YASKAWA Motoman GP8 EduCart User guide

Part Number: 186638-1CD
Revision: 2
Motoman GP8 EduCart
System Manual
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
keep for future reference.
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Copyright © 2020, 2019 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, 2019
YASKAWA America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com
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For Your Safety
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Safety
For Your Safety
Robots generally have requirements which are different from other
manufacturing equipment, such as larger working areas, high-speed
operation, rapid arm movements, etc., which can pose safety hazards.
Read and understand the instruction manuals and related documents, and
observe all precautions in order to avoid the risk of injury to personnel and
damage to equipment.
Carelessness contributes to serious accidents in the work area.
It is the user’s responsibility to ensure that all local, state, and national
codes, regulations, rules, or laws relating to safety and safe operating
conditions are met and followed.
DANGER
• Teaching, operations, and maintenance of the Robot must conform
to:
– Industrial Safety and Health Law
– Order for Enforcement of the Industrial Safety and Health Law
– Industrial Safety and Health Regulations
– Technical Standards for Electrical Facilities
Other related laws and regulations are:
– Occupational Safety and Health Act in USA
– Factory Act (Gewerbeordnung) in Germany
– Health and Safety at Work, etc. Act in UK
– EC Machinery Directive 2006/42/EC
• Prepare:
– SAFETY WORK REGULATIONS
based on concrete policies for safety management complying
with related laws and regulations.
• Observe:
– JIS B 8433-1: 2015 “Robots for industrial environments-Safety
requirements” (ISO 10218-1: 2011) for safe operation of the
robot. (JIS B 8433 is for Japan only)
• Reinforce:
– SAFETY MANAGEMENT SYSTEM
by designating authorized operators and safety managers for the
Robot, as well as giving continuing safety education and training.
• Teaching, operation, and maintenance of the Robot are specified as
“Hazardous Operations” in the Industrial Safety and Health Act (for
Japan only).
Personnel engaged in these operations must receive special
training offered by YASKAWA.
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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.
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.
DANGER
• Personnel engaged in operation, maintenance, or management of
the Robot must receive required training before using the Robot.
For more information on training, contact a local YASKAWA
representative.
• Make sure to have and follow all manuals, read them thoroughly
and understand the contents of them.
Confirm that you have all required manuals. If any of the manuals are
missing, contact a local YASKAWA representative.
• Read and understand these instructions throughly before installing,
operating, or maintaining the Robot.
Any matter not described in this manual must be regarded as
“prohibited” or “improper”.
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WARNING
• Safe operation of this equipment is the users responsibility.
– The conditions under which the equipment will be operated
safely should be reviewed by the user. The user must be aware of
the various national codes, ANSI/RIA R15.06-2012 safety
standards, and other local codes that may pertain to the
installation and use of this equipment.
Not following all national codes, safety standards and local codes can
result in death or serious injury
• Additional safety measures for personnel and equipment may be
required depending on system installation, operation, and/or
location.
– The following safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency Stop button
Not providing additional safety measures as required can result in
death or serious injury.
• Check all safety equipment frequently for proper operation.
– Repair or replace any non-functioning safety equipment
immediately.
If safety equipment does not operate properly death or serious injury
can result.
CAUTION
• Only trained personnel familiar with the operation, manuals,
electrical design, and interconnections of this equipment should
program, or maintain the system.
Any personnel involved with the operation of the equipment must
understand potential dangers of operation.
NOTICE
• The drawings and photos in this manual are examples. Differences
may exist between them and the delivered product.
• YASKAWA may modify this model without notice due to product
improvements, modifications, or changes in specifications. If such
modification is made, the manual number will also be revised.
• Some operations require standard passwords and while others
require special passwords.
• If a manual is damaged or lost, contact a local YASKAWA
representative to order a new copy. Make sure to tell the local
YASKAWA representative the Part Number listed on the front cover.
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Notes for Safe Operation
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Notes for Safe Operation
Read this manual carefully before installing, operating, maintaining, or
inspecting the system.
In this instruction, Safe Operations are classified as “DANGER”,
“WARNING”, “CAUTION” or “NOTICE”.
DANGER Indicates an imminently hazardous
situation which, if not avoided, WILL
result in death or serious injury.
WARNING Indicates a potentially hazardous
situation which, if not avoided, MAY
result in death or serious injury.
CAUTION
Indicates a hazardous situation,
which if not avoided, MAY result in
minor to moderate injury.
CAUTION Indicate a situation which if not
avoided may result in equipment
damage.
NOTICE Indicates practices not related to
personal injury.
