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YASKAWA MLX200 Hardware Installation & Software Upgrade

YASKAWA MLX200 Hardware Installation & Software Upgrade

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MLX200
HARDWARE INSTALLATION &
SOFTWARE UPGRADE
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
Part Number:
168283-1CD
Revision:
8
1 of 121

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Summary of Contents for YASKAWA MLX200

  • Page 1 MLX200 HARDWARE INSTALLATION & SOFTWARE UPGRADE INSTRUCTIONS Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain for future reference. Part Number: 168283-1CD Revision: 1 of 121...
  • Page 2 Copyright © 2015, 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 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 168283-1CD Hardware Installation & Software Upgrade Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the Hardware Installation & Software Upgrade. In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.” Indicates a potentially hazardous situation which, if not avoided, could WARNING...
  • Page 6 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 MLX200 Control Module power - Moving the manipulator with teach pendant or MLX HMI...
  • Page 7 Read and understand the Explanation of the Warning Labels before operating the manipulator. Definition of Terms Used Often in This Manual The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN consists of the manipulator, the drive panel, and manipulator cables.
  • Page 8 168283-1CD Hardware Installation & Software Upgrade Explanation of Warning Labels The following warning labels are attached to the manipulator. Fully comply with the precautions on the warning labels. WARNING • The label described below is attached to the manipulator. Observe the precautions on the warning labels.

  • Page 9: Table Of Contents

    Table of Contents Software Upgrade Table of Contents 1 Introduction ............................. 1-1 1.1 MLX200 Robot Control Module Components ..............1-1 1.1.1 User Supplied Components.................. 1-2 1.2 For Your Safety........................1-2 1.3 Special Training ......................... 1-3 1.4 Motoman Manual List ......................1-4 1.5 Personnel Safety .......................
  • Page 10 7.1.5 Procedure after the Alarm..................7-7 7.2 Tool Data Setting ....................... 7-8 7.2.1 Registering Tools....................7-8 7.2.2 Tool Calibration....................7-15 8 MLX200 Specification ........................8-1 8.1 Specification List ........................ 8-2 8.1.1 Panel Heat Loss (Estimate) .................. 8-2 8.2 Equipment Configuration ....................8-3 8.2.1 Arrangement of Units and Circuit Boards .............
  • Page 11 10.6 Import Tasks into the New RSLogix Ladder ..............10-5 10.7 Import the Robot Data into RSLogix ................10-6 10.8 Configure the new MLX200-HMI file to see the “MLX200x_x_x” processor....10-6 10.9 Teach Pendant Software Upgrade................10-7 11 Teach Pendant Software Upgrade Procedure (Fuji Pendant) ............ 11-1 11.1 Configure PC to use a Static IP ..................
  • Page 12 168283-1CD Hardware Installation & Table of Contents Software Upgrade Appendix A ............................A-1 A.1 Rockwell MobileView Support ...................A-1 A.1.1 Overview ......................A-1 A.1.2 Components ......................A-1 A.1.3 Wiring ........................A-2 A.1.4 Software .......................A-6 A.1.5 External References.....................A-6 12 of 121 168283-1CD...

  • Page 13: Introduction

    ControlLogix or CompactLogix controller and target manipulator. The MLX200 Robot Control Module includes the runtime from the MLX200 software. This is the operating system for the robot and provides full kinematics for the supplied manipulator. In addition, the software provides interference zones, robot jogging controls in multiple coordinate systems, and tool frame control.

  • Page 14: User Supplied Components

    • User Application • I/O and safety modules • FactoryTalk View Machine Edition or Studio Edition (v6.1) Many of these items can be purchased from Yaskawa. Contact your Yaskawa sales representative for more information. 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.

  • Page 15: Special Training

    Persons who teach or inspect the manipulator must undergo required training before using the manipulator. • For more information on training, inquire at the nearest YASKAWA branch office. The telephone numbers are listed on the back cover of this manual.

  • Page 16: Motoman Manual List

    MLX200 Software and Operation Manual (P/N 168542-1CD) Confirm that you have the appropriate manipulator manual and MLX200 Software and Operation Manual on hand. If any manuals are missing, contact your salesman from YASKAWA’s local branch office. The relevant telephone numbers are listed on the last page.

  • Page 17: Personnel Safety

    168283-1CD Hardware Installation & Introduction 1.5 Personnel Safety Software Upgrade Personnel Safety The entire manipulator P-point maximum envelope is potentially dangerous. All personnel working with the MOTOMAN (safety administration, installation, operation, and maintenance personnel) must always be prepared and “Safety First” minded, to ensure the safety of all personnel. CAUTION •...
  • Page 18 168283-1CD Hardware Installation & Introduction Software Upgrade 1.5 Personnel Safety CAUTION • Never forcibly move the manipulator axes. Failure to observe this caution may result in injury or equipment damage. • Never lean on Hardware Installation & Software Upgrade or other controllers, and avoid inadvertently pushing buttons.

