YASKAWA EcoTrim ET-1024 User guide

Part Number: 175932-1CD
Revision: 0
EcoTrim ET-1024
SYSTEM MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
MOTOMAN INSTRUCTIONS
MH24 MANIPULATOR INSTRUCTIONS
MSR-355 AND MSR-655 POSITIONER MANUAL
EcoTrim ET-1024 SYSTEM MANUAL
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL
DX200 MAINTENANCE MANUAL
The DX200 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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EcoTrim ET-1024 System
Copyright © 2016, 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, 2016
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com
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EcoTrim ET-1024 System
MANDATORY
• This system manual provides an overview of the Motoman EcoTrim
ET-1024 System. It gives general information about the system, a
description of its major components, and the procedures for
installation, system operation, and preventive and repair
maintenance. Be sure to read and understand this manual
thoroughly before installing and operating the EcoTrim ET-1024
System.
• General items related to safety are listed in Section 1 of the DX200
Controller Manual. To ensure correct and safe operation, carefully
read the DX200 Controller Manual before reading this manual.
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 revision 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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EcoTrim ET-1024 System Notes for Safe Operation
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the Motoman EcoTrim ET-1024 System.
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,”
"CAUTION" and "WARNING."
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Notes for Safe Operation
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WARNING
• Before operating the manipulator, check that servo power is turned
OFF by pressing the EMERGENCY STOP buttons on the front door
of the DX200 controller and on the Programming Pendant (refer to
Fig. 1). When 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.
Figure 1: EMERGENCY STOP Button
• Release the EMERGENCY STOP button (refer to Fig. 2). Once this
button is released, clear the cell of all items which could interfere
with the operation of the manipulator. Then turn servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of EMERGENCY STOP Button
TURN
• 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 to in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• 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 power for the DX200 controller.
– 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
immediately if there is a problem. The EMERGENCY STOP buttons are
located on the right of the front door of the DX200 controller and on the
Programming Pendant.
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EcoTrim ET-1024 System Definition of Terms Used Often in This Manual
Definition of Terms Used Often in This Manual
he MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the Programming
Pendant, and supply cables.
In this manual, the equipment is designated as follows:
This Robot Cell has Collaborative Motion functionality:
Collaboration is a special type of operation between a person and robot
sharing a common workspace. The following are the guidelines for
collaborative operation.
1. Used for pre-determined tasks.
2. Possible when all protective measures are active.
3. For robots with features specifically designed for collaborative
operation.
The integrator shall include in the information for use the safeguards and
mode selection required for collaborative operation.
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 cabinet
of the DX200 controller after use.
The Programming Pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX200 Controller Manual before operating the EcoTrim ET-1024
System.
CAUTION
Equipment Manual Designation
DX200 controller DX200
DX200 Programming Pendant Programming Pendant
Cable between the manipulator and the
controller
Manipulator cable
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Explanation of Warning Labels
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Explanation of Warning Labels
The following warning labels are attached to the manipulator
(refer to Fig. 3).
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Figure 3: Warning Labels Location
WARNING Label B
WARNING Label A
WARNING Label A
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
Nameplate:
WARNING Label B:
WARNING Label A:
NAMEPLATE
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EcoTrim ET-1024 System Table of Contents
Table of Contents
1 Introduction ..................................................................................................................................... 1-1
1.1 About This Document ........................................................................................................ 1-1
1.2 System Overview............................................................................................................... 1-2
1.2.1 System Layout...................................................................................................... 1-3
1.2.2 Major Components ............................................................................................... 1-4
1.2.3 Theory of Operation and Safe Guarding .............................................................. 1-4
1.2.3.1 System Teaching: ................................................................................... 1-6
1.2.3.2 System Operation: .................................................................................. 1-6
1.2.3.3 Key Safety Devices ................................................................................. 1-7
1.2.3.4 Safety Logic Implementation: .................................................................. 1-8
1.2.3.5 Functional Safety Setup .......................................................................... 1-8
1.3 Reference Documentation ............................................................................................... 1-10
1.3.1 Location of Operations in Reference Documentation......................................... 1-11
1.4 Customer Support Information......................................................................................... 1-14
2 Equipment Description.................................................................................................................... 2-1
2.1 Robot Description .............................................................................................................. 2-1
2.2 DX200 Controller ............................................................................................................... 2-1
2.3 Programming Pendant.......................................................................................................2-2
2.4 Operator Station ................................................................................................................ 2-3
2.4.1 Cycle Start/Cycle Latched .................................................................................... 2-4
2.4.2 Emergency Stop (E-STOP) .................................................................................. 2-4
2.4.3 Robot Hold ........................................................................................................... 2-4
2.4.4 Alarm .................................................................................................................... 2-4
2.4.5 Positioner Auto/Manual ........................................................................................ 2-4
2.4.6 Start...................................................................................................................... 2-4
2.4.7 Reset .................................................................................................................... 2-5
2.4.8 Servo On .............................................................................................................. 2-5
2.5 MSR Family Positioner ...................................................................................................... 2-6
2.6 Trimming Equipment.......................................................................................................... 2-7
2.6.1 Ultrasonic Cutting Tool (standard)........................................................................ 2-7
2.6.2 Hybrid Tool (optional) ........................................................................................... 2-7
2.7 Safety Features ................................................................................................................. 2-8
2.7.1 Safety Fencing ..................................................................................................... 2-8
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2.7.2 Safety Light Curtains ............................................................................................ 2-8
2.7.3 Emergency Stops (E-STOPS) .............................................................................. 2-8
2.7.4 Programming Pendant’s Enable Switch ............................................................... 2-9
2.7.5 Emergency Braking System ................................................................................. 2-9
2.7.6 Interlocked Work-cell Doors.................................................................................. 2-9
3 Installation ....................................................................................................................................... 3-1
3.1 Required Materials............................................................................................................. 3-1
3.1.1 Customer-supplied Items...................................................................................... 3-1
3.1.2 Recommended List of Hand Tools and Equipment .............................................. 3-2
3.2 Site Preparation ................................................................................................................. 3-3
3.3 Installing and Leveling the Common Base......................................................................... 3-4
3.4 Installing the Operator Station Pedestal (Option) .............................................................. 3-6
3.5 Light Curtain Alignment...................................................................................................... 3-6
3.6 Cable Connections............................................................................................................. 3-7
3.6.1 Connection to Earth Ground ................................................................................. 3-7
3.6.2 Connection to Local Electrical Service ................................................................. 3-8
3.7 Safety/Operation Check..................................................................................................... 3-9
3.8 Installation of Tooling and Fixtures .................................................................................. 3-10
4 Operation ........................................................................................................................................ 4-1
4.1 Programming ..................................................................................................................... 4-1
4.2 Sweeping the Positioner .................................................................................................... 4-2
4.3 Daily Operation .................................................................................................................. 4-3
4.3.1 Start-up Procedure ............................................................................................... 4-3
4.3.2 Robot HOME Position........................................................................................... 4-3
4.3.3 Control Master Job ............................................................................................... 4-4
4.3.4 Operation Cycle .................................................................................................... 4-4
4.3.5 Shutdown Procedure ............................................................................................ 4-5
4.4 System Recovery............................................................................................................... 4-6
4.4.1 Alarms and Errors................................................................................................. 4-6
4.4.1.1 Error Messages ....................................................................................... 4-6
4.4.1.2 Minor Alarms ........................................................................................... 4-6
4.4.1.3 Major Alarms ........................................................................................... 4-6
4.4.2 E-STOP Recovery ................................................................................................ 4-6
4.4.3 Brake Release ...................................................................................................... 4-8
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