YASKAWA EcoTrim ET-1024 System Manual
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YASKAWA EcoTrim ET-1024 System Manual

YASKAWA EcoTrim ET-1024 System Manual

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EcoTrim ET-1024
SYSTEM MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
MOTOMAN INSTRUCTIONS
MH24 MANIPULATOR INSTRUCTIONS
MSR-355 AND MSR-655 POSITIONER MANUAL
EcoTrim ET-1024 SYSTEM MANUAL
DX200 INSTRUCTIONS
DX200 OPERATOR'S MANUAL
DX200 MAINTENANCE MANUAL
The DX200 operator's manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number:
175932-1CD
Revision:
0
1 of 64

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Summary of Contents for YASKAWA EcoTrim ET-1024

  • Page 1 Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain for future reference. MOTOMAN INSTRUCTIONS MH24 MANIPULATOR INSTRUCTIONS MSR-355 AND MSR-655 POSITIONER MANUAL EcoTrim ET-1024 SYSTEM MANUAL DX200 INSTRUCTIONS DX200 OPERATOR’S MANUAL DX200 MAINTENANCE MANUAL The DX200 operator’s manual above corresponds to specific usage.
  • Page 2 Copyright © 2016, Yaskawa America, Inc. Terms of Use and Copyright Notice All rights reserved. This manual is freely available as a service to Yaskawa customers to assist in the operation of Motoman robots, related equipment and software This manual is copyrighted property of Yaskawa and may not be sold or redistributed in any way.
  • Page 3 If such a modification is made, the revision number will also be revised. • If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.
  • Page 4 ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR REPAIR THE EQUIPMENT! We recommend approved Yaskawa training courses for all personnel involved with the operation, programming, or repair of the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules.
  • Page 5 Notes for Safe Operation Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the Motoman EcoTrim ET-1024 System. In this manual, the Notes for Safe Operation are classified as “DANGER,” “WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.”...
  • Page 6 175932-1CD EcoTrim ET-1024 System Notes for Safe Operation WARNING • Before operating the manipulator, check that servo power is turned OFF by pressing the EMERGENCY STOP buttons on the front door of the DX200 controller and on the Programming Pendant (refer to Fig.
  • Page 7 • Read and understand the Explanation of Warning Labels in the DX200 Controller Manual before operating the EcoTrim ET-1024 System. Definition of Terms Used Often in This Manual he MOTOMAN manipulator is the YASKAWA industrial robot product.
  • Page 8 175932-1CD EcoTrim ET-1024 System Explanation of Warning Labels Explanation of Warning Labels The following warning labels are attached to the manipulator (refer to Fig. 3). Always follow the warnings on the labels. Also, an identification label with important information is placed on the body of the manipulator.

  • Page 9: Table Of Contents

    175932-1CD EcoTrim ET-1024 System Table of Contents Table of Contents 1 Introduction ............................. 1-1 1.1 About This Document ......................1-1 1.2 System Overview....................... 1-2 1.2.1 System Layout...................... 1-3 1.2.2 Major Components ....................1-4 1.2.3 Theory of Operation and Safe Guarding .............. 1-4 1.2.3.1 System Teaching: ...................
  • Page 10 175932-1CD EcoTrim ET-1024 System Table of Contents 2.7.2 Safety Light Curtains .................... 2-8 2.7.3 Emergency Stops (E-STOPS) ................2-8 2.7.4 Programming Pendant’s Enable Switch ............... 2-9 2.7.5 Emergency Braking System ................. 2-9 2.7.6 Interlocked Work-cell Doors.................. 2-9 3 Installation ............................3-1 3.1 Required Materials......................
  • Page 11 175932-1CD EcoTrim ET-1024 System Table of Contents 5 Maintenance ........................... 5-1 6 Anchor Requirements ........................6-1 Appendix A ............................A-1 A.1 Checklist..........................A-1 Appendix B ............................B-1 B.1 EcoTrim ETU-1024 Pneumatics..................B-1 B.1.1 Standard EcoTrim ETU-1024................B-2 B.1.2 Optional EcoTrim ETU-1024 ................B-3 Appendix C ............................C-1 C.1 Optional Equipment......................C-1...

  • Page 12: Introduction

    Appendix A Appendix A provides a check sheet on what is included with the documentation. Appendix B Appendix B provides pneumatic schematics for the EcoTrim ET-1024 System. Appendix C Appendix C provides optional and replacement parts for the EcoTrim ET- 1024 System.

