YASKAWA Motoman DX200 User manual

MANUAL NO.
HW1481983
Part Number: 165837-1CD
Revision: 1
1
DX200 OPTIONS
INSTRUCTIONS
FOR PROFINET COMMUNICATIONS FUNCTION
(FOR CP1616 MADE BY Siemens)
MOTOMAN INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN-- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENACE MANUAL
The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
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Copyright © 2016, 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 PROFINET board (CP1616 made by
Siemens) 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 Instruction before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.
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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
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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 “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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PROHIBITED
• Do not use or keep the board in the following environmental
conditions.
– Where exposed to direct sunshine
– Where vibration or impact occurs
– Where high humidity exists
– Where a strong magnetic field exists
– Where much dust exists
– Where a sudden change in the temperature occurs
– Where corrosive gases occur
– Where condensation occurs
Improper usage of the board may damage the board.
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Notes for Safe Operation
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WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop buttons on the front door of the
DX200 and programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
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 persons are present in the P-point maximum
envelope of the manipulator and that you are in a safe location
before:
– Turning ON the DX200 power
– Moving the manipulator with the programming pendant
– Running the system in the check mode
– Performing automatic operations
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there are problems.The emergency stop buttons are
located on the right of the front doorof the DX200 and the programming
pendant.
• 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.
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Notes for Safe Operation
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WARNING
• Do not touch the inside of the panel for 5 minutes after the power is
turned OFF.
The remaining charged voltage in the capacitor may cause an electric
shock or an injury.
• Be sure to close the door and install the protection cover while the
power is turned ON.
Failure to observe this warning may result in a fire or an electric shock.
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Notes for Safe Operation
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CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the 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:
• The wiring and mounting must be performed by authorized and
qualified personnel.
Failure to observe this caution may result in a fire or an electric shock.
• Make sure that there is no foreign matter such as metal chips on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Make sure that there is no damage or deflection of parts on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Correctly connect each cable and connector.
Failure to observe this caution may result in a fire or damage the board.
• Set the switches, etc. correctly.
Malfunction, caused by an incorrect setting, may result in an injury or
damage the board.
• Never touch the mounting surfaces of the board parts directly with
fingers.
The generated static electricity may damage the IC.
• Never touch the soldered surfaces of the board directly with fingers.
Protrusions on the soldered surface may result in an injury.
• No shock to the board.
The shock may damage the board.
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Definition of Terms Used Often in This Manual
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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:
Descriptions of the programming pendant, buttons, and displays are
shown as follows:
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.
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 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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Safeguarding Tips
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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
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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
ProfiNet Communications
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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
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Customer Support Information
If you need assistance with any aspect of your ProfiNet Communications
Function 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:
[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 ProfiNet Communications
Function
• 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
ProfiNet Communications
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Table of Contents
1 Outline ............................................................................................................................................1-1
1.1 System Configuration ........................................................................................................1-1
2 Hardware Specifications.................................................................................................................2-1
2.1 Board External View..........................................................................................................2-1
2.2 Board Specifications..........................................................................................................2-2
2.3 Communication Specifications...........................................................................................2-2
3 Attaching of the Board ....................................................................................................................3-1
3.1 Operating the Front Door of DX200 (Controller)................................................................3-2
3.2 Attaching the CP1616 to the DX200..................................................................................3-3
3.3 Connecting the Cable........................................................................................................3-3
3.4 Closing the Front Door of the DX200.................................................................................3-4
4 Setting of the Board........................................................................................................................4-1
4.1 CP1616 Communication Settings......................................................................................4-1
4.1.1 Network Interface Settings ...................................................................................4-1
4.1.2 IO Controller Settings...........................................................................................4-3
4.1.3 IO Device Settings................................................................................................4-9
4.1.3.1 Settings of Device Name and IP Address...............................................4-9
