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.
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.
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 precautions 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.
SAFETY PRECAUTIONS SAFETY PRECAUTIONS Be sure to observe 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.
1. Introduction This section provides safety precautions to be observed for the robot system. The installation shall be made by qualified personal and should confirm to all national and local codes. 2. Warning Labels The robot unit and controller have warning labels. These labels alert the user to the danger of the areas on which they are pasted. Be sure to observe the instructions printed on those labels. Warning label Instructions printed on the label Risk of injury. Never enter the restricted space.
SAFETY PRECAUTIONS 3. Installation Precautions 3.1 Insuring the proper installation environment For standard type The standard type has not been designed to withstand explosions, dust-proof, nor is it splash-proof.
3.3 Control devices outside the robot's restricted space The robot controller, teach pendant and mini-pendant should be installed outside the robot's restricted space and in a place where you can observe all of the robot’s movements when operating the robot controller, teach pendant, or mini-pendant. 3.4 Positioning of gauges Pressure gauges, oil pressure gauges and other gauges should be installed in an easy-to-check location. 3.
SAFETY PRECAUTIONS 3.9 Setting-up a safety fence A safety fence should be set up so that no one can easily enter the robot's restricted space. (1) The fence should be constructed so that it cannot be easily moved or removed. (2) The fence should be constructed so that it cannot be easily damaged or deformed through external force. (3) Establish the exit/entrance to the fence. Construct the fence so that no one can easily get past it by climbing over the fence.
3.11 No robot modification allowed Never modify the robot unit, robot controller, teach pendant or other devices. 3.12 Cleaning of tools 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. 3.13 Lighting Sufficient illumination should be assured for safe robot operation. 3.
SAFETY PRECAUTIONS 4. Precautions while Robot is Running 4.1 Creation of working regulations and assuring worker adherence Touching the robot while it is in Warning operation can lead to serious injury. Please ensure the following conditions are maintained and that the cautions listed from Section 4.1 and onwards are followed when any work is being performed. 1) Do not enter the robot's restricted space when the robot is in operation or when the motor power is on.
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". 4.
SAFETY PRECAUTIONS 4.5 Release of residual air pressure Before disassembling or replacing pneumatic parts, first release any residual air pressure in the drive cylinder. 4.6 Precautions for test runs Whenever possible, have the worker stay outside of the robot's restricted space when performing test runs. 4.
5. Daily and Periodical Inspections (1) Be sure to perform daily and periodical 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. (2) When carrying out periodical inspections or any repairs, maintain records and keep them for at least 3 years. 6.
Contents Preface ................................................................................................................................................................................ i How the documentation set is organized ........................................................................................................................ii How this book is organized ...............................................................................................................................
3.4 3.5 3.6 Usage of System Input Signals (Standard Mode) ..........................................................................................39 3.4.1 Enable Auto (Input).......................................................................................................................... 39 3.4.2 Robot Stop (Input) ........................................................................................................................... 40 3.4.3 Step Stop (All Tasks) (Input)....................
4.5 4.6 Example of Using System I/O Signals in Compatible Mode.......................................................................106 Selectable I/O Mode [Ver 1.95 or later].......................................................................................................110 4.6.1 What is a selectable I/O mode?...................................................................................................... 110 4.6.2 Setting up the selectable I/O mode.............................................
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.
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.
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.
1.2 Names of the Robot Controller Components The following figures show the names of the robot controller components.
For robot series except VM-D/HM-E Floppy disk drive (option) FG terminal Robot stop button Memory backup battery holder Pilot lamp Fuse box Power switch Output IC box Filters (exhaust) Radiating fin Filters (air intake) Note: CN13 is not provided on the VS-E and HS-E series.
Connectors for the VM-D, VS-E, and H∗-E series (Encoders connected via bus) Connector No. Marking CN1 RS232C CN2 CRT CN3 Name Connector No.
1.3 Robot Controller Specifications [ 1 ] Specifications The table below lists the robot controller specifications. Robot Controller Specifications Item Specifications Control system (NOTE 1) No. of controllable axes (NOTE 1) PTP, CP 3-dimensional linear, 3-dimensional circular H∗-D/-E, XYC-D: VC-E (5-axis models): Up to five axes simultaneously V∗-D/-E: Drive system Up to six axes simultaneously All axes: Full-digital AC servo Memory capacity Language used No.
WARNING ⋅ 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.
