Yaskawa Motoman DX100 Owner's Manual

DX100
INSTRUCTIONS
FOR NORTH AMERICAN (ANSI/RIA) STANDARD
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMANINSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
Part Number: 155494-1CD
Revision: 2
YASKAWA ELECTRIC CORPORATION
MANUAL NO. RE-CTO-A217 2
DX100
MANDATORY
•
This manual explains setup, diagnosis, maintenance, hardware,
etc. 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 Section 1. To ensure
correct and safe operation, carefully read the section.
CAUTION
•
Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
•
The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
•
YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
•
If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
•
YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.
ii
DX100
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY” or ”PROHIBITED”.
WARNING
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the
MANDATORY items listed under this heading.
PROHIBITED
Must never be performed.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “CAUTION” and “WARNING”.
iii
DX100
WARNING
•
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 DX100 power
- 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 the emergency stop button
immediately if there are problems. The emergency stop button is
located on the right of the programming pendant.
•
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.
- Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
•
Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on programming pendant is
pressed.
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 button does 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
iv
DX100
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 DX100
cabinet after use.
The programming pendant can be damaged if it is left in the P-point
maximum envelope of the manipulator’s work area, on the floor, or near
fixtures.
•
Read and understand the Explanation of the Warning Labels
before operating the manipulator.
Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows.
Equipment
Manual Designation
DX100 Controller
DX100
DX100 Programming Pendant
Programming Pendant
Cable between the manipulator and
the controller
Manipulator Cable
v
DX100
Descriptions of the programming pendant, buttons, and displays are
shown as follows:
Equipment
Manual Designation
Programming Character
Pendant
Keys
The keys which have characters printed on
them are denoted with [ ].
ex. [ENTER]
Symbol
Keys
The keys which have a symbol printed on them
are not denoted with [ ] but depicted with a small
picture.
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 When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]
Displays
The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
Description of the Operation Procedure
In the explanation of the operation procedure, the expression "Select • • • "
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
vi
DX100
Explanation of Warning Labels
The following warning labels are attached to the manipulator and DX100.
Fully comply with the precautions on the warning labels.
WARNING
•
The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
•
Failure to observe this caution may result in injury or damage to
equipment.
WARNING
WARNING
Moving parts
may cause
injury
Do not enter
robot
work area.
Refer to the manipulator manual for the warning label location.
•
The following warning labels are attached to DX100.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to
equipment.
WARNING
High Voltage
Do not open the door
with power ON.
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
PROGRAMMING PENDANT
X 8 1
vii
DX100
Contents
1 Safety .............................................................................................................................................. 1-1
1.1 For Your Safety.................................................................................................................. 1-1
1.2 Special Training ................................................................................................................. 1-2
1.3 Motoman Manual List......................................................................................................... 1-2
1.4 Personnel Safety................................................................................................................ 1-3
1.5 Motoman Safety................................................................................................................. 1-5
1.5.1 Installation and Wiring Safety ............................................................................... 1-5
1.5.2 Work Area Safety................................................................................................ 1-10
1.5.3 Operation Safety................................................................................................. 1-11
1.6 Notes for Moving and Transferring the MOTOMAN......................................................... 1-14
1.7 Notes on MOTOMAN Disposal ........................................................................................ 1-15
2 Product Confirmation ...................................................................................................................... 2-1
2.1 Contents Confirmation ....................................................................................................... 2-1
2.2 Order Number Confirmation............................................................................................... 2-2
3 Installation ....................................................................................................................................... 3-1
3.1 Handling Procedure ........................................................................................................... 3-1
3.1.1 Using a Crane to Move the Controller .................................................................. 3-1
3.1.2 Using a Forklift to Move the Controller ................................................................. 3-3
3.2 Place of Installation............................................................................................................ 3-4
3.3 Location ............................................................................................................................. 3-5
3.4 Mounting the Controller...................................................................................................... 3-6
4 Connection ...................................................................................................................................... 4-1
4.1 Notes on Cable Junctions .................................................................................................. 4-2
4.2 Power Supply..................................................................................................................... 4-3
4.2.1 Three-Phase Power Supply.................................................................................. 4-3
4.2.2 Noise Filter Installation ......................................................................................... 4-3
4.2.3 Leakage Breaker Installation ................................................................................ 4-4
4.2.4 Primary Power Supply Breaker/Fuse Installation ................................................. 4-5
4.3 Connection Methods .......................................................................................................... 4-6
4.3.1 Connecting the Primary Power Supply ................................................................. 4-6
4.3.2 Connecting the Manipulator Cable ....................................................................... 4-9
4.3.3 Connecting the Programming Pendant............................................................... 4-10
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DX100
Contents
5 Turning ON and OFF the Power Supply ......................................................................................... 5-1
5.1 Turning ON the Main Power Supply .................................................................................. 5-1
5.1.1 Initial Diagnosis .................................................................................................... 5-2
5.1.2 When Initial Diagnosis are Complete ................................................................... 5-2
5.2 Turning ON the Servo Power............................................................................................. 5-3
5.2.1 During Play Mode ................................................................................................. 5-3
5.2.2 During Teach Mode .............................................................................................. 5-3
5.3 Turning OFF the Power Supply ......................................................................................... 5-5
5.3.1 Turning OFF the Servo Power (Emergency Stop)................................................ 5-5
5.3.2 Turning OFF the Main Power ............................................................................... 5-5
6 Test of Program Operation ............................................................................................................. 6-1
6.1 Movement of the Axes ....................................................................................................... 6-2
7 Security System .............................................................................................................................. 7-1
7.1 Protection Through Security Mode Settings ...................................................................... 7-1
7.1.1 Security Mode ...................................................................................................... 7-1
7.1.1.1 Changing the Security Mode ................................................................... 7-5
7.1.2 User ID ................................................................................................................. 7-7
7.1.2.1 Changing User ID.................................................................................... 7-7
8 System Setup.................................................................................................................................. 8-1
8.1 Home Position Calibration ................................................................................................. 8-2
8.1.1 Home Position Calibration .................................................................................... 8-3
8.1.2 Calibrating Operation............................................................................................ 8-4
8.1.2.1 Registering All Axes at One Time ........................................................... 8-4
8.1.2.2 Registering Individual Axes ..................................................................... 8-6
8.1.2.3 Changing the Absolute Data ................................................................... 8-7
8.1.2.4 Clearing Absolute Data ........................................................................... 8-8
8.1.3 Home Position of the Robot................................................................................ 8-10
8.2 Setting the Second Home Position (Check Point) ........................................................... 8-11
8.2.1 Purpose of Position Check Operation ................................................................ 8-12
8.2.2 Procedure for the Second Home Position Setting (Check Point) ....................... 8-14
8.2.3 Procedure after the Alarm .................................................................................. 8-16
8.3 Tool Data Setting ............................................................................................................. 8-18
8.3.1 Registering Tool Files......................................................................................... 8-18
8.3.1.1 Number of Tool Files ............................................................................. 8-18
8.3.1.2 Registering Coordinate Data ................................................................. 8-18
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DX100
Contents
8.3.1.3 Registering Tool Angle .......................................................................... 8-20
8.3.1.4 Setting the Tool Load Information ......................................................... 8-22
8.3.2 Tool Calibration................................................................................................... 8-23
8.3.2.1 Tool Calibration ..................................................................................... 8-23
8.3.2.2 Setting of Tool Calibration Method ........................................................ 8-23
8.3.2.3 Teaching of Calibration Point ................................................................ 8-24
8.3.2.4 Clearing Calibration Data ...................................................................... 8-29
8.3.2.5 Checking the TCP ................................................................................. 8-30
8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity................. 8-32
8.3.3.1 What is the Automatic Measurement of the Tool Load and the
Center of Gravity? ................................................................................. 8-32
8.3.3.2 Measurement of the Tool Load and the Center of Gravity .................... 8-32
8.4 ARM Control .................................................................................................................... 8-37
8.4.1 ARM Control ....................................................................................................... 8-37
8.4.2 ARM CONTROL Window ................................................................................... 8-37
8.4.2.1 Robot Setup Condition .......................................................................... 8-37
8.4.3 Tool Load Information Setting............................................................................. 8-42
8.4.3.1 Tool Load Information ........................................................................... 8-42
8.4.3.2 How to Calculate Tool Load Information ............................................... 8-42
8.4.3.3 Tool Load Information Registering ........................................................ 8-48
8.5 Work Home Position ........................................................................................................ 8-51
8.5.1 What is the Work Home Position? ...................................................................... 8-51
8.5.2 Setting Work Home Position............................................................................... 8-51
8.5.2.1 Work Home Position Window ................................................................ 8-51
8.5.2.2 Registering/Changing the Work Home Position .................................... 8-52
8.5.2.3 Returning to the Work Home Position ................................................... 8-53
8.5.2.4 Output of the Work Home Position Signal ............................................. 8-54
8.6 Interference Area ............................................................................................................. 8-55
8.6.1 Interference Area ................................................................................................ 8-55
8.6.2 Cubic Interference Area...................................................................................... 8-55
8.6.2.1 Cubic Interference Area......................................................................... 8-55
8.6.2.2 Cube Setting Method............................................................................. 8-55
8.6.2.3 Setting Operation .................................................................................. 8-57
8.6.3 Axis Interference Area ........................................................................................ 8-63
8.6.3.1 Axis Interference Area ........................................................................... 8-63
8.6.3.2 Setting Operation .................................................................................. 8-63
8.6.4 Clearing the Interference Area Data ................................................................... 8-70
8.7 Shock Detection Function ................................................................................................ 8-72
8.7.1 Shock Detection Function................................................................................... 8-72
8.7.2 Shock Detection Function Setting....................................................................... 8-72
8.7.2.1 Shock Detection Level Setting............................................................... 8-72
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DX100
Contents
8.7.2.2 Tool Load Information Setting ............................................................... 8-75
8.7.2.3 Instruction of Shock Detection Function................................................ 8-75
8.7.2.4 Resetting the Shock Detected............................................................... 8-79
8.8 User Coordinate Setting .................................................................................................. 8-81
8.8.1 User Coordinates................................................................................................ 8-81
8.8.2 User Coordinate Setting ..................................................................................... 8-82
8.8.2.1 Selecting the User Coordinate File........................................................ 8-82
8.8.2.2 Teaching the User Coordinates............................................................. 8-83
8.8.2.3 Clearing the User Coordinates .............................................................. 8-85
8.9 Overrun / Tool Shock Sensor Releasing ......................................................................... 8-86
8.10 Soft Limit Release Function........................................................................................... 8-88
8.11 All Limit Release Function ............................................................................................. 8-89
8.12 Instruction Level Setting ................................................................................................ 8-91
8.12.1 Setting Contents ............................................................................................... 8-91
8.12.1.1 Instruction Set ..................................................................................... 8-91
8.12.1.2 Learning Function ............................................................................... 8-91
8.12.2 Setting the Instruction Set Level....................................................................... 8-92
8.12.3 Setting the Learning Function .......................................................................... 8-93
8.13 Setting the Controller Clock ........................................................................................... 8-95
8.14 Setting the Play Speed .................................................................................................. 8-96
8.15 Numeric Key Customize Function ................................................................................. 8-98
8.15.1 What is the Numeric Key Customize Function? ............................................... 8-98
8.15.2 Allocatable Functions ....................................................................................... 8-98
8.15.2.1 Key Allocation (EACH) ........................................................................ 8-98
8.15.2.2 Key Allocation (SIM)............................................................................ 8-98
8.15.3 Allocating an Operation .................................................................................... 8-99
8.15.3.1 Allocation Window ............................................................................... 8-99
8.15.3.2 Instruction Allocation ......................................................................... 8-100
8.15.3.3 Job Call Allocation............................................................................. 8-101
8.15.3.4 Display Allocation .............................................................................. 8-102
8.15.3.5 Alternate Output Allocation ............................................................... 8-103
8.15.3.6 Momentary Output Allocation ............................................................ 8-104
8.15.3.7 Pulse Output Allocation ..................................................................... 8-104
8.15.3.8 Group (4-bit/8-bit) Output Allocation.................................................. 8-105
8.15.3.9 Analog Output Allocation................................................................... 8-106
8.15.3.10 Analog Incremental Output Allocation ............................................. 8-106
8.15.4 Allocation of I/O Control Instructions .............................................................. 8-107
8.15.5 Execution of Allocation ................................................................................... 8-109
8.15.5.1 Executing the Instruction/Output Control Allocation .......................... 8-109
8.15.5.2 Executing the Job Call Allocation ...................................................... 8-109
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DX100
Contents
8.15.5.3 Executing the Display Allocation ....................................................... 8-109
8.15.5.4 Executing the I/O Control Allocation.................................................. 8-109
8.16 Changing the Output Status......................................................................................... 8-110
8.17 Changing the Parameter Setting.................................................................................. 8-112
8.18 File Initialization ........................................................................................................... 8-115
8.18.1 Initializing Job File .......................................................................................... 8-115
8.18.2 Initializing Data File......................................................................................... 8-115
8.18.3 Initializing Parameter File ............................................................................... 8-117
8.18.4 Initializing I/O Data.......................................................................................... 8-118
8.18.5 Initializing System Data .................................................................................. 8-119
8.19 Display Setting Function .............................................................................................. 8-121
8.19.1 Font Size Setting ............................................................................................ 8-121
8.19.1.1 Applicable Range for the Font Size Change ..................................... 8-121
8.19.1.2 Settable Font Size ............................................................................. 8-121
8.19.1.3 Setting the Font Size ......................................................................... 8-122
8.19.2 Operation Button Size Setting ........................................................................ 8-125
8.19.2.1 Applicable Range for the Button Size Change .................................. 8-125
8.19.2.2 Settable Button Size .......................................................................... 8-125
8.19.2.3 Setting the Button Size ...................................................................... 8-126
8.19.3 Initialization of Screen Layout......................................................................... 8-129
8.19.3.1 Initializing the Screen Layout............................................................. 8-129
8.19.4 Layout Storage ............................................................................................... 8-131
9 System Backup ............................................................................................................................... 9-1
9.1 System Backup with DX100............................................................................................... 9-1
9.1.1 Function Types of Data......................................................................................... 9-1
9.1.1.1 CMOS.BIN............................................................................................... 9-1
9.1.1.2 CMOSBK.BIN .......................................................................................... 9-1
9.1.1.3 CMOSxx.HEX.......................................................................................... 9-1
9.1.1.4 ALCMSxx.HEX ........................................................................................ 9-1
9.1.2 Device................................................................................................................... 9-2
9.2 Backup by CMOS.BIN ....................................................................................................... 9-3
9.2.1 CMOS.BIN Save................................................................................................... 9-3
9.2.2 CMOS.BIN Load ................................................................................................... 9-5
9.3 Automatic Backup Function ............................................................................................... 9-7
9.3.1 Automatic Backup Function .................................................................................. 9-7
9.3.1.1 Objective ................................................................................................. 9-7
9.3.1.2 Outline ..................................................................................................... 9-7
9.3.2 Settings for Automatic Backup.............................................................................. 9-9
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DX100
Contents
9.3.2.1 CompactFlash ......................................................................................... 9-9
9.3.2.2 AUTO BACKUP SET Display................................................................ 9-10
9.3.2.3 DX100 Status and Automatic Backup ................................................... 9-13
9.3.2.4 Setting Examples .................................................................................. 9-15
9.4 Loading the Backup Data from the CompactFlash .......................................................... 9-16
9.4.1 Loading Procedure ............................................................................................. 9-16
9.5 Error List .......................................................................................................................... 9-19
9.5.1 Error Contents .................................................................................................... 9-19
10 Upgrade Function ....................................................................................................................... 10-1
10.1 Functional Overview ...................................................................................................... 10-1
10.2 Upgrade Procedure ....................................................................................................... 10-1
10.2.1 Confirmation of Software Version..................................................................... 10-1
10.2.2 Automatic Upgrade of YPP01........................................................................... 10-2
10.3 Error Message ............................................................................................................... 10-4
11 Manual Brake Release Function................................................................................................. 11-1
11.1 Operating Conditions of Manual Brake Release............................................................ 11-1
11.2 Manual Brake Release Operation.................................................................................. 11-3
11.3 Warning Message Display ............................................................................................. 11-5
12 Modification of System Configuration ......................................................................................... 12-1
12.1 Addition of I/O Modules ................................................................................................. 12-1
12.2 Addition of Base and Station Axes ................................................................................ 12-3
12.2.1 Base Axis Setting ............................................................................................. 12-5
12.2.1.1 Selection of Base Axis Type................................................................ 12-5
12.2.1.2 Connection Setting .............................................................................. 12-8
12.2.1.3 Axis Configuration Setting ................................................................... 12-9
12.2.1.4 Mechanical Specification Setting....................................................... 12-10
12.2.1.5 Motor Specification Setting................................................................ 12-12
12.2.2 Station Axis Setting ........................................................................................ 12-13
12.2.2.1 Selection of Station Axis Type........................................................... 12-13
12.2.2.2 Connection Setting ............................................................................ 12-14
12.2.2.3 Axis Configuration Setting ................................................................. 12-16
12.2.2.4 Mechanical Specification Setting....................................................... 12-17
12.2.2.5 Motor Specification Setting................................................................ 12-20
13 DX100 Specification.................................................................................................................... 13-1
13.1 Specification List............................................................................................................ 13-3
13.2 Function List .................................................................................................................. 13-4
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Contents
13.3 Programming Pendant ................................................................................................... 13-5
13.4 Equipment Configuration ............................................................................................... 13-6
13.4.1 Arrangement of Units and Circuit Boards ......................................................... 13-6
13.4.2 Cooling System of the Controller Interior.......................................................... 13-8
14 Description of Units and Circuit Boards ...................................................................................... 14-1
14.1 Power Supply Contactor Unit......................................................................................... 14-4
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□) .................................................... 14-5
14.2.1 Major Axes Control Circuit Board (SRDA-EAXA01□) ....................................... 14-5
14.2.2 Connection for Tool Shock Sensor (SHOCK)................................................... 14-6
14.2.2.1 To connect the tool shock sensor directly to the tool shock sensor
signal line............................................................................................... 14-6
14.2.2.2 To connect the tool shock sensor with the cable that is built into
the manipulator...................................................................................... 14-7
14.2.3 Connection for Direct-in .................................................................................... 14-8
14.3 CPU Unit ........................................................................................................................ 14-9
14.3.1 CPU Unit Configuration .................................................................................... 14-9
14.3.2 Unit and Circuit Board in the CPU Unit........................................................... 14-10
14.3.2.1 Control Circuit Board (JANCD-YCP01-E).......................................... 14-10
14.3.2.2 Robot I/F Board (JANCD-YIF01-□E) ................................................. 14-10
14.4 CPS Unit (JZNC-YPS01-E).......................................................................................... 14-11
14.5 Brake Control Board (JANCD-YBK01-2E) ................................................................... 14-13
14.5.1 Brake Control Board (JANCD-YBK01-2E)...................................................... 14-13
14.6 Robot I/O Unit (JZNC-YIU01-E)................................................................................... 14-14
14.6.1 Robot I/O Unit (JZNC-YIU01-E)...................................................................... 14-14
14.7 Machine Safety Unit (JZNC-YSU01-1E) ...................................................................... 14-19
14.7.1 Machine Safety Unit (JZNC-YSU01-1E)......................................................... 14-19
14.7.2 Connection for Servo-ON Enable Input (ONEN1 and ONEN2) ...................... 14-20
14.7.3 Connection for External Axis Overrun (EXOT) ............................................... 14-21
14.8 WAGO Connector ........................................................................................................ 14-22
14.9 Robot Specific Input Terminal Block (MXT) ................................................................. 14-24
14.10 Contact Output of Emergency Stop Button................................................................ 14-35
14.11 SERVOPACK............................................................................................................. 14-36
14.11.1 Description of Each Unit ............................................................................... 14-36
14.11.1.1 Converter......................................................................................... 14-36
14.11.1.2 PWM Amplifier................................................................................. 14-36
14.11.2 SERVOPACK Configuration ......................................................................... 14-36
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DX100
Contents
14.12 Universal I/O Signal Assignment ............................................................................... 14-41
14.12.1 Arc Welding .................................................................................................. 14-41
14.12.2 Handling ....................................................................................................... 14-47
14.12.3 General Application ...................................................................................... 14-53
14.12.4 Spot Welding ................................................................................................ 14-59
14.12.5 JANCD-YEW01-E Circuit Board (Standard)................................................. 14-67
14.12.5.1 Arc Welding ..................................................................................... 14-67
xv
1
1.1
DX100
1
Safety
For Your Safety
Safety
1.1
For Your Safety
Robots generally have requirements which are different from other
manufacturing equipment, such as larger working areas, high-speed
operation, rapid arm movements, etc., which can pose safety hazards.
Read and understand the instruction manuals and related documents, and
observe all precautions in order to avoid the risk of injury to personnel and
damage to equipment.
It is the user’s responsibility to ensure that all local, state, and national
codes, regulations rules, or laws relating to safety and safe operating
conditions are met and followed.
MANDATORY
•
Teaching maintenance of the robot must conform to:
– Industrial Safety and Health Law
– Enforcement Order of Industrial Safety and Health Law
– Ordinance of Industrial Safety and Health Law
Other related laws are:
– Occupational Safety and Health Act in USA
– Factory Act (Gewerbeordnung) in Germany
– Health and Safety at Work, etc. Act in UK
– EC Machinery Directive 98/37/EC
•
Prepare
– SAFETY WORK REGULATIONS
based on concrete policies for safety management complying with
related laws.
•
Observe the
– MANIPULATING INDUSTRIAL ROBOTS-SAFETY (ISO 10218)
for safe operation of the robot. (Japan Only) (JIS B 8433)
•
Reinforce the
– SAFETY MANAGEMENT SYSTEM
by designating authorized workers and safety managers, as well as
giving continuing safety education.
•
Teaching and maintaining the robot are specified as
"Hazardous Operations" in the Industrial Safety and Health Law
(Japan only).
Workers employed in these above operations are requested to attend
special training offered by YASKAWA.
1-1
1
1.2
DX100
1.2
Safety
Special Training
Special Training
MANDATORY
•
Persons who teach or inspect the manipulator must undergo
required training before using the manipulator.
•
For more information on training, inquire at the nearest YASKAWA
branch office.
The telephone numbers are listed on the back cover of this manual.
1.3
Motoman Manual List
MANDATORY
•
It is important to have and be familiar with all manuals concerning
the MOTOMAN.
You should have the four manuals listed below:
– MOTOMAN-
INSTRUCTIONS
– DX100 INSTRUCTIONS
– DX100 OPERATOR’S MANUAL
Confirm that you have all these manuals on hand.
If any manuals are missing, contact your salesman from YASKAWA’s
local branch office.
The relevant telephone numbers are listed on the back cover.
1-2
1
1.4
DX100
1.4
Safety
Personnel Safety
Personnel Safety
The entire manipulator P-point maximum envelope is potentially
dangerous.
All personnel working with the MOTOMAN (safety administration,
installation, operation, and maintenance personnel) must always be
prepared and "Safety First" minded, to ensure the safety of all personnel.
CAUTION
•
Avoid any dangerous actions in the area where the MOTOMAN is
installed.
There is a danger of injury if there is contact with the manipulator or
peripheral equipment.
•
Please take strict safety precautions by placing signs such as
"Flammable", "High Voltage", "Waiting", and "Off-limits to
Unauthorized Personnel" in necessary areas in the factory.
Failure to observe these cautions may result in fire, electric shock, or
injury due to contact with the manipulator and other equipment.
•
Strictly observe the following items:
– Always wear approved work clothes (no loose-fitting clothes).
– Do not wear gloves when operating the MOTOMAN.
– Do not allow underwear, shirts, or neckties to hang out from the
work clothes.
– Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety
shoes (with slip-proof soles), face shields, safety glasses, and gloves
as necessary.
Improper clothing may result in injury.
•
Unauthorized persons should not approach the manipulator or
associated peripheral equipment.
Failure to observe this caution may result in injury due to contact with
DX100, controller, the workpiece, the positioner, etc.
1-3
DX100
1
1.4
Safety
Personnel Safety
CAUTION
•
Never forcibly move the manipulator axes.
Failure to observe this caution may result in injury or equipment
damage.
•
Never lean on DX100 or other controllers, and avoid inadvertently
pushing buttons.
Failure to observe this caution may result in injury or damage by
unexpected movement of the manipulator.
•
Never allow unauthorized personnel to touch the DX100 during
operation.
Failure to observe this caution may result in injury or damage resulting
from unexpected movement of the manipulator.
1-4
1
1.5
DX100
1.5
1.5.1
Safety
Motoman Safety
Motoman Safety
Installation and Wiring Safety
Refer to the MOTOMANInstructions manual and DX100
Instructions for details on installation and wiring.
In planning installation, adapt an easy to observe arrangement to ensure
safety. Take safety into consideration when planning the installation.
Observe the following when installing the manipulator:
WARNING
•
Select an area such as that described below to install the
manipulator:
Confirm that the area is large enough so that the fully extended
manipulator arm with tool will not reach a side wall, safeguarding, or
the controller.
Failure to observe this caution may result in injury or damage resulting
from unexpected movement of the manipulator.
Safeguarding
DX100
Door
1000 mm or more
1000 mm or more
1000 mm or more
P-point maximum envelope
of Manipulator
Maximum Working Envelope of
Manipulator Including Tool or
Workpiece End
1000 mm or more
•
Perform grounding in accordance with all applicable electrical
codes.
Failure to observe this caution may result in fire or electric shock.
1-5
DX100
1
1.5
Safety
Motoman Safety
CAUTION
•
Operation of the crane, sling, or forklift should only be performed by
authorized personnel.
Failure to observe this precaution may result in injury or equipment
damage.
MOTOMAN should be lifted with a crane using wire rope threaded
through the shipping bolts and positioners and the body should be lifted
in an upright posture as described in the manipulator instruction
manual.
Failure to observe these precautions may cause the manipulator to turn
downward, potentially causing injury or damage to equipment.
1-6
DX100
1
1.5
Safety
Motoman Safety
CAUTION
•
When lifting the DX100, please check the following:
– As a rule, handling of DX100 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 DX100.
Wire Rope
M16 Eye Bolt
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
PROGRAMMING PENDANT
X8 1
Table 1-1: Approx. Weight of DX100
Models Available for
DX100
small capacity:
MA1400, MA1900,
VA1400, MH5, MH5L,
MH6, HP20D, HP20D-6
Approx.
Weight (kg)
250
middle/large capacity:
MH50,MS80,ES165D,
ES200D,VS50,SIA50D
•
Be sure the eyebolts are securely fastened.
Failure to observe this caution may result in injury or damage to
equipment.
•
If storing the manipulator temporarily before installation, be sure to
place it on a stable and flat surface and take precautions to prevent
unauthorized personnel from touching it.
Failure to observe this precaution may result in injury of damage to
equipment.
1-7
1
1.5
Safety
Motoman Safety
CAUTION
•
Be sure there is sufficient room for maintenance on the manipulator,
DX100, and other peripheral equipment.
500
800
500
800
650
500
Failure to observe this precaution could result in injury during
maintenance.
650
500
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
DOOR
DX100 Maintenance Area (Unit: mm)
•
1000
782
NJ1530
890
DX100
PROGRAMMING PENDANT
X 8 1
DX100 External Dimensions (Unit: mm)
To ensure safety, be sure to operate the controller from a location
where the manipulator is easily visible.
Operation by unauthorized personnel may result in injury or equipment
damage.
•
Install the DX100 outside the safeguarding of the manipulator’s
safety enclosure.
Failure to observe this precaution may result in injury or damage to
equipment resulting from contact with the manipulator.
•
Install the manipulator using bolts of the size and type specified for
each MOTOMAN in the MOTOMAN INSTRUCTION MANUAL.
Failure to observe this caution may result in injury or damage to
equipment.
1-8
DX100
1
1.5
Safety
Motoman Safety
CAUTION
•
Secure the position of the DX100 after setting up.
Attach the DX100 to the floor or rack, etc., using the screw holes on the
bottom of the DX100.
Failure to observe this caution could lead to injury or equipment
damage if the DX100 should shift or fall.
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
40
12 dia.
(2 holes)
PROGRAMMING PENDANT
X81
30
50
30
50
(Unit: mm)
Tapped Holes for
M10 Screws on
the DX100 Side
•
Be familiar with the connection diagram before wiring the DX100,
and perform the wiring in accordance with the connection diagram.
There is a danger of equipment damage or injury due to miswiring and
unexpected movement of the equipment.
•
Take precautions when wiring and piping between the DX100,
manipulator, 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 the forklift.
SAFETY
FIRST
Piping
Lead
Cable Channnel
Operators and other personnel may stumble on exposed wiring or
piping. Cable damage can cause unexpected manipulator motion
resulting in injury or property damage.
1-9
1
1.5
DX100
1.5.2
Safety
Motoman Safety
Work Area Safety
Carelessness contributes to serious accidents in the work area.
To ensure safety, enforce the following precautions:
WARNING
•
Install a safeguarding around the manipulator to prevent any
accidental contact with the manipulator while the power is ON.
Post a warning sign stating "Off-limits During Operation" at the
entrance of the enclosure. The gate of the safeguarding must be
equipped with a safety interlock. Be sure the interlock operates
correctly before use.
Failure to observe this caution may result in a serious accident due to
contact with the manipulator.
CAUTION
•
Store tools and similar equipment in proper locations outside of the
enclosure.
Tools and loose equipment should not be left on the floor around the
manipulator, DX100, or welding fixture, etc., as injury or damage to
equipment can occur if the manipulator comes in contact with objects or
equipment left in the work area.
1-10
1
1.5
DX100
1.5.3
Safety
Motoman Safety
Operation Safety
WARNING
•
When attaching a tool such as the welding torch to the manipulator,
be sure to turn OFF the power supply of the DX100 and the tool,
lock the switch, and display a warning sign.
ON
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
ENERGIZING
PROHIBITED
PROGRAMMING PENDANT
X81
PADLOCK
Turning the power ON during tool installation may case electric shock
or injury due to unexpected movement of the manipulator.
•
Never exceed the rated capacity of the manipulator (capacity can
be found in the specifications section of the manipulator manual.)
Failure to observe this caution may result in injury or damage to
equipment.
•
Teach jobs from outside the manipulator’s work area whenever
possible.
•
Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– Always view the manipulator from the front.
– Always follow the predetermined operating procedure.
– Always have an escape plan in mind in case the manipulator
comes toward you unexpectedly.
– Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
1-11
DX100
1
1.5
Safety
Motoman Safety
WARNING
•
Before operating the manipulator, check that the SERVO ON lamp
on the programming pendant goes out when the emergency stop
buttons on the right of the programming pendant and on the
external control device, etc. are pressed. And confirm that the servo
lamp is turned OFF.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency.
•
Prior to performing the following operations, be sure that no one is
in the P-point maximum envelope of the manipulator when:
– Turning ON the DX100 power
– Moving the manipulator with the programming pendant.
– Running the system in the check mode
– Performing automatic operations
Injury may result from contact with the manipulator if persons enter the
P-point maximum envelope of the manipulator.
Press the emergency stop button immediately if there are problems.
The emergency stop button is located on the right of the programming
pendant.
Emergency Stop Button
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
PROGRAMMING PENDANT
X81
Programming Pendant
1-12
DX100
DX100
1
1.5
Safety
Motoman Safety
CAUTION
•
Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.
– Check for problems in manipulator movement.
– Check for damage to the insulation and sheathing of external
wires.
•
Always return the programming pendant to its hook on the DX100
cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injury or equipment
damage.
MANDATORY
•
Persons operating or inspecting the manipulator should be trained
as required by applicable laws and company policies.
•
Refer to chapter 1.2 “Special Training” at page 1-2
1-13
1
1.6
DX100
1.6
Safety
Notes for Moving and Transferring the MOTOMAN
Notes for Moving and Transferring the MOTOMAN
When moving or transferring the Motoman, observe the following safety
precautions:
CAUTION
•
Attach the instructions to the controller cabinet so that all users
have access to necessary manuals. See chapter 1.3 “Motoman
Manual List” at page 1-2 for a complete list of manuals.
If any manuals are missing, contact your Yaskawa representative.
•
If the warning labels on the manipulator and DX100 are illegible,
clean the labels so that they can be read clearly. Note that some
local laws may prohibit equipment operation if safety labels are not
in place.
Contact your YASKAWA representative if you require new warning
labels.
•
When the MOTOMAN is transferred, it is recommended to check
with Yaskawa Engineering Co. which is listed on back cover of this
manual.
Incorrect installation or wiring may result in personal injury and property
damage.
1-14
1
1.7
DX100
1.7
Safety
Notes on MOTOMAN Disposal
Notes on MOTOMAN Disposal
PROHIBITED
•
Never modify the manipulator or DX100.
Failure to observe this precaution could result in injury or damage
resulting from fire, power failure, or operation error.
CAUTION
•
When disposing of the MOTOMAN, follow the applicable national/
local laws and regulations.
•
Anchor the manipulator well, even when temporarily storing it
before disposal.
Failure to observe this precaution may result in injury due to the
manipulator falling down.
1-15
2
2.1
DX100
2
Product Confirmation
Contents Confirmation
Product Confirmation
2.1
Contents Confirmation
Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following five items (Information for the
content of optional goods is given separately):
• Manipulator
• DX100
• Programming Pendant
• Manipulator Cable (Between Manipulator and DX100)
• Complete Set of Manuals
Fig. 2-1: Standard Five Items
Manipulator
Programming
Pendant
DX100
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
PROGRAMMING PENDANT
X81
MOTOMAN
MANUAL
Complete Set of Manuals
2-1
Manipulator Cable
2
2.2
DX100
2.2
Product Confirmation
Order Number Confirmation
Order Number Confirmation
Confirm that the order number pasted on the manipulator and DX100
match.
The order number plates are affixed to the figure below.
<Example>
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
DX100
TYPE
ERDR-
POWER SUPPLY
PEAK
3PHASE
AC480V
MAXIMUM RATED CURRENT
SCCR
LARGEST LOAD
50/60Hz
AVERAGE
A DRAWING No.
KA SERIAL No.
A DATE
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
PROGRAMMING PENDANT
X81
2-2
S78796-1
3
3.1
DX100
3
Installation
Handling Procedure
Installation
3.1
Handling Procedure
CAUTION
•
Crane, sling, and forklift operations must be performed only by
authorized personnel.
Failure to observe this caution may result in injury or damage.
•
Avoid jarring, dropping, or hitting the controller during handling.
Excessive vibration or impacting the DX100 may adversely affect the
performance of the DX100.
3.1.1
Using a Crane to Move the Controller
Check the following before handling the DX100:
• Confirm the weight of the controller before handling, and use a wire
rope with a rating that is greater than the weight of the controller.
• Install eyebolts for handling and confirm they are securely fastened
before hoisting.
3-1
DX100
3
3.1
Installation
Handling Procedure
Wire Rope
M16 Eye Bolt
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
PROGRAMMING PENDANT
X8 1
Table 3-1: Approx. Weight of DX100
Models Available for
DX100
small capacity:
MA1400, MA1900,
VA1400, MH5, MH5L,
MH6, HP20D, HP20D-6
middle/large capacity:
MH50,MS80,ES165D,
ES200D,VS50,SIA50D
3-2
Approx.
Weight (kg)
250
DX100
3.1.2
3
3.1
Installation
Handling Procedure
Using a Forklift to Move the Controller
Observe the following precautions when using a forklift to handle the
controller:
• Confirm that there is a safe work environment and that the DX100
can be transported safely to the installation site.
• Inform people along the forklift route that equipment is being moved
in their area.
• Secure the controller so it cannot shift or fall during handling.
• Transport the controller at the lowest possible height.
• Avoid jarring, dropping, or hitting the controller during handling.
• When carrying the controller, operate the forklift at a safe speed.
Protective padding
Tiedown straps
Palette
Forklift
3-3
3
3.2
DX100
3.2
Installation
Place of Installation
Place of Installation
The conditions listed below must be met before installing the DX100:
• Ambient temperature must be 0 to 45° C (32 to 113°F) during operation and -10 to 60°C (14 to 140°F) during transportation and maintenance.
• Humidity must be low with no condensation (10~90%RH).
• It must be a place with little dirt, dust, or water.
• No flammable or corrosive liquids or gases, etc. in the area.
• Little jarring or potential for striking of the DX100 (under 0.5 oscillation).
• No large electric noise source (such as a TIG welding device, etc.)
nearby.
• No potential for collision with moving equipment such as forklifts.
3-4
3
3.3
DX100
3.3
Installation
Location
Location
1. Install the DX100 outside of the P-point maximum envelope of the
manipulator (outside of the safeguarding.)
Fig. 3-1: Location of DX100
SAFEGUARD
DX100
DOOR
1000 mm or more
1000 mm or more
1000 mm or more
WORKING ENVELOPE
OF MANIPULATOR
MAXIMUM WORKING ENVELOPE OF
MANIPULATOR INCLUDING TOOL
OR WORKPIECE END
1000 mm or more
2. Install the controller in a location from which the manipulator is easily
visible.
500
3. Install the controller in a location from which you can easily inspect it
when the door is open.
782
890
650
800
DOOR
4. Install the controller at least 500mm from the nearest wall to allow
maintenance access.
3-5
3
3.4
DX100
Installation
Mounting the Controller
800
650
500
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
1000
NJ1530
3.4
PROGRAMMING PENDANT
X81
Mounting the Controller
CAUTION
•
Do not climb on top of the DX100.
Failure to observe this caution could lead to injury or mechanical
failure.
Attach the controller to the floor using user-supplied brackets made
according to the specifications shown below.
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE
AC480V
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
50/60Hz
MAXIMUM RATED CURRENT A
SCCR
KA
LARGEST LOAD
A
MADE IN JAPAN
kVA
kVA
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
12 dia.
(2 holes)
40
PROGRAMMING PENDANT
X81
30
50
30
50
(Unit: mm)
Tapped Holes for
M10 Screws on
the DX100 Side
NOTE
Refer to the Instruction Manual for information on installation of the manipulator.
3-6
4
Connection
DX100
4
Connection
WARNING
•
The system must be grounded.
Failure to ground equipment may result in injury from fire or electric
shock.
•
Before wiring, make sure to turn OFF the primary power supply, and
put up a warning sign. (ex. DO NOT TURN THE POWER ON)
Failure to observe this caution may result in injury and electric shock.
•
Do not touch any board inside the controller for five minutes after
turning OFF the power supply.
Capacitors inside the controller store electricity after power is turned
OFF. Exercise caution whenever handling circuit boards. Failure to
observe this caution may cause electrical shock.
•
Power cannot be turned ON unless the door is closed. Interlocks
prevent power from being turned ON.
Failure to observe this caution may result in fire and electric shock.
•
Any occurrence during wiring while the DX100 is in the emergency
stop mode is the user’s responsibility. Do an operation check once
the wiring is completed.
Failure to observe this caution could lead to injury or mechanical
failure.
CAUTION
•
Wiring must be performed only by authorized personnel.
Incorrect wiring may cause fire and electric shock.
•
Perform wiring in accordance with the rated capacity as specified in
the Instructions.
Incorrect wiring may cause fire or mechanical breakdown.
•
Be sure the power circuit screws are securely tightened.
Loose power circuit wires can cause fire and electric shock.
•
Do not handle the circuit board directly by hand.
The IC board may malfunction due to electrostatics.
4-1
4
4.1
DX100
4.1
Connection
Notes on Cable Junctions
Notes on Cable Junctions
• The cables that connect the controller to peripheral device are low
voltage circuits. Keep controller signal cables away from the primary
power circuit. High voltage power lines should not be run in parallel
to controller signal cables. If running parallel cables is unavoidable,
use metal ducts or conduit to isolate electrical signal interference. 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 DX100.
Another connects the DX100 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.
Fig. 4-1: DX100 Cable Junction Diagram
SAFETY
FIRST
PIPING
4-2
LEAD
cable channel
4
4.2
DX100
4.2
4.2.1
Connection
Power Supply
Power Supply
Three-Phase Power Supply
NOTE
The power failure processing circuit operates when there is
a black out or drop in voltage, and the servo power turns
OFF.
