Yaskawa Motoman DX100 Instructions

DX100
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for
future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
Part Number:
Revision:
162536-1CD
9
MANUAL NO.
RE-CTO-A215
20
162536-1CD
DX100 Controller
Copyright ©2017, 2016, 2015, 2014, 2013, 2012 Yaskawa America, Inc.
Terms of Use and Copyright Notice
All rights reserved. This manual is freely available as a service to Yaskawa
customers to assist in the operation of Motoman robots, related equipment
and software This manual is copyrighted property of Yaskawa and may
not be sold or redistributed in any way. You are welcome to copy this
document to your computer or mobile device for easy access but you may
not copy the PDF files to another website, blog, cloud storage site or any
other means of storing or distributing online content.
Printed in the United States of America
First Printing, 2012
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200
www.motoman.com
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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.
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We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
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Notes for Safe Operation
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 “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
DANGER
Indicates an imminent hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
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
“DANGER”, “WARNING” and “CAUTION” .
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Notes for Safe Operation
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 an emergency stop button
immediately if there are problems.The emergency stop buttons are
located on the right of the front door of the DX100 and the programming
pendant.
•
Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
- Be sure to use a lockout device to the safeguarding when
going inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one
closes the safeguarding.
- 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 buttons on the front
door of the DX100 and programming pendant are 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 buttons do not function.
Figure 1: Emergency Stop Button
•
Once the emergency stop button is released, clear the cell of
all items which could interfere with the operation of the
manipulator. Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator
motion.
Figure 2: Release of Emergency Stop
TURN
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Definition of Terms Used In this Manual
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.
•
If the programming pendant is inadvertently left on the manipulator,
on a fixture, or on the floor, the angularities of the floor may activate
the Enable Switch, and the servo power could be turned ON as a
consequence. Also, when the manipulator starts its operation, the
manipulator or a tool could collide with the inadvertently left
programming pendant during manipulator movement, possibly
causing injury or equipment damage.
•
injury or equipment damage. Read and understand the Explanation
of the Warning Labels before operating the manipulator.
Definition of Terms Used In this Manual
The Motoman is the Yaskawa industrial robot product.
The Motoman usually consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows:
Equipment
Manual Designation
DX100 Controller
DX100
DX100 Programming Pendant
Programming Pendant
Cable between the manipulator and
the controller
Manipulator Cable
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Description of the Operation Procedure
Descriptions of the programming pendant, buttons, and displays are
shown as follows:
Equipment
Manual Designation
Programming Character
Pendant
Keys
The keys which have characters printed on
them are denoted with [ ].
ex. [ENTER]
Symbol
Keys
The keys which have a symbol printed on them
are not denoted with [ ] but depicted with a small
picture.
GO
BACK
ex. page key PAGE
The cursor key is an exception, and a picture is
not shown.
Axis Keys
Number Keys
“Axis Keys” and “Number Keys” are generic
names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]
Displays
The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
Description of the Operation Procedure
In the explanation of the operation procedure, the expression “Select • • •”
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
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Explanation of Warning Labels
Explanation of Warning Labels
The following warning labels are attached to the manipulator and DX100.
Fully comply with the precautions on the warning labels.
DANGER
•
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
Y
EM
E R GE N
C
WARNING
S T
O P
D ON
PE
IP
RE
T
OFF
SE
TR
High Voltage
Do not ope the cover.
May cause
electric shock.
Ground the earth
terminal based on
local and national
electric code.
PROGRAMMING PENDANT
X81
WARNING
Internal Breaker
High Voltage
Do not open the door
with power ON.
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Safeguarding Tips
Safeguarding Tips
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General
safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to
the equipment. Only trained personnel familiar with the operation of
this equipment, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this
equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
Mechanical Safety Devices
The safe operation of this equipment is ultimately the users responsibility.
The conditions under which the equipment will be operated safely should
be reviewed by the user. The user must be aware of the various national
codes, ANSI/RIA R15.06-2012 safety standards, and other local codes
that may pertain to the installation and use of this equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following
safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
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Programming, Operation, and Maintenance Safety
Programming, Operation, and Maintenance Safety
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. Improper operation can result in personal injury and/or
damage to the equipment. Only trained personnel familiar with the
operation, manuals, electrical design, and equipment interconnections of
this equipment should be permitted to program, or maintain the system.
All personnel involved with the operation of the equipment must
understand potential dangers of operation.
• Inspect the equipment to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment
for proper operation. Repair or replace any non-functioning safety
equipment immediately.
• Check the E-Stop button on the operator station for proper operation
before programming. The equipment must be placed in Emergency
Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are
done and before any changes are made to options, accessories, or
equipment.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot! Do not make any
modifications to the controller unit. Making any changes without the
written permission from Yaskawa will void the warranty.
• Some operations require standard passwords and some require
special passwords.
• The equipment allows modifications of the software for maximum
performance. Care must be taken when making these modifications.
All modifications made to the software will change the way the
equipment operates and can cause severe personal injury or death,
as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
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Maintenance Safety
Maintenance Safety
Turn the power OFF and disconnect and lockout/tagout all electrical
circuits before making any modifications or connections.
Perform only the maintenance described in this manual. Maintenance
other than specified in this manual should be performed only by Yaskawatrained, qualified personnel.
Summary of Warning Information
This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notes.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by Yaskawa. Address any questions regarding the safe and proper
operation of the equipment to Yaskawa Customer Support.
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Customer Support Information
Customer Support Information
If you need assistance with any aspect of your DX100 Controller system,
please contact Yaskawa Customer Support at the following 24-hour
telephone number:
(937) 847-3200
For routine technical inquiries, you can also contact Yaskawa Customer
Support at the following e-mail address:
[email protected]
When using e-mail to contact Yaskawa Customer Support, please provide
a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
NOTE
Please use e-mail for routine inquiries only. If you have an
urgent or emergency need for service, replacement parts,
or information, you must contact Yaskawa Customer
Support at the telephone number shown above.
Please have the following information ready before you call Customer
Support:
• System
DX100 Controller
• Robots
___________________________
• Primary Application
___________________________
• Controller
DX100
• Software Version
Access this information on the
Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} {VERSION}
• Robot Serial Number
Located on the robot data plate
• Robot Sales Order Number
Located on the DX100 controller
data plate
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Table of Contents
Table of 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 ................................................................. 3-2
3.2 Place and Condition for Installation ................................................................................... 3-3
3.3 Location ............................................................................................................................. 3-4
3.4 Mounting the Controller...................................................................................................... 3-5
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 Installation .......................................................... 4-5
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4.3 Connection Methods.......................................................................................................... 4-7
4.3.1 Connecting the Primary Power Supply................................................................. 4-7
4.3.2 Connecting the Manipulator Cable ..................................................................... 4-11
4.3.3 Connecting the Programming Pendant .............................................................. 4-12
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
5.3.3 The Method of Stopping Manipulator Operation................................................... 5-6
6 Test of Program Operation ............................................................................................................. 6-1
6.1 Movement of the Axes ....................................................................................................... 6-3
6.2 Manual Brake Release Function........................................................................................ 6-4
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 ................................................................... 7-6
7.1.2 User ID ................................................................................................................. 7-8
7.1.2.1 Changing User ID.................................................................................... 7-8
8 System Setup.................................................................................................................................. 8-1
8.1 Home Position Calibration ................................................................................................. 8-2
8.1.1 Home Position Calibration .................................................................................... 8-4
8.1.2 Calibrating Operation............................................................................................ 8-5
8.1.2.1 Registering All Axes at One Time ........................................................... 8-5
8.1.2.2 Registering Individual Axes ..................................................................... 8-8
8.1.2.3 Changing the Absolute Data ................................................................... 8-9
8.1.2.4 Clearing Absolute Data ........................................................................... 8-9
8.1.3 Home Position of the Robot................................................................................ 8-11
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8.2 Setting the Second Home Position (Check Point) ........................................................... 8-12
8.2.1 Purpose of Position Check Operation................................................................. 8-14
8.2.2 Procedure for the Second Home Position Setting (Check Point) ....................... 8-16
8.2.3 Procedure after the Alarm................................................................................... 8-18
8.3 Tool Data Setting ............................................................................................................. 8-20
8.3.1 Registering Tool Files ......................................................................................... 8-20
8.3.1.1 Number of Tool Files ............................................................................. 8-20
8.3.1.2 Registering Coordinate Data ................................................................. 8-20
8.3.1.3 Registering Tool Angle .......................................................................... 8-23
8.3.1.4 Setting the Tool Load Information ......................................................... 8-24
8.3.2 Tool Calibration................................................................................................... 8-25
8.3.2.1 Tool Calibration ..................................................................................... 8-25
8.3.2.2 Setting of Tool Calibration Method ........................................................ 8-25
8.3.2.3 Teaching of Calibration Point ................................................................ 8-26
8.3.2.4 Clearing Calibration Data ...................................................................... 8-31
8.3.2.5 Checking the TCP ................................................................................. 8-33
8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity................. 8-35
8.3.3.1 What is the Automatic Measurement of the Tool Load and
the Center of Gravity? ........................................................................... 8-35
8.3.3.2 Measurement of the Tool Load and the Center of Gravity .................... 8-35
8.4 ARM Control .................................................................................................................... 8-40
8.4.1 ARM Control ....................................................................................................... 8-40
8.4.2 ARM CONTROL Window ................................................................................... 8-40
8.4.2.1 Robot Setup Condition .......................................................................... 8-41
8.4.3 Tool Load Information Setting............................................................................. 8-45
8.4.3.1 Tool Load Information ........................................................................... 8-45
8.4.3.2 How to Calculate Tool Load Information ............................................... 8-46
8.4.3.3 Tool Load Information Registering ........................................................ 8-51
8.5 Work Home Position ........................................................................................................ 8-54
8.5.1 What is the Work Home Position? ...................................................................... 8-54
8.5.2 Setting Work Home Position............................................................................... 8-54
8.5.2.1 Work Home Position Window ................................................................ 8-54
8.5.2.2 Registering/Changing the Work Home Position .................................... 8-56
8.5.2.3 Returning to the Work Home Position ................................................... 8-57
8.5.2.4 Output of the Work Home Position Signal ............................................. 8-57
8.6 Interference Area ............................................................................................................. 8-58
8.6.1 Interference Area ................................................................................................ 8-58
8.6.2 Cubic Interference Area...................................................................................... 8-58
8.6.2.1 Cubic Interference Area......................................................................... 8-58
8.6.2.2 Cube Setting Method............................................................................. 8-59
8.6.2.3 Setting Operation .................................................................................. 8-60
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8.6.3 Axis Interference Area ........................................................................................ 8-69
8.6.3.1 Axis Interference Area........................................................................... 8-69
8.6.3.2 Setting Operation .................................................................................. 8-69
8.6.4 Clearing the Interference Area Data................................................................... 8-78
8.7 Shock Detection Function................................................................................................ 8-80
8.7.1 Shock Detection Function................................................................................... 8-80
8.7.2 Shock Detection Function Setting ...................................................................... 8-80
8.7.2.1 Shock Detection Level Setting .............................................................. 8-80
8.7.2.2 Tool Load Information Setting ............................................................... 8-85
8.7.2.3 U-Arm Payload Setting.......................................................................... 8-85
8.7.2.4 Instruction of Shock Detection Function................................................ 8-85
8.7.2.5 Resetting the Shock Detected............................................................... 8-90
8.7.3 High-Sensitivity Shock Detection Function (For Arc Welding Application Only). 8-91
8.7.3.1 Manipulator Type for High-Sensitivity Shock Detection Function.......... 8-91
8.7.3.2 Setting for High-Sensitivity Shock Detection Function .......................... 8-91
8.7.3.3 Reading the Tool Load Information on the
MAKER INITIAL VALUE Window .......................................................... 8-92
8.7.3.4 Explanation of Maker Initial Value ......................................................... 8-94
8.7.3.5 Reading the U-Arm Payload.................................................................. 8-95
8.7.3.6 Explanation of Maker Initial Value ......................................................... 8-98
8.8 User Coordinate Setting .................................................................................................. 8-99
8.8.1 User Coordinates................................................................................................ 8-99
8.8.2 User Coordinate Setting ................................................................................... 8-100
8.8.2.1 Selecting the User Coordinate File...................................................... 8-100
8.8.2.2 Teaching the User Coordinates........................................................... 8-101
8.8.2.3 Clearing the User Coordinates ............................................................ 8-103
8.9 Overrun/Tool Shock Sensor Releasing ......................................................................... 8-104
8.10 Soft Limit Release Function......................................................................................... 8-106
8.11 All Limit Release Function ........................................................................................... 8-107
8.12 Instruction Level Setting .............................................................................................. 8-109
8.12.1 Setting Contents ............................................................................................. 8-109
8.12.1.1 Instruction Set ................................................................................... 8-109
8.12.1.2 Learning Function ............................................................................. 8-110
8.12.2 Setting the Instruction Set Level..................................................................... 8-110
8.12.3 Setting the Learning Function ........................................................................ 8-112
8.13 Setting the Controller Clock ......................................................................................... 8-113
8.14 Setting the Play Speed ................................................................................................ 8-114
8.15 Numeric Key Customize Function ............................................................................... 8-116
8.15.1 What is the Numeric Key Customize Function? ............................................. 8-116
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8.15.2 Allocatable Functions...................................................................................... 8-116
8.15.2.1 Key Allocation (EACH) ...................................................................... 8-116
8.15.2.2 Key Allocation (SIM) .......................................................................... 8-117
8.15.3 Allocating Operation ....................................................................................... 8-118
8.15.3.1 Allocation Window ............................................................................. 8-118
8.15.3.2 Instruction Allocation ......................................................................... 8-119
8.15.3.3 Job Call Allocation ............................................................................. 8-121
8.15.3.4 Display Allocation .............................................................................. 8-121
8.15.3.5 Alternate Output Allocation................................................................ 8-123
8.15.3.6 Momentary Output Allocation ............................................................ 8-124
8.15.3.7 Pulse Output Allocation ..................................................................... 8-124
8.15.3.8 Group (4-bit/8-bit) Output Allocation.................................................. 8-125
8.15.3.9 Analog Output Allocation ................................................................... 8-125
8.15.3.10 Analog Incremental Output Allocation ............................................. 8-126
8.15.4 Allocation of I/O Control Instructions .............................................................. 8-127
8.15.5 Execution of Allocation ................................................................................... 8-128
8.15.5.1 Executing the Instruction/Output Control Allocation .......................... 8-128
8.15.5.2 Executing the Job Call Allocation ...................................................... 8-128
8.15.5.3 Executing the Display Allocation ....................................................... 8-128
8.15.5.4 Executing the I/O Control Allocation.................................................. 8-129
8.16 Changing the Output Status......................................................................................... 8-130
8.17 Changing the Parameter Setting.................................................................................. 8-132
8.18 File Initialization ........................................................................................................... 8-135
8.18.1 Initializing Job File .......................................................................................... 8-135
8.18.2 Initializing Data File......................................................................................... 8-136
8.18.3 Initializing Parameter File ............................................................................... 8-137
8.18.4 Initializing I/O Data.......................................................................................... 8-139
8.18.5 Initializing System Data .................................................................................. 8-140
8.19 Display Setting Function .............................................................................................. 8-142
8.19.1 Font Size Setting ............................................................................................ 8-142
8.19.1.1 Applicable Range for the Font Size Change ..................................... 8-142
8.19.1.2 Settable Font Size ............................................................................. 8-142
8.19.1.3 Setting the Font Size ......................................................................... 8-143
8.19.2 Operation Button Size Setting ........................................................................ 8-146
8.19.2.1 Applicable Range for the Button Size Change .................................. 8-146
8.19.2.2 Settable Button Size .......................................................................... 8-146
8.19.2.3 Setting the Button Size ...................................................................... 8-146
8.19.3 Initialization of Screen Layout......................................................................... 8-150
8.19.3.1 Initializing the Screen Layout............................................................. 8-150
8.19.4 Layout Storage ............................................................................................... 8-152
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8.20 Encoder Back-up Error Recovery Function ................................................................. 8-153
8.20.1 About Encoder Back-up Error Recovery Function.......................................... 8-153
8.20.2 Encoder Back-up Error Recovery Function Operation ................................... 8-153
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 ..................................................................................................... 9-8
9.3.2 Settings for Automatic Backup ........................................................................... 9-10
9.3.2.1 The CompactFlash of the Programming Pendant ................................. 9-10
9.3.2.2 The CompactFlash of the YCP01 Board ............................................... 9-11
9.3.2.3 RAMDISK on the YCP01 Board ............................................................ 9-11
9.3.2.4 DX100 Status and Automatic Backup ................................................... 9-12
9.3.2.5 Setting Examples .................................................................................. 9-14
9.3.2.6 AUTO BACKUP SET Window............................................................... 9-15
9.3.2.7 AUTO BACKUP EXTENSION FUNCTION SET Window ..................... 9-20
9.3.3 Limiting the Automatic Backup File Creation...................................................... 9-25
9.3.3.1 Setting to Limit the Automatic Backup File Creation ............................. 9-25
9.4 Loading the Backup Data from the CompactFlash .......................................................... 9-26
9.4.1 Loading Procedure ............................................................................................. 9-26
9.5 Error List .......................................................................................................................... 9-31
9.5.1 Error Contents .................................................................................................... 9-31
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
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10.3 Error Message ............................................................................................................... 10-4
11 Reset Function of the Programming Pendant ............................................................................. 11-1
12 Modification of System Configuration.......................................................................................... 12-1
12.1 Addition of I/O Modules.................................................................................................. 12-1
12.2 Addition of Base and Station Axes................................................................................. 12-4
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 .............................................................................. 12-9
12.2.1.3 Axis Configuration Setting ................................................................. 12-12
12.2.1.4 Mechanical Specification Setting....................................................... 12-13
12.2.1.5 Motor Specification Setting................................................................ 12-15
12.2.2 Station Axis Setting......................................................................................... 12-16
12.2.2.1 Selection of Station Axis Type........................................................... 12-16
12.2.2.2 Connection Setting ............................................................................ 12-18
12.2.2.3 Axis Configuration Setting ................................................................. 12-20
12.2.2.4 Mechanical Specification Setting....................................................... 12-21
12.2.2.5 Motor Specification Setting................................................................ 12-24
13 DX100 Specification.................................................................................................................... 13-1
13.1 Specification List ............................................................................................................ 13-2
13.2 Function List................................................................................................................... 13-3
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........................................................ 13-10
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
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14.3.2.1 Control Circuit Board (JANCD-YCP01-E) ......................................... 14-10
14.3.2.2 Robot I/F Board (JANCD-YIF01-1E) ................................................. 14-10
14.4 CPS Unit (JZNC-YPS01-E) ......................................................................................... 14-11
14.5 Brake Control Board (JANCD-YBK01-□E)................................................................... 14-13
14.5.1 Brake Control Board (JANCD-YBK01-□E) ..................................................... 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)...................................................................... 14-20
14.7.1 Machine Safety Unit (JZNC-YSU01-1E)......................................................... 14-20
14.7.2 Connection for Servo-ON Enable Input (ONEN1 and ONEN2)...................... 14-21
14.7.3 Connection for External Axis Overrun (EXOT) ............................................... 14-22
14.8 WAGO Connector........................................................................................................ 14-26
14.9 Robot System Input Terminal Block (MXT) ................................................................. 14-28
14.10 Contact Output of Emergency Stop Button................................................................ 14-42
14.11 SERVOPACK ............................................................................................................ 14-43
14.11.1 Description of Each Unit ............................................................................... 14-43
14.11.1.1 Converter ........................................................................................ 14-43
14.11.1.2 PWM Amplifier................................................................................. 14-43
14.11.2 SERVOPACK Configuration......................................................................... 14-43
14.12 Universal I/O Signal Assignment ............................................................................... 14-48
14.12.1 Arc Welding .................................................................................................. 14-48
14.12.2 Handling ....................................................................................................... 14-54
14.12.3 General Application ...................................................................................... 14-60
14.12.4 Spot Welding ................................................................................................ 14-66
14.12.5 JANCD-YEW01-E Circuit Board (Standard)................................................. 14-74
14.12.5.1 Arc Welding ..................................................................................... 14-74
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1
1 Safety
1.1 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
– JIS B 8433-1:2007
(ISO 10218-1:2006)
– INDUSTRIAL ROBOT- SAFETY REQUIREMENTS
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.
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1 Safety
1.2 Special Training
1.2
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
– DX100 MAINTENANCE 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.
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1 Safety
1.4 Personnel Safety
1.4
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.
WARNING
•
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.
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1.4 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.
ER
GE N
EM
T O P
S
GE N
T O P
TRIP
T OFF
PED
ON
PED
RESE
T OFF
TRIP
ON
PROGRAMMING PENDANT
PROGRAMMING PENDANT
X81
•
ER
Y
Y
S
C
C
EM
Failure to observe this caution may result in injury or damage by
unexpected movement of the manipulator.
RESE
DX100 Controller
X81
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.
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1 Safety
1.5 Motoman Safety
1.5
Motoman Safety
The followings are safty functions of Motoman / DX100.
• Emergency stop SW input (controller/programming pendant)
• Enable SW input (programming pendant)
• Safeguarding interlock signal input (safety plug)
• External emergency stop SW input
• External enable SW input
• Servo power enable input
• Overrun input (manipulator/external axis)
These safety functions conform to the following safety standards.
• EN ISO 13849-1:2008 + AC:2009 Cat.4 / PL e
• EN 62061:2005 / IEC 61508 Part 1-7:1998/2000 SIL3
The use frequency of each switch for safety functions is assumed as
below.
1.5.1
• Emergency stop SW
500 times/ year
• External emergency stop SW
500 times/ year
• Enable SW (programming pendant)
2000 times/ year
• External enable SW
2000 times/ year
Installation and Wiring Safety
Refer to the MOTOMAN- Instructions 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:
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1 Safety
1.5 Motoman Safety
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.
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.
CAUTION
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.
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1.5 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
E R GE N
C
Y
EM
M16 Eye Bolt
O P
T
OFF
SE
TR
IPP
ED
S T
ON
RE
DX100 Controller
PROGRAMMING PENDANT
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DX100
•
Table 1-1: Approx. Weight of DX100
Models Available for
DX100
Approx. Weight
(kg)
small capacity:
MA1400, MA1900,
VA1400, MH5, MH5L,
MH6, HP20D,
HP20D-6, HP20RD
A-Type
(standard)
100
middle/large capacity:
MH50, MH50-20,
MH50-35, MS80, VS50,
SIA50D, MA1800,
ES165D, ES165RD,
ES200D, ES200RD,
HP165D, UP350D
A-Type
(standard)
100
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.
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1.5 Motoman Safety
CAUTION
•
Be sure there is sufficient room for maintenance on the manipulator,
DX100, and other peripheral equipment.
425
EM
450
DX100
E R GE N
S T
O P
ON
DOOR
1200
ET
OFF
RES
TRIP
PED
500
Y
DX100
425
DX100
C
450
500
Failure to observe this precaution could result in injury during
maintenance.
510
406
DX100 Controller
PROGRAMMING PENDANT
X81
maintenance area
DX100 Maintenance Area (Unit: mm)
•
DX100 External Dimensions (Unit: mm)
A-Type (Standard)
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.
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1.5 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.
E R GE N
C
Y
EM
DX100
O P
TR
IP
PE
D
S T
ON
T
OFF
SE
RE
DX100 Controller
Tapped Holes for
M10 Screws on
the DX100 Side
12 dia.
(2 holes)
40
PROGRAMMING PENDANT
X81
30
30
50
50
(Unit: mm)
•
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.
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1.5 Motoman Safety
1.5.2
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.
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1.5 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.
ER
GE N
Y
E
C
M
•
T O P
ON
OFF
TR
IP
PE
RE
D
T
SEOFF
TR
IPP
ED
S
ON
SE
T
ENERGIZING
PROHIBITED
RE
1.5.3
PROGRAMMING PENDANT
X81
PADLOCK
DX100
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:
– Be sure to use a lockout device to the safeguarding when
going inside. Also, display the sign that the operation is
being performed inside the safeguarding and make sure no
one closes the safeguarding.
– 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.
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1.5 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 front door of the DX100, on 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 buttons are located on the right of the front door of
the DX100 and the programming pendant.
Emergency Stop Button
ER
GE N
Y
E
C
M
DX100
T O P
SE
TOFF
TR
IPP
ED
S
ON
RE
DX100 Controller
PROGRAMMING PENDANT
X81
Programming Pendant
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1.5 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 section 1.2 “Special Training”
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1.6 Notes for Moving and Transferring the Motoman
1.6
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 section 1.3 “Motoman
Manual List” 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.
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1.7 Notes on Motoman Disposal
1.7
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.
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2
2 Product Confirmation
2.1 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
DX100
Y
EM
E R GE N
C
Programming
Pendant
S T
D
O P
ON
PE
IP
RE
SE
TOFF
TR
PROGRAMMING PENDANT
X81
MOTOMAN
Complete Set of Manuals
Manipulator Cable
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2 Product Confirmation
2.2 Order Number Confirmation
2.2
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.
E R GE N
Y
D
S T
O P
ON
RE
T
SEOFF
TR
IP
PE
S78796-1
C
EM
ORDER NO.
PROGRAMMING PENDANT
X81
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DX100 Controller
3
3 Installation
3.1 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.
Table 3-1: Approx. Weight of DX100
Models Available for DX100
Wire Rope
E R GE N
C
Y
EM
M16 Eye Bolt
RE
T
OFF
SE
TR
IPP
ED
S T
ON
PROGRAMMING PENDANT
X81
DX100
O P
Approx.
Weight (kg)
A-Type
(standard)
100
Small MH5, MH5S, MH5L, MH5LS,
Capacity MH6, MH6S, MH6-10,
MA1400, MA1900,
MPK2,
VA1400,
HP20D, HP20D-6, HP20RD
A-Type
Middle, DX1350D,
(standard)
Large ES165D, ES165RD, ES165D-100, ES200D, ES200RD,
Capacity ES200RD-120,
100
HP165D,
MA1800,
MC2000,
MH50, MH50-20, MH50-35, MH80,
MPL80,
MS80, MS80W, MS120
SIA30D, SIA50D,
UP50SD, UP120ED-165, UP350D, UP350D-200, UP350D-500
VS50
A-Type
Large EPH130D, EPH130RLD,
Capacity ES280D, ES280D-230,
(standard)
MH165, MH200, MH215, MH250,
150
MPK50,
MPL100, MPL160, MPL300, MPL500
3-1
RE-CTO-A215
162536-1CD
DX100 Controller
3 Installation
3.1 Handling Procedure
3.1.2
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
3-2
RE-CTO-A215
162536-1CD
DX100 Controller
3 Installation
3.2 Place and Condition for Installation
3.2
Place and Condition for Installation
The conditions listed below must be met before installing the DX100.
• Ambient temperature: 0 to 45°C (32 to 113°F) during operation
-10 to 60°C (14 to 140°F) during transportation and maintenance
Temperature change: 0.3°C per minute or less
• Humidity: 10 to 90% RH with no condensation
• Only a small amount of dirt, dust, cutting oil, organic solvent, oil
fume, water, salt, etc. in the place
(Especially, avoid adhesion of chemicals, cutting oil including
coolant, rust preventive oil, organic solvent, etc. to the programming
pendant.)
• Free from flammable or corrosive liquid, gas, etc.
• Free from excessive shock, vibration, etc. (vibration: 0.5G or less)
• Free from large electrical noise
(An electrical noise source such as a TIG welding device must not
be placed close to the DX100.)
• Free from excessive microwaves, ultraviolet rays, X-rays, or
radiation
• Altitude: 1000 m or less
(To use the DX100 at the altitude over 1000 m, calculate the
maximum ambient temperature by decreasing it by 1% per 100 m.
The maximum allowable altitude is 2000 m. When the altitude is
2000 m, the maximum ambient temperature during operation is
40.5°C.)
NOTE
Due to external noise, an alarm may occur and the
manipulator may stop its operation.
If an alarm occurs and the manipulator stops its operation,
reset the alarm by referring to the “DX100 MAINTENANCE
MANUAL.”
3-3
RE-CTO-A215
162536-1CD
DX100 Controller
3 Installation
3.3 Location
3.3
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.
425
450
DX100
406
510
DOOR
maintenance area
A-Type (Standard)
4.
Install the controller at least 500mm from the nearest wall to allow
maintenance access.
3-4
RE-CTO-A215
162536-1CD
DX100 Controller
3 Installation
3.4 Mounting the Controller
450
DX100
E R GE N
Y
S T
1200
500
C
EM
425
DX100
O P
PROGRAMMING PENDANT
X81
A-Type (Standard)
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
E R GE N
C
Y
EM
3.4
S T
O P
Tapped Holes for
M10 Screws on
the DX100 Side
12 dia.
(2 holes)
40
PROGRAMMING PENDANT
X81
30
30
50
50
(Unit: mm)
NOTE
Refer to the Instruction Manual for information on
installation of the manipulator.
3-5
RE-CTO-A215
162536-1CD
DX100 Controller
4
4
Connection
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.
WARNING
•
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
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.1 Notes on Cable Junctions
4.1
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(a): DX100 Cable Junction Diagram
SAFETY
FIRST
PIPING
LEAD
cable channel
• When the power cable and the encoder cable of the manipulator
cable are located in the same cable duct, the two cables must be
separated from each other or install a separator between the two
cables.
Fig. 4-1(b): Example for the cable arrangement in the duct
Encoder cable
Power cable
Separator
Power cable
× Bad example
Encoder cable
○ Good example
4-2
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.2 Power Supply
4.2
Power Supply
4.2.1
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 of 200/220VAC at 60Hz and
200VAC at 50Hz.
Fig. 4-2: Input Power Connection
DX100
Contactor
2KM
1KM
Breaker
3-phase
200/220VAC at 60Hz
or
200VAC 50Hz
SERVOPACK
Fuse
Noise Filter
To control
power supply
unit
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
3-phase
Noise Filter
DX100
3-phase
200/220VAC at 60Hz
or
200VAC 50Hz
Contactor
2KM
1KM
Breaker
SERVOPACK
Fuse
Noise Filter
To control
power supply
unit
4-3
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.2 Power Supply
4.2.3
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.
Table 4-1: Example of High Frequency Leakage Breaker
Maker
Model
Mitsubishi Electric Co., Ltd.
NV series (manufactured since 1988)
Fuji Electric Co., Ltd.
EG or SG Series (manufactured since 1984)
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
Leakage
Breaker
DX100
Contactor
2KM
1KM
Breaker
3-phase
200/220VAC at 60Hz
or
200VAC 50Hz
SERVOPACK
Fuse
Noise Filter
To control
power supply
unit
4-4
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.2 Power Supply
4.2.4
Primary Power Supply Breaker Installation
Install the primary power supply breaker as shown below.
Fig. 4-5: Installation of the Primary Power Supply Breaker
Breaker
Breaker
Controller
for Positioner
DX100
Breaker
Power
Source
Table 4-2: DX100 Power Capacity, Cable Sizes, and Breaker Capacities
(kVA)
Cable size (size of terminal)
(In case of Cabtyre cable
(three cores))(mm2)
Capacity of
breaker in
DX100 (A)
MH5
MH5L
MH5S
MH5LS
1.0
3.5(M5)
15
MA1400
MH6
MH6S
MH6-10
MPK2
VA1400
1.5
3.5(M5)
15
HP20D
HP20D-6
HP20RD
MA1900
2.0
3.5(M5)
15
Manipulator
Power
capacity
MA1800
2.5
5.5(M5)
30
SIA30D
3.0
5.5(M5)
15
MC2000
3.5
5.5(M5)
30
MH50
MH50-20
MH50-35
MS80
MS80W
MPK50
MPL80
DX1350D
4.0
5.5(M5)
30
UP50SD
MH80
MS120
4.5
5.5(M5)
30
4-5
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.2 Power Supply
Table 4-2: DX100 Power Capacity, Cable Sizes, and Breaker Capacities
(kVA)
Cable size (size of terminal)
(In case of Cabtyre cable
(three cores))(mm2)
Capacity of
breaker in
DX100 (A)
UP120ED-165
ES165D
ES165RD
ES165D-100
ES200D
ES200RD
ES200RD-120
ES280D
ES280D-230
HP165D
VS50
SIA50D
MH165
MH200
5.0
5.5(M5)
30
UP350D
UP350D-200
UP350D-500
5.5
5.5(M5)
30
MH215
MH250
6.0
5.5(M5)
30
EPH130D
EPH130RLD
8.0
5.5(M5)
30
MPL100
MPL160
MPL300
MPL500
9.5
5.5(M5)
30
Manipulator
Power
capacity
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.
NOTE
The power capacity shown above is the continuous rating
value.
When the robot is rapidly accelerated, the power capacity of
several times the continuous rating value may be needed
instantly.
4-6
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.3 Connection Methods
4.3
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
Y
D
Manipulator
E R GE N
S T
O P
ON
RE
T
OFF
SE
TR
IP
PE
Primary Power Supply Cable
C
EM
DX100
PROGRAMMING PENDANT
X81
Manipulator
Cable
Programming
Pendant 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
4-7
RE-CTO-A215
162536-1CD
4 Connection
4.3 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
SE
T
OFF
TR
IP
PE
D
ON
RE
DX100 Controller
DX100
2. Confirm that the primary power supply is OFF.
3. Connect the primary power supply cable.
– Draw the primary power supply cable in from the cable entrance on
top side of DX100 and fix it firmly with the cable clamp so that it
won’t shift or slip out of place.
Fig. 4-9: Cable Clamp
DX100
Primary Power Supply Cable
WARNING
•
Cable clamp must be used when connecting primary power supply.
•
Make sure that the cable clamp is fastened tightly to prevent dust or
water from entering.
Failure to observe this caution may result in electric shock or
breakdown of DX100.
4-8
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.3 Connection Methods
(1) Pull off the primary cover of the switch which is on the upper right
side of the DX100.
Fig. 4-10: Pulling Off the Cover
(2) Connect a ground wire to reduce noise and prevent electric shock.
I)
Connect the ground wire to the ground terminal (screw) of the
switch which is on the upper left side of DX100.
Fig. 4-11: Connection of the Ground Wire
Ground wire
II)
NOTE
Ground terminal
(M6 screws)
Perform grounding in accordance with all relevant local and
national electrical codes. The size of ground wire must the
same as listed in Table 4-2 "DX100 Power Capacity, Cable
Sizes, and Breaker Capacities".
The customer must prepare the ground wire.
4-9
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.3 Connection Methods
Fig. 4-12: 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.
(3) Connect the primary power supply cable.
Fig. 4-13: Connection of the Primary Power Supply Cable
(4) Install the cover.
Fig. 4-14: Install the Cover
4-10
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.3 Connection Methods
4.3.2
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. 4-15: Connection of the Manipulator 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 lock counterclockwise 90 degrees.
Fig. 4-16: Rotating the Door Lock Counterclockwise
counterclockwise 90
door lock
flathead screw driver
4-11
RE-CTO-A215
162536-1CD
DX100 Controller
4 Connection
4.3 Connection Methods
WARNING
•
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. 4-17: Connecting the Programming Pendant
Alignment mark
– The manipulator, DX100, and the programming pendant
connections are now complete.
4-12
RE-CTO-A215
162536-1CD
DX100 Controller
Turning ON and OFF the Power Supply
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 buttons are located on the right side of the front
door of the DX100 and on the 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
T
OFF
TR
IP
PE
D
ON
SE
5.1
RE
5
5 Turning ON and OFF the Power Supply
5.1 Turning ON the Main Power Supply
DX100
5-1
RE-CTO-A215
162536-1CD
DX100 Controller
5 Turning ON and OFF the Power Supply
5.1 Turning ON the Main Power Supply
5.1.1
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
CAUTION
•
Make sure that a system manager stores the key of the mode select
switch on the programming pendant.
After operation, the key should be removed and stored by the
system manager.
Improper or unintended manipulator operation may result in injury.
Also, the key or the mode select switch may be damaged if the
programming pendant is dropped with the key inserted.
5-2
RE-CTO-A215
162536-1CD
DX100 Controller
5 Turning ON and OFF the Power Supply
5.2 Turning ON the Servo Power
5.2
Turning ON the Servo Power
5.2.1
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
RE-CTO-A215
162536-1CD
DX100 Controller
5 Turning ON and OFF the Power Supply
5.2 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.
SUPPLEMENT
Servo On
Release -> OFF
NOTE

