YASKAWA DX100 Instructions Manual
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YASKAWA DX100 Instructions Manual

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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.
YASKAWA ELECTRIC CORPORATION
MANUAL NO.
HW0486052
1/56

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  • Page 1 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. YASKAWA ELECTRIC CORPORATION MANUAL NO. HW0486052 1/56...
  • Page 2 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.
  • Page 3 HW0486052 DX100 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”. Indicates a potentially hazardous WARNING...
  • Page 4 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.
  • Page 5 Read and understand the Explanation of Warning Labels in the DX100 Instructions before operating the manipulator: 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.
  • Page 6 HW0486052 DX100 Descriptions of the programming pendant, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character The keys which have characters printed on Pendant Keys them are denoted with [ ]. ex. [ENTER] Symbol The keys which have a symbol printed on them...

  • Page 7: Table Of Contents

    HW0486052 DX100 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 ......................
  • Page 8 HW0486052 DX100 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 ................

  • Page 9: Function Overview

    HW0486052 Function Overview DX100 Preface Function Overview 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.

  • Page 10: System Configuration

    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.

  • Page 11: Signal Distribution Board

    (2) Signal distribution to the functional safety unit (3) Spare terminal block (for future extension) Robot system input termial block For the connection to the robot system input terminal block, NOTE refer to “13.9 Robot System Input Terminal Block (MXT)” in DX100 INSTRUCTIONS MANUAL. HW0486052 11/56...

  • Page 12: Communication I/F Gateway Unit

    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). Item specification Unit type...

  • Page 13: Power On Unit

    HW0486052 System Configuration DX100 Outline 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).

  • Page 14: Overview Of Unit Connection

    HW0486052 System Configuration DX100 Overview of Unit Connection 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) Power shutdown Teach pendant Primary...

  • Page 15: Description Of Unit Layout (Layout Drawing)

    DX100 Description of Unit Layout (Layout Drawing) 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)

  • Page 16: Setup (Safety Range Function For Robot)

    HW0486052 Setup (Safety Range Function for Robot) DX100 Changing Security Mode Setup (Safety Range Function for Robot) 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.

  • Page 17: Changing Security Mode

    HW0486052 Setup (Safety Range Function for Robot) DX100 Changing Security Mode 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].

  • Page 18: Preparation For Safety Range Function

    HW0486052 Setup (Safety Range Function for Robot) DX100 Preparation for Safety Range Function 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.
  • Page 19 HW0486052 Setup (Safety Range Function for Robot) DX100 Setting Tool Interference File 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.
  • Page 20 HW0486052 Setup (Safety Range Function for Robot) DX100 Setting Tool Interference File 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.
  • Page 21 HW0486052 Setup (Safety Range Function for Robot) DX100 Setting Tool Interference File <Tool interference file setting example> Robot Model 2 Point 1 Tool coodinate origin (flange surface) Model 1 Point 1 Model 1 Point 2 Tool Model 3 Point 1...

  • Page 22: Setting Safety Range For Robot

    HW0486052 Setup (Safety Range Function for Robot) DX100 Setting Safety Range for Robot Setting Safety Range for Robot Set the safety range for the robot arm as follows: 1. Select {ROBOT} under the main menu. 2. Move the cursor and display the following sub menu.
  • Page 23 HW0486052 Setup (Safety Range Function for Robot) DX100 Setting Safety Range for Robot STATUS: Indicates the status: SETTING or CONFIRMING or MONITORING. Status Contents SETTING “SETTING” is displayed when setting the data. CONFIRMING “CONFIRMING” is displayed when confirming the range after data setting.
  • Page 24 HW0486052 Setup (Safety Range Function for Robot) DX100 Setting Safety Range for Robot <Range setting example> To set the range with the X direction + side: 3000 mm, X direction - side: - 2000 mm, Y direction + side: 2500 mm, and Y direction - side: -1500 mm, enter the numbers as shown below.
  • Page 25 HW0486052 Setup (Safety Range Function for Robot) DX100 Setting Safety Range for Robot 6. 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 safety range.

  • Page 26: Confirming Safety Range For Robot

    HW0486052 Setup (Safety Range Function for Robot) DX100 Confirming Safety Range for Robot Confirming Safety Range for Robot After the completion of safety range setting, it is necessary to confirm if the monitoring is performed according to the safety range set in the chapter 3.4 “Setting Safety Range for Robot”...
  • Page 27 HW0486052 Setup (Safety Range Function for Robot) DX100 Switching Safety Range Switching Safety Range Multiple safety ranges can be set/confirmed in advance, and the ranges can be switched by external signals. For multiple safety ranges, set an overlap area. Switch between ranges only when the robot is in the overlap area.
  • Page 28 OPEN OPEN “SIGNAL COMPARISON ERROR (SAFETY)” alarm occurs. CLOSE 1 Terminal indicates the number of the functional safety system input terminal block on the JARCR-YCU02 board. DX100 connection diagram JARCR-YCU02 JZNC-NSU01 Functional safety system Functional safety unit input terminal block...

