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INTERFACE MANUAL

1. Operation preparation start Moving robot arm close to operation origin when external mode indicator lamp is ON and operation position 1 indicator lamp is OFF Robot operation origin indicator lamp ON Internal processing Operation position 1 Robot preparation OK When both are ON display Internal processing U Q Operation start area check Start and Stop Procedure and System I O Signals 1 Continued on following page 67 Continued from preceding page Worker s operation and display on equipment s operation panel Equipment s Automatic gt Program No Select ON Start Button ON Regular operation program is selected and output to data area 2 PLC processing Robot operation Automatic Operation Executing Program Program start indicator lamp ON Operation Command i END Program start Program No select ON 4 Robot in operation signal OFF Regular operation program is selected and output to data area 2 G Automatic operation Repeated Program start ON Equipment s Cycle Cycle Stop ON Executing 1 cycle Stop button ON i ee amp Operation end Automatic operation Internal processin indicator lamp OFF P 9 T
2. Internal circuit 680 Photo coupler Robot controller When the internal power source is used O POWER connector __ Power source Internal power source Internal circuit 680 Photo coupler Robot controller When an external power source is used Hand Input Circuits NPN type 126 5 2 2 Robot Stop and Enable Auto Input Circuits The Robot Stop and Enable Auto signals are important for safety The input circuit for these signals must have contacts as shown below Use the INPUT CN8 pins 1 and 3 of the robot controller for the power source irrespective of whether the power source to be used for other I O signals is the internal power source or an external power source Note For the Dual emergency stop type refer to Subsection 5 2 4 2 Robot Controller Internal Power Source 24V F8 1 3A Robot Stop Enble Auto Internal Power Source OV Note 1 For Double safety emergency stop type connector pins of CN10 Pin No 59 to 62 should be used for Robot Stop inputs Robot Stop and Enable Auto Input Circuits TIP For the configuration sample of an emergency stop output circuitry refer to Subsection 5 2 4 Emergency Stop Circuit 127 5 2 3 User Output System Output and Hand Output Circuits NPN type The following two pages show an example of
3. sess 4 Robot Controller I O Connectors 156 Robot Failure Output eese 33 80 Robot Initialization Complete Output 21 Robot Power ON Complete esses 70 Robot Stop Input eene 40 Robot Stop and Enable Auto Input Circuits 127 147 Robot Warning Output sees 34 81 Robot in operation Output sse 31 77 lepEcr Q eeates 119 RS232C CN1 RS232C connector 139 S Servo ON Output eese 30 72 Single Cycle End Output eese 78 SS mode Output 36 84 Standard Mode sess 14 22 26 Status Area ise ee PR entere en 51 Step Stop All Tasks Input 41 101 Strobe Signal Input seen 49 System I O Signals Compatible Mode 69 System I O Signals Standard Mode 26 System Input Signals Compatible Mode 86 System Input Signals Standard Mode 38 T Teaching Output eseeeeeeeerenerennere ien Type I Variable Read eese 39 Type I Variable Write eee 58 U User VO Sipnals 5 5 tnt ttt retentum 24 User Input Commands eee 24 User Output Com
4. 50 Compatible Mode sese 14 23 69 Connector Pin Assignment and I O Circuits PNP type M M 138 Connector Pin Assignment I O Circuits NPN type 118 Continue Start Input sse 105 Continue Start Permitted Output 36 84 Control System Configuration ssssss 12 Controller I O Circuits ssusesss 124 144 Controller I O Connectors uusss 136 156 Controller Specifications 7 D Dead Battery Warning Output 325 82 E Emergency Stop Output from a contact at 83 Emergency Stop Output Circuit 132 152 Enable Auto Input eee 39 87 Error No Output eese 83 Error Read iiec RR et Rd 51 External Mode Output sess 29 74 External Speed and Acceleration Setting 56 H HAND I O CN9 Connector for end effector I O common to both modes ss 118 138 Hand Input Circuits esses 126 146 Hand Output Circuits eseesess 130 150 I VO Command Seinneann entered et re tette pite ee 52 I O POWER CN7 Power connector for I O common to both modes 119 139 I O Power Connector sees 134 154 V
5. sese 142 6 2 Robot Controller I O Circuits PNP type essent ener enne nen ener eneennen 144 6 2 1 User Input System Input and Hand Input Circuits PNP type eene 144 6 2 2 Robot Stop and Enable Auto Input Circuits essent ener 147 6 2 3 User Output System Output and Hand Output Circuits PNP type eese 148 6 2 4 Emergency Stop Circuit 2n te reete e tee dots ee e e te aunts EE e De ve DR Re 152 6 2 5 VO Power Connector PNP type eet ete eerte bnt te pne hb torino eto trip ein 154 6 3 Wiring Notes for Robot Controller I O Connectors PNP type esses 156 Ir 158 7 1 Multi core Cables with COnn cCtors ieeie tede reete tbt ette ne nh a nee curo ee ene un aina Senis 158 43 27 AMammg ot Primary POWeESOUECE ict coc A e e RUE e Ee C Eee eed ere ede Pont 160 Chapter 1 General Information about RC5 Controller The RC5 controller is available in several models which differ in detailed specifications to match robot models of D E series 1 1 Controller Model Name on Nameplate The model name of the controller is printed on the nameplate attached to the side of the controller as shown below The model name is coded as listed below Nameplate Sample R C5 H4A _ DENSO 410000 7720 O8R004 MADE IN JAPAN Coding of Controller Model Name
6. sss 38 3 4 Usage of System Input Signals Standard Mode sess eren nennen 39 3AE Enable Auto Input 5i rent ceret edite FOE Peri te Ege eei 39 34 2 RobotStop Input e RISE que ee ERE 40 3 443 Step Stop All Tasks Input eoe reme er reete tit eoe eet rt oo e eet 41 3 4 4 Instantaneous Stop All Tasks Input essent nennen etre 42 3 4 5 Interr pt Skip Input eee Ni e pet Pan p a Ip p in tied 43 35 Command Execution I O Signals jgsifeci ml NICHE GB 45 3 5 1 General Information about Commands eese eerte nnne 45 3 3 2 Processing T O Comnminds 43 eret Ip peer eee ete epit E pe appe oe E Ree rer Se 46 35 3 I O Commands Details toe itr i n e br a hoi ea echten 52 3 6 Example of Using System I O Signals in Standard Mode sse 65 Chapter 4 System I O Signals METEO DT sesssescssssesssscssscnsccnccssscnscesscusscnscssscuscsuscssccnsceuccesscnsessccssesues 69 4 Types and Functions of System Output Signals Compatible Mode eee 69 4 2 Usage of System Output Signals in the Compatible Mode essere 70 4 2 1 Robot Power ON Complete proe hg ert get t eter rt egere eee cadens 70 4 22 Auto Mode Outpt ied tei rte ree iria ide ri ente Seaain 71 423 Servo ON QUtp t snc ate ete ea ten temet medie 72 42 4 CAE Complete Output neret eR ERR Re I re ASDA O AEAT E 73 4 2
7. RC5 VSE 6 B A P a c d e Position fecu Denotes Coding a VSE Robot model name VM VM D VS VS D VSE VS E VC VC E H HM HS D HSE HS E HME HM E HC HC D XYC XYC D EAH HM HS D with extended joint support EAHC HC D with extended joint support EAXYC XYC D with extended joint support EAVS VS D with extended joint support No of controllable axes 4 4 axes 5 5 axes 6 6 axes B Engineering symbol 1 A Encoders connected via parallel interface to CN13 B Encoders connected via bus to CN12 Engineering symbol 2 Blank or A P Types Blank I O of NPN type P I O of PNP type AN Robot System Type A and I O of NPN type Note For Robot System Type A refer to next page AP Robot System Type A and I O of PNP type BN Global type Dual emergency stop type Robot System Type A and I O of NPN type BP Global type Dual emergency stop type Robot System Type A and I O of PNP type Notes for Robot System Type A gt 1 Modified Deadman Switch Functions in Robot System Type A In Robot System Type A designed for the RC5 controller the functions of the deadman switches provided on the optional devices have been partially modified regarding the motor power ON OFF control Accordingly the description given in the instruction manuals that come with Type A is different from the actual functions When reading the deadman switch related sections
8. Robot stop Stops the robot by opening signals Robot stop Stops the robot by canceling signals Step stop Step stops all programs by opening signals Instantaneous stop A stops all programs Dy Clear robot failure Error clear Clears an error operation preparation start Prodram inteitupi Interrupt ski Interrupts the execution of the current step 9 P P P and starts the next step Continue start Continue stari Executes continue start program start Caution Two or more signal names listed in the signal name field indicate that they should be used in combination Program reset operation preparation start execution 86 4 4 Usage of System Input Signals in Compatible Mode The usage of each system input signal in compatible mode is described below 4 4 1 Enable Auto Input 1 Function The signal enables switching of the robot mode to the Auto mode shorted state The signal enables switching of the robot mode to the manual mode or the teach check mode open state 2 Terminal number No 4 of connector CN8 3 Usage The signal is used for the AUTO TEACHING selector switch of the external operating panel and can be combined with the safety fence switch 4 Input conditions and operation As shown below the selectable operation mode depends on whether this input is shorted or open If the input becomes open during automatic operation the mode will be switched to manual mode and ERROR
9. 2 During execution of the program Robot in operation signal ON the power to the motor will be turned OFF and the mode will be switched to internal mode after the robot decelerates to a stop 3 When the program is not executed in manual and auto modes in manual and auto modes everything will be the same except the power to the motor will be turned OFF The power to the motor can be turned ON and the suspended operation can therefore be resumed by shorting the ROBOT STOP input However the program will be executed from the beginning G Opening the ROBOT STOP input and pressing the ROBOT STOP button of the operating panel or the teach pendant function is the same 4 Timing of the input This input will be processed prior to all commands and input signals 40 3 4 3 Step Stop All Tasks Input 1 Function Input this signal to step stop the program being executed from the external device All tasks will be step stopped 2 Terminal No 5 of connector CN8 3 Input conditions and operation If the state of this signal is changed from ON shorted to OFF open the robot will stop all tasks as soon as the ongoing step is completed and the Robot in operation signal will be turned OFF However auto mode or external mode will remain valid and the suspended program will be resumed by inputting a program operation command start See the figure given below For resuming the program after a step stop see Chapter 5
10. Program start signal input ON shorted OFF open Program start ON Reset output OFF Program Start Reset Output ON Condition 76 4 2 8 Robot in operation Output 1 Function The signal outputs to the external device that the robot is in operation executing more than one task 2 Terminal number No 2 of connector CN10 3 Usage The signal is used to light the robot operating indicator lamp of the external operating panel Since the signal is turned OFF with STOP ALL PROGRAMS it outputs to the external device that all programs are stopped 4 ON conditions The signal will be turned ON while executing the program and also in the Wait State with a condition branch or timer command 5 OFF conditions The program will be turned OFF with STOP ALL PROGRAMS Caution STOP ALL PROGRAMS means the operation of the ROBOT STOP or STOP button of the operating panel or the teach pendant and INSTANTANEOUS TOP ALL TASKS STEP STOP ALL TASKS and ROBOT STOP inputs 77 4 2 9 Single Cycle End Output 1 Function The signal outputs to the external device that a single cycle of the program is completed Caution The single cycle end signal will be output upon reading END of the program However it will be output earlier than the end of the actual robot operation because the Robot Controller pre reads the program The single cycle end signal will be output on the premise that only one program i
11. gt STEP 8 Click on the Transfer button The Transfer Environment Table window appears Transfer Environment Table xc r Transfer Table Bian lt Receiye Cancel Select All Check off the check box by clicking on the Hard setting field gt STEP Q eee 755 lt Receive Cancel Select All Click on the Transfer button The following message window appears confirming that you are sure to gt STEP 10 update the data Click on the Yes button N 400F Data to be updated OK to transmit E No Cancel 20 The Transmitting hard setting table window appears displaying a bar graph gt STEP 1 1 that indicates the transfer progress 77 MEBNBEREENE After the Transmitting hard setting table window disappears turn the STEP 1 2 controller power OFF Turn the controller power ON gt STEP 1 3 The I O assignment mode is switched 21 2 3 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 User I O signals are compatible with conventional signals including the pin pattern in compatible mode Note that the connector pin meanings are different between standard mode and compatible mode Some of the signal lines used for user I O in compatible mode are used for system input in standard mode Additionally part of th
12. 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 Command Area input Data Area input Command and Data Area Odd Parity input Strobe Signal input Status Area output Status Parity output Command processing complete output Note 100 ms or less Robot Error output Outline of I O Command Processing 46 Set a command area a data area if necessary and command and data area odd parity for the command execution I O signal from the external device to the Robot Controller After the setting is completed turn ON the strobe signal Caution The data to be set in must be defined more at least 1 msec before the strobe signal is turned ON Perform command input with a strobe signal after the system output signal ROBOT INITIALIZATION COMPLETE is output The controller reads the command area the data area and the command and data area odd parity as the strobe signal is input The controller starts processing based on the command it read If the command is one that outputs a status the controller sets the status area and status parity After command processing has been completed and a status area has been set the controller turns ON the command processing complete signal If an error occurs in the while processing a robot failure signal will be outputted together with
13. Terminal Port Terminal No number High No number High Standard strength Standard strength 5 Handoutput 68 Violet Hand Input White Hand output Orange Hand Input Yellow Yellow Power E24V for Hand white Brown NOTE The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 11 2 and 12 410 and 20 118 2 O POWER CN7 Power connector for I O common to both modes CN7 Pin Assignment common to both modes NPN type 1 5 6 9 View from the cable side 6 oenen S s oeme o S s fwmmuEN S E NCaution When using the internal power source keep the total current capacity below 1 3 A To use the internal power source of the robot controller connect the wiring so that the internal power source will be separated from the external power source Improper wiring may damage the internal circuit 3 RS232C CN1 RS232C connector CN1 Pin Assignment 5 1 9 6 View from the cable side 119 5 1 2 Connector Pin Assignment in Standard Mode 1 OUTPUT CN10 User System output connector standard mode CN10 Pin Assignment in standard mode NPN type 68 35 View from the cable side number number number number Normal CPU Black 35 User output 106 Pink ZEE IE rox om epi ny ee Status area bt9 area Status area bt9 9 Brown 60 Robotstop1 Gray aes oe mmu e Status area bit11 area bit 11
14. The signal will be turned OFF when a robot failure or robot warning signal is turned ON Arobot error is cleared by the OK or Cancel key of the operating panel or teach pendant When a robot error was cleared with CLEAR The system properly ROBOT FAILURE and OPERATION PRE starts to operate after PARATION START signals from the external the power is turned device ON y y 4 Robot error Robot Power ON Complete Output 70 4 2 2 Auto Mode Output 1 Function The signal outputs to the external device that the robot is in the auto mode 2 Terminal number No 4 of connector CN10 3 Usage Starting the program from the external device requires an SWITCH EXT MODE input a PROGRAM NO SELECT input and a PROGRAM START input The signal is used to confirm that the robot is in the auto mode 4 ON conditions The signal will be output when the robot enters the auto mode under the following conditions The mode selector switch of the operating panel or the teach pendant is set to AUTO 5 OFF conditions The signal will be turned OFF under the following conditions When the mode selector switch of the operating panel is set to MANUAL or the teach pendant is set to MANUAL or TEACH CHECK When Enable Auto OFF is input Caution The signal will not be turned OFF in the pendantless state described in the OPTIONS MANUAL Chapter 1 Subsection 1 3 3 Caution The signal will not be turned OFF wi
15. permitted Outputs when the robot is in SS mode Refer to the Safe start function SS mode SETTING UP MANUAL Chapter 3 Subsection 3 4 6 SS Safe Start Function Outputs from a contact exclusively designed for an Emergency stop Emergency stop emergency stop circuitry 26 3 2 Usage of System Output Signals Standard Mode The usage of each system output signal in standard mode is described below 3 2 1 Robot Initialization Complete Output 1 Function The signal outputs to the external device that a MODE SWITCHING COMMAND is ready to execute from the device 2 Terminal number No 5 of connector CN10 3 Usage The mode switching command will be executed as soon as this signal and the auto mode signal are turned ON after the power is turned ON 4 ON conditions The signal will be turned ON when the system program for the Robot Controller normally starts after the power is turned ON and the mode switching command is ready to execute The signal will be turned ON when a robot failure is cleared by the CANCEL key of the operating panel or teach pendant or by a CLEAR ROBOT FAILURE command after the power is turned OFF 5 OFF condition The signal will be turned OFF when a robot failure or robot warning signal is turned ON Arobot error is cleared with the OK or CANCEL key of the operating panel or teach pendant The system properly started to A robot error is cleared with a CLEAR ROBOT o
16. 1 and 35 2 and 36 34 and 68 NOTE 2 The terminal number marked with is used only for Dual emergency stop type 142 2 INPUT CN8 User System input connector compatible mode CN8 Pin Assignment in compatible mode PNP type 50 26 View from the cable side number number number number z Instantaneous stop all tasks Operation preparation start Pink Pink Pink 27 White White Orange 32 User input Dwema 5 s Brown 3 O o ae a A a ae NOTE 1 The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 26 2 and 27 25 and 50 NOTE 2 The terminal number marked with is not used for Dual emergency stop type 14 C 6 2 Robot Controller I O Circuits PNP type 6 2 1 User Input System Input and Hand Input Circuits PNP type The following two pages show examples of the user input system input and hand input circuit configurations and connections of the robot controller The maximum allowable capacity of the robot controller s internal power source is 1 3 A Use the internal power source within this allowable range Caution Either an external power supply type or built in power type Output card is available for the PLC However an external power supply type requires an additional power source 24V to be installed The power capacity is 15W or more When contr
17. If this signal is on program numbers will be ignored at execution of Program start and the current program being on halt will be resumed If Continue Start Permitted signal is not ON the controller will issue ERROR27A8 105 4 5 Example of Using System I O Signals in Compatible Mode This section describes an example of starting and stopping the robot using system I O signals 1 Equipment setup example The example shown below assumes an equipment setup which allows you to run the robot by operating an external equipment s operation panel connected via the PLC to the robot controller It is assumed that the operation panel has a display lamps and switches listed on the next page Other equipment e g conveyor External equipment s operation panel Example of Equipment Setup Using a Robot 106 Function Example of Equipment Operating Panel Display Display aria messages such as ROBOT PREPARATION Lights during automatic operation Not illuminated when the robot is not in automatic operation Lamp Robot external mode Lights when the robot is in external mode indicator lamp Turned OFF when the robot is not in external mode Operation OK indicator Lights when the Enable Auto signal is ON lamp Turned OFF when the Enable Auto signal is OFF Automatic operation indicator lamp Robot operation button Starts the robot preparation Automatic start button Starts the operation of the
18. Standard type 132 5 2 4 2 Dual emergency stop type Prepared by customer External 24V ro External Q 24V External ov External ov OQ External 0 24V External ov OQ External robot stop 1 pA 1 63 64 65 l 1 1 l 1 I 1166 1 I 1 D 1 68 CN10 F10 0 3A i CR2 Robot Controller Internal 24V 0 F8 1 3A YW I 1 3 Robot stop button onthe frontpanel _ of the controller 1010 i Robot stop button a Software contorol Software contorol Card PC Stop Mutual command watch Emergency Stop Circuit Dual emergency stop type 133 5 2 5 I O Power Connector NPN type For the power source to communicate signals between the robot controller and the external device the internal power source of the robot controller or an external power source is used The figure below shows an example of connecting I O power connectors when the internal power source is used and the figure on the next page shows an example of connecting I O power connectors when an external power source is used ov Internal power source I O circuit Robot controller l O Power Connection Sample When the internal power source is used NPN type Caution To use the internal power source of the robot controller connect the wiring s
19. 2 O POWER CN7 Power connector for I O common to both modes CN7 Pin Assignment common to both modes PNP type Terminal No Internal power source output 24V Ps FERMEN ps FmewmtEM OOO 9 omeen NCaution When using the internal power source keep the total current capacity below 1 3 A To use the internal power source of the robot controller connect the wiring so that the internal power source will be separated from the external power source Improper wiring may damage the internal circuit 3 RS232C CN1 RS232C connector CN1 Pin Assignment 5 1 9 6 View from the cable side Terminal No 139 6 1 2 Connector Pin Assignment in Standard Mode 1 OUTPUT CN10 User System output connector standard mode CN10 Pin Assignment in standard mode PNP type u 68 35 View from the cable side number number number number 4 Servo ON 75 Orange 38 User output 109 Pink User output 8 White ms wwe 120 White let Oc1 eo nmi Green 4 Blue 4 Violet 4 o ELM 7 Teena Ju Tema o ew w NM NL o e oo User output o White 111 115 116 117 118 119 User output 120 User output 122 123 125 126 127 o Black 5 mio Brown 5 User output Status area bit 2 e e e a TENE z smemo f o oee eee Back er t Deacman suten 1 Bronn 68 1 Dedman swich 0 NOTE 1 The optional I O cable for the above connector consists of twisted pa
