YASKAWA DX100 NSU01 Functional Safety Unit Instructions

PDF

ドキュメント

DX100 OPTIONS
INSTRUCTIONS
FOR FUNCTIONAL SAFETY UNIT (NSU01)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-- INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 Operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number:
Revision:
157863-1CD
7
MANUAL NO.
HW0486052 6
1/61
157863-1CD
Functional Safety Unit
(NSU01)
MANDATORY
•
This manual explains the functional safety unit (NSU01) of the
DX100 system. Read this manual carefully and be sure to
understand its contents before handling the DX100.
•
General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instructions before reading this manual.
CAUTION
•
Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
•
The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
•
YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
•
If such modification is made, the manual number will also be
revised.
•
If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
•
YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
ii
HW0486052
2/61
157863-1CD
Functional Safety Unit
(NSU01)
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
WARNING
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the
MANDATORY items listed under this heading.
PROHIBITED
Must never be performed.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure to
follow all instructions, even if not designated as &quot;CAUTION&quot;
and &quot;WARNING&quot;.
iii
HW0486052
3/61
157863-1CD
Functional Safety Unit
(NSU01)
WARNING
•
Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Figure 1: Emergency Stop Button
•
Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN
•
Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
•
Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
iv
HW0486052
4/61
157863-1CD
Functional Safety Unit
(NSU01)
CAUTION
•
Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
•
Always return the programming pendant to the hook on the cabinet
of the DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
•
Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:
Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows:
Equipment
Manual Designation
DX100 controller
DX100
DX100 programming pendant
Programming pendant
Cable between the manipulator and the
controller
Manipulator cable
v
HW0486052
5/61
157863-1CD
Functional Safety Unit
(NSU01)
Descriptions of the programming pendant, buttons, and displays are
shown as follows:
Equipment
Manual Designation
Programming Character
Pendant
Keys
The keys which have characters printed on
them are denoted with [ ].
ex. [ENTER]
Symbol
Keys
The keys which have a symbol printed on them
are not denoted with [ ] but depicted with a small
picture.
GO
GO
BACK
BACK
ex. page key PAGE
PAGE
The cursor key is an exception, and a picture is
not shown.
Axis Keys
Number Keys
“Axis Keys” and “Number Keys” are generic
names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]
Displays
The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
Description of the Operation Procedure
In the explanation of the operation procedure, the expression “Select • • • “
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
vi
HW0486052
6/61
157863-1CD
Functional Safety Unit
(NSU01)
Table of Contents
Table of Contents
1 Function Overview .......................................................................................................................... 1-1
1.1 Preface .............................................................................................................................. 1-1
1.2 Function Overview ............................................................................................................. 1-1
2 System Configuration...................................................................................................................... 2-1
2.1 Outline ............................................................................................................................... 2-1
2.1.1 Functional Safety Unit .......................................................................................... 2-1
2.1.2 Signal Distribution Board ...................................................................................... 2-2
2.1.3 Communication I/F Gateway Unit......................................................................... 2-3
2.1.4 Power On Unit ...................................................................................................... 2-4
2.2 Description of Unit Layout (Layout Drawing) ..................................................................... 2-5
2.3 Spare Parts........................................................................................................................ 2-5
3 Setup (Safety Range Function for Robot)....................................................................................... 3-1
3.1 Changing Security Mode ................................................................................................... 3-1
3.2 Preparation for Safety Range Function ............................................................................. 3-3
3.3 Setting Tool Interference File............................................................................................. 3-3
3.4 Setting Safety Range for Robot ......................................................................................... 3-7
3.5 Confirming Safety Range for Robot................................................................................. 3-11
3.6 Switching Safety Range................................................................................................... 3-12
3.7 Starting Safety Range Function for Robot ....................................................................... 3-15
3.8 Confirming Safety Range and Robot Position ................................................................. 3-17
4 Setup (Safety Range Function for Each Axis) ................................................................................ 4-1
4.1 Preparation for Safety Range Function ............................................................................. 4-1
4.2 Setting Expected Stop Value ............................................................................................. 4-1
4.3 Setting Safety Range for Each Axis................................................................................... 4-4
4.4 Confirming Safety Range for Each Axis ............................................................................ 4-7
4.5 Starting Safety Range Function for Each Axis................................................................... 4-8
5 Stop Position Monitoring Function .................................................................................................. 5-1
5.1 Operating Condition Detection........................................................................................... 5-1
5.2 Turning Stop Position Monitoring Function VALID/INVALID ............................................. 5-1
vii
HW0486052
7/61
157863-1CD
Functional Safety Unit
(NSU01)
Table of Contents
6 Data Protection ............................................................................................................................... 6-1
6.1 Saving Dual Data ............................................................................................................... 6-1
6.2 Operation When VERIFY ERROR Occurs ........................................................................ 6-2
7 System Output Signal ..................................................................................................................... 7-1
8 Alarm............................................................................................................................................... 8-1
9 Error ................................................................................................................................................ 9-1
10 Restrictions ................................................................................................................................. 10-1
10.1 Confirming Safety Range and Robot Position ............................................................... 10-1
10.2 Software Version of Machine Safety Unit ...................................................................... 10-1
10.3 Software Version of Functional Safety Unit ................................................................... 10-2
10.4 System Restrictions ....................................................................................................... 10-2
11 Unit Setting (Precautions for exchange) ..................................................................................... 11-1
Revision History ...................................................................................................................................A-1
viii
HW0486052
8/61
157863-1CD
Functional Safety Unit
(NSU01)
1
1 Function Overview
1.1 Preface
Function Overview
1.1
Preface
This function limits the operating range of the robot and monitors its
speed.
With this function, the software monitors the robot arm or each axis so that
its position does not exceed the preset safety range. If any monitoring
error is detected, the contactors are cut off to stop the robot. With this
function, it is possible to improve the safety for robot operation, and
reduce the facility space for the robot system.
NOTE
1.2
Refer to section 10 for the restrictions.
Function Overview
(1) Range limit function (robot axis + servo track / unit)
This function is used to monitor the robot so that its position does
not exceed the preset safety range. Only one safety range can be
specified. The specified range can be applied to the following
configuration:
Robot (6 axes) + servo track (up to 3 axes)
or
Robot (7 axes) + servo track (up to 2 axes)
By the combination of 2 lines of dual input signals (range switch
signals) to the functional safety unit, 4 ranges (range: 1 to range:
4) can be set as the safety ranges.
To enable range switching, connect the range switch signals to the
functional safety system input terminal block shown in section
2.1.2 “Signal Distribution Board” on page 2-2. When range
switching is not used, i.e. only one safety range is set, there is no
need to connect the signals. (In this case, range: 1 is set.)
For signal connection, refer to section 3.7 “Starting Safety Range
Function for Robot” on page 3-15.
(2) Each axis angle limit function (9 axes/unit)
(3) Stop position monitoring function
(4) Safety speed monitoring function
This function monitors the robot to see that it operates at the
safety speed of 250 mm/sec. The speed is monitored at the TCP
(Tool Center Point) and flange.
• Teach mode (manual high speed specification is OFF)
NOTE
The safety speed monitoring function can monitor the
speed of one tool number per robot.
The speed of R1 and R2 is monitored using the file with the
tool numbers 0 and 1, respectively.
(5) Logical verification of safety signals
This function detects the unmatch of the dual safety signals
converted into the functional safety unit.
1-1
HW0486052
9/61
157863-1CD
Functional Safety Unit
(NSU01)
2
2 System Configuration
2.1 Outline
System Configuration
2.1
Outline
To achieve the functions described in this manual, the “functional safety
unit”, “signal distribution board”, “communication I/F gateway unit”, and
“power on unit” are added or replaced for the DX100.
2.1.1
Functional Safety Unit
The type and major specifications of functional safety unit are shown
below.
Item
specification
Unit type
JZNC-NSU01
Unit size
W120&times;H300&times;D194 [mm]
Input power supply
DC24V
Function
(1) Safety range setting function (robot axis + servo track / unit)
(2) Safety speed monitoring function
(3) Safety signal logical verification function
Setting (Rotary SW: S2) 0
Jumper cable
For the jumper cable setting in the unit, refer to Chapter 11
&quot;Unit Setting (Precautions for exchange)&quot;.
The outline of the functional safety unit: JZNC-NSU01 is shown below.
2-1
HW0486052
10/61
157863-1CD
Functional Safety Unit
(NSU01)
2.1.2
2 System Configuration
2.1 Outline
Signal Distribution Board
The signal distribution board is a special board equipped with an extended
function that distributes full-speed test signals to the functional safety unit
in addition to the standard functions of the robot system input terminal
block (MXT).
Item
Specification
Board type
JARCR-YCU02
Function
(1) Robot system input terminal block
(2) Signal distribution to the functional safety unit
(3) Spare terminal block (for future extension)
Robot system input termial block
NOTE
For the connection to the robot system input terminal block,
refer to section 13.9 “Robot System Input Terminal Block
(MXT)” in the DX100 INSTRUCTIONS MANUAL.
2-2
HW0486052
11/61
157863-1CD
Functional Safety Unit
(NSU01)
2.1.3
2 System Configuration
2.1 Outline
Communication I/F Gateway Unit
The gateway unit for host communication I/F is added to convert the
communication signals to enable the communications between DX100
and the functional safety unit (JZNC-NSU01).
This unit converts the communication signals between the robot I/F board
(JANCD-YIF01-□) in DX100 and the functional safety unit (JZNCNSU01).
