How it Works
Yaskawa
Loading...
DX100
User Manual
764 pgs14.97 Mb11
Table of contents
Loading...

Yaskawa DX100 User Manual

DX100
1 of 764
MAINTENANCE MANUAL
FOR EUROPEAN STANDARD
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS DX100 INSTRUCTIONS FOR EUROPEAN STANDARD DX100 OPERATOR’S MANUAL DX100 MAINTENANCE MANUAL FOR EUROPEAN STANDARD
The DX100 operator’s manual above correspond to specific usage. Be sure to use the appropriate manual.
Part Number: 171768-1CD Revision: 0
MANUAL NO.
RE-CHO-A109
2
DX100 European
2 of 764
Standard Maintenance
171768-1CD
Copyright © 2014, Yaskawa America, Inc. All Rights Reserved.
ii
RE-CHO-A109
171768-1CD
MANDATORY
CAUTION
3 of 764
DX100 European Standard Maintenance
• This instruction manual is intended to explain mainly on the mechanical part of the DX100 for the application to the actual operation and for proper maintenance and inspection. It describes on safety and handling, details on specifications, necessary items on maintenance and inspection, to explain operating instructions and maintenance procedures. Be sure to read and understand this instruction manual thoroughly before installing and operating the manipulator.
• General items related to safety are listed in Section 1: Safety of the DX100 Instructions. To ensure correct and safe operation, carefully read the DX100 Instructions before reading this manual.
• 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.
• YASKAWA 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 cover. 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.
iii
RE-CHO-A109
DX100 European
DANGER
WARNING
CAUTION
MANDATORY
PROHIBITED
NOTE
4 of 764
Standard Maintenance
Notes for Safe Operation
Read this manual carefully before maintenance or inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.”
171768-1CD
Indicates an imminent hazardous situation which, if not avoided, could result in death or serious injury to personnel.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.
Indicates a potentially hazardous situation which, if not avoided, 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.
Must never be performed.
Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.
To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “DANGER”, “WARNING” and “CAUTION”.
iv
RE-CHO-A109
171768-1CD
WARNING
TURN
5 of 764
DX100 European Standard Maintenance
• Confirm that no person is present in the P-point maximum envelope of the manipulator and that you are in a safe location before:
– Turning on the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there is a problem.
The emergency stop button is located on the right side of the programming pendant.
• Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being performed inside the safeguarding and make sure no one closes the safeguarding.
– View the manipulator 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 manipulator operation may result in injury.
• Before operating the manipulator, check that servo power is turned OFF pressing the emergency stop buttons on the programming pendant. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the manipulator during an emergency. The manipulator should not be used if the emergency stop buttons do not function.
Figure 1: Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator. Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
v
RE-CHO-A109
DX100 European
CAUTION
6 of 764
Standard Maintenance
171768-1CD
• Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet of the DX100 after use.
The programming pendant can be damaged if it is left in the manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the DX100 Instructions before operating the manipulator:
Definition of Terms Used Often in This Manual
The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows:.
Equipment Manual Designation
DX100 Controller DX100
DX100 Programming Pendant Programming Pendant
Cable between the manipulator and the controller
Manipulator cable
vi
RE-CHO-A109
171768-1CD
PAGE
GO BACK
PAGE
GO BACK
7 of 764
DX100 European Standard Maintenance
Descriptions of the programming pendant keys, buttons, and displays are shown as follows:
Equipment Manual Designation
Programming Pendant
Character Keys
Symbol Keys The keys which have a symbol printed on them
Axis Keys Numeric Keys
Keys pressed simultaneously
Displays The menu displayed in the programming
The keys which have characters printed on them are denoted with [ ]. ex. [ENTER]
are not denoted with [ ] but depicted with a small picture.
ex. page key
The cursor key is an exception, and a picture is not shown.
“Axis Keys” and “Numeric Keys” are generic names for the keys for axis operation and number input.
When two keys are to be pressed simultaneously, the keys are shown with a “+” sign between them. ex. [SHIFT]+[COORD]
pendant is denoted with { }. ex. {JOB}
Description of the Operation Procedure
In the explanation of the operation procedure, the expression “Select • • •” means that the cursor is moved to the object item and the SELECT key is pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and TM are omitted.
vii
RE-CHO-A109
DX100 European
X81
PROGRAMMING PENDANT
PROPERLY.
CHECK ALL THE DOOR LOCKS
NJ3005-1
kVA
kVA
ERDR-
Average
Peak
NJ3053-1
Kammerfeldstr. 1, D-85391 Allershausen
Motoman
2-1 Kurosaki Shiroishi Yahatanishi-Ku Kitakyushu-City Fukuoka 806-0004 Japan
YASKAWA Electric corporation
Robot Serial No.
Robot Order No.
Robot Type
Type
Date/Signature
Serial No.
AC 400/415/440 V
Power Supply
Part No.
Motoman DX100
with power ON.
WARNING
Do not open the door
High Voltage
with power ON.
WARNING
High Voltage
Do not open the door
8 of 764
Standard Maintenance
Explanation of Warning Labels
• The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
Failure to observe this caution may result in injury or damage to equipment.
Refer to the manipulator manual for the warning label location.
Figure 3: Warning Labels
171768-1CD
DANGER
• The following warning labels are attached to DX100.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to equipment.
Figure 4: Warning Label Location
viii
RE-CHO-A109
171768-1CD
9 of 764
DX100 European Standard Maintenance
Table of Contents
Table of Contents
1 Equipment Configuration ................................................................................................................ 1-1
1.1 Arrangement of Units and Circuit Boards .......................................................................... 1-1
1.1.1 Arrangement......................................................................................................... 1-1
1.1.1.1 Small-Capacity DX100 Controller............................................................ 1-1
1.1.1.2 Medium and Large-Capacity DX100 Controller....................................... 1-2
1.2 Power Flow ........................................................................................................................ 1-3
1.3 Signal Flow ........................................................................................................................ 1-4
2 Security System .............................................................................................................................. 2-1
2.1 Protection Through Security Mode Settings ...................................................................... 2-1
2.1.1 Security Mode ...................................................................................................... 2-1
2.1.1.1 Changing the Security Mode ................................................................... 2-6
2.1.2 User ID .................................................................................................................2-8
2.1.2.1 Changing a User ID................................................................................. 2-8
3 Inspections...................................................................................................................................... 3-1
3.1 Regular Inspections ........................................................................................................... 3-1
3.2 DX100 Inspections............................................................................................................. 3-2
3.2.1 Checking if the Doors are Firmly Closed .............................................................. 3-2
