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YASKAWA YRC1000, Instructions Manual

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YASKAWA YRC1000 Instructions Manual Download Page 19

Safety

2

 - 

19

2.3

Personal protection

The entire working area of the robot is potentially dangerous. The following staff must work
with appropriate preparation and subject to the maxim 

"Safety First"

 to ensure the safety

of all.
•

Safety management

•

Assembly staff

•

Operating staff

•

Maintenance staff

DANGER!

Death by electric shock; serious injury from fire hazard;

Avoid dangerous actions in the area where the robot is installed. Be sure to take safety
precautions

Unauthorised persons should not have access to the robot.

Unauthorised persons should not have access to the peripheral equipment.

Put up signs in the respective working area, such as 

"Highly flammable"

,

"High

voltage"

,

"Stop"

 and 

"No unauthorized access"

 .

WARNING!

There is a risk of injury if there is contact with the robot or peripheral equipment.

Strictly observe the following items:

Always wear approved work clothes (no loose-fitting clothes).

Do not wear gloves when operating the robot.

Personal Protective Equipment (PPE) is subject to the provisions of the 89/656/EEC
guideline.

Do not wear large jewellery, such as earrings, rings or pendants.

Always wear protective safety equipment such as protective helmets, safety shoes
(with anti-slip soles), face shields, safety goggles and gloves as necessary.

CAUTION!

Injury and material damage due to unforeseen movements.

Observe the following note:
•

Never forcibly move the robot axes.

•

Never sit against the robot control.

•

Avoid inadvertent pressing of the keys.

•

Do not allow unauthorized persons to touch the robot control during operation.

Summary of Contents for YRC1000

Page 1: ...ROBOTICS Instructions Robot controller User manual ...

Page 2: ...e made in subsequent editions Subject to technical modifications Created on 2017 08 Revision 04 Document number E1102000214GB04 Author WOE Changes made in revision Rev 01 Document created from the original RE CTO A221 1 Rev 02 Revised version of the original RE CTO A221 2 2017 02 Rev 03 Add the manual document no ME00115EN 00 2017 03 Rev 04 Revised version of the original RE CTO A221 3 and RE CTO ...

Page 3: ...ing safety 25 3 Supply 27 3 1 Checking the scope of delivery 27 3 2 Product confirmation 28 3 3 Position type plate 31 4 Installation 32 4 1 Transportation 32 4 1 1 Transporting method 32 4 2 Assembly and installation 35 4 2 1 Protection measures 36 4 2 2 Ambient conditions and installation location 37 4 2 3 Installation example 37 4 2 4 Installation options 38 4 2 5 Configurations 41 5 Connection...

Page 4: ...79 9 1 1 Registering all axes at the time 80 9 1 2 Registering individual axes 81 9 1 3 Changing the absolute data 82 9 1 4 Clearing absolute data 82 9 1 5 Home position posture of robot 84 9 2 Setting the second home position check point 85 9 2 1 Purpose of position check operation 85 9 2 2 Procedure for the second home position setting 87 9 2 3 Procedure after alarm 87 9 3 Tool data setting 90 9...

Page 5: ...e function 175 9 15 1 About the numeric key customize function 175 9 15 2 Allocatable Functions 175 9 15 3 Allocating operation 176 9 15 4 Allocation of I O Control Instructions 184 9 15 5 Execution of allocation 185 9 16 Changing output status 186 9 17 Changing the parameter setting 187 9 18 File Initialization 189 9 18 1 Initializing JOB files 189 9 18 2 Initialize data files 189 9 18 3 Initiali...

Page 6: ...SPIN xx 274 9 26 15 Output to the control status signal 275 9 26 16 Saving or loading the file 290 9 26 17 Initializing the safety logic circuit file 291 9 26 18 Example of safety logic circuit 294 9 26 19 Alarm list of the safety logic circuit 304 9 26 20 GP safety output monitoring signal 305 9 27 Robot stop factor monitor function 311 9 27 1 The robot stop factor 311 9 27 2 The robot stop facto...

Page 7: ...ication of System Configuration 362 13 1 Addition of I O Modules 362 13 2 Allocating External I O Signal 364 13 3 Addition of base and station axis 368 13 3 1 Base Axis Setting 370 13 3 2 Station axis setting 379 14 Robot controller specification 388 14 1 Specification list 389 14 2 Function list 390 14 3 Programming pendant 394 14 4 Device configuration 395 14 5 Spare parts 397 14 5 1 Optional ca...

Page 8: ...19 15 10 External emergency stop 420 15 11 Connection for SERVO ON enable input 420 15 12 External axes overrun 422 15 13 General purpose safety input 424 15 14 General purpose safety output 425 15 15 General purpose input SERVO 426 15 16 General purpose I O board 427 15 17 WAGO Connector 432 15 18 Assignment of universal I O signals 433 15 18 1 ARC welding 436 15 18 2 Handling 441 15 18 3 General...

Page 9: ...d information and application advice 1 2 Frequently used terms The YASKAWA robot is a product of YASKAWA Electric Corporation and is provided by default with the robot control the programming pendant and robot cable The terms are designated as follows in this manual Term Description Control Robot control Industrial robot Robot Programming pendant teach box Programming pendant or PP Supplying cable...

Page 10: ...ot system must receive training before they operate the robot For optimal use of our products we recommend our customers to take part in a training session at the YASKAWA Academy For more detailed information on the training programs please visit www yaskawa eu com or directly get in touch with your YASKAWA branch office 1 4 Intended use Typical applications Flange mounting tools Installation of s...

Page 11: ...g holes or similar modifications can damage parts This will be regarded as improper use i e use that deviates from the intended use and will lead to loss of warranty and liability claims as well as loss of the declaration of incorporation CAUTION The robot system is an incomplete machine The robot system may be put into operation only after it has been determined that the incomplete or complete ma...

Page 12: ...nual number in your order YASKAWA Europe GmbH is not responsible for damage caused due to unauthorised modification of the system If any impermissible modifications are made to the system and to the robot all warranty and liability claims as well as the declaration of incorporation will expire Descriptions of the programming pendant buttons and displays are shown as follows Description of the oper...

Page 13: ...oved to the object item and the SELECT key is pressed that the item is directly selected by touching the screen Registered Trademark The names of companies and or products used in this manual are trademarks The indications of and are omitted ...

Page 14: ...CORPORATION 2 1 KUROSAKISHIROISHI YAHATANISHI KU KITAKYUSHU JAPAN Address YASKAWA NORTIC AB P O Box 504 Verkstadsgatan 2 385 25 Torsås Sweden 1 8 Authorized representative Address YASKAWA Europe GmbH Robotics Division Yaskawastr 1 85391 Allershausen Germany ...

Page 15: ...e operating the robot check the function of the EMERGENCY STOP button The servo power must go off immediately when the EMERGENCY STOP button is pressed on the programming pendant see Fig 2 2 Emergency stop button When the servo power is turned off the SERVO ON LED on the programming pendant goes out see Fig 2 1 SERVO ON LED Fig 2 1 SERVO ON LED Fig 2 2 Emergency stop button Programming Pendant Eme...

Page 16: ...robot s operating range Position yourself in front of the robot whenever possible Always follow the prescribed operating steps see the instructions for the robot controller as well as the Handling and Universal Application manuals There must be a free space into which the operator can retreat in the event of an emergency The following test steps absolutely must be performed before you teach the ro...

Page 17: ...lations German Occupational Safety and Health Protection Act Implementation Order for the German Occupational Safety and Health Protection Act Ordinance Regarding the German Occupational Safety and Health Protection Act Other pertinent provisions are as follows U S American laws governing occupational safety and health protection EC Machinery Directive 2006 42 EC Fig 2 4 CE mark Observe internatio...

Page 18: ...ny manual please contact the local YASKAWA branch office You must have the YASKAWA manuals listed below available Instructions E1102000214XX01 and higher Maintenance E1102000215XX01 and higher Operator s manual for each purpose Install and Wiring E1102000216XX01 or higher Alarm list E1102000217XX01 or higher Operating and maintenance instructions for the specific robot type XX is the language of t...

Page 19: ...voltage Stop and No unauthorized access WARNING There is a risk of injury if there is contact with the robot or peripheral equipment Strictly observe the following items Always wear approved work clothes no loose fitting clothes Do not wear gloves when operating the robot Personal Protective Equipment PPE is subject to the provisions of the 89 656 EEC guideline Do not wear large jewellery such as ...

Page 20: ... enable SW input SERVO power enable input Overrun input robot external axis GP safety input including external enable SW input Safety logic circuit These safety functions conform to the following safety standards EN ISO 13849 1 2015 Cat 3 PL e EN 62061 IEC 61508 SIL CL3 The use frequency of each switch for safety functions is assumed as below Emergency stop SW Enable SW programming pendant Externa...

Page 21: ...heral equipment Run the piping wiring or cables through a pit or use a protective cover so that they are not stepped on by personnel or run over by a forklift For further details of the installation and the electrical connection please see Chapter 5 3 2 Connection of the robot controller on page 52 DANGER due to electric current Death and serious injury from electrical shock and fire hazard Carry ...

Page 22: ...low to install the robot Make sure the area is large enough so that the fully extended arm with tool does not collide with the wall the safeguards or the robot controller During installation pay attention to the following figure Required installation planning Required installation planning Safeguarding Robot controller door Safety distance with respect to the stopping time of the robot type Maximu...

Page 23: ...kg Check that the eyebolts are securely fastened To lift the robot use a crane with wire rope threaded through the eyebolts and positioner s Lift the body in an upright position as described in the robot operator s manual see 2 5 1 Using a crane If storing the robot temporarily before installation make sure to place it on a stable and flat surface and take precautions to prevent unauthorized perso...

Page 24: ...pecified in the operation and maintenance manual for each robot model Install the robot controller outside the safeguarding of the manipulator s safety enclosure CAUTION Danger of injury and material damage from falling or movements In case of improper installation of the robot controller it may move unexpectedly or fall down see the figure below Attaching the robot control Secure the position of ...

Page 25: ...imits During Operation at the entrance of the safety fence The gate of the safety fence must be equipped with a safety interlock safety plug to turn the servo power OFF when the gate opens Make sure that the interlock operates properly before use For details of installation refer to chapter 15 9 Installation of safety plug For areas not enclosed by safety fences use a photoelectric sensor a safety...

Page 26: ...ave an escape plan in mind in case the robot comes toward you unexpectedly There must be a free space to which the operator can retreat in the event of an emergency Fig 2 6 Secure the robot controller with a padlock 2 5 5 1 Emergency stop function The emergency stop circuits are designed according to category 1 EN 418 item 4 1 5 Using power to the servo motor to achieve the stop and then removal o...

Page 27: ...livery The standard delivery includes the following items Scope of delivery Programming pendant Robot controller Robot Cable The present assembly instruc tions 1 䠮䡋䠾䡋䡐 䠩䠽䡊䡑䠽䡈 READ ONLY MEMORY 䠮 䠾 䠩 䡈 䠮䡋䠾䡋䡐 䠩䠽䡊䡑䠽䡈 READ ONLY MEMORY 䠮 䠮 䠮 䠾 䡐 䠩 䡈 2 3 4 5 ...

Page 28: ...t confirmation Main module options Socket with angled connector plate height 250 mm Cabinet with or without angled connector plate standard height height 499 mm Cabinet with angled connector plate double height height 499 mm ...

Page 29: ...Supply 3 29 Additionals options Drawer for socket Mounting plate for I O unit in socket Swing frame for standard cabinet height 499 mm Swing frame high for double height cabinet height 989 mm ...

Page 30: ...Supply 3 30 Hood for CEE connector Covers ...

Page 31: ...YASKAWA branch office if the serial numbers do not match the information on the delivery note Verify whether the serial number of the robot the robot controller and the programming pendant with the delivery The serial number can be found on the type plate as shown below ...

Page 32: ...cts during transportation No external forces may be exerted on the robot controller on the robot or on other components 4 1 1 Transporting method Check that the eyebolts are securely fastened The robot controller weighs approximately Approx 70 kg Use load carrying devices strong enough to withstand the weight 4 1 1 1 Using a crane Adequate load handling devices must be used to transport the robot ...

Page 33: ... be secured with safety belts as shown in the figure Transport by forklift below Make sure that the forklift and the transportation route have sufficient bearing capacity Always take due care when transporting the robot controller Using a forklift Protective padding Safety rope Palette Forklift tines 1 2 3 4 ...

Page 34: ...arring dropping or hitting the controller during handling Excessive vibration or impacting the robot controller may adversely affect the performance of the robot controller Lift move or install the robot controller by two or more persons Use a lifting truck to carry the robot controller Fig 4 2 Using a lifting truck ...

Page 35: ...hstand lifting Fig 4 3 Transport using a crane NOTICE When the cabinets are mounted side by side they need to be separated before lifting 4 2 Assembly and installation CAUTION Personal injury and damage to property The following precautions must be taken Check that the robot controller is complete and not damaged Do not put into operation a robot controller that is damaged or incomplete Check that...

Page 36: ...vices Non contact protection devices Enclosures Marked areas Signs Emergency Stop button Display elements NOTICE Operator s responsibility The operator of a robot or a robot system must ensure that all specifications and requirements of the standards DIN EN ISO 10218 1 and DIN EN ISO 10218 2 are met In the first instance the following must be observed Preparing a risk assessment The installation o...

Page 37: ...door is open It is recommended that there is clearance of at least 500 mm around the controller of at least 500 mm to allow access for maintenance work The minimum clearance at the rear of the controller is 200 mm to ensure proper cooling Must comply with the requirements of Directive 2004 108 EC on electromagnetic compatibility 4 2 3 Installation example Fig 4 4 Fixing the robot controller Place ...

Page 38: ...t controller is stacked and fixed securely It is possible to stack the YRC1000 controllers Follow the procedures below when stacking the YRC1000 controllers 1 Remove the four eyebolts 4 places on the top of the YRC1000 to be stacked lower level 2 Lift the controller by using the crane and stack the controllers Refer to chapter 4 1 1 1 Using a crane when using the crane 4 x 12 eyebolts 1 A A ...

Page 39: ...the fixing screw NOTICE Damage to the cables Removing the back board from the robot controller must be performed by two operators and make sure that one of operators keep holding the removed back board with due care to prevent damage to the internal cables 2 x Grommet a enlarged view Robot controller upper Robot controller lower M12 x 35 Spring washer Washer A A Section view All dimensions in mm B...

Page 40: ... the stacking the controllers tighten the temporally 4 x M12 bolts firmly a b part tightening torque 35 Nm 7 Reinstall the removed back board and plate at procedure No 4 8 Remove the wire lifting the controller by the crane and stacking is completed 2 x Grommet a enlarged view Robot controller upper Robot controller lower M12 x 35 Spring washer Washer A A Section view All dimensions in mm 1 a a 2 ...

Page 41: ...0 at correct height in relation to the robot 4 2 5 1 Single robot system 4 2 5 2 Twin robot system Master controller Socket Master controller Optional cabinet Master controller Optional cabinet double height Master controller Slave controller 1 Optional cabinet Master controller Optional cabinet Master controller Slave controller 1 Optional cabinet double height A D 1 A D 2 A B 2 A C 1 A B B 2 A B...

Page 42: ...iple robot system Master controller Slave controller 1 Slave controller 2 Optional cabinet Master controller Slave controller 1 Optional cabinet double height Slave controller 2 Optional cabinet double height 1 A B B B 2 A B C B C ...

Page 43: ... Turn OFF the main power supply Attach the required warning sign e g Do not energize Install a switch on guard as prescribed Do not touch any board inside the controller for five minutes after turning OFF the power supply Power cannot be turned ON unless the door is closed Interlocks prevent power from being turned ON Any occurrence during wiring while the robot controller is in the emergency stop...

Page 44: ... connects the manipulator and robot controller Another connects the robot controller and peripheral device A wrong connection can cause damage to electronic equipment Clear the area of all unauthorized personnel while making cable connections Place all cables in a covered cable channel in the floor 5 2 Power supply DANGER due to electric current Death from electrical shock and risk of fire due to ...

Page 45: ...rated label on the door of YRC1000 YRC1000 type Power supply For Japan ERAR 1000 xxxxxxx A0x 3 phase 200 to 240 VAC 10 to 15 at 50 60 Hz 2 For Asia ERAR 1000 xxxxxxx A1x 3 phase 380 to 440 VAC 10 to 15 at 50 60 Hz 2 neutral earthing For Europe ERAR 1000 xxxxxxx E1x For North America ERAR 1000 xxxxxxx B1x 3 phase 380 to 480 VAC 10 to 15 at 50 60 Hz 2 neutral earthing 3 phase power supply Robot cont...

Page 46: ...rs which cannot handle high frequencies may malfunction Even with a leakage breaker installed there is still a possibility of some high frequency current leakage from the YRC1000 However this current leakage presents no safety risks 3 phase power supply Connection of the Leakage Breaker Leakage Breaker Robot controller Breaker Contactor 1KM To connector Fuse Noise filter To controller power supply...

Page 47: ...robot is rapidly accelerated the power capacity of several times the continuous rating value may be needed instantly The power capacity is changed when using an external axis For details of the power capacity with an external axis please contact to your YASKAWA representative or check the rated value name plate on the controller Breaker protector Robot controller Controller for positioner Power su...

Page 48: ...r supply Standard connection Connection is made directly to the main switch when in the cable goes through an opening at the back of the cabinet at the upper right corner Optional 1 connection CEE socket plug and cable length 5 m are included in the cabinet Optional 2 connection A CEE socket is mounted at the CEE hood at the back of the cabinet 1 2 3 ...

Page 49: ... inside the robot controller is factory assembled maximum grounding resistance of 0 1 1 Turn the main switch to the OFF position Fig 5 2 Main switch in OFF position 2 Open the front door of the YRC1000 3 Connect the primary power supply cable 4 Pull off the primary cover of the switch which is on the upper left side of the YRC1000 T R I P PED ON YRC1000 GP7 T R I P P E D O U T o ...

Page 50: ...ance with all relevant local and national electrical codes The size of ground wire must the same as listed on table Tab 5 1 YRC1000 Power capacity cable sizes and breaker capacities NOTICE Observe also local regulations 6 Connect the primary power supply cable 7 Install the cover Grounding terminal M6 screws Grounding wire Robot controller Maximum earthing resistance of 0 1Ω to DIN EN ISO 60204 1 ...

Page 51: ...Connection 5 51 8 Close the YRC1000 door ...

Page 52: ...s caused by high voltage Before carrying out the wiring ensure that the door of the robot controller is in principle closed NOTICE Before you connect the robot cable to the robot ensure that the plug connection fits together 1 Connect the robot cable to the connector on the back side of the robot controller Fig 5 3 Connection of the robot cable Robot cable 1 ...

Page 53: ...e I O board JANCD AIO0 E User connects general purpose I O signal through terminal blocks Material No 105507 that are mounted at the back side of the controller s front door Connect safety plug and system external signal for external emer gency stop etc to safety terminal block board IM YE250 5 80P Connect safety plug and system external signal for external emergency stop etc to safety terminal bl...

Page 54: ...signal to I O terminal blocks Material No 105507 connected to gener al purpose I O board JANCD AIO0 E Drawing length 1 5m Cable terminal process Unshielded Refer to Connection Wire with Ro bot General Purpose I O Connector CN306 307 308 309 in chapter 15 16 General purpose I O board Connect safety plug and sys tem external signal for exter nal emergency stop etc to safety terminal block board IM Y...

Page 55: ...onnection Wire with Robot General Purpose I O Connector CN306 307 308 309 in chapter 15 16 General purpose I O board 6 Run the system external signal cables such as the safety I O signals through the safety terminal block board IM YE250 5 80P as shown by the red line in the figure below NOTICE For the details of the connection refer to Wiring Procedure of the Terminal Block in chapter 15 7 Safety ...

