YASKAWA Motoman MLX200 Mounting instructions

Part Number: 168283-1CD
Revision: 8
MLX200
HARDWARE INSTALLATION &
SOFTWARE UPGRADE
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
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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
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MANDATORY
• This manual explains setup, diagnosis, maintenance, hardware,
etc. of the MLX200 Hardware Installation & Software Upgrade.
Read this manual carefully and be sure to understand its contents
before using the Hardware Installation & Software Upgrade.
• General items related to safety are listed in Chapter 1. To ensure
correct and safe operation, carefully read the section.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure that 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 a 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
Read this manual carefully before installation, operation, maintenance, or
inspection of the Hardware Installation & Software Upgrade.
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
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
“CAUTION” and “WARNING.”
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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 MLX200 Control Module power
- Moving the manipulator with teach pendant or MLX HMI
- 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 the emergency stop button
immediately if there are problems. The emergency stop button is
located on the right of the teach pendant.
• 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.
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on teach pendant is pressed.
When the servo power is turned OFF, the SERVO ON INDICATOR
on the teach pendant or MLX HMI is turned OFF.
Injury or damage to machinery may result if the Emergency Stop circuit
cannot stop the positioner during an emergency. The positioner should
not be used if the EMERGENCY STOP buttons do not function.
Figure 1: EMERGENCY STOP Button
• Release the EMERGENCY STOP button. Once this button is
released, clear the cell of all items which could interfere with the
operation of the positioner. Then turn servo power ON.
Injury may result from unintentional or unexpected positioner motion.
Figure 2 : Release of EMERGENCY STOP Button
TURN
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Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN consists of the manipulator, the drive panel, and
manipulator cables.
In this manual, the equipment is designated 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.
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.
The optional teach pendant can be damaged if it is left in the
P-point maximum envelope of the manipulator’s work area, on the floor,
or near fixtures.
• Read and understand the Explanation of the Warning Labels before
operating the manipulator.
Equipment Manual Designation
MLX200 Drive Panel MLX Drive Panel
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Explanation of Warning Labels
The following warning labels are attached to the manipulator.
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 caution may result in injury or damage to
equipment.
Refer to the manipulator manual for the warning label location.
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
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Table of Contents
Table of Contents
1 Introduction ..................................................................................................................................... 1-1
1.1 MLX200 Robot Control Module Components .................................................................... 1-1
1.1.1 User Supplied Components.................................................................................. 1-2
1.2 For Your Safety.................................................................................................................. 1-2
1.3 Special Training ................................................................................................................. 1-3
1.4 Motoman Manual List ........................................................................................................ 1-4
1.5 Personnel Safety ............................................................................................................... 1-5
1.6 Motoman Safety................................................................................................................. 1-7
1.6.1 Installation and Wiring Safety ............................................................................... 1-7
1.6.2 Work Area Safety ................................................................................................. 1-9
1.6.3 Operation Safety ................................................................................................ 1-10
1.7 Notes for Moving and Transferring the MOTOMAN ........................................................ 1-11
1.8 Notes on MOTOMAN Disposal........................................................................................ 1-12
2 Product Confirmation ...................................................................................................................... 2-1
2.1 Before Unpacking .............................................................................................................. 2-1
2.2 Unpacking.......................................................................................................................... 2-1
2.3 Contents Confirmation....................................................................................................... 2-1
2.3.1 Optional Teach Pendant (Fuji).............................................................................. 2-2
2.4 Warranty ID Confirmation ..................................................................................................2-
3
2.5 Customer Support Information........................................................................................... 2-5
3 Installation....................................................................................................................................... 3-1
3.1 Handling Procedure........................................................................................................... 3-1
3.1.1 Moving the Drive Panel ........................................................................................ 3-1
3.2 Installation Environment .................................................................................................... 3-1
3.3 Location ............................................................................................................................. 3-2
3.4 Cut-Outs for Emergency Stop and Auto/ Manual Buttons ................................................. 3-9
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4 Connections .................................................................................................................................... 4-1
4.1 Notes on Cable Junctions ..................................................................................................4-
2
4.2 Power Supply..................................................................................................................... 4-3
4.2.1 Three-Phase Power Supply.................................................................................. 4-3
4.2.2 Primary Power Supply Breaker/ Fuse Installation ................................................ 4-3
4.3 Connection Methods .......................................................................................................... 4-5
4.3.1 Connecting the Primary Power Supply ................................................................. 4-5
4.3.2 Connecting the Manipulator Cable ....................................................................... 4-6
4.3.3 Dual Robot Connection......................................................................................... 4-7
