Robostar RcT Series Instructions for use

R
Ro ob bo os st ta ar r R Ro ob bo ot t C Co on nt tr ro ol ll le er r
C
Co on nt tr ro ol ll le er r S Se er ri ie es s- -R Rc cT T
I
In ns st tr ru uc ct ti io on n a an nd d M Ma ai in nt te en na an nc ce e M Ma an nu ua al l
Robostar Robot Controller Manual
□
Instruction and Maintenance Manual
□
Operation Manual
□
Programming Manual
□
Unihost Manual
□
Alarm Code Manual
√
Robostar Co., Ltd.
Rbostar Robot Controller Manual

Robostar Co., Ltd
Copyright ⓒROBOSTAR Co., Ltd 2010
The copyright of this instruction manual belongs to Robostar Co., Ltd. No part of this manual can be used
in any form or by any means without the permission of Robostar Co., Ltd.
Specifications are subject to change without prior notice.

Before Reading the Operation Manual
Robostar Co., Ltd
B
Be ef fo or re e R Re ea ad di in ng g t th he e O Op pe er ra at ti io on n M Ma an nu ua al l
◈Most of all, read through safety precautions to use the controller properly.
◈Contents of the operation manual may vary depending on the software version
and may be notified to the user without notice.
◈Contact the person in charge in Robostar Co., Ltd for an inquiry about the updated
manual version.
◈Screens and pictures in the operation manual may be different from the actual
thing.
◈Prior to use, it is essential to check out the name plate of the controller and
whether the robot is consistent with S/N.

Product Warranty
Robostar Co., Ltd
Product Warranty
Robostar products are manufactured under strict quality control and all Robostar products
are warranted for one year from date of manufacture. During the warranty period, free
services shall be provided only for : mechanical failure due to the negligence of Robostar, or
failure caused by designs and in the manufacturing process during normal operation,
Free services are not provided in the following cases.
(1) After the warranty period expires.
(2) Failure caused by inappropriate repairs, alterations, and shifting that are instructed by your enterprise or the
third party, as well as other mishandling failure.
(3) Failure due to the use of unauthorized products, including parts and grease.
(4) Failure due to incidents involving fire, disasters, earthquakes, damage from storm and flood, and other force
majeure events.
(5) Failure caused by the use of products outside the environment specified in our product specifications, such as
in excretion and flooding.
(6) Wear-out failures for consumables.
(7) Failure due to the negligence of conducting maintenance and inspection work as specified in the operation
manual and the instruction manual.
(8) Damages other than robot repair costs.
Address and Contact Details for Robostar Co., Ltd
Head Office and Facility
119-38, Sasa-dong, Sangnok-gu,
Ansan-City, Gyeonggi-do, Republic of
South Korea (426-220)
Second Facility
(1st Floor, Lot 3, Block 4, Suwon Hi-tech
Industrial Complex)
960, Gosaek-dong, Gwonseon-gu,
Suwon-City, Gyeonggi-do, Republic of
South Korea (441-360)
Service Request and
Product Enquiries
-Sales Enquiry
TEL. [phone]
FAX. [phone]
-Customer Enquiry
TEL. [phone]
www.robostar.co.kr

Configuration of This Manual
Robostar Co., Ltd
C
Co on nf fi ig gu ur ra at ti io on n o of f T Th hi is s M Ma an nu ua al l
This manual consists of the following.
For safe use
Describes safety precautions in use of a robot.
Ch.1 Controller Overview
Describes controller’s features, model configuration, and the attachment location of a
name plate.
Ch.2 Basic Specifications
Describes controller installation environment, performance and specifications.
Ch.3 Controller Installation Method
Describes environmental conditions in controller installation and ventilation direction.
Ch.4 Controller Configuration
Describes controller size, Connector and names of main components.
Ch.5. Teach Pendant(T/P) Configuration
Describes how to connect T/P, how to use a Deadman.