  • Page 13: System Overview

    175932-1CD EcoTrim ET-1024 System Introduction 1.2 System Overview System Overview The EcoTrim-1024 System provides a complete trimming solution in a standardized configuration. There are two available tables that can be selected for the EcoTrim-1024 System cell assemblies, the MSR-355 (standard) and the MSR-655 (optional). The payloads are 355 and 655 kg per side of the table.

  • Page 14: System Layout

    175932-1CD EcoTrim ET-1024 System Introduction 1.2 System Overview Fig. 1-1: System Layout — EcoTrim-1024 Shown DX200 CONTROLLER MH24 ROBOT OPERATOR STATION (OPTION) LIGHT CURTAINS MSR SIGMA 5 POSITIONER 1.2.1 System Layout The MH24 manipulator (robot), an MSR positioner, and heavy-gauge,...

  • Page 15: Major Components

    175932-1CD EcoTrim ET-1024 System Introduction 1.2 System Overview 1.2.2 Major Components The EcoTrim-1024 System includes the following major components: • Motoman MH24 manipulator (robot) • DX200 controller • One MSR series rotary positioner • One Programming Pendant (located on the DX200 controller) •...
  • Page 16 175932-1CD EcoTrim ET-1024 System Introduction 1.2 System Overview Fig. 1-2(a): FSU Generated “At Side A/B” Signals Fig. 1-2(b): “Light Curtain Clear” or “At Side A/B” into E-Stop This logic ensures that the table is located at “Side A” or “Side B” when the light curtain is broken.

  • Page 17: System Teaching

    175932-1CD EcoTrim ET-1024 System Introduction 1.2 System Overview Fig. 1-3(a): ET-1024 Cell 480V O 1524 TOOLING ENVELOPE 1.2.3.1 System Teaching: Programming of the system is intended to take place from within the cell. In order to program the robot, the controller needs to be in “Teach Mode”...

  • Page 18: Key Safety Devices

    175932-1CD EcoTrim ET-1024 System Introduction 1.2 System Overview approaches the cell to load a part and breaks the light curtain, the rotary table will need to be at (and remain at) the “Side A” or “Side B” position. Once the part has been loaded, the operator steps out of the light curtain, the “Light Curtain Clear”...

  • Page 19: Safety Logic Implementation

    175932-1CD EcoTrim ET-1024 System Introduction 1.2 System Overview • Three button operator station: –Dual channel “Cycle Start” button –Dual channel “E-Stop” –Single channel “Auto/Manual” switch • Functional Safety Unit (FSU): –Responsible for monitoring the MSR rotary table to ensure no external motion occurs (via “Standstill monitor”...
  • Page 20 175932-1CD EcoTrim ET-1024 System Introduction 1.2 System Overview Fig. 1-4(b): “S1 Side A at Robot” Details: Fig. 1-4(c): “S1 Side B at Robot” Details 20 of 64 175932-1CD...

  • Page 21: Reference Documentation

    175932-1CD EcoTrim ET-1024 System Introduction 1.3 Reference Documentation Reference Documentation For additional information on individual components of the EcoTrim-1024 System, refer to the following documentation that is included with your delivered system: • Motoman MH24 Manipulator Manual (P/N 171483-1CD) • Motoman DX200 Controller Manual (P/N 165292-1CD) •...

  • Page 22: Location Of Operations In Reference Documentation

    175932-1CD EcoTrim ET-1024 System Introduction 1.3 Reference Documentation 1.3.1 Location of Operations in Reference Documentation The table below provides the location(s) for various operations within the included reference manuals. Table 1-1: Reference Table Description Manual/Chapter     ...
  • Page 23 175932-1CD EcoTrim ET-1024 System Introduction 1.3 Reference Documentation Description Manual/Chapter   Maintenance and Intended Life EcoTrim Chap 5   Interface Requirements EcoTrim Chap 3    Dynamic Limiting Zones EcoTrim Chap 2 & 4        ...
  • Page 24 175932-1CD EcoTrim ET-1024 System Introduction 1.3 Reference Documentation Description Manual/Chapter  Stopping Time and Distance Drawings; Positioner Chap 4   Specifications for Fluids Manipulator Chap 9 Positioner Chap 6  Limits for Range of Motion EcoTrim Chap 2 ...