Connect the power supply to a stable power source that is
not prone to power fluctuations.
The three-phase power supply consists as follows:
• With built-in transformer: 240/480/575 VAC at 50/60 Hz
• Without built-in transformer: 200 VAC at 50/60 Hz and 220 VAC at 60
Hz
Fig. 4-2: Input Power Connection
DX100
(With built-in transformer)
3-phase
240/480/575 VAC
at 50/60 Hz
(Without built-in transformer)
3-phase
200 VAC at 50/60 Hz
220 VAC at 60 Hz
Fuse
disconnect switch
Transformer
Fuse
Contactor
1KM
2KM
To SERVOPACK
N
Fuse
Noise filter
To control
power supply
unit
This circuit is not applied
to the DX100 without built-in
transformer.
4.2.2
Noise Filter Installation
Insert the three-phase noise filter into the primary station of the non-fuse
breaker filter if you hear noise coming from the power source.
Seal up each cable opening so that dust does not enter.
Fig. 4-3: Connection of Three-Phase Noise Filter
DX100
(With built-in transformer)
3-phase
240/480/575 VAC
at 50/60 Hz
(Without built-in transformer)
3-phase
200 VAC at 50/60 Hz,
220 VAC at 60 Hz
3-phase
noise filter
Fuse
disconnect switch
Transformer
Fuse
Contactor
1KM
2KM
To SERVOPACK
N
Fuse
Noise filter
This circuit is not
applied to the DX100
without built-in transformer
4-3
To control
power supply
unit
4
4.2
DX100
4.2.3
Connection
Power Supply
Leakage Breaker Installation
When connecting the leakage breaker to the controller power supply
wiring, use a leakage breaker which can handle high frequencies from the
DX100 inverter. Leakage breakers which cannot handle high frequencies
may malfunction.
For the leakage breakers, select UL-approved products taking into
consideration SCCR (Short Circuit Current Rating.)
Even with a leakage breaker installed, there is still a possibility of some
high frequency current leakage from the DX100 inverter. However, this
current leakage presents no safety risks.
Fig. 4-4: Connection of the Leakage Breaker
DX100
Leakage breaker
(With built-in transformer)
3-phase
240/480/575 VAC
at 50/60 Hz
(Without built-in transformer)
3-phase
200 VAC at 50/60 Hz,
220 VAC at 60 Hz
Fuse
disconnect switch
Transformer
Fuse
Contactor
1KM
2KM
To SERVOPACK
N
Fuse
Noise filter
This circuit is not
applied to the DX100
without built-in transformer.
4-4
To control
power supply
unit
4
4.2
DX100
4.2.4
Connection
Power Supply
Primary Power Supply Breaker/Fuse Installation
Install the primary power supply breaker/fuse as shown.
Fig. 4-5: Installation of the Primary Power Supply Breaker/Fuse
Breaker/Fuse
(Protector)
DX100
Breaker/Fuse
(Protector)
Controller
for Positioner
Breaker/Fuse
(Protector)
Power
Source
Table 4-1: DX100 Power Capacity, Cable Sizes, and Breaker/Fuse Capacities
Manipulator Power
Cable size
capacity (size of terminal)
(kVA)
Capacity of breaker/ Capacity of breaker/
fuse in DX100
fuse in DX100
(In case of Cabtyre (With transformer)
cable (three cores))
(A)
(AWG)
(Without transformer)
(A)
MH5, MH5L
1
12 (M5)
10
15
MH6,
MA1400,
VA1400
1.5
12 (M5)
10
15
HP20D,
HP20D-6,
MA1900
2.0
12 (M5)
10
15
MH50,
MS80
4.0
10 (M5)
20
30
VS50,
ES165D,
ES200D,
SIA50D
5.0
10 (M5)
20
30
Select and utilize the breaker/fuse with appropriate breaking capacity in
consideration of the DX100 power capacity for the manipulator to be used.
The maximum load value (payload, operation speed, and frequency, etc.)
is displayed.
However, the power capacity is different depending on work conditions.
Inquire at the nearest branch office listed on the back cover for information
when selecting the transformer.
4-5
4
4.3
DX100
4.3
Connection
Connection Methods
Connection Methods
A connection diagram for the manipulator, manipulator cable, primary
power cable and programming pendant is shown below.
Fig. 4-6: Cable Connection
DX100 Back View
Approx mass:
Kg
Manipulator
Cable
DX100 Front View
Manipulator
DX100
TYPE
ERDR-
POWER SUPPLY
3PHASE
AC200V
AC220V
50/60Hz
60Hz
PEAK
AVERAGE
INTERRUPT CURRENT
kVA
kVA
kA
SERIAL No.
DATE
MADE IN JAPAN
NJ2960-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
CHECK ALL THE DOOR LOCKS
PROPERLY.
NJ3005-1
PROGRAMMING PENDANT
X81
Programming
Pendant Cable
Primary Power Supply Cable
4.3.1
Connecting the Primary Power Supply
1.
Open the front door of the DX100.
(1) Using a flathead screwdriver, rotate the door locks on the front of
the DX100 (two places) 90 degrees clockwise.
Fig. 4-7: Rotating the Door Lock Clockwise
door lock
clockwise
90
flathead screw driver
4-6
DX100
4
4.3
Connection
Connection Methods
(2) Rotate the main power supply switch to the "OFF" position and
open the door gently.
Fig. 4-8: Rotating the Main Power Supply Switch to the OFF Position
Main power supply switch
(Fuse disconnect switch)
DX100
TYPE
ERDR-
POWER SUPPLY
kVA
kVA
PEAK
3PHASE
AC480V
MAXIMUM RATED CURRENT
SCCR
LARGEST LOAD
50/60Hz
AVERAGE
A DRAWING No.
KA SERIAL No.
A DATE
MADE IN JAPAN
NJ2999-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
2. Confirm that the primary power supply is OFF.
3. Remove the cover on the upper right side of the back of the DX100.
Run the primary power supply cable from the cable clamp below the
cover. Connect the cable to the terminal block ACINXT.
Connect a ground wire to the terminal block ACINXT to reduce noise
and prevent electric shock.
Fig. 4-9: Details for Running the Primary Power Supply Cable
Terminal block (ACINXT)
Refer to the details of
P2 terminal block (ACINXT)
Cover
Cable clamp
FGA26E-20B+SPR215-B
PG cable (X11)
PW cable (X21)
4-7
DX100
4
4.3
Connection
Connection Methods
Perform grounding in accordance with all relevant local and national
electrical codes. The size of ground wire must the same as listed on
table 4-1 “DX100 Power Capacity, Cable Sizes, and Breaker/Fuse
Capacities” at page 4-5.
NOTE
The customer must prepare the ground wire.
Fig. 4-10: Exclusive Grounding
DX100
Exclusive Grounding
100 ohm maximum ground resistance
NOTE
Don’t connect the grounding wire with the wires for the electric power source, the welder, etc.
Ground in accordance with all relevant governmental regulations when using metallic ducts, metallic conduits, and
cable tray to construct the cable.
4-8
DX100
4.3.2
4
4.3
Connection
Connection Methods
Connecting the Manipulator Cable
1. Remove the package, and take out the manipulator cable. Connect
the cable to the connectors on the back side of DX100.
Fig. 4-11: Connection of the Manipulator Cable
Approx mass:
Kg
Manipulator Cable
Primary Power Supply Cable
NOTE
For more information on connecting the manipulator cable,
please refer to the Instruction Manual which corresponds to
the particular DX100 model.
2. Connect the manipulator to the DX100.
– Confirm the shape and size of the cable connector, the key fitting,
and the position of the pins of the manipulator. Push the cable
connector into the manipulator side connector firmly, and tighten
securely.
3. Close the DX100 door.
(1) Close the door gently.
(2) Rotate the door locks (two places) 90 degrees counterclockwise.
Fig. 4-12: Rotating the Door Lock Counterclockwise
counterclockwise 90
door lock
(-)screwdriver
4-9
DX100
4
4.3
Connection
Connection Methods
CAUTION
Always close the door of the controller (DX100) except for maintenance.
Make sure to rotate all the door locks counterclockwise.
If dust or water enter inside the controller, electric shock or breakdown
of DX100 may result.
4.3.3
Connecting the Programming Pendant
1. Connect the programming pendant cable to the connector on the door
lower right side of the controller cabinet.
Fig. 4-13: Connecting the Programming Pendant
Alignment mark
– The manipulator, DX100, and the programming pendant
connections are now complete.
4-10
5
5.1
DX100
5
Turning ON and OFF the Power Supply
Turning ON the Main Power Supply
Turning ON and OFF the Power Supply
5.1
Turning ON the Main Power Supply
WARNING
•
Confirm that nobody is present in the P-point maximum envelope of
the manipulator when turning ON the DX100 power supply.
Failure to observe this caution could result in injury caused by
accidental contact with the manipulator.
Press the emergency stop button immediately if any problems occur.
The emergency stop button is located on the upper right side of the
programming pendant.
The main power supply is turned ON when the main power supply switch
on the front of the DX100 is turned to the "ON" position, and the initial
diagnosis and the current position setting begin.
Fig. 5-1: Turning ON the Main Power Supply
Main power supply switch
(Fuse disconnect switch)
DX100
TYPE
ERDR-
POWER SUPPLY
PEAK
3PHASE
AC480V
MAXIMUM RATED CURRENT
SCCR
LARGEST LOAD
50/60Hz
AVERAGE
A DRAWING No.
KA SERIAL No.
A DATE
kVA
kVA
MADE IN JAPAN
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
5-1
5
5.1
DX100
5.1.1
Turning ON and OFF the Power Supply
Turning ON the Main Power Supply
Initial Diagnosis
The initial diagnosis are performed in the DX100 when main power is
turned ON, and the startup window is shown on the programming pendant
screen.
Fig. 5-2: Startup Window
5.1.2
When Initial Diagnosis are Complete
When the power supply is turned OFF, the DX100 saves all condition
data, including:
• Mode of operation
• Called job (active job if the DX100 is in the play mode; edit job if the
DX100 is in the teach mode) and the cursor position in the job.
Fig. 5-3: Initial Window
5-2
5
5.2
DX100
5.2
5.2.1
Turning ON and OFF the Power Supply
Turning ON the Servo Power
Turning ON the Servo Power
During Play Mode
The worker’s safety is secure if the safety plug is turned ON.
• When the safeguarding is closed, press [SERVO ON READY] on the
programming pendant to turn ON the servo power supply. [SERVO
ON] lamp will light, when the servo power is turned ON.
SERVO ON
READY
Light
NOTE
5.2.2
SERVO ON
When the safeguarding is open, the servo power supply
cannot be turned ON.
During Teach Mode
1. Press [SERVO ON READY] on the programming pendant to turn ON
the servo power supply. [SERVO ON] lamp will flicker when the servo
power is turned ON.
SERVO ON
READY
Flicker
SERVO ON
2. The servo power is turned ON and [SERVO ON] lamp on the
programming pendant lights when the operator grips the Enable
switch.
5-3
DX100
5
5.2
Turning ON and OFF the Power Supply
Turning ON the Servo Power
Servo Power ON/OFF --- Enable Switch
When the operator grips the Enable switch, the servo power
turns ON. However, if the operator squeezes the switch until
a “click” is heard, the servo power will turn OFF.
SUPPLE
-MENT
Servo On
Release -> OFF
NOTE
Squeeze -> ON
Squeeze Tightly -> OFF
When performing emergency stop by the programming pendant or external signal, the servo power-on operation from
the Enable switch is cancelled. When turning the power
back ON, follow the previously listed instructions.
5-4
5
5.3
DX100
5.3
5.3.1
Turning ON and OFF the Power Supply
Turning OFF the Power Supply
Turning OFF the Power Supply
Turning OFF the Servo Power (Emergency Stop)
The manipulator cannot be operated when the emergency stop button is
pressed and the servo power supply is turned OFF.
• Press the emergency stop button and the servo power supply is
turned off.
The emergency stop button is located on the right side of the programming pendant.
• The brake operates once the servo power supply is turned OFF, and
the manipulator can no longer operate.
The emergency stop mode can be operated at any mode. (Teach
mode, Play mode, Remote mode)
Programming Pendant
5.3.2
Turning OFF the Main Power
After turning OFF the servo power, turn OFF the main power.
• When the main power switch on the front of DX100 is turned to the
“OFF” position, the main power is turned OFF.
Main power supply switch
(Fuse disconnect switch)
DX100
TYPE
ERDR-
POWER SUPPLY
PEAK
3PHASE
AC480V
MAXIMUM RATED CURRENT
SCCR
LARGEST LOAD
50/60Hz
AVERAGE
A DRAWING No.
KA SERIAL No.
A DATE
kVA
kVA
MADE IN JAPAN
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
5-5
6
Test of Program Operation
DX100
6
Test of Program Operation
WARNING
•
Press the emergency stop button on the right of the front door of the
DX100 and the programming pendant before operating the
manipulator. Confirm that the SERVO ON lamp is turned OFF.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency. The emergency stop buttons are
attached on the front door of the DX100 and right of the programming
pendant.
•
Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– Always view the manipulator from the front.
– Always follow the predetermined operating procedure.
– Always have an escape plan in mind in case the manipulator
comes toward you unexpectedly.
– Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
•
Prior to performing the following operations, be sure that there is no
one within the P-point maximum envelope of the manipulator, and
be sure that you are in a safe place yourself.
– Turning ON the DX100 power
– Moving the manipulator with the programming pendant
– Running the system in the check mode
– Performing automatic operations
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator.
6-1
6
6.1
DX100
Test of Program Operation
Movement of the Axes
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 manipulator 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 manipulator,
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injuries or equipment
damage.
6.1
Movement of the Axes
Move each axis of the manipulator by pressing the axis keys on the
programming pendant.
This figure illustrates each axis of motion in the joint coordinates.
Be sure to remove all items from the area before moving the
manipulator.
Refer to the INSTRUCTION MANUAL for the appropriate
position of the fixture.
NOTE
U-Axis
R-Axis
B-Axis
X-
S-
Y-
L-
Z-
U-
E-
X+
S+
Y+
L+
Z+
U+
E+
X-
X+
R-
R+
Y-
Y+
Z-
Z+
T-
T+
8-
8+
B-
T-Axis
E-Axis
B+
Axis Keys
L-Axis
S-Axis
6-2
DX100
6
6.1
Test of Program Operation
Movement of the Axes
Rotates main body
X-
Rotates upper arm
X+
S-
X+
S+
R+
XR-
Moves lower arm forward/
backward
Moves wrist up/down
Y-
B-
Y+
Y-
L+
L-
Y+
B+
Moves upper arm up/ down
Rotates wrist
Z+
U+
Z+
T+
ZT-
Z-
U-
E
Rotates lower arm
E-
E+
6-3
System Up
7
7.1
DX100
7
Security System
Protection Through Security Mode Settings
Security System
7.1
Protection Through Security Mode Settings
The DX100 modes setting are protected by a security system. The system
allows operation and modification of settings according to operator
clearance. Be sure operators have the correct level of training for each
level to which they are granted access.
7.1.1
Security Mode
There are three security modes. Editing mode and management mode
require a user ID. The user ID consists of numbers and letters, and
contains no less than 4 and no more than 8 characters. (Significant
numbers and signs: ”0 to 9”, “-”, “.”.
Table 7-1: Security Mode Descriptions
Security Mode
Explanation
Operation Mode
This mode allows basic operation of the robot (stopping,
starting, etc.) for people operating the robot work on the line.
Editing Mode
This mode allows the operator to teach and edit jobs and
robot settings.
Management
Mode
This mode allows those authorized to set up and maintain
robot system: parameters, system time and modifying user
IDs.
7-1
DX100
7
7.1
Security System
Protection Through Security Mode Settings
Table 7-2: Menu & Security Mode (Sheet 1 of 3)
Main Menu
JOB
Sub Menu
Allowed Security Mode
DISPLAY
EDIT
JOB
Operation
Edit
SELECT JOB
Operation
Operation
CREATE NEW JOB1)
Edit
Edit
MASTER JOB
Operation
Edit
Operation
-
RES. START (JOB)
Edit
Edit
RES. STATUS2)
Operation
-
CYCLE
Operation
Operation
BYTE
Operation
Edit
JOB CAPACITY
1)
VARIABLE
IN/OUT
INTEGER
Operation
Edit
DOUBLE
Operation
Edit
REAL
Operation
Edit
STRING
Operation
Edit
POSITION (ROBOT)
Operation
Edit
POSITION (BASE)
Operation
Edit
POSITION (ST)
Operation
Edit
LOCAL VARIABLE
Operation
-
EXTERNAL INPUT
Operation
-
EXTERNAL OUTPUT
Operation
-
UNIVERSAL INPUT
Operation
Edit
UNIVERSAL OUTPUT
Operation
Edit
SPECIFIC INPUT
Operation
-
SPECIFIC OUTPUT
Operation
-
RIN
Operation
-
CPRIN
Operation
-
REGISTER
Operation
-
AUXILIARY RELAY
Operation
-
CONTROL INPUT
Operation
-
PSEUDO INPUT SIG
Operation
Management
NETWORK INPUT
Operation
-
NETWORK OUTPUT
Operation
-
ANALOG OUTPUT
Operation
-
SV POWER STATUS
Operation
-
LADDER PROGRAM
Management
Management
I/O ALARM
Management
Management
I/O MESSAGE
Management
Management
7-2
DX100
7
7.1
Security System
Protection Through Security Mode Settings
Table 7-2: Menu & Security Mode (Sheet 2 of 3)
ROBOT
CURRENT POSITION
Operation
-
COMMAND POSITION
Operation
-
SERVO MONITOR
Management
-
WORK HOME POS
Operation
Edit
SECOND HOME POS
Operation
Edit
DROP AMOUNT
Management
Management
POWER ON/OFF POS
Operation
-
TOOL
Edit
Edit
INTERFERENCE
Management
Management
SHOCK SENS LEVEL
Operation
Management
USER COORDINATE
Edit
Edit
HOME POSITION
Management
Management
MANIPULATOR TYPE
Management
-
Management
Management
Edit
Edit
ANALOG MONITOR
OVERRUN&S-SENSOR
1)
LIMIT RELEASE
Edit
Edit
ARM CONTROL1)
Management
Management
SHIFT VALUE
Operation
-
Operation
-
MONITORING TIME
Operation
Management
ALARM HISTORY
Operation
Management
I/O MSG HISTORY
Operation
Management
SECURITY
Operation
Operation
LOAD
Edit
-
SAVE
Operation
-
VERIFY
Operation
-
DELETE
Operation
-
DEVICE
Operation
Operation
FOLDER
Edit
Management
INITIALIZE
Operation
-
S1CxG
Management
Management
S2C
Management
Management
S3C
Management
Management
S4C
Management
Management
A1P
Management
Management
A2P
Management
Management
A3P
Management
Management
A4P
Management
Management
RS
Management
Management
S1E
Management
Management
S2E
Management
Management
S3E
Management
Management
S4E
Management
Management
SYSTEM INFO VERSION
FD/CF
2)
PARAMETER
1)
7-3
DX100
7
7.1
Security System
Protection Through Security Mode Settings
Table 7-2: Menu & Security Mode (Sheet 3 of 3)
SETUP
TEACHING COND
Edit
Edit
OPERATE COND
Management
Management
Management
Management
DATE/TIME
3)
GRP COMBINATION
Management
Management
RESERVE JOB NAME
Edit
Edit
USER ID
Edit
Edit
SET SPEED
ARC
WELDING
Management
Management
1)
KEY ALLOCATION
Management
Management
RES. START (CNCT)
Management
Management
AUTO BACK SET
Management
Management
WRONG DATA LOG
Operation
Management
ARC START COND.
Operation
Edit
ARC END COND.
Operation
Edit
ARC AUX COND.
Operation
Edit
POWER SOURCE COND.
Operation
Edit
ARC WELD DIAG.
Operation
Edit
WEAVING
Operation
Edit
ARC MONITOR
Operation
-
ARC MONITOR (SAMPL)
Operation
-
HANDLING
HANDLING DIAGNOSIS
Operation
Edit
SPOT
WELDING
WELD DIAGNOSIS
Operation
Edit
I/O ALLOCATION
Management
Management
GUN CONDITION
Management
Management
4)
CLEARANCE SETTING
Operation
Edit
POWER SOURCE COND
Management
Management
Operation
Edit
Edit
Edit
SPOT
WELD DIAGNOSIS
WELDING
GUN PRESSURE
(MOTOR GUN)
PRESSURE
GENERAL
Edit
Edit
I/O ALLOCATION
Management
Management
GUN CONDITION
Management
Management
CLEARANCE SETTING
Operation
Edit
SPOT POWER
SOURCE COND
Management
Management
TIP INSTALLATION
Operation
Management
WEAVING
Operation
Edit
GENERAL DIAG.
Operation
Edit
Operation
Operation
COMMON TO
I/O VARIABLE CUSTOMIZE
ALL
APPLICATIONS
1
2
3
4
Displayed in the teach mode only.
It is possible to initialize a floppy at FC1/FC2.
Displayed only with two or more control groups.
Displayed in the teach mode only.
*Data is cleared in the edit mode or higher.
7-4
DX100
7.1.1.1
7
7.1
Security System
Protection Through Security Mode Settings
Changing the Security Mode
1. Select {SYSTEM INFO} under the main menu.
– The sub menu appears.
Note: Icons for the main menu such as arc welding system differ
depending on the system being used.
2. Select {SECURITY}.
– The selection window of security mode appears.
3. Press [SELECT].
7-5
DX100
7
7.1
Security System
Protection Through Security Mode Settings
– Select "SECURITY MODE".
4. Input the user ID.
– The user ID input window appears.
SUPPLE
-MENT
The following user ID numbers are set by default.
• Editing Mode: [00000000]
Management Mode: [99999999]
5. Press [ENTER].
– The input user ID is compared with the user ID of the selected
security mode. ]
– When the correct user ID is entered, the security mode is changed.
7-6
7
7.1
DX100
7.1.2
Security System
Protection Through Security Mode Settings
User ID
User ID is requested when Editing Mode or Management Mode is
operated.
Create the user ID with four to eight numbers and symbols: the numbers 0
to 9; the symbols
"-" and ".".
7.1.2.1
Changing User ID
In order to change the user ID, the DX100 must be in Editing Mode or
Management Mode. Higher security modes can make changes the user
ID of to lower security modes.
1. Select {SETUP} under the main menu.
– The sub menu appears.
2. Select {USER ID}.
– The USER ID window appears.
3. Select the desired ID.
7-7
DX100
7
7.1
Security System
Protection Through Security Mode Settings
– The character input line appears, and a message "Input current ID
no. (4 to 8 digits)" appears.
4. Input the current ID and press [ENTER].
– When the correct user ID is entered, a new ID is requested to be
input. "Input new ID no.(4 to 8 digits)" appears.
5. Input new ID and press [ENTER].
– User ID is changed.
7-8
8
System Setup
DX100
8
System Setup
WARNING
•
Various settings control system compatibility and manipulator
performance characteristics. Exercise caution when changing
settings that can result in improper manipulator operation.
Personal injury and/or equipment damage may result if incorrect
settings are applied by the user.
•
Observe the following precautions to safeguarding system settings:
•
Maintain supervisory control of user functions.
•
Retain data backups of control settings each time settings are
changed.
8-1
8
8.1
DX100
8.1
System Setup
Home Position Calibration
Home Position Calibration
WARNING
•
Before operating the manipulator, check that the SERVO ON lamp
goes out when the emergency stop buttons on the right of the front
door of the DX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency.
•
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.
– Always prepare your reactions to a manipulator’s unexpected
approach toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
•
Prior to performing the following operations, be sure that no one is
in the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place when:
– Turning ON the DX100 power.
– Operating the manipulator with the programming pendant.
Injury may result from contact with the manipulator if persons enter the
P-point maximum envelope of the manipulator.
Always press the emergency stop button immediately if there are
problems.
Emergency stop buttons are located on the right of the front door of the
DX100 and the programming pendant.
8-2
DX100
8
8.1
System Setup
Home Position Calibration
CAUTION
•
Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.
– Check for problems in manipulator movement.
– Check for damage to the insulation and sheathing of external
wires.
– Always return the programming pendant to its hook on the
DX100 cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injury or equipment
damage.
8.1.1
Home Position Calibration
NOTE
Teaching and playback are not possible before the completion of the home position calibration.
In a system with two or more manipulators, the home position of all the manipulators must be calibrated before starting teaching or playback.
Home position calibration is an operation in which the home position and
absolute encoder position coincide. Although this operation is performed
prior to shipment at the factory, the following cases require this operation
to be performed again.
• Change in the combination of the manipulator and DX100
• Replacement of the motor or absolute encoder
• Clearing stored memory (by replacement of NIF01 circuit board,
weak battery, etc.)
• Home position deviation caused by hitting the manipulator against a
workpiece, etc.
To calibrate the home position, use the axis keys to calibrate the home
position mark on each axis so that the manipulator can take its posture for
the home position. There are two operations for home position calibration:
• All the axes can be moved at the same time: Recalibrate the home
position by moving all the axes
together if changing the combination of manipulator and circuit
board.
• Axes can be moved individually: Recalibrate the home position for
the individual axes that were
affected by the replacement, if
replacing the motor or absolute
encoder.
8-3
DX100
8
8.1
System Setup
Home Position Calibration
If the absolute data of its posture for the home position is already known,
set the absolute data again after completing home position registration.
Home Position
SUPPLE
-MENT
8.1.2
Calibrating Operation
NOTE
8.1.2.1
The home position is the pulse value "0" for each axis and its
posture. See chapter 8.1.3 “Home Position of the Robot”
at page 8-10.
Home position calibration screen is displayed only in security mode or management mode.
Registering All Axes at One Time
1. Select {ROBOT} under the main menu.
– The sub menu appears
2. Select {HOME POSITION}.
– The HOME POSITIONING window appears.
8-4
DX100
8
8.1
System Setup
Home Position Calibration
3. Select {DISPLAY} under the menu.
– The pull-down menu appears.
– The same operation as the instruction 3 can also be performed by
selecting {PAGE}, and selection box appears.
4. Select the desired control group.
– Select the control group for HOME POSITIONING.
– The control group can also be selected by pressing page key
5. Select {EDIT} under the menu.
8-5
.
DX100
8
8.1
System Setup
Home Position Calibration
– The pull-down menu appears.
6. Select {SELECT ALL AXES}.
– The confirmation dialog box appears.
7. Select {YES}.
– Displayed position data of all axes are registered as home position.
When {NO} is selected, the registration will be canceled.
8.1.2.2
Registering Individual Axes
1. Select {ROBOT} under the main menu.
– The sub menu appears.
2. Select {HOME POSITION}.
3. Select the desired control group.
– Perform the step 3 and 4 of the “Registering All Axes at One Time”
to select the desired control group.
4. Select the axis to be registered.
8-6
DX100
8
8.1
System Setup
Home Position Calibration
– Move the cursor to the axis to be registered, and select it.
– A confirmation dialog box appears.
5. Select {YES}.
– Displayed position data of the axis is registered as home position.
When {NO} is selected, the registration will be canceled.
8.1.2.3
Changing the Absolute Data
To change the absolute data of the axis when home position calibration is
completed, perform the following:
1. Select {ROBOT} under the main menu.
2. Select {HOME POSITION}.
3. Select the desired control group.
– Perform the step 3 and 4 of the “Registering All Axes at One Time”
to select the desired control group.
4. Select the absolute data to be registered.
8-7
DX100
8
8.1
System Setup
Home Position Calibration
– The number can now be entered.
5. Enter the absolute data using the numeric keys.
6. Press [ENTER].
– Absolute data is modified.
8.1.2.4
Clearing Absolute Data
1. Select {ROBOT} under the main menu.
– The sub menu appears
2. Select {HOME POSITION}.
– Perform the step 3 and 4 of the “Registering All Axes at One Time”
to select the desired control group.
3. Select {DATA} under the main menu.
– The pull-down menu appears
4. Select [CLEAR ALL DATA].
8-8
DX100
8
8.1
System Setup
Home Position Calibration
– A confirmation dialog box appears.
5. Select {YES}.
– All absolute data are cleared.
– When {NO} is selected, the registration will be canceled.
8-9
DX100
8.1.3
8
8.1
System Setup
Home Position Calibration
Home Position of the Robot
In case of VA1400, the home position are as follows.
B-axis center line angle against
U-axis center line (-0°).
U-axis angle against horizontal
line on the ground (-0°).
L-axis angle against vertical
line to the ground(-0°).
NOTE
Other manipulator models have different positions. Always
refer to "MANIPULATOR INSTRUCTIONS" for the correct
manipulator model.
8-10
8
8.2
DX100
8.2
System Setup
Setting the Second Home Position (Check Point)
Setting the Second Home Position (Check Point)
WARNING
•
Be aware of safety hazards when performing the position
confirmation of the second home position (check point).
When "OUT OF RANGE (ABSO DATA)" alarm occurs, abnormality of
the PG system may be a cause of the alarm. The manipulator may
operate in an unexpected manner, and there is a risk of damage to
equipment or injury to personnel.
•
Before operating the manipulator, check that the SERVO ON lamp
goes out when the emergency stop buttons on the front door of
DX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency.
•
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.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
•
Prior to performing the following operations, be sure that no one is
in the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place when:
– Turning ON the DX100 power
– Moving the manipulator with the programming pendant
– Running the system in the check mode
– Performing automatic operations
Injury may result from contact with the manipulator if persons enter the
P-point maximum envelope of the manipulator.
Press the emergency stop button immediately whenever there are
problems.
•
Emergency stop buttons are attached on the front door of the
DX100 and the right side of the programming pendant.
8-11
DX100
8
8.2
System Setup
Setting the Second Home Position (Check Point)
CAUTION
•
Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.
– Check for problems in manipulator movement.
– Check for damage to the insulation and sheathing of external
wires.
•
Always return the programming pendant to its hook on the DX100
cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injury or equipment
damage.
8.2.1
Purpose of Position Check Operation
If the absolute number of rotation detected at power supply ON does not
match the data stored in the absolute encoder the last time the power
supply was turned OFF, an alarm is issued when the controller power is
turned ON.
There are two possible causes of this alarm:
• Error in the PG system
• The manipulator was moved after the power supply was turned OFF.
If there is an error with the PG system, the manipulator may stall when
playback is started. If the absolute data allowable range error alarm has
occurred, playback and test runs will not function and the position must be
checked.
8-12
8
8.2
DX100
System Setup
Setting the Second Home Position (Check Point)
"OUT OF RANGE (ABSO DATA)" alarm occurs
Reset alarm
Turn ON servo power
Procedure After Alarm Occurs
Position confirmation
operation
Compare second home
position (check point)*
pulses with current
position pulses
NG
Alarm occurs again
OK
Correct defective axis
• Replace PG system
• Home position calibration
∗ Position checking point
Playback possible
Position Check
After the "OUT OF RANGE (ABSO DATA)" alarm occurs, move to the
second home position using the axis keys and perform the position
confirmation. Playback, test runs, and FWD operation will not function
unless "CONFIRM POSITION" is performed.
Pulse Difference Check
The pulse number at the second home position is compared with that at
the current position. If the difference is within the allowable range,
playback is enabled. If not, the alarm occurs again.
• The allowable range pulse is the number of pulses per rotation of the
motor (PPR data).
• The initial value of the second home position is the home position
(where all axes are at pulse 0). The second home position can be
changed. For details, refer to chapter 8.2.2 “Procedure for the Second Home Position Setting (Check Point)” at page 8-14.
8-13
DX100
8
8.2
System Setup
Setting the Second Home Position (Check Point)
Alarm Occurrence
If the alarm occurs again, there may be an error in the PG system. Check
the system. After adjusting the erroneous axis, calibrate the home position
of the axis, then check the position again.
•
Home position calibration of all the axes at the same
time enables playback operations without having to
check the position.
•
Sometimes in a system with a manipulator with no
brake, it is possible to enable playback without position
checking after the alarm occurs. However, as a
rule, always perform "CONFIRM POSITION".
Under the above special conditions, the manipulator
moves as follows:
•
After the start, the manipulator moves at low speed (1/
10 of the maximum speed) to the step indicated by the
cursor. If it stops and restarts during this motion, the low
speed setting is retained until the step at cursor is
reached.
•
Regardless of cycle setting, the manipulator stops after
reaching to the step indicated by cursor. Starting the
manipulator again then moves it at the programmed
speed and cycle of the job.
NOTE
8.2.2
Procedure for the Second Home Position Setting (Check Point)
Apart from the "home position" of the manipulator, the second home
position can be set up as a check point for absolute data. Use the
following steps to set the specified point.
If two or more manipulators or stations are controlled by one controller, the
second home position must be set for each manipulator or station.
1. Select {ROBOT} under the main menu.
– The sub menu appears.
8-14
DX100
8
8.2
System Setup
Setting the Second Home Position (Check Point)
2. Select {SECOND HOME POS}.
– The SECOND HOME POS window appears.
A message “Available to move to and modify specified point” is
displayed.
3. Press the page key
, or select {PAGE} to display the selection
window for the control group.
– When there are two or more group axes, select the group axes to
which the second home position is to be specified.
4. Press the axis keys.
– Move the manipulator to the new second home position.
5. Press [MODIFY], then [ENTER].
– The second home position is changed.
8-15
DX100
8.2.3
8
8.2
System Setup
Setting the Second Home Position (Check Point)
Procedure after the Alarm
WARNING
•
Be aware of safety hazards when performing the position
confirmation of the specified point.
Abnormality of the PG system may be the cause of the alarm. The
manipulator may operate in an unexpected manner, and there is a risk
of damage to equipment or injury to personnel.
If the "OUT OF RANGE (ABSO DATA)" alarm occurs:
• Reset the alarm;
• Turn ON the servo power;
then confirm the second home position. After the confirmation, if the PG
system is found to be the cause of the alarm, perform the necessary
operation, such as replacing the PG, etc.
The robot current position data when turning main power supply OFF and
ON can be confirmed in “POWER ON/OFF POS" window.
SUPPLE
-MENT
For details on the “POWER ON/OFF POS" window, refer to "
7.7 Position Data When Power is Turned ON/OFF " in
DX100 MAINTENANCE MANUAL.
1. Select {ROBOT} under the main menu.
– The sub menu appears.
2. Select {SECOND HOME POS}.
– The SECOND HOME POS window appears.
3. Press the page key
, or select {PAGE} to display the selection
window for the control group.
8-16
DX100
8
8.2
System Setup
Setting the Second Home Position (Check Point)
– When there are two or more group axes, select the group axes to
which the second home position is to be specified.
4. Press [FWD].
– TCP moves to the second home position. The robot moving speed is
set as selected manual speed.
5. Select {DATA} under the menu.
6. Select {CONFIRM POSITION}.
– A message “Home position checked” appears.
– Pulse data of the second home position and current pulse data are
compared. If the compared error is in allowed range, playback
operation can be done.
– If the error is beyond the allowed range, the alarm occurs again.
8-17
8
8.3
DX100
8.3
System Setup
Tool Data Setting
Tool Data Setting
8.3.1
Registering Tool Files
8.3.1.1
Number of Tool Files
There are 64 tool files numbered 0 to 63. Each file is called as a tool file.
TOOL FILE 0
TOOL FILE 63
SUPPLE
-MENT
8.3.1.2
Tool File Extension Function
Normally, one robot uses one kind of tool file. The tool file
extension function can change many tool files to be used by
one robot. Use the following parameter to set this function.
S2C333: TOOL NO. SWITCHING (1: enabled; 0: disabled)
For more details, refer to “ 8 Parameter ” in DX100 OPERATOR’S MANUAL.
Registering Coordinate Data
When the number input operation is used for registering the tool file, input
the TCP of the tool on the flange coordinates.
XF
YF
Tool
TCP
ZF
1. Select {ROBOT} under the main menu.
8-18
DX100
8
8.3
System Setup
Tool Data Setting
– The sub menu appears.
2. Select {TOOL}.
(1) Move the cursor to the number of the desired tool, and press
{SELECT} in the tool list window.
(2)
The tool coordinate window of the selected number appears.
– In the tool coordinate window, the tool number can be changed by
pressing the page key
or selecting {PAGE} .
– To switch the tool list window and the tool coordinate window, press
{DISPLAY}
{LIST} or {DISPLAY}
{COORDINATE DATA}.
3. Select the desired tool number.
4. Place the cursor in the part to register the desired coordinate data and
press [SELECT].
– The number is ready to input.
5. Input the coordinate data.
6. Press [ENTER].
8-19
8
8.3
DX100
System Setup
Tool Data Setting
– The coordinate data is registered.
<Setting Example>
260 mm
260 mm
TCP
TCP
TCP
260 mm
ZF
ZF
Tool A
Tool B
145 mm
Tool C
In case of Tool A, B
In case of Tool C
8.3.1.3
Registering Tool Angle
The tool pose data is angle data which shows the relation between the
flange coordinates and the tool coordinates. The angle when the flange
coordinates are rotated to meet to the tool coordinates becomes an input
value. Clockwise toward the arrow is the positive direction. Register in the
order of Rz
Ry
Rx.
In the following case, register Rz=180, Ry=90, Rx=0
8-20
DX100
8
8.3
System Setup
Tool Data Setting
Flange
XF
coordinates
YF
ZF
XT
Tool
coordinates
YT
ZT
1. Select {ROBOT} under the main menu.
2. Select {TOOL}.
3. Select the desired tool number.
– In the same way as shown in Explanation 2, 3 in
chapter 8.3.1.2 “Registering Coordinate Data” at page 8-18,
display the desired tool coordinate window.
4. Select the desired coordinate axis to modify.
– First, select Rz.
5. Input the tool pose data.
– Input rotation angle around ZF of the flange coordinates.
XF
YF
YF
ZF
X F
Rz = 180
6. Press [ENTER].
– The rotation angle of Rz is registered.
In the same way, register the angle of Ry, Rx.
Ry must be the input rotation angle around Y’F flange coordinates.
X F
ZF
Y F (Y F )
Z F
8-21
Ry = 90
DX100
8
8.3
System Setup
Tool Data Setting
– Rx must be the input rotation angle around X’F of flange
coordinates.
X F
YF
Z F
8.3.1.4
Rx = 0
Setting the Tool Load Information
The tool load information includes weight, a center of gravity position, and
moment of inertia at the center of gravity of the tool installed at the flange.
SUPPLE
-MENT
For more details on the tool load information, refer to
chapter 8.4.3 “Tool Load Information Setting” at page 8-42.
8-22
8
8.3
DX100
8.3.2
Tool Calibration
8.3.2.1
Tool Calibration
System Setup
Tool Data Setting
To ensure that the manipulator can perform motion type operations such
as linear and circular motion type correctly, accurate dimensional
information on tools such as torches, tools, and guns must be registered
and the position of the TCP must be defined.
Tool calibration is a function that enables this dimensional information to
be registered easily and accurately. When this function is used, the TCP is
automatically calculated and registered in the tool file.
What is registered in tool calibration is the coordinates of the TCP and the
tool posture data in the flange coordinates.
XF
Flange
coordinates
ZF
<Flange coordinates>
XF: Vertically upward direction when the current
position on the T-axis of the manipulator is "0"
YF: Y-axis complementing XF and ZF
ZF: Direction perpendicular to the flange face
XT
YT
YF
Tool
coordinates
8.3.2.2
ZT
Setting of Tool Calibration Method
There are three tool calibration methods, which are selected by setting
parameter.
S2C432: Designation of tool calibration method
0: Calibrates only the coordinates.
“Coordinates” calculated from 5 calibration teaching points is
registered in the tool file.
In this case “Tool Posture Data” is all cleared to be 0.00.
1: Calibrates only the posture.
“Tool Posture Data” calculated from the first calibration
teaching point is registered in the tool file.
In this case, “Coordinates” will not be changed. (the prior
value is maintained.)
2: Calibrates the coordinates and the posture.
