YASKAWA MOTOMAN FS100 User manual

MANUAL NO.RE-CHO-A111
Part Number: 159645-1CD
Revision: 5
9
FS100
MAINTENANCE MANUAL
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
The FS100 OPERATOR’S MANUAL above is applicable to both FS100 and FS100L controllers.
1 of 348

ii
159645-1CD
RE-CHO-A111
FS100
Copyright © 2017, 2015, 2013, 2012, 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, 2012
YASKAWA America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com
2 of 348

iii
159645-1CD
RE-CHO-A111
FS100
MANDATORY
• This manual explains maintenance procedures 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.
3 of 348

iv
159645-1CD
RE-CHO-A111
FS100
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 348

v
159645-1CD
RE-CHO-A111
Notes for Safe Operation
FS100
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
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” .
5 of 348

Notes for Safe Operation
vi
159645-1CD
RE-CHO-A111
FS100
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.
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
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.
Fig. : 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.
– 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 348

vii
159645-1CD
RE-CHO-A111
Definition of Terms Used Often in This Manual
FS100
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:
CAUTION
• 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.
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
7 of 348

Description of the Operation Procedure
viii
159645-1CD
RE-CHO-A111
FS100
Descriptions of the programming pendant keys, 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 [ ].
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 348

ix
159645-1CD
RE-CHO-A111
Explanation of Warning Labels
FS100
Explanation of Warning Labels
DANGER
• The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
Failure to observe this caution may result in injury or damage to
equipment.
Fig. : Warning Labels
• The following warning labels are attached to FS100.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to
equipment.
Fig. : Location of Warning Labels
WARNING Label B:
WARNING Label A:
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
Heavy Object Warning NP
Electric Shock Warning NP
Electric Shock Warning NP
Top View
Front View
9 of 348

Safeguarding Tips
x
159645-1CD
RE-CHO-A111
FS100
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.
10 of 348