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TRANSCRIPT
Okura Yusoki Co., Ltd.
Robot Manual
Installation and Adjustment - Electrical -
GEN4(E)-NINSE-01
-Original instructions-
HHHHistoryistoryistoryistory
Version
(Date)
Content Page
01 (2011.09.22) First edition
Introduction Thank you for purchasing a model from the Okura Robot Palletizer A series.
This manual is a guidebook to help you safely and correctly use your A Series Robot Palletizer. It should be useful not only to beginners who are using an Okura Palletizer for the first time, but also to experienced users, who can use this Manual to
reconfirm their knowledge. Please read this Manual carefully and use the Palletizer with a clear understanding of its content.
NOTE
Unauthorized reproduction of part or all of the content of this manual is forbidden.
The content of this manual is subject to future change without prior notice.
Safety Instructions Each A Series Robotic Palletizer is equipped with a variety of protective features.
However, an increased level of safety results when these safety precautions are
constantly reviewed and consistently followed with a separate manual of “Safetey”.
IMPORTANT
IMPORTANT Only AUTHORIZED PERSONNEL can operate, maintain the robot or work on
programming.
The definition of “AUTHORIZED PERSON” is that the only personnel who can
operate the robot and/or robot system, are those who have enough knowledge or
experience of robot operation and have also been trained to operate the robot.
They must also have been authorized by the employer.
The safety instructions with left sign of IMPORTANT throughout this manual are enforcement or warning that
if not correctly operated or handled, you may be seriously injured or killed.
Be sure to follow those safety instructions.
Table of Contents
1. OUTLINE OF CONTROLLER 1111----1111
1.1. APPEARANCE OF CONTROLLER���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 1111----2222 1.2. TEACHING PENDANT (OPTION)�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 1111----3333
2. HARNESS CABLE CONNECTION 2222----1111
2.1. INSIDE-ROBOT HARNESS CABLE ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 2222----2222 2.2. SPARE CABLES ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 2222----7777 2.3. CONNECTION OF MAIN POWER SUPPLY WIRES���������������������������������������������������������������������������������������������������������������������������� 2222----8888 2.4. PROTECTION AGAINST LIGHTNING SURGE ����������������������������������������������������������������������������������������������������������������������������������������2222----10101010 2.5. OTHER NOTES (WIRING)������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������2222----10101010
3. CONTROLLER BOARDS AND UNITS 3333----1111
3.1. CPU BOARD (RC501) ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 3333----2222 3.2. I/O BOARD (RC512)�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 3333----5555 3.3. SERVO POWER UNIT (SPCU-1A) ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 3333----6666 3.4. CONTACTOR UNIT (MCRU-1) ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 3333----7777 3.5. SAFETY RELAY BOARD (RC516)������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 3333----8888 3.6. AMP UNIT ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������3333----10101010
3.7. FIELBUS BOARD (ETHERNET/IP AB6214)))) ������������������������������������������������������������������������������������������������������������������������ 3333----11111111
4. ADJUSTMENTS 4444----1111
4.1. ORIGIN STORING �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 4444----2222 4.2. BASIC POSTURE ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 4444----3333 4.3. AMP UNIT ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 4444----6666 4.4. COLLISION DETECTION ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 4444----7777
5. SYSTEM STORAGE 5555----8888
5.1. PERIPHERAL EQUIPMENT NAME INPUT ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 5555----9999 5.2. COMMUNICATION SETTING�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 5555----9999 5.3. EXTERNAL PLC COMMUNICATION SETUP ������������������������������������������������������������������������������������������������������������������������������������������������5555----10101010 5.4. PASSWORD SETTING����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----12121212 5.5. MEMORY SWITCH��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----12121212 5.6. PARAMETER SETTING (CONTROLLER DATA) ������������������������������������������������������������������������������������������������������������������������������������5555----16161616 5.7. FIRMWARE UPDATE ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----17171717 5.8. HOUR METER ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----19191919 5.9. SOFT LIMIT ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----20202020 5.10. HAND SETUP ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----21212121 5.11. PARAMETER SETTING (ROBOT DATA)��������������������������������������������������������������������������������������������������������������������������������������������������������5555----22222222 5.12. ORIGIN STORING ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----23232323 5.13. SERVO PARAMETER ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----23232323 5.14. EXPANSION AXIS SETTING ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������5555----24242424
6. MAINTENANCE FUNCTIONS 6666----1111
6.1. MENU STRUCTURE �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----2222 6.2. DATA MEMORY CONTENTS ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----4444
6.3. I////O MONITOR ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 6666----5555 6.4. OPERATION READY CONDITION �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----6666 6.5. KEY TRACE ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 6666----6666 6.6. FILE OPERATION ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----7777 6.7. LOGIC ANALYZER���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----9999 6.8. ID NO – PRG NO ALLOCATION ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������6666----11111111 6.9. BATTERY REPLACE ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 6666----12121212 6.10. CONVEYOR INFORMATION �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----12121212 6.11. STACKED COUNTER REVISION ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 6666----13131313 6.12. PROGRAM SELECTION METHOD �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----14141414 6.13. POSITON & ACCELERATION / DECELERATION TIME�������������������������������������������������������������������������������� 6666----14141414 6.14. EXECUTED SEQUENCE COMMAND������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 6666----15151515 6.15. OVERLAP TRACE ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 6666----15151515 6.16. SMOV CALCULATION �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----16161616 6.17. DEVIATION TRACE ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 6666----16161616 6.18. POSITION COMMAND TRACE �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----17171717 6.19. SERVO TORQUE INDICATE �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----18181818 6.20. COLLISION DETECTION ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 6666----19191919 6.21. EXPANSION AXIS TRACE ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 6666----19191919
7. TABLE OF BASIC SPECIFICATIONS 7777----1111
1-1
1. Outline of Controller
Names of part of controller and main parts are introduced in this section.
1-2
1.1. Appearance of Controller
1.1.1. Robot Controller
This is common among RC830 and RC840 (See 5. SYSTEM SPECIFICATIONS for model of
controller for detail.)
1-3
1.2. Teaching Pendant (Installation Personnel Only) Teaching pendant works at manual mode.
Note
・Manual operation on controller does not work once teaching pendnat is
connected.
How to set up teaching pendant
→See”Operation Manual” Section 4
① E/S push button switch
② Data display
③ Enable switch
①
②
③
2-1
2. Harness Cable Connection
2-2
2.1. Inside-Robot Harness Cable
The following shows the cable wiring inside robot and the composition of the cable
harness between robot and controller
[A1800V, A1800V----W]
Inside-robot wiring
Harness cables between robot and controller
CN1
CN2
CN3
CN4
CN5
RB721
RB722
RB723
RB724
RB725
ROBOT CONTROLLER
CN1 CN13 D-motor
CN14
CN15 O-motor
CN16
CN11 R-motor
CN12
CN8
CN9
CN10
CN7
CN2
CN3
RM815
RM816
RM817
RK831
RM832
RK833
CN6
CN18
CN4 CN22 D-encoder
CN23 O-encoder
CN24
CN26
CN31
RM851
RM852
RK853
RK854
RK855 RK873
RM856
CN34 RK857
CN21 R-encoder
T-AXIS
HAND
CN37
CN5
BAT
CN17 T-motor
CN25 T-encoder
CN33
CN32
RK874
CN36
CN35
RM871
RK781
RK782
AIR 12mm
10mm 12mm
12mm
AIR 12mm
R-LS RK858 CN39
RM835
ROTOR
BASE
CN40 FAN
RK875
DangerDangerDangerDanger EnforcementEnforcementEnforcementEnforcement
Make sure if primary power supply is securely connected with
controller. Otherwise, you may get an electric shock.