20. 4 2 15 Continue Start Permitted Output 1 Function The controller will output this signal when the continue start is permitted 2 Terminal number No 16 of connector CN10 3 Usage Use this signal when you want to know whether the continue start is permitted 4 ON condition This signal comes on when the continue start is permitted For details refer to the SETTING UP MANUAL 5 OFF condition This signal goes off by carrying out the Task Status Change Operation 4 2 16 SS mode Output 1 Function The controller will output this signal during the SS mode This mode is effective when the slow mode is selected 2 Terminal number No 29 of connector CN10 3 Usage This signal is used to warn workers that the robot is in the SS mode by beeping or lighting the lamp 4 ON condition This signal comes on when the SS mode is selected 5 OFF condition The signal goes off when the TS time passes so as to cancel SS mode This function is effective when the slow mode is selected Note If the TS time passes this signal goes off even when the robot is operation in the slow mode After this signal goes off the robot runs at the original speed 84 4 2 17 Emergency Stop Output from a contact 1 Function This signal outputs from a contact exclusively designed for an emergency stop circuitry you may configure It allows red mushroom buttons provided on the front panel of the robot controller on the teach pend
21. 5 External Mode OUtpUt rettet ti edit e eise gr Feed ie rg ep Peer Vira ende 74 42 6 Teaching Output anra e pedes eum edunt edem np ene 75 4 2 1 Program Start Reset Output endete tre hee een heb ee rue i 76 4 2 8 Robot in operation Output nr erret rne rer Pene roe ER HE en eden peteret teh et TI 42 9 Single Cycle End Output IRI HG ee eroe abeo ere DR ee e eek ete deese 78 4 2 10 Normal CPU Outp t 1 eret eR e E e IRR legs ete death RR nth tete entes 79 4 2 11 Robot Failure Output one Ie ee eee een Red ideis 80 4 212 Robot Warning Output ssie tres pepe nter r deeper e street sued repete 81 4 2 13 Dead Battery Warning Output 5 te pere nt terre eR Rte ta Cet obti pe tette tees 82 4 2 14 Error NO Qutput ette Pe earned es 83 4 2 15 Continue Start Permitted Output eese eee nne eere neen etre 84 4 2 16 SS mode Qutp t rer ete eren e e IE eed rt red re eee tege 84 4 2 17 Emergency Stop Output from a contact rennen eere enint 85 4 3 Types and Functions of System Input Signals Compatible Mode sess 86 4 4 Usage of System Input Signals in Compatible Mode sese 87 4AT Enable A toInput s tete det tete etr ice Botan SED ee RE Pee ede Tek eade en ts 87 4 4 2 Operation Preparation Start Input sessssesseseseeeeeeeeeeenne teen teen etre trennen enne 88 4 4 3 Program No Select Inp t ieu
22. 5 Program Reset Input 93 When the status of the program start signal is switched from OFF to ON with the program immediately stopped the program will resume from the suspended step and stop at the cycle end Robot status Single cycle operation Performing Operating On halt remaining halfway operation Program start ON shorted signal input OFF open Instantaneous stop ON shorted signal input OFF open Program Start Operation 3 Caution To cancel the execution of the remaining steps of an instantaneously stopped program and start it from the beginning input a program reset signal a program No select signal and a program start signal at the same time For further information refer to Subsection 6 4 5 Program Reset Input 94 Robot status External mode output 1 cycle end output Program start signal input 4 Example of program start signal rise ON and fall OFF timing Example of program start signal rise ON timing The figure below shows how to make the program start signal rise with robot system outputs external mode output and single cycle end output Single cycle Next cycle Wait for start i operation operation 1 4 ON OFF ON OFF 1 200 ms or A I more required ON shorted OFF open Example of Program Start Signal Rise Timing Caution The program start signal for the first cycle rises as soon as the external
23. 5 When using the internal power source prepare a PLC input circuit unit that does not contain a power source Caution Keep the total current capacity of the internal power source below 1 3A 6 Use a multi core shielding cable for the purpose of protecting the devices from external noise Ground it to the robot controller 7 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 128 1 0 POWER connector Robot controller When the internal power source is used 1 0 POWER connector Robot controller When an external power source is used User Output and System Output Circuits NPN type 129 1 0 POWER connector 24V Robot controller When the internal power source is used 1 0 POWER connector Power source Internal power source Robot controller When an external power source is used Hand Output Circuits NPN type 130 Supplied from the I O power connector when the internal power source is used CN Transistor array V 0 24 Controller Example of Circuit with Lamp NPN type 131 5 2 4 Emergency Stop Circuit The following fig
24. 60 Power source Hz RC5 for VC E Single phase 200 VAC 10 to 230 VAC 10 50 60 Hz Power capacity VM D 3 3 kVA HM E 2 5 kVA Hs D 2 0 kVA VS E 1 9 kVA NOTE 1 HS E 1 8 kVA VS D XYC D 1 5 kVA VC E 0 6 kVA Environmental conditions Temperature 0 to 40 C in operation Humidity 90 RH or less no condensation allowed Degree of protection IP20 VM D VS E H E Standard 4m 6m Highstrength 6m 12m_ selectable bl VS D H D XYC D 3m 6m selectable caog VC E 4m 6m selectable Cables mere 5m VM D Approx 19 kg excluding attached cables Weight VS D E VC E HS E Approx 17 kg excluding attached cables H D E XYC D Approx 16 kg excluding attached cables NOTE 1 For extended joint support controllers refer to the manual SUPPLEMENT Extended Joints Support separately issued Robot control 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 while the power switch is on Doing so may cause electric shock or controller failure N CAUTION IN INSTALLATION This controller is not
25. 88 1 989 1 989 1 8 pb NE Motor capacity W 750 100 200 200 400 1500 VS D ener JOBS ence ee ate erties S daos RU UNE NE d descr ad Te L 1PMmodel aaao E en ee SS L2 SS SS L2 S SL 8 Motor capacity W E 50 50 50 200 400 400 ig ae cee Sl aa NC na M NU E CETNA NER Sel asd di ee eee E LR L l1lPMmodel SNAM SS L2 SS SS L2 Su 9 cM Motor capacity W 50 80 100 200 400 750 VCE a JOS a e a e eaaa aee aa eae eee UR UNE LR NINE Lem LE L 1 Mmodel NAR E SS L2 SS 2s SS dL SS 41 88 1 388 Motor capacity W 30 30 30 80 80 80 HMHS D SONIS noe erui es ed B eel Beal sun ME ie eee a er beer IPM model Labod SNR cans Seal SS 1 Sadli MJM Motor capacity W 200 200 750 750 HM E huis Joints ahaaa d Ld CDM NIME HE d esos iua IPM model 5 LM ULUM uL be Motor capacity W E 300 300 600 1000 aa ee Joints ne ee en Oe ene NM coal Lees ZEN ene Ain Aled HOMI aes NE aera IPM model Le Exi M ZWEITE AM ee S Mi E oe Motor capacity W x 150 200 400 750 HOD irs Joints Re merces ME e MINE mato M ME 3i dies Zasas p mnt IPM model Le SANI S M LM SO uc SS L S M Motor capacity W E s E 50 100 400 750 XYC D is SIE ERA E E d E ellis M UNE dais Borde lacs LN LPM model ci eco tea aas SEE Sealed SS LL SNO ER E NN Motor capacity W 2 50 200 400 200 NOTE 1 No IPM board are installed to locations marked wi
26. Auto mode or external mode will remain valid and the suspended program will be resumed by inputting a program start signal Internal operation by the teach pendant is valid only when the status of this signal is changed from ON shorted to OFF open For resuming the program after an instantaneous stop refer to Subsection 4 4 4 Program Start Input The minimum required pulse width is 50 msec or more ON shorted Instantaneous stop OFF open 50 ms or more required Minimum Instantaneous Stop Pulse Width 102 4 4 9 Clear Robot Failure Input 1 Function The robot can recover from a stopped state resulting from a robot failure by turning ON shorted the operation preparation start signal with this signal ON shorted 2 Terminal number No 25 of connector CN8 NOTE Operation preparation start signal is inputted through No 8 of connector CN8 3 Usage The signal is used to clear an error that brought the robot to a stop 4 Input conditions and operation When a robot failure occurs clear the error display on the teach pendant and the external output ERROR NUMBER to ready the robot to operate When the Clear robot failure signal is turned ON shorted other input signals MOTOR POWER ON CAL EXECUTION SP100 and SWITCH EXT MODE which are to be used in combination with the operation preparation start signal will be ignored To turn ON the power to the motor after a r
27. Orange 62 Rebtsop2 Gray 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 NOTE 2 The terminal number marked with is used only for Dual emergency stop type a 120 2 INPUT CN8 User System input connector standard mode CN8 Pin Assignment in standard mode NPN type 50 26 View from the cable side Terminal Port Terminal number number number Power for robot stop internal 24V Data area 2 bit 7 Robot stop E ues Power for Enable Auto 3 internal 24V Red 28 Data area 2 bit 9 Enable Auto b see Black 29 Data area 2 bit 10 Step stop all tasks zs Brown 30 Data area 2 bit 11 Instantangous st p 2 Orange 32 Data area 2 bit 13 all tasks CE 8 Smbesgna 3 Yellow 33 Data area 2 bit 14 9 interuptskip o a Green 34 Data area 2 bit 15 Blue 35 Command area 0 bit 0 n Dataareatbto 6e Violet 36 Command area 0 bit 1 Black 37 Command area 0 bit 2 13 Dataareatbt2 8 Brown 38 Command area 0 bit 3 o EA Le s EES om m om EES EN Port number pare N N Data area 2 bit 8 N Co Pink 24 White 25 White 26 White 27 White 28 White 29 White 30 White 3 here White 3 N Gray 3 wo Gray 3 Gray 3 oa Gray 3 o Gray 16 Data area 1 bit 5 Yellow 41 User input Data area 1 bit 6 Green 42 User inpu
28. 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 24V terminal and External E24V terminal of the device controller OV terminal and EOV terminal of the controller Checking Example 136 Connector Terminals and Check Points NPN type Connector for hand I O Connector for user system input 25 1 50 26 View from cable side engaging face Terminal Number 24V internal 24V Hand output OV GND at power interna ae i power source terminal output source output terminal Power 17 terminal for d a hand E24V P Power terminal for hand EOV Power GND output Connector for user system output Connector for I O power source 34 1 1 5 oo0oo0o0o0 68 35 oo0oo0o0 6 9 View from cable side engaging face View from cable side engaging face Terminal Check Terminal Check number point number point 24V internal 24V internal power source power source terminal output OV GND at output Signal output terminal OV internal OV internal power source power source terminal output E24V input 24V power terminal input EOV GND Pow
29. Rete et tee nae tee ende eti 90 AAA Program Start Input eerte teet t emet ea tite de e orte bear e asis ede 92 AAS Program Reset Input 5i rc rete e rete i erre CR Re pe Pe CR ge CO E CORE S 98 4 4 6 Robot Stop Input eren eee oe eti oy e ee ete petes 100 4 4 7 Step Stop All Tasks Input iinn s i a nnne testet teeth enitn neon sette tnn 101 4 4 8 Instantaneous Stop All Tasks Input esee neret etre nennen 102 42 9 Clear Robot Failure Input ete eter et tete n etr a err ede 103 2 410 Interrupt Skip Input 02 tette tete err tet ERE D Pent 104 4 4 T1 Continue Start Input eren DO PPP Dreier tes 105 4 5 Example of Using System I O Signals in Compatible Mode sese 106 4 6 Selectable I O Mode Ver 1 95 or later esssessssssessesseeeeeee enne eene ren eiis terei isitin 110 4 6 Whatisa selectable l O mode ed dme Ren eee des 110 4 6 2 Setting up the selectable I O mode e atiii Sias kassa ori eere 111 4 6 3 System input signal lines that can serve as user I O signal lines ses 113 4 6 4 System output signal lines that can serve as user I O signal lines sese 115 4 6 5 Sample usage of selectable I O mode eese eere nenne 117 Chapter 5 Connector Pin Assignment and I O Circuits NPN type ee ceee ecce eese eene ette netten etes es tnu 118
30. Subsection 5 3 2 Program Operation Command 0001 Robot status 1 cycle operation Performin Operating halfway At step stop Ramaning operation 4 Program start signal input ON shorted OFF open Step stop signal input ON shorted OFF open Robot in operation output ON shorted OFF open Step Stop Signal 41 3 4 4 Instantaneous Stop All Tasks Input 1 Function Input this signal to instantaneously stop the running programs from an external device All tasks will stop 2 Terminal number No 7 of connector CN8 3 Input conditions and operation If the state of this signal is turned from ON shorted to OFF open the robot will immediately stop in the middle of the ongoing step and the Robot in operation signal will be turned OFF However auto mode or external mode will remain valid and the suspended programs will be resumed by inputting Program start signal For resuming the program after an instantaneous stop see Chapter 5 Subsection 5 3 2 Program Operation Command 0001 The minimum required pulse width is 50 milliseconds msec or more ON shorted Halt OFF open 50 ms or more required Minimum Instantaneous Stop Pulse Width 42 3 4 5 Interrupt Skip Input 1 Function If this signal is turned ON shorted during execution of the robot operation command within the range between INTERR
31. area 16 bits output Nothing will be output 3 Description This command substitutes the status specified in data area 1 for the 8 bit internal I O area starting from the number specified in data area 2 63 3 5 3 10 D O Read 1010 1 Function This command outputs to the lower 8 bits of the status area the status of the 8 bit internal I O area starting from the number specified in data area 2 2 Format Command area 4 bits input 1010 Data area 1 8 bits input Nothing will be input Data area 2 16 bits input This is the first number of the internal I O 8 bit area whose status will be output The number can be set between 128 and 504 If the number is out of this range an error ERROR2034 will occur Status area 16 bits output The status of the 8 bit internal I O area starting from the number specified in data area 2 will be output to the lower 8 bits of this area 3 Description This command outputs to the lower 8 bits of the status area the status of the 8 bit internal I O area starting from the number specified in data area 2 Zero will be output to the upper 8 bits 64 3 6 Example of Using System I O Signals in Standard Mode 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 equipment s operation panel
32. be about 5 seconds depending on CAL time The time is about 1 3 seconds without CAL Once CAL is completed it does not need to be executed again as long as the power to the Robot Controller is turned ON Determine whether to execute CAL according to the CAL complete output Automatic ON shorted operation enable OFF open i 1 ms or more Operation ON shorted po preparation start OFF open l I l wie power to the motor is turned ON Motor power ON ON shorted OFF open 2 CAL starts CAL ends N CAL execution ON shorted rA OFF open d G E SP is set to 100 SP100 ON shorted OFF open The mode is switched to external mode External ON shorted mode switching OFF open Automatic ON shorted mode output OFF open Servo ON ON shorted Approx 2 0s OFF open A Ue i CAL complete ON shorted pprox 2 5s CAL time OFF open External ON shorted ADON 0 5s mode output OFF open i gt indicates the input or output of the signal and indicates robot operation Example of Operation Preparation Start Signal Timing Chart 89 4 4 5 Program No Select Input 1 Function The program number to be executed can be specified from the external device by inputting this signal 2 Terminal numbers No 11 to No 18 of connector CN8 3 Input conditions and operation This signal is executable only in the external mode In other
33. cable for the above connector consists of twisted pair wires pairs of 1 and 26 2 and 27 25 and 50 NOTE 2 The terminal number marked with is not used for Dual emergency stop type 141 6 1 3 Connector Pin Assignment in Compatible Mode 1 OUTPUT CN10 User System output connector compatible mode CN10 Pin Assignment in compatible mode PNP type 68 35 View from the cable side Terminal number number Normal CPU a 9 s merus 7 5 Pooamsanest 7 s wes 79 9 Robot power oN compere so 35 Robotwaring f 99 s feror S 99 s Bmerwswmz 9 Ea d Errortensbit3 tens bit 3 ER Error hundreds bit 0 Ex Emorhundedsbit hundreds bit Emorhundedsbit EL Error hundreds bit 2 Error hundreds bit3 hundreds bit 3 E ELI mm UR Black Brown Red Orange Yellow Black Brown Red Orange Yellow Green Blue Violet Gray Pink Black Black Brown Red Orange Yellow Green Blue Gray Pink Brown Red Orange Yellow Green Blue Pink Black Brown 35 User output 106 Pink T 7 s s T s 2 i T r s a a T 5 s Z s T s s s7 Noteomecied vate ss Namens vote 3 rio ooa viet i roe e e e5 Emewesopzi Sey s Emewemysepz ey e pes NOTE 1 The optional I O cable for the above connector consists of twisted pair wires pairs of
34. connected via the PLC to the robot controller It is assumed that the operation panel has a display lamps and switches listed on the next page Other equipment e g conveyor Operating panel Example of Equipment Setup Using a Robot 65 Function Example of Equipment Operating Panel Classificati nc de Display Display ra messages such as ROBOT PREPARATION Lights during automatic operation Arat aa Turned OFF when the robot is not in automatic H operation Lam Robot external mode Lights when the robot is in external mode p indicator lamp Turned OFF when the robot is not in external mode Operation OK indicator Lights when the Enable Auto signal is ON lamp Turned OFF when the Enable Auto signal is OFF Robot preparation button Starts the preparation of the robot Automatic start button Starts the operation of the equipment Stops the equipment after a cycle of operations is completed Cycle stop button Automatic operation of the robot possible when Operation Adjustment OPERATION is selected selector switch Manual operation or teach check of the robot possible when ADJUSTMENT is selected Caution Actual equipment requires emergency stop interlock and other functions however described here are the necessary functions 2 Outline of procedure Described below is the outline of the procedure when using the equipment taken as an example shown on the previous page Follow steps
35. dark current 1 3 or less of the rated current to flow when the lamp goes OFF An example of connecting a lamp is shown on page 140 1 The User Output System Output and Hand Output Circuit are open collector output circuits 2 The maximum allowable sink current is 70 mA Keep the current consumption of a device to be connected to the Robot Controller such as a PLC and a relay 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 191888 Toshiba in close vicinity to the coil NCaution 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 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 Refer to page 140 5 When using the internal power source prepare a PLC input circuit unit that does not contain a power source Caution Keep the total current capacity of the internal power source below 1 3A 6 Use a multi core shielding cable for the purpose of protecting the devices from external noise Ground it to the robot controller 7 24V internal power source of the robot controller must not be groun
36. hydraulic pneumatic piping Positioning of emergency stop switches Positioning of operating status indicators The robot controller teach pendant and operating panel should be installed outside the robot s restricted space and in a place where you can observe all of the robot s movements when operating the robot controller teach pendant or operating panel 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 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 will 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 temporary halt or on an emergency or abnormal stop 2 8 Setting up the safety fence or enclosure X2 RX X09 0909050 SSS 2 9 Positioning of rope or chain A safety fence or enclosure should be set up so that no one can easily enter the robot s restricted space If it is impossible util
37. i Robot stop button a Software contorol Software contorol Card PC Stop Mutual command watch Emergency Stop Circuit Dual emergency stop type 153 6 2 5 I O Power Connector PNP type For the power source to communicate signals between the robot controller and the external device the internal power source of the robot controller or an external power source is used The figure below shows an example of connecting I O power connectors when the internal power source is used and the figure on the next page shows an example of connecting I O power connectors when an external power source is used or more ov or more Internal power source I O circuit Robot controller l O Power Connection Sample When the internal power source is used PNP type Caution To use the internal power source of the robot controller connect the wiring so that the internal power source will be separate from the external power source Improper wiring may damage the internal circuit The 24V internal power source of the robot controller must not be grounded 154 oV Internal power source 0 5 mm or more 0 5 mm or more External I O circuit power source Robot controller l O Power Connection Sample When an external power source is used PNP type Caution Use a cable of 0 5 mm or
38. 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 A WARNING of the safety fence or in a position MEM where it is easy to see Do not enter this safety fence during automatic operation Press emergency stop button before entering this safety fence Moving robot arm can cause serious injury Do not enter this safety fence during automatic operation Press emergency stop button before entering this safety fence 3 Precautions AWARNING A Touching the robot while it is while robot is running Warning in operation can lead to serious injury Please ensure the following conditions are maintained and that the cautions listed from Section 3 1 onwards are followed when any work is being performed Moving robot arm can cause serious injury Do not enter this safety fence during automatic operation Press emergency stop button before entering this safety fence Moving robot arm can cause serious injury Do not enter this safety fence during automatic operation Press emergency stop button before entering this safety fence Do not enter
