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Standard type of controller

1. Equivalent to AWG28x20P Crimp terminal Vinyl tube The connector shell should be made of conductive metal shielding wire I O cable Fasten to the connector I O power connector Modifying the Shielding Wire Example 85 6 3 2 Wiring of Primary Power Source Observe the following precautions when wiring the primary power source of the robot controller 1 Connect the robot power cable to a power source separate from the welder power source 2 Ground the protective grounding wire green yellow of the robot power cable 3 Ground the functional grounding terminal of the robot controller using a wire of 1 25 mm or more in size 4 For the robot power supply use a protective grounding wire with grounding resistance of 1000 or less 5 If the supply power source for the robot controller requires a leakage breaker use a high frequency proof leakage breaker for inverters 6 When inserting a circuit breaker between the robot and the AC input power supply select the circuit breaker with breaking capacity higher than the following specification Recommended circuit breaker example CP33V 20 Fuji Electric FA Components amp Systems Co Ltd Caution Using a circuit breaker with breaking capacity lower than the following specification may cause the circuit breaker to be shut down due to robot operation Breaking characteristics curve eo m C ab E TM O amp x ab M Eo
2. 105 e Daman SW Note Terminal numbers with asterisks are used only in the dual safety emergency stop circuit version enm i en A Ae 143 8 5 6 INPUT CNS in I O Box All User I O Mode emat me oz ema 0 ml X Rosp H Z7 ern z 3 emat E 2 quema EZ 4 Enable auto 29 Usern HT 5 Userinput 0 30 Usern 25 6 usrmu 1 31 serm 26 32 8 Userinput 3 39 Usermpu H 9 Userin 4 34 Urn 29 10 usrmu 5 35 Usern 30 uermu 6 39 Usern 31 13 Userinput 8 39 Usern 33 1 Userin 9 39 Usernu a Note Terminal numbers with asterisks are NOT used in the dual safety emergency stop circuit version el 144 8 5 7 Port No 512 513 514 515 516 517 518 519 520 52 522 523 524 525 526 527 528 529 530 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 to 763 764 765 766 767 INPUT 537 INPUT 540 145 DeviceNet Slave Board in I O Box Compatible Mode Port No 768 769 770 171 712 173 774 175 776 777 178 7179 780 781 782 783 784 785 786 187 788 789 790 791 192 1793 794 795 796 197 798 799 800 801 802 803 04 8 805 to 1019 1020 1021 1022 1023 8 5 8 512 StpSop Altass 514 instantaneous Stop All tasks Ha
3. 518 Reseved 519 Reseved 521 Program No selection bit1 1 Error in the units place bit O Error in the tens place bit O 7 7 Error in the units place bit 1 7 Error in the units place bit 2 7 T Error in the tens place bit 1 784 785 786 787 Ermorin the units place bit 3 788 789 790 Clear Robot Error 536 Error in the tens place bit 2 Error in the tens place bit 3 Port N Signal name Port No Signal name 774 775 84 85 86 187 88 89 790 794 795 197 798 799 O 018 019 521 30 35 39 40 41 42 43 44 45 536 794 Error in the hundreds place bit 2 795 Error in the hundreds place bit 3 797 X Reseved gt 798 Reserved 799 Reserved NEUEN INPUT 550 to INPUT 764 765 765 INPUT 765 INPUT 766 INPUT 767 NEL NN OUTPUT 806 to OUTPUT 1020 1021 1021 OUTPUT 1021 1022 OUTPUT 1022 1023 OUTPUT 1023 153 8 5 16 PROFIBUS DP Slave Board in I O Box Standard Mode Input data Output data Port No Signal name Port No Signal name Robot Running RobotRunning Robot Error SevoON _ __ O o O Robot Initialized 776 Robot Warning 520 Data area 1 b 540 Data area 2 bit 12 it 0 796 Status area bit 12 O Command area bit 1 INPUT 554 to
4. 55 Power output for hand p we w e E m External internal source Power output for hand Lv e wd External internal source 9 Hand input 48 19 Noconnection Hand input 49 20 fjNocomecin B PNP type a 1 8 2 CL DE 5 j Handoutpt 68 15 jHandipt 5 6 j Handoutpt 69 16 jHandipt 55 Power output for hand om E External internal source Power output for hand ENCCENMENEN GEN External internal source 9 j Handipt 48 19 jNocomecin 10 Handiput 49 20 Nocometon 138 8 5 I O Allocation Tables for Individual Allocation Modes 8 5 1 OUTPUT CN10 in I O Box Compatible Mode 1 CPU Normal No monitor allowed 72 35 Useroupu 106 2 Robot Running 73 36 Useoupt 10 3 RobotEmo 74 37 Useroutput 8 4 AutoMode 75 38 j Useroupt 109 5 ExternalMode 76 9 f Useroutput mo Ls D iom sse 41 Useoupu m Ls messes E att 9 9 Robot Power ON Completed 80 43 Useroupu ma 10 SevoON 81 44 jUseoupt ms 13 CydeEnd DD 47 j Userouput HB OE E 15 Robot Warning 49 User output 120 16 Coninue Stat Pomisson ar 50 User output at 18 Error in the units place bit 89 52 Useroutput 123 19 Error in the units place bit2 90
5. O port 782 Note 4 The output timing is the same as that of Robot Power ON Completed I O port 776 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 148 8 5 11 CC Link Board 4 stations occupied in I O Box Compatible Mode Output data Input data Remote Il Signal number output ee Signal number Remote Ipu number Note 1 number Note 1 Step Stop All tasks 768 O RXm Continue Start Robot Running Operation Preparation Start Auto Mode Interruption Skip External Mode Program Start Program Start Reset Program No selection bit 0 Robot Power ON Completed Program No selection bit 1 Program No selection bit 2 CAL Completed Program No selection bit 3 Teaching ON Program No selection bit 4 1 Cycle End Program No selection bit 5 Battery Warning Program No selection bit 6 Robot Warning 527 a en ul Continue Start Permission Motor Power ON RY n 1 0 Error in the units place bitO RX n 1 O CAL Execution RY n 1 1 Error in the units place bit 1 RX n 1 1 RY n 1 2 Error in the units place bit2 RX n 1 2 SP100 RY n 1 3 Error in the units place bit3 RX n 1 3 External Mode Change RY n 1 4 Error in the tens place bit O RX n 1 4 Program Reset RY n 1 5 Error in the tens place bit 1 RX n 1 5 Clear Robot Error RY n 1 6 Error in the tens place bit 2 RX n 1 6 RY n 1 7 Error i
6. Step Stop All tasks RYnO RXn0 RYn1 Robot Running RXn1 514 er HOD AN TASES RYn2 770 Robot Error RXn2 515 Strobe Signal RYn3 771 RXn3 516 Interruption Skip RYn4 772 Robot Initialized su RS 773 Auto Mode RXn5 518 RYn6 774 External Mode RXn6 780 RXnC 781 RXnD 782 RxnE 783 RXnF 0101201 0 AJ x X lt lt 2 lt x 51515 5 2 gt PlololN p O 784 Status area bit 0 RX n 1 785 Status area bit 1 RX 2 O oO LM 2 1 530 2 766 531 787 532 788 533 789 534 790 535 791 RX n 1 7 536 792 RX n 1 8 537 793 538 794 539 795 540 796 541 797 RX n 1 D 798 799 544 wo s 879 UU 0 E SO NEGE Note 2 EN EI um Not used x 623 RX n 7 F Ed E Not used 639 Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 The output timing is the same as that of Robot Error O port 770 and Robot Warning O port 776 Note 4 The output timing is the same as that of Robot Initialized O port 772 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 122 7 5 18 CC Link Board 2 stations occupied in All User I O Mode Input data Signal name INPUT 516 518 RYn6 519 RYn7 520 RYn8 521 RYn9 522 RYnA 523 RYnB 524 RYnC 525 RYnD 526 RYnE 527 RYnF User input INPUT m mer No
7. 1 input Pink Pink Protective Stop 2 2 input ink Enable Auto 1 1 input Enable Auto 1 2 input ink Enable Auto 2 1 input Reserved Reserved Reserved Pendant Emergency Stop 1 b 1 output Enable Auto 2 2 input Pendant Emergency Stop 1 b 2 output ray ray ray ray ray Pendant Emergency Stop 2 b 2 output Pendant Emergency Stop 2 b 1 output BERN O1 gt C2 Gray Deadman SW 1 1 output Enable SW 1 1 Safety relay Deadman SW 1 2 output Enable SW 1 2 Safety relay Gray Deadman SW 2 1 output Enable SW 2 1 Safety relay Deadman SW 2 2 output Enable SW 2 2 Safety relay White O Contactor Contact Monitor 1 2 Brown output Brom output GE The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 19 2 and 20 18 and 36 Contactor Contact Monitor 1 1 White N OO C1 ie oO OO OO A OO NO White o Z o et b Caution The reserved pins and output pins should be prevented from direct contact with other pins or conductive part Direct contact could result in a controller failure or damage Caution To use Pendant Emergency Stop output signals be sure to supply 24 V to terminals 13 and 14 69 5 2 Robot Controller I O Circuits PNP type 5 2 1 Setting up Mini I O Power Supply The power supply 24 VDC fo
8. The output timing is the same as that of Robot Error l O port 770 and Robot Warning O port 782 Note 4 The output timing is the same as that of Robot Power ON Completed UO port 776 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 117 7 5 13 CC Link Board 3 stations occupied in Compatible Mode Input data Output data Remote N Signal name Signal name input Note 1 Step Stop All tasks Reserved Continue Start 769 Robot Running Operation Preparation Start Auto Mode 518 5619 1 1 1 Program No selection bit 2 CAL Completed Program No selection bit 3 Teaching ON Program No selection bit 4 1 Cycle End Battery Warning Program No selection bit 6 Robot Warning 0 i RX n 1 8 i RX n 1 9 2 2 2 Reserved User input INPUT m Note 2 Error in the hundreds place bit 0 Error in the hundreds place bit 1 Error in the hundreds place bit 2 X n 1 JE F 0 591 gt 607 n 1 RX n 1 RX n 1 RX n 2 0 User output OUTPUT m RX Baz il RX n 4 F RX n 5 0 Not used Not used Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 The output timing is the same as that of Robot Error l O port 770 and Robo
9. be devoted solely to that task 3 10 Setting the robot s The area required for the robot to work is called the robot s motion space operating space If the robot s motion space is greater than the operating space it is recommended that you set a smaller motion space to prevent the robot from interfering or disrupting other equipment Refer to the INSTALLATION amp MAINTENANCE GUIDE Chapter 2 3 11 No robot modification allowed 3 12 Cleaning of tools 3 13 Lighting 3 14 Protection from objects thrown by the end effector 3 15 Affixing the warning label 3 16 Posting the moving directions of all axes Never modify the robot unit robot controller teach pendant or other devices If your robot uses welding guns paint spray nozzles or other end effectors requiring cleaning it is recommended that the cleaning process be carried out automatically Sufficient illumination should be assured for safe robot operation If there is any risk of workers being injured in the event that the object being held by the end effector is dropped or thrown by the end effector consider the size weight temperature and chemical nature of the object and take appropriate safeguards to ensure safety Place the warning label packaged with the robot on the exit entrance of the safety fence or in a position NWARN N G where it is easy to see RSS EU a Risk DRY 7 Do not enter safety fence area Unfallgefahr Nicht den Sic
10. oL LLL LLL S EEE DEE EEE EEE a a L L Wae L L L L 1 E LCLCCLCCN LL a Lo ID n eee eee 100 120 140 160 180 200 Breaking current Arms Circuit Breaker Characteristics 86 7 Prepare wires of an appropriate capacity for the 200 100 VAC main line and other cables according to the tables given below Robot Controller Power Supply Specifications feat Pin assignment on power connector CN6 S View from the pin face of cable Three phase Three phase 200 VAC 15 to 230 VAC 200 VAC 200 VAC 10 50 60 Hz phase R 200 VAC VMG6BA 3 3 kVA VSG6BA 1 85 kVA phase S Power supply capacity 200 VAC phase T Protective ground HSG4BA 1 8 kVA XRCABA RO kVA Arce eS Single phase Single phase 230 VAC 10 to 230 200 VAC VAG 10 50 60 Hz A ae Power VSGGBA 185 VA VEGSIBCA T WA k E FET Bower supply AMGABA 2 49 kVA HSG4BA 1 8 KVA phase S capacity D Protective XYCG4AA 1 15 kVA XRG4BA 1 8 kVA ground Single phase Single phase 100 VAC 10 to 110 VAC 100 VAC 10 50 60 Hz 100 VAC ee TEE TETERE VEER EEE esse phase R 100 VAC hase S Power supply VPG5 6CAA 1 kVA E capacity Protective ground Max rush current when the power is 40 A for 1 50 or 1 60 second turned ON Caution If ERROR6102 power voltage drop occurs when the
11. oum 7l 1 3A LS e a Mini I O CN5 Reference 640 PS i5 PolySwitch Emergency stop 7 41 P86 0 15A on Mini VO and Deadman g 45 Ps3 0 154 aded HEIL 943 PS4 0 15A 96 6 6 2 Replacing procedures Replace fuses and output ICs according to the following procedure Warning Do not touch the inside of controller before turning off the power switch and waiting 3 minutes or more or you can easily receive an electric shock NCaution 1 Wear a wristband and connect its terminal to a grounded portion before starting work 2 Do not touch elements or their terminals on any printed circuit board with bare hand elements could be destroyed by static electricity Replacing fuses gt Step 4 E Turn the controller power OFF Power switch Step 2 7 Remove the controller upper cover by unscrewing eight screws NWarning Do not touch the inside of controller before turning off the power switch and waiting 3 minutes or more or you can easily receive an electric shock 97 Pull out the fuse to check Step 3 If no continuity is observed with the fuse in Step 4 1 Check the wiring of the corresponding output connector and remove the cause of the blown fuse 2 Insert a new fuse into place in the controller Step 5 If continuity is observed with the fuse in Step 4 set the removed fuse back into place in the controller Set the contro
12. 19 5 2 4 Configuration of Emergency Stop Circuitry Standard type of controller 5 2 4 1 External Emergency Stop and Enable Auto Input Circuits Standard type of controller The External Emergency Stop and Enable Auto input signals are important for safety Be sure to configure their circuits with contacts as shown below TIP For the overall configuration sample of an emergency stop circuitry refer to Section 5 2 4 2 Emergency Stop Circuit Robot controller Internal power source 24V O Emergency stop M P S pon External Emergency Stop input 1 Ne External Emergency Stop input 2 CE 351 E Enable Auto input Internal power source OV External Emergency Stop and Enable Auto Input Circuits Standard type of controller TD 5 2 4 2 Emergency Stop Circuit Standard type of controller The following figure shows the example of configuration and connection of emergency stop circuit on the standard type of the controller In the RC7M controller the emergency stop circuit consists of dual safety circuits The emergency stop button on the teach pendant can be used also as an emergency stop switch of the equipment Emergency Stop and Pendant Emergency Stop output signals 1 Emergency Stop output signal The internal relay receives the External Emergency Stop input signal and the emergency stop input from the teach pendant to output this signal When the power is turned OFF the controller is in the emer
13. 5 5 5 5 5 5 5 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 760 761 762 763 764 765 766 767 Output data fee POPE Battery Warning Robot Warning Continue Start Permission Error in the units place bit O Error in the units place bit 1 Error in the units place bit 3 Error in the tens place bit 1 159 OUTPUT 816 to OUTPUT 1015 09 8 5 21 Ethernet IP Module in I O Box Standard Mode 8 39 ee 8 Data area 2 bit 15 160 766 INPUTT 0 T6 NPUTTG 544 545 546 547 548 549 550 551 552 953 554 555 556 557 558 559 760 761 762 763 764 765 766 767 Output data Robot Warning Continue Start Permission TE E p Status area odd parity Status area bit 8 Robot Running 161 QUTPUT81619 OUTPUT 1015 RC7M CONTROLLER INTERFACE MANUAL First Edition July 2005 Tenth Edition April 2009 Eleventh Edition March 2010 DENSO WAVE INCORPORATED 3M C The purpose of this manual is to provide accurate information in the handling and operating of the robot Please feel free to send your comments regarding any errors or omissions you may have found or any suggestions you may have for generally improving the manual In no event will DENSO WAVE INCORPORATED be liable for any direct or indirect damages resulting from the application of the information in th
14. 53 Useroupt 124 23 Erorinthe tens place t2 94 Sr nouse 4 Errorin the tens place t3 95 S5 Noued ERECTO o or meant ee 5 1 0 Eu ERESTOCODCOUBMEREA3 C A 0 28 Eror inthe hundreds piace bt3 99 67 RootSpp2 9 sswoe TH Sx Emergency Stop 30 Reserved 19 69 Emergency Stop 1 31 Reserved T 5 EmegenySep20 32 Reserved 39 6 EmegemySop2 Deadman SW C BER Deadman SWO wer Note Terminal numbers with asterisks are used only in the dual safety emergency stop circuit version 139 8 5 2 INPUT CNS in I O Box Compatible Mode oo jme n wem 0 0 nm z Robot stop 27 Uermu 22 9 emat E 2 quema EZ 4 EmbeAuo 29 Uermu 24 5 step Stop itas 1 o 30 Usermut 25 Operation Preparation Stat 3 33 Userinput 7 10 1 13 M CAL Executi Reserved s E User User CAL Execution 15 Bean Reset 79 Clear Robot Er 20 e Note Terminal numbers with asterisks are NOT used in the dual safety emergency stop circuit version 2 otor Power ON 4 6 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 5 T 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 2 140 8 5
15. 8 and 26 on CN10 Note For the circuit configuration refer to Sections 4 2 5 and 5 2 5 Two Enable Auto input signal circuits must be controlled with two separate contacts each Two circuits connected in parallel using a single contact or an always shorted circuit will be interpreted as an external circuit error so that the circuitry will not operate 3 Usage This signal is used to connect the AUTO TEACHING selector switch of an external operating panel 4 Input conditions and operation with Protective Stop input signal ON a As shown below the selectable operation mode depends on whether this input is shorted or open b Turning this signal OFF open during automatic operation turns the motor power OFF Continue stop and displays ERROR21FC c If manual operation or a teach check is conducted with this input shorted ERROR21F2 will be displayed d With this signal being opened turning the mode selector switch on the teach pendant or mini pendant from the MANUAL or TEACH CHECK to AUTO position triggers ERROR21F3 Since this state is shown as x in the table below this error will remain displayed until the robot exits this state e Although ERROR21FD or ERROR21FC will be displayed when the state is changed from O to A or x they will not be displayed when the state is changed from A or x to O f Turning this signal OFF open in External mode turns the motor and the Operation Preparation Completed output sign
16. Enable SW output 2 Deadman SW Output Enable SW Output Global type of controller 29 3 2 10 3 Contactor Contact Monitor output Global type of controller 1 Function This signal outputs the status of the auxiliary contact of the motor contactor in the robot controller The contact output signal comes on when the motor is turned on it comes off when the motor is turned off 2 Terminal number 17 and 35 on CN10 3 Usage This signal is used to confirm the ON OFF state of the motor on the monitor For details about the safety circuits refer to Sections 4 2 5 and 5 2 5 Robot controller Safety circuit 200 VAC Motor driver Contactor contact monitor output Contactor Contact Monitor Output Global type of controller 30 3 3 Types and Functions of System Input Signals The table below lists the system input signals Types and Functions of System Input Signals Use to alla Signal name Function controller type Stop Any type Step Stop All tasks Releasing the signal step stops all programs being executed Note 1 Instantaneous Stop Releasing this signal instantaneously stops all All tasks programs being executed Note 2 Standard type External Emergency Releasing this signal stops the robot in an Stop dual line emergency Global type External Emergency Releasing this signal stops the robot in an Stop dual line emergency oelect mode Standard type Enable Auto Short circuiting
17. Execution Reserved External Mode Change 533 bi 534 bi 535 bi 536 Program Reset Clear Robot Error Reserved INPUT 536 INPUT 537 INPUT 538 INPUT 539 S Mode S INPUT 541 O 539 gt WY J S Q gt o 8521 522 523 O 524 525 526 57 528 8529 50 831 533 534 535 56 539 540 541 542 543 544 545 546 547 548 549 INPUT 542 INPUT 543 INPUT 544 INPUT 545 INPUT 546 INPUT 547 INPUT 548 INPUT 549 INPUT 550 to INPUT 764 OUTPUT 806 to OUTPUT 1020 INPUT 765 OUTPUT 1021 INPUT 766 OUTPUT 1022 INPUT 767 1023 OUTPUT 1023 Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 126 7 5 22 PROFIBUS DP Slave Board in Standard Mode Input data Output data Port No Signal name Port No Signal name Robot Running RobotRunning Robot Error SevoON _ __ O o O Robot Initialized 776 Robot Warning 520 Data area 1 b 540 Data area 2 bit 12 it 0 796 Status area bit 12 ECCO INPUT552 0 0 0000 INPUT 552 INPUT 553 INPUT 554 to INPUT 765 INPUT 766 INPUT 767 1
18. Manual operation with the teach pendant or mini pendant Teach check mode Program check with the teach pendant or mini pendant NE NEN MEC INN intem cies Automatic operation with the teach pendant or S mini pendant External auto mode Automatic operation with the external device LO E ES Note O Mode selectable x Mode not selectable A Mode selectable but manual operation program not executable Caution In the pendantless state auto mode is valid even if the Enable Auto input is open The External mode cannot be switched and the program cannot begin execution Perform the following when operating the robot in the pendantless state a Set the robot so that it will not start to operate when the Enable Auto input is open b pee TM input open state and Auto Mode output See Section 3 2 2 Auto Mode output Set the equipment to make an emergency stop in an AND state 34 3 4 A Enable Auto input Global type of controller 1 Function a Turning this signal ON shorting enables switching to Auto mode Dual line Note The Enable Auto and Protective Stop input signal circuits are connected in series in the controller and those signals are used as an automatic operation permission signal when turned ON closed b Turning this signal OFF opening enables switching to Manual or Teach check mode 2 Terminal number Signal name Terminal number Enable Auto input 1 7 and 25 on CN10 Enable Auto input 2
19. No selection bit4 526 ProgramNo selecionbit 526 ProgramNo selecionbit 827 Program selection parity 828 MotorPowerON 529 CAL Execution 880 Reserved S 881 SPIO 582 External Mode Change 588 Program Reset 534 Clear Robot Error 888 536 INPUT536 oo S87 INPUT S87 588 INPUTS88 o 539 INPUT539 o 54 INPUT amp O o 945 INPUT541 00 542 INPUT542 0 0 00 0 548 NPUTSMB 0 00 0000 54 INPUT544 545 INPUTS 0 0 00000 546 INPUT546 o 547 INPUTBAT 00000000 548 INPUT S48 549 INPUTS49 0 0 QNPUTSSOtoINPUT764 765 INPUT 765 766 INPUT 766 Te INPUT 767 912 513 514 515 516 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 765 766 167 114 Robot Error Robot Power ON Completed Error in the units place bit O Error in the units place bit 1 770 776 ss ws OUTPUT 806 16 OUTPUT 1020 7 5 10 DeviceNet Slave Board in Standard Mode Note The table below applies also to the allocation of the slave area on the DeviceNet master slave board Input data Output data Signal name Step Stop All tasks Reserved 513 Reserved Robot Running B1 Instantaneous Stop All tasks Halt Robot Error Y ervo ON Robot Init
20. O board To use the I O conversion box select 24 V power supply internal or external on I O POWER CN7 You also need to set up the power supply for the mini I O board and parallel I O board to match the power supply setting on I O POWER CN7 The factory default is external power supply For details about the mini I O board see Section 4 2 1 or 5 2 1 For details about the parallel I O board refer to the RC7M Controller OPTIONS MANUAL Section 5 2 2 137 8 4 Allocation Common to All Allocation Modes The RC7M controller supports hand I O signals CN9 as standard This hand I O and I O POWER CN7 are common to all allocation modes 8 4 1 lO POWER CN9 Common to All Modes NPN type I O PNP type I O ius Ls Signal name Signal name p S Internal power source output 24V Internal power source output 24V 2 Internal power source output 24V Internal power source output 24V 3 Internal power source output my Internal power source output OV 4 Internal power source output OV SE OM EEE 6 Powerinput 24V 6 PowerinptOV 7 Powerinput 24V 8 Powerinputov 8 Powerinput 24V 9 Powerinputov 1 9 Powerinpt 24V _ 8 4 2 HAND I O CN9 Common to All Modes B NPN type 3 Handoutpt 66 13 jHandipt 52 5 j Handoutpt 68 15 jHandipt 5 6 Handoutpt 69 16 jHandipt
21. Program Stat Rest 9845 OUT 8 Reserved 3847 OUT 9 Robot Power ON Completed 3848 OUT 27 Instantaneous Stop All tasks 3586 IN Half 45 Powrszdv m 46 Powrszav m Lar Powers UN 48 Power N 110 50 Error in the hundreds place 3864 OUT bit O on in the hundreds place 3865 p in the hundreds place 3866 E in the hundreds place 3867 SS Mode 3868 OUT User output EDD ENNE INN 3605 an n 3607 Nn User input i Powry Im Power I Im Power I Im Powry I Im 7 5 6 Parallel I O Board in Standard Mode Signal Name eus Signal Name 3840 Status area bit 8 3664 2 Robot Running Status area bit 9 Robot Error 3842 51 Status area bit 10 3866 52 53 6 AutoMode 3845 OUT 54 55 8 Battery Warning Status area bit 15 OUT 9 Robot Warning 3848 OUT Completed User output nz Stop All tasks 3586 IN 76 Interruption Skip 77 79 80 81 82 83 84 85 86 87 88 89 T 90 91 92 45 Powrev IN 95 Power N 46 Power 24v IN 94 PowrV 0 IN 47 Powrsy m 95 PowrtV In as Powersziv n 96 Power IN 111 7 5 7 Parallel I O Board 1st in All User I O Mode 49 50 51 52 53 EE m 54 55 56 NN 57 58 59 Hsi 60 serous 61 62 63
22. area and the data area according to the input of Strobe Signal 4 The controller starts processing based on the command read 5 After completion of command processing the controller turns ON the Command Processing Completed signal If an error has occurred during processing a Robot Error signal will be outputted together with the Command Processing Completed signal Note If the Strobe Signal is turned OFF before the Command Processing Completed signal is turned ON the Command Processing Completed signal will be output and then turned OFF within 100 ms 6 The PLC waits until the Command Processing Completed signal is input In this case confirm that no error exists with the robot 7 The PLC turns OFF the command and data areas and the Strobe Signal 8 As soon as the Strobe Signal is turned OFF the controller turns OFF the Command Processing Completed signal The Robot Error signal which is outputted due to a command processing error remains ON until Clear Robot Error 001 is executed Note The maximum allowable time from when the Strobe Signal is turned OFF until the Command Processing Completed signal is turned OFF is 100 ms 3 5 2 2 Using Each Signal Line 1 Command and Data Areas This section describes the usage of the command area 3 bits input and data area 3 bits input 1 Function Specifies the commands to be executed by the Robot Controller Sets the command area at all times and data ar