“Coordinates” calculated from 5 calibration teaching points
and “Tool Posture Data” calculated from the first calibration
teaching point are registered in the tool file.
8-23
DX100
8
8.3
System Setup
Tool Data Setting
NOTE
8.3.2.3
•
In case of S2C432=0 (only coordinates is calibrated),
tool posture data is overwritten with 0.
(When the coordinates calculated from tool calibration is
registered in the tool file in which the tool posture data is
already registered, the tool posture data will be deleted.)
•
In case of S2C432=1 (only posture is calibrated), the
coordinates are maintained.
•
In case of S2C432=1, 5 teaching points need to be
registered though only the first point is used for
calculation.
Teaching of Calibration Point
Teaching for defining coordinates
In order to calibrate coordinates, five different postures (TC1 to 5) must be
taught with the TCP as the reference point. The tool dimensions are
automatically calculated on the basis of these five points.
TC2
TC1
TC3
TC4
TCP
TC5
Each posture must be arbitrary. Accuracy may decrease when pose
setting is rotated in a constant direction
Teaching for defining posture
The calibration of tool posture data is performed with the first calibration
teaching point (TC1).
Teach TC1 with Z-axis of the desired tool coordinates downward vertically
to the ground. (the Z-axis of the tool coordinates is parallel to the Z-axis of
the base tool and points to the opposite direction.)
Tool posture data is automatically calculated with this TC1 posture.
8-24
DX100
8
8.3
System Setup
Tool Data Setting
The X-axis of the tool coordinates is defined in the same direction as the
X-axis of the base coordinates.
Tool
TCP YT
XT
Tool
Coordinates
Z
Base
Coordinates
ZT
X
Y
In case of calibrating with S2C432=2, teach TC1 with Z-axis
of the desired tool coordinates downward vertically to the
ground. Then teach the other calibration teaching points
(TC2~TC5) with the all tool points meet at the TC1’s tool
point as shown in the figure below.
SUPPLE
-MENT
SUPPLE
-MENT
If teaching in one place as the figure above is impossible
due to the interference of peripheral equipment and so on,
perform calibration of coordinates with S2C432=0 or 2, and
then change to S2C432=1, teach only TC1 in a different
position and register the tool posture data.
•
There are 64 tool files numbered 0 to 63.
•
In a basic system with one manipulator and one tool, the
tool file for tool No.0 is used.
•
If there is more than one tool, for example when using a
multihand, use the tool numbers in the order of 0, 1, 2,
etc.
8-25
DX100
8
8.3
System Setup
Tool Data Setting
1. Select {ROBOT} under the main menu.
2. Select {TOOL}.
3. Select the desired tool number.
– In the same way as shown in the instruction 2 and 3 of the
chapter 8.3.1.2 “Registering Coordinate Data” at page 8-18,
display the desired tool coordinate window.
4. Select {UTILITY} under the menu.
– The pull-down menu appears.
5. Select {CALIBRATION}.
8-26
DX100
8
8.3
System Setup
Tool Data Setting
– The TOOL CALIBRATION window is shown.
6. Select the robot.
(1) Select the robot to calibrate.
(When the robot has already been selected or there is only one of
robot, this operation should not be performed.)
(2)
Select “**” in the TOOL CALIBRATION window and select the
robot in the shown selection dialog box.
(3) The robot is set.
7. Select “POSITION.”
– The selection dialog box is shown.
8-27
DX100
8
8.3
System Setup
Tool Data Setting
(1)
Select the teaching point for calibration.
8. Move the manipulator using the axis key.
9. Press [MODIFY] and [ENTER].
– Taught position is registered.
Repeat 7 to 9 operation to teach TC1 to TC5.
" " indicates that teaching is completed and " " indicates that it is
not completed.
– To check the taught positions, call up the required window among
TC1 to TC5 and press [FWD]. The manipulator moves to the set
position.
– If there is a difference between the current position of the
manipulator and the shown position data, “TC ” next to
“POSITION” in the window flashes.
10. Select “COMPLETE.”
8-28
DX100
8
8.3
System Setup
Tool Data Setting
– Calibration data is registered in the tool file. Once the calibration is
completed, the tool coordinate window is displayed on the screen.
8.3.2.4
Clearing Calibration Data
Before the calibration of a new tool, clear the robot information and
calibration data.
1. Select {DATA} under the pull-down menu.
– The pull-down menu appears.
2. Select {CLEAR DATA}.
8-29
8
8.3
DX100
System Setup
Tool Data Setting
– The confirmation dialog box is shown.
3. Select {YES}.
– All data is cleared.
SUPPLE
-MENT
8.3.2.5
If tool angle data is required, input the data number in the
tool coordinate window.
Refer to chapter 8.3.1.3 “Registering Tool Angle” at
page 8-20 for the operating instructions.
Checking the TCP
After registering the tool file, check if the TCP is correctly registered by
performing a TCP fixed operation like the one shown below, in any
coordinate system other than the joint.
8-30
DX100
8
8.3
System Setup
Tool Data Setting
Tool center
point
1. Press [COORD].
– Select any coordinate system except “
[COORD].
JOINT” by pressing
2. Select desired tool number.
– Show the tool coordinate window of the desired tool by pressing the
page key
or selecting it in the tool list window.
3. Move the R, B, or T axes using the axis key.
– By pressing the axis keys for the R, B, and T axes, change the
manipulator pose without changing the TCP position.
If this operation shows a large TCP error, adjust the tool data.
TCP
8-31
DX100
8
8.3
System Setup
Tool Data Setting
SUPPLE
-MENT
8.3.3
8.3.3.1
For details on the TCP fixed operation, see "2.8.1 Motion
about TCP" in OPERATOR’S MANUAL.
Automatic Measurement of the Tool Load and the Center of Gravity
What is the Automatic Measurement of the Tool Load and the Center of Gravity?
With this function, the user can register the load of tool and the position of
the tools center of gravity.
The tool load and the position of it’s center of gravity are measured and
registered in a tool file.
NOTE
8.3.3.2
This function can be used where the manipulator is installed
level on the ground.
For the conditions required for manipulator installation, refer
to chapter 8.4 “ARM Control” at page 8-37.
Measurement of the Tool Load and the Center of Gravity
To measure the tool load and the center of gravity, move the manipulator
to its home position (horizontal to the U-, B- and R-axes) and operate the
U-, B- and T-axes.
U-axis
U+
R-axis
B-axis
B+
T+
L-axis
U-
B- T-
T-axis
Home Position
(Horizontal to the U-,
B- and R-axes)
S-axis
Zero-degree Installation on the Ground
NOTE
To correctly measure the tool load or the center of gravity,
remove the cables or wires connected to the tool.
1. Select {ROBOT} under the main menu.
8-32
DX100
8
8.3
System Setup
Tool Data Setting
2. Select {TOOL}.
– The tool list window appears.
– The tool list window is called up only when the file extension function
is valid.
If the file extension function is invalid, the tool coordinate window appears.
3. Select the desired tool number.
– Move the cursor to the desired number in the tool list window and
press [SELECT].
– The tool coordinate window of the selected number is shown.
– In the tool coordinate window, the number can be changed by
pressing the page key
or selecting {PAGE}.
8-33
DX100
8
8.3
System Setup
Tool Data Setting
– To switch the tool list window and the tool coordinate window, press
{DISPLAY}
{LIST} or {DISPLAY}
{COORDINATE DATA}.
4. Select {UTILITY} under the menu.
5. Select {W.GRAV.POS MEASURE}.
– The window for the automatic measurement of the tool load and the
center of gravity is shown.
6. Press the page key
.
– In a system with several manipulators, use the page key
change the group to be controlled.
8-34
to
DX100
8
8.3
System Setup
Tool Data Setting
7. Press [FWD].
– Press [FWD] once, and the manipulator moves to the home position
(horizontal to the U-, B- and R-axes).
8. Press [FWD] again.
– Press [FWD] again, and measurement starts. Keep the button
pressed until measurement is completed.
The manipulator moves in the order listed below. Once measurement is
completed, “ “changes to “ “.
Measurement of the U-axis: U-axis home position +4.5 degrees
-4.5 degrees
Measurement of the B-axis: B-axis home position +4.5 degrees
-4.5 degrees
First measurement of the T-axis: T-axis home position +4.5 degrees
-4.5 degrees
Second measurement of the T-axis: T-axis home position +60
degrees
+4.5 degrees
-4.5 degrees
•
The speed during measurement automatically changes
to “Medium”.
•
During the measurement, “HOME” or “U” blinks on the
screen.
•
During the measurement, the [FWD] button has to be
kept pressed. If the button is released during the
measurement or if it is released before “ “changes into
“ “, the measurement is aborted and the following
message appears: “Stopped measurement”
•
The measurement starts again from the first home
position.
SUPPLE
-MENT
– When all the measurements are completed or when all the
“ “marks have changed into “ “, the measured data appears on the
screen.
8-35
DX100
8
8.3
System Setup
Tool Data Setting
9. Select “REGISTER”.
– The measured data is registered in the tool file, and the tool
coordinate window appears.
– Select “CANCEL” to call up the tool list window without registering
the measured data in the tool file.
8-36
8
8.4
DX100
8.4
8.4.1
System Setup
ARM Control
ARM Control
ARM Control
ARM Control, a control system originally developed by Yaskawa, achieves
an enhanced robot motion performance such as improved path accuracy
or educed cycle time.
The moment of inertia and the gravity moment etc. of each axis are
calculated by the ARM control function, and DX100 controls robot motion
according to the result. It is necessary to set the Robot setup condition
and the tool load information to request these accurately.
The robot setup condition is robot installation angle relative to ground and
the weight and a center of gravity position of the load installed at each part
of robot, etc.
The tool load information is weight, a center of gravity position, and
moment of inertia at the center of gravity, of the tool installed at the flange.
It is necessary to set these information correctly to do a better operation
control by the ARM control.
8.4.2
ARM CONTROL Window
CAUTION
•
Correctly set the robot setup condition.
Make sure to avoid any mistake in setting the unit indication or
specifying positive and negative values. Failure to observe this caution
may lead to improper control of the manipulator, resulting in error
occurrence or short life span of speed reducer.
•
Confirm the operation path of robot of each job when modifying
settings.
Set the robot setup condition when setting up the manipulator.
Confirm the operation path of manipulator of each job afterwards when
the setting should be modified after the installation.
Modifying the settings of the ARM control may slightly change the
operation path. To avoid injury or damage to machinery caused by
collision between tool and positioner, make sure to check the operation
path before executing a job.
8.4.2.1
Robot Setup Condition
Fulfill the following robot setup condition to enable the ARM control.
• Robot installation angle
• S-head payload
• U-arm payload
8-37
DX100
8
8.4
System Setup
ARM Control
Robot installation angle
The angle of the manipulator installed relative to ground is set in ANGLE
REL. TO GROUND to calculate the gravity moment which loads to each
axis of the manipulator.
The robot installation angle sets how much X axis of the robot coordinates
has inclined with the ground around Y axis of the robot coordinates. The
direction of + in the U axis operation from the home position posture of the
manipulator becomes direction of + of the robot installation angle.
Therefore, the robot installation angle for a vertical downward wall mount
specification becomes -90 degrees.
Z
X
Robot
installation
Angle
+
Y
-
<Example>
0 degrees
-90 degrees
+90 degrees
180 degrees
If the robot installation angle is not correctly set, the manipulator cannot be
properly controlled. Therefore, make sure to set the value correctly,
paying special attentions to the direction “+” or “-”.
NOTE
Only rotation angle around Y axis of the robot coordinates
can be set in the robot installation angle.
Contact YASKAWA representative when robots is installed
to incline Y axis of the robot coordinates relative to ground.
S-head payload
Set the weight and the center of gravity position roughly when the
equipment such as transformer is installed at the S-head.
It is not necessary to set these values when there is no installed load on
the S-head.
8-38
DX100
8
8.4
System Setup
ARM Control
WEIGHT (unit: kg)
The weight of the installed load is set.
It is not required to set a correct value, however, it is recommended to set
a value slightly larger than the actual load. (Round up the value with each
fraction between 0.5 to 1 kg.)
X (From S-Axis), Y (From S-Axis) (unit: mm)
The center of gravity position of the installed load is set by the distance in
the direction of X and the direction of Y from S axis center here. It can be
set with a rough value.
The direction of X and Y applies to the robot coordinates. The value is set
by a negative number when the position is in “-” direction.
Fig. 8-1: Load on the S-head (Top View)
-X
S axis center
-Y
+Y
(X position, Y position)
+X
U-arm payload
Set the weight and the center of gravity position roughly when the
equipment such as the wire supplying motors is installed on U arm.
A standard value is set when shipping from the factory.
Set the weight in “0” if there is no installing equipment on U arm.
WEIGHT (unit: kg)
The weight of the installing load is set here.
Set a little large value though it does not care by a rough value. (Rase to a
unit in each 0.5 to 1kg)
X (From U-Axis), HEIGHT (From U-Axis) (unit: mm)
The center of gravity position of the installing load is set here. It does not
care by a rough value.
X (From U-Axis) is horizontal distance from U axis rotation center to the
center of gravity position of the load. Set negative number when there is
mass side in the back from U-axis rotation center.
HEIGHT (From U-Axis) is height of the vertical direction from U-axis
rotation center to the center of gravity position of the load.
8-39
DX100
8
8.4
System Setup
ARM Control
Fig. 8-2: Load on the U-arm: Center of Gravity Position (Side View)
X (From U-Axis)
(-)
U-axis
rotation
center
(+)
Center of Gravity
Position
HEIGHT
(From U-Axis)
NOTE
ARM CONTROL window is displayed only when the security mode is set in the management mode.
1. Select {ROBOT} under the main menu.
2. Select {ARM CONTROL}.
8-40
DX100
8
8.4
System Setup
ARM Control
– The ARM CONTROL window appears.
3. Press the page key
, or select {PAGE}.
– Select the desired control group when there are two or more group
axes.
4. Select the desired item.
5. Input the value and press [ENTER].
8-41
8
8.4
DX100
8.4.3
System Setup
ARM Control
Tool Load Information Setting
CAUTION
•
Set the tool load information correctly.
The speed reducer longevity might decrease or the alarm might occur
when the tool load information is not set correctly.
•
Confirm the operation path of robot of each job which uses the tool
file after the tool load information is changed.
Set the tool load information before teaching the job after the tool is
installed.
Confirm the operation path of each job which uses the tool file when the
tool load information should be modified after teaching.
Modifying the tool load information may slightly change the operation
path. To avoid injury or damage to machinery caused by collision
between tool and positioner, make sure to check the operation path
before executing a job.
8.4.3.1
Tool Load Information
Tool load information includes weight, a center of gravity position, and
moment of inertia at the center of gravity of the tool installed at the flange.
These are registered in the tool file.
Moment of inertia around the Center of Gravity
Ix, Iy, Iz
XF'
XF
Ix
YF'
Iy
YF
ZF'
Iz
Weight:W
ZF
Center of Gravity Position
( Xg, Yg, Zg )
8.4.3.2
* Flange Coodinates
XF: It is a direction right above when T axis
is 0 pulse position and the flange surface
of the manipulator turned to the front.
YF: Y axis led by XF,ZF
ZF: Perpendicular direction from flange surface
How to Calculate Tool Load Information
Weight: W (Unit: kg)
The total weight of the installing tool is set.
It is not required to set a correct value, however, it is recommended to set
a value slightly larger than the actual load. (Round up the value with each
fraction between 0.5 to 1 kg for small and medium size manipulator, and 1
to 5 kgs for large manipulator.)
8-42
DX100
8
8.4
System Setup
ARM Control
Center of gravity position: xg, yg, zg (Unit: mm)
The center of gravity position of the installed tool is set as the position in
the flange coordinates.
Since it is usually difficult to get a strict center of gravity position, it can be
set with a rough value. Presume and set a center of gravity position
roughly from outline of the tool.
Set the value when the center of gravity position of the installed tool is
clear from specifications, etc.
Moment of inertia at the center of gravity: lx, ly, lz (Unit: kg·m2)
It is an moment of inertia of the tool at the center of gravity position.
The value is calculated around the each axis of the coordinates which is in
parallel to the flange coordinates and which home position is the center of
gravity position of the tool.
It is not required to set a correct value, however, it is recommended to set
a value slightly larger than the actual value.
This setting is used to calculate the moment of inertia which loads to each
axis of the manipulator. However, the moment of inertia at the center of
gravity does not need to be set when this data is small enough for the
moment of inertia calculated from weight and the center of gravity
position.
However, the setting is required when the moment of inertia of the tool is
large (as a rough guide, the tool is considered to be large when the tool
size is about more than 2-times the distance between the flange and the
center of gravity).
The size of the tool is not too big.
Setting the moment of inertia at center
of gravity is not necessary.
The size of the tool is big.
Setting the moment of inertia at center
of gravity is necessary.
Rough value of the moment of inertia at the center of gravity can be
calculated by the following methods.
• Method to approximate the entire tool in hexahedron or cylinder.
• Method to calculate from each weight and center of gravity position
of plural mass.
Refer to the following setting examples for details.
8-43
8
8.4
DX100
System Setup
ARM Control
<Example 1>
In the example of sealing gun of the figure below, the center of gravity is
set on the flange coordinates assuming that the center of gravity is
positioned slightly inclined to the head from the center.
There is no need to set the moment of inertia at the center of gravity since
the size of the gun is not too large.
<Setting>
YF
XF
70
Center of Gravity Position
= (100, 0, 70)
Total Weight
Approx. 6.3 [kg]
7.00 [kg]
•W
:
7.000 kg
• Xg
: 100.000 mm
• Yg
:
0.000 mm
• Zg
:
70.000 mm
• Ix
:
0.000 kg •m2
• Iy
:
0.000 kg •m2
• Iz
:
0.000 kg •m2
100
ZF
•
The own moment of inertia calculation for hexahedron
and cylinder
The own moment of inertia of hexahedron and cylinder can
be calculated by the next expression when the center of
gravity is at the center.
Refer to the expression when the calculation of the moment
of inertia at the center of gravity.
Z
Z
Ly
r
Lx
Iz
Iz
SUPPLE
-MENT
Iy
Lz
Ix
Y
X
Iy =
Iz =
Ly + Lz
Lx 2 + Lz 2
12
Lx 2 + Ly 2
12
8-44
Weight: W
2
12
Iy
Ix
X
Weight:W
2
Ix =
Y
H
2
*W
Ix = Iy =
r
3 r + H2
12
*W
2
*W
Iz =
*W
* Unit of Weight : [kg]
* Unit of Length : [m]
* Unit of Ix, Iy, Iz : [kgxm 2 ]
2
*W
8
8.4
DX100
System Setup
ARM Control
<Example 2>
It is necessary to set the moment of inertia at the center of gravity when
the entire size of the tool and workpiece is large compared to the distance
from the flange to the center of gravity position.
Calculate the moment of inertia at the center of gravity roughly from the
expression (refer to the forementioned supplement: "The own moment of
inertia calculation for hexahedron and cylinder"), by approximating the
entire tool in the shape of the hexahedron or the cylinder.
If the weight of held workpiece is greatly different in the handling usage
etc., it is more effective to set tool load information on each workpiece and
to switch the tool on each step according to the held workpiece. Set the
tool load information in the state to hold the heaviest workpiece when
using the tools without switching them.
500
YF
250
Weight of tool:
Approx. 55 kg.
XF
ZF
Weight of workpiece:
Approx. 40 kg.
400
1000
Weight:
W = 55 + 40 = 95
= approx. 100[kg]
Center of gravity: Position at flange right under 250mm almost
(Xg, Yg, Zg) = (0,0,250)
Moment of inertia at the center of gravity:
The hexahedron of 0.500 x 0.400 x 1.000[m] which encloses the
entire tool + workpiece is assumed.
By the expression to calculate the own moment of inertia of
hexahedron,
Ix = ( Ly2 + Lz2 / 12) * W
= ( (0.4002 + 1.0002) / 12 ) * 100 = 9.667 = approx. 10.000
Iy = ( Lx2 + Lz2 / 12) * W = ( (0.5002 + 0.4002) / 12 ) * 100 = 3.417 =
approx. 3.500
Iz = ( Lx2 + Ly2 / 12) * W = ( (0.5002 + 1.0002) / 12 ) * 100 = 10.417 =
approx. 10.500
8-45
8
8.4
DX100
System Setup
ARM Control
<Setting>
•W
: 100.000 kg
• Xg
:
0.000 mm
• Yg
:
0.000 mm
• Zg
: 250.000 mm
• Ix
:
10.000 kg.m2
• Iy
:
3.500 kg.m2
• Iz
:
10.500 kg.m2
How to calculate "Center of gravity position" and "moment of inertia at center of gravity" for plural mass
The center of gravity position and the moment of inertia at the center of gravity of the
entire tool can be calculated by the weight and the center of gravity position of each
mass when the tool can be thought that the tool consists of two or more big mass like
the twin gun system etc.
1. Divide the tool into some parts as the weight and the center of gravity position can
be roughly presumed. It is not necessary to divide in detail. The tool is
approximated in construction of rough parts.
2. Calculate the weight and the center of gravity position of the each parts on flange
coordinates. It does not care by a rough value. Calculate the own moments of
inertia of the big parts. (If parts are small, it is not necessary to calculate the own
moments of inertia. Refer to above-mentioned supplement: "The own moment of
inertia calculation for hexahedron and cylinder" for how to calculate the own
moment of inertia.)
wi
: Weight of the i-th parts [kg]
(xi, yi, zi)
: Center of gravity position of the i- th parts
(On flange coordinates) [mm]
Icxi, Icyi, Iczi : Own moments of inertia of the i-th parts [kg*m2]
SUPPLE
-MENT
3. The center of gravity position of the entire tool is calculated by the next
expression.
xg = {w1 * x1 + w2 * x2 + .... + wi * xi} / (w1 + w2 + .... + wi)
yg = {w1 * y1 + w2 * y2 + .... + wi * yi} / (w1 + w2 + .... + wi)
zg = {w1 * z1 + w2 * z2 + .... + wi * zi} / (w1 + w2 + .... + wi)
4. The moment of inertia at the center of gravity position of the entire tool is
calculated by the next expression.
Ix = { w1 * ((y1 - yg)2 + (z1 - zg)2) * 10-6 + Icx1} + { w2 * ((y2 - yg)2 +
(z2 - zg)2) * 10-6 + Icx2}
...................
+ { wi * ((yi - yg)2 + (zi - zg)2) * 10-6 + Icxi}
Iy = { w1 * ((x1 - xg)2 + (z1 - zg)2) * 10-6 + Icy1} + { w2 * ((x2 - xg)2 +
(z2 - zg)2) * 10-6 + Icy2}
.....................
+ { wi * ((xi - xg)2 + (zi - zg)2) * 10-6 + Icyi}
Iz = { w1 * ((x1 - xg)2 + (y1 - yg)2) * 10-6 + Icz1} + { w2 * ((x2 - xg)2 +
(y2 - yg)2) * 10-6 + Icz
.....................
+ { wi * ((xi - xg)2 + (yi - yg)2) * 10-6 + Iczi}
8-46
8
8.4
DX100
System Setup
ARM Control
<Example 3>
When there are two or more big mass such as the twin gun system as
shown in the figure below, perform:
1. Set the center of gravity position when the center of gravity position of
the entire tool is roughly understood, and set the moment of inertia at
the center of gravity calculated by approximating the entire tool in the
shape of hexahedron or cylinder. (It is enough in this setting usually.);
or
2. When weight in each mass and the center of gravity position are
understood, the center of gravity position and the moment of inertia at
the center of gravity of the entire tool can be calculated. (Refer to
forementioned supplement column: "How to calculate "Center of
gravity position" and "moment of inertia at the center of gravity" for
plural mass".)
This example shows the calculation with the method 2.
(Top View)
Center of Flange
YF
YF
100
XF
50
40
150
Gun 1
70
(Gun 1)
Weight: w1 = 3 kg
Center of Gravity:
x1 = 100 mm
y1 = 50 mm
z1 = 40 mm
Gun 1
ZF
Gun 2
Weight :
XF
Gun 2
(Gun 2)
Weight: w2 = 6 kg
Center of Gravity:
x2 = 100 mm
y2 = -150 mm
z2 = 70 mm
W = w1 + w2
= 3 + 6 = 9 = approx. 10[kg]
Center of gravity Xg = (w1 * x1 + w2 * x2) / (w1 + w2)
= (3 * 100 + 6 * 100) / (3+6)
= 100.0 [mm]
Yg = (3 * 50 + 6 * (-150)) / (3+6) = -83.333 [mm]
Zg = (3 * 40 + 6 * 70) / (3+6)
= 60.0 [mm]
The moment of inertia at the center of gravity position:
Ix = { w1 * ((y1 - Yg)2 + (z1 - Zg)2) * 10-6 + Icx1}
+ { w2 * ((y2 - Yg)2 + (z2 - Zg)2) * 10-6 + Icx2}
= 3 * ((50 - (-83))2 + (40 - 60)2) * 10-6
+
6 * (((-150) - (-83))2 + (70 - 60)2) * 10-6
= 0.082 = approx. 0.100
Iy = 3 * ((100 - 100)2 + (40 - 60)2) * 10-6
+
6 * ((100 - 100)2 + (70 - 60)2) * 10-6
= 0.002
= approx. 0.010
8-47
DX100
8
8.4
System Setup
ARM Control
Iz = 3 * ((100 - 100)2 + (50 - (-83))2) * 10-6
+
6 * ((100 - 100)2 + ((-150) - (-83))2) * 10-6
= 0.080 = approx. 0.100
* The own moment of inertia (Icxi, Icyi, Iczi) of the gun is disregarded in
this example, since each gun is smaller than the entire tool.
<Setting>
8.4.3.3
10.000 kg
•W
:
• Xg
: 100.000 mm
• Yg
: -83.333 mm
• Zg
: 60.000 mm
• Ix
:
0.100 kg.m2
• Iy
:
0.010 kg.m2
• Iz
:
0.100 kg.m2
Tool Load Information Registering
Tool load information is registered in the tool file.
1. Select {ROBOT} under the main menu.
2. Select {TOOL}.
– The tool coordinate window appears.
– The tool coordinate window appears only when the file extension
function is valid.
–
When the file extension function is invalid, the tool list window
appears.
8-48
DX100
8
8.4
System Setup
ARM Control
3. Select the desired tool number.
(1) Move the cursor to the number of the desired tool, and press
[SELECT] in the tool list window.
(2)
The tool coordinate window of the selected number appears.
(3) Select the desired number in the tool coordinate window by pressing the page key
or clicking on the {PAGE} button.
(4) To switch the tool list window and the tool coordinate window,
press {DISPLAY}
{LIST} or {DISPLAY}
{COORDINATE
DATA}.
4. Select the desired item to register and input the value.
– The window can be scrolled with the cursor.
– The menu enters the state of a numeric input if the cursor is on the
desired item to register and the [SELECT] is pressed.
5. Press [ENTER].
– The input value is registered.
– The servo power is automatically turned OFF when editing the value
while the servo power is ON, followed by a message "Servo off by
changing data" displayed for three seconds.
8-49
8
8.4
DX100
System Setup
ARM Control
When the data setting is not done
It is considered that data is not set correctly in tool load information in the following
cases.
• When the weight (W) is "0".
• When the center of gravity position (Xg, Yg, Zg) are all “0”.
In these cases, the manipulator is controlled by using the standard parameter values
(vary according to each robot model) which were set by default.
Standard Value:
Weight: W = Payload
Center of gravity position:
(Xg, Yg, Zg) = (0, 0, Allowed value of B-axis for payload)
NOTE
In this case, when an actual tool load is not large enough, the manipulator cannot sufficiently exert its function, (speed and acceleration / deceleration). Especially, when operating the manipulator with the standard value, a difference of 100 kg or more in the load
between the actual tool load and the standard value may cause vibrations in the manipulator motion: it is therefore essential to correctly set the tool load information for the
proper operation of the manipulator.
Moreover, when the tool which an actual tool center of gravity position greatly offsets in
X-direction or Y-direction is installed the generated moment by the tool cannot be compensated.
•
Switch of the tool file
In case that two or more tool files are used, information on an effective tool file is referred
for tool load information used by the ARM control at that time in according to switch tool
file.
Set the same value of tool load information in each tool file when the tool file is switched
to change only TCP (when neither the weight nor the center of gravity position of the
entire tool installed in the flange is changed).
Moreover, set tool load information to the corresponding tool file respectively when total
weight and the center of gravity position etc. of the tool is changed (when the system
which exchange the tool by automatic tool changer).
8-50
8
8.5
DX100
8.5
8.5.1
System Setup
Work Home Position
Work Home Position
What is the Work Home Position?
The Work Home Position is a reference point for manipulator operations. It
prevents interference with peripheral device by ensuring that the
manipulator is always within a set range as a precondition for operations
such as starting the line. The manipulator can be moved to the set work
home position by operation from the programming pendant, or by signal
input from an external device. When the manipulator is in the vicinity of the
work home position, the work home position signal turns ON.
8.5.2
Setting Work Home Position
8.5.2.1
Work Home Position Window
1. Select {ROBOT} under the main menu.
2. Select {WORK HOME POS}.
– The WORK HOME POSITION window is appears.
3. Press the page key
8-51
.
DX100
8
8.5
System Setup
Work Home Position
– When two or more manipulators exist in the system, use the page
key
to change the control group, or click on {PAGE} to select
the desired control group.
8.5.2.2
Registering/Changing the Work Home Position
1. Press the axis keys in the work home position display.
– Move the manipulator to the new work home position.
2. Press [MODIFY], [ENTER].
8-52
DX100
8
8.5
System Setup
Work Home Position
– New work home position is set.
When the work home position is changed, the cubic interference area is automatically set as cube 64 to 57 in the base
coordinate system.
NOTE
•
The cube 64 is for ROBOT1
•
The cube 63 is for ROBOT2
•
The cube 62 is for ROBOT3
•
The cube 61 is for ROBOT4
•
The cube 60 is for ROBOT5
•
The cube 59 is for ROBOT6
•
The cube 58 is for ROBOT7
•
The cube 57 is for ROBOT8
The work home position cube is a cube like the one shown
in the figure below; the length of its sides is determined by a
parameter setting made by the user (units: µm).
By changing this parameter setting, the size of the cube can
be changed.
Fig. 8-3: S3C805: The work home position cube length of
its sides (µm)
a
2
2
P
a
a
a
2
2
2
Specify whether “COMMAND POSITION” or “FEEDBACK
POSITION” is to be set to the work home position cube signal’s CHECK MEASURE in the interference area settings.
“COMMAND POSITION” is the default setting.
8.5.2.3
Returning to the Work Home Position
In the teach mode
1. Press [FWD] in the work home position display.
– The manipulator moves to the new work home position. The moving
speed is the selected manual speed.
In the play mode
When the work home position return signal is input (detected at leading
edge), the TCP of the manipulator is moved to the work home position.
When the manipulator moves, a message "Manipulator is moving to work
home position" is displayed. In this case, the move interpolation is
MOVJ, and the speed applied is the one set in the parameters.
(S1CxG56; units: 0.01 %.)
8-53
DX100
8
8.5
System Setup
Work Home Position
8.5.2.4
Output of the Work Home Position Signal
This signal is output any time the current position of the TCP of the
manipulator is checked and found to be within the work home position
cube.
8-54
8
8.6
DX100
8.6
8.6.1
System Setup
Interference Area
Interference Area
Interference Area
The interference area is a function that prevents interference between
multiple manipulators or the manipulator and peripheral device. The area
can be set up to 32 area. There are two types of interference areas, as
follows:
• Cubic Interference Area
• Axis Interference Area
The DX100 judges whether the TCP of the manipulator is inside or outside
this area, and outputs this status as a signal.
8.6.2
Cubic Interference Area
8.6.2.1
Cubic Interference Area
This area is a rectangular parallelepiped which is parallel to the base
coordinate, robot coordinate, or user coordinate. The DX100 judges
whether the current position of the manipulator’s TCP is inside or outside
this area, and outputs this status as a signal.
Robot coordinate
Z-axis
Cubic
interference
area
Cubic
interference
User Coordinates area
Z-axis
Y-axis
X-axis
Y-axis
X-axis
8.6.2.2
Cube Setting Method
There are three ways to set cubic a interference area as described in the
following sections:
1. Enter the maximum and minimum values for the cube coordinates.
8-55
DX100
8
8.6
System Setup
Interference Area
Z-axis
Maximum
value
Cubic
interference
area axis
X-axis
Minimum
value
Y-axis
2. Move the manipulator at the maximum and minimum value positions of
the cube corner using the axis keys.
Z-axis
Maximum
value
X-axis
Minimum
value
Y-axis
3. After entering the lengths of the three faces of the cube (axial length)
using the Numeric keys, move the manipulator to the center point of
the cube using the axis keys.
X
Y
Z
Center
point
Y-axis
8-56
X-axis
Z-axis
8
8.6
DX100
8.6.2.3
System Setup
Interference Area
Setting Operation
1. Select {ROBOT} under the main menu.
2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window is shown.
3. Select the desired cube number.
– Select the desired cube number with the page key
number input.
8-57
or by
DX100
8
8.6
System Setup
Interference Area
– When selecting the cube number by number input, select {PAGE} to
input the desired signal number.
4. Select “METHOD”.
– ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are
displayed alternately every time [SELECT] is pressed. If “CUBIC
INTERFERENCE” is selected, the window is changed.
5. Select “CONTROL GROUP”.
– A selection dialog box appears. Select the desired control group.
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Interference Area
6. Select “REF COORDINATES”.
(1) A selection box appears.
(2) Select the desired coordinate.
(3) If the user coordinates are selected, the number input line is displayed. Input the user coordinate number and press [ENTER].
7. Select “CHECK MEASURE.”
– Each time [SELECT] is pressed, “COMMAND POSITION” and
“FEEDBACK POSITION” are displayed alternately.
To stop the manipulator movement using the interference
signal (use the cube interference signal for mutual interference between robots), set CHECK MEASURE to “COMMAND POSITION”.
NOTE
When set to the “FEEDBACK POSITION”, the manipulator
decelerates to a stop after entering the interference area.
When using the interference signal to inform an external
unit of the actual manipulator position, use the "FEEDBACK
POSITION" setting to enable the signal output in more
accurate timing.
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8.6
System Setup
Interference Area
Number Input of the Cube Coordinates
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “MAX/MIN”.
2. Input number for “MAX” and “MIN” data and press [ENTER].
– The cubic interference area is set.
Teaching Corner
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “MAX/MIN”.
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2. Press [MODIFY].
– A message “Teach max./min. position” appears.
3. Move the cursor to “<MAX>” or “<MIN>.”
– Move the cursor to “<MAX>” when changing the maximum value,
and move cursor to “<MIN>” when changing the minimum value.
The cursor only moves to either “<MIN>” or “<MAX>” at this time.
4. Move the manipulator using the axis keys.
– Move the manipulator to the maximum or minimum position of the
cube using the axis keys.
5. Press [ENTER].
– The cubic interference area is registered.
Number Input of the Side of Cube and Teaching Center
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
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Interference Area
(2) Select “CENTER POS”.
2. Input data for length of the cube, then press [ENTER].
– The length is set.
3. Press [MODIFY].
– A message “Move to center point and teach” appears. The cursor
only moves to either “<MIN>” or “<MAX>” at this time.
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DX100
System Setup
Interference Area
4. Move the manipulator using the axis keys.
– Move the manipulator to the center point of the cube using the axis
keys.
5. Press [ENTER].
– The current position is registered as the center point of the cube.
8.6.3
Axis Interference Area
8.6.3.1
Axis Interference Area
The axis interference area is a function that judges the current position of
the each axis and outputs a signal. Once the maximum and minimum
values have been set at the plus and minus sides of the axis to define the
working range, a signal indicating whether the current position of the axis
is inside or outside this range is output. (ON: inside, OFF: outside)
Fig. 8-4: Axis Interference Signal for Station Axis
Max value
+ side
ON
Min value
- side
OFF
8.6.3.2
Setting Operation
1. Select {ROBOT} under the main menu.
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System Setup
Interference Area
2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window appears.
3. Select the desired interference signal number.
– Select the desired interference signal number using the page
key
or by number input.
– When selecting the desired interference signal number by number
input, select {PAGE} to input the desired signal number.
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8.6
System Setup
Interference Area
4. Select “METHOD”.
– ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are
displayed alternately every time [SELECT] is pressed. Select “AXIS
INTERFERENCE”.
5. Select “CONTROL GROUP”.
– A selection box appears. Select the desired control group.
6. Select “CHECK MEASURE”.
– Each time [SELECT] is pressed, “COMMAND POSITION” and
“FEEDBACK POSITION” switch alternately.
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System Setup
Interference Area
Number Input of the Axis Data Coordinates
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “MAX/MIN”.
2. Input number for “MAX” and “MIN” data and press [ENTER].
– The axis interference area is set.
Teaching Corner
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
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Interference Area
(2) Select “MAX/MIN”.
2. Press [MODIFY].
– A message “Teach max./min. position” appears.
3. Move the cursor to “<MAX>” or “<MIN>.”
– Move the cursor to “<MAX>” when changing the maximum value,
and move cursor to “<MIN>” when changing the minimum value.
The cursor only moves to either “<MIN>” or “<MAX>” at this time.
4. Move the manipulator using the axis keys.
– Move the manipulator to the maximum or minimum position of the
cube using the axis keys.
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System Setup
Interference Area
5. Press [ENTER].
– The cubic interference area is registered.
Number Input of Center Position (WIDTH) and Teaching Center
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “CENTER POS”.
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Interference Area
2. Input number for “WIDTH” data and press [ENTER].
– “WIDTH” is set.
3. Press [MODIFY]
– A message “Move to the center point and teach” appears.
– The cursor only moves to either “<MIN>” or “<MAX>” at this time.
4. Move the manipulator using the axis keys.
– Move the manipulator to the center position of the cube using the
axis keys.
5. Press [ENTER].
– The center position of the cube is registered.
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8
8.6
System Setup
Interference Area
Clearing the Interference Area Data
1. Select {ROBOT} under the main menu.
2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window is shown.
3. Select interference signal to be cleared.
– Select the desired interference signal number to be cleared using
the page key
or by number input.
– When selecting the desired interference signal number by number
input, select {PAGE} to input the desired signal number.
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Interference Area
4. Select {DATA} under the menu.
– The pull-down menu appears.
5. Select {CLEAR DATA}.
– The confirmation dialog box appears.
6. Select {YES}.
– All the data of the interference signal number are cleared.
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8.7
DX100
8.7
8.7.1
System Setup
Shock Detection Function
Shock Detection Function
Shock Detection Function
The shock detection function is a function to decrease damage due to the
collision by stopping the manipulator without any external sensor when
the tool or the manipulator collide with peripheral device.
When the shock is detected either in teach mode or in play mode, the
manipulator is stopped immediately.
WARNING
This function does not completely avoid damage to the peripheral
devices; moreover, it does not guarantee the user’s safety.
Make sure to prepare the safety measures such as the safeguarding
etc. Refer to chapter 1 “Safety” at page 1-1 to chapter 6 “Test of
Program Operation” at page 6-1 for the safety measures in details.
Failure to observe this warning may result in Injury or damage to
machinery caused by contact with the manipulator.
8.7.2
Shock Detection Function Setting
The shock detection function is set not to mis-detect the shock even if
operating by the ratings load with the maximum speed when shipping from
the factory. If tool load information is set correctly, the detection sensitivity
can be improved. Moreover, it is possible to set the lower sensitivity of
detection only for a specific section where the contact work etc. The
sensitivity of detection is set by setting the detection level.
8.7.2.1
Shock Detection Level Setting
The shock detection level is set in the shock detection level set file.
The shock detection level set file are nine condition files as following
figure.
• Condition number 1 to 7 are used when the detection level is
changed in a specific section in play mode.
• Condition number 8 is used as standard in play mode: this function is
operated by the detection level set in this file when playback operation.