Page 56: ...rminal Block in chapter 15 16 General purpose I O board Fix the cable on the door and right side by using the cable ties as the figure Note the following two points No tension is found to the cables when the door is fully opened Cable length between fixing part of the door side and the right side approximately 150 mm Be careful not to get stuck the cables between the main body of the controller an...

Page 57: ... envelope of the robot when turning on the robot controller power supply The main power supply is turned on when the main power supply switch on the front of the robot controller is turned to the ON position Then the initial diagnosis and the current position setting begin Fig 6 1 Turning on the main power supply 6 1 1 Initial diagnosis When the main power supply is turned on and the start screen ...

Page 58: ... edit JOB when the robot controller is in TEACH mode as well as the cursor position in the JOB Fig 6 3 Start window CAUTION Risk of injury due to incorrect or unintentional robot movements The key may be inserted in the key switch of the programming pendant only during teach operations after the teach operation it must immediately be removed and kept in a safe place Make sure that the key for the ...

Page 59: ...TEACH MODE 1 Press SERVO ON READY on the programming pendant to turn on the SERVO power The LED SERVO ON blinks when the SERVO power is turned on Fig 6 5 Blinking LED SERVO ON 2 The SERVO power is turned on and the LED SERVO ON on the programming pendant lights up when you press the enable switch NOTICE SERVO power ON OFF Enable switch When you press the enable switch the SERVO power is turned on ...

Page 60: ...ly in TEACH mode confirm that the signal of the safety circuit turns invalid Perform the operation with greatest caution Release OFF Squeezed tightly OFF Squeezed ON Operating mode PLAY mode TEACH mode Security mode Robot Controller Emergency Stop PBESP Valid Valid External Emergency Stop EXESP Valid Valid Programming Pendant Emergency stop PPESP Valid Valid Safety circuit SAFF Valid invalid Progr...

Page 61: ...f the SERVO power supply turn off the main power supply NOTICE When the hourglass symbol appears on the screen of the programming pendant data writing is in process If you turn off the power supply of the robot controller during data writing the data may be faulty Do not turn off the power supply while the hourglass symbol can be seen on the screen of the programming pendant 6 3 3 The method of st...

Page 62: ...ory 2 The robot and the external axis are decelerated in a controlled manner on the programmed path until they finally stop After the stop the SERVO motor is still connected to power Brakes do not tighten Stop category Safety Signal Mode Operation mode Stop cate gory 0 Stop cate gory 1 Stop Cate gory 2 Controller emergency stop PBESP TEACH Valid PLAY Valid External emergency stop EXESP TEACH Valid...

Page 63: ... in a safe place yourself Turning on the power supply for the robot controller Moving the robot using the programming pendant Running the system in check mode Running the system in automatic mode CAUTION The following inspection procedures must be performed prior to teaching the robot If problems are found correct them immediately and be sure that all other necessary measures have been performed C...

Page 64: ...p down Moves upper arm up down Rotates wrist Rotates lower arm S X S X L Y L Y U Z U Z E E R X R X B Y B Y T Z T Z 8 8 8 X R Y B Z T X R Y B Z T X S Y L Z U X S Y L Z U E E X S X S Y L Y L Z U Z U X R X R Y B Y B Z T Z T S L U R B T E S X S X L Y U Z U Z E E L Y R X R X B Y B Y T Z T Z 1 2 3 4 5 6 7 1 5 2 6 3 7 4 ...

Page 65: ...cal YASKAWA branch office The official branch offices are listed on the last page When the robot moves in an incorrect manner because of system or operation errors and the robot can no longer be moved you can use the brake release function optional to release the brake of the arbitrary robot axis and move it manually Fig 7 1 Brake release unit You can use this brake release unit if you cannot turn...

Page 66: ...mode settings The robot controller modes setting are protected by a security system The system allows operation and modification of settings according to operator clearance Be sure operators have the correct level of training for each level to which they are granted access ...

Page 67: ... s basic operations to be used stop start etc in a production line EDITING MODE In this mode JOBs can be taught and edited and robot set tings can be made MANAGEMENT MODE In this mode authorised users can set up and maintain the robot system parameters system time and user ID modi fication SAFETY MODE his mode allows the operator to setup the safety function and able to edit the files related to t...

Page 68: ...ion RES START JOB 1 Edit Edit RES STATUS2 Operation CYCLE Operation Operation TRASH JOB LIST3 Edit Edit JOB EDIT PLAY Edit Edit PLAY EDIT JOB LIST Edit Edit VARIABLES BYTE Operation Edit INTEGER Operation Edit DOUBLE Operation Edit REAL Operation Edit STRING Operation Edit POSITION ROBOT Operation Edit POSITION BASE Operation Edit POSITION ST Operation Edit LOCAL VARIABLE Operation FLAG Operation ...

Page 69: ...nagement AUXILIARY RELAY Operation CONTROL INPUT Operation PSEUDO INPUT SIG Operation Management NETWORK INPUT Operation NETWORK OUTPUT Operation ANALOG OUTPUT Operation SV POWER STATUS Operation LADDER PROGRAM Management Management I O ALARM Management Management I O MESSAGE Management Management TERMINAL Operation Edit I O SIMULATION LIST Management Management SERVO ON FACTOR Management SERVO OF...

Page 70: ...SENSOR1 Operation Operation LIMIT RELEASE1 Edit Edit ARM CONTROL 1 Management Management SHIFT VALUE Operation SOFTLIMIT SETTING Management Management SHOCK SEN LV CURRENT Operation SYSTEM INFO VERSION Operation MONITORING TIME Operation Management ALARM HISTORY Operation Management I O MSG HISTORY Operation Management LOGDATA Operation Management USER DEFINITION MENU Operation Edit SECURITY Opera...

Page 71: ...4P Management Management A5P Management Management A6P Management Management A7P Management Management A8P Management Management RS Management Management S1E Management Management S2E Management Management S3E Management Management S4E Management Management S5E Management Management S6E Management Management S7E Management Management S8E Management Management Main menu Sub menu Permitted security ...

Page 72: ...anagement Management AUTO BACK SET Management Management WRONG DATA LOG Edit Management ENERGY SAVING FUNC TION Edit Management ENCODER MAINTENANCE Edit Management SAFETY FUNC M SAFETY SIGNAL ALLOC Operation Management TIMER DELAY SET Operation Management SAFETY LOGIC CIRCUIT Operation Management PM PM REDUCER Operation Management INSPECTION RECORD Operation Management OPERATING STATUS Operation E...

Page 73: ...DING MOTOR GUN WELD DIAGNOSIS Operation Edit GUN PRESSURE Edit Edit PRESSURE Edit Edit I O ALLOCATION Management Management GUN CONDITION Management Management CLEARANCE SETTING Operation Edit SPOT POWER SOURCE COND Management Management TIP INSTALLATION Operation Management APPLICATION SETTING Management Management GENERAL WEAVING Operation Edit GENERAL DIAG Operation Edit COMMON TO ALL APPLICA T...

Page 74: ... main menu like the arc welding system depend on the system used 2 Select SECURITY The selection window for the security mode appears 3 Press SELECT and select SECURITY MODE 4 Enter the user ID The user ID input window appears The user ID is set as follows in the factory EDITING MODE 0000000000000000 MANAGEMENT MODE 9999999999999999 ...

Page 75: ... MODE 1 Change to the MANAGEMENT MODE When changing to the management mode security mode can be selected from OPERATION MODE EDITING MODE MANAGEMENT MODE SAFETY MODE or ONE TIME MANAGE MODE 2 Select ONE TIME MANAGE MODE A character string input keypad is displayed Input the one time security code which is issued by YASKAWA sales representative If the password is correct the security mode will be c...

Page 76: ... the management mode As for the safety mode it should be 9 or more and 16 or less characters with number s and symbol s In order to change the user ID the robot controller must be in the EDITING MODE MANAGEMENT MODE or the SAFETY MODE Higher security modes can make changes the user ID of to lower security modes Changing User ID 1 Select SETUP under the main menu The sub menu appears 2 Select USER ...

Page 77: ...is entered a new ID is requested to be input Input new ID no 4 or more digits appears As for the safety mode 9 or more digits 5 Input new ID and press ENTER User ID is changed 8 4 Main CPU SD card ID To display the Main CPU SD Card ID is described below The main CPU SD Card ID is necessary to issue the one time security code 1 Change the security mode to the MANAGEMENT mode 2 Select SYSTEM INFO in...

Page 78: ...Security system 8 78 3 Select VERSION VERSION window appears 4 Select UTILITY under the pull down menu SD Card ID appears 5 Select SD Card ID SD Card ID dialog of the main CPU appears ...

Page 79: ... setting the home position the position of the absolute encoder must match it 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 robot and robot controller Replacement of the motor or absolute encoder Clearing stored memory by replacement of the main CPU board weak battery pack etc ...

Page 80: ...2 Select HOME POSITION The HOME POSITIONING window appears 3 Select DISPLAY under the menu or select PAGE to display the selection window for the control group or press PAGE The pull down menu appears 4 Select the desired control group 5 Select EDIT in the main menu The pull down menu appears ...

Page 81: ...Select ROBOT on the main menu The sub menu choices appear 2 Select HOME POSITION 3 Select the module to be calibrated e g R1 ROBOT Perform steps 3 and 4 which have been described in Registering All Axes at One Time to select the desired control group 4 Select the axis to be registered A confirmation dialog box appears 5 Select YES Displayed position data of the axis are registered as home position...

Page 82: ...l Axes at One Time to select the desired control group 4 Select the absolute data to be registered The number can now be entered 5 Enter the absolute data using the numeric keys 6 Select ENTER Absolute data are modified 9 1 4 Clearing absolute data 1 Select ROBOT from the main menu 2 Select HOME POSITION Perform steps 2 3 and 4 which have been described in Registering All Axes at One Time to displ...

Page 83: ...System Setup 9 83 4 Select CLEAR ALL DATA The confirmation dialog box appears 5 Select YES The all absolute data are cleared When NO is selected the registration will be canceled ...

Page 84: ...S for the robot corresponding to its model The home position posture of a commonly used 6 axis vertically articulated robot is shown below Angle of the U axis with respect to the horizontal line of the ground 0 Angle of the B axis center line with respect to the U axis center line 0 Angle of the L axis with respect to the vertical line to the ground 0 1 2 3 ...

Page 85: ...ated components but the robot was moved after the power supply was turned OFF If there is an error in the encoder communication related components the robot may stall when playback is started If the absolute data allowable range error alarm has occurred playback and test runs will not function and the position must be checked If the OUT OF RANGE ABSO DATA alarm occurs Reset alarm Turn ON SERVO pow...

Page 86: ...etting Check Point 3 Alarm Occurrence If the alarm occurs again there may be an error in the encoder communication related components Check the components After adjusting the erroneous axis calibrate the home position of the axis and then check the position again NOTICE Home position calibration of all the axes at the same time enables playback operations without having to check the position Somet...

Page 87: ...N501 CN502 CN503 CN504 CN505 CN506 CN507 CN510 CN508 CN531 CN532 CN533 CN534 CN535 CN536 CN537 CN538 CN522 CNBX CNBX CN250 CN515 CN516 CN511 CN251 CN212 CN211 CN213 CNA CNA CN215 CN216 CN217 Terminal block CN219 CN214 CNB CNB CNC CNC CN218 CN403 CN405 CN400 CN401 CN404 CN513 CN402 PG5V BAT 24V1 CN521 CNAX CNAX CN523 CN524 CN552 A CN219 CN220 TB221 TB222 Terminal block CN220 CN601 CN602 CN605 CN604...

Page 88: ... POS window NOTICE For details on the POWER ON OFF POS window refer to Position Data When Power is Turned ON OFF in Maintenance manual 1 Select ROBOT on the main menu The sub menu choices appear 2 Select SECOND HOME POS on the main menu The SECOND HOME POS window appears 3 Press the page key or select PAGE to display the selection window for the control group Occurring two or more group axes selec...

Page 89: ...message Home position checked appears Pulse data of the second home position and current pulse data should be compared Automatic mode can be done if compared error is in allowed range If the error is beyond the allowed range the alarm occurs again ...

Page 90: ...The tool file extension function can change many tool files to be used by one robot Use the following parameter to set this function S2C333 TOOL NO SWITCHING 1 enabled 0 disabled For more details refer to Operators manual in chapter Parameter 9 3 2 Registering coordinate data If the tool file is registered with the number keys enter the TCP of the tool on the flange coordinates Tool TCP TOOL FILE ...

Page 91: ...f the selected number appears In the tool coordinate window the tool number can be changed by pressing the page button or PAGE To call the tool list window and the tool coordinate window press DISPLAY LIST or DISPLAY COORDINATE DATA 3 Select the desired tool number 4 Place the cursor in the section for registering the coordinates and then press SELECT The number can be entered 5 Enter the coordina...

Page 92: ...System Setup 9 92 6 Press ENTER The coordinates are registered In the case of tool A B In the case of tool C Setting example Tool A Tool B Tool C 1 ZF TCP 260 mm 145 mm ZF 260 mm 260 mm TCP TCP 2 3 ...

Page 93: ...n Register in the following order Rz Ry Rx In the following case register Rz 180 Ry 90 Rx 0 1 Select ROBOT from the main menu 2 Select TOOL 3 Select the desired tool number As shown in the explanation 2 3 in section 9 3 2 Registering coordinate data on page 90 the desired TOOL COORDINATE window appears 4 Select the coordinate axis to be changed Select Rz first 5 Enter the tool position data Enter ...

Page 94: ...z is registered Register the angles of Ry Rx in the same way Ry must be the entered angle of rotation around X F of the flange coordinates Rx must be the entered angle of rotation around X F of the flange coordinates Z F Z F Y F Y F X F Ry 90 Z F Y F X F Rx 0 ...

Page 95: ...l file Before the teach in for the JOB and after installing the tool carry out basic system settings for the tool load data Check the path for each JOB that accesses the tool file if the tool load data had to be changed after the teach in The tool load data is The weight The centre of gravity The moment of inertia at the centre of gravity of the tool installed on the flange NOTICE You will find mo...

Page 96: ...ibrates only the coordinates The coordinates calculated from five calibration teach points are registered in the tool file In this case all tool position data is set to 0 1 Only the position is calibrated The tool position data calculated from the first calibration point is registered in the tool file The coordinates remain unchanged in this case the previous value is retained 2 The coordinates an...

Page 97: ...rection Defining a position The calibration of the tool position is carried out with the first calibration teach point TC1 Teach TC1 with the Z axis of the desired tool coordinates vertically downwards in the direction of the floor the axis of the tool coordinates is parallel to the Y axis of the base tool and points in the opposite direction The tool position data is calculated automatically with...

Page 98: ...r 2 and then set S2C432 1 Teach only TC1 in a different position and register the tool position data NOTICE There are 64 tool files that are 0 to 63 numbered In a basic system with a robot and a tool the tool file is used for the tool number 0 If there are multiple tools e g a multihand use the tool numbers in the sequence 0 1 2 etc 1 Select ROBOT from the main menu 2 Select TOOL 3 Select the desi...

Page 99: ...t the robot to be calibrated Do not select the robot if the robot has already been selected or if there is only one robot 2 Select in the TOOL CALIBRATION window and select the robot in the open selection dialog box 3 The robot is set 7 Select POSITION The selection dialog box appears Select the teach in point for calibration 8 Move the robot with the axis buttons ...

Page 100: ...ck the taught positions open the required window for TC1 to TC5 and press FWD The robot moves to the set position If there is a difference between the current position of the robot and the displayed position data TC flashes next to the POSITION field in the window 10 Select COMPLETE The calibration data is registered in the tool file On completion of calibration the coordinate window is displayed ...

Page 101: ...elect DATA from the pull down menu The pull down menu appears 2 Select CLEAR DATA The confirmation dialog box appears 3 Select YES All data is deleted NOTICE If tool angle data is required enter the values in the tool coordinate window The required steps are described in section 9 3 3 Registering the posture data on page 93 ...

Page 102: ...not JOINT Press COORD 2 Select the desired tool number Open the tool coordinate window of the tool by pressing the page button or selecting the tool in the tool list window 3 Move the R B or T axis with the axis button Change the robot position without changing the TCP position by pressing the axis buttons for the R B and T axes If a serious TCP error is indicated here set the tool data again NOTI...

Page 103: ...vel surface The requirements for the installation of the robot are described in section 9 4 ARM Control on page 110 To measure the tool load and centre of gravity move the robot to its home position horizontal to the U B and R axes and move the U B and T axes NOTICE To measure the tool load or centre of gravity remove all cable connections to the tool 1 Select ROBOT from the main menu U axis R axi...

Page 104: ... Setup 9 104 2 Select TOOL The tool list window appears The tool list window only opens if the file extension function is valid IIf the tool extension function is invalid the tool coordinate window is opened ...

Page 105: ...ndow press DISPLAY LIST or DISPLAY COORDINATE DATA Move the cursor to the desired tool number in the tool list window and press SELECT The tool coordinate window of the selected number appears In the tool coordinate window the number can be changed by pressing the page button or by selecting PAGE To call the tool list window and the tool coordinate window press DISPLAY LIST or DISPLAY COORDINATE D...

Page 106: ...degrees 4 5 degrees 4 Second measurement of the T axis Home position of the T axis 60 degrees 4 5 degrees 4 5 degrees NOTICE During measurement the speed automatically changes to Medium During measurement HOME or U flashes on the screen Hold the FWD button down during measurement If the button is released during measurement or before changes to measurement is aborted The following message appears ...

Page 107: ...n the flange and the center of gravity 1 Press FWD Press FWD and the robot moves to the home position 1 U axis horizontal to the ground R axis rotating axis of B axis is vertical to the ground T axis T axis home position 90 degrees NOTICE If the tool is interfered with during the measurement operate the S L and R axes and move the robot to avoid the interference Then move the axis to the home posi...

Page 108: ...the screen NOTICE During the measurement the FWD button must be kept pressed If the button is released during the measurement or if it is released before changes into the measurement is aborted and the following message appears Stopped measurement The measurement starts again from the home position1 3 Press FWD Press FWD and the manipulator moves to the home position 2 R axis rotating axis of B ax...

Page 109: ...essed If the button is released during the measurement or if it is released before changes into the measurement is aborted and the following message appears Stopped measurement The measurement starts again from the home position2 5 Select REGISTER When measuring only the tool load and the center of gravity The measured data is registered in the tool file and the tool coordinate window appears Sele...

Page 110: ... tool installed at the flange It is necessary to set these information correctly to do a better operation control by the ARM control 9 4 1 ARM control window WARNING Injuries and damage in the event of a collision between the tool and positioner Changes to the settings of the ARM control system can result in minor changes to the robot path To prevent injuries or damage as a result of a collision b...

Page 111: ...nation of the X axis of the robot coordinates relative to the floor around the Y axis of the robot coordinates The direction for the U axis movement from the robot home position becomes the direction of the robot installation angle The robot installation angle for wall installation is thus 90 degrees Example If the robot installation angle is set incorrectly the robot cannot be controlled incorrec...

Page 112: ...ight unit kg The weight of the installed load is set It is not necessary to set the correct value However it is recommended to set a value that is somewhat higher than the actual load round the value up in the case of loads between 0 5 and 1 kg X from the S axis Y from the S axis unit mm The centre of gravity of the installed load results from the distance in the X and Y directions from the S axis...

Page 113: ... U axis unit mm The centre point of the installed load is set here This can be an approximate value X from the U axis is the horizontal distance between the centre of rotation of the U axis and the centre of gravity of the load Set a negative value if the mass is to the rear of the centre of rotation of the U axis Height from the U axis is the vertical distance between the centre of rotation of th...

Page 114: ...4 2 Select ARM CONTROL The ARM CONTROL window appears 3 Press GO BACK PAGE or select PAGE Select the desired control group if there are two or more group axes 4 Select the desired point 5 Enter the value and press ENTER ...

Page 115: ...ong tool information shortened life of the speed reducer or an alarm occurrence Using robot with wrong tool information may result in premature failure of the robot The following message appears as a reminder when the tool load information is input Input correct tool information Using robot with wrong tool information may result in premature failure of the robot Correctly set the tool load informa...