23. area tota 10 i Data area bs fH Data area tbt 12 Data area 1bt7 I Data area 2000 a Data area2btt i i i i Data area zbit 19 Data area 2 bit 6 20 4 Note Terminal numbers with asterisks are NOT used in the dual safety emergency stop circuit version D D D U U U U U U U U 24 5 6 T 8 9 0 3 32 33 34 3 36 3 38 39 0 2 3 4 2 2 2 3 4 4 4 4 4 T 10 11 1 12 13 14 15 5 16 17 T 18 19 20 21 1 22 23 24 5 5 2 142 8 5 5 OUTPUT CNI10 in I O Box All User I O Mode 6 Useroutput 77 40 j Useoupt 8 Useroutput 79 42 j Useoupt 13 9 Useroutput 80 43 j Useoupt ma 18 Useroutput 84 47 Useoupt HB uw r2 Dr 15 User output 49 User output 120 i ueram sr 59 seram 121 S EFI 4 122 18 User output 52 User output 123 18 ser ouput R o 25 userow H o 57 nouse 24 Useroutput 95 58 Noued 1 Dem em emm Internal power source 24V 26 usro HT o Robot Stop D ema T Internal power source 24V 28 Useoupt H H S ReotSop2 a 30 Useroupu 101 64 Emergency Stop 1 C NN 31 Useoupu 10 65 EmegenyStp2t 32 Useoupu 103 66 EmegemySop20 39 Userouwpt 108 67 pemmansW 3 userowpu
24. below T x lo e o 0 Air outlet Air inlet Controller mounting panel Stand alone installation Wall mounted installation Setting up the Robot Controller 84 6 3 I O and AC Input Wiring 6 3 1 Multi core Cables with Connectors Multi core cables with connectors to be used for the lO wiring of the Robot Controller are options Select an appropriate cable from the table given below if necessary I O Cables Options Standard I O cable set 8m 8m Mini I O cable set Hand l O cable set Standard I O cable set Mini I O cable set Hand l O cable set 410149 0940 410141 2700 410141 1740 410149 0950 410141 2710 410141 1750 Including Nos 1 1 and 1 2 Connector set 410159 0190 Including Nos 2 1 and 2 2 Connector set 410159 0190 If you do not use optional cables listed above use the recommended connectors and cables listed below Recommended Connectors for I O Cables and Cable Standards Connector Connector name model manufacturer PCR E68FS connector Mini VO PCS E68LPA 1E cover HONDA TSUSHIN KOGYO Co LTD PCR E20FS connector HAND I O PCS E20LA cover HONDA TSUSHIN KOGYO Co LTD Cable Standards Remarks UL2789 With shield Equivalent to AWG28x34P Caution Be sure to modify the shielding wire at the end of the cable to be used as shown below Without this modification the robot may malfunction due to UL2789 With shield noise
25. controller enters Auto mode by turning the mode selector switch on the teach pendant or mini pendant to AUTO with the Enable Auto input signal being ON 5 OFF conditions This signal will be turned OFF under the following conditions a The operation mode is switched to the Manual or Teach check mode by using the teach pendant or mini pendant b The Enable Auto input signal is OFF Note The Enable Auto input signal will not be turned OFF in the pendantless state described in the OPTIONS MANUAL Chapter 1 Section 1 3 3 Caution The Auto Mode output signal will not be turned OFF with INSTANTANEOUS STOP STEP STOP or CYCLE STOP commands When the mode selector switch of the teach pendant or mini pendant is set to AUTO Auto mode Output The mode selector switch on the teach pendant or mini pendant is set to MANUAL or TEACH CHECK Enable Auto OFF Auto Mode Output 18 3 2 3 Operation Preparation Completed output 1 Function This signal tells that the motor power is ON and the robot is in External auto mode 2 Terminal number 50 on connector CN5 3 Usage With this signal being ON the robot must be in External auto mode and the motor power must be ON to run the robot from the external device 4 ON conditions The signal will be turned ON under the External auto mode and motor ON Operation to switch to External auto mode a When the External mode is selected on the teach pendant or m
26. examples of the user input system input and hand input circuit configurations and connections of the robot controller Notes 1 In addition to PLCs proximity switches and relay contacts can be directly connected to the input terminals of the robot controller Note that the leakage current from the proximity switches should be 1 mA or below 2 Use multi core shielding cables for protecting the controller from external noise and ground them at the controller side Bras TH E SHOE ems inn dian 680 Photo coupler HAND lO CS T OUT fe eX 4 3k H c m NN ef dm tt hl ol I 1 3A 680 Photo coupler 5 D D j m Q Q c Robot controller When the external power source is used User Input System Input and Hand Input Circuits NPN type o4 WINDJIIO euJeju HAND I O uo ii OUT f N19 LL INNEN OV Internal power source 680 am coupler 4 3k ille 4 3k ei x 4 3k el C E A 680 Photo coupler Robot controller When the internal power source is used User Input System Input and Hand Input Circuits NPN type 55 4 2 3 User Output System Output and Hand Output Circuits NPN type The following pages show examples of the configuration and connection of the robot controller s user output system output and hand output circuits 1 The User Output System Output and Hand Output Circuits are open collector output circuits 2 The maximum allowa
27. for Enable auto Mini I O terminal 1 Internal 24V ok External emergency stop 1b 1 F5 1 3A Mini I O terminal 2 Internal 24V a m l External emergency stop 2b 1 Mini I O terminal 3 Internal 24V o Mini I O terminals 45 to 60 System output User output 16 to 31 Hand I O terminals 1 to 8 Hand output Hand I O terminal 17 Power supply for hand E24V Caution F2 fuse is provided for protecting the circuitry from getting damaged if a voltage of 30V or above is applied to the 24V external power source terminals F2 fuse is not mounted on a Mini I O board in controllers whose product number is 02H018 or later short circuited instead 95 The table below lists the output ICs and fuses for the Mini I O CN5 and HAND I O CN9 If an output signal error occurs check the corresponding fuse Note The Emergency Stop and Deadman output circuits use PolySwitches resettable fuses that trip in an overcurrent condition to open the circuits If a PolySwitch trips turn the power off and check the related circuit As long as the power is on a PolySwitch keeps tripping After checking therefore turn the controller power off and on then check the circuit again Output ICs and Fuses Application Pin No I O Port No Output IC HAND I O For output IC10 1 3A CN9 For power output ES E External Internal power power supply supply LLL S L 1 3A For 24 VDC L 1 3A L see jp e 538 E m Do
28. indicator ON Setting Mode selector switch of the teach pendant or the mini pendant to AUTO iji Note 1 button ON button ON Command area input ON Executing Operation Preparation command Motor power ON Setting SP100 a Operation preparation Switching mode to external mode 1 Operation Preparation Completed signal ON Internal processing Robot external running OK indicator ON Robot external running OK indicator Run the user program for moving robot arm close to the home position when the robot home position indicator is OFF dei Internal processin g indicator ON P Ing T for robot home position Robot preparation OK When both are ON display Internal processing Continued on following page b Operation start area check 46 Continued from preceding page Start and Stop Procedure and System I O Signals 2 Worker s operation and display on Step equipment s operation panel PLC processing Robot operation Equipment s Automatic Data area input ON Start Button ON Program Number selection Automatic Operation Executing Program Program start indicator ON Operation Command Program start Note 2 E I Program Number Robot Running signal selection OFF Program start command ON Repeated c Automatic operation Equipment s Cycle Cycle Stop ON Executing 1 cycle Stop button ON De d Operation end Automatic operation Int I i indicator
29. it will start from the beginning If the specified program is step stopped it will resume from the step following the suspended step If the specified program is instantaneously stopped Halt it will resume from the step following the suspended step When the program is instantaneously stopped in while in execution of an operation command it will resume from the operation still undone If the specified program is running an error ERROR21F5 will be displayed and the program will stop 42 3 5 3 5 CONTINUE START 011 1 Function This command starts Continue Start 2 Format Command area 3 bits input 011 Data area 3 bits input Nothing will be input 3 Description This command is executable only in External mode An error will occur in other modes An attempt to execute this command when the Continue Start Permission signal is off will cause an error ERROR 27A8 3 5 3 6 SPECIFIED PROGRAM RESET 100 1 Function This command immediately stops and also initializes the program of the program number specified in data area 2 Format Command area 3 bits input 100 Data area 3 bits input Program number The program number to be reset If the number n is specified in data area resets PRO n 3 Description This command can reset the programs for PRO 0 to PRO 7 One of the following operations takes place according to the operating status of the program When the specified pro
30. other conductive material flying about 3 there are any acidic alkaline or other corrosive material 4 there is a mist 5 there are any large sized inverters high output high frequency transmitters large contactors welders or other sources of electrical noise B Fordust amp splash proof The dust amp splash proof type has an IP54 equivalent structure type but it has not been designed to withstand explosions The HM HS G W and the wrist of the VM VS G W are an IP65 equivalent dust and splash proof structure Note that the robot controller is not a dust or splash proof structure Therefore when using the robot controller in an environment exposed to mist put it in an optional protective box The dust amp splash proof type should not be installed in any environment where 1 there are any flammable gases or liquids 2 there are any acidic alkaline or other corrosive material 3 there are any large sized inverters high output high frequency transmitters large contactors welders or other sources of electrical noise 4 it may likely be submerged in fluid 5 there are any grinding or machining chips or shavings 6 any machining oil not specified in this manual is in use or Note Yushiron Oil No 4C non soluble is specified 7 there is sulfuric cutting or grinding oil mist 3 2 Service space The robot and peripheral equipment should be installed so that sufficient service space is maintai
31. output 24V Resev 5 Gray Gray D lt 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 a l 6 6 Dedicated to conveyor tracking board when JP13 on mini I O board is shorted Gray Internal power source output OV 3 2 5 5 4 5 56 2 6 4 C2 oO wo _ S o aa Fen Kon DC power input OV when external power Gray 6 source is used Bue DC power output OV when internal Note 1 The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 35 2 and 36 34 and 68 32 33 DC power input 24V when external power source is used DC power output 24V when internal power source is used CL gt Caution The reserved pins and output pins should be prevented from direct contact with other pins or conductive part Direct contact could result in a controller failure or damage 68 5 1 4 Safety I O CN10 System I O connecter Global type of controller Safety I O CN10 Pin Assignment 36 19 View from the cable side Terminal Terminal Signal name Signal name External Emergency Stop 1 b 1 input External Emergency Stop 1 b 2 input External Emergency Stop 2 b 1 input 20 External Emergency Stop 2 b 2 input CIE Green Blue Port o o Pink Lg Lg wo 21 Reserved Protective Stop 1 2 input Reserved Protective Stop 1 1 input Protective Stop 2
32. robot is in operation then it may be due to an insufficient capacity of the primary power source 8 Do not bundle the teach pendant cables I O cables or motor cables together with high power lines such as 200 100 VAC lines and peripheral device cables or route the motor cables near high power devices motor welder parts feeder etc 9 Do not route any additional cables or air tubes of end effectors through the robot unit Doing so will result in broken cables or tubes 10 Use the correct power source 200 VAC or 100 VAC for the controller specification 87 6 3 3 Disconnecting the Robot from the Power Source If you need to cut off the power supply from the robot unit for maintenance or transportation purpose follow the steps below for safety Step 1 l Turn OFF the power switch of the robot controller Step 2 Check that the motor ON lamp is OFF Step 3 7 Disconnect the power cable from connector CN6 on the robot controller 88 6 4 Cleaning the Air Intake Filters The robot controller has three air intake filters If those filters are clogged the robot controller becomes insufficiently ventilated so that the internal electronic devices may be damaged due to heat If a power module error appears it may be caused by clogged filter so clean the filter Cleaning Procedures gt Step 1 Turn the controller power OFF Power switch Step 2 7 Remove the four filter covers from the front panel by loosen
33. section gives an example of replacing the memory backup battery Caution Before replacing the memory backup battery be sure to save the memory data in the robot controller to the PC Step 1 j Save the memory data held in the controller to the PC Step 2 2 Make a new memory backup battery ready for use Power switch 91 Step AT Remove two screws from the battery cover and pull them out together with the backup battery Step 5 Disconnect the backup battery harness Caution Complete Steps 5 through 7 within three minutes Taking more time will lose the memory data Step BS Set the new memory backup battery ready for use in Step 2 on the battery cover Step 7 Step 8 7 Mountthe battery cover with the new backup battery into the controller and secure the cover with the screw ACaution Take care not to pinch the battery lead wires between covers or internal parts Shorting may occur resulting in an unexpected failure 93 6 5 2 Setting the Next Battery Replacement Date After replacing the memory backup battery set the next battery replacement date from the teach pendant according to the following procedure Note Check that the system clock of the robot controller shows the correct date beforehand If it is incorrect the next replacement date will also become incorrect Step 1 On the top screen of the teach pendant press F6 Set The Settings Main window appears Press F6 M
34. servo lock 2 Single point of control function e us ml VS 6556G A Mem wotolf a2 1 0 Hardware n No of parameters 65 The global type of the robot controller supports the single point of control function while other types do not 1 Single point of control The single point of control function which is one of the robot safety functions limits the robot control sources command sources to only one This function is specified by the parameter Single point of control that limits the control to either Internal Auto or External Auto limited mode m Internal Auto limited mode The Auto mode is limited to the Internal Auto limited mode in which a program start can be triggered from the teach pendant but cannot from external equipment B External Auto limited mode The Auto mode is limited to the External Auto limited mode in which a program start can be triggered from external equipment but cannot from the teach pendant Note In this mode the controller running software version 2 801 or earlier cannot use the teach pendant operation panel editor Panel Designer in External Auto 2 Setting the Internal External Auto Limited Mode Parameters Using the teach pendant set the parameters with the following access Note 1 The Internal Auto Limited Mode is the factory default Note 2 The global type displays letter A following the robot type on the teach pendant screen Access Top scre
35. setis rganized a aa ii S AS RNC TSEADELCHIVASS PENES iii SAFETY PRECAUTIONS Chapter 1 General Information about RC7M Controller eee ee eee e e e ee eere eee eere eee eene eee e eee essa a setae tette eee eee 1 Ll Controller Model Name on Nam Pl ne Reel I 2 SNamesorthe Controllet Component rennen 4 L2 Controler OmpoHes eee arbre pu et ebat toam ee 4 1 22 Warhimne and C dion ia De Is oso tea atenta up t uum a MM EE LEE ELM EU EA 5 les Controler SPECI CAO een ERS tette PT etd tenu teu nti dau Iona M Ote Un 7 k Controler System C one uFdllOlt ea DM M E M IE 10 1 4 1 Internal Circuits of the Controller Typical configuration sss eee 10 1 42 Typical Robot Sy Stemi Conseil Urt embed 11 Chapter 2 General Information about the Interface ocssssssssseeccccccccccsssssssescccececcocccooccssssssesssceececocoseocsssssssseeesessoso 12 21 Type and General Intormation about VO Signals et ERR EAE EEA EEEE 12 2 1 1 Types of System I O Signals Standard type of controller 12 2 1 2 Types of System I O Signals Global type of controller sss 13 22 WO User iO Sera een 14 223 WOM pe Variable DeclatallObloeenestetesetecce edades tems Rees ee ee 14 2 252 VOOR pe Global Variables iiu esM MI IM UM ME 14 225 dO Type TOCA Var OC assesses tes oss euere 14 222 JXserInpubC Cra ih zustellen 14 2 253 User Ontpub COmtnatids oso os casera cree m MEM AR MC LL n E Ms RM ELE 5 Chapter 3 System WO SIENA er EE ard an
36. tasks input 1 Function This signal allows the external device to step stop all tasks being executed except supervisory tasks 2 Terminal 11 on connector CN5 3 Input conditions and operation a Turning opening this signal OFF stops all tasks upon completion of the on going step and turns OFF the Robot Running output signal b For resuming the program after a step stop see Chapter 3 Section 3 5 3 2 OPERATION PREPARATION 000 Step Stop All tasks ON shorted d EEE input OFF open Running Robot status Step Stop All tasks input Robot Running ON output or o o gt Step Stop All tasks Input 32 3 4 2 External Emergency Stop input 1 Function This signal allows the external device to emergency stop the robot 2 Terminal number Controller type External Emergency Stop 1 2 and 36 on CN5 External Emergency Stop 2 3 and 37 on CN5 External Emergency Stop 1 1 and 19 on CN10 External Emergency Stop 2 2 and 20 on CN10 The global type of controller must use two separate contacts to control two External Emergency Stop input signals Two circuits connected in parallel using a single contact or an always shorted circuit will be interpreted as an external circuit failure so that the circuitry will not operate Standard type Global type 3 Input conditions and operation a Turning opening this signal OFF emergency stops the robot 1 The OFF signal turns the mot
37. the safety I O CN10 given on the next page Mini I O CN5 Pin Assignment For global type of controller 68 35 View from the cable side Terminal No Signal name 3 3 Pink Pink Pink Pink Terminal Signal name E gg gt Re 37 Reserves H Reserved S range 39 Ree H Reed 1 ven 39 Resenenn H em Resev E Ba 49 Reewa ne is lt Ea EE a E n me 42 Reseed UU U U Step Stop All tasks input Green 4 Edge NO a 6 hite output 8 5 6 7 8 9 0 1 3 4 5 1 1 Strobe Signal input 1 Robot Running output hite T3 Data area bit 0 input Robot Error output hite Robot Initialized output hite 9 0 0 2 3 5 7 8 9 1 3 5 7 hite orange 45 Reserved hite 1 E u De 2 D Z 0 11 2 Data area bit 2 input 4 Auto Mode output White Operation Preparation Completed 24 output Command area bit 1 input 6 Black 51 Battery Warning output Violet Violet Command Processing Completed 23 output KM EN EM User output 24 Continue Start Permission output o5 55 56 NE NNI 58 59 uem o See E EN EN BE KM Violet Violet Violet Violet User output 28 User output 29 User output 5 5 2 ueram f 5 5 3 0 Reserved Reserved Dedicated to conveyor tracking board when JP12 on mini I O board is shorted Internal power source
38. this signal enables switching to Auto mode Global type Enable Auto Short circuiting this signal enables switching to dual line Auto mode Protective Stop The Enable Auto and Protective Stop input dual line signal circuits are connected in series in the controller so two types of inputs are available as an automatic operation permission signal Start program Data areas These areas are used to specify I O commands 3 bits that enable the following Start stop each task program Prepare for operation Clear robot errors Clear error Command areas 3 bits Note For details refer to Section 3 5 3 I O Commands Details Prepare for Any type Strobe Signal This signal initiates the processing of the I O operation commands set in the data and command areas Note 1 In External automatic operation be careful with the following The moment each of these signals is released the corresponding stop processing starts As long as it is not necessary to stop the robot these stop signals should be short circuited Note 2 The nstantaneous Stop signal becomes available only when an I O extension board is used and the allocation mode is changed to Standard or Compatible mode Like other stop signals this signal should be short circuited as long as it is not necessary to stop the robot 31 3 4 Usage of System Input Signals The usage of each system input signal is described below 3 4 1 Step Stop All
39. use its output as valid signals 56 Power source Z c o ClO 0 LJ LJ LJ N A d N Robot controller When the external power source is used User Output System Output and Hand Output Circuits NPN type 57 F3 1 3A OV Internal Mini I O output power Jalan Sul source Robot controller When the internal power source is used User Output System Output and Hand Output Circuits NPN type Robot controller Example of Circuit with Lamp NPN type 58 4 2 4 Configuration of Emergency Stop Circuitry Standard type of controller 4 2 4 1 External Emergency Stop and Enable Auto Input Circuits Standard type of controller The External Emergency Stop and Enable Auto input signals are important for safety Be sure to configure their circuits with contacts as shown below Note For the overall configuration sample of an emergency stop circuit refer to Section 4 2 4 2 Emergency Stop Circuit Robot controller Internal power source 24V e Emergency stop M ous 5 External Emergency Stop input 1 e External Emergency Stop input 2 mW 351 EN Enable Auto input Internal power source OV External Emergency Stop and Enable Auto Input Circuits Standard type of controller 59 4 2 4 2 Emergency Stop Circuit Standard type of controller The following figure shows the example of configuration and connection of emergency stop circuit on the st
40. will be turned ON upon completion of processing the I O command given b If an error occurs as a result of executing an I O command the Robot Error signal and the Command Processing Completed signal will be turned simultaneously ON 5 OFF conditions a The signal will be turned OFF when the Strobe Signal is turned OFF b If the Strobe Signal is turned OFF before command processing is completed the Command Processing Completed signal will be output and then turned OFF within 100 ms 40 3 5 3 I O Commands Details 3 5 3 1 List of I O Commands The table below lists lO commands List of I O Commands Command area Data area 001 Motor Power ON CAL Execution 000 010 External speed 100 i 100 External Mode switching Gaal Haa 111 Execution of all above Motor Power ON ACAL SP 00External 001 Clear Robot Error 010 Program Start Program number 011 Continue Start 100 Specified Program Reset Program number 101 All Programs Reset 3 5 3 2 OPERATION PREPARATION 000 1 Function Prepares to operate the robot by switching the operation mode from the external devices 2 Format Command area 3 bits input 000 Data area 3 bits input 0 bit Motor Power ON CAL Execution 1 bit External speed 100 2 bit External mode switching These bits can be set at the same time and can be executed If plural bits are set the commands are executed in order For example If the O bit 1 bit and 2
41. with SET and RESET HAND output commands etc Used for controlling the hand to open or close Note Terminal 53 on CN5 port 24 is assigned a user output by factory default It can be assigned the Continue Start Permission output signal with the I O hardware setting 12 2 1 3 Types of System I O Signals Global type of controller The global type of the controller concentrates emergency stop related system I Os on the safety I O CN10 so it does not use the Mini I O CN5 Refer to Sections 4 1 3 4 1 4 5 1 3 and 5 1 4 It issues PROGRAM START commands as I O commands by using seven command execution inputs The table below lists the types of system I O signals Types of System I O Signals Global type of controller Fixed by system The No of yP points Sans External Emergency Stop 1 External Emergency Stop 2 Enable Auto 1 y P Enable Auto 2 Step Stop All tasks Protective Stop 1 Protective Stop 2 Auto Mode Robot Initialized Robot Running CPU Normal Robot Error Operation Preparation Completed Battery Warning Pendant Emergency Stop 1 Pendant Emergency Stop 2 Deadman SW 1 Enable SW 1 Deadman SW 2 Enable SW 2 Contactor Contact Monitor Continue Start Permission selectable by I O hardware setting Note System output Input for command 7 Command 3 bits data area 3 bits and Strobe Signal execution Output for command Command Processing Completed execution Controlled by user progr
