YASKAWA Motoman DX200 User manual

MANUAL NO.
0
HW1486969
Part Number: 165632-1CD
Revision: 0
DX200 OPTIONS
JARCR-XFB03 BOARD
INSTRUCTIONS
FOR M-NET
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL
DX200 MAINTENANCE MANUAL
The DX200 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
1/44

ii
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
MANDATORY
• This manual explains the JARCR-XFB03 board of the DX200
system and general operations. Read this manual carefully and be
sure to understand its contents before handling the DX200.
• General items related to safety are listed in Chapter 1: Safety of the
DX200 Instructions. To ensure correct and safe operation, carefully
read the DX200 Instruction 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.
2/44

iii
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200.
In this manual,the Notes for Safe Operationare 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
personnelanddamagetoequipment.
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.”
3/44

iv
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
PROHIBITED
• 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.
4/44

v
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop buttons on the front door of the
DX200 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.
Figure 1: 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.
Figure 2: Release of Emergency Stop
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.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the P-point maximum
envelope of the manipulator and that you are in a safe location
before:
– Turning ON the DX200 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 DX200 and
the programming pendant.
5/44

vi
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
WARNING
• Do not touch the inside of the panel for 5 minutes after the power is
turned OFF.
The remaining charged voltage in the capacitor may cause an electric
shock or an injury.
• Be sure to close the door and install the protection cover while the
power is turned ON.
Failure to observe this warning may result in a fire or an electric shock.
6/44

vii
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
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 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
Instructions before operating the manipulator:
• The wiring and mounting must be performed by authorized and
qualified personnel.
Failure to observe this caution may result in a fire or an electric shock.
• Make sure that there is no foreign matter such as metal chips on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Make sure that there is no damage or deflection of parts on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Correctly connect each cable and connector.
Failure to observe this caution may result in a fire or damage the board.
• Set the switches, etc. correctly.
Malfunction, caused by an incorrect setting, may result in an injury or
damage the board.
• Never touch the mounting surfaces of the board parts directly with
fingers.
The generated static electricity may damage the IC.
• Never touch the soldered surfaces of the board directly with fingers.
Protrusions on the soldered surface may result in an injury.
• No shock to the board.
The shock may damage the board.
7/44

viii
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
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 supply cables.
In this manual, the equipment is designated as follows.
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 bland names for each company or
corporation. The indication of (R) and ™ are omitted.
Equipment Manual Designation
DX200 Controller DX200
DX200 Programming Pendant Programming Pendant
Cable between the manipulator and the
controller Manipulator cable
Equipment Manual Designation
Programming
Pendant Character Keys Symbol Keys The keys which have characters printed on them are denoted with [ ].
ex. [ENTER]
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]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
8/44

ix
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
Table of Contents
1 Outline
1.1 Features of System with the XFB03 Board.........................................................................1-1
1.2 System Configuration Example ..........................................................................................1-1
2 Hardware Specifications
2.1 Board External View...........................................................................................................2-1
2.2 Board Specifications...........................................................................................................2-1
2.3 Communication Specifications............................................................................................2-2
2.4 Connector...........................................................................................................................2-3
2.5 Connection of Transmission Cable.....................................................................................2-3
3 Setting the Functions
3.1 Function Setting Switches ..................................................................................................3-1
3.2 Switch Setting Method........................................................................................................3-3
4 Mounting the XFB03 Board
4.1 Opening Front Door of the DX200...................................................................................... 4-3
4.2 Confirming the Switch Settings on the XFB03 Board.........................................................4-3
4.3 Connecting Transmission Cable.........................................................................................4-3
4.4 Mounting the XFB03 Board on the DX200 .........................................................................4-3
4.5 Connecting Each Cable......................................................................................................4-4
4.6 Closing the Front Door of the DX200..................................................................................4-5
5 I/O Signal Allocation
5.1 I/O Module Setting..............................................................................................................5-1
5.2 Transmitting Data .............................................................................................................5-10
5.2.1 DX200 I/O Allocation Example (For Handling).................................................... 5-10
5.2.2 DX200 I/O Allocation Example (For Except Handling)........................................5-12
5.2.3 The Alarm when Communications Error Occurs Using the Board Status...........5-13
6 Error Indication
6.1 LED Indicators....................................................................................................................6-1
6.2 Corrective Actions...............................................................................................................6-2
9/44

