installation and adjustmentokura.pro.tok2.com/manuals/ul/ul-(5)ins-12(2009-12-05).pdf · 2011. 3....

Okura Yusoki Co., Ltd.

Robot Manual

Installation and Adjustment

UL-INS-12

UL(12)

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Introduction Thank you for purchasing a model from the Okura Robot Palletizer A series. This manual is a guidebook to help you safely and correctly use your A Series Robot

Palletizer. It should be useful not only to beginners who are using an Okura Palletizer for the first time, but also to experienced users, who can use this Manual to reconfirm their knowledge. Please read this Manual carefully and use the Palletizer with a clear understanding of its content.

Definition of Operator

THE INSTALLATION SHALL BE MADE BY QUALIFIED INSTALLATION PERSONNEL AND SHOULD CONFORM TO ALL NATIONAL AND LOCAL CODES. ONLY QUALIFIED SERVICE PERSONNEL MAY INSTALL OR SERVICE THE ROBOT SYSTEM.

Important! Definition of operator: Only AUTHORIZED PERSONNEL can operate the robot. The definition of “AUTHORIZED PERSON” is described below: The only personnel that can operate the robot and/or robot system, are those who have enough knowledge or experience of robot operation and have also been trained to operate the robot. They must also have been authorized by the employer.

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Table of Contents

1. BASIC SPECIFICATIONS ........................................................1-1

1.1. Operation Range.............................................................................1-2 1.2. T-axis Flange Details ......................................................................1-5 1.3. Internal Wiring Diagram.................................................................1-7 1.4. Spare Cable ..................................................................................1-10 1.5. Capacity........................................................................................1-11 1.6. Robot Installation Dimensions......................................................1-13 1.7. Transport Method .........................................................................1-13 1.8. Limiting Device.............................................................................1-16 1.9. Installation and Foundation..........................................................1-23 1.10. Necessary information on protective fence...................................1-24 1.11. Connection of main power supply wires .......................................1-25 1.12. Protection against lightning serge................................................1-26 1.13. Other notes (wiring).....................................................................1-26

2. SYSTEM STORAGE..................................................................2-1

2.1. Soft Limit........................................................................................2-2 2.2. Peripheral Equipment Name Input .................................................2-3 2.3. Hour Meter .....................................................................................2-4 2.4. Communication Setting ..................................................................2-4 2.5. External PLC Communication Setup................................................2-5 2.6. Memory Switch...............................................................................2-6 2.7. Axis Accuracy ...............................................................................2-11 2.8. Password Setting..........................................................................2-12 2.9. Origin Storing ...............................................................................2-12 2.10. Servo Parameter...........................................................................2-13 2.11. Hand Manual Operation Name Input.............................................2-13

3. CENTRONICS COMMUNICATION ............................................3-1

3.1. Purpose of Using Centronics Communication..................................3-2 3.2. Centronics Communication Start Timing.........................................3-3 3.3. Relationship with Ext PLC Control Interface ...................................3-4 3.4. Name and Meaning of Signals During Communication ....................3-5 3.5. Send/Receive Timing in Centronics Communication.......................3-6 3.6. Time Constraints in Centronics Communication..............................3-8

3.7. Details of Robot → PLC Data ...........................................................3-9

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3.8. Details of PLC → Robot Data......................................................... 3-24

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

4.1. Origin Storing ................................................................................ 4-2 4.2. Standard Storage ........................................................................... 4-3 4.3. How to place the optional stopper ................................................. 4-4 4.4. How to attach the hand to robot .................................................... 4-6 4.5. Servo amp replacement ................................................................. 4-8 4.6. Spare Parts .................................................................................... 4-9 4.7. At Dismantling ............................................................................... 4-9

5. PC BOARDS ........................................................................... 5-1

5.1. Main CPU Board（RC101） .............................................................. 5-4

5.2. I／O Board（RC102） ..................................................................... 5-6

5.3. Servo CPU Board（RC103） ............................................................ 5-8

5.4. Servo Power Supply Board（RC105） ........................................... 5-10

5.5. Safety Relay Board（RC106） ....................................................... 5-12

5.6. Fieldbus converter board (RC111) ............................................... 5-14 5.7. Fieldbus board CC-Link (COM-CA-CCS)........................................ 5-15 5.8. Fieldbus board Ethernet/IP (COM-CA-EIS) ................................. 5-16 5.9. Fieldbus board Profibus-DP (COM-CA-DSP)................................. 5-16

6. SERVO-AMPLIFIER RECEIPT BOX .......................................... 6-1

6.1. Servo-Amplifier Receipt Box Composition ...................................... 6-2 6.2. Servo-Amplifier.............................................................................. 6-3

7. EXTERNAL I/O SIGNALS........................................................ 7-1

7.1. I/O・Data-Memory Composition ................................................... 7-2

7.2. Construction of peripheral equipment control................................ 7-3 7.3. I/O board....................................................................................... 7-7 7.4. I/O Signals for Hand.................................................................... 7-37 7.5. Emergency ................................................................................... 7-38

8. MAINTENANCE MENU ............................................................ 8-1

8.1. Menu structure............................................................................... 8-2 8.2. Special maintenance menu ............................................................ 8-4

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1. Basic Specifications

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

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

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

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★

★

A-point

1.1. Operation Range A1800

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

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

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A-point operation range

Without mechanical stopper cam for small-foot-print

With mechanical stopper cam for small-foot-print

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A1600III



★

★


A-point

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120

145


A-point

115

125

90 40

★

★

A700III

(In case attached the optional stopper see 4.3.)



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1.2. T-axis Flange Details Installed Hand Conditions:

① Inertia A1800: Inertia of hand (include the handled article) must be 10.0kgm2 or less. (At a speed regulated condition 30kgm2 is MAX.) A1600III: Inertia of hand (include the handled article) must be 10.0kgm2 or less. (At a speed regulated condition 30kgm2 is MAX.) A700III: Inertia of hand (include the handled article) must be 10.0kgm2 or less. (At a speed regulated condition 30kgm2 is MAX.)

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

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

A1800

φ200

8-M10

φ150

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A1600III A700III

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1.3. Internal Wiring Diagram The following shows the wiring inside the robot and the composition of the harness between the robot and controller A1800 Inside the robot wiring Harness between the robot and controller

Location of CN1-CN5 on Robot Base

Air Pressure Max. 0.5Mpa, 72psi

CN1

POWER

CN2

CN3

CN5

CONTROL

AIR OPTION

CN4

AIR

Replace battery only with type Maxell ER6K-#17-A

CN1

CN2

CN3

CN4

CN5

RK721

RK722

RK723

RK724

RK725

ROBOT CONTROLLER

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CN1 CN13 D-motor

CN14

CN15 O-motor

CN16

CN11 R-motor

CN12

CN8

CN9

CN10

CN7

CN2

CN3

RK815

RK816

RK817

RK831

RK832

RK833

CN6

CN18

CN4

CN22 D-encoder

CN23 O-encoder

CN24

CN26

CN31

RK851

RK852

RK853

RK854

RK855 RK873

RK856

CN34 RK857

CN21 R-encoder

T-AXIS

HAND

CN37

CN5

CN17 T-motor

CN25 T-encoder

CN33

CN32

RK874

CN36

CN35

RK871

RK781

RK782

AIR 12mm

10mm 12mm

12mm

AIR 12mm

R-LS RK858 CN39

RK835

ROTOR

BASE

CN40 FAN

RK875

LAMP

RK889AU

L

D-LS

LS

D-LS

O-LS

RK776

BAT

BAT-R1/BAT-C1

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A1600III Inside the robot wiring Harness between the robot and controller

CN1

CN2

CN3

CN4

CN5

CN1C

CN2C

CN3C

CN4C

CN5C

RK721

RK722

RK723

RK724

RK725

ROBOT CONTROLLER


Air Pressure Max. 0.5Mpa, 72psi CN1

POWER

CN2

CN3

CN5

CONTROL

AIR

OPTION

Air tube connections on quick joint type

CN4

AIR

Replace battery only with type Maxell ER6K-#17-A

12mm

12mm

CN1 CN13 D-motor

CN14

CN15 O-motor

CN16

CN11 R-motor

CN12

CN8

CN9

CN10

CN7

CN2

CN3

RK731

RK735

RK733

RK731

RK732

RK733

CN6

CN18

CN4

CN22 D-encoder

CN23 O-encoder

CN24

CN26

CN31

RK751

RK752

RK753

RK754

RK755 RK773

RK757

CN34 RK758

CN21 R-encoder

ROTOR

T-AXIS

HAND

CN37

CN5

CN17 T-motor

CN25 T-encoder

CN33

CN32

RK774

CN36

CN35

RK771

RK781UL

RK782UL

AIR 12mm

10mm AIR 12mm

RK758

R-LS RK759 CN39

D-LS

O-LS

RK776

RK737

CN35A

LAMP

BAT

RK789AU

L

LS

BAT-R1/BAT-C1

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A700III Inside the robot wiring Harness between the robot and controller

CN1

CN2

CN4

CN5

CN1C

CN2C

CN4C

CN5C

RK721

RK722

RK724

RK725

ROBOT CONTROLLER


POWER

CN1

CN2

CN5

CONTROL

CN4

Air tube connections on quick joint type

Air Pressure Max. 0.5Mpa, 72psi

Replace battery only with type Maxell ER6K-#17-3

AIR

OPTION

AIR

T-AXIS

LAMP

CN1 CN13 D-motor

CN15 O-motor

CN11 R-motor

CN8

CN7

CN2

RK741

RK742

CN6

CN18

CN4

CN22 D-encoder

CN23 O-encoder

CN24

CN26

CN31

RK761

RK762

RK763

RK764

RK765 RK773

RK767

CN34 RK758

CN21 R-encoder

ROTOR

HAND

CN37

CN5

CN17 T-motor

CN25 T-encoder

CN33

CN32

RK774

CN36

CN35

RK771

RK781UL

RK782UL

AIR 12mm

10mm 12mm

12mm

AIR 12mm

RK768

R-LS RK769 CN39

D-LS

O-LS

RK776

RK737

CN35A

RK789AU

L

BAT

LS

BAT-R1/BAT-C1

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CN33 CN35

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

Robot main unit connector Connector in controller Connector

No. Pin No. Wire No. Connector

No. Pin No. Wire No. Cable size

3 S3 S3 4 S4 S4 13 S5 S5

CN33 [3191-15R1]

14 CLS CLS 1 S6 S6 2 S7 S7 3 S8 S8 4 S9 S9 5 S10 S10 6 S11 S11 7 S12 S12 8 S13 S13 9 S14 S14 10 S15 S15 11 S16 S16 12 S17 S17 13 S18 S18

CN35 [3191-15R1]

14 S19

TBR1

S19

0.3 mm2

TBR1

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

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

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

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

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

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

Pallet

Station

R-Axis Rotation angle

Bags Cases

650m

m 1500m

m

120m

m

Sta

ck H

eight

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1-12

[Bag] [Case]

300

400

500

600

700

800

900

1000

1100

40 60 80 100 120 140 160 180

Handling Capacity

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

40 60 80 100 120 140 160 180

R-Axis Rotation Angle(Degrees)

Handling Capacity

A1600III:10Kg bag special layout

A1600III

A700III

A700III

A1600III

60 100 140

Load Weight [kg]

60 100 140

Load Weight [Kg]

R-Axis Rotation Angle(Degrees)

[B/h]

[C/h]

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

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1.6. Robot Installation Dimensions [All types]

1.7. Transport Method The diagram below shows the posture and hoist position (rope tension).

A1800

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

8-∅22

∅850

□ 750

4-M20

10° 10°

D-axis：0.0° O-axis：130.0°

two right and left 5978N (610kg, 1345lb)/ each

：重心位置

AX = 1191 mm AZ = 1716 mm

center of gravity

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A1600III


two right and left A1600III :5782N (590kg, 1301lb)/ each

D-axis：－4.3° O-axis：134.3°

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A700III


CONTROLLER(RC710,RC720)

two right and left 6223N (635 kg, 1400lb) / each

D-axis： -17.0° O-axis：130.0°

AX=1147mmAZ=1632mm

#In the case of transportation by a forklift.

AX=1069mmAZ=1914mm

D-axis： 0° O-axis：140°

1600

16

50

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

Mechanical stoppers Limit switch(es)

R-axis adjustable fixed(*)

D,O-axis fixed adjustable

(*)Only a limit switch is used when larger than 250 revolution angles.

Mechanical stoppers do not use.

Capability

Mechanical stops are capable of stopping robot motion under rated payload, maximum speed conditions and at maximum extension.

Location

A1800 R-axis: R-axis:inside the base

Mechanical stoppers Limit switch

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A1800 O-axis:

A1800 D-axis:


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A1600III／A700III R-axis: Common to A1600III and A700III R-axis:inside the base

A1600III D/O-axis: D-axis:inside the rotor O-axis:inside the rotor and on the lower arm



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A700III D/O-axis: D-axis:inside the rotor O-axis:inside the rotor

Notes

R-axis and D,O-axis for A1600 stoppers absorb a shock by plastic modification. If it should collide, please exchange for a new one. It can detach and attach only by operation of a bolt in which the stopper is being fixed.

Please specify parts from a lower table at the time of stopper order.