42. 022 OUTPUT 1022 1023 OUTPUT 1023 127 7 5 23 PROFIBUS DP Slave Board in All User I O Mode Input data Output data Port No Signal name Port No Signal name DE INPUT 550 to INPUT 764 NEM OUTPUT 806 to OUTPUT 1020 INPUT 765 1021 OUTPUT 1021 INPUT 766 1022 OUTPUT 1022 INPUT 767 1023 OUTPUT 1023 128 7 5 24 DeviceNet Master Board in All User I O Mode Note The table below applies also to the allocation of the master area on the DeviceNet master slave board 1030 INPUT 1030 2054 OUTPUT 2054 QNPUTI021 INPUT204 OUTPUT 2086 to OUTPUT 3068 129 7 5 25 S Link V Master Board in All User I O Mode Input data Output data Port No Signal name Port No Signal name INPUT3110to INPUT 3324 OUTPUT 3366 to OUTPUT 3580 130 7 5 26 Ethernet IP Module in Standard Mode 8 om 39 ee 8 Data area 2 bit 5 Data area 2 bit 6 Data area 2 bit 15 131 NPUTSGUIINPUTTS Output data Robot Warning Continue Start Permission TE E p Status area odd parity Status area bit 8 Robot Running 132 88 OUTPUT8M 84 OUTPUTB4 QUTPUT81619 OUTPUT 1015 811 814 7 5 27 Ethernet IP Module in Compatible Mode fee ee px CAL Execution fee Sa 133 C zer input rey 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 36 37 38 39 40 41 42 43 44 45 46 47
43. 128 1 5 24 DeviceNet Master Board HE AL User VO MIST aus neis na Een 129 1 3 25 eL nk VMaster Boardam All User VOM9SE za eet ame CI eae ak eae Cb aid a DE 130 1 3 26 Ethernet IP Module im Standard L Te su 131 7 5 27 Ethernet IP Module in Compatible Mode 133 7 2 20 Ethernet IP Module MAI User VO Mode oce dte theta trie ette u eb t edes 135 Chapter 8 I O Allocation for I O Conversion Box only for standard type of controller 136 8 1 VO Allocation Modes with I O Conversion Box Mounted ccccccccccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee ey 136 8 2 TWO Allocation in Individual Allocation Tes T 137 8 3 8 4 8 5 Notes on Usine the TO Conversion BOX deceret tree tpe etatem esie ide V et aime tado utes 137 Allocation Common to All Allocation Modes na an 138 8 4 1 I O POWER CN9 Common to All Modes cccccccccccsseseeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeesseeesseeeeeeeess 138 8 4 2 HAND VO CN9 Common to All Modes eere t nee an 138 VO Allocation Tables for Individual Allocation Modes sss sss 139 amp oL OUTPUT CNI10 im O Box Compatible Mode Erebi ter ates rare Penne bc bes tee ines 139 8 52 INPUT CNS ii TOSBoxt ompdtbleMOLQO Aare ee ee ee 140 8 5 OUTPUT CN10 1n LO Box Standard Mode sn REI e RR ded a e aude RIPE 141 8 5 4 INPUT CN8 in I O Box Standard Mode ssssssse mme 142 8 5 5 OUTPUT CN10 in UO Box All User I O Mode ir
44. 2 P i i To the motor H driver circuit Contactor contact monitor MCI aE lieu output Ep EPFL EE EENE j CN10 PS PolySwitch Max 0 15A SAFETY I O Safety Circuit in the RC7M Controller Global type of controller Note Different stop states resulting from emergency stop input Protective Stop and Enable Auto OFF 1 The emergency stop input External Emergency Stop or teach pendant mini pendant input shuts down the power to the motor and resets the program provided that the Continue parameter is set to the default 0 Disable in Continue setting 2 The Protective Stop or Enable Auto OFF input signal shuts down the power to the motor and places the robot in the Continue Stop state 62 4 3 Wiring Notes for Controller I O Connectors NPN type After the wiring of the controller s I O connectors is completed check the following before turning ON the power Check point 1 Using a circuit tester check across the 24V terminal and OV terminal of each connector and across the E24V terminal and the EOV terminal to see that there is no continuity Caution If the connector wiring between the Robot Controller s 24V terminal and 0V terminal and between the E24V terminal and the EOV terminal is shorted damage to the power circuit of the Robot Controller will result Check point 2 Using a circuit tester check across each signal output terminal and 24V termin
45. 28 529 530 531 532 933 534 935 536 537 938 539 540 541 542 543 544 545 546 547 52 53 TDD 767 T67 INPUT 767 1023 OUTPUT 1023 115 7 5 11 DeviceNet Slave Board in All User I O Mode Note The table below applies also to the allocation of the slave area on the DeviceNet master slave board Input data INPUT 512 513 INPUT 513 INPUT 520 INPUT 524 765 INPUTT SSCS T6 NPUTTG 598 INPUTS38 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 765 766 167 116 768 769 OUTPUT 769 770 m 772 773 774 775 776 OUTPUT 776 777 778 779 780 OUTPUT 780 78 782 763 784 785 786 787 788 789 790 791 792 793 794 795 796 797 798 799 800 801 802 803 804 805 ves OuTPUT 788 OUTPUT 806 to OUTPUT 1020 _ 7 5 12 CC Link Board 2 stations occupied in Compatible Mode Input data Output data Remote Remote No Note 1 te i Note 1 E Note 1 512 513 s14 pa RR m 515 516 517 518 RY 519 1 RT 520 521 522 523 524 525 526 527 Seen L luae 21 S RY n 2 F BER 575 RX n 1 E User output OUTPUT m eames poe Note 2 RX n 2 F RX n 3 0 pz Notused an Dn RX n 3 9 Error status flag Note 3 RX n 3 A Not used KM S RX n 3 F Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3
46. 3 OUTPUT CN10 in I O Box Standard Mode 6 momo 77 40 Useoupt m 8 BatteryWarning 79 42 Useoupt 13 9 RobotWarning 80 43 Useroutput HH 14 Reserved 85 48 j Useoupt 008 15 Command Processing Completed 86 49 User output 120 16 Status area odd parity 87 50 Useroupt 121 LIJMEL H I 4 122 18 Status area bit 1 52 User output 123 i8 Sana 90 5 seramput 25 aas ae S 94 57 nouse J 24 Sewsaeabt H H 58 Noued Jemen Te or Bere NN 26 Status area bit9 97 60 RobotStopo Ca eman wea 28 Status areas 99 GF RootSop2 or I Er re 30 Stsarabtis 101 64 Emergency Stop 1 C NN 31 St samabiti4 102 65 EmegenyStp2 32 Status area bitis 108 66 EmemenySop20 39 Userowpt 108 67 Daman SEH 3 userowpu 105 e Daman SW Note Terminal numbers with asterisks are used only in the dual safety emergency stop circuit version enm i en A Ae 141 8 5 4 INPUT CNS in I O Box Standard Mode Terminal Port Terminal Port 2 Power supply for Robot Stop Internal 24V 26 Data area 2 bit 7 21 2 Rost stp I 27 Pasava2bt8 H gt free CD pe pemme 0 2 nstantaneous Stop All tasks Halt Strobe Signal E UE ata area 2 bit 14 C D D Data area tit 7 i Data
47. 35 View from the cable side Terminal 2 Terminal No Signal name N Signal name Enable Auto Internal 24V input Black Enable Auto input External Emergency Stop 1 b 1 input Internal 24V Brown External Emergency Stop 1 b 2 input Pink External Emergency Stop 2 b 1 input _ Red External Emergency Stop 2 b 2 0 Internal 24V a 41 input Pink 3 Ec Reseved Pink Emergency Stop 1 2 output White Mini relay uae E Emergency Stop 1 1 output Black Mini relay CT NN EB S BE NN Deadman SW 1 1 output 42 Deadman SW 1 2 output White Enable SW 1 1 Mini relay Enable SW 1 2 Mini relay Deadman SW 2 1 output Deadman SW 2 2 output i a Enable SW 2 1 Mini relay orange 4 Enable SW 2 2 Mini relay wale 10 44 Dedicated to conveyor tracking board when JP12 on mini I O board is shorted Dedicated to conveyor tracking board Pendant Emergency Stop 2 b 2 output G ray Dry output when JP13 on mini I O board is shorted Gray Internal power source output OV l Gray 65 DC power input 24V when external Pink DC power input OV when external power Gray power source is used source is used DC power output 24V when internal Black DC power output OV when internal power Blue power source is used Brown 68 source is used Blue Note 1 The optional I O cab
48. 38 39 DO Commands Desire seen een Sed OD e dus miae DONE 4 3 6 Example of Using System DO Signals ies an RE ee 44 Chapter 4 Connector Pin Assignment and I O Circuits NPN type sss0000000000000000000000000000000ssnnnnnnnnnnnssensssnssnnnnnes 48 4 1 Connector Pin Assipnment NPN Cy DE seee asi s enarsdeccasteeadeateeeueadiawena ea E EN 48 ALL BRS2DEIENDERS2 IE COMMS Bee 48 4 122 HANDTO CNO osteo a ee en tU D RN En EE LUE MU LUE 49 4 1 5 Mini VO CN5 User or System I O connector sss 50 4 1 4 Safety I O CNIO System I O connecter Global type of controller e 52 42 Robot Comtroiler DO Circuits NPN Pa ves itm ani mens bns tees sut Ue se Mene essen 53 421 sSetingupimr TO Power Supply soutenir Em oh Lone CARO es 53 4 2 2 User Input System Input and Hand Input Circuits NPN type nennen 54 4 2 3 User Output System Output and Hand Output Circuits NPN type 56 4 2 4 Configuration of Emergency Stop Circuitry Standard type of controller 59 4 2 5 Configuration of Safety Circuit Global type of controller eene 61 4 3 Wiring Notes for Controller I O Connectors NPN Ype 63 Chapter 5 Connector Pin Assignment and I O Circuits PNP type eee e eere eere eee eene neenon essa ss tet tnos 65 S Connector Pin Assretiment PNPWPE SE Yes dut i ues e ese ctatiedu at in eetut iae tesa a dcc terete 65 2 4 RS 292C CNID RS 2320 CONE CION een 65 SC MEM gt E KER WOON E
49. 48 49 50 51 52 53 54 55 56 57 58 59 760 761 762 763 764 765 766 767 Output data fee POPE Battery Warning Robot Warning Continue Start Permission Error in the units place bit O Error in the units place bit 1 Error in the units place bit 3 Error in the tens place bit 1 134 OUTPUT 816 to OUTPUT 1015 09 7 5 28 Ethernet IP Module in All User I O Mode Input data Output data Port No Signal name Port No Signal name DE INPUT 550 to INPUT 764 NEM OUTPUT 806 to OUTPUT 1020 INPUT 765 1021 OUTPUT 1021 INPUT 766 1022 OUTPUT 1022 INPUT 767 1023 OUTPUT 1023 135 Chapter 8 I O Allocation for I O Conversion Box only for standard type of controller This chapter lists the I O allocation tables to apply when the I O conversion box is mounted on the controller The I O conversion box should be used with an optional parallel lO board mounted so that the INPUT CN8 OUTPUT CN10 and I O POWER CN7 used on the RC5 controller can be used as is Note The I O conversion box cannot be used for the global type of the controller For details about the I O conversion box refer to the RC7M Controller OPTIONS MANUAL Chapter 4 Section 4 7 I O Conversion Box Minil O 7 PARALLEL I O E OUTPUT INPUT O POWER DE CO p Yqu b qu E Conncetor CN10 CN8 CN7 Extension board 1 FXtension board 2 i HAND I O CN9 Parallel I O board Extens
50. 64 65 66 67 68 69 70 71 24 3863 OUT 72 3887 OUT 73 26 3585 IN 74 IN 75 76 77 78 79 80 81 er 82 sein 83 84 85 86 87 88 89 90 91 92 45 Power 24V N 93 Powrov N 46 Power 2av N 94 Powrov N 47 Power 2av N 95 Powrov N 48 Power 24v IN 96 PowrOV IN 112 7 5 8 Parallel I O Board 2nd in All User I O Mode m e EET 49 50 51 52 53 ERN 54 55 Ese 56 L9 57 58 59 T 60 TN 61 E 62 63 64 65 66 67 68 69 70 71 24 3911 OUT 72 3935 OUT 73 26 3625 IN 74 IN 75 76 77 78 79 80 81 T 82 es E 83 P 84 85 86 87 88 89 90 91 92 45 Power 24V 0 N 93 PowrOV N 46 Power 24V N 94 PowrOV N 47 Power 2AV N 95 PowrOV N 48 Power 24v N 96 PowrOV Ton 113 7 5 9 DeviceNet Slave Board in Compatible Mode Note The table below applies also to the allocation of the slave area on the DeviceNet master slave board s2 Step Stop Altas 518 ComeSat Instantaneous Stop All tasks Halt 515 Operation Preparation Start 516 interruption Skip pec S Program No selection bit 0 518 599 521 Program No selection bit4 522 Program No selection bit2 528 Program No selection bit3 524 Program
51. 97 798 199 Status area bit 11 Status area bit 12 Status area bit 13 Status area bit 14 Status area bit 15 User output OUTPUT m Note 2 Y n 1 539 RY n 1 540 RY n 1 541 RY n 1 S 5 O n 1 Sax So 7m oO A x 0 x RY n 2 8 User input INPUT m S Note 2 2 2 A S 2 2 2 AJ AJ ee 2 4 N X Co I N N oe AJ 2U AJ L x 2 2 O1 GO IO 5 Remote station ready Note 4 A lt 2 NO NJ A pa 2 er UJ Not used A AJ x 2 2 591 Se Not used 607 X n 5 Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes I O port number Note 3 The output timing is the same as that of Robot Error O port 770 and Robot Warning O port 776 Note 4 The output timing is the same as that of Robot Initialized O port 772 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 121 7 5 17 CC Link Board 4 stations occupied in Standard Mode 519 RYn7 775 520 RYn8 521 RYn9 522 RYnA 523 RYnB 524 RYnC 525 RYnD 526 RYnE 527 RYnF 528 529 776 777 778 779 RXnB Input data Output data Remote Remote Signal name output SN Signal name input us Note 1 2 Note 1
52. Board 4 stations occupied in All User I O Mode Input data Signal name INPUT 516 Output data Signal name OUTPUT 772 Remote input Note 1 RXnO RXn1 RXn2 RXn3 RXn4 772 518 RYn6 519 RYn7 520 brn 521 RYno 522 RYnA 523 RYnB 524 RYnC 525 RYnD 526 RYnE 527 RYnF Ener RY n 1 8_ 782 _ coe n 6 F RY n 7 0 795 RX n 1 B Not used 706 OUTPUT796 RX 1 C 539 7 PRY n 7 F 798 OUTPUT 798 RX n 1 E 9 User output OUTPUT m S Note 2 879 RX n 6 F Note 1 Note 2 m denotes I O port number Note 3 indicates the system area that cannot be used for user I O Additional note n denotes station number 1 x 2 hexadecimal notation For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 125 7 5 2310 PROFIBUS DP Slave Board in Compatible Mode Input data O Signal name Port No Signal name Step Stop All tasks Continue Start Instantaneous Stop All tasks Halt Operation Preparation Start Interruption Skip Program Start Program No selection bi 776 Robot Power ON Completed e d Z 2 01 O1 O1 O1 O1 N CO OO COIN gt 521 522 523 524 525 526 527 528 529 530 531 Program No selection bit 1 Program No selection bit 2 Program No selection bit 3 Program No selection bit 4 Program No selection bit 5 Program No selection bit 6 Program No selection parity bit Motor power ON CAL
53. DENSO ROBOT RC7M CONTROLLER MANUAL Copyright DENSO WAVE INCORPORATED 2005 2010 All rights reserved No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher Specifications are subject to change without prior notice All products and company names mentioned are trademarks or registered trademarks of their respective holders Preface Thank you for purchasing this high speed high accuracy assembly robot This manual describes the RC7M controller configured in the G robot system It also covers interfacing required when you integrate your robot system into your facilities as well as providing the maintenance amp inspection procedures Before use read this manual carefully together with related manuals to safely get the maximum benefit from your robot in your assembling operations Note The name of this manual has changed from the RC7M Controller INTERFACE MANUAL to the RC7M CONTROLLER MANUAL Robot controller covered by this manual RC7M controller Caution in connecting disconnecting the motor amp encoder cable The CN7 MOTOR connector for the motor amp encoder cable on the RC7M controller uses a rigid structure Connection Lock the connector properly Disconnection Release the lock carefully and safely It cannot be easily released Connection Disconnection Release the lock carefully and safely Important To ensure operat
54. I Chapter 12 Section 12 5 WAIT 14 2 2 5 User Output Commands There are three types of user output commands SET RESET and OUT The SET and RESET commands turn ON and OFF all user outputs specified by I O type variables The OUT command outputs data to a specified user output e SET Command The SET command turns ON all user outputs specified by I O type variables For further information about the SET command refer to the PROGRAMMER S MANUAL I Chapter 13 Section 13 1 SET e RESET Command The RESET command turns OFF all user outputs specified by lO type variables For further information about the RESET command refer to the PROGRAMMER S MANUAL I Chapter 13 Section 13 1 RESET e OUT Command The OUT command outputs data to the user output specified by an I O type variable For further information about the OUT command refer to the PROGRAMMER S MANUAL I Chapter 13 Section 13 1 OUT 15 Chapter 3 System I O Signals 3 1 Types and Functions of System Output Signals The table below lists the system output signals Types and Functions of System Output Signals Outputs to the external device that the Robot Initialized OPERATION PREPARATION command is executable Start up Auto Mode Outputs when the robot is in Auto mode Operation Preparation Outputs when the motor power is turned on and the Completed robot is in External auto mode Program execution Robot Running Outputs when the robot is
55. I O Allocation Tables for Individual Allocation Modes 7 5 4 Mini VO Board CNS on standard type of controller in Mini I O Dedicated Mode mm Enable Auto Internal 24V input Em Enable Auto input Hj External Emergency Stop 1 b 1 External Emergency Stop 1 b 2 Internal 24V input input External Emergency Stop 2 b 1 External Emergency Stop 2 b 2 Internal 24V input input um __tont En nn M COR eei a a seris enl Emergency Stop 1 1 output Emergency Stop 1 2 output Mini relay Mini relay Emergency Stop 2 1 output Emergency Stop 2 2 output Mini relay Mini relay Deadman SW 1 1 output Deadman SW 1 2 output Enable SW 1 1 Mini relay Enable SW 1 2 Mini relay Deadman SW 2 1 output Deadman SW 2 2 output Enable SW 2 1 Mini relay Enable SW 2 2 Mini relay EE Step Stop All tasks input TF CPU Normal No monitor allowed output 12 Strobe Signal input 1 46 Robot Running output 13 Dataarea bit O input 2 47 Robot Error output aC Data area bit 1 input 3 48 Robot Initialized output Data area bit 2 input 4 49 Auto Mode output 3299 Cu A irip t ss Operation Preparation EL A Command area bit 1 input 6 51 Battery Warning output 22 EM a inputs EMEN Command Processing connie I output User output EN User input es Continue Start Permission output om 20 Useipt 9 54 Useroutput 21
56. INK V board 18 PROFIBUS DP slave board o 19 PROFIBUS DP slave board Parallel UG board 20 PROFIBUS DP slave board DeviceNetmasterboard 22 EtherNet IPAdapter y 23 EtherNet IP Adapter 1 Parallel I O board 24 EtherNet IP Adapter 1 DeviceNetmasterboard 25 EtherNet IPAdapter S LINKVboard N Note 1 Out of check marked modes in the Allocation modes column only one mode can be selected Note 2 Up to two I O extension boards can be mounted on the controller There are no restrictions on the choice of extension slots or the mounting order Note 3 When two I O extension boards are mounted the controller recognizes the one inserted in the left hand extension slot as Extension 1 The allocation I O port numbers on Extension 1 and 2 boards differ with each other mS s REM C gum WEE p BE a Eo Be ME BT NENNEN ae ubi Be a p 103 7 2 I O Allocation in Individual Allocation Modes The table below lists the I O allocation for extension boards in individual allocation modes For details refer to Section 7 5 I O Allocation Tables for Individual Allocation Modes Note For the I O allocation for the DeviceNet master slave board see the allocation tables for the DeviceNet master and slave boards I O Allocation of Extension Boards in Individual Allocatio
57. INPUT 765 INPUT 766 OUTPUT 804 OUTPUT 805 OUTPUT 806 1022 OUTPUT 1022 1023 OUTPUT 1023 INPUT 767 154 8 5 17 Parallel I O Board in I O Box Al User I O Mode 49 3864 OUT 50 51 3866 52 53 54 55 56 57 3841 3842 3843 3844 3845 3846 3847 3848 OUT OUT OUT OUT OUT OUT OUT Qo I co c Med E e aun 3857 OUT 66 3859 OUT 68 3860 OUT 69 30 3589 IN TD 3609 IN 3594 iN 80 a 3597 IN 86 360 iN 89 360 iN 90 45 Power 2a IN 935 Power IN 46 Power zev IN 9 amp 4 Powerov IN 41 Power 2av IN 95 Powerov IN 48 Powersa IN 96 Powerov IN 155 8 5 18 DeviceNet Master Board in I O Box All User I O Mode Note The table below applies also to the allocation of the master area on the DeviceNet master slave board 1030 INPUT 1030 2054 OUTPUT 2054 QNPUTI021 INPUT204 OUTPUT 2086 to OUTPUT 3068 156 8 5 19 S Link V Master Board in I O Box All User I O Mode Input data Output data Port No Signal name Port No Signal name INPUT3110to INPUT 3324 OUTPUT 3366 to OUTPUT 3580 157 8 5 20 Ethernet IP Module in I O Box Compatible Mode fee ee px CAL Execution fee Sa 158 C zer input rey 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
58. Labels on the Robot Controller Warning label 1 For maintenance of the controller AWARN ING Risk of electrical shock Never open the controller cover when the power is ON Risk of electrical shock Do not open controller cover when power is on Never touch the inside of the controller for at least 3 owe eid minutes even after turning the power OFF and Do not touch inside within 3 minutes of turning off power and disconnecting the power cable disconnecting cable Warning label 2 For controller power switch X Risk of injury s Be sure to perform lockout tagout before starting Risk of injury ge Do not turn on power when someone is inside safety fence Send Lockout and tagout power before servicing Turning the power ON may move the arm causing injuries if a person is inside the safety fence Caution label For cooling fans 7 Risk of injury AX Im NX CAUTI ON Do not insert fingers sticks or other foreign objects HPMEELANEVCE through the openings F NBTNEN DO NOT insert fingers Jor foreign objects into Jopening or personal linjury may occur Caution label The controller is not designed to be dust splash or AE EOXESIB Be Before installation be sure to read the REOM UNIRBSHEEED T ERATU Do not put anything on the controller or apply any impact AZzhH Z2IiBE E5 ESI I G TV ER A IYO FN L SRL EY ER R 3 LULE VC E SL AXCAUTION IN INSTALLATION This controller does not meet dust proof m
59. NI1O T OUTPUT CN10 in l O box standard mode DeviceNet slave INPUT CN8 in I O box all user I O mode board V GR compatible OUTPUT CN10 in O box all user I O mode CC Link board iag Extension 2 Extension boards in I O box compatible mode PROFIBUS DP INPUT CN8 in l O box all user I O mode P Slave board l O box standard CNi0 OUTPUT CN10 in l O box all user UO mode EtherNet IP mode Extension 2 Extension boards in I O box standard mode Adapter CN8 INPUT CN8 in I O box compatible mode Parallel I O board dd compatible N10 OUTPUT CN10 in O box compatible mode DeviceNet master Extension 2 Extension boards in l O box all user I O mode Dodo INPUT CN8 in I O box standard mode S LINK V board UO bexerandand T deli n ls c e Lou LLL co cM Le OUTPUT CN10 in l O box standard mode mode Weeeeccoceesbeebeer oec colo ie Quel do Lee ee Extension 2 Extension boards in l O box all user I O mode Note Extensions 1 and 2 correspond to the ones listed in the Allocation Mode Available with the I O Conversion Box table on the previous page 8 3 Notes on Using the I O Conversion Box 1 Parameter change for switching between allocation modes To switch to the l O box compatible or standard mode you need to change parameters using the teach pendant or WINCAPSIII For the changing procedure refer to the RC7M Controller OPTIONS MANUAL Section 4 6 2 Power supply setting for mini I O board CN5 or parallel I
60. NO White o Z o et b Caution The reserved pins and output pins should be prevented from direct contact with other pins or conductive part Direct contact could result in a controller failure or damage Caution To use Pendant Emergency Stop output signals be sure to supply 24 V to terminals 13 and 14 52 4 2 Robot Controller I O Circuits NPN type 4 2 1 Setting up Mini I O Power Supply The power supply 24 VDC for the Mini I O can be switched between internal and external power sources by changing the jumper switch setting as listed below The factory default is external power source setting Power supply Jumper switches JP1 and JP3 on the Beseacion for I O controller printed circuit board p Short circuit Do not change the pins 2 and 3 factory default setting factory default Short circuit Remove the controller pins 1 and 2 pu top cover and change and pins 3 Short socket the JP1 and JP3 and 4 settings with short 123 4 sockets that come with the robot Mini I O board Front panel IPM board Note Switching the power supply setting for I O from external to internal changes the assignment to terminals 32 to 34 and 66 to 68 on CN5 from external DC power input to internal DC power output For details refer to the circuit configuration examples in Sections 4 2 2 and 4 2 3 53 4 2 2 User Input System Input and Hand Input Circuits NPN type The figure below shows
61. O Board CNS on global type of controller in Compatible Standard and Ser TO OCC Saee atc d nio e tud ouem te ice eda osito ED 109 72 5 Parallel VO Board 1 Compatible MIR Ar a ee eek 110 5935 ParaldeL po Board i 5tandard Mode uns ee EE 111 7 5 7 Parallel I O Board 1st in All User I O Mode sss sss 112 ToS ParallcL DO Boatd 2 d 17 AIL ser DO OM OGG 2 einen 113 41 5 9 DeviceNet Slave Board m Compatible Mode anne a a onim ves Diete 114 15410 DeviceNet Slave Board in Standard Mode ihnen mmt tu eM hee ae Saas 115 7 5 11 DeviceNet Slave Board in All User UO Mode sss sss sese 116 7 5 12 CC Link Board 2 stations occupied in Compatible Mode sss sees 117 7 5 13 CC Link Board 3 stations occupied in Compatible Mode sss sese 118 7 5 14 CC Link Board 4 stations occupied in Compatible Mode sss sese 119 7 5 15 CC Link Board 2 stations occupied in Standard Mode u sss sss 120 7 5 16 CC Link Board 3 stations occupied in Standard Mode uuu sss 121 7 5 17 CC Link Board 4 stations occupied in Standard Mod sss sss 122 7 5 18 CC Link Board 2 stations occupied in All User I O Mode sss sss 123 7 5 19 CC Link Board 3 stations occupied in All User I O Mode sss sees 124 7 5 20 CC Link Board 4 stations occupied in All User I O Mode sss sss 125 7 5 21 PROFIBUS DP Slave Board in Compatible Mode sss 126 7 5 22 PROFIBUS DP Slave Board in Standard Mode sss 127 7 5 23 PROFIBUS DP Slave Board in All User UO Mode sss
62. OFF Ganl Robot Running signal Equipment power OFF Note 1 Refer to Section 3 5 3 2 OPERATION PREPARATION 000 Note 2 Refer to Section 3 5 3 4 PROGRAM START 010 Note 3 Symbol signification System I O signal Flow of signal 47 Chapter 4 Connector Pin Assignment and I O Circuits NPN type This chapter explains the connector pin assignment and circuits of NPN type source input and sink output on an lO board I O boards designed for the use in Japan are of an NPN type For a PNP type sink input and source output refer to Chapter 5 Connector Pin Assignment and I O Circuits PNP type 4 1 Connector Pin Assignment NPN type This section describes the pin assignment of I O connectors on the robot controller 4 1 1 RS 232C CN1 RS 232C connector RS 232C CN1 Pin Assignment 9 1 9 6 View from the cable side Terminal No 48 4 1 2 HAND UO CN9 HAND UO CN9 Pin Assignment NPN type 10 1 20 11 View from the cable side ined Standard LICHE m m Yellow Yellow Power output 24 VDC External inter nal source na Pink Pink Hand output Hand output Hand output Hand output Hand output Hand output Hand output Hand output 0 VDC External inter nal source The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 11 2 and 12 10 and 20 The unused pins should be prevented from direct cont
