ZC100 Robostar RCI (A) 4 Service Manual-10

ROBOT
RCI(A) Series SERVICE MANUAL
SM-RCM4-E0503
Preface
Thank you for purchasing a Robostar Robot. This assembly robot is the result of Robostar's technology. We are sure that this Robot, with its high performance and functions will be a great assess to your organization. Please read this manual thoroughly before operating the robot so that it can be operated safely and effectively. This Service manual is one of set for the robot.
Type of robot covered in this manual
This manual is designed for following types of robot. Cartesian Robot 1. RBC(D) Series 2. RH Series 3. RS Series 4. All models of Belt-driven type SCARA Robot 1. RSI series 2. RSA Series Desktop Robot 1. RDT-440F Series 2. RDT-340 Series Wafer Handling Robot RWTA Series
Request
Before operating the robot, make sure reading and understanding the section entitled "The Safe Use of Robot" in each User's and Service manual. This section gives you information on the safe operation of the robot.
Caution
Partial or total reproduction of this manual is forbidden without prior permission. The manual is subject to change without prior nitice.
Contents
Chapter 1
The Safe Use of Robot

1-1 1-5 1-7
1.1 Robot Safety in general 1.2 Details of Robot Safety 1.3 How to Treat Cables in Robot
Chapter 2
Overview of Robot
2-1 2-2 2-2 2-6 2-6
2.1 Product Composition 2.2 Robot Composition 2.2.1 Components of Robot System 2.2.2 Name of Each Component in Controller (1) RCM4-Series
2.3 Specification of Robot Controller 2.3.1 Features 2.3.2 Structure of Model Name 2.3.3 General Specification
2-7 2-7 2-8 2-9
2.4 Product Dimension 2.5 Warranty of Product
2-11 2-12
Chapter 3
Installation of Robot Devices

3-1 3-1 3-1 3-1
3.1 Appropriate Environment for Robot Installation 3.1.1 Conditions for Installation Environment 3.1.2 Ambient Temperature and Humidity 3.1.3 Vibration
3.2 Installation of Robot Controller 3.2.1 RCM4-Series
3-2 3-2
C-1
Contents
Chapter 4
Connection & Interface

4-1 4-1 4-1 4-4 4-4 4-18 4-21
4.1 Connection 4.2 RCM4-Series Connection 4.2.1 Robot Controller 4.2.2 Robot Controller Robot Mechanical Part Connection External PLC Connection
4.2.2.1 System I/O Connection 4.2.2.2 User I/O Connection 4.2.2.3 Option I/O Connection
4.3 Checking Input/output Monitoring using Teach Pendant after Connection
4-24
4.4
On-Line Connection
4-29 4-29 4-30
4.4.1 Serial Cable Standard 4.4.2 Serial Cable Connection Diagram
4.5
Cartesian Coordinate Robot Connector
4-31 4-31 4-35
4.5.1 Internal Circuit Diagram 4.5.2 Body Connector Wiring (refer to it when doing wiring job directly)
4.6
Scara Robot Connector
4-36 4-36
4.6.1 Air Piping & Signal Wire
4.7 Caution When Wiring for Non-Robostar Mechanical Part
4-37
C-2
Contents
Chapter 5
Time Chart of System Input/Output Operation

5-1 5-2 5-2 5-3 5-4
5.1 Basic Functions 5.1.1 Time Chart of System Input/Output (1) Time Chart of Normal Operation (2) Example of Operation Panel (3) System I/O Signal Sequence (for reference when programming PLC sequence) (4) When Changing JOB Program while Running (5) In case of Emergency Stop or Alarm while Running (6) In case of Servo Off after STOP while Running
5-6 5-8 5-11
5.2 Highly Sophiscated Functions 5.2.1 Mode Selection (1) Flow Chart of Mode Selection (2) Time Chart of Mode Selection just after Power ON
5-12 5-12 5-12 5-13
5.2.2 Mode Description 5.2.2.1 Auto Run Mode 5.2.2.2 Step Run Mode 5.2.2.3 Jog Mode 5.2.2.4 Host Mode
5-14 5-14 5-15 5-19 5-21
5.2.3 Teach Pendant Display of Each Mode & 7-Segment Display on Front Panel
5-25
Chapter 6
Maintenance and Reparing

6-1 6-2 6-45 6-45 6-46 6-47 6-49
6.1 Indication of Abnormal Condition 6.2 Abnormal Conditions and TroubleShooting (Error Code) 6.3 Quick Maintenance and Reparing Job 6.3.1 Initialization 6.3.2 How to troubleshoot an Error occurred during Origin Setting 6.3.3 Explanation of Z axis Weight Balance (using Air Cylinder) 6.3.4 Troubleshooting for Mechanical Parts of Robot
C-3
Contents
6.3.5 How to Set Proper Gains 6.3.6 How to Modify Offset Value When Changing SCARA Origin Position
6-52 6-53
6.4 Host Package Error
6-58
Chapter 7
Appendices
7-1 7-9 7-10 7-13 7-14 7-15 7-18 7-19 7-21
7.1 System I/O PLC Sequence Program 7.2 SPARE PARTS LIST (Controller) 7.3 SPARE PARTS LIST (Mechanical Part) 7.4 Considerations for Selecting Robot 7.5 Periodic Inspections 7.6 Robot Hand 7.7 Cartesian Coordinate Robot Structure 7.8 Picture of Connectors 7.9 Emergency Circuit Diagram
C-4
Chapter 1
1. The Safe Use of The Product
In order to use this product safely, please read this manual thoroughly before using the product. Each manual carries the following symbols that indicate contents or events where your careful attention is needed for further safe use. So, make sure you use this product with your complete understandings.
Safety Related Symbols

Indicates that severe damage on property or loss of human lives may occur when the product is misused.
Indicates that, if this product is misused, it may cause any troubles,
Indicates banned actions for correct use. For an example, the right hand side symbol indicates ban of fire.
Indicates what should be done so as to use this product properly For an example, the right hand side symbol means that the device are forced to be connected safely to the ground.
Indicates events or contents in which the product may fail to function in normal way or may not run at all due to misuse of it, or a case where your further attention is required.
1-1
Chapter 1
The Safe Use of The Product
This robot is a high-tech industrial devices. To avoid unexpected accidents, please observe the followings.
For safer and more efficient use, please have thorough knowledge of manual before using the product.
Always use the power supply and the load within the rated range.
Make sure the voltage is AC220 before use.
When installing robot, fix it firmly so that it won't be vibrating.
1-2
Chapter 1
To operate safely, set up the safe fence around the robot's arms reach.
Make sure to check wiring connections before turning the power of controller on. If wiring is wrong, the device may not work normally.
To prevent people from the hazards of getting electric shock, make sure Frame Ground (FG) has properly done.
1-3
Chapter 1
When the robot is working or is ready to work, keep always watching and that you should not be near its arms reach. Even if it doesn't work, always be careful.
Especially, at the time of switching the power On/Off and of running motor and of starting motor by manual under a situation of many people working together, check workers' safety matters first prior
to the job.
When checking and repairing the robot, make sure to unplug the controller.
1-4
Chapter 1

Details of Robot Safety
1.2 Details of Robot Safety
1) Wear a helmet and safe shoes for your safety. 2) Before switching the power ON, check if anyone is in the robot's arms reach and then operate robot. 3) When moving into the radius of robot's reach for checks or repairing jobs, you should always switch
the power OFF.

4) If the robot's cable is exposed to the pathway, cover it up or use duct to prevent it from being damaged. 5) If the cable is found as being damaged, immediately replace it. 6) When operating the robot, don't load any weight more than that of allowed. 7) Before operating the robot, be familiar with the user's manual. 8) Relating to installation of safe fence, Make it sufficient enough to resist reactive force or to overcome environmental conditions. Build it in a specific design in order not to easily allow people to move or withdraw it, and to climb over it . Remove any dangerous parts such as sharp edges and burrs, etc. Build it as a shape that can be fixed at the location. In case you build an exit door at the safe fence, install a detector i.e. sensor, so that the robot motions can be stopped at the moment of door opened. Install the safe fence at a distance with over 40cm from the arns or radius of robot's reach.
safety fence
1-5
Chapter 1

Details of Robot Safety
9) Emergency stop switch Install the emergency stop switch at a location where the worker can operate it easily. Paint it red so that one can identify its location easily and tape yellow stripe
around it.
Use the emergency stop switch having non-automatic return function.
EMERGENCY STOP SWITCH
EMERGENCY STOP INPUT (NORMAL CLOSE)
CONTROLLER
10) Grounding Standard Requires Class 3 grounding (Ground Resistance: 100
or below)
11) Warning light of power supply to the robot Install the warning light so that one can check if the power has been supplied to the robot.
HEAD LIGHT
Ready Output
MAX DC24 V Com Controller
CR
AC 200V
1-6
Chapter 1

How to Treat Cables in Robot
1.3 How to Treat Cables in Robot

1 ) Fix the cable in the way of which the particular point should not be bent forcedly.
STEEL BAND
bundle lightly
2) Do not fix the twisted part with cable tie, et
3) Avoid applying excessive tension.
1-7
Chapter 1

4) Do not use the ordinary cable with rotating part.
Use the Curl cable.
5) When fixing the cable, don't tighten it excessively in order to prevent the cable from being pressed.
6) Prevent the cable's surface from being damaged by applying pressure and striking it with force, etc.
1-8
Chapter 1

7) Do not use spiral tube at the part where it practices bending actions repeatedly.
8) The size of cables should be less than 60% of cableveyor's dimensions.
9) When wiring, the power cable should be distinguished from the signal cable.
power cable
duct signal cable
10) Do not fix cables in cableveyor with cable tie, etc in order for allowing it move freely. And comb down cables in order that it won' t be entangled.
Do not fix with cable tie. Avoid being entangled.
1-9
Chapter 1

When applying the cableveyor, Use the cableveyor having radius of curvature of more than 50R. Keep the size of cables less than 60% of the cableveyor's total dimensions.
11) When you install cableveyor and mount cable bracket, make sure you do it at the following designated places. If you'd like to install cableveyor and to mount cable bracket at areas other than the following designated places, please refer it to us. Base RBC-10 RBC-32 RBC-51 RBC-81 Cableveyor / Cableveyor Guide Lower and side part of base: T-Slot Lower and side part of base: T-Slot Lower and side part of base: T-Slot Lower and side part of base: T-Slot Cable Bracket Side part of Carrier: Tap Side part of Carrier: Tap Side part of Carrier: Tap Side part of Carrier: Tap
Note) You can purchase Plate Nuts for each Base additionally.
1 - 10
Chapter 2
Overview of Robot
Product Composition
2. Overview of Robot
2.1 Product composition
Components in RCM series

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Items Mechanical parts (cartesian coordinate or SCARA robot) Robot controller (RCM4-CE-A) Connectors (SystemI/O, UserI/O) : except Cable Software option (PLC, Palletizing, Interpolating Function) RS232C cable (length 3m) Power supply cord (for AC220V) Service manual User's manual Teach pendant (cable length 2m, 5m) Motor cable (length 5,7,10m/ flexible, inflexible) User I/O cable (5,10,15m/ flexible, inflexible) System I/O cable (5,10,15m/ flexible, inflexible) System unit(cable length 3,5m/ flexible, inflexible) OPT I/O Board (Extension I/O / Ethernet / Profi-Bus) OPT I/O cable (Extension I/O / Ethernet / Profi-Bus) I/O monitor (RCO-MIOM-S) I/O terminal(RCO-MTIO-S) I/O monitor cable(system I/O,user I/O-1, 3, 5, 7,10,15m) I/O terminal cable(system I/O,user I/O-1, 3, 5, 7,10,15m) : basic : optional RCM4
quantity
1 1 1 each 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2-1
Chapter 2
Overview of Robot
Robot Composition
2.2 Robot Composition
2.2.1 Components of robot system Composition 1) : Basic Specification
SCARA Robot
PLC
Rear of RCM4
AC220V RS232C communication
Front of RCM4
Teach Pendant
2-2
Chapter 2
Overview of Robot
Robot Composition
Composition 2) : Basic Specification + I/O Monitor + I/O Terminal
SCARA Robot
PLC
I/O Terminal
I/O Monitor
Rear of RCM4
AC220V
RS232C communication
Front of RCM4
Teach Pendant
2-3
Chapter 2
Overview of Robot
Robot Composition
Composition 3) : Basic Specification + System unit
SCARA Robot
PLC
For more details, see "13-8" in the User's manual.
System UNIT
Rear of RCM4
AC220V
RS232C communication Front of RCM4
Teach Pendant
2-4
Chapter 2
Overview of Robot
Name of each component in controller
2.2.2 Name of each component in controller
(1) RCM4-Series
Front
Note1) RS232C communication connector
Note 2) Teach Pendant connector
Note 1) Connector used (in the controller) : NS-9Pin(P) Connector to be used (in the opposite of controller) : 9Pin Dsub Connector(S) 2) Pleases use the cables for teach pendant manufactured by our company.
2-5
Chapter 2
Overview of Robot
Name of each component in controller
Rear
OPTION INPUT
OPTION OUTPUT
SYSTEM IN/OUT Cooling Fan
USER OUTPUT
USER INPUT Cooling Fan
Ground Connection Class 3
Ground Connection Class 3
A(X) axis ENCODER
W axis ENCODER
Note 3) FUSE Z, W axis Motor Connector
A(X), B(Y) axis Motor Connector
B(Y) axis ENCODER
Z axis ENCODER
Note 4) Power Connector
Note 3) When replacing the fuse, make sure to use the one of rated voltage. (250V/20A ) 4) Please confirm the power to be supplied. (single phase AC220V)
2-6
Chapter 2
Overview of Robot
Specification of Robot Controller
2.3 Specification of Robot Controller
2.3.1 Features
This Robot Controller(RCA(I)4 Series) is a compact model with built-in servo AMP and equipped with 32-bit RISC CPU, and has the following features: 2 ~ 4 axes cartesian coordination robot / SCARA driving Robot system composable without additional PLC(having a simple PLC built-in) Easy to modify various parameters and gains(modifiable on S/W) Monitoring is possible during operation. Provides abundant I/O Interface Basic: 16/16 points, Expanded: 64/64 points Full range of embedded robot commands Provides multi-functional host package(Dos, Windows)
In addition, with improvements of controlling performances of robot, it is now capable to perform the following jobs: Palletizing, Sealing and the likes. Two and three dimensional interpolating controls with arc, circle, high-speed, and high-precision motion. Perform parallel processing of robot commands during execution of Input/Output and move command, etc. according to the conditions. Variety of pass motions including PFOS(movement distance set-up) and FOS(movement distance ratio set-up) etc. Multi-tasking, that enables to manupulate robot's motion and simple PLC Sequence simultaneously, is possible.
2-7
Chapter 2
Overview of Robot
Structure of Model Name
2.3.2 Structure of Model Name
RCM4 Series
Option Card O : Extension I/O Board E : Ethernet Card P : Profi-Bus Card X : No Selection
I/O Type N : Input (NCOM), Output (PCOM) P : Input (PCOM), Output (NCOM)
RCA(I)4 - 4211 - PX
Encoder Type I : Incremental A : Absolute
AC 4 axes Absolute Controller
SERVO motor's capacity for each axis ; F:50W, 1:100W, 2:200W, --- 8: 750W, A: 1 kw
Ser. No. : 0412-001
Production Date : The 1st product on Dec. 2004
Ex.) Absolute 4 axes (X:400W,Y:200W,Z:100W,W:100W) Input NCOM, Output PCOM Option I/O : Ethernet Model : RCA4-4211-PE Serial No. :
2-8
Chapter 2
Overview of Robot
2.3.3 General Specification
1) Installation environment of controller Items Input power Capacity of power Encoder Ambient Temp. in use Ambient Hum. In use Ambient Temp. in storage Ambient Hum. In storage Contents AC 220V(+10% ~ -15%),50 ~ 60Hz 2 axes maximum 1.5kVA / 4 axes maximum 2.5kVA Incremental / Absolute Encoder (Line Driver Type) 0 ~ 40 C 20 ~ 80 % RH (No dew condensation) -15 ~ 60 C 10 ~ 90 % RH (No dew condensation)
2) Performance of controller Items Withstand Voltage Power noise Motor/Encoder Noise I/O Insulation resistance Program memory Instant power cut-off Positional precision Servo capacity I/O Voltage Minimum input current Maximum output current Brake control Motor control type 1,500Vp-p,1usec, for 1 min in induced noise between input power and FG : more than 20M 100 JOB (1 JOB = 1,000 STEP + 1,000POINT) 1/2 cycle per 10 periods of input power frequency within 1 pulse of encoder RCM4: Sum of 4 axes, maximum 4.0kW(maximum 1.0kW/1 axis) Internal power supply; 24V ,500mA 5 mA/1 point 50 mA/1 point 24V Motor Brake AC Servo Motor( Sine wave PWM current control ) AC 1.5kV ,10mA for 1 minute 1,500Vp-p,1usec, for 1 min. in common / normal condition 1,500Vp-p,1usec, for 1 min in induced noise Contents
2-9
Chapter 2
Overview of Robot
3) Standard of controller Function Items RCM4-Series Robot control Controlling axes Motion control Instruction Type Memory Type & Capacity 2 ~ 4 axes cartesian coordination robot, SCARA robot 2~4 axes PTP,CP, Arc Motion Teach Pendent(Direct Teaching, MDI), Host(On-Line) Lithium Battery Back-up: 128/512 Kbytes(On board),3.0 V,0.95Ah Emergency Stop, Power ON/OFF
Front operation panel
Switch
Digit, Increase & Decrease, MODE, RESET,HOME,START,STOP
Display 2 Communication Ports Simple PLC function System I/O I/O User I/O Option I/O Extension I/O Option Ethernet Profi-Bus On - Line function
7-Segment Teach Pendent, Host(RS232C) Program only for PLC built-in 19 / 17 points 16 / 16 points 64/ 64 points(= [32 /32] x 2) To extend User I/O To communicate by Ethernet To communicate by Profi-Bus Up/Down Load(PC S/W) : System,Job,Point, Job Run/ Stop, Point Move
Operational function Edit function Protective function
Single Step, Automatic operation, Speed Override Job File Programming : System, Job, Point Monitoring : File, Status Self-test, Emergent stop, Error Recovery Program control, Motion control, I/O control, built-in function
Robot's language function Operator, Variable control I/O Parallel treatment Interrupt function Point movements in operation by input condition, I/O parallel process Interrupt program execution(INTER.JOB) by system input
2 - 10
Chapter 2
Overview of Robot
Product Dimension
2.4 Product Dimension
RCM4-Series
Unit : mm
2 - 11
Chapter 2
Overview of Robot
Warranty of Product
2.5 Warranty of Product

Robostar's products are produced under stringent quality standards. We provide after-management services with the following terms and conditions.
Warranty Period
For 1 year from the date of manufacture.
Range of Warranty
We will provide our services, free of charge during the warranty period however, only for the faults or failures experienced under normal operations caused by defects of designs or manufacturing technologies relating to the products.
Exceptional Cases
Although such events will occur within the warranty period, the following cases are being excepted:
(1) Failures caused by inadquate repairig jobs, remodification, relocation, and other mishandlings of devices carried out by the operator (or user), or any third party. (2) Failures caused by using any parts or greases which are not designated by our company, the manufacturer. (3) Failures caused by fire, disaster and natural calamities, earthquake, and force majeure. (4) Failures caused by any uses under the situations of, such as, flooding and etc, which are not specified environments in our company's speicifcation. (5) Failures caused by complete consumption of consumable parts. (6) Failures caused by lack of checks and repairing jobs in accordance with the user's manual and /or the service manual. (7) Other losses and damages except the costs required to repair the robot.
2 - 12
Chapter 3
Installation of Robotic Devices
Ensuring Appropriate Environment for Robot Installation
3. Installation of Robotic Devices
3.1 Appropriate Environment for Robot Installation

The installation environment of robot's body and controller is very important. If installation environment is not appropriate, the robot may not perform or function to the full and also it may be a cause of reduced life and unexpected failiures as well.
3.1.1 Conditions for Installation Environment

Since the robot and controller have not been manufactured under the specifications of explosion-proof, absorbing vibration & noise, and of overload protection, it should not be installed in the following places: (1) Place where flammable gas and combustible liquid are used. (2) Place where conductive substances, i.e. metal chip, etc. are flying in all directions. (3) Place where corrosive gas, such as acid or alkali, etc. exists. (4) Place where mist from cutting fluid or grinding fluid are producing. (5) Place where mist that includes cutting oil or grinding oil are spreading. (6) Place near the source of electric noises, such as Inverter of large capacity, High Frequency Oscillator with large output, Conductor of large capacity and Welder, etc.
3.1.2 Ambient Temperature and Humidity

Keep ambient temperature in the range of 0 ~ 40 Keep ambient humidity less than 80% RH(MAX). Circulate air properly, and try to keep ambient air from gathering dusts and tiny airborne partilcles during operation.
and humidity at the possible lowest level.
3.1.3 Vibration
Install the robot keeping away from the place where excessive vibrations or impacts are anticipated.
3-1
Chapter 3
Installation of Robotic Devices

Installation of Robot Controller
3.2 Installation of Robot Controller

When installing the controller inside electric panel, you should consider such factors
as bendings of the cable and interference of cooling fan, etc. And fan must be fixed in the panel, so that air can properly be circulated.
When installing the controller outside electric panel, and if you want to locate the controller
on the bottom surface, then inflow of air should not be blocked.
3.2.1 RCM4-Series
When installing the controller inside electric panel:
Front of controller
Rear of controller
Space more than 35mm be secured
Space more than 200mm be secured
3-2
Chapter 4

Connection(RCM4)
4. Connection & Interface

4.1 Connection
Wrong connection may cause trouble for peripheral device as well as controller. Please pay special attention to it.
4.2.1 Robot Controller Robot Mechanical Part Connection (Page 4-1) 4.2.2 Robot Controller External PLC Connection (Page 4-4)
4.2 RCM4-Series Connection
4.2.1 Robot Controller

Part Connection
Robot Mechanical
1) 1,2axes(= A(X), B(Y)axes) connection (Page 4-2)
2) 3,4axis(= Z, W axis) connection (Page 4-4)
SCARA Robot
PLC
Rear of RCM4
AC220V
RS232C communication Front of RCM4
Teach pendant
4-1
Chapter 4

Connection(RCM4)
Note 1) Notice the place where the encoder connector and I/O connector are located. 2) Connection should be accorded with the connectors of each axis of robot cable
Model name of connector (Controller Side) -. Encoder : 10220-52A2JL (3M) -. Motor : 09-21-007-3131(HARTING)
Model name of connector(robot's body) -. Motor : SRCN6A16-10S(SAMWOO)
3) Use the robot cable manufactured by our company only. 4) Be sure to install FG(Frame Ground).
1,2axes (=A(X), B(Y) axes) connection

See, appendix "7.8"
1) Encoder Connection (of controller) Connector attached on controller(Encoder) : 10220-52A2JL (3M) The opponent connector(Encoder) : 10120-3000VE (3M) Specification of cable : 0.15 SQ x 25P (LG Cable) Length of cable : Max. 11m
The following pin diagram is the case veiwed from the point of the arrow direction as shown in the left side. (The same applies to No3, 4 axes) 11 20 1 10
Pin Assignment for Incremental Encoder (Same for all axis) Pin No. 1 2 3 4 5 Signal
ENCPWR0# ENCA0 ENCB0 ENCC0 ENCU0
Pin No. 6 7 8 9 10
Signal
ENCV0 ENCW0 /ORG01 FLS01 24V
Pin No. 11 12 13 14 15
Signal
GND /ENCA0 /ENCB0 /ENCC0 /ENCU0
Pin No. 16 17 18 19 20
Signal
/ENCV0 /ENCW0 BRK0+ RLS01 G24V
Pin Assignment for Absolute Encoder (Same for all axis) Pin No. 1 2 3 4 5 Signal
ENCPWR0# ENCA0 ENCB0 ENCC0 No Connect
Pin No. 6 7 8 9 10
Signal
No Connect Rx /ORG01 FLS01 24V
Pin No. 11 12 13 14 15
Signal
GND /ENCA0 /ENCB0 /ENCC0 No Connect
Pin No. 16 17 18 19 20
Signal
No Connect /Rx BRK0+ RLS01 G24V
4-2
Chapter 4

Connection(RCM4)
2) Motor power connection(of controller)
See the appendix "7.8"
Connector attached on motor :09-21-007-3131(HARTING) The opponent connector(Motor) : 09-21-007-3031(HARTING) Specification of cable : 0.15 SQ x 8C (LG Cable) Length of cable : Max. 11m Pin Standard
Pin No. 1 2
Signal
U(2) V(2)
Pin No. 3 4
Signal
W(2) W(1)
Pin No. 5 6
Signal
V(1) U(1)
Pin No. 7 8
Signal
FG(1) FG(2)
(1)
1(X) axis, (2)
2(Y) axis
3) Encoder & Motor power connection (of robot body) (1,2 axes)
Connector attached on mechanical part (Encoder + Motor) : JMSP2528F or JMLP2528F The opponent connector : JMSP2528M or JMLP2528M Pin Assignment for Incremental Encoder (same for all axis) Pin No. 1 2 3 4 5 6 Signal
5V 5V G5V G5V EA EA
Pin No. 7 8 9 10 11 12
Signal
EU /EU EB /EB EV /EV
Pin No. 13 14 15 16 17 18
Signal
EC /EC EW /EW SL+ SL-
Pin No. 19 20 21 22 23 24
Signal
S24V SGND SORG BRK+ BRKFG(Enc)
Pin No. A B C D
Signal
U V W FG(Motor)
Pin Assignment for Absolute Encoder (same for all axis) Pin No. 1 2 3 4 5 6 Signal
5V 5V G5V G5V EA EA
Pin No. 7 8 9 10 11 12
Signal
NC NC EB /EB NC NC
Pin No. 13 14 15 16 17 18
Signal
EC /EC Rx /Rx SL+ SL-
Pin No. 19 20 21 22 23 24
Signal
S24V SGND SORG BRK+ BRKFG(Enc)
Pin No. A B C D
Signal
U V W FG(Motor)
4-3
Chapter 4

Connection(RCM4)
Important !
Use motor power cable and encoder cable exclusively for robot. Incorrect wiring may break the elements. Check the wiring before plug-in. Use the flexible cable by all means when wiring at the flexion part.
3, 4 axes (=Z, W axes) connection
The same shall be applied as the case of 1, 2 axes (=A(X), B(Y)). Connect after checking the position of 3, 4 axes by referring to the name plate in the rear of the controller.
4.2.2 Robot Controller
External PLC Connection
4.2.2.1 System I/O connection (Page 4-4) 4.2.2.2 User I/O connection (Page 4-24)
Important !

