YASKAWA MOTOMAN FS100 User manual

MANUAL NO.
HW1480742
YASKAWA ELECTRIC CORPORATION
Part Number: 161366-1CD
Revision: 0
FS100 OPTIONS
INSTRUCTIONS
FOR PMT FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
FS100 INSTRUCTIONS
FS100 OPERATOR’S MANUAL
FS100 MAINTENANCE MANUAL

FS100
ii
161366-1CD
HW1480742
MANDATORY
• This manual explains the PMT function (Position Modification
Function for Tool Deformation) of the FS100 system. Read this
manual carefully and be sure to understand its contents before
handling the FS100.
• General items related to safety are listed in Chapter 1: Safety of the
FS100 Instructions. To ensure correct and safe operation, carefully
read the FS100 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.

FS100
iii
161366-1CD
HW1480742
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.
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
personnelanddamageto 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 "CAUTION"
and "WARNING".

FS100
iv
161366-1CD
HW1480742
WARNING
• Before operating the manipulator, check that servo power is turned
off when the emergency stop button on the programing pendant is
pressed.
When the servo power is turned off, the SERVO ON LED on the
programing 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
• In the case of not using the programming pendant, be sure to
supply the emergency stop button on the equipment. Then before
operating the manipulator, check to be sure that the servo power is
turned OFF by pressing the emergency stop button.
Connect the external emergency stop button to the 5-6 pin and 16-
17 pin of the robot system signal connector (CN2).
• Upon shipment of the FS100, this signal is connected by a jumper
cable in the dummy connector. To use the signal, make sure to
prepare a new connector, and then input it.
If the signal is input with the jumper cable connected, it does not
function, which may result in personal injury or equipment damage.
• 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 EM
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.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
The emergency stop button is located on the programing pendant.

FS100
v
161366-1CD
HW1480742
Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the FS100 controller,
manipulator cables, the FS100 programming pendant (optional), and the
FS100 programming pendant dummy connector (optional).
In this manual, the equipment is designated as follows:
WARNING
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning on the power for the FS100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the working envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there are problems.
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 FS100 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
FS100 Instructions before operating the manipulator:
Equipment Manual Designation
FS100 controller FS100
FS100 programming pendant Programming pendant
Cable between the manipulator
and the controller Manipulator Cable
FS100 programming pendant
dummy connector Programming pendant dummy connector

FS100
vi
161366-1CD
HW1480742
Descriptions of the programming pendant keys, buttons, displays and
keyboard of the PC 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 [ ].
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 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,
ex. SHIFTkey + 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 upper side 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 { }.
ex. {JOB}
PC Keyboard The name of the key is denoted
ex. Ctrl key on the keyboard
GO BACK
PAGE
SHIFT
TOOL SEL
COORD

FS100 Contents
vii
161366-1CD
HW1480742
1 PMT Function..................................................................................................................................1-1
2 Data Conversion by PMT Function.................................................................................................2-2
2.1 Outline ...............................................................................................................................2-2
2.1.1 PMT data conversion by instruction .....................................................................2-2
2.1.2 PMT data conversion by programming pendant...................................................2-3
2.2 PMT Data Conversion by Instruction.................................................................................2-5
2.2.1 Registering GETTOOL Instruction........................................................................2-5
2.2.2 Registering SETTOOL Instruction........................................................................2-6
2.2.3 Registering PMT Instruction.................................................................................2-7
2.3 PMT Data Conversion by Programming Pendant............................................................2-10
3 Tool Data Backup History...............................................................................................................3-1
3.1 Tool Backup Window.........................................................................................................3-1
4 Instruction List for PMT Function....................................................................................................4-1
5 Parameter.......................................................................................................................................5-1
6 Alarm List........................................................................................................................................6-1

1 PMT Function
FS100
1-1
161366-1CD
HW1480742
1 PMT Function
The PMT function corrects the position data when the tool is deformed
during operation
(PMT: Position Modification for Tool Deformation). When a tool
inadvertently collides with peripheral jigs or walls during operation and is
deformed, the tool center point will be dislocated and the taught position of
the job programmed would be shifted; it requires a great deal of time and
effort for correction. In such a case, the PMT function can be used to
correct the position data easily and accurately.
By specifying the desired job, the position data of the taught tool
dimensions before deformation are converted automatically to the position
data of the tool dimensions after deformation.
In the PMT function, the tool before deformation is called “the original tool”
and the tool after deformation is called “the orientation tool”.
NOTE
• For a job in which teaching is performed by using several
types of tools, only the position data obtained by the speci-
fied original tool is converted.
• The position variables are not converted in the PMT func-
tion.
Tool at teaching (Original tool)
Deformed tool
(Orientation tool)
Dislocation of tool center point
0016
0017
0018
MOVJ
WAIT IN#(1)=0
MOVL V=70
Position data of the step taught
by the original tool is converted.