1 Outline
1.1 Features of System with the XFB03 Board
1-1
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
1 Outline
By using the JARCR-XFB03 board (M-NET) for the DX200, the cost for
wiring between modules (sequencer, positioning unit, measuring unit, etc.)
that configure a system, can be reduced.
This manual explains how to use the JARCR-XFB03 board (hereinafter
called the XFB03 board).
1.1 Features of System with the XFB03 Board
• Wiring between modules requires only one transmission cable.
• The transmission cable can be extended up to 100 m (total length of
cables).
• A system can be constructed at lower cost because of minimal
wiring.
• Up to 112 transmission I/O points are available (input: 112 points,
output: 112 points).
• The XFB03 board is used exclusively for a slave station.
1.2 System Configuration Example
DX200
JARCR-XFB03 board
External PLC (sequencer)
Module for M-NET
Transmission Cable
10/44

2-1
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net 2 Hardware Specifications
2.1 Board External View
2 Hardware Specifications
2.1 Board External View
2.2 Board Specifications
Items Specifications
Interface to external
devices Interface between modules (M-NET)
Board mounting position Optional board mounting space in the DX200
Error indicator LED display
11/44

2 Hardware Specifications
2.3 Communication Specifications
2-2
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
2.3 Communication Specifications
Number of transmission
I/O points Maximum number of I/O points Input: 112 points
Output: 112 points
Note: The number of input points and the number of
output points can not be set individually.
Items Specifications
Items Specifications
Communication method Half-duplex system
Synchronization method Asynchronous system
Transmission distance Max. 100 m
Bit configuration JIS 7-unit system, 10 bits
Parity check Vertical parity detection (Even parity)
Horizontal parity detection (Even parity)
Signal level EIA standard, in conformity with RS-422
Transmission cable
specifications
1)
1 The transmission cable
specifications “JKEV-SB” is a
standard of Japan Cable Industry
Association.
The followingshows the cable name
of each manufacturer:
Sumitomo Electric Industries, Ltd.:
DPEV-SB
Fujikura Ltd.: IPEV-SB
The Furukawa Electric Co., Ltd.:
KPEV-SB
JKEV-SB, 0.75 sq 2 p
(Polyethylene insulationsheath cable with pair-type
copper braid shielding for measurement)
Transmission speed 19.2/38.4/57.6Kbps
Slave station address
2)
2 The XFB03 board is exclusive-use
for a slave station.
1 to 7
Transmission mode
3)
3 “Y-mode” can be used only when
the master station is a sequencer for
YASKAWA M-NET and a
communication is performed in “Y-
mode”.
T-mode/Y-mode
Number of transmission
I/O points Maximum number of I/O points Input: 112 points
Output: 112 points
Note: The number of input points and the number of
output points can not be set individually.
12/44

2-3
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net 2 Hardware Specifications
2.4 Connector
2.4 Connector
2.5 Connection of Transmission Cable
Connect the CN02 (terminal stand) on the XFB03 board and an external
sequencer with a transmission cable (refer to Section 2.3 “Communication
Specifications” on page 2-2).
The connection example between the XFB03 board and the B2806
(Memocon-SC 2000 series) is shown below.
Table 2-1: CN02 (Terminal Stand for Transmission Cable Connection)
Terminal No. Signal Name Meaning
1 DATA RS-422 communication signal (Terminal A)
2 *DATA RS-422 communication signal (Terminal B)
3 SG Signal line ground
4 FG Frame ground (For connecting transmission
cable shielded wire)
5 DATA RS-422 communication signal (Terminal A)
6 *DATA RS-422 communication signal (Terminal B)
7 SG Signal line ground
8 FG Frame ground (For connecting transmission
cable shielded wire)
JARCR-XFB03
DATA
*DATA
SG
FG
DATA
*DATA
SG
FG
B2806
Twisted Wire
Shielded Wire
13/44

