YASKAWA MOTOMAN FS100 User manual

MANUAL NO.
2
162181-1CD
Part Number: 162181-1CD
Revision: 2
FS100
INSTRUCTIONS
FOR MANUAL BRAKE RELEASE
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
FS100 INSTRUCTIONS
FS100 OPERATOR’S MANUAL
FS100 MAINTENANCE MANUAL

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FS100 Manual Brake
Release
MANDATORY
• This manual explains the FS100 Manual Brake Release system.
Read this manual carefully and be sure to understand its contents
before handling the FS100.
• General items related to safety are listed in Notes for Safe
Operation and Explanation of Warning Labels. To ensure correct
and safe operation, carefully read the FS100 Instructions Manual
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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FS100 Manual Brake
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the FS100.
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.
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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FS100 Manual Brake
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WARNING
• Confirm that no person is present in the manipulator’s operating
range and that you are in a safe location before:
– Turning ON the FS100 power.
– Moving the manipulator with the programming pendant.
– Running the system in play mode.
– Performing automatic operations.
Injury may result if anyone enters the manipulator’s operating range
during operation. Press the emergency stop button immediately if there
is a problem. The emergency stop button is located on the top right of
the programming pendant.
• Observe the following precautions when performing teaching
operations within the manipulator’s operating range:
– 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 there is a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
Before operating the manipulator verify the following:
• Servo power is turned OFF when the emergency stop button is
pressed.
• When servo poweer is turned ON, the servo ON light on the
programming pendant turns on.
• When servo power is turned OFF, the servo ON light on the
programming pendant turns 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 A: Emergency Stop Button
• An emergency stop button MUST be supplied on the equipment if
the programming pendant is not connected or used. Verify that
servo power is turned OFF when this emergency stop button is
pressed.
• Upon shipment of the FS100, the external emergency stop signal is
connected by a jumper in the bypass connector. To use the signal,
make sure to supply a new connector, and then input it.
If the emergency stop signal is input with the jumper cable connected, it
will not function, which may result in personal injury or equipment
damage.

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FS100 Manual Brake
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Definition of Terms Used Often in This Manual
This is a YASKAWA industrial robot product.
The robot assembly usually consists of the manipulator, the FS100
controller, manipulator cables, the FS100 programming pendant
(optional), and the FS100 programming pendant bypass connector
(optional).
In this manual, the equipment is designated as follows:
WARNING
• Before the emergency stop button is released or servo power is
turned ON, clear the work cell of all items which could interfere with
the operation of the manipulator.
Injury may result from unintentional or unexpected manipulator motion.
Fig B: Release of Emergency Stop
CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If a problem is found, correct it and take all
other necessary actions immediately.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Return the programming pendant to a safe place after use.
If the programming pendant is inadvertently left on the manipulator, on
a fixture, or on the floor, the manipulator or a tool may collide with the
programming pendant during manipulator movement, which may result
in personal injury or equipment damage.
• Read and understand all Warning Labels before operating the
manipulator.
Turn
Equipment Manual Designation
FS100 controller FS100
FS100 programming pendant Programming pendant
Cables between the manipulator
and the controller Manipulator Cables
FS100 programming pendant
bypass connector Programming pendant bypass connector

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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 brand 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 [ ].
e.g. [ENTER]
Symbol Keys The keys which have a symbol printed on them
are not denoted with [ ] but depicted with a
small picture.
e.g. PAGE key
The cursor key is an exception, and a picture is
not shown.
Axis Keys
Numeric Keys “Axis keys” and “Numeric keys” are generic names for the keys for axis operation and
number input.
Keys Pressed
Simultaneously When two keys are to be pressed simultaneously, the keys are shown with a “+”
sign between them.
e.g. SHIFT key + COORD key
Mode Key Three kinds of modes that can be selected by
the mode key are denoted as follows:
REMOTE, PLAY, or TEACH
Button Three buttons on the top front of the
programming pendant are denoted as follows:
HOLD button
START button
EMERGENCY STOP button
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
PC Keyboard The name of the key is denoted.
e.g. Ctrl key on the keyboard
GO BACK
PAGE
SHIFT
TOOL SEL
COORD

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Explanation of Warning Labels
The following warning labels are attached to the manipulator and FS100.
Fully comply with the precautions on the warning labels.
WARNING
• The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
• Failure to observe this warning may result in injury or damage to
equipment.
Refer to the manipulator manual for the warning label location.
• The following warning labels are attached to FS100.
Observe the precautions on the warning labels.
Failure to observe these warnings may result in injury or damage to
equipment.
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
Top View
Front View
Electric Shock Warning
Electric Shock Warning
Heavy Object Warning

1 Manual Brake Release Function
1.1 Outline
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1 Manual Brake Release Function
The “Manual Brake Release Function” is broken down to the following
sections:
• "Outline"
• "Activating the Manual Brake Release Function"
• "Manual Brake Release Procedure"
• "Warning Message"
1.1 Outline
With this function, the brake of each manipulator motor and external axis
can be released using the programming pendant.
The following operating conditions must be met to use the manual brake
release function:
• FS100 must be started up normally.
• Operating in any mode (REMOTE, PLAY, and TEACH.)
• All security modes (Operation, Edit, and Management.)
• Servo power is OFF.
• No Emergency Stop signal is present.
• The interlock connector FBB-CN210 is connected.
Due to the hardware configuration, brake release can only be performed
using the following groups:
• The S-, L-, and U-axes (the first, second, and third axes)
• The R-, B-, and T-axes (the fourth, fifth, and sixth axes)
• The seventh axis (either the E-axis or the first external axis.)
• The eigth axis (either the first or second external axis.)
CAUTION
Use caution when using this function because the brakes of up to three
axes are released.
NOTE
To restore power to the servo, remove the FBB-CN210
connector after completing a brake release operation.