R-axis D-axis O-axis

+ side D0802019

- side D0861003-2

D0802020 D0804006-1

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ⅰphase

ⅱphase

+1 +2

+3

+4

+5

+6

+7

+8 +9 -9

-8

-7

-6

-5

-4

-3

-2 -1

▲

Front of robot

How to adjust

A1800 R-axis

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

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

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

Installed Bolts Position Installed Bolts Position

+1 +2 +3 +4 +5 +6 +7 +8 +9

-1 -2 -3 -4 -5 -6 -7 -8 -9

0 A E 0 A E

+5 E A -5 E A

+10 C G -10 C G

+15 G C -15 G C

+20 A E -20 A E

+25 E A -25 E A

+30 C G -30 C G

+35 G C -35 G C

+40 A E -40 A E

+45 E A -45 E A

+50 C G -50 C G

+55 G C -55 G C

+60 A E -60 A E

+65 E A -65 E A

+70 C G -70 C G

+75 G C -75 G C

+80 A E -80 A E

+85 E A -85 E A

+90 C G -90 C G

+95 G C -95 G C

+100 A E -100 A E

+105 E A -105 E A

+110 C G -110 C G

+115 G C -115 G C

+120 A E -120 A E

+125 E A -125 E A

Lim

it S

witch

Angle

[deg

]

+130 C G

Lim

it S

witch

Angle

[deg

]

-130 C G

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

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A1600III/A700III R-axis

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

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

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

設置用ボルト位置設置用ボルト位置

+1 +2 +3 +4 +5 +6 +7 +8 +9

-1 -2 -3 -4 -5 -6 -7 -8 -9

0 A E 0 A E

+5 E A -5 E A

+10 C G -10 C G

+15 G C -15 G C

+20 A E -20 A E

+25 E A -25 E A

+30 C G -30 C G

+35 G C -35 G C

+40 A E -40 A E

+45 E A -45 E A

+50 C G -50 C G

+55 G C -55 G C

+60 A E -60 A E

+65 E A -65 E A

+70 C G -70 C G

+75 G C -75 G C

+80 A E -80 A E

+85 E A -85 E A

+90 C G -90 C G

+95 G C -95 G C

+100 A E -100 A E

+105 E A -105 E A

+110 C G -110 C G

+115 G C -115 G C

+120 A E -120 A E

+125 E A -125 E A

制限角度

[度

]

+130 C G

制限角度

[度

]

-130 C G

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

ⅰphase

+1 +2

+3

+4

+5

+6

+7

+8 +9 -9

-8

-7

-6

-5

-4

-3

-2 -1

ⅱphase

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A1800/A1600III/A700III D/O-axis

The plate for adjustment shown in the right figure is attached so that a limit switch may be effective at an angle of hope.

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1.9. Installation and Foundation Stand Strength and Rigidity The following standard values must be satisfied for the bending direction (M) and twisting direction (T) shown in the diagram below. A1600III, A1800 [Strength] The stand must withstand the following repetitive load. M =±16000 Nm T =±12500 Nm [Rigidity] Sufficient rigidity is required to avoid vibration during robot motion. Recommended values are KM=5.4x106 Nm/rad KT =5.4x106 Nm/rad [Set-up conditions]

Floor conditions: Concrete 150mm thick (MIN) 3.0t/m2. No water gradient. Concrete completion strength 21Mpa (MIN)

Fixing method: Chemical anchor M16-12. Pulling strength 1.8t. (Hole Dia.19mm, Hole depth 90mm,) Bolt tensile strength is 400N/mm2 or more. Bolt yield is 240N/mm2 or more.

A700III

[Strength] The stand must withstand the following repetitive load. M =±7500 Nm T =±6000 Nm [Rigidity] Sufficient rigidity is required to avoid vibration during robot motion. Recommended values are KM =3.9x106 Nm/rad KT =3.9x106 Nm/rad [Set-up conditions]

Floor conditions: Concrete 150mm thick (MIN) 2.0t/m2. No water gradient. Concrete completion strength 21Mpa (MIN).

Fixing method: Chemical anchor M16-8 pulling strength 1.8t. (Hole Dia.19mm, Hole depth 90mm,) Bolt tensile strength is 400N/mm2 or more. Bolt yield is 240N/mm2 or more.

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

Wire : IEC standard Wire diameter : 0.5 sqmm or more Wires length : 20 m or less Voltage : 24 V Current : 20 mA Output : dry output Standard : authenticated by NE/IEC standard, which include a dual channel mechanism with normally closed contacts.

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

2. .Emergency stop switch Satisfy common requirements above

3. Intrusion detection switch Satisfy common requirements above This can be connected to control category three

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

Follow EN953 in locating fixed guard.

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

2

2

Fence height

Safety distance A

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

1. Introduce of electric wires must be relevant position of controller.

2. Protection degree of the busing, for electric wires introduction must be equal or more than IP5X.

3. Connect external protective conductors to terminal with mark PE by the side of main breaker.

4. Put main power supply wires separately in the duct, and put a charging mark on the duct.

5. In connecting main power supply wires and external protective conductors vend wire adequately (if needed). And fix them firmly so that not to strain on the terminal.

Specification of main power supply wires Wires: UL standard Wires size: minimum AWG#6 Conductor: copper Temperature rating: minimum 90°C (194°F) Terminal processing: A round terminal (UL Listed one) that suits the size of the electric wire and tool of maker recommendation are used.

Grounding Specification of external protective conductors Wires: UL standard Wires size: minimum AWG#6 Conductor: copper Temperature rating: minimum 90°C (194°F) Color: Green/yellow Terminal processing: A round terminal (UL Listed one) that suits the size of the electric wire and tool of maker recommendation are used.

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

1.13. Other notes (wiring)

1.13.1. Attaching insulation cover Attach cover to O-axis and D-axis connector, which keeps more than 10 mm clearance and creepage distance not to touch.

1.13.2. Securing of earth continuity

6. Connect following wires between robot body and protective conductors inside controller. Wires: IEC standard Wires diameter : more than 10 sqmm Color : green/yellow

7. Measure resistance value between each motor frames and external protective conductor of controller, and confirm the value is less than following resistance value Resistance value : 0.1 ohm or less per 10 A

8. Attaching duct Harness between controller and robot must be put in metal duct. Divide power line and control line by separator. Minimum size of duct is 150 mm width and 100 mm height.

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

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Interface for hand

Interface of Air tube Option in Rotor inside.

1.13.3. Pneumatic system Pneumatic system is provided for hand. Pneumatic source interface is set on Robot Base panel. Air tube is passed in the flexible conduit and the interface is set on T-axis. Air tube Option interface is set on Robot Rotor inside. Air Pressure Max. 0.5Mpa, 72psi Interface

Pneumatic source：Model KQE12-00(SMC)/ Fitting Diameter 12mm Hand：Model KQH10-12(SMC)/ Fitting Diameter 10mm Option：Model KQH12-00(SMC)/ Fitting Diameter 12mm

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

Locations

Interface of pneumatic source

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

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2.1. Soft Limit The procedure for moving the soft limit screen is as follows; System Menu ↓ Soft limit

1. Soft limits -This displays the range in which R, D, O and T axis movement is possible, as an angle -The R-axis value is used for the R area in 5

2. Teaching range - This sets a movable range under the automatic operation - The range is to be indicated in arm coordinate - When the robot moves out of the designated range, situation is to be “Out of range error“ - During manual operation, the buzzer sounds at the point of 200mm or 20 degree (30 for T-axis) to the range limit

3. Origin offset -This is data for correcting the robot base posture (origin) -This cannot be set or changed by the user. - Numerical value is of the number of encoder pulse, meaning a deviation between the encoder pulse origin and robot base posture (origin)

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

5. R area - This is for informing the other control equipment of current R-axis angle - For the R-axis angle, the range set with soft limit is divided into 7 segments -These segments are labeled 1 -7 in order from minus side of R-axis angle - As for the value indicating the segment in the system parameter, set a plus side border angle in each segment 1 – 6 - A value is to be input in D6000 to indicate in which segment, 1 - 7, the robot is

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

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

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

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

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

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2.3. Hour Meter The procedure for moving to the hour meter screen is as follows System Menu ↓ Hour-Meter Revision The following two settings can be made at the hour meter revision screen [Date revision] Display the key input screen by pressing the display data of item to be changed. Then, input a value to be set by numeral keys, and press WRITING key. [User time clear]

Press TIME CLEAR key after pressing the USER TIME key.

(All the item of the user time shall be cleared to “0”)

Note Total hour cannot be cleared

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

System Menu ↓ Communication setup Setting shall be valid upon re-starting of power.

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

System Menu ↓ Ext PLC Com Setup

1. Interfacing with external PLC ・When M+D is selected, the interfacing signals are output to [M] and/or [D] to be separately set in the separate fieldbus communication. ・When X/Y is selected, the interfacing signals are output to X/Y at RC102 boards.

2. Centronics interfacing with external PLC

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

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

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

(4)All Special Data Advice When select [ No ], at the time robot transfer pattern information2 data in special stacking, quantity data is not transferred.

3. Fieldbus communication

E/IP to be selected allows you to connect with Ethernet/IP.

* Optional board needs to be added. See [5.PC Boards] for detail.

(1) Remote device setting

・Remote output(RY) to be selected allows you to assign the robot outputs to the device M. ・Remote input(RX) to be selected allows you to assign the robot inputs to the device M. ・Remote register(RWw) to be selected allows you to assign the robot outputs (word) to the device D. ・Remote register(RWr) to be selected allows you to assign the robot inputs (word) to the device D.

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(2)Input data at data link error

・Date clear to be selected allows to turn the device M assigned to [remove input (RY)]off at data link error. ・Data hold to be selected allows to hold the previous situation before the data link happens at data link error.

(3)Time to detect data link error

・Disable to be selected allows not detect data link error. ・Enable to be selected allows detect data link error. In this case, Setting of detection time is possible. happens at data link error.

(4)IP Address and Net Mask.

2.6. Memory Switch Procedure for moving to the memory switch screen is as follows. System Menu ↓

Memory Switch

- Set the memory switch inside robot (Normally, change will not be necessary.)

- The following items are set by turning memory switches ON and OFF. -For changing, press a switch to be changed, then turn ON and OFF.

- Descriptions come out in the bottom frame upon pressing the numeral key in left side

Use \\ key to move to SW4

(Use \\ key to return)

Danger Enforcement

Never ever send any signal associated with causing a hazardous situation should it failed to control by communication trouble.

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Name ON OFF Type Standard setting

1-1 T-axis motion T-axis turns to designated position, not taking short cut direction (for aging) (e.g.) Target position is -179 degree,

when current position is 179 degree. Move to -179 (Approx. 358 degree rotating)

T-axis turns, taking short cut direction Move to 181 (Approx. 2 degree rotating)

All OFF

1-2 Not used 1-3 C-axis Existing of C-axis No C-axis 1-4 Setting of A300S A300S A300 All OFF 1-5 Robot control

signals X,Y are used. M,D are used. All OFF

1-6 Program 0 function Upward motion at the then position. → RX Reverse to MIN → Only R-axis rotate to 0 position → move to 0 position (It is necessary to change the prg.0 sequence. 3 lines in the following are to be added twice in front of PGSEL D=D2+1

MOV 1 WTARM )

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

All OFF

1-7 Variable picking special movement

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

Ordinary handling

All OFF

SW1

1-8 Not used 2-1 Movement under

the condition of pallet floor placement

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

Ordinary calculation All OFF

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

Password is invalid Master password: 1952

All OFF

2-3 DMOV movement T-axis is non-synchronized (Only T-axis moves to the target position directly)

T-axis is synchronized (Palm moves in parallel)

All OFF

2-4 Operating movement

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

Robot collaborates with PLC signals

All ON

2-5 External operating button (X20)

Use Not used All ON

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

Log output → debug PORT No output All OFF

SW2

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

Use Not used All ON

3-1 Sequence reset handling setting

In an occasion of resetting Y30 (M6010) - Y35 (M6022) Y20 (M503A) 500mS ON

Ordinary handling

All OFF

3-2 Use Compact Frash card

Use Not use All OFF

3-3 SMOV parameter Use metric height parameter Use % parameter All OFF 3-4 Not used 3-5 Language Other language Japanese All ON 3-6 DA1800 mode DA1800 mode STD mode All OFF 3-7 Servo parameter

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

Not use All OFF

SW3

3-8 End of work button Use Not use All OFF 4-1 System reserved --- Always off All OFF SW4 4-2 System reserved --- Always off All OFF

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Name ON OFF Type

Standard setting

4-3 DA1800 For palette two or more one program

For palette two or more one program STD All OFF

4-4 Conveyer manual notification number in centronics communication

30 or less 15 or less All OFF

4-5 Timer value setting screen

use Not use All OFF

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

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

STD (The set number of palettes is effective.)

All OFF

SW5

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

written Not written All OFF

Note Upon pressing the number’s area of each switch, explanatory descriptions for

that switch come out in the bottom of screen

[POD screen display]

SW SH version (Add/Alter)

ON OFF

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

trajectory of T axis normal

5-2 2.03A Trigger which saves TraceData :MotorPower OFF

:When a Servo error occurred

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

:DISABLE

5-4 2.03O Default T-AXIS offset (A700 III)

T-AXIS offset = 60mm

5-5 2.07C Acc/Dec time minimized By default value 5-6 2.05B System reservation (Fixed

“ON”)

5-8 2.05L ON-Floor Pallet Qty Detection :ENABLE

:DISABLE

6-1 2.07 Condition of File Download :Motor Power OFF

:AnyTime

6-2 2.05N D4=Init Value LAY Cnt,D5=Init Value WRK Cnt.

:DISABLE

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

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

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

managed by Robot Controller.

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[Descriptions] Name ON OFF Type Factory

default

4-7

Production summary

Optional : Results of each hour Results of each day

Results of each program Results of each pallet

All OFF

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

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

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

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

SW4

4-8

T-axis acceleration and deceleration times

Compared with turning off, the capacity might decrease.

All OFF

5-2

Which timing trace data is stored at

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

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

All OFF

5-3

Position of STA

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

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

All OFF

SW5

5-4

A700 model (T-axis offset)

New model Using default offset value of T axis center.

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

A700 III A700 III-P

ON

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Name ON OFF Type Factory default

5-5

Minimum acceleration and deceleration times

Each axis has the minimum of acceleration and deceleration times. D/O-axis : 144msec R/T-axis : 192msec

All-axis have the common minimum acceleration and deceleration times. All-axis : 192msec

A1600 III A1600 III-P

OFF

5-6

System reserved

Keep ON always. --- All ON

5-8

Check on the pallet count change

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

No check the pallet count

All SHVer 2.05L-2.08C ：OFF 2.08D-

：ON Motor Power OFF. Anytime

6-1

File downloads When motor power is

ON, all downloads by PC are prohibited.

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

All ON

6-2

The initial values of counters are set in D4/D5

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

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

All OFF

6-4

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

Use RC102 or RC122 board. (Standard)

All OFF

6-6

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

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

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

A1600 III-W

ON

Managed by internal PLC.

Managed by robot controller.

SW6

6-7

Managing of station timer value. The values are saved

into latch area. Setting D2500 - D2515 need ladder logic when program is changed.

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

All SHVer 2.08C-2.08D ：ON 2.08E-

：OFF

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2.7. Axis Accuracy Procedure for moving to the axis accuracy screen is as follows. System Menu ↓ Axis Accuracy

1. Axis accuracy - Arrival confirmation is performed at this precision only when SPC is selected due to step parameter overlap

2. SMOV, SMOV2 parameter

No. Default Range Contents Description 1 100 Cornering status The bigger value, the smoother

cornering 2 0 For straight movement in

upward motion The bigger value, the shorter linear motion

3 0 For straight movement in Downward motion

The bigger value, the shorter linear motion

4 100 Speed limit for RX direction (Speed regulation for RX motion) 5 100

0~100 [%]

SMOV inner judgement (Speed regulation for RZ motion) 6 100 Step1 effective height 7 100

[mm] Step3 effective height

Parameter that calculates No.1-3 automatically(It is effective in memory switch 3-3.)