39. input from the external device or When a ROBOT FAILURE is outputted If errors 0 x 6071 to 607B 0 x 6671 to 667B 0 x 607F occur the servo will be turned OFF in automatic or external mode but will not be turned OFF in the manual or the teach check mode When the MOTOR key of the operating panel or teach pendant is activated When MOTOR ON AND CAL EXECUTION WITH MODE SWITCHING COMMAND is input from an external device ON Servo ON output OFF UM 4 When the MOTOR key of the operating panel or teach pendant is deactivated and the ROBOT STOP button is operated When ROBOT STOP is input from an external device When a ROBOT FAILURE occurs Servo ON Output 30 3 2 5 Robot in operation Output 1 Function This signal outputs to the external device that the robot is in operation 2 Terminal number No 2 of connector CN10 3 Usage The signal is used to light the robot operating indicator lamp of an external operating panel Since the signal is turned OFF with STOP ALL PROGRAMS outputs to the external device that all programs are stopped 4 ON conditions The signal will be turned ON during execution of the program and also while in the WAIT STATE with a condition branch or timer command 5 OFF conditions The signal will be turned OFF with STOP ALL PROGRAMS Caution STOP ALL PROGRAMS means the operation of the ROBOT STOP or STOP button of the operating panel or teach pendant and INSTANTANE
40. is input from the external device ROBOT FAILURE is outputted If any of errors 0 x 6071 to 607B O x 6671 to 667B 0 x 607F occurs the servo ON signal will be turned OFF in External Auto mode but will not be turned OFF in manual or teach check mode When the MOTOR button of the operating panel or the teach pendant is turned ON When MOTOR POWER ON and OPERATION PREPARATION START signals are input from the external device CIE E M Servo ON output OFF 4 When the MOTOR button of the operating panel or the teach pendant is turned OFF and the ROBOT STOP button is operated When a ROBOT STOP signal is input from an external device When a ROBOT FAILURE occurs Servo ON Output 72 4 2 4 CAL Complete Output 1 Function The signal outputs to the external device that CAL is completed 2 Terminal number No 11 of connector CN10 3 Usage This signal is used to determine whether to execute CAL Once CAL is completed it does not need to be executed again as long as the power to the Robot Controller is turned ON 4 ON conditions The signal will be turned ON upon proper completion of CAL under the following conditions When CAL is performed by the operating panel or teach pendant When CAL EXECUTION and OPERATION PREPARATION START signals are input from the external device 5 OFF conditions The signal will be turned OFF when CAL is not properly completed as shown below It will remain
41. mode 5 OFF conditions As shown below the robot warning signal will be turned OFF under the following conditions When CLEAR ROBOT FAILURE and OPERATION PREPARATION START signals are input from the external device and the existing error is cleared When the existing error is cleared by operating the OK or Cancel key of the operating panel or the teach pendant When a slight error occurs during I O processing execution of the program or servo processing Robot warning OFF T When a CLEAR ROBOT FAILURE command is inputted from the external device and the existing error is cleared When the existing error is cleared by operating the OK or Cancel key of the operating panel or teach pendant Robot Warning Output 81 4 2 13 Dead Battery Warning Output 1 Function The signal will be output when the voltage of the encoder back up battery or memory back up battery becomes dangerously low 2 Terminal number No 14 of connector CN10 3 Usage The signal is used to check the timing of battery replacement lowering of the battery voltage 4 ON conditions The signal will be turned ON when the voltage of the encoder back up battery or memory backup battery becomes dangerously low Caution Any error of ERROR64A1 to 64A6 indicating the dead encoder back up battery or ERROR6103 informing the dead memory back up battery will be displayed on the operating panel and the teach pendant 5 OFF
42. more in size for the wiring between the external power source and the I O power input connectors of the robot controller 155 6 3 Wiring Notes for Robot Controller I O Connectors PNP type Robot controller 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 See the figure below and the table given on the next page Z Caution If the connector wiring between the robot controller s 24V terminal and OV 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 terminal or E24V terminal of each connector to see that there is no continuity See the figure below and the table given on the next page NCaution 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 NCaution 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 short
43. 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 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 robot stop button on the teach pendant immediately if it should be necessary to do so 3 4 Inspections before Before starting work such as teaching inspect the following commencing 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 Ee Check the functioning of the emergency stop device S Check there is no leakage of air or oil from any pipes e Check there are no obstructive objects in or near the robot s restricted space 3 5 Release of residual air Before disassembling or replacing pneumatic parts first release pressure any residual air pressure in the drive cylinder 3 6 Precautions for test Whenever possible have the worker stay outside of the robot s runs restricted space when performing test runs 3 7 Precautio
44. output signals changes in sequence after the program start signal is input T TT in the figure given on the next page The change of the status of these signals takes place within 100 msec after the program start signal rises ON See the next page 96 Program start ON shorted signal input OFF open Robot in operation output Program start reset output Single cycle end output T Ts T4 within 100 ms Program Start Signal Rise Output Signal Timing 97 4 4 5 Program Reset Input 1 Function By turning ON short this signal any program can be forcibly executed from the beginning in a step stopped state and a suspended state Caution Generally a step stopped or suspended program resumes from where it stopped 2 Terminal number No 24 of connector CN8 3 Input conditions and operation When issued with the Program Start The figure below shows the input conditions and an operation timing chart Use the program reset signal together with a program No select signal and input it before the program start signal 1 msec or more G Turn OFF the program reset signal after the robot starts to operate after a program start reset signal is output A program No select signal is required to execute the same program number as the suspended one from the beginning Robot status Executing cycle Som Bean Step
45. the SETTING UP MANUAL 5 OFF condition This signal goes off by carrying out the Task Status Change Operation 3 2 11 SS mode Output 1 Function The controller will output this signal during the SS mode This mode is effective when the slow mode is selected 2 Terminal number No 11 of connector CN10 3 Usage This signal is used to warn workers that the robot is in the SS mode by beeping or lighting the lamp 4 ON condition This signal comes on when the SS mode is selected 5 OFF condition The signal goes off when the TS time passes so as to cancel SS mode This function is effective when the slow mode is selected Note If the TS time passes this signal goes off even when the robot is operation in the slow mode After this signal goes off the robot runs at the original speed 36 3 2 12 Emergency Stop Output from a contact 1 Function This signal outputs from a contact exclusively designed for an emergency stop circuitry you may configure It allows red mushroom buttons provided on the front panel of the robot controller on the teach pendant and on the operating panel to be used as emergency stop buttons of the facilities A 0 3A fuse is built in the contact 2 Terminal number No 65 of connector CN10 Emergency stop No 66 of connector CN10 Emergency stop 3 Usage This signal is used to stop the facilities or robot in an emergency Refer to Subsection 5 2 4 Emergency Stop Circuit
46. the command processing complete signal The PLC waits until the command processing complete signal is input and receives the status of the status area if necessary In this case confirmation that no error exists with the robot After the PLC has read the status it turns OFF the command and data areas and the strobe signal G As soon as the strobe signal is turned OFF the controller turns OFF the status area and the command processing complete signal The robot failure signal which is outputted due to a command processing error remains ON until a CLEAR ROBOT FAILURE command is executed Caution G The maximum time taken until the status area and the command processing complete signal are turned OFF after the strobe signal is turned OFF in is 100 msec If the strobe signal is turned OFF before the command processing complete signal is turned ON in the command processing complete signal and the status area will be output and then turned OFF within 100 msec 47 3 5 2 2 Using Each Signal Line 1 Command and Data Areas This section describes the usage of the command area 4 bits input data area 1 8 bits input data area 2 16 bits input and command and data area odd parity input 1 Function Specifies the commands to be executed by the Robot Controller Sets the command area at all times and data areas 1 and 2 if necessary 2 Terminal numbers Command area No 35 to No 38 of connecto
47. to G Operation preparation start After setting the MOTOR ON CAL EXECUTION EXTERNAL SPEED 100 and EXTERNAL MODE SWITCHING bits execute the mode switching command to bring the robot into external automatic operation mode This operation will be completed when the EXTERNAL MODE output signal is turned ON Automatic operation Start the program by which the robot starts from the operation origin performs operations and returns to the operation origin G 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 66 Worker s operation and display on equipment s operation panel PLC processing Robot operation Equipment power ON u Setting operation adjustment Hier wiek to Enable Auto ON Internal processing operation Operation OK indicator lamp ON U Setting Mode selector switch of the operating panel or the teach pendant to AUTO Il Note button ON button ON gt Data area 1 input ON Executing mode EN switching command Motor power ON Executing CAL U Setting SP 100 U Switching mode to external mode Robot external mode indicator lamp ON Internal processing External mode ON
48. 010000 Step stop 00100000 Instantaneous stop 01000000 Reset An error ERROR2032 will occur if data is other than the above is set Data area 2 16 bits input Program number Program number to start When the number given in data area 2 is nn the operating state of PROnn will be controlled as given in data area 1 If the program number is negative in the case of a step stop instantaneous stop or reset command all programs will stop or be reset If the program number is negative with a program reset start or program start command ERROR73E4 will result Status area 16 bits output Nothing will be output 3 Description Program reset start This command is executable only in external mode If executed in other mode an error will occur This command initializes and starts the program of the program number specified in data area 2 PROO to PRO32767 can be started If the program number specified in data area 2 is negative an error ERROR73E4 will occur Either of the following operations takes place according to the operating status of the program If the specified program is terminated stopped step stopped or immediately stopped it will start from the beginning If the specified program is running an error ERROR21F5 will be displayed and the program will stop 53 Program start This command is executable only in external mode An error ERROR2032 will occur in other modes This command starts the progra
49. 21FC will be displayed If manual operation or a teach check is conducted with this input shorted ERROR21F2 will be displayed f the mode selector switch of the teach pendant or the operating panel is set to AUTO with this input open ERROR21F3 will be displayed Since this state is x in the table below this error will remain displayed until the robot leaves this state Although ERROR21FD or ERROR21FC will be displayed when the state is changed from O to A or x shown in the table below they will not be displayed when the state is changed from A or x to O When the input is turned OFF open in external mode the external mode output will also be turned OFF Relationship Between Enable Auto Input and Selectable Mode Enable Auto Operation Mode Application ON OFF shorted open Manual operation with the operating panel or teach Teach check mode Program check with the teach pendant ck qt9 Automatic operation with the operating panel or teach External Auto mode Automatic operation with the external device BE EE AXE Note O Mode selectable x Mode not selectable A Mode selectable but manual operation and program execution impossible Caution In the pendantless state auto mode is valid even if the Enable Auto input is open external mode cannot be switched and the program cannot start to run Perform the following when operating the robot in the pendantless state Set the robot not to start to operate wh
50. 4 Contact This contact is a normal close one b contact If any of the emergency stop buttons is pressed then the contact turns off to output an emergency stop signal 37 3 3 Types and Functions of System Input Signals Standard Mode The table below lists the system input signals to be used in standard mode Types and Functions of System Input Signals to be Used in Standard Mode Start up Enable Auto Enables switching to automatic operation Robot stop Stops the robot with canceling signals Instantaneous Immediately stops all programs being executed with stop all tasks canceling signals Step stop all Step stops all programs being executed with canceling tasks signals Interrupts the execution of the current step and starts Program interrupt Interrupt skip executing the next step 38 3 4 Usage of System Input Signals Standard Mode The usage of each system input signal in standard mode is described below 3 4 1 Enable Auto Input 1 Function The signal enables switching of the robot mode to auto mode shorted state The signal enables switching of the robot mode to manual mode or teach check mode open state 2 Terminal number No 4 of connector CN8 3 Usage The signal is used for the AUTO TEACHING selector switch of an external operating panel and can be combined with a safety fence switch 4 Input conditions and operation As shown below the selectable operation mode
51. 5 1 Connector Pin Assignment NPN type penseer naa naaa enne RASE AKIA ENE enne nne EREE 118 5 1 1 Connector Pin Assignment Common to Both Modes NPN type seen 118 5 1 2 Connector Pin Assignment in Standard Mode sse 120 5 1 3 Connector Pin Assignment in Compatible Mode sess 122 5 2 Robot Controller I O Circuits NPN type nii ian a nennen etre a nennen 124 5 2 1 User Input System Input and Hand Input Circuits NPN type esee 124 5 2 2 Robot Stop and Enable Auto Input Circuits eese nennen 127 5 2 3 User Output System Output and Hand Output Circuits NPN type ees 128 5 24 Emergency Stop Circuits i t nete nre t e o Pete a entente quies 132 5 2 5 J O Powet Connector NBN type ete eere tete epe eee debe nre eae o Pure vae ka nee 134 5 3 Wiring Notes for Robot Controller I O Connectors NPN type eese 136 Chapter 6 Connector Pin Assignment and I O Circuits PNP type 4 eese eerte e creen ette netten etes ee enu 138 6 1 Connector Pin Assignment PNP type ssesesssseseeeeseeeeeee tenentem nenne nnet nennen etre nne nre etne nnn 138 6 1 1 Connector Pin Assignment Common to Both Modes PNP type sse 138 6 1 2 Connector Pin Assignment in Standard Mode sse 140 6 1 3 Connector Pin Assignment in Compatible Mode
52. 60 Hz Bud v7 Single phase power suppl g e p P PR Singe phase 230 VAC 10 RCS for VS D E H 7D tg 230 VAC 10 50 60 Hz XYC D A 230 VAC phase R B 230 VAC phase S C Not used D Ground Single phase power supply Singe phase 200 VAC 10 RC5 for VC E to 230 VAC 10 50 60 Hz Max rush current when the power is turned ON 50 A for 1 50 or 1 60 second 3 3 kVA 2 5 kVA 2 0kVA Power consumption of 19kVA robot 1 8 kVA 1 5 kVA 0 6 kVA Caution If ERROR6102 power voltage drop occurs when the robot is in operation then it may be due to an insufficient capacity of the primary power source 7 Do not bundle the teach pendant cables I O cables or motor cables together with high power lines such as 200 VAC lines and peripheral device cables or route the motor cables near high power devices motor welder parts feeder etc 8 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 160 A Auto Mode Output sese 28 71 C CAL Complete Output eee T3 Clear Robot Failure Input ess 103 Command and Data Areas sese 48 Command Execution I O Signals Dedicated to Standard Mode essere 45 Command Processing Complete Output
53. DENSO ROBOT RC5 CONTROLLER INTERFACE MANUAL Copyright DENSO WAVE INCORPORATED 2002 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 covers interfacing required when you integrate your robot system configured with the RC5 robot controller into your facilities Before use read this manual carefully together with related manuals to safely get the maximum benefit from your robot in your assembling operations Robot models covered by this manual All robot models configured with RC5 controller Important To ensure operator 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 componen
54. Dead battery warning output 1 Function The signal will be output when the voltage of the encoder back up battery or memory back up battery becomes lower than acceptable 2 Terminal number No 8 of connector CN10 3 Usage The signal is used to check the timing battery replacement For example the battery voltage becomes lower than acceptable 4 ON condition The signal will be turned ON when the voltage of the encoder back up battery or memory back up battery becomes lower than acceptable Caution The operating panel shows any of ERROR64A1 to 64A6 when the encoder back up battery voltage is low Meanwhile the teach pendant shows ERROR6103 when the memory back up ON OF 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 OFF Power ON Power OFF Power ON The voltage of the encoder backup battery or memory back up battery becomes dangerously low ee ee 1 Battery replaced Dead Battery Warning Output 35 3 2 10 Continue Start Permitted Output 1 Function The controller will output this signal when the continue start is permitted 2 Terminal number No 10 of connector CN10 3 Usage Use this signal when you want to know whether the continue start is permitted 4 ON condition This signal comes on when the continue start is permitted For details refer to
55. EXTERNAL INTERNAL is input on the operating panel in AUTO MODE and in the INTERNAL CONTROL OFF state amp When ROBOT STOP is input When ROBOT FAILURE is outputted Caution The signal will not be turned OFF with STEP STOP When an Enable Auto input is turned OFF When INTERNAL EXTERNAL is input on the teach pendant and external mode is selected When INTERNAL EXTERNAL is input on the operating panel in AUTO MODE and in the INTERNAL CONTROL ON state When EXTERNAL MODE SWITCHING and OPERATION PREPARATION START signals are input from the external device j i External mode output OFF When internal mode is selected on the teach pendant When INTERNAL EXTERNAL is input on the teach pendant and external mode is selected When INTERNAL EXTERNAL is input on the operating panel in AUTO MODE and in the INTERNAL CONTROL ON state When ROBOT STOP is input When ROBOT ERROR is output When an Enable Auto input is turned OFF External Mode Output 74 4 2 6 Teaching Output 1 Function The signal outputs to the external device that the robot is in the manual mode or teaches check mode 2 Terminal number No 12 of connector CN10 3 Usage This signal is used to inform an external operating panel that the robot is teaching when they are installed separately from each other 4 ON conditions The signal will be turned ON when the mode selector switch of the operating
56. O Re d reete ter N o E re ase 64 WO Sign ls oiseau o a 22 I O Type Variable eee 24 TAQ Wine oes tacos M 158 VO Write ccccssssssessssssssesssssssesssssuessssssevesssssesesesneeessee 63 INPUT CN8 User System input connector compatible mode eeeeeee 123 143 INPUT CN8 User System input connector standard mode sess 121 141 Instantaneous Stop All Tasks Input 42 102 I terfaCe mentre ee festo Rer core 14 Interrupt Skip Input eeseeess 43 104 M Mode Switching eese 60 N Normal CPU Output eese 32 79 NPN typescicese eee ccrte eee eee er hone bee rete EE p Red 118 0 Operation Preparation Start Input 88 OUTPUT CN10 User System output connector compatible mode sees 122 142 OUTPUT CN10 User System output connector standard mode sese 120 140 P PNP Ypes aineen Gath cis tete Eee Rainn 138 Processing I O Commands sese 46 Program No Select Input sess 90 Program Operation Command 23 Program Reset Input eese 98 Program Start Input sees 92 Program Start Reset Output ssesesess 76 R Robot Controller Components
57. OFF until CAL is performed again and properly completed CAL is performed by the teach pendant CAL EXECUTION and OPERATION PREPARATION START commands are input from the external device Prerequisite MOTOR POWER ON CAL is executed again i L When CAL has properly ended ON GALcomplete OFF m Normal CAL end When a CAL error occurs CAL Complete Output 73 4 2 5 External Mode Output 1 Function The signal outputs to the external device that the robot is in the external mode 2 Terminal number No 5 of connector CN10 3 Usage Starting the program from the external device requires an SWITCH EXT MODE input PROGRAM NO SELECT input and a PROGRAM START input The signal is used to confirm to the external device that the robot is in external mode 4 ON conditions The signal will be turned ON under the following conditions When INTERNAL EXTERNAL is input on the teach pendant and the external mode is selected When EXTERNAL INTERNAL is input on the operating panel in AUTO MODE and in the INTERNAL CONTROL ON state When SWITCH EXT MODE and OPERATION PREPARATION START signals are input from the external device 5 OFF conditions The signal will be turned OFF under the following conditions When the mode selector switch of the teach pendant is set to MANUAL or TEACH CHECK in external mode When EXTERNAL INTERNAL is input on the teach pendant and external mode is selected When
58. OUS STOP ALL TASKS STEP STOP ALL TASKS and ROBOT STOP inputs 31 3 2 6 Normal CPU Output ON 1 Function The signal outputs to the external device that the Robot Controller CPU hardware is normal 2 Terminal number No 1 of connector CN10 3 Usage The signal is used to light the Robot Controller external operating panel error indicator lamp Q The signal is used when a normal CPU SIGNAL is turned OFF because of an error and the PLC corrects it 4 ON conditions The signal will be turned ON by the hardware when the Robot Controller CPU operates normally with the power turned ON 5 OFF conditions The 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 output OFF kso cj Abnormal CPU hardware error Normal CPU Output 32 3 2 7 Robot Failure Output 1 Function The signal outputs to the external device that a problem such as a servo error or a program error occurs with the robot 2 Terminal number No 3 of connector CN10 3 Usage The signal is used to light the robot external operating panel error indicator lamp of an The signal is used to help the PLC clear an error in response to a
