Yamaha SRCP User Manual
YAMAHA SINGLE-AXIS ROBOT CONTROLLER
SRCP
User’s Manual
ENGLISH
E
E84-Ver. 2.04
General Contents
Chapter 1 OVERVIEW........................................................................................................... 1-1
1-1 Features of the SRCP Series Controller................................................................................... 1-2
1-2 Setting Up for Operation .......................................................................................................1-3
1-3 External View and Part Names ...............................................................................................1-4
1-3-1 SRCP controller ............................................................................................................................................. 1-4
1-3-2 TPB ................................................................................................................................................................ 1-7
1-4 System Configuration .............................................................................................................1-8
1-4-1 System configuration ..................................................................................................................................... 1-8
1-5 Accessories and Options ........................................................................................................ 1-9
1-5-1 Accessories .................................................................................................................................................... 1-9
1-5-2 Peripheral options ......................................................................................................................................... 1-9
Chapter 2 INSTALLATION AND CONNECTION .................................................................. 2-1
2-1 Installing the SRCP Controller................................................................................................2-2
2-1-1 Installation method ....................................................................................................................................... 2-2
2-1-2 Installation location ....................................................................................................................................... 2-2
2-2 Connecting the Power Supply ................................................................................................2-3
2-2-1 Power supply ................................................................................................................................................. 2-3
2-2-2 Connecting the power supply ........................................................................................................................ 2-3
2-2-3 Installing an external leakage breaker ........................................................................................................... 2-4
2-2-4 Installing a circuit protector .......................................................................................................................... 2-4
2-2-5 Installing current control switches ................................................................................................................ 2-5
2-2-6 Insulation resistance and voltage breakdown tests ........................................................................................ 2-5
2-3 Grounding..............................................................................................................................2-5
2-4 Connecting the SRCP to the Control Unit .............................................................................. 2-5
2-5 Connecting to the Robot ........................................................................................................ 2-6
2-5-1 Robot I/O connector and signal table ........................................................................................................... 2-6
2-5-2 Motor connector and signal table .................................................................................................................. 2-6
2-6 Connecting to the I/O. CN Connector ................................................................................... 2-7
2-7 Connecting to the EXT. CN Connector ...................................................................................2-8
2-8 Connecting to the Regenerative Unit ..................................................................................... 2-9
Chapter 3 I/O INTERFACE .................................................................................................... 3-1
3-1 I/O Signals .............................................................................................................................3-2
3-1-1 I/O. CN connector signals ............................................................................................................................. 3-2
3-1-2 EXT. CN connector signals ............................................................................................................................. 3-2
3-2 Input Signal Description ........................................................................................................ 3-3
3-2-1 Dedicated command input ............................................................................................................................ 3-3
3-2-2 General-purpose input (DI0 to DI7) .............................................................................................................. 3-6
3-2-3 SERVICE mode input (SVCE) .......................................................................................................................... 3-7
3-2-4 Interlock (LOCK) ........................................................................................................................................... 3-7
3-2-5 Emergency stop inputs 1, 2 (EMG1, EMG2) ................................................................................................... 3-7
3-3 Output Signal Description ..................................................................................................... 3-8
3-3-1 Dedicated output .......................................................................................................................................... 3-8
3-3-2 General-purpose output (DO0 to DO4) ........................................................................................................ 3-9
3-3-3 Feedback pulse output (PA±, PB±, PZ±, PZM±)............................................................................................. 3-9
3-4 I/O Circuits ..........................................................................................................................3-10
3-4-1 I/O circuit specifications ............................................................................................................................. 3-10
3-4-2 I/O circuit and connection example ............................................................................................................ 3-11
3-5 I/O Connection Diagram .....................................................................................................3-12
3-5-1 Connection to PLC output unit .................................................................................................................... 3-12
3-5-2 Connection to PLC input unit ...................................................................................................................... 3-13
3-6 I/O Control Timing Charts ................................................................................................... 3-14
3-6-1 When turning the power on ........................................................................................................................ 3-14
3-6-2 When executing a dedicated input command.............................................................................................. 3-15
3-6-3 When interlock signal is input ..................................................................................................................... 3-18
3-6-4 When emergency stop is input .................................................................................................................... 3-19
3-6-5 When alarm is issued ................................................................................................................................... 3-19
3-6-6 When executing a point movement command ............................................................................................ 3-20
i
Chapter 4 BASIC OPERATION OF THE TPB ......................................................................... 4-1
4-1 Connecting and Disconnecting the TPB .................................................................................4-2
4-1-1 Connecting the TPB to the SRCP controller ................................................................................................... 4-2
4-1-2 Disconnecting the TPB from the SRCP controller .......................................................................................... 4-3
4-2 Basic Key Operation .............................................................................................................. 4-4
4-3 Reading the Screen ................................................................................................................ 4-5
4-3-1 Program execution screen ............................................................................................................................. 4-5
4-3-2 Program edit screen....................................................................................................................................... 4-5
4-3-3 Point edit screen (teaching playback) ............................................................................................................ 4-6
4-3-4 DIO monitor screen ...................................................................................................................................... 4-6
4-4 Hierarchical Menu Structure.................................................................................................. 4-7
4-5 Restricting Key Operation by Access Level ............................................................................. 4-8
4-5-1 Explanation of access level ............................................................................................................................ 4-8
4-5-2 Changing an access level ............................................................................................................................... 4-9
Chapter 5 PARAMETERS ....................................................................................................... 5-1
5-1 Setting the Parameters ...........................................................................................................5-2
5-2 Parameter Description ........................................................................................................... 5-3
Chapter 6 PROGRAMMING ................................................................................................. 6-1
