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Nachi RMU20-20 Instruction Manual

Fd/cfd controller robot monitoring unit
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FD/CFD CONTROLLER
INSTRUCTION MANUAL
Robot Monitoring Unit
RMU20-20/30/40
・
Before attempting to operate the robot, please read through this operating manual
carefully, and comply with all the safety-related items and instructions in the text
・
The installation, operation and maintenance of this robot should be undertaken only
by those individuals who have attended one of our robot course
・When using this robot, observe the low related with industrial robot and with
safety issues in each country.
・
This operating manual must be given without fail to the individual who will be actually
.
operating the robot
・
Please direct any queries about parts of this operating manual which may not be
completely clear or any inquiries concerning the after-sale service of this robot to any
of the service centers listed on the back cover.
8th edition
1505, TFDEN-143-008, 001
.
.

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  • Page 1 1505, TFDEN-143-008, 001 FD/CFD CONTROLLER INSTRUCTION MANUAL Robot Monitoring Unit RMU20-20/30/40 8th edition ・ Before attempting to operate the robot, please read through this operating manual carefully, and comply with all the safety-related items and instructions in the text ・...

  • Page 3: Table Of Contents

    Contents Contents Chapter 1 Introduction 1.1 Outline ............................1-1 1.1.1 Features of robot monitoring unit ..................1-1 1.1.2 Functions of robot monitoring unit ..................1-1 1.1.3 Specifications........................1-2 1.1.4 Type and serial number ..................... 1-8 1.2 Risk Assessment ........................1-9 1.3 Connection..........................
  • Page 4 Contents 2.6.2 Motors ON condition......................2-32 2.6.3 Motor power-ON control ....................2-32 2.6.4 Timing chart ........................2-33 2.7 Logical operation output function..................... 2-35 2.8 RMU error signal output (Application signals) ................. 2-37 2.9 Enabling RMU.......................... 2-38 Chapter 3 Virtual Safety Fence Function Outline of Virtual Safety Fence Function................
  • Page 5 Contents 4.4.2 Robot Monitoring Unit simple approval operation ............4-34 4.5 Setting of disconnection ......................4-37 4.5.1 Setting of disconnection ....................4-37 4.6 Menu list ..........................4-39 4.6.1 Operating range monitoring..................... 4-39 4.6.2 Angle monitoring......................4-39 4.6.3 Speed monitoring......................4-39 4.6.4 Stop monitoring........................
  • Page 6 Contents...

  • Page 7: Chapter 1 Introduction

    Chapter 1 Introduction This chapter presents an outline of the robot monitoring unit (RMU) functions. 1.1 Outline ......................1-1 1.1.1 Features of robot monitoring unit ............1-1 1.1.2 Functions of robot monitoring unit............1-1 1.1.3 Specifications ..................1-2 1.1.4 Type and serial number.................1-8 1.2 Risk Assessment ..................1-9 1.3 Connection....................1-10 1.3.1 Required parts and installation (FD controller) ........1-10 1.3.2 Required parts and installation (CFD controller) .........1-10...

  • Page 9: Outline

    1.1 Outline 1.1 Outline 1.1.1 Features of robot monitoring unit The robot monitoring unit (RMU20) is a Category 4 and PLe compliant system which monitors the robot position and speed so as to shut off the power to the robot when its position or speed are deemed to be irregular. The robot position monitoring system consists of safety circuits using microcomputers and semiconductors, and input/output signals, redundant safety signals and other signals from the process control panel are connected as the input/output signals from outside the robot controller.

  • Page 10: Specifications

    1.1 Outline 1.1.3 Specifications General Specifications Item Specifications Remarks DC24V +10% Rated voltage -15% This value U24V 1.0A Rated current depends on the U24A 0.5V connected devices All 13 ports  Robot Emergency stop  Emergency stop  Safety plug ...
  • Page 11 1.1 Outline Safety performance Item Specifications Remarks Motor power control sequence. Category 4 Monitoring of position (operating range, PL(Performance Level)=e joint angle) MTTFd = 75.15 Monitoring of speed DC = 94.34 Monitoring of stop CCF = 75 Monitoring of stop in area SIL3 Safety network(RM20-30 only) PFD = 4.35e...
  • Page 12 1.1 Outline It is also possible to If the restricted object exceeds the restricted range, output a signal perform operation as follows: by using the <TEACH mode> logical operation Safety output OFF (Stop Category 0) function when <PLAYBACK mode> the robot enters Method of restriction Safety output OFF (Stop Category 0) the restricted...
  • Page 13 1.1 Outline Monitoring of stop in area Item Specifications Remarks If the run-out and stopping distance estimated from Basic functions the robot speed exceeds the restricted are, robot is stopped. If the restricted object exceeds the restricted range, perform operation as follows: <TEACH mode>...
  • Page 14 1.1 Outline Encoder and motor interface Item Specifications Remarks <Encoder> It is possible send/receive data to/from the bidirectional serial communication encoder. It is possible to read communication between servo Basic functions amplifier and encoder together with request data and encoder output data. <Motor>...
  • Page 15 1.1 Outline Environment Item Description Overvoltage category Overvoltage category 1 Protective class Protective class IP20 Temperature Operation temperature 0 to 55°C Storage temperature -25 to +70°C Ambient environment Degree of pollution 2 conditions Ambient humidity: Level RH1 30 to 85%RH (no condensation) Free from corrosive gas Altitude less than 1000m Vibration...

  • Page 16: Type And Serial Number

    1.1 Outline 1.1.4 Type and serial number Model and serial number of the robot monitoring unit can be checked on the nameplate that is attached to the monitoring unit. Type RMU20-20 or RMU20-30 or RMU20-40...

  • Page 17: Risk Assessment

    1.2 Risk Assessment 1.2 Risk Assessment Risk assessment involves ascertaining the sources of danger latent in a machine, assessing the extent of those dangers (risks) and reducing the risk until the system is deemed to be safe. Proceed with the risk assessment in accordance with the IEC 61508 standard. The procedure involved is as follows: Analyze the robot and its peripheral equipment, assess the entire system including its operating modes, identify the sources of danger, and estimate the risk of those dangers.

  • Page 18: Connection

    1.1 Outline 1.3 Connection 1.3.1 Required parts and installation (FD controller) To use this unit, the following optional products are also necessary. These parts are already installed in robot controllerr before shipment, so customer does not have to do installatrion work. Table 1-1 Optional products for RMU of FD controller Product name Model number...

  • Page 19: Sequence Board Um367-20

    1.1 Outline 1.3.3 Sequence board UM367-20 The sequence board UM367 controls the followings; - The digital I/O signal between the robot controller and the peripheral equipments. - Mode selection JP1,2 Fig.1.3.2 Overview of the sequence board Table 1.3.3 Connectors on the sequence board Name Function Connected to...