NOTICE
To ensure safe and efficient operation at all times, be sure to follow all
instructions, even if not designated as “DANGER”, “WARNING” or
“CAUTION”.
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EduCart Explanation of Safety Labels
GP8 EduCart
EduCart Explanation of Safety Labels
The following labels are attached to the EduCart. Always follow these
safety labels.
Fig. : EduCart Safety Labels Location
 Weight Limit Label
This label notifies that if someone leans on the panels damage can occur.
 Moving Parts
This label indicates that moving parts are present and there is a warning
that severe injury or death can occur.
 Manipulator Labels
Refer to Manipulator Documentation for details.
1
245
3
1
2
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EduCart Explanation of Safety Labels
GP8 EduCart
 Machine Nameplate Date
The Machine Nameplate Data supplies important electrical information
that is required for installation.
 Shock Hazard
This label indicates that hazardous voltages are present and there is a
danger of getting electrical shock.
 YRC1000micro Controller Labels
Refer to YRC1000micro Controller Documentation for details.
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Installation and Wiring Safety
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Installation and Wiring Safety
Review the Manipulator and YRC1000micro Controller Instructions for
details on installation and wiring.
In planning installation, adapt an easy to observe arrangement to ensure
safety. Take safety into consideration when planning the installation.
Observe the following when installing the Robot:
DANGER
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact a local YASKAWA
representative.
• Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or
serious injury from unexpected motion of the Robot's arm.
• Any person who programs, teaches, operates, maintains or repairs
the included system MUST be trained and demonstrates
competence to safely perform assigned tasks.
Failure to observe these safety precautions may result in death or
serious injury from unexpected movements.
WARNING
• Run the piping, wiring, and cables for the YRC1000micro Controller,
Manipulator, Positioner control panel, peripheral devices, etc. in a
pit so that they are not stepped on by personnel or run over by a
forklift.
Failure to observe this Warning may cause personnel to trip over
exposed piping, wiring, or a cables, which may result in personal injury.
Additionally it may also cause damage to piping, wiring, or cables, and
unexpected movement of the Robot, which may result in personal injury
and/or equipment damage.
SAFETY
FIRST
Piping Lead
Cable Channnel
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.
CAUTION
• Make sure all covers and shields are installed correctly before
operating.
– Some drawings in this manual may have protective covers or
shields removed to show details.
Not having all covers and shields installed correctly can result in injury.
• When installing the Robot system, avoid interference with buildings,
structures, utilities, other machines.
Not avoiding these items may create trapping or pinch points.
• Do not make unauthorized modifications.
Unauthorized modifications can result in injury or equipment damage
and will void the warranty.
• Inspect:
– For problems with movement
– Damages to external wires
Repair any problems immediately and perform all necessary
procedures. If problems are not repaired or procedures are not fixed
unexpected results can occur causing injury.
NOTICE
• If supplying a supplementary audible means for Robot operation, it
shall exceed the ambient noise at the end-use of the application.
• Any changes or additions to the applicable information as provided
by the manufacturer is to be provided by the party that makes the
change or addition to the Robot system
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Ensure Safety
GP8 EduCart
Ensure Safety
DANGER
• When the power supplies of the Manipulator and YRC1000micro
Controller are turned ON at start-up, be sure to confirm the
following:
– Safety protection devices such as the E-STOP circuit, door
interlocks, etc. operate normally.
– Each axis operates normally in TEACH mode.
– Robot operates normally at the speed limit or less in the TEACH
mode.(Speed limit: 250 mm/s at the TCP or the flange)
– The teaching function and the playback function operate normally.
• The Robot may stop movements while waiting for a condition to be
satisfied during operation.
Once meeting the condition, the Robot starts movement causing a
danger that will cause death or severe injury.
• Make sure to clearly indicate when the Robot is in operation:
– Use a pilot lamp and/or an audible alert or
– The Robot stops operation if the operator comes close.
• Install a safety fence around the Manipulator to prevent any
accidental contact with the Manipulator when power is applied.
– Display a warning sign stating “Off-Limits During Operation” at the
entrance of the safety fence.
– The gate of the safety fence must be equipped with a safety
interlock to turn the servo power OFF when the gate opens.
– Make sure interlocks operate properly before use.
• For areas not enclosed by safety fences, use a photoelectric
sensor, a safety light curtain, etc. to make sure that the Robot stops
its operation if the operator enters its operating range.
Failure to observe this Danger notice will result in death or serious
injury due to contact with the Robot.
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Ensure Safety
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WARNING
• Turn OFF servo power before operating.
– Press the Emergency Stop button to turn off SERVO POWER.
When servo power is OFF, the SERVO ON LED on the
Programming Pendant is OFF.
