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Robot Manual

Installation and Adjustment

Okura Yusoki Co., Ltd.

CE-INS-11

CE(11)Updating history

Version(Date)

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10 (2005.1.31) Newly released

10 (2005.3.31)

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Error correction Memory swith standard setting SW2-5 : OFF -> ON, SW2-7 : OFF -> ON 2-6Date update Last page

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Addition of Updating historyAddition of transportation by a forklift.Encoder battery tpye change(A400III, A700III)Correction of LED explanationScreen data changeDate update

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11 (2010.02.12)

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IntroductionThank 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.

Definition of OperatorTHE INSTALLATION SHALL BE MADE BY QUALIFIED INSTALLATION PERSONNEL AND

SHOULD CONFORM TO ALL NATIONAL AND LOCAL CODES.

Important!Definition of operator:Only AUTHORIZED PERSONNEL can operate the robot.The definition of “AUTHORIZED PERSON” is described below:

The only personnel that 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.

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Table of Contents

1. BASIC SPECIFICATIONS........................................................................1-11.1. Operation Range.........................................................................1-21.2. T-axis Flange Details...................................................................1-61.3. Internal Wiring Diagram..............................................................1-81.4. Spare Cable..............................................................................1-111.5. Capacity...................................................................................1-121.6. Robot Installation Dimensions...................................................1-141.7. Transport Method.....................................................................1-141.8. Limiting Device.........................................................................1-171.9. Installation and Foundation.......................................................1-231.10. Necessary information on protective fence................................1-241.11. Connection of main power supply wires.....................................1-251.12. Protection against lightning serge.............................................1-261.13. Other notes (wiring)..................................................................1-26

2. SYSTEM STORAGE...............................................................2-12.1. Soft Limit...................................................................................2-22.2. Peripheral Equipment Name Input...............................................2-32.3. Hour Meter.................................................................................2-42.4. Communication Setting...............................................................2-42.5. External PLC Communication Setup.............................................2-52.6. Memory Switch...........................................................................2-52.7. Axis Accuracy...........................................................................2-102.8. Password Setting......................................................................2-112.9. Origin Storing...........................................................................2-112.10. Servo Parameter.......................................................................2-122.11. Hand Manual Operation Name Input..........................................2-12

3. CENTRONICS COMMUNICATION............................................3-13.1. Purpose of Using Centronics Communication................................3-23.2. Centronics Communication Start Timing......................................3-33.3. Name and Meaning of Signals During Communication...................3-43.4. Send/Receive Timing in Centronics Communication......................3-53.5. Time Constraints in Centronics Communication............................3-73.6. Details of Robot PLC Data........................................................3-83.7. Details of PLC Robot Data......................................................3-23

4. SETUP................................................................................4-1

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4.1. Origin Storing.............................................................................4-14.2. Collision Detection......................................................................4-34.3. Standard Storage.......................................................................4-44.4. How to place the optional stopper...............................................4-54.5. How to attach the hand to robot..................................................4-74.6. Servo amp replacement..............................................................4-94.7. Spare Parts..............................................................................4-104.8. At Dismantling..........................................................................4-10

5. PC BOARDS.........................................................................5-15.1. Main CPU Board（RC101）...........................................................5-35.2. I／O Board（RC132）..................................................................5-55.3. Servo CPU Board（RC103）..........................................................5-75.4. Servo Power Supply Board（RC105）............................................5-95.5. Safety Relay Board（RC106）.....................................................5-11

6. SERVO-AMPLIFIER RECEIPT BOX..........................................6-16.1. Servo-Amplifier Receipt Box Composition.....................................6-26.2. Servo-Amplifier..........................................................................6-3

7. EXTERNAL I/O SIGNALS.......................................................7-17.1. I/O・Data-Memory Composition..................................................7-27.2. Construction of peripheral equipment control..............................7-37.3. I/O board....................................................................................7-57.4. I/O Signals for Hand..................................................................7-317.5. Emergency...............................................................................7-32

8. MAINTENANCE MENU..........................................................8-18.1. Menu structure...........................................................................8-28.2. Special maintenance menu..........................................................................8-4

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1. Basic Specifications

WARNINGThe Robot system shall be installed to avoid interference with buildings, structures, utilities, other machines and equipment that may create a trapping hazard or pinch points.

CAUTIONRobot control panel shall not be located inside of the robot work envelope / workcell.

CAUTIONStrong Electromagnetic Interference (EMI), Radio Frequency Interference (RFI) and Electro Static Discharge (ESD) can causes error of controller equipment. The Robot system shall be installed to avoid interference with these influences that machines and equipment generate.

1

11 (2009.07.13)

★

★

A-point

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1.1.Operation RangeA1800

Protective fence locates apart from mechanical movable area plus hand size and extra protective distance A. (Extra distance A must be based on EN294 on the basis of fence height and guard clearance.)

★If the restricted space is not required, it is possible to set it up to ±180 degrees by eliminating the R-axis limit switch. A usual setting range is ±175 degrees.

2

A-pointoperation range

Without mechanical stopper cam for small-foot-print

With mechanical stopper cam for small-foot-print

A-point

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A1800-W

Safety fence locates apart from mechanical movable area plus hand size and extra safety distance A. (Extra distance A must be based on EN294 on the basis of fence height and guard clearance.)


3

With mechanical stopper cam for small-foot-printWithout mechanical stopper cam for small-foot-print

A-pointoperation range

A-pointoperation

range

A-point

★

★

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A1200III, A1600III, A1600III-W

Protective fence locates apart from mechanical movable area plus hand size and extra protective distance A. (Extra distance A must be based on EN294 on the basis of fence height and guard clearance.)


4

A-pointoperation

range A-point

★

★

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A400III, A700III

(In case attached the optional stopper see 4.3.)Protective fence locates apart from mechanical movable area plus hand size and extra protective distance A. (Extra distance A must be based on EN294 on the basis of fence height and guard clearance.)★If the restricted space is not required, it is possible to set it up to ±180 degrees by eliminating the R-axis limit switch. A usual setting range is ±175 degrees.

5

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1.2.T-axis Flange DetailsInstalled Hand Conditions:

① InertiaA1800: Inertia of hand (include the handled article) must be 10.0kgm2 or less. (At a speed regulated condition 30kgm2 is MAX.)A1200III, A1600III: Inertia of hand (include the handled article) must be 10.0kgm2 or less. (At a speed regulated condition 30kgm2 is MAX.) A1600III-W,A1800-W: Inertia of hand (include the handled article) must be 15.0kgm2 or less. (At a speed regulated condition 90kgm2 is MAX.)A400III, A700III: Inertia of hand (include the handled article) must be 10.0kgm2 or less. (At a speed regulated condition 30kgm2 is MAX.)

② Installed Hand DimensionsTo prevent interference with the arm, the external dimensions of the installed hand must be within the regulation shown below.

③ Force to the handled articleCentrifugal and inertia forces work on the article carried by robot hand. These force can be calculated by speed spec and acceleration time of robot motion.Standad acceleration time is 0.28sec(A700III) 0.24sec(A1600III and A1800) 0.4sec(A1600III-W)

A1800,A1800-W

6

φ2008-M10

φ150

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A1200III, A1600III, A1600III-W

A400III, A700III

7

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1.3.Internal Wiring DiagramThe following shows the wiring inside the robot and the composition of the harness between the robot and controller

A1800,A1800-WInside the robot wiring

Harness between the robot and controller

8

CN1 CN13 D-motorCN14

CN15 O-motorCN16

CN11 R-motorCN12

CN8

CN9

CN10

CN7CN2

CN3

RK815

RK816

RK817

RK831

RK832

RK833

CN6

CN18CN4 CN22 D-encoder

CN23 O-encoder

CN24

CN26

CN31

RK851

RK852

RK853

RK854

RK855 RK873

RK856

CN34RK857CN21 R-encoder

BASE

T-AXIS

HAND

CN37

CN5

BAT

CN17 T-motor

CN25 T-encoder

CN33

CN32

RK874

CN36

CN35

RK871

RK781

RK782

AIR 12mm

10mm12mm

12mmAIR 12mm

R-LSRK858 CN39

RK835

ROTORBASE

CN40 FANRK875

Air tube connections on quick joint type

Location of CN1-CN5 on Robot Base

Air Pressure Max. 0.5Mpa, 72psi

CN1

POWER

CN2

CN3 CN5

CONTROL

AIROPTION

CN4

AIR

Replace batteryonly with typeMaxell ER6K-#17-A

CN1

CN2

CN3

CN4

CN5

CN1C

CN2C

CN3C

CN4C

CN5C

RK721

RK722

RK723

RK724

RK725

ROBOTCONTROLLER

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A1200III,A1600III,A1600III-WInside the robot wiring


9

CN1

CN2

CN3

CN4

CN5

CN1C

CN2C

CN3C

CN4C

CN5C

RK721

RK722

RK723

RK724

RK725

ROBOTCONTROLLER


Air Pressure Max. 0.5Mpa, 72psiCN1

POWER

CN2 CN3

CN5CONTROLAIR

OPTION


CN4

AIR

Replace batteryonly with typeMaxell ER6K-#17-A

CN1 CN13D-motorCN14

CN15O-motorCN16

CN11R-motorCN12

CN8

CN9

CN10

CN7CN2

CN3

RK731

RK735

RK733

RK731

RK732

RK733

CN6


CN23 O-encoder

CN24

CN26

CN31

RK751

RK752

RK753

RK754

RK755 RK773

RK757

CN34RK758

CN21 R-encoder

BASE

ROTOR

T-AXIS

HANDCN37

CN5

CN17 T-motor

CN25 T-encoder

CN33

CN32

RK774

CN36

CN35

RK771

RK781

RK782

AIR 12mm

10mm12mm

12mmAIR 12mm

RK758

R-LSRK759 CN39

RK737

BAT

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A400III, A700IIIInside the robot wiring


10

CN1

CN2

CN4

CN5

CN1C

CN2C

CN4C

CN5C

RK721

RK722

RK724

RK725

ROBOTCONTROLLER

T-AXIS

CN1 CN13D-motor

CN15O-motor

CN11R-motor

CN8

CN7CN2

RK741

RK742

CN6


CN23 O-encoder

CN24

CN26

CN31

RK761

RK762

RK763

RK764

RK765 RK773

RK767

CN34RK758

CN21 R-encoder

BASE

ROTOR

HANDCN37

CN5

CN17 T-motor

CN25 T-encoder

CN33

CN32

RK774

CN36

CN35

RK771

RK781

RK782

AIR 12mm

10mm12mm

12mmAIR 12mm

RK768

R-LSRK769 CN39D-LS

O-LSRK776

RK737

BAT


POWER

CN1 CN2 CN5

CONTROL

CN4



Replace batteryonly with typeMaxell ER6K-#17-3

AIROPTION

AIR

CN33CN35

TBR1

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1.4.Spare CableThe following spare cables are provided for an Okura A series robot palletizer.

Robot main unit connector Connector in controllerCable sizeConnector

No.Pin No. Wire No. Connector

No.Pin No. Wire No.

CN33[3191-15R1]

3 S3

TBR1

S3

0.3 mm2

4 S4 S413 S5 S514 CLS CLS

CN35[3191-15R1]

1 S6 S62 S7 S73 S8 S84 S9 S95 S10 S106 S11 S117 S12 S128 S13 S139 S14 S1410 S15 S1511 S16 S1612 S17 S1713 S18 S1814 S19 S19

11

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1.5.CapacityThe handling capacity of an A series robot palletizer varies depending on the [load

weight] (total weight of hand and handled article), and the layout.Among layout factors, the R-axis rotation angle of the robot has the greatest

influence on handling capacity. As shown in the diagram, the robot's R-axis rotation angle runs from the station conveyor to the pallet position in the layout diagram.

Handling capacity also varies depending in the nature of work, for example, when palletizing, fundamentally different robot movement paths are used with bags and cases, as shown in the diagram, so handling capacity also differs.

A series robot palletizers have standard patterns for robot movement paths. Based on Okura's experience with palletizing technology.

The following page shows the palletizing capacity when a standard pattern is used. The positional relationship between the station conveyor and the pallet is assumed to be like that in the diagram.

12

Pallet

Station

R-Axis Rotationangle

Bags Cases

650m

m

1500

mm

120

mm

Stac

k He

ight

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[Bag]

[Case]

13

300

400

500

600

700

800

900

1000

1100

40 60 80 100 120 140 160 180

Ha ndli

ng

Ca pac

ity

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

40 60 80 100 120 140 160 180R-Axis Rotation Angle(Degrees)

Han

dlin

g Cap

acit

yA1600III:10Kg bag special layout

A1600III

A700III400

500

600

700

800

900

1000

1100

1200

1300

40 60 80 100 120 140 160 180

A400III

A1200III

A1600III-W

300

400

500

600

700

800

900

40 60 80 100 120 140 160 180

A700III

A1600III

100

200

300

100

200

A1200III

A1600III-W

A400III

R-Axis Rotation Angle(Degrees)

[B/

h][C

/h]

60100140

Load Weight [kg]

200300

60100140

Load Weight [kg]

200300

*Please calculate the ability of A1800 with Oxpa-Qm2.

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1.6.Robot Installation Dimensions[All types]

1.7.Transport MethodThe diagram below shows the posture and hoist position (rope tension).A1800,A1800-W

Important!Be sure to remove the hoist bolts during robot operation.

14

8-22

850

□ 7504-M20

10°10°

45°

D-axis：0.0°O-axis：130.0°

two right and leftA1800 :5978N (610kg, 1345lb)/ eachA1800-W :6370N(650kg,1433lb)/each

：重心位置

AX = 1191 mmAZ = 1716 mm

center of gravity

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A1200III, A1600III, A1600III -W


15

: center of gravity

two right and leftA1600III :5782N (590kg, 1301lb)/ eachA1600III-W:5860N (598kg, 1318lb)/ each

D-axis：－4.3°O-axis：134.3°

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A400III, A700III


16

D-axis：　 0°O-axis：140°

two right and left6223N (635 kg, 1400lb) / each

D-axis： -17.0°O-axis：130.0°

AX=1069mmAZ=1914mm

AX=1147mmAZ=1632mm

#In the case of transportation by a forklift.

: center of gravity

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1.8.Limiting DeviceR,D,O-axis has limiting device as below.

Mechanical stoppers

Limit switch

R-axis adjustable fixed(*)D,O-axis fixed －

　　　　　(*)Only a limit switch is used when larger than 250 revolution angles. Mechanical stoppers do not use.

LocationR-axis: inside the base

A1800

17

Mechanical stoppersLimit switch

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A400III A700III A1200III A1600III

18

Mechanical stoppersLimit switch

ⅰphase

ⅱphase

+1+2

+3

+4

+5

+6

+7

+8+9 -9

-8

-7

-6

-5

-4

-3

-2-1

▲Front of robot

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R-axis How to adjustA1800

The attached bolts are installed in the position which corresponds from a lower table.

It attaches in the installed bolts and brackets positions in accordance with the stopper's holes(A～H) shown in the table.

※The stopper uses both sides of the inside and outside.

Installed Bolts Position Installed Bolts Position+1 +2 +3 +4 +5 +6 +7 +8 +9 -1 -2 -3 -4 -5 -6 -7 -8 -9

0 A E

Limit

Switc

h An

gle[

deg]

0 A E

+5 E A -5 E A

+10 C G -10 C G

+15 G C -15 G C

+20 A E -20 A E

+25 E A -25 E A

+30 C G -30 C G

+35 G C -35 G C

+40 A E -40 A E

+45 E A -45 E A

+50 C G -50 C G

+55 G C -55 G C

+60 A E -60 A E

+65 E A -65 E A

+70 C G -70 C G

+75 G C -75 G C

+80 A E -80 A E

+85 E A -85 E A

+90 C G -90 C G

+95 G C -95 G C

+100 A E -100 A E

+105 E A -105 E A

+110 C G -110 C G

+115 G C -115 G C

+120 A E -120 A E

+125 E A -125 E A

+130 C G -130 C G

19

※The shaded cells in above table show the installation with ⅱ phase.

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A400III A700III A1200III A1600III

The attached bolts are installed in the position which corresponds from a lower table.

It attaches in the installed bolts positions in accordance with the stopper's holes(A～H) shown in the table.

※The stopper uses both sides of the inside and outside.

Installed Bolts Position Installed Bolts Position+1 +2 +3 +4 +5 +6 +7 +8 +9 -1 -2 -3 -4 -5 -6 -7 -8 -9

0 A E

Limit

Switc

h An

gle[

deg]

0 A E

+5 E A -5 E A

+10 C G -10 C G

+15 G C -15 G C

+20 A E -20 A E

+25 E A -25 E A

+30 C G -30 C G

+35 G C -35 G C

+40 A E -40 A E

+45 E A -45 E A

+50 C G -50 C G

+55 G C -55 G C

+60 A E -60 A E

+65 E A -65 E A

+70 C G -70 C G

+75 G C -75 G C

+80 A E -80 A E

+85 E A -85 E A

+90 C G -90 C G

+95 G C -95 G C

+100 A E -100 A E

+105 E A -105 E A

+110 C G -110 C G

+115 G C -115 G C

+120 A E -120 A E

+125 E A -125 E A

+130 C G -130 C G

※The shaded cells in above table show the installation with ⅱ phase.

20

ⅰphase

+1+2

+3

+4

+5

+6

+7+8

+9 -9-8

-7

-6

-5

-4

-3-2

-1

ⅱphase

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D-Axis and O-Axis Mechanical Stoppers locations

A1800

A1200III A1600III

21

D axis O axis

D axis O axis

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A400III A700III

22

O axisD axis

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1.9.Installation and FoundationStand Strength and RigidityThe following standard values must be satisfied for the bending direction (M) and twisting direction (T) shown in the diagram below.

