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Agilebot IRC-I8A-S Product Manual

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Instructions for IRC-I8A-S Controller

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Summary of Contents for Agilebot IRC-I8A-S

  • Page 1 Product Manual Instructions for IRC-I8A-S Controller...
  • Page 2 Product Manual Instructions for IRC-I8A-S Controller V1.2 Copyright, 2022 Agilebot Robotics Co., Ltd. All rights reserved!
  • Page 3 Instructions for IRC-I8A-S Controller The information in this Manual must not be considered as a commitment of Agilebot and may be changed without prior notice. Agilebot assumes no responsibility for errors (if any) in this Manual. Except as expressly specified in this Manual, nothing in this Manual shall be construed as any warranty or guarantee made by Agilebot for personal loss, property damage or specific applicability.
  • Page 4 Instructions for IRC-I8A-S Controller Revised Ver. Date Status V1.2 Nov 30, 2023 Release Instructions for IRC-I8A-S Controller 4 / 73...

  • Page 5: Table Of Contents

    Instructions for IRC-I8A-S Controller Table of Contents Safety instructions ..........................7 I. Maintenance............................13 Summary ............................ 13 Structure ............................. 14 2.1 Appearance of controller ...................... 14 2.2 Functions of component units ....................17 2.3 Maintenance and repair......................19 Resolution of common faults ....................20 3.1 Don’t power on ........................
  • Page 6 Instructions for IRC-I8A-S Controller 1.1 System configuration ......................43 1.2 External ports ........................44 Connection with devices ......................46 2.1 Connecting cables of the robot ..................... 46 2.2 Cables of teach pendant ...................... 46 2.3 Preparation of input power cable ..................47 2.4 Grounding and shielding connection..................

  • Page 7: Safety Instructions

    Nobody is allowed to modify the industrial robot without authorization from Agilebot Robotics Co., Ltd. Agilebot Robotics Co., Ltd. shall assume no responsibility for any damage to the industrial robot or its components due to the use of any other components (software, tools, etc.) not provided by Agilebot.
  • Page 8 Instructions for IRC-I8A-S Controller Definition of user The operators are defined as follows: ➢ Operator Perform power-on/off operation on the robot. Start the robot program from the panel board. ➢ Robot Engineer Operate the robot. Perform teaching and programming debugging of the robot within the safety fence.
  • Page 9 Instructions for IRC-I8A-S Controller Definition of safety records This Manual includes safety warnings to ensure personal safety of the users and avoid any damage to the machine tool and describes them with "Danger" and "Warning" in the main text based on their importance in safety.
  • Page 10 Warnings and precautions related to operation of the controller 1. IRC-I8A-S is a closed structure. During design, it is required to prevent dust, oil mist and other conductive foreign objects around the controller from entering its interior. Regardless of whether the controller is running or not, its airtightness may be lost if it is not locked properly, leading to a malfunction and even possible electric shock, leakage or fire due to insulation degradation.
  • Page 11 Instructions for IRC-I8A-S Controller Safety warning label Both the robot and the controller bear several safety and information labels, which contain important information related to the product. This information is very useful for all persons operating the robot system, e.g. during mounting, maintenance or operation.
  • Page 12 Instructions for IRC-I8A-S Controller Sign Description Keep your hand away from moving parts, otherwise your hand or fingers may get stuck between the axis and the cover. The robots equipped with telescopic covers do not pose the risk of pinching hands or fingers. Therefore, they do not have this label.

  • Page 13: Maintenance

    This Instructions is applicable to the IRC-I8A-S controller. It describes the maintenance and connection of IRC-I8A-S for the robot. Maintenance: Resolution of common faults, unit setting, adjustment and replacement methods Connection: Methods for connecting IRC-I8A-S and the robot mechanism and peripheral devices and mounting the controller. Warning Provide more than one (inclusive) E-stop button within reach of the operator according to the system configuration.