  • Page 19: Motoman Safety

    1000 mm or more 1000 mm or more 1000 mm or more WORKING ENVELOPE OF MANIPULATOR MLX200 MAXIMUM WORKING ENVELOPE OF MANIPULATOR INCLUDING TOOL OR WORKPIECE END 1000 mm or more • Perform grounding in accordance with all applicable electrical codes.
  • Page 20 • When lifting the MLX200 drive panel, please check the following: – As a rule, handling of the MLX200 drive panel can be performed by two or more people. – The MLX200 drive panel weighs approximately 31 - 47 kg (69 - 104 lbs).

  • Page 21: Work Area Safety

    168283-1CD Hardware Installation & Introduction 1.6 Motoman Safety Software Upgrade CAUTION • Install the manipulator using bolts of the size and type specified for each MOTOMAN in the MOTOMAN INSTRUCTION MANUAL. Failure to observe this caution may result in injury or damage to equipment.

  • Page 22: Operation Safety

    168283-1CD Hardware Installation & Introduction Software Upgrade 1.6 Motoman Safety 1.6.3 Operation Safety • When attaching a tool such as the welding torch to the manipulator, be sure to turn OFF the power supply of the Hardware Installation & Software Upgrade and the tool, lock the switch, and display a warning sign.

  • Page 23: Notes For Moving And Transferring The Motoman

    Contact your YASKAWA representative if you require new warning labels. • When the MOTOMAN is transferred, it is recommended to check with Yaskawa which is listed on back cover of this manual. Incorrect installation or wiring may result in personal injury and property damage. 23 of 121...

  • Page 24: Notes On Motoman Disposal

    168283-1CD Hardware Installation & Introduction Software Upgrade 1.8 Notes on MOTOMAN Disposal Notes on MOTOMAN Disposal PROHIBITED • Never modify the manipulator. Failure to observe this precaution could result in injury or damage resulting from fire, power failure, or operation error. CAUTION •...

  • Page 25: Product Confirmation

    If any damage is indicated, request that the carrier’s agent be present at the time the container is unpacked. Unpacking The MLX200 drive panel is shipped in a crate along with any miscellaneous hardware and any accessories ordered. Contents Confirmation Confirm the contents of the delivery when the product arrives.

  • Page 26: Optional Teach Pendant (Fuji)

    Software Upgrade system. The pendant features a 7.5-inch, color LCD, touch-screen display (640 X 480 VGA). The features include a menu-driven interface unique to the MLX200 Control Module environment, by using the Teach Pendant, the operator can teach and adjust the robots points; perform programming, editing, maintenance, and diagnostic functions.

  • Page 27: Warranty Id Confirmation

    168283-1CD Hardware Installation & Product Confirmation 2.4 Warranty ID Confirmation Software Upgrade Call Out Name Description Enable/ Deadman Switch Enables and disables the teach pendant. The unit is operative when the switch is pressed. Emergency Stop Switch Implements an emergency stop condition and sends an emergency stop signal to the external equipment.
  • Page 28 168283-1CD Hardware Installation & Product Confirmation Software Upgrade 2.4 Warranty ID Confirmation THE MANIPULATOR, DRIVE PANEL AMPLIFIERS, CONTROLLER MODULE, AND REGEN CABINET SHOULD HAVE THE SAME WARRANTY ID. MLX200 DRIVE PANEL REGEN CABINET <Example> WARRANTY ID XXXXXX-X-X 28 of 121...

  • Page 29: Customer Support Information

    Please have the following information ready before you call: • System • Robots • Positioner • Primary Application • Controller MLX200 • Software Version Access this information on the Teach Pendant’s LCD display screen by selecting {MAIN MENU} - {SYSTEM INFO} - {VERSION} •...

  • Page 30: Installation

    Excessive vibration or impacting the MLX200 may adversely affect the performance of the MLX200. 3.1.1 Moving the Drive Panel The MLX200 drive panel weighs approximately 31 - 47 kg (68 - 104 lbs). Be sure movers are strong enough to handle this weight. Installation Environment The conditions listed below must be met before installing the MLX200: •...