Squeeze -> ON
Squeeze Tightly -> OFF
When performing emergency stop on the front door of the
DX100, 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.
The Valid / Invalid setting of safety signals in operation modes.
Safety functions of the robotic system are switched to valid or invalid
depending on operation modes. Particularly in teach mode, be aware the
safeguarding(safety plug) signal input becomes invalid. Perform the
operation with great caution.
Operation Mode
Play Mode
Teach Mode
Safety Signal
Controller Emergency Stop (PBESP)
Valid
Valid
External Emergency Stop (EXESP)
Valid
Valid
Programing Pendant Emergency Stop
(PPESP)
Valid
Valid
Safeguarding (safety plug)
(SAFF)
Valid
Invalid
Programing Pendant Enable SW (PPDSW)
Invalid
Valid
External Enable SW (EXDSW)
Invalid
Valid
Servo Power Enable (ONEN)
Valid
Valid
Manipulator Overrun (OT)
Valid
Valid
External Axis Overrun (EXOT)
Valid
Valid
Speed Limit
Invalid
Valid
5-4
RE-CTO-A215
162536-1CD
DX100 Controller
5 Turning ON and OFF the Power Supply
5.3 Turning OFF the Power Supply
5.3
Turning OFF the Power Supply
5.3.1
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 buttons are located on the front door of the
DX100 and 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
EMERGENCY STOP
Door upper side
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
T
SE
OFF
TR
IP
PE
D
ON
RE
5.3.2
DX100
5-5
RE-CTO-A215
162536-1CD
DX100 Controller
5 Turning ON and OFF the Power Supply
5.3 Turning OFF the Power Supply
5.3.3
The Method of Stopping Manipulator Operation
The following 3 categories are stop functions of the manipulator.
– Stop Category 0
The immediate insulation of the motor power source to servo motor
causes the stop.
After the motor power is insulated, the manipulator and the external
axis decelerate by the brake and stop.
The manipulator and the external axis may run off the operation
path(Path).
– Stop Category 1
The manipulator and the external axis are controlled on the
operation path, decelerate and then stop.
After the stop, the manipulator and the external axis are locked by
the brake and the motor power is insulated.
– Stop Category 2
The manipulator and the external axis are controlled on the
operation path, decelerate and then stop.
After the stop, the stop position is retained in a state that the motor
power is being supplied.
Besides the safety signals, the DX100 robotic system stops the
manipulator by the above three stop categories.
The method of stopping the manipulator by each stop signal is shown in
the following table.
Operation Mode
Safety Signal
Stop
Category 0
Stop
Category 1
External Emergency Stop (EXESP)


Programing Pendant Emergency Stop
(PPESP)

Safeguarding (safety plug)
(SAFF)

Controller Emergency Stop (PBESP)
Programing Pendant Enable SW
(PPDSW)

External Enable SW (EXDSW)

Servo Power Enable (ONEN)



Manipulator Overrun (OT)
External Axis Overrun (EXOT)
Programing Pendant (HOLD)
Stop
Category 2

