YASKAWA MOTOMAN FS100 Bedienungsanleitung

MANUAL NO. RE-CHO-A111

YASKAWA ELECTRIC CORPORATION

FS100

MAINTENANCE MANUAL

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

for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN- INSTRUCTIONS

FS100 INSTRUCTIONS

FS100 OPERATOR’S MANUAL

FS100 MAINTENANCE MANUAL

FS100

MANDATORY

• This manual explains maintenance procedures of the FS100

system. Read this manual carefully and be sure to understand its

contents before handling the FS100.

• General items related to safety are listed in Chapter 1: Safety of the

FS100 INSTRUCTIONS. To ensure correct and safe operation,

carefully read the FS100 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.

• 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.

FS100

iii

Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or

inspection of the FS100 .

In this manual, the Notes for Safe Operation are classified as “DANGER”,

“WARNING”, “CAUTION”, “MANDATORY”, or “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.

DANGER

Indicates an imminent hazardous

situation which, if not avoided, could

result in death or serious injury to

personnel.

WARNING

Indicates a potentially hazardous

situation which, if not avoided, could

result in death or serious injury to

personnel.

CAUTION

Indicates a potentially hazardous

situation which, if not avoided, could

result in minor or moderate injury to

personnelanddamageto equipment.

It may also be used to alert against

unsafe practices.

MANDATORY

Always be sure to follow explicitly the

items listed under this heading.

PROHIBITED

Must never be performed.

NOTE

To ensure safe and efficient operation at all times, be sure

to follow all instructions, even if not designated as “DAN-

GER”, “WARNING” and “CAUTION” .

FS100

WARNING

• Before operating the manipulator, check that servo power is turned

OFF when the emergency stop button on the programming pendant

is pressed.

When the servo power is turned OFF, the SERVO ON LED on the

programing 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 button does not function.

Fig. : Emergency Stop Button

• In the case of not using the programming pendant, be sure to

supply the emergency stop button on the equipment. Then before

operating the manipulator, check to be sure that the servo power is

turned OFF by pressing the emergency stop button.

Connect the external emergency stop button to the 5-6 pin and 16-

17 pin of the robot system signal connector (CN2).

• Upon shipment of the FS100, this signal is connected by a jumper

cable in the dummy connector. To use the signal, make sure to

supply a new connector, and then input it.

If the signal is input with the jumper cable connected, it does not

function, which may result in personal injury or equipment damage.

• 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.

Fig. : Release of Emergency Stop Button

• Observe the following precautions when performing teaching

operations within the manipulator’s operating range:

– 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.

TURN

FS100

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the FS100 controller,

manipulator cables, the FS100 programming pendant (optional), and the

FS100 programming pendant dummy connector (optional).

In this manual, the equipment is designated as follows:

WARNING

• Confirm that no person is present in the manipulator’s operating

range and that you are in a safe location before:

– Turning ON the power for the FS100.

– Moving the manipulator with the programming pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the manipulator’s operating range

during operation. Always press an emergency stop button immediately

if there are problems.

The emergency stop button is located on the programing pendant.

CAUTION

• Perform the following inspection procedures prior to teaching the

manipulator. If problems are found, correct them immediately, and

be sure that all other necessary tasks have been performed.

– Check for problems in manipulator movement.

– Check for damage to the insulation and sheathing of external

wires.

• Return the programming pendant to a safe place after use.

If the programming pendant is inadvertently left on the manipulator,

on a fixture, or on the floor, the manipulator or a tool may collide with

the programming pendant during manipulator movement, which may

result in personal injury or equipment damage.

• Read and understand the Explanation of Warning Labels in the

FS100 Instructions before operating the manipulator.

Equipment Manual Designation

FS100 controller FS100

FS100 programming pendant Programming pendant

Cable between the manipulator and

the controller Manipulator Cable

FS100 programming pendant

dummy connector Programming pendant

dummy connector

FS100

Descriptions of the programming pendant keys, buttons, and displays are

shown as follows:

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.