  • Page 25: Customer Support Information

    175932-1CD EcoTrim ET-1024 System Introduction 1.4 Customer Support Information Customer Support Information If you need technical assistance with any aspect of your EcoTrim-1024 System, please contact Motoman Customer Support at the following 24-hour support telephone number: (937) 847-3200 Please have the following information ready before you call: •...

  • Page 26: Equipment Description

    System (refer to section 1.3). DX200 Controller The EcoTrim ET-1024 System features a DX200 controller (see Fig. 2-5). The DX200 controls the movement of the robot. It also controls the Ultrasonic trimming process and MSR rotary positioner and provides the signals necessary to operate the trimming system.

  • Page 27: Programming Pendant

    EcoTrim ET-1024 System to or from the Operator Station. For detailed information on the pendant programming keys, programming functions, and display functions, please refer to the DX200 Operator’s Manual that is included with your EcoTrim ET-1024 System (see section 1.3).

  • Page 28: Operator Station

    • Operator Station “enable” or “disable” is accomplished NOTE with the Programming Pendant’s Mode Select Switch. To transfer control of the EcoTrim ET-1024 System to the Operator Station, set the Programming Pendant’s Mode Select Switch to REMOTE. The Operator Station enable/ disable function cannot be selected at the Operator Station.

  • Page 29: Cycle Start/Cycle Latched

    175932-1CD EcoTrim ET-1024 System Equipment Description 2.4 Operator Station 2.4.1 Cycle Start/Cycle Latched The operation of the Cycle Start/Cycle Latched button depends upon the structure of the Control Master job. The green Cycle Start/Cycle Latched button, located on the Operator Station, initiates a positioner sweep cycle if the robot is in the Home position.

  • Page 30: Reset

    175932-1CD EcoTrim ET-1024 System Equipment Description 2.4 Operator Station 2.4.7 Reset The black Reset button is used to clear a minor alarm or error condition. 2.4.8 Servo On The green Servo On push button turns servo power ON when the robot is in Play mode and the Operator Station is enabled.

  • Page 31: Msr Family Positioner

    2.5 MSR Family Positioner MSR Family Positioner The MSR Family positioner is part of the EcoTrim ET-1024 System. It is mounted on the same common equipment base as the MH24 robot and the wire-mesh safety fencing. The MSR family is a high-speed rotary positioner that features controlled rotary motion and a 355 kg (783 lb) and 655 kg (1444 lb) payload capacity per side.

  • Page 32: Trimming Equipment

    Equipment Description 2.6 Trimming Equipment Trimming Equipment In its standard configuration, the EcoTrim ET-1024 System includes a Ultrasonic blade sharpener, and blade sensor. Optional equipment may also be included with your EcoTrim ET-1024 System. The Ultrasonic cutting tool is used for high-speed cutting, trimming deburring and chamfering applications.

  • Page 33: Safety Features

    With the EcoTrim ET-1024 System, the safety light curtains are set up to protect personnel who might unintentionally enter the MSR rotary positioner area during the positioner sweeping process.

  • Page 34: Programming Pendant's Enable Switch

    For detailed information about the operation of the Enable switch, refer to the Operator’s Manual included with your EcoTrim ET-1024 System (see section 1.3). 2.7.5 Emergency Braking System...

  • Page 35: Installation

    Be sure to handle all components with care. The EcoTrim ET-1024 System can be installed in a short amount of time by two or three qualified technicians. Always comply with the established safety instructions and precautions given throughout this manual during the installation process.

  • Page 36: Recommended List Of Hand Tools And Equipment

    Special anchor bolts (lag bolts) are supplied by the customer. Refer to section 6 for a listing of special bolts that NOTE are required for anchoring the common equipment bases and other components of the EcoTrim ET-1024 System. 36 of 64 175932-1CD...

  • Page 37: Site Preparation

    To prepare your site, proceed as follows: 1. Clear the floor space needed for the EcoTrim ET-1024 System (see Fig. 3-1). Allow an additional 1.2 to 1.5 m (4 to 5 ft) on all sides of the work cell to facilitate installation.

  • Page 38: Installing And Leveling The Common Base

    175932-1CD EcoTrim ET-1024 System Installation 3.3 Installing and Leveling the Common Base Installing and Leveling the Common Base The common base is shipped on a wooden platform. To install the common base, refer to your system drawings and proceed as follows: CAUTION Handle system components carefully.
  • Page 39 175932-1CD EcoTrim ET-1024 System Installation 3.3 Installing and Leveling the Common Base 3. Place the common base in position (see Fig. 3-1)). Make sure that there is adequate room on all sides of the robot/positioner common base for the Operator Station, the...