Safe Use Guidelines
Robostar Co., Ltd
a
S
Sa af fe e U Us se e G Gu ui id de el li in ne es s
Robot Safety (General)
For safe use of this product, be sure to become well aware of the manual prior to use.
Each manual contains the following marks in where special attention is required for safe
use. So, take a close look the manual before using the product.
Safety Marks
Symbol
Description
It indicates that critical damage to persons or property may occur
if handled incorrectly.
It indicates that product failure, malfunction or incidents may arise
if handled incorrectly.
It indicates that the product may do wrong operation or fail to
operate due to incorrect use, which therefore requires special
attention.
It indicates things prohibited for the normal use of the product.
Ex.) Mark for use of fire prohibited
It indicates what should be done for normal use of the product.
Ex.) Mark for mandatory grounding
필수

Safe Use Guidelines
Robostar Co., Ltd
b
For safer and more effective use, be
sure to become aware of the manual
prior to use
Keep all loads and power supplies
within the rated range. Particularly,
do ensure input power supply
is AC 220V before use.
When installing a robot, fix it
firmly so that it cannot be moved.
This robot and the robot controller are industrial equipment manufactured with high
technology, therefore, be sure to follow the precautions listed below to be prepared
for possible incidents.

Safe Use Guidelines
Robostar Co., Ltd
c
For safe work, install a safety net
around the robot operating area.
Be sure to check the wiring before
turning ON the controller power.
An incorrect wiring may lead to the
abnormal system operation.
For prevention of electric shock
accidents, be sure to install
FG (Frame Ground).
필수

Safe Use Guidelines
Robostar Co., Ltd
d
While the robot is in motion or in
stand-by mode, take caution and do
not step into the robot operating
area. Take the same caution any time
even when the robot is stopped.
When several people are working at
a time, check for mutual safety before,
proceeding with the work, in particular,
involving power ON/OFF, motor
activation, and hand-operated
operation.
In robot maintenance, be sure to
Disconnect controller power switch,
remove the power plug from the
controller, and wait for over
3 minutes before starting the inspection.

Safe Use Guidelines
Robostar Co., Ltd
e
When turning off the controller
power while the robot is working
or Servo On, Z (up, down) axis may fall
5~10mm. Stop the robot from working,
turn Servo Off and turn the power Off.

Contents
Robostar Co., Ltd
i
Contents
CH.1 CONTROLLER OVERVIEW ..................................................................................1-1
1.1 FEATURES......................................................................... 오류!책갈피가 정의되어 있지 않습니다.
1.2 EXAMPLE OF MODEL NAME REFERENCE (COMMON) ..................................................................... 1-2
1.3 NAMEPLATE ....................................................................................................................... 1-3
1.3.1 M Type(Mid-size) .......................................................................................................................................... 1-3
1.3.2 L Type(Large Size).......................................................................................................................................... 1-3
CH.2 BASIC SPECIFICATIONS......................................................................................2-1
2.1 INSTALLATION AND SURROUNDING ENVIRONMENT ........................................................................ 2-3
2.2 PERFORMANCE................................................................... 오류!책갈피가 정의되어 있지 않습니다.
2.3 SPECIFICATIONS ................................................................. 오류!책갈피가 정의되어 있지 않습니다.
CH.3 HOW TO INSTALL A CONTROLLER .....................................................................3-1
3.1 SECURING SUITABLE INSTALLATION ENVIRONMENTS ...................................................................... 3-1
3.1.1 Requirements for Installation Environment....................................................오류! 책갈피가 정의되어 있지 않습니다.
3.1.2 Ambient Temperature and Humidity.............................................................. 오류! 책갈피가 정의되어 있지 않습니다.
3.1.3 Vibration ......................................................................................................오류! 책갈피가 정의되어 있지 않습니다.
3.2 SECURING INSTALLATION SPACE ............................................. 오류!책갈피가 정의되어 있지 않습니다.
3.3 VENTILATION DIRECTION........................................................................................................ 3-4
3.4 POWER SUPPLY AND CONNECTING METHOD............................... 오류!책갈피가 정의되어 있지 않습니다.
3.5 PROTECTIVE COVER INSTALLATION ........................................................................................... 3-7
CH.4 CONTROLLER CONFIGURATION.........................................................................4-1
4.1 M-TYPE(MID-SIZE) ............................................................................................................ 4-1
4.1.1 Size..............................................................................................................오류! 책갈피가 정의되어 있지 않습니다.
4.1.2 Controller Connector, Names and Description of Main Components ...............오류! 책갈피가 정의되어 있지 않습니다.
4.1.3 Connector In-depth Description ..................................................................................................................... 4-4
4.1.4 Option.......................................................................................................................................................... 4-30
4.1.5 Servo Driver Capacity and Assignment.......................................................................................................... 4-39
4.2 LTYPE(LARGE SIZE) .......................................................................................................... 4-40
4.2.1 Size..............................................................................................................오류! 책갈피가 정의되어 있지 않습니다.
4.2.2 Controller Connector, Names and Description of Main Components............오류! 책갈피가 정의되어 있지 않습니다.
4.2.3 Connector In-depth Description ................................................................................................................... 4-42
4.2.4 Option.......................................................................................................................................................... 4-70
4.2.5 Servo Driver Capacity and Assignment.......................................................................................................... 4-74
4.3 SAFETY INTERFACE OPTION(COMMON).................................................................................. 4-75
4.3.1 SD Version ................................................................................................................................................... 4-75
4.3.2 LD Version.................................................................................................................................................... 4-76
4.3.3 CS Version(Safety Unit Ver.)......................................................................................................................... 4-77
CH.5 TEACH PENDANT(T/P)......................................................................................5-1
5.1 HOW TO CONNECT T/P ........................................................ 오류!책갈피가 정의되어 있지 않습니다.
5.2 HOW TO USE DEADMAN ........................................................................................................ 5-2
5.3 MODE SWITCH ................................................................................................................... 5-3

