Robostar N2S Series User manual

Robostar Robot Controller
N2S Series
Instruction and handling Manual
Version: N2S-IM-E02
Issued Data: July 10, 2019

Copyright 2018, ROBOSTAR Co., Ltd. All right reserved.
Copyright of this instruction manual is reserved to Robostar Co., Ltd.
Any part of this manual cannot be used as other forms or other means without permission of Robostar.
The specifications are subject to change without notice in advance.

About Product Warranty
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About Product Warranty
Products of Robostar Co., Ltd. are manufactured under the strict quality control. All the
Robostar products’ warranty period is one year from the date of manufacture. During this
period, Robostar is only responsible for the mechanical failures due to negligence of
Robostar, or the problems on design and manufacture occurring during normal use, in
which the service is free of charge. However, the service is not free of charge service in the
following cases
(1) After the warranty period has expired
(2) Failures arising due to improper repair, alteration, redeployment, or other mishandling, under the instruction
of you or any third party
(3) Failures as a result of using parts, grease, etc. which have not been designated by Robostar
(4) Failures caused by accidents, such as fire, disaster, earthquake, storms, or other natural disasters
(5) Failures caused in manure, flooding, or other environment
(6) Failure caused by the consumption of consumable parts
(7) Failures arising when not being operated under the instructions listed in the user or instruction manual and the
maintenance manual
(8) Damages in cost other than the cost of robot repairing
Address and contact points of Robostar Co., Ltd.
Head Office & Factory
700, Suin-ro, Sangnok-gu, Ansan-City,
Gyeonggi-do, Republic of South Korea
(15523)
Request for service and inquiry
of products
- Information on Marketing
TEL. [phone]
FAX. [phone]
- Customer Service
TEL. [phone]
Suwon Factory
37, saneop-ro 155beon-gil,
Gwonseon-gu, Suwon-City,
Gyeonggi-do,
Republic of South Korea (16648)
www.robostar.co.kr

For safe use
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For safe use
I. Safety for robots (General)
Be sure to fully understand the manuals for safe use of this product. Each manual
includes the following notations for subjects requiring carefulness necessary for the
safe use of this product, and therefore carefully read the manual before using this
product
Safety Signs
Sign
Meaning
This sign indicates that, if handled incorrectly, the serious life or
property damage may be caused.
This sign indicates that, if handled incorrectly, the product
failure, malfunction or accident may arise.
This sign indicates that the product may malfunction or may not
work due to incorrect use, and shows a matter requiring
attention.
This sign shows the matter that is to be prohibited for normal
use of the product.
E.g.) Never use a fire.
This sign shows the matter that must be performed for normal
use of the product.
E.g.) Compulsory ground is required.
DANGER
WARNING
CAUTION
PROHIBITION
Required

For safe use
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For safe and more efficient use,
please operate the robot after
reading all the documentations.
All of the load and power must be
used within the range of rated load
and power spec.
In particular, make sure before use
that the input power is AC 220V.
When installed, the robot must be
securely fixed so as not to be
shaken.
Since this robot and robot controller are industrial equipment manufactured with
advanced technology, please be sure to observe the following matters in order to
prepare for accidents that may occur.
WARNING
CAUTION
CAUTION

For safe use
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For safe operation, a safety net must
be installed around the robot.
Make sure to check the wirings of a
controller before powering on it.
Due to the incorrect wirings, the
machine may not work properly.
To prevent electrical shock, be sure
to install FG (Frame Ground).
DANGER
CHECK

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Be careful not to move into the
range of motion of a robot while the
robot is operating or in the operable
state.
Please note such subject even if the
robot is in stationary state.
If many people work at the same time,
especially in powering ON/OFF and
driving a motor manually, be sure to
check the mutual safety before
starting the work.
When in maintenance of the robot,
be sure to unplug a power cord of the
controller
DANGER
CAUTION
DANGER

For safe use
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II. Safety for robots (Details)
(1) For the safety of workers, be sure to wear a helmet, safety shoes, etc.
(2) When before turn on the power, check that there is no person within the area of robot
motion and then operate the robot.
(3) When moving into the area of the robot motion for maintenance or inspection, be
sure to power OFF the robot.
(4) If a cable of the robot is installed in a pathway, prevent the cable from damage by using
a cover or a duct.
(5) As soon as the cable damage is found, replace it immediately.
(6) Do not operate the robot under the load exceeding nominal weight.
(7) Be sure to fully understand the instruction manual before operating the robot.
(8) In the case of installing a safety net
①Give it sufficient strength to withstand reactions that occur during work, or
environmental conditions, and do not have it be easily moved, destroyed, or
climbed.
②Remove the dangerous parts, such as sharp edges or burr.
③Firmly fix it.
④If you are installing a safety net having a door, install a detector or other sensors
so that the robot is stopped immediately after the door is opened.
⑤The safety net must be distanced by 40 cm or farther from robot motion area
and the robot body.

