IAI RoboNet Operation Manual

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Operation Manual Forth Edition

ROBONET

CAUTION

24-V Power Supply to Be Certified For UL Standards

Please see below for the 24-V power supply condition for UL certification.

• For UL certification, class2 power supply is required based on NEC NFPA 79 (Electrical Standard for Industrial Machinery).

• If a single class2 power supply unit is insufficient to provide enough power, use multiple class2 power supply units.

At that time, follow the (example) below for the wiring layout. Also, 0-V line to each power supply is required to be common.

Simple absolute R unit

R unit

unit unit unit unit unit

Power Supply

CAUTION

Teaching pendant

PC, etc.

Do not connect the FG.

Do not connect the FG of the PC to ground. If the FC may be connected to ground through other COM port, disconnect the communication cable from the applicable COM port.

PC software

RS232 connection type <Model: RCM-101-MW> USB connection type <Model: RCM-101-USB>

* The cable is supplied with the PC software.

SIO converter (optional) (with built-in terminal resistor) Model: RCB-TU-SIO-A (B)

* One e-CON connector, one junction and one

terminal resistor are supplied with one controller link cable.

e-CON connector (3-1473562-4 by AMP) Junction (5-1473574-4 by AMP)

GateWay

R unit

Terminal resistor

Controller link cable Model: CB-RCB-CTL002

24-V power supply

Notes on Connecting PC and Teaching Pendant to ROBONET Whose 24-V Power Supply Is Grounded at Positive Terminal

If the positive terminal of the ROBONET’s 24-V power supply is grounded, use a SIO converter as shown below

to connect a teaching pendant or PC to the GateWayR unit. At this time, do not connect the FG of the SIO converter.

CAUTION

If the positive terminal of the ROBONET’s 24-V power supply is grounded, a teaching pendant or PC cannot be connected directly to the GateWayR unit. If a teaching pendant or PC is connected directly to the GateWayR unit, the power supply may be short-circuited, causing the PC or teaching pendant to suffer damage.

Cannot be connected directly.

GateWay R unit

This teaching pendant cannot be used.

24-V power supply

Introduction

Thank you for purchasing IAI’s ROBONET. “ROBONET” is a general term for dedicated single-axis controllers used in a field network environment and characterized by their ultra-compact size, wire-saving features, and easy installation. This manual provides the information you need to know to use the ROBONET. Before using your ROBONET, peruse this manual and understand its contents fully.

• Unauthorized reproduction of this manual, whether in part or in whole, is strictly prohibited.

• The information provided in this manual is subject to change without notice for the sake of improvement.

• This manual has been created with the utmost attention to accuracy. Should you find any error, however, or have any

comment, please contact IAI.

Safety precautions

Safety Precautions (Please read before using the product.)

Carefully read this operation manual before using the product. In this operation manual, safety instructions are classified into “Danger,” “Warning,” “Caution” and “Note” as shown below.

Level Degree or danger/damage Symbol

Danger

Failure to observe the instruction will result in an imminent danger leading to death or serious injury.

Danger

Warning

Failure to observe the instruction may result in death or serious injury.

Warning

Caution

Failure to observe the instruction may result in injury or property damage.

Caution

Note

The user should take heed of this information to ensure the proper use of the product, although failure to do so will not re sult in injury.

Note

Also note that this product cannot be used in any way not described in this operation manual. IAI shall not assume any liability for unwanted outcomes of operations not described herein.

Safety precautions

The safety precautions pertaining to this product are listed below.

NO. Task Precautions

1 Model selection z This product is not planned or designed for uses requiring high degrees of safety.

Accordingly, it cannot be used to sustain or support life and must not be used in the following applications: [1] Medical devices relating to maintenance, management, etc., of life or health [2] Mechanisms or mechanical devices (vehicles, railway facilities, aircraft facilities, etc.)

intended to move or transport people

[3] Important safety parts in mechanical devices (safety devices, etc.)

z Do not use this product in the following environments:

[1] Place subject to flammable gases, ignitable objects, flammables, explosives, etc. [2] Place that may be exposed to radiation [3] Place where the surrounding air temperature or relative humidity exceeds the specified

range [4] Place subject to direct sunlight or radiated heat from large heat sources [5] Place subject to sudden temperature shift and the formation of moisture. [6] Place subject to corrosive gases (sulfuric acid, hydrochloric acid, etc.) [7] Place subject to excessive dust, salt or iron powder [8] Place where the product receives direct vibration or impact

z Do not use this product outside the specified ranges. Doing so may significantly shorten the

life of the product or result in product failure or facility stoppage.

2 Transportation z When transporting the product, exercise due caution not to bump or drop the product.

z Use appropriate means for transportation. z Do not step on the package. z Do not place on the package any heavy article that may deform the package. z When using a crane capable of 1t or more of weight, have an operator who has

qualifications for crane operation and sling work.

z When using a crane or equivalent equipments, make sure not to hang a load that weighs

more than the equipment’s limit.

z Use a hook that suits for the load. Consider the safety factor of the hook in such factors as

shear strength.

z Do not get on the load that is hanged on a crane. z Do not leave a load hanged up with a crane. z Do not stand under the load that is hanged up with a crane.

3 Storage and

Preservation

z The storage and preservation environment should conform to the installation environments.

Among others, be careful not to cause the formation of moisture. (1) Installing the robot, controller, etc.

z Be sure to firmly secure and affix the product (including its loads).