59. ROBOT FAILURE signal 4 ON conditions As shown below the signal will be turned ON under the following conditions When an error such as a servo error a program error or program undefined occurs at the start of the program and during execution of the program When an error occurs during execution of the program in internal operation by the operating panel or the teach pendant or in external operation by the PLC Caution The signal will not be outputted when an error such as a program input error occurs in manual operation except when a servo error occurs in manual operation For further information see the ERROR CODE TABLES 5 OFF conditions As shown below the signal will be turned OFF under the following conditions When a CLEAR ROBOT FAILURE command is inputted and the existing error is cleared When the existing error is cleared by operating the OK or Cancel key on the operating panel or the teach pendant Program number parity error or undefined program number at external start Robot failure during automatic operation both internal operation and external operation jy ON Robot failure OFF SEND Loo When a CLEAR ROBOT FAILURE command is inputted When the OK or Cancel key of the operating panel or teach pendant is operated Robot Failure Output 33 3 2 8 Robot Warning Output 1 Function The signal outputs to the external device that a minor error occurs w
60. SET 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 25 Chapter 3 System I O Signals QenUE BU UIG 3 1 Types and Functions of System Output Signals Standard Mode The table below lists the system output signals used in standard mode Types and Functions of System Output Signals to be Used in Standard Mode Robot initialization Outputs when preparations for operation are ready to complete start Outputs when the robot is in Auto mode Start up External mode Outputs when the robot is in external mode SewoON O ON Outputs when the power to the motor is turned ON when the power to the motor is turned Outputs when the power to the motor is turned ON Program execution Robot in operation Outputs when the robot is in operation the program is being executed Normal CPU Outputs when the CPU hardware of the Robot Controller is normal Outputs when a serious error such as a servo error Robot failure and a program error occurs Error Warning Robot warning Outputs when a slight error occurs Outputs when the voltage of the encoder back up Dead battery warning battery or memory back up battery dangerously low Continue start Continue u Outputs when Continue Start is enabled
61. UPT ON and INTERRUPT OFF in the program the correct step operation will immediately stop and the next step will start Caution For further information about the INTERRUPT ON and OFF commands see the PROGRAMMER S MANUAL I Chapter 12 12 3 INTERRUPT ON OFF Statement For further information about the robot operation command see the PROGRAMMER S MANUAL I Chapter 12 Robot Conirol Statements 2 Terminal number No 9 of connector CN8 3 Usage See the PROGRAMMER S MANUAL lI Chapter 12 12 3 INTERRUPT ON OFF 4 Input conditions and operation If this signal is turned ON shorted the robot will immediately stop the current operation and start executing the next step INTERRUPT ON Command Operating halfway Next operation Robot status K 9 J4 I Li 50 ms or more required Interrupt skip signal input ON shorted OFF open Input Conditions and Operation of Interrupt Skip 43 Z Caution When turning ON shorting the interrupt skip signal at a minimum either the program reset signal or the program start signal must be turned OFF open If the interrupt skip signal is turned ON the robot interprets the program start signal as immediately turned OFF open Consequently the program selected with the program No selection signal will be executed from the beginning See the figure given below Robot status Executing cycle halfway Executing c
62. able Solenoid valves relays Teach pendant Connect the O following if necessary Robot controller Power source Operating panel 24V CN11 CN10 Vision 200 VAC device Personal computer pun Power source operation 24V panel O Solenoid valves relay motors etc Photoelectric switches proximity switches etc Robot System Configuration 12 B Robot system configuration with encoders connected via a parallel interface VS D VC E H D and XYC D Robot unit Encoder cable CN12 CN13 Connect the T h 7 ifnecessary 77 CN5 Robot controller Source Operating panel 24V CN11 CN10 Vision device 200 VAC RS 232C Personal computer Equipment Power source 24V operation Solenoid valves relay motors etc panel Photoelectric switches proximity switches etc System Configuration Example 13 Chapter 2 General Information about the Interface 2 1 Standard Mode and Compatible Mode The robot controller can be operated in two different modes standard mode and compatible mode The default is standard mode Select either mode before operating the robot controller In the standard mode all of the advantages can be expected from the new model of the robot controller by simultaneously running two or more programs with multitasking The compatible mode focuses on compatibility with conventional DENSO robots Use this mode whenever compatibility is r
63. ad battery ward battery or memory backup battery lowers An error number will be outputted in BCD code if an error occurs Continue start Continue start permitted Outputs when Continue Start is enabled Outputs when the robot is in SS mode Refer to the Safe start function SS mode SETTING UP MANUAL Chapter 3 Subsection 3 4 6 SS Safe Start Function Outputs from a contact exclusively designed for an Emergency stop Emergency stop emergency stop circuitry 69 Robot failure Error No 4 2 Usage of System Output Signals in the Compatible Mode The usage of each system output signal in the compatible mode is described below 4 2 1 Robot Power ON Complete ROBOT POWER ON ON Ab OFF COMPLETE output 1 Function The signal outputs to the external device that OPERATION PREPARATION START is possible 2 Terminal number No 9 of connector CN10 3 Usage OPERATION PREPARATION START will be executed after this signal and the auto mode signal are turned ON after the power was turned ON 4 ON conditions The signal will be turned ON when the Robot Controller system program properly starts Preparations for operation can be started after the power was turned ON The signal will be turned ON when the robot failure is cleared by the OK or Cancel key of the operating panel or the teach pendant or by CLEAR ROBOT FAILURE and OPERATION PREPARATION START signals after the power was turned OFF 5 OFF conditions
64. al mode cannot be switched and the program cannot begin execution Perform the following when operating the robot in the pendantless state Set the robot so that it will not start to operate when the Enable Auto input is open Q Enable Auto input open state and auto mode output See Subsections 4 2 2 and 6 2 2 Auto Mode Set the equipment to make an emergency stop in an AND state Add and with the external sequence circuit 39 3 4 2 Robot Stop Input 1 Function The signal stops the robot from the external device by opening the robot stop input The signal readies the power to the robot motor to be turned ON by shorting the robot stop input 2 Terminal number No 2 of connector CN8 3 Input conditions and operation The robot stops with this input OFF open The power to the robot motor is made ready to be turned ON with this input ON shorted Irrespective of whether internal mode operation by the teach pendant or external mode remote operation by the external device is selected the power to the robot motor cannot be turned ON with this input OFF open and neither manual nor automatic operation can be performed until this input is turned ON shorted ERROR2008 will be displayed amp By turning OFF open this input the following conditions may result 1 The power to the motor will be turned OFF irrespective of whether manual automatic internal or external mode is selected
65. ant and on the operating panel to be used as emergency stop buttons of the facilities A 0 3A fuse is built in the contact 2 Terminal number No 10 of connector CN10 Emergency stop No 10 of connector CN10 Emergency stop 3 Usage This signal is used to stop the facilities or robot in an emergency Refer to Subsection 5 2 4 Emergency Stop Circuit 4 Contact This contact is a normal close one b contact If any of the emergency stop buttons is pressed then the contact turns off to output an emergency stop signal 85 4 3 Types and Functions of System Input Signals Compatible Mode The table below lists the system input signals to be used in compatible mode Types and Functions of System Input Signals to be Used in Compatible Mode Enable Auto Enables switching to Auto mode Mator power ON l Turns ON the power to the motor Operation preparation start CAL execution Ads Executes calibration operation preparation start SP100 5 Start up operation preparation start pO UIESpO OC TO Ne switch EM Mode Switches the mode to external mode Operation preparation start Initializes all programs on halt Starting a program after initialization will execute the program from the beginning Program No select Executes a specified program program start Program reset Cancels the current program and starts Program program No select executing a specified program from the program start beginning
66. be careful with the following modification 1 1 Deadman switches on optional devices Teach pendant operating panel and mini pendant Deadman switches are located as shown below Deadman switches Teach pendant Deadman switch Deadman switch N Operating panel Mini pendant 1 2 Modified deadman switch functions When you operate the teach pendant operating panel or mini pendant in Manual mode or Teach check mode the deadman switch controls the motor power ON OFF function in Robot System Type A while it does not in the description given in the instruction manuals Robot System Type A Description given in the instruction manuals 1 Unless the deadman switch is held down you may neither operate the robot nor turn the motor power ON 1 Unless the deadman switch is held down you may not operate the robot but you may turn the motor power ON 2 When the robot is in operation releasing the deadman switch will stop not only the robot but also turn the motor power OFF 2 When the robot is in operation releasing the deadman switch will stop the robot but not turn the motor power OFF servo lock How to identify your robot system as Type A Check the controller model on the nameplate located on the side of the robot controller or the robot model shown on the status bar of the teach pen
67. c Used to control the opening and closing of the end effector 23 2 4 2 4 1 2 4 2 2 4 3 2 4 4 Using User I O Signals common to both modes To use user I O signals you need to first declare in the program the use of user I O as I O type variables with a DEFIO command Next 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 two ways lO nn nn terminal number Example IO 104 lOnn nn terminal 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
68. conditions The signal will be turned OFF when the power is turned ON after the dead battery was replaced Power ON Power OFF Power ON Power OFF Power ON Robot power ON state 4 4 ple l ple The voltage of the encoder backup battery or memory back up battery becomes dangerously low Dead battery ON _ sf 4 Od warning output OFF Battery replaced Dead Battery Warning Output 82 4 2 14 Error No Output 1 Function When an error occurs the signal outputs the error number in a 3 digit 12 bit hexadecimal code 2 Terminal numbers No 17 to No 28 of connector CN10 3 Usage The signal is used to display an error number on the external device 4 Output conditions The signal will be output when an error occurs 5 Clear conditions The signal will be cleared when CLEAR ROBOT FAILURE and OPERATION PREPARATION START signals are inputted or by operating the Cancel key of the operating panel or the teach pendant When this signal is cleared all states will become OFF 0 6 Hexadecimal codes See the following figure Hexadecimal Codes The figure below shows an example of error number output when ERROR 174 overload error with the fourth axis occurs Hundreds of error No Tens of error No Units of error No Terminal No L 28 27 26 25 l 24 23 22 21 20 19 18 15 tor CN10 connector x eu x OO O0 x ox X T 4 1 1 7 4 Example of Error Number Output 83
69. d nothing will happen When the specified program is step stopped or immediately stopped it will be initialized The initialized program will resume from the beginning When the specified program is running it will immediately stop and also be initialized If started after an instantaneous stop the stopped program will resume from the beginning 55 3 5 3 3 External Speed and Acceleration Setting 0010 1 Function This command sets the external speed acceleration and deceleration values selected in data area 1 to the values specified in data area 2 This command is executable only in external mode An error will occur in other modes 2 Format Command area 4 bits input 0010 Data area 1 8 bits input 00000001 Speed setting 00000010 Acceleration setting 00000100 Deceleration setting An error ERROR2032 will occur if data other than the above is set Data area 2 16 bits input Set values Speed acceleration and deceleration to be set Enter any of the external speed acceleration and deceleration values specified in data area 1 The values must be between 1 and 100 If they are out of this range an error ERROR2003 will occur Status area 16 bits output Nothing will be output 3 Description Speed setting The external speed is set to the value specified in data area 2 The value must be between 1 and 100 An error ERROR2003 will occur if the value is out of this range The exter
70. dant screen The model name of Type A contains letter A as shown below Robot controller example RC5 H4A A N Robot example HM 40702D A Symbol denoting Type A 2 Single point of control function The Single point of control function is added only for Robot System Type A This function limits the robot start that other equipments except specified one device for example Teach Pendant cannot enable to start the robot The Auto mode of this function is usable in either Internal Auto Limited Mode or External Auto Limited Mode by setting the parameter 2 1 Internal Auto Limited Mode The operational permit of Internal Auto Limited Mode is the same range as the Internal Auto Mode Program Start can be executed from the teach pendant but cannot be executed from the external device The switching between Internal Auto and External Auto cannot be operated by the teach pendant 2 2 External Auto Limited Mode The operational permit of External Auto Limited Mode is the same range as the External Auto Mode Program Start can be executed from the external device but cannot be executed from the teach pendant The switching between Internal Auto and External Auto cannot be operated by the teach pendant 2 3 Setting the parameter Ext 1 Access Top screen F4 I O F6 Aux F1 Set H W F3 Jump To 31 Select the Internal Auto Limited Mode Int 0 or the Externa
71. ded Caution If the output terminal 24V of internal power source is grounded there may be a case where the controller is damaged 148 1 0 POWER connector 1 0 POWER connector Eg Ed 24V Robot controller When an external power source is used User Output and System Output Circuits PNP type 149 I O POWER connector Internal power source E24V 1 0 POWER connector s N gt o NW Robot controller When an external power source is used Hand Output Circuits PNP type 150 Supplied from the II O power connector when the internal power source is used as b y Transistor array 0424 Controller Example of Circuit with Lamp PNP type 151 6 2 4 Emergency Stop Circuit The following figures show the examples of configuration and connection of emergency stop circuit for the robot controller The red mushroom shaped switch provided on the robot controller front panel on the teach pendant or on the operating panel can be used as a switch for stopping the equipment in case of emergency 6 2 4 1 Standard type Robot controller F1 mema 24V Fuse 1 3A OV A d Fuse 1 3A Emergency stop circuit Internal OV F2 prepared by customers F9 Emergency f I Fuse 0 3A Sto
72. depends on whether this input is shorted or open If the input becomes open during automatic operation the mode will be switched to manual mode and ERROR21FC will be displayed If manual operation or a teach check is conducted with this input shorted ERROR21F2 will be displayed f the mode selector switch of the teach pendant or operating panel is set to AUTO with this input open ERROR21F3 will be displayed Since this state is shown as x in the table below this error will remain displayed until the robot exits this state 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 When the input is turned OFF open in external mode the external mode output will also be turned OFF Relationship Between Enable Auto Input and Selectable Mode Enable Auto Operation mode Application ON shorted OFF open Manual mode Manual operation with the operating panel or the teach pendant Teach check mode Program check with the teach pendant x Automatic operation with the operating panel or teach Internal auto mode pendant External auto mode Automatic operation with the external device Note O Mode selectable x Mode not selectable A Mode selectable but manual operation program not executable x Caution In the pendantless state auto mode is valid even if the Enable Auto input is open The extern
73. designed to be dust proof splash proof or explosion proof Read operation manuals before installation Do not place anything on the controller 2 Outer Dimensions The outer dimensions of the robot controller are shown below IPM board Name Plate Serial No Cabling space S E The mounting position of a sal ie the IPM board will differ cco O O O0O0c depending upon models o E 2 Unit mm Outer Dimensions of Robot Controller for VM D HM E series and extended joint support IPM board NNNUNN Name Plate Serial No Cabling space The mounting position of the IPM board will differ depending upon models Unit mm Outer Dimensions of Robot Controller for robot series except VM D HM E E Location of IPM boards The table below shows the location of IPM boards for robot series or models Rear view of the controller Series amp Location eI 8 C 0 o0 ww Item VM 6070D Joints tec ore ede ud Lodel as Bid oso Sot usd ramet ee 3al iade a dnd L DM model Md SS L2 SS SS L2 S pg Le me Motor capacity W 750 100 200 200 400 1500 z VM 6083D Joints laalaa ERE ae LEM NER S sli rd d edic SENIUM m Y DE VOR IPM model fa M
74. e Equipment power OFF Note In data area 1 the bit to each of motor ON CAL execution external speed 100 and External Mode switching will be turned ON Refer to Chapter 5 Subsection 5 3 7 Mode Switching 0111 L in the above figure indicates a system I O signal and represents the flow of signals Start and Stop Procedure and System I O Signals 2 68 Chapter 4 System I O Signals One CA ORT 4 1 Types and Functions of System Output Signals Compatible Mode The table below lists the system output signals used in the compatible mode er m and Functions of OC Io aE Signals to be Used in Compatible Mode Application Signalname name Robot power ON NUES ae when preparations for operation are ready complete to start Outputs when the robot is in auto mode Start up Outputs when the power to the motor is turned ON CAL complete Outputs when calibration is completed External mode Outputs when the robot is in external mode Program a g Teaching Outputs when the robot is in manual or teach check pre execution check mode Program execution ca unb robot is in operation the program Outputs when the CPU hardware of the Robot Normal CPU Controller is normal Outputs pat a failure such as a servo failure and program error occurs in the robot Error warning Robot warning Outputs when a slight error occurs Outputs when the voltage of the encoder backup pe
75. e following page 2 Assuring the safety of workers performing jobs within the robot s restricted space See Section 3 3 on the following page SAFETY PRECAUTIONS eS 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 installation 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 3 2 Display of operation To prevent anyone other than the worker from accessing the panel start switch or the changeover switch by accident during operation display something to indicate it is in operation on the operating panel or teach pendant Take any other steps as appropriate such as locking the cover 3 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
76. e e et ette etd 24 2 15 User Output Commands eie eee Ie e nee et ee Pe ers 25 Chapter 3 System I O Signals SENSERI BUT ssssscsssssscsssssscssscssccsccssscnscssscesccuscssscnscsuccesscusceuscsscenscssccsseeues 26 3 1 Types and Functions of System Output Signals Standard Mode sese 26 3 2 Usage of System Output Signals Standard Mode sess 27 3 22 1 Robot Initialization Complete Output eese eterne nnne etre nenne 27 S22 Auto Mode OUTDUt 5 2 d ett eter eet et eto e eile ei poto o RR eats n 28 3 2 3 External Mode Output x Re eee ed eee de e ied ee e 29 3 2 4 I Servo ON Output ee tege a deep ee qe egeo een ue ee ee Pe EM E eqs 30 32 5 Robot insoperation Output c etd PRU oe bos PORSCHE Che P DER Te rri Pie 31 3 2 6 Normal CPU Output tete t te E EP Oe 32 32 7 iRobotPadure O tp t nerc nratas p He lege e MERO sens edus t xt ro epe ae bae E e ep 33 3 2 8 Robot Warning Output iere iere eie Ebenen e Ei eed ee EPI P o even enu 34 32 9 jDead Battery Warning Output esti ete herede irr t linen e ette o 35 3 2 10 Continue Start Permitted Output ssie iseis iiinis miii iaaea ener nre teen enne nennen 36 3 241 T SS mode OUtput 2 metet ete rtt manete metere bn 36 3 2 12 Emergency Stop Output from a contact enne en enne enrennenne 37 3 3 Types and Functions of System Input Signals Standard Mode
77. e signal lines used for system I O in compatible mode is used for command execution I O signals in standard mode 2 3 1 Standard Mode In standard mode 30 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 I O signals used in standard mode Types of System I O Signals Used in Standard Mode Fixed by system No of ae ee Robot stop Enable Auto interrupt skip instantaneous stop all tasks System input step stop all tasks Robot initialization complete automatic operation mode external mode System ouibut 12 servo ON robot in operation normal CPU robot failure robot warning y P dead battery warning continue start permitted SS mode emergency stop Input for command Command 4 bits data area 1 8 bits data area 2 16 bits odd parity execution bit strobe signal F command Command processing complete status area 16 bits odd parity bit Controlled by user program Tvpe No of YP points Inputs to read the external I O status with an IN command or IO User input 12 vanao P Used for analysis condition identification condition satisfaction wait data input from the external device etc Outputs to issue a signal to the external device during program execution Beoueulen with a SET command RESET command etc Inputs to read the external I O status with an IN command or IO Hand input variable Used to confirm the end effect