A1200III, A1600III, A1600III -W, A1800,A1800-W[Strength]The stand must withstand the following repetitive load.

M =16000 NmT =12500 Nm

[Rigidity]Sufficient rigidity is required to avoid vibrationduring robot motion. Recommended values are KM=5.4x106 Nm/rad

KT =5.4x106 Nm/rad

[Set-up conditions]Floor conditions: Concrete 150mm thick (MIN) 3.0t/m2. No water gradient.

Concrete completion strength 21Mpa (MIN)Fixing method: Chemical anchor M16-12. Pulling strength 1.8t.

(Hole Dia.19mm, Hole depth 90mm,)Bolt tensile strength is 400N/mm2 or more.Bolt yield is 240N/mm2 or more.

A400III, A700III[Strength]The stand must withstand the following repetitive load.

M =7500 NmT =6000 Nm

[Rigidity]Sufficient rigidity is required to avoid vibrationduring robot motion. Recommended values are

KM=3.9x106 Nm/radKT =3.9x106 Nm/rad

[Set-up conditions]Floor conditions: Concrete 150mm thick (MIN) 2.0t/m2. No water gradient.

Concrete completion strength 21Mpa (MIN).Fixing method: Chemical anchor M16-8 pulling strength 1.8t.

(Hole Dia.19mm, Hole depth 90mm,) Bolt tensile strength is 400N/mm2 or more.Bolt yield is 240N/mm2 or more.

23

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1.10. Necessary information on protective fenceUse parts which satisfy the following common requirements for a protective fence door switch, emergency stop switch and intrusion detect switch.

Common requirementWire : IEC standardWire diameter : 0.5 sqmm or moreWires length : 20 m or less Voltage : 24 VCurrent : 20 mAOutput : dry outputStandard : authenticated by NE/IEC standard, which include a dual channel mechanism with normally closed contacts.

1. Protective fence door switchSatisfy the common requirements above.Door keys that are removable when the door is open cannot close without the key replaced.

2. Emergency stop switchSatisfy common requirements above

3. Intrusion detection switchSatisfy common requirements aboveThis can be connected to control category three

4. Height and region of protective fenceProtective fence height is recommended to be more than 2700 mm.Protective fence locates apart from robot mechanical movable area plus hand size and extra safety distance A. ( Extra distance A must be based on EN294 on the basis of fence height and guard clearance)

Follow EN953 in locating fixed guard.

5. Structure and dimension of protective fenceProtective fence requirement is having the capability to withstand the impact of the handling work dropped and released by the robot at maximum speed, and to prevent flying out the handling work from the fence inside at the same condition.Maximum speed is calculated by the maximum velocities of the robot axes and the robot position.

24

2 1 0

2 1 0

Fence height

Protective distance A

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1.11. Connection of main power supply wiresConnect main power supply wires on the basis of belows.

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.

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 wiresWires : IEC standardWires diameter: more than 10 sqmmTerminal processing: A round terminal that suits the size of the electric wire and tool of maker recommendation are used.

Specification of external protective conductorsWires: IEC standardWires diameter: more than 10 sqmmColor : Green/yellow

25

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1.12. Protection against lightning sergeThere is no protection against lightning serge inside of controller.Relevant protection against lightning shall be required when connecting main power supply.

1.13. Other notes (wiring)1.13.1. Attaching insulation coverAttach cover to O-axis and D-axis connector, which keeps more than 10 mm clearance and creepage distance not to touch.

1.13.2. Securing of earth 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 the value is less than following resistance valueResistance value : 0.1 ohm or less per 10 A

3. Attaching ductHarness 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 width and 100 mm height.

4. Fix protective conductor terminal with specified screw to the robot as shown in the figure. And fix insulator separately.

26

Interface for hand

Interface of Air tube Option in Rotor inside.

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1.13.3. Pneumatic system

Pneumatic system is provided for hand.Pneumatic source interface is set on Robot Base panel.Air tube is passed in the flexible conduit and the interface is set on T-axis. Air tube Option interface is set on Robot Rotor inside.


InterfacePneumatic source：Model KQE12-00(SMC)/ Fitting Diameter 12mmHand：Model KQH10-12(SMC)/ Fitting Diameter 10mmOption：Model KQH12-00(SMC)/ Fitting Diameter 12mm

See “1.2 Internal Wiring Diagram” for panel locations and diagram.

Locations

27

Interface of pneumatic source

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2. System StorageThis section explains the various system parameters. In ordinary operation, there is no need to change system parameters, ( However, resetting is necessary for making special setting and when motor replacement or other maintenance has been conducted.)The procedure for moving to the system parameter menu screen is as follows;

System Parameters Password input System Menu

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2.1.Soft LimitThe procedure for moving the soft limit screen is as follows;

System Menu 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)

4. Acceleration/Deceleration time-This sets the acceleration time and deceleration time for robot movement.(Unit :msec)

5. 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

6. Hand mass- Set hand mass (work is not included)- This is to be used for an automatic compensating calculation of handling rate

2.2.Peripheral Equipment Name Input The procedure for moving to the conveyor information is as follows.

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System Menu Peripheral Name Input

1. Peripheral conveyor Name- Input the conveyor name for display at the conveyor manual mode screen- When pressing a number key of item to be changed, mode turns to an input mode

2. Station No. Pallet No.- The values here define the design of the screen, especially automatic mode screen-The Okura A series robot controller can operate up to 4 stations and 6 pallets system-To avoid displaying the condition of unused stations or pallets, the value here regulate the area for display

3. POD → DM, DM → POD- This sets the number of memory to be used with the screen which is peculiar to the system(POD means the touch panel.)

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2.3.Hour Meter The procedure for moving to the hour meter screen is as follows

System Menu Hour-Meter Revision

The following two settings can be made at the hour meter revision screen

[Date revision] Display the key input screen by pressing the display data of item to be changed. Then, input 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 item of the user time shall be cleared to “0”)

NoteTotal hour cannot be cleared

2.4.Communication SettingThe serial communication format of 4 “S-I/O port”, except touch panel, shall be determined, Procedure for moving to the communication setting screen is as follows.

System Menu Communication setup

Setting shall be valid upon re-starting of power.

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2.5.External PLC Communication Setup Transfer data in Centronics communication can be selected in this menu.

System Menu Ext PLC Com Setup

1. Transmit error code to PLCWhen select [ Yes ] at the time robot error occurs, the error content is output to the PLC.

2. Program No. AdditionWhen select [ Yes ], at the time robot transfer “pattern information” data, program no., higher 6 bits and program No., lower order 6 bits are added after ID No. data.

3. Layer Data AdditionWhen select [ Yes ], at the time robot transfer “pattern information” data, layer data is added. (D7 data is always 1 in layer data)

4. All Special Data AdviceWhen select [ No ], at the time robot transfer “pattern information2 data in special stacking, quantity data is not transfered.

2.6.Memory SwitchProcedure for moving to the memory switch screen is as follows.

　System Menu

Memory Switch

- Set the memory switch inside robot(Normally, change will not be necessary.)- The following items are set by turning memory switches ON and OFF.-For changing, press a switch to be changed, then turn ON and OFF.- Descriptions come out in the bottom frame upon pressing the numeral key in left side

Use \\ key to move to SW4 (Use \\ key to return)

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Name ON OFF TypeStandard setting

SW1

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 Not used1-3 C-axis Existing of C-axis No C-axis1-4 Setting of A300S A300S A300 All OFF1-5 Robot control

signalsX,Y are used. M,D are used. All OFF

1-6 Program 0 function

Upward motion at the then position.→ RX Reverse to MIN→ Only R-axis rotate to 0 position→ move to 0 position(It is necessary to change the prg.0sequence. 3 lines in the following are to be added twice in front of PGSEL D=D2+1

MOV 1WTARM )

Upward motion at the then position,then move to 0 position (standard)

All OFF

1-7 Variable picking special movement

1st layer / 1st work is at the height ofstep 9.Same movement as variable picking

Ordinary handlingAll OFF

1-8 Not used

SW2

2-1 Movement under the condition of pallet floor placement

No shifting to upward when there is some more head-room, like steps of 5 and 8

Ordinary calculation All OFF

2-2 Use password Password is valid if the password has been set in the system parameter screen

Password is invalidMaster password: 1952

All OFF

2-3 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 OFF

2-4 Operating movement

Robot is under its independency.(PLC operation signal is to be ignored)

Robot collaborates with PLC signals

All OFF

2-5 External operating button(X20)

Use Not used All ON

2-6 Expanded PORT tele-com. Log output(for　debugging)

Log output → debug PORT No output All OFF

2-7 External stop button(X21: normal close contact)

Use Not used All ON

SW3

3-1 Sequence　reset handling setting

In an occasion of resettingY30 (M6010) - Y35 (M6022)Y20 (M503A) 500mS ON

Ordinary handlingAll OFF

3-2 Use Compact Frash card

Use Not use All OFF

3-3 SMOV parameter Use metric height parameter Use % parameter All OFF3-4 Not used3-5 Language Other language Japanese All ON3-6 DA1800 mode DA1800 mode STD mode All OFF3-7 Servo parameter

enhancing areaUseAddition of parameter for feed forward control(effective since Srvmain1.bin Ver. 1.02F)

Not use All OFF

3-8 End of work button

Use Not use All OFF

SW4 4-1 System reserved --- Always off All OFF4-2 System reserved --- Always off All OFF

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Name ON OFF TypeStandard setting

4-3 DA1800For palette two or more one program

For palette two or more one program STD All OFF

4-4 Conveyer manual notification number in centronics communication

30 or less 15 or less All OFF

4-5 Timer value setting screen

use Not use All OFF

4-6 For 14 palettes(Specific order exclusive use)

For 14 palettes(The set number of palettes is disregarded.)

STD(The set number of palettes is effective.)

All OFF

SW5

5-1 When the product type is set, the product type code is written in the device.

written Not written All OFF

NoteUpon pressing the number’s area of each switch, explanatory descriptions for that switch come out in the bottom of screen

[POD screen display]SW SH version

(Add/Alter)ON OFF

4-7 2.02B Production Data(Detail) Production Data(Standard)4-8 2.08B Improvement version at

trajectory of T axisnormal

5-2 2.03A Trigger which saves TraceData :MotorPower OFF :When a Servo error occurred

5-3 2.03J Variable pickup auto copy option :ENABLE

:DISABLE

5-4 2.03O Default T-AXIS offset (A700 III) T-AXIS offset = 60mm5-5 2.07C Acc/Dec time minimized By default value5-6 2.05B System reservation (Fixed

“ON”)5-8 2.05L ON-Floor Pallet Qty Detection

:ENABLE :DISABLE6-1 2.07 Condition of File Download

:Motor Power OFF :AnyTime6-2 2.05N D4=Init Value LAY Cnt,D5=Init

Value WRK Cnt.:DISABLE

6-4 2.08B Use RC122 board Use RC102 or RC112 board6-6 2.08B Default T-AXIS Revolutions

(A1600 III-W)T-AXIS Revolutions = 3525rpm

6-7 2.08C The Station Timer value is managed by PLC managed by Robot Controller.

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[Descriptions]Name ON OFF Type Factory

default

SW4

4-7

Production summary

Optional :Results of each hourResults of each day

Results of each programResults of each pallet

All OFF

4-8

T-axis acceleration and deceleration times

Calculating T-axis acceleration and deceleration times form the hand coordinate.(Including T-axis inertia increase/decrease due to R-axis revolution)

Calculating T-axis acceleration and deceleration times from the arm coordinate.

All OFF

T-axis inertia decided by linear approximate equation.When T-axis inertia is inputted, calculated result (using inputted value and product weight) is better than not inputted.

Calculating T-axis acceleration and deceleration times from T-axis inertia of each hand weight.The error with a real situation is large.

Compared with turning off, the capacity might decrease.

SW5

5-2

Which timing trace data is stored at

At motor power turned off.On and after Ver.2.03A.(Use for test)

At servo system faultedSaved trace data are effective to trouble shooting.Only last faulted data are saved. Old data are overwritten.

All OFF

5-3

Position of STA

Not automatically re-overwrite all STA data when a position and/or a picking direction is changed.

When position data of STA at a layer & a product is changed, the other same data at STA is automatically copied if grip direction is the same each other. Moreover, if the direction is changed, position data at STA is re-calculated.

All OFF

5-4

A700 model(T-axis offset)

New modelUsing default offset value of T axis center.

Compatible with the older models in offset value of T axis center.

A700 IIIA700 III-P

ON

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Name ON OFF Type Factory default

5-5

Minimum acceleration and deceleration times

Each axis has the minimum of acceleration and deceleration times.

D/O-axis : 144msecR/T-axis : 192msec

All-axis have the common minimum acceleration and deceleration times.

All-axis : 192msec

A1600 IIIA1600 III-P

OFF

5-6

System reserved

Keep ON always. --- All ON

5-8

Check on the pallet count change

When pallet on the floor, check the pallet count change with first stack product.

No check the pallet count

All SHVer2.05L-2.08C：OFF2.08D-：ON

SW6

6-1

File downloads

Motor Power OFF. Anytime All ONWhen motor power is ON, all downloads by PC are prohibited.

When motor power is ON, only system parameters download by OXPA are prohibited.

6-2

The initial values of counters are set in D4/D5

The initial value of counters are set in D4/D5.D4 : initial layerD5 : initial product

Do not set in D4/D5.Use D4/D5 freely.

All OFF

6-4

I/O board Use RC122 board.(Japan only)

Use RC102 or RC122 board. (Standard)

All OFF

6-5

Collision Detection valid invalid All OFF

6-6

A1600 III-W type(T-axis revolutions per minute)

Use standard T-axis revolutions per minute. (3825rpm)

Use non-standard T-axis revolutions per minute. (3525rpm)

A1600 III-W

ON

6-7

Managing of station timer value.

Managed by internal PLC.

Managed by robot controller.

All SHVer2.08C-2.08D：ON2.08E-：OFF

The values are saved into latch area.Setting D2500 - D2515 need ladder logic when program is changed.

The values are saved the D12-D15 of program parameters.Setting D6096 – D6111 is automatically done itself when program is changed.

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2.7.Axis AccuracyProcedure for moving to the axis accuracy screen is as follows.

System Menu Axis Accuracy

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 Contents Description

1 100 0~100[%]

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 Speed limit for RX direction (Speed regulation for RX motion)5 100 SMOV inner judgement (Speed regulation for RZ motion)6 100 [mm] Step1 effective height Parameter that calculates No.1-3

automatically(It is effective in memory switch 3-3.)

7 100 Step3 effective height

3. Type change (Please don’t touch this key)- On every pressing, type shall be turnedA700II -> A1600II -> A1600II-W -> A700II-P -> A1600II-P -> BltJr -> A1600II-PW -> A1600III -> A1600III-P -> A1600III-W -> A1600III-PW-> A1800 -> A1800-W

ImportantIf this machine type is changed, all programs are

erased.

4. Job number- Input Okura’s job number- Job number is displayed in the basic menu

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2.8.Password SettingIn standard setting, the password setting is necessary only at the time of system storing. Password setting can be done with each screen of setting for auto operation, teaching and conveyor data.

System Menu Password Setup

[ Procedure for storing ] ①Select an item to be set by pressing a key②Input 4 password③Press Set key

[ Procedure for resetting ]①Select an item to be reset by pressing a key②Press Clear key

Note-2-2 of the memory switch should be turned on to make this setting effective.- Standard password shall be invalid when setting a password into the system storing

2.9.Origin StoringPlease refer 4.1. Origin Storing

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2.10. Servo ParameterThis is a screen for displaying or changing the necessary parameter on the servo screen Procedure for moving to the servo parameter screen is as follows.

System Menu Servo Parameters

Note- Each parameter should be of within a due range, otherwise, the robot may malfunction with the possibility of damage to the robot and controller.-Only qualified individuals should change this value.

2.11. Hand Manual Operation Name InputInput the manual device names of the hand.Procedure for moving to the axis accuracy screen is as follows.

System Menu Hand Setup

[ Input procedure ]①Press a number key to be input②An Input screen comes out , and input the name③Press QUIT key

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3. Centronics CommunicationIf the Centronics communication is effectively done on "External PLC communication setup" screen of "System storage", the data communication between the robot and the sequencer becomes possible by using the I/O relay. (About external PLC communication setting, please refer 2.5. External PLC communication Setup.)

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3.1.Purpose of Using Centronics CommunicationExamples of the principal uses are shown below.■Transmitting pattern information when performing multiple pick-up.(Robot -> Sequencer)■ When performing peripheral conveyor reset, zero reset or manualoperation using the robot controller. (Sequencer -> Robot)■Displaying conveyor errors on the robot control panel. (Example: Safetyfence, station conveyor jamming) (Sequencer -> Robot)■Count setting. (Bi-directional)

Note) The robot sequence stops during Centronics communication. (Robot actions stop)

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3.2.Centronics Communication Start TimingThere are two types of Centronics communication: the type wherestarting can be done at any time, and the type where data isautomatically sent at an established timing.During Robot-> PLC communication

NO. Transmitted item Transmission timing.1 - a Stacking pattern information

send modeWhen 2-b or 2-d is received, or product type is set.

1 - b Conveyor reset At input from conveyor manual screen.

1 - c Conveyor all reset (Zero reset)

At input from conveyor manual screen.

1 - d Counter setting At input from the stacking counter change screen, or when 2-c is received at stacking counter initialization.

1 - e Conveyor manual At conveyor manual screen selection.

