Motoman MotoPos-T1000 Positioner Manual

Motoman® NX100 Controller

MotoPos-T1000
Positioner Manual

Part Number: 152163-1CD
Revision 0

Motoman, Incorporated
805 Liberty Lane
West Carrollton, Ohio 45449 USA

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937.847.3200 (24-Hour Support)

www.motoman.com
[e-mail]

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The information contained within this document is the proprietary property of Motoman, Inc., and may not be

copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

©2007 by MOTOMAN

Because we are constantly improving our products, we reserve the right to change specifications without

notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

Inc.

All Rights Reserved

MotoPos-T1000

152163-1

Chapter 1

Introduction

1.1 About This Document

This manual provides information for the MotoPos-T1000 positioner and contains the following sections:

CHAPTER 1 - INTRODUCTION

Provides general information about the structure of this manual, a list of reference documents, and
customer service information.

CHAPTER 2 - SAFETY

This section provides information regarding the safe use and operation of Motoman products.

CHAPTER 3 - MOTOPOS-T1000 INSTRUCTIONS

Provides detailed information for the MotoPos-T1000 positioner.

1.2 Reference to Other Documentation

For additional information refer to the following:

• NX100 Controller Manual (P/N 149201-1)

• Concurrent I/O Manual (P/N 149230-1)

• Operator’s Manual for your application

• Vendor manuals for system components not manufactured by Motoman

1.3 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at [phone]. Please have
the following information ready before you call:

• Robot Type (MotoPos-T1000)

• Application Type (welding, handling, etc.)

• Robot Serial Number (located on back side of robot arm)

• Robot Sales Order Number (located on back of controller)

Final page 1

Positioner Manual
Chapter 1 Introduction

Notes

page 2 Final

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Chapter 2

Safety

2.1 Introduction

It is the purchaser’s responsibility to ensure that all local, county, state,
and national codes, regulations, rules, or laws relating to safety and safe
operating conditions for each installation are met and followed.

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for
Industrial Robots and Robot Systems. This information can be obtained from the Robotic Industries
Association by requesting ANSI/RIA R15.06-1999. The address is as follows:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: [phone]
FAX: [phone]

INTERNET: www.roboticsonline.com

Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel
who are adequately trained to operate, program, and maintain the robot cell. The robot must not be

operated by personnel who have not been trained!

We recommend that all personnel who intend to operate, program, repair, or use the robot system be
trained in an approved Motoman training course and become familiar with the proper operation of the
system.

Final page 3

Positioner Manual
Chapter 2 Safety

This safety section addresses the following:

• Standard Conventions (Section 2.2)

• General Safeguarding Tips (Section 2.3)

• Mechanical Safety Devices (Section 2.4)

• Installation Safety (Section 2.5)

• Programming, Operation, and Maintenance Safety (Section 2.6)

2.2 Standard Conventions

This manual includes the following alerts – in descending order of severity – that are essential to the
safety of personnel and equipment. As you read this manual, pay close attention to these alerts to
insure safety when installing, operating, programming, and maintaining this equipment.

DANGER!

Information appearing in a DANGER concerns the protection of personnel from the immediate
and imminent hazards that, if not avoided, will result in immediate, serious personal injury or
loss of life in addition to equipment damage.

WARNING!

Information appearing in a WARNING concerns the protection of personnel and equipment from
potential hazards that can result in personal injury or loss of life in addition to equipment
damage.

CAUTION!

Information appearing in a CAUTION concerns the protection of personnel and equipment,
software, and data from hazards that can result in minor personal injury or equipment damage.

Note: Information appearing in a Note provides additional information which is helpful in understanding the item being
explained.

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2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. All
personnel involved with the operation of the equipment must understand potential dangers of
operation. General safeguarding tips are as follows:

• Improper operation can result in personal injury and/or damage to the equipment. Only
trained personnel familiar with the operation of this robot, the operator's manuals, the system
equipment, and options and accessories should be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation. Programmers must have the
teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in use.

• In accordance with ANSI/RIA R15.06-1999, section 4.2.5, Sources of Energy, use
lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147
(29CFR, Part 1910), Occupational Safety and Health Standards for General Industry
(OSHA).