  • Page 20: Connection Of Safety Inputs

    1.1 Outline 1.3.4 Connection of safety inputs Electrical Rating DC26V, 5mA max specifications Connect the relay contacts (dry contacts). To prevent defective contact and other problems, use a device which can turn on and off the very small load specified above. These input signals must have redundant circuit.
  • Page 21 1.1 Outline The teminal block type number (and its pin layout) differs from each other depending on the shipping date. (1) In case of PM5DW-50V4 (Manufacture: Yoshida Electric) (FD controller) 129mm 29 31 35 37 47 49 Table 1-5 Terminal block TBX-1 pin layout Pin No.
  • Page 22 1.1 Outline (2) In case of PCX-1H50 (Manufacture: Toyo) (FD controller, CFD controller) 92.5mm Table 1-6 Terminal block TBX-1 pin layout Pin No. Marking Signal name Pin No. Marking Signal name A1 (1) IN5A+ External emergency stop 1+ B1 (2) IN5A- External emergency stop 1- A2 (3)
  • Page 23 1.1 Outline Precautions related to the connection to the terminal block TBX-1 Applicable connection tool: Minus screw driver (Width of the edge is 2.6mm) Wire size Regarding the size of the wires for the external I/O device connection, refer to the following descriptions. Single wire: φ1.6 mm, Twisted wire(Flexible wire): φ1.25mm When connecting the wire as it is, the pealed length of the wire should be 11mm.

  • Page 24: Connection Of Safety Outputs

    1.1 Outline 1.3.5 Connection of safety outputs The general safety output signals should be connected to CNGP2 connector of RMU. Electrical FET output specifications for DC30V，100ｍA max each outputs Please be sure to make the connections so that the total current amount of the all outputs (2ch x 3 outputs) is 600mA or less.

  • Page 25: Ec Declaration Of Conformity For Machinery

    1.4 EC DECLARATION OF CONFORMITY FOR MACHINERY 1.4 EC DECLARATION OF CONFORMITY FOR MACHINERY EC DECLARATION OF CONFORMITY FOR MACHINERY (Directive 2006/42/EC - Annex II A) Manufacturer : NACHI-FUJIKOSHI CORP. Address : Head office 17F SHIODOME SUMITOMO BLDG. 1-9-2, Higashishinbashi, MINATO-KU, TOKYO, 105-0021, JAPAN...
  • Page 26 1.4 EC DECLARATION OF CONFORMITY FOR MACHINERY NOTE 1-18...

  • Page 27: Chapter 2 Monitoring Unit Configuration

    Chapter 2 Monitoring Unit Configuration This chapter shows the exterior of the RMU and its parts, and presents details on the connection signals supplied to the monitoring unit. Furthermore, the functions of the RMU are described. 2.1 Connections with External Equipment .................2-1 2.2 Description of Exterior and Parts .................2-3 2.2.1 View of exterior......................2-3 2.2.2 LED ........................2-5...
  • Page 28 2.7 Logical operation output function ................2-35 2.8 RMU error signal output (Application signals)............2-37 2.9 Enabling RMU......................2-38...

  • Page 29: Connections With External Equipment

    2.1 Connections with External Equipment 2.1 Connections with External Equipment This section gives an example of how the RMU, the robot controller and the external equipment may be connected. This particular example shows the connections for a system in which two robots are operated by one teach pendant, but it is just an example: in reality, there are many and varied systems, and the safety measures required are also different.
  • Page 30 2.1 Connections with External Equipment Name of equipment Description Teach Pendant This HMI unit enables the operator to run the robot, create the robot programs and perform the parameter setting operations. It displays the robot program data, operation statuses of the robot, etc. In addition, it displays the initial settings established for the robot safety units and the errors which have occurred in these units.

  • Page 31: Description Of Exterior And Parts

    2.2 Description of Exterior and Parts 2.2 Description of Exterior and Parts 2.2.1 View of exterior Fig. 2-2 Front view of RMU20-20 Fig. 2-3 Side view of robot monitoring (RMU20-20)
  • Page 32 2.2 Description of Exterior and Parts Fig. 2-2 Front view of RMU20-30, RMU20-40 Fig. 2-3 Side view of robot monitoring (RMU20-30, RMU20-40)

  • Page 33: Led

    2.2 Description of Exterior and Parts 2.2.2 LED 1) Status Display LED This displays the status of input/output signals. Table 2-1 Status of status display LED Classification Name Description Power-on Software version of the RMU is displayed. Ex: In case of software version V1.1. During During normal operation, the display is as follows.
  • Page 34 2.2 Description of Exterior and Parts When Error number is displayed. error occurs EX: In case of Error code 01, Assist code 2345H 最初へ戻る Back to the beginning...

  • Page 35: Connector

    2.2 Description of Exterior and Parts 2.2.3 Connector 1) CN1 Table 2-2 Connector CN1 pin allocation Signal name Signal name Pin no. Circuit code Pin no. Circuit code DC24V (+) DC24V (GND) (A1) U24V (B1) DC24V (+) DC24V (GND) (A2) U24V (B2) Robot emergency...
  • Page 36 2.2 Description of Exterior and Parts 2) CNE1 Table 2-3 Connector CNE1 pin allocation Signal name Signal name Pin no. Circuit code Pin no. Circuit code Encoder 1 Encoder 1 (A1) (B1) (Differential signal ) (Differential signal -) Encoder 2 Encoder 2 (A2) (B2)
  • Page 37 2.2 Description of Exterior and Parts 4) CNROT Table 2-4 Connector CNROT pin allocation Signal name Signal name Pin no. Circuit code Pin no. Circuit code J1 motor U-phase J1 motor V-phase (A1) (B1) J1 motor W-phase J1 motor L-phase (A2) (B2) J2 motor U-phase...
  • Page 38 2.2 Description of Exterior and Parts 6) CNGP1 (RMU20-20) Table 2-6 Connector CNGP1 pin allocation Signal name Signal name Pin no. Circuit code Pin no. Circuit code Emergency stop 1+ Emergency stop 1- (A1) IN5A+ (B1) IN5A- Emergency stop 2+...
  • Page 39 2.2 Description of Exterior and Parts 8) CNGP3 (RMU20-20) Table 2-8 Connector CNGP3 pin allocation Signal name Signal name Pin no. Circuit code Pin no. Circuit code General input 41+ General input 41- (A1) IN12A+ (B1) IN12A- (Note1) (Note1) General input 42+...
  • Page 40 2.2 Description of Exterior and Parts 10) CN2 (RMU20-30, RMU20-40) Table 2-10 Connector CN2 Pin no. Circuit code Signal name Pin no. Circuit code Signal name (A1) (B1) IN5A+ Emergency stop 1+ IN5A- Emergency stop 1- (A2) (B2) IN5B+ Emergency stop 2+ IN5B- Emergency stop 2- (A3)
  • Page 41 2.2 Description of Exterior and Parts 12) CN4 (RMU20-30, RMU20-40) Table 2-12 Connector CN4 Pin no. Circuit code Signal name Pin no. Circuit code Signal name (A1) IN9A+ (B1) IN9A- General input 11+ General input 11- (Note) (Note) (A2) IN9B+ (B2) IN9B- General input 12+...

  • Page 42: Connected Signals

    2.3 Connected signals 2.3 Connected signals The signals connected to the RMU are described hereinafter. 2.3.1 Signal connection diagram ロボット制御装置 Robot controller CNCOM D+,D- サーボ通信 Servo communication COM(24V) LS解除SW LS_RLS LS release SW 操作パネル System OK システム正常 operation panel 再生条件 Auto M_MODE モードＳＷ...