Page 116: ...lel to the flange coordinates and whose home position is the tool s center of gravity It is not necessary to set the correct value However it is recommended to set a value that is somewhat higher than the actual load The setting is used to calculate the moment of inertia for each robot axis However the moment of inertia at the center of gravity does not normally have to be set since this value is ...

Page 117: ... or cylinder The moment of inertia for hexahedron or cylinder can be calculated with the following formula when the center of gravity is near the center See the formula for the calculation of the moment of inertia at the center of gravity Centre of gravity 100 0 70 Total weight approx 6 3 kg 7 00 kg Setting W 7 000 kg Xg 100 000 mm Yg 0 000 mm Zg 70 000 mm lx 0 kgm ly 0 kgm lz 0 kgm Weight W Unit ...

Page 118: ...n the flange directly under 250 mm Xg Yg Zg 0 0 250 Moment of inertia at the center of gravity A hexahedron with dimensions of 0 500 x 0 400 x 1 000 m is assumed which encloses the entire tool and workpiece Calculation formula for calculating the moment of inertia of the hexahedron Calculation of the center of gravity and moment of inertia at the center of gravity for multiple loads The center of ...

Page 119: ...exahedron and cylinder wi Weight of the nth parts kg xi yi zi Centre of gravity of the nth parts on the flange coordinates mm Icxi Icyi Iczi Moments of inertia of the nth parts kgm 3 The center of gravity for the whole tool is calculated on the basis of the following formula 4 The center of gravity at the center of gravity for the whole tool is calculated on the basis of the following formula xg w...

Page 120: ... the center of gravity and moment of inertia at the center of gravity for multiple loads above In this example the calculation is shown using method 2 Weight W w1 w2 3 6 9 approx 10 kg Center of flange Gun 1 Weight w1 3 kg Center of gravity x1 100 mm y1 50 mm z1 40 mm View from above Gun 2 Weight w2 6 kg x2 100 mm y2 150 mm z2 70 mm Center of gravity Xg w1 x1 w2 x2 w1 w2 3 100 6 100 3 6 100 0 mm Y...

Page 121: ...RMIT in the TEACHING CONDITION window If TOOL NO SWITCH is set to PROHIBIT in the TEACHING CONDITION window the tool window appears 3 Select the desired tool number 1 Move the cursor to the desired tool number and press SELECT in the tool list window 2 The tool coordinate window of the selected number appears 3 Select the desired number in the tool list window by pressing the page button or clicki...

Page 122: ...u make the entry in the menu when the cursor is on the point to be registered and you press SELECT 5 Press ENTER The value entered is registered The servo power is switched off automatically when the value is edited with the servo power switched on The message SERVO OFF BY CHANGING DATA is then displayed for three seconds ...

Page 123: ...oad and the preset load can result in vibrations during the robot s movements To ensure correct operation of the robot it is therefore important to set the tool load correctly In addition the tool s moment of inertia cannot be compensated if a tool is installed whose center of gravity is shifted significantly in the X or Y direction Switching the tool file If two or more tool files are used Inform...

Page 124: ... set range as a precondition for operations such as starting the line The robot can be moved to the set work home position by operation from the programming pendant or by signal input from an external device When the robot is in the vicinity of the work home position the work home position signal turns ON 9 5 2 Setting the work home position 1 Select ROBOT from the main menu 2 Select WORK HOME POS...

Page 125: ...System Setup 9 125 3 Press the GO BACK PAGE button If there are two or more robots in the system use GO BACK PAGE to change the control group or click PAGE to select the desired control group ...

Page 126: ... Cube 59 is for ROBOT 6 Cube 58 is for ROBOT 7 Cube 57 is for ROBOT 8 The work home position cube is a cube as shown in figure below the length of its sides a in figure below is determined by a parameter of S3C1097 units μm By changing the contents of this parameter the size of the cube can be changed The initial value is 10cm Fig 9 3 S3C1097 The length of the sides of the work home position cube ...

Page 127: ... signal of the work home position is entered detected at the leading edge the robot s TCP is moved to the home position The message ROBOT IS MOVING TO WORK HOME POSITION is displayed when the robot moves In this case the movement interpolation is MOVJ and the speed set in the parameters applies S1CxG56 units 0 01 9 5 5 Output of the work home position signal This signal is output whenever the robo...

Page 128: ... coordinates or user coordinates The YRC1000 checks whether the robot s current TCP is inside or outside this area and outputs the status in the form of a signal Types of cubic interference area Cubic Interference Inside the specified cube is defined as the interference area When the current position of manipulator s TCP is located inside the cube the corresponding specific output signal is ON Out...

Page 129: ...ce Specified output signal ON Outside of cubic area Specified output signal OFF TCP is located outside the cube Cubic interference Specified output signal OFF Outside of cubic area Specified output signal ON Cubic Interference Area TCP 1 ...

Page 130: ...the positions of the maximum and minimum value of the cube corner 3 Once you have entered the lengths of the three cube sides axial length move the robot with the axis buttons to the cube s center point Setting options Z axis Minimum value X axis Y axis Cube interference area axis Maximum value Z axis Minimum value X axis Y axis Maximum value Z axis X axis Centre point Y axis 1 2 3 4 5 6 1 2 3 4 5...

Page 131: ...cube number Select the cube number with PAGE or enter the number directly Select PAGE when entering the cube number using the numeric keys to enter the signal number 4 Select METHOD Each time you press SELECT the display alternates between AXIS INTERFERENCE and CUBIC INTERFERENCE If CUBIC INTERFERENCE is selected a new window appears ...

Page 132: ...ss SELECT the display alternates between COMMAND POSITION and FEEDBACK POSITION NOTICE To stop the robot from moving by means of the interference signal use the signal for the cube interference area if multiple robots are interfering with each other set CHECK MEASURE to COMMAND POSITION When FEEDBACK POSITION is set the robot stops after entering the interference area When using the interference s...

Page 133: ...m occurs and the robot stops immediately AL4902 CUB Interference area TCP Number Input of the Cube Coordinates 1 Select METHOD Each time you press SELECT the display alternates between MAX MIN and CENTER POS 2 Select MAX MIN 3 Input number for MAX and MIN and press ENTER The cube interference area is set Teach in corner 1 Select METHOD Each time you press SELECT the display alternates between MAX ...

Page 134: ...nimum value The cursor moves to either MIN or MAX this time 5 Move the robot with the axis keys Move the robot with the axis keys to the positions of the maximum and minimum value of the cube 6 Press ENTER The cube interference area is registered Entering the cube side and teach in centre point using the numeric keys 1 Select METHOD Each time you press SELECT the display alternates between MAX MIN...

Page 135: ...is set 4 Press MODIFY The message MOVE TO CENTER POINT AND TEACH is displayed The cursor moves to either MIN or MAX this time 5 Move the robot with the axis keys Move the robot with the axis keys to the cube s center point 6 Press ENTER The current position is registered as the cube s center point ...

Page 136: ...hat indicates whether the current position of the axis is inside or outside this area on inside off outside 1 Select ROBOT from the main menu 2 Select INTERFERENCE The INTERFERENCE AREA window appears 3 Select the interference signal number Select the interference signal number with GO BACK PAGE or enter the number directly When selecting the desired interference signal number by number input sele...

Page 137: ...t CHECK MEASURE Each time you press SELECT the display alternates between COMMAND POSITION and FEEDBACK POSITION 7 Select ALARM OUTPUT Each time SELECT is pressed OFF and ON are displayed alternately When selecting ON and if the manipulator s axes approach inside the pre defined interference area the following alarm occurs and the manipulator stops immediately AL4901 AXIS INTERFERENCE ...

Page 138: ...LECT is pressed MAX MIN and CENTER POS switch alternately 2 Select MAX MIN 3 Input number for MAX and MIN data and press ENTER The axis interference area is set Teaching corner 1 Select METHOD Each time you press SELECT the display alternates between MAX MIN and CENTER POS 2 Select MAX MIN ...

Page 139: ...m value The cursor moves to either MIN or MAX this time 5 Move the robot with the axis keys Move the robot with the axis keys to the positions of the maximum and minimum value of the cube 6 Press ENTER The cube interference area is registered Numper input center point WIDTH and teaching center 1 Select METHOD 1 Each time SELECT is pressed MAX MIN and CENTER POS switch alternately 2 Select CENTER P...

Page 140: ...set 3 Press MODIFY The message MOVE TO THE CENTER POINT AND TEACH is displayed The cursor moves to either MIN or MAX this time 4 Move the robot with the axis keys Move the robot with the axis keys to the cube s center point 5 Press ENTER The center position of the cube is registered ...

Page 141: ...ct the interference signal to be deleted Select the interference signal number to be deleted with GO BACK PAGE or enter the number directly Select PAGE when entering the interference signal number using the numeric keys to enter the signal number 4 Select DATA from the menu The pull down menu appears 5 Select CLEAR DATA The confirmation dialog box appears ...

Page 142: ...System Setup 9 142 6 Select YES All data of the interference signal number is deleted ...

Page 143: ...collision during normal operation check the following points The tool s load and moment do not exceed the rated values The actual tool load and the tool file setting value are the same The U arm payload information and the set weight of U arm payload in the ARM CONTROL window are the same In addition detection sensitivity can be decreased for only a specific section where a contact task is perform...

Page 144: ...his function the detection level can be set for each axis S2C869 TEACH mode each axis setting function 1 VAILD 0 INVALID Condition number 1 to 9 1 to 7 For changing detection level in PLAY mode 8 For standard detection level in PLAY mode 9 For detection level in TEACH mode Robot select Select the robot for which you want to change the detection threshold Function select Sets collision detection to...

Page 145: ...efault the level 100 enables the function without false detection even if the robot is operated at the maximum speed To change DETECT LEVEL move the cursor to the subject robot and press SELECT to display the numeric input status input the value with a numeric key and press ENTER To increase the detection sensitivity set the level to small value and to decrease the sensitivity set the level to lar...

Page 146: ...et the total load information weight and center of gravity of the hand and the maximum load workpiece For other application Set the load information weight and center of gravity of the tool Set the detection threshold for all axes to 100 1 Open the SHOCK DETECT LEVEL window 2 Select DATA then CLEAR MAX VALUE Perform the JOB Setting all levels at once Open the SHOCK DETECTION LEVEL window Select DA...

Page 147: ...g modification etc measure the max disturbance force and set the DETECT LEVEL again When the load of tool or workpiece is greatly modified measure the max disturbance force and set the DETECT LEVEL again NOTICE To avoid false detection during robot operation set the following calculated value A or B whichever is larger to the DETECT LEVEL An emergency stop of the robot due to the false detection m...

Page 148: ...shock detection level of the slave axis group Shock detection level condition number 1 to 7 Specifies the shock detection level condition number in which the detection level in playback mode is set Changing the shock detection level for each axis Setting range 1 to 500 Change the shock detection level specified in the changing the shock detection level for the each axis If the shock detection leve...

Page 149: ...n To register the instruction move the cursor to the address area of the JOB CONTENT window in TEACH mode 1 Select JOB under the main menu 2 Select JOB 3 Move the cursor to the address area SHCKSET 1 Move the cursor to the line immediately before the position at which the SHCKSET instruction is to be registered 2 Press INFORM LIST The inform list dialog box is shown 3 Select the SHCKSET instructio...

Page 150: ...e is entered using the numeric keys press SELECT to call the input line 2 Press ENTER in order to change the number in the input line When the robot specification is added 1 When the robot specification is added move the cursor to the instruction in the input buffer line and press SELECT to display the DETAIL window 2 Move the cursor to UNUSED for ROBOT STATION and press SELECT 3 The selection box...

Page 151: ...ion level for the each axis move the cursor to the shock detection level hold down SHIFT and press the up down cursor key to change the level When the value is input with the numeric key 1 When the value is input with the numeric key press SELECT to display the input buffer line 2 Input the numbers and then press ENTER The value in the input buffers is changed 5 Press INSERT then ENTER The instruc...

Page 152: ... line and press SELECT to display the DETAIL window 2 Move the cursor to UNUSED for ROBOT STATION and press SELECT 3 The selection box appears 4 Position the cursor on the robot to be added and press SELECT 5 When the addition of robot is completed press ENTER 6 The DETAIL window is closed and the JOB CONTENT window appears 5 Press INSERT and then ENTER The instruction displayed in the input line ...

Page 153: ...ce the collision may be detected again after resetting In this case set the shock detection function INVALID or increase the detection level in teach mode and retreat the manipulator to a safety position 9 7 2 High sensitivity shock detection function for Arc Welding application only This function limits the damage caused by collisions by carrying out an emergency stop for the robot when the tool ...

Page 154: ...ccurate Reading the tool load information from the MAKER INITIAL VALUE window To enable the high sensitivity shock detection function read the tool load information prepared by YASKAWA on the MAKER INITIAL VALUE window Since this function works on the assumption that the tool file is correctly set read the tool load which is the same as the actual load on the MAKER INITIAL VALUE window When the to...

Page 155: ...value other than the STANDARD is selected The read tool load information cannot be changed because it is used for the high sensitivity shock detection function When the standard torch is read the function is disabled and the tool load information becomes editable In the case of using multiple tool files when the tool file is switched the tool load information is also switched When switching the to...

Page 156: ...R BUILT MODEL 308R OUT MODEL 500R BUILT MODEL 508R BUILT MODEL or 508R OUT MODEL 9 7 2 5 Reading the U arm payload 1 Change the SECURITY MODE to the MANAGEMENT MODE 2 Select ARM CONTROL The ARM CONTROL window appears 3 Select DATA under the menu The pull down menu appears 4 Select READING The MAKER INITIAL VALUE window appears 5 Select the number of the MAKER INITIAL VALUE to be read A confirmatio...

Page 157: ...tial Value U Arm payload NAME The name of U arm payload information prepared by YASKAWA is indicated When using the U arm payload in the following figure select from the MAKER INITIAL VALUE window NOTICE To perform shock detection more accurately even when the U arm payload information prepared by YASKAWA and the actual payload are the same DO NOT read the payload information if the robot types ar...

Page 158: ... axes are determined by point XY NOTICE It is important that the two points ORG and XX are taught exactly Specify the amount of change from the basic coordinates User coordinates are defined by specifying the coordinates as a basic coordinates base coordinates or user coordinates and the amount of change of coordinate value from the basic coordinates As shown in the following figure the data X Y Z...

Page 159: ...tem Setup 9 159 User coordinate files Up to 64 user coordinates can be registered Each coordinate has a user coordinate number and is specified in a user coordinate file User coordinate file 1 1 2 3 4 1 XX ...

Page 160: ...e mark indicates that the user coordinates is completed to set and the mark indicates that it is not completed 3 To check the position of the user coordinates select DISPLAY COORDINATE DATA 4 The following window appears Perform teaching by axis operations of the robot 1 Move the cursor to the user coordinate number to be set 2 Press SELECT The user coordinate setup window is shown ...

Page 161: ...TER Taught position is registered Repeat the steps 2 to 4 to teach ORG XX and XY indicates that teaching is completed and indicates that it is not completed To check the taught positions call up the required window among ORG to XY and press FWD The robot moves to the set position If there is a difference between the current position of the robot and the displayed position data ORG XX or XY flashes...

Page 162: ...he amount of change from the basic coordinate 1 Move the cursor to the user coordinate number to be set 2 Select DISPLAY of the main menu The pull down menu is shown 3 Select COORDINATE VALUE 4 Select ROBOT Select the target robot ...

Page 163: ...ISTERED STATUS or UNREGISTERED STATUS is shown Indicates the user coordinates number which is fully registered Indicates the user coordinates number which is not yet registered NOTICE If the user coordinates which specify another user coordinates number in unregistered status as the basic coordinates are used the alarm no 4508 SPECIFIED ERROR COORDINATE 18 occurs To select the user coordinates for...

Page 164: ...T The user coordinate is created and registered in the user coordinatefile 9 8 2 2 Clearing user coordinates 1 Select DATA from the pull down menu 2 Select CLEAR DATA The confirmation dialog box appears 3 Select YES All data is deleted ...

Page 165: ...ERRUN SHOCK SENSOR window appears Select either EMERGENCY STOP or HOLD to set the item SHOCK SENSOR STOP COMMAND which specifies the stop condition in the current shock sensor detection E STOP and HOLD are displayed alternately every time SELECT is pressed 3 Select RELEASE The control group in which overrun or shock sensor is detected is indicated with If RELEASE is selected overrun or tool shock ...

Page 166: ... reaches a soft limit When the robot is stopped at a soft limit temporarily release the soft limit by the following procedure then move the robot away from the soft limit in a direction opposite to the earlier operation direction 1 Select ROBOT from the main menu 2 Select LIMIT RELEASE The LIMIT RELEASE window appears 3 Select SOFT LIMIT RELEASE Each time SELECT is pressed INVALID and VALID are di...

Page 167: ...s on the SECURITY modes 1 Select ROBOT from the main menu 2 Select LIMIT RELEASE The LIMIT RELEASE window appears 3 Select ALL LIMITS RELEASE VALID and INVALID are displayed alternately every time SELECT is pressed When ALL LIMITS RELEASE is changed to VALID the message All limits have been released appears When the setting changes to INVALID the message All limits off released is displayed for a ...

Page 168: ...ndard instruction set the following functions cannot be used However operation becomes easier because the number of data items decreases when registering an instruction Use of local variables and arrangement variable Use of variables for additional items e g MOVJ VJ I000 When instructions are executed for example during playback all the instructions can be executed regardless of the instruction se...

Page 169: ... displayed in the input line as were registered last time 9 12 1 2 Setting the learning function The learning function is set to VALID by default 1 Select SETUP from the main menu 2 Select TEACHING CONDITION SETTING The TEACHING CONDITION SETTING window appears 3 Select INSTRUCTION INPUT LEARNING Press SELECT to switch between VALID and INVALID ...

Page 170: ... the instruction set level 1 Select SETUP from the main menu 2 Select TEACHING COND The TEACHING CONDITION window appears 3 Select LANGUAGE LEVEL The selection list appears 4 Select the desired language level The language level is set ...

Page 171: ...on The learning function is set at VALID by default 1 Select SETUP under the main menu 2 Select TEACHIG COND The TEACHING CONDITION window appears 3 Select INSTRUCTION INPUT LEARNING VALID and INVALID are displayed alternately every time SELECT is pressed ...

Page 172: ...ows 1 Select SETUP under main menu 2 Select DATE TIME The DATE TIME SET window appears 3 Select DATE or TIME The input buffer line appears 4 Input the new date time For instance to set the date to August 1 2008 input 2008 8 1 To set the time at twelve o clock enter 12 00 5 Press ENTER The date time is changed ...

Page 173: ...PAGE key When two or more robots and stations exist in the system use the GO BACK PAGE to change the control group or click on PAGE to select the desired control group 4 Select JOINT or LNR CIR The type of speed alternately changes from JOINT to LNR CIR 5 Select the speed to modify The input buffer line appears 6 Input the speed value ...

Page 174: ...System Setup 9 174 7 Press ENTER The speed is modified ...

Page 175: ...en the interlock key and the numeric key are pressed at the same time The allocatable functions are listed below Function Description Manufacturer allocation Assigned by YASKAWA Allocating another function invali dates the function allocated by the manufacturer Instruction Allocation Allocates any instructions assigned by the user Executing JOB Call Allo cation Allocates job call instructions CALL...

Page 176: ...output allocation 4 bit 8 bit Sends the specified output to the specified general purpose group output signals when the interlock key and the allocat ed Numeric key are pressed at the same time Analog output assignment Sends the specified voltage to the specified output port when the interlock key and the allocated Numeric key are pressed at the same time Analog incremental output allocation Sends...

Page 177: ...CATE SIM KEY The KEY ALLOCATION SIM window appears In a system with multiple applications press the page key to change the window to the allocation window for each application or click on PAGE to select the desired application number ...