If the product tips over, drops, malfunctions, etc., damage or injury may result.

z Do not step on the product or place any article on top. The product may tip over or the

article may drop, resulting in injury, product damage, loss of/drop in product function, shorter life, etc.

z If the product is used in any of the following places, provide sufficient shielding measures:

[1] Place subject to electrical noise [2] Place subject to a strong electric or magnetic field [3] Place where power lines or drive lines are wired nearby [4] Place subject to splashed water, oil or chemicals

4 Installation/startup

(2) Wiring the cables

z Use IAI’s genuine cables to connect the actuator and controller or connect a teaching tool,

etc.

z Do not damage, forcibly bend, pull, loop around an object or pinch the cables or place

heavy articles on top. Current leak or poor electrical continuity may occur, resulting in fire, electric shock or malfunction.

z Wire the product correctly after turning off the power. z When wiring a DC power supply (+24 V), pay attention to the positive and negative

polarities. Connecting the wires in wrong polarities may result in fire, product failure or malfunction.

Safety precautions

NO. Task Precautions

z Securely connect the cable connectors in a manner free from disconnection or looseness.

Failure to do so may result in fire, electric shock or product malfunction.

z Do not cut and reconnect the cables of the product to extend or shorten the cables. Doing

so may result in fire or product malfunction. (3) Grounding

z Be sure to provide class D (former class 3) grounding for the controller. Grounding is

required to prevent electric shock and electrostatic charges, improve noise resistance and suppress unnecessary electromagnetic radiation.

4 Installation/startup

(4) Safety measures

z Implement safety measures (such as installing safety fences, etc.) to prevent entry into the

movement range of the robot when the product is moving or can be moved. Contacting the moving robot may result in death or serious injury.

z Be sure to provide an emergency stop circuit so that the product can be stopped

immediately in case of emergency during operation.

z Implement safety measures so that the product cannot be started only by turning on the

power. If the product starts suddenly, injury or product damage may result.

z Implement safety measures so that the product will not start upon cancellation of an

emergency stop or recovery of power following a power outage. Failure to do so may result in injury, equipment damage, etc.

z Put up a sign saying “WORK IN PROGRESS. DO NOT TURN ON POWER,” etc., during

installation, adjustment, etc. If the power is accidently turned on, electric shock or injury may result.

z Implement measures to prevent the loads, etc., from dropping due to a power outage or

emergency stop.

z Ensure safety by wearing protective gloves, protective goggles and/or safety shoes, as

necessary.

z Do not insert fingers and objects into openings in the product. Doing so may result in injury,

electric shock, product damage, fire, etc.

5 Teaching z Whenever possible, perform teaching from outside the safety fences. If teaching must be

performed inside the safety fences, prepare “work rules” and make sure the operator understands the procedures thoroughly.

z When working inside the safety fences, the operator should carry a handy emergency stop

switch so that the operation can be stopped any time when an abnormality occurs.

z When working inside the safety fences, appoint a safety watcher in addition to the operator

so that the operation can be stopped any time when an abnormality occurs. The safety watcher must also make sure the switches are not operated inadvertently by a third party.

z Put up a sign saying “WORK IN PROGRESS” in a conspicuous location. * Safety fences --- Indicate the movement range if safety fences are not provided.

6 Confirmation

operation

z After teaching or programming, carry out step-by-step confirmation operation before

switching to automatic operation.

z When carrying out confirmation operation inside the safety fences, follow the specified work

procedure just like during teaching.

z When confirming the program operation, use the safety speed. Failure to do so may result

in an unexpected movement due to programming errors, etc., causing injury.

z Do not touch the terminal blocks and various setting switches while the power is supplied.

Touching these parts may result in electric shock or malfunction.

Safety precautions

NO.

7 Automatic operation z Before commencing automatic operation, make sure no one is inside the safety fences.

z Before commencing automatic operation, make sure all related peripherals are ready to

operate in the auto mode and no abnormalities are displayed or indicated.

z Be sure to start automatic operation from outside the safety fences. z If the product generated abnormal heat, smoke, odor or noise, stop the product

immediately and turn off the power switch. Failure to do so may result in fire or product damage.

z If a power outage occurred, turn off the power switch. Otherwise, the product may move

suddenly when the power is restored, resulting in injury or product damage.

8 Maintenance/

inspection

z Whenever possible, work from outside the safety fences. If work must be performed inside

the safety fences, prepare “work rules” and make sure the operator understands the procedures thoroughly.

z When working inside the safety fences, turn off the power switch, as a rule. z When working inside the safety fences, the operator should carry a handy emergency stop

switch so that the operation can be stopped any time when an abnormality occurs.

z When working inside the safety fences, appoint a safety watcher in addition to the operator

so that the operation can be stopped any time when an abnormality occurs. The safety watcher must also make sure the switches are not operated inadvertently by a third party.

z Put up a sign saying “WORK IN PROGRESS” in a conspicuous location. z Use appropriate grease for the guides and ball screws by checking the operation manual

for each model.

z Do not perform a withstand voltage test. Conducting this test may result in product damage. * Safety fences --- Indicate the movement range if safety fences are not provided.

9 Modification z The customer must not modify or disassemble/assemble the product or use maintenance

parts not specified in the manual without first consulting IAI.

z Any damage or loss resul ting from the above actions will be excluded from the scope of

warranty.

10 Disposal z When disposing of the product after it has become no longer usable or necessary, dispose

of it properly as an industrial waste.

z When disposing of the product, do not throw it into fire. The product may explode or

generate toxic gases.

CE Mark

1. EC Directives

The EC Directives are a new set of directives issued by the European Commission that are intended to protect the health and safety of users and consumers of products distributed within the EU (European Union) zone, while ensuring free movements of these products within the EU zone. Companies exporting to Europe or having a production facility in Europe must comply with the following directives in order to receive a CE Mark certification for their products.

The ROBONET is designed to comply with the Low Voltage Directive on its own. As for the EMC Directives, we determine connection/installation models (conditions) for controllers, actuators and peripherals and ensure compliance of these models with the related standards under the EMC Directives.

