YASKAWA MOTOMAN DX100 Instructions Manual
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DX100 OPTIONS
INSTRUCTIONS
FOR FUNCTIONAL SAFETY UNIT (NSU01)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 Operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
YASKAWA ELECTRIC CORPORATION
MANUAL NO.
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MANDATORY
• This manual explains the functional safety unit (NSU01) of the
DX100 system. Read this manual carefully and be sure to understand its contents before handling the DX100.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully read the DX100 Instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers or shields removed for clarity. Be sure all covers and shields are replaced before operating this product.
• The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product.
• YASKAWA may modify this model without notice when necessary due to product improvements, modifications, or changes in specifications.
• If such modification is made, the manual number will also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product's warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
WARNING
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.
Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to personnel and damage to equipment.
It may also be used to alert against unsafe practices.
MANDATORY
Always be sure to follow explicitly the items listed under this heading.
PROHIBITED
Must never be performed.
Even items described as “CAUTION” may result in a serious accident in some situations.
At any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as "CAUTION" and "WARNING".
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WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the manipulator during an emergency. The manipulator should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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CAUTION
• Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet of the DX100 after use.
The programming pendant can be damaged if it is left in the manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:
Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows:
Equipment
DX100 controller
DX100 programming pendant
Cable between the manipulator and the controller
Manual Designation
DX100
Programming pendant
Manipulator cable v
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Descriptions of the programming pendant, buttons, and displays are shown as follows:
Equipment
Programming
Pendant
Character
Keys
Symbol
Keys
Manual Designation
The keys which have characters printed on them are denoted with [ ].
ex. [ENTER]
The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture.
GO
BACK ex. page key
The cursor key is an exception, and a picture is not shown.
Axis Keys
Number Keys
“Axis Keys” and “Number Keys” are generic names for the keys for axis operation and number input.
Keys pressed simultaneously
When two keys are to be pressed simultaneously, the keys are shown with a “+” sign between them, ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming pendant is denoted with { }.
ex. {JOB}
Description of the Operation Procedure
In the explanation of the operation procedure, the expression “Select • • • “ means that the cursor is moved to the object item and the SELECT key is pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and TM are omitted. vi
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1 Function Overview .......................................................................................................................... 1-1
1.1 Preface .............................................................................................................................. 1-1
1.2 Function Overview ............................................................................................................. 1-1
2 System Configuration...................................................................................................................... 2-1
2.1 Outline ............................................................................................................................... 2-1
2.1.1 Functional Safety Unit........................................................................................... 2-1
2.1.2 Signal Distribution Board ...................................................................................... 2-2
2.1.3 Communication I/F Gateway Unit ......................................................................... 2-3
2.1.4 Power On Unit ...................................................................................................... 2-4
2.2 Overview of Unit Connection ............................................................................................. 2-5
2.3 Description of Unit Layout (Layout Drawing) ..................................................................... 2-6
2.4 Spare Parts ........................................................................................................................ 2-6
3 Setup (Safety Range Function for Robot) ....................................................................................... 3-1
3.1 Changing Security Mode.................................................................................................... 3-1
3.2 Preparation for Safety Range Function.............................................................................. 3-3
3.3 Setting Tool Interference File............................................................................................. 3-3
3.4 Setting Safety Range for Robot ......................................................................................... 3-7
3.5 Confirming Safety Range for Robot ................................................................................. 3-11
3.6 Switching Safety Range...................................................................................................3-12
3.7 Starting Safety Range Function for Robot ....................................................................... 3-15
3.8 Confirming Safety Range and Robot Position ................................................................. 3-17
4 Setup (Safety Range Function for Each Axis)................................................................................. 4-1
4.1 Preparation for Safety Range Function.............................................................................. 4-1
4.2 Setting Expected Stop Value ............................................................................................. 4-1
4.3 Setting Safety Range for Each Axis................................................................................... 4-4
4.4 Confirming Safety Range for Each Axis............................................................................. 4-7
4.5 Starting Safety Range Function for Each Axis................................................................... 4-8
5 Stop Position Monitoring Function .................................................................................................. 5-1
5.1 Operating Condition Detection........................................................................................... 5-1
5.2 Turning Stop Position Monitoring Function VALID/INVALID.............................................. 5-1 vii
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6 Data Protection ............................................................................................................................... 6-1
6.1 Saving Dual Data............................................................................................................... 6-1
6.2 Operation When VERIFY ERROR Occurs ........................................................................ 6-2
7 System Output Signal ..................................................................................................................... 7-1
8 Alarm............................................................................................................................................... 8-1
9 Restrictions ..................................................................................................................................... 9-1
9.1 Confirming Safety Range and Robot Position ................................................................... 9-1
9.2 Software Version of Machine Safety Unit .......................................................................... 9-1
9.3 Software Version of Functional Safety Unit ....................................................................... 9-2 viii
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1 Function Overview
1.1
Preface
1 Function Overview
1.1
Preface
This function limits the operating range of the robot and monitors its speed.
With this function, the software monitors the robot arm or each axis so that its position does not exceed the preset safety range. If any monitoring error is detected, the contactors are cut off to stop the robot. With this function, it is possible to improve the safety for robot operation, and reduce the facility space for the robot system.
1.2
Function Overview
(1) Range limit function (robot axis + servo track / unit)
This function is used to monitor the robot so that its position does not exceed the preset safety range. Only one safety range can be specified. The specified range can be applied to the following configuration:
Robot (6 axes) + servo track (up to 3 axes)
or
Robot (7 axes) + servo track (up to 2 axes)
By the combination of 2 lines of dual input signals (range switch signals) to the functional safety unit, 4 ranges (range: 1 to range:
4) can be set as the safety ranges.
To enable range switching, connect the range switch signals to the functional safety system input terminal block shown in chapter 2.1.2
“Signal Distribution Board” at page 2-2 . When range switching is not used, i.e. only one safety range is set, there is no need to connect the signals. (In this case, range: 1 is set.)
For signal connection, refer to chapter 3.7 “Starting Safety Range
Function for Robot” at page 3-15 .
(2) Each axis angle limit function (9 axes/unit)
(3) Stop position monitoring function
(4) Safety speed monitoring function
This function monitors the robot to see that it operates at the safety speed of 250 mm/sec. The speed is monitored at the TCP
(Tool Center Point) and flange.
• Teach mode (manual high speed specification is OFF)
NOTE
The safety speed monitoring function can monitor the speed of one tool number per robot.
The speed of R1 and R2 is monitored using the file with the tool numbers 0 and 1, respectively.
(5) Logical verification of safety signals
This function detects the unmatch of the dual safety signals converted into the functional safety unit.
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2 System Configuration
2.1
Outline
2 System Configuration
2.1
Outline
To achieve the functions described in this manual, the “functional safety unit”, “signal distribution board”, “communication I/F gateway unit”, and
“power on unit” are added or replaced for the DX100.
2.1.1
Functional Safety Unit
The type and major specifications of functional safety unit are shown below.
Item
Unit type
Unit size
JZNC-NSU01 specification
W120×H300×D194 [mm]
Input power supply DC24V
Function (1) Safety range setting function (robot axis + servo track / unit)
(2) Safety speed monitoring function
(3) Safety signal logical verification function
The outline of the functional safety unit: JZNC-NSU01 is shown below.
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2 System Configuration
2.1
Outline
2.1.2
Signal Distribution Board
The signal distribution board is a special board equipped with an extended function that distributes full-speed test signals to the functional safety unit in addition to the standard functions of the robot system input terminal block (MXT).
Item
Board type
Function specification
JARCR-YCU02
(1) Robot system input terminal block
(2) Signal distribution to the functional safety unit
(3) Spare terminal block (for future extension)
Robot system input termial block
NOTE
For the connection to the robot system input terminal block, refer to “13.9 Robot System Input Terminal Block (MXT)” in
DX100 INSTRUCTIONS MANUAL.
