Denso RC5 User Manual

ROBOT
RC5 CONTROLLER
INTERFACE MANUAL
Copyright © DENSO WAVE INCORPORATED, 2002 All rights reserved. No part of this publication may be reproduced in any form or by any means without
permission in writing from the publisher. Specifications are subject to change without prior notice.
All products and company names mentioned are trademarks or registered trademarks of their respective holders.

Preface

Thank you for purchasing this high-speed, high-accuracy assembly robot. This manual covers interfacing required when you integrate your robot system configured with the RC5
robot controller into your facilities. Before use, read this manual carefully together with related manuals to safely get the maximum benefit
from your robot in your assembling operations.
Robot models covered by this manual
All robot models configured with RC5 controller
Important
T o ensure operator safety , be sure to read the precautions and instructions in "SAFETY PRECAUTIONS."
i

How the documentation set is organized

The documentation set consists of the following books. If you are unfamiliar with this robot and option(s), please read all books and understand them fully before operating your robot and option(s).
GENERAL INFORMATION ABOUT ROBOT
Provides the packing list of the robot and outlines of the robot system, robot unit, and robot controller.
INSTALLATION & MAINTENANCE GUIDE
Provides instructions for installing the robot components and customizing your robot, and maintenance & inspection procedures.
BEGINNER'S GUIDE
Introduces you to the DENSO robot. Taking an equipment setup example, this book guides you through running your robot with the teach pendant, making a program in WINCAPSII, and running your robot automatically.
SETTING-UP MANUAL
Describes how to set-up or teach your robot with the teach pendant, operating panel, or mini-pendant.
WINCAPSII GUIDE
Provides instructions on how to use the teaching system WINCAPSII which runs on the PC connected to the robot controller for developing and managing programs.
PROGRAMMER'S MANUAL (I), (II)
Describes the PAC programming language, program development, and command specifications in PAC.
RC5 CONTROLLER INTERFACE MANUAL - this book -
Describes the RC5 controller, interfacing with external devices, system- and user-input/output signals, and I/O circuits.
ERROR CODE TABLES
List error codes that will appear on the teach pendant, operating panel, or PC screen if an error occurs in the robot series or WINCAPSII. These tables provide detailed description and recovery ways.
OPTIONS MANUAL
Describes the specifications, installation, and use of optional devices.
ii

How this book is organized

This book is just one part of the robot documentation set. This book consists of SAFETY PRECAUTIONS and chapters one through nine.
SAFETY PRECAUTIONS
Defines safety terms and related symbols and provides precautions that should be observed. Be sure to read this section before operating your robot.
Chapter 1 Outline of the RC5 Controller
Provides an outline of the RC5 controller. The robot controller is available in several models that will differ in detailed specifications to match robot models to be connected.
Chapter 2 General Information about the Interface
Introduces you to the interface required for connecting the robot controller with a PLC or other external equipment. It describes two I/O allocation modes available--standard mode and compatible mode, and the switching procedure between those modes.
Describes declaration of I/O variables and user I/O signals.
Chapter 3 System I/O Signals in Standard Mode
Describes system I/O signals available in standard mode, and describes I/O signals that execute I/O commands.
Chapter 4 System I/O Signals in Compatible Mode
Describes the functions, terminal numbers, and on/off conditions of system I/O signals in compatible mode.
Chapter 5 I/O Circuits and Connectors (NPN type)
Describes the I/O circuits and connector pin layout of an NPN I/O board (source input and sink output). The NPN I/O board is designed for the use in Japan.
Chapter 6 I/O Circuits and Connectors (PNP type)
Describes the I/O circuits and connector pin layout of a PNP I/O board (sink input and source output).
Chapter 7 I/O Wiring
Describes I/O cables and wiring.
iii

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
Be sure to observe all of the following safety precautions. Strict observance of these warning and caution indications are a MUST for preventing accidents, which
could result in bodily injury and substantial property damage. Make sure you fully understand all definitions of these terms and related symbols given below, before you proceed to the text itself.
WARNING
CAUTION
Alerts you to those conditions, which could result in serious bodily injury or death if the instructions are not followed correctly.
Alerts you to those conditions, which could result in minor bodily injury or substantial property damage if the instructions are not followed correctly.
Terminology and Definitions
Maximum space: Refers to the volume of space encompassing the maximum designed movements of
all robot parts including the end-effector, workpiece and attachments. (Quoted from the RIA* Committee Draft.)
Restricted space: Refers to the portion of the maximum space to which a robot is restricted by limiting devices (i.e., mechanical stops). The maximum distance that the robot, end-effector, and workpiece can travel after the limiting device is actuated defines the boundaries of the restricted space of the robot. (Quoted from the RIA Committee Draft.)
Motion space: Refers to the portion of the restricted space to which a robot is restricted by software motion limits. The maximum distance that the robot, end-effector, and workpiece can travel after the software motion limits are set defines the boundaries of the motion space of the robot. (The "motion space" is DENSO WAVE-proprietary terminology.)
Operating space: Refers to the portion of the restricted space (or motion space in Denso robot) that is actually used by the robot while performing its task program. (Quoted from the RIA Committee Draft.)
Task program: Refers to a set of instructions for motion and auxiliary functions that define the specific intended task of the robot system. (Quoted from the RIA Committee Draft.)
(*RIA: Robotic Industries Association)
1. Introduction
This section provides safety precautions to be observed during installation, teaching, inspection, adjustment, and maintenance of the robot.
2. Installation Precautions
2.1 Insuring the proper installation environment
2.1.1 For standard type The standard type has not been designed to withstand
explosions, dust-proof, nor is it splash-proof. Therefore, it should not be installed in any environment where:
(1) there are flammable gases or liquids, (2) there are any shavings from metal processing or other
conductive material flying about, (3) there are any acidic, alkaline or other corrosive gases, (4) there is cutting or grinding oil mist, (5) it may likely be submerged in fluid, (6) there is sulfuric cutting or grinding oil mist, or
2.1.2 For dust-proof, splash­proof type
(7) there are any large-sized inverters, high output/high
frequency transmitters, large contactors, welders, or other sources of electrical noise.
The dust-proof, splash-proof type is an IP54-equivalent structure, but it has not been designed to withstand explosions. (The HS-E-W and the wrist of the VM-D-W/VS-E-W are an IP65-equivalent dust-proof and splash-proof structure.)
Note that the robot controller is not a dust- or splash-proof structure. Therefore, when using the robot controller in an environment exposed to mist, put it in an optional protective box.
The dust-proof, splash-proof type should not be installed in any environment where:
(1) there are any flammable gases or liquids, (2) there are any acidic, alkaline or other corrosive gases, (3) there are any large-sized inverters, high output/high
frequency transmitters, large contactors, welders, or other
sources of electrical noise, (4) it may likely be submerged in fluid, (5) there are any grinding or machining chips or shavings,
2.2 Service space
(6) any machining oil not specified in this manual is in use, or
Note: Yushiron Oil No. 4C (non-soluble) is specified. (7) there is sulfuric cutting or grinding oil mist.
The robot and peripheral equipment should be installed so that sufficient service space is maintained for safe teaching, maintenance, and inspection.
SAFETY PRECAUTIONS
2.3 Control devices outside the robot's restricted space
2.4 Positioning of gauges
2.5 Protection of electrical wiring and hydraulic/pneumatic piping
2.6 Positioning of emergency stop switches
The robot controller, teach pendant, and operating panel should be installed outside the robot's restricted space and in a place where you can observe all of the robot’s movements when operating the robot controller, teach pendant, or operating panel.
Pressure gauges, oil pressure gauges and other gauges should be installed in an easy-to-check location.
If there is any possibility of the electrical wiring or hydraulic/pneumatic piping being damaged, protect them with a cover or similar item.
Emergency stop switches should be provided in a position where they can be reached easily should it be necessary to stop the robot immediately.
(1) The emergency stop switches should be red. (2) Emergency stop switches should be designed so that they
will not be released after pressed, automatically or mistakenly by any other person.
2.7 Positioning of operating status indicators
(3) Emergency stop switches should be separate from the
power switch.
Operating status indicators should be positioned in such a way where workers can easily see whether the robot is on temporary halt or on an emergency or abnormal stop.
2.8 Setting-up the safety fence or enclosure
A safety fence or enclosure should be set up so that no one can easily enter the robot's restricted space. If it is impossible, utilize other protectors as described in Sect ion 2. 9.
(1) The fence or enclosure should be constructed so that it
cannot be easily moved or removed.
(2) The fence or enclosure should be constructed so that it
cannot be easily damaged or deformed through external force.
(3) Establish the exit/entrance to the fence or enclosure.
Construct the fence or enclosure so that no one can easily get past it by climbing over the fence or enclosure.
(4) The fence or enclosure should be constructed to ensure
that it is not possible for hands or any other parts of the body to get through it.
(5) Take any one of the following protections for the entrance/
exit of the fence or enclosure:
1) Place a door, rope or chain across the entrance/exit of the fence or enclosure, and fit it with an interlock that ensures the emergency stop device operates automatically if it is opened or removed.
2) Post a warning notice at the entrance/exit of the fence or enclosure stating "In operation--Entry forbidden" or "Work in progress--Do not operate" and ensure that workers follow these instructions at all times.
2.9 Positioning of rope or chain
When mak ing a test run, before setting up the fence or enclosure, place an overseer in a position outside the robot’s restricted space and one in which he/she can see all of the robot’s movements. The overseer should prevent workers from entering the robot's restricted space and be devoted solely to that task.
If it is not possible to set up the safety fence or enclosure described in Section 2.8, hang a rope or chain around the perimeter of the robot’s restricted space to ensure that no one can enter the restricted space.
(1) Ensure the support posts cannot be moved easily. (2) Ensure that the rope or chain’s color or material can easily
be discerned from the surrounds.
(3) Post a warning notice in a position where it is easy to see
stating "In operation--Entry forbidden" or "W ork in progress
--Do not operate" and ensure that workers follow these instructions at all times.
(4) Set the exit/entrance, and follow the instructions given in
Section 2.8, (3) through (5).
SAFETY PRECAUTIONS
2.10 Setting the robot's motion space
2.11 No robot modification allowed
2.12 Cleaning of tools
2.13 Lighting
The area required for the robot to work is called the robot's operating space.
If the robot’s motion space is greater than the operating space, it is recommended that you set a smaller motion space to prevent the robot from interfering or disrupting other equipment.
Refer to the "INSTALLATION & MAINTENANCE GUIDE."
Never modify the robot unit, robot controller, teach pendant or other devices.
If your robot uses welding guns, paint spray nozzles, or other end-effectors requiring cleaning, it is recommended that the cleaning process be carried out automatically.
Sufficient illumination should be assured for safe robot operation.
2.14 Protection from objects thrown by the end­effector
2.15 Affixing the warning label
If there is any risk of workers being injured in the event that the object being held by the end-effector is dropped or thrown by the end-effector, consider the size, weight, temperature and chemical nature of the object and take appropriate safeguards to ensure safety.
Place the warning label packaged with the robot on the exit/entrance of the safety fence or in a position where it is easy to see.
3. Precautions
while r obot is running
Warning
Touching the robot while it is in operation can lead to serious injury. Please ensure the following conditions are maintained and that the cautions listed from Section
3.1 onwards are followed when any work is being performed.
1) Do not enter the robot's restricted space when the robot is in operation or when the motor power is on.
2) As a precaution against malfunction, ensure that an emergency stop device is activated to cut the power to the robot motor upon entry into the robot's restricted space.
3) When it is necessary to enter the robot's restricted space to perform teaching or maintenance work while the robot is running, ensure that the steps described in Section 3.3 "Ensuring safety of workers performing jobs within the robot's restricted space" are taken.
3.1 Creation of working regulations and assuring worker adherence
When entering the robot’s restricted space to perform teaching or maintenance inspections, set "working regulations" for the following items and ensure workers adhere to them.
(1) Operating procedures required to run the robot. (2) Robot speed when performing teaching. (3) Signaling methods to be used when more than one worker
is to perform work.
(4) Steps that must be taken by the worker in the event of a
malfunction, according to the contents of the malfunction.
(5) The necessary steps for checking release and safety of the
malfunction status, in order to restart the robot after robot movement has been stopped due to activation of the emergency stop device
(6) Apart from the above, any steps below necessary to
prevent danger from unexpected robot movement or malfunction of the robot.
1) Display of the control panel (See Section 3.2 on the following page)
2) Assuring the safety of workers performing jobs within the robot's restricted space (See Section 3.3 on the following page)
SAFETY PRECAUTIONS
3) Maintaining worker position and stance Position and stance that enables the worker to confirm
normal robot operation and to take immediate refuge if a malfunction occurs.
4) Implementation of measures for noise prevention
5) Signaling methods for workers of related equipment
6) Types of malfunctions and how to distinguish them
Please ensure "working regulations" are appropriate to the robot type, the place of installation and to the content of the work.
Be sure to consult the opinions of related workers, engineers at the equipment manufacturer and that of a labor safety consultant when creating these "working regulations".
3.2 Display of operation panel
3.3 Ensuring safety of workers performing jobs within the robot's restricted space
To prevent anyone other than the worker from accessing the start switch or the changeover switch by accident during operation, display something to indicate it is in operation on the operating panel or teach pendant. Take any other steps as appropriate, such as locking the cover.
When performing jobs within the robot’s restricted space, take any of the following steps to ensure that robot operation can be stopped immediately upon a malfunction.
(1) Ensure an overseer is placed in a position outside the
robot’s restricted space and one in which he/she can see all robot movements, and that he/she is devoted solely to that task.
An emergency stop device should be activated
Q
immediately upon a malfunction.
R Do not permit anyone other than the worker engaged
for that job to enter the robot’s restricted space.
(2) Ensure a worker within the robot's restricted space carries
the portable emergency stop switch so he/she can press it (the robot stop button on the teach pendant) imm ediately if it should be necessary to do so.
3.4 Inspections before commencing work such as teaching
Before starting work such as teaching, inspect the following items, carry out any repairs immediately upon detection of a malfunction and perform any other necessary measures.
(1) Check for any damage to the sheath or cover of the
external wiring or to the external devices.
(2) Check that the robot is functioning normally or not (any
unusual noise or vibration during operation). (3) Check the functioning of the emergency stop device. (4) Check there is no leakage of air or oil from any pipes. (5) Check there are no obstructive objects in or near the
robot’s restricted space.
3.5 Release of residual air pressure
3.6 Precautions for test runs
3.7 Precautions for automatic operation
Before disassembling or replacing pneumatic parts, first release any residual air pressure in the drive cylinder.
Whenever possible, have the worker stay outside of the robot's restricted space when performing test runs.
(1) At start-up
Before the robot is to be started up, first check the following items as well as setting the signals to be used and perform signaling practice with all related workers.
1) Check that there is no one inside the robot’s restricted space.
2) Check that the teach pendant and tools are in their designated places.
3) Check that no lamps indicating a malfunction on the robot or related equipment are lit.
(2) Check that the display lamp indicating automatic operation
is lit during automatic operation.
(3) Steps t o be taken when a malfunction occurs
Should a malfunction occur with the robot or related equipment and it is necessary to enter the robot's restricted space to perform emergency maintenance, stop the robot’s operation by activating the emergency stop device. Take any necessary steps such as placing a display on the starter switch to indicate work is in progress to prevent anyone from accessing the robot.
SAFETY PRECAUTIONS
3.8 Precautions in repairs
4. Daily and periodical inspections
5. Management of floppy disks
(1) Do not perform repairs outside of the designated range. (2) Under no circumstances should the interlock mechanism
be removed.
(3) When opening the robot controller's cover for battery
replacement or any other reasons, always turn the robot controller power off and disconnect the power cable.
(4) Use only spare tools specified in this manual.
(1) Be sure to perform daily and periodical inspections. Before
starting jobs, always check that there is no problem with the robot and related equipment. If any problems are found, take any necessary measures to correct them.
(2) When carrying out periodical inspections or any repairs,
maintain records and keep them for at least 3 years.
(1) Carefully handle and store the "Initial settings" floppy disks
packaged with the robot, which store special data exclusively prepared for your robot.
(2) After finishing teaching or making any changes, always
save the programs and data onto floppy disks. Making back-ups will help you recover if data stored in the
robot controller is lost due to the expired life of the back-up battery.
(3) Write the names of each of the floppy disks used for storing
task programs to prevent incorrect disks from loading into the robot controller.
(4) Store the floppy disks where they will not be exposed to
dust, humidity and magnetic field, which could corrupt the disks or data stored on them.