78. eleration and external deceleration of the Robot Controller will be set to 100 External mode switching bit 7 When this bit is set the mode of the Robot Controller will be switched from automatic to external 61 3 5 3 8 Clear Robot Failure 1000 1 Function This command clears a robot failure that has been caused 2 Format Command area 4 bits input 1000 Data area 1 8 bits input Nothing will be input Data area 2 16 bits input Nothing will be input Status area 16 bits output Nothing will be output 3 Description If a robot failure 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 operating panel or the teach pendant is operated will be performed 62 3 5 3 9 T O Write 1001 1 Function This command substitutes the status specified in data area 1 for the 8 bit internal I O area starting from the number specified in data area 2 2 Format Command area 4 bits input 1001 Data area 1 8 bits input The status to be set will be specified in the internal I O area starting from the number specified in data area 2 Data area 2 16 bits input This is first number of the internal I O 8 bit area for which the status will be substituted The number can be set between 128 and 504 If the number is out of this range an error ERROR2034 will occur Status
79. em input and hand input circuit configurations and connections of the robot controller The maximum allowable capacity of the robot controller s internal power source is 1 3 A Use the internal power source within this range Caution Either an external power supply type or built in power type Output card is available for the PLC However an external power supply type requires an additional power source 24V to be installed The power capacity is 15W or more When controlling two or more robots with a single PLC using the internal power source of the Robot Controller set a PLC Output card for each robot Other than a PLC a proximity switch or a relay contact may be connected directly to the input terminal of the Robot Controller In such a case use the power input to pins 6 to 9 of the I O power connector A two wire photoelectric switch or proximity switch can be connected if its leakage current is 1 mA or less Use a multi core shielding cable for the purpose of protecting the Robot Controller from noise Ground it to the Robot Controller 124 0 POWER OV Internal power source Internal circuit 1 0 POWER connector power source HEN 680 Photo coupler Internal circuit Robot controller When an external power source is used User Input and System Input Circuits NPN type 125 1 0 POWER Internal power source
80. en the Enable Auto input is open Q Enable Auto input open state and auto mode output See Subsections 4 2 2 and 6 2 2 Auto Mode Set the equipment to make an emergency stop in an AND state Add and with the external sequence circuit 87 4 4 2 Operation Preparation Start Input 1 Function By turning ON short this signal input signals to described in 3 input conditions and operation will be detected and the robot will automatically start to operate Input these signals with the system output ROBOT POWER ON COMPLETE turned ON By turning ON short CLEAR ROBOT FAILURE an error that has occurred will be cleared 2 Terminal number No 8 of connector CN8 3 Input conditions and operation Before inputting an operation preparation start signal turn ON short inputs to amp below Motor power ON input Terminal number No 19 of connector CN8 By turning ON short the operation preparation start signal with this signal turned ON shorted the power to the motor will be turned ON However this signal can be used only in the Auto mode Q CAL execution input Terminal number No 20 of connector CN8 By turning ON short the operation preparation start signal with this signal turned ON shorted calibration takes place However this signal cannot be used when the power to the motor is turned OFF not executed SP100 input Terminal number No 22 of connector CN8 By t
81. ence or enclosure described in Section 2 8 hang a rope or chain around the perimeter of the robot s restricted space to ensure that no one can enter the restricted space 1 Ensure the support posts cannot be moved easily 2 Ensure that the rope or chain s color or material can easily be discerned from the surrounds 3 Post a warning notice in a position where it is easy to see stating In operation Entry forbidden or Work in progress Do not operate and ensure that workers follow these instructions at all times 4 Set the exit entrance and follow the instructions given in Section 2 8 3 through 5 SAFETY PRECAUTIONS 2 10 Setting the robot s motion space 2 11 No robot modification allowed 2 12 Cleaning of tools 2 13 Lighting 2 14 Protection from objects thrown by the end effector 2 15 Affixing the warning label The area required for the robot to work is called the robot s 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 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
82. ent mode Then press OK The following system message appears gt STEP 4 e wq gm B w sosa xi notoli 1 System Message Completed setting parameters You must restart your controller before the new settings will take effect ie EN E PS SER E Press OK The screen returns to the Auxiliary Functions I O window gt STEP5 Turn the controller power OFF STEP 6 Turn the controller power ON again The I O assignment mode is switched 16 2 Switching from the Computer Follow the procedure below when switching from one mode to the other from the computer Start WINCAPSII on the computer Log in with Programmer gt STEP 1 Start WINCAPSII according to the procedure given in WINCAPSII GUIDE Chapter 3 Section 3 1 For details on the user level of Programmer refer to the WINCAPSII GUIDE Chapter 1 Section 1 3 gt STEP 2 Click on the DIO Manager button in the System Manager DIO Manager starts and the DIO Manager window opens C Program FileswINCAPS 2 IRA 00005IRA 0000 dio DIO Manager File Edit Actions Tool Help alojo eu mma Type Usage System input Step stop all tasks Q l OGFF Systeminput Reserved SIN2 OF Q 2 OFF System input Halt all tasks SINS OFF Of 3 OFF System input Strobe signal SINA OFF Or 4 OFF System input Interruption skip SINS QF Q B OFF System input Command data area o SING OFF On B OFF System input Data area 1 bi
83. equipment Stops the equipment after a cycle of operations is completed Switch Cycle stop button Automatic operation of the robot possible when Operation Adjustment OPERATION is selected selector switch Manual operation or teach check of the robot possible when ADJUSTMENT is selected Note Actual equipment requires emergency stop interlock and other functions However described here are only necessary functions and others are omitted 2 Outline of procedure Described below is the outline of the procedure when using the equipment as shown on the previous page Follow steps to G Operation preparation start Setting the MOTOR POWER ON CAL EXECUTION SP100 and SWITCH EXT MODE bits brings the robot into the External Auto mode This operation will be completed when the EXTERNAL MODE output signal is turned ON Automatic operation Start the program by which the robot starts from the operation origin performs operations and returns to the operation origin G 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 107 Worker s operation and display on equipment s operation panel PLC processing Robot operation Equipmen
84. equired For example when replacing a conventional robot with a new model However there are some restrictions on the use of new functions such as multitasking in this mode 2 2 Switching between Modes Switch from one mode to the other using the teach pendant or the PC teaching system Caution After switching between those modes restart the robot controller to make the new setting go into effect 14 1 Switching from the Teach Pendant Follow the procedure below when switching from one mode to the other from the teach pendant On the top screen press F4 I O gt STEP 1 The I O Monitor window appears Press F6 Aux The Auxiliary Functions I O window appears as shown below gt STEP 2 gt IN fiuxiliary Function I 0 Press F2 I O Assign For Version 1 6 or later NOTE For Version 1 5 or earlier press F1 Set H W and select the Allocation mode field in the I O Hardware Settings window 15 The Choose allocation window appears as shown below gt STEP3 NOTE If your robot controller has a built in DeviceNet master the Select Port Assignment window will appear instead of the Select I O Assignment Mode window Refer to the DeviceNet Master Unit user s manual Chapter 3 I O Assignment i amp go B m som a wotolf x Oh ito p a fuxiliai Choose allocation Compatible Allocation Standard Allocation Using the jog dial or cursor keys select the desired assignm
85. er GND input terminal input 137 Chapter 6 Connector Pin Assignment and I O Circuits PNP type This chapter explains the connector 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 5 Connector Pin Assignment and I O Circuits NPN type 6 1 Connector Pin Assignment PNP type This section describes the pin assignment of connectors on the robot controller The signals and pin assignments of output connector CN10 and input connector CN8 are differently defined in standard mode and compatible mode As for other connectors the definitions of pins are common to standard mode and compatible mode 6 1 1 Connector Pin Assignment Common to Both Modes PNP type 1 HAND I O CN9 Connector for end effector I O common to both modes CN9 Pin Assignment common to both modes PNP type View from the cable side Terminal No number Standard Hand output 1 64 s remm s preme m ome 9 Hand input 48 Blue 0 Wire color Wire color Terminal High No High strength pandara strength Violet Blue Yellow Green Red Hand Input 50 Pink mentors wie oe mentors we oe White 19 Not connected Brown NOTE The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 11 2 and 12 4 10 and 20 138
86. eriodical inspections Before starting jobs always check that there is no problem with the robot and related equipment If any problems are found take any necessary measures to correct them When carrying out periodical inspections or any repairs maintain records and keep them for at least 3 years Carefully handle and store the Initial settings floppy disks packaged with the robot which store special data exclusively prepared for your robot 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 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 Contents i How the documentation set is organized eere eee eee ee ee esee ee ette stent ta setate tasto seta setas etas e etas ete sese senses s stesse so ase ii How this DOOK is OF ri E o r ro o iii SAFETY PRECAUTIONS Chapter 1 General Information about RC5 Controller ssccsssccscsscscsscscsccssscsssscsssscssscccsscsssssssssssssssesenes 1 1 1 Controller Model Name on Namep
87. es Parameters Signal lines that can serve as user ones Step Stop Step Stop All tasks Interrupt Skip Interrupt Skip Program Select Program No select bit 0 Program No select bit 1 Program No select bit 2 Program No select bit 3 Program No select bit 4 Program No select bit 5 Program No select bit 6 Program No select odd parity bit Run Ready Motor power ON CAL execution SP100 Switch to Ext Mode 113 Parameter details No Parameters Function Step Stop If you will not use the Step Stop function in running your robot you may set this parameter to any choice other than enable Then the Step Stop input port may serve as a user I O port Note that this parameter provides no new choice so port addresses or line numbers in the user I O area will not be continuously assigned Interrupt Skip If you will not use the Interrupt Skip function in running your robot you may set this parameter to any choice other than enable Then the Interrupt Skip input port may serve as a user I O port Program Select If you will predetermine a particular program to be driven by external equipment and run your robot with the single program then you may set this parameter to any choice other than enable Then the Program Select input port may serve as a user I O port If initiated by the Program Start signal the particular
88. ftware 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 space or motion space in Denso robot that is actually used by the robot while performing its task program Quoted from the RIA Committee Draft 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 RIA Committee Draft RIA Robotic Industries Association 1 Introduction 2 Installation Precautions 2 1 Insuring the proper installation environment 2 1 1 For standard type 2 1 2 For dust proof splash proof type 2 2 Service space This section provides safety precautions to be observed during installation teaching inspection adjustment and maintenance of the robot The standard type has not been designed to 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 other conductive material flying about there are any acidic alkaline or other corrosive gases there is cutting or grinding oil mist 3 4 5 it may likely be submerged in fluid 6 there is sulfuric cutting or grinding oil mist or 7 there are any large sized inverters high ou
89. g panel is set to MANUAL or that of the teach pendant is set to MANUAL or TEACH CHECK When Enable Auto OFF is input Auto mode Output 28 3 2 5 External Mode Output 1 Function The signal outputs to the external device that the robot is in external mode 2 Terminal number No 7 of connector CN10 3 Usage Starting the program from the external device requires an EXTERNAL MODE SWITCHING BY MODE SWITCHING COMMAND input and a PROGRAM START BY PROGRAM OPERATION COMMAND input The signal is used to confirm that the robot is in external mode 4 ON conditions The signal will be turned ON under the following conditions The external mode is selected on the teach pendant Q The EXTERNAL INTERNAL is input on the operating panel in AUTO MODE and in the INTERNAL CONTROL ON state The EXTERNAL MODE SWITCHING BY MODE SWITCHING COMMAND is input from the external device 5 OFF conditions The signal will be turned ON under the following conditions When internal mode is selected on the teach pendant When the mode selector switch of the teach pendant is set to MANUAL or TEACH CHECK in external mode When EXTERNAL INTERNAL is input on the operating panel in AUTO MODE and in the INTERNAL CONTROL OFF state amp When ROBOT STOP is input When ROBOT FAILURE is outputted Caution The signal will not be turned OFF with INSTANTANEOUS STOP STEP STOP or CYCLE STOP When an Enable Auto input is
90. gth type Input Ce Cable Output Cable ere Y cos i Hand VO Cable high strength 1 type 8m 3 cable set of Nos 1 1 to 1 3 8m 3 cable set of Nos 2 1 to 2 3 8m 8m 15m 3 cable set of Nos 3 1 to 3 3 15m 15m 15m 15m 3 cable set of Nos 4 1 to 4 3 15m 15m 15m 158 Multi core cables with connectors to be used for the I O wiring of the Robot Controller are options Select an appropriate cable from the table given below if necessary 410149 0330 410141 1630 410141 1650 410141 1740 410149 0350 410141 1630 410141 1650 410141 1670 410149 0340 410141 1640 410141 1660 410141 1750 410149 0360 410141 1640 410141 1660 41014121680 If you do not use optional cables listed on the previous page use the recommended connectors and cables listed below Recommended Connectors for I O Cables and Cable Standards Connector Connector Cable Standards name model manufacturer POWER PCR E68FS connector PCS E68LA cover Honda Communications Industry Co Ltd PCR E20FS connector PCS E20LA cover Honda Communications Industry Co Ltd PCR E50FS connector PCS E50LA cover Honda Communications Industry Co Ltd DE 9P connector DE C4 J6 cover Japan Aviation Electronics Industry Ltd Braided shielding wire O cable UL2789 With shield Equivalent to AWG28 68P UL2789 With shield Equivalent to AWG28 20P UL2789 With shield Equivalen
91. ignal will be turned OFF under the following conditions When a CLEAR ROBOT FAILURE command is input from the external device and the existing error is cleared When the existing error is cleared by operating the Cancel key of the operating panel or the teach pendant Program number parity error or an undefined program number at external start The robot errors during automatic operation both internal operation and external operation m zc ER Robot failure OFF When CLEAR ROBOT FAILURE and OPERATION PREPARATION START signals are input When the Cancel key of the operating panel or the teach pendant is operated Robot Failure Output 80 4 2 12 Robot Warning Output 1 Function The signal outputs to the external device that a minor error has occurred with an I O command or during servo processing Caution The signal will not be output in case of a minor error such as a program selection error caused by the operation of the teach pendant or operating panel 2 Terminal number No 15 of connector CN10 3 Usage The signal is used to light the robot warning indicator lamp of an external operating panel The signal is used to help the PLC clear an error in response to a ROBOT WARNING signal 4 ON conditions As shown below the signal will be turned ON when a minor error occurs during I O processing execution of the program or servo processing irrespective of the operation
92. ing Circuit tester 24V terminal and External E24V terminal of the device controller OV terminal and EOV terminal of the controller Checking Example 156 Connector Terminals and Check Points PNP type Connector for hand I O Connector for user system input 25 1 CJ 50 26 20 11 View from cable side engaging face View from cable side engaging face Terminal Number 24V internal 24V internal Hand output sou B power source terminal erin output terminal Power Power GND terminal for output Power 18 terminal for hand E24V 24V power output D Connector for user system output Connector for I O power source 34 1 68 35 View from cable side engaging face Terminal Check number point Signal output terminal 24V internal power source output 24V internal power source terminal OV internal OV internal power source power source terminal output EOV GND Power GND input terminal input E24V input 24V power terminal input 157 Chapter 7 T O Wiring 7 1 Multi core Cables with Connectors I O Cable O Cable 1 O Cables Optional items I O Cable Set Input Cable Output Cable Hand I O Cable I O Cable Set hand I O cable high strength type Input Cz Cable Output Cable f Hand VO Cable high strength type I O Cable Set Input Cable Output Cable Hand I O Cable I O Cable Set hand I O cable high stren
93. ing 0100 Error read 0101 Type I variable write 0110 Type I variable read 0111 Mode switching 1000 Clear robot failure 1001 I O write 1010 I O read The table below lists I O commands List of I O Commands 00000001 Program reset start 00000010 Program start 00000100 Continue start 00010000 Step stop 00100000 Instantaneous stop 01000000 Reset 00000001 Speed setting 00000010 Acceleration setting 00000100 Deceleration setting Type I variable number Type I variable number j 00000001 Motor ON CAL execution 00000010 External speed 100 10000000 External mode switching 10000011 Execution of all above Motor ON gt CAL gt SP100 External Set I O value First internal I O port address First internal I O port address Program number Program number Note Program number Program number Program number Set speed value Set acceleration value Set deceleration value Set variable value lower 16 bits Error number Variable value lower 16 bits Note In execution of Continue Start command program numbers will be ignored 52 3 5 3 2 Program Operation Command 0001 1 Function This command controls the operating state of the program specified in data area 2 based on the setting of data area 1 2 Format Command area 4 bits input 0001 Data area 1 8 bits input 00000001 Program reset start 00000010 Program start 00000100 Continue start 00
94. ink Black Black Brown Red Orange Yellow Green Blue Gray Pink Brown Red Orange Yellow Green Blue Pink Black Brown 35 User output 106 Pink T 7 s s T s 2 i T r s a a T 5 s Z s T s s s7 Noteomecied vate ss Namens vote 3 rio ooa viet i roe e e e5 Emewesopzi Sey s Emewemysepz ey e pes 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 NOTE 2 The terminal number marked with is used only for Dual emergency stop type 122 2 INPUT CN8 User System input connector compatible mode CN8 Pin Assignment in compatible mode NPN type 50 26 View from the cable side number number number number z Instantaneous stop all tasks Operation preparation start Pink Pink Pink 27 White White Orange 32 User input Dwema 5 s Brown 3 O eo a ae a A a ae NOTE 1 The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 26 2 and 27 25 and 50 NOTE 2 The terminal number marked with is not used for Dual emergency stop type 12 C5 5 2 Robot Controller I O Circuits NPN type 5 2 1 User Input System Input and Hand Input Circuits NPN type The following two pages show examples of the user input syst
95. 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 I 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 I Chapter 12 Section 12 5 WAIT 24 2 4 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 I O type variables For further information about the RE
96. ion and start executing the next step INTERRUPT ON Robot status command _ Operating halfway Next operation d 94 9 50 ms or i more required I Interrupt skip ON shorted signal input OFF open Input Conditions and Operation of Interrupt Skip 104 Caution When turning ON shorted the interrupt skip signal at least either the program reset signal or the program start signal must be turned OFF open If the interrupt skip signal is turned ON the robot interprets the program start signal as instantaneously turned OFF open Consequently the program selected with the program No select signal will be executed from the beginning See the figure given below Executing cycle Robot status r Executing cycle halfway from Eanna Interrupt skip ON shorted signal input OFF open Program start ON shorted signal input OFF open o Program reset ON shorted signal input OFF open Program No select ON shorted signal input OFF open Example of Operation When an Interrupt Skip Signal is Input 4 4 11 Continue Start Input 1 Function Turning the program start signal ON when this continue start signal is ON will resume the current program being on halt 2 Terminal number No 6 of connector CN8 3 Input conditions and operation This signal is executable only in external mode
97. ir wires pairs of 1 and 35 2 and 36 34 and 68 NOTE 2 The terminal number marked with is used only for Dual emergency stop type Red 5 ABICO 8 82 83 84 85 8 88 9 Orange 5 92 o o User output oo e o hee o nm Emergency stop ud Emeen OT Emergono ry Een pce R Gray e Oo coc 140 2 INPUT CN8 User System input connector standard mode CN8 Pin Assignment in standard mode PNP type u 50 26 View from the cable side Terminal Port number number Power for robot stop internal 24V Robot stop ET Power for Enable Auto pss internal 24V Enable Auto a Step stop all tasks oo Instantaneous stop all tasks I n omasa f e z a oaaae NN w oaaae o s I 17 18 19 20 21 22 23 24 25 Data area 2 bit 6 Wire color Black Brown Red Black Brown Red Orange Yellow Green Blue Violet Black Brown Red Orange Yellow Green Blue Violet White Pink Black Brown Red Orange Port number Terminal number 26 Data area 2 bit 7 27 Data area 2 bit 8 28 Data area 2 bit 9 Data area 2 bit 10 Data area 2 bit 11 Data area 2 bit 12 Data area 2 bit 13 Pink Pink Pink White White White White White White White White Gray Gray Gray Gray Gray Gray Gray Gray Gray Gray Violet Violet Violet Violet NOTE 1 The optional I O