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

Important If this machine type is changed, all programs are erased.

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

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2.8. Password Setting In standard setting, the password setting is necessary only at the time of system storing. Password setting can be done with each screen of setting for auto operation, teaching and conveyor data. System Menu ↓ Password Setup [ Procedure for storing ] ①Select an item to be set by pressing a key

②Input 4 password

③Press Set key

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

②Press Clear key

Note -2-2 of the memory switch should be turned on to make this setting effective.

- Standard password shall be invalid when setting a password into the system storing

2.9. Origin Storing Please refer 4.1. Origin Storing

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2.10. Servo Parameter This is a screen for displaying or changing the necessary parameter on the servo screen Procedure for moving to the servo parameter screen is as follows. System Menu ↓ Servo Parameters

Note - Each parameter should be of within a due range, otherwise, the robot may

malfunction with the possibility of damage to the robot and controller. -Only qualified individuals should change this value.

2.11. Hand Manual Operation Name Input Input the manual device names of the hand. Procedure for moving to the axis accuracy screen is as follows. System Menu ↓ Hand Setup

[ Input procedure ] ①Press a number key to be input

②An Input screen comes out , and input the name

③Press QUIT key

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

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3.1. Purpose of Using Centronics Communication Examples of the principal uses are shown below. ■Transmitting pattern information when performing multiple pick-up. (Robot -> Sequencer) ■ When performing peripheral conveyor reset, zero reset or manual operation using the robot controller. (Sequencer -> Robot) ■Displaying conveyor errors on the robot control panel. (Example: Safety fence, station conveyor jamming) (Sequencer -> Robot) ■Count setting. (Bi-directional) Note) The robot sequence stops during Centronics communication. (Robot actions stop)

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3.2. Centronics Communication Start Timing There are two types of Centronics communication: the type where starting can be done at any time, and the type where data is automatically sent at an established timing.

During Robot -> PLC communication

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

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

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

1 - c Conveyor all reset (Zero reset)

At input from conveyor manual screen.

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

1 - e Conveyor manual At conveyor manual screen selection.

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

1 - g Overall time, automatic operation time

When 2-g is received.

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

During PLC -> Robot communication

No. Received item Reception timing 2 - a PLC error mode Any time after P-I/O alarm/error

bit ON 2 - b Request pattern data from

conveyor Any time (To 1-a)

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

pallet No. Any time (To 1-a)

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

Any time

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

time, and automatic operating time

Any time (To 1-g)

2 - h Data memory content request

Any time (To 1-h)

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

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3.3. Relationship with Ext PLC Control Interface

The interface via [X/Y] is in use when [Ext PLC Control Interface] is set to [X/Y] for the serial communication. 8 bits per a unit is transferred.

When it is set to [M+D] instead, the interface is via the fieldbus. A word per a unit is transferred. (See item 2.5) When it is set to [X/Y],

* The data of Pdat and Rdat is transferred byte by byte. * IDNo is in use.

When it is set to [M+D],

* The data of Pdat and Rdat is transferred in 8 words at a time. But, no the upper 8 bits but the lower 8 bits per a word are in use to transfer only.

* No IDNo. but program No. is in use. * In either case, the minimum unit of the transferred data is one byte so that the data

format is common except for IDNo or program No selection. (See the data for detail)

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3.4. Name and Meaning of Signals During Communication Relay PLC -> Robot Robot -> PLC Rmod Y10

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

Rdat Y0-Y7

Not used Command or data output to PLC side When [Ext PLC Control Interface] is set to [M+D], transferred in word. When to [X/Y], transferred in bit.

Rstb Y11

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

Pbsy X2A

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

Pack X2B

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

Pmod X28

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

Not used

Pdat X10-X17

Output of command or data to robot side When [Ext PLC Control Interface] is set to [M+D], transferred in word. When to [X/Y], transferred in bit.

Not used

Pstb X29

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

Not used

Rbsy Y12

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

Not used

Rack Y13

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

Not used

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3.5. Send/Receive Timing in Centronics Communication The timing chart for Centronics communication is as follows. The flow of signal passing is expressed in the diagram.

3.5.1. Centronics communication timing chart

Example 2: Ordinary Centronics communication

PLC Robot Turn ON Pmod, and communication is set to Centronics communication.

Within 5 secs

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

State where Rbsy is not ON.

Data reception Send Rack ON

Within 500ms Turn OFF Pstb

Turn OFF Rack

NULL reception Send Rack ON

Within 500ms Turn OFF Pstb

Turn OFF Rack

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

turn Pstb ON.

Pmod

Pdat (Bit)

Pstb

Rack

1Byte 1Byte 1Byte 1Byte

Example 1: PLC -> Robot

Pdat (Word)

Word Word Word Word *1

*1: Pdat is assigned at [Ext PLC Control Interface]. (See item.2.5)

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

PLC Robot

Turn ON Pmod, and communication is set to Centronics communication.

Within 5 secs

Rbsy is ON

Send Rack ON

Within 500ms

Turn OFF Pstb Turn Rack OFF

Robot is busy, so data cannot be send.

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

Data reception

Pstb goes OFF

Data reception

Send Rack ON

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

Rbsy is OFF

Example 3: Receiving side busy

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3.6. Time Constraints in Centronics Communication There are time constraints when sending command/data from PLC to robot. (Nos. are subcodes of error codes.) When the following constraints are violated, a PLC P-I/O error (62) results.

Subcode Nature of constraint. 05 When Rack is received (when robot side data reading is complete),

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

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

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

11

When sending command/data from robot to PLC. (Nos. are subcodes of error codes.)

When the following constraints are violated, a PLC P-I/O error results.

Subcode Nature of constraint 01 The PLC must always turn Pack OFF when communication from the robot

is starting 02 When Rstb has gone ON during PLC Pbsy output, the PLC must turn

OFF Pbsy within 2 seconds 03 After Rstb has gone ON, the PLC must complete data reading and turn

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

Pack within 500ms.

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

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3.7. Details of Robot → PLC Data The following types of data are sent from the robot to the PLC

1. Pattern information 2. Conveyor reset 3. Conveyor zero reset 4. Counter setting 5. Conveyor manual 6. No program for ID No. 7. Overall time, automatic operation time 8. Data memory output 9. Product dimension output 10. Error code output 11. Conveyor data read 12. Response of writing request to data memory

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

Details on pattern information are as follows.

Details of each piece of information are always expressed with 8 bits. NULL is always attached at the end of pattern information data. The shaded bits vary in value depending on the data. (Values are fixed for unshaded bits.)

1. Command

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

HEX D7 D6 D5 D4 D3 D2 D1 D0

80 1 0 0 0 0 0 0 0

2. ID No.

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

[Example]: IDNo.=95


5F 0 1 0 1 1 1 1 1

* This won’t be set if [Ext PLC Control Interface is set to [M+D].

3. Program No.

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

[Example] Program No. = 120


41 0 1 0 0 0 0 0 1

38 0 1 1 1 1 0 0 0

* Program No is as follows when [Ext PLC Control Interface is set to [M+D].

Program No ranging from 1 through 9999 uses every 6 bit at D0 – D5. D6 is fixed to ”1” and D7 to “0”.

[Example] Program No. = 9001


42 0 1 0 0 0 0 1 0

4C 0 1 0 0 1 1 0 0

69 0 1 1 0 1 0 0 1

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4. Pallet No.

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

[Example] Pallet No. = 3


03 0 0 0 0 0 0 1 1

5. Number of layers

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

[Example] Number of layers = 12 layers


0C 0 0 0 0 1 1 0 0

6. Stacking pattern

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

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

[Example] Stacking pattern = RP mode


04 0 0 0 0 0 1 0 0

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7. Stacking quantity

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

[Example] Stacking quantity = 8 pieces


08 0 0 0 0 1 0 0 0

8. Layer number of quantity data

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

[Example] Layer beginning data = 40


E4 1 1 1 0 1 0 0 0

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

[Example] Layer beginning data = 20


74 0 1 1 1 0 1 0 0

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9. Quantity data

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

● Meaning of each bit

D7 D6 D5 D4 D3 D2 D1 D0

Sam

e layer flag (S

ame layer =

1 /

Distin

ctive layer = 0

)

Distin

ctive layer = 1

(Null p

reventio

n),

Sam

e layer = 0

Auxiliary flag

(Distin

ctive layer)

Auxiliary flag

(Distin

ctive layer) / N

um

ber o

f layers (Sam

e layer)

Auxiliary flag

(Distin

ctive layer) / N

um

ber o

f layers (Sam

e layer)

1 layer en

d (N

o en

d =

0 / E

nd =

1)

Han

d clo

sed (O

pen

= 0

/ Clo

sed =

1)

Turn

(Yes = 1

/ No =

0)

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

● Same/Distinctive layers

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

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3-14

● Same layer data content

[Example] First layer stacking quantity is 8 pieces. Turn: There is a turn only at the 8th piece Hand: Hand closes at pieces 1, 2, 5, 6, 8 (Multiple pick-up) Same layer flag: Distinctive layer

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

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

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

Qty. HEX D7 D6 D5 D4 D3 D2 D1 D0 Qty. HEX D7 D6 D5 D4 D3 D2 D1 D0

1 42 0 1 0 0 0 0 1 0 1 42 0 1 0 0 0 0 1 0

2 42 0 1 0 0 0 0 1 0 2 43 0 1 0 0 0 0 1 1

3 40 0 1 0 0 0 0 0 0 3 40 0 1 0 0 0 0 0 0

4 40 0 1 0 0 0 0 0 0 4 40 0 1 0 0 0 0 0 0

5 42 0 1 0 0 0 0 1 0 5 42 0 1 0 0 0 0 1 0

6 42 0 1 0 0 0 0 1 0 6 43 0 1 0 0 0 0 1 1

7 40 0 1 0 0 0 0 0 0 7 40 0 1 0 0 0 0 0 0

8 47 0 1 0 0 0 1 1 1 8 46 0 1 0 0 0 1 1 0

1st layer 2nd layer

Layer HEX D7 D6 D5 D4 D3 D2 D1 D0 Layer HEX D7 D6 D5 D4 D3 D2 D1 D0

3 81 1 0 0 0 0 0 0 1 4 82 1 0 0 0 0 0 1 0

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


Null 0 0 0 0 0 0 0 0 0

End of data

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10. Example of send data

• Column stacking

HEX D7 D6 D5 D4 D3 D2 D1 D0 Current setting Data content

80 1 0 0 0 0 0 0 0 128 Command

5F 0 1 0 1 1 1 1 1 95 ID No.

41 0 1 0 0 0 0 0 1 Prg No. high order 6 bits 38 0 1 1 1 1 0 0 0

Prg120 Prg No. low order 6 bits

03 0 0 0 0 0 0 1 1 3 Pallet No.

04 0 0 0 0 0 1 0 0 4 Number of layers 01 0 0 0 0 0 0 0 1 1(Column tacking) Stacking pattern 08 0 0 0 0 1 0 0 0 8 Stacking quantity for each layer C1 1 1 0 0 0 0 0 1 1st layer Quantity data start

42 0 1 0 0 0 0 1 0 1st quantity data

42 0 1 0 0 0 0 1 0 2nd quantity data

40 0 1 0 0 0 0 0 0 3rd quantity data

40 0 1 0 0 0 0 0 0 4th quantity data

41 0 1 0 0 0 0 0 1 5th quantity data

41 0 1 0 0 0 0 0 1 6th quantity data

40 0 1 0 0 0 0 0 0 7th quantity data 47 0 1 0 0 0 1 1 1 8th quantity data + layer end 0 0 0 0 0 0 0 0 0 0 NULL(Data terminator)

*1: Program No

(1) When [Ext PLC Control Interface] is set to [X/Y]. This text is sent only when “Program No. Addition” mode. (cf. 2.5 External PLC communication set up)

(2) When [Ext PLC Control Interface] is set to [M+D].

It is set whichever [Pattern info PrgNo addition] is associated with. It is consist of 3 bytes to support programs up to 9999.

42 0 1 0 0 0 0 1 0 Program No. high order 6 bits

4C 0 1 0 0 1 1 0 0 Program No. middle order 6 bits

69 0 1 1 0 1 0 0 1

Prg9001

Program No. low order 6 bits

*2: This text is sent only when “Layer Data Addition” mode. (cf. 2.5 External PLC

communication set up) *3: IDNo can be set only when [Ext PLC Control Interface] is set to [X/Y].

It never be set when [M+D].

*2

*1 *1

*3

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3-16

• Alternating stacking

HEX D7 D6 D5 D4 D3 D2 D1 D0 Current setting Data content

80 1 0 0 0 0 0 0 0 128 Command

5F 0 1 0 1 1 1 1 1 95 ID No.



03 0 0 0 0 0 0 1 1 3 Pallet No.

04 0 0 0 0 0 1 0 0 4 layers Number of layers

02 0 0 0 0 0 0 1 0 2 (Alternating stacking)

Stacking pattern

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

C1 1 1 0 0 0 0 0 1 1st layer 1st layer data start

42 0 1 0 0 0 0 1 0 1st quantity data

42 0 1 0 0 0 0 1 0 2nd quantity data

40 0 1 0 0 0 0 0 0 3rd quantity data

40 0 1 0 0 0 0 0 0 4th quantity data

41 0 1 0 0 0 0 0 1 5th quantity data

41 0 1 0 0 0 0 0 1 6th quantity data

40 0 1 0 0 0 0 0 0 7th quantity data

47 0 1 0 0 0 1 1 1 8th quantity data + layer end

C2 1 1 0 0 0 0 1 0 2nd layer 2nd layer data start

42 0 1 0 0 0 0 1 0 1st quantity data

42 0 1 0 0 0 0 1 0 2nd quantity data

40 0 1 0 0 0 0 0 0 3rd quantity data

40 0 1 0 0 0 0 0 0 4th quantity data

41 0 1 0 0 0 0 0 1 5th quantity data

41 0 1 0 0 0 0 0 1 6th quantity data

40 0 1 0 0 0 0 0 0 7th quantity data


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

*1-3: See the case of [Column stacking]

*2

*1 *1

*2

*3

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3-17

• When there is same layer setting for special stacking and “Layer Data Addition” is “Yes”. (3rd layer is the same as 1st layer, and 4th layer is the same as 2nd layer) HEX D7 D6 D5 D4 D3 D2 D1 D0 Current setting Data content

80 1 0 0 0 0 0 0 0 128 Command

5F 0 1 0 1 1 1 1 1 95 ID No.