Item
specification
Unit type
JZNC-YGW01-E
Unit size
W30&times;H230&times;D1 [mm]
Input power supply
DC24V
Function
Conversion of the communication signals between
DX100 robot I/F board (JANCD-YIF01-□) and the
functional safety unit (JZNC-NSU01)
Setting (rotary SW: S1)
1st robot: 0
2nd to 4th robot: 1 to 3 (Number consecutively.)
Connector
CN902/CN903
For the connection of the robot I/F board (JANCDYIF01-□) and the functional safety unit (JZNCNSU01)
CN904
For the connection of the functional safety unit
(JZNC-NSU01)
CN901
For 24 VDC input
The outline of the communication I/F gateway unit: JZNC-YGW01-E is
shown below.
S1
Rotary SW
F1
Protection fuse
2-3
HW0486052
12/61
157863-1CD
Functional Safety Unit
(NSU01)
2.1.4
2 System Configuration
2.1 Outline
Power On Unit
This power on unit is the unit to which an “auxiliary contact block” is added
in order to feed back the status of the built-in contactor to the functional
safety unit (JZNC-NSU01).
The standard power on unit should be replaced with this unit if needed.
Item
specification
JZRCR-YPU0□-2
Unit type
Unit size
Same size as the standard power on unit
(interchangeable)
Function
Contactor auxiliary contact signal output is added.
(for the functional safety unit (JZNC-NSU01))
Connector
CN609
For the contactor auxiliary contact signal output
(added to the standard unit)
2-4
HW0486052
13/61
157863-1CD
Functional Safety Unit
(NSU01)
2 System Configuration
2.2 Description of Unit Layout (Layout Drawing)
2.2
Description of Unit Layout (Layout Drawing)
The figure below shows a layout drawing of the DX100 with which the
functional safety unit is added.
Fig. 2-1: Unit Layout Drawing (with the Door Open)
Power on unit (YPU)
JZRCR-YPU0-2
A
CN601
(QF3)
COULD
FUSE
COULD
FUSE
CN610
CU
1
CU
1FU
CN611
2FU
CN607
3
O
N
L
Y
3FU
4FU
BNL6
O
N
L
Y
A
BNL6
B
C
C.B.
R
489
CN609
NCM
20A
CU
O
N
L
Y
2
O
N
L
Y
CN606
SVMX2
~
CU
SVMX1
40 C
480Y/277V
4
CN608
CN612
(QS2)
CN605
CN604
CN603
CN602
CN158/159
(+5V/ALM)
SOURCE
P-ON
+5V
+24V
FAN
OHT
Functional safety unit (YPU)
JZNC-NSU01
CN156/157
(+24V2)
YCU
EXIN3_2EXIN3_2+
EXIN3_1EXIN3_1+
EXIN2_2EXIN2_2+
EXIN2_1EXIN2_1+
EXIN1_2EXIN1_2+
EXIN1_1EXIN1_1+
POWER SUPPLY
CPS-520F
C90AD XXXXX
NO.
DATE YYYY-MM
CN154/155
(+24V1/V2)
Fuji Electric Hi-Tech Corp.
L
K
J
I
H
G
F
E
D
C
B
A
MADE IN JAPAN
01 02 03 04 05 06 07 08 09 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B C D E F G H J K
L M N P Q R S T U V
34 EXDSW1- 17 SYSRUN+
50 GSOUTFB233 EXDSW1+ 16
49 GSOUTFB2+
32 EXHOLD- 15
48 GSOUT231 EXHOLD+ 14
47 GSOUT2+
CN153
(+24V3)
30 EXSVON- 13
46 GSOUTFB129 EXSVON+ 12 SAFF245 GSOUTFB1+
28
SSP-
11 SAFF2+
27
SSP+
10 SAFF1-
CN151
(AC IN)
44 GSOUT143 GSOUT1+
FST2-
9
FST2+
8
24
FST1-
7 GSIN22+
23
FST1+
6
26
42
SAFF1+
INPUT
200-240V AC
50/60Hz
3.4A-2.8A
024V2
25
41
GSIN22-
+24V2
40
024V2
39
+24V2
38
024V2
37
+24V2
GSIN21-
22 EXESP2-
5 GSIN21+
21 EXESP2+
4
20 EXESP1-
3 GSIN12+
19 EXESP1+
2
18 SYSRUN-
1 GSIN11+
CN152
(REMOTE)
GSIN12-
36 EXDSW2GSIN11-
35 EXDSW2+
NJ3114-1
A
B
A
1
CN207
A
CN213
CN216
CN212
CN206
CN202
CN211
FRC5-C50S52T-OLS(D20)
1
94V-0
MADE IN JAPAN
S/N
JARCR-YCU02 REV.A 0
HE0305598
CN205
FUSE
CN210
CN209
CN200 CN201
CN203 CN204
CN208
CNB
CNA
Terminal unit for NSU
JARCR-YCU02
CN215
CNNSUO
UL
CNYSUO
CNC
B
CNEXT
CN214
1
B
BNL6
BNL6
BNL6
Comm. I/F gateway unit
JZNC-YGW01-E
A
Section A-A
2.3
Spare Parts
To achieve the functions of range limit and speed monitoring for the
DX100 robot system, the recommended spare parts for the DX100 with
the functional safety unit are shown below.
Regarding the standard part of the DX100, refer to the “DX100
INSTRUCTIONS (162536-1CD)” and the “DX100 MAINTENANCE
MANUAL (155492-1CD)”.
Unit
Name
Model
Qty.
Manufacturer
Functional Safety
Unit
(JZNC-NSU01)
Fuse
(for F2 and F3)
0217001P
2
Littelfuse
Communication I/F
Gateway Unit
(JZNC-YGW01-E)
Fuse (for F1)
0217001P
1
Littelfuse
2-5
HW0486052
14/61
157863-1CD
Functional Safety Unit
(NSU01)
3
3 Setup (Safety Range Function for Robot)
3.1 Changing Security Mode
Setup (Safety Range Function for Robot)
3.1
Changing Security Mode
To limit the operating range of the robot, set the safety range.
To set the safety range, the security mode must be MANAGEMENT
MODE or higher. Thus, the administrator or a user with higher privilege
must set the range.
Change the security mode as follows:
1. Select {SYSTEM INFO} under the main menu.
2. Select {SECURITY} under the sub menu.
3-1
HW0486052
15/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.1 Changing Security Mode
3. Change the mode from EDITING MODE to MANAGEMENT MODE.
Press [ENTER] in the SECURITY screen. Move the cursor to
“MANAGEMENT MODE” and then press [ENTER] again.
4. Input the password for MANAGEMENT MODE and press [ENTER].
The security mode is changed to MANAGEMENT MODE.
NOTE
Security level
Items that can be manipulated
OPERATION
Data such as the operating range cannot be
edited or viewed.
EDITING
MANAGEMENT
Data such as the operating range can be
edited or viewed. The “Safety Unit FLASH
Erase” can be performed in the
maintenance mode.
3-2
HW0486052
16/61
157863-1CD
Functional Safety Unit
(NSU01)
3.2
3 Setup (Safety Range Function for Robot)
3.2 Preparation for Safety Range Function
Preparation for Safety Range Function
For the safety range function for the robot arm, set the safety range of the
robot arm as polygonal columns in advance. Then, the robot arm is
monitored so that it does not exceed the safety range.
If any monitoring error is detected, the servo power will be turned OFF.
The outline of the operating procedure is as follows:
(1) Setting tool interference file

(2) Setting safety range for robot

(3) Confirming safety range for robot

(4) Starting safety range function for robot
Each operating procedure is explained below.
3.3
Setting Tool Interference File
The safety unit also monitors that the robot tool does not exceed the
safety range. In this case, set the tool shape in the tool interference file.
To set the tool interference file, the security mode must be
MANAGEMENT MODE or higher.
&lt;Tool interference file&gt;
• Cylinders and spheres for up to 5 positions can be set.
• Both ends of a cylinder are set by POINT1 and POINT2.
The distance from the center of T axis flange should be set like tool
dimension setting.
• The radius of the spheres and cylinder between POINT1 and
POINT2 is set. The spheres are set to POINT1 and POINT2.
• The specified radius must have a margin of at least 10 mm
compared with the actual tool.
A single tool interference file can be used for a robot.
NOTE
The safety range function is set to the data in the tool
interference file #0 for R1 and that in the tool interference
file #1 for R2.
3-3
HW0486052
17/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.3 Setting Tool Interference File
Set a tool interference file as instructed below.
1. Select {ROBOT} under the main menu.
2. Select {TOOL INTERFERE} under the sub menu.
– The TOOL INTERFERE screen is displayed.
3-4
HW0486052
18/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.3 Setting Tool Interference File
3. If the data is set in TOOL INTERFERE screen, the READBACK screen
is shown.
– In READBACK screen, you can check if the set data is correct.
– Compare MODIFY VALUE with READBACK VALUE.
• If the data is OK, press “YES” on the screen to fix the tool interference file setting.
• If the data is NG, press “NO” on the screen to restore to the value
before change.
4. After READBACK screen is displayed, [WRITE] and [CANCEL]
buttons are displayed in the lower position of the screen.
&lt;Description of the screen&gt;
WRITE: Robot controller records the setting of the tool interference file.
CANCEL: Cancel the tool interference file setting to restore the setting to
the previous status.
NOTE
• Be sure to press [WRITE] after performing tool
interference file setting.
