YASKAWA MOTOMAN DX100 User manual

MANUAL NO.
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YASKAWA ELECTRIC CORPORATION
DX100 OPTIONS
INSTRUCTIONS
FOR FUNCTIONAL SAFETY UNIT (NSU01)
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 manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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DX100
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MANDATORY
• This manual explains the functional safety unit (NSU01) of the
DX100 system. Read this manual carefully and be sure to
understand its contents before handling the DX100.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 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 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
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
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.
Fig. : 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.
Fig. : 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 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 DX100.
– 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 is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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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 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 cabinet
of the DX100 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
DX100 Instructions 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
GO
BACK
PAGE
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1 Function Overview .......................................................................................................................... 1-1
1.1 Preface .............................................................................................................................. 1-1
1.2 Function Overview ............................................................................................................. 1-1
2 System Configuration...................................................................................................................... 2-1
2.1 Outline ............................................................................................................................... 2-1
2.1.1 Functional Safety Unit........................................................................................... 2-1
2.1.2 Signal Distribution Board ...................................................................................... 2-2
2.1.3 Communication I/F Gateway Unit ......................................................................... 2-3
2.1.4 Power On Unit ...................................................................................................... 2-4
2.2 Overview of Unit Connection ............................................................................................. 2-5
2.3 Description of Unit Layout (Layout Drawing) ..................................................................... 2-6
2.4 Spare Parts........................................................................................................................ 2-6
3 Setup (Safety Range Function for Robot) ....................................................................................... 3-1
3.1 Changing Security Mode....................................................................................................3-1
3.2 Preparation for Safety Range Function.............................................................................. 3-3
3.3 Setting Tool Interference File............................................................................................. 3-3
3.4 Setting Safety Range for Robot ......................................................................................... 3-7
3.5 Confirming Safety Range for Robot ................................................................................. 3-11
3.6 Switching Safety Range...................................................................................................3-12
3.7 Starting Safety Range Function for Robot ....................................................................... 3-15
3.8 Confirming Safety Range and Robot Position ................................................................. 3-17
4 Setup (Safety Range Function for Each Axis).................................................................................4-1
4.1 Preparation for Safety Range Function.............................................................................. 4-1
4.2 Setting Expected Stop Value ............................................................................................. 4-1
4.3 Setting Safety Range for Each Axis................................................................................... 4-4
4.4 Confirming Safety Range for Each Axis............................................................................. 4-7
4.5 Starting Safety Range Function for Each Axis................................................................... 4-8
5 Stop Position Monitoring Function .................................................................................................. 5-1
5.1 Operating Condition Detection........................................................................................... 5-1
5.2 Turning Stop Position Monitoring Function VALID/INVALID.............................................. 5-1
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6 Data Protection ............................................................................................................................... 6-1
6.1 Saving Dual Data............................................................................................................... 6-1
6.2 Operation When VERIFY ERROR Occurs ........................................................................ 6-2
7 System Output Signal ..................................................................................................................... 7-1
8 Alarm............................................................................................................................................... 8-1
9 Restrictions ..................................................................................................................................... 9-1
9.1 Confirming Safety Range and Robot Position ................................................................... 9-1
9.2 Software Version of Machine Safety Unit .......................................................................... 9-1
9.3 Software Version of Functional Safety Unit ....................................................................... 9-2
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1 Function Overview
DX100 1.1 Preface
1-1
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1 Function Overview
1.1 Preface
This function limits the operating range of the robot and monitors its
speed.
With this function, the software monitors the robot arm or each axis so that
its position does not exceed the preset safety range. If any monitoring
error is detected, the contactors are cut off to stop the robot. With this
function, it is possible to improve the safety for robot operation, and
reduce the facility space for the robot system.
1.2 Function Overview
(1) Range limit function (robot axis + servo track / unit)
This function is used to monitor the robot so that its position does
not exceed the preset safety range. Only one safety range can be
specified. The specified range can be applied to the following con-
figuration:
Robot (6 axes) + servo track (up to 3 axes)
or
Robot (7 axes) + servo track (up to 2 axes)
By the combination of 2 lines of dual input signals (range switch
signals) to the functional safety unit, 4 ranges (range: 1 to range:
4) can be set as the safety ranges.
To enable range switching, connect the range switch signals to the
functional safety system input terminal block shown in
chapter 2.1.2 “Signal Distribution Board” at page 2-2. When
range switching is not used, i.e. only one safety range is set, there
is no need to connect the signals. (In this case, range: 1 is set.)
