Sankyo R O B O T I C S™ SC3000 Series Installation and Specifications Manual CONTENTS Preface Safety Getting Ready for Your System Site Installation Requirements Installation Instructions Digital Input/Digital Output Specifications Glossary ADS Communications Port Cable Wiring RS-232C Communications Port Cable Wiring Physical (User) DI/DO Charts Warranty SC3000 Series Installation and Specifications Manual SC3000 Robot Systems Federal Communications (FCC) Statement Warning: This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instructions manual, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference. September 2001 SC3000 Series Installation and Specifications Manual Version 2.10 Updates text and graphics regarding AC power in Chapter 3, "Installation"; and specifications data in Chapter 5, "Specifications". Changes are periodically made to the information herein. Refer to the last page of the Preface Chapter to see a history of changes to this manual. Sankyo will make its best effort to report any changes in subsequent revisions, or in Technical Newsletters. This publication could contain technical inaccuracies or typographical errors. Also, illustrations contained herein may show prototype equipment. Your system configuration may differ slightly. Any questions concerning the use of a Sankyo robotic product or on the contents of this document should be directed to any of the Sankyo Seiki Robotics Divisions. Refer to the Preface for information on the nearest Sankyo Robotics Division contact. IBM is a registered trademark of International Business Machines Inc. Motorola is a trademark of Motorola Incorporated. Windows is a registered trademark of the Microsoft Corporation. Windows 95, Windows 98, Windows NT, Windows 2000 and Windows ME are registered trademarks of the Microsoft Corporation. Copyright Sankyo Seiki Mfg. Co., Ltd. 1994 - 2001 Sankyo is a trademark of Sankyo Seiki Mfg. Co., Ltd. SC3000 Series Installation and Specifications Manual CONTENTS Preface .......................................................................................................................... vii Audience .................................................................................................................................................vii About this Manual....................................................................................................................................vii Conventions used in this Manual ........................................................................................................... viii Related Publications ................................................................................................................................ix SC3000 Series Installation and Specifications Manual - History ............................................................. x Safety.............................................................................................................................. xi Installation Site Safety Precautions ....................................................................................... xi Safety Notices .........................................................................................................................................xii Operation and Maintenance Safety Procedures .....................................................................................xii Safety Inspection....................................................................................................................................xiv Electrical Safety.......................................................................................................................................xv Chapter 1 Getting Ready for Your System ................................................................ 1-1 Considerations ...................................................................................................................................... 1-3 Safety .................................................................................................................................................... 1-4 What You Supply - Summary................................................................................................................ 1-5 Schedule of Events ............................................................................................................................... 1-6 Important Contacts ................................................................................................................................ 1-7 Chapter 2 Site Installation Requirements.................................................................. 2-1 Power Distribution ................................................................................................................. 2-3 Emergency Power-Off........................................................................................................................... 2-3 Grounding.............................................................................................................................................. 2-3 Neutral................................................................................................................................................... 2-3 Convenience (Service) Outlets ............................................................................................................. 2-3 Preparation of the 19-inch Rack (option) ............................................................................. 2-4 Electrical Noise ...................................................................................................................... 2-5 EMI (Electromagnetic Interference) ...................................................................................................... 2-5 ESD (Electro Static Discharge) ............................................................................................................. 2-5 Safety and Remote Circuits................................................................................................... 2-6 Emergency Stop Circuit Extension........................................................................................................ 2-6 Remote Manipulator Power-On Switch ................................................................................................. 2-6 Remote "Error-On" Indicator ................................................................................................................. 2-6 Robot Mounting Dimensions ................................................................................................ 2-7 SR8437/SR8438 and SR8447/SR8448 Series .............................................................................. 2-7 CCR Models – Standard X Axis ..................................................................................................... 2-8 CCR Models – LONG X Axis.......................................................................................................... 2-9 Environment ......................................................................................................................... 2-10 Climate and Altitude ............................................................................................................................ 2-10 Atmosphere ......................................................................................................................................... 2-11 Particulate Contaminates .................................................................................................................... 2-11 Copyright © Sankyo Robotics, 1994-2001 CONTENTS i SC3000 Robot Systems Corrosive Gas Contaminates .............................................................................................................. 2-11 Vibration .............................................................................................................................................. 2-11 Lightning Protection ............................................................................................................ 2-12 Exhaust Piping ..................................................................................................................... 2-12 Chapter 3 Installation Instructions ............................................................................ 3-1 Installation .............................................................................................................................. 3-3 Lockout/Tagout...................................................................................................................................... 3-3 Installation Checklist ............................................................................................................. 3-4 Unpacking the Components.................................................................................................. 3-5 Packaging.............................................................................................................................................. 3-5 Installation Steps.................................................................................................................... 3-6 SC3000 Robot System Packing List ..................................................................................................... 3-6 Lifting the SR8437/38 and SR8447/48 Series Robot............................................................................ 3-7 Installing the SR8437/38 and SR8447/48 Series Robot ....................................................................... 3-8 Lifting the CCR-M Series Robot............................................................................................................ 3-9 Installing the CCR-M Series Robot ..................................................................................................... 3-12 Lifting the SC3000 Series Robot Controller ........................................................................................ 3-12 Installing the SC3000 Series Robot Controller ................................................................................... 3-12 AC Power Distribution ......................................................................................................... 3-13 Emergency Power-Off......................................................................................................................... 3-13 Grounding............................................................................................................................................ 3-13 Neutral................................................................................................................................................. 3-13 Convenience (Service) Outlets ........................................................................................................... 3-13 AC Power Considerations ................................................................................................... 3-14 Electrical Noise.................................................................................................................................... 3-14 EMI (Electromagnetic Interference) .................................................................................................... 3-14 ESD (Electro Static Discharge) ........................................................................................................... 3-14 SC3000 Series AC Power Wiring ........................................................................................ 3-15 SC3000 Series AC Connector wiring (SC3000-010/030) ................................................................... 3-15 SC3000 Series AC Connector wiring (SC3000-001/100) ................................................................... 3-16 SC3000 Series AC Wiring for Peripheral Devices .............................................................................. 3-17 Cabling the Robot System .................................................................................................................. 3-18 Connect the cables ....................................................................................................................... 3-18 Running the SC3000 Robot System for the first time ......................................................................... 3-18 Power-On Self-Test (POST) ............................................................................................................... 3-19 Absolute Home Position (Pendant) ..................................................................................................... 3-20 Absolute Home Position (ADSMT)...................................................................................................... 3-21 Installation Checkout Procedure ......................................................................................................... 3-22 Optional Tasks – SCARA Series Robot models ................................................................ 3-23 End-of-Arm Interface........................................................................................................................... 3-23 End-of-Arm Interface Installation......................................................................................................... 3-23 Installation procedure ................................................................................................................... 3-23 Cable Connector chart......................................................................................................... 3-25 ii SC3000 Series Installation and Specifications Manual Option Boards and Features ............................................................................................... 3-26 Description .......................................................................................................................................... 3-26 Expansion Slots................................................................................................................................... 3-26 Optional Feature Installation ............................................................................................................... 3-27 3101 CPU Board Removal and Replacement..............................................................................3-27 3102 AD1319 – 64 Point DI/DO Board (P/N SCF323) ................................................................ 3-28 RS-232C Port ............................................................................................................................3-28 3103 AD1309 128-Point DI/DO Board (P/N SCF302)................................................................. 3-29 RS-232C Port ............................................................................................................................3-29 3104 AD1308 32/64-Point DI/DO Board...................................................................................... 3-30 3105 AD1313-4 Axis HS Board P/N SCF310) ............................................................................ 3-31 RS-232C Port ............................................................................................................................3-31 3106 Over Drive Processor (ODP) Board (P/N SCF317)............................................................ 3-32 Follow-on Topics ................................................................................................................................. 3-34 Chapter 4 Digital Input/Digital Output (DI/DO) .......................................................... 4-1 Digital Input / Digital Output Points...................................................................................... 4-3 DI/DO Configuration:............................................................................................................................. 4-3 Physical DI/DO ...................................................................................................................................... 4-4 Physical DI/DO Address Chart ....................................................................................................... 4-5 Standard DI/DO....................................................................................................................... 4-6 Standard Input circuit...................................................................................................................... 4-7 DI Point Specifications.................................................................................................................... 4-7 Standard Output circuit ................................................................................................................... 4-7 DO Point Specifications .................................................................................................................. 4-7 Standard Digital Input (DI)..................................................................................................................... 4-8 Open collector type sensor DI - I/O 1 connector ............................................................................ 4-8 Using the Internal +24V supply ...................................................................................................4-9 Open collector type sensor DI - I/O 2 connector .......................................................................... 4-10 Using the Internal +24V supply .................................................................................................4-11 Open emitter type sensor DI - I/O 1 connector............................................................................. 4-12 Open emitter type sensor DI - I/O 2 connector............................................................................. 4-14 Standard Digital Output (DO) .............................................................................................................. 4-16 Open collector sinking type DO - I/O 1 connector ........................................................................ 4-16 Using the Internal +24V supply .................................................................................................4-17 Open collector sinking type DO - I/O 2 connector ........................................................................ 4-18 Using the Internal +24V supply .................................................................................................4-19 Open emitter sourcing type DO - I/O 1 connector ........................................................................ 4-20 Open emitter sourcing type DO - I/O 2 connector ........................................................................ 4-22 Customer D/O Error circuit.................................................................................................................. 4-24 Customer Safety circuits - Before May, 1995 ..................................................................................... 4-25 Customer Safety circuits - After May, 1995 ........................................................................................ 4-26 I/O 1 Connector Pin Assignments ....................................................................................................... 4-27 I/O 2 Connector pin assignments........................................................................................................ 4-28 128 Point DI/DO Option (P/N SCF302) ................................................................................ 4-29 DO Point Fuses ............................................................................................................................ 4-29 CONTENTS iii SC3000 Robot Systems Card Jumpers ............................................................................................................................... 4-29 Modifying the HWDEF.CFG file.................................................................................................... 4-29 128 Point I/O - DI Circuit diagram................................................................................................. 4-30 128 Point I/O - DO Circuit diagram............................................................................................... 4-30 128 Point I/O - Wiring DI/DO points.............................................................................................. 4-31 Connector Charts ................................................................................................................................ 4-32 128 Point I/O - CN1 Connector..................................................................................................... 4-32 128 Point I/O - CN2 Connector..................................................................................................... 4-33 128 Point I/O - CN3 Connector..................................................................................................... 4-34 128 Point I/O - CN4 Connector..................................................................................................... 4-35 128 Point - DATA Communications.............................................................................................. 4-36 64 Point DI/DO Option (P/N SCF323) .................................................................................. 4-37 DO Point Fuses ............................................................................................................................ 4-37 Card Jumper ................................................................................................................................. 4-37 Modifying the HWDEF.CFG file.................................................................................................... 4-37 64 Point I/O - DI Circuit Diagram .................................................................................................. 4-38 64 Point I/O - DO Circuit Diagram ................................................................................................ 4-38 64 Point I/O - Wiring DI/DO points................................................................................................ 4-39 Connector Charts ................................................................................................................................ 4-40 64 Point I/O - CN1 Connector (DI Only) ....................................................................................... 4-40 64 Point I/O - CN2 Connector (DO Only) ..................................................................................... 4-41 64 Point I/O - CN3 Connector (DI Only) ....................................................................................... 4-42 64 Point I/O - CN4 Connector (DO Only) ..................................................................................... 4-43 External DI/DO Cable Routing............................................................................................. 4-44 Some Good Rules To Follow .............................................................................................................. 4-44 Signal Cable Selection ........................................................................................................................ 4-45 Chapter 5 Specifications............................................................................................. 5-1 Introduction ............................................................................................................................ 5-3 Sankyo SC3000 Series Robot Controller ............................................................................. 5-4 SC3000 Series Controller - Dimensions and Operating Specifications ................................................ 5-5 Environment.................................................................................................................................... 5-5 Motion Control Specifications................................................................................................................ 5-6 Option Boards ........................................................................................................................ 5-7 128 Point DI/DO Option (P/N SCF302) .......................................................................................... 5-7 High Speed (HS) Processor Option (P/N SCF310)........................................................................ 5-7 Over Drive Processor (ODP) Option (P/N SCF317)....................................................................... 5-7 64 Point DI/DO Option (P/N SCF323) ............................................................................................ 5-8 Expansion RS-232C Panel (P/N SCF324) ..................................................................................... 5-8 DeviceNet Option (P/N SCF336).................................................................................................... 5-8 Sankyo SR8437/SR8447 Series Robot ................................................................................. 5-9 SR8437/SR8447 Dimensions and Operating Specifications .............................................................. 5-10 SR8437/SR8447 Robot Arm Dimensions..................................................................................... 5-11 SR8437/SR8447 Robot Arm Clearance Dimensions ................................................................... 5-12 SR8437/SR8447 Robot Workspace ............................................................................................. 5-13 SR8437/SR8447 Robot Workspace Dimensions ......................................................................... 5-14 iv SC3000 Series Installation and Specifications Manual SR8437/SR8447 Robot Performance Specifications ................................................................... 5-15 SR8437/SR8447 Robot Positioning Specifications ......................................................................5-15 Sankyo SR8438/SR8448 Series Robot ............................................................................... 5-16 SR8438/SR8448 Dimensions and Operating Specifications .............................................................. 5-17 SR8438/SR8448 Robot Arm Dimensions..................................................................................... 5-18 SR8438/SR8448 Robot Arm Clearance Dimensions ................................................................... 5-19 SR8438/SR8448 Robot Workspace ............................................................................................. 5-20 SR8438/SR8448 Robot Workspace Dimensions ......................................................................... 5-21 SR8438/SR8448 Robot Performance Specifications ................................................................... 5-22 SR8438 Positioning Specifications............................................................................................... 5-22 SR8437/SR8447 and SR8438/SR8448 Robot Tool Tip....................................................... 5-23 SR8437/SR8447 Series Robot Tool Tip Dimensions ......................................................................... 5-23 SR8438/SR8448 Series Robot Tool Tip Dimensions ......................................................................... 5-23 SR8437/SR8447 Series Robot Tool Tip Flange .................................................................................5-24 SR8438/SR8448 Series Robot Tool Tip Flange .................................................................................5-25 Sankyo CCR Model 1X Series Robot.................................................................................. 5-26 CCR-M1X Dimensions and Operating Specifications......................................................................... 5-27 CCR-M1X Series - X Axis Base mounting plates......................................................................... 5-28 CCR-M1X Series – X to Y Axis mounting bracket........................................................................ 5-29 CCR-M10 Lite Dimensions ........................................................................................................... 5-30 CCR-M10 Dimensions / Standard X Axis ..................................................................................... 5-31 CCR-M10 Dimensions / Long X Axis............................................................................................ 5-32 CCR-M12 Dimensions / Standard X Axis ..................................................................................... 5-33 CCR-M12 Dimensions / Long X Axis............................................................................................ 5-34 CCR-M14 Dimensions / Standard X Axis ..................................................................................... 5-35 CCR-M14 Dimensions / Long X Motor ......................................................................................... 5-36 CCR-M14 Series Robot Tool Tip Dimensions (Servo Z).............................................................. 5-37 CCR-M1X Robot Workspace........................................................................................................5-38 CCR-M1X Robot Performance Specifications..............................................................................5-39 CCR-M10 Lite Robot Performance Specifications ....................................................................... 5-40 CCR-M1X Positioning Specifications ........................................................................................... 