[ 2 ] Outer Dimensions The outer dimensions of the robot controller are shown below.
Location of IPM boards The table below shows the location of IPM boards for robot series or models.
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.
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.
Robot system configuration with encoders connected via a parallel interface (VS-D, VC-E, H*-D, and XYC-D) 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.
[ 1 ] Switching from the Teach Pendant Follow the procedure below when switching from one mode to the other from the teach pendant: 4STEP 1 On the top screen, press [F4 I/O]. The I/O Monitor window appears. F6 Press [F6 Aux.]. 4STEP 2 The Auxiliary Functions (I/O) window appears as shown below. F2 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.
4STEP 3 The Choose allocation window appears as shown below. 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." Using the jog dial or cursor keys, select the desired assignment mode. Then press OK. 4STEP 4 The following system message appears. Press OK.
[ 2 ] Switching from the Computer Follow the procedure below when switching from one mode to the other from the computer. 4STEP 1 Start WINCAPSII on the computer. Log in with Programmer. 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. 4STEP 2 Click on the DIO Manager button in the System Manager. DIO Manager starts and the DIO Manager window opens.
4STEP 3 Select the SETTING command from the Tools menu of DIO Manager. 4STEP 4 Click on the Hardware tab in the Options window. The Options window will appear as shown below. The hardware settings will appear.
4STEP 5 Select the desired assignment mode from the right-hand popup menu in the I/O Allocation frame (Ver. 1.6 or later). 4STEP 6 Click on OK in the Options window. 4STEP 7 Click on the Connect button controller. The Options window closes. to connect the computer to the robot The Connect button appears in a pressed state.
4STEP 8 Click on the Transfer button. 4STEP 9 Check off the check box by clicking on the Hard setting field. The Transfer Environment Table window appears. Click on the Transfer button. 4STEP 10 The following message window appears confirming that you are sure to update the data. Click on the Yes button.
4STEP 11 The Transmitting hard setting table window appears displaying a bar graph that indicates the transfer progress. 4STEP 12 After the Transmitting hard setting table window disappears, turn the controller power OFF. 4STEP 13 Turn the controller power ON. The I/O assignment mode is switched.
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.
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 Type No. of points Function System input 22 Inputs to turn ON the power to the robot from the external device (PLC), start CAL or select and start a program instead of operations by the operating panel or teach pendant.
2.4 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. 2.4.1 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. 2.4.
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. • 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.
Chapter 3 System I/O Signals Standard Mode 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 Application Signal name Function Robot initialization complete Outputs when preparations for operation are ready to start. Auto mode Outputs when the robot is in Auto mode.
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.
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.
3.2.3 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.
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.
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.
3.2.6 Normal CPU (Output) (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. The signal is used when a normal CPU SIGNAL is turned OFF because of an error and the PLC corrects it.
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 ROBOT FAILURE signal. (4) ON conditions As shown below, the signal will be turned ON under the following conditions.
3.2.8 Robot Warning (Output) (1) Function The signal outputs to the external device that a minor error occurs with 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.
3.2.9 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.
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 the SETTING-UP MANUAL. (5) OFF condition This signal goes off by carrying out the "Task Status Change Operation." 3.2.
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.
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 Application Signal Name Start-up Enable Auto Enables switching to automatic operation. Robot stop Stops the robot with canceling signals. Stop Program interrupt Instantaneous stop (all tasks) Function Immediately stops all programs being executed with canceling signals.
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.
3.4.2 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).
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.
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.
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 INTERRUPT 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).
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.
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.
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) Note 1 ms or more ⋅ Status Area (output) ⋅ Status Parity (output) ⋅ Command processing complete (output) Note ⋅ Robot Error (output) Outline of I/O Command Processing 46 100 ms.
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.
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 connector CN8. Data area 1: No.11 to No.18 of connector CN8.
[ 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 ] 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.
[ 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.
3.5.3 I/O Commands Details 3.5.3.1 List of I/O Commands The table below lists I/O commands.
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 00010000: Step stop 00100000: Instantaneous stop 01000000: Reset An error (ERROR2032) will occur if data is other than the above is set.
Program start This command is executable only in external mode. An error (ERROR2032) will occur in other modes. This command starts the program of the program number specified in data area 2. PRO0 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.
Reset This command immediately stops and also initializes the program of the program number specified in data area 2. PRO0 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.
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.
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.
