Nachi RMU20-20 User manual

FD/CFD CONTROLLER
INSTRUCTION MANUAL
Robot Monitoring Unit
RMU20-20/30/40
・Before attempting to operate the robot, please read through this operating manual
carefully, and comply with all the safety-related items and instructions in the text.
・The installation, operation and maintenance of this robot should be undertaken only
by those individuals who have attended one of our robot course.
・When using this robot, observe the low related with industrial robot and with
safety issues in each country.
・This operating manual must be given without fail to the individual who will be actually
operating the robot.
・Please direct any queries about parts of this operating manual which may not be
completely clear or any inquiries concerning the after-sale service of this robot to any
of the service centers listed on the back cover.
8th edition
1505, TFDEN-143-008, 001

Contents
1
Contents
Chapter 1 Introduction
1.1 Outline ....................................................................................................................................... 1-1
1.1.1 Features of robot monitoring unit ...................................................................................... 1-1
1.1.2 Functions of robot monitoring unit ..................................................................................... 1-1
1.1.3 Specifications..................................................................................................................... 1-2
1.1.4 Type and serial number ..................................................................................................... 1-8
1.2 Risk Assessment ....................................................................................................................... 1-9
1.3 Connection...............................................................................................................................1-10
1.3.1 Required parts and installation (FD controller)................................................................ 1-10
1.3.2 Required parts and installation (CFD controller) .............................................................1-10
1.3.3 Sequence board UM367-20 ............................................................................................ 1-11
1.3.4 Connection of safety inputs .............................................................................................1-12
1.3.5 Connection of safety outputs...........................................................................................1-16
1.4 EC DECLARATION OF CONFORMITY FOR MACHINERY................................................... 1-17
Chapter 2 Monitoring Unit Configuration
2.1 Connections with External Equipment....................................................................................... 2-1
2.2 Description of Exterior and Parts............................................................................................... 2-3
2.2.1 View of exterior.................................................................................................................. 2-3
2.2.2 LED.................................................................................................................................... 2-5
2.2.3 Connector .......................................................................................................................... 2-7
2.3 Connected signals ...................................................................................................................2-14
2.3.1 Signal connection diagram .............................................................................................. 2-14
2.3.2 Safety inputs .................................................................................................................... 2-15
2.3.3 Safety outputs.................................................................................................................. 2-18
2.3.4 Back check circuit............................................................................................................2-19
2.3.5 Monitor inputs .................................................................................................................. 2-20
2.3.6 Monitor outputs................................................................................................................2-21
2.3.7 Motion controller interface ...............................................................................................2-22
2.3.8 Encoder interface ............................................................................................................2-22
2.3.9 Motor interface.................................................................................................................2-22
2.3.10 Power supply .................................................................................................................2-22
2.4 Precautions when Installing RMU inside the Controller ..........................................................2-23
2.4.1 Low-Voltage Directive requirements to be satisfied (compliance with EN50178)...........2-23
2.4.2 EMC Directive requirements to be satisfied (compliance with EN61326-3-1) ................2-23
2.4.3 Other: processing the cables connected to RMU20 ....................................................... 2-24
2.5 Operating Range, Angle and Speed Monitoring Function ....................................................... 2-25
2.5.1 Collaborative operation with human ................................................................................ 2-25
2.5.2 Operating range monitoring............................................................................................. 2-26
2.5.3 Angle monitoring..............................................................................................................2-27
2.5.4 How to reset operating range and angle monitoring function ......................................... 2-27
2.5.5 Speed monitoring.............................................................................................................2-27
2.5.6 Stop monitoring................................................................................................................2-27
2.5.7 Stop Control monitoring Function in Area........................................................................ 2-28
2.5.8 Tool Number monitoring Function ...................................................................................2-29
2.6 Motor Power Control Sequence ..............................................................................................2-31
2.6.1 Outline of motor power control sequence ....................................................................... 2-31