5-40 Sankyo CCR Model 3X Series Robot.................................................................................. 5-41 CCR-M3X Dimensions and Operating Specifications......................................................................... 5-42 CCR-M3X Dimensions / Standard X Axis..................................................................................... 5-43 CCR-M3X Workspace .................................................................................................................. 5-44 CCR-M3X Performance Specifications ........................................................................................ 5-45 CCR-M3X Positioning Specifications ........................................................................................... 5-45 Glossary .......................................................................................................................... 1 Appendix A ADS Communications Port Cable Wiring ................................................ 1 ADS Port .................................................................................................................................................. 1 9 pin to 9 pin Cable – Buzz version ................................................................................................... 1 Appendix B RS-232C Communications Port Cable Wiring......................................... 1 RS-232C Port ........................................................................................................................................... 1 CONTENTS v SC3000 Robot Systems 9 Pin to 9 Pin RS-232C Cable ........................................................................................................... 1 9 Pin to 25 Pin RS-232C Cable ......................................................................................................... 2 Appendix C Physical (User) DI/DO Charts ................................................................... 1 Standard DI/DO........................................................................................................................................ 1 Expanded DI/DO - First Option-64 I/O Board .......................................................................................... 2 First 32 Points of 64 I/O Board: ......................................................................................................... 2 Second 32 Points of 64 I/O Board: .................................................................................................... 3 Expanded DI/DO - First Option-128 I/O Board ........................................................................................ 4 First 32 Points of 128 I/O Board: ....................................................................................................... 4 Expanded DI/DO ...................................................................................................................................... 5 Second 32 Points of 128 I/O Board: .................................................................................................. 5 Expanded DI/DO ...................................................................................................................................... 6 Third 32 Points of 128 I/O Board: ...................................................................................................... 6 Expanded DI/DO ...................................................................................................................................... 7 Last 32 Points of 128 I/O Board: ....................................................................................................... 7 Appendix D Warranty ..................................................................................................... 1 LIMITED PRODUCT WARRANTY (United States and Puerto Rico) ...................................... 1 Sankyo Robot Systems............................................................................................................................ 1 Sankyo Maintenance Parts ...................................................................................................................... 1 vi SC3000 Series Installation and Specifications Manual Preface Audience For safety reasons, users of this manual are expected to be trained on the operation of the SR8437/SR8447 and the SR8438/SR8448 Series Robot Systems, or, the CCR-M10 and CCR-M30 Series Robot Systems. Users should also be familiar with Robot System safety. The Safety chapter, which immediately follows, should be read and understood in its entirety before any Robot System work begins. About this Manual This manual provides information for planning the installation of the SR8437/SR8447 Series, the SR8438/SR8448 Series, and the CCR-M Series Robot Systems. Each chapter is complete for the topic. For example, Chapter 1, "Getting Ready for Your System", contains the information for all components associated with any Sankyo Robot System. The subject matter in this manual is divided into the following chapters and appendices: • Preface, This chapter • Safety, Safety guidelines are presented • Chapter 1, "Getting Ready for Your System," explains the steps necessary to complete before your Robot System arrives. • Chapter 2, "Site Installation Requirements" discusses power distribution, grounding, safety devices and Robot System mounting structures. • Chapter 3, "Installation Instructions", contains step by step instructions for installing your Robot System. • Chapter 4, "Digital Input/Digital Output (DI/DO)," contains information on installing external devices through the digital input / digital output feature. • Chapter 5, "Specifications," provides complete specifications and dimensions for all Robots. • Glossary, provides definitions of the special terms used in this manual. • Appendix A, "ADS Communications Port Cable Wiring", explains how the ADS cable is wired. • Appendix B, "RS-232C Communications Port Cable Wiring", explains how the RS232C cable is wired. • Appendix C, "Physical (User) DI/DO Charts", is a form for the user to record pertinent data about the physical DI/DO wiring for an Robot system. Make copies for additional systems. • Appendix D, "Warranty", explains the terms and conditions of the SC3000 Robot System product warranty. Copyright © Sankyo Robotics, 1994-2001 Preface vii SC3000 Robot Systems Conventions used in this Manual ADS for DOS is the Application Development System for use with DOS Version 5.0 and higher. Buzz, (ADS for Windows), is the Application Development System for use with Windows 95, Windows 98, Windows NT, Windows 2000 and Windows ME. The SC3000 Robot Controller is known throughout this manual as "Controller". The Manipulator, or, the Industrial Robot, is known throughout this manual as "Robot". Manip.-Power, Servo power and Robot power are the same, power applied to the robot. Unless specifically stated, a high quality, digital multi-meter should be used for voltage and resistance checks. The SR8437/SR8447 Series Robot System is meant to include the SC3000 Series Robot Controller, the optional Pendant, and one of the following Robot models: • SR8437, the standard model • SR8437C, the Cleanroom model • SR8437C-550Z, the Cleanroom model with an extended 550mm Z axis • SR8437DP, the Dustproof model • SR8437WP, the Water proof model • SR8447, the standard model • SR8447C, the Cleanroom model The SR8438/SR8448 Series Robot System is meant to include the SC3000 Series Robot Controller, the optional Pendant, and one of the following Robot models: • SR8438, the standard model • SR8438C, the Cleanroom model • SR8438DP, the Dust Proof model • SR8448, the standard model • SR8448C, the Cleanroom model The CCR-M10 Series Robot System is meant to include the CCR-M10 Series Robot, the SC3000 Series Robot Controller and the optional Pendant. The CCR-M30 Series Robot System is meant to include the CCR-M30 Series Robot, the SC3000 Series Robot Controller and the optional Pendant. viii SC3000 Series Installation and Specifications Manual Related Publications Related publications can be ordered directly from Sankyo Robotics: Sankyo Robotics 1001-D Broken Sound Parkway NW Boca Raton, FL 33487 USA AES Motomation GmbH Nikolaus-Otto-Str. 8 D-40670 Meerbusch Germany 561-998-9775 561-998-9778 FAX (49) 2159-4088 (49) 2159-3872 FAX Sankyo Seiki Mfg. Co., Ltd. Machine Tools Division 17-2, 1 Chome, Shinbashi Minato-Ku, Tokyo, 105 Japan (81) 3-3508-1156 (81) 3-3502-1353 FAX [email protected] Related publications are: • Buzz Application Development System User’s Guide • Sankyo CCR-M Series Hardware Manual • Sankyo SCARA Series Hardware Manual • Sankyo SSL/E Language Reference Manual • Sankyo SC3000 Robot System User’s Guide Preface ix SC3000 Robot Systems SC3000 Series Installation and Specifications Manual - History Version 2.10 - 09/01 Updates text and graphics regarding AC power in Chapter 3, "Installation"; and specifications data in Chapter 5, "Specifications". Version 2.00 - 11/00 Changes the name of this manual to the “SC3000 Series Installation and Specifications Manual”, from “SR8437/SR8438 and CCR-M Series Site Preparation, Installation and Specifications Manual”. Updates text in Chapter 3 and 4 for reasons of clarity. Updates drawings in Chapter 4 and 5, deleting CCR Series Inline axes drawings in Chapter 5. Updates the entire manual with references to the SR8447/SR8447C Robot models, and the SR8448/SR8448C Robot models. Version 1.60 - 12/99 Updates the DI/DO charts and Communications port addresses in Chapter 4, and deletes the inline axes CCR drawings in Chapter 5. Version 1.50 - 11/98 Updates the CCR drawings in Chapter 5 and deletes the information on the CCR-M20 Series Robot models. Updates the Preface Chapter with a History of Manual revisions. Version 1.40 - 10/97 Introduces Buzz (ADS for Windows) information. Version 1.30 - 03/97 This Version updates the manual with an example of Data communications as used with the 128 I/O feature card, p/n SCF302. The 64 I/O feature card is also introduced, p/n SCF323. Version 1.21 - 07/96 This Version updated the manual with information on the SC3000-030 model Controller and its features (DRAM, etc.). Version 1.2 - 03/96 This Version of the manual includes minor corrections. Drawings were added to provide more comprehensive data for the Chapter 3, “Installation”. Additional data for Chapter 4, “Digital Input/Digital Output (DI/DO)” and their associated features is provided. Version 1.11 - 04/95 Versions 1.11 and prior contain introductory information. x SC3000 Series Installation and Specifications Manual Safety Safety cannot be overemphasized when using Robot Systems. Only qualified service personnel may install or service the Robot System. Before operating, installing or performing any maintenance on these systems, be sure to read and understand the following safety notices: Installation Site Safety Precautions Be familiar with the American National Standards Institute/Robotic Industries Association (ANSI/RIA) safety standard R15.06-1999. As of September 1999, this is the latest published safety standards for Robotic systems. Some countries require a lock out/tag out for the primary power when the Robot System is being serviced. If your country has this requirement, it is the users responsibility to ensure that the primary power source has a disconnecting means in the OFF or OPEN position which can be locked, and/or tagged. Therefore, the Robot System cannot be operated until the locking means is removed. • Ensure compliance with all local and national safety and electrical codes for the installation and operation of the Robot System. • Observe the power and grounding instructions given in the SC3000 Series Installation and Specifications Manual. • The Robot System should not be installed in an explosive atmosphere. • Fire extinguishers must be located within easy access of the Robot System. • Consider installing intrusion devices or safety mats around the Robot to stop Robot motion if the work area is penetrated. • Consider installing additional Emergency Stop switches for feeders and other fixtures to stop the Robot System’s motion. • Consider installing an Emergency Stop switch in any mounting enclosure, to simultaneously turn off the Robot Controller and stop Robot motion. Copyright © Sankyo Robotics, 1994-2001 Safety xi SC3000 Robot Systems Safety Notices This document may contain the following safety notices: DANGER This notice advises of a condition that could present a potential hazard where serious personal injury or loss of life is possible unless care is exercised. CAUTION: This notice advises of a condition that could present a potential hazard where serious personal injury, except as defined for a DANGER notice, is possible unless care is exercised Warning: This notice advises of a potential condition that could cause machine or program damage unless care is exercised. NOTE: This notice advises of information that is important to consider during this particular step or action. Operation and Maintenance Safety Procedures Safety precautions should always be observed when operating or servicing Robot Systems. As with any electromechanical machine or component, unpredictable failures could occur while the system is in operation. CAUTION: Whenever possible, electrical power and air pressure to the Robot System should be turned off and disconnected before any maintenance or penetration of the Robot work area begins. If it is not possible to disconnect power and air pressure due to the nature of maintenance, extreme caution must be observed. If you must penetrate the work area without disconnecting electrical power and air pressure, press the Emergency Stop push-button on the Robot Controller front panel, or the remote cable, to remove power to the Robot. Then place a "DO NOT OPERATE" sign near the front of the Robot Controller, and, if possible, carry the remote cable into the work area with you, to ensure that you remain in control of Robot power. NOTE: Pressing the Emergency Stop push-button on the Robot Controller or the remote cable does not remove potential dangers created by other devices in the work area. You must ensure that all potentially hazardous devices are powered-off or otherwise secured before penetrating the work area. The Robot arm moves with great force and speed. Therefore, serious injury could result from failure to observe caution when the work area is penetrated. As stated above, power and air pressure to the Robot must be turned off and disconnected first, whenever possible. Before reconnecting power and air pressure, always check the Robot work area for adequate clearance; be absolutely sure no one is in the Robot work area. xii SC3000 Series Installation and Specifications Manual In addition to the precautions previously stated, the following precautions must also be observed when performing any maintenance or service on any Robot System: • All personnel working with the system must have, at minimum, instruction and practice in the use of the safety devices on the system. Safety procedures should be thoroughly reviewed to ensure complete understanding. • Observe safe access routes to and from the Robot. • Utilize signs around the Robot and at power disconnects to alert others to potential hazards. • Remove watches, rings, and all other jewelry before performing any service. • Always wear safety glasses when servicing the system. • If heavy units are to be installed or removed, wear safety shoes or other appropriate foot protection. • Stay out of the Robot work area when Robot power is on. The Robot arm moves rapidly and with great force. • Press the Emergency Stop push-button on the Robot Controller front panel, or the remote cable, to stop the Robot in an emergency. Safety xiii SC3000 Robot Systems Safety Inspection Before you service the Robot System, you should perform the following inspection. Verify that: xiv • Any safety shield installed over electrical components that was previously removed, is now in place. • Pressing the Emergency Stop push-button on the Robot Controller front panel, or on the remote cable, causes Robot power to drop immediately. • The Power switch located on the Robot Controller front panel will drop all power to the Robot Controller and Robot. • The Power indicator located on the Robot Controller front panel is illuminated when there is power applied to the Robot Controller. • All primary power cord grounds are properly attached and labeled. • Line voltage warning labels are located near the Power switch inside the Robot Controller. • No external wiring is connected to the power supply of the Robot Controller. SC3000 Series Installation and Specifications Manual Electrical Safety Look for similar warning labels as shown below, when working on electrical equipment. • You should not work alone under hazardous conditions or around equipment that could expose you to hazardous voltages. • Disconnect all power before removing or assembling major components, working in the immediate area of power supplies, performing mechanical inspection of power supplies, or installing changes to the machine circuitry. • Unplug the machine's power cord whenever possible before working on the machine. The wall box switch, when turned off, should be locked in the "Off" position or tagged with a "DO NOT OPERATE" sign. Be aware that a non-Sankyo attachment to a Sankyo Robot System may be powered from another source and be controlled by a different disconnect, circuit breaker or process. • Always advise your manager or supervisor if there is a potential problem, or if you must work alone. • Observe special safety instructions when working with extremely high voltages. These instructions are stated in the Safety chapter of the maintenance documentation for that equipment. Use extreme care when measuring high voltage. • Avoid use of tools and test equipment that have not been approved. Electrical hand tools, such as wire wrap guns, drills, etc., should be inspected periodically. • Do not use worn or broken tools and test equipment. • After maintenance, restore all safety devices such as shields, guards, ground leads, etc. Replace any safety device that is defective. (These safety devices are there to protect you from hazards; you can defeat their purpose by not replacing defective items upon completion of service.) • When it is absolutely necessary to work on equipment having exposed electrical circuitry, observe the following precautions: • Another person familiar with power-off controls must be in the immediate vicinity to turn the power off should it become necessary. • Do not wear metallic items such as watches, jewelry, metallic frame eyeglasses, etc. More electrical current can flow because of the greater contact area provided by the metal surfaces. • Use only those tools and test equipment that are necessary for the task being performed. Safety xv SC3000 Robot Systems CAUTION: Cushioning grips for tools are designed for comfort and do not provide adequate insulation for working with live electrical circuits. NOTE: • When possible, use only one hand when working on energized equipment. Keep the other hand in your pocket or behind your back. This procedure will help prevent an electrical current path through vital organs of the body. • When using test equipment, be certain that controls are set correctly and that insulated probes of the proper capacity are used. • Avoid contacting ground potential such as metal floor strips and machine frames. Many customers use rubber floor mats which contain tiny carbon or metal fibers to help reduce static discharge. Be especially cautious of this type of mat and do not use it to provide protection from electrical shock. Purchase rubber mats locally if necessary. Safety glasses must be worn when: xvi • Using a hammer to drive pins, etc. • Power hand drilling • Using spring hooks, attaching springs • Soldering, wire cutting, removing steel bands • Parts cleaning, using solvents, chemicals and cleaners • All other conditions which might be hazardous to your eyes • Never assume that a circuit is de-energized. Check it first. • Always be alert to potential hazards in your working environment, for example; damp floors, non-grounded extension cords, power surges, missing safety grounds, etc. • Do not touch live electrical circuits with the surface of the plastic dental mirrors. The glass surface of the mirror is conductive and can result in machine damage or personal injury. • A power supply, circuit board, sensor, or other electronic component must not be serviced with power applied when it is removed from its normally mounted position, unless specifically stated in the documentation. (This is done to ensure that proper grounding is maintained.) SC3000 Series Installation and Specifications Manual Chapter 1 Getting Ready for Your System CONTENTS Considerations ...................................................................................................................................... 1-3 Safety .................................................................................................................................................... 1-4 What You Supply - Summary................................................................................................................ 1-5 Schedule of Events ............................................................................................................................... 1-6 Important Contacts ................................................................................................................................ 1-7 Copyright © Sankyo Robotics, 1994-2001 Chapter 1 Getting Ready for Your System 1-1 SC3000 Robot Systems This page left blank intentionally 1-2 SC3000 Series Installation and Specifications Manual Considerations When getting ready for your Sankyo Robot System, you should consider the following: • Review the dimensions, specifications, and recommendations provided in this manual, then select a suitable site in which to install your Sankyo Robot System. • Carefully plan the placement and installation of feeders, fixtures, conveyors, and other equipment that will enhance your total manufacturing operation. • Be sure to allow for additional space to store all supplies, parts, and other essentials to your operation. • Complete a realistic, complete, and orderly schedule for accomplishing the installation. • Generate all drawings and written explanations that are necessary to define your installation plans clearly. • Personal safety must be considered in every step of the plan. Make sure that your plans conform to all local, state, and national safety codes. Chapter 1 Getting Ready for Your System 1-3 SC3000 Robot Systems Safety Safety cannot be overemphasized. As with any electromechanical machine an unpredictable failure can occur. Keep this in mind when you plan operator and service access areas. REMEMBER: YOU ARE RESPONSIBLE FOR OPERATOR AND MAINTENANCE PERSONNEL SAFETY. 1-4 • Observe all power and grounding instructions. • All power connections must be made by qualified personnel. • Do not install the system in an explosive atmosphere. • Provide safe access routes to and from the system. • Consider installing intrusion devices or safety mats around the industrial Robot to provide an emergency stop if the work area is penetrated. For information about this topic, refer to "Safety Devices" in this chapter and to Chapter 4 of this manual, "Controller Digital Input/Digital Output (Dl/DO).'' • Consider installing signals to warn people when the machine is in an automatic operational mode. For information about this topic, refer to "Safety Devices'' in this chapter and to Chapter 4 of this manual, " Digital Input/Digital Output (Dl/DO).'' • Plan to install warning signs around the system alerting people to potential hazards. Also, mark an area on the floor or table showing the full sweep of the industrial Robot arm with end-of-arm tooling. • Consider installing additional emergency-off switches for feeders, fixtures, and other application devices. These switches must disconnect the power service to the system Controller and to other equipment in the general work area. SC3000 Series Installation and Specifications Manual What You Supply - Summary While planning your installation, keep in mind that you must supply the following items. Specifications for most of these items appear in this manual. NOTE: • A suitable flat surface to hold the SC3000 Series Robot Controller • An optional 19” rack and mounting slides for the Robot Controller • AC Electrical power: In the United States and all other countries: • 200 - 240V AC 50 - 60 Hz, 20 amp circuit for the Robot Controller • Convenience (service) outlets for peripheral and servicing equipment Sankyo supplies the Robot Controller AC power receptacle and a mating connector. It is the responsibility of the user to supply the wiring and an electrical connector that matches the user wall receptacle. The installer/technician must attach wiring from the Sankyo supplied mating connector to the user supplied AC power. Instructions for this task are found in Chapter 3 of this manual, “Installation Instructions”. • Proper environment • Moisture-free (as through a moisture separator), shop-type compressed air and hoses • Industry standard optical isolation input/output circuit boards and modules. • Dl/DO external circuitry and power source (for the input/output circuit isolation boards, if used) • Mounting fixture and bolts to secure the industrial Robot • Service access areas The following items are recommended: • Safety signs and other safety-related equipment • Fire extinguishers • Mobile cart for the roll-up programming tool Chapter 1 Getting Ready for Your System 1-5 SC3000 Robot Systems Schedule of Events The smoothness with which your system is installed greatly depends upon meeting your schedule of events. The following schedule lists the tasks to be performed for a typical installation, and includes a column for tracking dates. This schedule is based on a 12week countdown, which should provide ample time for a well planned and well carried out installation. Consult your Sankyo Robotic Systems Representative for additional suggestions and advice. Week 12 or prior Target Date Date Complete Event Assign a project leader responsible for the overall installation, including software. Assign a person to install power, air and external devices. Contact suppliers for feeders, fixtures and external devices. Complete a Robot cell layout plan showing positions for Controller, Robot arm, and workspace items such as feeders, fixtures and external devices. Include power and air drawings. 11 Resolve any questions/concerns on layout. 10 Release work orders for all installation services, including external devices. 9 Define training program for all employees involved, including safety. 8 Review plan for fixtures, feeders and external devices. Resolve any schedule conflicts. Review overall plan, resolve schedule conflicts. 7 Start installation of hardware, air and power. 6 Start maintenance training. Review plan with Sankyo Representative. 1-6 5 Start employee training, including safety. 4 Complete installation of mounting hardware, air and power. 3 Review total installation. 2 Move Robot System to installation site. Review system with Installation manual. 1 Install, test and run application. Person Assigned SC3000 Series Installation and Specifications Manual Important Contacts List here the names, functions, and phone numbers of people you will be depending on to support your installation. Name / Function Phone Number Sankyo Robotics, Boca Raton, FL / Technical Support 561-998-9775 Chapter 1 Getting Ready for Your System 1-7 SC3000 Robot Systems This page left blank intentionally 1-8 SC3000 Series Installation and Specifications Manual Chapter 2 Site Installation Requirements CONTENTS Power Distribution ................................................................................................................. 2-3 Emergency Power-Off........................................................................................................................... 2-3 Grounding.............................................................................................................................................. 2-3 Neutral................................................................................................................................................... 2-3 Convenience (Service) Outlets ............................................................................................................. 2-3 Preparation of the 19-inch Rack (option) ............................................................................. 2-4 Electrical Noise ...................................................................................................................... 2-5 EMI (Electromagnetic Interference) ...................................................................................................... 2-5 ESD (Electro Static Discharge) ............................................................................................................. 2-5 Safety and Remote Circuits................................................................................................... 2-6 Emergency Stop Circuit Extension........................................................................................................ 2-6 Remote Manipulator Power-On Switch ................................................................................................. 2-6 Remote "Error-On" Indicator ................................................................................................................. 