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Okura Yusoki A Series Original Instructions Manual

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UL-CE-VINSE-01
Robot Manual
-Original instructions-
Installation and Adjustment
- Electrical -
Okura Yusoki Co., Ltd.

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  • Page 1 UL-CE-VINSE-01 Robot Manual -Original instructions- Installation and Adjustment - Electrical - Okura Yusoki Co., Ltd.
  • Page 2 History Version Content Page (Date) 01 (2012.04.24) First edition...
  • Page 3 Introduction Thank you for purchasing a model from the Okura Robot Palletizer A series. This manual is a guidebook to help you safely and correctly use your A Series Robot Palletizer. It should be useful not only to beginners who are using an Okura Palletizer for the first time, but also to experienced users, who can use this Manual to reconfirm their knowledge.

  • Page 5: Table Of Contents

    Table of Contents OUTLINE OF CONTROLLER 1.1. ······················································ 1-2 PPEARANCE OF ONTROLLER 1.2. )················ 1-3 EACHING ENDANT NSTALLATION ERSONNEL HARNESS CABLE CONNECTION 2.1. ·················································· 2-2 NSIDE OBOT ARNESS ABLE 2.2. ··········································································· 2-5 PARE ABLES 2.3. ································ 2-6 ONNECTION OF MAIN POWER SUPPLY WIRES 2.4.
  • Page 6 MAINTENANCE FUNCTIONS 6.1. ······································································ 6-2 TRUCTURE 6.2. ···························································· 6-4 ATA MEMORY CONTENTS 6.3. I／O M ·········································································· 6-5 ONITOR 6.4. ···················································· 6-6 PERATION READY CONDITION 6.5. ················································································ 6-6 EY TRACE 6.6. ········································································ 6-7 ILE OPERATION 6.7. ······································································· 6-9 OGIC ANALYZER ID N –...

  • Page 7: Outline Of Controller

    1. Outline of Controller Names of part of controller and main parts are introduced in this section.

  • Page 8: Appearance Of Controller

    1.1. Appearance of Controller 1.1.1. Robot Controller This is common among RC830 and RC840 (See 5. SYSTEM SPECIFICATIONS for model of controller for detail.)

  • Page 9: Teaching Pendant (Installation Personnel Only )

    1.2. Teaching Pendant (Installation Personnel Only) Teaching pendant works at manual mode. Note ・Manual operation on controller does not work once teaching pendnat is connected. ② ① ① E/S push button switch ② Data display ③ ③ Enable switch How to set up teaching pendant →See”Operation Manual”...

  • Page 11: Harness Cable Connection

    2. Harness Cable Connection...

  • Page 12: Inside-Robot Harness Cable

    2.1. Inside-Robot Harness Cable The following shows the cable wiring inside robot and the composition of the cable harness between robot and controller [A1800V/A1800V－W] Inside-robot wiring BASE ROTOR RK831 CN13 D-motor RM815 CN14 RM832 CN15 O-motor RM816 CN16 RK833 CN11 R-motor RM817 CN10...
  • Page 13 [A1600V/ A1600V－W] Inside-robot wiring BASE ROTOR RK731 CN13 D-motor RM731 CN14 RM732 CN15 O-motor RM735 CN16 RK733 CN11 R-motor RM733 CN10 CN12 T-AXIS RM751 CN22 D-encoder CN17 T-motor RM737 CN18 RM752 CN23 O-encoder RK753 RM771 CN24 CN25 T-encoder RK754 CN26 RK755 RK773 CN31...
  • Page 14 [A700V] Inside-robot wiring BASE ROTOR RM741 CN13 D-motor CN15 O-motor RM742 CN11 R-motor T-AXIS RK761 CN22 D-encoder CN17 T-motor CN18 RK762 RM736 CN23 O-encoder RK763 RM770 CN24 CN25 T-encoder RM764 CN26 RK765 RK773 CN31 CN32 HAND CN37 RK781 CN33 CN36 RK767 RK782 CN21...

  • Page 15: Spare Cables

    2.2. Spare Cables The following spare cables for between robot and controller are provided for Okura A series robot palletizer as shown on the below table. [A1800V/A1600V/A700V] Robot main unit connector Connector in controller Wire Connector Pin No. Wire No. Connector No.

  • Page 16: Connection Of Main Power Supply Wires

    2.3. Connection of main power supply wires Connect main power supply wires on the basis of bellows. Introduce of electric wires must be relevant position of controller. Protection degree of the busing, for electric wires introduction must be equal or more than IP5X.