  • Page 29: Switching Safety Range

    500 ms or more, the alarm of “INPUT SIGNAL ERROR” occurs. • For the details of wiring to the functional safety system input terminal block, refer to “DX100 INSTRUCTIONS (RE-CTO-A215) 13.9 Robot System Input Terminal Block (MXT)”. 3-14 HW0486052...

  • Page 30: Starting Safety Range Function For Robot

    HW0486052 Setup (Safety Range Function for Robot) DX100 Starting Safety Range Function for Robot Starting Safety Range Function for Robot After confirming that the robot can move in the set safety range, press [CONFIRM]. The STATUS indication is changed to “MONITORING” and the safety unit starts the safety range function for the robot.
  • Page 31 HW0486052 Setup (Safety Range Function for Robot) DX100 Starting Safety Range Function for Robot 2. Endurance running must be normally performed. Try to move the actual job. If the robot moves near the specified range, an alarm may occur. In such a case, modify teaching or slow down the speed.

  • Page 32: Confirming Safety Range And Robot Position

    HW0486052 Setup (Safety Range Function for Robot) DX100 Confirming Safety Range and Robot Position Confirming Safety Range and Robot Position The positional relation between the specified safety range and the actual robot posture can be checked by showing them on the programming pendant.
  • Page 33 HW0486052 Setup (Safety Range Function for Robot) DX100 Confirming Safety Range and Robot Position The number of the robot currently displayed The coordinate system of the safety range The correspondence table of the illustrated straight lines The numbers of straight lines correspond to the straight line numbers on ROBOT RANGE screen.

  • Page 34: Setup (Safety Range Function For Each Axis)

    HW0486052 Setup (Safety Range Function for Each Axis) DX100 Preparation for Safety Range Function Setup (Safety Range Function for Each Axis) Preparation for Safety Range Function For the safety range function for each axis, set the movement amount of each axis of the robot in advance. Then, each axis is monitored so that it does not exceed the safety range.
  • Page 35 HW0486052 Setup (Safety Range Function for Each Axis) DX100 Setting Expected Stop Value 1. Change the security mode to MANAGEMENT MODE, then select {ROBOT} under the main menu. 2. Select {COASTING VALUE SETTING} under the sub menu. – The COASTING VALUE SETTING screen is displayed.
  • Page 36 HW0486052 Setup (Safety Range Function for Each Axis) DX100 Setting Expected Stop Value 3. Select the axis to set the coasting value, and edit the EXPECTED STOP VALUE. Then the READBACK screen appears. – Check that MODIFY VALUE and READBACK VALUE are the same, then press [YES].

  • Page 37: Setting Safety Range For Each Axis

    HW0486052 Setup (Safety Range Function for Each Axis) DX100 Setting Safety Range for Each Axis • When the IMMEDIATE STOP is set to VALID, the stop cat- egory of the robot and external axes is set to 0. Be sure to return the IMMEDIATE STOP to INVALID after measuring the coasting value.
  • Page 38 HW0486052 Setup (Safety Range Function for Each Axis) DX100 Setting Safety Range for Each Axis 2. Select {AXIS RANGE} under the sub menu. – The AXIS RANGE screen is displayed. <Description of the screen> CTRL GROUP: Selects a control group to be set in the case of a multiple control group system.
  • Page 39 HW0486052 Setup (Safety Range Function for Each Axis) DX100 Setting Safety Range for Each Axis 3. Select a control group. The AXIS RANGE screen of the selected control group will be displayed. <Description of the screen> STATUS: Indicates the status: SETTING or CONFIRMING or MONITORING.

  • Page 40: Confirming Safety Range For Each Axis

    HW0486052 Setup (Safety Range Function for Each Axis) DX100 Confirming Safety Range for Each Axis 5. When the data are set, [WRITE] and [CANCEL] buttons are displayed in the lower position of the screen. <Description of the screen> WRITE: Robot controller records the setting of MAX/MIN.

  • Page 41: Starting Safety Range Function For Each Axis

    HW0486052 Setup (Safety Range Function for Each Axis) DX100 Starting Safety Range Function for Each Axis Starting Safety Range Function for Each Axis After confirming that the manipulator/external axis can move in the set safety range, press [CONFIRM]. The STATUS indication is changed to “MONITORING”...

