YASKAWA MOTOMAN Series User manual

MANUAL NO.
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YRC1000 OPTIONS
EtherCAT COMMUNICATION FUNCTION
INSTRUCTIONS
FOR INpact MADE BY HMS, Inc.
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-  INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
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DANGER
• This manual explains the INpact board for EtherCAT (manufactured
by HMS, Inc.) of the YRC1000 system. Read this manual carefully
and be sure to understand its contents before handling the
YRC1000. Any matter not described in this manual must be
regarded as “prohibited” or “improper”.
• General information related to safety are described in “Chapter 1.
Safety” of the YRC1000 INSTRUCTIONS. To ensure correct and
safe operation, carefully read “Chapter 1. Safety” of the YRC1000
INSTRUCTIONS.
CAUTION
• In some drawings in this manual, protective covers or shields are
removed to show details. Make sure that all the covers or shields
are installed in place before operating this product.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids the
product warranty.
NOTICE
• 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.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the YRC1000.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.
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 imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.
CAUTION
Indicates a hazardous situation,
which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.
NOTICE
NOTICE is the preferred signal word
to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION”.
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NOTICE
• Do not use or keep the board in the following environmental
conditions.
– Where exposed to direct sunshine
– Where vibration or impact occurs
– Where high humidity exists
– Where a strong magnetic field exists
– Where much dust exists
– Where a sudden change in the temperature occurs
– Where corrosive gases occur
– Where condensation occurs
• Improper usage of the board may damage the board.
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DANGER
• Before operating the manipulator, make sure the servo power is
turned OFF by performing the following operations. When the servo
power is turned OFF, the SERVO ON LED on the programming
pendant is turned OFF.
– Press the emergency stop buttons on the front door of the
YRC1000, on the programming pendant, on the external control
device, etc.
– Disconnect the safety plug of the safety fence.
(when in the play mode or in the remote mode)
If operation of the manipulator cannot be stopped in an emergency,
personal injury and/or equipment damage may result.
Fig. : Emergency Stop Button
• Before releasing the emergency stop, make sure to remove the
obstacle or error caused the emergency stop, if any, and then turn
the servo power ON.
Failure to observe this instruction may cause unintended movement of
the manipulator, which may result in personal injury.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing a teaching
operation within the manipulator's operating range:
– Be sure to perform lockout by putting a lockout device on the
safety fence when going into the area enclosed by the safety
fence. In addition, the operator of the teaching operation must
display the sign that the operation is being performed so that no
other person closes the safety fence.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind emergency response measures against the
manipulator’s unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may cause improper or unintended
movement of the manipulator, which may result in personal injury.
• Confirm that no person is present in the manipulator's operating
range and that the operator is in a safe location before:
– Turning ON the YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
Personal injury may result if a person enters the manipulator's
operating range during operation. Immediately press an emergency
stop button whenever there is a problem. The emergency stop buttons
are located on the front panel of the YRC1000 and on the right of the
programming pendant.
• Read and understand the Explanation of the Warning Labels before
operating the manipulator.
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WARNING
• Do not touch the inside of the controller cabinet for at least 5
minutes after turning the power off.
Failure to observe this warning may result in electric shock or personal
injury because of the residual voltage of the condenser.
• During power ON, do not touch the board.
Failure to observe this warning may result in fire or electric shock.
• Perform the following inspection procedures prior to conducting
manipulator teaching. If there is any problem, immediately take
necessary steps to solve it, such as maintenance and repair.
– Check for a problem 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 left unattended on the manipulator, on a
fixture, or on the floor, etc., the Enable Switch may be activated due to
surface irregularities of where it is left, and the servo power may be
turned ON. In addition, in case the operation of the manipulator starts,
the manipulator or the tool may hit the programming pendant left
unattended, which may result in personal injury and/or equipment
damage.
• Wiring and installation must be performed by authorized or certified
personnel.
Failure to observe this caution may result in fire or electric shock.
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CAUTION
• Check to be sure that there is no foreign matter (metal piece, etc.)
on the board.
Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.
• Check to be sure that there is no problem (damage, bend, etc.) with
the components of the board.
Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.
• Connect the cables and connectors properly.
Failure to observe this caution may result in fire or equipment failure.
• Make sure to properly perform the setting of the switches, etc.
Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.
• Do not touch the solder surface of the board directly with a finger.
Failure to observe this caution may result in personal injury because of
solder projection, etc.
NOTICE
• Do not touch the component-mounting surface of the board directly
with a finger.
Failure to observe this caution may result in the failure of IC, etc.
because of static electricity.
• Avoid shock on the board.
Failure to observe this caution may result in the failure of the board.
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Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the YRC1000
controller, the YRC1000 programming pendant, and the manipulator
cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
YRC1000 controller YRC1000
YRC1000 programming pendant Programming pendant
Cable between the manipulator
and the controller
Manipulator cable
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Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Equipment Manual Designation
Programming
Pendant
Character Keys
/Symbol Keys
The keys which have characters or symbols
printed on them are denoted with [ ].
e.g. [ENTER]
Axis Keys
/Numeric Keys
[Axis Key] and [Numeric Key] 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]+[COORD].
Mode Switch Mode Switch can select three kinds of modes
that are denoted as follows: REMOTE, PLAY or
TEACH.
(The switch names are denoted as symbols)
Button The three buttons on the upper side of the
programming pendant are denoted as follows:
START, HOLD, or EMERGENCY STOP.
(The button names are denoted as symbols)
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
E
M
E
R
G
E
N
C
Y
S
T
O
P
Numeric keys
Axis keys
Enter key
Mode switch*
Start button* Hold button*
Emergency stop button
Shift key
Page key
Coordinate key
PLAY
REMOTE
TEACH
START
*The button/switch names
are denoted as symbols.
HOLD
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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 [SELECT] 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.
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Contents
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1 Outline ............................................................................................................................................ 1-1
1.1 System Configuration ........................................................................................................ 1-1
2 Hardware Specifications ................................................................................................................. 2-1
2.1 Board External View .......................................................................................................... 2-1
2.2 Board Specifications .......................................................................................................... 2-2
2.3 Communication Specifications........................................................................................... 2-2
3 Mounting the INpact Board ............................................................................................................. 3-1
3.1 Opening the Front Door of the YRC1000 .......................................................................... 3-2
3.2 Mounting the INpact Board on the YRC1000 .................................................................... 3-3
3.3 Cable Connection .............................................................................................................. 3-4
3.4 Closing Front Door of the YRC1000.................................................................................. 3-5
4 I/O Signal Allocation........................................................................................................................ 4-1
4.1 Setting of Option Board and I/O Module............................................................................ 4-1
4.2 Transmission Data........................................................................................................... 4-10
4.2.1 I/O Allocation Examples for YRC1000 (For Handling)........................................ 4-11
4.2.2 I/O Allocation Examples for YRC1000 (Except for Handling)............................. 4-13
4.2.3 The Alarm when Communication Error Occurs Using the Board Status ............ 4-15
5 Error Indication................................................................................................................................ 5-1
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1 Outline
1.1 System Configuration
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1Outline
This manual describes the INpact board for EtherCAT (manufactured by
HMS Inc.) to be used in the YRC1000.
The application of the INpact board allows the general-purpose I/O data
exchange between a EtherCAT device and the YRC1000.
1.1 System Configuration
The following diagram shows an example of the configuration of a system
with an INpact board used in EtherCAT slave.
Switching
HUB
EtherCAT
EtherCAT Slave
Cable
EtherCAT Master
External PLC (Seaquencer) YRC1000 Controller
INpact
EtherCAT Slave
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2 Hardware Specifications
2.1 Board External View
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2 Hardware Specifications
2.1 Board External View
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2 Hardware Specifications
2.2 Board Specifications
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2.2 Board Specifications
2.3 Communication Specifications
Items Specifications
Interface to the external
device
EtherCAT
Board mounting position Option PCI Express slot on the YRC1000
Error indicator LED display
Number of transmission I/O
points
Maximum number of I/O points for INpact:
Input: 4032 points; Output: 4032 points
NOTE
Note on Transmission I/O Points
1. Input points and output points cannot be configured indi-
vidually.
2. YRC1000 has 4096 inputs and 4096 outputs prepared for
the I/O board.
Of these, 40 inputs and 40 outputs are pre-allocated.
In addition, 8 I/O points per channel are required for
INpact communication status.
