YASKAWA Motoman DX200 User manual

Part Number: 182582-1CD
Revision: 0
MOTOMAN-MH900,
DX200 CONTROLLER
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MH900: INSTRUCTIONS
DX200 CONTROLLER FOR THE MH900: INSTRUCTIONS
DX200 CONTROLLER FOR THE MH900: MAINTENANCE
DX200 CONTROLLER (for each purpose): OPERATOR’S
The DX200 CONTROLLER operator’s manual above corresponds to a specific usage. Be sure to use the appropriate
manual.
TYPE:
YR-MH00900-A00 (
STANDARD SPECIFICATION)
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Copyright © 2018, Yaskawa America, Inc.
Terms of Use and Copyright Notice
All rights reserved. This manual is freely available as a service to
Yaskawa customers to assist in the operation of Motoman robots, related
equipment and software This manual is copyrighted property of Yaskawa
and may not be sold or redistributed in any way. You are welcome to copy
this document to your computer or mobile device for easy access but you
may not copy the PDF files to another website, blog, cloud storage site or
any other means of storing or distributing online content.
Printed in the United States of America
First Printing, 2018
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com
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Safety
Summary of Warning Information
MH900, DX200 Controller
Summary of Warning Information
This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notice.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by Yaskawa. Address any questions regarding the safe and proper
operation of the equipment to Yaskawa Customer Support.
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the MH900, DX200 Controller.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
DANGER
Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury. Safety Signs
identified by the signal word DANGER
should be used sparingly and only for
those situations presenting the most
serious hazards.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, will result in death or
serious injury. Hazards identified by the
signal word WARNING present a lesser
degree of risk of injury or death than those
identified by the signal word DANGER.
Indicates a hazardous situation, which if
not avoided, could result in minor or
moderate injury. It may also be used
without the safety alert symbol as an
alternative to “NOTICE”.
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as
“DANGER”, “WARNING” and “CAUTION”.
Safety
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Safety
Notes for Safe Operation
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Make sure to follow these important items
WARNING
• This manual explains setup, diagnosis, maintenance, hardware,
etc. of the MH900, DX200 Controller. Read this manual carefully
and be sure to understand its contents before handling the MH900,
DX200 Controller.
• General information related to safety are described in Chapter 1.
“Safety”. To ensure correct and safe operation, carefully read
Chapter 1. “Safety” of these instructions.
Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
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Safety
Notes for Safe Operation
MH900, DX200 Controller
WARNING
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the controller 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 button is
located on the right of the programming pendant.
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop buttons on the programming
pendant is pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop button does not function.
Fig. : Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which can interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
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Notes for Safe Operation
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WARNING
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury. For
disassembly or repair, contact a Yaskawa representative.
• Read and understand the Explanation of Warning Labels in the
DX200 Instructions before operating the manipulator.
• In some drawings in this manual, protective covers or shields are
removed to show details. Make sure that all the covers or shields
are installed in place 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 is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids the
product warranty.
• 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 with 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 DX200 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
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Safety
Notes for Safe Operation
MH900, DX200 Controller
• 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.
• To ensure safe and efficient operation at all times, be
sure to follow all instructions, even if not designated as
“DANGER”, “WARNING” or “CAUTION”.
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Safety
Explanation of Warning Labels
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MH900, DX200 Controller
Explanation of Warning Labels
The following warning labels are attached to the controller.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the controller. Prior to operating the controller, confirm the
contents.
Fig. : Warning Label Locations
WARNING
WARNING
HIGH VOLTAGE
DO NOT OPEN DOOR
WITH POWER ON
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
ENSURE DOOR LATCHES
WARNING
HIGH VOLTAGE
DO NOT OPEN DOOR
WITH POWER ON
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
ENSURE DOOR LATCHES ARE SECURELYLOCKED
Arc Flash Hazard
Appropriate PPE Required
Donot operate controls or open covers without
appropriatepersonal protectoin equipment.
Failureto comply may result in injury or death!.
WARNING
HIGH VOLTAGE
DO NOT OPEN DOOR
WITH POWER ON
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
ENSURE DOOR LATCHES
ARE SECURELY LOCKED
WARNING
HIGH VOLTAGE
DO NOT OPEN DOOR
WITH POWER ON
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
ENSURE DOOR LATCHES
ARE SECURELY LOCKED
WARNING
Arc Flash Hazard
Appropriate PPE Required
Do not operate controls or open covers without
appropriate personal protectoin equipment.
Failure to comply may result in injury or death!.
