YASKAWA XRC 2001 Function Manual

XRC and XRC 2001 Controller

Twin Drive
Function Manual

for UP/SKX-Series Robots

Part Number 148308-1

July 15, 2003

MOTO MAN

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, Inc.

©2003 by MOTO MAN

All Rights Reserved

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.

TABLE OF CONTENTS

Section

1 INTRODUCTION

1.1 About this Document .................................................................................................... 1-1

1.2 Reference to Other Documentation................................................................................ 1-1

1.3 Customer Service Information....................................................................................... 1-1

2 SAFETY

2.1 Introduction .................................................................................................................. 2-1

2.2 Standard Conventions................................................................................................... 2-2

2.3 General Safeguarding Tips............................................................................................ 2-4

2.4 Mechanical Safety Devices............................................................................................ 2-4

2.5 Installation Safety.......................................................................................................... 2-5

2.6 Programming Safety ..................................................................................................... 2-5

2.7 Operation Safety............................................................................................................ 2-6

2.8 Maintenance Safety....................................................................................................... 2-7

3 TWIN DRIVE INSTRUCTIONS

1 Outline for Twin Drive Instructions................................................................................ 1-1

2 Applicable Stations...................................................................................................... 2-1

3 Operation......................................................................................................................3-1

4 Setting Parameters........................................................................................................ 4-1

5 Status Display...............................................................................................................5-1

6 Precautions...................................................................................................................6-1

Page

MOTO MAN i Twin Drive Function Manual

NOTES

Twin Drive Function Manual ii

MOTO MAN

SECTION 1

INTRODUCTION

1.1 About this Document

This manual provides information on how to use the Twin Drive Function on the
XRC controller.

This manual is organized as follows:

SECTION 1 – INTRODUCTION

General information about this manual, a list of reference documents, and
customer service information.

SECTION 2 – SAFETY

Provides information for the safe use and operation of Motoman products.

SECTION 3 – TWIN DRIVE FUNCTION INSTRUCTIONS

Provides detailed instructions for setting up and using the Twin Drive Function on
the XRC controller.

1.2 Reference to Other Documentation

For additional information refer to the following:

• Concurrent I/O Parameters Manual for XRC 2001 (P/N 147626-1)

• Operator’s Manual for General Purpose (P/N 142099-1)

• Operator’s Manual for Handling (P/N 142100-1)

• Operator’s Manual for Spot Welding (P/N 142101-1)

• Operator’s Manual for Arc Welding (P/N 142098-1)

• Motoman UP6, XRC 2001 Manipulator Manual (P/N 145960-1)

• Motoman UP20, XRC 2001 Manipulator Manual (P/N 145965-1)

• Motoman UP50, XRC 2001 Manipulator Manual (P/N 145964-1)

• Motoman UP130/165, XRC 2001 Manipulator Manual (P/N 145967-1)

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 (UP6, UP130, UP165, etc.)

• Application Type (welding, handling, etc.)

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

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

MOTO MAN 1-1 Twin Drive Function Manual

INTRODUCTION

NOTES

Twin Drive Function Manual 1-2

MOTO MAN

SECTION 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. The address is as follows:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: [phone]
FAX: [phone]

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.

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 Safety (Section 2.6)

• Operation Safety (Section 2.7)

• Maintenance Safety (Section 2.8)

MOTO MAN 2-1 Twin Drive Function Manual

SAFETY

2.2 Standard Conventions

This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:

• DANGER

• WARNING

• CAUTION

•NOTE

Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).

DANGER!

Information appearing under the DANGER caption 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 under the WARNING caption 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 under the CAUTION caption 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 caption provides additional information which is helpful in

understanding the item being explained.

Twin Drive Function Manual 2-2

MOTO MAN

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.

SAFETY

• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, 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 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
measures are available:

• Safety fences and barriers

• Light curtains

• Door interlocks

• Safety mats

• Floor markings

• Warning lights

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

MOTO MAN 2-3 Twin Drive Function Manual

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 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 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. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Programming tips are
as follows:

• Any modifications of the controller PLC can cause severe personal injury or
death, as well as damage to the robot! Do not make any modifications to the
PLC. 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.

• Back up all programs and jobs onto a floppy disk whenever 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.

• The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.

• 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 operate the system.

Twin Drive Function Manual 2-4

MOTO MAN

• 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 the E-STOP button on the teach pendant for proper operation before
programming.

• Carry the teach pendant with you when you enter the workcell.

• Be sure that only the person holding the teach pendant enters the workcell.

• Test any new or modified program at low speed for at least one full cycle.

2.7 Operation 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. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Operation tips are as
follows:

• Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.

SAFETY

• Check all safety equipment for proper operation. Repair or replace any non­functioning safety equipment immediately.

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

• Ensure that all safeguards are in place.

• 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 operate the system.

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

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

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

• 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. This includes controller parameters, ladder, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.

MOTO MAN 2-5 Twin Drive Function Manual