98. ith an I O command or during servo processing Caution The signal will not be outputted if a minor error such as a program selection error occurs by the operation of the teach pendant or operating panel 2 Terminal number No 9 of connector CN10 3 Usage The signal is used to light the robot warning indicator lamp of the external operating panel The signal is used to help the PLC clear an error in response to a ROBOT WARNING signal 4 ON condition As shown below the signal will be turned ON if a minor error occurs during I O processing execution of the program or servo processing irrespective of the operation mode 5 OFF conditions As shown below the robot warning signal will be turned OFF under the following conditions When a CLEAR ROBOT WARNING command is inputted from the external device and the existing error is cleared When operating the OK or Cancel key on the operating panel or the teach pendant clears the existing error When a slight error occurs during I O processing execution of the program or servo processing ON Robot warning OFF 1 When a CLEAR ROBOT WARNING command is inputted from an external device and the existing error is cleared When the existing error is cleared by operating the OK or Cancel key of the operating panel or teach pendant Robot Warning Output 34 3 2 9 Dead Battery Warning Output Robot power ON state 4 l se pe yq
99. ituted for the Type variable specified in data area 1 Although the type variable has a storage area of 32 bits the 16 bit data in data area 2 will be substituted for the lower 16 bits Zero will be substituted for the upper 16 bits of the Type variable 58 3 5 3 6 Type I Variable Read 0110 1 Function This command outputs to the status area the value of the Type I integer type global variable of the number specified in data area 1 2 Format Command area 4 bits input 0110 Data area 1 8 bits input The number of the Type I variable for which a value will be substituted Any number between I 0 and I 255 can be specified When the input data in data area 1 is nn the value specified in data area 2 will be substituted for the Type I variable I nn Data area 2 16 bits input Nothing will be input Status area 16 bits output The lower 16 bit value of the Type I variable specified in data area 1 will be output 3 Description The value of the Type I variable specified in data area 1 is output to the status area Although the Type I variable has a storage area of 32 bits the lower 16 bits will be output to the status area Therefore any value between 32768 and 32767 can be output properly However if the value is out of this range only the lower 16 bits of the data will be output 59 3 5 3 7 Mode Switching 0111 1 Function This command switches the robot mode from the externa
100. ize other protectors as described in Section 2 9 1 The fence or enclosure should be constructed so that it cannot be easily moved or removed 2 The fence or enclosure should be constructed so that it cannot be easily damaged or deformed through external force 3 Establish the exit entrance to the fence or enclosure Construct the fence or enclosure so that no one can easily get past it by climbing over the fence or enclosure 4 The fence or enclosure 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 or enclosure 1 Place a door rope or chain across the entrance exit of the fence or enclosure and fit it with an interlock that ensures the emergency stop device operates automatically if it is opened or removed 2 Post a warning notice at the entrance exit of the fence or enclosure 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 or enclosure place an overseer in a position outside the robot s restricted space and one in which he she can see all of the robot s movements The overseer should prevent workers from entering the robot s restricted space and be devoted solely to that task If it is not possible to set up the safety f
101. l Auto Limited Mode TIP Before shipping from the factory the single point of control is set to 0 Internal Auto Limited Mode by default amp dq B vse R ei ia I 0 0 Monito laxziceMe I 0 Hardware Settings No of parameters 321 27 Selectable I0 RunReadyOut 0 enable 1 ne 28 Selectable I0 RunProgram enable 1 new 29 Selectable I0 ErrorOut enable 1 new 2 30 Selectable IO F 31 Single point of control Int 0 Ext 1 Cancel OK 9 0 D E F5 Change the selection OK Exit with saving Cr al 1 3 Names of the Robot Controller Components The following figures show the names of the robot controller components B For VM D HM E series Front CN1 CN CN4 A DCN JI PT 2 CN LE L IL Lj Floppy disk drive option 3 L cc y7 Ce S Memory backup battery holder Output IC box switch lt Left side gt lt Right side gt Filters exhaust Radiating fin Filters air intake Names of Robot Controller Components VM D HM E series E For robot series except VM D HM E lt Front gt Floppy disk drive option FG terminal Robot stop button Memory backup battery holder Pilot lamp Fuse box Output IC box c Power switch lt Left side gt lt Right side gt Filters exhaust Filters air intake Note CN13 is not provided on the VS E and HS E series Names of Robot Control
102. l device to prepare the robot for operation This command is executable only in auto mode An error will occur in other modes Before executing this command select auto mode on the operating panel or the teach pendant 2 Format Command area 4 bits input 0111 Data area 1 8 bits input Bit O 00000001 Motor ON CAL execution Bit 1 00000010 External speed 100 Bit 7 10000000 External mode switching These bits can be set together to execute commands When two or more bits are set commands will be executed one after another For example when bits 0 1 and 7 are set motor ON CAL execution external speed 100 and external mode will be executed in this order If bits other than the above are set an error will result Data area 2 16 bits input Nothing will be input Status area 16 bits output Nothing will be output 3 Description This command is used for equipment using the robot to switch the operation mode of the robot to external mode from the external device The processing operations to be executed are specified by the bits set in data area 1 and will be executed from bit 0 to bit 7 Motor ON CAL execution bit 0 When this bit is set the power to the Robot Controller motor will be turned ON and CAL will be executed If CAL is executed once after the power is turned ON no processing will take place 60 External speed 100 bit 1 When this bit is set the external speed external acc
103. late essent nennen asip enne teen enne nenne 1 1 2 Names of the Robot Controller Components 00 0 0 eee cceecececeesecsecesceseesecsesseeesecsecseseesesesaeseseesesesseeeseaseas 4 1 3 Robot Controller Specifications sess tenente nne iesi ai iora enn enne 7 LA Controller System Configuration 2 oe nr en eere Bate eO pe a Ute ere 11 1 4 1 Internal Circuits of the Controller Typical configuration eee 11 1 4 2 Typical Robot System Configurations reete neen enne enne 12 Chapter 2 General Information about the Interface eee ecce eee eese eee eee ee sette setas etta sena se eene seno ses 14 2 1 Standard Mode and Compatible Mode essent enne n en et retnetnennes 14 2 2 Switching between Modes ti iter nb rt i eee nt UI ean ete bine aote sasaa eed 14 2 3 Types and General Information about I O Signals sess nennen 22 2 3 1 lt Standard Mode secina eani eee tee e E ERO den rr Re ER Ee En EATE 22 2 3 2 Compatible Mode eire tree EE Fei EIE Fe eer EE Fed e Eg eb ed rr Eee eia 23 2 4 Using User I O Signals common to both modes essere 24 24 1 JO Type Variable Decl ration ether deterrere eon ees 24 ZAZ HO Type Global Variable Sonenn trt Oe Ce Dee re ne iur ete Pontes 24 243 I O Type Local Vatiables nt RR eR Ii ete er eee epe e E seb d RS 24 244 User Input Commands uere ete t
104. ler Components Robot series except VM D HM E Connectors for the VM D VS E and H E series Encoders connected via bus Connector Ma adi CN1 RS232C Serial interface connector CRT connector Keyboard connector Connector for PS 2 mouse Connector for teach pendant Printer connector Not used Connector No I O Power connector for POWER O INPUT Connector for user input or system input HAND I O Connector for end effector I O OUTPUT Connector for user output or system output MOTOR Connector for motor encoder Connectors for the VS D VC E H D and XYC D series Encoders connected via parallel interface Connector Name No o CN6 PRINTER Marking Serial interface connector CRT connector Keyboard connector Connector for PS 2 mouse Connector for teach pendant Printer connector Not used Power connector for CN7 1 0 POWER y o Connector No CN8 CN9 CN10 CN11 CN12 CN13 Marking Name INPUT Connector for user input or system input HAND I O Connector for end effector I O OUTPUT Connector for user output or system output ENCODER Encoder connector Caution 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 disco
105. m of the program number specified in data area 2 PROO to PRO32767 can be started If the program number specified in data area 2 is negative an error ERROR73E4 will occur One of the following operations takes place according to the operating status of the program If the specified program is terminated stopped 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 immediately stopped 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 G Continue start This command is executable only in external mode when the Continue Start Permitted signal is on The data area will be ignored Step stop This command step stops the program of the program number specified in data area 2 PROO to PR032767 can be step stopped If the program number specified in data area 2 is negative all programs being executed will step stop Either of the following operations takes place according to the operating status of the program If the specified program is terminated stopped step stopped or immediately stopped nothing will happen If the specified program is running it will step stop If s
106. mands esee 25 User Input and System Input Circuits 125 145 User Output and System Output Circuits 129 149 W WIELD BE 520s 160 Wiring Notes for Robot Controller I O Connectors GE MMC MM 136 156 RC5 CONTROLLER INTERFACE MANUAL First Edition February 2002 Second Edition June 2002 Third Edition September 2002 DENSO WAVE INCORPORATED Factory Automation Division 9D15C 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 this manual
107. mode becomes valid and the conditions of the peripheral devices are met The program start signal for subsequent cycles rises after output of a single cycle end signal 95 Robot status Program start reset output Program start signal input Robot status Program start signal input Q Example of program start signal fall OFF timing a The following figure shows how to make the program start signal fall with a robot system output program start reset output When the robot program starts to run a program start reset signal is output The external device receives it and makes the program start signal fall OFF Wait for start or preceding cycle sa Single cycle operation ON OFF ON shorted OFF open Example of Program Start Signal Fall Timing 1 b The figure below shows how to make the program start signal fall with the simplified method 1 shot method using a timer Wait for start NP Single cycle operation 50 ms or more required ON shorted OFF open Example of Program Start Signal Fall Timing 2 Caution Although the 1 shot method is easy the timer setting for falling to raise the program start signal in the middle of the preceding cycle is difficult Use this method only to raise the program start signal after the robot stops at the end of each cycle The status of the robot in operation program start reset and single cycle end
108. modes an error ERROR21E2 21E4 21E6 will be displayed and the terminal motor power will be turned OFF As shown in the table given on the next page the program No select signal is made up of eight bits of 2 to 2 and the parity bit Input a decimal program number by converting it into binary 2 to 2 and parity bit Short represents the bit value 1 open represents the bit value 0 and the parity bit is odd parity As shown below input the program No select signal before the program start signal 1 msec or more and hold the state until the robot starts to operate If this condition is not met ERROR2031 or ERROR2033 will be displayed the power to the motor will be turned OFF and the mode will be switched to the Auto mode Wait for start Robot status or preceding cycle Single cycle operation j EAE Program ON shorted start input OFF open l _ lt ims or more required Program No select signal 2 to 2 ON shorted Parity OFF open Program No Select Signal Input 1 or O as the parity bit so that the total of 1 s existing in the eight bits of 2 to 2 and the parity bit will be odd Example When the program number is 15 the bit status of 2 to 2 is 001111 and the total number of 1s is four an even number Set 1 as the parity bit to make the total number of 1s five an odd number Caution The bit value 1 represents sh
109. nable 1 new 2 change 6 State Output 0 enable 1 new 2 change 7 Run Ready Output 0 enable 1 new 2 change 8 Run Program 0 enable 1 new 2 change 9 Error Output 0 enable 1 new 2 change 10 Start Program No 0 enable 1 new 2 change You may make one of three choices 0 enable 1 new 2 change 0 enable X Enable this signal line as is that is as a system I O signal line 1 new Release this signal line and make it serve as a user I O signal line The user I O area will be reconfigured so that port addresses and line numbers will be newly assigned Continuous assignment 2 change Release this signal line and make it serve as a user I O signal line The port address and line number of the released signal line will be used as is and just relocated in the user I O area Discrete assignment Enable the selectable I O mode 1 and set up parameters 2 through 10 above as you want Then reboot the robot controller to make those settings go into effect In the selectable I O mode you may make those released I O signal lines serve as user I O signal lines The reconfigured or relocated hardware I O assignment will be listed in I O manager of WINCAPSII 110 4 6 2 Setting up the selectable I O mode 1 From the teach pendant 1 In the Choose allocation window choose Compatible Allocation Access F4 l O F6 Aux F2 AlocMode fluxiliay Choose allocation Compatible Allocati
110. nal acceleration and deceleration will be set simultaneously as shown below by setting the external speed External acceleration and external deceleration External speed 100 minimum value 1 Acceleration setting The external acceleration is set to the value specified in data area 2 The value must be between 1 and 100 An error ERROR2003 will occur if the value is out of this range Deceleration setting The external deceleration is set to the value specified in data area 2 The value must be between 1 and 100 An error ERROR2003 will occur if the value is out of this range 56 3 5 3 4 Error Read 0100 1 Function This command outputs the existing error number to the status area This command is output to the status area only when the strobe signal remains ON Caution This command will not be output if a minor error occurs such as a program selection error caused by the operation of the teach pendant or the operating panel 2 Format Command area 4 bits input 0100 Data area 1 8 bits input Nothing will be input Data area 2 16 bits input Nothing will be input Status area 16 bits output The existing error code will be output 3 Hexadecimal codes Refer to the figure given below xOxO 95 xOOx 96 xOOO 97 Oxxx o8 OxxO 98 The following figure shows an example of error number output when ERROR6174 overload error with the fourth axis occurs Thousands of error Hundred
111. nd processing is completed the command processing complete signal will be output and then turned OFF within 100 msec 50 4 Status Area This section describes the usage of the status area 16 bits output and of status area odd parity output 1 Function The signal outputs the result of I O command processing to the external device 2 Terminal numbers Nos 17 to 32 of connector CN10 3 Usage The signal is used to execute an I O command and obtain the result of the PLC 4 ON conditions When processing of the I O given is completed the status corresponding to the command will be set Q ON represents the bit value 1 OFF represents the bit value 0 Parity bit is odd parity Input 1 or O as the parity bit so that the total of 1s existing in the command area and status area parity will be odd The status area counts even commands which do not require any data area in a parity calculation Parity can be set valid or invalid with a parameter When parity is invalid no parity check will be performed 5 OFF conditions The signal will be turned OFF when the strobe signal is turned OFF If the strobe signal is turned OFF before command processing is completed the status signal will be output and then turned OFF within 100 msec 51 3 5 3 I O Commands Details 3 5 3 1 List of O Commands Command area 0001 Program operation 0010 External speed and acceleration sett
112. nes may serve as user input signal lines as shown below Q amp o8 we werolf n I 0 Monitor Selectable Model a Enable futo r Deadman SH Robot stop e Wedet INB nescio oec mirs IDedct IN Step stop Continue start Halt OperatinRdyStrt Bi nena e ico U Skip interrupt Start program 36enrl INi 366i a Mb 16e IN 14 JDedct INS IDedct IN Power on motor Execute CAL F5 0K Turns the selection on or off gom Bo 3 ws JGenr1 IN User I O signal lines reconfigured 117 Chapter 5 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 I O 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 6 Connector Pin Assignment and I O Circuits PNP type 5 1 Connector Pin Assignment NPN type This section describes the pin assignment of connectors on the robot controller The signals and pin assignments of output connector CN10 and input connector CN8 are differently defined in standard mode and compatible mode As for other connectors the definitions of pins are common to standard mode and compatible mode 5 1 1 Connector Pin Assignment Common to Both Modes NPN type 1 HAND I O CN9 Connector for end effector I O common to both modes CN9 Pin Assignment common to both modes NPN type View from the cable side Port
113. ngle cycle Single cycle Wait for start operation Wait for start operation i Robot status Program ON shorted start signal OFF open 50 ms or more required I I I i Program Start Operation 1 Caution The program start signal requires program start preparation time 50 msec or more before input from OFF open to ON shorted The program start signal must remain OFF open during the program start preparation time If it is turned ON shorted during that time the next cycle will not start to run To start a new cycle the status of the external start signal must be switched from OFF to ON before each cycle 92 When the status of the program start signal is switched from OFF to ON with the program step stopped the program will resume from the step following the suspended step and stop at the cycle end Single cycle operation Robot status DO UM Performing Operating halfway At step stop operation i ri Program start ON shorted signal input OFF open Step stop ON shorted signal input OFF open Program Start Operation 2 Caution To cancel the execution of the remaining steps of a step stopped program and start it from the beginning input a program reset signal a program No select signal and a program start signal at the same time For further information refer to Subsection 6 4
114. nnecting the power connector or motor connector Otherwise the internal circuits of the robot controller may be damaged 1 3 Robot Controller Specifications 1 Specifications The table below lists the robot controller specifications Robot Controller Specifications tem Specifications Control system NOTE 1 PTP CP 3 dimensional linear 3 dimensional circular H D E XYC D Up to four axes simultaneously No of controllable axes NOTE 1 Up to six axes simultaneously All axes Full digital AC servo Memory capacity 1 25 MB equivalent to 5000 steps 13 000 points Language used DENSO robot language conforming to SLIM No of teach programs 255 loadable to the memory Teaching system 1 Remote teaching 2 Numerical input MDI External Input signal 20 user open points PLC 12 hand input 8 36 fixed system points signals 3 I O Output signal 32 user open points PLC 24 hand output 8 33 fixed system points External RS 232C 1 line communication Ethernet 1 line option 0 02 to 10 sec in units of 1 60 sec Self diagnosis Overrun servo error memory error input error etc function Error displ Error codes will be displayed on the external I O or the operating panel option ied Error messages will be displayed in English on the teach pendant option All RC5 models 3 phase 200 VAC 15 to 230 VAC 10 50 60 Hz RC5 for VS D E H D E XYC D Single phase 230 VAC 10 to 230 VAC 10 50
115. ns for 1 Atstart up automatic operation Before the robot is to be started up first 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 robot s restricted space 2 Check that the teach pendant and tools are in their designated places 3 Check that no lamps indicating a malfunction on the robot or related equipment are lit 2 Check that the display lamp indicating automatic operation is lit during automatic operation 3 Steps to be taken when a malfunction occurs Should a malfunction occur with the robot or related equipment and it is necessary to enter the robot s restricted space to perform emergency maintenance stop the robot s operation by activating the emergency stop device Take any necessary steps such as placing a display on the starter switch to indicate work is in progress to prevent anyone from accessing the robot SAFETY PRECAUTIONS 3 8 Precautions in repairs 4 Daily and periodical inspections 5 Management of floppy disks Do not perform repairs outside of the designated range Under no circumstances should the interlock mechanism be removed When opening the robot controller s 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 Be sure to perform daily and p
116. o that the internal power source will be separate from the external power source Improper wiring may damage the internal circuit 134 0v Internal power source External v I O circuit power source Robot controller l O Power Connection Sample When an external power source is used NPN type Caution Use a cable of 0 5 mm or more in size for the wiring between the external power source and the I O power input connectors of the robot controller 135 5 3 Wiring Notes for Robot 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 See the figure below and the table given on the next page ACaution If the connector wiring between the Robot Controller s 24V terminal and OV 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 See the figure below and the table given on the next page ACaution If the wiring between each signal