1 Manual Brake Release Function
1.2 Activating the Manual Brake Release Function
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1.2 Activating the Manual Brake Release Function
To activate the manual break release feature, follow the directions below:
1. Turn OFF the power to the FS100.
2. Remove the thumb-screw and panel as shown.
3. Remove the interlock connector labeled FBB-CN210, and then re-
install the panel.

1 Manual Brake Release Function
1.2 Activating the Manual Brake Release Function
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4. Loosen the thumb-screw located next to the CN210 label, and raise
the door.
1.2.1 Single Robots:
5. Install the interlock connector FBB-CN210 into connector CN210 as
shown below.
1.2.2 Dual Robots:
5. For dual robot controllers (such as DRC’s, SDA5F, SDA10F, and
SDA20F) there are two CN210 connectors, one for each robot or
group of axes. Install FBB-CN10 into the controller of the robot or
group of axes that needs to be released. If two FBB-CN210’s are
available, they can both be installed, making all axes available for
release at the same time.
OR

1 Manual Brake Release Function
1.3 Manual Brake Release Procedure
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1.3 Manual Brake Release Procedure
1. Select {ROBOT} under the main menu, then select the submenu
{MANUAL BRAKE RELEASE}.
2. Select {YES}.
– When the manual brake release menu is selected, a warning
message appears to prevent improper operation.

1 Manual Brake Release Function
1.3 Manual Brake Release Procedure
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– Select {YES} to display the MANUAL BRAKE RELEASE window.
– If the interlock connector, FBB-CN210, is not installed, the following
window appears.
– Select {NO} to display the following window. The same window is
displayed if the interlock connector is removed while the MANUAL
BRAKE RELEASE window is being displayed.

1 Manual Brake Release Function
1.3 Manual Brake Release Procedure
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3. Move the cursor to the axis whose brake is to be released. Then press
the interlock key + [SELECT] while gripping the enable switch.
– Since the brakes of multiple axes will be released if the S-, L-, or U-
axis (the first, second, or third axis) or the R-, B-, or T-axis (the
fourth, fifth, or sixth axes) is selected, one of the following
confirmation dialog boxes appears. Proceed to the step 4.
INTER
LOCK

1 Manual Brake Release Function
1.3 Manual Brake Release Procedure
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– If the E-axis, the first external axis, or the second external axis (the
seventh or eighth axis) is selected, the brake is released and the
BRAKE STATUS is displayed.
BRAKE STATUS : Brake locked :Brake released
– The brake is locked with one of the following conditions:
• [SELECT] is released. (See the CAUTION box below.)
• The emergency stop button on the programming pendant, the
FS100 (optional), or the external device is pressed.
• The enable switch is not in the middle (teach) position.
• The window is switched from the MANUAL BRAKE RELEASE
window to another.
• The interlock connector FBB-CN210, is removed.
4. Select {YES} in the selection dialog box.
– Select {NO} or press [CANCEL] to close the confirmation dialog box
without releasing the brake.
After that, press the interlock key + [SELECT] while gripping the
enable switch to display the confirmation dialog box again. Proceed
to step 4.
CAUTION
• The brake is released by pressing the interlock key + [SELECT]
while gripping the enable switch. At this time, note that the brake
remains released when the interlock key is released.
INTER
LOCK
INTER
LOCK
INTER
LOCK

1 Manual Brake Release Function
1.3 Manual Brake Release Procedure
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– When {YES} is selected, the brake is not released immediately. Do
not move the cursor, and press the interlock key + [SELECT]
while gripping the enable switch again to release the brakes of the
three axes including the axis at which the cursor points.
BRAKE STATUS : Brake locked :Brake released
– When the axis whose brake is to be released is changed by moving
the cursor, proceed to the step 3.
– The brake is locked with one of the following conditions:
• [SELECT] is released. (See the CAUTION box below.)
• The emergency stop button on the programming pendant, the
FS100 (optional), or the external device is pressed.
• The enable switch is released, or gripped more tightly, so that it is
not in the middle (teach) position.
• The window is switched from the MANUAL BRAKE RELEASE
window to another.
• The interlock connector, FBB-CN210, is removed.
5. After completing the brake release operation, remove connector
FBB-CN21. Replace the connector back on the panel for future use.
CAUTION
• The brake is released by pressing the interlock key + [SELECT]
while gripping the enable switch. At this time, note that the brake
remains released when the interlock key is released.
NOTE
To restore power to the servo, remove the FBB-CN210
connector after completing a brake release operation.
INTER
LOCK
INTER
LOCK
INTER
LOCK

1 Manual Brake Release Function
1.4 Warning Message
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1.4 Warning Message
If the manual brake release is performed under one of the following
conditions, a warning message appears in the message area on the
screen stating that the brakes cannot be released.
• Servo power is turned ON.
• The emergency stop button on the programming pendant is pressed.
• An emergency stop button on the FS100 (optional) is pressed.
• The external emergency stop signal is incoming.
• The interlock connector, FBB-CN210, is not connected.

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MANUAL NO.
Specifications are subject to change without notice
for ongoing product modifications and improvements.
FS100
INSTRUCTIONS