  • Page 31: Location

    Installation 3.3 Location Software Upgrade Location 1. The MLX200 drive panel is designed to be installed in a suitable industrial cabinet located outside of the P-point maximum envelope of the manipulator (outside of the safeguarding.) Fig. 3-1: Location of MLX200...
  • Page 32 Installation Software Upgrade 3.3 Location Fig. 3-2: MLX200 Drive Panel Dimensions FLOW MINIMUM CLEARANCE ABOVE EQIPMENT PANEL MOUNTING HOLES Table 3-1: MLX200 Drive Panel Dimensions (mm) Manipulator Drive Panel Approximate Weight (kg) MH5S, MH5LS, 159181-1 MH5S II MH5LS II MH12...
  • Page 33 168283-1CD Hardware Installation & Installation 3.3 Location Software Upgrade Fig. 3-3(a): MPK50/ MPL80/ MPL80 Pigtail Connections Cutout For Pigtail, Power Cutout For Optional Fuji Cutout For Pigtail, Encoder 28C Manipulator Cable 1BC Manipulator Cable Teach Pendant Cable 2X M4 Clearance 54.0 or Tap 4X M4 Clearance...
  • Page 34 168283-1CD Hardware Installation & Installation Software Upgrade 3.3 Location Fig. 3-3(c): MPL160 / MPL300 Pigtail Connections Cutout For Pigtail, Encoder Cutout For Optional Fuj Cutout For Pigtail, 1BC Manipulator Cable Teach Pendant Cable Regen Resistors 29.4 2X M4 Clearance 14.7 or Tap 22.9 +0.1...
  • Page 35 168283-1CD Hardware Installation & Installation 3.3 Location Software Upgrade Fig. 3-3(d): MH5S/ MH5S II/ MH5LS/ MH5LS II Pigtail Connections Cutout For Pigtail, Cutout For Optional Fuji Cutout For Pigtail, Encoder Regen Resistors Teach Pendant Cable 1BC Manipulator Cable 29.4 2X M4 Clearance 14.7 or Tap +0.1...
  • Page 36 168283-1CD Hardware Installation & Installation Software Upgrade 3.3 Location 7. The Regen cabinet may produce significant heat and should be mounted outside the main cabinet with the fans directed up. See Fig. 3-5(a) and Fig. 3-5(b). Fig. 3-5(a): MH5S/ MH5S II/ MH5LS/ MH5LS II Regen Cabinet Mounting Dimensions and Weight 4X ( Ø...
  • Page 37 168283-1CD Hardware Installation & Installation 3.3 Location Software Upgrade Fig. 3-5(b): MH12, HP20D, MPK50, MPL80, MPL160, MPL300, MPL80 II, MPL160 II, MPL300 II, Regen Cabinet Mounting Dimensions and Weight 6X ( Ø Weight: 13 kg 37 of 121 168283-1CD...

  • Page 38: Cut-Outs For Emergency Stop And Auto/ Manual Buttons

    3.4 Cut-Outs for Emergency Stop and Auto/ Manual Buttons Cut-Outs for Emergency Stop and Auto/ Manual Buttons Each MLX200 Master Control panel is supplied with one Emergency Stop button and one Auto/ Manual button that should be mounted to the enclosure for users to interact with.

  • Page 39: Connections

    ON. Failure to observe this caution may result in fire and electric shock. • Any occurrence during wiring while the MLX200 is in the emergency stop mode is the user’s responsibility. Do an operation check once the wiring is completed.

  • Page 40: Notes On Cable Junctions

    • Confirm the connector and cable numbers to prevent misconnection and equipment damage. One connects the manipulator and MLX200. Another connects the MLX200 and peripheral device. A wrong connection can cause damage to electronic equipment. • Clear the area of all unauthorized personnel while making cable connections.

  • Page 41: Power Supply

    (Protector) MLX200 Power MLX200 Additional Axillary Additional Robot Equipment Robot Positioner Table 4-1: MLX200 Power Capacity, Cable Sizes, and Breaker/ Fuse Capacities Cable size Capacity of Power (In case of Cabtyre breaker/ fuse in Manipulator Capacity cable (three cores)) (kVA)
  • Page 42 Software Upgrade 4.2 Power Supply Select and utilize the breaker/ fuse with appropriate breaking capacity in consideration of the MLX200 panel power capacity for the manipulator to be used. The maximum load value (payload, operation speed, and frequency, etc.) is displayed.

  • Page 43: Connection Methods

    (Customer must provide fusing). Perform grounding in accordance with all relevant local and national electrical codes. The size of ground wire must the same as listed on Table 4-1 "MLX200 Power Capacity, Cable Sizes, and Breaker/ Fuse Capacities" on page 4-3. NOTE The customer must prepare the ground wire.

  • Page 44: Connecting The Manipulator Cable

    CAUTION Always keep the MLX200 panel in an isolated enclosure. If dust or water enter inside the drive panel, electric shock or breakdown of MLX200 may result. 44 of 121...

  • Page 45: Dual Robot Connection

    When using a dual robot the basic connections for the slave robot is the same as the first except; • No MLX200 Control Module • Make the interlock cable connections • Connection from EtherCat from the last amp (SV(ӿ)) on the master panel to the first amp (SV0) on slave panel.

  • Page 46: Turning On And Off The Power Supply

    Turning ON the Main Power Supply Confirm that nobody is present in the P-point maximum envelope of the manipulator when turning ON the MLX200 power supply. Failure to observe this caution could result in injury caused by accidental contact with the manipulator.