5-6
RE-CTO-A215
162536-1CD
DX100 Controller
6
6
Test of Program Operation
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:
– Be sure to use a lockout device to the safeguarding when
going inside. Also, display the sign that the operation is
being performed inside the safeguarding and make sure no
one closes the safeguarding.
– 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
RE-CTO-A215
162536-1CD
DX100 Controller
6
Test of Program Operation
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.
•
Make sure that a system manager stores the key of the mode select
switch on the programming pendant.
After operation, the key should be removed and stored by the
system manager.
Improper or unintended manipulator operation may result in injury.
Also, the key or the mode select switch may be damaged if the
programming pendant is dropped with the key inserted.
6-2
RE-CTO-A215
162536-1CD
DX100 Controller
6 Test of Program Operation
6.1 Movement of the Axes
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.
NOTE
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.
U-Axis
R-Axis
B-Axis
X-
X+
X-
X+
Y-
Y+
Y-
Y+
Z-
Z+
Z-
Z+
E-
E+
8-
8+
S-
S+
L-
R-
L+
U-
B-
U+
T-
T-Axis
R+
E-Axis
B+
L-Axis
T+
Axis Keys
S-Axis
S
Rotates main body
X-
X+
S-
R
Rotates upper arm
X+
S+
R+
X-
R-
L
Moves lower arm forward/
backward
Moves wrist up/down
B
Y+
B+
Y+
Y-
L+
L-
YB-
U
Moves upper arm up/ down
T
Rotates wrist
Z+
U+
Z+
T+
ZT-
Z-
U-
E
Rotates lower arm
E-
E+
6-3
RE-CTO-A215
162536-1CD
DX100 Controller
6 Test of Program Operation
6.2 Manual Brake Release Function
6.2
Manual Brake Release Function
When the manipulator moves to unexpected places because of system or
operation errors and the operation can not be maintained, using the brake
release unit(optional) enables to release the brake of the arbitrary working
axis of the manipulator and operate manually.
Table 6-1: Brake Release Unit (Separate Unit Type)
Brake release unit side
manipulator side
1CP
ゲ଻ᜬ⸃᡼
BRAKE RELEASE
㔚Ḯ
POWER
4000
ON
(1CN)
OFF
(1SS)
(1LMP)
L
U
R
B
T
(1PB)
(2PB)
(3PB)
(4PB)
(5PB)
(6PB)
(2CN)
2BC
S
2CN
(1CP)
Cable for brake release unit
Name
Power cable㧦2 m
Weight㧦3 kg
Unit㧦mm
This brake release unit can be used in a state that the motor servo ON can
not be executed from the DX100 controller.
Be very careful about the followings when using.
CAUTION
•
When releasing the brake, pay attention to surroundings.
The robot arm may move under its own weight, and personal injury
or equipment damage may result.
•
Release the brake for one axis at a time.
If the brakes of multiple axes are released out of necessity, the
robot arm may move in an unexpected way. Pay attention to
surroundings. Personal injury or equipment damage may result.
In case of purchase, inquire at the nearest Yaskawa branch office listed on
the back cover.
6-4
RE-CTO-A215
162536-1CD
DX100 Controller
7
7 Security System
7.1 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
RE-CTO-A215
162536-1CD
DX100 Controller
7 Security System
7.1 Protection Through Security Mode Settings
Table 7-2: Menu & Security Mode (Sheet 1 of 4)
Main Menu
Sub Menu
Allowed Security Mode
DISPLAY
JOB
JOB
Operation
Edit
SELECT JOB
Operation
Operation
CREATE NEW JOB1)
Edit
Edit
MASTER JOB
Operation
Edit
JOB CAPACITY
Operation
-
RES. START (JOB)1)
Edit
Edit
Operation
-
Operation
Operation
RES. STATUS
2)
CYCLE
VARIABLE
IN/OUT
EDIT
BYTE
Operation
Edit
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
Edit
EXTERNAL OUTPUT
Operation
Edit
UNIVERSAL INPUT
Operation
Operation
UNIVERSAL OUTPUT
Operation
Operation
SPECIFIC INPUT
Operation
-
SPECIFIC OUTPUT
Operation
-
RIN
Operation
-
CPRIN
Operation
-
REGISTER
Operation
Management
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
RE-CTO-A215
162536-1CD
DX100 Controller
7 Security System
7.1 Protection Through Security Mode Settings
Table 7-2: Menu & Security Mode (Sheet 2 of 4)
Main Menu
ROBOT
Sub Menu
Allowed Security Mode
DISPLAY
EDIT
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
CURRENT POSITION
SHOCK SENS LEVEL
Operation
Edit
USER COORDINATE
Edit
Edit
HOME POSITION
Management Management
MANIPULATOR TYPE
Management -
ANALOG MONITOR
Management Management
OVERRUN&S-SENSOR1)
Edit
Edit
1)
Edit
Edit
1)
Management Management
LIMIT RELEASE
ARM CONTROL
SYSTEM INFO
FD/CF
SHIFT VALUE
Operation
-
VERSION
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
Edit
Management
Operation
-
FOLDER
1)
INITIALIZE
7-3
RE-CTO-A215
162536-1CD
DX100 Controller
7 Security System
7.1 Protection Through Security Mode Settings
Table 7-2: Menu & Security Mode (Sheet 3 of 4)
Main Menu
Sub Menu
Allowed Security Mode
DISPLAY
PARAMETER
SETUP
S1CxG
Management Management
S2C
Management Management
S3C
Management Management
S4C
Management Management
A1P
Management Management
A2P
Management Management
A3P
Management Management
A4P
Management Management
A5P
Management Management
A6P
Management Management
A7P
Management Management
A8P
Management Management
RS
Management Management
S1E
Management Management
S2E
Management Management
S3E
Management Management
S4E
Management Management
S5E
Management Management
S6E
Management Management
S7E
Management Management
S8E
Management Management
TEACHING COND.
Edit
OPERATE COND.
Management Management
OPERATE ENABLE
Management Management
FUNCTION ENABLE
Management Management
JOG COND.
Management Management
PLAYBACK COND.
Management Management
FUNCTION COND.
Management Management
DATE/TIME
GRP COMBINATION
DISPLAY
SETUP
EDIT
Edit
Management Management
2)
Management Management
RESERVE JOB NAME
Edit
Edit
USER ID
Edit
Edit
SET SPEED
Management Management
KEY ALLOCATION
Management Management
JOG KEY ALLOC.
Edit
RES. START (CNCT)
Management Management
AUTO BACK SET
Management Management
WRONG DATA LOG
Edit
Management
ENERGY SAVING FUNCTION
Edit
Management
CHANGE FONT
Operation
Operation
CHANGE BUTTON
Operation
Operation
INITIALIZE LAYOUT
Operation
Operation
CHANGE WINDOW PATTERN
Operation
Operation
Management
7-4
RE-CTO-A215
162536-1CD
DX100 Controller
7 Security System
7.1 Protection Through Security Mode Settings
Table 7-2: Menu & Security Mode (Sheet 4 of 4)
Main Menu
Sub Menu
Allowed Security Mode
DISPLAY
EDIT
Operation
Edit
ARC END COND.
Operation
Edit
ARC AUX COND.
Operation
Edit
POWER SOURCE COND.
Operation
Edit
ARC WELD DIAG.
Operation
Edit
ARC WELDING ARC START COND.
WEAVING
Operation
Edit
ARC MONITOR
Operation
Edit
ARC MONITOR (SAMPL)
Operation
-
HANDLING
HANDLING DIAGNOSIS
Operation
Edit
SPOT
WELDING
WELD DIAGNOSIS
Operation
Edit
I/O ALLOCATION
Management Management
GUN CONDITION
Management Management
SPOT POWER SOURCE
COND.
Management Management
APPLICATION CONDITION
SETTING
Management Management
WELD DIAGNOSIS
Operation
SPOT
WELDING
(MOTOR GUN)
GENERAL
COMMON TO
ALL
APPLICATIONS
Edit
GUN PRESSURE
Edit
Edit
PRESSURE
Edit
Edit
I/O ALLOCATION
Management Management
GUN CONDITION
Management Management
CLEARANCE SETTING
Operation
SPOT POWER SOURCE
COND.
Management Management
Edit
TIP INSTALLATION
Operation
APPLICATION CONDITION
SETTING
Management Management
WEAVING
Operation
Edit
GENERAL DIAG.
Operation
Edit
I/O VARIABLE CUSTOMIZE
Operation
Operation
Management
1 Displayed in the teach mode only.
2 Displayed in the play mode only.
7-5
RE-CTO-A215
162536-1CD
DX100 Controller
7 Security System
7.1 Protection Through Security Mode Settings
7.1.1.1
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.
7-6
RE-CTO-A215
162536-1CD
DX100 Controller
7 Security System
7.1 Protection Through Security Mode Settings
3. Press [SELECT].
– Select "SECURITY MODE".
4. Input the user ID.
– The user ID input window appears.
SUPPLEMENT
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.
7-7
RE-CTO-A215
162536-1CD
DX100 Controller
7 Security System
7.1 Protection Through Security Mode Settings
7.1.2
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.
7-8
RE-CTO-A215
162536-1CD
DX100 Controller
7 Security System
7.1 Protection Through Security Mode Settings
3. Select the desired ID.
– 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.
7-9
RE-CTO-A215
162536-1CD
DX100 Controller
8
8
System Setup
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
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 Home Position Calibration
8.1
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:
– Be sure to use a lockout device to the safeguarding when
going inside. Also, display the sign that the operation is
being performed inside the safeguarding and make sure no
one closes the safeguarding.
– 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
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 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.
•
Make sure that a system manager stores the key of the mode select
switch on the programming pendant.
After operation, the key should be removed and stored by the
system manager.
Improper or unintended manipulator operation may result in injury.
Also, the key or the mode select switch may be damaged if the
programming pendant is dropped with the key inserted.
8-3
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 Home Position Calibration
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.
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
SUPPLEMENT
The home position is the pulse value "0" for each axis and its
posture. See section 8.1.3 “Home Position of the Robot”.
8-4
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 Home Position Calibration
8.1.2
Calibrating Operation
NOTE
8.1.2.1
Home position calibration screen is displayed only in the
security mode or the 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.
8-5
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 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
GO
BACK
PAGE
.
8-6
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 Home Position Calibration
5. Select {EDIT} under the menu.
– 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.
8-7
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 Home Position Calibration
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.
– 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.
8-8
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 Home Position Calibration
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 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.
– 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 step 3 and 4 of the “Registering All Axes at One Time” to
select the desired control group.
8-9
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 Home Position Calibration
3. Select {DATA} under the main menu.
– The pull-down menu appears
4. Select [CLEAR ALL DATA].
– A confirmation dialog box appears.
5. Select {YES}.
– All absolute data are cleared.
– When {NO} is selected, the registration will be canceled.
8-10
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.1 Home Position Calibration
8.1.3
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.
8-11
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.2 Setting the Second Home Position (Check Point)
8.2
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:
– Be sure to use a lockout device to the safeguarding when
going inside. Also, display the sign that the operation is
being performed inside the safeguarding and make sure no
one closes the safeguarding.
– 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.
8-12
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.2 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.
•
Make sure that a system manager stores the key of the mode select
switch on the programming pendant.
After operation, the key should be removed and stored by the
system manager.
Improper or unintended manipulator operation may result in injury.
Also, the key or the mode select switch may be damaged if the
programming pendant is dropped with the key inserted.
8-13
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.2 Setting the Second Home Position (Check Point)
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.
"OUT OF RANGE (ABSO DATA)" alarm occurs
Reset alarm
Turn ON servo power
Procedure After Alarm Occurs
1
Position confirmation
operation
2
Compare second home
position (check point)*
pulses with current
position pulses
NG
Alarm occurs again
OK
3
Correct defective axis
Replace PG system
Home position calibration
Position checking point
Playback possible
1
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.
8-14
RE-CTO-A215
162536-1CD
DX100 Controller
8 System Setup
8.2 Setting the Second Home Position (Check Point)
2
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 section 8.2.2 “Procedure for the
Second Home Position Setting (Check Point)”.
3
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.
NOTE
•
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.
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8 System Setup
8.2 Setting the Second Home Position (Check Point)
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.
2. Select {SECOND HOME POS}.
– The SECOND HOME POS window appears.
A message “Available to move to and modify specified point” is
displayed.
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8.2 Setting the Second Home Position (Check Point)
3. Press the page key
GO
BACK
PAGE
, 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.
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8.2 Setting the Second Home Position (Check Point)
8.2.3
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.
SUPPLEMENT
For details on the “POWER ON/OFF POS" window, refer to
section 7.7 “Position Data When Power is Turned ON/OFF”
in the 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.
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8.2 Setting the Second Home Position (Check Point)
3. Press the page key
GO
BACK
PAGE
, 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 [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.
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8 System Setup
8.3 Tool Data Setting
8.3
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
SUPPLEMENT
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 chapter 8 “Parameter” in the
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
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8.3 Tool Data Setting
1. Select {ROBOT} under the main menu.
– 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
GO
BACK
PAGE
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.
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8.3 Tool Data Setting
6. Press [ENTER].
– The coordinate data is registered.
<Setting Example>
260 mm
TCP
ZF
260 mm
TCP
TCP
Tool A
260 mm
ZF
Tool B
145 mm
Tool C
In case of Tool A, B
In case of Tool C
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8.3 Tool Data Setting
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
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 section 8.3.1.2
“Registering Coordinate Data”, 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
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8.3 Tool Data Setting
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
Ry = 90
– 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.
SUPPLEMENT
For more details on the tool load information, refer to section
8.4.3 “Tool Load Information Setting”
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8.3 Tool Data Setting
8.3.2
Tool Calibration
8.3.2.1
Tool Calibration
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
YF
XT
YT
Tool
coordinates
8.3.2.2
<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
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.
1: Calibrates only the posture.
“Tool Posture Data” calculated from the first calibration
teaching point is registered in the tool file.
In this case, “Coodinates” 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.
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8.3 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.
The X-axis of the tool coordinates is defined in the same direction as the
X-axis of the base coordinates.
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8.3 Tool Data Setting
Tool
TCP YT
Tool
Coordinates
XT
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.
TC2
TC4
TC3
SUPPLEMENT
TC1
TC5
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.
TC2
TC1
TC1
TC4
TC3
TC5
[S2C432 = 0 or 2 ]
SUPPLEMENT
[S2C432 = 1 ]
•
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.
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8.3 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 section
8.3.1.2 “Registering Coordinate Data”, display the desired tool
coordinate window.
4. Select {UTILITY} under the menu.
– The pull-down menu appears.
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8.3 Tool Data Setting
5. Select {CALIBRATION}.
– 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.
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8.3 Tool Data Setting
7. Select “POSITION”.
– The selection dialog box is shown.
(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.
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8.3 Tool Data Setting
10. Select “COMPLETE”.
– 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.
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8.3 Tool Data Setting
2. Select {CLEAR DATA}.
– The confirmation dialog box is shown.
3. Select {YES}.
– All data is cleared.
SUPPLEMENT
If tool angle data is required, input the data number in the
tool coordinate window.
Refer to section 8.3.1.3 “Registering Tool Angle” for the
operating instructions.
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8.3 Tool Data Setting
8.3.2.5
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.
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
GO
BACK
PAGE
or selecting it in the tool list window.
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8.3 Tool Data Setting
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
SUPPLEMENT
For details on the TCP fixed operation, see section 2.8.1
“Motion about TCP" in the OPERATOR’S MANUAL.
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8.3 Tool Data Setting
8.3.3
Automatic Measurement of the Tool Load and the Center of Gravity
8.3.3.1
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 section 8.4 “ARM Control”.
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+
L-axis
U-
B- T-
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.
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8.3 Tool Data Setting
1. Select {ROBOT} under the main menu.
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.
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8.3 Tool Data Setting
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
GO
BACK
or selecting {PAGE}.
PAGE
– To switch the tool list window and the tool coordinate window, press
{DISPLAY}  {LIST} or {DISPLAY}  {COORDINATE DATA}.
4. Select {UTILITY} under the menu.
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8.3 Tool Data Setting
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
GO
BACK
PAGE
.
– In a system with several manipulators, use the page key
change the group to be controlled.
GO
BACK
PAGE
to
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 ““.
1
Measurement of the U-axis: U-axis home position +4.5 degrees 
-4.5 degrees
2
Measurement of the B-axis: B-axis home position +4.5 degrees 
-4.5 degrees
3
First measurement of the T-axis: T-axis home position +4.5 degrees
 -4.5 degrees
4
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.
SUPPLEMENT
• 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.
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8.3 Tool Data Setting
– When all the measurements are completed or when all the “”
marks have changed into ““, the measured data appears on the
screen.
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.
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8.4 ARM Control
8.4
ARM Control
8.4.1
ARM Control
ARM Control, a control system originally developed by Yaskawa, achieves
an enhanced robot motion performance such as improved path accuracy
or reduced 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.
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8.4 ARM Control
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

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.
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8.4 ARM Control

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.
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.
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.
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8.4 ARM Control
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.
Fig. 8-1: 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.
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8.4 ARM Control
2. Select {ARM CONTROL}.
– The ARM CONTROL window appears.
3. Press the page key
GO
BACK
PAGE
, 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].
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8.4 ARM Control
8.4.3
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.
To set the tool load information correctly, following message appears
when inputting the information (DS2.00.00A(*)-00 or later version).
“Input correct tool information. Using robot with wrong tool information
may result in premature failure of the robot.”
•
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 )
* 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
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8.4.3.2

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.)

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.
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8.4 ARM Control
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.
<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
70
XF
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
SUPPLEMENT
Iz
Iz
Iy
Lz
Ix
Y
X
Iy =
Iz =
Ly + Lz
Weight: W
2
12
Lx 2 + Lz 2
12
Lx 2 + Ly 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]
2
* Unit of Ix, Iy, Iz : [kgm ]
2
*W
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<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.
YF
500
XF
250
DX100 Controller
Weight of tool:
Approx. 55 kg.
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
<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
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8.4 ARM Control
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]
SUPPLEMENT
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}
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<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
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8.4 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
•W
:
10.000 kg
• 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 list window appears.
– The tool coordinate list window appears only when TOOL NO.
SWITCH in the TEACHING CONDITION window is set to PERMIT.
– When TOOL NO. SWITCH in the TEACHING CONDITION window
is set to PROHIBIT, the tool window appears.
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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
GO
BACK
PAGE
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.
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• 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 the initial
setting values (vary according to each robot model) which
were set to the parameter before shipping.
Initial Setting 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 initial setting value, a
difference of 100 kg or more in the load between the actual
tool load and the initial setting 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.
To set the tool load information correctly, following message
appears when the playback operation is executed by using
the initial setting value (DS2.00.00A(*)-00 or later version).
“Using robot without setting tool info. may result in
premature failure of the robot. Set W, Xg, Yg, and Zg in the
tool file.”
• 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).
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8.5 Work Home Position
8.5
Work Home Position
8.5.1
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.
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8.5 Work Home Position
3. Press the page key
GO
BACK
PAGE
.
– When two or more manipulators exist in the system, use the page
key
GO
BACK
PAGE
to change the control group, or click on {PAGE} to select
the desired control group.
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8.5 Work Home Position
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].
– 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.
• 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
NOTE
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. 8-2: S3C805: The work home position cube length of its
sides (µm)
a
P
a
a
a
2
2
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.
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8.5 Work Home Position
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.

8.5.2.4
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 %.)
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.
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8.6 Interference Area
8.6
Interference Area
8.6.1
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
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8.6 Interference Area
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.
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
Z-axis
X-axis
Y-axis
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8.6.2.3
Setting Operation
1. Select {ROBOT} under the main menu.
2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window is shown.
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3. Select the desired cube number.
– Select the desired cube number with the page key
number input.
GO
BACK
PAGE
or by
– 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.
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5. Select “CONTROL GROUP”.
– A selection dialog box appears.
(1) Select the desired control group.
6. Select “REF COORDINATES”.
– 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].
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7. Select “CHECK MEASURE.”
– Each time [SELECT] is pressed, “COMMAND POSITION” and
“FEEDBACK POSITION” are displayed alternately.
– “COMMAND POSITION” : When the command position (which is
displayed on the current position window) is in the interference area,
the signal is turned ON.
– “FEEDBACK POSITION” : When the actual position of the
manipulator is in the interference area, the signal is turned ON.
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.
8. Select “ALARM OUTPUT.”
– Each time [SELECT] is pressed, “OFF” and “ON” are displayed
alternately.
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8.6 Interference Area
When selecting “ON” and if the manipulator’s TCP approaches
inside the pre-defined interference area, the following alarm occurs
and the manipulator stoppes immediately.
AL4902 CUBE INTERFERENCE (TCP)

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.
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8.6 Interference Area

Teaching Corner
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “MAX/MIN”.
2. Press [MODIFY].
– A message “Teach max./min. position” appears.
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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.
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8.6 Interference Area

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.
(2) Select “CENTER POS”.
2. Input data for length of the cube, then press [ENTER].
– The length is set.
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8.6 Interference Area
3. Press [MODIFY].
– A message “Move to 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 point of the cube using the axis
keys.
5. Press [ENTER].
– The current position is registered as the center point of the cube.
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8.6 Interference Area
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. 8-3: Axis Interference Signal for Station Axis
Max value
+ side
0
ON
Min value
- side
OFF
8.6.3.2
Setting Operation
1. Select {ROBOT} under the main menu.
2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window appears.
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3. Select the desired interference signal number.
– Select the desired interference signal number using the page key
GO
BACK
PAGE
or by number input.
– When selecting the desired interference signal 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. Select “AXIS
INTERFERENCE”.
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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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7. Select “ALARM OUTPUT”.
– Each time [SELECT] is pressed, “OFF” and “ON” are displayed
alternately.
When selecting “ON” and if the manipulator’s axes approach inside
the pre-defined interference area, the following alarm occurs and the
manipulator stoppes immediaterly.
AL4901 AXIS INTERFERENCE
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
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.
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
Teaching Corner
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(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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5. Press [ENTER].
– The cubic interference area is registered.
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
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”.
2. Input number for “WIDTH” data and press [ENTER].
– “WIDTH” is set.
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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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8.6.4
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
GO
BACK
PAGE
or by number input.
– When selecting the desired interference signal number by number
input, select {PAGE} to input the desired signal number.
4. Select {DATA} under the menu.
– The pull-down menu appears.
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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 Shock Detection Function
8.7
Shock Detection Function
8.7.1
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” to chapter 6 “Test of Program
Operation” 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
At the factory default setting, the threshold value is set to detect a collision
without a miss even when the manipulator is operating at the maximum
speed, on the assumption that the tool file is correctly set. To detect a
collision during normal operation, check the following points:
• The tool’s load and moment do not exceed the rated values.
• The actual tool load and the tool file setting value are the same.
• The U-arm payload information and the set weight of U-arm payload
in the ARM CONTROL window are the same.
In addition, detection sensitivity can be decreased for only a specific
section where a contact task is performed.
The detection sensitivity 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 numbers 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 during 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.
• Condition numbers 1 to 8 are set for each axis and condition 9 is set
for each group.
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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.
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
SUPPLEMENT
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.
Teach Mode Each Axis Setting Function
Usually, the detection level setting of teach mode is set for
each group.
SUPPLEMENT
By using this function, the detection level can be set for each
axis.
S2C869: Teach Mode Each Axis Setting Function
(1: VALID, 0: INVALID)
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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.
1
Robot Select
Select the manipulator whose detection level is to be changed.
2
Function Select
Specifies VALID/INVALID of the shock detection function. The shock
detection function is specified for each manipulator.
1. Select the manipulator whose function is to be enabled or disabled.
3
2. Move the cursor to “VALID” or “INVALID” and press [SELECT]. Each
time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately. The change is available for all the condition numbers.
Max. Disturbance Force
Indicates the maximum disturbance force to the manipulator when the
manipulator is moved in play back operation or axis operation.
4
Refer to this value when inputting the detection level value in 5 .
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.
5
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
Method of Shock Detection Level File Setting
1. Select {ROBOT} under the main menu.
2. Select {SHOCK SENS LEVEL}.
– The EACH AXIS LEVEL window appears.
– Perform either of the following operations to display the page of
desired condition number:
(1) Press {PAGE} in the window. Enter the desired condition number
using numeric keys and press [ENTER]. Then the page of the
condition number appears.
(2) Press the page key
GO
BACK
PAGE
to change the condition number.
3. Level setting for the condition numbers 1 to 8.
Level setting values can be set for each axis on the EACH AXIS
LEVEL window.
Perform the following “Disturbance force measurement”, then perform
“Setting all levels at once”.

Disturbance force measurement
1
Mount the tool, workpiece, external equipment, and equipment on
the arm to the manipulator.
2
Set the tool file correctly.
For spot welding
: Set the gun load information (weight and center
of gravity). To use the gun change function,
while removing the gun, switch to the tool file
with which the load information without a gun
is set.
For handling
: Set the total load information (weight and
center of gravity) of the hand and the maximum
load workpiece.
For other applications: Set the load information (weight and center of
gravity) of the tool.
3
Set the detection level values of all the axes to 100.
(1) Open the SHOCK DETECT LEVEL window.
(2) Select {DATA}, then {CLEAR MAX VALUE}.
4

Perform the JOB.
Setting all levels at once
1
Open the SHOCK DETECT LEVEL window.
2
Select {DATA}, then {CHANGE EVERY LEVEL}.
3
Enter 120 in the coefficient (%) by which the max. disturbance force
is multiplied.
The following calculated value A or B, whichever is larger, is set to
the DETECT LEVEL.
A: (Max. disturbance force) x (coefficient = 120%)
B: (Max. disturbance force) + 15
<Example>
When the max. disturbance force is 80, the DETECT LEVEL is 96.
When the max. disturbance force is 10, the DETECT LEVEL is 25.
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4. Level setting for the condition number 9.
The level setting for the condition number 9 is for the teach mode.
This setting is made for each group.
Refer to the max. disturbance force to set the DETECT LEVEL.
• Perform all the jobs to use for 5 to 6 hours.
• For handling application, if a work job is performed both
with holding a workpiece and without holding a workpiece,
measure both patterns.
• In the event of a collision while measuring the max.
disturbance force, clear the max. disturbance force by
selecting {DATA}, then {CLEAR MAX VALUE}. Then try
again.
NOTE
• The max. disturbance force is cleared when the power is
turned ON/OFF. Therefore, DO NOT set the level based
on the max. disturbance force immediately after turning
ON/OFF the power.
• When the teaching point, operation speed, operation
position, etc. of a job are greatly changed due to teaching
modification, etc., measure the max. disturbance force
and set the DETECT LEVEL again.
• When the load of tool or workpiece is greatly modified,
measure the max. disturbance force and set the DETECT
LEVEL again.
To avoid false detection during manipulator operation, set
the following calculated value A or B, whichever is larger, to
the DETECT LEVEL. An emergency stop of the
manipulator due to the false detection may become a factor
to damage the speed reducers and tools.
NOTE
A: (Max. disturbance force) x (coefficient = 120%)
B: (Max. disturbance force) + 15
<Example>
When the max. disturbance force is 80, set the
DETECT LEVEL to 96 or more.
When the max. disturbance force is 10, set the
DETECT LEVEL to 25 or more.
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8.7.2.2
NOTE
To adjust to the change in the grease viscosity at a cold
start, the offset value is automatically added to DETECT
LEVEL until the robot has operated for a certain period of
time.
Thus, at a cold start, the shock detection will be performed
only when the value is more than or equal to the sum of
DETECT LEVEL and the offset value.
The offset value varies depending on the manipulator type.
NOTE
DETECT LEVEL can be modified only when the security
mode is set in the management mode.
Tool Load Information Setting
To increase the accuracy of shock detection, set the tool load information
in the tool file. Refer to section 8.4.3 “Tool Load Information Setting” for
details of the tool load information setting.
8.7.2.3
U-Arm Payload Setting
To perform shock detection more accurately, set the U-arm payload.
See section 8.4.2 “ARM CONTROL Window” for details of the U-arm
payload setting.
8.7.2.4

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.
1
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.
2
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
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.
1

