YASKAWA MOTOMAN FS100 User manual

MANUAL NO. RE-CHO-A111
YASKAWA ELECTRIC CORPORATION
5
FS100
MAINTENANCE MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
FS100 INSTRUCTIONS
FS100 OPERATOR’S MANUAL
FS100 MAINTENANCE MANUAL

FS100
ii
MANDATORY
• This manual explains maintenance procedures of the FS100
system. Read this manual carefully and be sure to understand its
contents before handling the FS100.
• General items related to safety are listed in Chapter 1: Safety of the
FS100 INSTRUCTIONS. To ensure correct and safe operation,
carefully read the FS100 Instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.

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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the FS100 .
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
DANGER
Indicates an imminent hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnelanddamageto 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 “DAN-
GER”, “WARNING” and “CAUTION” .

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WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on the programming pendant
is pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programing pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop button does not function.
Fig. : Emergency Stop Button
• In the case of not using the programming pendant, be sure to
supply the emergency stop button on the equipment. Then before
operating the manipulator, check to be sure that the servo power is
turned OFF by pressing the emergency stop button.
Connect the external emergency stop button to the 5-6 pin and 16-
17 pin of the robot system signal connector (CN2).
• Upon shipment of the FS100, this signal is connected by a jumper
cable in the dummy connector. To use the signal, make sure to
supply a new connector, and then input it.
If the signal is input with the jumper cable connected, it does not
function, which may result in personal injury or equipment damage.
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop Button
• Observe the following precautions when performing teaching
operations within the manipulator’s operating range:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
TURN

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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 FS100 controller,
manipulator cables, the FS100 programming pendant (optional), and the
FS100 programming pendant dummy connector (optional).
In this manual, the equipment is designated as follows:
WARNING
• Confirm that no person is present in the manipulator’s operating
range and that you are in a safe location before:
– Turning ON the power for the FS100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the manipulator’s operating range
during operation. Always press an emergency stop button immediately
if there are problems.
The emergency stop button is located on the programing pendant.
CAUTION
• Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.
– Check for problems in manipulator movement.
– Check for damage to the insulation and sheathing of external
wires.
• Return the programming pendant to a safe place after use.
If the programming pendant is inadvertently left on the manipulator,
on a fixture, or on the floor, the manipulator or a tool may collide with
the programming pendant during manipulator movement, which may
result in personal injury or equipment damage.
• Read and understand the Explanation of Warning Labels in the
FS100 Instructions before operating the manipulator.
Equipment Manual Designation
FS100 controller FS100
FS100 programming pendant Programming pendant
Cable between the manipulator and
the controller Manipulator Cable
FS100 programming pendant
dummy connector Programming pendant dummy connector

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Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Description of the Operation Procedure
In the explanation of the operation procedure, the expression "Select • • • "
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
Equipment Manual Designation
Programming
Pendant Character Keys The keys which have characters printed on them are denoted with [ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on
them are not denoted with [ ] but depicted
with a small picture.
ex. PAGE key
The Cursor is an exception, and a picture is
not shown.
Axis Keys
Numeric Keys “Axis Keys” and “Numeric Keys” are generic names for the keys for axis operation and
number input.
Keys pressed
simultaneously When two keys are to be pressed simultaneously, the keys are shown with a
“+” sign between them,
ex. SHIFT key +COORD key
Mode Key Three kinds of modes that can be selected
by the mode key are denoted as follows:
REMOTE, PLAY, or TEACH
Button Three buttons on the upper side of the
programming pendant are denoted as
follows:
HOLD button
START button
EMERGENCY STOP button
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
PC Keyboard The name of the key is denoted
ex. Ctrl key on the keyboard
GO BACK
PAGE
SHIFT
TOOL SEL
COORD

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

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1 Equipment Configuration.................................................................................................................1-1
1.1 Arrangement of Units and Circuit Boards ..........................................................................1-1
1.2 Power Flow...................................................................................................................................... 1-2
1.3 Signal Flow...................................................................................................................................... 1-3
2 Security System..............................................................................................................................2-1
2.1 Protection Through Security Mode Settings ......................................................................2-1
2.1.1 Security Mode.......................................................................................................2-1
2.1.1.1 Changing the Security Mode...................................................................2-5
2.1.2 User ID..................................................................................................................2-7
2.1.2.1 Changing a User ID.................................................................................2-7
3 Maintenance and Inspections .........................................................................................................3-1
3.1 Daily Inspections................................................................................................................3-1
3.2 Cooling Fan Inspections ....................................................................................................3-3
3.3 Emergency Stop Button Inspections..................................................................................3-4
3.4 Enable Switch Inspections.................................................................................................3-4
3.5 Battery Inspections ............................................................................................................3-5
4 Preparation before Replacing Parts................................................................................................4-1
4.1 Creating a Check Program ................................................................................................4-3
5 Replacing Parts...............................................................................................................................5-1
5.1 Fuse Replacement.............................................................................................................5-1
5.2 Interior Circulation Fan Replacement ................................................................................5-3
5.3 Battery Replacement .........................................................................................................5-4
6 Recommended Spare Parts............................................................................................................6-1
6.1 List of Accessories.............................................................................................................6-1
6.2 Recommended Spare Parts...............................................................................................6-2
7 Operations After Replacing Parts....................................................................................................7-1
7.1 Home Position Calibration .................................................................................................7-2
7.1.1 Home Position Calibration....................................................................................7-2
7.1.2 Calibrating Operation............................................................................................7-4
7.1.2.1 Registering All Axes at One Time............................................................7-4
7.1.2.2 Registering Individual Axes.....................................................................7-6
7.1.2.3 Changing the Absolute Data ...................................................................7-7
7.1.2.4 Clearing Absolute Data............................................................................7-8