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Safety
Programming, Operation, and Maintenance Safety
MH900, DX200 Controller
Programming, Operation, and Maintenance Safety
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the
operation of this equipment.
Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this equipment
should be permitted to program, or maintain the system. All personnel
involved with the operation of the equipment must understand potential
dangers of operation.
• Inspect the equipment to be sure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil,
debris, etc.
• Be sure that all safeguards are in place. Check all safety
equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Check the E-Stop button at the operator station for proper
operation before programming. The equipment must be in
Emergency Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before
program changes are made. To avoid loss of information,
programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to
options, accessories, or equipment.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot. Do not make any
modifications to the controller unit. Making any changes without
the written permission from Yaskawa will void the warranty.
• Some operations require standard passwords and some require
special passwords.
• The equipment allows modifications to the software for maximum
performance. Care must be taken when making modifications. All
modifications made to the software will change the way the
equipment operates and can cause severe personal injury or
death, as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of
the equipment.
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Safety
Safeguarding Tips
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MH900, DX200 Controller
Safeguarding Tips
Mechanical Safety Devices
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the
operation of this equipment. All personnel involved with the operation of
the equipment must understand potential dangers of operation.
General safeguarding tips are as follows:
Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this
equipment, the operator's manuals, the system equipment, and options
and accessories should be permitted to operate this equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources
of Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
The safe operation of this equipment is ultimately the users
responsibility. The conditions under which the equipment will be
operated safely should be reviewed by the user. The user must be
aware of the various national codes, ANSI/RIA R15.06-2012 safety
standards, and other local codes that may pertain to the installation and
use of this equipment.
Additional safety measures for personnel and equipment may be
required depending on system installation, operation, and/or location.
The following safety equipment is provided as standard:
Additional safety measures for personnel and equipment may be
required depending on system installation, operation, and/or location.
The following safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
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Safety
Maintenance Safety
MH900, DX200 Controller
Maintenance Safety
National Safety Standard
We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: [phone]
FAX: [phone]
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment.
NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM,
OR REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
WARNING
Turn the power OFF, disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Perform only the maintenance described in this manual.
Maintenance other than specified in this manual should be
performed only by Yaskawa-trained, qualified personnel.
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Safety
Definition of Terms Used Often in This Manual
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Definition of Terms Used Often in This Manual
The Yaskawa Motoman MH900, DX200 Controller is a Yaskawa industrial
robot product.
A Motoman usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows:
Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or bland names for each company or
corporation. The indications of (R) and TM are omitted.
Equipment Manual Designation
DX200 controller DX200
DX200 programming pendant Programming pendant
Cable between the manipulator and the
controller
Manipulator cable
HC10 manipulator Manipulator
Equipment Manual Designation
Programming
Pendant
Character
Keys
Symbol
Keys
The keys which have characters or symbols
printed on them are denoted with [ ].
ex. [ENTER]
Axis Keys
Number Keys
[Axis Keys] and [Number Keys] are generic
names for the keys for axis operation and
number input.
Keys pressed
simultaneously
When two keys are to be pressed
simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
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Safety
Customer Support Information
MH900, DX200 Controller
Customer Support Information
If assistance is needed with any aspect of the MH900, DX200 Controller
system, please contact your local Yaskawa Customer Support (see back
cover for details.)
When contacting Yaskawa Customer Support please have the following
information:
• System: MH900, DX200 Controller
• Primary Application:
• Software Version:
Located on programming pendant
by selecting {Main Menu} -
{System Info} - {Version}
• Robot Serial Number:
(Located on robot data plate)
• Robot Sales Order Number:
(Located on controller data plate)
WARNING
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact your Yaskawa representative.
• Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
Use e-mail for routine inquiries only. If there is an urgent or
emergency need for service, replacement parts, or
information, contact Yaskawa Customer Support.