Page 178: ...ress SELECT Selection list appears 2 Select INSTRUCTION The instruction is shown in the ALLOCATION CONTENT 1 To change the instruction move the cursor to the instruction and press SELECT Then the instruction group list appears 2 Select the group which contains the instruction to modify 3 When the instruction list dialog box is shown select the instruction to be changed ...

Page 179: ...ation no move the cursor to the no and press SELECT Then input buffer line appears 2 Input the number to be changed and press ENTER 9 15 3 4 Display allocation Set this function in the KEY ALLOCATION EACH window 1 Move the cursor to the FUNCTION of the key to be allocated and press SELECT Selection list appears 2 Select DISPLAY 3 Move the cursor to ALLOCATION CONTENT and press SELECT Character inp...

Page 180: ...ey key allocation SIM will be set to the display set Unable to allocate the display allocation and the another function to the same key 9 15 3 5 Alternate output allocation Set this function in the KEY ALLOCATION SIM window 1 Move the cursor to the FUNCTION of the key to be allocated and press SELECT Selection list appears 2 Select ALTERNATE OUTPUT The output No is displayed in the ALLOCATION CONT...

Page 181: ... SELECT Then numeric value can be entered 2 Input the number to be changed and press ENTER 9 15 3 7 Pulse output allocation Set this function in the KEY ALLOCATION SIM window 1 Move the cursor to the FUNCTION of the key to be allocated and press SELECT A selection list appears 2 Select PULSE OUTPUT The output No and output time are displayed in the ALLOCATION CONTENT 1 To change the output No or o...

Page 182: ...SELECT Then numeric value can be entered 2 Input the number or value to be changed and press ENTER 9 15 3 9 Analog output allocation Set this function in the KEY ALLOCATION SIM window 1 Move the cursor to the FUNCTION of the key to be allocated and press SELECT A selection list appears 2 Select ANALOG OUTPUT The output port number and the output voltage value are displayed in the ALLOCATION CONTEN...

Page 183: ...ted and press SELECT A selection list appears 2 Select ANALOG OUTPUT The output port number and the output voltage value are displayed in the ALLOCATION CONTENT 1 To change the output port No or output voltage value move the cursor to the No or voltage value and press SELECT Then numeric value can be entered 2 Input the number or voltage value to be changed and press ENTER ...

Page 184: ...NST The instruction corresponding to the I O control allocated by key allocation SIM is displayed in the ALLOCATION CONTENT The allocated instruction changes automatically when ALLOCATION CONTENT is changed by key allocation SIM Even if the I O control allocation is changed to the default setting allocated by the manufacturer with key allocation SIM the settings for key allocation EACH remain the ...

Page 185: ...is displayed in the input buffer line 2 Press INSERT and then press ENTER The CALL instruction shown in the input buffer line is registered 9 15 5 3 Executing the display allocation 1 Press the key allocated for the display allocation The allocated display appears 9 15 5 4 Executing the I O control allocation Alternate output allocation momentary output allocation pulse output allocation group out...

Page 186: ... can be shown on the RELAY ON window and they must be set in advance to parameters S4C327 to S4C390 If they are not set the sub menu in the RELAY ON window will not be displayed 1 Select IN OUT under main menu 2 Select RELAY ON The RELAY ON window appears 3 Select the desired signal to change the output status Select the status or of the desired signal 4 Press INTERLOCK SELECT The output status is...

Page 187: ...METER under the main menu 2 Select the parameter type The PARAMETER window appears Select the desired parameter 3 Move the cursor to the desired parameter number When the desired parameter number is not in the current window move the cursor in the following way 1 Move the cursor to a parameter number and press SELECT 2 Enter the desired parameter number with the numeric keys and press ENTER 3 Pres...

Page 188: ...gure 3 To enter a binary setting select the binary figure 2 Enter the value If a decimal figure is selected enter a decimal value with the numeric keys If a binary figure is selected move the cursor to the binary figure data in the input buffer line and press SELECT Each time SELECT is pressed 0 and 1 alternate in the window 0 or 1 can also be entered with the numeric keys 3 Press ENTER The new se...

Page 189: ...alog box appears 6 Select YES The JOB data is initialized NOTICE When JOB is initialized the following files are reset at the same time Be careful when initializing JOB User coordinates Memory play file only for extended CMOS Spot monitor data only for extended CMOS Variable data System definition parameter S4D Robot calibration data Conveyor calibration data 9 18 2 Initialize data files 1 Turn th...

Page 190: ...ct FILE GENERAL DATA The INITIALIZE window appears 6 Select the data file to be initialized The selected data is marked with The I O data marked with cannot be selected 7 Press ENTER A confirmation dialog box appears 8 Select YES The selected data file general data are initialized ...

Page 191: ...ged to the MANAGEMENT mode 3 Select FILE under the main menu 4 Select INITIALIZE 5 Select PARAMETER The parameter selection window appears 6 Select the parameter to be initialized The selected data is marked with The I O data marked with cannot be selected 7 Press ENTER A confirmation dialog box appears 8 Select YES The parameter data is initialized ...

Page 192: ...is changed to the MANAGEMENT mode 3 Select FILE under the main menu 4 Select INITIALIZE 5 Select I O DATA The I O data selection window appears 6 Select data to be initialized The selected data is marked with The I O data marked with cannot be selected 7 Press ENTER A confirmation dialog box appears 8 Select YES The I O data is initialized ...

Page 193: ...to the MANAGEMENT mode 3 Select FILE under the main menu 4 Select INITIALIZE 5 Select SYSTEM DATA The System data selection window appears 6 Select the parameter to be initialized The selected data is marked with The I O data marked with cannot be selected 7 Press ENTER A confirmation dialog box appears 8 Select YES The selected data is initialized ...

Page 194: ... MAINTENANCE mode The zeroing function is performed Encoder is reset In case one of the above mentioned operations is performed re set the data following the procedures shown in chapter 9 18 6 2 FLASH data reset In the MAINTENANCE mode there are cases when parameters related to the safety function are rewrote by several setting operations For this reason the message Select Safety Board FLASH Reset...

Page 195: ...4 Move the cursor to Safety Board FLASH Reset and press ENTER 5 The dialog box Reset is displayed Select YES The data of the safety circuit board is re set A few seconds later the buzzer sounds and the data setting is completed 6 When the data reset is completed turn the control power OFF and then turn the power ON again ...

Page 196: ... 1 1 Applicable range for the font size change Changing the font size is allowed in the general display area indicated in the following figure 9 19 1 2 Settable font size The following eight patterns of fonts are available in setting the size of fonts displayed on the screen General display area No Font size Font style 1 Small Regular 2 Small Bold 3 Regular Regular 4 Regular Bold 5 Large Regular 6...

Page 197: ...ialog box appears on the center of the current window To set the font size in the font size setting dialog box follow the procedure below 1 Specify the font style The Bold Type check box can be checked or unchecked alternately each time the check box is selected Check the Bold Type check box as follows to set the font to the bold style Clear the Bold Type check box as follows to set the font to th...

Page 198: ...dialog box 3 The font size setting dialog box is closed and the screen displays the font specified in the dialog box To cancel the setting of the font size follow the procedure below 1 Select Cancel in the font size setting dialog box 2 The dialog box closes without changing the font size ...

Page 199: ...er enables changing the size of operation buttons The button size in the main menu area menu area and instruction list can be respectively selected from three sizes 9 19 2 1 Applicable range for button size change Changing the button size is allowed in the main menu menu pull down menu and instruction list indicated in the following figure Menu area pull down menu Main menu Instruction list 1 1 2 ...

Page 200: ...following three sizes of buttons are available in setting the size of each operation button the font style of the character string on buttons can also be specified No Button size Font style 1 Small Regular Bold 2 Regular Regular Bold 3 Large Regular Bold ...

Page 201: ... Specify the area to set the button size 1 Specify the area to set the button size 2 The buttons in the selected area is subject to size setting 3 Note that only the last selected button determines the area subject to size setting even if settings are performed several times before then 2 Specify the font style The Bold Type check box can be checked or unchecked alternately each time the check box...

Page 202: ...setting button in this example the change is applied only to the pull down menu buttons in the menu area To cancel the setting of the button size follow the procedure below 1 Select Cancel in the button size setting dialog box The dialog box closes without changing the button size NOTICE Do not turn OFF the robot controller power supply when the button size is being changed when the button size se...

Page 203: ...n the middle of the screen The settings carried out with the font button setting function can be reset together and the default setting can be restored To initialize the screen layout follow the procedure below 1 Select DISPLAY SETUP and then INITIALIZE LAYOUT from the main menu A confirmation dialog box appears in the middle of the current window 2 Select OK closed and the default setting for the...

Page 204: ...orage The settings of the font size and button size are saved The screen is displayed with the font size and button size specified last time by the current controller NOTICE In the MAINTENANCE mode the screen is displayed with the standard font size and button size regardless of the settings of them The font size and button size can be changed in the MAINTENANCE mode but the settings are not saved...

Page 205: ...the absolute encoder This function is used to recover the absolute data by moving the axis whose position information is lost to a position close to the home position by axis operation 9 20 2 Encoder backup error recovery function operation 1 Press SELECT When select the RESET in the alarm display the alarm is reset The robot can be move by the axis operation key 2 Adjust the alarm occurring axis ...

Page 206: ...nd higherchapter System Diagnosis Current Position 12 Confirm the current position Confirm the recovered current position and modify the followings depending on its values 1 The pulse number is approximately 0 a Recovered normally 2 The pulse number is approximately 4096 a Move the recovered axis to the 4096 pulse position and register the individual axis to calibrate the home position 3 The pulse...

Page 207: ... reducer If the periodic grease replenishment and grease replacement are not performed or the excessive pressure is applied to the speed reducer such as the mechanical interference etc it will be failed before reaching to the diagnosis period The diagnosis is performed by executing the JOB in the play mode When operate the robot in the teach mode operation by the axis key FWD operation and test op...

Page 208: ... under the pull down menu 5 Select SETUP CONDITION The condition setup window is appears 6 Move the cursor to over the REPLACEMENT SIGNAL and select Able to enter the values 7 Enter the general purpose output signal Lifetime calculation window 1 Select PM in the main menu ...

Page 209: ... the speed reducer The calculation of the subtraction of the number is operated automatically by performing the JOB in the play mode NOTICE TIME By setting the time in this section the replacement time is informed by displaying the message and turning the replacement signal ON before the TIME TO REPLACE MENT becomes 0 For example when set with 100 the message will be displayed 100 hours before the...

Page 210: ...f the another window appears select Display and select the LIFE CALCULATION in the pull down menu to display the lifetime calculation window 4 Move the cursor over the WARNING to invalidate the desired axis and select Select Invalid and Valid will alternate each time when press the Select ...

Page 211: ...t so that it is possible to check visually how the lifetime decreases Use this function as a method to judge the lifetime of the speed reducer The graph is shown by the following procedures 1 Select PM of main menu 2 Select PM REDUCER 3 Select DISPLAY The pull down menu is shown 4 Select GRAPH The graph is shown 5 Select GRAPH The pull down menu is shown ...

Page 212: ...o change the display range of the horizontal axis modify the MIN and MAX values of display time To change the display range of the vertical axis modify the MIN and MAX values of time to replace By pressing CSV Save the lifetime calculation data can be saved as a CSV format into the external memory device For the other operations refer to chapter 9 21 1 2 Diagnose by the torque average value ...

Page 213: ...d diagnoses the lifetime of the speed reducer by monitoring the change of the torque element By operating a JOB in the PLAY mode a data the torque element arising from the deterioration of the speed reducer for each axis is recorded automatically on a daily basis and the data is accumulated When the difference value between the latest value the average value from the measured result of the five da...

Page 214: ...y in the menu The SETUP CONDITION appears in the pull down menu Torque average value Average value average value of the av erage period Average period 30 days Prior to 60 days from the day to diag nose Latest period 5 days Prior to 90 days Latest value average of the nearest value Prior to 60 days When the measured value is greater than the threshold value it outputs the warning A day to diagnose ...

Page 215: ...set the item 0 The initial value of this item is 0 ACCEPT RATE MID LOW The general purpose output signal which is set by ACCEPT RATE MID and ACCEPT RATE LOW is turned ON when it is deter mined as follows The latest value the average value ACCEPT RATE MID The latest value the average value ACCEPT RATE LOW If unnecessary to output the signal set the item 0 The initial value of this item is 0 CONSECU...

Page 216: ...elete the error when calculate the average value The following values torque average are excepted from the calculation of the average value The average from the previous day exists The average from the previous day any measurement value of the average peri od 100 filter setting value The any measurement value of the average period the average from the previous day 100 filter setting value The aver...

Page 217: ... CM will not be reset MEASURED DATE Shows the date of the measurement or the updated speed reducer diagnosis data base MEAS Shows the measured torque average AVE Set the period to calculate the average value from the day to diagnose The initial val ue of this item is 60 days LATEST MEASURED DAYS Shows the arithmetic mean of the average period certain number of the days which is calculated in the p...

Page 218: ...ppears Move the cursor over the WARNING of the desired axis to invalidate and press Select Invalid and Valid will alternate each time when press the Select Graph display After the measurement the variation can be checked by a graph The graph is updated every 24 hours automatically The measured value and changes of the variation can be displayed on the programming pendant Thus the changes of the to...

Page 219: ...System Setup 9 219 4 Select GRAPH The graph appears 4 5 6 7 8 9 10 1 2 3 ...

Page 220: ...means the torque variation accept high Mid means the torque variation accept mideum Lo means the torque variation accept low When change the torque variation accept high the torque variation accept medium or the torque variation accept low on the each set ting window the lines for Hi Mid and Lo on the graph also correspond to the set ting values In case of the graph above it shows a variation Lo o...

Page 221: ...e Axis Removing the tick in the box hides the axis on the screen Save CSV Pressing the CSV button saves the variation and measured value into the external memory device as CSV format As for the external device it can be saved into both CF card and USB but the data is priory save into the CF card The followings are the name for a file and a folder to be saved File name the name which is set in the ...

Page 222: ...laced and press Select The confirmation dialog appears 6 Select Yes The data of its axis is reset and the replacement day is recorded into the INSPECTION RECORD window The operation is canceled when select No The procedures above can be performed in the lifetime window or the torque monitor window The replacement day is recorded into the INSPECTION RECORD window by performing the procedures above ...

Page 223: ...fy each items if necessary TIME Before the remaining time to the inspection is 0 the message is shown and the in spection signal is ON at the time which is set in this item For example if 100 is set the message is shown and the signal is ON 100 hours before the remaining time to the inspection is 0 The time can be set in the MANAGEMENT mode SIGNAL Set the general purpose output number which notifi...

Page 224: ...yed continuously until the robot controller is inspected Inspection items The contents of the inspection are shown The contents differ depending on the model of manipulators For details of the contents refer to the robots instruction manual corresponding to the model REMAINING The remaining time to the inspection is shown When the SERVO power is ON the measurement automatically starts and the nume...

Page 225: ... and the replacement day by following procedures 1 Select PM in the main menu 2 Select INSPECTION RECORD 3 Select Display and select INSPECTION DATE in the pull down menu Able to confirm the inspection day 4 Select Display and select REPLACEMENT DATE in the pull down menu Able to confirm the replacement day ...

Page 226: ...t can be load save by the external memory device As for the external device menu refer in the to Chapter External Memory Devices of Basic Programming MANUAL for more details 1 Select External memory in the main menu The external memory menu window appears 2 Select Load or Save The load window or the save window is appears 3 Select the System data The system data selection window appears The follow...

Page 227: ...s the life span of the controller components by calculating the consumed amount with considering the usage environment and the load and outputs general purpose signals to be the reference for the replacement time The function overview is described below Target components for diagnosis Regarding the following calculations of the consumed amount and outputs of the general purpose signals to be the r...

Page 228: ...ral purpose output signal temporarily Even if the masking is performed D remains to be displayed for the component judged that it should be replaced Replacement of component Record of replacement date of component When the component is replaced the replacement date year month day can be recorded It can be used for the reference for the next replacement time or for the estimation of the failure mod...

Page 229: ...ears The operation icons on the main menu vary depending on the system usage 2 Select PM HARDWARE Alarm signal setting and unit selection window appears 3 Input the numerical value of the alarm signal When any of components in this controller comes to the replacement time the general purpose output signal which is already set turns ON For example 125 is input ...

Page 230: ...System Setup 9 230 4 Select the unit Or select the unit from DISPLAY in the menu For example COOLING FAN is selected ...

Page 231: ...ent name 3 General purpose output signal valid invalid 4 The first day of use 5 Leftover life judgment When COOLING FAN is selected When CAPACITOR is selected When AMPLIFIER IGBT is selected When CONTACTOR is selected 6 When replaced with a new component select A confirmation dialog box appears When replaced with a new component select YES 1 2 3 4 5 ...

Page 232: ...g the approximate value to the leftover life input the numerical value 0 100 9 When the numerical value displayed in the confirmation dialog box is correct select YES Mask of replacement time display Signal display Perform the masking of the replacement time display according to the following procedures 1 When any of the components comes to the replacement time the message is displayed per unit 2 ...

Page 233: ...ents because only one general purpose output of life diagnosis can be output for one controller That is Replacement time of component Turn ON the general purpose output Check the component and invalidate the output Turn OFF the general purpose output Replacement time of other component Turn ON the general purpose output Display of the numbers of motor revolution and reverse revolution 1 Select PM ...

Page 234: ...e 1 Select of the axis to be reset by moving the cursor to it and then select YES on the dialog box The day of the first use BEGINNING is automatically changed Changing the numbers of revolution and reverse revolution Used when the motor replaced with an used one 1 Select the number of the axis to be reset by moving the cursor to it and then set the number To set the day of the first use BEGINNING...

Page 235: ...atus window is shown 3 Select END The initial window is shown again Each item on the screen represents the following description OPERATE Indicates the cumulative time for executing the move instruction IO WAIT Indicates the cumulative time for which the robots operation is stopped by the WAIT instruction or etc ENERG SAVE Indicates the cumulative time for which the SERVO power is OFF by the energy...

Page 236: ...of the graph is the hour For the item no the value can be set in the range from 96 to 0 DAY is selected The unit of the horizontal axis of the graph is the day For the item no the value can be set in the range from 100 to 3 MONTH is selected The unit of the horizontal axis of the graph is the month For the item no the value can be set in the range from 60 to 3 UPDATE By pressing UPDATE the data ca...

Page 237: ...d ratio of each axis for each JOB JOB Registration For the JOB registered on the JOB MONITOR ENTRY window the measurement is performed A JOB is registered by the following steps The maximum 10 JOBs can be registered 1 Select PM in the main menu 2 Select JOB MONITOR The JOB MONITOR window is shown 3 Select DATA The pull down menu is shown 4 Select JOB MONITOR ENTRY The JOB MONITOR ENTRY window is s...

Page 238: ...red in the JOB MONITOR ENTRY window measurement automatically starts The data is automatically updated every time the playback is performed Measurement is performed for the section from NOP to END or RET of the registered job And if the hold the emergency stop or the alarm occurs during measurement the measurement ends Also if 600 seconds pass after starting the measurement and the conditions ment...

Page 239: ...to the number of pressing PAGE Modify if necessary The data of the current day is updated with the latest data every time a JOB is executed For the previous data the average values of the day are shown The data of the maximum 50 days can be checked Example 3 The hold the emergency stop or the alarm stop occurs during measurement TEST1 JBI NOP measurement starts MOVJ MOVJ measurement ends The hold ...

Page 240: ... a JOB is executed For the previous data the average values of the day are shown The data of the maximum 50 days can be checked 5 Press CLOSE The JOB MONITOR window is shown again Management of Data The job monitor data can be saved by the external memory menu For details of the external memory menu refer to GENERAL OPERATOR S MANUAL Document no E1102000220XX1 01 or higher to chapter External Memo...

