Programming pendant specifications. YASKAWA Motoman DX200
YASKAWA Motoman DX200 is a versatile and powerful robot controller that offers a wide range of features and capabilities. It is designed for use in a variety of industrial applications, including welding, assembly, painting, and material handling. The DX200 is known for its high precision, speed, and reliability, making it an excellent choice for demanding applications.
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Maintenance and inspection
7 Maintenance and inspection
7.1
Periodic inspection
DANGER!
Death from electrical shock, risk of injury and fire due to short circuit
Do not touch the cooling fan or other equipment while the power is turned ON.
Carry out the following inspections.
Components Inspection Method
Robot controller Check that the casing is completely closed and not damaged.
Power cable
Interior circulation fan and backside duct fan.
Emergency stop button
Check for gaps or damage to the sealed construction.
Check for damage and deterioration of leads.
Check the function (while power
ON).
Check the function (while servo power ON).
Visual inspection
Visual inspection
Visual inspection
Visual inspection
By pressing the keys
Inspection frequency
Daily
Monthly as required as required
Before the robot is put into operation.
Enabeling device Check the function (in teach mode).
Battery
Power supply
Confirm battery alarm or message is displayed or not.
Check power supply voltage is normal as required as required
Visual inspection as required
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Maintenance and inspection
7.2
Cooling fan inspections
Inspect the cooling fans as required. A defective fan can cause the robot controller to malfunction because of excessive high temperatures inside.
The interior circulation fan and backside duct fan normally operate while the power is turned
ON. Check if the fans are operating correctly by visual inspection and by feeling air moving into the air inlet and from the air outlet.
-Q1M
-X9
-FS1
-TP1
-AE2
1
Option
-TA9
-AE6.0
-TA8
-TA7
-TA6
-TA5
-TA4
-TA3
-TA2
-TA1
-AE3 -AE1.0
-AE4
-AE7
-X181
Option
-X18
-X810
Option
-X12A -X12B -X13A -X13B Option
3
-X81
-G1
FM
4
2
-G2
FM
3
3
-Q1M
-G3
FM
-G4
FM
5
-G5
FM
-R1-R6
2
-T1
-C1
-V1
-EP2
1
2
3
Front view
Interior circulation fan
Air outlet
Fig. 7-1: Ventilation system
4
5
Door
Back View
NOTICE
When the message of the "Cooling fan in YPS power supply stopped. Exchange fan" is displayed, it may be caused by the error occurrence at the internal cooling fan (JZNC-
YZU01-E) inside CPU unit (JZNC-YPS21-E).
When the message of the "Cooling fan in YPS unit stopped, replace cooling fan" is displayed, carry out an inspection and the replacement of the cooling fan in the CPS unit
(JZNC-YPS21-E)as soon as possible.
7.3
Emergency Stop Button Inspections
The emergency stop button is located on the programming pendant. Before operating the robot, make sure the SERVO voltage is switched off. For this, press the emergency stop button after switching on the SERVO voltage.
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Maintenance and inspection
7.4
Inspection of the enabling switch
The programing pendant is equipped with a 3-position enable switch. Perform the following operation to confirm the enable switch operates.
1. Set the mode switch with key on the programming pendant to "TEACH".
1 3
2
Fig. 7-2: Enabling device
3
TEACH
1
2
REMOTE
PLAY
2. Press [SERVO ON READY] on the programming pendant. The [SERVO ON] lamp will flashes.
1
2
1
SERVO ON reading
Fig. 7-3: Flashing light SERVO ON
2
SERVO ON (flashing light)
3. When the enable switch is grasped lightly, the servo power is turned ON.
When the enable switch is grasped firmly or released, the servo power is turned OFF.
NOTICE
If the [SERVO ON] lamp does not light in previous operation, check the following:
The emergency stop button on the programming pendant is being pressed.
The emergency stop signal was triggered by an external device.
If a major alarm is occurring
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Maintenance and inspection
7.5
Check battery unit
The robot controller has a battery unit that backs up the important program files for user data in the CMOS memory.
A battery alarm indicates when a battery has expired and must be replaced. The programming pendant display and the message "Memory battery weak" appears at the bottom of the display.
Check that the message is NOT not displayed on the programming pendant.
7.6
Check the power supply
Check the voltage of 1, 3, 5 terminal of the main power switch (Q1M) with an electric tester.
Measuring Items
correlate voltage
Voltage between earth (phase ground)
Terminals
between
1 and 3 (R-S),
3 and 5 (S-T),
1 and 5 (R-T) between
1 and E (R-E),
5 and E (R-E) between
3 and E (S-G)
Correct Value
400/415/440V +/- 10%
230/240/255V +/- 10%
About 0V
1 3 5
2 4 6
Fig. 7-4: Main switch
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44
Maintenance and inspection
7.7
Open Phase Check
Check Item
Lead cable check
Input Power Supply
Check
Main switch (Q1M) control
Operation
Confirm if the lead cable for the power supply is wired as shown in the following without any falling out, looseness or breaking from the connecting part.
Check the open phase voltage of input power supply with an electric tester. (Normal value: AC400/415/440V +10%, -15%)
Turn ON the main power switch and check the open phase voltage of “2, 4, 6 of the main power switch (Q1M) with an electric tester. If abnormal, replace the main power switch (Q1M).
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45
Maintenance and inspection
1
1(R) 3(S) 5(T)
2
(Q1M)
2(U) 4(V) 6(W)
X9
1
4
7
2
5
3
6
V1
3
T1
AC400-415-440V/200V
TP1
5
4
㸦
FS1
㸧
CN555
1KM
AE2
6
2KM
3
4
1
2
Power Supply X4
Main switch
Transfer
Fuse
Fig. 7-5: Open Phase Check
5
6
7
Converter
Power Supply Contactor Unit
Filters
7
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46
Description of Units and Circuit Boards
8 Description of Units and Circuit Boards
• Cautions for connection of dual input signals.
Please follow the safety instructions in chapter 1.7 "Safety" on page 10.
5
6
3
4
1
2
CAUTION!
Connect the switch (contact), which at the same time switches the 2-channel signals ON and OFF.
If the timing that turns the two signals ON and OFF is not right, a disagreement alarm occurs.
Connection of 2-channel inputs Robot controller
Input for the robot system
Turn ON/OFF at the same time
Input signal 1
Input signal 2
Switch
CAUTION!
Damage to property caused by short-circuit
As power supply is reversed for each signal, a short-circuit and thus a possible a robot control failure occurs.
Do not connect the two signals to the same contact (use two separate contacts).
Connecting 2-channel inputs to the same contact
6
7
3
4
5
1
2
Robot controller
Input for the robot system
Input signal 1
Input signal 2
Short circuit current
The same contact
Switch
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47
Description of Units and Circuit Boards
4
5
6
7
8.1
Power ON unit
The power ON unit consists of the power ON control circuit board (JARCR-YPC21-1) and the main circuit contactor and the line filter. It turns the main circuit control contactor ON and OFF using the signal for the servo power control from the machine safety I/O logic circuit board, and supplies power (3-phase AC200/220V) to the converter.
The power supply (single phase AC200/220V) is supplied to the control power supply via the line filter.
1
2
3
8
Main power supply input connector (601)
Input connector contactor control (607)
AC control power supply connector (CN603,
CN604, CN605)
Brake interlock output connector (CN608)
Main power supply output connector (CN602)
AC Cooling fan connector (CN606)
Fuse for AC cooling fan GP25 (2.5A
250V)(3FU), (4FU)
Fuse for AC Control Power Supply 0215010MXP
(10A 250V) (1FU, 2FU)
Configuration power ON unit
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Description of Units and Circuit Boards
8.2
Axes control circuit board
8.2.1
Major axes control circuit board
The major axes control circuit board controls the servomotors of the robot’s six axes. It also controls the converter and the PWM amplifiers. Mounting an external axes control circuit board of an option makes it possible to control the servomotor of nine axes, including the robot axes.
The major axes control circuit board also has the following functions:
• Brake power supply control circuit
• Shock sensor (shock) input circuit
• Direct-in circuit
Major axes control circuit board
1
2
6
7
8
9
3
4
5
10
Machine safety I/O I/F (CN511)
Brake control signal (CN513
STO control signal I/F (CN521)
LED
Control communication (CN515)
Control communication (CN516)
PWM amplifier 2 I/F (CN502)
11
12
13
14
15
16
PWM amplifier 4 I/F(CN504)
PWM amplifier 5 I/F (CN505)
PWM amplifier 3 I/F (CN503)
PWM amplifier 1 I/F (CN501)
Analog monitor I/F (CN519)
Rotary switch (S1)
Encoder signal (CN508)
DC control power supply (CN510)
Converter I/F (CN507)
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Description of Units and Circuit Boards
8.2.2
External axes control circuit board
An external axes control circuit board is an optional, and it can control the additional three axes. It can be mounted on the external axes control circuit board.
External axes control circuit board
1
2
3
4
5
6
7
8
9
10
11
12
STO control signal I/F (CN524)
STO control signal I/F (CN523)
STO control signal I/F (CN522)
PWM amplifier 9 I/F (CN533)
PWM amplifier 7 I/F (Lower) (CN531)
PWM amplifier 8 I/F (Upper) (CN532)
Encoder distribution for the machine safety system (9th axis) (CN542)
Encoder distribution for the machine safety system (8th axis) (CN541)
Encoder distribution for the machine safety system (7th axis) (CN540)
Encoder I/F(9th axis) (CN536)
Encoder I/F(8th axis) (CN535)
Encoder I/F(7th axis) (CN534)
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Description of Units and Circuit Boards
8.3
CPU unit configuration
CPU unit consists of circuit board racks (flame, back circuit board, PCI riser circuit board),
CPU circuit board, robot I/F circuit board and the machine safety CPU circuit board. The
CPU unit contains only circuit board racks and CPU circuit boards.
Be sure that it does not contain robot I/F circuit board and the machine safety CPU circuit board.
1
2
3
4
5
6
7
8
Fig. 8-1: CPU Unit Configuration
PCI Slot for Sensor Board x 1
Rotary switch (S1)
I/O I/F (Communication with the optional I/O) (CN114)
Drive I/F (communication with basic axis control circuit board) (CN113)
LED
Robot I/F circuit board JANCD-YIF01-
2E
CPU board (machine safety) JANCD-
YSF21-E
12
13
14
15
9
10
11
CPU board JANCD-YCP21-E
16
Compact Flash (CN107)
USB (CN106)
For Programming Pendant (CN105)
For LAN (CN104)
Serial port (RS232C) (CN103)
I/O I/F (Communication with the functional safety circuit board) (CN203)
I/O I/F (Communication with the machine safety I/O logic circuit board: 2channel side) (CN202)
PCI Slot X2
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Description of Units and Circuit Boards
8.3.1
Unit and circuit board in the CPU unit
8.3.1.1
CPU board
The entire system is controlled with this circuit board. It controls the display on the programming pendant, the control keys and the movements, and it calculates the interpolation. This control circuit board has the serial interface for RS-232C/RS-422 and a
LAN connection (100Base-TX/10Base-T), USB (USB2.0).
8.3.1.2
Robot I/O circuit board
The robot I/F circuit board controls the entire robot system. It is connected to the control circuit board (JANCD-YCP01-E) with a PCI bus interface on the rear. Connection to the basic axis control circuit board (SRDA-EAXA21A) for high speed transmission.