03 0 0 0 0 0 0 1 1 3 Pallet No.

04 0 0 0 0 0 1 0 0 4 layers Number of layers

03 0 0 0 0 0 0 1 1 3 (Special stacking)

Stacking pattern


C1 1 1 0 0 0 0 0 1 1st layer 1st layer data start

42 0 1 0 0 0 0 1 0 1st quantity data

42 0 1 0 0 0 0 1 0 2nd quantity data

40 0 1 0 0 0 0 0 0 3rd quantity data

40 0 1 0 0 0 0 0 0 4th quantity data

41 0 1 0 0 0 0 0 1 5th quantity data

41 0 1 0 0 0 0 0 1 6th quantity data

40 0 1 0 0 0 0 0 0 7th quantity data


C2 1 1 0 0 0 0 1 0 2nd layer 2nd layer data start

42 0 1 0 0 0 0 1 0 1st quantity data

42 0 1 0 0 0 0 1 0 2nd quantity data

40 0 1 0 0 0 0 0 0 3rd quantity data

40 0 1 0 0 0 0 0 0 4th quantity data

41 0 1 0 0 0 0 0 1 5th quantity data

41 0 1 0 0 0 0 0 1 6th quantity data

40 0 1 0 0 0 0 0 0 7th quantity data


C3 1 1 0 0 0 0 1 1 3rd layer 3rd layer data start

81 1 0 0 0 0 0 0 1 Same layer (1st layer)

Same layer flag

C4 1 1 0 0 1 0 0 0 4th layer 4th layer data start

82 1 0 0 0 0 0 1 0 Same layer (2nd layer)

Same layer flag

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


*1 *1

*2

*2

*2

*2

*3

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

HEX D7 D6 D5 D4 D3 D2 D1 D0 Current Setting

Data contents

80 1 0 0 0 0 0 0 0 128 Command

5F 0 1 0 1 1 1 1 1 95 ID No.



03 0 0 0 0 0 0 1 1 3 Pallet No.

04 0 0 0 0 0 1 0 0 4th layer Number of layers


Stacking pattern


61 0 1 1 0 0 0 0 1 1st layer 1st layer data start

42 0 1 0 0 0 0 1 0 1st quantity data

42 0 1 0 0 0 0 1 0 2nd quantity data

40 0 1 0 0 0 0 0 0 3rd quantity data

40 0 1 0 0 0 0 0 0 4th quantity data

41 0 1 0 0 0 0 0 1 5th quantity data

41 0 1 0 0 0 0 0 1 6th quantity data

40 0 1 0 0 0 0 0 0 7th quantity data


62 0 1 1 0 0 0 1 0 2nd layer 2nd layer data start

42 0 1 0 0 0 0 1 0 1st quantity data

42 0 1 0 0 0 0 1 0 2nd quantity data

40 0 1 0 0 0 0 0 0 3rd quantity data

40 0 1 0 0 0 0 0 0 4th quantity data

41 0 1 0 0 0 0 0 1 5th quantity data

41 0 1 0 0 0 0 0 1 6th quantity data

40 0 1 0 0 0 0 0 0 7th quantity data

47 0 1 0 0 0 1 1 1 47 8th quantity data + layer end

63 0 1 1 0 0 0 1 1 3rd layer 3rd layer data start

81 1 0 0 0 0 0 0 1 Same layer (1st layer)

Same layer flag

64 0 1 1 0 1 0 0 0 4th layer 4th layer data start

82 1 0 0 0 0 0 1 0 Same layer (2nd layer)

Same layer flag



*2

*2

*2

*2

*1 *1

*3

UL(12)

3-19

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

HEX D7 D6 D5 D4 D3 D2 D1 D0 Current Setting Data contents

80 1 0 0 0 0 0 0 0 128 Command

5F 0 1 0 1 1 1 1 1 95 ID No.



03 0 0 0 0 0 0 1 1 3 Pallet No.

04 0 0 0 0 0 1 0 0 4th layer Number of layers


Stacking pattern




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

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content

82 1 0 0 0 0 0 1 0 Conveyor reset command

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

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


83 1 0 0 0 0 0 1 1 Conveyor zero reset command

03 0 0 0 0 0 0 1 1 Station conveyor no. Example: Conveyor No. 3

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

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


84 1 0 0 0 0 1 0 0 Counter setting command

06 0 0 0 0 0 1 1 0 ID No.

*1 *1

*3

UL(12)

3-20

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

48 0 1 0 0 1 0 0 0 Layer data (Using D0~D5 bit). Example: Layer 8

49 0 1 0 0 1 0 0 1 Quantity data (Using D0~D5 bit). Example: 9 pieces

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

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

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

Quantity data = Quantity counter value (displayed value) –1 *3: IDNo is set only when [Ext PLC Control Interface] is set to [X/Y].

Program No is set instead when set to [M+D]. (See item2.5) 42 0 1 0 0 0 0 1 0 Program No. high order 6 bits


69 0 1 1 0 1 0 0 1

Prg9001


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


85 1 0 0 0 0 1 0 1 Counter setting command

50 0 1 0 1 0 0 0 0 Data 1. Bits D0~D5 indicate conveyors 1~6. Example: 5

48 0 1 0 0 1 0 0 0 Data 2. Bits D0~D5 indicate conveyors 1~7. Example: 10

42 0 1 0 0 0 0 1 0 Data 3. Bits D0~D4 indicates conveyors 13~16. Example: 14

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

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


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

03 0 0 0 0 0 0 1 1 Use bits D0~D2 for pallet. Example: Pallet No. 3

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

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


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

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




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

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

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

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

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

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

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


89 1 0 0 0 1 0 0 1 Data memory output command

41 0 1 0 0 0 0 0 1 Data memory No. data higher-order 6 bits

43 0 1 0 0 0 0 1 1 Data memory No. data lower-order 6 bits

40 0 1 0 0 0 0 0 0 Data memory 1 is indicated with the 6 bits of D12~D17



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

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

Units are mm.


8C 1 0 0 0 1 1 0 0 Command for product dimension data output

127 0 1 1 1 1 1 1 1 ID No. Example: ID No. 127 （*3）

44 0 1 0 0 0 1 0 0 Product length data higher-order 6 bits, Length 300mm=12C

6C 0 1 1 0 1 1 0 0 Product length data lower-order 6 bits

43 0 1 0 0 0 0 1 1 Product width data higher-order 6 bits, Width 250mm=FA

7A 0 1 1 1 1 0 1 0 Product width data lower-order 6 bits

43 0 1 0 0 0 0 1 1 Product height data higher-order 6 bits, Height 200mm =C8

48 0 1 0 0 1 0 0 0 Product height data lower-order 6 bits

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

*3: IDNo is set only when [Ext PLC Control Interface] is set to [X/Y].

Program No is set instead when set to [M+D]. (See item2.5) 42 0 1 0 0 0 0 1 0 Program No. high order 6 bits


69 0 1 1 0 1 0 0 1

Prg9001


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


87 1 0 0 0 0 1 1 1 Error output command

01 0 0 0 0 0 0 0 1 Error No. (7F in the case of "0") Subcode 1

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

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

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


8A 1 0 0 0 0 1 1 0 Command for no program to ID.

06 0 0 0 0 0 1 1 0 ID No.

41 0 1 0 0 0 0 0 1 Program No. data higher-order 6 bits

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3-23

43 0 1 0 0 0 0 1 1 Program No. data lower-order 6 bits

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

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

* This command is disable when [Ext PLC Control Interface] is set to [M+D].

(See item2.5)

3.7.12. Response of writing request to data memory

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content 8B 1 0 0 0 1 0 1 1 Response command is “8B” 41 0 1 0 0 0 0 0 1 Actual written data word numbers（example. 1）40 0 1 0 0 0 0 0 0 Result 0 0 0 0 0 0 0 0 0 NULL

Result: 0 (40H) Processing ended correctly.

1 (41H) Address range over. 2 (42H) Format is abnormal. The error whose number of words is out of range is included.

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

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3.8. Details of PLC → Robot Data The following types of data are sent from the PLC to the robot.

1. PLC error code 2. Pattern data request from conveyor 3. Count setting from conveyor 4. Pattern data request for pallet No. 5. Allocation of PRG No. for ID No. 6. Stacking height setting 7. Request for robot overall time, automatic operation time 8. Data memory content request 9. Product dimension request

10. Sequence reset request 11. Allocation of PRG No. for ID No. and pattern data request 12. Writing request to Data memory

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


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

2 0 0 0 0 0 0 1 0 Error data No. (1~99)

1 0 0 0 0 0 0 0 1 Error sub No. (7F in the case of "0"), Lower order bits

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

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

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


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

7F 0 1 1 1 1 1 1 1 ID No. (The ID No. can be omitted). Example: ID No. 127

03 0 0 0 0 0 0 1 1 Pallet No. Example: Pallet No. 3 （*3）

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

*3: IDNo is set only when [Ext PLC Control Interface] is set to [X/Y]. Program No is set instead when set to [M+D]. (See item2.5)

42 0 1 0 0 0 0 1 0 Program.No high order 6 bits

4C 0 1 0 0 1 1 0 0 Program.No middle order 6 bits

69 0 1 1 0 1 0 0 1

Prg9001

Program.No low order 6 bits

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


92 1 0 0 1 0 0 1 0 Count setting command from PLC. "82" or "92"

10 0 0 0 1 0 0 0 0 ID No. Example ID No.=16 （*3）

42 0 1 0 0 0 0 1 0 Layer number data (Example: When robot layer counter is "3")

43 0 1 0 0 0 0 1 1 Quantity data (Example: When robot quantity count is "4")

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

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3-26

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

PLC layer number = Robot layer number - 1 layer

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

PLC quantity = Robot quantity - 1 piece


Program No is set instead when set to [M+D]. (See item2.5) 42 0 1 0 0 0 0 1 0 Program.No high order 6 bits


69 0 1 1 0 1 0 0 1

Prg9001 Program.No low order 6 bits

All programs are to be initialized when the first bit (D7 bit) out of the upper 6 bits is ON (“1”).

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


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

04 1 0 0 0 0 1 0 0 Pallet No. Example: Pallet No. 4

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

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


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

06 0 0 0 0 0 1 1 0 ID No. Example: ID No. 6

41 0 1 0 0 0 0 0 1 Higher order 6 bits of program No.

43 0 1 0 0 0 0 1 1 Lower order 6 bits of program No.67 hex in this example

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

After receiving data successfully, robot sends back the following data to PLC. (If program No. is invalid 0x7F will send as program No. data).


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

06 0 0 0 0 0 1 1 0 ID No. Example: ID No. 6

41 0 1 0 0 0 0 0 1 Higher order 6 bits of program No.

43 0 1 0 0 0 0 1 1 Lower order 6 bits of program No. 67 hex in this example

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3-27

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

*1: It works only when [Ext PLC Control Interface] is set to [X/Y]. It won’t work at [M+D]. (See item2.5)

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


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

06 0 0 0 0 0 1 1 0 ID No. Example: ID No. 6 （*3）

41 0 1 0 0 0 0 0 1 Height data, higher order 6 bits

45 0 1 0 0 0 1 0 1 Height data, lower order 6 bits, 69hex in the example

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


Program No is set instead when set to [M+D]. (See item2.5)



69 0 1 1 0 1 0 0 1

Prg9001


3.8.7. Request for robot overall time, automatic operation time Command to request for robot overall time, automatic operation time to robot controller.


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

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

3.8.8. Data memory content request Command to request content of robot controller's corresponding data memory


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

42 0 1 0 0 0 0 1 0 Data memory, higher order 6 bits

43 0 1 0 0 0 0 1 1 Data memory lower order 6 bits

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

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3.8.9. Product dimension request Command to request product dimension of program corresponding robot controller's ID No.


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

02 0 0 0 0 0 0 1 0 ID No. （*3）

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

*3: IDNo is set only when [Ext PLC Control Interface] is set to [X/Y]. Program No is set instead when set to [M+D]. (See item2.5)



69 0 1 1 0 1 0 0 1

Prg9001


3.8.10. Sequence reset request Command to make robot controller compulsorily sequence reset.


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

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

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3.8.11. Allocation of PRG No. for ID No. and pattern data request Command to make robot controller compulsorily sequence reset.


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

06 0 0 0 0 0 1 1 0 ID No.

41 0 1 0 0 0 0 0 1 Program No. data higher-order 6 bits

43 0 1 0 0 0 0 1 1 Program No. data lower-order 6 bits

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

*1: It works only when [Ext PLC Control Interface] is set to [X/Y].

It won’t work at [M+D]. (See item2.5)

3.8.12. Writing request to Data memory One word is consisted of 16 bits.

HEX D7 D6 D5 D4 D3 D2 D1 D0 Data content 98 1 0 0 1 1 0 0 0 Data memory write command “98” 4F 0 1 0 0 1 1 1 1 Start address high 6bitt （example. D1000） 68 0 1 1 0 1 0 0 0 Start address low 6bit 41 0 1 0 0 0 0 0 1 Data BIT15 to BIT12 （example. 1234H） 48 0 1 0 0 1 0 0 0 Data BIT11 to BIT6 74 0 1 1 1 0 1 0 0 Data BIT5 to BIT0

Some data continues.

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

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4. SETUP

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

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

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

System storing menu ↓ Origin storing [ Operating procedure ] ①With manual operation, move the axis to be stored to the basic position

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

②Press the appropriate axis button to be stored

③Press STORE key

④Current position (pulse) of a stored axis should be within range of 0 - 65535 pulse upon completion of storing in good order

（＊１）In case of "Encoder Battery Voltage Drop", The axis can be specified by the Error

Message Sub No. 1 (Bit 0): D axis 2 (Bit 1): O axis 4 (Bit 2): R axis 8 (Bit 3): T axis

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

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4.2. Standard Storage When the robot is set in the base posture, and standard storage is performed, the

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

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

Axis Base posture How to set to base posture

R

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

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

D

0 degree (horizontal) is taken as the origin.

Move the D-axis and align the match marks on the rotor and lever.

90 degrees (vertical) is taken as the origin.

