YASKAWA Motoman DX200 User manual

MANUAL NO.
0
HW1481811
Part Number: 165259-1CD
Revision: 0
DX200 OPTIONS
INSTRUCTIONS
FOR THE INTERRUPT JOB FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL
DX200 MAINTENANCE MANUAL
The DX200 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
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MANDATORY
• This manual explains the interrupt job function of the DX200 system
and general operations. Read this manual carefully and be sure to
understand its contents before handling the DX200.
• General items related to safety are listed in Chapter 1: Safety of the
DX200 Instructions. To ensure correct and safe operation, carefully
read the DX200 Instructions 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 DX200.
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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WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX200 and the programming pendant.
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 person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX200.
– 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 is a problem.
The emergency stop buttons are located on the right of front door of the
DX200 and the programming pendant.
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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 supply cables.
In this manual, the equipment is designated as follows:
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 DX200
cabinet after use.
The programming pendant can be damaged if it is left in the P-point
maximum envelope of the manipulator, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX200 Instructions before operating the manipulator.
Equipment Manual Designation
DX200 controller DX200
DX200 programming pendant Programming pendant
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Descriptions of the programming pendant, 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.
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
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
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}
PAGE
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Table of Contents
1 What is the Interrupt Job Function?................................................................................................1-1
2 Setting of the Interrupt Job Function...............................................................................................2-1
2.1 Interruption Table Display..................................................................................................2-1
2.2 Setting of Interruption Table ..............................................................................................2-3
2.2.1 Setting of Signals .................................................................................................2-3
2.2.2 Setting of Job Names...........................................................................................2-4
2.3 Setting of Interruption Levels.............................................................................................2-5
3 Registration of Instructions ............................................................................................................. 3-1
3.1 EI (Enable Interruption) Instruction....................................................................................3-1
3.2 DI (Disable Interruption) Instruction...................................................................................3-3
4 Execution of an Interrupt Job..........................................................................................................4-1
4.1 Interruption Signal Detection .............................................................................................4-1
4.2 Timing for Interrupt Job Execution.....................................................................................4-1
4.3 Deceleration Before Interrupt Job Execution.....................................................................4-1
4.4 Interruption Signal Entered During Another Interrupt Job..................................................4-1
4.5 Output Signal of “Interrupt Job in Execution”.....................................................................4-2
4.6 Automatic Interruption Disabled Status .............................................................................4-2
4.7 Job Call Stack....................................................................................................................4-2
4.8 If an interrupt job cannot be executed ...............................................................................4-2
5 Application Examples...................................................................................................................... 5-1
5.1 Interruption During Timer Instruction.................................................................................5-1
5.2 Interruption During Move Instruction..................................................................................5-1
5.3 Interruption During Move Instruction with NWAIT..............................................................5-2
5.4 Interruption During Circular Interpolation Move Instruction (MOVC)................................5-3
6 System with Independent Control...................................................................................................6-1
7 Instruction List.................................................................................................................................7-1
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1 What is the Interrupt Job Function?
1 What is the Interrupt Job Function?
The interrupt job function is a kind of call job. When a signal to interrupt
the job is sent from a peripheral device or another system, this function
momentarily suspends a job in progress, and executes the job
corresponding to the signal.
This function is useful when an error occurs in a peripheral device or in
another system, or when the manipulator should be withdrawn in an
emergency.
An interruption table defines the relation among the interruption levels
(priority of an interruption signal), the interruption signals, and the
interrupting jobs.
Sending a user input signal specified in the table calls, a job
corresponding to that signal. When interrupt job is completed, the
suspended job is restarted from the instruction line where the cursor was
at the time of interruption.
The smaller the interruption level number becomes, the higher the priority
of the processing becomes.
Since the DX200 determines which interrupt job is to be executed
according to this interruption table, make sure the settings for this table
are correct. The system engineer sets up this interruption table.
NOTE
If an interruption signal is received while the manipulator is in
the “step” cycle, the manipulator stops at once, and then the
next starting operation starts the interrupt job.
Interrupt job Job in progress
NOP
END
NOP
END
Interruption
INTERRUPT JOB
LEVEL SIGNAL JOB NAME
IN#01 JIG STOP
NOP
END
Interrupt job
"JIG STOP" NOP
END
Job in progress
Interruption
Interruption
signal IN#01
Interruption table
INTERRUPT JOB
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1 What is the Interrupt Job Function?