If I/O on Model Name(RCI4-8422-PX). is 'N', Input -> Negative Common, Output -> Positive Common If I/O on Model Name(RCI4-8422-NX). is 'P', Input -> Positive Common, Output -> Negative Common Hereinafter, distinguish as NP, PN.
4.2.2.1 System I/O connection
See appendix "connector".
You can operate the robot automatically by the system I/O signals. You can operate the robot automatically by connecting the system I/O signals with PLC or system operating panel. You can choose 32 jobs(P00~P31) by the system input signals. The wiring of system I/O can be divided into three parts as the followings. -. Basic function : operating the interface and PLC / operating panel(AUTO Mode) -. Highly sophiscated function : operating the interface with PLC / operating panel (AUTO,STEP,JOG,HOST Mode). (JOG Mode can not be accessed throug System I/O. It is optional) -. Operation with 7 segments connection : in this application, you can identify "Job program selection", "Status Display" and the likes on the 7 segments.(The 7-segment is identical with the front display of the controller.)
4-4
Chapter 4

Connection(RCM4)
1) Specification of System I/O

Items Rated I/O voltage(V) Rated I/O current(mA) Insulating method Time delay of signal(ms) Input resistance(k) Number of I/O points Connector attached on controller Opponent connector Cable Solder Type:57FE-30500(D8)(DDK) Internal power DC 24V (max. 300mA) 4.7 19 points 57LE-40500(DDK) Cable Solder Type:57-30500(DDK) Min. 5/1 node System Input DC24 Max. 30/1 node System Output
Insulation by Photocoupler within 1 17 points
2) Wiring of System I/O (3 parts)
Operation method
I/O
Input
Function
Origin setting, JOB Start, Stop, Program Choice
1. Basic function Output 2. Highyl Sophiscated Function (Functions are added on basic) Input Output Input Output
Emergency Stop, Reset Alarm, Ready, Origin-ok, INPOS/INRNG, Run INT_REQ, MODE(AXIS) option,VEL-/MOV-,VEL+/MOV+, Velocity, Brake (added on the basic function input) Same as the basic function VEL-/MOV-, VEL+/MOV+ 7-Segment Enable, Segment signal(A ~ H)
3. 7-Segment Connection Application
4-5
Chapter 4

Connection(RCM4)
The following pin diagram is the case viewed from the point of the arrow direction as shown in the left side 1 25
3) Pin Assignment of system I/O

26 50
3-1) Pin Assignment of N type system I/O
Pin No 1 (P)
Signal 24V
Name 24V Power
Description Power supplied from inside of controller <Caution> When using the external power do not connect these pins with the external power supply VCC Common for SYSTEM INPUT <Note> For wiring, see system I/O circuit diagram in 4.2.3 on page 4-14.
26 (P) 2 (G) 27 (G) 3 (C) 28 (C) 37 (C) 38 (C) 4 (I) 29 (I) 31 (I) 6 (I) 30 (I) 5 (I) PROG0 PROG1 PROG2 PROG3 PROG4 PROG_SEL lect Mode#0 25 (IG) MODE0/AXIS0 Axis#0 Mode#1 50 (IG) MODE1/AXIS1 Axis#1 13 (IG) MODE_SEL Mode Select Program#0 Program#1 Program#2 Program#3 Program#4 Program SeSYS_N_COM G24V COMMON SYS_P_COM 24V COMMON G24V G24V Power
GND Common for SYSTEM OUTPUT <Note> For wiring, see system I/O circuit diagram in 4.2.3 on page 4-14. If all Bits are OFF, run Program#0 If all Bits are OFF, run Program#31 All Bits are defined as Binary Run program#0 ~ 31 by using Bit combination For more details, see <Ref.1> in page 4-12 Signal indicates "now selecting job wanted " by using the above 5 bits (PROG0, PROG1, PROG2, PROG3, PROG4) Setting Mode: function to shift modes Setting Axis: function to choose the axis in Jog mode. For the details, see <Ref 2> in Page 4-10.
Signal indicates "now selecting mode wanted" by using the above 2 bits (MODE0/AXIS0, MODE1/AXIS1).
46 (IG)
INT_REQ
Interrupt Request
If this signal is input when a Job is running in the Auto Run Mode of the System Mode, "The INTER. Job" is automatically operated. <Caution> INTER.Job should be in Job Directory.
(O): Output, (I): Input for basic function, (IG): Input for high class function, (P):VCC, (G):GND, (C):COMMON
4-6
Chapter 4

Connection(RCM4)
Pin No
Signal
Name
Description
48 (IG)
VEL
Velocity
Set the velocity of Jog motion in Jog mode. When VEL is ON, robot moves at the velocity set as jog velocity values in the parameter descripted in user's manual. While VEL is OFF, it moves at the one-half the velocity of that value.
14 (IG)
VEL-/MOV-
Velocity- Direction
Shift of velocity in running: In running, you can shift the working velocity of robot. The velocity is indicated on the teach pendant, and It is applied after the completion of 1 point motion. It will be increased or decreased at the increment of 10% per inputted signal with range of 20~100%. These signals move the selected axis in Jog Mode: They move the selected axis in the direction of + or Signal indicates START JOB. Once this signal is inputted, the controller moves the robot according to the selected program & point. You should choose desired JOB before-hand.
39 (IG)
VEL+/MOV+
Velocity+ + Direction
4. 32 (I) 4. START
Start Restart
There are Start and Restart. <Ref>See, Operation Time Chart". Signal indicates STOP JOB. The robot will be paused a moment by this signal. Servo Off: With receiving this signal after stop, Servo will be off. Alarm Reset : When the alarm activates, the alarm will be released by this signal. Signal indicates Origin Setting. With this signal, the controller performs Move to Origin according to the parameter set. Signal indicates initialization. <Caution> use this signal very carefully during run. 34 (I) 9 (I) /EMG/EMG+ /Emergency/Emergency+ Signal indicates Emergency Stop. When this signal is inputted, the controller stops all the jobs and the robot carries Emergency Stop. (Alarm status)
<Ref> When wiring, see " System I/O Circuit Diagram of Basic Function (Page 4-11).
Stop 8 (I) STOP Servo Off Alarm Reset
7 (I)
ORG
Origin
33 (I)
RST
Reset
47 (IG)
BRK
Brake
It executes forcible brake ON or OFF at Jog Mode. If you want to move the brake locked axis manually, you may use this function. When power ON, the controller inspects all of the system. If the system is normal, this signal will be On. If the system is abnormal, Alarm signal will be ON.
35 (O)
READY
Ready
4-7
Chapter 4

Connection(RCM4)
Pin No 11 (O)
Signal ORG_OK
Name Origin OK
Description When the signal "Org" is inputted, the controller performs the origin setting. After the completion of this process, this signal will be outputted.
12 (O)
RUN
Run
With selection of job and input of "Start" signal, robot then starts to run from the first step and will output this signal.
10 (O)
ALARM
Alarm
When error occurs in the initial stage or during run, this signal then will be outputted. Alarm message is indicated on the teach pendant. When the robot reaches the target point (the Teach Point) during run, this signal will be On. When the robot reaches within the inposition pulse set in the parameter mode, this signal is On.
36 (O)
INPOS/INRNG <Ref 3>
In Position In Range
When the robot's mechanical part reaches within the range set in the parameter mode after origin setting, this signal is On.
Regardless of the controller's status, if the current position of robot's mechanical part is within the value of 'In Range' in the parameter mode, this signal is On.
15 (O) 40 (O) 16 (O) 41 (O) 17 (O) 42 (O) 18 (O) 43 (O) 19 (O) 44 (O) 20 (O) 45 (O)
SEG_ENB0 SEG_ENB1 SEG_ENB2 SEG_ENB3 SEG_A SEG_B SEG_C SEG_D SEG_E SEG_F SEG_G SEG_H
7 Segment Enable 0 7 Segment Enable 1 7 Segment Enable 2 7 Segment Enable 3 7 Segment A 7 Segment B 7 Segment C 7 Segment D 7 Segment E 7 Segment F 7 Segment G 7 Segment H 24V COMMON Not Used -.VCC Common for SYSTEM INPUT
21 ~24 SYS_P_COM1,2 49
4-8
Chapter 4

Connection(RCM4)
3-2) Pin Assignment of P type system I/O
Pin No. 1 (P)
Signal 24V
Name 24V Power
Description Power supplied from inside of controller <Caution> When using the external power, do not connect these pins with the external power supply.
26 (P) 2 (G) 27 (G) 3 (C) 28 (C) 21 (C) 22 (C) 23 (C) 37 (C) 38 (C) 4 (I) 29 (I) 31 (I) 6 (I) 30 (I) 5 (I) PROG0 PROG1 PROG2 PROG3 PROG4 PROG_SEL Select Mode#0 25 (IG) MODE0/AXIS0 Axis#0 Mode#1 50 (IG) MODE1/AXIS1 Axis#1 13 (IG) MODE_SEL Mode Select SYS_IN_COM3 SYS_IN_COM2 SYS_IN_COM1 G24V COMMON G24V G24V Power
SYS_OUT_COM
GND Common for system input <Ref> When wiring, see "System I/O diagram in the basic function (Page 4-16)" GND Common for system input <Ref> When wiring, see "System I/O diagram in the highly G24V COMMON sophiscated function (Page4-17)" GND Common for system input <Ref> When wiring, see "System I/O diagram in the highly G24V COMMON sophiscated function (Page4-17)" VCC Common for system output 24V COMMON <Ref> When wiring, see "System I/O diagram in the basic function (Page 4-16)" Program#0 Program#1 Program#2 Program#3 Program#4 Program All bits being OFF, execute the program "0" All bits being ON, execute the program "31" All bits are defined as "Binary". Using the combination of bits, execute the programs " No. 0~31" For the details, see <Ref 1> in Page 4-12. Signal indicates "now selecting job wanted " by using the above 5 bits (PROG0, PROG1, PROG2, PROG3, PROG4) -.Setting Mode: function to shift modes -.Setting Axis: function to choose the axis in Jog mode. -.For the details, see <Ref 2> in Page 4-13.
Signal indicates "now selecting mode wanted" by using the above 2 bits (MODE0/AXIS0, MODE1/AXIS1). If this signal is input when a Job is running in the Auto Run Mode of the System Mode, "The INTER. Job" is automatically operated. <Caution> INTER.Job should be in Job Directory.
Interrupt 46 (IG) INT_REQ Request
4-9
Chapter 4

Connection(RCM4)
Pin No
Signal
Name
Description
48 (IG)
VEL
Velocity
Set the velocity of Jog motion in Jog mode. When VEL is ON, robot moves at the velocity set as jog velocity values in the parameter descripted in user's manual. While VEL is OFF, it moves at the one-half the velocity of that value.
14 (IG)
VEL-/MOV-
Velocity- Direction
Shift of velocity in running: In running, you can shift the working velocity of robot. The velocity is indicated on the teach pendant, and It is applied after the completion of 1 point motion. It will be increased or decreased at the increment of 10% per inputted signal with range of 20~100%. These signals move the selected axis in Jog Mode: They move the selected axis in the direction of + or Signal indicates START JOB. Once this signal is inputted, the controller moves the robot according to the selected program & point. You should choose desired JOB before-hand.
39 (IG)
VEL+/MOV+
Velocity+ + Direction
Start 32 (I) START Restart
There are Start and Restart. <Ref>See, Operation Time Chart". Signal indicates STOP JOB. The robot will be paused a moment by this signal. Servo Off: With receiving this signal after stop, Servo will be off. Alarm Reset : When the alarm activates, the alarm will be released by this signal. Signal indicates Origin Setting. With this signal, the controller performs Move to Origin according to the parameter set. Signal indicates initialization. <Caution> use this signal very carefully during run. 34 (I) 9 (I) /EMG/EMG+ /Emergency/Emergency+ Signal indicates Emergency Stop. When this signal is inputted, the controller stops all the jobs and the robot carries Emergency Stop. (Alarm status)
<Ref> When wiring, see " System I/O Circuit Diagram of Basic Function (Page 4-16).
Stop 8 (I) STOP Servo Off Alarm Reset
7 (I)
ORG
Origin
33 (I)
RST
Reset
47 (IG)
BRK
Brake
It executes forcible brake ON or OFF at Jog Mode. If you want to move the brake locked axis manually, you may use this function. When power ON, the controller inspects all of the system. If the system is normal, this signal will be On. If the system is abnormal, Alarm signal will be ON.
35 (O)
READY
Ready
(O):Output, (I):Input basic functions, (IG):Input high-class functions, (P):VCC, (G):GND, (C):COMMON
4 - 10
Chapter 4

Connection(RCM4)
Pin No. 11 (O)
Signal ORG_OK
Name Origin OK
Description When the signal "Org" is inputted, the controller performs the origin setting. After the completion of this process, this signal will be outputted.
12 (O)
RUN
Run
With selection of job and input of "Start" signal, robot then starts to run from the first step and will output this signal.
10 (O)
ALARM
Alarm
When error occurs in the initial stage or during run, this signal then will be outputted. Alarm message is indicated on the teach pendant. When the robot reaches the target point (the Teach Point) during run, this signal will be On. When the robot reaches within the inposition pulse set in the parameter mode, this signal is On.
INPOS/INRNG 36 (O) <Ref 3>
In Position In Range
When the robot's mechanical part reaches within the range set in the parameter mode after origin setting, this signal is On.
Regardless of the controller's status, if the current position of robot's mechanical part is within the value of 'In Range' in the parameter mode, this signal is On.
15 (O) 40 (O) 16 (O) 41 (O) 17 (O) 42 (O) 18 (O) 43 (O) 19 (O) 44 (O) 20 (O) 45 (O) 24,49
SEG_ENB0 SEG_ENB1 SEG_ENB2 SEG_ENB3 SEG_A SEG_B SEG_C SEG_D SEG_E SEG_F SEG_G SEG_H
7 Segment Enable 0 7 Segment Enable 1 7 Segment Enable 2 7 Segment Enable 3 7 Segment A 7 Segment B 7 Segment C 7 Segment D 7 Segment E 7 Segment F 7 Segment G 7 Segment H Not Used
(O):Output, (I):Input basic function, (IG):Input high-class function (P):VCC, (G):GND, (C):COMMON
4 - 11
Chapter 4

Connection(RCM4)
Ref. 1 : How to select a program
1. In case "Program Number" is not chosen, the Job "O" will be chosen automatically. (The same is performed in case of input signal not wired, PROG0 ~ 4,PROG_SEL.
2. Selecting "Program No" You can choose total 32 jobs by using PROG0 ~ PROG4.
PROG4 OFF OFF OFF OFF ~ ON ON ON ON
PROG1 OFF OFF ON ON ~ OFF OFF ON ON
PROG0 OFF ON OFF ON ~ OFF ON OFF ON
JOB DIR No. 0 1 2 3 ~ 28 29 30 31
Ref. 3 : Setting up INPOS / INRNG
-. You should determine to use either "In Position" or "In Range" in the parameter mode. -. Set IN Position/Range in the Parameter Mode.
Ref. 4 : System Operation (Highly Sophiscated Fuction) & Flow Chart of Functions
MODE1 OFF OFF ON ON
MODE0 OFF ON OFF ON
Code M00 M01 M10 M11
MODE Auto Run Mode Step Run Mode Jog Mode Host MODE
Remarks System MODE
(Option) Host MODE
4 - 12
Chapter 4

Connection(RCM4)
Ref. 2 : Setting Operation Mode
MODE1 / AXIS1 OFF OFF ON ON
MODE0 / AXIS0 OFF ON OFF ON
Operation Mode Auto Run Mode Step Run Mode Jog Mode Host Mode
Moving axis in Jog Mode
Remarks
1(X) axis System Mode 2(Y) axis 3(Z) axis 4(W) axis (Option) Host Mode
1. System Mode
-. Once the power is turned ON, System Mode is automatically set: (provided HOST Cable is not connected.) Auto Run Mode ; When system I/O is connected to the peripheral devices with the basic function, this mode is automatically set just after the power is turned ON.
; In case of highly sophiscated function, when turning power On, Operation Mode will be set as Auto Run Mode.
Step Run Mode If System I/O is configured to use the highly sophiscated function, it is possible to set Step Run Mode by selection procedure. Jog Mode (option) If System I/O is configured to use the highly sophiscated function, it is possible to set JOG Mode by selection procedure.
2. Host Mode
-. After connecting HOST Cable, this mode is automatically set after the power is turned ON. -. If system I/O is configured to use the highly sophiscated function, it is possible to set On-Line Mode by selection procedure.
4 - 13
Chapter 4

System I/O of RCM4-series
4) System I/O schematic
4-1-1) Operation of Basic function (N type)
Be carefule to connect Common - It is possible to choose 32 (2 5) programs externally. - You can change the number of connections as required. - Binary format. - when you need to choose 4 programs: connect the 2 pins, PROG 0 and PROG 1.
3,28
4.7K
SYS_P_COM0 ORG RST START STOP PROG 0 PROG 1 PROG 2 PROG 3 PROG 4 PROG_SEL EMG+ EMG-
DC24V
7 33 32
4.7K
S Y S T E M I N P U T
8 4 29 31 6
4.7 K
30 5 9
DC24V
4.7K
34
10
ALARM RDY ORIGIN-OK INPOS/INRNG RUN SYS_N_COM
S Y S T E M O U T P U T
35 11 36 12 37,38 1,26
LOAD LOAD LOAD LOAD LOAD
1) NC node 2) If power is turned ON without connecting the System I/O connectors, the error "SYSTEM EMERGENCY" would appear. To escape from error status, connect System I/O connectors. you can remove the error by forcing EMG pins short-circuit, and then use the controller. (EMG pins are in mainboard of controller.) (Under this situation, pressing the EMG key doesn't work.)
DC24V
2,27
Internal Current (MAX MAX.500mA
DC24V .500 m
Be careful to connect Common
When wiring the power supply, check if the polarity in connection of DC24V is correct. Wiring mistakes may result in damages of elements inside the circuit. Particularly, note the polarity of terminals' common connection. Please use an external power supply as much as possible.
4 - 14
Chapter 4

4-1-2) Operation of Highly Sophiscated Functions (N type)
21
4.7K
SYS_P_COM
INT_REQ
DC24V
46 22
SYS_P_COM
BRK
DC24V
S Y S T E M I N P U T
4.7K
47
23
4.7K
SYS_P_COM
VEL
DC24V
48
24
4.7K
SYS_P_COM1 MODE0/AXIS0
SYS_P_COM
DC24V
25
4.7K
50
MODE1/AXIS1
Add above wirings to the wirings for "Operation of basic functions", which has been described in the previous page, . That is, add the wirings exhibited above to SYSTEM INPUT of "Operation of basic functions". SYSTEM OUTPUT is the same as "Operation of basic functions". You can't use the pin-function related JOG mode. Those functions are optional.
When wiring the power supply, check if the polarity of DC24V is correct. Wiring mistakes may result in damages of elements inside the circuit. Particularly, note the polarity of terminal's common connection.
4 - 15
Chapter 4

4-2-1) Operation of basic functions (P type)

When it is open, Servo Not Ready error occur
Note "Common connection".
- It is possible to choose 32 (2 5) programs externally. - You can change the number of connections as required. - Binary format. - when you need to choose 4 programs: connect the 2 pins, PROG 0 and PROG 1.
Internal Current MAX.500mA Note "Common connection".
<Caution> When wiring the power supply, check if the polarity in connection of DC24V is correct. Wiring mistakes may result in damages of elements inside the circuit. Particularly, note the polarity of terminals' common connection. Please use an external power supply as much as possible.
4 - 16
Chapter 4

4-2-2) Operation of Highly Sophiscated Functions (P type)
Add above wirings to the wirings for "Operation of basic functions", which has been described in the previous page, . That is, add the wirings exhibited above to SYSTEM INPUT of "Operation of basic functions". SYSTEM OUTPUT is the same as "Operation of basic functions". You can't use the pin-function related JOG mode. Those functions are optional.
<Caution> When wiring the power supply, check if the polarity of DC24V is correct. Wiring mistakes may result in damages of elements inside the circuit. Particularly, note the polarity of terminal's common connection.
4 - 17
Chapter 4

4-3) Descriptions of input signal according to operation modes in highly sophiscated functions
Mode
Description
Description of input signal PROG_SEL: After inputting job number(Binary format) at P0~P4, the pertinent job is selected by pressing this key.
Output ALARM :
on at Alarm.
Auto
In this mode Job is automatically run.
Run Mode
VEL-/MOV-: shifts the decimal point of the job number which are displayed at 7 segments. (Multi-function) - Inputted while the job is run, robot's moving speed is decreased. VEL+/MOV+: increases the job number. (Multi-function) -. Inputted while the job is run, robot's moving speed is increased.
READY :
on at normal waiting status.
ORIGIN :
on when origin setting is completed.
INPOS :
OFF when robot is moving.
MODE_SEL: Pressing the key after the signals M1/A1 & M0/A0 inputted, the relevant mode is selected START: runs the selected job. After the robot is paused due to inputting STOP in job run - Inputting START signal:first runs from the paused step Inputting - START signal as soon as STOP inputted : runs from the first step of the paused job.
On when robot reaches target point.
RUN :
on in job run.
7 Segment :
- Alarm: displays E alarm code - pausing job run: displays "P job number"
STOP: pauses the job in progress (Multi-function) - Clears the alarm when Alarm activiates. - Additional Input turns off Servo after first STOP inputted - stops the origin setting in progress. Perform IP: Interrupt function. If IP input becomes ON(1) while selected job running, that job will be stopped(if robot is moving, it will be stopped) and INTER.JOB runs. At this time, a job file with the file name of "INTER" must be located in the job directory. Interrupt run can be transformed when the selected job is run only in Auto Run Mode.
- when Job is running : displays "A step number" - when origin setting : displays "org".
4 - 18
Chapter 4

