YASKAWA Motoman DX200 User Manual

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Document

ROBOTICS

Installation and Wiring

Robot controller

User manual

Created on:

Revision:

2015-10

Document number: E1102000143GB06 Author: WOE

Changes made in revision:

Rev. 01: Revision in YEU-R style

Rev. 02: Revision of the entire manual

Rev. 03: Added chapter recommended spare parts (11-2013

Rev. 04: Added chapter robot controller specification, Revised version of the original RE-

CTO-A220.5 (2015-01)

Rev. 05: Revision of the chapter: Wiring

Rev. 06: Correction of the chapter „Connection to main power supply“ and „Connection of the robot controller“/ Cover new in all languages (2015/WAC)

This documentation – also in part – may be reproduced or made available to third parties only with the express approval of YASKAWA Europe "Robotics Division GmbH".

We have checked the content of this publication for compliance with the hardware described.

Nevertheless, discrepancies cannot be ruled out. Therefore, we cannot guarantee full compliance.

However, the information given in this publication is checked regularly and any necessary corrections will be made in subsequent editions.

Subject to technical modifications.

Table of contents

1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.7.1 For your security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.7.2 YASKAWA manual list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.7.3 Personal protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.7.4 Safety during installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.8 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.9 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.2 Position type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.1 Transporting method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.1.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.1.2 Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.1.3 Using a lifting truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.1 Protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2 Ambient conditions and installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3 Installation options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 Notes on cable junctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2 Power supply / feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2.1 Installing residual current circuit breakers (optional) . . . . . . . . . . . . . . . . . . . . . 33

5.2.2 Installation of primary power supply breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.3 Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.3.1 Connection to main power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.3.2 Connection of the robot controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.3.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.1 Basic specifications robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.2 Programming pendant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Table of contents

7 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.1 Periodic inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2 Cooling fan inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.3 Emergency Stop Button Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.4 Inspection of the enabling switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.5 Check battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.6 Check the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.7 Open Phase Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8 Description of Units and Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.1 Power ON unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.2 Axes control circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.2.1 Major axes control circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.2.2 External axes control circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.3 CPU unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.3.1 Unit and circuit board in the CPU unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.4 CPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.5 Machine safety I/O logic circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.5.1 Connection for tool shock sensor (SHOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.6 Machine safety terminal block circuit board (JANCD-YFC22-E). . . . . . . . . . . . . . . . . . . 59

8.7 External emergency stop signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

8.8 Safety plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

8.9 Installation of safety plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.10 External enable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.11 Full speed test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

8.12 Slow speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

8.13 External hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

8.14 External SERVO-ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

8.15 SYSRUN Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.16 External axes overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8.17 SERVO-ON enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

8.18 Emergency stop button output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

8.19 Universal safety input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

8.20 Universal safety output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

8.21 Direct-in (SERVO) 1 to 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

8.22 Universal input (SERVO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8.23 Universal output (SERVO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8.24 Universal I/O circuit board (JANCD-YIO22-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

8.25 Brake control circuit board (JANCD-YBK21-3E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.26 Converter (SRDA-COA30A21B-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

8.27 Capacitor module (SRDA-CUA  AA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

8.28 Amplifier module (SDRA-SDA  A01A-E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

8.29 Assignment of general I/O signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

8.29.1 ARC welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8.29.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.29.3 General application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.29.4 Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8.29.5 JANCD-YEW01-E circuit board (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Table of contents

8.29.6 The list of the Equipment configuration by model. . . . . . . . . . . . . . . . . . . . . . . 105

9 Robot controller specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

9.1 Specification list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

9.2 Function list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

9.3 Programming Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

9.4 Device configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

10 Recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

General

1 General

1.1 Notes for safe operation

DANGER!

Indicating immediate danger at high risk, hazard that can cause death or serious bodily injuries if no precautions are taken.

WARNING!

Indicating possible medium risk hazard situation which can cause death or serious bodily injuries if it is not avoided.

CAUTION!

Indicating potentially dangerous situation with low risk of minor or moderate bodily injuries result if it is not avoided. This signal word can also be used for property damage warnings.

1.2 Frequently used terms

The YASKAWA robot is a product of YASKAWA Electric Corporation, and is provided by default with the robot control, the programming pendant and robot cable.

The terms are designated as follows in this manual:

Term

Control

Industrial robot

Programming pendant / teach box

Supplying cable between robot and robot control

Robot, robot control and cable

Yaskawa Electric Corporation

YASKAWA Robotics Division

Moving, calibrating and setting up of the robot

Movement sequences of the robot

Technical customer service

Description

Robot control

Robot

Programming pendant

Cable

Robot system

YEC

YEU-R

Teachen

JOBs

TCS

General

1.3 Target group

This manual is directed at users with the following knowledge:

• Advanced knowledge of mechanical engineering

• Advanced knowledge of electrical engineering

• System knowledge of the robot control

• Specially trained staff

NOTICE

According to the international DIN EN ISO 10218-1 standard, operators of a robot system must receive training before they operate the robot.

For optimal use of our products, we recommend our customers to take part in a training session at the YASKAWA Academy. For more detailed information on the training programme, please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA branch office.

1.4 Intended use

Typical applications:

• Flange-mounting tools

• Installation of spot welding guns

• Installation of arc welding equipment

• Installation of grippers

• Machining and transporting workpieces or products

General

1.5 Improper use

Any use that deviates from the intended use shall be regarded as impermissible misuse.

This includes:

• Transport of people and animals

• Use as ascending aid.

• Use outside the permissible operating limits.

• Use in environments with risk of explosion (except for ATEX-approved robots).

• Overload

• Use without protective equipment.

NOTICE

Modifications to the robot, e.g. drilling holes or similar modifications, can damage parts.

This will be regarded as improper use (i.e. use that deviates from the intended use) and will lead to loss of warranty and liability claims as well as loss of the declaration of incorporation.

CAUTION!

The robot system is an incomplete machine.

The robot system may be put into operation only after it has been determined that the incomplete or complete machine in which the robot system is being installed:

 Corresponds to the provisions of the machinery directive.



Complies with all relevant (harmonized) standards.

 Corresponds to the state of the art.

General

1.6 About this manual

• This manual explains the various components of the robot controller and the general operating functions. Be sure to read and understand this instruction manual thoroughly before installing and operating the robot controller.

• To ensure correct and safe operation, read the robot controller operating instructions

(Basic Information, Installation and Wiring and System Setup).

• In order to illustrate details clearly, some drawings are shown with the protective covers or shields removed. All protective covers and shields must be mounted before the robot is operated.

• The drawings and figures in this manual are representative illustrations. They may differ from the product delivered.

• YEU-R reserves the right to make technical changes. These changes may include product improvements, modifications or changes in specifications

• If your copy of the operating and maintenance instructions is damaged or lost, please contact the local YASKAWA branch office to order a new copy. The official branch offices are listed on the last page. Please mention the manual number in your order.

• YASKAWA Europe GmbH is not responsible for damage caused due to unauthorized modification of the system. If any impermissible modifications are made to the system and to the robot, all warranty and liability claims as well as the declaration of incorporation will expire.

Descriptions of the programming pendant, buttons, and displays are shown as follows

Programming pendant

Character keys

Symbol keys

Mode selection switch

Manual designation

The keys which have characters printed on them are denoted with [ ], e. g. [ENTER]

The keys which have a symbol printed on them are illustrated with a small picture.

e. g. There is no picture for the cursor key.

Three kinds of modes that can be selected by the mode key are denoted as follows: REMOTE, PLAY and

TEACH

Keys There are three keys on the programming pendant, which are referred to as follows: HOLD key; START key; Emergency stop button

Controlling the axes Axis keys

Numeric keys Number input

Simultaneously pressed keys A plus sign between the keys indicates that it is necessary to press two keys simultaneously.

e.g. [SHIFT]

SHIFT

+ [COORD]

TOOL SEL

COORD

Display The menu displayed is denoted with { }.

e.g. {JOB}

General

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.

• that the item is directly selected by touching the screen.

Registered Trademark

The names of companies and/or products used in this manual are trademarks. The indications of ® and



are omitted.

1.7 Safety

REMOTE

PLAY

TEACH

START

JOB

EDIT DISPLAY

JOB CONTENT

TEST01

CONTROL GROUP:R1

0000

0001

NOP

SET B000 1

0002

0003

0004

0005

0006

0007

0008

SET B001 0

MOVJ VJ=80.00

DOUT OT#(10) ON

TIMER T=3.00

MOVJ VJ=80.00

MOVJ VJ=100.00

0009

0010

0011

MOVJ VJ=100.00

MOVJ VJ=0.78

UTILITY

S:0000

TOOL:

HOLD

Main Menu Short Cut Turn on servo power

X-

S-

Y-

L-

Z-

U-

E-

MAIN

SIMPLE

SERVO

ASSIST

X+

S+

Y+

L+

Z+

U+

E+

HIGH

SPEED

FAST

MANUAL SPEED

SLOW

X-

R-

Y-

B-

Z-

T-

SHIFT

INTER

LOCK

ROBOT INFORM

LIST

EX.AXIS

WELD

ON/OFF

AUX

MOTION

TYPE

X+

R+

Y+

B+

Z+

T+

SELECT

TEST

START

SHIFT

BWD FWD

DELETE INSERT

MODIFY ENTER

Fig. 1-1: Programming pendant

Emergency Stop button

WARNING!

Death or injury because of danger of crushing

If the emergency stop button does not function properly, the robot cannot be stopped in the event of an emergency.

 The robot should not be used if the emergency stop button does not function.

 Before operating the robot check the function of the emergency stop button. The

SERVO power has to immediately go off once the emergency stop button on the programming pendant has been pressed (seeFig. 1-3: "Emergency Stop button").

 When the SERVO power is turned OFF, the SERVO ON LED on the programming pendant goes off (see Fig. 1-2: "LED SERVO ON").

Fig. 1-2: LED SERVO ON

Fig. 1-3: Emergency Stop button

General

WARNING!

Death or injury because of danger of crushing

Before you release the emergency stop button (see Fig. 1-4: "Release of emergency stop button by turning") note the following:

 Make sure that there is no one within the maximum working range of the robot.

 Clear the cell of all items which could collide with the robot.



Now you can switch ON the SERVO power by pressing the enable switch on the programming pendant.

Fig. 1-4: Release of emergency stop button by turning

WARNING!

Death or injury because of danger of crushing

if anyone enters the working area of the robot during operation or any problems occur, always press the emergency stop button immediately. The emergency stop button is located on the programming pendant (see Fig. 1-1: "Programming pendant").

Observe the following precautions when performing teaching operations within the robot’s working range:

 View the Robot from the front whenever possible.



Always follow the prescribed operating procedure (see the instructions on robot control as well as the operating instructions on "Handling" or "Universal Application").

 An area must be left clear so that the operator can retreat to it in case of emergency.

The following inspection procedures must be performed prior to teaching the robot. If problems are found, correct them immediately, and be sure that all other necessary measures have been performed.

• Check for problems in robot movement.

• Check the connectors for tight fit and all cables for damage.

• Hang the programming pendant back on the robot control after use.

• Make sure that the key for the key switch (Teach/Automatic) of the programming pendant is kept by a skilled person who has been specially trained.

• The key may be inserted in the key switch of the programming pendant only during teach operation; after the teach operation it must be immediately removed and kept in a safe place.

General

1.7.1 For your security

Robots generally have requirements,different from other manufacturing equipment, such as larger working areas, high-speed operation, rapid arm movements, etc., which may pose safety hazards.

Please read and understand the instruction manuals and related documents. Observe all precautions in order to avoid the risk of injury to personnel and damage to equipment.

The user’s responsible for ensuring that all local, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions are met and followed.

CAUTION!

In the Industrial Safety and Health Law teaching and maintaining the robot are specified as

"Hazardous Operations" and teaching maintenance of the robot have to be conform to following rules and regulations:

– Industrial Safety and Health Law.

– Enforcement Order of Industrial Safety and Health Law.

– Ordinance of Industrial Safety and Health Law.

Other related laws are as follows:

– Occupational Safety and Health Act in USA.

– Machinery Directive 2006/42/EC

Fig. 1-5: CE marking

Please note the international standard DIN EN ISO PROTECTED-1, for safe operation of the robot or the jigs of robot.

Increase the efficiency of your safety management system by specifying authorized personnel and safety managers and conduct training regularly.

NOTICE

According to the international DIN EN ISO 10218-1 standard, operators of a robot system must receive training before they operate the robot.

General

1.7.2 YASKAWA manual list

It is important to have all the manuals on the YASKAWA control or robot available and to know their contents. Please make sure you have all these manuals. If you are missing any manual, please contact the local YASKAWA branch office.

You must have the YASKAWA manuals listed below available.

• Beginner's Reference (E1102000144XX01* or higher).

• Install and Wiring (E1102000143XX01* or higher).

• Basic programming (E1102000147XX01* or higher).

• System Setup (E1102000145XX01* or higher).

• Alarm list (E1102000146XX01* or higher).

• Operating and maintenance instructions for the specific robot type.

* "XX" is the language of the document.

1.7.3 Personal protection

The entire working area of the robot is potentially dangerous. The following staff must work with appropriate preparation and subject to the maxim

"Safety First"

to ensure the safety of all.

• Safety management

• Assembly staff

• Operating staff

• Maintenance staff

DANGER!

Death by electric shock; serious injury from fire hazard;

Avoid dangerous actions in the area where the robot is installed. Be sure to take safety precautions

 Unauthorised persons should not have access to the robot.

 Unauthorised persons should not have access to the peripheral equipment.



Put up signs in the respective working area, such as

"Highly flammable"

"High voltage"

"Stop"

and

"No unauthorized access"

WARNING!

There is a risk of injury if there is contact with the robot or peripheral equipment.

Strictly observe the following items:

 Always wear approved work clothes (no loose-fitting clothes).

 Do not wear gloves when operating the robot.



Personal Protective Equipment (PPE) is subject to the provisions of the 89/656/EEC guideline.

 Do not wear large jewellery, such as earrings, rings or pendants.



Always wear protective safety equipment such as protective helmets, safety shoes

(with anti-slip soles), face shields, safety goggles and gloves as necessary.

General

CAUTION!

Injury and material damage due to unforeseen movements.

Observe the following note:

• Never forcibly move the robot axes.

• Never lean against the robot control.

• Avoid inadvertent pressing of the keys.

• Do not allow unauthorised persons to touch the robot control during operation.

Fig. 1-6: Do not lean on

General

1.7.4 Safety during installation and wiring

For further details of the installation and the electrical connection please see Chapter 5.3.2

"Connection of the robot controller" on page 38.

DANGER due to electric current!

Death and serious injury from electrical shock and fire hazard.

Carry out earthing in accordance with all applicable electrical regulations.

 Comply with the standard "Electrical Equipment of Machines" according to IEC 60204-

1:2005 (EN 60204-1:2006).

WARNING!

Injury and material damage due to unforeseen movements.