For signal connection, refer to chapter 3.7 “Starting Safety Range
Function for Robot” at page 3-15.
(2) Each axis angle limit function (9 axes/unit)
(3) Stop position monitoring function
(4) Safety speed monitoring function
This function monitors the robot to see that it operates at the
safety speed of 250 mm/sec. The speed is monitored at the TCP
(Tool Center Point) and flange.
• Teach mode (manual high speed specification is OFF)
(5) Logical verification of safety signals
This function detects the unmatch of the dual safety signals
converted into the functional safety unit.
NOTE
The safety speed monitoring function can monitor the
speed of one tool number per robot.
The speed of R1 and R2 is monitored using the file with the
tool numbers 0 and 1, respectively.
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2 System Configuration
DX100 2.1 Outline
2-1
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2 System Configuration
2.1 Outline
To achieve the functions described in this manual, the “functional safety
unit”, “signal distribution board”, “communication I/F gateway unit”, and
“power on unit” are added or replaced for the DX100.
2.1.1 Functional Safety Unit
The type and major specifications of functional safety unit are shown
below.
The outline of the functional safety unit: JZNC-NSU01 is shown below.
Item specification
Unit type JZNC-NSU01
Unit size W120×H300×D194 [mm]
Input power supply DC24V
Function (1)
Safety range setting function (robot axis + servo track / unit)
(2) Safety speed monitoring function
(3) Safety signal logical verification function
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2 System Configuration
DX100 2.1 Outline
2-2
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2.1.2 Signal Distribution Board
The signal distribution board is a special board equipped with an extended
function that distributes full-speed test signals to the functional safety unit
in addition to the standard functions of the robot system input terminal
block (MXT).
Item specification
Board type JARCR-YCU02
Function (1) Robot system input terminal block
(2) Signal distribution to the functional safety unit
(3) Spare terminal block (for future extension)
NOTE For the connection to the robot system input terminal block,
refer to “13.9 Robot System Input Terminal Block (MXT)” in
DX100 INSTRUCTIONS MANUAL.
Robot system input termial block
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2 System Configuration
DX100 2.1 Outline
2-3
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2.1.3 Communication I/F Gateway Unit
The gateway unit for host communication I/F is added to convert the
communication signals to enable the communications between DX100
and the functional safety unit (JZNC-NSU01).
This unit converts the communication signals between the robot I/F board
(JANCD-YIF01-□) in DX100 and the functional safety unit (JZNC-
NSU01).
The outline of the communication I/F gateway unit: JZNC-YGW01-E is
shown below.
Item specification
Unit type JZNC-YGW01-E
Unit size W30×H230×D1 [mm]
Input power supply DC24V
Function
Conversion of the communication signals between
DX100 robot I/F board (JANCD-YIF01-
□ ) and the
functional safety unit (JZNC-NSU01)
Setting (rotary SW: S1) 1st robot: 0
2nd to 4th robot: 1 to 3 (Number consecutively.)
Connector CN902/CN903 For the connection of the robot I/F board (JANCD-
YIF01- □ ) and the functional safety unit (JZNC-
NSU01)
CN904 For the connection of the functional safety unit
(JZNC-NSU01)
CN901 For 24 VDC input
S1
Rotary SW
F1
Protection fuse
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2 System Configuration
DX100 2.1 Outline
2-4
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2.1.4 Power On Unit
This power on unit is the unit to which an “auxiliary contact block” is added
in order to feed back the status of the built-in contactor to the functional
safety unit (JZNC-NSU01).
The standard power on unit should be replaced with this unit if needed.
Item specification
Unit type JZRCR-YPU0
□ -2
Unit size Same size as the standard power on unit
(interchangeable)
Function
Contactor auxiliary contact signal output is added.
(for the functional safety unit (JZNC-NSU01))
Connector CN609 For the contactor auxiliary contact signal output
(added to the standard unit)
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2 System Configuration
DX100 2.2 Overview of Unit Connection
2-5
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2.2 Overview of Unit Connection
The figure below shows a rough connection diagram where the functional
safety unit is added to the DX100 control panel.