3.5.3.5 Type I Variable Write (0101) (1) Function This command substitutes the value specified in data area 2 for the Type I (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 I variable for which a value will be substituted. Any number between I[0] and I[255] can be specified.
3.5.3.6 Type I Variable Read (0110) (1) Function This command outputs to the status area the value of the Type Ι (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.
3.5.3.7 Mode Switching (0111) (1) Function This command switches the robot mode from the external 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.
External speed 100 (bit 1) When this bit is set, the external speed, external acceleration 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.
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.
3.5.3.9 I/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.
3.5.3.10 I/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.
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 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.
Function Example of Equipment Operating Panel Classificati on Display Lamp Part Displays messages, such as ROBOT PREPARATION OK. Display Automatic operation indicator lamp ⋅ Lights during automatic operation. ⋅ Turned OFF when the robot is not in automatic operation. Robot external mode indicator lamp ⋅ Lights when the robot is in external mode. ⋅ Turned OFF when the robot is not in external mode. Operation OK indicator lamp Switch Application ⋅ Lights when the Enable Auto signal is ON.
Step Worker’s operation and display on equipment’s operation panel PLC processing Robot operation Enable Auto ON (Internal processing) Equipment power ON Setting operation/adjustment selector switch to operation Operation preparation start Operation OK indicator lamp ON Setting Mode selector switch of the operating panel or the teach pendant to AUTO (Note Robot preparation button ON ) Data area 1 input ON Executing mode switching command Motor power ON Executing CAL Setting SP 100 Switching
(Continued from preceding page) Automatic operation Step Worker’s operation and display on equipment’s operation panel PLC processing Equipment’s Automatic Program No. Select ON Robot operation Regular operation program is selected and output to data area 2. Automatic Operation indicator lamp ON Executing Program Operation Command (Program start) Program start END Program No. select ON Regular operation program is selected and output to data area 2.
Chapter 4 System I/O Signals Compatible Mode 4.1 Types and Functions of System Output Signals (Compatible Mode) The table below lists the system output signals used in the compatible mode.
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 (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.
4.2.2 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.
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.
4.2.4 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.
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.
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 panel or the teach pendant is set to MANUAL or TEACH CHECK, as shown below.
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. The signal is used as a condition to turn OFF the PROGRAM START signal sent from the external device to the robot.
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.
4.2.9 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 is executed at a time.
4.2.10 Normal CPU (Output) (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.
4.2.11 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.
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.
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.
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.
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.
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 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. 10 of connector CN10: Emergency stop (+) No.
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 Application Signal name Function Enable Auto Enables switching to Auto mode. Motor power ON + operation preparation start Turns ON the power to the motor. CAL execution + operation preparation start Executes calibration. SP100 + operation preparation start Sets the speed to 100%.
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.
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.
For the input timing of the operation preparation start signal and the figure given below. to , see 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.
4.4.3 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 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.
Example of Program No. Select Signals Input signal Program No. (decimal) 1 15 26 65 2 = 1 1 1 0 1 2 = 2 0 1 1 0 2 = 4 0 1 0 0 2 = 8 0 1 1 0 2 = 16 0 0 1 0 2 = 32 0 0 0 0 2 = 64 0 0 0 1 0 1 0 1 0 1 2 3 4 5 6 Parity The figure below shows an example of a program No. select signal sequence circuit considering parity. Example of Program No.
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 , and described below will take place. (The status of the signal must be switched from OFF to ON.
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.
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.
(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). Wait for start Robot status External mode (output) ON OFF 1-cycle end (output) ON OFF Program start signal (input) Single-cycle operation Next cycle operation 200 ms.
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).
T1, T2, T3: within 100 ms.
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.
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). 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.
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).
4.4.7 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 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.
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.
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.
4.4.10 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).
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.
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.
Function Example of Equipment Operating Panel Classification Display Lamp Switch Part Application Displays messages, such as ROBOT PREPARATION OK. Display Automatic operation indicator lamp ⋅ Lights during automatic operation. ⋅ Not illuminated when the robot is not in automatic operation. Robot external mode indicator lamp ⋅ Lights when the robot is in external mode. ⋅ Turned OFF when the robot is not in external mode. Operation OK indicator lamp ⋅ Lights when the Enable Auto signal is ON.