  • Page 40: Installing The Operator Station Pedestal (Option)

    The light curtain Send unit and Receive unit must be accurately positioned, relative to each other, to ensure correct operation. Complete alignment procedures are included in the light curtain documentation that is included with your EcoTrim ET-1024 System (refer to section 1.3). 40 of 64 175932-1CD...

  • Page 41: Cable Connections

    3.6.1 Connection to Earth Ground WARNING Do not use the EcoTrim ET-1024 System unless specified components are connected to a low-resistance earth ground. Do not connect the earth ground wire with the wires for the electric power source. The low- resistance earth ground must be a “dedicated”...

  • Page 42: Connection To Local Electrical Service

    3.6 Cable Connections 3.6.2 Connection to Local Electrical Service WARNING Connection of the EcoTrim ET-1024 System to local electrical service must be done by a qualified, licensed electrician. Electrical and grounding connections must comply with the National Electrical Code (NEC), as well as local electrical codes.

  • Page 43: Safety/Operation Check

    7. Verify that the local electrical service complies with the voltage and phase requirements for your EcoTrim ET-1024 System. CAUTION The EcoTrim ET-1024 System is now ready for power-up. Ensure that qualified, trained operators who are familiar with the EcoTrim ET-1024 System perform this power-up sequence.

  • Page 44: Installation Of Tooling And Fixtures

    3.8 Installation of Tooling and Fixtures Installation of Tooling and Fixtures Your EcoTrim ET-1024 System is now ready for the installation of tooling and fixtures for your particular application. Personnel who are familiar with the operation of the EcoTrim ET-1024 System should do the installation.

  • Page 45: Operation

    Do not modify the original. Modifications must be performed by trained and experienced personnel who are familiar with the operation of the EcoTrim ET-1024 System. If you have questions concerning the configuration of your EcoTrim ET-1024 System, please contact Motoman 24-hour Customer Support (refer to section 1.4).

  • Page 46: Sweeping The Positioner

    175932-1CD EcoTrim ET-1024 System Operation 4.2 Sweeping the Positioner Sweeping the Positioner The robot must be in HOME position before you can sweep NOTE the positioner. MANUAL mode allows you to sweep the MSR positioner without activating the robot. Parts can be loaded onto the fixture to achieve the most efficient configuration and then swept into the trimming zone before teaching the robot a series of moves.

  • Page 47: Daily Operation

    • Perform the shutdown procedure (refer to section 4.3.5). 4.3.1 Start-up Procedure To start up the EcoTrim ET-1024 System work cell from a power-off condition, proceed as follows: 1. Set the power ON-OFF switch on DX200 controller to ON (see Fig.

  • Page 48: Control Master Job

    7. Transfer control to the Operator Station by selecting REMOTE on the Programming Pendant’s Mode Select Switch. The EcoTrim ET-1024 System work cell is now ready for operation. 4.3.4 Operation Cycle The following is the typical sequence of operation for the EcoTrim ET-...

  • Page 49: Shutdown Procedure

    3. Select TEACH mode on the Programming Pendant. 4. Set the DX200 controller’s power ON-OFF switch to the OFF position. 5. Close the main shutoff valve. 6. Switch all electrical service disconnect boxes to OFF. The EcoTrim ET-1024 System is now shut down. 49 of 64 175932-1CD...

  • Page 50: System Recovery

    For more detailed information on alarm and error recovery, refer to the DX200 controller and MH24 robot documentation that is included with your EcoTrim ET-1024 System (refer to section 1.3). 4.4.1.1 Error Messages Error messages are usually the result of simple, easily cleared operation errors.
  • Page 51 175932-1CD EcoTrim ET-1024 System Operation 4.4 System Recovery To restart the EcoTrim ET-1024 System after an E-STOP condition occurs, follow the procedures below. 1. To clear the E-STOP condition, perform any of the following actions that apply: • Release the activated E-STOP push button.

  • Page 52: Brake Release

    175932-1CD EcoTrim ET-1024 System Operation 4.4 System Recovery 4.4.3 Brake Release The robot brakes are designed to protect the robot and other system components from damage in the event of a system or robot failure, a loss of drive power, or any other occurrence that activates the brakes. It is then necessary to release the brakes on the robot in order to move it.

