YASKAWA MOTOMAN DX100 User manual

MANUAL NO.
HW1480826
Part Number: 156527-1CD
Revision: 1
DX100 OPTIONS
JARCR-XOI02B BOARD
INSTRUCTIONS
FOR I/O EXPANSION FOR EUROPEAN STANDARDS
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.
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Standard (PNP)
MANDATORY
• This manual explains the JARCR-XOI02B board of the DX100
system and general operations. Read this manual carefully and be
sure to understand its contents before handling the DX100.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instruction before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as “WARNING,”
“CAUTION,” “MANDATORY,” or ”PROHIBITED.”
Even items described as “CAUTION” may result in a serious accident in
some situations. At any rate, be sure to follow these important items.
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
personnelanddamagetoequipment.
It may also be used to alert against
unsafe practices.
MANDATORY
Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED
Must never be performed.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as
“CAUTION” and “WARNING.”
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PROHIBITED
• Do not use or keep the board in the following environmental
conditions.
– Where exposed to direct sunshine
– Where vibration or impact occurs
– Where high humidity exists
– Where a strong magnetic field exists
– Where much dust exists
– Where a sudden change in the temperature occurs
– Where corrosive gases occur
– Where condensation occurs
Improper usage of the board may damage the board.
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WARNING
• 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
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the manipulator
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are 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.
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WARNING
• Do not touch the inside of the panel for 5 minutes after the power is
turned OFF.
The remaining charged voltage in the capacitor may cause an electric
shock or an injury.
• Be sure to close the door and install the protection cover while the
power is turned ON.
Failure to observe this warning may result in a fire or an electric shock.
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CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
Read and understand the Explanation of Warning Labels in the DX100
Instructions before operating the manipulator:
• The wiring and mounting must be performed by authorized and
qualified personnel.
Failure to observe this caution may result in a fire or an electric shock.
• Make sure that there is no foreign matter such as metal chips on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Make sure that there is no damage or deflection of parts on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Correctly connect each cable and connector.
Failure to observe this caution may result in a fire or damage the board.
• Set the switches, etc. correctly.
Malfunction, caused by an incorrect setting, may result in an injury or
damage the board.
• Never touch the mounting surfaces of the board parts directly with
fingers.
The generated static electricity may damage the IC.
• Never touch the soldered surfaces of the board directly with fingers.
Protrusions on the soldered surface may result in an injury.
• No shock to the board.
The shock may damage the board.
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Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows.
Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
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.
Equipment Manual Designation
DX100 Controller DX100
DX100 Programming Pendant Programming Pendant
Cable between the manipulator and the
controller Manipulator cable
JARCR-XOI02B board XOI02B board
Equipment Manual Designation
Programming
Pendant Character Keys The keys which have characters printed on them are denoted with [ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on
them are not denoted with [ ] but depicted
with a small picture.
ex. page key
The cursor key is an exception, and a picture
is not shown.
Axis Keys
Numeric Keys “Axis Keys” and “Numeric Keys” are generic names for the keys for axis operation and
number input.
Keys pressed
simultaneously When two keys are to be pressed simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
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Standard (PNP) Table of Contents
Table of Contents
1 Outline
1.1 System Configuration Example ...........................................................................................1-1
2 Hardware Specifications
2.1 Board External View............................................................................................................2-1
2.2 Board Specifications............................................................................................................2-1
2.3 User Input/Output Connectors.............................................................................................2-2
3 Setting the Functions
3.1 Function Setting Switches ...................................................................................................3-1
3.2 Setting Method............................................................................................ 3-2
4 Mounting the XOI02B Board
4.1 Opening Front Door of the DX100.......................................................................................4-2
4.2 Confirming the Switch Settings on the XOI02B Board.........................................................4-2
4.3 Mounting the XOI02B Board on the DX100.........................................................................4-2
4.4 Connecting Each Cable.......................................................................................................4-3
4.5 Closing the Front Door of the DX100...................................................................................4-4
5 I/O Signal Allocation
5.1 I/O Module Setting...............................................................................................................5-1
5.2 I/O Data ...............................................................................................................................5-5
6 I/O Circuits
6.1 Input Circuit..........................................................................................................................6-1
6.1.1 Input Circuit 1 (CN10 to CN13)...............................................................................6-1
6.2 Output Circuits.....................................................................................................................6-2
6.2.1 Output Circuit 1 CN12 and CN13 (Transistor Output)..........................................6-2
6.2.2 Output Circuit 2 CN10 and CN11 (Relay Output).................................................6-3
6.3 Connection Example............................................................................................................6-4
6.3.1 Handling Application...............................................................................................6-5
6.3.2 Arc Welding, Spot Welding, and General-Purpose Applications............................6-9
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1 Outline
1.1 System Configuration Example
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1 Outline
This instruction manual describes the I/O expansion board, the XOI02B.