• A single tool interference file can be used for a robot.
3-5
HW0486052
19/61
157863-1CD
3 Setup (Safety Range Function for Robot)
3.3 Setting Tool Interference File
&lt;Tool interference file setting example&gt;
140
25
Robot
30
Model 2
Point 1
Tool coodinate origin
(flange surface)
X
85
20
Model 1
Point 1
Model 1
Point 2
Tool
Model 3
Point 1
350
250
Functional Safety Unit
(NSU01)
Model 2
Point 2
Model 3
Point 2
Z
Model 1: Set the flange surface as Point 1, and (X=140, Z=85) as Point 2.
Model 2: Set (X=140, Z=-30) as Point 1, and (X=140, Z=250) as Point 2.
This setting defines a model that is parallel to the Z direction of
the tool coordinates.
Model 3: Set (X=140, Z=250) as Point 1, and (X=25, Z=350) as Point 2.
Models 2 and 3 are defined at consecutive positions when point
2 of model 2 and point 1 of model 3 are set at the same position.
3-6
HW0486052
20/61
157863-1CD
Functional Safety Unit
(NSU01)
3.4
3 Setup (Safety Range Function for Robot)
3.4 Setting Safety Range for Robot
Setting Safety Range for Robot
Set the safety range for the robot arm as follows:
1. Select {ROBOT} under the main menu.
2. Move the cursor and display the following sub menu.
3. Select {ROBOT RANGE} under the sub menu.
– The ROBOT RANGE screen is displayed.
&lt;Description of the screen&gt;
ROBOT: Selects a robot to be set in case the of a multiple robot system.
To set R1, move the cursor to “R1” and press [SELECT].
SETTING: Sets the safety range limit function status.
Status
Detail
INVALID
The safety range function can be disabled temporarily.
The system output signal “Range Monitoring” is turned OFF.
(Refer to chapter 7 “System Output Signal” on page 7-1.)
VALID
The safety range function is enabled.
The system output signal “Range Monitoring” is turned ON.
(Refer to chapter 7 “System Output Signal” on page 7-1.)
3-7
HW0486052
21/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.4 Setting Safety Range for Robot
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING.
Status
Contents
SETTING
“SETTING” is displayed when setting the data.
CONFIRMING
“CONFIRMING” is displayed when confirming the range
after data setting.
MONITORING
“MONITORING” is displayed after confirming the data.
While “MONITORING” is displayed, the safety range
function is performed.
4. Select “R1”. Then ROBOT RANGE screen is shown.
&lt;Description of the screen&gt;
COORD: Select a coordinate type; ROBOT or BASE.
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING
Status
Contents
SETTING
“SETTING” is displayed when setting the data.
CONFIRMING
“CONFIRMING” is displayed when confirming the range
after data setting.
MONITORING
“MONITORING” is displayed after confirming the data.
While “MONITORING” is displayed, the safety range
function is performed.
LINE 1 to 16: Make line segments connecting &lt;X1&gt; and &lt;Y1&gt;, &lt;X2&gt; and
&lt;Y2&gt;, to set the safety range. Up to 16 line segments can be
used for setting.
Z TOP: Sets the safety range of Z-direction top surface.
Z BOTTOM: Sets the safety range of Z-direction bottom surface.
3-8
HW0486052
22/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.4 Setting Safety Range for Robot
&lt;Range setting example&gt;
To set the range with the X direction + side: 3000 mm, X direction - side: 2000 mm, Y direction + side: 2500 mm, and Y direction - side: -1500 mm,
enter the numbers as shown below.
X1
Y1
X2
Y2
Line 1
3000
2500
-2000
2500
Line 2
-2000
2500
-2000
-1500
Line 3
-2000
-1500
3000
-1500
Line 4
3000
-1500
3000
2500
X+: 3000 mm
Line 4
Line 3
Line 1
Y+: 2500 mm
Line 2
Y-: 1500 mm
X-: -2000 mm
5. If the data is set in ROBOT RANGE screen, the READBACK screen is
shown.
– In READBACK screen, you can check if the set data is correct.
Compare MODIFY VALUE with READBACK VALUE.
• If the data is OK, press [YES] on the screen to fix the setting in
ROBOT RANGE screen.
• If the data is NG, press [NO] on the screen to restore to the value
before change.
3-9
HW0486052
23/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.4 Setting Safety Range for Robot
6. After READBACK screen is displayed, [WRITE] and [CANCEL]
buttons are displayed in the lower position of the screen.
&lt;Description of the screen&gt;
WRITE: Robot controller records the setting of the safety range.
CANCEL: Cancel the safety range setting to restore the setting to the
previous status.
• Be sure to press [WRITE] after performing the safety
range setting.
NOTE
• Unless the safety ranges are set and the status is set to
MONITORING for all the robots used in the system, robot
operations by the axis keys cannot be performed except
for each axis operation.
Before performing the following operations, make sure to
complete the safety range setting.
– Job playback
– [FWD], [BWD], [TEST START] key operations
GO
BACK
7. When setting multiple ranges, press the page key PAGE and switch the
screen to make the settings.
For multiple ranges, set an overlap area. Switch between ranges only
when the robot is in the overlap area.
&lt;Setting example&gt;
Range 2
Range 1
Area where the ranges
can be switched.
3-10
HW0486052
24/61
157863-1CD
Functional Safety Unit
(NSU01)
3.5
3 Setup (Safety Range Function for Robot)
3.5 Confirming Safety Range for Robot
Confirming Safety Range for Robot
After the completion of safety range setting, it is necessary to confirm if
the monitoring is performed according to the safety range set in
section 3.4 “Setting Safety Range for Robot” on page 3-7.
At that time, the “STATUS” in ROBOT RANGE screen indicates
“CONFIRMING”. Move the robot to check if the manipulator stops before
it exceeds the safety range.
When multiple ranges are set, change the range switch signals to check
for all the ranges.
&lt;How to check the safety range with the jog operation&gt;
Check that the specified safety range is correct with the jog operation.
Make the robot operate toward the specified four limits to see that the
robot stops operating within the range. If the range is not rectangular
solid, check that the robot stops before all the limits of the range.
CAUTION
Do not forget to move the robot to see that it stops within the specified
safety range.
3-11
HW0486052
25/61
157863-1CD
Functional Safety Unit
(NSU01)
3.6
3 Setup (Safety Range Function for Robot)
3.6 Switching Safety Range
Switching Safety Range
Multiple safety ranges can be set/confirmed in advance, and the ranges
can be switched by external signals.
For multiple safety ranges, set an overlap area. Switch between ranges
only when the robot is in the overlap area.
Use the dual input signal of the functional safety unit to switch between
safety ranges. If the range is selected by the signal while the range is
being set, the following alarm occurs. Select another range already
confirmed to reset the alarm.
Alarm to occur:
Alarm 4691: “OPERATION AREA SET ERR (SAFETY)”
If the range is selected while it is being set or confirmed during the robot
program operation, the following alarm occurs. Select another range
already confirmed to reset the alarm.
Alarm to occur:
Alarm 4679: “SPECIFIED MOTION RANGE ERROR”
Selected safety range numbers are output to the following system output
signals. (Refer to chapter 7 “System Output Signal” on page 7-1.)
50940 to 50947: Selected RANGE NUMBER (d0)
50950 to 50957: Selected RANGE NUMBER (d1)
CAUTION
•
Before using the safety range switching function, give due
consideration (risk assessment) to the potential danger by switching
between ranges.
•
When performing the teaching operation of the robot program, the
operator should always check the range number before each
operation.
•
Prepare a means to identify the selected range number, and check
the selected range number before performing operations.
•
Check that the robot is stopped before switching between ranges.
Switching between ranges during the robot program operation may
result in the following risks.
– Risk of selecting a wrong range
– Risk that the robot may exceed the range after switch when the
ranges before and after switch are greatly different or the overlap
area of them are small
3-12
HW0486052
26/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.6 Switching Safety Range
The combinations of safety ranges and range switch signals are shown
below.
Table 3-1: Setting of Safety Range
Safety
Range No.
1
2
3
4
N/A
N/A
N/A
N/A
Welder 1
Status
Welder 2
1)
Terminal
Status
Notes
1)
Terminal
CLOSE
A/B
CLOSE
E/F
CLOSE
C/D
CLOSE
G/H
OPEN
A/B
CLOSE
E/F
OPEN
C/D
CLOSE
G/H
CLOSE
A/B
OPEN
E/F
CLOSE
C/D
OPEN
G/H
OPEN
A/B
OPEN
E/F
OPEN
C/D
OPEN
G/H
CLOSE
A/B
*
E/F
OPEN
C/D
*
G/H
OPEN
A/B
*
E/F
CLOSE
C/D
*
G/H
*
A/B
CLOSE
E/F
*
C/D
OPEN
G/H
*
A/B
OPEN
E/F
*
C/D
CLOSE
G/H
Default setting
“SIGNAL COMPARISON ERROR
(SAFETY)” alarm occurs.
“SIGNAL COMPARISON ERROR
(SAFETY)” alarm occurs.
“SIGNAL COMPARISON ERROR
(SAFETY)” alarm occurs.
“SIGNAL COMPARISON ERROR
(SAFETY)” alarm occurs.