63. PE ME pM ase Pad MEM MM d 16 3 1 Fypes and Functions of System Output Signals nee er Eee 16 32 Wsaeeor System Output sionals uso e are Es Een en less 17 52978 MODOLINMGAIZEH TUPU risia EET 17 322 ANO Mode O0 S a a E te IM E N 18 3 2 3 Operation Preparation Completed pulse 19 3 24 JODOLARUHIHE OULU oi rase teta Deseo A cade tuta E ea Ren Boo 20 323 CPU NOFPOLCOUIBUD oi eter teli atendido etate a testalem ule ae ep etes Lie I 21 SEU NES 001510 D a cd OPI eee TAE 22 327 Battery WAIN Ie ol ee 23 3 2 8 Continue Start Permission output Selectable by I O hardware setting 24 3 2 9 Emergency Stop Circuit Contact Outputs Standard type of controller sss sese 25 3 2 10 Safety Circuit Contact Outputs Global type of controller sss sese 28 3 9 Typesand Functions ot System Input T UARFaE URS RHEURE 3l S4 Usascobsyslem Input S estet a ea an er 32 Ad Sep SOPA task MMOL sbeebs arses er ater te eee aaa tl ak ar a ia ea te pals 32 342 JExrermmat EmereencysSropA ID eoin a sees aut tous eisen ee 33 3 4 3 Enable Auto input Standard type of controller 34 3 4 4 Enable Auto input Global type of controller sss sese 35 3 4 5 Protective Stop input Global type of controller sss sese 36 39 Command Execution DO 818728 ern Etpe es e DR Rubi Y Ra Rep ies eris 37 Sock XweneraLIntormiatiot about Commands 2 baee oe o ond ordo a Leva HAS O tesa O Dep m Desa a ded 37 3 5 2 Processing VO Command Sevememe RARE LM eM M LM ME
64. PIS 66 3 13 Mini VO CN5 User or System l Tony lo ya ee 67 5 1 4 Safety I O CN10 System I O connecter Global type of controller ee 69 52 Jrobot Controller VO Circuits PINP type es BE 70 24 petting up Mim D O POWSE Supply arena lee om bateria bibat 70 5 2 2 User Input System Input and Hand Input Circuits PNP type 71 5 2 3 User Output System Output and Hand Output Circuits PNP type eeeeeeeeeeeeeeeeeeeeeeeennnenneeeneeeeeeeeeeeenn 73 5 2 4 Configuration of Emergency Stop Circuitry Standard type of controller 76 5 2 5 Configuration of Safety Circuit Global type of controller sss sese 78 5 3 Wiring Notes for Controller I O Connectors PNP Ype 80 Chapter 6 Installation and Maintenance of the RC7M Controller 0000000000000000000000000000000sssnnnnnnnnnnsssssnsssnnnnnnnse 82 D SJSUppHeS Jor the Conroe cee nn reae en ee ee ee eee eee 82 62 MountinsAhe Controller i325 acs seksi dp Ee tonno itam ceed Mud Ee ud oii Ide tutam e edo em ues 82 6 2 1 Installation Requirements for the Controller sss 82 6 22 Mounting the RobobCOoDtEollel ons ec eii He 83 63 Vand AC Hiput We le cM ee 85 63 1 Multiccore Cables with Connector ooo des olboa o poaae tradet nomea dust tes esta dau gues oU at due tarn RERS 85 6 3 2 Wiring of Primary Power Source Su d eoi ee erie ee oa 86 6 3 3 Disconnecting the Robot from the Power Source cccccccccccccccccccecccccccccccececeeccececccccecececcee
65. STO m Command Processing gia a omo User output 9 userino e 5 Comme an au 5 Usermu 9 4 User output User output User output 2 2a ED L G Reeve Dedicated to conveyor tracking board when JP13 on mini I O board is shorted Internal power source OV 2 28 29 Dedicated to conveyor tracking board when JP12 on mini I O board is shorted Internal power source 24V C2 C2 NO DC power input OV when external power source is used DC power input 24V when external power source is used C2 Co O DC power output 24V when internal power source is used DC power output OV when internal power source is used Q D gt 107 7 5 3 Mini I O Board CN5 on standard type of controller in Compatible Standard and All User I O Modes M Enable Auto Internal 24V input 35 Enable Auto input 2 External Emergency Stop 1 b 1 36 External Emergency Stop 1 b 2 Internal 24V input input 3 External Emergency Stop 2 b 1 37 External Emergency Stop 2 b 2 Internal 24V input input 4 Reswed 38 Reswed 5 Resev Reses Emergency Stop 1 1 output 40 Emergency Stop 1 2 output Mini relay Mini relay Emergency Stop 2 1 output 41 Emergency Stop 2 2 output Mini relay Mini relay Deadman SW 1 1 output 42 Deadman SW 1 2 out
66. This signal outputs the emergency stop status dual line 2 Terminal number Signal name Terminal number Emergency Stop 1 6 and 40 on CN5 Emergency Stop 2 7 and 41 on CN5 3 Usage This signal is used to confirm that an Emergency Stop input has been entered For details about the emergency stop circuits refer to Sections 4 2 4 and 5 2 4 This signal can emergency stop the external device when the emergency stop button on the teach pendant or mini pendant is pressed Turning the controller power OFF is functionally equivalent to the Emergency Stop output Note Do not enter this signal into the controller s External Emergency Stop input circuit Doing so makes it impossible to reset the emergency stop state 4 Output conditions Turning an External Emergency Stop input signal OFF or pressing the emergency stop button on the teach pendant or mini pendant turns OFF the Emergency Stop output signal mini relay contact in the controller Prepared by customer Emergency stop SW on the equipment Emergency stop input 1 IN Emergency stop input 2 OOO 24 VDC Q TL Mini relay I ie O PS PolySwitch Max 0 15A Robot controller Emergency Stop Output Standard type of controller 25 3 2 0 2 Pendant Emergency Stop Output Standard type of controller 1 Function This signal outputs the status of the emergency stop button on the teach pendant or mini pendant d
67. Types of System I O Signals Standard type of controller Seven input points for command execution are used to direct program start and other instructions as I O commands The table below lists the types of system I O signals Types of System I O Signals Standard type of controller Fixed by system No of External Emergency Stop 1 External Emergency Stop 2 ET Enable Auto Step Stop All tasks Auto Mode Robot Initialized Robot Running CPU Normal Robot Error Operation Preparation Completed Battery Warning Emergency Stop 1 Emergency Stop 2 System output Deadman SW 1 Enable SW 1 Deadman SW 2 Enable SW 2 Pendant Emergency Stop 1 Pendant Emergency Stop 2 Continue Start Permission selectable by I O hardware setting See Note below Input for command 7 Command 3 bits data area 3 bits and Strobe Signal execution Output for command Command Processing Completed execution Controlled by user program Inputs to read the external I O status with an IN command or IO variable User input Used for analysis condition identification condition satisfaction wait data input from the external device etc 8 Outputs to issue a signal to the external device during program execution User output Note with SET and RESET commands etc HAND input Inputs to read the external I O status with an IN command or IO variable p Used for checking the hand status Outputs to issue signals to the external devices
68. Useipu HTH 55 User output 22 Useipu m 56 Useroutput 25 Usripu 12 S7 Useroutput 28 24 Useimu 13 58 Userouput 29 25 Useipu 14 59 Userouput EEN 28 uem H feo ueram a Pendant Emergency Stop 1 b 1 Pendant Emergency Stop 1 b 2 Dry output output Dry output output Pendant Emergency Stop 2 b 1 Pendant Emergency Stop 2 b 2 EAF output output Dry output output Dedicated to conveyor tracking board Dedicated to conveyor tracking board 30 when JP12 on mini I O board is when JP13 on mini I O board is shorted Internal power source Fr ne a Internal power source saat N DC power input 24V when external DC power input OV when external Se oe 33 power source is used power source is used DC power output 24V when internal DC power output OV when internal power source is used a power source is used 106 7 5 0 Mini I O Board CNS on global type of controller in Mini I O Dedicated Mode 1 Remei 2 Reewd Reewed H Reserved 3 4 Reserved s Reed J e Reeva J 7 Reed e Reed o Reed NT I on Step Stop Am mm 0 12 Srobe Signal input 1 715 Data area bitO Gew 2 4a Danara oti nputy 3 lt N 3 u Data area bit 2 input Command area bit 0 input 5 Command area bit 1 input Fro Battery Warning output
69. act with other pins or conductive part Direct contact could result in a controller failure or damage Hand input Port Wirecolor No Z 9 Hand input 49 4 1 3 Mini VO CNS User or System I O connector 1 Standard type of controller Mini I O CN5 Pin Assignment For standard type of controller 68 35 View from the cable side User output 29 Vi User output 30 Vi User output User input ray ink rown s s olo D r mt C2 oO User input User input G a o lt N co Pendant Emergency Stop 1 b 1 output Dry output Pendant Emergency Stop 1 b 2 output N O U Z S 01 la D H y o Diu j o z 9 A Q lt K OM Dry output 3 Pendant Emergency Stop 2 b 2 output Dry output Pendant Emergency Stop 2 b 1 output Dry output N ellow Dedicated to conveyor tracking board 30 when JP12 on mini I O board is shorted Internal power source 24V Dedicated to conveyor tracking board 64 when JP13 on mini I O board is shorted Internal power source OV DC power input OV when external power Gray source is used DC power output OV when internal power Blue source is used Blue Note 1 The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 35 2 and 36 34 and 68 G reen ray Oo UJ on lue o o Y o lt lt lt lt 32 DC power input 24V when extern
70. age of each system output signal is described below 3 2 1 Robot Initialized output 1 Function This signal tells the external device that the OPERATION PREPARATION command is ready to execute 2 Terminal number 48 on connector CN5 3 Usage With this signal and Auto Mode output signal being ON the OPERATION PREPARATION command must be executed 4 ON conditions This signal will be turned ON when a Turning the controller power on normally starts the system program in it and the OPERATION PREPARATION command becomes ready to execute b A robot error is cleared by the OK or Cancel key on the teach pendant or mini pendant or by Clear Robot Error 001 after this signal has been turned OFF 5 OFF condition This signal will be turned OFF when a robot error occurs Pressing the OK or Cancel key on the teach pendant of mini pendant has cleared a robot error After the power was turned ON the system has started normally Entry of Clear Robot Error 001 from an external device has cleared a robot error Robot initialized output Robot error Robot Initialized Output 17 3 2 2 Auto Mode output 1 Function This signal tells the external device that the robot is in Auto mode 2 Terminal number 49 on connector CN5 3 Usage With this signal being ON the OPERATION PREPARATION or PROGRAM START command must be executed 4 ON condition This signal will be turned ON when the robot
71. aint in the Settings Main window The Maintenance menu appears Press F4 Battery in the Maintenance menu The Next Battery Replacement Date window appears In the top of the window the current setting is displayed The date entry areas show the default replacement date that is two years later the current data at which you open this window assuming that the battery service life is two years Press OK Note If you do not want to change the replacement date press Cancel The message Are you sure you want to set the next battery replacement date appears Press OK The screen returns to the Settings Main window 94 6 6 Replacing Fuses and Output ICs 6 6 1 Positions of Fuses and Output ICs The robot controller is equipped with fuses to protect it from external wiring shorted If any fuse is blown replace it according to the following procedure If an output signal error persists even after replacement of the output fuse the related output IC needs to be replaced Fuses and output ICs are located in the robot controller as shown in the figure below Mini I O board Front panel side IPM board IC10 IC8 IC6 Positions of Fuses with the controller top cover removed Corresponding output l I O port Mini I O terminals 66 to 68 DC power input OV EOV Mini I O terminals 32 to 34 DC power input 24V E24V Mini I O terminals 66 to 68 DC power input OV EOV E Power supply
72. al or E24V terminal of each connector to see that there is no continuity Caution If the wiring between each signal output terminal and 24V terminal or E24V terminal of each connector is shorted damage to the output circuit and power circuit of the Robot Controller will result Caution Wind adhesive vinyl tape around all ends of the unconnected wiring of each connector to prevent them from contacting other wiring and parts which results in shorting Circuit tester Robot controller External device 24V terminal and E24V terminal of the controller OV terminal and EOV terminal of the controller Checking Example 63 Mini I O connector CNS 34 1 68 35 View from the cable side 24V internal power source terminal 24V internal power output 45 to 60 Signal output terminal OV GND at output 1 RES EE a 24 VDC power source input 24 VDC power input source uu 24 VDC power source output 24 VDC power output Source SOOO L a 0 VDC power source input DC power input GND Source ds PR 0 VDC power source output DC power output GND HAND I O connector CN9 10 1 20 11 View from the cable side Hand output terminal OV GND at output Power output terminal 24 VDC External internal source PA NOC POWGF PUDU Power output terminal 0 VDC External internal source EC POWT OPNE 64 Chapter 5 Connector Pin Assignment and I O Circuits PNP type This chapter explains the co
73. al power source is used C2 oO Black SE DC power output 24V when internal power source is used a wee e e e ee TE m Enable Auto Internal 24V em See a5 Enable Auto input Pink ap ern ame emen mn Im External Emergency Stop 2 b 1 input Internal 24V External Emergency Stop 2 b 2 input Pink BENI Joe S ter pem Stop 1 1 output Beene Stop 1 2 output ca Mini relay lack 40 Mini relay while 7 Emergency Stop 2 1 output ve 41 Emergency Stop 2 2 output White Mini relay Mini relay Deadman SW 1 1 output 42 Deadman SW 1 2 output White Enable SW 1 1 Mini relay Enable SW 1 2 Mini relay Deadman SW 2 1 output Deadman SW 2 2 output RN Enable SW 2 1 Mini relay TaN Enable SW 2 2 Mini relay sae EXE Step Stop All tasks input 28 3 Green lt CPU Normal No monitor allowed output E42 Strobe Signal input Blue 46 Robot Running output HE Data area bit 0 input Violet a Robot Error output s 7 Data area bit 1 input 48 Robot Initialized output 19 en Data area bit 2 input ink 49 Auto Mode output 36 Command area bit 0 input 9505 3 Operation Preparation Completed output Ee 39 7 Command area bit 1 input E38 lack re Battery Warning output Command area bit 2 input NE Brown Ped Command Processing Completed output Violet User output d pee nl ES Continue Start Permission output MIDI 20 User in
74. al OFF Relationship Between Enable Auto Input and Selectable Mode With Protective Stop input signal ON en Enable Auto Operation mode Application ON shorted OFF open Manual operation with the teach pendant or mini pendant Teach check mode Program check with the teach pendant or mini pendant Internal auto mode Automatic operation with the teach pendant or mini pendant External auto mode Automatic operation with the external device Note O Mode selectable x Mode not selectable 7 Mode selectable but manual operation program not executable 35 Caution In the pendantless state Auto mode is valid even if the Enable Auto input is open The External mode cannot be switched and the program cannot begin execution Perform the following when operating the robot in the pendantless state a Set the robot so that it will not start to operate when the Enable Auto input is open b pe TM input open state and Auto Mode output See Section 3 2 2 Auto Mode output Set the equipment to make an emergency stop in an AND state 3 4 5 Protective Stop input Global type of controller 1 Function Opening this input signal circuit in Auto mode allows the external device to continue stop the robot dual line Note The Enable Auto and Protective Stop input signal circuits are connected in series in the controller and those signals are used as an automatic operation permission signal when turned ON clos
75. am Inputs to read the external I O status with an IN command or IO variable User input Used for analysis condition identification condition satisfaction wait data input from the external device etc T Outputs to issue a signal to the external device during program execution User output Note with SET and RESET commands etc HAND input Inputs to read the external I O status with an IN command or IO variable P Used for checking the hand status Outputs to issue signals to the external devices with SET and RESET HAND output commands etc Used for controlling the hand to open or close Note Terminal 53 on CN5 port 24 is assigned a user output by factory default It can be assigned the Continue Start Permission output signal with the I O hardware setting 13 2 2 Usage of User I O Signals 2 2 1 2 22 2 2 3 2 2 4 User I O signals are used as I O type variables Access the user I O by writing it to the I O type variables or reading it I O Type Variable Declaration I O type variables are classified into I O type global variables that are available without any declaration and I O type local variables that are not available without a declaration I O Type Global Variables I O type global variables are used to refer to or change user I O signals bit by bit Since they are global variables they can be used without any declaration I O type global variables are expressed in either of the following
76. ame 1 Reed 3 Rem 2 Reed 9 Reserved 1 3 Reserved Reserved a F Resev 39 Reews 5 Rem 3 Rem 6 Rem 4 Rem 7 Reed f 4 Rem 8 Reed Reserved 9 Reserved 43 Reserved 0 T L4 E CZ m Userinput 9 48 CPU Norma No monitor alowed oupu 16 1 Uermu HH 46 19 Uermu 2 4 L wea S ss oO TR HH 4 36 uermu 5 59 L7 uenmu Uerotu 22 s2_ seroupet fae 719 Usrmu 8 53 Useroupu 20 Usermu H 9 4 Useroumui BE 55 Useoupt TR 56 Useroupu 27 57 s 5o Dm quema 0 s ps LES E aje RN 62 resev ea Reser Dedicated to conveyor tracking board Dedicated to conveyor tracking board 30 when JP12 on mini I O board is 64 when JP13 on mini I O board is shorted Internal power source 24V shorted Internal power source OV 31 65 32 DC power input 24V when external 66 DC power input OV when external 33 power source is used 67 power source is used DC power output 24V when internal power source is used 68 DC power output OV when internal 34 power source is used 109 7 5 5 Parallel I O Board in Mode Tem ep o E 5 External Mode 3844 OUT 6
77. andard type of the controller In the RC7M controller the emergency stop circuit consists of dual safety circuits The emergency stop button on the teach pendant can be used also as an emergency stop switch of the equipment Emergency Stop and Pendant Emergency Stop output signals 1 Emergency Stop output signal The internal relay receives the External Emergency Stop input signal and the emergency stop input from the teach pendant to output this signal When the power is turned OFF the controller is in the emergency stop state 2 Pendant Emergency Stop output signal Dry output The two contacts on the emergency stop button 4b on the teach pendant are connected This signal will be issued independent of the ON OFF state of the controller power Enable Deadman SW 1 Emergency stop button 4b Auto Enable SW 1 CN EE Robot controller Id p o Internal 3 3V TEE O OV o Interna Internal 24V Prepared by customer Emergency stop ie T T gt 1 IC ae Emergency IStop input 1 External Emergency v E SW output Enable SW output 1 mu i Deadman SW output 2 Enable SW output 2 v o v o v LD Pendant Emergency Stop output 1 v o Pendant Emergency Stop output 2 PS PolySwitch Max 0 15A S IIRI bobo GU CNS Mini I O Emergency Stop Circuit in the RC7M Controller Standard type of controller 60 4 2 5 Configuration of Safety Circuit Global type of control
78. ared for your robot 2 After finishing teaching or making any changes always save the programs and data onto floppy disks Making back ups will help you recover if data stored in the robot controller is lost due to the expired life of the back up battery 3 Write the names of each of the floppy disks used for storing task programs to prevent incorrect disks from loading into the robot controller Store the floppy disks where they will not be exposed to dust humidity and magnetic field which could corrupt the disks or data stored on them E T Safety Codes The safety standards relating to robot systems are listed below As well as observing the safety precautions given in this manual ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system Standards Title ANSI RIA R15 06 1999 Industrial Robots and Robot Systems Safety Requirements ANSI UL 1740 1998 Safety for Robots and Robotic Equipment CAN CSA Z434 03 Industrial Robots and Robot Systems General Safety Requirements ISO10218 1 2006 Robots for industrial environments Safety requirements Part 1 Robot NFPA 79 2002 Electrical Standard for Industrial Machinery 8 Battery Recycling DENSO Robot uses lithium batteries Discard batteries according to your local and national recycling e RE Sh as a UN EU Contents Preface c Lx sv i How the documentation
79. below They alert the user to the dangers of the areas on which they are pasted Be sure to observe the instructions printed on those labels Controller setting table Caution label Warning label 1 ASS CAUTION R Th E BENENE IY hO SR SR THE SETPRM LIST D 24 45 PARAMETER 7ZE r7 Ver SOFTWARE Ver S LEES DATE OF RENEWING BAT I TYPE i 29277 yey I SUBASSEMBLY IPM SLOT5 SLOT6 BOARD SLOT3 SLOT4 SLOTI SLOT2 Dt 0 4th 4E SA OTHER MODIFICATIONS i y i i MODEL NO PART NO i POWER CAPACITY TYP OUTPUT WEIGHT CONDITION SERIAL NO YEAR OF PRODUCTION DENSO WAVE INCORPORATED 4 2 12 TORANOMON MINATO KU TOKYO JAPAN RENHEHA ADVSBELERTAINSE F LERNENEN RTA DH 777 h 4277 LL AAWARNING Risk of injury Do not turn on power when someone is inside safety fence Lockout and tagout power before servicing P ANWARNUNG Bei Durchf hrungen von Instandsetzungs und Instandhaltunsarbeiten sind die Energiezuf hrungen elektr Und pneumat abzuschalten der Hauptschalter ist in OFF AUS Stellung zu sichern L A AH RS XIS JIo Aero UNS d Has JOH 4y est gs HSHH Aol 50 HIRE A WMRERSHPREAAANT TERR SAV AAEM ER TATE AZ BI UAB UBF DILE RE ER SE e I I I I I L L i I I I P I I I I I I I I I I THOR ZTE SEXUS I DO NOT insert fingers L I I or foreign obje
80. bit 14 RX n 1 Data area 2 bit 15 RY n 1 Status area bit 15 RX n 1 Command area bit 0 RY n 2 RX n 2 0 Command area bit 1 Bo cx eere es Command area bit 2 RY n 2 RX n 4 F 2 RX n 5 0 Notused RX n 5 User input INPUT m iu RYE SIE E J Notused Rr 25 nim C N o Gn 1 AJIO O 591 Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 The output timing is the same as that of Robot Error O port 770 and Robot Warning O port 776 Note 4 The output timing is the same as that of Robot Initialized O port 772 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 151 8 5 14 CC Link Board 4 stations occupied in I O Box Standard Mode Input data Output data Remote input Note 1 Battery Warning 020 521 Data area 1 bit 0 Robot Warning Data area 1 bit 1 Continue Start Permission Data area 1 bit 2 SS Mode 9 524 525 526 Ol C2 Data area 1 bit 3 eserved Data area 1 bit 4 RYnC Data area 1 bit 5 RYnD 781 Data area 1 bit 6 ompleted RYnF n 1 B E F 527 528 529 530 531 532 533 534 535 536 537 538 539 Data area 1 bit 7 Data area 2 bit O Data area 2 bit 1 Data area 2 bit 2 Data area 2 bit 3 Data area 2 bit 4 Data area 2 bit 5 Data area 2 bit 6 Da
81. bit are set commands are executed as follows Motor Power ON CAL Execution External speed 100 and External mode switching 3 Description This command can be executed in Auto mode In other modes an error occurs at execution When executing this command select the Internal auto mode on the teach pendant or mini pendant beforehand 41 3 5 3 3 CLEAR ROBOT ERROR 001 1 Function This command clears a robot error that has been caused 2 Format Command area 3 bits input 001 Data area 3 bits input Nothing will be input 3 Description If a robot error occurs this command clears it When there is no failure no processing will take place When an error is displayed the same processing as when the OK or Cancel key of the teach pendant or the mini pendant is operated will be performed 3 5 3 4 PROGRAM START 010 1 Function This command starts the specified program in the data area 2 Format Command area 3 bits input 010 Data area 3 bits input Program number Program number to be started If the specified number is n PRO n starts 3 Description This command is executable only in External mode An error will occur in other modes This command starts the program of the program number specified in data area PRO 0 to PRO 7 can be started One of the following operations takes place according to the operating status of the program If the specified program is terminated stopped
82. ble source current is 70 mA Keep the current consumption of a device to be connected to the Robot Controller such as a PLC and arelay coil below the allowable current 3 Select an induction load such as a relay coil which has a built in diode for absorbing inverse electromotive force To use an induction load without a built in diode add a diode equivalent to the 181888 Toshiba in close vicinity to the coil Caution When externally attaching a diode connect it with correct polarity Incorrect polarity may damage the Output circuit 4 Connecting a lamp requires a circuit through which dark current flows and use a lamp whose rating is 0 5W or less N Caution Since the initial resistance of a lamp is small the output circuit may be damaged by rush current that flows when the lamp lights To reduce rush current select and connect a resistor R that allows dark current 1 3 or less of the rated current to flow when the lamp goes OFF Refer to next page 5 Use a multi core shielding cable for the purpose of protecting the devices from external noise Ground it to the robot controller 6 24V internal power source of the robot controller must not be grounded NCaution If the output terminal 24V of internal power source is grounded there may be a case where the controller is damaged 7 For three seconds after the controller power is turned on the I O board will be in a transient state so do not
