Okura Yusoki A Series User manual

Okura Yusoki Co., Ltd.
Robot Manual
Installation and Adjustment
- Electrical -
UL-CE-VINSE-01
-Ori
g
inal instructions-

History
Version
(Date)
Content Page
01 (2012.04.24) First edition

Introduction
Thank you for purchasing a model from the Okura Robot Palletizer A series.
This manual is a guidebook to help you safely and correctly use your A Series
Robot Palletizer. It should be useful not only to beginners who are using an Okura
Palletizer for the first time, but also to experienced users, who can use this Manual to
reconfirm their knowledge. Please read this Manual carefully and use the Palletizer
with a clear understanding of its content.
NOTE
Unauthorized reproduction of part or all of the content of this manual is forbidden.
The content of this manual is subject to future change without prior notice.
Safety Instructions
Each A Series Robotic Palletizer is equipped with a variety of protective features.
However, an increased level of safety results when these safety precautions are
constantly reviewed and consistently followed with a separate manual of “Safetey”.
IMPORTANT
IMPORTANT
Only AUTHORIZED PERSONNEL can operate, maintain the robot or work on
programming.
The definition of “AUTHORIZED PERSON” is that the only personnel who can
operate the robot and/or robot system, are those who have enough knowledge or
experience of robot operation and have also been trained to operate the robot.
They must also have been authorized by the employer.
The safety instructions with left sign of IMPORTANT
throughout this manual are enforcement or warning that
if not correctly operated or handled, you may be
seriously injured or killed.
Be sure to follow those safety instructions.

Table of Contents
1. OUTLINE OF CONTROLLER 1-1
1.1. APPEARANCE OF CONTROLLER······················································ 1-2
1.2. TEACHING PENDANT (INSTALLATION PERSONNEL ONLY)················ 1-3
2. HARNESS CABLE CONNECTION 2-1
2.1. INSIDE-ROBOT HARNESS CABLE ·················································· 2-2
2.2. SPARE CABLES ··········································································· 2-5
2.3. CONNECTION OF MAIN POWER SUPPLY WIRES ································ 2-6
2.4. PROTECTION AGAINST LIGHTNING SURGE········································· 2-7
2.5. OTHER NOTES (WIRING)···························································· 2-7
3. CONTROLLER BOARDS AND UNITS 3-1
3.1. CPU BOARD (RC501)································································ 3-2
3.2. I/O BOARD (RC512) ································································ 3-5
3.3. SERVO POWER UNIT (SPCU-1A) ················································ 3-6
3.4. CONTACTOR UNIT (MCRU-1-UL/CE)·········································· 3-7
3.5. SAFETY RELAY BOARD (RC516)·················································· 3-8
3.6. AMP UNIT ··············································································· 3-10
3.7. FIELDBUS BOARD (ETHERNET/IP AB6214）·····························3-11
4. ADJUSTMENTS 4-1
4.1. ORIGIN STORING ······································································· 4-2
4.2. BASIC POSTURE ········································································· 4-4
4.3. AMP UNIT ················································································· 4-5
4.4. COLLISION DETECTION ······························································· 4-6
5. SYSTEM STORAGE 5-1
5.1. PERIPHERAL EQUIPMENT NAME INPUT·········································· 5-2
5.2. COMMUNICATION SETTING ·························································· 5-2
5.3. EXTERNAL PLC COMMUNICATION SETUP ······································· 5-3
5.4. PASSWORD SETTING ··································································· 5-5
5.5. MEMORY SWITCH ······································································· 5-5
5.6. PARAMETER SETTING (CONTROLLER DATA)··································· 5-9
5.7. FIRMWARE UPDATE··································································· 5-10
5.8. HOUR METER············································································ 5-12
5.9. SOFT LIMIT ·············································································· 5-13
5.10. HAND SETUP ············································································ 5-14
5.11. PARAMETER SETTING (ROBOT DATA)········································· 5-15
5.12. ORIGIN STORING ····································································· 5-16
5.13. SERVO PARAMETER··································································· 5-16
5.14. EXPANSION AXIS SETTING ························································ 5-17