1 Terminal indicates the number of the functional safety system input terminal block on the JARCR-YCU02 board.
DX100 connection diagram
JARCR-YCU02
Functional safety system
input terminal block
A
B
Welder 1
C
D
E
F
Welder 2
G
H
JZNC-NSU01
Functional safety unit
EXIN1_1+
EXIN1_1EXIN1_2+
EXIN1_2EXIN2_1+
EXIN2_1EXIN2_2+
EXIN2_2-
3-13
HW0486052
27/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.6 Switching Safety Range
If the functional safety unit detects the safety signal inconsistency, the
following alarm occurs.
Alarm 4705: “SIGNAL COMPARISON ERROR (SAFETY)”
Subcode 5: Signal inconsistency of YCU02 board A to D
3: Signal inconsistency of YCU02 board E to H
CAUTION
•
Connect an independent switch (dry contact) for the range switch
signal.
•
The load current of 24 VDC/6.5 mA (typ) flows through each input
circuit.
For the connection, use a switching device capable of switching
24 VDC at 6.5 mA (typ).
•
The dual input signals are checked whether they are synchronized.
Set the dual input signals as the signals which turn ON and OFF
simultaneously. If the dual input signal’s turning ON and OFF are
different in timings with 500 ms or more, the alarm of “INPUT
SIGNAL ERROR” occurs.
•
For the details of wiring to the functional safety system input
terminal block, refer to DX100 INSTRUCTIONS (162536-1CD)
section 13.9 “Robot System Input Terminal Block (MXT)”.
3-14
HW0486052
28/61
157863-1CD
Functional Safety Unit
(NSU01)
3.7
3 Setup (Safety Range Function for Robot)
3.7 Starting Safety Range Function for Robot
Starting Safety Range Function for Robot
After confirming that the robot can move in the set safety range, press
[CONFIRM]. The STATUS indication is changed to “MONITORING” and
the safety unit starts the safety range function for the robot.
Check the following items with the actual job.
&lt;How to check the safety range in the play mode&gt;
1. Check the teaching point of job.
If an alarm occurs and the robot does not operate when the job is
played back, the following causes are possible:
• The specified range is inappropriate.
• Teaching is inappropriate.
In such a case, recalculate the range or modify teaching.
Alarm 4682: “MOTION RANGE LIMIT INTERFERENCE”
&lt;Cause&gt;
The teaching position is out of the specified range.
&lt;Countermeasure&gt;
Check that the specified range is correct.
Change the teaching position so that it falls in the range.
3-15
HW0486052
29/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.7 Starting Safety Range Function for Robot
2. Endurance running must be normally performed.
Try to move the actual job. If the robot moves near the specified
range, an alarm may occur. In such a case, modify teaching or slow
down the speed.
Alarm 1629: “OPERATION AREA MON. ERR(ROBOT)”
&lt;Cause&gt;
The range error was detected when the robot operated.
&lt;Reason&gt;
This alarm was detected by the safety unit. The safety unit monitors
the position based on the feedback pulse from the motor. The
speed and coasting value is considered during calculation so that
the robot does not move out of the range. Thus, this alarm occurs
when the teaching position is near the safety range or the teaching
speed is fast.
&lt;Countermeasure&gt;
Modify teaching so that the teaching position is not near the safety
range.
Reduce the teaching speed.
NOTE
If the STATUS is “CONFIRMING”, PLAY mode operation is
disabled. Be sure to perform confirming operation and
press [CONFIRM] button on the screen.
3-16
HW0486052
30/61
157863-1CD
Functional Safety Unit
(NSU01)
3.8
3 Setup (Safety Range Function for Robot)
3.8 Confirming Safety Range and Robot Position
Confirming Safety Range and Robot Position
The positional relation between the specified safety range and the actual
robot posture can be checked by showing them on the programming
pendant.
1. Select {ROBOT} under the main menu.
2. Move the cursor to display the following sub menu.
3. Select {OPERATION AREA MONITOR} under the sub menu.
– The Disp Operation Area screen is displayed.
1
2
3
5
4
6
&lt;Description of the screen&gt;
 The plane currently displayed
This is the plane currently displayed. The brown section indicates the
area out of the safety range.
• X-Y plane: The safety range is a white area enclosed with straight
lines.
• Y-Z and X-Z planes: The sides of the safety range.
3-17
HW0486052
31/61
157863-1CD
Functional Safety Unit
(NSU01)
3 Setup (Safety Range Function for Robot)
3.8 Confirming Safety Range and Robot Position
 The number of the robot currently displayed
 The coordinate system of the safety range
 The correspondence table of the illustrated straight lines
The numbers of straight lines correspond to the straight line numbers
on ROBOT RANGE screen.
 [Change Plane] key
Each time pressed, the displayed plane is switched (X-Y, Y-Z, X-Z).
 [Exit] key
Closes the Disp Operation Area screen.
NOTE
When the Disp Operation Area screen is closed, other
opened screens are also closed. This means that data not
yet confirmed is discarded if the Disp Operation Area
screen is opened while editing the data. Thus, make sure
to confirm the editing data before opening the Disp
Operation Area screen.
3-18
HW0486052
32/61
157863-1CD
Functional Safety Unit
(NSU01)
4
4 Setup (Safety Range Function for Each Axis)
4.1 Preparation for Safety Range Function
Setup (Safety Range Function for Each Axis)
4.1
Preparation for Safety Range Function
For the safety range function for each axis, set the movement amount of
each axis of the robot in advance. Then, each axis is monitored so that it
does not exceed the safety range.
If any monitoring error is detected, the servo power will be turned OFF.
The outline of the operating procedure is as follows:
(1) Setting expected stop value

(2) Setting safety range for each axis

(3) Confirming safety range for each axis

(4) Starting safety range function for each axis
Each operating procedure is explained below.
4.2
Setting Expected Stop Value
When the servo power is turned OFF during robot operation, the robot
keeps moving due to inertia until it stops completely. The functional safety
unit predicts the movement distance (hereinafter called the coasting
value) according to the speed of each axis until the robot actually stops.
By predicting the coasting value, the robot does not exceed the safety
range even if an error, such as the robot’s exceeding the safety range, is
detected.
For example, when the robot is operating at 100% of its motion speed, the
functional safety unit starts to stop it from “the distance of the coasting
value of 100% motion speed”. When the robot is operating at 50% of its
motion speed, the functional safety unit starts to stop it from “the distance
of the coasting value of 50% motion speed”.
To perform the above predictive control, the robot may stop before the
safety range when it moves to the teaching point near the safety range.
To add an teaching point near the safety range, take the following
measures:
(1) Lower the teaching speed
(2) Change the teaching point
(3) Change the setting of the safety range to widen it
Regarding the coasting value of the external axis, settings must be made
by the user as instructed in the following.
If settings of the coasting value are not completed, the following error
occurs and playback cannot be performed.
Error 0384: “Coasting value setting of Ex-axis is not completed.”
4-1
HW0486052
33/61
157863-1CD
Functional Safety Unit
(NSU01)
4 Setup (Safety Range Function for Each Axis)
4.2 Setting Expected Stop Value
1. Change the security mode to MANAGEMENT MODE, then select
{ROBOT} under the main menu.
2. Select {COASTING VALUE SETTING} under the sub menu.
– The COASTING VALUE SETTING screen is displayed.
NOTE
The sub menu {COASTING VALUE SETTING} is not
displayed when the system does not have any external
axis. It is not displayed either when the security mode is not
MANAGEMENT MODE.
GO
BACK
– When 2 or more external axes are used, press the page key
switch between the external axes.
PAGE
to
4-2
HW0486052
34/61
157863-1CD
Functional Safety Unit
(NSU01)
4 Setup (Safety Range Function for Each Axis)
4.2 Setting Expected Stop Value
3. Select the axis to set the coasting value, and edit the EXPECTED
STOP VALUE. Then the READBACK screen appears.
– Check that MODIFY VALUE and READBACK VALUE are the same,
then press [YES]. The COASTING VALUE SETTING screen is
displayed again, and the edited coasting value of axis is changed to
the input EXPECTED STOP VALUE. Press [NO] to cancel editing.
• The coasting value can be set from 0.000 to 999.999.
NOTE

• When the coasting value is edited, the servo power is
turned OFF, and the robot and external axes cannot be
operated until the control power is turned OFF and ON
again. Since the setting of the coasting value can be
continued, turn OFF and ON the control power after
setting the coasting values of all axes.
How to Change the Stop Category
To measure the coasting value, the stop category can be changed.
In the COASTING VALUE SETTING screen, select IMMEDIATE STOP to
show INVALID and VALID. Select one of them to display the READBACK
screen in the same way when editing the coasting value. Check that the
READBACK VALUE is the same as the value shown right next to the
selected item of INVALID or VALID. Then press [YES] to switch between
INVALID and VALID.
4-3
HW0486052
35/61
157863-1CD
Functional Safety Unit
(NSU01)
4 Setup (Safety Range Function for Each Axis)
4.3 Setting Safety Range for Each Axis
• When the IMMEDIATE STOP is set to VALID, the stop
category of the robot and external axes is set to 0. Be
sure to return the IMMEDIATE STOP to INVALID after
measuring the coasting value.
• If the start operation is performed when the IMMEDIATE
STOP is VALID, a confirmation dialog box appears.
Select [YES] and perform the start operation again to
perform playback.
NOTE
4.3
Setting Safety Range for Each Axis
Set the safety range for each axis as instructed below.
1. Change the security mode to MANAGEMENT MODE, then select
{ROBOT} under the main menu.
