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Robostar N2S Series Manual

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Robostar Robot Controller
N2S Series
Instruction and handling Manual
Version: N2S-IM-E02
Issued Data: July 10, 2019

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  • Page 1 Robostar Robot Controller N2S Series Instruction and handling Manual Version: N2S-IM-E02 Issued Data: July 10, 2019...
  • Page 2 Copyright 2018, ROBOSTAR Co., Ltd. All right reserved. Copyright of this instruction manual is reserved to Robostar Co., Ltd. Any part of this manual cannot be used as other forms or other means without permission of Robostar. The specifications are subject to change without notice in advance.
  • Page 3 (2) Failures arising due to improper repair, alteration, redeployment, or other mishandling, under the instruction of you or any third party (3) Failures as a result of using parts, grease, etc. which have not been designated by Robostar (4) Failures caused by accidents, such as fire, disaster, earthquake, storms, or other natural disasters...

  • Page 4: Safety For Robots (General)

    This sign shows the matter that is to be prohibited for normal use of the product. PROHIBITION E.g.) Never use a fire. This sign shows the matter that must be performed for normal use of the product. Required E.g.) Compulsory ground is required. Robostar Co., Ltd. 4 / 81...
  • Page 5 In particular, make sure before use that the input power is AC 220V. When installed, the robot must be securely fixed so as not to be shaken. Robostar Co., Ltd. 5 / 81...
  • Page 6 Make sure to check the wirings of a CHECK controller before powering on it. Due to the incorrect wirings, the machine may not work properly. To prevent electrical shock, be sure to install FG (Frame Ground). Robostar Co., Ltd. 6 / 81...
  • Page 7 ON/OFF and driving a motor manually, be sure to DANGER check the mutual safety before starting the work. When in maintenance of the robot, be sure to unplug a power cord of the controller Robostar Co., Ltd. 7 / 81...

  • Page 8: Safety For Robots (Details)

    If you are installing a safety net having a door, install a detector or other sensors so that the robot is stopped immediately after the door is opened. ⑤ The safety net must be distanced by 40 cm or farther from robot motion area and the robot body. Robostar Co., Ltd. 8 / 81...
  • Page 9 - Class 3 Ground (Ground resistance is not more than 100Ω.) (11) Lamp indicating the robot power supplying status - Install a lamp which indicates whether the power source is being supplied to the robot Robostar Co., Ltd. 9 / 81...

  • Page 10: Table Of Contents

    1. Features ....................................12 2. Name Plate Configuration .............................13 2.1 Locations of Name Plate .............................13 2.2 Name Plates ................................14 3. N2S Series Controller Product Code .........................15 4. Software version .................................16 5. Name of Each Part ................................17 5.1 General 8 axes controller appearance ......................17 6.
  • Page 11 2.2 Inspection and replacement method for air filter ..................75 2.3 Inspection and replacement method for RTC battery ................76 3. Works after replacing parts ............................78 3.1 Origin position setup ............................78 Chapter 7 Revision ........................79 Literature Reference ....................80 Robostar Co., Ltd. 11 / 81...

  • Page 12: Chapter 1 Controller Overview

    Controller Overview Chapter 1 Controller Overview 1. Features N2S Series Controller is a high-performance robot controller for a wide variety of applications and has the following features. 6 axes Vertical articulated robot  Controls 4 to 6 axes Cartesian coordinate robot, SCARA robot and semiconductor ...

  • Page 13: Name Plate Configuration

    The model name of the controller is written on a name plate or paper which is attached to a front side of the controller as shown below. For identification of the model name, refer to a code table below. 2.1 Locations of Name Plate ② <Top > ① <Front > Robostar Co., Ltd. 13 / 81...

  • Page 14: Name Plates

    ② Safety name plate -. Controller Only Robostar N2S CONTROLLER MODEL : N2S SPEC. : N2S-8X8X4111 -G-NS-C-I-X-X-S0 SER. NO. : Robostar Co., Ltd. -. With Robot Robostar N2S CONTROLLER MODEL : N2S-RA007 SPEC. : N2S-8X8X4111 -G-NS-C-I-X-X-S0 SER. NO. : Robostar Co., Ltd.