Step Worker’s operation and display on equipment’s operation panel PLC processing Robot operation Enable Auto ON (Internal processing) Equipment power ON Operation preparation start Setting operation/adjustment selector switch to operation Operation OK indicator lamp ON (Note Robot preparation button ON ) System input for start-up ON Operation Preparation Start ON Motor power ON Executing CAL Setting SP 100 Switching mode to external mode Operation start area check Robot external mode indic
(Continued from preceding page) Step Worker’s operation and display on equipment’s operation panel Equipment’s Automatic Start PLC processing Robot operation Program No. Select ON Automatic operation Regular Operation Program is selected. Automatic Operation indicator lamp ON Program start Program start ON END Program No. select ON Single-cycle End ON Regular Operation Program is selected.
4.6 4.6.1 Selectable I/O Mode [Ver 1.95 or later] 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.
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 I/O.]—[F6 Aux.]—[F2 AlocMode] (2) In the I/O Hardware Settings window, modify parameters as you want. Access: [F4 I/O.]—[F6 Aux.]—[F1 Set H/W] (3) Reboot the robot controller to make new settings go into effect.
[ 2 ] In WINCAPSII (1) From the Tool menu of DIO Manager, select the Options command. (2) Click on the Hardware tab in the Options window. (3) In the I/O Allocation, choose the Parallel and Selectable.
(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. (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.
Parameter details No. 1 2 3 Parameters Step Stop Interrupt Skip Program Select Function 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.
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.
Parameter details No. 1 Parameters State Output Function 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.
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.]—[F2 AlocMode] (2) In the I/O Hardware Settings window, modify parameters as shown below. Access: [F4 I/O.]—[F6 Aux.]—[F1 Set H/W] 21: Selectable IO mode 24: Selectable IO--Program Select 1 2 (3) Reboot the robot controller to make new settings go into effect.
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.
(2) I/O POWER CN7: Power connector for I/O (common to both modes) CN7 Pin Assignment, common to both modes (NPN type) View from the cable side Terminal No. Name 1 Internal power source output +24V 2 Internal power source output +24V 3 Internal power source output 0V 4 Internal power source output 0V 5 FG 6 Power input E24V 7 Power input E24V 8 Power input E0V 9 Power input E0V Caution: When using the internal power source, keep the total current capacity below 1.3 A.
5.1.
(2) INPUT CN8: User-/System-input connector (standard mode) CN8 Pin Assignment, in standard mode (NPN type) View from the cable side Terminal number Name Port number Wire color Terminal number Name Port number Wire color *1 Power for robot stop (internal +24V) ⎯ Black 26 Data area 2 bit 7 21 Pink *2 Robot stop ⎯ Brown 27 Data area 2 bit 8 22 Pink 3 Power for Enable Auto (internal +24V) ⎯ Red 28 Data area 2 bit 9 23 Pink 4 Enable Auto ⎯ Black 29 Data area 2 bit 10 24 W
5.1.
(2) INPUT CN8: User-/System-input connector (compatible mode) CN8 Pin Assignment, in compatible mode (NPN type) View from the cable side Terminal number Name Port number Wire Terminal color number Name Port number Wire color *1 Power for robot stop (internal +24V) - Black 26 User input 21 Pink *2 Robot stop - Brown 27 User input 22 Pink 3 Power for Enable Auto (internal +24V) - Red 28 User input 23 Pink 4 Enable Auto - Black 29 User input 24 White 5 Step-stop (all ta
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, 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 range. Caution Either an external power supply type or built-in power type Output card is available for the PLC.
(When the internal power source is used) (When an external power source is used) User-Input and System-Input Circuits (NPN type) 125
(When the internal power source is used) (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.
5.2.3 User-Output, System-Output, and Hand-Output Circuits (NPN 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 ON and OFF a lamp, use a lamp whose rating is 0.5W or less.
(When the internal power source is used) (When an external power source is used) User-Output and System-Output Circuits (NPN type) 129
(When the internal power source is used) (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 Lamp Transistor array Controller Example of Circuit with Lamp (NPN type) 131
5.2.4 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. 5.2.4.1 Standard type Robot controller F1 Internal 24V Fuse (1.3A) CN7 Fuse (1.3A) Internal 0V F2 F9 Emergency CN10 Fuse (0.
5.2.4.
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.
I/O Power Connection Sample (When an external power source is used) (NPN type) Caution: Use a cable of 0.5 mm2 or more in size for the wiring between the external power source and the I/O power input connectors of the robot controller.
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 "0V terminal" of each connector and across the "E24V terminal" and the "E0V terminal" to see that there is no continuity. See the figure below and the table given on the next page.