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

T

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

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

Origin

origin

Right PalmLeft Palm

Auxiliary Palm(Vacuum Assist)

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4.3. How to place the optional stopper 【A1800】

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

(a) When standard mechanical stopper cams are mounted

(b) When standard mechanical stopper cams are removed

Figure 1: Operation range with/without mechanical stopper cams

2. How to remove mechanical stopper cams

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

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

(3) Remove parallel pins.

Be careful with loose stopper cams

as they may move.

(4) Unbolt and take the cams away.

* Remove the other side of cam.

2676 mm 2929 mm

A

Fixing bolt

Standard mechanical stopper cam

Parallel pins

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【A700III】

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

Figure 1: A700III operation range

2. How to place the optional stopper ①A robot is manually moved to the position which can perform attachment of a stopper. Required position : D-axis 0-10degrees(O axis angle is arbitrary) ②A stopper is attached as shown in a figure.

With optional Stopper

1318mm

1900mm

1750mm

Without optional stopper

2300mm

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4.4. How to attach the hand to robot

1. Put on the hand harness (Hand cable) cover to hand. Use only for A1600.

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

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

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

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

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

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

8. Hand attachment is completed.

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4.5. Servo amp replacement To replace a servo amp follow the instruction below. For more easy replacement, take the whole servo amp Box out from the controller and replace the servo amp. < Procedure to replace servo amp >

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

Note For R,D,O Axis, servo board and IPM(Intelligent Power Module) can be replaced separately. For T Axis,(C Axis option), IPM is connected to the board by solder, so IPM cannot be replaced separately In case of replacing IPM, seal the thermal compound between heat sink and IPM module, so that to minimize the heat resistance between them.

thermal compound 0.5 g

Recommended thermal compound

Type Maker G746 Shin-Etsu Chemical SC102 Dow Corning Toray Silicone YG6260 GE Toshiba Silicones

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

A1600III, A1800 No. Name Model Qty. Area used 1 Switching regulator ZWQ80-5225 1 Controller (AVR1) 2 Switching regulator ZWS100AF-24/J 1 Controller (AVR2) 3 Servo Amp 1 Controller 4 Electromagnetic

switch SC-N2/G 1 Controller (MC1,2)

5 Electromagnetic switch

SC-N1/G 1 Controller (MC3)

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

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

A700III No. Name Model Qty. Area used 1 Switching regulator ZWQ80-5225 1 Controller (AVR1) 2 Switching regulator ZWS100AF-24/J 1 Controller (AVR2) 3 Servo Amp 1 Controller 4 Electromagnetic

switch SC-N1/G 1 Controller (MC1,2)

5 Electromagnetic switch

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

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

ER6K-#17-4 1 Controller (CPU board)

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

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

Eyes: Immediately flush with water for at least 15 minutes. Get medical attention if eye irritation persists. Skin: Remove excess with cloth or paper and wash area thoroughly with soap and water. Inhalation: Keep the victim warm and quiet. Remove the victim from the contamination immediately to fresh air.

11 (2009.01.28)

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5. PC Boards

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5-2

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

RC133 I/O Board

RC133 I/O Board

RC105 Servo Power Supply Board

RC106 Safety Relay Board

RC101 Main CPU Board

RC103 Servo CPU Board

RC107 (RC104)*

Current Board Motor

Motor

Motor

Motor

R axis

D axis

O axis

T axis

Touch Panel PLC OXPA

Teaching Pendant

RC107 (RC104)*

Current Board

RC107 (RC104)*

Current Board

RC108 (RC110)*

Current Board

Hand

*(In case of A700III)

option

COM-C-xxx RC111

（Fieldbus Board）

How to choose I/O board combination is described later on.

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How to choose I/O board combination There are several possible I/O-board combinations from A thru E available. The default # of I/O is two RC102 board mounted only. (*1)The setting of“External PLC control interface”is disable when memory SW1-5 is off. 【Additions】

Field bus can be used for other than the purpose of “External PLC control interface”like the cases of (B) or(D).(Examples: for interfacing with other control blocks)

I/O board setting

Required

boards

Memory SW1-5

ON: Controlled by ext PLC

OFF: Controlled by int PLC

Ext PLC Com Setup：

Field bus com

Ext PLC Com Setup：

Ext PLC controlled

Interface

A ①RC133

②RC133

OFF None （*1）

B ①RC133

②RC133

③RC111

④COM-CA-xxx

OFF selected （*1）

C ①RC133

②RC133

ON None X/Y

D ①RC133

②RC133

③RC111

④COM-CA-xxx

ON selected X/Y

E ①RC133

②RC111

③COM-CA-xxx

ON selected M+D

Ext

PLC

Int

PLC

C/V

controlled

by? No

Yes

No

Yes

X/Y

M+D

Ext PLC

controlled

interface

Field

bus in

use？

Field

bus in

use？

START

Prg selected by?

M+D area linked with

field bus in use for

the interface.

X/Y area of 2-RC133s in

use for interface

between robot & Ext PLC.

See item「7.2.2」「7.3.3」

See item「7.2.2」「7.3.3」

See item「7.2.1-1」「7.3.2-1」

See item「7.2.1-1」「7.3.2-1」

See item「7.2.1-1」「7.3.2-1」

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

LED Explanation

LED No. Lighting condition LED1 - 6 Not use LED7 5 V is supplied LED8 An error occurs LED9 Battery voltage drops

Switch Explanation

Switch No. Explanation S1 CPU reset switch

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

DSW1

7SEG1

LED7 LED8 LED9

S1

CF slot

LED1

LED2

LED3

LED4

LED5

LED6

JP4

JP2 JP3

JP1

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Jumper Explanation

JP. Explanation Normal setting JP1 CPU configuration setting 3-10 short JP2 Setting for using CPU debugger Open JP3 CPU configuration setting Open JP4 Reserved ：Short (do not change) short

DIP switch DSW1 Explanation

No. Explanation Normal setting １ RISC program down load execute OFF ２ Debugger use OFF ３ No use OFF ４ No use OFF ５ Motor rotation test mode OFF ６ No use OFF ７ DSP program down load execute ON ８ All memory clear OFF

7-segment Display Explanation

No. Explanation Dot Display １ TLB Miss／Invalid TLB ON：Read OFF：Write ２ Initial page write exception ３ TLB Protection exception ON：Read OFF：Write ４ CPU address error ON：Read OFF：Write ５ Unconditional trap ６ Reserved instruction exception ７ Illegal Slot Instruction ８ DMA address error ９ User break point exception

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5.2. I／O Board（RC133） The arrangement of LED's and Jumper on the I/O board is as follows. CN８ Jumper Explanation

JP. Explanation Ordinary setting JP1 JP2

Board Address Select 1st: JP1 short, JP2 open 2nd: JP1 open, JP2 short

JP3 No use (Please do not short.) Open JP4 Reserved ：1‐2 Short (do not change) 1-2 short

ＴＢ４

CN９

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

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

JP4

JP3

JP2

JP1

CN1

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CN7 CN８ CN11

CN10

CN4

CN12

CN6

CN5

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LED Explanation Input relay

Relay No. Relay No. Relay No. Relay No. D No. 1st

board 2nd

board D No. 1st

board 2nd

board D No. 1st

board 2nd

board D No. 1st

board 2nd

board 0 X00 X28 10 X0A X32 20 X14 X3C 30 X1E X46 1 X01 X29 11 X0B X33 21 X15 X3D 31 X1F X47 2 X02 X2A 12 X0C X34 22 X16 X3E 32 X20 X48 3 X03 X2B 13 X0D X35 23 X17 X3F 33 X21 X49 4 X04 X2C 14 X0E X36 24 X18 X40 34 X22 X4A 5 X05 X2D 15 X0F X37 25 X19 X41 35 X23 X4B 6 X06 X2E 16 X10 X38 26 X1A X42 36 X24 X4C 7 X07 X2F 17 X11 X39 27 X1B X43 37 X25 X4D 8 X08 X30 18 X12 X3A 28 X1C X44 38 X26 X4E 9 X09 X31

19 X13 X3B

29 X1D X45

39 X27 X4F Output relay

Relay No. Relay No. Relay No. Relay No. D No. 1st

board 2nd

board D No. 1st

board 2nd

board D No. 1st

board 2nd

board D No. 1st

board 2nd

board 50 Y00 Y20 58 Y08 Y28 66 Y10 Y30 74 Y18 Y38 51 Y01 Y21 59 Y09 Y29 67 Y11 Y31 75 Y19 Y39 52 Y02 Y22 60 Y0A Y2A 68 Y12 Y32 76 Y1A Y3A 53 Y03 Y23 61 Y0B Y2B 69 Y13 Y33 77 Y1B Y3B 54 Y04 Y24 62 Y0C Y2C 70 Y14 Y34 78 Y1C Y3C 55 Y05 Y25 63 Y0D Y2D 71 Y15 Y35 79 Y1D Y3D 56 Y06 Y26 64 Y0E Y2E 72 Y16 Y36 80 Y1E Y3E 57 Y07 Y27

65 Y0F Y2F

73 Y17 Y37

81 Y1F Y3F

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

LED Explanation

D No. Lighting condition

D1 During sub DSP operation(D,O axis) * D2 During sub DSP operation(R,T axis) * D3 During sub DSP operation(C axis) * D4 Motor power is ON D5 Watchdog error occurs D6 During main DSP operation *

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

DIP switch U3 Explanation

No. Explanation Ordinary setting

1 No use OFF 2 No use OFF 3 No use OFF 4 No use OFF 5 No use OFF 6 No use OFF 7 No use OFF 8 No use OFF

JP1

U3

D1 D2 D3 D4 D5

D6

JP5

JP2 JP3 JP6

JP11

JP4

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Jumper Explanation

JP. Explanation Normal setting JP1 1-2 short JP2 1-2 short JP3 1-2 short JP4 All open JP5 All open JP6 1-2 short

JP11

Reserved (do not change)

1-2 short 3-4 open 5-6 short 7-8 short 9-10 open

11-12 short 13-14 open 15-16 open 17-18 short 19-20 short 21-22 short 23-24 short

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

No. Lighting Lights out

D30 Motor brake open signal ON OFF

D31 Motor power ON OFF

D32 Emergency stop OFF ON

D33 Regenerative resistance temperature

normal abnormal

Motor power OFF abnormal normal D34 Servo power voltage

Motor power ON normal overvoltege

D35 Servo power voltage drop normal

D37 Magnet switch ON enable unable

D38 Operation mode manual mode automatic mode

D39 Abnormal reset PB ON OFF

D40 Teaching pendant(remote box) connection Non-connection

D41 Motor power switch ON or middle position

OFF

D43 Primary power voltage normal drop

ＣＮ４

ＣＮ５

ＣＮ３

D35 D34

JP2

D39 D36 D42

D40 D38 D43

D41 D37 D33

D31

D29

D32

D30

JP3

JP1

JP6

TSW3

JP5

TSW2

JP4

TSW1

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Jumper Explanation

№ Explanation Ordinary setting

JP1 Please do not touch. 1-2 short

JP2 Please do not touch. Open

JP3 Please do not touch. Open

JP4 Short when you use the brake release(R, T and C axis) switch of RC105

Open

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

Open

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

Open

Toggle switch Explanation


TSW1 For R, T and C axis brake release OFF

TSW2 For D axis brake release OFF

TSW3 For O axis brake release OFF

※It is invalid in the UL type

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


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

Open

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

Open

JP3 Short when “Safety Fence Signal” disable JP4 Short when “Unauthorized Access-detect Signal” disable JP5 Short when “Safety Fence Signal” disable JP6 Short when “Unauthorized Access-detect Signal” disable

Depend on the system

JP7 Short when “Key Switch” disable (Teaching pendant) Open JP8 Short when “Enable Switch” disable (Teaching pendant) open JP9 Short when “Enable Switch” disable (Teaching pendant) Open JP10 Short when “Key Switch” disable (Operation Panel, Teach

mode only) Short

・ When safety fence switch is connected with safety circuit,

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

JP4 and JP6 are opened.

ＣＮ４ＣＮ３ＣＮ５

ＣＮ６

ＣＮ１

ＣＮ７

ＣＮ２

LD24

LD16 LD14 LD22 LD20

LD15 LD23 LD21

LD10 LD12 LD13

LD3 LD2 LD1 LD6 LD5 LD4 LD8 LD7

LD9

JP5 JP6

JP9

JP10

JP2 JP1

JP8

JP7

JP3 JP4

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LED Explanation

No. Lighting condition LD1 Emergency stop signal is OFF LD2 Emergency stop signal is OFF LD3 Abnormal reset PB is ON LD4 Safety fence is closed LD5 Safety fence is closed LD6 Abnormal reset PB is ON LD7 Unauthorized access-detect signal is OFF LD8 Unauthorized access-detect signal is OFF LD9 Abnormal reset PB is ON LD10 Magnet switch ON enable is ON LD12 Magnet switch ON enable is ON LD13 Motor power enable is ON LD14 Soft charge ON enable is ON LD15 Motor power is ON LD16 Motor power is OFF LD20 No use LD21 No use LD22 No use LD23 No use LD24 Main power is supplied

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5.6. Fieldbus converter board (RC111) Jumper pins are set as follows.

Descriptions of jumper pins

Signs Descriptions

JP1 Close

JP2 Open

The board connects RC101 with fieldbus board (COM-CA-XXX) to convert data.

(1) It connects RC111 (CN2) with RC101 (CN2/CN4). (2) It connects RC111 (CN1) with COM-C board.

(3) [CN3] (Dsub9pin male) is of RS232C serial port to connect with a computer. It is not for CC-Ling but for maintenance of COM-CA-XXX board.

CN

3

JP2 JP1

CN

1

CN

2

RC101-X

Power

CF

↓Dip switch

7 seg↑

RC111

← CN2/CN4

COM-CA-XXX Link cable

Link cable

[Important] On and after RC101-4 board is to be used for the application.

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5.7. Fieldbus board CC-Link (COM-CA-CCS) LEDs and switches are located on CC-Link board as follows. １．Switches

①Switch for bus address (10x) ：１～６４ ②Switch for bus address (1x) ③Baud rate ：０～４

２．Connectors

①DA ：Data A ②DB ：Data B ③DG ：Data Ground ④FG ：Function Ground ⑤SLD ：Shield

３．Descriptions of LEDs ①SYS－LED Color

State Frequency rate Meaning

Yellow Flashing cyclic

Slowly at 1Hz rate

DEVICE is in boot loader mode and is waiting for firmware download.