Instruction Registration
The instruction is registered when the cursor is in the address area in the
JOB CONTENT window in teach mode.
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.
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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]
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.
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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.
2. Press [INFORM LIST].
– The inform list appears.
3. Select SHCKRST instruction.
– SHCKRST instruction appears in the input buffer line.
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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.
(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.
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8.7.2.5
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.
– 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 shock detection function "INVALID", or
increase the detection level in teach mode and retreat the
manipulator to a safety position.
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8.7 Shock Detection Function
8.7.3
High-Sensitivity Shock Detection Function (For Arc Welding
Application Only)
This function is designed to reduce the damage caused by a collision by
bringing the manipulator to an emergency stop when the tool or
manipulator collides with peripheral equipment. By increasing the
sensitivity to a collision, the damage caused by a collision can be reduced,
compared to the normal shock detection function.
To use this function, it is necessary to set the robot setup conditions and
the tool load information correctly.
The robot setup conditions include the weight and the center of gravity
position of the load installed at each part of robot, etc.
The tool load information includes the weight, the center of gravity
position, and the moment of inertia at the center of gravity, of the tool
installed at the flange.
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 safety measures such as safeguarding etc.
Refer to chapter 1 “Safety” to chapter 6 “Test of Program
Operation” 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.
8.7.3.1
Manipulator Type for High-Sensitivity Shock Detection Function
The following manipulator types for arc welding support the highsensitivity shock detection function. To enable this function, read the tool
load information prepared by Yaskawa on the MAKER INITIAL VALUE
window.
Types for high-sensitivity shock detection function
• MA1400, MA1900, VA1400
• MH6, HP20
8.7.3.2
Setting for High-Sensitivity Shock Detection Function
To enable the high-sensitivity shock detection function, perform the
settings 1 and 2 as shown below. The function is enabled only with
the setting 1 , but perform both 1 and 2 to make the shock detection
more accurate.
Reading the tool load information from the MAKER
INITIAL VALUE window
To enable the high-sensitivity shock detection function, read the tool
load information prepared by Yaskawa on the MAKER INITIAL VALUE
window. Since this function works on the assumption that the tool file is
correctly set, read the tool load which is the same as the actual load on
the MAKER INITIAL VALUE window. When the tool other than the tool
for high-sensitivity indicated in section 8.7.3.6 “Explanation of Maker
Initial Value” is used, DO NOT use this function.
1
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8.7 Shock Detection Function
Setting the U-arm payload
To perform shock detection more accurately, set the U-arm payload
referring to section 8.4.2 “ARM CONTROL Window”.
The U-arm payload prepared by Yaskawa can be read on the MAKER
INITIAL VALUE window. Read the same data as the actual U-arm
payload on the MAKER INITIAL VALUE window.
2
8.7.3.3
Reading the Tool Load Information on the MAKER INITIAL VALUE
Window
1. Change the “SECURITY MODE” to the “MANAGEMENT MODE”, then
select {ROBOT} under the main menu.
2. Select {TOOL}.
– The TOOL window appears.
3. Select the desired tool number.
4. Select {DATA} under the menu.
– The pull-down menu appears.
5. Select {READING}.
– The MAKER INITIAL VALUE window appears.
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6. Select the number of the maker initial value to be read.
– A confirmation dialog box appears.
– Select a maker initial value other than the “STANDARD” to enable
the high-sensitivity shock detection function.
7. Select {YES}.
– The tool load information is read into the tool file, and the TOOL
window appears.
When “NO” is selected, the tool load information is NOT read into
the tool file, and the TOOL window appears.
NOTE
The high-sensitivity shock detection function is enabled
when a maker initial value other than the “STANDARD” is
selected. The read tool load information cannot be
changed because it is used for the high-sensitivity shock
detection function. When the standard torch is read, the
function is disabled and the tool load information becomes
editable.
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NOTE
In the case of using multiple tool files, when the tool file is
switched, the tool load information is also switched. When
switching the tool file only to switch the TCP (when the
weight or the center of gravity position, etc. of the whole tool
installed at the flange does not change), perform the same
settings to the tool load information of each file.
In addition, when the total weight or the center of gravity
position of the tool changes (with the system in which the
tool is exchanged by a tool changer, etc.), set the tool load
information for each tool file.
8.7.3.4
Explanation of Maker Initial Value
①
NAME
The name of tool load information prepared by Yaskawa is indicated.
When using the tool in the following figure, select 300R BUILT MODEL,
308R BUILT MODEL, or 308RR UNIV MODEL.
1
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325
(312.1)
397.7
(385.4)
395
Fig. 8-4: Tool for High-Sensitivity Shock Detection
40°
35°
15
15
31°
(116.5)
82.5
125
NOTE
8.7.3.5
15
(74.8)
The high-sensitivity shock detection function works on the
assumption that the tool file is correctly set.
To perform shock detection more accurately, read the tool
load which is the same as the actual load on the MAKER
INITIAL VALUE window.
Reading the U-Arm Payload
1. Change the “SECURITY MODE” to the “MANAGEMENT MODE”.
2. Select {ARM CONTROL}.
– The ARM CONTROL window appears.
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3. Select {DATA} under the menu.
– The pull-down menu appears.
4. Select {READING}.
– The MAKER INITIAL VALUE window appears.
5. Select the number of the MAKER INITIAL VALUE to be read.
– A confirmation dialog box appears.
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6. Select {YES}.
– The U-arm payload is read into the ARM CONTROL window, and
the ARM CONTROL window appears.
When {NO} is selected, the ARM CONTROL window appears
without the U-arm payload being read into the ARM CONTROL
window.
U-arm payload information
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8.7.3.6
Explanation of Maker Initial Value
①
1
4
NAME
The name of U-arm payload information prepared by Yaskawa is
indicated.
When using the U-arm payload in the following figure, select from the
MAKER INITIAL VALUE window.
4
340MELC
310ELC
340ELC
Name
Payload
Type
340MELC (For MA/VA)
340MELC
MA1400, MA1900,
VA1400
310ELC (For MA/VA)
310ELC
MA1400, MA1900,
VA1400
340ELC (For MA/VA)
340ELC
MA1400, MA1900,
VA1400
340MELC (For MH/HP)
340MELC
MH6, HP20
310ELC (For MH/HP)
310ELC
MH6, HP20
340ELC (For MH/HP)
340ELC
MH6, HP20
NOTE
To perform shock detection more accurately, even when the
U-arm payload information prepared by Yaskawa and the
actual payload are the same, DO NOT read the payload
information if the robot types are different.
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8.8 User Coordinate Setting
8.8
User Coordinate Setting
8.8.1
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 User Coordinate Setting
8.8.2
User Coordinate Setting
8.8.2.1
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 User Coordinate Setting
8.8.2.2
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.
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8.8 User Coordinate Setting
4. Press [MODIFY] then [ENTER].
– Taught position is registered.
– Repeat the steps 2 to 4 to teach ORG, XX and XY.
– ““ 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 User Coordinate Setting
8.8.2.3
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 Overrun/Tool Shock Sensor Releasing
8.9
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.
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8.9 Overrun/Tool Shock Sensor Releasing
3. Select “RELEASE”.
– The control group in which overrun or shock sensor is detected is
indicated with “".
– 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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8.10 Soft Limit Release Function
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.
NOTE
• 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.
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8.11 All Limit Release Function
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” 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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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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8.12 Instruction Level Setting
8.12
Instruction Level Setting
8.12.1 Setting Contents
8.12.1.1
Instruction Set
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
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8.12 Instruction Level Setting
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.
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.
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8.12 Instruction Level Setting
3. Select “LANGUAGE LEVEL”.
– The selection list appears.
4. Select desired language level.
– Language level is set.
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8.12 Instruction Level Setting
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.
3. Select "INSTRUCTION INPUT LEARNING".
– VALID” and “INVALID” are displayed alternately every time
[SELECT] is pressed.
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8.13 Setting the Controller Clock
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/TIME SET window appears.
3. Select “DATE” or “TIME”.
– ”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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8.14 Setting the Play Speed
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
GO
BACK
PAGE
.
– When two or more manipulators and stations exist in the system,
use the page key
GO
BACK
PAGE
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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8.14 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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8.15 Numeric Key Customize Function
8.15
Numeric Key Customize Function
8.15.1
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
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.
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8.15 Numeric Key Customize Function
8.15.2.2
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.
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.
SUPPLEMENT
In a system for multiple applications, a numeric key can be
allocated for each application.
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8.15 Numeric Key Customize Function
8.15.3
Allocating Operation
8.15.3.1 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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8.15 Numeric Key Customize Function
4. Select {ALLOCATE SIM. KEY}.
– The KEY ALLOCATION (SIM) window appears.
GO
BACK
– In a system multiple applications, press the page key PAGE 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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(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.
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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.
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.
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4. Input the name of the reserved window and press [ENTER].
– The reserved name input to the “ALLOCATION CONTENT” is
shown.
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.
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8.15 Numeric Key Customize Function
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”.
– 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].
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8.15 Numeric Key Customize Function
8.15.3.6 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.
2. Select “PULSE OUTPUT”.
– The output No. and output time are displayed in the “ALLOCATION
CONTENT”.
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(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)
8.15.3.9
Input the number or value to be changed, and press [ENTER].
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.
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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”.
– 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)
Input the number or incremental value to be changed, and press
[ENTER].
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8.15 Numeric Key Customize Function
8.15.4 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
AOUT AO# (No.) output voltage value
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.
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8.15 Numeric Key Customize Function
3. Select “OUTPUT CONTROL INST”.
– The instruction corresponding to the I/O control allocated by key
allocation (SIM) is displayed in the “ALLOCATION CONTENT”.
– 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
Execution of Allocation
8.15.5.1 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.
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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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8.16 Changing the Output Status
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; : status OFF.)
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8.16 Changing the Output Status
SUPPLEMENT
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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8.17 Changing the Parameter Setting
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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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.
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8.17 Changing the Parameter Setting
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].
(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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8 System Setup
8.18 File Initialization
8.18
File Initialization
8.18.1 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.
When JOB is initialized, the following files are reset at the
same time.
Be careful when initializing JOB.
NOTE
• User coordinates
• Memory play file (only for extended CMOS)
• Spot monitor data (only for extended CMOS)
• Variable data
• System definition parameter (S4D)
• Robot calibration data
• Conveyor calibration data
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8 System Setup
8.18 File Initialization
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}.
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.
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8.18 File Initialization
7. Press [ENTER].
– A confirmation dialog box appears.
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.
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8.18 File Initialization
6. Select the parameter to be initialized.
– The selected parameter is marked with ““.
– The parameters marked with "" cannot be selected.
7. Press [ENTER].
– A confirmation dialog box appears.
8. Select {YES}.
– The selected parameter is initialized.
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8.18 File Initialization
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 ““.
– The I/O data marked with "" cannot be selected.
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8.18 File Initialization
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}.
– The system data selection window appears.
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8.18 File Initialization
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
8.19
Display Setting Function
8.19.1
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 Display Setting Function
8.19.1.3
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.
• Check the {Bold Type} check box as follows to set the font to the bold
style.
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8.19 Display Setting Function
• 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.
3. The font size setting dialog box is closed, and the screen displays the
font specified in the dialog box.
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8.19 Display Setting Function

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.
NOTE
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).
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8 System Setup
8.19 Display Setting Function
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
Bold
3
Large
Regular
Bold
8.19.2.3 Setting the Button Size
To set the button size, first off display the button size setting dialog box as
follows.
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8 System Setup
8.19 Display Setting Function
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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8 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.
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8 System Setup
8.19 Display Setting Function
4. The font size setting dialog box is closed, and the screen displays the
buttons specified in the dialog box.
– 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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8.19 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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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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8.19 Display Setting Function
– 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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8 System Setup
8.20 Encoder Back-up Error Recovery Function
8.20
Encoder Back-up Error Recovery Function
8.20.1 About Encoder Back-up Error Recovery Function
A motor of the robot, the travel axis or the rotation station which is
controlled by the DX100 is connected with the back-up buttery in order to
keep the position information even though the control power is
disconnected. This buttery consumes buttery power through time, and the
alarm “4312 ENCODER BATTERY ERROR” occurs when the voltage
becomes lower than 2.8V. If the battery is not replaced and keep
consuming more battery power, it will cause the lost of the position
information. In addition, the alarm “4311 ENCODER BACK-UP ERROR”
occurs. Meanwhile, there would be a gap between the manipulator
position and the position of the absolute encoder.
This function allows to recover the absolute data by moving the axis
operation to the home position from the position information where the
axis is lost.
8.20.2 Encoder Back-up Error Recovery Function Operation
1. Press {SELECT}.
– When select the “RESET” in the alarm display, the alarm is reset.
The manipulator can be move by the axis operation key.
2. Adjust the alarm occurring axis to the home position mark of the each
manipulator axis by the axis operation key.
3. Change the security mode to the management mode.
– Refer to section 7.1.1.1 “Changing the Security Mode” for the
operation of the changing the security mode.
4. Select {ROBOT} in the main menu.
5. Select {HOME POSITIONNING}.
– The home positioning display appears. The absolute data of the axis
which is occurring the encoder back-up error appears with the “ ✻ ”
which indicates the undefined state.
6. Select the control group.
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8 System Setup
8.20 Encoder Back-up Error Recovery Function
7. Select {UTILITY} in the menu.
– The pull-down menu appears.
8. Select {BACKUP ALM RECOVERY} in the menu.
– The back-up alarm recovery display appears.
9. Select the axis to be fixed.
– Move the cursor over the axis to fix, and select it. The confirmation
dialog appears.
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8.20 Encoder Back-up Error Recovery Function
10. Select {YES}.
– The absolute data of the selected axis is recovered.
– Select {NO} to cancel the operation.
11. Select the current position.
– To display the current position window, refer to “DX100
MAINTENANCE MANUAL (155492-1CD) section 7.8.1 Current
Position Window”.
12. Confirm the current position.
– Confirm the recovered current position, and modify the followings
depending on its values.
(1) The pulse number is approximately “0”.
• Recovered normally.
(2) The pulse number is approximately “4096”.
• Move the recovered axis to the 4096 pulse position, and register
the individual axis to calibrate the home position.
(3) The pulse number is approximately “-4096”.
• Move the recovered axis to the -4096 pulse position, and register
the individual axis to calibrate the home position.
As for the registering the individual axis, refer to section 8.1.2.2
“Registering Individual Axes”.
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9
9 System Backup
9.1 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
Function Types of Data
9.1.1.1
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 section 9.2 “Backup by
CMOS.BIN”.
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 section 9.3 “Automatic Backup Function”.
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.
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9 System Backup
9.1 System Backup with DX100
9.1.2
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
Hagiwara Solutions
MCF10P-256MS-YE
256MB
2
Hagiwara Solutions
MCF10P-512MS
512MB
3
Hagiwara Solutions
MCF10P-A01GS
1GB
4
Hagiwara Solutions
MCF10P-A02GS
2GB
< Recommended USB Memory>
No. Manufacturer
Model
Remarks
1
UBA2-xxxGSRB
(TBAIA)
1GB, 2GB, and 4GB are
available.
“xxx” indicates “001” for
“1GB”, “002” for “2GB” and
“004” for “4GB”.
Hagiwara Solutions
In order to save the batch data, the following free space per file is needed
in the media.
JZNC-YIF01-1E: 18 MByte
JZNC-YIF01-2E: 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.
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9 System Backup
9.2 Backup by CMOS.BIN
9.2
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.
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9.2 Backup by CMOS.BIN
4. Select {SAVE}.
– The save display appears.
– The items marked with "" cannot be selected.
5. Select {CMOS}.
– The confirmation dialog box appears.
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9.2 Backup by CMOS.BIN
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.
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.
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9.2 Backup by CMOS.BIN
5. Select {LOAD}.
– The load display appears.
– The items marked with "" cannot be selected.
6. Select {CMOS}.
– 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.
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9 System Backup
9.3 Automatic Backup Function
9.3
Automatic Backup Function
9.3.1
Automatic Backup Function
9.3.1.1
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 stored in the programming pendant, or the
selected device at the automatic backup window. It is possible to select
the device, when the system software is version DS3.00 or higher.
DS1.00 or DS2.xx series: it can store to the CompactFlash of the
programming pendant to back up.
DS3.00: Able to back up to following devices.
• The CompactFlash of the programming pendant
• The CompactFlash of the YCP01 board
• The RAM AREA of the YCP01 board (It will display, when the high
speed ethernet server function is effective.)
DS3.95-00 or higher: The automatic backup function is expanded. In
order to use the automatic backup extension function, set the following
parameter.
For the setting of the automatic backup extension function, refer to section
9.3.2.7 “AUTO BACKUP EXTENSION FUNCTION SET Window” .
Parameter
Content
Initial Value
S2C737
Automatic backup extension
function
1
NOTE
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.
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9 System Backup
9.3 Automatic Backup Function
9.3.1.2
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.
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9.3 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 DX100 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.
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9.3 Automatic Backup Function
9.3.2
Settings for Automatic Backup
To set the automatic backup function, set each item at the automatic
backup display.
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".
NOTE
The automatic backup can be performed only when the
robot is not during playback, and the robot is stopped.
As for the system software version DS3.00 or higher,
Automatic backup function can be set from the command of
the optional high speed ethernet server function.
9.3.2.1
The CompactFlash of the Programming Pendant
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.
Regarding the Compact Flash for auto backup, refer to <Recommended
CompactFlash> in section 9.1.2 “Device”.
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.
(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.
9-10
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DX100 Controller
9 System Backup
9.3 Automatic Backup Function
9.3.2.2
The CompactFlash of the YCP01 Board
Set the following procedures in advance to back up to the CompactFlash
of the YCP01 board. If following procedures are not done, “CF:
Controller” would not be shown on the device list of the auto backup set
display.
1. Turn ON the Power supply while pressing the {MAIN MENU} on the
programming pendant.
2. After starting maintenance mode, change the security mode to the
management mode.
3. Select {SYSTEM} in the main menu.
– When the sub menu will appear, select {SETTING}-{OPTION
FUNCTION}. The list of the optional function will appear.
4. Select {Automatic backup (YCP01)}, and change the “UNUSE” to
”USE”.
– Select {YES}, when the confirmation dialog appears.
– Select {YES}, when the confirmation dialog appears, and ask
“initialized related files?” “CMOSBK. BIN?”
– It will allocate automatic backup to the CompactFlash of the YCP01.
During allocating, the massage of do not turn the power off appears.
– The message of the maintenance mode will appear, when finished
allocating.
5. Turn ON the power supply again.
6. The online window appears on the programming pendant.
7. Change the security mode to the management mode.
8. Select {CONTROLLER SET}-{SET AUTO BACKUP}.
9. It would be error without inserting the CompactFlash in the
programming pendant, when the device is set on the CompactFlash in
the programming pendant. Push down the [cancel], when the error
occurs.
10. Select the device, and change to “CF: Controller”.
Backup setting to the CompactFlash of the YCP01 board
should be done while the robot is not operating.
NOTE
When access to CompactFlash of the YCP01 by using
other than the auto backup function, the auto backup
function and the exclusive process would be run.
Therefore, the save time of the auto backup will extend.
(Normally, it takes about three minutes to finish backing-up.
However, duplication access to the CompactFlash of the
YCP01 board takes three to ten minutes.)
9.3.2.3
RAMDISK on the YCP01 Board
RAMDISK will be shown when the high speed ethernet server function is
effective. Refer to the instruction of the DX100 HIGH-SPEED
ETHERNET SERVER FUNCTION for more details.
9-11
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9 System Backup
9.3 Automatic Backup Function
9.3.2.4
DX100 Status and Automatic Backup
Backup Timing DX100 Status
From a
specified
starting time
Teach mode
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
When a
specified signal
(#40560) is
input
Error
Play mode
Remote mode
Executing jobs
Disabled
Disabled
When stopped
Backup
Error
Teach mode
Editing
(Accessing to
the memory)
Error
Error
Play mode
Remote mode
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.
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9 System Backup
9.3 Automatic Backup Function

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 DX100 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.
9-13
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9 System Backup
9.3 Automatic Backup Function
9.3.2.5

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.
9-14
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9 System Backup
9.3 Automatic Backup Function
9.3.2.6

AUTO BACKUP SET Window
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
DX100 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 (It is possible to set when CF:pendant is
set on the device.)
When the “CF: pendant” or “CF:Controller” is selected on
the auto backup window, the capacity of the CompactFlash
card in the specified device will be checked. Therefore, a
few seconds may be needed to open the setting window.
For the “CF:Pendant”, an error may occur without setting in
the CompactFlash card.
NOTE
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.
While an error occurring, the setting of the each item on the
auto backup set display cannot be changed.
9-15
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9 System Backup
9.3 Automatic Backup Function
1. Turn ON the DX100.
– Insert the CompactFlash to the programming pendant, when the
backup is set on the CompactFlash of the programming pendant.
2. Change the security mode to the management mode.
3. Select {SETUP} under the main menu.
4. Select {AUTO BACKUP SET}.
– The AUTO BACKUP SET display appears.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
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 DX100 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.
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9 System Backup
9.3 Automatic Backup Function
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
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
DX100 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.
Table 9-1: 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 occurs.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
9-17
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9 System Backup
9.3 Automatic Backup Function
K.DEVICE
Backup device can be selected from the system software DS3.00 or
higher. However, when the system software is DS1.00 to DS2.xx
series, device items do not appear on the auto backup display. The
CompactFlash of the programming pendant can be only set the backup.
Press {SELECT} to display the device list.
The Device Name in Display
Explanation
CF: pendant
Set the backup to the CompactFlash
of the programming pendant.
CF: controller
Set the backup to the CompactFlash
of the YCP01 base board. When the
“CF: controller” of the device name is
not shown, refer to 9.3.2.2 the
CompactFlash of the YCP01.
RAMDISK
It will be shown when the optional
function of High Speed Ethernet
Server function is effective. It can
back up by the DX100 high speed
ethernet server function command.
Refer to the [Dx100 Instruction HIGHSPEED ETHERNET SERVER
FUNCTION].
L. 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. (Max is 100.)
M. BACKUP FILES
Indicates the existence of the files or the number of backup files stored
in the CompactFlash inserted when this window is displayed.
N. LATEST BACKUP FILE
Indicates the date of the latest file in the CompactFlash inserted when
this window is displayed.
O. 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.
ARRANGE will not be displayed when the device of the CF: controller is
set on.
5. Set the desired item, and press [ENTER].
9-18
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9 System Backup
9.3 Automatic Backup Function

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.
D7 D6 D5 D4 D3 D2 D1 D0
RESERVE TIME BACKUP
MODE CHANGE BACKUP
STARTUP BACKUP
RETRY CYCLE
DURING ALARM BACKUP
SPECIFIC INPUT BACKUP
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9 System Backup
9.3 Automatic Backup Function
9.3.2.7