2-6 Robot Mounting Dimensions ................................................................................................ 2-7 SR8437/SR8438 and SR8447/SR8448 Series .............................................................................. 2-7 CCR Models – Standard X Axis ..................................................................................................... 2-8 CCR Models – LONG X Axis.......................................................................................................... 2-9 Environment ......................................................................................................................... 2-10 Climate and Altitude ............................................................................................................................ 2-10 Atmosphere ......................................................................................................................................... 2-11 Particulate Contaminates .................................................................................................................... 2-11 Corrosive Gas Contaminates .............................................................................................................. 2-11 Vibration .............................................................................................................................................. 2-11 Lightning Protection ............................................................................................................ 2-12 Exhaust Piping ..................................................................................................................... 2-12 Copyright © Sankyo Robotics, 1994-2001 Chapter 2 Site Installation Requirements 2-1 SC3000 Robot Systems This page left blank intentionally 2-2 SC3000 Series Installation and Specifications Manual Power Distribution The system requires standard 200-240V AC single phase power distribution. Ensure the power distribution circuits you intend to use are compatible with the system's power requirements and comply with all local, state, and national safety and electrical codes. Branch circuits should be protected by circuit breakers that limit branch current to 20 amperes. These circuit breakers should be placed in a well-lighted spot near the system, with unobstructed access. Emergency Power-Off An Emergency Power-Off switch should be installed on any optional 19” rack , if your SC3000 Series Controller is installed in such a rack. When operated, all power to the rack and its Robot System components is immediately removed. This also pertains to any peripheral equipment installed in the rack. Grounding The branch circuit you install must have a grounding conductor for connecting to any optional 19-inch rack or to any Robot System Component. Also: • Any branch-circuit receptacles must have mating equipment ground. • Any ground wire must be at least as large as the current-carrying wires for that circuit. Conduit ground is not recommended as there exists a possibility of separation, or poor connection/connectivity over time. • A single, common-ground wire must run from the distribution panel ground bus back to a suitable building earth ground, typically to the MAIN distribution panel and its ground rod. • Multiple grounds are not recommended and can introduce “ground loops”, which may cause intermittent problems in an otherwise properly installed location. Neutral An isolated branch circuit neutral line for 110/120 Volt circuits should be tied to the neutral bus at the distribution panel, then routed to receptacles providing electrical service to any Robot System peripheral equipment. In no case should neutral and ground be tied together at any distribution panel. Convenience (Service) Outlets Convenience (service) outlets should be installed within 1.8 m (6 ft.) from the Robot System for service personnel and for powering the ADS personal computer. Chapter 2 Site Installation Requirements 2-3 SC3000 Robot Systems Preparation of the 19-inch Rack (option) The SC3000 Robot Controller is optionally designed for installation inside a standard 19-inch rack. The rack must meet Electronic Industries Association (EIA) standards for 19-inch rack mounting. It must also comply with RS-310B (ANSI C83.9 1972) dimensional specifications and use the universal mounting rail hole pattern. Any mounting rack should be of sufficient size to house the Robot Controller. The front opening of the rack must have a minimum height of at least 200 mm (7.9 inches). (This opening size allows sufficient air flow around the Controller and assumes that no optional features are to be installed in the rack. If such features are to be installed, the opening size must be appropriately larger.) The following preparations should be made to the mounting rack before attempting to install the Robot Controller: NOTE: • An emergency power-off (EPO) switch should be installed in the rack to remove all power from the Robot System when the switch is operated. The EPO switch should be mounted in a prominent area on the front of the rack. • An electrical power distribution box should be installed to accommodate the power requirements of the system. If plug-in connectors are to be used (rather than permanent wiring), be sure to install the appropriate matching receptacles. Warning: Rubber grommets must be inserted in all cable entry holes to prevent damage to the cable jackets. NOTE: 2-4 • To provide for maintenance access, chassis slide mounts are installed for mounting the Robot Controller. • The cables from the industrial Robot(s) must be routed into the mounting cabinet. • The rack should be bolted down or otherwise secured to prevent it from tipping, especially when units are pulled forward for servicing. Rack-mounting hardware features for the SC3000 may be purchased from Sankyo Robotics. SC3000 Series Installation and Specifications Manual Electrical Noise Ensure that the electrical power source (branch circuit) you intend to use for your Robot system does not exhibit excessive electrical noise. Some common sources of electrical noise are: • Air conditioning units • Electric welders • Electric furnaces • Elevators • Electrostatic copiers • Any large, brush-type motor If high noise levels cannot be avoided, it may be necessary to install an RF filter or an isolation transformer or both. In either case, the filter and transformer must be capable of withstanding an in-rush current 11 times the rated system load while maintaining voltage within ±5% of nominal. EMI (Electromagnetic Interference) Avoid placing the system near sources of radiated or conducted electromagnetic energy. Such areas may exist near: • Radio-transmitting antennas • Radar • Radio Frequency (RF) induction welders, RF arc welders, and insulation testers • Time clocks • High-energy power lines If placing your system near any of these is unavoidable, contact your Sankyo Robotic Systems Representative. ESD (Electro Static Discharge) Listed below are possible sources and conditions of ESD energy: • Plastic or plastic coated parts • Rubber or rubber coated parts • Areas where low temperature and/or low humidity may be present High levels of ESD may diminish the operation and performance of the Sankyo Robotic System. The customer is responsible for isolating and minimizing the sources and conditions of ESD energy. NOTE: If electrical noise is suspected in your environment, refer to Chapter 4 of your Hardware Manual, topic, “Other Problems”. This topic is near the end of Chapter 4. Chapter 2 Site Installation Requirements 2-5 SC3000 Robot Systems Safety and Remote Circuits Emergency Stop Circuit Extension I/O connectors 1 and 2 allow an extension of the industrial Robot Emergency stop circuit. This extension operates with a "safety extra low voltage" of 24V DC. Current is approximately 200 ma. Extensions of the stop circuit should be resistive only and should not exceed 5 ohms. A safety zone can be established around the industrial Robot by installing intrusion warning devices on the I/O connectors. Some such devices are: • safety mats • gates with safety interlocks • photoelectric cells and light beams. I/O 1. At the rear of the Robot Controller, the I/O 1 connector allows a connection at pins 13 and 25 for a normally closed switch to act as a safety intrusion device. This is an extension of the Emergency stop switch function. If the safety device is not to be installed at this time, pins 13 and 25 must be jumpered (on all SC3000 Controller models) in order to provide servo motor power to the Robot. I/O 2. At the rear of the Robot Controller, the I/O 2 connector allows a connection at pins 1 and 25 for a normally closed switch to act as a safety intrusion device. This is an extension of the Emergency stop switch function. If the safety device is not to be installed at this time, pins 1 and 25 must be jumpered (on the SC3000-010 and 030 Controller models) in order to provide servo motor power to the Robot. (On the SC3000-100 Controllers, pins 14 and 25 are jumpered.) NOTE: For convenience, these jumpers are factory-installed on each connector provided with your Controller. Thus, if you install the recommended external safety circuit, you must remove the factory-installed jumper. Refer to Chapter 4, “Digital Input/Digital Output (DI/DO)”, topic, “Customer Safety circuits” for wiring instructions. Remote Manipulator Power-On Switch Pins 1 and 12 of the I/O 2 connector allow for the installation of a remote servo motor power (Manip. power) on switch. This should be a toggle switch, that when a normally opened switch is installed across pins 1 and 12, then momentarily activated, servo motor power (Manip. power) comes on. The switch does not need to stay in a normally closed state, only activated to the normally closed state. Refer to Chapter 4 of this manual, topic “Customer Safety circuits” for details. Remote "Error-On" Indicator Pins 19 and 24 of the I/O 2 connector allow for an error output signal (DO), when the Controller has detected an error. When the Controller Error LED is on or flashing, a DO signal is present on pin 19 (ERRN) and pin 24 (ERRP) of I/O 2. Refer to Chapter 4, topic “Customer DO Error circuit” for details. 2-6 SC3000 Series Installation and Specifications Manual Robot Mounting Dimensions Whatever the application, the Robot must be securely bolted to a sturdy base. At minimum, the base or stand should be a steel plate that is: • 25 mm (1 in.) thick • Flat within 0.05 mm (0.002 in.) The hole dimensions for mounting the Robot are shown in the following figures. For additional physical dimensions, refer to Chapter 5, "Specifications". SR8437/SR8438 and SR8447/SR8448 Series NOTE: The 4 - 16mm holes are not threaded, and four bolts are supplied for mounting the Robot securely to a table or stand. Chapter 2 Site Installation Requirements 2-7 SC3000 Robot Systems CCR Models – Standard X Axis NOTES: Standard X Axis lengths range from 200 to 800 mm in length. Inside holes are 6 mm threaded, for mounting to the X axis. Outside holes are 7 mm (not threaded), for mounting to a table or stand. Two mounting plates per X Axis. 2-8 SC3000 Series Installation and Specifications Manual CCR Models – LONG X Axis NOTES: Long X Axis lengths are 1000, 1250, 1500, and optionally 1750 and 2000 mm in length. Inside holes are 6 mm threaded, for mounting to the X axis. Outside holes are 7 mm (not threaded), for mounting to the table or stand. Three mounting plates per Long X Axis. Chapter 2 Site Installation Requirements 2-9 SC3000 Robot Systems Environment This equipment is designed to operate in an area that stays within the following environmental limits. Climate and Altitude Acceptable climate and altitude ranges (upper and lower limits) are: • • • NOTE: 2-10 Temperature: • Operating: 0 ° C to 40 ° C (32 ° F to 104 ° F) • Storage: -15 ° C to 60 ° C (5 ° F to 140 ° F) Relative humidity: • Operating: 8% to 80% (non-condensing) • Storage: 5% to 80% Maximum wet bulb temperature: 26.7 ° C (80 ° F) High-precision applications can tolerate small ambient temperature variations. To ensure machine repeatability, plan to run the application at the same temperature range for which the application points are taught. SC3000 Series Installation and Specifications Manual Atmosphere This equipment must not be installed or operated in an explosive atmosphere or in an environment where the concentration of particulate, liquid or gaseous atmospheric contaminants exceeds the following limits. Such environments can cause corrosion, contact failures, and electrical short circuits. Particulate Contaminates The following specifications represent a "P1-Extended" environment. The upper limit is expressed as arithmetic mean values in µg/m3 (micrograms per cubic meter) or µ g/cm2/30 days (micrograms per square centimeter per 30 days). • Suspended particles: 500 µg/m3 • Benzene soluble organics 30 µg/m3 Settling particles: 1500 µg/cm2/30 days. • Corrosive Gas Contaminates The following specifications represent a "clean" industrial environment. Corrosive gas upper limit is expressed as arithmetic mean values (averaged over one year) in micrograms per cubic meter (µg/m3) and parts per billion (ppb), by volume. • • Total reactive sulfur: 3.2 µg/m3). This includes elemental sulfur vapor (S ) of up to 2.1 µg/m3. Total reactive sulfur is the quantity of elemental sulfur expressed in µ g/m3 in all gaseous species that react with silver to form silver sulfide (such as S H S, CH SH, etc., but not SO ). The 3.2 µg/m3 of reactive sulfur is equivalent to 3.4 µ g/m3 or 2.5 ppb of H S. Sulfur dioxide: 262 µg/m3 (100 ppb). • Nitrogen dioxide: 141 µg/m3 (75 ppb). Acidic gaseous chlorine: 3 µg/m3. Acidic gaseous chlorine is the quantity of elemental chlorine expressed in µg/m3 in chlorine containing acidic gases (such as HCI Cl CIO etc.). The 3 µg/m3is equivalent to 2 ppb of HCI or 1 ppb of Cl. • Ozone: 98 µg/m3 (50 ppb). • Vibration This equipment is designed to operate within the following limits of vibration: • 5 to 17 Hz at 0.1270 mm (0.005 inch) double amplitude displacement • 17 to 200 Hz at 0.07 G peak • 200 to 500 Hz at 0.036 G peak. System performance can be affected by excessive vibration from other machinery or heavy moving equipment. You should try to minimize vibration in the area where your industrial Robot system is to be installed. If you think the vibration at your site could be detrimental to your system's performance, contact your Sankyo Robotic Systems Representative. Chapter 2 Site Installation Requirements 2-11 SC3000 Robot Systems Lightning Protection The communications interface is not lightning protected internally. You should protect the communications lines under either of the following conditions: • When using communications lines that run between buildings • When using communications lines that exceed 122 m (400 ft.) in length Lightning protection devices should be installed by a qualified electrician. If you desire more information, contact your Sankyo Robotic Systems Representative. Exhaust Piping Piping the exhaust from the user-installed gripper (or other user-installed industrial Robot tooling) can result in a quieter operation. 2-12 SC3000 Series Installation and Specifications Manual Chapter 3 Installation Instructions CONTENTS Installation .............................................................................................................................. 3-3 Lockout/Tagout...................................................................................................................................... 3-3 Installation Checklist ............................................................................................................. 3-4 Unpacking the Components.................................................................................................. 3-5 Packaging.............................................................................................................................................. 3-5 Installation Steps.................................................................................................................... 3-6 SC3000 Robot System Packing List ..................................................................................................... 3-6 Lifting the SR8437/38 and SR8447/48 Series Robot............................................................................ 3-7 Installing the SR8437/38 and SR8447/48 Series Robot ....................................................................... 3-8 Lifting the CCR-M Series Robot............................................................................................................ 3-9 Installing the CCR-M Series Robot ..................................................................................................... 3-12 Lifting the SC3000 Series Robot Controller ........................................................................................ 3-12 Installing the SC3000 Series Robot Controller ................................................................................... 3-12 AC Power Distribution ......................................................................................................... 3-13 Emergency Power-Off......................................................................................................................... 3-13 Grounding............................................................................................................................................ 3-13 Neutral................................................................................................................................................. 3-13 Convenience (Service) Outlets ........................................................................................................... 3-13 AC Power Considerations ................................................................................................... 3-14 Electrical Noise.................................................................................................................................... 3-14 EMI (Electromagnetic Interference) .................................................................................................... 3-14 ESD (Electro Static Discharge) ........................................................................................................... 3-14 SC3000 Series AC Power Wiring ........................................................................................ 3-15 SC3000 Series AC Connector wiring (SC3000-010/030) ................................................................... 3-15 SC3000 Series AC Connector wiring (SC3000-001/100) ................................................................... 3-16 SC3000 Series AC Wiring for Peripheral Devices .............................................................................. 3-17 Cabling the Robot System .................................................................................................................. 3-18 Connect the cables ....................................................................................................................... 3-18 Running the SC3000 Robot System for the first time ......................................................................... 3-18 Power-On Self-Test (POST) ............................................................................................................... 3-19 Absolute Home Position (Pendant) ..................................................................................................... 3-20 Absolute Home Position (ADSMT)...................................................................................................... 3-21 Installation Checkout Procedure ......................................................................................................... 3-22 Optional Tasks – SCARA Series Robot models ................................................................ 3-23 End-of-Arm Interface........................................................................................................................... 3-23 End-of-Arm Interface Installation......................................................................................................... 3-23 Installation procedure ................................................................................................................... 3-23 Cable Connector chart......................................................................................................... 3-25 Option Boards and Features ............................................................................................... 3-26 Description .......................................................................................................................................... 3-26 Copyright © Sankyo Robotics, 1994-2001 Chapter 3 Installation Instructions 3-1 SC3000 Robot Systems Expansion Slots................................................................................................................................... 3-26 Optional Feature Installation ............................................................................................................... 3-27 3101 CPU Board Removal and Replacement..............................................................................3-27 3102 AD1319 – 64 Point DI/DO Board (P/N SCF323) ................................................................ 3-28 RS-232C Port ............................................................................................................................3-28 3103 AD1309 128-Point DI/DO Board (P/N SCF302)................................................................. 3-29 RS-232C Port ............................................................................................................................3-29 3104 AD1308 32/64-Point DI/DO Board...................................................................................... 3-30 3105 AD1313-4 Axis HS Board P/N SCF310) ............................................................................ 3-31 RS-232C Port ............................................................................................................................3-31 3106 Over Drive Processor (ODP) Board (P/N SCF317)............................................................ 3-32 Follow-on Topics ................................................................................................................................. 3-34 3-2 SC3000 Series Installation and Specifications Manual Installation Lockout/Tagout Some countries require a lock out/tag out for the primary power when the Robot System is being installed and/or serviced. If your country has this requirement, it is the users responsibility to ensure that the primary power source has a disconnecting means in the OFF or OPEN position which can be locked and tagged by a servicing technician. For safety considerations, the Robot System cannot be operated until the locking means is removed by the servicing technician. NOTE: Installation of the Sankyo Robot System must only be performed by qualified service personnel. This chapter describes the procedures for the installation and setup of the Sankyo Robot System. Your Robot System should be already configured to your specifications. If you need options installed after purchasing the SC3000 Series Robot Controller, you will need to go that specific option in this chapter. Particular emphasis is given to the discussion dealing with the preparation, installation, and setup of the SC3000 Series Robot Controller. Since only a few optional Controller features are available, procedures for the installation of supported Controller features are included in this chapter. During the initial installation of a Sankyo Robot System, the procedures in this chapter should be performed in the order in which they appear; however, individual procedures may also be used for reference when features are added or replaced. The mounting platform or table on which the Robot is to be installed must be drilled and the mounting holes tapped as described in the topic "Robot Mounting Structure" in Chapter 2, and "Specifications" in Chapter 5 of this manual. Also, the user-supplied optional 19-inch rack into which the Controller can be installed must be of adequate size and prepared as described in the topic "Preparation of the 19Inch Rack" in Chapter 2 of this manual. CAUTION: 1. Before starting any installation procedure in this section, ensure that the SC3000 Series Robot Controller power switch is off and that the AC power cable is removed. 2. Observe cable routing and other precautionary measures to avoid damage to cables, connectors, and other components. 3. While removing or replacing any component in the Controller, maintain contact with frame ground. (This is necessary because components could otherwise be damaged by static discharge.) Chapter 3 Installation Instructions 3-3 SC3000 Robot Systems Installation Checklist The installation of your Sankyo Robot System can be made easier by the planning and preparation discussed in this manual. You should prepare the following in advance: • Robot mounting table or stand • Optional 19-inch rack (including rack-mounting hardware, electrical service, and an optional emergency power-off (EPO) switch) • Safety devices and related cabling • Input and output devices The following checklist can be used to guide you through the installation of your Sankyo Robot System: Check √ Description ◊ Unpack the components, use the Customer checklists 3 ◊ Lift and carry components to the installation site 3 ◊ Ensure the Robot base mounting hole pattern is prepared 2,5 ◊ Install the Robot 3 ◊ Ensure the optional 19” rack is prepared, if needed 2 ◊ Install any Controller options not already installed 3 ◊ Install the SC3000 Robot Controller 3 ◊ Install the cables and connect power 3 ◊ Power on and run POST 3 ◊ Attach the ADS PC or the Pendant and perform the Absolute 3 Home adjustment 3-4 Chapter SC3000 Series Installation and Specifications Manual Unpacking the Components For each Sankyo Robot System, you will receive the following packages: NOTE: • A wood crate containing a cardboard box with the SC3000 Series Robot Controller inside, along with the Robot. (The Controller may also be shipped separately.) • A cardboard box containing the ship group (cables, rack-mounting shim strips, manuals, etc.). • A cardboard box containing any multiple Robot Controller Interface unit required for multiple Robot use (option). Be sure to leave any shipping straps around the Robot arm or axes to hold it secure while the Robot is being transported to its final destination. An inventory checklist is included in the SC3000 Robot Controller box. You should inventory and check off all items on the list. Packaging Sankyo 8437/38 or SR8447/48 Series Robot. SC3000 may be boxed inside. Sankyo Robot System Controller or ship group. (cardboard box) Sankyo CCR-M Series Robot. SC3000 may be boxed inside. (wood crate package) Multiple Robot Controller Interface unit. (cardboard box) Chapter 3 Installation Instructions 3-5 SC3000 Robot Systems Installation Steps SC3000 Robot System Packing List The following information is supplied on a Packing List sheet with your new Robot System. Check √ the appropriate items for your Robot System. ◊ SC3000 Series Controller ◊ Serial number ◊ C-Code ◊ Controller to Robot Motor cable (1 per Robot) ◊ Controller to Robot Encoder cable (1 per Robot) ◊ ADS Cable ◊ ADS Software ◊ I/O 1 connector ◊ I/O 2 connector ◊ Aux connector ◊ Pendant connector ◊ Power cord connector ◊ 2 - 10 amp Fuses, AC line ◊ SC3000 Series Robot Arm Robot model Serial number C-Code ◊ Optional Accessories Teach Pendant Emergency stop switch assembly with 3 or 5 meter cable (attaches to Pendant) Feature AD1309, 128 point DI/DO board (3 maximum may be installed) Feature AD1319, 64 point DI/DO board (2 maximum may be installed) Over Drive Processor (ODP) option (SC3000-030 models only) Front Bezel kit Five (5) meter Robot Motor and Encoder cable kit Ten (10) meter Robot Motor and Encoder cable kit Robot Expansion unit with cables (for multiple Robot Systems) High Speed Processor option 3-6 SC3000 Series Installation and Specifications Manual Lifting the SR8437/38 and SR8447/48 Series Robot The SR8437/SR8438 and SR8447/SR8448 Series Robots weigh from 70 kg (154 lb.) to 90 kg (198 lb.). They should be hoisted with a lifting device, such as a lift truck, attaching a sling through the eyebolts. 1. The top portion of the crate is held around the bottom outside edge with 10mm or 17mm lag bolts. Remove these lag bolts and employ at least two people to remove the top portion of the crate. 2. Remove the Robot base screws near the Theta 1 end, so that the Robot may be lifted from the shipping container base. 3. Remove any shipping or strapping material, and cartons that may contain peripheral equipment and books, that would prevent lifting the Robot cleanly from the shipping container. 4. Ensure the two eyebolts are securely fastened near the top of the Theta 1 axis, one on each side. 5. Attach a lifting sling (a chain will scratch the surface) through the eyebolts and lift according to the following CAUTION steps. CAUTION: 1. Do not put the lifting sling around the Robot arm. Lift only by the eyebolts. 2. Be sure that the Robot arm is secured by a strap, as shown in the figure below, to prevent it from swinging. (The original shipping strap around the Robot arm should still be in place.) 