NOTICE
Please do not change the factory setting of S1 (Factory setting is [0]).
8.3.1.3
CPU board (machine safety)
This circuit board (JANCD-YSF21-E) performs I/O processing or diagnosis processing for the safety sequence, and it is connected with the CPU circuit board (JANCD-YCP21-E) by the PCI Express bus I/F in the back circuit board.
It is also connected with the machine safety I/O logic circuit board by the high speed serial communications (two lines).
8.4
CPS
This unit (JZNC-YPS21-E) supplies the DC power (DC5V, DC24V) for control (system, I/O, brake). It is also equipped with the input function for turning the control power supply ON and OFF.
1
2
Connection with CPU 1 (CN158)
Connection with CPU 2 (CN159)
+24V2 Power Supply Output (CN156/
CN157)
3
+24V1/+24V2 Power Supply Output
(CN154/CN155)
+24V3 Power Supply Output (CN153)
4
5
6
7
Remote Control (CN152)
AC Power Supply Input (CN151)
Monitor Alarm Display
Control power supply unit
JZNC-YPS21-E
7
1
2
3
4
6
5
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52
Description of Units and Circuit Boards
• Input
Rating Input Voltage: 200/240VAC
Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)
Frequency: 50/60Hz ± 2Hz (48 to 62Hz)
• Output Voltage
DC + 5V
DC +24V (24V1: System, 24V2: I/O, 24V3: Brake)
• Indicator
Display
SOURCE
Color
Green
POWER ON
+5V
+24V
FAN
OHT
Green
Red
Red
Red
Red
Status
Lights with power supply input. Lights out when internal live part completes discharge (Power supply status: being input).
Lights when PWR_OK output signal is ON (Power supply status: being output).
Lights with +5V over-current (ON when abnormal).
Lights with +24V over-current (ON when abnormal).
Lights when FAN error occurs.
Lights when unit interior overheats.
3
4
1
2
• Control Power ON/OFF
To turn ON the robot controller power, turn ON the non-fuse breaker of the controller so that the control power supply is turned ON. If the controller is not located at the workplace, the control power supply can be turned ON/OFF by an external device, etc.
after the non-fuse breaker of the controller is turned ON. It is operated by the external switch connected with CN152 of the Control power supply unit as shown in the following figure (CN152-1 and CN152-2 is shortaged when shipment).
Robot controller
Control power supply unit
Remove the short-circuit positioner
Control power supply ON/OFF switch
Connection to control power supply unit
See chapter 8.25 "Brake control circuit board (JANCD-YBK21-3E)" at page 89 for wiring of
CN152 connector.
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Description of Units and Circuit Boards
8.5
Machine safety I/O logic circuit board
Followings are the main functions of machine safety I/O logic unit.
It processes external safety signals with the dual processing circuits and control ON/OFF of the main circuit control contactor of the power ON unit according to conditions.
Followings are the main functions of machine safety I/O Logic unit.
• System safety input circuit (dual circuits)
• User safety input circuit (dual circuits)
• User safety output circuit (dual circuits)
• Emergency stop signal input circuit (dual circuits)
• SERVO power control signal output circuit (dual circuits)
• Anti-safety I/O circuit for the robot system
• Machine safety terminal block circuit board I/F
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NOTICE
If the F1 fuse becomes blown, it will cause a damage on the inner circuit of the board.
Replace the board instead of replacing the fuse (there is no attached spare of the fuse).
Description of Units and Circuit Boards
8.5.1
Connection for tool shock sensor (SHOCK)
Directly to the tool shock sensor signal line
1. Disconnect the minus SHOCK (-) and +24V2 pin terminal from the DINAMIC connector, the machine safety I/O logic circuit board (YSF22-CN214). The pin terminal for the shock sensor is attached on the right side of the controller.
2. Connect the minus SHOCK (-) and +24V2 pin terminals to the signal line of the tool shock sensor. Use the following plug-in terminals for the end of the signal line.
Pin terminal name Terminal model
SHOCKTMEDN-630809-MA
+24V2 TMEDN-630809-FA
Signal line terminal model
TMEDN-630809-FA (manufactured by NICHIFU Co., Ltd.)
TMEDN-630809-MA (manufactured by NICHIFU Co., Ltd.)
2
1
4
3
(JANCD-YSF22-E)
CN215
A3
SHOCK+
8
5
B3
SHOCK-
6
7
1
2
3
4
Robot
Machine safety I/O logic circuit board
TMEDN-630809-FA (NICHIFU)
+24V2
Fig. 8-2: Direct Connection to Tool Shock Sensor Signal Line
Robot controller
5
6
7
8
TMEDN-630809-MA (NICHIFU)
TMEDN-630809-FA (NICHIFU)
SHOCK- TMEDN-630809-MA
(NICHIFU)
SHOCK sensor signal cable
Contact sensor (optional)
The pin terminal for the shock sensor is attached on the right side of the controller.
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Description of Units and Circuit Boards
With the cable that is built into the robot
1. Disconnect the minus SHOCK (-) and +24V2 pin terminal from the DINAMIC connector, the machine safety I/O logic circuit board (YSF22-CN214). The pin terminal for the shock sensor is attached on the right side of the controller.
2. Connect the SHOCK (-) plug-in terminal to the SHOCK (+) plug-in terminal of the robot.
NOTICE
The cable installed on the robot is not connected to the shock sensor because the tool shock sensor is an option. For connecting the tool shock sensor, refer to the wiring diagrams in the INSTRUCTIONS for the robot.
2
1
3
(JANCD-YSF22-E)
CN215
A3
SHOCK+
4
8
5
B3
SHOCK-
6
7
1
2
3
4
Robot
Robot controller
Fig. 8-3: Connection with robot cable
Machine safety I/O logic circuit board
TMEDN-630809-FA (NICHIFU)
+24V2
5
6
7
8
TMEDN-630809-FA (NICHIFU)
SHOCK- TMEDN-630809-MA
(NICHIFU)
Supply cables (PG)
Contact sensor (optional)
NOTICE
If the tool shock sensor input signal is used, the method for stopping the robot can be specified. The stop procedures stop and switch off the SERVO power supply. Selection of the stopping method is set in the display of the programing pendant (Refer to explanations in the "System Setup" manual (Document number: E1102000145XX01 or higher) in
Chapter "System Setup".
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Description of Units and Circuit Boards
8.6
Machine safety terminal block circuit board (JANCD-YFC22-
E)
The machine safety terminal block circuit board (JANCD-YFC22-E) is for the system external signal to connect with the safety I/O signals. For connection, refer to the connection diagrams of each item.
1-25
26-50
51-75
76-100
-AE4
1
-CN219
(348744-10)
Fig. 8-4: Machine safety terminal block (-X18)
Machine safety I/O logic circuit board I/F connector (CN219)
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Description of Units and Circuit Boards
Signal name Connection no.
SAFF_1+ 1
SAFF_1-
SAFF_2+
SAFF_2-
2
3
4
EXESP_1+
EXESP_1-
EXESP_2+
EXESP_2-
EXDSW_1+
EXDSW_1-
EXDSW_2+
EXDSW_2-
FST_1+
FST_1-
FST_2+
FST_2-
5
6
7
8
9
10
11
12
13
14
15
16
Double channel
Function
Possible Safety plug
Used to turn OFF the servo power if the door on the safeguarding is opened.
Connect to the interlock signal from the safety plug on the safeguarding door. If the interlock signal is input, the servo voltage is turned ON.
As long as the signal is ON.
The servo power cannot be turned ON. Note that these signals are disabled in teach mode.
Possible External emergency stop signal
Used to connect the emergency stop switch of an external device.
If the signal is input, the servo power is turned OFF and the job is stopped.
As long as the signal input is active, the servo power cannot be turned ON.
Possible External enable switch
Used to connect a Enable switch other than the one on the programming pendant when two people are teaching.
Possible Full-speed Test
Used to reset the slow speed limit for the test run in the teach mode.
If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the teach mode. If this signal’s circuit is open, the status SSP input signal determines the safety speed:
The first slow speed (16%) or second slow speed (2%).
Factory setting
Short-circuit with a jumper cable
Short-circuit with a jumper cable
Short-circuit with a jumper cable
Open
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58
Description of Units and Circuit Boards
Signal name Connection no.
SSP+ 17
SSP18
EXHOLD+
EXHOLD-
EXSVON+
EXSVON-
SYSRUN+
SYSRUN-
19
20
21
22
23
24
Double channel
-
-
-
-
Function Factory setting
Slow speed mode selection Short-circuit
Used to determine the speed of the test run when with a jumper cable the FST (full-speed test) signal input circuit is open.
Open: Second slow speed
(2%)
Short circuit: First slow speed (16%)
External hold
Used to connect the temporary stop switch of an external device.
If the signal is input, the job is stopped.
Short-circuit with a jumper cable
As long as the signal is ON, starting and axis movements cannot be enabled.
External SERVO-ON
Use to connect the servo
ON switch of an external operation device.
Upon entry of this signal, the SERVO power supply is turned ON.
SYSRUN signal
Use to determine the normal/abnormal condition of the robot controller by SYS-
RUN signal.
Open
Open
+24V2U3 25
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59
Description of Units and Circuit Boards
Signal name Connection no.
ONEN1_1+ 26
ONEN1_1-
ONEN1_2+
ONEN1_2-
27
28
29
ONEN2_1+
ONEN2_1-
ONEN2_2+
ONEN2_2-
ONEN3_1+
ONEN3_1-
ONEN3_2+
ONEN3_2-
33
34
35
36
30
31
32
ONEN4_1+
ONEN4_1-
ONEN4_2+
ONEN4_2-
OT2_1+
OT2_1-
OT2_2+
OT2_2-
40
41
42
43
37
38
39
44
45
Double channel
Function
Possible SERVO-ON enable
Connected to use a function which distributes the robot system to the multiple servo areas, and turns the servo power ON/OFF.
Factory setting
Short-circuit with a jumper cable
External axis overun
Used to input the overrun in the external axes other than the main body of the robot.
Open
OT3_1+
OT3_1-
OT3_2+
OT3_2-
024V2
OT4_1+
OT4_1-
OT4_2+
OT4_2-
PBESP_3+
PBESP_3-
PBESP_4+
PBESP_4-
50
51
52
46
47
48
49
53
54
55
56
57
58
PBESP_3+
PBESP_3-
PBESP_4+
PBESP_4-
59
60
61
62
-
-
-
-
External axis overun
Used to input the overrun in the external axes other than the main body of the robot.
Contact output emergency stop button
Used to output a contact point of the emergency stop button on the programing pendant.
Used to output a contact point of the emergency stop button on the front door of the robot controller Control panel.
Open
Open
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60
Description of Units and Circuit Boards
Signal name Connection no.
GSIN1_1+ 63
GSIN1_1-
GSIN1-2+
GSIN1_2-
64
65
66
GSIN2_1+
GSIN2_1-
GSIN2_2+
GSIN2_2-
GSOUT11+
GSOUT11-
GSOUT12+
GSOUT12-
70
71
72
73
74
67
68
69
-
Double channel
Function
Possible Universal safety input
The universal safety input signal is used in the safety logical circuit function.
Factory setting
Open
Possible
Universal safety output
The universal safety output signal is used in the safety logical circuit function.
Also, inputs and uses the driven connection device status as the monitoring signal by the output signal.