  • Page 15: N2S Series Controller Product Code

    Controller Overview 3. N2S Series Controller Product Code N2 Code Table - G - N S - X - C - - X - X - SERIES N2 CONTROLLER CASE Small 8axes Case Medium Case Large Case POWER SINGLE POWER...

  • Page 16: Software Version

    5.ORIGIN 6. I/O 7.GVAL 8. GPNT 9.INFO ITEM # Select 2.CONT <INFO> 1. ROBOT 2.CONT 3. LOG 4.USB ITEM # Check Software Version <INFO:CONT(1/3)> N2-SERIES MAIN B/D VER. 01.00.01-C3 (AR 190224) PRE NEXT EXIT Robostar Co., Ltd. 16 / 81...

  • Page 17: Name Of Each Part

    5. Name of Each Part The following shows the names of each part of the appearance of the controller. For more information, see the table below. 5.1 General 8 axes controller appearance <Top> <Front> <Side> <Back> <Bottom> Robostar Co., Ltd. 17 / 81...
  • Page 18 Controller Overview  Names and description of each part (General 8 axes controller) 13 15 Robostar Co., Ltd. 18 / 81...
  • Page 19 Motor power output connector (4A, 4B) Regenerative resistor connector(4A, 4B) Ventilation hole on top Inhaling ventilation hole and air filter Regenerative resistor Servo module regenerative resistor Ventilation hole on bottom Exhausting ventilation hole and fan Robostar Co., Ltd. 19 / 81...

  • Page 20: Specifications

    Servo Capacity 3.2 kW max for overall 8 axes module Minimum Input 5mA/1point Current Maximum 50mA/1point Output Current Brake Control 24V motor brake drive Motor Control AC servo motor drive (Sine wave PWM current control) Robostar Co., Ltd. 20 / 81...
  • Page 21 (I/O) Option Option In/Out(32 pts/32 pts) , Maximum (64 pts/64 pts) Direct Teaching (Teach Pendant) Teaching Type On-Line Teaching (Uni-Host) Robot Language RRL 2.0 (ROBOSTAR Robot Language Version 2) Maximum 250 pcs Robot Program Step Maximum 10,000 steps Support Standard...

  • Page 22: Specifications Of Power Circuit Electrical Parts

    Connect FG terminal and factory ground.  Use 600V, PVC insulated wires.  Use the wires conforming to the standard.  In case of other special specifications, please use the same or equivalent wires listed. Robostar Co., Ltd. 22 / 81...

  • Page 23: Power Supply

    When all axes servo is on 750W 1.3A @220V 290VA 0.8A @220V820VA 400W 0.7A @220V 160VA 0.4A @220V820VA 200W 0.5A @220V 110VA 0.3A @220V820VA 100W 0.25A @220V 60VA 0.15A @220V 820VA 0.12A @220V 30VA 0.07A @220V 820VA Table [6.3.B] Robostar Co., Ltd. 23 / 81...
  • Page 24 High Real Grade 100W High Real Grade 100W High Real Grade 100W High Real Grade Table [6.3.C]  Power consumption may be different depending on usage conditions.  Design the power plant considering the safety factor. Robostar Co., Ltd. 24 / 81...

  • Page 25: Product Dimension

    Controller Overview 6.4 Product Dimension [Unit: mm] Item Size Controller only 520 (W) x 255 (D) x 210 (H) Handles included 523 (W) x 280 (D) x 210 (H) Robostar Co., Ltd. 25 / 81...

  • Page 26: Chapter 2 Installing Method Of Controller

    If the installation environment is not proper, the function and performance may not be fully accomplished, as well as the life of the device may be shortened and unexpected failures may be caused. Robostar Co., Ltd. 26 / 81...