83. ceccccceceeees 88 6d Olean ns ihe Adr Intake PAGES ae Diss vos Dace conti m Ene Pre os sie see 89 65 Replacine the Memory Backup Battery iens sacs ere ae eiie a e eS 91 69 3 Repl cme proced re Socinano A E eier 91 652 Seting the Next Battery Replacement Date essen caret itii 94 6 5 Replace Puses atid OUDDUE ICH ee Ure Eben es aedem epo dept ees 95 66 1 Positions OF FUSES and OUtpul Ian 95 60 2 Replaciie Procedures eue Ese at REA muta ems 97 67 Replac ne IPM Gard TTT 100 OLL DocatomorIPM Boards ans ne Eee 100 572 JReplacme the TPN Board 2 oso Ure etant ie Nono Uem eee eee este ee 101 Chapter 7 I O Allocation for I O Extension Board Ss ee ee eere eere eene eee eene e e e ette oett tette esee sees esas ss ette eoo 103 7 Combination of I O Extension Boards and Allocation Modes sss 103 72 Vl OAllocation in Individual Allocation Modes 104 io Noson Using LO Extension Boards nn ae nen see 104 74 Hand I O CN9 Common to All Allocation Modes sss 105 7 5 I O Allocation Tables for Individual Allocation Modes sss sss 106 7 5 Mini I O Board CN5 on standard type of controller in Mini I O Dedicated Mode 106 7 5 2 Mini I O Board CNS on global type of controller in Mini I O Dedicated Mode 107 7 5 3 Mini I O Board CNS on standard type of controller in Compatible Standard and ANN User DO Moden eese ete a E 108 7 5 4 Mini I
84. close type b contact Two contacts of the emergency stop button 4b on each of the teach pendant or mini pendant are connected each other Pressing the emergency stop button turns the Pendant Emergency Stop output signal contacts OFF Pendant emergency stop ouput 1 Pendant emergency stop output2 i CN10 SAFETY I O 7 Tr PS PolySwitch Max 0 15A Robot controller Pendant Emergency Stop Output Global type of controller 28 3 2 10 2 Deadman SW Enable SW output Global type of controller 1 Function This signal outputs the status of the deadman switch enable switch on the teach pendant or mini pendant dual line 2 Terminal number Signal name Terminal number Deadman SW 1 Enable SW 1 15 and 33 on CN10 Deadman SW 2 Enable SW 2 16 and 34 on CN10 3 Usage This signal is used to display the operation status of the deadman switch or interlock the deadman switch with other device e g stopping or running the conveyor For details about the safety circuits refer to Sections 4 2 5 and 5 2 5 4 Output conditions Holding down the deadman switch closes the safety relay contact in the controller turning ON the Deadman SW output signal Contact output close Deadman SW 1 Deadman SW 2 Enable SW 1 Enable SW 2 I Internal 24V Internal 24V Robot controller 24 VDC CR Deadman SW output 1 Enable SW output 1 Deadman SW output 2
85. cts into usu 87 2 v amp 4 c 359 19 3P 8 ED opening or personal I l injury may occur AWARN NG ANSIB EORR p Risk of electrical shock 1 3z D 22858 i DOGS CIE o COE A Do not open controller cover when power is on i EIE LU pth chy PER F po not touch inside within 3 minutes of turning off power and Il disconnecting cable 1 ZAXCAUTION IN INSTALLATION 1 AWARNUNG This controller does not meet dust proof Vorsicht Hochspannung mist proof or explosion proof specifications Read operation manual before installation Im Nicht den Controller unter Spannung ffnen Nach dem Abschalten E und ziehen des Netzsteckers ist eine Entladezeit von 3 Minuten Do not place anything on the controller A 3xx CAUTION p abzuwarten Spannungsfreiheit pr fen and do not impact against the controller ABEREA SBA EHO BE E HHL vC 11 N a a SEAN AY REI TERRIER LU T Hug F47 RE SuSE AHE Era 71 AAS nu da alles MSZ SIE WS YSS aa gr A DO NOT input the wrong voltage when using the JH external power source It may cause the controller failure N ac FE B d item Specification Mini 1 0 DC21 6V 26 4V I I Parallel 1 0 DC21 6V 26 4V DC216V 264V V Amer VO Conversion BOX DC21 6V 264V isieibe seres IT S LINK V DC22 8V 26 4V TEBDERIBIHARERUBAUR IPPUALE MEA Caution label Warning label 2 Caution label only on 100V models Caution label Location of Labels on the Controller Warning and Caution
86. cy or abnormal stop Note The UL Listed robot units have motor ON lamps on their robot arms SAFETY PRECAUTIONS 3 9 Setting up a safety A safety fence should be set up so that no one can easily enter fence the robot s restricted space 1 The fence should be constructed so that it cannot be easily moved or removed 2 The fence should be constructed so that it cannot be easily damaged or deformed through external force 3 Establish the exit entrance to the fence Construct the fence so that no one can easily get past it by climbing over the fence 4 The fence should be constructed to ensure that it is not possible for hands or any other parts of the body to get through it 5 Take any one of the following protections for the entrance exit of the fence 1 Place a door rope or chain across the entrance exit of ER D the fence and fit it with an interlock that ensures the XXX S y emergency stop device operates automatically if it is opened or removed 2 Post a warning notice at the entrance exit of the fence stating In operation Entry forbidden or Work in progress Do not operate and ensure that workers follow these instructions at all times When making a test run before setting up the fence place an overseer in a position outside the robot s restricted space and one in which he she can see all of the robots movements The overseer should prevent workers from entering the robot s restricted space and
87. d 50 2 output 51 Battery Warning output 52 Command Processing Completed output EJ U Ga Permission output Violet BE BE IE 28 BEE 30 vi Command area bit 1 input Violet T 8 9 1 2 3 Command area bit 2 input 2 Violet User output Violet Violet Violet Violet User output User output User output 2 30 0 a lt lt User output Violet Reserved ee Dedicated to conveyor tracking board when JP12 on mini I O board is shorted Internal power source 24V DC power input 24V when external power source is used C2 oO o w w 1 Z 2 R O Qn 1 lG 1 KM o 2 5 f 64 Dedicated to conveyor tracking board when JP13 on mini I O board is shorted Gray Internal power source OV m c Gre DC power input OV when external power Gray source is used Blue DC power output OV when internal power source is used Blue Note 1 The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 35 2 and 36 34 and 68 amp C25 NI D DC power output 24V when internal power source is used KS UD 3 O za D L L 5 o Reserved mew Yellow Caution The reserved pins and output pins should be prevented from direct contact with other pins or conductive part Direct contact could result in a controller failure or damage 51 4 1 4 Safety I O CN10 System I O connecter Globa
88. e 24 V power supply internal or external The factory default is external power supply For details about the mini I O board see Section 4 2 1 or 5 2 1 For details about the parallel I O board refer to the RC7M Controller OPTIONS MANUAL Section 5 2 2 104 7 4 Hand I O CN9 Common to All Allocation Modes The RC7M controller supports hand I O signals CN9 as standard This hand I O is common to all allocation modes m HAND I O CN9 NPN type 2 Handoutpt 12 jHandipt 5 3 Handoutpt 66 13 jHandipt 52 4 jHandoutpt 67 14 jHandiptt 5 5 j Handoutpt 68 15 jHandipt 5 6 j Handoutpt 69 16 jHandipt 55 Power output for hand T Hand output 70 17 24 VDC External internal source Power output for hand Hand output 71 18 0 VDC External internal source 9 Handinput 48 19 jNocomecin Hand input 49 20 jNocomedin B HAND lO CN9 PNP type 3 Handoutpt 66 13 jHandipt 52 5 j Handoutpt 68 15 jHandipt 5 6 Handoutptt 69 16 jHandipt 55 Power output for hand T Hand output 70 17 0 VDC External internal source Power output for hand Hand output 71 18 24 VDC External internal source 9 Handinput 48 19 Nocomedon Hand input 49 20 Nocomecdin 105 75
89. e of these warning and caution indications are a MUST for preventing accidents which could result in bodily injury and substantial property damage Make sure you fully understand all definitions of these terms and related symbols given below before you proceed to the text itself N WARNING Alerts you to those conditions which could result in serious bodily injury or death if the instructions are not followed correctly N CAUTION Alerts you to those conditions which could result in minor bodily injury or substantial property damage if the instructions are not followed correctly Terminology and Definitions Maximum space Refers to the space which can be swept by the moving parts of the robot as defined by the manufacturer plus the space which can be swept by the end effector and the workpiece Quoted from the ISO 10218 1 2006 Restricted space Refers to the portion of the maximum space restricted by limiting devices i e mechanical stops that establish limits which will not be exceeded Quoted from the ISO 10218 1 2006 Motion space Refers to the portion of the restricted space to which a robot is restricted by software motion limits The maximum distance that the robot end effector and workpiece can travel after the software motion limits are set defines the boundaries of the motion space of the robot The motion space is DENSO WAVE proprietary terminology Operating space Refers to the portion of the restricted
90. e output circuit 4 Connecting a lamp requires a circuit through which dark current flows and use a lamp whose rating is 0 5W or less N Caution Since the initial resistance of a lamp is small the output circuit may be damaged by rush current that flows when the lamp lights To reduce rush current select and connect a resistor R that allows dark current 1 3 or less of the rated current to flow when the lamp goes OFF Refer to next page 5 Use a multi core shielding cable for the purpose of protecting the devices from external noise Ground it to the robot controller 6 24V internal power source of the robot controller must not be grounded NCaution If the output terminal 24V of internal power source is grounded there may be a case where the controller is damaged 7 For three seconds after the controller power is turned on the I O board will be in a transient state so do not use its output as valid signals 13 Power source 24V OV Mini I O output pa E HUE A Alam Robot controller When the external power source is used User Output System Output and Hand Output Circuits PNP type 74 F3 1 3A A o 1 24V OV Internal power source m Mini I O output LL LL ee ee OUT n Robot controller When the internal power source is used User Output System Output and Hand Output Circuits PNP type Robot controller Example of Circuit with Lamp PNP type
91. e registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 147 8 5 10 CC Link Board 3 stations occupied in I O Box Compatible Mode Input data Remote Signal name output Port No Signal name EGE Note 1 Note 1 512 Step Stop All tasks RYnO 768 RXnO 513 Continue Start Robot Running 515 516 772 517 773 518 774 519 775 520 776 521 777 522 778 523 779 524 Program No selection bit 4 780 1 Cycle End 525 Program No selection bit 5 781 Battery Warning 526 Program No selection bit 6 782 Robot Warning i P E Motor Power ON Error in the units place bitO RX n 1 0 Error in the units place bit1 RX n 1 1 Error in the units place bit2 RX n 1 2 SP100 Error in the units place bit3 RX n 1 3 xternal Mode Change Error in the tens place bit O RX n 1 4 Error in the tens place bit 1 RX n 1 5 Clear Robot Error Error in the tens place bit 2 RX n 1 6 Error in the tens place bit3 RX n 1 7 536 au in the hundreds place RX n 1 8 User input INPUT m Error in the hundreds place 2 in the hundreds place RX n 1 A aun in the hundreds place RX n 1 B px y SS Mode RX n 1 C 607 RX n 1 D RX n 1 E RX n 1 F RX n 2 0 User output OUTPUT m S ee p 047 RX n 4 F pel Not used Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 The output timing is the same as that of Robot Error l O port 770 and Robot Warning
92. e teta Pete eerte tee hotte oa ds 143 8 36 INPUT CNS 1TLO Box All User VO Modesto a ee 144 8 5 7 DeviceNet Slave Board in I O Box Compatible Mode sese 145 8 5 8 DeviceNet Slave Board in I O Box Standard Mode sss sees 146 8 5 9 CC Link Board 2 stations occupied in I O Box Compatible Mode sss 147 8 5 10 CC Link Board 3 stations occupied in I O Box Compatible Mode sss 148 8 5 11 CC Link Board 4 stations occupied in I O Box Compatible Mode sss 149 8 5 12 CC Link Board 2 stations occupied in I O Box Standard Mode sssssssssssssssnnnennnnn 150 8 5 13 CC Link Board 3 stations occupied in I O Box Standard Mode ssssssssssssssennnnnnnn 151 8 5 14 CC Link Board 4 stations occupied in I O Box Standard Mode essssssssssssssennnnnnnn 152 8 5 15 PROFIBUS DP Slave Board in I O Box Compatible Mode een 153 8 5 16 PROFIBUS DP Slave Board in I O Box Standard Mode sss 154 8 5 17 Parallel I O Board in I O Box Al User YO Mode ccccccccccccccccccccesseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee es 155 8 5 18 DeviceNet Master Board in I O Box All User I O Mode sss sees 156 8 5 19 S Link V Master Board in I O Box All User I O Mode esse 157 8 5 20 Ethernet IP Module in I O Box Compatible Mode sss sees 158 8 5 2 Ethernet IP Module in I O Box Standard Mode c ccc cccceeccesccecccsccesccescesccesccescenccesccescescceseaescessc
93. ea if necessary 2 Terminal numbers Command area 16 to 18 on connector CN5 Data area 13 to 15 on connector CN5 3 Input conditions and operation a Set the command area whenever lO commands are to be executed Set data for data area if commands require them b Shorted represents the bit value 1 Open represents the bit value O c Input the command area and data area before the Strobe Signal 1 ms or more Retain the status until the Command Processing Completed signal is output 39 2 Strobe Signal input 1 Function This signal informs the Robot Controller that the command area and data area have been set Additionally it directs the start of command processing Caution Perform command Except Clear Robot Error 001 input with a Strobe Signal after the system output signal Robot Initialized Is output 2 Terminal number 12 on connector CN5 3 Input conditions and operation By turning ON this input in Auto or External mode the robot controller reads the command area and data area and starts processing 3 Command Processing Completed output 1 Function This signal outputs to the external device that I O command processing is completed 2 Terminal number 52 on connector CN5 3 Usage The signal is used to confirm that I O command processing is complete or as a timing signal for obtaining the result of I O command processing 4 ON conditions a The signal
94. ed 2 Terminal number Signal name Terminal number Protective Stop input 1 5 and 23 on CN10 Protective Stop input 2 6 and 24 on CN10 3 Usage This signal is used for a safety door switch and other safety devices 4 Input conditions and operation with Enable Auto input signal ON Note The Enable Auto and Protective Stop input signal circuits are connected in series in the controller and have the same function See Section 3 4 4 a Turning this signal OFF open in Auto mode turns the motor power OFF and continue stops the robot b Turning this signal OFF open in Manual mode turns the motor power OFF Note For the circuit configuration refer to Sections 4 2 5 and 5 2 5 Two Protective Stop input signal circuits must be controlled with two separate contacts each Two circuits connected in parallel using a single contact or an always shorted circuit will be interpreted as an external circuit error so that the circuitry will not operate 5 Input timing In Auto mode this signal will be processed prior to other input signals and all commands Note Switching the Protective Stop and Enable Auto input signals from open to close does not require temporal conditions but requires any action to switch 36 3 5 Command Execution I O Signals The lO commands can be executed using command execution I O signals I O commands execute the following Start stop each task program Enable running the robot f
95. en F4 I O F6 Aux F1 Set H W F3 Jump To 31 In Ver 2 3 or later Access Top screen F4 I O F6 Aux F4 Int Ext A displayed A displayed ij e Y qi vse n Joint wotolf m ey ae fiuxiliar Single point of control 31 Single point of control Int 0 Ext 1 e nl print DE Eee a Set H I Internal automatic mode 33 DeviceNet Node address DENN F1 External automatic mode 34 DeviceNet Bit Rate 0 125KB 1 250KB 2 2 65280 V0 L Cancel OK Cancel OK ZU Lot F7 F5 Change the selection UK Exit with saving ur OK Exit with saving Ci e Back Next Jump To Change e Setting on the I O Hardware Settings window Setting on the Single point of control window Ver 2 3 or later 1 2 Names of the Controller Components 1 2 1 Controller Components The following figures show the names of the robot controller components Front Panel SAFETY BOX SAFETY BOARD Only for global type with safety box Only for global type with safety board TOT IN LITT o Front panel Air intake filters Connector Na Making Name O Mini VO CN10 SAFETY I O Safety I O connector only on the global type Names of RC7M Robot Controller 1 2 2 Warning and Caution Labels The robot unit has warning and caution labels pasted as shown
96. er before servicing Label 4 This section provides safety precautions to be observed for the robot system The installation shall be made by qualified personal and should confirm to all national and local codes The robot unit and controller have warning labels These labels alert the user to the danger of the areas on which they are pasted Be sure to observe the instructions printed on those labels Instructions printed on the label Risk of injury Never enter the restricted space For UL Listed robot units only Risk of injury This label alerts the user that pressing the brake release switch could drop the arm Risk of electrical shock Never open the controller cover when the power is on Never touch the inside of the controller for at least 3 minutes even after turning the power off and disconnecting the power cable Risk of injury Be sure to perform before starting servicing lockout tagout Turning the power ON when a person is inside the safety fence may move the arm Causing injuries SAFETY PRECAUTIONS 3 Installation Precautions 3 1 Insuring the proper installation environment B For standard type and The standard and cleanroom types have not been designed to cleanroom type withstand explosions dust proof nor is it splash proof Therefore it should not be installed in any environment where 1 there are flammable gases or liquids 2 there are any shavings from metal processing or
97. ergency Stop input 2 Safety relay U Internal 24V t Protective Stop input 1 Protective Stop input 2 Safety relay Enable Auto input 1 i Enable Auto input 2 1 R 1 aes NUM ee CN10 SAFETY I O aula Input Circuits to the Safety Circuits Global type of controller 61 4 2 5 2 Safety Circuit Global type of controller The figure below shows an internal connection equivalent circuit for the safety circuit in the global type of the controller The actual safety circuit is configured with safety relays and others TP MP Mode selector SW Deadman SW Emergency stop button Manual Auto Enable SW Internal 24V Pt Tt Prepared by customer me l Dez i Bn TTT 24V 24V 24V Ex o oj sam De O e 24 VDC 0 0 mE ALL External Emergency Stop input 2 Pendant Emergency Stop output 1 L Pendant Emergency Stop output 2 I id o 6G a UR ER e d est Fe pae up Pa s 00 900 O999999 6099 9989 Q Internal Internal Q Internal 24V 24V 24V Protective Stop input 1 CR CR Protective Stop EMG2 EMG1 input 2 CR CR Enable Auto input 1 PRT ENA2 Enable Auto input 2 CR CR PRT1 ENA T B i CR CR CR21 CR22 CR22 AUTO MAN eyes Deadman SW output 1 Gas Enable SW output 1 CR ENA2 EE SS S S S Z2 CR To the contactor Deadman SW output 2 T ENA contact monitor i Enable SW output 2 A TT ENA2 Mc1 MC
98. ess 160 Chapter 1 General Information about RC7M Controller The RC7M controller is available in several models which differ in detailed specifications to match robot models 1 1 Controller Model Name on Nameplate The model name of the controller is printed on the nameplate attached to the rear side of the controller as shown below The model name is coded as listed below DENSO 410200 x 08G 004 MADE IN JAPAN Nameplate c e 0 9 Em i sample VSG Robot model name VMG VM G series VSG VS G series VPG VP G series HMG HM G series HSG HS G series XRG XR G series XYCG XYC 4G series Wby eo No of controllable axes 4 4 axes 5 6 5 or 6 axes 6 6 axes c Engineering symbol 1 A Encoder A B Encoder B C Encoder C A Engineering symbol 2 A 24V brake Engineering symbol 3 Lo 200 VAC power 100 VAC power Controller type Note Blank Standard type B Global type with safety board C Global type with safety box D Global type UL Listed with safety board Global type UL Listed with safety box I O type or N NPN I O PNP I O Note For the differences between the global and standard types see the next page 1 Differences between Global and Standard Tvpes of Robot Controllers The global type of the robot controller has either a safety board or safety box which the standard type has not Described below are the functional differences between the global and standard
99. fety circuit in the global type of the controller The actual safety circuit is configured with safety relays and others TP MP Mode selector SW Deadman SW Emergency stop button Manual Auto Enable SW Internal 24V Prepared by customer niji O Internal l O Internal l DEIIZ TTT ONES 24V 24V 424V External Emergency A U Stop input 1 1 i 9 e 24 vDC 010 7 E ULL External Emergency v H BE Stop input 2 Io 7 p c3 e 9 Pendant Emergency il 4 Stop output 2 62 Q Internal Internal Q Internal 24V 24V 24V Protective Stop Id i input 1 TEE E CR CR Protective Stop LO il 6 7 EMG2 EMG1 input 2 6 Enable Auto input 1 Jer E us AS en crtt cRI2 V cR CR12 lll Enable Auto input 2 i e e 1 06 m MN T CR22 HS 2 eyed Deadman SW output 1 Ga Enable SW output 1 CR 63 ENA2 Hh a ra a CR To the contactor Deadman SW output 2 ENA i contact monitor l Enable SW output 2 CR 200 VAC E D ENA2 de MC2 o l D T To the motor i 07 IN LS driver circuit Contactor contact monitor MCI To the safety dirc lt output L 1H8 PETENDUM er m PS PolySwitch Max 0 154 SAFETY I O Safety Circuit in the RC7M Controller Global type of controller Note Different stop states resulting from emergency stop input Protective Stop and Enable Auto OFF 1 The emergency stop input External Emergency Stop or teach pendant mini pendant input shu
100. function on the robot or related equipment are lit Check that the display lamp indicating automatic operation is lit during automatic operation oteps to be taken when a malfunction occurs otop the robot s operation by activating the emergency stop device when it is necessary to enter the safeguarded space with a safety fence to perform emergency maintenance in the case of malfunction of the robots or related equipment Take any necessary steps such as posting a notice on the start switch to indicate work is in progress to prevent anyone from accessing the robot Do not perform repairs outside of the designated range Under no circumstances should the interlock mechanism be removed When opening the robot controllers cover for battery replacement or any other reasons always turn the robot controller power off and disconnect the power cable Use only spare tools specified in this manual 5 Daily and Periodical 1 Be sure to perform daily and periodical inspections Before In tion starting jobs always check that there is no problem with the FPE CTSS robot and related equipment If any problems are found take any necessary measures to correct them 2 When carrying out periodical inspections or any repairs maintain records and keep them for at least 3 years 6 Management of 1 Carefully handle and store the Initial settings floppy disks packaged with the robot which store special data Floppy Disks exclusively prep
101. gency stop state 2 Pendant Emergency Stop output signal Dry output The two contacts on the emergency stop button 4b on the teach pendant are connected This signal will be issued independent of the ON OFF state of the controller power Emergency stop button 4b ar an D i Ra quud 3 Robot controller HERBES iu o Internal 3 3V PI O OV o Interna Internal 24 Q m gt Prepared by customer Emergency stop er ena Emergency IStop input 1 External Emergency T SW output 1 Enable SW output 1 H Deadman SW output 2 Enable SW output 2 U v 02 Au Stop outpu v o arch Stop output 2 v LD Pendant Emergency Stop output 1 Pendant Emergency Stop output 2 v o PS PolySwitch Max 0 15A deje ooo bobo QUE CNS Mini I O Emergency Stop Circuit in the RC7M Controller Standard type of controller f 5 2 5 Configuration of Safety Circuit Global type of controller 5 2 5 1 Input Circuit to the Safety Circuit Input signals to the safety circuit are important for safety Be sure to configure their circuits with contacts as shown below observing the notes given below Note For the overall configuration sample of a safety circuitry refer to Section 5 2 5 2 Safety Circuit Precautions on Connecting the Safety I O CN10 1 Two External Emergency Stop input signals must be controlled with separate contacts Two circuits connected in parallel using a s
102. gram is terminated stopped nothing will happen When the specified program is step stopped or immediately stopped halt it will be initialized The initialized program will resume from the beginning When the specified program is running it will immediately stop halt and also be initialized If started after the stop the stopped program will resume from the beginning 43 3 5 3 7 ALL PROGRAMS RESET 101 1 Function This command immediately stops all programs and also initializes them 2 Format Command area 3 bits input 101 Data area 3 bits input Nothing will be input 3 Description This command can reset all programs One of the following operations takes place according to the operating status of the program When the specified program is terminated stopped nothing will happen When the specified program is step stopped or immediately stopped halt it will be initialized The initialized program will resume from the beginning When the specified program is running it will immediately stop halt and also be initialized If started after the stop the stopped program will resume from the beginning 3 6 Example of Using System I O Signals This section illustrates an example of starting and stopping the robot using system I O signals 1 Equipment setup example This example shown below assumes an equipment setup which allows you to run the robot by operating an external equipmen