Open
24V2U3
GSOUT2_1+
GSOUT2_1-
GSOUT2_2+
GSOUT2_2-
75
76
77
78
79
GSEDM1+
GSEDM1-
GSEDM2+
GSEDM2-
80
81
82
83
-
-
-
Universal safety output
The universal safety output signal is used in the safety logical circuit function.
Also, inputs and uses the driven connection device status as the monitoring signal by the output signal.
The universal safety output signal is used in the safety logical circuit function.
Also, inputs and uses the driven connection device status as the monitoring signal by the output signal.
Open
Open
AXDIN_COM
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
AXDIN6
+24V2U3
+24V2U3
024V2
024V2
87
88
89
90
84
85
86
91
92
93
94
Direct-in (SERVO)
Used to input the quick responding signals in the search function etc.
Open
DC +24V2 output terminal
DC +24V2 output terminal
DC +24V2 output terminal
DC +24V2 output terminal
Open
Open
Open
Open
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Description of Units and Circuit Boards
Signal name Connection no.
AIN_COM 95
AXIN1
AXIN2
96
97
AXOUT1
AXOUT2
98
99
024V2 100
Double channel
-
-
Function Factory setting
Universal input (SERVO)
Used to input the universal signal from the external device.
Open
Universal output (SERCO) Open
Used to output the universal signal to the external device.
DC +24V2 output terminal Open
Tab. 8-1: JANCD-YFC22-E details for the connection terminal (-X18)
8.7
External emergency stop signal
This signal is used to connect the emergency stop switch of an external device. If the signal is input, the servo power is turned OFF and the job is stopped. As long as the signal input is active, the servo power cannot be turned ON.
CAUTION!
Injuries and machine damages caused by short-circuit
Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.
Be sure to remove the jumper before using.
1
2
-X18
5
6
3
(JANCD-YSF22-E)
CN219
EXESP_1+
EXESP_1-
4
6
7
8
EXESP_2+
EXESP_2-
5
1
2
3
Fig. 8-5: Connection external emergency stop signal
Robot controller
I/O terminal (machine safety)
I/O board (machine safety)
4
5
6
External emergency stop signal
Remove the jumper cable
Turn OFF/ON at the same time
8
-
62
Description of Units and Circuit Boards
8.8
Safety plug
This signal is used to turn OFF the servo power if the door of the protective device is opened. Connect to the interlock signal from the safety plug on the safeguarding door. If the interlock signal is input, the servo voltage is turned ON, as long as the signal is ON. The servo power cannot be turned ON. Note that these signals are disabled in teach mode.
CAUTION!
Injuries and machine damages caused by short-circuit
Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.
Be sure to remove the jumper before using.
1
2
-X18
1
2
3
(JANCD-YSF22-E)
CN219
SAFF_1+
SAFF_1-
4
6
3
4
SAFF_2+
SAFF_2-
5
1
2
3
Fig. 8-6: Connection for safety plug
Robot controller
I/O terminal (machine safety)
I/O board (machine safety)
4
5
6
Safety plug
Remove the jumper cable
Turn OFF/ON at the same time
8
-
63
Description of Units and Circuit Boards
8.9
Installation of safety plug
NOTICE
Observe DIN EN ISO 10218-2 with respect to the safety measures.
Installation of Saftey Plug
5
6
3
4
1
2
Robot working area
Safety casing
Service door
Emergency shut-off
Plug
Safety plug
1
2
4
3
6
5
4
If the SERVO power is ON when the interlock signal is input, the SERVO power turns OFF.
As long as the interlock signal is active, the SERVO power cannot be turned ON.
However, the servo power does not turn OFF when the door is opened only during the
TEACH mode.
In this case, the SERVO power can be turned ON while the interlock signal is input.
8
-
64
Description of Units and Circuit Boards
8.10
External enable switch
This signal is used to connect Enable switch other than the one on the programming pendant when two people are teaching.
CAUTION!
Injuries and machine damages caused by short-circuit
Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.
Be sure to remove the jumper before using.
1
2
-X18
9
10
3
(JANCD-YSF22-E)
CN219
EXDSW1+
EXDSW1-
4
6
11
12
EXDSW2+
EXDSW2-
5
1
2
3
Fig. 8-7: Connection external emergency stop signal
Robot controller
I/O terminal (machine safety)
I/O board (machine safety)
4
5
6
External enable switch
Remove the jumper cable
Turn OFF/ON at the same time
8
-
65
Description of Units and Circuit Boards
8.11
Full speed test
This signal is used to reset the slow speed limit for the test run in the teach mode.
If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the play mode.
If this signal’s circuit is open, the status SSP input signal determines the slow speed: The first slow speed (16%) or second slow speed (2%).
Setting Method
1. Short-circuit terminal numbers 13 and 14 of the machine safety terminal block circuit board (JANCD-YFC22-E), and 15 and 16 as well (Normally, each terminal is unwired).
4
1
2
-X18
13
14
3
(JANCD-YSF22-E)
CN219
FST_1+
FST_1-
5
15
16
FST_2+
FST_2-
1
2
3
Robot controller
Fig. 8-8: Connection for Full-speed Test
I/O terminal (machine safety)
I/O board (machine safety)
4
5
External enable switch
Full-speed Test
8
-
66
Description of Units and Circuit Boards
2. The message "Full-speed test mode" is displayed as follows when the setting is finished.
Operation Method
When the full-speed test mode is set, operation speed is set depending on the setting of manual speed as follows.
At the time of setting the full-speed mode, the setting of manual speed shifts to Inching automatically.
When changing the setting of manual speed, make sure that there is no person around the robot and pay great attention to perform the operation.
Parameter (Unit: 0.01%) Manual speed Limit of operation speed
(default value)
Inching 20%
Slow
Medium
Fast
50%
75%
100% (fixed value)
S1CxG60 (default value: 2000)
S1CxG61 (default value: 5000)
S1CxG62 (default value: 7500)
-
NOTICE
The limit values of operation speed described in the table above are the ratio against the robot’s maximum speed, not against the taught speed. The values are for restraining the operation speed not to exceed the limit values of operation speed against the robot’s maximum speed during the test run or FWD/BWD operation.
Manual full-speed function allows the manipulator to perform the test run or FWD/BWD operation at the taught speed by a JOB during the teach mode. Perform the operation outside the motion range.
If the full-speed test mode is set or released while a SERVO power is ON, the servo power turns OFF.
8
-
67
Description of Units and Circuit Boards
8.12
Slow speed mode
This signal is used to determine the speed of the test run when the FST (full-speed test) signal input circuit is open.
Open: Second slow speed (2%)
Short circuit: First slow speed (16%)
CAUTION!
Injuries and machine damages caused by short-circuit
Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.
Be sure to remove the jumper before using.
5
4
1
2
-X18
17
18
3
(JANCD-YSF22-E)
CN219
SSP+
SSP-
1
2
3
Robot controller
Fig. 8-9: Connection for slow operation mode
I/O terminal (machine safety)
I/O board (machine safety)
4
5
Remove the jumper cable
Slow mode selection
8.13
External hold
This signal is used to connect a stop switch of an external device. If the signal is input, the job is stopped. As long as the signal is ON, starting and axis movements cannot be enabled.
CAUTION!
Injuries and machine damages caused by short-circuit
Jumpers are installed at the factory. If the jumpers are not removed, the external emergency stop will not work even with incoming signal.
Be sure to remove the jumper before using.
8
-
68
4
1
2
-X18
19
20
Description of Units and Circuit Boards
3
(JANCD-YSF22-E)
CN219
EXHOLD+
EXHOLD-
5
1
2
3
Robot controller
Fig. 8-10: Connection for external hold
I/O terminal (machine safety)
I/O board (machine safety)
4
5
Remove the jumper cable
External hold
8.14
External SERVO-ON
External SERVO-ON
This signal is used to connect the servo ON switch of an external operation device. If the signal is input, the servo power is turned ON.
1
4
2
-X18
21
22
3
(JANCD-YSF22-E)
CN219
EXSVON+
EXSVON-
1
2
Fig. 8-11: Connection for external SERVO-ON
Robot controller
I/O terminal (machine safety)
3
4
I/O board (machine safety)
External SERVO-ON
8
-
69
Description of Units and Circuit Boards
8.15
SYSRUN Signal Output
This signal is used to check whether the robot control status is normal or abnormal.
This signal is output on the following conditions.
1
2
3
Fig. 8-12: (1) Connection for SYSRUN signal output
1
2
Main power supply ON/OFF
Robot control status normal/abnormal
3
SYSRUN ON/OFF
Because the pulse signal is outputted from the specific output signal (#50911) to the external device for each 100ms, it is also able to check whether the robot controller control circuit board is normal or abnormal (Refer to Instructions for Concurrent I/O for more details).
2
(JANCD-YFC22-E)
1
-X18
CN219
SYSRUN+
SYSRUN-
23
24
SYSRUN+
SYSRUN-
1
Fig. 8-13: (2) Connection for SYSRUN signal output
I/O board (machine safety)
2
I/O terminal (machine safety)
8
-
70
Description of Units and Circuit Boards
8.16
External axes overrun
CAUTION!
Injury and material damage in case of a non-functional signal
Jumper cables are installed at the factory. If the cables are not removed, injury or damage to machinery may result and the external emergency stop will not work even if the signal is input.
Be sure to remove the jumper cables before using.
With a unit of standard specifications without an external axis, the external axis overrun input signal is not used. In this case, a jumper cable is connected as shown in the following figure.
If an overrun input signal for an axis other than manipulator axes, for example the external axis, is required, connect the signal input circuit in the following manner.
For safe reason, a dual circuits are used for the external axis overrun signal input. Connect the external axis overrun signal so that both input signals are turned ON or OFF at the same time.
If only one signal is turned ON, the machine safety signal error occurs.
4
1
42
43
2
-X18
3
(JANCD-YSF22-E)
CN219
OT2_1+
OT2_1-
6
44
45
OT2_2+
OT2_2-
5
Fig. 8-14: Connection for external axis overrun
1
2
Robot controller
I/O terminal (machine safety)
4
5
External axis overun
Remove the jumper cable
3
I/O board (machine safety)
6
Turn OFF/ON at the same time
The following figure shows the external axis overrun wiring of the factory default setting when the external axes are connected to the robot controller.
Please refer to the following figure to connect the external axes overrun signal to wire in the another route. On that occasion, confirm the external axes overrun setting to connect.
8
-
71
Description of Units and Circuit Boards
5
4
5
6
1
2
-X18
42
43
3
(JANCD-YSF22-E)
CN219
OT2_1+
OT2_1-
44
45
OT2_2+
OT2_2-
46
47
48
49
OT3_1+
OT3_1-
OT3_2+
OT3_2-
5
7
51
52
53
54
OT4_1+
OT4_1-
OT4_2+
OT4_2-
3
4
1
2
Fig. 8-15: Connection for external axis overrun (multiple lines)
Robot controller
I/O-Terminal (machine safety)
I/O Platine (machine safety)
External axis overrun 1. line
5
6
7
Turn ON/OFF at the same time
External axis overrun 2. line
External axis overrun 3. line
8
-
72
Description of Units and Circuit Boards
8.17
SERVO-ON enable input
Connect the ONEN signal lines to enable the function to turn ON or OFF the servo power supply of an individual servo when a robotic system is divided into areas.
Because these signals are not used for units of standard specifications, a jumper cable is connected as shown in the following figure.
For safety reasons, dual circuits are used for the SERVO-ON enable input signals. Connect the signal switch so that both input signals are turned ON or OFF at the same time. If only one signal is turned ON, an alarm occurs.
