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YASKAWA 175932-1CD, System Manual, Page: 1 / 64

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YASKAWA 175932-1CD System Manual Download Page 1

Part Number:

175932-1CD

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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.

1 of 64

Summary of Contents for 175932-1CD

Page 1: ...ons 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...

Page 2: ...copyrighted property of Yaskawa and may not be sold or redistributed in any way You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF fil...

Page 3: ...own with the protective covers or shields removed for clarity Be sure that all covers and shields are replaced before operating this product The drawings and photos in this manual are representative e...

Page 4: ...responsible for providing adequately trained personnel to operate program and maintain the equipment NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE PROGRAM OR REPAIR THE EQUIPMENT We recommend approved Y...

Page 5: ...azardous situation which if not avoided could result in death or serious injury to personnel WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious i...

Page 6: ...xpected manipulator motion Figure 2 Release of EMERGENCY STOP Button TURN Observe the following precautions when performing teaching operations within the P point maximum envelope of the manipulator V...

Page 7: ...ll include in the information for use the safeguards and mode selection required for collaborative operation CAUTION Perform the following inspection procedures prior to conducting manipulator teachin...

Page 8: ...w the warnings on the labels Also an identification label with important information is placed on the body of the manipulator Prior to operating the manipulator confirm the contents Figure 3 Warning L...

Page 9: ...ce Documentation 1 10 1 3 1 Location of Operations in Reference Documentation 1 11 1 4 Customer Support Information 1 14 2 Equipment Description 2 1 2 1 Robot Description 2 1 2 2 DX200 Controller 2 1...

Page 10: ...erator Station Pedestal Option 3 6 3 5 Light Curtain Alignment 3 6 3 6 Cable Connections 3 7 3 6 1 Connection to Earth Ground 3 7 3 6 2 Connection to Local Electrical Service 3 8 3 7 Safety Operation...

Page 11: ...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: ...4 System and its components a list of reference documents and customer service contact information chapter 2 Equipment Description This chapter provides a description of the major components of the Ec...

Page 13: ...tive A dual channel safety light curtain system provides a sensing field in front of the rotary positioner through use of an infrared light beam Rotary positioner motion is prevented whenever an opera...

Page 14: ...mpletely surrounds the EcoTrim 1024 work cell The equipment platform is located outside and to the rear of the work cell This arrangement allows most of the component wiring interconnects to be pre wi...

Page 15: ...rid tool controls are located behind the cell Two sliding doors with safety interlocks allow access from either side The MH24 sits on a 610 mm raiser The standard servo driven MSR positioner provides...

Page 16: ...roken when the table is out of position stopped or moving the External E Stop signal will open resulting in a category 1 stop in either Play or Teach Mode The integrator or end user may implement addi...

Page 17: ...t s external axis keys on the pendant or by selecting the Sweep job and test starting through the job logic If the operator or another person enters the light curtain while teaching the cell the exter...

Page 18: ...he operator can safely enter the light curtain to remove the processed part and begin installation of a new part into the fixture Assuming there are no faults or issues during the production of the pa...

Page 19: ...ct connections for use in the external E Stop logic 1 2 3 4 Safety Logic Implementation 1 In Play Mode and Teach Mode FSU based Axis Range Limit functions generate At Side A B outputs which prevent th...

Page 20: ...1 Introduction 1 2 System Overview 1 9 175932 1CD 175932 1CD EcoTrim ET 1024 System Fig 1 4 b S1 Side A at Robot Details Fig 1 4 c S1 Side B at Robot Details 20 of 64...

Page 21: ...292 1CD Motoman Maintenance Manual for DX200 P N 165293 1CD Motoman DX200 Concurrent I O Manual P N 165294 1CD Motoman MSR 355 and MSR 655 Positioner Manual P N 169856 1CD Motoman DX200 For Cutting De...

Page 22: ...p 3 Assembly Mounting Condition Positioner Chap 2 Manipulator Chap 3 Space Needed for Maintenance EcoTrim Chap 3 Connecting Power EcoTrim Chap 3 Waste Removal Controller Chap 1 Protective Measures by...

Page 23: ...Throughout Manuals Test and Examination After Changing Components EcoTrim Chap 3 4 Instructions for Disconnecting Pendants Controller Chap 4 Instructions for Fault and Emergency Recovery EcoTrim Chap...