  • Page 43: Safety Inputs

    2.3 Connected signals 2.3.2 Safety inputs Safety inputs are redundant contact input signals, related to the power supply permission to the robot. When a disconnection, short-circuit, ground fault or other trouble has detected due to signal disparity or diagnosis of input signals, robot is stopped immediately by turning off the safety output signal.
  • Page 44 2.3 Connected signals General input 21+ IN10A+ General-purpose safety input signal Photo-coupler input General input 21- IN10A- Used for area select signal, stop monitoring Rating DC26V General input 22+ IN10B+ signal or playback speed monitoring select Input current 5mA General input 22- IN10B- signal.
  • Page 45 2.3 Connected signals Input signal diagnosis With input signal diagnosis, troubles caused by the input devices (short-circuit trouble, open-circuit trouble, stuck-at faults, etc) are detected. The trouble in the input circuit is diagnosed by the diagnosis circuit so that it is possible to reliably detect it when the input signals have been turned OFF.

  • Page 46: Safety Outputs

    2.3 Connected signals 2.3.3 Safety outputs Electrical FET output specifications Max. DC30V, 100mA Table 2-14 Safety outputs Signal name Circuit code Description Robot power ON 1+ OUT1A+ This is robot power ON signal. Robot power ON 1- OUT1A- Connect to magnet switch contact for servo drive. Robot power ON 2+ OUT1B+ When being used as a slave unit, this is regareded as "Slave...

  • Page 47: Back Check Circuit

    2.3 Connected signals 2.3.4 Back check circuit Table 2-15 Back check Signal name Circuit Description Electrical specifications code Robot power supply back BK1+ Signal from magnet switch “b” contact. Photo-coupler input check 1+ BK1- Signal for detecting the welding (back Rating DC26V Robot power supply back check) of the magnet switch...

  • Page 48: Monitor Inputs

    2.3 Connected signals 2.3.5 Monitor inputs Electrical Rating DC26V, 5mA specifications Connect the dry contacts. To prevent defective contact and other problems, use a device which can turn on and off the very small load specified above. Table 2-16 Monitor inputs Circuit Electrical Signal name...

  • Page 49: Monitor Outputs

    2.3 Connected signals ＲＭＵ２０ Internal circuit 内部回路 GPINx Diagnosis circuit 診断回路 Fig. 2-6 Example of monitor input circuit Input signal diagnosis To detect trouble occurring in the input device, the same input signal diagnosis as for the safety input circuit is performed.

  • Page 50: Motion Controller Interface

    2.3 Connected signals 2.3.7 Motion controller interface This communication line is for receiving the parameters required for the purpose of the position and speed monitoring function. Table 2-15 Motion interface Signal name Description D-/D+ The interface connects these signals for communicating with the motion controller. Communication specification: USB1.1 2.3.8 Encoder interface This line is for communication with the encoder for obtaining the current position of the robot for the purpose of...

  • Page 51: Precautions When Installing Rmu Inside The Controller

    2.4 Precautions when Installing RMU inside the Controller 2.4 Precautions when Installing RMU inside the Controller In the use of this unit, the following requirements of each standard. The RMU is constructed to be installed inside the robot controller. 2.4.1 Low-Voltage Directive requirements to be satisfied (compliance with EN50178) ■...

  • Page 52: Other: Processing The Cables Connected To Rmu20

    2.4 Precautions when Installing RMU inside the Controller ■ Installation of controller In case of installing the RMU, it is recommended to use the EMI shielded cabinet. IMPORTANT Tests under the following standards have been conducted on RMU20 in accordance with the IEC 61326-3-1 standard.

  • Page 53: Operating Range, Angle And Speed Monitoring Function

    2.5 Operating Range, Angle and Speed Monitoring Function 2.5 Operating Range, Angle and Speed Monitoring Function During operating range or speed monitoring operations, the motor position is received from the servo motor and the current value data of the robot is received from the encoders, and the area and speed set are monitored by the monitoring routine inside the RMU.

  • Page 54: Operating Range Monitoring

    2.5 Operating Range, Angle and Speed Monitoring Function 2.5.2 Operating range monitoring “Operating range monitoring” is a function which shuts off the safety outputs and enables the robot to be stopped safely when a robot wrist, tool, work or arm has protruded beyond one of the operating ranges. By setting the operation restricted ranges (linear restriction/partial restriction) and sphere and arm surface points, it shuts off the safety outputs and enables the robot to be stopped safely when the tool sphere or arm surface point has protruded beyond one of the operation restricted ranges.

  • Page 55: Angle Monitoring

    2.5 Operating Range, Angle and Speed Monitoring Function 2.5.3 Angle monitoring This function monitors the operating ranges of the robot axes, and when any of the axes has exceeded the operating range, it shuts off the safety outputs to stop the robot safely. The “soft limit function”...

  • Page 56: Stop Control Monitoring Function In Area

    2.5 Operating Range, Angle and Speed Monitoring Function 2.5.7 Stop Control monitoring Function in Area The run-over distance that will be made when the robot make an emergency stop will be estimated by referring to the robot motion speed. And the RMU shuts off the safety output to stop the robot safely considering the estimated run-over distance.

  • Page 57: Tool Number Monitoring Function

    2.5 Operating Range, Angle and Speed Monitoring Function 2.5.8 Tool Number monitoring Function The tool number of robot program and tool number signal that are output from the tool is compared, If they are mismatched, RMU shuts off the safety outputs to stop the robot safely. Up to 9 tool numbers can be set by using monitor input signals.
  • Page 58 2.5 Operating Range, Angle and Speed Monitoring Function When using the tool number monitoring function, prepare a tool that can output 4 bit binary output signals to output the tool number. Connect the signals from the tool to the "Tool No. 1 -4" on the terminal block TBX-1 in the robot controller as follows;...

  • Page 59: Motor Power Control Sequence

    2.6 Motor Power Control Sequence 2.6 Motor Power Control Sequence This section describes the motor power control sequence that is to supply the drive power to the robot and to enable robot operation. 2.6.1 Outline of motor power control sequence Motor power control sequence executes status transition for the following three modes, and controls the motor power-ON output signal in accordance with the input signals.

  • Page 60: Motors On Condition

    2.6 Motor Power Control Sequence 2.6.2 Motors ON condition Table 2-19 Motors ON condition PLAYBACK mode TEACH mode Signal name ON condition ON condition PLAYBACK mode TEACH mode External Robot emergency stop Enable switch Slave error Robot LS detection Emergency stop Safety stop Protective stop External enable...

  • Page 61: Timing Chart

    2.6 Motor Power Control Sequence 2.6.4 Timing chart Motors Motors 運転準備 運転準備 Power Power Power Power 動力供給 動力供給 動力供給 動力供給 Supply Supply Supply Supply PLAYBACK mode 再生モード (motion （ﾓｰｼｮﾝ通信) communication) TEACH mode 再生モード (motion （ﾓｰｼｮﾝ通信) communication) ES fault ＥＳ異常 Robot ロボット...
  • Page 62 2.6 Motor Power Control Sequence Motors Motors 運転準備 運転準備 Power Power Power Power Power 動力供給 動力供給 動力供給 動力供給 動力供給 Supply Supply Supply Supply Supply PLAYBACK mode 再生モード (motion （ﾓｰｼｮﾝ通信) communication) TEACH mode 再生モード (motion （ﾓｰｼｮﾝ通信) communication) ＥＳ異常 ES fault Robot ロボット...