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2 System Configuration
2.1
Outline
2.1.3
Communication I/F Gateway Unit
The gateway unit for host communication I/F is added to convert the communication signals to enable the communications between DX100 and the functional safety unit (JZNC-NSU01).
This unit converts the communication signals between the robot I/F board
(JANCD-YIF01-
□
) in DX100 and the functional safety unit (JZNC-
NSU01).
Item
Unit type
Unit size
Input power supply
Function specification
JZNC-YGW01-E
W30×H230×D1 [mm]
DC24V
Conversion of the communication signals between
DX100 robot I/F board (JANCD-YIF01-
□
) and the functional safety unit (JZNC-NSU01)
1st robot: 0 Setting (rotary SW: S1)
2nd to 4th robot: 1 to 3 (Number consecutively.)
Connector CN902/CN903 For the connection of the robot I/F board (JANCD-
YIF01-
□
) and the functional safety unit (JZNC-
NSU01)
CN904
CN901
For the connection of the functional safety unit
(JZNC-NSU01)
For 24 VDC input
The outline of the communication I/F gateway unit: JZNC-YGW01-E is shown below.
S1
Rotary SW
F1
Protection fuse
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2.1.4
Power On Unit
2 System Configuration
2.1
Outline
This power on unit is the unit to which an “auxiliary contact block” is added in order to feed back the status of the built-in contactor to the functional safety unit (JZNC-NSU01).
The standard power on unit should be replaced with this unit if needed.
Item
Unit type
Unit size
Function
Connector CN609
JZRCR-YPU0
□
-2 specification
Same size as the standard power on unit
(interchangeable)
Contactor auxiliary contact signal output is added.
(for the functional safety unit (JZNC-NSU01))
For the contactor auxiliary contact signal output
(added to the standard unit)
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2 System Configuration
2.2
Overview of Unit Connection
2.2
Overview of Unit Connection
The figure below shows a rough connection diagram where the functional safety unit is added to the DX100 control panel.
(Current DX100 system)
Teach pendant
Main CPU
(1) Target positioning
(2) Current position monitoring with soft limit
(3) Safety speed monitoring (*)
(4) Various types of error monitoring
Position instruction
Current position
Servo control
CPU
(1) Safety speed monitoring (*)
(2) Various types of error monitoring
Power shutdown
Machine safety control
Contactor control
Current instruction
Alarm information
Servo amplifier
Various types of error monitoring
& power shutdown
Current position
Primary power supply
Motor
Detector
(DX100 system with the function added)
Power shutdown
Teach pendant
Main CPU
(1) Target positioning
(2) Current position monitoring with soft limit
(3) Safety speed monitoring (*)
(4) Various types of error monitoring
(5) Safety range control and monitoring
Position instruction
Current position
Servo control
CPU
(1) Safety speed monitoring (*)
(2) Various types of error monitoring
Dual safety signal
(*) Safety speed monitoring:
Monitoring the speed of 250 mm/sec or slower
Functional safety unit
(1) Safety range monitoring
(2) Safety speed monitoring (*)
(3) Logical verification of safety signals
(A)
Machine safety control
Contactor control
Current instruction
Alarm information
Servo amplifier
Various types of error monitoring
& power shutdown
Current position
Power shutdown
Current position
(A)
Primary power supply
Motor
Detector
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2 System Configuration
2.3
Description of Unit Layout (Layout Drawing)
2.3
Description of Unit Layout (Layout Drawing)
The figure below shows a layout drawing of the DX100 with which the functional safety unit is added.
Fig. 2-1: Unit Layout Drawing (with the Door Open)
YCU
50
49
GSOUTFB2-
GSOUTFB2+
34
33
32
31
EXDSW1-
EXDSW1+
EXHOLD-
EXHOLD+
17
16
15
14 48
47
46
45
GSOUT2-
GSOUT2+
GSOUTFB1-
GSOUTFB1+
30
29
28
27
EXSVON-
EXSVON+
SSP-
SSP+
13
12
11
10 44
43
42
41
GSOUT1-
GSOUT1+
024V2
+24V2
26
25
24
23
FST2-
FST2+
FST1-
FST1+ 40
39
38
37
024V2
+24V2
024V2
+24V2
36
35
EXDSW2-
EXDSW2+
NJ3114-1
22
21
20
19
EXESP2-
EXESP2+
EXESP1-
EXESP1+
18 SYSRUN-
SYSRUN+
SAFF2-
SAFF2+
SAFF1-
SAFF1+
GSIN22-
GSIN22+
GSIN21-
GSIN21+
GSIN12-
GSIN12+
GSIN11-
GSIN11+
Power on unit (YPU)
JZRCR-YPU0 -2
A
(QF3)
CN601
COULD
FUSE
CN610
3FU
1FU 2FU
4FU
CN611
CN607
COULD
FUSE
480Y/277V
C.B.
(QS2)
NCM
CN606
CN605
CN604
CN603
CN612
CN602
SOURCE
P-ON
+5V
+24V
FAN
OHT
CN158/159
(+5V/ALM)
CN156/157
(+24V2)
POWER SUPPLY
CPS-520F
NO.
YYYY-MM
Fuji Electric Hi-Tech Corp.
MADE IN JAPAN
CN154/155
(+24V1/V2)
CN153
(+24V3)
CN151
(AC IN)
INPUT
200-240V AC
50/60Hz
3.4A-2.8A
CN152
(REMOTE)
Functional safety unit (YPU)
JZNC-NSU01
CNNSUO CNYSUO
BNL6
Terminal unit for NSU
JARCR-YCU02
Comm. I/F gateway unit
JZNC-YGW01-E
Section A-A
A
2.4
Spare Parts
To achieve the functions of range limit and speed monitoring for the
DX100 robot system, the recommended spare parts for the DX100 with the functional safety unit are shown below.
Regarding the standard part of the DX100, refer to “DX100
INSTRUCTIONS (RE-CTO-A215)” and “DX100 MAINTENANCE
MANUAL (RE-CHO-A108)”.
Unit
Functional Safety
Unit
(JZNC-NSU01)
Name
Fuse
(for F2 and F3)
Communication I/F
Gateway Unit
(JZNC-YGW01-E)
Fuse (for F1)
Model Qty.
Manufacturer
0217001P 2 Littelfuse
0217001P 1 Littelfuse
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3 Setup (Safety Range Function for Robot)
3.1
Changing Security Mode
3 Setup (Safety Range Function for Robot)
3.1
Changing Security Mode
To limit the operating range of the robot, set the safety range.
To set the safety range, the security mode must be MANAGEMENT
MODE or higher. Thus, the administrator or a user with higher privilege must set the range.
Change the security mode as follows:
1. Select {SYSTEM INFO} under the main menu.
2. Select {SECURITY} under the sub menu.
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3.1
Changing Security Mode
3. Change the mode from EDITING MODE to MANAGEMENT MODE.
Press [ENTER] in the SECURITY screen. Move the cursor to
“MANAGEMENT MODE” and then press [ENTER] again.
4. Input the password for MANAGEMENT MODE and press [ENTER].
The security mode is changed to MANAGEMENT MODE.
NOTE
Security level
OPERATION
Items that can be manipulated
Data such as the operating range cannot be edited or viewed.
EDITING
MANAGEMENT Data such as the operating range can be edited or viewed. The “Safety Unit FLASH
Erase” can be performed in the maintenance mode.
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3 Setup (Safety Range Function for Robot)
3.2
Preparation for Safety Range Function
3.2
Preparation for Safety Range Function
For the safety range function for the robot arm, set the safety range of the robot arm as polygonal columns in advance. Then, the robot arm is monitored so that it does not exceed the safety range.