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7.1.3 Manipulator Home Position ................................................................................ 7-10
7.2 Position Deviation Check Using the Check Program.......................................................7-11
7.3 Checking of the Check Program......................................................................................7-12
7.3.1 Motion of the Check Program.............................................................................7-12
7.3.2 Checking of the Check Program.........................................................................7-12
7.3.3 Home Position Data Correction..........................................................................7-13
7.4 Setting the Second Home Position (Check Point)...........................................................7-14
7.4.1 Purpose of Position Check Operation ................................................................7-16
7.4.2 Procedure for the Second Home Position Setting (Check Point).......................7-18
7.4.3 Procedure after the Alarm ..................................................................................7-19
8 System Diagnosis...........................................................................................................................8-1
8.1 System Version..................................................................................................................8-1
8.2 Manipulator Model.............................................................................................................8-1
8.3 Input/Output Status............................................................................................................8-2
8.3.1 Universal Input .....................................................................................................8-2
8.3.1.1 Universal Input Window...........................................................................8-2
8.3.1.2 Universal Input Simple Window...............................................................8-2
8.3.2 Universal Output...................................................................................................8-3
8.3.2.1 Universal Output Window........................................................................8-3
8.3.2.2 Universal Output Simple Window............................................................8-3
8.3.2.3 Modifying the Output Status....................................................................8-4
8.3.3 Specific Input........................................................................................................8-5
8.3.3.1 Specified Input Window...........................................................................8-5
8.3.3.2 Specific Input Simple Window.................................................................8-5
8.3.4 Specific Output.....................................................................................................8-6
8.3.4.1 Specified Output Window........................................................................8-6
8.3.4.2 Specific Output Simple Window..............................................................8-6
8.3.5 RIN Input ..............................................................................................................8-7
8.3.5.1 RIN Input Window ...................................................................................8-7
8.3.6 Signal Number Search .........................................................................................8-8
8.3.6.1 Direct Search on the Universal/Specified Input/Output Window.............8-9
8.3.6.2 Search from the Menu...........................................................................8-10
8.3.7 Relay Number Search........................................................................................8-11
8.3.7.1 Direct Search on the Universal/Specified Input/Output Window...........8-12
8.3.7.2 Search from the Menu...........................................................................8-13
8.3.8 Modification of the Signal Name.........................................................................8-14
8.3.8.1 Direct Modification on the Universal/Specified Input/Output Window ...8-14
8.3.8.2 Modification from the Menu...................................................................8-15

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8.4 System Monitoring Time Display .....................................................................................8-16
8.4.1 System Monitoring Time Display Window ..........................................................8-16
8.4.2 Individual Window of the System Monitoring Time Display................................8-17
8.4.3 Clearing the System Monitoring Time Display....................................................8-18
8.5 Alarm History ...................................................................................................................8-19
8.5.1 Alarm History Window ........................................................................................8-19
8.5.2 Clearing the Alarm History..................................................................................8-20
8.6 I/O Message History ........................................................................................................8-21
8.6.1 I/O Message History Window .............................................................................8-21
8.6.1.1 Search...................................................................................................8-21
8.6.2 Clearing the I/O Message History.......................................................................8-22
8.7 Position Data When Power is Turned ON/OFF ...............................................................8-23
8.7.1 Power ON/OFF Position Window .......................................................................8-23
8.8 Current Position...............................................................................................................8-24
8.8.1 Current Position Window....................................................................................8-24
8.9 Servo Monitoring..............................................................................................................8-25
8.9.1 Servo Monitor Window........................................................................................8-25
8.9.1.1 Changing the Monitor Items ..................................................................8-26
8.9.1.2 Clearing Maximum Torque Data............................................................8-28
9 Alarm...............................................................................................................................................9-1
9.1 Outline of Alarm.................................................................................................................9-1
9.2 Alarm Display.....................................................................................................................9-2
9.2.1 Displaying and Releasing Alarm...........................................................................9-2
9.2.1.1 Releasing Alarms ....................................................................................9-2
9.2.2 Special Alarm Display...........................................................................................9-3
9.3 Display of Alarm Details.....................................................................................................9-5
9.3.1 Parameter.............................................................................................................9-5
9.3.2 Display of Alarm Detail Window...........................................................................9-5
9.3.3 Transition of Alarm Detail Window........................................................................9-7
9.4 Alarm Message List ...........................................................................................................9-8
10 Error...........................................................................................................................................10-1
10.1 Error Message ...............................................................................................................10-1
10.1.1 System and General Operation........................................................................10-2
10.1.2 Editing...............................................................................................................10-5