2-3
[A1600V, A1600V----W]
Inside-robot wiring
Harness cables between robot and controller
CN1 CN13 D-motor
CN14
CN15 O-motor
CN16
CN11 R-motor
CN12
CN8
CN9
CN10
CN7
CN2
CN3
RM731
RM735
RM733
RK731
RM732
RK733
CN6
CN18
CN4
CN22 D-encoder
CN23 O-encoder
CN24
CN26
CN31
RM751
RM752
RK753
RK754
RK755 RK773
RM757
CN34 RK758
CN21 R-encoder
T-AXIS
HAND
CN37
CN5
BAT
CN17 T-motor
CN25 T-encoder
CN33
CN32
RK774
CN36
CN35
RM771
RK781
RK782
AIR 12mm
10mm 12mm
12mm
AIR 12mm
R-LS RK759
CN39
RM737
ROTOR
BASE
CN1
CN2
CN3
CN4
CN5
RB721
RB722
RB723
RB724
RB725
ROBOT CONTROLLER
DangerDangerDangerDanger EnforcementEnforcementEnforcementEnforcement
Make sure if primary power supply is securely connected with
controller. Otherwise, you may get an electric shock.
2-4
[A700V, A700V----P]
Inside-robot wiring
Harness cables between robot and controller
BASE
CN1 CN13 D-motor
CN15 O-motor
CN11 R-motor
CN8
CN7
CN2
RM741
RM742
CN6
CN18
CN4 CN22 D-encoder
CN23 O-encoder
CN24
CN26
CN31
RK761
RK762
RK763
RM764
RK765 RK773
RK767
CN34 RK768
CN21 R-encoder
ROTOR
HAND
CN37
CN5
BAT
CN17 T-motor
CN25 T-encoder
CN33
CN32
RK774
CN36
CN35
RM770
RK781
RK782
AIR 12mm
10mm 12mm
12mm
AIR 12mm
R-LS RK769 CN39
RM736
T-AXIS
CN1
CN2
CN4
CN5
RB728
RB729
RB724
RB725
ROBOT CONTROLLER
DangerDangerDangerDanger EnforcementEnforcementEnforcementEnforcement
Make sure if primary power supply is securely connected with
controller. Otherwise, you may get an electric shock.
2-5
[A400V]
Harness cables inside robot and between robot – controller are composed as shown
below.
Inside-robot
Harness cables between robot and controller
CN1
CN2
CN3
CN4
RB726
RB727
RK714
ROBOT CONTROLLER
CN5
CN6
CN7
DangerDangerDangerDanger EnforcementEnforcementEnforcementEnforcement
Make sure if primary power supply is securely connected with
controller. Otherwise, you may get an electric shock.
BASE
CN13 D-motor
CN11 R-motor
CN15 O-motor
CN8
RM050
CN22 D-encoder
CN23 O-encoder
CN21 R-encoder
ROTOR
HAND
CN37 BAT
CN17 T-motor
CN25 T-encoder
CN33 CN32
12mm 12mm AIR 12mm
T-AXIS
CN1
CN3
CN4
CN5
CN6
CN7
CN2
RM051
RK052
2-6
[AP30V]
Harness cables inside robot and between robot – controller are composed as shown
below.
Inside-robot
Harness cables between robot and controller
*CN3 is not in use
BASE
CN13 D-motor
CN15 O-motor
CN22 D-encoder
CN23 O-encoder
LOWER ARM
HARNESS BOX
CN37 BAT
CN17 C-motor
CN25 C-encoder
CN33 CN32
8mm 12mm AIR 8mm
UPPER ARM
CN1
CN4
CN5
CN6
CN7
CN2
12mm 12mm AIR 12mm
HAND
CN1
CN2
CN3
CN4
RB726
RB727
RK714
ROBOT CONTROLLER
CN5
CN6
CN7
DangerDangerDangerDanger EnforcementEnforcementEnforcementEnforcement
Make sure if primary power supply is securely connected with
controller. Otherwise, you may get an electric shock.
2-7
2.2. Spare Cables The following spare cables for between robot and controller are provided for Okura A
series robot palletizer as shown on the below table.
[A1800V,A1600V,A700V,A400V]
Robot main unit connector Connector in controller
Connector
No.
Pin No. Wire No. Connector No. Pin
No.
Wire No. Wire
size
3 S3 1 S3
4 S4 2 S4
13 S5 3 S5
CN33
[3191-15R1]
14 CLS
CNH2
[F31FSS-05V-KX]
4 CLS
1 S6 A1 S6
2 S7 A 2 S7
3 S8 A 3 S8
4 S9 A 4 S9
5 S10 A 5 S10
6 S11 A 6 S11
7 S12 A 7 S12
8 S13 A 8 S13
9 S14 B1 S14
10 S15 B2 S15
11 S16 B3 S16
12 S17 B4 S17
13 S18 B5 S18
CN35
[3191-15R1]
14 S19
CNH3※2
[F31FDS-16V-K]
B6 S19
0.3 ㎜2
※1 A400V can use a set of CN33 only.
※2 It is optional for such 2-axis robot.
CN33,CN35
(Only CN33 for A400V)
CNH2
CNH3
2-8
2.3. Connection of main power supply wires Connect main power supply wires on the basis of bellows.
1. Introduce of electric wires must be relevant
position of controller.
2. Protection degree of the busing, for electric wires introduction must be equal or more
than IP5X.
3. Connect external protective conductors to
terminal with mark PE by the side of main
breaker(NFB0).
4. Put main power supply wires separately in
the duct, and put a charging mark on the
duct.
5. In connecting main power supply wires and
external protective conductors vend wire
adequately (if needed). And fix them firmly
so that not to strain on the terminal.
Specification of main power supply wires
Wires: UL standard
Wires size: minimum AWG#6
Conductor: copper
Temperature rating: minimum 90°C (194°F)
Terminal processing: A round terminal (UL Listed one) that suits the size of
the electric wire and tool of maker recommendation are used.
Grounding
Specification of external protective conductors
Wires: UL standard
Wires size: minimum AWG#6
Conductor: copper
Temperature rating: minimum 90°C (194°F)
Color: Green/yellow
Terminal processing: A round terminal (UL Listed one) that suits the size of
the electric wire and tool of maker recommendation are used.
2-9
Specification of a main breaker (NFB0)
The robotic control circuit is protected by NFB1 or F0.
A main breaker (NFB0) also protects the control circuit for peripheral conveyors.
NFB0 F0 NFB1 TR
15A
(10A)
20A
(10A)
50A
(30A)
control circuit
of a robot
control circuit
of peripheral
conveyors
*Amperage rating: RC830(RC840)
2-10
2.4. Protection Against Lightning Surge There is no protection against lightning surge inside of controller.
Relevant protection against lightning shall be required when connecting main power
supply.
2.5. Other Notes (Wiring)
2.5.1. Attaching insulation cover
Attach cover to O-axis and D-axis connector, which keep more than 10 mm clearance and
creepage distance not to touch.
2.5.2. Securing of Grounding Continuity
1. Connect following wires between robot body
and protective conductors inside controller. Wires: IEC standard
Wires diameter: more than 10 sqmm
Color: green/yellow
2. Measure resistance value between each
motor frames and external protective
conductor of controller, and confirm if the
value is less than following resistance value.
Resistance value : 0.1 ohm or less per 10 A
3. Attaching duct Harness between controller and robot must
be put in metal duct.
Divide power line and control line by
separator.
Minimum size of duct is 150 mm wide and
100 mm deep.
4. Fix protective conductor terminal with
specified screw to the robot as shown in the
figure. And fix insulator separately.
3-1
3. Controller Boards and Units
The boards inside the controller and their configuration are as follows.
RC512
I/O Board
RC512
I/O Board
SPCU-1A
Servo Power Unit
RC516
Safety Board
RC501
CPUCPUCPUCPU Board
AP507
(AP504)* Amp Unit
Servo
motor
Servo
motor
Servo
motor
Servo motor
R axis
D axis
O axis
T axis
Touch Panel
(POD) OXPA
Teaching
Pendant
AP507 (AP504)* Amp Unit
AP507 (AP504)* Amp Unit
AP508 Amp Unit
*( A700V)
Optional Hand External PLC
RC512
I/O Board
Amp Unit
Amp Unit
Servo
motor
Servo
motor
Spare axis
Spare axis
3-2
3.1. CPU Board (RC501) The arrangement of LED's、switches and 7-segment displays on Main CPU board is as
follows.