If any monitoring error is detected, the servo power will be turned OFF.
The outline of the operating procedure is as follows:
(1) Setting tool interference file
È
(2) Setting safety range for robot
È
(3) Confirming safety range for robot
È
(4) Starting safety range function for robot
Each operating procedure is explained below.
3.3
Setting Tool Interference File
The safety unit also monitors that the robot tool does not exceed the safety range. In this case, set the tool shape in the tool interference file.
To set the tool interference file, the security mode must be EDITING
MODE or higher.
<Tool interference file>
• Cylinders and spheres for up to 5 positions can be set.
• Both ends of a cylinder are set by POINT1 and POINT2.
The distance from the center of T axis flange should be set like tool dimension setting.
• The radius of the spheres and cylinder between POINT1 and
POINT2 is set. The spheres are set to POINT1 and POINT2.
• The specified radius must have a margin of at least 10 mm compared with the actual tool.
NOTE
A single tool interference file can be used for a robot.
The safety range function is set to the data in the tool interference file #0 for R1 and that in the tool interference file #1 for R2.
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3 Setup (Safety Range Function for Robot)
3.3
Setting Tool Interference File
Set a tool interference file as instructed below.
1. Select {ROBOT} under the main menu.
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2. Select {TOOL INTERFERE} under the sub menu.
– The TOOL INTERFERE screen is displayed.
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3 Setup (Safety Range Function for Robot)
3.3
Setting Tool Interference File
3. If the data is set in TOOL INTERFERE screen, the READBACK screen is shown.
– In READBACK screen, you can check if the set data is correct.
– Compare MODIFY VALUE with READBACK VALUE.
• If the data is OK, press “YES” on the screen to fix the tool interference file setting.
• If the data is NG, press “NO” on the screen to restore to the value before change.
4. After READBACK screen is displayed, [WRITE] and [CANCEL] buttons are displayed in the lower position of the screen.
<Description of the screen>
WRITE: Robot controller records the setting of the tool interference file.
CANCEL: Cancel the tool interference file setting to restore the setting to the previous status.
NOTE
• Be sure to press [WRITE] after performing tool interference file setting.
• A single tool interference file can be used for a robot.
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3 Setup (Safety Range Function for Robot)
3.3
Setting Tool Interference File
<Tool interference file setting example>
140
Robot
25
Model 2
Point 1
Tool coodinate origin
(flange surface)
Model 1
Point 1
Model 1
Point 2
Tool
X
Model 3
Point 1 Model 2
Point 2
Model 3
Point 2
Z
Model 1: Set the flange surface as Point 1, and (X=140, Z=85) as Point 2.
Model 2: Set (X=140, Z=-30) as Point 1, and (X=140, Z=250) as Point 2.
This setting defines a model that is parallel to the Z direction of the tool coordinates.
Model 3: Set (X=140, Z=250) as Point 1, and (X=25, Z=350) as Point 2.
Models 2 and 3 are defined at consecutive positions when point
2 of model 2 and point 1 of model 3 are set at the same position.
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3 Setup (Safety Range Function for Robot)
3.4
Setting Safety Range for Robot
3.4
Setting Safety Range for Robot
Set the safety range for the robot arm as follows:
1. Select {ROBOT} under the main menu.
2. Move the cursor and display the following sub menu.
3. Select {ROBOT RANGE} under the sub menu.
– The ROBOT RANGE screen is displayed.
<Description of the screen>
ROBOT: Selects a robot to be set in case the of a multiple robot system.
To set R1, move the cursor to “R1” and press [SELECT].
SETTING: Sets the safety range limit function status.
Status
INVALID
VALID
Detail
The safety range function can be disabled temporarily.
The system output signal “Range Monitoring” is turned OFF.
(Refer to chapter 7 “System Output Signal” at page 7-1
.)
The safety range function is enabled.
The system output signal “Range Monitoring” is turned ON.
(Refer to chapter 7 “System Output Signal” at page 7-1 .)
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3 Setup (Safety Range Function for Robot)
3.4
Setting Safety Range for Robot
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING.
Status
SETTING
CONFIRMING
MONITORING
Contents
“SETTING” is displayed when setting the data.
“CONFIRMING” is displayed when confirming the range after data setting.
“MONITORING” is displayed after confirming the data.
While “MONITORING” is displayed, the safety range function is performed.
4. Select “R1”. Then ROBOT RANGE screen is shown.
<Description of the screen>
COORD: Select a coordinate type; ROBOT or BASE.
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING
Status
SETTING
CONFIRMING
MONITORING
Contents
“SETTING” is displayed when setting the data.
“CONFIRMING” is displayed when confirming the range after data setting.
“MONITORING” is displayed after confirming the data.
While “MONITORING” is displayed, the safety range function is performed.
LINE 1 to 16: Make line segments connecting <X1> and <Y1>, <X2> and
<Y2>, to set the safety range. Up to 16 line segments can be used for setting.
Z TOP: Sets the safety range of Z-direction top surface.
Z BOTTOM: Sets the safety range of Z-direction bottom surface.
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3 Setup (Safety Range Function for Robot)
3.4
Setting Safety Range for Robot
<Range setting example>
To set the range with the X direction + side: 3000 mm, X direction - side: -
2000 mm, Y direction + side: 2500 mm, and Y direction - side: -1500 mm, enter the numbers as shown below.
Line 1
Line 2
Line 3
Line 4
X1
3000
-2000
-2000
3000
Y1
2500
2500
-1500
-1500
X2
-2000
-2000
3000
3000
Y2
2500
-1500
-1500
2500
Line 1
Y+: 2500 mm
X+: 3000 mm Line 4
Line 3
Y-: 1500 mm
Line 2 X-: -2000 mm
5. If the data is set in ROBOT RANGE screen, the READBACK screen is shown.
– In READBACK screen, you can check if the set data is correct.
Compare MODIFY VALUE with READBACK VALUE.
• If the data is OK, press [YES] on the screen to fix the setting in
ROBOT RANGE screen.
• If the data is NG, press [NO] on the screen to restore to the value before change.
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3.4
Setting Safety Range for Robot
6. After READBACK screen is displayed, [WRITE] and [CANCEL] buttons are displayed in the lower position of the screen.
<Description of the screen>
WRITE: Robot controller records the setting of the safety range.
CANCEL: Cancel the safety range setting to restore the setting to the previous status.
NOTE
• Be sure to press [WRITE] after performing the safety range setting.
• Unless the safety ranges are set and the status is set to
MONITORING for all the robots used in the system, robot operations by the axis keys cannot be performed except for each axis operation.
Before performing the following operations, make sure to complete the safety range setting.
– Job playback
– [FWD], [BWD], [TEST START] key operations
GO
BACK
7. When setting multiple ranges, press the page key screen to make the settings.
PAGE
and switch the
For multiple ranges, set an overlap area. Switch between ranges only when the robot is in the overlap area.
<Setting example>
Range 2
Range 1
Area where the ranges can be switched.
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3.5
Confirming Safety Range for Robot
3.5
Confirming Safety Range for Robot
After the completion of safety range setting, it is necessary to confirm if the monitoring is performed according to the safety range set in the chapter 3.4 “Setting Safety Range for Robot” at page 3-7
.
At that time, the “STATUS” in ROBOT RANGE screen indicates
“CONFIRMING”. Move the robot to check if the manipulator stops before it exceeds the safety range.
When multiple ranges are set, change the range switch signals to check for all the ranges.
<How to check the safety range with the jog operation>
Check that the specified safety range is correct with the jog operation.
Make the robot operate toward the specified four limits to see that the robot stops operating within the range. If the range is not rectangular solid, check that the robot stops before all the limits of the range.