2. Applicable Standards

<Low-voltage Directive>

EN50178 (Electronic equipment used in electrical installations)

EN55011 (Radio interference characteristics of industrial, scientific and medical equipment generating radio

frequency) EN61000-6-2 (Immunity in industrial environment) EN61000-4-2 (Immunity to electrostatic discharge) EN61000-4-3 (Immunity to electromagnetic field generated by irradiated radio frequency) EN61000-4-4 (Electrical first transient/burst immunity test) EN61000-4-5 (Surge immunity test) EN61000-4-6 (Immunity test against conductive interference induced by radio-frequency electromagnetic field) EN61000-4-8 (Immunity test against power-frequency magnetic field) EN61000-4-11 (Immunity test against voltage dip, momentary power failure and voltage fluctuation)

CE Mark

Use Environment Item Standard Remarks

Overvoltage category II Pollution degree II Protection code IP 20 Protection class *1 I Altitude 2000 m or less

*1) Protection class I device

A device in which additional safety measures are taken against electric shock, without depending solely on the basic insulation, by connecting conductors that may become contactable should the basic insulation fail to a protective grounding conductor of a fixed cable of the facility. In other words, a protection class I device refers to a device for which grounding connection is required.

CE Mark

100 or 200-VAC power supply bus

Control panel

Field network cable

PLC

master

Clamp filter

Circuit

breaker

Earth leakage breaker

24-VDC

power supply

Surge

protector

Network

connector

Power-

supply

terminal

FG ground

ROBONET

controller

Encoder cable

Actuator

Motor cable

Actuator

Encoder cable

Motor cable

3. Configuration of Peripherals

(1) Environment

Use the ROBONET in an environment of pollution degree 1 or 2 as specified in IEC 60664-1. Example) Install it in a control panel constructed to shut off water, oil, carbon, dust, etc. (IP54).

(2) Power supply

A) Use the ROBONET in an environment of overvoltage category II as specified in IEC 60664-1. Accordingly, be sure to

install a circuit breaker between the power distribution board and ROBONET controller.

B) For the 24-VDC power supply, use a (SELV) power supply bearing a CE Mark with reinforced insulation of

inputs/outputs.

(3) Grounding

Be sure to connect the protective grounding terminal $$ of the ROBONET with the protective earth (grounding plate) of the control panel to prevent electric shock.

(4) Earth leakage breaker

Install an inverter earth leakage breaker on the primary side of the ROBONET.

CE Mark

(5) Clamp filter

Install clamp filters of the following type on the field network cable, motor cable and encoder cable. Install them immediately near the cable connectors on the controller unit. One clamp filter is required for each gateway unit, and two for each controller unit. On the field network cable, install each clamp filter by looping it twice around the cable.

Manufacturer: TDK Corp. Model: ZCAT3035-1330

External View of Clamp Filter

Shape/dimensions (mm)

Shape/dimensions ZCAT type

CE Mark

(6) Surge protector

Install a surge protector on the primary side of the 24-VDC power supply to protect the equipment from surge noise generated by lightning, etc.

Manufacturer: Okaya Electric Model: ZCAT3035-1330

External View of Surge Protector

(7) Cables

Take note that cables are also subject to various limitations. A) All cables connected to the ROBONET, such as the motor cable, encoder cable and various network cables, must

be less than 30 m long.

B) For the CC-Link cable, use a dedicated Version 1.10 cable (terminal resistance: 110 Ω).

BWZ series

Warranty

The ROBONET you have purchased passed our strict outgoing inspection. This unit is covered by the following warranty: The details of the warranty are described below.

(1) Warranty Period

The warranty period ends upon either of the following, whichever occurs first:

• 18 months after shipment from our factory

• 12 months after delivery to a specified location

(2) Scope of Warranty

The warranty covers only the IAI product you have purchased. If the product fails due to a defective material or poor workmanship during the above warranty period despite use in a proper condition, we will provide a replacement unit or repair the failed product free of charge. Note, however, that the following items are not covered by the warranty: [1] Problem resulting from handling or use of the product under any condition or environment not specified in the catalog

or operation manual [2] Problem due to use of any product not manufactured by IAI [3] Problem resulting from alteration or repair not performed by IAI or its sales agent [4] Problem that was unforeseeable based on the science or technology available when the product was shipped from

IAI [5] Problem resulting from an act of God, natural disaster, accident or any other event beyond the control of IAI [6] Natural fading of paint or other deterioration normally expected over time [7] Wear of consumable parts due to use [8] Noise and other perceptive phenom ena that do not affect the function of the facility

The warranty only covers the product as delivered. IAI is not responsible for any losses arising from a defect in the delivered product. The customer must hand-carry the product to IAI’s factory to receive repair.

(3) Limited Liability

IAI shall bear no responsibility for any special damage, in direct loss or passive loss arising from IAI’s product.

(4) Scope of service

The price of the delivered product does not include costs of programming, dispatching engineers, etc. Accordingly, separate fees will be charged for the following services even during the warranty period:

• Guidance on installation/adjustment and witnessing of trial operation

• Maintenance/inspection

• Technical guidance and training on operating/wiring procedures, etc.