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 is an exception, and a picture is

not shown.

Axis Keys

Numeric Keys “Axis Keys” and “Numeric Keys” are generic

names for the keys for axis operation and

number input.

Keys pressed

simultaneously When two keys are to be pressed

simultaneously, the keys are shown with a

“+” sign between them,

ex. SHIFT key +COORD key

Mode Key Three kinds of modes that can be selected

by the mode key are denoted as follows:

REMOTE, PLAY, or TEACH

Button Three buttons on the upper side of the

programming pendant are denoted as

follows:

HOLD button

START button

EMERGENCY STOP button

Displays The menu displayed in the programming

pendant is denoted with { }.

ex. {JOB}

PC Keyboard The name of the key is denoted

ex. Ctrl key on the keyboard

GO BACK

PAGE

SHIFT

TOOL SEL

COORD

FS100

vii

Explanation of Warning Labels

DANGER

• 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.

Fig. : Warning Labels

• The following warning labels are attached to FS100.

Observe the precautions on the warning labels.

Failure to observe this warning may result in injury or damage to

equipment.

Fig. : Location of Warning Labels

WARNING Label B:

WARNING Label A:

WARNING

Do not enter

robot

work area.

WARNING

Moving parts

may cause

injury

Heavy Object Warning NP

Electric Shock Warning NP

Top View

Front View

FS100

viii

1 Equipment Configuration.................................................................................................................1-1

1.1 Arrangement of Units and Circuit Boards ..........................................................................1-1

1.2 Power Flow...................................................................................................................................... 1-2

1.3 Signal Flow...................................................................................................................................... 1-3

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...................................................................2-5

2.1.2 User ID..................................................................................................................2-7

2.1.2.1 Changing a User ID.................................................................................2-7

3 Maintenance and Inspections .........................................................................................................3-1

3.1 Daily Inspections................................................................................................................3-1

3.2 Cooling Fan Inspections ....................................................................................................3-3

3.3 Emergency Stop Button Inspections..................................................................................3-4

3.4 Enable Switch Inspections.................................................................................................3-4

3.5 Battery Inspections ............................................................................................................3-5

4 Preparation before Replacing Parts................................................................................................4-1

4.1 Creating a Check Program ................................................................................................4-3

5 Replacing Parts...............................................................................................................................5-1

5.1 Fuse Replacement.............................................................................................................5-1

5.2 Interior Circulation Fan Replacement ................................................................................5-3

5.3 Battery Replacement .........................................................................................................5-4

6 Recommended Spare Parts............................................................................................................6-1

6.1 List of Accessories.............................................................................................................6-1

6.2 Recommended Spare Parts...............................................................................................6-2

7 Operations After Replacing Parts....................................................................................................7-1

7.1 Home Position Calibration .................................................................................................7-2

7.1.1 Home Position Calibration....................................................................................7-2

7.1.2 Calibrating Operation............................................................................................7-4

7.1.2.1 Registering All Axes at One Time............................................................7-4

7.1.2.2 Registering Individual Axes.....................................................................7-6

7.1.2.3 Changing the Absolute Data ...................................................................7-7

7.1.2.4 Clearing Absolute Data............................................................................7-8

FS100

7.1.3 Manipulator Home Position ................................................................................ 7-10

7.2 Position Deviation Check Using the Check Program.......................................................7-11

7.3 Checking of the Check Program......................................................................................7-12

7.3.1 Motion of the Check Program.............................................................................7-12

7.3.2 Checking of the Check Program.........................................................................7-12

7.3.3 Home Position Data Correction..........................................................................7-13

7.4 Setting the Second Home Position (Check Point)...........................................................7-14

7.4.1 Purpose of Position Check Operation ................................................................7-16

7.4.2 Procedure for the Second Home Position Setting (Check Point).......................7-18

7.4.3 Procedure after the Alarm ..................................................................................7-19

8 System Diagnosis...........................................................................................................................8-1