When planning installation, draw up easy-to-observe guidelines to ensure safety. Take safety aspects into consideration when planning the installation. Observe the following when installing the robot:

 Select an area such as that described below to install the robot



Make sure the area is large enough so that the fully extended arm with tool does not collide with the wall, the safeguards or the robot controller.

 During installation, pay attention to the following figure "Required installation planning".

3 3

Safeguarding

Robot controller door

Fig. 1-7: Required installation planning

Maximum P-point range of the robot

Maximum working area of the robot including tool or workpiece

Safety distance with respect to the stopping time of the robot type

General

CAUTION!

Danger of injury and material damage from improper means of transport

Crane, forklifts or slings may only be operated by authorised personnel. When lifting the robot controller, please check the following:



As a rule, handling of robot controller must be performed using a crane with wire rope threaded through attached eyebolts.

 Be sure to use wire that is strong enough to handle the weight of the robot controller

(Weight of robot controller 140 - 180 kg).



Check that the eyebolts are securely fastened.

 To lift the robot, use a crane with wire rope threaded through the eyebolts and positioner(s). Lift the body in an upright position as described in the robot operator's manual (see Fig. 1-8: "Using a crane").



If storing the robot temporarily before installation, make sure to place it on a stable and flat surface, and take precautions to prevent unauthorized personnel from touching it.

1 Wire rope

Fig. 1-8: Using a crane

4 M16 eye bolts

CAUTION!

Risk of injury during maintenance work

Make sure there is sufficient room for maintenance work on the robot, the robot controller and the peripheral equipment (see the following illustration).

General

800 800 800

800

650 500

Xxxxxxxxx Xxxxxx

XXX

2 3

Door

Fig. 1-9: Space for maintenance

Robot controller maintenance area

At least 1,000 mm

All dimensions in mm

CAUTION!

Danger of injury and material damage in case of non-compliance with protective measures

For safe operations, the following points must be observed.

 The equipment may be operated only by persons with sufficient training.



Install the controller only in a safe location from which the robot is visible at any time.

 Fasten the robot with the specified bolts (listed in the operating and maintenance manual for each robot model).



Pay attention to the size and type of bolts (specified in the operation and maintenance manual for each robot model).

 Install the robot controller outside the safeguarding of the manipulator’s safety enclosure.

CAUTION!

Danger of injury and material damage from falling or movements

In case of improper installation of the robot controller it may move unexpectedly or fall down

(see the figure below: "Attaching the robot control").

 Secure the position of the robot controller after setting up.



Fasten the robot controller to the ground or slot.

 Use the screw holes on the underside of the robot controller.

General

Xxxxxxxxx Xxxxxx

XXX

2 holes Ø 12

Fig. 1-10: Fixing the robot controller

Threaded holes for M10 screws

CAUTION!

Personal injury and damage from improper connections and unforeseen movements

Operators and other personnel may sturnble on exposed wiring or piping. Damaged cables may cause unexpected robot movements.

 Familiarize yourself with the wiring diagram and take notice thereof when establishing the connections.



Take precautions when wiring and piping between the robot controller, robot, and peripheral equipment.

 Run the piping, wiring, or cables through a pit or use a protective cover, so that they are not stepped on by personnel or run over by a forklift.

Piping

Cable duct

Fig. 1-11: Protective cover for forklift

Cables and tubes

General

1.7.4.1

Safety in the work area

WARNING!

Risk of injury from movements of the robot

To ensure safety, enforce the following precautions:

 Install a safeguarding.



Post a warning sign stating

"Off-limits During Operation"

at the entrance of the enclosure.

 The gate of the barrier must be equipped with a safety interlock.



Make sure the interlock operates correctly before operation.

CAUTION!

Risk of injury from collisions of objects or equipment

Do not store items and equipment near the robot and robot control.



Keep the tools at appropriate locations outside the barrier.

 Keep the equipment at appropriate locations outside the barrier.



Tools and loose equipment must not be deposited on the floor around the robot, robot controller and other components.

1.7.4.2

Operating safety

DANGER!

Death and fire caused by short circuiting

Switching on the power supply during tool installation may result in electric shock.

 Before fixing a tool (e.g. welding torch), make sure the power supply to the robot controller is turned off.



Lock the switch, and display a warning sign (refer to EN 60204-1).

 Never exceed the rated capacity of the robot (the robot capacity can be found in the

"Technical Data" section of this manual).

WARNING!

Danger of injury and material damage caused by unforeseen movements of the robot

If possible, teach jobs from outside the robot’s maximum work area.

Observe the following precautions when performing teaching operations within the manipulator’s operating range:



Always view the robot from the front.

 Always follow the predetermined operating procedure.



Always have an escape plan in mind in case the robot comes toward you unexpectedly.

 Ensure that you have a place to retreat to in case of emergency.

General

Xxxxxxxxx Xxxxxx

XXX

"OFF" position

Fig. 1-12: Secure the robot controller with a padlock

Padlock

External safety

The robot and its auxiliary equipment must be surronded by a safetyguard. Entrances

(doors, gates, etc.) must be protected by interlockings, electro-sensitive devices or similar.

Opening of the gates or entrance to the robot working area must stop all motions inside the cell. Before taking the robot into operation, the complete machine must fulfill the “Essential health and safety requirements relating to the design and construction of machinery” according to the EU Machinery Directive.

Emergency stop function

The emergency stop circuits are designed according to category 1 (EN 418 item 4.1.5)

Using power to the servo motor to achieve the stop and then removal of power when stop is achieved. If stop is not achieved after 0.8 seconds, mechanical brakes are engaged automatically to support stopping.

1.8 Manufacturer

Address:

YASKAWA ELECTRIC CORPORATION

2-1 KUROSAKISHIROISHI

YAHATANISHI-KU

KITAKYUSHU

JAPAN

1.9 Authorized representative

Address:

YASKAWA Europe GmbH

Robotics Division

Yaskawastr. 1

85391 Allershausen

Germany

General

Supply

2 Supply

2.1 Checking the scope of delivery

The standard delivery includes the following items:

MOTOMAN MANUAL

Programming pendant

Robot controller

Robot

Fig. 2-1: Scope of supply

The present assembly instructions

Cable

Supply

2.2 Position type plate

Verify whether the serial number of the robot, the robot controller and the programming pendant with the delivery. The serial number can be found on the type plate as shown below.

S/N.

Part No.

Power Supply Peak kVA

Serial No.

Date/Signature

Robot Type

Robot Order No.

Robot Serial No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen

Fig. 2-2: Position type plate

NOTICE

Please contact the local YASKAWA branch office if the serial numbers do not match the information on the delivery note.

Transportation

3 Transportation

CAUTION!

Personal injury or damage to property

The system consists of precision components. If this precaution is not taken, performance may be impaired.

 A crane or forklift may only be operated by authorized personnel. The same applies to the use of slings.

 Avoid strong vibrations or impacts during transportation.

 No external forces may be exerted on the robot controller, on the robot or on other components.

3.1 Transporting method

• Check that the eyebolts are securely fastened.

• The robot controller weighs approximately 140 - 180 kg. Use load-carrying devices strong enough to withstand the weight.

3.1.1 Using a crane

Adequate load handling devices must be used to transport the robot controller. Make sure that the robot controller is lifted as shown in the diagram "Transport by crane" below.

YASAKAW DX200

Power Supply Peak kVA Part No.

Serial No.

AC 400/415/440 Average kVA

Type ERDRDate/Signature

Robot Type

Robot Serial No.

Robot Order No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

Yaskawastr. 1, D-85391 Allershausen YASKAWA Europe „Robotics Division“ GmbH

YASAKAW DX200

Power Supply Peak kVA Part No.

Serial No.

AC 400/415/440 Average kVA

Type ERDRDate/Signature

Robot Type

Robot Serial No.

Robot Order No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

Yaskawastr. 1, D-85391 Allershausen YASKAWA Europe „Robotics Division“ GmbH

Fig. 3-1: Transport with crane

Transportation

3.1.2 Using a forklift

If the robot controller is to be transported by forklift, it must be secured with safety belts, as shown in the figure "Transport by forklift" below. Make sure that the forklift and the transportation route have sufficient bearing capacity.

Always take due care when transporting the robot controller.

Protective padding

Tiedown straps

Fig. 3-2: Using a forklift

Palette

Forklift tines

3.1.3 Using a lifting truck

By removing the lower front cover you will access to a tunnel under the cabinet. Normally cables are led through this opening. However, it can also be used to lift the control cabinet.

1. Remove the lower front cover by grabbing it at left and right side.

2. Pull it straight out.

Fig. 3-3: Using a lifting truck

Assembly and installation

4 Assembly and installation

CAUTION!

Personal injury and damage to property

The following precautions must be taken.

 Check that the robot controller is complete and not damaged.

 Do not put into operation a robot controller that is damaged or incomplete.



Check that all transport safety devices and transport screws have been removed.

4.1 Protection measures

DANGER!

Personal injury and material damage

The robot system must not be operated without protective devices. Starting up without appropriate protective measures can lead to death of people, serious bodily harm or material damage.

Implement the following protection measures

 Separating protection devices

 Non-contact protection devices



Enclosures

 Marked areas



Signs

 Emergency Stop button

 Display elements

NOTICE

Operator's responsibility

The operator of a robot or a robot system must ensure that all specifications and requirements of the standards DIN EN ISO 10218-1 and DIN EN ISO 10218-2 are met.

In the first instance, the following must be observed:

 Preparing a risk assessment

 The installation of protective devices

 Regular training of the employees

 Regular inspection of all protective devices



Checking for compliance with intended use

Assembly and installation

4.2 Ambient conditions and installation location

When installing a robot controller, it is necessary to satisfy the undermentioned environmental conditions:

• Ambient temperature: 0° C to + 45° C.

• Air humidity: 20% to 80% relative humidity (non-condensing).

• Must be as dust-free, clean and dry as possible.

• Free from corrosive gas or liquid, or explosive gas or liquid

• Free from excessive vibration (Vibration acceleration: 4.9 m/s² [0.5 G] or less).

• Free from large electrical noise (plasma).

• Must be protected against collisions with moving equipment such as forklifts.

• Install the controller in a location from which the robot is easily visible.

• Install the controller in a location from which you can easily inspect it when the door is open.

• It is recommended to have a free area around the controller of at least 500 mm to allow maintenance acces. Minimum is 200 mm on the controllers backside for proper cooling.

• Must comply with the requirements of Directive 2004/108/EC on Electromagnetic

Compatibility.

4.3 Installation options

4 x M12 x 20

YASAKAW DX200

Part No.

AC 400/415/440 Average kVA Power Supply Peak kVA

Date/Signature Serial No.

Robot Type Type ERDR-

Robot Order No.

Robot Serial No.

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN YASKAWA ELECTRIC CORPORATION

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen

Part No.

YASAKAW DX200

AC 400/415/440 Average kVA Power Supply Peak kVA

Serial No.

Type ERDRDate/Signature

Robot Order No.

Robot Type

Robot Serial No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

Yaskawastr. 1, D-85391 Allershausen YASKAWA Europe „Robotics Division“ GmbH

4x M12

Fig. 4-1: Connecting two cabinets

4 x M10 x35

Assembly and installation

4 x M12 x 20

YASAKAW DX200

Power Supply Peak kVA Part No.

Serial No.

AC 400/415/440 Average kVA

Type ERDRDate/Signature

Robot Type

Robot Serial No.

Robot Order No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

Yaskawastr. 1, D-85391 Allershausen YASKAWA Europe „Robotics Division“ GmbH

4 x M10 x35

4x M12

Fig. 4-2: Connecting three cabinets

4.4 Installation example

Anchor the controller to the ground. To this purpose, use the bolts as shown below.

Part No.

YASAKAW DX200

Power Supply Peak kVA

Serial No.

AC 400/415/440 Average kVA

Type ERDRDate/Signature

Robot Type

Robot Serial No.

Robot Order No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

Yaskawastr. 1, D-85391 Allershausen YASKAWA Europe „Robotics Division“ GmbH

2 holes Ø 12

Holes for M10 screws

NOTICE

For more information about the installation of the robot please refer to the operating and maintenance manual for each robot type.

Wiring

5 Wiring

DANGER!

Death from electrical shock, risk of fire due to short circuit.

Wiring must be performed by authorized or certified personnel.

Failure to ground equipment may result in fire or electric shock.

Capacitors inside the robot controller store electricity after power is turned OFF. Exercise caution whenever handling circuit boards.

Loose power circuit wires can cause fire and electric shock.

Incorrect wiring may cause fire and electric shock.



Make sure that the earthing resistance does not exceed 0.1 Ω .

 Turn OFF the main power supply.

 Attach the required warning sign, e.g.

"Do not energize!"

 Install a switch-on guard as prescribed.

 Do not touch any board inside the controller for five minutes after turning OFF the power supply.



Power cannot be turned ON unless the door is closed. Interlocks prevent power from being turned ON.

 Any occurrence during wiring while the robot controller is in the emergency stop mode is the user’s responsibility. Do an operation check once the wiring is completed.



Wiring must be performed only by authorized personnel.

 Perform wiring in accordance with the rated capacity as specified in the Instructions.



Be sure the power circuit screws are securely tightened.

 Do not handle the circuit board directly by hand.

Wiring

5.1 Notes on cable junctions

• The cables that connect the controller to peripheral device are low voltage circuits.

Keep robot controller signal cables away from the primary power circuit. High voltage power lines should not be run in parallel to controller signal cables. Use metal ducts for protection against electrical interference with the signals. If cables must be crossed, run the power cables perpendicular across the signal cables.

• Confirm the connector and cable numbers to prevent misconnection and equipment damage. One connects the manipulator and robot controller. Another connects the robot controller and peripheral device. A wrong connection can cause damage to electronic equipment.

• Clear the area of all unauthorized personnel while making cable connections. Place all cables in a covered cable channel in the floor.

Piping

Cable duct

Wire

5.2 Power supply / feed

DANGER!

Death from electrical shock and risk of fire due to short circuit

If the robot controller for European standards is used in Japan, an electric shock may result from increase in leakage current due to differences in power supply condition.

 The robot controller must be grounded.

NOTICE

Connect the power supply to a stable power source that is not prone to power fluctuations.

Wiring

5.2.1 Installing residual current circuit breakers (optional)

For connection of an all-current sensitive ELCB use a switch suitable for the high frequency of the robot controller inverter. Leakage breakers which cannot handle high frequencies may malfunction.

Manufacturer Model

Mitsubishi Electric Co., Ltd.

NV series (manufactured since 1988)

Fuji Electric Co., Ltd.

EG or SG Series (manufactured since 1984)

Tab. 5-1: Example of High Frequency Leakage Breaker

Even with a leakage breaker installed, there is still a possibility of some high frequency current leakage from the robot controller.

However, this current leakage presents no safety risks.