Ch.1 Controller Overview
Robostar Co., Ltd
1-1
Ch.1 Controller Overview
1.1 Features
RcT Series is a high-performance robot motion controller suitable for a variety of
applications, containing the following features below
PC-based robot controller
Multitasking support
Easy to expand an Option Card by employing an industrial standard PCI bus
Enables driving maximum 16 axes by employing the Servo amp of communication
Type
Provides rich input/output interface
-User In/Out(32점/32점), Option In/Out(32점/32점)
Rich built-in robot commands
-User definition function
-String manipulation function
-Special function function (Align, Mapping, etc)
Monitoring function while in operation
Provides data backup and edit program
Besides, robot control performance improvement enables
Parallel processing of robot commands while in operation, such as input/output by
conditions and processing of transfer instruction
Pass Motion function such as travel distance ratio setup (FOS) becomes possible.

Ch.1 Controller Overview
Robostar Co., Ltd
1-2
1.2 Examples of Model Configuration (Common)
C
T
C
1
E
M
N
C
P
U
F
0
L
1
2
3
4
5
6
7
8
9
10
Classifi-
cation
Name
Description
1
Controller Classification
Controller Model :RcT 1st generation
2
Servo Type
E : EtherCat
P : Pulse
S : Serial
3
Main B/D Option
X : None
M : Ext Memory
4
Ext B/D Option 1
N : Standard I/O
I : Basic I/O + Extension I/O N com
5
Ext B/D Option 2
C : CCLink
I : PIO(NPN)
2 : RS232
6
Motor/Servo Maker
P : Panasonic
T : Servotronix
7
Safety Level
2 : Category2
3 : Categor3 –CS PLC(Omron)
U: Categor3 –CS Unit(Omron)
4 : Categor4 –PLC(Omron)
T : Categor3 –CS PLC(Pilz)
F : Categor4 –PLC(Pilz)
8
Axis Number
0 ~ Z
9
Option 1(Servo List)
0 ~ Z
10
Option 2(Size)
S : Small Type
M : Middle Type
L : Large Type

Ch.1 Controller Overview
Robostar Co., Ltd
1-3
1.3 Nameplate
1.3.1M Type(Mid-size)
1.3.2L Type(Large Size)
(Attached inside
Door)
EMO Emergency
Power OFF
Front EMO Cover
(CS Version)
EMO Emergency
Power OFF
(CS Version)

Ch.2 Basic Specifications
Robostar Co., Ltd
2-1
Ch.2 Basic Specifications
2.1 Size
2.1.1M type
(Unit : mm)
743
600
550
500
50
Connector
Protective
Cover

Ch.2 Basic Specifications
Robostar Co., Ltd
2-2
2.1.2L type
When installing a controller, keep the front/rear at an
interval of 250mm or over to connect robot cables.
(Unit : mm)
1300
550
600
70
157.5
Connector
Protective
Cover