1 - f No program No. for ID No. Decision at ID strobe reception. (Decision also when OX81 or OX83 command is received)

1 - g Overall time, automatic operation time

When 2-g is received.

1 - h Data memory output When 2-h is received.1 - i Product dimension output When 2-i is received.

During PLC-> Robot communicationNo. Received item Reception timing2 - a PLC error mode Any time after P-I/O alarm/error

bit ON2 - b Request pattern data from

conveyorAny time (To 1-a)

2 - c Count setting from conveyor Any time2 - d Pattern data request for

pallet No.Any time (To 1-a)

2 - e Allocation of PRG No. for ID No.

Any time

2 - f Stacking position setting Any time2 - g Request for robot overall

time, and automatic operating time

Any time (To 1-g)

2 - h Data memory content request

Any time (To 1-h)

2 - i Product dimension request Any time (To 1-j)

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3.3.Name and Meaning of Signals During Communication

Relay PLC -> Robot Robot -> PLCRmodY10

Not used When this signal goes ON, the system enters the Centronics communication mode (robot output), and the Y0-Y7 input switches to Rdat.

RdatY0-Y7

Not used Command or data output to PLC side

RstbY11

Not used If Rstb is turned ON when Rmod is ON and Pbsy is OFF, the PLC side receives data and (after reception) sends Pack to the robot. When the PLC side receives Pack, Rstb goes OFF.

PbsyX2A

Not used This is set to ON when the PLC side cannot receive data (During data reception etc.)

PackX2B

Not used When the PLC side receives Rstb and finishes reading data, Pack is turned ON. When Rstb goes OFF, Pack also goes OFF.

PmodX28

When this signal goes ON, the system enters the Centronicscommunications mode (PLC output) and the X10-X17 input switches to Pdat

Not used

PdatX10-X17

Output of command or data to robot side

Not used

PstbX29

If Pstb is turned on when Pmod is ON and Rbsy is OFF, the robot sidereceives data, and (after data reception) sends Rack to the PLC

Not used

RbsyY12

This is turned ON when the robot side cannot receive data (during data reception etc.) When this signal is ON, the PLC Pstb cannot be turned ON.

Not used

RackY13

When the robot side receives Pstb and finishes reading data, Rack isturned ON. When Pstb goes OFF, Rack also goes OFF.

Not used

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3.4.Send/Receive Timing in Centronics CommunicationThe timing chart for Centronics communication is as follows. The flowof signal passing is expressed in the diagram.3.4.1. Centronics communication timing chart

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Example 2: Ordinary Centronics communication

PLC RobotTurn ON Pmod, and communication is set to Centronics communication.

Within 5 secs

Send the next data after checking that receiving station is not busy, and turn ON strobe.

State where Rbsy is not ON.

Data receptionSend Rack ON

Within 500msTurn OFF Pstb

Turn OFF Rack

NULL receptionSend Rack ON

Within 500msTurn OFF Pstb Turn OFF Rack

Send data after checking that receiving station is not busy, and

turn Pstb ON.

Pmod

Pdat

Rack

COMMAND DATA DATA NULL

Example 1: PLC -> Robot

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*The transmitting station checks that the receiving station is not busy, and then sends data if the receiving side is not busy. If the receiving side is busy, the sending side cannot send data, so the system waits until the busy signal is OFF.

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PLC RobotTurn ON Pmod, and communication is set to Centronics communication.

Within 5 secs

Rbsy is ON

Send Rack ONWithin 500ms

Turn OFF Pstb Turn Rack OFF

Robot is busy, so data cannot be send.

Send data after checking that receiving station is not busy, and turn Pstb ON.

Data reception

Pstb goes OFF

Data reception

Send Rack ON

After checking (with a retry) that the receiving station is not busy, turn ON Pstb.

Rbsy is OFF

Example 3: Receiving side busy

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3.5.Time Constraints in Centronics CommunicationThere are time constraints when sending command/data from PLC to robot. (Nos. are subcodes of error codes.)When the following constraints are violated, a PLC P-I/O error (62) results.Subcode Nature of constraint.05 When Rack is received (when robot side data reading is complete),

the PLC must turn OFF Pstb within 500ms.06 After Pmod goes ON and the system switches to Centronics

communication, the PLC must turn ON Pstb and output a data read request to the robot side within 5 seconds.

07 After the robot side receives NULL data and turns Rack OFF, the PLC must turn OFF Pmod and complete communication within 500ms. When sending command/data from robot to PLC. (Nos. are subcodes of error codes.)

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When sending command/data from robot to PLC. (Nos. are subcodes of error codes.)When the following constraints are violated, a PLC P-I/O error results.Subcode Nature of constraint01 The PLC must always turn Pack OFF when communication from the robot

is starting02 When Rstb has gone ON during PLC Pbsy output, the PLC must turn

OFF Pbsy within 2 seconds03 After Rstb has gone ON, the PLC must complete data reading and turn

ON Pack within 500ms.04 After the robot side has turned OFF Rstb, the PLC must turn OFF

Pack within 500ms.

*If processing does not finish, even though time equivalent to at least the communicated data length (bytes) x 1 second has passed since the start of processing, then error 62-11 is output. The data length varies depending on the communication content.Example: Count initialization is 4 bytes, so the time to error is 4 seconds.

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3.6.Details of Robot PLC DataThe following types of data are sent from the robot to the PLC

1. Pattern information 2. Conveyor reset 3. Conveyor zero reset 4. Counter setting 5. Conveyor manual 6. No program for ID No. 7. Overall time, automatic operation time 8. Data memory output 9. Product dimension output10. Error code output11. Conveyor data read12. Response of writing request to data memory

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3.6.1. Pattern informationThe term "pattern information" means the content of the stacking pattern program. The elevation of stoppers and other mechanisms can be controlled by sending pattern information to the PLC. If there has been a conveyor pattern request 4.2 (2-b) or pattern data request for pallet no. 3.2 (2-d) from the PLC, the pattern information data is send from the robot. Even when product type setting has been done, pattern information data is sent from the robot.

Details on pattern information are as follows.Details of each piece of information are always expressed with 8 bits.NULL is always attached at the end of pattern information data. Theshaded bits vary in value depending on the data. (Values are fixed forunshaded bits.)

1. CommandThis signal indicates that data is pattern information. The command is fixed: 0X80

HEX D7 D6 D5 D4 D3 D2 D1 D080 1 0 0 0 0 0 0 0

2. ID No.This signal indicates an ID No. ID Nos. fall in the range 1~27, and bits D0~D6 are used. D7 is fixed at "0".

[Example]: IDNo.=95HEX D7 D6 D5 D4 D3 D2 D1 D05F 0 1 0 1 1 1 1 1

3. Program No.This signal indicates a program No. Program Nos. fall in the range 1~999. D0~D5 are used by high order 6bits and low order 6bits, in that order. D6 is fixed at "1", and D7 is fixed at “0”..

[Example] Program No. = 120HEX D7 D6 D5 D4 D3 D2 D1 D041 0 1 0 0 0 0 0 138 0 1 1 1 1 0 0 0

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4. Pallet No.This signal indicates a pallet No. Pallet Nos. fall in the range 1~4, and bits D0~D2 are used. D3~D7 are fixed at "0".

[Example] Pallet No. = 3HEX D7 D6 D5 D4 D3 D2 D1 D003 0 0 0 0 0 0 1 1

5. Number of layersThis signal indicates the number of layers for stacking. The number of stacking layers falls in the range 1~63 (The range can be extended to 1~127 by turning OFF switch SW3-5) and bits D0~D5 are used. D6~D7 are fixed at "0".

[Example] Number of layers = 12 layersHEX D7 D6 D5 D4 D3 D2 D1 D00C 0 0 0 0 1 1 0 0

6. Stacking patternThis signal indicates the pattern for stacking. The following four types of stacking pattern are available, and bits D0~D2 are used. Bits D3~D7 are fixed at "0".

Layer information 1=Column stacking Layer information 2=Alternating stacking Layer information 3=Special stacking Layer information 4=RP mode (Stacking into pyramid shape)[Example] Stacking pattern = RP mode

HEX D7 D6 D5 D4 D3 D2 D1 D004 0 0 0 0 0 1 0 0

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7. Stacking quantityThis signal indicates the stacking quantity in the first layer. The stacking quantity falls in the range 1~127, and bits D0~D6 are used. D7 is fixed at "0".

[Example] Stacking quantity = 8 piecesHEX D7 D6 D5 D4 D3 D2 D1 D008 0 0 0 0 1 0 0 0

8. Layer number of quantity dataThis signal is added when “Lay data addition" is “Yes”. (see: 2.5)The layer number falls in the range 1~63, and bits D0~D5 are used. D6~D7 are fixed at "1".

[Example] Layer beginning data = 40HEX D7 D6 D5 D4 D3 D2 D1 D0E4 1 1 1 0 1 0 0 0

Although “Lay data addition" is “No”, if “All Special Advice” is “Yes”, this signal is added for special stacking. (see 2.5)The layer number falls in the range 1~31, and bits D0~D4 are used. D5~D6 are fixed at "1". D7 is fixed at "0".

[Example] Layer beginning data = 20HEX D7 D6 D5 D4 D3 D2 D1 D074 0 1 1 1 0 1 0 0

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9. Quantity dataThis signal indicates data on each individual product. In the case of column stacking, data is created for all products on the first layer. In the case of alternating stacking, data is created for all products on the first two layers. In the case of special stacking, data is created for all products for the distinctive layers. The bits used vary depending on whether the layer is the same or distinctive.

● Meaning of each bitD7 D6 D5 D4 D3 D2 D1 D0

Same layer flag (Sam

e layer = 1 / Distinctive layer = 0)

Distinctive layer = 1 (Null prevention), Sam

e layer = 0

Auxiliary flag (Distinctive layer)

Auxiliary flag (Distinctive layer) / Num

ber of layers (Same layer)

Auxiliary flag (Distinctive layer) / Num

ber of layers (Same layer)

1 layer end (No end = 0 / End = 1)

Hand closed (Open = 0 / Closed = 1)

Turn (Yes = 1 / No = 0)

- When same layer flag = 1, bits D0~D4 indicate the number of layerswhere the same pattern is used.

● Same/Distinctive layersThe term "distinctive layer" means that there is no pattern for the layer to be stacked. The term "same layer" means that the pattern to be stacked is the same as the previous layer (in alternating stacking, this means layer 3 is the same as layer 1, and layer 4 is the same as layer.Distinctive layers are used in special stacking and in RP mode.

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● Same layer data content[Example] First layer stacking quantity is 8 pieces.

Turn: There is a turn only at the 8th pieceHand: Hand closes at pieces 1, 2, 5, 6, 8 (Multiple pick-up)Same layer flag: Distinctive layer

Stacking quantity for the second layer is 8 pieces.Turn: There is a turn only at the 2nd and 6th pieces.

Hand: Hand closes at pieces 1, 2, 5, 6, 8 Same layer flag: Distinctive layer

The 3rd layer is the same as the 1st layer (Same layer during special stacking)The 4th layer is the same as the 2nd layer (Same layer during special stacking)

Qty. HEX D7 D6 D5 D4 D3 D2 D1 D0 Qty. HEX D7 D6 D5 D4 D3 D2 D1 D01 42 0 1 0 0 0 0 1 0 1 42 0 1 0 0 0 0 1 02 42 0 1 0 0 0 0 1 0 2 43 0 1 0 0 0 0 1 13 40 0 1 0 0 0 0 0 0 3 40 0 1 0 0 0 0 0 04 40 0 1 0 0 0 0 0 0 4 40 0 1 0 0 0 0 0 05 42 0 1 0 0 0 0 1 0 5 42 0 1 0 0 0 0 1 06 42 0 1 0 0 0 0 1 0 6 43 0 1 0 0 0 0 1 17 40 0 1 0 0 0 0 0 0 7 40 0 1 0 0 0 0 0 08 47 0 1 0 0 0 1 1 1 8 46 0 1 0 0 0 1 1 0

1st layer 2nd layer

Layer HEX D7 D6 D5 D4 D3 D2 D1 D0 Layer HEX D7 D6 D5 D4 D3 D2 D1 D03 81 1 0 0 0 0 0 0 1 4 82 1 0 0 0 0 0 1 0

3rd layer (Same as 1st layer) 4th layer (Same as 2ndlayer)

HEX D7 D6 D5 D4 D3 D2 D1 D0Null 0 0 0 0 0 0 0 0 0

End of data

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10. Example of send data Column stackingHEX D7 D6 D5 D4 D3 D2 D1 D0 Current setting Data content80 1 0 0 0 0 0 0 0 128 Command5F 0 1 0 1 1 1 1 1 95 ID No.

41 0 1 0 0 0 0 0 1 Prg120 Prg No. high order 6 bits38 0 1 1 1 1 0 0 0 Prg No. low order 6 bits03 0 0 0 0 0 0 1 1 3 Pallet No.04 0 0 0 0 0 1 0 0 4 Number of layers01 0 0 0 0 0 0 0 1 1(Column tacking) Stacking pattern08 0 0 0 0 1 0 0 0 8 Stacking quantity for each layerC1 1 1 0 0 0 0 0 1 1st layer Quantity data start42 0 1 0 0 0 0 1 0 1st quantity data42 0 1 0 0 0 0 1 0 2nd quantity data40 0 1 0 0 0 0 0 0 3rd quantity data40 0 1 0 0 0 0 0 0 4th quantity data41 0 1 0 0 0 0 0 1 5th quantity data41 0 1 0 0 0 0 0 1 6th quantity data40 0 1 0 0 0 0 0 0 7th quantity data47 0 1 0 0 0 1 1 1 8th quantity data + layer end0 0 0 0 0 0 0 0 0 0 NULL(Data terminator)

*1: This text is sent only when “Program No. Addition” mode. (cf. 2.5 External PLC communication set up)

*2: This text is sent only when “Layer Date Addition” mode. (cf. 2.5 External PLC communication set up)

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Alternating stacking

HEX D7 D6 D5 D4 D3 D2 D1 D0 Current setting Data content 80 1 0 0 0 0 0 0 0 128 Command5F 0 1 0 1 1 1 1 1 95 ID No.41 0 1 0 0 0 0 0 1 Prg120 Prg No. high order 6 bits38 0 1 1 1 1 0 0 0 Prg No. low order 6 bits03 0 0 0 0 0 0 1 1 3 Pallet No.04 0 0 0 0 0 1 0 0 4 layers Number of layers02 0 0 0 0 0 0 1 0 2

(Alternating stacking)Stacking pattern

08 0 0 0 0 1 0 0 0 8 pieces Stacking quantity in each layer

C1 1 1 0 0 0 0 0 1 1st layer 1st layer data start42 0 1 0 0 0 0 1 0 1st quantity data42 0 1 0 0 0 0 1 0 2nd quantity data40 0 1 0 0 0 0 0 0 3rd quantity data40 0 1 0 0 0 0 0 0 4th quantity data41 0 1 0 0 0 0 0 1 5th quantity data41 0 1 0 0 0 0 0 1 6th quantity data40 0 1 0 0 0 0 0 0 7th quantity data47 0 1 0 0 0 1 1 1 8th quantity data + layer

endC2 1 1 0 0 0 0 1 0 2nd layer 2nd layer data start 42 0 1 0 0 0 0 1 0 1st quantity data42 0 1 0 0 0 0 1 0 2nd quantity data40 0 1 0 0 0 0 0 0 3rd quantity data40 0 1 0 0 0 0 0 0 4th quantity data41 0 1 0 0 0 0 0 1 5th quantity data41 0 1 0 0 0 0 0 1 6th quantity data40 0 1 0 0 0 0 0 0 7th quantity data47 0 1 0 0 0 1 1 1 8th quantity data + layer

end0 0 0 0 0 0 0 0 0 0 NULL(Data terminator)



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When there is same layer setting for special stacking and “Layer Data Addition” is “Yes”. (3rd layer is the same as 1st layer, and 4th layer is the same as 2nd layer)

HEX D7 D6 D5 D4 D3 D2 D1 D0 Current setting Data content80 1 0 0 0 0 0 0 0 128 Command5F 0 1 0 1 1 1 1 1 95 ID No.

41 0 1 0 0 0 0 0 1 Prg120 Prg No. high order 6 bits38 0 1 1 1 1 0 0 0 Prg No. low order 6 bits03 0 0 0 0 0 0 1 1 3 Pallet No.04 0 0 0 0 0 1 0 0 4 layers Number of layers03 0 0 0 0 0 0 1 1 3

(Special stacking)Stacking pattern

08 0 0 0 0 1 0 0 0 8 pieces Stacking quantity in each layerC1 1 1 0 0 0 0 0 1 1st layer 1st layer data start42 0 1 0 0 0 0 1 0 1st quantity data42 0 1 0 0 0 0 1 0 2nd quantity data40 0 1 0 0 0 0 0 0 3rd quantity data40 0 1 0 0 0 0 0 0 4th quantity data41 0 1 0 0 0 0 0 1 5th quantity data41 0 1 0 0 0 0 0 1 6th quantity data40 0 1 0 0 0 0 0 0 7th quantity data47 0 1 0 0 0 1 1 1 8th quantity data + layer endC2 1 1 0 0 0 0 1 0 2nd layer 2nd layer data start 42 0 1 0 0 0 0 1 0 1st quantity data42 0 1 0 0 0 0 1 0 2nd quantity data40 0 1 0 0 0 0 0 0 3rd quantity data40 0 1 0 0 0 0 0 0 4th quantity data41 0 1 0 0 0 0 0 1 5th quantity data41 0 1 0 0 0 0 0 1 6th quantity data40 0 1 0 0 0 0 0 0 7th quantity data47 0 1 0 0 0 1 1 1 8th quantity data + layer endC3 1 1 0 0 0 0 1 1 3rd layer 3rd layer data start81 1 0 0 0 0 0 0 1 Same layer

(1st layer) Same layer flag

C4 1 1 0 0 1 0 0 0 4th layer 4th layer data start82 1 0 0 0 0 0 1 0 Same layer

(2nd layer) Same layer flag

0 0 0 0 0 0 0 0 0 0 NULL (Data terminator)



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When there is same layer setting for special stacking and “Layer Data Addition” is “No”. (3rd layer is the same as 1st layer and 4th layer is the same as 2nd layer)

HEX D7 D6 D5 D4 D3 D2 D1 D0 Current Setting

Data contents

80 1 0 0 0 0 0 0 0 128 Command5F 0 1 0 1 1 1 1 1 95 ID No.