Contents

Preface.........................................................................................................................................................i
How the documentation set is o rganized...................................................................................................ii
How this bo ok is organized .......................................................................................................................iii
SAFETY PRECAUTIONS
Chapter 1 General Information about RC5 Controller
1.1 Controller Model Name on Nameplate..........................................................................................1
1.2 Names of the Robot Controller Components ................................................................................. 4
1.3 Robot Controller Specifications......................................................................................................7
1.4 Controller System Configuration..................................................................................................11
1.4.1 Internal Circuits of the Controller (Typical configuration)..................................................11
1.4.2 Typica l Robot System Configurations..................................................................................12
Chapter 2 General Information about the Interface
2.1 Standard Mode and Compatible Mode ........................................................................................ 14
2.2 Switching between Modes............................................................................................................ 14
2.3 Types and General Information about I/O Signals ..................................................................... 22
2.3.1 Standard Mode...................................................................................................................... 22
2.3.2 Compatible Mode..................................................................................................................23
2.4 Using User I/O Signals (common to both modes)........................................................................24
2.4.1 I/O Type Variable Declaration.............................................................................................. 24
2.4.2 I/O Type Global Variables..................................................................................................... 24
2.4.3 I/O Type Local Variables....................................................................................................... 24
2.4.4 User Input Commands.......................................................................................................... 24
2.4.5 User Output Commands.......................................................................................................25
Chapter 3 System I/O Signals Standard Mode
3.1 Types and Functions of System Output Signals (Standard Mode)............................................. 26
3.2 Usage of System Output Signals (Standard Mo de).....................................................................27
3.2.1 Robot Initialization Complete (Outpu t)...............................................................................27
3.2.2 Auto Mode (Output).............................................................................................................. 28
3.2.3 External Mode (Output)....................................................................................................... 29
3.2.4 Servo ON (Output)................................................................................................................ 30
3.2.5 Robot-in-operation (Output)................................................................................................. 31
3.2.6 Normal CPU (Output)...........................................................................................................32
3.2.7 Robot Failure (Output).........................................................................................................33
3.2.8 Robot Warning (Output).......................................................................................................34
3.2.9 Dead Battery Warning (Output)........................................................................................... 35
3.2.10 Continue Start Permitted (Output)...................................................................................... 36
3.2.11 SS mode (Output).................................................................................................................. 36
3.2.12 Emergency Stop (Output from a contact)............................................................................. 37
3.3 Types and Functions of System Input Signals (Standard Mode)................................................ 38
3.4 Usage of System Input Signals (Standard Mode) ....................................................................... 39
3.4.1 Enable Auto (Input) .............................................................................................................. 39
3.4.2 Robot Stop (Input)................................................................................................................. 40
3.4.3 Step Stop (All Tasks) (Input)................................................................................................41
3.4.4 Instantaneous Stop (All Tasks) (Input)................................................................................ 42
3.4.5 Interrupt Skip (Input)...........................................................................................................43
3.5 Command Execution I/O Signals Dedicated to Standard Mode.................................................45
3.5.1 General Information about Commands................................................................................ 45
3.5.2 Processing I/O Commands....................................................................................................46
3.5.3 I/O Commands Details..........................................................................................................52
3.6 Example of Using System I/O Signal s in St andard Mode .......................................................... 65
Chapter 4 System I/O Signals Compatible Mode
4.1 Types and Functions of System Output Signals (Compatible Mode)......................................... 69
4.2 Usage of System Output Signals in the Compatible Mode......................................................... 70
4.2.1 Robot Power ON Complete................................................................................................... 70
4.2.2 Auto Mode (Output).............................................................................................................. 71
4.2.3 Servo ON (Output)................................................................................................................ 72
4.2.4 CAL Complete (Output)........................................................................................................ 73
4.2.5 External Mode (Output)....................................................................................................... 74
4.2.6 Teaching (Output).................................................................................................................75
4.2.7 Program Start Reset (Output).............................................................................................. 76
4.2.8 Robot-in-operation (Output)................................................................................................. 77
4.2.9 Single-Cycle End (Output)....................................................................................................78
4.2.10 Normal CPU (Output)........................................................................................................... 79
4.2.11 Robot Failure (Output).........................................................................................................80
4.2.12 Robot Warning (Output) ....................................................................................................... 81
4.2.13 Dead Battery Warnin g (Output)........................................................................................... 82
4.2.14 Error No. (Output)................................................................................................................83
4.2.15 Continue Start Permitted (Output)...................................................................................... 84
4.2.16 SS mode (Output).................................................................................................................. 84
4.2.17 Emergency Stop (Output from a contact)............................................................................. 85
4.3 Types and Functions of System Input Signals (Compatible Mode)........................................... 86
4.4 Usage of System Input Signals in C o mpatible Mode..................................................................87
4.4.1 Enable Auto (Input) .............................................................................................................. 87
4.4.2 Operation Preparation Start (Input).................................................................................... 88
4.4.3 Program No. Select (Input)...................................................................................................90
4.4.4 Program Start (Input)........................................................................................................... 92
4.4.5 Program Reset (Input).......................................................................................................... 98
4.4.6 Robot Stop (Input)............................................................................................................... 100
4.4.7 Step Stop (All Tasks) (Input)..............................................................................................101
4.4.8 Instantaneous Stop (All Tasks) (Inpu t ).............................................................................. 102
4.4.9 Clear Robot Failure (Input)................................................................................................ 103
4.4.10 Interrupt Skip (Input).........................................................................................................104
4.4.11 Continue Start (Input) ........................................................................................................ 105
4.5 Example of Using Syste m I/O Signals in Compatible Mode..................................................... 106
Chapter 5 Connector Pin Assignment and I/O Circuits (NPN type)
5.1 Connector Pin Assignment (NPN type)......................................................................................110
5.1.1 Connector Pin Assignment Common to Both Modes (NPN type ).......................................110
5.1.2 Connector Pin Assignment in Standard Mode....................................................................112
5.1.3 Connector Pin Assignment in Compatible Mode................................................................114
5.2 Robot Controller I/O Circuits (NP N type) ..................................................................................116
5.2.1 User-Input, System-Input and Hand-Input Circuits (NPN type)......................................116
5.2.2 Robot Stop and Enable Auto Input Circuits........................................................................119
5.2.3 User-Output, System -Output, and Hand-Output Circuits (NPN type)............................ 120
5.2.4 Emergency Stop Circuit...................................................................................................... 124
5.2.5 I/O Power Connector (NPN type) ....................................................................................... 126
5.3 Wiring No tes for Robot Controller I/O Connectors (NPN type)................................................128
Chapter 6 Connector Pin Assignment and I/O Circuits (PNP type)
6.1 Connector Pin Assignment (PNP type)...................................................................................... 130
6.1.1 Connector Pin Assignment Common to Both Modes (PNP type) ...................................... 130
6.1.2 Connector Pin Assignment in Standard Mo de................................................................... 132
6.1.3 Connector Pin Assignment in Compatible Mode ............................................................... 134
6.2 Robot Controller I/O Circuits (PNP type)..................................................................................136
6.2.1 User-Input, System-Input and Hand-Input Circuits (PN P type)...................................... 136
6.2.2 Robot Stop and Enable Auto Input Circuits.......................................................................139
6.2.3 User-Output, System-Output, and Hand-Output Circuits (PNP type)............................. 140
6.2.4 Emergency Stop Circuit...................................................................................................... 144
6.2.5 I/O Power Connector (PNP type)........................................................................................ 146
6.3 Wiring Notes for Robot Controller I/O Connectors (PNP type)................................................. 148
Chapter 7 I/O Wiring
7.1 Multi-core Cables with Connectors............................................................................................150
7.2 Wiring of Primary Power Source ............................................................................................... 152
Index
Chapter 1
General Information about RC5 Controller
The RC5 controller is available in several models which differ in detailed specifications to mat ch robot models of **-D/-E series.

1.1 Controller Model Name on Nameplate

The model name of the controller is printed on the nameplate attached to the side of the controller as shown below. The model name is coded as listed below.
Nameplate (Sample)
Coding of Controller Model Name
RC5 - VSE 6 B A - P
(a) (b) (c) (d) (e)
Position
(a) VSE Robot model name VM: VM-D, VS: VS-D, VSE: VS-E, VC: VC-E,
(b) 6 No. of controllable axes 4: 4 axes, 5: 5 axes, 6: 6 axes (c) B Engineering symbol 1 A: Encoders connected via parallel interface to CN13
(d) A Engineering symbol 2 Blank or A (e) P Types Blank: I/O of NPN type
Code
sample
Denotes: Coding
H: HM/HS-D, HSE: HS-E, HME: HM-E, HC: HC-D, XYC:XYC-D EAH: HM/HS-D with extended-joint support
EAHC: HC-D with extended-joint support EAXYC: XYC-D with extended-joint support EAVS: VS-D with extended-joint support
B: Encoders connected via bus to CN12
P: I/O of PNP type AN: Robot System “Type A” and I/O of NPN type (Note: For Robot System “Type A” refer to next page.) AP: Robot System “Type A” and I/O of PNP type BN: Global type (:Dual emergency stop type +
Robot System “Type A”) and I/O of NPN type
BP: Global type (:Dual emergency stop type +
Robot System “Type A”) and I/O of PNP type
1
<Notes for Robot System “ Type A”>
1 Modified Deadman Switch Functions in Robot System "Type A"
In Robot System "Type A" designed for the RC5 controller, the functions of the deadman switches provided on the optional devices have been partially modified regarding the motor power ON/OFF control. Accordingly, the description given in the instruction manuals that come with "Type A" is different from the actual functions. When reading the deadman switch related sections, be careful with the following modification.
1.1 Deadman switches on optional devices
(Teach pendant, operating panel, and mini-pendant)
Deadman switches are locat ed as shown below.
Deadman switches
Teach pendant
1.2 Modified deadman switch functions
When you operate the teach pendant, operating panel, or mini-pendant in Manual mode or Teach check mode, the deadman switch controls the motor power ON/OFF function in Robot System "Type A," while it does not in the description given in the instruction manuals.
Robot System "Type A" Description given in the instruction manuals
Deadman switch
Operating panel
Deadman switch
Mini-pendant
(1) Unless t he deadman switch is held down,
you may neither operate the robot nor turn the motor power ON.
(2) When the robot is in operation, releasing
the deadman switch will stop not only the robot but also turn the motor power OFF.
(1) Unless t he deadman switch is held down,
you may not operate the robot, but you may turn the motor power ON.
(2) When the robot is in operation, releasing
the deadman switch will stop the robot but not turn the motor power OFF (servo lock).
How to identify your robot system as "Type A"
Check the controller model on the nameplate located on the side of the robot controller or the robot model shown on the status bar of the teach pendant screen. The model name of "Type A" contains letter "A" as shown below.
Robot controller example: RC5-H4A-A N Robot example: HM-40702D A Symbol denoting "Ty pe A"
2
2 “Single point of control” function
r
The “Single point of control” function is added only for Robot System “Type A”. This function limits the robot-start that other equipments except specified one device (for example: Teach Pendant) cannot en able to start the robot. The “Auto mode” of this function is usable in either “Internal Auto Limited Mode” or “External Auto Limited Mode” by set t ing the parameter.
2.1 Internal Auto Limited Mode
The operational permit of “Internal Auto Limited Mode” is the same range as the “Internal Auto Mode”. Program Start can be executed from the teach pendant, but cannot be executed from the external device. The switching between Internal Auto and External Auto cannot be operated by the teach pendant.
2.2 External Auto Limited Mode
The operational permit of “External Auto Limited Mode” is the same range as the “External Auto Mode”. Program Start can be executed from the external device, but cannot be executed from the teach pendant. The switching between Internal Auto and External Auto cannot be operated by the teach pendant.
2.3 Setting the parameter
Access: [Top screen] - [F4 I/O] - [F6 Aux.] - [F1 Set H/W] - [F3 Jump To] - “31”
Select the Internal Auto Limited Mode (Int:0) or the External Auto Limited Mode
(Ext:1).
TIP: Before shipping from the factory, the single point of control is set to 0 (Internal Auto Limited Mode) by default .
Type A
Setting paramete
3