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NOTE
An interrupt job can be executed when the start lamp is ON
and between the execution of the EI (enable interruption)
instruction and the DI (disable interruption) instruction.
A different interruption level can be specified for both EI and
DI.
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2 Setting of the Interrupt Job Function
2.1 Interruption Table Display
2 Setting of the Interrupt Job Function
2.1 Interruption Table Display
1. Select {JOB} under the main menu.
2. Select {INTERRUPT JOB} in the sub menu.
TABLE NO. (Initial value: 1)
 OUTPUT SIGNAL (Initial value: no setting)
A user output signal that is turned ON during the execution of an inter-
rupt job.
 LEVEL
The interruption level indicates the priority of the interruption signal.
The smaller the interruption level number becomes, the higher the prior-
ity of the processing becomes. Eight levels from 0 to 7 can be set.
 SIGNAL (Initial value: no setting)
A user input signal serves as an interruption signal.
 JOB NAME (Initial value: no setting)
A job name corresponding to an interruption signal
 PERMIT
Interruption enabled or disabled status (for diagnosis)
(Enabled): Interruption enabled by the execution of the EI instruction
(Disabled): Interruption disabled
1
2
3
4
567
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2 Setting of the Interrupt Job Function
2.1 Interruption Table Display
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EXEC
(ON): Interrupting job in progress
(OFF): Interrupting job not in progress
“Exec” turns ON when an interruption signal is received and the inter-
rupt job is called, and turns OFF when the job is completed.
“Exec” turns OFF in the following cases:
• An interrupt job is completed and the suspended job is restarted.
• Another job is called.
• CLEAR STACK instruction is executed.
NOTE
{INTERRUPT JOB} appears when the security mode is the
edit mode or management mode.
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2 Setting of the Interrupt Job Function
2.2 Setting of Interruption Table
2.2 Setting of Interruption Table
In a system where an independent control is used simultaneously with the
interrupt job function, an interrupt job can be set and executed for each
task.
When using four tasks (16 tasks maximum) for the independent control:
Pressing the page key changes the table No. in this order : “1” “2”
“3” “4” “1.”
Pressing [SHIFT] + the page key changes the table No. in the
reverse order : “4” “3” “2” “1” “4.”
2.2.1 Setting of Signals
1. Move the cursor to the item to be selected, and press [SELECT].
2. Enter a numerical value using the Numeric keys.
PAGE
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PAGE
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PAGE
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PAGE
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NOTE
Entering “0” in SIGNAL clears the set signal No. and job
name.
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2 Setting of the Interrupt Job Function
2.2 Setting of Interruption Table
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2.2.2 Setting of Job Names
1. Move the cursor to the item to be selected, and press [SELECT].
2. Select a job in the JOB LIST window.
3. Press [ENTER].
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2 Setting of the Interrupt Job Function
2.3 Setting of Interruption Levels
2.3 Setting of Interruption Levels
To specify the levels where interruptions can be enabled or disabled by
the EI and DI instructions respectively, set the bits corresponding to the
levels to “1.”
For example, the set value of level 0 is “1” and the set value of level 2 is
“4,” with a total set value of “5.” Therefore, to permit levels 0 and 2, set the
EI instruction to “5.”
The status of other interruption levels remains unchanged.
NOTE
• If no interruption level is specified, all levels from 0 to 7
enable or disable interruption.
• If the interruption level is set to “0,” it is treated like an NOP
instruction where no operation is executed and proceeds to
the next instruction.
LEVEL7
d7 d6 d5 d4 d3 d2 d1 d0
128 64 32 16 8 4 2 1
The set values for
the EI/DI instructions
LEVEL6 LEVEL5 LEVEL4 LEVEL3 LEVEL2 LEVEL1 LEVEL0
d7
4 + 1 5
EI
LEVEL=5
00000101
d6 d5 d4 d3 d2 d1 d0
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3 Registration of Instructions
3.1 EI (Enable Interruption) Instruction
3 Registration of Instructions
3.1 EI (Enable Interruption) Instruction
Executing an EI instruction activates the specified interruption levels set in
the additional item.
To specify the levels where interruptions can be enabled, set the bits
corresponding to the levels to “1.” The status of the other interruption
levels remains unchanged.
1. Move the cursor to the address area.
2. Press [INFORM LIST].
3. Select {CONTROL}.
4. Move the cursor to “EI.”
– The EI instruction appears in the input buffer line with the previously
registered additional items.