41 0 1 0 0 0 0 0 1 Prg120 Prg No. high order 6 bits38 0 1 1 1 1 0 0 0 Prg No. low order 6 bits03 0 0 0 0 0 0 1 1 3 Pallet No.04 0 0 0 0 0 1 0 0 4th layer Number of layers03 0 0 0 0 0 0 1 1 3

(Special stacking)

Stacking pattern

08 0 0 0 0 1 0 0 0 8 pieces Stacking quantity in each layer61 0 1 1 0 0 0 0 1 1st layer 1st layer data start42 0 1 0 0 0 0 1 0 1st quantity data42 0 1 0 0 0 0 1 0 2nd quantity data40 0 1 0 0 0 0 0 0 3rd quantity data40 0 1 0 0 0 0 0 0 4th quantity data41 0 1 0 0 0 0 0 1 5th quantity data41 0 1 0 0 0 0 0 1 6th quantity data40 0 1 0 0 0 0 0 0 7th quantity data47 0 1 0 0 0 1 1 1 8th quantity data + layer end62 0 1 1 0 0 0 1 0 2nd layer 2nd layer data start 42 0 1 0 0 0 0 1 0 1st quantity data42 0 1 0 0 0 0 1 0 2nd quantity data40 0 1 0 0 0 0 0 0 3rd quantity data40 0 1 0 0 0 0 0 0 4th quantity data41 0 1 0 0 0 0 0 1 5th quantity data41 0 1 0 0 0 0 0 1 6th quantity data40 0 1 0 0 0 0 0 0 7th quantity data47 0 1 0 0 0 1 1 1 47 8th quantity data + layer end63 0 1 1 0 0 0 1 1 3rd layer 3rd layer data start81 1 0 0 0 0 0 0 1 Same layer

(1st layer)Same layer flag

64 0 1 1 0 1 0 0 0 4th layer 4th layer data start82 1 0 0 0 0 0 1 0 Same layer

(2nd layer) Same layer flag



*2: This text is sent only when “Layer Data Addition” is “No” and “All Special Data

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Advice” is “Yes”. (cf. 2.5 External PLC communication set up)

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When “All Special Data Advice” is “No”.

HEX D7 D6 D5 D4 D3 D2 D1 D0 Current Setting Data contents80 1 0 0 0 0 0 0 0 128 Command5F 0 1 0 1 1 1 1 1 95 ID No.

41 0 1 0 0 0 0 0 1 Prg120 Prg No. high order 6 bits38 0 1 1 1 1 0 0 0 Prg No. low order 6 bits03 0 0 0 0 0 0 1 1 3 Pallet No.04 0 0 0 0 0 1 0 0 4th layer Number of layers03 0 0 0 0 0 0 1 1 3

(Special stacking)Stacking pattern

08 0 0 0 0 1 0 0 0 8 pieces Stacking quantity in each layer



3.6.2. Conveyor reset When conveyor reset operation is performed using the conveyor manual screen on the robot control panel, the following data is output. Conveyor reset performs resetting of the number of stacking layers/quantity/conveyor for the robot.

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content82 1 0 0 0 0 0 1 0 Conveyor reset command0 0 0 0 0 0 0 0 0 NULL: Data end

3.6.3. Conveyor zero reset When conveyor zero reset operation is performed using the conveyor manual screen on the robot control panel, the following data is output. Conveyor zero reset performs reset of the just the station conveyor. The command value is fixed. For the station no., bits D3~D7 are fixed at "0" and bits D0~D2 indicate the station No.

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content83 1 0 0 0 0 0 1 1 Conveyor zero reset command03 0 0 0 0 0 0 1 1 Station conveyor no. Example: Conveyor No. 30 0 0 0 0 0 0 0 0 NULL: Data end

3.6.4. Counter settingSetting correction or initialization is executed from the stacking counter correction screen on the robot control panel, the changed values are output using the following data. When the counter is initialized, the numbers of layers and pieces are set to "0".

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content

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84 1 0 0 0 0 1 0 0 Counter setting command06 0 0 0 0 0 1 1 0 ID No.

03 0 0 0 0 0 0 1 1 Pallet No. (Using D0~D2 bit).Example: Pallet No. 3

48 0 1 0 0 1 0 0 0 Layer data (Using D0~D5 bit). Example: Layer 849 0 1 0 0 1 0 0 1 Quantity data (Using D0~D5 bit).

Example: 9 pieces0 0 0 0 0 0 0 0 0 NULL: Data end

*1: When counter setting initialization or correction has been performed, the internal data memory in the robot is rewritten (current stacking program). The following number of layers is displayed on the robot side, so the sent data is as follows.

Layer data = Layer counter value (displayed value) –1

*2: Quantity data is also processed the same as layer data. Quantity data = Quantity counter value (displayed value) –1

3.6.5. Conveyor manualWhen the conveyor setting has been changed using the setting/cancel keys on the conveyor manual screen of the robot control panel, the following data is output.

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content85 1 0 0 0 0 1 0 1 Counter setting command50 0 1 0 1 0 0 0 0 Data 1. Bits D0~D5 indicate conveyors 1~6.

Example: 548 0 1 0 0 1 0 0 0 Data 2. Bits D0~D5 indicate conveyors 1~7.

Example: 1042 0 1 0 0 0 0 1 0 Data 3. Bits D0~D4 indicates conveyors 13~16.

Example: 140 0 0 0 0 0 0 0 0 NULL: Data end

3.6.6. No program for ID no.If there is no program for an ID No. designated from the PLC, this fact is determined at ID No. strobe reception, and this data is output. If there has been a pattern data request (2-b, 2-d) from the PLC, and there was no program for the designated ID No., this data is output when pattern data is requested.


86 1 0 0 0 0 1 1 0 Command when there is no program for the ID No.

03 0 0 0 0 0 0 1 1 Use bits D0~D2 for pallet. Example: Pallet No. 30 0 0 0 0 0 0 0 0 NULL: Data end

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3.6.7. Overall time, automatic operation timeIn response to a request from the PLC (2-g), the overall time and automatic operation time are output using the following data.


88 1 0 0 0 1 0 0 0 Command for overall time, automatic operation time

40 0 1 0 0 0 0 0 0 Bits 18~23 of overall time are indicated with bits D0~D5.




40 0 1 0 0 0 0 0 0 Bits 18~23 of automatic operation time are indicated with bits D0~D5

40 0 1 0 0 0 0 0 0 Bits 12~17 of automatic operation time are indicated with bits D0~D5

40 0 1 0 0 0 0 0 0 Bits 6~11 of automatic operation time are indicated with bits D0~D5.

40 0 1 0 0 0 0 0 0 Bits 1~5 of automatic operation time are indicated with bits D0~D5.

0 0 0 0 0 0 0 0 0 NULL: Data end

Total time and automatic operation time are indicated with 23 bits, so they are sent by segmenting the data into 6 bit units.

3.6.8. Data memory outputIn response to a request from the PLC (2-h), the content of robot data memory is output using the following data.

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content89 1 0 0 0 1 0 0 1 Data memory output command41 0 1 0 0 0 0 0 1 Data memory No. data higher-order 6 bits43 0 1 0 0 0 0 1 1 Data memory No. data lower-order 6 bits40 0 1 0 0 0 0 0 0 Data memory 1 is indicated with the 6 bits of

D12~D1740 0 1 0 0 0 0 0 0 Data memory 1 is indicated with the 6 bits of

D6~D1140 0 1 0 0 0 0 0 0 Data memory 1 is indicated with the 6 bits of

D0~D50 0 0 0 0 0 0 0 0 NULL: Data end

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3.6.9. Product dimension outputWhen there is a request from the PLC (2-i), dimensions are output using the following data.

Units are mm.HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content8C 1 0 0 0 1 1 0 0 Command for product dimension data output127 0 1 1 1 1 1 1 1 ID No. Example: ID No. 12744 0 1 0 0 0 1 0 0 Product length data higher-order 6 bits, Length

300mm=12C6C 0 1 1 0 1 1 0 0 Product length data lower-order 6 bits43 0 1 0 0 0 0 1 1 Product width data higher-order 6 bits, Width

250mm=FA7A 0 1 1 1 1 0 1 0 Product width data lower-order 6 bits43 0 1 0 0 0 0 1 1 Product height data higher-order 6 bits, Height

200mm =C848 0 1 0 0 1 0 0 0 Product height data lower-order 6 bits0 0 0 0 0 0 0 0 0 NULL: Data end

3.6.10. Error code outputWhen a robot error occurs, the error content is output to the PLC using the following data. This is done to notify the PLC of the error content. Applicable error codes range from "0" to "99". However, this is effective only when “Transmit error code to PLC” mode. (cf. 2.5 External PLC communication set up)

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content87 1 0 0 0 0 1 1 1 Error output command01 0 0 0 0 0 0 0 1 Error No. (7F in the case of "0") Subcode 1

40 0 0 1 0 0 0 0 0 Error sub-No. (7F in the case of "0") Subcode 32

0 0 0 0 0 0 0 0 0 NULL: Data end

3.6.11. Response for allocation of PRG No. for ID No.In response to a request from the PLC (2-e), the content of robot data memory is output using the following data.

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content8A 1 0 0 0 0 1 1 0 Command for no program to ID.06 0 0 0 0 0 1 1 0 ID No.41 0 1 0 0 0 0 0 1 Program No. data higher-order 6 bits43 0 1 0 0 0 0 1 1 Program No. data lower-order 6 bits0 0 0 0 0 0 0 0 0 NULL: Data end

-If the requested ID No. is abnormal or the program No. doesn’t exist, 7F(HEX) is set for both high and low order bits of program No.. And it diesn’t allocate in this case.

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3.6.12. Response of writing request to data memory

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content8B 1 0 0 0 1 0 1 1 Response command is “8B”41 0 1 0 0 0 0 0 1 Actual written data word numbers （ example.

1）40 0 1 0 0 0 0 0 0 Result0 0 0 0 0 0 0 0 0 NULL

Result: 0 (40H) Processing ended correctly.1 (41H) Address range over.2 (42H) Format is abnormal. The error whose number of words is out of range is included.

If the result is not 0, all data are not changed.

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3.7.Details of PLC Robot DataThe following types of data are sent from the PLC to the robot.

1. PLC error code2. Pattern data request from conveyor3. Count setting from conveyor4. Pattern data request for pallet No.5. Allocation of PRG No. for ID No.6. Stacking height setting7. Request for robot overall time, automatic operation time8. Data memory content request9. Product dimension request

10. Sequence reset request11. Allocation of PRG No. for ID No. and pattern data request12. Writing request to Data memory

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3.7.1. PLC error code When this signal is received from the PLC, a message (stored at error No. + 100) and subcode are displayed at the error data No. on the robot control panel CRT.


90 1 0 0 1 0 0 0 0 Output of PLC error mode signal. Command "80" or "90"

2 0 0 0 0 0 0 1 0 Error data No. (1~99)1 0 0 0 0 0 0 0 1 Error sub No. (7F in the case of "0"), Lower order

bits1 0 0 0 0 0 0 0 1 Error sub No. Example: Subcode is 65, Higher

order bits0 0 0 0 0 0 0 0 0 NULL: Data end

3.7.2. Pattern data request from conveyor Command to request pattern information to robot controller


91 1 0 0 1 0 0 0 1 Pattern data request command. Command is "81" or "91"

03 0 0 0 0 0 0 1 1 Pallet No. Example: Pallet No. 37F 0 1 1 1 1 1 1 1 ID No. (The ID No. can be omitted). Example: ID

No. 1270 0 0 0 0 0 0 0 0 NULL: Data end

*The ID No. can be omitted.

3.7.3. Count setting from conveyorCommand to change the count value of the program of robot controller's corresponding ID No.If the ID No. is 0xFF, or if the highest order bit (D7) is ON ("1"), all programs are initialized. (In this case, the subsequent data field is ignored.)

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content92 1 0 0 1 0 0 1 0 Count setting command from PLC. "82" or "92"10 0 0 0 1 0 0 0 0 ID No. Example ID No.=1642 0 1 0 0 0 0 1 0 Layer number data

(Example: When robot layer counter is "3")43 0 1 0 0 0 0 1 1 Quantity data

(Example: When robot quantity count is "4")0 0 0 0 0 0 0 0 0 NULL: Data end

*1: For layer number data sent from PLC to robot, use the layer number obtained by subtracting "1" from the number of layers the robot will stack.

PLC layer number = Robot layer number - 1 layer *2: For quantity data sent from PLC to robot, use the quantity obtained by subtracting "1" from the quantity the robot will stack.

PLC quantity = Robot quantity - 1 piece

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3.7.4. Pattern data request for pallet No.Command to request to robot controller pattern information corresponding palette No..


93 1 0 0 1 0 0 1 1 Pattern data request for pallet No. Command is "83" or "93".

04 1 0 0 0 0 1 0 0 Pallet No. Example: Pallet No. 40 0 0 0 0 0 0 0 0 NULL: Data end

3.7.5. Allocation of PRG No. for ID No.Command to allocates program No. to robot controller's ID No.


94 1 0 0 1 0 1 0 0 Command for allocating PRG No.to ID No. Command is "84" or "94".

06 0 0 0 0 0 1 1 0 ID No. Example: ID No. 641 0 1 0 0 0 0 0 1 Higher order 6 bits of program No.43 0 1 0 0 0 0 1 1 Lower order 6 bits of program No.67 hex in this

example0 0 0 0 0 0 0 0 0 NULL: Data end

After receiving data successfully, robot sends back the following data to PLC.(If program No. is invalid 0x7F will send as program No. data).HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content

8A 1 0 0 0 0 1 1 0 Command for sending back allocating PRG No.data

06 0 0 0 0 0 1 1 0 ID No. Example: ID No. 641 0 1 0 0 0 0 0 1 Higher order 6 bits of program No.43 0 1 0 0 0 0 1 1 Lower order 6 bits of program No. 67 hex in this


3.7.6. Stacking height setting (DA1800 model only)This setting is special for the DA1800 (Robo-gator). When SW1-1 is ON, and this signal is received from the PLC, the height data in step 7 is changed to the setting in the received signal. In the following, the height in step 7 of the program with ID No. 6 is set to 69mm.


95 1 0 0 1 0 1 0 1 Command for changing height in step 7 of program. The command is "85" or "95"

06 0 0 0 0 0 1 1 0 ID No. Example: ID No. 641 0 1 0 0 0 0 0 1 Height data, higher order 6 bits45 0 1 0 0 0 1 0 1 Height data, lower order 6 bits, 69hex in the


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3.7.7. Request for robot overall time, automatic operation timeCommand to request for robot overall time, automatic operation time to robot controller.


96 1 0 0 1 0 1 1 0 Request command for robot overall time/automatic operation. The command is "96".

0 0 0 0 0 0 0 0 0 NULL: Data end

3.7.8. Data memory content requestCommand to request content of robot controller's corresponding data memory


97 1 0 0 1 0 1 1 1 Data memory content request command. The command is "97".

42 0 1 0 0 0 0 1 0 Data memory, higher order 6 bits43 0 1 0 0 0 0 1 1 Data memory lower order 6 bits0 0 0 0 0 0 0 0 0 NULL: Data end

3.7.9. Product dimension requestCommand to request product dimension of program corresponding robot controller's ID No.


9C 1 0 0 1 1 0 1 1 Product dimension request command. The command is "9C"

02 0 0 0 0 0 0 1 0 ID No.0 0 0 0 0 0 0 0 0 NULL: Data end

3.7.10. Sequence reset requestCommand to make robot controller compulsorily sequence reset.


9D 1 0 0 1 1 1 0 1 Request command for sequence reset.The command is "9D".

0 0 0 0 0 0 0 0 0 NULL: Data end

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3.7.11. Allocation of PRG No. for ID No. and pattern data requestCommand to make robot controller compulsorily sequence reset.


9E 1 0 0 1 1 1 0 1 Request command for sequence reset.The command is "9D".

06 0 0 0 0 0 1 1 0 ID No.41 0 1 0 0 0 0 0 1 Program No. data higher-order 6 bits43 0 1 0 0 0 0 1 1 Program No. data lower-order 6 bits0 0 0 0 0 0 0 0 0 NULL: Data end

3.7.12. Writing request to Data memory

One word is consisted of 16 bits.

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content98 1 0 0 1 1 0 0 0 Data memory write command “98”4F 0 1 0 0 1 1 1 1 Start address high 6bitt （example. D1000）68 0 1 1 0 1 0 0 0 Start address low 6bit41 0 1 0 0 0 0 0 1 Data BIT15 to BIT12 （example. 1234H）48 0 1 0 0 1 0 0 0 Data BIT11 to BIT674 0 1 1 1 0 1 0 0 Data BIT5 to BIT0

Some data continues.