  • Page 17: Protection Against Lightning Surge

    2.4. Protection Against Lightning Surge There is no protection against lightning surge inside of controller. Relevant protection against lightning shall be required when connecting main power supply. 2.5. Other Notes (Wiring) 2.5.1. Attaching insulation cover Attach cover to O-axis and D-axis connector, which keep more than 10 mm clearance and creepage distance not to touch.
  • Page 18 2.5.3. Cables to enter into control panel Cables to enter into panel like I/O cables to/from peripheral conveyors need to be installed following the below way. The cables to enter through opening at bottom of panel need to be fixed around opening to not come out.

  • Page 19: Controller Boards And Units

    3. Controller Boards and Units The boards inside the controller and their configuration are as follows. Teaching Touch Panel Hand OXPA External PLC Pendant Optional (POD) RC501 RC512 ＣＰＵ Board I/O Board RC516 Safety Board RC512 I/O Board RC512 I/O Board Amp Unit Spare axis Servo...

  • Page 20: Cpu Board (Rc501)

    3.1. CPU Board (RC501) The arrangement of LED's、switches and 7-segment displays on Main CPU board is as follows. DIP switch DSW1 Explanation Descriptions Default setting Firmware Serial transfer １ System reserve ２ System reserve ３ System reserve ４ Motor rotation test ５...
  • Page 21 LED Explanation LED No. Lighting condition CPU(SH) being operated D１ NMI Detected D２ CPU(SH) 7-segment display D３ （7seg） USB access D４ Master DSP 7-segment display D７ Slave DSP (D/O axis) 7-seg display D８ （7seg） Slave DSP (R/T axis) 7-seg display D９...
  • Page 22 Jumper Explanation Signs. Descriptions Default setting FPGA type setting TYPE1(YaskawaΣⅡ) Ｗ１ *It varies depending on the type of encoder 1-4 close /2-3 close used. TYPE2(YaskawaΣⅤ) 1-4 open/2-3 close TYPE3(Tamagawa) 1-4 close/2-3open DSP reset mode setting Close Ｗ２ Don’t touch (SH endian setting) Open Ｗ３...

  • Page 23: I/O Board (Rc512)

    I/O Board (RC512) 3.2. The arrangement of LED's and Jumper pins on the I/O board is as follows. Jumper Pin Explanation Signs Descriptions Default setting ：Only JP1 close Board address setting ：Only JP2 close ：Only JP3 close LED Explanation LED No. Lighting conditions When 5VDC is supplied D１...

  • Page 24: Servo Power Unit (Spcu-1A)

    3.3. Servo Power Unit (SPCU-1A) The arrangement of LED's displays on the servo power unit is as follows. Jumper Pin Explanation Signs Descriptions Default setting Switching supply voltage over ２－３ close LED Explanation LED No. Lighting condition Regen resistor temperature failure Soft charging completed Servo power over voltage Servo power low voltage...

  • Page 25: Contactor Unit (Mcru-1-Ul/Ce)

    3.4. Contactor Unit (MCRU-1-UL/CE) Neither LED nor jumper pin is on contactor unit.

  • Page 26: Safety Relay Board (Rc516)

    3.5. Safety Relay Board (RC516) The arrangement of LED's and jumper pins’ displays on the safety relay board is as follows. LED17 LED8 LED1 LED9 Jumper Explanation Descriptions Default setting I/O Type selection (*1) Upto system JP１A I/O Type selection (*1) Upto system JP１B Sink（option）...
  • Page 27 ■ LED Explanation Lighting condition LED1 24VDC power supply for external use LED2 For internal use (for CN4 line) 24VDC power supply (lit at overload) LED3 In course of motor power turned ON LED4 Abnormal reset button LED5 Brake release（line １） LED6 Brake release（line ２）...

  • Page 28: Amp Unit

    3.6. Amp Unit ■ What is the Amp Unit? “Amp Unit” is composed of individual axis current board, IPM, heat sink and current sensor. A1600ⅢN、A1800N A700ⅢN Servo amp Board IPM type Board IPM type R axis RC507 PM200CL1A060 RC504 PM100CL1A060 D axis RC507 PM200CL1A060...

