YASKAWA Motoman NX100 Job Data Restoration Function Manual

Motoman NX100 Controller

Job Data
Restoration
Function Manual

Part Number: 152178-1CD
Revision: 0

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: [phone]
FAX: [phone]
24-Hour Service Hotline: [phone]

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,

©2006 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

Job Data Restoration

152178-1

Chapter 1

Introduction

1.1 About This Document

This manual provides information for the Job Data Restoration Function 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 - JOB DATA RESTORATION INSTRUCTIONS

Provides detailed information for the Job Data Restoration Function.

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 (EA1900N, HP50, etc.)

• Application Type (handling, welding, etc.)

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

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

Final page 1

Function Manual
Chapter 1 Introduction

Notes

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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

Function 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

Function 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

Function Manual
Chapter 2 Safety

Notes

page 8 Final

YASKAWA

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NX100 OPTIONS

INSTRUCTIONS

FOR JOB DATA SIMPLIFIED RESTORATION FUNCTION

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

for future reference.
MOTOMAN INSTRUCTIONS

MOTOMAN- INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERA TOR’S MANUAL
NX100 MAINTENANCE MANUAL

The NX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.

YASKAWA

MANUAL NO.

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MANDATORY

• This manual explains Job data simplified restoration function of the
NX100 system. Read this manual carefully and be sure to understand its
contents before handling the NX100.

• General items related to safety are listed in Section 1: Safety of the
NX100 Instructions. To ensure correct and safe operation, carefully
read the NX100 Instructions 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.

ii

Notes for Safe Operation

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Read this manual carefully before maintenance or inspection of the NX100.
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

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.

MANDATORY

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.”

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

Must never be performed.

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WARNING

• Before maintenance, inspection, and wiring, check that servo power is
turned OFF when the emergency stop buttons on the front door of the
NX100 and programming pendant are pressed.
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.

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.

TURN

Release of Emergency Stop

• Observe the following precautions when performing teaching operations
within the P-point maximum envelope of the manipulator :

- 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.

• Confirm that no persons are present in the P-point maximum envelope of
the manipulator and that you are in a safe location before:

- Turning ON the NX100 power

- 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 are prob­lems.The emergency stop buttons are located on the right of the front door of the NX100
and the programming pendant.

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CAUTION

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• 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 NX100 cabi­net after use.

The programming pendant can be damaged if it is left in the P-point maximum envelope
of the manipulator, on the floor, or near fixtures.

• Read and understand the Explanation of Warning Labels in the NX100
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 supply
cables.
In this manual, the equipment is designated as follows.

Equipment Manual Designation

NX100 Controller NX100
NX100 Programming Pendant Programming Pendant
Cable between the manipulator and the controller Manipulator cable

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Descriptions of the programming pendant keys, buttons, and displays are shown as follows:

Equipment Manual Designation

Programming
Pendant

Character Keys The keys which have characters printed on them are

denoted with [ ].
ex. [ENTER]

Symbol Keys The keys which have a symbol printed on them 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
Numeric Keys

Keys pressed
simultaneously

Displays The menu displayed in the programming pendant is

“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]

denoted with { }.
ex. {JOB}

GO BACK

PAGE

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.

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1 Outline

2 Job Data Restoration

2.1 How to Check Job Data Inconsistent Status . . . . . . . . 2-1

2.2 Job Data Restoration Method . . . . . . . . . . . . . . . . . . . . . .2-3

2.2.1 In Case Same Position Data is Chained. . . . . . . . . . . . . . . . . . 2-3

2.2.2 In Case Not-Registered Position Data is Chained . . . . . . . . . . 2-5

2.2.3 In Case Not-Chained Position Data Exists. . . . . . . . . . . . . . . . 2-7

3 If Fail in Simplified Restoration

3.1 Rechecking Job Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 If Data Inconsistency Alarm Occurs Again. . . . . . . . . . 3-2

4 Related Parameters

5 Specific Output Signal

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1 Outline

There are some cases where the data in file system becomes inconsistent status if the con­troller power is turned off during edit operation.
If this data inconsistent status is neglected, the following data errors (inconsistent status)
might occur in rare cases.
This Job data simplified restoration function checks the inconsistent status of the file and
restore the data error status of the file system.