4
1
2
-X18
26
27
3
(JANCD-YSF22-E)
CN219
ONEN1_1+
ONEN1_1-
6
28
29
ONEN1_2+
ONEN1_2-
1
2
3
5
Fig. 8-16: Connection for SERVO-ON enable input
Robot controller
I/O terminal (machine safety)
I/O board (machine safety)
4
5
6
SERVO-ON enable input
Remove the jumper cable
Turn OFF/ON at the same time
8
-
73
Description of Units and Circuit Boards
8.18
Emergency stop button output
The extra contact output terminals of the emergency stop button on the programming pendant are provided on the terminal block on the cabinet door.
These contacts are always valid no matter if the robot controller power supply is ON or OFF.
CAUTION!
Damage to property caused by short-circuit
Do not use the emergency stop button with a voltage of 24 V AC, 0.5 A or more.
1
2
3
-X18
CN219
PBESP3+
PBESP3-
PBESP4+
PBESP4-
4
(JANCD-YFC22-E)
5
59
60
61
62
PBESP3+
PBESP3-
PBESP4+
PBESP4-
6
2
PPESP3+
PPESP3-
PPESP4+
PPESP4-
55
56
57
58
PPESP3+
PPESP3-
PPESP4+
PPESP4-
1
2
3 troller
Fig. 8-17: Emergency stop button output
Control cabinet door of the robot con-
Emergency stop button
I/O board (machine safety)
4
5
6
I/O terminal board (machine safety)
Robot controller
Programming pendant
8
-
74
Description of Units and Circuit Boards
8.19
Universal safety input
The universal safety input signal is used in the safety logic circuit function. universal safety input.
1
4
2
-X18
63
64
3
(JANCD-YSF22-E)
CN219
GSIN1_1+
GSIN1_1-
5
65
66
GSIN1_2+
GSIN1_2-
1
2
3
Robot controller
Machine safety terminal block circuit board
Fig. 8-18: Universal safety input
4
5
Universal safety input
Turn ON/OFF at the same time
Machine safety I/O logic ciruit board
8
-
75
Description of Units and Circuit Boards
8.20
Universal safety output
The universal safety output signal is used in the safety logic circuit function.
For example, composing the circuit to output the status signal, such as the servo ON signal or the emergency stop button by the safety logic circuit function enables to output the signals to the external device.
The signal is outputted as the dual signals, and inputs the status of the driven devices by the output signal as the monitoring signal.
1
2
-X18
CN219
GSOUT1_1+
3
(JANCD-YFC22-E)
71
GSOUT1_172
4
GSOUT1_2+
GSOUT1_2-
73
74
5
GSEDM1+
GSEDM1-
80
81
6
1
2
3
Robotcontroller board
Fig. 8-19: Universal safety output
Machine safety terminal block circuit
Machine safety I/O logic ciruit board
4
5
6
Universal safety output 1
Universal safety output 2
Monitoring signal
NOTICE
Rated output value is DC24V and less than 50mA. Avoid excessive load when connect.
When connect the inductive load, such as the safety relay, with the output circuit, use of the built-in protective circuit for the surge suppressor or connect the flyback diode in parallel to the inductive load to suppress the surge voltage. It may cause the damage on the output circuit.
The feedback signal must be inputted to the robot controller when use the universal safety output signal.
8
-
76
Description of Units and Circuit Boards
8.21
Direct-in (SERVO) 1 to 6
This signal is used to input a response signal in search functions.
4
1
2
3
4
5
6
1
-X18
93,94
85
86
87
88
89
90
84
91,92
2
(JANCD-YSF22-E)
CN219
024V2
3
(SRDA-EAXA21A)
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
AXDIN6
AXDIN_COM
+24V2
5
5
1
(JANCD-YFC22-E)
89
90
84
93,94
85
86
87
88
91,92
2
(JANCD-YSF22-E)
CN219
024V2
3
(SRDA-EAXA21A)
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
AXDIN6
AXDIN_COM
+24V2
1
2
3
Fig. 8-20: Connection for Direct-in (SERVO) 1 to 6
This part of the wiring is for the SLAVE, for control voltage supply and for the control card for the main axles of the slave robot, SRDA-EAXA01.
I/O terminal board (machine safety)
I/O board (machine safety)
Connect the jumper cable
4
5
6
Direct-in (SERVO)
Connect the jumper cable
8
-
77
Description of Units and Circuit Boards
8.22
Universal input (SERVO)
Connect when use the universal signal
1
2
-X18
93,94
96
3
(JANCD-YSF22-E)
CN219
024V2
4
(SRDA-EAXA21A)
AXIN1
5
1
2
97
95
91,92
AXIN2
AXIN_COM
+24V2
6
1
2
3
Robot controller board
Fig. 8-21: Universal input (SERVO)
Machine safety terminal block circuit
Machine safety I/O logic ciruit board
4
5
6
Major axes control circuit board
Universal input (SERVO)
Connect the jumper cable.
8.23
Universal output (SERVO)
Connect when use the universal signal
1
2
(SRDA-EAXA21A)
AXOUT1
3
(JANCD-YSF22-E)
CN219
4
-X18
98
5
AXOUT2
99
91,92
+24V2
1
2
3
Robotcontroller
Machine safety terminal block circuit board
Fig. 8-22: Universal input (SERVO)
4
5
Major axes control circuit board
Universal output (SERVO)
Machine safety I/O logic ciruit board
8
-
78
Description of Units and Circuit Boards
8.24
Universal I/O circuit board (JANCD-YIO22-E)
Four digital I/O connectors for the robot universal I/O are provided:
40 inputs and 40 outputs. The I/Os are divided into two types: universal I/O and specific I/O.
The I/O assignment differs depending on the application. Specific I/O is a signal in which the part is decided in advance. Specific I/O is used when the external operation equipment, such as position controller and central controller, controls the robot and the connected devices as a system. Universal I/O are mainly used as timing signals for the robot and peripheral devices in jobs that require robot motion.
Refer to chapter „Universal I/O signal assignment“ for more details on signal allocation.
For the connection of the robot’s universal I/O signal connectors, and the I/O signal related to start and stop to refer to "Connetion wire with universal I/O Connector (CN306, 307, 308,
309)" and "Specific I/O Signal Related to Start and Stop".
1
2
3
4
For switching external power supply
(CN303)
Power Supply Protective Fuse (F1, F2)
3.15A/250 V
Power Supply Output (CN304)
Digital I/O (CN307, CN306, CN308 and
CN309)
1
2
3
4
(CN307)
4
(CN309)
4 (CN306)
4 (CN308)
•
Connection wire with robot universal I/O connector (CN306, 307, 308, 309)
Please refer to the figure below when you manufacture the cable connecting with robot universal I/O connector (CN306, 307, 308, 309) of robot I/O unit (JZNC-YIU01-E).
Unshielded twisted pair cable must be used (the cable side connector and the I/O terminal block are the options).
-X18 A1 A3 A5 A7 A9 A11
Fig. 8-23: PNP logic
A13 A15 A17 A19 A31
8
-
79
Description of Units and Circuit Boards
NOTICE
When connecting an inductive load to the output circuit, connect a flyback (snubber) diode in parallel to the inductive load to suppress the surge voltage. Not using a fly-wheel diode may damage the output circuit.
When connecting a load with a large inrush current such as a lamp, connect a current limiting resistance in series to the load, so that the output current does not exceed its maximum value. Exceeding the maximum output current value may damage the output circuit.
3
4
5
1
2
Universal I/O circuit board
Inductive load
Flywheel diode
Lamp
Current limiting resistor
1
(JANCD-YIO22-E)
+24VU
2
3
5 4
024VU
Refer to chapter 8.29 "Assignment of general I/O signal" from 92 about the maximum current of the transistor and the relay output circuits.
•
Specific I/O signal related to start and stop
The following signals are specific I/O signals related to start and stop.
• SERVO ON (depending on application: JANCD-YIO22-E)
• External SERVO ON (common to all application: JANCD-YFC22-E) external start
(depending on application: JANCD-YIO22-E)
• Operating (depending on application: JANCD-YIO22-E)
• External Hold (common to all application: JANCD-YFC22-E)
• External Emergency Stop (common to all application: JANCD-YFC22-E)
Timing chart
6
7
3
4
5
1
2
Robot
While SERVO-ON
SERVO-ON
External start
Execution
Extern Stop
Emergency shut-off
1
2
RUN
STOP
ON
OFF
3
ON
OFF
4
5
6
7
ON
OFF
ON
OFF
ON
OFF
ON
OFF
T
T
T
Note: set T = 100 ms minimum
8
-
80
Description of Units and Circuit Boards
•
Example of SERVO ON Sequence Circuit from External Device
Only the rising edge of the SERVO ON signal is valid. This signal turns ON the robot
SERVO power supply. The set and reset timings are shown in the following.
8
9
6
7
3
4
5
1
2
10
SERVO ON PB
SERVO ON confirmation
SERVO_ON command
Robot controller
Machine safety terminal block circuit board
Machine safety I/O logic circuit board
Universal I/O circuit board
SERVO-ON power ON
SERVO-ON is output
SERVO-ON power ON X3
1
㼄㻝
10
(30011)
2
3
X1
2
X2
PL
3
X1
4
5
(JANCD-YFC22-E)
21
22
6
(JANCD-YSF22-E)
CN219
+24V2
EXSVON
8
X3
7
JANCD-YIO21-E
CN308
+24VU
A18
A8
9 (30011)
NOTICE
Number in ( ) means output signal number assigned to YIU21.
PL: Pilot lamp
8
-
81
Description of Units and Circuit Boards
•
Example of start sequence circuit from external device
Only the rising edge of the external start signal is valid. This signal starts the robot. Set this signal with the interlock configuration which determines whether operation can be started.
The playback signal (RUNNING) confirms that the robot is actually moving.
7
8
9
5
6
3
4
1
2
Run PB
While SERVO-ON
Selects PLAY mode
Alarm/Error Occurring
Running confirmation
Start (Command)
10
11
12
Robot controller
External Start Command
External start input
Ongoing output
Running, etc.
Running X6
12
㻼㻸 㼄㻡
5
4
㼄㻠
6
5
1
2
3
㼄㻢
11 8
7
10
NOTICE
Number in ( ) means output signal number assigned to YIU21.
PL: Pilot lamp
9
8
-
82
Description of Units and Circuit Boards
•
Connection of the external power supply for I/O
In the factory setting, the internal power supply for I/O is used. If the external power supply for I/O is used, connect it as described below.
1. Remove the wire connected between CN303-1 to -3 and CN303-2 to -4 of the universal
I/O circuit board.
2. Connect +24V of the external power supply to CN303-1 and 0V to CN303-2 of the robot
I/O unit.
3
4
5
1
2
Universal I/O circuit board
External supply
Provided by the customer
In case of using external power supply.
In case of using internal power supply (factory settings).
2
+24V
0V
3
(JANCD-YIO21-E)
CN303
1
+24VU
1(EX+24VIN)
F1
2(EX024VIN)
F2
3.15A
3.15A
024VU
3(+24V)
+24V
4(024V)
024V
5
(JANCD-YIO21-E)
CN303
1
+24VU
1(EX+24VIN)
F1
2(EX024VIN)
F2
3.15A
3.15A
024VU
3(+24V)
4(024V)
+24V
024V
4
NOTICE
The internal power supply of 24V of about 1.5 A of robot control can be used for I/O.