Mode
Description
Description of input signal - How to run the first job while INTER.Job running. (the job runs from the first step) input the followings: Reset, Job, No. to run, PROG_SEL, START STOP, Job No. to run, PROG_SEL, START
Output
Step Run Mode
In this mode, Job is run step by step
VEL-/MOV-: shifts the decimal point of the step number which is displayed at 7 segments. (Multi-function). - Inputting while the job running, 1 step is decreased.
ALARM : on at Alarm. READY : on at normal waiting status.
VEL+/MOV+: increases the step number. (Multi-function). - Inputting while the job is run, 1 step is decreased.
ORIGIN : on when origin setting is completed. INPOS :

Off while moving On when robot reaches target point.
MODE_SEL: Pressing the key after the signals M1/A1 & M0/A0 inputted, the concerned mode is selected START : runs the selected job. By one input, Job Program One step that is displayed in 7segment will be run. - START Signal Input: Runs from the paused step. When inputing START signal, Stop Signal is inputted simultaneously: Performs from the first step of the job stopped.
RUN : on in job run. 7 Segment :
- Alarm: displays E inputted: alarm code. - pausing job runs: displays "P job number"
STOP: pauses the job in progress (Multi-function) - Clears the alarm when Alarm activates. - Additional input turns off Servo after first STOP inputted. - Stops origin setting in the progress - when Job runs: displays "r step number" - origin setting: displays "org".
4 - 19
Chapter 4

Mode
Description of Mode
Description of the input signal Status that enables controller to communicate with PC
Output ALARM : On at Alarm READY : On at Normal waiting status ORIGIN : On when origin setting completed. INPOS :
Host Mode
In this mode, PC With Communication Protocol, you can do 'origin setting', communicates with the controller by the 'Job Selection', 'Job Program Up/Down Load', 'Job Run', serial Monitoring the current status of the controller', etc. communication protocol. VEL-/MOV-: Decreases the speed of the robot motion while the job is running. VEL+/MOV+: Increases the speed of the robot motion while the job is running. START :This signal is valid after selected job runs and then stops due to STOP inputted. Under the condition that selected job doesn't run, inputting START signal causes the error "File Not found".
is
OFF while moving ON when robot reaches target point.
RUN :
-.START Signal Input: Runs the job from the STEP stopped. On in job run. - When inputing START signal, Stop Signal is inputted simultaneously: Performs from the first step of the job stopped. -.STOP: Job executed in PC is being stopped temporarily (Multi-function) -.Clears the alarm when Alarm activates. Stops origin setting in progress. 7 Segment :
-. Alarm:
displays E alarm code. -.Origin setting: displays "org"
4-20
Robostar Co., Ltd.
Chapter 4

7 - Segment Connection Application (N-type)
Signal
Port
Wiring Diagram
S Y S T E M
SYS_N_COM 37,38
DC 24V
TR
O U T P U T
SEG_ENB0 SEG_ENB1 SEG_ENB2 SEG_ENB3
15 40 16 41
SEG_A ... SEG_F
17 ~ 20 42 ~ 45
R R
SYS_N_COM 37,38
DC 24V I N P U T
SYS_P_COM 3,28 MODE_SEL VEL-/MOVVEL+/MOV+ 13 14 39
Components Standard R : 1.2 kW TR : 2N2907 (PNP type) 7- Segment : SND517 (Common Anode type)
4 - 21
Chapter 4

7 - Segment Connection Application (P-type)
Signal
SYS_OUT_COM
Port
37,38
Wiring Diagram
DC 24V
S Y S T E M
SEG_A ... SEG_H
17 ~ 20 42 ~ 45
R R
O U T P U T
FNT_SEL0 FNT_SEL1 FNT_SEL2 FNT_SEL3 15 40 16 41
TR
DC 24V I N P U T
SYS_IN_COM1 MODE_SEL VEL-/MOVVEL+/MOV+ 3,28 13 14 39
Components Standard R : 470 TR : 2N2222 (NPN type) 7- Segment : Common Cathode Type
4 - 22
Chapter 4

User I/O of RCM4-series
4.2.2.2 USER I/O Connection
User I/O is a general-purpose I/O signal connected to external devices and peripheral devices. It exchanges signals each other by Robot Program and simple PLC program.
Connection Point for each of the User I/O are 16.
1) User I/O Specification

Item
Rated I/O Voltage (V) Rated I/O Current (mA) Insulation Method Time delay of signal(ms) Input Resistence(k) Number of I/O points Connector attached on Controller Opponent connector Internal Power 4.7 16points(8points/1Common) RDCD-25S 25Pin Dsub Con.(P) DC 24V (max. 300mA) Min. 5/1 point
User Input
DC24
User Output
Max. 30/1 point
Insulation by Photocoupler 1 16points(8points/1Common) RDCD-25P 25Pin Dsub Con.(S) DC 24V (max. 500mA)
4 - 23
Chapter 4

The following pin diagram is the case viewed from the point of arrow direction as shown at left side.
13
14
25
2) User I/O Pin Assignment (N-type)
User Input Pin Assignment Pin No. 1 2 3 4 5 6 7 8 9 INCOM0+ IN1 IN3 IN5 IN7 INCOM1+ Signal DC24V DC 24V GND Pin No. 10 11 12 13 14 15 16 17 18 Signal IN9 IN11 IN13 IN15 DC 24V DC 24V GND INCOM0+ IN0 IN2 Pin No. 19 20 21 22 23 24 25 Signal IN4 IN6 INCOM1+ IN8 IN10 IN12 IN14 Not Used
13
User Output Pin Assignment Pin No. 1 2 3 4 5 6 7 8 9 Signal OUTCOM0OUT0 OUT2 OUT4 OUT6 OUTCOM1OUT8 OUT10 OUT12 Pin No. 10 11 12 13 14 15 16 17 18 DC 24V GND DC 24V OUTCOM0OUT1 OUT3 OUT5 OUT7 Signal OUT14 Pin No. 19 20 21 22 23 24 25 Signal OUTCOM1OUT9 OUT11 OUT13 OUT15 GND DC 24V Not Used
25
14
When using internal power being supplied by controller, check its maximum capacity. To prevent devices from experiencing power shortage, please use the external power supply as much as possible. When using the external power, be cautious about "short-circuit" with the internal power lines.
4 - 24
Chapter 4

1 The following pin diagram is the case viewed from the point of arrow direction as shown at left side. 14
13
25
3) User I/O Pin Assignment (P-type)

User Input Pin Assignment Pin No. 1 2 3 4 5 6 7 8 9 Signal DC24V DC 24V GND Not Used INCOM1 IN1 IN3 IN5 IN7 INCOM2 Pin No. 10 11 12 13 14 15 16 17 18 Signal IN9 IN11 IN13 IN15 DC 24V DC 24V GND INCOM1 IN0 IN2
25 14
Pin No. 19 20 21 22 23 24 25
Signal IN4 IN6 INCOM2 IN8 IN10 IN12 IN14
The following pin diagram is the case viewed from the point of arrow direction as shown at left side.
User Output Pin Assignment Pin No. 1 2 3 4 5 6 7 8 9 Signal OUTCOM1 OUT0 OUT2 OUT4 OUT6 OUTCOM2 OUT8 OUT10 OUT12 Pin No. 10 11 12 13 14 15 16 17 18 Signal OUT14 Not Used DC 24V GND DC 24V OUTCOM1 OUT1 OUT3 OUT5 OUT7 Pin No. 19 20 21 22 23 24 25 Signal OUTCOM2 OUT9 OUT11 OUT13 OUT15 DC 24V GND DC 24V
13
When using internal power being supplied by controller, check its maximum capacity. To prevent devices from experiencing power shortage, please use the external power supply as much as possible. When using the external power, be cautious about "short-circuit" with the internal power lines.
4 - 25
Chapter 4

4) User I/O Circuit Diagram (N-type)
User-Input Circuit Diagram

Be careful when treating "Common Connection"
4,16
4.7K
User-Output Circuit Diagram

INCOM0+ IN0 IN1 IN2 IN3 IN4 IN5 IN6
DC24V
17 5 18 6 19 7 20
2 15 3 16 4 17 5 18 1,14
OUT0 OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 OUTCOM0 -
LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD
4.7K
I N P U T
4.7K
IN7
9,21
4.7K
INCOM1+ IN8 IN9 IN10 IN11 IN12 IN13 IN14
DC24V
O U T P U T
DC 24V
7 20 8 21 9 22 10 23 6,19 OUT8 OUT9 OUT10 OUT11 OUT12 OUT13 OUT14 OUT15 OUTCOM1 LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD
22 10 23 11 24 12 25
4.7K
DC 24V
4.7K
13 1,14
IN15
DC24V
2,15
Internal Current (MAX.500mA) MAX Be careful when 500mA treating "Common Connection"
13,25
DC 24V
12,24
Internal Current MAX (MAX 500mA
.500mA) treating when
Be careful
"Common Connection"
* When COM type of PLC output port is the same as that of User I/O, additional relays are not necessary * External supplying power is DC24V 10%. * When wiring cable to connector pin by soldering, tube insulation is nesessary so that pins would not be short circuited.
4 - 26
Chapter 4

User I/O Circuit Diagram
5) User I/O Circuit Diagram (P-type)

Be careful when treating "Common Connection" Be careful when treating "Common Connection"
User-Input Circuit Diagram
User-Output Circuit Diagram
Internal Current MAX 500mA
Internal Current MAX 500mA
* When COM type of PLC output port is the same as that of User I/O, additional relays are not necessary * External supplying power is DC24V 10%. * When wiring cable to connector pin by soldering, tube insulation is nesessary so that pins would not be short circuited.
4 - 27
Chapter 4

Option I/O of RCM4-series
4.2.2.3 Option I/O Connection
User I/O is a general-purpose I/O signal connected to external devices and peripheral devices. It exchanges signals each other by Robot Program and simple PLC program.
Option I/O is used for expanding User I/O, and "Option I/O Board" must have been installed. One "Option I/O Board" has 32/32 I/O points .
1) Option I/O Specification

Item
Rated I/O Voltage (V) Rated I/O Current (mA) Insulation Method Time delay of signal(ms) Input Resistence(k) Number of I/O points Connector attached on Controller Opponent connector 4.7 32points(8points/1Common) NS-DMR-37S 37Pin Dsub Con.(P) Min. 5/1 point
User Input
DC24
User Output
Max. 30/1 point
Insulation by Photocoupler within1 32points(8points/1Common) NS-DMR-37P 37Pin Dsub Con.(S)
4 - 28
Chapter 4

The following pin diagram is the case viewed from the point of arrow direction as shown at left side. 1 19
2) Option I/O Pin Assignment (N-type)
Option Input Pin Assignment Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Signal FG IN16 IN18 IN20 IN22 INCOM3 IN25 IN27 IN29 IN31 IN32 IN34 IN36 Pin No. 14 15 16 17 18 19 20 21 22 23 24 25 26 Signal IN38 INCOM5 IN41 IN43 IN45 IN47 INCOM2 IN17 IN19 IN21 IN23 IN24 IN26 Pin No. 27 28 29 30 31 32 33 34 35 36 37
20
37
Signal IN28 IN30 INCOM4 IN33 IN35 IN37 IN39 IN40 IN42 IN44 IN46
19 1
Option Output Pin Assignment Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Signal FG OUT46 OUT44 OUT42 OUT40 OUT39 OUT37 OUT35 OUT33 OUTCOM4 OUT30 OUT28 OUT26 Pin No. 14 15 16 17 18 19 20 21 22 23 24 25 26 Signal OUT24 OUT23 OUT21 OUT19 OUT17 OUTCOM2 OUT47 OUT45 OUT43 OUT41 OUTCOM5 OUT38 OUT36 Pin No. 27 28 29 30 31 32 33 34 35 36 37
37
20
Signal OUT34 OUT32 OUT31 OUT29 OUT27 OUT25 OUTCOM3 OUT22 OUT20 OUT18 OUT16 Not Used
4 - 29
Chapter 4

The following pin diagram is the case viewed from the point of arrow direction as shown at left side. 1 19
3) Option I/O Pin Assignment (P-type)
Option Input Pin Assignment Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Signal FG IN16 IN18 IN20 IN22 INCOM3 IN25 IN27 IN29 IN31 IN32 IN34 IN36 Pin No. 14 15 16 17 18 19 20 21 22 23 24 25 26 Signal IN38 INCOM5 IN41 IN43 IN45 IN47 INCOM2 IN17 IN19 IN21 IN23 IN24 IN26 Pin No. 27 28 29 30 31 32 33 34 35 36 37
20
37
Signal IN28 IN30 INCOM4 IN33 IN35 IN37 IN39 IN40 IN42 IN44 IN46
19 1
Option Output Pin Assignment Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Signal FG OUT46 OUT44 OUT42 OUT40 OUT39 OUT37 OUT35 OUT33 OUTCOM4 OUT30 OUT28 OUT26 Pin No. 14 15 16 17 18 19 20 21 22 23 24 25 26 Signal OUT24 OUT23 OUT21 OUT19 OUT17 OUTCOM2 OUT47 OUT45 OUT43 OUT41 OUTCOM5 OUT38 OUT36 Pin No. 27 28 29 30 31 32 33 34 35 36 37
37
20
Signal OUT34 OUT32 OUT31 OUT29 OUT27 OUT25 OUTCOM3 OUT22 OUT20 OUT18 OUT16
4 - 30
Chapter 4

4) Option I/O Circuit Diagram (N-type)
Option Input Circuit Diagram

External power connection
Option Output Circuit Diagram
4,16 20/ 29
4.7K
INCOM2+/COM4+ INCOM0+ IN16/IN32 IN0
DC24V
37/2 2
OUT0 OUT16/OUT32
OUT17/OUT33 OUT1
2/11 17 21/30 5 3/12 18
15 18/9 3 36/2
17/8 16 35/2 4
OUT2 OUT18/OUT34 OUT3 OUT19/OUT35 OUT4 OUT20/OUT36 OUT5 OUT21/OUT37

OUT22/OUT38 OUT6 OUT23/OUT39 OUT7
4.7K
IN1 IN17/IN33
IN18/IN34 IN2 IN19/IN35 IN3 IN20/IN36 IN4 IN21/IN37 IN5
6 22/31 19 4/13
23/32 7
17 16/7
34/2 5
18 15/6
19/1 1,14
20 5/14
IN6 IN22/IN38
OUTCOM0 OUTCOM2-
I N P U T
4.7K
24/33 8
IN23/IN39 IN7
6/15 9,21
4.7K
INCOM3+/COM5+ INCOM1+ IN24/IN40 IN8 IN25/IN41 IN9
DC24V
O U T P U T
DC 24V
14/5 7 32/2 20 13/4 8 OUT24/OUT40 OUT8 OUT25/OUT41 OUT9 OUT26/OUT42 OUT10 OUT27/OUT43 OUT11 OUT28/OUT44 OUT12
22 25/34
7/16 10
21 31/2
4.7K
9 12/3
30/2 22 11/2 10
23 26/35 11 8/17
27/36 24 9/18 12
IN10 IN26/IN 42 IN11 IN27/IN43

IN28/IN44 IN12 IN29/IN45 IN13 IN30/IN46 IN14
OUT13 OUT29/OUT45
OUT30/OUT46 OUT14
23 29/2
33/2 6,19
OUT15 OUT31/OUT47
OUTCOM3OUTCOM1 -
25 28/37
DC 24V
4.7K
13 10/19 1,14
IN31/IN47 IN15
13,25
External power connection
DC24V
2,15
(MAX.500mA)
DC 24V
12,24
(MAX.500mA
* When COM type of PLC output port is the same as that of User I/O, additional relays are not necessary. * External supplying power is DC24V 10%. * When wiring cable to connector pin by soldering, tube insulation is nesessary so that pins would not be short circuited.
4 - 31
Chapter 4

Option I/O Circuit Diagram
5) Option I/O Circuit Diagram (P-type)
Option Input Circuit Diagram
Option Output Circuit Diagram
* When COM type of PLC output port is the same as that of User I/O, additional relays are not necessary. * External supplying power is DC24V 10%. * When wiring cable to connector pin by soldering, tube insulation is nesessary so that pins would not be short circuited.
4 - 32
Chapter 4

Input/Output Monitoring
4.3 Checking Input/output Monitoring using Teach Pendant after connection
How to check input/output signal when the robot is not running, but stops.
No. Power ON 1 (If an error occurs, check the error code for the troubleshooting.) EXIT Robostar NewRo RCM4-Series Ver 2.0A Press ENTER Key 1.JOB 3.HOST 5.ORIGIN 7.SYSTEM 2.RUN 4.PARA 6.I/O SELECT# Contents Key What screen showes SYSTEM MODE Auto Run Mode
Exit from system mode.
F1
Screen showes initial menu.
ENTE R
Screen of monitoring user-output points.
(By pressing "PgDn" on this screen, it shifts to the screen of monitoring system-output points.) Screen of monitoring user-input points.)
6 N
OUT 0123456789ABCDEF USR:0000000000000000
(By pressing "PgDn" on this screen, it shifts to the screen of monitoring system-output points.)
F1
IN 0123456789ABCDEF USR:0000000000000000
The screen of monitoring PLC points.
F1
PLC 0123456789ABCDEF 080:0000000000000000 096 0000000000000000 112 0000000000000000 OUT 0123456789ABCDEF USR:0000000000000000
The screen of monitoring User-output points.
F1
Screen showes initial menu.
ESC
1.JOB 3.HOST 5.ORIGIN 7.SYSTEM
2.RUN 4.PARA 6.I/O SELECT#
4 - 33
Chapter 4

Description : Checking and monitoring user-output points

Description of user-output screen OUT : Indicates Output screen 0 : Signal OFF 1 : Signal ON 0 ~ F : Output point number USR : Indicates user-output OP0 : Indicates option output status (OUT16~31) OP1 : Indicates option output status (OUT32~47) OP2 : Indicates option output status (OUT48~63) OP3 : Indicates option output status (OUT64~79)
OUT 0123456789ABCDEF USR:0000100000100000 OP0 0000000000000000 OP1 0000000000000000
User-output point screen

Without any option board OUT 0123456789ABCDEF USR:0000000000000000 With one option board added OUT 0123456789ABCDEF USR:0000000000000000 OP0 0000000000000000 OP1 0000000000000000 With two option boards added OUT 0123456789ABCDEF OP2: 0000000000000000 OP3 0000000000000000
Important
OP0 and OP1 will be appeared on the screen under the following conditions.
First, After having installed option I/O board(s) Second, when system parameter displays correct information about whether or not option I/O is usable.
How to set the user-output point signal ON ex) To set OUT6 ON(=1)/OFF(=0),
OUT 0123456789ABCDEF USR:0000000000000000 6 N OUT 0123456789ABCDEF USR:0000001000000000
ex) To set OUT20 ON(=1)/OFF(=0), Move cursor(:) from USR : to OP0 : with pressing PgDn key.
OUT 0123456789ABCDEF USR 0000000000000000 OP0: 0000000000000000 4 L OUT 0123456789ABCDEF USR 0000000000000000 OP0: 0000100000000000
4 - 34
Chapter 4

: Checking and monitoring user-input points Description of user-input screen

IN 0123456789ABCDEF USR:0000100000100000 OP0 0000000001000000 OP1 0000000000000000
User-input point screen

Without any option board IN 0123456789ABCDEF USR:0000000000000000
IN : Indicated Output screen 0 : Signal OFF 1 : Signal ON 0 ~ F : Input point number USR : Indicate user-input OP0 : Indicates option-input point status (IN16~31) OP1 : Indicates option-input point status (IN32~47) OP2 : Indicates option-input point status (IN48~63) OP3 : Indicates option-input point status (IN64~79)
With one option board added IN 0123456789ABCDEF USR:0000000000000000 OP0 0000000000000000 OP1 0000000000000000 With two option boards added IN 0123456789ABCDEF OP2:0000000000000000 OP3 0000000000000000
: Monitoring Internal Point Description of internal point(total 192 points)screen

PLC 0123456789ABCDEF 080: 0000100000000000 096 0000000000000000 112 0000000000000000
PgUp PgDn
PLC : Indicates internal node screen 0 : Signal OFF 1 : Signal ON 0 ~ F : Internal point number 080 : Indicates internal point status(M080~M095) 096 : Indicates internal point status(M096~M111) 112 : Indicates internal point status(M112~M128)
PLC 0123456789ABCDEF 128: 0000100000000000 144 0000000000000000 160 0000000000000000

PgUp PgDn
move a point with screen
PLC 0123456789ABCDEF 176: 0000100000000000 192 0000000000000000 208 0000000000000000

PgUp PgDn
The way to set an internal point ON/OFF is the same as output point.(refer to 4-22page)
PLC 0123456789ABCDEF 224: 0000100000000000 240 0000000000000000 256 0000000000000000
4 - 35
Chapter 4

Checking and monitoring system points (1)

How to shift to system I/O screen
User-output screen OUT 0123456789ABCDEF USR:0000000000000000 User-input screen IN 0123456789ABCDEF USR:0000000000000000
PgUp PgDn
PgDn
PgUp
System-output screen
System-input screen
OUT 0123456789ABCDEF SS0: 0000000000000000
IN 0123456789ABCDEF SS0: 0000000000000000 SS1: 0000000000000000
Description of system-output screen
OUT 0123456789ABCDEF SS0: 0000000000000000
Point No. on screen
System-output name RDY ORG_OK INPOS RUN Not used
System-output port number RCA(I)4-Series 35 11 36 12
0 1 2 3 Others
Example of system-output screen operation

OUT 0123456789ABCDEF SS0: 1000000000000000 READY (PIN 35): ON OUT 0123456789ABCDEF SS0:0100000000000000 ORG (PIN 11) : ON
OUT 0123456789ABCDEF SS0:0010000000000000 INPOS (PIN 36): ON
OUT 0123456789ABCDEF SS0:0001000000000000 RUN (PIN 12) : ON
4 - 36
Chapter 4

Checking and monitoring system points (2)

Description of system-input screen
IN 0123456789ABCDEF SS0: 0000000000000000 SS1: 0000000000000000
System-input port number Point No. on screen System-input name RCA(I)4-Series 0 1 2 3 4 5 PROG0 PROG1 PROG2 PROG3 PROG4 PROG_SEL ORG STOP START RST MODE_SEL VEL-/MOVVEL+/MOV+ IP BRK VEL MODE0/AXIS0 MODE1/AXIS1 4 29 31 6 30 5 7 8 32 33 13 14 39 46 47 48 25 50
SS0
6 7 8 9 A B C 0 1
SS1
2 3 4
Example of system-input operation

IN 0123456789ABCDEF SS0: 0000000001000000 SS1: 0000000000000000 MODE (PIN 13) : OK IN 0123456789ABCDEF SS0: 1110010000000000 SS1: 0000000000000000 PROG. SEL #7 : OK
4 - 37
Chapter 4