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(9) Emergency Stop Switch
①Mount an emergency stop switch at the place where an operator can easily
operate the robot.
②The color of the emergency stop switch is to be red with yellow circumferential
band for easy discrimination of its position.
③Use the emergency stop switch which does not automatically return.
(10) Ground Specification
- Class 3 Ground (Ground resistance is not more than 100Ω.)
(11) Lamp indicating the robot power supplying status
- Install a lamp which indicates whether the power source is being supplied to the robot

Contents
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Table of Contents
I. Safety for robots (General)...........................................................................................4
II. Safety for robots (Details) ............................................................................................8
Chapter 1 Controller Overview ...................................................................................................12
1. Features ..................................................................................................................................................................................12
2. Name Plate Configuration.............................................................................................................................................13
2.1 Locations of Name Plate .....................................................................................................................................13
2.2 Name Plates...............................................................................................................................................................14
3. N2S Series Controller Product Code .........................................................................................................................15
4. Software version.................................................................................................................................................................16
5. Name of Each Part.............................................................................................................................................................17
5.1 General 8 axes controller appearance .........................................................................................................17
6. Specifications .......................................................................................................................................................................20
6.1 General Specifications..........................................................................................................................................20
6.2 Specifications of Power Circuit Electrical Parts ........................................................................................22
6.3 Power Supply ............................................................................................................................................................23
6.4 Product Dimension ................................................................................................................................................25
Chapter 2 Installing Method of Controller ..................................................................................26
1. Getting Proper Installation Environment................................................................................................................26
1.1 Conditions for installation environment .....................................................................................................26
1.2 Ambient temperature and humidity .............................................................................................................26
1.3 Vibration .....................................................................................................................................................................26
2. Installation Space ...............................................................................................................................................................27
3. Ventilation direction .........................................................................................................................................................32
Chapter 3 Robot Connection and External Interface ...................................................................33
1. Construction of robot system ......................................................................................................................................33
2. Controller Unit Connection Method ........................................................................................................................34
2.1 AC Power Cable ......................................................................................................................................................34
3.1.1 EtherCAT Interface .....................................................................................................................................35
2.2 Teach Pendant Interface......................................................................................................................................36
2.3 Machine Safety Circuit Interface .....................................................................................................................38
2.4 Controller Safety circuit block diagram .......................................................................................................45
3. Online Connection ............................................................................................................................................................46
4. Robot connection ..............................................................................................................................................................47
4.1 Encoder, Sensor and Brake Interface............................................................................................................48
4.2 Motor Power Interface.........................................................................................................................................49
5. Input/output Connection ...............................................................................................................................................50
5.1 Input/output Assignment ...................................................................................................................................50

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5.2 Input/output Specification.................................................................................................................................50
5.3 I/O Interface ..............................................................................................................................................................51
5.4 User I/O Circuit Diagram .....................................................................................................................................52
5.5 User I/O connector Specification and Circuit Diagram ........................................................................54
5.6 Extension user I/O Interface ..............................................................................................................................56
5.7 Extension User I/O Circuit Diagram ...............................................................................................................57
5.8 Extension User I/O Connector Specification and Circuit Diagram .................................................59
Chapter 4 About Teach Pendent.................................................................................................61
1. Connection of Teach Pendent......................................................................................................................................61
2. Appearance and How to Operate .............................................................................................................................62
2.1 Size.................................................................................................................................................................................62
2.2 Construction of Operation Keys ......................................................................................................................63
2.3 Functions of Operation Keys.............................................................................................................................64
2.4 Deadman Switch.....................................................................................................................................................68
Chapter 5 Controller Alarm Code ...............................................................................................69
1. Alarm Summary List..........................................................................................................................................................69
2. How to clear Alarms and Warnings ..........................................................................................................................72
Chapter 6 Maintenance .............................................................................................................73
1. Inspection and troubleshooting..................................................................................................................................73
2. Parts Replacement .............................................................................................................................................................73
2.1 Inspection and replacement method for cooling fan...........................................................................74
2.2 Inspection and replacement method for air filter ..................................................................................75
2.3 Inspection and replacement method for RTC battery ..........................................................................76
3. Works after replacing parts...........................................................................................................................................78
3.1 Origin position setup ............................................................................................................................................78
Chapter 7 Revision .....................................................................................................................79
A. Literature Reference...................................................................................................80