6-1 Basic Contents ....................................................................................................................... 6-2
6-1-1 Robot language and point data ...................................................................................................................... 6-2
6-1-2 Using the TPB to enter the robot language .................................................................................................... 6-2
6-1-3 Program specifications .................................................................................................................................. 6-2
6-2 Editing Programs .................................................................................................................... 6-3
6-2-1 Creating programs after initialization ............................................................................................................ 6-4
6-2-2 Creating a new program ................................................................................................................................ 6-6
6-2-3 Adding a step ................................................................................................................................................. 6-7
6-2-4 Correcting a step ........................................................................................................................................... 6-9
6-2-5 Inserting a step ............................................................................................................................................ 6-10
6-2-6 Deleting a step ............................................................................................................................................ 6-11
6-3 Program Utility ....................................................................................................................6-12
6-3-1 Copying a program ...................................................................................................................................... 6-12
6-3-2 Deleting a program...................................................................................................................................... 6-13
6-3-3 Viewing the program information ................................................................................................................ 6-14
Chapter 7 EDITING POINT DATA ........................................................................................ 7-1
7-1 Manual Data Input .................................................................................................................7-2
7-2 Teaching Playback.................................................................................................................. 7-3
7-3 Direct Teaching ......................................................................................................................7-5
7-4 Manual Control of General-Purpose Output ..........................................................................7-7
7-5 Manual Release of Holding Brake ..........................................................................................7-8
7-6 Deleting Point Data ............................................................................................................... 7-9
7-7 Tracing Points (Moving to a registered data point) ............................................................... 7-10
Chapter 8 ROBOT LANGUAGE ............................................................................................ 8-1
8-1 Robot Language Table ............................................................................................................8-2
8-2 Robot Language Syntax Rules ................................................................................................ 8-3
8-2-1 Command statement format .......................................................................................................................... 8-3
8-2-2 Variables........................................................................................................................................................ 8-4
8-3 Program Function .................................................................................................................. 8-5
8-3-1 Multi-task function ........................................................................................................................................ 8-5
ii
8-4 Robot Language Description .................................................................................................. 8-6
8-4-1 MOVA ........................................................................................................................................................... 8-6
8-4-2 MOVI ............................................................................................................................................................ 8-6
8-4-3 MOVF ............................................................................................................................................................ 8-7
8-4-4 JMP ................................................................................................................................................................ 8-7
8-4-5 JMPF .............................................................................................................................................................. 8-8
8-4-6 JMPB ............................................................................................................................................................. 8-9
8-4-7 L .................................................................................................................................................................... 8-9
8-4-8 CALL ............................................................................................................................................................ 8-10
8-4-9 DO .............................................................................................................................................................. 8-10
8-4-10 WAIT ........................................................................................................................................................... 8-11
8-4-11 TIMR ........................................................................................................................................................... 8-11
8-4-12 P .................................................................................................................................................................. 8-12
8-4-13 P+ ................................................................................................................................................................ 8-12
8-4-14 P- ................................................................................................................................................................. 8-12
8-4-15 SRVO ........................................................................................................................................................... 8-13
8-4-16 STOP ........................................................................................................................................................... 8-13
8-4-17 ORGN ......................................................................................................................................................... 8-14
8-4-18 TON ............................................................................................................................................................ 8-15
8-4-19 TOFF ........................................................................................................................................................... 8-15
8-4-20 JMPP ............................................................................................................................................................ 8-16
8-4-21 MAT............................................................................................................................................................. 8-17
8-4-22 MSEL ........................................................................................................................................................... 8-18
8-4-23 MOVM ........................................................................................................................................................ 8-19
8-4-24 JMPC ........................................................................................................................................................... 8-20
8-4-25 JMPD ........................................................................................................................................................... 8-20
8-4-26 CSEL ............................................................................................................................................................ 8-21
8-4-27 C .................................................................................................................................................................. 8-21
8-4-28 C+ ............................................................................................................................................................... 8-22
8-4-29 C- ................................................................................................................................................................ 8-22
8-4-30 D ................................................................................................................................................................. 8-22
8-4-31 D+ ............................................................................................................................................................... 8-22
8-4-32 D- ................................................................................................................................................................ 8-23
8-4-33 SHFT ............................................................................................................................................................ 8-23
8-5 Sample Programs ................................................................................................................. 8-24
8-5-1 Moving between two points ........................................................................................................................ 8-24
8-5-2 Moving at an equal pitch ............................................................................................................................. 8-24
8-5-3 Positioning 2 points and sending job commands to a PLC at each position ................................................. 8-25
8-5-4 Robot stands by at P0, and moves to P1 and then to P2 to pick and place a workpiece .............................. 8-26
8-5-5
Picking up 3 kinds of workpieces flowing on the front conveyor and placing them on the next conveyors while sorting ...