  • Page 53: Maintenance

    For periodic maintenance procedures and schedules for the individual components of your EcoTrim ET-1024 System, refer to the documentation that is included with your EcoTrim ET-1024 System (refer to section 1.3). Table 5-1: Periodic Maintenance FREQUENCY...

  • Page 54: Anchor Requirements

    Anchor Requirements The purchaser must determine all anchoring and foundation requirements and supply the appropriate anchoring hardware for a particular installation. Before installing the EcoTrim ET-1024 System, refer to Table 6-1 to determine special anchor and foundation requirements. WARNING Do not mount robot directly to the floor without the indicated floor plate.
  • Page 55 175932-1CD EcoTrim ET-1024 System Anchor Requirements Table 6-1: Minimum Recommended Equipment Anchor Requirements ® EQUIPMENT MINIMUM HILTI MINIMUM FLOOR-PLATE MINIMUM FOUNDATION ANCHOR ROD REQUIREMENTS REQUIREMENTS DIAMETER/TYPE 3-inch minimum thickness or 3/8-inch Kwik Bolt II WORK-CELL 1.3 embedment depth Style Anchor...

  • Page 56: Checklist

    175932-1CD EcoTrim ET-1024 System Appendix A A.1 Checklist Appendix A Checklist This checklist is provided as a convenience to help with the proper installation, startup and maintenance of the work cell. Time/Date Checked By BEFORE APPLYING POWER (Refer to System Drawings)
  • Page 57 175932-1CD EcoTrim ET-1024 System Appendix A A.1 Checklist Time/Date Checked By AFTER APPLYING POWER Check Control Switches (Refer to Operator Station, Controller Mnl) Check Axis Move and are Restricted (Refer to Basic Specifications, Manipulator Mnl) Check Emergency Stop(s) (Refer to E-Stop in all Mnls)
  • Page 58 175932-1CD EcoTrim ET-1024 System Appendix A A.1 Checklist Time/Date Checked By DOCUMENTATION INCLUDED System Drawings Modifications Made to Original Protective Equipment End Effector Load Analysis Instructions on Synchronized Motion (More than one piece of equipment) Programmed Limits Collaborative Operation Declaration...
  • Page 59 175932-1CD EcoTrim ET-1024 System Appendix A A.1 Checklist Time/Date Checked By MARKINGS INCLUDED ON EQUIPMENT Business Name, Address, Info Machinery Designation and Type Year Built Explosive Proof Order Number (Serial Number) Other Markings on Equipment (Vendor Machine Designation, Type, Serial No, Version, etc.)

  • Page 60: Ecotrim Etu-1024 Pneumatics

    Appendix B EcoTrim ETU-1024 Pneumatics Fig. B-1: EcoTrim ETU-1024 Pneumatics Location SECTION K-K 60 of 64...
  • Page 61 B.1.1 Standard EcoTrim ETU-1024 Fig. B-2: EcoTrim ETU-1024 Pneumatic Schematic (Standard) ROUTER BLADE SHARPENER TOOL BALL ROUTER INDEX MOTOR COOLING CYLINDER CAP CYLINDER CYLINDER E3000 ULTRASONIC CONTROLLER TRANSDUCER MOTOR COOLING SET PRESSURE SET PRESSURE SET PRESSURE REGULATOR TO 12 PSI REGULATOR TO 60 PSI REGULATOR TO 40 PSI MIN./MAX.
  • Page 62 B.1.2 Optional EcoTrim ETU-1024 Fig. B-3: EcoTrim ETU-1024 Pneumatic Schematic (Optional) BLADE SHARPENER CYLINDER ULTRASONIC ULTRASONIC COMPLIANCE TRANSDUCER CYLINDER MOTOR COOLING SET PRESSURE SET PRESSURE PRESSURE TO BE SET REGULATOR TO 12 PSI REGULATOR TO 60 PSI MIN./MAX. 10/15 PSI PER APPLICATION MIN./MAX.

  • Page 63: Optional Equipment

    175932-1CD EcoTrim ET-1024 System Appendix C C.1 Optional Equipment Appendix C Optional Equipment C.1.1 Replacement Blades Part Number Description 174862-1 Blade, Oscillator, Standard Style 174863-1 Blade, Oscillator, Single Edge, Half Style Blade, Oscillator, Compliant, Standard Style 174864-1 174865-1 Blade, Oscillator, Compliant Single Edge Style...
  • Page 64 SYSTEM MANUAL HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802 YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Europe GmbH Robotics Divsion ) Yaskawastrasse 1, 85391 Allershausen, Germany...

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