The XOI02B board can be used to expand the number of I/O points when
more DX100 I/O points are needed.
1.1 System Configuration Example
SW
LED
SW
RY
JARCR-XOI02B board
DX100
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2-1
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Standard (PNP) 2 Hardware Specifications
2.1 Board External View
2 Hardware Specifications
2.1 Board External View
2.2 Board Specifications
FUSE1
FUSE1 and FUSE2: Fuse 3.15 A 250 V
2183.15 (Littelfuse)
JP1: Communication
speed setting switch
JP2: I/O Communication
mode setting switch
CN02
CN01
S1
FUSE2
CN10
CN11
CN12
CN13
JARCR-
REV.
XOI02B
CN02
CN10 CN11
CN12 CN13
CN01
S1
24 VDC power supply connectors
User input/output connectors
User input/output connectors
Station setting switch
I/O data transmission connectors
Items Specifications
Board mounting
position Optional board mounting space in the DX100
Number of I/O
points Input: 40 points Output: 40 points (PNP transistor output 24 points,
relay output 16 points)
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2 Hardware Specifications
2.3 User Input/Output Connectors
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2.3 User Input/Output Connectors
B20
A20
B1
A1
B20
A20
B1
A1
(MT Type)
CN306,307,308,309
+24VU +24VU +24VU +24VU
+24VU +24VU +24VU +24VU
FG+24VU+24VU
+24VU
+24VU
024VU
024VU
024VU
024VU
024VU
024VU
024VU 024VU
024VU024VU B1 B2 B3 B4 B5 B6 024VU B8 B9 B10 B11 B12 B13 B14 B15
A15A14A13A12A11A10A9A8
024VU A6A5A4A3A2A1
TIFS553YS 21-187-3201 R
Connector C detail (cable side)
Connector A
I/O Cable (XOI ~ external)
Connector C
I/O Cable (YIU ~ Terminal Block)
Connector B
Connector B details
Connector Model: 1747053-1
(Tyco Electronics Amp)
I/O Terminal Block
Stripped length: 10mm
Applicable max cable outside diameter: 3mm dia.
Model: TIFS553YS (KASUGA ELECTRIC)
Connector Model: 1903404-1
(Tyco Electronics Amp)
(XOI02B board)
CN12 CN13
CN10 CN11
I/O expansion board
B20
A20
B1
A1
Connector A detail (cable side)
Connector Model: FCN-361J040-AU (FUJITSU)
(Soldered Pin type)
Hood Model: FCN-360C040-B (FUJITSU)
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3-1
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Standard (PNP) 3 Setting the Functions
3.1 Function Setting Switches
3 Setting the Functions
3.1 Function Setting Switches
The section explains the switches that set the functions of the XOI02B
board. Make the proper settings following the instructions. For details of
the settings, refer to page 3-2.
S1: Sets the stations for the XOI02B board on the DX100.
The setting range for a station is 1 (ST#01) to D (ST#13).
Do not set the station to 0 (ST#00), E (ST#14), or F (ST#15).
JP1: Sets the communication speed.
This switch sets the communication speed to 4 Mbps or 10 Mbps.