8-5-6 Switching the program from I/O ................................................................................................................. 8-29
8-5-7 Axis movement and I/O multi-task .............................................................................................................. 8-31
8-5-8 Turning ON general-purpose outputs during robot movement after a certain time has elapsed .................. 8-32
8-5-9 Turning ON a general-purpose output during robot movement when it has passed a specified position ..... 8-33
8-27
Chapter 9 OPERATING THE ROBOT .................................................................................... 9-1
9-1 Performing Return-to-Origin.................................................................................................. 9-2
9-2 Using Step Operation.............................................................................................................9-4
9-3 Using Automatic Operation ................................................................................................... 9-7
9-4 Switching the Execution Program........................................................................................... 9-9
9-5 Emergency Stop Function.....................................................................................................9-10
9-5-1 Initiating an emergency stop ....................................................................................................................... 9-10
9-5-2 Recovering from an emergency stop ............................................................................................................ 9-10
9-6 Displaying the Memory I/O Status .......................................................................................9-12
9-7 Displaying the Variables .......................................................................................................9-13
Chapter 10 OTHER OPERATIONS ........................................................................................ 10-1
10-1 Initialization ........................................................................................................................10-2
10-2 DIO Monitor Display ...........................................................................................................10-4
10-2-1 Display from the monitor menu .................................................................................................................. 10-4
10-2-2 Display from the DIO key operation ........................................................................................................... 10-5
10-3 System Information Display .................................................................................................10-5
10-4 SERVICE mode function .......................................................................................................10-6
10-4-1 Safety settings for SERVICE mode ................................................................................................................ 10-7
10-4-2 Enabling/disabling the SERVICE mode function ........................................................................................... 10-9
10-4-3 Setting the SERVICE mode functions ......................................................................................................... 10-11
10-5 System utilities ...................................................................................................................10-13
10-5-1 Viewing hidden parameters ....................................................................................................................... 10-13
iii
10-6 Using a Memory Card ........................................................................................................10-14
10-6-1 Saving controller data to a memory card................................................................................................... 10-14
10-6-2 Loading data from a memory card............................................................................................................. 10-16
10-6-3 Formatting a memory card ........................................................................................................................ 10-18
10-6-4 Viewing the ID number for memory card data .......................................................................................... 10-19
10-7 Duty (load factor) monitor ................................................................................................. 10-20
10-7-1 Measuring the duty (load factor) ............................................................................................................... 10-22
10-8 Using the internal flash ROM ............................................................................................. 10-23
10-8-1 Saving the parameter data onto the flash ROM ......................................................................................... 10-24
10-8-2 Manually loading the data from flash ROM ............................................................................................... 10-26
10-8-3 Initializing the flash ROM data .................................................................................................................. 10-28
Chapter 11 COMMUNICATION WITH PC ........................................................................... 11-1
11-1 Communication Parameter Specifications............................................................................11-2
11-2 Communication Cable Specifications ................................................................................... 11-3
11-2-1 Connecting to the computer with a 25-pin D-sub connector ...................................................................... 11-3
11-2-2 Connecting to the computer with a 9-pin D-sub connector ........................................................................ 11-3
11-3 Communication Command Specifications ........................................................................... 11-4
11-4 Communication Command List ............................................................................................11-5
11-5 Communication Command Description ...............................................................................11-8
11-5-1 Robot movements ........................................................................................................................................ 11-8
11-5-2 Data handling ............................................................................................................................................ 11-17
11-5-3 Utilities ...................................................................................................................................................... 11-29
Chapter 12 MESSAGE TABLES............................................................................................... 12-1
12-1 Error Messages .....................................................................................................................12-2
12-1-1 Error message specifications ........................................................................................................................ 12-2
12-1-2 Command error message ............................................................................................................................. 12-2
12-1-3 Operation error message ............................................................................................................................. 12-3
12-1-4 Program error message ................................................................................................................................ 12-4
12-1-5 System error message .................................................................................................................................. 12-5
12-1-6 Multi-task error message ............................................................................................................................. 12-5
12-2 TPB Error Messages ..............................................................................................................12-6
12-3 Stop Messages ......................................................................................................................12-7
12-3-1 Message specifications ................................................................................................................................ 12-7
12-3-2 Stop messages .............................................................................................................................................. 12-7
12-4 Displaying the Error History ................................................................................................ 12-8
Chapter 13 TROUBLESHOOTING ........................................................................................ 13-1
13-1 If A Trouble Occurs .............................................................................................................. 13-2
13-2 Alarm and Countermeasures ................................................................................................13-3
13-2-1 Alarm specifications .................................................................................................................................... 13-3
13-2-2 Alarm message list ....................................................................................................................................... 13-4
13-3 Troubleshooting for Specific Symptom................................................................................. 13-7
13-3-1 Relating to the robot movement .................................................................................................................. 13-7
13-3-2 Relating to the I/O ...................................................................................................................................... 13-9
13-3-3 Other ......................................................................................................................................................... 13-10
13-4 Displaying the Alarm History .............................................................................................13-11
Chapter 14 MAINTENANCE AND WARRANTY .................................................................... 14-1
14-1 Warranty.............................................................................................................................. 14-2
14-1-1 Warranty description................................................................................................................................... 14-2
14-1-2 Warranty Period .......................................................................................................................................... 14-2
14-1-3 Exceptions to the Warranty ......................................................................................................................... 14-2
14-2 Replacing the System Backup Battery ..................................................................................14-3
14-3 Updating the System ............................................................................................................14-4
iv
Chapter 15 SPECIFICATIONS ............................................................................................... 15-1
15-1 SRCP sereis .......................................................................................................................... 15-2
15-1-1 Basic specifications ..................................................................................................................................... 15-2
15-1-2 Robot number list ........................................................................................................................................ 15-3
15-1-3 LED display .................................................................................................................................................. 15-3
15-2 TPB ...................................................................................................................................... 15-4
15-2-1 Basic specifications ..................................................................................................................................... 15-4
15-3 Regenerative Unit (RGU-2) ..................................................................................................15-5
15-3-1 Basic specifications ..................................................................................................................................... 15-5
15-3-2 Dimensions .................................................................................................................................................. 15-5
Chapter 16 APPENDIX .......................................................................................................... 16-1
16-1 How to Handle Options .......................................................................................................16-2
16-1-1 Memory card ............................................................................................................................................... 16-2
16-1-2 POPCOM communication cable ................................................................................................................. 16-4
v
MEMO
vi
Chapter 1 OVERVIEW
Thank you for purchasing the YAMAHA single-axis robot controller SRCP series (hereafter called "SRCP controller" or simply "SRCP" or "this controller"). This manual describes SRCP controller features and operating procedures.
When used with a YAMAHA single-axis PHASER series robot, the SRCP controller performs positioning and
pick-and-place tasks of various mechanical parts and devices.
This first chapter explains basic information you should know before using the SRCP controller such as names and
functions of the various parts, steps necessary to prepare the robot for operation, and the architecture of the system
itself. Please read this chapter carefully for a basic overview of the SRCP controller.
