YASKAWA MOTOMAN FS100 User manual

Part Number: 174512-1CD
Revision: 0
MANUAL NO.
HW1483164
FS100 OPTIONS
INSTRUCTIONS
FOR CONVEYOR COORDINATED FUNCTION
• Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
• This instruction is applicable to both FS100 and FS100L controllers.
MOTOMAN INSTRUCTIONS
(FOR SMALL -SIZED MANIPULATORS)
MOTOMAN- INSTRUCTIONS
FS100 INSTRUCTIONS
FS100 OPERATOR’S MANUAL
FS100 MAINTENANCE MANUAL
(FOR LARGE AND MEDIUM-SIZED MANIPULATORS)
MOTOMAN- INSTRUCTIONS
FS100L INSTRUCTIONS
FS100LOPERATOR’S MANUAL
FS100L MAINTENANCE MANUAL
The FS100 OPERATOR’S MANUAL above is applicable to both FS100 and FS100L controllers.
1 of 28

ii
174512-1CD
HW1483164
Conveyor Coordinated
Function
Copyright © 2015, 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, 2015
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com
2 of 28

iii
174512-1CD
HW1483164
Conveyor Coordinated
Function
MANDATORY
• This manual explains the conveyor coordinated function of the
FS100. 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.
NOTE
This instruction manual is applicable to both FS100 (a
controller for small-sized manipulators) and FS100L (a
controller for large and medium-sized manipulators).
The description of “FS100” refers to both ”FS100” and
“FS100L” in this manual unless otherwise specified.
3 of 28

iv
174512-1CD
HW1483164
Conveyor Coordinated
Function
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.
4 of 28

v
174512-1CD
HW1483164
Conveyor Coordinated
Function Notes for Safe Operation
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 “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
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
“DANGER”, “WARNING” and “CAUTION”.
5 of 28

Notes for Safe Operation
vi
174512-1CD
HW1483164
Conveyor Coordinated
Function
WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on the programming 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 button does not function.
Figure 1: 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
supply 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.
Figure 2: Release of Emergency Stop Button
• Observe the following precautions when performing teaching
operations within the manipulator’s operating range:
– 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.
TURN
6 of 28

vii
174512-1CD
HW1483164
Conveyor Coordinated
Function Notes for Safe Operation
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 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 manipulator’s operating range
during operation. Always press an emergency stop button immediately
if there are problems.
The emergency stop button is located on the programing pendant.
CAUTION
• Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.
– Check for problems in manipulator movement.
– Check for damage to the 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 the Explanation of Warning Labels in the
FS100 Instructions before operating the manipulator.
7 of 28

Definition of Terms Used Often in This Manual
viii
174512-1CD
HW1483164
Conveyor Coordinated
Function
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:
Descriptions of the programming pendant, buttons, and displays are
shown as follows:
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
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. 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 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
8 of 28

ix
174512-1CD
HW1483164
Conveyor Coordinated
Function Description of the Operation Procedure
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.
9 of 28

Customer Support Information
x
174512-1CD
HW1483164
Conveyor Coordinated
Function
Customer Support Information
If you need assistance with any aspect of your Conveyor Coordinated
Function system, please contact Motoman Customer Support at the
following 24-hour telephone number:
For routine technical inquiries, you can also contact Motoman Customer
Support at the following e-mail address:
When using e-mail tocontact Motoman 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 Motoman Customer
Support at the telephone number shown above.
• System Conveyor Coordinated Function
• Robots ___________________________
• Primary Application ___________________________
• Controller FS100 & FS100L
• 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 FS100 & FS100L
controller data plate
[phone]
10 of 28

xi
174512-1CD
HW1483164
Conveyor Coordinated
Function Table of Contents
Table of Contents
1 Conveyor Coordinated Function.....................................................................................................1-1
1.1 Conveyor Coordinated Function........................................................................................1-1
1.2 Configuration of Conveyor Coordinated Function..............................................................1-1
2 Setting.............................................................................................................................................2-1
2.1 Setting the Mechanical Specification for the Conveyor Coordinated Axis.........................2-1
2.1.1 Confirmation of the “Mechanical Specifications” of the Station Axis....................2-1
2.1.2 Setting Conveyor Coordinate Mechanical Specification.......................................2-3
2.2 Setting for the Conveyor Synchronization Operation.........................................................2-5
2.2.1 Conveyor Condition File.......................................................................................2-5
2.2.2 Conveyor Home Position Signal (LS Signal)........................................................2-6
3 Conveyor Coordinated Axis Operation ...........................................................................................3-1
4 Job Example...................................................................................................................................4-1
4.1 System Configuration ........................................................................................................4-1
4.2 Conveyor Coordinated Axis Job........................................................................................4-2
4.3 Manipulator Job.................................................................................................................4-4
4.4 Master Job.........................................................................................................................4-5
5 Supplementary Contents ................................................................................................................5-1
5.1 Adjusting the Conveyor Coordinated Axis Accuracy .........................................................5-1
11 of 28