CAUTION
Do not forget to move the robot to see that it stops within the specified safety range.
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3.6
Switching Safety Range
3.6
Switching Safety Range
Multiple safety ranges can be set/confirmed in advance, and the ranges can be switched by external signals.
For multiple safety ranges, set an overlap area. Switch between ranges only when the robot is in the overlap area.
Use the dual input signal of the functional safety unit to switch between safety ranges. If the range is selected by the signal while the range is being set, the following alarm occurs. Select another range already confirmed to reset the alarm.
Alarm to occur:
Alarm 4691: “OPERATION AREA SET ERR (SAFETY)”
If the range is selected while it is being set or confirmed during the robot program operation, the following alarm occurs. Select another range already confirmed to reset the alarm.
Alarm to occur:
Alarm 4679: “SPECIFIED MOTION RANGE ERROR”
Selected safety range numbers are output to the following system output signals. (Refer to chapter 7 “System Output Signal” at page 7-1 .)
50940 to 50947: Selected RANGE NUMBER (d0)
50950 to 50957: Selected RANGE NUMBER (d1)
CAUTION
• Before using the safety range switching function, give due consideration (risk assessment) to the potential danger by switching between ranges.
• When performing the teaching operation of the robot program, the operator should always check the range number before each operation.
• Prepare a means to identify the selected range number, and check the selected range number before performing operations.
• Check that the robot is stopped before switching between ranges.
Switching between ranges during the robot program operation may result in the following risks.
– Risk of selecting a wrong range
– Risk that the robot may exceed the range after switch when the ranges before and after switch are greatly different or the overlap area of them are small
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3 Setup (Safety Range Function for Robot)
3.6
Switching Safety Range
The combinations of safety ranges and range switch signals are shown below.
Table 3-1: Setting of Safety Range
Safety
Range No.
1
2
3
4
N/A
N/A
N/A
N/A
OPEN
CLOSE
OPEN
OPEN
CLOSE
*
*
*
*
Status
CLOSE
Welder 1
Terminal
1)
A/B
CLOSE
OPEN
OPEN
CLOSE
CLOSE
OPEN
C/D
A/B
C/D
A/B
C/D
A/B
C/D
A/B
C/D
A/B
C/D
A/B
C/D
A/B
C/D
Status
CLOSE
CLOSE
CLOSE
CLOSE
OPEN
OPEN
OPEN
OPEN
*
*
*
*
CLOSE
OPEN
OPEN
Welder 2
Terminal
1)
E/F
CLOSE
G/H
E/F
G/H
E/F
G/H
E/F
G/H
E/F
G/H
E/F
G/H
E/F
G/H
E/F
G/H
Default setting
Notes
“SIGNAL COMPARISON ERROR
(SAFETY)” alarm occurs.
“SIGNAL COMPARISON ERROR
(SAFETY)” alarm occurs.
“SIGNAL COMPARISON ERROR
(SAFETY)” alarm occurs.
“SIGNAL COMPARISON ERROR
(SAFETY)” alarm occurs.
1 Terminal indicates the number of the functional safety system input terminal block on the JARCR-YCU02 board.
Welder 1
Welder 2
DX100 connection diagram
JARCR-YCU02
Functional safety system input terminal block
A
JZNC-NSU01
Functional safety unit
EXIN1_1+
B
EXIN1_1-
C
EXIN1_2+
D
EXIN1_2-
E
EXIN2_1+
F
EXIN2_1-
G
EXIN2_2+
H
EXIN2_2-
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3.6
Switching Safety Range
If the functional safety unit detects the safety signal inconsistency, the following alarm occurs.
Alarm 4705: “SIGNAL COMPARISON ERROR (SAFETY)”
Subcode 5: Signal inconsistency of YCU02 board A to D
3: Signal inconsistency of YCU02 board E to H
CAUTION
• Connect an independent switch (dry contact) for the range switch signal.
• The load current of 24 VDC/6.5 mA (typ) flows through each input circuit.
For the connection, use a switching device capable of switching 24
VDC at 6.5 mA (typ).
• The dual input signals are checked whether they are synchronized.
Set the dual input signals as the signals which turn ON and OFF simultaneously. If the dual input signal’s turning ON and OFF are different in timings with 500 ms or more, the alarm of “INPUT
SIGNAL ERROR” occurs.
• For the details of wiring to the functional safety system input terminal block, refer to “DX100 INSTRUCTIONS (RE-CTO-A215)
13.9 Robot System Input Terminal Block (MXT)”.
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3 Setup (Safety Range Function for Robot)
3.7
Starting Safety Range Function for Robot
3.7
Starting Safety Range Function for Robot
After confirming that the robot can move in the set safety range, press
[CONFIRM]. The STATUS indication is changed to “MONITORING” and the safety unit starts the safety range function for the robot.
Check the following items with the actual job.
<How to check the safety range in the play mode>
1. Check the teaching point of job.
If an alarm occurs and the robot does not operate when the job is played back, the following causes are possible:
• The specified range is inappropriate.
• Teaching is inappropriate.
In such a case, recalculate the range or modify teaching.
Alarm 4682: “MOTION RANGE LIMIT INTERFERENCE”
<Cause>
The teaching position is out of the specified range.
<Countermeasure>
Check that the specified range is correct.
Change the teaching position so that it falls in the range.
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3.7
Starting Safety Range Function for Robot
2. Endurance running must be normally performed.
Try to move the actual job. If the robot moves near the specified range, an alarm may occur. In such a case, modify teaching or slow down the speed.
Alarm 1629: “OPERATION AREA MON. ERR(ROBOT)”
<Cause>
The range error was detected when the robot operated.
<Reason>
This alarm was detected by the safety unit. The safety unit monitors the position based on the feedback pulse from the motor. The speed and coasting value is considered during calculation so that the robot does not move out of the range. Thus, this alarm occurs when the teaching position is near the safety range or the teaching speed is fast.
<Countermeasure>
Modify teaching so that the teaching position is not near the safety range.
Reduce the teaching speed.
NOTE
If the STATUS is “CONFIRMING”, PLAY mode operation is disabled. Be sure to perform confirming operation and press [CONFIRM] button on the screen.
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3 Setup (Safety Range Function for Robot)
3.8
Confirming Safety Range and Robot Position
3.8
Confirming Safety Range and Robot Position
The positional relation between the specified safety range and the actual robot posture can be checked by showing them on the programming pendant.
1. Select {ROBOT} under the main menu.
2. Move the cursor to display the following sub menu.
3. Select {OPERATION AREA MONITOR} under the sub menu.
– The Disp Operation Area screen is displayed.
1 2
3
4
5
6
<Description of the screen> c The plane currently displayed
This is the plane currently displayed. The brown section indicates the area out of the safety range.
• X-Y plane: The safety range is a white area enclosed with straight
lines.
• Y-Z and X-Z planes: The sides of the safety range.
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3.8
Confirming Safety Range and Robot Position
HW0486052 d The number of the robot currently displayed e The coordinate system of the safety range f The correspondence table of the illustrated straight lines
The numbers of straight lines correspond to the straight line numbers on ROBOT RANGE screen.
g [Change Plane] key
Each time pressed, the displayed plane is switched (X-Y, Y-Z, X-Z).
h [Exit] key
Closes the Disp Operation Area screen.
NOTE
When the Disp Operation Area screen is closed, other opened screens are also closed. This means that data not yet confirmed is discarded if the Disp Operation Area screen is opened while editing the data. Thus, make sure to confirm the editing data before opening the Disp Operation Area screen.
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4 Setup (Safety Range Function for Each Axis)
4.1
Preparation for Safety Range Function
4 Setup (Safety Range Function for Each Axis)
4.1
Preparation for Safety Range Function
For the safety range function for each axis, set the movement amount of each axis of the robot in advance. Then, each axis is monitored so that it does not exceed the safety range.