2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's
responsibility. The conditions under which the equipment will be operated safely should be reviewed
by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-1999 safety
standards, and other local codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required depending on system
installation, operation, and/or location. The following safety equipment is provided as standard:

• Safety fences and barriers

• Light curtains and/or safety mats

• Door interlocks

• Emergency stop palm buttons located on operator station, robot controller, and
programming pendant

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning
safety equipment immediately.

Final page 5

Positioner Manual
Chapter 2 Safety

2.5 Installation Safety

Safe installation is essential for protection of people and equipment. The following suggestions are
intended to supplement, but not replace, existing federal, local, and state laws and regulations.
Additional safety measures for personnel and equipment may be required depending on system
installation, operation, and/or location. Installation tips are as follows:

• Be sure that only qualified personnel familiar with national codes, local codes, and
ANSI/RIA R15.06-1999 safety standards are permitted to install the equipment.

• Identify the work envelope of each robot with floor markings, signs, and barriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entry into the work
envelope.

• Eliminate areas where personnel might get trapped between a moving robot and other
equipment (pinch points).

• Provide sufficient room inside the workcell to permit safe teaching and maintenance
procedures.

2.6 Programming, Operation, and Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. Improper
operation can result in personal injury and/or damage to the equipment. Only trained personnel
familiar with the operation, manuals, electrical design, and equipment interconnections of this robot
should be permitted to program, operate, and maintain the system. All personnel involved with the
operation of the equipment must understand potential dangers of operation.

• Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be
sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place. Check all safety equipment for proper operation.
Repair or replace any non-functioning safety equipment immediately.

• Do not enter the robot cell while it is in automatic operation. Be sure that only the person
holding the programming pendant enters the workcell.

• Check the E-STOP button on the programming pendant for proper operation before
programming. The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.

• Back up all programs and jobs onto suitable media before program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.

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• Any modifications to PART 1, System Section, of the robot controller concurrent I/O
program can cause severe personal injury or death, as well as damage to the robot! Do not
make any modifications to PART 1, System Section. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!

• Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use
these special passwords.

• The robot controller allows modifications of PART 2, User Section, of the concurrent I/O
program and modifications to controller parameters for maximum robot performance. Great
care must be taken when making these modifications. All modifications made to the
controller will change the way the robot operates and can cause severe personal injury or
death, as well as damage the robot and other parts of the system. Double-check all
modifications under every mode of robot operation to ensure that you have not created
hazards or dangerous situations.

• Check and test any new or modified program at low speed for at least one full cycle.

• This equipment has multiple sources of electrical supply. Electrical interconnections are
made between the controller and other equipment. Disconnect and lockout/tagout all
electrical circuits before making any modifications or connections.

• Do not perform any maintenance procedures before reading and understanding the proper
procedures in the appropriate manual.

• Use proper replacement parts.

• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).

Final page 7

Positioner Manual
Chapter 2 Safety

Notes

page 8 Final

YASKAWA

MOTOPOS-T1000 POSITIONER

INSTRUCTIONS

TYPE: YR-MPT1000-A15 (WITH 2000 kg P A YLO AD)

TYPE: YR-MPT1000-A16
TYP: EYR-MPT1000-F00 (FOR SPECIAL SPECIFICAT ION WITH 2000 kg P A YLO AD)
YPE: : YR-MPT1000-F01 (FOR SPECIAL SPECIFICATION WITH 2000 kg P AYLOAD)
YPE: : YR-MPT1000-F02 (FOR SPECIAL SPECIFICATION WITH 2000 kg P AYLOAD)
YPE: : YR-MPT1000-F03 (FOR SPECIAL SPECIFICATION WITH 2000 kg P AYLOAD)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.

MOTOPOS INSTRUCTIONS

MOTOMAN SETUP MANUAL
MOTOMAN-MANIPULA T OR INSTRUCTIONS
Y ASNAC XRC INSTRUCTIONS
Y ASNAC XRC OPERATOR’S MANUAL
Y ASNAC XRC OPERATOR’S MANUAL FOR BEGINNERS
MOTOPOS INSTRUCTIONS

The YASNAC XRC operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.