The remaining number of I/O points are available for
transmission. The number must be a multiple of 32.
Items Specifications
Transmission speed 100Mbps Full Duplex
Transmission media EtherCAT cable
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3 Mounting the INpact Board
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3 Mounting the INpact Board
WARNING
• Before wiring or installation, make sure to turn the primary power
supply off, and put up a warning sign. (e.g. DO NOT TURN THE
POWER ON.)
Failure to observe this warning may result in electric shock or personal
injury.
• Do not touch the inside of the controller cabinet for at least 5
minutes after turning the power off.
Failure to observe this warning may result in electric shock or personal
injury because of the residual voltage of the capacitors.
• During power ON, do not touch the board.
Failure to observe this warning may result in fire or electric shock.
• Wiring and installation must be performed by authorized or certified
personnel.
Failure to observe this caution may result in fire or electric shock.
CAUTION
• Check to be sure that there is no foreign matter (metal piece, etc.)
on the board.
Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.
• Check to be sure that there is no problem (damage, bend, etc.) with
the components of the board.
Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.
• Connect the cables and connectors properly.
Failure to observe this caution may result in fire or equipment failure.
• Make sure to properly perform the setting of the switches, etc.
Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.
• Do not touch the solder surface of the board directly with a finger.
Failure to observe this caution may result in personal injury because of
solder projection, etc.
NOTICE
• Do not touch the component-mounting surface of the board directly
with a finger.
Failure to observe this caution may result in the failure of IC, etc.
because of static electricity.
• Avoid shock on the board.
Failure to observe this caution may result in the failure of the board.
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3 Mounting the INpact Board
3.1 Opening the Front Door of the YRC1000
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3.1 Opening the Front Door of the YRC1000
Mount the INpact board in the following manner.
1. Open the front door of YRC1000.
(1) Turn the door lock on the front face of the YRC1000 clockwise for
90 ° with a coin or a flat tip screwdriver.
Fig. 3-1: Door Unlock
(2) With the door locks turned clockwise for 90 °, turn the main switch
handle to the “OFF” position, and slowly open the door.
Fig. 3-2: Open the Door "OFF" Position (Horizontal)
Clockwise
Flat Tip Screwdriver
Door Lock
YRC1000
Main switch
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3 Mounting the INpact Board
3.2 Mounting the INpact Board on the YRC1000
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3.2 Mounting the INpact Board on the YRC1000
1. Remove the riser board (JANCD-ABB02-E) from the CPU rack.
2. Mount the INpact board on the riser board, then securely tighten the
INpact board with a screw.
3. Mount the riser board in the CPU rack.
Fig. 3-3: When the INpact Board is Inserted into Option: Slot1
Fix with a screw
Option slot1 Option slot2
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3 Mounting the INpact Board
3.3 Cable Connection
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3.3 Cable Connection
1. Connect the EtherCAT cable to EtherCAT connector of the INpact
board.
Fig. 3-4: When the INpact Board is Inserted into Option: Slot1
Connect the EtherCAT
cable to EtherCAT connector
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3 Mounting the INpact Board
3.4 Closing Front Door of the YRC1000
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3.4 Closing Front Door of the YRC1000
1. Close the front door of YRC1000.
(1) Close the door gently.
(2) Turn the door lock on the front face of the YRC1000 counterclock-
wise for 90 ° .
Fig. 3-5: Lock the Door
WARNING
Make sure to close the door and close all the door locks of the
YRC1000 whenever it is used, except for maintenance.
Failure to observe this instruction may cause the ingress of dust, dirt, or
water, which may result in electric shock and/or mechanical failure.
Counter
Clockwise
Flat Tip
Screwdriver
Door Lock
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4 I/O Signal Allocation
4.1 Setting of Option Board and I/O Module
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4 I/O Signal Allocation
4.1 Setting of Option Board and I/O Module
In order to use the INpact board in the YRC1000, perform the setting of
the option board and I/O module in the following manner.
1. Turn ON the power supply while pressing {MAIN MENU}.
– The Maintenance mode starts.
2. Set the security mode to the “Management Mode”.
3. Select {SYSTEM} under the main menu.
– The sub menu appears.
SUPPLE
-MENT
Set the option board and I/O module in the management
mode.
In the operation mode and the editing mode, the settings are
for reference only.
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