• Condition number 9 is for teach mode: the shock detection function
applies the detection level set here when the manipulator is operated
in teach mode.
The detection level is changed by a job instruction SHCKSET.
• After the instruction is executed, the shock will be detected by the
specified detection level when the condition number is specified with
the SHCKSET instruction.
• The detection level is returned to standard level when the SHCKRST
instruction is executed.
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System Setup
Shock Detection Function
Setting in the specific section
in play mode
(Condition number 1 to 7)
Standard used
for play mode
(Condition
number 1 to 8)
Shock Detection
Level File
Condition number 1
Used for teach mode
(Condition number 9)
Condition number 7
Condition number 8
Condition number 9
SUPPLE
-MENT
The detection level of condition number 8 (a standard in play
mode) is adopted in play mode excluding the range between
SHCKSET and SHCKRST in the job.
Detection Mode
Indicates the shock detection mode.
Condition Number (1 to 9)
1 to 7: for changing detection level in play mode.
8: for standard detection level in play mode.
9: for detection level in teach mode.
Function Select
Specifies VALID/INVALID of the shock detection function. The shock
detection function is specified by each manipulator with this function.
1. Move the cursor to the manipulator of which function is to be enabled
or disabled; press [SELECT] to change the function to "VALID" or
"INVALID".
2. "VALID" and "INVALID" can be changed alternately whenever
[SELECT] is pressed. The change is available for all the condition
numbers.
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8.7
System Setup
Shock Detection Function
Max. Disturbance Force
Indicates the maximum disturbance force to the manipulator when the
manipulator is moved in play back operation or axis operation.
Refer to this value when inputting the detection level value in .
The maximum disturbance force can be cleared by selecting {DATA}
{CLEAR MAX VALUE} in the menu.
Detection Level (Level range: 1 to 500)
Specifies the shock detection level. Set a value larger than the maximum disturbance force.
The value set by default (the level 100) enables the function without
false detection even if the manipulator is operated at the maximum
speed.
To change DETECT LEVEL, move the cursor to the subject manipulator, and press [SELECT] to display the numeric input status; input the
value with a numeric key and press [ENTER]. To increase the detection
sensitivity, set the level to small value, and to decrease the sensitivity,
set the level to large value.
Method of Shock Detection Level File Setting
1. Select {ROBOT} under the main menu.
2. Select {SHOCK SENS LEVEL}.
– The SHOCK DETECT LEVEL window appears.
– Perform either of the following operations to display the page of
desired condition number:
(1) Select {PAGE} and input the desired condition number, then press
[ENTER].
(2) Press the page key
to change the page of condition number.
3. Select the desired condition number.
4. Select the desired item and perform setting.
To avoid false detection during the manipulator operation,
set the detection level greater than the maximum disturbance force by 20%.
NOTE
An emergency stop of the manipulator due to the false
detection may become a factor to damage the speed reducers and tools.
<Example>
When the maximum disturbance force is 80, set the detection level at 96 or more.
NOTE
"Detection level” can be modified only when the security
mode is set in management mode.
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8.7.2.2
8
8.7
System Setup
Shock Detection Function
Tool Load Information Setting
To increase the accuracy of shock detection, set the tool load information
in the tool file. Refer to chapter 8.4.3 “Tool Load Information Setting” at
page 8-42 for details of the tool load information setting.
8.7.2.3
Instruction of Shock Detection Function
SHCKSET instruction
The SHCKSET instruction changes the shock detection level to the value
set in the shock detection level file during play back operation.
The additional items of the SHCKSET instruction are as follows.
SHCKSET R1 SSL#(1)
Robot Setting
Specifies the manipulator of which shock detection level is to be modified. If nothing is specified, the modification is applied to the shock
detection level of the job control group in this instruction. However, in
case of coordinated job, the modification is applied to the shock detection level of the slave axis group.
Shock Detection Level Condition Number (1 to 7)
Specifies the shock detection level condition number in which the detection level in playback mode is set.
SHCKRST instruction
The shock detection level changed by the SHCKSET instruction is reset
and returned to the detection level of the standard (value set in condition
number 8) by the SHCKRST instruction.
The additional item of the SHCKRST instruction is as follows.
SHCKRST R1
Robot Setting
Specifies the manipulator of which shock detection level is to be reset.
If nothing is specified, the modification will be applied to the shock
detection level of the job control group of this instruction. However, in
case of coordinated job, the modification is applied to the shock detection level of the slave axis group.
Instruction Registration
The instruction is registered when the cursor is in the address area in the
JOB CONTENT window in teach mode.
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System Setup
Shock Detection Function
1. Select {JOB} under the main menu.
Instruction
Address
Area
2. Select {JOB}.
3. Move the cursor in the address area.
SHCKSET
1. Move the cursor to the immediately preceding line where the
SHCKSET instruction is to be registered.
2. Press [INFORM LIST].
– The inform list dialog box is shown.
3. Select SHCKSET instruction.
(1) SHCKSET instruction is shown in the input buffer line.
(2) Change the value of additional item and numerical data.
(3) Press [INSERT] then [ENTER].
4. Change the value of additional item and numerical data.
– < When registering the instruction as it is >
Operate the step 5 when registering the instruction in the input
buffer line as it is.
– < When adding or changing the additional item >
• When changing the shock detection level
(1) When changing the shock detection level, move the cursor to the
shock detection level condition number; hold down [SHIFT] and
press the up/down cursor key to change the condition number.
• When the value is input with the numeric key
I)
When the value is input with the numeric key, press [SELECT]
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System Setup
Shock Detection Function
to display the input buffer line.
II)
Press [ENTER] to change the number in the input buffer line.
• When robot specification is added
I)
When robot specification is added, move the cursor to the
instruction in the input buffer line and press [SELECT] to display the DETAIL window.
II)
Move the cursor to "UNUSED" of "ROBOT/STATION", and
press [SELECT].
III)
The selection box appears.
IV) Point the cursor to the robot to be added and press [SELECT].
V) When the addition of robot is completed, press [ENTER].
VI)
The DETAIL window closes and the JOB CONTENT window
appears.
5. Press [INSERT] then [ENTER].
– The instruction displayed in the input buffer line is registered.
SHCKRST
1. Move the cursor to the immediately preceding line where the
SHCKRST instruction is to be registered.
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System Setup
Shock Detection Function
2. Press [INFORM LIST].
– The inform list appears.
3. Select SHCKRST instruction.
– SHCKRST instruction appears in the input buffer line.
4. Change the value of the additional item.
– < When registering the instruction as it is >
Operate the step 5 when registering the instruction in the input
buffer line as it is.
– < When adding or changing the additional item >
(1) When adding the robot specification, move the cursor to instruction in the input buffer line and press [SELECT] to display the
DETAIL window.
(2) Move the cursor to "UNUSED" of "ROBOT/STATION", and press
[SELECT].
(3) The selection box appears.
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System Setup
Shock Detection Function
(4) Point the cursor to the robot to be added and press [SELECT].
(5) When the addition of robot is completed, press [ENTER].
(6)
The DETAIL window closes and the JOB CONTENT window
appears.
5. Press [INSERT] then [ENTER].
– The instruction displayed in the input buffer line is registered.
8.7.2.4
Resetting the Shock Detected
When the collision of tool/manipulator and peripheral device is detected
with the shock detection function, the manipulator stops instantaneously
with alarm output. In this case, the shock detection alarm is displayed.
The shock detection alarm in teach mode and play mode can be reset by
the following operation.
1. Press [SELECT].
– The alarm is reset when “RESET” is selected on the alarm display,
and the shock detection status is released.
2. Operation after resetting the detection status.
– In teach mode, the JOG operation of the manipulator is enabled by
resetting the status.
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8.7
System Setup
Shock Detection Function
– In the play mode, move the manipulator once to the safety position
in the teach mode to check the damage though the playback
operation is possible after resetting the status.
NOTE
When manipulator is stopped instantaneously while having
contact with the object and the detection alarm is tried to
reset on the alarm window, the situation in which the alarm
cannot be reset may occur since the collision may be
detected again after resetting.
In this case, set the collision detection function "INVALID",
or increase the detection level in teach mode and retreat
the manipulator to a safety position.
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8.8
DX100
8.8
8.8.1
System Setup
User Coordinate Setting
User Coordinate Setting
User Coordinates
Definition of the User Coordinates
User coordinates are defined by three points that have been taught to the
manipulator through axis operations. These three defining points are
ORG, XX, and XY, as shown in the diagram below. These three points of
positional data are registered in a user coordinate file.
Z-axis
X-axis
XX
XY
Y-axis
ORG
User coordinate definition point
ORG: Home position
XX: Point on the X-axis
XY: Point on the Y-axis
ORG is the home position, and XX is a point on the X-axis. XY is a point
on the Y-axis side of the user coordinates that has been taught, and the
directions of Y- and Z-axes are determined by point XY.
NOTE
It is important that the two points ORG and XX be taught
accurately.
User Coordinate Files
Up to 63 kinds of user coordinates can be registered. Each coordinate has
a user coordinate No. and is called a user coordinate file.
User coordinate file 1
User coordinate file 2
User coordinate file 3
User coordinate file 4
User coordinate file 63
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8.8.2
8.8.2.1
8
8.8
System Setup
User Coordinate Setting
User Coordinate Setting
Selecting the User Coordinate File
1. Select {ROBOT} under the main menu.
2. Select {USER COORDINATE}.
(1) The USER COORDINATE window appears.
(2) The " " mark indicates that the user coordinates is completed to
set and the " " mark indicates that it is not completed.
(3) To check the position of the user coordinates select {DISPLAY}
{COORDINATE DATA}.
(4) The following window appears.
3. Select the user coordinate number.
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8
8.8
System Setup
User Coordinate Setting
Teaching the User Coordinates
1. Select the robot.
– Select "**" on the upper left of the window to select the subject robot.
(This operation can be omitted if the robot selection has already
been made or if there is only one robot.)
2. Select “SET POS”.
– Select the teaching point.
3. Move the manipulator to the desired position with the axis keys.
4. Press [MODIFY] then [ENTER].
– Taught position is registered.
– Repeat the steps 2 to 4 to teach ORG, XX and XY.
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8.8
System Setup
User Coordinate Setting
– “ “ indicates that teaching is completed and " " indicates that it is
not completed.
– To check the taught positions, call up the required window among
ORG to XY and press [FWD]. The manipulator moves to the set
position.
– If there is a difference between the current position of the
manipulator and the displayed position data, “ORG”, “XX”, or “XY”
flashes.
5. Select “COMPLETE”.
– User coordinates are registered in the file.
– Once the user coordinate setting is completed, the following
window appears.
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8.8.2.3
8
8.8
System Setup
User Coordinate Setting
Clearing the User Coordinates
1. Select {DATA} under the pull-down menu.
2. Select {CLEAR DATA}.
– The confirmation dialog box appears.
3. Select {YES}.
– All data is cleared.
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8.9
DX100
8.9
System Setup
Overrun / Tool Shock Sensor Releasing
Overrun / Tool Shock Sensor Releasing
CAUTION
To operate the manipulator with the overrun or shock sensor released,
pay extra attention to the safety of the surrounding operation
environment.
If the manipulator stops by overrun detection or tool shock sensor
detection, release the overrun or tool shock sensor by the following
procedure and reset the alarm and move the manipulator with the axis
keys.
1. Select {ROBOT} under the main menu.
2. Select {OVERRUN & S-SENSOR}.
– The OVERRUN & SHOCK SENSOR window appears.
– Select either "EMERGENCY STOP" or "HOLD" to set the item
"SHOCK SENSOR STOP COMMAND" which specifies the stop
condition in the current shock sensor detection.
– “E-STOP” and “HOLD” are displayed alternately every time
[SELECT] is pressed.
3. Select “RELEASE”.
– The control group in which overrun or shock sensor is detected is
indicated with “ ".
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8.9
System Setup
Overrun / Tool Shock Sensor Releasing
– If “RELEASE” is selected, overrun or tool shock sensor is released
and “CANCEL” indication will be displayed.
4. Select “ALM RST”.
– The alarm is reset and manipulator can be moved with the axis
keys.
NOTE
After releasing the overrun or tool shock sensor, if “CANCEL” is selected or the window is changed to the other one,
the release of the overrun or tool shock sensor will be canceled.
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System Setup
8.10 Soft Limit Release Function
DX100
8.10
Soft Limit Release Function
The switches that are set to detect the motion range of the manipulator
are called limit switches. The operating range is monitored by the software
in order to stop motion before these limit switches are reached. These
software limits are called "soft limits". The operating range of the
manipulator is controlled by the following two soft limits.
• Maximum motion range for each axis
• Cubic operation area set parallel to the robot coordinate system
These soft limits are continually monitored by the system, and the
manipulator automatically stops when the its TCP reaches a soft limit.
When the manipulator is stopped at a soft limit, temporarily release the
soft limit by the following procedure, then move the manipulator away from
the soft limit in a direction opposite to the earlier operation direction.
1. Select {ROBOT} under the main menu.
2. Select {LIMIT RELEASE}.
– The LIMIT RELEASE window appears.
3. Select “SOFT LIMIT RELEASE”.
– Each time [SELECT] is pressed, “VALID” and “INVALID” switch
alternately.
– When “SOFT LIMIT RELEASE” is set to “VALID”, a message “Soft
limits have been released” appears.
– When “SOFT LIMIT RELEASE” is set to “INVALID,” a message
"Softlimits off released" is displayed for a few seconds.
•
The taught data cannot be registered when the soft limit
is being released.
•
The setting of "SOFT LIMIT RELEASE" becomes
"INVALID" when the mode is changed to the play mode.
NOTE
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System Setup
8.11 All Limit Release Function
DX100
8.11
All Limit Release Function
CAUTION
To operate the manipulator with all limits released, pay extra attention
to ensure the safety of the surrounding operation environment.
Failure to observe this caution may result in injury or damage to
equipment due to the unexpected manipulator motion exceeding its
range of motion.
The following limits can be released with the All Limit Release function:
Limit Type
Contents
Mechanical Limit
Limit to check manipulator’s range of motion.
L-U Interference
Limit to check L- and U-axis interference area.
Soft Limit on Each Axis
Soft limit to check manipulator’s range of motion.
Cube Interference
Limit to check cube interference area set by user.
NOTE
All limit release function is not available if the security mode
is not in the management mode. Refer to chapter 7 “Security System” at page 7-1 for details on the security modes.
1. Select {ROBOT} under the main menu.
2. Select {LIMIT RELEASE}.
– The LIMIT RELEASE window appears.
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System Setup
8.11 All Limit Release Function
3. Select “ALL LIMITS RELEASE”.
– “VALID” and “INVALID” are displayed alternately every time
[SELECT] is pressed.
– When ALL LIMIT RELEASE is changed to “VALID”, a message “All
limits have been released” is displayed. When the setting changes
to “INVALID”, a message “All limits off released” is displayed for a
few seconds.
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System Setup
8.12 Instruction Level Setting
DX100
8.12
8.12.1
Setting Contents
8.12.1.1
Instruction Set
Instruction Level Setting
There are three instruction sets that can be used when registering the
instructions for the robot programming language (INFORM III): the subset
instruction set, the standard instruction set, and the expanded instruction
set.
Subset Instruction Set
The instructions displayed in the instruction list are limited to just those
that are most frequently used, reducing the number of instructions that
can be registered. Since few instructions are shown, selection and input
are simple.
Standard Instruction Set / Expanded Instruction Set
All the INFORM III instructions can be used. The number of additional
items to be used in each instruction differ in the standard instruction set
and expansion instruction set.
In the standard instruction set, the following functions cannot be used.
However, operation becomes easier because the number of data items
decreases when registering an instruction.
• Use of local variables and arrangement variable
• Use of variables for additional items (Example: MOVJ VJ = I000)
When instructions are executed, for example during playback, all the
instructions can be executed regardless of the instruction set used.
Expanded instruction set
Standard instruction set
Subset instruction set
All instructions
Frequency used
instructions
Use of local variables and arrangement variables
Use of variables for additional items
Job calls with arguments
Instruction set
8.12.1.2
Learning Function
When an instruction is entered from the instruction list, the additional
items that were entered last time are also shown. This function can
simplify instruction input.
To register the same additional items as those in the former operation,
register them without changing.
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System Setup
8.12 Instruction Level Setting
1. An instructions are registered.
2. The next time an attempt is made to register the same instruction as in
1, the same additional items as were registered last time are also
shown in the input buffer line.
8.12.2
Setting the Instruction Set Level
1. Select {SETUP} under the main menu.
2. Select {TEACHIG COND}.
– The TEACHING CONDITION window appears.
3. Select “LANGUAGE LEVEL”.
– The selection list appears.
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System Setup
8.12 Instruction Level Setting
4. Select desired language level.
– Language level is set.
8.12.3
Setting the Learning Function
The learning function is set at "VALID" by default.
1.
Select {SETUP} under the main menu.
2. Select {TEACHIG COND}.
– The TEACHING CONDITION window appears.
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System Setup
8.12 Instruction Level Setting
3. Select "INSTRUCTION INPUT LEARNING".
– VALID” and “INVALID” are displayed alternately every time
[SELECT] is pressed.
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8
System Setup
8.13 Setting the Controller Clock
DX100
8.13
Setting the Controller Clock
The clock inside the DX100 controller can be set as follows.
1. Select {SETUP} under the main menu.
2. Select {DATE/TIME}.
– The DATE/CLOCK SET window appears.
3. Select “DATE” or “CLOCK.
– ”The input buffer line appears.
4. Input the new date/time.
– For instance, to set the date to August 1, 2008, input "2008.8.1". To
set the time at twelve o’clock, enter "12.00".
5. Press [ENTER].
– The date/time is changed.
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8
System Setup
8.14 Setting the Play Speed
DX100
8.14
Setting the Play Speed
1. Select {SETUP} under the main menu.
2. Select {SET SPEED}.
– The SPEED SET window is shown.
3. Press the page key
.
– When two or more manipulators and stations exist in the system,
use the page key
to change the control group, or click on
{PAGE} to select the desired control group.
4. Select “JOINT” or “LNR/CIR”.
– The type of speed alternately changes from “JOINT” to “LNR/CIR”.
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8
System Setup
8.14 Setting the Play Speed
5. Select the speed to modify.
– The input buffer line appears.
6. Input the speed value.
7. Press [ENTER].
– The speed is modified.
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8
System Setup
8.15 Numeric Key Customize Function
DX100
8.15
8.15.1
Numeric Key Customize Function
What is the Numeric Key Customize Function?
With this function, the user can set the function of an application that has
been allocated to the numeric keys of the programming pendant to the
other function.
Since any frequently used operation can be allocated to the numeric keys
on the programming pendant, decreased key operations reduce the
teaching time.
NOTE
8.15.2
The Numeric Key Customize Function is allowed to set only
when the security mode is in the management mode.
Allocatable Functions
There are two allocation methods as follows:
• Key Allocation (EACH)
• Key Allocation (SIM)
8.15.2.1
Key Allocation (EACH)
With key allocation (EACH), the manipulator operates according to the
allocated function when the numeric key is pressed. The allocatable
functions are listed below.
Function
Description
Manufacturer
Allocated by Yaskawa. Allocating another function
invalidates the function allocated by the manufacturer.
allocation
8.15.2.2
Instruction
allocation
Allocates any instructions assigned by the user.
Job call allocation
Allocates job call instructions (CALL instructions). The
jobs to be called are only those registered in the reserved
job names. (Specified by the registration No.)
Display allocation
Allocates any displays assigned by the user.
Key Allocation (SIM)
With key allocation (SIM), the manipulator operates according to the
allocated function when the [INTERLOCK] and the numeric key are
pressed at the same time. The allocatable functions are listed below.
Function
Description
Alternate output
allocation
Turns ON/OFF the specified user output signal when
[INTERLOCK] and the allocated Numeric key are
pressed at the same time.
Momentary output
allocation
Turns ON the specified user output signal user when
[INTERLOCK] and the allocated user key are pressed at
the same time.
Pulse output
allocation
Turns ON the specified user output signal only for the
specified period when [INTERLOCK] and the allocated
Numeric key are pressed at the same time.
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System Setup
8.15 Numeric Key Customize Function
Function
Description
Group output
allocation
(4-bit/8-bit)
Sends the specified output to the specified general group
output signals when [INTERLOCK] and the allocated
Numeric key are pressed at the same time.
Analog output
allocation
Sends the specified voltage to the specified output port
when [INTERLOCK] and the allocated Numeric key are
pressed at the same time.
Analog incremental
output allocation
Sends the voltage increased by the specified value to the
specified output port when [INTERLOCK] and the
allocated Numeric key are pressed at the same time.
SUPPLE
-MENT
8.15.3
8.15.3.1
In a system for multiple applications, a numeric key can be
allocated for each application.
Allocating an Operation
Allocation Window
1. Select {SETUP} under the main menu.
2. Select {KEY ALLOCATION}.
– The KEY ALLOCATION (EACH) window appears.
3. Select {DISPLAY}.
– Pull-down menu appears.
– To call up the KEY ALLOCATION (SIM) window, select {ALLOCATE
SIM. KEY}.
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8
System Setup
8.15 Numeric Key Customize Function
4. Select {ALLOCATE SIM. KEY}.
– The KEY ALLOCATION (SIM) window appears.
– In a system multiple applications, press the page key
to
change the window to the allocation window for each application, or
click on {PAGE} to select the desired application number.
8.15.3.2
Instruction Allocation
1. Set this function in the KEY ALLOCATION (EACH) window. Move the
cursor to “FUNCTION” of the key to be allocated and press [SELECT].
– Selection list appears.
2. Select “INSTRUCTION”.
– The instruction is shown in the “ALLOCATION CONTENT”.
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DX100
8
System Setup
8.15 Numeric Key Customize Function
(1) To change the instruction, move the cursor to the instruction and
press [SELECT]. Then the instruction group list appears.
(2) Select the group which contains the instruction to modify.
(3) When the instruction list dialog box is shown, select the instruction
to be changed.
8.15.3.3
Job Call Allocation
Set this function in the KEY ALLOCATION (EACH) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
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8
System Setup
8.15 Numeric Key Customize Function
DX100
2. Select “JOB CALL”.
– The reserved job registration No. is shown in the “ALLOCATION
CONTENT” (reserved job registration No.: 1 to 10).
(1) To change the reserved job registration No. move the cursor to the
No. and press [SELECT]. Then input buffer line appears.
(2)
8.15.3.4
Input the number to be changed, and press [ENTER].
Display Allocation
Set this function in the KEY ALLOCATION (EACH) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– Selection list appears.
2. Select [DISPLAY].
3. Move the cursor to “ALLOCATION CONTENT” and press [SELECT].
– Character input is available.
4. Input the name of the reserved window and press [ENTER].
– The reserved name input to the “ALLOCATION CONTENT” is
shown.
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8
System Setup
8.15 Numeric Key Customize Function
5. Open the window for allocation.
6. Press [INTERLOCK] and the allocated key at the same time.
– A message “Reserved display registered” appears, and the window
is registered.
– In this case, the CURRENT POSITION window is registered by
pressing [INTERLOCK] + [0] with the CURRENT POSITION window
displayed on the screen.
8.15.3.5
Alternate Output Allocation
Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– Selection list appears.
2. Select “ALTERNATE OUTPUT”.
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System Setup
8.15 Numeric Key Customize Function
– The output No. is displayed in the “ALLOCATION CONTENT”.
(1) To change the output No., move the cursor to the No. and press
[SELECT]. Then numeric value can be entered.
(2)
8.15.3.6
Input the number to be changed, and press [ENTER].
Momentary Output Allocation
Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
2. Select “MOMENTARY OUTPUT”.
– The output No. is displayed in the “ALLOCATION CONTENT”.
(1) To change the output No., move the cursor to the No. and press
[SELECT]. Then numeric value can be entered.
(2) Input the number to be changed, and press [ENTER].
8.15.3.7
Pulse Output Allocation
Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
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System Setup
8.15 Numeric Key Customize Function
2. Select “PULSE OUTPUT”.
– The output No. and output time are displayed in the “ALLOCATION
CONTENT”.
(1) To change the output No. or output time, move the cursor to the
No. or time and press [SELECT]. Then numeric value can be
entered.
(2) Input the number or time to be changed, and press [ENTER].
8.15.3.8
Group (4-bit/8-bit) Output Allocation
Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
2. Select “4 BIT OUTPUT” or “8 BIT OUTPUT”.
– The output No. and output value are displayed in the “ALLOCATION
CONTENT”.
(1) To change the output No. or output value, move the cursor to the
No. or value and press [SELECT]. Then numeric value can be
entered.
(2)
Input the number or value to be changed, and press [ENTER].
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DX100
8.15.3.9
8
System Setup
8.15 Numeric Key Customize Function
Analog Output Allocation
Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
2. Select “ANALOG OUTPUT”.
– The output port number and the output voltage value are displayed
in the “ALLOCATION CONTENT”.
(1) To change the output port No. or output voltage value, move the
cursor to the No. or voltage value and press [SELECT]. Then
numeric value can be entered.
(2)
8.15.3.10
Input the number or voltage value to be changed, and press
[ENTER]
Analog Incremental Output Allocation
Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
2. Select “ANALOG INC OUTPUT.”
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System Setup
8.15 Numeric Key Customize Function
– The output port No. and incremental value are displayed in the
“ALLOCATION CONTENT”.
(1) To change the output port No. or incremental value, move the cursor to the No. or incremental value and press [SELECT]. Then
numeric values can be entered.
(2)
8.15.4
Input the number or incremental value to be changed, and press
[ENTER].
Allocation of I/O Control Instructions
In key allocation (SIM), output control instructions can be allocated to the
numeric keys that have been allocated one of the following I/O controls
with key allocation (EACH).
Function
Output Control Instruction allowed to be
Allocated
Alternate output allocation
DOUT OT# (No.) ON
Momentary output allocation
Pulse output allocation
PULSE OT# (No.) T = output time
Group output allocation (4-bit) DOUT OGH (No.) output value
Group output allocation (8-bit) DOUT OG# (No.) output value
Analog output allocation
8-107
AOUT AO# (No.) output voltage value
DX100
8
System Setup
8.15 Numeric Key Customize Function
1. Allocation of I/O control instruction.
– Allocate the I/O control instruction with key allocation (SIM) following
the forementioned procedure.
2. Move the cursor to the “FUNCTION” of the key that has been allocated
with I/O control with key allocation (SIM) and press [SELECT].
– Selection list appears.
3. Select “OUTPUT CONTROL INST”.
– The instruction corresponding to the I/O control allocated by key
allocation (SIM) is displayed in the “ALLOCATION CONTENT”.
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System Setup
8.15 Numeric Key Customize Function
– The allocated instruction changes automatically when
“ALLOCATION CONTENT” is changed by key allocation (SIM).
Even if the I/O control allocation is changed to the default setting
allocated by the manufacturer with key allocation (SIM), the settings
for key allocation (EACH) remain the same.
8.15.5
8.15.5.1
Execution of Allocation
Executing the Instruction/Output Control Allocation
1. Press the key allocated for instruction allocation or output control
allocation.
– The allocated instruction is displayed in the input buffer line.
2. Press [INSERT] and [ENTER].
– The instruction displayed in the input buffer line is registered.
8.15.5.2
Executing the Job Call Allocation
1. Press the key allocated for the job call allocation.
– The CALL instruction is displayed in the input buffer line.
2. Press [INSERT] then [ENTER].
– The CALL instruction shown in the input buffer line is registered.
8.15.5.3
Executing the Display Allocation
1. Press the key allocated for the display allocation.
– The allocated display appears.
8.15.5.4
Executing the I/O Control Allocation
Alternate output allocation, momentary output allocation, pulse output
allocation, group output allocation (4-bit/8-bit), analog output allocation,
analog incremental output allocation are executed by the following
operation.
1. Press [INTERLOCK] and the key allocated for I/O control allocation at
the same time.
– Allocated functions are executed.
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8
System Setup
8.16 Changing the Output Status
DX100
8.16
Changing the Output Status
The status of external output signals can be changed from the
programming pendant by using either of the following two methods.
• On the user output status window
• On the RELAY ON window
The method that uses the RELAY ON window, which is described here,
simplifies the operation for changing the status of signals that are used
frequently.
NOTE
A maximum of 64 output signals can be shown on the
RELAY ON window and they must be set in advance to
parameters S4C327 to S4C390. If they are not set, the sub
menu in the RELAY ON window will not be displayed.
1. Select {IN/OUT} under the main menu.
2. Select {RELAY ON}.
– The RELAY ON window appears.
3. Select the desired signal to change the output status.
– Select the status (
or
) of the desired signal.
4. Press [INTERLOCK] +[SELECT].
– The output status is changed. ( : status ON;
8-110
: status OFF.)
DX100
8
System Setup
8.16 Changing the Output Status
SUPPLE
-MENT
It is also possible to turn the relevant external output signal
on only for the duration that [INTERLOCK]+[SELECT] are
pressed. This selection is made in advance by setting the
parameters (S4C391 to 454) to “1”.
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8
System Setup
8.17 Changing the Parameter Setting
DX100
8.17
Changing the Parameter Setting
The parameter settings can be changed only by the operator who has the
correct user ID number for the management mode.
1. Select {PARAMETER} under the main menu.
2. Select the parameter type.
– The PARAMETER window appears. Select the desired parameter.
Binary Data
Decimal Data
3. Move the cursor to the desired parameter number.
– When the desired parameter number is not in the current window,
move the cursor in the following way:
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System Setup
8.17 Changing the Parameter Setting
(1) Move the cursor to a parameter number and press [SELECT].
(2)
Enter the desired parameter number with the numeric keys.
(3) Press [ENTER].
(4) The cursor moves to the selected parameter number.
Set the parameters in the following manner.
1. Select the parameter data to be set.
(1) Move the cursor to the parameter number data (decimal or binary)
in the PARAMETER window, and press [SELECT].
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System Setup
8.17 Changing the Parameter Setting
(2)
To enter a decimal setting, select the decimal figure.
(3)
To enter a binary setting, select the binary figure.
2. Enter the value.
– If a decimal figure is selected, enter a decimal value with the
numeric keys.
– If a binary figure is selected, move the cursor to the binary figure
data in the input buffer line, and press [SELECT].
– Each time [SELECT] is pressed, “0” and “1” alternate in the window.
– “0” or “1” can also be entered with the numeric keys.
3. Press [ENTER].
– The new setting appears in the position where the cursor is located.
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System Setup
8.18 File Initialization
DX100
8.18
8.18.1
File Initialization
Initializing Job File
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the security mode to the management mode.
3. Select {FILE} under the main menu.
4. Select {INITIALIZE}.
– The INITIALIZE window appears.
5. Select {JOB}.
– A confirmation dialog box appears.
6. Select {YES}.
– The job data is initialized.
8.18.2
Initializing Data File
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the security mode to the management mode.
3. Select {FILE} under the main menu.
4. Select {INITIALIZE}.
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System Setup
8.18 File Initialization
5. Select {FILE/GENERAL DATA}.
– The INITIALIZE window appears.
6. Select the data file to be initialized.
– The selected data file/general data are marked with “ “.
– The parameters marked with " " cannot be selected.
7. Press [ENTER].
– A confirmation dialog box appears.
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System Setup
8.18 File Initialization
8. Select {YES}.
– The selected data file/general data are initialized.
8.18.3
Initializing Parameter File
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the security mode to the management mode.
3. Select {FILE} under the main menu.
4. Select {INITIALIZE}.
5. Select {PARAMETER}.
– The parameter selection window appears.
6. Select the parameter to be initialized.
– The selected parameter is marked with “ “.
– The parameters marked with " " cannot be selected.
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System Setup
8.18 File Initialization
DX100
7. Press [ENTER].
– A confirmation dialog box appears.
8. Select {YES}.
– The selected parameter is initialized.
8.18.4
Initializing I/O Data
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the security mode to the management mode.
3. Select {FILE} under the main menu.
4. Select {INITIALIZE}.
5. Select {I/O DATA}.
– The I/O data selection window appears.
6. Select data to be initialized.
– The selected data is marked with “ “.
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System Setup
8.18 File Initialization
– The I/O data marked with " " cannot be selected.
7. Press [ENTER].
– A confirmation dialog box appears.
8. Select {YES}.
– The selected data is initialized.
8.18.5
Initializing System Data
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the security mode to the management mode.
3. Select {FILE} under the main menu.
4. Select {INITIALIZE}.
5. Select {SYSTEM DATA}.
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System Setup
8.18 File Initialization
– The system data selection window appears.
6. Select the parameter to be initialized.
– The selected data is marked with “ “.
– The system data marked with " " cannot be selected
7. Press [ENTER].
– A confirmation dialog box appears.
8. Select {YES}.
– The selected data is initialized.
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8
System Setup
8.19 Display Setting Function
DX100
8.19
8.19.1
Display Setting Function
Font Size Setting
DX100 enables changing the font size displayed on the screen.
The fonts displayed on the screen can be selected from eight patterns of
fonts in the font size setting dialog box.
8.19.1.1
Applicable Range for the Font Size Change
Changing the font size is allowed in the general display area indicated in
the following figure:
General display area
8.19.1.2
Settable Font Size
The following eight patterns of fonts are available in setting the size of
fonts displayed on the screen.
Font Size
Font Style
1
Small
Regular
2
Small
Bold
3
Regular
Regular
4
Regular
Bold
5
Large
Regular
6
Large
Bold
7
Extra large
Regular
8
Extra large
Bold
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8.19.1.3
8
System Setup
8.19 Display Setting Function
Setting the Font Size
To set the font size, first off display the font size setting dialog box as
follows.
1. Select {DISPLAY SETUP} then {CHANGE FONT} under the main
menu.
2. The font size setting dialog box appears on the center of the current
window.
To set the font size in the font size setting dialog box, follow the
procedure below.
1. Specify the font style.
– The {Bold Type} check box can be checked or unchecked
alternately each time the check box is selected.
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System Setup
8.19 Display Setting Function
• Check the {Bold Type} check box as follows to set the font to the bold
style.
• Clear the {Bold Type} check box as follows to set the font to the regular style.
2. Specify the font size.
– Select a button from the four buttons in the dialog box.
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System Setup
8.19 Display Setting Function
3. The font size setting dialog box is closed, and the screen displays the
font specified in the dialog box.
To cancel the setting of the font size, follow the procedure below.
1. Select {Cancel} in the font size setting dialog box.
2. The dialog box closes without changing the font size.
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System Setup
8.19 Display Setting Function
Do not turn OFF the DX100 power supply when the font
size is being changed (when the font size setting dialog box
is on the screen).
NOTE
8.19.2
Operation Button Size Setting
DX100 enables changing the size of operation buttons.
The button size in the main menu area, menu area, and instruction list can
be respectively selected from three sizes.
8.19.2.1
Applicable Range for the Button Size Change
Changing the button size is allowed in the main menu, menu (pull-down
menu), and instruction list indicated in the following figure:
Menu area
(pull-down menu)
Instruction list
Main menu area
8.19.2.2
Settable Button Size
The following three sizes of buttons are available in setting the size of
each operation button; the font style of the character string on buttons can
also be specified.
1
Button Size
Font Style
Small
Regular
Bold
2
Regular
Regular
3
Large
Regular
Bold
Bold
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8.19.2.3
8
System Setup
8.19 Display Setting Function
Setting the Button Size
To set the button size, first off display the button size setting dialog box as
follows.
1. Select {DISPLAY SETUP} then {CHANGE BUTTON} under the main
menu.
– The font size setting dialog box appears on the center of the current
window.
To set the button size in the button size setting dialog box, follow the
procedure below.
1. Specify the area to set the button size.
(1) Select the desired area from the area setting buttons.
(2) The buttons in the selected area is subject to size setting.
(3) Note that only the last-selected button determines the area subject
to size setting, even if settings are performed several times before
then.
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System Setup
8.19 Display Setting Function
2. Specify the font style.
– The {Bold Type} check box can be checked or unchecked
alternately each time the check box is selected.
• Check the {Bold Type} check box as follows to set the font to the bold
style.
• Clear the {Bold Type} check box as follows to set the font to the regular style.
3. Specify the button size.
– Select a button from the three buttons in the dialog box.
4. The font size setting dialog box is closed, and the screen displays the
buttons specified in the dialog box.
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System Setup
8.19 Display Setting Function
– The modification is applied only to the buttons in the area selected
with the area setting button. (In this example, the change is applied
only to the pull-down menu buttons in the menu area.)
To cancel the setting of the button size, follow the procedure below.
1. Select {Cancel} in the button size setting dialog box.
– The dialog box closes without changing the button size.
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8
System Setup
8.19 Display Setting Function
NOTE
8.19.3
Do not turn OFF the DX100 power supply when the button
size is being changed (when the button size setting dialog
box is on the screen, or when an hourglass is indicated in
the middle of the screen).
Initialization of Screen Layout
The font/button size changed with the font/button size setting function can
be collectively changed back to the regular size.
8.19.3.1
Initializing the Screen Layout
To initialize the screen layout, follow the procedure below.
1. Select {DISPLAY SETUP} then {INITIALIZE LAYOUT} under the main
menu.
– A confirmation dialog box appears on the center of the current
window.
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System Setup
8.19 Display Setting Function
To Initialize the screen layout, follow the procedure below.
1. select {OK}.
– The dialog box is closed, and the font/button sizes are collectively
changed to the regular size.
To cancel the Initialized screen layout, follow the procedure below.
1. Select {CANCEL}.
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System Setup
8.19 Display Setting Function
DX100
– The dialog box closes without changing the current screen layout.
NOTE
8.19.4
Do not turn OFF the DX100 power supply when the screen
layout is being initialized (when the confirmation dialog box
is on the screen, or when an hourglass is indicated in the
middle of the screen).
Layout Storage
The settings of the font or button sizes are saved in the programming
pendant. The screen displays the font/button size specified last time with
the current programming pendant.
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9
9.1
DX100
9
System Backup
System Backup with DX100
System Backup
For the DX100, the system data can be collectively backed up in advance
so that the data can be immediately loaded and restored in case of an
unexpected trouble such as data loss.
9.1
System Backup with DX100
For the DX100, four types of collective backup are available: CMOS.BIN,
CMOSBK.BIN, ALCMSxx.HEX, and CMOSxx.HEX.
9.1.1
9.1.1.1
Function Types of Data
CMOS.BIN
For the normal backup, use this data.
Save: Perform in the maintenance mode (the editing mode or higher.)
Load: Perform in the maintenance mode (the management mode.)
As for the load/save procedures, refer to chapter 9.2 “Backup by
CMOS.BIN” at page 9-3.
Target Area: All areas of the internally stored data. (Note that the
monitoring time is not loaded.)
9.1.1.2
CMOSBK.BIN
This data is used in the automatic backup function.
Save: Saves with the preset conditions in the normal mode.
Load: Perform for the system restoration in the maintenance mode (the
management mode.)
For details, refer to chapter 9.5 “Error List” at page 9-19.
Target Area: All areas of the internally stored data. (Note that the
monitoring time is not loaded.)
9.1.1.3
CMOSxx.HEX
This data is loaded/saved in the FD/CF menu in the normal mode.
Save: Perform in the normal mode (the editing mode or higher.)
Load: Perform in the normal mode (the management mode.)
For details, refer to "DX100 OPERATOR’S MANUAL".
Target Area: The collected data including "Job File", "Data File",
"Parameter File", "System Data", and "I/O Data" which can
be individually loaded/saved in the FD/CF menu. Because
the setting information of robot etc. are not included in this
collected data, the system cannot be completely restored.
9.1.1.4
ALCMSxx.HEX
This data is for the manufacturer only. Users can save but cannot load
this data.
9-1
9
9.1
DX100
9.1.2
System Backup
System Backup with DX100
Device
For the backup of the DX100 system, the CompactFlash can be used.
The following tables show the recommended CompactFlash.
<Recommended CompactFlash>
No.
Manufacturer
Model
Remarks
1
2
Hagiwara Sys-Com
MCF10P-256MS-YE2
(256MB)
Hagiwara Sys-Com
MCF10P-512MS
(512MB)
3
Hagiwara Sys-Com
MCF10P-A01GS
(1GB)
4
Hagiwara Sys-Com
MCF10P-A02GS
(2GB)
5
SiliconSystems, Inc.