DIP switch DSW1 Explanation
No. Descriptions Default setting
1 Firmware Serial transfer OFF
2 System reserve OFF
3 System reserve OFF
4 System reserve OFF
5 Motor rotation test OFF
6 System reserve OFF
7 Execution of master DSP program loading ON
8 Execution of initialization OFF
3-3
LED Explanation
LED No. Lighting condition
D1 CPU(SH) being operated
D2 NMI Detected
D3 (7seg) CPU(SH) 7-segment display
D4 USB access
D7 Master DSP 7-segment display
D8 (7seg) Slave DSP (D/O axis) 7-seg display
D9 (7seg) Slave DSP (R/T axis) 7-seg display
D10(7seg) Slave DSP (C/X axis) 7-seg display
D11 Memory backup battery voltage dropped
D12 Encoder battery voltage dropped
D13 Gate ON
D14 Master DSP watchdog
* 7-segment light display is rotating under normal condition.
3-4
Jumper Explanation
Signs. Descriptions Default setting
W1 FPGA type setting
*It varies depending on the type of encoder
used.
TYPE1(YaskawaΣⅡ)
1-4 close /2-3 close
TYPE2(YaskawaΣⅤ)
1-4 open/2-3 close
TYPE3(Tamagawa)
1-4 close/2-3open
W2 DSP reset mode setting Close
W3 Don’t touch (SH endian setting) Open
W4 Connection setting with FG & SG(CN2) Close
W5 SH manual resetting Close
W6 Anybus mode setting 1-6、2-5、3-4 Close
W7 Master DSP watchdog setting 2-3 Close
W8 ADC reference power setting on slave DSP 1-2 Close
W9 Connection with analog and digital GND Open
W10 Connection setting with FG & SG(CN6) Close
W11 Not installed yet (Direct Close)
W12 Not installed yet (Open)
W13 Slave DSP boot mode setting Open
W14 Slave DSP boot mode setting Open
W15 Slave DSP boot mode setting Open
W16 Connection setting with FG & SG(CN2) Close
W17 Connection setting with FG & SG(CN4) Close
W18 Connection setting with FG & SG(CN7) Close
W19 Connection setting with FG & SG(CN17) Close
W20 Connection setting with FG & SG(CN18) Close
W21 Connection setting with FG & SG(CN19) Close
3-5
3.2. I/O Board (RC512) The arrangement of LED's and Jumper pins on the I/O board is as follows.
Jumper Pin Explanation
Signs Descriptions Default setting
JP1
JP2
JP3
Board address setting
1st :Only JP1 close
2nd :Only JP2 close
3rd :Only JP3 close
LED Explanation
LED No. Lighting conditions
D1 When 5VDC is supplied
D2 When 24VDC is supplied
3-6
3.3. Servo Power Unit (SPCU-1A) The arrangement of LED's displays on the servo power unit is as follows.
Jumper Pin Explanation
Signs Descriptions Default setting
JP1 Switching supply voltage over 2-3 close
LED Explanation
LED No. Lighting condition
LD1 Regen resistor temperature failure
LD2 Soft charging completed
LD3 Servo power over voltage
LD4 Servo power low voltage
LD5 In course of charging 300VDC
3-7
3.4. Contactor Unit (MCRU-1-UL/CE) Neither LED nor jumper pin is on contactor unit.
3-8
3.5. Safety Relay Board (RC516) The arrangement of LED's and jumper pins’ displays on the safety relay board is as
follows.
Jumper Explanation
No. Descriptions Default setting
JP1A I/O Type selection (*1) Upto system
JP1B I/O Type selection (*1) Upto system
*RC516B board is supposed to be shipped out being set on Source (default).
*Don’t use any IC else instead of the attached to replace IC7(transistor array IC).
(*1) Sink(option) Source(default)
JP1A 1-2 close 2-3 close
JP1B 1-2 close 2-3 close
IC7
NPN transistor array IC
PNP transistor array IC
LED1 LED9
LED17
LED8
3-9
■ LED Explanation
No. Lighting condition
LED1 24VDC power supply for external use
LED2 For internal use (for CN4 line) 24VDC power supply (lit at
overload)
LED3 In course of motor power turned ON
LED4 Abnormal reset button
LED5 Brake release(line 1)
LED6 Brake release(line 2)
LED7 Operation mode switch manual (line 1)
LED8 Operation mode switch manual (line 2)
LED9 Motor power switch neutral position
LED10 Motor power switch turning on
LED11 Ready to turn Motor power on
LED12 XRUN
LED13 Enable to turn motor power ON (RC501 output signal)
LED14 Brake release (RC501 output signal)
LED15 Buzzer(RC501 output signal)
LED16 In course of motor power turned ON
LED17 Soft charging completed
3-10
3.6. Amp Unit ■ What is the Amp Unit?
“Amp Unit” is composed of individual axis current board, IPM, heat sink and current
sensor.
A1600ⅢN、A1800N A700ⅢN
Servo amp Board IPM type Board IPM type
R axis RC507 PM200CL1A060 RC504 PM100CL1A060
D axis RC507 PM200CL1A060 RC504 PM100CL1A060
O axis RC507 PM200CL1A060 RC504 PM100CL1A060
T axis(C axis) RC508 PS21765 RC508 PS21765
Current board is connected with IPM as shown below.
・R,D,O axes:By connector
・T (C) axes: By soldering
(Example) Amp unit of R, D, O for A1600V and A1800V
RC507RC507RC507RC507
3-11
3.7. Fieldbus board (Ethernet/IP AB6214)))) The arrangement of LED’s displays on fieldbus board is as follows.
# Item
1 Network Status LED
2 Module Status LED
3 Link/Activity 4 Ethernet Interface
Network Status LED
Note: A test sequence is performed on this LED during startup.
LED State Description
Off No power or no IP address
Green On-line, one or more connections established (CIP Class 1
or 3)
Green, flashing On-line, no connections established
Red Duplicate IP address, FATAL error
Red, flashing One or more connections timed out (CIP Class 1 or 3)
Module Status LED
Note: A test sequence is performed on this LED during startup.
LED State Description
Off No power
Green Controlled by a Scanner in Run state
Green, flashing Not configured, or Scanner in Idle state
Red Major fault (EXCEPTION-state, FATAL error etc.)
Red, flashing Recoverable fault(s)
LINK/Activity LED
LED State Description
Off No link, no activity
Green Link established
Green, flickering Activity
Ethernet Interface
The Ethernet interface supports 10/100Mbit, full or half duplex operation.
4-1
4. Adjustments
4-2
4.1. Origin Storing
Operation for automatically calculating origin offset and setting it is called origin storing.
Origin storing is required in the following cases.
A. When encoder cable at motor connector is disconnected.
B. When latched error of [Encoder Battery Voltage Drop] needs to be reset.(*1)
Procedure for moving to the origin storing screen is as follows.
System storing menu
↓
Motor axis data
↓
Origin storing
[Operation procedure]
① In manual operation, move the axis to be stored to the basic position
See [4.2 Basic posture] for the positions of each axis to store in detail.
② Press the axis to highlight in display. Press [STORE] to store the origin.
③ Cycle main power.
※When origin storing is successfully completed, the current position in pulse to be stored
should be between 0 and 65535.
※If error of “Out of range” occurs during operation ①, move robot arm into the operation
range pressing and holding abnormal reset button.
CautionCautionCautionCaution EnforcementEnforcementEnforcementEnforcement
Make sure if the robot posture is precisely equal to the designated
basic positions when you work on the origin storing. Otherwise, robot
moves unexpectedly to hit conveyors or to have bad shape stacking.