If any monitoring error is detected, the servo power will be turned OFF.
The outline of the operating procedure is as follows:
(1) Setting expected stop value
È
(2) Setting safety range for each axis
È
(3) Confirming safety range for each axis
È
(4) Starting safety range function for each axis
Each operating procedure is explained below.
4.2
Setting Expected Stop Value
When the servo power is turned OFF during robot operation, the robot keeps moving due to inertia until it stops completely. The functional safety unit predicts the movement distance (hereinafter called the coasting value) according to the speed of each axis until the robot actually stops.
By predicting the coasting value, the robot does not exceed the safety range even if an error, such as the robot’s exceeding the safety range, is detected.
For example, when the robot is operating at 100% of its motion speed, the functional safety unit starts to stop it from “the distance of the coasting value of 100% motion speed”. When the robot is operating at 50% of its motion speed, the functional safety unit starts to stop it from “the distance of the coasting value of 50% motion speed”.
To perform the above predictive control, the robot may stop before the safety range when it moves to the teaching point near the safety range.
To add an teaching point near the safety range, take the following measures:
(1) Lower the teaching speed
(2) Change the teaching point
(3) Change the setting of the safety range to widen it
Regarding the coasting value of the external axis, settings must be made by the user as instructed in the following.
If settings of the coasting value are not completed, the following error occurs and playback cannot be performed.
Error 0384: “Coasting value setting of Ex-axis is not completed.”
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4.2
Setting Expected Stop Value
1. Change the security mode to MANAGEMENT MODE, then select
{ROBOT} under the main menu.
2. Select {COASTING VALUE SETTING} under the sub menu.
– The COASTING VALUE SETTING screen is displayed.
NOTE
The sub menu {COASTING VALUE SETTING} is not displayed when the system does not have any external axis. It is not displayed either when the security mode is not MAN-
AGEMENT MODE.
– When 2 or more external axes are used, press the page key switch between the external axes.
GO
BACK
PAGE
to
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4 Setup (Safety Range Function for Each Axis)
4.2
Setting Expected Stop Value
3. Select the axis to set the coasting value, and edit the EXPECTED
STOP VALUE. Then the READBACK screen appears.
– Check that MODIFY VALUE and READBACK VALUE are the same, then press [YES]. The COASTING VALUE SETTING screen is displayed again, and the edited coasting value of axis is changed to the input EXPECTED STOP VALUE. Press [NO] to cancel editing.
NOTE
• The coasting value can be set from 0.000 to 999.999.
• When the coasting value is edited, the servo power is turned OFF, and the robot and external axes cannot be operated until the control power is turned OFF and ON again. Since the setting of the coasting value can be continued, turn OFF and ON the control power after setting the coasting values of all axes.
How to Change the Stop Category
To measure the coasting value, the stop category can be changed.
In the COASTING VALUE SETTING screen, select IMMEDIATE STOP to show INVALID and VALID. Select one of them to display the READBACK screen in the same way when editing the coasting value. Check that the
READBACK VALUE is the same as the value shown right next to the selected item of INVALID or VALID. Then press [YES] to switch between
INVALID and VALID.
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4.3
Setting Safety Range for Each Axis
• When the IMMEDIATE STOP is set to VALID, the stop category of the robot and external axes is set to 0. Be sure to return the IMMEDIATE STOP to INVALID after measuring the coasting value.
• If the start operation is performed when the IMMEDIATE
STOP is VALID, a confirmation dialog box appears.
Select [YES] and perform the start operation again to perform playback.
NOTE
4.3
Setting Safety Range for Each Axis
Set the safety range for each axis as instructed below.
1. Change the security mode to MANAGEMENT MODE, then select
{ROBOT} under the main menu.
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4 Setup (Safety Range Function for Each Axis)
4.3
Setting Safety Range for Each Axis
2. Select {AXIS RANGE} under the sub menu.
– The AXIS RANGE screen is displayed.
<Description of the screen>
CTRL GROUP: Selects a control group to be set in the case of a multiple
control group system.
To set S1, move the cursor to “S1” and press [SELECT].
SETTING: Sets the safety range limit function (for each axis) status.
Status
INVALID
VALID
Detail
The safety range function for each axis can be disabled temporarily.
The safety range function for each axis is enabled.
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING.
Status
SETTING
CONFIRMING
MONITORING
Contents
“SETTING” is displayed when setting the data.
“CONFIRMING” is displayed when confirming the range after data setting.
“MONITORING” is displayed after confirming the data.
While “MONITORING” is displayed, the safety range function for each axis is performed.
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4.3
Setting Safety Range for Each Axis
3. Select a control group. The AXIS RANGE screen of the selected control group will be displayed.
<Description of the screen>
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING.
Status
SETTING
CONFIRMING
MONITORING
Contents
“SETTING” is displayed when setting the data.
“CONFIRMING” is displayed when confirming the range after data setting.
“MONITORING” is displayed after confirming the data.
While “MONITORING” is displayed, the safety range function for each axis is performed.
MAX/MIN: The maximum and minimum values of the safety range are
shown for each axis of the selected control group.
4. When MAX/MIN data are set, the following READBACK screen is displayed.
– Check that MODIFY VALUE and READBACK VALUE are the same, then press [YES]. The selected data will be changed. Press [NO] to cancel editing.
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4 Setup (Safety Range Function for Each Axis)
4.4
Confirming Safety Range for Each Axis
5. When the data are set, [WRITE] and [CANCEL] buttons are displayed in the lower position of the screen.
<Description of the screen>
WRITE: Robot controller records the setting of MAX/MIN.
CANCEL: Cancel the MAX/MIN setting to restore the setting to the previous status.
NOTE
The functional safety unit predicts the coasting values of the robot and external axes (see chapter 4.2 “Setting Expected
Stop Value” at page 4-1
) when monitoring the safety range.
Therefore, the robot may stop before the safety range when it moves to the teaching point near the safety range.
4.4
Confirming Safety Range for Each Axis
After the completion of safety range (for each axis) setting, it is necessary to confirm if the monitoring is performed according to the safety range set in the chapter 4.3 “Setting Safety Range for Each Axis” at page 4-4
.
At that time, the “STATUS” in ROBOT RANGE screen indicates
“CONFIRMING”. Move the manipulator or the external axis to check if it stops before it exceeds the safety range.
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4.5
Starting Safety Range Function for Each Axis
4.5
Starting Safety Range Function for Each Axis
After confirming that the manipulator/external axis can move in the set safety range, press [CONFIRM]. The STATUS indication is changed to
“MONITORING” and the safety unit starts the safety range function for each axis.
Check the following items with the actual job.
<How to check the safety range in the play mode>
1. Check the teaching point of job.
If an alarm occurs and the robot does not operate when the job is played back, the following causes are possible:
• The specified range is inappropriate.
• Teaching is inappropriate.
In such a case, recalculate the range or modify teaching.
Alarm 4683: “AXIS MOTION RANGE LIMIT”
<Cause>
The teaching position is out of the specified range.
<Countermeasure>
Check that the specified range is correct.
Change the teaching position so that it falls in the range.
2. Endurance running must be normally performed.
Try to move the actual job. If the robot moves near the specified range, an alarm may occur. In such a case, modify teaching or slow down the speed.
Alarm 1625: “OPERATION AREA MON. ERR(AXIS)”
<Cause>
The range error was detected when the robot operated.
<Reason>
This alarm was detected by the safety unit. The safety unit monitors the position based on the feedback pulse from the motor. The speed and coasting value is considered during calculation so that the robot does not move out of the range. Thus, this alarm occurs when the teaching position is near the safety range or the teaching speed is fast.