[Inconsistent status]

inconsistent chain status between position data and instruction file

1) Overlapped chain with same position data

2) Unregistered position data is chained with instruction file

3) Registered position data is not chained

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2.1 How to Check Job Data Inconsistent Status

2 Job Data Restoration

2.1 How to Check Job Data Inconsistent Status

* “FILE” in WRONG DATA LOG screen corresponds to the following data.

① Job data
　　　　② User coordinate data (UFRAME)
　　　　③ Robot calibration file (RBCAL)
　　　　④ Edit buffer (-CUTBUF）

• Execute Job data restoration in management mode.

SUPPLE-

MENT

• Operation mode and editing mode permit monitoring only.

Operation Explanation

1 Detect data error ALARM screen appears.

DOUT
MOVE
END

B001

Out

CF

a

A

2 Press [SYSTEM INFO] under

main menu and select [SECU­RITY]

DOUT
MOVE
END

B001

CF

a

A

Out

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2.1 How to Check Job Data Inconsistent Status

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Operation Explanation

3 Select “MANAGEMENT

MODE”

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DOUT
MOVE
END

CF

4 Press [SETUP] under main

menu and select [WRONG
DATA LOG]

B001

Out

a

A

Input password to switch the mode to Management mode.

DOUT
MOVE
END

B001

Out

CF

a

A

5 Check the details of data incon-

sistency

WRONG DATA LOG screen appears.

DOUT
MOVE
END

B001

Out

CF

a

A

Check the error contents, then execute restoration follow­ing “2.2 JOB data restoration method“.

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2.2 Job Data Restoration Method

2.2 Job Data Restoration Method

2.2.1 In Case Same Position Data is Chained

DOUT
MOVE
END

CF

B001

Operation Explanation

1 Press [UTILITY] to select

[RESTORE]

a

A

Out

Press [RESTORE] to reset the overlapped position data
chain.

DOUT
MOVE
END

B001

Out

CF

a

A

The indication changes from “OCCURRED ON“ to
“RESTORED ON“.

DOUT
MOVE
END

B001

Out

CF

a

A

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2.2 Job Data Restoration Method

* If fail in the restoration If the indication doesn’t change from “OCCURRED ON“ to

“RESTORED ON“, refer to Chapter 3 “If fail in simplified
restoration“.

2 Start up the system again After the restoration, the system must be started up again.

Turn the control power OFF/ON an d then execute the fol­lowing checking operation.

3 Press [SETUP] under main

menu and select [WRONG
DATA LOG]

DOUT
MOVE
END

B001

Out

CF

a

A

WRONG DATA LOG screen appears.

DOUT
MOVE
END

B001

Out

CF

a

A

4 Check the position Check the position of two lines indicated in the screen

DOUT
MOVE
END

B001

Out

CF

a

A

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2.2 Job Data Restoration Method

2.2.2 In Case Not-Registered Position Data is Chained

DOUT
MOVE
END

CF

B001

Out

Operation Explanation

1 Press [UTILITY] and select

[RESTORE]

a

A

Press [RESTORE] button to register the position of the file
indicated in WRONG DATA LOG screen tentatively, which
enables to register position again.

DOUT
MOVE
END

B001

Out

CF

a

A

The indication changes from “OCCURRED ON“ to “REG­ISTERED ON“.

DOUT
MOVE
END

B001

Out

CF

a

A

* If fail in the restoration If the indication doesn’t change from “OCCURRED ON“ to

“RESTORED ON“, refer to Chapter 3 “If fail in simplified
restoration“.

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2.2 Job Data Restoration Method

2 Start up the system again After the restoration, the system must be started up again.

Turn the control power OFF/ON an d then execute the fol­lowing checking operation.

3 Press [SETUP] under main

menu and select [WRONG
DATA LOG]

DOUT
MOVE
END

B001

Out

CF

a

A

WRONG DATA LOG appears.

4 Register teaching position

again

DOUT
MOVE
END

B001

Out

CF

a

A

Register the position data of the file in the screen again.