  • Page 47: Test Of Program Operation

    P-point maximum envelope of the manipulator, and be sure that you are in a safe place yourself. – Turning ON the MLX200 power – Moving the manipulator with the teach pendant – Running the system in the check mode –...

  • Page 48: Movement Of The Axes

    168283-1CD Hardware Installation & Test of Program Operation Software Upgrade 6.1 Movement of the Axes Movement of the Axes Move each axis of the manipulator by pressing the appropriate axis buttons on the MLX HMI. The following figures illustrate each axis of motion in the joint coordinates. Be sure to remove all items from the area before moving the manipulator.
  • Page 49 168283-1CD Hardware Installation & Test of Program Operation 6.1 Movement of the Axes Software Upgrade Fig. 6-2: 5-Axis Manipulator Wrist Upper arm U-arm Wrist flange Lower arm L-arm Rotary head S-head Manipulator base Fig. 6-3: 6-Axis Manipulator Wrist Upper arm (U-arm) A 2+ A 4+...
  • Page 50 168283-1CD Hardware Installation & Test of Program Operation Software Upgrade 6.1 Movement of the Axes Fig. 6-4: 7-Axis Manipulator T-axis B-axis R-axis U-axis E-axis L-axis Reference coordinates of base/robot axes S-axis 50 of 121 168283-1CD...

  • Page 51: System Setup

    P-point maximum envelope of the manipulator, and be sure that you are in a safe place when: – Turning ON the MLX200 power. Injury may result from contact with the manipulator if persons enter the P-point maximum envelope of the manipulator.
  • Page 52 Although this operation is performed prior to shipment at the factory, the following cases require this operation to be performed again. • Change in the combination of the manipulator and MLX200 drive panel • Replacement of the motor or absolute encoder •...

  • Page 53: Calibrating Operation

    The main screen shows “EXPERT” when successful. 2. Press the [Menu] button and then select the [Teach Screen] button. The MLX200 - Teaching and Jogging screen appears. 3. Set Jog Speed to “Inch” and Coordinate System to “Axis.” 4. Turn servo power ON by pressing [Reset], and then the [Enable Servos] button.
  • Page 54 168283-1CD Hardware Installation & System Setup Software Upgrade 7.1 Home Position Calibration 5. Jog the robot to its home position marks. Adjust the Jog Speed as required. 6. When in home position, press [MENU], then [Robot Configuration]. 7. Establish the Home position. Press [Get Current]. The values update. Alternative: the home position values can also be read from a home position sticker located on the robot and entered into the “Home Offset”...
  • Page 55 When communication is re-established, the Axis Position list values should be close to zero. The robot may have drifted slightly at servo off. It should take 20 to 30 seconds for the MLX200 Robot Control Module to return to active NOTE communication.

  • Page 56: Home Position Of The Robot

    168283-1CD Hardware Installation & System Setup Software Upgrade 7.1 Home Position Calibration 7.1.3 Home Position of the Robot In case of MH5S, the home position are as follows. Wrist Upper arm (U-arm) A 2+ A 4+ A 3+ A 5+ A 5- A 3- Lower arm...

  • Page 57: Purpose Of Position Check Operation

    168283-1CD Hardware Installation & System Setup 7.1 Home Position Calibration Software Upgrade 7.1.4 Purpose of Position Check Operation If the absolute number of rotation detected at power supply ON does not match the data stored in the absolute encoder the last time the power supply was turned OFF, an alarm is issued when the drive panel power is turned ON.

  • Page 58: Tool Data Setting

    168283-1CD Hardware Installation & System Setup Software Upgrade 7.2 Tool Data Setting Tool Data Setting 7.2.1 Registering Tools 7.2.1.1 Number of Tools There are 24 tool files numbered 0 to 23. TOOL FILE 0 TOOL FILE 23 7.2.1.2 Registering Coordinate Data When the number input operation is used for registering the tool file, input the TCP of the tool on the flange coordinates.
  • Page 59 168283-1CD Hardware Installation & System Setup 7.2 Tool Data Setting Software Upgrade 2. The system must be in Teach mode with all errors cleared before adjustments can be made to Tool Data. The message “Switch to TEACH mode to set” appears if the system is left in Play mode. Fig.
  • Page 60 168283-1CD Hardware Installation & System Setup Software Upgrade 7.2 Tool Data Setting Fig. 7-2: Tool A 260 mm Tool A 60 of 121 7-10 168283-1CD...
  • Page 61 145 mm Tool B 6. Click the [Save Tool Data] button to store the modified tool information. Tool data is not saved to the MLX200 Control Module until the [Save Tool Data] button is clicked. If data is incorrectly NOTE modified, simply close this screen and no changes will be made to the tool data.
  • Page 62 168283-1CD Hardware Installation & System Setup Software Upgrade 7.2 Tool Data Setting 7. Click on the [Execute Change Tool] button to have the robot use this tool when moving in the Tool Coordinate system. The tool appears as the active tool on the Teach screen. Fig.
  • Page 63 168283-1CD Hardware Installation & System Setup 7.2 Tool Data Setting Software Upgrade 7.2.1.3 Registering Tool Angle The tool pose data is angle data which shows the relation between the flange coordinates and the tool coordinates. The angle when the flange coordinates are rotated to meet to the tool coordinates becomes an input value.
  • Page 64 168283-1CD Hardware Installation & System Setup Software Upgrade 7.2 Tool Data Setting Ry must be the input rotation angle around Y’ flange coordinates. Ry = 90 – Rx must be the input rotation angle around X’ of flange coordinates. Rx = 0 64 of 121 7-14 168283-1CD...

