YASKAWA MOTOMAN DX100 User manual

Part Number: 158604-1CD
Revision: 1
MANUAL NO.
1
HW1480185
DX100 OPTIONS
INSTRUCTIONS
STANDARD I/O SIGNAL ASSIGNMENT TABLE (PNP SPECIFICATION)
FOR ROBOT I/F UNIT TYPE: JZNC-YIU02-E
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
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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 supplementary manual describes the standard I/O signal
assignments for the PNP specification. Read this manual carefully
and be sure to understand its contents before handling the DX100.
• The differences are described based on "13.12.1 to 13.12.4 User I/
O Signal Assignment" in "DX100 INSTRUCTIONS" (Manual No.
RE-CTO-A215). Read this manual thoroughly replacing the subject
matters for changes with this supplementary instruction manual.
• General items related to safety are listed in Section 1: Safety of the
DX100 Instructions. 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 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.
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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 DX100.
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 DX100 power
- Moving the manipulator with the programming pendant
- 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 an emergency stop button
immediately if there are problems.The emergency stop buttons are
located on the right of the front door of the DX100 and the programming
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 buttons on the front
door of the DX100 and programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming 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.
Emergency Stop Button
• 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.
Release of Emergency Stop
TURN
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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 controller, the
programming pendant, and the manipulator cables.
In this manual, the equipment is designated as follows:
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
DX100 cabinet after use.
The programming 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
DX100 Controller DX100
DX100 Programming Pendant Programming Pendant
Cable between the manipulator and
the controller
Manipulator Cable
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Descriptions of the programming pendant, 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 key is an exception, and a picture is
not shown.
Axis Keys
Number Keys
“Axis Keys” and “Number 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]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
GO
BACK
PAGE
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Customer Support Information
If you need assistance with any aspect of your Standard I/O Signal
Assignment Table (PNP) 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 to contact 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:
techsupp[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
• Robots
• Positioner
• Primary Application
• Controller DX100
• 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 controller data
plate
[phone]
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Table of Contents
Table of Contents
1 Arc Welding..................................................................................................................................... 1-1
2 Handling.......................................................................................................................................... 2-1
3 General Application......................................................................................................................... 3-1
4 Spot Welding................................................................................................................................... 4-1
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1 Arc Welding
1 Arc Welding
Fig. 1-1: JZNC-YIU02-E(CN308 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
Each Point
24VDC
8mA max.
Each Point
24VDC
50mA max.
External
Power Supply
+24 VE
024 VE
Internal
Power Supply
+24 V
024 V
(24V,1.5A)
CN303
I/O Unit (JZNC-YIU02 -E)
DX100
Name
Signal
Terminal
Number
Logical
Number
Connector
Number
Connector Terminal Converter
(Optional)
Model:TIFS553YS
* Remove the Jumper-pins between CN303-1 to -3, CN303-2 to -4
when the external power supply is used.
CN308 Connector
External Start
Call Master Job
Alarm/Error Reset
Interference1 Entrance
Prohibited
Work Prohibited
Work Response
Running
Servo is ON
Top of Master Job
Alarm/Error Occurred
Battery Alarm
Remote Mode Selected
Play Mode Selected
Teach Mode Selected
In Cube 1
In Cube 2
Work Home Position
Intermediate Start OK
(Sequence Continuing)
Interference2 Entrance
Prohibited
Select Play Mode
Select Teach Mode
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1 Arc Welding
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Fig. 1-2: JZNC-YIU02-E (CN309 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
Each Point
24VDC
8mA max.
Each Point
24VDC
50mA max.
Internal
Power Supply
+24 V
024 V
(24V,1.5A)
External
Power Supply
+24 VE
024 VE
CN303
CN309 Connector
DX100
I/O Unit (JZNC-YIU02-E)
Logical
Number Signal
Name
Connector Terminal Converter
(Optional)
Model:TIFS553YS
Terminal
Number
Connector
Number
* Remove the Jumper-pins between CN303-1 to -3, CN303-2 to -4
when the external power supply is used.
Weaving Prohibited
Sensing Prohibited
IN01 User Input
IN02 User Input
IN03 User Input
IN04 User Input
IN05 User Input
IN06 User Input
IN07 User Input
IN08 User Input
Wire Sticking (Monitor)
Gas Shortage (Monitor)
Wire Shortage (Monitor)
Arc Shortage (Monitor)
OUT01 User Output
OUT02 User Output
OUT03 User Output
OUT04 User Output
OUT05 User Output
OUT06 User Output
OUT07 User Output
OUT08 User Output
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1 Arc Welding
Fig. 1-3: JZNC-YIU02-E (CN306 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
I/O Unit (JZNC-YIU02-E)
Each Point
24VDC
8mA max.
Each Point
24VDC
50mA max.
Internal
Power Supply
+24 V
024 V
(24V,1.5A)
External
Power Supply
+24 VE
024 VE
CN303
CN306 Connector
DX100
Logical
Number
Name
Signal
Connector
Number
Terminal
Number
Connector Terminal Converter
(Optional)
Model:TIFS553YS
* Remove the Jumper-pins between CN303-1 to -3, CN303-2 to -4
when the external power supply is used.