Use external 24V power supply for higher currents and to isolate the circuit inside and outside the robot control.
Power supply circuit for I/O (+24 VU, 024 VU) has 3.15A fuses (F1, F2).
Install the external power supply outside the DX200 to avoid electric noise problems.
If the internal power supply is selected and the external power supply is connected to
CN303-1 to -3 and CN303-2 to -4, do not connect the external power supply line to the
+24VU and 0VU terminals. The unit may malfunction if the external power supply is also connected.
8
-
83
Description of Units and Circuit Boards
8.25
Brake control circuit board (JANCD-YBK21-3E)
The brake control circuit board controls ON/OFF of the brakes of total nine axes (Robot + external axes) according to the command signal from the major axes control circuit board
(SRDA-EAXA21A).
3
4
1
2
5
6
7
Axes control cicuit board I/F (CN405)
For external brake power supply (CN404)
Brake power supply input (CN403)
Brake power supply fuse (F1: For external axes) 3,15A/
250V
Brake interlock (CN402)
Handbrake release unit I/F (CN401)
Brake I/F (CN400)
1
2
3
4
5
6
7
8
-
84
Description of Units and Circuit Boards
8.26
Converter (SRDA-COA30A21B-E)
The converter (SRDA-COA30A21B-E) exchanges the power supply (3-phase: AC200/
220V) supplied by the power ON unit for DC power supply and supplies the power to the amplifier module (PWM amplifiers).
3
4
5
1
2
Grounding detection input (CN554)
Converter control signal (CN553)
Monitor/Alarm indication LED
6
DC control power supply (CN551)
Control power supply output for six axes amplifier
(CN552A)
Control power supply output for external axes amplifier
(CN552B)
Grounding terminal
7
8
9
10
11
12
13
Charge lamp
External axes main circuit connection (CN558)
Power supply regenerative unit connection (CN559)
Main circuit power supply output (CN556)
Regenerative resistor (CN557)
Main circuit power supply input (CN555)
14
13
12
11
9
8
6
1
2
3
5
4
7
8
-
85
Description of Units and Circuit Boards
8.27
Capacitor module (SRDA-CUA
AA)
The capacitor module smooth the DC voltage (PN voltage) created in the converter and also save the electric energy.
There are two type of the capacitors shown below:
• Small capacity: SRDA-CUA662AA
• Medium / Large capacity: SRDA-CUA133AA
SRDA-CUA492AA SRDA-CUA662AA SRDA-CUA133AA
Fig. 8-24: Capacitor module (SDRA-CUA
AA)
8
-
86
Description of Units and Circuit Boards
3
4
1
2
8.28
Amplifier module (SDRA-SDA
A01A-E)
The amplifier module exchanges the DC power supply supplied by a converter for a 3phase motor power source and outputs to each servo motor.
Main circuit power supply input (CN583)
Control power supply input (CN582)
PWM signal (CN581)
Motor power output (CN584)
Fig. 8-25: Amplifier Position
8
-
87
Description of Units and Circuit Boards
8.29
Assignment of general I/O signal
NOTICE
Damage to property caused by short-circuit
For details on wiring, see the circuit diagram.
-AE7
&EFA/14.4
JANCD-YIO22-E
-CN306
IN009
IN010
IN011
IN012
IN013
IN014
IN015
IN016
20040
20041
20042
20043
20044
20045
20046
20047
024VU
NC1
NC2
NC3
NC4
024VU
024VU
B7
A7
B5
A5
B6
A6
B1
A1
B2
A2
B3
A3
B4
A4
+24VU
OUT009
OUT010
OUT011
OUT012
OUT013
OUT014
OUT015
OUT016
30040
30041
30042
30043
30044
30045
30046
30047
NC5
NC6
NC7
NC8
B12
A12
B13
A13
NC9
NC10
NC11
NC12
B14
A14
B15
A15
B8
A8
B9
A9
B10
A10
B11
A11
024VU
024VU
024VU
024VU
B16
A16
B17
A17
+24VU
+24VU
+24VU
+24VU
B18
A18
B19
A19
FG
NC13
B20
A20 assignment interface board
B8
A8
B9
A9
B10
A10
B11
A11
B12
A12
B13
A13
B14
A4
B5
A5
B6
A6
B7
A7
A2
B3
A3
B4
-XD306
B1
A1
B2
A14
B15
A15
B16
A16
B17
A17
B18
A18
B19
A19
B20
A20
A14
B15
A15
B16
A16
B17
A17
B18
A18
B19
A19
B20
A20
B8
A8
B9
A9
B10
A10
B11
A11
B12
A12
B13
A13
B14
A4
B5
A5
B6
A6
B7
A7
A2
B3
A3
B4
-AE7-CN306
B1
A1
B2
Fig. 8-26: JANCD-YIO22-E (CN306-Connector) I/O allocation
8
-
88
Description of Units and Circuit Boards
-AE7
&EFA/14.4
JANCD-YIO22-E
-CN307
IN017
IN018
IN019
IN020
IN021
IN022
IN023
IN024
20050
20051
20052
20053
20054
20055
20056
20057
024VU
NC14
NC15
NC16
NC17
B5
A5
B6
A6
OUT017
OUT017
OUT018
OUT018
OUT019
OUT019
OUT020
OUT020
OUT021
OUT021
OUT022
OUT022
OUT023
OUT023
OUT024
OUT024
30050
30050
30051
30051
30052
30052
30053
30053
30054
30054
30055
30055
30056
30056
30057
30057
A10
B11
A11
B12
A12
B13
B8
A8
B9
A9
B10
A13
B14
A14
B15
A15
B1
A1
B2
A2
B3
A3
B4
A4
024VU
024VU
B7
A7 assignment interface board
024VU
024VU
024VU
024VU
B16
A16
B17
A17
+24VU
+24VU
+24VU
+24VU
B18
A18
B19
A19
FG
NC18
B20
A20
Fig. 8-27: JANCD-YIO22-E (CN307-Connector) I/O allocation
A17
B18
A18
B19
A19
B20
A20
A13
B14
A14
B15
A15
B16
A16
B17
A9
B10
A10
B11
A11
B12
A12
B13
A7
B8
A8
B9
A5
B6
A6
B7
A2
B3
A3
B4
-XD307
B1
A1
B2
A4
B5
A17
B18
A18
B19
A19
B20
A20
A13
B14
A14
B15
A15
B16
A16
B17
A9
B10
A10
B11
A11
B12
A12
B13
A7
B8
A8
B9
A5
B6
A6
B7
A2
B3
A3
B4
-AE7-CN307
B1
A1
B2
A4
B5
8
-
89
Description of Units and Circuit Boards
-AE7
&EFA/14.4
JANCD-YIO22-E
-CN308
20010
20011
20012
20013
20014
20015
20016
20017
20020
20021
20022
20023
B4
A4
B5
A5
B6
A6
B1
A1
B2
A2
B3
A3
NC19
NC20
NC21
NC22
B14
A14
B15
A15
024VU
024VU
024VU
024VU
B16
A16
B17
A17
+24VU
+24VU
+24VU
+24VU
B18
A18
B19
A19
FG
NC23
B20
A20
024VU
024VU
B7
A7
30010
30011
30012
30013
30014
30015
30016
30017
30020
30021
30022
30023
B11
A11
B12
A12
B13
A13
B8
A8
B9
A9
B10
A10
Fig. 8-28: JANCD-YIO22-E (CN308-Connector) I/O allocation
assignment interface board
A12
B13
A13
B14
A14
B15
A15
B16
A8
B9
A9
B10
A10
B11
A11
B12
A16
B17
A17
B18
A18
B19
A19
B20
A20
A6
B7
A7
B8
A4
B5
A5
B6
A2
B3
A3
B4
-AE7-CN308
B1
A1
B2
A12
B13
A13
B14
A14
B15
A15
B16
A8
B9
A9
B10
A10
B11
A11
B12
A16
B17
A17
B18
A18
B19
A19
B20
A20
A6
B7
A7
B8
A4
B5
A5
B6
A2
B3
A3
B4
-XD308
B1
A1
B2
8
-
90
Description of Units and Circuit Boards
-AE7
&EFA/14.4
JANCD-YIO22-E
-CN309
IN001
IN002
IN003
IN004
IN005
IN006
IN007
IN008
20024
20025
20026
20027
20030
20031
20032
20033
20034
20035
20036
20037
A3
B4
A4
B5
A5
B6
A6
B1
A1
B2
A2
B3
024VU
024VU
B7
A7
OUT001
OUT002
OUT003
OUT004
OUT005
OUT006
OUT007
OUT008
30024
30025
30026
30027
30030
30031
30032
30033
30034
30035
30036
30037
B8
A8
B9
A9
B10
A10
B11
A11
B12
A12
B13
A13
NC24
NC25
NC26
NC27
B14
A14
B15
A15
024VU
024VU
024VU
024VU
B16
A16
B17
A17
+24VU
+24VU
+24VU
+24VU
B18
A18
B19
A19
FG
NC28
B20
A20
Fig. 8-29: JANCD-YIO22-E (CN309-Connector) I/O allocation
assignment interface board
B13
A13
B14
A14
B15
A15
B16
A16
B17
A17
B18
A18
B19
A19
B20
A20
A6
B7
A7
B8
A8
B9
A9
B10
A10
B11
A11
B12
A12
A4
B5
A5
B6
A2
B3
A3
B4
-AE7-CN309
B1
A1
B2
B13
A13
B14
A14
B15
A15
B16
A16
B17
A17
B18
A18
B19
A19
B20
A20
A6
B7
A7
B8
A8
B9
A9
B10
A10
B11
A11
B12
A12
A4
B5
A5
B6
A2
B3
A3
B4
-XD309
B1
A1
B2
8
-
91
Description of Units and Circuit Boards
Logical number
20010
Input name / Function
EXTERNAL START
Functions the same as the [START] button in the programming pendant. Only the rising edge of the signal is valid. It starts robot operation (playback). This signal is invalid if external start is prohibited from the playback condition display.
20012
CALL MASTER JOB
Only the rising edge of the signal is valid. It calls up the top of the robot program, that is the top of the master JOB
1
. This signal is invalid during playback, during teach lock and when play master or call is prohibited (set from the playback operation condition display).
20013
ALARM/ERROR RESET
After an alarm or error has occurred and the cause been corrected, this signal resets the alarm or error.
20015
SELECT PLAY MODE
The play mode is selected when the mode key on the programming pendant is set at "REMOTE". Only the rising edge of the signal is valid. When this selection signal assigned concurrently with other mode selection signal, the teach mode is selected on a priority basis. The signal is invalid while EXTERNAL MODE
SWITCH is prohibited.
20016
SELECT TEACH MODE
The TEACH mode is selected when the mode key of the programming pendant is set at "REMOTE". The other mode selection is unavailable when this signal is ON; the signal is selected by priority even when the other selection signal is ON, enabling the
TEACH mode selection.
20020
INTERFERENCE 1 ENTRANCE PROHIBITED
If the robot attempts to enter the cube 1
2
area while this signal is
ON, the robot goes to wait status (with SERVO power ON). During wait status, the robot operation restarts if this signal turns OFF.
20021
INTERFERENCE 2 ENTRANCE PROHIBITED
If the robot attempts to enter the cube 2
2
area while this signal is
ON, the robot goes to wait status (with SERVO power ON). During wait status, the robot operation restarts if this signal turns OFF.