Yellow Flashing cyclic

Fast at 5Hz rate Firmware download in progress

Yellow Flashing acyclic

3 times fast at 5Hz rate,8 times between 0,5Hz and 1Hz

Hardware or heavy runtime error detected, DEVICE or firmware needs replacement.

Green

Flashing cyclic

Fast at 5Hz rate

No error in configuration found, DEVICE is on-line and ready for fieldbus communication and tries to connect, but is not connected to any fieldbus device

Green

Flashing acyclic

3 times fast at 5Hz rate, 8 times between 0,5Hz and 1Hz

Power Up: Configuration missing and DEVICE needs commissioning Runtime: Firmware has found a critical link problem. like HOST-Watchdog timeout

Green

Static on DEVICE has established at least one configured fieldbus connection.

Off DEVICE has no power

Baud rate 0: 156kbps 1: 625kbps 2: 2.5Mbps（Default） 3: 5Mbps 4: 10Mbps

Connector

Switch

3 2 1LED

←SYS ←COM 5 4 3 2 1

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②COM－LED Color

State Frequency rate Meaning

Red Static on CRC error detected or station red address not valid or baud rate not valid of value 0 .. 4

Red Flashing cyclic

2.5Hz rate Station or baud rate was changed since the last reset

Yellow Static on Slave in cyclic data exchange with CC-Link Master

Off No Communication

5.8. Fieldbus board Ethernet/IP (COM-CA-EIS) See [Okura Robot Palletizer Fieldbus Installation(Ethernet/IP)] for detail.

5.9. Fieldbus board Profibus-DP (COM-CA-DSP) See [Okura Robot Palletizer Fieldbus Installation(Profibus-DP)] for detail.

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

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6.1. Servo-Amplifier Receipt Box Composition The servo-amplifier receipt box composition is as follows. It is possible to remove the servo-amplifier receipt box from a robot controller. ＜In the case of A1600III＞

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

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

A1600III A700III Servo-Amplifier Board

Name IPM Form Board

Name IPM Form

R-Axis RC107 6MBP200RA060 RC104 6MBP100RA060-05

D-Axis RC107 6MBP200RA060 RC104 6MBP100RA060-05

O-Axis RC107 6MBP200RA060 RC104 6MBP100RA060-05

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

Board Size([mm])

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

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

RC107

160

140 RC104

220

121

180

110 RC108 RC110

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

Inputs and outputs vary upon the type of I/O board configuration to be used. Refer to I/O board selection guide at [5. PC Boards] for system pattern of I/O board.

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

Symbol Classification Type Indication PointsStart

numberEnd

number Power ON

X Input (*1) Hex 120 0 77h

Y Output (*1) " 96 0 5Fh Off

M User (*2) Universal " 2048 0 7FFhM0-6FF: OFF Others hold

M System１ Fixed " 80 5000h 504Fh Hold

M System２ " " 1280 6000h 64FFh "

M Supervisor " " 32 7000h 701Fh "

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

Others hold

D System１ Fixed " 16 5000 5015 Hold

D System２ " " 128 6000 6127 "

D Supervisor " " 16 7000 7015 "

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

chapter.) （*2）User area of “D”and”M” is a domain which can be treated universally by the user.

However, on the following conditions, it becomes system reservation(Fixed). No The conditions of system reservation Points Reservation range

93 D2590 ～ D2682 1 Memory SW 4-6 is ON (Usually, OFF) 72 M07B0 ～ M07F7

2 "BCR" is set as Serial-communication. 57 D2683 ～ D2739 3 “PLC”or ”FBUS" is set as

Serial-communication. 50 D2740 ～ D2789

4 Memory SW 1-5 is OFF 10 D2790 ～ D2799 5 “POD�DM” transmission is set up. (10) D2800 ～ D2899 6 “DM�POD“ transmission is set up. (10) D2900 ～ D2999

※As for No5.6, ten points are reserved by the default.

The setup of a maximum of 100 points is possible. The reservation range changes with a setup.

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

7.2.1. Memory switch 1-5 ON

When External PLC is in use, [Ext PLC Control Interface] needs to be set as follows. (See item 2.5) Ext PLC Control Interface]

Requirements System examples

Set to [X/Y] RC133 x 2 Robot can work with fieldbus while PLC can’t work with it.

Set to [M+D] RC133 (for hand I/O control) RC111 + COM-CA-XXX

PLC can work with fieldbus which robot can work with.

1. When [Ext PLC Control Interface] is set to [X/Y] It interfaces via I/O board (RC133).

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

I/O board

RC133

External PLC

Hand

Quantity of Input:76

Quantity of Output:60

Motor

Electromagnetic valve

Mechanical switch

Optical switch

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External I/O signals are classified as following:

Quantity No. Type Explanation

Input Output Connection

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

24 37 I/O board in controller (RC133) *1

2 Universal I/O

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


3 Hand I/O

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

4 4 Connector on robot T-Axis frame CN33 *2

4 Emergency For emergency stop and a person's safety

3 0 See 7.4 Emergency

*1 The arrangement of I/O board(RC133) is printed in this manual”5.2. I/O Board(RC133)” *2 The arrangement of Connector on robot T-Axis frame（CN33）is printed in this

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

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

2. When [Ext PLC Control Interface] is set to [M+D] It interfaces on common memories of [M] and [D].

Memory Link Input: 126bit+16Word

Output: 126bit+16Word


External PLC

Hand

Motor


Mechanical switch

Optical switch

Fieldbus Board

with RC111

I/O board RC133

RC101

Danger Enforcement

Never ever send any signal associated with causing a hazardous situation should it failed to control by communication trouble.

12 (2009.11.30)

UL(12)

7-5






2 Universal I/O



3 Hand I/O








*4 Fixed I/O

X1F Limit switch Limit switch

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

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

12 (2009.11.30)

UL(12)

7-6

7.2.2. Memory switch 1-5 OFF






2 Universal I/O



3 Hand I/O








I/O board

RC133

Internal PLC

Hand


Quantity of Input:76

Quantity ofOutput:60

Motor


Mechanical switch

Optical switch

12 (2009.11.30)

UL(12)

7-7

7.3. I/O board The external I/O signal lines is connected by the I/O board(TB1,TB2,and,TB3 on the RC133). The hand I/O signals are connected by CN1 on the RC133.

Figure. I/O board (RC133)

TB4

Terminal odd No. are connected with each other.（P24） Terminal even No. are connected with each other.（N24） Please use for common and etc.

CN5 CN10 CN9

TB4

12 (2009.11.30)

CN7 CN8

CN1

CN11

CN12

CN4 CN6

UL(12)

7-8

7.3.1. Internal PLC relay

CN4 CN5 CN6

＊ N24 are connected in the substrate. ＊ After RC102-3, P24 are not ＊ short-circuited in the substrate.

Before RC102-2, P24 are short-circuited in the substrate. ＊ : The usage is allocated, when memory switch 1-5 is ON.

No. 1st

board No.

2nd board

１Ｘ００１Ｘ２８

２Ｘ０１２Ｘ２９

３Ｘ０２３Ｘ２A

４Ｘ０３４Ｘ２B

５Ｘ０４５Ｘ２C

６Ｘ０５６Ｘ２D

７Ｘ０６７Ｘ２E

８Ｘ０７８Ｘ２F

No. 1st

board No.

2nd board

１Ｘ０８１Ｘ３０

２Ｘ０９２Ｘ３１

３Ｘ０A ３Ｘ３２

４Ｘ０B ４Ｘ３３

５Ｘ０C ５Ｘ３４

６Ｘ０D ６Ｘ３５

７Ｘ０E ７Ｘ３６

８Ｘ０F ８Ｘ３７

No. 1st

board No.

2nd board

１Ｘ１０１Ｘ３８

２Ｘ１１２Ｘ３９

３Ｘ１２３Ｘ３A

４Ｘ１３４Ｘ３B

５Ｘ１４５Ｘ３C

６Ｘ１５６Ｘ３D

７Ｘ１６７Ｘ３E

８Ｘ１７８Ｘ３F

N N

N N

N N

12 (2009.11.30)

UL(12)

7-9

CN7 CN9

＊ N24 are connected in the substrate. ＊ After RC102-3, P24 are not ＊ short-circuited in the substrate.

Before RC102-2, P24 are short-circuited in the substrate. ＊ : The usage is allocated, when memory switch 1-5 is ON.

No. 1st

board No.

2nd board

１Ｘ１８１Ｘ４０

２Ｘ１９２Ｘ４１

３Ｘ１A ３Ｘ４２

４Ｘ１B ４Ｘ４３

５Ｘ１C ５Ｘ４４

６Ｘ１D ６Ｘ４５

７Ｘ１E ７Ｘ４６

８Ｘ１F ８Ｘ４７

No. 1st

board No.

2nd board

１Ｘ２０１Ｘ４８

２Ｘ２１２Ｘ４９

３Ｘ２２３Ｘ４A

４Ｘ２３４Ｘ４B

５Ｘ２４５Ｘ４C

６Ｘ２５６Ｘ４D

７Ｘ２６７Ｘ４E

８Ｘ２７８Ｘ４F

N N

N N

12 (2009.11.30)

UL(12)

7-10

CN11

CN12

CN8

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

No.

1st board

No.

2nd board

１Ｙ００１Ｙ２０

２Ｙ０１２Ｙ２１

３Ｙ０２３Ｙ２２

４Ｙ０３４Ｙ２３

５Ｙ０４５Ｙ２４

６Ｙ０５６Ｙ２５

７Ｙ０６７Ｙ２６

８Ｙ０７８Ｙ２７

No.

1st board

No.

2nd board

１Ｙ０８１Ｙ２８

２Ｙ０９２Ｙ２９

３Ｙ０A ３Ｙ２A

４Ｙ０B ４Ｙ２B

５Ｙ０C ５Ｙ２C

６Ｙ０D ６Ｙ２D

７Ｙ０E ７Ｙ２E

８Ｙ０F ８Ｙ２F

No.

1st board

No.

2nd board

１Ｙ１０１Ｙ３０

２Ｙ１１２Ｙ３１

３Ｙ１２３Ｙ３２

４Ｙ１３４Ｙ３３

５Ｙ１４５Ｙ３４

６Ｙ１５６Ｙ３５

７Ｙ１６７Ｙ３６

８Ｙ１７８Ｙ３７

P P

P P

P P

12 (2009.11.30)

12 (2009.11.30)

UL(12)

7-11

CN10

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

Figure. Input circuit Figure. Output circuit

No.

1st board

No.

2nd board

１Ｙ１８１Ｙ３８

２Ｙ１９２Ｙ３９

３Ｙ１A ３Ｙ３A

４Ｙ１B ４Ｙ３B

５Ｙ１C ５Ｙ３C

６Ｙ１D ６Ｙ３D

７Ｙ１E ７Ｙ３E

８Ｙ１F ８Ｙ３F

Input current ７mA

P24

3.3K

IN

LED

4.7K

7.2K

3K

２４V １００mA Output On max. voltage １．１Ｖ

P24

OUT

N24

P P

UL(12)

7-12

ＣＮ１

No. 1st board

No. 2nd

board

１Ｐ２４１Ｐ２４

2 Ｐ２４ 2 Ｐ２４

3 Ｐ２４ 3 Ｐ２４

4 Ｘ２４※ 4 Ｘ４Ｃ

5 Ｘ２５※ 5 Ｘ４Ｄ

6 Ｘ２６※ 6 Ｘ４Ｅ

7 Ｘ２７※ 7 Ｘ４Ｆ

8 Ｙ１Ｃ※ 8 Ｙ３Ｃ

9 Ｙ１Ｄ※ 9 Ｙ３Ｄ

１０Ｙ１Ｅ※ １０Ｙ３Ｅ

１１Ｙ１Ｆ※ １１Ｙ３Ｆ

１２Ｎ２４１２Ｎ２４

１３Ｎ２４１３Ｎ２４

１４Ｎ２４１４Ｎ２４ *:Signals are connected to CN33 in T-axis connector box.(See.7.4.I/O signals for

Hand) -If CN1 is in use, An attachment is needed for connecting.(CN1 is not terminal box.) N24, P24 are connected with TB4 in the substrate.（ODD No.:P24、 EVN No.:N24） The pin array of CN1 is as follows:

1 2

13 14

A

B

C

D

UL(12)

7-13

7.3.2. I/O signals (Fixed and Universal when memory switch 1-5 ON)

1. When [Ext PLC Control Interface] is set to 「X/Y」 It explains the data communication of PLC and the robot when external PLC is used (About the process of the PLC side). 1. Motor power ON enable signal

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

2. Start key signal

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

3. Start of program

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

4. Partial discharge

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

5. Product type setting

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

6. Stacking count value change

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

7. Sequence reset

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

8. Zero reset

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

UL(12)

7-14

9. Conveyor reset

When conveyor reset is done on controller, conveyor reset command is sent by centronics communication. (only when centronics communication is selected)

10. Conveyor manual operation

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

11. Abnormality of PLC

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

UL(12)

7-15

Output signals

Type Relay Name

At communicati

on

Description

Y00 (Station loading enable 1)

Rdat0


Rdat1


Rdat2

Universal


Rdat3

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

Y04 (Stacking complete 1) Rdat4 Y05 (Stacking complete 2) Rdat5 Y06 (Stacking complete 3) Rdat6

Y07 (Stacking complete 4) Rdat7

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

Y08 Station ON 1

Y09 Station ON 2

Y0A Station ON 3

Y0B Station ON 4

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

Y0C Internal operation

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

Y0D Discharge start strobe

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

Y0E Forward-Up-Open manual strobe

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

Fixed

Y0F Reverse-Down-Close manual strobe

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

Fixed

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

UL(12)

7-16

Type Relay Name

At communicati

on

Description

Y11 RStb

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

Y12 Rbsy

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

Y13 Rack

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

Y14 R Area 20

Y15 R Area 21

Fixed

Y16 R Area 22

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

Y17 Spare Y18 Spare Y19 Spare Y1A Spare

Universal

Y1B Spare

Y20 Robot Abnormality

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

Y21 Automatic mode

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

Y22 Discharge in progress

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

Y23 Pallet No. 20

Y24 Pallet No. 21

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

Y25 Stop buzzer

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

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

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

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

Y29 Abnormal reset push button

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

Fixed

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

UL(12)

7-17

Type Relay Name

At communicati

on

Description

Y2B Motor power ON enable

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

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

Y2D Sequence reset

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

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

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

Y30 (First article 1) Y31 (First article 2) Y32 (First article 3) Y33 (First article 4) Y34 (First article 5)

Y35 (First article 6)

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

Y36 Y37

Universal

Y38 Spare

Y39 Pallet No. 22 See Relay Y03 Y3A Stacking complete 5

Fixed

Y3B Stacking complete 6 See Relay Y04 to Y07

Y3C Y3D Y3E

Universal Y3F

Spare

UL(12)

7-18

Input signals

Type Relay Name

At communicati

on

Description

X00 ID No. Selection 20 X01 ID No. Selection 21 X02 ID No. Selection 22 X03 ID No. Selection 23 X04 ID No. Selection 24 X05 ID No. Selection 25

X06 ID No. Selection 2６

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

X07 ID No. Strobe

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

X08 Number of pallet 20 X09 Number of pallet 21 X0A Number of pallet 22

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

Fixed

X0B Partial discharge strobe

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

X0C (Pallet detection 1) X0D (Pallet detection 2) X0E (Pallet detection 3)

X0F (Pallet detection 4)

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

X10 (Pallet being transferred 1)

Pdat 0


Pdat 1


Pdat 2


Pdat 3

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


Pdat 4


Pdat 5

X16 Spare Pdat 6

X17 Spare Pdat 7

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

X18 X19 X1A

Universal

X1B

Spare

UL(12)

7-19

Type Relay Name

At communicati

on

Description

X1C X1D X1E X1F Limit switch Limit switch

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

Fixed

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

X22

Universal X23

Spare

X28 PMod

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

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

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

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

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

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

X2E Buzzer Sound buzzer

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

Fixed

X30 Motor power on Enable

Close to enable the motor power ON.