EI Interruption level
constants
0 to 255
Interruption level
variables Bxxx
Interruption level
variables LBxxx
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3 Registration of Instructions
3.1 EI (Enable Interruption) Instruction
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5. Press [SELECT] twice to set an interruption level in the DETAIL EDIT
window.
– Enter the interruption level using the Numeric keys.
6.
Press [ENTER] twice .
– Pressing [ENTER] once shows the set contents in the input buffer
line. Pressing [ENTER] again registers the set contents in the job.
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3 Registration of Instructions
3.2 DI (Disable Interruption) Instruction
3.2 DI (Disable Interruption) Instruction
Executing a DI instruction activates the specified interruption levels set in
the additional item.
To specify the levels where interruptions can be disabled, set the bits
corresponding to the levels to “1.” The status of the other interruption
levels remains unchanged.
1. Move the cursor to the address area.
2. Press [INFORM LIST].
3. Select {CONTROL}.
4. Move the cursor to “DI”.
– The DI instruction appears in the input buffer line with the previously
registered additional items.
DI Interruption level
constants
0 to 255
Interruption level
variables Bxxx
Interruption level
variables LBxxx
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3 Registration of Instructions
3.2 DI (Disable Interruption) Instruction
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5. Press [SELECT] twice to set an interruption level in the DETAIL EDIT
window.
– Enter the interruption level using the Numeric keys.
6. Enter the interruption level using the Numeric keys.
– Pressing [ENTER] once shows the set contents in the input buffer
line. Pressing [ENTER] again registers the set contents in the job.
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4 Execution of an Interrupt Job
4.1 Interruption Signal Detection
4 Execution of an Interrupt Job
4.1 Interruption Signal Detection
An interruption signal is detected at the rising edge of the signal.
If more than one interruption signal is detected at the same time, the job
for the level with higher priority is executed.
4.2 Timing for Interrupt Job Execution
The timing of executing an interrupt job depends on what instruction is
being executed when the interruption signal is received, and can be
divided into the following two types.
• Suspends the instruction being executed to do an interrupt job
The following instructions are suspended while executing an inter-
rupt job.
• Executes an interrupt job after the completion of the instruction being
executed.
Any instructions other than those listed above are completed before
starting an interrupt job.
4.3 Deceleration Before Interrupt Job Execution
If the manipulator is moving at a high speed and the interrupt job is
executed immediately after the interruption signal is received, an
excessive shock to the manipulator may result.
To avoid this risk, the manipulator automatically decelerates upon receipt
of the interruption signal, and then the interrupt job is executed.
4.4 Interruption Signal Entered During Another Interrupt Job
All interruptions are automatically disabled during the execution of an
interrupt job. Therefore, if another interruption signal with a higher priority
is received, its corresponding job is not executed.
The new signal is ignored. When an interrupt job is completed, even if
any interruption signal is ON, the corresponding interrupt job is not
executed until the rising edge of the interruption signal is detected.
Move Instructions MOVJ MOVL MOVC IMOV
I/O Instruction WAIT
Control Instruction TIMER
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4 Execution of an Interrupt Job
4.5 Output Signal of “Interrupt Job in Execution”
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4.5 Output Signal of “Interrupt Job in Execution”
During execution of an interrupt job, the output signal turns ON to indicate
that the interrupt job is being executed. This output signal turns ON when
an interruption signal is received and the interrupt job is called, and turns
OFF when the interrupt job completes.
The output signal “Interrupt Job in Execution” turns OFF in the following
cases:
• The execution of an interrupt job completes and the suspended job is
restarted.
• Another job is called.
• The CLEAR STACK instruction is executed.
4.6 Automatic Interruption Disabled Status
Only execution of the EI instruction enables interruptions. Even after the
main power supply turns OFF, the interruption enabled/disabled status is
kept.
However, when a job is called, all interruption levels are automatically
disabled for security.
4.7 Job Call Stack
Job calls made by interruptions are processed like other job calls. The
same job call stack is used for both kinds of job calls.
Therefore, adding an interrupt job to a job call stack filled to level 8 causes
the stack to overflow.
4.8 If an interrupt job cannot be executed
An interrupt job cannot be executed in any of the following cases:
• During 1 step-back operation caused by the dedicated input
#40090-#40097 " 1 step-back operation command”
• During return operation of a restart function for arcing application
If an interrupt job is attempted, "AL4525: Specified job not executable" is
displayed.
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