1 Conveyor Coordinated Function
1.1 Conveyor Coordinated Function
1-1
174512-1CD
HW1483164
Conveyor Coordinated
Function
This manual explains the conveyor coordinated function of the FS100.
1 Conveyor Coordinated Function
1.1 Conveyor Coordinated Function
The conveyor coordinated function enables the manipulator to follow the
conveyor controlled as a station axis of the FS100.
Controlling the manipulator and a conveyor axis by the FS100 makes it
possible for the manipulator to follow the conveyor more accurately than in
the conventional conveyor synchronized function, even though the
conveyor repeats the acceleration-deceleration operation.
1.2 Configuration of Conveyor Coordinated Function
The conveyor coordinated function is what the conventional conveyor
synchronized function is expanded. It became possible to use a station
axis of the FS100 as a conveyor axis. (Hereinafter, a station axis used as
a conveyor is described as a “conveyor coordinated axis”.)
In the same way as the usual station axis, a conveyor coordinated axis is
moved by the move instruction of the job.
Set the conveyor condition file to register the conveyor coordinated axis
as the conveyor before use.
To make the manipulator follow the conveyor coordinated axis, use the
same instructions for conveyor synchronized operation (SYSTART/
SYMOVL/SYEND, etc.) as used in the conventional conveyor
synchronized control. The same jobs used in the conventional conveyor
synchronized control can be also used in this function.
Also, the conveyor coordinated axis can be used together with an external
conveyor synchronized by the conventional synchronized function. At this
time, the counter module: CNTR-01R is necessary to read the encoder. In
a system synchronizing only a conveyor coordinated axis, CNTR-01R is
not necessary.
12 of 28

1-2
174512-1CD
HW1483164
Conveyor Coordinated
Function 1 Conveyor Coordinated Function
1.2 Configuration of Conveyor Coordinated Function
When using both the external conveyor and the conveyor coordinated
axis, CNTR-01R is necessary.
Fig. 1-1: External Conveyor and Conveyor Coordinated Axis
When using only the conveyor coordinated axis, CNTR-01R is not
necessary.
Fig. 1-2: Conveyor Coordinated Axis Only
CV#2
Conveyor
CV#1
Conveyor Coordinated
Axis (S1)
CV#2
Conveyor Coordinated
Axis (S1)
CV#1
Conveyor Coordinated
Axis (S1)
13 of 28

1 Conveyor Coordinated Function
1.2 Configuration of Conveyor Coordinated Function
1-3
174512-1CD
HW1483164
Conveyor Coordinated
Function
NOTE
The conveyor coordinated function is what the conveyor
synchronized function is expanded. This manual explains
only the contents specific to the conveyor coordinated
function. For the conventional conveyor synchronized
function, refer to the following manuals.
FS100 OPTIONS INSTRUCTIONS FOR CONVEYOR
SYNCHRONIZED FUNCTION (161365-1CD)
FS100 OPTIONS INSTRUCTIONS FOR CONVEYOR
SYNCHRONIZED FUNCTION SUPPLEMENTARY FOR
CONVEYOR SYNCHRONIZED FUNCTION WITH SHIFT
FUNCTIONS (161595-1CD)
FS100 OPTIONS INSTRUCTIONS FOR CONVEYOR
SYNCHRONIZED FUNCTION SUPPLEMENTARY FOR
CONTINUOUS OPERATION CONVEYOR
SYNCHRONIZED FUNCTION (164097-1CD)
14 of 28

2-1
174512-1CD
HW1483164
Conveyor Coordinated
Function 2 Setting
2.1 Setting the Mechanical Specification for the Conveyor Coordinated
Axis
2 Setting
2.1 Setting the Mechanical Specification for the Conveyor
Coordinated Axis
To coordinate the manipulator and the conveyor coordinated axis
accurately, the conveyor coordinated axis is registered as a specific
station type.
Set the mechanical specifications of the conveyor coordinated axis as
follows.
2.1.1 Confirmation of the “Mechanical Specifications” of the Station Axis
Select {SYSTEM} and {SETTING} to display “CONTROL GROUP”
window in the maintenance mode.
Select “DETAILE” at “CV-MPP0003-A0*” of S1 or S2.
Press [Enter] to display “CONNECT” and “AXES CONFIG” windows.
15 of 28