0 0 0 0 0 0 0 0 0 NULL:

1) Address range 1000 to 2999 (3E8H to BB7H)2) Word numbers range 1 to 5 words3) Data range 0 to 65535 (0H to FFFFH)4) NULL Terminator

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4. SETUP

4.1.Origin StoringAn operation for calculating an origin offset automatically and setting is called origin storing.Origin storing is required the following cases.

A. When encoder cable at motor connector is disconnected.B. When an [Encoder Battery Voltage Drop] set the latch occurred.（＊１）

Procedure for moving to the origin storing screen is as follows.

System storing menu Origin storing

[ Operating procedure ]①With manual operation, move the axis to be stored to the basic position

Operating position of each axis should be as followsR, D and O ; A matching mark positionT ; The hand is parallel or 90 degree rotated with the arm

②Press the appropriate axis button to be stored③Press STORE key to store the origin.

However, when motors, etc. are replaced, do "Temporal storing" just to move arm near the origin first in PTP mode then do the origin storing second. CP / PM mode doesn't work for manual operation during Temp-storing. Cycle main power every after Temp-storing or Storing is done.

④Current position (pulse) of a stored axis should be within range of0 - 65535 pulse upon completion of storing in good order

* If an error occurs during the above operation (1), move arm holding an abnormal reset button pressed down. The operation works only at PTP mode (one motor driven at a time).

Important! (Caution when Temporal-storing is required other than the origin storing)Do "Temporal storing" just to move arm near the origin first when motors, etc. are replaced then do the origin storing second. CP / PM mode doesn't work for manual operation during Temp Storing.

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（＊１） In case of "Encoder Battery Voltage Drop", The axis can be specified by the Error Message Sub No.

1 (Bit 0): D axis2 (Bit 1): O axis4 (Bit 2): R axis8 (Bit 3): T axis

When the errors in the two or more axes are generated, Sub No. becomes a total of the number.

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Danger Enforcement

The origin storing must be appropriately conducted keeping each axis of arm at the exact matching mark position. Otherwise, arm may hit the peripheral equipment.

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4.2.Collision DetectionIn 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!This 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.

4.2.1. 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 small 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 it is 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.

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4.3.Standard StorageWhen the robot is set in the base posture, and standard storage is performed, the

system reads the encoder pulse and amount of shift (number of pulses) from the robot base posture, and the offset value is automatically calculated.

For R-axis, standard storage can be done at the 90 degree and –90 degrees positions in addition to the standard 0 degree, so select this position to suit the operating range.

Axis Base posture How to set to base posture

R

Robot arm orienting the opposite direction of the base wiring connector is taken as the origin.

Move the R-axis, and align the match marks on the base and rotor.Example)A1800

D

0 degree (horizontal) is taken as the origin. Move the D-axis and align the

match marks on the rotor and lever.

90 degrees (vertical) is taken as the origin.

Move the O-axis and align the match marks on the rotor and arm.

T

Hand palm setting parallel to the robot arm is taken as the origin (See diagram below). Standard wiring for hand circles 2 times around T-axis flange.

Move the T-axis and align the match marks.(See 4.4. How to attach the hand to robot)

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Origin

origin

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4.4. How to place the optional stopper

【A1800】

1. OutlinesStandard mechanical stopper cam can allow robot arm to make smaller foot print.Area "A" can be used for programming only when the cam is taken away.* Extreme end stops for moving forward and backward still work when no cam is mounted.

(a) When standard mechanical stopper cams are mounted

(b) When standard mechanical stopper cams are removed

Figure 1: Operation range with/without mechanical stopper cams

2. How to remove mechanical stopper cams

(1) Get robot arm at basic posture - operate in manual mode.

(2) Not unbolt but just loosen the bolts a bit.

(3) Remove parallel pins.

Be careful with loose stopper cams as they may move.

(4) Unbolt and take the cams away.

* Remove the other side of cam.

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Fixing bolt

Standard mechanical stopper cam

Parallel pins

2676 mm 2929 mm

A

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【A400III/A700III】

1. OutlineThis optional stopper uses for to make robot operation range as same as A700. See figure 1 for operation range.

Figure 1:A400III, A700III operation range

2. How to place the optional stopper①A robot is manually moved to the position which can perform attachment of a stopper.　　Required position : D-axis 0-10degrees(O axis angle is arbitrary)②A stopper is attached as shown in a figure.

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With optionalStopper

1318mm

1900mm

1750mm

Without optional stopper

2300mm

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4.5. How to attach the hand to robot1. Put on the hand harness (Hand cable) cover

to hand. Use for A1600III and A1800.

2. Attach the hand to robot. Hand attachment angle is not necessary.

3. Stand front center of robot and rotate the hand until hand is parallel to the robot. Vacuum or any support device attached side is left.

4. Go to the home position store screen then store the current T-axis position. Do not store the any another axis position.

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5. Rotate the hand to 220 degrees (Clockwise).

6. Wind up the hand harness (hand cable) about 2 and half (Clockwise).

7. Connect the hand connectors and an Air hose. Make sure hand harness is not tight. If the hand harness is too tight, rotate the hand to counterclockwise and loosen the hand harness. Then change the T-axis softlimit to current angle.

8. Hand attachment is completed.

8

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4.6.Servo amp replacement To replace a servo amp follow the instruction below.For more easy replacement, take the whole servo amp Box out from the controller and replace the servo amp.

< Procedure to replace servo amp >1. Turn off the main power supply.2. Disconnect the connector to the servo amp and wiring at the terminal block.3. Unscrew and replace the servo amp.4. Connect the disconnected connector or wiring.5. Check the connection above and turn on the main power supply.

NoteFor R,D,O Axis, servo board and IPM(Intelligent Power Module) can be replaced separately.For T Axis,(C Axis option), IPM is connected to the board by solder, so IPM cannot be replaced separately

In case of replacing IPM, seal the thermal compound between heat sink and IPM module, so that to minimize the heat resistance between them.

9

thermal compound 0.5 gGur サーマルコンパウンド約0.5g

Recommended thermal compoundType Maker

G746 Shin-Etsu Chemical SC102 Dow Corning Toray

SiliconeYG6260 GE Toshiba Silicones

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4.7.Spare PartsStocking the most common replacement parts improves productivity by controlling down time, and promotes safe and productive work habits among personnel. Customers are urged to stock the type and quantities shown below.

A1200III, A1600III, A1600III-W, A1800, A1800-WNo. Name Model Qty. Area used1 Switching

regulatorZWQ80-5225 1 Controller (AVR1)

2 Switching regulator

ZWS100AF-24/J 1 Controller (AVR2)

3 Servo Amp 1 Controller4 Electromagnetic

switchSC-N2/G 1 Controller (MC1,2)

5 Electromagnetic switch

SC-N1/G 1 Controller (MC3)

6 Relay G7J-4A-B-KM 1 Controller (RBR)7 Servo Motor SGMGH55 1 Robot (R,D,O)8 Servo Motor SGMPH04 1 Robot (T)9 Battery ER6K-#17-A 1 Controller (CPU board)

Robot (Base)10 Touch Panel UG330H-SS4 1 Controller (TP)

A400III, A700IIINo. Name Model Qty. Area used1 Switching regulator ZWQ80-5225 1 Controller (AVR1)2 Switching regulator ZWS100AF-24/J 1 Controller (AVR2)3 Servo Amp 1 Controller 4 Electromagnetic

switchSC-N1/G 1 Controller (MC1,2)

5 Electromagnetic switch

SC-4-1/G 1 Controller (MC3)

6 Relay G7J-4A-B-KM 1 Controller (RBR)7 Servo Motor TS4836 1 Robot (R,D,O)8 Servo Motor TS4609 1 Robot (T)9 Battery ER6K-#17-A

ER6K-#17-41 Controller (CPU board)

Robot (Base)10 Touch Panel UG330H-SS4 1 Controller (TP)

4.8.At DismantlingA series robot palletizer uses grease for lubricating the gear reducers.The amount of grease for each gear reducer is 2 liters or less.Grease is hazardous and the following should be noted if grease enters through the :

Eyes: Immediately flush with water for at least 15 minutes. Get medical attention if eye irritation persists.

Skin: Remove excess with cloth or paper and wash area thoroughly with soap and water.

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Inhalation: Keep the victim warm and quiet. Remove the victim from the contamination immediately to fresh air.

11

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5. PC Boards

1

RC132I/O Board

RC132I/O Board

RC105Servo Power Supply Board

RC106Safety Relay Board

RC101Main CPU Board

RC103Servo CPU Board

RC107(RC104)*

Current BoardMotor

Motor

Motor

Motor

R axis

D axis

O axis

T axis

Touch PanelPLCOXPATeachingPendant

RC107(RC104)*

Current Board

RC107(RC104)*

Current Board

RC108(RC110)*

Current Board

Hand

*( in case of A400III,A700III)

option

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The boards inside the controller and their configuration are as follows.

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5.1.Main CPU Board（RC101）The arrangement of LED's、switch and 7-segment displays on the Main CPU board is as follows.

LED Explanation

LED　No. Lighting conditionLED1 - 6 Not useLED7 5 V is suppliedLED8 An error occursLED9 Battery voltage drops

Switch Explanation

Switch No. ExplanationS1 CPU reset switch

WARNINGProhibit the using of S1 switch. The Servo Amp becomes damaged when S1 Switch ON in the motor power ON.

3

DSW1

7SEG1LED7 LED8 LED9

S1

CF slot

LED1

LED2

LED3

LED4

LED5

LED6

JP4

JP2 JP3

JP1

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Jumper Explanation

JP. Explanation Normal settingJP1 CPU configuration setting 3-10 shortJP2 Setting for using CPU debugger OpenJP3 CPU configuration setting OpenJP4 Reserved ：Short (do not change) short

DIP switch DSW1 Explanation

No. Explanation Normal setting１ RISC program down load execute OFF２ Debugger use OFF３ No use OFF４ Use of A1200III or A400III OFF５ Motor rotation test mode OFF６ No use OFF７ DSP program down load execute ON８ All memory clear OFF

7-segment Display Explanation

No. Explanation Dot Display１ TLB Miss／Invalid TLB ON：Read　 OFF：Write２ Initial page write exception３ TLB Protection exception ON：Read　 OFF：Write４ CPU address error ON：Read　 OFF：Write５ Unconditional trap６ Reserved instruction exception７ Illegal Slot Instruction８ DMA address error９ User break point exception

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5.2.I／O Board（RC132）The arrangement of LED's and Jumper on the I/O board is as follows.

CN8 CN8

Jumper Explanation

JP. Explanation Ordinary settingJP1 Board Address Select 1st: JP1 short, JP2 open

2nd: JP1 open, JP2 shortJP2JP3 No use (Please do not short.) OpenJP4 Reserved ：1‐2　Short (do not change) 1-2 short

5

ＴＢ４

CN9

D24 D30 D32 D38 D66 D72 D74 D80 D50 D56 D58 D64 D0 D6 D8 014 D16 D22

D25 D31 D33 D39 D67 D73 D75 D81 D51 D57 D59 D65 D1 D7 D9 D15 D17 D23

JP4

JP3JP2JP1

CN1

CN7 CN8 CN11CN10

CN4CN12

CN6CN5

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LED Explanation

Input relay　

D No.Relay No.

D No.Relay No.

D No.Relay No.

D No.Relay No.

1stboard

2ndboard

1stboard

2ndboard

1stboard

2ndboard

1stboard

2ndboard

0 X00 X28 10 X0A X32 20 X14 X3C 30 X1E X461 X01 X29 11 X0B X33 21 X15 X3D 31 X1F X472 X02 X2A 12 X0C X34 22 X16 X3E 32 X20 X483 X03 X2B 13 X0D X35 23 X17 X3F 33 X21 X494 X04 X2C 14 X0E X36 24 X18 X40 34 X22 X4A5 X05 X2D 15 X0F X37 25 X19 X41 35 X23 X4B6 X06 X2E 16 X10 X38 26 X1A X42 36 X24 X4C7 X07 X2F 17 X11 X39 27 X1B X43 37 X25 X4D8 X08 X30 18 X12 X3A 28 X1C X44 38 X26 X4E9 X09 X31 19 X13 X3B 29 X1D X45 39 X27 X4F

Output relay

D No.Relay No.

D No.Relay No.

D No.Relay No.

D No.Relay No.

1stboard

2ndboard

1stboard

2ndboard

1stboard

2ndboard

1stboard

2ndboard

50 Y00 Y20 58 Y08 Y28 66 Y10 Y30 74 Y18 Y3851 Y01 Y21 59 Y09 Y29 67 Y11 Y31 75 Y19 Y3952 Y02 Y22 60 Y0A Y2A 68 Y12 Y32 76 Y1A Y3A53 Y03 Y23 61 Y0B Y2B 69 Y13 Y33 77 Y1B Y3B54 Y04 Y24 62 Y0C Y2C 70 Y14 Y34 78 Y1C Y3C55 Y05 Y25 63 Y0D Y2D 71 Y15 Y35 79 Y1D Y3D56 Y06 Y26 64 Y0E Y2E 72 Y16 Y36 80 Y1E Y3E57 Y07 Y27 65 Y0F Y2F 73 Y17 Y37 81 Y1F Y3F

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5.3.Servo CPU Board（RC103）The arrangement of LED's、switch and 7-segment displays on the servo CPU board is as follows.

LED Explanation

D No. Lighting conditionD1 During sub DSP operation(D,O axis) *D2 During sub DSP operation(R,T axis) *D3 During sub DSP operation(C axis) *D4 Motor power is OND5 Watchdog error occursD6 During main DSP operation *

*: If the light doesn't rotate, it is abnormal (An abnormal cause is uncertain).

DIP switch U3 Explanation

No. Explanation Ordinary setting

1 No use OFF2 No use OFF3 No use OFF4 No use OFF5 No use OFF6 No use OFF7 No use OFF8 No use OFF

7

JP1

U3D1D2D3 D4 D5

D6

JP5

JP2 JP3 JP6

JP11

JP4

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Jumper Explanation

JP. Explanation Normal settingJP1

Reserved (do not change)

1-2 shortJP2 1-2 shortJP3 1-2 shortJP4 All openJP5 All openJP6 1-2 short

JP11

1-2 short3-4 open5-6 short7-8 short9-10 open

11-12 short13-14 open15-16 open17-18 short19-20 short21-22 short23-24 short

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5.4.Servo Power Supply Board（RC105）The arrangement of LED's, Jumpers and Toggle switches on the servo power supply board is as follows.

LED Explanation

No. Lighting Lights outD30 Motor brake open signal ON OFFD31 Motor power ON OFFD32 Emergency stop OFF OND33 Regenerative resistance

temperaturenormal abnormal

D34 Servo power voltage

Motor power OFF abnormal normalMotor power ON normal overvoltege

D35 Servo power voltage drop normalD37 Magnet switch ON enable unableD38 Operation mode manual mode automatic mode D39 Abnormal reset PB ON OFFD40 Teaching pendant(remote box) connection Non-connectionD41 Motor power switch ON or

middle positionOFF

D43 Primary power voltage normal drop

9

ＣＮ４ＣＮ５

ＣＮ３

D35 D34

JP2

D39 D36 D42

D40 D38 D43

D41 D37 D33

D31

D29

D32 D30

JP3

JP1

JP6TSW3

JP5TSW2

JP4TSW1

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Jumper Explanation

№ Explanation Ordinary setting

JP1 Please do not touch. 1-2 shortJP2 Please do not touch. OpenJP3 Please do not touch. OpenJP4 Short when you use the brake release(R, T and C axis)

switch of RC105Open

JP5 Short when you use the brake release (D axis) switch of RC105

Open

JP6 Short when you use the brake release (O axis) switch of RC105

Open

Toggle switch Explanation


TSW1 For R, T and C axis brake release OFFTSW2 For D axis brake release OFFTSW3 For O axis brake release OFF

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5.5.Safety Relay Board（RC106）The arrangement of LED's and Jumper on the safety relay board is as follows.

Jumper Explanation


JP1 Short when “Emergency Stop Signal” disable (Teaching pendant)

Open

JP2 Short when “Emergency Stop Signal” disable (Teaching pendant)

Open

JP3 Short when “Safety Fence Signal” disable Depend on the system

JP4 Short when “Unauthorized Access-detect Signal” disableJP5 Short when “Safety Fence Signal” disableJP6 Short when “Unauthorized Access-detect Signal” disableJP7 Short when “Key Switch” disable (Teaching pendant) OpenJP8 Short when “Enable Switch” disable (Teaching pendant) openJP9 Short when “Enable Switch” disable (Teaching pendant) OpenJP10 Short when “Key Switch” disable (Operation Panel, Teach

mode only)Short

・ When safety fence switch is connected with safety circuit, JP3 and JP5 are opened.

・ When invasion detection switch is connected with safety circuit, JP4 and JP6 are opened.

11

ＣＮ４ＣＮ３ＣＮ５

ＣＮ６

ＣＮ１

ＣＮ７

ＣＮ２

LD24

LD16 LD14 LD22 LD20

LD15 　 LD23 LD21

LD10 LD12 LD13

LD3 　 LD2 LD1 LD6 LD5 LD4 LD8 LD7

LD9 JP5 　 JP6

JP9　JP10

JP2 　 JP1

JP8

JP7

JP3 JP4

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LED Explanation

No. Lighting conditionLD1 Emergency stop signal is OFFLD2 Emergency stop signal is OFFLD3 Abnormal reset PB is ONLD4 Safety fence is closedLD5 Safety fence is closedLD6 Abnormal reset PB is ONLD7 Unauthorized access-detect signal is OFFLD8 Unauthorized access-detect signal is OFFLD9 Abnormal reset PB is ONLD10 Magnet switch ON enable is ONLD12 Magnet switch ON enable is ONLD13 Motor power enable is ONLD14 Soft charge ON enable is ONLD15 Motor power is ONLD16 Motor power is OFFLD20 No useLD21 No useLD22 No useLD23 No useLD24 Main power is supplied

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6. Servo-Amplifier Receipt Box　This section explains the servo-amplifier receipt box and the servo-amplifier.