  • Page 27: Installation Space

    520 (W) x 255 (D) x 210 (H)  The cooling system of the controller is a fan forced ventilation type.  Be sure to prepare the space so that the cooling fan is not subjected to the occurrence of interference. Robostar Co., Ltd. 27 / 81...
  • Page 28 Installing Method of Controller  Attaching Rack Bracket Rack bracket can be attached at holes of right/left side covers of N2S series product. Secure the attachment hole and space as follows when attaching the rack bracket. <Rack Bracket> <Holes for Bracket>...
  • Page 29 Depending on the installation space, the rubber foot can be attached to the bottom, and locations for attachment are as below.  When attaching the rubber foot to the bottom Div. Gap between rubber foots General 8 Axes 470(L) x 210.6 Robostar Co., Ltd. 29 / 81...
  • Page 30 Installing Method of Controller  When attaching the rubber foot to the back side Div. Gap between rubber foots General 8 Axes 460(L) x 140 Robostar Co., Ltd. 30 / 81...
  • Page 31 Installing Method of Controller  Attaching Regenerative resistor Regenerative resistor can be externally attached, using the bottom of controller as follows. Robostar Co., Ltd. 31 / 81...

  • Page 32: Ventilation Direction

    (2) Inside air exhausted Ventilation Ventilation Ventilation Hole Hole Hole  An air filter for the top ventilation holes must be replaced from time to time by checking the contaminated state.  (Replacement period: 3 months). Robostar Co., Ltd. 32 / 81...

  • Page 33: Chapter 3 Robot Connection And External Interface

    Robot Connection and Ext. Interface Chapter 3 Robot Connection and External Interface 1. Construction of robot system N2S Series Robot System is constructed as follows. For the interface of each part, see the next chapter.  Construction of robot system Higher level...

  • Page 34: Controller Unit Connection Method

    AC230V ±10%, 50-60Hz, Input, L AC230V ±10%, 50-60Hz, Input, N  In case the connector of the power cable to robot is wrongly connected, a circuit breaker shuts off or the inside of the controller may be damaged. Robostar Co., Ltd. 34 / 81...

  • Page 35: Ethercat Interface

    ② ② ② ① ① ① ①  Cable Specification Cable SFTP CAT.7, 27AWG, NETmate Connector RJ45(8P8C) Male, Pin Gold-Plated 50u  Pinmap of Connector TIA/EIA-568B Connector pinmap is compliant. <Connector and cable connection> Robostar Co., Ltd. 35 / 81...

  • Page 36: Teach Pendant Interface

    Controller Connector 10236-5212PC (3M) T/P Connector 10136-3000PE (3M) T/P Cable Hood 10368-52A0-008 (3M)  Be sure to make screw-lock when connecting the connector. If the connector is disconnected, controller status will be emergency stop. Robostar Co., Ltd. 36 / 81...
  • Page 37 T/P Emergency NC contact 11 EMG NC 12 T/P Emergency NC contact 12 EMG NC 21 T/P Emergency NC contact 21 EMG NC 22 T/P Emergency NC contact 22  ‘-‘sign means the unused pins. Robostar Co., Ltd. 37 / 81...

  • Page 38: Machine Safety Circuit Interface

    MODE OUT NC2 User mode output NC contact 2 MODE OUT NO1 User mode output NO contact 1 MODE OUT NO2 User mode output NO contact 2  ‘-’ sign means the unused pin. Robostar Co., Ltd. 38 / 81...
  • Page 39 NC contact is an abbreviation of Normally Close, which means that the contact is closed when it is in the default condition.  NO contact is an abbreviation of Normally Open, which means that the contact is opened when it is in the default condition. Robostar Co., Ltd. 39 / 81...
  • Page 40 INDEX MODE NC1 External Operation Mode NC contact 1 INDEX MODE NC2 External Operation Mode NC contact 2 INDEX MODE NO1 External Operation Mode NO contact 1 INDEX MODE NO2 External Operation Mode NO contact 2 Robostar Co., Ltd. 40 / 81...
  • Page 41 It is an emergency stop signal in automatic(system) mode. The customer have to input NC when normal state. If an alarm occurs, the customer has to input NO. If the signal is NO, Interlock Auto alarm turns on and motor will be shut off. Robostar Co., Ltd. 41 / 81...
  • Page 42 NC 11 ↔ NC 12, NC 21 ↔ NC 22  The contacts must be ON-OFF simultaneously. (2B / 2B-1A contact applied)  Normal state : Normal Close signal input Alarm state : Normal Open signal input Robostar Co., Ltd. 42 / 81...
  • Page 43 Controller (T/P) mode External operation mode Controller active mode MANUAL MANUAL MANUAL AUTO(SYSTEM) MANUAL MANUAL MANUAL AUTO MANUAL AUTO(SYSTEM) AUTO AUTO(SYSTEM)  For index mode input contact, NC and NO signals must be entered simultaneously. Robostar Co., Ltd. 43 / 81...
  • Page 44  Safety level is not recognized when used as an interface used in the robot manufacturing process.  The user must use the contact with the contact open. Robostar Co., Ltd. 44 / 81...