6. MAINTENANCE FUNCTIONS 6-1
6.1. MENU STRUCTURE ······································································ 6-2
6.2. DATA MEMORY CONTENTS···························································· 6-4
6.3. I／OMONITOR ·········································································· 6-5
6.4. OPERATION READY CONDITION···················································· 6-6
6.5. KEY TRACE ················································································ 6-6
6.6. FILE OPERATION ········································································ 6-7
6.7. LOGIC ANALYZER ······································································· 6-9
6.8. ID NO –PRG NO ALLOCATION ··················································· 6-11
6.9. BATTERY REPLACE ·····································································6-12
6.10. CONVEYOR INFORMATION ··························································6-12
6.11. STACKED COUNTER REVISION ·····················································6-13
6.12. PROGRAM SELECTION METHOD ····················································6-14
6.13. POSITION &ACCELERATION /DECELERATION TIME ······················6-14
6.14. EXECUTED SEQUENCE COMMAND··················································6-15
6.15. OVERLAP TRACE ········································································6-15
6.16. SMOV CALCULATION·································································6-16
6.17. DEVIATION TRACE·····································································6-16
6.18. POSITION COMMAND TRACE ·······················································6-17
6.19. SERVO TORQUE INDICATE···························································6-18
6.20. COLLISION DETECTION ······························································6-19
6.21. EXPANSION AXIS TRACE·····························································6-19
7. TABLE OF BASIC SPECIFICATIONS 7-1

1-1
1. Outline of Controller
Names of part of controller and main parts are introduced in this section.

1-2
1.1. Appearance of Controller
1.1.1. Robot Controller
This is common among RC830 and RC840 (See 5. SYSTEM SPECIFICATIONS for model of
controller for detail.)

1-3
1.2. Teaching Pendant (Installation Personnel Only)
Teaching pendant works at manual mode.
Note
・Manual operation on controller does not work once teaching pendnat is
connected.
How to set up teaching pendant
→See”Operation Manual” Section 4
① E/S push button switch
② Data display
③ Enable switch
①
②
③

2-1
2. Harness Cable Connection

2-2
2.1. Inside-Robot Harness Cable
The following shows the cable wiring inside robot and the composition of the cable
harness between robot and controller
[A1800V/A1800V－W]
Inside-robot wiring
Harness cables between robot and controller
CN1
CN2
CN3
CN4
CN5
RB721
RB722
RB723
R
B724
R
B725
ROBOTCONTROLLER
CN1 CN13
D-motor
CN14
CN15
O-motor
CN16
CN11
R-motor
CN12
CN8
CN9
CN10
CN7
CN2
CN3
RM815
RM816
RM817
RK831
RM832
RK833
CN6
CN18
CN4 CN22 D-encoder
CN23 O-encoder
CN24
CN26
CN31
RM851
RM852
RK853
RK854
RK855 RK873
RM856
CN34
RK857
CN21 R-encoder
T-AXIS
HAND
CN37
CN5
BAT
CN17 T-motor
CN25 T-encoder
CN33
CN32
RK874
CN36
CN35
RM871
RK781
RK782
AIR 12mm
10mm
12mm
12mm
AIR 12mm
R-LS
RK858 CN39
RM835
ROTORBASE
CN40 FAN
RK875
Danger Enforcement
Make sure if primary power supply is securely connected with
controller. Otherwise, you may get an electric shock.

2-3
[A1600V/ A1600V－W]
Inside-robot wiring
Harness cables between robot and controller
CN1 CN13 D-motor
CN14
CN15 O-motor
CN16
CN11 R-motor
CN12
CN8
CN9
CN10
CN7
CN2
CN3
RM731
RM735
RM733
RK731
RM732
RK733
CN6
CN18
CN4 CN22 D-encoder
CN23 O-encoder
CN24
CN26
CN31
RM751
RM752
RK753
RK754
RK755 RK773
RM757
CN34
RK758
CN21 R-encoder
T-AXIS
HAND
CN37
CN5
BAT
CN17 T-motor
CN25 T-encoder
CN33
CN32
RK774
CN36
CN35
RM771
RK781
RK782
AIR 12mm
10mm
12mm
12mm
AIR 12mm
R-LS
RK759 CN39
RM737
ROTORBASE
CN1
CN2
CN3
CN4
CN5
RB721
RB722
RB723
R
B724
R
B725
ROBOTCONTROLLER
Danger Enforcement
Make sure if primary power supply is securely connected with
controller. Otherwise, you may get an electric shock.

2-4
[A700V]
Inside-robot wiring
Harness cables between robot and controller
BASE
CN1 CN13 D-motor
CN15 O-motor
CN11 R-motor
CN8
CN7
CN2
RM741
RM742
CN6
CN18
CN4 CN22 D-encoder
CN23 O-encoder
CN24
CN26
CN31
RK761
RK762
RK763
RM764
RK765 RK773
RK767
CN34
RK768
CN21 R-encoder
ROTOR
HAND
CN37
CN5
BAT
CN17 T-motor
CN25 T-encoder
CN33
CN32
RK774
CN36
CN35
RM770
RK781
RK782
AIR 12mm
10mm12mm
12mm
AIR 12mm
R-LS
RK769 CN39
RM736
T-AXIS
CN1
CN2
CN4
CN5
RB728
RB729
R
B724
R
B725
ROBOTCONTROLLER
Danger Enforcement
Make sure if primary power supply is securely connected with
controller. Otherwise, you may get an electric shock.