  • Page 14: Structure

    Instructions for IRC-I8A-S Controller Structure 2.1 Appearance of controller The appearance and components of the controller may vary slightly according to the robot, various option configurations and application programs. E-stop button Manual brake release button controller body Release button on controller body...
  • Page 15 Instructions for IRC-I8A-S Controller Top view Front view Fig. 2.2 Dimensions of Controller On/Off E-stop ModeSwitch Start Pause/stop Manual control Reset Optional area Fig. 2.3 Front View of Teach Pendant Instructions for IRC-I8A-S Controller 15 / 73...
  • Page 16 Instructions for IRC-I8A-S Controller Three-Postion Enabling Switches Fig. 2.4 Rear View of Teach Pendant Caution When the USB port on the controller is used to back up related data of the robot, it is recommended to use a storage device in the FAT32 format of the USB2.0 protocol and with a capacity between 8G- 32GB, such as USB flash drive, mobile hard drive, etc.

  • Page 17: Functions Of Component Units

    Instructions for IRC-I8A-S Controller 2.2 Functions of component units The following figure illustrates the internal structure and main component functions of the IRC-I8A-S controller. Drive board Controller Main Board Controller Core Board Fig. 2.5 Interior of Controller Safety board board...
  • Page 18 Instructions for IRC-I8A-S Controller Power Soft Start Circuit Board Fig. 2.7 Interior of Controller Controller Core Board: The core circuit of main control mainly realizes servo control and motion control of the robot controller. Controller Main Board: Peripheral circuits of main control, including the circuits for encoder port, IO port, Ethernet port, USB port, RS485, RS232 and other ports;...

  • Page 19: Maintenance And Repair

    Instructions for IRC-I8A-S Controller 2.3 Maintenance and repair It is possible to maintain the performance of the robot in a long-term stable state through daily maintenance, regular maintenance and regular repair. ⚫ Daily maintenance During daily operation of the system, clean and repair all parts, check for cracks or damage on each part and conduct maintenance for the following items at any time.

  • Page 20: Resolution Of Common Faults

    Instructions for IRC-I8A-S Controller Resolution of common faults 3.1 Don’t power on Inspection and treatment Diagram Inspection 1: Confirm that the Circuit Breaker has been switched on. Treatment 1: Switch on the Circuit Breaker when it is not connected. Treatment 2: Check if the Circuit Breaker is in a trip state.

  • Page 21: Alarm Screen

    Instructions for IRC-I8A-S Controller 3.3 Alarm screen Check if the robot currently has alarms and view the alarm history by the following operations. In the main screen of the teach pendant, click on the tab in the red box below in Fig. 3.1 for the Active Alarm to pop up as shown in Fig.
  • Page 22 Instructions for IRC-I8A-S Controller Fig. 3.3 History Event Screen After filtering the event levels, you can see corresponding event descriptions as shown in Fig. 3.4. Fig. 3.4 Selection of Event Levels Instructions for IRC-I8A-S Controller 22 / 73...

  • Page 23: Stop Signal

    Instructions for IRC-I8A-S Controller 3.4 Stop signal The following table describes stop signals of the controller. The controller can stop the motion of the robot through external buttons and the means in the following table. Stop signal Description It indicates the status of the external emergency stop signal and is External E-stop button pressed to stop running.

  • Page 24: Zero Calibration

    Instructions for IRC-I8A-S Controller 3.5 Zero calibration Zero calibration is required in the following two cases. Case 1: A zero-calibration loss alarm or zero-calibration abnormality alarm occurs. Case 2: The motor is replaced, the battery discharged or the encoder cable disconnected.
  • Page 25 Instructions for IRC-I8A-S Controller Fig. 3.7 Click on “System” in the Menu Click on the “Basic Setting” option. Fig. 3.8 Click on “Basic Setting” in System Click on the “Encoder Calibration” option. Fig. 3.9 Click on “Encoder Calibration” in Basic Setting If the Status is “uncalibrated”...
  • Page 26 Instructions for IRC-I8A-S Controller Fig. 3.10 Zero-calibration Status Screen Select between “General Encoder Calibration” and “Direct Input Encoder Calibration”. Fig. 3.11 Selecting Calibration Methods Select the axis to be calibrated on the left and click “Calibrate” to perform the calibration.