DOUT
MOVE
END

B001

Out

CF

a

A

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2.2 Job Data Restoration Method

2.2.3 In Case Not-Chained Position Data Exists

DOUT
MOVE
END

CF

B001

Out

Operation Explanation

1 Press [UTILITY] and select

[RESTORE]

a

A

Press [RESTORE] to correct the chain.

DOUT
MOVE
END

B001

Out

CF

a

A

The indication changes from “OCCURRED ON“ to “REG­ISTERED ON“

DOUT
MOVE
END

B001

Out

CF

a

A

* If fail in the restoration If the indication doesn’t change from “OCCURRED ON“ to

“RESTORED ON“, refer to Chapter 3 “If fail in simplified
restoration“.

2 Start up the system again After the restoration, the system must be started up again.

Turn the control power OFF/ON.

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3.1 Rechecking Job Data

3 If Fail in Simplified Restoration

Execute the following procedure if failing in the restoration by Job data simplified restoration
method.

3.1 Rechecking Job Data

Operation Explanation

1 Select [RE CHECK] under

[UTILITY]

2

Restoration is completed

Press [RE CHECK]

DOUT
MOVE
END

B001

Out

CF

a

A

* Proceed to the next operation “3.2 If Data Inconsis­tency Alarm Occurs Again“ if the alarm occurs again
after this operation.

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3.2 If Data Inconsistency Alarm Occurs Again

3.2 If Data Inconsistency Alarm Occurs Again

Execute the following procedure if the data inconsistency alarm occurs again even after
rechecking Job data.

Operation Explanation

1 1) Delete the position data of

the file indicated in WRONG
DATA LOG screen

2) Register position data

Refer to “2.2 Job data restoration method” for chekcing
operation after registration. (See the operations after
procedure 2 “

Execute the following procedure if the position data cannot be deleted or re-registered with the oper­ation indicated above.

Operation Explanation

21)

Save Job data and User
Coordinate file and Robot
Calibration.

*Delete the position data of the file indicated in
WRONG DATA LOG screen in case the following error
occurs while saving.

Start up the system again“)

ERROR: 0040 Undefined robot position variable

* Refer to NX100 OPERATOR’S MANUAL “8.1.2. File
Management“ for details.

2)

Initialize Job area in
maintenance mode.

* Refer to NX100 INSTRUCTIONS “9.18.1 Initialize
Job file“ for details.

3)

Load the data saved in
the procedure 1.

4)

Check the motion of the
manipulator after loading.

* Refer to NX100 OPERATOR’S MANUAL “8.1.2. File
Management“ for details.

* Refer to the procedure from “2 Start up the system

again.”

in 2.2 Job data restoration method.

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4 Related Parameters

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Parameter Meaning Setting value

S2C221 Data inconsistency check specification

S2C222 Inconsistency detection method in play mode

0：Valid
1：Invalid

0：Warning
1：Stop with alarm

Initial
value

0

0

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5 Specific Output Signal

The following signal outputs the status of data inconsistency occurrence.

Output signal Meaning

50356 Indicate the data inconsistency occurrence

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5-2

NX100 OPTIONS

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INSTRUCTIONS

FOR JOB DATA SIMPLIFIED RESTORATION FUNCTION

HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi -ku, Kitakyusyu -shi, 806-0004, Japan
Phone [phone] Fax [phone]

MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone [phone] Fax [phone]

YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone [phone] Fax [phone]

MOTOMAN ROBOTICS E UR OPE AB
Franska Vagen 1039854, K almar, Sweden
Phone [phone] Fax [phone]

MOTOMAN RO BOTEC G mbH
Kammerfel d strasse 1, DE-85 391 A l lershausen, Germ an y
Phone [phone] Fax [phone]

YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1 , Shinchun-dong, Donk-K u , Daegu, Korea
Phone [phone] Fax [phone]

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singa pore
Phone [phone] Fax [phone]

YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysi a
Phone [phone] Fax [phone]

YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei , T ai wan
Phone [phone] Fax [phone]

SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone [phone] Fax [phone]

YASKAWA ELECTRIC CORPORATION

YASKAWA

Specifications are subject to change without notice
for ongoing product modifications and improvements.

MANUAL NO.

C

Printed in Japan January 2006 06-1