Severe injury or death may result during an emergency if the
Emergency Stop button(s) do not work correctly. Do not use if the
Emergency Stop button(s) do not perform correctly.
Fig. : Emergency Stop Button(s)
• Clear the cell of all items which could interfere with the operation
before releasing the Emergency Stop button.
Injury may result from unintentional or unexpected motion.
Fig. : Release of Emergency Stop button
TURN
• Make sure no person is in the operating range and the operator is in
a safe location before:
– Turning ON power to the YRC1000micro Controller
– Moving the Robot with the Programming Pendant
– Running the system in the TEACH mode
– Performing automatic operations
Personal injury may result if a person enters the operating range during
operation. Immediately press an Emergency Stop button whenever
there is a problem.
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Ensure Safety
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All personnel working with the Robot (safety administration, installation,
operation, and maintenance personnel) must always be prepared and
“Safety First” minded, to ensure the safety of all personnel.
WARNING
• In the vicinity of the area where the Robot is installed, avoid any
dangerous actions, such as entering the Robot's operating range
without due care.
Failure to observe this instruction may cause contact with the
Manipulator or peripheral equipment, which may result in death or
serious injury.
• Strictly observe the safety precautions and signs in the factory, such
as “Flammable”, “High Voltage”, “Danger”, “Off-limits to
Unauthorized Personnel”.
Failure to observe this instruction may result in death or serious injury
do to fire, electric shock, caused by contact with the Manipulator or
other equipment.
• Strictly observe the following precautions about clothing:
– Always wear approved work clothes (no loose-fitting clothes).
– To prevent mis-operation, do not wear gloves when operating the
Robot.
– Do not allow underwear, shirts, or neckties hang out from the
work clothes.
– Do not wear accessories, such as earrings, rings, or necklaces.
– Always wear protective safety equipment, such as hard hats,
safety shoes (with slip-proof soles), face shields, safety glasses,
and gloves as necessary.
Failure to observe this instruction may result in death or serious injury.
• The following must be understood and strictly observed by all
personnel as rules:
– Unauthorized personnel other than the operator must not
approach the area where the Robot is installed.
Failure to observe this instruction may cause contact with the
Manipulator, YRC1000micro Controller, control panel, workpiece, or
Positioner, etc., may result in death or serious injury.
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Ensure Safety
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CAUTION
• All operators, programmers, maintenance personnel, supervisors,
and anyone working near the system must be familiar with the
operation of this equipment.
– All personnel involved with the operation of the equipment must
understand potential dangers of operation.
• General safeguarding tips:
– Place system in E-STOP mode whenever it is not in use.
– Use lockout/tagout procedures during equipment maintenance in
accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources
of Energy. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
– Only trained personnel familiar with the operation of this
equipment, the operator's manuals, the system equipment, and
options and accessories can operate equipment.
Improper operation can result in personal injury and/or damage to the
equipment.
• If the light in the operator's working space is not bright enough,
provide the space with appropriate lighting.
CAUTION
• Store industrial tools, etc. in a safe location outside the Robot's
operating range.
If an industrial tool, etc. is left unattended on the Robot, on a fixture, or
on the floor, etc., the Robot may come in contact with the industrial tool
left unattended, which may result in damage to the Robot and/or the
fixture.
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Operation Safety
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Operation Safety
DANGER
• Personnel engaged in teaching or inspection, etc. of the Robot must
receive special training required by applicable laws and regulations.
• While performing inspection and maintenance, wiring, or attaching a
tool to the Robot, etc., make sure to turn OFF the power supply of
the YRC1000micro Controller and the tool, and keep the switch of
the power supply locked so that unauthorized personnel cannot turn
ON the power supply.
In addition, display a warning sign stating “Energizing Prohibited”.
Turning ON the power supply without due care during inspection
and maintenance, etc., may cause electric shock or unexpected
movement of the Robot, which may result in personal injury.
• Use the Robot only within the specifications described in the
manuals for the Robot.
Failure to observe this instruction may result in personal injury and/or
equipment damage.
• Observe the following precautions when performing a teaching
operation within the Robot'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 a sign that an 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
Robot’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 Robot, which may result in personal injury.
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Operation Safety
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DANGER
• Before operating the Robot, 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
YRC1000micro Controller, on the Programming Pendant, on the
external control device, etc.
– Disconnect the safety plug of the safety fence.
(when in PLAY mode or REMOTE mode)
If operation of the Robot cannot be stopped in an emergency, personal
injury and/or equipment damage may result.
• Make sure that all safety protection devices are activated before
starting a job in PLAY mode.