3. Take precaution to keep the lifting sling or chain from scratching the paint on the Robot. Chapter 3 Installation Instructions 3-7 SC3000 Robot Systems Installing the SR8437/38 and SR8447/48 Series Robot The mounting platform or table on which the Robot is to be installed must be drilled and the mounting holes tapped as described in the topic "Robot Mounting Dimensions" in Chapter 2, or in Chapter 5, "Specifications". The recommended surface is a bolted down, steel table; or a platform of equal strength. The Sankyo Robot is capable of very high speed and high torque movement, and a very secure mounting is required. 1. Install the two eyebolts in the back support of the Robot, one on each side of the Theta 1 axis, if they are not already installed. 2. Attach a lifting sling securely between the eyebolts. 3. Use a lift truck or portable crane to lift the Robot into position on the table. 4. Install the four base mounting bolts and tighten. 5. Remove the lift truck or portable crane. 6. Remove the lifting sling from the eyebolts. 7. Remove the two eyebolts. (Store them for possible use in the future.) CAUTION: The two eyebolts must be removed; they are in the path of the Robot arm. 8. Remove the strap that secured the Robot arm. 3-8 SC3000 Series Installation and Specifications Manual Lifting the CCR-M Series Robot The minimum weight of a standard CCR Robot is 23.0 kg (50.6 lb.), and the maximum weight is approximately 75 kg (165.0 lb.). Two (2) or three (3) people are required to lift the Robot from the shipping crate, depending on the Robot model. CAUTION: A multi-axis CCR-M Series Robot can be top or side heavy (unbalanced). 1. The top portion of the crate is held around the bottom outside edge with 10mm or 17mm lag bolts. Remove these lag bolts and employ at least two people to remove the top portion of the crate. 2. With a shipment of a new multiple axis Robot, a strap should already be tied around adjacent axes, or an L shaped bracket is bolted into the axis side plate with 2-4mm screws, so that one axis may not move away from its adjacent axis. 3. Remove the 3 or 4 pallet mounting screws from each X axis base (2). One of the 4 holes in the base may used for a locating bolt. This allows the Robot to be lifted from the crate. 4. Remove any shipping or strapping material, and cartons that may contain peripheral equipment and books, that would prevent lifting the Robot cleanly from the shipping container. 5. It is advised to place one person on each end of the X (base) axis, and one person on the end of the Y axis, if your Robot has a Y axis. 6. After lifting the Robot from the crate, you should place the Robot on a carrying device with casters (wheels), in order to move the Robot to its mounting destination. X axis only, one person on each end. X Axis One person here One person here For other CCR-M Series Robots, continue with the following topics. Chapter 3 Installation Instructions 3-9 SC3000 Robot Systems X and Y axis only, one person on each end of X axis, one person on Y axis end. If the Y axis has shifted during shipment, perform all the steps below. If not, perform steps 2 and 3. X Motor end Move Y Y Axis X Axis One person here One person here Y axis end One person here 1. If the Y axis has moved during shipment, tie a strap which can reach around the Y axis and the X axis, so that the Y axis cannot move away from the X axis motor end. 2. Ensure the 3 or 4 pallet mounting screws were removed from each X axis base (2). One of the 4 holes in the base may used for a locating bolt. 3. Employ three (3) people to lift the Robot from its crate. 3-10 SC3000 Series Installation and Specifications Manual X, Y and Z axis models, one person on each end of X axis, one person on the Y axis end. If the Y or Z axis has shifted during shipment, perform the steps below. If not, perform steps 5 and 6. X Y Axis One person here Z A x i s Motor end Move Y Z X Axis One person here Y axis end One person here 1. Move the Y axis toward the X axis Motor end, until it reaches the limit of its travel. 2. Move the Z axis all the way up to the limit of its travel. 3. Tie a strap which can reach around the Y axis and the X axis, so that the Y axis cannot move away from the X axis motor end. 4. Tie a strap which can reach around the Z axis and the Y axis, so that the Z axis cannot move downward. 5. Ensure the 3 or 4 pallet mounting screws were removed from each X axis base (2). One of the 4 holes in the base may used for a locating bolt. 6. Employ three (3) people to lift the Robot from its crate. Chapter 3 Installation Instructions 3-11 SC3000 Robot Systems Installing the CCR-M Series Robot The mounting platform or table on which the Robot is to be installed must be drilled and the mounting holes tapped as described in the topic "Robot Mounting Dimensions" in Chapter 2, or in Chapter 5, "Specifications". The recommended surface is a bolted down, steel table; or a platform of equal strength. The Sankyo Robot is capable of very high speed and high torque movement, and a very secure mounting is required. NOTE: It is possible for 2 people to manually lift and handle small 1 and 2 axis CCR-M Series Robots. For 3 axis Robots, or for multiple axis Robots that exceed a 600mm axis length, it is possible for 3 people to move the Robot from the carrying device to the mounting table. If you wish to use a sling, the following procedure is recommended: 1. Attach a lifting sling around the outside areas of the 2 end base sections for the X (base) axis. See the previous page for an axis reference. If the sling overlaps the axis ends, fold the sling so it cannot slip off. 2. Ensure the sling is long enough to clear any attached vertical axis (Z axis) and is secure at the lifting point. 3. Use a lift truck or portable crane to lift the Robot from the crate or carrying device and into position on the table. If the Robot has a Y axis, manually support this axis to keep the load balanced. 4. Install the eight or twelve base mounting bolts (depending on your Robot model) and tighten. 5. Remove the lift truck or portable crane. 6. Remove the lifting sling from the outside end base sections of the X axis. 7. Remove the shipping strap(s) that secure any Robot axis. Lifting the SC3000 Series Robot Controller The SC3000 Series Robot Controller unit weighs approximately 12 kg (26.4 lb.), and is easily handled by one person. Installing the SC3000 Series Robot Controller 1. Unpack the system unit. 2. Ensure that all items checked with the Packing list on page 6 of this chapter were received in good condition. 3. If you wish to install the optional rack mount feature, or any other optional feature, proceed to the topic, “Optional Feature Installation Procedures”. Otherwise, proceed to the "AC Power Distribution" topic, which follows. NOTE: 3-12 Any optional feature that was ordered with the Robot system should already be installed. If not, refer to the appropriate Hardware Manual, Chapter 2, for instructions. SC3000 Series Installation and Specifications Manual AC Power Distribution The system requires standard 200-240V AC single phase power distribution. Ensure the power distribution circuits you intend to use are compatible with the system's power requirements and comply with all local, state, and national safety and electrical codes. Branch circuits should be protected by circuit breakers that limit branch current to 20 amperes. These circuit breakers should be placed near the system, with unobstructed access. A typical installation provides one of the two following wiring configurations: Emergency Power-Off An Emergency Power-Off switch should be installed on any optional 19” rack , if your SC3000 Series Controller is installed in such a rack. When operated, all power to the rack and its Robot System components is immediately removed. This also pertains to any peripheral equipment installed in the rack. Grounding The branch circuit you install must have a grounding conductor for connecting to any optional 19-inch rack or to any Robot System Component. Also: • Any branch-circuit receptacles must have mating equipment ground. • A ground wire must be at least as large as the current-carrying wires for that circuit. • Conduit ground is not recommended as there exists a possibility of separation, or poor connection/connectivity over time. • A single, common-ground wire must run from the distribution panel ground bus back to a suitable building earth ground, typically to the MAIN distribution panel and its ground rod. • Multiple grounds are not recommended and can introduce “ground loops”, which may cause intermittent problems in an otherwise properly installed location. Neutral An isolated branch circuit neutral line should be tied to the neutral bus at the distribution panel, then routed to receptacles providing electrical service to any Robot Controller or peripheral equipment. In no case should neutral and ground be tied together at any distribution panel. Convenience (Service) Outlets Convenience (service) outlets should be installed within 1.8 m (6 ft.) from the Robot System for service personnel and for powering the Buzz/ADS PC. Chapter 3 Installation Instructions 3-13 SC3000 Robot Systems AC Power Considerations Certain problems can occur in any electrical environment. Review the following potential problem areas for AC power. Electrical Noise Ensure that the electrical power source (branch circuit) you intend to use for your Robot system does not exhibit excessive electrical noise. Some common sources of electrical noise are: • Air conditioning units • Electric welders • Electric furnaces • Elevators • Electrostatic copiers • Any large, brush-type motor If high noise levels cannot be avoided, it may be necessary to install an RF filter or an isolation transformer or both. In either case, the filter and transformer must be capable of withstanding an in-rush current 11 times the rated system load while maintaining voltage within ±5% of nominal. EMI (Electromagnetic Interference) Avoid placing the system near sources of radiated or conducted electromagnetic energy. Such areas may exist near: • Radio-transmitting antennas • Radar • Radio Frequency (RF) induction welders, RF arc welders, and insulation testers • Time clocks • High-energy power lines If placing your system near any of these is unavoidable, contact your Sankyo Robotic Systems Representative. ESD (Electro Static Discharge) Listed below are possible sources and conditions of ESD energy: • Plastic or plastic coated parts • Rubber or rubber coated parts • Areas where low temperature and/or low humidity may be present High levels of ESD may diminish the operation and performance of the Sankyo Robotic System. The customer is responsible for isolating and minimizing the sources and conditions of ESD energy. NOTE: 3-14 If electrical noise is suspected in your environment, refer to Chapter 4 of your Hardware Manual, topic, “Other Problems”. This topic is near the end of Chapter 4. SC3000 Series Installation and Specifications Manual SC3000 Series AC Power Wiring NOTES: Any 2 lines may be used, but they must be different, i.e. 1 and 2, or 2 and 3, etc. Ground and Neutral are only connected at the Main Electrical Power source (outside). Conduit ground is not recommended. Over time this has proven to be ineffective. SC3000 Series AC Connector wiring (SC3000-010/030) 1. Attach AC wiring (14 gauge) to the Sankyo supplied AC power connector, then to the user supplied AC plug connector or electrical box. See the drawing below: Sankyo supplied AC connector (female) A = LINE 1 B = LINE 2 C = Not connected D = GROUND A D B C Chapter 3 Installation Instructions 3-15 SC3000 Robot Systems SC3000 Series AC Connector wiring (SC3000-001/100) 1. Attach AC wiring (14 gauge) to the Sankyo supplied AC power connector, then to the user supplied AC plug connector or electrical box. See the drawing below: Sankyo supplied AC connector (female) 1 = Line 1 2 = Ground 3 = Line 2 3 1 2 3-16 SC3000 Series Installation and Specifications Manual SC3000 Series AC Wiring for Peripheral Devices MAIN ELECTRICAL POWER G N 15 AMP CIRCUIT BREAKER 15 N GROUND STAKE 1 2 3 110/120 VOLTS 15 AMP CIRCUIT SINGLE PHASE GROUND 110/120 Volt RECEPTACLE For Peripheral Equipment DISTRIBUTION PANEL NOTES: Any 1 line may be used, i.e. 1, or 2, or 3. Ground and Neutral are only connected at the Main Electrical Power source (outside). Conduit ground is not recommended. Over time this has proven to be ineffective. If AC power problems are suspected, use a Power Conditioner Unit (PCU), or an Isolation Transformer. Chapter 3 Installation Instructions 3-17 SC3000 Robot Systems Cabling the Robot System After all components of the Robot system are properly mounted, use the following procedure to connect any cables that were not already connected in a previous procedure. Be careful to route each cable so that it will not be pinched or scraped, especially if the SC3000 is moved on its optional rack mounting slides. CAUTION: Ensure that all power switches are off and that power is removed from the Controller Connect the cables 1. Install the C1 Motor, and C5 Encoders, cables between the Controller and the Robot arm. Each end has different connectors, and cannot be attached incorrectly. 2. Install the remote Emergency Stop switch cable to the SC3000 Controller Pendant port. If this cable is not supplied for the Controller, attach the Pendant dummy connector. The Emergency Stop switch cable or the dummy connector must be attached for the Robot to power on. The dummy Pendant connector has pins 10, 23 and 24 jumpered. 3. If desired, connect the Pendant to the remote Emergency stop switch. 4. If an external safety circuit is not to be connected to I/O 1 or I/O 2, ensure their dummy connectors are in place. Install the AUX connector as well. These connectors are shipped with the Robot System. They are jumpered as follows: • The dummy I/O 1 connector has pins 13 and 25 jumpered on all Controller models. • The dummy I/O 2 connector has pins 1 and 25 jumpered. (Pins 14 and 25 are jumpered on systems prior to May 1995, and on the SC3000-100 models.) • The AUX connector is jumpered as follows: 1. SC3000-010 model - pins 4 and 5 jumpered, pins 7 and 14 a 470 ohm resistor. 2. SC3000-030 model - pins 1 and 27 jumpered, pins 23 and 48 a 470 ohm resistor. 3. SC3000-100 model - pins 4 and 12 jumpered, pins 7 and 14 a 470 ohm resistor. 5. If an external safety circuit is to be installed, remove the jumpers on the dummy I/O connectors (step 4), and the external safety circuit wiring attached in their place. 6. Attach the Sankyo supplied AC connector, that you wired in a previous step, to the Controller AC receptacle. 7. Attach the other end (the user supplied plug connector) to the appropriate AC outlet receptacle. 8. Connect AC power to any optional Robot System peripheral user equipment that require their own power source and proceed to "Running the SC3000 Robot System for the first time", which follows. Running the SC3000 Robot System for the first time Before powering on, ensure the following: 3-18 • All mounting screws are tightened and all cables and connectors are properly connected. • The power cords are attached correctly and are tight. • The Controller, if extended out from the rack, does not bind, chip, or jam with any other installed device. SC3000 Series Installation and Specifications Manual Power on the SC3000 Series Controller. Power-On Self-Test (POST) The Sankyo SC3000 Series Robot Controller automatically runs a Power-On Self-Test (POST) every time the power is switched on. The Power-On Self-Test checks out the base SC3000 system and memory and takes approximately 20 - 30 seconds to run. If any error occurs other than those discussed in the following text, refer to Chapter 4, “Symptom/Fix”, of the SCARA Series Hardware Manual, or the CCR-M Series Hardware Manual. The first time the Robot system is powered on, one of two errors may occur: 1. The Controller error LED flashes 4 times, pauses, then repeats. This a normal condition and is error code 250, “Zero point lost”. For this error, go to the following procedure, “Absolute Home Position adjustment”, which follows this topic. 2. The Controller error LED flashes 6 times, pauses, then repeats. This is error code 252, “Real-time error”. Power off, then on the Controller and try again. If this error persists, refer to Chapter 4, “Symptom/Fix” of the SCARA Series Hardware Manual, or the CCR-M Series Hardware Manual. NOTE: If any other error occurs, it is unexpected. Refer to Chapter 4, “Symptom Fix”, of the SCARA Series Hardware Manual, or the CCR-M Series Hardware Manual, depending on your robot type. Chapter 3 Installation Instructions 3-19 SC3000 Robot Systems Absolute Home Position (Pendant) Before the Robot System can be used for the first time, you must perform the absolute home adjustment. This procedure describes the Pendant method. (1) 1. Place the Pendant key switch in Local mode. 2. Press the blue Error button at the top of the Pendant to reset the Error pop-up. For the SR8437/SR8438 and SR8447/SR8448 Series Robot, ensure that Servo Power is on. If not, press the green Manip. Power button. CCR-M Series Robots are homed manually. 3. From the Local mode display, press the ABS HOME button (1), as pictured above. The following pop-up appears: CAUTION: Ensure the Robot can be returned to the home position without striking fixtures and feeders in the work space. 4. Press and hold the Servo Enable key, then press ENTER. Press ESC (2) if you change your mind. 5. Follow the remaining prompts on the Pendant for homing your specific Robot. A detailed homing procedure (screen by screen), appears in the SCARA Series Hardware Manual, or the CCR-M Series Hardware Manual. Refer to Chapter 3, “Checks and Adjustments”, for your Robot type. This completes the installation setup procedure. You should now proceed to the "Installation Checkout Procedure", which follows the Buzz homing procedure. 3-20 SC3000 Series Installation and Specifications Manual Absolute Home Position (ADSMT) If you have already performed an ABS Home procedure with the Pendant, skip to the “Installation Checkout Procedure”. Before the Robot System can be used for the first time, you must perform the absolute home adjustment. This procedure describes the ADS for DOS method. 1. Obtain the ADS computer and attach the cable from the PC COM1 or COM2 serial port to the ADS port on the Robot Controller. In the ship group, this is a 9 pin to 9 pin cable. 2. After the ADS PC boots, change directory to ADS. Type cd\ads press enter. 3. At the \ads prompt, type ADSMT press enter. NOTE: If a problem exists with the ADS software or the communications cable, the adsmt program will terminate. If so, refer to Chapter 4, "Symptom/Fix", in the SCARA Series Hardware Manual, or the CCR-M Series Hardware Manual, topic - “ADS or ADSMT exits”. 4. When the main adsmt screen appears on the PC monitor, select the Manip. Robot Action Bar item with a mouse. You may also press function key F10 on the keyboard and use the cursor keys. CAUTION: Ensure the Robot can be returned to the home position without striking fixtures and feeders in the work space. 5. Select the ABS Homing... option from the Manip. Robot pull-down menu. 6. For SCARA Robots, right home position is the default and the adjustment requires no manual intervention. However, for CCR Robots you are required to manually place the Robot at the home position, which requires placing each linear axis toward its motor end. In either case, follow the instructions given on the PC display. This completes the installation setup procedure. You should now proceed to the "Installation Checkout Procedure", which follows. Chapter 3 Installation Instructions 3-21 SC3000 Robot Systems Installation Checkout Procedure If you have a SCARA series robot model, continue with the following page. If you have a CCR series robot model, skip to “Optional Features”, following the SCARA robot topics. After all units have been properly installed and “homed” according to the procedures given in the prior topics, the Robot System is ready for the application/programmer engineer. Before any end-of-arm tooling or any fixtures are installed in the Robot workspace, the Robot may be exercised. 3-22 SC3000 Series Installation and Specifications Manual Optional Tasks – SCARA Series Robot models End-of-Arm Interface The following air lines and cable are pre-installed inside the SCARA Robot models and routed through to the End-of-Arm (EOA) interface.. These provide pneumatic and electric power to an end-of-arm device, such as a gripper. • *Air lines 6 mm (O.D.) x 4 mm (I.D.) 4 mm (O.D.) x 2.5 mm (I.D.) • User cable 15-pin female D shell (both ends) *The SR8437/SR8447C model Robot can have up to 6 air lines. These air lines can be 4 mm O.D., or a combination of 4 and 6 mm O.D. The air lines are of polyurethane construction and can be used for both pressurized air and vacuum air. These air lines and cable are passed through the Robot from its base connector panel to the user interface bracket at the Z axis assembly. Source air can be supplied to the air fittings installed on the Robot base connector panel. End-of-Arm Interface Installation The standard three air lines and the 15 wire user interface cable are incorporated inside the Robot as shown on the next page. (Standard SR8437/SR8438 and SR8447/SR8448 models). • *Pneumatic Interface: 6 mm (OD) x 4 mm (ID) 4 mm (OD) x 2.5 mm (ID) • Electrical Interface: 1 - 15 wire cable with a 15-pin female D shell at each end. Voltage load is +/- 24V DC or less, amperage load is 0.5 amps or less *The SR8437C/SR8447C model Robot can have up to 6 air lines. These air lines can be 4 mm O.D., or a combination of 4 and 6 mm O.D. The electrical interface is factory installed from the Robot base to the Z axis. The user is responsible for the attachment of a mating 15-pin male D shell at the Robot base, and a 15-pin male D shell at the Z axis. Installation procedure 1. Remove the Z axis head cover. The internal air lines and EOA cable should already be installed, per the drawing on the following page. If not, continue. Otherwise, skip to “Optional features”, third page following. 2. Install the air lines to the fittings on the inside of the robot base connector bracket. The air lines you provide are recommended to be polyurethane or vinyl tubes with either 4 mm or 6 mm O.D. construction. 3. Lace the air lines through the robot arm to the Z Axis flex guide. Then, through the Z Axis flex guide and on through the center of the Z shaft. 4. The air lines, and cable if installed, should be clamped with cable ties at appropriate locations so as to prevent chafing. Do not pull tightly on the cable ties. 5. Install source air lines, to the air fittings on the Robot rear main connector panel. Chapter 3 Installation Instructions 3-23 SC3000 Robot Systems Standard SR8437/SR8438 and SR8447/SR8448 Series Robot EOA Air lines and Cable 3-24 SC3000 Series Installation and Specifications Manual Cable Connector chart User User 15-pin D shell (At the SCARA Robot base only) C1 Encoder I/O 1 I/O 2 Controller motor drive output to Robot Controller (Encoders and Sensors), to/from Robot Controller User DI/DO 1 and external user Safety circuit Controller User DI/DO 2 also, external use Safety circuit, remote Servo power on, and DO Error On signal RS-232C Aux Controller RS-232C connection to a host (optional) Controller attachment of optional features Pendant ADS Controller remote Emergency Stop (Pendant attaches to this cable end) Controller Application Development System to PC serial port AC Power Controller AC input NOTES: All Robot connectors are male, except for the User 15-pin D shell. All Controller connectors are female, except for AC power input Chapter 3 Installation Instructions 3-25 SC3000 Robot Systems Option Boards and Features Description If adding or removing any of the following options at a later time, do so with the referenced procedures, described on the following pages. • 3101 CPU Board • 3102 AD1319 64-Point I/O Board (up to two maximum). • 3103 AD1309 128-Point I/O Board (up to three maximum). • 3104 AD1308 64-Point I/O Board (up to two maximum). • 3105 AD1313 – 4 Axis HS Board option (SC3000-010). • 3106 Over Drive Processor (ODP) Board (SC3000-030 models only). Expansion Slots The SC3000 Controller has 3 available board slots for the expansion of optional features. They are listed as follows, in relation to the mounting of the CPU board. The CPU board is always installed as the bottom board. SC3000 Unit (rear of the unit) • The highest priority feature option is the “High Speed Board”, and if installed, it must always be the top option board. If any option board is installed after the “HS Board”, the “HS board” must be moved upward. • Since DI/DO boards have fixed addressing, the lowest addressable board is the top board. For example, if the maximum of 2 - 64 DI/DO boards (AD1319) are installed: • • 3-26 • DI/DO board #1 (Addresses 25-88) • DI/DO board #2 (Addresses 89-152) -bottom board- expansion slot 1 -top board- expansion slot 2 And, if the maximum of 3 - 128 DI/DO boards (AD1309) are installed: • DI/DO board #1 (Addresses 153-280) • DI/DO board #2 (Addresses 281-408) • DI/DO board #3 (Addresses 409-536) -top board- expansion slot 3 -bottom board- expansion slot 1 The Over Drive Processor (ODP) board installs directly on the CPU board. SC3000 Series Installation and Specifications Manual Optional Feature Installation Normally, when your Robot System is ordered, any option board(s) is installed and checked out for you, before shipment. If however, any options are ordered after shipment of your Robot System, you must install them. 3101 CPU Board Removal and Replacement Perform the following procedure only if your CPU board does not have standoff screws installed in each corner of the CPU board, and you need to install an option board. CAUTION: Any time the C5 or CN9 cable on the CPU board is disconnected, absolute home position is LOST! NOTES: A Personal Computer, capable of communicating with the SC3000 Robot Controller ADS port, and an ADS software package, or a Pendant, is required to re-establish the absolute home position. 1. Ensure that electrical power and air pressure has been turned off and removed from all units. 2. Remove the 5 top cover screws and the top cover. Ensure the orange LED on the Mother board is extinguished. (As viewed from the Controller rear, the orange LED is on the lower right corner of the Mother board). 3. Remove the 2 rear screws that mount each dummy Controller connector plate(s) to the rear of the unit. Remove each CPU corner mounting screw (4) and replace with a standoff screw (4). 4. Attach one end of the 50 core flat cable to the CN1 connector on the CPU board, that was shipped with your option board. 5. Verify that all cables are properly seated. 6. If you were sent here from the topic, “Installing the SC3000 Series Robot Controller”, step 3, return there now, or, go to the appropriate option installation procedure, 3102 through 3106. Chapter 3 Installation Instructions 3-27 SC3000 Robot Systems 3102 AD1319 – 64 Point DI/DO Board (P/N SCF323) 1. This procedure requires that the HWDEF.CFG file be updated. Before starting this procedure, upload a current copy of the HWDEF.CFG file from the Controller and: • Send an email to [email protected] and attach a copy of your HWDEF.CFG file. In the email text, state the number of 32/64 Point I/O board(s) you installed; or, • Call 1-561-998-9775 and request technical support (North America and Puerto Rico only). If you are outside North America, refer to the Preface Chapter and contact the nearest Sankyo office for assistance with your HWDEF.CFG file. 2. Power off the Controller. Remove the 5 screws and the top cover. Ensure the orange LED on the Mother board is extinguished (high voltage). 3. Remove the rear dummy Controller plate(s) (2 screws in each plate). When removing the rear dummy Controller plate(s), always break off and remove the top dummy plate, as the bottom dummy plate has a lip to ensure proper air flow inside the Controller. 4. Up to 2 AD1319 feature boards may be installed above the CPU board. 5. If you have an AD1313 HS board already installed, you must remove it now and place to one side. (This board must be re-installed later as the top board.) 6. If not already installed, install the 50 pin flat pigtail cable to CN1 of the CPU board, any remaining pigtail connectors may attach to any installed option board. 7. Install the AD1319 board(s) using the following table for jumpers. • DI/DO board #1 (Addresses 25-88) • DI/DO board #2 (Addresses 89-152) -bottom board-, expansion slot 1 -top board-, expansion slot 2 Function Board 1 Expansion Slot 2 Board 2 1 Jumper JP1 OFF ON AD1319 Option board Controller rear 8. If you removed an AD1313 HS board, go to Procedure 3106 or 3107 now to re-install this feature. Return here when finished. 9. Install all board screws, and verify that all cables are properly installed. RS-232C Port 1. A second RS-232C communications port is available on the AD1319 board, and the Port address is 2 or 3. To use this port, install companion option SCF324. Connect the flat cable between CN4 of the AD1319 board to CN4 of option SCF324. 2. Install any remaining hardware, and test the Robot system. 3-28 SC3000 Series Installation and Specifications Manual 3103 AD1309 128-Point DI/DO Board (P/N SCF302) 1. Power off the Controller. Remove the 5 screws and the top cover. Ensure the orange LED on the Mother board is extinguished (high voltage). 2. Remove the rear dummy Controller plate(s) (2 screws in each plate). When removing the rear dummy Controller plate(s), always break off and remove the top one, as the bottom one has a lip to ensure proper air flow inside the Controller. 3. Up to 3 AD1309 feature boards may be installed above the CPU board. 