  • Page 63: Logical Operation Output Function

    2.7 Logical operation output function 2.7 Logical operation output function This section describes a function that sets logical operation for general safety output signals and output those signals. In this function, safety related information e.g. monitoring results of the motion range, angles, motion speed, or safety inputs etc.
  • Page 64 2.7 Logical operation output function Group Item Description Safety out.relay Rob.Power-ON Turns ON when the "Robot Power-ON" turns ON. Safety out.1 Turns ON when the "General safety output 1" turns ON. Safety out.2 Turns ON when the "General safety output 2" turns ON. Safety out.3 Turns ON when the "General safety output 3"...

  • Page 65: Rmu Error Signal Output (Application Signals)

    2.7 Logical operation output function 2.8 RMU error signal output (Application signals) The errors of the RMU can be assigned to the output signals of application signals. By assigning those signals, it is possible to detect the condition of the RMU from the external devices e.g. PLC etc. When shipping, those signals are not assigned.

  • Page 66: Enabling Rmu

    2.9 Enabling RMU 2.9 Enabling RMU In this section, how to enable the RMU setting is described. If a new RMU is connected to the robot controller, it is necessary to enable the setting for the concerned RMU. If the RMU itself is not enabled, the parameter setting menu for the RMU is not displayed. (In case of the FD controller) If the RMU has already been connected to the FD controller when shipping from our factory, The RMU setting is enabled.
  • Page 67 2.9 Enabling RMU Without changing the setting, just press <f12 Complete>. >>The following screen will be displayed. NOTE) This screen will be displayed only when the RMU is recognized by the robot controller. Change the setting for the Servo Amplifier 1 to “Connect” Press f12 <Complete>...
  • Page 68 2.9 Enabling RMU NOTE 2-40...
  • Page 69 Chapter 3 Virtual Safety Fence Function 3.1 Outline of Virtual Safety Fence Function ..........3-1 3.2 Operation procedure ................3-2 3.2.1 Installation angle ................3-2 3.2.2 Virtual safety fence settings ............3-4 3.2.3 Range setting ..................3-5 3.2.4 Tool limit setting................3-13 3.2.5 Arm limit setting................3-20 3.2.6 Other settings ................3-22 3.2.7...

  • Page 71: Outline Of Virtual Safety Fence Function

    3.1 Outline of Virtual Safety Fence Function Outline of Virtual Safety Fence Function The “Virtual Safety Fence Function” is a system to monitor with software so that the “robot wrist / tool / work-piece / arm / rear” limits will not go beyond the movement area. By making setting of movement limit area (linear limit and partial limit) and the shape of the robot, this function prevents the robot body or the tool from going outside of the movement limit area.

  • Page 72: Operation Procedure

    3.2Operation procedure Operation procedure 3.2.1 Installation angle Used to define the position and the angle of the robot based on the reference coordinate system (=world coordinate system). When using the virtual safety fence function or interlock automatic generation function, make this setting. By this setting, the position and the angle of the respective robots (or other mechanisms like sliders etc.) will be decided.
  • Page 73 3.2Operation procedure (Reference) setting examples Floor mount type setting example INFO. - The all rotation angles are zero. - If necessary, set the XYZ coordinates referring to the layout drawing. If the robot is installed on the origin of the world coordinate system, set (0,0,0). - In the screen of “Mechanism relation”, set the installation place for the robot as “Ground”.

  • Page 74: Virtual Safety Fence Settings

    3.2Operation procedure 3.2.2 Virtual safety fence settings While one of the screens under the menu of [33 Virtual Safety Fence] is being displayed, the checking function of the VSF function is temporally disabled and motion regulation is not performed. When the robot makes unexpected movement and a person is caught or sandwiched by the DANGER robot arm, death or serious injury may occur.

  • Page 75: Range Setting

    3.2Operation procedure 3.2.3 Range setting The range setting is the function of making setting of the safety fence and the part range as well as the “Robot wrist / tool / workpiece / arm” movement limit areas. If the robot wrist, tool, workpiece, arm, reaches the limit range, an error will occur. Safety fence Safety fence Part range...
  • Page 76 3.2Operation procedure Press the f key “Part Range”. >> The “Part setting” screen shown below will appear. Press the f key “Fence Range”. >> The “Range setting” screen shown below will appear. Each time when the f key “Fence Range” and the f key “Part Range” are pressed, the “Range setting”...
  • Page 77 3.2Operation procedure “Part Range” Press the f key “Plane change”. >> The points of sight of the “Graphic Display” screen will be switched. Each time when the f key “Plane change” key on the “Graphic Display” screen is pressed, the screen will be switched from Top  Side  Rear  Top  in the order described.
  • Page 78 3.2Operation procedure “Rear display” Press the f key “Tool sph.”. >> The following window will appear. Enter the desired "Tool sphere No." >> The displayed No. on the f key will be changed. Press the f key “Terminate”. >> The Graphic Display will be closed to return to the “Range setting” screen. After the completion of settings, press the <Complete>.
  • Page 79 3.2Operation procedure Table 3.2.3 Items to be set on Range Setting Screen Parameter Function Fence Range This range covers outside of a maximum of eight lines, which are defined from the center of the robot at random, as the limit area. It also enables specification of limit area in the Z direction.
  • Page 80 3.2Operation procedure Simplified setting In order to make settings of the fence range and the part range taking limit lines as a enclosed area, these settings can be made following the procedure shown below. Make setting of four start points. >>...
  • Page 81 3.2Operation procedure Safety Fence 1 Safety Fence 4 Safety Fence 2 Safety Fence 3 Fig. 3.2.2 Typical Safety Fence Range (Limit Lines 1 to 4) Upper limit value: + 3000 (mm) Lower limit value: - 800 (mm) * The lower limit value varies with installation locations. If “A” is set, the lower limit value will come to “0” (mm). Fig.
  • Page 82 3.2Operation procedure Part Range 1 Part Range 2 Part Range 3 Part Range 2 Part Range 1 Part Range 3 Fig. 3.2.4 Typical Part Ranges (1 to 3) 3-12...

  • Page 83: Tool Limit Setting

    3.2Operation procedure 3.2.4 Tool limit setting The tool limit setting function is used to make setting of sphere and form (cylinder or rectangular) by tool as limit objects. It enables individual limit settings of a maximum of 20 spheres, 1 cylinder, and 1 rectangular by tool for nine tools.
  • Page 84 3.2Operation procedure Press the f key “Form Limit”. >>The “Form Limit” Setting screen shown below will appear. *”Offset” of the forms represents distances from the distances from the tool installation flange, respectively. Press the f key “Sphere Limit”. >>Each time when the f key “Sphere Limit” and the f key “Form Limit” are pressed, the “Sphere Limit”...
  • Page 85 3.2Operation procedure Press the f key “Graphic Display”. >> The Graphic Display screen (Top) shown below will appear. “Sphere Limit” “Form Limit” Press the f key “Plane change”. >> The points of sight of the “Graphic Display” screen will be switched. Each time when the f key “Plane change”...
  • Page 86 3.2Operation procedure “Top Display – Form Limit” ↓ “Side Display – Sphere Limit” “Side Display – Form Limit” ↓ 3-16...
  • Page 87 3.2Operation procedure “Rear Display – Sphere Limit” “Rear Display – Form Limit” [Sphere Limit] Press the f key “Tool sph.” >> The following window will appear. Enter the desired "Tool sphere No." >> The displayed No. on the f key will be changed. [Form Limit] Press the f key “Tool sph.”.
  • Page 88 3.2Operation procedure After the completion of settings, press the <Complete>. Table 3.2.5 Items to be set on Sphere and Form Limit Setting Screen Parameter Function Used to specify the radius of sphere. If “0.0” is specified to the radius, the sphere concerned will be disabled. Radius Furthermore, if “0.0”...
  • Page 89 3.2Operation procedure Radius Center Used to make setting of distance from the center of the flange surface. Fig. 3.2.5 Sphere Setting Width Height Offset Used to make setting of Thickness distance from the center of the flange surface. Fig. 3.2.6 Form Limit Setting (Rectangular) 3-19...