Page 241: ...trol group in the pull down menu 4 Set the ITEM Select the item Torque collision detect external value speed FB error pulse in the pull down menu 5 Set the threshold value Move the cursor to VALUE of the desired axis and input the threshold value 6 Set the general purpose output number Move the cursor to OUT of the desired axis and input the general purpose output number Management of data The rob...

Page 242: ...arm 1683 DC24V POWER SUPPLY FAILURE SV occurs This function identifies the position where the ground fault occurred after arising the alarm 1683 DC24V POWER SUPPLY FAILURE SV It is able to identify which axis break line does the ground fault occur by inspecting the each axis from the programming pendant Identify the ground fault of the break line by the following methods 1 Turn the SERVO ON the gr...

Page 243: ...rgency signal is not input Pendant controller external signal The SERVO power is not disconnected by the SERVO power supply individual control function 9 25 3 Operation 9 25 3 1 Occurrence of a DC 24V power supply failure SERVO When detecting either the ground fault or the short circuit of the break line the alarm 1683 DC24V POWER SUPPLY FAILURE SV occurs Restart the control power and perform the ...

Page 244: ...SELECT is detached The emergency button of the programming pendant controller or external signal is pressed The servo power is disconnected by the SERVO power supply individual control function The SERVO alarm occurs 4 Detecting the break line ground fault When the break line ground fault or the short circuit is detected the alarm 1694 GROUND FAULT BRAKE LINE occurs Inspect the break line of the a...

Page 245: ...ng the ROBOT in the main menu 2 Select DATA in the menu The pull down menu appears 3 Select CLEAR The confirmation dialog appears 4 Press YES The related information of the break line ground check is initialized BREAK LINE GROUND CHECK does not appear in the Main Menu until the alarm 1683 DC24V POWER SUPPLY FAILURE SV occurs ...

Page 246: ...uts and 1 output or a circuit with 1 input and 1 output Both system and user section of the safety logic circuit consist of 128 lines Both system and user section of the safety logic circuit are operated in every 2ms cycle Both system and user section of the safety logic circuit can be referred by the all modes regardless the SECURITY mode however the user section can be edit only when the SECURIT...

Page 247: ...al can be used JANCD ASU03 E For both input and output 16 points of general purpose safety I O signal can be used 9 26 2 Changing the SECURITY mode To create edit the safety logic circuit change the SECURITY mode to the SAFETY mode 1 Select SYSTEM INFO from Main Menu The sub menu appears 2 Select SECURITY The SECURITY window appears Select SAFETY MODE 3 Select the desired security mode If the sele...

Page 248: ...f the numerical input display available and hide non available can be switched by selecting the SETTING OF WINDOW in the main menu shown on the programming pendant At factory setting the key pad is set as display available 9 26 3 Available I O signals and instructions in safety logic circuit The following is the explanation of the input and output signals and logic instructions available in the sa...

Page 249: ...ety I O board option is connect ed 4 FS OUT x Functional safety output in the safety logic circuit 64 points ON status OFF status This signal is shown when the functional safety function option is enabled 5 n GSIN x General purpose safety input sig nal 2 points OFF release ON short cir cuit 6 n GSOUT x General purpose output signal 2 points ON output OFF output 7 HOLD Hold OFF Hold signal is not i...

Page 250: ...PROFISafe communication sta tus Communication OK Error communication Appears only when the op tional PROFISafe is en abled 17 R x Work area 128 points auxiliary relay ON status OFF status 18 REMOTE Remote mode REMOTE mode Not RE MOTE mode 19 S EXDSW External enable switch signal in the safety logic circuit ON SERVO ON enabled OFF SERVO OFF status 20 S EXESP External emergency stop signal in the sa...

Page 251: ...nts ON status OFF status This signal is shown when the optional safety field bus function is enabled 28 n SFRON x SERVO ON OFF signal 4 points SERVO ON SERVO OFF 29 SPIN x Specific input signal 32 points ON status OFF status 30 SVON SERVO ON OFF status SERVO ON SERVO OFF 31 SVONRDY0 SERVO ON ready SERVO ON available status SERVO OFF 32 TEACH TEACH mode TEACH mode Not TEACH mode 1 n The number of t...

Page 252: ...refer to chapter 9 26 3 1 Full speed mode 9 n S ONEN x SERVO power supply individual control input signal in the safety logic circuit 4 points Individual control group SER VO OFF status SERVO ON status SERVO ON enabled sta tus 10 S SAFF Safety fence signal in the safety logic circuit Close Open SERVO OFF status 11 S SVON_EN SERVO ON enable signal in the safety logic circuit SERVO ON enabled status...

Page 253: ...circuit is turned ON 14 SVOFF CAT1 Turns OFF the SERVO power supply to the robot Category1 stopped Robot stop request Not ro bot stop request 1 n The number of the safety circuit board Maximum 8 TIMER No Display Contents Note 1 TMR 8 One shot pulse width timer 8 timer 2 TM 4 OFF DE LAY OFF Delay timer 4 timer 3 TM 4 ON DE LAY ON Delay timer 4 timer Comment It is possible to input up to 32 characte...

Page 254: ...speed These are specified in order to control the operation speed so that it does not exceed the robots maximum speed during a test run or a forward backward operation CAUTION When using the full speed test function the robot moves at a high speed Thus make sure to secure a place where the operator can visually check the robots movement in the area outside the robots operating range and perform op...

Page 255: ...here is no message next to STS in the title line while the user section is shown NOTICE There is a case that the system section of the safety logic circuit is not defined at factory setting For the display of the system section SYSTEM is shown in the title line For the display of the user section No message is shown next to STS in the title line 1 1 ...

Page 256: ...d INPUT2 must be set When setting the input 1 or 2 LOGIC is also must to be set OUTPUT is also must be set The same output signal cannot be set to the multiple logic circuit After creating the safety logic circuit the status changes from DONE to NOT DONE The WRITE button is shown on the left down corner of the screen 3 Canceling the edit To start over the editing select CANCEL EDIT from EDIT in th...

Page 257: ... clear the all line select ALL LINE CLEAR from EDIT in the pull down menu 6 Copy Choose the desired area to make a copy and select COPY from EDIT in the pull down menu Go to the area to paste select PASTE from EDIT in the main menu to paste ...

Page 258: ...If press NO the file will not be updated The status remains NOT DONE NOTICE If press YES on the confirmation dialog the all information related to the safety logic circuit is transferred to the safety circuit board as the safety logic circuit file and written in the FLASH ROM of the safety circuit board If select WRITE the all output signals output from the safety circuit board are turned OFF unti...

Page 259: ...sed in the safety logic circuit is shown 1 Select SAFETY FUNC SLC SIGNAL DISPLAY 2 The signals used in the safety logic circuit is shown If the optional safety field bus function is enabled its signals are also shown The signal list when the safety field bus function option is enabled ...

Page 260: ...cy stop Normal External emergency stop input signal Normal Under emergency stop 2 FSBIN GP safety input signal ASF02 or ASU03 OFF release ON short circuit General purpose safety input signal ASF02 or ASU03 ON short circuit OFF release 3 GSIN General purpose safety input signal ASF01 OFF release ON short circuit General purpose safety input signal ASF01 ON short circuit OFF release 4 HOLD Hold ON H...

Page 261: ...put signals are changed outputting the signals that have been output normally may fail This may lead to a serious accident After changing the ON OFF settings of the input signals be sure to confirm the safety logic circuit operates normally 6 PPDSW Programming pendant enable switch signal Grip Not grip SERVO OFF Programming pendant enable switch signal Not grip SERVO OFF Grip 7 PPESP Programming p...

Page 262: ...e SAFETY mode and press ENTER 4 When the correct password is input the mode is changed to SAFETY MODE After changing to the safety mode the icon shown on the status area is changed to 5 After changing the security select each menu in the following order SYSTEM SETUP OPTION FUNCTION SAFETY I O BOARD SETTING 6 Press SELECT on the programming pendant and set the general purpose safety I O board ASF02...

Page 263: ...orm Safety Board FLASH reset 9 Turn OFF ON the YRC1000 Setting for the general purpose safety output signals 1 Select SAFETY FUNC F SAFETY SIGNAL ALLOC The following window is shown The mark at the center of the window indicates ON OFF status means OFF and means ON 2 To use the general purpose safety output signals in the safety logic circuit press SELECT on the programming pendant and set ASF01 E...

Page 264: ...rs in two byte can be input 2 The initial status is set as NOT USED Press SELECT on the programming pendant and select one of NOT USED SAFETY LOGIC CIRCUIT or FUNCTIONAL SAFETY When the functional safety optional is disabled the menu of FUNCTIONAL SAFETY is not shown When the functional safety circuit board is disabled When the functional safety circuit board is enabled NOT USED Not available in t...

Page 265: ... status in the title line becomes NOT DONE and WRITE menu is shown Update the data 4 When the data update is completed the status in the title line becomes DONE and the WRITE menu disappears 5 When either NOT USED or FUNCTIONAL SAFETY is set the output signal in the safety logic circuit is not available 6 The display of input and output signal used in the safety field bust function can be switched...

Page 266: ... 25 x 2 ms It is able to set every 4ms up to 399 996 99 999 x 25 ms 1 Displaying the window Select TIMER DELAY from SAFETY FUNC in the main menu 2 Set up the delay time Set the value of the delay timer to use After the setting the status changes from DONE to NOT DONE WRITE is shown on the left down corner of the screen Safety logic output When setting the 500msec to ON DELAY TIME When setting the ...

Page 267: ...en the file is updated The safety logic circuit file which has been transferred to the safety circuit board is written in the FLASH ROM The status becomes DONE from NOT DONE NOTICE If press YES on the confirmation dialog the all information related to the safety logic circuit is transferred as the safety logic circuit file to the safety circuit board and written in the FLASH ROM of the safety circ...

Page 268: ...ne second one shot signal is output from the general purpose safety output signal 1 Select SAFETY FUNC TIMER DELAY 2 Select PAGE TIMER 3 Input 250 at TIMER1 4 Create the following safety logic circuit 001 DSU 1GSIN1 1 GSOUT1 TMR1 5 When the edit is done select WRITE The safety logic circuit file is transferred to the safety circuit board 1s 1 GSIN1 1 GSOUT1 ...

Page 269: ...e When both the S EXDSW signal and the enable switch on the programming pendant are ON the SERVO power can be turned ON When the S EXDSW signal is not used in the safety logic circuit the machine safety board regards this as the short circuit status S EXESP EXESP This is the external emergency stop input signal When the S EXDSW signal is turned OFF the sig nal performs the similar control to the E...

Page 270: ... the S SAFF signal is turned OFF the signal performs the same control as the SAFF signal The hard wired SAFF signal is always monitored When either the SAFF signal or the S SAFF signal is OFF the SERVO power supply is turned OFF S SVON_EN None For details refer to chapter 9 26 13 Enable switch link function MS OUT None This is the data to transfer the data created in the safety logic circuit to th...

Page 271: ...nipulator is stopped by the signals input from the safety logic circuit None The appropriate signals do not exist Signal name Message on the programming pendant None S FST Full speed test mode Safety logical circuit EXESP Robot is stopped by external emergency stop S EXESP Robot is stopped by external emergency stop Safety logical circuit None S EXDSW EXDSW signal is OFF Safety logical circuit SAF...

Page 272: ...the security When the MAINTENANCE mode is started Select SECURITY from SYSTEM 3 Change to the SAFETY mode 1 Select SAFETY MODE 2 Input the password for the SAFETY mode and press ENTER 4 When the correct password is input the mode is changed to SAFETY MODE After changing to the SAFETY mode the icon shown on the status area is changed to 5 After changing the security select each menu in the followin...

Page 273: ...The SERVO ON OFF status when the SERVO ON Enable S SVON_EN signal is enabled Note Not Used means the S EXDSW signal is not used as the output signal of the safety logic circuit The Timing Chart When the SERVO ON Enable S SVON_EN Signal is Enabled NOTICE When this function is enabled configure the circuit of the safety PLC optional to turn OFF the servo ON enable signal S SVON_EN by releasing the E...

Page 274: ...01 40797 40796 40795 40794 40793 40792 40791 40790 Safety log ic circuit Safety log ic circuit Safety log ic circuit Safety log ic circuit Safety log ic circuit Safety log ic circuit Safety log ic circuit Safety log ic circuit Specific input 16 Specific input 15 Specific input 14 Specific input 13 Specific input 12 Specific input 11 Specific input 10 Specific input 9 SPIN16 SPIN15 SPIN14 SPIN13 SP...

Page 275: ...P safety Input sig nal GP safety Input sig nal GP safety Output signal GP safety Output signal GP safety Input sig nal GP safety Input sig nal GSOUT 2 GSOUT 1 GSIN 2 GSIN 1 GSOUT 2 GSOUT 1 GSIN 2 GSIN 1 ASF01 4 ASF01 4 ASF01 4 ASF01 4 ASF01 3 ASF01 3 ASF01 3 ASF01 3 80427 80426 80425 80424 80423 80422 80421 80420 GP safety Output signal GP safety Output signal GP safety Input sig nal GP safety Inp...

Page 276: ...80564 80563 80562 80561 80560 Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus SFBIN40 SFBIN39 SFBIN38 SFBIN37 SFBIN36 SFBIN35 SFBIN34 SFBIN33 80577 80576 80575 80574 80573 80572 80571 80570 Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Saf...

Page 277: ...eld bus Safety Field bus Safety Field bus SF BOUT40 SF BOUT39 SF BOUT38 SF BOUT37 SF BOUT36 SF BOUT35 SF BOUT34 SF BOUT33 80657 80656 80655 80654 80653 80652 80651 80650 Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus Safety Field bus SF BOUT48 SF BOUT47 SF BOUT46 SF BOUT45 SF BOUT44 SF BOUT43 SF BOUT42 SF BOUT41 80667 80666 80...

Page 278: ... 2 ASU03 2 80717 80716 80715 80714 80713 80712 80711 80710 GP safety Output signal GP safety Output signal GP safety Output signal GP safety Output signal GP safety Output signal GP safety Output signal GP safety Output signal GP safety Output signal FSBOUT8 FSBOUT7 FSBOUT6 FSBOUT5 FSBOUT4 FSBOUT3 FSBOUT2 FSBOUT1 ASF02 2 ASU03 2 ASF02 2 ASU03 2 ASF02 2 ASU03 2 ASF02 2 ASU03 2 ASF02 2 ASU03 2 ASF02...

Page 279: ...fety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal FSBIN8 FSBIN7 FSBIN6 FSBIN5 FSBIN4 FSBIN3 FSBIN2 FSBIN1 ASF02 5 ASU03 5 ASF02 5 ASU03 5 ASF02 5 ASU03 5 ASF02 5 ASU03 5 ASF02 5 ASU03 5 ASF02 5 ASU03 5 ASF02 5 ASU03 5 ASF02 5 ASU03 5 80777 80776 80775 80774 80773 80772 80771 80770 GP safety Output signal GP sa...

Page 280: ...al FSBOUT8 FSBOUT7 FSBOUT6 FSBOUT5 FSBOUT4 FSBOUT3 FSBOUT2 FSBOUT1 ASF02 7 ASU03 7 ASF02 7 ASU03 7 ASF02 7 ASU03 7 ASF02 7 ASU03 7 ASF02 7 ASU03 7 ASF02 7 ASU03 7 ASF02 7 ASU03 7 ASF02 7 ASU03 7 80827 80826 80825 80824 80823 80822 80821 80820 GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Inp...

Page 281: ...rcuit Circuit Circuit Circuit Circuit MS OUT32 MS OUT31 MS OUT30 MS OUT29 MS OUT28 MS OUT27 MS OUT26 MS OUT25 81367 81366 81365 81364 81363 81362 81361 81360 Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Circuit Circuit Circuit Circuit Circuit Circuit Circuit Circuit MS OUT40 MS OUT39 MS OUT38 MS OUT37 MS OUT36 MS OUT35 MS OUT34 MS OUT33 81...

Page 282: ...it Circuit Circuit Circuit Circuit FS OUT16 FS OUT15 FS OUT14 FS OUT13 FS OUT12 FS OUT11 FS OUT10 FS OUT9 81427 81426 81425 81424 81423 81422 81421 81420 Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Circuit Circuit Circuit Circuit Circuit Circuit Circuit Circuit FS OUT24 FS OUT23 FS OUT22 FS OUT21 FS OUT20 FS OUT19 FS OUT18 FS OUT17 81437 ...

Page 283: ...85 81484 81483 81482 81481 81480 GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal FSBIN16 FSBIN15 FSBIN14 FSBIN13 FSBIN12 FSBIN11 FSBIN10 FSBIN9 ASU03 1 ASU03 1 ASU03 1 ASU03 1 ASU03 1 ASU03 1 ASU03 1 ASU03 1 81497 81496 81495 81494 81493 81492 81491 81490 ...

Page 284: ...OUT14 FS BOUT13 FS BOUT12 FS BOUT11 FS BOUT10 FSBOUT9 ASU03 3 ASU03 3 ASU03 3 ASU03 3 ASU03 3 ASU03 3 ASU03 3 ASU03 3 81547 81546 81545 81544 81543 81542 81541 81540 GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal FSBIN16 FSBIN15 FSBIN14 FSBIN13 FSBIN12 FS...

Page 285: ...OUT14 FS BOUT13 FS BOUT12 FS BOUT11 FS BOUT10 FSBOUT9 ASU03 5 ASU03 5 ASU03 5 ASU03 5 ASU03 5 ASU03 5 ASU03 5 ASU03 5 81587 81586 51585 81584 81583 81582 81581 81580 GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal GP safety Input sig nal FSBIN16 FSBIN15 FSBIN14 FSBIN13 FSBIN12 FS...

Page 286: ...S BOUT10 FSBOUT9 ASU03 8 ASU03 8 ASU03 8 ASU03 8 ASU03 8 ASU03 8 ASU03 8 ASU03 8 81647 81646 81645 81644 81643 81642 81641 81640 PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFLIN8 PFLIN7 PFLIN6 PFLIN5 PFLIN4 PFLIN3 PFLIN...

Page 287: ... tion Output signal PFL func tion Output signal PFL func tion Output signal PFL func tion Output signal PFL func tion Output signal PFL func tion Output signal PFLOUT1 6 PFLOUT1 5 PFLOUT1 4 PFLOUT1 3 PFLOUT1 2 PFLOUT1 1 PFLOUT1 0 PFLOUT9 ASF04 1 ASF04 1 ASF04 1 ASF04 1 ASF04 1 ASF04 1 ASF04 1 ASF04 1 81707 81706 81705 81704 81703 81702 81701 81700 PFL func tion Output signal PFL func tion Output s...

Page 288: ...t sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFL func tion Input sig nal PFLIN24 PFLIN23 PFLIN22 PFLIN21 PFLIN20 PFLIN19 PFLIN18 PFLIN17 ASF04 2 ASF04 2 ASF04 2 ASF04 2 ASF04 2 ASF04 2 ASF04 2 ASF04 2 81757 81756 81755 81754 81753 81752 81751 81750 PFL func tion Input sig nal PFL func tion Inpu...

Page 289: ...Output signal PFL func tion Output signal PFL func tion Output signal PFL func tion Output signal PFL func tion Output signal PFL func tion Output signal PFL func tion Output signal PFLOUT2 4 PFLOUT2 3 PFLOUT2 2 PFLOUT2 1 PFLOUT2 0 PFLOUT1 9 PFLOUT1 8 PFLOUT1 7 81787 81786 81785 81784 81783 81782 81781 81780 81797 81796 81795 81794 81793 81792 81791 81790 PFL func tion Output signal PFL func tion ...

Page 290: ...rmation dialog appears and select YES 3 The safety logic circuit file File name YSFLOGIC DAT is saved in the specified device 9 26 16 2 Loading the file The safety logic circuit file can be loaded from the SD card USB memory stick of the programming pendant or the USB memory stick of the CPU board Make sure the medium is inserted into the device of the load destination Perform the following operat...