• Technical guidance and training on programming and other items relating to programs

• Other services and tasks specified by IAI as chargeable

Warranty

Related manuals

• PC Software RCM-101-** Operation Manual

• RCM-* Teaching Pendant Operation Manual

• ROBO CYLINDER Series – Serial Communication [Modbus Version] Operation Manual

• Touch Panel Display RCM-PM-01 Operation Manual (Not sold in the US market)

Manual revision history

[1] August 2008– First edition Integration of the ROBONET Operation Manual “Specification,” ROBONET

Operation Manual “Startup/Maintenance” and operation manual of the ROBONET

extension unit [2] F ebruary 2009– Second edition Addition of UL standards application page [3] March 2009– Third edition Change in Gateway Parameter Setting Tool

Table of Contents

Introduction Safety Precautions CE Mark Warranty Related manuals

Manual revision history

Part 1 Specification........................................................................................1

Chapter 1 Overview of ROBONET ........................................................................ ... ....... ... ... ... ...... ... ... .... . ..1

1.1 Overview.....................................................................................................................................................1

1.2 Features......................................................................................................................................................2

Chapter 2 System Configuration and General Specifications.................................................................6

2.1 System Configuration..................................................................................................................................6

2.2 List of Component Units..............................................................................................................................6

2.3 General Specifications................................................................................................................................9

2.4 24-V Power Current Consumption of Each Unit..........................................................................................9

2.5 Connection Diagram .................................................................................................................................11

Chapter 3 GateWayR unit..........................................................................................................................12

3.1 Overview...................................................................................................................................................12

3.3 GateWayR unit and Accessories...............................................................................................................13

3.4 General Specifications..............................................................................................................................14

3.4.1 CC-Link.........................................................................................................................................14

3.4.2 DeviceNet.....................................................................................................................................16

3.4.3 PROFIBUS ...................................................................................................................................17

3.4.4 RS485 SIO....................................................................................................................................18

3.5 Name/Function of Each Part and External Dimensions ............................................................................19

3.5.1 Name of Each Part........................................................................................................................19

3.5.2 LED Indicators..............................................................................................................................20

3.5.3 MODE Switch ...................................................................... .........................................................22

3.5.4 TP Connector................................................................................................................................22

3.5.5 User Setting Switches...................................................................................................................22

3.5.6 ROBONET Communication Connector.........................................................................................22

3.5.7 Power-supply Input Terminal Block ..............................................................................................22

3.5.8 FG Terminal (Frame Ground).......................................................................................................23

3.5.9 EMG Connector (Emergency Stop) ..............................................................................................23

3.5.10 Field Network Connector..............................................................................................................25

3.5.11 External Dimensions .....................................................................................................................29

3.6 Operation Function List.............................................................................................................................30

3.7 Address Configuration...............................................................................................................................32

3.7.1 Examples of Overall Address Configuration.................................................................................33

(1) CC-Link ................................................................................................................................33

(2) DeviceNet.............................................................................................................................36

(3) PROFIBUS...........................................................................................................................38

(4) RS485SIO............................................................................................................................40

3.7.2 Gateway Control/Status Signals...................................................................................................42

3.7.3 Command Area.............................................................................................................................44

3.7.4 Position Table...............................................................................................................................52

3.7.5 Assignments in the Positioner 1 Mode or Simple Direct Mode .....................................................59

3.7.6 Assignments in the Direct Numerical Specification Mode.............................................................63

3.7.7 Assignment in Positioner 2 Mode .................................................................................................68

3.7.8 Solenoid valve mode 1..................................................................................................................69

3.7.9 Solenoid valve mode 2..................................................................................................................71

Table of Contents

3.8 I/O Signals ................................................................................................................................................73

3.8.1 I/O Signal Timings ........................................................................................................................73

3.8.2 I/O Signal Functions......................................................................................................................74

3.8.3 Basic Operation Timings...............................................................................................................85

3.8.4 Other Basic Operations.................................................................................................................97

3.8.5 Command Transmission.............................................................................................................109

3.9 Modbus Gateway Mode of RS485 SIO...................................................................................................110

3.9.1 Overview.....................................................................................................................................110

3.9.2 Modbus/RTU Protocol Specification...........................................................................................111

3.9.9 Protocol Format ..........................................................................................................................115

3.9.3.1 Gateway Address Map...............................................................................................115

3.9.3.2 Query List...................................................................................................................117

3.9.3.3 Read Holding Registers (Query using FC = 03H).......................................................119

3.9.3.4 Preset Single Register (Query using FC = 06H).........................................................130

3.9.3.5 Preset Multiple Registers (Query using FC = 10H).....................................................147

3.9.4 Function Block............................................................................................................................165

3.9.4.1 Dedicated ROBONET Function Block........................................................................165

3.9.4.2 What Is A Function Block? .........................................................................................176

Chapter 4 Controller Unit.................................................................................... .....................................180

4.1 Overview.................................................................................................................................................180

4.1.1 Features......................................................................................................................................180

4.1.2 How to Read the Model Name....................................................................................................180

4.2 Basic Specifications................................................................................................................................182

4.3 Name/Function of Each Part and External Dimensions. .........................................................................183

4.3.1 Name of Each Part......................................................................................................................183

4.3.2 LED Indicators............................................................................................................................184

4.3.3 Brake Release Switch.................................................................................................................186

4.3.4 User Setting Switches.................................................................................................................186

4.3.5 Axis Number Setting Switch........................................................................................................186

4.3.6 ROBONET Communication Connector.......................................................................................187

4.3.7 Simple Absolute R Unit Connector..............................................................................................187

4.3.8 Power-supply Input Terminal Block ............................................................................................187

4.3.9 Motor Cable Connector...............................................................................................................189

4.3.10 Encoder Cable Connector...........................................................................................................190

4.3.11 External Dimensions ...................................................................................................................191

4.4 Parameters .............................................................................................................................................192

4.4.1 Parameter List ............................................................................................................................192

4.4.2 Parameters Relating to Actuator Stroke......................................................................................194

4.4.3 Parameters Relating to Actuator Operating Characteristics........................................................196

4.4.4 Parameters Relating to External Interface..................................................................................206

4.4.5 Parameters Relating to Servo Gain Adjustment .........................................................................207

4.5 Notes on ROBO Rotary...........................................................................................................................210

4.6 Notes on ROBO Gripper.........................................................................................................................212