Controller Overview
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Chapter 1 Controller Overview
1. Features
N2S Series Controller is a high-performance robot controller for a wide variety of applications
and has the following features.
6 axes Vertical articulated robot
Controls 4 to 6 axes Cartesian coordinate robot, SCARA robot and semiconductor
robot
Full-digital servo system
Modularized 2 axes servo amplifiers
Easy to change various parameters and the gain (changeable by the software)
Monitoring available while in operation
Provides rich input-output interfaces
-System In/Out(20 points/20 points), Option In/Out(32 points/32 points)
Plenty of robot commands included
Offers the versatile online program (Unihost)
In addition, to improve the robot control functions.
Palletizing, sealing, etc.
2D and 3D interpolation control of the arc, circle, high-speed, and high precision
Parallel processing of the robot commands while processing the input and output
and the movement command depending on the conditions
Variety of pass motions, such as Position Factor Of Successive Path(PFOS), Factor Of
Successive Path(FOS), etc.

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2. Name Plate Configuration
The model name of the controller is written on a name plate or paper which is attached
to a front side of the controller as shown below. For identification of the model name,
refer to a code table below.
2.1 Locations of Name Plate
<Top >
<Front >
②
①

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2.2 Name Plates
CE Certified
①Standard Name plate
-. Controller Only
-. With Robot
②Safety name plate
KCs Certified
①Standard Name plate
-. With Robot
②Safety name plate
Robostar
N2S CONTROLLER
MODEL : N2S-RA007
SPEC. : N2S-8X8X4111
-G-NS-C-I-X-X-S0
SER. NO. :
Robostar Co., Ltd.
Robostar
N2S CONTROLLER
MODEL : N2S
SPEC. : N2S-8X8X4111
-G-NS-C-I-X-X-S0
SER. NO. :
Robostar Co., Ltd.
Robostar
N2S CONTROLLER
MODEL : N2S-RA007
SPEC. : N2S-8X8X4111
-G-NS-C-I-X-X-S0
SER. NO. :
Robostar Co., Ltd.

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3. N2S Series Controller Product Code
N2 Code Table
N 2
-
S
-
G
-
N S
-
X
-
C
-
I
-
X
-
X
-
S 0
SERIES
N2 CONTROLLER
CASE
S : Small 8axes Case
M: Medium Case
L: Large Case
POWER
G : SINGLE POWER
U : DUAL POWER
INTERFACE
NS : NPN
PS : PNP
NL :
NPN + LED Control
PL : PNP + LED Control
MAIN
X : STANDARD
E: Ethernet Port
OPTION 1
C CCLINK I Ext. I/O NCOM
L CCLINK IE O Ext. I/O PCOM
E ETHERCAT T TRACKING
P PETHERNET IP
G PROFINET
X NONE
OPTION 2
- Same as OPTION 1
SERVO IO
X: None
L: Limit Sensor
M: Mapping Sensor
R: Align Sensor
AGENT
X: None
A: AGENT PC
Special Version
S0 : Safety Categry 3 Standard

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4. Software version
The version of software in the controller can be checked by a teaching pendant, as
shown below.
Step 1.
Screen Display
After controller booting is completed,
select 9. INFO
<MANUAL MODE>
1. JOB 2.RUN
3. HOST 4.PARA
5.ORIGIN 6. I/O
7.GVAL 8. GPNT
9.INFO
ITEM #
Select 2.CONT
Check Software Version
<INFO>
1. ROBOT 2.CONT
3. LOG 4.USB
ITEM #
<INFO:CONT(1/3)>
N2-SERIES
MAIN B/D VER.
01.00.01-C3
(AR 190224)
PRE NEXT EXIT

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5. Name of Each Part
The following shows the names of each part of the appearance of the controller. For
more information, see the table below.
5.1 General 8 axes controller appearance
<Top>
<Front> <Side>
<Back>
<Bottom>

