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ROKAE XBC5 Product Manual

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XBC5 Controller
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Summary of Contents for ROKAE XBC5

  • Page 1 XBC5 Controller Product Manual...
  • Page 3 XBC5 Controller Product Manual Document ID: DOC-00001231 Document Version: A Copyright © ROKAE 2015. All rights reserved.
  • Page 4 Do not copy or reprint part or all of this manual without the consent of ROKAE. ROKAE has proofread the contents of this manual. However, the possibility of errors or inconsistencies cannot be ruled out, and ROKAE shall not be held liable for any errors or inconsistencies.

  • Page 5: Table Of Contents

    2.3.12 Safe handling of fire accidents .................... 14 2.3.13 Safe handling of electric shock accidents ................. 15 2.4 Personnel and work content requirements ..................16 2.4.1 Definition of personnel ......................16 2.4.2 Personnel requirements ......................16 2.4.3 Work content requirements ....................17 XBC5 ControllerProduct Manual...
  • Page 6 4.3 Teach Pendant specifications ......................31 4.4 Product appearance and dimensions ....................31 5 Installation ........................33 5.1 Environmental conditions ........................33 5.2 On-site installation ..........................33 5.2.1 Transportation ......................... 33 5.2.2 Installation ..........................34 6 Electrical Connections ....................37 XBC5 ControllerProduct Manual...
  • Page 7 8.2 Daily maintenance ..........................55 8.2.1 Maintenance schedule ......................55 8.2.2 Interval ............................55 8.3 Troubleshooting ............................. 56 8.3.1 Common faults ........................56 8.3.2 Troubleshooting ........................58 8.3.3 Log number and faults ......................58 Revision History ......................63 XBC5 ControllerProduct Manual...

  • Page 9: Manual Overview

    1 Manual Overview 1 Manual Overview 1.1 About this manual Thank you for choosing the ROKAE robot system. This manual contains the following instructions for correct installation and use of XBC5 controllers: Mechanical and electrical installation of the controller ⚫...

  • Page 11: Safety

    2.1.1 Safety responsibilities ROKAE is dedicated to but not liable for providing reliable safety information. Even if all operations are carried out according to the safe operation instructions, we can not guarantee that our industrial robots will not cause personal and property losses.

  • Page 12: Hazard Description

    There may be a serious injury to the operators and maintenance personnel who enter into the motion range of Parts Fly the robot during debugging, repair, overhaul and tool installation when tools or workpieces fly out due to loose clamping. XBC5 ControllerProduct Manual...

  • Page 13: Safety Features

    2.2.3 Safety features 2.2.3.1 Explanation This robot system is equipped with a special safety controller for handling safety-related signals, and provides external safety symbol interfaces such as the safety gate and emergency stop button. XBC5 ControllerProduct Manual...

  • Page 14: Motion Enabling And Safe Stop

    STO (Safe Torque Off) via safety output signal. Manual operation of the robot by the user and automatic running of the program are not allowed by the control system before the safety controller determines that it is safe at the moment. XBC5 ControllerProduct Manual...
  • Page 15 Emergency stop is only used to stop the robot immediately in case of danger and cannot be used as a normal program; otherwise, extra and unnecessary abrasion will be caused to the band-type brake system and drive system of the robot to reduce the service life of the robot. XBC5 ControllerProduct Manual...

  • Page 16: Safety Devices

    Fig. 1 Schematic diagram of the enabling switch Name Position 1 Position 2 Position 3 Press tightly Release Warning It is strictly prohibited to use any external devices to keep the enabling switch locked or stopped in the middle position! XBC5 ControllerProduct Manual...

  • Page 17: Safety Precautions

    Pay attention to the electrical components in the robot control cabinet. Even if the ⚫ power supply is interrupted, the remaining power in the component is still very dangerous. XBC5 ControllerProduct Manual...

  • Page 18: Safety Precautions For Operating The Teach Pendant

    A user of higher level can modify the password of a same- or lower-level user. You cannot modify the password of an operator. XBC5 ControllerProduct Manual...

  • Page 19: Safety Precautions For Using The Control Cabinet

    XBC5 ControllerProduct Manual...

  • Page 20: Resetting The Emergency Stop

    Operation In manual mode, run each axis to its maximum load position. Press the enabling switch and keep it in the middle position. Then the motor power supply is switched on and the band-type brakes are disengaged. XBC5 ControllerProduct Manual...

  • Page 21: Manual Release Of The Band-Type Brake

    The motion velocity of the robot end is limited to less than 250mm/s in manual mode. This means that the maximum motion velocity of the robot end will not exceed 250mm/s whether you perform Jog or run programs on the robot, regardless of the set velocity in the program. XBC5 ControllerProduct Manual...

