must be placed
in an enclosure supplied by I&J Fisnar Inc. The enclosure will prevent the operator
from entering the robot’s work area and will generate an emergency stop signal if the
enclosure’s door switch is opened while the robot is running. Connect the external start
/ stop box and door switch or light curtain to the Ext. Control connector on the main
unit. For further information, see SECTION 7:2.2 Ext. Control Connector.
If an enclosure is NOT being used, the enclosure door switch can be bypassed
by connecting the plug labeled SHORTED (included in the robot accessories
box) to the Ext. Control Connector.
2.2. The I&J4300-LF and I&J4400-LF robots are shipped from the factory with a
shipping bracket installed. The shipping bracket secures the worktable to the X/Z
head to prevent movement and damage during shipment.
Remove the shipping bracket by removing the screws which secure it. Keep the
shipping bracket and screws in a safe place for future use.

I&J4000-LF Series Operating Manual
Section 2: Setup
Part # 562187
Rev. E - Jan. 08
- Page 13 - © 2008 I&J Fisnar Inc.
2.3. Standard systems are shipped with a barrel holder, which must be mounted on the
Z head of the robot. The barrel holder will hold a 30 cc or 55 cc barrel on the robot’s
head. An optional valve holder may be used as a replacement for the barrel holder
if the application so requires.
2.4. The dispenser, such as the DSP501A, is connected to the robot via the dispenser
interface cable. Connect the female round connector of the dispenser interface
cable to the DISPENSER connector on the robot.
Connect the small plastic connector from the other end of the dispenser interface
cable to the FOOT PEDAL connector at the back side of the dispenser.
2.5. Connect the male end of the barrel adapter assembly provided with the DSP501A
dispenser to the air output connector on the front side of the DSP501A.
Connect the barrel adapter end of the barrel adapter assembly to a 30 cc or 55 cc
barrel of material. Connect the appropriate luer lock dispensing tip to the end of the
barrel. Place the barrel in the barrel holder on the robot’s Z head.
Detailed instructions for setting up the DSP501A dispenser can be found in the
manual provided with the DSP501A.
2.6. For normal operation, the orange TIMER / NO TIMER switch on the DSP501A
dispenser should be in the NO TIMER position (a picture of a clock with a X
through it is shown).
2.7. Connect one end of the Teach Pendant cable to the Teach Pendant and the other
end to the Teach Pendant connection on the robot.
2.8. Connect the power cord of the DSP501A to the back side of the dispenser. Be sure
to use the correct power cord and power source for the dispenser model you are
using (110 V or 220 V).
2.9. Connect the power cord of the I&J4000 robot to the power socket on the robot. Be
sure to use the correct power cord and power source for the robot model you are
using (110 V or 220 V).
2.10. Tie back all cables and air lines so that they will not interfere with the robot’s motion
when the robot is operating. Be sure that the cables and air lines do not restrict the
motion of the robot’s head and the robot’s table and make sure that they can not
become jammed as the robot moves through the work area.

I&J4000-LF Series Operating Manual
Section 3: Teaching Overview
Part # 562187
Rev. E - Jan. 08
- Page 14 - © 2008 I&J Fisnar Inc.
SECTION 3: Teaching Overview

I&J4000-LF Series Operating Manual
Section 3: Teaching Overview
Part # 562187
Rev. E - Jan. 08
- Page 15 - © 2008 I&J Fisnar Inc.
1. Teaching Overview
A program consists of a series of instructions stored in the main unit memory. Each
instruction is stored in a numbered memory address. A memory address may record a
point location, with an X, Y, and Z-axis value and point type or it may store an instruction,
which sets a parameter, such as a dispensing time or line speed.
When the program is executed, the robot will step through each memory address in
sequence and execute the instruction found there. If the memory address contains a point
location, the robot will move the X, Y, and Z axes to that location. Depending on the type
of point registered at that location, the robot may also perform other functions, such as
turn the dispenser on or off.
The most commonly used point types are Dispense Dot, Line Start, Line Passing, Arc
Point, and Line End.
To program the robot to dispense a ‘dot’ of material, the dispensing tip must be jogged to
the desired XYZ location, then that location is registered as a DISPENSE DOT point type
by pressing the appropriate keys on the Teach Pendant.
To program the robot to dispense a bead of material along a linear path, the XYZ location
of the start of the line is registered as a LINE START point type. The locations where the
tip changes direction are registered as LINE PASSING points. The end of the line is
registered as a LINE END point:
Dispense Dot

I&J4000-LF Series Operating Manual
Section 3: Teaching Overview
Part # 562187
Rev. E - Jan. 08
- Page 16 - © 2008 I&J Fisnar Inc.
To dispense a bead of material in an arc, the XYZ location of the start of the line is
registered as a LINE START point type. The high point of the arc is registered as an ARC
POINT. The end of the arc is registered as a LINE END point:
Lines and arcs can also be combined to dispense a bead of material along a complex
path:
Once the required point locations for your program have been taught, the teach pendant is
no longer required. The unit can be switched to RUN mode and operated using the
buttons and switches on the main unit control panel.