1. A master JOB is a JOB (program) which can be called by CALL MASTER JOB.Other functions are the same as for normal JOBs. Normally, the parent JOB, which manages the child JOBs called up immediately after the power is turned ON, is set as the master JOB.
2. See you System Setup Manual chapter "Interference area".
Logical Number
30010
Output Name / Function
RUNNING
This signal signifies that the job is running. (Signifies that the job is running, system status is waiting reserved start, or test run is running.) This signal status is the same status as [START] in the programming pendant.
8
-
92
Description of Units and Circuit Boards
Logical Number
30011
Output Name / Function
SERVO IS ON
This signal signifies that the SERVO power is turned ON, internal processing such as current position creation is complete, and the system is able to receive the START command. This signal turns
OFF when the SERVO power supply turns OFF. It can be used for
DX200 status diagnosis for an external start.
30012
TOP OF MASTER JOB
This signal signifies that the execution position is the top of the master job. This signal can be used to confirm that the master job has been called
1
.
30013
30014
ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error occurred. If a major error occurs, this signal remains ON until the main power is turned
OFF.
B
ATTERY ALARM
This signal turns ON to notify that the battery requires replacing when the voltage drops from the battery for backup memory of the encoder. Major problems may result if memory data is lost because of an expired battery. It is recommended to avoid these problems by using this signal as a warning signal.
30015 to30017
REMOTE/PLAY/TEACH MODE SELECTED
This signal notifies the current mode setting. These signals are synchronized with the mode select switch in the programming pendant. The signal corresponding to the selected mode turns
ON.
30020
IN CUBE 1
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1). Use this signal to prevent interference with other robots and positioners.
30021
30022
IN CUBE 2
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2). Use this signal to prevent interference with other robots and positioners.
WORK HOME POSITION (IN CUBE 64)
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 robot operates. It turns OFF when the currently executed line is moved with the cursor or when editing operation is carried out after HOLD is applied during operation. Therefore, this signal can be used as a restart interlock after a HOLD is applied. However, it also turns ON in the TEACH mode and TEACH MODE SELECTED signal must be referred together.
1. This signal is not output during operation.
2. Der CUBE der Arbeitsausgangsstellung und der CUBE 64 sind identisch.
8
-
93
Description of Units and Circuit Boards
8.29.1
ARC welding
Logical number I/O Name / Function
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.
20022
WORK PROHIBITED (Arc Generation Prohibited)
Arc generation is prohibited while this signal is ON. Arc generation starts when this signal turns OFF inside the arc-generation area. Use this signal to confirm teaching.
20023
WORK RESPONSE (Pseudo Arc ON Response)
This signal is used as a pseudo signal in cases that “Arc Generation
Confirmation” signal is not equipped on a welding power supply. Wire this signal ON normally (short to OV).
20026
WEAVING PROHIBITED
Weaving is prohibited while this signal is ON. Use this signal to check taught steps and movements without performing the weaving operation.
20027
SENSlNG PROHIBITED
Arc sensing is prohibited while this signal is ON. Use this signal to check taught steps and movements if an arc sensor is mounted.
30010
RUNNING
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
DX200 status diagnosis for an external start.
30012
TOP OF MASTER JOB
This signal signifies that the execution position is the top of the master job. This signal can be used to confirm that the master job has been called
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.
1. This signal is not output during operation.
8
-
94
Description of Units and Circuit Boards
8.29.2
Handling
Logical number I/O Name / Function
20026
TOOL SHOCK SENSOR
This is normally ON (NC) signal input. When it turns OFF, an DX200 displays a message "HAND TOOL SHOCK SENSOR OPERATING" and a HOLD is applied. The releasing in teach mode is done on the handling application diagnostic display. Set TOOL SHOCK SENSOR function “NOT USE” on the handling applications diagnostic display if this signal is not be used.
20027
LOW AIR PRESSURE
This signal is normally OFF (NO). When it turns ON, robot controller displays user alarm in the PLAY mode or displays user message in the TEACH mode.
20050 to20057
SENSOR INPUT 1 - 8
Inputs 1 to 8 are monitored with the HSEN handling specific instructions. Sensor inputs 1 to 8 correspond to HSEN 1 to 8.
30050 to30057
HAND VALVE 1-4
These outputs are controlled by the HAND handling specific instructions. Hand valves 1 to 4 correspond to HAND 1 to 4.
8.29.3
General application
Logical number I/O Name / Function
20024
INTERFERENCE 3 ENTRANCE PROHIBITED
If the robot attempts to enter the cube 3
2
area while this signal is ON, the robot goes to wait status (with SERVO power ON). During wait status, the robot operation restarts if this signal turns OFF.
20025
INTERFERENCE 4 ENTRANCE PROHIBITED
If the robot attempts to enter the cube 4
2
area while this signal is ON, the robot goes to wait status (with SERVO power ON). During wait status, the robot operation restarts if this signal turns OFF.
30024
IN CUBE 3
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 3). Use this signal to prevent interference with other robots and positioners.
30025
IN CUBE 4
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 4). Use this signal to prevent interference with other robots and positioners.
8
-
95
Description of Units and Circuit Boards
8.29.4
Spot welding
Logical number
20022
Input name / Function
20023
20024
20025
20050
20051
20052
20053
1
1
1
1
WELDING ON/OFF (from sequencer)
This signal inputs the welding ON/OFF selector switch status from the sequencer in the interlock unit. The WELD ON/OFF signal is output to the Power Source according to this signal and the robot status.
WELDING PAUSE (from sequencer)
This signal is used to move the robot to the home position when an error occurs in the Power Source or the gun.
The robot ignores the spot welding instruction and operates playback motion.
INTERFERENCE 3 ENTRANCE PROHIBITED
If the robot attempts to enter cube 3
2
while this signal is ON, the robot is put into wait status (with servo power ON). During wait status, robot movement is started as soon as this signal turns OFF.
INTERFERENCE 4 ENTRANCE PROHIBITED
If the robot attempts to enter cube 4
2
while this signal is ON, the robot is put into wait status (with servo power ON). During wait status, robot movement is started as soon as this signal turns OFF.
TIMER COOLING WATER ERROR
This signal monitors the status of timer cooling water. The robot displays alarm and stops when this signal is input. The SERVO power supply remains ON.
GUN COOLING WATER ERROR
This signal monitors the status of gun cooling water. The robot displays alarm and stops when this signal is input. The SERVO power supply remains ON.
TRANSTHERMO ERROR
Error signal is sent from the transformer in the gun to the robot. The signal is normally an ON (NC) signal. An alarm occurs when the signal is
OFF. The SERVO power supply remains ON.
LOW AIR PRESSURE
When air pressure is reduced and this input is turned ON, an alarm occurs. The SERVO power supply remains ON.
WELD COMPLETION
This signal indicates that the Power Source completed welding without error. This signal is used as a confirmation signal for welding instruction execution and manual spot welding.
After this signal is input, the welding sequence is completed and the next step is executed when confirmation limit switch is not provided.
WELDING ERROR
This signal indicates an abnormal welding result or Power Source’s error. Alarm occurs and the manipulator stops if this signal is input during welding.
8
-
96
Description of Units and Circuit Boards
Logical number
Input name / Function
30057
30024
30025
30050
30051
2
3
(30052 to
300564)
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.
GUN FULL OPEN DETECTION
This signal indicates that the stroke of the double stroke gun is full open.
GUN SHORT OPEN DETECTION
This signal is connected with a single gun open verification limit switch or a double stroke gun short open verification limit switch to verify the gun open.
GUN PRESSURE DETECTION
This signal indicates that a gun is in pressing status.
TIP REPLACE COMPLETION
When this signal is input after tip replacement, the TIP REPLACE RE-
QUEST signal turns OFF, and the stored number of welding is cleared.
TIP REPLACE REQUEST
This signal is output when the stored number of welding reaches the number of welding set for the tip replacement.
IN CUBE 3
This signal is turned ON when the current TCP lies within a pre-defined area (cube 3). Use this signal to prevent faults due to other robots or positioners.
IN CUBE 4
This signal is turned ON when the current TCP lies within a pre-defined area (cube 4). Use this signal to prevent faults due to other robots or positioners.
WELD ON/OFF
Outputs a signal input from the interlock panel, etc.considering the robot status.
WELD ERROR RESET
This signal commands the reset error status of the power source. This is operated with the programing pendant operation.
WELD CONDITION (Level-Signal)
1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8)
Sets the welding conditions for the power source.
The output format can be set as binary or discrete (bit number.) It can handle up to 255 conditions. Most-significant bit is the parity bit (when specified).
WELDING COMMAND
This signal outputs execution command signal to the power source.
This signal is not necessary for a power source which is executed using the WELDING CONDITION signal.
8
-
97
Description of Units and Circuit Boards
Logical number
Input name / Function
STROKE CHANGE1
SINGLE SOLENOID
DOUBLE SOLENOID
This is a signal, when a double stroke gun is used, to change the open stroke of the welding gun.
GUN PRESS COMMAND
This outputs gun press command.
1. This signal can be set as “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is selected, this signal can be used as the universal I/O signal described in parentheses.
2. This signal can be select “USE” or “NOT USE” by pseudo input signal "8202x". If "NOT USE" is selected, this signal can be used as the universal I/O signal described in parentheses.
3. This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
6
7 6 5 4 3 2 1 0
0 0 0 1 1 1 1 1
5
3
4
1
2
1
2
3
Timer cooling water error validating ( or IN09)
GUN Cooling Water Error Validating
(or IN10)
Transthermo error validating (or
IN11)
4
5
6
Low air pressure validating (or IN12)
Weld ON/OFF Validating (or OUT09)
Pseudo Input Signal 8202x
8
-
98
Description of Units and Circuit Boards
8.29.5
JANCD-YEW01-E circuit board (Standard)
JANCD-YEW01-E Circuit Board: Analog outputs ´ 2 ports, Analog inputs ´ 2 ports + Status signal I/O of a Welder.
MR Connector MS Connector
Each point
24 VDC
5mA MAX
A/D +5V
A/D +5V
DC24V
5mA MAX
DC24V
0.5A MAX
Detector
D/A ±14V
1
SW2
3
D/A ±14V
17BYTE 32BYTE
DC24V
0.5A MAX
Logical
Number
Connector
Pin No.