  • Page 90: Arm Limit Setting

    3.2Operation procedure 3.2.5 Arm limit setting By setting this screen, it becomes possible to regulate the arm of the robot going outside of the limit area. This setting is finished when shipping. it is not necessary to setup this screen by customer.
  • Page 91 3.2Operation procedure (Reference) Robot coordinate system (Machine coordinate system) Robot coordinate system origin (Reference) Start point and end point for an arm (example) Please set the parameters based on the robot coordinate system origin. And, in this case, the robot posture should be the “Machine reference posture”...

  • Page 92: Other Settings

    3.2Operation procedure 3.2.6 Other settings Used to make settings of a variety of conditions for movement range limit of the virtual safety fence. Open <Constant Setting> - [3 Machine constants] [33 Virtual safety fence] [4 Other settings] menu. After the completion of settings, press the <Complete>. Table 3.2.7 Items to be set on Other Settings Screen Parameter Function...

  • Page 93: Vsf Approach Area" Output Signal

    3.2Operation procedure 3.2.7 “VSF approach area” output signal Used to make setting of signals to be output when the “VSF” is enabled and the robot is located in the virtual safety fence. Open <Constant Setting> [6 Signal attributes] [3 Output signal assignment] [1 Standard Outputs].

  • Page 94: Setting Example Of The Limit Line

    3.2Operation procedure 3.2.8 Setting example of the limit line The following section shows a typical limit line setting. 1 Make setting of movement area of the robot so that it will move in a circular pattern. 2 Make setting so as to limit the robot movement to the front and the side. 3 Make setting of further limit area to the movement area.

  • Page 95: Creation Of Data File

    3.2Operation procedure 3.2.9 Creation of data file The setting content of the Virtual Safety Fence function is stored to the VSF file (AC**VSF.CON). When a VSF file (AC**VSF.CON) is copied from an external memory media to the internal memory of this robot controller, the main power must be turned OFF and ON again. (NOTE) No file transfer by FTP is enabled.

  • Page 96: List Of Error Codes

    3.3 List of Error Codes List of Error Codes The following section shows the list of error codes of the virtual safety fence. 1170 Message Command position pass across the limit line. Occurrence timing When any of the sphere, form, and arm limits come close to the movement limit area. Possible causes The sphere defined on the tool pass across the border of limit area.

  • Page 97: Setting When A Slider Unit Is Used

    3.4 Setting when a slider unit is used Setting when a slider unit is used When a robot is installed on a slider (traverse unit), it is necessary to setup the “Mechanism relation” and the “Installation angle” correctly. Please be sure that when not correct, the TCP position check cannot executed normally.

  • Page 98: Installation Angle (Example1)

    3.4 Setting when a slider unit is used 3.4.2 Installation angle (Example1) <Constant Setting> - [12 Format and Configuration] [5 Installation Angle] Robot side (Initial setting) Slider side (Initial setting) In this initial setting, the relationship between the robot and the slider will be like the following picture. If the world coordinate system - The slider moves as Y axis direction linear joint.

  • Page 99: Installation Posture (Example2)

    3.4 Setting when a slider unit is used 3.4.3 Installation posture (Example2) An example in which the robot is rotated along Z axis (-90deg) and the slider is rotated along Z axis (+90deg) is shown as below. Please be sure that the slider rotates against the ground and the robot rotates against the parent mechanism (slider).
  • Page 100 3.4 Setting when a slider unit is used NOTE 3-30...

  • Page 101: Chapter 4 Monitoring Unit Settings

    Chapter 4 Monitoring Unit Settings This chapter presents the steps taken to establish the initial settings for the controller of the RMU. 4.1 Configuration flow of setting procedure ............4-1 4.2 Setting of parameters .................4-4 4.2.1 Setting of mechanism parameters ............4-5 4.2.2 Setting of axis parameters ..............4-6 4.2.3 Tool parameters ..................4-8 4.2.4 Setting of stop parameters ..............4-9...

  • Page 103: Configuration Flow Of Setting Procedure

    4.1Configuration flow of setting procedure 4.1 Configuration flow of setting procedure This section describes the initial settings for the RMU. The parameters required for monitoring the operating ranges, angles and speeds are stored inside the RMU. So parameters must be set for both robot controller and RMU. All settings have been completed for the RMU when shipped.
  • Page 104 4.1Configuration flow of setting procedure <1> In case that the RMU has been replaced or the data was initialized When the RMU is replaced, or backup-restore is executed, perform the settings in the following sequence. When the power is turned on, "E1107 Robot monitoring unit is not approved" will occur. But this is normal. In that case, perform the following steps.
  • Page 105 4.1Configuration flow of setting procedure <2> Parameters related to the RMU has been changed When parameters listed below are set, these parameters are also set to the RMU. Table 4-1 Settings related to the RMU Settings related to the RMU <Constants>...

  • Page 106: Setting Of Parameters

    4.2Setting of parameters 4.2 Setting of parameters If the RMU has been replaced or backup-restore operation has been executed, setting screen that is listed below shall be opened and perform writing operation. If the RMU had been replaced or backup-restore operation had been executed, perform writing operation even if there are no IMPORTANT modified parameters.

  • Page 107: Setting Of Mechanism Parameters

    4.2 Setting of parameters 4.2.1 Setting of mechanism parameters Open <Constant Setting> - [3 machine constants] – [34 Robot monitoring unit] – [1 Setting] – [1 Mechanism parameters]. The following screen will be displayed. Set the required parameters with reference to the following table. If there is no parameter to be updated, following operation is necessary.

  • Page 108: Setting Of Axis Parameters

    4.2Setting of parameters 4.2.2 Setting of axis parameters Open <Constant Setting> - [3 machine constants] – [34 Robot monitoring unit] – [1 Setting] – [2 Axis parameters]. >> The following screen will be displayed. Set the required parameters with reference to the following table. If there is no parameter to be updated, following operation is necessary.
  • Page 109 4.2 Setting of parameters Table 4-4 Axis parameters Default Parameter Function value Connection This is the setting whether connect to the RMU or not connected to the － RMU doe each axis. (Connect=0) This parameter is necessary for “axis separation function”. For more information, see "4.5Setting of disconnection”.

  • Page 110: Tool Parameters

    4.2Setting of parameters 4.2.3 Tool parameters Open <Constant Setting> - [3 machine constants] – [34 Robot monitoring unit] – [1 Setting] – [3 Tool parameters]. >> The following screen will be displayed. Set the required parameters with reference to the following table. If there is no parameter to be updated, following operation is necessary.

  • Page 111: Setting Of Stop Parameters

    4.2 Setting of parameters 4.2.4 Setting of stop parameters Open <Constant Setting> - [3 machine constants] – [34 Robot monitoring unit] – [1 Setting] – [6 Stop parameters]. >> The following screen will be displayed. Set the required parameters with reference to the following table. If there is no parameter to be updated, following operation is necessary.