SSD-C25M3512
(2GB)
< Recommended USB Memory>
No.
Manufacturer
Model
Remarks
1
Hagiwara Sys-Com
UDG3-GA series
(1GB, 2GB)
In order to save the batch data, the following free space per file is needed
in the media.
JZNC-NIF01-1: 18 MByte
JZNC-NIF01-2: 21 MByte
JZNC-NIF01-3: 21 MByte
Note that the free space for one working file is needed in addition to the
free space for the stored files when using the automatic backup function.
Also, it is recommended to store the backup data in two or more media
cards to minimize problems if the media is damaged.
The water-proof function of the Pendant is not effective
while the USB memory is connected.
NOTE
If USB memory is connected constantly, there is a risk it
drops off.
Use CompactFlash if there is no measures to maintain
water-proof function or to prevent USB memory from dropping off.
9-2
9
9.2
DX100
9.2
System Backup
Backup by CMOS.BIN
Backup by CMOS.BIN
Perform the backup by CMOS.BIN in the maintenance mode.
The chart below shows the availability of CMOS save/CMOS load in each
security mode in the maintenance mode.
9.2.1
Security
CMOS Save
CMOS Load
Operation Mode
X
X
Editing Mode
O
X
Management Mode
O
O
Yaskawa Mode
O
O
CMOS.BIN Save
Follow the procedures below to save CMOS.BIN.
1. Turn ON the DX100 power supply while pressing [MAIN MENU].
2. Insert a CompactFlash into the CompactFlash slot on the
programming pendant.
– when USB memory is used instead of CompactFlash, mount the
USB memory and select {DEVICE} → ”USB: PENDANT”
3. Select {FD/PC CARD} under the main menu.
– The sub menu appears.
4. Select {SAVE}.
9-3
DX100
9
9.2
System Backup
Backup by CMOS.BIN
– The save display appears.
– The items marked with " " cannot be selected.
5. Select {CMOS SAVE}.
The confirmation dialog box appears.
6. Select {YES}.
– Select {YES} to save the CMOS data into the CompactFlash.
– When saving the file, if the CMOS.BIN file already exists in the
CompactFlash, the following confirmation dialog box appears.
9-4
9
9.2
DX100
System Backup
Backup by CMOS.BIN
7. Select {YES}.
– The CMOS.BIN file is overwritten in the CompactFlash.
9.2.2
CMOS.BIN Load
Follow the procedures below to load CMOS.BIN.
1. Turn ON the DX100 power supply while pressing [MAIN MENU].
2. Change the security mode to the maintenance mode, or Yaskawa
mode.
3. Insert a CompactFlash into the CompactFlash on the programming
pendant.
– When USB memory is used instead of CompactFlash, mount USB
memory and select {DEVICE} → “USB: PENDANT”.
4. Select {FD/PC CARD} under the main menu.
– The sub menu appears.
5. Select {LOAD}.
The load display appears.
– The items marked with " " cannot be selected.
9-5
DX100
9
9.2
System Backup
Backup by CMOS.BIN
6. Select {CMOS LOAD}.
– The confirmation dialog box appears.
7. Select {YES}.
– The loaded CMOS.BIN file contents are reflected in the data inside
the robot,
CAUTION
When the {CMOS LOAD} is performed, the current CMOS data is
replaced with the CMOS data (the contents of "CMOS.BIN") in the
CompactFlash. Therefore, before performing the load, make sure to
perform the {CMOS SAVE} of the CMOS data to be loaded.
9-6
9
9.3
DX100
9.3
9.3.1
9.3.1.1
System Backup
Automatic Backup Function
Automatic Backup Function
Automatic Backup Function
Objective
With the automatic backup function, the data saved in the DX100 such as
system setting or operational condition are collectively backed up in the
CompactFlash which is inserted in the programming pendant.
In case of an unexpected trouble such as data loss, the backup data
saved in the CompactFlash by the automatic backup function can be
loaded to the DX100 memory to restore the file data.
NOTE
9.3.1.2
The automatic backup function is enabled only while the
DX100 power supply is ON whereas it isn’t while in the
maintenance mode or the power supply is OFF.
Outline
The automatic backup function saves the internally stored data in a single
file in advance for the smooth restoration from unexpected troubles of the
DX100.
The teaching operation is one of the factors that changes the internally
stored data. Thus, a mode which backs up the latest data after the
teaching operation is prepared. To confirm the termination of the teaching
operation, check the mode key whether it is changed from teach mode to
play mode.
Other than the teaching operation, the present position of the robot or the
value of a variable can be pointed out as the factors to change the
internally stored data. These data, however, are changed after each
operation and have very little need to be retained permanently.
Accordingly, backing up these data at regular interval should be well
enough to operate and the mode to back up the data at regular interval is
also prepared.
Furthermore, the mode to back up the data when starting up the DX100
and when inputting signals are also available for some specific versions.
With the automatic backup function, all the part where the internal data is
stored in the physical memory area is collectively saved. If there is any
data which is in the middle of changing while executing the automatic
backup function, the data might not be usable for restoration because of
its inconsistency. Therefore, the function is terminated with an error
during the play back operation or while the manipulator is in motion so that
the automatic backup cannot be operated. Set the automatic backup
function to be executed while the manipulator is not in the playback status
and while the manipulator is stopped.
9-7
DX100
9
9.3
System Backup
Automatic Backup Function
The automatic backup function has the following functions and features.
No
Function/Feature
Explanation
1
Cyclic backup
In the teach mode, the data in
memory is backed up in a specified
cycle from a specified starting time.
This function backs up as much of
the latest data as possible during
editing. The backup data saved in
the CompactFlash can be loaded to
the DX100 in case of data loss so
that the damage can be minimized.
2
Backup when switching modes
When switching the mode from the
teach mode to the play mode, the
data in memory is backed up.
The editing data is backed up when
editing is completed. The latest
data is automatically backed up with
this mode.
3
Backup when start-up
When the DX100 is start-up, the data
in memory is backed up.
When the DX 100 starts up, the
data in memory is backed up. Since
the editing/playback operation is
usually completed when the DX100
power is turned OFF, the latest data
is automatically backed up with this
mode.
4
Backup when inputting specified
signals
The data in memory is backed up
when a specified signal(#40560) is
input.
The data in memory is backed up by
the signal from the host at the
intended timing. Although the
above mentioned items 1 to 3 are
designed to back up the data
automatically, this function backs up
the data in accordance with the
instruction from the host.
5
Backs up the variables for essential
Backup while robot program is
stopped
data.
The backup during playback is
disabled. However, in the play mode,
the backup is enabled if the robot is
stopped. ("Cyclic backup" and
"Backup when inputting specified
signals")
6
Backup and retry at low priority
The data in memory is backed up at
low priority so that this operation
does not affect the other operations.
When other operations affect the
backup operation, the backup is
suspended and retried later.
The backup operation hardly affects
the other operations so that the
programming pendant can be used
even during the backup operation.
7
Backup in binary
The data is saved as binary data.
The range is same as that of the
"ALL CMOS AREA" in {FD/CF}, but
the data type is different.
Backup in binary allows the system
to be easily and speedily restored.
8
Setting of items
Parameters can limit the settings of
the backup condition.
Unnecessary settings can be
avoided with this setting.
9-8
9
9.3
DX100
9.3.2
System Backup
Automatic Backup Function
Settings for Automatic Backup
To set the automatic backup function, insert a CompactFlash in the
CompactFlash slot on the programming pendant, then set each item on
the AUTO BACKUP SET display.
NOTE
Four ways to perform the automatic backup are available:
"Cyclic backup", "Backup when switching modes", "Backup
when start-up", and "Backup when inputting specified signals".
The automatic backup can be performed only when the
robot is not during playback and the robot is stopped.
9.3.2.1
CompactFlash
To use the automatic backup function, insert CompactFlash in the
CompactFlash slot on the programming pendant. Only while the DX100
power supply is OFF, the CompactFlash can be inserted or removed.
When the data could not be saved in CompactFlash during an automatic
backup due to the absence or insufficient capacity of the CompactFlash,
an error message “Cannot backup CompactFlash” appears. At the same
time, the signal “occurrence of error” is output, but the robot program will
not be stopped. Check if CompactFlash is inserted and if it has enough
capacity, and take the necessary actions. If no actions are taken while the
error occurs, the data cannot be saved.
Yaskawa recommends that the data be saved in two or more
CompactFlash to minimize problems if the CompactFlash should be
damaged.
The products in the table below are recommended as Compact Flash for
auto backup.
<Currently recommended products>
No.
Manufacturer
Model
Remarks
1
Hagiwara Sys-Com
MCF10P-256MS
(IOOAII-YE2)
256MB
2
SiliconSystems, Inc.
SSD-C25M-3512
256MB
Storage capacities needed for CompactFlash are as follows:
When using JANCD-YIF01-1E, JANCD-YIF01-1EV:
(The number of stored files + 1) X 17.8MByte
When using JANCD-YIF01-2E, JANCD-YIF01-2EV, JANCD-YIF01-3E,
JANCD-IF01-3EV:
(The number of stored files + 1) X 20.8MByte
The number of storable files is automatically calculated and the MAX
value is shown when AUTO BACKUP SET display appears.
9-9
DX100
9.3.2.2
9
9.3
System Backup
Automatic Backup Function
AUTO BACKUP SET Display
Settings
Select the following items on the AUTO BACKUP SET display and set
values for the automatic backup.
• RESERVE TIME BACKUP (VALID/INVALID of the cyclic backup)
• BASE TIME
• BACKUP CYCLE
• RETRY CYCLE
• MODE CHANGE BACKUP (VALID/INVALID of the backup when
switching the mode from teach mode to play mode)
• STARTUP AUTO BACKUP (VALID/INVALID of the backup when the
DX 100 is started up)
• SPECIFIC INPUT BACKUP (VALID/INVALID of the backup when
inputting specified signals)
• UNIV.OUT NO. ON ERROR
• DISPLAY AT EMERGENCY
• DURING ALARM OCCURENCE
• STORED FILE SETTING
NOTE
With the version in which "STORED FILE SETTING" is settable, the capacity of a CompactFlash card inserted in the
programming pendant is checked when the setting window
appears. Therefore, a few seconds may be needed to open
the setting window and an error may occur if no CompactFlash is inserted.
When changing the settings of "STORED FILE SETTING"
or executing "ARRANGE", the files "CMOSBK.BIN" and
"CMOSBK??.BIN" (?? denotes figures) in the CompactFlash card are changed in name or deleted. If a certain file
of this type is needed to be saved before changed in name
or deleted, evacuate it into a PC, etc. beforehand.
1.
Turn ON the DX100.
– If the auto backup function is already set valid, insert a
CompactFlash.
2. Insert a CompactFlash in the CompactFlash slot on the programming
pendant.
3. Change the security mode to the management mode.
4. Select {SETUP} under the main menu.
9-10
DX100
9
9.3
System Backup
Automatic Backup Function
5. Select {AUTO BACKUP SET}.
– The AUTO BACKUP SET display appears.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
A. RESERVE TIME BACKUP
Set the backup function to valid or invalid in a specified cycle from a
specified starting time.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
The reserve time can be set by inputting values in B,C and D in the display.
Every time values are set to these three items, reset the RESERVE
TIME BACKUP to VALID.
If these settings are incorrect, the RESERVE TIME BACKUP cannot be
reset to VALID.
If so, check and then change the values to the correct settings.
B. BASE TIME
Specify the reference time to start reserve time backup.
The time elapsed from the reference time for a BACKUP CYCLE period
is recognized as the BACKUP TIME.
The first automatic backup is performed at the first BACKUP TIME after
the power of the DX 100 is turned ON.
The automatic backup after the first time, is performed at the interval of
BACKUP CYCLES.
The reference time ranges from 0:00 to 23:59.
C. BACKUP CYCLE
Specify the length of time for a cycle to back up. After the first
backup, the next backup is performed automatically in the time specified
in the BACKUP CYCLE.
Set the backup cycle in units of minutes. The cycle setting ranges from
10 to 9999 minutes, and is longer than the RETRY CYCLE.
D. RETRY CYCLE
Specify the length of time for a cycle to retry backing up when the
backup operation is suspended.
After being suspended, the backup is retried in the time specified in the
RETRY CYCLE.
Set the retry cycle in units of minutes. The cycle setting ranges from 0
9-11
DX100
9
9.3
System Backup
Automatic Backup Function
to 255, and is shorter than the BACKUP CYCLE.
When it is set to 0, retry will not be performed.
E. MODE CHANGE BACKUP
Set the automatic backup function to be valid or invalid when the mode
is switched from teach mode to play mode.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
F. STARTUP AUTO BACKUP
Set the backup function to be valid or invalid when the power of the DX
100 is turned ON.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
G. SPECIFIC INPUT BACKUP
Set the backup function to be valid or invalid when specific input signal
(# 40560) is input (rising edge from 0 to 1).
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
H. UNIV.OUT NO. ON ERROR
Set "1" to the specified user output signal which was specified in this
chapter when the automatic backup error occurs.
The term "automatic backup error" here means that the backup is not
performed successfully before the next backup (including retry operation) starts.
I. DISPLAY AT EMERGENCY
Set the method of notification of the automatic backup error to
"ERROR" or "MESSAGE."
Each time [SELECT] is pressed, "ERROR" and "MESSAGE" are displayed alternately.
J. DURING ALARM OCCURENCE
Set the backup function to be valid or invalid when an alarm is
occurred.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
K. STORED FILE SETTING
Set the number of files to be stored by the automatic backup function.
The number mentioned on the right side of this item with "(Max)" indication is the maximum number of files that can be stored in the CompactFlash inserted when this window is displayed.
The settings range from 1 to (Max). When this setting value is changed,
the backup file arrangement starts.
L. BACKUP FILES
Indicates the existence of the files or the number of backup files stored
in the CompactFlash inserted when this window is displayed.
M. LATEST BACKUP FILE
Indicates the date of the latest file in the CompactFlash inserted when
this window is displayed.
9-12
DX100
9
9.3
System Backup
Automatic Backup Function
N. ARRANGE
When the setting of maximum number of stored files is changed, the file
arrangement of the backup files in the CompactFlash is executed.
With this operation, the file arrangement can be performed without
changing the maximum number of stored files.
6. Set the desired item, and press [ENTER].
Window Settings
RS parameter can restrict the settings of some items in the automatic
backup window.
When setting the bit of RS096 parameter shown below to "1", the
corresponding items are restricted. The restricted items are indicated with
"INVALID" in the display and inputting/modification to the item becomes
impossible. Also, the automatic backup does not function with the
restricted items.
9.3.2.3
DX100 Status and Automatic Backup
Backup
Timing
DX100 Status
From a
specified
starting time
Teach mode
Play mode
Remote mode
9-13
Automatic Backup
Editing
(Accessing to
the memory)
Compact
Flash
ready to
save the
data
Absence or
insufficient
capacity of the
CompactFlash
Retry
Retry
When editing is Backup
interrupted
Error
Executing jobs
Disabled
Disabled
When stopped
Backup
Error
DX100
9
9.3
System Backup
Automatic Backup Function
When a
specified
signal(#40560)
is input
Teach mode
Play mode
Remote mode
Editing
(Accessing to
the memory)
Error
Error
When editing is Backup
interrupted
Error
Executing jobs
Disabled
Disabled
When stopped
Backup
Error
When
switching the
mode from the
teach mode to
the play mode
-
Backup
Error
When the
DX100 starts
up
-
Backup
Error
* Retry is not performed when an error occurs.
* An error can be indicated by a message depending on setting.
Reserve Time Backup
While the data in the DX100 memory is being edited or overwritten, the
automatic backup is not performed at the specified backup starting time
and is suspended and retried later. To start the backup at the reserved
time, set to the time when the robot program is stopped and no job or file
is edited.
Backup when Switching from Teach Mode to Play Mode
When the mode is repeatedly switched from the teach mode to the play
mode or vice versa within 1 to 2 seconds, backup starts after the last time
the mode is switched.
Backup when the DX 100 starts up
Since the automatic backup process is added to the DX100 start-up
process, a few extra seconds are needed to start up the DX100.
Backup when Specific Signal is Input
While the DX100 memory is edited such as overwriting, the backup
operation becomes an error even if there is an input to a specific signal
(#40560). To start the specific input backup, perform it while the robot
program is stopped and a job or file is not being modified.
Also, since the signal input is executed at rising detection, turn the signal
to "0" if it is already "1", then return to "1" again.
Overwriting Limit in CompactFlash
The number of times that the CompactFlash can be overwritten is limited
to approx. 100,000 times. Because frequent backup operations may
shorten the life of CompactFlash, the number of backup times should be
minimized as much as possible.
9-14
9
9.3
DX100
9.3.2.4
System Backup
Automatic Backup Function
Setting Examples
Setting Example 1
The following diagram shows a setting example with the following
conditions:
BASE TIME: 12:30
BACKUP CYCLE: 60 (minutes)
RETRY CYCLE: 10 (minutes)
BASE TIME
Power ON
BACKUP CYCLE
RETRY CYCLE
11:00
1st day
11:30 11:40
1st day
11:50
Backup
12:30
1st day
13:30
1st day
Backup
Backup
Setting Example 2
The following diagram shows a setting example with the following
conditions:
BASE TIME: 20:00
BACKUP CYCLE: 1440 (minutes) (24 hours)
RETRY CYCLE: 60 (minutes)
Power ON
BASE TIME
BACKUP CYCLE
RETRY CYCLE
8:00
1st day
20:00 21:00
1st day
22:00
Backup
NOTE
20:00
2nd day
20:00
3rd day
Backup
Backup
While a job is being executed, the automatic backup or retry
is not performed. Also, after an error occurs in writing into
the CompactFlash, the retry is not performed until the next
backup starting time.
9-15
9
9.4
DX100
9.4
System Backup
Loading the Backup Data from the CompactFlash
Loading the Backup Data from the CompactFlash
Restore the backup data saved in the CompactFlash to the DX100 in
maintenance mode.
9.4.1
Loading Procedure
1. Insert the CompactFlash with the backup data in the CompactFlash
slot on the programming pendant.
– The backup data is stored under the file name "CMOSBK.BIN" or
"CMOSBK??.BIN" (?? denotes figures.)
2. Turn ON the DX100 power supply while pressing [MAIN MENU].
3. Change the security mode to the management mode.
4. Select {EX. MEMORY} under the main menu.
– The sub menu appears.
5. Select {CompactFlash}.
– The CompactFlash display appears.
9-16
DX100
9
9.4
System Backup
Loading the Backup Data from the CompactFlash
6. Select {SYSTEM RESTORE} in the CompactFlash display.
– The Backup File list display appears.
7. Select the file to be loaded.
– The dialog box appears for the YIF/YCP01 board replacement
confirmation.
– Select {YES} if the YIF/YCP01 board has been replaced, or select
{NO} if it has not been replaced.
– Selecting {YES} initializes the system monitoring time.
Selecting {NO} continues the counting of the current system’s
monitoring time.
9-17
DX100
9
9.4
System Backup
Loading the Backup Data from the CompactFlash
8. Select {YES} or {NO} for the message "Exchanged YIF/YCP01
board?"
– The dialog box appears for the loading confirmation.
– Select {YES} in the loading confirmation dialog box to start loading
the contents of "CMOSBK.BIN" or "CMOSBK??.BIN" (?? denotes
figures) from the CompactFlash to the DX100 CMOS.
9. Select {YES}.
CAUTION
Note that executing "SYSTEM RESTORE" replaces the current CMOS
data with the data of the file "CMOSBK.BIN" or "CMOSBK??.BIN" (??
denotes figures) in the CompactFlash.
After "CMOSBK.BIN" has been loaded, check if the new data is the
same as the previously saved data in the CMOS, and call the master
job to confirm that the current manipulator position is correct and safe.
Then, start moving the manipulator.
9-18
9
9.5
DX100
9.5
9.5.1
System Backup
Error List
Error List
Error Contents
Error
Data
Message
Cause
*
The robot or the station is in
motion.
The automatic backup would not
work when the robot or a
manipulator is in motion.
File not found
The file to be loaded no longer
exists.
No.
0770
3390
3460
*
Cannot backup CompactFlash
1
Insufficient capacity of the
CompactFlash
2
Cannot access the
CompactFlash
3501
*
Confirm the status of
CompactFlash.
Cannot access the
CompactFlash
3550
*
The automatic backup is
executed. Try it later.
The automatic backup window
cannot be called to display while
the automatic backup is being
processed.
3551
*
The automatic backup is
executed. Arrange the file after
it is finished.
The file arrangement cannot be
operated during the automatic
backup operation.
3560
*
Failed to re-arrange the
backup file.
Failed to re-arrange the backup
file for another reason than the
access to CompactFlash.
3580
*
Accessing to backup file. Try it
later.
To display another window and
then display the automatic
backup window again after
"ARRANGE" operation,
“ARRANGE” process should be
completely finished.
3581
*
Accessing to backup file. Try
"ARRANGE"operation later.
The previous "ARRANGE"
process should be completely
finished to perform the next
"ARRANGE" operation.
9-19
10
Upgrade Function
10.1 Functional Overview
DX100
10 Upgrade Function
10.1
Functional Overview
DX100 applies two software for the CPU configuration: a software for
YCP01 (for the main CPU board) and a software for YPP01 (for
programming pendant). The system works only with the combination of
certain versions due to a compatibility problem of each software.
Therefore, with the system version NS3.00 and the subsequent versions,
DX100 can upgrade the software for YPP01 if the combination of the
software for YCP01 and YPP01 is invalid.
10.2
10.2.1
Upgrade Procedure
Confirmation of Software Version
The compatibility of the versions of YCP01 and YPP01 are automatically
checked in 20 seconds after the DX100 power supply is turned on.
• In case the versions of YCP01 and YPP01 matches.
1. Automatic upgrade process completes and the communication
process between YCP01 and YPP01is restarted.
10-1
DX100
10
Upgrade Function
10.2 Upgrade Procedure
2. Initial window appears approx. 40 seconds later.
10.2.2
Automatic Upgrade of YPP01
In case that the pendant application version of YPP01 is older than the
one of YCP01 or the pendant application version of YPP01 is not
compatible to the one of YCP01, the YPP01 is automatically upgraded.
Not only the application software but the OS of the Programming Pendant
is also upgraded automatically.
(OS: Operating System)
1. Automatic upgrade process completes and the communication
process between YCP01 and YPP01is restarted.
– Some upgraded software require restart.
In this case restart is done automatically and the communication
process between YPP01 and YCP01 starts again.
2. Initial window appears approx. 40 seconds later.
NOTE
Every time the OS is upgraded automatically, restart is
done. There is no need of calibrating, for the calibration
data is taken over.
10-2
DX100
10
Upgrade Function
10.2 Upgrade Procedure
DO NOT turn off the main power supply during automatic
upgrade process.
In case the main power supply is turned off, exercise the
following process.
•
Turn on the main power supply of DX100.
– Automatic upgrade might be exercised again.
•
In case error occurs during automatic upgrade process.
(1) Prepare CF for upgrading or USB memory.
NOTE
(2) Press [2], [8] and [HIGH SPEED] at the same time.
-Upgrade of the OS of Programming Pendant
(3) Press [INTERLOCK], [8] and [SELECT] at the same
time.
(4) Exercise manual upgrading.
- Refer to “DX100 Upgrade Procedure”
(HW0485193).
•
If no recovery is made with all the procedure above,
replace the pendant.
10-3
10
Upgrade Function
10.3 Error Message
DX100
10.3
Error Message
If Error occurs while automatic upgrading, exercise the following
procedure.
•
Turn on the main power supply of DX100.
– Automatic upgrade might be exercised again.
•
In case error occurs during automatic upgrade process.
(1) Prepare CF for upgrading or USB memory.
(2) Press [2], [8] and [HIGH SPEED] at the same time.
-Upgrade of the OS of Programming Pendant
(3) Press [INTERLOCK], [8] and [SELECT] at the same time.
(4) Exercise manual upgrading.
-Refer to “DX100 Upgrade Procedure” (HW0485193) for detail.
10-4
11
Manual Brake Release Function
11.1 Operating Conditions of Manual Brake Release
DX100
11 Manual Brake Release Function
The manual brake release function allows forcible release of each motor
brakes of the manipulator and external axes by programming pendant
operation.
The following operating conditions have to be met before performing the
manual brake release function since this function releases brakes by
software, which is different from the conventional brake release by
hardware.
The manual brake release is an optional function set by parameter.
11.1
Operating Conditions of Manual Brake Release
1. DX100 Status
The DX100 has to be launched correctly*1.
2. Mode: Mode switch on the programming pendant
The function can be used in all modes: Remote / Play / Teach.
3. Security Mode
The function can be used in all modes: Operation / Editing /
Management.
4. Others
• Servo power is OFF
• Emergency stop is OFF (programming pendant, DX100, external
signals)
• Power supply unit circuit board is JANCD-YBK01-2E
If the circuit board JANCD-YBK01-1E is used for any of the axes
in the control group of manipulator, base, or station, the manual
brake release function is not available for the group with an axis
using JANCD-YBK01-1E.
11-1
DX100
11
Manual Brake Release Function
11.1 Operating Conditions of Manual Brake Release
*1 Basically, the manual brake release function is available even at alarm
occurrence.
However, the manual brake release function cannot be used if the
communication failure between each boards (YCP01, EAXA01, YIF01,
YSU01) occurs due to board failure, etc.
<Example>
The manual brake release cannot be performed at occurrence of the
alarm 1204 as shown in the following window, since the communication with the board YIF01 becomes unavailable.
In this case, reset IO modules in Maintenance mode, i.e. separate the
board, then perform the manual brake release.
Fig. 11-1: Alarm Window
If the power supply unit circuit board is JANCD-YBK01-1E and
[MANUAL BRAKE RELEASE] menu is selected, the message
"No axis for Manual Brake Release" is displayed as shown below.
Fig. 11-2: Brake Release Window
11-2
11
Manual Brake Release Function
11.2 Manual Brake Release Operation
DX100
11.2
Manual Brake Release Operation
1. Select [ROBOT] under the main menu, then select [MANUAL BRAKE
RELEASE] under the submenu.
– [MANUAL BRAKE RELEASE] is shown under the submenu of the
main menu [ROBOT].
2. Select "YES".
– To avoid careless operation mistake, a warning message appears
when [MANUAL BRAKE RELEASE] menu is selected.
– Select "YES" to display [MANUAL BRAKE RELEASE] window.
– Select "NO" to return to the main menu.
11-3
DX100
11
Manual Brake Release Function
11.2 Manual Brake Release Operation
3. Move a cursor to the axis of which the brake is to be released.
– The brake is released by following the operation: Move a cursor to
the axis of which the brake is to be released and press
[INTERLOCK] + [SELECT] while gripping Enable switch. Then the
brake status is shown.
– The brake is locked under one of the following conditions:
• When [SELECT] is released.
Also, see the following
CAUTION
• When the emergency stop button on the programming pendant,
DX100 or external device is pressed.
• When Enable switch is released or gripped further.
• When the window is switched from the Manual Brake Release window to another window.
Fig. 11-3: Manual Brake Release Window
Brake Status:
: Brake locked
: Brake released
4. Press [INTERLOCK] + [SELECT] while gripping Enable switch.
CAUTION
•
Brake can be released by pressing [INTERLOCK] + [SELECT] while
gripping Enable switch.
Note that the brake remains released even though [INTERLOCK] is
released at this time.
11-4
11
Manual Brake Release Function
11.3 Warning Message Display
DX100
11.3
Warning Message Display
If the manual brake release is performed under the following conditions,
the warning message appears in the message area bottom right of the
window as shown in fig. 11-2 “Brake Release Window” at page 11-2.
In this case, the brake release cannot be performed.
• Servo power is turned ON.
• Emergency stop button on the programming pendant is pressed.
• Emergency stop button on DX100 is pressed.
• External emergency stop signal is input.
11-5
12
Modification of System Configuration
12.1 Addition of I/O Modules
DX100
12 Modification of System Configuration
12.1
Addition of I/O Modules
To add I/O modules, turn OFF the power supply.
SUPPLE
-MENT
Addition operation must be performed in the management
mode.
In the operation mode or editing mode, only reference of status setting is possible.
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the "SECURITY MODE" to the "MANAGEMENT MODE".
3. Select {SYSTEM} under the main menu.
– The system window appears.
4. Select {SETUP}.
– The SETUP window appears.
– The items marked with " " cannot be selected.
12-1
DX100
12
Modification of System Configuration
12.1 Addition of I/O Modules
5. Select {IO MODULE}.
– The current status of the mounted I/O module is shown.
6. Confirm the status of mounted I/O module.
– Confirm that each station (ST#) window is the same as the I/O
module’s actual mounting status.
– The following information is shown for each station.
ST#
Station address of I/O module
DI
Number of contact input points1)
DO
Number of contact output points1)
AI
Number of analog input points1)
AO
Number of analog output points1)
BOARD
Circuit board type2)
1) A hyphen, -, indicates that the corresponding I/O section is not mounted.
2) If the system cannot recognize the circuit board type, a row of stars
(*****) are shown. No problem will occur as long as the values
displayed in DI, DO, AI, and AO are correct.
7. Press [ENTER].
– Confirm the statuses of the mounted I/O modules for the other
stations.
12-2
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
DX100
8. Press [ENTER].
– The confirmation dialog box is shown.
9. Select {YES}.
– The system parameters are then set automatically according to the
current mounted hardware status. The procedure for the addition of
the I/O module is complete.
NOTE
12.2
If there is a difference between the displayed contents and
the actual mounted status, confirm the status again. If the
status is correct, the I/O module may be defective: in such a
case, contact your Yaskawa representative.
Addition of Base and Station Axes
To add the base and station axes, mount all hardware correctly and then
execute maintenance mode.
SUPPLE
-MENT
Addition operation must be performed in the management
mode.
In the operation mode or editing mode, only reference of status setting is possible.
When adding a base and a station axis, set the following items:
•
TYPE
Select one in the type list.
• In case of base axis (B1,B2,B3...B8)
Select one of RECT-X, -Y, -Z, -XY, -XZ, -YZ or -XYZ.
• In case of station axis (S1,S2,S3,S4,S5... S24)
Select UNIV-* ("*" represents the number of axes) when using a
mechanism other than the registered type as a station axis.
•
CONNECTION
In the CONNECTION window, specify the SERVOPACK which is
connected with each axis group and the contactor which is used for the
SERVOPACK.
12-3
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
•
AXIS TYPE
Select from the axis type list.
• In case of TURN-* type
No need to select (The axis type is set as TURN type.)
• In case of RECT-* type
Select BALL-SCREW type or RACK & PINION type.
• In case of UNIV-* type
Select BALL-SCREW type, RACK & PINION type or TURN type.
•
MECHANICAL SPECIFICATION
• If axis type is ball-screw type, set the following items:
• MOTION RANGE (+)
[mm]
• MOTION RANGE (-)
[mm]
• REDUCTION RATIO (numerator)
• REDUCTION RATIO (denominator)
• BALL-SCREW PITCH
[mm/r]
• If axis type is rack & pinion type, set the following items.
• MOTION RANGE (+)
[mm]
• MOTION RANGE (-)
[mm]
• REDUCTION RATIO (numerator)
• REDUCTION RATIO (denominator)
• PINION DIAMETER
[mm]
• If axis type is turn type, set the following items.
• MOTION RANGE (+)
[deg]
• MOTION RANGE (-)
[deg]
• REDUCTION RATIO (numerator)
• REDUCTION RATIO (denominator)
• OFFSET (1st and 2nd axis)
•
[mm]
MOTOR SPECIFICATION
Set the following items.
• MOTOR
• SERVO AMP
• CONVERTER
• ROTATION DIRECTION
[normal/reverse]
• MAX. RPM
[rpm]
• ACCELERATION SPEED [sec]
• INERTIA RATIO
* Select MOTOR, AMPLIFIER and CONVERTER from each type list on the
display.
12-4
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
DX100
12.2.1
12.2.1.1
Base Axis Setting
Selection of Base Axis Type
Select the type of base axis to be added/modified.
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the "SECURITY MODE" to the "MANAGEMENT MODE".
3. Select {SYSTEM} under the main menu.
– The system window appears.
4. Select {SETUP}.
– The SETUP window appears.
– Note that the items marked with " " cannot be set.
5. Select {CONTROL GROUP}.
12-5
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
– The current control group type is displayed.
6. Point the cursor to the type of control group to be modified, and press
[SELECT].
– The MACHINE LIST window is displayed.
RECT-X: traverse X-axis base
RECT-Y: traverse Y-axis base
RECT-Z: traverse Z-axis base
RECT-XZ: traverse XZ-axis base
RECT-XY: traverse XY-axis base
RECT-XYZ: traverse XYZ-axis base
(See the figures on the next page)
7. Select one in the type list.
– After the type selection, the window returns to the CONTROL
GROUP window.
8. Press [ENTER] in CONTROL GROUP window.
– The window moves to the CONNECTION window.
12-6
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
RECT-X
RECT-Y
RECT-Z
CARTESIAN
X-AXIS
CARTESIAN
Y-AXIS
CARTESIAN
Z-AXIS
Base axis direction of travel coincides
with robot coordinate X-Axis.
Base axis direction of travel coincides
with robot coordinate Y-Axis.
Base axis direction of travel coincides
with robot coordinate Z-Axis.
RECT-XY
RECT-YZ
RECT-XZ
CARTESIAN
Y-AXIS
CARTESIAN
CARTESIAN X-AXIS
Y-AXIS
Base 1st and 2nd axes directions of
travel coincide with robot coordinate
X-Axis and Y-Axis, respecitively.
CARTESIAN
Z-AXIS
Base 1st and 2nd axes directions of
travel coincide with robot coordinate
Y-Axis and Z-Axis, respectively.
RECT-XYZ
CARTESIAN
Y-AXIS
CARTESIAN
Z-AXIS
CARTESIAN
X-AXIS
Base 1st, 2nd, and 3rd axes directions
of travel coincide with robot coordinate
X-Axis, Y-Axis, and Z-Axis, respectively.
12-7
CARTESIAN
CARTESIAN X-AXIS
Z-AXIS
Base 1st and 2nd axes directions of
travel coincide with robot coordinate
X-Axis and Z-Axis,respectively.
DX100
12.2.1.2
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
Connection Setting
In the CONNECT window, each axis in respective control groups is
specified to be connected to which connector of the SERVO board, or to
which brake of the contactor unit, or to which converter.
1. Confirm type of each control group in the CONNECTION window.
– The connection status of each control group is displayed.
the control group which
is set "NONE" in the
CONTROLGROUPE
window is not displayed.
2. Select the connection item of desired control group.
– The settable items are displayed.
– When the item is selected, the window returns to the CONNECTION
window.
– It is possible to change the connection freely between each axis
of each control group and each connector (CN) of a SERVO
board. The number in [ ] represents the axis number, and it
indicates which axis is to be connected with which connector.
– It is possible to change the connection freely between each axis
of each control group and each brake (BRK) of a contactor unit.
The number in [ ] represents the axis number, and it indicates
which axis is to be connected with which brake.
– It is possible to change the connection freely between each axis
of each control group and each converter (CV). The number in
[ ] represents the converter number, and it indicates which axis is
to be connected with which converter.
12-8
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
– In this example, B1 (Base) is to be connected as shown in the
following manner:
1st axis
SERVO Board (SV #2),
Connector (7CN),
Contactor Unit (TU #1),
Brake Connector (BRK7),
Converter (CV #1)
2nd
axis
SERVO Board (SV #2),
Connector (8CN)
Contactor Unit (TU #1),
Brake Connector (BRK8)
Converter (CV #2)
3rd
axis
SERVO Board (SV #2),
Connector (9CN)
Contactor Unit (TU #1),
Brake Connector (BRK9)
Converter (CV #3)
3. Select the desired item.
4. Press [ENTER] in the CONNECTION window.
– The setting in the CONNECTION window is completed and the
window moves to the AXES CONFIG window.
12.2.1.3
Axis Configuration Setting
The axis type is specified in the AXES CONFIG window.
1. Confirm axis type of each axis in the AXES CONFIG window.
– The axis type of each axis is displayed.
2. Select the axis type to be modified.
12-9
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
(1) The settable axis type is displayed.
(2) Select "BALL-SCREW" when the servo track is ball-screw type,
and "RACK&PINION" when the servo track is rack & pinion type.
After the selection, the window returns to the AXES CONFIG window.
(3) Select the axis type.
3. Press [ENTER] in the AXES CONFIG window.
4. The setting in the AXES CONFIG window is completed and the
window moves to the MECHANICAL SPEC window.
12.2.1.4
Mechanical Specification Setting
The mechanical data is specified in the MECHANICAL SPEC window.
1. Confirm specification of each axis in the MECHANICAL SPEC window.
– The mechanical specification of axis is shown.
The MECHANICAL SPEC window (in case of the BALL-SCREW type)
Selected group, type, axis no.
and axis type are shown.
– MOTION RANGE
12-10
: Input maximum moving position (positive (+)
direction and negative (-) direction) from
home position when setting the home
position to 0. (Unit: mm)
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
– REDUCTION RATIO : Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/2, the
numerator should be set as 1.0 and the
denominator should be set as 2.0.
– BALL-SCREW PITCH: Input the traveling length when the ballscrew rotates once. (Unit: mm/r)
The MECHANICAL SPEC window (in case of the RACK&PINION type)
Selected group, type, axis no.
and axis type are shown.
– MOTION RANGE
: Input maximum moving position (positive (+)
direction and negative (-) direction) from
home position when setting the home position
to 0. (Unit: mm)
– REDUCTION RATIO: Input the numerator and the denominator.
<e.g.>If the reduction ratio is 1/120, the
numerator should be set as 1.0 and the
denominator should be set as 120.0.
– PINION DIAMETER : Input the diameter of a pinion. (Unit: mm)
2. Select the item to be modified.
– Point the cursor to the item subject for setting value modification,
and press [SELECT].
3. Modify the settings.
– The selected item is in the input status.
Input the setting value, and press [ENTER].
4. Press [ENTER] in the MECHANICAL SPEC window.
– After the setting, the current window moves to the window for the
next axis setting. Complete the settings for all axes in the same
manner.
– When [ENTER] is pressed in the MECHANICAL SPEC window for
the last axis, the setting in the MECHANICAL SPEC window is
completed and the window moves to the MOTOR SPEC window.
12-11
DX100
12.2.1.5
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
Motor Specification Setting
The motor data is specified in the MOTOR SPEC window.
1. Confirm specification of each axis in the MOTOR SPEC window.
– The motor specification of each axis is displayed.
2. Select the desired item.
– When a numerical value is selected, the number input buffer line
appears.
– When MOTOR (or SERVO AMP or CONVERTER) is selected, the
list window of MOTOR (SERVO AMP, or CONVERTER) appears.
– ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The counterclockwise view from the
loaded side is the normal rotation.)
Fig. 12-1: AC Servo Motor
Normal direction
– MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)
– ACCELARATION TIME: Input time between 0.01 and 1.00 to reach
maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
– INERTIA RATIO: The initial value is set at 300 in case of servo track;
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with
the followed procedure.
– <Phenomenon1>
During motion, the axis moves unsteady on advance direction.
Confirm the motion with increasing this ratio in each 100.
12-12
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
– <Phenomenon2>
During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
3. Modify the settings.
4. Press [ENTER] in the MOTOR SPEC window.
– After the setting, the current window moves to the window for the
next axis setting. Complete the settings for all axes in the same
manner.
– When [ENTER] is pressed in the MOTOR SPEC window for the last
axis, the setting in the MOTOR SPEC window is completed and the
confirmation dialog box appears.
– If {YES} is selected, the system parameter is set automatically.
12.2.2
12.2.2.1
Station Axis Setting
Selection of Station Axis Type
Select the type of station axis to be added/modified.