4-4
HW0486052
36/61
157863-1CD
Functional Safety Unit
(NSU01)
4 Setup (Safety Range Function for Each Axis)
4.3 Setting Safety Range for Each Axis
2. Select {AXIS RANGE} under the sub menu.
– The AXIS RANGE screen is displayed.
&lt;Description of the screen&gt;
CTRL GROUP: Selects a control group to be set in the case of a multiple
control group system.
To set S1, move the cursor to “S1” and press [SELECT].
SETTING: Sets the safety range limit function (for each axis) status.
Status
Detail
INVALID
The safety range function for each axis can be disabled
temporarily.
VALID
The safety range function for each axis is enabled.
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING.
Status
Contents
SETTING
“SETTING” is displayed when setting the data.
CONFIRMING
“CONFIRMING” is displayed when confirming the range
after data setting.
MONITORING
“MONITORING” is displayed after confirming the data.
While “MONITORING” is displayed, the safety range
function for each axis is performed.
4-5
HW0486052
37/61
157863-1CD
Functional Safety Unit
(NSU01)
4 Setup (Safety Range Function for Each Axis)
4.3 Setting Safety Range for Each Axis
3. Select a control group. The AXIS RANGE screen of the selected
control group will be displayed.
&lt;Description of the screen&gt;
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING.
Status
Contents
SETTING
“SETTING” is displayed when setting the data.
CONFIRMING
“CONFIRMING” is displayed when confirming the range
after data setting.
MONITORING
“MONITORING” is displayed after confirming the data.
While “MONITORING” is displayed, the safety range
function for each axis is performed.
MAX/MIN: The maximum and minimum values of the safety range are
shown for each axis of the selected control group.
4. When MAX/MIN data are set, the following READBACK screen is
displayed.
– Check that MODIFY VALUE and READBACK VALUE are the same,
then press [YES]. The selected data will be changed. Press [NO] to
cancel editing.
4-6
HW0486052
38/61
157863-1CD
Functional Safety Unit
(NSU01)
4 Setup (Safety Range Function for Each Axis)
4.4 Confirming Safety Range for Each Axis
5. When the data are set, [WRITE] and [CANCEL] buttons are displayed
in the lower position of the screen.
&lt;Description of the screen&gt;
WRITE: Robot controller records the setting of MAX/MIN.
CANCEL: Cancel the MAX/MIN setting to restore the setting to the
previous status.
NOTE
4.4
The functional safety unit predicts the coasting values of the
robot and external axes (see section 4.2 “Setting Expected
Stop Value” on page 4-1) when monitoring the safety range.
Therefore, the robot may stop before the safety range when
it moves to the teaching point near the safety range.
Confirming Safety Range for Each Axis
After the completion of safety range (for each axis) setting, it is necessary
to confirm if the monitoring is performed according to the safety range set
in the section 4.3 “Setting Safety Range for Each Axis” on page 4-4.
At that time, the “STATUS” in ROBOT RANGE screen indicates
“CONFIRMING”. Move the manipulator or the external axis to check if it
stops before it exceeds the safety range.
4-7
HW0486052
39/61
157863-1CD
Functional Safety Unit
(NSU01)
4.5
4 Setup (Safety Range Function for Each Axis)
4.5 Starting Safety Range Function for Each Axis
Starting Safety Range Function for Each Axis
After confirming that the manipulator/external axis can move in the set
safety range, press [CONFIRM]. The STATUS indication is changed to
“MONITORING” and the safety unit starts the safety range function for
each axis.
Check the following items with the actual job.
&lt;How to check the safety range in the play mode&gt;
1. Check the teaching point of job.
If an alarm occurs and the robot does not operate when the job is
played back, the following causes are possible:
• The specified range is inappropriate.
• Teaching is inappropriate.
In such a case, recalculate the range or modify teaching.
Alarm 4683: “AXIS MOTION RANGE LIMIT”
&lt;Cause&gt;
The teaching position is out of the specified range.
&lt;Countermeasure&gt;
Check that the specified range is correct.
Change the teaching position so that it falls in the range.
2. Endurance running must be normally performed.
Try to move the actual job. If the robot moves near the specified
range, an alarm may occur. In such a case, modify teaching or slow
down the speed.
Alarm 1625: “OPERATION AREA MON. ERR(AXIS)”
&lt;Cause&gt;
The range error was detected when the robot operated.
&lt;Reason&gt;
This alarm was detected by the safety unit. The safety unit monitors
the position based on the feedback pulse from the motor. The
speed and coasting value is considered during calculation so that
the robot does not move out of the range. Thus, this alarm occurs
when the teaching position is near the safety range or the teaching
speed is fast.
&lt;Countermeasure&gt;
Make the safety range setting INVALID, move the robot within the
safety range, then make the setting VALID again.
Modify teaching so that the teaching position is not near the safety
range.
Reduce the teaching speed.
NOTE
If the STATUS is “CONFIRMING”, PLAY mode operation is
disabled. Be sure to perform confirming operation and
press [CONFIRM] button on the screen.
4-8
HW0486052
40/61
157863-1CD
Functional Safety Unit
(NSU01)
5
5 Stop Position Monitoring Function
5.1 Operating Condition Detection
Stop Position Monitoring Function
5.1
Operating Condition Detection
The stop position monitoring function is one of the functions of the
functional safety unit. With this function, the encoder information of the
robot or external axis is monitored. If the robot or external axis moves
when the function is valid, the power supply to the servo is shut off
immediately to turn the servo power OFF.
The VALID/INVALID setting of the stop position monitoring function is
performed by the turning ON/OFF of the external dual signal (e.g. area
sensor, mat switch).
When using this function, refer to section 5.2 “Turning Stop Position
Monitoring Function VALID/INVALID” and connect the dual signal.
If the movement of each axis is detected, the following alarm occurs and
the servo power is turned OFF.
Alarm 4704: “STOPPING POS. MON. ERR (SAFETY)
Countermeasure:
(1) Short-circuit the GSIN signal.
(2) Reset the alarm.
NOTE
5.2
If the system consists of multiple control groups (e.g. robot
+ external axis), the stop position monitoring cannot be
performed for each axis separately. The monitoring is
performed only for the whole controller.
Turning Stop Position Monitoring Function VALID/INVALID
The combination of the VALID/INVALID status of the stop position
monitoring function and the ON/OFF status of the signal is shown in
Table 5-1 &quot;VALID/INVALID Setting of Stop Position Monitoring Function&quot;
on page 5-2 and the connection diagram is shown in section 5-1
“Connection Diagram Example” on page 5-2.
If the functional safety unit detects the inconsistency of GSIN signal, the
following alarm occurs:
Alarm 4705: “SIGNAL COMPARISON ERROR (SAFETY)”
Subcode 40, 41: GSIN SIGNAL INCONSISTENT
5-1
HW0486052
41/61
157863-1CD
Functional Safety Unit
(NSU01)
5 Stop Position Monitoring Function
5.2 Turning Stop Position Monitoring Function VALID/INVALID
Table 5-1: VALID/INVALID Setting of Stop Position Monitoring Function
Status
Signal
Terminal
INVALID
ON
GSI01+/GSI01-
ON
GSI02+/GSI02-
OFF
GSI01+/GSI01-
OFF
GSI02+/GSI02-
OFF
GSI01+/GSI01-
ON
GSI02+/GSI02-
ON
GSI01+/GSI01-
OFF
GSI02+/GSI02-
VALID
VALID
VALID
Remarks
Default setting
Input signal
inconsistent alarm
occurs
Input signal
inconsistent alarm
occurs
Fig. 5-1: Connection Diagram Example
Remove the jumper cable.
Functional safety unit
5-2
HW0486052
42/61
157863-1CD
Functional Safety Unit
(NSU01)
5 Stop Position Monitoring Function
5.2 Turning Stop Position Monitoring Function VALID/INVALID
CAUTION
•
Connect an independent switch (dry contact) for the signal.
If the semiconductor output (*periodic OFF check diagnosis) is
directly connected, the input circuit may malfunction.
The signal must be received by a control device such as a safety
relay unit before connecting the contact signal.
Note that an appropriate control device must be used to achieve the
safety function.
•
The load current of 24 VDC/8.5 mA (typ) flows through each input
circuit.
For the connection, use a switching device capable of switching
24 VDC at 8.5 mA (typ).
•
The dual input signals are checked whether they are synchronized.
Set the dual input signals as the signals which turn ON and OFF
simultaneously. If the dual input signal’s turning ON and OFF are
different in timings with 500 ms or more, the alarm of “INPUT
SIGNAL ERROR” occurs.
•
A screwless terminal block is used as the terminal block 151XT.
See below for the applicable wire and wire termination.
Applicable wire: 0.3 to 1.0 mm dia. (AWG 28 to 18)
0.08 to 1.25 mm2 (AWG 28 to 16)
* When using a ferrule, a wire of up to 0.5 mm2
(AWG20) is applicable.
* Wire strip size (mm)
8
Solid wire
Stranded wire
Ferrule
5-3
HW0486052
43/61
157863-1CD
Functional Safety Unit
(NSU01)
6
6 Data Protection
6.1 Saving Dual Data
Data Protection
6.1
Saving Dual Data
The data related to this function is saved in a duplicated manner for safety.
When the control power is turned ON, check is performed to see that dual
data sets are the same.
If they are different when the control power is turned ON, the following
alarm occurs.
When the following alarm occurs, set up data according to the procedure
described in section 6.2 “Operation When VERIFY ERROR Occurs” on
page 6-2.