Chapter 5 Simple Absolute R Unit.................................................. ... .... ... ...... ... ... ... ....... ... ... ... ...... ... ... ...214

5.1 Overview.................................................................................................................................................214

5.2 How to Read the Model Name................................................................................................................ 215

5.3 Specifications..........................................................................................................................................216

5.3.1 General Specifications................................................................................................................216

5.3.2 Backup Battery ...........................................................................................................................217

5.4 Name/Function of Each Part and External Dimensions ..........................................................................218

5.4.1 Name of Each Part......................................................................................................................218

5.4.2 Functions....................................................................................................................................219

5.4.3 External Dimensions...................................................................................................................222

5.5 Notes ...................................................................................................................................................223

Chapter 6 Extension unit.......................................................................................................... ...............224

6.1 Overview.................................................................................................................................................224

6.2 Specifications..........................................................................................................................................225

6.3 Product Configuration .............................................................................................................................226

Table of Contents

6.4 Name of Each Part and External Dimensions .........................................................................................230

6.4.1 Name of Each Part......................................................................................................................230

6.4.2 External Dimensions...................................................................................................................231

Part 2 Startup..............................................................................................232

Chapter 1 Overview................................................. ...................................................................... ...........232

1.1 Required Tools........................................................................................................................................232

1.2 Startup Procedure...................................................................................................................................233

Chapter 2 Mounting and Installation......................................................................................................234

2.1 Installation...............................................................................................................................................234

2.1.1 Important Information and Items to Note.....................................................................................234

2.1.2 Mounting on a DIN Rail...............................................................................................................238

2.1.3 Interconnecting Multiple Units.....................................................................................................240

2.1.4 Installing in a Control Panel........................................................................................................242

2.2 Wiring ...................................................................................................................................................243

2.2.1 Wiring the Power Supply.............................................................................................................243

2.2.2 Grounding Wire...........................................................................................................................245

2.2.3 EMG Connector..........................................................................................................................245

2.2.4 Motor Cable and Encoder Cable.................................................................................................246

2.2.5 Multi-stage ROBONET Layout....................................................................................................248

2.2.6 External SIO Link of ROBONET.................................................................................................250

2.2.7 Emergency Stop Circuit..............................................................................................................253

2.2.8 Network Wiring ...........................................................................................................................256

(1) CC-Link ..............................................................................................................................256

(2) DeviceNet...........................................................................................................................257

(3) PROFIBUS-DP ...................................................................................................................259

(3) RS485SIO..........................................................................................................................261

2.2.9 How to Connect Teaching Tool When Grounding Positive Terminal of 24-V Power Supply.......262

Chapter 3 Controller Address Setting............................................................... ................... ..................263

Chapter 4 Absolute Reset............................................................................. ...........................................264

4.1 Overview of Simple Absolute System.....................................................................................................264

4.2 Setting the Configuration Switches.........................................................................................................265

4.3 Connecting the Backup Battery...............................................................................................................267

4.4 Setting the Parameters...........................................................................................................................267

4.5 Performing an Absolute Reset................................................................................................................267

4.5.1 Performing an Absolute Reset in the PC Software.....................................................................267

4.5.2 Performing an Absolute Reset from the Host..............................................................................269

Chapter 5 Network Setup.........................................................................................................................270

5.1 How to Use the ROBONET Gateway Parameter Setting Tool................................................................270

5.1.1 Operating Environment...............................................................................................................270

5.1.2 Launching the Setting Tool.........................................................................................................270

5.1.3 Explanation of the Main Screen..................................................................................................271

5.1.4 Operating Procedures.................................................................................................................276

5.2 Setting Up the Master .............................................................................................................................294

5.2.1 CC-Link.......................................................................................................................................294

5.2.2 DeviceNet...................................................................................................................................300

5.2.3 PROFIBUS .................................................................................................................................313

5.2.4 RS485SIO...................................................................................................................................318

5.3 Creating a Controller Position Table.......................................................................................................333

5.4 Address Correlation Diagram..................................................................................................................335

5.4.1 Address Correlation Diagram for CC-Link System (Example) ....................................................336

5.4.2 Address Correlation Diagram for DeviceNet System (Example).................................................338

5.4.3 Address Correlation Diagram for RS485SIO System (Example)................................................339

Table of Contents

Chapter 6 Setting for External SIO Link and Other ............. ...... ... ... .... ...... ... ... ... ...... ... .... ... ...... ... ... ... ...340

6.1 SCON/PCON-CF Settings and Signal Assignments...............................................................................340

6.2 Other ...................................................................................................................................................341

Part 3 Maintenance.....................................................................................342

Chapter 1 Troubleshooting................................................................................................. .....................342

1.1 Actions to Be Taken upon Problems.......................................................................................................342

1.2 Alarms of the GateWayR unit..................................................................................................................343

1.2.1 Common Alarms.........................................................................................................................344

1.2.2 Alarms by Field Network Type....................................................................................................345

1.2.3 Examples of Indicator Statuses Corresponding to Representative Alarms.................................348

1.3 Alarms of the Controller Unit and Simple Absolute R Unit ......................................................................349

1.3.1 Overview of Alarms.....................................................................................................................349

1.3.2 Alarms, Causes and Actions.......................................................................................................352

1.3.3 Messages Displayed during Operation Using the Teaching Pendant or PC Software................360

Chapter2 Maintenance/Inspection..................................... ....................................................................362

2.1 Periodic Inspection Items........................................................................................................................363

2.2 Important Information on Unit Replacement............................................................................................364

2.3 Replacing the Backup Battery.................................................................................................................365

Appendix ..................................................................................................................................................365

RACON Specification List of Supported Actuators...................................................................................366

RPCON Specification List of Supported Actuators...................................................................................367