1. Confirm the type of control group in CONTROL GROUP window.
– The CONTROL GROUP window appears.
2. Select the type of control group to be modified.
12-13
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
– The MACHINE LIST window appears.
TURN-1: TURN 1 AXIS STATION
TURN-2: TURN 2 AXIS STATION
UNIV-1: UNIVERSAL 1 AXIS STATIO
UNIV-2: UNIVERSAL 2 AXIS STATIO
...
3. Select desired type in the type list.
– After the type selection, the window returns to CONTROL GROUP
window.
– Select "UNIV" (universal) when using a mechanism other than the
registered type (such as a servo track) as a station axis. When
“UNIV” is selected, interpolation motion (linear, circular, etc.) is not
supported.
TURN-1
STATION 1ST AXIS
12.2.2.2
Connection Setting
In the CONNECTION window, each axis in respective control group is
specified to be connected to which connector of the SERVO board, or to
which brake of the contactor unit, or to which converter.
1. Confirm type of each control group in the CONNECTION window.
12-14
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
– Connection status of each control group is displayed.
the control group which
is set "NONE" in the
CONTROLGROUP
window is not displayed.
2. Select the connection item of desired control group.
– The settable items are displayed.
– When the item is selected, the window returns to the CONNECTION
window.
– It is possible to change the connection freely between each axis
of each control group and each connector (CN) of a SERVO
board. The number in [ ] represents the axis number, and it
indicates which axis is to be connected with which connector.
– It is possible to change the connection freely between each axis
of each control group and each brake (BRK) of a contactor unit.
The number in [ ] represents the axis number, and it indicates
which axis is to be connected with which brake.
– It is possible to change the connection freely between each axis
of each control group and each converter (CV). The number in
[ ] represents the converter number, and it indicates which axis is
to be connected with which converter.
– In this example, S1 (station) is to be connected as shown in the
following manner:
1st axis
SERVO Board (SV #1),
Connector (7CN),
Contactor Unit (TU #1),
Brake Connector (BRK7),
Converter (CV #2)
2nd
axis
SERVO Board (SV #1),
Connector (8CN),
Contactor Unit (TU #1),
Brake Connector (BRK8),
Converter (CV #3)
3. Select the desired item.
4. Press [ENTER] in the CONNECTION window.
– The setting in the CONNECTION window is completed and the
window moves to the AXES CONFIG window.
12-15
DX100
12.2.2.3
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
Axis Configuration Setting
The axis type and motor type are specified in the AXES CONFIG window.
1. Confirm axis type of each axis in the AXES CONFIG window.
– The axis type of each axis is displayed.
The AXES CONFIG window (in case of the TURN type)
when axis type is "ROTATION",
the axis type cannot be changed
The AXES CONFIG window (in case of the UNIVERSAL type)
BALL- SCREW: Traverse axis (ball-screw)
RACK&PINION: Traverse axis (rack&pinion)
ROTATION: Rotation axis
2. Select the axis type to be modified.
– The settable axis type is displayed.
12-16
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
3. Select the desired axis type.
4. Press [ENTER] in the AXES CONFIG window
– The setting in the AXES CONFIG window is completed and the
window moves to the MECHANICAL SPEC window.
12.2.2.4
Mechanical Specification Setting
The mechanical data is specified in the MECHANICAL SPEC window.
1. Confirm specification of each axis in the MECHANICAL SPEC window.
– The mechanical specification of axis is shown.
Selected group, type, axis no.
and axis type are shown
OFFSET is displayed on
the screen of the 1st axis
only when the TURN-2 type
is selected.
– MOTION RANGE
: Input maximum moving position (positive (+)
direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: deg)
– REDUCTION RATIO: Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/120, the
numerator should be set as 1.0 and the
denominator should be set as 120.0.
– OFFSET
: Offset should be specified at “TURN-2” type
only.
Input length between the center of bending
12-17
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
axis (1st axis) and the turning table (2nd axis).
(Unit: mm)
TURN-2
STATION 2ND AXIS
(ROTATION TABLE)
OFFSET
STATION 1ST AXIS
(INCLINATION AXIS)
The MECHANICAL SPEC window (In case of the BALL-SCREW type)
Selected group, type, axis no.
and axis type are shown.
– MOTION RANGE
: Input maximum moving position (positive (+)
direction and negative (-) direction) from
home position when setting the home
position to 0. (Unit: mm)
– REDUCTION RATIO : Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/2, the
numerator should be set as 1.0 and the
denominator should be set as 2.0.
– BALL-SCREW PITCH: Input the traveling length when the ballscrew rotates once. (Unit: mm/r)
12-18
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
The MECHANICAL SPEC window (In case of the RACK&PINION type)
Selected group, type, axis no.
and axis type are shown.
– MOTION RANGE
: Input maximum moving position (positive (+)
direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: mm)
– REDUCTION RATIO: Input the numerator and the denominator.
<e.g.>If the reduction ratio is 1/120, the
numerator should be set as 1.0 and the
denominator should be set as 120.0.
– PINION DIAMETER : Input the diameter of a pinion. (Unit: mm)
The MECHANICAL SPEC window (In case of the ROTATION type)
Selected group, type, axis no.
and axis type are shown.
– MOTION RANGE: Input maximum moving position (positive (+)
direction and negative (-) direction) from home position when setting
the home position to 0. (Unit: deg)
– REDUCTION RATIO: Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/120, the numerator should be set as
1.0 and the denominator should be set as 120.0.
2. Modify the settings.
3. Press [ENTER] in the MECHANICAL SPEC window.
– After the setting, the current window moves to the window for the
next axis setting. Complete the settings for all axes in the same
manner.When [ENTER] is pressed in the MECHANICAL SPEC
12-19
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
window for the last axis, the setting in the MECHANICAL SPEC
window is completed and the window moves to the MOTOR SPEC
window.
12.2.2.5
Motor Specification Setting
The motor data is specified in the MOTOR SPEC window.
1. Confirm specification of each axis in the MOTOR SPEC window.
– The motor specification of each axis is displayed.
Selected group,
type, axis no. and
axis type are shown.
2. Select desired item.
– When a numerical value is selected, the number input buffer line
appears.
When MOTOR (or SERVO AMP or CONVERTER) is selected, the
list window of MOTOR (SERVO AMP or CONVERTER) appears.
– When the type is selected, the window returns to the AXES CONFIG
window.
– ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The counterclockwise view from the
loaded side is the normal rotation.)
Fig. 12-2: AC Servo Motor
Normal direction
– MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)
– ACCELARATION TIME: Input time between 0.01 and 1.00 to reach
maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
– INERTIA RATIO: The initial value is set at 300 in case of servo track;
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with
the followed procedure.
12-20
DX100
12
Modification of System Configuration
12.2 Addition of Base and Station Axes
– <Phenomenon1> During motion, the axis moves unsteady on
advance direction.
Confirm the motion with increasing this ratio in each 100.
– <Phenomenon2> During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
3. Modify the settings.
CAUTION
If the control axis configuration is changed by addition of a
base axis or station axis, the internal data of the job file are
also changed so that the job file data should be initialized.
Initialize the job file data with procedure “File Initialize” in this
manual after changing the construction.
When the data, motion range for example, should be changed
after the addition of a base axis or station axis, the change can
be done in the same procedure as shown above.
In that case, the control axis configuration is not changed so
the job file data should not be initialized.
12-21
13
DX100 Specification
DX100
13 DX100 Specification
WARNING
•
When turning ON the power to DX100, be sure that there is no one
within the P-point maximum envelope of the manipulator, and that
you are in a safe place.
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator. Always press the
emergency stop button immediately if there are problems.
•
Always set the teach lock before starting teaching.
•
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.
– Always have an escape plan in mind in case the manipulator
comes toward you unexpectedly.
– Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
•
Before operating the manipulator, check that the SERVO ON lamp
goes out when the emergency stop button on the programming
pendant is pressed.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency. The emergency stop button is
located on the right of the programming pendant.
13-1
13
DX100 Specification
DX100
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 manipulator 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 manipulator,
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injuries or equipment
damage.
13-2
13
DX100 Specification
13.1 Specification List
DX100
13.1
Specification List
Controller Construction
Free-standing, enclosed type
Dimensions
Refer to following
Cooling System
Indirect cooling
Ambient
0°C to + 45°C (During operation)
-10°C to + 60°C (During transit and
storage)
Temperature
Relative Humidity
10% to 90%RH (non-condensing)
Power Supply
3-phase, 240/480/575 VAC(+10% to -15%)
at 50/60Hz(±2%) (Built-in transformer tap
switchable)
Built-in transformer 240V-480V-575V/208V
(autotransformer - )
* Switch the built-in transformer tap
according to the supplied voltage on your
side. (480 VAC is set before shipment.)
Without a step-down transformer: 3-phase,
200 VAC (+10% to -15%) at 50/ 60Hz
220 VAC (+10% to -15%) at 60Hz
Grounding
Grounding resistance: 100Ω or less
Exclusive grounding
Digital I/O
Specific signal (hardware)
23 inputs and 5 outputs
General signals (standard, max.)
40 inputs and 40 outputs
(Transistor: 32 outputs, Relay: 8 outputs)
Positioning System
By serial communication
(absolute encoder)
Drive Unit
SERVOPACK for AC servomotors
Acceleration/
Software servo control
Deceleration
Memory Capacity
Common to
small, medium,
and large
capacities
200000 steps, 10000 instructions
MA1400, MA1900, VA1400, MH5, MH5L, MH6, HP20D,
HP20D-6, MH50, MS80, ES165D, ES200D, VS50, SIA50D
800(W) × 1000(H) × 650(D) mm
13-3
13
DX100 Specification
13.2 Function List
DX100
13.2
Function List
Programming Coordinate
Joint, Rectangular/Cylindrical, Tool, User
Coordinates
Pendant
System
Operation
Modification of
Teaching Points
Adding, Deleting, Correcting (Robot axes
and external axes respectively can be
corrected.)
Inching Operation
Possible
Path
Forward/Reverse step, Continuous
feeding
Confirmation
Speed Adjustment Fine adjustment possible during operating
or pausing
Timer Setting
Possible every 0.01 s
Short-cut Function Direct-open function, Multi-window
Safety
Feature
Maintenance
Function
Interface
CF (Compact Flash) card slot, USB port
(USB1.1) (At Programming Pendant)
RS232C (At Control Circuit Board)
LAN (100 BASE-TX/10BASE-T) (At
Control Circuit Board) (Option)
Application
Arc welding, Spot welding, Handling,
General, Others
Essential
Measures
JIS (Japanese Industrial Standard)
Running Speed
Limit
User definable
Enable Switch
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
Possible to display alarm messages for
peripheral device
Machine Lock
Test-run of peripheral devices without
robot motion
Door Interlock
A door can be opened only when a circuit
breaker is OFF.
Operation Time
Display
Control power-on time, Servo power-on
time, Playback time, Operation time, Work
time
Alarm Display
Alarm message, troubleshooting, previous
alarm records
I/O Diagnosis
Simulated enabled/disabled output
possible
T.C.P. Calibration
Automatically calibrates parameters for
end effectors using a master positioner
13-4
13
DX100 Specification
13.3 Programming Pendant
DX100
Programing
Functions
Programming
Interactive programming
Language
Robot language: INFORM II
Robot Motion
Control
Joint coordinates, Linear/Circular
interpolations, Tool coordinates
Speed Setting
Percentage for joint coordinates, 0.1mm/s
units for interpolations, Angular velocity
for T.C.P. fixed motion
Program Control
Jumps, Calls, Timer, Robot stop,
Execution of some instructions during
manipulator motion
Instructions
13.3
Operation
Instructions
Preparing the operation instructions for
each application Arc (ON), Arc (OFF), etc.
Variable
Global variable, Local variable
Variable Type
Byte type, Integer-type, Double precisiontype, Real type, Position type
I/O Instructions
Discrete I/O, Pattern I/O processing
Programming Pendant
Material
Reinforced thermoplastic enclosure with a detachable
suspending strap
Dimensions
169(W) × 314.5(H) × 50(D) mm (excluding protrusions)
Displayed Units
TFT Color liquid crystal display, VGA (640 × 480)
Touch panel
Operated Units
Three-position Enable switch, Start switch, Hold switch,
Mode select switch (with key, three mode)
Others
Provided with CF (Compact Flash) card slot
USB port (USB1.1) X 1
13-5
13
DX100 Specification
13.4 Equipment Configuration
DX100
13.4
Equipment Configuration
The DX100 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 DX100 equipment.
13.4.1
Arrangement of Units and Circuit Boards
The arrangements of units and circuit boards in small-capacity, mediumcapacity, and large-capacity DX100s are shown.
„
Small Capacity
SERVOPACK, Fuse (Disconnect Switch), Power Supply Unit
Fig. 13-1: Configuration for Small-Capacity
Backside Duct Fan
4715MS-22T-B50-B00
Disconnect Switch
194RC-301753
Shaft
194RNHR1
Handle
194RHS4
Fuse:
Power Supply Unit
Refer to the
Regenerative Resistor
JZRCR-YPU03-1
SMRK220W12R5K A5979 following table.
A
(*for HP20D, HP20D-6:
RDC50N12R5JI800ZZ)
SERVOPACK
Robot I/F Board
(Refer to the
JANCD-YIF01-1E
following table)
CPS Unit
JZNC-YPS01-E
CPU Unit
JZNC-YRK01-1E
SAFETY UNIT
JZNC-YSU01-1E
Brake Control Board
(MXT)
JANCD-YBK01-2E
Robot System Input
I/O Unit
Terminal Block
A
JZNC-YIU01-E
Interior Circuration Fan
4715MS-22T-B50-B00
WARNING
QS1
BNL6
BNL6
CU
1 CU
O
N
L
Y
3
O
N
L
Y
C.B. R
489
40C
480Y/277V
~
20A
FAZ - C20 /2-NA
CU
OFF
PE
Ground the earth terminal
based on local code.
CU
O
N
L
Y
O
N
L
Y
4
B
A
1
CN213
1
B
A
CN216
CN212
CN206
CN202
CN211
CN205
FUSE
CN210
CN215
CN209
CN203 CN204
CN208
CN200 CN201
Back View
(without cover)
FRC5-C50S52T-OLS(D20)
CN207
CN214
1
2
B
A
May cause
electric shock.
Inside Controller
Front View
F Door
Inside View
Sectional View A-A’
Table 13-1: Configuration for Small Capacity
Model
Type
MH5
DX100
SERVOPACK
Fuse
(Converter integrated) (Disconnect Switch)
Power Supply
Contact Unit
ERDR-MH00005-B00
JZRCR-YSV01-11
ATDR10
JZRCR-YPU03-1
MH6
ERDR-MH00006-B00
JZRCR-YSV02-11
ATDR10
JZRCR-YPU03-1
MA1400
ERDR-MA01400-B00
JZRCR-YSV02-11
ATDR10
JZRCR-YPU03-1
VA1400
ERDR-VA01400-B00
JZRCR-YSV02-31
ATDR10
JZRCR-YPU03-1
MA1900
ERDR-MA01900-B00
JZRCR-YSV03-11
ATDR10
JZRCR-YPU03-1
HP20D
ERDR-HP0020D-B00
JZRCR-YSV03-11
ATDR10
JZRCR-YPU03-1
MH5L
HP20D-6
13-6
13
DX100 Specification
13.4 Equipment Configuration
DX100
„
Medium and Large Capacity
Fig. 13-2: Configuration for Medium and Large Capacity
Backside Duct Fan
4715MS-22T-B50-B00
Regenerative Resistor
SMVK500W2R0J A5978 (3 resistors)
Disconnect Switch
194RC-301753
Shaft
194RNHR1
Handle
194RHS4
Fuse:
Refer to the
following table.
Power Supply Unit
JZRCR-YPU03-1
CONVERTER
(Refer to the
following table.)
WARNING
Back View
(without cover)
May cause
electric shock.
PE
Ground the earth terminal
based on local code.
QS1
CU
1 CU
O
N
L
Y
3
O
N
L
Y
C.B. R
489
40C
480Y/277V
~
20A
FAZ - C20 /2-NA
OFF
Robot I/F Board
JANCD-YIF01-1E
CPS Unit
JZNC-YPS01-E
CPU Unit
JZNC-YRK01-1E
SAFETY UNIT
JZNC-YSU01-1E
Brake Control Board
JANCD-YBK01-2E
I/O Unit
JZNC-YIU01-E
CU
CU
O
N
L
Y
O
N
L
Y
2
Interior Circuration Fan
4715MS-22T-B50-B00
A
4
(EV1)
(EV2)
SERVOPACK
(Refer to the
following table)
(MXT)
Robot System Input
Terminal Block
A
Inside Controller
Front View
F Door
Inside View
Sectional View A-A’
Fuse
(Disconnect Switch)
Power Supply
Contact Unit
Table 13-2(a): Configuration for Medium Capacity
Model
Type
DX100
SERVOPACK
Converter
MH50
ERDR-MH00050-B00 JZRCRYSV04-11
SRDACOA30A01A-E
ATDR20
JZRCR-YPU03-1
MS80
ERDR-MS00080-B00 JZRCRYSV05-11
SRDACOA30A01A-E
ATDR20
JZRCR-YPU03-1
VS50
ERDR-VS00050-B00
JZRCRYSV05-41
SRDACOA30A01A-E
ATDR20
JZRCR-YPU03-1
SIA50D
ERDR-SIA050D-B00
JZRCRYSV05-41
SRDACOA30A01A-E
ATDR20
JZRCR-YPU03-1
Table 13-2(b): Configuration for Large Capacity
Model
Type
Fuse
DX100
SERVOPACK
Converter
(Disconnect
Switch)
Power Supply
Contact Unit
ES165D
ERDR-ES0165D-B00 JZRCRYSV06-11
SRDACOA30A01A-E
ATDR20
JZRCR-YPU03-1
ES200D
ERDR-ES0200D-B00 JZRCRYSV06-11
SRDACOA30A01A-E
ATDR20
JZRCR-YPU03-1
13-7
DX100
13.4.2
13
DX100 Specification
13.4 Equipment Configuration
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
DX100. Make sure the door of the DX100 is closed when it’s used to keep
this cooling system effective.
Fig. 13-3: .Cooling System
Air Intake
Circuration Fan
Backside Duct Fan
Air Outlet
13-8
14
Description of Units and Circuit Boards
DX100
14 Description of Units and Circuit Boards
WARNING
•
When turning ON the power to DX100, be sure that there is no one
within the P-point maximum envelope of the manipulator, and that
you are in a safe place.
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator. Always press the
emergency stop button immediately if there are problems.
•
Always set the teach lock before starting teaching.
•
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.
– Always have an escape plan in mind in case the manipulator
comes toward you unexpectedly.
– Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
•
Before operating the manipulator, check that the SERVO ON lamp
goes out when the emergency stop button on the programming
pendant is pressed.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency. The emergency stop button is
located on the right of the programming pendant.
14-1
14
Description of Units and Circuit Boards
DX100
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 manipulator movement.
– Check for damage to 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 manipulator or
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injuries or equipment
damage.
14-2
14
Description of Units and Circuit Boards
DX100
Cautions for Connection of Dual Input Signals
CAUTION
•
Connect the switch (contact) that turns the dual signals ON and
OFF simultaneously.
•
If the timing that turns the two signals ON and OFF is not right, a
disagreement alarm occurs. Refer to the figure below.
DX100
Input for the robot system
+24V2
Input signal 1
Switch
-19
-20
Turn ON/OFF
at the same time
-21
Input signal 2
024V
-22
CAUTION
•
Do not connect two signals to the same contact point.
(Prepare two individual contact points)
•
Since the power supply for each signal is reversed, it will shortcircuit and may cause breakdown of DX100 Unit if the signals are
connected to the same contact point.
DX100
Input for the robot system
Switch
+24V2
Input signal 1
-19
-20
The same contact
-21
Input signal 2
024V
-22
Short-circuit current
14-3
14
Description of Units and Circuit Boards
14.1 Power Supply Contactor Unit
Power Supply Contactor Unit
The power supply contactor unit consists of the power supply contactor
sequence circuit board (JARCR-YPC01-2) and the contactor (1KM, 2KM)
for servo power and the line filter (1Z). It turns the contactor servo power
ON and OFF using the signal for servo power control from the power
supply contactor sequence circuit board and supplies power (3-phase
AC200/220V) to the unit.
The power supply (single phase AC200/220V) is supplied to the control
power supply via the line filter.
Table 14-1: Power Supply Contactor Unit Models
Model
Robot Type
JZRCRYPU03-□
MH5, MH5L, MH6, MA1400, VA1400, MA1900, HP20D,
HP20D-6, MH50, MS80, VS50, ES165D, ES200D, SIA50D
Fig. 14-1: Power Supply Unit Configuration (JZRCR-YPU03-□)
(1FU),(2FU)
Fuse for AC Control Power
Supply ATDR10 (10A 250V)
(CN601)
Main Power Supply Input
CN601
1FU
10A600V
2FU
10A600V
COULD
FUSE
COULD
FUSE
JZRCR-YPU03-*
CN611
CN610
CN607
(CN606)
AC Cooling Fan
(CN605,CN604,CN603)
AC Control Power Supply
CN609
14.1
Contactor Control Input
CN601
SVMX1
SVMX2
CN606
CN608
DX100
CN612
CN605
CN604
(CN608)
Brake Interlock Output
CN603
CN602
(CN602)
Converter Output
14-4
14
Description of Units and Circuit Boards
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
DX100
14.2
14.2.1
Major Axes Control Circuit Board (SRDA-EAXA01□)
Major Axes Control Circuit Board (SRDA-EAXA01□)
The major axes control circuit board (SRDA-EAXA01□) controls the
servomotors of the manipulator’s six axes. It also controls the converter,
the PWM amplifiers, and the power supply contactor circuit board of the
power supply contactor unit. Mounting an external axes control circuit
board of an option (SRDA-EAXB01□) makes it possible to control the
servomotor of nine axes, including the robot axes.
The major axes control circuit board (SRDA-EAXA01□) also has the
following functions.
• Brake Power Supply Control Circuit
• Shock sensor (shock) input circuit
• Direct-in circuit
Fig. 14-2: Major Axes Control Circuit Board (SRDA-EAXA01□)
(CN510)
Converter Power Supply Output
(CN513)
Brake Control Signal
(CN512)
SHOCK Signal Input
(CN511)
Safety Unit I/F
(CN509)
Control Power Supply Input
(CN514)
Direct-in
(CN508)
Encoder Signal
(CN507)
Converter Control Signal
(CN518)
I/O Communication
(CN502)
AMP2 PWM Signal
(CN517)
I/O Communication
(CN501)
AMP1 PWM Signal
(CN516)
Control Communication
(CN504)
AMP4 PWM Signal
(CN515)
Control Communication
(CN503)
AMP3 PWM Signal
(CN506)
AMP6 PWM Signal
(CN505)
AMP5 PWM Signal
14-5
14
Description of Units and Circuit Boards
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
DX100
14.2.2
Connection for Tool Shock Sensor (SHOCK)
14.2.2.1
To connect the tool shock sensor directly to the tool shock sensor signal line
1. Disconnect the minus SHOCK (-) and plus SHOCK (+) pin terminal
from the DINAMIC connector, the EAXA-CN512 major axes control
circuit board.
2. Connect the minus SHOCK (-) and plus SHOCK (+) pin terminals to
the signal line of the tool shock sensor. Use the following pin terminals
for preparing the end of the signal line.
Pin Terminal Name
Pin Terminal Model
Signal Line Terminal Model
SHOCK-
TMEDN-630809-MA
TMEDN-630809-FA
(manufactured by NICHIFU Co.,
Ltd.)
SHOCK+
TMEDN-630809-FA
TMEDN-630809-MA
(manufactured by NICHIFU Co.,
Ltd.)
Fig. 14-3: Direct Connection to Tool Shock Sensor Signal Line
Major Axes Control Circuit Board
SRDA-EAXA01
CN512
Manipulator
TMEDN-630809-FA (NICHIFU)
SHOCK+
Manipulator cable (signal)
-3
+24V
SHOCK
-4
TMEDN-630809-MA
(NICHIFU)
TMEDN-630809-FA
(NICHIFU)
SHOCKTMEDN-630809-MA (NICHIFU)
14-6
Shock sensor
(Option)
Shock sensor signal cable
14
Description of Units and Circuit Boards
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
DX100
14.2.2.2
To connect the tool shock sensor with the cable that is built into the manipulator
1. Disconnect the minus SHOCK (-) and plus SHOCK (+) pin terminal
from the DINAMIC connector, the EAXA-CN512 major axes control
circuit board.
2. Connect the minus SHOCK (-) pin terminal to the minus SHOCK (-) pin
terminal of the manipulator.
NOTE
Cable that is built into the manipulator is not connected to
shocks sensor because the tool shock sensor is a option.
For connecting the tool shock sensor, refer to the wiring diagrams in the INSTRUCTIONS for the manipulator.
Fig. 14-4: Connection with Manipulator Cable
Major Axes Control Circuit Board
SRDA-EAXA01
Manipulator
CN512
+24V 2
-1
SHOCK+
TMEDN-630809-FA (NICHIFU)
-3
SHOCKTMEDN-630809-MA (NICHIFU)
SHOCK
Shock sensor
(Option)
-4
SHOCKTMEDN-630809-MA (NICHIFU)
SUPPLE
-MENT
Supply cables (PG)
Use the manipulator cable
When the tool shock sensor input signal is used, the
stopping method of the robot can be specified. The stopping
methods are hold stop and servo power supply OFF.
Selection of the stopping method is set in the display of the
programing pendant. Refer to explanations in chapter 8
“System Setup” at page 8-1 for details.
14-7
14
Description of Units and Circuit Boards
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
DX100
14.2.3
Connection for Direct-in
Direct-in (Servo) 1 to 6
This signal is used to input a responsive signal in search functions.
Fig. 14-5: Connection for Direct-in (Servo) 1 to 6
Major Axes Control Circuit Board
(SRDA-EAXA01 )
Applicable
Connector
AXDIN1
CN514
B1
024V
B3
AXDIN2
A4
A4
AXDIN3
B4
B4
AXDIN4
A5
A5
AXDIN5
B5
B5
AXDIN6
A6
A6
AXINCOM
A3
A3
A1
+24V2
A1
JFA J2000 Series
J21DF-20V-KX-L Maker JST
SJ2F-01GF-P1.0(AWG20
24)
B1
B3
Direct-in (Servo) 1
Direct-in (Servo) 2
Direct-in (Servo) 3
Direct-in (Servo) 4
Direct-in (Servo) 5
Direct-in (Servo) 6
Connect the jumper cable.
Slave for the coordinated control side
Major Axes Control Circuit Board
SRDA-EAXA01D
CN514
B1
024V
AXDIN1
B3
B1
B3
AXDIN2
A4
A4
AXDIN3
B4
B4
AXDIN4
A5
A5
AXDIN5
B5
B5
AXDIN6
A6
A3
A6
+24V2 A1
A1
AXINCOM
A3
Applicable Connector
Connect the jumper cable.
JFA J2000 Series
J21DF-20V-KX-L
JST
SJ2F-01GF-P1.0(AWG20
24)
The part of wiring is for the slave for the coordinated control side major axes control circuit board, SRDA-EAXA01
14-8
14
Description of Units and Circuit Boards
14.3 CPU Unit
DX100
14.3
14.3.1
CPU Unit
CPU Unit Configuration
CPU unit consists of circuit board racks, control circuit boards, robot I/F
board. The JZNC-YRK01-1E CPU unit contains only circuit board racks
and control circuit boards. It does not contain robot I/F board.
Fig. 14-6: CPU Unit Configuration (JZNC- YRK01-1E)
PCI Slot for Sensor Board x 1
Robot I/F Circuit Board
JANCD-YIF01- E
(CN114)
IO I/F( Communication with YIU)
Control Circuit Board
JANCD-YCP01-E
LED
(CN107)
Compact Flash
CN107
(CN113)
Drive I/F(Communication with EAXA)
(CN106)
USB
(CN105)
For Programming Pendant
PCI Slot X2
CN106
CN105
(CN104)
For LAN
CN104
CN103
(CN103)
Serial Port(RS232C)
Battery
14-9
DX100
14.3.2
14.3.2.1
14
Description of Units and Circuit Boards
14.3 CPU Unit
Unit and Circuit Board in the CPU Unit
Control Circuit Board (JANCD-YCP01-E)
This board performs to control the entire system, display to the
programming pendant, control the operating keys, control operation and
calculate interpolation. This board has the Serial interface for RS-232C
and LAN (100BASE-TX/10BASE-T).
14.3.2.2
Robot I/F Board (JANCD-YIF01-□E)
The robot I/F board controls the entire robotic system. It is connected to
the control circuit board (JANCD-YCP01-E) with a PCI bus interface on
the backboard, and to the major axes control circuit board (SRDAEAXA01A-□) with high-speed serial transmissions.
14-10
14
Description of Units and Circuit Boards
14.4 CPS Unit (JZNC-YPS01-E)
DX100
14.4
CPS Unit (JZNC-YPS01-E)
This unit (JZNC-YPS01-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.
Fig. 14-7: CPS Unit JZNC-YPS01-E
Monitor
Connection with CPU 1 (CN158)
Connection with CPU 2 (CN159)
Alarm Display
CN159
(ALM)
SOURCE
P-ON
+5V
+24V
FAN
OHT
CN158
(+5V)
CN156/157
(+24V2)
POWER SUPPLY
CPS-520F
C90AD XXXXX
NO.
DATE YYYY-MM
CN155
(+24V1/+24V2)
Fuji Electric Hi-Tech Corp.
MADE IN JAPAN
01 02 03 04 05 06 07 08 09 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B C D E F G H J K
L M N P Q R S T U V
CN151
(AC IN)
INPUT
200-240V AC
50/60Hz
3.4A-2.8A
14-11
(CN154/CN155)
+24V1/+24V2 Power Supply Output
(CN153)
+24V3 Power Supply Output
CN154
(+24V1/+24V2)
CN153
(+24V3)
(CN151)
AC Power Supply Input
(CN156/CN157)
+24V2 Power Supply Output
CN152
(REMOTE)
(CN152)
Remote Control
DX100
14
Description of Units and Circuit Boards
14.4 CPS Unit (JZNC-YPS01-E)
Items
Specifications
Input
Rating Input Voltage:
200/220VAC
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
Control Power
ON/OFF
DISPLAY
Color
Status
SOURCE
Green
Lights with power supply input.
Lights out when internal live part completes
discharge.
(Power supply status: being input)
POWER ON
Green
Lights when PWR_OK output signal is ON.
(Power supply status: being output)
+5V
Red
Lights with +5V over-current
(ON when abnormal)
+24V
Red
Lights with +24V over-current
(ON when abnormal)
FAN
Red
Lights when FAN error occurs.
OHT
Red
Lights when unit interior overheats
To turn ON the DX100 controller power, turn ON the fuse disconnect switch 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 fuse disconnect switch of the controller is turned ON. It is
operated by the external switch connected with CN152 of the CPS unit as shown in
the following figure. (CN152-1 and CN152-2 is shortaged when shipment)
Fig. 14-8: Connection to Control Power Supply Unit
DX100
CPS Unit
JZNC-YPS01-E
Remove the short-circuit positioner
CN152
-1
Control Power Supply ON/OFF Switch
R-IN
R-INCOM
-2
See chapter 14.8 “WAGO Connector” at page 14-22 for wiring of CN152 connector.
14-12
14
Description of Units and Circuit Boards
14.5 Brake Control Board (JANCD-YBK01-2E)
DX100
14.5
14.5.1
Brake Control Board (JANCD-YBK01-2E)
Brake Control Board (JANCD-YBK01-2E)
Brake Control Board controls ON/OFF of the brakes of total nine axes
(Robot + external axes) according to the command signal from Major
Axes Control Circuit Board (SRDA-EAXA01□).
(CN405)
Brake Command Input
(CN404)
For Switching External Power Supply
(CN402)
Contactor Interlock Input
(CN401)
Brake Release Switch Connection
(CN400)
Brake Output
14-13
(CN403)
Brake Power Supply Input
F1:Fuse
3.15 A/250 V
14
Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)
DX100
14.6
14.6.1
Robot I/O Unit (JZNC-YIU01-E)
Robot I/O Unit (JZNC-YIU01-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 positioner controller and
centralized controller control the manipulator and related equipment as a
system. Universal I/O are mainly used as timing signals for the
manipulator and peripheral devices in jobs that require robot motion.
Refer to chapter 14.12 “Universal I/O Signal Assignment” at page 14-41
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, refer to “Connection Wire with
Universal I/O Connector (CN306, 307, 308, 309)” at page 14-15 and
“Specific I/O Signal Related to Start and Stop” at page 14-16
Fig. 14-9: I/O Unit (JZNC-YIU01-E)
(CN305)
Power Supply Input
(CN304)
Power Supply Output
D1:24V2IN LED
(CN309)
Digital I/O
(CN308)
Digital I/O
(CN303)
For Switching External Power Supply
F1, F2
Power Supply Protective Fuse
3.15 A/250 V
(CN302)
Direct-in
(optional)
(CN301)
Panel IO
D2: FUSE CUT LED
S1: Rotary Switch
(CN300)
Communication Connector
14-14
(CN307)
Digital I/O
(CN306)
Digital I/O
14
Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)
DX100
Connection Wire with 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.)
Connector A detail (cable side)
B20
B1
A20
A1
Connector C detail (cable side)
B20
B1
A20
A1
Connector Model: FCN-361J040-AU (FUJITSU)
(Soldered Pin type)
Hood Model : FCN-360C040-B (
)
Connector Model: 1903404-1
(Tyco Electronics Amp)
(MT Type
I/O Unit
(JZNC-YIU01-E)
Connector A
CN309 CN308
I/O Cable (YIU ~ external)
Connector C
CN307 CN306
I/O Cable (YIU ~ Terminal Block)
Connector B
CN306,307,308,309 Connector B details
B1
B20
A1
A20
Connector Model: 1747053-1
(Tyco Electronics Amp)
TIFS553YS
B1
A1
B2
A2
B3
A3
B4
A4
B5
A5
B6
A6
21-187-3201 R
024VU 024VU 024VU 024VU 024VU 024VU
024VU 024VU 024VU 024VU 024VU 024VU
I/O Terminal Block
B8
A8
B9
A9
B10
A10
B11
A11
+24VU +24VU
B12
A12
B13
A13
A14
B15 +24VU +24VU +24VU +24VU +24VU
A15 +24VU +24VU +24VU +24VU +24VU
Stripped length: 10mm
Applicable max cable outside diameter: 3.3 mm dia.
Model: TIFS553YS (KASUGA ELECTRIC)
14-15
B14
FG
DX100
14
Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)
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: JZNC-YIU01-E)
• External Servo ON
(common to all application: Specific input
terminal block MXT)
• External Start
(depending on application: JZNC-YIU01-E)
• Operating
(depending on application: JZNC-YIU01-E)
• External Hold
(common to all application:
Specific input terminal block MXT)
• External Emergency Stop (common to all application:
Specific input terminal block MXT)
<Timing Chart>
Manipulator
RUN
STOP
ON
While Servo ON OFF
Servo ON
ON
OFF
External Start
ON
OFF
Operating
ON
OFF
T
External Hold
ON
OFF
Ext. E-Stop
ON
OFF
T
T
Note: Set T=100 msec or more
14-16
14
Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)
DX100
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 manipulator servo power supply. The set and reset timings are shown
in the following.
DX100
Servo ON PB
Servo ON
Confirmation
X2
Servo ON
Command
X1
MXT
X1
-29
X1
+24VU
External Servo
ON Input
(EXSVON)
Robot I/O Unit
JZNC-YIU01
+24VU
CN308
-30
Servo ON
Confirmation
Servo Power ON
X3 (30011)
System Input Terminal
Block (MXT)
Servo ON
Command
X2
Servo Power ON
-A18
X3
PL
Servo ON
Output
(30011)
-A8
Note: Number in (
) means output signal number assigned to YIU01.
PL: Pilot Lamp
Example of Start Sequence Circuit from External Device
Only the rising edge of the external start signal is valid. This signal starts
the manipulator. Reset this signal with the interlock configuration that
determines if operation can start and with the playback (RUNNING) signal
confirming that the manipulator has actually started moving.
DX100
Run PB
While
Play mode
Servo ON
select
(30011)
(30016)
Alarm/Error
Occuring
(30013)
Running
Confirmation Start
(Command)
X5
X4
Robot I/O Unit
JZNC-YIU01
Ex. Start
Command
X4
X3
Running
X6 (30010)
CN308
External Start
-B1
Input
(20010)
-B7
Running
Confirmation
X5
PL
Note: Number in ( ) means output signal number assigned to YIU01.
14-17
OVU
Running, etc.
X6
-B18
-B8
+24VU
Running Output
(30010), etc.
14
Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)
DX100
Connection of External Power Supply for I/O
At factory setting, the internal power supply for I/O is used. If the external
power supply for I/O is used, connect it with following procedure.
1. Remove the wire connected between CN303-1 to -3 and CN303-2 to -4
of the robot I/O unit.
2. Connect +24V of the external power supply to CN303-1 and 0V to
CN303-2 of the robot I/O unit.
For the connection of the CN303 connector, refer to chapter 14.8 “WAGO
Connector” at page 14-22.
Fig. 14-10: Connection of External Power Supply for I/O
Robot I/O unit (JZNC-YIU01-E)
Robot I/O unit (JZNC-YIU01-E)
+24VU
CN303
-1 (EX24VIN)
F1
3.15A
-2 (EX024VIN)
+24VU
CN303
External
Power Supply
-1 (EX24VIN)
3.15A
+24V
F2
0V
-2 (EX024VIN)
F2
3.15A
3.15A
024VU (Ready by Customer)
+24V
F1
+24V
-3 (+24V)
-3 (+24V)
-4 (024V)
-4 (024V)
024VU
024V
024V
In case of using external power supply
In case of using internal power supply
NOTE
•
The internal power supply of 24V of about 1.5A of
DX100 can be used for I/O.
Use external 24V power supply for higher currents and
to isolate the circuit inside and outside the DX100.
•
Power supply circuit for I/O (+24 VU, 024 VU) has 3.15A
fuses (F1, F2).
•
Install the external power supply outside the DX100 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 line of the external
power supply to the +24VU and 0VU terminals. The unit
may malfunction if the external power supply is also
connected.
14-18
14
Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
DX100
14.7
Machine Safety Unit (JZNC-YSU01-1E)
This unit contains dual processing circuits for safety signal.
It processes external safety signals with the dual processing circuits and
control ON/OFF of the contactor for SERVO power supply of the contactor
unit (JZRCR-YPU) according to conditions.
Followings are the main functions of Machine Safety Unit.
• Robot specific I/O circuit (safety signal dual circuits)
• Servo-ON Enable (ONEN) Input Circuit (dual circuits)
• Overrun (OT, EXOT) Input Circuit (dual circuits)
• Programming Pendant Signal PPESP, PPDSW, etc. Input Circuit
(safety signal dual circuits)
• Contactor Control Signal Output Circuit (dual circuits)
• Emergency Stop Signal Input Circuit (dual circuits)
(CN214)
Contactor Control 1
B
A
(CN213)
Contactor Control 2
(CN212)
FANALM,FANCTL,LAMP
CN206
A
CN211
(CN211)
ONEN,EXONEN,EXOT
CN210
CN209
CN215
CN205
(CN203)
OT Input Connector
(CN216)
MXT Connection
(CN210)
I/F between Major Axes
Control Circuit Boards
CN208
(CN200)
Power Supply Input Connector
CN203
(CN201)
Power Supply Output Connector
FUSE
F1,F2: Fuse
3.15A/250V
CN202
(CN205)
I/F-OUT for Machine Safety Unit
CN216
(CN202)
I/F for Major Axes Control Circuit Board - Communication
FRC5-C50S52T-OLS(D20)
CN212
1
B
CN213
CN207
(CN206)
I/F-IN for Machine Safety Unit
1
CN214
1
A
s
B
(CN207)
I/F for Machine Safety Unit
CN200 CN201
14.7.1
Machine Safety Unit (JZNC-YSU01-1E)
(CN215)
For Contactor Control 3 and 4
(CN209)
PP I/F
(CN208)
Door Emergency Stop Button
14-19
14
Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
DX100
14.7.2
Connection for Servo-ON Enable Input (ONEN1 and ONEN2)
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 so that both input signals are turned ON or
OFF at the same time. If only one signal is turned ON, an alarm occurs.