Be sure to set this switch to 4 Mbps.
Do not set it to 10 Mbps.
If the number of I/O points on the XOI02B board does not appear
on the Programming Pendant, check if the communication cable
or power cable is connected correctly, referring to the I/O module
setting in Chapter 5 "I/O Signal Allocation" on page 5-1. When the
cables are correctly connected, the JP1 may be set to 10 Mbps.
Change the setting to 4 Mbps.
JP2: Sets the communication mode.
This switch sets the communication mode to 16 bytes, 17 bytes, or
32 bytes.
Be sure to set this switch to 17 bytes.
Do not set it to 16 bytes and 32 bytes.
If the number of I/O points on the XOI02B board does not appear
on the Programming Pendant, check if the communication cable
or power cable is connected correctly, referring to the I/O module
setting in Chapter 5 "I/O Signal Allocation" on page 5-1. When the
cables are correctly connected, the JP2 may be set to 16 bytes or
32 bytes.
Change the setting to 17 bytes.
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3 Setting the Functions
3.2 Setting Method
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3.2 Setting Method
Switches Setting Method
S1
Station setting
Sets the stations.
The relation between the switch setting and the station is shown below.
Turn the arrow to the number corresponding to the desired station.
(Use a flat tip screwdriver.)
0: Cannot be set 8: ST#08
1: ST#01 9: ST#09
2: ST#02 A: ST#10
3: ST#03 (Default setting) B: ST#11
4: ST#04 C: ST#12
5: ST#05 D: ST#13
6: ST#06 E: Can not be set
7: ST#07 F: Can not be set
The number after ST# is the station number displayed on the programming pendent of
the DX100 when setting I/O modules.
The default setting is ST#03.
JP1
Setting of the
communication speed
Short circuit between 1 and 2: 10 Mbps
*Setting unavailable
Short circuit between 2 and 3: 4 Mbps
(Default setting)
*Setting indispensable
JP2
Setting of the I/O
communication mode
Short circuit between 1 and 2, 5 and 6: 16 byte mode
*Setting unavailable
Short circuit between 3 and 4, 7 and 8: 17 byte mode
(Default setting)
*Setting indispensable
Short circuit between 1 and 2, 3 and 4: 32 byte mode
*Setting unavailable
JP1
10M
4M
3
1
JP1
10M
4M
3
1
32B
17B 16B
JP2
12
78
32B
17B 16B
JP2
12
78
32B
17B 16B
JP2
12
78
NOTE
Do not set S1 to 0, E or F. Do not set more than one board
to one ST#.
Improper settings may prevent the I/O module from being
recognized correctly.
Also, do not set JP1 to 10 Mbps and do not set JP2 to
16 bytes or 32 bytes.
If 10 Mbps, 16 bytes, and 32 bytes are selected, the I/O
module is not recognized.
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Standard (PNP) 4 Mounting the XOI02B Board
4 Mounting the XOI02B Board
WARNING
• Before wiring, be sure to turn OFF the power supply and put up a
warning sign, such as “DO NOT TURN ON THE POWER.”
Failure to observe this warning may result in an electric shock or an
injury.
• Do not touch the inside of the panel for 5 minutes after the power is
turned OFF.
The remaining charged voltage in the capacitor may cause an electric
shock or an injury.
• Be sure to close the door and install the protection cover while the
power is turned ON.
Failure to observe this warning may result in a fire or an electric shock.
CAUTION
• The wiring and mounting must be performed by authorized and
qualified personnel.
Failure to observe this caution may result in a fire or an electric shock.
• Make sure that there is no foreign matter such as metal chips on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Make sure that there is no damage or deflection of parts on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Correctly connect each cable and connector.
Failure to observe this caution may result in a fire or damage the board.
• Set the switches, etc. correctly.
Malfunction, caused by an incorrect setting, may result in an injury or
damage the board.
• Never touch the mounting surfaces of the board parts directly with
fingers.
The generated static electricity may damage the IC.