Contents
2
2.6.2 Motors ON condition........................................................................................................2-32
2.6.3 Motor power-ON control ..................................................................................................2-32
2.6.4 Timing chart .....................................................................................................................2-33
2.7 Logical operation output function.............................................................................................2-35
2.8 RMU error signal output (Application signals)......................................................................... 2-37
2.9 Enabling RMU.......................................................................................................................... 2-38
Chapter 3 Virtual Safety Fence Function
3.1 Outline of Virtual Safety Fence Function............................................................................. 3-1
3.2 Operation procedure ........................................................................................................... 3-2
3.2.1 Installation angle............................................................................................................. 3-2
3.2.2 Virtual safety fence settings............................................................................................ 3-4
3.2.3 Range setting..................................................................................................................3-5
3.2.4 Tool limit setting ............................................................................................................ 3-13
3.2.5 Arm limit setting ............................................................................................................ 3-20
3.2.6 Other settings ............................................................................................................... 3-22
3.2.7 “VSF approach area” output signal...............................................................................3-23
3.2.8 Setting example of the limit line.................................................................................... 3-24
3.2.9 Creation of data file....................................................................................................... 3-25
3.2.10 Convenient shortcut....................................................................................................3-25
3.3 List of Error Codes ............................................................................................................3-26
3.4 Setting when a slider unit is used...................................................................................... 3-27
3.4.1 Mechanism relation....................................................................................................... 3-27
3.4.2 Installation angle (Example1) .......................................................................................3-28
3.4.3 Installation posture (Example2) ....................................................................................3-29
Chapter 4 Monitoring Unit Settings
4.1 Configuration flow of setting procedure.....................................................................................4-1
4.2 Setting of parameters ................................................................................................................ 4-4
4.2.1 Setting of mechanism parameters..................................................................................... 4-5
4.2.2 Setting of axis parameters................................................................................................. 4-6
4.2.3 Tool parameters ................................................................................................................. 4-8
4.2.4 Setting of stop parameters ................................................................................................4-9
4.2.5 Setting of signal parameters............................................................................................ 4-10
4.2.6 Setting the logical operation parameters......................................................................... 4-12
4.2.7 Setting the Safety network parameters (RMU20-30) ......................................................4-14
4.2.8 Setting the Safety network parameters (RMU20-40) ......................................................4-15
4.3 Confirmation of parameters ..................................................................................................... 4-16
4.3.1 Conformation of mechanism parameters ........................................................................4-17
4.3.2 Conformation of axis parameters ....................................................................................4-19
4.3.3 Conformation of tool parameters..................................................................................... 4-21
4.3.4 Conformation of area parameters ...................................................................................4-22
4.3.5 Conformation of limit parameters ....................................................................................4-24
4.3.6 Conformation of stop parameters....................................................................................4-26
4.3.7 Conformation of signal parameters .................................................................................4-27
4.3.8 Confirmation of Logic parameters ...................................................................................4-29
4.3.9 Confirmation of Safety network parameter (RMU20-30)................................................. 4-30
4.3.10 Confirmation of Safety network parameter (RMU20-40)............................................... 4-31
4.4 Approval...................................................................................................................................4-32
4.4.1 Approval procedure .........................................................................................................4-32

Contents
3
4.4.2 Robot Monitoring Unit simple approval operation ........................................................... 4-34
4.5 Setting of disconnection ..........................................................................................................4-37
4.5.1 Setting of disconnection ..................................................................................................4-37
4.6 Menu list ..................................................................................................................................4-39
4.6.1 Operating range monitoring............................................................................................. 4-39
4.6.2 Angle monitoring..............................................................................................................4-39
4.6.3 Speed monitoring.............................................................................................................4-39
4.6.4 Stop monitoring................................................................................................................4-39
4.6.5 Tool number monitoring ................................................................................................... 4-40
4.6.6 Safety network parameters (RMU20-40) ........................................................................4-40
Chapter 5 EtherNet/IP Safety network
5.1 Outline of the EtherNet/IP safety network function ............................................................. 5-1
5.2 Setting for RMU................................................................................................................... 5-2
5.2.1 Safety network parameter............................................................................................... 5-2
5.2.2 Assignment of the network I/O signals ........................................................................... 5-2
5.3 Settings for the safety PLC ................................................................................................. 5-4
5.3.1 Setting procedure ...........................................................................................................5-4
5.4 Trouble shooting.................................................................................................................. 5-9
5.4.1 Trouble shooting via the LEDs........................................................................................ 5-9
5.4.2 Error codes .....................................................................................................................5-9
Chapter 6 PROFINET Safety network function
6.1 Outline of the PROFINET safety network function.............................................................. 6-1
6.2 Setting for PROFINET module ............................................................................................ 6-2
6.2.1 Fieldbus settings............................................................................................................. 6-2
6.2.2 Setting for the PROFINET Safety ................................................................................... 6-4
6.3 Safety network parameters ................................................................................................. 6-6
6.3.1 Assignment of the network I/O signals ........................................................................... 6-6
6.4 Trouble shooting.................................................................................................................. 6-8
6.4.1 Trouble shooting via the LEDs........................................................................................ 6-8
6.4.2 Error codes .....................................................................................................................6-9
Chapter 7 Maintenance and Inspections
7.1 Periodic Inspections ............................................................................................................7-1
7.1.1 Inspection schedule........................................................................................................ 7-2
7.1.2 Routine inspection items ................................................................................................ 7-2
7.1.3 Periodic inspection items ................................................................................................ 7-3
7.1.4 Replacing of the RMU..................................................................................................... 7-4
7.2 Troubleshooting................................................................................................................... 7-5
7.2.1 Example of trouble shooting .........................................................................................7-16
7.2.2 Procedures to be performed after encoder replacement work.....................................7-16
7.2.3 Trouble shooting example for input signal inconsistency failure .................................. 7-19