Refer to “8 Servo Power Supply Individual Control Function” of
“Independent/Coordinated Function Instructions Manual” for the usage of
the Servo-ON Enable signals.
For the connection of CN211 Connector, refer to chapter 14.8 “WAGO
Connector” at page 14-22
Fig. 14-11: Connection for Servo-ON Enable Input
DX100
Machine safety unit
JZNC-YSU01-1E
Remove the jumper cable
CN211
ONEN1_1+
ONEN1_1ONEN1_2+
ONEN1_2-
Servo-ON enable input signal
-1
-2
Turn ON/OFF
at the same time
-3
-4
14-20
DX100
14.7.3
14
Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
Connection for External Axis Overrun (EXOT)
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, an alarm occurs.
1. Remove the jumper cable between the connectors CN211-9 and -10
and between the connectors CN211-11 and -12 of the JZNC-YSU011E machine safety unit.
2. Connect the external axis overrun wiring between the connectors
CN211-9 and -10 and between the connectors CN211-11 and -12 of
the JZNC-YSU01-1E machine safety unit.
For the connection of CN211 Connector, refer to chapter 14.8 “WAGO
Connector” at page 14-22.
CAUTION
•
Remove jumper cable installed on specific input signal before
connecting the input signal lines.
Failure to observe this caution could lead to injury or mechanical
failure.
Fig. 14-12: Connection for External Axis Overrun
DX100
Machine Safety Unit
JZNC-YSU01-1E
Remove the jumper cable
CN211
-9
OT2_1+
OT2_1-
External axis overrun
-10
Turn ON/OFF
at the same time
-11
OT2_2+
-12
OT2_2-
14-21
14
Description of Units and Circuit Boards
14.8 WAGO Connector
DX100
14.8
WAGO Connector
CN211 on the machine safety unit (JZNC-YSU01-1E), CN152 on the CPS
unit (JZNC-YPS01-E), and CN303 on the robot I/O unit (JZNC-YIU01-E)
are equipped with a connector made by WAGO.
The “wiring tool for the WAGO connector” is necessary to wire the WAGO
connector.
The tools (total 3, 2 types) are supplied with the DX100.
Use them with the appropriate sizes of connectors.
The wiring procedure is described as follows:
1. Insert part A of the wiring tool into one of the holes designed for the
tool.
Wiring tool for WAGO connector
(Supplied parts - 2 types)
Hole for the wiring tool
Part A
WAGO connector (e.g. 4 pins type)
Wire
Connector to be applied
CPS unit:
(JZNC-YPS01-E) CN152
Machine safety unit: (JZNC-YSU01-1E) CN211
Robot I/O unit: (JZNC-YIU02-E) CN303
14-22
Specification
Max cable outside diameter: 4.1mm dia.
Stripped lentgh:
8-9mm
Max cable outside diameter: 3.4mm dia.
7mm
Stripped lentgh:
DX100
14
Description of Units and Circuit Boards
14.8 WAGO Connector
2. Insert or pull out the wire while pushing the wiring tool downward
(Direction of the arrow).
Wiring tool for WAGO connector
Push
3. Remove the wiring tool from the connector. (Complete)
Keep this wiring tool for the future use.
14-23
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
Robot Specific Input Terminal Block (MXT)
The robot specific input terminal block (MXT) is equipped at lower part of
the right side of DX100 as shown below. The input terminal block (MXT) is
used for the input of robot system signals.
For connections, refer to connection diagrams for each corresponding
items.
Fig. 14-13: Robot Specific Input Terminal Block (MXT)
MXT EXDSW1SYSRUN+
34
17
GSOUTFB2-50
33
16
EXDSW1+
49
GSOUTFB2+
32
15
EXHOLDGSOUT2-48
31
14
EXHOLD+
GSOUT2+47
30
13
EXSVONGSOUTFB1-46
29SAFF2-12
EXSVON+
45
GSOUTFB1+
SSP-28
SAFF2+
11
GSOUT1-44SSP+
27SAFF1-10
GSOUT1+43FST226
SAFF1+9
024V2 42
25
GSIN22-8
+24V2 41FST2+
FST1-24
GSIN22+7
024V2 40FST1+
23
GSIN21-6
+24V2 39
EXESP222
GSIN21+5
024V2 38
EXESP2+
21
GSIN12-4
+24V2 37
EXESP120
GSIN12+3
EXDSW2-36
EXESP1+
19
GSIN11-2
EXDSW2+35
SYSRUN18
GSIN11+1
NJ2959-1
BNL6
BNL6
BNL6
DX100 Inside Right Side
14-24
(MXT)
10 11 12 13 14 15 16 17
9
8
7
6
5
4
3
2
1
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
BNL6
14.9
BNL6
DX100
DX100
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
Wiring Procedure of the MXT Connector
For your safety, appropriate work must be done by following the
instructions below.
1. Tool: Screwdriver
– For the connection, be sure to use a screwdriver of an applicable
size and configuration.
* WAGO standard screwdriver
WAGO 210-119
WAGO 210-119SB (Short,
delivered with the product)
2. Applicable Wires
(1) The length of the exposed conductor (L) should be as follows:
– * The length of the exposed conductor set for the terminal block (L)
WAGO series 250 (with 5.0 mm pitch): 9-10 mm
– * Applicable max cable outside diameter: 3.1 mm dia.
L
(2) In case that the conductor is bent or feazed, make it straight as
illustrated in the figure above.
14-25
DX100
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
3. Wire Connection
Terminal block: screwless clamp
terminal WAGO series 250
250
250
250
209-188
(1) Place the screwdriver on the lever upright as shown in the figure
below and push straight down.
(2) Insert the wire into the connection hole slowly until its leading end
touches the end of the hole.
For thin wires, never insert the wire with force, or the wire
jacket may get caught in.
(3) Pull out the screwdriver to clamp the conductor with a spring.
(4) Check if the wire is connected firmly by pulling the wire softly.
14-26
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
DX100
External Emergency Stop
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. While the signal is input, the servo power cannot be turned ON.
CAUTION
•
Always connect the signals after removing jumper cable.
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.
Fig. 14-14: Connection for External Emergency Stop
DX100
JZNC
-YSU01-1E
EXESP1+
EXESP1-
JANCDYSF03
Robot system input
terminal block
MXT
-19
External emergency stop
-20
Turn ON/OFF
at the same time
-21
EXESP2+
EXESP2-
Remove the jumper cable
-22
14-27
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
DX100
Safety Plug
This signal is 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
power turns OFF. While the signal is turned ON. The servo power cannot
be turned ON. Note that these signals are disabled in teach mode.
CAUTION
•
Always connect the signals after removing jumper cable.
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.
Fig. 14-15: Connection for Safety Plug
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
Remove the jumper cable
-9
SAFF1+
SAFF1-
Safety plug
-10
Turn ON/OFF
at the same time
-11
SAFF2+
-12
SAFF2-
14-28
DX100
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
Installation of Safety Plug
The manipulator must be surrounded by a safeguarding and a door
protected by an interlock function. The door must be opened by the
technician to enter and the interlock function stops the robot operation
when the door is open. The safety plug input signal is connected to the
interlock signal from the gate.
Manipulator
Working Area
Safeguarding
Servo ON Lamp (Option)
DX100
Safeguarding
Safety Plug
Taked Plug
Emergency
Stop
If the servo power is ON when the interlock signal is input, the servo
power turns OFF. The servo power cannot be turned ON while the
interlock signal is input. 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.
14-29
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
DX100
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%).
Fig. 14-16: Connection for Full-speed Test
D X100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
-23
Full-speed test
FST1+
-24
FST1-25
FST2+
FST2-
-26
14-30
Turned ON/OFF
at the same time
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
DX100
Slow Speed Mode Selection
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%)
Fig. 14-17: Connection for Slow Speed Mode Selection
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
Remove the jumper cable
-27
Slow speed mode selection
SSP+
-28
SSP-
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 supply is turned
ON.
Fig. 14-18: Connection for External Servo ON
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
-29
EXSVON+
-30
EXSVON-
14-31
External servo ON
DX100
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
External Hold
This signal is used to connect the temporary stop switch of an external
device. If the signal is input, the job is stopped. While the signal is input,
starting and axis operations are disabled.
CAUTION
•
Always connect the signals after removing jumper cable.
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.
Fig. 14-19: Connection for External Hold
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
Remove the jumper cable
EXHOLD+
-31
-32
EXHOLD-
14-32
External Hold
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
DX100
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
•
Always connect the signals after removing jumper cable.
Injury or damage to machinery may result because the external
emergency stop do not work even if the signal is input.
Fig. 14-20: Connection for External Enable Switch
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
Remove the jumper cable
-33
EXDSW1+
External Enable Switch
-34
EXDSW1-
Turned ON/OFF
at the same time
-35
EXDSW2+
-36
EXDSW2-
14-33
14
Description of Units and Circuit Boards
14.9 Robot Specific Input Terminal Block (MXT)
DX100
Signal Name Connection Dual
No. (MXT)
input
Function
Factory Setting
EXESP1+
EXESP1-
-19
-20
External Emergency Stop
Short-circuit with a
jumper cable
EXESP2+
EXESP2-
-21
-22
SAFF1+
SAFF1-
-9
-10
SAFF2+
SAFF2-
-11
-12
FST1+
FST1-
-23
-24
FST2+
FST2-
-25
-26
SSP+
SSP-
-27
-28
-
EXSVON+
EXSVON-
-29
-30
-
EXHOLD+
EXHOLD-
-31
-32
-
EXDSW1+
EXDSW1-
-33
-34
Applicable
EXDSW2+
EXDSW2-
-35
-36
Applicable
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.
While the signal is input, the servo power cannot
be turned ON.
Applicable
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 power turns OFF. While the signal is
turned ON. The servo power cannot be turned
ON. Note that these signals are disabled in
teach mode.
Applicable
Full-speed Test
Short-circuit with a
jumper cable
Open
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%).
Slow Speed Mode Selection
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%)
External Servo ON
Short-circuit with a
jumper cable
Open
Use to connect the servo ON switch of an
external operation device.
If the signal is input, the servo power supply is
turned ON.
External Hold
Used to connect the temporary stop switch of an
external device.
If the signal is input, the job is stopped.
While the signal is input, starting and axis
operations are disabled.
External Enable Switch
Used to connect a Enable switch other than the
one on the programming pendant when two
people are teaching.
14-34
Short-circuit with a
jumper cable
Short-circuit with a
jumper cable
14
Description of Units and Circuit Boards
14.10 Contact Output of Emergency Stop Button
DX100
14.10
Contact Output of Emergency Stop Button
The contact output terminals for the emergency stop button on the
programming pendant is provided on the terminal block 2XT (screw size
M3.5) at lower part of the right side of DX100.
This contact output is always valid no matter whether the DX100 main
power supply status is ON or OFF. (Status output signal: normally closed
contact)
CAUTION
•
Do not use the emergency stop button with 24 VAC, 0.5 A or more.
Failure to observe this instruction may result in damage to equipment.
Fig. 14-21: Contact Output Terminal Block of Emergency Button (2XT)
2XT
EXT
Programming pendant
Emergency stop button
PPESP3+
PPESP3−
PPESP4+
PPESP4−
14-35
PPESP3+
PPESP3−
PPESP4+
PPESP4−
14
Description of Units and Circuit Boards
14.11 SERVOPACK
DX100
14.11
SERVOPACK
A SERVOPACK consists of a converter and a PWM amplifier of which
there are two types. One type is the SERVOPACK with a combined
converter and a PWM amplifier and the other type is one where both units
are separate. (Refer to attached table “SERVOPACK Configuration.”)
14.11.1
Description of Each Unit
14.11.1.1
Converter
This exchanges the power supply (3-phase: AC200/220V) supplied by the
contactor unit for DC power supply and supplies the power to PWM
amplifiers for each axis.
14.11.1.2
PWM Amplifier
This exchanges the DC power supply supplied by a converter for a
3-phase motor power source and outputs to each servo motor.
14.11.2
SERVOPACK Configuration
Table 14-2:
Configuration Device
MH5/MH5L
MH6
MA1400
VA1400
Model
Model
Model
Model
SERVOPACK
JZRCR-YSV01-11
JZRCR-YSV02-11
JZRCR-YSV02-11
JZRCR-YSV02-31
Converter
SRDACOA12A01A-E
SRDACOA12A01A-E
SRDACOA12A01A-E
SRDACOA12A01A-E
S
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
L
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
U
SRDASDA06A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
R
SRDASDA03A01A-E
SRDASDA06A01A-E
SRDASDA06A01A-E
SRDASDA06A01A-E
B
SRDASDA03A01A-E
SRDASDA06A01A-E
SRDASDA06A01A-E
SRDASDA06A01A-E
T
SRDASDA03A01A-E
SRDASDA06A01A-E
SRDASDA06A01A-E
SRDASDA06A01A-E
PWM
Amplifier
E
SRDASDA14A01A-E
14-36
14
Description of Units and Circuit Boards
14.11 SERVOPACK
DX100
Table 14-3:
Configuration Device
MA1900
HP20D
HP20D-6
Model
SERVOPACK
JZRCR-YSV03-11
Converter
Model
JZRCR-YSV03-11
SRDA-COA12A01A-E
SRDA-COA12A01A-E
S
SRDA-SDA14A01A-E
SRDA-SDA14A01A-E
L
SRDA-SDA21A01A-E
SRDA-SDA21A01A-E
U
SRDA-SDA14A01A-E
SRDA-SDA14A01A-E
R
SRDA-SDA06A01A-E
SRDA-SDA06A01A-E
B
SRDA-SDA06A01A-E
SRDA-SDA06A01A-E
T
SRDA-SDA06A01A-E
SRDA-SDA06A01A-E
MH50
MS80
VS50/SIA50D
Model
Model
Model
PWM
Amplifier
E
Table 14-4:
Configuration Device
Converter
SERVOPACK
PWM
Amplifier
SRDA-COA30A01A-E
SRDA-COA30A01A-E
SRDA-COA30A01A-E
JZRCR-YSV04-11
JZRCR-YSV05-11
JZRCR-YSV05-41
S
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
L
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
U
SRDA-SDA35A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
R
SRDA-SDA14A01A-E
SRDA-SDA14A01A-E
SRDA-SDA14A01A-E
B
SRDA-SDA14A01A-E
SRDA-SDA14A01A-E
SRDA-SDA14A01A-E
T
SRDA-SDA14A01A-E
SRDA-SDA14A01A-E
SRDA-SDA14A01A-E
E
SRDA-SDA71A01A-E
Table 14-5:
Configuration Device
Converter
SERVOPACK
PWM
Amplifier
ES165D
ES200D
Model
Model
SRDA-COA30A01A-E
SRDA-COA30A01A-E
JZRCR-YSV06-11
JZRCR-YSV06-11
S
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
L
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
U
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
R
SRDA-SDA35A01A-E
SRDA-SDA35A01A-E
B
SRDA-SDA21A01A-E
SRDA-SDA21A01A-E
T
SRDA-SDA21A01A-E
SRDA-SDA21A01A-E
E
14-37
14
Description of Units and Circuit Boards
14.11 SERVOPACK
DX100
Fig. 14-22: SERVOPACK Configuration for MH5, MH5L, MH6, MA1400,
MA1900, HP20D, HP20D-6
(CN551)
Control Power Supply Input
Monitor Alarm
Display LED
(CN553)
Converter Control Signal
(CN554)
Grounding Detection Input
Ground Terminal
(CN557)
Regenerative Resister
(CN555)
Main Circuit Power
Supply Input
EAXA Base Fixing
Screw (top)
(CN512)
SHOCK Signal Input
(CN509)
Control Power Supply Input
(CN508)
Encoder Signal
(CN518)
I/O Communication
(CN517)
I/O Communication
(CN516)
Control Communication
(CN515)
Control Communication
(CN552A)
Control Power Supply
Output for 6-Axis Amplifier
Converter
(CN552B)
Control Power Supply Output
for External Axis Amplifier
(AMP1,3,5-CN583)
Amplifier Main Circuit
Power Supply
(AMP2,4,6-CN583)
Amplifier Main Circuit
Power Supply
(CN556)
Main Circuit Power Supply Output
for 6-Axis Amplifier
Charge Lamp
(AMP1,3,5-CN581)
PWM Signal
(CN558)
Main Circuit Power Supply Output
for External Axis Amplifier
AMP1
EAXA Base Fixing Screw (top)
EAXA Board
(CN511)
Safety Unit I/O
AMP3
(CN513)
Brake Control Signal
(CN514)
AMP5
Direct-in
(CN507)
Converter Control Signal
(CN502)
AMP2 PWM Signal (AMP1,3,5-CN584)
Motor Power Output
(CN504)
AMP4 PWM Signal
(CN506)
AMP6 PWM Signal
(CN505)
AMP5 PWM Signal
(CN503)
AMP3
PWM
Signal
(CN501)
AMP1 PWM Signal
(AMP1,3,5-CN582)
Amplifier Control Power Supply
EAXA Base
Ground Terminal
EAXA Base Fixing
Screw (bottom)
(EAXA Base is closed)
(AMP2,4,6-CN584)
Motor Power Output
AMP2
AMP4
AMP6
(AMP2,4,6-CN581)
PWM Signal
(AMP2,4,6-CN582)
Amplifier Control
Power Supply
(EAXA Base is open)
Fig. 14-23: SERVOPACK Configuration for VA1400
Monitor Alarm
Display LED
(CN553)
Converter Control Signal
(CN554)
Grounding Detection Input
(CN551)
Control Power Supply Input
(CN552A)
Control Power Supply
Output for 6-Axis Amplifier
Ground Terminal
(CN557)
Regenerative Resister
(CN555)
Main Circuit Power Supply Input
EAXA Base Fixing Screw (top)
(CN512)
SHOCK Signal Input
(CN509)
Control Power Supply Input
(CN508)
Encoder Signal
(CN531)
PWM Amplifier 7 Signal (back)
(CN532)
PWM Amplifier 8 Signal (front)
(CN517,CN518)
I/O Communication
(CN533)
PWM Amplifier 9 Signal
(CN515,CN516)
Control Communication
EAXA Base
Ground Terminal
EAXA Base Fixing Screw (bottom)
Converter
(AMP1,3,5,7-CN583)
(CN552B)
Amplifier Main Circuit
Power Supply
Control Power Supply Output
for External Axis Amplifier
(AMP1,3,5,7-CN581)
(CN556) Main Circuit Power Supply PWM Signal
Output for 6-Axis Amplifier
(CN558) Main Circuit Power Supply
Output for External Axis Amplifier
Charge Lamp
EAXA Base Fixing Screw (top)
(CN513)
Brake Control Signal
(CN511)
AMP1
Safety Unit I/O
EAXA Board
(CN514)
Direct-in
(CN507)
Converter Control Signal
(CN502)
AMP2 PWM Signal
(CN501)
AMP1 PWM Signal
(CN504)
AMP4 PWM Signal
(CN506)
AMP6 PWM Signal
(CN505)
AMP5 PWM Signal
(CN534) (left)
(CN535) (middle)
(CN536) (right)
Encoder Signal
(AMP2,4,6-CN583)
Amplifier Main Circuit
Power Supply
AMP4
AMP5
AMP6
(AMP2,4,6-CN581)
PWM Signal
AMP7
EAXA Base Fixing Screw (bottom)
(CN503)
AMP3 PWM Signal
(AMP1,3,5,7-CN582)
Amplifier Control Power Supply
(AMP2,4,6-CN582)
Amplifier Control
Power Supply
(EAXA Base is open)
14-38
AMP2
AMP3
(AMP1,3,5,7-CN584)
Motor Power Output
(EAXA Base is closed)
(AMP2,4,6-CN584)
Motor Power Output
14
Description of Units and Circuit Boards
14.11 SERVOPACK
DX100
Fig. 14-24: SERVOPACK Configuration for MH50, MS80
Monitor Alarm Display LED (CN551)
(CN553)
Control Power Supply
I/O Signal Connecting Terminal
(CN552A)
Upper Grip
(AMP1,3,5-CN583)
(CN554)
(CN552B)
Control Power
Amplifier Main Circuit
Grounding Detection Input
Control Power Supply
Supply
Power Supply
Ground Terminal
Converter
(CN557)
Charge Lamp
Regenerative Resister
(CN556)
(CN555)
Main Circuit Power Supply Output
Main Circuit Power
Supply Input
(CN558)
Main Circuit Output for External Axis
(CN510)
Control Power Supply
Upper Grip
Output for Converter
EAXA Base Fixing
AMP1
EAXA Base Fixing
Screw (top)
Screw (top)
(CN513)
(CN512)
Brake Control Signal (AMP1,3,5-CN581)
SHOCK Signal Input
PWM Signal
(CN511)
Safety Unit I/F
(CN509)
Control Power Supply Input
EAXA Board
(CN508)
(CN514)
AMP3
Encoder Signal
Direct-in
(CN518)
(CN507)
I/O Communication
Converter Control Signal
(CN502)
(CN517)
AMP2 PWM Signal
I/O Communication
(CN504)
(CN516)
AMP5
AMP4 PWM Signal
Control Communication
(CN506)
(CN515)
AMP6 PWM Signal
Control Communication
(AMP1,3,5-CN584)
EAXA Base
Motor Power Output
(CN505)
(AMP2,4,6-CN583)
Amplifier Main Circuit Power Supply
(AMP2,4,6-CN582)
Amplifier Control Power Supply
(AMP2,4,6-CN584)
Motor Power Output
AMP2
AMP4
(AMP2,4,6-CN581)
PWM Signal
AMP6
AMP5 PWM Signal
EAXA Base Fixing Screw (bottom)
Ground Terminal
EAXA Base Fixing
Screw (bottom)
(AMP1,3,5-CN582)
Amplifier Control
Power Supply
(CN503)
AMP3 PWM Signal
(CN501)
AMP1 PWM Signal
Lower Grip
Lower Grip
(EAXA Base is open)
(EAXA Base is closed)
Fig. 14-25: SERVOPACK Configuration for VS50/SIA50D
(CN553)
I/O Signal Connecting Terminal
(CN554)
Grounding Detection Input
Monitor Alarm
Display LED
(CN551)
Control Power Supply
Upper Grip
(CN552A)
Control Power Supply
(CN552B)
Control Power Supply
Converter
Ground Terminal
(CN557)
Regenerative Resister
(CN555)
Main Circuit Power
Supply Input
(CN510)
Control Power Supply
Output for Converter
EAXA Base Fixing Screw (top)
(CN512)
SHOCK Signal Input
(CN509)
Control Power Supply Input
(CN508)
Encoder Signal
(CN531) PWM Amplifier 7
Signal (back)
(CN532) PWM Amplifier 8
Signal (front)
(CN517,CN518)
I/O Communication
(CN533)
PWM Amplifier 9 Signal
(CN515,CN516)
Control Communication
EAXA Base
Ground Terminal
EAXA Base Fixing
Screw (bottom)
(AMP1,3,5,7-CN583)
Amplifier Main Circuit Power Supply
(AMP2,4,6-CN583)
Amplifier Main Circuit Power Supply
(AMP1,3,5,7-CN581)
PWM Signal
(AMP2,4,6-CN582)
Amplifier Control Power Supply
Charge Lamp
(CN556)
Main Circuit Power Supply Output
(CN558)
Main Circuit Output for External Axis
Upper Grip
EAXA Base Fixing
Screw (top)
(CN513)
Brake Control Signal
(CN511)
Safety Unit I/F
AMP1
EAXA Board
(CN514)
Direct-in
(CN507)
Converter Control Signal
(CN502)
AMP2 PWM Signal
(CN504)
AMP4 PWM Signal
(AMP2,4,6-CN584)
Motor Power Output
AMP2
AMP3
AMP4
(AMP2,4,6-CN581)
PWM Signal
AMP5
(CN506)
AMP6 PWM Signal
(CN505)
AMP5 PWM Signal
(AMP1,3,5,7-CN584)
Motor Power Output
AMP6
EAXA Base Fixing Screw (bottom)
(CN503)
AMP7
AMP3 PWM Signal
(CN501)
AMP1 PWM Signal
(CN534) (left)
(CN535) (middle)
(CN536) (right)
Encoder Signal
Lower Grip
(AMP1,3,5,7-CN582)
Amplifier Control Power Supply
Lower Grip
(EAXA Base is open)
(EAXA Base is closed)
14-39
14
Description of Units and Circuit Boards
14.11 SERVOPACK
DX100
Fig. 14-26: SERVOPACK Configuration for ES165D, ES200D
(CN553)
I/O Signal Connecting Terminal
(CN554)
Grounding Detection Input
Monitor Alarm
Display LED
(CN551)
Control Power Supply
Upper Grip
(CN552A)
Control Power Supply
(CN552B)
Control Power Supply
(AMP1,3,5-CN583)
Amplifier Main Circuit
Power Supply
Converter
(AMP2,4,6-CN583)
Amplifier Main Circuit Power Supply
(AMP2,4,6-CN582)
Amplifier Control Power Supply
Charge Lamp
Ground Terminal
(CN556)
Main Circuit Power Supply Output
(CN557)
Regenerative Resister
(CN558)
Main Circuit Output for External Axis
(CN555)
Main Circuit Power
Supply Input
(CN510)
Control Power Supply
Output for Converter
EAXA Base Fixing
Screw (top)
(CN512)
SHOCK Signal Input
(CN509)
Control Power Supply Input
(CN508)
Encoder Signal
(CN518)
I/O Communication
(CN517)
I/O Communication
(CN516)
Control Communication
(CN515)
Control Communication
EAXA Base
Upper Grip
EAXA Base Fixing
Screw (top)
AMP1
(CN513)
Brake Control Signal
(AMP1,3,5-CN581)
(CN511)
PWM Signal
Safety Unit I/F
EAXA Board
(CN514)
Direct-in
(CN507)
Converter Control Signal
(CN502)
AMP2 PWM Signal
(CN504)
AMP4 PWM Signal
(AMP2,4,6-CN584)
Motor Power Output
AMP2
AMP3
AMP4
AMP5
(AMP2,4,6-CN581)
PWM Signal
(CN506)
AMP6 PWM Signal (AMP1,3,5-CN584)
Motor Power Output
(CN505)
AMP6
AMP5 PWM Signal
EAXA Base Fixing Screw (bottom)
(CN503)
(AMP1,3,5-CN582)
AMP3 PWM Signal
Amplifier Control
Power Supply
(CN501)
AMP1 PWM Signal
Ground Terminal
EAXA Base Fixing
Screw (bottom)
Lower Grip
Lower Grip
(EAXA Base is closed)
(EAXA Base is open)
14-40
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
14.12
14.12.1
Universal I/O Signal Assignment
Arc Welding
Fig. 14-27: JZNC-YIU01-E(CN308 Connector) I/O Allocation and
Connection Diagram (For Arc Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
Connector Terminal Converter
(Optional)
Model:TIFS553YS
CN308 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
20010 B1
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20021 A5
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
A8
A8
30012 B9
Top of Master Job
OUT
B9
B9
OUT
A9
A9
30010 B8
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
OUT
B10
B10
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
A10
A10
B11
B11
30017 A11 Teach Mode Selected OUT
A11
A11
OUT
B12
B12
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
A12
A12
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
+24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
+24VU
A19
+24VU
B20
FG
A20
A20
024VU
30020 B12 In Cube 1
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
B4
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
20020 B5
Each Point
24VDC
50mA max.
Terminal
Number
Signal
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-41
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-28: JZNC-YIU01-E (CN309 Connector) I/O Allocation and
Connection Diagram (For Arc Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN309 Connector
Logical
Number
Each Point
24VDC
8mA max.
Connector
Number
Name
Signal
IN
B1
B1
IN
A1
A1
20026 B2
20027 A2
Weaving Prohibited
IN
B2
B2
Sensing Prohibited
IN
20030 B3
IN01 User Output
IN
A2
B3
A2
B3
20025 A1
20031 A3
IN02
A3
IN03
IN
IN
A3
20032 B4
B4
B4
20033 A4
IN04
IN
A4
A4
20034 B5
IN05
IN
B5
20035 A5
IN06
A5
B5
A5
20036 B6
IN07
IN
IN
20037 A6
IN08
IN
024VU
024VU
30024 B8 Gas Shortage (Monitor) OUT
30025 A8 Wire Shortage (Monitor) OUT
30026 B9 Wire Sticking (Monitor) OUT
30027 A9
Arc Shortage (Monitor) OUT
-4
External
Power Supply
+24 VE
024 VE
+24VU
-2
024VU
B7
A7
024VU
024VU
B8
B8
A8
B9
A8
B9
A6
A9
A9
B10
OUT
OUT
A10
A10
30032 B11 OUT03
30033 A11 OUT04
OUT
B11
B11
OUT
A11
30034 B12 OUT05
OUT
A11
B12
30035 A12 OUT06
30036 B13 OUT07
30037 A13 OUT08
OUT
A12
A12
OUT
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU
OUT
B14
A17 024VU
B18 +24VU
-1
B6
30031 A10 OUT02
A14
+24 V
024 V
(24V,1A)
B6
A6
B10
30030 B10 OUT01 User Output
CN303
Internal
Power Supply
-3
Terminal
Number
-
20024 B1
B7
A7
Each Point
24VDC
50mA max.
Connector Terminal Converter
(Optional)
Model:TIFS553YS
B12
024VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
+24VU
A19
+24VU
B20
FG
A20
A20
024VU
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-42
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-29: JZNC-YIU01-E (CN306 Connector) I/O Allocation and
Connection Diagram (For Arc Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
Connector Terminal Converter
(Optional)
Model: TIFS553YS
+24VU
CN306 Connector
Logical
Number
Each Point
24VDC
8mA max.
Connector
Number
Name
20040 B1
IN09
20041 A1
20042 B2
20043 A2
20044 B3
IN13
Signal
B1
B1
IN10
IN
A1
A1
IN11
IN
B2
B2
IN12
IN
IN
A2
B3
A2
B3
20045 A3
IN14
IN15
IN
IN
A3
B4
A3
20046 B4
20047 A4
IN16
IN
A4
A4
B5
B5
A5
A5
B5
A5
B6
B6
A6
B6
B7
A7
024VU
024VU
A6
B7
A7
Each Point
24VDC
50mA max.
External
Power Supply
+24 VE
024 VE
Terminal
Number
IN
User Input
024VU
024VU
B4
A6
30040 B8
OUT09 User Input OUT
B8
B8
30041 A8
OUT10
OUT
30042 B9
OUT11
OUT
A8
B9
A8
B9
30043 A9
OUT12
OUT
A9
A9
30044 B10 OUT13
30045 A10 OUT14
OUT
B10
B10
OUT
A10
A10
30046 B11 OUT15
30047 A11 OUT16
OUT
B11
B11
OUT
A11
B12
A11
B12
A12
A12
A12
B13
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
B16
A16
024VU
024VU
024VU
A13
B12
CN303 Internal
Power Supply
-3
A16 024VU
-4
A17 024VU
B17
A17
B18 +24VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
B19
+24VU
A19
+24VU
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
B17 024VU
A19 +24VU
B20 FG
A20
024VU
B20
FG
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-43
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-30: JZNC-YIU01-E (CN307 Connector) I/O Allocation and
Connection Diagram (For Arc Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
Connector Terminal Converter
(Optional)
Model: TIFS553YS
+24VU
CN307 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Each Point
24VDC
500mA max.
Name
-4
External
Power Supply
+24 VE
024 VE
-1
-2
024 V
(24V,1A)
+24VU
024VU
Terminal
Number
IN17
IN
B1
B1
20051 A1
IN18
IN
A1
A1
20052 B2
20053 A2
IN19
IN
B2
B2
IN20
IN
20054 B3
IN21
IN
A2
B3
A2
B3
20055 A3
IN22
IN23
IN
IN
A3
20056 B4
B4
A3
B4
20057 A4
IN24
IN
A4
A4
B5
B5
A5
A5
B5
A5
B6
A6
B6
A6
B6
B7
A7
024VU
024VU
A6
B7
A7
024VU
30050 B8
OUT17-
OUT
B8
B8
A8
OUT17+
OUT
A8
OUT18-
OUT
B9
A8
B9
RLY
30051 B9
A9
RLY
024VU
OUT18+
OUT
A9
A9
30052 B10 OUT19-
OUT
B10
B10
A10 OUT19+
30053 B11 OUT20A11 OUT20+
OUT
A10
A10
OUT
B11
B11
OUT
OUT
A11
B12
A11
30054 B12 OUT21-
RLY
RLY
B12
A12 OUT21+
OUT
A12
A12
RLY
30055 B13 OUT22-
OUT
A13 OUT22+
30056 B14 OUT23-
OUT
OUT
B13
A13
B13
A13
RLY
B14
B14
A14 OUT23+
30057 B15 OUT24-
OUT
A14
A14
OUT
B15
B15
A15 OUT24+
OUT
A15
A15
B16
A16
024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
B18
+24VU
A18
+24VU
B19
+24VU
A19
+24VU
B16 024VU
CN303 Internal
Power Supply
-3
+24 V
Signal
20050 B1
A16 024VU
B17 024VU
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
B20
FG
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-44
RLY
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
RLY
*
means internal relay
RLY means
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-6: Specific Input (Arc Welding)
Logical
Input Name / Function
Number
20010
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 job1). 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 manipulator attempts to enter the cube 12) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021
INTERFERENCE 2 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 22) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
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.
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 chapter 8.6 “Interference Area” at page 8-55.
14-45
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-7: Specific Output (Arc Welding)
Logical
Output Name / Function
Number
30010
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.
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 DX100 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.1)
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.
30014
BATTERY 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 to
30017
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 manipulators and positioners.
30021
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 manipulators and positioners.
30022
WORK HOME POSITION (IN CUBE 32)2)
This signal turns ON when the current TCP lies inside the work home position area.
Use this signal to evaluate whether the manipulator is in the start position.
30023
INTERMEDIATE START OK
This signal turns ON when the manipulator 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.
30024
GAS SHORTAGE (MONITOR)
This signal stays ON while the gas shortage signal from the welding power supply is
ON.
30025
WIRE SHORTAGE (MONITOR)
This signal status ON while the wire shortage signal from the welding power supply is
ON.
30026
WIRE STICKING (MONITOR)
The wire sticking check is conducted automatically when the arc turns OFF. If wire
sticking is detected, this signal remains ON until the wire sticking is released.
30027
ARC SHORTAGE (MONITOR)
This signal stays ON while the arc shortage signal from the welding power supply is
ON.
1 This signal is not output during operation.
2 The work home position cube and Cube 32 are same.
14-46
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
14.12.2
Handling
Fig. 14-31: JZNC-YIU01-E (CN308 Connector) I/O Allocation and
Connection Diagram (For Handling)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN308 Connector
Each Point
24VDC
8mA max.
Logical Connector
Number Number
Name
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
IN
20014 B3
-
IN
A2
B3
A2
B3
20015 A3
Select Play Mode
Select Teach Mode
IN
IN
A3
20016 B4
B4
A3
B4
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
IN
024VU
024VU
-2
024VU
B6
A6
B6
B7
A7
024VU
024VU
A6
30010 B8
Running
OUT
B8
B8
30011 A8
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
OUT
A9
A9
OUT
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
B10
B10
A10
A10
B11
B11
30017 A11 Teach Mode Selected
OUT
A11
30020 B12 In Cube 1
OUT
In Cube 2
OUT
A11
B12
A12
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
+24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
Intermediate Start OK
+24VU
B5
A5
-
30023 A13 (continuousing Sequence)
-1
A5
-
30022 B13 Work Home Position
External
Power Supply
+24 VE
024 VE
A4
B5
20023 A6
30021 A12
-4
A4
20022 B6
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
+24 V
024 V
(24V,1A)
IN
IN
IN
IN
B7
A7
CN303 Internal
Power Supply
-3
Terminal
Number
External Start
20017 A4
Each Point
24VDC
50mA max.
Signal
20010 B1
OUT
OUT
B12
A12
024VU
+24VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-47
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-32: JZNC-YIU01-E (CN309 Connector) I/O Allocation and
Connection Diagram (For Handling)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN309 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
IN
B1
B1
20025 A1
-
IN
A1
A1
Shock Sensor (NC)
- Hold
IN
B2
B2
Low Air Pressure
IN
20030 B3
IN01
IN
A2
B3
A2
B3
20031 A3
IN02
A3
IN03
IN
IN
A3
20032 B4
B4
B4
20033 A4
IN04
IN
A4
A4
20034 B5
IN05
IN
B5
20035 A5
IN06
A5
B5
A5
20036 B6
IN07
IN
IN
20037 A6
IN08
IN
B7
A7
024VU
024VU
-4
External
Power Supply
+24 VE
024 VE
+24 V
024 V
(24V,1A)
+24VU
-2
024VU
B6
B7
A7
024VU
024VU
A6
-
OUT
B8
B8
30025 A8
-
OUT
A8
A8
30026 B9
-
OUT
B9
B9
30027 A9
-
OUT
A9
A9
30030 B10 OUT01 User Output
OUT
B10
B10
30031 A10 OUT02
30032 B11 OUT03
OUT
A10
A10
OUT
B11
B11
OUT
A11
OUT
A11
B12
B12
30035 A12 OUT06
30036 B13 OUT07
OUT
A12
A12
OUT
30037 A13 OUT08
OUT
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU
B14
A14
A17 024VU
B18 +24VU
-1
B6
A6
30024 B8
30033 A11 OUT04
30034 B12 OUT05
CN303 Internal
Power Supply
-3
Terminal
Number
-
20026 B2
20027 A2
Each Point
24VDC
50mA max.
Signal
20024 B1
024VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
+24VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-48
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-33: JZNC-YIU01-E (CN306 Connector) I/O Allocation and
Connection Diagram (For Handling)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN306 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
B1
B1
20041 A1
IN10
IN
A1
A1
20042 B2
20043 A2
IN11
IN
B2
B2
IN12
IN13
IN
IN
A2
B3
A2
B3
20045 A3
IN14
20046 B4
20047 A4
IN15
IN
IN
A3
B4
A3
B4
IN16
IN
A4
A4
B5
A5
B5
B5
A5
B6
A6
B6
A6
B6
B7
A7
024VU
024VU
A5
024VU
30040 B8
OUT09
OUT10
OUT
B8
B8
OUT
A8
OUT11
OUT12
OUT
A8
B9
OUT
A9
A9
30044 B10 OUT13
30045 A10 OUT14
OUT
B10
B10
OUT
A10
A10
30046 B11 OUT15
30047 A11 OUT16
OUT
B11
B11
OUT
A11
B12
A11
B12
A12
A12
A12
B13
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
+24VU
A19
+24VU
30043 A9
024VU
A13
B14
A14
A16 024VU
B17 024VU
A17 024VU
B18 +24VU
-1
+24VU
-2
024VU
A6
B7
A7
30042 B9
External
Power Supply
+24 VE
024 VE
Terminal
Number
IN
30041 A8
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Signal
IN09
20044 B3
Each Point
24VDC
50mA max.