3.2.2 Checking for Gaps or Damage in the Sealed Construction Section..................... 3-2
3.3 Cooling Fan Inspections ................................................................................................... 3-3
3.4 Emergency Stop Button Inspections.................................................................................. 3-4
3.5 Enable Switch Inspections.................................................................................................3-4
3.6 Battery Inspections ............................................................................................................ 3-5
3.7 Power Supply Voltage Confirmation .................................................................................. 3-5
3.8 Open Phase Check............................................................................................................ 3-6
4 Preparation before Replacing Parts................................................................................................ 4-1
4.1 Creating a Check Program ................................................................................................ 4-3
ix
RE-CHO-A109
171768-1CD
10 of 764
DX100 European Standard Maintenance
5 Replacing Parts............................................................................................................................... 5-1
5.1 Replacing DX100 Parts...................................................................................................... 5-1
5.1.1 Replacing Parts of the CPU Unit .......................................................................... 5-2
5.1.1.1 Replacing the Battery ..............................................................................5-3
5.1.1.2 Replacing the Control Circuit Board (JANCD-YCP01-E)......................... 5-3
5.1.1.3 Replacing the CPS Unit (JZNC-YPS01-E) .............................................. 5-5
5.1.1.4 Replacing the Robot I/F Board (JANCD-YIF01-oE) ................................ 5-6
5.1.1.5 Replacing the I/O Unit (JZNC-YIU02-E) .................................................. 5-8
5.1.1.6 Replacing the Power Supply Contactor Unit (JZRCR-YPU01-o) ..........5-10
5.1.1.7 Replacing the Brake Control Board (JANCD-YBK01-1E)...................... 5-11
5.1.1.8 Replacing the Machine Safety Unit (JZNC-YSU01-1E)......................... 5-12
5.1.2 Replacing the SERVOPACK .............................................................................. 5-14
5.1.3 Replacing the Converter ..................................................................................... 5-18
5.1.4 Replacing the Major Axes Control Circuit Board (SRDA-EAXA01A).................. 5-22
Table of Contents
5.1.5 Checking and Replacing Fuses.......................................................................... 5-23
5.1.5.1 Power Supply Contactor Unit ................................................................ 5-23
5.1.5.2 I/O Unit .................................................................................................. 5-24
5.1.5.3 Machine Safety Unit .............................................................................. 5-25
5.1.5.4 Brake Control Board.............................................................................. 5-26
5.1.6 Interior Circulation Fan ....................................................................................... 5-27
5.1.6.1 Replacing the Interior Circulation Fan ................................................... 5-27
5.1.6.2 Replacing the Backside Duct Fan ......................................................... 5-28
5.2 DX100 Parts List .............................................................................................................. 5-29
5.3 Supplied Parts List ........................................................................................................... 5-31
5.4 Recommended Spare Parts............................................................................................. 5-32
6 Operations After Replacing Parts.................................................................................................... 6-1
6.1 Home Position Calibration .................................................................................................6-2
6.1.1 Home Position Calibration .................................................................................... 6-2
6.1.2 Calibrating Operation............................................................................................ 6-4
6.1.2.1 Registering All Axes at One Time............................................................ 6-4
6.1.2.2 Registering Individual Axes ..................................................................... 6-5
6.1.2.3 Changing the Absolute Data ................................................................... 6-7
6.1.2.4 Clearing Absolute Data............................................................................ 6-7
6.1.3 Manipulator Home Position................................................................................... 6-9
6.2 Position Deviation Check Using the Check Program....................................................... 6-10
6.3 Checking of the Check Program ...................................................................................... 6-11
6.3.1 Motion of the Check Program ............................................................................. 6-11
6.3.2 Checking of the Check Program......................................................................... 6-11
6.3.3 Home Position Data Correction .......................................................................... 6-12
x
RE-CHO-A109
171768-1CD
11 of 764
DX100 European Standard Maintenance
6.4 Setting the Second Home Position (Check Point) ................................ 6-13
6.4.1 Purpose of Position Check Operation ................................................................ 6-15
6.4.2 Procedure for the Second Home Position Setting (Check Point) ....................... 6-17
6.4.3 Procedure after the Alarm .................................................................................. 6-18
7 System Diagnosis ........................................................................................................................... 7-1
7.1 System Version.................................................................................................................. 7-1
7.2 Manipulator Model ............................................................................................................. 7-1
7.3 Input/Output Status............................................................................................................ 7-2
7.3.1 Universal Input ..................................................................................................... 7-2
7.3.1.1 Universal Input Window........................................................................... 7-2
7.3.1.2 Universal Input Simple Window............................................................... 7-2
7.3.2 Universal Output................................................................................................... 7-3
7.3.2.1 Universal Output Window........................................................................ 7-3
7.3.2.2 Universal Output Simple Window............................................................ 7-3
7.3.2.3 Modifying the Output Status .................................................................... 7-4
Table of Contents
7.3.3 Specific Input ........................................................................................................ 7-5
7.3.3.1 Specific Input Window ............................................................................. 7-5
7.3.3.2 Specific Input Simple Window ................................................................. 7-5
7.3.4 Specific Output ..................................................................................................... 7-6
7.3.4.1 Specific Output Window .......................................................................... 7-6
7.3.4.2 Specific Output Simple Window .............................................................. 7-6
7.3.5 RIN Input .............................................................................................................. 7-7
7.3.5.1 RIN Input Window ................................................................................... 7-7