  • Page 29: Fieldbus Board

    3.7. Fieldbus board (Ethernet/IP AB6214） The arrangement of LED’s displays on fieldbus board is as follows. # Item 1 Network Status LED 2 Module Status LED 3 Link/Activity 4 Ethernet Interface Network Status LED Note: A test sequence is performed on this LED during startup. LED State Description No power or no IP address...

  • Page 31: Adjustments

    4. Adjustments...

  • Page 32: Origin Storing

    4.1. Origin Storing Operation for automatically calculating origin offset and setting it is called origin storing. Origin storing is required in the following cases. A. When encoder cable at motor connector is disconnected. B. When latched error of [Encoder Battery Voltage Drop] needs to be reset.（＊１） Procedure for moving to the origin storing screen is as follows.
  • Page 33 （＊１） In case of "Encoder Battery Voltage Drop", The axis can be specified by the Error Message Sub 1 (Bit 0): D axis 2 (Bit 1): O axis 4 (Bit 2): R axis 8 (Bit 3): T axis When the errors in the two or more axes are generated, Sub No. becomes a total of the number.

  • Page 34: Basic Posture

    4.2. Basic Posture When the robot is set in the basic posture, and origin storing is performed, the system reads the encoder pulses and amount of shift (number of pulses) off the robot basic posture, and the offset value is automatically calculated. [A1800V/A1600V/A700V] Axis Basic posture...

  • Page 35: Amp Unit

    4.3. Amp Unit To replace a amp unit follow the instruction below. <Replacement procedure> ① Shut main power down. ② Disconnect the connectors to/from amp unit and wiring to terminals. ③ Unbolt the mounting screws out of amp unit. Replace whole unit (including bracket and heat sink) at a time.

  • Page 36: Collision Detection

    4.4. Collision Detection In case of collision, overload has previously errored out to mainly prevent servo motor from being burnout. Therefore, the robot doesn't stop immediately when collision occurs if the servo motor reserves strength and there is a possibility that peripheral equipment, handling products, etc.

  • Page 37: System Storage

    5. System Storage The various system parameters are explained in the section. In ordinary operation, there is no need to change the system parameters. However, resetting them is necessary when special setting was made, motor has been replaced or other maintenance has been conducted.

  • Page 38: Peripheral Equipment Name Input

    5.1. Peripheral Equipment Name Input The procedure for moving to the conveyor information is as follows. System Storage Menu ↓ Controller Data ↓ Peripheral Equipment Name Input Peripheral conveyor name ・ Enter conveyor names at the conveyor manual mode screen. ・Pressing number of item you want allows to turn to the input mode.

  • Page 39: External Plc Communication Setup

    5.3. External PLC Communication Setup This screen interfacing wit external PLC. The directory to external PLC I/F setting screen is as follows. System storage menu ↓ Controller data ↓ External PLC I/F setting １．PLC standard interface Standard interfacing with PLC is set up. *See [I/O interfacing with PLC] edition for detail.
  • Page 40 ・If [VISION] is selected, it can link with VISION system through serial port of RC501(CN4). ４．Fieldbus communication If [CC-link] is selected, it can link with CC-link on Mitsubishi PLC. *A option board needs to be added. See the section of [Controller board and Unit] for detail.

  • Page 41: Password Setting

    5.4. Password setting In standard setting, the password setting is necessary only at the time of system storing. Password setting can also be done with each screen of setting for auto operation, teaching and conveyor data. The directory is as follows. System storage menu ↓...
  • Page 42 key to move to next screen (Use key to return) SW No. Name Type Default T-axis motion T-axis turns to designated T-axis turns, taking position, not taking short cut short cut direction direction (for aging) g.) Target position is -179 degree, when current position is 179 degree.
  • Page 43 SW No. Name Type Default Trace data is saved Trace data is Which timing when motor power is saved when servo turned off. is failed. trace data is stored at Does not change STA position even if picking direction is exact same when STA position is Recalculating changed.
  • Page 44 SW No. Name Type Default ＳＷ６ Note Pressing No. of switches allows to display its explanation at bottom of screen.

  • Page 45: Parameter Setting

    5.6. Parameter setting (Controller data) directory parameter setting screen is as follows. System storage menu ↓ Controller data ↓ Parameter setting １．Job number ・ Enter the job number you work ・The job number is shown up at the basic menu. ２．Top of latch range ・...