  • Page 27: Resolution Of Common Faults Based On Alarm Codes

    Instructions for IRC-I8A-S Controller Fig. 3.13 Click “Save” to complete the Calibration 3.6 Resolution of common faults based on alarm codes Motion-A32097 - UI servo enable is off* Phenomenon: UI servo enable is off Result: Stop Cause: triggered by UI signal Countermeasure: Keep the UI signal at a high level.
  • Page 28 Instructions for IRC-I8A-S Controller (3) On the “IO status” screen as shown below, click on the button circled in red to view different types of signals. (4) UI1, UI2 and UI5 should be normally closed signals as shown below. Safety-2115 - The safety board dual channel data are not the same.*...
  • Page 29 Instructions for IRC-I8A-S Controller Phenomenon: The safety board dual channel data are not the same. Result: ESTOP status Cause: error in hardware signal Countermeasure: Check if the safety circuit on the safety board is normal. Safety-2116 - The safety board detects external stop signal.* Phenomenon: The safety board detects external stop signal.
  • Page 30 Instructions for IRC-I8A-S Controller Cause: status of hardware signal Countermeasure: Check if the Deadman button is pressed in the manual mode. Safety-2122 - The safety board detects TP-ESTOP signal.* Phenomenon: The safety board detects TP-ESTOP signal. Result: ESTOP status Cause: status of hardware signal Countermeasure: Check the TP-ESTOP button.
  • Page 31 Instructions for IRC-I8A-S Controller 2. After clicking “Current Pose”, you can view the position information of each axis as shown below. 3. Switch relative coordinate systems to view the position information of each axis under different coordinate systems, as shown below.
  • Page 32 Instructions for IRC-I8A-S Controller 5. Click “Soft Limits” to view the soft limit positions of each axis. 6. The Soft Lower and Soft Upper of each axis are shown as below. Operation steps for Case 2 are as follows: 1. The soft limit error may also be caused in case of loss of zero calibration. Click Basic Setting - Encoder Calibration to open the calibration screen.
  • Page 33 Instructions for IRC-I8A-S Controller again. 2. A prompt message indicating “Calibration success” will appear on the upper right corner after successful calibration. Click "Save" to complete the calibration. Instructions for IRC-I8A-S Controller 33 / 73...

  • Page 34: Replacement Of Units

    Instructions for IRC-I8A-S Controller Replacement of units This chapter describes the methods for replacing each unit in the controller. Warning When units or printed circuit boards are replaced through maintenance and repair, turn off the Circuit Breaker and remove the power cord. Do not touch internal units or printed circuit boards in 1 min after the Circuit Breaker is turned off.

  • Page 35: Steps Before Replacement

    Instructions for IRC-I8A-S Controller 4.1 Steps before replacement Disconnect the power supply of the controller. (1) Switch off the Circuit Breaker. (2) Remove the power cable. Circuit Breaker 220V power inlet Power cable Fig. 4.1 Power Inlet Remove the top cover of the controller.

  • Page 36: Replacement Of Safety Board

    Instructions for IRC-I8A-S Controller Fig. 4.2 Top Cover Fig. 4.3 Back Cover 4.2 Replacement of safety board (1) Remove cables on safety board. (2) Dismantle M3 nuts to replace the safety board. (3) Mount the safety board according to the reverse steps of removal.

  • Page 37: Replacement Of Filter Board

    Instructions for IRC-I8A-S Controller Safety board I/O board Fig. 4.5 I/O Board 4.4 Replacement of EMI filter board (1) Unscrew the fixing screws on the EMI filter board. (2) Remove cables on the EMI filter board. (3) Mount the EMI filter board according to the reverse steps of removal.

  • Page 38: Replacement Of Power Input Port

    Instructions for IRC-I8A-S Controller Circuit Breaker EMI Filter board Fig. 4.7 Circuit Breaker 4.6 Replacement of power inlet (1) Unscrew the screws on the power inlet. (2) Mount the power inlet according to the reverse steps of removal. Power inlet Fig.