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Table of Contents
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1 Safety..............................................................................................................................................1-1
1.1 For Your Safety..................................................................................................................1-1
1.2 Special Training .................................................................................................................1-2
1.3 Motoman Manual List.........................................................................................................1-3
1.4 Personnel Safety................................................................................................................1-4
1.5 Motoman Safety.................................................................................................................1-6
1.5.1 Installation and Wiring Safety ...............................................................................1-6
1.5.2 Work Area Safety................................................................................................1-10
1.5.3 Operation Safety.................................................................................................1-11
1.6 Notes for Moving and Transferring the Motoman ............................................................1-14
1.7 Notes on Motoman Disposal............................................................................................1-14
2 Product Confirmation ......................................................................................................................2-1
2.1 Contents Confirmation .......................................................................................................2-1
2.2 Order Number Confirmation...............................................................................................2-2
3 Installation.......................................................................................................................................3-1
3.1 Handling Procedure ...........................................................................................................3-1
3.1.1 Using a Crane to Move the Controller ..................................................................3-1
3.1.2 Using a Forklift to Move the Controller .................................................................3-2
3.2 Place of Installation............................................................................................................3-3
3.3 Location .............................................................................................................................3-4
3.4 Mounting the Controller......................................................................................................3-5
4 Connection......................................................................................................................................4-1
4.1 Notes on Cable Junctions..................................................................................................4-2
4.2 Power Supply.....................................................................................................................4-3
4.2.1 Three-Phase Power Supply..................................................................................4-3
4.2.2 Noise Filter Installation .........................................................................................4-3
4.2.3 Leakage Breaker Installation ................................................................................4-4
4.2.4 Primary Power Supply Breaker Installation ..........................................................4-5
4.3 Connection Methods..........................................................................................................4-6
4.3.1 Connecting the Primary Power Supply .................................................................4-6
4.3.2 Connecting the Manipulator Cable .....................................................................4-11
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4.3.3 Connection to the Manipulator............................................................................ 4-13
4.3.4 Connection to the Controller............................................................................... 4-14
4.3.5 Connecting the Programming Pendant ............................................................. 4-15
4.3.6 User I/O Cable Connection................................................................................. 4-16
5 Turning ON and OFF the Power Supply ......................................................................................... 5-1
5.1 Turning ON the Main Power Supply .................................................................................. 5-1
5.1.1 Initial Diagnosis .................................................................................................... 5-2
5.1.2 When Initial Diagnoses are Complete .................................................................. 5-2
5.2 Turning ON the Servo Power............................................................................................. 5-3
5.2.1 During Play Mode ................................................................................................. 5-3
5.2.2 During Teach Mode .............................................................................................. 5-3
5.3 Turning OFF the Power Supply ......................................................................................... 5-5
5.3.1 Turning OFF the Servo Power (Emergency Stop)................................................ 5-5
5.3.2 Turning OFF Main Power ..................................................................................... 5-5
5.3.3 Stopping Manipulator Operation........................................................................... 5-6
6 Testing Program Operation............................................................................................................. 6-1
6.1 Preparation for Startup Checklist....................................................................................... 6-3
6.2 Troubleshooting at Startup ................................................................................................ 6-4
6.3 Movement of the Axes ....................................................................................................... 6-5
6.4 Manual Brake Release Function........................................................................................ 6-6
7 Security System .............................................................................................................................. 7-1
7.1 Protection Through Security Mode Settings ...................................................................... 7-1
7.1.1 Security Mode....................................................................................................... 7-1
7.1.1.1 User ID .................................................................................................... 7-1
7.1.1.2 Menus...................................................................................................... 7-2
7.1.1.3 Changing the Security Mode ................................................................... 7-6
7.1.2 User ID ................................................................................................................. 7-8
7.1.2.1 Changing User ID.................................................................................... 7-9