Part 1 Specification

Part 1 Specification Chapter 1 Overview of ROBONET

1.1 Overview

“ROBONET” is a general term for dedicated controllers used to operate ROBO Cylinders (RCA/RCA2/RCL/RCP2/RCP3) over a field network connected to a host programmable controller (hereinafter referred to as “PLC”). A ROBONET system can be configured with a desired combination of a GateWayR unit, which serves as a field network connection interface, and one or more RACON units (RAC/RCA2/RCL controllers) and RPCON unit (RCP2/RCP3 controllers). Up to 16 axes can be controlled in one ROBONET system. You can also configure an absolute system by connecting a simple absolute R unit to the controller of each axis. The GateWayR unit is available in four types: DeviceNet type, CC-Link type, PROFIBUS type, and RS485 SIO type. The ROBONET is treated as a slave station in a field network. RS485 SIO communication is implemented according to the Modbus-RTU protocol. The ROBONET extension unit can be used to implement a ROBONET system of multi-stage layout and connect non-ROBONET controllers (SCON, PCON-CF, ERC2) (via external SIO link).

Part 1 Specification

1.2 Features

(1) Fiv e Types of Component Units

The five types of units specified below can be combined in a desired fashion to build a ROBONET system. The maximum number of component axes is 16. [1] GateWayR unit

Four types—DeviceNet type, CC-Link type, PROFIBUS type, and RS485 SIO communication type—are available. [2] RACON unit --- RCA/RCA2/RCL control ler [3] RPCON unit --- RCP2/RCP3 controller [4] Simple absolute R unit [5] ROBONET extension unit

(2) Ultra-compact Size

Each unit has an ultra-compact design with external dimensions of 34 mm in width, 100 mm in height, and 73 mm in depth. Accordingly, you can reduce the control panel size for your ROBONET system.

(3) Wire-saving

Units are interconnected by dedicated power-supply connection plates and communication connection circuit boards, which substantially reduces the hassle of wiring.

(4) Easy Installation

All units are installed on a DIN rail (35 mm), so installation to a control panel or equipment is easy. Units can also be installed side by side with other components.

(5) Simple Absolute System

The axis-drive unit is either a RPCON unit for 24-V pulse motor actuators or RACON unit for 24-V servo motor actuators. Although both use an incremental encoder, they can be used as an absolute axis when a simple absolute R unit is connected.

(6) Four Types of GateWayR units

To support various field networks, the GateWayR unit (gateway function) is available in the following four types, each supporting a different field network.

• DeviceNet type • CC-Link type • PROFIBUS type

• RS485 SIO communication type

GateWayR unit

RACON unit

Simple absolute R unit

RPCON unit

ROBONET communication connection circuit boards

Power-supply connection plates

(Interconnections of ROBONET units)

Terminal resistor circuit board

Part 1 Specification

(7) Six ROBONET operation modes

The ROBONET can operate ROBO Cylinders in one of the following six modes under the control of the GateWayR unit, regardless of the type of the host fieldbus. The following three modes under [1] to [3] can be combined together. Also, the three modes under [4] to [6] can be combined. However, [1] to [3] and [4] to [6] cannot be combined with each other, i.e. combination of [1] and [4] is not possible.

[1] Positioner mode (Number of positions: 768 points)

In this mode, the actuator is operated by specifying a position number. The position data, speed,

acceleration/deceleration and other data are input in the position table beforehand. Up to 768 points can be

registered as positions for each axis.

The various status signals of t he controller uni t can be monitored, and so can the current actuator position, but the

alarm codes, speed and electrical current cannot be monitored. If an alarm occurs, however, a corresponding simple

alarm code will be output to the completed position number area, so you can monitor simple alarm codes in this area. [2] Simple direct mode (Number of positions: 768 points)

In this mode, the actuator is operated by specifying only the position data directly as a numerical value, and

specifying all other data including the speed, acceleration/deceleration, positioning band and push-current limiting

value using a position number. Up to 768 points can be registered as positions.

The various status signals of t he controller uni t can be monitored, and so can the current actuator position, but the

alarm codes, speed and electrical current cannot be monitored. If an alarm occurs, however, a corresponding simple

alarm code will be output to the completed position number area, so you can monitor simple alarm codes in this area. [3] Direct numerical specification mode

In this mode, the actuator is operated by specifying the position data, speed, acceleration/deceleration, positioning

band and push-current limiting value directly as numerical values. The various status signals of the controller unit,

current actuator position, alarm codes and speed/electrical current can be monitored at all times. [4] Positioner 2 mode (Number of positions: 768 points)

This mode is the same as the positioner 1 mode. It cannot be combined with the positioner 1 mode, simple direct mode or direct numerical specification mode. The positioner 2 mode, Solenoid valve mode 1 and Solenoid valve mode 2 can be combined. This mode is supported by Gateway Firmware Version 000B or later.

[5] Solenoid valve mode 1 (Number of positions: 7 points)

It is a mode of which the operation is simplified with the positioning numbers controlled to 7 points. Operation can be performed only by indicating the target position number. (no start signal is required.) Therefore, PLC ladder sequence circuit is easily created.

[6] Solenoid valve mode 2 (Number of positions: 3 points)

It is a mode with an easy operation like Solenoid valve mode 1. Operation can be performed with the same control as the solenoid valve.

In the positioner mode or simple direct mode, position table data can be read, written or otherwise manipulated using

dedicated commands.

Even in the AUTO mode, the various information of each axis (alarm codes, speed, electrical current, etc.) can be

monitored on the touch panel display (RCM-PM-01) connected to the TP connector.