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6.1.Servo-Amplifier Receipt Box Composition　The servo-amplifier receipt box composition is as follows.　It is possible to remove the servo-amplifier receipt box from a robot controller.

＜In the case of A1200III, A1600III, A1600III-W, A1800＞

In the servo-amplifier receipt box, the Servo Power Supply Board (RC105) and Safety Relay Board (RC106) other than servo-amplifier are contained.Please look at description of the following page about servo-amplifier.

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6.2.Servo-Amplifier　■ About Servo-Amplifier It is called servo-amplifier combining the current board and IPM of each axis.

A1200III,A1600III,A1600III-W,A1800

A400III, A700III

Servo-Amplifier Board Name

IPM Form Board Name

IPM Form

R-Axis RC107 6MBP200RA060 RC104 6MBP100RA060-05D-Axis RC107 6MBP200RA060 RC104 6MBP100RA060-05O-Axis RC107 6MBP200RA060 RC104 6MBP100RA060-05

T-Axis（C-Axis） RC108 6MBP20RH060 RC110 6MBP20RH060

Board Size([mm])

･A current board and IPM are connected for R,D and O-axes servo-amplifier by the connector. ･A current board and IPM are connected for T-axis(and C-axis) servo-amplifier with solder.

The exchange method of servo-amplifier should look at section 4.5 of this manual.

3

RC107

160

140 RC104

220

121

180

110RC108RC110

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7. External I/O SignalsThis explains the external I/O signals to control peripheral equipment.

1

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7.1.I/O・Data-Memory Composition【I/O・Data-Memory Composition list】

Symbol Classification Type Indication Points Start number

End number Power ON

X Input (*1) Hex 120 0 77hY Output (*1) " 96 0 5Fh Off

M User　(*2) Universal " 2048 0 7FFh M0-6FF: OFFOthers hold

M System １ Fixed " 80 5000h 504Fh HoldM System ２ " " 1280 6000h 64FFh "M Supervisor " " 32 7000h 701Fh "

D User　(*2) Universal Dec 2000 1000 2999D1000-2499: 0Others hold

D System １ Fixed " 16 5000 5015 HoldD System ２ " " 128 6000 6127 "D Supervisor " " 16 7000 7015 "

（*1）It changes with conditions of a Memory SW 1-5. (Please refer to the following chapter.)

（*2）User area of “D”and”M” is a domain which can be treated universally by the user.However, on the following conditions, it becomes system reservation(Fixed).

No

The conditions of system reservation Points Reservation range

1 Memory SW 4-6 is ON (Usually, OFF) 93 D2590 ～ D268272 M07B0 ～ M07F7

2 "BCR" is set as Serial-communication. 57 D2683 ～ D27393 “PLC” or ”FBUS" is set as Serial-

communication.50 D2740 ～ D2789

4 Memory SW 1-5 is OFF 10 D2790 ～ D27995 “POD“->“DM” transmission is set up. (10) D2800 ～ D28996 “DM“->“POD“ transmission is set up. (10) D2900 ～ D2999

※As for No5.6, ten points are reserved by the default.The setup of a maximum of 100 points is possible. The reservation range changes with a setup.

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7.2.Construction of peripheral equipment controlThe following figure is Construction of the peripheral equipment control.The peripheral equipment indicate the station conveyor, pallet the conveyor, and the pallet dispenser.

7.2.1. Memory switch 1-5 ON

External I/O signals are classified as following:

No. Type Explanation Quantity ConnectionInput Output

1 Fixed I/O I/O signal that function is fixed. 24 37

I/O board in controller (RC112) *1

2 Universal I/O

I/O signal that function is not specified (Can be used in robot Sequence program)

52 23I/O board in controller (RC112) *1

3 Hand I/OI/O signal for hand operation (Can be used in robot Sequence program)

4 4Connectoron robot T-Axis frame CN33 *2

4 Emergency For emergency stop and a person's safety 3 0 See 7.4 Emergency

*1 The arrangement of I/O board(RC132) is printed in this manual”5.2. I/O Board(RC132)”*2 The arrangement of Connector on robot T-Axis frame（CN33）is printed in this

manual”1.4 Spare Cable”*3 In manual operation, signals for hand are output to Y1C-Y1F(for hand 1-3), to

M5028-M502D(for hand 4-9), not relate to memory switch 1-5. When signals for hand4-9 is output to Y, M is replaced to Y as it is by using internal PLC.

3

Quantity of intput:4（ Standard ）Quantity of output:4（ Standard ）

I/O board

RC132External

PLC

Hand

Quantity of Input:76

Quantity of Output:60

MotorElectromagnetic

valveMechanical

switch

Optical switch

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7.2.2. Memory switch 1-5 OFF

External I/O signals are classified as following:


1 Fixed I/O I/O signal that function is fixed. 1 0

I/O board in controller (RC112) *1

2 Universal I/O

I/O signal that function is not specified (Can be used in robot Sequence program)

75 60I/O board in controller (RC112) *1

3 Hand I/OI/O signal for hand operation (Can be used in robot Sequence program)

4 4Connectoron robot T-Axis frame CN33 *2

4 Emergency For emergency stop and a person's safety 3 0 See 7.5 Emergency

*1 The arrangement of I/O board(RC132) is printed in this manual”5.2. I/O Board(RC132)”*2 The arrangement of Connector on robot T-Axis frame（CN33）is printed in this

manual”1.4 Spare Cable”*3 In manual operation, signals for hand are output to Y1C-Y1F(for hand 1-3), to

M5028-M502D(for hand 4-9), not relate to memory switch 1-5. When signals for hand4-9 is output to Y, M is replaced to Y as it is by using internal PLC.

4

I/O board

RC132Internal

PLC

Hand

Quantity of intput:4（ Standard ）Quantity of output:4（ Standard ）

Quantity of Input:76

Quantity of Output:60

MotorElectromagnetic

valveMechanical

switchOptical switch

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7.3.I/O boardThe external I/O signal lines is connected by the I/O board(TB1,TB2,and,TB3 on the RC132).The hand I/O signals are connected by CN1 on the RC132.

Figure. I/O board (RC132)

　　　　　　　　Figure．I/O board（RC132）

Only TB4Terminal odd No. are connected with each other.Terminal even No. are connected with each other.Please use for common and etc.

5

CN5 CN12 CN1TB4CN6 CN4

CN10

CN11 CN8

CN9

CN7

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7.3.1. Internal PLC relay

CN4

CN ５

＊ N24 are connected in the substrate. ＊　　　: The usage is allocated, when memory switch 1-5 is ON.

6

No. 1stboard No. 2nd

board１ N ２４１ N ２４2 Ｘ００ 2 Ｘ２８

3 Ｘ０１ 3 Ｘ２９

4 Ｘ０２ 4 Ｘ２ A5 Ｘ０３ 5 Ｘ２ B6 Ｘ０４ 6 Ｘ２ C7 Ｘ０５ 7 Ｘ２ D8 Ｘ０６ 8 Ｘ２ E9 Ｘ０７ 9 Ｘ２ F10 N ２４ 10 N ２４


board１ N ２４１ N ２４2 Ｘ０８ 2 Ｘ３０

3 Ｘ０９ 3 Ｘ３１

4 Ｘ０ A 4 Ｘ３２

5 Ｘ０ B 5 Ｘ３３

6 Ｘ０ C 6 Ｘ３４

7 Ｘ０ D 7 Ｘ３５

8 Ｘ０ E 8 Ｘ３６

9 Ｘ０ F 9 Ｘ３７

10 N ２４ 10 N ２４

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CN ６

CN ７

＊ N24 are connected in the substrate. ＊　　　: The usage is allocated, when memory switch 1-5 is ON. (Only X1F is always allocated.)

CN ９

7


board１ N ２４１ N ２４2 Ｘ１０ 2 Ｘ３８

3 Ｘ１１ 3 Ｘ３９

4 Ｘ１２ 4 Ｘ３ A5 Ｘ１３ 5 Ｘ３ B6 Ｘ１４ 6 Ｘ３ C7 Ｘ１５ 7 Ｘ３ D8 Ｘ１６ 8 Ｘ３ E9 Ｘ１７ 9 Ｘ３ F10 N ２４ 10 N ２４


board１ N ２４１ N ２４2 Ｘ１８ 2 Ｘ４０

3 Ｘ１９ 3 Ｘ４１

4 Ｘ１ A 4 Ｘ４２

5 Ｘ１ B 5 Ｘ４３

6 Ｘ１ C 6 Ｘ４４

7 Ｘ１ D 7 Ｘ４５

8 Ｘ１ E 8 Ｘ４６

9 Ｘ１ F 9 Ｘ４７

10 N ２４ 10 N ２４

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＊ N24 are connected in the substrate. ＊　　　: The usage is allocated, when memory switch 1-5 is ON.

CN11

＊　N24, P24 are connected in the substrate.＊　　　: The usage is allocated, when memory switch 1-5 is ON.

CN12

8


board１ N ２４１ N ２４2 Ｘ２０ 2 Ｘ４８

3 Ｘ２１ 3 Ｘ４９

4 Ｘ２２ 4 Ｘ４ A5 Ｘ２３ 5 Ｘ４ B6 Ｘ２４ 6 Ｘ４ C7 Ｘ２５ 7 Ｘ４ D8 Ｘ２６ 8 Ｘ４ E9 Ｘ２７ 9 Ｘ４ F10 N ２４ 10 N ２４


board１ P ２４１ N ２４2 N ２４ 2 P ２４

3 Y ００ 3 Ｙ２０

4 Ｙ０１ 4 Ｙ２１

5 Ｙ０２ 5 Ｙ２２

6 Ｙ０３ 6 Ｙ２３

7 Ｙ０４ 7 Ｙ２４

8 Ｙ０５ 8 Ｙ２５

9 Ｙ０６ 9 Ｙ２６

10 Ｙ０７ 10 Ｙ２７

11 P ２４ 11 N ２４

12 N ２４ 12 P ２４

A C

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CN8


CN10

9


board１ P ２４１ N ２４2 N ２４ 2 P ２４

3 Y ０８ 3 Ｙ２８

4 Ｙ０９ 4 Ｙ２９

5 Ｙ０ A 5 Ｙ２ A6 Ｙ０ B 6 Ｙ２ B7 Ｙ０ C 7 Ｙ２ C8 Ｙ０ D 8 Ｙ２ D9 Ｙ０ E 9 Ｙ２ E10 Ｙ０ F 10 Ｙ２ F11 P ２４ 11 N ２４

12 N ２４ 12 P ２４


board１ P ２４１ N ２４2 N ２４ 2 P ２４

3 Ｙ１０ 3 Ｙ３０

4 Ｙ１１ 4 Ｙ３１

5 Ｙ１２ 5 Ｙ３２

6 Ｙ１３ 6 Ｙ３３

7 Ｙ１４ 7 Ｙ３４

8 Ｙ１５ 8 Ｙ３５

9 Ｙ１６ 9 Ｙ３６

10 Ｙ１７ 10 Ｙ３７

11 P ２４ 11 N ２４

12 N ２４ 12 P ２４

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Figure. Input circuit Figure. Output circuit

10


board１ P ２４１ N ２４2 N ２４ 2 P ２４

3 Ｙ１８ 3 Ｙ３８

4 Ｙ１９ 4 Ｙ３９

5 Ｙ１ A 5 Ｙ３ A6 Ｙ１ B 6 Ｙ３ B7 Ｙ１ C 7 Ｙ３ C8 Ｙ１ D 8 Ｙ３ D9 Ｙ１ E 9 Ｙ３ E10 Ｙ１ F 10 Ｙ３ F11 P ２４ 11 N ２４

12 N ２４ 12 P ２４

N24

IN3.3K

Input current 7mA

24V 100mAOutput On max. voltage 1.1V

N24

OUT

P24

A C

B D

F1N24A N24B CN1、CN9

CN1、CN10P24A F2 P24B

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ＣＮ１

No.

1stboard No. 2nd

board

１ N ２４１ N ２４

2 N ２４ 2 N ２４3 N ２４ 3 N ２４4 Ｘ２４※ 4 Ｘ４Ｃ5 Ｘ２５※ 5 Ｘ４Ｄ6 Ｘ２６※ 6 Ｘ４Ｅ7 Ｘ２７※ 7 Ｘ４Ｆ8 Ｙ１Ｃ※ 8 Ｙ３Ｃ9 Ｙ１Ｄ※ 9 Ｙ３Ｄ

１０Ｙ１Ｅ※ １０Ｙ３Ｅ１１Ｙ１Ｆ※ １１Ｙ３Ｆ１２ P ２４１２ P ２４１３ P ２４１３ P ２４１４ P ２４１４ P ２４

*:Signals are connected to CN33 in T-axis connector box.(See.7.4.I/O signals for

11

A

B

C

D

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Hand)-If CN1 is in use, An attachment is needed for connecting.(CN1 is not terminal box.)

N24, P24 are connected with N24, P24 of CN9、CN10 in the substrate.

The pin array of CN1 is as follows:

12

12

1314

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7.3.2. I/O signals (Fixed and Universal when memory switch 1-5 ON)It explains the data communication of PLC and the robot when external PLC is used (About the process of the PLC side).

1. Motor power ON enable signalTurn on the motor power ON enable signal (X30), on condition that the PLC has no abnormality in internal process and the motor power ON enable signal from robot (Y2B) is turned on.

2. Start key signalRobot controller starts(stops) operation on condition that operation signal (X2D) from PLC is turned on(off). If PLC has no abnormality in internal process and motor power switch is in neutral position(Y2E) and operation key signal(Y27) is turned on, operation signal(X2D) is turned on, and keep the status even if operation key signal(Y27) is turned off. (Unrelated with motor power status)In automatic mode, operation key signal(Y27) is not turned on even if start key is pressed on condition that motor power is turned on.

3. Start of programWhen external PLC is used, the program is specified by ID-No.. PLC sets ID-No. to start in X00-X06, and turns on ID strobe (X07). X07 is usually turned off with station loading enable ON(Y00-) from robot.

4. Partial dischargeWhen discharging on controller, requested pallet no. is set for Y23, Y24 or Y39(e.g. for pallet 1, only Y24 is turned on, for pallet 3, Y23 and Y24 are turned on), and discharge start strobe(Y0D) is turned on for 500 msec. PLC sets ID No. to discharge in the rising up detection of the relay to X00-X06, and turns on discharge start strobe(Y0D).X0B is usually turned off with stacking complete(Y04-) from robot.

5. Product type settingWhen product type is set on controller, .program data is sent by centronics communication.(only when centronics communication is selected) It is no need to set product type when centronics communication is not selected.

6. Stacking count value changeWhen count value is changed or initialized on controller, changed count value of the program is sent by centronics communication. (only when centronics communication is selected)

7. Sequence resetOnly when memory switch 3-1 is ON, Y2D is turned on for 500 msec and first article signals(Y30-) are turned off for the number of sheets set by the system parameter.

8. Zero resetWhen zero reset is done on controller, zero reset command is sent by centronics communication. (only when centronics communication is selected)

9. Conveyor resetWhen conveyor reset is done on controller, conveyor reset command is sent by centronics communication. (only when centronics communication is

13

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selected)

10. Conveyor manual operationWhen the conveyor(s) is(are) selected, selected data is sent by centronics communication. (only when centronics communication is selected)During “Forward-Up-Open” has been pressed, Forward-Up-Open manual strobe(Y0E) is turned on.During “Reverse-Down-Close” has been pressed, Reverse-Down-Close manual strobe(Y0F) is turned on.

11. Abnormality of PLCWhen PLC occurs or detects abnormality, error command is sent by centronics communication. To sound the buzzer, X2E should be turned on. (Buzzer should be turned off in the rising up detection of stop buzzer(Y25)) When error command is sent by centronics communication, it is displayed on the touch panel and memorized in error history. But operation and motor power are not turned off automatically. In accordance with content of error, please handle it on PLC side. (only when centronics communication is selected)

14

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Output signals

Type Relay NameAt

communicati

onDescription

Universal

Y00 (Station loading enable 1) Rdat0 This signal is used to indicate robot incline

motion is completed after holding article on station conveyer and ready to next article to come into the station conveyer.In a standard robot sequence program, this signal is turned ON when positioning is completed in step 4 and turned OFF at step 5.On PLC program this signal is used as a trigger to let next article to come into the station conveyer.In case Rmod(Y10) signal is ON, this port is used for transfer data.

Y01 (Station loading enable 2) Rdat1



Fixed

Y04 (Stacking complete 1) Rdat4 This signal is used to indicate stacking is completed.In a standard robot sequence program, this signal is turned ON at step 8 and turned OFF at step 1 when stacking is considered completed. Usually ENCHK command is used to turn this signal in robot sequence program.On PLC program this signal is used as a trigger to discharge pallet.In case Rmod(Y10) signal is ON, this port is used for transfer data.

Y05 (Stacking complete 2) Rdat5Y06 (Stacking complete 3) Rdat6

Y07 (Stacking complete 4) Rdat7

Y08 Station ON 1 This signal is turned ON when select “Station ON” in station on/off menuOn PLC program this signal is used to prohibit next article to come into the station conveyer.

Y09 Station ON 2Y0A Station ON 3Y0B Station ON 4

Y0C Internal operationThis signal is turned ON when select “internal mode” in Automatic operation condition menu.On PLC program this signal is used to prohibit next article to come into the station conveyer.