  • Page 45: Controller Safety Circuit Block Diagram

    The contacts of SYS EMG NC 11 ↔ SYS EMG NC 12, SYS EMG NC 21 ↔ SYS EMG NC 22 N.C must be ON/-OFF.. (Use 2B or 2B-1A contact)  Use after connecting teach pendant, as, if not, ‘T/P Emergency Alarm’ is generated. Robostar Co., Ltd. 45 / 81...

  • Page 46: Online Connection

    Computer. (Using a wire 2mm or more, connect the FG terminal of the controller with the FG terminal of the host computer.) ■ Use a serial cable not longer than 10m. ■ Connector Spec.: D-Sub 9s (Socket Type) Robostar Co., Ltd. 46 / 81...

  • Page 47: Robot Connection

    After connecting the robot cable, make sure that housing locks (a connector locking device) of the controller-side connector are completely engaged with each other.  Controller labels are subject to change depending on the robot Robostar Co., Ltd. 47 / 81...

  • Page 48: Encoder, Sensor And Brake Interface

    6320-014TIS0MNT01, WCON (Refer to1) <S3> Reference 1) Connected 1:1 to pins of a robot cable-side connector Encoder Signal Signal P5V(B) G5V(B) /SD(B) SD(B) /SD(A) SD(A) P5V(A) G5V(A) CASE  ‘-‘sign means the unused pin. Robostar Co., Ltd. 48 / 81...

  • Page 49: Motor Power Interface

    Interface for Motor Power Connection.  Controller Interface Controller Connector(Power) 76825-0012 Molex Robot Connector (Power) 171692-0012, Molex < S4> Power Pin No. Signal Pin No. Signal FG(B) W(B) BRK-(B) V(B) BRK+(B) U(B) FG(A) W(A) BRK-(A) V(A) BRK+(A) U(A) Robostar Co., Ltd. 49 / 81...

  • Page 50: Input/Output Connection

    User I/O 20pts 20pts Contacts Controller Connector MDR 10250-52A2PL, 3M External Connector MDR 10250-3000PE, 3M  N2S-Series does not provide internal power source for I/O.  Be sure to use the external power source. Robostar Co., Ltd. 50 / 81...

  • Page 51: I/O Interface

     If I/O marking on a controller model name is ‘P’ (P-TYPE) Input → Negative Common (24V-) and Output → Positive Common (24V+)  Connect the power supply N • P type distinctly. Incorrect wiring may cause damage to the controller Robostar Co., Ltd. 51 / 81...

  • Page 52: User I/O Circuit Diagram

    Mis-wiring may cause the internal parts to be destroyed. Pay special attention to the polarity of the common contacts.  The external supply voltage has to be DC 24V±10%  When soldering connector pins, provide pins with tubes to prevent short-circuit of pins. Robostar Co., Ltd. 52 / 81...
  • Page 53 Mis-wiring may cause the internal parts to be destroyed. Pay special attention to the polarity of the common contacts.  The external supply voltage has to be DC 24V±10%  When soldering connector pins, provide pins with tubes to prevent short-circuit of pins. Robostar Co., Ltd. 53 / 81...