4-3
4.2. Basic Posture When the robot is set in the basic posture, and origin storing is performed, the system
reads the encoder pulses and amount of shift (number of pulses) off the robot basic posture,
and the offset value is automatically calculated.
[A1800V,A1600V,A700V]
Axis Basic posture How to set to basic posture
R
Robot arm oriented in the opposite
direction of the base wiring connector at
bottom is taken as the origin.
With A1600V,A700VSeries)Move
the R-axis, and align the scribed
lines on the base and base.
With A1800V)Move the R-axis,
and align the match marks on the
base and rotor.
D 0 degree (horizontal) is taken as the
origin.
Move the D-axis and align the
match marks on the rotor and
lever.
O
90 degrees (vertical) is taken as the
origin.
Move the O-axis and align the
match marks on the rotor and
arm.
Origin
Origin
4-4
T
Hand palm set in parallel with the robot
arm is taken as the origin.
Choose the center position of T axis
cable turning around as the axis can
make multi-turns.
Move the T-axis and align the
match marks (scribed mark).
[A400V] Axis Basic posture How to set to basic posture
R Robot arm oriented in the opposite
direction of the base wiring connector at
bottom is taken as the origin.
Move the R-axis, and align the
match (scribed) marks on the
base and rotor.
D
0 degree (horizontal) is taken as the
origin.
Move the D-axis and align the
match marks on rotor & lever.
O
90 degrees (vertical) is taken as the
origin.
Move the O-axis and align the
match marks on the rotor and
arm.
Origin
Origin
Origin
4-5
T
Hand palm set in parallel with the robot
arm is taken as the origin.
Choose the center position of T axis cable
turning around as the axis can make
multi-turns.
Move the T-axis and align the
match marks (scribed mark).
[AP30V]
Axis Basic posture How to set to basic posture
D
0 degree (horizontal) is taken as the
origin.
Move the D-axis and align the
match marks on upper and lower
arms.
O
90 degrees (vertical) is taken as the
origin.
Move the O-axis and align the
match marks on the rotor and
arm.
Origin
Origin
4-6
4.3. Amp Unit To replace a amp unit follow the instruction below.
<Replacement procedure>
① Shut main power down.
② Disconnect the connectors to/from amp unit and wiring to terminals.
③ Unbolt the mounting screws out of amp unit. Replace whole unit
(including bracket and heat sink) at a time.
④ Connect the connectors and wiring to terminal.
⑤ Make sure if all the connections are correct then turn main power on.
4-7
4.4. Collision Detection
In case of collision, overload has previously errored out to mainly prevent servo motor from
being burnout. Therefore, the robot doesn't stop immediately when collision occurs if the
servo motor reserves strength and there is a possibility that peripheral equipment, handling
products, etc. are damaged a lot.
The collision detection is a function to reduce the damage to station, robot hand, etc. When
hand or arm of robot collides with such peripherals as stations, pallets, handling products, etc,
the robot is stopped detecting collision with sensorless way.
IMPORTANT
The function doesn't work during the manual operation, even when
this function is turned on.
It cannot eliminate the damage by the collision to peripherals at all
even when the collision detection function is turned on.
This function doesn't guarantee safety to the person. Please work
in compliance with all the provided standards.
4.4.1. False detection and the preventative measures
The sensitivity of the detection is decided depending on the servo parameter, when the
collision detection function is turned on. The servo parameter is set at the system storage
mode.
The larger the value of the servo parameter set is, the larger the threshold is. So, the
detection falls down to less sensitive (It becomes more difficult to properly detect).
On the contrary, the smaller the value of the servo parameter is, the smaller the threshold is.
So, the detection goes up to more sensitive and the collision is much more accurately
detected. But higher sensitivity tends to allow the function to more often make false
detection. It can be seen in such that the robot may falsely collide despite usual operation.
In addition, the maximum value of the data by which collision detection is judged is recorded
at the screen display “collision detection”. It is judged that the robot collides when this
maximum value exceeds the threshold, and the robot stops.
The maximum value might change by addition of new products or new patterns. Moreover, it
is likely to change depending on an external factor like the temperature or the lubrication
condition of the grease etc, even if they are the same products, patterns and/or programs.
There is a possibility still remained that the change above mentioned may cause false
detection.
If false detection occurs frequently, it is necessary to fix the value of the servo parameter
again, because the root causes mentioned above can be possible. In that case, please
contact with the customer support desk of service department.
5-8
5. System Storage
The various system parameters are explained in the section. In ordinary operation, there is
no need to change the system parameters. However, resetting them is necessary when
special setting was made, motor has been replaced or other maintenance has been
conducted.
The directory to the system storage menu screen is: Select [S: System storage mode] on
basic menu and enter the password to go.
System storage menu branches off to [Controller data], [Robot data] and [Motor axis data].
Basic menu
A:Auto operation mode
S:System storage mode
M:Maintenance mode
T:Teaching mode
Robot data
Motor axis data
Controller data
5-9
5.1. Peripheral Equipment Name Input The procedure for moving to the conveyor information is as follows.
System Storage Menu
↓
Controller Data
↓
Peripheral Equipment Name Input
1. Peripheral conveyor name
・ Enter conveyor names at the
conveyor manual mode screen.
・Pressing number of item you want
allows to turn to the input mode.
5.2. Communication Setting The serial communication format of “S-I/O port” is determined. Procedure for moving to the
communication setting screen is as follows.
System storage menu
↓
Controller data
↓
Communication setting
The setting becomes effective when
main power is cycled.
5-10
5.3. External PLC Communication Setup This is screen to set up
interfacing wit external PLC.
The directory to external PLC
I/F setting screen is as follows.
System storage menu
↓
Controller data
↓
External PLC I/F setting
1.PLC standard interface
Standard way of interfacing
with PLC is set up.
*See [I/O interfacing with PLC]
edition for detail.
2.PLC expansion interface
Expansion interfacing with PLC
is set up.
*Also set up the below when
[Centronix] is set up.
①Error notice
・If [Do] is selected, error code
is notified to PLC
when error occurs inside
controller.
②Prg No. addition
・ If [Do] is selected,
upper 6 bits and lower
6 bits are added next to ID
No. in this order.
③Layer data addition
・ If [Do] is selected, number of layer is set in front of quantity data of products per
each layer.
(D7 and D6 are always “1”.)
④Special data all notice
・If [Do] is selected, the quantity data of products for special stacking is sent.
* See [I/O interfacing with PLC] edition for detail.
3.Expansion serial communication
・If [BCR] is selected, BCR data can be received through serial port of RC501(CN4).
5-11
・If [VISION] is selected, it can link with VISION system through serial port of RC501(CN4).
4.Fieldbus communication
If [CC-link] is selected, it can link with CC-link on Mitsubishi PLC.
*A option board needs to be added. See the section of [Controller board and Unit] for
detail.
①Remove device setting
・If [Remove output (RY) is selected, robot output can be assigned to device M.
・If [Remove input (RX) is selected, robot input can be assigned to device M.
・If [Remote register (RWw)] is selected, robot output data (word) can be assigned to
device D.
・If [Remote register (RWr)] is selected, robot input data (word) can be assigned to device
D.
・Number of shared I/O are set by [Allocation number of I/O].
・Number of shared devices are set by [Allocation number of devices].
・If [Built-in + CC link setting] is selected, it is allocated as follows.
Remote output(RY) M500
Remote input(RX) M400
Remote register(RWw) D1500
Remote register(RWr) D1400
・If [Pre-set value] is selected, it is allocated as follows.
Remote output(RY) M5000
Remote input(RX) M6000
Remote register(RWw) D5000
Remote register(RWr) D6000
②Input data when data link is failed
・If [Data clear] is selected, device M allocated to [Remote input (RY)] is turned off when
data link is failed.
・If [Data reserve] is selected, it reserves the status before failure when data link is failed.