  • Page 112: Setting Of Signal Parameters

    4.2Setting of parameters 4.2.5 Setting of signal parameters Open <Constants> - [2 machine constants] – [29 Robot monitoring unit] – [1 Setting] – [7 Signal parameters]. >> The following screen will be displayed. Set the required parameters with reference to the "Table 4-6 Signal parameters".
  • Page 113 4.2 Setting of parameters Table 4-6 Signal parameters Default Parameter Function value Tool number watch Enable / Disable the Tool number watch function. Disabled Teach protect stop Enable / Disable the protective stop function in the Teach mode. Disabled H-teach (safety plug) Enable / Disable the safety plug condition in the High-speed teach mode.

  • Page 114: Setting The Logical Operation Parameters

    4.2Setting of parameters 4.2.6 Setting the logical operation parameters Open <Constants> - [3 machine constants] – [34 Robot monitoring unit] – [1 Setting] – [8 Logic parameters]. >> The following screen will be displayed. General safety output 1 General safety output 2 General safety output 3 SPECIALIST Operator class...
  • Page 115 4.2 Setting of parameters After setting, press f12 <Complete>. >> When setting is done correctly, following message is displayed. But this is normal. After closing this message with [R] key, perform the confirmation operation. For details of the logical operation relays, see "2.7 Logical operation output function". (Supplement) In case of RMU20-30 or RMU20-40, the Safety network output signals (N1-N64) are also available.

  • Page 116: Setting The Safety Network Parameters (Rmu20-30)

    4.2Setting of parameters 4.2.7 Setting the Safety network parameters (RMU20-30) This screen is displayed only for RMU20-30. Open <Constant Setting> - [3 Machine constants] – [34 Robot monitoring unit] – [1 Setting] – [9 Safety network parameters]. >> The following screen will be displayed. Set the required parameters with reference to the Table 4-8.

  • Page 117: Setting The Safety Network Parameters (Rmu20-40)

    4.2 Setting of parameters 4.2.8 Setting the Safety network parameters (RMU20-40) This screen is displayed only for RMU20-40. Open <Constant Setting> - [3 Machine constants] – [34 Robot monitoring unit] – [1 Setting] – [9 Safety network parameters]. >> The following screen will be displayed. Set the required parameters with reference to the Table 4-9.

  • Page 118: Confirmation Of Parameters

    4.3Confirmation of parameters Confirmation of parameters It is necessary to confirm parameters stored in the RMU by teach pendant. Prior to this procedure, prepare the memo of modified parameters or prepare the print of all backup parameters in order to check them visually. CAUTION Text data file of the RMU parameters can be created in <Service Utilities>...

  • Page 119: Conformation Of Mechanism Parameters

    When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. 4-17...
  • Page 120 4.3Confirmation of parameters Table 4-10 Mechanism parameters Parameter Function TCP stop watch limit TCP position abnormal deviation (mm) when stop monitoring is input TCP speed level (H) TCP abnormal speed (mm/sec) in high speed Distance of tool watch TCP position abnormal deviation (mm) when verifying the tool Arm length One of the mechanism parameter to define the arm length Setting angle...

  • Page 121: Conformation Of Axis Parameters

    When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. 4-19...
  • Page 122 4.3Confirmation of parameters Table 4-11 Axes parameters Parameter Function Link coef. 1 Unique parameter due to the robot type Link coef. 2 Unique parameter due to the robot type Link coef. 3 Unique parameter due to the robot type Link coef. 4 Unique parameter due to the robot type Link coef.

  • Page 123: Conformation Of Tool Parameters

    When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. Table 4-9 Tool parameters Parameter...

  • Page 124: Conformation Of Area Parameters

    If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. Press <Area Change> key. >> The following screen will be displayed.
  • Page 125 When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. Table 4-13 Area parameters Parameter...

  • Page 126: Conformation Of Limit Parameters

    If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. Press <Limit Change> key. >> The following screen will be displayed.
  • Page 127 4.3Confirmation of parameters Table 4-14 Limit parameters Parameter Function Sphere 1 to 20 Parameter to define the size of sphere that means the tool area Radius Sphere 1 to 20 Parameter to define the center position of sphere that means the tool area Center Joint Joint number with which robot arm synchronizes...

  • Page 128: Conformation Of Stop Parameters

    When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. Table 4-15 Stop parameters Parameter...

  • Page 129: Conformation Of Signal Parameters

    When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. 4-27...
  • Page 130 4.3Confirmation of parameters Table 4-16 Signal parameters Parameter Function Tool number watch Enable / Disable the Tool number watch function. Teach protect stop Enable / Disable the protective stop function in the Teach mode. H-teach (safety plug) Enable / Disable the safety plug condition in the High-speed teach mode. Logic condition Enable / Disable the MOTORS ON condition of the logical operation function.

  • Page 131: Confirmation Of Logic Parameters

    When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. 4-29...

  • Page 132: Confirmation Of Safety Network Parameter (Rmu20-30)

    When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. 4-30...

  • Page 133: Confirmation Of Safety Network Parameter (Rmu20-40)

    When all parameters are correct, press <OK> key. If wrong parameters are displayed, please try to perform the writing procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. 4-31...

  • Page 134: Approval

    4.4Approval 4.4 Approval After the parameters stored in the RMU are confirmed same as those stored in the controller, "Approval" procedure is necessary. This procedure is to finish the confirmation of parameters stored in the RMU, and to read the RMU ID and controller ID number, and to enable the function of the RMU. Robot can not be operated without approval.
  • Page 135 4.4Approval Press <Execute> key. >> Dialog to request the password is displayed at the bottom of screen. Press the password [7] [1] [0] and [Enter] key. >>The following message will be displayed. >> The following screen will be displayed. Now controller ID and RMU ID become the same.

  • Page 136: Robot Monitoring Unit Simple Approval Operation

    4.4Approval 4.4.2 Robot Monitoring Unit simple approval operation By using this operation, it is possible to complete the all operations of setting, confirmation, and approval altogether. This operation is available in the system software version FDV4.14 or after. EXPERT Change the operator class to or higher.
  • Page 137 4.4Approval After the setting operation is finished, proceed with the confirmation operation. >>A screen like the following will be displayed. Check all parameters. When all parameters are correct, press <OK> key. (NOTE) The unfinished screens will appear one after another. Check the parameters in the same way and press <OK>...
  • Page 138 4.4Approval Approval is completed. >> The following screen will be displayed. 4-36...

  • Page 139: Setting Of Disconnection

    4.5Setting of disconnection 4.5 Setting of disconnection In case of “Axis disconnection utility” and or so, RMU will detect the encoder error because the specified axis is physically disconnected. Therefore, monitoring function must be set to disabled for this specified axis before utilizing these utility.
  • Page 140 4.5Setting of disconnection After setting, press f12 <Complete>. >> Following confirmation message will be displayed. When disconnected axis is correct, press <OK>. Then setting will be started. >> When setting is done correctly, following message is displayed. But this is normal. Close this message with [R] key.

  • Page 141: Menu List

    4.6Menu list 4.6 Menu list In this section, setting menu list is shown. 4.6.1 Operating range monitoring Table 4-17 Settings for operating range monitoring Setting menu Description Remark <Constant Setting> [3 Machine constants] [1 Tool Tool length and tool angle can be set －...