CN1

5 6 7

CN1

5 6 7

2 8

Fig. 5-1: Connection of the Leakage Breaker

3-phase 400/415/440 VAC at 50/60

Hz (only with transformer)

1-phase* 200/230 VAC at 50/60 Hz

Mains disconnecter

For 1-phase power supply

Fuse

Line filter

Power relay MC1

To converter (main circuit)

To converter (control circuit)

Wiring

* With a single-phase power supply, the following robot models can be used: MHJ, MH5F,

MH5LF, SIA5F, SIA10F, SIA20F,SDA10F, SDA20F

3-phase 200/220V AC at 60Hz or

200V AC 50Hz

Leakage Breaker

Robot controller

Breaker

Contactor (1KM)

To connector

Fuse

Noise filter

To controller power supply unit

Connection of the Leakage Breaker

5.2.2 Installation of primary power supply breaker

Robot

MA1440

MH12

MS210

Power capacity (kVA)

1.5

5.0

Cable size (Size of terminal) (In case of Cabtyre cable (three cores) (mm²)

3.5 (M5)

5.5 (M5)

Capacity of breaker in robot controller (A)

NOTICE

The power capacity shown above is the continuous rating value.

When the robot is rapidly accelerated, the power capacity of several times the continuous rating value may be needed instantly.

Wiring

5.3 Cable connections

Outline connection diagram

Part No.

YASAKAW DX200

AC 400/415/440 Average kVA Power Supply Peak kVA

Date/Signature Serial No.

Type ERDR-

Robot Order No.

Robot Type

Robot Serial No.

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN YASKAWA ELECTRIC CORPORATION

Yaskawastr. 1, D-85391 Allershausen YASKAWA Europe „Robotics Division“ GmbH

PROGRAMMING PENDANT X81

1 (432BS6/ABB)

-X4

-X1

-X2

-X3

7 6

Power supply connection

Robot cable

Robot

Rear view

All dimensions in mm

Fig. 5-2: Cable connection

Primary power supply cable

Programming pendant cable

Front view

5.3.1 Connection to main power supply

 Before you turn on the main power supply, first connect all other cables which are needed such as the cables between robot and robot controller.

NOTICE

 To connect the robot controller to the main power supply, a CEE connector must be prepared (type: 432C6).



The grounding inside the robot controller is factory assembled (maximum grounding resistance of 0.1



1. Turn the main switch to the OFF position.

YASAKAW DX200

Part No.

Power Supply Peak kVA

AC 400/415/440 Average kVA

Serial No.

Date/Signature

Type ERDR-

Robot Type

Robot Order No.

Robot Serial No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen

Fig. 5-3: Main switch in OFF position

Main switch at the front side of the robot controller

Wiring

2. Connect the power supply cable to the CEE connector at the back side of the robot controller

432BS6 (ABB)

432C6 (ABB)

Connector type (back side of robot controller)

Connector type (cable side)

Wiring

5.3.2 Connection of the robot controller

DANGER due to electric current!

Danger to life due to electric shock!

Danger to life and serious injuries caused by high voltage.

 Before carrying out the wiring, ensure that the door of the robot controller is in principle closed.

NOTICE



Before you connect the robot cable to the robot, ensure that the plug connection fits together.

1. Connect the robot cable to the connector on the back side of the robot controller.

-X4

-X1

-X2

-X3

Fig. 5-4: Connection of the robot cable

Robot cable Robot controller (back side)

Power supply cable for the connection to the main power supply

5.3.3 Connecting the programming pendant

Connect the programming pendant cable to the connector connection (X81) on the door of the robot controller (see figure „Connection programming pendant“).

X81

Part No.

YASAKAW DX200

Power Supply Peak kVA

Serial No.

AC 400/415/440 Average kVA

Date/Signature

Type ERDR-

Robot Order No.

Robot Type

Robot Serial No.

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN YASKAWA ELECTRIC CORPORATION

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen

PROGRAMMING PENDANT

X81

Alignment marks

Fig. 5-5: Connection programming pendant

Technical data

6 Technical data

6.1 Basic specifications robot controller

Type:

Cabinet:

Dimensions (H x L x W)

Mass

Cooling System

Ambient temperature

Relative humidity

Main circuit power input

Digital I/O

Analog I/O

Positioning system

Programming capacity

Interface

DX200

1000 x 800 x 650

140 - 180 kg

Indirect cooling

0° C to + 45° C

Maximum 90 % non-condensing

3-phase 400/415/440 VAC at 50/60

25 inputs/5 outputs (specific signals hardware) 40 inputs/40 outputs

(standard) (expandable to 2048 inputs/2048 outputs)

40 channels (optional)

Absolute encoder / serial interface

200,000 steps, 10,000 instructions and 20,000 PLC steps

RS-232C, Ethernet

Protection class:

Cabinet

Cooling fan

Motor and signal cable

Robot

Programming pendant

Noise level:

Measured at 1.2 m distance from the cabinet, infront of the door at 1.0 m over the floor.

Measured at 1.6 m distance from the cabinet, behind the cabinet, at 1.0 m over the floor.

* Measured using standard cooling fans

IP54

Not classified

IP67

See the operation and maintenance manual of the robot

IP65

Emitted noise

53 dB

54 dB

Maintenance function:

Functions

Self-Diagnosis

Operation Time Display

System monitor, internal counter (for example power-on time SERVO power).

Classifies errors, major or minor alarms and displays the data.

Control power-on time, SERVO power-on time, Playback time, Operation time, Work time

User Alarm Display

Alarmdisplay

I/O diagnosis

T.C.P. Calibration

Security:

Specification

Collision avoidance

Shock detection function

Machine lock

Programming functions:

Programming language

Robot motion control

Speed setting

Program Control Instructions

Operation Instructions

Variable

Variable type

I/O instruction

Technical data

Alarm messages for peripheral devices.

Alarm message, troubleshooting, previous alarm records

Simulated enable/disable signals possible.

Automatic calculation of tool center point (TCP).

2-channel safety system (emergency stop, safety interlock) 3-position hold-to-run button, European safety standard (EN ISO 10218-1).

Freely definable interference areas.

Monitoring of the torque levels of the robot axes.

Test-run of the peripheral device is possible without robot movement.

INFORM III

Joint coordinates, linear/circular interpolations, Tool coordinates.

Percentage for joint coordinates,

0.1 mm/s units for interpolations, Angular velocity for T.C.P. fixed motion

Jumps, Calls, Timer, Robot stop, execution of some instructions during robot motion.

Preparing the operation instructions for each application Arc (ON), Arc

(OFF), etc.

global variable, local variable

Byte type, Integer-type, Double precision-type, Real-type, Position-type

Discrete I/O, pattern I/O processing

Technical data

6.2 Programming pendant specifications

Programming pendant:

material

Dimensions (L x H x W)

Mass

Displayed units

Reinforced thermoplastic enclosure with a detachable suspending strap.

1000 x 800 x 650

0.986 kg

Coordinate system

Speed setting

Shortcuts

Language

Interface

TFT Color liquid crystal display, VGA (640 × 480),

Touch panel.

Joint, Rectangular/Cylindrical, Tool, User Coordinates.

Fine adjustment possible during OPERATION or

TEACH mode.

Direct access keys and user selectable screen keys possible.

Most important languages available (worldwide)

Compact Flash card slot, USB port (USB1.1)

Operating system Windows CE

At the back of the programming pendant a three position enable device (Dead-mansswitch (DSW) is placed.

Function:

Relased

Middle positon

Squeezed

No function (circuit open).

Operation (circuit closed).

No function (circuit open)

1 2 3 4

Technical data

11 10 9 13

Start key

Hold key

Emergency stop button

Insertion slot for CF-Card

Page key

"SELECT" selection key

Speed keys

Axis keys

ENTER Key

Number keys / function keys

Keys for movement types

3-position hold-to-run button

Optional position of the 3-position hold-to-run button

Cursor key

Color display with touch screen

Menu area

Key switch for selecting the operating mode

USB connection

Holder

To get from sqeezed position to middle position the deadman switch be completely released first.

When safety circuit is OK (all gates closed and reset), the DSW has no effect.

When safety circuit is down (gate open), servo power can be activated by DSW.

See table for combinations:

Technical data

Released = OFF

Squeezed = ON

Servo On

Squeezed tightly = OFF

Maintenance and inspection

7 Maintenance and inspection

7.1 Periodic inspection

DANGER!

Death from electrical shock, risk of injury and fire due to short circuit

 Do not touch the cooling fan or other equipment while the power is turned ON.

Carry out the following inspections.

Components Inspection Method

Robot controller Check that the casing is completely closed and not damaged.

Power cable

Interior circulation fan and backside duct fan.

Emergency stop button

Check for gaps or damage to the sealed construction.

Check for damage and deterioration of leads.

Check the function (while power

ON).

Check the function (while servo power ON).

Visual inspection

By pressing the keys

Inspection frequency

Daily

Monthly as required as required

Before the robot is put into operation.

Enabeling device Check the function (in teach mode).

Battery

Power supply

Confirm battery alarm or message is displayed or not.

Check power supply voltage is normal as required as required

Visual inspection as required

Maintenance and inspection

7.2 Cooling fan inspections

Inspect the cooling fans as required. A defective fan can cause the robot controller to malfunction because of excessive high temperatures inside.

The interior circulation fan and backside duct fan normally operate while the power is turned

ON. Check if the fans are operating correctly by visual inspection and by feeling air moving into the air inlet and from the air outlet.

-Q1M

-X9

-FS1

-TP1

-AE2

Option

-TA9

-AE6.0

-TA8

-TA7

-TA6

-TA5

-TA4

-TA3

-TA2

-TA1

-AE3 -AE1.0

-AE4

-AE7

-X181

Option

-X18

-X810

Option

-X12A -X12B -X13A -X13B Option

-X81

-G1

-G2

-Q1M

-G3

-G4

-G5

-R1-R6

-T1

-C1

-V1

-EP2

Front view

Interior circulation fan

Air outlet

Fig. 7-1: Ventilation system

Door

Back View

NOTICE

When the message of the "Cooling fan in YPS power supply stopped. Exchange fan" is displayed, it may be caused by the error occurrence at the internal cooling fan (JZNC-

YZU01-E) inside CPU unit (JZNC-YPS21-E).

When the message of the "Cooling fan in YPS unit stopped, replace cooling fan" is displayed, carry out an inspection and the replacement of the cooling fan in the CPS unit

(JZNC-YPS21-E)as soon as possible.

7.3 Emergency Stop Button Inspections

The emergency stop button is located on the programming pendant. Before operating the robot, make sure the SERVO voltage is switched off. For this, press the emergency stop button after switching on the SERVO voltage.

Maintenance and inspection

7.4 Inspection of the enabling switch

The programing pendant is equipped with a 3-position enable switch. Perform the following operation to confirm the enable switch operates.

1. Set the mode switch with key on the programming pendant to "TEACH".

1 3

Fig. 7-2: Enabling device

TEACH

REMOTE

PLAY

2. Press [SERVO ON READY] on the programming pendant. The [SERVO ON] lamp will flashes.

SERVO ON reading

Fig. 7-3: Flashing light SERVO ON

SERVO ON (flashing light)

3. When the enable switch is grasped lightly, the servo power is turned ON.

When the enable switch is grasped firmly or released, the servo power is turned OFF.

NOTICE

If the [SERVO ON] lamp does not light in previous operation, check the following:

 The emergency stop button on the programming pendant is being pressed.

 The emergency stop signal was triggered by an external device.

 If a major alarm is occurring

Maintenance and inspection

7.5 Check battery unit

The robot controller has a battery unit that backs up the important program files for user data in the CMOS memory.

A battery alarm indicates when a battery has expired and must be replaced. The programming pendant display and the message "Memory battery weak" appears at the bottom of the display.

Check that the message is NOT not displayed on the programming pendant.

7.6 Check the power supply

Check the voltage of 1, 3, 5 terminal of the main power switch (Q1M) with an electric tester.

Measuring Items

correlate voltage

Voltage between earth (phase ground)

Terminals

between

1 and 3 (R-S),

3 and 5 (S-T),

1 and 5 (R-T) between

1 and E (R-E),

5 and E (R-E) between

3 and E (S-G)

Correct Value

400/415/440V +/- 10%

230/240/255V +/- 10%

About 0V

1 3 5

2 4 6

Fig. 7-4: Main switch

Maintenance and inspection

7.7 Open Phase Check

Check Item

Lead cable check

Input Power Supply

Check

Main switch (Q1M) control

Operation

Confirm if the lead cable for the power supply is wired as shown in the following without any falling out, looseness or breaking from the connecting part.

Check the open phase voltage of input power supply with an electric tester. (Normal value: AC400/415/440V +10%, -15%)

Turn ON the main power switch and check the open phase voltage of “2, 4, 6 of the main power switch (Q1M) with an electric tester. If abnormal, replace the main power switch (Q1M).

Maintenance and inspection

1(R) 3(S) 5(T)

(Q1M)

2(U) 4(V) 6(W)

AC400-415-440V/200V

TP1

㸦

FS1

㸧

CN555

1KM

AE2

2KM

Power Supply X4

Main switch

Transfer

Fuse

Fig. 7-5: Open Phase Check

Converter

Power Supply Contactor Unit

Filters

Description of Units and Circuit Boards

8 Description of Units and Circuit Boards

• Cautions for connection of dual input signals.

Please follow the safety instructions in chapter 1.7 "Safety" on page 10.

CAUTION!

Connect the switch (contact), which at the same time switches the 2-channel signals ON and OFF.

If the timing that turns the two signals ON and OFF is not right, a disagreement alarm occurs.

Connection of 2-channel inputs Robot controller

Input for the robot system

Turn ON/OFF at the same time

Input signal 1

Input signal 2

Switch

CAUTION!

Damage to property caused by short-circuit

As power supply is reversed for each signal, a short-circuit and thus a possible a robot control failure occurs.



Do not connect the two signals to the same contact (use two separate contacts).

Connecting 2-channel inputs to the same contact

Robot controller

Input for the robot system

Input signal 1

Input signal 2

Short circuit current

The same contact

Switch

Description of Units and Circuit Boards

8.1 Power ON unit

The power ON unit consists of the power ON control circuit board (JARCR-YPC21-1) and the main circuit contactor and the line filter. It turns the main circuit control contactor ON and OFF using the signal for the servo power control from the machine safety I/O logic circuit board, and supplies power (3-phase AC200/220V) to the converter.

The power supply (single phase AC200/220V) is supplied to the control power supply via the line filter.

Main power supply input connector (601)

Input connector contactor control (607)

AC control power supply connector (CN603,

CN604, CN605)

Brake interlock output connector (CN608)

Main power supply output connector (CN602)

AC Cooling fan connector (CN606)

Fuse for AC cooling fan GP25 (2.5A

250V)(3FU), (4FU)

Fuse for AC Control Power Supply 0215010MXP

(10A 250V) (1FU, 2FU)

Configuration power ON unit

Description of Units and Circuit Boards

8.2 Axes control circuit board

8.2.1 Major axes control circuit board

The major axes control circuit board controls the servomotors of the robot’s six axes. It also controls the converter and the PWM amplifiers. Mounting an external axes control circuit board of an option makes it possible to control the servomotor of nine axes, including the robot axes.