<Countermeasure>
Make the safety range setting INVALID, move the robot within the safety range, then make the setting VALID again.
Modify teaching so that the teaching position is not near the safety range.
Reduce the teaching speed.
NOTE
If the STATUS is “CONFIRMING”, PLAY mode operation is disabled. Be sure to perform confirming operation and press [CONFIRM] button on the screen.
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5 Stop Position Monitoring Function
5.1
Operating Condition Detection
5 Stop Position Monitoring Function
5.1
Operating Condition Detection
The stop position monitoring function is one of the functions of the functional safety unit. With this function, the encoder information of the robot or external axis is monitored. If the robot or external axis moves when the function is valid, the power supply to the servo is shut off immediately to turn the servo power OFF.
The VALID/INVALID setting of the stop position monitoring function is performed by the turning ON/OFF of the external dual signal (e.g. area sensor, mat switch).
When using this function, refer to chapter 5.2 “Turning Stop Position
Monitoring Function VALID/INVALID” and connect the dual signal.
If the movement of each axis is detected, the following alarm occurs and the servo power is turned OFF.
Alarm 4704: “STOPPING POS. MON. ERR (SAFETY)
Countermeasure:
(1) Short-circuit the GSIN signal.
(2) Reset the alarm.
NOTE
If the system consists of multiple control groups (e.g. robot
+ external axis), the stop position monitoring cannot be performed for each axis separately. The monitoring is performed only for the whole controller.
5.2
Turning Stop Position Monitoring Function VALID/INVALID
The combination of the VALID/INVALID status of the stop position monitoring function and the ON/OFF status of the signal is shown in table 5-1 “VALID/INVALID Setting of Stop Position Monitoring Function” at page 5-2 and the connection diagram is shown in chapter Fig. 5-1:
“Connection Diagram Example” at page 5-2
.
If the functional safety unit detects the inconsistency of GSIN signal, the following alarm occurs:
Alarm 4705: “SIGNAL COMPARISON ERROR (SAFETY)”
Subcode 40, 41: GSIN SIGNAL INCONSISTENT
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5 Stop Position Monitoring Function
5.2
Turning Stop Position Monitoring Function VALID/INVALID
HW0486052
Table 5-1: VALID/INVALID Setting of Stop Position Monitoring Function
Status
INVALID
VALID
VALID
VALID
Signal
ON
ON
OFF
OFF
OFF
ON
ON
OFF
Terminal
GSI01+/GSI01-
GSI02+/GSI02-
GSI01+/GSI01-
GSI02+/GSI02-
GSI01+/GSI01-
GSI02+/GSI02-
GSI01+/GSI01-
GSI02+/GSI02-
Remarks
Default setting
Input signal inconsistent alarm occurs
Input signal inconsistent alarm occurs
Fig. 5-1: Connection Diagram Example
Remove the jumper cable.
Functional safety unit
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5 Stop Position Monitoring Function
5.2
Turning Stop Position Monitoring Function VALID/INVALID
CAUTION
• Connect an independent switch (dry contact) for the signal.
If the semiconductor output (*periodic OFF check diagnosis) is directly connected, the input circuit may malfunction.
The signal must be received by a control device such as a safety relay unit before connecting the contact signal.
Note that an appropriate control device must be used to achieve the safety function.
• The load current of 24 VDC/8.5 mA (typ) flows through each input circuit.
For the connection, use a switching device capable of switching 24
VDC at 8.5 mA (typ).
• The dual input signals are checked whether they are synchronized.
Set the dual input signals as the signals which turn ON and OFF simultaneously. If the dual input signal’s turning ON and OFF are different in timings with 500 ms or more, the alarm of “INPUT
SIGNAL ERROR” occurs.
• A screwless terminal block is used as the terminal block 151XT.
See below for the applicable wire and wire termination.
Applicable wire: 0.3 to 1.0 mm dia. (AWG 28 to 18)
0.08 to 1.25 mm
2
(AWG 28 to 16)
* When using a ferrule, a wire of up to 0.5 mm
2
(AWG20) is applicable.
* Wire strip size (mm)
8
Solid wire
Stranded wire
Ferrule
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6 Data Protection
6 Data Protection
6.1
Saving Dual Data
6.1
Saving Dual Data
The data related to this function is saved in a duplicated manner for safety.
When the control power is turned ON, check is performed to see that dual data sets are the same.
If they are different when the control power is turned ON, the following alarm occurs.
When the following alarm occurs, set up data according to the procedure described in chapter 6.2 “Operation When VERIFY ERROR Occurs” at page 6-2
.
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]”
If the alarm occurs, the following causes are possible:
• The data related to this function is loaded from an external storage.
• The home position calibration or the home position change operation is performed.
• The tool calibration operation is performed.
• The data saving has not been performed correctly.
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6 Data Protection
6.2
Operation When VERIFY ERROR Occurs
6.2
Operation When VERIFY ERROR Occurs
If the following alarm occurs when the control power is turned ON,
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]” perform the following operations to re-set the data of the functional safety unit.
1. When the controller power is turned ON,
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]” occurs and the maintenance mode is started up.
– Select {SYSTEM} under the main menu. Then, change the security mode from EDIT MODE to MANAGEMENT MODE with the procedure described in chapter 3.1 “Changing Security Mode” at page 3-1
.
2. Select {FILE} under the main menu. Then, select {INITIALIZE} under the sub menu.
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6.2
Operation When VERIFY ERROR Occurs
3. Move the cursor to “Safety Unit FLASH Reset” and press [ENTER].
4. The dialog box “Reset?” is displayed. Select [YES].
– The data of the safety unit is re-set. A few seconds later, the buzzer sounds and the data setting is completed.
5. When the data reset is completed, turn the control power OFF and then turn the power ON again.
NOTE
To set the safety unit data, the security mode must be MAN-
AGEMENT MODE or higher. Thus, the administrator or a user with higher privilege must perform these settings.
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7 System Output Signal
7 System Output Signal
The signals output while using the functional safety unit are shorn below.
50917 50916 50915 50914 50913 50912 50911 50910
SOUT#728 SOUT#727 SOUT#726 SOUT#725 SOUT#724 SOUT#723 SOUT#722 SOUT#721
SF. UNIT
CONNECT
• 50910: SF. UNIT CONNECT
When one or more functional safety units (NSU01) are connected with the system, this signal turns ON.
50937 50936 50935 50934 50933 50932 50931 50930
SOUT#744 SOUT#743 SOUT#742 SOUT#741 SOUT#740 SOUT#739 SOUT#738 SOUT#737
MONITOR
RANGE
(R8)
MONITOR
RANGE
(R7)
MONITOR
RANGE
(R6)
MONITOR
RANGE
(R5)
MONITOR
RANGE
(R4)
MONITOR
RANGE
(R3)
MONITOR
RANGE
(R2)
MONITOR
RANGE
(R1)
• 50930 to 50937: MONITOR RANGE (R1 to 8)
This signal shows the operation status of the safety range function for each robot. Set VALID/INVALID to turn ON/OFF this signal on the ROBOT RANGE window. (Refer to chapter 3.4 “Setting Safety
Range for Robot” at page 3-7
.)