5 Turning ON and OFF the Power Supply .........................................................................................5-
1
5.1 Turning ON the Main Power Supply .................................................................................. 5-1
5.2 Turning OFF the Power Supply ......................................................................................... 5-1
5.2.1 Turning OFF the Servo Power (Emergency Stop)................................................ 5-1
6 Test of Program Operation.............................................................................................................. 6-1
6.1 Movement of the Axes ....................................................................................................... 6-2
7 System Setup.................................................................................................................................. 7-1
7.1 Home Position Calibration .................................................................................................7-1
7.1.1 Home Position Calibration .................................................................................... 7-2
7.1.2 Calibrating Operation............................................................................................ 7-3
7.1.3 Home Position of the Robot.................................................................................. 7-6
7.1.4 Purpose of Position Check Operation................................................................... 7-7
7.1.5 Procedure after the Alarm..................................................................................... 7-7
7.2 Tool Data Setting ............................................................................................................... 7-8
7.2.1 Registering Tools.................................................................................................. 7-8
7.2.2 Tool Calibration................................................................................................... 7-15
8 MLX200 Specification ..................................................................................................................... 8-1
8.1 Specification List ................................................................................................................ 8-2
8.1.1 Panel Heat Loss (Estimate) .................................................................................. 8-2
8.2 Equipment Configuration ...................................................................................................8-
3
8.2.1 Arrangement of Units and Circuit Boards ............................................................. 8-3
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9 Description of Units and Circuit Boards .......................................................................................... 9-1
9.1 SERVOPACK .................................................................................................................... 9-9
9.1.1 SERVOPACK Configuration................................................................................. 9-9
10 MLX200 Control Module Software Version Upgrade Procedure ................................................ 10-1
10.1 Upgrade the Application on the MLX200 Control Module.............................................. 10-1
10.2 Export Robot Data for RSLogix Ladder ......................................................................... 10-4
10.3 Export non-MLX Tasks from the RSLogix Ladder ......................................................... 10-5
10.4 Download New Version of MLX200 Control Module Software ...................................... 10-5
10.5 Setup I/O Configuration in RSLogix Ladder................................................................... 10-5
10.6 Import Tasks into the New RSLogix Ladder .................................................................. 10-5
10.7 Import the Robot Data into RSLogix .............................................................................. 10-6
10.8 Configure the new MLX200-HMI file to see the “MLX200x_x_x” processor. ................. 10-6
10.9 Teach Pendant Software Upgrade. ............................................................................... 10-7
11 Teach Pendant Software Upgrade Procedure (Fuji Pendant) .................................................... 11-1
11.1 Configure PC to use a Static IP ..................................................................................... 11-2
11.1.1 Prepare Pendant to Set the IP Address for the NEW/
UN-PROGRAMMED System.............................................................................. 11-3
11.1.2 Prepare Pendant to Change IP Address for an Upgraded System .................. 11-3
11.1.3 Setting IP Address for Pendant ........................................................................ 11-4
11.2 Setup the Fuji V-SFTV5 Monitouch Program ................................................................ 11-5
11.3 Transfer Screen Data to Teach Pendant (Version 5) .................................................... 11-7
11.4 Setup the Fuji V-SFTV6 Monitouch Program ................................................................ 11-9
11.5 Transfer Screen Data to Teach Pendant (Version 6) .................................................. 11-11
11.6 Install the MLX Version Label ...................................................................................... 11-13
12 Sigma-5 Amplifier Parameter Upgrade Procedure ..................................................................... 12-1
13 HMI Communications Setup Procedure...................................................................................... 13-1
13.1 Version Note.................................................................................................................. 13-1
13.2 Configuring Factory Talk Administration Console.......................................................... 13-1
13.3 Copy PLC Design to Runtime........................................................................................ 13-6
13.4 Starting up the HMI........................................................................................................ 13-8
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Appendix A ........................................................................................................................................A-1
A.1 Rockwell MobileView Support ...........................................................................................A-1
A.1.1 Overview ..............................................................................................................A-1
A.1.2 Components .........................................................................................................A-1
A.1.3 Wiring ...................................................................................................................A-2
A.1.4 Software ...............................................................................................................A-6
A.1.5 External References.............................................................................................A-6
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1 Introduction
1.1 MLX200 Robot Control Module Components
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1 Introduction
The MLX200 Control Module solution enables the user to replace the
traditional robot controller with PLC-based software and general purpose
motion control hardware.
The Hardware Installation & Software Upgrade enables the user to
integrate select Yaskawa manipulator models with Rockwell Automation
ControlLogix Programmable or CompactLogix Automation Controller
(PAC) and RSLogix 5000 development software via a customized set of
MLX200 Control module software, Add-On Instructions and associated
computer hardware.