  • Page 22: Safety Precautions In Automatic Mode

    Do not panic and keep calm when a fire hazard is imminent or has not yet begun to spread; you can use on-site fire-extinguishing devices to put out the flame. It is strictly prohibited to use water to put out a fire caused by short circuits. XBC5 ControllerProduct Manual...

  • Page 23: Safe Handling Of Electric Shock Accidents

    Call the wounded or pat him/her on the shoulder at an interval of 5 seconds to judge if he/she loses consciousness. Do not call the wounded by shaking his/her head. Meanwhile, contact the hospital as soon as possible. XBC5 ControllerProduct Manual...

  • Page 24: Personnel And Work Content Requirements

    The operating personnel may not take items that may reduce mental level (such as medicines, alcohol and drugs) during work. The operating personnel should understand applicable local safety regulations, such as ⚫ the work safety and health regulations and the industrial accident prevention regulations. XBC5 ControllerProduct Manual...

  • Page 25: Work Content Requirements

    When debugging is finished, the debugging personnel must stay outside the safety zone. 2.4.3.3 Safety requirements for maintenance Carefully check the situation inside the safety zone and enter into it only after ⚫ confirming no danger exists. XBC5 ControllerProduct Manual...

  • Page 26: Safety Training

    Appropriate lighting should be provided during the maintenance. ⚫ In case of part replacement, make sure to use a part specified by ROKAE. Otherwise, ⚫ the robot equipment may be damaged.
  • Page 27 "under repair" sign in order to prevent other personnel from operating the equipment accidentally. Never enter into the working range of the robot while it is moving. ⚫ Never execute automatic running of the program when there are other personnel ⚫ within the working range of the robot. XBC5 ControllerProduct Manual...
  • Page 28 When servicing the interior of the control cabinet, if it is necessary to touch the power ⚫ supply unit or printed circuit board, make sure to switch off the power supply of the main circuit breaker of the control cabinet first to prevent electric shock. XBC5 ControllerProduct Manual...

  • Page 29: Product Overview

    All the main components of the robot control system are installed in a control cabinet called XBC (short for xBot Control Cabinet). The model number on the nameplate of the robot control cabinet generally begins with XBC. The XBC5 and XBC5M control cabinets are shown in Fig. 3 and Fig. 4.

  • Page 30: Control Cabinet Components

    3 Product Overview Fig. 3 XBC5 control cabinet Fig. 4 XBC5M control cabinet 3.2.2 Control cabinet components The XBC control cabinet consists of all the necessary components to control the robot motion, including: Strong current module - Controls the overall power supply and circuit protection ➢...

  • Page 31: Robot Teach Pendant Overview

    3 Product Overview Expansion Module Strong Current Module Weak Current Module Fig. 5 XBC5 layout Expansion Module Weak Current Module Strong Current Module Fig. 6 XBC5M layout 3.3 Robot Teach Pendant overview 3.3.1 Teach Pendant overview The Teach Pendant is an embedded handheld device integrated with complete hardware and software.

  • Page 32: Teach Pendant Components

    The information on the control cabinet nameplate is shown in Fig. 8. Fig. 8 Control cabinet nameplate 3.4.2 Control cabinet IO wiring diagram The IO information in the cabinet is shown in Fig. 9. Please refer to the actual IO configuration in the control cabinet. XBC5 ControllerProduct Manual...

  • Page 33: Teach Pendant Nameplate

    Optional for all industrial robots cable, length: 10m Side-outlet relay cable, Optional for all industrial robots length: 10m Front-outlet relay Optional for all industrial robots cable, length: 15m Side-outlet relay cable, Optional for all industrial robots length: 15m XBC5 ControllerProduct Manual...

  • Page 34: Optional Relay Cable Configuration

    Description Remarks XBC5M Single-phase power cord, default length: 5m XBC5 Single-phase power cord, default length: 5m; three-phase power cord, default length:10m 3.5.5 Optional Features Function Remarks Collision detection Function enabled before use (supported by the Titanite system) XBC5 ControllerProduct Manual...
  • Page 35 Track enabled before use External expansion Expansion modules installed outside the control AI/AO cabinet before use (optional) Ethernet/IP Expansion modules installed in the control cabinet before use (optional) Profinet Expansion modules installed in the control cabinet before use (optional) XBC5 ControllerProduct Manual...
  • Page 36 3 Product Overview XBC5 ControllerProduct Manual...