(FOR NORTH AMERICAN ST ANDARD WITH 2000 kg PAYLOAD)

YASKAWA

MANUAL NO.

HS0481357

1

HS0481357

MANDATORY

• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOPOS.

• General items related to safety are listed in the Setup Manual Section 1:
Safety. To ensure correct and safe operation, carefully read the Setup
Manual before reading this manual.

CAUTION

• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.

• The drawings and photos in this manual are representative examples
and differences may exist between them and the delivered product.

• Y ASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA rep­resentative to order a new copy. The representatives are listed on the
back cov er. Be sure to tell the representative the manual number listed
on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your prod­uct’s warranty.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the
MOTOPOS and YASNAC XRC.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.

Indicates a potentially hazardous situation wh ich, if not avo id ed ,

WARNING

CAUTION

MANDATORY

could result in death or serious injury to personnel.

Indicates a potentially hazardous situation wh ich, if not avo id ed ,
could result in minor or moderate injury to personnel and dam­age to equipment. It may also be used to alert against unsafe
practices.

Always be sure to follow explicitly the items listed under this
heading.

PROHIBITED

Even items described as “CAUTION” may result in a serious accident in some situations. At
any rate, be sure to follow these important items.

NOTE

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING”.

Must never be performed.

iii

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HS0481357

WARNING

• Before operating the MOTOPOS, check that servo power is turned OFF
when the emergency stop buttons on the playback panel or program­ming pendant are pressed.
When the servo power is turned OFF, the SERVO ON READY lamp on the
playback panel and the SERV O ON LED on the programming pendant are
turned OFF.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the
MOTOPOS during an emergency. The MOTOPOS should not be used if the emergency
stop buttons do not function.

Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the MOTOPOS. Then turn the
servo power ON.

Injury may result from unintentional or unexpected MOTOPOS motion.

TURN

Release of Emergency Stop

• Always set the T each Lock bef ore entering the MOTOPOS w ork envelope
to teach a job.

Operator injury can occur if the Teach Lock is not set and the MOTOPOS is started from
the playback panel.

• Observe the following precautions when performing teaching operations
within the working envelope of the MOTOPOS :

- View the MOTOPOS from the front whenever possible.

- Always follow the predetermined operating procedure.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended MOTOPOS operation may result in injury.

• Confirm that no persons are present in the work envelope of MOTOPOS
and that you are in a safe location before:

- Turning ON the YASNAC XRC power.

- Operating the MOTOPOS with the programming pendant.

- Running check operations.

- Performing automatic operations.

Injury may result if anyone enters the working envelope of the MOTOPOS during opera­tion. Always press an emergency stop button immediately if there is a problem.The emer­gency stop buttons are located on the right side of both the YASNAC XRC playback panel
and programming pendant.

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CAUTION

• Perform the following inspection procedures prior to conducting MOTO­POS teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.

-Check for problems in MOTOPOS movement.

-Check for damage on insulation and sheathing of external cables.

• Always return the programming pendant to the hook on the XRC cabinet
after use.

The programming pendant can be damaged if it is left in work area of the MOTOPOS, on
the floor, or near fixtures.

• Read and understand the Explanation of the Warning Labels in the Setup
Manual before operating the MOTOPOS.

Definition of Terms Used Often in This Manual

The MOTOPOS is the positioner for the YASKAWA industrial robot.
The MOTOPOS usually consists of MOTOPOS positioner unit, a controller unit, a playback
panel, a programming pendant, and power cables.
In this manual, the equipment is defined as follows:

Equipment Definition in this Manual

YASNAC XRC Controller XRC
YASNAC XRC Playback Panel Playback Panel
YASNAC XRC Programming Pendant Programming Pendant

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Explanation of Warning Labels

The following warning labels are attached to the MOTOPOS.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the body of the MOTO­POS. Prior to operating the MOTOPOS, confirm the contents.

WARNING

WARNING

Do not enter

Moving parts may

robot work area

cause injury

Warning label A

Motoman

No.

Warning label B

Nameplate

WARNING Label A:

WARNING

Moving parts may
cause injury

WARNING Label B:

WARNING

Do not enter
robot work area

Nameplate

kgkg

YASKAWA ELECTRIC CORPORATION JAPAN

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