  • Page 65: Tool Calibration

    168283-1CD Hardware Installation & System Setup 7.2 Tool Data Setting Software Upgrade 7.2.1.4 Setting the Tool Load Information The tool load information includes weight, a center of gravity position, and moment of inertia at the center of gravity of the tool installed at the flange. 7.2.2 Tool Calibration To ensure that the manipulator can perform motion type operations such as linear and circular motion types correctly, accurate dimensional...
  • Page 66 168283-1CD Hardware Installation & System Setup Software Upgrade 7.2 Tool Data Setting 7.2.2.1 Checking the TCP After registering the tool file, check if the TCP is correctly registered by performing a TCP fixed operation like the one shown below, in any coordinate system other than the joint.

  • Page 67: Mlx200 Specification

    MLX200 Specification WARNING • When turning ON the power to MLX200 Control Module, be sure that there is no one within the P-point maximum envelope of the manipulator, and that you are in a safe place. Injury may result from collision with the manipulator to anyone entering the P-point maximum envelope of the manipulator.

  • Page 68: Specification List

    168283-1CD Hardware Installation & MLX200 Specification Software Upgrade 8.1 Specification List Specification List Free-standing, open sub panel Drive Construction Panel Refer to following Dimensions Indirect cooling Cooling System -5°C to + 55°C (During operation) Ambient -5°C to + 55°C (During transit and storage)

  • Page 69: Equipment Configuration

    8.2 Equipment Configuration Software Upgrade Equipment Configuration The MLX200 drive panel is comprised of individual units and modules. Malfunctioning components can generally be easily repaired after a failure by replacing a unit or a module. This section explains the configuration of the MLX200 equipment.
  • Page 70 168283-1CD Hardware Installation & MLX200 Specification Software Upgrade 8.2 Equipment Configuration Table 8-2(b): MLX200 Parts (Continued) Description MH12 HP20D MPL80 MPL80 II MLX200 Robot Package 170146-* 168840-* 168361-* 174744-1 MLX200 Control Panel 170094-* 167761-* 159431-1 159431-1 Robot Manipulator 166525-3 155500-9...

  • Page 71: Description Of Units And Circuit Boards

    Description of Units and Circuit Boards WARNING • When turning ON the power to MLX200, be sure that there is no one within the P-point maximum envelope of the manipulator, and that you are in a safe place. Injury may result from collision with the manipulator to anyone entering the P-point maximum envelope of the manipulator.
  • Page 72 Connect the switch (contact) that turns the dual signals ON and OFF simultaneously. • If the timing that turns the two signals ON and OFF is not right, a disagreement alarm occurs. Refer to the figure below. MLX200 Input for the robot system Switch TB2-7 Safety Ch 1...
  • Page 73 If the jumpers are not removed, injury or damage to machinery may result and the external emergency stop will not work even if the signal is input. Fig. 9-1: Connection for External Emergency Stop MLX200 Robot system safety input terminal blocks Remove the jumpers...
  • Page 74 If the jumpers are not removed, injury or damage to machinery may result and the external emergency stop will not work even if the signal is input. Fig. 9-2: Connection for Safety Plug MLX200 Robot system safety input terminal blocks Remove the jumpers...
  • Page 75 The safety plug input signal is connected to the interlock signal from the gate. Manipulator Working Area Safeguarding Servo ON Lamp (Option) MLX200 Safeguarding Safety Plug Emergency Stop Taked Plug If the servo power is ON when the interlock signal is input, the servo power turns OFF.
  • Page 76 Always connect the signals after removing the jumpers. Injury or damage to machinery may result because the external emergency stop do not work even if the signal is input. Fig. 9-3: Connection for External Enable Switch MLX200 Robot system safety input terminal blocks Remove the jumpers...
  • Page 77 168283-1CD Hardware Installation & Description of Units and Circuit Boards Software Upgrade Table 9-1: Signal Connections and Settings Signal Name Connection Dual Function Factory Setting No. (TB2) input EXTESP1+ TB2-7 Applicable External Emergency Stop Switch included EXTESP1- TB2-8 and wired. Used to connect the emergency stop switch of an external device.
  • Page 78 168283-1CD Hardware Installation & Description of Units and Circuit Boards Software Upgrade Signal Name Connection Dual Function Factory Setting No. (TB2) input ENABLE/ TB2-5 Single External Enable Switch Status Monitor Jumper to DEADMAN by default Allows the software to know the status of the SWITCH External Enable Switch.