1.2 Names of the Robot Controller Components

x
x
r
The following figures show the names of the robot controller components.
n
n For VM-D/HM-E series
nn
<Front>
Floppy disk drive (option)
CN1 CN2 CN3 CN4 CN5
Robot stop button
Memory backup battery holder
FG terminal
Pilot lamp
Filters (air intake)
Output IC bo
<Left side>
CN8
CN6
CN9
CN7
CN10
Fuse bo
Power switch
<Right side>
Names of Robot Controller Components (VM-D/HM-E series)
CN11
CN12
Filte
s (exhaust)
Radiating fin
4
n
x
r
x
n For robot series except VM-D/HM-E
nn
<Front>
Floppy disk drive (option)
Robot stop button
Memory backup battery holder
Pilot lamp
s (air intake)
Filte
<Left side>
Output IC bo
Fuse bo
Filters (exhaust)
FG terminal
Power switch
<Right side>
Radiating fin
Note: CN13 is not provided on the VS-E and HS-E series.
Names of Robot Controller Components (Robot series except VM-D/HM-E)
5
Connectors for the VM-D, VS-E, and H∗∗∗-E series (Encoders connected via bus)
Connector
No.
CN1 RS232C
CN2 CRT
CN3 KEYBD
CN4 MOUSE
CN5 PENDANT
CN6 PRINTER
Connectors for the VS-D, VC-E, H∗∗∗-D and XYC-D series (Encoders connected via parallel interface)
Connector
No.
CN1 RS232C
Marking Name Connector
No.
Serial interface connector
CRT connector
Keyboard connector
Connector for PS/2 mouse
Connector for teach pendant
Printer connector (Not used.)
Marking Name Connector
Serial interface connector
CN7 I/O
CN8 INPUT
CN9 HAND I/O
CN10 OUTPUT
CN1 1 INPUT AC
CN12 MOTOR
No.
CN8 INPUT
Marking Name
Power connector for
POWER
Marking Name
I/O Connector for user input
or system input Connector for end-
effector I/O Connector for user output
or system output Power connector
Connector for motor/encoder
Connector for user input or system input
CN2 CRT
CN3 KEYBD
CN4 MOUSE
CN5 PENDANT
CN6 PRINTER
CN7 I/O
POWER
CRT connector
Keyboard connector
Connector for PS/2 mouse
Connector for teach pendant
Printer connector (Not used.)
Power connector for I/O
CN9 HAND I/O
CN10 OUTPUT
CN1 1 INPUT AC
CN12 MOTOR
CN13 ENCODER
Connector for end­effector I/O
Connector for user output or system output
Power connector
Motor connector
Encoder connector
Caution: The robot controller connectors are of a screw-lock type or
ring-lock type. Lock the connectors securely. If even one of the connectors is not locked, weak contact may result thereby causing an error.
Be sure to turn the robot controller OFF before connecting/ disconnecting the power connector or motor connector. Otherwise, the internal circuits of the robot controller may be damaged.
6
1.3 Robot Controller Specifications
[ 1 ] Specifications
The table below lists the robot controller specifications.

Robot Controller Specifications

Item Specifications
Control system
(NOTE 1)
No. of controllable axes
(NOTE 1)
Drive system All axes: Full-digital AC servo
Memory capacity
Language used
No. of teach programs
loadable to the memory
Teaching system
Input signal 20 user open points (PLC 12, hand input 8) + 36 fixed system pointsExternal
signals
(I/O)
Output signal 32 user open points (PLC 24, hand output 8) + 33 fixed system points
External
communication
Timer function 0.02 to 10 sec. (in units of 1/60 sec.) Self-diagnosis
function
Error display
PTP, CP 3-dimensional linear, 3-dimensional circular H-D/-E, XYC-D: Up to four axes simultaneously
VC-E (5-axis models): Up to five axes simultaneously V-D/-E: Up to six axes simultaneously
1.25 MB (equivalent to 5000 steps, 13,000 points) DENSO robot language (conforming to SLIM)
255
1) Remote teaching 2) Numerical input (MDI)
RS-232C: 1 line Ethernet: 1 line (option)
Overrun, servo error, memory error, input error, etc.
Error codes will be displayed on the external I/O or the operating panel (option). Error messages will be displayed in English on the teach pendant (option).
Power source
Power capacity
(NOTE 1)
Environmental conditions
(in operation)
Degree of protection IP20
Robot control
Cables
(option)
cable
I/O cable 8 m, 15 m Power cable 5 m
Weight
NOTE 1: For extended-joint support controllers, refer to the manual "SUPPLEMENT Extended-Joints Support" separately issued.
All RC5 models: 3-phase, 200 VAC-15% to 230 VAC+10%, 50/60 Hz
RC5 for VS-D/-E, H-D/-E, XYC-D: Single-phase, 230 VAC-10% to 230 VAC+10%,
50/60 Hz
RC5 for VC-E: Single-phase, 200 VAC-10% to 230 VAC+10%,
50/60 Hz
VM-D/HM-E: 3.3 kVA H-D: 2.0 kVA VS-E: 1.9 kVA HS-E: 1.8 kVA VS-D, XYC-D: 1.5 kVA VC-E: 0.6 kVA
Temperature: 0 to 40°C Humidity: 90% RH or less (no condensation allowed)
VM-D, VS-E, H-E: Standard: 4 m, 6 m High strength: 6 m, 12 m (selectable) VS-D, H-D, XYC-D: 3 m, 6 m (selectable) VC-E: 4 m, 6 m (selectable)
VM-D: Approx. 19 kg (excluding attached cables) VS-D/-E, VC-E, HS-E: Approx. 17 kg (excluding attached cables) H-D/E, XYC-D: Approx. 16 kg (excluding attached cables)
7
WARNING
⋅⋅⋅⋅ DO NOT touch fins. Their hot surfaces may cause severe
burns.
⋅⋅⋅⋅ DO NOT insert fingers or foreign objects into openings.
Doing so may cause bodily injury .
⋅⋅⋅⋅ Before opening the controller cover and accessing the
inside of the controll er f or m aintenance, be sure to turn off the power switch, discon nect the power cable, and wait 3 minutes or more. T hi s is for protecting you from electr i c shock.
⋅⋅⋅⋅ DO NOT connect or disconnect connectors to/f rom th e
controller while the power switch is on. Doing so may cause electric shock or controller failure.
CAUTION IN INSTALLATION
⋅⋅⋅⋅ This controller is not designed to b e dust-proof, splash-
proof, or explosio n- pr oof.
⋅⋅⋅⋅ Read operation manuals before instal l ati on. ⋅⋅⋅⋅ Do not place anything on the controller.
8
[ 2 ] Outer Dimensions
The outer dimensions of the robot cont roller are shown below.
Outer Dimensions of Robot Controller (for VM-D/HM-E series and extended-joint support)
Outer Dimensions of Robot Controller (for robot series except VM-D/HM-E)
9
n
p
)
p
)
p
)
p
)
p
)
p
)
p
)
p
)
p
)
p
)
n Location of IPM boards
nn
The table below shows the location of IPM boards for robot series or models.
Rear view of the controller
Series &
models
VM-6070D
VM-6083D/
VM-60B1D
VS-D
VS-E
VC-E
HM/HS-D
HM-E
HS-E
HC-D
XYC-D
Location
(8) (7) (6) (5) (4) (3) (2) (1)
Item
Joints -165432-
IPM model - M SS SS SS S L -
Motor ca
Motor ca
Motor ca
Motor ca
Motor ca
Motor ca
Motor ca
Motor ca
Motor ca
Motor ca
acity (W
Joints -265431-
IPM model - M SS SS SS S L -
acity (W
Joints --654321
IPM model - - SS SS SS S S S
acity (W
Joints --654321
IPM model - - SS SS SS S S M
acity (W
Joints --654321
IPM model - - SS SS SS SS SS SS
acity (W
Joints ----4321
IPM model ----SSSMM
acity (W
Joints - - 4 3 2 1
IPM model - - M M LL LL
acity (W
Joints ----4321
IPM model ----SSML
acity (W
Joints ----4321
IPM model ----SSSSSM
acity (W
Joints ----4321
IPM model ----SSSSS
acity (W
- 750 100 200 200 400 1500 -
- 750 100 200 200 400 1500 -
- - 50 50 50 200 400 400
- - 50 80 100 200 400 750
- - 30 30 30 80 80 80
----200200750750
- - 300 300 600 1000
----150200400750
----50100400750
----50200400200
NOTE 1: No IPM board are installed to locations marked with "-." Those locations
are covered with blank caps.
NOTE 2: For details about extended-joint support controllers, refer to the manual
"SUPPLEMENT Ext ended-Joints Support."
10

1.4 Controller System Configuration

1.4.1 Internal Circuits of the C ontroller (Typical config uration)
The block diagram below show s t he internal circuits of an RC5 controller designed for a 6-joint robot.
11
1.4.2 Typical Robot System Configurations
The block diagrams below show t ypical robot system configurations. To connect encoders via a time-division multiplexed bus: Connect the robot controller
(CN12) to the robot unit with a motor/enc oder cable (see below). To connect encoders via parallel interface: Connect the robot controller (CN12 and
CN13) to the robot unit with a motor cable a nd encoder cable, respectively.
n
n Robot system configuration with encoders connected via a multiplexed bus
nn
(VM-D, VS-E, HS-E, and HM-E)
Robot System Configuration
12
n
n Robot system configuration with encoders connected via a parallel interface
nn
(VS-D, VC-E, H*-D, and XYC-D)
System Configuration Example
13
Chapter 2
General Information about the Interface

2.1 Standard Mode and Compatible Mode

The robot controller can be operated in two different modes – standard mode and compatible mode. The default is standard mode. Select either mode before operating the robot controller.
In the standard mode, all of the advantages can be expected from the new model of the robot controller by simultaneously running two or more programs with multitasking.
The compatible mode focuses on compatibility with conventional DENSO robots. Use this mode whenever compatibility is required. For example, when replacing a conventional robot with a new model. However, there are some restrictions on the use of new functions, such as mu lt itasking, in this mode.

2.2 Switching between Modes

Switch from one mode to the other using the teach pendant or the PC teaching system.
Caution: After switching between those modes, restart the robot controller to
make the new setting go into effect.
14
[ 1 ] Switching from the Teach Pendant
Follow the procedure below when switching from one mode to the other from the teach pendant:
On the top screen, press [F4 I/O].
STEP 1
"
The I/O Monitor window appears.
F6
STEP 2
"
Press [F6 Aux.].
The Auxiliary Functions (I/O) window appears as shown below.
F2
Press [F2 I/O Assign]. (For Version 1.6 or later) NOTE: For Version 1.5 or earlier, press [F1 Set H/W] and select the
Allocation mode field in the I/O Hardware Settings window.
15
STEP 3
"
The Choose allocation win dow appears as shown below. NOTE: If your robot controller has a built-in DeviceNet master, the Select
Port Assignment window will appear instead of the Select I/O Assignment Mode window. Refer to the DeviceNet Master Unit user's manual, Chapter 3, "I/O Assignment."
Using the jog dial or cursor keys, select the desired assignment mode. Then press OK.
STEP 4
"
STEP 5
"
The following system message appears.
Press OK.
The screen returns to the Auxiliary Functions (I/O) window.
Turn the controller power OFF.
STEP 6
"
Turn the controller power ON again.
The I/O assignment mode is switched.
16
[ 2 ] Switching from the Computer
Follow the procedure below when switching from one mode to the other from the computer.
Start WINCAPSII on the computer. Log in with Programmer.
STEP 1
"
STEP 2
"
Start WINCAPSII according to the procedure given in WINCAPSII GUID E, Chapter 3, Section 3.1.
For details on the user level of Programmer, refer to the WINCAPSII GUIDE, Chapter 1, Sect ion 1.3.
Click on the DIO Manager b utton in the System Manager.
DIO Manager starts an d t he DI O Manager window opens.
17
STEP 3
"
STEP 4
"
Select the SETTING command from the Tools menu of DIO Manager.
The Options window will ap pear as shown below.
Click on the Hardware tab in the Options window.
The hardware settings will a ppear.
18
STEP 5
"
STEP 6
"
Select the desired assignment mode from the right-hand popup menu in the I/O Allocation frame (Ver. 1.6 or later).
Click on OK in the Options window.
The Options window closes.
STEP 7
"
Click on the Connect button to connect the computer to the robot controller.
The Connect button appears in a pressed state.
19
STEP 8
"
STEP 9
"
Click on the Transfer button.
The Transfer Environment Table window appears.
Check off the check box by clicking on the Hard setting field.
STEP 10
"
Click on the Transfer button.
The following message window appears confirming that you are sure to update the data.
Click on the Yes button.
20
STEP 11
"
STEP 12
"
STEP 13
"
The Transmitting hard setting table window appears displaying a bar graph that indicates the transfer progres s.
After the Transmitting hard setting table window disappears, turn the controller power OFF.
Turn the controller power ON.
The I/O assignment mode is switched.
21