On-Line Connection
4.4 On-Line Connection
You can run robot automatically through serial communication (RS-22C) with Host computer. After power turns ON, it automatically runs in "HOST mode" by "H-OPEN" signal of serial communication cable (when communication cable is connected with controller) For more details, please refer to "Unihost User's Manual". Before using "HOST mode", set the controller parameters by using Teach Pendant and then set computer parameters identically.
4.4.1 Serial Cable Standard
Use the cable with the shield larger than 0.3mm 2 (min. lead thickness). Connect both shields (controller and computer) to the case of D-Sub Connector. Make the level of controller and FG (Frame Ground) of Host computer identical. (Connect the controller FG terminal and Host computer's FG terminal with the wire larger than 2mm 2.)
Keep the length of serial cable less than 10m. Connector Standard : D-Sub 9s (Socket Type)
4 - 38
Chapter 4

On-Line Connection
4.4.2 Serial Cable Connection Diagram
Serial Cable
FG FG
Computer
Robot Controller
Ground Ground
Controller Signal
RxD TxD GND H-OPEN
Computer Pin No. Pin No. 9 PIN

2 3 5 6 2 3 5 4 6 7 8
Signal 25 PIN
2 3 7 20 6 4 5 RxD TxD GND DTR DSR RTS CTS
<Note> Connection described above is standard robot specification. When using ordinary serial cable, please connect the Pin #6 of controller side to GND (#5). H-OPEN : When power On (Reset), it is automatically converted into PC communication mode with grounding pin #6. When the H-OPEN signal is high, select 3. HOST mode of Teach Pendant to convert to PC communication mode.
4 - 39
Chapter 4
4.5 Cartesian Coordinate Robot Connector (Incremental)
4.5.1 Internal Circuit Diagram
Body connector : 28 pin
4 8 12 16 20 24 11 7
1 5 10 14 9 13 17 21
A C B
15 D 19 23 22 18
Picture of Actual Product
4 - 40
Chapter 4
Body Connector : 28 pin

PART NO CONNECTOR NO CONNECTOR NAME Pin No.- Wire color Signal +5V not use GND5 not use EA /EA EU /EU EB /EB EV /EV EC /EC EW /EW SL+ SL+24V GND24 SORG BRK+ BRKFG(encoder) U V W FG(motor) No.1 Connector JMR2528 BODY CONNECTOR Contents ENCODER 5VOLTS NO CONNECTOR ENCODER GROUND NO CONNECTOR ENCODER A PHASE ENCODER /A PHASE ENCODER U PHASE ENCODER /U PHASE ENCODER B PHASE ENCODER /B PHASE ENCODER V PHASE ENCODER /V PHASE ENCODER C PHASE ENCODER /C PHASE ENCODER W PHASE ENCODER /W PHASE + LIMIT SENSOR - LIMIT SENSOR SENSOR 24VOLTS SENSOR GROUND ORIGIN BRAKE+ BRAKEFRAME GROUND(ENCODER) MOTOR U PHASE MOTOR V PHASE MOTOR W PHASE FRAME GROUND(MOTOR)
1 - red,red(white) 2 3 - black,black(white) 4 5 - brown 6 - brown(white) 7 - purple 8 - purple(white) 9 - orange 10 -orange(black) 11 - gray 12 - gray(black) 13 - yellow 14 - yellow(black) 15 - pink 16 - pink(black) 17 - white 18 - white(black) 19 - green 20 - green(white),blue(white) 21 - blue 22 - green 23 - green(black) 24 - black A - red B - white C - black D - green(yellow)
4 - 41
Chapter 4
Motor Connector : 4 pin
PART NO CONNECTOR NO CONNECTOR NAME Pin No. (wire color) (Red) (White) (Black) (Green-Yellow)
BODY CON PIN No.
No.2 / 6 Connector 172159-1 / 172167-1 MOTOR CONNECTOR Signal U V W FG(U,V,W) Contents MOTOR U PHASE MOTOR V PHASE MOTOR W PHASE FRAME GROUND (MOTOR)
A B C D
Encoder Connector : 15 pin
PART NO CONNECTOR NO CONNECTOR NAME Pin No. / Body Pin No. / 5 (Brown) / 6 (Brown-White) / 9 (Orange) / 10 (Orange-Black) / 13 (Yellow) / 14 (Yellow-Black) / 7 (Purple) / 8 (Purple-White) Signal EA /EA EB /EB EC /EC EU /EU
No. 3 / 7 Connector 172163-1 / 172171-1 ENCODER CONNECTOR Contents ENCODER A PHASE ENCODER /A PHASE ENCODER B PHASE ENCODER /B PHASE ENCODER C PHASE ENCODER /C PHASE ENCODER U PHASE ENCODER /U PHASE
4 - 42
Chapter 4
/ 11 (Gray) / 12 (Gray-Black) / 15 (Pink) / 16 (Pink-Black) / 1 (Red, Red-White) / 3 (Black, Black-White) / 24 (Black)
EV /EV EW /EW +5V GND5 FG(ENCODER)
ENCODER V PHASE ENCODER /V PHASE ENCODER W PHASE ENCODER /W PHASE ENCODER 5VOLTS ENCODER GROUND FRAME GROUND(ENCODER)
Sensor connector : 6 pin
PART NO CONNECTOR NO CONNECTOR NAME Pin No./Body Pin No. / 19 (Green) / 20 (Green-White, Blue-White) / 17 (White) / 18 (White-Black) / 21 (Blue) Signal S24V SGND SL+ SLSORG not use
No. 4 / 8 Connector 5559-06 / 5557-06 SENSOR CONNECTOR Contents SENSOR 24VOLTS SENSOR GROUND + LIMIT SENSOR - LIMIT SENSOR ORIGIN NO CONNECTOR
Brake connector : 2 pin

PART NO CONNECTOR NO CONNECTOR NAME Pin No. / Body Pin No. / 22 (Green) / 23 (Green-Black) Signal BRK + BRK -
No. 5 / 9 Connector 172157-1 / 172165-1 BRAKE CONNECTOR Contents BRAKE + BRAKE -
4 - 43
Chapter 4
4.5.2 Body Connector Wiring

If you want to wire motor (TAMAGAWA,LG,MINAS), sensor, and brake onto body connector, do as follows. (for RCM4) BODY CONNECTOR ( JMR2528 DDK ) : For contents of signals, refer to 4.5.1 (page 4-29).
Signal Wire color (Tamakawa) Wire color (LG) Wire color (Minas)
Pin No. - Wire color 1 - Red, Red(White) 2 3 - Black, Black(White) 4 5 - Brown 6 - Brown(White) 7 - Purple 8 - Purple(White) 9 - Orange 10 -Orange(Black) 11 - Gray 12 - Gray(Black) 13 - Yellow 14 - Yellow(Black) 15 - Pink 16 - Pink(Black) 17 - White 18 - White(Black) 19 - Green
20 - Green(White), Blue (White)
+5V not used GND5 not used EA /EA EU /EU EB /EB EV /EV EC /EC EW /EW SL+ SL+24V GND24 SORG BRK+ BRKFG(Encoder) U V W FG(Motor)
Red
White
White
Black
Black
Black
Blue Blue(Black) Brown Brown(Black) Green Green(Black) Gray Gray(Black) Yellow Yellow(Black) White White(Black) Yellow Yellow shield Red White Black Green
Green Blue Green Gray Red Pink Light pink Brown Yellow Orange Sky blue Purple -
Red Pink Peach Brown Green Blue Green Gray Yellow Orange Sky blue Purple Yellow Yellow shield Pink White Black Green(Yellow)
21 - Blue 22 - Green 23 - Green(Black) 24 - Black A - Red B - White C - Black D - Green(Yellow)
4 - 44
Chapter 4
4.6 Cartesian Coordinate Robot Connector (Absolute) 4.6.1 Internal circuit diagram It is assembled in Robot body and has connectors for Motor power, Encoder and Sensor.
4 8 12 16 20 11 15 7
3 A C D 19
2 6 B
1 5 10 14 18 17 21 9 13
24
23
22
4 - 45
Chapter 4
Motor connector : 4 pin
BODY CON PIN No.
A B C D
4 - 46
Chapter 4
PART NO CONNECTOR NO CONNECTOR NAME Pin No./Body Pin No. / 19 (Green) / 20 (Green-White, Blue-White) / 17 (White) / 18 (White-Black) / 21 (Blue) Signal S24V SGND SL+ SLSORG not used

4 - 47
Chapter 4
Encoder Battery connector : 4 pin
CONNECTOR NO. CONNECTOR NAME Pin No./Body Pin No. (Green) / 1 (RED) (Black) (White) Signal Encoder Reset +5V GND5 BAT +
5102-4 ENCODER BATTERY CONNECTOR Contents Encoder Data Reset Signal ENCODER +5VOLT ENCODER GROUND (Battery common use) BATTERY + Power
4 - 48
Chapter 4
4.6.2 Body Connector Pin Array

If you want to wire Motor(KOMOTEK), Sensor, Brake onto Body Connector, do as follows. (Applied Controller : RCA(I)4 Series) BODY CONNECTOR ( JMR2528 DDK ) : See 4.6.1 for the explanation of signal name. PIN No. Color
1 - Red,Red(White) 2 3 - Black,Black(White) 4 5 - Brown 6 - Brown(White) 7 - Purple 8 - Purple(White) 9 - Orange 10 - Orange(Black) 11 - Gray 12 - Gray(Black) 13 - Yellow 14 - Yellow(Black) 15 - Pink 16 - Pink(Black) 17 - White 18 - White(Black) 19 - Green 20 - Green(White),Blue(White) 21 - Blue 22 - Light Green 23 - Light Green(Black) 24 - Black A - Red B - White C - Black D - Green(Yellow)
Signal +5V not use GND5 not use EA /EA Not Used Not Used EB /EB Not Used Not Used EC /EC Rx /Rx SL+ SL+24V GND24 SORG BRK+ BRKFG(Encoder) U V W FG(Motor)
Color (Tamakawa) -
Color (LG) -
Color (Minas) -
Blue Blue(Black) Brown Brown(Black) Light green Light green(Black) Gray Gray(Black) Yellow Yellow(Black) White White(Black) Yellow Yellow shield Red White Black
Light Green Blue Green Gray Red Pink Light Pink Brown Yellow Orange Sky blue Purple -
Red Pink Peach Brown Light Green Blue Green Gray Yellow Orange Sky Blue Purple Yellow Yellow shield Pink White Black Green(Yellow)
Light Green
4 - 49
Chapter 4
4.5 Cartesian Coordinate Robot Connector (Incremental)
4.5.1 Internal Circuit Diagram
4 8 12 16 20 24 11 7
1 5 10 14 9 13 17 21
A C B
15 D 19 23 22 18
4 - 40
Chapter 4
Body Connector : 28 pin

PART NO CONNECTOR NO CONNECTOR NAME Pin No.- Wire color Signal +5V not use GND5 not use EA /EA EU /EU EB /EB EV /EV EC /EC EW /EW SL+ SL+24V GND24 SORG BRK+ BRKFG(encoder) U V W FG(motor) No.1 Connector JMR2528 BODY CONNECTOR Contents ENCODER 5VOLTS NO CONNECTOR ENCODER GROUND NO CONNECTOR ENCODER A PHASE ENCODER /A PHASE ENCODER U PHASE ENCODER /U PHASE ENCODER B PHASE ENCODER /B PHASE ENCODER V PHASE ENCODER /V PHASE ENCODER C PHASE ENCODER /C PHASE ENCODER W PHASE ENCODER /W PHASE + LIMIT SENSOR - LIMIT SENSOR SENSOR 24VOLTS SENSOR GROUND ORIGIN BRAKE+ BRAKEFRAME GROUND(ENCODER) MOTOR U PHASE MOTOR V PHASE MOTOR W PHASE FRAME GROUND(MOTOR)
1 - red,red(white) 2 3 - black,black(white) 4 5 - brown 6 - brown(white) 7 - purple 8 - purple(white) 9 - orange 10 -orange(black) 11 - gray 12 - gray(black) 13 - yellow 14 - yellow(black) 15 - pink 16 - pink(black) 17 - white 18 - white(black) 19 - green 20 - green(white),blue(white) 21 - blue 22 - green 23 - green(black) 24 - black A - red B - white C - black D - green(yellow)
4 - 41
Chapter 4
Motor Connector : 4 pin
BODY CON PIN No.
A B C D
4 - 42
Chapter 4
PART NO CONNECTOR NO CONNECTOR NAME Pin No./Body Pin No. / 19 (Green) / 20 (Green-White, Blue-White) / 17 (White) / 18 (White-Black) / 21 (Blue) Signal S24V SGND SL+ SLSORG not use

4 - 43
Chapter 4
4.5.2 Body Connector Wiring

If you want to wire motor (TAMAGAWA,LG,MINAS), sensor, and brake onto body connector, do as follows. (for RCM4) BODY CONNECTOR ( JMR2528 DDK ) : For contents of signals, refer to 4.5.1 (page 4-29).
Signal Wire color (Tamakawa) Wire color (LG) Wire color (Minas)
Pin No. - Wire color 1 - Red, Red(White) 2 3 - Black, Black(White) 4 5 - Brown 6 - Brown(White) 7 - Purple 8 - Purple(White) 9 - Orange 10 -Orange(Black) 11 - Gray 12 - Gray(Black) 13 - Yellow 14 - Yellow(Black) 15 - Pink 16 - Pink(Black) 17 - White 18 - White(Black) 19 - Green
20 - Green(White), Blue (White)
+5V not used GND5 not used EA /EA EU /EU EB /EB EV /EV EC /EC EW /EW SL+ SL+24V GND24 SORG BRK+ BRKFG(Encoder) U V W FG(Motor)
Red
White
White
Black
Black
Black
Blue Blue(Black) Brown Brown(Black) Green Green(Black) Gray Gray(Black) Yellow Yellow(Black) White White(Black) Yellow Yellow shield Red White Black Green
Green Blue Green Gray Red Pink Light pink Brown Yellow Orange Sky blue Purple -
Red Pink Peach Brown Green Blue Green Gray Yellow Orange Sky blue Purple Yellow Yellow shield Pink White Black Green(Yellow)
21 - Blue 22 - Green 23 - Green(Black) 24 - Black A - Red B - White C - Black D - Green(Yellow)
4 - 44
Chapter 4
4.6 Cartesian Coordinate Robot Connector (Absolute) 4.6.1 Internal circuit diagram It is assembled in Robot body and has connectors for Motor power, Encoder and Sensor.
4 8 12 16 20 11 15 7
3 A C D 19
2 6 B
1 5 10 14 18 17 21 9 13
24
23
22
4 - 45
Chapter 4
Motor connector : 4 pin
BODY CON PIN No.
A B C D
4 - 46
Chapter 4
PART NO CONNECTOR NO CONNECTOR NAME Pin No./Body Pin No. / 19 (Green) / 20 (Green-White, Blue-White) / 17 (White) / 18 (White-Black) / 21 (Blue) Signal S24V SGND SL+ SLSORG not used

4 - 47
Chapter 4
Encoder Battery connector : 4 pin
CONNECTOR NO. CONNECTOR NAME Pin No./Body Pin No. (Green) / 1 (RED) (Black) (White) Signal Encoder Reset +5V GND5 BAT +
5102-4 ENCODER BATTERY CONNECTOR Contents Encoder Data Reset Signal ENCODER +5VOLT ENCODER GROUND (Battery common use) BATTERY + Power
4 - 48
Chapter 4
4.6.2 Body Connector Pin Array

If you want to wire Motor(KOMOTEK), Sensor, Brake onto Body Connector, do as follows. (Applied Controller : RCA(I)4 Series) BODY CONNECTOR ( JMR2528 DDK ) : See 4.6.1 for the explanation of signal name. PIN No. Color
1 - Red,Red(White) 2 3 - Black,Black(White) 4 5 - Brown 6 - Brown(White) 7 - Purple 8 - Purple(White) 9 - Orange 10 - Orange(Black) 11 - Gray 12 - Gray(Black) 13 - Yellow 14 - Yellow(Black) 15 - Pink 16 - Pink(Black) 17 - White 18 - White(Black) 19 - Green 20 - Green(White),Blue(White) 21 - Blue 22 - Light Green 23 - Light Green(Black) 24 - Black A - Red B - White C - Black D - Green(Yellow)
Signal +5V not use GND5 not use EA /EA Not Used Not Used EB /EB Not Used Not Used EC /EC Rx /Rx SL+ SL+24V GND24 SORG BRK+ BRKFG(Encoder) U V W FG(Motor)
Color (Tamakawa) -
Color (LG) -
Color (Minas) -
Blue Blue(Black) Brown Brown(Black) Light green Light green(Black) Gray Gray(Black) Yellow Yellow(Black) White White(Black) Yellow Yellow shield Red White Black
Light Green Blue Green Gray Red Pink Light Pink Brown Yellow Orange Sky blue Purple -
Red Pink Peach Brown Light Green Blue Green Gray Yellow Orange Sky Blue Purple Yellow Yellow shield Pink White Black Green(Yellow)
Light Green
4 - 49
Chapter 4

SCARA Robot Connector
4.7 Scara Robot Connector
B B Upper Connection Panel

for Utility
AIR-1
AIR-2
Attach SOL V/V to be used with robot hand
I/O
A
Rear Connection Panel
6 Air fitting 2 pcs (PMM0600) * To connect Air tube for Hand 4 Ports is option
10 pins body I/O connector (SRCN2A16-10S:Samwoo) It is connected to upper panel of B ARM * To use connection of I/O for Hand tool (Sensor,sol coil, . . .) 24 pins connector is option.
Absolute Encoder Clear Button When needed to clear Encoder Data, press button of each axis for about 6~7 seconds
4 - 50
Chapter 4

4.7.2 Absolute Encoder Backup Battery Board (only for Absolute)
When take the 'A' panel out from SCARA body, you can see the battery board.
Battery Board
Two methods to replace battery (No. 1) method is recommended) 1) Battery must be replaced when POWER of controller is ON. (But, for safety, it should be in EMG state) 2) In the state of which Encoder internal capacitor is fully charged by keeping power on for certain hours, turn the power of controller off and replace the batteries as quickly as possible.
To avoid damage on board by electrical shock, it is recommended to use insulation glove when replacing battery.
4 - 51
Chapter 4

Limit Sensor specification : DC 24V, NC(Normal Close) type ORIGIN sensor specification : DC 24V, NO(Normal Open) type
Wiring of connector, refer to chapter 4.5 and 4.6
4 - 52
Chapter 5

5. Time Chart of System Input/Output Operation
5.1 Basic Functions * In case of N type, refer to Chapter 4.

When open, "Servo Not Ready" error occurs Refer to Appendix 7.9
Note "Common connection".
It is possible to choose 32 (25) programs externally. You can change the number of connections as required. - Binary format. - when you need to choose 4 programs: connect the 2 pins, PROG 0 and PROG 1.
Internal Current MAX.500mA Note "Common connection".
* When you use external DC24V power supply, DO NOT connect internal power. * External supplying power is DC24V 10% * When soldering connector pins during wiring jobs, pins should be isolated or insulated by using tube so that pins would not be shortcircuited . * Use external power supply as much as possible.
5-1
Chapter 5

Time Chart of System Input/Output
5.1.1 Time Chart of System Input/Output
For PLC sequence program, refer to "Chapter 7 Appendices".

(1) Time Chart of Normal Operation
Power ON
ON OFF ON OFF
Only after servo OFF, you can reset.
Input EMG
Output Alarm
ON OFF
Input Reset
ON OFF ON OFF
Output Ready
more than 50ms
Input Origin
Output Origin OK
ON OFF ON OFF
Within 10ms after origin setting
Input Program 0~4
ON OFF ON OFF ON OFF
Select Program Input Start
Prog. No. detected at Falling Edge.

more than 10ms
Output Run
ON OFF
Very Important
Input Stop
ON OFF
Pulse width of standard single shot signal is more than 30ms. If you start it without inputting 'Program Select', then program no. 0 will run. Signal is checked at every 10ms. So if you set interval between input signals more than 10ms, then there may be no errors.
If you start under a state without having these two signals, the program will select " # 0 " unconitionally.
5-2
Chapter 5

Example of Operation Panel
(2) Example of Operation Panel
Robot ORIGIN OK System Output Signal Connection
Robot RUN System Output Signal Connection
Robot Alarm System Output Signal Connection
Operation Panel
Robot Origin Lamp Robot RUN Lamp Robot alarm lamp
Machine Type Selection Switch
Stopping robot, when shifting its operation into manual mode it does not matter.
Robot Program Selection System Input Signal Connection The situation that allows a continuous input of Program Selection Signal it does not matter.
Power
Automatic
manual
Select Manual
Add origin setting to the manual mode and allow origin setting to perform in manual model. Operation Ready Automatic Start Manual Return to
The finger" of the Robot should be able to be operated separately in the manual mode.
Emergency Stop Automatic Stop Reset

Emergency Reversing
Robot START System Input Signal Connection After inputting program selector signal first, and at the moment of OFF after 10ms, then turn START ON.
Robot Emergency Stop System Input Signal Connection
Robot STOP System Input signal Connection Robot will be stopped. When the safety door sensor is OPEN; it will stop, and when it is CLOSE; it will run.
Robot Reset System Input Signal Connection Reset when Alarm activates. If Alarm does not activate, input the Emergency STOP signal of PLC sequence forcedly, and input the reset signal, then you can exit the program.
5-3
Chapter 5

System I/O Signal Sequence
(3) System I/O Signal Sequence (for reference when programming PLC sequence)
Sequence
Operation & Operating Panel Display
PLC Sequence Process
Robot Operation
Facility Power ON
Ready Switch ON
Ready to Run
Auto/Manual Selection Switch Select Manual
In manual mode, select 'origin setting' and 'ON'
Origin input signal ON
Origin Setting Start
Robot origin lamp ON
(Internal Process)
Origin OK output ON
Auto/Manual Selection Switch Select Auto
Auto start Switch ON
EMG input signal ON
Auto Run
Robot Alarm lamp ON (Internal Process) Alarm Output ON
Reset Input ON
5-4
Chapter 5

System Input/Output Signal Sequence
Sequence
Operation & Operating Panel Display
PLC Sequence Process
Robot Operation
Ready Output ON
Auto Run
Job program selection ON (Internal Processing) Prog. Sel Input Signal ON Prog.0~4 Input Signal ON
after 10ms from Prog.Sel input signal OFF
START Input Signal ON
Robot RUN lamp ON
(Internal Process)
RUN Output Signal ON
Note
Robot system input signal must be a pulse signal (over 30ms). It is because robot will not stop but keeps running even after STOP signal turned ON while keeping START signal ON. Robot system output signal remains ON.
5-5
Chapter 5

System Input/Output (Basic Function)
(4) When Changing JOB PROGRAM while running
JOB PROG. 0
JOB PROG. 1
000 001 002 003 004
MAIN JMOV P0 JMOV P1 JMOV P2 EOP
000 001 002 003 004
MAIN JMOV P3 JMOV P4 JMOV P5 EOP
: When you want to run Job Prog. 1 while Job Prog. 0 running
Origin OK (Output)
ON OFF ON OFF
RUN (Output )
STOP (Input )
ON OFF
PROG.0~4 (Input) PROG.SEL (Input)
ON OFF ON OFF ON OFF over 10ms
START (Input)
5-6
Chapter 5

: When you want to run Job Prog. 1 after completing Job Prog. 0 (EOP executed)
Note 2)
Origin OK (Output)
ON OFF EOP ON OFF
Note 1)
RUN (Output)
PROG.0~4 (Input) PROG.SEL (Input) START (Input)
ON OFF ON OFF ON OFF over 10ms
Note 1) If Run output turns OFF while Job Program is running normally, these are the cases: - When Stop signal has been inputted (Servo remains ON) - When processing the command ("EOP") that indicates the end of Program while Job Program is running. (Servo turns OFF, Run output turns OFF without external input)
Note 2) After completion of Origin Setting by initial Origin Setting input, Origin OK output remains ON until power OFF unless a new Origin Setting signal is inputted. Therefore, the initial origin is maintained even though the system is resetted by Job program change, EMG or Alarm occurrence, and so on.
5-7
Chapter 5

(5) In case of Emergency Stop or Alarm while Running

Input "STOP" signal in system input.
First of all, release the alarm.