103. hen entering the robot s restricted space to perform teaching regulations and or maintenance inspections set working regulations for the assuring worker following items and ensure workers adhere to them adherence 1 Operating procedures required to run the robot 2 Robot speed when performing teaching 3 Signaling methods to be used when more than one worker is to perform work 4 Steps that must be taken by the worker in the event of a malfunction according to the contents of the malfunction 5 The necessary steps for checking release and safety of the malfunction status in order to restart the robot after robot movement has been stopped due to activation of the emergency stop device 6 Apart from the above any steps below necessary to prevent danger from unexpected robot movement or malfunction of the robot 1 Display of the control panel See Section 4 2 on the next page 2 Assuring the safety of workers performing jobs within the robot s restricted space See Section 4 3 on the next page 3 Maintaining worker position and stance Position and stance that enables the worker to confirm normal robot operation and to take immediate refuge if a malfunction occurs 4 Implementation of measures for noise prevention 5 Signaling methods for workers of related equipment 6 Types of malfunctions and how to distinguish them Please ensure working regulations are appropriate to the robot type the place of insta
104. herheitsbereich des Roboters betreten 5a eat Us oe HS XIe ulol So Al er A ANHEE TRENZEIFMER Post a notice showing axes names and moving directions in a visible location on the robot unit The posted moving directions should match the actual directions No posting or wrong direction posting may result in bodily injuries or property damages due to incorrect operation SAFETY PRECAUTIONS 4 Precautions N Touching the robot while it is in while Robot is Warning Operation can lead to serious NWARNING Running injury Please ensure the fol lowing conditions are maintained and that the cautions listed from Section 4 1 and onwards are followed when any work is being TROEN TESEESACASS performed Risk of injury Do not enter restricted space Unfallgefahr Nicht die Sperrzone betreten 259 FHAS 715 Ast AA Yo SHOW 9 7 AMEER AREA A AR el Mah Do not enter the robot s restricted space when the robot is in operation or when the motor power is on As a precaution against malfunction ensure that an emergency stop device is activated to cut the power to the robot motor upon entry into the robot s restricted space When it is necessary to enter the robot s restricted space to perform teaching or maintenance work while the robot is running ensure that the steps described in Section 4 3 Ensuring safety of workers performing jobs within the robot s restricted space are taken 4 1 Creation of working W
105. ialized Auto Mode External Mode Battery Warning Robot Warning Continue Start Permission Strobe Signal Interruption Skip LA es Command data odd parity Data area 1 bit O Data area 1 bit 1 Data area 1 bit 2 Data area 1 bit 3 Data area 1 bit 4 Data area 1 bit 6 Data area 2 bit 3 P 532 Data area 2 bit 4 768 769 770 771 772 773 774 775 776 777 778 1779 eserved 780 eserved 781 eserved 782 Command Processing Completed 783 tatus area odd parity 1784 tatus area bit O 785 tatus area bit 1 786 tatus area bit 2 787 788 789 790 791 792 793 794 795 796 797 798 799 800 801 802 803 804 805 06 CD VINJO DIDI DIO LD S Q D Status area bit 4 Status area bit 5 Status area bit 6 Status area bit 7 Status area bit 8 tatus area bit 9 tatus area bit 10 tatus area bit 11 tatus area bit 12 tatus area bit 13 tatus area bit 14 tatus area bit 15 UTPUT 800 Data area 2 bit 5 Data area 2 bit 6 Data area 2 bit 7 Data area 2 bit 8 Data area 2 bit 9 Data area 2 bit 10 Data area 2 bit 11 Data area 2 bit 13 CD UTPUT 801 UTPUT 802 UTPUT 803 UTPUT 804 UTPUT 805 Command area bit 1 Command area bit 2 Command area bit 3 5 INPUT 553 OUTPUT 806 EEE EN INPUT 554 to INPUT 765 21 OUTPUT 807 to OUTPUT 1021 766 INPUT 766 1022 OUTPUT 1022 787 Status area bit 3 514 518 519 520 521 522 523 524 525 526 527 5
106. in shorting Circuit tester Robot controller External device 24V terminal and E24V terminal of the controller OV terminal and EOV terminal of the controller Checking Example 80 Mini I O connector CNS 34 1 68 35 View from the cable side 24V internal power source terminal 24V internal power output 45 to 60 Signal output terminal 24 V at output 1 RES EE a 24 VDC power source input 24 VDC power input source uu 24 VDC power source output 24 VDC power output Source SOOO L a 0 VDC power source input DC power input GND Source ds PR 0 VDC power source output DC power output GND HAND I O connector CN9 10 1 20 11 View from the cable side Hand output terminal 24 V at output Power output terminal 0 VDC External internal source PE PONET OUIPUE SOL Power output terminal 24 VDC External internal source STESSO 81 Chapter 6 Installation and Maintenance of the RC7M Controller 6 1 Supplies for the Controller The table below lists the supplies for the RC7M controller List of Supplies for the RC7M Controller Air inlet filter set 410053 0100 For standard type FS 1705W 410053 0110 For global type FS 1705 6 2 Mounting the Controller 6 2 1 Installation Requirements for the Controller The table below lists the installation requirements for the RC7M controller Installation Requirements for the RC7M Controller Item Environmental Requirements Installa
107. in operation one or more tasks are being executed CPU Normal Outputs when the CPU of the robot controller is normal Bobot Eror Outputs when a servo error program error or any Error Warning other serious error occurs Outputs when the voltage of the encoder or Battery Warning memory backup battery drops below the specified level Continue Start Permission Continue Note It is necessary to specify this output signal by I O hardware setting beforehand Emergency Stop dual line Outputs when the robot is emergency stopped Emergency stop circuit Pendant Emergency Stop Outputs the status of the emergency stop button Standard type of dual line on the teach pendant or mini pendant controller Deadman SW Enable SW Outputs the status of the deadman switch enable dual line switch on the teach pendant or mini ird Pendant Emergency Stop Outputs the status of the emergency stop button dual line on the teach pendant or mini pendant Deadman SW Enable SW Outputs the status of the deadman switch enable dual line switch on the teach pendant or mini pecia Outputs when Continue Start is permitted Safety circuit Global type of controller Outputs the status of the auxiliary contact of the motor contactor in the robot controller Contactor Contact Monitor This signal comes on when the motor is turned on it comes off when the motor is turned off 16 3 2 Usage of System Output Signals The us
108. ing the screw each Screws DA 89 Step 35 Blow compressed air to the filter in the direction opposite to the regular air flow Note Use dehumidified oil free pure compressed air for cleaning Direction of air blow at cleaning Air intake filters Filter covers Direction of intake If the filter is excessively dirty wash it with water or warm water 40 C or lower A neutral detergent is most effective Notes 1 Dry the washed filter completely before mounting it 2 If the filter is still dirty after air blowing or washing replace it with new one Step al Set the filters back into place in the reverse order of removal 90 6 5 Replacing the Memory Backup Battery Programs parameters CAL data etc are stored in the internal memory of the robot controller The memory backup battery retains the above data while the power to the robot controller is turned OFF However the battery has a limited lifetime and must therefore be replaced regularly Note If two years elapse from replacement of backup battery the Time to change controller backup battery message will appear on the teach pendant N Caution Without replacing the memory backup battery important robot specific data held in the memory will be lost This caution applies ONLY in CALIFORNIA USA Perchlorate Material special handling may apply See www dtsc ca gov hazardouswaste perchlorate 6 5 1 Replacing procedures This
109. ingle contact or an always shorted circuit will be interpreted as an external circuit failure so that the emergency stop state cannot be reset 2 Two Protective Stop input signals and two Enable Auto input signals each must be controlled with separate contacts Two circuits connected in parallel using a single contact or an always shorted circuit will be interpreted as an external circuit failure so that the circuitry will not operate 3 The Enable Auto and Protective Stop input signals are connected in series in the controller so two types of inputs are available as an automatic operation permission signal 4 Switching the External Emergency Stop Protective Stop and Enable Auto input signals from open to close does not require temporal conditions but requires any action to switch Robot controller Prepared by customer O Internal 24V CR External Emergency EMG2 Stop input 1 External Emergency Stop input 2 Safety relay Hi E EMG1 Safety relay QO Internal 24V MEER Protective Stop input 1 Protective Stop input 2 safety relay Enable Auto input 1 i Enable Auto input 2 T 1 id UNES eet ee CN10 SAFETY I O Sale Telay Input Circuits to the Safety Circuits Global type of controller 78 5 2 5 2 Safety Circuit Global type of controller The figure below shows an internal connection equivalent circuit for the sa
110. ini pendant b When the External mode is turned ON by the OPERATION PREPARATION command from the external device Operation to switch the motor ON a When the motor key is pushed on the teach pendant or mini pendant b When the motor is turned ON by the OPERATION PREPARATION command from the external device 5 OFF conditions The signal will be turned OFF under the following conditions Out of the External auto mode Under the motor OFF Operation to exit External auto mode a When internal mode is selected on the teach pendant or mini pendant b When the mode selector switch of the teach pendant or mini pendant is set to MANUAL or TEACH CHECK in External mode c When an Emergency Stop input signal is turned ON d When a Robot Error output signal is turned ON Except level 2 error e When an Enable Auto input signal is turned OFF f When a Protective Stop input signal is turned OFF Only for the global type of controller Operation to switch the motor OFF a When the motor power is turned off with the MOTOR key or the emergency stop button is pressed on the teach pendant or mini pendant b When a Robot Error output signal is turned ON Note If any of ERROR 6071 to 607B 6671 to 667B and 607F occurs in the Manual mode or Teach check mode the motor power will not be turned OFF 6 Note for software version 2 00 or later To get the Operation Preparation Completed signal status using an SYSSTATE c
111. ion RXn9 778 SS Mode RXnA Interruption Skip RYn4 5177 SRY 58 RE 519 Command data area odd RYn7 parity 520 Data area 1 bit O RYn8 521 Data area 1 bit 1 RYn9 Data area 1 bit 2 RYnA 523 Data area 1 bit 3 779 Reserved RXnB Data area 1 bit 4 Data area 1 bit 5 526 Data area 1 bit 6 RYnE vaa mane Rrecessing RXnE Completed Data area 1 bit 7 Status area odd parity ata area I atus area DI n 528 Dat 2 bit 0 RY n 1 O 784 Stat bit 0 RX n 1 0 Data area 2 bit 1 RY n 1 1 Status area bit 1 RX n 1 1 Data area 2 bit 2 RY n 1 2 Status area bit 2 RX n 1 2 Data area 2 bit 3 RY n 1 3 Status area bit 3 RX n 1 3 Data area 2 bit 4 RY n 1 4 Status area bit 4 RX n 1 4 Data area 2 bit 5 RY n 1 5 Status area bit 5 RX n 1 5 Data area 2 bit 6 RY n 1 6 Status area bit 6 RX n 1 6 Data area 2 bit 7 RY n 1 7 Status area bit 7 RX n 1 7 Data area 2 bit 8 RY n 1 8 Status area bit 8 RX n 1 8 Data area 2 bit 9 RY n 1 9 Status area bit 9 RX n 1 9 Data area 2 bit 10 RY n 1 A Status area bit 10 RX n 1 A Data area 2 bit 11 RY n 1 B Status area bit 11 RX n 1 B Data area 2 bit 12 RY n 1 C Status area bit 12 RX n 1 C Data area 2 bit 13 RY n 1 D Status area bit 13 RX n 1 D Data area 2 bit 14 RY n 1 E Status area bit 14 RX n 1 E Data area 2 bit 15 RY n 1 F Status area bit 15 RX n 1 F Command area bit 0 RY n 2 0 RX n 2 0 Command area bit 1 Bez Eee p Command area bit 2 RY n 2 RX n 2 F GW N RX n 3 0 Command area bit 3 RY n 2 RY
112. ion SI CN9 8 1 I O Allocation Modes with I O Conversion Box Mounted Using the I O conversion box requires an optional parallel I O board to be mounted for compatibility with the RC5 controller The ports on the parallel I O board offset the shortage of standard mini I O ports The table below lists the selectable allocation modes when the I O conversion box is used Allocation Mode Available with the I O Conversion Box I O extension boards Allocation modes No I O conversion box Extension 1 Extension 2 f Parallel VOboard OSS 6 Parallel WO board T CC Linkboard EE 7 Parallel I O board PROFIBUS DP slave board 8 Parallel I O board S LINK V board 9 Parallel I O board Ethernet IP adapter 136 8 2 I O Allocation in Individual Allocation Modes The table below lists the I O allocation for extension boards in individual allocation modes For details refer to Section 8 5 I O Allocation Tables for Individual Allocation Modes Note For the I O allocation for the DeviceNet master slave board see the allocation tables for the DeviceNet master and slave boards I O Allocation of Extension Boards in Individual Allocation Modes I O extension boards Assum dee Allocation for CN8 CN10 and extension boards Allocation tables to apply l O box compatible INPUT CN8 in I O box compatible mode mode OUTPUT CN10 in l O box compatible mode l O box standard INPUT CN8 in I O box standard mode mode C
113. is manual
114. ist proof or explosion proof specifications Read operation manual before installation Do not place anything on the controller and do not impact against the controller or shock to it Caution label When using an external power source never apply the A538 CAUTION voltage not specified Doing so can result in a controller failure ABB RS SRA LIS LL SLS EE GEO LC BILL YC CSU LDR DIR L EUST DO NOT input the wrong voltage when using the external power source It may cause the controller failuer Caution label After turning the power switch OFF do not turn it ON for at least si ds OFF4 amp 68 EAAIZONL Zr LX E east six seconds Do not turn on within 6sec after switch OFF 1 3 Controller Specifications 1 Specifications The table below lists the robot controller specifications RC7M Robot Controller Specifications Specifications l l l XYC 4G XR G VSG HSG on Ed ie Control system PTP CP 3 dimensional linear 3 dimensional circular DENSO robot language conforming to SLIM 1 Direct teaching 1 Remote teaching 2 Remote teaching 2 Numerical input 3 Numerical input MDI MDI Input 8 user open points 11 fixed system points Mini I O Output 8 user open points 14 fixed system points in Note The global type of the controller cannot use system fixed emergency stop I Os Input 8 user open points Dal m Output 8 fixed system points SAFETY I O Input 6 fixed system points only on global t
115. l 5 Data area 1 bit 1 512 514 20 21 22 23 24 25 26 27 28 29 30 31 32 533 540 Data area 2 bit 5 to Budd UN 764 765 766 767 INPUT 553 INPUT 554 76 INPUT7 4 O 765 INPUTT B 766 INPUT 766 767 INPUTTS 146 DeviceNet Slave Board in I O Box Standard Mode 768 769 770 ri 772 773 774 775 776 777 Continue Start Permission 778 779 780 781 782 783 784 785 786 787 788 789 790 791 792 793 794 795 796 797 798 799 800 801 802 803 804 li T787 Status area bit 3 Status area bit 4 Status area bit 5 8 5 9 CC Link Board 2 stations occupied in I O Box Compatible Mode Input data Output data REMO Remote input Port No Signal name output Port No Signal name Note 1 Note 1 768 2 2 RXn0 User input INPUT m Error in the hundreds place o Nea LT gla Not used bit 3 pm DEN TENE 575 RY nt3 E 798 RX n 1 E User output OUTPUT m gt u Bil RX n 2 F Not used J Not used Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 The output timing is the same as that of Robot Error l O port 770 and Robot Warning O port 782 Note 4 The output timing is the same as that of Robot Power ON Completed I O port 776 Note 5 indicates the system area that cannot be used for user I O Additional note For remot
116. l type of controller Safety I O CN10 Pin Assignment 36 19 View from the cable side Terminal Terminal Signal name Signal name External Emergency Stop 7 b 1 input External Emergency Stop 1 b 2 input External Emergency Stop 2 b 1 input 20 External Emergency Stop 2 b 2 input CIE Green Blue Port o o Pink ES L3 E 21 Reserved Protective Stop 1 2 input Reserved Protective Stop 1 1 input Protective Stop 2 1 input Pink Pink Protective Stop 2 2 input ink Enable Auto 1 1 input Enable Auto 1 2 input ink Enable Auto 2 1 input Reserved Reserved Reserved Pendant Emergency Stop 1 b 1 output Enable Auto 2 2 input Pendant Emergency Stop 1 b 2 output ray ray ray ray ray Pendant Emergency Stop 2 b 2 output Pendant Emergency Stop 2 b 1 output Gray Deadman SW 1 2 output Enable SW 1 2 Deadman SW 1 1 output Enable SW 1 1 Safety relay Gray Safety relay Deadman SW 2 2 output Enable SW 2 2 Safety relay oO O1 A oO Deadman SW 2 1 output Enable SW 2 1 Safety relay White Contactor Contact Monitor 1 2 Brown output output EE The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 19 2 and 20 18 and 36 Contactor Contact Monitor 1 1 White N OO C1 LO OO OO C2 A OO
117. le for the above connector consists of twisted pair wires pairs of 1 and 35 2 and 36 34 and 68 Green Internal power source output 24V COO Pendant Emergency Stop 2 b 1 output Yellow Dry output Yellow White Step Stop All tasks input 0 Green 45 CPU Normal No monitor allowed output Strobe Signal input Robot Running output Data area bit O input Robot Error output Data area bit 1 input Robot Initialized output Data area bit 2 input Auto Mode output Command area bit 0 input Operation Preparation Completed output Command area bit 1 input 6 Black 51 Battery Warning output Command area bit 2 input Command Processing Completed output l User output 29 Userinpt 9 Oremge 54 User output User output TENET er User output Tr 260 Userinput 15 Brown 60 User output pare o O ee He O 28 Pendant Emergency Stop 1 b 1 output Orange 62 Pendant Emergency Stop 1 b 2 output Gray Dry output Dry output BCE Caution The reserved pins and output pins should be prevented from direct contact with other pins or conductive part Direct contact could result in a controller failure or damage Caution To use Pendant Emergency Stop output signals be sure to supply 24 V to terminals 28 and 29 2 Global type of controller with safety board or safety box The global type of the controller handles stop related I Os by using
118. ler 4 2 5 1 Input Circuit to the Safety Circuit Input signals to the safety circuit are important for safety Be sure to configure their circuits with contacts as shown below observing the notes given below Note For the overall configuration sample of a safety circuitry refer to Section 4 2 5 2 Safety Circuit Precautions on Connecting the Safety I O CN10 1 Two External Emergency Stop input signals must be controlled with separate contacts Two circuits connected in parallel using a single contact or an always shorted circuit will be interpreted as an external circuit failure so that the emergency stop state cannot be reset 2 Two Protective Stop input signals and two Enable Auto input signals each must be controlled with separate contacts Two circuits connected in parallel using a single contact or an always shorted circuit will be interpreted as an external circuit failure so that the circuitry will not operate 3 The Enable Auto and Protective Stop input signals are connected in series in the controller so two types of inputs are available as an automatic operation permission signal 4 Switching the External Emergency Stop Protective Stop and Enable Auto input signals from open to close does not require temporal conditions but requires any action to switch Robot controller Prepared by customer O Internal 24V CR External Emergency EMG2 Stop input 1 Safety relay Hi E EMG1 External Em
119. ler side 4 3k iHe axe ul NA ax E unie 680 Photo coupler HAND 1 O can OUT IN 4 3k 3 3k 3 LT NT eilt F amp 1 3A eso Photo coupler i E24V Robot controller gt rm D D 5 D O O c When the external power source is used User Input System Input and Hand Input Circuits PNP type 71 s m D x 5 v O O C E F3 1 3A A 9 24V OV Internal power source Robot controller When the internal power source is used User Input System Input and Hand Input Circuits PNP type 12 5 2 3 User Output System Output and Hand Output Circuits PNP type The following pages show examples of the configuration and connection of the robot controller s user output system output and hand output circuit 1 The User Output System Output and Hand Output Circuits are open collector output circuits 2 The maximum allowable source current is 70 mA Keep the current consumption of a device to be connected to the Robot Controller such as a PLC and arelay coil below the allowable current 3 Select an induction load such as a relay coil which has a built in diode for absorbing inverse electromotive force To use an induction load without a built in diode add a diode equivalent to the 181888 Toshiba in close vicinity to the coil Caution When externally attaching a diode connect it with correct polarity Incorrect polarity may damage th
120. ler to the Controller Mounting Panel 1 The figure below shows the bottom view of the robot controller Five M4 nut welded holes may be used for securing the robot controller to the mounting panel 2 Prepare a mounting panel large enough for mounting the robot controller and secure the robot controller onto the mounting panel using five screws Caution 1 The controller mounting screws must not be more than the thickness of the mounting panel plus 4 mm in length If their length is out of the specified range the nut welded holes may be damaged 2 Fix the robot controller at all of the five nut welded holes Bottom plate of controller t 1 6mm 7 4 Mounting M4 welded nut L 4mm panel M4 screw With safety box Bottom view of controller U i Unit mm 5 screw tightening positions on the controller mounting panel Location of Mounting Screw Holes on the bottom of the robot controller 83 2 Installing the Robot Controller The robot controller can be installed stand alone or on the wall Set up the robot controller as shown in the figure below ACaution Do not place anything within 200 mm from the air inlet and outlet of the robot controller Caution The robot controller has no air filter on the air outlet side In wall mounted installation therefore to prevent free fall dust or dirt from getting into the controller set up the controller with the air outlet side not facing upward as shown
121. llation and to the content of the work Be sure to consult the opinions of related workers engineers at the equipment manufacturer and that of a labor safety consultant when creating these working regulations 4 2 Display of operation To prevent anyone other than the worker from accessing the start panel switch or the changeover switch by accident during operation display something to indicate it is in operation on the operation panel or teach pendant Take any other steps as appropriate such as locking the cover 4 3 Ensuring safety of When performing jobs within the robot s restricted space take workers performing any of the following steps to ensure that robot operation can be jobs within the robot s stopped immediately upon a malfunction restricted space 1 Ensure an overseer is placed in a position outside the robot s restricted space and one in which he she can see all robot movements and that he she is devoted solely to that task D An emergency stop device should be activated immediately upon a malfunction 2 Do not permit anyone other than the worker engaged for that job to enter the robot s restricted space 2 Ensure a worker within the robot s restricted space carries the portable emergency stop switch so he she can press it the emergency button on the teach pendant immediately if it should be necessary to do so 4 4 Inspections before Before starting work such as teaching inspect the following commencing
122. ller upper cover back into place and restart the controller in the reverse Step 6 order of Steps 1 through 3 Step Using a circuit tester check the removed fuse for continuity 98 Proceed to the following steps when replacing output ICs Step 1 S Ifan output signal error persists even after replacement of the output fuse the related output IC needs to be replaced Caution 1 When replacing a damaged output IC fix the cause that damages the IC before replacement 2 Do not directly touch the electronic devices and their terminals on printed circuit boards by hand Remove the three screws and take the Mini I O board out of the controller Mini I O board Screws Step 8 7 Check the IC No on the printed circuit board and pull out the target output IC with an IC pull out jig Mount a new output IC Q m 0 n U 0 ao OO MN LETT TTT OO OOOO OOOO oO LITT 99 6 7 Replacing IPM Boards 6 7 1 Location of IPM Boards The IPM boards are located in the robot controller as shown below 8 d s Store score or on BOARD vo IPM models and mounting slots Location of IPM boards The set program list l A l l IPM cee SLOT SLOT aAa ou oj aio SLOT 6 SLOT 5 SLOT 4 SLOT 3 SLOT 2 SLOT 1 6 5 4 3 1 2 Joint IPM model Motor capacity W Joint IPM model Motor capacit