117. obot failure is cleared turn OFF open the Clear robot failure signal after turning OFF the Robot failure signal output as shown below Input the Clear robot failure signal before 1 msec or more the operation preparation start signal Stop due to Robot status a robot failure Cigar robolfailure Motor power ON gt Operation preparation ON start input OF i 50 ms or more required I Clear robot failure input Motor power ON input Robot failure output Servo ON output Input Conditions and Operation of Clear Robot Failure Signal 103 4 4 10 Interrupt Skip Input 1 Function If this signal is turned ON shorted during execution of the robot operation command within the range between INTERRUPT ON and INTERRUPT OFF in the program the operation of the ongoing step will stop and the next step will start Note For further information about the INTERRUPT ON and OFF commands refer to the PROGRAMMER S MANUAL I Chapter 12 12 3 INTERRUPT ON OFF Statement For further information about robot motion commands refer to the PROGRAMMER S MANUAL I Chapter 12 Robot Control Statements 2 Terminal number No 9 of connector CN8 3 Usage Refer to the PROGRAMMER S MANUAL I Chapter 12 12 3 INTERRUPT ON OFF 4 Input conditions and operation If this signal is turned ON shorted the robot will immediately stop the Ongoing operat
118. of connector CN8 3 Input conditions and operation If the status of this signal is changed from ON shorted to OFF open the robot will stop all tasks immediately after the ongoing step is completed and the Robot in operation signal will be turned OFF However External Auto mode will remain valid and the suspended program will be resumed by inputting a program start signal See the figure given below Turning OFF open this signal when inputting a program start signal makes the robot stop step by step Internal operation with the teach pendant is valid only when the status of this signal is changed from ON shorted to OFF open For resuming the program after a step stop refer to Subsection 4 4 4 Program Start Input Single cycle operation Performing remaining Operating halfway Step stop operation ON shorted OFF open ON shorted OFF open ON OFF Step Stop Signal 101 4 4 8 Instantaneous Stop All Tasks Input 1 Function Input this signal to instantaneously stop the program being executed from the external device All tasks will instantaneously stop 2 Terminal number No 7 of connector CN8 3 Input conditions and operation If the status of this signal is changed from ON shorted to OFF open the robot will instantaneously stop in the middle of the ongoing step and the Robot in operation signal will be turned OFF However
119. olling two or more robots with a single PLC using the internal power source of the robot controller set a PLC Output card for each robot Other than a PLC a proximity switch or a relay contact may be connected directly to the input terminal of the Robot Controller In such a case use the power input to pins 6 to 9 of the I O power connector A two wire photoelectric switch or proximity switch can be connected if its leakage current is 1 mA or less Use a multi core shielding cable for the purpose of protecting the robot controller from noise Ground it to the robot controller 144 1 0 POWER connector Internal power source Internal circuit 680 Photo coupler Robot controller When the internal power source is used I O POWER connector Power Source Internal power source Internal circuit 680 Photo coupler Robot controller When an external power source is used User Input and System Input Circuits PNP type 145 I O POWER connector Internal power source 680 Photo coupler Robot controller When the internal power source is used 1 0 POWER connector Power Source Internal power source 680 Photo coupler Robot controller When an external powe
120. on Standard Allocation 2 In the I O Hardware Settings window modify parameters as you want Access F4 l O F6 Aux F1 Set H W I 0 Hardware Settings No of parameters 35 A 21 Selectable I0 mode diseble t eneble 1 peTUPECUETUNTUETTTNEN Li m ow SIDES 3 Reboot the robot controller to make new settings go into effect 111 2 In WINCAPSII 1 From the Tool menu of DIO Manager select the Options command Options 2 Click on the Hardware tab in the Options window 3 Inthe I O Allocation choose the Parallel and Selectable Options few I 112 4 In the Selectable I O Setting window select the I O allocation type New or Modify and check off the check boxes as you want Xt Selectable I O Setting mlO Allocation New C Modify r Parameter A Sten Stop 4 Iv State Output E Iv Interrupt Skip s B Iv Run Ready Output G Iv Program Select C Iv Run Program Output H Start Program No Hl v Error Output 1 Iv Run Ready E OK Cancel 5 To fix your settings click on the OK button 6 Transmit the hardware allocation to the robot controller 7 Reboot the robot controller to make new settings go into effect 4 6 5 System input signal lines that can serve as user I O signal lines In the selectable I O mode you may modify the following parameters to make system input signal lines serve as user I O signal lin
121. oncurrently or use the Continue function then you may set this parameter to any choice other than enable The Program start reset Single cycle complete and Continue start permit ports may serve as user I O ports When those ports serve as user I O ports the system may use the Robot running signal instead of Program start reset signal for starting a program from the external equipment And the system may use the Robot running signal being OFF instead of a Single cycle complete signal Note that the above signal substitution may be allowed only when you will not run programs concurrently Error Output If you do not need to get error codes from the external equipment e g when using the robot controller standalone in running your robot then you may set this parameter to any choice other than enable The error code output ports may serve as user I O ports 116 4 6 5 Sample usage of selectable I O mode The sample below gives instructions on how to add user I O signal lines 1 From the teach pendant choose Compatible Allocation in the Choose allocation window Access F4 I O F6 Aux J F2 AlocMode 2 In the I O Hardware Settings window modify parameters as shown below Access F4 l O F6 Aux F1 Set H W 21 Selectable IO mode 1 24 Selectable IO Program Select 2 3 Reboot the robot controller to make new settings go into effect You may check that 6 through 13 signal li
122. operation By turning ON this input in automatic or external mode the Robot Controller reads the command area data areas 1 and 2 and the command and data area odd parity bit starts processing Retain the status until a command processing complete signal is output and the necessary status data is read If the strobe signal is turned OFF before a command processing complete signal is output the status area will not be output G By turning OFF this input after the status is read the command processing complete output the status area and the status parity will be turned OFF 49 3 Command Processing Complete Output 1 Function The signal outputs to the external device that I O command processing is completed 2 Terminal number No 15 of connector CN10 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 The signal will be turned ON upon completion of processing the I O command given and determination of outputting the status area If an error occurs as a result of executing an I O command the result will not be output to the status area but the robot failure signal and the command processing complete signal will be turned simultaneously ON 5 OFF conditions The signal will be turned OFF when the strobe signal is turned OFF If the strobe signal is turned OFF before comma
123. or check status etc Outputs to issue a signal to the external device with a SET command Hand output RESET command etc Used to control the opening and closing of the end effector 22 2 3 2 Compatible Mode In the compatible mode the input and output points are arranged in disregard of compatibility with conventional VS series robots The table below lists the types of I O signals used in compatible mode Types of I O Signals Used in Compatible Mode Fixed by system Tuna No of YP points Inputs to turn ON the power to the robot from the external device PLC System input start CAL or select and start a program instead of operations by is operating panel or teach pendant Outputs to inform the external device PLC of the robot status such as System output 27 robot in operation or occurrence of an error Controlled by user program No of BENI NN RN Inputs to read the external I O status with an IN command or IO User input 25 vanana p Used for analysis condition identification condition satisfaction wait data input from the external device etc Outputs to issue a signal to the external device during program execution Voer gupa with a SET command RESET command etc Inputs to read the external I O status with an IN command or IO Hand input variable Used to confirm the end effector check status etc Outputs to issue a signal to the external device valve with a SET Hand output command RESET command et
124. ort and the bit value 0 represents open Q The program numbers executable from the external device are limited to ProO to Pro127 90 Example of Program No Select Signals Program No decimal 1 15 26 65 2 2 22 23 24 25 25 O O 0 2 oo O O0O o a O OOOO The figure below shows an example of a program No select signal sequence circuit considering parity Lower 4 bit odd Upper 3 bit odd N Program No select 2 2 2 2 2 25 25 P N NIN fis ba de ES ee ee ee IS c amp X N ag N a N gt Co e co Example of Program No Select Signal Sequence Circuit 91 4 4 4 Program Start Input 1 Function This signal starts the program specified with the program No select signal from the external device 2 Terminal number No 10 of connector CN8 3 Input conditions and operation By switching the status of this signal from ON open to ON shorted in external mode operations O and described below will take place The status of the signal must be switched from OFF to ON If the program start signal is input switched from OFF to ON when the robot has not yet completed the program or is at rest after it has completed a cycle of the program the program No select signal will be read the program will execute a cycle and the robot will come to a stop Si
125. p Av Emergency Stop Is i Internal i 24V F8 CN8 Fuse 1 3 1 Robot stop switch circuit Mo 2 prepared by customers Emergency stop switch on the front panel of the Input controller Ez mi ets DF oV cn5 Teach pendant Emergency stop switch on teach pendant When the internal power source is used Robot controller f Emergency stop circuit prepared by customers F Emergency CN10 B Fuse 03A Stop i External 24V ve i 9 Emergency ES Stop Output La Etema oV Internal 24V CN8 o Fuse 1 3A 1 A alc Robot stop switch circuit prepared by customers Emergency stop switch on the front panel of the controller cine Internal OV Teach pendant aTa Emergency stop switch CNS on teach pendant When an external power source is used Emergency Stop Circuit Standard type 152 6 2 4 2 Dual emergency stop type Prepared by customer External 24V ro External Q 24V External ov External ov OQ External 0 24V External ov OQ External robot stop 1 pA 1 63 64 65 l 1 1 l 1 I 1166 1 I 1 D 1 68 CN10 F10 0 3A i CR2 Robot Controller Internal 24V 0 F8 1 3A YW I 1 3 Robot stop button onthe frontpanel _ of the controller 1010
126. panel or the teach pendant is set to MANUAL or TEACH CHECK as shown below 5 OFF conditions The signal will be turned OFF when the mode selector switch of the operating panel or teach pendant is set to AUTO and the Enable Auto input is turned ON When the mode selector switch of the operating panel is set to MANUAL When the mode selector switch of the teach pendant is set to MANUAL or TEACH CHECK jy Teaching 1 When the mode selector switch of the operating panel or the teach pendant is set to AUTO and the Enable Auto input is turned ON from the external device Teaching Output 75 4 2 7 Program Start Reset Output 1 Function This signal is output to the external device when the robot receives a start signal from the external device and starts to operate 2 Terminal number No 6 of connector CN10 3 Usage The signal is used to prompt the external device to receive information that the robot program has started to run and to process subsequent sequence programs Q The signal is used as a condition to turn OFF the PROGRAM START signal sent from the external device to the robot 4 ON conditions The signal will be turned ON immediately after the robot program starts to run as shown below 5 OFF conditions The signal will be turned OFF automatically when the PROGRAM START signal sent to the robot is turned OFF Robot status Single cycle operation Single cycle operation
127. perate after the power was FAILURE command from an external device turned ON y y ROBOT POWER ON ON COMPLETE output OFF f Robot error or robot warning Robot Power ON Complete Output 27 3 2 2 Auto Mode Output 1 Function The signal outputs to the external device that the robot is in auto mode 2 Terminal number No 6 of connector CN10 3 Usage Starting the program from the external device requires an EXTERNAL MODE SWITCHING BY MODE SWITCHING COMMAND input and a PROGRAM START BY PROGRAM OPERATION COMMAND input The signal is used to monitor the auto mode output signal and determine whether to execute the command 4 ON condition The signal will be output when the robot enters auto mode by setting the mode selector switch of the operating panel or teach pendant to AUTO 5 OFF conditions The signal will be turned OFF under the following conditions The mode selector switch of the operating panel is set to MANUAL or the teach pendant is set to MANUAL or TEACH CHECK The Enable Auto OFF is input Note The signal will not be turned OFF in the pendantless state described in the OPTIONS MANUAL Chapter 1 Subsection 1 3 3 Caution The signal will not be turned OFF with INSTANTANEOUS STOP STEP STOP or CYCLE STOP commands When the mode selector switch of the operating panel or teach pendant is set to AUTO Auto mode ON output OFF ooo When the mode selector switch of the operatin
128. program you have predetermined with the Start Program No will run Run Ready If it is possible to set up all of these four functions Motor power ON CAL execution SP100 and Switch to Ext Mode at one time not to set them individually then you may set this parameter to any choice other than enable Those input ports may serve as user I O ports When those ports serve as user I O ports receiving the Operation preparation start signal will carry out the above four functions independently of the current input states Note that when the robot is in machine lock no Motor power ON or CAL execution will be carried out Start Program No If the Program Select parameter is set to any choice other than enable a program specified by this Start Program No parameter will be initiated by the Program Start signal 114 4 6 4 System output signal lines that can serve as user I O signal lines In the selectable I O mode you may modify the following parameters to make system output signal lines serve as user I O signal lines Parameters Signal lines that can serve as user ones State Output Robot power ON complete External mode Run Ready Output CAL complete Teaching Program start reset Run Program Output Single cycle complete Continue start permit Error units bit O Error units bit 1 Error units bit 2 Error units bit 3 Error tens bit 0 Error tens bi
129. r CN8 Data area 1 No 11 to No 18 of connector CN8 Data area 2 No 19 to No 34 of connector CN8 Command and data area odd parity No 10 of connector CN8 3 Input conditions and operation Set the command area whenever I O commands are to be executed Set data for data areas 1 and 2 if commands require them Shorted represents the bit value 1 Open represents the bit value 0 Parity bit is odd parity Input the command area data areas 1 and 2 and command and data area odd parity before the strobe signal 1 msec or more Retain the status until the command processing complete signal is output Input 1 or O as the parity bit so that the total of 1s existing in the command area data areas 1 and 2 and the command and data area odd parity will be odd The data areas count even commands which do not require any data area in a check sum calculation Checksum can be set valid or invalid using a parameter When checksum is invalid no checksum check will be performed 48 2 Strobe Signal Input 1 Function This signal informs the Robot Controller that the command area data areas 1 and 2 and the command and data area odd parity bit have been set Additionally it directs the start of command processing Caution Perform command input with a strobe signal after the system output signal ROBOT INITIALIZATION COMPLETE is output 2 Terminal number No 8 of connector CN8 3 Input conditions and
130. r source is used Hand Input Circuits PNP type 146 6 2 2 Robot Stop and Enable Auto Input Circuits The Robot Stop and Enable Auto signals are important for safety The input circuit for these signals must have contacts as shown below Use the INPUT CN8 pins 1 and 3 of the robot controller for the power source irrespective of whether the power source to be used for other I O signals is the internal power source or an external power source Note For the Dual emergency stop type refer to Subsection 6 2 4 2 Robot Controller Internal Power Source 24V F8 1 3A Robot Stop Enble Auto Internal Power Source OV Note 1 For Double safety emergency stop type connector pins of CN10 Pin No 59 to 62 should be used for Robot Stop inputs Robot Stop and Enable Auto Input Circuits TIP The configuration sample of an emergency stop output circuitry is shown in Subsection 6 2 4 Emergency Stop Circuit 147 6 2 3 User Output System Output and Hand Output Circuits PNP type The following two pages show an example of the configuration and connection of the Robot Controller s user input output system output and hand output circuit Since the initial resistance of a lamp is small the output circuit may be damaged by rush current that flows when the lamp lights When directly turning a lamp ON or OFF use a lamp whose rating is 0 5W or less To reduce rush current connect a resistor R that allows
131. rnal arithmetic circuit of the Robot Controller may be damaged and ROBOT ERROR ERROR NUMBER and other outputs may not be correct Power ON CPU operates properly Normal CPU output OFF CPU error hardware error Normal CPU Output 79 4 2 11 Robot Failure Output 1 Function The signal outputs to the external device that a problem such as a servo error and a program error occurs with the robot 2 Terminal number No 3 of connector CN10 3 Usage The signal is used to light the robot failure indicator lamp of an external operating panel The signal is used to help the PLC clear an error in response to a ROBOT FAILURE signal 4 ON conditions As shown below the signal will be turned ON under the following conditions When an error such as a servo error a program error and undefined program occurs at the start of the program and during execution of the program When an error occurs during execution of the program in internal operation by the operating panel or the teach pendant or in external operation by the PLC When an error such as undefined program occurs at the start of the program only in external operation Caution The signal will not be output when an error such as a program input error occurs in manual operation except when a servo error occurs in manual operation For further information see ERROR CODE TABLES 5 OFF conditions As shown below the s
132. s executed at a time If two or more programs are executed simultaneously multi tasks the single cycle end signal will be turned ON immediately after any of the programs reads an END command 2 Terminal number No 13 of connector CN10 3 Usage The signal is used to operate another equipment in synchronization with a single cycle end of the program 4 ON conditions The signal will be turned ON when the program is read to the end 5 OFF conditions The signal will be turned OFF immediately after the program starts to run Robot status Single cycle Single cycle operation Wait for start operation 4 PROGRAM START input 1 CYCLE END Single Cycle End Output 78 4 2 10 Normal CPU Output ON 1 Function The signal outputs to the external device that the CPU hardware of the Robot Controller is normal 2 Terminal number No 1 of connector CN10 3 Usage The signal is used to light the Robot Controller error indicator lamp of an external operating panel The signal is used when the NORMAL CPU signal is turned OFF because of an error and the PLC corrects it 4 ON conditions The signal will be turned ON by the hardware when the CPU of the Robot Controller operates normally with the power turned ON 5 OFF conditions The 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 inte
133. s of error No Tens of error No Units of error No 32 31 30 29 E 28 27 26 25 z uE 24 23 22 21 zl 20 19 18 17 x OO x x x xO x OOO x Ox x Comector onto 4p t fT tH ERROR 6 1 7 4 Example of Error Number Output 4 Description If a command is executed when a robot failure or the robot warning signal is output the error number which caused the robot failure or robot warning signal to be output will be output to the status area If no error exists after an error has been cleared O will be output to the status area Also when there is an error that does not output any robot failure or robot warning signal 0 will be outputted 57 3 5 3 5 Type I Variable Write 0101 1 Function This command substitutes the value specified in data area 2 for the Type integer type global variable of the number specified in data area 1 2 Format Command area 4 bits input 0101 Data area 1 8 bits input The number of the Type variable for which a value will be substituted Any number between I 0 and I 255 can be specified When the input data in data area 1 is nn the value specified in data area 2 will be substituted for the Type variable nn Data area 2 16 bits input The value to be substituted for the Type variable specified in data area 1 Any value between 32768 and 32767 can be set Status area 16 bits output Nothing will be output 3 Description The value specified in data area 2 is subst
134. serve all of the following safety precautions Strict observance 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 AN WARNING Alerts you to those conditions which could result in serious bodily injury or death if the instructions are not followed correctly AN 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 volume of space encompassing the maximum designed movements of all robot parts including the end effector workpiece and attachments Quoted from the RIA Committee Draft Restricted space Refers to the portion of the maximum space to which a robot is restricted by limiting devices i e mechanical stops The maximum distance that the robot end effector and workpiece can travel after the limiting device is actuated defines the boundaries of the restricted space of the robot Quoted from the RIA Committee Draft 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 so