Input "RESET" signal in system input.
Input "START" signal after "STOP" signal inputted (page 5-9) Input "RESTART"signal after "STOP" inputted (page 5-9) Input "START" signal after "RESET" inputted (page 5-10)
After then, run again.
Important
Difference between "START" and "RESTART" ? - RESTART : Start from the step just when alarm occurs . - START : Start program from the first step.
EMG or Alarm
Ex) P0
START RESTART
P1
Program MAIN VEL 10 WHILE 1 JMOV P0 JMOV P1 ENDWL EOP START
RESTART
5-8
Chapter 5

Input "START" after "STOP" inputted
EMG (Input)
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF over 20ms To release Alarm To start from the first step
ALARM (Output) READY (Output) RUN (Output) STOP (Input) START (Input)
Input "RESTART" after "STOP" inputted
EMG (Input)
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF
ALARM (Output) READY (Output) RUN (Output) STOP (Input) START (Input)
5-9
Chapter 5

Input "START" after "RESET" inputted
RUN (Output)
ON OFF Within 350ms ON OFF Within 5ms Within 80ms after RESET ON OFF Within 650ms Within 3s after RESET ON OFF ON OFF ON OFF more than 10ms more than 10ms ON OFF more than 10ms ON OFF more than 30ms more than 10ms after READY output OFF more than 10ms
EMG(Input) or ALARM(Input)
ALARM (Output) READY (Output) RESET (Input) PROG.0~4 (Input) PROG.SEL (Input) START (Input)
RESET (Input)
Initialize PROG. NO. Release ALARM, and turn ON READY output.
5 - 10
Chapter 5
Time Chart of SystemInput/Output Operation

(6) In case of Servo Off after STOP while Running
START (Input)
ON OFF ON OFF ON OFF ON OFF Servo OFF after recognizing STOP twice
STOP (Input) Servo ON RUN (Output)
Servo ON
System I/O does not have Servo ON signal pin. You can verify Servo ON/OFF by "SVON Lamp" of Teach Pendant.
5 - 11
Chapter 5

System Input/Output (Highly Sophiscated Functions)
5.2 Highly Sophiscated Functions
5.2.1 Mode Selection

(1) Flow Chart of Mode Selection (JOG Mode is Option)
Start
@1
MODE SEL signal OPEN?
YES
AUTO MODE
NO YES
M0/A0:OFF M1/A1:OFF MODE SEL
@1
AUTO MODE
NO YES
M0/A0:ON M1/A1:OFF MODE SEL
@2
STEP MODE
NO YES
M0/A0:OFF M1/A1:ON MODE SEL
@3
JOG MODE
NO YES
M0/A0:ON M1/A1:ON MODE SEL
@4
HOST MODE
NO YES
Mode Change?
NO
End
Note
< You can't use JOG mode. JOG mode is optional.>
5 - 12
Chapter 5

(2) Time Chart of Mode Selection just after Power ON < You can't use JOG mode. JOG mode is optional.>
Power ON MODE0/AXIS0 (Input)
ON OFF #1 ON OFF
@1
@2
@3
@4
@1 #2
MODE1/AXIS1 (Input)
ON OFF ON OFF
MODE SEL (Input)
For the descriptions about @1 ~ @12, refer to 5.2.3(page 5-25).
Description of Time Chart (JOG Mode is Option)

MODE1/AXIS1 MODE0/AXIS0 Operation Mode AUTO RUN MODE STEP RUN MODE JOG MODE SYSTEM MODE (Option)
Remarks @1 @2 @3 @4
OFF OFF ON ON
OFF ON OFF ON
HOST MODE
Important
#1 : Operation mode is automatically set in AUTO RUN MODE after power ON. The condition with three signals(MODE1/AXIS1, MODE0/AXIS0, MODE SEL) not wired on the controller(basic function configuration) is the same condition as of #1. #2 : Changing operation mode to AUTO RUN MODE. Operation mode does not change successively in the above-described sequence. After power ON, you can freely select mode according to MODE1/AXIS1, MODE0/AXIS0, MODE SEL.
5 - 13
Chapter 5

5.2.2 Mode Description
5.2.2.1 AUTO RUN MODE (page 5-14) 5.2.2.2 STEP RUN MODE (page 5-15) 5.2.2.3 JOG MODE(option) (page 5-19)
5.2.2.1 AUTO RUN MODE
1) AUTO RUN MODE Time Chart

In Auto Run Mode after power ON, the time chart about the functions of Origin Setting, PROG.SEL, START, STOP are identical with basic function time chart. (Refer to basic function time chart.) For the descriptions about @1 ~ @12, refer to 5.2.3 (page 5-25).
ON OFF ON OFF ON OFF ON OFF ON OFF ORIGIN (Input) ORIGIN OK (Output) PROG.0~4 (Input) PROG.SEL (Input) START (Input) RUN (Output) STOP (Input) ON OFF ON OFF ON OFF ON OFF To change operation mode to Auto RUN Mode after STEP, JOG(option), HOST MODE, input MODE SEL.
POWER ON
READY (Output) MODE0/AXIS0 (Input)
MODE1/AXIS1 (Input)
MODE SEL
@5
ON OFF ON OFF
@1
ON OFF
#1
5 - 14
Chapter 5

2) Changing operation mode from AUTO RUN MODE
Run in AUTO MODE
#1
MODE Change ?
STEP MODE
JOG MODE (option)
HOST MODE
5.2.2.2 STEP RUN MODE
(1) Changing AUTO RUN MODE to STEP RUN MODE while job running
Flow Chart
Power ON
MODE Selection
AUTO MODE
STEP MODE
JOG MODE (option)
HOST MODE
YES
MODE SEL OPEN?
NO
End
5 - 15
Chapter 5

Time Chart
RUN (Output) ON OFF ON OFF ON OFF ON OFF
In AUTO RUN MODE
STOP (Input) MODE0/AXIS0 (Input)
Job stops in AUTO RUN MODE
MODE1/AXIS1 (Input)
@6
MODE SEL ON OFF
When MODE SEL ON, operation mode changes to STEP RUN MODE
Start from the step stopped in AUTO RUN MODE - Input START : Run by 1 STEP - VEL-/MOV- : Decrease by 1 STEP - VEL+/MOV+ : Increase by 1 STEP
@7
START (Input) RUN (Output) STOP (Input) VEL-/MOV(Input) ON OFF ON OFF ON OFF
@8
@8
#1
@13
@7
ON OFF
@9
VEL+/MOV+ (Input) ON OFF
#1 : RUN output is ON while 1 STEP is running.
For descriptions about @1 ~ @12, refer to 5.2.3 (page 5-25).
5 - 16
Chapter 5

(2) STEP RUN MODE after initial Power ON
Flow Chart
Power ON
MODE SELECTION
AUTO MODE
STEP MODE
JOG MODE
HOST MODE
YES
MODE SEL OPEN?
NO
END
The Time Chart of "Origin Setting", "Job Selection" in STEP RUN MODE is identical with AUTO RUN MODE. (refer to page 5-14)
5 - 17
Chapter 5

Time Chart
For the descriptions about @1 ~ @12, refer to 5.2.3(page 5-25).
MODE0/AXIS0 (Input) ON OFF ON OFF
MODE1/AXIS1 (Input)
@6
MODE SEL ON OFF
When MODE SEL ON, operation mode changes to STEP RUN MODE.
Start from the step stopped in AUTO RUN MODE. - Input START : Run by 1 STEP - VEL-/MOV- : Decrease by 1 STEP - VEL+/MOV+ : Increase by 1 STEP
@7
START (Input) RUN (Output) STOP (Input) VEL-/MOV(Input) ON OFF ON OFF ON OFF
@8
@8
#1
@13
@7
ON OFF
#1
@9
VEL+/MOV+ (Input) ON OFF
Run in JOG MODE
#1 NO
MODE Change ?
YES
AUTO MODE
JOG MODE(option)
HOST MODE
1. For continuous STEP RUN MODE MODE change Input START 2. For a new JOB MODE change Job Selection input START
5 - 18
Chapter 5


5.2.2.3 JOG MODE
JOG MODE Time Chart

Axis 1
MODE0/AXIS0 (Input) ON OFF ON OFF ON OFF VEL-/MOV(Input) VEL+/MOV+ (Input) ON OFF ON OFF ON OFF
Axis 1
Axis 2
MODE1/AXIS1 (Input)
@3
MODE SEL
@10
@12
@11
RUN (Output)
For the descriptions about @1 ~ @12, refer to 5.2.3 (page 5-25).
1. After operation mode changed to JOG MODE, MODE0/AXIS0 and MODE1/AXIS1 will be changed to signals used for selecting the axis to move in JOG MODE. The axis, according to ON, OFF combination of Two signals(MODE0/AXIS0, MODE1/AXIS!), moves when each of VEL-/MOV- and VEL+/MOV+ has been inputted.
Combination of selecting axis MODE1/AXIS1 OFF OFF ON ON MODE0/AXIS0 OFF ON OFF ON Selected Axis Axis 1 Axis 2 Axis 3 Axis 4
5 - 19
Chapter 5

2. When changing operation mode to other mode from JOG MODE, inputting "STOP" is not necessary.
Run JOG MODE
NO
MODE Change ?
YES
AUTO MODE
JOG MODE
HOST MODE
5 - 20
Chapter 5

5.2.2.4 HOST MODE
(1) After "Origin Setting, Job selection, Job running" by using PC system I/O
"Stop running Job and then Restart" by using
Flow Chart - 1)
MODE Change ?
YES
AUTO MODE
STEP MODE
Run in HOST MODE
JOG MODE(option)
1. Origin setting, Job selection, Job running
2. JOB FILE UPLOAD, DOWNLOAD, POSITION MOVEMENT
NO
MODE Change ?
YES
Input STOP of system I/O Stop running job START,STOP signals available (AUTO MODE function)
5 - 21
Chapter 5

Flow Chart - 2)
MODE Change ?
YES
AUTO MODE
STEP MODE
Run in HOST MODE
JOG MODE(option)
1. Origin Setting, Job selection, Job running
2. JOB FILE UPLOAD, DOWNLOAD, POSITION MOVEMENT
NO
MODE Change ?
YES
Input STOP of system I/O Stop running job START,STOP signals available (AUTO MODE function)
5 - 22
Chapter 5

Time Chart
MODE0/AXIS0 (Input)
ON OFF ON OFF
MODE1/AXIS1 (Input)
@4
MODE SEL ON OFF
When MODE SEL ON, operation mode changes to HOST MODE.
"Origin Setting", "Job selection", "Job running" by using PC
"STOP", "START" running job by using system I/O
STOP (Input) START (Input) RUN (Output)
ON OFF ON OFF ON OFF
5 - 23
Chapter 5

(2) After "Origin Setting, Job selection, Job running" by using PC
"Stop running job, Restart" by using system I/O
Time Chart
MODE0/AXIS0 (Input)
ON OFF ON OFF
MODE1/AXIS1 (Input)
@4
MODE SEL ON OFF
@1
Using PC, perform JOB FILE UPLOAD, DOWNLOAD, POSITION MOVEMENT

ORIGIN (Input) ORIGIN OK (Output) PROG.0~4 (Input) PROG.SEL (Input) START (Input) RUN (Output) STOP (Input) ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF Over 10 ms
MODE Selection : AUTO MODE
5 - 24
Chapter 5

5.2.3 TEACH PENDANT Display of each mode and 7-Segment Display in Front Panel
TEACH PENDANT Display 7-Segment Display
No.
SYSTEM MODE
@1
Auto Run Mode
SYSTEM MODE
@2
Step Run Mode
SYSTEM MODE
@3
Jog Mode
@4
HOST MODE COM : STA :
@5
AUTO RUN F:TEST S:16 V:20 INS : JMOV P0 STOP
SYSTEM MODE
@6
Step Run Mode
@7
STEP RUN F:TEST S:16 V:20 INS : JMOV P1 INC DEC EXEC STOP
5 - 25
Chapter 5

No.
TEACH PENDANT Display
7-Segment Display
@8
@9
@10
-150.64 52.54 1 AXIS MOVING -
@11
-110.55 32.66 1 AXIS MOVING +
SYSTEM MODE
@12
-110.55 32.66 2 AXIS MOVING -
SYSTEM MODE
@13
Step Run Mode
5 - 26
Chapter 6
Maintenance and Repairing

Indication of Abnormal Condition
6. Maintenance and Reparing

6.1 Indication of Abnormal Condition
When the robot is abnormal (alarm or protective circuit will run), the controller turns OFF Servo and turns on dynamic brake to stop the robot and then indicates the error code on the front panel 7 segments and displays a simple error message on the screen of Teach Pendant.
If any error occurs, please find out the cause of error and take appropriate action on that error. After the troubleshooting is completed, you can release the alarm by Reset key of front panel or Teach Pendant.
If an error occurs while running by Teach Pendant, press ESC, and then you can continue the job other than robot operation.
7-Segment Indications in normal operation
Indications Operation Teach Pendant Initial Power ON Main Menu Running Origin Setting Complete Initial Screen

System P000 orG. P000 P000 P000~P031 P000~P099 r000~r999 r022
Host Host rdy. orG. rdy. P000 P000~P099 r000~r999 r022
P000 rdy. orG. rdy. P000 P000~P099
Input JOB Prog. Sel Input Digit, increase RUN Mode or decrease signals Running JOB Prog. Input STOP Key
r000~r999 r022
: Indicates the Job No. selected according to ON/OFF combination of Program 0 ~ Program 4 in system mode. : Selects JOB Program between 0 and 99 by using digit and increase/decrease signals. : Indicates Program Step currently running in JOB Program. : Indicates Program Step NO. at the time when STOP signal was inputted.
6-1
Chapter 6

E001
6.2 Abnormal Conditions and Troubleshooting (Error Code)
E001 ---- Following Error
Explanation> Movement delay error : Motor's following position delays beyond the specified values comparing the positions being commanded. Check Point of Control Part
Cause 1) System parameter (FOW) setting is abnormal. Troubleshooting 1) Adjust FOW value of PROTECT : Standard set value is 10. If error occurs during the process of acceleration or deceleration, standard value will be increased by 2 ~ 5 (within 12,15,. . . . ,50) Teach Pendant Operation Sequence)
Select 4. PARA in main menu screen Input "1111" (Ver. 1.0A or above) "Valid" message is displayed. Change setting value
Select 4. PROTECT from PARAMETER(0) ESC ENTER ESC ESC
Select 2.FOW from PROTECT(0)
Reboot controller (Press F1 after pressing EMG, and then ENTER)
Cause 2) rated velocity (Mv) is set excessively. Troubleshooting 2) Check RPM setting (Mv) of parameter : 3000 or less is proper.
Set operating velocity(VEL) of robot program (JOB) with consideration of loading capacity : For Scara, operating velocity varies depending on payload. Standard SCARA : 10kgf(medium speed), 5kgf(high speed). Long type SCARA : 15kgf(medium speed), 10kgf(high speed).
Teach Pendant Operation Sequence)

Select 4.PARA from main menu screen Input "1111" (Ver. 1.0A or above) Select 2.JONT "Valid" message is displayed.
Select 2.MOTION from PARAMETER(0) ESC ENTER ESC ESC
Change Mv setting value

Change Mv setting value
Reboot controller (Press F1 after pressing EMG, and enter ENTER)
6-2
Chapter 6

E001
Cause 3) Rated acceleration/deceleration time (At) has been set excessively. Troubleshooting 3) Check the acceleration/deceleration time (At) setting of parameter In case of cartesian coordinate robot, more than 0.15sec. But if Ball Screw Lead is over 20mm or if there is frequent overshoots, then increase the acceleration/deceleration time. Standard SCARA : 0.3sec, Long type SCARA : Over 0.4sec is proper.

Change At setting value
Cause 4) Inappropriate gain setting (PVG) of each axis Troubleshooting 4) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. Teach Pendant Operation Sequence)
Select 4.PARA from main menu screen Select 3.GAIN from PARAMETER(0) ESC ENTER ESC ESC Input "1111" (Ver. 1.0A or above) Select 1.PVG "Valid" message is dislayed.
Change setting value
Check Point of Mechanical Part
Cause 1) In case of overload by either excessive payload or interference with peripheral devices during running Troubleshooting 1) Check if payload is proper.
Do not exceed Loading Capacity compared with operation velocity. (For SCARA, payload varies depending on velocity.) -. Standard SCARA : 10kgf (medium velocity), 5kgf(high velocity). -. Long type SCARA : 15kgf (medium velocity), 10kgf(high velocity).
6-3
Chapter 6

E002
E002 ---- S/W Limit
Explanation> Go beyond the movement limit set by the user.
Cause 1) Go beyond the operation range(RANGE) of system parameter Troubleshooting 1) For the errors occurring during origin setting or job running, check and adjust
job teaching point. Adjust the operation range(RANGE) of system parameter at rated value.
- For cartesian coordinate robot : Set at about -5(min) ~ Stroke(max) as arm length - For SCARA : in case of A, B, W axes, it will be set by angle, and for Z axis, it wil be done by stroke length. Teach Pendant Operation Sequence) Check the point in trouble Change position of teaching point and save it.

Select 4.PARA from main menu screen Select 1.BODY from PARAMETER(0) ESC ENTER ESC ESC Input "1111" (Ver. 1.0A or above) Select 3.RANG "Valid" message is displayed.
Change setting value
Cause 2) Robot goes beyond the operation range set by LIMT command during job running. Troubleshooting 2) , Adjust the operation range set in program with LIMT command.
Check and adjust the teaching points coordinate is within operation range.
Teach Pendant Operation Sequence) Change position of teaching point and save it.
Check the point in trouble
6-4
Chapter 6

E003
E003 ---- Over-Speed
Explanation> Over-speed Error : Running speed exceeds 110% of the rated speed.
Cause 1) OVS of system parameter has been set incorrectly. Troubleshooting 1) Check if OVS of PROTECT meets 110% of Joint speed (Mv). Ex) When Mv is 3000, set OVS at 3300. Teach Pendant Operation Sequence)
Select 4.PARA from main menu screen Input "1111" (Ver. 1.0A or above) "Valid" message is displayed. Change setting
Select 4.PROTECT from PARAMETER(0) ESC ENTER ESC ESC
Select 3.OVS from PTOTECT(0)
Cause 2) Encoder, encoder cable or encoder connector are out of order. Troubleshooting 2) Confirm it with running JOG Mode (direction key of Teach Pendant) if its status is normal. If abnormal, check and replace encoder, encorder cable or encoder connector. Teach Pendant Operation Sequence)
Select 1.JOB from main menu screen F2 (Select POINT) F1 (Select DIR) Select FILE F4 (Select EDIT)
F2 (Select CURR)
Move the robot with hand or Jog key
You will see the coordinate of moving axis changing. If the value changes, it's normal, but if not, encoder trouble For encoder trouble, motor should be replaced (Contact our company)
6-5
Chapter 6

E004
E004 ---- Excessive Acceleration
Explanation> Excessive acceleration error : Motor acceleration exceeds the setting value.
Cause 1) OVA of system parameter is set too low. Troubleshooting 1) Check if the OVA of Protect is over 2000. (adjustment range: 1000 ~ 5000) Teach Pendant Operation Sequence)
Select 4.PARA from main menu screen Input "1111" (Ver. 1.0A or above) "Valid" message is displayed. Change the setting value
Select 5.OVA from PTOTECT(0)
Cause 2) Encoder, encoder cable or encoder connector are out of order. Troubleshooting 2) Confirm it with running JOG Mode (direction key of Teach Pendant) if its status is normal. If abnormal, check and replace encoder, encoder cable or encoder connector. Teach Pendant Operation Sequence)
F2 (Select CURR)
6-6
Chapter 6

E005
E005 ---- Inposition Error
Explanation> Inposition Error: Motor does not stop within a specified time.
Cause 1) IPE and IPA of system parameter are set too low. Troubleshooting 1) , Check if the IPE of Protection is over 50 (adjustment range 50~100).
Check the IPA of Protection is over 100 (adjustment range: 100~200).

Input "1111" (Ver. 1.0A or above) "Valid" message is displayed. Change the setting value
Select 4.PARA from main menu screen
Select 6.IPE, 7.IPA from PROTECT(0)
Cause 2) Inappropriate gain (PVG) setting of each axis. Troubleshooting 2) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, confirm operation whether or not it is normal by operating JOG mode (direction key of Teach Pendant), also vibration and chattering. If robot keeps vibrating, lower the PP,VP,VI gains. Teach Pendant Operation Sequence)
Select 4.PARA from main menu screen Select 3.GAIN from PARAMETER(0) ESC ENTER ESC ESC Input "1111" (Ver. 1.0A or above) Select 1.PVG "Valid" message is displayed.
Change the setting values
6-7
Chapter 6

E006
E006 ---- Settling Error
Explanation> Settling Error : When level of mechanical disturbances (vibration, chattering, etc) exceeds its allowance limits.
Cause 1) System Parameter (SET) has been set too low. Troubleshooting 1) Check if the SET of Protection is over 1000 (adjustment range : 1000~3000). For the vertical movement, around 2000 is proper. Teach Pendant Operation Sequence)
Select 1.SET from PROTECT(0)
Cause 2) Inappropriate gain (PVG) setting of each axis Troubleshooting 2) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, Run Jog mode (direction key of Teach Pendant) to check if operation, vibration and chattering are normal. If robot keeps vibrating, lower the PP,VP,VI gains. Teach Pendant Operation Sequence)
6-8
Chapter 6

E008
E008 ---- Power Alarm
Explanation> Servo Amp Error : Trouble in Servo Amp
Cause 1) IPM error of Servo (Over Current, Over Voltage, Over Heat) Troubleshooting 1) Check wiring. In case wiring is normal, the Amp should be replaced.
Cause 2) Motor trouble Troubleshooting 2) Demagnetization of Motor. In this case, Motor should be replaced.
Cause 3) Encoder, encoder cable or encoder connector are out of order. Troubleshooting 3) Run JOG mode (direction key of Teach Pendant) to check if operation is normal. If it is abnormal, check and replace the encoder, encoder cable or encoder connector.
6-9
Chapter 6

E009
E009 ---- H/W Limit
Explanation> H/W Limit : H/W limit signal is ON.
Cause 1) Trouble with limit sensor system Troubleshooting 1) Move robot into H/W limit reach by operating JOG, and check whether or not H/W limit sensor is normally operating. If it is abnormal, check and replace the sensor, cable and connector. Teach Pendant Operation Sequence)
Move robot into H/W limit reach manually or by JOG key Normal if "H/W Limit ? Axis" message is displayed on Teach Pendant with "beep" sound, and if not, abnormal If abnormal Adjust the distance between sensors (2.5mm)/ Replace a sensor/ set origin parameter again.
Cause 2) Trouble with Controller Input Port Troubleshooting 2) Check or replace main board Teach Pendant Operation Sequence) Check controller input port connection. If normal Check and replace main board.
Cause 3) Limit sensor is activating during robot running Troubleshooting 3) Check teaching point or system parameter Check standard parameters corresponding to Arm length (LENG), Operation Range (RANG), Origin Offset(OFFS), Deceleration Ratio (GEAR) and Robot Body.
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Chapter 6

E010
E010 ---- Excessive Velocity (reference)
Explanation> Excessive reference velocityr : reference velocity exceeds 110% of rated speed.
Cause 1) System parameters related to motion are set improperly. Troubleshooting 1) Check if the OVS of PROTECT is 110% of Joint Velocity (Mv). When the Mv is 3000, set OVS at 3300. Check LINR parameters related to Motion. Mv: less than 1000, Jv: less than 300 At: Cartesian Coordinate Robot(over 0.3), SCARA (over 0.5) Teach Pendant Operation Sequence)
Select 3.OVS from PTOTECT(0)
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Chapter 6