7.3.6 Signal Number Search ......................................................................................... 7-7
7.3.6.1 Direct Search on the Universal/Specified Input/Output Window ............. 7-8
7.3.6.2 Search from the Menu............................................................................. 7-9
7.3.7 Relay Number Search ........................................................................................ 7-10
7.3.7.1 Direct Search on the Universal/Specified Input/Output Window ........... 7-10
7.3.7.2 Search from the Menu........................................................................... 7-11
7.3.8 Modification of the Signal Name......................................................................... 7-12
7.3.8.1 Direct Modification on the Universal/Specified Input/Output Window ... 7-12
7.3.8.2 Modification from the Menu ................................................................... 7-13
7.4 System Monitoring Time Display ..................................................................................... 7-14
7.4.1 System Monitoring Time Display Window .......................................................... 7-14
7.4.2 Individual Window of the System Monitoring Time Display ................................ 7-15
7.4.3 Clearing the System Monitoring Time Display.................................................... 7-16
xi
RE-CHO-A109
DX100 European
12 of 764
Standard Maintenance
7.5 Alarm History ...................................................................................................................7-17
7.5.1 Alarm History Window ........................................................................................ 7-17
7.5.2 Clearing the Alarm History.................................................................................. 7-18
7.6 I/O Message History ........................................................................................................7-19
7.6.1 I/O Message History Window ............................................................................. 7-19
7.6.1.1 Search ................................................................................................... 7-19
7.6.2 Clearing the I/O Message History....................................................................... 7-20
7.7 Position Data When Power is Turned ON/OFF ............................................................... 7-21
7.7.1 Power ON/OFF Position Window ....................................................................... 7-21
7.8 Current Position ............................................................................................................... 7-22
7.8.1 Current Position Window .................................................................................... 7-22
7.9 Servo Monitoring.............................................................................................................. 7-23
Table of Contents
171768-1CD
7.9.1 Servo Monitor Window........................................................................................ 7-23
7.9.1.1 Changing the Monitor Items .................................................................. 7-23
7.9.1.2 Clearing Maximum Torque Data............................................................ 7-25
8 Alarm............................................................................................................................................... 8-1
8.1 Outline of Alarm ................................................................................................................. 8-1
8.2 Alarm Display..................................................................................................................... 8-2
8.2.1 Displaying and Releasing Alarm........................................................................... 8-2
8.2.1.1 Releasing Alarms .................................................................................... 8-2
8.2.2 Special Alarm Display........................................................................................... 8-3
8.3 Display of Alarm Details..................................................................................................... 8-5
8.3.1 Parameter ............................................................................................................. 8-5
8.3.2 Display of Alarm Detail Window........................................................................... 8-5
8.3.3 Transition of Alarm Detail Window........................................................................ 8-7
8.4 Alarm Message List ........................................................................................................... 8-8
9 Error ............................................................................................................................................... 9-1
9.1 Error Message List............................................................................................................. 9-1
9.1.1 System and General Operation ............................................................................9-2
9.1.2 Editing................................................................................................................... 9-6
9.1.3 Job Defined Data .................................................................................................. 9-7
9.1.4 External Memory Equipment .............................................................................. 9-11
9.1.5 Concurrent I/O .................................................................................................... 9-16
9.1.6 Maintenance Mode ............................................................................................. 9-18
xii
RE-CHO-A109
171768-1CD
13 of 764
DX100 European Standard Maintenance
9.2 Particular Error Message ................................................................................................. 9-20
9.2.1 Message............................................................................................................. 9-20
9.2.1.1 Fatal Error ............................................................................................. 9-20
9.2.1.2 Application Transaction Error ................................................................ 9-20
9.2.1.3 Other Errors .......................................................................................... 9-21
9.2.2 When the Error is Indicated ................................................................................ 9-22
9.2.2.1 Fatal Error ............................................................................................. 9-22
9.2.2.2 Application Transaction Error ................................................................ 9-22
9.2.2.3 Other Errors .......................................................................................... 9-22
10 LED Indicator on Circuit Board .................................................................................................. 10-1
10.1 LED Indicator on YCP 01 Circuit Board......................................................................... 10-1
10.2 LED Indicator on Robot I/F Circuit Board ...................................................................... 10-2
10.3 7 SEG-LED Indicator ..................................................................................................... 10-3
10.3.0.1 7 SEG-LED Indicator Status (1-digit indication)
10.3.0.2 7 SEG-LED Indicator Status (4 digit-indication)
Table of Contents
of Each Unit at Error Occurrence ........................................................ 10-4
of Each Unit at Error Occurrence ....................................................... 10-5
11 Trouble Shooting When Alarm is not Displayed ......................................................................... 11-1
xiii
RE-CHO-A109
DX100 European
JZRCR-YPU01-1
Interior circulation fan:
4715MS-22T-B5A-B00
194E-A40-1753-6G
JANCD-YIF01-1E
JZNC-YPS01-E
JZNC-YRK01-1E
JZNC-YIU02-E
JZNC-YSU01-1E
Backside duct fan:
4715MS-22T-B5A-B00
A
A
A-A’ Section
Inside View of Door
Front View
Inside the Controller
Back View
(without cover)
Power supply contractor unit
CPS Unit
CPU Unit
Machine safety unit
Robot I/F board
I/O Unit
Main power switch
(-X18) Robot system input terminal block
SERVOPACK: Refer to the following table.
JANCD-YBK01-1E
Brake control board
14 of 764
Standard Maintenance