Name
CN322-1
25110
CN322-2
+GASOF (Gas Shortage)
25111
CN322-3
CN322-4
-GASOF (Gas Shortage)
+WIRCUT (Wire Shortage)
-WIRCUT (Wire Shortage)
CN322-5
25113 CN322-6 +ARCACT (
Arc Generation Confirm
)
CN322-7
CN322-8
-ARCACT (
Arc Generation Confirm
)
CH2 (Current Input)
Signal
IN
IN
IN
IN
IN
IN
IN
CN322-9
CN322-10
CN322-11
CH1 (Voltage Input)
CN322-12
25112 CN322-13
+ARCOFF (Arc Shortage)
CN322-14
-ARCOFF (Arc Shortage)
35111
CN322-15
ARCON (Arc ON) A
CN322-16
ARCON (Arc ON) B
35112 CN322-17
WIRINCH (Wire Inching) A
CN322-18 WIRINCH (Wire Inching) B
35113 CN322-19
WIRINCH (Wire Retract) A
CN322-20
WIRINCH (Wire Retract) B
35127
CN322-21
GAS Checking OUT A
CN322-22
GAS Checking OUT B
CN322-23
CN322-24
IN
IN
IN
IN
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
CN322-25
25114
CN322-26
STICK (Wire Sticking)
CN322-27
*STICK (Wire Sticking)
CN322-28
CN322-29
+24VU
CN322-30
0
24
VU
CN322-31
CH1 (Voltage Command)
CN322-32
CN322-33
CH2 (Current Command)
CN322-34
IN
IN
IN
OUT
OUT
OUT
OUT
CN321-1
+24VU
35115
CN321-2
Search Command A (Optional)
CN321-4 Search Command B (Optional)
CN321-5
0
24
VU
OUT
OUT
29
30
31
32
26
27
28
33
34
17
18
19
20
21
22
23
24
25
6
7
4
5
8
1
2
3
13
14
15
16
9
10
11
12
S
T
P
M
N
E
A
B
C
D
L
F
G
R
K
H
J
Power
Source
WAGO Connector(231-105/026-A0)
MRP-34M01 Insulator
MRP-M112 Contactor
RP-34 Casing
MS3106 A, 20-29P
MS3106 A, 20-29S
Fig. 8-30: JANCD-YEW01-E circuit board (Standard)
8
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99
Description of Units and Circuit Boards
8.29.6
The list of the Equipment configuration by model
Model
Type
Dimension W x H x D (mm)
Breaker
Control power supply unit
CPU unit
-
CPU circuit board
Back circuit board
PCI raiser circuit board
Robot I/F circuit board
Machine safety CPU circuit board
Machine safety I/O logic circuit board
Machine safety terminal block
Universal I/O circuit board
Power ON unit
Major axes control circuit board
Brake control circuit board
Converter
Capacitor module
Amplifier module AMP1 (S-axis)
AMP2 (L-axis)
AMP3 (U-axis)
AMP4 (R-axis)
AMP5 (B-axis)
AMP6 (T-axis)
Regenerative resistor Type
Rated value
Register value
Heat exchanger
Colling fan
MA1440/MH12
ERER-MA1440/MH12-A00
1000 x 800 x 650
NF32-SVF 3P 15A
JZNC-YPS21-E
JZNC-YRK21-1E
JANCD-YCP21-E
JANCD-YBB21-E
JANCD-YBB22-E
JANCD-YIF01-2E
JANCD-YSF21-E
JANCD-YSF22-E
JANCD-YFC22-E
JANCD-YIO22-E
JZRCR-YPU51-1
SRDA-EAXA21A
JANCD-YBK21-3E
SRDA-COA30A21B-E
SRDA-CUA662AA
SRDA-SDA14A01A-E
SRDA-SDA21A01A-E
SRDA-SDA14A01A-E
SRDA-SDA06A01A-E
SRDA-SDA06A01A-E
SRDA-SDA06A01A-E
SMVK500W6R0J/R0 A6103
500W
6 Ω
4715MS-22T-B50-B00 x2
4715MS-22T-B50-B00 x3 or
11938MB-B2N-EA-01 x3
Tab. 8-2: Model MA1440 and MH12
8
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100
Description of Units and Circuit Boards
Model
Type
Dimension W x H x D (mm)
Breaker
Control power supply unit
CPU unit
-
CPU circuit board
Back circuit board
PCI raiser circuit board
Robot I/F circuit board
Machine safety CPU circuit board
Machine safety I/O logic circuit board
Machine safety terminal block
Universal I/O circuit board
Power ON unit
Major axes control circuit board
Brake control circuit board
Converter
Capacitor module
Amplifier module AMP1 (S-axis)
AMP2 (L-axis)
AMP3 (U-axis)
AMP4 (R-axis)
AMP5 (B-axis)
AMP6 (T-axis)
Regenerative resistor Type
Rated value
Register value
Heat exchanger
Cooling fan
MS210/MH225
ERER-MS210/MH225-A00
1000 x 800 x 650
NF32-SVF 3P 30A
JZNC-YPS21-E
JZNC-YRK21-1E
JANCD-YCP21-E
JANCD-YBB21-E
JANCD-YBB22-E
JANCD-YIF01-2E
JANCD-YSF21-E
JANCD-YSF22-E
JANCD-YFC22-E
JANCD-YIO22-E
JZRCR-YPU51-1
SRDA-EAXA21A
JANCD-YBK21-3E
SRDA-COA30A21B-E
SRDA-CUA133AA
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA35A01A-E
SRDA-SDA35A01A-E
SRDA-SDA35A01A-E
SMVK500W2R0J A5978 x3
1500W
6 Ω
TCSIP-16A4Y-0C
4715MS-22T-B50-B00 x3 or
11938MB-B2N-EA-01 x3
Tab. 8-3: Model MS210/MH225
8
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101
Description of Units and Circuit Boards
Model
Type
Dimension W x H x D (mm)
Breaker
Control power supply unit
CPU unit
-
CPU circuit board
Back circuit board
PCI raiser circuit board
Robot I/F circuit board
Machine safety CPU circuit board
Machine safety I/O logic circuit board
Machine safety terminal block
Universal I/O circuit board
Power ON unit
Major axes control circuit board
Brake control circuit board
Converter
Capacitor module
Amplifier module AMP1 (S-axis)
AMP2 (L-axis)
AMP3 (U-axis)
AMP4 (R-axis)
AMP5 (B-axis)
AMP6 (T-axis)
Regenerative resistor Type
Rated value
Register value
Heat exchanger
Cooling fan
MS165/MH180
ERER-MS165/MH180-A00
1000 x 800 x 650
NF32-SVF 3P 30A
JZNC-YPS21-E
JZNC-YRK21-1E
JANCD-YCP21-E
JANCD-YBB21-E
JANCD-YBB22-E
JANCD-YIF01-2E
JANCD-YSF21-E
JANCD-YSF22-E
JANCD-YFC22-E
JANCD-YIO22-E
JZRCR-YPU51-1
SRDA-EAXA21A
JANCD-YBK21-3E
SRDA-COA30A21B-E
SRDA-CUA133AA
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA35A01A-E
SRDA-SDA35A01A-E
SRDA-SDA35A01A-E
SMVK500W2R0J A5978 x3
1500W
6 Ω
TCSIP-16A4Y-0C
4715MS-22T-B50-B00 x3 or
11938MB-B2N-EA-01 x3
Tab. 8-4: Model MS165/MH180
8
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102
Robot controller specification
9 Robot controller specification
WARNING!
Make sure that there is no one within the P-point maximum envelope of the robot and that you are in a safe place before turning ON the robot controller power.
Injury may result from collision with the robot to anyone entering the P-point maximum envelope of the robot.
• Always set the teach lock before starting teaching.
• Observe the following precautions when performing teaching operations within the Ppoint maximum envelope of the robot:
– View the robot from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always have an escape plan in mind in case the robot comes toward you unexpectedly.
– Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional robot operation can result in injury.
• Before operating the robot, check that the SERVO ON lamp goes out when the emergency stop buttons the programming pendant are pressed.
Injury or damage to machinery may result if the robot cannot be stopped in case of an emergency.
The emergency stop buttons are located on the right of the front door of the robot controller and the programming pendant.
CAUTION!
• Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed.
– Check for problems in robot movement.
– Check for damage to the insulation and sheathing of external wires.
• Always return the programming pendant to its specified position after use.
If the programming pendant is inadvertently left on the robot, fixture, or on the floor, the robot or a tool could collide with it during robot movement, possibly causing injuries or equipment damage.
• Make sure that a system manager stores the key of the mode select switch on the programming pendant. After operation, the key should be removed and stored by the system manager.
Improper or unintended robot operation may result in injury.
Also, the key or the mode select switch may be damaged if the programming pendant is dropped with the key inserted.
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103
Robot controller specification
9.1
Specification list
Controller
Dimension (W x H x D)
Weight
Protection class
Cooling system
Ambient temperature
Relative humidity
Vibration Acceleration
Power supply
Grounding
Noise Level
Digital I/O
800 x 1000 x 600 approx. 180 kg
IP54 (The back fan is IP2X.)
Indirect cooling
0°C to + 45°C (During operation)
-10°C to + 60°C (During transit and storage)
10% to 90% RH (non-condensing)
0.5G or less
3-phase 400/415/440 VAC at 50/60 Hz
Grounding resistance: 0,1 Ω
Less than 62 dB
General signals (standard, max.): 40 inputs and 40 outputs
(Transistor: 32 outputs, Relay: 8 outputs)
Positioning system
Drive unit
Acceleration / Deceleration Software SERVO control
Program memory 200,000 steps, 10,000 instructions and 15.000 PLC steps
Interface
Color
Ethernet
RAL 7024, Graphite Grey, RAL 7026, Granite Grey, RAL
7043, Traffic Grey B
Others
Specific signal (hardware): 25 inputs and 7 outputs
Absolute encoder / serial interface
SERVOPACK for AC SERVO motors
Free from corrosive gas or liquid, or explosive gas.
Free from exposure to water, oil, or dust.
Free from excessive electrical noise (plasma).
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104
Robot controller specification
9.2
Function list
Programming pendant operation
Coordinate
System
• Joint
• Rectangular/Cylindrical
• Tool
Modification of Teaching Points
• User Coordinates
• Adding
Inching Operation
Path Confirmation
• Deleting
• Correcting (Robot axes and external axes respectively can be corrected)
Possible
Speed Adjustment
Timer Setting
Short-cut Function
Interface
• Forward/Reverse step
• Continuous feeding
Fine adjustment possible during operating or pausing
Possible every 0.01 s
Direct-open function, Multi-window
• CF card slot
• USB port (USB1.1) (At Programming Pendant)
Application
• RS-232C, RS-232C/RS-422 (Exclusion use)
• USB port (USB1.1): 2 ports
• LAN (100 BASE-TX/10BASE-T): 2 ports (At CPU circuit board)
• Arc welding
• Spot welding
• Handling
• General
Essential Measures
Running Speed Limit
Enable Switch
• Others
JIS (Japanese Industrial Standard)
User definable
3 position type. SERVO power can be turned on at the middle position only. (Located on programming pendant)
Collision proof Frames S-axis frame (doughnut-sector)
Cubic frame (user coordinate)
Self-Diagnosis Classifies error and two types of alarms (major and minor) and displays the data
User Alarm Display
Machine Lock
Door Interlock
Possible to display alarm messages for peripheral device
Test-run of peripheral devices without robot motion
A door can be opened only when a circuit breaker is OFF.
9
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105
Robot controller specification
Programming pendant operation
Operation Time
Display
• Control power-on time
• SERVO power-on time
Alarm Display
• PLAYBACK time
• Operation time
• Work time
• Alarm message
• Troubleshooting
I/O Diagnosis
T.C.P. Calibration
• Previous alarm records
Simulated enabled/disabled output possible
Automatically calibrates parameters for end effectors using a master positioner
Interactive programming Programming Type
Language
Robot Motion Control
Speed Setting
Robot language: INFORM II
• Joint coordinates
• Linear/Circular interpolations
• Tool coordinates
• Percentage for joint coordinates
• 0.1mm/s units for interpolations
• Angular velocity for T.C.P. fixed motion
Program Control Instructions
I/O Instructions
• Jumps, Calls
• Timer
• Robot stop
• Execution of some instructions during robot motion
Operation Instructions Preparing the operation instructions for each application Arc
(ON), Arc (OFF), etc.