User Input
User Input
User Input
User Input
User Input
User Input
User Input
User Input
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
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1 Arc Welding
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Fig. 1-4: JZNC-YIU02-E (CN307 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
Each Point
24VDC
500mA max.
Internal
Power Supply
+24 V
024 V
(24V,1.5A)
External
Power Supply
+24 VE
024 VE
Each Point
24VDC
8mA max.
I/O Unit (JZNC-YIU02-E)
CN303
CN307 Connector
DX100
Terminal
Number
Logical
Number
Connector
Number
Signal
Name
Connector Terminal Converter
(Optional)
Model:TIFS553YS
* Remove the Jumper-pins between CN303-1 to -3, CN303-2 to -4
when the external power supply is used.
* means internal relay
means
RLY
User Input
User Input
User Input
User Input
User Input
User Input
User Input
User Input
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
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1 Arc Welding
Table 1-1: Specific Input (Arc Welding)
Logical
Number
Input Name / Function
20010 EXTERNAL START
Functions the same as the [START] button in the programming pendant. Only the rising
edge of the signal is valid. It starts robot operation (playback). This signal is invalid if
external start is prohibited from the playback condition display.
20012 CALL MASTER JOB
Only the rising edge of the signal is valid. It calls up the top of the robot program, that is
the top of the master job1) . This signal is invalid during playback, during teach lock and
when play master or call is prohibited (set from the playback operation condition display).
20013 ALARM/ERROR RESET
After an alarm or error has occurred and the cause been corrected, this signal resets the
alarm or error.
20015 SELECT PLAY MODE
The play mode is selected when the mode key on the programming pendant is set at
"REMOTE". Only the rising edge of the signal is valid. When this selection signal
assigned concurrently with other mode selection signal, the teach mode is selected on a
priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE
The teach mode is selected when the mode key of the programming pendant is set at
"REMOTE". The other mode selection is unavailable when this signal is ON; the signal is
selected by priority even when the other selection signal is ON, enabling the teach mode
selection.
20020 INTERFERENCE 1 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 12) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021 INTERFERENCE 2 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 22) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20022 WORK PROHIBITED (Arc Generation Prohibited)
Arc generation is prohibited while this signal is ON. Arc generation starts when this signal
turns OFF inside the arc-generation area. Use this signal to confirm teaching.
20023 WORK RESPONSE (Pseudo Arc ON Response)
This signal is used as a pseudo signal in cases that “Arc Generation Confirmation” signal
is not equipped on a welding power supply. Wire this signal ON normally (short to OV).
20026 WEAVING PROHIBITED
Weaving is prohibited while this signal is ON. Use this signal to check taught steps and
movements without performing the weaving operation.
20027 SENSlNG PROHIBITED
Arc sensing is prohibited while this signal is ON. Use this signal to check taught steps and
movements if an arc sensor is mounted.
1 A master job is a job (program) which can be called by CALL MASTER JOB.Other functions are the same as for
normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is
turned ON, is set as the master job.
2 See section 8.6 “Interference Area” in the “DX100 INSTRUCTIONS.”
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1 Arc Welding
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Table 1-2: Specific Output (Arc Welding)
Logical
Number
Input Name / Function
30010 RUNNING
This signal signifies that the job is running. (Signifies that the job is running, system status
is waiting reserved start, or test run is running.) This signal status is the same status as
[START] in the programming pendant.
30011 SERVO IS ON
This signal signifies that the servo power is turned ON, internal processing such as
current position creation is complete, and the system is able to receive the START
command. This signal turns OFF when the servo power supply turns OFF. It can be used
for DX100 status diagnosis for an external start.
30012 TOP OF MASTER JOB
This signal signifies that the execution position is the top of the master job. This signal can
be used to confirm that the master job has been called.1)
30013 ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error occurred. If a major error occurs, this signal
remains ON until the main power is turned OFF.
30014 BATTERY ALARM
This signal turns ON to notify that the battery requires replacing when the voltage drops
from the battery for backup memory of the encoder. Major problems may result if memory
data is lost because of an expired battery. It is recommended to avoid these problems by
using this signal as a warning signal.
30015 to
30017
REMOTE/PLAY/TEACH MODE SELECTED
This signal notifies the current mode setting. These signals are synchronized with the
mode select switch in the programming pendant. The signal corresponding to the
selected mode turns ON.
30020 IN CUBE 1
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1). Use
this signal to prevent interference with other manipulators and positioners.
30021 IN CUBE 2
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2). Use
this signal to prevent interference with other manipulators and positioners.
30022 WORK HOME POSITION (IN CUBE 32)2)
This signal turns ON when the current TCP lies inside the work home position area. Use
this signal to evaluate whether the manipulator is in the start position.