The major axes control circuit board also has the following functions:

• Brake power supply control circuit

• Shock sensor (shock) input circuit

• Direct-in circuit

Major axes control circuit board

Machine safety I/O I/F (CN511)

Brake control signal (CN513

STO control signal I/F (CN521)

LED

Control communication (CN515)

Control communication (CN516)

PWM amplifier 2 I/F (CN502)

PWM amplifier 4 I/F(CN504)

PWM amplifier 5 I/F (CN505)

PWM amplifier 3 I/F (CN503)

PWM amplifier 1 I/F (CN501)

Analog monitor I/F (CN519)

Rotary switch (S1)

Encoder signal (CN508)

DC control power supply (CN510)

Converter I/F (CN507)

Description of Units and Circuit Boards

8.2.2 External axes control circuit board

An external axes control circuit board is an optional, and it can control the additional three axes. It can be mounted on the external axes control circuit board.

External axes control circuit board

STO control signal I/F (CN524)

STO control signal I/F (CN523)

STO control signal I/F (CN522)

PWM amplifier 9 I/F (CN533)

PWM amplifier 7 I/F (Lower) (CN531)

PWM amplifier 8 I/F (Upper) (CN532)

Encoder distribution for the machine safety system (9th axis) (CN542)

Encoder distribution for the machine safety system (8th axis) (CN541)

Encoder distribution for the machine safety system (7th axis) (CN540)

Encoder I/F(9th axis) (CN536)

Encoder I/F(8th axis) (CN535)

Encoder I/F(7th axis) (CN534)

Description of Units and Circuit Boards

8.3 CPU unit configuration

CPU unit consists of circuit board racks (flame, back circuit board, PCI riser circuit board),

CPU circuit board, robot I/F circuit board and the machine safety CPU circuit board. The

CPU unit contains only circuit board racks and CPU circuit boards.

Be sure that it does not contain robot I/F circuit board and the machine safety CPU circuit board.

Fig. 8-1: CPU Unit Configuration

PCI Slot for Sensor Board x 1

Rotary switch (S1)

I/O I/F (Communication with the optional I/O) (CN114)

Drive I/F (communication with basic axis control circuit board) (CN113)

LED

Robot I/F circuit board JANCD-YIF01-

CPU board (machine safety) JANCD-

YSF21-E

CPU board JANCD-YCP21-E

Compact Flash (CN107)

USB (CN106)

For Programming Pendant (CN105)

For LAN (CN104)

Serial port (RS232C) (CN103)

I/O I/F (Communication with the functional safety circuit board) (CN203)

I/O I/F (Communication with the machine safety I/O logic circuit board: 2channel side) (CN202)

PCI Slot X2

Description of Units and Circuit Boards

8.3.1 Unit and circuit board in the CPU unit

8.3.1.1

CPU board

The entire system is controlled with this circuit board. It controls the display on the programming pendant, the control keys and the movements, and it calculates the interpolation. This control circuit board has the serial interface for RS-232C/RS-422 and a

LAN connection (100Base-TX/10Base-T), USB (USB2.0).

8.3.1.2

Robot I/O circuit board

The robot I/F circuit board controls the entire robot system. It is connected to the control circuit board (JANCD-YCP01-E) with a PCI bus interface on the rear. Connection to the basic axis control circuit board (SRDA-EAXA21A) for high speed transmission.

NOTICE

Please do not change the factory setting of S1 (Factory setting is [0]).

8.3.1.3

CPU board (machine safety)

This circuit board (JANCD-YSF21-E) performs I/O processing or diagnosis processing for the safety sequence, and it is connected with the CPU circuit board (JANCD-YCP21-E) by the PCI Express bus I/F in the back circuit board.

It is also connected with the machine safety I/O logic circuit board by the high speed serial communications (two lines).

8.4 CPS

This unit (JZNC-YPS21-E) supplies the DC power (DC5V, DC24V) for control (system, I/O, brake). It is also equipped with the input function for turning the control power supply ON and OFF.

Connection with CPU 1 (CN158)

Connection with CPU 2 (CN159)

+24V2 Power Supply Output (CN156/

CN157)

+24V1/+24V2 Power Supply Output

(CN154/CN155)

+24V3 Power Supply Output (CN153)

Remote Control (CN152)

AC Power Supply Input (CN151)

Monitor Alarm Display

Control power supply unit

JZNC-YPS21-E

Description of Units and Circuit Boards

• Input

Rating Input Voltage: 200/240VAC

Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)

Frequency: 50/60Hz ± 2Hz (48 to 62Hz)

• Output Voltage

DC + 5V

DC +24V (24V1: System, 24V2: I/O, 24V3: Brake)

• Indicator

Display

SOURCE

Color

Green

POWER ON

+5V

+24V

FAN

OHT

Green

Red

Status

Lights with power supply input. Lights out when internal live part completes discharge (Power supply status: being input).

Lights when PWR_OK output signal is ON (Power supply status: being output).

Lights with +5V over-current (ON when abnormal).

Lights with +24V over-current (ON when abnormal).

Lights when FAN error occurs.

Lights when unit interior overheats.

• Control Power ON/OFF

To turn ON the robot controller power, turn ON the non-fuse breaker of the controller so that the control power supply is turned ON. If the controller is not located at the workplace, the control power supply can be turned ON/OFF by an external device, etc.

after the non-fuse breaker of the controller is turned ON. It is operated by the external switch connected with CN152 of the Control power supply unit as shown in the following figure (CN152-1 and CN152-2 is shortaged when shipment).

Robot controller

Control power supply unit

Remove the short-circuit positioner

Control power supply ON/OFF switch

Connection to control power supply unit

See chapter 8.25 "Brake control circuit board (JANCD-YBK21-3E)" at page 89 for wiring of

CN152 connector.

Description of Units and Circuit Boards

8.5 Machine safety I/O logic circuit board

Followings are the main functions of machine safety I/O logic unit.

It processes external safety signals with the dual processing circuits and control ON/OFF of the main circuit control contactor of the power ON unit according to conditions.

Followings are the main functions of machine safety I/O Logic unit.

• System safety input circuit (dual circuits)

• User safety input circuit (dual circuits)

• User safety output circuit (dual circuits)

• Emergency stop signal input circuit (dual circuits)

• SERVO power control signal output circuit (dual circuits)

• Anti-safety I/O circuit for the robot system

• Machine safety terminal block circuit board I/F

NOTICE

If the F1 fuse becomes blown, it will cause a damage on the inner circuit of the board.

Replace the board instead of replacing the fuse (there is no attached spare of the fuse).

Description of Units and Circuit Boards

8.5.1 Connection for tool shock sensor (SHOCK)

Directly to the tool shock sensor signal line

1. Disconnect the minus SHOCK (-) and +24V2 pin terminal from the DINAMIC connector, the machine safety I/O logic circuit board (YSF22-CN214). The pin terminal for the shock sensor is attached on the right side of the controller.

2. Connect the minus SHOCK (-) and +24V2 pin terminals to the signal line of the tool shock sensor. Use the following plug-in terminals for the end of the signal line.

Pin terminal name Terminal model

SHOCKTMEDN-630809-MA

+24V2 TMEDN-630809-FA

Signal line terminal model

TMEDN-630809-FA (manufactured by NICHIFU Co., Ltd.)

TMEDN-630809-MA (manufactured by NICHIFU Co., Ltd.)

(JANCD-YSF22-E)

CN215

SHOCK+

SHOCK-

Robot

Machine safety I/O logic circuit board

TMEDN-630809-FA (NICHIFU)

+24V2

Fig. 8-2: Direct Connection to Tool Shock Sensor Signal Line

Robot controller

TMEDN-630809-MA (NICHIFU)

TMEDN-630809-FA (NICHIFU)

SHOCK- TMEDN-630809-MA

(NICHIFU)

SHOCK sensor signal cable

Contact sensor (optional)

The pin terminal for the shock sensor is attached on the right side of the controller.

Description of Units and Circuit Boards

With the cable that is built into the robot

2. Connect the SHOCK (-) plug-in terminal to the SHOCK (+) plug-in terminal of the robot.

NOTICE

The cable installed on the robot is not connected to the shock sensor because the tool shock sensor is an option. For connecting the tool shock sensor, refer to the wiring diagrams in the INSTRUCTIONS for the robot.

(JANCD-YSF22-E)

CN215

SHOCK+

SHOCK-

Robot

Robot controller

Fig. 8-3: Connection with robot cable

Machine safety I/O logic circuit board

TMEDN-630809-FA (NICHIFU)

+24V2

TMEDN-630809-FA (NICHIFU)

SHOCK- TMEDN-630809-MA

(NICHIFU)

Supply cables (PG)

Contact sensor (optional)

NOTICE

If the tool shock sensor input signal is used, the method for stopping the robot can be specified. The stop procedures stop and switch off the SERVO power supply. Selection of the stopping method is set in the display of the programing pendant (Refer to explanations in the "System Setup" manual (Document number: E1102000145XX01 or higher) in

Chapter "System Setup".

Description of Units and Circuit Boards

8.6 Machine safety terminal block circuit board (JANCD-YFC22-

E)

The machine safety terminal block circuit board (JANCD-YFC22-E) is for the system external signal to connect with the safety I/O signals. For connection, refer to the connection diagrams of each item.

1-25

26-50

51-75

76-100

-AE4

-CN219

(348744-10)

Fig. 8-4: Machine safety terminal block (-X18)

Machine safety I/O logic circuit board I/F connector (CN219)

Description of Units and Circuit Boards

Signal name Connection no.

SAFF_1+ 1

SAFF_1-

SAFF_2+

SAFF_2-

EXESP_1+

EXESP_1-

EXESP_2+

EXESP_2-

EXDSW_1+

EXDSW_1-

EXDSW_2+

EXDSW_2-

FST_1+

FST_1-

FST_2+

FST_2-

Double channel

Function

Possible Safety plug

Used to turn OFF the servo power if the door on the safeguarding is opened.

Connect to the interlock signal from the safety plug on the safeguarding door. If the interlock signal is input, the servo voltage is turned ON.

As long as the signal is ON.

The servo power cannot be turned ON. Note that these signals are disabled in teach mode.

Possible External emergency stop signal

Used to connect the emergency stop switch of an external device.

If the signal is input, the servo power is turned OFF and the job is stopped.

As long as the signal input is active, the servo power cannot be turned ON.

Possible External enable switch

Used to connect a Enable switch other than the one on the programming pendant when two people are teaching.

Possible Full-speed Test

Used to reset the slow speed limit for the test run in the teach mode.

If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the teach mode. If this signal’s circuit is open, the status SSP input signal determines the safety speed:

The first slow speed (16%) or second slow speed (2%).

Factory setting

Short-circuit with a jumper cable

Open

Description of Units and Circuit Boards

Signal name Connection no.

SSP+ 17

SSP18

EXHOLD+

EXHOLD-

EXSVON+

EXSVON-

SYSRUN+

SYSRUN-

Double channel

Function Factory setting

Slow speed mode selection Short-circuit

Used to determine the speed of the test run when with a jumper cable the FST (full-speed test) signal input circuit is open.

Open: Second slow speed

(2%)

Short circuit: First slow speed (16%)

External hold

Used to connect the temporary stop switch of an external device.

If the signal is input, the job is stopped.

Short-circuit with a jumper cable

As long as the signal is ON, starting and axis movements cannot be enabled.

External SERVO-ON

Use to connect the servo

ON switch of an external operation device.

Upon entry of this signal, the SERVO power supply is turned ON.

SYSRUN signal

Use to determine the normal/abnormal condition of the robot controller by SYS-

RUN signal.

Open

+24V2U3 25

Description of Units and Circuit Boards

Signal name Connection no.

ONEN1_1+ 26

ONEN1_1-

ONEN1_2+

ONEN1_2-

ONEN2_1+

ONEN2_1-

ONEN2_2+

ONEN2_2-

ONEN3_1+

ONEN3_1-

ONEN3_2+

ONEN3_2-

ONEN4_1+

ONEN4_1-

ONEN4_2+

ONEN4_2-

OT2_1+

OT2_1-

OT2_2+

OT2_2-

Double channel

Function

Possible SERVO-ON enable

Connected to use a function which distributes the robot system to the multiple servo areas, and turns the servo power ON/OFF.

Factory setting

Short-circuit with a jumper cable

External axis overun

Used to input the overrun in the external axes other than the main body of the robot.

Open

OT3_1+

OT3_1-

OT3_2+

OT3_2-

024V2

OT4_1+

OT4_1-

OT4_2+

OT4_2-

PBESP_3+

PBESP_3-

PBESP_4+

PBESP_4-

PBESP_3+

PBESP_3-

PBESP_4+

PBESP_4-

External axis overun

Used to input the overrun in the external axes other than the main body of the robot.

Contact output emergency stop button

Used to output a contact point of the emergency stop button on the programing pendant.

Used to output a contact point of the emergency stop button on the front door of the robot controller Control panel.

Open

Description of Units and Circuit Boards

Signal name Connection no.

GSIN1_1+ 63

GSIN1_1-

GSIN1-2+

GSIN1_2-

GSIN2_1+

GSIN2_1-

GSIN2_2+

GSIN2_2-

GSOUT11+

GSOUT11-

GSOUT12+

GSOUT12-

Double channel

Function

Possible Universal safety input

The universal safety input signal is used in the safety logical circuit function.

Factory setting

Open

Possible

Universal safety output

The universal safety output signal is used in the safety logical circuit function.

Also, inputs and uses the driven connection device status as the monitoring signal by the output signal.

Open

24V2U3

GSOUT2_1+

GSOUT2_1-

GSOUT2_2+

GSOUT2_2-

GSEDM1+

GSEDM1-

GSEDM2+

GSEDM2-

Universal safety output

The universal safety output signal is used in the safety logical circuit function.

Also, inputs and uses the driven connection device status as the monitoring signal by the output signal.

The universal safety output signal is used in the safety logical circuit function.

Also, inputs and uses the driven connection device status as the monitoring signal by the output signal.

Open

AXDIN_COM

AXDIN1

AXDIN2

AXDIN3

AXDIN4

AXDIN5

AXDIN6

+24V2U3

024V2

Direct-in (SERVO)

Used to input the quick responding signals in the search function etc.

Open

DC +24V2 output terminal

Open

Description of Units and Circuit Boards

Signal name Connection no.

AIN_COM 95

AXIN1

AXIN2

AXOUT1

AXOUT2

024V2 100

Double channel

Function Factory setting

Universal input (SERVO)

Used to input the universal signal from the external device.

Open

Universal output (SERCO) Open

Used to output the universal signal to the external device.

DC +24V2 output terminal Open

Tab. 8-1: JANCD-YFC22-E details for the connection terminal (-X18)

8.7 External emergency stop signal

This signal is used to connect the emergency stop switch of an external device. If the signal is input, the servo power is turned OFF and the job is stopped. As long as the signal input is active, the servo power cannot be turned ON.

CAUTION!

Injuries and machine damages caused by short-circuit

Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.

 Be sure to remove the jumper before using.