  • Page 39: Replacement Of Controller Main Board

    Instructions for IRC-I8A-S Controller Controller core board Fig. 4.9 Controller Core Board 4.8 Replacement of Controller Main Board (1) Dismantle the controller core board firstly before replacing the Controller Main Board. Please refer to Section 4.7 for details. (2) Remove cables on Controller Main Board.

  • Page 40: Replacement Of Power Soft Start Circuit Board

    Instructions for IRC-I8A-S Controller Drive board Fig. 4.11 Drive Board 4.10 Replacement of Power Soft Start Circuit Board (1) Remove cables on the Power Soft Start Circuit Board. (2) Unscrew the fixing screws M3 to remove the Power Soft Start Circuit Board.

  • Page 41: Replacement Of Fan Unit

    Instructions for IRC-I8A-S Controller 24V power (10A) 24V power (5A) Fig. 4.13 AC-DC Power Supply 4.12 Replacement of fan unit (1) Remove cables of the fan unit. (2) Unscrew the fixing screws M3 to remove the fan unit. (3) Dismantle the outer fan filter screen of the controller to remove the outer fan (Fig. 4.15).
  • Page 42 Instructions for IRC-I8A-S Controller Filter screen of outer fan Fig. 4.15 Fan Unit 2 Inner Fan Fig. 4.16 Fan Unit 3 Instructions for IRC-I8A-S Controller 42 / 73...

  • Page 43: Connection

    Instructions for IRC-I8A-S Controller II. Connection Summary 1.1 System configuration Fig. 1.1 illustrates relevant ports configured on the IRC-I8A-S controller. Communication area Motor power supply and encoder connector I/O communication Ethernet port port (Communication area) External safety port Fig. 1.1 Illustration of Controller Ports...

  • Page 44: External Ports

    Instructions for IRC-I8A-S Controller 1.2 External ports The following diagram describes the connection ports on the front panel of the IRC-I8A-S controller. Caution Before connecting the connector to the controller, make sure to check for dirt or damage. Please clean the components or replace damaged ones.
  • Page 45 Instructions for IRC-I8A-S Controller Part name Function communication between the control system and TP. Release button on Orange indicates the function of reset. Note: The function of this controller body button is completely consistent with the reset button of TP! Control system switch Start/stop the control system.

  • Page 46: Connection With Devices

    Ground the controller before startup. Otherwise, the risk of electric shock exists. 2.2 Cables of teach pendant The teach pendant connector on the IRC-I8A-S controller is located at the front of the controller. Before connecting the connector to the controller, make sure to check for dirt or damage. Please clean the components or replace damaged ones.

  • Page 47: Preparation Of Input Power Cable

    Instructions for IRC-I8A-S Controller 2.3 Preparation of power cable Connect the power cable on IRC-I8A-S, or use accessories provided by us, or the user should prepare them independently. Prepare the power cable according to the following requirements. Connect the power side according to the customer's device.

  • Page 48: Grounding And Shielding Connection

    Instructions for IRC-I8A-S Controller 2.4 Grounding and shielding connection The following figure shows two examples of grounding and shielding methods. Fig. 2.4 Grounding Connection Example 1: If all components are well grounded, the best shielding effect can be achieved by grounding all shielding layers at both ends of all components.

  • Page 49: Elimination Of Interference

    Instructions for IRC-I8A-S Controller 2.5 Elimination of interference For internal relay coils and other components possibly causing interference inside the controller, their interference is eliminated through offset. External relay coils and other components must be c lighted in the same manner. The following figure shows the specific method. Please note that the closing time of the DC relay may increase after offset, especially if a diode is connected through a coil.

  • Page 50: About Leakage Circuit Breaker

    Instructions for IRC-I8A-S Controller 2.6 About power protection device The robot generates high-frequency leakage current during operation, which sometimes causes the leakage circuit breaker or leakage protector of the controller’s power supply to trip. Therefore, such false tripping is to be avoided when selecting leakage circuit breaker or leakage protector.