8 System Setup.................................................................................................................................. 8-1
8.1 Home Position Calibration ................................................................................................. 8-2
8.1.1 Home Position Calibration .................................................................................... 8-4
8.1.2 Calibrating Operation............................................................................................ 8-5
8.1.2.1 Registering All Axes at One Time ........................................................... 8-5
8.1.2.2 Registering Individual Axes ..................................................................... 8-8
8.1.2.3 Changing the Absolute Data ................................................................... 8-9
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8.1.2.4 Clearing ABSOLUTE DATA ..................................................................8-10
8.1.3 Home Position of the Robot................................................................................8-11
8.2 Setting the Second Home Position (Check Point) ...........................................................8-12
8.2.1 Purpose of Position Check Operation.................................................................8-14
8.2.2 Procedure for the Second Home Position Setting (Check Point) .......................8-16
8.2.3 Procedure after the Alarm...................................................................................8-18
8.3 Tool Data Setting .............................................................................................................8-20
8.3.1 Registering Tool Files .........................................................................................8-20
8.3.1.1 Number of Tool Files .............................................................................8-20
8.3.1.2 Registering Coordinate Data .................................................................8-20
8.3.1.3 Registering Tool Angle ..........................................................................8-22
8.3.1.4 Setting the Tool Load Information .........................................................8-24
8.3.2 Tool Calibration...................................................................................................8-24
8.3.2.1 Tool Calibration .....................................................................................8-24
8.3.2.2 Setting of Tool Calibration Method ........................................................8-25
8.3.2.3 Teaching of Calibration Point ................................................................8-26
8.3.2.4 Clearing Calibration Data ......................................................................8-30
8.3.2.5 Checking the TCP .................................................................................8-32
8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity.................8-33
8.3.3.1 What is the Automatic Measurement of the Tool Load and the Center of
Gravity? .................................................................................................8-33
8.3.3.2 Measurement of the Tool Load and the Center of Gravity ....................8-34
8.4 ARM Control ....................................................................................................................8-38
8.4.1 ARM Control .......................................................................................................8-38
8.4.2 ARM CONTROL Window ...................................................................................8-38
8.4.2.1 Robot Setup Condition ..........................................................................8-38
8.4.3 Tool Load Information Setting.............................................................................8-43
8.4.3.1 Tool Load Information............................................................................8-43
8.4.3.2 How to Calculate Tool Load Information ...............................................8-44
8.4.3.3 Tool Load Information Registering ........................................................8-50
8.5 Work Home Position ........................................................................................................8-53
8.5.1 What is the Work Home Position? ......................................................................8-53
8.5.2 Setting Work Home Position...............................................................................8-53
8.5.2.1 Work Home Position Window ................................................................8-53
8.5.2.2 Registering/Changing the Work Home Position ....................................8-54
8.5.2.3 Returning to the Work Home Position ...................................................8-55
8.5.2.4 Output of the Work Home Position Signal .............................................8-56
8.6 Interference Area .............................................................................................................8-57
8.6.1 Interference Area................................................................................................8-57
8.6.2 Cubic Interference Area......................................................................................8-57
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8.6.2.1 Cubic Interference Area ........................................................................ 8-57
8.6.2.2 Cube Setting Method............................................................................. 8-57
8.6.2.3 Setting Operation .................................................................................. 8-59
8.6.3 Axis Interference Area ........................................................................................ 8-69
8.6.3.1 Axis Interference Area........................................................................... 8-69
8.6.3.2 Setting Operation .................................................................................. 8-69
8.6.4 Clearing the Interference Area Data................................................................... 8-77
8.7 Shock Detection Function................................................................................................ 8-79
8.7.1 Shock Detection Function................................................................................... 8-79
8.7.2 Shock Detection Function Setting ...................................................................... 8-79
8.7.2.1 Shock Detection Level Setting .............................................................. 8-79
8.7.2.2 EACH AXIS LEVEL (CURRENT) Window ............................................ 8-84
8.7.2.3 Tool Load Information Setting ............................................................... 8-85
8.7.2.4 U-Arm Payload Setting.......................................................................... 8-85
8.7.2.5 Instruction of Shock Detection Function................................................ 8-85
8.7.2.6 Resetting the Shock Detected............................................................... 8-93
8.7.3 High-Sensitivity Shock Detection Function (For Arc Welding Application Only). 8-94
8.7.3.1 Manipulator Type for High-Sensitivity Shock Detection Function.......... 8-94
8.7.3.2 Setting for High-Sensitivity Shock Detection Function .......................... 8-94
8.7.3.3 Reading the Tool Load Information on
the MAKER INITIAL VALUE Window.................................................... 8-95
8.7.3.4 Explanation of Maker Initial Value ......................................................... 8-97
8.7.3.5 Reading the U-Arm Payload.................................................................. 8-98