2.3 Types and General Information about I/O Signals

This section describes the I/O signals for the Robot Controller. The I/O signals are grouped into user I/O signals and system I/O signals. User I/O signals are compatible with conventional signals, including the pin
pattern, in compat ibl e mode. Note that the connector pin meanings are dif ferent between standard mode and compatible mode. Some of the signal lines used for user I/O in compatible mode are used for system input in standard mode.
Additionally, part of the signal lines used for system I/O in compatible mode is used for command execution I/O signals in standard mode.
2.3.1 Standard Mode
In standard mode, 30 input points for command execution are used to direct program start and other instructions as I/O commands. The table below lists the types of I/O signals used in standard mode.
Ty pes of System I/O Signals Used in Standard Mode
Fixed by system
Type
System input 5
System output 12
Input for command execution
Output for command execution
Type
User input 12
No. of
points
30
18
No. of
points
Function
Robot stop, Enable Auto, interrupt skip, instantaneous stop (all tasks), step stop (all tasks)
Robot initialization complete, automatic operation mode, external mode, servo ON, robot-in-operation, normal CPU, robot failure, robot warning, dead battery warning, continue start permitted, SS mode, emergency stop
Command (4 bits) data area 1 (8 bits), data area 2 (16 bits), odd parity bit, strobe signal
Command processing complete, status area (16 bits), odd parity bit
Controlled by user program
Function
Inputs to read the external I/O status with an IN command or IO [ ] variable. Used for analysis condition identification, condition satisfaction wait, data input from the external device, etc.
User output 24
Hand input 8
Hand output 8
Outputs to issue a signal to the external device during program execution with a SET command, RESET command, etc.
Inputs to read the external I/O status with an IN command or IO [ ] variable. Used to confirm the end-effector check status, etc.
Outputs to issue a signal to the external device with a SET command, RESET command, etc. Used to control the opening and closing of the end-effector.
22
2.3.2 Compatible Mode
In the compatible mode, the input and output points are arranged in disregard of compatibility with conventional VS series robots.
The table below lists the types of I/O signals used in compatible mode.
Types of I/O Signals Used in Compatible Mode
Fixed by system
Type
System input 22
System output 27
Type
User input 25
User output 24
Hand input 8
No. of
points
No. of
points
Function
Inputs to turn ON the power to the robot from the external device (PLC), start CAL or select and start a program instead of operations by the operating panel or teach pendant.
Outputs to inform the external device (PLC) of the robot status, such as robot-in-operation or occurrence of an error.
Controlled by user program
Function
Inputs to read the external I/O status with an IN command or IO [ ] variable. Used for analysis condition identification, condition satisfaction wait, data input from the external device, etc.
Outputs to issue a signal to the external device during program execution with a SET command, RESET command, etc.
Inputs to read the external I/O status with an IN command or IO [ ] variable. Used to confirm the end-effector check status, etc.
Hand output 8
Outputs to issue a signal to the external device (valve) with a SET command, RESET command, etc. Used to control the opening and closing of the end-effector.
23

2.4 Using User I/O Signals (common to both modes)

To use user I/O signals you need to first declare, in the program, the use of u ser I/O as I/O type variables with a DEFIO command. Next, access the user I/O by writing it to the I/O type variables or reading it.
2.4.1 I/O T ype Variable Declaration
I/O type variables are classified into I/O type global variables that are available without any declaration, and I/O type local variables that are not available without a declaration.
2.4.2 I/O T ype Global Variables
I/O type global variables are used to refer to or change user I/O signals bit by bi t. Since they are global variab les, they can be used without any declaration.
I/O type global variables are expressed in either of the following two ways: IO[nn] (nn: terminal number) Example: IO[104]
IOnn (nn: terminal number) Example: IO104
2.4.3 I/O Type Local Variables
I/O type local variables are used to collectively refer to or change 1-bit, 8-bit, 16-bit or 32-bit user I/O signals starting from a specified terminal number.
I/O type local variables require a declaration, which will be made with a DEFIO command, before they are used. For further information about declarations with a DEFIO command, refer to the PROGRAMMER'S MANUAL (I), Chapter 9, Section
9.7 "DEFIO (Statement) [Conforms to SLIM]."
2.4.4 User Input Commands
There are two types of user input commands, IN and WAIT. The IN command substitutes the input result for a variable. The WAIT command waits until the input result meets specified conditions.
IN Command
The IN command inputs a signal from the user input specified by an IO type variable and substitutes it for an arith meti c variable.
For further information about the IN command, refer to the PROGRAMMER'S MANUAL (I), Chapter 13, Sect ion 13.1 "IN."
WAIT Command
The WAIT command suspends the execution of the program until specified conditions are met. If an I/O type variable is u sed for the condition al statement, this command suspends the execution of the program until the status of the signal from a specified user input is checked and meets the specified conditions. For further information about the WAIT command, refer to the PROGRAMMER'S MANUAL (I), Chapter 12, Section 12.5 "WAIT."
24
2.4.5 User Output Commands
There are three types of user output commands, SET, RESET and OUT. The SET and RESET commands turn ON and OFF all user outputs specified by I/O type variables. The OUT co mma nd outputs data to a specified user output.
SET Command
The SET command turns ON all user outputs specified by I/O type variables. For further information about the SET command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "SET."
RESET Command
The RESET command turns OFF all user outputs specified by I/O type variables. For further information about the RESET command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "RESET ."
OUT Command
The OUT command outputs data to the user output specified by an I/O type variable. For further information about the OUT command, refer to the PROGRAMMER'S
MANUAL (I), Chapter 13, Section 13.1 "OUT."
25
Chapter 3
System I/O Signals Standard Mode
3.1 Types and Functions of System Output Signals (Standard
Mode)
The table below lists the system output signals used in standard mode.
Types and Functions of System Output Signals to be Used in Standard Mode
Application Signal name Function
Robot initialization
complete
Auto mode
Start-up
External mode Outputs when the robot is in external mode.
Servo ON
Program execution Robot-in-operation
Normal CPU
Robot failure
Error/Warning
Robot warning Outputs wh en a slight err or occ urs .
Dead battery warning
Continue start
Continue start
permitted
Outputs when preparations for operation are ready to start.
Outputs when the robot is in Auto mode.
Outputs when the power to the motor is turned ON. Outputs when the robot is in operation (the program is
being executed). Outputs when the CPU (hardware) of the Robot
Controller is normal. Outputs when a serious error, such as a servo error
and a program error, occurs.
Outputs when the voltage of the encoder back-up battery or memory back-up battery dangerously low.
Outputs when Continue Start is enabled.
Safe start function SS mode
Emergency stop Emergency stop
Outputs when the robot is in SS mode. Refer to the SETTING-UP MANUAL, Chapter 3, Subsection 3.4.6 "SS (Safe Start) Function."
Outputs from a contact exclusively designed for an emergency stop circuitry.
26

3.2 Usage of System Output Signals (Standard Mode)

L
T
o
The usage of each system output signal in standard mode is described below :

3.2.1 Robot Initialization Complete (Output)

(1) Function
The signal outputs to the external device that a MODE SWITCHING COMMAND is ready to execute from the device.
(2) Terminal number
No.5 of connector CN10.
(3) Usage
The "mode switching command" will be executed as soon as this signal and the auto mode signal are turned ON, aft er t he power is turned ON.
(4) ON conditions
The signal will be turned ON when the system program for the Robot
Controller normally starts, after the power, is turned ON and the mode switching command is ready to execute.
The signal will be turned ON when a robot failure is cleared by the
CANCEL key of the operating panel or teach pendant or by a CLEAR ROBOT FAILURE command, after the power is turned OFF.
ROBOT PO WER ON COM P LET E output
(5) OFF condition
The signal will be turned OFF when a robot failure or robot warning signal is turned ON.
A robot error is cleared with the OK or CANCE
The system properly started t
operate after the power was turned ON.
⋅ Robot error or robot warning
Robot Power ON Complete Output
key of the operating panel or teach pendant.
A robot error is clear ed wi th a CLEAR ROBO
FA ILURE com m and from an ex ternal device.
27
3.2.2 Auto Mode (Output)
L
(1) Function
The signal outputs to t he ext ernal device that the robot is in auto mode.
(2) Terminal number
No.6 of connector CN10.
(3) Usage
Starting the program from the external device requires an EXTERNAL MODE SWITCHING BY MODE SWITCHING COMMAND input and a PROGRAM START BY PROGRAM OPERATION COMMAND input. The signal is used to monitor the auto mode output signal and determine whether to execute the command.
(4) ON condition
The signal will be output when the robot enters auto mode by setting the mode selector switch of the operating panel or teach pendant to AUTO.
(5) OFF conditions
The signal will be turned OFF under the following conditions. The mode selector switch of the operating panel is set to MANUAL or the
teach pendant is set to MAN UAL or TEACH CHECK.
The Enable Auto OFF is input..
(Note: The signal will not be turned OFF in the pendantless state described in the OPTIONS MANUAL, Chapter 1, Subsection 1.3.3.)
Auto mode output
Caution: Th e signal will not b e turned OFF w ith INSTANTANEOUS STOP,
STEP ST OP or CYCLE STOP commands.
When the mode selector switch of the operating panel or teach
pendant is set to AUTO.
When the mode selector switch of the operating panel is set
to MANUAL or that of the teach pendant is set to MANUA or TEACH CHECK.
When Enable Auto OFF is input
Auto mode Output
28

3.2.3 External Mode (Output)

(1) Function
The signal outputs to t he ext ernal device that the robot is in external mode.
(2) Terminal number
No.7 of connector CN10.
(3) Usage
Starting the program from the external device requires an EXTERNAL MODE SWITCHING BY MODE SWITCHING COMMAND input and a PROGRAM START BY PROGRAM OPERATION COMMAND input. The signal is used to confirm that the robot is in external mode.
(4) ON conditions
The signal will be turned ON under the follow i ng conditions.
The external mode is selecte d on t he t each pendant.
The EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTER NA L CONTROL ON state.
The EXTERNAL MODE SWITCHING BY MODE SWITCHING
COMMAND is input from the external device.
(5) OFF conditions
The signal will be turned ON under the following conditions.
When internal mode is selected on the teach pendant.W hen the mode selector switch of the teach pendant is set to MANUAL
or TEACH CHECK in ex t ernal mode.
W hen EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTER NA L CONTROL OFF state.
When ROBOT STOP is input.When ROBOT FAILURE is outputted.
External mode output
Caution: Th e signal will not b e turned OFF w ith INSTANTANEOUS STOP,
STEP STOP or CYCLE STOP.
When an Enable Auto input is turned OFF.
When the mode is switched to external mode on the teach pendant.
When EXTERNAL/INTERNAL is input on the operating panel.
When a MODE SWITCHING COMMAND (EXTERNAL MODE SWITCHING) is input from an external device.
When internal mode is selected on the teach pendant.
When the mode selector switch of the teaching pendant is set to MANUAL or TEACH CHECK.
When EXTERNAL/INTERNAL is input on the operating panel.
ROBOT STOP or ROBOT ERROR
When an Enable Auto input is turned OFF.
External Mode Output
29

3.2.4 Servo ON (Output)

(1) Function
The signal outputs to the external device that the power to the motor of the robot is turned ON.
(2) Terminal number
No.4 of connector CN10.
(3) Usage
Start i ng t he program requires the power to the motor to be turned ON. This signal is used to light the motor power ON indicator lamp on an external operating panel.
(4) ON conditions
The signal will be turned O N when t he power to the motor is turned ON. When the MOTOR key of the operating panel or teach pendant is
activated; or
When the motor runs with a MOTOR ON AND CAL EXECUTION BY
MODE SWITCHING COMMAND input from the external device.
(5) OFF conditions
The signal will be turned OFF when the power to the motor is turned OFF. When the MOTOR key of the operating panel or teach pendant is
deactivated and the ROBOT STOP button is oper ated;
When ROBOT STOP is input from the external device; or When a ROBOT FAILURE is outputted. If errors 0 × 6071 to 607B, 0 ×
6671 to 667B, 0 × 607F occur, the servo will be turned OFF in automatic or external mode but will not be turned OFF in the manual or the teach check mode.
ON
Servo ON output OFF
When the MOTOR key of the operating panel or teach pendant is activated.When MOTOR ON AND CAL EXECUTION WITH MODE SWITCHING
COMMAND is input from an external device.
When the MOTOR key of the operating panel or teach pendant is
deactivated and the ROBOT STOP button is operated.
When ROBOT STOP is input from an external device.When a ROBOT FAILURE occurs.
Servo ON Output
30