AUTO BACKUP EXTENSION FUNCTION SET Window
Settings
Automatic backup setting is performed by setting the following items on
the AUTO BACKUP SET window:
• RESERVE TIME BACKUP
(Setting for performing the backup on what day of the week, every
day, or in a specific cycle)
• BASE TIME
• BACKUP CYCLE
• RETRY CYCLE
• MODE CHANGE BACKUP
(VALID/INVALID of the backup when switching the mode from the
teach mode to the play mode)
• STARTUP AUTO BACKUP
(VALID/INVALID of the backup when the DX100 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
• DEVICE
(Setting of the device to store the automatic backup file)
• STORED FILE SETTING
(It is possible to set when “CF:Pendant” is set in DEVICE.)
When the “CF: pendant” or “CF:Controller” is selected on
the auto backup window, the capacity of the CompactFlash
card in the specified device will be checked. Therefore, a
few seconds may be needed to open the setting window.
For the “CF:Pendant”, an error may occur without setting in
the CompactFlash card.
NOTE
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.
While an error occurring, the setting of the each item on the
auto backup set display cannot be changed.
9-20
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9 System Backup
9.3 Automatic Backup Function
1.
Turn ON the DX100.
– Insert the CompactFlash to the programming pendant, when the
backup is set on the CompactFlash of the programming pendant.
2. Change the security mode to the management mode.
3. Select {PARAMETER} in the main menu.
4. Select {S2C}.
– The parameter setting window appears. Set the value of S2C737 to "1".
5. Select {SETUP} under the main menu.
6. Select {AUTO BACKUP SET}.
– The AUTO BACKUP SET display appears.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
A. RESERVE TIME BACKUP
Pressing [SELECT] displays the following list. Select the item from
"SET CYCLE", "EVERY DAY", or the day of the week ("MONDAY" to
"SUNDAY").
Please note that after setting the base time, the backup cycle, and the
retry cycle, select the item from "SET CYCLE", "EVERY DAY", or the
day of the week ("MONDAY" to "SUNDAY").
If "SET CYCLE", "EVERY DAY", or the day of the week ("MONDAY" to
"SUNDAY") is set before setting one of the base time, the backup cycle,
and the retry cycle, "INVALID" is selected for RESERVE TIME BACKUP.
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9 System Backup
9.3 Automatic Backup Function
"INVALID"
"SET CYCLE"
: RESERVE TIME BACKUP is not performed.
: The automatic backup is performed every
BACKUP CYCLE based on the specified
BASE TIME.
"EVERY DAY"
: The automatic backup is performed at the
specified BASE TIME every day.
"MONDAY" to "SUNDAY" : The automatic backup is performed at the
specified BASE TIME every week.
– Setting example for the automatic backup at 11:29 every day
– Setting example for the automatic backup at 11:29 on every
Thursday
B. BASE TIME
Specify the reference time to start the automatic backup.
The reference time ranges from 0:00 to 23:59.
C. BACKUP CYCLE
Specify the backup cycle to perform the cyclic back up.
Set the backup cycle in units of minutes. The cycle setting ranges from
10 to 9999 minutes. After the first backup, the following backups are
performed automatically in every BACKUP CYCLE.
When "EVERY DAY" or the day of the week ("MONDAY" to "SUNDAY")
for RESERVE TIME BACKUP is selected, BACKUP CYCLE cannot be
input.
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9 System Backup
9.3 Automatic Backup Function
D. RETRY CYCLE
Every time the automatic backup is implemented, the memory data in
the controller is obtained, and the data is compared with the original
memory data. If they are not the same, the retry of the automatic
backup is implemented. However, please note that when the device is
not inserted and the automatic backup is failed, for example, the retry is
not executed.
Set the retry cycle in units of minutes. The cycle setting ranges from 0
to 255, and should be shorter than the BACKUP CYCLE. If the value is
the same as or longer than the BACKUP CYCLE, RESERVE TIME
BACKUP cannot set to "VALID".
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
DX100 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.
Table 9-2: 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 occurs.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
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9 System Backup
9.3 Automatic Backup Function
K.DEVICE
Backup device can be selected from the system software DS3.00 or
higher. However, when the system software is DS1.00 to DS2.xx
series, device items do not appear on the auto backup display. The
CompactFlash of the programming pendant can be only set the backup.
Press {SELECT} to display the device list.
The Device Name in Display
Explanation
CF: pendant
Set the backup to the CompactFlash
of the programming pendant.
CF: controller
Set the backup to the CompactFlash
of the YCP01 base board. When the
“CF: controller” of the device name is
not shown, refer to section 9.3.2.2 the
CompactFlash of the YCP01.
RAMDISK
It will be shown when the optional
function of High Speed Ethernet
Server function is effective. It can
back up by the DX100 high speed
ethernet server function command.
Refer to the [Dx100 Instruction HIGHSPEED ETHERNET SERVER
FUNCTION].
L. 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. (Max is 100.)
M. BACKUP FILES
Indicates the existence of the files or the number of backup files stored
in the CompactFlash inserted when this window is displayed.
N. LATEST BACKUP FILE
Indicates the date of the latest file in the CompactFlash inserted when
this window is displayed.
O. 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.
ARRANGE will not be displayed when the device of the CF: controller is
set on.
7. Set the desired item, and press [ENTER].
9-24
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9 System Backup
9.3 Automatic Backup Function

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.
D7 D6 D5 D4 D3 D2 D1 D0
RESERVE TIME BACKUP
MODE CHANGE BACKUP
STARTUP BACKUP
RETRY CYCLE
DURING ALARM BACKUP
SPECIFIC INPUT BACKUP
NOTE
When the value of the parameter S2C737 is changed from
"0" to "1" or "1" to "0", the setting details of RESERVE TIME
BACKUP are not taken over, but the others are.
9.3.3
Limiting the Automatic Backup File Creation
9.3.3.1
Setting to Limit the Automatic Backup File Creation
It is applicable from version DS4.00-00 to limit the backup file creation
executed by the automatic backup function to once a day.
To limit the backup file creation to once a day, set the following parameter.
Parameter number
Contents
Setting value
S0C682
Limits the backup file creation
executed by the automatic backup
function to once a day.
0 (Invalid)
1 (Valid)
When the automatic backup function is requested to start in
the state of limiting the automatic backup file to once a day,
an error occurs to notify that the backup has not been
processed.
NOTE
To avoid the above error, set DISPLAY AT EMERGENCY to
“message”.
For the setting of DISPLAY AT EMERGENCY, refer to
section 9.3.2.6 “AUTO BACKUP SET Window” and section
9.3.2.7 “AUTO BACKUP EXTENSION FUNCTION SET
Window”.
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9 System Backup
9.4 Loading the Backup Data from the CompactFlash
9.4
Loading the Backup Data from the CompactFlash
To restore the backup memory in the auto backup function is done in the
maintenance mode. Otherwise, restore from the CompactFlash of the
programming pendant or USB memory when backup is done at the
optional high speed ethernet server function command. Prepare either of
the CompactFlash or the USB memory to make copies.
9.4.1
Loading Procedure
To restore from the CompactFlash of the programming pendant, perform
the following procedures No.1 to 8. To restore from the CompactFlash on
the YCP01 base board, perform the following procedures from No.9.
For the USB memory, change the “USB pendant” in the {EX. MEMORY} {DEVICE} to restore.
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.
– The system software is version DS1.00 or DS2.xx series.
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9.4 Loading the Backup Data from the CompactFlash
– The system software is version DS3.00 or higher.
5. Select {SYSTEM RESTORE}.
– The BACKUP FILE LIST display appears.
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9 System Backup
9.4 Loading the Backup Data from the CompactFlash
6. 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.
7. Select from the confirmation dialog box.
– 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.
8. Select {YES}.
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9 System Backup
9.4 Loading the Backup Data from the CompactFlash
9. Turn the power on, while pressing the [MAIN MENU].
10. Change the security mode to the management mode.
11. Select {External memory} in the main menu.
– The sub menu will appear. .
12. Select {SYSTEM RESTORE (YCP01)}.
– The backup-file list display will appear.
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9 System Backup
9.4 Loading the Backup Data from the CompactFlash
13. Select desired date file.
– The YIF/YCP01 board dialog will appear.
– Select [YES] when exchanged the YIF/YCP01 board. If not, select
[NO].
– When select [YES], cumulative time display will be initialized. For
selecting [NO], cumulative time display will continue.
14. Select from the confirmation dialog box.
– The dialog box appears for the loading confirmation.
– Selecting [YES] in the confirmation dialog starts loading the content
of [CMOSBK.BIN] to CMOS of the YCP01 board.
15. Select [YES].
CAUTION
Note that executing "SYSTEM RESTORE" or “SYSTEM RESTORE
(YCP01)” 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.
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9 System Backup
9.5 Error List
9.5
Error List
9.5.1
Error Contents
Error Data Message
Cause
No.
0770
*
3390
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.
The capacity of the
CompactFlash is 128MB.
Change the CompactFlash to
256MB.
3430
*
I/O error on the drive
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.
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10 Upgrade Function
10.1 Functional Overview
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
Upgrade Procedure
10.2.1 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.
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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. After the automatic upgrade process is completed, the communication
process between YCP01 and YPP01 is 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.
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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.
NOTE
(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”
(161409-1CD).
• If no recovery is made with all the procedure above,
replace the pendant.
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10 Upgrade Function
10.3 Error Message
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” (161409-1CD) for detail.
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11
Reset Function of the Programming Pendant
11 Reset Function of the Programming Pendant
This function enables to restart only the programming pendant while the
main power supply of the controller is ON.
Please use this function when the Communication Error or ACK Receive
Error occurs.
This temporal interception of the communication between the controller
and the programming pendant enables the pendant to restart still the robot
is in operation.
1. “Communication Error” or “ACK Receive Error” message
– “Communication Error” or “ACK Receive Error” message appears
due to the communication error or internal processing error.
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11
Reset Function of the Programming Pendant
2. Confirmation of the LED (DS1) display on the robot I/F board
– Check the LED display on the robot I/F board (JANCD-YIF01-1E).
• Check that an alphabet letter or a number is displayed on
the LED display.
SUPPLEMENT
• Check that a dot is displayed at the lower right of the LED.
If it is, check that the dot is blinking or lighted.
• If the displayed alphabet or the number is continuously
changing, write down them in order.
3. Reset the programming pendant
– Open the CF slot cover on the programming pendant.
– There is a small hole below the CF insertion slot. Insert a spit to
press inside the hole.
– The programming pendant is rebooted and it starts connecting to the
controller again.
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12 Modification of System Configuration
12.1 Addition of I/O Modules
12 Modification of System Configuration
12.1
Addition of I/O Modules
To add I/O modules, turn OFF the power supply.
SUPPLEMENT
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.
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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.
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12 Modification of System Configuration
12.1 Addition of I/O Modules
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
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.
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12 Modification of System Configuration
12.2 Addition of Base and Station Axes
12.2
Addition of Base and Station Axes
To add the base and station axes, mount all hardware correctly and then
execute maintenance mode.
SUPPLEMENT
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, the contactor which is used for the
SERVOPACK, and the overrun signal (OT).
•
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]
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12 Modification of System Configuration
12.2 Addition of Base and Station Axes
• 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.
12.2.1 Base Axis Setting
12.2.1.1
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.
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12 Modification of System Configuration
12.2 Addition of Base and Station Axes
4. Select {SETUP}.
– The SETUP window appears.
– Note that the items marked with "" cannot be set.
5. Select {CONTROL GROUP}.
– The current control group type is displayed.
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12 Modification of System Configuration
12.2 Addition of Base and Station Axes
6. Move 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.
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12.2 Addition of Base and Station Axes
RECT-X
RECT-Y
RECT-Z
Z
Z
Z
Y
Y
Y
X
X
X
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
Z
Z
Z
Y
Y
Y
X
X
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
Z
X
CARTESIAN
CARTESIAN X-AXIS
Z-AXIS
Base 1st and 2nd axes directions of
travel coincide with robot coordinate
X-Axis and Z-Axis,respectively.
CARTESIAN
Z-AXIS
X
Y
CARTESIAN
Y-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.
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12 Modification of System Configuration
12.2 Addition of Base and Station Axes
12.2.1.2
Connection Setting
In the CONNECT window, it is specified that each axis of each control
group is connected to which connector of the SERVO board, which brake
of the contactor unit, which converter, and which overrun signal.
Note that the software version should be DS1.20.00(A)-00 or higher to set
the overrun signal.
1. Confirm the type of each control group in the CONNECT window.
– The connection status of each control group is displayed.
[Display with a software version before DS1.20.00(A)-00]
the control group
which is set
"NONE" in the
CONTROL GROUP
window is not
displayed.
[After the software with a version before DS1.20.00(A)-00 is initialized
and upgraded to a version DS1.20.00(A)-00 or higher]
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12.2 Addition of Base and Station Axes
[Display with a software version DS1.20.00(A)-00 or higher]
2. Select the connection item of a desired control group.
– The settable items are displayed.
– Select an item to change the setting. Select {Cancel} to return to the
CONNECT window.
[Display with a software version before DS1.20.00(A)-00]
[After the software with a version before DS1.20.00(A)-00 is initialized
and upgraded to a version DS1.20.00(A)-00 or higher]
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12 Modification of System Configuration
12.2 Addition of Base and Station Axes
[Display with a software version DS1.20.00(A)-00 or higher]
– Specify which connector (CN) of the SERVO board each axis of
each control group is connected to.
The numbers in [ ] represent axis numbers, and indicate which axis
is connected to which connector.
– Specify which brake (BRK) of the contactor unit each axis of each
control group is connected to.
The numbers in [ ] represent the axis numbers, and indicate which
axis is connected to which brake.
– Specify which converter (CV) each axis of each control group is
connected to.
The numbers in [ ] represent the converter numbers, and indicate
which axis is connected to which converter.
– Specify which overrun signal (OT) each control group is connected
to.
– In this example, B1 (Base) is connected 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)
Overrun

(OT2)
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12.2 Addition of Base and Station Axes
3. In software of the version DS1.20.00(A)-00 or higher, an overrun signal
is allocated to a control group. Therefore, when an overrun alarm
occurs, the subcode is indicated by the control group. (With software
of a version before DS1.20.00(A)-00, the subcode is indicated in
binary.)
However, select “NOT CONNECT” if an overrun switch is not installed
to the control group or the allocation of the external axis overrun signal
is not needed.
Regarding the connection of the external axis overrun signal, refer to
section 14.7.3 “Connection for External Axis Overrun (EXOT)”.
4. Select a desired item.
5. Press [ENTER] in the CONNECT window.
– The setting in the CONNECT window is completed and the window
moves to the AXES CONFIG window.
As for DS3.10.00 (A)-00 or later software versions, an error
massage Error 8217 ‟Cannot change setting. Check the
setting of spot high speed spec.” may appear when press
[ENTER] in the CONNECT window.
SUPPLEMENT
When the error massage appears, invalid SPOT HIGH
SPEED SPEC or review the configuration of the control
group by referring to section 9.12 ‟High Speed Spot Welding
Function” in the DX100 OPERATOR’S MANUAL FOR SPOT
WELDING USING MOTOR GUN.
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.
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12.2 Addition of Base and Station Axes
2. Select the axis type to be modified.
(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
: Input maximum moving position (positive (+)
direction and negative (-) direction) from
home position when setting the home
position to 0. (Unit: mm)
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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.
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12.2 Addition of Base and Station Axes
12.2.1.5
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.
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.
– <Phenomenon2>
During pause, the motor makes a lot of noise.
 Confirm the motion with decreasing this ratio in each 100.
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12.2 Addition of Base and Station Axes
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
Station Axis Setting
12.2.2.1 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.
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12 Modification of System Configuration
12.2 Addition of Base and Station Axes
2. Select the type of control group to be modified.
– 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
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12.2 Addition of Base and Station Axes
12.2.2.2 Connection Setting
In the CONNECT window, it is specified that each axis of each control
group is connected to which connector of the SERVO board, which brake
of the contactor unit, which converter, and which overrun signal.
Note that the software version should be DS1.20.00(A)-00 or higher to set
the overrun signal.
1. Confirm the type of each control group in the CONNECT window.
– Connection status of each control group is displayed.
[Display with a software version before DS1.20.00(A)-00]
the control group
which is set
"NONE" in the
CONTROL GROUP
window is not
displayed.
[After the software with a version before DS1.20.00(A)-00 is initialized
and upgraded to a version DS1.20.00(A)-00 or higher]
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[Display with a software version DS1.20.00(A)-00 or higher]
2. Select the connection item of desired control group.
– The settable items are displayed.
– Select an item to change the setting. Select {Cancel} to return to the
CONNECT window.
– Specify which connector (CN) of the SERVO board each axis of
each control group is connected to.
The numbers in [ ] represent axis numbers, and indicate which axis
is connected to which connector.
– Specify which brake (BRK) of the contactor unit each axis of each
control group is connected to.
The numbers in [ ] represent the axis numbers, and indicate which
axis is connected to which brake.
– Specify which converter (CV) each axis of each control group is
connected to.
The numbers in [ ] represent the converter numbers, and indicate
which axis is connected to which converter.
– Specify which overrun signal (OT) each control group is connected
to.
– In this example, S1 (Station) is connected 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)
Overrun

(OT2)
12-19
RE-CTO-A215
162536-1CD
DX100 Controller
12 Modification of System Configuration
12.2 Addition of Base and Station Axes
3. In software of the version DS1.20.00(A)-00 or higher, an overrun signal
is allocated to a control group. Therefore, when an overrun alarm
occurs, the subcode is indicated by the control group. (With software
of a version before DS1.20.00(A)-00, the subcode is indicated in
binary.)
However, select “NOT CONNECT” if an overrun switch is not installed
to the control group or the allocation of the external axis overrun signal
is not needed.
Regarding the connection of the external axis overrun signal, refer to
section 14.7.3 “Connection for External Axis Overrun (EXOT)”.
4. Select a desired item.
5. Press [ENTER] in the CONNECT window.
– The setting in the CONNECT window is completed and the window
moves to the AXES CONFIG window.
12.2.2.3 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
12-20
RE-CTO-A215
162536-1CD
DX100 Controller
12 Modification of System Configuration
12.2 Addition of Base and Station Axes
2. Select the axis type to be modified.
– The settable axis type is displayed.
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.
12-21
RE-CTO-A215
162536-1CD
DX100 Controller
12 Modification of System Configuration
12.2 Addition of Base and Station Axes
– OFFSET
: Offset should be specified at “TURN-2” type
only.
Input length between the center of bending
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)
12-22
RE-CTO-A215
162536-1CD
DX100 Controller
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.
12-23
RE-CTO-A215
162536-1CD
DX100 Controller
12 Modification of System Configuration
12.2 Addition of Base and Station Axes
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
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 a 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 SPEED: Input time between 0.01 and 1.00 to
reach maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
12-24
RE-CTO-A215
162536-1CD
DX100 Controller
12 Modification of System Configuration
12.2 Addition of Base and Station Axes
– 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.
– <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 this case, the control axis configuration is not changed so the job
file data should not be initialized.
12-25
RE-CTO-A215
162536-1CD
DX100 Controller
13
DX100 Specification
13 DX100 Specification
WARNING
Make sure that there is no one within the P-point maximum envelope of
the manipulator and that you are in a safe place before turning ON the
DX100 power.
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator.
•
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:
– Be sure to use a lockout device to the safeguarding when
going inside. Also, display the sign that the operation is
being performed inside the safeguarding and make sure no
one closes the safeguarding.
– 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 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.
The emergency stop buttons are located on the right of the front door of
the DX100 and the programming pendant.
13-1
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.1 Specification List
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.
•
Make sure that a system manager stores the key of the mode select
switch on the programming pendant.
After operation, the key should be removed and stored by the
system manager.
Improper or unintended manipulator operation may result in injury.
Also, the key or the mode select switch may be damaged if the
programming pendant is dropped with the key inserted.
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, 200/220 VAC (+10% to -15%)
at 60Hz(±2%)
200 VAC(+10% to -15%) at 50Hz(±2%)
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
200000 steps, 10000 instructions
13-2
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.2 Function List
13.2
Small capacity
A-Type (standard)
MH5, MH5S, MH5L, MH5LS, MH6, MH6S, MH6-10,
MA1400, MA1900,
HP20D, HP20D-6, HP20RD,
MPK2,
VA1400,
425(W) x 1200(H) x 450(D) mm
Medium and Large capacity
A-Type (standard)
DX1350D,
ES165D, ES165D-100, ES165RD, ES200D,
ES200RD, ES200RD-120
HP165D,
MA1800,
MC2000,
MH50, MH50-20, MH50-35, MH80,
MPL80,
MS80, MS80W,
SIA30D, SIA50D,
UP50SD, UP350D, UP350D-200, UP350D-500,
VS50
425(W) x 1200(H) x 450(D) mm
Large capacity
A-Type (standard)
(backside-mounted
regenerative resistor
specification)
MPL100, MPL160, MPL300, MPL500,
ES280D, ES280D-230,
MPK50,
MH165, MH200, MH215, MH250,
MS120,
UP120ED-165
425(W) x 1200(H) x 570(D) mm
Large capacity
A-Type (standard)
(ceiling-mounted regenerative
resistor specification)
EPH130D, EPH130RLD
425(W) x 1400(H) x 450(D) mm
Function List
Programming Coordinate
System
Pendant
Modification of
Operation
Teaching Points
Joint, Rectangular/Cylindrical, Tool, User
Coordinates
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
Interface
CF (Compact Flash) card slot, USB port
(USB1.1) (Programming Pendant)
Application
Arc welding, Spot welding, Handling,
General, Others
13-3
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.2 Function List
Safety
Feature
Maintenance
Function
Programing
Functions
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
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
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, String type
I/O Instructions
Discrete I/O, Pattern I/O processing
13-4
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.3 Programming Pendant
13.3
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, and
mode select switch (with key, three mode)
Type of the key for the mode select switch: AS6-SK-132
(manufactured by IDEC Corp.)
* Two keys are shipped with the programming pendant.
Others
Provided with CF (Compact Flash) card slot
USB port (USB1.1) X 1
13-5
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.4 Equipment Configuration
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 Breaker Power Supply Contact Unit