  • Page 54: User I/O Connector Specification And Circuit Diagram

    User Input Contact 17 USER IN 18 User Input Contact 18 USER IN 19 User Input Contact 19 ‘-’ sign means the unused pin.  Ref 1) Refer to 5.4 User I/O circuit diagram Robostar Co., Ltd. 54 / 81...
  • Page 55 User Output Contact 17 USER OUT 18 User Output Contact 18 USER OUT 19 User Output Contact 19 ‘-’ sign means the unused pin.  Ref 1) Refer to 5.4 User I/O circuit diagram Robostar Co., Ltd. 55 / 81...

  • Page 56: Extension User I/O Interface

     If I/O marking on a controller model name is ‘P’ (P-TYPE) Input → Negative Common (24V-) and Output → Positive Common (24V+)  Connect the power supply N • P type distinctly.  Incorrect wiring may cause damage to the controller Robostar Co., Ltd. 56 / 81...

  • Page 57: Extension User I/O Circuit Diagram

    Mis-wiring may cause the internal parts to be destroyed. Pay special attention to the polarity of the common contacts.  The external supply voltage has to be DC 24V±10%  When soldering connector pins, provide pins with tubes to prevent short-circuit of pins. Robostar Co., Ltd. 57 / 81...
  • Page 58 Mis-wiring may cause the internal parts to be destroyed. Pay special attention to the polarity of the common contacts.  The external supply voltage has to be DC 24V±10%  When soldering connector pins, provide pins with tubes to prevent short-circuit of pins. Robostar Co., Ltd. 58 / 81...

  • Page 59: Extension User I/O Connector Specification And Circuit Diagram

    Extended User Input Contact 51(83)  ‘-’ sign means the unused pin. The numbers in ‘( )’ is applied when using 2 Ext. user I/O board.  Ref 1) Refer to 5.7 User I/O circuit diagram Robostar Co., Ltd. 59 / 81...
  • Page 60 P type : VCC Common (Ref. 1.)  ‘-’ sign means the unused pin.  The numbers in ‘( )’ is applied when using 2 Ext. user I/O board. Ref 1) Refer to 5.7 User I/O circuit diagram Robostar Co., Ltd. 60 / 81...

  • Page 61: Chapter 4 About Teach Pendent

    Robot controller Connection with teach pendant ▶ After connector connection, be sure to engage a screw-lock of the connector. ▶ If the connector is unexpectedly separated, the controller will fall into the emergency state. Robostar Co., Ltd. 61 / 81...

  • Page 62: Appearance And How To Operate

    About Teach Pendent 2. Appearance and How to Operate 2.1 Size Item Size TPN-9000 110 (W) x 258.2 (D) x 38 (H) Robostar Co., Ltd. 62 / 81...

  • Page 63: Construction Of Operation Keys

    2.2 Construction of Operation Keys ① : Emergency stop switch ② : Mode select switch ③ : LCD display ④ : Model name of teach pendant ⑤ : LED indicator ⑥ : Function key ⑦ : Deadman switch Robostar Co., Ltd. 63 / 81...

  • Page 64: Functions Of Operation Keys

    Ex.) When to write a robot program in JOB mode ▶ Only four commands can be displayed on 1 screen and so, if the direction key is used when more than 4 commands are necessary, other commands can be shown. Robostar Co., Ltd. 64 / 81...
  • Page 65 Used to input the desired data. ▶ Usage is dependent on a mode. ex.) Parameter mode→ The sign changes when this key is pressed. JOB mode→ This key is used to input the command when writing a program. Robostar Co., Ltd. 65 / 81...
  • Page 66 JOG movement and INCH movement can be performed. (12) Character Key ▶ Used to enter the characters. ▶ Used to type JOB name, or to enter variable name, label name, sub-execution sentence name in commands Robostar Co., Ltd. 66 / 81...
  • Page 67 On a point teaching (CURR) screen, the brake of each axis can be turned on/off. ▶ While in operation (RUN mode), robot moving speed is increased. ▶ While in operation (RUN mode), robot moving speed is decreased. Robostar Co., Ltd. 67 / 81...