Page 291: ...MENT mode The alarm occurs when the file does not match the file written in the FLASH ROM of the safety circuit board For example if the safety circuit board is replaced the spared part the alarm will occur When the alarm occurs perform the following procedures to restore 9 26 17 1 Initializing the safety logic circuit file 1 Displaying the window Select SEECURITY from SYSTEM in the main menu 2 Ch...

Page 292: ...NITIALIZE from FILE in the main menu The I O data file list is displayed and then select YSF LOGIC FILE 5 Perform the initialization Select ENTER The confirmation dialog appears Select YES The file written in the FLASH ROM of the machine safety circuit board type YSF21 E is initialized ...

Page 293: ... The safety logic circuit file written in the FLASH ROM of the safety circuit board is cleared NOTICE After performing the Safety circuit board FLASH erase and turning the YRC1000power supply ON OFF Next time when turning the power supply ON the alarm 0300 VERIFY ERROR SYSTEM CONFIG DATA occurs Therefore when performing the Machine safety board FLASH erase the Safety FLASH restart needs to be perf...

Page 294: ...al1 1 GSOUT1 while the universal safety input signal1 1 GSIN1 and 2 2 GSIN2 are ON 2 Displays the time chart 3 Verifying the safety logic circuit Switch ON the general purpose safety signal 1 and 2 The mark becomes Signal 1 General purpose safety input signal 1 1 GSIN1 Signal 2 General purpose safety input signal 2 1 GSIN2 Logic AND Output signal General purpose output signal 1 1 GSOUT1 1 GSIN and...

Page 295: ...ng the programming pendant and switching the general purpose safety signal ON The mark of the general purpose safety output signal 1 becomes after one second passed The safety logic circuit example 3 Signal 1 Programming pendant emergency button PPESP Signal 2 NOT general purpose safety input signal 1 1 GSIN1 Logic AND Output signal General purpose safety output signal 0 1 GSOUT0 Timer ON delay ti...

Page 296: ...llowing safety logic circuit is created 2 Displays the time chart Signal 1 TEACH mode TEACH Signal 2 general purpose safety input signal 1 1 GSIN1 Logic AND Output signal Robot deceleration to a stop SVOFF CAT1 Start decelerating processing End decelerating processing Under the TEACH mode and 1 GSIN1 is ON so that the SERVO will be turned ON after the decelerating processing 1 2 3 ...

Page 297: ...of the programming pendant NOTICE For the safety logic circuit of the YRC1000 even if the robot deceleration to a stop SVOFF CAT1 is turned ON the robot stops its operation instantly without decelerating Under the play mode if the robot deceleration to a stop SVOFF CAT1 is turned ON the robot decelerates and stops its operation NOTICE When the robot is stopped by the safety logic circuit signal Ro...

Page 298: ...ted 2 Displays the time chart 3 Verifying the safety logic circuit When the one of the programming pendant emergency stop controller emergency stop or the external emergency stop is inputted the mark of the general purpose safety output signal 1 becomes Signal 1 Programming pendant emergency stop PPESP Signal 2 Controller emergency stop PPESP Signal 3 External emergency stop EXESP Logic AND Output...

Page 299: ...afety output signal 1 GSOUT1 is ON for one second 1 Select SAFETY FUNC TIMER DELAY 2 Select PAGE TIMER 3 Input 250 at TIMER1 4 Create the following safety logic circuit 001 DSU 1GSIN1 1 GSOUT1 TMR1 When 1 GSIN 1 signal is turned ON 1 GSOUT 1 is ON for one second When the data is updated correctly the status on the title line is changed from NOT DONE to DONE 1s 1 GSIN1 1 GSOUT1 ...

Page 300: ...ons are satisfied but it is too short for visual check Thus display chapter 9 26 5 Signal list window and the SAFETY LOGIC CIRCUIT window together to check the ON OFF status of the input signal The safety logic circuit example 6 The following is the setting example of the one second one shot output signal when two signals are turned ON at the same time 1 The following safety logic circuit is creat...

Page 301: ... Select each menu in the following order SYSTEM SETTING CONTROL GROUP Check each control group is allocated to which ON ENABLE signal For the above example the allocation of control group and ON ENABLE signal is the following Control group R1 is allocated to ON ENABLE 1 signal ON_EN1 Control group S1 is allocated to ON ENABLE 2 signal ON_EN2 Control group S2 is allocated to ON ENABLE 3 signal ON_E...

Page 302: ...SERVO OFF the servo is not turned ON for the control group allocated to the ON_ENABLE signal For details of the SERVO power individual control function refer to INSTRUCTIONS FOR INDEPENDENT COORDINATED CONTROL FUNCTION manual in chapter SERVO Power Individual Control Function The safety logic circuit example 8 In the following example the specific input signal is output to the safety PLC optional ...

Page 303: ...urned ON 3 When S FST signal is turned ON Full speed test mode Safety logic circuit is shown on the message area of the programming pendant Also the control status signal 80047 is turned ON NOTICE S FST signal is enabled only in the TEACH mode The safety logic circuit example 10 The method to use MS OUT signal is explained in the following 1 The following safety logic circuit is created 01 1 GSIN1...

Page 304: ...etails to restore 4776 M SAFETY YSF LOGIC FILE SIGNAL ERR 0 Start up in reading infor mation from the FlashROM of ASF01 board ASF01 board has detected an un defined signal The error of the safety logic circuit is de tected when startup Check the safety log ic circuit because an invalid I O signal is used by the safety logic signal 1 In the receiving information on safe logic circuit infor mation A...

Page 305: ...send the safety logic circuit file 4 Safety signal board alloc information transmission error was detected An alarm occurred while transferring the safety logic circuit file to the machine safe ty circuit board Reset the alarm and re send the safety logic circuit file 253 M safety command recep tion time out was detected No response from the machine safety cir cuit board while transferring the saf...

Page 306: ...t B the judgment is made as follows Specify whether to enable or disable the monitoring signal of the GP safety output signal on the following window 1 Turn ON the YRC1000 power while pressing MAIN MENU of the PP 2 Select SYSTEM SECURITY and then change the SECURITY mode to the SAFETY mode 3 Select SYSTEM SETUP OPTION FUNCTION SAFETY LOGICAL CIRCUIT SETTING The following window appears Output valu...

Page 307: ...ty monitoring signal NOTICE When the monitoring signal is set to UNUSED the monitoring of the safety GP output monitoring signal is disabled 5 Select DETAIL of XOUT Feedback SETTING The following window appears and the setting can be performed NOTICE Perform this step 5 only in the system where the safety I O expansion board optional is enabled The setting can be switched by pressing SELECT After ...

Page 308: ... and select YES At the sound of the beep the re setting is completed and the message on the PP disappears 8 Turn the YRC1000 power OFF and then ON again 9 Select SYSTEM SECURITY and change the SECURITY mode to the SAFETY mode 10 Select SAFETY FUNC SAFETY LOGIC CIRCUIT The following window appears and the setting of the safety logic circuit can be performed ...

Page 309: ...eedback signal monitor ing signal GSOUT1 GSEDM1 GSOUT2 GSEDM2 The following signals can be specified only in the system where the safety I O expansion board optional is enabled FSBOUT1 XOUT1 XEDM1 FSBOUT1 XOUT2 XEDM2 FSBOUT1 XOUT3 XEDM3 FSBOUT1 XOUT4 XEDM4 FSBOUT1 XOUT5 XEDM5 FSBOUT1 XOUT6 XEDM6 FSBOUT1 XOUT7 XEDM7 FSBOUT1 XOUT8 XEDM8 FSBOUT1 XOUT9 XEDM9 FSBOUT1 XOUT10 XEDM10 FSBOUT1 XOUT11 XEDM11...

Page 310: ...System Setup 9 310 12 After completing the writing press CONFIRM and then YES 13 The setting is completed when the status of the safety logic circuit turns to DONE ...

Page 311: ...ignals The detection items are described as follows Tab 9 1 The List of the SERVO OFF factors by main CPU instructions Displayed item Secondary indication EX SERVO OFF1 HOLD STOP System input signal number 40065 EX SERVO OFF2 CATEGORY0 STOP System input signal number 40066 EX SERVO OFF3 CATEGORY1 STOP System input signal number 40064 TEACH PLAY MODE CHANGE None PLAY TEACH MODE CHANGE None MAIN CPU...

Page 312: ...the functional safety CATEGORY1 SAFETY LOGIC CIRCUIT Category 1 stop request from the safety logic circuit CATEGORY1 FUNCTION SAFETY Category 1 stop request from the functional safety ASF01 ALARM Alarm of the machine safety CATEGORY0 STOP The time of the machine safety cat egory 0 stop timer is up and switch OFF the SERVO of the machine safety CATEGORY1 STOP The time of the machine safety cat egor...

Page 313: ...the control group connected to ON_ENABLE3 ON ENABLE4 Safety circuit board No 1 to 8 SERVO OFF of the control group connected to ON_ENABLE4 CATEGORY ON ENABLE1 Safety circuit board No 1 to 8 The time of the category 0 is up after inputting the ON_ENABLE1 signal then switch OFF the SERVO of the machine safety CATEGORY ON ENABLE2 Safety circuit board No 1 to 8 The time of the category 0 is up after i...

Page 314: ...67 INDIVIDUAL HOLD System input signal number 40270 to 40287 TASK 0 to TASK 15 HOLD SHOCK SENSOR None HOLD DATA TRANSMISSION None HOLD API CTL None HOLD API None HOLD HIGH SPEED ES None SKIP WAIT INST STOP PLAYBACK Task number TASK 0 to TASK 15 GUN TEACH SIG OFF STOP PLAY BACK System input signal number 41231 GUN TEACH STEPOVER STOP PLAY BACK None ALARM STOP QUE None ...

Page 315: ... FACTOP MONITOR can be referred by following procedures Operation Select ROB STOP FACTOR MMONITOR under the IN OUT in the main menu The RB STOP FACTOR MONITOR window appears The following items are displayed on the RB STOP FACTOR MONITOR window DETECT TIME Shows the time when the robot stop factor was detected The factor detected by the main CPU is displayed on the first line The factor s detected...

Page 316: ... MANAGEMENT or higher mode CLEAR is displayed 2 Select CLEAR and the confirmation dialog Initialize appears Press YES and the all information of the robot stop factor is cleared NOTICE The robot stop factor information is not saved when turning the power supply OFF Therefore it will be initialized when turning the power supply ON again If it is necessary to save the data please store the data into...

Page 317: ...e robot system 1 Turn the power ON while pressing MAIN MENU button MAINTENANCE mode screen starts up 2 Select SYSTEM under the main menu Sub menu is shown 3 Select SECURITY Mode selection screen is shown 4 Press SELECT to select the mode Mode selection list is shown 5 Move the cursor to SAFETY MODE and select Password input box is shown ...

Page 318: ...erator can set or modify the setting items for robot detachment function in detail setting screen The specified parameters are to be set automatically according to the setting contents in detail setting screen 1 Select SYSTEM under main menu Sub menu is shown 2 Select SETUP SETUP screen is shown 3 Move the cursor to OPTION FUNCTION and select OPTION FUNCTION screen is shown ...

Page 319: ...or to the JOB setting item and select Every pressing the SELECT switches the indication between and Description for the setting items on JOB When is selected The JOB including detached group cannot be started up When is selected The JOB including detached group can be started up However the detached axes cannot be operated 7 Press ENTER Confirmation message for parameter change is shown 8 Press EN...

Page 320: ...ing performed so that no other person closes the safety fence View the robot from the front whenever possible Always follow the predetermined operating procedure Always keep in mind emergency response measures against the robots unexpected movement toward a person Ensure a safe place to retreat in case of emergency CAUTION If operation of the robot cannot be stopped in an emergency personal injury...

Page 321: ...ers are to be set automatically according to the setting contents in detail setting screen 1 Select SYSTEM under the main menu Sub menu is shown 2 Select SETUP Setting selection screen is shown 3 Move the cursor to OPTION FUNCTION and select OPTION FUNCTION screen is shown 4 Move the cursor to AXES DETACHMENT and select Detail setting screen for axes detachment function is shown ...

Page 322: ...ontents Move the cursor to the target axis and select to change the setting Select ATTACHED or DETACHED 7 Press ENTER Confirmation message for parameter change is shown 8 Select YES to confirm the change System parameters are to be set automatically then the screen returns to the option function screen ...

Page 323: ...s Playback Test run JOB registration insert modify delete JOBS in the target control group Variable registration Second home position registration Home position registration Work home position registration NOTICE Use the robot detachment function chapter 9 28 when performing the playback operation in the state that the specific manipulator the base or the station is detached Followings are the err...

Page 324: ...reful to the robots motion and the interference between the robot and the peripheral devices The axes detachment function doesn t restrict the following operations though be careful when performing JOG operation link cartesian user tool cylindrical and I O JOG Next Back operation Variable movement Second home position movement Work home position return 3 Restriction in using with other function Be...

Page 325: ...UT window is shown 3 Select SETTING of DISPLAY in the pull down menu The USER GROUP INPUT SETTING window is shown 4 The user group input is set START Specify the first number of the general purpose input signal to be allocated LENGTH Specify the number of the signals which is allocated to one group 1 to 32 When the parity check is specified the parity bit is the highest bit When the length is 1 th...

Page 326: ...ual operation is possible Blank Normal status 9 30 2 User group output 9 30 2 1 User group output setting Set the security to the MANAGEMENT mode 1 Select I O in the main menu 2 Select USER GROUP OUTPUT The USER GROUP OUTPUT window is shown SIM Normally the input status of the user group cannot be changed by manual operation However the status can be set to be changeable for the operation check an...

Page 327: ...utput signal to be allocated LENGTH Specify the number of the signals which is allocated to one group 1 to 32 When the parity check is specified the parity bit is the highest bit When the length is 1 the parity check cannot be specified PARITY Specify the parity check NONE Parity check is not specified ODD Odd parity is specified EVEN Even parity is specified NAME The group signal name is set 1 2 ...

Page 328: ...up output 1 Select I O in the main menu 2 Select USER GROUP OUTPUT The USER GROUP OUTPUT window is shown VALUE The output status of the user group PARITY Specify the parity check No parity check 0 1 ERR Parity error NAME The group signal name 1 2 3 ...

Page 329: ...ramming pendant turn ON the power 2 Select SYSTEM in the main menu 3 Select SYSTEM in the main menu 4 Select SETUP 5 Select OPTION FUNCTION 6 Select DETAIL of the variable allocation The DETAIL window of the variable allocation is shown The number can be changed by selecting or inputting the number directly The changeable minimum and maximum value are shown in RANGE Since the global variable share...

Page 330: ...ES for all the confirmation dialog of initialization 9 After the initialization of file is completed the option function window is shown NOTICE When the position variable allocation is changed not only the data of variable variable name but also the following files are cleared Be sure to handle the data properly User coordinate Memory play file Spot monitor data Robot calibration data Conveyor cal...

Page 331: ...checked by the following procedures 1 Select SYSTEM INFO in the main menu 2 Select CONTROLLER INFORMATION 3 Select DISPLAY 4 Select OPTION BOARD INFO The OPTION BOARD INFO window is shown Move the cursor to the option board to show the details 5 Press SELECT The setting contents of the option board information is shown ...

Page 332: ...hile the CONTROLLER INFORMATION window is shown the following display is shown by performing the bilingual operation SHIFT and AREA on the programming pendant are pressed Select CONTROLLER INFORMATION from SYSTEM INFO once again ...

Page 333: ...ENANCE mode the EDITING mode or higher Load Perform in the MAINTENANCE mode the MANAGEMENT mode As for the load save procedures refer to chapter 10 2 Backup by CMOS BIN at page 336 Target Area All areas of the internally stored data Note that the monitoring time is not loaded 10 1 1 2 CMOSBK BIN This data is used in the automatic backup function Save Saves with the preset conditions in the normal ...

Page 334: ...ed NOTICE The water proof function of the Pendant is not effective while the USB memory is connected If USB memory is connected constantly there is a risk it drops off Use SD card if there is no measures to maintain water proof function or to prevent USB memory from dropping off Recommended SD card No Manufacturer Model Capacity 1 Hagiwara Solutions NSD6 512MH A01SDI YE 512 MB 2 Hagiwara Solutions...

Page 335: ...the USB connector of the CPU board Be careful about the insertion direction of the connector The USB memory should be inserted slowly with the upper surface right Forcible insertion may result in the damage of the USB memory and the USB connector USB connector 1 ...

Page 336: ...troller power supply while pressing MAIN MENU 2 Insert a SD card into the SD card slot on the programming pendant When USB memory is used instead of SD card mount USB memory and select one among USB PENDANT USB1 CONTROLLER and USB2 CONTROLLER in the DEVICE 3 Select EX MEMORY under the main menu The sub menu appears 4 Select SAVE The items marked with can not be selected The save display appears Se...

Page 337: ...the data stored in the portable memory device make sure to keep the device under an appropriate management 10 2 2 CMOS BIN load Follow the procedures below to load CMOS BIN 1 Turn ON the YRC1000 power supply while pressing MAIN MENU 2 Change the SECURITY mode to the MAINTENANCE mode or higher mode 3 Insert a SD card into the SD card on the programming pendant When USB memory is used instead of SD ...

Page 338: ...d 10 3 Automatic Backup function 10 3 1 Objective With the automatic backup function the data saved in the YRC1000 such as system setting or operational condition are collectively backed up in the SD card which is stored in the programming pendant or the selected device at the automatic backup window Able to back up to the following devices The SD card of the programming pendant The SD card of the...

Page 339: ...rminated with an error during the play back operation or while the robot is in motion so that the automatic backup can not be operated Set the automatic backup function to be executed while the robot is not in the playback status and while the robot is stopped The automatic backup function has the following functions and features No Function Feature Explanation 1 Cyclic backup In the teach mode th...

Page 340: ... this operation does not affect the other operations When other operations affect the back up operation the backup is suspended and retried later The backup operation hardly affects the other operations so that the programming pendant can be used even during the backup operation 7 Backup in binary The data is saved as binary data Backup in binary allows the system to be easily and speedily restore...

Page 341: ... perform the automatic backup are available Cyclic backup Backup when switching modes Backup when start up and Backup when inputting specified signals The automatic backup can be performed only when the robot is not during playback and the robot is stopped Automatic backup function can be set from the command of the optional high speed ethernet server function ...

Page 342: ...isplay appears 10 3 3 2 The memory medium of the main CPU board Set the following procedures in advance to back up to the SD card of the ACP01 board If the following procedures are not done SD card Controller would not be shown on the device list of the auto backup set display 1 Turn ON the Power supply while pressing the MAIN MENU on the programming pendant 2 After starting MAINTENANCE mode chang...

Page 343: ...kup function and the exclusive process would be run Therefore the save time of the auto backup will extend Normally it takes about three minutes to finish backing up However duplication access to the SD card of the ACP01 board takes three to ten minutes 10 3 3 3 RAMDISK on the main CPU board RAMDISK will be shown when the high speed Ethernet server function is effective Refer to the instruction of...

Page 344: ...nt capacity of the SD card From a specified starting time TEACH MODE Editing Access ing to the memo ry Retry Retry When editing is interrupted Backup Error PLAY MODE REMOTE MODE Executing JOBs Disabled Disabled When stopped Backup Error When a specified signal 40560 is input TEACH MODE Error Error Backup Error PLAY MODE REMOTE MODE Disabled Disabled Backup Error When switching the mode from the TE...

Page 345: ...p process a few extra seconds are needed to start up the robot controller Backup when specific signal is input While the robot controller memory is edited such as overwriting the backup operation becomes an error even if there is an input to a specific signal 40560 To start the specific input backup perform it while the robot program is stopped and a JOB or file is not being modified Also since th...

Page 346: ...tes 24 hours RETRY CYCLE 60 minutes Fig 10 2 Example 2 NOTICE While a JOB is being executed the automatic backup or retry is not performed Also after an error occurs in writing into the selected device the retry is not performed until the next backup starting time Power ON Backup cycle Retry cycle Base time 1st day Backup Power ON 2nd day Retry cycle 3rd day 1st day Base time Backup cycle Backup 1...