Fig. 13-1: Configuration for Small-Capacity A-Type (Standard)
A
Breaker
(Refer to the following table)
Machine Safety Unit
JZNC-YSU01-1E
Emergency Stop
Button (S1)
HW1B-V404R
B
1
CN214
B
A
1
CN207
B
A
CN213
CN611
CN607
CN211
1 FU
10 A
4FU
SVMX1
CN205
FUSE
SVMX2
CN608
CN612
CN605
CN604
CN603
CN603
CN608
CN612
CN605
CN215
CN210
CN107
CN609
SVMX1
SVMX2
CN606
CN606
CN203 CN204
NCM
CN200 CN201
CN601
CN604
Interior Circuration Fan
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
CN607
4FU
5A125V
CN209
2FU
CN202
CN610
1FU
3FU
3FU
5A125V
Power Supply Contactor Unit
JZRCR-YPU01-1
Brake Control Board
JANCD-YBK01-1E
1
CN611
CN216
CN212
CN206
CN601
FRC5-C50S52T-OLS(D20)
CN601
CN610
2FU
10 A
CN208
Backside Duct Fan
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
A
PE
CN602
CN602
I/O Unit
JZNC-YIU01-E
Converter
(Refer to the following table)
SERVOPACK
(Refer to the following table)
(
MXT NP
(MXT)
Robot System Input
Terminal Block
CN158/159
(+5V/ALM)
SOURCE
P-ON
+5V
+24V
FAN
OHT
(
CN156/157
(+24V2)
CPS Unit
JZNC-YPS01-E
POWER SUPPLY
CPS-520F
NO.
C90AD XXXXX
DATE YYYY-MM
EXDSW1- 34 SYSRUN+ 17
GSOUTFB2-
50
GSOUTFB2+
49
GSOUT2-
48
GSOUT2+
47
GSOUTFB1-
46
GSOUTFB1+
45
EXDSW1+ 33
16
EXHOLD- 32
15
EXHOLD+ 31
14
EXSVON- 30
13
EXSVON+ 29 SAFF2- 12
GSOUT1-
44
GSOUT1+
43
024V2
42
+24V2
41
SSP-
28 SAFF2+ 11
SSP+
27 SAFF1- 10
FST2-
26 SAFF1+ 9
FST2+ 25 GSIN22- 8
FST1024V2
40
+24V2
39
024V2
38
+24V2
37
24 GSIN22+ 7
FST1+ 23 GSIN21- 6
FAN1
EXESP2- 22 GSIN21+ 5
EXESP2+ 21 GSIN12- 4
EXESP1- 20 GSIN12+ 3
EXDSW2-
36
EXDSW2+
35
EXESP1+ 19 GSIN11- 2
FAN2
SYSRUN- 18 GSIN11+ 1
NJ2959-1
FAN
CN154/155
(+24V1/V2)
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
CN153
(+24V3)
CN151
(AC IN)
INPUT
200-240V AC
50/60Hz
3.4A-2.8A
Robot I/F Board
JANCD-YIF01-1E
CPU Unit
JZNC-YRK01-1E
CN152
(REMOTE)
A
1
R-IN
2
R-INCOM
3
R-OUT
4
R-OUTCOM
F Door
Inside View
Inside Controller
Front View
Back View
(without cover)
MXT
CN152
Regenerative Resistor
SMRK220W12R5K A5979
*for MA1900, HP20D,
HP20D-6, HP20RD
RDC50N12R5JI800ZZ
Sectional View A-A'
Table 13-1: Configuration for Small Capacity
Model
DX100
Type
SERVOPACK
Breaker
Power Supply
Contactor Unit
(Converter integrated)
MH5
MH5S
MH5L
MH5LS
ERDR-MH00005-A00
JZRCR-YSV01-11
NF32-SW 3P 15A
JZRCR-YPU01-1
MH6
MH6S
MH6-10
ERDR-MH00006-A00
JZRCR-YSV02-11
NF32-SW 3P 15A
JZRCR-YPU01-1
MA1400
ERDR-MA01400-A00
JZRCR-YSV02-11
NF32-SW 3P 15A
JZRCR-YPU01-1
MPK2
ERDR-MPK0002-A03
JZRCR-YSV03-11
NF32-SW 3P 15A
JZRCR-YPU01-1
VA1400
ERDR-VA01400-A00
JZRCR-YSV02-31
NF32-SW 3P 15A
JZRCR-YPU01-1
MA1900
ERDR-MA01900-A00
JZRCR-YSV03-11
NF32-SW 3P 15A
JZRCR-YPU01-1
HP20D
HP20D-6
HP20RD
ERDR-HP0020D-A00
JZRCR-YSV03-11
NF32-SW 3P 15A
JZRCR-YPU01-1
13-6
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.4 Equipment Configuration

Medium and Large Capacity
Fig. 13-2: Configuration for Medium and Large Capacity A-Type (Standard)
Breaker
(Refer to the
following table)
Backside Duct Fan
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
(Air inlet)
A
Machine Safety Unit
JZNC-YSU01-1E
Emergency Stop Button
HW1B-V404R
Converter
(Refer to the
following table)
Brake Control Board
JANCD-YBK01-1E
Puwer Supply
Contactor Unit
JZRCR-YPU01-1
SE RVO PACK
(Refer to the
following table)
Interior Circuration Fan
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
(Air inlet)
I/O Unit JZNC-YIU01-E
Interior Circuration Fan
3610PS-22T-B30-B00 or
09225PB-B2L-EA-02
(Air : Upper direction)
(MXT) Robot System Input
Terminal Block
Regenerative Resistor
SMVK500W2R0J A5978 X3
Robot I/F Board
JANCD-YIF01-1
CPU Unit
JZNC-YRK01
CPS Unit
JZNC-YPS01-E
A
Back View
(without cover)
F Door
Inside View
Inside Controller
Front View
Sectional View A-A'
Table 13-2(a): Configuration for Medium and Large Capacity
Model
DX100
SERVOPACK
Converter
Breaker
Power Supply
Contactor Unit
ERDR-MH00050-A00
JZRCRYSV04-11
SRDACOA30A01A-E
NF32-SW 3P
30A
JZRCR-YPU01-1
ERDR-MS00080-A00
JZRCRYSV05-11
JZRCRYSV05-41
JZRCRYSV05-41
JZRCRYSV04-21
JZRCRYSV08-11
JZRCRYSV04-11
JZRCRYSV04-11
JZRCRYSV05-11
JZRCRYSV06-11
JZRCRYSV04-11
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
NF32-SW 3P
30A
NF32-SW 3P
30A
NF32-SW 3P
30A
NF32-SW 3P
15A
NF32-SW 3P
30A
NF32-SW 3P
30A
NF32-SW 3P
30A
NF32-SW 3P
30A
NF32-SW 3P
30A
NF32-SW 3P
30A
JZRCR-YPU01-1
ERDR-ES0165D-A00
JZRCRYSV06-11
SRDACOA30A01A-E
NF32-SW 3P
30A
JZRCR-YPU01-1
ERDR-ES0200D-A00
JZRCRYSV06-11
SRDACOA30A01A-E
NF32-SW 3P
30A
JZRCR-YPU01-1
ERDR-HP0165D-A00
JZRCRYSV06-11
JZRCRYSV07-11
SRDACOA30A01A-E
SRDACOA30A01A-E
NF32-SW 3P
30A
NF32-SW 3P
30A
JZRCR-YPU01-1
Type
Medium Capacity
MH50
MH50-20
MH50-35
MS80
MS80W
VS50
ERDR-VS00050-A00
SIA50D
ERDR-SIA050D-A00
SIA30D
ERDR-SIA030D-A00
MA1800
ERDR-MA01800-A00
UP50SD
ERDR-UP050SD-A00
MPL80
ERDR-MPL0080-A00
MH80
ERDR-MH00080-A00
MC2000
ERDR-MC2000-A00
DX1350D
ERDR-DX1350D-A00
JZRCR-YPU01-1
JZRCR-YPU01-1
JZRCR-YPU01-1
JZRCR-YPU01-1
JZRCR-YPU01-1
JZRCR-YPU01-1
JZRCR-YPU01-1
JZRCR-YPU01-1
JZRCR-YPU01-1
Large Capacity
ES165D
ES165D-100
ES165RD
ES200D
ES200RD-120
ES200RD
HP165D
UP350D
UP350D-200
UP350D-500
ERDR-UP0350D-A00
JZRCR-YPU01-1
13-7
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.4 Equipment Configuration
Fig. 13-3: Configuration for Large Capacity A-Type (Standard) (Backside-Mounted Regenerative Resistor
Specification)
Breaker
(Refer to the
following table)
Backside Duct Fan
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
(Air inlet)
Machine Safety Unit
JZNC-YSU01-1E
A
Emergency Stop
Button
HW1B-V404R
Power Supply
Contactor Unit
JZRCR-YPU01-1
Converter
(Refer to the following table)
Brake Control Board
JANCD-YBK01-1E
SE RVO PACK
(Refer to the
following table)
Interior Circuration Fan
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
(Air inlet)
I/O Unit
JZNC-YIU01-E
For the regenerative resistor
refer to the following table
Interior Circuration Fan
3610PS-22T-B30-B00 or
09225PB-B2L-EA-02
(Air : Upper direction)
Regenerative Resistor
Cooling Fan
3610PS-22T-B30-B00 or
09225PB-B2L-EA-02
(Air : Upper direction)
(MXT) Robot System Input
Terminal Block
Robot I/F Board
JANCD-YIF01-1
CPU Unit
JZNC-YRK01
CPS Unit
JZNC-YPS01-E
A
F Door
Inside View
Inside Controller
Front View
Back View
(without cover)
Sectional View A-A
Table 13-2(b): Configuration for Large Capacity (Backside-Mounted Regenerative Resistor
Specification)
DX100
Model
SERVOPA Converter
CK
Breaker
JZRCRYSV06-11
JZRCRYSV06-11
JZRCRYSV06-11
JZRCRYSV06-11
JZRCRYSV06-11
JZRCRYSV06-11
JZRCRYSV05-11
JZRCRYSV06-11
JZRCRYSV06-11
JZRCRYSV07-11
JZRCRYSV07-11
JZRCRYSV07-11
JZRCRYSV06-11
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
NF32-SW
3P30A
Type
MPL100
ERDRMPL0100-A00
MPL160
ERDRMPL0160-A00
MPL300
ERDRMPL0300-A00
MPL500
ERDRMPL0500-A00
ES280D
ERDRES0280D-A00
ES280D
ERDR-230
ES0280D-A00
MPK50
ERDRMPK0050-A00
MH165
ERDRMH00165-A00
MH200
ERDRMH00200-A00
MH215
ERDRMH00215-A00
MH250
ERDRMH00250-A00
MS120
ERDRMS00120-A00
UP120ED ERDR-165
UP120ED-A00
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
Power
Supply
Contactor
Unit
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
JZRCRYPU01-1
Generative Register
SMVK500W1R0J A5998 X6
(3000W 6.0Ω)
SMVK500W1R0J A5998 X6
(3000W 6.0Ω)
SMVK500W1R0J A5998 X6
(3000W 6.0Ω)
SMVK500W1R0J A5998 X6
(3000W 6.0Ω)
SMVK500W1R0J A5998 X5
(2500W 5.0Ω)
SMVK500W1R0J A5998 X5
(2500W 5.0Ω)
SMVK500W2R0J A5978 X3
(1500W 6.0Ω)
SMVK500W2R0J A5978 X3
(1500W 6.0Ω)
SMVK500W2R0J A5978 X3
(1500W 6.0Ω)
SMVK500W2R0J A5978 X3
(1500W 6.0Ω)
SMVK500W2R0J A5978 X3
(1500W 6.0Ω)
SMVK500W2R0J A5978 X3
(1500W 6.0Ω)
SMVK500W2R0J A5978 X3
(1500W 6.0Ω)
13-8
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.4 Equipment Configuration
Fig. 13-4: Configuration for Large Capacity A-Type (Standard) (Ceiling-Mounted Regenerative Resistor
Specification)
A
Regenerative Resistor
Cooling Fan
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
SAFETY UNIT㸦YSU㸧
Breaker
(Refer to the
following table)
Regenerative Resistor
609:5-$;
:㸧
Backside Duct Fan
JZNC-YSU01-1E
Emergency Stop Button (S1)
HW1B-V404R
Power Supply Contactor
Unite (YPU)
5915PC-22T-B30-B00 or
15038PB-B2L-EP-03
Converter
(Refer to the following table)
Brake Control Board
JANCD-YBK01-1E
JZRCR-YPU01-1
SE RVO PACK
(Refer to the
following table)
Interior Circuration Fan
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
I/O UNIT㸦YIU㸧
JZNC-YIU01-E
Interior Circuration Fan
3610PS-22T-B30-B00 or
09225PB-B2L-EA-02
CPS UNIT(YPS)
JZNC-YPS01-E
A
Back View
(without cover)
(MXT) Robot System Input
Terminal Block
Robot I/F Board
JANCD-YIF01-1
CPU UNIT㸦YRK㸧
MXT NP
JZNC-YRK01
F Door
Inside View
Inside Controller
Front View
Sectional View A-A'
Table 13-2(c): Configuration for Large Capacity (Ceiling-Mounted Regenerative Resistor Specification)
Model
DX100
SERVOPACK
Converter
Breaker
Type
EPH130D
Power Supply
Contactor Unit
ERDR-EPH130D-A00
ERDR-PH13RLD-A00
SRDACOA30A01A-E
SRDACOA30A01A-E
NF32-SW 3P
30A
NF32-SW 3P
30A
JZRCR-YPU01C-1
EPH130RLD
JZRCRYSV07-11
JZRCRYSV07-11
JZRCR-YPU01C-1
13-9
RE-CTO-A215
162536-1CD
DX100 Controller
13 DX100 Specification
13.4 Equipment Configuration
13.4.2 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. 13-5: .Cooling System
Interior Circuration Fan
Air Intake
Interior Circuration Fan
Air Intake
Backside Duct Fan
Backside Duct Fan
Air Outlet
Air Outlet
Interior Circuration Fan
Cooling System (Small Capacity)
Cooling System (Medium and Large Capacity)
Regenerative Resistor
Cooling Fan
Interior Circuration Fan
Air Intake
Interior Circuration Fan
Backside Duct Fan
Air Intake
Backside Duct Fan
Regenerative Resistor
Cooling Fan
Interior Circuration Fan
Interior Circuration Fan
Air Outlet
Cooling System (Large Capacity)
(Backside-Mounted Regenerative Resistor Specification)
Air Outlet
Cooling System (Large Capacity)
(Ceiling-Mounted Regenerative Resistor Specification)
13-10
RE-CTO-A215
162536-1CD
DX100 Controller
14
Description of Units and Circuit Boards
14 Description of Units and Circuit Boards
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 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. The emergency stop buttons are
located on the right of the front door of DX100 and the programming
pendant.
•
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:
– Be sure to use a lockout device to the safeguarding when
going inside. Also, display the sign that the operation is
being performed inside the safeguarding and make sure no
one closes the safeguarding.
– 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.
•
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.
14-1
RE-CTO-A215
162536-1CD
DX100 Controller
14
Description of Units and Circuit Boards
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.
•
Make sure that a system manager stores the key of the mode select
switch on the programming pendant.
After operation, the key should be removed and stored by the
system manager.
Improper or unintended manipulator operation may result in injury.
Also, the key or the mode select switch may be damaged if the
programming pendant is dropped with the key inserted.
14-2
RE-CTO-A215
162536-1CD
DX100 Controller
14

Description of Units and Circuit Boards
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
Input signal 2
024V
Switch
-19
-20
Turn ON/OFF
at the same time
-21
-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
Input signal 2
024V
-19
-20
The same contact
-21
-22
Short-circuit current
14-3
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.1 Power Supply Contactor Unit
14.1
Power Supply Contactor Unit
The power supply contactor unit consists of the power supply contactor
sequence circuit board (JARCR-YPC01-1) 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
JZRCRYPU01-
□
DX1350D,
EPH130D, EPH130RLD,
ES165D, ES165D-100, ES165RD, ES200D, ES200RD,
ES200RD-120, ES280D, ES280D-230,
HP20D, HP20D-6, HP20RD, HP165D,
MA1400, MA1800, MA1900,
MC2000,
MH5, MH5S, MH5L, MH5LS, MH6, MH6S, MH6-10, MH50, MH50-20,
MH50-35, MH80, MH165, MH200, MH215, MH250,
MPK2, MPK50,
MPL80, MPL100, MPL160, MPL300, MPL500,
MS80, MS80W, MS120,
SIA30D, SIA50D,
UP50SD, UP120ED-165, UP350D, UP350D-200, UP350D-500,
VA1400,
VS50,
Fig. 14-1: Power Supply Unit Configuration (JZRCR-YPU01-□)
(CN601)
Main Power Supply Input
(2FU), (1FU)
Fuse for AC Control Power Supply
0218010P(10A 250V)
CN601
CN601
CN610
CN611
1FU
2FU
10 A
2FU
1 FU
10 A
CN607
4FU
(CN607)
Contactor Control Input
CN607
3FU 2.5A
4FU 2.5A
3FU
(CN606)
AC Cooling Fan
CN611
CN610
SVMX1 SVMX2
CN601
CN606
CN612
SVMX2
CN606
SVMX1
SVMX1
SVMX2
CN612
CN605
CN605
CN604
CN604
CN603
CN603
CN608
(CN605,CN604,CN603)
AC Control Power Supply
CN609
NCM
CN608
(4FU), (3FU)
Fuse for AC Cooling Fan
GP25 (2.5A 250V)
(CN608)
Brake Interlock Output
CN602
CN602
(CN602)
Converter Output
14-4
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
14.2
Major Axes Control Circuit Board (SRDA-EAXA01□)
14.2.1
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□)
(CN512)
SHOCK Signal Input
(CN510)
Converter Power Supply Output
(CN513)
Brake Control Signal
(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
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
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
+24V
SHOCK
Manipulator
TMEDN-630809-FA (NICHIFU)
SHOCK+
Manipulator cable (signal)
-3
-4
TMEDN-630809-MA
(NICHIFU)
TMEDN-630809-FA
(NICHIFU)
SHOCKTMEDN-630809-MA (NICHIFU)
Shock sensor
(Option)
Shock sensor signal cable
14-6
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
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 plus 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
+24 V2
-1
-3
SHOCK+
TMEDN-630809-FA (NICHIFU)
SHOCK+
TMEDN-630809-FA (NICHIFU)
SHOCK
Shock sensor
(Option)
-4
SHOCKTMEDN-630809-MA (NICHIFU)
SUPPLEMENT
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” for details.
14-7
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
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
Contact: 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 Maker: JST
Contact: 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
Note: Direct-in relay cables (CBL-YRC057-1 : 1m) are prepared as an
optional.
14-8
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.3 CPU Unit
14.3
CPU Unit
14.3.1 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
CN103
Battery
14-9
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.3 CPU Unit
14.3.2
Unit and Circuit Board in the CPU Unit
14.3.2.1
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.
14.3.2.2
Robot I/F Board (JANCD-YIF01-1E)
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 (SRDAEAXA01□) with high-speed serial transmissions.
14-10
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.4 CPS Unit (JZNC-YPS01-E)
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: CPU Unit JZNC-YPS01-E
Connection with CPU 1 (CN158)
Connection with CPU 2 (CN159)
Monitor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
Fuji Electric Hi-Tech Corp.
MADE IN JAPAN
(CN151)
AC Power Supply Input
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
CN155
(+24V1/+24V2)
(CN156/CN157)
+24V2 Power Supply Output
(CN154/CN155)
+24V1/+24V2 Power Supply Output
(CN153)
+24V3 Power Supply Output
CN154
(+24V1/+24V2)
CN153
(+24V3)
(CN152)
Remote Control
CN151
(AC IN)
INPUT
200-240V AC
50/60Hz
3.4A-2.8A
CN152
(REMOTE)
14-11
RE-CTO-A215
162536-1CD
DX100 Controller
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 non-fuse breaker of the controller
so that the control power supply is turned ON. If the controller is not located at the
workplace, the control power supply can be turned ON/OFF by an external device,
etc. after the non-fuse breaker of the controller is turned ON. It is operated by the
external switch connected with CN152 of the 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
Control Power Supply
CPS-420F
Remove the short-circuit positioner
CN152
R-IN
R-INCOM
-1
Control Power Supply ON/OFF Switch
-2
See section 14.8 “WAGO Connector” for wiring of CN152 connector.
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14 Description of Units and Circuit Boards
14.5 Brake Control Board (JANCD-YBK01-□E)
14.5
Brake Control Board (JANCD-YBK01-□E)
14.5.1
Brake Control Board (JANCD-YBK01-□E)
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
(CN403)
Brake Power Supply Input
F1:Fuse
3.15A/250V
(CN400)
Brake Output
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14 Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)
14.6
Robot I/O Unit (JZNC-YIU01-E)
14.6.1 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 section 14.12 “Universal I/O Signal Assignment” for more details
on signal allocation.
For the connection of the robot’s universal I/O signal connectors, and the
I/O signal related to start and stop, refer to "Connection wire with
Universal I/O Connector (CN306, 307, 308, 309)" and "Specific I/O Signal
Related to Start and Stop"
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
3.15A/250V
(CN302)
Direct-in
(optional)
(CN301)
Panel IO
(CN307)
Digital I/O
(CN306)
Digital I/O
D2:FUSE CUT LED
S1: Rotary Switch
(CN300)
Communication Connector
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14 Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)

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 (FUJITSU)
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
B14
A14
FG
B15 +24VU +24VU +24VU +24VU +24VU
A15 +24VU +24VU +24VU +24VU +24VU
Stripped length: 10mm
Applicable max cable outside diameter: 3mm dia.
Model: TIFS553YS (KASUGA ELECTRIC)
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14 Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)
When connecting an inductive load to the output circuit,
connect a flyback (snubber) diode in parallel to the inductive
load to suppress the surge voltage. Not using the flyback
(snubber) diode may damage the output circuit.
When connecting the load with a large inrush current such
as the lamp, connect the current limiting resistor in series to
the load, so that the output current does not exceed its
maximum value. Exceeding the maximum output current
value may damage the output circuit.
JZNC-YIU01-E
+24VU
Inductive load
NOTE
Flyback Diode
Current limiting
resistor
Lamp
024VU
Refer to section 14.12 “Universal I/O Signal
Assignment”from page14-44 to 14-70 about the maximum
current of the transistor and the relay output circuits.
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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: System 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:
System input terminal block MXT)
• External Emergency Stop (common to all application:
System 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
External Hold
ON
OFF
Ext. E-Stop
ON
OFF
T
T
T
Note: Set T=100msec or more
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14 Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)

Servo ON PB
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.
Servo ON
Confirmation
X2
DX100
Servo ON
Command
X1
System Input Terminal
Block (MXT)
Servo ON
Command
MXT
X1
-29
X1
External Servo
ON Input
(EXSVON)
Robot I/O Unit
JZNC-YIU01
+24VU
CN308
-30
Servo ON
Confirmation
Servo Power ON
X3 (30011)
X2
Servo Power ON
-A18
X3
PL
-A8
Note: Number in (
+24VU
Servo ON
Output
(30011)
) 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
Ex. Start
Command
X4
X3
Running
X6 (30010)
Robot I/O Unit
JZNC-YIU01
CN308
External Start
-B1
Input
(20010)
-B7
Running
Confirmation
X5
PL
OVU
Running, etc.
X6
-B18
-B8
+24VU
Running Output
(30010), etc.
Note: Number in ( ) means output signal number assigned to YIU01.
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14 Description of Units and Circuit Boards
14.6 Robot I/O Unit (JZNC-YIU01-E)