Fig. 1-1: Layout (MPL160 Shown)
1.1 MLX200 Robot Control Module Components
Several Hardware Installation & Software Upgrade configurations are
available and include the appropriate control panel, servo amplifiers,
cables, and components required to interface with the Rockwell
ControlLogix or CompactLogix controller and target manipulator.
The MLX200 Robot Control Module includes the runtime from the
MLX200 software. This is the operating system for the robot and provides
full kinematics for the supplied manipulator. In addition, the software
provides interference zones, robot jogging controls in multiple coordinate
systems, and tool frame control. The control module handles all motion
control tasks.
MLX APPLICATION
ROCKWELL AUTOMATION
COMPACTLOGIX OR
CONTROLLOGIX PAC
ROCKWELL AUTOMATION
RSLOGIX 5000
YASKAWACUSTOMER SUPPLIED
PROGRAMMING
PENDANT
(OPTION)
ETHERNET
HUB
MLX200 CONTROL MODULE
& SERVO PANEL ASSY
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1.2 For Your Safety
1.1.1 User Supplied Components
When using an Hardware Installation & Software Upgrade controlled
robot, the user must supply the following items:
• Rockwell Programmable Automation Controller (PAC). Either;
• ControlLogix: 1756-L61 minimum
• CompactLogix: L2 or L3 controller minimum, with 1 MB of
memory
• Ethernet/ IP Communication port
• Rockwell Automation RSLogix 5000 software (v19)
• Switch (managed switch suggested)
• User Application
• I/O and safety modules
• FactoryTalk View Machine Edition or Studio Edition (v6.1)
Many of these items can be purchased from Yaskawa. Contact your
Yaskawa sales representative for more information.
1.2 For Your Safety
Robots generally have requirements which are different from other
manufacturing equipment, such as larger working areas, high-speed
operation, rapid arm movements, etc., which can pose safety hazards.
Read and understand the instruction manuals and related documents, and
observe all precautions in order to avoid the risk of injury to personnel and
damage to equipment.
It is the user’s responsibility to ensure that all local, state, and national
codes, regulations rules, or laws relating to safety and safe operating
conditions are met and followed.
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1.3 Special Training
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1.3 Special Training
MANDATORY
• Teaching maintenance of the robot must conform to:
– Industrial Safety and Health Law
– Enforcement Order of Industrial Safety and Health Law
– Ordinance of Industrial Safety and Health Law
Other related laws are:
– Occupational Safety and Health Act in USA
– Factory Act (Gewerbeordnung) in Germany
– Health and Safety at Work, etc. Act in UK
– EC Machinery Directive 98/37/EC
• Prepare
– SAFETY WORK REGULATIONS
based on concrete policies for safety management complying
with related laws.
• Observe the
– MANIPULATING INDUSTRIAL ROBOTS-SAFETY (ISO 10218)
for safe operation of the robot. (Japan Only) (JIS B 8433)
• Reinforce the
– SAFETY MANAGEMENT SYSTEM
by designating authorized workers and safety managers, as well
as giving continuing safety education.
• Teaching and maintaining the robot are specified as
“Hazardous Operations” in the Industrial Safety and Health Law
MANDATORY
• Persons who teach or inspect the manipulator must undergo
required training before using the manipulator.
• For more information on training, inquire at the nearest YASKAWA
branch office.
The telephone numbers are listed on the back cover of this manual.
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1.4 Motoman Manual List
1.4 Motoman Manual List
The instruction manuals below describe how the manipulators with the
MLX200 Hardware Installation & Software Upgrade are different from
those with the standard DX100/ DX200/ FS100 Controller.
MANDATORY
Read this instruction manual thoroughly together with the following
instruction manuals:
• Yaskawa Motoman Manipulator Instructions for your model.
Disregard all references to the “DX100 or DX200” Controller when
reading using the manipulator manual. This manual is to be used for
manipulator hardware only.
– Motoman-MH5S Instructions (P/N 160475-1CD)
– Motoman-MH5S II Instructions (P/N 172401-1CD)
– Motoman-MH5LS Instructions (P/N 161052-1CD)
– Motoman-MH5LS II Instructions (P/N 170780-1CD)
– Motoman-MH12 Instructions (P/N 167105-1CD)
– Motoman-HP20D Instructions (P/N 168283-1CD)
– Motoman-SIA20D Instructions (P/N 156387-1CD)
– Motoman-MPK50 Instructions (P/N 156865-1CD)
– Motoman-MPL80 Instructions (P/N 157283-1CD)
– Motoman-MPL80 II Instructions (P/N 170904-1CD)
– Motoman-MPL160 Instructions (P/N 156830-1CD)
– Motoman-MPL160 II Instructions (P/N 172536-1CD)
– Motoman-MPL300 Instructions (P/N 157284-1CD)
– Motoman-MPL300 II Instructions (P/N 173124-1CD)
• MLX200 Software and Operation Manual (P/N 168542-1CD)
Confirm that you have the appropriate manipulator manual and
MLX200 Software and Operation Manual on hand. If any manuals are
missing, contact your salesman from YASKAWA’s local branch office.