  • Page 37: Specifications

    Protection rating code: Side-outlet heavy- duty Blank IP54 cabinet Custom IP40 cabinet XBC5 and XBC5M model description 4.1.2 xPad Teach Pendant model description Cable length Cable length: 5m Cable length: 7m Cable length: 10m Connector type Threaded Teach Pendant model description 4.2 Control cabinet specifications...
  • Page 38 Altitude: below 1000m electrical interference Altitude: below 1000m Dimensions 448 mm × 446 mm × 522 mm × 408 mm × Physical (W × D × H) 268 mm 425 mm properties Weight Approx. 28 kg Approx. 35 kg XBC5 ControllerProduct Manual...

  • Page 39: Teach Pendant Specifications

    External interface USB2.0 Operating temperature 0℃ to +45℃ Storage temperature -10°C to +55°C Environment Maximum humidity for ≤80%, non-condensing, non-frost operation/storage 4.4 Product appearance and dimensions The XBC5 controller appearance and dimensions are shown in Fig. 12: XBC5 ControllerProduct Manual...
  • Page 40 4 Specifications Fig. 12 XBC5 appearance and dimensions The XBC5M controller appearance and dimensions are shown in Fig. 13: Fig. 13 XBC5M appearance and dimensions XBC5 ControllerProduct Manual...

  • Page 41: Installation

    The control cabinet is made of precision components. Make sure to avoid excessive ⚫ shock and vibration during transportation. In order to ensure safe transportation and installation, remove all obstacles in advance ⚫ to keep the passage clear. During transportation of the control cabinet: ⚫ XBC5 ControllerProduct Manual...

  • Page 42: Installation

    5.2.2 Installation The XBC5M control cabinet adopts desktop mounting, and the XBC5 control cabinet adopts floor mounting. Please note the following during installation: To ensure effective heat dissipation and avoid overheating the control system, keep a ⚫...
  • Page 43 5 Installation prohibited from opening the cabinet case. Otherwise, severe or even fatal injuries may occur! XBC5 ControllerProduct Manual...
  • Page 44 5 Installation XBC5 ControllerProduct Manual...

  • Page 45: Electrical Connections

    6.1 Interface description 6.1.1 Control cabinet Interface description The interfaces of the XBC5 control cabinet are shown in Fig. 16: Fig. 16 Interfaces of the XBC5 control cabinet The interfaces of the XBC5M control cabinet are shown in Fig. 17: Fig.
  • Page 46 Network interface ⚫ The XBC5 control cabinet has no external network interface. It is connected to the IPC. The interfaces on the IPC are shown in Fig. 18: Fig. 18 IPC interfaces The function of each IPC interface is shown in the table below:...
  • Page 47 The user can modify the debug IP and visual IP via Control Panel - Communication - External Communication. After the modification is completed, click Save to take effect immediately. The external communication interface is shown in Fig. 20. XBC5 ControllerProduct Manual...

  • Page 48: Teach Pendant Interface Description

    Power cord, fixed on the control cabinet power supply cable Robot relay Combination cable for power and signal with a cable heavy-duty connector, fixed on the control cabinet Teach Pendant Fixed on the Teach Pendant, with an aviation cable plug XBC5 ControllerProduct Manual...
  • Page 49 Heavy-duty socket on the robot Heavy-duty connector of the relay cable The XBC5 series of control cabinet comes standard with a next-generation heavy-duty connector. Please connect the robot relay cable as shows in Fig. 24. The item 1 in Fig. 24 is the wiring panel on the rear side of the robot base, and the item 2 is the heavy-duty connector of the relay cable on the control cabinet.
  • Page 50 Connecting the power supply ⚫ The XBC5/XBC5M control cabinet powered by single-phase 220V AC comes standard with a power cord with a Chinese standard three-pin power plug. The XBC5 control cabinet powered by three-phase 380V AC comes standard with rod terminals for the user to connect the power plug.

  • Page 51: User Wiring

    Note: The wiring of the XBC5 control cabinet of high protection rating The XBC5 control cabinet has an IP54 rating, and there is no interface window on the cabinet. The cables for custom IO signals (including safety IOs and general-purpose IOs) and network/communication signals need to be routed through the foam with pre-opened holes on the right side of the cabinet.