-X18

(JANCD-YSF22-E)

CN219

EXESP_1+

EXESP_1-

EXESP_2+

EXESP_2-

Fig. 8-5: Connection external emergency stop signal

Robot controller

I/O terminal (machine safety)

I/O board (machine safety)

External emergency stop signal

Remove the jumper cable

Turn OFF/ON at the same time

Description of Units and Circuit Boards

8.8 Safety plug

This signal is used to turn OFF the servo power if the door of the protective device is opened. Connect to the interlock signal from the safety plug on the safeguarding door. If the interlock signal is input, the servo voltage is turned ON, as long as the signal is ON. The servo power cannot be turned ON. Note that these signals are disabled in teach mode.

CAUTION!

Injuries and machine damages caused by short-circuit

Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.



Be sure to remove the jumper before using.

-X18

(JANCD-YSF22-E)

CN219

SAFF_1+

SAFF_1-

SAFF_2+

SAFF_2-

Fig. 8-6: Connection for safety plug

Robot controller

I/O terminal (machine safety)

I/O board (machine safety)

Safety plug

Remove the jumper cable

Turn OFF/ON at the same time

Description of Units and Circuit Boards

8.9 Installation of safety plug

NOTICE

Observe DIN EN ISO 10218-2 with respect to the safety measures.

Installation of Saftey Plug

Robot working area

Safety casing

Service door

Emergency shut-off

Plug

Safety plug

If the SERVO power is ON when the interlock signal is input, the SERVO power turns OFF.

As long as the interlock signal is active, the SERVO power cannot be turned ON.

However, the servo power does not turn OFF when the door is opened only during the

TEACH mode.

In this case, the SERVO power can be turned ON while the interlock signal is input.

Description of Units and Circuit Boards

8.10 External enable switch

This signal is used to connect Enable switch other than the one on the programming pendant when two people are teaching.

CAUTION!

Injuries and machine damages caused by short-circuit

Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.

 Be sure to remove the jumper before using.

-X18

(JANCD-YSF22-E)

CN219

EXDSW1+

EXDSW1-

EXDSW2+

EXDSW2-

Fig. 8-7: Connection external emergency stop signal

Robot controller

I/O terminal (machine safety)

I/O board (machine safety)

External enable switch

Remove the jumper cable

Turn OFF/ON at the same time

Description of Units and Circuit Boards

8.11 Full speed test

This signal is used to reset the slow speed limit for the test run in the teach mode.

If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the play mode.

If this signal’s circuit is open, the status SSP input signal determines the slow speed: The first slow speed (16%) or second slow speed (2%).



Setting Method

1. Short-circuit terminal numbers 13 and 14 of the machine safety terminal block circuit board (JANCD-YFC22-E), and 15 and 16 as well (Normally, each terminal is unwired).

-X18

(JANCD-YSF22-E)

CN219

FST_1+

FST_1-

FST_2+

FST_2-

Robot controller

Fig. 8-8: Connection for Full-speed Test

I/O terminal (machine safety)

I/O board (machine safety)

External enable switch

Full-speed Test

Description of Units and Circuit Boards

2. The message "Full-speed test mode" is displayed as follows when the setting is finished.



Operation Method

When the full-speed test mode is set, operation speed is set depending on the setting of manual speed as follows.

At the time of setting the full-speed mode, the setting of manual speed shifts to Inching automatically.

When changing the setting of manual speed, make sure that there is no person around the robot and pay great attention to perform the operation.

Parameter (Unit: 0.01%) Manual speed Limit of operation speed

(default value)

Inching 20%

Slow

Medium

Fast

50%

75%

100% (fixed value)

S1CxG60 (default value: 2000)

S1CxG61 (default value: 5000)

S1CxG62 (default value: 7500)

NOTICE



The limit values of operation speed described in the table above are the ratio against the robot’s maximum speed, not against the taught speed. The values are for restraining the operation speed not to exceed the limit values of operation speed against the robot’s maximum speed during the test run or FWD/BWD operation.

 Manual full-speed function allows the manipulator to perform the test run or FWD/BWD operation at the taught speed by a JOB during the teach mode. Perform the operation outside the motion range.

 If the full-speed test mode is set or released while a SERVO power is ON, the servo power turns OFF.

Description of Units and Circuit Boards

8.12 Slow speed mode

This signal is used to determine the speed of the test run when the FST (full-speed test) signal input circuit is open.

Open: Second slow speed (2%)

Short circuit: First slow speed (16%)

CAUTION!

Injuries and machine damages caused by short-circuit

Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.

 Be sure to remove the jumper before using.

-X18

(JANCD-YSF22-E)

CN219

SSP+

SSP-

Robot controller

Fig. 8-9: Connection for slow operation mode

I/O terminal (machine safety)

I/O board (machine safety)

Remove the jumper cable

Slow mode selection

8.13 External hold

This signal is used to connect a stop switch of an external device. If the signal is input, the job is stopped. As long as the signal is ON, starting and axis movements cannot be enabled.

CAUTION!

Injuries and machine damages caused by short-circuit

Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.

 Be sure to remove the jumper before using.

-X18

Description of Units and Circuit Boards

(JANCD-YSF22-E)

CN219

EXHOLD+

EXHOLD-

Robot controller

Fig. 8-10: Connection for external hold

I/O terminal (machine safety)

I/O board (machine safety)

Remove the jumper cable

External hold

8.14 External SERVO-ON

External SERVO-ON

This signal is used to connect the servo ON switch of an external operation device. If the signal is input, the servo power is turned ON.

-X18

(JANCD-YSF22-E)

CN219

EXSVON+

EXSVON-

Fig. 8-11: Connection for external SERVO-ON

Robot controller

I/O terminal (machine safety)

I/O board (machine safety)

External SERVO-ON

Description of Units and Circuit Boards

8.15 SYSRUN Signal Output

This signal is used to check whether the robot control status is normal or abnormal.

This signal is output on the following conditions.

Fig. 8-12: (1) Connection for SYSRUN signal output

Main power supply ON/OFF

Robot control status normal/abnormal

SYSRUN ON/OFF

Because the pulse signal is outputted from the specific output signal (#50911) to the external device for each 100ms, it is also able to check whether the robot controller control circuit board is normal or abnormal (Refer to Instructions for Concurrent I/O for more details).

(JANCD-YFC22-E)

-X18

CN219

SYSRUN+

SYSRUN-

SYSRUN+

SYSRUN-

Fig. 8-13: (2) Connection for SYSRUN signal output

I/O board (machine safety)

I/O terminal (machine safety)

Description of Units and Circuit Boards

8.16 External axes overrun

CAUTION!

Injury and material damage in case of a non-functional signal

Jumper cables are installed at the factory. If the cables are not removed, injury or damage to machinery may result and the external emergency stop will not work even if the signal is input.

 Be sure to remove the jumper cables before using.

With a unit of standard specifications without an external axis, the external axis overrun input signal is not used. In this case, a jumper cable is connected as shown in the following figure.

If an overrun input signal for an axis other than manipulator axes, for example the external axis, is required, connect the signal input circuit in the following manner.

For safe reason, a dual circuits are used for the external axis overrun signal input. Connect the external axis overrun signal so that both input signals are turned ON or OFF at the same time.

If only one signal is turned ON, the machine safety signal error occurs.

-X18

(JANCD-YSF22-E)

CN219

OT2_1+

OT2_1-

OT2_2+

OT2_2-

Fig. 8-14: Connection for external axis overrun

Robot controller

I/O terminal (machine safety)

External axis overun

Remove the jumper cable

I/O board (machine safety)

Turn OFF/ON at the same time

The following figure shows the external axis overrun wiring of the factory default setting when the external axes are connected to the robot controller.

Please refer to the following figure to connect the external axes overrun signal to wire in the another route. On that occasion, confirm the external axes overrun setting to connect.

Description of Units and Circuit Boards

-X18

(JANCD-YSF22-E)

CN219

OT2_1+

OT2_1-

OT2_2+

OT2_2-

OT3_1+

OT3_1-

OT3_2+

OT3_2-

OT4_1+

OT4_1-

OT4_2+

OT4_2-

Fig. 8-15: Connection for external axis overrun (multiple lines)

Robot controller

I/O-Terminal (machine safety)

I/O Platine (machine safety)

External axis overrun 1. line

Turn ON/OFF at the same time

External axis overrun 2. line

External axis overrun 3. line

Description of Units and Circuit Boards

8.17 SERVO-ON enable input

Connect the ONEN signal lines to enable the function to turn ON or OFF the servo power supply of an individual servo when a robotic system is divided into areas.

Because these signals are not used for units of standard specifications, a jumper cable is connected as shown in the following figure.

For safety reasons, dual circuits are used for the SERVO-ON enable input signals. Connect the signal switch so that both input signals are turned ON or OFF at the same time. If only one signal is turned ON, an alarm occurs.

-X18

(JANCD-YSF22-E)

CN219

ONEN1_1+

ONEN1_1-

ONEN1_2+

ONEN1_2-

Fig. 8-16: Connection for SERVO-ON enable input

Robot controller

I/O terminal (machine safety)

I/O board (machine safety)

SERVO-ON enable input

Remove the jumper cable

Turn OFF/ON at the same time

Description of Units and Circuit Boards

8.18 Emergency stop button output

The extra contact output terminals of the emergency stop button on the programming pendant are provided on the terminal block on the cabinet door.

These contacts are always valid no matter if the robot controller power supply is ON or OFF.

CAUTION!

Damage to property caused by short-circuit

 Do not use the emergency stop button with a voltage of 24 V AC, 0.5 A or more.

-X18

CN219

PBESP3+

PBESP3-

PBESP4+

PBESP4-

(JANCD-YFC22-E)

PBESP3+

PBESP3-

PBESP4+

PBESP4-

PPESP3+

PPESP3-

PPESP4+

PPESP4-

PPESP3+

PPESP3-

PPESP4+

PPESP4-

3 troller

Fig. 8-17: Emergency stop button output

Control cabinet door of the robot con-

Emergency stop button

I/O board (machine safety)

I/O terminal board (machine safety)

Robot controller

Programming pendant

Description of Units and Circuit Boards

8.19 Universal safety input

The universal safety input signal is used in the safety logic circuit function. universal safety input.

-X18

(JANCD-YSF22-E)

CN219

GSIN1_1+

GSIN1_1-

GSIN1_2+

GSIN1_2-

Robot controller

Machine safety terminal block circuit board

Fig. 8-18: Universal safety input

Universal safety input

Turn ON/OFF at the same time

Machine safety I/O logic ciruit board

Description of Units and Circuit Boards

8.20 Universal safety output

The universal safety output signal is used in the safety logic circuit function.

For example, composing the circuit to output the status signal, such as the servo ON signal or the emergency stop button by the safety logic circuit function enables to output the signals to the external device.

The signal is outputted as the dual signals, and inputs the status of the driven devices by the output signal as the monitoring signal.

-X18

CN219

GSOUT1_1+

(JANCD-YFC22-E)

GSOUT1_172

GSOUT1_2+

GSOUT1_2-

GSEDM1+

GSEDM1-

Robotcontroller board

Fig. 8-19: Universal safety output

Machine safety terminal block circuit

Machine safety I/O logic ciruit board

Universal safety output 1

Universal safety output 2

Monitoring signal

NOTICE

 Rated output value is DC24V and less than 50mA. Avoid excessive load when connect.



When connect the inductive load, such as the safety relay, with the output circuit, use of the built-in protective circuit for the surge suppressor or connect the flyback diode in parallel to the inductive load to suppress the surge voltage. It may cause the damage on the output circuit.

 The feedback signal must be inputted to the robot controller when use the universal safety output signal.

Description of Units and Circuit Boards

8.21 Direct-in (SERVO) 1 to 6

This signal is used to input a response signal in search functions.

-X18

93,94

91,92

(JANCD-YSF22-E)

CN219

024V2

(SRDA-EAXA21A)

AXDIN1

AXDIN2

AXDIN3

AXDIN4

AXDIN5

AXDIN6

AXDIN_COM

+24V2

(JANCD-YFC22-E)

93,94

91,92

(JANCD-YSF22-E)

CN219

024V2

(SRDA-EAXA21A)

AXDIN1

AXDIN2

AXDIN3

AXDIN4

AXDIN5

AXDIN6

AXDIN_COM

+24V2

Fig. 8-20: Connection for Direct-in (SERVO) 1 to 6

This part of the wiring is for the SLAVE, for control voltage supply and for the control card for the main axles of the slave robot, SRDA-EAXA01.

I/O terminal board (machine safety)

I/O board (machine safety)

Connect the jumper cable

Direct-in (SERVO)

Connect the jumper cable

Description of Units and Circuit Boards

8.22 Universal input (SERVO)

Connect when use the universal signal

-X18

93,94

(JANCD-YSF22-E)

CN219

024V2

(SRDA-EAXA21A)

AXIN1

91,92

AXIN2

AXIN_COM

+24V2

Robot controller board

Fig. 8-21: Universal input (SERVO)

Machine safety terminal block circuit

Machine safety I/O logic ciruit board

Major axes control circuit board

Universal input (SERVO)

Connect the jumper cable.

8.23 Universal output (SERVO)

Connect when use the universal signal

(SRDA-EAXA21A)

AXOUT1

(JANCD-YSF22-E)

CN219

-X18

AXOUT2

91,92

+24V2

Robotcontroller

Machine safety terminal block circuit board

Fig. 8-22: Universal input (SERVO)

Major axes control circuit board

Universal output (SERVO)

Machine safety I/O logic ciruit board

Description of Units and Circuit Boards

8.24 Universal I/O circuit board (JANCD-YIO22-E)

Four digital I/O connectors for the robot universal I/O are provided:

40 inputs and 40 outputs. The I/Os are divided into two types: universal I/O and specific I/O.

The I/O assignment differs depending on the application. Specific I/O is a signal in which the part is decided in advance. Specific I/O is used when the external operation equipment, such as position controller and central controller, controls the robot and the connected devices as a system. Universal I/O are mainly used as timing signals for the robot and peripheral devices in jobs that require robot motion.

Refer to chapter „Universal I/O signal assignment“ for more details on signal allocation.

For the connection of the robot’s universal I/O signal connectors, and the I/O signal related to start and stop to refer to "Connetion wire with universal I/O Connector (CN306, 307, 308,

309)" and "Specific I/O Signal Related to Start and Stop".

For switching external power supply

(CN303)

Power Supply Protective Fuse (F1, F2)

3.15A/250 V

Power Supply Output (CN304)

Digital I/O (CN307, CN306, CN308 and

CN309)

(CN307)

(CN309)

4 (CN306)

4 (CN308)

•

Connection wire with robot universal I/O connector (CN306, 307, 308, 309)

Please refer to the figure below when you manufacture the cable connecting with robot universal I/O connector (CN306, 307, 308, 309) of robot I/O unit (JZNC-YIU01-E).

Unshielded twisted pair cable must be used (the cable side connector and the I/O terminal block are the options).

-X18 A1 A3 A5 A7 A9 A11

Fig. 8-23: PNP logic

A13 A15 A17 A19 A31

Description of Units and Circuit Boards

NOTICE

When connecting an inductive load to the output circuit, connect a flyback (snubber) diode in parallel to the inductive load to suppress the surge voltage. Not using a fly-wheel diode may damage the output circuit.