Page 24: ...imits for Range of Motion EcoTrim Chap 2 Relevant Standards Included Outside Manuals Instruction on Synchronized Motion EcoTrim Chap 2 Programmed Limits Controller Chap 11 Robot Suitable for Integrati...

Page 25: ...r Please have the following information ready before you call System EcoTrim 1024 System DX Series Robot MH24 Positioner MSR 355 and MSR 655 Primary Application Trimming Controller DX200 Software Vers...

Page 26: ...Twist can rotate the trimming tool 200 degrees without cable interference For additional information on the Motoman MH24 robot please refer to the MH24 Manipulator Manual that is included with your E...

Page 27: ...TENT 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 TEST01 TOOL CONTROL GROUP R1 S 0000 NOP SET B000 1 SET B001 0 MOVJ VJ 80 00 MOVJ VJ 80 00 DOUT OT 10 ON TIMER T 3 00 MOVJ VJ 80 00 MOVJ...

Page 28: ...stand alone pedestal Fig 2 8 Optional Pedestal Operator Station NOTE The Programming Pendant s LCD display goes dark after a few minutes of inactivity Press any key to restore the screen Operator Sta...

Page 29: ...ters the safety zone created by the light curtain system the Cycle Start command will unlatch and the positioner will not sweep 2 4 2 Emergency Stop E STOP Pressing the red Emergency Stop E STOP butto...

Page 30: ...75932 1CD EcoTrim ET 1024 System 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...

Page 31: ...ng operation The MSR family uses a rotary motion to sweep each side of the circular turntable 180 from the operator s loading zone into the robot s work zone and back to the operator again The positio...

Page 32: ...de tight against part fixtures for precise and repeatable cuts There are six different blades available but it is recommended to try the standard blade first The ultrasonic oscillator is cooled with c...

Page 33: ...the light curtains 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 sweep...

Page 34: ...ction 1 3 2 7 5 Emergency Braking System The MH24 manipulator incorporates a series of brakes that are designed to protect the robot and other system components from damage in the event of a software...

Page 35: ...of the EcoTrim ET 1024 System are included with your shipment There are however some required items that the customer must supply hand tools special anchor bolts etc These are not included with your s...

Page 36: ...ith appropriate concrete bits Phillips and flat blade screwdrivers Hammers dead blow and steel Hammer non marring Socket sets SAE and Metric Air impact gun with 3 4 inch hex socket Open end wrench set...

Page 37: ...t on all sides of the work cell to facilitate installation 2 Gather all customer supplied items and required tools refer to section 3 1 Fig 3 1 Installation Dimensions for the EcoTrim 1024 System WARN...

Page 38: ...aded into the wooden platform see Fig 3 2 It may be necessary to hold the leveling screws in place with a suitable open end wrench while removing the shipping bolts Figure 3 2 Stabilizing and Lag Poin...

Page 39: ...floor Use a suitable concrete drill bit and special anchor lag bolts refer to chapter 6 Anchor Requirements for the correct drill bit and anchor bolt Be sure to remove all concrete dust from the drill...

Page 40: ...to the floor Use a suitable concrete drill bit and special anchor lag bolts refer to section 6 for the correct drill bit and anchor bolt Be sure to remove all concrete dust from the drilled hole befor...

Page 41: ...specialized measuring equipment is usually required to get an accurate resistance to ground reading Consult a specialist in this field if required Connect robot and DX200 controller to the earth groun...

Page 42: ...1 1 and Fig 2 5 and the system diagram supplied with the system WARNING Connection of the EcoTrim ET 1024 System to local electrical service must be done by a qualified licensed electrician Electrical...

Page 43: ...ON see Fig 2 5 9 Check for correct operation of system E STOP push buttons 10 Check for correct operation of the system HOLD buttons on the Programming Pendant and Operation Station ROBOT HOLD Refer t...

Page 44: ...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: ...rom that presented here however basic operation will be the same For additional programming procedures and information refer to the DX200 controller and operator documentation that is included with yo...

Page 46: ...ng Pendant s Mode Select Switch set to REMOTE 3 Set the Operator Station s POSITIONER AUTO MANUAL switch to MANUAL mode and start the Control Master job see section 4 3 3 Normally the robot will not m...