  • Page 52: Grounding Instructions

    6.2.4 Definition of IOs and wiring in the cabinet The XBC5 control cabinet consists of safety IOs and general-purpose IOs. Please perform wiring properly as per the instructions on the sticker with the IO schematic diagram in the control cabinet.
  • Page 53 J15-3 Remote power The wiring point for remote power on/off on/off of robot controller cabinet J15-4 Remote power on/off J15-5 to Reserved J15-10 J16-1 to 24V guest power, supply current lower J16-4 than 5A XBC5 ControllerProduct Manual...
  • Page 54 General-purpose IO: Fig. 28 General-purpose IO terminals The XBC5 control cabinet defaults to the ROKAE DI/DO board with 16 digital input and 16 digital output contacts. If more IO signals are needed on site, new IO modules can be expanded. The control cabinet supports up to 64 (4 × 16) IOs. The overall system supports up to 128 (8 ×...
  • Page 55 J10-10 Custom J12-1 Common DO power, to be provided on site terminal J12-2 Common terminal J12-3 Custom J12-4 Custom J12-5 DO10 Custom J12-6 DO11 Custom J12-7 DO12 Custom J12-8 DO13 Custom J12-9 DO14 Custom J12-10 DO15 Custom XBC5 ControllerProduct Manual...
  • Page 56 The DI/DO low-level input wiring diagram is shown in Fig. 30: Fig. 30 DI/DO low-level input wiring diagram Explanation User Equipment XBC Controller DI control point DI power The DI/DO high-level output wiring diagram is shown in Fig. 31: XBC5 ControllerProduct Manual...
  • Page 57 The DI/DO low-level output wiring diagram is shown in Fig. 32: Fig. 32 DI/DO low-level output wiring diagram Explanation User Equipment XBC Controller DO control point DO power Refer to the actual information for other IO modules. XBC5 ControllerProduct Manual...
  • Page 58 6 Electrical Connections XBC5 ControllerProduct Manual...

  • Page 59: Quick Operation Guide

    7 Quick Operation Guide 7 Quick Operation Guide 7.1 Buttons and indicators 7.1.1 Control cabinet buttons and indicators Fig. 33 XBC5 control cabinet buttons and indicators Fig. 34 XBC5M control cabinet buttons and indicators Description ① Emergency stop button: The robot will be shut down immediately when it is pressed.

  • Page 60: Teach Pendant Buttons

    Please keep the key to the mode selector switch properly. Otherwise, the use of the robots will be affected, or production loss will be caused if the robots are unable to work due to the change of operating mode by unauthorized personnel. XBC5 ControllerProduct Manual...

  • Page 61: How To Hold The Teach Pendant

    Only after confirming the normal operation of the emergency stop function can you conduct configuration or programming on the robot. For more information on the robot operating system, programming, and parameter Operation Manual of Titanite Robot Control System settings, refer to the ® XBC5 ControllerProduct Manual...
  • Page 62 7 Quick Operation Guide XBC5 ControllerProduct Manual...

  • Page 63: Maintenance

    The maintenance personnel must prepare maintenance plans and implement such plans strictly. 8.2.2 Interval Interval Item Position Daily month months months months Tighten the Externally visible screws if they screws on the ● are loosened. controller XBC5 ControllerProduct Manual...

  • Page 64: Troubleshooting

    Do not disassemble the robot by yourself. 8.3.1 Common faults Faults Possible Causes Recommended Operation No system response. ➢ The power cord is ➢ Check if the power cord is The indicator does not connected connected properly. XBC5 ControllerProduct Manual...
  • Page 65 ➢ Replace the Teach Pendant. malfunctions. ➢ If possible, connect the ➢ The Teach Teach Pendant to another Pendant is control cabinet to exclude damaged. malfunctions caused by the XBC5 ControllerProduct Manual...

  • Page 66: Troubleshooting

    8.3.3 Log number and faults Troubleshooting according to the log number: Only the log numbers of some common faults are listed in the section. Please check the detailed description of the log on the HMI interface of the Teach Pendant for XBC5 ControllerProduct Manual...
  • Page 67 4. Replace the damaged parts. 1. Re-import the configuration The configuration fails files, and restart the control due to mismatched 38008 Bus scan failure system. EtherCAT configuration 2. Check the connection of the files. network cables in the cabinet. XBC5 ControllerProduct Manual...
  • Page 68 2. Check the wiring of the slave match that of topology. devices. scanned slaves. 2. The hardware of the 3. Contact ROKAE Technical EtherCAT slave devices Support. malfunctions. The configuration fails Failed to Re-import the configuration due to mismatched...
  • Page 69 60054 battery is low, and the some time until it returns to the battery line resistance is high. room temperature. undervoltage 3. Log in as Administrator, clear the alarms, and re-calibrate the zero point. XBC5 ControllerProduct Manual...

  • Page 71: Revision History

    Revision History Revision History Version Date Revision Apr. 11, 2022 Initial version XBC5 ControllerProduct Manual...
  • Page 73 [Back cover page]...

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