1 Equipment Configuration

1.1 Arrangement of Units and Circuit Boards

1 Equipment Configuration
The DX100 is comprised of individual units and modules (circuit boards). Malfunctioning components can generally be easily repaired after a failure by replacing a unit or a module. This section explains the configuration of the DX100 equipment.
1.1 Arrangement of Units and Circuit Boards

1.1.1 Arrangement

The arrangements of units and circuit boards in small-capacity, medium­capacity, and large-capacity DX100s are shown.
1.1.1.1 Small-Capacity DX100 Controller
Fig. 1-1: Configuration of Small Capacity DX100
171768-1CD
Model DX100 SERVOPACK (Converter Integrated)
MH5L ERDR-MH00005-E02 JZRCR-YSV01-11
MH5
MH6 ERDR-MH00006-E02 JZRCR-YSV02-11
MA1400 ERDR-MA01400-E02
JZRCR-YSV02-11 ERDR-MA01400-E04 (without JANCD-YEW01-E)
VA1400 ERDR-VA01400-E02
JZRCR-YSV02-31 ERDR-VA01400-E04 (without JANCD-YEW01-E)
MA1900 ERDR-MA01900-E02
ERDR-MA01900-E04 (without JANCD-YEW01-E)
HP20D ERDR-HP0020D-E02 JZRCR-YSV03-11
HP20D-6
HP20RD
JZRCR-YSV03-11
1-1
RE-CHO-A109
171768-1CD
4715MS-22T-B5A-B00
A
A
JZRCR-YPU01-1
A-A’ Section
Inside View of Door
Front View
Inside the Controller
Power supply contactor unit
(-X18) Robot system input terminal block
SERVOPACK: Refer to the following table.
Interior circulation fan:
4715MS-22T-B5A-B00
194E-A40-1753-6G
JANCD-YIF01-1E
JZNC-YPS01-E
JZNC-YRK01-1E
JANCD-YBK01-1E
JZNC-YIU02-E
JZNC-YSU01-1E
Back View
(without cover)
Backside duct fan:
Main power switch
CPS Unit
CPU Unit
Machine safety unit
Robot I/F board
I/O Unit
Brake control board
15 of 764
DX100 European Standard Maintenance
1 Equipment Configuration
1.1 Arrangement of Units and Circuit Boards
1.1.1.2 Medium and Large-Capacity DX100 Controller
Fig. 1-2: Configuration of Medium and Large Capacity DX100
Model DX100 SERVOPACK Converter
MH50 ERDR-MH00050-E02 JZRCR-YSV04-11 SRDA-COA30A01A-E
MH50-20
MH50-35
MS80 ERDR-MS00080-E02 JZRCR-YSV05-11 SRDA-COA30A01A-E
VS50 ERDR-VS00050-E02 JZRCR-YSV05-41 SRDA-COA30A01A-E
SIA50D ERDR-SIA050D-E02 JZRCR-YSV05-41 SRDA-COA30A01A-E
MA1800 ERDR-MA01800-E02
ES165D ERDR-ES0165D-E02 JZRCR-YSV06-11 SRDA-COA30A01A-E
ES200D ERDR-ES0200D-E02 JZRCR-YSV06-11 SRDA-COA30A01A-E
ES165RD ERDR-ES165RD-E02 JZRCR-YSV06-11 SRDA-COA30A01A-E
ES200RD ERDR-ES200RD-E02 JZRCR-YSV06-11 SRDA-COA30A01A-E
HP165D ERDR-HP0165D-E02 JZRCR-YSV06-11 SRDA-COA30A01A-E
UP350D ERDR-UP0350D-E02 JZRCR-YSV07-11 SRDA-COA30A01A-E
JZRCR-YSV08-11 SRDA-COA30A01A-E ERDR-MA01800-E04 (without JANCD-YEW01-E)
1-2
RE-CHO-A109
DX100 European
(2.5A)4FU
(2.5A)3FU
(10A)
(10A)
2FU
1FU
(SRDA-EAXA01A)
DC24V (Brake)
DC24V
DC24V
DC24V
DC24V
DC24V
(SRDA-COA )
(JZNC-YPS01-E)
(JZNC-YRK01-1E)
(JZNC-YIU02-E)
(JZNC-YSU01-1E)
(JANCD-YBK01-1E)
Power supply contactor unit (JZRCR-YPU01-1)
X81
(+24V1)
CN209
(+24V3)
CN400
+24V2)
CN584
CN583
CN584
CN583
CN584
CN583
CN584
CN583
CN584
CN583
CN404
(+24VU)
(+24V3)
CN403
(+24V1)
(+24V1
/
CN510
CN508
CN509
AMP6
AMP5
AMP4
AMP3
AMP2
CN551
CN556CN552
CN555
CN554
AMP1
CN584
CN583
+24VU)
(+24V2
/
(+24V2)
CN304
CN303
CN305
(+24V1/+24V2)
CN200
(+24V2)
CN158
+24V2 )
(+24V1/
CN5
CN2
CN1
Control circuit board
BACK BOARD
JANCD-YBB01
BATTERY
CN110
JANCD-YIF01- E CNBUS
ROBOT I/F BOARD
JANCD-YCP01-E
CN1A/1B
(+5V)
+24V2 )
(+24V1/
CN157
CN154
(AC200V IN)
CN151
(+24V3)
CN153
CN155
(+24V2)
CN156
CN159
CN604
CN603
CN606
CN602
2KM
2KM1KM
10A
AC250V
1KM
E
E
E
CN582
CN582
CN582
CN582
CN582
CN582
-G1
-G3
-G4
E
-G2
- AE2
- AE3
- AE1
- AE7
- AE4
- AE5
- TP1
- AE6
- TA1
- TA2
- TA3
- TA4
- TA5
- TA6
L2(S)
L1(R)
PE
L3(T)
-X4
1 2
CN601
3
2
4
1
3
- Q1M
6
5
2
4
1
3
- FS1
6
5
L1’
L2’
- V1
L3’
L1
L2
L3
u
v
- T1
w
U
V
W
3 phase 400 VAC 50/60 Hz
Filter
CPS Unit
Backside duct fan
Interior circulation fan
CPU Unit
Machine safety unit
Programming pendant
Brake control board
Major axes control circuit board
Converter
Manipulator
SERVOPACK
I O Unit
SGDR-FBA A
24V(IN)
5V(OUT)
Brake
Power
Brake
Power
Brake
Power
Brake
Power
Brake
Power
Brake
Power
T-axis motor
B-axis motor
R-axis motor
U-axis motor
L-axis motor
S-axis motor
16 of 764
Standard Maintenance
171768-1CD
1 Equipment Configuration