E011
E011 ---- Excessive Acceleration (reference)
Explanation> Excessive reference acceleration error : acceleration exceeds the specified value.
Cause 1) OVA of system parameter has been set too low. Troubleshooting 1) Check if the OVA of Protection is over 2000. (adjustment range: 1000~5000) Teach Pendant Operation Sequence)
Select 5.OVA from PTOTECT(0)
Cause 2) Robot Operation Command is used improperly. Troubleshooting 2) Check if MOVE commands, operation condition commands, and teaching point in user JOB program are used properly. Teach Pendant Operation Sequence)
Watch Teach Pendant screen during Auto Run to find the step exactly where the trouble occurs Modify program and change teaching point.
Cause 3) Check LINR parameters related to Motion Troubleshooting 3) Mv: less than 1000, Jv: less than 300 At: Cartesian Coordinate Robot(over 0.3), SCARA (over 0.5). Teach Pendant Operation Sequence)
Select 4.PARA from main menu screen Input "1111" (Ver. 1.0A or above) Select 2..JONT or 3.LINR "Valid" message is displayed. Change the Mv, At setting values.
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Chapter 6

E012
E012 ---- Over Load
Explanation> Motor's overload error : When the torque of motor exceeds the specified value Adjust it below 1.0 in case of running it at lower value than the rated.
Cause 1) OVL of System parameter is set too low. Troubleshooting 1) Check if the OVL of Protection is over 1.0 (adjustment range : 0.7~1.5) Teach Pendant Operation Sequence)
Select 4.PARA from main menu screen Input "1111" (Ver. 1.0A or above) "Valid" message is displayed. Change the setting value.
Select 4. OVL from PTOTECT(0)
Cause 2) Over rated load or interference with obstacles. Troubleshooting 2) Check if loading capacity is within the rated setting. Check if loading capacity compared with operating velocity is adequate. Check if obstacles exist in the path of robot movement.
Cause 3) Motor, Motor cable or Motor connector troubles. Troubleshooting 3) Check if Motor cable or connector are short-circuitted, and if it is so, replace them. Teach Pendant Operation Sequence)
Check robot mechanical part when moving robot manually. Check motor coil resistance (scores of is fair)
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Chapter 6

E012
Cause 4) Encoder or encoder cable are out of order. Troubleshooting 4) Run JOG mode (direction key of Teach Pendant) to check if operation is normal. If abnormal, check or replace encoder, encoder cable or encoder connector. Teach Pendant Operation Sequence)
F2 (Select CURR)
Cause 5) Inappropriate gain (PVG) settings of each axis Troubleshooting 5) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, run JOG mode (direction key of Teach Pendant) to check if operation and vibration are normal. If robot keeps vibrating, lower the PP,VP,VI gains. Teach Pendant Operation Sequence)
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Chapter 6

E014
E014 ---- Amp Over Heat
Explanation> Over heat of power element (IPM) of Servo Amp
Cause 1) Heat sink is excessively hot. Troubleshooting 1) Check if the environment of use matches to the requirements for its usage. Check if there is no problem with Fan of controller in rear side. Check the air filter of controller in front side.
Cause 2) Servo Amp trouble Troubleshooting 2) Repair or replace the Servo Amp (Contact our A/S team)
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Chapter 6

E015
E015 ---- Amp Over Voltage
Explanation> Over voltage of Servo Amp
Cause 1) When input voltage is too high Troubleshooting 1) Check input voltage. It should be 220V, within -15% ~ 10%. Teach Pendant Operation Sequence)
Check input voltage (AC 220V) with a tester(multimeter). Select 4.PROTECT from PARAMETER(0) ESC ENTER ESC ESC Select 4.OVL from PROTECT(0) Change the setting value
Cause 2) Servo Amp trouble Troubleshooting 2) Check discharging circuit or replace Servo Amp.
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Chapter 6

E016
E016 ---- Amp Over Load
Explanation> Over load of Servo Amp : When the torque of Motor exceeds the specified value.
Cause 1) Over load or interference with obstacles. Troubleshooting 1) Check if loading capacity is within rated set value. Check if the loading capacity compared with operation velocity is adequate. Check if obstacles exist in the path of robot movement.
Cause 2) Motor, Motor cable or Motor connector troubles. Troubleshooting 2) Check if motor cable or connector are short-circuited, and if it is so, replace them. Teach Pendant Operation Sequence)
Check robot mechanical part when moving robot manually. Check motor coil resistance (scores of is fair)
Cause 3) Encoder system trouble Troubleshooting 3) Run JOG mode (direction key of Teach Pendant) to check if operation is normal. If abnormal, check or replace encoder, encoder cable or encoder connector. Teach Pendant Operation)
F2 (Select CURR)
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Chapter 6

E016
Cause 4) Inappropriate gain (PVG) settings of each axis Troubleshooting 4) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, run JOG mode (direction key of Teach Pendant) to check if operation and vibration are normal. If robot keeps vibrating, lower the PP,VP,VI gains. Teach Pendant Operation Sequence)
Change the setting values.
Cause 5) Servo Amp trouble Troubleshooting 5) Repair or replace the Servo Amp (Contact our A/S team)
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Chapter 6

E017
E017 ---- Over Current
Explanation> Over current of Servo Amp
Cause 1) Over current occurs while Servo On. Troubleshooting 1) Some elements(Hall Sensor, OP Amp, etc) of Servo Amp are broken. (Contact our A/S team)
Cause 2) Motor or Motor cable trouble Troubleshooting 2) Check if Motor cable or connector are short-circuited, and if it is so, replace them. Teach Pendant Operation Sequence)
Check and find the situations of robot's mechanical part when moving it manually. Check motor coil resistance (scores of is fair)
Cause 3) Encoder, encoder cable or encoder connector are out of order. Troubleshooting 3) Operate in JOG mode (direction key of Teach Pendant) to check if operation is normal. If abnormal, check or replace encoder, encoder cable or encoder connector. Teach Pendant Operation Sequence)
F2 (Select CURR)
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Chapter 6

E017
Cause 4) Inappropriate gain (PVG) settings of each axis Troubleshooting 4) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, operate in JOG mode (direction key of Teach Pendant) to check if operation and vibration are normal. If robot keeps vibrating, lower the PP,VP,VI gains. Teach Pendent Operation Sequence)
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Chapter 6

E020
E020 ---- Servo Not Ready
Explanation> Servo Amp is not ready.
Cause 1) Trouble with motor power supply of Servo Amp Troubleshooting 1) Check if Motor power cable, if connector and relays in controller are normal.
Cause 2) Trouble with releasing Servo Amp Alarm. Troubleshooting 2) Release the alarm again.
Cause 3) DC link voltage (motor driving power) of Servo Amp is low, or DC link voltage condender is not charged due to trouble with discharge system. Troubleshooting 3) Repair or replace Servo Amp.
Cause 4) Inappropriate gain (PVG) settings of each axis. Troubleshooting 4) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, operate in JOG mode(direction key of Teach Pendant) to check if operation and vibration are normal. If robot keeps vibrating without stop, lower the PP,VP,VI gains. Teach Pendent Operation Sequence)
Change the settings values.
Reboot controller (press F1 after pressing EMG key, and then ENTER)
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Chapter 6

E021
E021 ---- Sensor Error
Explanation> Trouble with sensor system
Cause 1) Trouble with sensor cable. Troubleshooting 1) Check or replace sensor cable.
Cause 2) Sensor motor connector disconnected or broken Troubleshooting 2) Check or replace sensor motor connector.
Cause 3) Trouble with 24V power in controller Troubleshooting 3) Check or replace 24V power.
Cause 4) Sensor broken Troubleshooting 4) Replace sensor.
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Chapter 6

E022
E022 ---- AB Phase Error
Explanation> A, B Phase error of encoder
Cause 1) Trouble with A, B phase encoder cable or connector of corresponding axis Troubleshooting 1) Check and replace encoder, encoder cable or encoder connector. Teach Pendent Operation Sequence)
F2 (Select CURR)
Move the robot manually or by Jog key
Cause 2) Inappropriate gain (PVG) settings of each axis. Troubleshooting 2-1) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, operate in JOG mode (direction key of Teach Pendant) to check if operation and vibration are normal. If robot keeps vibrating, lower the PP,VP,VI gains. Teach Pendent Operation Sequence)
Troubleshooting 2-2) Adjust Servo Amp current offset value of corresponding axis.
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Chapter 6

E023
E023 ---- Z Phase Error
Explanation> Z phase error of encoder
Check point of control part
Cause 1) Trouble with Z phase encoder cable or connector of corresponding axis Troubleshooting 1) Check and replace encoder cable or connector. Teach Pendent Operation Sequence)
F2 (Select CURR)
Cause 2) Inappropriate gain (PVG) settings of each axis. Troubleshooting 2-1) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, operate in JOG mode (direction key of Teach Pendant) to check if operation and vibration are normal. If robot keeps vibrating, lower the PP,VP,VI gains. Teach Pendent Operation Sequence)
Troubleshooting 2-2) Adjust Servo Amp current offset value of corresponding axis.
Cause 3) Motor connector disconnected or broken Troubleshooting 3) Check or replace connector.
Check point of mechanical part
Cause 1) There are noises and vibrations, and interferences with obstacles. Troubleshooting) Check the status of mechanical part.
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Chapter 6

E024
E024 ---- Abnormal Gain
Explanation> Gain Error
Cause 1) Inappropriate gain (PVG) settings of each axis Troubleshooting 1-1) Adjust PVG gains. Check PP,FF,VP,VI,ER,IR values. After adjusting gains, operate in JOG mode (direction key of Teach Pendant) to check if operation and vibration are normal. If robot keeps vibrating, lower the PP,VP,VI gains.
Teach Pendent Operation Sequence)

Select 4.PARA from main menu screen Select 3.GAIN from PARAMETER(0) ESC ENTER Input "1111" (Ver. 1.0A or above) Select 1.PVG "Valid" message is displayed.
Troubleshooting 1-2) Adjust Servo Amp current offset of corresponding axis.
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Chapter 6

E025, E027
E025 ---- Amp IPM Error
Explanation> Trouble with Servo Amp IPM element
Cause 1) Trouble with Servo Amp IPM element of corresponding axis Troubleshooting 1) Replace IPM element (Contact our A/S team.)
E027 ---- No Enc Signal
Explanation> Encoder RX signal detection error : RX siganl is not input in encoder or incorrect
Cause 1) Problem on RX, /Rx line system of corresponding axis Troubleshooting 1) Check encoder line system and replace
Check items ) 1. Check if the encoder 5V line is OK 2. Check if encoder RX, /RX line is OK 3. Check if encoder RX DATA is OK by using oscilloscope or scope meter (refer to Tamakawa, SA 35 series encoder Datasheet)
Cause 2) Problem on encoder receive board Troubleshooting 2) Replace encoder receive board (consult with factory)
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Chapter 6

E028, E029, E030
E028 ---- Enc Sys Down
Explanation> Error occurred by lower voltage of encoder power than rated voltage (5V or battery power)
Cause 1) in case of voltage of super capacitor inside of encoder decreases below than 2.5V Troubleshooting 1) Exchange motor (consult with factory)
Cause 2) Trouble on encoder 5V power line system Troubleshooting 2) Check encoder 5V power line, clear encoder of corresponding axis and move to mechanical CALSET position 4.parameter-> 1.body-> 4.offset-> ACAL execution and use Note) Motor encoder clearing : multi rotation, encoder system down, over speed error information are cleared. Refer to Service manual Chapter 4.6 SCARA connector
E029 ---- Enc Overflow
Explanation> When the encoder multo rotation data is overflow from counter capacity.
Cause 1) When encoder of an axis rotates to one direction and overturn than capacity Troubleshooting 1) Clear encoder and move to CALSET position 4.parameter-> 1.body-> 4.offset-> ACAL execution and use Note) Motor encoder clearing : multi rotation, encoder system down, over speed error information are cleared. Refer to Service manual Chapter 4.6 SCARA connector
E030 ---- Enc Overspeed
Explanation> When 5V power is Off and encoder doesn't detect motor's position due to motor rotates with higher accelation than 200 rad/sec2
Cause 1) in case of voltage of super capacitor inside of encoder decreases below than 2.5V Troubleshooting 1) Clear encoder and move to CALSET position 4.parameter-> 1.body-> 4.offset-> ACAL execution and use Note) Motor encoder clearing : multi rotation, encoder system down, over speed error information are cleared. Refer to Service manual Chapter 4.6 SCARA connector
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Chapter 6

E031, E032
E031 ---- Enc Battery Low
Explanation> Error occurred by lower voltage of encoder backup battery than 3.25V
Cause 1) Trouble on encoder backup battery power line system Troubleshooting 1) Check encoder backup battery power line, clear encoder of corresponding axis and move to mechanical CALSET position 4.parameter-> 1.body-> 4.Offset-> ACAL execution and use
Cause 2) When encoder backup battery running time is exceeded Troubleshooting 2) Exchange encoder backup battery, clear encoder of corresponding axis and move to mechanical CALSET position 4.parameter-> 1.body-> 4.Offset-> ACAL execution and use Note) Motor encoder clearing : multi rotation, encoder system down, over speed error information are cleared. Refer to Service manual Chapter 4.6 SCARA connector
E032 ---- Enc Data Wrong
Explanation> Error occurred when reading two values are different between the first and second encoder RX datas in controller internal process Cause 1) when robot moves during encoder initializing by external factor Troubleshooting 1) if it still occurs after reinitializing of encoder, check vibration surrounding mechanical parts and do action to reduce vibration
Cause 2) when RX Data receiving is unstable by trouble on encoder RX, /RX line system Troubleshooting 2) Check encoder RX, /RX line (check line Noise) and reinitialize encoder
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Chapter 6

E033, E034
E033 ---- Enc Preset Fail
Explanation> In case of Semi (compact) absolute encoder, it receives full rotation data after encoder rotates 2 (preset) when controller power is on (over 10sec with power off). At this moment, the error occurs when motor overdrives beyond range.
Cause 1) when the gain of corresponding axis is not set properly Troubleshooting 1) After change proper gain, reinitialize encoder
Cause 2) when it detects wrong rotation data of corresponding axis encoder Troubleshooting 2) exchange motor (consult with factory)
E034 ---- Enc Init Fail
Explanation> It indicates when encoder initialization is failed and when servo on or jog, run execution after initialization fail
Cause 1) when initialization is failed by one of E027 ~ E033 during initializing Troubleshooting 1) After analyzing and correction of error code, reinitialize encoder
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Chapter 6

E050, E051, E052
E050 ---- System Emergency
Explanation> Emergency Stop status due to system I/O operation
Cause 1) System Emergency Stop by user Troubleshooting 1) Turn OFF the Emergency Stop and reset controller.
Cause 2) Trouble with system Emergency Stop cable and connector Troubleshooting 2) Check system I/O cable and connector.
Cause 3) Trouble with 24V power in controller. Troubleshooting 3) Check or replace 24V power.
E051 ---- Front Emergency
Explanation> Emergency Stop status by Emergency Stop switch on front panel
Cause 1) Emergency Stop switch on front panel was pressed. Troubleshooting 1) Turn OFF the Emergency Stop switch on front panel and reset controller.
Cause 2) Trouble with 24V power in controller Troubleshooting 2) Check or replace 24V power.
E052 ---- Teach Pendant Emergency
Explanation> Emergency Stop status by Emergency Stop switch of Teach Pendant
Cause 1) Emergency Stop switch of Teach Pendant was pressed. Troubleshooting 1) Turn OFF Emergency Stop and then reset controller.
Cause 2) Trouble with Emergency Stop switch line system of Teach Pendant Troubleshooting 2) Repair or replace Teach Pendant.
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Chapter 6

E054, E055
E054 ---- 24V Power Down
Explanation> 24V power trouble in controller
Cause 1) Trouble with 24V power connector or SMPS Troubleshooting 1) Check or replace connector and SMPS.
Cause 2) Sensor connector disconnected or broken Troubleshooting 2) Check or replace sensor connector
Cause 3) Inappropriate sensor specification (Limit sensor NO type used.) Troubleshooting 3) Limit sensor : Use NC type (normally closed). ORG sensor : Use NO type (normally open).
E055 ---- Battery Low
Explanation> Trouble with Backup RAM Battery
Reason 1) Battery trouble or over time Measure 1) Replace battery. Battery size : CR 1/2AA,3V(No Lead).
* Function of battery - Power supply to the memory chip(RAM) for back up data as JOB, PNT and etc. * Life of battery - When controller is not used for a long time : about 4 years - When controller is continuously used : about 50 years * Replacement method - For using Unihost : Replace battery after back up of Job file and Pallet system parameters - For not using Unihost : Make sure to prepare the battery for replacement and replace in minutes only when the controller power is OFF because data files may be lost.
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Chapter 6

E56, E101
E056 ---- Host Emergency
Explanation> Emergency Stop state by Emergency Stop protocol in Host mode
Cause 1) In Host mode, Emergency Stop protocol was received. Troubleshooting 1) Turn OFF Emergency Stop, and reset controller.
E101 ---- File Not Found
Explanation> No JOB file exists.
Cause 1) The Job no. selected by system I/O does not exist. Troubleshooting 1) Check selected Job no. Ex) When selecting NO.1 JOB, there is no Job file in No. 1
Cause 2) Trouble with wiring system of system I/O input Program 0~4 Troubleshooting 2) Check wiring.
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Chapter 6

E102
E102 ---- Range Over
Explanation> Operation beyond allowance limits of numeric values in parameter, command or variable.
Cause 1) The values used in command (VEL, ACC, PLUP, FORM ...) go beyond allowance limits. Troubleshooting 1) Correct the values. (Refer to Command Usage in User's Manual.)
Cause 2) Output port, type or time value set in Pallet data are improper. Troubleshooting 2) Correct the values. (Refer to Pallet System Parameter Setting in User's Manual.)
Cause 3) System variable has been used improperly in program Troubleshooting 3) Correct CNT no. (within 0~15 available) or TMR no. (within 0~1 available)
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Chapter 6

E105
E105 ---- Inverse Error
Explanation> Error occurred by changing coordinate of SCARA to Joint mode (A,B,Z,W) from X,Y mode (X,Y,Z,W).
Cause 1) Teaching point or track in CP movement is wrong. Troubleshooting 1) Check and correct track according to teaching point or operation condition.
Cause 2) XPOS variable value used in CP command is improper. Troubleshooting 2) Check and correct XPOS variable value(XYZW coordinates, FORM value)
Cause 3) Error occurred during the process of calculation or conversion of XPOS variable into POS variable. Troubleshooting 3) Check and correct XPOS variable value (XYZW coordinates, FORM value).
Cause 4) Pallet data in PMOV movement is improper. Troubleshooting 4) Check and correct Pallet position data. (Refer to Pallet System Parameter Setting in User's Manual.)
PMOV Teaching Point Pallet
When the robot arm cannot reach this point in actual job
Cause 5) In HOST mode, when moving robot in INCH mode and XYZW coordinate, point data is improper. Troubleshooting 5) Check the direction whether it can be reached by the robot.
Cause 6) In HOST mode, when moving robot in teaching point mode and XYZW coordinate, point data is improper.
Troubleshooting 6) Check after checking if robot can move to the point in XYZ coordinate.
Cause 7) In Host mode when downloading Point file, point data is improper. Troubleshooting 7) By using Teach Pendant, check point data download from PC. The Point which has a fault in coordinate conversion has position value 999.99 of every axis. Check and correct point data which has error.
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Chapter 6

E107, E108
E107 ---- Range Over A(X)
Explanation> A(X) axis goes beyond the range
Cause 1) Inappropriate system parameter (Range) setting of A(X) axis Troubleshooting 1) Correct system parameter (Range) of A(X) Axis.
Cause 2) Teaching point goes beyond the range of A(X) axis Troubleshooting 2) Check and adjust the teaching point within the range of A(X) axis.
Cause 3) A(X) axis goes beyond the range. Troubleshooting 3) Move A(X) axis within the range and then verify again.
E108 ---- Range Over B(Y)
Explanation> B(Y) axis goes beyond the range
Cause 1) Inappropriate system parameter (Range) setting of B(Y) axis Troubleshooting 1) Correct system parameter (Range) of B(Y) Axis.
Cause 2) Teaching point setting over of B(Y) axis Troubleshooting 2) Check and adjust the teaching point within the range of B(Y) axis.
Cause 3) B(Y) axis goes beyond the range Troubleshooting 3) Move B(Y) axis within the range and then verify again.
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Chapter 6

E109, E110
E109 ---- Range Over Z
Explanation> Z axis goes beyond the range
Cause 1) Inappropriate system parameter (Range) setting of Z axis Troubleshooting 1) Correct system parameter (Range) of Z Axis.
Cause 2) Teaching point goes beyond the range of Z axis Troubleshooting 2) Check and adjust the teaching point within the range of Z axis.
Cause 3) Z axis goes beyond the range Troubleshooting 3) Move Z axis within the range and then verify again.
E110 ---- Range Over W
Explanation> W axis goes beyond the range
Cause 1) Inappropriate system parameter (Range) setting of W axis Troubleshooting 1) Correct system parameter (Range) of W Axis.
Cause 2) Teaching point goes beyond the range of W axis Troubleshooting 2) Check and adjust the teaching point within the range of W axis.
Cause 3) W axis goes beyond the range Troubleshooting 3) Move W axis within the range and then verify again.
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Chapter 6

E111
E111 ---- Not Teaching Point
Explanation> Not Teaching Point used
Cause 1) When using robot movement command, not teaching point was used. Troubleshooting 1) Check or creat Point. (Refer to JEDIT mode in User's Manual.)
Cause 2) When using OFFS command, not teaching point was used. Troubleshooting 2) Check or creat Point. (Refer to JEDIT mode in User's Manual.)
Cause 3) When moving point in HOST mode, not teaching point used Troubleshooting 3) Check or create Point. (Refer to JOB mode in User's Manual.)
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Chapter 6

E112, E113, E114
E112 ---- Please Origin
Explanation> Request for Origin Setting
Cause 1) It occurs when trying to run robot without origin setting. Troubleshooting 1) Do origin setting. : Press 5. ORIGIN in initial menu screen.
E113 ---- Job Depth Over
Explanation> The number of times that JCALL is used exceeds 3.
Cause 1) Multiple JCALLs(successive JCALLs) are used more than 3 times. Troubleshooting 1) Modify robot program. Reduce multiple JCALLs.
E114 ---- Call Depth Over
Explanation> The number of times that CALL is used exceeds 8.
Cause 1) Multiple CALLs(successive CALLs) are used more than 8 times. Troubleshooting 1) Modify robot program. Reduce multiple CALLs.
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Chapter 6

E115, E117, E118
E115 ---- FOS Error
Explanation> Inappropriate FOS command
Cause 1) TOOL command used while robot is continuously moving by FOS command Troubleshooting 1) Stop FOS move by FOS 0 command and then modify program to use TOOL command.
E117 ---- Format Error
Explanation> Though communication data is received in Host mode, the data has not been received in the specified format. Cause 1) Wrong format of Point file transmitted Troubleshooting 1) Modify Point file.
Cause 2) Wrong format of system parameter file transmitted Troubleshooting 2) Modify system parameter.
Cause 3) Communication connector and cable are short-circuited or inferior quality. Troubleshooting 3) Check communication connector and cable.
E118 ---- LRC Error
Explanation> In Host mode, communication data error check byte is not normally received.
Cause 1) Communication connector and cable become short or are in trouble during communication. Troubleshooting 1) Check communication cable.
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Chapter 6

E119, E121, E122
E119 ---- Pallet Data Error
Explanation Pallet data error of system parameter
Cause 1) Data ( the number of material in Pallet) is less than CNT number of starting point in Pallet. Troubleshooting 1) Modify parameter data or CNT. (Refer to User's Manual.)
Cause 2) Pallet data was used without initialization or have trouble. Troubleshooting 2) Initialize Pallet data. (Refer to User's Manual.)
E121 ---- Unreachable Point
Explanation> Teaching Point that robot cannot reach Cause 1) When robot was teached to an impossble point to reach with existing sets of velocity or acceleration. Troubleshooting 1) Modify teaching point or movement condition command.
Cause 2) the teaching points that are supposed to move to CMOV or AMOV are neither circle nor arc, or radius is so small. (In case interior angles of three points that form circle or arc are less than 0.1 deg., or in case of more than 179.9 deg., or in case the radius is less than 1 mm.) Troubleshooting 2) Modify teaching point.
E122 ---- Exit Instruction
Explanation> EXIT command processed.
Cause 1) Program stopped by user's EXIT command. Troubleshooting 1) Press Enter and the Alarm will be OFF and return to Job start status.
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Chapter 6