When connecting a load with a large inrush current such as a lamp, connect a current limiting resistance in series to the load, so that the output current does not exceed its maximum value. Exceeding the maximum output current value may damage the output circuit.

Universal I/O circuit board

Inductive load

Flywheel diode

Lamp

Current limiting resistor

(JANCD-YIO22-E)

+24VU

5 4

024VU

Refer to chapter 8.29 "Assignment of general I/O signal" from 92 about the maximum current of the transistor and the relay output circuits.

•

Specific I/O signal related to start and stop

The following signals are specific I/O signals related to start and stop.

• SERVO ON (depending on application: JANCD-YIO22-E)

• External SERVO ON (common to all application: JANCD-YFC22-E) external start

(depending on application: JANCD-YIO22-E)

• Operating (depending on application: JANCD-YIO22-E)

• External Hold (common to all application: JANCD-YFC22-E)

• External Emergency Stop (common to all application: JANCD-YFC22-E)

Timing chart

Robot

While SERVO-ON

SERVO-ON

External start

Execution

Extern Stop

Emergency shut-off

RUN

STOP

OFF

Note: set T = 100 ms minimum

Description of Units and Circuit Boards

•

Example of SERVO ON Sequence Circuit from External Device

Only the rising edge of the SERVO ON signal is valid. This signal turns ON the robot

SERVO power supply. The set and reset timings are shown in the following.

SERVO ON PB

SERVO ON confirmation

SERVO_ON command

Robot controller

Machine safety terminal block circuit board

Machine safety I/O logic circuit board

Universal I/O circuit board

SERVO-ON power ON

SERVO-ON is output

SERVO-ON power ON X3

㼄㻝

(30011)

(JANCD-YFC22-E)

(JANCD-YSF22-E)

CN219

+24V2

EXSVON

JANCD-YIO21-E

CN308

+24VU

A18

9 (30011)

NOTICE

Number in ( ) means output signal number assigned to YIU21.

PL: Pilot lamp

Description of Units and Circuit Boards

•

Example of start sequence circuit from external device

Only the rising edge of the external start signal is valid. This signal starts the robot. Set this signal with the interlock configuration which determines whether operation can be started.

The playback signal (RUNNING) confirms that the robot is actually moving.

Run PB

While SERVO-ON

Selects PLAY mode

Alarm/Error Occurring

Running confirmation

Start (Command)

Robot controller

External Start Command

External start input

Ongoing output

Running, etc.

Running X6

㻼㻸㼄㻡

㼄㻠

㼄㻢

11 8

NOTICE

Number in ( ) means output signal number assigned to YIU21.

PL: Pilot lamp

Description of Units and Circuit Boards

•

Connection of the external power supply for I/O

In the factory setting, the internal power supply for I/O is used. If the external power supply for I/O is used, connect it as described below.

1. Remove the wire connected between CN303-1 to -3 and CN303-2 to -4 of the universal

I/O circuit board.

2. Connect +24V of the external power supply to CN303-1 and 0V to CN303-2 of the robot

I/O unit.

Universal I/O circuit board

External supply

Provided by the customer

In case of using external power supply.

In case of using internal power supply (factory settings).

+24V

(JANCD-YIO21-E)

CN303

+24VU

1(EX+24VIN)

2(EX024VIN)

3.15A

024VU

3(+24V)

+24V

4(024V)

024V

(JANCD-YIO21-E)

CN303

+24VU

1(EX+24VIN)

2(EX024VIN)

3.15A

024VU

3(+24V)

4(024V)

+24V

024V

NOTICE

 The internal power supply of 24V of about 1.5 A of robot control can be used for I/O.

Use external 24V power supply for higher currents and to isolate the circuit inside and outside the robot control.



Power supply circuit for I/O (+24 VU, 024 VU) has 3.15A fuses (F1, F2).

 Install the external power supply outside the DX200 to avoid electric noise problems.



If the internal power supply is selected and the external power supply is connected to

CN303-1 to -3 and CN303-2 to -4, do not connect the external power supply line to the

+24VU and 0VU terminals. The unit may malfunction if the external power supply is also connected.

Description of Units and Circuit Boards

8.25 Brake control circuit board (JANCD-YBK21-3E)

The brake control circuit board controls ON/OFF of the brakes of total nine axes (Robot + external axes) according to the command signal from the major axes control circuit board

(SRDA-EAXA21A).

Axes control cicuit board I/F (CN405)

For external brake power supply (CN404)

Brake power supply input (CN403)

Brake power supply fuse (F1: For external axes) 3,15A/

250V

Brake interlock (CN402)

Handbrake release unit I/F (CN401)

Brake I/F (CN400)

Description of Units and Circuit Boards

8.26 Converter (SRDA-COA30A21B-E)

The converter (SRDA-COA30A21B-E) exchanges the power supply (3-phase: AC200/

220V) supplied by the power ON unit for DC power supply and supplies the power to the amplifier module (PWM amplifiers).

Grounding detection input (CN554)

Converter control signal (CN553)

Monitor/Alarm indication LED

DC control power supply (CN551)

Control power supply output for six axes amplifier

(CN552A)

Control power supply output for external axes amplifier

(CN552B)

Grounding terminal

Charge lamp

External axes main circuit connection (CN558)

Power supply regenerative unit connection (CN559)

Main circuit power supply output (CN556)

Regenerative resistor (CN557)

Main circuit power supply input (CN555)

Description of Units and Circuit Boards

8.27 Capacitor module (SRDA-CUA



AA)

The capacitor module smooth the DC voltage (PN voltage) created in the converter and also save the electric energy.

There are two type of the capacitors shown below:

• Small capacity: SRDA-CUA662AA

• Medium / Large capacity: SRDA-CUA133AA

SRDA-CUA492AA SRDA-CUA662AA SRDA-CUA133AA

Fig. 8-24: Capacitor module (SDRA-CUA



AA)

Description of Units and Circuit Boards

8.28 Amplifier module (SDRA-SDA



A01A-E)

The amplifier module exchanges the DC power supply supplied by a converter for a 3phase motor power source and outputs to each servo motor.

Main circuit power supply input (CN583)

Control power supply input (CN582)

PWM signal (CN581)

Motor power output (CN584)

Fig. 8-25: Amplifier Position

Description of Units and Circuit Boards

8.29 Assignment of general I/O signal

NOTICE

Damage to property caused by short-circuit

For details on wiring, see the circuit diagram.

-AE7

&EFA/14.4

JANCD-YIO22-E

-CN306

IN009

IN010

IN011

IN012

IN013

IN014

IN015

IN016

20040

20041

20042

20043

20044

20045

20046

20047

024VU

NC1

NC2

NC3

NC4

024VU

+24VU

OUT009

OUT010

OUT011

OUT012

OUT013

OUT014

OUT015

OUT016

30040

30041

30042

30043

30044

30045

30046

30047

NC5

NC6

NC7

NC8

B12

A12

B13

A13

NC9

NC10

NC11

NC12

B14

A14

B15

A15

B10

A10

B11

A11

024VU

B16

A16

B17

A17

+24VU

B18

A18

B19

A19

NC13

B20

A20 assignment interface board

B10

A10

B11

A11

B12

A12

B13

A13

B14

-XD306

A14

B15

A15

B16

A16

B17

A17

B18

A18

B19

A19

B20

A20

A14

B15

A15

B16

A16

B17

A17

B18

A18

B19

A19

B20

A20

B10

A10

B11

A11

B12

A12

B13

A13

B14

-AE7-CN306

Fig. 8-26: JANCD-YIO22-E (CN306-Connector) I/O allocation

Description of Units and Circuit Boards

-AE7

&EFA/14.4

JANCD-YIO22-E

-CN307

IN017

IN018

IN019

IN020

IN021

IN022

IN023

IN024

20050

20051

20052

20053

20054

20055

20056

20057

024VU

NC14

NC15

NC16

NC17

OUT017

OUT018

OUT019

OUT020

OUT021

OUT022

OUT023

OUT024

30050

30051

30052

30053

30054

30055

30056

30057

A10

B11

A11

B12

A12

B13

B10

A13

B14

A14

B15

A15

024VU

A7 assignment interface board

024VU

B16

A16

B17

A17

+24VU

B18

A18

B19

A19

NC18

B20

A20

Fig. 8-27: JANCD-YIO22-E (CN307-Connector) I/O allocation

A17

B18

A18

B19

A19

B20

A20

A13

B14

A14

B15

A15

B16

A16

B17

B10

A10

B11

A11

B12

A12

B13

-XD307

A17

B18

A18

B19

A19

B20

A20

A13

B14

A14

B15

A15

B16

A16

B17

B10

A10

B11

A11

B12

A12

B13

-AE7-CN307

Description of Units and Circuit Boards

-AE7

&EFA/14.4

JANCD-YIO22-E

-CN308

20010

20011

20012

20013

20014

20015

20016

20017

20020

20021

20022

20023

NC19

NC20

NC21

NC22

B14

A14

B15

A15

024VU

B16

A16

B17

A17

+24VU

B18

A18

B19

A19

NC23

B20

A20

024VU

30010

30011

30012

30013

30014

30015

30016

30017

30020

30021

30022

30023

B11

A11

B12

A12

B13

A13

B10

A10

Fig. 8-28: JANCD-YIO22-E (CN308-Connector) I/O allocation

assignment interface board

A12

B13

A13

B14

A14

B15

A15

B16

B10

A10

B11

A11

B12

A16

B17

A17

B18

A18

B19

A19

B20

A20

-AE7-CN308

A12

B13

A13

B14

A14

B15

A15

B16

B10

A10

B11

A11

B12

A16

B17

A17

B18

A18

B19

A19

B20

A20

-XD308

Description of Units and Circuit Boards

-AE7

&EFA/14.4

JANCD-YIO22-E

-CN309

IN001

IN002

IN003

IN004

IN005

IN006

IN007

IN008

20024

20025

20026

20027

20030

20031

20032

20033

20034

20035

20036

20037

024VU

OUT001

OUT002

OUT003

OUT004

OUT005

OUT006

OUT007

OUT008

30024

30025

30026

30027

30030

30031

30032

30033

30034

30035

30036

30037

B10

A10

B11

A11

B12

A12

B13

A13

NC24

NC25

NC26

NC27

B14

A14

B15

A15

024VU

B16

A16

B17

A17

+24VU

B18

A18

B19

A19

NC28

B20

A20

Fig. 8-29: JANCD-YIO22-E (CN309-Connector) I/O allocation

assignment interface board

B13

A13

B14

A14

B15

A15

B16

A16

B17

A17

B18

A18

B19

A19

B20

A20

B10

A10

B11

A11

B12

A12

-AE7-CN309

B13

A13

B14

A14

B15

A15

B16

A16

B17

A17

B18

A18

B19

A19

B20

A20

B10

A10

B11

A11

B12

A12

-XD309

Description of Units and Circuit Boards

Logical number

20010

Input name / Function

EXTERNAL START

Functions the same as the [START] button in the programming pendant. Only the rising edge of the signal is valid. It starts robot operation (playback). This signal is invalid if external start is prohibited from the playback condition display.

20012

CALL MASTER JOB

Only the rising edge of the signal is valid. It calls up the top of the robot program, that is the top of the master JOB

. This signal is invalid during playback, during teach lock and when play master or call is prohibited (set from the playback operation condition display).

20013

ALARM/ERROR RESET

After an alarm or error has occurred and the cause been corrected, this signal resets the alarm or error.

20015

SELECT PLAY MODE

The play mode is selected when the mode key on the programming pendant is set at "REMOTE". Only the rising edge of the signal is valid. When this selection signal assigned concurrently with other mode selection signal, the teach mode is selected on a priority basis. The signal is invalid while EXTERNAL MODE

SWITCH is prohibited.

20016

SELECT TEACH MODE

The TEACH mode is selected when the mode key of the programming pendant is set at "REMOTE". The other mode selection is unavailable when this signal is ON; the signal is selected by priority even when the other selection signal is ON, enabling the

TEACH mode selection.

20020

INTERFERENCE 1 ENTRANCE PROHIBITED

If the robot attempts to enter the cube 1

area while this signal is

ON, the robot goes to wait status (with SERVO power ON). During wait status, the robot operation restarts if this signal turns OFF.

20021

INTERFERENCE 2 ENTRANCE PROHIBITED

If the robot attempts to enter the cube 2

area while this signal is

ON, the robot goes to wait status (with SERVO power ON). During wait status, the robot operation restarts if this signal turns OFF.

1. A master JOB is a JOB (program) which can be called by CALL MASTER JOB.Other functions are the same as for normal JOBs. Normally, the parent JOB, which manages the child JOBs called up immediately after the power is turned ON, is set as the master JOB.

2. See you System Setup Manual chapter "Interference area".

Logical Number

30010

Output Name / Function

RUNNING

This signal signifies that the job is running. (Signifies that the job is running, system status is waiting reserved start, or test run is running.) This signal status is the same status as [START] in the programming pendant.

Description of Units and Circuit Boards

Logical Number

30011

Output Name / Function

SERVO IS ON

This signal signifies that the SERVO power is turned ON, internal processing such as current position creation is complete, and the system is able to receive the START command. This signal turns

OFF when the SERVO power supply turns OFF. It can be used for

DX200 status diagnosis for an external start.

30012

TOP OF MASTER JOB

This signal signifies that the execution position is the top of the master job. This signal can be used to confirm that the master job has been called

30013

30014

ALARM/ERROR OCCURRED

This signal signifies that an alarm or an error occurred. If a major error occurs, this signal remains ON until the main power is turned

OFF.

ATTERY ALARM

This signal turns ON to notify that the battery requires replacing when the voltage drops from the battery for backup memory of the encoder. Major problems may result if memory data is lost because of an expired battery. It is recommended to avoid these problems by using this signal as a warning signal.

30015 to30017

REMOTE/PLAY/TEACH MODE SELECTED

This signal notifies the current mode setting. These signals are synchronized with the mode select switch in the programming pendant. The signal corresponding to the selected mode turns

ON.

30020

IN CUBE 1

This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1). Use this signal to prevent interference with other robots and positioners.

30021

30022

IN CUBE 2

This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2). Use this signal to prevent interference with other robots and positioners.

WORK HOME POSITION (IN CUBE 64)

This signal turns ON when the current TCP lies inside the work home position area. Use this signal to evaluate whether the robot is in the start position.

30023

INTERMEDIATE START OK

This signal turns ON when the robot operates. It turns OFF when the currently executed line is moved with the cursor or when editing operation is carried out after HOLD is applied during operation. Therefore, this signal can be used as a restart interlock after a HOLD is applied. However, it also turns ON in the TEACH mode and TEACH MODE SELECTED signal must be referred together.

1. This signal is not output during operation.

2. Der CUBE der Arbeitsausgangsstellung und der CUBE 64 sind identisch.

Description of Units and Circuit Boards

8.29.1 ARC welding

Logical number I/O Name / Function

20010

EXTERNAL START

20022

WORK PROHIBITED (Arc Generation Prohibited)

Arc generation is prohibited while this signal is ON. Arc generation starts when this signal turns OFF inside the arc-generation area. Use this signal to confirm teaching.