30023 INTERMEDIATE START OK (Sequence Continuing)
This signal turns ON when the manipulator operates. It turns OFF when the currently
executed line is moved with the cursor or when editing operation is carried out after HOLD
is applied during operation. Therefore, this signal can be used as a restart interlock after a
HOLD is applied. However, it also turns ON in the teach mode and TEACH MODE
SELECTED signal must be referred together.
30024 GAS SHORTAGE (MONITOR)
This signal stays ON while the gas shortage signal from the welding power supply is ON.
30025 WIRE SHORTAGE (MONITOR)
This signal status ON while the wire shortage signal from the welding power supply is ON.
30026 WIRE STICKING (MONITOR)
The wire sticking check is conducted automatically when the arc turns OFF. If wire
sticking is detected, this signal remains ON until the wire sticking is released.
30027 ARC SHORTAGE (MONITOR)
This signal stays ON while the arc shortage signal from the welding power supply is ON.
1 This signal is not output during operation.
2 The work home position cube and Cube 32 are the same.
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2 Handling
2Handling
Fig. 2-1: JZNC-YIU02-E (CN308 Connector) I/O Allocation and Connection Diagram (For Handling)
Each Point
24VDC
8mA max.
Each Point
24VDC
50mA max.
External
Power Supply
+24 VE
024 VE
Internal
Power Supply
+24 V
024 V
(24V,1.5A)
CN303
CN308 Connector
DX100
Name Signal
I/O Unit (JZNC-YIU02-E)
Connector Terminal Converter
(Optional)
Model:
TIFS553YS
Terminal
Number
Logical
Number
Connector
Number
* Remove the Jumper-pins between CN303-1 to -3, CN303-2 to -4
when the external power supply is used.
External Start
Call Master Job
Alarm/Error Reset
Interference1 Entrance
Prohibited
Running
Servo is ON
Top of Master Job
Alarm/Error Occurred
Battery Alarm
Remote Mode Selected
Play Mode Selected
Teach Mode Selected
In Cube 1
In Cube 2
Work Home Position
Intermediate Start OK
Interference2 Entrance
Prohibited
Select Play Mode
Select Teach Mode
(Sequence Continuing)
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2 Handling
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Fig. 2-2: JZNC-YIU02-E (CN309 Connector) I/O Allocation and Connection Diagram (For Handling)
Each Point
24VDC
8mA max.
Each Point
24VDC
50mA max.
Internal
Power Supply
+24 V
024 V
(24V,1.5A)
External
Power Supply
+24 VE
024 VE
CN303
CN309 Connector
DX100
I/O Unit (JZNC-YIU02-E)
Logical
Number
Signal Name
Connector Terminal Converter
(Optional)
Model:
TIFS553YS
Terminal
Number
Connector
Number
* Remove the Jumper-pins between CN303-1 to -3, CN303-2 to -4
when the external power supply is used.
Shock Sensor (NC)
- Hold
Low Air Pressure
User Output
User Input
User Input
User Input
User Input
User Input
User Input
User Input
User Input
User Output
User Output
User Output
User Output
User Output
User Output
User Output
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2 Handling
Fig. 2-3: JZNC-YIU02-E (CN306 Connector) I/O Allocation and Connection Diagram (For Handling)
Each Point
24VDC
8mA max.
Each Point
24VDC
50mA max.
Internal
Power Supply
+24 V
024 V
(24V,1.5A)
External
Power Supply
+24 VE
024 VE
CN303
CN306 Connector
DX100
I/O Unit (JZNC-YIU02-E)
Logical
Number
Name Signal
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Connector
Number
Terminal
Number
* Remove the Jumper-pins between CN303-1 to -3, CN303-2 to -4
when the external power supply is used.
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Output
User Input
User Input
User Input
User Input
User Input
User Input
User Input
User Input
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2 Handling
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Fig. 2-4: JZNC-YIU02-E (CN307 Connector) I/O Allocation and Connection Diagram (For Handling)
Each Point
24VDC
8mA max.
Each Point
24VDC
500mA max.
Internal
Power Supply
+24 V
024 V
(24V,1.5A)
External
Power Supply
+24 VE
024 VE
CN303
CN307 Connector
DX100
I/O Unit (JZNC-YIU02-E)
Connector Terminal Converter
(Optional)
Model: TIFS553YS
Terminal
Number
Logical
Number
Connector
Number
Signal Name
* Remove the Jumper-pins between CN303-1 to -3, CN303-2 to -4
when the external power supply is used.
Sensor Input 8
Sensor Input 1
Sensor Input 2
Sensor Input 3
Sensor Input 4
Sensor Input 5
Sensor Input 6
Sensor Input 7
Hand Valve 1-1-
Hand Valve 1-1+
Hand Valve 1-2-
Hand Valve 1-2+
Hand Valve 2-1-
Hand Valve 2-1+
Hand Valve 2-2-
Hand Valve 2-2+
Hand Valve 3-1-
Hand Valve 3-1+
Hand Valve 3-2-
Hand Valve 3-2+
Hand Valve 4-1-
Hand Valve 4-1+
Hand Valve 4-2-
Hand Valve 4-2+
* means internal relay
means
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