I&J4000-LF Series Operating Manual
Section 3: Teaching Overview
Part # 562187
Rev. E - Jan. 08
- Page 17 - © 2008 I&J Fisnar Inc.
2. Using the Teach Pendant
The teach pendant enables the user to jog robot to input program data.
2.1 Key Selection
There are several functions assigned to most keys on the Teach pendant. When a key is
pressed alone, the function shown in the white colored area on the key is executed. For
example, MENU 1, MENU 2, and Setup are the default key functions, which are executed
when that key is pressed alone.
To access the function shown in the blue area at the top of a key, press and release the
Shift key first, then press the desired key. For example, to select the Speed function,
press and release Shift, then press the Speed key.
When a number is required, the teach pendant will automatically switch to numeric entry
mode. The number represented by each key is shown in the lower right corner of the key.
If Shift is pressed, released,
then the Menu1 key is
pressed, Point Setup
(• Setup) is executed.
If this key is pressed alone,
Setu
p
is executed.
When entering
numbers, this key
is 0.

I&J4000-LF Series Operating Manual
Section 3: Teaching Overview
Part # 562187
Rev. E - Jan. 08
- Page 18 - © 2008 I&J Fisnar Inc.
2.2 Key Assignments
Menu Keys
Opens the Point registration menu.
Opens the Setup menu.
Opens Menu # 1.
Opens Menu # 2.
Jog Keys
Jogs the X-axis in the left direction.
Jogs the X-axis in the right direction.
Jogs the Y-axis in the backward direction.
Jogs the Y-axis in the forward direction.
Jogs the Z-axis UP.
Jogs the Z-axis DOWN.
Accelerates jog speed – used with X+, X-. Y+, Y-, Z Up, Z
Down
Navigation Display
Moves forward (1) memory address.
Moves backward (1) memory address.
Moves forward (10) memory addresses.
Moves backward (10) memory addresses.

I&J4000-LF Series Operating Manual
Section 3: Teaching Overview
Part # 562187
Rev. E - Jan. 08
- Page 19 - © 2008 I&J Fisnar Inc.
2.3 Navigation Menu
Pressing any of the keys shown on the right will open the
corresponding menu.
Once the menu is open, use the up and down arrows to
move through the items on the menu.
Use left and right arrows to change to the next page or
previous page of the menu.
Press ENTER to select the current item.
2.4 Jogging
The tip is jogged by pressing the jog buttons
If the FAST button is pressed and held first, then one of
the jog buttons is pressed, the axis will be jogged at the
maximum jog speed.
If one of the jog buttons is pressed first, then the FAST
button is pressed, the jog motion will accelerate.
If the FAST button is released, the jog motion will
decelerate.
2.5 Data Entry
If a numeric value is required, the teach pendant will automatically switch to numeric
mode. Use the keys 0 – 9, (.) and the minus sign (-) to enter numbers.
2.6 Running a Program
Press the key to run the program.

I&J4000-LF Series Operating Manual
Section 3: Teaching Overview
Part # 562187
Rev. E - Jan. 08
- Page 20 - © 2008 I&J Fisnar Inc.
3. Teach Box Key Assignments
Key Function
Used to select options shown on the display.
The use of this key depends on the current menu displayed.
Used to select options shown on the display.
The use of this key depends on the current menu displayed.
Used to select options shown on the display.
The use of this key depends on the current menu displayed.
Rotates 'R' axis clockwise (Four axis robots only)
Rotates 'R' axis counter-clockwise (Four axis robots only)
Jogs the Z-axis UP.
Jogs the Z-axis DOWN.
Reserved for future use.
Reserved for future use.
Jogs the Y-axis in the forward direction.
Jogs the Y-axis in the backward direction.
Jogs the X-axis in the left direction.
Jogs the X-axis in the right direction.
Accelerates the jog speed when used with X+, X-. Y+, Y-, Z
Up, Z Down.
If Shift is pressed and released, then another key is
pressed, the secondary function of that key (shown in blue)
will be executed.
Inserts a memory address before the current address.
Deletes the current memory address.