YASKAWA Motoman NX100 User manual

Motoman, Incorporated

805 Liberty Lane

West Carrollton, OH 45449

TEL: (937) 847-6200

FAX: (937) 847-6277

24-Hour Service Hotline: (937) 847-3200

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Part Number: 149201-1

Release Date: February 5, 2004

Document Version: 3

Document Status: Final

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.

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.

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The Motoman NX100 controller represents state-of-the-art technology in robotics today. The

NX100 controller coodinates the operation of the robot with external equipment such as

power supply and positioning tables. The NX100 processes input and output signals,

maintains variable data, and performs numeric processing to convert to and from different

coordinate systems. Furthermore, it provides main logic functions, servo control, program

and constant data memory, and power distribution. Please read this manual thoroughly to

familiarize yourself with the many aspects of the NX100 controller.

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This manual provides system information for the NX100 controller and contains the following

sections:

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Provides general information about the structure of this manual, a list of reference documents,

and customer service information.

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This section provides information regarding the safe use and operation of the NX100

controller.

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Provides detailed information about the NX100, including installation, wiring, specifications,

and maintenance.

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For additional information refer to the following:

• Manipulator Manual

• Operator’s Manual for your application

•ConcurrentI/OManual(P/N)

• Vendor manuals for system components not manufactured by Motoman

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If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200.

Please have the following information ready before you call:

• Robot Type (ES165N, HP6, EA1400N, etc.)

• Application Type (arc welding, spot welding, etc.)

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

• Robot Sales Order Number (located on back of NX100 controller)

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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:

RoboticIndustriesAssociation

900VictorsWay

P.O.Box3724

AnnArbor,Michigan48106

TEL:(734)994-6088

FAX:(734)994-3338

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.

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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)

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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:

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NOTE:

Pay particular attention to the information provided under these headings which are defined

below (in descending order of severity).

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Note: Information appearing in a Note caption provides additional information which is helpful in

understanding the item being explained.

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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, 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).

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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

•Safetymats

•Floormarkings

• Warning lights

Check all safety equipment frequently for proper operation. Repair or replace any

non-functioning safety equipment immediately.

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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.

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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 to PART 1 of the NX100 controller PLC can cause severe personal injury or

death, as well as damage to the robot! Do not make any modifications to PART 1. 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.

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