1.2 Power Flow

1.2 Power Flow
1-3
RE-CHO-A109
(SRDA-EAXA01A)
(SRDA- )
(SRDA-COA )
(JANCD-YBK01-1E)
(JZNC-YSU01-1E)
(JZNC-YRK01-1E)
(JZNC-YPS01-E)
Power supply contactor unit (JZRCR-YPU01-1)
(JZRCR-YPP01-
)
I/O=8/8
I
/
O=8/8
I
/
O=12/12
I
/
O=12/12
(JZNC-YIU02-E)
CN607
CN608
RY1 RY2
CN602
1KM
CN601
2KM
CN203CN202
CN209
CN216
CN212
CN211
CN210
CN214
CN208
- X18
CN103
(RS232C)
CN101 (RS422)
CN102
(RS232C)
CN105
(LAN:PP)
(LAN:Ethernet)
CN104
CN581
CN581
CN581
CN581
CN581
CN405
CN402
SHOCK.LAMP
OT
X81
CN512
CN518
CN517
CN516
CN515
CN511
CN513
AMP6
AMP5
AMP4
AMP3
AMP2
AMP1
CN581
CN553
CN507
CN502
CN504
CN506
CN501
CN503
CN505
CN508
(I/O I/F)
CN300
CN309
CN308
CN307
CN306
CN5
CN2
CN1
Control circuit board
BACK BOARD
JANCD-YBB01
BATTERY
CN110
CN113
JANCD-YIF01- E
CN114
CNBUS
ROBOT I/F BOARD
JANCD-YCP01-E
CN1A/1B
CN159
- AE2
- AE3
- AE1
- AE7
- AE4
- AE5
- TP1
- AE6
- TA1
- TA2
- TA3
- TA4
- TA5
- TA6
CPS Unit
I/O Unit
Terminal resistor
(Universal I/O)
(Robot system input terminal block)
Machine safety unit
Terminal resistor
(P.P.
Emergency stop signal)
(Specified I/O)
(Lump)
(External axis overrun)
(Emergency stop signal)
(Overrun)
CPU Unit
Brake control board
Programming pendant
Manipulator
S-axis motor
L-axis motor
U-axis motor
R-axis motor
B-axis motor
T-axis motor
(Optional )
Major axes control circuit board
SERVOPACK
Converter
Terminal resistor
(Shock sensor)
17 of 764
171768-1CD
DX100 European Standard Maintenance
1 Equipment Configuration

1.3 Signal Flow

1.3 Signal Flow
1-4
RE-CHO-A109
DX100 European
18 of 764
Standard Maintenance

2 Security System

2.1 Protection Through Security Mode Settings

2 Security System
2.1 Protection Through Security Mode Settings
The DX100 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.