2 Data Conversion by PMT Function
FS100 2.1 Outline
2-2
161366-1CD
HW1480742
2 Data Conversion by PMT Function
2.1 Outline
The data can be converted by the PMT function using instructions or the
programming pendant.
2.1.1 PMT data conversion by instruction
The following window is a job example (PMT0) to convert the data
by instructions.
Carry out Job PMT0 to convert the data using the PMT function.
Refer to chapter 2.2 “PMT Data Conversion by Instruction” for the
programming of each instruction, GETTOOL, SETTOOL, and PMT.
Before converting the data, prepare a job, like TOOL0 in the
preceding example, to obtain the amount of tool deformation by
using a touch sensor or other device.
NOTE
When the PMT function is used, the tool dimensions and the
job taught position data are rewritten. In order to secure the
data, prepare the backup files beforehand.
Saves the tool constants used before
deformation as the original tool data.
Calls the job to obtain the amount of
tool deformation.
Sets the tool constants after
deformation.
Job : Converts WORK1 using the
PMT function.
Job : Converts WORK11 using the
PMT function.
NOTE
• Before converting the data by a PMT instruction, be sure to
save the data of the original tool by using a GETTOOL
instruction.
• For a system with the independent control function
enabled, do not use PSTART, an independent control
instruction, to start a job that includes a PMT instruction.

2 Data Conversion by PMT Function
FS100 2.1 Outline
2-3
161366-1CD
HW1480742
2.1.2 PMT data conversion by programming pendant
The following outline describes how to convert the data by using the
programming pendant.
Refer to chapter 2.3 “PMT Data Conversion by Programming Pen-
dant” for more information.
1. Select {PMT} under {UTILITY} in JOB CONTENT window.
2. Save the tool constants used before the tool deformation as the
original tool data.

2 Data Conversion by PMT Function
FS100 2.1 Outline
2-4
161366-1CD
HW1480742
3. Set the new tool constants to be used after the tool’s deformation.
4. Convert the data of WORK1 using the PMT function.

2 Data Conversion by PMT Function
FS100 2.2 PMT Data Conversion by Instruction
2-5
161366-1CD
HW1480742
2.2 PMT Data Conversion by Instruction
2.2.1 Registering GETTOOL Instruction
1. Press [INFORM LIST]
2. Select the instruction group “ARITH”
3. Select “GETTOOL”
– The instruction appears, with the same additional items that were
previously set, in the input buffer line.
4. Select any additional items in the DETAIL EDIT window
(1) Press [SELECT] two times, and the DETAIL EDIT window of the
GETTOOL instruction appears.
(2) Move the cursor to “PUT TO” and press [SELECT]. The selection
dialog box appears.
(3) Select “PMT DATA,” and the following window appears.
5. Press [ENTER]
– The GETTOOL instruction with the additional items is added to the
program for the job.
– To cancel these settings, press [CANCEL], and the JOB CONTENT
window reappears.

2 Data Conversion by PMT Function
FS100 2.2 PMT Data Conversion by Instruction
2-6
161366-1CD
HW1480742
2.2.2 Registering SETTOOL Instruction
1. Press [INFORM LIST]
2. Select the instruction group “ARITH”
3. Select “SETTOOL”
– The instruction appears, with the same additional items that were
previously set, in the input buffer line.
4. Select any additional items in the DETAIL EDIT window
(1) Press [SELECT] two times, and the DETAIL EDIT window of the
SETTOOL instruction appears.
(2) Set the TOOL FILE and the P-VAR ROBOT.
5. Press [ENTER]
– The SETTOOL instruction is registered with the additional items.
– To cancel these settings, press [CANCEL], and the JOB CONTENT
window reappears.

2 Data Conversion by PMT Function
FS100 2.2 PMT Data Conversion by Instruction
2-7
161366-1CD
HW1480742
2.2.3 Registering PMT Instruction
1. Press [INFORM LIST]
2. Select the instruction group “ARITH”
3. Select “PMT” instruction
– The instruction appears, with the same additional items that were
previously set, in the input buffer line.
4. Select any additional items
(1) Move the cursor to the tool file number and push [Select]. Then, it
becomes possible to input the number by "Numeric Value."
NOTE
Add PMT instructions for the number of jobs to be con-
verted.