③Data link failure detection
・If [Effective] is selected, robot controller detects link failure.
Motor power is turned off when link failure is detected.
・If [Ineffective] is selected, robot controller does not detect link failure.
④CC-link setting
Items to be set Contents to be set Setting range
1 Station No. Station No. 1-64
2 Communication
setting
Transmit speed 0-4 (*1)
3 Version CC-link Version 1/2
4 Number of stations
occupied
Number of stations
occupied
1-4
5 Expansion cyclic
setting
Expansion cyclic
setting
1/2/4/8
(*1)Transmit speed
0:156kbps
1:625kbps
2:2.5Mbps
3:5Mbps
4:10Mbps
DangerDangerDangerDanger EnforcementEnforcementEnforcementEnforcement
Never ever use any safety signals on fieldbus or serial
communication. Those may not be detected in case of
communication failure.
5-12
5.4. Password setting In standard setting, the password setting is necessary only at the time of system storing.
Password setting can also be done with each screen of setting for auto operation, teaching
and conveyor data.
The directory is as follows.
System storage menu
↓
Controller data
↓
Password setting
[ Procedure for storing ]
①Select an item to be set by
pressing a key
②Input 4 passwords
③Press Set key
[Procedure for resetting]
①Select an item to be reset by pressing a key
②Press Clear key
Note
The memory switch 1-5 is turned on to make this setting effective.
- As the standard password is master one, it still works even after the system
storing
5.5. Memory Switch The directory to memory switch screen is as follows.
System storage menu
↓
Controller data
↓
Memory switch
- Set the memory switch inside robot.
(Normally, no change is necessary.)
- The following items are set by turning
memory switches ON and OFF.
-For changing, press a switch to be
changed then turn it ON and OFF.
- Descriptions come out in the bottom frame upon pressing the numeral key in left side
5-13
Use key to move to next screen
(Use key to return)
SW No. Name ON OFF Type Default
1-1
T-axis motion T-axis turns to designated position, not taking short cut direction (for aging)
(e.g.) Target position is -179 degree, when current position is 179 degree.
Move to -179 (Approx. 358 degree rotating)
T-axis turns, taking short cut direction
Move to 181 (Approx. 2 degree rotating)
All OFF
1-2 System reserve
All ON
1-3
Variable picking
special movement
1st layer / 1st work is at the height of step 9.
( It is turned on when COUNT in not-variable picking program is between MOV8 and MOV9, as arm may hit conveyors or
others around)
Normal process All OFF
1-4 Movement with pallet on floor
No shifting upward when there is enough head-room at step 5 and 8.
Normal calculation All OFF
1-5 Use password Password is valid if the password has been set in the system parameter screen
Password is invalid
All OFF
1-6 DMOV movement
T axis is non-synchronized (Only T-axis moves to the target position directly)
T-axis is synchronized (Palm moves in parallel)
All ON
1-7 Operating movement
Robot is under its independency.
(PLC operation signal is to be ignored)
Robot collaborates with PLC signals
All OFF
SW1
1-8
Expanded PORT tele-com. Log output
(for debugging)
Log output → debug PORT No output All OFF
2-1 Sequence reset handling setting
At resetting,
Y30(M601D)~Y35(M6022)OFF
Y2D(M503A)500mS ON
No change on output relay
All OFF
2-2
Language on POD & Teaching pendant
Foreign language Japanese All OFF
2-3 DA1800 mode DA1800 mode Standard mode All OFF
2-4
DA1800
Multi-pallets per one program
Multi-pallets per one program Standard All OFF
2-5 Timer value setting screen
Use Timer value setting screen
Don’t use All OFF
SW2
2-6
When product type is set, its code is written in the device
Product code is written Not written All OFF
5-14
SW No. Name ON OFF Type Default
2-7
Which
timing
trace data
is stored at
Trace data is saved
when motor power is
turned off.
Trace data is
saved when servo
is failed.
All OFF
2-8 Recalculating STA position when changed
Does not change STA
position even if picking
direction is exact same
when STA position is
changed. Moreover,
position data at steps
of station side is not
changed even if picking
direction is changed.
Standard All OFF
3-1 PC communication restriction
Disable to download from PC while motor power is on.
Normally enable to download
All ON
3-2 Collision
Detection
Valid Invalid All OFF
3-3 System reserve
All OFF
3-4 T axis path improved
T axis path improved Standard All OFF
3-5
Acceleratio
n &
deceleratio
n times
improved
Acceleration &
deceleration times are
shortened.
Standard All OFF
3-6
Managing
of station
timer value
Managed by built-in
PLC.
(D2500-D2515 are usedl)
Managed by robot
( D6219-D6234 are
used)
All OFF
3-7 A700V Cold weather specs
Valid Invalid All OFF
SW3
3-8
4-1
4-2
4-3
4-4
4-5
4-6
4-7
SW4
4-8
5-1
5-2
5-3
5-4
5-5
5-6
SW5
5-7
5-15
SW No. Name ON OFF Type Default
5-8
6-1
6-2
6-3
6-4
6-5
6-6
SW6
6-7
Note
Pressing No. of switches allows to display its explanation at bottom of screen.
5-16
5.6. Parameter setting (Controller data) The directory to parameter
setting screen is as follows.
System storage menu
↓
Controller data
↓
Parameter setting
1.Job number
・Enter the job number you work
on.
・The job number is shown up at
the basic menu.
2.Top of latch range
・The range on and after the
device No. is set becomes
latched.
3.Number of I/O board
・Number of RC502 boards to be
used is set.
4.IP address
・IP address, Net mask and default gateway of RC501 board are set.
5.Touch panel (POD) IP address
・IP address to be set to touch panel is set.
5-17
5.7. Firmware update The directory to Firmware update
is as follows.
System storage menu
↓
Controller data
↓
Firmware update
IMPORTANT ・・・・Robot may be crashed if wrong firmware is written by mistakes.
・・・・Only the qualified service person can work on the following procedure.
1.List of firmware
List of firmware files (SH software) in the [SH] folder in external memory selected is
displayed.
To select firmware file, pressing No. in the list allows to be reversed into blue color.
*External memory (USB/CF) to be used can be selected by pressing [USB] ([CF])button.
*When USB memory is used, insert a USB memory stick into controller before opening this
screen.
2.Firmware loading
It reads files selected at firmware list.
The version read out of file is shown up as [Version of selected file].
It can be compared with the [Current version].
3.Write firmware
Firmware of the version shown on [Version of selected file] is written to RC501.
Cycle main power after written.
Caution
Never ever shut down main power during writing it.
It won’t operate correctly if shut down.
5-18
4.Firmware backup
It reads firmware that is being executed on the current RC501 and that is stored into SH
folder of external memory. The file name is “RC_GEN2_123A.BIN” if [Current version]
display is “1.23A” for example.
6.System parameter initialization
When main power is cycled while the switch is being turned on, the system parameters
are initialized at the system to be booted. Don’t use this normally.
7.System file backup
①Export
Whole the files stored into RC501 are saved into folder of [BACKUP] in a external
memory. If there is already a folder of [BACKUP], a confirmation message to delete it
pops up. It will be overwritten if nothing done upon the message.
*Unnecessary files are recommended to be deleted as much as possible as all the files in
[BACKUP] folder are imported.
②Import
All files in folder of [BACKUP] in a external memory are copied into RC501. After
imported, cycle main power.
Note
See [Note] of [6.6 File operation] for detailed folder structure.
5-19
5.8. Hour meter The directory to the hour meter
screen is as follows.
System storage menu
↓
Controller data
↓
Hour meter
[Date change]
Display the key input screen by pressing the display data of item to be changed. Then,
enter a value to be set by numeral keys, and press WRITING key.
[User time clear]
Press TIME CLEAR key after pressing the USER TIME key.
(All the items of the user time are cleared to “0”)
[Maintenance frequency]
Press [Change] key, display key input screen and enter values you want to change.