8.7.3.6 Explanation of Maker Initial Value ....................................................... 8-101
8.8 User Coordinate Setting ................................................................................................ 8-103
8.8.1 User Coordinates.............................................................................................. 8-103
8.8.2 User Coordinate Setting ................................................................................... 8-104
8.8.2.1 Selecting the User Coordinate File...................................................... 8-104
8.8.2.2 Teaching the User Coordinates........................................................... 8-105
8.8.2.3 Clearing the User Coordinates ............................................................ 8-107
8.9 Overrun/Tool Shock Sensor Releasing ......................................................................... 8-108
8.10 Soft Limit Release Function......................................................................................... 8-110
8.11 All Limit Release Function ........................................................................................... 8-111
8.12 Instruction Level Setting .............................................................................................. 8-113
8.12.1 Setting Contents ............................................................................................. 8-113
8.12.1.1 Instruction Set ................................................................................... 8-113
8.12.1.2 Learning Function.............................................................................. 8-114
8.12.2 Setting the Instruction Set Level..................................................................... 8-114
8.12.3 Setting the Learning Function......................................................................... 8-116
8.13 Setting the Controller Clock ......................................................................................... 8-117
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8.14 Setting the Play Speed ................................................................................................ 8-118
8.15 Numeric Key Customize Function................................................................................8-120
8.15.1 What is the Numeric Key Customize Function? .............................................8-120
8.15.2 Allocatable Functions......................................................................................8-120
8.15.2.1 Key Allocation (EACH) ......................................................................8-120
8.15.2.2 Key Allocation (SIM) ..........................................................................8-121
8.15.2.3 Allocation Window .............................................................................8-121
8.15.2.4 Instruction Allocation .........................................................................8-122
8.15.2.5 Job Call Allocation .............................................................................8-123
8.15.2.6 Display Allocation ..............................................................................8-124
8.15.2.7 Alternate Output Allocation................................................................8-125
8.15.2.8 Momentary Output Allocation ............................................................8-126
8.15.2.9 Pulse Output Allocation .....................................................................8-127
8.15.2.10 Group (4-bit/8-bit) Output Allocation................................................8-128
8.15.2.11 Analog Output Allocation .................................................................8-129
8.15.2.12 Analog Incremental Output Allocation .............................................8-130
8.15.3 Allocation of I/O Control Instructions ..............................................................8-131
8.15.4 Execution of Allocation ...................................................................................8-132
8.15.4.1 Executing the Instruction/Output Control Allocation ..........................8-132
8.15.4.2 Executing the Job Call Allocation ......................................................8-132
8.15.4.3 Executing the Display Allocation .......................................................8-132
8.15.4.4 Executing the I/O Control Allocation..................................................8-133
8.16 Changing the Output Status.........................................................................................8-134
8.17 Changing the Parameter Setting..................................................................................8-136
8.18 File Initialization ...........................................................................................................8-139
8.18.1 Initializing Job File ..........................................................................................8-139
8.18.2 Initializing Data File.........................................................................................8-140
8.18.3 Initializing Parameter File ...............................................................................8-142
8.18.4 Initializing I/O Data..........................................................................................8-144
8.18.5 Initializing System Data ..................................................................................8-146
8.19 Display Setting Function ..............................................................................................8-148
8.19.1 Font Size Setting ............................................................................................ 8-148
8.19.1.1 Applicable Range for the Font Size Change .....................................8-148
8.19.1.2 Settable Font Size .............................................................................8-148
8.19.1.3 Setting the Font Size .........................................................................8-149
8.19.2 Operation Button Size Setting ........................................................................8-152
8.19.2.1 Applicable Range for the Button Size Change ..................................8-152
8.19.2.2 Settable Button Size ..........................................................................8-152
8.19.2.3 Setting the Button Size ......................................................................8-153
8.19.3 Initialization of Screen Layout.........................................................................8-157
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8.19.3.1 Initializing the Screen Layout ............................................................ 8-157
8.19.4 Layout Storage ............................................................................................... 8-159
8.20 Encoder Back-up Error Recovery Function ................................................................. 8-160
8.20.1 About Encoder Back-up Error Recovery Function.......................................... 8-160
8.20.2 Encoder Back-up Error Recovery Function Operation ................................... 8-160
8.21 Preventive Maintenance Function ............................................................................... 8-163
8.21.1 Preventive Maintenance Function .................................................................. 8-163
8.21.2 Preventive Maintenance Function for the Speed Reducer ............................. 8-163
8.21.2.1 Diagnose by the Lifetime Calculation ................................................ 8-163
8.21.2.2 Diagnose by the Torque Average Value ........................................... 8-167