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]”
If the alarm occurs, the following causes are possible:
• The data related to this function is loaded from an external storage.
• The home position calibration or the home position change operation
is performed.
• The tool calibration operation is performed.
• The data saving has not been performed correctly.
• The zeroing function is performed.
NOTE
When the zeroing function is performed, make sure to
perform “Safety Unit FLASH Reset“ after recalibrating the
home position.
6-1
HW0486052
44/61
157863-1CD
Functional Safety Unit
(NSU01)
6.2
6 Data Protection
6.2 Operation When VERIFY ERROR Occurs
Operation When VERIFY ERROR Occurs
If the following alarm occurs when the control power is turned ON,
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]”
perform the following operations to re-set the data of the functional safety
unit.
1. When the controller power is turned ON,
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]” occurs
and the maintenance mode is started up.
– Select {SYSTEM} under the main menu. Then, change the security
mode from EDIT MODE to MANAGEMENT MODE with the
procedure described in section 3.1 “Changing Security Mode” on
page 3-1.
2. Select {FILE} under the main menu. Then, select {INITIALIZE} under
the sub menu.
6-2
HW0486052
45/61
157863-1CD
Functional Safety Unit
(NSU01)
6 Data Protection
6.2 Operation When VERIFY ERROR Occurs
3. Move the cursor to “Safety Unit FLASH Reset” and press [ENTER].
4. The dialog box “Reset?” is displayed. Select [YES].
– The data of the safety unit is re-set. A few seconds later, the buzzer
sounds and the data setting is completed.
5. When the data reset is completed, turn the control power OFF and
then turn the power ON again.
NOTE
To set the safety unit data, the security mode must be
MANAGEMENT MODE or higher. Thus, the administrator
or a user with higher privilege must perform these settings.
6-3
HW0486052
46/61
157863-1CD
Functional Safety Unit
(NSU01)
7
7
System Output Signal
System Output Signal
The signals output while using the functional safety unit are shorn below.
50917
50916
50915
50914
50913
50912
50911
50910
SOUT#728
SOUT#727
SOUT#726
SOUT#725
SOUT#724
SOUT#723
SOUT#722
SOUT#721
SF. UNIT
CONNECT
• 50910: SF. UNIT CONNECT
When one or more functional safety units (NSU01) are connected
with the system, this signal turns ON.
50937
50936
50935
50934
50933
50932
50931
50930
SOUT#744
SOUT#743
SOUT#742
SOUT#741
SOUT#740
SOUT#739
SOUT#738
SOUT#737
MONITOR
RANGE
(R8)
MONITOR
RANGE
(R7)
MONITOR
RANGE
(R6)
MONITOR
RANGE
(R5)
MONITOR
RANGE
(R4)
MONITOR
RANGE
(R3)
MONITOR
RANGE
(R2)
MONITOR
RANGE
(R1)
• 50930 to 50937: MONITOR RANGE (R1 to 8)
This signal shows the operation status of the safety range function
for each robot. Set VALID/INVALID to turn ON/OFF this signal on
the ROBOT RANGE window. (Refer to section 3.4 “Setting Safety
Range for Robot” on page 3-7.)
50947
50946
50945
50944
50943
50942
50941
50940
SOUT#752
SOUT#751
SOUT#750
SOUT#749
SOUT#748
SOUT#747
SOUT#746
SOUT#745
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
NO.: d0 (R8) NO.: d0 (R7) NO.: d0 (R6) NO.: d0 (R5) NO.: d0 (R4) NO.: d0 (R3) NO.: d0 (R2) NO.: d0 (R1)
50957
50956
50955
50954
50953
50952
50951
50950
SOUT#760
SOUT#759
SOUT#758
SOUT#757
SOUT#756
SOUT#755
SOUT#754
SOUT#753
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
NO.: d1 (R8) NO.: d1 (R7) NO.: d1 (R6) NO.: d1 (R5) NO.: d1 (R4) NO.: d1 (R3) NO.: d1 (R2) NO.: d1 (R1)
• 50940 to 50947: RANGE NO.: d0 (R1 to 8)
• 50950 to 50957: RANGE NO.: d1 (R1 to 8)
When the safety range switch function is used (refer to section 3.6
“Switching Safety Range” on page 3-12), the monitored safety range
number for each robot is shown. The ranges 1 to 4 are indicated by
the combination of 2 bits, d0 and d1.
Selected safety range
No.
d1
d0
1
OFF
OFF
2
OFF
ON
3
ON
OFF
4
ON
ON
7-1
HW0486052
47/61
157863-1CD
Functional Safety Unit
(NSU01)
8
8
Alarm
Alarm
Alarm
No.
Message
Explanation
0020
CPU COMMUNICATION
ERROR
The connected board’s presence was not confirmed.
This alarm also occurs when an error is detected in the serial
communication via YIF01, EAXA01, YGW01, and NSU01.
Subcode 1: YCP01 (main CPU board)
50 to 57: EAXA01, YGW01
60 to 67: NSU01, YGW01
0021
COMMUNICATION ERROR
(SERVO)
An error is detected in the serial communication via YIF01, EAXA01,
YGW01, and NSU01.
Subcode 50 to 57: EAXA01, YGW01
60 to 67: NSU01, YGW01
0110
to
0117
COMMUNICATION ERROR
(SU#1 to 8)
An error is detected in the serial communication via YIF01, EAXA01 ,
YGW01, and NSU01. The last digit of the alarm number indicates the
node number.
Alarm 0110: the 1st node of YGW01, the 1st node of NSU01
Alarm 0111: the 2nd node of YGW01, the 2nd node of NSU01
0300
VERIFY ERROR (SYSTEM
CONFIG-DATA)
The DX100 has detected an error in the validity check on the data files
between YCP01 and the safety unit (NSU01) when the power is
turned ON. Execute “Safety Unit FLASH Erase” in the maintenance
mode.
This alarm also occurs when the functional safety unit is replaced with
the unit whose data has not been set.
0400
PARAMETER
TRANSMISSION ERROR
An error is detected in the parameter transmission via YIF01,
EAXA01, YIF, and NSU01.
Subcode: same as the alarm 0021
0410
MODE CHANGE ERROR
The DX100 changes its operation modes during a startup process
from the power-on operation until the startup process completion. An
unsuccessful mode change was detected.
Subcode: same as the alarm 0021
0510
SOFTWARE VERSION
UNMATCH
The combination of software is incorrect.
Subcode 60: The software version of the functional safety unit
(NSU01) is incorrect.
1610
SAFETY UNIT CPU
SYNCHRO ERROR
The DX100 has detected an error in the communication between
YCP01 and the safety unit (NSU01) when the power is turned ON.
Check the cables and connectors between these boards, then turn
the power OFF and ON again.
1612
COMMUNICATION ERROR
(SAFETY)
There is a communication error between YIF01 and NSU01. There
may be poor contact of connectors. Check the cables and connectors
between these boards, then turn the power OFF and ON again.
1613
ENCODER COMM. ERR 1
(SAFETY)
The DX100 has detected an error in the communication between the
encoder (each axis) and the safety unit (NSU). Check the encoder
cables, then turn the power OFF and ON again.
1614
ENCODER COMM. ERR 2
(SAFETY)
The DX100 has detected an error in the communication between the
encoder (all axes) and the safety unit (NSU). Check the encoder
cables and connectors, then turn the power OFF and ON again.
1615
SYSTEM ERROR (SAFETY)
NSU01 could not execute the process successfully.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1616
SYSTEM ERROR 1
(SAFETY)
NSU01 could not execute the process successfully.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
8-1
HW0486052
48/61
157863-1CD
Functional Safety Unit
(NSU01)
8
Alarm
Alarm
No.
Message
Explanation
1618
ARITHMETIC ERROR
(SAFETY)
NSU01 detected an arithmetic error.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1619
PARAMETER ERROR
(SAFETY)
NSU01 detected an error in the setting value of parameter or file.
Check for an error in the setting of the safety range, then turn the
power OFF and ON again. If this alarm occurs frequently, replace
NSU01 unit.
1622
DEFECTIVE ENCODER
(SAFETY)
NSU01 detected an error in the encoder data.
Check the encoder cables, then turn the power OFF and ON again.
1623
ENCODER CORR. NUM
OVER (SAFETY)
Reading encoder data failed multiple times in a row.
Turn the power OFF and ON again.
If this alarm occurs again, replace NSU01 unit.
1625
OPERATION AREA MON.
ERR (AXIS)
The safety unit (NSU01) has detected the manipulator motion
exceeding the safety range of each axis. Check the teaching points
and range setting.
1628
STOPPING POS. MON. ERR
(SAFETY)
The function safety unit (NSU01) has detected the manipulator motion
during the stop monitoring function is activated.
Confirm that CNGS1. 0 is connected to the NSU.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace the NSU01 unit.
1629
OPERATION AREA MON.
ERR (ROBOT)
The safety unit (NSU01) has detected the manipulator motion
exceeding the safety range. Check the teaching points, range setting,
and motion speed near the edge of the range.
The function safety unit cannot be used with the tool file number
change.
In the case of [S2C431: specifies switching the tool No.] is [1: able to
switch], change the setting as follows.
R1: Tool interference file No. is 0
R2: Tool interference file No. is 1
R3: Tool interference file No. is 2
R4: Tool interference file No. is 3
1630
MUTUAL DIAGNOSIS ERR
(WDT)
Data inconsistency occurred in the duplicated monitoring by the safety
unit (NSU01). One CPU detected an error in the timing check of the
other.