  • Page 79: Servopack

    168283-1CD Hardware Installation & Description of Units and Circuit Boards 9.1 SERVOPACK Software Upgrade SERVOPACK A SERVOPACK in the MLX environment consists of a converter, PWM amplifier, and EtherCAT communication option card. 9.1.1 SERVOPACK Configuration Table 9-2: Servopack Configuration MH5S, MH5LS, MH12 HP20D MPK50...

  • Page 80: Mlx200 Control Module Software Version Upgrade Procedure

    10.1 Upgrade the Application on the MLX200 Control Module The MLX200 Control Module software upgrades includes a maintenance tool to make it easier to upgrade new versions of software on the MLX200 Control Module. 1. Click on cerhost.exe. MLX200-x.x.x > Tools > MLX200 Remote Display Application >...
  • Page 81 168283-1CD Hardware Installation & MLX200 Control Module Software Version Upgrade Procedure 10.1 Upgrade the Application on the MLX200 Control Module Software Upgrade 4. Press the [Maintenance] button. 5. Copy the entire folder supplied with the firmware update package to a USB Disk.
  • Page 82 Software Upgrade 10.1 Upgrade the Application on the MLX200 Control Module 9. To reboot the MLX200 Control Module, click on the [Settings] category on the left and select the [Update MLX200 Control Module Firmware]. Press the [Execute] button, and then [OK].

  • Page 83: Export Robot Data For Rslogix Ladder

    168283-1CD Hardware Installation & MLX200 Control Module Software Version Upgrade Procedure 10.2 Export Robot Data for RSLogix Ladder Software Upgrade 10.2 Export Robot Data for RSLogix Ladder 1. Using the MLXData200 Software, export the teach points, interference zones, tools, and user frames.

  • Page 84: Export Non-Mlx Tasks From The Rslogix Ladder

    168283-1CD Hardware Installation & MLX200 Control Module Software Version Upgrade Procedure Software Upgrade 10.3 Export non-MLX Tasks from the RSLogix Ladder 4. Select [Export All User Data] from the pull down list, and press [Start Export]. The following files will be exported.

  • Page 85: Import The Robot Data Into Rslogix

    Data for RSLogix Ladder”. 1. Place the PLC in program mode. 2. In the Import Data area of the MLx200 Job main screen, press [...] to browse to a directory location where the data was stored. 3. Highlight each file to be imported, by pressing [Cntrl]-[Left Mouse Button], and press [Open].Observe all data in section 10.2 “Export...

  • Page 86: Teach Pendant Software Upgrade

    If a Fuji teach pendant is installed on the cell, complete chapter 11 "Teach Pendant Software Upgrade Procedure (Fuji Pendant)" steps. If a MobileView teach pendant is installed on the cell use the APA file provided with the newer version of MLX200 software. 86 of 121 10-7...

  • Page 87: Teach Pendant Software Upgrade Procedure (Fuji Pendant)

    168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) Software Upgrade 11 Teach Pendant Software Upgrade Procedure (Fuji Pendant) These steps are for the Fuji Teach Pendant (V8). If Rockwell's MobileView is used, this section is not applicable. Follow the steps below when installing a new MLX software version or adjusting the IP address of the PLC or teach pendant in the system.

  • Page 88: Configure Pc To Use A Static Ip

    168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) Software Upgrade 11.1 Configure PC to use a Static IP 11.1 Configure PC to use a Static IP 1. Attach Ethernet cable between the teach pendant and the PC. 2.

  • Page 89: Prepare Pendant To Set The Ip Address For The New/ Un-Programmed System

    168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) 11.1 Configure PC to use a Static IP Software Upgrade 11.1.1 Prepare Pendant to Set the IP Address for the NEW/ UN-PROGRAMMED System After power up, if the screen below is displayed, this is an un-programmed pendant if this screen does not appear complete section 11.1.2 “Prepare Pendant to Change IP Address for an Upgraded System”...

  • Page 90: Setting Ip Address For Pendant

    • If VSFT version 5 go to section 11.2. • If V-SFT version 6 go to section 11.4. • Yaskawa part number 160708-1 is V-SFT version 5. • Yaskawa part number 160708-2 is V-SFT version 6. NOTE •...