1
OVERVIEW
1-1
1-1 Features of the SRCP Series Controller
1-1 Features of the SRCP Series Controller
1
The SRCP series is a high-performance robot controller using a 32-bit RISC chip CPU.
When used with a YAMAHA single-axis PHASER series robot, the SRCP controller performs positioning tasks of various mechanical parts and devices. The SRCP controller also performs I/O control
of solenoid valves and sensors, and controls communication with a PC (personal computer).
Using only one SRCP controller allows configuring a complete system for simple applications such
as pick-and-place tasks.
OVERVIEW
The SRCP series has the following features:
■ A high-performance 32-bit RISC chip CPU is used for high-speed, high-precision software
servo control.
■ Program assets created with the previous SRC, SRCA, ERC, SRCH, ERCX and SRCX series
can be used without any modifications.
■ Ideal acceleration and deceleration speeds can be obtained by simply entering the number of
the robot to control and the payload parameter. No troublesome servo adjustments are required.
■ The I/O interface provides 8 input and 5 output points for general-purpose user wiring as a
standard feature.
■ The TPB programming box (option) allows interactive user operation by simple menus that
permit immediate use. The robot can also be operated from a personal computer (PC) just the
same as TPB when the POPCOM software (option) is installed in the PC.
■ Programs for robot operation can be written with an easy-to-learn robot language that closely
resembles BASIC. Even first-time users will find it easy to use.
■ Users not accustomed to robot language can use a PLC (programmable logic controller) to
directly move the robot by specifying the operation points.
■ Users can create programs and control the robot on a personal computer (PC). Communication
with the PC is performed with an easy-to-learn robot language similar to BASIC. Even firsttime users will find it easy to use.
■ A built-in multi-task function allows efficiently creating the programs.
■ The I/O interface supports pulse trains to allow position control by input of a pulse train.
NOTE
n
The SRCP controller can be operated from either a TPB (programming box) or a PC running with communication
software such as POPCOM. This user's manual mainly describes operations using the TPB. For details on
operation with POPCOM, refer to the POPCOM manual. If you want to use your own methods to operate the
SRCP controller from a PC, refer to Chapter 11 "Communications with PC" for pertinent information.
1-2
1-2 Setting Up for Operation
1-2 Setting Up for Operation
The chart below illustrates the basic steps to follow from the time of purchase of this controller until
it is ready for use. The chapters of this user's manual are organized according to the operation procedures, and allow first time users to proceed one step at a time.
Basic steps
Operation Information to be familiar with Refer to
Installation • Installing the controller 2-1
Wiring and connection • Connecting the power supply 2-2
• Grounding 2-3
• Connecting peripheral equipment
• Understanding the I/O interface Chapter 3
Setting parameters • Understanding basic TPB Chapter 4
operations
• Setting the various parameters Chapter 5
2-4 to 2-8
1
OVERVIEW
Programming • Inputting or editing programs Chapter 6
• Editing point data Chapter 7
• Robot language
Running the robot • Return-to-origin Chapter 9
• Various operation steps
• Emergency stop
Chapter 8
1-3
1-3 External View and Part Names
1
OVERVIEW
1-3 External View and Part Names
This section explains part names of the SRCP controller and TPB along with their functions. Note
that the external view and specifications are subject to change without prior notice to the user.
1-3-1 SRCP controller
1. Status Display Lamp
This lamp indicates the operating status of the robot and controller.
Refer to "15-1-3 LED display" for information on controller status and the matching LED
display.
2. Escape Switch (ESC switch)
Hold down this switch when connecting or disconnecting the TPB from the SRCP controller.
(See "4-1 Connecting and Disconnecting the TPB.")
3. TPB Connector
This is used to connect the TPB or the RS-232C terminal of a PC (personal computer).
4. COM Connector
This is used to connect a network system when the optional network card is installed. (This is
covered when the option is not in use.)
5. Robot I/O Connector
Input/output connector for robot peripheral device signals such as position signals.
6. I/O. CN
This is used to connect external equipment such as a PLC.
7. EXT. CN
Connector for emergency stop signal input. This connector also supplies 24V power for the
I/O devices.
8.Motor Connector
This is the power line connector for the servo motor.
9. Regenerative Unit Connector (RGEN connector)
Some types of robots require connection to a regenerative unit. In such cases, use this to connect the regenerative unit (RGU-2).
10.
Terminal Block
ACIN (L, N, )
These are terminals for supplying AC power to the SRCP controller. The ground terminal must
be properly grounded to prevent electrical shock to the human body and to maintain equipment
reliability.
NC
No connection. Do not use.
T1, T2
These are input power voltage switching terminals. When an input power voltage of AC100 to
115V is used, short the T1 and T2 terminals. When an input power voltage of AC200 to 230V
is used, leave the T1 and T2 terminals open. (SRCP-05A, 10A, 20A only)
1-4
11. Serial number nameplate
MODEL.
SER. NO.
FACTORY AUTOMATION EQUIPMENT MADE IN JAPAN
SRCP 05
370001
Controller model No.
Production No. (Serial No.)
Example:
370001
Consecutive numbers
Month of production
Year of production (lowest digit of year)
Fig. 1-1 Exterior of the SRCP controller
1-3 External View and Part Names
1
OVERVIEW
10
1
2
8
SRCP-05 SRCP-10, 20
3
4
5
6
7
11
8
9
10
1
2
3
4
5
6
7
11
8
9
10
SRCP-05A, 10A, 20A
1
2
3
4
5
6
7
11
1-5
1-3 External View and Part Names
1
OVERVIEW
Fig. 1-2 Three-side view of the SRCP controller
SRCP-05
250
157
注意
CAUTION
高温注意
HIGH TEMPERATURE
78
19
40
5.5
SRCP
MOTOR
TPB
U
V
W
COM
ROB
I/O
L
ACIN
N
I/O
200-230V~
50-60Hz
MAX. 400VA
2
PWR
(G)
ESC
EMG
24V
24G
MODEL.