  • Page 68: Deadman Switch

    When the moderate pressure is applied to the switch When too strong pressure is applied to the switch If the Deadman Switch is turned OFF, the robot does not operate or stops while in operation. Robostar Co., Ltd. 68 / 81...

  • Page 69: Chapter 5 Controller Alarm Code

    Motion command time planning failure. 1423 Over Range error Position command exceeds RANG (SW-Limit) setting range. 1424 Over Speed error Speed command exceeds tolerance range. 1425 Over Accel. error Acceleration command exceeds tolerance range. Robostar Co., Ltd. 69 / 81...
  • Page 70 Over temperature at motor. (overload) 4230 Encoder comm err Encoder communication error. 4231 Encoder cable open Encoder cable disconnection. 4232 Encoder data err Encoder data error. 4233 Motor ID setting Setting an undefined motor ID. Robostar Co., Ltd. 70 / 81...
  • Page 71 Ethercat Comm fail An error occurred during EtherCAT communication Communication between the graphic T/P and the controller 5001 Socket hung up is disconnected Timeout occurs during communication between graphic T/P 5002 GTP timeout and controller Robostar Co., Ltd. 71 / 81...

  • Page 72: How To Clear Alarms And Warnings

    If the alarm is not released, the alarm message is occurred again. ⑥ When the alarm release is completed, the alarm message window disappears and the alarm LED is turned off, and the controller and the robot can be driven normally. Robostar Co., Ltd. 72 / 81...

  • Page 73: Chapter 6 Maintenance

    For installation location and replacement method for robot encoder battery, refer to relevant robot instruction manual. (General replacement period under conditions of operation for 8 hours a day is 3 years.)  To replace parts, be sure to shut OFF power. Robostar Co., Ltd. 73 / 81...

  • Page 74: Inspection And Replacement Method For Cooling Fan

    ③ Separate the lead wire connected to the fan. ④ Remove screw2 (4 points) on the fan and separate it from the fan net. ⑤ Install a new fan in reverse order of ④→②. Robostar Co., Ltd. 74 / 81...

  • Page 75: Inspection And Replacement Method For Air Filter

    ② Remove fixing screw1 (each 4 points, total 12 points) on the top air filter. ③ Remove air filter fixing screw2 (2 points). ④ Install a new air filter in reverse order of ③→②. Robostar Co., Ltd. 75 / 81...

  • Page 76: Inspection And Replacement Method For Rtc Battery

    Check location of mainboard battery of the main module. ④ Connect probes of a Multimeter onto ground of the board and positive terminal of the battery to measure DC voltage when a battery is installed on the board. [Figure] Example of Measurement Robostar Co., Ltd. 76 / 81...
  • Page 77  Be cautious of shorting of battery terminals and inflow of ESD during battery replacement.  Store the battery at temperature and humidity recommended by the maker. If not, lifetime it can lifetime decrease. Robostar Co., Ltd. 77 / 81...

  • Page 78: Works After Replacing Parts

    PARA(1) – BODY – OFFS – ZCAL - MDI  Since origin position and posture differ depending on robot capacity and model, refer to relevant robot instruction manual.  For detailed operating method, refer to Operation Manual for N2S controller. Robostar Co., Ltd. 78 / 81...

  • Page 79: Chapter 7 Revision

    Revision Chapter 7 Revision Revision Date Revised Detail 2019.01.21 Initial Distribution 2019.07.10 Parts replacement Robostar Co., Ltd. 79 / 81...

  • Page 80: Literature Reference

    This explains the method to use the controller and teach pendant, parameter setting, JOB program editing and additional functions. Programming manual N2-PM-E□□ This explains the method to create RRL (Robostar robot language) that is the Robostar robot program and describes the commands. Unihost manual N2-HM-E□□...
  • Page 81 N2S Series Controller Instruction and Handling Manual First edition, March 7, 2019 ROBOSTAR CO., LTD. ROBOT R&D CENTER...

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