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Names and description of each part (General 8 axes controller)
1
2
3
4
5
6
7
8
9
10
11
12
13
15
14
16
17
18
19
20
21
22
23
24
25
26
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
43
44
44
44
44
45
45
45
43

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Connector NO
Exterior Marking
Description
1
MAIN 12V/IO24V/SAFE24V/BRK24V
SMPS Status Indicator
2
AC 220V, 1Ø50/60Hz
AC power input connector
3
POWER SWITCH
AC power input switch
4
FG (Frame Ground) Connection Terminal
5
PWR/HDD
LED for main board status
6
M1
Ethernet, USB Connector
7
M2
RS-232C Connector
8
RUN/ERR
LED for Interface board status
9
M3 OUT
Field Bus(EtherCAT) output connector(Interface)
10
MX1
User in/out connector
11
M4
Teach pendant connector
12
MX2
Safety Input1 connector
13
MX3
Safety Input2 connector
14
MX4
Safety Output connector
15
MX5
Deadman Mute connector
16
OPTION B/D 1
Extension slot for Option I/O, Field Bus, analog B/D, etc.
17
OPTION B/D 2
Extension slot for Option I/O, Field Bus, analog B/D, etc.
18
SERVO I/O B/D
Extension slot for servo module I/O
19
S1 IN
Field Bus(EtherCAT) input connector (1A, 1B)
20
S1 OUT
Field Bus(EtherCAT) output connector (1A, 1B)
21
S2
Servo module update and monitoring (1A, 1B)
22
S3
Encoder input connector(1A, 1B)
23
S4
Motor power output connector (1A, 1B)
24
S5
Regenerative resistor connector(1A, 1B)
25
S1 IN
Field Bus(EtherCAT) input connector (2A, 2B)
26
S1 OUT
Field Bus(EtherCAT) output connector(2A, 2B)
27
S2
Servo module update and monitoring (2A, 2B)
28
S3
Encoder input connector(2A, 2B)
29
S4
Motor power output connector (2A, 2B)
30
S5
Regenerative resistor connector(2A, 2B)
31
S1 IN
Field Bus(EtherCAT) input connector (3A, 3B)
32
S1 OUT
Field Bus(EtherCAT) output connector(3A, 3B)
33
S2
Servo module update and monitoring (3A, 3B)
34
S3
Encoder input connector(3A, 3B)
35
S4
Motor power output connector (3A, 3B)
36
S5
Regenerative resistor connector(3A, 3B)
37
S1 IN
Field Bus(EtherCAT) input connector (4A, 4B)
38
S1 OUT
Field Bus(EtherCAT) output connector(4A, 4B)
39
S2
Servo module update and monitoring (4A, 4B)
40
S3
Encoder input connector(4A, 4B)
41
S4
Motor power output connector (4A, 4B)
42
S5
Regenerative resistor connector(4A, 4B)
43
Ventilation hole on top
Inhaling ventilation hole and air filter
44
Regenerative resistor
Servo module regenerative resistor
45
Ventilation hole on bottom
Exhausting ventilation hole and fan

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6. Specifications
6.1 General Specifications
Installation Environment
Performance
Item
Description
Supply Power
AC 220V(+10% ~ -15%) , 50 ~ 60Hz, 20A(MAX)
Power Capacity
3.2kVA (Max load)
Encoder Specification
17bit/23bit Encoder (Serial Type)
Ambient temperature for use
0 ~ 40°C
Ambient humidity for use
20 ~ 80% RH (No dew formed)
Ambient temperature for
storage
-15 ~ 60°C
Ambient humidity for
storage
10 ~ 90% RH (No dew formed)
Item
Description
Withstanding Voltage
AC-FG 1.5kV for 1 min., Primary-Secondary 3kV for 1 min.
Immunity to Source Noise
±2,500Vp-p , 1usec , for COMMON and Normal each,
for 1 min.
Noise
Immunity
Motor/Encoder
±2,500Vp-p , 1usec , under induced noise for 1 min.
I/O
±2,500Vp-p , 1usec , under induced noise for 1 min.
Insulation Resistance
Input power-to-FG: 1MΩor more
Immunity to Instantaneous
Power Failure
1/2 cycle per 10 periods of the Input power frequency
Servo Capacity
0.8 kW max for 2 axes module,
3.2 kW max for overall 8 axes module
I/O
Minimum Input
Current
5mA/1point
Maximum
Output Current
50mA/1point
Brake Control
24V motor brake drive
Motor Control
AC servo motor drive (Sine wave PWM current control)