SER. NO.
FACTORY AUTOMATION EQUIPMENT MADE IN JAPAN
SRCP 05
ERR
(R)
265
290
SRCP-10, 20
250
SRCP-05A, 10A, 20A
250
157
157
78
40
19
5.5
SRCP
MOTOR
U
V
W
RGEN
N
P
L
ACIN1
(PWR)
N
NC
•
NC
200-230V~
50-60Hz
MAX.1000VA
T1
T1/T2
T2
DONT CONNECT
78
40
19
5.5
SRCP
MOTOR
U
V
W
RGEN
N
P
L
ACIN1
(PWR)
N
NC
NC
T1
T2
ERR
PWR
(R)
(G)
ESC
TPB
COM
ROB
I/O
I/O
SRCP 10
MODEL.
SER. NO.
FACTORY AUTOMATION EQUIPMENT MADE IN JAPAN
ERR
PWR
(R)
(G)
ESC
TPB
COM
ROB
I/O
I/O
SRCP 10A
MODEL.
SER. NO.
FACTORY AUTOMATION EQUIPMENT MADE IN JAPAN
250
265
290
EMG
24V
24G
250
265
290
EMG
24V
24G
1-6
1-3 External View and Part Names
1-3-2 TPB
1. Liquid Crystal Display (LCD) Screen
This display has four lines of twenty characters each and is used as a program console.
2. Memory Card Slot
An IC memory card can be inserted here. Be careful not to insert the card upside-down.
3. Control Keys
The TPB can be operated in interactive data entry mode. Instructions are input through the
control keys while reading the contents on the LCD screen.
4. Connection Cable
This cable connects the TPB to the SRCP controller.
5. DC Power Input Terminal
Not used.
6. Emergency Stop Button
This is the emergency stop button. When pressed, it locks in the depressed position. To
release this button, turn it clockwise.
To cancel emergency stop, first release this button and then use the servo recovery command
via the I/O interface or the servo recovery operation from the TPB.
1
OVERVIEW
Fig. 1-3 Exterior of the TPB
4
5
Fig. 1-4 Three-side view of the TPB
F I
F 2
CHG
STOP
DIO
RUN
89
7
TIMR P L
456
CALL
WAIT
1
23
JMP
JMPB
JMPF
•
0
MOVF
MOVI
MOVA
TPB
F 3 F 4
DO
_
X
-
Z
Y
R
STEPUPSTEP
YAM
1
A
HA
T
6
PB
EM
G
2
3
EMG
ESC
BS
X
+
Z
Y
+
R
DOWN
1-7
1-4 System Configuration
1
OVERVIEW
1-4 System Configuration
1-4-1 System configuration
The SRCP controller can be combined with various peripheral units and optional products to configure
a robot system as shown below.
Fig.1-5 System configuration diagram
SRCP Controller
or
RS-232C
communication
control
TPB programming box IC memory card
I/O control
Personal computer
General-purpose input: 8 points, dedicated input: 8 points
Power
supply
Single-axis robot (PHASER series)
* Programming box TPB and support software POPCOM are sold separately.
24VDC for
I/O devices
General-purpose output: 5 points, dedicated output: 3 points
Gripper, limit switches, etc.
Support software
POPCOM
External control
(PLC and similar units)
1-8
1-5 Accessories and Options
1-5 Accessories and Options
1
1-5-1 Accessories
The SRCP robot controller comes with the following accessories. After unpacking, check that all
items are included.
1. EXT. CN connector
Connector : 733-104 made by WAGO 1 piece
2. I/O. CN connector with flat cable (option)
Connector : XG4M-4030-U made by OMRON 1 piece
3. RS-232C dust cover
XM2T-2501 made by OMRON 1 piece
1-5-2 Peripheral options
The following options are available for the SRCP controller:
1. TPB
This is a hand-held programming box that connects to the SRCP controller for teaching point
data, editing robot programs and operating the robot. The TPB allows interactive user operation by simple menus so that even first-time users can easily operate the robot with the TPB.
2. IC memory card
An IC memory card can be used with the TPB to back up programs, point data and parameter
data.
OVERVIEW
3. POPCOM
The POPCOM is support software that runs on a PC (personal computer) connected to the
SRCP controller. The POPCOM software allows easy editing of robot programs and operation
of a robot just the same as with a TPB.
1-9
MEMO
1-10
Chapter 2 INSTALLATION AND CONNECTION
This chapter contains precautions that should be observed when installing the controller, as well as procedures and
precautions for wiring the controller to the robot and to external equipment.
2
INSTALLATION AND CONNECTION
2-1
2-1 Installing the SRCP Controller
2-1 Installing the SRCP Controller
2
2-1-1 Installation method
Using the L-shaped brackets attached to the top and bottom of the controller, install the controller
from the front or rear position. (See Fig.1-2 Three-side view of the SRCP controller.)
2-1-2 Installation location
INSTALLATION AND CONNECTION
■ Install the controller in locations where the ambient temperature is between 0 to 40°C and the
humidity is between 35 to 85% without condensation.
■ Do not install the controller upside down or at an angle.
■ Install the controller in locations with sufficient space (at least 20mm away from the wall or
other object) for good ventilation and air flow.
■ Do not install the controller in locations where corrosive gases such as sulfuric acid or hydro-
chloric acid gas are present, or in atmosphere containing flammable gases and liquids.
■ Install the controller in locations with a minimal amount of dust.
■ Avoid installing the controller in locations subject to cutting chips, oil or water from other
machines.
■ Avoid installing the controller in locations where electromagnetic noise or electrostatic noise
is generated.