  • Page 51: Peripheral Devices

    Instructions for IRC-I8A-S Controller Peripheral devices 3.1 Ports of peripheral devices The peripheral device ports of IRC-I8A-S are divided into IO board, safety board and arm I/O signal ports. Fig. 3.1 External IO Board 155mm Fig. 3.2 Dimensions of External IO Board The controller IRC-I8A-S provides 25 DI/DO ports and the I/O adapter totally has 4 sets of terminal blocks, of which the terminal block A is for DI ports and the terminal block B is for DO ports.
  • Page 52 Instructions for IRC-I8A-S Controller Input Port 5 UI_5 Program abort signal IO_0V IO_0V Input Port 6 UI_6 Trigger signal Input Port 7 UI_7 MPLCS start signal Input Port 8 UI_8 MPLCS main program Input Port 9 UI_9 status signal, 6 bits in...
  • Page 53 Instructions for IRC-I8A-S Controller User’s output signal Output Port 17 DO_4 DO power selector DO_PS_IN4 DO_PS_IN4 port User’s output signal Output Port 16 DO_3 User’s output signal Output Port 15 DO_2 User’s output signal Output Port 14 DO_1 MPLCS main program...
  • Page 54 Instructions for IRC-I8A-S Controller Fig. 3.3 External Safety Board 90mm Fig. 3.4 Dimensions of External Safety Board Fig. 3.5 Safety Plug If safety signals are not used in practical applications, it is required to insert the safety plug into the safety port.
  • Page 55 Instructions for IRC-I8A-S Controller Limit_stop_1 Limit signal 1 Limit_stop_2 Limit signal 2 External emergency Ext_E_stop_1 stop 1 External emergency Ext_E_stop_2 stop 2 Safety_Door_1 Safety door signal 1 Safety_Door_2 Safety door signal 2 User’s reset, reserved User_reset_1 Blank Blank 24V power supply 24V power supply Table 3.3 Definition of Safety Board Wire Sequence...
  • Page 56 Instructions for IRC-I8A-S Controller Pin No. Function IO_24V IO_0V Table 3.5 Definition of EE2 Aviation Plug Instructions for IRC-I8A-S Controller 56 / 73...

  • Page 57: Ports And Connection Of Peripheral Devices

    Instructions for IRC-I8A-S Controller 3.2 Ports and connection of peripheral devices Terminal Peripheral devices IO board: DI (PNP) block PNP connection method Using internal power supply Note: It is not recommended to mix the power supplies of the robot IO module; when an external power supply is used, it is for all IO.
  • Page 58 Instructions for IRC-I8A-S Controller Terminal Peripheral devices IO board: DI (PNP) block PNP connection method Using external power supply Fig. 3.7 Connection of DI Signals Instructions for IRC-I8A-S Controller 58 / 73...
  • Page 59 Instructions for IRC-I8A-S Controller Terminal Peripheral devices block IO board: DO (PNP) PNP connection method Using internal power supply Note: It is not recommended to mix the power supplies of the robot IO module; when an external power supply is used, it is for all IO.
  • Page 60 Instructions for IRC-I8A-S Controller Terminal Peripheral devices IO board: DO (PNP) block PNP connection method Using external power supply Fig. 3.9 Connection of DO Signals Instructions for IRC-I8A-S Controller 60 / 73...

  • Page 61: Connection Between Safety Board And Peripheral Devices

    Instructions for IRC-I8A-S Controller 3.3 Connection between safety board and peripheral devices The safety circuit ports for the users can only support the 24V power supply inside the controller rather than external 24V power supply. Therefore, the user can only use safety devices with passive and normally-closed contacts.

  • Page 62: Connection Between Arm I/O Port And Peripheral Devices

    Instructions for IRC-I8A-S Controller 3.4 Connection between arm I/O port and peripheral devices There are two I/O signal ports on the wrist of the robot, with EE1 near the air pipe and EE2 on the other end. A total of 6 RI and 6 RO ports are provided and directly connected to the dedicated IO ports on the controller's I/O board.