2.1.1 Security Mode

There are three security modes. Editing mode and management mode require a user ID. The user ID consists of numbers and letters, and contains no less than 4 and no more than 8 characters. (Significant numbers and signs: “0 to 9”, “-”, “.”.
171768-1CD
Security Mode Explanation
Operation Mode This mode allows basic operation of the robot (stopping,
starting, etc.) for people operating the robot work on the line.
Editing Mode This mode allows the operator to teach and edit jobs and
robot settings.
Management Mode
This mode allows those authorized to set up and maintain robot system: parameters, system time and modifying user IDs.
2-1
RE-CHO-A109
171768-1CD
19 of 764
DX100 European Standard Maintenance
2 Security System
2.1 Protection Through Security Mode Settings
Table 2-1: Menu & Security Mode (Sheet 1 of 4)
Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT
JOB JOB Operation Edit
SELECT JOB Operation Operation
CREATE NEW JOB
MASTER JOB Operation Edit
JOB CAPACITY Operation -
RES. START (JOB)
RES. STATUS
CYCLE Operation Operation
VARIABLE 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 -
IN/OUT EXTERNAL INPUT Operation Edit
EXTERNAL OUTPUT Operation Edit
UNIVERSAL INPUT Operation Operation
UNIVERSAL OUTPUT Operation Operation
SPECIFIC INPUT Operation -
SPECIFIC OUTPUT Operation -
RIN Operation -
CPRIN Operation -
REGISTER Operation Management
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
1)
1)
2)
Edit Edit
Edit Edit
Operation -
2-2
RE-CHO-A109
DX100 European
20 of 764
Standard Maintenance
171768-1CD
2 Security System
2.1 Protection Through Security Mode Settings
Table 2-1: Menu & Security Mode (Sheet 2 of 4)
Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT
ROBOT CURRENT POSITION Operation -
COMMAND POSITION Operation -
SERVO MONITOR Management -
WORK HOME POS Operation Edit
SECOND HOME POS Operation Edit
DROP AMOUNT Management Management
POWER ON/OFF POS Operation -
TOOL Edit Edit
INTERFERENCE Management Management
SHOCK SENS LEVEL Operation Edit
USER COORDINATE Edit Edit
HOME POSITION Management Management
MANIPULATOR TYPE Management -
ANALOG MONITOR Management Management
OVERRUN&S-SENSOR
LIMIT RELEASE
ARM CONTROL
SHIFT VALUE Operation -
SYSTEM INFO VERSION Operation -
MONITORING TIME Operation Management
ALARM HISTORY Operation Management
I/O MSG HISTORY Operation Management
SECURITY Operation Operation
EX.MEMORY LOAD Edit -
SAVE Operation -
VERIFY Operation -
DELETE Operation -
DEVICE Operation Operation
FOLDER Edit Management
INITIALIZE
1)
1)
1)
1)
Edit Edit
Edit Edit
Management Management
Operation -
2-3
RE-CHO-A109
171768-1CD
21 of 764
DX100 European Standard Maintenance
2 Security System
2.1 Protection Through Security Mode Settings
Table 2-1: Menu & Security Mode (Sheet 3 of 4)
Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT
PARAMETER S1CxG Management Management
S2C Management Management
S3C Management Management
S4C Management Management
A1P Management Management
A2P Management Management
A3P Management Management
A4P 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
SETUP TEACHING COND. Edit Edit
OPERATE COND. Management Management
OPERATE ENABLE Management Management
FUNCTION ENABLE Management Management
JOG COND. Management Management
PLAYBACK COND. Management Management
FUNCTION COND. Management Management
DATE/TIME Management Management
DISPLAY SETUP
GRP COMBINATION
RESERVE JOB NAME Edit Edit
USER ID Edit Edit
SET SPEED Management Management
KEY ALLOCATION Management Management
JOG KEY ALLOC. Edit Management
RES. START (CNCT) Management Management