  • Page 46: Firmware Update

    5.7. Firmware update The directory to Firmware update is as follows. System storage menu ↓ Controller data ↓ Firmware update IMPORTANT ・Robot may be crashed if wrong firmware is written by mistakes. ・Only the qualified service person can work on the following procedure. １．List of firmware List of firmware files (SH software) in the [SH] folder in external memory selected is displayed.
  • Page 47 ４．Firmware backup It reads firmware that is being executed on the current RC501 and that is stored into SH folder of external memory. The file name is “RC_GEN2_123A.BIN” if [Current version] display is “1.23A” for example. ６．System parameter initialization When main power is cycled while the switch is being turned on, the system parameters are initialized at the system to be booted.

  • Page 48: Hour Meter

    5.8. Hour meter The directory to the hour meter screen is as follows. System storage menu ↓ Controller data ↓ Hour meter [Date change] Display the key input screen by pressing the display data of item to be changed. Then, enter a value to be set by numeral keys, and press WRITING key.

  • Page 49: Soft Limit

    5.9. Soft Limit The directory to soft limit screen is as follows. System storage menu ↓ Robot data ↓ Soft limit 1． Soft limits -This displays the range in which R, D, O and T axis movement is possible, as an angle -The R-axis value is used for the R area in 5...

  • Page 50: Hand Setup

    5.10. Hand Setup directory hand setup screen is as follows. System storage menu ↓ Controller data ↓ Hand Setup １．Hand manual operation name input [Input procedure] ① Press No. key to enter. ② Enter name input screen to pop up. ③...

  • Page 51: Parameter Setting (Robot Data)

    5.11. Parameter Setting (Robot Data) The directory to parameter setting screen is as follows. System storage menu ↓ Robot data ↓ Parameter setting １．Axis accuracy ・Arrival confirmation is performed at this precision only when SPC is selected due to step parameter overlap ２．SMOV, SMOV2 parameter Default...

  • Page 52: Origin Storing

    5.12. Origin Storing See 4.1 Origin storing for detail. 5.13. Servo Parameter This is a screen for displaying or changing the necessary parameters for the servo control. The directory to the servo parameter screen is as follows. System storage menu ↓...

  • Page 53: Expansion Axis Setting

    5.14. Expansion Axis Setting This screen is for setting expansion axis. The directory to expansion axis setting is as follows. System storage menu ↓ Motor axis data ↓ Expansion axis setting Note) Amp unit is required to add expansion axis. １．Set expansion axis Select type of servo motor to be installed.
  • Page 54 Enter axis accuracy. To enter [0] allows to set it zero overlap. ７．Origin offset It is entered by itself when others are set at the origin storage screen. It can also be entered on the screen. ８．Revolving direction Select [Forward] or [Reverse]. ９．Auto operation speed To select [Synchronize] allows to enable to change by itself the speed proportional to robot auto operation speed.

  • Page 55: Maintenance Functions

    6. Maintenance Functions Maintenance on Touch panel (POD) is explained.

  • Page 56: Menu Structure

    6.1. Menu Structure Select [M: Maintenance] on main menu. You can operate various maintenance functions on the screen. A:Automatic operation T:Teaching mode Main menu S:System storage mode M:Maintenance mode 6.1.1. Move to maintenance menu under operation Maintenance menu is basically selected only when a robot is stopped. To move to maintenance menu under operation, press the hidden key located below on the auto mode screen.
  • Page 57 6.1.2. Maintenance menu detail The maintenance menu branches off to [Controller data], [Robot data] and [Motor axis data]. Versions of software are displayed over here. Robot data Controller data Motor axis data...

  • Page 58: Data Memory Contents

    6.2. Data memory contents Internal data memory contents (data held for each program) and external data memory contents (Dn) can be monitored and modified on this screen. Maintenance menu ↓ Controller data ↓ Data memory contents 【Internal data memory】 data held for each program. D 0 ：stacking layer D 1 ：stacking product D 2 ：picking quantity...

  • Page 59: I／O Monitor

    6.3. I／O Monitor The directory to I/O monitor screen is as follows. Maintenance menu ↓ Controller data ↓ I/O Monitor The status of various relays can be monitored and/or changed on the relay monitor screen. The contents of relays are normally retained and continue to be displayed when and after you get into the...

  • Page 60: Operation Ready Condition

    6.4. Operation ready condition The directory to operation status screen is as follows. Maintenance menu ↓ Controller data ↓ Operation status 1. If motor power ON enabling and operation start enabling are fulfilled or not is displayed. In case all conditions are highlighted, you can turn motor power or operation on.