3.2.5 Robot-in-operation (Output)

(1) Function
This signal outputs t o t he external device that the robot is in operation.
(2) Terminal number
No.2 of connector CN10.
(3) Usage
The signal is used to light the robot operating indicator lamp of an external operating panel.
Since the signal is turned OFF with STOP ALL PROGRAMS, outputs to the external device that all programs are stopped.
(4) ON conditions
The signal will be turned ON during execution of the program and also while in the WA I T STATE with a condition branch or t imer command.
(5) OFF conditions
The signal will be turned OFF with STOP ALL PROGRAMS.
Caution: STOP ALL PROGRAMS means the operation of the ROBOT
STOP or STOP button of the operating panel or teach pendant and INSTANTANEOUS STOP (ALL TASKS), STEP STOP (ALL TASKS) and ROBOT STOP inputs.
31
3.2.6 Normal CPU (Output)
A
(1) Function
The signal outputs to the external device that the Robot Controller CPU (hardware) is normal.
(2) Terminal number
No.1 of connector CN10.
(3) Usage
The signal is used to light the Robot Controller external operating panel
error indicator lamp.
The signal is used when a normal CPU SIGNAL is turned OFF because
of an error and the PLC corrects it.
(4) ON conditions
The signal will be turned ON by the hardware when the Robot Controller CPU operates normally with the power turned ON.
(5) OFF conditions
The signal will be turned OFF by the hardware when the CPU does not operate normally.
Normal CPU output
Caution: The OFF state of this signal indicates that the Robot Controller
internal arithmetic circuit may be damaged. Therefore, ROBOT ERROR, ERROR NUMBER, and other outputs may not be correct.
Power ON (CPU operating properly)
bnormal CPU (hardware error)
Normal CPU Output
32

3.2.7 Robot Failure (Output)

(1) Function
The signal outputs to the external device that a problem (such as a servo error or a program error) occurs with the robot.
(2) Terminal number
No.3 of connector CN10.
(3) Usage
The signal is used to light the robot external operating panel error
indicator lamp of an.
The signal is used to help the PLC clear an error in response to a
ROBOT FAILURE signal.
(4) ON conditions
As shown below, the signal will be turned ON under the following conditions.
When an error, such as a servo error, a program error or program
undefined, occurs at the start of the program and during execution of the program.
When an error occurs during execution of the program in internal
operation by the operating panel or the teach pendant or in external operation by the PLC.
Robot failure
Caution: The signal will not be outputted when an error, such as a
program input error occurs in manual operation, except when a servo error occurs in manual operation. For further information, see the "ERRO R CODE TABLES. "
(5) OFF conditions
As shown below, the signal will be turned OFF under the following conditions.
When a CLEAR ROBOT FAILURE command is inputted and the
existing error is cleared.
W hen the existing error is cleared by operating the OK or Cancel key
on the operating pane l or t he t each pendant.
Program number, parity error, or undefined program number, at
external start.
Robot failure during automatic operation (both internal operation
and external operation)
When a CLEAR ROBOT FAILURE command is inputted.W hen the OK or Cancel key of the operating panel or teach
pendant is operated.
ƒpƒŠƒeƒB [ƒGƒ‰ [ A
Robot Failure Output
33

3.2.8 Robot W arning (Output)

(1) Function
The signal outputs to the external device that a minor error occurs with an I/O command or during servo processing.
Caution: The signal will not be outputted if a minor error, such as a
program selection error occurs by the operation of the teach pendant or operatin g panel.
(2) Terminal number
No.9 of connector CN10.
(3) Usage
The signal is used to light t he robot warning indi cator lamp of the external
operating panel.
The signal is used to help the PLC clear an error in response to a
ROBOT WA RN ING signal.
(4) ON condition
As shown below, the signal will be turned ON if a minor error occurs during I/O processing, execution of the program or servo processing, irrespective of the operation mode.
Robot warning
(5) OFF conditions
As shown below, the robot-warning signal will be turned OFF under the following conditi ons. When a CLEAR ROBOT WARNING command is inputted from the
external device and the existing error is cleared.
When operating the OK or Cancel key on the operating panel or the
teach pendant clears the exist in g error.
W hen a slight error occurs during I/O processing, execution of the
program or servo processing.
When a CLEAR ROBOT WARNING command is inputted from an
external device and the existing error is cleared .
W hen the existing error is cleared by operating the OK or Cancel key
of the operating panel or teach pendant.
Robot Warning Output
34

3.2.9 Dead Battery Warning (Output)

(1) Function
The signal will be output when the voltage of the encoder back-up battery or memory back-up battery becomes lower than acceptable.
(2) Terminal number
No.8 of connector CN10.
(3) Usage
The signal is used to check the timing battery replacement. For example, the battery voltage beco me s lower than acceptable.
(4) ON condition
The signal will be turned ON when the voltage of the encoder back-up battery or memory back-up battery beco mes lower t han acceptable.
Caution: The operating panel shows any of ERROR64A1 to 64A6 when
the encoder back-up battery voltage is low. Meanwhile, the teach pendant shows ERROR6103 when the memory back-up battery voltage is low.
(5) OFF condition
The signal will be turned OFF when the power is turned ON after the dead battery was replaced.
Robot power ON state
Dead battery warning output
Power ON
The voltage of the
encoder backup battery or memory back-up battery becomes dangerously low.
Dead Battery Warning Output
Power OFF
Power ON
Power OFF
Battery replaced
Power ON
35

3.2.10 Continue Start Permitted (Output)

(1) Function
The controller will output t his signal when the continue start is per mit ted.
(2) Terminal number
No.10 of connector CN10.
(3) Usage
Use this signal when you want to know whether the continue start is permitted.
(4) ON condition
This signal comes on when the continue start is permitted. For details, refer to the SETTING-UP MANUAL.
(5) OFF condition
This signal goes of f by carrying out the "Task Status Change Operation."

3.2.11 SS mode (Output)

(1) Function
The controller will output t his signal during the SS mode. This mode is effective when the slow mode is selected.
(2) Terminal number
No.11 of connector CN10
(3) Usage
This signal is used to warn workers that the robot is in the SS mode by beeping or lighting the lamp.
(4) ON condition
This signal comes on when th e SS mode is selected.
(5) OFF condition
The signal goes off when the TS time passes so as to cancel SS mode. This function is eff ect ive when the slow mode is selected.
Note: If the TS time passes, this signal goes off even when the robot is operation in the slow mode. After this signal goes off, the robot runs at the original speed.
36

3.2.12 Emergency Stop (Output from a contact)

(1) Function
This signal outputs from a contact exclusively designed for an emergency stop circuitry you may configure. It allows red mushroom buttons provided on the front panel of the robot controller, on the teach pendant, and on the operating panel to be us ed as emergency stop buttons of the facilities.
A 0.3A fuse is built in the contact.
(2) Terminal number
No. 65 of connector CN10: Emerge ncy stop (+) No. 66 of connector CN10: Emerge ncy stop (-)
(3) Usage
This signal is used to stop the facilities or robot in an emergency. (Refer to Subsection 5.2.4 "Emergency Stop Circuit.")
(4) Contact
This contact is a normal close one (b contact). If any of the emergency stop buttons is pressed, then the contact turns off to output an emergency stop signal.
37
3.3 Types and Functions of System Input Signals (Standard
Mode)
The table below lists the system input signals to be used in standard mode:
Types and Functions of System Input Signals to be Used in Standard Mode
Application Signal Name Function
Start-up Enable Auto
Robot stop Stops the robot with canceling signals.
Stop
Program interrupt Interrupt skip
Instantaneous
stop (all ta sks)
Step stop (all
tasks)
Enables switching to automatic operation.
Immediately stops all programs being executed with canceling signals.
Step-stops all programs being executed with canceling signals.
Interrupts the execution of the current step and starts executing the next step.
38

3.4 Usage of System Input Signals (Standard Mode)

The usage of each system in put signal in standard mode is described below.

3.4.1 Enable Auto (Input)

(1) Function
The signal enables switching of the robot mode to auto mode (shorted
state).
The signal enables switching of the robot mode to manual mode or
teach check mode (open state).
(2) Terminal number
No. 4 of connector CN8.
(3) Usage
The signal is used for the AUTO/TEACHING selector switch of an external operating panel and can be combined with a safety fence switch.
(4) Input conditions and operation
As shown below, the selectable operation mode depends on whether
this input is shorted or open.
If the input becomes open during automatic operation, the mode will be
switched to manua l mode and ERROR21FC will be displayed.
If manual operation or a teach check is conducted with this input
shorted, ERROR21F2 w ill be displayed.
If the mode selector switch of the teach pendant or operating panel is
set to AUTO wit h t h is input open, ERROR21F3 will be displayed.
Since this state is shown as × in the table below, this error will remain
displayed until the robot exits this state.
Although ERROR21FD or ERROR21FC will be displayed when the
state is changed from state is changed fro m or × to
When the input is turned OFF (open) in external mode, the external
mode output will also be turned O FF.
Relationship Between Enable Auto Input and Selectable Mode
¡ to or ×, they will not be displayed when the
¡.
Operation mode Application
Manual mode
Teach check mode Program check with the teach pendant. ¡ Internal auto mode
External auto mode Automati c operation with the external device. ¡ ×
Note: ¡ = Mode selectable × = Mode not selectable
= Mode selectable but manual o peration program not executable
Manual operation with the operating panel or the teach pendant.
Automatic operation with the operating panel or teach pendant.
Caution: In the pendantless state, auto mode is valid even if the Enable Auto
input is open. (The external mode cannot be switched and the program cannot begin execution.) Perform the following when operating the robot in the pendantless state:
QQQQ
Set the robot so that it will not start to operate when the Enable Auto input is open.
RRRR
Enable Auto input open state and auto mode output (See Subsections 4.2.2 and 6.2.2 "Auto Mode".) Set the equipment to make an emergency stop in an AND state.
Add
QQQQ
and
RRRR
with the external sequence circuit.
ON (shorted) OFF (open)
Enable Auto
¡
¡ ×
39

3.4.2 Robot St op (Input)

(1) Function
The signal stops the robot from the external device by opening the
robot stop input.
The signal readies the power to the robot motor to be turned ON by
shorting the robot stop input.
(2) Terminal number
No.2 of connector CN8.
(3) Input conditions and operation
The robot stops with this input OFF (open).The power to the robot motor is made ready to be turned ON with this
input ON (shorted).
Irrespective of whether internal mode, operation by the teach pendant,
or external mode, remote operation by the external device, is selected, the power to the robot motor cannot be turned ON with this input OFF (open) and neither manual nor automatic operation can be performed until this input is turned ON (s horted). (ERROR2008 will be displayed.)
By turning OFF (open) this input the following co nditions may result.
1) The power to the motor will be turned OFF irrespective of whether
2) During execution of the program (Robot-in-operation signal ON), the
3) When the program is not executed in manual and auto modes in
Opening the ROBOT STOP input and pressing the ROBOT STOP
button of the operating p anel or the teach pendant function is the same.
manual, automatic, internal or external mode is selected. power to the motor will be turned OFF and the mode will be
switched to internal mode a f ter the robot decelerates to a stop; manual and auto modes, everything will be the same except the
power to the motor will be turned OFF. The power to the motor can be turned ON and the suspended operation can, therefore, be resumed by shorting the ROBOT STOP input. (However, the program will be executed from the beginning.)
(4) Timing of the input
This input will be processed prior to all commands and input signals.
40

3.4.3 Step Stop (All Tasks) (Input)

(1) Function
Input this signal to step-stop the program being executed from the external device. All t asks will be step-stopped.
(2) Terminal
No.5 of connector CN8.
(3) Input conditions and operation
If the state of this signal is changed from ON (shorted) to OFF (open),
the robot will stop all tasks as soon as the ongoing step is completed, and the Robot-in-operation signal will be turned OFF. However, auto mode or external m ode will remain valid, and the suspended program will be resumed by inputting a program operation command (start). See the figure given below.
For resuming the program after a step stop, see Chapter 5, Subsection
5.3.2 "Program Operation Command (000 1)".
Robot status
Program start signal (input) ON (shorted)
OFF (open)
Step-stop signal (input) ON (shorted)
OFF (open)
Robot-in-operation (output) ON (shorted)
OFF (open)
Operating halfway
Step Stop Signal
1-cycle operation
At step-stop
Performing Remaining operation
41

3.4.4 Instantaneous Stop (All Tasks) (Input)

(1) Function
Input this signal to instantaneously stop the running programs from an external device. All tasks will stop.
(2) Terminal number
No.7 of connector CN8.
(3) Input conditions and operation
If the state of this signal is turned from ON (shorted) to OFF (open), the
robot will immediately stop in the middle of the ongoing step, and the Robot-in-operation signal will be turned OFF. However, auto mode or external mode will remain valid, and the suspended programs will be resumed by inputting Program start signal.
For resuming the program after an instantaneous stop, see Chapter 5,
Subsection 5.3.2 "Program Operation Command (0001)".
The minimum required pulse width is 50 milliseconds (msec.) or more.
ON (shorted)
Halt OFF (open)
50 ms. or more required
Minimum Instantaneous Stop Pulse Width
42