8.21.2.3 After Replacement of the Speed Reducer......................................... 8-177
8.21.3 Inspection Notice Function ............................................................................. 8-179
8.21.3.1 Inspection Signal ............................................................................... 8-179
8.21.3.2 The Inspection Notice Window.......................................................... 8-180
8.21.4 Record of the Inspection Day ෬ the Replacement Day ................................... 8-181
8.21.5 Management of the Data ................................................................................ 8-182
8.21.6 Preventive Maintenance for the Hardware ..................................................... 8-184
8.21.6.1 Target Components for Diagnosis..................................................... 8-184
8.21.6.2 Replacement Time Display ............................................................... 8-184
8.21.6.3 Replacement of Component.............................................................. 8-185
8.21.7 Setting of Preventive Maintenance for the Hardware ..................................... 8-186
8.21.7.1 Setting of Replacement Time Display ............................................... 8-186
8.21.7.2 Mask of Replacement Time Display (Signal Display)........................ 8-190
8.21.8 Display of the Numbers of Motor Revolution and Reverse Revolution........... 8-192
8.21.8.1 Display of the Numbers of Revolution and Reverse Revolution........ 8-192
8.21.8.2 Percent Display of the Number of Motor Revolution ......................... 8-192
8.21.8.3 Resetting the Number of Revolution ................................................. 8-193
8.21.8.4 Changing the Numbers of Revolution and Reverse Revolution ........ 8-193
8.22 Break Line Ground Judgment Function ....................................................................... 8-195
8.22.1 About the break Line Ground Judgment Function.......................................... 8-195
8.22.2 Operating Condition........................................................................................ 8-195
8.22.3 Operation........................................................................................................ 8-196
8.22.3.1 Arising the DC 24V Power Supply Failure (SERVO)......................... 8-196
8.22.3.2 Break Line Ground Check ................................................................. 8-196
8.22.3.3 Initializing the Related Information .................................................... 8-198
8.23 Safety Logic Circuit...................................................................................................... 8-200
8.23.1 Outline ............................................................................................................ 8-200
8.23.2 Set up the Safety Logic Circuit ....................................................................... 8-201
8.23.2.1 Changing the Security Mode ............................................................. 8-201
8.23.2.2 Allocating the Machine Safety Signal ............................................... 8-203
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8.23.2.3 Allocating the Safety Signal Board ....................................................8-206
8.23.2.4 Timer Delay .......................................................................................8-209
8.23.2.5 Safety Logic Circuit............................................................................8-213
8.23.3 Performing the Safety Logic Circuit ................................................................8-226
8.23.4 The Safety Logic Circuit Expansion Function .................................................8-226
8.23.4.1 Setting for the Safety Logic Circuit Expansion Function....................8-226
8.23.4.2 Outline of the Safety Logic Circuit Expansion Function.....................8-230
8.23.4.3 Setting the Comment.........................................................................8-232
8.23.4.4 Adding Input and Output Signals and Instructions
in Safety Logic Circuit Expansion Function .........................................8-233
8.23.4.5 Output Signal.....................................................................................8-237
8.23.4.6 Message of Output Signals ............................................................... 8-238
8.23.4.7 Enable Switch Link Function ............................................................. 8-239
8.23.4.8 Signal List Window ............................................................................8-240
8.23.4.9 Setting ON/OFF to the Input Signals .................................................8-241
8.23.4.10 Setting for the Universal Safety Output Signals .............................. 8-244
8.23.4.11 Setting for the Safety Signal Allocation Board.................................8-245
8.23.4.12 Update and Execution of the Safety Logic Circuit ...........................8-248
8.23.4.13 Sample of the Safety Logic Circuit Expansion Function..................8-250
8.23.4.14 Saving or Loading the File..............................................................8-258
8.23.4.15 Alarm List of the Safety Logic Circuit...............................................8-258
8.23.4.16 Specific Input Signals allocated to SPIN[xx]....................................8-259
8.23.4.17 Output to the Control Status Signal .................................................8-260
8.23.5 Saving or Loading the File..............................................................................8-266
8.23.5.1 Saving the File...................................................................................8-266
8.23.5.2 Loading the File.................................................................................8-267
8.23.6 Initializing the Safety Logic Circuit File ...........................................................8-268
8.23.6.1 Initializing the Safety Logic Circuit File ..............................................8-269
8.23.6.2 Machine Safety Flash Data Erase or Reset ...................................... 8-271
8.23.7 Example of Safety Logic Circuit......................................................................8-273
8.23.8 Alarm List of the Safety Logic Circuit..............................................................8-281
8.24 Robot Stop Factor Monitor Function ............................................................................8-282
8.24.1 Outline ............................................................................................................ 8-282
8.24.1.1 The Robot Stop Factor ......................................................................8-282
8.24.1.2 The Robot Stop Factor Record Number............................................8-285
8.24.2 Operation........................................................................................................8-286
8.24.2.1 Displaying the Robot Stop Factor Monitor.........................................8-286
8.24.2.2 Clear the Robot Stop Factor Information...........................................8-287
8.25 Robot Detachment Function ........................................................................................8-289
8.25.1 Setting Maintenance Mode.............................................................................8-289
8.25.2 Setting Robot Detachment Function...............................................................8-291
8.26 Axes Detachment Function..........................................................................................8-295
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