YASKAWA Motoman DX200 User manual

MANUAL NO.
HW1481985
Part Number: 165838-1CD
Revision: 2
3
DX200 OPTIONS
INSTRUCTIONS
EtherNet/IP COMMUNICATION FUNCTION
(FOR STANDARD LAN PORT)
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 (for each purpose)
DX200 MAINTENANCE MANUAL
The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
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Copyright © 2016, 2014, 2013 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, 2016
YASKAWA America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com
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MANDATORY
• This manual explains the EtherNet/IP communication 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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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.
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Notes for Safe Operation
EtherNet/IP
Communication
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 “DANGER”,
“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.
DANGER
Indicates an imminent hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to
equipment. It may also be used to
alert against unsafe practices.
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 “DANGER”,
“WARNING” and “CAUTION”.
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Notes for Safe Operation
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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.
Fig. : 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.
Fig. : Release of Emergency Stop
TURN
• 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.
– 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
EtherNet/IP
Communication
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:
Descriptions of the programming pendant keys, buttons, and displays are
shown 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 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.
• 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
Cable between the manipulator and the
controller
Manipulator cable
Equipment Manual Designation
Programming
Pendant
Character Keys
/Symbol Keys
The keys which have characters or its
symbol printed on them are denoted with [ ].
ex. [ENTER]
Axis Keys
/Numeric Keys
[Axis Key] and [Numeric Key] 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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Description of the Operation Procedure
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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] is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
Safeguarding Tips
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General
safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to
the equipment. Only trained personnel familiar with the operation of
this equipment, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this
equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
Mechanical Safety Devices
The safe operation of this equipment is ultimately the users responsibility.
The conditions under which the equipment will be operated safely should
be reviewed by the user. The user must be aware of the various national
codes, ANSI/RIA R15.06-2012 safety standards, and other local codes
that may pertain to the installation and use of this equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following
safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
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Programming, Operation, and Maintenance Safety
EtherNet/IP
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Programming, Operation, and Maintenance Safety
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. Improper operation can result in personal injury and/or
damage to the equipment. Only trained personnel familiar with the
operation, manuals, electrical design, and equipment interconnections of
this equipment should be permitted to program, or maintain the system.
All personnel involved with the operation of the equipment must
understand potential dangers of operation.
• Inspect the equipment to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment
for proper operation. Repair or replace any non-functioning safety
equipment immediately.
• Check the E-Stop button on the operator station for proper operation
before programming. The equipment must be placed in Emergency
Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are
done and before any changes are made to options, accessories, or
equipment.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot! Do not make any
modifications to the controller unit. Making any changes without the
written permission from YASKAWA will void the warranty.
• Some operations require a standard passwords and some require
special passwords.
• The equipment allows modifications of the software for maximum
performance. Care must be taken when making these modifications.
All modifications made to the software will change the way the
equipment operates and can cause severe personal injury or death,
as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
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Maintenance Safety
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Maintenance Safety
Turn the power OFF and disconnect and lockout/tagout all electrical
circuits before making any modifications or connections.
Perform only the maintenance described in this manual. Maintenance
other than specified in this manual should be performed only by
YASKAWA-trained, qualified personnel.
Summary of Warning Information
This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notes.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by YASKAWA. Address any questions regarding the safe and proper
operation of the equipment to YASKAWA Customer Support.
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Customer Support Information
EtherNet/IP
Communication
Customer Support Information
If you need assistance with any aspect of your EtherNet/IP
Communication system, please contact YASKAWA Customer Support at
the following 24-hour telephone number:
For routine technical inquiries, you can also contact YASKAWA Customer
Support at the following e-mail address:
When using e-mail to contact YASKAWA Customer Support, please
provide a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
Please have the following information ready before you call Customer
Support:
techsupp[email protected]
NOTE
Please use e-mail for routine inquiries only. If you have an
urgent or emergency need for service, replacement parts,
or information, you must contact YASKAWA Customer
Support at the telephone number shown above.