E123, E124
E123 ---- POS Variable Error
Explanation> POS Variable error
Cause 1) Use of POS variables with values not designated Troubleshooting 1)Modify program in order to it can be used after setting values in POS variable. : Refer to User's Manual (Variable part).
Cause 2) POS array variable used beyond user defined range. Troubleshooting 2) Modify program in order to use it within range set. : Refer to User's Manual (Variable part).
Cause 3) XPOS variable used for OFFS or LIMT command. Troubleshooting 3) Use of teaching point or POS variable in OFFS or LIMT command. : Refer to User's Manual (Variable part).
E124 ---- JCALL Error
Explanation> JCALL command improper use
Cause 1) Insufficient memory in processing JCALL. Troubleshooting 1) When JCALL is processed to call another job which has many program steps or variables, the JOB program can not run normally because of insufficient memory if a large part of the memory is assigned to insufficient memory if a large part of the memory is already assigned to program steps, teaching points and variables of the JOB program.
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Chapter 6

E127, E131
E127 ---- Not Sufficient Memory
Explanation> Insufficient memory
Cause 1) When a large part of memory is assigned to program steps, teaching points or variables there may be insufficient memory in compiling or file transmission. Troubleshooting 1) Reduce program steps or teaching points. Or, avoid using several programs simultaneously like JCALL.
E131 ---- Syntax Error
Explanation> JOB Program Syntax Error
Cause 1) Undefined or inappropriate robot command used. Troubleshooting 1) Have thorough knowledge of robot command usage and compose the program again after debugging. Ex) When input numeric 0 instead of English O Omitting space, Omitting ENDIF in IF statement
: :
Cause 2) A variable is declared the same name with command, system variable or the variable name used in controller. Troubleshooting 2) Change the variable name.
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Chapter 6

E132, E133, E134
E132 ---- Not Initialized System Variable
Explanation> System variable initialization error
Cause 1) System variables (TMR,CNT) have been used without initialization. Troubleshooting 1) Use system variables after initialization.
E133 ---- Undefined Symbol
Explanation> Undefined names used
Cause 1) Undefined commands or undeclard variables used. Troubleshooting 1) Use defined commands or declared variables.
E134 ---- Duplicated Symbol
Explanation> Duplicated names used
Cause 1) Duplicated variable names declared. Troubleshooting 1) Make those variables be different each other.
Cause 2) Duplicated LABLs used. Troubleshooting 2) Delete one of the duplicated, or make the LABLs have different names each other.
6 - 43
Chapter 6

E135, E136, E137
E135 ---- Impossible Branch
Explanation > Branch Command Execution Error
Cause 1) Executing GOTO branch into IF - ENDIF, WHILE - ENDWL , FOR - NEXT blocks. Troubleshooting 1) You should not execute GOTO branch into IF - ENDIF, WHILE - ENDWL and FOR - NEXT blocks. Modify program according to the syntax. : Refer to User's Manual.
Cause 2) Executing GOTO branch between MAIN - EOP command block and SUBR - RET command block, or between SUBR - RET command blocks. Troubleshooting 2) You should not execute GOTO branch between MAIN - EOP and SUBR - RET block or between SUBR-RET blocks.
Modify program according to the syntax.
E136 ---- Too Many Parameters
Explanation > Excessive Parameters
Cause 1) Parameters are used excessively when execuinting mathematical function. Troubleshooting 1) Verify and correct parameteers of mathematical function where error occurred.
E137 ---- Not Sufficient Parameters
Explanation > Parameters are not sufficient enough to execute mathematical functions.
Cause 1) Parameters are not suffcient enough to execute mathematical functions. Troubleshooting 1) Verify and correct the parameters of mathematical function when error occurred.
6 - 44
Chapter 6

E138, E139, E140
E138 ----Illegal Expression
Explanation > Operation Format Error
Cause 1) Mathematical expressions do not follow specified operation format. Troubleshooting 1) Verify and correct the mathematical expressions. (Refer to User's Manual - Commands - operators)
E139 ---- Illegal Variable Type
Explanation > Variable type error
Cause 1) When the index of FOR statement is not integer type. Troubleshooting 1) Make correction on integer type variable or integer constant.
Cause 2) When the index value of array variables(general variable, I/O variable, teaching point variable, POS variable, XPOS variable) are not integer type. Troubleshooting 2) Make correction on integer type variable or integer constant.
E140 ---- Impossible to Assign
Explanation > Impossible to assign a value to variable.
Cause 1) In case data type of operation results of mathematic expressions are different from that of
the variables to which the operation results is assigned.

Troubleshooting 1) Correct the program making two data types identical.
6 - 45
Chapter 6

E141, E142, E143
E141 ---- EOF In Comment
Explanation > Comment error
Cause 1) Improper use of comment. Troubleshooting 1) Verify program and make correction on comment symbols(/* , */) to make a pair.
E142 ---- No Exist Label
Explanation > LABL branch error
Cause 1) There is no LABL name branched by CALL or GOTO Troubleshooting 1) Create one newly when the corresponding LABL command does not exist in program. Or, change LABL name if there is an existing LABL command.
E143 ---- Declaration Error
Explanation > Array declaration error
Cause 1) Array declared in INT or REAL data type Troubleshooting 1) Array can be declared only in POS data type. Verify or correct program. : Refer to User's Manual.
Cause 2) The array size declared in POS data type is less than 1. Troubleshooting 2) POS array size should be more than 2. Declare it more than 2 or change it to a simple variable. : Refer to User's Manual.
6 - 46
Chapter 6

E144, E150
E144 ---- Passing Pallet over
Explanation > PASS commands used too many.
Cause 1) PASS command used per pallet exceeds 21. Cause 2) The number of Pallet using PASS command exceeds 5 Troubleshooting 1,2 ) Set the number of Pallets, that is to use PASS command, less than 5, and use less than 21 PASS command per Pallet.
E150 ---- Compile Error
Explanation > Compile error.
Cause 1) Program compile error Troubleshooting 1) When an error occurs between error code131~149, the display panel of controller exhibits only E150 . Debug the JOB program where the error occurred, and then run the JOB program again.
6 - 47
Chapter 6
Quick Maintenance and Reparing Job
6.3 Quick Maintenance and Reparing Job
6.3.1 Initialization
3 kind of initializations : PARAMETER, JOB, PALLET DATA When initialization is required : Replacing MAIN BOARD & initializing existing saved data Note : You must backup existing data before initialization.
1) Parameter Data Initialization
Turn OFF the controller Open the controller upper cover and turn ON the No.2 of Deep switch on main board. Turn on the controller You can see initialization process on Teach Pendant
2) JOB Data Initialization
Refer to "User's Manual 7.5 All deletion of JOB (All Clear)".
3) Pallet Data Initialization
Refer to "User's Manual 5.3.2 "Parameter (1) group".
6 - 48
Chapter 6
6.3.2 How to troubleshoot an Error occurred during Origin Setting
1) When AB PHASE ERROR - axis occurs during origin setting
Cause 1) In most cases, setting value related to the ORG of PARA are improper. Troubleshooting 1) Go to 4.PARA PARAMETER(1) ORG DIR,SENS on Teach Pendant,
check settings and modify them. (Refer to "User's Manual Chapter 5 Parameter Mode, ORG".) Cause 2) If error occurs in the origin sensor of corresponding axis without having problems with the setting of PARA, and then, it is judged that the sensor may be located at the outside of the damper. Troubleshooting 2) In this case, you need to relocate the sensor of corresponding axis. Change the sensor position so it can start sensing before approaching the damper.
In case of SCARA, the origin is apt to be changed. So please record the origin coordinate before an error occurs in order to check if the origin has been changed.
6 - 49
Chapter 6
6.3.3 Explanation of Z axis Weight Balance (using Air Cylinder) Circuit Diagram
Fine Lock Cylinder 3 Port solenoid v/v (connect Brake ON/OFF or press switch points) LOCK Lock open port
press switch (connect SYS I/O, EMG points)
Precision Regulator IR401(SMC) Input pressure : max 9.9 kg Output pressure : 0.1~4.0 kg
Silencer attached
Parts suppied by robot manufacturer when it is purchased
6 - 50
Chapter 6
Explanation of Diagram
3port sol v/v : Power OFF (Air supply stopped : Brake on) Power ON (Air supplied : Brake OFF) Brake OFF When the air comes in air port and pushes piston, the brake metal gets widen and piston rod can move freely.
Brake ON When the air flows out air port, the piston and brake metal returns to the original position and rod gets braked.
Press switch If air supply stops, the air pressure will decrease. If it decreases below the value set at press switch, then output point signal is ON. By sending this point signal to system I/O EMG, every job stops.
Precision Regulator You need to set proper air volume based on the load weight on vertical movement axis. If not proper, the vertical movement is not smooth and several errors occur. So it is very important to set proper volume.
6 - 51
Chapter 6
6.3.4 Troubleshooting for Mechanical Parts of Robot
For mechanical noise

NO 1 Cause Bad accuracy (level) of installation surface Thickness Tape and then re-install it. Remove grease and imperities 2 Impurities mixed and then re-inject grease. 3 Speed exceeds the limit Lower speed below the limit. Tighten coupling again (Because of the vibration and too Short acceleration time, coupling may be loosened.) Remove grease and impurities and then reinject grease. Adjust P, I Gain. Troubleshooting Calibrate precision (level) with using
Coupling loosens
Grease shortage
Improper GAIN setting
Inappropriate Timing Belt tension Ball screw damaged or used over 15000 hours run Linear movement bearing damaged
Adjust Timing Belt tension.
Replace ball screw.
9 or used over 25000km 10 Abnormal operation of brake Interference due to mechanical body breakdown
Replace straight movement bearing.
Replace brake.
11
Replace the part.
6 - 52
Chapter 6
Quick Mainterance and Repairing Job
For Vibration
NO 1 Cause Velocity exceeds the limit Troubleshooting Lower velocity below the limit
Used at too short acceleration time
Luse as longer acceleration time Make installation table more stiff, and fix it with bottom bolt. Check if bolts are perfectly fastened. Check if bolt length is proper.
Robot installation table is not stiff enough.
Robot installation bolt is fastened improperly.
After checking fasten the bolt with standard torque, prevent bolt from loosening. (Apply Loctite and Nylok bolts)
Overload
Lower velocity or increase acceleration time.
Improper Gain setting
Adjust P, I Gain.
Resonance with other devices
Adjust acceleration time and velocity.
For bad positioning accuracy

NO 1 Cause Mechanical Lead Error Troubleshooting If you need high positioning accuracy in process, please contact us.
6 - 53
Chapter 6
Bad repetitive positioning accuracy

NO 1 Ball nut damaged Cause Troubleshooting Replace ball nut.
Bad installation surface accuracy (level)
Refer to page 6-4a
Low Position Gain
Increase Position Gain.
Robot installation bolt fastened improperly
Refer to page 6-50
Robot installation table is not stiff enough
Refer to page 6-50
Coupling loosened or damaged
Refasten or replace coupling.
Bad limit (origin) sensor operation

NO 1 (Reed switch) and Magnet is big. 2 Proximity Sensor(Reed switch) damaged (Reed switch) (below 1mm) Replace proximity sensor (Reed switch) Cause The gap between sensor Troubleshooting Adjust the position of with proximity sensor
Incorrect origin parameter setting
Set origin parameter correctly.
Unstable robot operation & excessive run

NO 1 Cause Incorrect Pitch/Rev(Gear Ratio) value Origin sensor and encoder Z phase are idential or proximate. 2 origin setting or coupling positions. Troubleshooting Adjust Pitch/Rev(Gear Ratio) value Unless Z phase pulse is 1000~9000 after origin setting on Teach Pendant, adjust
6 - 54
Chapter 6
6.3.5 Set Parameter on Main Board Replacement or Parameter Initialize ** For Absolute Only
1) Parameter Group 0-> BODY-> OFFS-> EDIT --- Offset setting When replacing main board or initializing paremeter, it can cause error in coordinate value by Offset parameter changing. Error can be clearred by correcting Offset Parameter. If the parameter has not been modified before, refer to the Offset parameter written in the label of Robot Body to correct by using EDIT function.
When changing Offset by using EDIT function and saving it, the changes is applied after soft reboot or power reboot of controller. Therefore you will see the request message for rebooting on T/P after changing and saving.
NO
Content
Key
Display OFFSET A:0 B:0 Z:0 W:0 EDIT CALIB ACAL EPOS OFFSET A: B:0 Z:0 W:0 EDIT CALIB ACAL EPOS OFFSET A:.23 B:-5.25 Z:0.00 W:0.00 EDIT CALIB ACAL EPOS OFFSET A:.23 B:-5.25 Z:0.00 W:0.00 update? (enter/esc) OFFSET A:1.23 B:-5.25 Z:0.00 W:0.00 Please Reboot! GROUP:BODY 1:CONF 2:LENG 3:RANG 4:OFFS 5:GEAR 6:TOOL 7:MOTOR item #
4. Select OFFS
4 L
Select EDIT by pressing F1
F1
Change OFFSET values using Numeric Keys
Move to Main Menu after changing OFFS
ESC
Save by pressing ENTER
ENTER
Move to upper Menu by pressing ENTER
ENTER
6 - 55
Chapter 6
2) Parameter Group 0-> BODY-> OFFS-> EPOS --- EPOS (Standard coordinate value) setting When using ACAL function due to Main board replacement or parameter initialization, EPOS value used as standard coordinate value for internal calculation must be recovered. Correct EPOS value is saved in factory before shipping out and marked in label of robot body. Enter the EPOS value in label by MDI (Manual Direct Input) mode.
No
Content
Key
Display END ANGLE SET A:113.25 B:-98.73 Z:-13.50 W:107.60 MDI CURR MDI SET B A:13.25 B:-98.73 Z:-13.50 W:107.60
Select F4 EPOS
F4
Select MDI mode by pressing F1
F1
Change EPOS value of corresponding axis
0 V
9 I
MDI SET A:114.50 Z:-13.50
B B:-97.65 W:107.60
Move to upper menu by pressing ESC
ESC
MDI SET B A:114.50 B:-97.65 Z:-13.50 W:107.60 update? (enter/esc) MDI SET B A:114.50 B:-97.65 Z:-13.50 W:107.60 Please Reboot! END ANGLE SET A:114.50 B:-97.65 Z:-13.50 W:107.60 MDI CURR
Save by pressing ENTER and move to upper menu
ENTER
ENTER
6 - 56
Chapter 6
3) Parameter Group 0-> BODY-> OFFS-> EPOS --- EPOS (Standard coordinate value) setting Even though EPOS value has to be recoverred, if EPOS value is not saved or recorded, EPOS value can be saved by moving each axis of robot to calibrarion position. At this moment, Offset value must be saved correctly. The other method is to request to Manufacturer's customer service team to get the information on EPOS and enter at MDI mode. For more information on the calibration position, refer to Chapter 6.3.7 Absolute SCARA Calibration Position and Fixing Jig.
No
Content
Key
Display END ANGLE SET A:114.50 B:-97.65 Z:-13.50 W:107.60 MDI CURR CURR SET B A:114.50 B:-97.65 Z:-13.50 W:107.60 A B Z W ABS CALIBRATION B A:114.50 B:-97.65 Z:-13.50 W:107.60 save A?(enter/esc) ABS CALIBRATION B A:113.20 B:-97.65 Z:-13.50 W:107.60 A B Z W END ANGLE SET A:113.20 B:-97.65 Z:-13.50 W:107.60 Please Reboot!
Select F4 EPOS
F4
Select CURR mode by pressing F2
F2
Change EPOS value of corresponding axis by pressing F1~F4
F1
ENTER
ESC
6 - 57
Chapter 6
6.3.6 Change Offset parameter after changing motor ** For Absolute Only
1) Parameter Group 0-> BODY-> OFFS --- Using ACAL in Offset Set function When an error occurs on coordinate value due to changing motor or position moving of motor by external impact, locate screw jig in position of corresponding axis and move the axis to touch to the jig. After that, change the Offset of corresponding axis as below table. For the information on calibration position, refer to Chapter 6.3.7. Absolute SCARA Calibration position and Fixing Jig. When calibrating of Z axis, the Offset Value of W axis must be in state of setting in allowance error range. (If the difference between W axis and Z axis is in 2 o, It is normal) If it needs to calibrate both Z & W, do W first and then do Z axis.
No
Content
Key
Display ABS CALIBRATION B A:1.23 B:-5.25 Z:0.00 W:0.00 A B Z W ABS CALIBRATION B A:1.23 B:-5.25 Z:0.00 W:0.00 update A?(enter/esc) ABS CALIBRATION B A:4.52 B:-5.25 Z:0.00 W:0.00 A B Z W ABS CALIBRATION B A:4.52 B:-5.25 Z:0.00 W:0.00 Please Reboot! OFFSET A:4.52 B:-5.25 Z:0 W:0 EDIT CALIB ACAL EPOS
Select F3 ACAL
F3
Select Offset of corresponding axis by pressing F1 ~ F4
F1
Change Offset by pressing ENTER
ENTER
ESC
ENTER
6 - 58
Chapter 6
6.3.7 Absolute SCARA Calibration position and Fixing Jig
Jig Set for fixing the position of robot body to calibrate to Offset change
A axis
B axis
Z axis
W axis
Jig for A axis M6 X 8
Jig for B axis M5 X 5
Jig for Z axis M4 X 5
Jig for W axis M3 X 5
Location for Jig of each axis
1) A axis
6 - 59
Chapter 6
2) B axis
3) Z axis, W axis
Front side of B axis
It is the picture in front view of B axis
6 - 60
Chapter 6
Calibration Form using Jig
1) Front View
2) Top View
6 - 61
Chapter 6
6.3.8 Battery lifetime for Data Backup

1) Battery specification and life time There are two kinds of batteries. One is for backup memory of main board and the other is for Absolute SCARA's encoder data backup memory. The battery location of Absolute SCARA is referred at Chapter 4-7. Figure. Both batteries are Lithium Battery
Model
Part No.
Maker
Size
Volt
Part for use Main Board Encoder
Current consumtion in ready state MAX 60 uA MAX 100 uA
Tekcell
SB-AA02
VITZROCELL 1/2 AA
3.6V
Official capacity: Max. 1200mAh. But it can be changed to 60~80% according to circumstance. The backup battery for main board will be totally dissipated when power is not supplied to controller in ambient temperature during 18,000 hours. The backup battery for encoder will be totally dissipated when power is not supplied to controller in ambient temperature during 10,000 hours. This lifetime data is not considered for leak current
2) Battery exchange
The lifetime of battery can be reduced according to circumstances like temperature and humidity. It is recommended to exchange the battery to new one to keep Absolute encoder data every 10 months. Refer to Chapter 4.6.2. Absolute Encoder Backup Battery Board (page 4-51).
6 - 62
Chapter 6
6.3.9 How to set proper gains
RCM Model
Open Gain screen : 4.PARA
PARAMETER(0)
ESC
3.GAIN
ENTER
1.PVG Controller power off on.
Save gain value : After input or change
PVG (Position Velocity Gain)

Screen
PP : ER : VP :
FF : VI: IR:
For noise or vibration Lower gain value
PP (Position Proportional Gain) Value up : Correct inposition, Overshoot increases when stop.(Vibration increase). Better response. : Incorrect inposition, Overshoot decreases when stop.(vibration decrease). Worse response. FF (Feedfordward Gain) Without filtering position variation, feedforward it to final speed reference. Value up : Better response, Cycle time up
Value down
ER (Estimator Response) When speed is low, this parameter is used to improve it. Compensate the difference between real speed and estimated speed. VI (Velocity Integral) : 1/10 of VP Adjust the value up precisively after adjusting VP. VP (Velocity Proportional) Value up : Toque increases at a stop or deceleration (Vibration is restrained).
If IR and ER values are being adjusted, VP value is changed internally. IR (Inertia Ratio) If load " " , then IR also " ".
6 - 63
Chapter 6
6.3.10 How to Modify Offset Value When Changing SCARA Origin Position ** For Incremental Only
*** Refer to User's Manual 5.3.1(1)
Origin position when shipped from factory (NO.1) (The value indicated on the rear side of robot main body is input as offset.)
B Arm
A Arm Origin position (NO.6) (The offset should be calculated as follows.)
How to modify offset when changing origin position from No.1 to No.6 Set data in Parameter 2.ORG No.6 position. Change all of 4.OFFS values of parameter to "0". Turn power OFF/ON, and then do 5. Implement origin setting (5. ORIGIN). After origin setting, move to point teaching CURR mode and confirm coordinate values of No.6 position. Make notes about coordinate values of A,B arms. Move A,B arms of robot to No.1 position and align UP( ) and DOWN( ) marks attached on the arms to make it of one accord. Make notes about coordinate values of this moment after checking it in CURR mode. (A,B arm coordinate values in ) minus (A,B arm coordinates of ) = ? Input ? value with inverse sign into 4.OFFS in parameter. (ex. -140 +140) Turn power OFF/ON, and then implement origin setting(5. ORIGIN). After origin setting, move to point teaching CURR mode and confirm coordinate value of No.6 position. If the coordinate of A,B arm displays "0", the offset is correct. If not, it is incorrect. In that case, repeat above steps from .
6 - 64
Chapter 6

Host Package Error
E001 ---- Serial Port Initialization Failed
Cause) When you use the serial port under using or not existing. Troubleshooting) Set available serial port in HOST mode.
E002 ---- Timeout Error On Communication
Cause) Serial communication doesn't work at all. Troubleshooting1) Check if the communication cable or connector is properly connected. Troubleshooting2) Check if there is no problem with serial chip of controller or PC. Troubleshooting3) Check the power of controller.
Cause) Serial port setting error Troubleshooting) Check if the serial connector is properly connected maching with the serial port values (COM1,COM2) set in Config. Dialog box of Unihost.
Cause) Inconsistent Baud rate. Troubleshooting) Match the baud rate, the communication parameter of controller with the baud rate set in config. dialog box of Unihost.
Cause) The controller is not in HOST mode. Troubleshooting) Change it into HOST mode using Teach Pendant.
6 - 65
Chapter 6

Host Package Error
E003 ---- Data Packet Is Invalid
Cause) Inconsistent data length and communication parameter Troubleshooting) Match the data length, the communication parameter of controller with that set in config. Dialog box of Uniost.
E004 ---- Communication Error
Cause) Communication error occurring while job program runs Troubleshooting) Confirm classification number 0 and 3 in error code 001~003. (If you run the job again before troubleshooing, communication may work.)
E005 ---- Communication Error. Exit the run dialog?
Cause) Communication error occurring while doing job program Troubleshooting) Confirm error code (001~003). (If you run the job again before troubleshooting, communication may work.)
E006 ---- Please move origin
Cause) When the origin setting of robot has not been executed Troubleshooting) Execute 'Origin setting' from JOB menu.
6 - 66
Chapter 6

Host Package Error
E008 ---- Not Sufficient Memory For This Operation
Cause) Not sufficent Heap Memory that requred for execution of any functions upon your free choices Troubleshooting1) Close the file of which program size is relatively bigger than the one among editors
currently opened.
Troubleshooting2) If other application programs are running besides Unihost, terminate them and rerun Unihost.
E009 ---- Port Number Is Invalid
Cause) Wrong Port number of input or output dialog box. Troubleshooting) Port number : 0 ~ 2.
E010 ---- Output Bits Are Invalid
Cause) Wrong data input in 16 bit field of output dialog box. Troubleshooting) Input 0 or 1 only.
E011 ---- Velocity Data Is invalid
Cause) Wrong velocity input in Point No, Joint, Linear of 'Manual' menu. Troubleshooting) Velocity range: 0 ~ 99.
6 - 67
Chapter 6