Alert message pops up at the interval you set. (It ranges between 1 – 32767 hours)
Note
Total hour cannot be cleared
5-20
5.9. Soft Limit
The directory to soft limit screen is as
follows.
System storage menu
↓
Robot data
↓
Soft limit
1. Soft limits
-This displays the range in which R, D, O
and T axis movement is possible, as an
angle
-The R-axis value is used for the R area
in 5
2. Teaching range
- This sets a movable range under the
automatic operation
- The range is to be indicated in arm
coordinate
- When the robot moves out of the
designated range, situation is to be “Out
of range error“
- During manual operation, the buzzer
sounds at the point of 200mm or 20
degree (30 for T-axis) to the range limit
3. Origin offset
-This is data for correcting the robot base posture (origin)
-This cannot be set or changed by the user.
- Numerical value is of the number of encoder pulse, meaning a deviation between the
encoder pulse origin and robot base posture (origin)
1. Acceleration/Deceleration time
-This sets the acceleration time and deceleration time for robot movement.(Unit :msec)
2. R area
- This is for informing the other control equipment of current R-axis angle
- For the R-axis angle, the range set with soft limit is divided into 7 segments
-These segments are labeled 1 -7 in order from minus side of R-axis angle
- As for the value indicating the segment in the system parameter, set a plus side border
angle in each segment 1 – 6
- A value is to be input in D6000 to indicate in which segment, 1 - 7, the robot is
3. Hand mass
- Set hand mass (work is not included)
- This is to be used for an automatic compensating calculation of handling rate
5-21
5.10. Hand Setup The directory to hand setup
screen is as follows.
System storage menu
↓
Controller data
↓
Hand Setup
1.Hand manual operation name
input
[Input procedure]
① Press No. key to enter.
② Enter name on input
screen to pop up.
③ Press [Quit] key.
2・Hand weight (hand mass)
・Enter empty hand weight (hand mass). (excluding products)
・This is used to calculate the automatic acceleration / deceleration time.
3.Inertia of T axis
Enter the inertia of T axis. Enter “0” if don’t want.
4.Number of T axis revolution
Enter the max number of T axis revolution. Enter “0” for the default.
5.Number of steps of C axis Enter number of steps of C axis to automatically create a new program.
6.Distance off products
・Enter parameters to automatically generate steps for C axis at a new program creation.
・Positions of steps are calculated by the following equations.
(Step No.1 of C axis) = (width of product) - (value of argue)
(Step No.2 of C axis) = (width of product) + (value of [jog opened])
(Step No.3 of C axis) = (width of product) + (value of [fully opened])
5-22
5.11. Parameter Setting (Robot Data) The directory to parameter
setting screen is as follows.
System storage menu
↓
Robot data
↓
Parameter setting
1.Axis accuracy
・Arrival confirmation is performed
at this precision only when SPC is
selected due to step parameter
overlap
2.SMOV, SMOV2 parameter
No.
Default Range What it means How it works
1 100 Cornering status The bigger value, the smoother
cornering
2 0 For straight movement in
upward motion
The bigger value, the shorter
linear motion
3 0 For straight movement in
Downward motion
The bigger value, the shorter
linear motion
4 100 SMOV inner judgment (Speed regulation for RX motion)
5 100
0~100
[%]
SMOV inner judgment (Speed regulation for RZ motion)
6 100 Step1 effective height
7 100
[mm]
Step3 effective height
Parameter that calculates No.1-3
automatically
3. Robot type change (Never ever touch this key)
IMPORTANT If the machine type is changed, all the programs are
erased.
Select type of robot pressing [Robot type] key.
4.Station No. and Pallet No. Enter number of stations and that of pallets to be used for the system.
5.Acceleration / deceleration time
Enter time to calculate the specified acceleration / deceleration time unless those are
automatically executed having the factor of “0” in step parameter.
5-23
5.12. Origin Storing See 4.1 Origin storing for detail.
5.13. Servo Parameter
This is a screen for displaying or
changing the necessary
parameters for the servo control.
The directory to the servo
parameter screen is as follows.
System storage menu
↓
Motor axis data
↓
Servo parameter
IMPORTANT
・・・・Each parameter should be of within a due range, otherwise,
the robot may malfunction with the possibility of damage to
the robot, controller and/or peripheral equipment.
・・・・Only qualified individuals should change this value.
5-24
5.14. Expansion Axis Setting
This screen is for setting
expansion axis.
The directory to expansion axis
setting is as follows.
System storage menu
↓
Motor axis data
↓
Expansion axis setting
Note) Amp unit is required to add expansion axis.
1.Set expansion axis
Select type of servo motor to be installed.
2.Relationship between expansion axis and C axis
What is difference from expansion axis to be used as C axis from not as C axis.
For C axis Not for C axis
Control
method
Robot sequence commands
(HMOV/HMOVD/TRQC)
*Can be synchronized with
robot sequence.
Built-in PLC commands
(EXMOVA/EXMOVR)
Step
storing
Store per every program
Max 9 steps per a program
Stored per every axis
Max 99 steps per a axis
3.Coordinates offset
・For the expansion axis that [Not use as C axis] is selected, enter the distance of offset
off the position where encoder origin is stored. Normally don’t need to enter as those
are the exact same position.
・For the expansion axis that [Use as C axis] is selected, enter the distance between
palms (paddles) where encoder origin is stored. Normally don’t need to enter as those
are the exact same position.
4.Operation range+-
Enter operation range for the expanded area.
5.Acceleration / deceleration time
Enter Acceleration / deceleration time.
6.Axis accuracy
5-25
Enter axis accuracy.
To enter [0] allows to set it zero overlap.
7.Origin offset
It is entered by itself when others are set at the origin storage screen.
It can also be entered on the screen.
8.Revolving direction
Select [Forward] or [Reverse].
9.Auto operation speed
To select [Synchronize] allows to enable to change by itself the speed proportional to
robot auto operation speed.
To select [Asynchronize] allows to operate it according to the specified.
10.Unit
Select “mm” or “deg(angle)”.
11.Teaching range offset (margin)
The teaching range is narrower than the operation range by the offset (margin) off this
range.
12.Reduction ratio and moving speed
Enter reduction ratio and moving speed.
Number of motor revolution that is equivalent to the value entered is displayed.
Note Cycle main power every after any setting is changed.
6-1
6. Maintenance Functions
Maintenance on Touch panel (POD) is explained.
6-2
6.1. Menu Structure Select [M: Maintenance] on main menu. You can operate various maintenance functions
on the screen.
6.1.1. Move to maintenance menu under operation
Maintenance menu is basically selected only when a robot is stopped. To move to
maintenance menu under operation, press the hidden key located below on the auto
mode screen.
※ In the case of returning from
maintenance menu, it returns to auto
mode screen instead of back to main
menu screen.
Auto mode
screen
Maintenance
mode screen
Main menu
:under operation
:under stop
Auto mode screen (under operation)
Hidden key
S:System storage mode
T:Teaching mode
M:Maintenance mode
Main menu
A:Automatic operation mode
6-3
6.1.2. Maintenance menu detail
The maintenance menu branches off to [Controller data], [Robot data] and [Motor axis
data].
Versions of software are displayed
over here.
Controller
data
Motor
axis data
Robot data
6-4
6.2. Data memory contents Internal data memory contents (data held for each program) and external data
memory contents (Dn) can be monitored and modified on this screen.
Maintenance menu
↓
Controller data
↓
Data memory contents
【【【【Internal data memory】】】】
data held for each program.
D 0 :stacking layer
D 1 :stacking product
D 2 :picking quantity
D 3 :robot data
D 12 :stop position (for the
1st bag)
D 13 :stop position (for the
2nd bag)
D 14 :centering position
D 15 :pressing height
D 4 ~ 11 :universal
【【【【External data memory】】】】
D 1000 ~ D3999 :user area
D 5000 ~ D 5999 :system and user area (the system is for input) * 1
D 6000 ~ D 6999 :system and user area (the system is for output) * 1
D 7000 ~ D 7019 :supervisor area * 2
(*1:Universal area can be used by user.)