(Current DX100 system)
Main CPU
Main CPU
Servo control
CPU
Servo control
CPU
error monitoring
(2) Various types of
Machine safety control
Contactor control
Servo amplifier
Servo amplifier
error monitoring
Various types of
& power shutdown
error monitoring
Various types of
& power shutdown
Current position
Current
instruction
Current
position
Position
instruction
Power
shutdown
Teach pendant
Teach pendant
Current position
Current
instruction
Current
position
Position
instruction
Power
shutdown
Power
shutdown
(DX100 system with the function added)
Functional safety unit
(1) Safety range monitoring
(2) Safety speed monitoring (*)
safety signals
(3) Logical verification of (A)
(A)
Current position
(*) Safety speed monitoring:
Monitoring the speed of 250 mm/sec or slower
Primary
power
supply
Alarm
information
Alarm
information
Motor
Detector
Motor
Detector
Machine safety control
Contactor control Primary
power
supply
monitoring (*)
(1) Safety speed
error monitoring
(2) Various types of
monitoring (*)
(1) Safety speed
Dual safety signal
error monitoring
(4) Various types of
monitoring (*)
(3) Safety speed
soft limit
monitoring with
(2) Current position
(1) Target positioning
control and monitoring
(5) Safety range
error monitoring
(4) Various types of
monitoring (*)
(3) Safety speed
soft limit
monitoring with
(2) Current position
(1) Target positioning
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2 System Configuration
DX100 2.3 Description of Unit Layout (Layout Drawing)
2-6
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2.3 Description of Unit Layout (Layout Drawing)
The figure below shows a layout drawing of the DX100 with which the
functional safety unit is added.
Fig. 2-1: Unit Layout Drawing (with the Door Open)
2.4 Spare Parts
To achieve the functions of range limit and speed monitoring for the
DX100 robot system, the recommended spare parts for the DX100 with
the functional safety unit are shown below.
Regarding the standard part of the DX100, refer to “DX100
INSTRUCTIONS (RE-CTO-A215)” and “DX100 MAINTENANCE
MANUAL (RE-CHO-A108)”.
BNL6
BNL6
3
CU
Y
L
N
O
1
CU
Y
L
N
O
R
489
C
20A
~
480Y/277V
40
CU
Y
L
N
O
42 Y
L
N
O
CU
C.B.
V U T S R Q P N M L
K J H G F E DC BA
30 29282726
14
25242322 21
20 19181716151312 11
10 0908070605040302 01
C90ADXXXXX
MADEINJAPAN
FujiElectric Hi-Tech Corp.
DATE
NO.
POWERSUPPLY
CPS-520F
YYYY-MM
V U T S R Q P N M L
K J H G F E DC BA
30 29282726
14
25242322 21
20 19181716151312 11
10 0908070605040302 01
CN158/159
CN154/155
(+24V1/V2)
(+24V2)
CN156/157
(+24V3)
CN153
(REMOTE)
CN152
(+5V/ALM)
SOURCE
OHT
INPUT
FAN
+24V
+5V
P-ON
50/60Hz
(ACIN)
CN151
200-240VAC
3.4A-2.8A
FUSE
CN215 CN216
CN208 CN209 CN210 CN211 CN212 CN213 CN214
CN200 CN201 CN202
CN203 CN204 CN205 CN206 CN207
A B
1
A B
1
FRC5-C50S52T-OLS(D20)
A B
1
SVMX2 SVMX1
CN603
CN604
CN605
CN612
CN606
NCM
CN607
CN611
4FU3FU
2FU1FU
CN610
CN601
CN609CN608
CN602
COULD
FUSE
COULD
FUSE
CBA
Functional safety unit (YPU)
Power on unit (YPU)
Comm. I/F gateway unit
JZNC-YGW01-E
JZNC-NSU01
(QS2)
(QF3)
JZRCR-YPU0-2
A
A
BNL6
BNL6
CNYSUO
CNEXT
CNNSUO
CNC CNB CNA
MADEINJAPAN
S/N 94V-0
UL
HE0305598
JARCR-YCU02REV.A0
BNL6
EXIN3_2+
EXIN3_2-
EXIN3_1+
EXIN3_1-
EXIN2_2+
EXIN2_2-
EXIN2_1+
EXIN2_1-
EXIN1_2+
EXIN1_2- EXIN1_1-
EXIN1_1+
L
K
J
I
H
G
F
E
D C
B A
YCU
EXHOLD+
GSOUTFB2-
GSOUTFB2+
GSOUT2-
GSOUT2+
GSOUTFB1-
GSOUTFB1+
GSOUT1-
GSOUT1+
+24V2
+24V2
+24V2
024V2
024V2
024V2
EXDSW2-
EXDSW2+
EXDSW1-
EXHOLD-
EXSVON+
SSP+
EXDSW1+
EXSVON-
SSP-
FST2-
FST2+
FST1-
FST1+
EXESP2-
EXESP2+
EXESP1-
EXESP1+
SYSRUN-
SYSRUN+
SAFF2-
SAFF2+
SAFF1-
SAFF1+
GSIN22-
GSIN22+
GSIN21-
GSIN12-
GSIN12+
GSIN11-
GSIN21+
GSIN11+
NJ3114-1
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
JARCR-YCU02
Terminal unit for NSU
Section A-A
Unit Name Model Qty. Manufacturer
Functional Safety
Unit
(JZNC-NSU01)
Fuse
(for F2 and F3)
0217001P 2 Littelfuse
Communication I/F
Gateway Unit
(JZNC-YGW01-E)
Fuse (for F1) 0217001P 1 Littelfuse
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3 Setup (Safety Range Function for Robot)
DX100 3.1 Changing Security Mode
3-1
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3 Setup (Safety Range Function for Robot)
3.1 Changing Security Mode
To limit the operating range of the robot, set the safety range.