3.4.5 Interrupt Skip (Input)

(1) Function
If this signal is turned ON (shorted) during execution of the robot operation command, within the range between INTERRUPT ON and INTERRUPT OFF in the program, the correct step operation will immediately stop and the next step will start.
Caution: For further information about the INTERRUPT ON and OFF
commands, see the PROGRAMMER'S MANUAL (I), Chapter 12, "12.3 INTERRUPT ON/OFF (Statement)." For further information about the robot operation command, see the PROGRAMMER'S MANUAL (I), Chapter 12, "Robot Control Statements."
(2) Terminal number
No.9 of connector CN8.
(3) Usage
See the PROGRAMMER'S MANUAL (I), Chapter 12, "12.3 INTERRUPT ON/OFF."
(4) Input conditions and operation
If this signal is turned ON (shorted), the robot will immediately stop the current operation and start executing the next step.
Robot status
Interrupt skip signal (input) ON (shorted)
OFF (open)
Input Conditions and Operation of Interrupt Skip
INTERRUPT ON
Command
Operating halfway
Next operation
50 ms. or more required
43
Caution: When turning ON (shorting) the interrupt skip signal, at a
minimum either the program reset signal or the program start signal must be turned OFF (open). If the interrupt skip signal is turned ON, the robot interprets the program start signal as immediatel y turned OFF (open). Consequently, the program selected with the program No. selection signal will be executed from the beginning. (See the figure given below.)
Robot status
Interrupt skip signal (input) ON (shorted)
OFF (open)
Program start signal (input) ON (shorted)
OFF (open)
Program reset signal (input) ON (shorted)
OFF (open)
Program No. select signal (input) ON (shorted)
OFF (open)
Example of Operation When an Interrupt Skip is Input
Executing cycle halfway
WRONG
Executing cycle from beginning
44
3.5 Command Execution I/O Signals
Dedicated to Standard Mode
In standard mode the I/O commands can be executed using command execution I/O signals. I/O commands execute the following.
Operate (start and stop) a program for each t ask. Refer to or change variables from the external device. Refer to or change inputs and out puts from the external device.
3.5.1 General Information about Commands
The table below shows the I/O commands functions.
I/O Command Functions
Command Description of function
Starts the program cycle (specified program). Step-stops the program (specified program/all programs).
Program operation
Immediately stops the program (specified program/all
programs).
Speed setting
Error number read
Type I variable write
Type I variable read
Mode switching
Clear robot failure
Internal I/O write Internal I/O read
Resets the program (specified program/all programs). Sets the external speed. Sets the external acceleration. Sets the external deceleration. Outputs the error number to the system I/O area.
Reads a value from the system I/O area and substitutes it for a
Type I variable.
Outputs a Type I variable to the system I/O area. Switches the robot operation mode. Clears a robot failure from the external device. Sets the state of internal inputs and outputs. Outputs the state of internal inputs and outputs to the system I/O
area.
45
3.5.2 Processing I/O Commands
3.5.2.1 General Information about Processing
I/O commands to be executed are processed as shown below.
Command Area (input)Data Area (input)Command and Data Area
Odd Parity (input)
Strobe Signal (input)
Status Area (output)
Status Parity (output)
Command processing complete (output)
Q
Note 1 ms or more
X
S
X
R
U
Y
Y
V
Robot Error (output)
Note 100 ms. or less
V
Outline of I/O Command Processing
46
Set a command area, a data area (if necessary) and command and data
area odd parity for the command execution I/O signal from the external device to the Robot Controller.
After the setting is completed, turn ON the strobe s ign al.
Caution: QQQQ The data to be set in QQQQ must be defined more at least 1
msec. before the strobe signal is turned O N.
R
R Perform command input with a strobe signal after the
RR
system output signal ROBOT INITIALIZATION COMPLETE is output.
The controller reads the command area, the data area and the command
and data area odd par ity as the strobe signal is input.
The controller starts processing based on the command it read.
If the command is one that outputs a status, the controller sets the status
area and status parity.
After command processing has been completed and a status area has
been set, the controller turns ON the command processing complete signal.
If an error occurs in the while processing, a robot failure signal will be outputted together with the command processing complete signal.
The PLC waits until the command processing complete signal is input, and
receives the status of the status area, if necessary. In this case, confirmation that no error exists with the robot.
After the PLC has read the status, it turns OFF the command and data
areas and the strobe signal.
As soon as the strobe signal is turned OFF, the controller turns OFF the
status area and the command processing complete signal. The robot failure signal, which is outputted due to a command processing
error, rema ins ON until a CLEAR ROBOT FAILURE command is executed.
Caution: SSSS The maximum time taken until the status area and the
command processing complete signal are turned OFF, after the strobe signal is turned OFF in XXXX, is 100 msec.
T
T If the strobe signal is turned OFF before the command
TT
processing complete signal is turned ON in VVVV, the command processing complete signal and the status area will be output and then turned OFF within 100 msec.
47
3.5.2.2 Using Each Signal Line
[ 1 ] Command and Data Areas
This section describes the usage of the command area (4 bits, input), data area 1 (8 bits, input), data area 2 (16 bits, input) and command and data area odd parity (input).
(1) Function
Specif ies t he commands to be executed by the Robot Controller. Sets the command area at all times, and data areas 1 and 2, if necessary.
(2) Terminal numbers
Command area: No.35 to No.38 of connector CN8. Data area 1: No.11 to No.18 of connector CN8. Data area 2: No.19 to No. 34 of connector CN8. Command and data area odd parity: No.10 of connector CN8.
(3) Input conditions and operation
Set the command area whenever I/O commands are to be executed.
Set data for data areas 1 and 2 if commands require them.
"Shorted" represents the bit value = 1.
"Open" represents the bit value = 0. "Parity bit " is odd parity.
Input the command area, data areas 1 and 2, and command and data
area odd parity before the strobe signal (1 msec. or more). Retain the status until the command processing complete signal is output.
Input 1 or 0 as the parity bit so that the total of 1s existing in the
command area, data areas 1 and 2 and the command and data area odd parity will be odd The data areas count even commands, which do not require any data area, in a check sum calculation.
Checksum can be set valid or invalid using a parameter. When
checksum is invalid, no checksum check will be performed.
48
[ 2 ] Strobe Signal (Input)
(1) Function
This signal informs the Robot Controller that the command area, data areas 1 and 2, and the command and data area odd parity bit have been set. Additionally it directs the start of command processing.
Caution: Perform command input with a strobe signal after the system
(2) Terminal number
No. 8 of connector CN8.
(3) Input conditions and operation
By turning ON this input in automatic or external mode, the Robot
Controller reads the command area, data areas 1 and 2, and the command and data area odd parity bit starts processing.
Retain the status until a command processing complete signal is output
and the necessary status data is read. If the strobe signal is turned OFF before a command processing complete signal is output, the status area will not be output.
By turning OFF this input after the status is read, the command
processing complete output, the status area and the status parity will be turned OFF.
output signal ROBOT INITIALIZATION COMPLETE is output.
49
[ 3 ] Command Processing Complete (Output)
(1) Function
The signal outputs to the external device that I/O command processing is completed.
(2) Terminal number
No. 15 of connector CN10.
(3) Usage
The signal is used to confi rm that I/O command processing is complete, or as a timing signal for obtaining the result of I/O command processing.
(4) ON conditions
The signal will be turned ON upon completion of processing the I/O
command given and determination of outputting the status area.
If an error occurs a s a result of executing an I/O co mmand, the result
will not be output to the status area, but the robot failure signal and the command processing complete signal will be turned simultaneously ON.
(5) OFF conditions
The signal will be turned OFF when the strobe signal is turned OFF.If the strobe signal is turned OFF, before command processing is
completed, the command processing complete signal will be output and then turned OFF within 100 msec.
50
[ 4 ] Status Are a
This section describes the usage of the status area (16 bits, output) and of status area odd parity (output).
(1) Function
The signal outputs the result of I/O command processing to the external device.
(2) Terminal numbers
Nos. 17 to 32 of connector CN10.
(3) Usage
The signal is used to execute an I/O command and obtain the result of the PLC.
(4) ON conditions
When processing of the I/O given is completed, the status
corresponding to the command will be set.
"ON" represents the bit value = 1.
"OFF" represents the bit value = 0. "Parity bit" is odd parity.
Input 1 or 0 as the parity bit so that the total of 1s existing in the
command area and status area parity will be odd.
The status area counts even commands, which do not require any data
area, in a parity calculation.
Parity can be set valid or invalid with a parameter. When parity is
invalid, no parity check will be performed.
(5) OFF conditions
The signal will be turned OFF when the strobe signal is turned OFF.If the strobe signal is turned OFF, before command processing is
completed, the status signal will be output and then turned OFF within 100 msec.
51
3.5.3 I/O Commands Details
3.5.3.1 List of I/O Commands
The table below lists I/O commands.
List of I/O Commands
Command area Data area 1 Data area 2 Status area
0001 Program operation
0010 External speed and
acceleration setting
0100 Error read 0101 Type I variable
write 0110 Type I variable read
0111 Mode switching
1000 Clear robot failure 1001 I/O write 1010 I/O read
00000001 Program reset start 00000010 Program start 00000100 Continue start 00010000 Step stop 00100000 Instantaneous stop 01000000 Reset 00000001 Speed setting 00000010 Acceleration setting 00000100 Deceleration setting
Error
Type I variable number
Type I variable number
00000001 Motor ON, CAL execution 00000010 External speed 100 10000000 External mode switching 10000011 Execution of all above (Motor ON→CAL→SP100→External)

Set I/O value First internal I/O port
First internal I/O port
Program number Program number
(Note)
Program number Program number Program number Set speed value Set acceleration
value Set deceleration
value
Set variable value (lower 16 bits)