• System EtherNet/IP Communication
• Primary Application ___________________________
• Controller DX200
• Software Version Access this information on the
Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX200 controller
data plate
[phone]
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Table of Contents
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Table of Contents
1 Introductions.................................................................................................................................... 1-1
1.1 System Configuration......................................................................................................... 1-1
1.1.1 System Configuration Example ............................................................................ 1-1
1.1.2 Adaptor .................................................................................................................1-1
1.1.3 Scanner ................................................................................................................1-1
1.1.4 Message Communication ..................................................................................... 1-2
1.1.5 IO Communication by InputOnly........................................................................... 1-2
1.1.6 Message Communication Using CIP .................................................................... 1-2
2 Board Specifications ....................................................................................................................... 2-1
3 How to Connect Communication Cable ..........................................................................................3-1
3.1 Operating the Front Door of the DX200 (Controller).......................................................... 3-2
3.2 Mounting the EtherNet/IP (CPU board) to DX200 ............................................................. 3-3
3.3 Closing the Front Door of the DX200................................................................................. 3-4
4 EtherNet/IP Function Setting........................................................................................................... 4-1
4.1 Outline ............................................................................................................................... 4-1
4.1.1 Window Composition ............................................................................................ 4-2
4.2 Setup Procedure ................................................................................................................ 4-3
4.2.1 Calling the SETUP Window for the EtherNet/IP (CPU board) ..............................4-3
4.2.2 Setting the Device Information List ....................................................................... 4-5
4.2.3 General Setup for the EtherNet/IP (CPU board)................................................... 4-8
4.2.4 Ethernet Setting .................................................................................................... 4-8
4.2.5 Adaptor Setting ................................................................................................... 4-13
4.2.6 Scanner Setting .................................................................................................. 4-15
4.2.7 IO Module Re-configuration................................................................................ 4-19
4.2.8 External I/O Setup .............................................................................................. 4-21
4.2.9 Reset Safety Circuit Board FLASH Data ............................................................ 4-25
4.3 IO Assignment Example .................................................................................................. 4-27
4.3.1 Setting ExclusiveOwner Communication............................................................ 4-27
4.3.2 Setting InputOnly Communication ...................................................................... 4-27
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4.4 Communication Data ....................................................................................................... 4-29
4.4.1 DX200 IO Data Allocation (For the Handling Purpose) ...................................... 4-31
4.4.2 DX200 IO Data Allocation (For other than Handling Purpose)........................... 4-35
4.5 Communication Status..................................................................................................... 4-39
4.6 Managing Setting Data .................................................................................................... 4-44
4.6.1 How to Save Data .............................................................................................. 4-44
4.6.2 How to Load Data............................................................................................... 4-46
4.7 Creating an EDS File ....................................................................................................... 4-48
4.7.1 Creating Procedures of EDS File ....................................................................... 4-48
5 Message Communication ............................................................................................................... 5-1
5.1 Conventional Message Communication ............................................................................ 5-1
5.2 Message Communication Using CIP ................................................................................. 5-1
5.2.1 Details on Commands for Message Communication Using CIP .......................... 5-2
5.3 Related Parameters......................................................................................................... 5-18
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1 Introductions
1.1 System Configuration
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1 Introductions
In the DX200 system, the EtherNet/IP communication function (hereinafter
referred to as EtherNet/IP (CPU board)) to which a standard LAN port of
the YPC21 board (CN104 connector) is used can be employed. The
Ethernet communication function of the DX200 provides the following
features: an IO transmission/reception function that enables to exchange
external input/output signals between the DX200 and other EtherNet/IP
supported devices and a message communication function that realizes
data transmission equal to the one realized by the DX200 Ethernet
function. Also, this function makes it possible to carry out IO
communication by Input Only as well as message communication using
CIP. This manual describes the settings necessary for using this function
and its related information.
1.1 System Configuration
1.1.1 System Configuration Example
A system configuration example when using the EtherNet/IP (CPU board)
is as follows.
1.1.2 Adaptor
When the IO transmission/reception function is used, the DX200 can
operate as an adaptor (communication slave) for the scanner
(communication master). In the system configuration example, IO
communication is carried out with the external PLC being a scanner and
the DX200's EtherNet/IP (CPU board) being an adaptor.
1.1.3 Scanner
When the IO transmission/reception function is used, the DX200 can
operate as a scanner (communication master) for the adaptor
(communication slave). In the system configuration example, IO
communications is carried out with DX200's EtherNet/IP (CPU board)
being a scanner and the IO unit being an adaptor.
EtherNet/IP
Scanner
PLC (sequencer) DX200
YCP21
CN104
EtherNet/IP
Adaptor/Scanner
EtherNet/IP
Adaptor
I/O unit
HUB
PC
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1 Introductions
1.1 System Configuration
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1.1.4 Message Communication
Message communication can be carried out in parallel with IO
transmission and reception. In the system configuration example,
message communication with a PC is carried out. The DX200 Ethernet
function, the FTP function, and the EtherNet server function (the latter two
are extended functions) can be used for this message communication.