This alarm may be accompanied by the alarm 1610 and 1615.
Turn the power OFF and ON again.
1631
MUTUAL DIAGNOSIS ERR
(HW SETTING)
Data inconsistency occurred in the duplicated monitoring by the safety
unit (NSU01). The hardware setting failure of one of the dual systems
was detected.
This alarm may occur due to the failure of the rotary switch. Turn the
power OFF and ON again.
Subcode 1: rotary switch setting error
2: other errors
1632
MUTUAL DIAGNOSIS ERR
(MONITOR)
Data inconsistency occurred in the duplicated monitoring by the safety
unit (NSU01). Turn the power OFF and ON again. This alarm occurs
when an error was detected in one of the CPUs.
1633
SIGNAL COMPARISON
ERROR (SAFETY)
The function safety unit is configured by duplicated systems to check
the operations each other. Signal inconsistency status has continued
for more than 500msec among two systems.
Check the connectors, and then Turn the power OFF and ON again.
If this alarm occurs frequently, replace the NSU01 unit.
1634
FEEDBACK SIGNAL ERROR
(SAFETY)
Data inconsistency occurred in the feedback monitoring of the safety
signal outputs. Check the safety signal cables, then turn the power
ON again.
&lt;Check point&gt; Connectors and cables of NSU01: CNLO, CNSF 1 to 4
8-2
HW0486052
49/61
157863-1CD
Functional Safety Unit
(NSU01)
8
Alarm
Alarm
No.
Message
Explanation
1635
LOW VOLTAGE (SAFETY)
The internally-generated voltage of NSU01 fell below the low voltage
threshold. The failure of the unit may have occurred. Replace
NSU01 unit.
1636
OVER VOLTAGE (SAFETY)
The internally-generated voltage of NSU01 exceeded the over voltage
threshold. The failure of the unit may have occurred. Replace
NSU01 unit.
1637
RAM DIAGNOSIS ERROR
(SAFETY)
An error was detected by the hardware diagnosis of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1639
RAM AREA CONVERSION
ERR (SAFETY)
An error was detected by the hardware diagnosis of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1640
REAL TIME MONITOR
ERROR (SAFETY)
An error was detected by the hardware diagnosis of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1641
SAFETY OUTPUT FB
ERROR (SAFETY)
An error was detected in the connection between NSU01 and another
unit. Check the safety signal cables, then turn the power OFF and
ON again.
&lt;Check point 1&gt; communication cable between NSU01 (CNSF1
connector) and YSU (CN207 connector)
&lt;Check point 2&gt; communication cable between NSU01 (CNSF1
connector) and YPU (CN609 connector)
1642
WATCHDOG SIGNAL
ERROR (SAFETY)
An error was detected by the hardware diagnosis of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1643
SIGNAL SETTING ERROR
(SAFETY)
When a multiple robot system (with 2 or more manipulators) is used,
the DX100 has detected an error in the link signal between the safety
units (NSU01) or in the jumper cable setting of NSF02 board. Turn
the power OFF and then ON again.
&lt;Check point&gt; CNLO connector of NSU01 of the first robot, CNLI
connector of NSU01 of the second robot, and the cables between the
connectors
&lt;Check point&gt; The jumper cable setting of NSF02 board of the rotary
switch (Refer to Chapter 11 &quot;Unit Setting (Precautions for
exchange)&quot;.)
1644
24V LOW VOLTAGE
(SAFETY)
The externally supplied 24V voltage for NSU01 is not supplied.
Check the fuse, power supply connector, and cables of NSU01.
&lt;Check point&gt; F2, F3 fuses, CN01 connector, and power cable of
NSU01
1645
CRC ERROR (SAFETY)
An error was detected in the stored data of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1646
COMM. SETTING ERROR
(SAFETY)
An error was detected by the hardware diagnosis of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1647
DETECT
DISCONNECTION
(NSU-YSU)
Communication between CNSF connector of the NSU and CN207
connector of the YSU has been disconnected.
Check the all communication cables between NSU (CNSF1
connector) and YSU (CN207 connector).
8-3
HW0486052
50/61
157863-1CD
Functional Safety Unit
(NSU01)
8
Alarm
Alarm
No.
Message
Explanation
1648
PENDANT MODE SIGNAL
ERROR
A mode signal error has been detected.
Check the connection of the following communication cables.
• Communication cables between NSU board (CNMA
connector) and YCU board (CNNSU0, CNYSU0).
• Communication cables between YIF01 board (CN13) and
EAXA board (CN515, CN516).
• Communication cables between EAXA board (CN517) and
YSU01(CN202).
4208
SYSTEM ERROR (ARITH)
A teaching point is set outside the range. Check the teaching points
and range setting.
4676
BROKEN FAN FUSE
The fuse(3FU/4FU) is blown in the YPU unit.
Check if there is a ground fault or short circuit of the power line to the
fan.
Sub code 1 to 8: EAXA/EAXB board No. where the alarm occurred.
Sub code 101: FAN ALARM 4: DIRECT-IN (SYSTEM)1
Sub code 102: FAN ALARM 5: DIRECT-IN (SYSTEM)2
Sub code 103: FAN ALARM 6: DIRECT-IN (SYSTEM)3
Sub code 104: FAN ALARM 7: DIRECT-IN (SYSTEM)4
4679
SPECIFIED MOTION RANGE Upper YCP01 detected that the range whose setting and confirmation
ERROR
are not completed is selected.
Check the status of range selection signal and the setting of the safety
range.
4680
SAFETY UNIT COMMAND
ERROR
An error is detected in the serial communication via YIF01, EAXA01,
YGW01, and NSU01. This alarm may be accompanied by the alarm
0020 or 0100. Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4682
MOTION RANGE LIMIT
INTERFERENCE
Upper YCP01 detected the manipulator motion exceeding the safety
range. Check the teaching points and range setting.
4683
AXIS MOTION RANGE LIMIT Upper YCP01 detected the motion of each axis exceeding the safety
range. Check the teaching points and range setting.
4685
WRITE ERROR (SAFETY)
Data was not recorded successfully in the functional safety unit.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4686
DATA SETTING
ERROR (SAFETY)
An error occurred when setting the data in the function safety unit
(NSU01).
Reset the alarm, and then try again after turning the power OFF and
ON again.
4687
OPERATION AREA MON.
ERR 2 (AXIS)
The safety unit (NSU01) detected the motion of each axis exceeding
the safety range. Check the teaching points and range setting.
4688
OPERATION MODE ERROR
(AXIS)
Reset the alarm, and then turn the power OFF and ON again.
4689
OPERATION AREA MON.
ERR 2 (ROBOT)
The safety unit (NSU01) detected the manipulator motion exceeding
the safety range. Check the teaching points and range setting.
The function safety unit cannot be used with the tool file number
change.
In the case of [S2C431: specifies switching the tool No.] is [1: able to
switch], change the setting as follows.
R1: Tool interference file No. is 0
R2: Tool interference file No. is 1
R3: Tool interference file No. is 2
R4: Tool interference file No. is 3
4690
OPERATION MODE ERROR
(ROBOT)
Reset the alarm, and then turn the power OFF and ON again.
8-4
HW0486052
51/61
157863-1CD
Functional Safety Unit
(NSU01)
8
Alarm
Alarm
No.
Message
Explanation
4691
OPERATION AREA SET ERR The safety unit (NSU01) detected that the range whose setting is not
(SAFETY)
completed is selected.
Check the status of range selection signal and the setting of the safety
range.
4692
ENCODER BACKUP ERROR
(SAFETY)
This alarm occurs when the voltage of encoder battery drops.
Replace the encoder battery.
&lt;Check point&gt; CN03A connector and connection cables of NSU01
4693
READBACK PROC. ERROR
(SAFETY)
An error was detected in the readback process at the data change
between NSU01 and the programming pendant.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4694
SPEED MONITOR ERROR 1
(SAFETY)
The speed at TCP exceeded the safety speed. Lower the operation
speed.
The function safety unit cannot be used with the tool file number
change.
In the case of [S2C431: specifies switching the tool No.] is [1: able to
switch], change the setting as follows.
R1: Tool interference file No. is 0
R2: Tool interference file No. is 1
R3: Tool interference file No. is 2
R4: Tool interference file No. is 3
4695
SPEED MONITOR ERROR 2
(SAFETY)
The speed at the manipulator flange exceeded the safety speed.
Lower the operation speed.
The function safety unit cannot be used with the tool file number
change.
In the case of [S2C431: specifies switching the tool No.] is [1: able to
switch], change the setting as follows.
R1: Tool interference file No. is 0
R2: Tool interference file No. is 1
R3: Tool interference file No. is 2
R4: Tool interference file No. is 3
4703
OPERATION MODE ERROR
An error was detected by the internal diagnosis of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4704
STOPPING POS. MON. ERR
(SAFETY)
NSU01 detected that the robot moved when the stop position
monitoring function was enabled.
Check the status of GSIN signal, set GSIN signal to the short-circuit
status, then reset the alarm.
4705
SIGNAL COMPARISON
ERROR (SAFETY)
Data inconsistency occurred in the duplicated monitoring of the safety
signals. Check the safety signal cables, then turn the power ON
again.