  • Page 91: Setup The Fuji V-Sftv5 Monitouch Program

    168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) 11.2 Setup the Fuji V-SFTV5 Monitouch Program Software Upgrade 11.2 Setup the Fuji V-SFTV5 Monitouch Program 1. Start the Fuji V-SFTV5 Monitouch programming software. 2. Open the project file (*.v8). 3.
  • Page 92 168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) Software Upgrade 11.2 Setup the Fuji V-SFTV5 Monitouch Program 5. Adjust the network table by navigating to Ethernet and double clicking on “Network Table” in the left hand window. 6.

  • Page 93: Transfer Screen Data To Teach Pendant (Version 5)

    168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) 11.3 Transfer Screen Data to Teach Pendant (Version 5) Software Upgrade 11.3 Transfer Screen Data to Teach Pendant (Version 5) 1. Select “Transfer” from the File menu and verify the IP address of the pendant at bottom of the screen is correct (192.168.1.100) If the correct address is not displayed, press NOTE...
  • Page 94 168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) Software Upgrade 11.3 Transfer Screen Data to Teach Pendant (Version 5) 4. Observe the following screens appear on the PC and a blue message in the bottom left corner of the Teach Pendant saying “TransferData” indicating a transfer is taking place 5.

  • Page 95: Setup The Fuji V-Sftv6 Monitouch Program

    168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) 11.4 Setup the Fuji V-SFTV6 Monitouch Program Software Upgrade 11.4 Setup the Fuji V-SFTV6 Monitouch Program 1. Start the Fuji V-SFTV6 Monitouch programming software. 2. Open the project file (*.v8) 3.
  • Page 96 168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) Software Upgrade 11.4 Setup the Fuji V-SFTV6 Monitouch Program 5. Press the blue text – “Setting…” on the Hardware Setting window that appears. CAUTION Do not edit the PLC Table, Port Name. Editing the PLC Table Port Name can cause the software to work incorrectly or not at all.

  • Page 97: Transfer Screen Data To Teach Pendant (Version 6)

    168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) 11.5 Transfer Screen Data to Teach Pendant (Version 6) Software Upgrade 11.5 Transfer Screen Data to Teach Pendant (Version 6) 1. Go to Main Menu, select “Transfer” then press the “Download” icon: 2.
  • Page 98 168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) Software Upgrade 11.5 Transfer Screen Data to Teach Pendant (Version 6) 4. Press the [PC ->] button to transfer the program to the unit. • The following screens indicate that data is transferring successfully •...

  • Page 99: Install The Mlx Version Label

    168283-1CD Hardware Installation & Teach Pendant Software Upgrade Procedure (Fuji Pendant) 11.6 Install the MLX Version Label Software Upgrade 11.6 Install the MLX Version Label Place the MLX version label on the back of the pendant to indicate the software version. Label Part No.

  • Page 100: Sigma-5 Amplifier Parameter Upgrade Procedure

    168283-1CD Hardware Installation & Sigma-5 Amplifier Parameter Upgrade Procedure Software Upgrade 12 Sigma-5 Amplifier Parameter Upgrade Procedure 1. Attach a USB cable between the PC, and the SV0 port labeled CN7. 2. Start the SigmaWin+ program, select [Online] mode and then click [Search].
  • Page 101 168283-1CD Hardware Installation & Sigma-5 Amplifier Parameter Upgrade Procedure Software Upgrade 5. Observe the Searching screen appears indicating that SigmaWin has begun searching. 6. Observe a Servopack and Servomotor with Option is available, if successful. Click on the item in the list and select [Connect]. 7.
  • Page 102 168283-1CD Hardware Installation & Sigma-5 Amplifier Parameter Upgrade Procedure Software Upgrade 8. Select [Import] from the Parameter Editing screen. 9. Select the file for this servopack and press [Open]. 10. Select the checkbox “Select All” and press [Write]. 102 of 121 12-3 168283-1CD...
  • Page 103 168283-1CD Hardware Installation & Sigma-5 Amplifier Parameter Upgrade Procedure Software Upgrade 11. Observe transfer screen appears showing parameters are transferring. 12. Press [OK] when the “Verification” screen appears. 13. Move the USB cable to the next servo pack. Select the [File] tab, and press [Connect].

  • Page 104: Hmi Communications Setup Procedure

    13 HMI Communications Setup Procedure 13.1 Version Note The processes described in chapter 13 apply to MLX200 software versions prior to 1.3. Software versions 1.3 and later include the APA file which allows the customer / user to easily customize and integrate this file using FactoryTalk View.