2-5
2.2. Spare Cables
The following spare cables for between robot and controller are provided for Okura A
series robot palletizer as shown on the below table.
[A1800V/A1600V/A700V]
Robot main unit connector Connector in controller
Connector
No.
Pin No. Wire No. Connector No. Pin
No.
Wire No. Wire
size
3 S3 1 S3
4 S4 2 S4
13 S5 3 S5
CN33
[3191-15R1]
14 CLS
CNH2
[F31FSS-05V-KX]
4 CLS
1 S6 A1 S6
2 S7 A 2 S7
3 S8 A 3 S8
4 S9 A 4 S9
5 S10 A 5 S10
6 S11 A 6 S11
7 S12 A 7 S12
8 S13 A 8 S13
9 S14 B1 S14
10 S15 B2 S15
11 S16 B3 S16
12 S17 B4 S17
13 S18 B5 S18
CN35
[3191-15R1]
14 S19
CNH3※２
[F31FDS-16V-K]
B6 S19
0.3 ㎜２
CN33，CN35
CNH2
CNH3

2-6
2.3. Connection of main power supply wires
Connect main power supply wires on the basis of bellows.
1. Introduce of electric wires must be relevant
position of controller.
2. Protection degree of the busing, for electric
wires introduction must be equal or more
than IP5X.
3. Connect external protective conductors to
terminal with mark PE by the side of main
breaker(NFB0).
4. Put main power supply wires separately in
the duct, and put a charging mark on the
duct.
5. In connecting main power supply wires and
external protective conductors vend wire
adequately (if needed). And fix them firmly
so that not to strain on the terminal.
Specification of main power supply wires
Wires: UL standard
Wires size: minimum AWG#10
Conductor: copper
Temperature rating: minimum 90°C (194°F)
Terminal processing: A round terminal (UL Listed one) that suits the size of
the electric wire and tool of maker recommendation are used.
Grounding
Specification of external protective conductors
Wires: UL standard
Wires size: minimum AWG#10
Conductor: copper
Temperature rating: minimum 90°C (194°F)
Color: Green/yellow
Terminal processing: A round terminal (UL Listed one) that suits the size of
the electric wire and tool of maker recommendation are used.
Entrance of wires
Bottom view

2-7
2.4. Protection Against Lightning Surge
There is no protection against lightning surge inside of controller.
Relevant protection against lightning shall be required when connecting main power
supply.
2.5. Other Notes (Wiring)
2.5.1. Attaching insulation cover
Attach cover to O-axis and D-axis connector, which keep more than 10 mm clearance and
creepage distance not to touch.
2.5.2. Securing of Grounding Continuity
1. Connect following wires between robot body and protective conductors inside
controller.
Wires: IEC standard
Wires diameter: more than 10 sqmm
Color: green/yellow
2. Measure resistance value between each motor frames and external protective
conductor of controller, and confirm if the value is less than following resistance
value.
Resistance value : 0.1 ohm or less per 10 A
3. Attaching duct
Harness between controller and robot must be put in metal duct.
Divide power line and control line by separator.
Minimum size of duct is 150 mm wide and 100 mm deep.
4. Fix protective conductor terminal with specified screw to the robot as shown in the
figure. And fix insulator separately.

2-8
2.5.3. Cables to enter into control panel
Cables to enter into panel like I/O cables to/from peripheral conveyors need to be
installed following the below way.
1. The cables to enter through opening at bottom of panel need to be fixed around
opening to not come out.
The cables are fixed by saddles to bracket near opening or fixed by cable grips at
opening.
2. Fill in the opening after installed.
*Bracket near opening

3-1
3. Controller Boards and Units
The boards inside the controller and their configuration are as follows.
RC512
I/O Board
RC512
I/O Board
SPCU-1A
Servo Power Unit
RC516
Safety Board
RC501
ＣＰＵ Board
AP507
(AP504)*
Amp Unit
Servo
motor
Servo
motor
Servo
motor
Servo
motor
Ｒaxis
D axis
O axis
T axis
Touch Panel
(
POD
)
OXPA
Teaching
Pendant
AP507
(AP504)*
Amp Unit
AP507
(AP504)*
Amp Unit
AP508
Amp Unit
*( A700V)
Optional
Hand External PLC
RC512
I/O Board
Amp Unit
Amp Unit
Servo
motor
Servo
motor
Spare axis
Spare axis

3-2
3.1. CPU Board (RC501)
The arrangement of LED's、switches and 7-segment displays on Main CPU board is as
follows.
DIP switch DSW1 Explanation
No. Descriptions Default setting
１Firmware Serial transfer OFF
２System reserve OFF
３System reserve OFF
４System reserve OFF
５Motor rotation test OFF
６System reserve OFF
７Execution of master DSP program loading ON
８Execution of initialization OFF