Contents
4

Chapter 1 Introduction
This chapter presents an outline of the robot monitoring unit (RMU) functions.
1.1 Outline ........................................................................................................1-1
1.1.1 Features of robot monitoring unit ..........................................................1-1
1.1.2 Functions of robot monitoring unit.........................................................1-1
1.1.3 Specifications ........................................................................................1-2
1.1.4 Type and serial number.........................................................................1-8
1.2 Risk Assessment ........................................................................................1-9
1.3 Connection................................................................................................1-10
1.3.1 Required parts and installation (FD controller) ....................................1-10
1.3.2 Required parts and installation (CFD controller) .................................1-10
1.3.3 Sequence board UM367-20 ................................................................ 1-11
1.3.4 Connection of safety inputs.................................................................1-12
1.3.5 Connection of safety outputs...............................................................1-16
1.4 EC DECLARATION OF CONFORMITY FOR MACHINERY.....................1-17

1.1 Outline
1-1
1.1 Outline
1.1.1 Features of robot monitoring unit
The robot monitoring unit (RMU20) is a Category 4 and PLe compliant system which monitors the robot
position and speed so as to shut off the power to the robot when its position or speed are deemed to be irregular.
The robot position monitoring system consists of safety circuits using microcomputers and semiconductors,
and input/output signals, redundant safety signals and other signals from the process control panel are
connected as the input/output signals from outside the robot controller.
Control signals of emergency stop button, operation switches, and magnetic switch of the robot controller are
connected as the internal input/output signals, and the unit has functions for monitoring the sequence and
status.
The robot monitoring unit is connected by a cable to the position encoder of the drive motor so that the unit
can monitor the robot operations, and the system ensures that the robot will stop safely when the robot has
operated irregularly.
1.1.2 Functions of robot monitoring unit
The robot monitoring unit is equipped with the following safety functions.
Operating range monitoring function
This function shuts off the safety outputs and stops the robot safely when the robot wrist, tool, work or robot
arm is about to move outside any of the operating ranges which have been set.
Angle monitoring function
This function monitors the operating ranges of the robot axes, and it shuts off the safety outputs and stops the
robot safely when movement along any one of the axes is about to exceed an operating range which has been
set.
Speed monitoring function
This function shuts off the safety outputs and stops the robot safely when the TCP speed exceeds 250
mm/sec. in TEACH mode.
Also this function shuts off the safety outputs and stops the robot safely when the TCP speed or each joint
speed has exceeded the pre-determined level in AUTO and MANUAL mode.
Stop monitoring function
When the "Stop watch signal" (stop monitoring input signal) has been cut off, this function monitors
whether the TCP and each joint angle are operating or not. This function shuts off the safety outputs and stops
the robot safely when they have exceeded the pre-determined level.
Robot controller communication
This function enables the parameters required for monitoring to be set from the robot controller.
Encoder and motor I/F
This function is for reading out the position information required for monitoring the robot position and speed
from the encoder and motor power lines.
Input/output signal, Motor power control sequence
This function always monitors statuses of redundant emergency stop and enable switch, and it executes the
servo power on/off sequences. It uses the B (normally closed) contact of the magnet switch that turns the drive
power of the motor on and off as a start condition of the robot, and enables the melting of the magnet switch to
be back-checked.

1.1 Outline
1-2
1.1.3 Specifications
General Specifications
Item Specifications Remarks
1 Rated voltage DC24V +10%
-15%
2 Rated current U24V 1.0A
U24A 0.5V
This value
depends on the
connected devices
3 Safety input signals
All 13 ports
Robot Emergency stop
Emergency stop
Safety plug
Protective stop
Enable switch
External enable input
Robot over travel Limit Switch
Slave error
General-purpose safety input 1-5
Selctable as “area selection signal”, “stop monitoring
signal” or “playback speed monitoring signal”
Redundant
safety input
4 Safety output signals
All 4 ports
Robot servo ON
General safety output (3 points)
Redundant
safety output
with back-check
5 Monitor input signals All 16 ports
6 Monitor output signals All 9 ports
7 Number of axes to be
monitored
Max. 8 axes
8 Position detector
Serial encoder
Panasonic N400 format
Nikon A format (also bus communication type)
Magnetic pole position detection circuit of the motor
9 Parameter transfer Transferred from the robot controller
10 Communication of the
parameter
USB
11 External dimensions 54 (W) x 242 (H) x 251 (D) mm Including
mounting bracket
12 Protective structure IP20
13 Ambient temperature 0 to 55 ℃
14 Ambient humidity 30 to 85% Without condensation
15 Safety network
(RMU20-30 only) CIP Safety on Ethernet/IP RMU20-30 only
16 PROFINET Safety PROFIsafe on PROFINET
RMU20-40 only
The PROFINET
Device
communication
board is also
necessary.
(FD11-OP162-B,
C,D)