Connector Terminals and Check Points (NPN type) Connector for hand I/O Connector for user/system input View from cable side engaging face Terminal Number Name 1 to 8 Hand output terminal 17 18 View from cable side engaging face Check point Terminal Number 0V (GND) at output (2) 1, 3 Power terminal for hand (E24V) 24V power output (1) Power terminal for hand (E0V) Power (GND) output (1) Meaning Connector for user/system output Name +24V internal power source terminal Meaning Check po
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.
(2) I/O POWER CN7: Power connector for I/O (common to both modes) CN7 Pin Assignment, common to both modes (PNP type) View from the cable side Terminal No. Name 1 Internal power source output +24V 2 Internal power source output +24V 3 Internal power source output 0V 4 Internal power source output 0V 5 FG 6 Power input E0V 7 Power input E0V 8 Power input E24V 9 Power input E24V Caution: When using the internal power source, keep the total current capacity below 1.3 A.
6.1.
(2) INPUT CN8: User-/System-input connector (standard mode) CN8 Pin Assignment, in standard mode (PNP type) View from the cable side Terminal number Name Port number Wire color Terminal number Name Port number Wire color *1 Power for robot stop (internal +24V) ⎯ Black 26 Data area 2 bit 7 21 Pink *2 Robot stop ⎯ Brown 27 Data area 2 bit 8 22 Pink 3 Power for Enable Auto (internal +24V) ⎯ Red 28 Data area 2 bit 9 23 Pink 4 Enable Auto ⎯ Black 29 Data area 2 bit 10 24 W
6.1.
(2) INPUT CN8: User-/System-input connector (compatible mode) CN8 Pin Assignment, in compatible mode (PNP type) View from the cable side Terminal number Name Port number Wire Terminal color number Name Port number Wire color *1 Power for robot stop (internal +24V) - Black 26 User input 21 Pink *2 Robot stop - Brown 27 User input 22 Pink 3 Power for Enable Auto (internal +24V) - Red 28 User input 23 Pink 4 Enable Auto - Black 29 User input 24 White 5 Step-stop (all ta
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.
(When the internal power source is used) (When an external power source is used) User-Input and System-Input Circuits (PNP type) 145
(When the internal power source is used) (When an external power 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.
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.
(When the internal power source is used) (When an external power source is used) User-Output and System-Output Circuits (PNP type) 149
(When the internal power source is used) (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 Lamp Transistor array 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 Internal 24V Fuse (1.3A) CN7 Fuse (1.3A) Internal 0V F2 F9 Emergency CN10 Fuse (0.
6.2.4.
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.
I/O Power Connection Sample (When an external power source is used) (PNP type) Caution: Use a cable of 0.5 mm2 or more in size for the wiring between the external power source and the I/O power input connectors of the robot controller.
6.3 Wiring Notes for Robot Controller I/O Connectors (PNP type) After the wiring of the controller's I/O connectors is completed, check the following before turning ON the power: Check point (1) Using a circuit tester, check across the "+24V terminal" and "0V terminal" of each connector and across the "E24V terminal" and the "E0V terminal" to see that there is no continuity. See the figure below and the table given on the next page.
Connector Terminals and Check Points (PNP type) Connector for hand I/O Connector for user/system input View from cable side engaging face View from cable side engaging face Terminal Number Name Meaning Check point Terminal Number 1 to 8 Hand output terminal 24V at output (2) 1, 3 17 Power terminal for hand (E0V) Power (GND) output (1) 18 Power terminal for hand (E24V) 24V power output (1) Connector for user/system output Name +24V internal power source terminal Meaning Check point +
Chapter 7 I/O Wiring 7.1 Multi-core Cables with Connectors 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. I/O Cables (Optional items) Classification No. 1 I/O Cable Remarks Part Number I/O Cable Set (8m) (3-cable set of Nos.
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 name OUTPUT HAND I/O INPUT I/O POWER Connector model/manufacturer Cable Standards PCR-E68FS connector UL2789 - With shield PCS-E68LA cover Equivalent to AWG28-68P Honda Communications Industry Co., Ltd.
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 mm2 or more in size. (4) For the robot power supply, use a grounding wire with grounding resistance of 100 Ω or less.
RC5 CONTROLLER INTERFACE MANUAL First Edition Third Edition Fourth Edition February 2002 September 2002 January 2006 DENSO WAVE INCORPORATED 1H40C 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.