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 section 14.8 “WAGO
Connector”.
Fig. 14-10: Connection of External Power Supply for I/O
Robot I/O unit (JZNC-YIU01-E)
+24VU
CN303
-1 (EX24VIN)
F1
3.15A
-2 (EX024VIN)
Robot I/O unit (JZNC-YIU01-E)
External
Power Supply
0V
F1
3.15A
-2 (EX024VIN)
F2
3.15A
024VU (Ready by Customer)
+24V
-1 (EX24VIN)
+24V
F2
3.15A
+24VU
CN303
+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
• 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.
NOTE
• 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.
14-19
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14 Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
14.7
Machine Safety Unit (JZNC-YSU01-1E)
14.7.1 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 (OT1, OT2) 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
A
(CN213)
Contactor Control 2
CN206
(CN203)
OT1 Input Connector
A
CN211
(CN211)
ONEN, ONEN2, OT2
CN215
CN205
CN210
CN209
CN203
(CN216)
MXT Connection
(CN210)
I/F between Major Axes
Control Circuit Boards
CN208
(CN200)
Power Supply Input Connector
FUSE
(CN201)
Power Supply Output Connector
CN200 CN201
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
CN207
(CN212)
FANALM,FANCTL,LAMP
CN213
(CN206)
I/F-IN for Machine Safety Unit
1
CN214
1
s
B
(CN207)
I/F for Machine Safety Unit
(CN215)
For Contactor Control 3 and 4
(CN209)
PP I/F
(CN208)
Door Emergency Stop Button
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14 Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
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 section 14.8 “WAGO
Connector”
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
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14 Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
14.7.3 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, the machine safety signal error 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 section 14.8 “WAGO
Connector”.
For the setting of the external axis overrun, refer to section 12.2.1.2
“Connection Setting”.
CAUTION
•
Jumper cables are installed at the factory. Be sure to remove the
jumper cables before using.
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. 14-12(a): Connection for External Axis Overrun
DX100
Machine Safety Unit
JZNC-YSU01-1E
Remove the jumper cable
CN211
OT2_1+
OT2_1OT2_2+
OT2_2 -
-9
External axis overrun
-10
Turn ON/OFF
at the same time
-11
-12
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14 Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
Following figures show the external axis overrun wirings before shipment
if external axes are conncted to the DX100.
Each figure shows the wirings for the overrun system No.1, 2 and 3
respectively including the connector connections.
(Prepare connectors or ternminals for brancing when the overrun is added
by the user.)
Fig. 14-12(b): Connection for External Axis Overrun (Overrun System No.1)
DX100
Machine safety unit
JZNC-YSU01-1E
CN211
OTXT1
1
2
3
4
OT2_1+ 9
OT2_1- 10
OT2_2+ 11
OT2_2- 12
1
2
3
4
OT connector (OTXT1)
231-104/037-000
(WAGO)
External axis overrun
Turn ON/OFF
simultaneously
Fig. 14-12(c): Connection for External Axis Overrun (Overrun System No.2)
DX100
Machine safety unit
JZNC-YSU01-1E
CN211
OTXT1
OT connector (OTXT1)
231-104/037-000
(WAGO)
External axis overrun
OT2_1+ 9
OT2_1- 10
OT2_2+ 11
OT2_2- 12
1
2
3
4
1
2
3
4
Turn ON/OFF
simultaneously
OT connector (OTXT2)
OTXT2
1
2
3
4
1
2
3
4
231-104/037-000
(WAGO)
External axis overrun
Turn ON/OFF
simultaneously
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14 Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
Fig. 14-12(d): Connection for External Axis Overrun (Overrun System No.3)
DX100
Machine safety unit
JZNC-YSU01-1E
CN211
OT2_1+ 9
OT2_1- 10
OT2_2+ 11
OT2_2- 12
OTXT1
1
2
3
4
1
2
3
4
OT connector (OTXT1)
231-104/037-000
(WAGO)
External axis overrun
Turn ON/OFF
simultaneously
OT connector (OTXT2)
OTXT2
1
2
3
4
1
2
3
4
OTXT3
231-104/037-000
(WAGO)
External axis overrun
Turn ON/OFF
simultaneously
OT connector (OTXT3)
231-104/037-000
(WAGO)
External axis overrun
1
2
3
4
1
2
3
4
Turn ON/OFF
simultaneously
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14 Description of Units and Circuit Boards
14.7 Machine Safety Unit (JZNC-YSU01-1E)
Fig. 14-12(e): Connection for External Axis Overrun
(Connector Connection)
(OTXT3)
OT connector (OTXT3)
231-604/018-000
Adapter X2
209-137
(WAGO)
(20) (20)
OT connector (OTXT2)
231-604/018-000
Adapter X2
209-137
(OTXT2) (WAGO)
(OTXT1)
(10)
BNL6
(MXT)
OT connector (OTXT1)
231-604/018-000
Adapter X2
209-137
(WAGO)
BNL6
(2XT)
BNL6
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
10 11 12 13 14 15 16 17
BNL6
BNL6
DX100 Controller
BNL6
Side View inside the DX100
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14 Description of Units and Circuit Boards
14.8 WAGO Connector
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
Specification
Max cable outside diameter: 4.1mm dia.
Stripped lentgh:
8-9mm
Max cable outside diameter: 3.4mm dia.
7mm
Stripped lentgh:
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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.
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14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)
Robot System Input Terminal Block (MXT)
The robot system 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 System Input Terminal Block (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
BNL6
14.9
(MXT)
DX100 Inside Right Side
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14 Description of Units and Circuit Boards
14.9 Robot System 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.
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14 Description of Units and Circuit Boards
14.9 Robot System 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.
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14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)

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
•
Jumper cables are installed at the factory. Be sure to remove the
jumper cables before using.
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+
EXESP1EXESP2+
EXESP2-
JANCDYSF03
Robot system input
terminal block
MXT
Remove the jumper cable
-19
External emergency stop
-20
Turn ON/OFF
at the same time
-21
-22
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14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)

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
•
Jumper cables are installed at the factory. Be sure to remove the
jumper cables before using.
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
SAFF1+
SAFF1SAFF2+
-9
Safety plug
-10
Turn ON/OFF
at the same time
-11
-12
SAFF2-
14-32
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DX100 Controller
14 Description of Units and Circuit Boards
14.9 Robot System 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.
Fig. 14-16: Installation of Safety Plug
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.
14-33
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DX100 Controller
14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)

Full-speed Test
This signal is used to reset the slow speed limit for the test run in the teach
mode.
If this signal input circuit is short-circuited, the speed of the test run
becomes 100% in the play mode.
If this signal’s circuit is open, the status SSP input signal determines the
slow speed: The first slow speed (16%) or second slow speed (2%).
• Setting Method
1. Short-circuit terminal number 23 and 24 of the robot system input
terminal block (MXT), and 25 and 26 as well. (Normally, each terninal
is unwired.)
Fig. 14-17: Connection for Full-speed Test
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
-23
Full-speed test
FST1+
-24
FST1-
Turned ON/OFF
at the same time
-25
FST2+
-26
FST2-
2. Switch the operation mode to “management mode” and set the
following parameter.
Parameter
Content and Setting Value
Initial Value
S2C233
Switches to valid/invalid of fullspeed test.
0: Invalid
1: Valid
0
14-34
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14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)
3. The message "Full-speed test mode" is displayed as follows when the
setting is finished.
• Operation Speed
When the full-speed test mode is set, operation speed is set depending on
the setting of manual speed as follows.
At the time of setting the full-speed mode, the setting of manual speed
shifts to Inching automatically.
When changing the setting of manual speed, make sure that there is no
person around the manipulator and pay great attention to perform the
operation.
Manual
speed
Limit of operation speed
(default value)
Parameter (Unit: 0.01%)
Inching
20%
S1CxG60 (default value: 2000)
Slow
50%
S1CxG61 (default value: 5000)
Medium
75%
S1CxG62 (default value: 7500)
Fast
100% (fixed value)
-
NOTE
• The limit values of operation speed described in the table
above are the ratio against the manipulator's maximum
speed, not against the taught speed. The values are for
restraining the operation speed not to exceed the limit
values of operation speed against the manipulator's
maximum speed during the test run or FWD/BWD
operation.
• Manual full-speed function allows the manipulator to
perform the test run or FWD/BWD operation at the taught
speed by a job during the teach mode. Perform the
operation outside the motion range.
• If the full-speed test mode is set or released while a servo
power is ON, the servo power turns OFF.
14-35
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DX100 Controller
14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)

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%)
CAUTION
•
Jumper cables are installed at the factory. Be sure to remove the
jumper cables before using.
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. 14-18: Connection for Slow Speed Mode Selection
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
Remove the jumper cable
SSP+
-27
Slow speed mode selection
-28
SSP-
14-36
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162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)

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. 14-19: Connection for External Servo ON
DX100
JZNC
-YSU01-1E
EXSVON+
JANCD
-YSF03
Robot system input
terminal block
MXT
-29
External servo ON
-30
EXSVON-
14-37
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162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.9 Robot System 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
•
Jumper cables are installed at the factory. Be sure to remove the
jumper cables before using.
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. 14-20: Connection for External Hold
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input
terminal block
MXT
Remove the jumper cable
EXHOLD+
-31
-32
EXHOLD-
External Hold
14-38
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DX100 Controller
14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)

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
•
Jumper cables are installed at the factory. Be sure to remove the
jumper cables before using.
Injury or damage to machinery may result because the external
emergency stop do not work even if the signal is input.
Fig. 14-21: 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+
EXDSW2-
-36
14-39
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DX100 Controller
14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)