2 Data Conversion by PMT Function
FS100 2.2 PMT Data Conversion by Instruction
2-8
161366-1CD
HW1480742
(2) Move the cursor to the name of the job of which data is to be con-
verted, and press [SELECT]. A list of jobs appears.
(3) Select the job subject to conversion for PMT function.
– Push "Page." Then, the screen changes to a text input screen. It is
also possible to input a job name in the text input screen.
(4) Move the cursor to the name of the job to save the data, and press
[SELECT]. A list of jobs appears.
– Push "Page." Then, the screen changes to a text input screen. It is
also possible to input a job name in the text input screen.

2 Data Conversion by PMT Function
FS100 2.2 PMT Data Conversion by Instruction
2-9
161366-1CD
HW1480742
(5) When the name of the job to save the data does not have to be
specified, move the cursor to “PMT,” and press [SELECT]. The
DETAIL EDIT window appears.
I) For the “BACKUP JOB,” select “UNUSED”.
5. Press [ENTER]
– The PMT instruction with the additional items is added to the
program.

2 Data Conversion by PMT Function
FS100 2.3 PMT Data Conversion by Programming Pendant
2-10
161366-1CD
HW1480742
2.3 PMT Data Conversion by Programming Pendant
1. Select {UTILITY} from the main menu in the job contents window in
teach mode
– The JOB CONTENT window appears.
2. Select {PMT}
– The PMT window appears.
NOTE
When the PMT function is used, the tool dimensions and the
job taught position data are rewritten.
In order to secure the data, prepare the backup files before-
hand.

2 Data Conversion by PMT Function
FS100 2.3 PMT Data Conversion by Programming Pendant
2-11
161366-1CD
HW1480742
3. Select No. of the tool for conversion
– The confirmation dialog to save the tool dimensions before
deformation appears.
(1) Select "NO" if the tool dimensions after deformation are already
registered.
Select "YES" if the tool dimensions after deformation are not regis-
tered yet.
4. Register and confirm tool dimensions
(1) Set the tool dimensions by inputting with the Numeric Keys or by
selecting {TOOL CALIBRATION} of {UTILITY}.
– For details of methods to set tool dimensions, refer to “8.3 Tool Data
Setting” of the FS100 Instruction manual.
(2) Confirm the tool dimensions before and after the PMT conversion
(ORIGINAL TOOL and ORIENTATION TOOL), then select “EXE-
CUTE”.
The indication of " "
would appear on the
display if the registered
tool demensions are
the ones before
deformation.

2 Data Conversion by PMT Function
FS100 2.3 PMT Data Conversion by Programming Pendant
2-12
161366-1CD
HW1480742
5. Select “CONVERSION MODE”.
– The following three methods are available for selecting a job.
• Method 1: SINGLE
When only the specified job is to be converted, select
“SINGLE” from “CONVERSION MODE”.
• Method 2: RELATED
When the jobs related to the specified job are to be converted
together, select “RELATED” from “CONVERSION MODE”.
• Method 3: ALL
When all the jobs registered in FS100 are to be converted,
select “ALL” from “CONVERSION MODE”.
6. Select the job for conversion
– Select “JOB NAME” to display the Job List, then select the job to be
converted.
7. Select “EXECUTE”
– Job conversion is performed based on the settings of conversion
mode.
– The window returns to the JOB CONTENT window when the
conversion is completed.

2 Data Conversion by PMT Function
FS100 2.3 PMT Data Conversion by Programming Pendant
2-13
161366-1CD
HW1480742
NOTE
For a job after conversion, be sure to confirm the path after
conversion by performing FWD/BWD operations.
If the steps beyond the manipulator’s range of motion are
created, “/0V” will be indicated in the corresponding step as
shown in the following window. The “/0V” will disappear by
correcting the positions.
However, if any step beyond the scope of operation is cre-
ated at the time of conversion, it is also possible to indicate
an error and not to allow conversion by setting Parameter
S2C390. ( Refer to chapter 5 “Parameter” at page 5-1 )
In this case, "Error 2790: Step exceeding operation range (J:
Job name, L: Line number)" is indicated.
In the step which is out of the
manipulator’s range of motion,
"/OV" is indicated for a move
instruction.