123. mini pendant shows any of ERROR64A1 to 64A6 when the encoder backup battery voltage is low Meanwhile the teach pendant shows ERROR6103 when the memory backup battery voltage is low 5 OFF condition The signal will be turned OFF when the power is turned ON after the dead battery was replaced Power ON Power ON Power ON Robot power state The encoder or memory backup battery has dropped below the specified level v Battery warning ON output OFF Battery replaced Battery Warning Output 23 3 2 8 Continue Start Permission output Selectable by I O hardware setting Terminal 53 on CN5 port 24 is assigned a user output by factory default It can be assigned the Continue Start Permission output signal with the I O hardware setting When the Continue Start Permission is set 1 Function The controller will output this signal when Continue Start is permitted 2 Terminal number 53 on connector CN5 3 Usage Use this signal when you want to know whether Continue Start is permitted 4 ON condition This signal comes on when Continue Start is permitted For details refer to the SETTING UP MANUAL Chapter 3 Section 3 4 5 Continue Function 5 OFF condition This signal goes off by carrying out the Task Status Change Operation 24 3 2 9 Emergency Stop Circuit Contact Outputs Standard type of controller 3 2 9 1 Emergency Stop output Standard type of controller 1 Function
124. n 2 u AX 3 2 UJ Yio RY n 2 RY n 2 Error status flag Note 3 er Note 4 552 n 2 8 erc d DLE aap E RY n 2 F 829 Od O01 amp A lt I x 2 C2 A lt NO NJ I 559 560 3560 EC oe Not used Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 The output timing is the same as that of Robot Error l O port 770 and Robot Warning O port 776 Note 4 The output timing is the same as that of Robot Initialized O port 772 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 150 8 5 13 CC Link Board 3 stations occupied in I O Box Standard Mode Input data Output data Command data area odd Battery Warning parity Data area 1 bit 3 9 eserved 524 RYnC 525 RYnD 781 526 Data area 1 bit 6 RYnE Command Processing Completed 527 Data area 1 bit 7 RYnF Status area odd parity 528 Data area 2 bit O Status area bit O 529 Data area 2 bit 1 Status area bit 1 C1 oO AJ ES gt X 930 531 532 Data area 2 bit 2 Status area bit 2 Data area 2 bit 3 Status area bit 3 Data area 2 bit 4 Status area bit 4 533 534 535 536 537 538 RY n 1 539 RY n 1 n 1 B E F 2 5 Q U gt 2 Data area 2 bit 14 RY n 1 Status area
125. n Modes Allocation for CN5 and extension boards Allocation modes Allocation tables to apply CN5 Tables for mini I O board in mini I O dedicated mode Extensions 1 2 3 Tables for extension boards in all user I O mode CN5 Tables for mini I O board in compatible standard and all user O modes Extension 1 Tables for extension boards in compatible mode Extensions 2 3 Tables for extension boards in all user I O mode CN5 Tables for mini I O boards in compatible standard and all user I O modes Extension 1 Tables for extension boards in standard mode Mini I O dedicated mode Compatible mode Standard mode Extensions 2 3 Tables for extension boards in all user I O mode Tables for mini I O board in compatible standard and all user All user I O mode I O modes Extensions 1 2 3 Tables for extension boards in all user I O mode Note Extensions 1 2 and 3 correspond to the ones listed in the Combination of I O Extension Boards table on the previous page 7 3 Notes on Using I O Extension Boards 1 Parameter change for switching between allocation modes To switch between the compatible standard and all user I O modes you need to change parameters using the teach pendant or WINCAPSIII For the changing procedure refer to the RC7M Controller OPTIONS MANUAL Section 4 6 2 Power supply setting for mini I O board CN5 or parallel I O board When using the mini I O board CN5 or parallel I O board you need to set up th
126. n includes the following Depression of the emergency stop button and STOP key and input of Step Stop All task and External Emergency Stop signals When the program runs Robot Running ON 1 output OFF A When all programs are stopped Robot Running Output 20 3 2 5 CPU Normal output 1 Function This signal tells the external device that the CPU of the robot controller is normal 2 Terminal number 45 on connector CN5 3 Usage a This signal is used to light the robot controller error indicator lamp on the external operating panel b If this signal is turned OFF perform the error recovery with the PLC 4 ON conditions This signal will be turned ON by the hardware when the CPU of the robot controller operates normally 5 OFF conditions This signal will be turned OFF by the hardware when the CPU does not operate normally Caution The OFF state of this signal indicates that the robot controller internal arithmetic circuit may be damaged Therefore ROBOT ERROR ERROR NUMBER and other outputs may not be correct Power ON CPU operating properly Normal CPU ON y output OFF I Abnormal CPU hardware error CPU Normal Output 21 3 2 6 Robot Error output 1 Function This signal tells the external device that a servo error program error or any other serious error has occurred in the robot 2 Terminal number 47 on connector CN5 3 Usage a This sig
127. n the tens place bit3 RX n 1 7 536 RY n 1 8 e in the hundreds place RX n 1 8 User input INPUT m Error in the hundreds place EN NON Rene 623 a in the hundreds place RX n 1 A 795 aig in the hundreds place RX n 1 B Not used 796 SS Mode 797 R 798 Reserved A ZIAZ 2 2 AMA x 2 Kl u o n m C om iaio User output OUTPUT m Note 2 879 RX n 6 F RX n 7 O EU U Not used Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 The output timing is the same as that of Robot Error l O port 770 and Robot Warning O port 782 Note 4 The output timing is the same as that of Robot Power ON Completed I O port 776 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 149 8 5 12 CC Link Board 2 stations occupied in I O Box Standard Mode Input data Output data Bono Remote input Port No Signal name output Port No Signal name Note 1 Note 1 512 Step Stop All tasks RYnO 513 RYn1 514 Instantaneous Stop All tasks RYn Halt Strobe Signal 768 RXnO 769 Robot Running RXn1 770 Robot Error RXn2 772 Robot Initialized RXn4 173 Auto Mode RXn5 774 External Mode RXn6 75 7 Battery Warning RXn7 7 6 Robot Warning RXn8 777 Continue Start Permiss
128. nal is used to light the robot error indicator lamp on the external operating panel b If this signal is turned ON perform the error recovery with the PLC 4 ON conditions When a level 2 error or higher one occurs Note Except the error caused by the wrong operation of the teach pendant or mini pendant 5 OFF conditions As shown below the signal will be turned OFF under the following conditions a When a Clear Robot Error 001 signal is inputted and the existing error is cleared b When the existing error is cleared by operating the OK or Cancel key on the teach pendant or the mini pendant When a level 2 error or higher one occurs Note Except the error caused by the wrong operation of the TP or MP Robot Error ON V output OFF Q Input of Clear Robot Error 001 OK or CANCEL key operation on the teach pendant or mini pendant Robot Error Output 22 3 2 7 Battery Warning output 1 Function This signal tells the external device that the voltage of the encoder or memory backup battery has dropped below the specified level 2 Terminal number 51 on connector CN5 3 Usage This signal is used to check the timing for battery replacement to check when the battery voltage drops below the specified lower level 4 Output condition This signal will be issued when the voltage of the encoder or memory backup battery has dropped below the specified level Note The teach pendant or
129. name input us Note 1 gt Note 1 Step Stop All tasks RYnO RXn0 RYn1 Robot Running RXn1 514 o HOD e RYn2 770 Robot Error RXn2 515 Strobe Signal RYn3 771 RXn3 516 Interruption Skip RYn4 772 Robot Initialized 517 1 RYn5 773 Auto Mode RXn5 518 RYn6 774 External Mode RXn6 780 RXnC 781 RXnD 782 RXnE 783 RXnF UID AJ XX X Xx x gt 5 5 2 2 gt 00 4 gt oO 784 Status area bit O RX n 1 785 Status area bit 1 RX 2 O LM 2 RY n 2 8 User input INPUT m Note 2 2 User output OUTPUT m A A A 2 N 7 T Note 2 8 5 X n RX n 3 0 IL 530 1 2 786 531 1 3 787 532 788 533 789 534 790 535 791 RX n 1 7 536 792 RX n 1 8 537 793 538 794 539 795 540 796 541 797 RX n 1 D 798 799 0 A x 2 Ol On Kio INI gt iol nim C A pas 5S wlw Error status flag Note 3 Remote station ready Note 4 aet DE N A A x 2 ES UJ AJ x 2 559 Fe Not used RY n 2 F RX n 3 F Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes I O port number Note 3 The output timing is the same as that of Robot Error l O port 770 and Robot Warning O port 776 Note 4 The output timing is the same as that of Robot Initialized O port 772 Note 5 indicates the system area that cannot be used for user I O Additional no
130. ned for safe teaching maintenance and inspection 3 3 3 4 3 5 3 6 3 7 3 8 Control devices outside the robot s restricted space Positioning of gauges Protection of electrical wiring and hydraulic pneumatic piping Grounding resistance Positioning of emergency stop switches Positioning of operating status indicators The robot controller teach pendant and mini pendant should be installed outside the robot s restricted space and in a place where you can observe all of the robots movements and operate the robot easily Pressure gauges oil pressure gauges and other gauges should be installed in an easy to check location If there is any possibility of the electrical wiring or hydraulic pneumatic piping being damaged protect them with a cover or similar item The protective grounding resistance of the robot power supply should not be more than 1000 Emergency stop switches should be provided in a position where they can be reached easily should it be necessary to stop the robot immediately 1 The emergency stop switches should be red 2 Emergency stop switches should be designed so that they wil not be released after pressed automatically or mistakenly by any other person 3 Emergency stop switches should be separate from the power switch Operating status indicators should be positioned in such a way where workers can easily see whether the robot is on a temporary halt or on an emergen
131. nnector pin assignment and circuits of PNP type sink input and source output on an I O board For an NPN type source input and sink output refer to Chapter 4 Connector Pin Assignment and I O Circuits NPN type 5 1 Connector Pin Assignment PNP type This section describes the pin assignment of I O connectors on the robot controller 5 1 1 RS 232C CN1 RS 232C connector RS 232C CN1 Pin Assignment D 1 9 6 View from the cable side Terminal No 65 5 1 2 HAND UO CN9 HAND UO CN9 Pin Assignment PNP type 10 1 20 11 View from the cable side Port Terminal Port Wire color oO re ve 70 Yellow Yellow 17 Power output White Brown 0 VDC External intern al source Terminal No Hand output Hand output Hand output Hand output Hand output Hand output Hand output Hand output 71 Green Green Power output White Brown 24 VDC External intern al source af oe lee JET De ome s Note 1 The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 11 2 and 12 10 and 20 Hand input Hand input Caution The unused pins should be prevented from direct contact with other pins or conductive part Direct contact could result in a controller failure or damage 66 5 1 3 Mini VO CN5 User or System I O connector 1 Standard type of controller Mini I O CN5 Pin Assignment For standard type of controller 68
132. ock and other functions however described here are the necessary functions 2 Outline of procedure Described below is the outline of the procedure for using the equipment taken as an example shown on the previous page Follow steps a to d a Operation preparation The OPERATION PREPARATION command brings to be able to operate the robot into external automatic operation mode This operation will be completed when the Operation Preparation Completed signal is turned ON b Operation start area check When the robot arm is in the home position for working the robot home position indicator lights and ROBOT PREPARATION OK displays c Automatic operation Start the program by which the robot starts from the home position for working performs operations and returns to the home position d Operation end Terminate the day s operations with a cycle stop and turn OFF the power 3 Start and stop procedure and system I O signals The following pages show the relationship between the system I O signals for start and stop worker s operation display on the equipment operation panel PLC proceeding and robot motion 45 Start and Stop Procedure and System I O Signals 1 Worker s operation and display on S Step equipment s operation panel PLC processing Robot operation Equipment power ON I Setting operation adjustment selector switch to Enable Auto ON Internal processing operation Operation OK
133. ommand AND Bit 2 Servo ON and Bit 5 External Mode to use the result of the logical operation 19 When turned on the External Auto Mode and MOTOR ON by the teach pendant mini pendant or external Operation Preparation command Operation preparation ON V completed output OFF When the operation mode is switched to the Internal auto Manual or Teach check mode with the teach pendant or mini pendant When the motor power is turned OFF with the MOTOR key or the emergency stop button is pressed When an Emergency Stop is input When a Robot Failure Error level 3 or higher is output When an Enable Auto or Protective Stop input signal is turned OFF Operation Preparation Completed Output 3 2 4 Robot Running output 1 Function This signal tells the external device that the robot is in operation that is one or more tasks are being executed 2 Terminal number 46 on connector CN5 3 Usage This signal is used to light the robot operating indicator lamp of an external operating panel Performing the Stop all programs operation turns this signal OFF allowing you to check that all programs are stopped 4 ON conditions This signal will be turned ON during execution of the program and also in the WAIT STATE with a conditional branch or timer command 5 OFF conditions This signal will be turned OFF with the Stop all programs operation Stop all programs operation This operatio
134. or power OFF irrespective of whether the robot is in Manual Internal auto or External auto mode 2 During execution of programs Robot Running signal ON the OFF signal turns the motor power OFF and places the robot in internal mode after decelerating the robot to a stop It also resets programs so as not to execute the subsequent and the following steps 3 When the program is stopped in Manual or Auto mode the OFF signal produces nothing except it turns the power to the motor OFF b This signal must be turned ON shorted in order to turn the motor power ON and run the robot in Manual or Auto mode c Opening the External Emergency Stop input is functionally equivalent to pressing the emergency stop button on the teach pendant or mini pendant 4 Input timing This input signal will be processed prior to all commands and input signals Notes 1 The different status between two emergency stop circuits if kept for at least approx one second will be interpreted as an occurrence of trouble triggering an error 279E Inconsistent robot stop input and shutting down the motor power The global type of controller should control two external emergency stop inputs with separate contacts Two circuits connected in parallel with a single contact or either one circuit always short circuited will be interpreted as an external circuit error producing no circuit operation 33 3 4 5 Enable Auto input Standard type of controlle
135. or safety be sure to read the precautions and instructions in SAFETY PRECAUTIONS How the documentation set is organized The documentation set consists of the following books If you are unfamiliar with this robot and option s please read all books and understand them fully before operating your robot and option s GENERAL INFORMATION ABOUT ROBOT Provides the packing list of the robot and outlines of the robot system robot unit and robot controller INSTALLATION amp MAINTENANCE GUIDE Provides instructions for installing the robot components and customizing your robot and maintenance amp inspection procedures STARTUP HANDBOOK Introduces you to the DENSO robot system and guides you through connecting the robot unit and controller with each other running the robot with the teach pendant and making and verifying a program This manual is a comprehensive guide to starting up your robot system SETTING UP MANUAL Describes how to set up or teach your robot with the teach pendant or mini pendant For the panel designer functions refer to the Panel Designer User s Manual SUPPLEMENT WINCAPSIII GUIDE Provides instructions on how to use the programming support tool WINCAPSIII which runs on the PC connected to the robot controller for developing and managing programs PROGRAMMER S MANUAL I Program Design and Commands Describes the PAC programming language program development and command specifications in PAC This manual consist
136. put Enable SW 1 4 Mini relay Enable SW 1 2 Mini relay Deadman SW 2 1 output 43 Deadman SW 2 2 output Enable SW 2 1 Mini relay Enable SW 2 2 Hr relay L9 H 2 users EH a6 uero 19 Userin 2 47 Useroutu ERE En 48 User output i seins TT ir pueris ase 18 Userin 7 82 Useroupu 19 Usermu e ss Useroupu 29 Usrmu HH 54 Useroutpui 21 Usermu 10 55 Useroupu 22 Usrmu m 56 Useroutpui 23 Usrimu H 57 Useroupu 24 Usern H 13 s Useroupu 25 Userin 44 59 Useroupu 26 Usrmu H 15 60 Useroupu A BEE 7 I NE Pendant Emergency Stop 1 b 1 62 Pendant Emergency Stop 1 b 2 Dry output output Dry output MEE Pendant Emergency Stop 2 b 1 63 Pendant Emergency Stop 2 b 2 Dry output output Dry output Seal Dedicated to conveyor tracking board Dedicated to conveyor tracking board when JP12 on mini I O board is 64 when JP13 on mini I O board is dude Internal power source 24V shorted Internal power source OV ai A a S Lom 32 DC power input 24V when external 66 DC power input OV when external FE power source is used m 67 power source is used DC power output 24V when internal DC power output OV when internal power source is used 68 power source is used 108 7 5 4 Mini I O Board CNS on global type of controller in Compatible Standard and All User I O Modes Signal Name signal N
137. put 9 Orange mm User output 21 User input Yellow 55 User output L User input Green 867 User output Violet cor User input lue BE m User output Violet p 58 25 59 ED es pep ELE Q ER Brown Caution The reserved pins and output pins should be prevented from direct contact with other pins or conductive part Direct contact could result in a controller failure or damage Caution To use Pendant Emergency Stop output signals be sure to supply 24 V to terminals 28 and 29 2 Global type of controller with safety board or safety box The global type of the controller handles stop related I Os by using the safety I O CN10 given on the next page Mini I O CN5 Pin Assignment For global type of controller 68 35 View from the cable side Terminal Signal name Signal name EN Yellow Reserved gw Pink Black Reserved ETE White Reserved Reserved Reserved ETE EZ a a NT per EX Reserved Em White Ex ds Stop All tasks input Green ER NN EN 13 Reserved gu White Reserved EE REN CPU Normal No monitor allowed 16 output Robot Running hite hite PERE S 1919 13 Data area bit 0 input O c O c I I x Violet Robot Error output hite Data area bit 1 input Gray Robot Initialized output White Data area bit 2 input Pink Auto Mode output White Command area bit 0 input Operation Preparation Complete
138. r 1 Function a Turning this signal ON shorting enables switching to Auto mode b Turning this signal OFF opening enables switching to Manual or Teach check mode 2 Terminal number 1 and 35 on connector CN5 3 Usage This signal is used to connect the Auto Teaching selector switch of an external operating panel 4 Input conditions and operation a As shown below the selectable operation mode depends on whether this input is shorted or open b If the input becomes open during automatic operation the mode will be switched to Manual mode and ERROR21FC will be displayed c If manual operation or a teach check is conducted with this input shorted ERROR21F2 will be displayed d With this signal being opened turning the mode selector switch on the teach pendant or mini pendant from the MANUAL or TEACH CHECK to AUTO position triggers ERROR21F3 Since this state is shown as x in the table below this error will remain displayed until the robot exits this state e Although ERROR21FD or ERROR21FC will be displayed when the state is changed from O to A or x they will not be displayed when the state is changed from A or x to O f Turning this signal OFF open in External mode switches to the internal mode and turns the Operation Preparation Completed output signal OFF Relationship Between Enable Auto Input and Selectable Mode Enable Auto Operation mode Application ON shorted OFF open Manual mode
139. r fie ooo F PENDANT CN3 AN INPUT Sis G9 OUTPUT SOURCE Mw 9 UL uL Extension slots SAFETY BOX SAFETY BOARD Only for global type with safety box Only for global type with safety board 7 1 Combination of I O Extension Boards and Allocation Modes The table below lists the permitted combination of I O extension boards and selectable allocation modes Combination of I O Extension Boards I O extension boards Max 2 boards Allocation modes Allocated to Extension 1 All Mini I O user Extension 1 Extension 2 Extension 3 dedicated VO ee Compatible Standard S LINK V board MEC REN 2 Z DevieNetmasterbard DeviceNet master board Parallel UO board Combination lt _ 1 2 3 4 Parallel I O board EEE ee CEEEEH 6 Parallel I O board Parallel VOboard 7 Parallel I O board S LINK V board 8 DeviceNetslaveboard o Z 9 DeviceNetslaveboard Parallel O board 10 DeviceNet slave board S LINKVboard 11 DeviceNet master slave board 12 DeviceNet master slave board Parallel I O board 13 DeviceNet master slave board S LINKVboard 14 CC Linkboard gt S ou m 15 CC Link board Parallel I O board 16 CC Link board DeviceNet master board 17 CC Link board S L
140. r the Mini I O can be switched between internal and external power sources by changing the jumper switch setting as listed below The factory default is external power source setting Power supply Jumper switches JP1 and JP3 on the u for O controller printed circuit board Description Short circuit Do not change the pins 2 and 3 factory default setting factory default zum 12 3 4 Short circuit Remove the controller top cover and change S Short socket the JP1 and JP3 settings with short 12 3 4 sockets that come with the robot JP3 JP1 Mini I O board Front panel IPM board Note Switching the power supply setting for I O from external to internal changes the assignment to terminals 32 to 34 and 66 to 68 on CN5 from external DC power input to internal DC power output For details refer to the circuit configuration examples in Sections 5 2 2 and 5 2 3 70 5 2 2 User Input System Input and Hand Input Circuits PNP type The figure below shows examples of the user input system input and hand input circuit configurations and connections of the robot controller Notes 1 In addition to PLCs proximity switches and relay contacts can be directly connected to the input terminals of the robot controller Note that the leakage current from the proximity switches should be 1 mA or below 2 Use multi core shielding cables for protecting the controller from external noise and ground them at the control
141. rcuit Brake Encoder I F IP IPM board board SLQT3 SIIOTA IP IPM board board 16cm 1 SLOT1 SHOT2 i Extension _ boards option Breaker Mini VO board I O board INPUT AC RS232C use LAN PENDANT Mini O CNS ND CN6 CN1 CN2 CN4 CN3 HAND I O CN9 aS E 5 Teach I O Personal pendant PLC sensors Robot computer Block Diagram of the RC7M Controller 10 1 4 2 Typical Robot System Configuration The block diagram below shows a typical robot system configuration Robot unit Connect the following Motor Encoder if necessary MOTOR CN7 Teach pendant nd PENDANT CN3 RC7M Robot controller RS232C CN1 Mini pendant Personal computer Mini I O LAN CN4 INPUT AC CNS os HAND I O CN9 Ethernet connection PLC source 24V Equipment Solenoid valves relays motors etc operation panel Photoelectric switches proximity switches etc Robot System Configuration 11 Chapter 2 General Information about the Interface 2 1 Types and General Information about I O Signals This section describes the I O signals for the Robot Controller The I O signals are grouped into user I O signals and system I O signals Note For the interface to apply when an I O extension board or I O conversion box is mounted refer to Chapter 7 or 8 in this manual respectively and the OPTIONS MANUAL 2 1 1
142. rds safety I O board Cables Powercable m han Specifications Environmental conditions Temperature 0 to 40 C in operation Humidity 90 RH or less no condensation allowed Altitude 1 000m or less Three phase 200 VAC 15 to 230 VAC 10 50 60 Hz 3 3 kVA Three phase 200 VAC 15 to 230 VAC 10 50 60 Hz 1 85 kVA Single phase 230 VAC 10 to 230 VAC 10 50 60 Hz 1 85 kVA Three phase 200 VAC 15 to 230 VAC 10 50 60 Hz 1 kVA Single phase 230 VAC 10 to 230 VAC 10 50 60 Hz 1 kVA 100 VAC type Single phase 100 VAC 10 to 110 VAC 10 50 60 Hz 1 kVA Power sire canc Three phase 200 VAC 15 to 230 VAC 10 50 60 Hz 2 45 kVA source Single phase 230 VAC 10 to 230 VAC 10 50 60 Hz 2 45 kVA HS G series Three phase 200 VAC 15 to 230 VAC 10 50 60 Hz 1 8 kVA Single phase 230 VAC 10 to 230 VAC 10 50 60 Hz 1 8 kVA XYC 4G series Three phase 200 VAC 15 to 230 VAC 10 50 60 Hz 1 15 kVA Single phase 230 VAC 10 to 230 VAC 10 50 60 Hz 1 15 kVA Three phase 200 VAC 15 to 230 VAC 10 50 60 Hz 1 8 kVA Single phase 230 VAC 10 to 230 VAC 10 50 60 Hz 1 8 kVA External power Note Refer to Sections A 24 VDC 10 should be supplied from external e ment I O power source a Edd boz 4 2 1 and 5 2 1 Setting source Internal power A 24 VDC 10 should be supplied internally in the robot up Mini I O Power source controller Supply VM G series Approx 20 A VS G