3 Setting the Functions
3.1 Function Setting Switches
3-1
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
3 Setting the Functions
3.1 Function Setting Switches
The section explains the switches that set the functions of the XFB03
board following the instructions. Make the correct settings. For more
details about the settings, refer to Section 3.2 “Switch Setting Method” on
page 3-3.
S1: I/O POINT
Sets the number of transmission I/O points.
(Set value of S1) 8 is the actual number of I/O points.
The range for the S1 setting is from "1" to "E". (Max. 112 points each for
input and output)
Set the number of points to be transferred to the sequencer side.
<Example>
When S1 is set to "E", the number of I/O points is as follows.
• Input: 112 points
• Output: 112 points
S2: Sets the stations for the XFB03 board on the DX200.
The range for the station setting is from "1" (ST#01) to "D" (ST#13).
Do not set to "0" (ST#00), "E" (ST#14) and "F" (ST#15).
S3: RST
Resets the XFB03 board.
S4-1: TERM
Sets the termination resistance.
When the XFB03 board is at the termination of the network, set to "ON:
termination resistance provided".
S4-3: FIL
Sets a noise filter for the communication line.
If problems occur during communications, noise may be the cause. To
reduce the noise, set to "Filter provided". Normally, set S4-3 to "Filter not
provided".
NOTE
Do not use the S3 since it is for maintenance only.
14/44

3-2
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net 3 Setting the Functions
3.1 Function Setting Switches
S4-4: Same as S4-3.
Be sure to set it to the same setting as S4-3.
S5: SLAVE ADDRESS
Sets a slave address.
The XFB03 board is regarded as one of the slave stations by an external
sequencer, the master station. Using S5, set a slave address. The setting
range of S5 is "1" to "7".
S6: 16/17 BYTE
Switches the communication modes between 16 and 17 bytes.
Be sure to set to 17 BYTE.
16 BYTE is not applicable.
If the I/O points of the XFB03 board do not appear on the P.P. although the
communication cable and the power cable are connected correctly as
indicated in Chapter 5 I/O Signal Allocation on page 5-1, S6 might be set
to 16 BYTE. In this case, modify the setting to 17 BYTE.
S7, 8, and 9: 19.2 K, 38.4 K, 57.6 K
Sets a transmission baud rate for the M-NET.
Choose from 19.2 kbps, 38.4 kbps, and 57.6 kbps.
S10: Y/T MODE
Sets the transmission mode for the M-NET.
In the "T-mode", a communication of interface specifications between
modules is performed.
The "Y-mode" can be used when the master station is a sequencer for
YASKAWA M-NET and communications are performed in the "Y-mode".
(Communications are performed according to the YASKAWA
specifications.)
For details on the "Y-mode", refer to the instruction manual for the station
sequencer.
S11: TEST/SYS
Sets the operation mode of the XFB03 board.
NOTE
Do not set to 16 BYTE. When setting to 16 BYTE, the I/O
modules are not recognized properly.
NOTE
Set S11 to "SYS" (normal mode).
Never set to "TEST" (test mode) since the test mode is for
maintenance only.
15/44

3 Setting the Functions
3.2 Switch Setting Method
3-3
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
3.2 Switch Setting Method
Switches Setting Method
S1
Setting of the number of
I/O points
Sets the number of transmission I/O points.
Turn the arrows to the numbers corresponding to the desired
number of I/O points.
Use a flat tip driver.
The following shows the relation between the switch settings and the actual
number of I/O points.
The value in [ ] is the number of I/O points reserved for the XFB03 board
inside the DX200. (The area for the board status is included.)
S2
Setting of the station
Sets the station.
Turn the arrows to the numbers corresponding to the desired
station number.
Use a flat tip driver.
The following shows the relation between the switch settings and the station.
The value of ST# is the station number display on the programming pendant
of the DX200 when setting the I/O modules.
S3 The push button S3 resets the XFB03 board.
Never use the S3 since it is for maintenance only.
0: Unavailable 8: 64[72]
1: 8[16] 9: 72[80]
2: 16[24] A: 80[88]
3: 24[32] B: 88[96]
4: 32[40] C: 92[104]
5: 40[48] D: 104[112]
6: 48[56] E: 112[120] (Default setting)
7: 56[64] F: Unavailable
0: Unavailable 8: ST#08
1: ST#01 9: ST#09
2: ST#02 A: ST#10
3: ST#03 B: ST#11
4: ST#04 C: ST#12
5: ST#05 (Default setting) D: ST#13
6: ST#06 E: Unavailable
7: ST#07 F: Unavailable
16/44