4. If you have an AD1313 HS board already installed, you must remove it now and place to one side. (This board must be re-installed later as the top board.) 5. If not already installed, install the 50 pin flat pigtail cable to CN1 of the CPU board, any remaining pigtail connectors may attach to any installed option board. 6. Install the AD1309 board(s) using the following table for jumpering. • DI/DO board #1 (Addresses 153-280) • DI/DO board #2 (Addresses 281-408) • DI/DO board #3 (Addresses 409-536) • The application person requires this information. -top board-, expansion slot 3 -bottom board-, expansion slot 1 Board 1 Board 2 Board 3 Expansion Slot 3 2 1 Jumper JP1 Jumper JP2 OFF OFF ON OFF OFF ON AD1309 Option board Controller rear 7. If you removed an AD1313 HS board, go to Procedure 3106 or 3107 now to re-install this feature. Return here when finished. 8. Install all board screws, and verify that all cables are properly installed. RS-232C Port 1. A second RS-232C communications port is available on the AD1309 board, and the Port address is 4, 5 or 6. To use this port, install companion option SCF324. Connect the flat cable between CN4 of the AD1309 board to CN4 of option SCF324. 2. Install any remaining hardware, and test the Robot system. Chapter 3 Installation Instructions 3-29 SC3000 Robot Systems 3104 AD1308 32/64-Point DI/DO Board NOTE: The AD1308 option is not available in the USA and some other countries. This procedure requires that the HWDEF.CFG file be updated. Refer to the Preface Chapter and contact the nearest Sankyo office for assistance with the HWDEF.CFG file update. 1. Power off the Controller. Remove the 5 screws and the top cover. Ensure the orange LED on the Mother board is extinguished (high voltage). 2. Remove the rear dummy Controller plate(s) (2 screws in each plate). When removing the rear dummy Controller plate(s), always break off and remove the top one, as the bottom one has a lip to ensure proper air flow inside the Controller. 3. Up to 2 AD1308 feature boards may be installed above the CPU board. 4. If you have an AD1313 HS board already installed, you must remove it now and place to one side. (This board must be re-installed later as the top board.) 5. Install the adapter board(s) using the following table. If you are installing more than one DI/DO option board, refer to the following: • DI/DO board #1 (Addresses 25-88) • DI/DO board #2 (Addresses 89-152) -bottom board-, expansion slot 1 -top board-, expansion slot 2 Board 1 Board 2 Expansion Slot 2 1 Jumper JP1 OFF ON AD1308 Option board Controller rear 6. Install any remaining board hardware, and verify the cabling. 7. If you removed an AD1313 HS board, go to Procedure 3106 or 3107 now to re-install this board. Return here when finished. 8. Install any remaining hardware, and test the Robot system. 3-30 SC3000 Series Installation and Specifications Manual 3105 AD1313-4 Axis HS Board P/N SCF310) NOTE: This option is available for the SC3000-010 4 Axis Controller only. 1. Turn the Controller off. Wait for one minute for the orange LED on the Mother board to turn off and show that the high voltage has discharged sufficiently. 2. Remove the 5 screws from the top cover, and remove the top cover. 3. Remove the rear dummy Controller plate(s) (2 screws in each plate). When removing the rear dummy Controller plate(s), always break off and remove the top one, as the bottom one has a lip to ensure proper air flow inside the Controller. NOTE: The HS option board must always be the top board in the Controller. 4. Insert the HS option board from the rear and install the following cables: Rear of Controller 5. Install any remaining board hardware, and verify the cabling. 6. Install any remaining hardware, and test the Robot system, or, return to the procedure that sent you here. RS-232C Port 1. A second RS-232C communications port is available on the HS board, and the Port address is 7. The RS-232C connector is at the rear of this board. 2. Install all remaining hardware, and perform the "Absolute Home Position" adjustment depending on your Robot type, found in a previous topic in this chapter. Test the Robot System. Chapter 3 Installation Instructions 3-31 SC3000 Robot Systems 3106 Over Drive Processor (ODP) Board (P/N SCF317) Pre-requisites: A. SC3000-030 Controller. B. CPU Board - must be at level SB225008 (P/N E10A65P ) - refer to Installation, step 2, below. C. Robot System / ODP Files: • STRATE.BIN V203.11 or later • SC3000.BIN (Companion file to STRATE.BIN) • HSENGINE.BIN (Companion file to STRATE.BIN) • HSBOOT.BIN (Companion file to STRATE.BIN) D. Buzz application development software,-orADS for DOS software All SC3000-030 systems E. Pendant w/V2.02 software or later All SC3000-030 systems with a Pendant Installation: 1. Power on the Controller and use the Buzz File manager or ADSMT to upload all critical files: • HWDEF.CFG • JOBDEF.CFG • Retrieve the JOB, or upload all files with an extension of .DAT (Unique teaching data files), and any other user files (these may be *.TXT, *.TSK, SSL, etc. , if they are not part of a Cell Controller download process) 2. Power off the Controller and remove the 5 screws and the top cover. Ensure the Controller CPU board is at level SB225008, and contains 1MB of Flash Memory: • If any option board is installed above the CPU board, disconnect any cables to the board, and remove the four board corner screws. Perform this step for each option board. • Look between the AUX and I/O 1 connectors on the CPU Board component side for the number -SB225008. Also, 1MB of Flash Memory MUST be installed. See the following drawing: Rear of Controller 3-32 • If the CPU board is not at level SB225008 with 1MB of Flash Memory, it must be replaced with a CPU board with 1 MB of memory. Continue with step 3. • If the CPU board is at level SB225008 with 1 MB of Flash Memory, skip to step 12. SC3000 Series Installation and Specifications Manual 3. Ensure that electrical power and air pressure has been turned off and removed from all units, if possible. 4. Ensure the orange LED on the Mother board is extinguished, usually one minute after removing power from the Controller. 5. Disconnect, and label if necessary, all cables from the CPU Board. 6. Remove the four corner screws that mount the CPU Board to the unit base. 7. Remove the 2 rear screws that mount the CPU Board connector plate to the rear of the unit. It may also be necessary to remove any blank rear plates, 2 screws per plate. 8. Carefully remove the 512K CPU board through the rear of the unit. 9. For replacement of the 1 MB CPU board, reverse steps 3 through 8. 10. Download the files that were uploaded in step 1. See the following CAUTION note. Caution: If you Deploy the JOB with Buzz, you could create a new blank Teaching data file. DO NOT Deploy the JOB, unless you want to reteach the points! Use the Buzz File Manager or the ADSMT program for downloading. 11. Power on the Controller and test the Robot System by performing an ABS Home procedure. This verifies the integrity of the new CPU board before installing the ODP board and supporting files. CAUTION: Do not power off the SC3000 until after all four of the following files are downloaded. 12. Ensure the Controller power is on and download the four ODP System files, in the sequence given. Use the Buzz File Manager or the ADSMT program. Download sequence: • STRATE.BIN • SC3000.BIN • HSENGINE.BIN • HSBOOT.BIN 13. If you skipped steps 3 through 11, download the files uploaded in step 1. See the following CAUTION note. Caution: If you Deploy the JOB with Buzz, you could create a new blank Teaching data file. DO NOT Deploy the JOB, unless you want to reteach the points! Use the Buzz File Manager or the ADSMT program for downloading. • HWDEF.CFG • JOBDEF.CFG • All files with an extension of .DAT (Unique teaching data files) • Any other user files (These may be *.TXT, *.TSK, etc. , if they are not part of a Cell Controller download process) 14. Power off the Controller, wait one minute, then install the ODP board on top of the CPU board. Temporarily disconnect, then re-connect, any cables that may interfere with the safe plugging of the ODP board. Refer to the drawing on the following page. Chapter 3 Installation Instructions 3-33 SC3000 Robot Systems 15. Install the ODP board power connector to CN9 of the Power Supply. As viewed from the front of the Controller, CN9 is at the upper right hand corner of the Power Supply. Ensure the power connector locking tab is toward the P/S connector locking clip. Refer to the following drawing. (back of Controller ) mounting screws Fan ODP board CPU board DC Power supply (top view) CN9 location 16. Remove the rear blank mounting plate just above the CPU board, and replace it with the rear vented mounting plate that is supplied with the ODP board option. 17. Install all remaining cables and hardware. 18. Power on the Controller. Sometimes a false Real-time error occurs on the first power on. If this condition occurs, power the Controller off, then on again. The normal condition is Error 250, “Home Position Lost”. 19. Perform an “ABS Home Procedure”. Test the system. Follow-on Topics The following topics may be researched in this manual. 3-34 • Wiring the User (physical) DI/DO points, Chapter 4. • ADS Communications port cable wiring, Appendix A. • RS-232C Communications port cable wiring, Appendix B. • DI/DO wiring charts to keep track of User DI/DO wiring, Appendix C. SC3000 Series Installation and Specifications Manual Chapter 4 Digital Input/Digital Output (DI/DO) CONTENTS Digital Input / Digital Output Points ...................................................................................... 4-3 DI/DO Configuration: ............................................................................................................................. 4-3 Physical DI/DO ...................................................................................................................................... 4-4 Physical DI/DO Address Chart ....................................................................................................... 4-5 Standard DI/DO ....................................................................................................................... 4-6 Standard Input circuit ...................................................................................................................... 4-7 DI Point Specifications .................................................................................................................... 4-7 Standard Output circuit ................................................................................................................... 4-7 DO Point Specifications .................................................................................................................. 4-7 Standard Digital Input (DI)..................................................................................................................... 4-8 Open collector type sensor DI - I/O 1 connector ............................................................................ 4-8 Using the Internal +24V supply ...................................................................................................4-9 Open collector type sensor DI - I/O 2 connector .......................................................................... 4-10 Using the Internal +24V supply .................................................................................................4-11 Open emitter type sensor DI - I/O 1 connector ............................................................................. 4-12 Open emitter type sensor DI - I/O 2 connector ............................................................................. 4-14 Standard Digital Output (DO) .............................................................................................................. 4-16 Open collector sinking type DO - I/O 1 connector ........................................................................ 4-16 Using the Internal +24V supply .................................................................................................4-17 Open collector sinking type DO - I/O 2 connector ........................................................................ 4-18 Using the Internal +24V supply .................................................................................................4-19 Open emitter sourcing type DO - I/O 1 connector ........................................................................ 4-20 Open emitter sourcing type DO - I/O 2 connector ........................................................................ 4-22 Customer D/O Error circuit .................................................................................................................. 4-24 Customer Safety circuits - Before May, 1995 ..................................................................................... 4-25 Customer Safety circuits - After May, 1995 ........................................................................................ 4-26 I/O 1 Connector Pin Assignments ....................................................................................................... 4-27 I/O 2 Connector pin assignments........................................................................................................ 4-28 128 Point DI/DO Option (P/N SCF302) ................................................................................ 4-29 DO Point Fuses ............................................................................................................................ 4-29 Card Jumpers ............................................................................................................................... 4-29 Modifying the HWDEF.CFG file.................................................................................................... 4-29 128 Point I/O - DI Circuit diagram................................................................................................. 4-30 128 Point I/O - DO Circuit diagram............................................................................................... 4-30 128 Point I/O - Wiring DI/DO points.............................................................................................. 4-31 Connector Charts ................................................................................................................................ 4-32 128 Point I/O - CN1 Connector..................................................................................................... 4-32 128 Point I/O - CN2 Connector..................................................................................................... 4-33 128 Point I/O - CN3 Connector..................................................................................................... 4-34 128 Point I/O - CN4 Connector ..................................................................................................... 4-35 128 Point - DATA Communications.............................................................................................. 4-36 Copyright © Sankyo Robotics, 1994-2001 Chapter 4 Digital Input/Digital Output (DI/DO) 4-1 SC3000 Robot Systems 64 Point DI/DO Option (P/N SCF323) .................................................................................. 4-37 DO Point Fuses ............................................................................................................................ 4-37 Card Jumper ................................................................................................................................. 4-37 Modifying the HWDEF.CFG file.................................................................................................... 4-37 64 Point I/O - DI Circuit Diagram .................................................................................................. 4-38 64 Point I/O - DO Circuit Diagram ................................................................................................ 4-38 64 Point I/O - Wiring DI/DO points................................................................................................ 4-39 Connector Charts ................................................................................................................................ 4-40 64 Point I/O - CN1 Connector (DI Only) ....................................................................................... 4-40 64 Point I/O - CN2 Connector (DO Only) ..................................................................................... 4-41 64 Point I/O - CN3 Connector (DI Only) ....................................................................................... 4-42 64 Point I/O - CN4 Connector (DO Only) ..................................................................................... 4-43 External DI/DO Cable Routing............................................................................................. 4-44 Some Good Rules To Follow .............................................................................................................. 4-44 Signal Cable Selection ........................................................................................................................ 4-45 4-2 SC3000 Series Installation and Specifications Manual Digital Input / Digital Output Points The SC3000 Series Controllers utilize three types of Digital Input and Digital Output (DI/DO) points. DI/DO is also called I/O. In some documentation you may see the term “port” or “ports”, when I/O points are discussed. Point(s), port(s), I/O and DI/DO are all interchangeable terms. The three types of DI/DO are: Physical I/O is the I/O that will be utilized by the customer for wiring external devices that interact with the application. The user has 24 points of I/O standard, and up to 384 points of extended I/O. This chapter describes the use of physical DI/DO. Memory I/O is used by the customer for task to task communication. 1024 points are reserved by the system for this purpose. This type of DI/DO is not discussed in this manual. Refer to the SC3000 SSL/E Language Reference, “Chapter 3”, for additional information on this topic. System I/O contains useful information about each task. 2048 points are available , 64 points per task, 32 for SI (System Input), and 32 for SL (System Load). For System Load, the term Load is the same as Output. This type of DI/DO is not discussed in this manual. Refer to the SC3000 SSL/E Language Reference, “Chapter 3”, for additional information on this topic DI/DO Configuration: I/O Type Point # Physical I/O 1 CPU Board Physical I/O 24 25 Extended Board(s) Memory I/O 536 1025 CPU Board System I/O 2048 2049 CPU Board 4096 4097 All DI/DO points with a value or status of 1 is true. Likewise, a value or status of 0 is false. The monitoring of all DI/DO points can be done with the Pendant or the ADS personal computer. Reserved nnnn Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-3 SC3000 Robot Systems Physical DI/DO Physical DI/DO is also called User DI/DO. This is the DI/DO furnished by the SC3000 Series Controller for customer use with external devices. The SC3000 Series Controllers contains 2 types of DI/DO: 1. Standard DI/DO • Points 1 - 16 are DI and points 17 - 24 are DO points. They are supplied on the CPU board, through connectors I/O 1 and I/O 2 as follows: • I/O 1. DI Points 1 - 8 and DO points 17 - 20. • I/O 2. DI Points 9 - 16 and DO points 21 - 24. • Standard DI/DO points are fixed, not selectable or programmable. 2. Extended DI/DO (optional) 32/64 Point Extended DI/DO option, up to 64 points per board, and up to 2 boards per Controller. This provides a total of an additional 128 DI/DO points. The DI/DO points have fixed addresses, but each point may be configured individually as a DI or a DO point. This is option AD1319 or AD1308. • A maximum of 2 Option boards (total) may be added to the Controller. • Each DI/DO point has a unique address, regardless of the option(s) installed, but may be a DI or a DO point. Each I/O point definition is selectable. • The first DI/DO point on the first option board is point number 25 and by default is configured as a DI point. By default, the first DO point on the first option board is point number 41. • If you were to install one DI/DO expansion board now, you may add one later without changing any DI/DO address. All physical DI/DO points have unique addresses. 128 Point Extended DI/DO option, 128 points per board, and up to 3 boards per Controller. This provides a total of an additional 384 DI/DO points. The Extended DI/DO points, like the Standard DI/DO points, are fixed, not selectable, and each point has a unique address. This is option AD1309. • A maximum of 3 Option boards (total) may be added to the Controller. • Each 128 POINT DI/DO point has a unique address, regardless of the option(s) installed. • The first DI/DO point on the first 128 POINT expansion option is point number 153, and it is a DI point. The first DO point on the first 128 POINT option is point number 217. • If you were to install one DI/DO expansion board now, you may add one later without changing any DI/DO address. All physical DI/DO points have unique addresses. You can mix and match these I/O board options. You can have one 32/64 POINT option and one 128 POINT option installed on your Controller. Refer to the Address Chart on the following page for Physical I/O addresses. 4-4 SC3000 Series Installation and Specifications Manual Physical DI/DO Address Chart DI/DO Type Board ID Address Range Standard I/O 24 points total CPU 1-24 1-16 DI 17-24 DO Expanded I/O Board 1 25-88 25-40 DI 41-56 DO 57-72 DI 73-88 DO Board 2 89-152 89-104 DI 105-120 DO 121-136 DI 137-152 DO Board 1 153 - 280 153 - 216 DI 217 - 280 DO Board 2 281 - 408 281 - 344 DI 345 - 408 DO Board 3 409 - 536 409 - 472 DI 473 - 536 DO AD1319 Feature or *AD1308 Feature 64 points total Expanded I/O Definition AD1309 Feature 128 points total *AD1308 Feature is not available in all countries. • All addresses are fixed for standard and extended Physical (user) DI/DO. • The AD1308 32/64 POINT option DI/DO points are individually selectable. • All Standard, AD1309 and AD1319 Feature option DI/DO points are fixed, not programmable or selectable. Chapter 4 Digital Input/Digital Output (DI/DO) 4-5 SC3000 Robot Systems Standard DI/DO Connector I/O 1 at the rear of the Controller contains DI points 1 through 8, and DO points 17 through 20. Connector I/O 2 at the rear of the Controller contains DI points 9 through 16, and DO points 21 through 24. Each of the DO points are fused on the CPU board, to protect circuit logic and each has its own spare logic fuse. The user must supply a +24V DC power source to power external devices. The +24V DC supply should meet international requirements for safety isolation transformers and provide safety extra-low voltages (SELV). The SC3000 Series Controllers provides a +24V DC level at 2 amps for DI/DO test purposes only. The +24V DC is present at pin 1 on both I/O connectors, +24V DC common is present on pin 14 on both I/O connectors. It is recommended to use this internal +24V DC power only as a way to test DI/DO points when an external +24V DC power supply is not readily available. Once the application design is complete, the user should have acquired an external +24V DC power supply to meet the requirements of the application. CAUTION: Any user wiring attached to the Robot Controller other than at the user interface connectors may cause: • a safety hazard • warranty invalidation • unexplained system errors • unreliable operation. Refer to the following wiring examples for Standard DI/DO. 4-6 SC3000 Series Installation and Specifications Manual Standard Input circuit DI Point Specifications • DI points are powered by an external +24V DC power supply (± 10 %). • The minimum current draw for each DI point is 10 ma. Standard Output circuit DO Point Specifications • DO points are powered by an external +24V DC power supply (± 10 %). • The maximum current draw for any DO point is 500 ma. Chapter 4 Digital Input/Digital Output (DI/DO) 4-7 SC3000 Robot Systems Standard Digital Input (DI) Open collector type sensor DI - I/O 1 connector The following figure shows the digital input I/O 1 connector pin assignments from the 16-point standard DI group that is part of the CPU board logic. Any DI optical isolation circuit can be used as an open collector DI type as follows: 4-8 NOTE: Pins 1 and 14 (Controller internal 24V DC and DC Common) are used for test purposes. NOTE: The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. SC3000 Series Installation and Specifications Manual The preceding page shows: • The external power source +24V DC, connected at pin 2 of I/O connector 1. • The external power source DC common, connects to one side of the user sensor. • The other side of the user sensor is connected to any DI input pin, 3 through 10, of I/O connector 1, depending on the DI point used. NOTES: Minimum of 10 ma per DI point is expected Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO sensors. It is recommended to copy the blank charts in Appendix C, and keep the originals as master copies. Using the Internal +24V supply If you want to test with the internal +24V DC power supply: 1. Jumper pin 1 to pin 2 on I/O 1. (The internal +24V DC is present at pin 1). 2. Use pin 14 of I/O 1 as the DC common side to connect to one side of any sensor. 3. Connect the other side of the user sensor to pins 3 through 10 of I/O connector 1, depending on the DI point you want to use. (In our example, pin 5, DI point 3). NOTE: The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. Chapter 4 Digital Input/Digital Output (DI/DO) 4-9 SC3000 Robot Systems Open collector type sensor DI - I/O 2 connector The following figure shows the digital input I/O 2 connector pin assignments from the 16-point standard DI group that is part of the CPU board logic. Any DI optical isolation circuit can be used as an open collector DI type as follows: 4-10 NOTE: Pins 1 and 14 (Controller internal 24V and DC common) are used for test purposes. NOTE: The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. SC3000 Series Installation and Specifications Manual The preceding page shows: • The external power source +24V DC, connected at pin 2 of I/O connector 2. • The external power source DC common, connects to one side of the user sensor. • The other side of the user sensor is connected to any DI input pin, 3 through 10, of I/O connector 2, depending on the DI point used. NOTES: Minimum of 10 ma per DI point is expected Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO sensors. It is recommended to copy the blank charts in Appendix C, and keep the originals as master copies. Using the Internal +24V supply If you want to test with the internal +24V DC power supply: 1. Jumper pin 1 to pin 2 on I/O 2. The internal +24V DC is present at pin 1. 2. Use pin 14 of I/O 2 as the DC Common side to one side of the sensor. 3. Connect the other side of the user sensor to pins 3 through 10 of I/O connector 2, depending on the DI point you want to use. In our example, pin 5, DI point 11. NOTE: The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. Chapter 4 Digital Input/Digital Output (DI/DO) 4-11 SC3000 Robot Systems Open emitter type sensor DI - I/O 1 connector The following figure shows the digital input I/O 1 connector pin assignments from the 16-point standard DI group that is part of the CPU board logic. Any DI optical isolation circuit can be used as an open emitter DI type as follows: NOTE: 4-12 The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. SC3000 Series Installation and Specifications Manual The example on the preceding page shows: • The external power source DC common, connected at pin 2 of I/O connector 1. • The external power source +24V DC connects to one side of the user sensor. • The other side of the user sensor is connected to any DI input pin, 3 through 10, of I/O connector 1, depending on the DI point used. NOTES: Minimum of 10 ma per DI point is expected Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO points. It is recommended to copy the blank charts in Appendix C, and keep the originals as master copies. If you want to test with the internal +24V DC power supply: Use the open collector DI type, explained in the previous topic. Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-13 SC3000 Robot Systems Open emitter type sensor DI - I/O 2 connector The following figure shows the digital input I/O 2 connector pin assignments from the 16-point standard DI group that is part of the CPU board logic. Any DI optical isolation circuit can be used as an open emitter DI type as follows: NOTE: 4-14 The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. SC3000 Series Installation and Specifications Manual The example on the preceding page shows: • The external power source DC common, connected at pin 2 of I/O connector 2. • The external power source +24V DC, connects to one side of the user sensor. • The other side of the user sensor is connected to any DI input pin, 3 through 10, of I/O connector 2, depending on the DI point used. NOTES: Minimum of 10 ma per DI point is expected Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO points. It is recommended to copy the blank charts in Appendix C, and keep the originals as master copies. If you want to test with the internal +24V DC power supply: Use the open collector DI type, explained in the previous topic. Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-15 SC3000 Robot Systems Standard Digital Output (DO) Open collector sinking type DO - I/O 1 connector The following figure shows the digital output I/O 1 connector pin assignments from the 8-point standard DO group that is part of the CPU board logic. Any DO optical isolation circuit can be used as an open collector DO type as follows: NOTE: Pins 1 and 14 (internal 24V and DC common) are used for test purposes. See the following page, "Using the Internal +24V supply". NOTES: The arc suppression diode, pictured above across each user output device, is customer supplied. Each DO point is fused on the CPU board. Refer to Chapter 2.2, the topic “Repairing Standard DO fuses” of the SR8437 and SR8438 Series Hardware Manual, or the CCRM Series Hardware Manual for more information on repairing DO fuses. The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. 4-16 SC3000 Series Installation and Specifications Manual The example on the preceding page shows: • The external power source +24V DC, connected to one side of the user device. This can be a relay, solenoid, etc. • The other side of the user device is connected to a DO pin, 20 through 23, of I/O connector 1, depending on the DO point used • The external power source DC common is connected to a DO pin, 15 through 18, of I/O connector 1, depending on the DO point used. • The arc suppression diode is installed across the DO load for the user output device. NOTES: Maximum of 500 ma per DO point is expected, 2 amps per group of 4 DO points. Each DO point is individually fused on the CPU board. Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO sensors. It is recommended to copy the blank charts in Appendix C, and keep the originals as master copies. Using the Internal +24V supply 1. For test purposes only. Use pin 1 as a common to one side of the user device. The internal +24V DC is present at pin 1 of the I/O 1 connector. 2. Connect the other side of the user device to a DO pin, 20 through 23, of I/O connector 1, depending on the DO point used. In our example, pin 22 for DO point 19. 3. Use pin 14 of I/O 1 as the DC common side, connecting to a DO pin, 15 through 18, of I/O connector 1, depending on the DO point used. In our example, pin 17, DO point 19. Chapter 4 Digital Input/Digital Output (DI/DO) 4-17 SC3000 Robot Systems Open collector sinking type DO - I/O 2 connector The following figure shows the digital output I/O 2 connector pin assignments from the 8-point standard DO group that is part of the CPU board logic. Any DO optical isolation circuit can be used as an open collector DO type as follows: NOTE: Pins 1 and 14 (internal 24V and DC common) must only be used for test purposes. See the following page, "Using the Internal +24V supply". NOTES: The arc suppression diode, pictured above across each user device, is customer supplied. Each DO point is fused on the CPU board, and a spare circuit fuse is provided in the event the primary fuse becomes defective. Refer to Chapter 2.2, “Repairing Standard DO fuses” of the SR8437 and SR8438 Series Hardware Manual, or the CCR-M Series Hardware Manual for more information on repairing DO fuses. The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. 4-18 SC3000 Series Installation and Specifications Manual The example on the preceding page shows: • The external power source +24V DC, connected to one side of the user device. This can be a relay, solenoid, etc. • The other side of the user device is connected to a DO pin, 20 through 23, of I/O connector 2, depending on the DO point used • The external power source DC common is connected to a DO pin, 15 through 18, of I/O connector 2, depending on the DO point used. • The arc suppression diode is installed across the DO load for the user output device. NOTES: Maximum of 500 ma per DO point is expected, 2 amps per group of 4 DO points. Each DO point is individually fused. Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO sensors. It is recommended to copy the blank charts in Appendix C, and keep the originals as master copies. Using the Internal +24V supply 1. For test purposes only. Use pin 1 as a common to one side of the user device. The internal +24V DC is present at pin 1 of the I/O 2 connector. 2. Connect the other side of the user device to a DO pin, 20 through 23, of I/O connector 2, depending on the DO point used. In our example, DO point 23. 3. Use pin 14 of I/O 2 as the DC common side, connecting to a DO pin, 15 through 18, of I/O connector 2, depending on the DO point used. In our example, DO point 23. NOTE: The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. Chapter 4 Digital Input/Digital Output (DI/DO) 4-19 SC3000 Robot Systems Open emitter sourcing type DO - I/O 1 connector The following figure shows the digital output I/O 1 connector pin assignments from the 8-point standard DO group that is part of the CPU board logic. Any DO optical isolation circuit can be used as an open emitter DO type as follows: NOTES: The arc suppression diode, pictured above across each user device, is customer supplied. Each DO point is fused on the CPU board, and a spare circuit fuse is provided in the event the primary fuse becomes defective. Refer to Chapter 2.2, “Repairing Standard DO fuses” of the SR8437 and SR8438 Series Hardware Manual, or the CCR-M Series Hardware Manual for more information on repairing DO fuses. The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. 4-20 SC3000 Series Installation and Specifications Manual The example on the preceding page shows: • The external power source DC common, connected to one side of the user device. This can be a relay, solenoid, etc. • The other side of the user device is connected to a DO pin, 15 through 18, of I/O connector 1, depending on the DO point used • The external power source 24V DC is connected to a DO pin, 20 through 23, of I/O connector 1, depending on the DO point used. • The arc suppression diode is installed across the inductive load for the user device. NOTES: Maximum of 500 ma per DO point is expected, 2 amps per group of 4 DO points. Each DO point is individually fused. Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO sensors. It is recommended to copy the blank charts in Appendix C, and keep the originals as master copies. If you want to test with the internal +24V DC power supply: Use the open collector DO type, explained in the previous topic. Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-21 SC3000 Robot Systems Open emitter sourcing type DO - I/O 2 connector The following figure shows the digital output I/O 2 connector pin assignments from the 8-point standard DO group that is part of the CPU board logic. Any DO optical isolation circuit can be used as an open emitter DO type as follows: NOTES: The arc suppression diode, pictured above across each user device, is customer supplied. Each DO point is fused on the CPU board, and a spare circuit fuse is provided in the event the primary fuse becomes defective. Refer to Chapter 2.2, “Repairing Standard DO fuses” of the SR8437 and SR8438 Series Hardware Manual, or the CCR-M Series Hardware Manual for more information on repairing DO fuses. The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. 4-22 SC3000 Series Installation and Specifications Manual The example on the preceding page shows: • The external power source DC common, connected to one side of the user device. This can be a relay, solenoid, etc. • The other side of the user device is connected to a DO pin, 15 through 18, of I/O connector 2, depending on the DO point used • The external power source 24V DC is connected to a DO pin, 20 through 23, of I/O connector 2, depending on the DO point used. • The arc suppression diode is installed across the inductive load for the user device. NOTES: Maximum of 500 ma per DO point is expected, 2 amps per group of 4 DO points. Each DO point is individually fused. Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO sensors. It is recommended to copy the blank charts in Appendix C, and keep the originals as master copies. If you want to test with the internal +24V DC power supply: Use the open collector DO type, explained in a previous topic. Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-23 SC3000 Robot Systems Customer D/O Error circuit When the Controller front panel Error LED is on or flashing, pin 24 and pin 19 of the I/O 2 connector provide a DO signal: (This signal is not present on I/O 1) Pin 19 is the Error N signal Pin 24 is the Error P signal This can be connected via the open collector type, or the open emitter type, as shown above. The purpose is to provide an Error output signal (DO) when the Robot Controller has detected an error. NOTES: Maximum of 500 ma for the DO point is expected, not fused. Install an arc suppression diode across any user load that is being utilized as a DO device. See circuit example above. Appendix C contains blank Physical (user) DI/DO charts that can be used to keep track of all DI/DO sensors. It is recommended to copy the blank charts in Appendix C and keep the originals as master copies. The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. 4-24 SC3000 Series Installation and Specifications Manual Customer Safety circuits - Before May, 1995 CAUTION: If pins 12 and 14 of I/O 2 are jumpered, Servo power can come on automatically. You are advised not to jumper pins 12 and 14. If necessary, place a momentary type toggle switch across pins 12 and 14, so that Servo power may be controlled by this momentary switch. (Pendant must be in Remote Mode.) NOTES: The Emergency stop (n/c) switch must exceed a 24V, 200 ma rating. The Servo power on (n/o) switch must exceed a 24V, 10 ma rating. The Aux L connector has pins 4 and 12 jumpered, pins 7 and 14 have a 470 ohm resistor, for noise suppression. If the Pendant is not attached, the dummy Pendant connector must be installed for Servo power to be switched on. If an E-Stop switch circuit is not used with I/O 1 and/or I/O 2, then the dummy I/O 1 and/or I/O 2 connectors must be installed for Servo power to be switched on. Chapter 4 Digital Input/Digital Output (DI/DO) 4-25 SC3000 Robot Systems Customer Safety circuits - After May, 1995 CAUTION: If pins 12 and 14 of I/O 2 are jumpered, Servo power can come on automatically. You are advised not to jumper pins 12 and 14. Place a momentary type toggle switch across pins 12 and 14, so that Servo power may be controlled by this momentary switch. (Pendant must be in Remote Mode.) NOTES: The Emergency stop (n/c) switch must exceed a 24V, 200 ma rating. The Servo power on (n/o) switch must exceed a 24V, 10 ma rating. The SC3000-010 Aux H connector has pins 4 and 5 jumpered, pins 7 and 14 have a 470 ohm resistor, for noise suppression. See the drawing above. The SC3000-030 Aux H connector has pins 1 and 27 jumpered, pins 23 and 48 have a 470 ohm resistor, for noise suppression. (Not shown in drawing above.) If the Pendant is not attached, the Dummy Pendant connector must be installed. If an E-Stop switch circuit is not used with I/O 1 and/or I/O 2, then the dummy I/O 1 and/or I/O 2 connectors must be installed for Servo power to be switched on. 4-26 SC3000 Series Installation and Specifications Manual I/O 1 Connector Pin Assignments Pin # Name Description I/O point # 1 2 24V DC ICOM2 Internal +24V DC P/S Input circuit common 3 4 5 6 I1 I2 I3 I4 DI point 1 DI point 2 DI point 3 DI point 4 1 2 3 4 7 8 9 10 I5 I6 I7 I8 DI point 5 DI point 6 DI point 7 DI point 8 5 6 7 8 11 12 13 14 EMS1 G24 not connected not connected Servo power source switch Internal 24V DC P/S common 15 16 17 18 O 1N O 2N O 3N O 4N DO point 1 emitter DO point 2 emitter DO point 3 emitter DO point 4 emitter 19 20 21 22 23 not connected O 1P O 2P O 3P O 4P 24 25 17 18 19 20 DO point 1 collector DO point 2 collector DO point 3 collector DO point 4 collector 17 18 19 20 not connected EMS2 Servo power source switch Chapter 4 Digital Input/Digital Output (DI/DO) 4-27 SC3000 Robot Systems I/O 2 Connector pin assignments 4-28 Pin # Name 1 2 24V DC ICOM2 Internal +24V DC P/S Input circuit common 3 4 5 6 I9 I 10 I 11 I 12 DI point 9 DI point 10 DI point 11 DI point 12 9 10 11 12 7 8 9 10 I 13 I 14 I 15 I 16 DI point 13 DI point 14 DI point 15 DI point 16 13 14 15 16 Description I/O point # 11 12 13 14 G24 Sankyo reserved Servo power source on not connected Internal 24V DC P/S common 15 16 17 18 O 5N O 6N O 7N O 8N Output 5 emitter Output 6 emitter Output 7 emitter Output 8 emitter 19 ERRN Error (LED) output collector N 20 21 22 23 O 5P O 6P O 7P O 8P Output 5 collector Output 6 collector Output 7 collector Output 8 collector 24 ERRP Error (LED) output collector P 25 EMS2 Servo power source switch /STBY 21 22 23 24 21 22 23 24 SC3000 Series Installation and Specifications Manual 128 Point DI/DO Option (P/N SCF302) The 128 POINT DI/DO option board (Feature AD1309) contains 64 points of DI and 64 points of DO, and one RS-232C communications port: • All addresses on the adapter board(s) are fixed and unique for all DI/DO points. • Up to three 128 POINT DI/DO adapter boards may be installed in any one SC3000 Series Controller. Refer to the Card Jumpers topic below, for jumpering information when more than one 128 POINT option board is installed. • An external +24V DC power supply is required to power the DI/DO points and their devices. • The communications port number address is 4 through 6, depending on the board number being used. Option SCF324, “Expansion RS-232C Panel, SC3000”, is recommended for use with the RS-232C communications port. DO Point Fuses Each group of 16 DO points is fused (2.0 amps), P/N E10A43P. The fuse is the only board component that may be replaced, and 2 spare fuses come with each board. Card Jumpers When more than one 128 Point I/O board is installed, jumper the boards as follows: Jumper JP1 and JP2 chart First board JP1 is OFF, JP2 is OFF, RS-232C port ID is 4 Second board JP1 is ON, JP2 is OFF, RS-232C port ID is 5 Third board JP1 is OFF, JP2 is ON, RS-232C port ID is 6 Modifying the HWDEF.CFG file The HWDEF.CFG file does not require changes with the 128 I/O Board option. Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-29 SC3000 Robot Systems 128 Point I/O - DI Circuit diagram Input Circuit DI Point Specifications • DI points are powered by an external +24V DC power supply (± 10 %). • The minimum current draw for each DI point is 10 ma. 128 Point I/O - DO Circuit diagram Output Circuit DO Point Specifications 4-30 • DO points are powered by an external +24V DC power supply (± 10 %). • The maximum current draw for any one DO point is 500 ma. • The maximum current draw for any group of 16 DO points is 2.0 amps. • Each group of 16 DO points is protected with a 2.0 amp replaceable fuse. SC3000 Series Installation and Specifications Manual 128 Point I/O - Wiring DI/DO points Every DI/DO point on each adapter board is associated with its unique address as shown in the following CN1 through CN4 connector charts. Record this “Card n Addr” as this is the address you will use when referencing the DI/DO point in your program. Pin 20 is DI point 298, on the CN2 connector for adapter board #2. Pin 9 is the common that services this DI point. The DI points may be wired in either manner as shown below. Pin 17 is DO point 375, on the CN2 connector for adapter board # 2. Pin 37 is the common to use for this DO point. DO points can only be wired in this manner. See the drawing below CAUTION: The 128 point AD1309 feature for DO point wiring does not work the same as the standard DO. The +24VDC must not be wired to the common as allowed for the standard DO. Use the example above for wiring your DO points. For DI points only, when wiring a CN connector common pin to the external Power Supply Plus side or ground side, all 8 points serviced by that common must be wired in the exact same manner. NOTE: The SC3000 Controller requires a 2.6mm threaded screw to fasten any user D-shell connector to its mating board connector. DO points should have an arc suppression diode installed across the DO load device, as shown in the example above. Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-31 SC3000 Robot Systems Connector Charts 128 Point I/O - CN1 Connector P in N o. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 NOTE: T ype Input Input Input Input Input Input Input Input Input C om m on O utput O utput O utput O utput O utput O utput O utput O utput O utput C om m on N ot connected Input Input Input Input Input Input Input Input Input C om m on O utput O utput O utput O utput O utput O utput O utput O utput O utput C om m on C ard 1 A ddr C ard 2 A ddr C ard 3 A ddr 153 281 409 155 283 411 157 285 413 159 287 415 161 289 417 163 291 419 165 293 421 167 295 423 S ee N ote 217 345 473 219 347 475 221 349 477 223 351 479 225 353 481 227 355 483 229 357 485 231 359 487 S ee N ote 154 156 158 160 162 164 166 168 218 220 222 224 226 228 230 232 282 284 286 288 290 292 294 296 S ee N ote 346 348 350 352 354 356 358 360 S ee N ote 410 412 414 416 418 420 422 424 474 476 478 480 482 484 486 488 The CN1 Input or Output Common services 8 DI or DO points as follows: Pin # Pin 9 Pin 18 Pin 28 Pin 37 Card 1 DI points 153 – 160 DO points 217- 224 DI points 161 - 168 DO points 225 - 232 Card 2 DI points 281 – 288 DO points 345 - 352 DI points 289 - 296 DO points 353 - 360 Card 3 DI points 409 – 416 DO points 473 - 480 DI points 417 - 424 DO points 481 - 488 Appendix C contains blank DI/DO charts for recording the points used in your application. Each group of 16 DO points is fused. To Replace, refer to Chapter 2.2 of the SR8437 and SR8438 Series Hardware Manual, or the CCR-M Series Hardware Manual. 4-32 SC3000 Series Installation and Specifications Manual 128 Point I/O - CN2 Connector P in N o . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 NOTE: T yp e In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t C o m m o n O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t C o m m o n N o t C o n n e c te d In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t C o m m o n O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t C o m m o n C a rd 1 A d d r 169 171 173 175 177 179 181 183 233 235 237 239 241 243 245 247 170 172 174 176 178 180 182 184 234 236 238 240 242 244 246 248 C a rd 2 A d d r C a rd 3 A d d r 297 425 299 427 301 429 303 431 305 433 307 435 309 437 311 439 S e e N o te 361 489 363 491 365 493 367 495 369 497 371 499 373 501 375 503 S e e N o te 298 300 302 304 306 308 310 312 S e e N o te 362 364 366 368 370 372 374 376 S e e N o te 426 428 430 432 434 436 438 440 490 492 494 496 498 500 502 504 The CN2 Input or Output Common services 8 DI or DO points as follows: Pin # Pin 9 Pin 18 Pin 28 Pin 37 Card 1 DI points 169 - 176 DO points 233 - 240 DI points 177 - 184 DO points 241 - 248 Card 2 DI points 297 - 304 DO points 361 - 368 DI points 305 - 312 DO points 369 - 376 Card 3 DI points 425 - 432 DO points 489 - 496 DI points 433 - 440 DO points 497 - 504 Appendix C contains blank DI/DO charts for recording the points used in your application. Each group of 16 DO points is fused. To replace, refer to Chapter 2.2 of the SR8437 and SR8438 Series Hardware Manual, or the CCR-M Series Hardware Manual. Chapter 4 Digital Input/Digital Output (DI/DO) 4-33 SC3000 Robot Systems 128 Point I/O - CN3 Connector P in N o . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 NOTE: T yp e In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t C o m m o n O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t C o m m o n N o t c o n n e c te d In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t C o m m o n O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t C o m m o n C a rd 1 A d d r 185 187 189 191 193 195 197 199 249 251 253 255 257 259 261 263 186 188 190 192 194 196 198 200 250 252 254 256 258 260 262 264 C a rd 2 A d d r 313 315 317 319 321 323 325 327 S e e N o te 377 379 381 383 385 387 389 391 S e e N o te C a rd 3 A d d r 441 443 445 447 449 451 453 455 314 316 318 320 322 324 326 328 S e e N o te 378 380 382 384 386 388 390 392 S e e N o te 442 444 446 448 450 452 454 456 505 507 509 511 513 515 517 519 506 508 510 512 514 516 518 520 The CN3 Input or Output Common services 8 DI or DO points as follows: Pin # Pin 9 Pin 18 Pin 28 Pin 37 Card 1 DI points 185 - 192 DO points 249- 256 DI points 193 - 200 DO points 257 - 264 Card 2 DI points 313 - 320 DO points 377 - 384 DI points 321 - 328 DO points 385 - 392 Card 3 DI points 441 - 448 DO points 505 - 512 DI points 449 - 456 DO points 513 - 520 Appendix C contains blank DI/DO charts for recording the points used in your application. Each group of 16 DO points is fused. To replace, refer to Chapter 2.2 of the SR8437 and SR8438 Series Hardware Manual, or the CCR-M Series Hardware Manual. 4-34 SC3000 Series Installation and Specifications Manual 128 Point I/O - CN4 Connector P in N o . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 NOTE: T yp e In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t C o m m o n O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t C o m m o n N o t c o n n e c te d In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t In p u t C o m m o n O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t O u tp u t C o m m o n C a rd 1 A d d r 201 203 205 207 209 211 213 215 265 267 269 271 273 275 277 279 202 204 206 208 210 212 214 216 266 268 270 272 274 276 278 280 C a rd 2 A d d r 329 331 333 335 337 339 341 343 S e e N o te 393 395 397 399 401 403 405 407 S e e N o te C a rd 3 A d d r 457 459 461 463 465 467 469 471 330 332 334 336 338 340 342 344 S e e N o te 394 396 398 400 402 404 406 408 S e e N o te 458 460 462 464 466 468 470 472 521 523 525 527 529 531 533 535 522 524 526 528 530 532 534 536 The CN4 Input or Output Common services 8 DI or DO points as follows: Pin # Pin 9 Pin 18 Pin 28 Pin 37 Card 1 DI points 201 - 208 DO points 265- 272 DI points 209 - 216 DO points 273 - 280 Card 2 DI points 329 - 336 DO points 393 - 400 DI points 337 - 344 DO points 401 - 408 Card 3 DI points 457 - 464 DO points 521 - 528 DI points 465 - 472 DO points 529 - 536 Appendix C contains blank DI/DO charts for recording the points used in your application. Each group of 16 DO points is fused. To replace, refer to Chapter 2.2 of the SR8437 and SR8438 Series Hardware Manual, or the CCR-M Series Hardware Manual. Chapter 4 Digital Input/Digital Output (DI/DO) 4-35 SC3000 Robot Systems 128 Point - DATA Communications High speed data communications may be accomplished between two SC3000 Controllers by wiring the 128 DI/DO option cards back-to-back. An 8-bit wiring example for CN1 is shown below, and the remainder of CN1, as well as the CN2 - CN4 connectors may be wired accordingly: 4-36 SC3000 Series Installation and Specifications Manual 64 Point DI/DO Option (P/N SCF323) The 64 POINT DI/DO option board contains 32 points of DI and 32 points of DO, and one RS-232C communications port: • All addresses on the adapter board(s) are fixed and unique for all DI/DO points. • Up to two 64 Point DI/DO adapter boards may be installed in any one SC3000 Series Controller. Refer to the Card Jumper topic below for jumpering instructions. • An external +24V DC power supply is required to power the DI/DO points and their devices. • Each DO Point is fused (0.5 amps) on the board, and a secondary DO point fuse may be soldered into the circuit if the primary fuse becomes defective. • The communications port number address is 2 or 3, depending on the board number being used. Option SCF324, “Expansion RS-232C Panel, SC3000”, is recommended for use with the RS-232C communications port. DO Point Fuses Each DO point is fused (0.5 amps). The replacement fuse is already on the board and must be soldered into the circuit. Before soldering, ensure the cause of the problem has been isolated and repaired. Refer to Chapter 2.2, of the SCARA Series Hardware Manual, or the CCR-M Series Hardware Manual, as necessary, for soldering instructions. Card Jumper When more than one 64 Point I/O board is installed, jumper the boards as follows: I/O Board First board Second board Jumper JP1 is OFF, RS-232C port ID is 2 JP1 is ON, RS-232C port ID is 3 Modifying the HWDEF.CFG file The 64 point I/O board requires a modification to the HWDEF.CFG file. Obtain the HWDEF.CFG file for your SC3000 Controller and forward this file via email to [email protected] for modification: 1. Sankyo technical support will modify and send the HWDEF file back to you. 2. Download this file to your Controller. 3. Power off your Controller, then power on, and your 64 point I/O board is configured. or: Call Sankyo Technical Support at 561-998-9775, (North America and Puerto Rico, only). For all other countries, refer to the Preface chapter of any Sankyo manual, and call the nearest Sankyo office for assistance. Chapter 4 Digital Input/Digital Output (DI/DO) 4-37 SC3000 Robot Systems 64 Point I/O - DI Circuit Diagram DI Point Specifications • DI points are powered by an external +24V DC power supply (± 10 %). • The minimum current draw for each DI point is 10 ma. 64 Point I/O - DO Circuit Diagram DO Point Specifications 4-38 • DO points are powered by an external +24V DC power supply (± 10 %). • The maximum current draw for any one DO point is 500 ma. • Each DO point is protected with a 0.5 amp replaceable (by soldering) fuse. SC3000 Series Installation and Specifications Manual 64 Point I/O - Wiring DI/DO points Every DI/DO point on each adapter board is associated with its unique address as shown in the following CN1 through CN4 connector charts. Record this “Card n Addr” as this is the address you will use when referencing the DI/DO point in your program. Pin 1 is DI point 25, on the CN1 connector for I/O board # 1. Pin 20 is the common that services this DI point. This DI point may also be wired with the DI load in series with the P/S common side. See the DI wiring examples below. Pin 1 is DO point 41, on the CN2 connector for I/O board # 1. Pin 20 is the common that services this DO point. This DO point may also be wired with the DO load in series with the P/S common side. See the DO wiring examples below. DO points should have an arc suppression diode installed across the DO load device, as shown in the examples above. Chapter 4 Digital Input/Digital Output (DI/DO) 4-39 SC3000 Robot Systems Connector Charts 64 Point I/O - CN1 Connector (DI Only) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 4-40 Type Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Reserved Reserved Reserved Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Reserved Reserved Common pin Card 1 Addr Card 2 Addr 20 25 89 21 26 90 22 27 91 23 28 92 24 29 93 25 30 94 26 31 95 27 32 96 28 33 97 29 34 98 30 35 99 31 36 100 32 37 101 33 38 102 34 39 103 35 40 104 SC3000 Series Installation and Specifications Manual 64 Point I/O - CN2 Connector (DO Only) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Type Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output Reserved Reserved Reserved Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Reserved Reserved Common pin Card 1 Addr Card 2 Addr 20 41 105 21 42 106 22 43 107 23 44 108 24 45 109 25 46 110 26 47 111 27 48 112 28 49 113 29 50 114 30 51 115 31 52 116 32 53 117 33 54 118 34 55 119 35 56 120 Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-41 SC3000 Robot Systems 64 Point I/O - CN3 Connector (DI Only) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 4-42 Type Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Input + Reserved Reserved Reserved Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Common, Input Reserved Reserved Common pin Card 1 Addr Card 2 Addr 20 57 121 21 58 122 22 59 123 23 60 124 24 61 125 25 62 126 26 63 127 27 64 128 28 65 129 29 66 130 30 67 131 31 68 132 32 69 133 33 70 134 34 71 135 35 72 136 SC3000 Series Installation and Specifications Manual 64 Point I/O - CN4 Connector (DO Only) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Type Output + Output + Output + Output + Output + Output + Output + Output + Output + Output + Output + Output + Output + Output + Output + Output + Reserved Reserved Reserved Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Common, Output Reserved Reserved Common pin Card 1 Addr Card 2 Addr 20 73 137 21 74 138 22 75 139 23 76 140 24 77 141 25 78 142 26 79 143 27 80 144 28 81 145 29 82 146 30 83 147 31 84 148 32 85 149 33 86 150 34 87 151 35 88 152 Chapter apter 4 Digital Input/Digital Output (DI/DO) 4-43 SC3000 Robot Systems External DI/DO Cable Routing Interference between DI/DO cables and typical sources of electrical noise will more likely occur with long, parallel runs. A good rule to follow is to keep all DI/DO cables at least 0.3 m (1 ft.) away from any power line or other AC source. In addition to the electrical noise sources listed under "Electrical Noise" in Chapter 2, the following sources should be avoided when cabling DI/DO. • Fluorescent and neon lighting fixtures. • Power distribution systems, including wiring, transformers, generators, and alternators. • Signal generators, intercommunications systems, and security signal systems. • Ultrasonic cleaning equipment. • Electromagnetic equipment, such as degaussers, magnetic chucks, etc. • Control equipment (relays, contactors, etc.) for machinery and other switching devices that carry or switch relatively large amounts of currents. Some Good Rules To Follow NOTE: 4-44 • Comply with all local, state, and national safety and electrical codes. • Enclose overhead cables in a grounded trough. • Keep cable lengths as short as possible. • When several cables are coming from the same signal source, lay them along the same route. • Store excess cable in an "S" shape, not coiled up. All unused wires in multi-conductor cables must be grounded at the optical isolation board end only, when such boards are used. SC3000 Series Installation and Specifications Manual Signal Cable Selection Three general categories of wiring and cabling are suggested for designing cabling to the system Dl/DO points. The following three categories are listed in order of preference: • Shielded twisted-pair. This is an individually-shielded wire-pair instrumentation cable. It is available with either a braided shield or conductive foil-wrapped shield and drain wire. Twin axial cable may be used to get controlled high-frequency characteristics. The shielded twisted-pair types of cable substantially reduce crosstalk. • Unshielded twisted-pair. This is a general purpose cabling of stranded wire. It is available with or without a protective jacket. Cross-talk is the most serious application problem encountered with this type of cable. If this type of cable is used to carry unbalanced signals, the signals must be of similar amplitude and speed. • Coaxial cable. This is a single-conductor cable with a braided and insulated shield. This has high-frequency controlled losses and a constant characteristic impedance. It may also be used as low-frequency shielded cable in a noisy environment. The following general information should be considered when selecting cables: • Shielded twisted-pair is generally considered the best type of cable. • Shielded cable is preferred for high-speed digital signal applications and for use in industrial or noisy environments. The shield should be grounded according to the specific recommendations for the attaching device. • Stranded conductor cable is easier to install and is less susceptible to conductor breakage than single strand conductor. • The external protective jacket of the cable must withstand the environment in which it is installed. Temperature range, humidity range, and the possibility of chemical contamination must all be considered. Chapter 4 Digital Input/Digital Output (DI/DO) 4-45 SC3000 Robot Systems This page left blank intentionally 4-46 SC3000 Series Installation and Specifications Manual Chapter 5 Specifications CONTENTS Introduction ............................................................................................................................ 