20023

WORK RESPONSE (Pseudo Arc ON Response)

This signal is used as a pseudo signal in cases that “Arc Generation

Confirmation” signal is not equipped on a welding power supply. Wire this signal ON normally (short to OV).

20026

WEAVING PROHIBITED

Weaving is prohibited while this signal is ON. Use this signal to check taught steps and movements without performing the weaving operation.

20027

SENSlNG PROHIBITED

Arc sensing is prohibited while this signal is ON. Use this signal to check taught steps and movements if an arc sensor is mounted.

30010

RUNNING

30011

SERVO IS ON

This signal signifies that the SERVO power is turned ON, internal processing such as current position creation is complete, and the system is able to receive the START command. This signal turns

OFF when the SERVO power supply turns OFF. It can be used for

DX200 status diagnosis for an external start.

30012

TOP OF MASTER JOB

This signal signifies that the execution position is the top of the master job. This signal can be used to confirm that the master job has been called

30013

ALARM/ERROR OCCURRED

This signal signifies that an alarm or an error occurred. If a major error occurs, this signal remains ON until the main power is turned OFF.

1. This signal is not output during operation.

Description of Units and Circuit Boards

8.29.2 Handling

Logical number I/O Name / Function

20026

TOOL SHOCK SENSOR

This is normally ON (NC) signal input. When it turns OFF, an DX200 displays a message "HAND TOOL SHOCK SENSOR OPERATING" and a HOLD is applied. The releasing in teach mode is done on the handling application diagnostic display. Set TOOL SHOCK SENSOR function “NOT USE” on the handling applications diagnostic display if this signal is not be used.

20027

LOW AIR PRESSURE

This signal is normally OFF (NO). When it turns ON, robot controller displays user alarm in the PLAY mode or displays user message in the TEACH mode.

20050 to20057

SENSOR INPUT 1 - 8

Inputs 1 to 8 are monitored with the HSEN handling specific instructions. Sensor inputs 1 to 8 correspond to HSEN 1 to 8.

30050 to30057

HAND VALVE 1-4

These outputs are controlled by the HAND handling specific instructions. Hand valves 1 to 4 correspond to HAND 1 to 4.

8.29.3 General application

Logical number I/O Name / Function

20024

INTERFERENCE 3 ENTRANCE PROHIBITED

If the robot attempts to enter the cube 3

area while this signal is ON, the robot goes to wait status (with SERVO power ON). During wait status, the robot operation restarts if this signal turns OFF.

20025

INTERFERENCE 4 ENTRANCE PROHIBITED

If the robot attempts to enter the cube 4

area while this signal is ON, the robot goes to wait status (with SERVO power ON). During wait status, the robot operation restarts if this signal turns OFF.

30024

IN CUBE 3

This signal turns ON when the current TCP lies inside a pre-defined space (Cube 3). Use this signal to prevent interference with other robots and positioners.

30025

IN CUBE 4

This signal turns ON when the current TCP lies inside a pre-defined space (Cube 4). Use this signal to prevent interference with other robots and positioners.

Description of Units and Circuit Boards

8.29.4 Spot welding

Logical number

20022

Input name / Function

20023

20024

20025

20050

20051

20052

20053

WELDING ON/OFF (from sequencer)

This signal inputs the welding ON/OFF selector switch status from the sequencer in the interlock unit. The WELD ON/OFF signal is output to the Power Source according to this signal and the robot status.

WELDING PAUSE (from sequencer)

This signal is used to move the robot to the home position when an error occurs in the Power Source or the gun.

The robot ignores the spot welding instruction and operates playback motion.

INTERFERENCE 3 ENTRANCE PROHIBITED

If the robot attempts to enter cube 3

while this signal is ON, the robot is put into wait status (with servo power ON). During wait status, robot movement is started as soon as this signal turns OFF.

INTERFERENCE 4 ENTRANCE PROHIBITED

If the robot attempts to enter cube 4

while this signal is ON, the robot is put into wait status (with servo power ON). During wait status, robot movement is started as soon as this signal turns OFF.

TIMER COOLING WATER ERROR

This signal monitors the status of timer cooling water. The robot displays alarm and stops when this signal is input. The SERVO power supply remains ON.

GUN COOLING WATER ERROR

This signal monitors the status of gun cooling water. The robot displays alarm and stops when this signal is input. The SERVO power supply remains ON.

TRANSTHERMO ERROR

Error signal is sent from the transformer in the gun to the robot. The signal is normally an ON (NC) signal. An alarm occurs when the signal is

OFF. The SERVO power supply remains ON.

LOW AIR PRESSURE

When air pressure is reduced and this input is turned ON, an alarm occurs. The SERVO power supply remains ON.

WELD COMPLETION

This signal indicates that the Power Source completed welding without error. This signal is used as a confirmation signal for welding instruction execution and manual spot welding.

After this signal is input, the welding sequence is completed and the next step is executed when confirmation limit switch is not provided.

WELDING ERROR

This signal indicates an abnormal welding result or Power Source’s error. Alarm occurs and the manipulator stops if this signal is input during welding.

Description of Units and Circuit Boards

Logical number

Input name / Function

30057

30024

30025

30050

30051

(30052 to

300564)

STICK DETECTION

This signal indicates an abnormal welding result or Power Source’s error. Alarm occurs and the manipulator stops if this signal is input during welding.

GUN FULL OPEN DETECTION

This signal indicates that the stroke of the double stroke gun is full open.

GUN SHORT OPEN DETECTION

This signal is connected with a single gun open verification limit switch or a double stroke gun short open verification limit switch to verify the gun open.

GUN PRESSURE DETECTION

This signal indicates that a gun is in pressing status.

TIP REPLACE COMPLETION

When this signal is input after tip replacement, the TIP REPLACE RE-

QUEST signal turns OFF, and the stored number of welding is cleared.

TIP REPLACE REQUEST

This signal is output when the stored number of welding reaches the number of welding set for the tip replacement.

IN CUBE 3

This signal is turned ON when the current TCP lies within a pre-defined area (cube 3). Use this signal to prevent faults due to other robots or positioners.

IN CUBE 4

This signal is turned ON when the current TCP lies within a pre-defined area (cube 4). Use this signal to prevent faults due to other robots or positioners.

WELD ON/OFF

Outputs a signal input from the interlock panel, etc.considering the robot status.

WELD ERROR RESET

This signal commands the reset error status of the power source. This is operated with the programing pendant operation.

WELD CONDITION (Level-Signal)

1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8)

Sets the welding conditions for the power source.

The output format can be set as binary or discrete (bit number.) It can handle up to 255 conditions. Most-significant bit is the parity bit (when specified).

WELDING COMMAND

This signal outputs execution command signal to the power source.

This signal is not necessary for a power source which is executed using the WELDING CONDITION signal.

Description of Units and Circuit Boards

Logical number

Input name / Function

STROKE CHANGE1

SINGLE SOLENOID

DOUBLE SOLENOID

This is a signal, when a double stroke gun is used, to change the open stroke of the welding gun.

GUN PRESS COMMAND

This outputs gun press command.

1. This signal can be set as “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is selected, this signal can be used as the universal I/O signal described in parentheses.

2. This signal can be select “USE” or “NOT USE” by pseudo input signal "8202x". If "NOT USE" is selected, this signal can be used as the universal I/O signal described in parentheses.

3. This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.

7 6 5 4 3 2 1 0

0 0 0 1 1 1 1 1

Timer cooling water error validating ( or IN09)

GUN Cooling Water Error Validating

(or IN10)

Transthermo error validating (or

IN11)

Low air pressure validating (or IN12)

Weld ON/OFF Validating (or OUT09)

Pseudo Input Signal 8202x

Description of Units and Circuit Boards

8.29.5 JANCD-YEW01-E circuit board (Standard)

JANCD-YEW01-E Circuit Board: Analog outputs ´ 2 ports, Analog inputs ´ 2 ports + Status signal I/O of a Welder.

MR Connector MS Connector

Each point

24 VDC

5mA MAX

A/D +5V

DC24V

5mA MAX

DC24V

0.5A MAX

Detector

D/A ±14V

SW2

D/A ±14V

17BYTE 32BYTE

DC24V

0.5A MAX

Logical

Number

Connector

Pin No.

Name

CN322-1

25110

CN322-2

+GASOF (Gas Shortage)

25111

CN322-3

CN322-4

-GASOF (Gas Shortage)

+WIRCUT (Wire Shortage)

-WIRCUT (Wire Shortage)

CN322-5

25113 CN322-6 +ARCACT (

Arc Generation Confirm

)

CN322-7

CN322-8

-ARCACT (

Arc Generation Confirm

)

CH2 (Current Input)

Signal

CN322-9

CN322-10

CN322-11

CH1 (Voltage Input)

CN322-12

25112 CN322-13

+ARCOFF (Arc Shortage)

CN322-14

-ARCOFF (Arc Shortage)

35111

CN322-15

ARCON (Arc ON) A

CN322-16

ARCON (Arc ON) B

35112 CN322-17

WIRINCH (Wire Inching) A

CN322-18 WIRINCH (Wire Inching) B

35113 CN322-19

WIRINCH (Wire Retract) A

CN322-20

WIRINCH (Wire Retract) B

35127

CN322-21

GAS Checking OUT A

CN322-22

GAS Checking OUT B

CN322-23

CN322-24

OUT

CN322-25

25114

CN322-26

STICK (Wire Sticking)

CN322-27

*STICK (Wire Sticking)

CN322-28

CN322-29

+24VU

CN322-30

CN322-31

CH1 (Voltage Command)

CN322-32

CN322-33

CH2 (Current Command)

CN322-34

OUT

CN321-1

+24VU

35115

CN321-2

Search Command A (Optional)

CN321-4 Search Command B (Optional)

CN321-5

OUT

Power

Source

WAGO Connector(231-105/026-A0)

MRP-34M01 Insulator

MRP-M112 Contactor

RP-34 Casing

MS3106 A, 20-29P

MS3106 A, 20-29S

Fig. 8-30: JANCD-YEW01-E circuit board (Standard)

Description of Units and Circuit Boards

8.29.6 The list of the Equipment configuration by model

Model

Type

Dimension W x H x D (mm)

Breaker

Control power supply unit

CPU unit

CPU circuit board

Back circuit board

PCI raiser circuit board

Robot I/F circuit board

Machine safety CPU circuit board

Machine safety I/O logic circuit board

Machine safety terminal block

Universal I/O circuit board

Power ON unit

Major axes control circuit board

Brake control circuit board

Converter

Capacitor module

Amplifier module AMP1 (S-axis)

AMP2 (L-axis)

AMP3 (U-axis)

AMP4 (R-axis)

AMP5 (B-axis)

AMP6 (T-axis)

Regenerative resistor Type

Rated value

Register value

Heat exchanger

Colling fan

MA1440/MH12

ERER-MA1440/MH12-A00

1000 x 800 x 650

NF32-SVF 3P 15A

JZNC-YPS21-E

JZNC-YRK21-1E

JANCD-YCP21-E

JANCD-YBB21-E

JANCD-YBB22-E

JANCD-YIF01-2E

JANCD-YSF21-E

JANCD-YSF22-E

JANCD-YFC22-E

JANCD-YIO22-E

JZRCR-YPU51-1

SRDA-EAXA21A

JANCD-YBK21-3E

SRDA-COA30A21B-E

SRDA-CUA662AA

SRDA-SDA14A01A-E

SRDA-SDA21A01A-E

SRDA-SDA14A01A-E

SRDA-SDA06A01A-E

SMVK500W6R0J/R0 A6103

500W

6 Ω

4715MS-22T-B50-B00 x2

4715MS-22T-B50-B00 x3 or

11938MB-B2N-EA-01 x3

Tab. 8-2: Model MA1440 and MH12

100

Description of Units and Circuit Boards

Model

Type

Dimension W x H x D (mm)

Breaker

Control power supply unit

CPU unit

CPU circuit board

Back circuit board

PCI raiser circuit board

Robot I/F circuit board

Machine safety CPU circuit board

Machine safety I/O logic circuit board

Machine safety terminal block

Universal I/O circuit board

Power ON unit

Major axes control circuit board

Brake control circuit board

Converter

Capacitor module

Amplifier module AMP1 (S-axis)

AMP2 (L-axis)

AMP3 (U-axis)

AMP4 (R-axis)

AMP5 (B-axis)

AMP6 (T-axis)

Regenerative resistor Type

Rated value

Register value

Heat exchanger

Cooling fan

MS210/MH225

ERER-MS210/MH225-A00

1000 x 800 x 650

NF32-SVF 3P 30A

JZNC-YPS21-E

JZNC-YRK21-1E

JANCD-YCP21-E

JANCD-YBB21-E

JANCD-YBB22-E

JANCD-YIF01-2E

JANCD-YSF21-E

JANCD-YSF22-E

JANCD-YFC22-E

JANCD-YIO22-E

JZRCR-YPU51-1

SRDA-EAXA21A

JANCD-YBK21-3E

SRDA-COA30A21B-E

SRDA-CUA133AA

SRDA-SDA71A01A-E

SRDA-SDA35A01A-E

SMVK500W2R0J A5978 x3

1500W

6 Ω

TCSIP-16A4Y-0C

4715MS-22T-B50-B00 x3 or

11938MB-B2N-EA-01 x3

Tab. 8-3: Model MS210/MH225

101

Description of Units and Circuit Boards

Model

Type

Dimension W x H x D (mm)

Breaker

Control power supply unit

CPU unit

CPU circuit board

Back circuit board

PCI raiser circuit board

Robot I/F circuit board

Machine safety CPU circuit board

Machine safety I/O logic circuit board

Machine safety terminal block

Universal I/O circuit board

Power ON unit

Major axes control circuit board

Brake control circuit board

Converter

Capacitor module

Amplifier module AMP1 (S-axis)

AMP2 (L-axis)

AMP3 (U-axis)

AMP4 (R-axis)

AMP5 (B-axis)

AMP6 (T-axis)

Regenerative resistor Type

Rated value

Register value

Heat exchanger

Cooling fan

MS165/MH180

ERER-MS165/MH180-A00

1000 x 800 x 650

NF32-SVF 3P 30A

JZNC-YPS21-E

JZNC-YRK21-1E

JANCD-YCP21-E

JANCD-YBB21-E

JANCD-YBB22-E

JANCD-YIF01-2E

JANCD-YSF21-E

JANCD-YSF22-E

JANCD-YFC22-E

JANCD-YIO22-E

JZRCR-YPU51-1

SRDA-EAXA21A

JANCD-YBK21-3E

SRDA-COA30A21B-E

SRDA-CUA133AA

SRDA-SDA71A01A-E

SRDA-SDA35A01A-E

SMVK500W2R0J A5978 x3

1500W

6 Ω

TCSIP-16A4Y-0C

4715MS-22T-B50-B00 x3 or

11938MB-B2N-EA-01 x3

Tab. 8-4: Model MS165/MH180

102

Robot controller specification

9 Robot controller specification

WARNING!