address
address
 
     
number
Variable value (lower 16 bits)
I/O
(Note) In execution of Continue Start command, program numbers will be ignored.
52
3.5.3.2 Program Operation Command (0001)
(1) Function
This command controls the operating state of the program specified in data area 2 based on the setti ng of data area 1.
(2) Format
Command area (4 bits, input) 0001
Data area 1 (8 bit s, input) 00000001: Program reset start 00000010: Program start 00000100: Continue start 00010000: Step stop 00100000: Instant aneous stop 01000000: Reset An error (ERROR2032) will occur if dat a i s ot her t han t he above is set.
Data area 2 (16 bits, input) Program number: Program number to start When the number given in data area 2 is nn, the operating state of PR0nn will be controlled as given in data area 1. If the program number is negative in the case of a step stop, instantaneous stop or reset command, all programs will stop or be reset. If the program number is negative with a program reset start or program start command, ERROR73E4 will result.
Stat us area (16 bits, output) Nothing will be output.
(3) Description
Program reset start
This command is execut able only in external mode. If executed in other mode an error will occur. This command initializes and starts the program of the program number specified in data area 2. PRO0 to PRO32767 can be started. If the program number specified in data area 2 is negative, an error (ERROR73E4) will occur. Either of the following operations takes place according to the operating status of the program:
If the specified program is terminated (stopped), step-stopped or
immediately stopped, it will start from the beginning.
If the specified program is running, an error (ERROR21F5) will be
displayed, and the program w ill stop.
53
Program start
This command is executable only in external mode. An error (ERROR2032) will occur in ot her modes. This command starts the program of the program number specified in data area 2. PRO0 to PRO32767 can be started. If the program number specified in data area 2 is negative, an error (ERROR73E4) will occur. One of the following operations takes place according to the operating status of the program.
If the specified program is terminated (stopped), it will start from the
beginning.
If the specified program is step-stopped, it will resume from the step
following the suspended step.
If the specified program is immediately stopped, it will resume from
the step following the suspended step. When the program is instantaneously stopped in while in execution of an operation command, it will resume from the o peration still undone.
If the specified program is running, an error (ERROR21F5) will be
displayed, and the program w ill stop.
Continue start
This command is executable only in external mode when the Continue Start Permitted signal is on. The data area will be ign ored.
Step stop
This command step-stops the program of the program number specified in data area 2. PRO0 to PR032767 can be step-stopped. If the program number specified in data area 2 is negative, all programs being executed will step-stop. Either of the following operations takes place according to the operating status of the program.
If the specified program is terminated (stopped), step-stopped or
immediately stopped, not hing will happen.
If the specified program is running, it will step-stop. If started after a
step stop, the stopped program will resume from the step following the suspended step.
Instantaneous top
This command immediately stops the program of the program number specified in data area 2. PRO0 to PR032767 can be stopped immediately. If the program number specified in data area 2 is negative, all programs being executed will step-stop. Either of the following operations takes place according to the operating status of the program:
If the specified program is terminated (stopped), step-stopped or
immediately stopped, not hing will happen.
If the specified program is running, it will immediately stop. If
started after an instantaneous stop, the stopped program will resume from the suspended step. If the program is immediately stopped in the middle of execution of an operation command, it will resume, starting from the last uncompleted operation.
54
Reset
This command immediately stops and also initializes the program of the program number specified in data area 2. PRO0 to PR032767 can be stopped. This command cannot be used together with the program start command. To start a step-stopped or cycle-stopped program from the beginning, use the program reset start command. If the program number specified in data area 2 is negative, all programs being executed will be reset. One of the following operations takes place according to the operating status of the program.
When the specified program is terminated (stopped), nothing will
happen.
When the specified program is step-stopped or immediately
stopped, it will be initialized. The initialized program will resume from the beginning.
W hen the specified program is running, it will immediately stop and
also be initialized. If started after an instantaneous stop, the stopped program will resume from the beginning.
55
3.5.3.3 External Speed and Acceleration Setting (0010)
(1) Function
This command sets the external speed, acceleration and deceleration values selected in data area 1 to the values specified in data area 2. This command is executable only in external mode. An error will occur in other modes.
(2) Format
Command area (4 bits, input) 0010
Data area 1 (8 bit s, input) 00000001: Speed setting 00000010: Accelerat ion setting 00000100: Deceleration set t ing An error (ERROR2032) will occur if dat a ot her t han the above is set.
Data area 2 (16 bits, input) Set values: Speed, acceleration and deceleration to be set Enter any of the external speed, acceleration and deceleration values specified in dat a area 1. The values must be between 1 and 100. If they are out of this range, an error (ERROR2003) will occur.
Stat us area (16 bits, output) Nothing will be output.
(3) Description
Speed setting
The external speed is set to the value specified in data area 2. The value must be between 1 and 100. An error (ERROR2003) will occur if the value is out of this range. The external acceleration and deceleration will be set simultaneously as shown below by setting the external speed: External acceleration and external deceleration = External speed (minimum value: 1)
Acceleration setting
The external acceleration is set to the value specified in data area 2. The value must be between 1 and 100. An error (ERROR2003) will occur if the value is out of this range.
Deceleration setting
The external deceleration is set to the value specified in data area 2. The value must be between 1 and 100. An error (ERROR2003) will occur if the value is out of this range.
2
/100
56
3.5.3.4 Error Read (0100)
(1) Function
This command outputs the ex ist i ng error number to the status area. This command is output to the status area only when the strobe signal remains ON.
Caution: This command will not be output if a minor erro r occurs, such
as a program selection error, caused by the operation of the teach pendant or the operating panel.
(2) Format
Command area (4 bits, input) 0100 Data area 1 (8 bit s, input) Nothing will be input. Data area 2 (16 bits, input) Nothing will be input. Stat us area (16 bits, output) The existing error code will be out put .
(3) Hexadecimal codes
Refer to the figure given below.
Thousands of error
Terminal No. (Connector CN10)
ERROR
The following figure shows an example of error number output when ERROR6174 (overload error with t he fourth axis) occurs.
32 31 30 29
× ¡¡ ×
6
(4) Description
×××× 0 סס 5 ¡×¡×→ A ××ס 1 ס¡×→ 6 ¡×¡¡ → B ×ס×→ 2 ס¡¡ → 7 ¡¡×× → C ×ס¡ 3 ¡××× 8 ¡¡×¡ D ס×× 4 ¡×ס 8 ¡¡¡×→ E ¡⋅⋅⋅ON
¡¡¡¡ → F ×⋅⋅⋅⋅OFF
Hundreds of error No.
28 27 26 25
×× ×¡
1
Example of Error Number Output
Tens of error No.
24 23 22 21
× ¡¡ ¡
7
Units of error No.
20 19 18 17
× ¡ ××
4
If a command is executed when a robot failure or the robot warning signal is output, the error number, which caused the robot failure or robot warning signal to be output, will be output to the status area. If no error exists after an error has been cleared, 0 will be output to the status area. Also, when there is an error that does not output any robot failure or robot warning signal, 0 w il l be o ut putted.
57
3.5.3.5 T ype I Variable W rite (0101)
(1) Function
This command substitutes the value specified in data area 2 for the Type I (integer type) global variable of the number specified in data area 1.
(2) Format
Command area (4 bits, input) 0101
Data area 1 (8 bit s, input) The number of the Type I variable for which a value will be substituted. Any number between I[0] and I[255] can be specified. When the input data in data area 1 is nn, the value specified in data area 2 will be substituted for the Ty pe I variable I [nn].
Data area 2 (16 bits, input) The value to be substituted for the Type I variable specified in data area 1. Any value between -32768 and 32767 can be set.
Stat us area (16 bits, output) Nothing will be output.
(3) Description
The value specified in data area 2 is substituted for the Type I variable specified in dat a area 1. Although the type I variable has a storage area of 32 bits, the 16-bit data in data area 2 will be substituted for the lower 16 bits. Zero will be substituted for the upper 16 bits of the Type I variable.
58
3.5.3.6
Type I Variable Read (011 0)
(1) Function
This command outputs to the status area the value of the Type Ι (integer type) global variable o f the number specified in data area 1.
(2) Format
Command area (4 bits, input) 0110
Data area 1 (8 bit s, input) The number of the Type I variable for which a value will be substituted. Any number between I [0] and I [255] can be specified. When the input data in data area 1 is nn, the value specified in data area 2 will be substituted for the Type I variable I [nn].
Data area 2 (16 bits, input) Nothing will be input.
Stat us area (16 bits, output) The lower 16 bit value of the Type I variable specified in data area 1 will be output.
(3) Description
The value of the Type I variable specified in data area 1 is output to the status area. Although the Type I variable has a storage area of 32 bits, the lower 16 bits will be output t o t he status area. Therefore, any value between -32768 and 32767 can be output properly. However, if the value is out of this range, only the lower 16 bits of the data will be output.
59
3.5.3.7 Mode Switching (0111)
(1) Function
This command switches the robot mode from the external device to prepare the robot for operation. This command is executable only in auto mode. An error will occur in other modes. Before executing this command, select auto mode on the operating panel or the teach pendant.
(2) Format
Command area (4 bits, input) 0111
Data area 1 (8 bit s, input) Bit 0 (00000001): Motor ON, CAL execution Bit 1 (00000010): External speed 100 Bit 7 (10000000): External mo de sw it ching These bits can be set together to execute commands. When two or more bits are set, commands will be ex ecut ed one after another.
For example, when bits 0, 1 and 7 are set, motor ON, CAL execution, external speed 100 and external mode will be executed in this order. If bits other than the above are set, an error will result.
Data area 2 (16 bits, input) Nothing will be input.
Stat us area (16 bits, output) Nothing will be output.
(3) Description
This command is used for equipment using the robot to switch the operation mode of the robot to externa l mod e from the external device
The processing operations to be executed are specified by the bits set in data area 1 and will be executed from bit 0 to bit 7.
Motor ON, CAL execution (bit 0)
When this bit is set, the power to the Robot Controller motor will be turned ON and CAL will be executed. If CAL is executed once after the power is turned ON, no processing wil l take place.
60
External speed 100 (bit 1)
When this bit is set, the external speed, external acceleration and external deceleration of the Robot Controller will be set to 100.
External mode switching (bit 7)
When this bit is set, the mode of the Robot Controller will be switched from automatic to external.
61
3.5.3.8 Clear Robot Failure (1000)
(1) Function
This command clears a robot failure that has been caused.
(2) Format
Command area (4 bits, input) 1000
Data area 1 (8 bit s, input) Nothing will be input.
Data area 2 (16 bits, input) Nothing will be input.
Stat us area (16 bits, output) Nothing will be output.
(3) Description
If a robot failure occurs, this command clears it. When there is no failure, no processing will ta ke pl ace When an error is displayed, the same processing as when the OK or Cancel key of the operating panel or the teach pendant is operated will be performed.
62
3.5.3.9 I/O Write (1001)
(1) Function
This command substitutes the status specified in data area 1 for the 8-bit internal I/O area starting from the number specified in data area 2.
(2) Format
Command area (4 bits, input) 1001
Data area 1 (8 bit s, input) The status to be set will be specified in the internal I/O area starti ng from the number specified in data area 2.
Data area 2 (16 bits, input) This is first number of th e internal I/O (8-bi t) area for which the status wil l be substituted. The number can be set between 128 and 504. If the number is out of this range, an error (ERROR2034) will occur.
Stat us area (16 bits, output) Nothing will be output.
(3) Description
This command substitutes the status specified in data area 1 for the 8-bit internal I/O area starting from the number specified in data area 2.
63
3.5.3.10 I/O Read (1010)
(1) Function
This command outputs to the lower 8 bits of the status area the status of the 8-bit internal I/O area starting from the numbe r specified in data area
2.
(2) Format
Command area (4 bits, input) 1010
Data area 1 (8 bit s, input) Nothing will be input.
Data area 2 (16 bits, input) This is the first numbe r of the i nternal I/O (8-bi t) are a whose status wil l be output. The number can be set between 128 and 504. If the number is out of this range, an error (ERROR2034) w i ll occur.
Stat us area (16 bits, output) The status of the 8-bit i nternal I/O a rea startin g f rom the number specifie d in data area 2 will be output to the lower 8 bits of this area.
(3) Description
This command outputs to the lower 8 bits of the status area the status of the 8-bit internal I/O area starting from the numbe r specified in data area
2. Zero will be output to the upper 8 bit s.
64

3.6 Example of Using System I/O Signals in Standard Mode

This section illustrates an example of starting and stopping the robot using system I/O signals.
(1) Equipment setup example
This example shown below assumes an equipment setup which allows you to run the robot by operating an external equipment’s operation panel connected via the PLC to the robot controller. It is assumed that the operation panel has a display, lamps and switches listed on t he next page.
Robot
Robot controller
Other equipment
(e.g. conveyor)
Operating panel
Example of Equipment Setup Using a Robot
PLC
65
Function Example of Equipment Operating Panel
Classificati
on
Display
Lamp
Switch
Part Application
Display
Q Automatic operation
indicator lamp
R Robot external mode
indicator lamp
S Operation OK indicator lamp
Q Robot preparation button Starts the preparation of the robot.
R Automatic start button Starts the operation of the equipment.
S Cycle stop button
T Operation/Adjustment
selector switch
Displays messages, such as ROBOT PREPARATION OK.
Lights during automatic operation.Turned OFF when the robot is not in automatic
operation.
Lights when the robot is in external mode.Turned OFF when the robot is not in external mode.
Lights when the Enable Auto signal is ON.Turned OFF when the Enable Auto signal is OFF.
Stops the equipment after a cycle of operations is completed.
Automatic operation of the robot possible when OPERATION is selected. Manual operation or teach check of the robot possible when ADJUSTMENT is selected.
Caution: Actual equipment requires emergency stop, interlock and other functions; however,
described here are the nece ssary functions.
(2) Outline of procedure
Described below is the outline of the procedure when using the equipment taken as an example shown on the previous page. Follow steps  to .
Operation preparation start
After setting the MOTOR ON, CAL EXECUTION, EXTERNAL SPEED 100 and EXTERNAL MODE SWITCHING bits, execute the mode switching command to bring the robot into external automatic operation mode. This operation will be completed when the EXTERNAL MODE output signal is turned ON.
Automatic operation
Start the program by which the robot starts from the operation origin, performs operations, and return s t o t he operat ion origin.
Operation end
Terminate the day’s operations with a cycle stop, and turn OFF the power.
(3) Start and stop procedure, and system I/O signals
The following pages show the relationship between the system I/O si gnals for start and stop, worker’s operation, display on the equipment operation panel, PLC procee di ng, and robot motion.
66
Step
r
r
g
K
Worker’s operation and display on
equipment’s operation panel
Equipment power ON
Setting operation/adjustment selector switch to operation
Operation OK indicato lamp ON
Setting Mode selecto switch of the operating panel or the teach pendant to AUTO
PLC processing Robot operation
Enable Auto ON
(Note )
(Internal processing)
Q
Q Operation preparation start
Q
Q
Robot preparation button ON
Robot external mode indicator lamp ON
Moving robot arm close to operation origin, when external mode indicator lamp is ON and operation position 1 indicator lamp is OFF.
Data area 1 input ON
Executing mode switchin
(Internal processing)
command
Motor power ON
Executing CAL
Setting SP 100
Switching mode to
external mode
External mode ON
R
R Operation start area check
R
R
Robot operation origin indicator lamp ON
Robot preparation O display
(Internal processing)
When both are ON
(Internal processing)
Operation position 1
Start and Stop Procedure and System I/O Signals-1
(Continued on following page)
67
(Continued from preceding page)
Step
Worker’s operation and display on
equipment’s operation panel
PLC processing Robot operation
S
S Automatic operation
S
S
Equipment’s Automatic
Start Button ON
Automatic Operation indicator lamp ON
Equipment’s Cycle Stop button ON
Program No. Select ON
Regular operation program is selected and output to data area 2.
Executing Program Operation Command (Program start)
Program No. select ON
Regular operation program is selected and output to data area 2.
Program start ON
Cycle Stop ON
Program start
END
Robot-in-operation
signal OFF
Repeated
Executing 1-cycle
END
T
T Operation end
T
T
Automatic operation indicator lamp OFF
Equipment power OFF
(Internal processing)
Robot-in-operation
signal OFF
Note SSSS In data area 1, the bit to each of "motor ON , CAL execution," "ex ternal spe ed 100" an d
"External Mode switching" will be turned ON. Refer to Chapter 5, Subsection 5.3.7 "Mode Switching (0111)".
T
T in the above figure indicates a system I/O signal, and ←←←represents the flow of
TT
signals.
Start and Stop Procedure and System I/O Signals-2
68
Chapter 4
System I/O Signals Compatible Mode
4.1 Types and Functions of System Output Signals (Compatible
Mode)
The table below lists the system output signals used in the compatible mode.
Types and Functions of System Output Signals to be Used in Compatible Mode
Application Signal name Function
Robot power ON
complete
Auto mode Outputs when the robot is in auto mode.
Start-up
Program pre-execution check
Program execution
Program end Single cycle end Outputs when the program completes a cycle.
Servo ON Outputs when the power to the motor is turned ON.
CAL complete Outputs when calibration is completed.
External mode Outputs when the robot is in external mode.
Teaching
Program start reset
Robot-in-operation
Continue start
permitted
Normal CPU
Outputs when preparations for operation are ready to start.
Outputs when the robot is in manual or teach ch eck mode.
Outputs when execution of the program starts in response to the program start signal received.
Outputs when the robot is in operation (the pr ogram is being executed).
Outputs when the continue start is permitted.
Outputs when the CPU (hardware) of the Robot Controller is normal.
Robot failure
Error/warning
Continue start Continue start permitted Outputs when Continue Start is enabled.
Safe start function SS mode
Emergency stop Emergency stop
Robot warning Outputs when a slight error occur s.
Dead battery warning
Error No.
Outputs when a failure (such as a servo f ailure and program error) occurs in the robot.
Outputs when the voltage of the encoder backup battery or memory backup battery lowers.
An error number wil l be outputted in BCD code if an error occurs.
Outputs when the robot is in SS mode. Refer to the SETTING-UP MANUAL, Chapter 3, Subsection 3.4.6 "SS (Safe Start) Function."
Outputs from a contact exclusively designed for an emergency stop circuitry.
69

4.2 Usage of System Output Signals in the Compatible Mode

r
The usage of each system output signal in the compatible mode is described below.