SYSRUN Signal Output
This signal is used to check whether the DX100’s status is normal or
abnormal.
This signal is output on the following conditions.
ON
Primary power supply OFF
Normal
DX100 status Abnormal
ON
SYSRUN OFF
Fig. 14-22: Connection for SYSRUN Signal Output
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
Robot system input terminal block
MXT
+24V
-17
SYSRUN +
-18
SYSRUN 024V
14-40
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162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.9 Robot System Input Terminal Block (MXT)
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.
Short-circuit with a
jumper cable
Short-circuit with a
jumper cable
14-41
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162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.10 Contact Output of Emergency Stop Button
14.10
Contact Output of Emergency Stop Button
The contact output terminals for the emergency stop button on the
programming pendant and the door front are provided on the terminal
block 2XT (screw size M3.5) at lower part of the right side of DX100.
These contact outputs are always valid no matter of the DX100 main
power supply status 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. 14-23: Contact Output Terminal Block of Emergency Button (2XT)
Front door of DX100
Emergency stop button
2XT
PBESP3+
PBESP3−
PBESP4+
PBESP4−
EXT
PBESP3+
PBESP3−
PBESP4+
PBESP4−
Programming pendant
Emergency stop button
PPESP3+
PPESP3−
PPESP4+
PPESP4−
PPESP3+
PPESP3−
PPESP4+
PPESP4−
14-42
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DX100 Controller
14 Description of Units and Circuit Boards
14.11 SERVOPACK
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 Table 14-2 "SERVOPACK Model List (Integrated
Type)"- Table 14-4 "SERVOPACK Model List (Separated Type)" ).
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: SERVOPACK Model List (Integrated Type)
Configuration Device
MH5,MH5S,
MH5L, MH5LS
MA1400,
MH6, MH6S, MH610
VA1400
MA1900,
HP20D, HP20D-6,
HP20RD, MPK2
Model
Model
Model
Model
JZRCR-YSV01-11
JZRCR-YSV02-11
JZRCR-YSV02-31
JZRCR-YSV03-11
S
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
L
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA21A01A-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
SERVOPACK
PWM
Amplifier
E
Converter
SRDASDA14A01A-E
SRDACOA12A01A-E
SRDACOA12A01A-E
SRDACOA12A01A-E
SRDACOA12A01A-E
14-43
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162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.11 SERVOPACK
Table 14-3: SERVOPACK Model List (Separated Type)
Configuration Device
MH50, MH50-20,
MH50-35,
UP50SD,
DX1350D,
MPL80, MPL800
Model
Model
Model
Model
SERVOPACK
JZRCR-YSV04-11
JZRCR-YSV05-11
JZRCR-YSV05-41
JZRCR-YSV06-11
S
SRDASDA71A01A-E
SRDASDA71A01A-E
SRDASDA71A01A-E
SRDASDA71A01A-E
L
SRDASDA71A01A-E
SRDASDA71A01A-E
SRDASDA71A01A-E
SRDASDA71A01A-E
U
SRDASDA35A01A-E
SRDASDA71A01A-E
SRDASDA71A01A-E
SRDASDA71A01A-E
R
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA35A01A-E
B
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA21A01A-E
T
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA14A01A-E
SRDASDA21A01A-E
PWM
Amplifier
MS80, MS80W,
MH80
MPK50
E
VS50,
SIA50D
ES165D, ES165D-100,
ES165RD, ES200D,
ES200RD,
ES200RD-120,
ES280D, ES280D-230,
HP165D
MH165, MH200,
MC2000,
UP120ED-165,
MPL100, MPL160,
MPL300, MPL500
SRDASDA71A01A-E
Converter
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
SRDACOA30A01A-E
Table 14-4: SERVOPACK Model List (Separated Type)
Configuration Device
MH215, MH250,
UP350D, UP350D-200,
UP350D-500,
MS120
EPH130D,
EPH130RLD
MA1800
SIA30D
Model
Model
Model
JZRCR-YSV07-11
JZRCR-YSV08-11
JZRCR-YSV04-21
S
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
L
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
U
SRDA-SDA71A01A-E
SRDA-SDA35A01A-E
SRDA-SDA35A01A-E
R
SRDA-SDA35A01A-E
SRDA-SDA06A01A-E
SRDA-SDA14A01A-E
B
SRDA-SDA35A01A-E
SRDA-SDA06A01A-E
SRDA-SDA14A01A-E
T
SRDA-SDA35A01A-E
SRDA-SDA06A01A-E
SRDA-SDA14A01A-E
SERVOPACK
PWM
Amplifier
E
Converter
SRDA-SDA06A01A-E
SRDA-COA30A01A-E
SRDA-COA30A01A-E
SRDA-COA30A01A-E
14-44
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.11 SERVOPACK
Fig. 14-24: SERVOPACK Configuration for MH5, MH5S, MH5L, MH5LS, MH6, MH6S, MH6-10, MA1400,
MA1900, HP20D, HP20D-6, HP20RD, MPK2
(CN554)
Grounding Detection Input
Ground Terminal
(CN553)
Converter Control Signal
Monitor Alarm
Display LED
Converter
(CN552B)
Control Power SupplyOutput
for External Axis Amplifier
(CN556)
Control Power SupplyOutput for 6-Axis Amplifier
(CN558)
Main Circuit Power Supply Output for External Axis Amplifier
Charge Lamp
EAXA Base Fixing Screw (top)
(CN551)
Control Power Supply Input
(CN552A)
Control Power SupplyOutput
for 6-Axis Amplifier
(CN557)
Regenerative Resister
(CN555)
Main Circuit Power Supply Input
EAXA Board
(CN513)
Brake Control Signal
(CN511)
Safety Unit I/O
(CN514)
Direct-in
(CN507)
Converter Control Signal
(CN502)
AMP2 PWM Signal
(CN501)
AMP1 PWM Signal
(CN504)
AMP4 PWM Signal
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
(CN503)
AMP3 PWM Signal
(AMP1,3,5-CN583)
Amplifier Main Circuit
Power Supply
(AMP2,4,6-CN583)
Amplifier Main Circuit
Power Supply
(AMP2,4,6-CN584)
Motor Power Output
(AMP1,3,5-CN581)
PWM Signal
AMP1
AMP2
AMP3
AMP4
AMP6
AMP5
(AMP2,4,6-CN581)
PWM Signal
(AMP1,3,5-CN584)
Motor Power Output
(CN515)
Control Communication
EAXA Base
(CN506)
AMP6 PWM Signal
(CN505)
AMP5 PWM Signal
(AMP1,3,5-CN582)
Amplifier Control Power Supply
Ground Terminal
EAXA Base Fixing
Screw (bottom)
(EAXA Base is closed)
(AMP2,4,6-CN582)
Amplifier Control
Power Supply
(EAXA Base is open)
Fig. 14-25: SERVOPACK Configuration for VA1400
(CN551)
Control Power Supply Input
(CN554)
Grounding Detection Input
Ground Terminal
(CN553)
Converter Control Signal
Monitor Alarm
Display LED
(CN552A)
Control Power Supply Output
for 6-Axis Amplifier
(CN557)
Regenerative Resister
(CN555)
Main Circuit Power Supply Input
EAXA Base Fixing Screw (top)
(CN512)
SHOCK Signal Input
(AMP1,3,5,7-CN583)
Amplifier Main Circuit
Power Supply
Converter
(CN552B) Control Power Supply Output
for External Axis Amplifier
(CN556) Main Circuit Power Supply
Output for 6-Axis Amplifier
(CN558) Main Circuit Power Supply
Output for External Axis Amplifier
Charge Lamp
(AMP1,3,5,7-CN581)
PWM Signal
(AMP2,4,6-CN583)
Amplifier Main Circuit
Power Supply
(AMP2,4,6-CN584)
Motor Power Output
EAXA Base Fixing Screw (top)
EAXA Board
(CN511)
AMP1
Safety Unit I/O
(CN513)
Brake Control Signal
(CN514)
AMP3
Direct-in
(CN507)
Converter Control Signal
AMP5
(CN502)
AMP2 PWM Signal
(CN501)
AMP1 PWM Signal (AMP1,3,5,7-CN584)
Motor Power Output
(CN504)
AMP4 PWM Signal
(CN503)
AMP3 PWM Signal
AMP7
(CN506)
AMP6 PWM Signal
(CN509)
Control Power Supply Input
(CN508)
Encoder Signal
(CN531) PWM Amplifier 7 Signal
(back)
(CN532) PWM Amplifier 8 Signal
(frond)
(CN517,CN518)
I/O Communication
(CN533)
PWM Amplifier 9 Signal
(CN515,CN516)
Control Communication
EAXA Base
Ground Terminal
AMP2
AMP4
AMP6
(AMP2,4,6-CN581)
PWM Signal
(CN505)
AMP5 PWM Signal
EAXA Base Fixing
Screw (bottom)
(AMP2,4,6-CN582)
Amplifier Control
Power Supply
(AMP1,3,5,7-CN582)
Amplifier Control Power Supply
(EAXA Base is open)
(EAXA Base is closed)
14-45
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.11 SERVOPACK
Fig. 14-26: SERVOPACK Configuration for MH50, MH50-20, MH50-35, MH80, MS80, MS80W, MA1800,
UP50SD, MPK50, MPL80, DX1350
(CN551)
(CN553)
Converter Control Signal
Monitor Alarm Display LED
(CN554)
Grounding Detection Input
Upper Grip
Control Power Supply Input
(CN552A) Control Power Supply
Output for 6-Axis Amplifier
(CN552B) Control Power Supply
Output for External Axis Amplifier
Ground Terminal
Converter
(CN557)
Regenerative Resister
(CN556)
(AMP1,3,5-CN583)
Amplifier Main Circuit
Power Supply
(AMP2,4,6-CN583)
Amplifier Main Circuit Power Supply
(AMP2,4,6-CN582)
Amplifier Control Power Supply
Charge Lamp
Main Circuit Power Supply Output
(CN555)
Main Circuit Power Supply Input
(CN510)
Control Power Supply Output
for Converter
EAXA Base Fixing
Screw (top)
(CN558)
Main Circuit Output for External Axis
Upper Grip
EAXA Base Fixing
Screw (top)
AMP1
EAXA Board
(CN511)
(AMP1,3,5-CN581)
Safety Unit I/F
PWM Signal
(CN513)
Brake Control Signal
(CN514)
AMP3
Direct-in
(CN507)
Converter Control Signal
(CN502)
AMP2 PWM Signal
(CN501)
AMP1 PWM Signal
(CN504)
AMP5
AMP4 PWM Signal
(CN506)
AMP6 PWM Signal
(AMP1,3,5-CN584)
(CN505)
Motor Power Output
AMP5 PWM Signal
(CN503)
AMP3 PWM Signal
(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
Ground Terminal
EAXA Base Fixing
Screw (bottom)
(AMP2,4,6-CN584)
Motor Power Output
AMP2
AMP4
(AMP2,4,6-CN581)
PWM Signal
AMP6
(AMP1,3,5-CN582)
Amplifier Control
Power Supply
Lower Grip
Lower Grip
(EAXA Base is closed)
(EAXA Base is open)
Fig. 14-27: SERVOPACK Configuration for VS50, SIA30D, SIA50D
(CN553)
I/O Signal Connecting Terminal
(CN554)
Grounding Detection Input
Monitor Alarm
Display LED
Upper Grip
(CN551)
Control Power Supply
(CN552A)
Control Power Supply
Converter
Ground Terminal
(CN557)
Regenerative Resister
(AMP2,4,6-CN583)
Amplifier Main Circuit Power Supply
(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)
(CN555) Main Circuit
Power Supply Input
(CN510) Control Power Supply
Output for Converter
EAXA Base Fixing Screw (top)
(CN509)
Control Power Supply Input
(CN512)
SHOCK Signal 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 Board
(CN511)
Safety Unit I/F
AMP1
(CN513)
Brake Control Signal
(CN514)
Direct-in
(CN507)
Converter Control Signal
(CN502)
AMP2 PWM Signal
(CN501)
AMP1 PWM Signal
(CN504)
AMP4 PWM Signal
(CN506)
AMP6 PWM Signal
EAXA Base
(AMP2,4,6-CN584)
Motor Power Output
AMP2
AMP3
AMP4
AMP5
(AMP2,4,6-CN581)
PWM Signal
AMP6
(AMP1,3,5,7-CN584)
Motor Power Output
Ground Terminal
(CN505)
AMP5 PWM Signal
EAXA Base Fixing
Screw (bottom)
AMP7
EAXA Base Fixing
Screw (bottom)
(CN503)
AMP3 PWM Signal
(CN534)
Encoder Signal
(7th Axis)
(CN535)
Encoder Signal
(8th Axis)
(AMP1,3,5,7-CN583)
Amplifier Main Circuit Power Supply
(AMP1,3,5,7-CN581)
PWM Signal
(CN552B)
Control Power Supply
(CN536)
Encoder Signal
(9th Axis)
Lower Grip
(AMP1,3,5,7-CN582)
Amplifier Control Power Supply
(EAXA Base is closed)
Lower Grip
(EAXA Base is open)
14-46
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.11 SERVOPACK
Fig. 14-28: SERVOPACK Configuration for EPH130D, EPH130RLD, ES165D, ES165D-100,
ES165RD,ES200D, ES200RD, ES200RD-120, ES280D, ES280D-230, HP165D, MC2000, MH165,
MH200, MH215, MH250, MPL100, MPL160, MPL300, MPL500, MS120, UP120ED-165, UP350D,
UP350D-200, UP350D-500
(CN553) I/O Signal Connecting Terminal
(CN554)
Grounding Detection Input
Monitor Alarm Display LED (CN551)
Control Power Supply
Upper Grip
(CN552A)
Control Power Supply
(AMP1,3,5-CN583)
Amplifier Main Circuit
Power Supply
(CN552B)
Control Power Supply
Ground Terminal
Converter
(CN557)
Regenerative Resister
Charge Lamp
(CN556)
Main Circuit Power Supply Output
(CN558)
Main Circuit Output for External Axis
(CN555) Main Circuit
Power Supply Input
(AMP2,4,6-CN583)
Amplifier Main Circuit Power Supply
(AMP2,4,6-CN582)
Amplifier Control Power Supply
Upper Grip
EAXA Base
Fixing Screw (top)
(CN510)
Control Power Supply
Output for Converter
EAXA Base
Fixing Screw (top)
(CN512)
SHOCK Signal Input
EAXA Board
AMP1
(CN513)
Brake Control Signal
(AMP1,3,5-CN581)
(CN511)
PWM Signal
Safety Unit I/F
(CN514)
Direct-in
AMP3
(CN507)
Converter Control Signal
(CN502)
AMP2 PWM Signal
(CN501)
AMP1 PWM Signal
(CN504)
AMP4 PWM Signal
AMP5
(CN503)
AMP3 PWM Signal
(AMP1,3,5-CN584)
Motor Power Output
(CN506)
AMP6 PWM Signal
(CN509)
Control Power Supply Input
(CN508)
Encoder Signal
(CN518)
I/O Communication
(CN517)
I/O Communication
(CN516)
Control Communication
(CN515)
Control Communication
EAXA Base
Ground Terminal
(CN505)
AMP5 PWM Signal
EAXA Base Fixing
Screw (bottom)
AMP2
(AMP2,4,6-CN584)
Motor Power Output
AMP4
(AMP2,4,6-CN581)
PWM Signal
AMP6
(AMP1,3,5-CN582)
Amplifier Control
Power Supply
Lower Grip
Lower Grip
(EAXA Base is open)
(EAXA Base is closed)
14-47
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
14.12
14.12.1
Universal I/O Signal Assignment
Arc Welding
Fig. 14-29: JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection Diagram (For Arc
Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN308 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
External Start
IN
B1
20011 A1
-
IN
A1
B1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
A5
A5
B6
B6
A6
A6
B7
024VU
024VU
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20021 A5
20022 B6
Work Prohibited
IN
IN
20023 A6
Work Response
IN
B7
A7
024VU
A7
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
A8
30012 B9
Top of Master Job
OUT
B9
A8
B9
OUT
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
A11
OUT
B12
A12
B12
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
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
B20
FG
A20
A20
024VU
30010 B8
30013 A9
Alarm/Error Occurred
30014 B10 Battery Alarm
30020 B12 In Cube 1
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
IN
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
20020 B5
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
Signal
20010 B1
20014 B3
Each Point
24VDC
50mA max.
Connector Terminal Converter
(Optional)
Model:TIFS553YS
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
A12
024VU
+24VU
+24VU
+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
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-30: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For Arc
Welding)
DX100
Connector Terminal Converter
(Optional)
Model:TIFS553YS
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
IN03
IN
IN
A3
B4
A3
20032 B4
20033 A4
IN04
IN
A4
A4
20034 B5
20035 A5
IN05
IN
B5
IN06
A5
B5
A5
20036 B6
IN07
IN
IN
20037 A6
IN08
IN
B7
A7
024VU
024VU
30024 B8 Gas Shortage (Monitor) OUT
30025 A8 Wire Shortage (Monitor) OUT
30026 B9 Wire Sticking (Monitor) OUT
-4
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
B6
B7
A7
024VU
024VU
B8
B8
A8
B9
A8
B9
A6
A9
A9
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
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
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
A19 +24VU
B19
+24VU
A19
+24VU
OUT
B14
A14
+24 V
024 V
(24V,1A)
B6
A6
B10
Arc Shortage (Monitor) OUT
30030 B10 OUT01 User Output
CN303
Internal
Power Supply
-3
B4
OUT
30027 A9
Each Point
24VDC
50mA max.
Terminal
Number
-
20024 B1
B20 FG
A20
B12
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
14-49
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-31: JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (For Arc
Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+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
20045 A3
IN14
20046 B4
20047 A4
Terminal
Number
B1
B1
IN10
IN
A1
A1
IN11
IN
B2
B2
IN12
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
IN15
IN16
IN
A4
A4
B5
B5
A5
A5
B5
A5
B6
A6
B6
A6
B6
B7
A7
024VU
024VU
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
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
B16
A16
024VU
024VU
024VU
B12
A12
External
Power Supply
+24 VE
024 VE
Signal
IN
B7
A7
Each Point
24VDC
50mA max.
Connector Terminal Converter
(Optional)
Model: TIFS553YS
B13
A13
B12
A12
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
14-50
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-32: JZNC-YIU01-E (CN307 Connector) I/O Allocation and Connection Diagram (For Arc
Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
Each Point
24VDC
8mA max.
Each Point
24VDC
500mA max.
CN307 Connector
Logical Connector
Number Number
Name
-4
024 V
(24V,1A)
-1
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
20056 B4
IN23
IN
IN
A3
B4
A3
B4
20057 A4
IN24
IN
A4
A4
B5
A5
B5
B5
A5
B6
A6
B6
A6
B6
B7
A7
024VU
024VU
A5
-2
024VU
A6
B7
A7
024VU
30050 B8
OUT17-
OUT
B8
B8
A8
OUT17+
OUT
A8
OUT18-
OUT
B9
A8
B9
RLY
30051 B9
A9
OUT18+
RLY
024VU
OUT
A9
A9
30052 B10 OUT19-
OUT
B10
B10
A10 OUT19+
30053 B11 OUT20-
OUT
A10
A10
OUT
B11
B11
A11 OUT20+
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
B17
A17
024VU
024VU
B18
A18
+24VU
B19
A19
+24VU
A16 024VU
B17 024VU
A17 024VU
+24VU
Terminal
Number
IN17
B18 +24VU
External
Power Supply
+24 VE
024 VE
Signal
20050 B1
B16 024VU
CN303 Internal
Power Supply
-3
+24 V
Connector Terminal Converter
(Optional)
Model: TIFS553YS
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
RLY
RLY
024VU
+24VU
+24VU
B20
FG
A20
024VU
*
means internal relay
RLY means
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
14-51
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-5: 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 section 8.6 “Interference Area”.
14-52
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-6: 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 64)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 64 are the same.
14-53
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
14.12.2
Handling
Fig. 14-33: 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
Each Point
24VDC
8mA max.
CN308 Connector
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
A3
Select Teach Mode
IN
IN
A3
20016 B4
B4
B4
20017 A4
-
IN
A4
A4
IN
B5
A5
B5
A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
20022 B6
-
IN
IN
20023 A6
-
IN
B7
A7
024VU
024VU
-4
External
Power Supply
+24 VE
024 VE
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
B6
A6
B6
B7
A7
024VU
024VU
A6
30010 B8
Running
OUT
B8
B8
30011 A8
Servo is ON
OUT
A8
A8
30012 B9
Top of Master Job
OUT
B9
B9
30013 A9
Alarm/Error Occurred
OUT
A9
A9
OUT
30014 B10 Battery Alarm
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
A11
B12
30021 A12 In Cube 2
30022 B13 Work Home Position
OUT
A12
A12
OUT
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
CN303 Internal
Power Supply
-3
Terminal
Number
External Start
20020 B5
20021 A5
Each Point
24VDC
50mA max.
Signal
20010 B1
30023 A13 (continuousing Sequence)
OUT
B12
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
14-54
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-34: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For Handling)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
Each Point
24VDC
8mA max.
CN309 Connector
Logical Connector
Number Number
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
20026 B2
20027 A2
20031 A3
IN02
A3
IN03
IN
IN
A3
20032 B4
B4
B4
20033 A4
IN04
IN
A4
A4
20034 B5
IN05
IN06
IN
B5
A5
B5
A5
20036 B6
IN07
IN
IN
20037 A6
IN08
IN
024VU
024VU
-4
External
Power Supply
+24 VE
024 VE
+24VU
-2
024VU
B6
B7
A7
024VU
024VU
A6
-
OUT
B8
B8
30025 A8
-
OUT
30026 B9
-
OUT
A8
B9
A8
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
B12
A12
A11
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
30035 A12 OUT06
30036 B13 OUT07
OUT
30037 A13 OUT08
OUT
OUT
B14
A14
A17 024VU
B18 +24VU
-1
B6
A6
30024 B8
30033 A11 OUT04
30034 B12 OUT05
+24 V
024 V
(24V,1A)
Terminal
Number
-
B7
A7
CN303 Internal
Power Supply
-3
Signal
20024 B1
20035 A5
Each Point
24VDC
50mA max.
Connector Terminal Converter
(Optional)
Model: TIFS553YS
B12
A12
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
14-55
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-35: JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (For Handling)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN306 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
IN
B1
B1
20041 A1
IN10
IN
A1
A1
20042 B2
20043 A2
IN11
IN
B2
B2
IN12
IN13
IN
A2
B3
A2
B3
IN
20045 A3
IN14
A3
IN15
IN
IN
A3
20046 B4
20047 A4
B4
B4
IN16
IN
A4
A4
B5
A5
B5
B5
A5
B6
A6
B6
A6
B6
B7
A5
024VU
A7
024VU
024VU
30040 B8
30041 A8
OUT09
OUT10
OUT
B8
B8
OUT
A8
30042 B9
30043 A9
OUT11
OUT12
OUT
B9
A8
B9
024VU
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
A13
A16 024VU
B17 024VU
A17 024VU
B18 +24VU
-1
+24VU
-2
024VU
A6
B7
A7
A14
External
Power Supply
+24 VE
024 VE
Terminal
Number
IN09
B14
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Signal
20040 B1
20044 B3
Each Point
24VDC
50mA max.
Connector Terminal Converter
(Optional)
Model: TIFS553YS
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
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
14-56
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-36: 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
A7
024VU
024VU
+24VU
-2
024VU
024VU
024VU
A6
OUT
B8
B8
A8
OUT
A8
A8
30051 B9
Hand Value 1-2-
OUT
B9
B9
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
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
A14 Hand Value 4-1+
30057 B15 Hand Value 4-2-
OUT
OUT
A15 Hand Value 4-2+
OUT
B17 024VU
A17 024VU
A18 +24VU
B19 +24VU
A19 +24VU
OUT
RLY
RLY
B12
A15
A15
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
RLY
RLY
024VU
+24VU
B20
FG
A20
024VU
B20 FG
A20
RLY
A9
OUT
A16 024VU
RLY
B10
OUT
A13 Hand Value 3-2+
30056 B14 Hand Value 4-1-
B18 +24VU
-1
B7
A7
Hand Value 1-1+
B16 024VU
External
Power Supply
+24 VE
024 VE
B6
Hand Value 1-1-
A12 Hand Value 3-1+
30055 B13 Hand Value 3-2-
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
B6
A6
30050 B8
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
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
14-57
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-7: 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 section 8.6 “Interference Area”.
14-58
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-8: 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 64)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 64 are the same.
14-59
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
14.12.3
General Application
Fig. 14-37: 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
Each Point
24VDC
8mA max.
CN308 Connector
Logical Connector
Number Number
Name
20010 B1
External Start
20011 A1
B1
B1
IN
A1
A1
Call Master Job
IN
B2
B2
Alarm/Error Reset
IN
A2
B3
A2
B3
-
IN
20015 A3
Select Play Mode
Select Teach Mode
IN
IN
A3
20016 B4
B4
A3
B4
IN
A4
A4
20020 B5
Interference1 Entrance
Prohibited
IN
B5
20021 A5
Interference2 Entrance
Prohibited
IN
IN
A5
B5
A5
20017 A4
-
Work Prohibited
20022 B6
20023 A6
IN
-
+24VU
-2
024VU
A6
A7
OUT
B8
B8
30011 A8
Servo is ON
OUT
A8
A8
30012 B9
Top of Master Job
OUT
B9
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
OUT
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
B14
A14
B15
-1
B7
Running
A7
30020 B12 In Cube 1
30021 A12 In Cube 2
External
Power Supply
+24 VE
024 VE
B6
30010 B8
024VU
30013 A9
30014 B10 Battery Alarm
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
B6
A6
024VU
024VU
B7
Alarm/Error Occurred
Each Point
24VDC
50mA max.
Terminal
Number
IN
-
20012 B2
20013 A2
20014 B3
Signal
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
14-60
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-38: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For General
Application)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN309 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
Signal
Terminal
Number
Interference3 Entrance
Prohibited
Interference4 Entrance
Prohibited
IN
B1
B1
IN
A1
A1
20026 B2
20027 A2
-
IN
B2
B2
-
IN
20030 B3
IN01 User Input
IN
A2
B3
A2
B3
20024 B1
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
IN
IN
A5
B5
A5
20036 B6
IN06
IN07
20037 A6
IN08
IN
B7
024VU
A7
024VU
B6
A6
B6
B7
A6
A7
024VU
024VU
30024 B8
In Cube 3
OUT
B8
B8
30025 A8
In Cube 4
OUT
A8
A8
30026 B9
Work Instruction
OUT
B9
B9
30030 B10 OUT01 User Output
OUT
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
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
30027 A9
Each Point
24VDC
50mA max.
Connector Terminal Converter
(Optional)
Model: TIFS553YS
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
14-61
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-39: JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (General
Application)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
Each Point
24VDC
8m A max.
Connector Terminal Converter
(Optional)
Model: TIFS553YS
CN306 Connector
Name
Logical Connector
Number Number
Terminal
Number
Signal
IN
B1
B1
IN10
IN
A1
A1
IN11
IN
B2
B2
IN12
IN
A2
B3
A2
B3
A3
A3
B4
B4
A4
A4
B5
B5
A5
20040 B1
IN09
20041 A1
20042 B2
20043 A2
20044 B3
IN13
IN
20045 A3
IN14
20046 B4
IN15
IN
IN
20047 A4
IN16
IN
General Input
B5
A5
A5
B6
B6
A6
B6
B7
A7
024VU
024VU
B8
B8
A8
A8
A6
B7
A7
024VU
024VU
30040 B8
OUT09 General 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
A12
B13
A13
Each Point
24VDC
50m A max.
B14
A14
B15
A15
B16 024VU
CN303 Internal
Power Supply
-3
+24V
-4
024V
A16 024VU
B17 024VU
A17 024VU
(24V, 1A)
B18 +24VU
External
Power Supply
+24VE
024VE
-1
-2
+24VU
024VU
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
A6
B9
B9
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
A15
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
+24VU
A19
+24VU
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
14-62
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-40: JZNC-YIU01-E (CN307 Connector) I/O Allocation and Connection Diagram (For General
Application)
DX100
Robot I/O Unit ( JZNC-YIU01-E)
+24VU
Each Point
24VDC
8m A max.
Connector Terminal Converter
(Optional)
Model: TIFS553YS
CN307 Connector
Logical
Number
Connector
Number
Name
20050 B1
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
Each Point
24VDC
500m A max.
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
B6
A6
B6
B7
A6
B7
A7
024VU
A7
024VU
024VU
30050 B8
OUT17-
OUT
B8
B8
A8
OUT17+
OUT
A8
OUT18-
OUT
B9
A8
B9
RLY
30051 B9
A9
OUT18+
OUT
RLY
024VU
A9
A9
OUT
B10
B10
OUT
A10
A10
OUT
B11
B11
A11
B12
A11
A12
A12
RLY
B13
A13
B13
A13
RLY
B14
B14
A14
A14
B15
30052 B10 OUT19A10 OUT19+
30053 B11 OUT20A11 OUT20+
OUT
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
OUT
A16 024VU
B17 024VU
A17 024VU
B18 +24VU
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
RLY
RLY
B12
A13 OUT22+
30056 B14 OUT23-
B16 024VU
CN303 Internal
Power Supply
-3
+24 V
-4
024 V
(24V,1A)
Terminal
Number
Signal
RLY
RLY
024VU
+24VU
B20
FG
A20
024VU
means internal relay
*
RLY
means
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
14-63
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-9: 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 section 8.6 “Interference Area”.
14-64
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-10: 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 64)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 64 are the same.
14-65
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
14.12.4
Spot Welding
Fig. 14-41: JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection Diagram (For Spot
Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN308 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Name
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
20020 B5
Interference1 Entrance
Prohibited
IN
B5
20021 A5
Interference2 Entrance
Prohibited
B5
A5
20022 B6
Welding ON/OFF
Welding Pause
IN
IN
20011 A1
External Start
-
20012 B2
20013 A2
-
IN
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
20023 A6
-
IN
-1
+24VU
-2
024VU
B6
A6
B6
B7
A6
A7
30010 B8
Running
OUT
B8
B8
30011 A8
Servo is ON
OUT
A8
A8
30012 B9
Top of Master Job
OUT
30013 A9
Alarm/Error Occurred OUT
024VU
024VU
B9
B9
A9
A9
OUT
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
B10
B10
A10
A10
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
OUT
30020 B12 In Cube 1
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
B14
A14
B15
External
Power Supply
+24 VE
024 VE
A5
024VU
024VU
B7
A7
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
Signal
IN
20010 B1
20014 B3
Each Point
24VDC
50mA max.
Connector Terminal Converter
(Optional)
Model: TIFS553YS
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
14-66
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-42: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For Spot
Welding)
DX100
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
20026 B2
20027 A2
-
IN
B2
B2
-
IN
20030 B3
IN1 USER INPUT
IN
A2
B3
A2
B3
IN
IN
A3
A3
B4
B4
IN
A4
A4
IN
B5
A5
B5
A5
20031 A3
IN2
20032 B4
IN3
20033 A4
IN4
IN5
20034 B5
20035 A5
IN6
20036 B6
IN7
IN
IN
IN8
IN
-4
External
Power Supply
+24 VE
024 VE
+24 V
024 V
(24V,1A)
-2
024VU
B7
A6
A7
A7
30024 B8
024VU
In Cube 3
024VU
024VU
OUT
B8
B8
30025 A8
In Cube 4
OUT
A8
B9
A8
A9
A9
B9
30026 B9
OUT
30027 A9 30030 B10 OUT01 User Output
OUT
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
A11
B12
A12
OUT
30037 A13 OUT08
OUT
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
OUT
B14
A14
B12
A12
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
A18 +24VU
+24VU
B6
024VU
A17 024VU
B18 +24VU
-1
B6
A6
B7
B15
CN303 Internal
Power Supply
-3
Terminal
Number
Signal
Interference3 Entrance
Prohibited
Interference4 Entrance
Prohibited
20024 B1
20037 A6
Each Point
24VDC
50mA max.
Connector Terminal Converter
(Optional)
Model:TIFS553YS
B19 +24VU
A19 +24VU
B20 FG
A20
024VU
+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
14-67
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-43: JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (For Spot
Welding)
DX100
Robot I/O Unit (JZNC-YIU01-E)
+24VU
CN306 Connector
Logical Connector
Number Number
Each Point
24VDC
8mA max.
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Name
IN
B1
IN
A1
A1
IN19
IN
B2
B2
20044 B3
IN20
IN21
IN
A2
B3
A2
B3
20045 A3
IN22
A3
A3
20046 B4
20047 A4
IN23
IN24
B4
B4
A4
A4
B5
B5
A5
20040 B1
20041 A1
IN18
20042 B2
20043 A2
IN
IN
IN
IN
B5
A5
A5
B6
A6
B7
A7
024VU
30040 B8
OUT17
30041 A8
30042 B9
30043 A9
024VU
OUT
OUT18
OUT
OUT19
OUT
OUT
OUT20
30044 B10 OUT21
30045 A10 OUT22
30046 B11 OUT23
OUT
OUT
OUT
30047 A11 OUT24
OUT
B12
A12
B13
Each Point
24VDC
50mA max.
A13
B14
A14
B15
-2
024VU
A7
024VU
024VU
B8
B8
A8
B9
A8
A9
A9
B10
B10
A10
A10
B11
B11
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
A6
B9
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
+24VU
B7
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
B1
IN17
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
14-68
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Fig. 14-44: 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
Each Point
24VDC
8mA max.
CN307 Connector
Logical Connector
Number Number
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
20051 A1
20055 A3
IN14
IN15
IN
IN
A3
20056 B4
B4
A3
B4
20057 A4
IN16
IN
A4
A4
B5
B5
A5
B5
A5
A5
B6
A6
B7
A7
A8
30051 B9
A9
B8
B8
OUT
A8
A8
OUT
B9
B9
A9
A9
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
+24VU
A19
+24VU
A16 024VU
B17 024VU
A17 024VU
-2
A18 +24VU
024VU
B19 +24VU
A19 +24VU
B20 FG
A20
RLY
RLY
RLY
B12
A15 Tip Change Request (OUT16)** OUT
B18 +24VU
+24VU
RLY
B10
A12 Weld Condition 3 (OUT13)** OUT
-1
A6
OUT
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
RLY
RLY
024VU
B20
FG
A20
024VU
*
means internal relay
RLY means
024VU
024VU
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.
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-69
RE-CTO-A215
162536-1CD
DX100 Controller
14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-11: 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)
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14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-11: 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 section 8.6 “Interference Area”.
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)
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14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-12: 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 64)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.
30051
WELD ERROR RESET
This signal commands the reset error status of the Power Source. This is operated
with the programing pendant operation.
3)
4)
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14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
Table 14-12: Specific Output (Spot Welding) (Sheet 2 of 2)
Logical
Output Name / Function
Number
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)
1 This signal is not output during operation.
2 The work home position cube and Cube 64 are the 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)
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14 Description of Units and Circuit Boards
14.12 Universal I/O Signal Assignment
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
Logical Connector
Number
Pin No.
Name
MR Connector
Signal
1
CN322-1
Each point
24 VDC
5mA MAX
22550 CN322-2 +GASOF (Gas Shortage)
IN
CN322-3 -GASOF (Gas Shortage)
IN
2
3
IN
4
22551 CN322-4 +WIRCUT (Wire Shortage)
CN322-5 -WIRCUT (Wire Shortage)
22553 CN322-6 +ARCACT (Arc Generation Confirm)
CN322-7 -ARCACT (Arc Generation Confirm)
CN322-8 CH2 (Current Input)
A/D +5V
A/D +5V
IN
5
IN
IN
IN
6
7
9
CN322-10
10
CN322-11 CH1 (Voltage Input)
CN322-12 CH1-G
S
T
P
8
CN322-9
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
Detector
22554 CN322-26 STICK (Wire Sticking)
IN
26
M
CN322-27 *STICK (Wire Sticking)
IN
27
N
CN322-28 CH2 -G
IN
28
29
CN322-29 +24VU
30
E
OUT
31
A
CN322-32 CH1-G
OUT
32
B
CN322-33 CH2 (Current Command)
OUT
33
C
CN322-34 CH2 -G
OUT
34
D
CN322-30 024VU
D/A –14V
D/A –14V
3
17BYTE 32BYTE
DC24V
0.5A MAX
Power
Source
25
CN322-25
SW2
1
MS Connector
CN322-31 CH1 (Voltage Command)
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
MS3106 A, 20-29P
MS3106 A, 20-29S
14-74
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INSTRUCTIONS
HEAD OFFICE
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Phone +81-93-645-7703
Fax +81-93-645-7802
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Phone +1-937-847-6200
Fax +1-937-847-6277
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Phone +49-8166-90-100
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Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800
Fax +46-486-414-10
YASKAWA Electric (China) Co., Ltd.
22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200
Fax 㸩86-21-5385-3299
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Phone +86-10-6788-2858
Fax +86-10-6788-2878
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#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500
Fax +91-124-475-8542
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35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea
Phone +82-2-784-7844
Fax +82-2-784-8495
07326
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12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333
Fax +886-2-8913-1513
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Phone +65-6282-3003
Fax +65-6289-3003
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59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099
Fax +66-2-017-0199
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Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470
Fax +62-21-2982-6741
Specifications are subject to change without notice
for ongoing product modifications and improvements.
MANUAL NO.
RE-CTO-A215
20
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