Y0D Discharge start strobe

This signal is turned ON when select “pallet discharge” in pallet discharge menu.(for　500msec)At the same time rely Y23, Y24, and Y39 output the selected pallet No. data by bit code.On PLC program this signal is used as a trigger to output ID No. and pallet discharge strobe(XB).

Y0E Forward-Up-Open manual strobe

This signal is turned ON while pressing [FORWARD-UP-OPEN] key in conveyer manual operation menu.On PLC program this signal is used as a trigger to operate conveyor according to the previously transferred “Conveyor Manual” data.

Y0F Reverse-Down-Close manual strobe

This signal is turned ON while pressing [REVERSE-DOWN-CLOSE] key in conveyer manual operation menu.On PLC program this signal is used as a trigger to operate conveyor according to the previously transferred “Conveyor Manual” data.

Fixed Y10 RModThis signal is turned ON while data transfer from robot controller to PLC is executed.Data transfer start timing is as follows

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Type Relay NameAt

communicati

onDescription

Fixed

Y11 RStb

When Rmod signal turns ON and Pbsy port receives no signal, centronics communication from robot to PLC has started.On PLC program this signal is used as a trigger to read date from robot controller.This signal turn OFF when PLC send Pack data which means finish reading data.

Y12 RbsyWhen robot is not ready to receive data this signal is turned ON.On PLC program forbid turning on Pmod when this signal is ON.

Y13 RackWhen robot side receives Pstb and finishes reading data, Rack is turned ON.On PLC program turn OFF Pstb when receive this signal.

Y14 R Area 20 These three bits data indicate Robot R axis current position. For this use, R area parameter in system parameter must be defined in advance.

Y15 R Area 21

Y16 R Area 22

Universal

Y17 SpareY18 SpareY19 SpareY1A 　SpareY1B Spare

Fixed

Y20 Robot AbnormalityWhen abnormality occurs this signal is turned ON.On PLC program turn OFF operation signal (X2D) when receive this signal.

Y21 Automatic modeThis signal is turned ON when select “Auto mode” in main menu.On PLC program forbid manual operation of conveyer when receive this signal.

Y22 Discharge in progress

This signal is turned ON when receiving discharge strobe (X0B).This signal is turned OFF when stacking completed signal turned ON in ENCHK command.

Y23 Pallet No. 20 These three bits data indicate pallet No. to be discharged. Signals are turned ON when select “pallet discharge” in pallet discharge menu.

Y24 Pallet No. 21

Y25 Stop buzzerThis signal is turned ON when pressing alarm stop push button under the abnormal condition.On PLC program this signal is used to turn OFF the buzzer signal (X2E).

Y26 Motor power on This signal is turned ON when motor power is ON.

Y27 Operation keyThis signal is turned ON while pressing start key.On PLC program, turn and keep ON operation signal (X2D) when receiving this signal.

Y28 Stop keyThis signal is turned OFF while pressing stop key.On PLC program, turn OFF operation signal (X2D) when receiving this signal.

Y29 Abnormal reset push button

This signal is turned ON while pressing abnormal reset push button.On PLC program, reset abnormal signal when receiving this signal.

Y2A Emergency stop This signal is turned ON when emergency switch is turned ON.

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Type Relay NameAt

communicati

onDescription

Y2B Motor power ON enable

This signal is turned ON when all the servo amp is in ready condition.On PLC program forbid motor power ON enable ON unless this signal is OFF

Y2C Robot independent This signal is turned ON when memory switch 2-4 is set OFF.

Y2D Sequence resetThis signal is turned ON when sequence reset is executed.For this use, memory switch 3-1 must be set ON in advance.

Y2E Control power On This signal is turned ON when motor power switch is in neutral positionUniversal

Y2F (Basic position) Okura standard usage :This signal is turned ON when Waiting Position for input signal

Universal

Y30 (First article 1) Okura standard usage: In robot sequence program turn on this signal in the step to palletizing the first article on the pallet.On PLC program if the article is detected while this signal is ON then stop robot to avoid collision.For this use, article detection sensor is required.

Y31 (First article 2)Y32 (First article 3)Y33 (First article 4)Y34 (First article 5)

Y35 (First article 6)

Y36SpareY37

Y38

Fixed

Y39 Pallet No. 22 See Relay Y03Y3A Stacking complete 5 See Relay Y04 to Y07Y3B Stacking complete 6

Universal

Y3C

SpareY3DY3EY3F

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Input signals

Type Relay NameAt

communicati

onDescription

Fixed

X00 ID No. Selection　20

These 7 digits designate which ID No. program to run at PGSEL command..Preferable timing to set these signals ON is when the article is set to the picking position.This signal must be set at least 0.3 second before the ID No. strobe (X07) or Partial discharge strobe (X0B) is turned ON.Turn OFF this signal when the article is undetected on the picking position or stacking complete signal is ON under discharging process.






X06 ID No. Selection 2 ６

X07 ID No. Strobe

Run the program at PGSEL command.Program selection is executed in PGSEL command in robot sequence program.Turn OFF this signal at the same time when turn off ID No. selection signal.

X08 Number of pallet 20 Execute the partial discharge process at PGSEL command.Turn OFF this signal at the same time when turn off ID No. selection signal.

X09 Number of pallet 21

X0A Number of pallet 22

X0B Partial discharge strobe

Okura standard usage: turn OFF while pallet being discharged.In robot sequence program, stop robot motion in step 4 while this signal is OFF.IN case of multi pallet layout, forbid program selection while this signal in OFF on PLC program.In case Pmod(X28) signal is ON, this port is used for transfer data.

Universal

X0C (Pallet detection 1) Okura standard usage: turn on when detect pallet and turn off while discharge is in process after stacking completely.In robot sequence program, stop robot motion in step 6 while this signal is OFF.In case of multi pallet layout, forbid program selection while this signal is OFF on PLC program.

X0D (Pallet detection 2)X0E (Pallet detection 3)

X0F (Pallet detection 4)

X10 (Pallet being transferred 1) Pdat 0 Okura standard usage: turn OFF while pallet

being discharged.In robot sequence program, stop robot motion in step 4 while this signal is OFF.IN case of multi pallet layout, forbid program selection while this signal in OFF on PLC program.In case Pmod(X28) signal is ON, this port is used for transfer data.

X11 (Pallet being transferred 2) Pdat 1




In case Pmod(X28) signal is ON, this port is used for transfer data.X15 (Pallet being

transferred 6) Pdat 5

X16 Spare Pdat 6X17 Spare Pdat 7X18

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Type Relay NameAt

communicati

onDescription

Spare

X19X1AX1BX1CX1DX1E

Fixed

X1F Limit switch Limit switch

X20 Start keyParallel circuit of start key (Switch to a contact with memory switch)

X21 stop key Series circuit of stop key (Switch to b contact with memory switch)

Universal

X22Spare

X23

Fixed

X28 PMod

When this signal turns ON and Rbsy port is OFF, centronics communication from PLC to robot starts.For this use, memory switch in system parameter must be defined in advance.

X29 PStbWhen this signal is turned ON and Pmod is ON and Rbsy is OFF, robot side receives data and (after data reception) sends Rack to the PLC.

X2A Pbsy This is set ON when PLC side cannot receive data.

X2B PAckWhen PLC side receives Pstb and finish reading data, Pack is turned ON. When Rstb goes OFF, Pack also goes OFF.

X2C External hold When set ON, stop executing a new Mov command in robot sequence program.

X2D Operation On PLC program, turn and keep ON this signal when receiving Y27 signal.

X2E Buzzer Sound buzzer

X2F Operation enableClose to set operation enable.Normally keep ON this signal and turn OFF when abnormality occurs.

X30 Motor power on Enable Close to enable the motor power ON.

Universal

X31

Spare

X32X33X34X35X36X37X38X39X3AX3BX3CX3DX3E (Pallet detection 5) See Relay X0C to X0F

19

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Type Relay NameAt

communicati

onDescription

X3F (Pallet detection 6)X40

Spare

X41X42X43X44X45X46X47X48X49X4AX4BX4CX4DX4EX4F

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7.3.3. I/O signal (memory switch 1-5 OFF)It explains the data communication of PLC and the robot when internal PLC is used (About the process of the PLC side).

1. Motor power ON enable signalTurn on the motor power ON enable signal (M5025), on condition that the PLC has no abnormality in internal process and the motor power ON enable signal from robot (M503E) is turned on.

2. Start key signalRobot controller starts(stops) operation on condition that operation signal (M503D) from PLC is turned on(off). If PLC has no abnormality in internal process and motor power switch is in neutral position(M6040) and operation key signal(M5027) is turned on, operation signal(M503D) is turned on, and keep the status even if operation key signal(M5027) is turned off. (Unrelated with motor power status)In automatic mode, operation key signal(M5027) is not turned on even if start key is pressed on condition that motor power is turned on.

3. Start of programAfter program No. to start is set to D5000, Program No. Strobe(M5000) is turned on. M5000 is usually turned off with station loading enable ON(M6002-) from robot.

4. Partial dischargeWhen discharging on controller, discharge start strobe corresponding to pallet No.(M501C-) is turned on. PLC sets program No. to discharge in the rising up detection of the relay to D5000, and turns on discharge start strobe(M5001).Discharge start strobe(M501C-) should be turned off on PLC side.(It occurs an error when it is not turned off within one second.)M5001 is usually turned off with stacking complete(M6006-) from robot.

5. Product type settingWhen product type is set on controller, program data is sent to corresponding data memory(D6016, D6024,･･), and pallet program allocation relay(M5034-) is turned on. After necessary process on PLC in the rising up detection of the relay, this relay should be turned off on PLC side. (It occurs an error when it is not turned off within one second.)

6. Stacking count value changeWhen count value is changed or initialized on controller, changed count value is set to corresponding data memory(D6018, D6019,･･ ), and pallet counter setting relay(M502E-) is turned on. After necessary process on PLC in the rising up detection of the relay, this relay should be turned off on PLC side. (It occurs an error when it is not turned off within one second.)

7. Sequence resetSequence reset relay(M503A) is turned on, and first article signals(M601D-) are turned off. After necessary process on PLC in the rising up detection of the relay, this relay should be turned off on PLC side. (It occurs an error when it is not turned off within one second.)

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8. Zero resetZero reset relay(M5015-) corresponding to pallet No. is turned on. After necessary process on PLC in the rising up detection of the relay, this relay should be turned off on PLC side. (It occurs an error when it is not turned off within one second.)

9. Conveyor resetConveyor reset relay(M501B) is turned on. After necessary process on PLC in the rising up detection of the relay, this relay should be turned off on PLC side. (It occurs an error when it is not turned off within one second.)

10. Conveyor manual operationThe bits corresponding to selected conveyor(s) are set to D6001 and D6002. During “Forward-Up-Open” has been pressed, Forward-Up-Open manual strobe(M6014) is turned on.During “Reverse-Down-Close” has been pressed, Reverse-Down-Close manual strobe(M6015) is turned on.

11. Abnormality of PLCWhen PLC occurs or detects abnormality, ERR and ERRP commands are operated. To sound the buzzer, M5023 should be turned on. (Buzzer should be turned off in the rising up detection of stop buzzer(M5026)) When ERR and ERRP commands are operated, it is displayed on the touch panel and memorized in error history. But operation and motor power are not turned off automatically. In accordance with content of error, please handle it on PLC side.

22

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RelayRelay No. Name Ext. PLC mode In ／ Out

M5000 Program No. Strobe X07 InM5001 Partial discharge strobe X0B InM5002 Pallet detection １ X0C InM5003 Pallet detection ２ X0D InM5004 Pallet detection ３ X0E InM5005 Pallet detection ４ X0F InM5006 Pallet detection ５ X3E InM5007 Pallet detection ６ X3F InM5008 Pallet being transferred 1 ―― OutM5009 Pallet being transferred ２ ―― OutM500A Pallet being transferred ３ ―― OutM500B Pallet being transferred ４ ―― OutM500C Pallet being transferred ５ ―― OutM500D Pallet being transferred ６ ―― OutM500E External hold X2C InM500F Stacking complete 1 acknowledge ―― InM5010 Stacking complete 2 acknowledge ―― InM5011 Stacking complete 3 acknowledge ―― InM5012 Stacking complete 4 acknowledge ―― InM5013 Stacking complete 5 acknowledge ―― InM5014 Stacking complete 6 acknowledge ―― InM5015 Pallet 1 zero reset ―― OutM5016 Pallet ２ zero reset ―― OutM5017 Pallet ３ zero reset ―― OutM5018 Pallet ４ zero reset ―― OutM5019 Pallet ５ zero reset ―― OutM501A Pallet ６ zero reset ―― OutM501B Conveyor reset ―― OutM501C Pallet １ discharge start strobe ―― OutM501D Pallet ２ discharge start strobe ―― OutM501E Pallet ３ discharge start strobe ―― OutM501F Pallet ４ discharge start strobe ―― OutM5020 Pallet ５ discharge start strobe ―― OutM5021 Pallet ６ discharge start strobe ―― OutM5022 Spare ―― ――M5023 Buzzer X2E InM5024 Stop X2F InM5025 Motor power ON enable X30 InM5026 Stop　buzzer Y25 OutM5027 Start key Y27 OutM5028 Hand 4 ―― OutM5029 Hand ５ ―― OutM502A Hand ６ ―― OutM502B Hand ７ ―― OutM502C Hand ８ ―― Out

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Relay No. Name Ext. PLC mode In ／ OutM502D Hand ９ ―― OutM502E Pallet 1 counter setting ―― OutM502F Pallet 2 counter setting ―― OutM5030 Pallet 3 counter setting ―― OutM5031 Pallet 4 counter setting ―― OutM5032 Pallet 5 counter setting ―― OutM5033 Pallet 6 counter setting ―― OutM5034 Pallet 1 program allocating ―― OutM5035 Pallet 2 program allocating ―― OutM5036 Pallet 3 program allocating ―― OutM5037 Pallet 4 program allocating ―― OutM5038 Pallet 5 program allocating ―― OutM5039 Pallet 6 program allocating ―― OutM503A Sequence reset Y2D OutM503B Display is Int. PLC mode ―― OutM503C Stop key Y28 OutM503D Operation X2D OutM503E Motor power ON enable Y2B InM503F System reserve (for DA) ―― ――M5040 System reserve (for DA) ―― ――M5041 System reserve (for DA) ―― ――M5042 Flag for notices of error ―― OutM5043 System reserve ―― ――M5044 System reserve ―― ――M5045 PLC timer1 coil ―― InM5046 PLC timer2 coil ―― InM5047 PLC timer3 coil ―― InM5048 PLC timer4 coil ―― InM5049 PLC timer5 coil ―― InM504A PLC timer6 coil ―― InM504B PLC timer7 coil ―― InM504C PLC timer8 coil ―― InM504D System reserve ―― ――M504E System reserve ―― ――

Relay No. Name Ext. PLC mode In ／ OutM6000 Operation ―― InM6001 Motor Power ON Y26 OutM6002 Station 1 loading enable Y00 OutM6003 Station 2 loading enable Y01 OutM6004 Station 3 loading enable Y02 OutM6005 Station 4 loading enable Y03 OutM6006 Stacking complete 1 Y04 OutM6007 Stacking complete ２ Y05 OutM6008 Stacking complete ３ Y06 OutM6009 Stacking complete ４ Y07 OutM600A Stacking complete ５ Y3A Out

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Relay No. Name Ext. PLC mode In ／ OutM600B Stacking complete ６ Y3B OutM600C Station ON 1 Y08 OutM600D Station ON 2 Y09 OutM600E Station ON 3 Y0A OutM600F Station ON 4 Y0B OutM6010 Spare ―― ――M6011 Spare ―― ――M6012 Internal operation Y0C OutM6013 Spare ―― ――M6014 Forward-Up-Open manual strobe Y0E OutM6015 Reverse-Down-Close manual strobe Y0F OutM6016 Spare ―― ――M6017 Robot Abnormality Y20 OutM6018 Automatic mode Y21 OutM6019 Spare ―― ――M601A Spare ―― ――M601B Spare ―― ――M601C Spare ―― ――M601D First article １ Y30 OutM601E First article ２ Y31 OutM601F First article ３ Y32 OutM6020 First article ４ Y33 OutM6021 First article ５ Y34 OutM6022 First article ６ Y35 OutM6023 Spare ―― ――M6024 Spare ―― ――M6025 Spare ―― ――M6026 Spare ―― ――M6027 Spare ―― ――M6028 Spare ―― ――M6029 Spare ―― ――M602A Emergency stop Y2A OutM602B Abnormal reset push button Y29 OutM602C Spare ―― ――M602D 0.1 sec clock ―― OutM602E 0.2 sec clock ―― OutM602F 1 sec clock ―― OutM6030 2 sec clock ―― OutM6031 1 min clock ―― OutM6032 AC Power Down detect ―― OutM6033 Battery voltage drop ―― OutM6034 Battery voltage drop (latch) ―― OutM6035 Watch data error ―― OutM6036 Normal PLC execute latch ―― OutM6037 Normal PLC execute flag ―― OutM6038 High speed PLC execute latch ―― OutM6039 High speed PLC execute flag ―― OutM603A Normal PLC scan over ―― OutM603B High speed PLC scan over ―― OutM603C Error ―― Out