135. stop ON shorted input OFF open Program start ON shorted input OFF open Program No ON shorted select signal input OFF open Program reset ON shorted input OFF open Input Conditions and Operation of Program Reset Signal 98 When issued with the Operation Preparation Start The figure below shows the input conditions and an operation timing chart Input Program Reset before Operation Preparation Start 1 msec or more G After turned ON this signal may take a maximum of one second for initializing all programs During the period do not input signals to the robot Initializing all Executing cycle programs Max 1 sec Instantaneous stop signal input Operation preparation start signal input Program reset input L j1 1ms or more I Continue start permitted output Input Conditions and Operation of Program Reset Signal 99 4 4 6 Robot Stop Input 2 Function The signal stops the robot with the external device by opening the robot stop input The signal readies the power to the robot motor to be turned ON by shorting the robot stop input 2 Terminal number No 2 of connector CN8 3 Input conditions and operation The robot stops with this signal OFF open The power to the robot motor is ready to be turned ON with this signal ON shorted Irrespective of whether internal mode opera
136. t 17 3 A Gray 18 Data area 1 bit 7 Blue 43 User input 3 oo Gray 19 Data area 2 bit 0 Violet 44 User input 20 Data area 2 bit 1 White 45 User input 21 Data area 2 bit 2 Pink 46 User input 3 o Gray 4 o Gray 4 Gray 22 42 Data area 2 bit 3 Black 47 User input Data area 2 bit 4 Brown 48 User input Data area 2 bit 5 Red 49 User input Data area 2 bit 6 Orange 50 User input NOTE 1 The optional I O cable for the above connector consists of twisted pair wires pairs of 1 and 26 2 and 27 25 and 50 NOTE 2 The terminal number marked with is not used for Dual emergency stop type Violet 23 43 Violet 24 44 Violet 25 45 Violet 121 5 1 3 Connector Pin Assignment in Compatible Mode 1 OUTPUT CN10 User System output connector compatible mode CN10 Pin Assignment in compatible mode NPN type 68 35 View from the cable side Terminal number number Normal CPU a 9 s merus 7 5 Pooamsanest 7 s wes 79 9 Robot power oN compere so 35 Robotwaring f 99 s feror S 99 s Bmerwswmz 9 Ea d Errortensbit3 tens bit 3 ER Error hundreds bit 0 Ex Emorhundedsbit hundreds bit Emorhundedsbit EL Error hundreds bit 2 Error hundreds bit3 hundreds bit 3 E ELI mm UR Black Brown Red Orange Yellow Black Brown Red Orange Yellow Green Blue Violet Gray P
137. t Sbit SIN OFF OF T OFF System input Data areal bit abit SING QF OF B OFF Systerninput Deta area bit2 Bbit SINS OFF OF S OFF Systeminput Data area 1 bit 3 Sbit SINTDO OFF OF OFF System input Data area 1 bit4 Gbit SINTI OF 1 4i mo 4 17 gt STEP 3 gt STEP 4 Select the SETTING command from the Tools menu of DIO Manager The Options window will appear as shown below Options Click on the Hardware tab in the Options window The hardware settings will appear Options S PROFIBUS DP Slave Ef Compatible 18 Select the desired assignment mode from the right hand popup menu gt STEP 5 in the I O Allocation frame Ver 1 6 or later E Options k PROFIBUS DP Sieve Gl N ible Eb i a Click on OK in the Options window gt STEP 6 The Options window closes Click on the Connect button to connect the computer to the robot gt STEP T controller The Connect button appears in a pressed state Step stop all tasks System input Reserved System input Halt fall tasks System input Strobe signal Syeieminput Imemuptian skip SINS System input Command data area o System input Deta area bit 0 8bit System input Data area 1 bit 1 abit System input Data area 1 bit 2 Bbit system input Data area 1 bit 3 obit System input Data area 1 bit 4 Bbit mnm mnn n n m my n T 19
138. t 1 Error Output Error tens bit 2 Error tens bit 3 Error hundreds bit 0 Error hundreds bit 1 Error hundreds bit 2 Error hundreds bit 3 115 Parameter details No Parameters Function State Output If you do not need to confirm the Robot power ON complete signal with the external equipment e g when using the robot controller standalone in running your robot then you may set this parameter to any choice other than enable The Robot power ON complete port may serve as a user I O port Run Ready Output You may set this parameter to any choice other than enable if itis possible to set up all of the Motor power ON CAL execution SP100 and Switch to Ext Mode functions at one time so that you do not need to manage those signal lines individually or if the system can treat the Auto mode output being OFF as a condition required for teaching The External mode CAL complete and Teaching signal lines may serve as user I O signal lines When those signal lines serve as user I O signal lines the ON conditions of the Servo ON output signal displayed as Run Ready are Servo ON CAL complete External mode If one or more of those three signal lines are turned OFF the Servo ON output signal goes OFF And when the Auto mode output signal is OFF the system will interpret it as in teaching Run Program Output If you will not run more than one programs c
139. t power ON i Setting operation adjustment F Tor witch to Enable Auto ON Internal processing operation Operation OK indicator lamp ON Note Robot preparation Ly S ystem input button ON for start up ON Operation Preparation Start ON Motor power ON U Executing CAL U Setting SP 100 U Switching mode to external mode Robot external mode i indicator lamp ON Internal processing I Motor power ON Moving robot arm close to operation origin when external mode indicator lamp is ON and operation position 1 indicator lamp is OFF Operation preparation start Robot operation origin Internal pr in a indicator lamp ON Vntermal processing Operation position 1 Robot preparation OK When both are ON display Internal processing U Q Operation start area check Start and Stop Procedure and System I O Signals 1 Continued on the next page 108 Continued from preceding page Worker s operation and display on equipment s operation panel i Equipment s gt Program No Select ON Automatic Start PLC processing Robot operation Regular Operation Program is selected Automatic Operation Program start ON Program start indicator lamp ON Au
140. t to AWG28 50P UL2405 With shield Equivalent to AWG20 2P Crimp terminal 3 Vinyl tube I O power connector Shielding wire 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 noise The connector shell should be made of conductive metal Fasten to the connector Modifying the Shielding Wire Example 159 7 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 grounding wire green of the robot power cable 3 Ground the 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 grounding wire with grounding resistance of 100 Q or less b If the supply power source for the robot controller requires a leakage breaker use a high frequency proof leakage breaker for inverters 6 Prepare wires of an appropriate capacity for the 200 VAC main line and other cables according to the tables given below Robot Controller Power Supply Specifications Pin assignment on power connector CN11 Item Specifications View from the pin face of cable A 200 VAC phase R 3 phase power supply 3 phase 200 VAC 15 to e A ies Ms RC5 all models 230 VAC 10 50
141. tarted after a step stop the stopped program will resume from the step following the suspended step Instantaneous top This command immediately stops the program of the program number specified in data area 2 PROO to PR032767 can be stopped immediately If the program number specified in data area 2 is negative all programs being executed will step stop Either of the following operations takes place according to the opera ing status of the program If the specified program is terminated stopped step stopped or immediately stopped nothing will happen If the specified program is running it will immediately stop If started after an instantaneous stop the stopped program will resume from the suspended step If the program is immediately stopped in the middle of execution of an operation command it will resume starting from the last uncompleted operation 54 Reset This command immediately stops and also initializes the program of the program number specified in data area 2 PROO to PR032767 can be stopped This command cannot be used together with the program start command To start a step stopped or cycle stopped program from the beginning use the program reset start command If the program number specified in data area 2 is negative all programs being executed will be reset One of the following operations takes place according to the operating status of the program When the specified program is terminated stoppe
142. th Those locations are covered with blank caps NOTE 2 For details about extended joint support controllers refer to the manual SUPPLEMENT Extended Joints Support 10 1 4 Controller System Configuration 1 4 1 Internal Circuits of the Controller Typical configuration The block diagram below shows the internal circuits of an RC5 controller designed for a 6 joint robot Controller Max 8 joints 200 to 230 are controllable VAC 36 Main board AC servomotor Absolute encoder IPM board 1st joint Floppy disk drive i IPM board 2nd joint IPM board 3rd joint FH CRT RS232C pu Vision PC TP Printer Not used i Parallel port circuit lt li Input circuit J PLC sensors mme mem toad DeviceNet board 11 1 4 2 Typical Robot System Configurations The block diagrams below show typical robot system configurations To connect encoders via a time division multiplexed bus Connect the robot controller CN12 to the robot unit with a motor encoder cable see below To connect encoders via parallel interface Connect the robot controller CN12 and CN13 to the robot unit with a motor cable and encoder cable respectively B Robot system configuration with encoders connected via a multiplexed bus VM D VS E HS E and HM E Robot unit Motor Directly controlled from the robot encoder C
143. th INSTANTANEOUS STOP STEP STOP or CYCLE STOP The Mode selector switch of the operating panel or the teach pendant is set to AUTO SWITCH AUTO MODE and OPERATION PREPARATION START are input from the external device NA Auto mode output OFF 4 The mode selector switch of the operating panel is set to MANUAL or that of the teach pendant is set to MANUAL or TEACH CHECK Enable Auto OFF is input Auto Mode Output 71 4 2 3 Servo ON Output 1 Function The signal outputs to the external device that the power to the robot motor is turned ON 2 Terminal number No 10 of connector CN10 3 Usage Executing CAL from the external device or starting the program requires the power to the motor to be turned ON This signal is used to confirm that the power to the motor is turned ON and to light the motor power ON indicator lamp on an external operating panel 4 ON conditions The signal will be turned ON when the power to the motor is turned ON under the following conditions The MOTOR switch on the operating panel or the teach pendant is activated MOTOR POWER ON OPERATION PREPARATION START signals are input from the external device 5 OFF conditions The signal will be turned OFF when the power to the motor is turned OFF under the following conditions The MOTOR switch of the operating panel or the teach pendant is deactivated and the ROBOT STOP button is operated ROBOT STOP
144. the configuration and connection of the Robot Controller s user input output system output and hand output circuit Since the initial resistance of a lamp is small the output circuit may be damaged by rush current that flows when the lamp lights When directly turning ON and OFF a lamp use a lamp whose rating is 0 5W or less 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 An example of connecting a lamp is shown on page 121 1 The User Output System Output and Hand Output Circuit 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 a relay 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 191888 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 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 Refer to page 121
145. 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 3 3 Ensuring safety of workers performing jobs within the robot s restricted space are taken When entering the robot s restricted space to perform teaching or maintenance inspections set working regulations for the following items and ensure workers adhere to them 3 1 Creation of working regulations and assuring worker 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 3 2 on th
146. tion with the teach pendant or external mode remote operation by the external device is selected the power to the robot motor cannot be turned ON with this signal OFF open Neither manual nor automatic operation can be performed until this signal is turned ON shorted ERROR2008 will be displayed amp By turning OFF open this signal under the following conditions 1 The power to the motor will be turned OFF irrespective of whether Manual Internal Auto or External Auto mode is selected 2 During execution of the program Robot in operation signal ON the power to the motor will be turned OFF and the mode will be switched to internal mode after the robot decelerates to a stop 3 When the program is at a stop in the Manual and the Auto mode the power to the motor will be turned OFF The suspended operation can be resumed by turning ON the power to the motor and shorting the ROBOT STOP signal Opening the ROBOT STOP signal and pressing the ROBOT STOP button of the operating panel or the teach pendant function the same 4 Input timing This signal will be processed prior to all commands and input signals 100 4 4 7 Robot status Program start signal input Step stop signal input Robot in operation output Step Stop All Tasks Input 1 Function Input this signal to step stop the program being executed from the external device All tasks will be step stopped 2 Terminal number No 5
147. tions that should be observed Be sure to read this section before operating your robot Chapter 1 Outline of the RC5 Controller Provides an outline of the RC5 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 required for connecting the robot controller with a PLC or other external equipment It describes two I O allocation modes available standard mode and compatible mode and the switching procedure between those modes Describes declaration of I O variables and user I O signals Chapter 3 System I O Signals in Standard Mode Describes system I O signals available in standard mode and describes I O signals that execute I O commands Chapter 4 System I O Signals in Compatible Mode Describes the functions terminal numbers and on off conditions of system I O signals in compatible mode Chapter 5 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 6 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 7 I O Wiring Describes I O cables and wiring SAFETY PRECAUTIONS SAFETY PRECAUTIONS Be sure to ob
148. tomatic operation Program No select ON 4 Single cycle End ON Regular Operation Program is selected Repeated Program start ON Equipment s Cycle Cycle Stop ON Executing single cycle Stop button ON f END amp Operation end Automatic operation internal processi ES seqaaiceecie CATON indicator lamp OFF p 9 gle cy Equipment power OFF The system inputs for startup here are four types of system inputs motor power ON CAL execution SP100 and External Mode switching Refer to Subsection 6 4 2 Operation Preparation Start Input L1 in the above figure indicates a system I O signal and lt represents the flow of the signal Start and Stop Procedure and System I O Signals 2 109 4 6 Selectable I O Mode Ver 1 95 or later 4 6 1 What is a selectable I O mode Version 1 95 has added a selectable I O mode a mode that allows you to release system I O signal lines not used in compatible mode and make them serve as user I O signal lines To extend user I O signal lines in the selectable I O mode you need to choose or set up the following parameters with the teach pendant or in WINCAPSII 1 Selectable I O mode 0 disable 1 enable 2 Step Stop 0 enable 1 change 3 Interrupt Skip 0 enable 1 new 2 change 4 Program Select 0 enable 1 new 2 change 5 Run Ready 0 e
149. tput high frequency transmitters large contactors welders or other sources of electrical noise The dust proof splash proof type is an IP54 equivalent structure but it has not been designed to withstand explosions The HS E W and the wrist of the VM D W VS E W are an IP65 equivalent dust proof 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 proof 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 gases 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 The robot and peripheral equipment should be installed so that sufficient service space is maintained for safe teaching maintenance and inspection SAFETY PRECAUTIONS 2 3 2 4 2 5 2 6 2 7 Control devices outside the robot s restricted space Positioning of gauges Protection of electrical wiring and
150. ts and customizing your robot and maintenance amp inspection procedures BEGINNER S GUIDE Introduces you to the DENSO robot Taking an equipment setup example this book guides you through running your robot with the teach pendant making a program in WINCAPSII and running your robot automatically SETTING UP MANUAL Describes how to set up or teach your robot with the teach pendant operating panel or mini pendant WINCAPSII GUIDE Provides instructions on how to use the teaching system WINCAPSII which runs on the PC connected to the robot controller for developing and managing programs PROGRAMMER S MANUAL I II Describes the PAC programming language program development and command specifications in PAC RC5 CONTROLLER INTERFACE MANUAL this book Describes the RC5 controller interfacing with external devices system and user input output signals and l O circuits ERROR CODE TABLES List error codes that will appear on the teach pendant operating panel or PC screen if an error occurs in the robot series or WINCAPSII These tables provide detailed description and recovery ways OPTIONS MANUAL Describes the specifications installation and use of optional devices 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 nine SAFETY PRECAUTIONS Defines safety terms and related symbols and provides precau
151. turned OFF When the mode is switched to external mode on the teach pendant When EXTERNAL INTERNAL is input on the operating panel When a MODE SWITCHING COMMAND EXTERNAL MODE SWITCHING is input from an external device External mode ON output OFF T When internal mode is selected on the teach pendant When the mode selector switch of the teaching pendant is set to MANUAL or TEACH CHECK When EXTERNAL INTERNAL is input on the operating panel ROBOT STOP or ROBOT ERROR When an Enable Auto input is turned OFF External Mode Output 29 3 2 4 Servo ON Output 1 Function The signal outputs to the external device that the power to the motor of the robot is turned ON 2 Terminal number No 4 of connector CN10 3 Usage Starting the program requires the power to the motor to be turned ON This signal is used to light the motor power ON indicator lamp on an external operating panel 4 ON conditions The signal will be turned ON when the power to the motor is turned ON When the MOTOR key of the operating panel or teach pendant is activated or When the motor runs with a MOTOR ON AND CAL EXECUTION BY MODE SWITCHING COMMAND input from the external device 5 OFF conditions The signal will be turned OFF when the power to the motor is turned OFF When the MOTOR key of the operating panel or teach pendant is deactivated and the ROBOT STOP button is operated When ROBOT STOP is
152. ures show the examples of configuration and connection of emergency stop circuit for the robot controller The red mushroom shaped switch provided on the robot controller front panel on the teach pendant or on the operating panel can be used as a switch for stopping the equipment in case of emergency 5 2 4 1 Standard type Robot controller F1 mema 24V Fuse 1 3A OV A d Fuse 1 3A Emergency stop circuit Internal OV F2 prepared by customers F9 Emergency f I Fuse 0 3A Stop Av Emergency Stop Is i Internal i 24V F8 CN8 Fuse 1 3 1 Robot stop switch circuit Mo 2 prepared by customers Emergency stop switch on the front panel of the Input controller Ez mi ets DF oV cn5 Teach pendant Emergency stop switch on teach pendant When the internal power source is used Robot controller f Emergency stop circuit prepared by customers F Emergency CN10 B Fuse 03A Stop i External 24V ve i 9 Emergency ES Stop Output La Etema oV Internal 24V CN8 o Fuse 1 3A 1 A alc Robot stop switch circuit prepared by customers Emergency stop switch on the front panel of the controller cine Internal OV Teach pendant aTa Emergency stop switch CNS on teach pendant When an external power source is used Emergency Stop Circuit
153. urning ON short the operation preparation start signal with this signal turned ON shorted SP100 will be set Switch Ext Mode input Terminal number No 23 of connector CN8 By turning ON short the operation preparation start signal with this signal turned ON shorted the mode will be set to the external mode However this signal cannot be used when the power to the motor is turned OFF and CAL is not completed Program reset input Terminal number No 24 of connector CN8 By turning ON short the operation preparation start signal with this signal turned ON shorted all programs will be initialized By turning ON short the operation preparation start signal with all inputs to turned ON shorted to will be executed one by one Input cannot be executed until input is completed Inputs to will also become valid when part of them are executed by the operating panel or teach pendant 88 For the input timing of the operation preparation start signal and to see the figure given below Caution The operation preparation start signal and each input signal except the Enable Auto signal will be turned OFF falling upon turning ON of the external mode output is turned ON Although the robot is made to execute all items at start up execute only necessary items at the time of recovery from suspension during operation to reduce recovery time The required time to execute all items may
154. ycle from beginning Interrupt skip signal input ON shorted OFF open Program start signal input ON shorted OFF open Program reset signal input ON shorted OFF open Program No select signal input ON shorted OFF open Example of Operation When an Interrupt Skip is Input 44 3 5 Command Execution I O Signals Dedicated to Standard Mode In standard mode the I O commands can be executed using command execution I O signals I O commands execute the following Operate start and stop a program for each task Refer to or change variables from the external device Refer to or change inputs and outputs from the external device 3 5 1 General Information about Commands The table below shows the I O commands functions I O Command Functions Description of function Starts the program cycle specified program Step stops the program specified program all programs Program operation Immediately stops the program specified program all programs Resets the program specified program all programs Sets the external speed Speed setting Sets the external acceleration Sets the external deceleration Outputs the error number to the system I O area Type I variable write Reads a value from the system I O area and substitutes it for a Type I variable Internal I O read Outputs the state of internal inputs and outputs to the system I O area 45

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