Name
20040 B1
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
B9
B12
024VU
B20
FG
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-49
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-34: JZNC-YIU01-E (CN307 Connector) I/O Allocation and
Connection Diagram (For Handling)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN307 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
20050 B1
Name
IN
B1
B1
20051 A1
IN
A1
A1
20052 B2
20053 A2
Sensor Input 3
IN
B2
B2
Sensor Input 4
IN
20054 B3
Sensor Input 5
IN
A2
B3
A2
B3
20055 A3
Sensor Input 6
A3
Sensor Input 7
IN
IN
A3
20056 B4
B4
B4
20057 A4
Sensor Input 8
IN
A4
A4
B5
B5
A5
B5
A5
A5
B6
A6
B7
024VU
A7
024VU
30050 B8
Hand Value 1-1-
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
-1
+24VU
-2
024VU
A8
B9
RLY
RLY
OUT
A9 Hand Value 1-2+
30052 B10 Hand Value 2-1-
OUT
A10 Hand Value 2-1+
30053 B11 Hand Value 2-2-
OUT
A9
A9
B10
OUT
A10
A10
OUT
B11
B11
A11
B12
A11
A12
A12
RLY
B13
A13
B13
A13
RLY
B14
B14
A14
A14
B15
B15
OUT
OUT
OUT
OUT
A14 Hand Value 4-1+
30057 B15 Hand Value 4-2-
OUT
OUT
A15 Hand Value 4-2+
OUT
A17 024VU
A18 +24VU
B19 +24VU
A19 +24VU
B9
B10
OUT
A13 Hand Value 3-2+
30056 B14 Hand Value 4-1-
B18 +24VU
External
Power Supply
+24 VE
024 VE
B8
A8
OUT
B17 024VU
OUT
A15
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
+24VU
B20
FG
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-50
RLY
RLY
RLY
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
RLY
B12
A15
B20 FG
A20
A6
B8
Hand Value 1-2-
A16 024VU
B7
A7
Hand Value 1-1+
B16 024VU
B6
OUT
A8
A12 Hand Value 3-1+
30055 B13 Hand Value 3-2-
B6
A6
024VU
024VU
30051 B9
A11 Hand Value 2-2+
30054 B12 Hand Value 3-1-
Each Point
24VDC
500mA max.
Terminal
Number
Signal
Sensor Input 1
Sensor Input 2
*
means internal relay
RLY means
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-8: Specific Input (Handling)
Logical
Input Name / Function
Number
20010
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 job1). 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 manipulator attempts to enter the cube 12) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021
INTERFERENCE 2 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 22) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20026
TOOL SHOCK SENSOR
This is normally ON (NC) signal input. When it turns OFF, an DX100 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, DX100 displays user alarm in the
PLAY mode or displays user message in the teach mode.
20050 to
20057
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.
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 chapter 8.6 “Interference Area” at page 8-55.
14-51
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-9: Specific Output (Handling)
Logical
Output Name / Function
Number
30010
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.
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 DX100 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.1)
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.
30014
BATTERY 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 to
30017
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 manipulators and positioners.
30021
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 manipulators and positioners.
30022
WORK HOME POSITION (IN CUBE 32)2)
This signal turns ON when the current TCP lies inside the work home position area.
Use this signal to evaluate whether the manipulator is in the start position.
30023
INTERMEDIATE START OK
This signal turns ON when the manipulator 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.
30050 to
30057
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.
1 This signal is not output during operation.
2 The work home position cube and Cube 32 are same.
14-52
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
14.12.3
General Application
Fig. 14-35: JZNC-YIU01-E (CN308 Connector) I/O Allocation and
Connection Diagram (For General Application)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN308 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
20010 B1
20011 A1
B1
B1
IN
A1
A1
Call Master Job
IN
B2
B2
Alarm/Error Reset
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
IN
A4
A4
Interference1 Entrance
Prohibited
IN
B5
Interference2 Entrance
Prohibited
IN
IN
A5
B5
A5
External Start
-
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Work Prohibited
20022 B6
20023 A6
IN
-
-1
+24VU
-2
024VU
B6
B7
A6
A7
Running
OUT
B8
B8
30011 A8
Servo is ON
OUT
A8
30012 B9
Top of Master Job
OUT
A8
B9
A9
A9
OUT
B10
B10
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
A10
A10
B11
B11
30017 A11 Teach Mode Selected OUT
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
024VU
OUT
OUT
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
B14
A14
B15
External
Power Supply
+24 VE
024 VE
B6
A6
30010 B8
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
B4
024VU
024VU
B7
A7
Each Point
24VDC
50mA max.
Terminal
Number
IN
-
20012 B2
20013 A2
20014 B3
Signal
B9
B12
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
B19 +24VU
A19 +24VU
B20 FG
A20
024VU
+24VU
B20
FG
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-53
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-36: JZNC-YIU01-E (CN309 Connector) I/O Allocation and
Connection Diagram (For General Application)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN309 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
B1
B1
IN
A1
A1
20026 B2
20027 A2
-
IN
B2
B2
-
IN
20030 B3
IN01 User Input
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
20025 A1
20031 A3
IN02
20032 B4
IN03
20033 A4
IN04
IN
A4
A4
20034 B5
20035 A5
IN05
IN
B5
IN
IN
A5
B5
A5
20036 B6
IN06
IN07
20037 A6
IN08
IN
024VU
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
B6
A6
B6
B7
A6
A7
024VU
024VU
30024 B8
In Cube 3
OUT
B8
B8
30025 A8
In Cube 4
OUT
A8
30026 B9
Work Instruction
OUT
B9
A8
B9
024VU
30027 A9 30030 B10 OUT01 User Output
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
IN
B7
A7
Each Point
24VDC
50mA max.
Signal
Interference3 Entrance
Prohibited
Interference4 Entrance
Prohibited
20024 B1
OUT
A9
A9
B10
OUT
B10
30031 A10 OUT02
OUT
A10
A10
30032 B11 OUT03
30033 A11 OUT04
OUT
B11
B11
OUT
A11
30034 B12 OUT05
OUT
A11
B12
30035 A12 OUT06
30036 B13 OUT07
OUT
A12
A12
OUT
30037 A13 OUT08
OUT
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU
B14
A14
A17 024VU
B18 +24VU
B12
024VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
+24VU
A19
+24VU
B20
FG
A20
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-54
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-37: JZNC-YIU01-E (CN306 Connector) I/O Allocation and
Connection Diagram (General Application)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN306 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
20040 B1
IN09 User Input
IN
B1
B1
20041 A1
IN10
IN
A1
A1
20042 B2
20043 A2
IN11
IN
B2
B2
A2
B3
A2
B3
A3
A3
B4
B4
A4
A4
B5
B5
A5
IN12
IN
20044 B3
IN13
IN
20045 A3
IN14
20046 B4
IN15
IN
IN
20047 A4
IN16
IN
B5
A5
A5
B6
A6
B7
A7
024VU
024VU
30040 B8
OUT09 User Output
OUT
30041 A8
OUT10
OUT
30042 B9
OUT11
OUT
30043 A9
OUT12
OUT
30044 B10 OUT13
30045 A10 OUT14
OUT
30046 B11 OUT15
30047 A11 OUT16
OUT
OUT
OUT
B12
Each Point
24VDC
50mA max.
A12
B13
A13
B14
A14
B15
-2
+24VU
024VU
B7
A7
024VU
024VU
B8
B8
A8
A8
B9
B9
A6
A9
A9
B10
B10
A10
A10
B11
B11
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B12
A15
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
+24VU
B19 +24VU
A19
+24VU
A19 +24VU
B20
FG
A20
024VU
A16 024VU
B17 024VU
A17 024VU
B18 +24VU
-1
B6
B16
A16
B16 024VU
External
Power Supply
+24 VE
024 VE
B6
A6
A15
A15
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
Signal
A18 +24VU
B20 FG
A20
024VU
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-55
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-38: JZNC-YIU01-E (CN307 Connector ) I/O Allocation and
Connection Diagram (For General Application)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN307 Connector
Each Point
24VDC
8mA max.
Logical
Number
Connector
Number
Name
IN17
IN
B1
B1
20051 A1
IN18
IN
A1
A1
20052 B2
20053 A2
IN19
IN
B2
B2
IN20
IN
20054 B3
IN21
IN
A2
B3
A2
B3
20055 A3
IN22
A3
IN23
IN
IN
A3
20056 B4
B4
B4
20057 A4
IN24
IN
A4
A4
B5
B5
A5
B5
A5
A5
B6
A6
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
B6
B7
A6
A7
024VU
A7
30050 B8
OUT17-
OUT
B8
B8
A8
OUT17+
OUT
A8
30051 B9
OUT18-
OUT
A8
B9
A9
024VU
RLY
B9
OUT18+
OUT
A9
A9
30052 B10 OUT19A10 OUT19+
OUT
B10
B10
OUT
A10
A10
30053 B11 OUT20A11 OUT20+
OUT
B11
B11
OUT
A11
B12
A11
A12
A12
RLY
B13
A13
B13
A13
RLY
B14
B14
A14
A14
B15
30054 B12 OUT21-
OUT
A12 OUT21+
30055 B13 OUT22-
OUT
OUT
OUT
A14 OUT23+
30057 B15 OUT24-
OUT
OUT
B15
A15 OUT24+
OUT
A15
A15
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
B20
FG
OUT
A16 024VU
B17 024VU
A17 024VU
B18 +24VU
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
A20
RLY
RLY
RLY
+24VU
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-56
RLY
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
RLY
B12
A13 OUT22+
30056 B14 OUT23-
B16 024VU
CN303 Internal
Power Supply
-3
+24 V
-4
024 V
(24V,1A)
B6
A6
024VU
024VU
B7
Each Point
24VDC
500mA max.
Terminal
Number
Signal
20050 B1
means internal relay
*
RLY
means
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-10: Specific Input (General Application)
Logical
Input Name / Function
Number
20010
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 job1). 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 manipulator attempts to enter the cube 12) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021
INTERFERENCE 2 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 22) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20022
WORK PROHIBITED (Tool ON Prohibited)
Even if TOOLON instruction is executed, DX100 doesn’t output to external while this
signal is ON.
20024
INTERFERENCE 3 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 32) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20025
INTERFERENCE 4 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 42) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator 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 chapter 8.6 “Interference Area” at page 8-55.
14-57
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-11: Specific Output (General Application)
Logical
Output Name / Function
Number
30010
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.
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 DX100 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.1)*1
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.
30014
BATTERY 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 to
30017
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 manipulators and positioners.
30021
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 manipulators and positioners.
30022
WORK HOME POSITION (IN CUBE 32)2)
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 manipulator 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.
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 manipulators 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 manipulators and positioners.
30026
WORK COMMAND
This signal provides the command for the general tool to operate. TOOL ON
instruction execution or the [TOOL ON] key in the programming pendant turns this
signal ON and TOOL OFF instruction execution or the [TOOL OFF] key in the
programming pendant turns it OFF. However, it remains OFF while the WORK
PROHIBITED signal (2022) is input or while the robot is stopped.
1 This signal is not output during operation.
2 The work home position cube and Cube 32 are same.
14-58
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
14.12.4
Spot Welding
Fig. 14-39: JZNC-YIU01-E (CN308 Connector) I/O Allocation and
Connection Diagram (For Spot Welding)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN308 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
20010 B1
20011 A1
20014 B3
IN
B1
B1
IN
A1
A1
Call Master Job
IN
B2
B2
Alarm/Error Reset
IN
A2
B3
A2
B3
IN
IN
A3
A3
B4
B4
IN
A4
A4
Interference1 Entrance
Prohibited
IN
B5
Interference2 Entrance
Prohibited
IN
IN
B5
A5
External Start
-
20012 B2
20013 A2
-
IN
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
20020 B5
20021 A5
20022 B6
20023 A6
-
Welding ON/OFF
Welding Pause
IN
B8
30011 A8
OUT
A8
30012 B9
Top of Master Job
OUT
A8
B9
OUT
OUT
OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
B14
A14
B15
-2
024VU
A6
B8
30022 B13 Work Home Position
+24VU
B7
Servo is ON
Running
30020 B12 In Cube 1
30021 A12 In Cube 2
-1
B6
A7
024VU
30010 B8
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
External
Power Supply
+24 VE
024 VE
B6
A6
OUT
024VU
Alarm/Error Occurred OUT
30013 A9
OUT
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
A5
024VU
024VU
B7
A7
Each Point
24VDC
50mA max.
Terminal
Number
Signal
B9
A9
A9
B10
B10
A10
A10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B12
A12
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
+24VU
A18
+24VU
B19
+24VU
A19
+24VU
B19 +24VU
A19 +24VU
B20 FG
A20
024VU
B20
FG
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-59
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-40: JZNC-YIU01-E (CN309 Connector) I/O Allocation and
Connection Diagram (For Spot Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
Connector Terminal Converter
(Optional)
Model:TIFS553YS
+24VU
CN309 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
IN
B1
B1
20025 A1
IN
A1
A1
20026 B2
20027 A2
-
IN
B2
B2
-
IN
20030 B3
IN1 USER INPUT
IN
A2
B3
A2
B3
20031 A3
IN2
IN3
IN
IN
A3
20032 B4
B4
A3
B4
20033 A4
IN4
IN5
IN
A4
A4
IN
B5
IN
IN
A5
B5
A5
20034 B5
20035 A5
20036 B6
20037 A6
IN6
IN7
IN8
IN
A7
B8
B8
30025 A8
In Cube 4
OUT
A8
A8
OUT
B9
B9
A9
A9
OUT
B10
B10
30031 A10 OUT02
OUT
A10
A10
30032 B11 OUT03
30033 A11 OUT04
OUT
B11
B11
OUT
A11
30034 B12 OUT05
OUT
30035 A12 OUT06
30036 B13 OUT07
30037 A13 OUT08
A11
B12
A12
OUT
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
OUT
-
OUT
OUT
B14
A14
B15
External
Power Supply
+24 VE
024 VE
-1
-2
A12
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
+24VU
A19
+24VU
A18 +24VU
024VU
B12
A15
A17 024VU
B18 +24VU
+24VU
A6
OUT
30030 B10 OUT01 User Output
-4
B7
024VU
In Cube 3
30027 A9
+24 V
024 V
(24V,1A)
B6
30024 B8
024VU
30026 B9
CN303 Internal
Power Supply
-3
B6
A6
024VU
024VU
B7
A7
Each Point
24VDC
50mA max.
Terminal
Number
Signal
Interference3 Entrance
Prohibited
Interference4 Entrance
Prohibited
20024 B1
B19 +24VU
A19 +24VU
B20 FG
A20
024VU
B20
FG
A20
024VU
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-60
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-41: JZNC-YIU01-E (CN306 Connector) I/O Allocation and
Connection Diagram (For Spot Welding)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN306 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
IN17
IN
B1
B1
20041 A1
IN18
IN
A1
A1
20042 B2
20043 A2
IN19
IN
B2
B2
IN
20044 B3
IN20
IN21
A2
B3
A2
B3
20045 A3
IN22
A3
A3
B4
B4
A4
A4
B5
B5
A5
20046 B4
20047 A4
IN
IN
IN
IN23
IN24
IN
B5
A5
A5
B6
A6
024VU
024VU
A7
30040 B8
OUT17
OUT
B8
B8
30041 A8
OUT18
OUT
A8
30042 B9
30043 A9
OUT19
OUT
A8
B9
OUT20
OUT
30044 B10 OUT21
30045 A10 OUT22
30046 B11 OUT23
30047 A11 OUT24
OUT
OUT
OUT
OUT
A13
B14
A14
B15
A10
A10
B11
B11
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B12
A15
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
+24VU
B19 +24VU
B19
A19
A19 +24VU
B20 FG
B20
FG
A20
024VU
A16 024VU
B17 024VU
A17 024VU
A18 +24VU
024VU
A9
B10
024VU
B18 +24VU
-2
A9
B10
B16
A16
B16 024VU
+24VU
B9
A15
A15
-1
A6
B7
A7
B13
External
Power Supply
+24 VE
024 VE
B6
024VU
024VU
A12
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
B6
A6
B7
B12
Each Point
24VDC
50mA max.
Terminal
Number
Signal
20040 B1
A20
024VU
+24VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-61
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
Fig. 14-42: JZNC-YIU01-E (CN307 Connector) I/O Allocation and
Connection Diagram (For Spot Welding)
DX100
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN307 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
20050 B1
Name
Timer Cooling Water
Error (IN09)
Gun Cooling Water
Error (IN10)
Signal
B1
B1
IN
A1
A1
20052 B2
20053 A2
Transthermo Error (IN11) IN
B2
B2
Low Air Pressure (IN12)
IN
20054 B3
IN13
IN
A2
B3
A2
B3
20055 A3
IN14
A3
20056 B4
IN
IN
A3
IN15
B4
B4
20057 A4
IN16
IN
A4
A4
B5
B5
A5
20051 A1
B5
A5
A5
B6
A6
B7
A7
A8
30051 B9
A9
B8
B8
OUT
A8
A8
OUT
B9
B9
A9
OUT
B10
A10 Weld Condition 1 (OUT11)** OUT
OUT
30053 B11
A11 Weld Condition 2 (OUT12)** OUT
A10
A10
B11
B11
A11
B12
A11
A12
A12
RLY
B13
A13
B13
A13
RLY
B14
B14
A14
A14
B15
B15
OUT
OUT
30055 B13
A13 Weld Condition 4 (OUT14)** OUT
30056 B14
OUT
A14 Weld Condition 5 (OUT15)** OUT
OUT
30057 B15
A15
A15
B16 024VU
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
A16 024VU
B17 024VU
A17 024VU
-2
A18 +24VU
024VU
B19 +24VU
A19 +24VU
B20 FG
A20
+24VU
B20
FG
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-62
RLY
RLY
RLY
RLY
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
** This assignment can be changed at the I/O assignment display.
Refer to System Input List YIU01 and System Output List YIU01 for detail.
*** This assignment can be changed at the PSEDU input display.
Refer to System Input List YIU01 and System Output List YIU01 for detail.
RLY
B12
A15 Tip Change Request (OUT16)** OUT
B18 +24VU
+24VU
RLY
A9
A12 Weld Condition 3 (OUT13)** OUT
-1
A6
B10
30054 B12
External
Power Supply
+24 VE
024 VE
B7
A7
Weld Error Reset (OUT10)** OUT
30052 B10
CN303
Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
B6
OUT
024VU
Weld ON/OFF (OUT09)***
B6
A6
024VU
024VU
024VU
30050 B8
Each Point
24VDC
500mA max.
Terminal
Number
IN
*
means internal relay
RLY means
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-12: Specific Input (Spot Welding) (Sheet 1 of 2)
Logical
Input Name / Function
Number
20010
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 job1). 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 manipulator attempts to enter the cube 12) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021
INTERFERENCE 2 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 22) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20022
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 manipulator status.
20023
WELDING PAUSE (From sequencer)
This signal is used to move the manipulator 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.
20024
INTERFERENCE 3 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 32) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20025
INTERFERENCE 4 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 42) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20050
TIMER COOLING WATER ERROR
This signal monitors the status of timer cooling water. The manipulator displays alarm
and stops when this signal is input. The servo power remains ON.
20051
GUN COOLING WATER ERROR
This signal monitors the status of gun cooling water. The manipulator displays alarm
and stops when this signal is input. The servo power supply remains ON.
3)
3)
14-63
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-12: Specific Input (Spot Welding) (Sheet 2 of 2)
Logical
Input Name / Function
Number
20052
TRANSTHERMO ERROR
Error signal is sent from the transformer in the gun to the robot. This signal is ON
normally (NC) and an alarm occurs when the signal is OFF. The servo power supply
remains ON.
20053
LOW AIR PRESSURE
When air pressure is reduced and this input is turned ON, an alarm occurs. The servo
power supply remains ON.
4)
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.
4)
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.
4)
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.
4)
GUN FULL OPEN DETECTION
This signal indicates that the stroke of the double stroke gun is full open.
4)
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.
4)
GUN PRESSURE DETECTION
This signal indicates that a gun is in pressing status.
4)
TIP REPLACE COMPLETION
When this signal is input after tip replacement, the TIP REPLACE REQUEST signal
turns OFF, and the stored number of welding is cleared.
3)
3)
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 chapter 8.6 “Interference Area” at page 8-55.
3 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.
4 This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
Pseudo Input
Signal 8202x
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)
14-64
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-13: Specific Output (Spot Welding) (Sheet 1 of 2)
Logical
Output Name / Function
Number
30010
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.
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 DX100 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.1)
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.
30014
BATTERY 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 to
30017
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 manipulators and positioners.
30021
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 manipulators and positioners.
30022
WORK HOME POSITION (IN CUBE 32)2)
This signal turns ON when the current TCP lies inside a the work home position area.
Use this signal to evaluate whether the robot is in the start position.
30057
TIP REPLACE REQUEST
This signal is output when the stored number of welding reaches the number of
welding set for the tip replacement.
30023
INTERMEDIATE START OK
This signal turns ON when the manipulator 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.
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 manipulators 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 manipulators and positioners.
30050
WELD ON/OFF
Outputs a signal input from the interlock panel, etc.considering the robot status.
3)
3)
14-65
DX100
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-13: Specific Output (Spot Welding) (Sheet 2 of 2)
Logical
Output Name / Function
Number
30051
WELD ERROR RESET
This signal commands the reset error status of the Power Source. This is operated
with the programing pendant operation.
30052 to
30056
WELD CONDITION (Level signals)
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 selected as binary or discrete (bit number). It can handle up
to 255 conditions. Most-significant bit is the parity bit (when specified).
4)
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.
4)
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.
4)
GUN PRESS COMMAND
This outputs gun press command.
4)
4)
1 This signal is not output during operation.
2 The work home position cube and Cube 32 are same.
3 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.
4 This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
Pseudo Input
Signal 8202x
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)
14-66
14
Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
DX100
14.12.5 JANCD-YEW01-E Circuit Board (Standard)
14.12.5.1
Arc Welding
JANCD-YEW01-E Circuit Board: Analog outputs ×2 ports, Analog inputs ×
2 ports + Status signal I/O of a Welder.
DX100
MR Connector
Logical Connector
Number
Pin No.
Name
Signal
22550 CN322-2 +GASOF (Gas Shortage)
IN
CN322-3 -GASOF (Gas Shortage)
IN
1
2
3
IN
4
CN322-1
Each point
24 VDC
5mA MAX
22551 CN322-4 +WIRCUT (Wire Shortage)
CN322-5 -WIRCUT (Wire Shortage)
A/D +5V
IN
5
22553 CN322-6 +ARCACT (Arc Generation Confirm) IN
CN322-7 -ARCACT (Arc Generation Confirm) IN
IN
CN322-8 CH2 (Current Input)
6
CN322-9
T
P
8
10
CN322-11 CH1 (Voltage Input)
CN322-12 CH1-G
IN
IN
11
12
13
DC24V
5mA MAX
22552 CN322-13 +ARCOFF (Arc Shortage)
CN322-14 -ARCOFF (Arc Shortage)
IN
IN
14
R
DC24V
0.5A MAX
32551 CN322-15 ARCON (Arc ON) A
OUT
15
K
CN322-16 ARCON (Arc ON) B
OUT
16
L
32552 CN322-17 WIRINCH (Wire Inching) A
OUT
17
F
CN322-18 WIRINCH (Wire Inching) B
OUT
18
G
32553 CN322-19 WIRINCH (Wire Retract) A
OUT
19
H
CN322-20 WIRINCH (Wire Retract) B
OUT
20
J
32567 CN322-21 GAS Checking OUT A
OUT
CN322-22 GAS Checking OUT B
OUT
21
22
CN322-23
23
CN322-24
24
25
CN322-25
Detector
D/A –14V
SW2
1
7
S
9
CN322-10
A/D +5V
MS Connector
D/A –14V
3
17BYTE 32BYTE
DC24V
0.5A MAX
22554 CN322-26 STICK (Wire Sticking)
IN
26
M
CN322-27 *STICK (Wire Sticking)
IN
27
N
CN322-28 CH2 -G
IN
28
CN322-29 +24VU
29
CN322-30 024VU
30
E
CN322-31 CH1 (Voltage Command)
31
A
OUT
CN322-32 CH1-G
OUT
32
B
CN322-33 CH2 (Current Command)
OUT
33
C
CN322-34 CH2 -G
OUT
34
D
CN321-1 +24VU
32555 CN321-2 Search Command A (Optional)
OUT
CN321-4 Search Command B (Optional)
OUT
CN321-5 024VU
WAGO Connector (231-105/026-A0)
MRP-34M01 Insulator
MRP-M112 Contactor
RP-34 Casing
14-67
MS3106 A, 20-29P
MS3106 A, 20-29S
Power
Source
DX100
Index
A
absolute data ........................................................................................ 8-4
absolute encoder ................................................................................... 8-3
AC Servo Motor ....................................................................... 12-12, 12-20
ACCELARATION TIME ............................................................ 12-12, 12-20
acceleration/deceleration...................................................................... 13-3
Addition of Base and Station Axes ........................................................ 12-3
Addition of I/O Modules ........................................................................ 12-1
alarm display ....................................................................................... 13-4
ALARM HISTORY ................................................................................. 7-3
All Limit Release Function .................................................................... 8-89
allocating an operation ......................................................................... 8-99
allocation of I/O control instructions ..................................................... 8-107
allocation window ................................................................................ 8-99
alternate output allocation .......................................................... 8-98, 8-103
ambient temperature ............................................................................ 13-3
analog incremental output allocation............................................ 8-99, 8-106
ANALOG MONITOR .............................................................................. 7-3
analog output allocation ............................................................. 8-99, 8-106
application .......................................................................................... 13-4
ARC SHORTAGE (MONITOR) ........................................................... 14-46
ARM CONTROL .................................................................................... 7-3
ARM control ........................................................................................ 8-37
automatic measurement of the tool load and the center of gravity ............ 8-32
AXES CONFIG window .............................................................. 12-9, 12-16
axis interference area........................................................................... 8-63
Axis keys .............................................................................................. 6-2
B
BALL-SCREW ................................................................................... 12-10
BALL-SCREW PITCH .............................................................. 12-11, 12-18
base coordinate ................................................................................... 8-55
B-Axis................................................................................................... 6-2
C
cable junctions ...................................................................................... 4-2
changing the absolute data ..................................................................... 8-7
changing the output status.................................................................. 8-110
changing the parameter setting ........................................................... 8-112
checking the TCP ................................................................................ 8-30
circuit board racks ............................................................................... 14-9
clearing absolute data ............................................................................ 8-8
clearing calibration data ....................................................................... 8-29
clearing the interference area data ........................................................ 8-70
clearing the user coordinates ................................................................ 8-85
collision proof frames ........................................................................... 13-4
COMMAND POSITION .......................................................................... 7-3
connecting the manipulator cable ............................................................ 4-9
connecting the primary power supply ....................................................... 4-6
connecting the programming pendant .................................................... 4-10
connection ............................................................................................ 4-1
construction ........................................................................................ 13-3
contents confirmation ............................................................................. 2-1
control circuit board (JANCD-YCP01-E) ............................................... 14-10
Index-1
DX100
Index
control circuit boards ............................................................................ 14-9
CONTROL GROUP ........................................................................... 12-14
control group ....................................................................................... 12-6
CONVERTER .................................................................................... 12-12
converter ........................................................................................... 14-36
cooling system ..................................................................................... 13-3
coordinate system ................................................................................ 13-4
CPU unit configuration.......................................................................... 14-9
CREATE NEW JOB ............................................................................... 7-2
cube ................................................................................................... 8-56
cube interference ................................................................................. 8-89
cube number ....................................................................................... 8-57
cubic interference area ......................................................................... 8-55
CURRENT POSITION ............................................................................ 7-3
D
DATE/TIME ........................................................................................... 7-4
definition of the user coordinates ........................................................... 8-81
DELETE................................................................................................ 7-3
detection level (level range:1 to 500)...................................................... 8-74
detection mode .................................................................................... 8-73
DEVICE ................................................................................................ 7-3
digital I/O ............................................................................................ 13-3
dimensions .......................................................................................... 13-3
display allocation ....................................................................... 8-98, 8-102
door interlock ....................................................................................... 13-4
drive unit ............................................................................................. 13-3
DROP AMOUNT .................................................................................... 7-3
E
E-Axis ................................................................................................... 6-2
editing mode.......................................................................................... 7-1
emergency stop ..................................................................................... 5-5
enable switch ............................................................................... 5-4, 13-4
essential measures .............................................................................. 13-4
executing the display allocation ........................................................... 8-109
executing the I/O control allocation ...................................................... 8-109
executing the instruction/output control allocation.................................. 8-109
executing the job call allocation ........................................................... 8-109
execution of allocation ........................................................................ 8-109
expanded instruction set ....................................................................... 8-91
external emergency stop ................................................ 14-16, 14-27, 14-34
external enable switch .............................................................. 14-33, 14-34
external hold.................................................................. 14-16, 14-32, 14-34
external servo ON .......................................................... 14-16, 14-31, 14-34
external start ..................................................................................... 14-16
eyebolt .................................................................................................. 1-7
F
FD/CF ................................................................................................... 7-3
file initialization .................................................................................. 8-115
full-speed test .......................................................................... 14-30, 14-34
Index-2
DX100
Index
function list.......................................................................................... 13-4
fuse (disconnect switch) ....................................................................... 13-6
G
GAS SHORTAGE (MONITOR) ........................................................... 14-46
grounding ..................................................................................... 1-5, 13-3
group (4-bit/8-bit) output allocation ...................................................... 8-105
group output allocation (4-bit/8-bit) ........................................................ 8-99
GRP CONBINATION ............................................................................. 7-4
GUN COOLING WATER ERROR ....................................................... 14-63
GUN FULL OPEN DETECTION .......................................................... 14-64
GUN PRESSURE DETECTION .......................................................... 14-64
GUN SHORT OPEN DETECTION ...................................................... 14-64
H
HAND VALVE ................................................................................... 14-52
handling procedure ................................................................................ 3-1
HOME POSITION.................................................................................. 7-3
home position ........................................................................................ 8-4
home position calibration ........................................................................ 8-2
home position of the robot .................................................................... 8-10
how to calculate tool load information .................................................... 8-42
I
I/O diagnosis ....................................................................................... 13-4
I/O instructions .................................................................................... 13-5
I/O modules ........................................................................................ 12-1
I/O MSG HISTORY ................................................................................ 7-3
IN/OUT ................................................................................................. 7-2
inching operation ................................................................................. 13-4
INERTIA RATIO ...................................................................... 12-12, 12-20
initial diagnosis ...................................................................................... 5-2
initializing data file ............................................................................. 8-115
initializing I/O data ............................................................................. 8-118
initializing job file ............................................................................... 8-115
initializing parameter file ..................................................................... 8-117
initializing system data ....................................................................... 8-119
installation and wiring safety ................................................................... 1-5
instruction allocation .................................................................. 8-98, 8-100
instruction level setting ......................................................................... 8-91
instruction of shock detection function ................................................... 8-75
instruction set ...................................................................................... 8-91
interface ............................................................................................. 13-4
INTERFERENCE................................................................................... 7-3
interference area ................................................................................. 8-55
J
JANCD-YEW01-E circuit board (standard) ........................................... 14-67
Index-3
DX100
Index
JOB ...................................................................................................... 7-2
job call allocation ....................................................................... 8-98, 8-101
JOB CAPACITY ..................................................................................... 7-2
K
KEY ALLOCATION ................................................................................ 7-4
key allocation (EACH) .......................................................................... 8-98
key allocation (SIM).............................................................................. 8-98
L
language ............................................................................................. 13-5
L-axis.................................................................................................... 6-2
leakage breaker installation .................................................................... 4-4
learning function .................................................................................. 8-91
lifting the DX100 .................................................................................... 1-7
LIMIT RELEASE .................................................................................... 7-3
limit switch .......................................................................................... 8-88
LOAD ................................................................................................... 7-3
LOW AIR PRESSURE.............................................................. 14-51, 14-64
L-U interference ................................................................................... 8-89
M
machine lock ....................................................................................... 13-4
major axes control circuit board (SRDA-EAXA01□) ................................. 14-5
management mode ................................................................................ 7-1
MANIPULATOR TYPE ........................................................................... 7-3
manufacturer allocation ........................................................................ 8-98
MASTER JOB ....................................................................................... 7-2
max. disturbance force ......................................................................... 8-74
MAX. RPM .............................................................................. 12-12, 12-20
measurement of the tool load and the center of gravity ............................ 8-32
mechanical limit ................................................................................... 8-89
MECHANICAL SPEC window ............................... 12-10, 12-11, 12-18, 12-19
memory capacity.................................................................................. 13-3
modification of system configuration ...................................................... 12-1
modification of teaching points .............................................................. 13-4
momentary output allocation ....................................................... 8-98, 8-104
MONITORING TIME .............................................................................. 7-3
MOTION RANGE ....................................... 12-10, 12-11, 12-17, 12-18, 12-19
MOTOR ............................................................................................ 12-12
MOTOR SPEC window ...................................................................... 12-12
moving the MOTOMAN ........................................................................ 1-14
N
noise filter ............................................................................................. 4-3
number of tool files ............................................................................... 8-18
numeric key customize function ............................................................. 8-98
Index-4
DX100
Index
O
OPERATE COND .................................................................................. 7-4
operating .......................................................................................... 14-16
operation instructions ........................................................................... 13-5
operation mode ..................................................................................... 7-1
operation time display .......................................................................... 13-4
order number ........................................................................................ 2-2
ORG................................................................................................... 8-81
output of the work home position signal ................................................. 8-54
overrun releasing ................................................................................. 8-86
OVERRUN&S-SENSOR ........................................................................ 7-3
P
PARAMETER ........................................................................................ 7-3
path confirmation ................................................................................. 13-4
PINION DIAMETER ................................................................. 12-11, 12-19
positioning system ............................................................................... 13-3
POWER ON/OFF POS........................................................................... 7-3
power supply ................................................................................. 4-3, 13-3
power supply contactor unit .................................................................. 14-4
power supply unit................................................................................. 13-6
primary power supply breaker/fuse installation ......................................... 4-5
program control instructions.................................................................. 13-5
programming ....................................................................................... 13-5
programming pendant .......................................................................... 13-5
pulse output allocation ............................................................... 8-98, 8-104
PWM amplifier ................................................................................... 14-36
R
RACK&PINION ................................................................................. 12-10
R-Axis .................................................................................................. 6-2
REDUCTION RATIO............................................ 12-11, 12-17, 12-18, 12-19
registering tool angle............................................................................ 8-20
registering/changing the work home position .......................................... 8-52
relative humidity .................................................................................. 13-3
RES. STARG (CNCT) ............................................................................ 7-4
RES. START (JOB) ............................................................................... 7-2
RES. STATUS....................................................................................... 7-2
RESERVE JOB NAME ........................................................................... 7-4
resetting the shock detected ................................................................. 8-79
returning to the work home position ....................................................... 8-53
ROBOT ................................................................................................ 7-3
robot coordinate .................................................................................. 8-55
robot I/F board..................................................................................... 14-9
robot I/O unit (JZNC-YIU01-E) .................................................. 14-14, 14-15
robot installation angle ......................................................................... 8-38
robot motion control ............................................................................. 13-5
robot programming language (INFORM III) ............................................ 8-91
robot setup condition............................................................................ 8-37
ROTATION DIRECTION .................................................................... 12-20
running speed limit............................................................................... 13-4
Index-5
DX100
Index
S
safeguarding ......................................................................................... 5-3
safety.................................................................................................... 1-3
safety plug .............................................................................. 14-28, 14-34
SAVE.................................................................................................... 7-3
S-Axis ................................................................................................... 6-2
SECOND HOME POS ............................................................................ 7-3
security mode ........................................................................................ 7-1
security system ...................................................................................... 7-1
SELECT JOB ........................................................................................ 7-2
selecting user coordinates file ............................................................... 8-82
self-diagnosis ...................................................................................... 13-4
SENSOR INPUT ................................................................................ 14-51
SERVO AMP ..................................................................................... 12-12
SERVO MONITOR ................................................................................ 7-3
SERVO ON ................................................................................. 5-3, 14-16
SERVO ON READY ............................................................................... 5-3
servo-ON enable input........................................................................ 14-20
SERVOPACK ............................................................................ 13-6, 14-36
SET SPEED .......................................................................................... 7-4
setting contents ................................................................................... 8-91
setting play speed ................................................................................ 8-96
setting shock detection function ............................................................. 8-72
setting the controller clock .................................................................... 8-95
setting the tool load information ............................................................. 8-22
setting work home position.................................................................... 8-51
SETUP ................................................................................................. 7-4
SHCKRST instruction ........................................................................... 8-75
SHCKSET instruction ................................................................... 8-72, 8-75
S-head payload ................................................................................... 8-38
shock detection function ....................................................................... 8-72
shock sensor ....................................................................................... 14-6
short-cut function ................................................................................. 13-4
slow speed mode selection ....................................................... 14-31, 14-34
soft limit on each axis ........................................................................... 8-89
software limit ....................................................................................... 8-88
special training ...................................................................................... 1-2
specification list ................................................................................... 13-3
speed adjustment ................................................................................ 13-4
speed setting ....................................................................................... 13-5
standard instruction set ........................................................................ 8-91
station axis setting ............................................................................. 12-13
STICK DETECTION ........................................................................... 14-64
subset instruction set............................................................................ 8-91
switch of the tool file ............................................................................. 8-50
SYSTEM INFO ...................................................................................... 7-3
T
T.C.P. calibration ................................................................................. 13-4
T-Axis ................................................................................................... 6-2
TEACHING COND ................................................................................. 7-4
teaching user coordinates ..................................................................... 8-83
temporary release of soft limits .............................................................. 8-88
three-phase noise filter ........................................................................... 4-3
three-phase power supply ....................................................................... 4-3
TIMER COOLING WATER ERROR ..................................................... 14-63
timer setting ........................................................................................ 13-4
TIP REPLACE COMPLETION ............................................................ 14-64
Index-6
DX100
Index
TIP REPLACE REQUEST .................................................................. 14-65
TOOL ................................................................................................... 7-3
tool calibration ..................................................................................... 8-23
tool data setting ................................................................................... 8-18
tool file ................................................................................................ 8-18
tool load information............................................................................. 8-42
tool load information registering ............................................................ 8-48
tool load information setting .......................................................... 8-42, 8-75
tool shock sensor................................................................................. 14-6
tool shock sensor releasing .................................................................. 8-86
transferring the MOTOMAN .................................................................. 1-14
TRANSTHERMO ERROR .................................................................. 14-64
turning OFF the main power ................................................................... 5-5
turning OFF the servo power .................................................................. 5-5
turning ON the main power supply........................................................... 5-1
turning ON the servo power .................................................................... 5-3
U
U-arm payload..................................................................................... 8-39
U-Axis .................................................................................................. 6-2
user alarm display ............................................................................... 13-4
USER COORDINATE ............................................................................ 7-3
user coordinate ................................................................................... 8-55
user coordinate files ............................................................................. 8-81
user coordinate setting ......................................................................... 8-81
user coordinates .................................................................................. 8-81
user ID .......................................................................................... 7-4, 7-6
V
VARIABLE ............................................................................................ 7-2
variable............................................................................................... 13-5
variable type ....................................................................................... 13-5
VERIFY ................................................................................................ 7-3
VERSION ............................................................................................. 7-3
W
WEAVING PROHIBITED.................................................................... 14-45
WELD COMPLETION ........................................................................ 14-64
WELD CONDITION ........................................................................... 14-66
WELD ERROR RESET ...................................................................... 14-66
WELD ON/OFF ................................................................................. 14-65
WELDING COMMAND....................................................................... 14-66
WELDING ERROR ............................................................................ 14-64
WELDING ON/OFF (from sequencer).................................................. 14-63
WELDING PAUSE (from sequencer) ................................................... 14-63
WIRE SHORTAGE (MONITOR).......................................................... 14-46
WIRE STICKING (MONITOR)............................................................. 14-46
WORK COMMAND............................................................................ 14-58
WORK HOME POS ............................................................................... 7-3
work home position .............................................................................. 8-51
work home position cube length of its sides............................................ 8-53
WORK PROHIBITED (arc generation prohibited).................................. 14-45
Index-7
DX100
Index
WORK RESPONSE (pseudo arc ON response) .................................... 14-45
X
XX ...................................................................................................... 8-81
XY ...................................................................................................... 8-81
Index-8
DX100
INSTRUCTIONS
FOR NORTH AMERICAN (ANSI/RIA) STANDARD
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
MANUAL NO. RE-CTO-A217 2
C Printed in Japan February 2011 09-04
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