25

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Relay No. Name Ext. PLC mode In ／ OutM603D Error (warning) ―― OutM603E Error (caution) ―― OutM603F Error (notice) ―― OutM6040 Control power On Y2E OutM6041 System reserve ―― ――M6042 System reserve ―― ――M6043 System reserve ―― ――M6044 C-axis torque level arrived ―― OutM6045 PLC timer1 contact ―― OutM6046 PLC timer2 contact ―― OutM6047 PLC timer3 contact ―― OutM6048 PLC timer4 contact ―― OutM6049 PLC timer5 contact ―― OutM604A PLC timer6 contact ―― OutM604B PLC timer7 contact ―― OutM604C PLC timer8 contact ―― OutM604D System reserve ―― ――

Relay No. Name Ext. PLC mode In ／ OutM7000 ON ―― OutM7001 OFF ―― OutM7002 Normal PLC automatic start ―― InM7003 High speed PLC automatic start ―― InM7004 Memory initial flag ―― InM7005 Memory clear flag ―― In

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Data memory

Dm No. Name Ext. PLC mode DescriptionD5000 Program NO select X00～X06D5001 Pallet piece No. X08～X0A 0 when one palletD5002 AC DOWN Counter ――D5003 System reserve (for DA) ――D5004 System reserve (for DA) ――D5005 System reserve (for DA) ――D5006 System reserve (for DA) ――D5007 System reserve (for DA) ――D5008 System reserve (for DA) ――D5009 Pallet1 D1 ――D5010 Pallet2 D1 ――D5011 Pallet3 D1 ――D5012 Pallet4 D1 ――D5013 Pallet5 D1 ――D5014 Pallet6 D1 ――D5015 PLC timer1 value ――D5016 PLC timer2 value ――D5017 PLC timer3 value ――D5018 PLC timer4 value ――D5019 PLC timer5 value ――D5020 PLC timer6 value ――D5021 PLC timer7 value ――D5022 PLC timer8 value ――

Dm No. Name Ext. PLC mode DescriptionD6000 R area Y14～Y16D6001 Conveyor manual 1/2 CentronicsD6002 Conveyor manual 2/2 CentronicsD6003 Date (Year、Month)

――<BCD>U8bit ：Year(L2digit) L8bit ：Month

D6004 Date, Time (Day、Hour) ―― <BCD>U8bit ： Day L8bit：Time

D6005 Time (Min、Sec) ―― <BCD>U8bit ： Min L8bit：Sec

D6006 Normal PLC status ―― 0:stop 1:run 2:errorD6007 Normal PLC 1sec counter ――D6008 Normal PLC max scan time ―― mSecD6009 Normal PLC scan time ―― mSecD6010 Normal PLC minimum scan ―― mSecD6011 High speed PLC status ―― 0:stop 1:run 2:errorD6012 High speed PLC 1sec counter ――D6013 High speed PLC max scan ―― mSecD6014 High speed PLC scan time ―― mSecD6015 High speed PLC minimum scan ―― mSecD6016 Pallet 1 execute Program No ――D6017 Pallet 1 stack lay No. ―― １～D6018 Pallet 1 current lay No ―― １～D6019 Pallet 1 current work No ―― １～D6020 Pallet 1 work size (L) ―― [mm]D6021 Pallet 1 work size (W) ―― [mm]D6022 Pallet 1 work size (H) ―― [mm]D6023 Pallet 1 number of pallets ――

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Dm No. Name Ext. PLC mode DescriptionD6024 Pallet 2 execute Program No ――D6025 Pallet 2 stack lay No. ―― １～D6026 Pallet 2 current lay No ―― １～D6027 Pallet 2 current work No ―― １～D6028 Pallet 2 work size (L) ―― [mm]D6029 Pallet 2 work size (W) ―― [mm]D6030 Pallet 2 work size (H) ―― [mm]D6031 Pallet 2 number of pallets ――D6032 Pallet 3 execute Program No ――D6033 Pallet 3 stack lay No. ―― １～D6034 Pallet 3 current lay No ―― １～D6035 Pallet 3 current work No ―― １～D6036 Pallet 3 work size (L) ―― [mm]D6037 Pallet 3 work size (W) ―― [mm]D6038 Pallet 3 work size (H) ―― [mm]D6039 Pallet 3 number of pallets ――D6040 Pallet 4 execute Program No ――D6041 Pallet 4 stack lay No. ―― １～D6042 Pallet 4 current lay No ―― １～D6043 Pallet 4 current work No ―― １～D6044 Pallet 4 work size (L) ―― [mm]D6045 Pallet 4 work size (W) ―― [mm]D6046 Pallet 4 work size (H) ―― [mm]D6047 Pallet 5 number of pallets ――D6048 Pallet 5 execute Program No ――D6049 Pallet 5 stack lay No. ―― １～D6050 Pallet 5 current lay No. ―― １～D6051 Pallet 5 current work No ―― １～D6052 Pallet 5 work size (L) ―― [mm]D6053 Pallet 5 work size (W) ―― [mm]D6054 Pallet 5 work size (H) ―― [mm]D6055 Pallet 6 number of pallets ――D6056 Pallet 6 execute Program No ――D6057 Pallet 6 stack lay No. ―― １～D6058 Pallet 6 current lay No ―― １～D6059 Pallet 6 current work No ―― １～D6060 Pallet 6 work size (L) ―― [mm]D6061 Pallet 6 work size (W) ―― [mm]D6062 Pallet 6 work size (H) ―― [mm]D6063 Pallet 6 number of pallets ――D6064 Stacking pallet No ――D6065 Current position R ―― X100 [°]D6066 Current position D ―― X100 [°]D6067 Current position O ―― X100 [°]D6068 Current position T ―― X100 [°]D6069 Current position C ―― X100 [°]D6070 Current position AR ―― X100 [°]D6071 Current position AX ―― X10 [mm]

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Dm No. Name Ext. PLC mode DescriptionD6072 Current position AT ―― X100 [°]D6073 Current position AZ ―― X10 [mm]D6074 Current position AC ―― X10 [mm]D6075 Current position HX ―― X10 [mm]D6076 Current position HY ―― X10 [mm]D6077 Current position HZ ―― X10 [mm]D6078 Current position HT ―― X100 [°]D6079 Current position HC ―― X10 [mm]D6080 Normal PLC execute status ――D6081 High speed PLC execute status ――D6082 CPU Idle % ――D6083 CPU board temperature ―― X100°CD6084 Number of stacking pieces 1 ――D6085 Number of stacking pieces 2 ――D6086 Number of stacking pieces 3 ――D6087 Number of stacking pieces 4 ――D6088 Number of stacking pieces 5 ――D6089 Number of stacking pieces 6 ――D6090 Stack pattern pallet 1 ―― 1:BAR,2:INTRK,3:SPCL,4:

RPMD,5:ZSPLD6091 Stack pattern pallet 2 ―― 1:BAR,2:INTRK,3:SPCL,4:





RPMD,5:ZSPLD6096 Stop position(1st) St1 ――D6097 Stop position(2nd) St1 ――D6098 Centering position St1 ――D6099 Press height St1 ――D6100 Stop position(1st) St2 ――D6101 Stop position(2nd)St2 ――D6102 Centering position St2 ――D6103 Press height St2 ――D6104 Stop position(1st) St3 ――D6105 Stop position(2nd)St3 ――D6106 Centering position St3 ――D6107 Press height St3 ――D6108 Stop position(1st) St4 ――D6109 Stop position(2nd)St4 ――D6110 Centering position St4 ――D6111 Press height St4 ――D6112 Hand No. ――D6113 System reserve (for DA) ――

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Dm No. Name Ext. PLC mode DescriptionD6114 System reserve (for DA) ――D6115 System reserve (for DA) ――D6116 System reserve (for DA) ――D6117 System reserve (for DA) ――D6118 System reserve (for DA) ――D6119 System reserve (for DA) ――D6120 System reserve (for DA) ――D6121 System reserve (for DA) ――D6122 System reserve (for DA) ――D6123 Error no ――D6124 Error sub no ――D6125 Pallet1 work No.of current lay ――D6126 Pallet2 work No.of current lay ――D6127 Pallet3 work No.of current lay ――D6128 Pallet4 work No.of current lay ――D6129 Pallet5 work No.of current lay ――D6130 Pallet6 work No.of current lay ――D6131 System reserve ――D6132 System reserve ――

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Dm No. Name Description SH Ver.D6133 POD Screen No. POD screen No. under display

2.07-D6134 Current Step No. Step No. under executionD6135 C-axis Torque Current C-axis torque 2.07B-D6136 Password1

for maintenanceSet in ASCII code. If the password is 1234,

D6136：0x3231D6137：0x3433

[How to use]In your various applications, numbers entered through the screen in internal PLC logic can be compared with the above data memory contents.

2.08D-

D6137 Password2for maintenance

D6138 Pallet1 work weight [Kg] 2.08H-D6139 Pallet2 work weight [Kg]D6140 Pallet3 work weight [Kg]D6141 Pallet4 work weight [Kg]D6142 Pallet5 work weight [Kg]D6143 Pallet6 work weight [Kg]D6144 System reserveD6145 Pallet1 Current data *See[Device(D6145-D6156) descriptions].

*When device is set and how often updated1) When product is set up2) When a program starts to be operated by

external PLC (X7 or M5000)3) When COUNT command is executed

*Outlines of the process of PLCPLC download D6145 and D6146 to local devices at the station-loading-enable.(Example: D2145, D2146) PLC controls stations upon the number of products gripped and turn information on D2146. But the program is controlled with D2145 for the first time.

2.09-D6146 Pallet2 Current dataD6147 Pallet3 Current dataD6148 Pallet4 Current dataD6149 Pallet5 Current dataD6150 Pallet6 Current dataD6151 Pallet1 Next dataD6152 Pallet2 Next dataD6153 Pallet3 Next dataD6154 Pallet4 Next dataD6155 Pallet5 Next dataD6156 Pallet6 Next dataD6157 How long since

batteres replaced.[date]for encoder

D6158 for boardsD6159 How long motor

power turned ON. [hour]for lower 16 bits

D6160 for upper 16 bitsD6161 How long

auto-operation ON.[hour]for lower 16 bits

D6162 for upper 16 bits

*Device(D6145-D6156) descriptionsBit Descriptions Bit DescriptionsBIT 0 Robot data

(Data 1)BIT 8 Turn information

BIT 1 BIT 9 Drop highBIT 2 BIT 10 Direction of grippingBIT 3 Not in use BIT 11BIT 4 Direction of approach BIT 12 Number of grippingBIT 5 BIT 13BIT 6 BIT 14BIT 7 Not in use BIT 15

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7.4.I/O Signals for HandI/O signals for hand will be connected to CN 33 in T-axis connector box.

Type Name Description Relay CN33

Universal

Spare S3

See “1.4.”

3

Spare S4 4

Spare S5 13

Spare CLS 14

Fixed

Hand OPEN SL1O In manual mode, the keys [1],[2],[3] are used to operate this relay.Standard program uses output relay for this purpose.

Y1C 5

Hand CLOSE SL1C Y1D 6

Hand OPEN SL2 Y1E 7

Hand OPEN SL3 Y1F 8

Power supply (N24A) 9

Hand Reed switch HRS1 Standard programs uses input relays for this purpose.

X24 10

Hand Reed Switch HRS2 X25 11

Power supply(P24A) 12Universal

Spare S1 These are assigned and connected to the input relay of the account of the right.

X26 1

Spare S2 X27 2

Frame ground FG 15

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7.5.EmergencyNote:Initial test is necessary after change of component parts or addition of equipment as affect the safety functions. (See Initial test procedure in Safety manual.)

Input signals for safety stop will be connected to 3 terminals in controller as follows,-PLC should notify emergency stop to the robot, when sensor is turned on on condition that memory switch 2-4 is off.-After sensor is turned on, it can return by abnormal release button.

If it can not return, turn off the main power supply.


１ Emergency switch*1 For emergency stop 1 0

PES1 and PES2 on the TBR1 (terminal) *2

２Sensing Safety fence’s door open*1

For a person's safety 1 0PDS1 and PDS2 on the TBR1 (terminal) *2

３

Sensing invasion of the dangerous area*1

For a person's safety 1 0PSE1 and PSE2 on the TBR1 (terminal) *2

*1 Control system performance: Safety Category3 (ISO13849-1)*2 Two terminals are ready for the double safety circuit.

The TBR1 is set on the inner side panel of controller as follows,

Figure. The arrangement of the TBR1

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TBR1

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Two terminals must be connected as follows,

34

PES1

LS1b

PES2

LS2b

TBR1TBR1

PDS1PDS2P24

PSE1PSE2P24

Figure (a). The example connection of PES1 and PES2

Figure (b). The example connection of PDS1 and PDS2

PSE1 and PSE2

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8. Maintenance menuThere is some useful information on maintenance menu in a touch panel.

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8.1.Menu structure

Maintenance menu is displayed by choosing "Maintenance mode" in main menu, and every maintenance menu can be operated.

8.1.1. Move to maintenance menu under operation

Basically maintenance menu is 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.

Error: Reference source not found

* In the case of returning from maintenance menu, it returns to auto mode screen instead of main menu screen.

2

System storage mode

Teaching mode

Maintenance mode

Basic menu

Automatic operation mode

Auto mode screen

Maintenance mode screen

Main menu

： under operation： during stop

Auto mode screen (under operation)

Hidden key

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8.1.2. Two types of maintenance menu

Basically, ordinary maintenance menu is displayed on the maintenance menu screen.Apart from this, special maintenance menu is displayed by pressing the hidden key upper left on the maintenance menu screen.

3

ordinary maintenance menu

Software versions are shown as below: POD soft: POD screen data SH soft: Main program for RC101 (rc101.bin) VC33 soft: Main DSP program (srvmain1.bin) lf24 soft: Sub DSP program

hidden keyspecial maintenance menu

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8.2.Special maintenance menu

8.2.1. Overlap trace

1. Last executed 12 steps overlap trace state at is displayed.

* A variable value in the program is displayed.

8.2.2. RISC output data

1. The position data of each axis can be displayed as an instruction value to servo motor control board (RC103).

* Last about 20 seconds data can be shown. but, in case a motor power is OFF, data is not automatically updated. So in case a motor power turns off by occurrence of abnormalities, the data of the about 20 seconds before can be shown.

● Press [Write] key to save data to file.● Press [Read] key to read saved data.

* [Write] and [Read] operation cannot be performed under operation. * The data saved to file can be taken in by Oxpa-Qm2, and can be treated as a CSV file.

● Press [Gragh (Pos)] to display the position data by graph.● Press [Gragh (Spd)] to display the speed data by graph.

* Press [Axial change] key to show the graph of a different axis.

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8.2.3. SMOV calculation

1. In case SMOV command is executed, executed step No., location data, and acceleration and deceleration time can be shown.

8.2.4. Operation Trace

1. Last 112 histories of operation by touch-panel can be shown.

Display content Date : DD HH:MM Scrn : Base screen No. Sub : Overlap screen No. Key : Operation content Result : Operation content (Detailed code)

8.2.5. PLC & Tie-in Trace

1. Last 90 special commands (stcnt/sthgt/wtrspd etc.) of the palletize system executed from Built-in PLC are displayed.

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8.2.6. Task Counter

1. The executed situation of every task of a program is monitored.

● Press [Measure Start]. The number of executed times of each task is counted until the“move”task (the highest priority task) adds up 1000 times.

* As a result of measurement, in the case of few executed time of a lower ranked task by CPU load, trouble is caused to processing operation of the corresponded task.

8.2.7. Damaged File List

1. The file damaged at the time of a file check at power starting is displayed.

* The damaged file itself is scrapped automatically.In case a power is intercepted during communication with Oxpa, abnormalities (RAMDISK breakage) occur in a file check at the time of starting next time.

Please check the damaged file on this screen in that case.

8.2.8. Servo Current Setting

1. An offset value of servo motor currentcan be shown and registered.

* In case a servo amplifier board (it contains board“RC103”) and a servo motor are exchanged, a current offset value needs to be re-set up. But, by setting up automatically at the time of a power injection, especially operation is not required on this screen.

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Press [Re-indicate] key, the present current value is displayed as an offset value.● Press [Enter] key, a current offset value on display is reflected to apparatus.A power re-injection is not necessary.● Press [Saving the File] key, the offset value on display is saved to file.

* [Enter] and [Saving the File] key cannot be pressed under robot operation.

8.2.9. Servo Torque indicate

1. D/A Output SettingThe motor rotation speed and desired torque of the axis whose switch is ON are outputted to the D/A terminal of board“RC101”.

D/A terminal ch0 : Motor rotation speed D/A terminal ch1 : Desired torque

* Select [Test] to output a triangular waveform.

* It is outputted only at the time of a motor power injection.In the case of a motor power ON, show after turning off a motor power since data is always updated.

● Press [Save the File] key, last about 10 seconds D/A output data is saved to file.● Press [Graphic] key, last about 10 seconds D/A output data is displayed by graph.

* The data saved to file can be taken in by Oxpa-Qm2, and can be treated as a CSV file.

On a graph display screen,* Press [Axial change] key to change the axis to display.* Press [Display change] key to change the data (motor rotation speed or desired torque) to display.

Sampling CycleThe data sampling cycle of motor rotation speed and desired torque is set up.Both of D/A output data and graph display (or saved file) data are reflected.By this setup, the time to indicate by graph display (or saved file) is different.

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2. Effective Torque

● Press [Measure Start] key to measure effective torque value.Press [Measure Stop] key to stop measuring, the measurement value at the time of pressing [Measure Stop] key is displayed.

8.2.10. Motor Rotation Test

This operation is for the test only in a motor before shipment.Usually ( in case the control board is connected to a robot), do not operate it.

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Robot manual

Installation and Adjustment

11 Version: 2012.02.21

Robot Palletizer described in this manual is under production since Jun 2005.

<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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