2 Setting
2.1 Setting the Mechanical Specification for the Conveyor Coordinated
Axis
2-2
174512-1CD
HW1483164
Conveyor Coordinated
Function
“MECHANICAL SPEC” window appears. Confirm the following values are
set.
MOTION RANGE (+) 360.000 deg
MOTION RANGE (-) -360.000 deg
REDUCTION RATIO (NUMER) 1.000
REDUCTION RATIO (DENOM) 9999.000
16 of 28

2-3
174512-1CD
HW1483164
Conveyor Coordinated
Function 2 Setting
2.1 Setting the Mechanical Specification for the Conveyor Coordinated
Axis
2.1.2 Setting Conveyor Coordinate Mechanical Specification
The following settings are necessary to move the conveyor.
Perform the setting in the following procedure.
<Setup procedure>
1. Select {SYSTEM}, {SETTING} and then “CONVEYOR COORDINATE
MECHA SPEC” in the maintenance mode.
2. Set the gear ratio, rotation ratio and load inertia ratio and “enable” the
function. Then press [ENTER] to complete the setting.
Set the following values for the gear ratio, rotation ratio and load inertia
ratio.
GEAR RATIO Reduction ratio of the speed reducer etc.
(If there is a sprocket, set the rotation ratio
between the sprocket and the motor.)
ROTATION RATIO
Rotation ratio between the conveyor and the motor
(How many times the motor rotates per one whole
rotation of the conveyor operated as the conveyor
coordinated axis.)
INERTIA Perform the setting in the same way as the usual
external axis.
Calculation example of rotation ratio
Rotation ratio = sprocket tooth number ÷chain number of the whole
conveyor x gear ratio
* When one chain moves per two sprocket teeth, calculate the
sprocket tooth number by “the actual sprocket tooth number / 2”.
17 of 28

2 Setting
2.1 Setting the Mechanical Specification for the Conveyor Coordinated
Axis
2-4
174512-1CD
HW1483164
Conveyor Coordinated
Function
The setting in the maintenance mode is completed.
NOTE
<Rotation Ratio>
After the normal setup and on-line (normal) startup, if the
conveyor coordinated axis rotates one time from where the
pulse is “0” in the jog operation, the axis comes where the
pulse is “0”. In case of a half rotation, the axis comes where
the pulse is “4096 x rotation ratio / 2”. (In the example,
4096 x 98437 / 1000 / 2 = 201599 pulse) When the values
are different from the above, confirm the rotation ratio
because it may be wrong.
NOTE
<Gear Ratio and Load Inertia Ratio>
When the gear ratio and load inertia ratio are wrong, the
conveyor coordinated axis may move vibrationally. In this
case, confirm the values of the gear ratio and load inertia
ratio.
18 of 28

2-5
174512-1CD
HW1483164
Conveyor Coordinated
Function 2 Setting
2.2 Setting for the Conveyor Synchronization Operation
2.2 Setting for the Conveyor Synchronization Operation
2.2.1 Conveyor Condition File
By setting the conveyor condition file, the conveyor coordinated axis can
be recognized as the synchronizing target conveyor.
When using the usual conveyor, “CN1” or “CN2” is set for “PORT NO.” In
the case of registering the conveyor coordinated axis, register “S1” or “S2”
there.
For other settings than “PORT NO.”, set values in the same way as the
conventional conveyor synchronized control.
(Example)
As shown in the following figure, when using CV#1 as the conveyor
coordinated axis and CV#2 as the external conveyor, set S1 for the PORT
NO. in the conveyor condition file of CV#1. (For the PORT NO. of CV#2,
set CN1 etc.)
Fig. 2-1: Setting the Port No.
CV#1
Conveyor Coordinated
Axis (S1)
CV#2
Conveyor
19 of 28

2 Setting
2.2 Setting for the Conveyor Synchronization Operation
2-6
174512-1CD
HW1483164
Conveyor Coordinated
Function
2.2.2 Conveyor Home Position Signal (LS Signal)
Conveyor home position signal (LS signal) for the conveyor specified as
the conveyor coordinated axis can be turned ON by inputing the specific
input.
Create the job and ladder so that the specific input is turned ON at the
timing when the conveyor coordinated axis moves to the home position.
(Refer to chapter 4 “Job Example”.)
Also, conveyor home position signal for the external conveyor can be
turned ON by the specific input.
(Instead of using the specific input, the external LS signal can be also
used as usual.)
40660 40661 40662
Conveyor Conveyor Conveyor
Home position signal Home position signal Home position signal
S1 S2 S3
40670 40671 40672 40673 40674 40675
Conveyor Conveyor Conveyor Conveyor Conveyor Conveyor
Home
position
signal
Home
position
signal
Home
position
signal
Home
position
signal
Home
position
signal
Home
position
signal
CN1 CN2 CN3 CN4 CN5 CN6
20 of 28