&lt;Check point&gt; Connectors and cables of NSU01: CNMA, CNMB,
CNIFA, CNIFB, and CNSF 1 to 4
Subcode 1: Signal inconsistency in PPDSW
5: Signal inconsistency in YCU02 board A to D
3: Signal inconsistency in YCU02 board E to H
40: Signal inconsistency in GSIN signal
41: Signal inconsistency in GSIN signal
NOTE
Investigation is required If the error occurs again. Contact
your Yaskawa representative.
8-5
HW0486052
52/61
157863-1CD
Functional Safety Unit
(NSU01)
8

Alarm
7 segment LED indication of safety unit NSU01
7 segment LED indication of safety unit NSU01 are as follows.
(Left side LED: CPU1, Right side LED: CPU2)
7 seg. LED indication
Status
All Lit
After power on
[0] to [C]
Under boot up
[d]
Normal status
[E]
Error status
8-6
HW0486052
53/61
157863-1CD
Functional Safety Unit
(NSU01)
8
Alarm
When an error occurs in safety unit, 5 digits LED are indicated with 7 seg.
LED.
Each digit is indicated for 1.0sec and all turning off status is for 0.3sec.
Following is the example of “F001.” error.
Sequence 7 seg. LED indication
Indication time
Total time
1
[F]
1.0 [sec]
1.0 [sec]
2
Turning off
0.3 [sec]
1.3 [sec]
3
[0]
1.0 [sec]
2.3 [sec]
4
Turning off
0.3 [sec]
2.6 [sec]
5
[0]
1.0 [sec]
3.6 [sec]
6
Turning off
0.3 [sec]
3.9 [sec]
7
[1]
1.0 [sec]
4.9 [sec]
8
Turning off
0.3 [sec]
5.2 [sec]
9
[.]
1.0 [sec]
6.2 [sec]
10
Turning off
0.3 [sec]
6.5 [sec]
Meaning of 7 segment LED indication are as follows.
5 digits
Error meaning
indication
code
F001.
F002.
Cause
Communication
error
Data communication error occurs.Check cable
wiring and a terminator then power on again.
CPU error
CPU internal error occurs.
Power on again.
F003.
F004.
F010.
0100.
0200.
0210.
0300.
0400.
0500.
0600.
0700.
0800.
0900.
0C00.
0D00.
1000.
1100.
1200.
1300.
1400.
NOTE
Investigation is required If the error occurs again. Contact
your Yaskawa representative.
8-7
HW0486052
54/61
157863-1CD
Functional Safety Unit
(NSU01)
9
9
Error
Error
Error No. data Message
Contents
381
-
Robot range not checked.
Please perform chapter 3
“Setup (Safety Range Function
for Robot)” in this manual.
(157863-1CD)
382
-
Axis range not checked.
Please perform chapter 4
“Setup (Safety Range Function
for Each Axis)” in this manual.
(157863-1CD)
9-1
HW0486052
55/61
157863-1CD
Functional Safety Unit
(NSU01)
10 Restrictions
10.1 Confirming Safety Range and Robot Position
10 Restrictions
10.1
Confirming Safety Range and Robot Position
This function also records parameters, files and other data in the safety
unit.
Therefore, this function cannot be used with a function that changes
parameters or files during playback.
• T axis endless function and external axis endless function
• PMT function
• Gun change function and group change function
• Tool file number change
10.2
Software Version of Machine Safety Unit
This function checks the signals from the functional safety unit in the
machine safety unit (YSU01-1E). The machine safety unit must have the
following version:
YSU01-1: 1.08-00 or later
If the YSU version is earlier than the above version, ALARM 510
“SOFTWARE VERSION UNMATCH [70]” occurs.
10-1
HW0486052
56/61
157863-1CD
Functional Safety Unit
(NSU01)
10.3
10 Restrictions
10.3 Software Version of Functional Safety Unit
Software Version of Functional Safety Unit
The functional safety unit (NSU01) must have the following version:
NSU01: V3.00-00 or later
If the NSU version is earlier than the above version, ALARM 510
“SOFTWARE VERSION UNMATCH [70]” occurs.
10.4
System Restrictions
There are the following restrictions to use this function.
• This function cannot be used on the system using 5 or more robots.
• This function cannot be used on the system using 36 or more axes.
• When the functional safety unit is applied to the system 24 or more
tools, ALARM4693 “READBACK PROC. ERROR (SAFETY)”
occurs. In this case, initialize the TOOL.CND file in the maintenance
mode.
• One servo board cannot be used for 2 or more robots.
• In the case of the system with the servo track, the robot and the
servo track cannot be connected to different servo boards. Connect
them to the identical servo board.
• Connect one control group to the identical servo board.
• This function cannot be used on the system using the twin drive
function to the robot axis or the servo track.
10-2
HW0486052
57/61
157863-1CD
Functional Safety Unit
(NSU01)
11
Unit Setting (Precautions for exchange)
11 Unit Setting (Precautions for exchange)
When NSU01 unit is exchanged, the rotary switch and the jumper cable
setting is necessary for each robot.
Following boxes indicate the location of the rotary switch and the jumpers.
• Rotary switch
Setting for serial communication number.
• Jumpers
Serial communication setting for start and termination in case of
multi NSU01 units connection for multi robot system.
11-1
HW0486052
58/61
157863-1CD
Functional Safety Unit
(NSU01)
11
Unit Setting (Precautions for exchange)
1. One robot system setting
057,#0%&amp;05(
5(7.
5* 5(7.
5*
1
5 2
3
1
2 5
3
$ % &amp;'
1
2 5
3
#
1
5 2
3
5
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
( 1
2 5
3
1
5 2
3
5(7.
/2% 5(7.
/2%
1
1
2 5
5 2
3
3
5(7.
5* 5(7.
5*
057,#0%&amp;05(
5
5(7.
/2% 5(7.
/2%
2. Two robots system setting (Upper: R1, Lower: R2)
057,#0%&amp;05(
1
2 5
3
$ % &amp;'
057,#0%&amp;05(
5(7.
/2% 5(7.
/2%
1
5 2
3
1
2 5
3
1
5 2
3
1
2 5
3
5
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
$ % &amp;'
1
2 5
3
#
1
5 2
3
( 1
2 5
3
1
5 2
3
5(7.
5* 5(7.
5*
#
5(7.
/2% 5(7.
/2%
057,#0%&amp;05(
5(7.
5* 5(7.
5*
5
5(7.
5* 5(7.
5*
1
5 2
3
( 1
2 5
3
5
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
5UJQTVEKTEWKV
1
5 2
3
5(7.
/2% 5(7.
/2%
1
1
2 5
5 2
3
3
5(7.
5* 5(7.
5*
1
1
2 5
5 2
3
3
057,#0%&amp;05(
5
5(7.
/2% 5(7.
/2%
11-2
HW0486052
59/61
157863-1CD
Functional Safety Unit
(NSU01)
Revision History
Revision History
Date
CEN /
ECN
8/7/2012
11/30/2012
7/12/2013
10/6/2014
12-1314M
13-0833M
14-1235M
Revision
No.
Reason For Revision
Initials
4
Revise manual per HW0486052 Rev 3.
JFC
JFC
5
Modify pages: 8-2 through 8-6. Changed Chapter 9 to
Chapter 10 and added a new Chapter 9. Revised per
HW0486052 Rev 4.
6
Updated the 7 segment LED indication of safety unit NSU01 JFC
section. Added Chapter 10 Restrictions
7
1. Add Note box to &quot;Refer to chapter 10 for the restrictions.&quot; JFC
For 1 Preface section.
2. Add the following to section 10.4 &quot;System Restrictions&quot;
• One servo board cannot be used for 2 or more robots.
• In the case of the system with the servo track, the robot
and the servo track cannot be connected to different servo
boards. Connect them to the identical servo board.
• Connect one control group to the identical servo board.
• This function cannot be used on the system using the twin
drive function to the robot axis or the servo track.
A-1
HW0486052
60/61
DX100 OPTIONS
INSTRUCTIONS
FOR FUNCTIONAL SAFETY UNIT (NSU01)
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703
Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200
Fax +1-937-847-6277
YASKAWA Europe GmbH
Robotics Divsion )
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100
Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 v&aring;n. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800
Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.
22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200
Fax 㧗86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&amp;T Development AreaChina 100176
Phone +86-10-6788-2858
Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)
#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500
Fax +91-124-475-8542
YASKAWA Electric Korea Co., Ltd
9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844
Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333
Fax +886-2-8913-1513
YASKAWA Electric (Singapore) PTE Ltd.
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003
Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.
252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek Road㧘Huaykwang, Bangkok 10320, Thailand
Phone +66-2693-2200
Fax +66-2693-4200
PT. YASKAWA Electric Indonesia
Menara Anugrah Lantai 1, Kantor Taman E.3.3, JI Mega Kuningan Lot 8.6-8.7, Kawasan
Mega Kuningan, Jakarta, Indonesia
Phone +62-21-57941845
Fax +62-21-57941843
Specifications are subject to change without notice
for ongoing product modifications and improvements.
MANUAL NO.
HW0486052
6
61/61
">

こんにちは！私はAIチャットボットで、YASKAWA DX100 NSU01 Functional Safety Unit Instructionsに関するサポートをするために特別にトレーニングされています。すでにドキュメントを徹底的に確認しており、必要な情報を正確に見つけたり、内容をわかりやすく説明したりできます。特定の機能に関するガイダンス、トラブルシューティングの手順、または一般的な使い方について知りたい場合でも、遠慮なく質問してください。問題やニーズについて詳細を教えていただければ、より正確かつ効果的にお手伝いできます！