■ Avoid installing the controller in locations subject to shock or large vibration.
2-2
2-2 Connecting the Power Supply
2-2 Connecting the Power Supply
2-2-1 Power supply
Type and Item
SRCP-05
SRCP-10
SRCP-20
SRCP-05A
SRCP-10A
SRCP-20A
CAUTION
c
If the power supply voltage drops below the above range during operation, the alarm circuit will work and return
Power supply voltage
AC200 to 230V ±10%
AC200 to 230V ±10%
AC200 to 230V ±10%
AC100 to 115/200 to 230V ±10%
AC100 to 115/200 to 230V ±10%
AC100 to 115/200 to 230V ±10%
the SRCP controller to the initial state the same as just after power-on, or stop operation. To avoid this problem,
use a regulated power supply with voltage fluctuations of less than ±10%.
Since the SRCP controller uses a capacitor input type power supply circuit, a large inrush current flows when
the power is turned on. Do not use fast-blow circuit breakers and fuses. For the same reason, avoid turning the
power off and on again repeatedly in intervals of less than 10 seconds. This could harm the main circuit elements in the SRCP controller.
No. of phases
Single-phase
Single-phase
Single-phase
Single-phase
Single-phase
Single-phase
Frequency
50/60Hz
50/60Hz
50/60Hz
50/60Hz
50/60Hz
50/60Hz
Max. power consumption
400VA or less
600VA or less
1000VA or less
400VA or less
600VA or less
1000VA or less
2-2-2 Connecting the power supply
Connect the power supply to the power terminal block on the front panel of the SRCP controller.
Make correct connections while referring to the printed letters and mark. Misconnections may result
in serious danger such as fire. Securely connect the end of each wire to the terminal so that it will not
come loose.
2
INSTALLATION AND CONNECTION
Fig. 2-1 Power supply connections (SRCP-05, SRCP-10, SRCP-20)
1.
1.
L
N
L (AC IN)
2.
N (AC IN)
3.
(Ground)
L
N
NC
NC
T1
T2
L (AC IN)
2.
N (AC IN)
3.
(Ground)
Do not connect.
SRCP-10, 20SRCP-05
The SRCP-05A, SRCP-10A and SRCP-20A have different connections to T1 and T2, depending on
the input voltage.
Fig. 2-2 Power supply connections (SRCP-05A, SRCP-10A, SRCP-20A)
1.
L (AC IN)
N (AC IN)
2.
3.
(Ground)
NC
NC
L
N
1.
L (AC IN)
2.
N (AC IN)
3.
(Ground)
Do not connect. Do not connect.
L
N
NC
NC
T1
T2
4. 4.
Short T1 and T2
when input voltage
is AC100 to 115V.
2
or more
0.75mm
(equivalent to AWG18)
AC 100V-115V AC 200V-230V
T1
T2
Leave T1 and T2 open
when input voltage is
AC200 to 230V.
2-3
2-2 Connecting the Power Supply
2
CAUTION
c
The SRCP series controller does not have a power switch. Be sure to provide a power supply breaker (insulation)
of the correct specifications that will turn the power on or off to the entire system including the robot controller.
Power to EXT. CN must first be supplied before supplying power to the power supply terminal block. If this order
is reversed, an alarm (06: 24V POWER OFF) might be issued to prevent operation. (See "2.7 Connecting to the
EXT. CN Connector" in this chapter and Chapter 3, "I/O INTERFACE".)
WARNING
w
Before beginning the wiring work, make sure that the power supply for the entire system is
turned off. Doing the wiring work while power is still turned on may cause electrical shocks.
2-2-3 Installing an external leakage breaker
To ensure safety, a leakage breaker must be installed in the power supply connection section of the
robot controller. Since the robot controller drives the motors by PWM control, leakage current flows
at high frequencies. This might cause the external leakage breaker to malfunction.
When installing an external leakage current breaker, it is important to choose the optimum sensitivity
current rating (IΔn). (Check the leakage breaker manufacturer's data sheets to select the optimum
product compatible with inverters.)
Leakage current
CAUTION
c
1. Leak current was measured with a leak tester with a low-pass filter turned on (100Hz).
INSTALLATION AND CONNECTION
2. When using two or more controllers, sum the leakage current of each controller.
3. Make sure that the controller is securely grounded.
4. Stray capacitance between the cable and FG may vary depending on the cable installation condition, causing
WARNING
w
Electrical shocks, injuries or fires might occur if the motor breaks down while the robot controller
is used without installing a leakage breaker.
2-2-4 Installing a circuit protector
To ensure safety, a circuit protector must be installed in the power supply connection section of the
robot controller. An inrush current, which might be from several to nearly 20 times higher than the
rated current, flows at the instant that the SRCP controller is turned on or the robot motors start to
operate.
When installing an external circuit protector for the robot controller, select a circuit protector that
provides optimum operating characteristics.
To ensure proper operation, we recommend using a medium to slow response circuit protector with
an inertial delay function. (Refer to the circuit protector manufacturer's data sheets for making the
selection.)
SRCP 4mA (Max.)
Leak tester: Hioki Electric 3283
the leakage current to fluctuate.
2-4
Example
Rated current
SRCP 20A
WARNING
w
Electrical shocks, injuries or fires might occur if the motor breaks down while the robot controller
is used without installing a circuit protector.
Operating characteristics
Slow type with inertia delay
300% 2 sec.
(
1000% 0.01 sec.
)
2-2 Connecting the Power Supply
2-2-5 Installing current control switches
When controlling the power on/off of the robot controller from an external device such as a PLC, a
current control switch (contactor, breaker, etc.) may be used. In this case, the current control switch
usually creates a large on/off inrush current. To minimize this on/off inrush current, surge killers
must be installed for surge absorption. Connect a surge killer in parallel with and close to each
contact of the current control switch.