Also, communication using CIP is possible. To use the DX200 Ethernet
function and the extended option function, settings need to be made
separately.
1.1.5 IO Communication by InputOnly
When communication stations on the network communicate with one
another, in conventional ExlusiveOwner connection, as the number of
communication stations increases, the number of transmitted packets
increases sharply, placing considerable strain on the network band. To
cope with this problem, the multicast communication called InputOnly
connection is introduced to keep the increase in the number of packets
low.
1.1.6 Message Communication Using CIP
CIP for message communication is used so that communication with
general panel computer is possible.
NOTE
When this system valid, PCU-ETHIO (EtherNet/IP board
made by Molex) is unavailable.
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2 Board Specifications
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2 Board Specifications
Items Specifications
Interface to external devices EtherNet/IP
Transmission I/O points (max.) Input: 4040 points/Output: 4040 points
Processing capacity
(max. number of packets)
3000 packets/sec
Connection type Star (Connection by HUB)
Communication speed 10 Mbps/100 Mbps (Detected automatically
during startup)
Communication media Use category 5 or higher shielded Ethernet
cables.
NOTE
The above mentioned maximum transmission I/O points
(input: 4040 points/output: 4040 points) is a limitation by
EtherNet/IP communication specification. Because the
upper limit of the I/O points in the DX200 system is 4096
points when using this board with other board
simultaneously, the upper limit of the total of the I/O points
and the communication status used by this function or other
functions is also 4096 points. The communication status
occupies either 8 points or 16 points per network. For the
details, refer to the instructions of the I/O circuit board.
NOTE
Use this board within the above mentioned processing
capacity (3000 packets/sec). If it is used process beyond its
processing capacity, the alarm 100 “COMMUNICATION
ERROR (EAXA#1)” or 500 “SEGMENT PROC NOT
READY” may occur so that it won’t work properly.
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2 Board Specifications
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Fig. 2-1: Description of the Processing Capacity
Reference: Solution to reduce the packet numbers
A packet carrying the large data in the network might be caused by the
communication station performing a broadcast (a message or signal is
sent to all connected devices) or a multicast (one device communicates
with several devices with a single transmission). Perform the following
measures to reduce the packet numbers in the network.
(1) Limits the packet transmission route by Managed HUB
Install the Managed HUB instead of the Switching HUB, and set it
to send the packets to the necessary route. In addition, refer to a
guide book of installing the Managed HUB for installation
procedures.
Fig. 2-2: Limits the Packet Transmission Route by Managed HUB
PLC PC
DX200
Switching HUB
Ethernet
The total number of sending/receiving packets should be less
than 3000 packets/sec at this position.
Use the packet capture tool, such as Wireshark, to confirm
the packet number.
PC
PC PLC PLC
DX200DX200
Ethernet Ethernet
Switching HUB Managed HUB
Multicast
Communication stationCommunication station
Multicast
Multicast
Use of the Switching HUB transmits the packets
to all devices
Use of the Managed HUB transmits the packets with
a single transmission
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2 Board Specifications
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(2) Change the packet transmission method
Change the packet transmission method of communication station
from broadcast/ multicast to the unicast (point-to-point
transmission from one device to another). Refer to a guide book
of each device for setup procedures.
Fig. 2-3: Limits the Packet Transmission Route by Unicast
PC
PC PLC PLC
DX200
DX200
Ethernet Ethernet
Switching HUB Switching HUB
Broadcast/multicast transmits the packets
to all devices.
Unicast transmits the packets to a specified device.
Unicast
Unicast
Multicast
Communication station Communication station
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3 How to Connect Communication Cable
EtherNet/IP
Communication
3 How to Connect Communication Cable
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.
WARNING
• 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.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Never touch the mounting surfaces and the soldered surfaces of the
board parts directly with fingers.
The generated static electricity may damage the IC, and protrusions on
the soldered surface may result in an injury.
• Never touch the soldered surfaces of the board directly with fingers.
Protrusions on the soldered surface may result in an injury.
• Never give any shock to the board.
The shock may damage the board.
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3 How to Connect Communication Cable
3.1 Operating the Front Door of the DX200 (Controller)
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3.1 Operating the Front Door of the DX200 (Controller)
Take the following procedure to mount the EtherNet/IP (CPU board).
1. Using a coin or a flathead screwdriver, rotate the door locks on the
front of the DX200 (two places) 90 degrees to clockwise.
2. Rotate the main power supply switch to the “OFF” position and open
the door gently.
Clockwise
Flathed screw driver
Door lock
90
ON
O
OFF
RESET
TRIPPED
I
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