Part 1 Specification

List of ROBONET Operation Functions

Operation mode

Item

Positioner 1

mode

Simple direct

mode

Direct numerical

specification

mode

Positioner 2

mode

Solenoid valve

mode 1

Solenoid valve

mode 2

Axis area (Both input and output)

4 words 8 words 2 words 2 words

Fixed area (Both input and output)

8 words

(The command area can be used.)

8 words (The command area cannot be

used.)

8 words

(The command

area can be

used.)

8 words

(The command area can be used.)

Number of registrable positions

768 points/axis 768 points/axis - 768 points/axis 7 points/axis 3 points/axis

Operation by position number specification

{ {

Direct position data specification

X (Position table)

{ {

X (Position table) X (Position table)

Direct speed & acceleration/deceleratio n specification

X (Position table) X (Position table) { *3 X (Position table) X (Position table)

Direct positioning band specification

X (Position table) X (Position table)

{

X (Position table) X (Position table)

Push operation { (Position table) { (Position table){(Direct specification)

{ (Position table) { (Position table)

Completed position number monitor

{ {

Zone output monitor

{ { { { {

Position zone output monitor

{ {

Teaching operation

{

X X

{

Jogging operation

{ { { {

Inching operation

{ { { {

Various status signal monitor *1

{ { { {

Current position monitor

{ { { {

Alarm code monitor *1

{ { { {

Speed/electrical current monitor *1

X X

{

X X

Axis monitor function in AUTO mode *2

{ { { { {

Handshake

{ {

Position table data read/write

{ {

Current position read

X X X X X

Command

Broadcast

{

X X

{ {

Maximum specifiable position data value

9999.99 mm (When a

command

is used)

9999.99 mm 9999.99 mm

9999.99 mm (When a

command

is used)

9999.99 mm

(When a command is used)

Number of connectable axes

16 16 8 16 16

*1 Various status signals, current position, alarm codes and speed/electrical current can be monitored by accessing each

address of the gateway unit from the PLC.

*2 Before, axis monitor was not possible in the AUTO mode. This has become possible with the ROBONET, even when the

MODE switch is set to AUTO, by connecting a dedicated touch panel to the TP connector.

*3 Separate values cannot be set for acceleration and deceleration. The acceleration and deceleration are always the same.

Part 1 Specification

(8) Easy Setting Using the ROBONET Gateway Parameter Setting Tool

With this tool, you can set the station number, baud rate, and operation mode of each axis, and also check the occupied areas.

Also, reserved axes can be set in consideration of expansion of axis configuration in the future. [1] Station number setting ------------------------- Set the station number (node address) in the field network. [2] Baud rate setting -------------------------------- Set the baud rate over the field network. The setting must be the same as

the baud rate set on the master side. [3] Operation mode setting for each axis [4] Setting of reserved axes [5] Checking of occupied area information --- The ROBONET-occupied area information set on the master side can be

checked. [6] Operation of parameter files

Setting of the positioner 2 mode, setting of reserved axes and operation of parameter files are supported when the version of the parameter setting tool is 1.0.3.0 or l ater and the firmware version of the GateWayR unit is 000B or later. Settings of the Solenoid valve mode 1, Solenoid valve mode 2 and special parameters are supported when the version of the Parameter Setting Tool is 1.0.4.0 or later and the firmware version of the GateWayR unit is 000E or later.

(9) Multi-stage layout

The extension unit can be used to implement a ROBONET system of multi-stage layout.

(10) External SIO link

The extension unit can be used to connect non-ROBONET controllers (SCON, PCON-CF, ERC2).

Part 1 Specification

Chapter 2 System Configuration and General Specifications

2.1 System Configuration

A ROBONET system is comprised of one GateWayR unit and up to 16 axes of controller units. The GateWayR unit is available in four types—DeviceNet specification, CC-Link specification, PROFIBUS specification, and RS485 SIO specification—to support various field networks. The controller unit may be a RPCON unit for 24-V pulse motor actuators or RACON unit for 24-V servo motor actuators. When a simple absolute R unit is connected to the controller unit, the controller can be used as an absolute axis. Also, the ROBONET extension unit can be used to implement a ROBONET system of multiple-row layout (multi-stage layout) and connect non-ROBONET controller units (SCON, PCON-CF, ERC2) to a ROBONET system (via external SIO link). A ROBONET system configuration is shown on the next page.

2.2 List of Component Units

The units comprising a ROBONET system are listed below.

Product name Model

DeviceNet specification RGW-DV CC-Link specification RGW-CC PROFIBUS specification RGW-PR

GateWayR unit

RS485SIO specification RGW-SIO RACON (for RCA□, RCL actuators)

RACON-10I/20S/30 *

Controller unit

RPCON (for RCP□ actuators)

RACON-20P/28P/28SP/42P/56P *

Simple absolute R unit Common to the RACON and RPCON RABU ROBONET extension (Optional) REXT

* If a simple absolute R unit is connected, “-ABU” is appended at the end of the model name.

Part 1 Specification

Field network (DeviceNet, CC-Link, PROFIBUS) RS485 SIO

Axis 0 Axis 1 Axis 2 Axis 3 Axis 14 Axis 15

GateWay

R unit

RACON

unit

RPCON

unit

RAON

unit

Simple

absolute

R unit

RPCON

unit

Simple

absolute

R unit

Simple absolute connection circuit board

Terminal resistor circuit board

ROBONET communication connection circuit board

Power-supply connection plates

RACON

unit

RPCON

unit

Emergency

stop circuit

RCA□, RCL

actuators

RCP□

actuator

RCA□, RCL

actuators

RCP□

actuator

RCA□, RCL

actuators

RCP□

actuator

ROBONET Configuration (1) (Basic)

Part 1 Specification

Gateway

R unit

RACON

unit

RPCON

unit

RAON

unit

Simple

absolute

R unit

Extension

unit

Simple absolute connection circuit board

ROBONET communication connection circuit boa

Power-supply connection plates

Extension

unit

RACON

unit

RPCON

unit

Extension

unit

Unit link cable

<Multi-stage layout>

Controller connection cable

4-way junction 4-way junction

Terminal resistor

Axis 0

Axis 1

Axis 2

Axis 3

Axis 4

Axis 5 Axis 6

Axis 7

Field network (DeviceNet, CC-Link, PROFIBUS) RS485 SIO

ROBONET Configuration (2) (Multi-stage layout and external SIO link)

Part 1 Specification

2.3 General Specifications

The general specifications of a ROBONET system are listed below.