3-4
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net 3 Setting the Functions
3.2 Switch Setting Method
S4-1
Setting of termination
resistance
ON: Termination resistance provided (upper)
OFF: Termination resistance not provided (lower)
(Default setting)
When the XFB03 board is configured at the termination of slave stations, set
the S4-1 to “ON: Termination provided”.
S4-3 and S4-4
Setting of noise filter for
communication
OFF: Noise filter not provided (upper) (Default
setting)
ON: Noise filter provided (lower)
When the XFB03 board is used under the conditions with excessive noise,
set the S4-3 and S4-4 to “ON” (Noise filter provided).
S5
Setting of slave address
Sets the slave address of XFB03 board.
Turn the arrows to the numbers corresponding to the desired
slave address.
Use a flat tip driver.
The following shows the relation between the switch settings and the slave
addresses.
0: Unavailable
1: Address 1 (Default setting)
2: Address 2
3: Address 3
4: Address 4
5: Address 5
6: Address 6
7: Address 7
8: Unavailable
9: Unavailable
S6
Settingofcommunication
bytes
Short-circuited between 1 and 2: 17-byte mode
*Setting indispensable
Short-circuited between 2 and 3: 16-byte mode
(Default setting)
*Setting unavailable
Be sure to set to "17-byte mode".
Modify the setting to 17-byte mode as the default setting is 16-byte mode.
Switches Setting Method
1234
1234
1234
1234
31
16/17BYTE
S6
31
16/17BYTE
S6
17/44

3 Setting the Functions
3.2 Switch Setting Method
3-5
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
S7, S8, S9 *
Settingofcommunication
baud rate
Short-circuited between 1 and 2 of
S7: 19.2 kbps (Default setting)
Short-circuited between 1 and 2 of
S8: 38.4 kbps
Short-circuited between 1 and 2 of
S9: 57.6 kbps
Sets a transmission baud rate.
*Note: A transmission baud rate is 9.6 Kbps when S7, S8, and S9 are not
used for short-circuit applications.
S10
Settingofcommunication
mode
Short-circuited between 1 and 2: T-mode
Short-circuited between 2 and 3: Y-mode
(Default setting)
"Y-mode” can be used only when the master station is a sequencer for
YASKAWA M-NET and a communication is performed in the “Y-mode”.
S11
Setting of the operation
mode
Short-circuited between 1 and 2: Normal (SYS) mode
(Default setting)
*Setting indispensable
Short-circuited between 2 and 3: Test mode
*Setting unavailable
Be sure to set to the "Normal (SYS) mode".
Switches Setting Method
1
2
19.2K
S7
1
2
38.4K
S8 1
2
57.6K
S9
Y/T MODE
31
S10
Y/T MODE
31
S10
TEST/SYS
31
S11
TEST/SYS
31
S11
18/44

4-1
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net 4 Mounting the XFB03 Board
4 Mounting the XFB03 Board
WARNING
• Before wiring, be sure to turn OFF the power supply and put up a
warning sign, such as “DO NOT TURN ON THE POWER.”
Failure to observe this warning may result in an electric shock or an
injury.
• Do not touch the inside of the panel for 5 minutes after the power is
turned OFF.
The remaining charged voltage in the capacitor may cause an electric
shock or an injury.
• Be sure to close the door and install the protection cover while the
power is turned ON.
Failure to observe this warning may result in a fire or an electric shock.
19/44

4 Mounting the XFB03 Board
4-2
165632-1CD
HW1486969
JARCR-XFB03 Board for
M-Net
CAUTION
• The wiring and mounting must be performed by authorized and
qualified personnel.
Failure to observe this caution may result in a fire or an electric shock.
• Make sure that there is no foreign matter such as metal chips on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Make sure that there is no damage or deflection of parts on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Correctly connect each cable and connector.
Failure to observe this caution may result in a fire or damage the board.
• Set the switches, etc. correctly.
Malfunction, caused by an incorrect setting, may result in an injury or
damage the board.
• Never touch the mounting surfaces of the board parts directly with
fingers.
The generated static electricity may damage the IC.
• Never touch the soldered surfaces of the board directly with fingers.
Protrusions on the soldered surface may result in an injury.
• No shock to the board.
The shock may damage the board.
20/44