4.2.1 Robot Power ON Complete

(1) Function
The signal outputs to the external device that OPERATION PREPARATION START is possible.
(2) Terminal number
No.9 of connector CN10.
(3) Usage
OPERATION PREPARAT ION START will be executed after this signal and the auto mode signal are turned ON after the power was turned ON.
(4) ON conditions
The signal will be turned ON when the Robot Controller system
program properly starts. Preparations for operation can be started after the power was turned ON.
The signal will be turned ON when the robot failure is cleared by the
OK or Cancel key of the operating panel or the teach pendant or by CLEAR ROBOT FAILURE and OPERATION PREPARATION START signals, after the power was turned O F F.
ROBOT POWER ON COMPLETE output
(5) OFF conditions
The signal will be turned OFF when a robot failure or robot warning signal is turned ON.
A robot error is cleared by the OK or Cancel
key of the operating panel or teach
When a robot error was cleared with CLEAR
The system properly
starts to operate after the power is turned ON.
Robot erro
Robot Power ON Complete Output
ROBOT FAILURE and OPERATION PRE­PARATION START signals from the external device.
pendant.
70
4.2.2 Auto Mode (Output)
r
p
A
(1) Function
The signal outputs to the external device that the robot is in the auto mode.
(2) Terminal number
No.4 of connector CN10.
(3) Usage
Starting the program from the external device requires an SW ITCH EXT MODE input, a PROGRAM NO. SELECT input and a PROGRAM START input. The signal is used t o confirm that the robot is in the auto mode.
(4) ON conditions
The signal will be output when the robot enters the auto mode under the following conditi ons.
The mode selector switch of the operating panel or the teach pendant
is set to AUTO.
(5) OFF conditions
The signal will be turned OFF under the following conditions. When the mode selector switch of the operating panel is set to
MANUAL or t he teach pendant is set to MANUAL or TEAC H CHECK.
When Enable Auto OFF is input.
(Caution: The signal will not be turned OFF in the pendantless state described in the OPTIONS MANUAL, Chapter 1, Subsection 1.3.3.)
uto mode output
Caution: The signal will not be turned OFF with INSTANTANEOUS
STOP, STEP STOP or CYCLE STOP.
The Mode selector switch of the operating panel or the teach pendant is
set to AUTO.
SWITCH AUTO MODE and OPERATION PREPARATION START are
in
ut from the external device.
The mode selector switch of the operating panel is set to
MANUAL or that of the teach pendant is set to MANUAL o TEACH CHECK.
Enable Auto OFF is input.
Auto Mode Output
71
4.2.3 Servo ON (Output)
F
(1) Function
The signal outputs to the external device that the power to the robot motor is turned ON.
(2) Terminal number
No. 10 of connector CN10.
(3) Usage
Executing CAL from the external device or starting the program requires the power to the motor to be turned ON. This signal is used to confirm that the power to the motor is turned ON and to light the motor power ON indicator lamp on an external operat ing panel.
(4) ON conditions
The signal will be turned ON when the power to the motor is turned ON under the following condit ions. The MOTOR switch on the operating panel or the teach pendant is
activated.
MOTOR POWER ON + OPERATION PREPARATION START signals
are input from the external device.
(5) OFF conditions
The signal will be turned OFF when the power to the motor is turned OFF under the following condit ions. The MOTOR switch of the operating panel or the teach pendant is
deactivated and the ROBOT STOP button is operated.
ROBOT STOP is input from the external device.ROBOT FAILURE is outputted. If any of errors 0 × 6071 to 607B, 0 ×
6671 to 667B, 0 × 607F occurs, the servo ON signal will be turned OFF in External Auto mode but will not be turned OFF in manual or teach check mode.
Servo ON output
W hen th e MOTOR button of the operating panel or the teach pendant is
turned ON.
uMOTOR vON ì
W hen MOTOR POWER ON and OPERATION PREPARATION START
signals are input from the external device.
W hen the MOTOR button of the operating panel or the teach pendant is
turned OFF and the ROBOT STOP button is operated.
uMOTOR vOF
When a ROBOT STOP signal is input from an external device.When a ROBOT FAILURE occurs.
Servo ON Output
72

4.2.4 CAL Complete (Output)

(1) Function
The signal outputs to t he ext ernal device that CAL is compl et ed.
(2) Terminal number
No. 11 of connector CN10.
(3) Usage
This signal is used to deter mine whether to execute CAL. Once CAL is completed, it does not need to be executed again as long as the power to the Robot Controller is turned ON.
(4) ON conditions
The signal will be turned ON upon proper completion of CAL under the following conditi ons.
When CAL is performed by the operating panel or t each pendant.When CAL EXECUTION and OPERATION PREPARATION START
signals are input from the ext ernal device.
(5) OFF conditions
The signal will be turned OFF when CAL is not properly completed as shown below. It will remain O FF until CAL is perfor med again and properly completed.
CAL complete
CAL is performed by the teach pendant.CAL EXECUTION and OPERATION
PREPARATION START commands are input from the external device. (Prerequisite: MOTOR POWER ON)
Normal CAL end
CAL Complete Output
CAL is executed again.
When CAL has properly ended
When a CAL error occurs.
73
4.2.5 External Mode (Output)
p
(1) Function
The signal outputs to the external device that the robot is in the external mode.
(2) Terminal number
No. 5 of connector CN10.
(3) Usage
Starting the program from the external device requires an SW ITCH EXT MODE input, PROGRAM NO. SELECT input and a PROGRAM START input. The signal is used to confirm to the external device that the robot is in external mode.
(4) ON conditions
The signal will be turned ON under the following conditions. When INTERNAL/EXTERNAL is input on the teach pendant and the
external mode is selected.
W hen EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTER NA L CONTROL ON state.
When SW ITCH EXT MODE and OPERATION PREPARATION START
signals are input from the ext ernal device.
(5) OFF conditions
The signal will be turned OFF under the following conditions. W hen the mode selector switch of the teach pendant is set to MANUAL
or TEACH CHECK in ex t ernal mode.
When EXTERNAL/INTERNAL is input on the teach pendant and
external mode is selected.
W hen EXTERNAL/INTERNAL is input on the operating panel in AUTO
MODE and in the INTER NA L CONTROL OFF state.
When ROBOT STOP is input.When ROBOT F AI L URE is outp utt ed.
Caution: The signal will not be turned OFF with STEP STOP.
When an Enable Auto inp ut is t urned OFF.
When INTERNAL/EXTERNAL is input on the teach pendant and external mode is selected.When INTERNAL/EXTERNAL is input on the operating panel in AUTO MODE and in the
INTERNAL CONTROL ON state.
When EXTERNAL MODE SWITCHING and OPERATION PREPARATION START signals are
input from the external device.
ON
External mode output OFF
When internal mode is selected on the teach pendant.When INTERNAL/EXTERNAL is input on the teach pendant
and external mode is selected.
When INTERNAL/EXTERNAL is input on the operating panel in
AUTO MODE and in the INTERNAL CONTROL ON state.
When ROBOT STOP is input.When ROBOT ERROR is output.When an Enable Auto in
External Mode Output
ut is turned OFF.
74
4.2.6 Teaching (Output)
h
Š
Ž
(1) Function
The signal outputs to the external device that the robot is in the manual mode or teaches check mode.
(2) Terminal number
No. 12 of connector CN10.
(3) Usage
This signal is used to inf orm an exter nal operatin g panel that the robot is teaching when they are inst alled separately from each other.
(4) ON conditions
The signal will be turned ON when the mode selector switch of the operating panel or the teach pendant is set to MANUAL or TEACH CHECK, as shown below.
(5) OFF conditions
The signal will be turned OFF when the mode selector switch of the operating panel or teach pendant is set to AUTO and the Enable Auto input is turned ON.
Teaching
EƒIƒyƒŒ [ƒeƒBƒ“ƒOƒpƒlƒ‹‚Å uManual v‘€ ì
When the mode selector switch of the operating panel is set to
EƒeƒB [ƒ`ƒ“ƒOƒyƒ“ƒ_ƒ“ƒg‚Å uMANUAL v E uTeac
MANUAL.
Check v‘€ ì
When the mode selector switch of the teach pendant is set to
MANUAL or TEACH CHECK.
When the mode selector switch of the operating panel or the
EƒIƒyƒŒ [ƒeƒBƒ“ƒOƒpƒlƒ‹Ü‚½ÍƒeƒB [ƒ`ƒ“ƒ
teach pendant is set to AUTO and the Enable Auto input is turned ON from the external device.
Teaching Output
ƒyƒ“ƒ_ƒ“ƒg‚Å uAuto v‘€ ì A‚© “®‰^“]ƒCƒl [ƒuƒ‹“ü—Í‚ªON
O•”‚æ‚è
75
4.2.7 Program Start Reset (Output)
(1) Function
This signal is output to the external device when the robot receives a start signal from the external device and starts to operate.
(2) Terminal number
No. 6 of connector CN10.
(3) Usage
The signal is used to prompt the external device to receive information
that the robot program has started to run, and to process subsequent sequence programs.
The signal is used as a condition to turn OFF the PROGRAM START
signal sent from the external device to the robot.
(4) ON conditions
The signal will be turned ON immediately after the robot program starts to run, as shown below.
(5) OFF conditions
The signal will be turned OFF automatically when the PROGRAM START signal sent to the robot is turne d O FF.
Robot status
Program start signal (input) ON (shorted)
OFF (open)

Program start Reset (output)

Program Start Reset Output ON Condition
Single-cycle operation
Single-cycle operation
76

4.2.8 Robot-in-operation (Output)

(1) Function
The signal outputs to the external device that the robot is in operation (executing more than one task ).
(2) Terminal number
No. 2 of connector CN10.
(3) Usage
The signal is used to light the robot operating indicator lamp of the external operating panel. Since the signal is turned OFF with STOP ALL PROGRAMS, it outputs to the external device that all programs are stopped.
(4) ON conditions
The signal will be turned ON while executing the program and also in the Wait State with a condition branch or t i mer co mmand.
(5) OFF conditions
The program will be turned OFF with STOP ALL PROGRAMS.
Caution: STOP ALL PROGRAMS means the operation of the ROBOT
STOP or STOP button of the operating panel or the teach pendant and INSTANTANEOUS TOP (ALL TASKS), STEP STOP (ALL TASKS) and ROBO T STOP input s.
77

4.2.9 Single-Cycle End (Output)

(1) Function
The signal outputs to the external device that a single-cycle of the program is completed.
Caution QQQQ The single-cycle end signal will be output upon reading
END of the program. However, it will be output earlier th an the end of the actual robot operation because the Robot Controller pre-reads the program.
R
R The single-cycle end signal will be output on the premise
RR
that only one program is executed at a time. If two or more programs are executed simultaneously (multi-tasks), the single-cycle end signal w ill be turned ON immediately after any of the programs reads an E ND command.
(2) Terminal number
No. 13 of connector CN10.
(3) Usage
The signal is used to operate another equipment in synchronization with a single-cycle end of the program.
(4) ON conditions
(5) OFF conditions
Robot status
PROGRAM START input
1-CYCLE END
The signal will be turned ON when the program is read to the end.
The signal will be turned O FF i mmediately after the program starts to run.
Single-cycle operation
Single-Cycle End Output
Wait for start
Single-cycle operation
78

4.2.10 Normal CPU (Output)

(1) Function
The signal outputs to the external device that the CPU (hardware) of the Robot Control ler is normal.
(2) Terminal number
No. 1 of connector CN10.
(3) Usage
The signal is used to light the Robot Controller error indicator lamp of
an external operating pa nel.
The signal is used when the NORMAL CPU signal is turned OFF
because of an error and the PLC correct s it .
(4) ON conditions
The signal will be turned ON by the hardware when the CPU of the Robot Controller operates normally w ith t he pow er t urned ON.
(5) OFF conditions
The signal will be turned OFF by the hardware when the CPU does not operate normally.
Normal CPU output
Caution: The OFF state of this signal indicates that the internal
arithmetic circuit of t he Robot Controller may be damaged and ROBOT ERROR, ERROR NUMBER and other outputs may not be correct.
Power ON (CPU operates properly)
CPU error (hardware error)
Normal CPU Output
79

4.2.11 Robot Failure (Output)

(1) Function
The signal outputs to the external device that a problem, such as a servo error and a program error, occurs with the robot.
(2) Terminal number
No. 3 of connector CN10.
(3) Usage
The signal is used to light the robot failure indicator lamp of an external
operating panel.
The signal is used to help the PLC clear an error in response to a
ROBOT FAILURE signal.
(4) ON conditions
As shown below, the signal will be turned ON under the following conditions. W hen an error, such as a servo error, a program error and undefined
program, occurs at the start of the program and during execution of the program.
When an error occurs during execution of the program in internal
operation by the operating panel or the teach pendant or in external operation by the PLC.
W hen an error, such as undefined program, occurs at the start of the
program only in external operati on.
Robot failure
Caution: The signal will not be output when an error, such as a
program input error occurs in manual operation, except when a servo error occurs in manual operation. For further information, see "ERROR CODE TABL ES. "
(5) OFF conditions
As shown below, the signal will be turned OFF under the following conditions. W hen a CLEAR ROBOT FAILURE command is input from the external
device and the existing error is c leared.
W hen the existing error is cleared by operating the Cancel key of the
operating panel or the teach pendant.
Program number, parity error, or an undefined program number at
external start.
The robot errors during automatic operation (both internal operation and
external operation).
When CLEAR ROBOT FAILURE and OPERATION PREPARATION
START signals are input.
When the Cancel key of the operating panel or the teach pendant is
operated.
uCancel vƒL [‘€ ì
ƒoƒŠƒeƒB [ƒGƒ‰ [ A
Robot Failure Output
80
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