• Never touch the soldered surfaces of the board directly with fingers.
Protrusions on the soldered surface may result in an injury.
• No shock to the board.
The shock may damage the board.
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4 Mounting the XOI02B Board
4.1 Opening Front Door of the DX100
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4.1 Opening Front Door of the DX100
Mount the XOI02B board in the following manner.
1. Turn the two door locks on the front face of the DX100 clockwise for
90° with a coin or a flat tip screwdriver.
2. With the door locks turned clockwise for 90°, turn the main switch
handle to the “OFF” position, and slowly open the door.
4.2 Confirming the Switch Settings on the XOI02B Board
1. Be sure that the settings of switches on the board are correct.
2. For the switch settings, refer to Chapter 3 "Setting the Functions" on
page 3-1.
4.3 Mounting the XOI02B Board on the DX100
1. Be sure that the main power supply is OFF.
2. Fix the XOI02B board on the DX100 with the board fixing screws
securely tightened.
Clockwise
Flat tip screwdriver
Door lock
ON
O
OFF
RESET
TRIPPED
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Standard (PNP) 4 Mounting the XOI02B Board
4.4 Connecting Each Cable
4.4 Connecting Each Cable
1. Connect the 24 VDC power supply cable to the CN02 on the XOI02B
board.
2. Connect the I/O communication cable to the CN01 on the XOI02B
board. Disconnect the terminal connector from CN0303 (right) on the
JZNC-YIU02 unit, and connect it to the non-occupied CN01 on the
XOI02B board.
3. Connect the I/O cables to the CN10 through CN13 on the XOI02B
board.
24VDC power cable
I/O communication cable
CN304
CN300(right)
I/O cable 1
I/O cable 3
I/O cable 2
I/O cable 4
CN02(top)
CN01(left)
Terminal
connector
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4 Mounting the XOI02B Board
4.5 Closing the Front Door of the DX100
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4.5 Closing the Front Door of the DX100
1. Close the door slowly.
2. Turn the two door locks counterclockwise for 90° using a coin or a flat
tip screwdriver.
NOTE
A dummy connector is inserted into the CN02 of the 24 VDC power supply connector on
the XOI02B board.
Do not remove this connector because it is inserted to prevent incorrect cable
connections. Removing this connector may result in incorrect connection of the 24 VDC
power cable to the CN02. This prevents power from being supplied normally to the
board, and the board may not start up.
Dummy connector
CN02
24V
24VU
24V
24VU
Not used
Not used
CN02
24VDC
power cable 24VDC
power cable 24VDC
power cable
CN02
* Do not remove the dummy connector inserted in this position.
Correct Connecting
Position Incorrect Connecting Position
* Because the dummy connector is removed,
the 24VDC power cable is incorrectly connected,
and power cannot be supplied to the board.
CN02
Counter clockwise
Door lock
Flat tip screwdriver
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Standard (PNP) 5 I/O Signal Allocation
5.1 I/O Module Setting
5 I/O Signal Allocation
5.1 I/O Module Setting
In order to use a XOI02B board on the DX100, perform the I/O module
setting in the following manner.
Make sure that the power supply to the DX100 is OFF. Then, mount the
XOI02B board, for which all of its switches have been set, inside the
DX100. For the board mounting method, refer to Chapter 4 "Mounting the
XOI02B Board" on page 4-1.
1. Turn the power supply ON again while pressing [MAIN MENU]
simultaneously.
– The main menu appears.
2. Select {SYSTEM} under the main menu.
– The sub menu appears.
3. Change the security mode to management mode.
SUPPLE-
MENT
Add an I/O module in the management mode.
In the operation mode and the editing mode, the settings are
for reference only.
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5 I/O Signal Allocation
5.1 I/O Module Setting
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4. Select {SETUP}.
– The SETUP window appears.
5. Select {IO MODULE}.
– The current mounted status of the I/O modules is shown as in the
following example.
– To view the current mounted status of the I/O modules for stations
that are not displayed, press [ENTER].
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