8.1 System Version..................................................................................................................8-1

8.2 Manipulator Model.............................................................................................................8-1

8.3 Input/Output Status............................................................................................................8-2

8.3.1 Universal Input .....................................................................................................8-2

8.3.1.1 Universal Input Window...........................................................................8-2

8.3.1.2 Universal Input Simple Window...............................................................8-2

8.3.2 Universal Output...................................................................................................8-3

8.3.2.1 Universal Output Window........................................................................8-3

8.3.2.2 Universal Output Simple Window............................................................8-3

8.3.2.3 Modifying the Output Status....................................................................8-4

8.3.3 Specific Input........................................................................................................8-5

8.3.3.1 Specified Input Window...........................................................................8-5

8.3.3.2 Specific Input Simple Window.................................................................8-5

8.3.4 Specific Output.....................................................................................................8-6

8.3.4.1 Specified Output Window........................................................................8-6

8.3.4.2 Specific Output Simple Window..............................................................8-6

8.3.5 RIN Input ..............................................................................................................8-7

8.3.5.1 RIN Input Window ...................................................................................8-7

8.3.6 Signal Number Search .........................................................................................8-8

8.3.6.1 Direct Search on the Universal/Specified Input/Output Window.............8-9

8.3.6.2 Search from the Menu...........................................................................8-10

8.3.7 Relay Number Search........................................................................................8-11

8.3.7.1 Direct Search on the Universal/Specified Input/Output Window...........8-12

8.3.7.2 Search from the Menu...........................................................................8-13

8.3.8 Modification of the Signal Name.........................................................................8-14

8.3.8.1 Direct Modification on the Universal/Specified Input/Output Window ...8-14

8.3.8.2 Modification from the Menu...................................................................8-15

FS100

8.4 System Monitoring Time Display .....................................................................................8-16

8.4.1 System Monitoring Time Display Window ..........................................................8-16

8.4.2 Individual Window of the System Monitoring Time Display................................8-17

8.4.3 Clearing the System Monitoring Time Display....................................................8-18

8.5 Alarm History ...................................................................................................................8-19

8.5.1 Alarm History Window ........................................................................................8-19

8.5.2 Clearing the Alarm History..................................................................................8-20

8.6 I/O Message History ........................................................................................................8-21

8.6.1 I/O Message History Window .............................................................................8-21

8.6.1.1 Search...................................................................................................8-21

8.6.2 Clearing the I/O Message History.......................................................................8-22

8.7 Position Data When Power is Turned ON/OFF ...............................................................8-23

8.7.1 Power ON/OFF Position Window .......................................................................8-23

8.8 Current Position...............................................................................................................8-24

8.8.1 Current Position Window....................................................................................8-24

8.9 Servo Monitoring..............................................................................................................8-25

8.9.1 Servo Monitor Window........................................................................................8-25

8.9.1.1 Changing the Monitor Items ..................................................................8-26

8.9.1.2 Clearing Maximum Torque Data............................................................8-28

9 Alarm...............................................................................................................................................9-1

9.1 Outline of Alarm.................................................................................................................9-1

9.2 Alarm Display.....................................................................................................................9-2

9.2.1 Displaying and Releasing Alarm...........................................................................9-2

9.2.1.1 Releasing Alarms ....................................................................................9-2

9.2.2 Special Alarm Display...........................................................................................9-3

9.3 Display of Alarm Details.....................................................................................................9-5

9.3.1 Parameter.............................................................................................................9-5

9.3.2 Display of Alarm Detail Window...........................................................................9-5

9.3.3 Transition of Alarm Detail Window........................................................................9-7

9.4 Alarm Message List ...........................................................................................................9-8

10 Error...........................................................................................................................................10-1

10.1 Error Message ...............................................................................................................10-1

10.1.1 System and General Operation........................................................................10-2

10.1.2 Editing...............................................................................................................10-5