  • Page 105: Configuring Factory Talk Administration Console

    168283-1CD Hardware Installation & HMI Communications Setup Procedure 13.2 Configuring Factory Talk Administration Console Software Upgrade If the PLC has already been configured on the local computer, you will see a screen like Fig. 13-3. Skip to step 11 otherwise configure the Ethernet connections using step 5 through step 10.
  • Page 106 168283-1CD Hardware Installation & HMI Communications Setup Procedure Software Upgrade 13.2 Configuring Factory Talk Administration Console 7. Next you will be presented with the “Ethernet Driver” properties screen shown in Fig.13-6 "Administration Console - Driver Configuration". Fig. 13-6: Administration Console - Driver Configuration 8.
  • Page 107 PLC in the Explorer window. 11. Open the RSLinx Enterprise tree, until the PLC processor is found. 12. Open the MLX200 RSLogix program and verify the processor name is the same in both applications. 107 of 121...
  • Page 108 13.2 Configuring Factory Talk Administration Console 13. If the processor names are not the same, highlight the PLC processor in the FactoryTalk Administration Console. Right-Click and select Properties. Change the name to match the MLX200 RSLogix Control Module name. 14. Close the FactoryTalk Administration Console.

  • Page 109: Copy Plc Design To Runtime

    168283-1CD Hardware Installation & HMI Communications Setup Procedure 13.3 Copy PLC Design to Runtime Software Upgrade 13.3 Copy PLC Design to Runtime 1. Select Start → Programs → Rockwell Software → FactoryTalk View → FactoryTalk View Studio (Version 6.1 or newer) 2.
  • Page 110 168283-1CD Hardware Installation & HMI Communications Setup Procedure Software Upgrade 13.3 Copy PLC Design to Runtime 10. Highlight the Control Module, and press [Copy from Design to Runtime]. When prompted, press [Yes]. 11. Press [OK] at the bottom of the screen, and choose [Yes] when prompted.

  • Page 111: Starting Up The Hmi

    168283-1CD Hardware Installation & HMI Communications Setup Procedure 13.4 Starting up the HMI Software Upgrade 13.4 Starting up the HMI 1. Click on the MLX200_HMI.mer file to start up FactoryTalk View Machine Edition. 2. Select [YES] at the first prompt. 3.
  • Page 112 168283-1CD Hardware Installation & HMI Communications Setup Procedure Software Upgrade 13.4 Starting up the HMI 4. Select “Networks and Communications”, and press [Enter]. 5. Select “RSLinx Enterprise Communications”, and press [Enter]. 112 of 121 13-9 168283-1CD...
  • Page 113 HMI Communications Setup Procedure 13.4 Starting up the HMI Software Upgrade 6. Highlight the MLX200 processor, and press [Close] three times to get back to the main screen. 7. Click on [Application Settings], (see “FactoryTalk View ME Station” screen in step 3.) 8.
  • Page 114 13.4 Starting up the HMI 9. Select “AX”, and press [Enter]. 10. Highlight the “MLX200 PLC” processor, and press [OK], and then [Close] two times to get back to the main screen. 11. Press [Run Application] the software shows display without “shadows”...

  • Page 115: Rockwell Mobileview Support

    MobileView for the remainder of this document. Yaskawa suggests that all customers and integrators use this product with the MLX200 solution from October 2015 on forward. Yaskawa will end sales of the Fuji pendant and instead recommend that the end user acquire hardware from their Rockwell distributor independently.

  • Page 116: Wiring

    A.1.3 Wiring Always follow appropriate national, local, and state laws and regulations when completing wiring. These diagrams are provided for reference only and imply no warranty or guarantee when followed. Safe practices and common industrial knowledge should always be applied when working around electricity. The following diagrams are for reference only. Fig.
  • Page 117 Fig. A-1(b): Pendant Interface without Pendant Includes Junction Box and Safety Interface MobileView (For Reference Only) +24VDC 0VDC CR534 TB2-8 TB2-9 TB2-10 502A 502B PBESP1 CR514 TB2-13 502B CR534 TB2-15 TB2-16 TB2-17 505A 505B PBESP1 CR514 TB2-20 505B MOBILEVIEW JUNCTION BOX X1-1 X1-2 313A...
  • Page 118 Fig. A-1(c): Pendant Interface without Pendant Includes Junction Box and Safety Interface MobileView (For Reference Only) +24 VDC 0 VDC CR534 TEACH PENDANT MSR 127TP E-STOP 502, 505, 606 313A MOBILEVIEW JUNCTION BOX X1-3 X1-4 E-STOP 1 E-STOP 1 X1-5 X1-6 E-STOP 2 E-STOP 2...
  • Page 119 Fig. A-1(d): Pendant Interface without Pendant Includes Junction Box and Safety Interface MobileView (For Reference Only) +24 VDC 0 VDC +24 VDC 0 VDC 0SV CN1 0SV CN1 CABLE CN1-1 TB2-1 BLU/RED 0SV BRAKE CONTROL RELAY CR603 CN1-2 0SV BRAKE RELAY BLU/BLK #18 WHT/BLU CN1-6...

  • Page 120: Software

    PanelView stations! The default resolution of the MLX200 HMI Project is 640x480. This should be changed to match the desired resolution for the MobileView (1280x800). This can be done under the “Project Settings” in Factory Talk View Studio, after making the change all screens will automatically scale to the new size.
  • Page 121 INSTRUCTIONS 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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