Variable
Variable Type
• Global variable
• Local variable
• Byte type
• Integer type
• Double precision type
• Real type
• Position type
• String type
• Discrete I/O
• Pattern I/O processing
9
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106
Robot controller specification
9.3
Programming Pendant
Type
Material
Dimensions
(W x H x D) in mm
Material
Displayed Units
JZRCR-YPP03-1 or JZRCR-YPP13-1
Reinforced thermoplastic enclosure with a detachable suspending strap
169 x 314.5 x 50 mm (excluding protrusions)
Operated Units
IEC protection class
Cable length
Others
Key sheet
Reinforced plastic
TFT Color liquid crystal display, VGA (640 x 480)
Touch panel
• 3-position enable switch, start switch, hold switch, and mode select switch (with key, three mode)
• Type of the key for the mode select switch: AS6-SK-132
(manufactured by IDEC Corp.)
* Two keys are shipped with the programming pendant.
IP65
Standard: 8 m, Max.: 20 m (optional)
• Provided with CF (Compact Flash) card slot
• USB port (USB1.1) x 1
General (1 sheet only)
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107
Robot controller specification
9.4
Device configuration
The robot controller is comprised of individual units and modules (circuit boards).
Malfunctioning components can generally be easily repaired after a failure by replacing a unit or a module.
This section explains the configuration of the robot controller equipment.
Arrangement of units and circuit boards
BRAKE CONTROL BOARD (-AE5),
BACKSIDE OF AXIS CONTROL BOARD
AXIS CONTROL BOARD (-AE6.0)
EX.AXIS CONTROL BOARD (-AE6.1)OPTION
SAFETY FUNCTIONAL BOARD (-AE6.2)OPTION
MAIN SWITCH (-Q1M)
TERMINAL (-X9)
CIRCUIT BREAKER (-FS1)
CONVERTER UNIT (-TP1)
SERVOPACK (-TA1-TA9) *
-TA7(Option)
-TA8(Option)
-TA9(Option)
-TA4
-TA5
-TA6
-TA1
-TA2
-TA3
MACHINE SAFETY I/O
LOGIC BOARD( -AE4)
POWER ON UNIT (-AE2)
CPS UNIT (-AE3)
CPU UNIT (-AE1)
I/O TERMINAL (-X12A-X13B) OPTION
FUNCTIONAL SAFETY (-X181) OPTION
MACHINE SAFETY TERMINAL
BOARD( -X18)
GENERAL I/O BOARD (-AE7)
FUNCTIONAL SAFETY
I/O BOARD (-AE8) OPTION
DSW 1-2 (-X810) OPTION
OPTION BOARD (-AE9, AE10,-AE11)
Fig. 9-1: Configuration robot controller (master)
BRAKE CONTROL BOARD (-AE5),
BACKSIDE OF AXIS CONTROL BOARD
AXIS CONTROL BOARD (-AE6.0)
EX.AXIS CONTROL BOARD (-AE6.1)OPTION
SAFETY FUNCTIONAL BOARD (-AE6.2)OPTION
SERVOPACK (-TA1-TA9)*
-TA7(Option)
-TA8(Option)
-TA9(Option)
-TA4
-TA5
-TA6
-TA1
-TA2
-TA3
TERMINAL (-X9)
CIRCUIT BREAKER (-FS1)
CONVERTER UNIT (-TP1)
MACHINE SAFETY I/O
LOGIC BOARD( -AE4)
POWER ON UNIT (-AE2)
CPS UNIT (-AE3)
FUNCTIONAL SAFETY (-X181) OPTION
MACHINE SAFETY TERMINAL
BOARD( -X18)
FUNCTIONAL SAFETY
I/O BOARD (-AE8) OPTION
I/O TERMINAL OPTION
OPTION BOARD (-AE9, AE10,-AE11)
Fig. 9-2: Configuration robot controller (slave)
* The SERVOPACK types is different depending on robot model
9
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108
Robot controller specification
Cooling System of the controller interior
The backside duct fan draws in air from the air intake and expels it from the air outlet to cool the SERVOPACK. The fan mounted inside the door circulates the air to keep temperature even throughout the interior of the robot controller. Make sure the door of the robot controller is closed when it’s used to keep this cooling system effective.
-Q1M
-X9
-FS1
-TP1
-AE2
1
Option
-TA9
-TA8
-TA7
-AE6.0
-TA6
-TA5
-TA4
-TA3
-TA2
-TA1
-AE3
-AE1.0
-AE4
-AE7
-X181
Option
-X18
-X81
-G1
FM
4
2
-G2
FM
3
-Q1M
-G3
FM
-G4
FM
5
-G5
FM
-R1-R6
2
-C1
-V1
-T1
-X12A -X12B
-X13A
-X13B Option
3
3
-EP2
1
2
3
Front view
Interior circulation fan
Air outlet
Fig. 9-3: Cooling System
4
5
Door
Back View
9
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109
Recommended spare parts list
10 Recommended spare parts list
It is recommended to keep in stock parts and components in the following table as spare parts to use. Product performance cannot be guaranteed when using spare parts from any company other than YASKAWA.
NOTICE
Please contact your YASKAWA branch office if you need spare or replacement parts.
1
3
2
13
4
5
6
7
8
9
10
12
11
14
15
16
17
18
19
20
1
Brake control board (-AE5), backside of axis control board
2
3
4
Axis control board (-AE6.0)
Ex. axis control board (-AE6.1)
Safety functional board (-AE6.2
5
6
Main switch (-Q1M)
Terminal (-X9)
7
Circuit breaker (-FS1)
11
15
16
17
12
13
14
8
9
10
Converter unit (-TP1)
Power on unit (-AE2)
CPS unit (-AE3)
CPU unit (-AE1)
18
19
I/O Terminal (-X12A-X13B) option
Machine Safety I/O logic board (-AE4)
Functional safety (-X181) option
Machine safety terminal board (-X18)
General I/O board (-AE7)
Functional safety I/O board (-AE8) option
DSW 1-2 (-X810) option
Option board (-AE9, AE10,-AE11)
Tab. 10-1: Unit layout master
10
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110
-TA7
(Option)
-TA8
(Option)
-TA9
(Option)
Recommended spare parts list
-TA4
-TA5
-TA1
-TA2
Fig. 10-1: SERVOPACK (-TA1 to -TA9)
The SERVOPACK types is different depending on robot model
-TA6
-TA3
10
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111
Recommended spare parts list
3 2
1
4
5
6
7
9
8
10
11
12
13
14
15
2
3
4
5
6
1
7
8
Brake control board (-AE5), backside of axis control board
Axis control board (-AE6.0)
Ex. axis control board (-AE6.1)
Safety functional board (-AE6.2
Terminal (-X9)
Circuit breaker (-FS1)
9
10
11
12
13
14
Converter unit (-TP1)
Power on unit (-AE2)
CPS unit (-AE3)
15
I/O Terminal option
Machine Safety I/O logic board (-AE4)
Functional safety (-X181) option
Machine safety terminal board (-X18)
Functional safety I/O board (-AE8) option
Option board (-AE9, AE10,-AE11)
Tab. 10-2: Unit layout slave
10
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112
-TA7
(Option)
-TA8
(Option)
-TA9
(Option)
Recommended spare parts list
-TA4
-TA5
-TA1
-TA2
-TA6
-TA3
Fig. 10-2: SERVOPACK (-TA1 to -TA9)
The SERVOPACK types is different depending on robot model
Spare parts list robot controller for MA1440/MH12
Power supply additional power supply
JZNC-YPS21-E
JZNC-YPS02-E
Rack-circuit board JZNC-YRK21-1E
I/F board JANCD-YIF01-2E
Safety CPU board JANCD-YSF21-E
Safety I/O board
I/O board (PNP type)
JANCD-YSF22-E
JANCD-YIO22-E
Power supply unit JZRCR-YPU52-1
Converter
Capacity module
12A
SERVO package
SRDA-COA30A21B-E
SRDA-CUA662AA
JZRCR-YSV24-111 master
Slave
164754 YEC
E147571 YEC master 164756 YEC master master
E145855 YEC
164757 YEC
Master/Slave 164758 master 164762
YEC
YEC
Master/Slave 164764
Master/Slave 164767
Master/Slave 164781
YEC
YEC
YEC
Master/Slave 164772 YEC
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113
Recommended spare parts list
Spare parts list robot controller for MA1440/MH12
Resistor
Memory card
SMVK500W6R0J A6103 Master/Slave 164775
MCF10P256MS(A00ACIYE) master 151281
YEC
YEC
Spare parts list robot controller for MS165/MH180
Power supply additional power supply
JZNC-YPS21-E
JZNC-YPS02-E
Rack-circuit board JZNC-YRK21-1E
I/F board JANCD-YIF01-2E
Safety CPU board JANCD-YSF21-E
Safety I/O board
I/O board (PNP type)
JANCD-YSF22-E
JANCD-YIO22-E
Power supply unit JZRCR-YPU52-1
Converter SRDA-COA30A21B-E
Capacity module
30A
SRDA-CUA133AA
SERVO package
Resistor
Memory card master
Slave master master master
Master/Slave
Master/Slave
Master/Slave
164754
E147571
164756
E145855
164757
Master/Slave 164758 master 164762
164764
164767
164782
YEC
YEC
YEC
YEC
YEC
YEC
YEC
YEC
YEC
YEC
JZRCR-YSV27-111
SMVK500W2R0J A5978
Master/Slave
MCF10P256MS(A00ACIYE) master
164774
Master/Slave E143574 YEC
151281
YEC
YEC
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114
Recommended spare parts list
Spare parts list robot controller for MS210/MH225
Power supply additional power supply
JZNC-YPS21-E
JZNC-YPS02-E
Rack-circuit board JZNC-YRK21-1E
I/F board
Safety CPU board
Safety I/O board
JANCD-YIF01-2E
JANCD-YSF21-E
JANCD-YSF22-E master
Slave
164754
E147571
YEC
YEC master master
164756 YEC
E145855 YEC master 164757
Master/Slave 164758
YEC
YEC
I/O board (PNP type)
JANCD-YIO22-E
Power supply unit JZRCR-YPU52-1
Converter SRDA-COA30A21B-E
SRDA-CUA133AA Capacity module
30A
SERVO package JZRCR-YSV27-111
Resistor
Memory card master
Master/Slave
Master/Slave
Master/Slave
164762
164764
164767
164782
YEC
YEC
YEC
YEC
Master/Slave 164774 YEC
SMVK500W2R0J A5978 Master/Slave E143574 YEC
MCF10P256MS(A00ACIYE) master 151281 YEC
NOTICE
Product performance cannot be guaranteed when using spare parts from any company other than YASKAWA.
Please contact your YASKAWA branch office if you need spare or replacement parts.
10
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YASKAWA Headquarter
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Key features
Compact and lightweight, making it easy to install and maintain
High speed and precision, ensuring accurate and efficient operation
Built-in safety features to protect operators and equipment
Flexible programming options, allowing for easy customization
Versatile connectivity options, enabling integration with a variety of devices
User-friendly interface, making it easy to operate and maintain
Advanced motion control algorithms, ensuring smooth and precise robot movements
Wide range of supported applications, including welding, assembly, and material handling
Frequently asked questions
The DX200 is not specifically designed for use in harsh or hazardous environments. Please consult the user manual or contact YASKAWA for more information.
The DX200 supports a variety of programming languages, including INFORM, RAPID, and Python.
Yes, the DX200 offers a variety of connectivity options, including EtherNet/IP, PROFINET, and DeviceNet.