(*2:Don’t change normally although those could be.)
● Press both [Dis Prog No.=] and [Display Start No.=] keys. Enter the required program
No. on the key input screen.
●Press [Continuous start] key allows to monitor continuously.
6-5
6.3. I////O Monitor The directory to I/O monitor screen is as follows.
Maintenance menu
↓
Controller data
↓
I/O Monitor
The status of various relays
can be monitored and/or
changed on the relay monitor
screen.
The contents of relays are
normally retained and
continue to be displayed when
and after you get into the
screen. If [Continuous start]
is pressed, the screen is
continuously updated at every
designated interval.
The status of internal or external relays being operated is separately displayed.
【【【【Internal relays】】】】
Eight internal relays per a program are available.
Those are used for relay logical operation.
R0~R7:Universal usage
[Force ON/OFF procedure]
・Press a relay displayed that you want to change.
【【【【External relays】】】】
The allocation of external relay No. is as follows.
X0 ~X7F Input relay {when (3)-RC502s are used}
Y0 ~Y67 Output relay {when (3)-RC502s are used}
M5000~M57FF User and system relay (system area for input)※1
M6000~M67FF User and system relay (system area for output)※1
M7000~M704F Supervisor relay ※2
(*1:Universal area can be used by user.)
(*2:Don’t change normally although those could be.)
[How to display]
① Select type of relays (X, Y, M).
② Press [Display start No.=] key to display input screen.
③ Enter relay No. you want to display.
[Force ON/OFF procedure]
① Press a relay displayed that you want to change.
※ Cannot do Force ON/OFF with input relay and supervisor.
□(Blue)OFF
■(Red)ON
6-6
6.4. Operation ready condition The directory to operation
status screen
is as follows.
Maintenance menu
↓
Controller data
↓
Operation status
1. If motor power ON
enabling and
operation start enabling are
fulfilled
or not is displayed.
In case all conditions are
highlighted,
you can turn motor power or
operation on.
* In case either motor power or operation is not turned, check if every condition in this
screen comes on.
2. You can see the status of inputs/outputs ON/OFF to/from each CPU at bottom of screen.
6.5. Key trace The directory to key trace
screen is as follow.
Maintenance menu
↓
Controller data
↓
Key trace
1.You can see the
recent 112 logs of touch panel (POD) operation.
※What’s displayed
Date and time:
DD HH:MM
Screen:
Basic screen No.
Sub:Overlap screen No.
Key:Operation contents
Results:Operation results (detailed code)
6-7
6.6. File operation Files can be transferred
between external
memory and robot controller.
The directory to file operation
screen is
as follows.
Maintenance menu
↓
Controller data
↓
File operation
1.Transfer direction
Select file transfer
direction.
Display of the button
toggles between
[external memory <-> robot] whenever it is pressed.
2.File list
①When [external memory -> robot] is selected, file list of external memory as origin side
is displayed. Robot (memory inside controller) is target side in this case.
②When [robot -> external memory] is selected, file list of robot as origin side is
displayed. External memory is target side in this case.
③Pressing No. in the list allows to select file to be transferred (or deleted). The
selected file turns to reversed blue color.
*External memory can be selected with [USB] or [CF].
*Folder of external memory can be selected with [Work folder] or [Backup folder].
(See the note)
*All the files displayed in the list are [grog] only. However, pressing [system] allows to
display system file or pressing all for all files. Password is required to see the all
though.
3.All selection
All the files at origin are selected.
4.Transfer
The selected files are transferred to the target.
*Instruction of overwriting all programs
If [Do] is chosen, files at the target side with same names are forced to be
overwritten all.
If [Don’t do] is chosen, a confirmation message of overwriting pops up when files with
same names exist at the target side.
5.Log file transfer
6-8
Five recent trace data is transferred to external memory.
The file name is changed to that added on with date at the upfront.
(Example: 20100930150157_risc.err)
6.Deletion
Files chosen are deleted.
7.Cancel
Pressing [Cancel] during transferring allows to cancel the process.
Note
External memory
Either USB memory or CF (compact flash) can be connected.
USB memory is regularly used.
・USB memory of 2GBytes or less is to be used.
・The below mentioned folders are to be prepared by computer.
Folder structure of external memory
1)Work folder
Create a folder on root directory in external memory with a exact same name
as [job number] set at [S1-6: Parameter setting ] screen (see section 5.6).The
root directory becomes work folder unless [job number] is designated. File
sending/receiving can be done between job folder of external memory and
robot controller. This kind of file accessing can easily be achieved directory
to/from external memory without computer.
2)Backup folder
¥BACKUP¥
This is a folder that system files of robot is stored as a backup at a time.
3)Folder for firmware (SH software)
¥SH¥
This is a folder that SH software is saved.
6-9
6.7. Logic analyzer The directory to logic analyzer
is as follows.
Maintenance menu
↓
Controller data
↓
Logic analyzer
Select (8)-points out of relays
(X/Y/M) of robot controller,
set a trigger to one of the
selected relays.
The status of timing (as
timing chart) of the relays
before and after the triggered
is shown.
1.How to setup
①Select relays to be monitored
Pressing relay No. shown at left side allows to show ten key and enable to enter
relay No.
※Relay No. to not be selected is shown like 「_ _ _ _」.
②Trigger setting
After entering relay No., press No. ( 1~8) at left side to be highlighted in red
color.
The highlighted is trigger.
③Trigger level setting
Touching [TRIGER-EDGE] at bottom left allows to toggle between UP or DOWN.
When [UP] is chosen, rising timing of relay is going to be triggered. When [DOWN],
it is going down timing.
④ Recording time setting
Time interval (100 – 500ms) for one DIV (a division in memory) is to be set using
+ ― keys. Recording time is also shown depending on the set time.
※Example, when if it is set to 100ms (min), the recording time is 8 seconds. The
sampling frequency is 10msec.
1DIV set Record time Sampling frequency
100ms 8 sec 10ms
200ms 16 sec 20ms
300ms 24 sec 30ms
400ms 32 sec 40ms
500ms 40 sec 50ms
6-10
⑤Recorded data after triggered
Enter number of data after triggered you want. The max number is 80 DIV so 40DIV
is mid point of trigger to enable to evenly see both sides.
2.After setting is completed, press RUN/STOP button to monitor. The indicator below the
button is changed whenever pressed.
※Impossible to set up under RUN status.
※Even if screen is switched over, the status of RUN/STOP can be kept.
※Once triggered, it comes to STOP status.
3.How to see data after triggered
Data of (8)-pages (10DIV/PAGE) can be seen. Page scrolling can be done with < >
buttons.
※Once triggered, the same data can be kept as is until it comes to [RUN] status
even after screen is changed to something else. But all data is cleared when main
power is cycled.
6-11
6.8. ID No – Prg No allocation IDNo-PrgNo. allocation screen is displayed only at the time of the starting mode from
external PLC ( [X/Y] is selected at sys-para PLC control interface).
The directory to ID NO – Prg No allocation screen is as follows.
Maintenance menu
↓
Controller data
↓
IDNo-PrgNo allocation
- ID and program allocation
for
Centronix communication can
be shown and registered.
- To press [Cancel] allows to
cancel all the allocation of
IDNo.1 to 127.
-To press [Change] allows to
display IDNo. allocation
change screen.
ID No.assignment change
1. Enter ID No. with ten key.
Some number next to [Present Prg No.]
is shown up if it exists.
Cursor moves by itself to location of Prg No.
input
after entering ID No.
* A cursor can be also moved manually by
pressing [IDNo.] key or [PrgNo.] key.
2. Enter PrgNo. with ten-key.
Press [Cancel] key to cancel PrgNo. that is already assigned.
3. Press [Set] key after entering ID No. & Prg No.
6-12
6.9. Battery replace The directory to battery
replacement
screen is as follows.