The relevant telephone numbers are listed on the last page.
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1.5 Personnel Safety
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1.5 Personnel Safety
The entire manipulator P-point maximum envelope is potentially
dangerous.
All personnel working with the MOTOMAN (safety administration,
installation, operation, and maintenance personnel) must always be
prepared and “Safety First” minded, to ensure the safety of all personnel.
CAUTION
• Avoid any dangerous actions in the area where the MOTOMAN is
installed.
There is a danger of injury if there is contact with the manipulator or
peripheral equipment.
• Please take strict safety precautions by placing signs such as
“Flammable”, “High Voltage”, “Waiting”, and “Off-limits to
Unauthorized Personnel” in necessary areas in the factory.
Failure to observe these cautions may result in fire, electric shock, or
injury due to contact with the manipulator and other equipment.
• Strictly observe the following items:
– Always wear approved work clothes (no loose-fitting clothes).
– Do not wear gloves when operating the MOTOMAN.
– Do not allow underwear, shirts, or neckties to hang out from the
work clothes.
– Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety
shoes (with slip-proof soles), face shields, safety glasses, and gloves
as necessary.
Improper clothing may result in injury.
• Unauthorized persons should not approach the manipulator or
associated peripheral equipment.
Failure to observe this caution may result in injury due to contact with
the Hardware Installation & Software Upgrade, the workpiece, the
robot, etc.
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1.5 Personnel Safety
CAUTION
• Never forcibly move the manipulator axes.
Failure to observe this caution may result in injury or equipment
damage.
• Never lean on Hardware Installation & Software Upgrade or other
controllers, and avoid inadvertently pushing buttons.
Failure to observe this caution may result in injury or damage by
unexpected movement of the manipulator.
• Never allow unauthorized personnel to touch the Hardware
Installation & Software Upgrade during operation.
Failure to observe this caution may result in injury or damage resulting
from unexpected movement of the manipulator.
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1.6 Motoman Safety
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1.6 Motoman Safety
1.6.1 Installation and Wiring Safety
In planning installation, adapt an easy to observe arrangement to ensure
safety. Take safety into consideration when planning the installation.
Observe the following when installing the manipulator:
• Select an area such as that described below to install the
manipulator:
Confirm that the area is large enough so that the fully extended
manipulator arm with tool will not reach a side wall, safeguarding, or
the drive panel.
Failure to observe this Warning may result in injury or damage resulting
from unexpected movement of the manipulator.
• Perform grounding in accordance with all applicable electrical
codes.
Failure to observe this caution may result in fire or electric shock.
CAUTION
• Operation of cranes, slings, or forklifts should only be performed by
authorized personnel.
Failure to observe this precaution may result in injury or equipment
damage.
1000 mm or more
1000 mm or more
1000 mm or more 1000 mm or more
MLX200
MLX200 MAXIMUM WORKING ENVELOPE
OF MANIPULATOR INCLUDING TOOL OR
WORKPIECE END
WORKING ENVELOPE
OF MANIPULATOR
SAFEGUARD
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1.6 Motoman Safety
MOTOMAN should be lifted with a crane using appropriately rated
cable or strapping threaded through the provided lifting eyes and lifted
in an upright posture as described in the manipulator instruction
manual.
Failure to observe these precautions may cause the manipulator to turn
downward, potentially causing injury or damage to equipment.
CAUTION
• When lifting the MLX200 drive panel, please check the following:
– As a rule, handling of the MLX200 drive panel can be performed
by two or more people.
– The MLX200 drive panel weighs approximately 31 - 47 kg (69 -
104 lbs). Be sure movers are strong enough to handle this
weight.
Failure to observe this caution may result in injury or damage to
equipment.
• If storing the manipulator temporarily before installation, be sure to
place it on a stable and flat surface and take precautions to prevent
unauthorized personnel from touching it.
Failure to observe this precaution may result in injury of damage to
equipment.
CAUTION
• Be sure there is sufficient room for maintenance on the manipulator,
Hardware Installation & Software Upgrade, and other peripheral
equipment.
Failure to observe this precaution could result in injury during
maintenance.
• To ensure safety, be sure to operate the drive panel from a location
where the manipulator is easily visible.
Operation by unauthorized personnel may result in injury or equipment
damage.
• Install the MLX200 drive panel outside the safeguarding of the
manipulator’s safety enclosure.
Failure to observe this precaution may result in injury or damage to
equipment resulting from contact with the manipulator.
CAUTION
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