X31 X32 X33 X34 X35 X36 X37 X38 X39 X3A X3B X3C X3D

Spare

X3E (Pallet detection 5) X3F (Pallet detection 6)

See Relay X0C to X0F

X40

Universal

X41 Spare

UL(12)

7-20

Type Relay Name

At communicati

on

Description

X42 X43 X44 X45 X46 X47 X48 X49 X4A X4B X4C X4D X4E X4F

UL(12)

7-21

2. When [Ext PLC Control Interface] is set to [M+D] It explains the data communication of PLC and the robot when external PLC is used (About the process of the PLC side). (Note) The memory No of [M] and [D] in this text are in the case when the remote device setting for fieldbus communication at [Ext PLC Communication setting] is set by default. (See item 2.5) 1. Motor power ON enable signal

Turn on the motor power ON enable signal (MB0), on condition that the PLC has no abnormality in internal process and the motor power ON enable signal from robot (M2B) is turned on.

2. Start key signal

Robot controller starts(stops) operation on condition that operation signal (MAD) from PLC is turned on(off). If PLC has no abnormality in internal process and motor power switch is in neutral position(M2E) and operation key signal(M27) is turned on, operation signal(MAD) is turned on, and keep the status even if operation key signal(M27) is turned off. (Unrelated with motor power status) In automatic mode, operation key signal(M27) is not turned on even if start key is pressed on condition that motor power is turned on.

3. Start of program

When [External PLC Control Interface] is set to [M+D], no ID-No but program No is instructed.

PLC sets the required program No to (D1030) to make strobe signal (M87). M87 is normally turned off by station enable (M00 -).


When discharging on controller, requested pallet no. is set for D1015., and discharge start strobe(M0D) is turned on for 500 msec. PLC sets Program No. to discharge in the rising up detection of the device to D1030, and turns on discharge start strobe(M0D). M8B is usually turned off with stacking complete(M04-) from robot.


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


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

7. Sequence reset

Only when memory switch 3-1 is ON, M2D is turned on for 500 msec and first article signals(M30-) are turned off for the number of sheets set by the system parameter.

8. Zero reset

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

UL(12)

7-22

9. Conveyor reset

When conveyor reset is done on controller, conveyor reset command is sent by centronics communication. (only when centronics communication is selected)


When the conveyor(s) is(are) selected, selected data is sent by centronics communication. (only when centronics communication is selected) During “Forward-Up-Open” has been pressed, Forward-Up-Open manual strobe(M0E) is turned on. During “Reverse-Down-Close” has been pressed, Reverse-Down-Close manual strobe(M0F) is turned on.


When PLC occurs or detects abnormality, error command is sent by centronics communication. To sound the buzzer, MAE should be turned on. (Buzzer should be turned off in the rising up detection of stop buzzer(M25)) When error command is sent by centronics communication, it is displayed on the touch panel and memorized in error history. But operation and motor power are not turned off automatically. In accordance with content of error, please handle it on PLC side. (only when centronics communication is selected)

UL(12)

7-23

Output signals(RY) The relay No on the table are the defaulted values at the remote device setting for fieldbus communication. (See item 2.5) Type Relay Name Description

M00 (Station loading enable 1)



Universal


This signal is used to indicate robot incline motion is completed after holding article on station conveyer and ready to next article to come into the station conveyer. In a standard robot sequence program, this signal is turned ON when positioning is completed in step 4 and turned OFF at step 5. On PLC program this signal is used as a trigger to let next article to come into the station conveyer.

M04 (Stacking complete 1) M05 (Stacking complete 2) M06 (Stacking complete 3)

M07 (Stacking complete 4)

This signal is used to indicate stacking is completed. In a standard robot sequence program, this signal is turned ON at step 8 and turned OFF at step 1 when stacking is considered completed. Usually ENCHK command is used to turn this signal in robot sequence program. On PLC program this signal is used as a trigger to discharge pallet.

M08 Station ON 1 M09 Station ON 2 M0A Station ON 3 M0B Station ON 4

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

M0C Internal operation

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

M0D Discharge start strobe

This signal is turned ON when select “pallet discharge” in pallet discharge menu. (for 500msec) At the same time “D0015”output the selected pallet No. data by word data. On PLC program this signal is used as a trigger to output ID No. and pallet discharge strobe(X8B).

M0E Forward-Up-Open manual strobe

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

Fixed

M0F Reverse-Down-Close manual strobe

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

Fixed

M10 Rmod This signal is turned ON while data transfer from robot controller to PLC is executed. Data transfer start timing is as follows

Fixed

M11 Rstb

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

UL(12)

7-24

Type Relay Name Description

M12 Rbsy

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

M13 Rack

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

M14 M15 M16 M17 M18 M19 M1A M1B M1C M1D M1E

Universal

M1F

Spare

M20 Robot Abnormality When abnormality occurs this signal is turned ON. On PLC program turn OFF operation signal (MAD) when receive this signal.

M21 Automatic mode

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

Fixed

M22 Discharge in progress

This signal is turned ON when receiving discharge strobe (M8B). This signal is turned OFF when stacking completed signal turned ON in ENCHK command.

M23 U

M24 Spare Universal

M25 Stop buzzer

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

M26 Motor power on This signal is turned ON when motor power is ON.

M27 Operation key This signal is turned ON while pressing start key. On PLC program, turn and keep ON operation signal (MAD) when receiving this signal.

M28 Stop key This signal is turned OFF while pressing stop key. On PLC program, turn OFF operation signal (MAD) when receiving this signal.

M29 Abnormal reset push button

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

M2A Emergency stop This signal is turned ON when emergency switch is turned ON.

M2B Motor power ON enable

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

M2C Robot independent This signal is turned ON when memory switch 2-4 is set OFF.

M2D Sequence reset

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

Fixed

M2E Control power On This signal is turned ON when motor power switch is in neutral position

UL(12)

7-25


M2F (Basic position) Okura standard usage :This signal is turned ON when Waiting Position for input signal

M30 (First article 1) M31 (First article 2) M32 (First article 3) M33 (First article 4) M34 (First article 5) M35 (First article 6)

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

M36 M37 M38

Universal

M39

Spare

M3A Stacking complete 5 Fix

M3B Stacking complete 6 See Relay M04 to M07

M3C M3D M3E ･･･

･･･ M7C M7D

Spare

M7E Not use

Universal

M7F Not use

Output signals(RWw) The device No on the table are the defaulted values at the remote device setting for fieldbus communication. (See item 2.5) Class Device Signals Descriptions

D1000 D1001 D1002 D1003 D1004 D1005 D1006

Fixed

D1007

Rdat Data communication for Centronics. The upper 8 bits is not in use.

D1008 D1009 D1010 D1011 D1012

Universal

D1013

Spares

D1014 R area

The R area is set in the system parameters to enable robot to know where arm locates. PLC logic needs to be implemented to control for the purpose of the pallet direct on-floor placement.

Fixed

D1015 Discharging pallet No.

Pallet No upon when discharging start strobe is made.

UL(12)

7-26

Input signals Type Relay Name Description

M80 M81 M82 M83 M84 M85

Universal

M86

Spare

Fixed

M87 ID No. Strobe

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

M88 M89

Univ

ersal M8A Spare

Fixed

M8B Partial discharge strobe

Okura standard usage: turn OFF while pallet being discharged. In robot sequence program, stop robot motion in step 4 while this signal is OFF. IN case of multi pallet layout, forbid program selection while this signal in OFF on PLC program.

M8C (Pallet detection 1)

M8D (Pallet detection 2)

M8E (Pallet detection 3)

M8F (Pallet detection 4)

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

M90 (Pallet being transferred 1)






Okura standard usage: turn OFF while pallet being discharged. In robot sequence program, stop robot motion in step 4 while this signal is OFF. IN case of multi pallet layout, forbid program selection while this signal in OFF on PLC program.

M96 M97 M98 M99 M9A M9B M9C M9D M9E M9F MA0 MA1 MA2

Universal

MA3

Spare

UL(12)

7-27


MA8 Pmod

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

MA9 Pstb When this signal is turned ON and Pmod is ON and Rbsy is OFF, robot side receives data and (after data reception) sends Rack to the PLC.

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

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

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

MAD Operation On PLC program, turn and keep ON this signal when receiving M27 signal.

Fixed

MAE Buzzer Sound buzzer

U MAF Spare (Universal)

Fix MB0 Motor power on Enable

Close to enable the motor power ON.

MB1 MB2 MB3 MB4 MB5 MB6 MB7 MB8 MB9 MBA MBB MBC MBD

Spare

MBE (Pallet detection 5) MBF (Pallet detection 6)

See Relay M8C to M8F

MC0 MC1 MC2 MC3 MC4 MC5 MC6 MC7 MC8 MC9 MCA ･･･

･･･ MFC

Universal

MFD

Spare

MFE Not use

MFF Not use

UL(12)

7-28

Input signals(RWr) The device No on the table are the defaulted values at the remote device setting for fieldbus communication. (See item 2.5)

Class Device Signals Descriptions D1016 D1017 D1018 D1019 D1020 D1021 D1022

Fixed

D1023

Pdat For data communication in Centronics

D1024 D1025 D1026 D1027 D1028

Universal

D1029

Spare

D1030 Start program No

This needs to be output as a signal of product-on-station-per-one-hand or as a hold signal of partial discharge. The program is switched over at PGSEL command. The type of strobe decides to execute either program to be set or partial discharge. This signal needs to be output 0.3 second before IDNo strobe (M87) or partial discharge strobe (M88).

Fixed

D1031 On-floor placement pallet

When [On-floor placement pallet] is set in the program parameters, this signal shifts the stacking data upward by (# of pallets x thickness). This data is sucked up when program is selected by PGSEL command. # of pallets is: 0: # of pallets = 1 1: # of pallets = 2 2: # of pallets = 3 Like this order.

UL(12)

7-29

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

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

2. Start key signal

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

3. Start of program

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


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


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


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

7. Sequence reset

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

UL(12)

7-30

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

9. Conveyor reset

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


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


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

UL(12)

7-31

Relay Relay No. Name Ext. PLC mode In ／ Out

M5000 Program No. Strobe X07 In

M5001 Partial discharge strobe X0B In

M5002 Pallet detection １ X0C In

M5003 Pallet detection ２ X0D In

M5004 Pallet detection ３ X0E In

M5005 Pallet detection ４ X0F In

M5006 Pallet detection ５ X3E In

M5007 Pallet detection ６ X3F In

M5008 Pallet being transferred 1 ―― Out

M5009 Pallet being transferred ２ ―― Out

M500A Pallet being transferred ３ ―― Out

M500B Pallet being transferred ４ ―― Out

M500C Pallet being transferred ５ ―― Out

M500D Pallet being transferred ６ ―― Out

M500E External hold X2C In

M500F Stacking complete 1 acknowledge ―― In

M5010 Stacking complete 2 acknowledge ―― In





M5015 Pallet 1 zero reset ―― Out

M5016 Pallet ２ zero reset ―― Out

M5017 Pallet ３ zero reset ―― Out

M5018 Pallet ４ zero reset ―― Out

M5019 Pallet ５ zero reset ―― Out

M501A Pallet ６ zero reset ―― Out

M501B Conveyor reset ―― Out

M501C Pallet １ discharge start strobe ―― Out

M501D Pallet ２ discharge start strobe ―― Out

M501E Pallet ３ discharge start strobe ―― Out

M501F Pallet ４ discharge start strobe ―― Out

M5020 Pallet ５ discharge start strobe ―― Out

M5021 Pallet ６ discharge start strobe ―― Out

M5022 Spare ―― ――

M5023 Buzzer X2E In

M5024 Stop X2F In

M5025 Motor power ON enable X30 In

M5026 Stop buzzer Y25 Out

M5027 Start key Y27 Out

M5028 Hand 4 ―― Out M5029 Hand ５ ―― Out M502A Hand ６ ―― Out M502B Hand ７ ―― Out M502C Hand ８ ―― Out M502D Hand ９ ―― Out

UL(12)

7-32

Relay No. Name Ext. PLC mode In ／ Out M502E Pallet 1 counter setting ―― Out M502F Pallet 2 counter setting ―― Out M5030 Pallet 3 counter setting ―― Out M5031 Pallet 4 counter setting ―― Out M5032 Pallet 5 counter setting ―― Out M5033 Pallet 6 counter setting ―― Out M5034 Pallet 1 program allocating ―― Out M5035 Pallet 2 program allocating ―― Out M5036 Pallet 3 program allocating ―― Out M5037 Pallet 4 program allocating ―― Out M5038 Pallet 5 program allocating ―― Out M5039 Pallet 6 program allocating ―― Out M503A Sequence reset Y2D Out M503B Display is Int. PLC mode ―― Out M503C Stop key Y28 Out M503D Operation X2D Out M503E Motor power ON enable Y2B In M503F Spare ―― ――