  • Page 42: Stop Position Monitoring Function

    HW0486052 Stop Position Monitoring Function DX100 Operating Condition Detection Stop Position Monitoring Function Operating Condition Detection The stop position monitoring function is one of the functions of the functional safety unit. With this function, the encoder information of the robot or external axis is monitored. If the robot or external axis moves when the function is valid, the power supply to the servo is shut off immediately to turn the servo power OFF.
  • Page 43 HW0486052 Stop Position Monitoring Function DX100 Turning Stop Position Monitoring Function VALID/INVALID Table 5-1: VALID/INVALID Setting of Stop Position Monitoring Function Status Signal Terminal Remarks INVALID GSI01+/GSI01- Default setting GSI02+/GSI02- VALID GSI01+/GSI01- GSI02+/GSI02- VALID GSI01+/GSI01- Input signal inconsistent alarm GSI02+/GSI02-...
  • Page 44 HW0486052 Stop Position Monitoring Function DX100 Turning Stop Position Monitoring Function VALID/INVALID CAUTION • Connect an independent switch (dry contact) for the signal. If the semiconductor output (*periodic OFF check diagnosis) is directly connected, the input circuit may malfunction. The signal must be received by a control device such as a safety relay unit before connecting the contact signal.

  • Page 45: Data Protection

    HW0486052 Data Protection DX100 Saving Dual Data Data Protection Saving Dual Data The data related to this function is saved in a duplicated manner for safety. When the control power is turned ON, check is performed to see that dual data sets are the same.

  • Page 46: Operation When Verify Error Occurs

    HW0486052 Data Protection DX100 Operation When VERIFY ERROR Occurs Operation When VERIFY ERROR Occurs If the following alarm occurs when the control power is turned ON, Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]” perform the following operations to re-set the data of the functional safety unit.
  • Page 47 HW0486052 Data Protection DX100 Operation When VERIFY ERROR Occurs 3. Move the cursor to “Safety Unit FLASH Reset” and press [ENTER]. 4. The dialog box “Reset?” is displayed. Select [YES]. – The data of the safety unit is re-set. A few seconds later, the buzzer sounds and the data setting is completed.

  • Page 48: System Output Signal

    HW0486052 System Output Signal DX100 System Output Signal The signals output while using the functional safety unit are shorn below. 50917 50916 50915 50914 50913 50912 50911 50910 SOUT#728 SOUT#727 SOUT#726 SOUT#725 SOUT#724 SOUT#723 SOUT#722 SOUT#721 SF. UNIT CONNECT • 50910: SF. UNIT CONNECT When one or more functional safety units (NSU01) are connected with the system, this signal turns ON.

  • Page 49: Alarm

    Alarm 0111: NSU 2nd node 0300 VERIFY ERROR (SYSTEM The DX100 has detected an error in the validity check on the data CONFIG-DATA) files between YCP01 and the safety unit (NSU) when the power is turned ON. Execute “Safety Unit FLASH Erase” in the maintenance mode.
  • Page 50 HW0486052 Alarm DX100 Alarm Message Explanation 1618 ARITHMETIC ERROR NSU01 detected an arithmetic error. (SAFETY) Turn the power OFF and ON again. If this alarm occurs frequently, replace NSU01 unit. 1619 PARAMETER ERROR NSU01 detected an error in the setting value of parameter or file.
  • Page 51 When a multiple robot system (with 2 or more manipulators) is used, (SAFETY) the DX100 has detected an error in the link signal between the safety units (NSU01) or in the jumper cable setting of NSF02 board. Turn the power OFF and then ON again.
  • Page 52 41: Signal inconsistency in GSIN signal Investigation is required If the error occurs again. Contact NOTE your Yaskawa representative. 7 segment LED indication of safety unit NSU01 7 segment LED indication of safety unit NSU01 are as follows. (Left side LED: CPU1, Right side LED: CPU2) 7 seg.
  • Page 53 CPU error CPU internal error occurs. Power on again. 0200. 0210. 0300. 0400. 0500. 0600. 0700. 0800. 0900. 0C00. 0D00. 1000. 1100. 1200. 1300. 1400. Investigation is required If the error occurs again. Contact NOTE your Yaskawa representative. HW0486052 53/56...

  • Page 54: Restrictions

    HW0486052 Restrictions DX100 Confirming Safety Range and Robot Position Restrictions Confirming Safety Range and Robot Position This function also records parameters, files and other data in the safety unit. Therefore, this function cannot be used with a function that changes parameters or files during playback.

  • Page 55: Software Version Of Functional Safety Unit

    HW0486052 Restrictions DX100 Software Version of Functional Safety Unit Software Version of Functional Safety Unit The functional safety unit (NSU01) must have the following version: NSU01: V3.00-00 or later If the NSU version is earlier than the above version, ALARM 510 “SOFTWARE VERSION UNMATCH [70]”...
  • Page 56 FOR FUNCTIONAL SAFETY UNIT (NSU01) HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan Phone +81-93-645-7745 Fax +81-93-645-7746 YASKAWA America Inc. MOTOMAN Robotics Division 805 Liberty Lane, West Carrollton, OH 45449, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Nordic AB Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden...

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