  • Page 142: Tool Number Monitoring

    4.6Menu list 4.6.5 Tool number monitoring Table 4-21 Settings for tool number monitoring Setting menu Description Remark <Constant Setting > [3 Machine constants] [34 Robot In "Tool watch" function, if the TCP － monitoring unit] Settings] Mechanism moves in the distance of "Distance of parameters] "Distance of tool watch"...
  • Page 143 Chapter 5 EtherNet/IP Safety network This chapter presents the EtherNet/IP Safety network function. 5.1 Outline of the EtherNet/IP safety network function ........5-1 5.2 Setting for RMU..................5-2 5.2.1 Safety network parameter..............5-2 5.2.2 Assignment of the network I/O signals ..........5-2 5.3 Settings for the safety PLC...............5-4 5.3.1 Setting procedure ................5-4 5.4 Trouble shooting..................5-9...

  • Page 145: Outline Of The Ethernet/Ip Safety Network Function

    5.1 Outline of the EtherNet/IP safety network function Outline of the EtherNet/IP safety network function This section describes the setting procedures for RMU20-30 that supports EtherNet/IP safety network function. This function is available only in the RMU20-30. Using the RMU20-30, it is possible to use the safety network based on EtherNet/IP Safety. Using the safety network, for example, it is possible to input emergency stop signal etc.

  • Page 146: Setting For Rmu

    5.2Setting for RMU Setting for RMU Safety network parameter 5.2.1 The RMU communication parameters are to be set using the teach pendant. It is not possible to make the setting using a safety network setting utilities like RSLogix5000 etc. The Safety network parameters can be set in the menu of <Constant settings> - [3 Machine constant] [34 Robot Monitoring Unit] [1 Settings] [9 Safety network parameters].
  • Page 147 5.1 Outline of the EtherNet/IP safety network function Network safety plug signal By assigning this signal, it becomes possible to get the safety plug input signal from the safety network. If this signal is assigned, this signal must be kept ON to playback the robot program. If "0"...

  • Page 148: Settings For The Safety Plc

    5.3Settings for the safety PLC Settings for the safety PLC As an example of the Safety PLC setting, how to add a setting of RMU for the Rockwell Compact GuardLogix L43S is shown hereinafter. The procedures shown in this section are described mainly to change the settings. Therefore, safety is not considered.
  • Page 149 5.3Settings for the safety PLC Select "Generic EtherNet/IP Safety Module" in the "Select Module Type". Make the setting of the Module. - "Name" : Set a plain name. - "Description" : Write descriptions freely. - "IP address" : Set the IP address of the RMU. Make the setting of network parameters.
  • Page 150 5.3Settings for the safety PLC Make the setting of "IO Connection". Select the "Connection" tab. - Set the following values. Item Setting value Safety Input Input Assembly Instance Set the value of "768 + (The value that is set in the "Safety Input -> Size") For example, is the Size is 8 bytes, input 776.
  • Page 151 5.3Settings for the safety PLC Press the button of "Close" in the screen of "Select Module Type" >>The added module will be displayed in the "Controller Organizer". Make a connection with the Safety PLC. Select "Who Active" from the "Communications" menu.
  • Page 152 5.3Settings for the safety PLC Select the "General" tab and press "..." button displayed on the right side of the "Safety Network Number". Press "Set" button. If the settings are correct, the SNN (Safety Network Number) is set and the communication will start.

  • Page 153: Trouble Shooting

    5.4Trouble shooting Trouble shooting Trouble shooting via the LEDs 5.4.1 In this Safety network function, the network status is displayed using the 4 LEDs (LED4, LED5, LED6, LED7) on the UM374 board. Those LEDs display the status with a set of 2. LED4 and LED5 show "Module status" and LED5 and LED6 show "Network status".
  • Page 154 5.4Trouble shooting NOTE 5-10...

  • Page 155: Chapter 6 Profinet Safety Network Function

    Chapter 6 PROFINET Safety network function This chapter presents the PROFINET Safety network function. 6.1 Outline of the PROFINET safety network function ........6-1 6.2 Setting for PROFINET module ..............6-2 6.2.1 Fieldbus settings................6-2 6.2.2 Setting for the PROFINET Safety ............6-4 6.3 Safety network parameters ..............6-6 6.3.1 Assignment of the network I/O signals..........6-6 6.4 Trouble shooting..................6-8...

  • Page 157: Outline Of The Profinet Safety Network Function

    6.1 Outline of the PROFINET safety network function Outline of the PROFINET safety network function This section describes the setting procedures for RMU20-40 that supports PROFINET safety function. This function is available only in the RMU20-40. Using the RMU20-40, it is possible to use the safety network based on PROFINET Safety. Using the safety network, for example, it is possible to input emergency stop signal etc.

  • Page 158: Setting For Profinet Module

    6.2Setting for Setting for PROFINET module Fieldbus settings 6.2.1 Protocol settings Open <Constant Setting> - [8 Communication] - [3 Fieldbus]. Align the cursor with the combo box of a channel which is going to use the PROFINET safety, and press [Enter] key. >>Select the [PROFINET Safety] using the cursor key and press [Enter] key.
  • Page 159 6.1 Outline of the PROFINET safety network function Align the cursor with the edit box of the "module". Input the applicable module number, and press [Enter] key. >> The module” number is necessary to confirm the installed position on the “FIELDBUS base board”.

  • Page 160: Setting For The Profinet Safety

    6.2Setting for Setting for the PROFINET Safety 6.2.2 Channel settings In [3 Fieldbus] screen, align the cursor with the channel where PROFINET safety is selected and press <Refer>. >> Following screen is displayed. Set the respective parameters. Item Description Input the station name for the concerned node. Use alphanumeric (small letter) for the station name.
  • Page 161 A "GSDML" file that is necessary to use this controller as a SLAVE device is stored in the system memory of this controller. Please copy this file to your Master device's configuration tool in advance. The file is "PLCEngine／GSDML-V2.3-NACHI-COMX 100 RE PNS-20140317.xml".

  • Page 162: Safety Network Parameters

    The GSDML file that is necessary to setup this controller as a SLAVE device is in the system memory of this robot controller. The file name is ; “PLCEngine/GSDML-V2.3-NACHI-COMX 100 RE PNS-20140317.xml”. This RMU is designed intending that the minimum watch-dog time is 70ms. But, there is a possibility that the communication speed cannot work in time depending on the network configuration.
  • Page 163 6.3Safety network parameters Network logic condition This is a software switch to decide if the "Motors ON condition" is included to the logical operation of the safety network output signal or not. When "Enabled", the safety network output signal turns OFF if the "Motors ON condition"...

  • Page 164: Trouble Shooting

    6.4Trouble shooting Trouble shooting Trouble shooting via the LEDs 6.4.1 The PROFINET module shows its present condition using 3 LEDs. LED3 LED2 Channel 1 Channel 0 LED1 Ethernet IF Either channel can be used. LED1 : Module status LED2 : Ethernet connection status LED3 : IO connection status Hilscher PROFINET module comX The LED status and PROFINET SLAVE module (comX) status...

  • Page 165: Error Codes

    6.4Trouble shooting Error codes 6.4.2 E1116 Message Communication fault in the Safety network communication was detected. Cause Communication fault in the Safety network communication was detected. Remedy Please check if the network or the master device has no problem.
  • Page 166 6.4Trouble shooting NOTE 6-10...