• Confirm that no person is present in the Robot's operating range
and that the operator is in a safe location before:
– Turning ON the YRC1000micro Controller
– Moving the Robot by using the Programming Pendant
– Running the system in the TEACH mode
– Performing automatic operations
Personal injury may result if a person enters the Robot's operating
range during operation
• Immediately press an Emergency Stop button whenever there is a
problem.
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Operation Safety
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WARNING
• Read “Safety” of the YRC1000micro Controller instructions before
operating.
Not reading and understanding chapter 1 of the YRC1000micro
Controller instruction can result in death or serious injury.
• Read and understand all Warning Labels before operating.
Not reading and understanding all Warning Labels can result in death
or serious injury.
• Confirm that no person is present in the P-point maximum envelope
of the Robot before:
– Turning on the power for the YRC1000micro Controller.
– Moving the Robot with the Programming Pendant.
– Running the system in TEACH mode.
– Performing automatic operations.
Injury may result if anyone enters the working envelope of the Robot
during operation. Always press an Emergency Stop button immediately
if there are problems.
• Observe the following when performing teaching operation within
the operating range:
– Lockout by putting a lockout device on the safety fence when
going into the area enclosed by the safety fence.
– Display a sign that operations are being performed so no other
person closes the safety fence.
– View from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind an emergency response measures against
unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this precautions may cause improper or unintended
movement, which may result in personal injury.
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this Warning may result in electric shock or injury.
• Contact a local YASKAWA representative for disassembly or
repairs.
Not contacting a local YASKAWA representative can result in electrical
shock or injury.
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CAUTION
• Do not operate the Robot when a [COOLING FAN2 ERROR]
appears on the Programming Pendant.
If operation continues with a warning message, equipment damage can
occur.
• During high speed continuous operation the Robot temperature
may rise quickly depending on ambient temperature and operation
pattern.
If a warning message displays stop operations or equipment damage
may occur.
• Monitor warning messages on the Programming Pendant.
Not monitoring warning messages may cause equipment damage.
• Refer to the YRC1000micro Controller Concurrent I/O manual for
details on the signal output.
Not referring to YRC1000micro Controller Concurrent I/O manual can
result in equipment damage.
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Maintenance Safety
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Maintenance Safety
WARNING
• Make sure equipment has no potentially hazardous conditions.
– area is clean and free of water, oil, debris, etc.
– all safeguards are in place.
– all safety equipment work correctly. Repair or replace any non-
functioning safety equipment immediately.
– Check the EMEREGENCY STOP button(s) for proper operation
before programming. The equipment must be in E-STOP mode
when not in use.
If a hazardous condition is present death or serious injury may occur.
• Use care when modifying software.
– The equipment allows modifications to the software for maximum
performance.
All modifications made to the software will change the way the
equipment operates and may cause death or serious injury, as well as
damage parts of the system.
• Make sure all modifications did not make create a hazardous or
dangerous condition in all modes.
All modifications made to the software will change the way the
equipment operates and may cause death or serious injury, as well as
damage parts of the system.
• Disconnect and lockout/tagout all sources of energy before making
modifications or connections.
Not disconnecting and doing lockout/tagout of all sources of energy can
result in death or serious injury.
• Read and understand all maintenance procedures before
completing procedures.
Not reading and understanding maintenance procedure may result in
death or serious injury.
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Notes for Moving and Transferring the Robot
GP8 EduCart
Notes for Moving and Transferring the Robot
CAUTION
• Do not modify the YRC1000micro Controller.
Making modifications without written permission from YASKAWA will
void the warranty.
• Back up all programs and jobs onto suitable media before program
changes are made.
To avoid loss of information, programs, or jobs, a backup must always
be made before any service procedures are done and before any
changes are made to options, accessories, or equipment.
• Use proper replacement parts only.
Not using proper replacement parts can cause damage to equipment.
• All connections must be made within the standard voltage and
current ratings of the equipment.
Improper connections can damage the equipment.
DANGER
• When relocating, transferring, or selling the Robot, make sure that
the Robot is always accompanied by its manuals so that all users
have access to necessary manuals.
See the Bill of Material for a list of the manuals.
If any of them are missing, contact a local YASKAWA representative.
The telephone numbers of our offices are listed on the back cover of
this manual.
• If a warning label on the Robot is dirty and unreadable, clean the
label to make it clearly readable. If a warning label has come off, put
the label back in place. Note that some local laws and regulations
may prohibit equipment operation if safety labels are not in place.
Contact a local YASKAWA representative if requiring a new warning
labels.
• After the Robot is relocated, inspection by a local YASKAWA
representative is recommended.
If installation or wiring of a device is incorrect, personal injury and/or
equipment damage may result.
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