5-3 Sankyo SC3000 Series Robot Controller ............................................................................. 5-4 SC3000 Series Controller - Dimensions and Operating Specifications ................................................ 5-5 Environment.................................................................................................................................... 5-5 Motion Control Specifications................................................................................................................ 5-6 Optional Feature Boards ....................................................................................................... 5-7 128 Point DI/DO Option (P/N SCF302) .......................................................................................... 5-7 High Speed (HS) Processor Option (P/N SCF310)........................................................................ 5-7 Over Drive Processor (ODP) Option (P/N SCF317)....................................................................... 5-7 64 Point DI/DO Option (P/N SCF323) ............................................................................................ 5-8 Expansion RS-232C Panel (P/N SCF324) ..................................................................................... 5-8 DeviceNet Option (P/N SCF336).................................................................................................... 5-8 Sankyo SR8437/SR8447 Series Robot ................................................................................. 5-9 SR8437/SR8447 Dimensions and Operating Specifications .............................................................. 5-10 SR8437/SR8447 Robot Arm Dimensions..................................................................................... 5-11 SR8437/SR8447 Robot Arm Clearance Dimensions ................................................................... 5-12 SR8437/SR8447 Robot Workspace ............................................................................................. 5-13 SR8437/SR8447 Robot Workspace Dimensions ......................................................................... 5-14 SR8437/SR8447 Robot Performance Specifications ................................................................... 5-15 SR8437/SR8447 Robot Positioning Specifications ......................................................................5-15 Sankyo SR8438/SR8448 Series Robot ............................................................................... 5-16 SR8438/SR8448 Dimensions and Operating Specifications .............................................................. 5-17 SR8438/SR8448 Robot Arm Dimensions..................................................................................... 5-18 SR8438/SR8448 Robot Arm Clearance Dimensions ................................................................... 5-19 SR8438/SR8448 Robot Workspace ............................................................................................. 5-20 SR8438/SR8448 Robot Workspace Dimensions ......................................................................... 5-21 SR8438/SR8448 Robot Performance Specifications ................................................................... 5-22 SR8438 Positioning Specifications............................................................................................... 5-22 SR8437/SR8447 and SR8438/SR8448 Robot Tool Tip ..................................................................... 5-23 SR8437/SR8447 Series Robot Tool Tip Dimensions................................................................... 5-23 SR8438/SR8448 Series Robot Tool Tip Dimensions................................................................... 5-23 SR8437/SR8447 Series Robot Tool Tip Flange...........................................................................5-24 SR8438/SR8448 Series Robot Tool Tip Flange...........................................................................5-25 Sankyo CCR Model 1X Series Robot.................................................................................. 5-26 CCR-M1X Dimensions and Operating Specifications......................................................................... 5-27 CCR-M1X Series - X Axis Base mounting plates......................................................................... 5-28 CCR-M1X Series – X to Y Axis mounting bracket........................................................................ 5-29 CCR-M10 Lite Dimensions ........................................................................................................... 5-30 CCR-M10 Dimensions / Standard X Axis ..................................................................................... 5-31 CCR-M10 Dimensions / Long X Axis............................................................................................ 5-32 CCR-M12 Dimensions / Standard X Axis ..................................................................................... 5-33 CCR-M12 Dimensions / Long X Axis............................................................................................ 5-34 CCR-M14 Dimensions / Standard X Axis ..................................................................................... 5-35 Copyright © Sankyo Robotics, 1994-2001 Chapter 5 Specifications 5-1 SC3000 Robot Systems CCR-M14 Dimensions / Long X Motor ......................................................................................... 5-36 CCR-M14 Series Robot Tool Tip Dimensions (Servo Z).............................................................. 5-37 CCR-M1X Robot Workspace........................................................................................................5-38 CCR-M1X Robot Performance Specifications..............................................................................5-39 CCR-M10 Lite Robot Performance Specifications ....................................................................... 5-40 CCR-M1X Positioning Specifications ........................................................................................... 5-40 Sankyo CCR Model 3X Series Robot.................................................................................. 5-41 CCR-M3X Dimensions and Operating Specifications......................................................................... 5-42 CCR-M3X Dimensions / Standard X Axis..................................................................................... 5-43 CCR-M3X Workspace .................................................................................................................. 5-44 CCR-M3X Performance Specifications ........................................................................................ 5-45 CCR-M3X Positioning Specifications ........................................................................................... 5-45 5-2 SC3000 Series Installation and Specifications Manual Introduction This chapter provides the specifications of the major components of the Sankyo Robot Systems, specifically the Sankyo SC3000 Series Robot Controller, the Sankyo SCARA Series Robots, and the CCR-M Series Robots. The information contained in this chapter includes: NOTE: • Component descriptions. • Component dimensions. • Component operating specifications. • Robot workspace dimensions. • Robot performance specifications. • Robot tool tip and tool tip flange dimensions. All descriptions, specifications and dimensions subject to modification without notice. Chapter 5 Specifications 5-3 SC3000 Robot Systems Sankyo SC3000 Series Robot Controller The SC3000 Series Robot Controller is used as the processor module for the Sankyo SCARA Series, and the CCR Model 10 and 30 Series Robot Systems. The Controller is based on the high performance Motorola 68EC020 microprocessor and operates at 24MHz. Three basic Models of the SC3000 Robot Controller are available: • SC3000-001 • SC3000-010 / 100 • SC3000-030 / 300 All Controller models function in a similar manner and are of the same physical size. Minor differences exist between the Controller models. For information on these differences, refer to Chapter 1 of the “SC3000 Robot System User’s Guide”. The SC3000 Series Robot Controller is configured with the following: • 1024K Main memory • 512K/1024K Flash memory • Application Development System (ADS) communications port (9600 baud) • 16 DI points • 8 DO points • “Error on” DO point • Safety circuit extension for I/O 1 and I/O 2 Connectors • RS232 Asynchronous Communications port (up to 19200 baud*) • Auxiliary port for Arcnet and Stepper motor features • Pendant port (2.5 megabits per second) Arcnet Sankyo field bus *The SC3000-030 Controller supports 19200 baud, all other models support 9600. The Controller is optionally designed for installation inside a standard 19-inch rack. It requires a minimum of 4 U of rack height (U = 1.75 inches, the basic unit of rack measure). The standard 19-inch rack must comply with Electronic Industries Association (EIA) RS-310B (ANSI C83.9-1972) dimensional specifications and use the universal mounting rail hole pattern. For ease of servicing, optional rack mounting slides are also available. 5-4 SC3000 Series Installation and Specifications Manual SC3000 Series Controller - Dimensions and Operating Specifications SC3000 Series Controller / Four Axis Model Height Width Depth Weight Electrical consumption Temperature/humidity Heat output 125 mm (5.0 in.) + 15 mm (0.6 in.) for foot pads 430 mm (17.0 in.) 475 mm (18.75 in.) + 205 mm (8.0 in.) for cable relief 12.0 kg (26.4 lb.) 200 - 230V AC nominal, single phase 50 - 60 Hz ±3 Hz 6.0 Amperes maximum at 220 VAC 1.20 KVA maximum 0 ∼ 40°C/30 ∼ 90 % (non-condensing) 600 Watts (2065 BTU/hr.) SC3000 Series Controller / Six Axis Model Height Width Depth Weight Electrical consumption Temperature/humidity Heat output 125 mm (5.0 in.) + 15 mm (0.6 in.) for foot pads 430 mm (17.0 in.) 475 mm (18.75 in.) + 205 mm (8.0 in.) for cable relief 12.0 kg (26.4 lb.) 200 - 230V AC nominal, single phase 50 - 60 Hz ±3 Hz 7.5 Amperes maximum at 220 VAC 1.50 KVA maximum 0 ∼ 40°C/30 ∼ 90 % (non-condensing) 720 Watts (2065 BTU/hr.) Pendant Height Width Depth Weight Electrical consumption Touch key force Operating temperature/humidity Heat output 166 mm (6.54 in.) 245 mm (9.65 in.) 55 mm (2.17 in.) 1.0 kg (2.2 lb.) without E-Stop cable 3.5 ∼ 5.25 V DC (Controller supplied) 300 grams 0 ∼ 40°C/30 ∼ 90 % (non-condensing) Low - not specified Environment Environmental specifications are presented in Chapter 2, “Site Installation Requirements", topic "Environment", of this manual. Chapter 5 Specifications 5-5 SC3000 Robot Systems Motion Control Specifications The following specifications reflect the Motion Control System software relative to the Sankyo SC3000 series Robot Controller hardware: Timing Specifications Real-time I/O Base Real-time period Real-time tasks (I/O TASKS) Servo Controls: Inverse Kinematics transform period Fine Interpolation period Analog servo command period SC3000-010 SC3000-030 12.8 ms 13 ms 10 ms 13 ms 12.8 ms 3.8 ms 1.5 ms 10 ms 0.625 ms 0.625 ms Kinematics Specifications Point to Point Three dimensional straight lines Three dimensional arcs and circles Appending of multiple moves (up to eight maximum) Asynchronous or synchronous joint accelerations Programmable speed control Programmable acceleration control Rate of acceleration change control Motion stop on I/O change of state Guarded workspace areas 1-6 axes of motion (axes 5 and 6 option, 2nd robot) 4 axes SCARA 4 axes CCR expandable to 5th and 6th axis (options) Move Types Move Planning Controls Kinematics Types Supported Acceleration Specifications Robot /payload Axis Axis Axis Axis Theta 1 rad/sec² Theta 2 rad/sec² Z mm/sec² Roll rad/sec² 8437/8447 - 1kg 13 21 6500 95 8438/8448 - 1kg 33 X mm/sec² 40 Y mm/sec² 7500 Z mm/sec² 120 Roll rad/sec² 2500 40 CCR-M10 500X400/0kg CCR-M14 500X400/0kg 8000 5600 8000 5600 NOTES: All rotational axes are specified as rad/sec² (radians per second ²) All linear axes are specified as mm/sec² (millimeters per second ²) 5-6 SC3000 Series Installation and Specifications Manual Option Boards The following list of Sankyo board options are supported when installed or attached to the appropriate Sankyo SC3000 Series Robot Controller. Feature P/N Description P/N SCF302 P/N SCF310 P/N SCF317 P/N SCF323 P/N SCF324 P/N SCF336 128 point I/O option, 3 options maximum HS (High Speed) option SC3000-010 only Over Drive Processor (ODP) option 64 point I/O option, 2 options maximum Expansion RS-232C Panel, SC3000 DeviceNet option, 3 options maximum 128 Point DI/DO Option (P/N SCF302) The 128 Point DI/DO Adapter provides the user I/O interface that can be controlled and sensed from the user application code. Refer to Chapter 4 for the technical specifications of interfacing to the 128 Point DI/DO circuits. • Board type Sankyo AD1309 • Total I/O points 128, optically isolated • DI 64 points • DO 64 points • I/O addresses Fixed, not selectable • I/O accessible D-shell, 37 pin X 4 • Additional RS-232C Comm port Communication port address = 4, 5 or 6 High Speed (HS) Processor Option (P/N SCF310) High Speed Processor option, for the SC3000-010 / 100 models only. • Board Type Sankyo AD1313 • Processor type RISC - Hitachi SH7032 • Additional RS-232C Comm port Communication port address = 7 Over Drive Processor (ODP) Option (P/N SCF317) High Speed OverDrive Processor option, for the SC3000-030 / 300models only. • Board Type Sankyo AD1322 • Processor type Motorola MC68040RC33 / 32.5MHz Chapter 5 Specifications 5-7 SC3000 Robot Systems 64 Point DI/DO Option (P/N SCF323) The 64 Point DI/DO Adapter provides the user I/O interface that can be controlled and sensed from the user application code. Refer to Chapter 4 for the technical specifications of interfacing to the 64 Point DI/DO circuits. • Board type Sankyo AD1319 • Total I/O points 64, optically isolated • DI 32 points • DO 32 points • I/O addresses Fixed, not selectable • I/O accessible D-shell 37 pin X 4 • Additional RS-232C Comm port Communication port address = 2 or 3 Expansion RS-232C Panel (P/N SCF324) The Expansion RS-232C panel allows the Communications port for any DI/DO option to be used with a 9-Pin D-shell, Null modem cable. • Comm port accessible D-shell 9 pin X 1 DeviceNet Option (P/N SCF336) The Sankyo DeviceNet option complies and is listed with the Open DEVICENET Vendor Association (ODVA) standards. A Communications port for any DI/DO option to be used with a 9-Pin D-shell, Null modem cable. 5-8 • Board type Sankyo AD1325 • Total I/O points 64, optically isolated • DI 32 points • DO 32 points • I/O addresses Fixed, not selectable • I/O accessible Phoenix connector, 5 pin X 1 (Via PLC) • Additional RS-232C Comm port Communication port address = 8, 9 or 10 SC3000 Series Installation and Specifications Manual Sankyo SR8437/SR8447 Series Robot The Sankyo SR8437/SR8447 Series Robot is an updated and improved version of the previous Sankyo SCARA Robot models. The enhancements are: • Enhanced Z-shaft • Incorporated end-of-arm (EOA) interface • ”Brush-less” servo motors • Absolute encoders (Robot need not be homed after power on) • An SR8437C/SR8447C, a Class 10 Clean room model • An SR8437C-550Z, a Class 10 Clean room model with a 550mm Z axis • An SR8437DP, a Dust Proof model • An SR8437WP, A Water Proof model The key features are: • 4 servo axes: Theta 1, Theta 2, Z and Roll • Coordinated natural arc, linear, and circular motions, with 3D support • Power-on teaching via the hand-held Pendant (in TEACH mode) • Manual power-off teaching (in TEACH mode) • Z axis brake with manual release • Removable tool tip flange for mounting end-of-arm tooling • 15-wire Z Axis cable, for End-Of-Arm attachments (factory wired) The Robot interfaces directly to the SC3000 Series Robot Controller through a standard cable set. Cable options are 3 meter, 5-meter or 10-meter cable set. The standard Robot cables are: • Motor cable • Encoder cable Chapter 5 Specifications 5-9 SC3000 Robot Systems SR8437/SR8447 Dimensions and Operating Specifications SR8437 / SR8447 Series Robot Height 925 mm (36.45 in.) Width 230 mm (9.1 in.) Depth 870 mm (34.26 in.) Weight 90 kg (198 lb.) Compressed air for gripper Not to exceed 6 kgf /cm² One fitting with 6 mm (OD) tubing Two fittings with 4 mm OD tubing (Six 4mm fittings for the SR8437C model only) See NOTE Electrical specifications Motors: Theta 1 Theta 2 Z Roll Harmonic Drives: Theta 1 Theta 2 Roll NOTE: 5-10 All power originates from the SC3000 Series Controller SR8447 366 Watt 267 Watt 200 Watt 100 Watt SR8437 366 Watt 267 Watt. 118 Watt 70 Watt Reduction Ratios 120 : 1 51 : 1 50 : 1 Encoders 5.0 VDC, class 2 Photo sensors 24.0 VDC, class 2 Z axis brake 24.0 VDC Operating temperature/humidity 5° C - 40° C (40° F - 104° F) 30% - 90% non condensing The air lines are factory installed in the Robot arm, routed from the base of the Robot through to the Z Axis. SC3000 Series Installation and Specifications Manual SR8437/SR8447 Robot Arm Dimensions 136° 110 180 136° 117° 70 400 400 550 25 925 850 I.D. 18 250 O.D. 25 375 4-M16 50 30 180 55 30 hole NOTES: The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. All straight line dimensions are in mm. The base mounting bolts, M-16 (Qty 4), are shipped for mounting the base of the Robot to a table or stand. The SR8437C/SR8447C model has a Z axis length of 240 mm. The end-of-arm camera mounting surface is 40mm from the center of the Z axis. Chapter 5 Specifications 5-11 SC3000 Robot Systems SR8437/SR8447 Robot Arm Clearance Dimensions 5-12 SC3000 Series Installation and Specifications Manual SR8437/SR8447 Robot Workspace The workspace of the SR8437/SR8447 Series Robot is the three dimensional area through which the robot's tool tip can travel. Positions within an robot's workspace are located in an X-Y-Z coordinate system. The origin of the horizontal plane (X = 0 and Y = 0) is defined as the axis of rotation of the Theta 1 joint. Z positions are located relative to the upper-most position of the robot tool tip (Z = 0). Thus, all Z positions within the workspace are positive. Roll motion is the rotational motion of the robot's tool tip about its own axis, with positive motion being clockwise, and negative motion being counter-clockwise. The X and Y motion is specified in millimeters or degrees, the Z axis motion is given in millimeters, and the Roll axis motion is given in degrees. The home position is a special reference point. It is the location at which the Robot initializes its servo motors for proper orientation, one time only. This is due to the fact that all robot encoders are battery-backed and the “homing” requirement is no longer necessary, each time the Robot is powered off, then on. Thus, home is the fixed reference point for program-controlled movements. A readjustment of the home position is only required after certain types of maintenance. The workspace of the Robot is pictured on the next page, with the key dimensions outlined below: (Right Home is the default) Reference Dimension * a b c d e f 300 500 800 400 400 250 (240 for SR8437C) HOME ** Right = 236.155, 184.505, 0, 0 Left = -236.155, -184.505, 0 0 • *All dimensions are ±1.0 mm (0.04 in.). • *Home position includes X, Y, Z, and Roll. The home position given above does not take each Robot's unique offset into consideration. True home position could vary by up to 5 mm. Chapter 5 Specifications 5-13 SC3000 Robot Systems SR8437/SR8447 Robot Workspace Dimensions b 5-14 SC3000 Series Installation and Specifications Manual SR8437/SR8447 Robot Performance Specifications SR8437/SR8447 Series Robot Performance Specifications Maximum payload 10 kg (22 lb.) with reduced acceleration 1 kg (2.2 lb.) with full acceleration Theta 1 axis: range speed of rotation ±117 ° 5200 mm/sec range speed of rotation ±136 ° 5200 mm/sec range speed rotating torque inertial load of rotation ±360 ° 510 °/second 6 Nm 0.03 kg-m² maximum Theta 2 axis: Roll axis: NOTE: Off-center loads may cause unexpected Roll-axis rotation during acceleration or deceleration movements in the X-Y plane. Z axis: range 0 to 250 mm / SR8437/SR8447 (0 to 240 mm / SR8437C/SR8447C) (0 to 550 mm / SR8437C-550Z) SR8437 Series speed SR8447 Series speed force 610 mm / sec 1140 mm / sec 16 kgf (35.2 lb.) maximum Axis resolution Motor torque Theta 1 Theta 2 Z Roll 0.00146 ° / pulse 0.00246 ° / pulse 0.00421 mm / pulse 0.00352 ° / pulse Theta 1 366 watt - 0.870 Nm / 7.70 in lb Theta 2 267 watt - 0.640 Nm / 5.66 in lb 8447 Z 200 watt - 0.640 Nm / 5.66 in lb 8437 Z 118 watt - 0.280 Nm / 2.48 in lb 8447 R 100 watt – 0.320 Nm / 2.83 in lb 8437 R 70 watt - 0.170 Nm / 1.51 in lb SR8437/SR8447 Robot Positioning Specifications The following positioning specifications assume a constant payload and an environment of 23.9 ± 2.8 °C (75 ± 2.8 °F). Repeatability XY plane Z Roll rotation ±0.03 mm (±0.0015 in.) ±0.02 mm (±0.001 in.) ±0.02 ° Chapter 5 Specifications 5-15 SC3000 Robot Systems Sankyo SR8438/SR8448 Series Robot The Sankyo SR8438/SR8448 Series Robot is an updated and improved version of the previous Sankyo SCARA Robot models. The enhancements are: • Absolute encoders (Robot need not be homed after power on) • ”Brush-less” servo motors • Enhanced Z-shaft • Incorporated end-of-arm (EOA) interface • An SR8438C/SR8448C, a Class 10 Clean room model • An SR8438DP, a Dust Proof model The key features are: • 4 servo axes: Theta 1, Theta 2, Z, and Roll • Coordinated natural arc, linear, and circular motions • Power-on teaching via the hand-held Pendant (in TEACH mode) • Manual power-off teaching (in TEACH mode) • Z axis brake and manual release • Removable tool tip flange for mounting end-of-arm devices • 15-wire Z Axis cable, for End-Of-Arm attachments (factory wired) The Robot interfaces directly to the SC3000 Series Robot Controller through a standard cable set. Cable options are 3 meter, 5-meter or 10-meter cable set. The standard Robot cables are: 5-16 • Motor cable • Encoder cable SC3000 Series Installation and Specifications Manual SR8438/SR8448 Dimensions and Operating Specifications SR8438/SR8448 Series Robot Height 705 mm (27.76 in.) Width 230 mm (9.1 in.) Depth 710 mm (29.30 in.) Weight 70 kg (154 lb.) Compressed air for gripper See NOTE Not to exceed 6 kgf /cm² One fitting for 6 mm (OD) tubing Two fittings for 4 mm OD tubing Electrical specifications All power originates from the SC3000 Series Controller Motors: Theta 1 Theta 2 Z Roll Harmonic Drives: Theta 1 Theta 2 Roll NOTE: SR8448 366 Watt 267 Watt 200 Watt 100 Watt SR8438 366 Watt 267 Watt. 118 Watt 70 Watt Reduction Ratios 60 : 1 51 : 1 50 : 1 Encoders 5.0 VDC, class 2 Photo sensors 24.0 VDC, class 2 Z axis brake 24.0 VDC Operating temperature/humidity 5° C - 40° C (40° F - 104° F) 30% - 90% non condensing The air lines are factory installed in the Robot arm, routed from the base of the Robot through to the Z Axis. Chapter 5 Specifications 5-17 SC3000 Robot Systems SR8438/SR8448 Robot Arm Dimensions NOTES: The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. All straight-line dimensions are in mm. The base mounting bolts, M-16 (Qty 4), are shipped for mounting the base of the Robot to a table or stand. The end-of-arm camera mounting surface is 30mm from the center of the Z axis. The SR8438 Dust Proof Robot model has a reduced Theta 1 workspace of +60 degrees and – 90 degrees. 5-18 SC3000 Series Installation and Specifications Manual SR8438/SR8448 Robot Arm Clearance Dimensions The SR8438 Dust Proof Robot model has a reduced Theta 1 workspace of +60 degrees and – 90 degrees. Chapter 5 Specifications 5-19 SC3000 Robot Systems SR8438/SR8448 Robot Workspace The workspace of the SR8438/SR8448 Series Robot is the three dimensional area through which the robot's tool tip can travel. Positions within a robot's workspace are located in an X-Y-Z coordinate system. The origin of the horizontal plane (X = 0 and Y = 0) is defined as the axis of rotation of the Theta 1 joint. Z positions are located relative to the upper-most position of the Robot tool tip (Z = 0). Thus, all Z positions within the workspace are positive. Roll motion is the rotational motion of the robot's tool tip about its own axis, with positive motion being clockwise, and negative motion being counter-clockwise. The X and Y motion is specified in millimeters or degrees, the Z axis motion is given in millimeters, and the Roll axis motion is given in degrees. The home position is a special reference point. It is the location at which the Robot initializes its servo motors for proper orientation one time only. This is due to the fact that all robot encoders are battery-backed and the “homing” requirement found on other Robot models is no longer necessary, each time the Robot is powered off, then on. Thus, home is still the fixed reference point for program-controlled movements. A readjustment of the home position is only required after certain types of maintenance. The workspace of the Robot is pictured on the next page, with the key dimensions outlined below: (Right Home is the default) Reference Dimension * a b c d e f 216 334 550 300 250 150 HOME ** Right = 123.223, 176.777, 0, 0 Left = -123.223, -176.777, 0, 0 5-20 • All dimensions are ±1.0 mm (0.04 in.). • Home position includes X, Y, Z, and Roll. The home position given above does not take each Robot's unique offset into consideration. True home position could vary by up to 5 mm. SC3000 Series Installation and Specifications Manual SR8438/SR8448 Robot Workspace Dimensions NOTE: The SR8438 Dust Proof Robot model has a reduced Theta 1 workspace of +60 degrees and – 90 degrees. Chapter 5 Specifications 5-21 SC3000 Robot Systems SR8438/SR8448 Robot Performance Specifications SR8438/SR8448 Series Robot Performance Specifications Maximum payload 5 kg (11 lb.) with reduced acceleration 1 kg (2.2 lb.) with full acceleration Theta 1 axis: range speed of rotation ± 90 ° 5100 mm / second range speed of rotation ± 135 ° 5100 mm / second range speed rotating torque inertial load of rotation ± 220 ° 770 degrees / second 4 Nm 0.03 kg-m² maximum Theta 2 axis: Roll axis: NOTE: Off-center loads may cause unexpected Roll-axis rotation during acceleration or deceleration movements in the X-Y plane. Z axis: range SR8438 Series speed SR8448 Series speed force Axis resolution Motor torque 0 to 150 mm (0 to 5.90 in.) 830 mm/second 1060 mm/second 10 kgf (22.0 lb.) maximum Theta 1 Theta 2 Z Roll 0.00244° / pulse 0.00294° / pulse 0.00547 mm / pulse 0.00509° / pulse Theta 1 366 watt - 0.870 Nm / 7.70 in lb Theta 2 267 watt - 0.640 Nm / 5.66 in lb 8447 Z 200 watt - 0.640 Nm / 5.66 in lb 8437 Z 118 watt - 0.280 Nm / 2.48 in lb 8447 R 100 watt – 0.320 Nm / 2.83 in lb 8437 R 70 watt - 0.170 Nm / 1.51 in lb SR8438 Positioning Specifications The following positioning specifications assume a constant payload and an environment of 23.9 ± 2.8 °C (75 ± 2.8 °F). Repeatability 5-22 XY plane Z Roll rotation ±0.03 mm (±0.0015 in.) ±0.02 mm (±0.001 in.) ±0.02 ° SC3000 Series Installation and Specifications Manual SR8437/SR8447 and SR8438/SR8448 Robot Tool Tip The Robot Tool Tip, at the end of the Z axis, is used for attaching a hand like device. The sizes for the SR8437/SR8447 and SR8438/SR8448 Series Robots are different. The dimensions are highlighted below. SR8437/SR8447 Series Robot Tool Tip Dimensions SR8438/SR8448 Series Robot Tool Tip Dimensions Chapter 5 Specifications 5-23 SC3000 Robot Systems SR8437/SR8447 Series Robot Tool Tip Flange The Robot Tool Tip Flange, provided with the SR8437/SR8447 Series Robot as an option, mounts to the Robot Tool Tip interface and provides a more functional mounting surface for end-of-arm devices. The dimensions are highlighted below. NOTE: The weight of the tool tip flange, Sankyo part number M03D09A, is 0.50 Kg (1.10 lbs). Consider this factor when computing your payload needs. 