Relay No. Name Ext. PLC mode In ／ Out M6000 Operation ―― In M6001 Motor Power ON Y26 Out M6002 Station 1 loading enable Y00 Out M6003 Station 2 loading enable Y01 Out M6004 Station 3 loading enable Y02 Out M6005 Station 4 loading enable Y03 Out M6006 Stacking complete 1 Y04 Out M6007 Stacking complete ２ Y05 Out M6008 Stacking complete ３ Y06 Out M6009 Stacking complete ４ Y07 Out M600A Stacking complete ５ Y3A Out M600B Stacking complete ６ Y3B Out M600C Station ON 1 Y08 Out M600D Station ON 2 Y09 Out M600E Station ON 3 Y0A Out M600F Station ON 4 Y0B Out M6010 Spare ―― ―― M6011 Spare ―― ―― M6012 Internal operation Y0C Out M6013 Spare ―― ―― M6014 Forward-Up-Open manual strobe Y0E Out M6015 Reverse-Down-Close manual strobe Y0F Out M6016 Spare ―― ―― M6017 Robot Abnormality Y20 Out M6018 Automatic mode Y21 Out M6019 Spare ―― ―― M601A Spare ―― ――

UL(12)

7-33

Relay No. Name Ext. PLC mode In ／ Out M601B Spare ―― ―― M601C Spare ―― ―― M601D First article １ Y30 Out M601E First article ２ Y31 Out M601F First article ３ Y32 Out M6020 First article ４ Y33 Out M6021 First article ５ Y34 Out M6022 First article ６ Y35 Out M6023 Spare ―― ―― M6024 Spare ―― ―― M6025 Spare ―― ―― M6026 Spare ―― ―― M6027 Spare ―― ―― M6028 Spare ―― ―― M6029 Spare ―― ―― M602A Emergency stop Y2A Out M602B Abnormal reset push button Y29 Out M602C Spare ―― ―― M602D 0.1 sec clock ―― Out M602E 0.2 sec clock ―― Out M602F 1 sec clock ―― Out M6030 2 sec clock ―― Out M6031 1 min clock ―― Out M6032 AC Power Down detect ―― Out M6033 Battery voltage drop ―― Out M6034 Battery voltage drop (latch) ―― Out M6035 Watch data error ―― Out M6036 Normal PLC execute latch ―― Out M6037 Normal PLC execute flag ―― Out M6038 High speed PLC execute latch ―― Out M6039 High speed PLC execute flag ―― Out M603A Normal PLC scan over ―― Out M603B High speed PLC scan over ―― Out M603C Error ―― Out M603D Error (warning) ―― Out M603E Error (caution) ―― Out M603F Error (notice) ―― Out M6040 Control power On Y2E Out

Relay No. Name Ext. PLC mode In ／ Out M7000 ON ―― Out M7001 OFF ―― Out M7002 Normal PLC automatic start ―― In M7003 High speed PLC automatic start ―― In M7004 Memory initial flag ―― In M7005 Memory clear flag ―― In

UL(12)

7-34

Data memory

Dm No. Name Ext. PLC mode Description D5000 Program NO select X00～X06 D5001 Pallet piece No. X08～X0A 0 when one pallet D5002 AC DOWN Counter ――

Dm No. Name Ext. PLC mode Description D6000 R area Y14～Y16 D6001 Conveyor manual 1/2 Centronics D6002 Conveyor manual 2/2 Centronics D6003 Date (Year、Month)

―― <BCD>U8bit ：

Year(L2digit) L8bit：Month D6004 Date, Time (Day、Hour)

―― <BCD>U8bit：Day L8bit：Time

D6005 Time (Min、Sec) ――

<BCD>U8bit：Min L8bit：Sec

D6006 Normal PLC status ―― 0:stop 1:run 2:error D6007 Normal PLC 1sec counter ―― D6008 Normal PLC max scan time ―― mSec D6009 Normal PLC scan time ―― mSec D6010 Normal PLC minimum scan ―― mSec D6011 High speed PLC status ―― 0:stop 1:run 2:error D6012 High speed PLC 1sec counter ―― D6013 High speed PLC max scan ―― mSec D6014 High speed PLC scan time ―― mSec D6015 High speed PLC minimum scan ―― mSec D6016 Pallet 1 execute Program No ―― D6017 Pallet 1 stack lay No. ―― １～ D6018 Pallet 1 current lay No ―― １～ D6019 Pallet 1 current work No ―― １～ D6020 Pallet 1 work size (L) ―― [mm] D6021 Pallet 1 work size (W) ―― [mm] D6022 Pallet 1 work size (H) ―― [mm] D6023 Pallet 1 number of pallets ―― D6024 Pallet 2 execute Program No ―― D6025 Pallet 2 stack lay No. ―― １～ D6026 Pallet 2 current lay No ―― １～ D6027 Pallet 2 current work No ―― １～ D6028 Pallet 2 work size (L) ―― [mm] D6029 Pallet 2 work size (W) ―― [mm] D6030 Pallet 2 work size (H) ―― [mm] D6031 Pallet 2 number of pallets ―― D6032 Pallet 3 execute Program No ―― D6033 Pallet 3 stack lay No. ―― １～ D6034 Pallet 3 current lay No ―― １～ D6035 Pallet 3 current work No ―― １～ D6036 Pallet 3 work size (L) ―― [mm] D6037 Pallet 3 work size (W) ―― [mm] D6038 Pallet 3 work size (H) ―― [mm] D6039 Pallet 3 number of pallets ――

UL(12)

7-35

Dm No. Name Ext. PLC mode Description D6040 Pallet 4 execute Program No ―― D6041 Pallet 4 stack lay No. ―― １～ D6042 Pallet 4 current lay No ―― １～ D6043 Pallet 4 current work No ―― １～ D6044 Pallet 4 work size (L) ―― [mm] D6045 Pallet 4 work size (W) ―― [mm] D6046 Pallet 4 work size (H) ―― [mm] D6047 Pallet 5 number of pallets ―― D6048 Pallet 5 execute Program No ―― D6049 Pallet 5 stack lay No. ―― １～ D6050 Pallet 5 current lay No. ―― １～ D6051 Pallet 5 current work No ―― １～ D6052 Pallet 5 work size (L) ―― [mm] D6053 Pallet 5 work size (W) ―― [mm] D6054 Pallet 5 work size (H) ―― [mm] D6055 Pallet 6 number of pallets ―― D6056 Pallet 6 execute Program No ―― D6057 Pallet 6 stack lay No. ―― １～ D6058 Pallet 6 current lay No ―― １～ D6059 Pallet 6 current work No ―― １～ D6060 Pallet 6 work size (L) ―― [mm] D6061 Pallet 6 work size (W) ―― [mm] D6062 Pallet 6 work size (H) ―― [mm] D6063 Pallet 6 number of pallets ―― D6064 Stacking pallet No ―― D6065 Current position R ―― X100 [°] D6066 Current position D ―― X100 [°] D6067 Current position O ―― X100 [°] D6068 Current position T ―― X100 [°] D6069 Current position C ―― X100 [°] D6070 Current position AR ―― X100 [°] D6071 Current position AX ―― X10 [mm] D6072 Current position AT ―― X100 [°] D6073 Current position AZ ―― X10 [mm] D6074 Current position AC ―― X10 [mm] D6075 Current position HX ―― X10 [mm] D6076 Current position HY ―― X10 [mm] D6077 Current position HZ ―― X10 [mm] D6078 Current position HT ―― X100 [°] D6079 Current position HC ―― X10 [mm] D6080 Normal PLC execute status ―― D6081 High speed PLC execute status ―― D6082 CPU Idle % ―― D6083 CPU board temperature ―― X100°C D6084 Number of stacking pieces 1 ―― D6085 Number of stacking pieces 2 ―― D6086 Number of stacking pieces 3 ――

UL(12)

7-36

Dm No. Name Ext. PLC mode Description D6087 Number of stacking pieces 4 ―― D6088 Number of stacking pieces 5 ―― D6089 Number of stacking pieces 6 ―― D6090 Stack pattern pallet 1

―― 1:BAR,2:INTRK,3:SPCL,4:RPMD,5:ZSPL

D6091 Stack pattern pallet 2 ―― 1:BAR,2:INTRK,3:SPCL,4

:RPMD,5:ZSPL D6092 Stack pattern pallet 3



:RPMD,5:ZSPL D6094 Stack pattern pallet 5



:RPMD,5:ZSPL D6096 Stop position(1st) St1 ―― D6097 Stop position(2nd) St1 ―― D6098 Centering position St1 ―― D6099 Press height St1 ―― D6100 Stop position(1st) St2 ―― D6101 Stop position(2nd)St2 ―― D6102 Centering position St2 ―― D6103 Press height St2 ―― D6104 Stop position(1st) St3 ―― D6105 Stop position(2nd)St3 ―― D6106 Centering position St3 ―― D6107 Press height St3 ―― D6108 Stop position(1st) St4 ―― D6109 Stop position(2nd)St4 ―― D6110 Centering position St4 ―― D6111 Press height St4 ―― D6112 Hand No. ――

Dm No. Name Ext. PLC mode Description SH Ver.

D6133 POD Screen No. - POD screen No. under display D6134 Current Step No. - Step No. under execution

2.07-

D6135 C-axis Torque - Current C-axis torque 2.07B- D6136 Password1

for maintenance -

D6137 Password2 for maintenance

-

Set in ASCII code. If the password is 1234,

D6136：0x3231 D6137：0x3433

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

2.08D-

10(2008.06.13)

UL(12)

7-37

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

Type Name Description Relay CN33

Spare S3 3

Spare S4 4

Spare S5 13

Universal

Spare CLS

See “1.4.”

14

Hand OPEN SL1O Y1C 5

Hand CLOSE SL1C Y1D 6

Hand OPEN SL2 Y1E 7

Hand OPEN SL3

In manual mode, the keys [1],[2],[3] are used to operate this relay. Standard program uses output relay for this purpose. Y1F

8

Power supply (P24) 9

Hand Reed switch HRS1 X24 10

Hand Reed Switch HRS2

Standard programs uses input relays for this purpose. X25

11

Fixed

Power supply(NP24) 12

Spare S1 X26 1

Universal Spare S2

These are assigned and connected to the input relay of the account of the right. X27

2

Frame ground FG 15

UL(12)

7-38

7.5. Emergency Input signals for safety stop will be connected to 3 terminals in controller as follows, -PLC should notify emergency stop to the robot, when sensor is turned on on condition that memory switch 2-4 is off. -After sensor is turned on, it can return by abnormal release button. If it can not return, turn off the main power supply.



１ Emergency switch*1

For emergency stop 1 0 PES1 and PES2 on the TBR1 (terminal) *2

２ Sensing Safety fence’s door open*1

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

３

Sensing invasion of the dangerous area*1

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

*1: Safety Category 3 (ISO13849-1) *2: Two terminals are ready for the double safety circuit.

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

Figure. The arrangement of the TBR1

Two terminals must be connected as follows,

TBR1

PES1

LS1b

PES2

LS2b

TBR1

TBR1

PDS1

PDS2

P24

PSE1

PSE2

P24

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

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

PSE1 and PSE2

10(2007.9.1)

UL(12)

8-1

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

UL(12)

8-2

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

8.1.1. Move to maintenance menu under operation

Basically maintenance menu is selected only when a robot is stopped. To move to maintenance menu under operation, press the hidden key located below on the auto mode screen. * In the case of returning from maintenance menu, it returns to auto mode screen

instead of main menu screen.

System storage mode

Teaching mode

Maintenance mode

Basic menu

Automatic operation mode

Auto mode screen

Maintenance mode screen

Main menu

：under operation

：during stop

Auto mode screen (under operation)

Hidden key

10 (2006.11.01)

UL(12)

8-3

8.1.2. Two types of maintenance menu

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

ordinary maintenance menu

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

hidden key

special maintenance menu

10 (2006.11.01)

UL(12)

8-4

8.2. Special maintenance menu

8.2.1. Overlap trace

1. Last executed 12 steps overlap trace state at is displayed. * A variable value in the program is displayed.

8.2.2. RISC output data

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

* Last about 20 seconds data can be shown. but, in case a motor power is OFF, data is not automatically updated. So in case a motor power turns off by occurrence of abnormalities, the data of the about 20 seconds before can be shown. ● Press [Write] key to save data to file. ● Press [Read] key to read saved data. * [Write] and [Read] operation cannot be performed under operation. * The data saved to file can be taken in by Oxpa-Qm2, and can be treated as a CSV file. ● Press [Gragh (Pos)] to display the position data by graph. ● Press [Gragh (Spd)] to display the speed data by graph. * Press [Axial change] key to show the graph of a different axis.

UL(12)

8-5

8.2.3. SMOV calculation

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

8.2.4. Operation Trace

1. Last 112 histories of operation by touch-panel can be shown. Display content Date : DD HH:MM Scrn : Base screen No. Sub : Overlap screen No. Key : Operation content Result : Operation content (Detailed code)

8.2.5. PLC & Tie-in Trace

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

UL(12)

8-6

8.2.6. Task Counter

1. The executed situation of every task of a program is monitored. ● Press [Measure Start]. The number of executed times of each task is counted until the“move”task (the highest priority task) adds up 1000 times. * As a result of measurement, in the case of few executed time of a lower ranked task by CPU load, trouble is caused to processing operation of the corresponded task.

8.2.7. Damaged File List

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

8.2.8. Servo Current Setting

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

UL(12)

8-7

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

8.2.9. Servo Torque indicate

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

D/A terminal ch0 : Motor rotation speed D/A terminal ch1 : Desired torque * Select [Test] to output a triangular waveform. * It is outputted only at the time of a motor power injection. In the case of a motor power ON, show after turning off a motor power since data is always updated. ● Press [Save the File] key, last about 10 seconds D/A output data is saved to file. ● Press [Graphic] key, last about 10 seconds D/A output data is displayed by graph. * The data saved to file can be taken in by Oxpa-Qm2, and can be treated as a CSV file. On a graph display screen, * Press [Axial change] key to change the axis to display. * Press [Display change] key to change the data (motor rotation speed or desired torque) to display.

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

UL(12)

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2. Effective Torque

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

8.2.10. Motor Rotation Test

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

UL(12)

Robot manual

Installation and Adjustment

12 Version: 2009.11.30

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

<caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice.

Okura Yusoki Co., Ltd. 900 Furuouchi, Noguchi-cho, Kakogawa,

Hyogo 675-8675 Japan

installation and adjustmentokura.pro.tok2.com/manuals/ul/ul-(5)ins-12(2009-12-05).pdf · 2011. 3....

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