AUTO BACK SET Management Management
WRONG DATA LOG Edit Management
ENERGY SAVING FUNCTION Edit Management
CHANGE FONT Operation Operation
CHANGE BUTTON Operation Operation
INITIALIZE LAYOUT Operation Operation
CHANGE WINDOW PATTERN Operation Operation
2)
Management Management
2-4
RE-CHO-A109
DX100 European
22 of 764
Standard Maintenance
171768-1CD
2 Security System
2.1 Protection Through Security Mode Settings
Table 2-1: Menu & Security Mode (Sheet 4 of 4)
Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT
ARC WELDING ARC START COND. Operation Edit
ARC END COND. Operation Edit
ARC AUX COND. Operation Edit
POWER SOURCE COND. Operation Edit
ARC WELD DIAG. Operation Edit
WEAVING Operation Edit
ARC MONITOR Operation Edit
ARC MONITOR (SAMPL) Operation -
HANDLING HANDLING DIAGNOSIS Operation Edit
SPOT WELDING
SPOT WELDING (MOTOR GUN)
GENERAL WEAVING Operation Edit
COMMON TO ALL APPLICATIONS
1 Displayed in the teach mode only. 2 Displayed in the play mode only.
WELD DIAGNOSIS Operation Edit
I/O ALLOCATION Management Management
GUN CONDITION Management Management
SPOT POWER SOURCE COND.
APPLICATION CONDITION SETTING
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.
TIP INSTALLATION Operation Management
APPLICATION SETTING Management Management
GENERAL DIAG. Operation Edit
I/O VARIABLE CUSTOMIZE Operation Operation
Management Management
Management Management
Management Management
2-5
RE-CHO-A109
171768-1CD
23 of 764
DX100 European Standard Maintenance
2.1.1.1 Changing the Security Mode
2 Security System
2.1 Protection Through Security Mode Settings
1. Select {SYSTEM INFO} under the main menu.
– The sub menu appears.
– Note: Icons for the main menu such as arc welding system differ
depending on the system being used.
2. Select {SECURITY}.
– The selection window of security mode appears.
3. Press [SELECT] and select “SEC
URITY MODE”
2-6
RE-CHO-A109
DX100 European
SUPPLE-
MENT
24 of 764
Standard Maintenance
171768-1CD
2 Security System
2.1 Protection Through Security Mode Settings
4. Input the user ID.
– The user ID input window appears.
At the factory, the following below user ID number is preset.
• Editing Mode:[00000000]
Management Mode:[99999999]
5. Press [ENTER].
– The input user ID is compared with the user ID of the selected
security mode. When the correct user ID is entered, the security mode is changed.
2-7
RE-CHO-A109
171768-1CD
25 of 764
DX100 European Standard Maintenance

2.1.2 User ID

2.1.2.1 Changing a User ID
2 Security System
2.1 Protection Through Security Mode Settings
User ID is requested when Editing Mode or Management Mode is operated.
User ID must be between 4 characters and 8, and they must be numbers and symbols. (“0 to 9”,“-” and “.”)
In order to change the user ID, the DX100 must be in Editing Mode or Management Mode. Higher security modes can make changes the user ID of to lower security modes.
1. Select {SETUP} under the main menu.
– The sub menu appears.
2. Select {USER ID}.
– The USER ID window appears.
2-8
RE-CHO-A109
DX100 European
26 of 764
Standard Maintenance
171768-1CD
2 Security System
2.1 Protection Through Security Mode Settings
3. Select the desired ID.
– The character input line appears, a
no. (4 to 8 digits)” is shown.
4. Input current ID and press [ENTER].
– When the correct user ID is entered, a new ID is requested to be
in
put. “Input new ID no.(4 to 8 digits)” appears.
nd the message “Input current ID
5. Input new ID and press [ENTER].
– User ID is changed.
2-9
RE-CHO-A109
171768-1CD
WARNING
27 of 764
DX100 European Standard Maintenance
3 Inspections
3.1 Regular Inspections