Host Package Error
E012 ---- File Is Not Found In The Controller
Cause) The job program file does not exist in controller. Troubleshooting) Download more than one job file in controller or create the job file with Teach Pendant.
E013 ---- Syntax Error
Cause) Undefined command or improper command used. Troubleshooting) Have a good knowledge about robot command usage, and debug the program for the parts where error occurred.
E014 ---- Not Initialized System Variable
Cause) System variables (TMR,CNT) used without initialization Troubleshooting) Use system variables after initializing it as required values.
E015 ---- Undefined Symbol
Cause) Undefined command or undeclared variable used Troubleshooting) Use defined command or declared variable.
E016 ---- Duplicated Symbol
Cause) Duplicate variable name declared Troubleshooting) Change the duplicated variable name to another one.
Cause) Duplicate LABL command used Troubleshooting) Delete one of the duplicated LABL commands or change it into another name.
6 - 68
Chapter 6

Host Package Error
E017 ---- Impossible Branch
Explanation > Branch Command Execution Error
Cause 1) Executing GOTO branch into IF - ENDIF, WHILE - ENDWL , FOR - NEXT blocks. Troubleshooting 1) You should not execute GOTO branch into IF - ENDIF, WHILE - ENDWL and FOR - NEXT blocks. Modify program according to the syntax. : Refer to User's Manual.
Cause 2) Executing GOTO branch between MAIN - EOP command block and SUBR - RET command block, or between SUBR - RET command blocks. Troubleshooting 2) You should not execute GOTO branch between MAIN - EOP and SUBR - RET block or between SUBR-RET blocks. Modify program according to the syntax.
E018 ---- Too Many Parameters
Cause) Parameters are used excessively when using mathematical function. Troubleshooting) Confirm and and correct parameters of mathematical function where error occurred.
E019 ---- Not Sufficient Parameters
Cause) Parameters are not sufficient enough to cover mathematical functions being used. Troubleshooting) Verify and correct the parameters of mathematical function where error occurred
E020 ---- Illegal Expression
Cause) Mathematical expressions do not follow the specified operation format. Troubleshooting) Confirm whether or not it is possible for the mathematical expression to perform operation, and correct it accordingly. (Refer to User's Manual - Commands & Program - Operator)
6 - 69
Chapter 6

Host Package Error
E021 ---- Illegal Variable Type
Cause) When the index of FOR statement is not integer type. Troubleshooting) Make correction on integer type variable.
Cause) When the index of array variables (IO variable, Teaching point variable, POS variable) are not integer type. Troubleshooting) Make correction on integer type variable or integer constant.
E022 ---- Impossible to Assign
Cause) When the data type of operation result of mathematical expression is different from that of the variableto which the operation results are to be assigned Troubleshooting) Correct the program in order to make data types identical.
E023 ---- EOF In Comment
Cause) Improper use of comments. Troubleshooting) Verify and correct program for comment sybomls(/*, */) to make a pair.
E024 ---- No exist Label
Cause) There is no LABL name branched by CALL or GOTO Troubleshooting) Create one newly when the corresponding LABL command does not exist in program. Or, change LABL name if there is an existing LABL command.
6 - 70
Chapter 6

Host Package Error
E025 ---- Declaration Error
Cause) Array declared in INT or REAL data type Troubleshooting) Array can be declared only in POS data type. Verify or correct program.
Cause) The array size declared in POS command is less than 1. Troubleshooting) POS array size should be more than 2. Declare it more than 2 or change it to a simple variable.
6 - 71
Chapter 7
Appendices
PLC Program
7. Appendices
7.1 System I/O PLC Sequence Program
PLC sequence may vary depending on the facility system conditions, but the below program will be helpful.
JOB Program Selector
With five points, you can select 32 programs (NO.0~31).
Ex)
b point
Robot PROG 0 (20)
Robot PROG 1 (21)
Robot PROG 2 (22)
Robot PROG 3 (23)
Robot PROG 4 (24)
a point M10 Robot PROG. NO.0 M11 Robot PROG. NO.1 M12 Robot PROG. NO.2 M13 Robot PROG. NO.3 M14 Robot PROG. NO.4
output point
M30 Robot PROG. NO.29 M31 Robot PROG. NO.30 M32 Robot PROG. NO.31
7-1
Chapter 7
Appendices
PLC Program
M11
PLC manual selection switch
Y51
Robot PROG 0 (1) input
M13
M15
M17
M19
M21
M23
M25
M27
M29
M31
M33
M35
M37
M39
M41
7-2
Chapter 7
Appendices
PLC Program
M12
Y52
M13
M16
M17
M20
M21
M24
M25
M28
M29
M32
M33
M36
M37
M40
M41
7-3
Chapter 7
Appendices
PLC Program
M14
Y53
M15
M16
M17
M22
M23
M24
M25
M30
M31
M32
M33
M38
M39
M40
M41
7-4
Chapter 7
Appendices
PLC Program
M18
Y54
M19
M20
M21
M22
M23
M24
M25
M34
M35
M36
M38
M39
M40
M41
7-5
Chapter 7
Appendices
PLC Program
M26
Y55
M27
M28
M29
M30
M31
M32
M33
M34
M35
M36
M37
M38
M39
M40
M41
7-6
Chapter 7
Appendices
PLC Program
Robot Auto Run / STOP / START or RESTART
: System I/O
Robot START switch
Robot READY output
ORG.OK output
PLC auto selection switch
T01
Y40 Robot PROG. SEL input
Y40
T01 over 0.3 sec.
Y40
T03
Robot RUN output
M00 Internal coil
M00
Y40
T02 over 0.1 sec.
M00
T02
Y42
Y41 Robot START input T03 over 0.3 sec.
PLC STOP Switch
Y42 Robot STOP input
PLC manual selection Switch
DOOR OPEN sensor
Conditions of Robot STOP : OPEN Safety door, STOP, Select manual mode robot stop CLOSE safety door, START, Select auto mode Robot START Switch ON -> Robot program restarted
7-7
Chapter 7
Appendices
PLC Program
Robot Alarm Reset operation
STOP signal can be used instead of inputting EMG. (input pulse twice)
PLC alarm reset switxh
Robot ALARM output
T10
Y60 Robot EMG input
Y60
T10 over 0.3 sec.
Robot ALARM output
Y60
Robot READY output
T11
Y61 Robot RESET input
Y61
T11 over 0.3 sec.
The Robot RESET signal ON, and teach pendant screen will change as follows. SYSTEM MODE Auto Run Mode
EXIT It can recognize the output signal sent from PLC only with the above screen. Note) If robot does not run even though START signal was sent from PLC, don't forget to verify the teach pendant screen is as above. To change to this screen from another screen, do as below.
Important
Select 7.SYSTEM from initial menu screen of teach pendant and then, drive with PLC. Create "Robot Alarm Reset" PLC program in the above.
7-8
Chapter 7
Appendices
SPARE PARTS
7.2 SPARE PARTS LIST (Controller)
RCM4-Series (2~4 axis)

NO. 1 2 3 4 5 6 7 8 9 Fuse Battery Cooling Fan Emergency switch Power switch Main board Servo Amp Servo Amp Cable (Motor & encoder) Part Name Type GTF, 250V, 10A, 30MM CR1/2AA, 3V (No Lead) DC24V, 0.12A 3A-125 250VAC DWL-4215(Lamp),20A NewRo RCM-CE 2.0A A(X), B(Y) axes Z, W axes 4 axis run (inflexible) Q'ty 1 1 2 1 1 1 1 1 1 Where to install Rear of cont. Main board Rear of cont. Front of cont. Front of cont. Inside the cont. Inside the cont. Inside the cont. Rear of cont.
7-9
Chapter 7
Appendices
SPARE PARTS
7.3 SPARE PARTS LIST (Mechanical Part)
Cartesian Coordinate Robot (parallel type)- based on 1 axis

NO. 1 2 3 4 5 6 7 Part Name Limit sensor Origin sensor Timing belt Fully Note1) Electronic brake Body Harness Servo motor 803NC 803NO Depending on spec. Depending on spec. XS-05-10 24V, XS-06-10 24V Depending on spec. Type Q'ty 2 1 2 1 1 1 1 Where to install
Inside the machine
Cartesian Coordinate Robot (series type)- per 1 axis

NO. 1 2 3 4 5 6 Part Name Limit sensor Origin sensor Coupling Note1) Electronic brake Body Harness Servo motor 803NC 803NO Depending on spec. XS-05-10 24V, XS-06-10 24V Depending on spec. Type Q'ty 2 1 1 1 1 1 Where to install
Inside the machine
Note 1) For details, please refer to product catalog.
7 - 10
Chapter 7
Appendices
SPARE PARTS
SCARA Robot
NO. 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17
Part Name
A axis CW,CCW sensor (black) A axis ORG sensor (white) B axis CW,CCW sensor (black) B axis ORG sensor(white) Z axis CW,CCW sensor W axis ORG sensor Reducer(A axis)-100:1 Reducer(A axis)-50:1 Reducer(B axis)-80:1 Reducer(B axis)-50:1 Reducer(B axis)-50:1 Reducer(W axis)-20:1 Timing Belt (Z axis) Timing Belt (W axis) Ball screw (Z axis) Ball spline (Z axis) Servo motor Refer to page 7-12.
Type
Proximate sensor,GXL-8FIB Proximate sensor,GXL-8FB Proximate sensor,GXL-8FIB Proximate sensor,GXL-8FB Photo sensor,EE-SX671 Photo sensor,EE-SX673 Harmonic Drive CSS-32-100-2A-GR Harmonic Drive CS-32-50-2A-GR Harmonic Drive CSS-25-80-2A-GR Harmonic Drive CSS-25-50-2A-GR Harmonic Drive CS-25-50-2A-GR Camo Reducer BR-65-UH-20-K
Q'ty 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 3~4
Where to install
Inside the machine
7 - 11
Chapter 7
Appendices
SPARE PARTS
AC Servo Motor
NO. 1 2 3 4 5 6 7 8 9 10 Part Name Minas 100W Minas 100W (BK) Minas 200W Minas 200W Minas 200W (BK) Minas 400W Minas 400W Minas 400W Minas 750W Minas 750W MSMZ012B1E MSMZ012B1F(BK) MSMZ022B2S MSMZ022B1E MSMZ022B1F(BK) MSMZ042B2U MSMZ042B1E MSMZ042B2S MSMZ082B2U MSMZ082B1E SCARA SCARA SCARA SCARA Type Remarks
Type Name
1. Panasonic Incremental Motor
220V
Version
MSMZ
01
Motor Capacity 01: 100W 02: 200W 04: 400W 08: 750W
MSMZ Series
Encoder spec : 17Bit
#1 spec
2. Komotek Absolute Motor
220V
Standard
1 ; ROUND 2 : KEY 5 : SPECIAL
KANZ
01
N(B)
KANZ Series
Motor Capacity 01: 100W 02: 200W 04: 400W 08: 750W
Encoder spec : 11Bit
N: Normal B: Brake
7 - 12
Chapter 7
Appendices
Considerations for selecting robot
7.4 Considerations for Selecting Robot
1) Stroke
- Optimize working area to minimize stroke. - Arrange the stroke of second axis (Y axis) to be shortter than that of first axis (X axis) as much as possible. - Note that long stroke may bring enlargement of base size and price increase, also limit velocity.
2) Load
- Use within rated payload - Consider horizontal load and vertical load separately. - Note that loading capacity varies depending on acceleration time(Cycle time).
3) Velocity
-Take notice of whether or not robot can be used within limited velocity per stroke of each base.
4) Moment
- Note that robot life cycle and its motion (acceleration and deceleration time) may be affected by robot position, even if loads are same.
5) Accuracy
- Figure out the kinds of required accuracy and allowable error value. - If you require repetitive positioning accuracy over standard specification, please contact us.
6) Installation Conditions
- Make sure if the site meets requirements of installlation environment for robot. - Install robot at the location where you can do maintenance and reparing jobs easily.
7 - 13
Chapter 7
Appendices
Regular Checkup
7.5 Periodic Inspections
1) Grease Injection
Greased part Recommend grease Injection Cycle How to inject
Ball Screw Ball Screw(1632) LM Guide Note) Do not mix grease.

Shell Albanis G2
Once / 6 months Apply on Axis. Once / 6 months Inject in Nipple. Once / year Inject in Nipple.
2) Cleaning Inner Parts of Robot

Method : Open the top cover and clean impurities with vacuum cleaner. Cycle : at any time
3) Robot Cable Damage

If the covering materials (rubber) of cable are separating in shapes of powder, paste some grease between cables. If the damage is serious, replace it.
4) Status of Fastening of Installation Table and Bracket Fixing Bolts

After one month from installation, check the status of the bolts and refasten them.
7 - 14
Chapter 7
Appendices
Robot hand
7.6 Robot Hand
Kind of Hand
Mechanical chuck
Kind> External Diameter Chuck, internal Diameter Chuck Feature> The most common hand. There are many in the market. Not suitable for thin and smooth works as glass, etc. which are fragile and easily modified.
Vacuum chuck Kind>. Vaccum pad , air float Feature> Suitable for chucking thin work, Unable to perform centering motion by chuck Work stained with oil and powder is apt to choke the chamber. Chuck only for IC WAFER (negative pressure generated)
Magnet chuck Kind> Electromagnets, Permanent magnets Feature> Suitable for thin iron plate Electromagnet type is simple with no driving part. But electromagnet is heavy. Permanent magnet type can be compact sized and light-weighted, but needs knock out device for unchucking.
Special Type Kind> Niddle pointing, rubber actuator Feature> With soft and full contact, possible to chuck fragile things like glass. Simple and light weight / Low chuck accuracy (Note its durability)
Exclusive Tools > Bolt fastening tool > Soldering tool > Pasting gun > Measurement unit (camera,sensor,measuring equipment) > Sealing tool > Welding gun > Others
7 - 15
Chapter 7
Appendices
Robot hand
Multiple Functions of Hand
Multihand Kind> 90 deg. 180 deg. Revolution Purpose> To reduce time for loading/unloading work To carry multi-assembling jobs in a single process To perform flexible movements covering variety of products To carry collective assembling jobs Feature> Rapid hand exchange time It is the best to make hand for commonized use.
Hand Exchange Kind> Use robot tool adaptor. Purpose> To perform flexible movements covering variety of products To carry multi-assembling jobs in a single process To meet changes or alterations of facilities Feature> It requires 5~6 sec. for hand exchange. So you cannot disregard this exchange time in case of many- kind-small-lot process.
Servo hand Purpose> To perform flexible movements covering variety of products To carry multi-assembling jobs in a single process To meet changes or alterations of facilities To alter sequential procedures
7 - 16
Chapter 7
Appendices
Robot hand
Chuck Verification
Chucking Kind> Check it with auto hand open/close switch Check work with direct sensor of hand (photoelectric or proximity switch, negative pressure sensor for vacuum absorption) Check with photoelectric switch on the work returning path.
Assembly Kind> Check it with installing a sensor as basic reference (case working). Check new axis position of hand with proximity sensor. After assembly, check if work exists with the proximity sensor installed in hand.
Hand Design
Considerations in designing > Total weights of hand and tool : Maximum total weights (including work weight) Max. Loading Capacity
> Center of hand
> W axis spin inertia moment W axis spin inertia moment of hand & tool (including work weight) Max. allowable inertia moment
7 - 17
Chapter 7
Appendices
Cartesian Coordinate Robot Structure
7.7 Cartesian Coordinate Robot Structure
Serial type
Parallel type
7 - 18
Chapter 7
Appendices
Picture of Connectors
7.8 Picture of Connectors

1) Encoder Connector & Motor Connector connected to the controller connector
Motor Connector
Encoder Connector
2) System I/O Connector & User I/O Connector & Option I/O Connector
User IN Connector
User OUT Connector
System I/O Connector
Option IN Connector
Option OUT Connector
7 - 19
Chapter 7
Appendices
Picture of Connectors
3) Body Connector connected to the robot body connector
4) Connection Cable
7 - 20
Chapter 7
Appendices
Emergency Circuit Diagram
7. 9 Emergency Circuit Diagram TP EMG TP EMG I/F Main Board Relay Control
Front EMG I/F
Front EMG
SYS_EMG SYS_EMG +
+24
SYS_EMG_NC1 (Pin 24) SYS_EMG_NC2 (Pin 49)
G24 Power Relay AC Input
Note 1: Front Emergency and System Emergency are connected in wired-OR type 24V power must be connected to EMG+, EMG-. If there is not proper wiring, EMG error will be occurred. Note 2: If EMG_NC1 and EMG_NC2 are OPEN, Servo Not Ready error is occurred. So, it should be short. Note 3: If T/P is not connected, T/P EMG error will be occurred. So, connect T/P to controller. Or connect T/P dummy connector provided by Robostar. Note 4: In case of N type I/O connection, SYS_EMG_NC1,2 are not needed to connect.
7 - 21
Contents
Chapter 1

1-1 1-5 1-7
1.1 Robot Safety in general 1.2 Details of Robot Safety 1.3 How to Treat Cables in Robot
Chapter 2
Overview of Robot
2-1 2-2 2-2 2-6 2-6
2.1 Product Composition 2.2 Robot Composition 2.2.1 Components of Robot System 2.2.2 Name of Each Component in Controller (1) RCM4-Series
2.3 Specification of Robot Controller 2.3.1 Features 2.3.2 Structure of Model Name 2.3.3 General Specification
2-7 2-7 2-8 2-9
2.4 Product Dimension 2.5 Warranty of Product
2-11 2-12
Chapter 3
Installation of Robot Devices

3-1 3-1 3-1 3-1
3.1 Appropriate Environment for Robot Installation 3.1.1 Conditions for Installation Environment 3.1.2 Ambient Temperature and Humidity 3.1.3 Vibration
3.2 Installation of Robot Controller 3.2.1 RCM4-Series
3-2 3-2
C-1
Contents
Chapter 4

4-1 4-1 4-1 4-4 4-4 4-18 4-21
4.1 Connection 4.2 RCM4-Series Connection 4.2.1 Robot Controller 4.2.2 Robot Controller Robot Mechanical Part Connection External PLC Connection
4.2.2.1 System I/O Connection 4.2.2.2 User I/O Connection 4.2.2.3 Option I/O Connection
4.3 Checking Input/output Monitoring using Teach Pendant after Connection
4-24
4.4
On-Line Connection
4-29 4-29 4-30
4.4.1 Serial Cable Standard 4.4.2 Serial Cable Connection Diagram
4.5
4-31 4-31 4-35
4.5.1 Internal Circuit Diagram 4.5.2 Body Connector Wiring (refer to it when doing wiring job directly)
4.6
Scara Robot Connector
4-36 4-36
4-37
C-2
Contents
Chapter 5

5-1 5-2 5-2 5-3 5-4
5.1 Basic Functions 5.1.1 Time Chart of System Input/Output (1) Time Chart of Normal Operation (2) Example of Operation Panel (3) System I/O Signal Sequence (for reference when programming PLC sequence) (4) When Changing JOB Program while Running (5) In case of Emergency Stop or Alarm while Running (6) In case of Servo Off after STOP while Running
5-6 5-8 5-11
5.2 Highly Sophiscated Functions 5.2.1 Mode Selection (1) Flow Chart of Mode Selection (2) Time Chart of Mode Selection just after Power ON
5-12 5-12 5-12 5-13
5.2.2 Mode Description 5.2.2.1 Auto Run Mode 5.2.2.2 Step Run Mode 5.2.2.3 Jog Mode 5.2.2.4 Host Mode
5-14 5-14 5-15 5-19 5-21
5.2.3 Teach Pendant Display of Each Mode & 7-Segment Display on Front Panel
5-25
Chapter 6

6-1 6-2 6-45 6-45 6-46 6-47 6-49
6.1 Indication of Abnormal Condition 6.2 Abnormal Conditions and TroubleShooting (Error Code) 6.3 Quick Maintenance and Reparing Job 6.3.1 Initialization 6.3.2 How to troubleshoot an Error occurred during Origin Setting 6.3.3 Explanation of Z axis Weight Balance (using Air Cylinder) 6.3.4 Troubleshooting for Mechanical Parts of Robot
C-3
Contents
6.3.5 How to Set Proper Gains 6.3.6 How to Modify Offset Value When Changing SCARA Origin Position
6-52 6-53
6-58
Chapter 7
Appendices
7-1 7-9 7-10 7-13 7-14 7-15 7-18 7-19 7-21
7.1 System I/O PLC Sequence Program 7.2 SPARE PARTS LIST (Controller) 7.3 SPARE PARTS LIST (Mechanical Part) 7.4 Considerations for Selecting Robot 7.5 Periodic Inspections 7.6 Robot Hand 7.7 Cartesian Coordinate Robot Structure 7.8 Picture of Connectors 7.9 Emergency Circuit Diagram
C-4
ROBOSTAR CO.,LTD.
907-5, Hogye2-dong, Dongan-gu, Anyang-city, Kyonggi-do 431-836, Korea TEL: 82-31-455-0684(Rep.) FAX: 82-31-455-0687
Web Site E-mail
www.robostar.com sales@robostar.com
Copyright Robostar, 2005 All right reserved. No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher. Specifications are subject to change without prior notice. Robostar are trademark of ROBOSTAR CO.,LTD.

ZC100 Robostar RCI (A) 4 Service Manual-10

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ZC100 Robostar RCI (A) 4 Service Manual-10

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ROBOT

RCI(A) Series SERVICE MANUAL

Type of robot covered in this manual

The Safe Use of Robot

2-7 2-7 2-8 2-9

2.4 Product Dimension 2.5 Warranty of Product

Installation of Robot Devices

3.2 Installation of Robot Controller 3.2.1 RCM4-Series

Connection & Interface

4.3 Checking Input/output Monitoring using Teach Pendant after Connection

4-29 4-29 4-30

4.4.1 Serial Cable Standard 4.4.2 Serial Cable Connection Diagram

Cartesian Coordinate Robot Connector

4-31 4-31 4-35

Scara Robot Connector

4.6.1 Air Piping & Signal Wire

4.7 Caution When Wiring for Non-Robostar Mechanical Part

Time Chart of System Input/Output Operation

5-6 5-8 5-11

5-12 5-12 5-12 5-13

5-14 5-14 5-15 5-19 5-21

Maintenance and Reparing

6.4 Host Package Error

The Safe Use of Robot

1. The Safe Use of The Product

Safety Related Symbols

Indicates that, if this product is misused, it may cause any troubles,

The Safe Use of Robot

The Safe Use of The Product

Make sure the voltage is AC220 before use.

When installing robot, fix it firmly so that it won't be vibrating.

The Safe Use of Robot

The Safe Use of Robot

The Safe Use of Robot

1.2 Details of Robot Safety

the power OFF.

The Safe Use of Robot

EMERGENCY STOP SWITCH

EMERGENCY STOP INPUT (NORMAL CLOSE)

10) Grounding Standard Requires Class 3 grounding (Ground Resistance: 100

MAX DC24 V Com Controller

The Safe Use of Robot

1.3 How to Treat Cables in Robot

2) Do not fix the twisted part with cable tie, et

3) Avoid applying excessive tension.

The Safe Use of Robot

4) Do not use the ordinary cable with rotating part.

Use the Curl cable.

The Safe Use of Robot

8) The size of cables should be less than 60% of cableveyor's dimensions.

duct signal cable

The Safe Use of Robot

2.1 Product composition

Components in RCM series

2.2 Robot Composition

2.2.1 Components of robot system Composition 1) : Basic Specification

AC220V RS232C communication

Composition 2) : Basic Specification + I/O Monitor + I/O Terminal

Composition 3) : Basic Specification + System unit

For more details, see "13-8" in the User's manual.

RS232C communication Front of RCM4

Name of each component in controller