Recommended surge killer:
Okaya Electric XE1201, XE1202, RE1202
Example:
Controller
: Surge killer
L
: Contactor
2
INSTALLATION AND CONNECTION
AC IN
N
2-2-6 Insulation resistance and voltage breakdown tests
Never attempt insulation resistance tests or voltage breakdown tests on the SRCP controller. Since
capacitive grounding is provided between the controller body and 0V, these tests may mistakenly
detect excess leakage current or damage the internal circuitry. If these tests are required, please
consult your YAMAHA sales office or representative.
2-3 Grounding
The SRCP controller must be grounded to prevent danger to personnel from electrical shocks in case
of electrical leakage and prevent equipment malfunctions due to electrical noise.
We strongly recommend that Class D (grounding resistance of 100 ohms or less) or higher grounding
be provided. For grounding the controller, use the ground terminal on the power supply terminal
block.
* Class D grounding is the same as Class 3 grounding previously used.
2-4 Connecting the SRCP to the Control Unit
The SRCP controller can be operated either through the TPB programming box or through a PC
(personal computer) equipped with an RS-232C terminal.
When using the TPB, plug the TPB cable connector into the TPB connector of the SRCP controller.
(Refer to "4-1-1 Connecting the TPB to the SRCP controller".)
When using a PC, plug the RS-232C interface cable connector (25 pins) into the TPB connector of
the SRCP controller. (Refer to "11-2 Communication Cable Specifications".)
To prevent equipment malfunction due to noise, we strongly recommend that Class D (grounding
resistance of 100 ohms or less) or higher grounding be provided.
2-5
2-5 Connecting to the Robot
2
2-5 Connecting to the Robot
First make sure that the power to the SRCP controller is turned off, and then connect the robot cable
to the robot I/O connector and motor connector on the front panel of the SRCP controller. Fully insert
the robot cable until it clicks in position.
* When the robot cable is disconnected from the controller, an alarm (15: FEEDBACK ERROR
2) is issued.
2-5-1 Robot I/O connector and signal table
Mating connector type No. : 0-174047-2 (AMP)
Mating connector contact type No. : 0-175180-2
SRCP’s connector type No. : 0-174055-2
Signal table
Terminal No.
INSTALLATION AND CONNECTION
2-5-2 Motor connector and signal table
Mating connector type No. : 1-178128-4 (AMP)
Mating connector contact type No. : 1-175218-5
SRCP's connector type No. : 1-179277-5
Signal table
Terminal No.
1
2
3
4
5
6
7
8
9
10
1
2
Signal name
PS+
PSPC+
PC+5V
GND
Z+
ZDG
DG
Signal name
FG
MU
Position SIN input (+)
Description
Position SIN input (-)
Position COS input (+)
Position COS input (-)
+5V
GND
Linear scale Z+
Linear scale Z-
Digital ground
Digital ground
Description
Frame ground
Motor U-phase output
Terminal No.
11
12
13
14
15
16
17
18
19
20
Terminal No.
3
4
Signal name
NC
ORG
+24V
+24V
0V
0V
BK+
BKNC
FG
Signal name
MV
MW
No connection
Description
Origin sensor input
Origin sensor, +24V
Origin sensor, +24V
Origin sensor, 24GND
Origin sensor, 24GND
Brake (+)
Brake (-)
No connection
Frame ground
Description
Motor V-phase output
Motor W-phase output
2-6
2-6 Connecting to the I/O. CN Connector
2-6 Connecting to the I/O. CN Connector
The I/O. CN connector is used for connecting the SRCP controller to external equipment such as a
PLC. When using external equipment for I/O control, connect the wiring to the I/O. CN connector
(with a flat cable) supplied as an accessory and then plug it into the I/O. CN connector on the SRCP
controller.
Signals assigned to the I/O. CN connector terminals and their functions are described in detail in
Chapter 3.
The mating connector with a flat cable (option) for the I/O. CN terminal on the SRCP series controller is as follows:
Mating connector type No. : XG4M-4030-U (OMRON)
SRCP's I/O. CN connector type No. : XG4C-4034
2
INSTALLATION AND CONNECTION
B20
A20
B19
A19
B18
A18
.
.
.
.
.
.
.
.
.
B3
A3
B2
A2
B1
A1
Triangular mark
CAUTION
c
Regardless of whether I/O control is used or not, DC 24V power must be supplied to EXT. CN to enable robot
A20
A19
A18
A17
A16
A15
A6
A5
A4
A3
A2
A1
.
.
.
.
.
.
.
.
.
operation. If no power is supplied to EXT. CN, an alarm (06: 24V POWER OFF) is issued to prevent operation.
(See "2.7 Connecting to the EXT. CN Connector" in this chapter.)
If not using I/O control, disable the interlock function in PRM34 (System mode selection parameter). If the
interlock function is not disabled, it will be triggered during operation to prohibit the robot from operating.
B20
B19
B18
B17
B16
B15
B6
B5
B4
B3
B2
B1
.
.
.
.
.
.
.
.
.
2-7
2-7 Connecting to the EXT. CN Connector
2-7 Connecting to the EXT. CN Connector
Connect an emergency stop circuit and a 24V power supply for I/O control to the EXT. CN connector. Make the necessary wiring hookup (see below) to the mating connector that comes with the
2
SRCP controller and then plug it into the EXT. CN connector. Make sure the wiring is correct since
miswiring may cause serious accidents such as fire. Regardless of whether I/O control is used or not,
24V power for I/O control must always be supplied to the EXT. CN connector.
The meaning and operation of signals assigned to each terminal on the EXT. CN connector are
explained in detail in Chapter 3, "I/O INTERFACE".