143. required for connecting the robot controller with a PLC or other external equipment Chapter 3 System I O Signals Describes system I O signals and describes I O signals that execute I O commands Chapter 4 I O Circuits and Connectors NPN type Describes the I O circuits and connector pin layout of an NPN I O board source input and sink output The NPN I O board is designed for the use in Japan Chapter 5 I O Circuits and Connectors PNP type Describes the I O circuits and connector pin layout of a PNP I O board sink input and source output Chapter 6 Installation amp Maintenance for the RC7M controller Provides instructions for installing the robot controller and maintenance amp inspection procedures Chapter 7 I O Allocation for I O Extension Board s Lists the I O allocation tables to apply when I O extension boards are mounted Chapter 8 I O Allocation for I O Conversion Box only for standard type of controller Lists the I O allocation tables to apply when the I O conversion box is mounted Using the I O conversion box on the RC7M controller with an optional parallel I O board mounted allows the INPUT CN8 OUTPUT CN10 and I O POWER CN7 used on the RC5 controller to be used on the RC7M controller as is Note The I O conversion box cannot be used for the global type of the controller SAFETY PRECAUTIONS SAFETY PRECAUTIONS Be sure to observe all of the following safety precautions otrict observanc
144. rom the external device Clear robot errors 3 5 1 General Information about Commands The table below shows the I O commands functions lO Command Functions Starts the program cycle specified program Program Operation Step stops the program specified program all programs Resets the program specified program all programs Operation Preparation Enables running the robot from the external device Clear Robot Error Clears a robot error from the external device 3 3 5 2 Processing I O Commands 3 5 2 1 General Information about Processing I O commands to be executed are processed as shown below 1 Command Area input Data Area input 3 otrobe Signal input D o I I lt gt 1 ms min Command processing complete output Wa 100 ms max Robot Error output Outline of I O Command Processing 1 Set a command area and a data area if necessary for the command execution I O signal from the external device to the robot controller Note The data to be set must be defined at least 1 ms before the Strobe Signal is turned ON 2 After completion of setting turn the Strobe Signal ON Note The command input with a Strobe Signal should be preceded by the output of the Robot Initialized If a Robot Error signal has been issued however execute a Clear Robot Error 001 since no Robot Initialized will be issued 38 3 The controller reads the command
145. s refer to Sections 4 2 4 and 5 2 4 4 Output conditions Holding down the deadman switch closes the mini relay contact in the controller turning ON the Deadman SW output signal Contact output close Deadman SW 1 Deadman SW 2 Enable SW 1 Enable SW 2 I Internal 24V Robot controller Internal 24V 9 Prepared by customer E 24 VDC ow f aM Deadman SW output 1 Enable SW output 1 oH E i 77 i TK l rO TEL o CI C Deadman SW output 2 Enable SW output 2 OEC Med i Ley L O CN5 Mini relay 77 PS PolySwitch Max 0 15A Mini relay c D Jj Deadman SW Output Enable SW Output Standard type of controller 2f 3 2 10 Safety Circuit Contact Outputs Global type of controller 3 2 10 1 Pendant Emergency Stop output Global type of controller 1 Function This signal outputs the status of the emergency stop button on the teach pendant or mini pendant dual line 2 Terminal number Signal name Terminal number Pendant Emergency Stop 1 13 and 31 on CN10 Pendant Emergency Stop 2 14 and 32 on CN10 3 Usage This signal is used to emergency stop the external device when the emergency stop button on the teach pendant or mini pendant is pressed This signal is issued independently of the controller ON OFF state For details about the safety circuits refer to Sections 4 2 5 and 5 2 5 4 Output conditions Normal
146. s of two parts Part 1 provides the basic programming knowledge and Part 2 details of individual commands PROGRAMMER S MANUAL II PAC Library Describes the program libraries that come with WINCAPSIII as standard RC7M CONTROLLER MANUAL this book Provides the specifications installation and maintenance of the RC7M controller It also describes interfacing with external devices system and user input output signals and I O circuits ERROR CODE TABLES List error codes that will appear on the teach pendant or mini pendant if an error occurs in the robot system These tables also provide detailed description and recovery ways OPTIONS MANUAL Describes the specifications installation and use of optional devices For the extension board conveyer tracking board refer to the OPTIONS MANUAL SUPPLEMENT How this book is organized This book is just one part of the robot documentation set This book consists of SAFETY PRECAUTIONS and chapters one through eight SAFETY PRECAUTIONS Defines safety terms and related symbols and provides precautions that should be observed Be sure to read this section before operating your robot Chapter 1 Outline of the RC7M Controller Provides an outline of the RC7M controller The robot controller is available in several models that will differ in detailed specifications to match robot models to be connected Chapter 2 General Information about the Interface Introduces you to the interface
147. series Approx 11 A VP G series Approx 5A Rated output current HM G series Approx 19 A HS G series Approx 14 A XR G series Approx 10A XYC 4G series Approx 8 A With safety board Compliant with safety category 3 Safety category With safety box Compliant with safety category 4 Only the controller with safety box is available to the XY C 4G series of robots Degree of protection IP20 4 axis standard type Approx 17 kg 6 axis standard type Approx 18 kg 4 axis global type UL Listed w safety board Approx 18 kg 6 axis global type UL Listed w safety board Approx 19 kg 4 axis global type UL Listed w safety box Approx 21 kg 6 axis global type UL Listed w safety box Approx 22 kg VS G series VP G 200 VAC type series XR G series Weight Mass Controller Handling Notes NWARNING DO NOT touch fins Their hot surfaces may cause severe burns DO NOT insert fingers or foreign objects into openings Doing so may cause bodily injury Before opening the controller cover and accessing the inside of the controller for maintenance be sure to turn off the power switch disconnect the power cable and wait 3 minutes or more This is for protecting you from electric shock DO NOT connect or disconnect connectors to from the controller when the AC power or the 24 VDC power for I O is being supplied Doing so may cause electric shock or controller failure N CAUTION IN INSTALLATION This con
148. space that is actually used while performing all motions commanded by the task program Quoted from the ISO 10218 1 2006 Task program Refers to a set of instructions for motion and auxiliary functions that define the specific intended task of the robot system Quoted from the ISO 10218 1 2006 1 Introduction 2 Warning Labels Label 1 DENSO Label 4 l Label 3 E EI Label 2 Example Location of labels Warning label A AB BRORNG THURRAAICASS Risk of injury Do not enter restricted space Unfallgefahr Nicht die Sperrzone betreten SEA 1 01 YE 718 AB SS UH sop 9 7 HIST TEEN TRETEN Label 1 lt Except HM gt ANWARNING TARTE Moving robot can cause serious injury Durch Roboterbewegungen k nnen Verletzungen verursacht werden ef ARM 5 79 TERIS Bo HM A WARNING E gt 7 LAEMEXE xe tA AX Label 2 Part No 410985 406 Moving robot can cause serious injury Durch Roboterbewegungen k nnen Verletzungen verursacht werden HARM 34 F79 HEME IE Z WARNING Risk of electrical shock Do not open controller cover when power is on Do not touch inside within 3 minutes of turning off power and disconnecting cable Label 3 Z WARNING Risk of injury Do not turn on power when someone is inside safety fence Lockout and tagout pow
149. t Warning O port 782 Note 4 The output timing is the same as that of Robot Power ON Completed UO port 776 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 118 7 5 14 CC Link Board 4 stations occupied in Compatible Mode Input data Output data Remote Remote No Note 1 te i Note 1 Note 1 512 513 ZA RR m 515 516 517 518 RY 519 1 RT 520 521 522 523 524 525 526 527 T onen BEER E RY n 6 F Ec EUH RX n 1 E ae User output OUTPUT m S Note 2 879 RX n 6 F Dou 4 Not used Not used LI Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes lO port number Note 3 The output timing is the same as that of Robot Error l O port 770 and Robot Warning O port 782 Note 4 The output timing is the same as that of Robot Power ON Completed UO port 776 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 119 7 5 15 CC Link Board stations occupied in Standard Mode 519 RYn7 520 RYn8 521 RYn9 522 RYnA 523 RYnB 524 RYnC 525 RYnD 526 RYnE 527 RYnF 528 529 775 776 777 778 RXnA 779 RXnB Input data Output data Remote Remote a Signal name output a Signal
150. t s operation panel connected via the PLC to the robot controller It is assumed that the operating panel has a display lamps and switches listed on the next page 48 Ba Other equipment Example conveyer Operating panel Example of Equipment Setup Using a Robot 44 Function Example of External Equipment Operating Panel Display Display Displays messages such as ROBOT PREPARATION OK 1 Automatic operation Lights during automatic operation indicator Turned OFF when the robot is not in automatic operation Lights when the Operation Preparation Completed signal 2 Robot external is ON running OK indicator Turned OFF when the Operation Preparation Completed signal is OFF 3 Operation OK Lights when the Enable Auto input signal is ON indicator Turned OFF when the Enable Auto input signal is OFF Lights when the robot is in the home position for working 4 Robot home Turned OFF when the robot is out of the home position position indicator for working By programming with an user output 1 S preparation Starts the preparation of the robot 2 nz start Starts the operation of the equipment Switch 3 Cycle stop button RAUM Eu PIS after a cycle of operations is Automatic operation of the robot possible when 4 Operation elector OPERATION is selected a Manual operation or teach check of the robot possible when ADJUSTMENT is selected Caution Actual equipment requires emergency stop interl
151. ta area 2 bit 7 Data area 2 bit 8 Data area 2 bit 9 Data area 2 bit 10 Data area 2 bit 11 2 O T 1 1 i 1 1 N 1 1 2 CO Ni O 01 B GO RDO gt R R 532 Dataarea2bit4 RY nt14 Y n 1 Y n 1 25 l OT C3 100 Data area 2 bit 14 RY n 1 Status area bit 14 RX n 1 Data area 2 bit 15 RY n 1 Status area bit 15 RX n 1 Command area bit 0 RY n 2 RX n 2 0 Command area bit 1 RM en L TEE qe n Command area bit 2 RY n 2 RX n 6 F 2 RX n 7 0 Notused RX n 7 RY n 2 8 RX n 7 C EE aa iT N 2 603 2 Ed RY n 6 F EN CI Not used 639 2 2 7 NO O O1 Go A lt 2 NO NJ AJ Z 2 NO Co Note 1 n denotes station number 1 x 2 hexadecimal notation Note 2 m denotes l O port number Note 3 The output timing is the same as that of Robot Error I O port 770 and Robot Warning UO port 776 Note 4 The output timing is the same as that of Robot Initialized O port 772 Note 5 indicates the system area that cannot be used for user I O Additional note For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 152 8 5 15 PROFIBUS DP Slave Board in I O Box Compatible Mode Input data Output data L 08 0 0 010 0 20 Instantaneous Stop All tasks Halt 774 Reserved 7T5
152. te For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 120 7 5 16 CC Link Board 3 stations occupied in Standard Mode Output data Input data Port Remote Port Remote R Signal name output Re Signal name input o Note 1 P Note 1 2 O 512 Step Stop All tasks RYnO 768 Reserved RXnO 013 Reserved RYn1 769 Robot Running RXn1 514 o HOD e RYn2 770 Robot Error RXn2 771 772 173 774 115 776 TTT 178 779 780 781 182 Servo ON RXn3 Robot Initialized Auto Mode External Mode Battery Warning Robot Warning Continue Start Permission SS Mode Reserved Reserved Reserved Command Processing Completed 515 Strobe Signal RYn3 516 Interruption Skip RYn4 517 RYn5 518 RYn6 519 RYn7 520 RYn8 521 RYn9 522 RYnA 523 RYnB 524 RYnC 525 RYnD 526 RYnE RXn5 RXn6 RXnB RXnC RXnD RxnE 01201 201 0 AJ x X lt lt gt lt x 51515 5 PlololN pP 527 RYnF 783 Status area odd parity RXnF 528 784 Status area bit O RX n 1 O 529 785 Status area bit 1 530 1 2 786 Status area bit 2 531 1 3 787 Status area bit 3 RX n 1 3 532 788 Status area bit 4 533 789 Status area bit 5 534 790 Status area bit 6 RX n 1 6 535 791 Status area bit 7 RX n 1 7 536 792 Status area bit 8 RX n 1 8 537 793 Status area bit 9 538 794 Status area bit 10 RX n 1 A B 1 1 AN 0 XX 2 1515 k olnm C1 C3 10 795 796 7
153. te 2 n 2 F RY n 3 0 Not used 575 RY n 3 F Note 1 n denotes station number 1 x 2 hexadecimal Note 2 m denotes I O port number Note 3 Additional note Output data Signal name OUTPUT 772 Remote input Note 1 RXnO RXn1 RXn2 RXn3 RXn4 772 795 OUTPUT 795 RX n 1 B 796 OUTPUT796 RX n 1 C 798 OUTPUT 798 RX n 1 E User output OUTPUT m eae Meee RX n 2 F notation indicates the system area that cannot be used for user I O For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 123 7 5 19 CC Link Board 3 stations occupied in All User I O Mode Input data Signal name INPUT 516 Output data Signal name OUTPUT 772 Remote input Note 1 RXnO RXn1 RXn2 RXn3 RXn4 772 518 RYn6 519 RYn7 520 brn 521 RYno 522 RYnA 523 RYnB 524 RYnC 525 RYnD 526 RYnE 527 RYnF BBC CHE Useri RY n 1 8_ 792 coe n RY n 5 0 795 RX n 1 B Not used 706 OUTPUT796 RX 1 C 307 Ryn 798 OUTPUT 798 RX n 1 E 2 User output OUTPUT m 02 Note 2 847 RX n 4 F Note 1 Note 2 m denotes lO port number Note 3 indicates the system area that cannot be used for user I O Additional note n denotes station number 1 x 2 hexadecimal notation For remote registers RWw and RWr refer to the Options Manual Remote Resistors RWw and RWr 124 7 5 20 CC Link
154. tion type Stand alone and Wall mount Ambient temperature In operation 0 to 40 C In storage or during transportation 10 to 60 C Humidity In operation 90 or less No dew condensation is allowed In storage or during transportation 75 or less No dew condensation is allowed Safe installation The robot should not be installed in an environment where environment e there are flammable gases or liquids there are any acidic alkaline or other corrosive material e there is a mist or there are any large sized inverters high output high frequency transmitters large contactors welders or other sources of electrical noise Working space Sufficient service space must be available for inspection and disassembly Grounding conditions Grounding resistance protective ground 1000 or less 82 6 2 2 Mounting the Robot Controller Before mounting the robot controller to the target position you need to secure the robot controller to the controller mounting panel The robot controller supported by the mounting panel may be either stand alone or wall mounted Caution When using the robot controller in any environment where there is mist put the controller in an optional robot controller protective box The robot controller is not dust proof splash proof or explosion proof Set up the controller at the place where it is easy to replace the memory backup battery and air filters 1 Securing the Robot Control
155. troller is not designed to be dust splash or explosion proof Read operation manuals before installation Do not place anything on the controller or apply an impact or shock to the controller Avoid mounting the controller in an environment where excessive vibration is applied to the controller NCAUTION The robot controller connectors are of a screw lock type or ring lock type Lock the connectors securely If even one of the connectors is not locked weak contact may result thereby causing an error Be sure to turn the robot controller OFF before connecting disconnecting the power connector or motor connector Otherwise the internal circuits of the robot controller may be damaged 2 Outer Dimensions The outer dimensions of the robot controller are shown below GDE LL N gt ID N 440 in es I e LJ O L m He je 9 m Jou oq 2241 amp 7NO7I BI TT 498440 L M vl U D 8 o D l K d L Safety board Safety box Only for global type with safety box Outer Dimensions of RC7M Robot Controller Only for global type with safety board Unit mm Cabling space 1 4 Controller System Configuration 1 4 1 Internal Circuits of the Controller Typical configuration The block diagram below shows the internal circuits of the RC7M controller designed for a 6 joint robot Robot controller Power supply board Bus power Harness board Memory Servo ci
156. ts down the power to the motor and resets the program provided that the Continue parameter is set to the default 0 Disable in Continue setting 2 The Protective Stop or Enable Auto OFF input signal shuts down the power to the motor and places the robot in the Continue Stop state 79 5 3 Wiring Notes for Controller I O Connectors PNP type After the wiring of the controller s I O connectors is completed check the following before turning ON the power Check point 1 Using a circuit tester check across the 24V terminal and OV terminal of each connector and across the E24V terminal and the EOV terminal to see that there is no continuity Caution If the connector wiring between the Robot Controller s 24V terminal and 0V terminal and between the E24V terminal and the EOV terminal is shorted damage to the power circuit of the Robot Controller will result Check point 2 Using a tester check across each signal output terminal and 24V terminal or E24V terminal of each connector to see that there is no continuity Caution If the wiring between each signal output terminal and 24V terminal or E24V terminal of each connector is shorted damage to the Output circuit and power circuit of the Robot Controller will result Caution Wind adhesive vinyl tape around all ends of the unconnected wiring of each connector to prevent them from contacting other wiring and parts which results
157. two ways IO nn nn denotes I O port number Example IO 104 IOnn nn denotes I O port number Example 10104 I O Type Local Variables I O type local variables are used to collectively refer to or change 1 bit 8 bit 16 bit or 32 bit user I O signals starting from a specified terminal number I O type local variables require a declaration which will be made with a DEFIO command before they are used For further information about declarations with a DEFIO command refer to the PROGRAMMER S MANUAL I Chapter 9 Section 9 7 DEFIO Statement Conforms to SLIM User Input Commands There are two types of user input commands IN and WAIT The IN command substitutes the input result for a variable The WAIT command waits until the input result meets specified conditions e IN Command The IN command inputs a signal from the user input specified by an IO type variable and substitutes it for an arithmetic variable For further information about the IN command refer to the PROGRAMMER S MANUAL 1 Chapter 13 Section 13 1 IN e WAIT Command The WAIT command suspends the execution of the program until specified conditions are met If an I O type variable is used for the conditional statement this command suspends the execution of the program until the status of the signal from a specified user input is checked and meets the specified conditions For further information about the WAIT command refer to the PROGRAMMER S MANUAL
158. types SAFETY BOX SAFETY BOARD Only for global type with safety box Only for global type with safety board 1 Deadman switch function Enable switch function The global type controls the deadman switch provided on the teach pendant or mini pendant in a partially different way than the standard type does When reading the instruction manuals that are prepared for the standard type be careful with the following differences 1 Location of deadman switches enable switches on the teach pendant and mini pendant Deadman switch Enable switch Deadman switch Teach pendant hui Mini pendant 2 Difference in deadman switch operation The table below lists the functional differences of the teach pendant and mini pendant between the global and standard types in Manual mode and Teach check mode Standard type Global type described in the instruction manuals 1 Unless the deadman switch is held down you 1 Unless the deadman switch is held down you can neither operate the robot nor turn the motor cannot operate the robot but you can turn the power ON motor power ON 2 When the robot is in operation releasing the 2 When the robot is in operation releasing the deadman switch will stop not only the robot but deadman switch will stop the robot but not turn also turn the motor power OFF the motor power OFF
159. ual line 2 Terminal number Pendant Emergency Stop 1 28 and 62 on CN5 Pendant Emergency Stop 2 29 and 63 on CN5 3 Usage This signal is used to emergency stop the external device when the emergency stop button on the teach pendant or mini pendant is pressed This signal is issued independently of the controller ON OFF state For details about the emergency stop circuits refer to Sections 4 2 4 and 5 2 4 4 Output conditions Normal close type b contact Two contacts of the emergency stop button 4b on each of the teach pendant or mini pendant are connected each other Pressing the emergency stop button turns the Pendant Emergency Stop output signal contacts OFF Pendant emergency stop output 1 Pendant emergency stop output 2 PS PolySwitch Max 0 15A 1 Robot controller Pendant Emergency Stop Output Standard type of controller 26 3 2 9 3 Deadman SW Enable SW output Standard type of controller 1 Function This signal outputs the status of the deadman switch enable switch on the teach pendant or mini pendant dual line 2 Terminal number Deadman SW 1 Enable SW 1 8 and 42 on CN5 Deadman SW 2 Enable SW 2 9 and 43 on CN5 3 Usage This signal is used to display the operation status of the deadman switch or interlock the deadman switch with other device e g stopping or running the conveyor For details about the emergency stop circuit
160. work items carry out any repairs immediately upon detection of a such as teaching malfunction and perform any other necessary measures 1 Check for any damage to the sheath or cover of the external wiring or to the external devices 2 Check that the robot is functioning normally or not any unusual noise or vibration during operation 3 Check the functioning of the emergency stop device 4 Check there is no leakage of air or oil from any pipes 5 Check there are no obstructive objects in or near the robot s restricted space SAFETY PRECAUTIONS 4 5 Release of residual air pressure 4 6 Precautions for test runs 4 7 Precautions for automatic operation 4 8 Precautions in repairs Before disassembling or replacing pneumatic parts first release any residual air pressure in the drive cylinder Whenever possible have the worker stay outside of the robot s restricted space when performing test runs 1 At start up 4 otay out of the safeguarded space with a safety fence when starting the robot in particular take extra caution in Internal automatic operation Before starting the robot check the following items as well as setting the signals to be used and perform signaling practice with all related workers 1 Check that there is no one inside the safeguarded space with a safety fence 2 Check that the teach pendant and tools are in their designated places 3 Check that no lamps indicating a mal
161. y W Joint IPM model Motor capacity W Joint Motor capacity W 750 400 Note The in the above table denotes no board installed Differs depending on the controller model 100 6 7 2 Replacing the IPM board Replace the IPM board with the procedure below Step 4 Turn the controller power OFF Power switch Step 2 S Remove the eight screws and take off the top cover of the controller Z Warning Do not touch the inside of controller before turning off the power switch and waiting 3 minutes or more or you can easily receive an electric shock 101 Step 3 2 Remove the two screws from the IPM board to be replaced Disconnect the board from its two connectors and connect a new one Screws for IPM board 2 screws joint IN SS C ALES STL NL IPM board connectors 2 connectors joint IPM board Step 4 7 Secure the top cover of the controller with eight screws Tightening torque 1 35 to 1 45 Nm 102 Chapter 7 I O Allocation for I O Extension Board s This chapter lists the I O allocation tables to apply when I O extension boards are mounted on the controller For details about I O extension boards refer to the RC7M CONTROLLER OPTIONS MANUAL HSR DL IET 0LNO Ol AL34YS BATTERY ORUNO m rover ta
162. ype Output 5 fixed system points Parallel I O 2 boards Input 80 user open points 7 extensi n mounted Output 96 user open points addition possible boards Single Input 40 user open points option board l S is option mounted Output 48 user open points addition possible Masteri Input 1024 points master 256 points slave Slave Output 1024 points master 256 points slave DEVIS gI Input 1024 points board Master hus Pol i Output 1024 points option Input 256 points Output 256 points Input 384 points Slave Output 384 points including remote registers RWw and RWr RS 232C 1line External communication Ethernet 1 line USB 2 lines Supporting flash memory Extension slots 3 For optional boards Self diagnosis function Overrun servo error memory error input error etc 0 02 to 10 sec in units of 1 60 sec Error codes will be outputted on the external I O Error display Error messages will be displayed in English on the teach pendant option Error codes will be displayed on the mini pendant option 2m 4m 6m 12m 2m 4m 6m 2m 4 m 6 m 12 m 2m 4m 4m 6m 6m 12m 20 m Standard type 12m 20m 20 m Standard Standard 20 m 1 Remote teaching Teaching system 2 Numerical input MDI Robot control cable option splash proof type Standard type splash proof type Standard I O cable option 8 m 15 m for Mini I O HAND V O parallel I O extension boa

Standard type of controller

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