Make sure that there is no one within the P-point maximum envelope of the robot and that you are in a safe place before turning ON the robot controller power.

Injury may result from collision with the robot to anyone entering the P-point maximum envelope of the robot.

• Always set the teach lock before starting teaching.

• Observe the following precautions when performing teaching operations within the Ppoint maximum envelope of the robot:

– View the robot from the front whenever possible.

– Always follow the predetermined operating procedure.

– Always have an escape plan in mind in case the robot comes toward you unexpectedly.

– Ensure that you have a place to retreat to in case of emergency.

Improper or unintentional robot operation can result in injury.

• Before operating the robot, check that the SERVO ON lamp goes out when the emergency stop buttons the programming pendant are pressed.

Injury or damage to machinery may result if the robot cannot be stopped in case of an emergency.

The emergency stop buttons are located on the right of the front door of the robot controller and the programming pendant.

CAUTION!

• Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed.

– Check for problems in robot movement.

– Check for damage to the insulation and sheathing of external wires.

• Always return the programming pendant to its specified position after use.

If the programming pendant is inadvertently left on the robot, fixture, or on the floor, the robot or a tool could collide with it during robot movement, possibly causing injuries or equipment damage.

• Make sure that a system manager stores the key of the mode select switch on the programming pendant. After operation, the key should be removed and stored by the system manager.

Improper or unintended robot operation may result in injury.

Also, the key or the mode select switch may be damaged if the programming pendant is dropped with the key inserted.

103

Robot controller specification

9.1 Specification list

Controller

Dimension (W x H x D)

Weight

Protection class

Cooling system

Ambient temperature

Relative humidity

Vibration Acceleration

Power supply

Grounding

Noise Level

Digital I/O

800 x 1000 x 600 approx. 180 kg

IP54 (The back fan is IP2X.)

Indirect cooling

0°C to + 45°C (During operation)

-10°C to + 60°C (During transit and storage)

10% to 90% RH (non-condensing)

0.5G or less

3-phase 400/415/440 VAC at 50/60 Hz

Grounding resistance: 0,1 Ω

Less than 62 dB

General signals (standard, max.): 40 inputs and 40 outputs

(Transistor: 32 outputs, Relay: 8 outputs)

Positioning system

Drive unit

Acceleration / Deceleration Software SERVO control

Program memory 200,000 steps, 10,000 instructions and 15.000 PLC steps

Interface

Color

Ethernet

RAL 7024, Graphite Grey, RAL 7026, Granite Grey, RAL

7043, Traffic Grey B

Others

Specific signal (hardware): 25 inputs and 7 outputs

Absolute encoder / serial interface

SERVOPACK for AC SERVO motors

Free from corrosive gas or liquid, or explosive gas.

Free from exposure to water, oil, or dust.

Free from excessive electrical noise (plasma).

104

Robot controller specification

9.2 Function list

Programming pendant operation

Coordinate

System

• Joint

• Rectangular/Cylindrical

• Tool

Modification of Teaching Points

• User Coordinates

• Adding

Inching Operation

Path Confirmation

• Deleting

• Correcting (Robot axes and external axes respectively can be corrected)

Possible

Speed Adjustment

Timer Setting

Short-cut Function

Interface

• Forward/Reverse step

• Continuous feeding

Fine adjustment possible during operating or pausing

Possible every 0.01 s

Direct-open function, Multi-window

• CF card slot

• USB port (USB1.1) (At Programming Pendant)

Application

• RS-232C, RS-232C/RS-422 (Exclusion use)

• USB port (USB1.1): 2 ports

• LAN (100 BASE-TX/10BASE-T): 2 ports (At CPU circuit board)

• Arc welding

• Spot welding

• Handling

• General

Essential Measures

Running Speed Limit

Enable Switch

• Others

JIS (Japanese Industrial Standard)

User definable

3 position type. SERVO power can be turned on at the middle position only. (Located on programming pendant)

Collision proof Frames S-axis frame (doughnut-sector)

Cubic frame (user coordinate)

Self-Diagnosis Classifies error and two types of alarms (major and minor) and displays the data

User Alarm Display

Machine Lock

Door Interlock

Possible to display alarm messages for peripheral device

Test-run of peripheral devices without robot motion

A door can be opened only when a circuit breaker is OFF.

105

Robot controller specification

Programming pendant operation

Operation Time

Display

• Control power-on time

• SERVO power-on time

Alarm Display

• PLAYBACK time

• Operation time

• Work time

• Alarm message

• Troubleshooting

I/O Diagnosis

T.C.P. Calibration

• Previous alarm records

Simulated enabled/disabled output possible

Automatically calibrates parameters for end effectors using a master positioner

Interactive programming Programming Type

Language

Robot Motion Control

Speed Setting

Robot language: INFORM II

• Joint coordinates

• Linear/Circular interpolations

• Tool coordinates

• Percentage for joint coordinates

• 0.1mm/s units for interpolations

• Angular velocity for T.C.P. fixed motion

Program Control Instructions

I/O Instructions

• Jumps, Calls

• Timer

• Robot stop

• Execution of some instructions during robot motion

Operation Instructions Preparing the operation instructions for each application Arc

(ON), Arc (OFF), etc.

Variable

Variable Type

• Global variable

• Local variable

• Byte type

• Integer type

• Double precision type

• Real type

• Position type

• String type

• Discrete I/O

• Pattern I/O processing

106

Robot controller specification

9.3 Programming Pendant

Type

Material

Dimensions

(W x H x D) in mm

Material

Displayed Units

JZRCR-YPP03-1 or JZRCR-YPP13-1

Reinforced thermoplastic enclosure with a detachable suspending strap

169 x 314.5 x 50 mm (excluding protrusions)

Operated Units

IEC protection class

Cable length

Others

Key sheet

Reinforced plastic

TFT Color liquid crystal display, VGA (640 x 480)

Touch panel

• 3-position enable switch, start switch, hold switch, and mode select switch (with key, three mode)

• Type of the key for the mode select switch: AS6-SK-132

(manufactured by IDEC Corp.)

* Two keys are shipped with the programming pendant.

IP65

Standard: 8 m, Max.: 20 m (optional)

• Provided with CF (Compact Flash) card slot

• USB port (USB1.1) x 1

General (1 sheet only)

107

Robot controller specification

9.4 Device configuration

The robot controller is comprised of individual units and modules (circuit boards).

Malfunctioning components can generally be easily repaired after a failure by replacing a unit or a module.

This section explains the configuration of the robot controller equipment.



Arrangement of units and circuit boards

BRAKE CONTROL BOARD (-AE5),

BACKSIDE OF AXIS CONTROL BOARD

AXIS CONTROL BOARD (-AE6.0)

EX.AXIS CONTROL BOARD (-AE6.1)OPTION

SAFETY FUNCTIONAL BOARD (-AE6.2)OPTION

MAIN SWITCH (-Q1M)

TERMINAL (-X9)

CIRCUIT BREAKER (-FS1)

CONVERTER UNIT (-TP1)

SERVOPACK (-TA1-TA9) *

-TA7(Option)

-TA8(Option)

-TA9(Option)

-TA4

-TA5

-TA6

-TA1

-TA2

-TA3

MACHINE SAFETY I/O

LOGIC BOARD( -AE4)

POWER ON UNIT (-AE2)

CPS UNIT (-AE3)

CPU UNIT (-AE1)

I/O TERMINAL (-X12A-X13B) OPTION

FUNCTIONAL SAFETY (-X181) OPTION

MACHINE SAFETY TERMINAL

BOARD( -X18)

GENERAL I/O BOARD (-AE7)

FUNCTIONAL SAFETY

I/O BOARD (-AE8) OPTION

DSW 1-2 (-X810) OPTION

OPTION BOARD (-AE9, AE10,-AE11)

Fig. 9-1: Configuration robot controller (master)

BRAKE CONTROL BOARD (-AE5),

BACKSIDE OF AXIS CONTROL BOARD

AXIS CONTROL BOARD (-AE6.0)

EX.AXIS CONTROL BOARD (-AE6.1)OPTION

SAFETY FUNCTIONAL BOARD (-AE6.2)OPTION

SERVOPACK (-TA1-TA9)*

-TA7(Option)

-TA8(Option)

-TA9(Option)

-TA4

-TA5

-TA6

-TA1

-TA2

-TA3

TERMINAL (-X9)

CIRCUIT BREAKER (-FS1)

CONVERTER UNIT (-TP1)

MACHINE SAFETY I/O

LOGIC BOARD( -AE4)

POWER ON UNIT (-AE2)

CPS UNIT (-AE3)

FUNCTIONAL SAFETY (-X181) OPTION

MACHINE SAFETY TERMINAL

BOARD( -X18)

FUNCTIONAL SAFETY

I/O BOARD (-AE8) OPTION

I/O TERMINAL OPTION

OPTION BOARD (-AE9, AE10,-AE11)

Fig. 9-2: Configuration robot controller (slave)

* The SERVOPACK types is different depending on robot model

108

Robot controller specification



Cooling System of the controller interior

The backside duct fan draws in air from the air intake and expels it from the air outlet to cool the SERVOPACK. The fan mounted inside the door circulates the air to keep temperature even throughout the interior of the robot controller. Make sure the door of the robot controller is closed when it’s used to keep this cooling system effective.

-Q1M

-X9

-FS1

-TP1

-AE2

Option

-TA9

-TA8

-TA7

-AE6.0

-TA6

-TA5

-TA4

-TA3

-TA2

-TA1

-AE3

-AE1.0

-AE4

-AE7

-X181

Option

-X18

-X81

-G1

-G2

-Q1M

-G3

-G4

-G5

-R1-R6

-C1

-V1

-T1

-X12A -X12B

-X13A

-X13B Option

-EP2

Front view

Interior circulation fan

Air outlet

Fig. 9-3: Cooling System

Door

Back View

109

Recommended spare parts list

10 Recommended spare parts list

It is recommended to keep in stock parts and components in the following table as spare parts to use. Product performance cannot be guaranteed when using spare parts from any company other than YASKAWA.

NOTICE

Please contact your YASKAWA branch office if you need spare or replacement parts.

Brake control board (-AE5), backside of axis control board

Axis control board (-AE6.0)

Ex. axis control board (-AE6.1)

Safety functional board (-AE6.2

Main switch (-Q1M)

Terminal (-X9)

Circuit breaker (-FS1)

Converter unit (-TP1)

Power on unit (-AE2)

CPS unit (-AE3)

CPU unit (-AE1)

I/O Terminal (-X12A-X13B) option

Machine Safety I/O logic board (-AE4)

Functional safety (-X181) option

Machine safety terminal board (-X18)

General I/O board (-AE7)

Functional safety I/O board (-AE8) option

DSW 1-2 (-X810) option

Option board (-AE9, AE10,-AE11)

Tab. 10-1: Unit layout master

110

-TA7

(Option)

-TA8

(Option)

-TA9

(Option)

Recommended spare parts list

-TA4

-TA5

-TA1

-TA2

Fig. 10-1: SERVOPACK (-TA1 to -TA9)

The SERVOPACK types is different depending on robot model

-TA6

-TA3

111

Recommended spare parts list

3 2

Brake control board (-AE5), backside of axis control board

Axis control board (-AE6.0)

Ex. axis control board (-AE6.1)

Safety functional board (-AE6.2

Terminal (-X9)

Circuit breaker (-FS1)

Converter unit (-TP1)

Power on unit (-AE2)

CPS unit (-AE3)

I/O Terminal option

Machine Safety I/O logic board (-AE4)

Functional safety (-X181) option

Machine safety terminal board (-X18)

Functional safety I/O board (-AE8) option

Option board (-AE9, AE10,-AE11)

Tab. 10-2: Unit layout slave

112

-TA7

(Option)

-TA8

(Option)

-TA9

(Option)

Recommended spare parts list

-TA4

-TA5

-TA1

-TA2

-TA6

-TA3

Fig. 10-2: SERVOPACK (-TA1 to -TA9)

The SERVOPACK types is different depending on robot model

Spare parts list robot controller for MA1440/MH12

Power supply additional power supply

JZNC-YPS21-E

JZNC-YPS02-E

Rack-circuit board JZNC-YRK21-1E

I/F board JANCD-YIF01-2E

Safety CPU board JANCD-YSF21-E

Safety I/O board

I/O board (PNP type)

JANCD-YSF22-E

JANCD-YIO22-E

Power supply unit JZRCR-YPU52-1

Converter

Capacity module

12A

SERVO package

SRDA-COA30A21B-E

SRDA-CUA662AA

JZRCR-YSV24-111 master

Slave

164754 YEC

E147571 YEC master 164756 YEC master master

E145855 YEC

164757 YEC

Master/Slave 164758 master 164762

YEC

Master/Slave 164764

Master/Slave 164767

Master/Slave 164781

YEC

Master/Slave 164772 YEC

113

Recommended spare parts list

Spare parts list robot controller for MA1440/MH12

Resistor

Memory card

SMVK500W6R0J A6103 Master/Slave 164775

MCF10P256MS(A00ACIYE) master 151281

YEC

Spare parts list robot controller for MS165/MH180

Power supply additional power supply

JZNC-YPS21-E

JZNC-YPS02-E

Rack-circuit board JZNC-YRK21-1E

I/F board JANCD-YIF01-2E

Safety CPU board JANCD-YSF21-E

Safety I/O board

I/O board (PNP type)

JANCD-YSF22-E

JANCD-YIO22-E

Power supply unit JZRCR-YPU52-1

Converter SRDA-COA30A21B-E

Capacity module

30A

SRDA-CUA133AA

SERVO package

Resistor

Memory card master

Slave master master master

Master/Slave

164754

E147571

164756

E145855

164757

Master/Slave 164758 master 164762

164764

164767

164782

YEC

JZRCR-YSV27-111

SMVK500W2R0J A5978

Master/Slave

MCF10P256MS(A00ACIYE) master

164774

Master/Slave E143574 YEC

151281

YEC

114

Recommended spare parts list

Spare parts list robot controller for MS210/MH225

Power supply additional power supply

JZNC-YPS21-E

JZNC-YPS02-E

Rack-circuit board JZNC-YRK21-1E

I/F board

Safety CPU board

Safety I/O board

JANCD-YIF01-2E

JANCD-YSF21-E

JANCD-YSF22-E master

Slave

164754

E147571

YEC

YEC master master

164756 YEC

E145855 YEC master 164757

Master/Slave 164758

YEC

I/O board (PNP type)

JANCD-YIO22-E

Power supply unit JZRCR-YPU52-1

Converter SRDA-COA30A21B-E

SRDA-CUA133AA Capacity module

30A

SERVO package JZRCR-YSV27-111

Resistor

Memory card master

Master/Slave

164762

164764

164767

164782

YEC

Master/Slave 164774 YEC

SMVK500W2R0J A5978 Master/Slave E143574 YEC

MCF10P256MS(A00ACIYE) master 151281 YEC

NOTICE

Product performance cannot be guaranteed when using spare parts from any company other than YASKAWA.

Please contact your YASKAWA branch office if you need spare or replacement parts.

115

YASKAWA Headquarter