  • Page 61: File Operation

    6.6. File operation Files can be transferred between external memory and robot controller. The directory to file operation screen is as follows. Maintenance menu ↓ Controller data ↓ File operation １．Transfer direction Select file transfer direction. Display of the button toggles between [external memory <->...
  • Page 62 Five recent trace data is transferred to external memory. The file name is changed to that added on with date at the upfront. (Example: 20100930150157_risc.err) ６．Deletion Files chosen are deleted. ７．Cancel Pressing [Cancel] during transferring allows to cancel the process. Note External memory Either USB memory or CF (compact flash) can be connected.

  • Page 63: Logic Analyzer

    6.7. Logic analyzer The directory to logic analyzer is as follows. Maintenance menu ↓ Controller data ↓ Logic analyzer Select (8)-points out of relays (X/Y/M) of robot controller, set a trigger to one of the selected relays. The status of timing (as timing chart) of the relays before and after the triggered is shown.
  • Page 64 ⑤Recorded data after triggered Enter number of data after triggered you want. The max number is 80 DIV so 40DIV is mid point of trigger to enable to evenly see both sides. ２． After setting is completed, press RUN/STOP button to monitor. The indicator below the button is changed whenever pressed.

  • Page 65: Id No - Prg No Allocation

    6.8. ID No – Prg No allocation IDNo-PrgNo. allocation screen is displayed only at the time of the starting mode from external PLC ( [X/Y] is selected at sys-para PLC control interface). The directory to ID NO – Prg No allocation screen is as follows. Maintenance menu ↓...

  • Page 66: Battery Replace

    6.9. Battery replace The directory to battery replacement screen is as follows. Maintenance menu ↓ Controller data ↓ Battery replace Press respective corresponding [Replace] button when battery is replaced for either [for robot], [for controller] or [for touch panel]. The current date is stored.

  • Page 67: Stacked Counter Revision

    6.11. Stacked counter revision The directory to stacked counter revision is as follows. Maintenance menu ↓ Robot data ↓ Stacked counter revision Initialize Pallet Selected 1.To press pallet key to initialize allows to display the count value of corresponding program. 2.

  • Page 68: Program Selection Method

    6.12. Program selection method The directory to program selection method is as follows. Maintenance menu ↓ Robot data ↓ Program selection method See 1.3 Program confirmation procedure on manual of [Teaching pallet on floor] for detail. Position & acceleration / deceleration time 6.13.

  • Page 69: Executed Sequence Command

    6.14. Executed sequence command The directory to executed sequence command is as follows. Maintenance menu ↓ Robot data ↓ Executed sequence command Up to (40) sequence commands robot has executed are displayed on the executed sequence command screen. Scroll key can move screen upward or downward to show you all the rest of the commands.

  • Page 70: Smov Calculation

    6.16. SMOV calculation The directory to SMOV Calculation screen is as follows. Maintenance menu ↓ Robot data ↓ SMOV calculation １． Executed step No., position data and acc/dec time are displayed when SMOV is executed. 6.17. Deviation trace The directory to deviation trace is as follows.

  • Page 71: Position Command Trace

    6.18. Position command trace The directory to position command trace is as follows. Maintenance menu ↓ Motor axis data ↓ Position command trace The position data of each axis can be displayed as an instruction value to CPU (DS) for servo motor control.

  • Page 72: Servo Torque Indicate

    6.19. Servo torque indicate The directory to servo torque indicate is as follows. Maintenance menu ↓ Motor axis data ↓ Servo torque indicate １．Measurement of torque Press [Start/Clear] button to start. (960) – data are recorded in the preset sampling frequency.

  • Page 73: Collision Detection

    6.20. Collision detection The directory to collision detection is as follows. Maintenance menu ↓ Motor axis data ↓ Collision detection trace 6.21. Expansion axis trace The directory to expansion axis trace is as follows. Maintenance menu ↓ Motor axis data ↓...

  • Page 75: Table Of Basic Specifications

    7. Table of Basic Specifications RC840 RC830 Model (A700V) (A1800V , A1600V) 4-axes simultaneous + 2 axes (for hand axis etc. Number of control axis optional) Path control system PTP (R,T Axes) CP (O,D Axes) Position detection Absolute encoder system Position control system Digital closed loop Motor control system...
  • Page 78 Version 01: 2012.04.24 <Caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice. Okura Yusoki Co., Ltd. 900 Furuouchi, Noguchi-cho, Kakogawa, Hyogo 675-8675 Japan...

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