Item Specification

Power-supply voltage

24 VDC ± 10 % Power-supply current Varies depending on the system configuration. Maximum number of connectable axes 16 axes (Controller units can be combined freely.) Supported field networks CC-Link, DeviceNet, PROFIBUS, RS485 SIO

(slave station) ROBONET communication protocol Modbus protocol Component units GateWayR unit, controller unit, simple absolute R unit

ROBONET extension

(Refer to 2.2 for details.) Emergency stop/enable operation The entire system is stopped by the emergency stop input from the GateWayR

unit. Each controller unit has a built-in drive-source cutoff relay. Surrounding air temperature

0 to 40°C Surrounding humidity 95% RH max. (non-condensing) Protection degree IP20 External dimensions of each unit 34 W x 105 H x 73.3 D [mm]

All units have the same dimensions. Interconnection of units Power-supply connection plate

Unit link cable or controller connection cable when the ROBONET communication

connection circuit board, simple absolute connection circuit board or ROBONET

extension unit is used (multi-stage layout or external SIO link) Installation method Installation on a DIN rail (35 mm)

(However, controllers corresponding to external SIO link axes are excluded.)

2.4 24-V Power Current Consumption of Each Unit

Current consumption GateWayR unit 600 mA max. (Common to all four types)

Standard specification, high

acceleration/deceleration type

Energy-saving type

Actuator

Rating Max. *1 Rating Max. *1 SA3 (10) 1.3 A 4.0 A 1.3 A 2.2 A SA4ySA5yRA4 (20) 1.3 A 4.4 A 1.3 A 2.5 A SA6yRA4 (30) 1.3 A 4.0 A 1.3 A 2.2 A

RACON unit

RA3 (20S) 1.7 A 5.1 A 1.7 A 3.4 A Actuator Rating Max. *2 20P, 28P, 28SP motors 0.4 A 2.0 A

RPCON unit

42P, 56P motors 1.2 A 2.0 A

Simple absolute R unit 300 mA max. ROBONET extension 100 mA max. *1 The current becomes the maximum during the excited-phase detection of the servo motor performed when the servo is

turned on for the first time following the power on. (Normal: Approx. 1 to 2 seconds, Maximum: 10 seconds)

*2 The current becomes the maximum during the excited-phase detection performed when the servo is turned on for the first

time following the power on. (Normal: 100 msec)

Part 1 Specification

Gateway

R unit

ROBONET

RACON or RPCON

(up

to 16 axes)

Circuit

breaker

Power supply

<Selection of P ower-supply Ca pacity> The method to select an appropriate 24-VDC power supply to be used with your ROBONET system is explained below.

(1) Current consumption of controller units when the respective axes operate simultaneously

Rated RACON current x Number of RACON controllers operating simultaneously (≥ 1) + Rated RPCON current x Number of RPCON controllers operating simultaneously (≥ 1) --- [1]

(2) Current consumption of other units

= 0.6 A x Number of GateWayR units + 0.3 A x Number of simple absolute R units + 0.1 A x Number of extension units --- [2]

The current consumption is calculated by [1] + [2] in a steady state.

(3) Current consumption during excited-phase detection

Maximum RACON current x Number of RACON controllers performing excited-phase detection simultaneously (≥ 1) + Maximum RPCON current x Number of RPCON controllers performing excited-phase detection simultaneously (≥ 1)

--- [3] Normally a power supply whose rated current is equivalent to ([1] + [2]) x 1.3 or more is selected by considering 20 to 30% of allowance in addition to the above current consumption of [1] + [2]. However, make sure you select a power supply of “peak load accommodation” specification or having a sufficient allowance because the current of [3] will flow for a brief moment. Exercise special caution in the ca se that a remote sensing function is equipped.

(1) It is recommended that the ROBONET power be turned on/off on the AC power supply side (primary side of the 24-V

power supply). If the ROBONET power is turned on/off on the output side of the 24-V power supply, the large current will flow for a brief moment when the power is turned on, as explained in (2).

Turning on the power on the AC power supply side causes a rush current (*1) to flow where the size of this rush current is determined by the 24-V power supply used. Accordingly, select a circuit breaker that will not trip when this rush current flows. (Example) If the PS241 is used as the 24-V power supply, a rush current of approx. 50 t o 60 A will fl ow throu gh the

power supply for approx. 3 ms. (Measured value)

*1 The specific value varies depending on the model of the 24-V power supply and impedance of the power-supply line.

(2) The table below lists the measured ROBONET rush currents (*2) that generate when the ROBONET power is turned

on/off on the DC side (secondary side of the 24-V power supply). (These values assume parallel connection of three PS241s as 24-V power supplies.)

Number of axes

1 to 3 axes 4 to 8 axes 9 to 12 axes 13 to 16 axes

ROBONET rush

current

Approx. 50 to 60 A,

0.2 ms

Approx. 100 to 120 A,

0.2 to 0.5 ms

Approx. 120 to 130 A ,

0.6 to 0.8 ms

Approx. 130 A

1.0 to 1.5 ms

*2 The specific ROBONET rush current varies depending on the model of the 24-V power supply and impedance of the

power-supply line. The values in the above table are reference values only and not guaranteed.

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