5-24 SC3000 Series Installation and Specifications Manual SR8438/SR8448 Series Robot Tool Tip Flange The Robot Tool Tip Flange, provided with the SR8438/SR8448 Series Robot as an option, mounts to the Robot Tool Tip interface and provides a more functional mounting surface for end-of-arm devices. The dimensions are highlighted below: NOTE: The weight of the tool tip flange, Sankyo part number M05D21A, is 0.40 Kg (0.88 lbs). Consider this factor when computing your payload needs. Chapter 5 Specifications 5-25 SC3000 Robot Systems Sankyo CCR Model 1X Series Robot The Sankyo CCR Model 10 is a cartesian Robot addition to the Sankyo Robot family. The features are: • Linear X and Y axes • Y axis features a horizontal “slider”, that travels the length of the Y axis • Payload can attach to the Y axis “slider“ (payload depends on Y axis length) • ”Brush-less” servo motors • Absolute encoders (Robot need not be homed after power on) • Coordinated linear and circular motions • Power-on teaching via the hand-held Pendant (in TEACH mode) • Manual power-off teaching (in TEACH mode) The Robot interfaces directly to the SC3000 Series Robot Controller through a standard cable set. Cable options are 3 meter, 5-meter or 10-meter cable set. The standard Robot cables are: 5-26 • Motor cable • Encoder cable SC3000 Series Installation and Specifications Manual CCR-M1X Dimensions and Operating Specifications CCR-M1X Series Robot Height 226 mm (8.9 in.) without flexible cable harness 685.8 mm (27.0 in.) with flexible cable harness Width 559 mm (22.0 in.) + X axis length Depth 440 mm (17.33 in.) + Y axis length Weight 41.5 kg (91.3 lb.) with 200 mm X and 200 mm Y axis Add 1.5 kg (3.3 lb.) for each 100 mm addition to any axis Compressed air for gripper Not to exceed 6 kgf /cm² Electrical specifications Motors: All power originates from the SC3000 Series Controller X (200-800mm) X (1000-2000mm) Y (200-800mm) 267 Watt Motor 366 Watt Motor 267 Watt Motor Y (Lite) Z (M12) 118 Watt Motor 118 Watt Motor Z (M14) R (M14) 50 Watt Motor 50 Watt Motor Encoders Operating temperature/humidity 5.0 VDC, class 2 5° C - 40° C (40° F - 104° F) 30% - 90% non condensing Chapter 5 Specifications 5-27 SC3000 Robot Systems CCR-M1X Series - X Axis Base mounting plates 5-28 SC3000 Series Installation and Specifications Manual CCR-M1X Series – X to Y Axis mounting bracket NOTE: One mounting bracket required for mounting the Y axis to the X axis. Chapter 5 Specifications 5-29 SC3000 Robot Systems CCR-M10 Lite Dimensions The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. 5-30 SC3000 Series Installation and Specifications Manual CCR-M10 Dimensions / Standard X Axis NOTE: The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. Chapter 5 Specifications 5-31 SC3000 Robot Systems CCR-M10 Dimensions / Long X Axis NOTE: 5-32 The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. SC3000 Series Installation and Specifications Manual CCR-M12 Dimensions / Standard X Axis NOTE: The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. Chapter 5 Specifications 5-33 SC3000 Robot Systems CCR-M12 Dimensions / Long X Axis NOTE: 5-34 The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. SC3000 Series Installation and Specifications Manual CCR-M14 Dimensions / Standard X Axis NOTE: The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. Chapter 5 Specifications 5-35 SC3000 Robot Systems CCR-M14 Dimensions / Long X Motor NOTE: 5-36 The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. SC3000 Series Installation and Specifications Manual CCR-M14 Series Robot Tool Tip Dimensions (Servo Z) The Robot Tool Tip, at the end of the Z axis, is used for installing a hand like device. The dimensions are highlighted below. Chapter 5 Specifications 5-37 SC3000 Robot Systems CCR-M1X Robot Workspace The workspace of the CCR-M 1x Series Robot is a two or three dimensional area through which the robot's tool tip can travel. Some CCR-M1x Series Robots have a Z axis, defined as the vertical plane, which makes an X, Y and Z workspace. Positions within a robot's workspace are located in an X-Y coordinate system. The origin of the horizontal plane (X = 0 and Y = 0) is defined as the linear reach of the X axis and Y positions are located at a right angle to the X axis. For programming purposes, all X, Y and Z coordinate locations are (+) values only, and must be given in millimeters. Any optional Roll axis (rotation about the Z axis), coordinates are specified in degrees. The home position is a special reference point. It is the location at which the Robot initializes its servo motors for proper orientation one time only. This is due to the fact that all robot encoders are battery-backed and the “homing” requirement found on other Robot models is no longer necessary, each time the Robot is powered off and on. Thus, home is the fixed reference point for program-controlled movements. (A readjustment of the home position is only required after certain types of maintenance.) The two dimensional workspace of the CCR-M1x Series Robot is pictured below: Default Home Position for X and Y, (0, 0), is shown in the drawing below: NOTE: 5-38 If a Z axis (vertical plane), is attached to the CCR-M1x Series Robot, the workspace becomes a three dimensional rectangle, according to the axis lengths of the X, Y and Z axes. An optional Roll axis provides rotation around the Z axis. SC3000 Series Installation and Specifications Manual CCR-M1X Robot Performance Specifications CCR-M1X Series Robot M10 - X axis: length 200 - 500 mm length = 600 mm length = 700 mm length = 800 mm length = 1000 mm length = 1250 mm length = 1500 mm length = 2000 mm M10 - Y axis: length = 200 mm length = 300 mm length = 400 mm length = 500 mm length = 600 mm length = 700 mm length = 800 mm speed 1400 mm/sec 1400 mm/sec 1400 mm/sec 1400 mm/sec 1100 mm/sec 900 mm/sec 700 mm/sec M12 - Y axis: length = 200 mm length = 300 mm length = 400 mm length = 500 mm speed 1400 mm/sec 1400 mm/sec 1400 mm/sec 1400 mm/sec speed 1400 mm/sec 1100 mm/sec 900 mm/sec 700 mm/sec 1000 mm/sec 1000 mm/sec 400 mm/sec 200 mm/sec payload payload X = 200-800mm X = 1000-2000mm 25 Kg 30 Kg 18 Kg 25 Kg 14 Kg 21 Kg 10 Kg 17 Kg 6 Kg 14 Kg 2 Kg 12 Kg -10 Kg payload payload payload Z = 100mm Z = 200mm Z =300mm 10.0 Kg 10.0 Kg 10.0 Kg 10.0 Kg 10.0 Kg 9.0 Kg 6.5 Kg 6.0 Kg 5.0 Kg 2.5 Kg 2.0 Kg 1.5 Kg M12 - Z axis: speed range M14 - Y axis: length = 200 mm length = 300 mm length = 400 mm length = 500 mm speed 610 mm/sec 610 mm/sec 610 mm/sec 610 mm/sec 450 mm / second 100/200/300 mm (0 to 11.81 in.) payload payload Z = 150mm Z = 250mm 17 Kg 16 Kg 10 Kg 9 Kg 5 Kg 4 Kg 2 Kg 1 Kg M14 - Roll axis: speed 510 degrees/sec range ±360 degrees rotating torque 4Nm Axis resolution Motor torque : 0.1 mm/pulse All Long X 366 watt – 0.870 Nm / 7.70 in lb Standard - X and Y 267 watt - 0.640 Nm / 5.66 in lb M12 - Z 118 watt - 0.280 Nm / 2.48 in lb M14 - Z 50 watt - 0.159 Nm / 1.51 in lb M14 – R 50 watt - 0.159 Nm / 1.41 in lb Chapter 5 Specifications 5-39 SC3000 Robot Systems CCR-M10 Lite Robot Performance Specifications CCR-M10 Lite Series Robot M10 Lite - X axis: length = 300 mm length = 500 mm speed 1400 mm/sec 1400 mm/sec M10 Lite - Y axis: length = 300 mm length = 500 mm speed 450 mm/sec 450 mm/sec payload 3 Kg 3 Kg Axis resolution 0.1 mm/pulse Motor torque : All - X 267 watt - 0.640 Nm / 5.66 in lb All - Y 118 watt - 0.280 Nm / 2.48 in lb CCR-M1X Positioning Specifications The following positioning specifications assume a constant payload and an environment of 23.9 ± 2.8 °C (75 ± 2.8 °F). Repeatability 5-40 XY plane Z Roll rotation ±0.03 mm (±0.0015 in.) ±0.02 mm (±0.001 in.) ±0.02 ° SC3000 Series Installation and Specifications Manual Sankyo CCR Model 3X Series Robot The Sankyo CCR Model 30 is a new cartesian Robot addition to the Sankyo Robot family. The features are: • Linear X and Y axes • Y axis features a horizontal "slider” • Z axis standard • Payload depends on Y axis length • ”Brush-less” servo motors • Absolute encoders (Robot need not be homed after power on) • Coordinated linear and circular motions • Power-on teaching via the hand-held Pendant (in TEACH mode) • Manual power-off teaching (in TEACH mode) • Optional Roll axis The Robot interfaces directly to the SC3000 Series Robot Controller through a standard cable set. Cable options are 3 meter, 5-meter or 10-meter cable set. The standard Robot cables are: • Motor cable • Encoder cable Chapter 5 Specifications 5-41 SC3000 Robot Systems CCR-M3X Dimensions and Operating Specifications CCR-M3X Series Robot Height 457.2 mm (18.0 in.) add Z axis height Width 559 mm (22.0 in.) + X axis length Depth 440.0m (17.33 in.) + Y axis length over 200mm Weight 53.0 kg (116.6 lb.) with 300mm X, 300mm Z, and 300mm Y axis Add 1.5 kg (3.3 lb.) for each 100 mm addition to any axis Compressed air for gripper Not to exceed 6 kgf /cm² Electrical specifications All power originates from the SC3000 Series Controller Motors: 5-42 X Z Y 267 Watt Motor 267 Watt Motor 118 Watt Motor Encoders 5.0 VDC, class 2 Operating temperature/humidity 5° C - 40° C (40° F - 104° F) 30% - 90% non condensing SC3000 Series Installation and Specifications Manual CCR-M3X Dimensions / Standard X Axis NOTE: The Sankyo SC3000 ship CD contains CAD drawings for all Robot models. Chapter 5 Specifications 5-43 SC3000 Robot Systems CCR-M3X Workspace The workspace of the CCR Model 3x Series Robot is the three dimensional area through which the robot's tool tip can travel. Positions within a robot's workspace are located in an X-Z coordinate system. The origin of the horizontal plane (X = 0) and the vertical plane (Z = 0) is defined as the linear reach of the X joint. Y positions are located at a right angle to the X joint. Z positions are located relative to the upper-most position of the robot tool tip (Z = 0). Therefore, all Z positions within the workspace are positive. For programming purposes, all X, Z, and Y coordinate locations are (+) values only, and must be given in millimeters. The home position is a special reference point. It is the location at which the Robot initializes its servo motors for proper orientation one time only. This is due to the fact that all robot encoders are battery-backed and the “homing” requirement found on other Robot models is no longer necessary, each time the Robot is powered off and on. Therefore, home is the fixed reference point for program-controlled movements. A readjustment of the home position is only required after certain types of maintenance. Default Home Position (0, 0): NOTE: Home positions include X and Z. The Y axis is optional. As the Z axis is attached to the X axis of the CCR-M30 Series Robot as the second axis, the workspace becomes a three dimensional rectangle (cube), according to the axis lengths of the X, Z and optional Y axes. 5-44 SC3000 Series Installation and Specifications Manual CCR-M3X Performance Specifications CCR-M3X Series Robot M3x - X axis: length 200 - 500 mm length = 600 mm length = 700 mm length = 800 mm speed 1400 mm/sec 1100 mm/sec 900 mm/sec 700 mm/sec M3x - Z axis: length = 300 mm length = 400 mm length = 500 mm speed 1100 mm/sec 1100 mm/sec 1100 mm/sec payload 18 Kg 14 Kg 10 Kg M3x - Y axis: length = 300 mm length = 500 mm speed 450 mm/sec 450 mm/sec payload 5 Kg 4 Kg Axis resolution 0.1 mm/pulse Motor torque : All - X 267 watt - 0.640 Nm / 5.66 in lb All - Z 267 watt - 0.640 Nm / 5.66 in lb All - Y 118 watt - 0.280 Nm / 2.48 in lb CCR-M3X Positioning Specifications The following positioning specifications assume a constant payload and an environment of 23.9 ± 2.8 °C (75 ± 2.8 °F). Repeatability XZ plane Y ±0.03 mm (±0.0015 in.) ±0.02 mm (±0.001 in.) Chapter 5 Specifications 5-45 SC3000 Robot Systems This page left blank intentionally 5-46 SC3000 Series Installation and Specifications Manual Glossary ADS is the abbreviation for Application Development System, a software package to assist in developing robot applications for the SC3000 family of robot systems. It also contains built in maintenance functions. Accuracy is a measure of a Robot's ability to move to a commanded position that has been theoretically computed. Accuracy is the difference between the commanded position and the actual achieved position. Errors from commanded positions that were obtained by teaching points is measured by the term "Repeatability". Actuator is a motor or transducer which converts electrical, hydraulic or pneumatic energy to effect motion of the Robot. Analog is an expression of a value that changes continuously, such as analog voltage. Anthropomorphic Robot is a Robot that has all the rotary joints and motions that imitate movements similar to a human arm. Axis (Linear type) is a reference to a linear direction of movement for an Axis. Typically, Linear Robots have a rectangular work envelope. Axis (SCARA type) is a reference to an Axis for a Selective Compliance Assembly Robot Arm , or simply, SCARA Robot. Typically, SCARA Robots are mounted to a pedestal base, and have a circular (arc) type of work envelope. Byte is a reference to a single character in a computer. Cartesian is a reference to a rectangular workspace, or profile. Also, Robots with two or more linear axes mounted perpendicular to each other are referred to as Cartesian Coordinate Robots. Compensation refers to an operation used to counteract (compensate) for dynamic lags in any Robot Axis movement. This allows for prompt, stable responses. Compliance is the quality or state of bending as it relates to mechanical stress. Sometimes referred to as mechanical compliance. Coordinated Axis Control refers to a multiple Axis movement, which appears to end simultaneously. Sometimes referred to as a coordinated move CMOS is the abbreviation for Complementary Metallic Oxide Semiconductor, a type of electronic circuit chip used in computers. CP is a reference to Continuous Path, which is a type of Robot arm movement. This move is in the shape of an arc, circle, or rectangular and the like. Damping is the absorbing of mechanical energy from any Axis. Its purpose is to control mechanical vibration. DI/DO is the abbreviation for Digital Input/Digital Output. DRAM is the abbreviation for Dynamic Random Access Memory, a type of PC chip memory. Different from SRAM, DRAM must be refreshed several times each second. Drift is the gradual movement of any Axis away from its commanded position. Copyright © Sankyo Robotics, 1994-2001 Glossary 1 SC3000 Robot Systems Droop is the mechanical compliance of a Robot arm, as measured at the end of the arm with respect to the base. This is the loss of its ability to maintain a parallel respective position (to the earth), between the base and the end of the arm, and is an important consideration with high payloads. Elbow is also known as the Theta 2 joint. It connects Theta 1 and Theta 2 Axes on a SCARA Robot. Electrical-Optical Isolator is a device which couples input to output using a light source and a detector in the same package. It provides electrical isolation between input circuitry and output circuitry. Emergency Stop Switch is a push-button switch that controls power to the Robot, and as its name implies, when activated, will remove power immediately to the Robot. Encoder is a device which transmits pulses that relate to Axis position. Each pulse equates to a precise length of movement, and is the basis for determining the position and repeatability of any Axis. End-Effector or, End of Arm Effector, is any device attached to the Robot end of arm, typically the Z-axis, which acts as a hand or gripper, that can grasp or act upon parts and tools in the work envelope. This is also known as end of arm tooling. Envelope or, Work Envelope. See Work Envelope. EOA is the abbreviation for End-Of-Arm. EPROM is the abbreviation for Electrically Programmable Read Only Memory. This is a non volatile semiconductor memory chip, which can be removed, erased, and reprogrammed. It is typically where a software program is permanently stored, and cannot be changed by an end user. ESD is the abbreviation for Electrostatic Discharge. EPO is the abbreviation for Emergency Power-Off. Feeder is a device that provides parts or tools to complete a Robot application. Fixture is any device, other than a feeder, that is required to complete a Robot application. For example, a fixture will house a tool required to complete a Robot application. Flash Memory is a non destructive memory in a computer. This means that when power is turned off or removed from the computer, any programs or data residing in flash memory will not be lost. FRU is the abbreviation for Field Replaceable Unit, a mechanical or electronic component which is a replaceable part. Gantry is a Robot suspended from a bridge-like frame. Sometimes called a box-frame Robot. Typically, the work envelope is rectangular. Gripper See End Effector. Hand See End Effector. 2 SC3000 Series Installation and Specifications Manual Host Computer is a computer that can control, monitor, or upload and download files to, a Robot System. They are also called Roll-up computers. Industrial Robot is a multi-functional, multiple axis robot that is re-programmable, and capable of assembly and disassembly for a variety of tasks. Also known as an Intelligent Robot. Inertial Load is the first mass moment of inertia of an object. In this context it refers to the moment of inertia the payload reflects on a specific Axis, such as the Z, or vertical, Axis. Joint is another name for Axis. Sometimes meant only to refer to a rotational Axis. Manip or Manipulator is another name for Robot, or Robot arm. Matrix is a type of feeder or fixture where items are organized on a rectangular grid, and any item can be referenced by their position on the grid. Maximum Speed is the speed maintained by an Axis after acceleration and prior to deceleration at the end of the move. Speed at the end of the arm may be greater than the specified maximum speed when multiple joints are used on a single move. MB is the abbreviation for megabyte, related to memory or storage in a computer. A megabyte is equal to one million characters. MCS is the abbreviation for Motion Control System. Memory is another term for storage, and refers to the area where computer programs and data are temporarily stored. Unless otherwise stated, this type of memory is lost when power is turned off, or removed from the computer. See Flash Memory. Noise is extraneous signals or disturbances which can interfere with desired signals. Overload defines exceeding the maximum payload that the Robot is designed to carry. Overshoot is the undesirable movement of an Axis past its commanded position. Pause/Interrupt is the stopping of all movement of a Robot, without removing Robot power. Payload is the maximum weight the Robot is designed to carry. (Ability to firmly grip such a payload is affected by choice of grippers or end-of-arm effectors). Pendant is the Robot System device which allows for the monitoring and teaching of points for a Robot application. It can also be used to verify machine operation, such as starting and stopping of diagnostic or exerciser programs, or to individually move any Axis. It is also known as a Teach Pendant. PLC is the abbreviation for Programmable Logic Controller. Position is the location of the Robot in the work envelope. POST is the abbreviation for Power-On Self-Test. Glossary 3 SC3000 Robot Systems PTP is a reference to Point-To-Point, which is a type of Robot arm movement. This move is a straight line, or, with SCARA Robots it may be a natural arc motion. RAM is the abbreviation for Random Access Memory, a type of electronic memory circuit chip used in computers. Repeatability is the variation in returning to a given point and is expressed as a distance from the mean within which at least 99.5% of all measurements fall. This is based on fixed temperature, speed, payload, and direction within the operating range. Robot is a mechanical device that can be programmed to automatically perform a variety of tasks. It may contain two or more axes. Robot System, or, Robotic System, is comprised of the Robot, any computer or controller containing the necessary software, any end effector, feeders, fixtures, and tools that are required to complete the Robot task. ROM is the abbreviation for Read Only Memory, a type of electronic circuit chip used in computers. SSL/E is the abbreviation for Sankyo Structured Language/Enhanced software language. This language supports the SC3000 family of Sankyo robot systems. Settling time is the time required to settle any axis to its final destination within the repeatability range. Shoulder is another name for the Theta 1 Axis. It is the Axis directly mounted to the pedestal on SCARA Robots. SPM is the abbreviation for Servo Power Module, a power unit required for driving the axes on certain types of Robots. SRAM is the abbreviation for Static Random Access Memory, a type of electronic memory circuit chip used in computers. Typically battery backed. Strain gages are analog voltage force sensors that are typically installed on endeffectors (hand). They are also known as Tactile sensors. Teach Pendant See Pendant. Undershoot is the undesirable movement of an Axis where a commanded position was not reached. Velocity is the measure of speed or rate of motion. Vision System allows for the interfacing of a high resolution camera to determine the actual commanded position that a Robot must attain. This permits flexibility in the Robot application. Work Envelope is a reference to the maximum area of extent which any Axis or axes, can access. This is also known as the Workspace. Work space is the same as work envelope. 4 SC3000 Series Installation and Specifications Manual Appendix A ADS Communications Port Cable Wiring ADS Port The following figure describes the connections for the cable that allows the attachment of a PC to the SC3000 Robot Controller ADS Communications Port. This cable is provided with the Robot System, Sankyo P/N SCF309. 9 pin to 9 pin Cable – Buzz version NOTES: Connect shield ground to connector housing. ADS for DOS is configured for COM1 or COM2 on an IBM compatible PC. ADS for Windows (Buzz), is configured for COM1 to COM9 on an IBM compatible PC. ADS port default specifications chart: Specification Configuration Data Bits Stop Bits Parity Speed 8 2 Even 9600baud Copyright © Sankyo Robotics, 1994-2001 ADS Communications Port Cable Wiring A-1 SC3000 Robot Systems This page left blank intentionally A-2 SC3000 Series Installation and Specifications Manual Appendix B RS-232C Communications Port Cable Wiring RS-232C Port The following figures describes the connections for the cable that attaches from the Host computer to any SC3000 Controller RS-232C Communications Port. This cable is not provided with the Robot System. 9 Pin to 9 Pin RS-232C Cable Notes: Connect shield ground to pin 1 at the host computer (PC) side. Refer to the following page for the RS-232C Port default configuration. Refer to the following page for the RS-232C Port Address chart. Copyright © Sankyo Robotics, 1994-2001 RS-232C Communications Port Cable Wiring B-1 SC3000 Robot Systems 9 Pin to 25 Pin RS-232C Cable This cable is not provided with the Robot System. Note: Connect shield ground to pin 1 at the host computer (PC) side. RS-232C Port default configuration chart: Specification Data Bits Stop Bits Parity Speed Value 8 2 Even 9600baud - SC3000-010 / 19200baud - SC3000-030 RS-232C Port address chart: RS-232C Port # 1 2 3 4 5 6 7 8 9 10 B-2 Physical Port CPU Board 64 I/O Board Option/Expansion Panel # 1 64 I/O Board Option/Expansion Panel # 2 128 I/O Board Option/Expansion Panel # 1 128 I/O Board Option/Expansion Panel # 2 128 I/O Board Option/Expansion Panel # 3 SC3000-010 HS Board option DeviceNet board # 1 DeviceNet board # 2 DeviceNet board # 3 SC3000 Series Installation and Specifications Manual Appendix C Physical (User) DI/DO Charts Standard DI/DO Point # Purpose Point # DI1 DO17 DI2 DO18 DI3 DO19 DI4 DO20 DI5 DO21 DI6 DO22 DI7 DO23 DI8 DO24 Purpose DI9 DI10 DI11 DI12 DI13 DI14 DI15 DI16 Copyright © Sankyo Robotics, 1994-2001 Physical (User) DI/DO Charts C-1 SC3000 Robot Systems Expanded DI/DO - First Option-64 I/O Board First 32 Points of 64 I/O Board: Point # C-2 Purpose Point # DI25 DO41 DI26 DO42 DI27 DO43 DI28 DO44 DI29 DO45 DI30 DO46 DI31 DO47 DI32 DO48 DI33 DO49 DI34 DO50 DI35 DO51 DI36 DO52 DI37 DO53 DI38 DO54 DI39 DO55 DI40 DO56 Purpose SC3000 Series Installation and Specifications Manual Second 32 Points of 64 I/O Board: Point # Purpose Point # DI57 DO73 DI58 DO74 DI59 DO75 DI60 DO76 DI61 DO77 DI62 DO78 DI63 DO79 DI64 DO80 DI65 DO81 DI66 DO82 DI67 DO83 DI68 DO84 DI69 DO85 DI70 DO86 DI71 DO87 DI72 DO88 Purpose Physical (User) DI/DO Charts C-3 SC3000 Robot Systems Expanded DI/DO - First Option-128 I/O Board First 32 Points of 128 I/O Board: Point # C-4 Purpose Point # DI153 DO217 DI154 DO218 DI155 DO219 DI156 DO220 DI157 DO221 DI158 DO222 DI159 DO223 DI160 DO224 DI161 DO225 DI162 DO226 DI163 DO227 DI164 DO228 DI165 DO229 DI166 DO230 DI167 DO231 DI168 DO232 Purpose SC3000 Series Installation and Specifications Manual Expanded DI/DO Second 32 Points of 128 I/O Board: Point # Purpose Point # DI169 DO233 DI170 DO234 DI171 DO235 DI172 DO236 DI173 DO237 DI174 DO238 DI175 DO239 DI176 DO240 DI177 DO241 DI178 DO242 DI179 DO243 DI180 DO244 DI181 DO245 DI182 DO246 DI183 DO247 DI184 DO248 Purpose Physical (User) DI/DO Charts C-5 SC3000 Robot Systems Expanded DI/DO Third 32 Points of 128 I/O Board: Point # C-6 Purpose Point # DI185 DO249 DI186 DO250 DI187 DO251 DI188 DO252 DI189 DO253 DI190 DO254 DI191 DO255 DI192 DO256 DI193 DO257 DI194 DO258 DI195 DO259 DI196 DO260 DI197 DO261 DI198 DO262 DI199 DO263 DI200 DO264 Purpose SC3000 Series Installation and Specifications Manual Expanded DI/DO Last 32 Points of 128 I/O Board: Point # Purpose Point # DI201 DO265 DI202 DO266 DI203 DO267 DI204 DO268 DI205 DO269 DI206 DO270 DI207 DO271 DI208 DO272 DI209 DO273 DI210 DO274 DI211 DO275 DI212 DO276 DI213 DO277 DI214 DO278 DI215 DO279 DI216 DO280 Purpose Physical (User) DI/DO Charts C-7 SC3000 Robot Systems This page left blank intentionally C-8 SC3000 Series Installation and Specifications Manual Appendix D Warranty LIMITED PRODUCT WARRANTY (United States and Puerto Rico) Sankyo Robot Systems Each Sankyo robot system, and any associated Sankyo feature or accessory ordered with the robot system, excluding Cognex Vision, is covered by a 12-month warranty against manufacturing defects in materials or workmanship. This warranty only provides for a replacement robot system part, feature or accessory, and does not include installation or warranty service. This warranty commences on the date of delivery, provided however, that the Sankyo robot system, and any Sankyo feature or accessory, is: (a) installed as specified by Sankyo Robotics; (b) maintained by qualified service personnel; and, (c) operated in a normal manner consistent with Sankyo Robotics’ operating instructions. Service parts and replacement products will be furnished on an exchange basis and will be either reconditioned or new. All replaced parts and products become the property of Sankyo. This limited warranty excludes damage to the product resulting from accident, disaster, misuse, abuse or non-Sankyo modification of the Product. The Sankyo Robot Systems warranty expressed above defines new robot systems only, and does not cover the sale of any used Sankyo robot system from any source, regardless of the date of manufacture Sankyo Maintenance Parts Each Sankyo spare part, and any Sankyo feature or accessory ordered without a robot system, is covered by a 90-day warranty, against manufacturing defects in materials or workmanship. This warranty only provides for a replacement Sankyo spare part, feature or accessory, and does not include installation or warranty service. This warranty commences on the date of delivery, provided however, that the Sankyo spare part, feature or accessory is: (a) installed as specified by Sankyo Robotics; (b) maintained by qualified service personnel; and, (c) operated in a normal manner consistent with Sankyo Robotics’ operating instructions. The warranties set forth above do not apply to lubricants, filters and other supplies used in connection with any Sankyo robot system or system component. THE WARRANTIES SET FORTH HEREIN ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED OR STATUATORY; INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR USE. THE CUSTOMER’S SOLE REMEDY FOR BREACH OF THESE WARRANTIES SHALL BE TO REQUIRE SANKYO ROBOTICS TO REPLACE THE DEFECTIVE ROBOT SYSTEM COMPONENT OR PRODUCT. Sankyo Seiki, (America), Inc., is not responsible for providing any warranty for products located outside the United States and Puerto Rico, unless otherwise agreed to in writing. Copyright © Sankyo Robotics, 1994-2001 Warranty D-1 SC3000 Robot Systems IN NO EVENT WILL SANKYO BE LIABLE TO YOU FOR ANY DAMAGES, INCLUDING ANY LOST PROFITS, LOST SAVINGS, OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OF OR INABILITY TO USE SUCH PRODUCT, EVEN IF SANKYO OR AN AUTHORIZED SANKYO ROBOT SYSTEMS INTEGRATOR HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM BY ANY OTHER PARTY. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH CAN VARY FROM STATE TO STATE. FOR WARRANTY SERVICE OR ASSISTANCE ON THIS PRODUCT, IT IS RECOMMENDED THAT YOU CONTACT SANKYO AT THE LOCATIONS FOUND IN THE PREFACE CHAPTER AT THE BEGINNING OF THIS MANUAL, OR THE AUTHORIZED SANKYO ROBOT SYSTEMS INTEGRATOR FROM WHOM THE PRODUCT WAS PURCHASED. D-2
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