  • Page 167: Chapter 7 Maintenance And Inspections

    Chapter 7 Maintenance and Inspections This chapter presents the maintenance and inspections of the RMU. 7.1 Periodic Inspections .................7-1 7.1.1 Inspection schedule ................7-2 7.1.2 Routine inspection items ..............7-2 7.1.3 Periodic inspection items ..............7-3 7.1.4 Replacing of the RMU ...............7-4 7.2 Troubleshooting..................7-5 7.2.1 Example of trouble shooting............7-16 7.2.2...

  • Page 169: Periodic Inspections

    7.1Periodic Inspections Periodic Inspections When inspecting the RMU or replacing its parts, proceed with the work while observing the cautions below. To avoid electric shocks, allow 5 minutes to pass after turning off the primary power of the controller before proceeding to replace any parts. Even when the power of the controller is turned off, power may still be supplied from the DANGER process control panel.

  • Page 170: Inspection Schedule

    7.1Periodic Inspections In order to prevent trouble, ensure safety and maintain performance, conduct the necessary routine inspections and periodic inspections. This section describes the precautions to be observed when performing the periodic inspections, and gives details of the work. 7.1.1 Inspection schedule As a general rule, conduct the inspections in accordance with the following RMU inspection schedule.

  • Page 171: Periodic Inspection Items

    7.1Periodic Inspections 7.1.3 Periodic inspection items 1) Inspection of safety inputs When the RMU continues to be used with two safety input signals in the closed state, the input circuit for the two signals cannot be diagnosed. Therefore, the two contacts of the safety inputs must be opened at periodic intervals to perform the inspections.

  • Page 172: Replacing Of The Rmu

    7.1Periodic Inspections 7.1.4 Replacing of the RMU If the RMU is broken due to some abnormalities, the RMU needs to be replaced to the new one. The replacement work must be done only by individuals who have attended the robot school (maintenance course) held by the manufacturer.

  • Page 173: Troubleshooting

    7.2Troubleshooting Troubleshooting This section describes the RMU errors which may occur and the action taken to remedy them. Assist code (#UNIT NO.: SUB1:SUB2:SUB3) When error occurs, “assist code” is displayed with error code in error message. Information to identify where trouble happens can be get by this “assist code”. In the Table 5-1, the error code and the assis code are listed.
  • Page 174 7.2Troubleshooting Error code Assist code Error Description of trouble Remedy Top: Controller SUB1 SUB2 SUB3 Bottom: RMU Axis angle error E1101 0 to 7 This error occurs when axis Open <Machine constant> Axis angle exceeds the specified - [Soft limit] in constant range.
  • Page 175 7.2Troubleshooting Error code Assist code Error Description of trouble Remedy Top: Controller SUB1 SUB2 SUB3 Bottom: RMU Operating range E1102 Border Sphere This error occurs when for a Open <Machine constant> line No. limit error tool, tool sphere or rear - [Soft limit] in constant position calculated from the mode, the input Motors...
  • Page 176 7.2Troubleshooting Assist code Error code Error Description of trouble Remedy Top: Controller SUB1 SUB2 SUB3 Bottom: RMU Speed error E1103 This error occurs when the This error is cleared when Teach TCP speed calculated from its cause is removed. the encoder data of the RMU The robot can be operated speed has exceeded 250 mm/sec.
  • Page 177 7.2Troubleshooting Assist code Error code Error Description of trouble Remedy Top: Controller SUB1 SUB2 SUB3 Bottom: RMU Over current E1104 1 Safety input 1 This error occurs when an Operation 2 Safety input 2 of input signal over current been restored 4 Safety input 3 detected in one of the input...
  • Page 178 7.2Troubleshooting Error code Assist code Error Description of trouble Remedy Top: Controller Bottom: RMU Disparity error E1105 1 Safety input 1 This error occurs when After removing the cause 2 Safety input 2 of input signal redundant safety of the error, turn OFF both 4 Safety input 3 signals which are input of those redundunt...
  • Page 179 7.2Troubleshooting Error code Assist code Error Description of trouble Remedy Top: Controller SUB1 SUB2 SUB3 Bottom: RMU Stop monitoring E1109 16 to 23 This error occurs if the robot The RMU may be to Axis No, error has moved when the stop broken if there is no (Encoder monitoring input has been...
  • Page 180 7.2Troubleshooting Error code Assist code Error Description of trouble Remedy Top: Controller Bottom: RMU Position E1110 16-23 This error occurs if a failure Check motor Pole monitoring error happen in the monitoring of encoder connections. position the pole position. differen Check the pole position signal cable between the 32-39...
  • Page 181 7.2Troubleshooting Error code Assist code Error Description of trouble Remedy Top: Controller SUB1 SUB 2 SUB 3 Bottom: RMU Internal error E1106 This error occurs if the back Check if the wiring of the Safety output 1 E20-E22 check of the safety output 1 safety output 1 is normally is not inputted normally.
  • Page 182 7.2Troubleshooting Error code Assist code Error Description of trouble Remedy Top: Controller SUB1 SUB 2 SUB 3 Bottom: RMU Internal error E1106 This error occurs if a failure Turn OFF and ON the Diagnostic happens in the diagnostic controller power. circuit circuit of the output signal.
  • Page 183 7.2Troubleshooting Error code Assist code Error Description of trouble Remedy Top: Controller SUB1 SUB 2 SUB 3 Bottom: RMU Internal error E1106 This error occurs if a failure Turn OFF and ON the Internal memory happens in the diagnostic for controller power.

  • Page 184: Example Of Trouble Shooting

    When all parameters are correct, press <OK> key. If some of them were incorrect, please try to perform the writing register procedure. If some of them were incorrect even after writing procedure, the RMU may malfunction. Please consult with each NACHI-FUJIKOSHI service office. 7-16...
  • Page 185 7.2Troubleshooting Open <Constant> - [3 Machine constants] – [34 Robot monitoring unit] – [3 Approval]. >> When confirmation of all parameters is completed, following screen will be displayed. RMU ID number is 0. This means approval is not completed. Press <Execute> key. >>...
  • Page 186 7.2Troubleshooting Press the password [7] [1] [0] and [Enter] key. >>The following message will be displayed. >> Then the following screen will be displayed. Now controller ID and RMU ID is coincident. Approval is completed. After closing the screen with [R] key on the teach pendant, reset the error. To make the error reset operation, press [R] key 2 times.

  • Page 187: Trouble Shooting Example For Input Signal Inconsistency Failure

    7.2Troubleshooting 7.2.3 Trouble shooting example for input signal inconsistency failure When an inconsistency is detected in the redundunt type signals that are inputted to the RMU, "E1105" will be detected. When this happens, please check the error code and assis code to ideitify the signal in which the error is detected.
  • Page 188 7.2Troubleshooting [Troubleshooting for the "Robot emergency stop input signal inconsistency"] Press [R] key of the teach pendant twice to reset the error Was the error released? Press the emergency stop button of the Teach pendant or the operation panel and then press [R] key 2 times to reset the error.
  • Page 190 Phone +81-76-423-5137 +81-76-493-5252 NACHI-FUJIKOSHI CORP. holds all rights of this document. No part of this manual may be photocopied or reproduced in any from without prior written consent from NACHI-FUJIKOSHI CORP. Contents of this document may be modified without notice. Any missing page or erratic pagination in this document will be replaced.

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