50947 50946 50945 50944 50943 50942 50941 50940
SOUT#752 SOUT#751 SOUT#750 SOUT#749 SOUT#748 SOUT#747 SOUT#746 SOUT#745
RANGE
NO.: d0 (R8)
RANGE
NO.: d0 (R7)
RANGE
NO.: d0 (R6)
RANGE
NO.: d0 (R5)
RANGE
NO.: d0 (R4)
RANGE
NO.: d0 (R3)
RANGE
NO.: d0 (R2)
RANGE
NO.: d0 (R1)
50957 50956 50955 50954 50953 50952 50951 50950
SOUT#760 SOUT#759 SOUT#758 SOUT#757 SOUT#756 SOUT#755 SOUT#754 SOUT#753
RANGE
NO.: d1 (R8)
RANGE
NO.: d1 (R7)
RANGE
NO.: d1 (R6)
RANGE
NO.: d1 (R5)
RANGE
NO.: d1 (R4)
RANGE
NO.: d1 (R3)
RANGE
NO.: d1 (R2)
RANGE
NO.: d1 (R1)
• 50940 to 50947: RANGE NO.: d0 (R1 to 8)
• 50950 to 50957: RANGE NO.: d1 (R1 to 8)
When the safety range switch function is used (refer to chapter 3.6
“Switching Safety Range” at page 3-12 ), the monitored safety range number for each robot is shown. The ranges 1 to 4 are indicated by the combination of 2 bits, d0 and d1. d1 d0 Selected safety range
No.
1
2
3
4
OFF
OFF
ON
ON
OFF
ON
OFF
ON
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DX100
8 Alarm
Alarm
No.
0020
Message
0021
0110 to
0117
0300
0400
0410
0510
1610
1612
1613
1614
1615
1616
Explanation
CPU COMMUNICATION
ERROR
COMMUNICATION ERROR
(SERVO)
COMMUNICATION ERROR
(SU#1 to 8)
VERIFY ERROR (SYSTEM
CONFIG-DATA)
The connected board’s presence was not confirmed.
This alarm also occurs when an error is detected in the serial communication between YIF01 and EAXA01 or YIF01 and NSU01.
Subcode 1: YCP01 (main CPU board)
50 to 57: EAXA01
60 to 67: NSU01
An error is detected in the serial communication between YIF01 and
EAXA01 or YIF01 and NSU01.
Subcode 50 to 57: EAXA01
60 to 67: NSU01
An error is detected in the serial communication between YIF01 and
NSU01. The last digit of the alarm number indicates the node number.
Alarm 0110: NSU 1st node
Alarm 0111: NSU 2nd node
The DX100 has detected an error in the validity check on the data files between YCP01 and the safety unit (NSU) when the power is turned ON. Execute “Safety Unit FLASH Erase” in the maintenance mode.
This alarm also occurs when the functional safety unit is replaced with the unit whose data has not been set.
PARAMETER
TRANSMISSION ERROR
MODE CHANGE ERROR
SOFTWARE VERSION
UNMATCH
SAFETY UNIT CPU
SYNCHRO ERROR
An error is detected in the parameter transmission between YIF01 and EAXA board or YIF and NSU.
Subcode: same as the alarm 0021
The DX100 changes its operation modes during a startup process from the power-on operation until the startup process completion. An unsuccessful mode change was detected.
Subcode: same as the alarm 0021
The combination of software is incorrect.
Subcode 60: The software version of the functional safety unit
(NSU01) is incorrect.
The DX100 has detected an error in the communication between
YCP01 and the safety unit (NSU) when the power is turned ON.
Check the cables and connectors between these boards, then turn the power OFF and ON again.
COMMUNICATION ERROR
(SAFETY)
ENCODER COMM. ERR 1
(SAFETY)
There is a communication error between YIF01 and NSU. There may be poor contact of connectors. Check the cables and connectors between these boards, then turn the power OFF and ON again.
The DX100 has detected an error in the communication between the encoder (each axis) and the safety unit (NSU). Check the encoder cables, then turn the power OFF and ON again.
ENCODER COMM. ERR 2
(SAFETY)
The DX100 has detected an error in the communication between the encoder (all axes) and the safety unit (NSU). Check the encoder cables and connectors, then turn the power OFF and ON again.
SYSTEM ERROR (SAFETY) NSU01 could not execute the process successfully.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
SYSTEM ERROR 1
(SAFETY)
NSU01 could not execute the process successfully.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
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8 Alarm
Alarm
No.
1618
1619
1622
1623
1625
1629
1630
1631
1632
1634
1635
1636
1637
1639
1640
Message Explanation
ARITHMETIC ERROR
(SAFETY)
PARAMETER ERROR
(SAFETY)
DEFECTIVE ENCODER
(SAFETY)
ENCODER CORR. NUM
OVER (SAFETY)
OPERATION AREA MON.
ERR (AXIS)
OPERATION AREA MON.
ERR (ROBOT)
NSU01 detected an arithmetic error.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
NSU01 detected an error in the setting value of parameter or file.
Check for an error in the setting of the safety range, then turn the power OFF and ON again. If this alarm occurs frequently, replace
NSU01 unit.
NSU01 detected an error in the encoder data.
Check the encoder cables, then turn the power OFF and ON again.
Reading encoder data failed multiple times in a row.
Turn the power OFF and ON again.
If this alarm occurs again, replace NSU01 unit.
The safety unit (NSU) has detected the manipulator motion exceeding the safety range of each axis. Check the teaching points and range setting.
The safety unit (NSU) has detected the manipulator motion exceeding the safety range. Check the teaching points, range setting, and motion speed near the end of the range.
MUTUAL DIAGNOSIS ERR
(WDT)
MUTUAL DIAGNOSIS ERR
(HW SETTING)
Data inconsistency occurred in the duplicated monitoring by the safety unit (NSU). One CPU detected an error in the timing check of the other.
This alarm may be accompanied by the alarm 1610 and 1615.
Turn the power OFF and ON again.
Data inconsistency occurred in the duplicated monitoring by the safety unit (NSU). The hardware setting failure of one of the dual systems was detected.
This alarm may occur due to the failure of the rotary switch. Turn the power OFF and ON again.
Subcode 1: rotary switch setting error
2: other errors
MUTUAL DIAGNOSIS ERR
(MONITOR)
FEEDBACK SIGNAL ERROR
(SAFETY)
LOW VOLTAGE (SAFETY) The internally-generated voltage of NSU fell below the low voltage threshold. The failure of the unit may have occurred. Replace
NSU01 unit.
OVER VOLTAGE (SAFETY) The internally-generated voltage of NSU exceeded the over voltage threshold. The failure of the unit may have occurred. Replace
NSU01 unit.
RAM DIAGNOSIS ERROR
(SAFETY)
An error was detected by the hardware diagnosis of NSU.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
RAM AREA CONVERSION
ERR (SAFETY)
Data inconsistency occurred in the duplicated monitoring by the safety unit (NSU). Turn the power OFF and ON again. This alarm occurs when an error was detected in one of the CPUs.
Data inconsistency occurred in the feedback monitoring of the safety signal outputs. Check the safety signal cables, then turn the power
ON again.
<Check point> Connectors and cables of NSU01: CNLO, CNSF 1 to 4
REAL TIME MONITOR
ERROR (SAFETY)
An error was detected by the hardware diagnosis of NSU.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
An error was detected by the hardware diagnosis of NSU.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
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DX100
Alarm
No.
1641
1642
1643
1644
1645
1646
Message
SAFETY OUTPUT FB
ERROR (SAFETY)
WATCHDOG SIGNAL
ERROR (SAFETY)
SIGNAL SETTING ERROR
(SAFETY)
24V LOW VOLTAGE
(SAFETY)
CRC ERROR (SAFETY)
COMM. SETTING ERROR
(SAFETY)
Explanation
An error was detected in the connection between NSU and another unit. Check the safety signal cables, then turn the power OFF and
ON again.
<Check point 1> communication cable between NSU (CNSF1 connector) and YSU (CN207 connector)
<Check point 2> communication cable between NSU (CNSF1 connector) and YPU (CN609 connector)
An error was detected by the hardware diagnosis of NSU.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
When a multiple robot system (with 2 or more manipulators) is used, the DX100 has detected an error in the link signal between the safety units (NSU01) or in the jumper cable setting of NSF02 board. Turn the power OFF and then ON again.