The mating connector for the EXT. CN terminal on the SRCP series controller is as follows:
Mating connector type No. : 733-104 (WAGO)
SRCP's EXT. CN connector type No. : 733-364
Slotted screwdriver
Terminal numbers are not actually
indicated, but designated from 1 to
4, from the left as viewed from the
front (wire insertion side) as shown
4
3
2
1
in the drawing.
INSTALLATION AND CONNECTION
To make the wiring hookup to the mating connector (WAGO 733-104), insert the wire lead into the
terminal slot while pressing down the internal spring with a slotted screwdriver through the top slot.
(If you have a dedicated tool, insert it into the smaller slot just above each terminal slot for wire
insertion to make a quick connection.
CAUTION
c
Regardless of whether I/O control is used or not, DC 24V power must be supplied to EXT. CN to enable robot
operation. If no power is supplied to EXT. CN, an alarm (06: 24V POWER OFF) is issued to prevent operation.
Power to EXT. CN must first be supplied before supplying AC power to the power supply terminal block. If this
order is reversed, an alarm (06: 24V POWER OFF) might be issued.
CAUTION
c
If you do not configure an emergency stop circuit, then short terminal No. 1 (EMG1) to terminal No. 2 (EMG2).
Unless these terminals are shorted, emergency stop is always activated to prohibit the robot from operating.
DANGER
w
Be sure to turn off the power to the entire robot system before doing any wiring to the SRCP
controller. Failure to do so may cause electrical shocks.
2-8
2-8 Connecting to the Regenerative Unit
2-8 Connecting to the Regenerative Unit
Some types of robots must be connected to a regenerative unit. In such cases, use the interconnection
cable to connect the SRCP controller to the regenerative unit.
Fig. 2-3 Connecting the SRCP controller to a regenerative unit
2
INSTALLATION AND CONNECTION
Use the interconnection
cable to make connections.
2-9
MEMO
2-10
Chapter 3 I/O INTERFACE
The SRCP series has I/O interface connectors (EXT. CN and I/O. CN) as a standard feature. The EXT. CN is used
for emergency stop input and 24V power input for I/O control. The I/O. CN consists of an interlock input, 7
dedicated command inputs, 3 dedicated outputs, 8 general-purpose inputs, 5 general-purpose outputs, feedback
pulse outputs, etc. These I/O interfaces allow exchanging commands and data between the SRCP series and external equipment. These I/O interfaces can also directly connect to and control actuators such as valves and sensors. To
construct a system utilizing the features of the SRCP series, you must understand the signals assigned to each
terminal on the I/O. CN and EXT. CN and how they work. This chapter covers this fundamental information. This
chapter also provides examples of I/O circuit connections and timing charts for expanding the system by using a
PLC or similar devices. Refer to these diagrams and examples when creating sequence programs.
Terms "ON" and "OFF" used in this chapter mean "on" and "off" of switches connected to the input terminal when
referring to input signals. They also mean "on" and "off" of output transistors when referring to output signals.
3
I/O INTERFACE
3-1
3-1 I/O Signals
3-1 I/O Signals
The SRCP controller has two I/O interface connectors (EXT. CN and I/O. CN) as a standard feature.
The EXT. CN is used for emergency stop input and 24V power input for I/O control. The I/O. CN is
used for interlock signal input, dedicated command input, dedicated output, general-purpose input
and output, and feedback pulse output.
3
I/O INTERFACE
3-1-1 I/O. CN connector signals
The I/O. CN connector of the SRCP controller has 40 pins, with an individual signal assigned to each
pin. The following table shows the pin number as well as the name and description of each signal
assigned to each pin. For a more detailed description of each signal, refer to "3-2 Input Signal Description" and onwards.
Pin No.
No.
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
n
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
Signal name
ABS-PT
AUTO-R
ORG-S
SERVO
BUSY
PZM+
Absolute point movement
command
Automatic operation start command
Return-to-origin command
Servo recovery command
General-purpose input 0
DI0
General-purpose input 2
DI2
General-purpose input 4
DI4
General-purpose input 6
DI6
General-purpose output 0
DO0
General-purpose output 2
DO2
General-purpose output 4
DO4
Command-in-progress output
Frame ground
FG
Signal ground
GND
Reserved (Do not use.)
NC
Reserved (Do not use.)
NC
Feedback pulse output
PA+
Feedback pulse output
PB+
Feedback pulse output
PZ+
Feedback pulse output
NOTE
Pin B8 functions as the SERVICE mode input terminal only when the SERVICE mode function is enabled.
Description
No.
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
2
4
6
8
Pin No.
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
Signal name
INC-PT
STEP-R
RESET
LOCK
DI1
DI3
DI5
DI7/SVCE
DO1
DO3
END
READY
FG
GND
NC
NC
PAPBPZ-
PZM-
Relative point movement command
Description
Step operation start command
Reset command
Interlock
General-purpose input 1
General-purpose input 3
General-purpose input 5
General-purpose input 7/SERVICE mode input
General-purpose output 1
General-purpose output 3
End-of-run output
Ready-to-operate output
Frame ground
Signal ground
Reserved (Do not use.)
Reserved (Do not use.)
Feedback pulse output
Feedback pulse output
Feedback pulse output
Feedback pulse output
3-1-2 EXT. CN connector signals
The EXT. CN connector of the SRCP controller has 4 pins, with an individual signal assigned to each
pin. The following table shows the pin number as well as the name and description of each signal
assigned to each pin. For a more detailed description of each signal, refer to "3-2 Input Signal Description" and onwards.
Pin No.
Signal name
1
EMG1
3
NOTE
n
The positive polarity of the 24V DC must be connected to pin 3 (24V) and the negative polarity to pin 4 (24G).
Emergency stop input 1 (used with
EMG2)
24V power supply for sequence input
24V
Description
Pin No.
2
4
Signal name
EMG2
24G
Emergency stop input 2 (used with
Description
EMG1)
24V power supply for sequence input
3-2
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