To set the safety range, the security mode must be MANAGEMENT
MODE or higher. Thus, the administrator or a user with higher privilege
must set the range.
Change the security mode as follows:
1. Select {SYSTEM INFO} under the main menu.
2. Select {SECURITY} under the sub menu.
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3 Setup (Safety Range Function for Robot)
DX100 3.1 Changing Security Mode
3-2
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3. Change the mode from EDITING MODE to MANAGEMENT MODE.
Press [ENTER] in the SECURITY screen. Move the cursor to
“MANAGEMENT MODE” and then press [ENTER] again.
4. Input the password for MANAGEMENT MODE and press [ENTER].
The security mode is changed to MANAGEMENT MODE.
NOTE
Security level Items that can be manipulated
OPERATION Data such as the operating range cannot be
edited or viewed.
EDITING
MANAGEMENT Data such as the operating range can be
edited or viewed. The “Safety Unit FLASH
Erase” can be performed in the
maintenance mode.
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3 Setup (Safety Range Function for Robot)
DX100 3.2 Preparation for Safety Range Function
3-3
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3.2 Preparation for Safety Range Function
For the safety range function for the robot arm, set the safety range of the
robot arm as polygonal columns in advance. Then, the robot arm is
monitored so that it does not exceed the safety range.
If any monitoring error is detected, the servo power will be turned OFF.
The outline of the operating procedure is as follows:
(1) Setting tool interference file
È
(2) Setting safety range for robot
È
(3) Confirming safety range for robot
È
(4) Starting safety range function for robot
Each operating procedure is explained below.
3.3 Setting Tool Interference File
The safety unit also monitors that the robot tool does not exceed the
safety range. In this case, set the tool shape in the tool interference file.
To set the tool interference file, the security mode must be EDITING
MODE or higher.
<Tool interference file>
• Cylinders and spheres for up to 5 positions can be set.
• Both ends of a cylinder are set by POINT1 and POINT2.
The distance from the center of T axis flange should be set like tool
dimension setting.
• The radius of the spheres and cylinder between POINT1 and
POINT2 is set. The spheres are set to POINT1 and POINT2.
• The specified radius must have a margin of at least 10 mm com-
pared with the actual tool.
NOTE
A single tool interference file can be used for a robot.
The safety range function is set to the data in the tool inter-
ference file #0 for R1 and that in the tool interference file #1
for R2.
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3 Setup (Safety Range Function for Robot)
DX100 3.3 Setting Tool Interference File
3-4
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Set a tool interference file as instructed below.
1. Select {ROBOT} under the main menu.
2. Select {TOOL INTERFERE} under the sub menu.
– The TOOL INTERFERE screen is displayed.
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3 Setup (Safety Range Function for Robot)
DX100 3.3 Setting Tool Interference File
3-5
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3. If the data is set in TOOL INTERFERE screen, the READBACK screen
is shown.
– In READBACK screen, you can check if the set data is correct.
– Compare MODIFY VALUE with READBACK VALUE.
• If the data is OK, press “YES” on the screen to fix the tool inter-
ference file setting.
• If the data is NG, press “NO” on the screen to restore to the value
before change.
4. After READBACK screen is displayed, [WRITE] and [CANCEL]
buttons are displayed in the lower position of the screen.
<Description of the screen>
WRITE: Robot controller records the setting of the tool interference file.
CANCEL: Cancel the tool interference file setting to restore the setting to
the previous status.
NOTE
• Be sure to press [WRITE] after performing tool interfer-
ence file setting.
• A single tool interference file can be used for a robot.
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