<Check point> CNMA connector of NSU01 of the first robot, CNMB connector of NSU01 of the second robot, and the cables between the connectors
<Check point> CNLO connector of NSU01 of the first robot, CNLI connector of NSU01 of the second robot, and the cables between the connectors
<Check point> The jumper cable setting of NSF02 board of the rotary switch
The externally supplied 24V voltage for NSU is not supplied.
Check the fuse, power supply connector, and cables of NSU01.
<Check point> F2, F3 fuses, CN01 connector, and power cable of
NSU01
An error was detected in the stored data of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
An error was detected by the hardware diagnosis of NSU.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4208
4679
4680
4682
4683
4685
4687
4689
SYSTEM ERROR (ARITH)
SPECIFIED MOTION RANGE
ERROR
A teaching point is set outside the range. Check the teaching points and range setting.
Upper YCP01 detected that the range whose setting and confirmation are not completed is selected.
Check the status of range selection signal and the setting of the safety range.
SAFETY UNIT COMMAND
ERROR
An error is detected in the serial communication between NIF01 and
NSU01. This alarm may be accompanied by the alarm 0020 or 0100.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
MOTION RANGE LIMIT
INTERFERENCE
Upper YCP01 detected the manipulator motion exceeding the safety range. Check the teaching points and range setting.
AXIS MOTION RANGE LIMIT Upper YCP01 detected the motion of each axis exceeding the safety range. Check the teaching points and range setting.
WRITE ERROR (SAFETY)
OPERATION AREA MON.
ERR 2 (AXIS)
OPERATION AREA MON.
ERR 2 (ROBOT)
Data was not recorded successfully in the functional safety unit.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
The safety unit (NSU) detected the motion of each axis exceeding the safety range. Check the teaching points and range setting.
The safety unit (NSU) detected the manipulator motion exceeding the safety range. Check the teaching points and range setting.
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8 Alarm
Alarm
No.
4691
4692
4693
4694
4695
4703
4704
4705
Message Explanation
OPERATION AREA SET ERR
(SAFETY)
ENCODER BACKUP ERROR
(SAFETY)
READBACK PROC. ERROR
(SAFETY)
SIGNAL COMPARISON
ERROR (SAFETY)
The safety unit (NSU) detected that the range whose setting is not completed is selected.
Check the status of range selection signal and the setting of the safety range.
This alarm occurs when the voltage of encoder battery drops.
Replace the encoder battery.
<Check point> CN03A connector and connection cables of NSU01
An error was detected in the readback process at the data change between NSU01 and the programming pendant.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
The speed at TCP exceeded the safety speed. Lower the operation speed.
SPEED MONITOR ERROR 1
(SAFETY)
SPEED MONITOR ERROR 2
(SAFETY)
The speed at the manipulator flange exceeded the safety speed.
Lower the operation speed.
OPERATION MODE ERROR An error was detected by the internal diagnosis of NSU.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
STOPPING POS. MON. ERR
(SAFETY)
NSU01 detected that the robot moved when the stop position monitoring function was enabled.
Check the status of GSIN signal, set GSIN signal to the short-circuit status, then reset the alarm.
Data inconsistency occurred in the duplicated monitoring of the safety signals. Check the safety signal cables, then turn the power ON again.
<Check point> Connectors and cables of NSU01: CNMA, CNMB,
CNIFA, CNIFB, and CNSF 1 to 4
Subcode 1: Signal inconsistency in PPDSW
5: Signal inconsistency in YCU02 board A to D
3: Signal inconsistency in YCU02 board E to H
40: Signal inconsistency in GSIN signal
41: Signal inconsistency in GSIN signal
NOTE Investigation is required If the error occurs again. Contact your Yaskawa representative.
7 segment LED indication of safety unit NSU01
7 segment LED indication of safety unit NSU01 are as follows.
(Left side LED: CPU1, Right side LED: CPU2)
7 seg. LED indication
All Lit
[0] to [C]
[d]
[E]
Status
After power on
Under boot up
Normal status
Error status
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When an error occurs in safety unit, 5 digits LED are indicated with 7 seg.
LED.
Each digit is indicated for 1.0sec and all turning off status is for 0.3sec.
Following is the example of “F001.” error.
Sequence 7 seg. LED indication Indication time
1 [F] 1.0 [sec]
2
3
Turning off
[0]
0.3 [sec]
1.0 [sec]
4
5
Turning off
[0]
0.3 [sec]
1.0 [sec]
8
9
6
7
10
Turning off
[1]
Turning off
[.]
Turning off
0.3 [sec]
1.0 [sec]
0.3 [sec]
1.0 [sec]
0.3 [sec]
Total time
1.0 [sec]
1.3 [sec]
2.3 [sec]
2.6 [sec]
3.6 [sec]
3.9 [sec]
4.9 [sec]
5.2 [sec]
6.2 [sec]
6.5 [sec]
Meaning of 7 segment LED indication are as follows.
Cause
0700.
0800.
0900.
0C00.
0D00.
1000.
0200.
0210.
0300.
0400.
0500.
0600.
1100.
1200.
1300.
1400.
5 digits indication code
Error meaning
F001.
F002.
F003.
F004.
Communication error
F010.
0100.
CPU error
Data communication error occurs.Check cable wiring and a terminator then power on again.
CPU internal error occurs.
Power on again.
NOTE Investigation is required If the error occurs again. Contact your Yaskawa representative.
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9 Restrictions
9 Restrictions
9.1
Confirming Safety Range and Robot Position
9.1
Confirming Safety Range and Robot Position
This function also records parameters, files and other data in the safety unit.
Therefore, this function cannot be used with a function that changes parameters or files during playback.
• T axis endless function and external axis endless function
• PMT function
• Gun change function and group change function
• System for painting
• Tool file number change
9.2
Software Version of Machine Safety Unit
This function checks the signals from the functional safety unit in the machine safety unit (YSU01-1E). The machine safety unit must have the following version:
YSU01-1: 1.08-00 or later
If the YSU version is earlier than the above version, ALARM 510
“SOFTWARE VERSION UNMATCH [70]” occurs.
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9.3
Software Version of Functional Safety Unit
9.3
Software Version of Functional Safety Unit
The functional safety unit (NSU01) must have the following version:
NSU01: V3.00-00 or later
If the NSU version is earlier than the above version, ALARM 510
“SOFTWARE VERSION UNMATCH [70]” occurs.
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DX100 OPTIONS
INSTRUCTIONS
FOR FUNCTIONAL SAFETY UNIT (NSU01)
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan
Phone +81-93-645-7745 Fax +81-93-645-7746
YASKAWA America Inc. MOTOMAN Robotics Division
805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Nordic AB
Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden
Phone +46-480-417800 Fax +46-480-417999
YASKAWA Europe GmbH Robotics Division
Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Electric Korea Co., Ltd.
7F, Doore Bldg.; 24, Yeoido-Dong Youngdungpo-ku, Seoul, KOREA
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric (Singapore) PTE Ltd.
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.
252/246, 4th Floor. Muang Thai-Phatra Office Tower II Rachadaphisek Road, Huaykwang Bangkok, 10320 Thailand
Phone +66-2-693-2200 Fax +66-2-693-4200
Shougang MOTOMAN Robot Co. Ltd.
No.7, Yongchang-North Road, Beijing E&T Development Area, China 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
MOTOMAN Motherson Robotics Ltd.
Plot No.195-196, 1st Floor, Sec.4 IMT Manesar, Gurgaon 122050, Haryana
Phone +91-124-475-8500 Fax +91-124-414-8016
Specifications are subject to change without notice for ongoing product modifications and improvements.
YASKAWA ELECTRIC CORPORATION
C Printed in Japan July 2010 10-07
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