Page 347: ...e NOTICE With the version in which STORED FILE SETTING is settable the capacity of a SD card inserted into the programming pendant is checked when the setting window appears Therefore a few seconds may be needed to open the setting window and an error may occur if no SD card is inserted When changing the settings of STORED FILE SETTING or executing ARRANGE the files CMOSBK BIN and CMOSBK BIN denot...

Page 348: ...CKUP TIME The first automatic backup is performed at the first BACKUP TIME after the power of the robot controller is turned ON The automatic backup after the first time is performed at the interval of BACKUP CYCLES The reference time ranges from 0 00 to 23 59 BACKUP CYCLE Specify the length of time for a cycle to back up After the first backup the next backup is performed automatically in the tim...

Page 349: ...unction to be valid or invalid when an alarm occurs Each time SELECT is pressed INVALID and VALID are displayed alternately DEVICE Press SELECT to display the device list STORED FILE SETTING Set the number of files to be stored by the automatic backup function The number mentioned on the right side of this item with Max indication is the maximum number of files that can be stored in the SD card in...

Page 350: ...en setting the bit of RS096 parameter shown below to 1 the corresponding items are restricted The restricted items are indicated with INVALID in the display and inputting modification to the item becomes impossible Also the automatic backup does not function with the restricted items Output the Backup Processing Status Able to confirm the backup processing status by the system output signal 50766 ...

Page 351: ...tore from the SD card of the programming pendant or USB memory when backup is done at the optional high speed Ethernet server function command Prepare either of the SD card or the USB memory to make copies Loading Procedure To restore from the SD card of the programming pendant perform the following procedures No 1 to 8 To restore from the SD card on the ACP01 base board perform the following proc...

Page 352: ...eplacement confirmation Select YES if the AIF ACP01 board has been replaced or select NO if it has not been replaced Selecting YES initializes the system monitoring time Selecting NO continues the counting of the current system s monitoring time 7 Select from the confirmation dialog box The dialog box appears for the loading confirmation Select YES in the loading confirmation dialog box to start l...

Page 353: ...O cumulative time display will continue 14 Select from the confirmation dialog box The dialog box appears for the loading confirmation Selecting YES in the confirmation dialog starts loading the content of CMOSBK BIN to CMOS of the ACP01 board 15 Select YES CAUTION Note that executing SYSTEM RESTORE or SYSTEM RESTORE ACP01 replaces the current CMOS data with the data of the file CMOSBK BIN or CMOS...

Page 354: ...tion Operate after the back up is completed The automatic backup window cannot be called to display while the automatic backup is being processed 3551 Under automatic backup oper ation Operate SORT FILE after the backup is completed The file arrangement can not be operated during the automatic backup operation 3560 Failed in sorting backup file Failed to re arrange the backup file for another reas...

Page 355: ...nds after the YRC1000 power supply is turned on In case the versions of ACP01 and the programming pendant matches 1 Automatic upgrade process completes and the communication process between ACP01 and the programming pendant is restarted 2 Initial window appears approx 50 seconds later Automatic upgrade of programming pendant In case that the pendant application version of the programming pendant i...

Page 356: ...uto upgrade process press all of the INTERLOCK 5 SELECT keys at the same time to start NOTICE DO NOT turn off the main power supply during automatic upgrade process In case the main power supply is turned off exercise the following process Turn on the main power supply of robot controller Automatic upgrade might be exercised again In case error occurs during automatic upgrade process 1 Prepare SD ...

Page 357: ...c upgrade process 1 Prepare SD card for upgrading or USB memory 2 Press 2 8 and HIGH SPEED at the same time a Upgrade of the OS of Programming Pendant 3 Press INTERLOCK 8 and SELECT at the same time 4 Exercise manual upgrading a Refer to Upgrade Procedure Manual E1102000223XX01 and higher for detail Pendant software upgrade failed Cause version txt file acquisition via FTP failed Remedy turn the p...

Page 358: ... the Communication is selected in other than REMOTE mode 4 Select YES to disconnect the communication between the controller and the programming pendant After disconnecting the communication the message is displayed 5 Press OK on the message dialog otherwise the window is closed automatically after 10 seconds since the window appears on the screen and then the programming pendant startup window is...

Page 359: ...t only the programming pendant while the main power supply of the controller is ON If unable to operation the robot by the programming pendant causing from the communications error of the programming pendant recover the programming pendant by following procedures 1 Confirmation of the 7SEG LED DS1 display on the JANCD ACP01 E Check the 7SEG LED on the JANCD ACP01 E NOTICE Check that an alphabet le...

Page 360: ... Press Select key The touch panel becomes invalid When the touch panel is invalid an icon which shows the invalidating the touch panel is displayed on the status area and the message Touch operation is invalid is displayed on the message area Validate the Touch Panel 1 Push down the INTER LOCK AUX keys at the same time The confirmation dialog to validate the touch panel appears 2 Move the focus ar...

Page 361: ...power is ON Confirm that the servo power is OFF before rebooting 1 Select SYSTEM INFO CPU RESET in the main menu 2 Confirm the SERVO power is OFF and select RESET 3 The confirmation dialog appears Select YES to reboot the robot system 4 If the operation to reboot the robot system is performed when the SERVO power is ON the following error message appears Select CANCEL to cancel the error message ...

Page 362: ...de In the OPERATION mode or EDITING mode only reference of status setting is possible 1 Turn the power supply ON while pressing Main Menu simultaneously 2 The SECURITY mode is changed to the MANAGEMENT mode 3 Select SYSTEM from the main menu The system window appears 4 Select SETUP The SETUP window appears The I O data marked with cannot be selected 5 Select IO MODULE The current status of the mou...

Page 363: ... for the addition of the I O module is complete NOTICE If there is a difference between the displayed contents and the actual mounted status confirm the status again If the status is correct the I O module may be defective Contact the local YASKAWA branch office ST Station address of I O module DI Number of contact input points1 1 A hyphen indicates that the corresponding I O section is not mounte...

Page 364: ...nce 3 Select the allocation mode to set To operate the I O signal allocation automatically select the allocation mode AUTO To operate the I O signal allocation manually select the allocation mode MANUAL Selected allocation mode appears 4 Select DETAIL under the EXTERNAL IO ALLOCATION The External Input Signals Allocation window appears When select the AUTO skip the following procedures from No 5 t...

Page 365: ...n 8 Press ENTER The External Output Signals Allocation window appears 9 Like the case of the external input signal select modify the external output signal Repeat select modify until it becomes the desired allocation 10 Press ENTER The confirmation dialog box appears 11 Select YES The settings are confirmed and the SETUP window reappears Explanation about the External I O Signal Allocation Window ...

Page 366: ...eneral I O board JANCD YIO21 1 to 13 Optional I O board which is connected to the JANCD YSF21 using a serial communication cable The serial communication station number is determined by the rotary switch setting on each board 16 The first fieldbus board Normally optional board inserted into CN1 of the riser card in the CPU rack 17 The second fieldbus board Normally optional board inserted into CN2...

Page 367: ...herNet IP board PCU ETHIO 1 to 251 Network communication station number 1 to 251 Adapter station of Eth erNet IP board PCU ETHIO Scanner allocation number sequence 252 Unallocated I O area of channel 1 253 Unallocated I O area of channel 2 254 Communication status area of channel 1 255 Communication status area of channel 2 ADDR Indicates the offset address from the beginning of each I O area when...

Page 368: ...NIV represents the number of axes when using a mechanism other than the registered type as a station axis CONNECTION In the CONNECTION window specify the SERVOPACK which is connected with each axis group the contactor which is used for the SERVOPACK and the overrun signal OT AXIS TYPE Select from the axis type list In case of TURN type No need to select The axis type is set as TURN type In case of...

Page 369: ...owing items MOTION RANGE mm MOTION RANGE mm REDUCTION RATIO numerator PINION DIAMETER mm If axis type is turn type set the following items MOTION RANGE deg MOTION RANGE deg REDUCTION RATIO numerator REDUCTION RATIO denominator OFFSET 1st and 2nd axis mm MOTOR SPECIFICATION Set the following items MOTOR SERVO AMP CONVERTER ROTATION DIRECTION normal reverse MAX SPEED rpm ACCELARATION SPEED sec INERT...

Page 370: ...fied 1 Turn the power supply ON while pressing Main Menu simultaneously 2 The SECURITY mode is changed to the MANAGEMENT mode 3 Select SYSTEM from the main menu The system window appears 4 Select SETUP The SETUP window appears Please note that the points marked with cannot be selected 5 Select CONTROL GROUP The current control group type is displayed ...

Page 371: ...ECT XYZ traverse XYZ axis base see the figures on the next page 7 Select desired type in the type list After the type selection the window returns to the CONTROL GROUP window 8 Press ENTER in CONTROL GROUP window The window moves to the CONNECTION window Base axis direction of travel coincides with robot coordinate X Axis Base axis direction of travel coincides with robot coordinate Z Axis Base ax...

Page 372: ...s directions of travel coincide with robot coordinate Y Axis and Z Axis respectively Base 1st and 2nd axes directions of travel coincide with robot coordinate Y Axis and Z Axis respectively Base 1st 2nd and 3rd axes directions of travel coincide with robot coordinate X Ax is Y Axis and Z Axis respectively RECT XY RECT YZ RECT XZ Z Y X Z Y X Z Y X 1 3 2 RECT XYZ Z Y X 1 ...

Page 373: ...ied that each axis of each control group is connected to which connector of the SERVO board which brake which converter and which overrun signal 1 Confirm the type of each control group in the CONNECT window The connection status of each control group is displayed CONNECT STO window CONNECT CONTACTOR window ...

Page 374: ...bling signal ON_EN the control group is connected Specify which overrun signal OT each control group is connected to CONNECT CONTACTOR window Specify which connector CN of the SERVO board each axis of each control group is connected to The numbers in represent axis numbers and indicate which axis is connected to which connector Specify which break BRK of the contactor unit each axis of each contro...

Page 375: ...run 4 Select a desired item 5 Press ENTER in the CONNECT window The setting in the CONNECT window is completed and the window moves to the AXES CONFIG window NOTICE An error massage Error 8217 Cannot change setting Check the setting of spot high speed spec may appear when press ENTER in the CONNECT window When the error massage appears invalid SPOT HIGH SPEED SPEC or review the configuration of th...

Page 376: ...ed 2 Select the axis type to be modified 1 The settable axis type is displayed 2 Select BALL SCREW when the servo track is ball screw type and RACK PINION when the servo track is rack and pinion type After the selection the window returns to the AXES CONFIG window 3 Select the axis type 3 Press ENTER in the AXES CONFIG window 4 The setting in the AXES CONFIG window is completed and the window move...

Page 377: ... are shown MOTION RANGE Input maximum moving position positive direction and negative direction from home position when setting the home position to 0 Unit mm REDUCTION RATIO Input the numerator and the denominator ex If the reduc tion ratio is 1 2 the numerator should be set as 1 0 and the de nominator should be set as 2 0 BALL SCREW PITCH Input the traveling length when the ball screw rotates on...

Page 378: ...dow The motor specification of each axis is displayed 2 Select a desired item When a numerical value is selected the number input buffer line appears When MOTOR or SERVO AMP or CONVERTER is selected the list window of MOTOR SERVO AMP or CONVERTER appears ROTATION DIRECTION Set the rotation direction to which the current position is in creased the counterclockwise view from the loaded side is the n...

Page 379: ...s If YES is selected the system parameter is set automatically 5 Initialize the related files To add and modify the base axis in completed 13 3 2 Station axis setting 13 3 2 1 Selecting the station axis type Select the type of station axis to be added modified 1 Confirm the type of control group in CONTROL GROUP window The CONTROL GROUP window appears Phenomenon1 During motion the axis moves unste...

Page 380: ...on the window returns to the CONTROL GROUP window Select UNIV universal when using a mechanism other than the registered type such as a servo track as a station axis When UNIV is selected interpolation motion linear circular etc is not supported TURN 1 TURN 1 AXIS STATION TURN 2 TURN 2 AXIS STATION UNIV 1 UNIVERSAL 1 AXIS STATION UNIV 2 UNIVERSAL 2 AXIS STATION Station 1st Axis 1 TURN 1 ...

Page 381: ...ected to which break Specify which converter CV each axis of each control group is connected to The numbers in represent the converter numbers and indicate which axis is connected to which converter Specify which on enable signal ON_EN each control group is connected to Specify which overrun signal OT each control group is connected to CONNECT CONTACTOR window Specify which connector CN of the SER...

Page 382: ...ocation of the external axis overrun signal is not needed Regarding the connection of the external axis overrun signal refer to chapter 15 12 External axes overrun 4 Select a desired item 5 Press ENTER in the CONNECT window The setting in the CONNECT window is completed and the window moves to the AXES CONFIG window Contactor unit TU 1 Brake connector BRK7 Converter CV 2 2 Axis SERVO board SV 1 Co...

Page 383: ... the UNIVERSAL type 2 Select the axis type to be modified The settable axis type is displayed 3 Select the desired axis type 4 Press ENTER in the AXES CONFIG window The setting in the AXES CONFIG window is completed and the window moves to the MECHANICAL SPEC window 13 3 2 4 Mechanical Specification Setting The mechanical data is specified in the MECHANICAL SPEC window When axis type is ROTATION t...

Page 384: ...ion when setting the home position to 0 unit deg REDUCTION RATIO Input the numerator and the denominator ex If the reduc tion ratio is 1 120 the numerator should be set as 1 0 and the denominator should be set as 120 0 OFFSET Offset should be specified at TURN 2 type only Input length between the center of bending axis 1st axis and the turning table 2nd axis Unit mm Station 2nd axis Rotation table...

Page 385: ... 0 BALL SCREW PITCH Input the traveling length when the ball screw rotates once Unit mm r Selected group type axis no and axis type are shown MOTION RANGE Input maximum moving position positive direction and negative direction from home position when setting the home position to 0 unit mm REDUCTION RATIO Input the numerator and the denominator ex If the reduc tion ratio is 1 120 the numerator shou...

Page 386: ...et the rotation direction to which the current position is in creased the counterclockwise view from the loaded side is the normal rotation AC SERVO motor Normal operation mode Normal operation mode MAX RPM Input maximum rotation speed of a motor Unit rpm ACCELARATION SPEED Input time between 0 01 and 1 00 to reach maximum speed from stopping status at 100 JOINT speed unit sec INERTIA RATIO The in...

Page 387: ...hould be initialized Initialize the JOB file data with procedure File Initialize in this manual after changing the construction When the data motion range for example should be changed after the addition of a base axis or station axis the change can be done in the same procedure as shown above In this case the control axis configuration is not changed so the JOB file data should not be initialized...

Page 388: ...pressed Injury or damage to machinery may result if the robot cannot be stopped in case of an emergency The emergency stop buttons are located on the right of the front door of the robot controller and the programming pendant CAUTION Perform the following inspection procedures prior to performing teaching operations If problems are found correct them immediately and be sure that all other necessar...

Page 389: ...apacity 200 000 steps 10 000 instructions CIO ladder Max 20 000 steps Safety category Safety category 3 PL e Ambient conditions Ambient temperature 0 C to 45 C During operation 10 C to 60 C During transit and storage Temperature change 0 3 C min or less Relative humidity 10 to 90 RH non condensing Allowable altitude 1000 m or less To use the robot controller at the altitude over 1000 m calculate t...

Page 390: ...amming Pendant Application Arc welding Spot welding Handling Press tending Cutting Others Essential Measures JIS Japanese Industrial Standard Running Speed Limit User definable Enable Switch 3 position type SERVO power can be turned on at the middle position only Located on programming pendant Collision proof Frames S axis frame doughnut sector Cubic frame Self Diagnosis Classifies error and two t...

Page 391: ...t motion Operation Instructions Preparing the operation instructions for each application Arc ON Arc OFF etc Variable Global variable Local variable Variable Type Byte type Integer type Double precision type Real type Position type String type I O Instructions Discrete I O Pattern I O processing Safety feature Essential Measures JIS Japanese Industrial Standard Running Speed Limit User definable E...

Page 392: ...programming Language Robot language INFORM II Robot Motion Control Joint coordinates Linear Circular interpolations Tool coordinates Speed Setting Percentage for joint coordinates 0 1mm s units for interpolations Angular velocity for T C P fixed motion Program Control In structions Jumps Calls Timer Robot stop Execution of some instructions during robot motion Operation Instructions Preparing the ...

Page 393: ...ming Language Robot language INFORM II Robot Motion Control Joint coordinates Linear Circular interpolations Tool coordinates Speed Setting Percentage for joint coordinates 0 1mm s units for interpolations Angular velocity for T C P fixed motion Program Control In structions Jumps Calls Timer Robot stop Execution of some instructions during robot motion Operation Instructions Preparing the operati...

Page 394: ... characters Chi nese characters Japanese letters etc Touch Panel Operating modes Select keys Axis keys Numerical application keys Mode select switch with a key mode TEACH PLAY and RE MOTE Emergency stop button Enable switch SD card slot 1 port USB port 1 port IEC protection class IP54 Length of cable Standard 8m Max 36m optional Interface Provided with SD card slot SD SDHC SDXC type USB connector ...

Page 395: ... SMVK500W260J RO A6667 Regenerative resistor SMVK500W7R0J RO A6666 DC reactor 85R 15014A Inside Controller Back view Breaker Power supply contactor unit JZRCR APU0 1 Converter CSRA CV05D01A Inverter unit CSRA SDA H01A Safety circuit board JANCD ASF01 E General purpose I O board JANCD AIO0 E Control power supply unit CSRA CPS01KA CPU unit JZNC ARK01 E Inside Controller Front view Heat exchanger TCM...

Page 396: ...PACK The fan mounted inside the door circulates the air to keep temperature even throughout the interior of the robot controller Make sure the door of the robot controller is closed when it s used to keep this cooling system effective GP12 ERAR 1000 06VXH25 E10 AR1440 GP25 AR1700 Cooling system Backside duct fan Air inlet Air outlet Heat exchanger Robot model YRC1000 controller 1 2 3 4 ...

Page 397: ... 100 Cabinet without angled connector plate Height 499 mm 143816 110 Cabinet double height with angled connector plate Height 989 mm 187153 See chap ter 14 5 5 2 Connector plate for 9 flanges 409026 xx and 1 larger flange 409023 xx Included in all optional cabinets Connector plate for 8 flanges 409026 xx Included in socket and optional cabinet with angled connector plate Earthing strap To be mount...

Page 398: ...no Part no Part name Material no 143818 100 Drawer to socket 143815 100 187154 143889 100 Mounting plate for I O unit in cabinet 187155 Pos no Part no Part name Material no 144270 100 Swing frame for standard cabinet Height 499 mm 187156 144270 110 Swing frame high for double height cabinet Height 989 mm 187157 1 2 1 2 ...

Page 399: ...d for CEE connector BAIS CEE socket 8233005 Potential equalizer bars 8090101 Earthing strap 144259 100 Mounting plate for DIN rail on door 187159 348952 100 Main power supply cable 5 with CEE conector 348952 101 PotCEE connector directly 348952 102 Main power supply cable 5 m with Harting connector 1 2 3 4 5 ...

Page 400: ...4 5 5 1 Covers for controller cabinet Pos no Part no Part name 144620 100 Large cover plate backside 144621 100 Cover plate side 144262 100 Small cover plate backside extern SERVO I O 144263 100 Cover plate on side of backside connector box strap 1 2 3 4 ...

Page 401: ...ge flange Daimler 409023 90 Adapter flange VW DX200 409023 91 Adapter plate Paint standard 409024 Adapter large to small flange HDC24 409026 Cover plate el HSD 24 pol 409026 81 Harting flange h a 16 409026 82 Harting flange 2 x HA 3 409026 83 Harting flange 1 openings Ø 16 409026 84 Harting flange 1 openings Ø 20 4 409026 85 Harting flange 2 openings Ø 21 409026 86 Harting flange 2 openings Ø 20 4...