  • Page 63: Connection Of Communication Device (Ethernet Port)

    Instructions for IRC-I8A-S Controller 3.5 Connection of communication device (Ethernet port) The IRC-I8A-S controller is provided with standard Ethernet RJ45 ports and supports multiple protocols, and two Ethernet ports are interconnected internally. Caution Please consult various device manufacturers for the construction of the network or the operating conditions of the devices other than robot controller (HUBs, transceivers, cables, etc.).

  • Page 64: Handling And Mounting

    Instructions for IRC-I8A-S Controller Handling and mounting 4.1 Handling method Handle the robot in a stationary mode. (1) Move the robot to the handling position. (2) Fix the robot on a wooden bracket with M10 screws. (3) Put the controller into the box.

  • Page 65: Mounting Method

    Instructions for IRC-I8A-S Controller 4.2 Mounting method Fig. 4.3 Mounting of Controller • If mounted on a desktop (without a rack), the controller requires 100mm free space on the left and 200mm free space on the right. • The controller requires 200mm free space on the back to ensure proper cooling. Never place the customer’s cable on the fan cover on the back of the controller.

  • Page 66: Mounting Conditions

    Instructions for IRC-I8A-S Controller 4.3 Mounting conditions During operation, the IRC-I8A-S controller may generate electromagnetic interference to the outside, which mainly affects peripheral devices by conduction and radiation. In non -industrial environments, the electromagnetic interference generated by the controller may affect peripheral devices occasionally. So, do not use this controller in residential areas.

  • Page 67: Adjustment And Confirmation Items During Mounting

    Instructions for IRC-I8A-S Controller 4.4 Adjustment and confirmation items during mounting Item Contents Check internal and external appearance of the controller. Check if the fixing screw terminals have been properly connected. Confirm the insertion status at mounting positions of connectors and printed circuit board.

  • Page 68: Appendice

    Instructions for IRC-I8A-S Controller Appendice A. List of Specifications Overall unit Description of Material No. Description of model and specification Note material 404AP_SSA0 IRC-I8A-S brake board AP_SSA00101_E/2.441x2.283in./R010A-03 0101_E0100 IRC-I8A-S controller 404AP_CCB0 AP_CCB00402_E/4.102x3.730in./R010A-03 core board 0402_E0110 IRC-I8A-S Controller 404AP_CMB0 AP_CMB00401_E/10.00x6.220in./R010A-03 Main Board...
  • Page 69 Description of model and specification Note material IO signal cables outside IRC-I8A-S SN-2019-GBT-021; IO board adapter cable; controller 4010300012 5m; specific for IRC-I8A-S controller Safety board signal cables outside IRC-I8A- SN-2019-GBT-020; pre-wires for safety board; S controller 4010300011 5m; specific for IRC-I8A-S controller 404AP_ISA00...

  • Page 70: Meaning Of Control System I/O Signals Of Peripheral Devices

    Instructions for IRC-I8A-S Controller B. Meaning of control system I/O signals of peripheral devices The following table lists the system I/O signals for the ports of the peripheral devices on IRC-I8A-S. List of UI/UO signals Servo_Ena Servo_Enable is usually ON. When the peripheral...
  • Page 71 Instructions for IRC-I8A-S Controller program. Request to terminate a program in execution or paused state. It is usually ON. In the OFF state, the system performs following processing: The alarm bar indicates a This signal is set to program abort...
  • Page 72 Instructions for IRC-I8A-S Controller set to "Start by Main is set to "Start by Main Program Number" Program Number" or "Simple Start Mode by "Simple Start Mode by Main Program Number". Main Program The 6-digit binary number Number". of the program number is...
  • Page 73 Instructions for IRC-I8A-S Controller Contact us Agilebot Robotics Co., Ltd. (Shanghai Headquarters): Floor 8, Tower 6, Zhongjian Jinxiu Plaza, No. 50, Lane 308, Xumin Road, Qingpu District, Shanghai Agilebot Operation and Technical Service Center: Building 1, No. 338 Jiuye Road, Qingpu District, Shanghai Service hotline: +86-21-5986 0805 Website: www.sh-agilebot.com...

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