Ch.2 Basic Specifications
Robostar Co., Ltd
2-3
2.2 Installation and Surrounding Environment
Item
Description
Controller Input Power
AC 220V, ±10% 2Phase, 50-60Hz
Motor Input Power
AC 220V, ±10% 3Phase, 50-60Hz
Controller Input Capacity
Max. 1.46VA
Motor Input Capacity
Max. 20kVA
Encoder Size
17bit Absolute Encoder (Serial Type)
Operating Ambient
Temperature
0 ~ 40°C
Operating Ambient Humidity
20 ~ 80% RH (Should be condensation free)
Ambient Temperature for
Storage
-15 ~ 60°C
Ambient Humidity for
Storage
１０ 90% RH (Should be condensation free)
.
2.3 Performance
Item
Description
Withstanding Voltage
AC-FG간1.5kV ,10mA 1minute, between 1st-2nd 3kV, 10mA 1minute
Power Noise Withstand
Capability
±1,500Vp-p, 1usec, COMMON and Normal 1minute
Noise
Withstand
Capability
Motor/Encoder
±1,500Vp-p, 1usec, induction Noise 1minute
I/O
±1,500Vp-p, 1usec, induction Noise 1minute
Insulation Resistance
Between input power and FG : Over 20MΩ
Instantaneous Interruption
Withstand Capability
1/2 CYCLE per 10 cycle of input power frequency
Position Precision
±1 PULSE of ENCODER
Servo Capacity
Max. 5Kw
I/O
Min Input Current
5mA/1 point
Max Output
Current
50mA/1 point
Brake Control
24V Motor Brake operation
Motor Control Method
AC Servo Motor operation (Sine wave PWM current control)

Ch.2 Basic Specifications
Robostar Co., Ltd
2-4
2.4 Specifications
Item
Description
Robot Application
Transfer Robot
Operation Control Method
Point To Point Motion
Control Axis Setting
Max 15 axes
Position Feedback
By absolute encoder
Drive System
AC Servomotor
Digital I/O
Basic I/O
Input :32 Points
Output :32 Points
Extension I/O
Input : 32 Points
Output : 32 Points
Teaching Method
Direct Teaching (Teach Pendant)
On-Line Teaching (Uni-Host)
Multi-robot Support
Maximum 3
Robot Language
RRL (ROBOSTAR Robot Language)
Specifications
for Robot
Program
Support
Job
Max 250/ Channel(3Ch)
Point
Max 40000
Step
Max 10000
Global Variable
Integer-type max 1000, real-type max 1000
External Communication
Specification (Option)
CC Link, PIO, RS232
Error Display
7-Segment , Teach Pendant
On - Line Function
Job, Point, Parameter edit, save function
Protection Function
OverCurrent, OverLoad, OverSpeed, Position Error, etc
Specific Function
Position Latch
Safety Specification
Category 3, Category4
Cooling Method
Forced Ventilation
Weight
M Type
Max 75 Kg
L Type
Max 200Kg

Ch.3 How to Install a Controller
Robostar Co., Ltd
3-1
Ch.3 How to Install a Controller
3.1 Securing Appropriate Installation Environment
3.1.1 Requirements for Installation Environment
■As the robot and the controller are not made free of explosion, dust and splash, they
are unable to be installed in the following places.
▶Operating environment associated with flammable gas and combustible liquid.
▶Environment where conductive materials such as processed metal chips are being
scattered.
▶Environment where corrosive gas such as acids and alkalis exists.
▶Environment where mist such as cutting fluid and abrasive fluid exists.
▶Environment where mist such as oil-containing cutting fluid and abrasive fluid
exists.
▶Environment close to the source of electric noise such as a large inverter, a high
power & high-frequency oscillator, a large conductor and a welder.
3.1.2 Ambient Temperature and Humidity
■Set the ambient temperature at the range of 0 ~ 40 ℃while operating.
■Keep the humidity below 80 % RH(MAX).
■Keep the place well ventilated, and dust, dirt and humidity at minimized level.
3.1.3 Vibration
■Install the machine away from the environment where an excessive vibration and
impacts are imposed.
Installation environment for the robot body and controller is very important,
so be sure to implement installation environment specified below. If
installation environment is found to be inappropriate, it may prevent functions
and performances from fully working, cause the machine life to be shortened,
further cause an unexpected machine failure.

Ch.3 How to Install a Controller
Robostar Co., Ltd
3-2
3.2 Securing Installation Space
Be sure to secure enough space, as shown below, by considering the interference of a cooling fan, the
securing of ventilation space and the bend of a robot cable.
3.2.1M Type
▶The controller runs by a forced ventilation method as a way of cooling
method. Be sure to secure some space so no interference is generated in the
cooling fan.
▶ Secure space including the protective cover when installing a protective
cover. This is for robot cables not to have a sharp curve.
▶Secure space in the right part in charge of storing T/P so that an
emergency switch should not operate. Robot can stop in an emergency by
operating the emergency switch.
Over 50mm
Over 50mm
Over 100mm
Over 100mm