Maintenance menu
↓
Controller data
↓
Battery replace
Press respective
corresponding [Replace]
button when battery is
replaced for either [for robot],
[for controller] or [for touch
panel]. The current date is
stored. Or you can directly
change year, month and/or
day pressing those displayed.
Note If wrong date is entered, waring message for replacing battery will be wrong
accordingly.
6.10. Conveyor information The directory to conveyor
information is as
Follows.
Maintenance menu
↓
Controller data
↓
Conveyor information
Start, stop, and latch
clearance of
Built-in PLC can be carried out
- Press [Change] key to change
operation or stop in corresponding PLC.
Password is required (For system registration).
- Press [Latch clearance] key to clear latching in Built-in PLC (regular speed + high
speed).
Only under stop state, both regular and high speed PLC can be cleared.
6-13
6.11. Stacked counter revision The directory to stacked
counter revision
is as follows.
Maintenance menu
↓
Robot data
↓
Stacked counter revision
Initialize Pallet Selected
1.To press pallet key to
initialize allows
to display the count value of
the
corresponding program.
2. Press [Initialize Pallet Selected] key to initialize the counter value of the displayed
program.
※In case [All] key is selected in pallet selection, the counter values of all pallet (1 - 6)
are initialized.
※Press [Initialize All Programs] key to initialize the counter values of all program stored
in robot counter.
Counter Revision
Counter value of each program No. can be changed in this screen.
● Press [Prog No.=] key and input the program No. to revise the counter.
●Press [Change] to input the value to revise.
● Press [Enter] to execute the counter revision.
* To hold a count value not per pallet but per program, counter revision of the
program which is not being stacked is also possible.
* In case of moving to maintenance menu under operation, this screen is not
displayed.
6-14
6.12. Program selection method The directory to program
selection method
is as follows.
Maintenance menu
↓
Robot data
↓
Program selection method
See 1.3 Program confirmation
procedure on manual of
[Teaching pallet on floor] for
detail.
6.13. Position & acceleration / deceleration time The directory to acceleration/
Deceleration time screen is as
follows.
Maintenance menu
↓
Robot data
↓
Position, acc/dec time
Last executed 12 steps trace
data is displayed.
(Displayed data are position,
acceleration time, and
deceleration time.)
*The screen is being
automatically updated.
6-15
6.14. Executed sequence command The directory to executed sequence command is as follows.
Maintenance menu
↓
Robot data
↓
Executed sequence command
Up to (40) sequence commands robot has executed are displayed on the executed
sequence command screen. Scroll key can move screen upward or downward to show
you all the rest of the commands.
[Screen explanation]
1. Executed sequence
No.
Numbering is made in
order of new to old.
2. Program No.
Program Nos to be
executed are displayed.
3. Line No.
Line Nos. in sequence
program to be executed
are displayed.
4. Sequence command
Sequence commands to
be executed are
displayed.
6.15. Overlap trace The directory to overlap trace
is as follows.
Maintenance menu
↓
Robot data
↓
Overlap trace
1. Up to (12)-overlapping
among steps executed are
displayed.
① ② ③ ④
6-16
6.16. SMOV calculation The directory to SMOV
Calculation screen is as
follows.
Maintenance menu
↓
Robot data
↓
SMOV calculation
1. Executed step No.,
position data and
acc/dec time are
displayed when SMOV
is executed.
6.17. Deviation trace The directory to deviation
trace is as follows.
Maintenance menu
↓
Motor axis data
↓
Deviation trace
It displays max and min
deviation
of each axis of robot.
※ Press [Max val clear] key
to clear Max value.
(Max value is stored even if
the power is OFF.)
6-17
6.18. Position command trace The directory to position
command trace is as follows.
Maintenance menu
↓
Motor axis data
↓
Position command trace
The position data of each axis
can be displayed as an
instruction value to CPU
(DS) for servo motor
control.
※ Last data for about 20
seconds can be shown.
But, in case a motor
power is off, the data is
not updated by itself.
In case a motor power is
turned off by occurrence of
failure, the data for about
20 seconds before the error
can be shown.
● Press [Write] key to save
data to file.
* [Write] operation cannot be
performed during operation.
* The data saved to file can
be taken in by Oxpa-Qm2,
and can be treated as CSV file.
● Press [Gragh] key to display
speed and position data in
graph.
* Press [Axial change] key to
show the graph of a different
axis.
6-18
6.19. Servo torque indicate The directory to servo torque
indicate is as follows.
Maintenance menu
↓
Motor axis data
↓
Servo torque indicate
1.Measurement of torque
Press [Start/Clear] button
to start.
(960) – data are recorded
in the preset sampling
frequency.
The measurement is
completed up to 960 data.
If [Start/Clear] is pressed
during measured, it is
cancelled.
●Press [Save To File] to save
the measured data.
※ The data saved to file can
be taken in by OXPA-Qm
as CSV file.
●Press [Data display] key to
show speed, torque in
graph.
※ Selecting axis allows to
show each axis data.
Press [Speed/Torque] key
to toggle to show Speed
or Torque.
2.Trace data indicate
While robot is in operation, torque is always being monitored and recorded
automatically. The sampling time is 24 msec and the data is up to 960.
Press [Trace indicate] to show the trace data and press [Trace save] to save data to
file.
6-19
6.20. Collision detection The directory to collision
detection is as follows.
Maintenance menu
↓
Motor axis data
↓
Collision detection trace
6.21. Expansion axis trace The directory to expansion
axis trace is
as follows.
Maintenance menu
↓
Motor axis data
↓
Expansion axis trace
It shows the data of positions
and acc/dec time of last (12)
- steps to be executed.
7-1
7. Table of Basic Specifications
Model RC840
(A700V, A400V,AP30V)
RC830
(A1800V, A1600V)
Number of control axis 4-axes simultaneous + 2 axes (for hand axis etc.
optional)
Path control system PTP (R,T Axes) CP (O,D Axes)
Position detection
system
Absolute encoder
Position control system Digital closed loop
Control Syste
m
Motor control system Digital AC servo control
Program storage system SRAM (battery back-up)
Compact flash (option)
Mem
ory
Memory capacity Max 2000 patterns (Varies depending on stacking
program)
Display device 8.7 inch FTP color LCD touch panel (KANJI supported)
Display
External storage device PC (Needs special program to transfer data )
Teaching system - Teaching play-back and numerical input
- Off-line programming by computer
Number of simultaneous
loading points
Max 14 pallets, 4 stations
Repeat speed 10 levels (1 ~10)
Editor functions Revise, Addition, Delete, Transfer, Copy, Labels
Outside
Teachin
g, Opera
tion
Remote operation Teaching Pendant (For Installation Personnel)
Number of I/O points Standard input 4 (124 Max option)
Standard output 3 ( 99 Max option)
External communication
USB x 1
Ethernet x 1
RS422 x 1
CC-Link x (option)
(All the software is optional)
I/O
I/O points of Hand Input 4, Output 4
Dimension [mm] 940W x 640D x 1150H mm
Weight [kg] 275 kg 250Kg
Ambient temperature 0 ~ 40 Degrees C
Storage temperature 0 ~ 50 Degrees C
Altitude 1000 m or less
Relative humidity 35 ~ 85 %
AC 200 / 220V ±5% 50 / 60 Hz ±1Hz, 3phase
Required power supply 2.5 kVA for robot +
(peripheral conveyors)
6.5 kVA for robot +
(peripheral conveyors)
Controller
Conveyor control Typical simple layout can be controlled by built-in PLC
Robot manual
Installation and Adjustment
- Electrical -
Version 01: 2011.09.22
<Caution>
Unauthorized reproduction of part or all of the content of this manual is forbidden.
The content of this manual is subject to future change without prior notice.
Okura Yusoki Co., Ltd. 900 Furuouchi, Noguchi-cho, Kakogawa,
Hyogo 675-8675 Japan
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