4.1.3.2 CP1616 (IO Device) Settings with IO Controller ...................................4-10
4.1.4 Coupling Settings ............................................................................................... 4-14
4.2 Calling Up the CP1616 Setting Window..........................................................................4-27
4.3 IO Controller Settings ......................................................................................................4-31
4.4 IO Device Settings...........................................................................................................4-33
4.5 IO Module Settings..........................................................................................................4-38
4.6 External IO Settings.........................................................................................................4-40
4.7 GSD File Creation............................................................................................................4-46
4.7.1 Creating Procedures of GSD File.......................................................................4-46
5 Allocating I/O Signals......................................................................................................................5-1
5.1 Transmission Data.............................................................................................................5-1
5.1.1 I/O Allocation Examples for DX200 (For Handling)..............................................5-1
5.1.2 I/O Allocation Examples for DX200 (Except for Handling) ...................................5-4
5.2 Board Status......................................................................................................................5-6
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6 Management of Setting Data ..........................................................................................................6-1
6.1 Procedures for Saving .......................................................................................................6-1
6.2 Procedures for Loading......................................................................................................6-4
7 Additional Functions for IO Controller.............................................................................................7-1
7.1 IOPS Status Monitor Function ...........................................................................................7-1
7.1.1 Outline ..................................................................................................................7-1
7.1.2 Usage Method ......................................................................................................7-1
7.2 Message Communication Function....................................................................................7-3
7.2.1 Outline ..................................................................................................................7-3
7.2.2 Usage Method ......................................................................................................7-3
7.2.3 Supplementary Note.............................................................................................7-7
7.3 Alarm History Displaying Function.....................................................................................7-8
7.3.1 Outline ..................................................................................................................7-8
7.3.2 Usage Method ......................................................................................................7-8
8 Error Indication................................................................................................................................8-1
8.1 LED Display.......................................................................................................................8-1
9 Trouble Shooting.............................................................................................................................9-1
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1 Outline
1.1 System Configuration
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1 Outline
This instruction manual describes settings and other information required
for the PROFINET board CP1616 (made by Siemens, hereinafter referred
to as the CP1616) to be used with DX200.
The use of this board enables DX200 general IO data to be transferred to
and from other PROFINET communication stations.
1.1 System Configuration
Example of system configuration when using as PROFINET IO
Device
NOTE
The CP1616 has multiple firmware versions.
Depending on the DX200 software version, use the
following firmware version for the CP1616.
If an unsupported firmware version is used with the
software version of DN1.56.00A()-00 or later, an alarm
4918 "PROFINET SETTING ERROR" occurs.
NOTE
This manual describes communication settings of the
CP1616 board using the Siemens "STEP 7" software
application.
When using other software, refer to the manual of each
software.
DX200 software version CP1616 firmware version
DN1.47.00A()-00 or earlier V2.5.2.0
From DN1.50.00A()-00 to
DN1.80.00A()-00 V2.6.1.0
DN1.81.00A()-00 or later V2.6.1.6
PROFINET IO Controller
External PLC (sequencer)
PROFINET IO Device
CP1616
PROFINET Cable
HUB
DX200 Controller
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1 Outline
1.1 System Configuration
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Example of system configuration when using as PROFINET IO
Controller
Example of system configuration when using as PROFINET IO
Controller and IO Device simultaneously
PROFINET IO Device
DX200 Controller
HUB
PROFINET
IO Controller
CP1616
PROFINET Cable
NOTE
The CP1616 can be used as the IO Controller and the IO
Device simultaneously only when connecting equipment
made by Siemens as the host IO Controller. When
connecting equipment not made by Siemens, the CP1616
cannot be used as the IO Controller and the IO Device
simultaneously.
DX200 Controller
PROFINET IO
Controller/
IO Device
CP1616
HUB
PROFINET IO Controller
External PLC (Made by Siemens)
PROFINET Cable
PROFINET IO Device
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2 Hardware Specifications
2.1 Board External View
ProfiNet Communications
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2 Hardware Specifications
2.1 Board External View
PROFINET Connector
(RJ45)
Activity LED
link LED
SF (group fault) LED
BF (bus fault) LED
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2 Hardware Specifications
2.2 Board Specifications
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2.2 Board Specifications
2.3 Communication Specifications
Items Specifications
Interface to
external devices PROFINET
Board mounting
position PCI Slot in the DX200
Error display LED display
Maximumnumber
of I/O Input: 4048 points Output: 4048 points However, the Input points and Output points cannot be set
individually.
NOTE
The maximum I/O numbers above (Input: 4048 points
Output: 4048 points) only applies when this board is used
as the optional IO module. If optional IO modules other
than this board have been installed, the I/O number above
may not be available.
Explanation
Connection type Star (connected via a HUB)
Communication speed 10Mbps/100Mbps (detected automatically when
startup)
Communication media Use a PROFINET cable
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