Page 47: ...cell doors are closed and operating properly and the door safety interlocks are engaged 4 Make sure that all E STOP buttons are released E STOP buttons are installed at the following locations Progra...

Page 48: ...of the positioner with parts to be processed 2 The operator steps out of the safety zone created by the safety light curtain system and moves to the front of the Operator Station 3 The operator presse...

Page 49: ...hat the robot is in HOME position 2 Turn off system servo power by pressing the E STOP button on the Operator Station pedestal or Programming Pendant 3 Select TEACH mode on the Programming Pendant 4 S...

Page 50: ...red operation errors One example of this type of error is pressing the START button when the robot is not in PLAY mode Clear errors of this type by pressing the CANCEL button on the Programming Pendan...

Page 51: ...ront of the MSR positioner that is protected by the safety light curtain system 2 Press the SERVO ON button on the Operator Station or Programming Pendant 3 Ensure that the Programming Pendant is in R...

Page 52: ...order to move it To release the brakes proceed as follows 1 On the Programming Pendant select TEACH mode 2 Select ROBOT on the Programming Pendant touch screen 3 Select the BRAKE RELEASE option 4 Sel...

Page 53: ...al Be advised that the maintenance intervals given in Table 5 1 are recommendations only Adjust the frequency and level to suit your specific equipment schedules and shop environment For periodic main...

Page 54: ...UP50 SP80 Note 2 7 8 inch HVA Chemical Style Anchor Note 3 900 mm 35 in Length 900 mm 35 in Width 50 8 mm 2 in Thick 60 in x 60 in x 9 in Thick 4000 psi Reinforced Concrete ROBOTS UP120 UP130 UP165 S...

Page 55: ...and the Hilti Anchor Design Program v3 3b 2 SP series robots require base plates and or risers to be level within 2 Grout if necessary 3 Reference source Hilti Product Technical Guide section 4 2 1 f...

Page 56: ...n all Mnls Check Power Refer to Connections Controller Mnl Check Ground Refer to Grounding in all Mnls Check Water Refer to Operation and Vendor Mnls Check Air Refer to Manipulator and Vendor Mnls Che...

Page 57: ...External Power Disconnect Refer to Turning OFF The Power Supply Check Teach Mode Refer to Teach Mode Controller Mnl Check Playback Mode Refer to Play Mode Controller Mnl Check Environment Refer to Lo...

Page 58: ...Load Analysis Instructions on Synchronized Motion More than one piece of equipment Programmed Limits Collaborative Operation Declaration Robot is suitable for integration that includes Compliance Doc...

Page 59: ...ist 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 Designatio...

Page 60: ...ndix B B 1 EcoTrim ETU 1024 Pneumatics B 1 175932 1CD 175932 1CD EcoTrim ET 1024 System Appendix B B 1 EcoTrim ETU 1024 Pneumatics Fig B 1 EcoTrim ETU 1024 Pneumatics Location K K SECTION K K 1 5 60 o...

Page 61: ...R VALVE MANIFOLD ASSY SET PRESSURE REGULATOR TO 60 PSI MIN MAX 55 65 PSI SET PRESSURE REGULATOR TO 40 PSI MIN MAX 36 43 PSI ULTRASONIC TRANSDUCER MOTOR COOLING ROUTER MOTOR COOLING ROUTER INDEX CYLIND...

Page 62: ...OOL KIT FILTER REGULATOR SUPPLY AIR VALVE MANIFOLD ASSY SET PRESSURE REGULATOR TO 60 PSI MIN MAX 55 65 PSI ULTRASONIC TRANSDUCER MOTOR COOLING ULTRASONIC COMPLIANCE CYLINDER BLADE SHARPENER CYLINDER S...

Page 63: ...or Single Edge Tip Tracing Style 174868 1 Tool Blade Fixing Screw Part Number Description 174482 1 Accessory Kit Blade Sensor Sharpening Alignment Includes 174474 1 174860 1 174457 1 174454 1 Stand an...

Page 64: ...88 2858 Fax 86 10 6788 2878 YASKAWA SHOUGANG ROBOT Co Ltd 426 Udyog Vihar Phase IV Gurgaon Haryana India Fax 91 124 475 8542 Phone 91 124 475 8500 YASKAWA India Private Ltd Robotics Division YASKAWA E...

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