3 Inspections

3.1 Regular Inspections

• Do not touch the cooling fan or other equipment while the power is turned ON.
Failure to observe this caution may result in electric shock or injury.
Carry out the following inspections.
Inspection Equipment
DX100 Controller Check that the doors
Interior circulation fan and backside duct fan
Emergency stop button
Enable switch Check operation As required In teach mode
Battery Confirm battery
Power Supply Check power supply
Inspection Item Inspection
Frequency
Daily are completely closed
Check for gaps or damage to the sealed construction
Check operation As required While power ON
Check operation As required While servo ON
alarm or message is displayed or not
voltage is normal
Monthly
As required
As required
Comments
Lead Cables for main power switch
Check falling out, loosing or breaking of the lead cables Check the correlate voltage
3-1
As required
RE-CHO-A109
DX100 European
X81
PROGRAMMING PENDANT
PROPERLY.
CHECK ALL THE DOOR LOCKS
NJ3005-1
kVA
kVA
ERDR-
Average
Peak
NJ3053-1
Kammerfeldstr. 1, D-85391 Allershausen
Motoman
2-1 Kurosaki Shiroishi Yahatanishi-Ku Kitakyushu-City Fukuoka 806-0004 Japan
YASKAWA Electric corporation
Robot Serial No.
Robot Order No.
Robot Type
Type
Date/Signature
Serial No.
AC 400/415/440 V
Power Supply
Part No.
Motoman DX100
with power ON.
WARNING
Do not open the door
High Voltage
X81
PROGRAMMING PENDANT
PROGRAMMING PENDANT
Main power switch
Door lock
X 8 1
28 of 764
Standard Maintenance

3.2.1 Checking if the Doors are Firmly Closed

171768-1CD
3 Inspections

3.2 DX100 Inspections

3.2 DX100 Inspections
• The DX100 has a fully sealed construction, designed to keep external air containing oil mist out of the DX100. Be sure to keep the DX100 doors fully closed at all times, even when the controller is not operating.
• When opening or closing the doors for maintenance, use the specific key for this operation after the main power is turned OFF with the main power switch. (CW: Open, CCW: Close) Make sure to push the door and turn the door-lock with the specific key to open or close the door. When closing the door, turn the door lock until it clicks.
Fig. 3-1: DX100 Front View

3.2.2 Checking for Gaps or Damage in the Sealed Construction Section

• Open the door and check that the seal around the door is undamaged.
• Check that the inside of the DX100 is not stained badly. If it is, determine the cause, take measures and immediately clean it.
• Firmly lock each door and check that no excessive gaps exist around the edge of the door.
3-2
RE-CHO-A109
171768-1CD
NOTE
Air intake
Air outlet
Backside duct fan
Interior circulation fan
29 of 764
DX100 European Standard Maintenance
3 Inspections

3.3 Cooling Fan Inspections

3.3 Cooling Fan Inspections
Inspect the cooling fans as required. A defective fan can cause the DX100 to malfunction because of excessive high temperatures inside.
The interior circulation fan and backside duct fan normally operate while the power is turned ON. Check if the fans are operating correctly by visual inspection and by feeling air moving into the air inlet and from the outlet.
Fig. 3-2: Cooling Fan Construction
When the message of the “Cooling fan in YPS power supply stopped. Exchange fan” is displayed, it may be caused by the error occurrence at the cooling fan (JZNC-YZU01-E) inside CPU unit (JZNC-YPS01-E).
When the message of the “Cooling fan in YPS unit stopped, replace cooling fan” is displayed, carry out an inspection and the replacement of the cooling fan in the CPS unit (JZNC-YPS01-E) as soon as possible.
3-3
RE-CHO-A109
DX100 European
NOTE
REMOTE
TEACH
PLAY
SERVO
ON
READY
SERVO ON
Blinking
30 of 764
Standard Maintenance
3 Inspections

3.4 Emergency Stop Button Inspections

3.4 Emergency Stop Button Inspections
The emergency stop button is located on the programming pendant. Before operating the manipulator, confirm the servo power is OFF by pressing the emergency stop button after the servo ON

3.5 Enable Switch Inspections

The programing pendant is equipped with a three-position enable switch. Perform the following operation to confirm the enable switch operates.
1. Set the mode switch with key on the programming pendant to "TEACH."
Mode switch with key
171768-1CD
2. Press [SERVO ON READY] on the programming pendant. The [SERVO ON] lamp blinks.
3. When the enable switch is grasped lightly, the servo power is turned ON. When the enable switch is grasped fir
mly or released, the servo power
is turned OFF.
If the [SERVO ON] lamp does not light in previous operation (2), check the following:
• The emergency stop button on the programming pendant is being pressed.
• The emergency stop signal is input from external.
• If a major alarm is occurring.
3-4
RE-CHO-A109
Loading...
+ 734 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use