Page 402: ...o property caused by short circuit As power supply is reversed for each signal a short circuit and thus a possible a robot control failure occurs Do not connect the two signals to the same contact use two separate contacts An alarm occurs due to the judgment of the safety circuit Robot controller Connection of 2 channel inputs Input for the robot system Turn ON OFF at the same time Input signal 1 ...

Page 403: ...from the safety circuit board and supplies power 3 phase to the converter The power supply 1 phase is supplied to the control power supply unit AC control power supply fuse Fixing screw hole Contactor control input connector AC control power supply connector Front view Power input connector Power output connector Right side view 1 CN602 CN601 CN604 CN603 2FU 10A 500V 1FU 10A 500V YASKAWA ELECTRIC ...

Page 404: ... voltage Voltage Fluctuation Range Frequency 200 to 480VAC 10 to 15 170 to 528VAC 50 60Hz 2Hz 48 to 62Hz Output voltage DC 12V DC 24V 24V1 System 24V2 I O DC 26V Indicator Display Color Status POWER ON White Lights with 12V output Power supply status being output 12V Red Lights with 12V low voltage over cur rent ON when abnormal FAN Red Lights when FAN error occurs OHT Red Lights when unit interio...

Page 405: ...ernal device etc after the non fuse breaker of the controller is turned ON It is operated by the exter nal switch connected with CN152 of the Control power supply unit as shown in the following figure CN152 3 and CN152 4 are short circuit ed when shipment 1 Control Power Supply ON OFF Switch 2 Remove the short circuit positioner 3 YRC1000 4 Control power supply unit CSRA CPS01KA See chapter 15 18 ...

Page 406: ...Board JANCD AIF01 E The robot I F circuit board JANCD AIF01 E controls the entire robotic system It is connected to the CPU board JANCD ACP01 E with a communication connector and to the servo control board CSRA SDCA01AA with a communication cable NOTICE Please do not change the factory setting of S1 Factory setting is 0 CPU board JANCD ACP01 E CN105 LAN1 for programming pendant SD card CN104 CPS i...

Page 407: ...wer supply and supplies the power to the inverter unit Input voltage 380 to 480 VAC Main circuit power supply input Regenerative resistor connection Charge lamp LED Monitor alarm indicator SERVO control board communication Main circuit power supply output 24V1 input Grounding terminal 1 CHARGE CN552 CN561 CN556 CN555 CN554 CN560 CN569 CN551 ALM COM RDY PON 2 3 4 5 6 7 8 ...

Page 408: ...tion of Units and Circuit Boards 15 408 15 5 Inverter Unit CSRA SDA H01A 15 5 1 Inverter unit configuration The inverter unit consists of following circuit boards 1 Inverter 2 SERVO control board CSRA SDCA01AA ...

Page 409: ...ower output 1 CN573 External axes PN output 1 CN580 Motor power output 3 CN575 Motor power output 4 CN576 External axes PN output 2 CN581 External axes PN output 3 CN582 Power supply output for external axes 3 CN585 Power supply output for external axes 2 CN584 Power supply output for external axes 1 CN583 Motor power output 5 CN577 Ground terminal PN input CN572 Motor power output 6 CN578 Motor F...

Page 410: ...nverter I F connector CN533 Encoder signal connector 3 CN535 Encoder signal connector 4 CN536 Encoder signal connector 2 CN534 Encoder signal connector 1 CN508 Handbrake release unit I F connector CN541 Brake I F connector CN540 External brake power supply input connector CN543 Brake power supply input connector CN544 Fan power supply connector CN520 Power supply input connector CN509 Converter I ...

Page 411: ...ual circuits Emergency stop signal input circuit dual circuits Servo power control signal output circuit dual circuits Non safe I O circuit for the robot system Safety terminal block board I F General purpose I O board I F connector CNAX Expansion safety I O board I F connector CN208 Power supply input connector CN207 Terminal block board I F connector CN206 Contactor control output connector CN20...

Page 412: ...the electromagnetic resistant can be properly performed Then the shield of shielded cable must come into contact with the controller s body Fig 15 1 Safety terminal block board Safety circuit board I F connector CN220 1 2 3 4 5 6 7 8 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 18 18 35 35 19 19 36 36 20 20 37...

Page 413: ...rned ON Note that these signals are disabled in TEACH mode EXESP_1 EXESP_1 EXESP_2 EXESP_2 5 6 7 8 Applicable External emergency stop Short circuit with a jumper cable Used to connect the emer gency stop switch of an ex ternal device If the contact is OPEN the servo power is turned OFF and the JOB is stopped While the signal is input the SERVO power cannot be turned ON OT2_1 OT2_1 OT2_2 OT2_2 9 10...

Page 414: ...t of the emergency stop button on the programing pendant and the front door of the YRC1000 Control panel GSIN1_1 GSIN1_1 GSIN1 2 GSIN1_2 41 42 43 44 Applicable General purpose safety in put Open The general purpose safety output signal is used in the safety logical circuit func tion Also inputs and uses the driven connection device status as the monitoring sig nal by the output signal GSIN2_1 GSIN...

Page 415: ...4 65 66 67 68 69 Direct in SERVO Open Used to input the quick re sponding signals in the search function etc 024VAX 024VAX 70 71 DC024V2 output terminal Open Rated current output 150mA or less 024V2 024V2 72 73 DC 024V2 output terminal Open AIN_COM AXIN1 AXIN2 74 75 76 General purpose input SERVO Open Used to input the general purpose signal from the ex ternal device This signal is optional This s...

Page 416: ...SB short delivered with the product 2 Strip wires The length of the exposed conductor L should be as follows The 9 10mm length of the exposed conductor for the terminal block WAGO series 250 with 5 0 mm pitch Maximum cable with an outer diameter of Ø 3 1 mm A bent or wound up conductor should be adjusted as illustrated in the figure above 3 Wire connections 1 Place the screwdriver on the lever upr...

Page 417: ...tion hole slowly until its leading end touches the end of the hole For thin wires never insert the wire with force or the wire jacket may get caught in 3 Pull out the screwdriver to clamp the conductor with a spring 4 Check if the wire is connected firmly by pulling the wire softly ...

Page 418: ...machine damage as a result of short circuiting Jumpers are installed at the factory If the jumpers are not removed the external emergency stop will not work even when the signal is received Always remove the jumpers before operation NOTICE Because of the its dual circuits signal to input the alarm occurs if the signal does not much However in the TEACH mode even though the signal does not much the...

Page 419: ... interlock signal from the gate NOTICE Observe DIN EN ISO 10218 2 with respect to the safety measures If the SERVO power is ON when the interlock signal is input the SERVO power turns OFF As long as the interlock signal is active the SERVO power cannot be turned ON However the servo power does not turn OFF when the door is opened only during the TEACH mode In this case the SERVO power can be turne...

Page 420: ...led at the factory If the jumpers are not removed the external emergency stop will not work even when the signal is received Always remove the jumpers before operation Connect the ONEN signal lines to enable the function to turn ON or OFF the SERVO power supply of an individual SERVO when a robotic system is divided into SERVO systems Because these signals are not used for units of standard specif...

Page 421: ...t YRC1000 Safety terminal block board Safety circuit board SERVO ON enable input signal System1 Turn ON OFF at the same time Remove the jumper SERVO ON enable input signal System2 SERVO ON enable input signal System3 SERVO ON enable input signal System4 1 21 22 CN206 CN220 ONEN1_1 ONEN1_1 23 24 ONEN1_2 ONEN1_2 25 26 27 28 ONEN2_1 ONEN2_2 ONEN2_2 ONEN2_1 29 30 31 32 ONEN3_1 ONEN3_2 ONEN3_2 ONEN3_1 ...

Page 422: ...ing figure If an input signal overspeed is necessary for an external axis connect the signal input circuits as described below For safety reasons redundant two channel switches have to be used for the overrun signal input for external axes Connect the signal input of the external axis this way that both input signals are turned ON or OFF at the same time If only one signal is turned ON the machine...

Page 423: ...e and Station axes to the manual Instructions with the document no E1102000214XX01 and higher Connection for external axis overrun Multiple lines YRC1000 Safety terminal block board Safety circuit board External axis overrun 1st line Turn ON OFF at the same time External axis overrun 2nd line External axis overrun 3rd line 1 X18 9 10 11 12 CN206 CN220 OT2_1 OT2_2 OT2_2 OT2_1 13 14 OT3_1 OT3_1 15 1...

Page 424: ...itch EXDSW or the full speed test FST refer to chapter Axes detachment function to the manual Instructions with the document no E1102000214XX01 and higher General purpose safety input YRC1000 Safety terminal block board Safety circuit board General purpose safety input Turn ON OFF at the same 1 41 42 43 44 CN206 CN220 X18 GSIN1_1 GSIN1_2 GSIN1_2 GSIN1_1 45 46 47 48 GSIN2_1 GSIN2_2 GSIN2_2 GSIN2_1 ...

Page 425: ...ct When connect the inductive load such as the safety relay with the output circuit use of the built in protective circuit for the surge suppressor or connect the flyback diode in parallel to the inductive load to suppress the surge voltage It may cause the damage on the output circuit An error e g relay contact sticking of the device e g safety relay contactor controlled by the general purpose sa...

Page 426: ...pose signal This signal cannot be used for standard specification because this signal is optional General purpose input SERVO YRC1000 Safety terminal block board Safety circuit board General purpose input SER VO Connect the jumper 1 75 76 74 70 71 72 73 CN206 CN220 X18 024V2 24VAX AXIN1 AXIN2 AXIN_COM 1 2 2 3 4 5 ...

Page 427: ...on signal allocation For the connection of the robot s general purpose I O signal connectors and the I O signal related to start and stop refer to Connection wire with robot general purpose I O Connector CN306 307 308 309 and Specific I O signal related to start and stop Connection wire with robot general purpose I O connector CN306 307 308 309 Please refer to the figure below when manufacturing t...

Page 428: ... signals from 433 about the maximum current of the transistor and the relay output circuits Specific I O signal related to start and stop The following signals are specific I O signals related to start and stop SERVO ON depending on application External SERVO ON common to all application External start depending on application Operating depending on application External hold common to all applicat...

Page 429: ... circuit from the external device SERVO ON PB SERVO ON confirmation X2 SERVO ON command SERVO ON power ON X3 SERVO ON confirmation Note Number in means output signal number assigned to AIO01 PL Pilot lamp YRC1000 General purpose I O board External SERVO ON SERVO ON power ON Output while SERVO ON Note This circuit is example in case of AIO01 1 X1 X2 PL 30011 X1 2 3 4 5 6 B3 B7 X1 CN308 24VU A8 A18 ...

Page 430: ...ly moving Example of start sequence circuit from the external device Note Number in means output signal number assigned to AIO01 PL Pilot lamp This circuit is example in case of AIO01 Run PB Robot controller While SERVO ON External Start Command Selects PLAY mode External start input Alarm Error occurring Ongoing output Running confirmation Running etc Start Command Execute X6 㻯㻺㻟㻜㻤 㻮㻣 㻮㻝 㻗㻞㻠㼂㼁 㻮㻤...

Page 431: ...rd 2 Connect 24V of the external power supply to CN303 1 and 0V to CN303 2 of the robot I O unit Connection of the external power supply for I O General purpose I O board In case of using internal power supply The factory default settings External power supply Ready by cus tomer In case of using external power supply 1 JANCD AIO0 E CN303 1 EX 24VIN 24VU 024VU 2 EX024VIN 24V 024V 3 24V 4 024V 3 15A...

Page 432: ...ply is also connected 15 17 WAGO Connector The control power supply unit CN152 on CSRA CPS01KA and CN303 on the general purpose I O board JANCD AIO0 E are equipped with a connector made by WAGO The wiring tool for the WAGO connector is necessary to wire the WAGO connector The tools total 3 2 types are supplied with the robot controller Use them with the appropriate sizes of connectors The wiring p...

Page 433: ... 20012 CALL MASTER JOB Only the rising edge of the signal is valid It calls up the top of the robot pro gram that is the top of the master JOB1 This signal is invalid during play back during teach lock and when play master or call is prohibited set from the playback operation condition display 20013 ALARM ERROR RESET After an alarm or error has occurred and the cause been corrected this sig nal re...

Page 434: ...the job is running Signifies that the job is running system status is waiting reserved start or test run is running This signal status is the same status as START in the programming pendant 30011 SERVO IS ON This signal signifies that the SERVO power is turned ON internal process ing such as current position creation is complete and the system is able to receive the START command This signal turns...

Page 435: ...rrent TCP lies inside the work home posi tion area Use this signal to evaluate whether the manipulator is in the start position 30023 INTERMEDIATE START OK This signal turns ON when the robot operates It turns OFF when the cur rently executed line is moved with the cursor or when editing operation is carried out after HOLD is applied during operation Therefore this signal can be used as a restart ...

Page 436: ...ogical Number Name Signal Connector Number Terminal Number Connector Terminal Converter Optional Model TIFS553YS Remove the Jumper pins between CN303 1 to 3 CN303 2 to 4 when the external power supply is used GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output General purpose I O board JANCD AIO02 E...

Page 437: ...nal Model TIFS553YS Remove the Jumper pins between CN303 1 to 3 CN303 2 to 4 when the external power supply is used means internal relay means RLY GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output YRC1000 General purpo...

Page 438: ...er supply is used CN308 Connector External Start External Hold External Servo ON Call Master Job Alarm Error Reset Interference1 Entrance Prohibited Work Prohibited Work Response Running Servo is ON Top of Master Job Alarm Error Occurred Battery Alarm Remote Mode Selected Play Mode Selected Teach Mode Selected In Cube 1 In Cube 2 Work Home Position Intermediate Start OK Sequence Continuing Interfe...

Page 439: ...mber Signal Name Connector Terminal Converter Optional Model TIFS553YS Terminal Number Connector Number Remove the Jumper pins between CN303 1 to 3 CN303 2 to 4 when the external power supply is used Weaving Prohibited Sensing Prohibited IN01 GP Input IN02 GP Input IN03 GP Input IN04 GP Input IN05 GP Input IN06 GP Input IN07 GP Input IN08 GP Input Wire Sticking Monitor Gas Shortage Monitor Wire Sh...

Page 440: ...D Arc sensing is prohibited while this signal is ON Use this signal to check taught steps and movements if an arc sensor is mounted Logical number Input name Function 30024 This signal stays ON while the gas shortage signal from the welding power supply is ON 30025 This signal status ON while the wire shortage signal from the welding pow er supply is ON 30026 The wire sticking check is conducted a...

Page 441: ...cal Number Name Signal Connector Terminal Converter Optional Model TIFS553YS Connector Number Terminal Number Remove the Jumper pins between CN303 1 to 3 CN303 2 to 4 when the external power supply is used GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Input YRC1000 General purpose I O board JANCD AI...

Page 442: ...3 CN303 2 to 4 when the external power supply is used Sensor Input 8 Sensor Input 1 Sensor Input 2 Sensor Input 3 Sensor Input 4 Sensor Input 5 Sensor Input 6 Sensor Input 7 Hand Valve 1 1 Hand Valve 1 1 Hand Valve 1 2 Hand Valve 1 2 Hand Valve 2 1 Hand Valve 2 1 Hand Valve 2 2 Hand Valve 2 2 Hand Valve 3 1 Hand Valve 3 1 Hand Valve 3 2 Hand Valve 3 2 Hand Valve 4 1 Hand Valve 4 1 Hand Valve 4 2 H...

Page 443: ...03 2 to 4 when the external power supply is used External Start External Hold Call Master Job Alarm Error Reset External Servo ON Interference1 Entrance Prohibited Running Servo is ON Top of Master Job Alarm Error Occurred Battery Alarm Remote Mode Selected Play Mode Selected Teach Mode Selected In Cube 1 In Cube 2 Work Home Position Intermediate Start OK Interference2 Entrance Prohibited Select P...

Page 444: ...gnostic display if this signal is not be used Internal Power Supply 24 V 024 V 24V 1 5A External PowerSupply 24VE 024VE CN303 CN309 Connector Logical Number Signal Name Connector Terminal Converter Optional Model TIFS553YS Terminal Number Connector Number Remove the Jumper pins between CN303 1 to 3 CN303 2 to 4 when the external power supply is used Shock Sensor NC Hold Low Air Pressure GP Output ...

Page 445: ...ge in the TEACH mode 20050 to20057 SENSOR INPUT 1 8 Inputs 1 to 8 are monitored with the HSEN handling specific instructions Sensor inputs 1 to 8 correspond to HSEN 1 to 8 Logical number Input name Function 30050 to30057 HAND VALVE 1 4 These outputs are controlled by the HAND handling specific instructions Hand valves 1 to 4 correspond to HAND 1 to 4 Logical number Input name Function ...

Page 446: ...onnector GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output Logical Number Name Signal Connector Terminal Converter Optional Model TIFS553YS Connector Number Terminal Number Remove the Jumper pins between CN303 1 to 3 CN303 2 to 4 when the external power supply is used YRC1000 General purpose I O b...

Page 447: ...the external power supply is used means internal relay means Internal Power Supply 24 V 024 V 24V 1 5A External PowerSupply 24 VE 024 VE RLY CN303 GP Input GP Output GP Input GP Output GP Input GP Output GP Input GP Output GP Input GP Output GP Input GP Output GP Input GP Output GP Input GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output YRC1000 General purpo...

Page 448: ...4 when the external power supply is used External Start External Hold Call Master Job Alarm Error Reset External Servo ON Interference1 Entrance Prohibited Work Prohibited Running Servo is ON Top of Master Job Alarm Error Occurred Battery Alarm Remote Mode Selected Play Mode Selected Teach Mode Selected In Cube 1 In Cube 2 Work Home Position Intermediate Start OK Interference2 Entrance Prohibited ...

Page 449: ...9 Connector GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Input GP Output GP Output GP Output GP Output GP Output GP Output GP Output GP Output Logical Number Signal Name Connector Terminal Converter Optional Model TIFS553YS Terminal Number Connector Number Remove the Jumper pins between CN303 1 to 3 CN303 2 to 4 when the external power supply is used Interference3 Entrance Pro...

Page 450: ...opped Logical number Input name Function 20022 WORK PROHIBITED Tool ON Prohibited Even if TOOLON instruction is executed YRC1000 doesn t output to external while this signal is ON 20024 INTERFERENCE 3 ENTRANCE PROHIBITEDIf the robot attempts to en ter the cube 31 area while this signal is ON the robot goes to wait status with SERVO power ON During wait status the robot operation restarts if this s...

Page 451: ... JANCD ABB02 E Robot I F board JANCD AIF01 1E Safety terminal block board IM YE250 5 80P General purpose I O board JANCD AIO02 E Power supply contactor unit JZRCR APU01 1 Inverter unit Refer to Tab 15 3 Capacity model SERVO control board CSRA SDCA01AA Safety circuit board JANCD ASF01 E Converter JZRCR YPU51 1 Main axis control board SRDA EAXA21A Control board brake JANCD YBK21 3E Converter CSRA CV...

Page 452: ...Description of Units and Circuit Boards 15 452 Tab 15 3 Capacity model Model Inverter unit GP7 CSRA SDA01H01A AR900 GP8 AR700 GP12 CSRA SDA02H01A AR1440 GP25 AR1700 ...

Page 453: ...Description of Units and Circuit Boards 15 453 ...

Page 454: ...ayin 972 3 9004114 NL YASKAWA Benelux B V Son 31 40 2895500 PL YASKAWA Polska Sp z o o Wrocław 48 71 7928670 RUS YASKAWA Nordic AB Moskva 46 480 417 800 SE YASKAWA Nordic AB Torsås 46 480 417 800 SI YASKAWA Slovenia Ribnica 386 1 8372 410 TR YASKAWA Turkey Elektrik Ticaret Ltd Sti İstanbul 90 216 5273450 ZA YASKAWA Southern Africa PTY Ltd Johannesburg 27 11 6083182 DISTRIBUTORS BG ARAMET ROBOTICS ...

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