NXC100 MAINTENANCE MANUAL

Transcription

1 NXC100 MAINTENANCE MANUAL Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS NXC100 INSTRUCTIONS NXC100 REPLACEMENT MANUAL Part : CD Revision: 0 MANUAL NO. RE-CHO-A /245

2 CD MANDATORY This manual explains maintenance procedures of the NXC100 system. Read this manual carefully and be sure to understand its contents before handling the NXC100. General items related to safety are listed in the NXC100 Instructions. To ensure correct and safe operation, carefully read the NXC100 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 Motoman 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 Motoman is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product s warranty. ii RE-CHO-A105 2/245

3 CD Notes for Safe Operation Read this manual carefully before maintenance or inspection of the NXC100. In this manual, the Notes for Safe Operation are classified as WARNING, CAUTION, MANDATORY, or PROHIBITED. WARNING CAUTION 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. MANDATORY Always be sure to follow explicitly the items listed under this heading. PROHIBITED 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. NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as CAUTION and WARNING. iii RE-CHO-A105 3/245

4 CD WARNING Before maintenance, inspection, and wiring, check that servo power is turned OFF when the emergency stop buttons on the front face of the NXC100 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 NXC100 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 front face of the NXC100 and the programming pendant. iv RE-CHO-A105 4/245

5 CD CAUTION 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 user s designated place 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 NXC100 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 NXC100 Controller NXC100 Programming Pendant Cable between the manipulator and the controller NXC100 Programming Pendant Manipulator cable v RE-CHO-A105 5/245

6 CD Descriptions of the programming pendant keys, buttons, and displays are shown as follows: Equipment Manual Designation Programming Pendant Character Keys Symbol Keys Axis Keys Numeric Keys Keys pressed simultaneously Displays The keys which have characters printed on them are denoted with [ ]. ex. [ENTER] The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture. GO BACK ex. page key PAGE 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] The menu displayed in the programming 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. vi RE-CHO-A105 6/245

7 1 Equipment Configuration 1.1 Arrangement of Units and Circuit Boards Configuration Signal Flow Security System 2.1 Protection Through Security Mode Settings Security Mode Changing the Security Mode User ID Changing a User ID Inspections 3.1 Inspection Schedule Inspection Items Cable Inspection Inspection of Whole Exterior Inspection of Air Filter Inspection of Cover Mounting Screws Inspection of Emergency Stop Button Inspection of Enable Switch Battery Inspection Preparation before Replacing Parts 4.1 Creating a Check Program Saving of the NXC100 Data Replacing Parts 5.1 Replacing NXC100 Parts Replacing the Battery Replacement Procedure Checking and Replacing Fuses Replacing the Air Filter Replacing the NXC vii 7/245

8 5.3 Supplied Parts List Recommended Spare Parts Operations after Replacing Parts 6.1 Home Position Calibration Home Position Calibration Calibrating Operation Registering All Axes at One Time Registering Individual Axes Changing the Absolute Data Clearing Absolute Data Manipulator Home Position Position Deviation Check Using the Check Program Verifying the Check Program Verifying the Check Program Operation Verifying the Check Point Home Position Data Correction Setting the Second Home Position (Check Point) Purpose of Position Check Operation Procedure for the Second Home Position Setting (Check Point) Procedure after the Loading the NXC100 Data System Diagnosis 7.1 System Version Manipulator Model Input/Output Status Universal Input Universal Input Window Universal Input Simple Window Universal Output Universal Output Window Universal Output Simple Window Modifying the Output Status Specific Input Specific Input Window Specific Input Simple Window Specific Output Specific Output Window Specific Output Simple Window RIN Input RIN Input Window viii 8/245

9 7.3.6 Signal Search Direct Search on the Universal/Specified Input/Output Window Search from the Menu Relay Search Direct Search on the Universal/Specified Input/Output Window Search from the Menu Modification of the Signal Name Direct Modification on the Universal/Specified Input/Output Window Modification from the Menu System Monitoring Time Display System Monitoring Time Display Window Individual Window of the System Monitoring Time Display Clearing the System Monitoring Time Display History History Window Clearing the History I/O History I/O History Window Search Clearing the I/O History Position Data When Power is Turned ON/OFF Power ON/OFF Position Window Current Position Current Position Window Servo Monitoring Servo Monitor Window Changing the Monitor Items Clearing Maximum Torque Data Outline of Display Displaying and Releasing Releasing s Special Display Data Multiple SERVOPACK System Independent Control Function (Optional) List ix 9/245

10 9 Error 9.1 Error List System and General Operation Editing Job Defined Data External Memory Equipment Concurrent I/O Maintenance Mode LED Indicators Segment LED and Battery LED Indicators SEG-LED Indicator SEG-LED Indicator Status (1-digit indication) of Each Unit at Error Occurrence SEG-LED Indicator Status (4 digit-indication) of Each Unit at Error Occurrence x 10/245

11 1.1 Arrangement of Units and Circuit Boards 1 Equipment Configuration The NXC100 is comprised of individual units and modules (circuit boards). This section explains the configuration of the NXC100 equipment. 1.1 Arrangement of Units and Circuit Boards Configuration PPESP X32 PBESP FAN guard (Installed in the controller) FAN guard (Installed in the controller) I/O circuit board JANCD-NIO30B-1 Safety ciruit board JANCD-NIF30B-1 AXIS circuit board SGDR-AXC01B CB circuit board SGDR-COBCB030GAB AMP1 SGDR-SDCCA02AAB Resistor RF70 50ΩK Surge absorber RAV-781BWZ-4 Filter SUP-EL10-E1R-6 Handle Power supply CPS-320F CA circuit board SGDR-COBCA01AB Power-ON circuit board JANCD-NTU30B CPU circuit board JANCD-NCP30 FAN AMP2 SGDR-SDCCA01AAB Left-Inner face Fuse ( 2) NXC100 Configuration /245

12 1.2 Signal Flow 1.2 Signal Flow EXTENTION SIGNAL X62 SON1,SON2 BON1,2 SVMAIN1,2 SVMXOK1 4 SVMXOKCOM SPM0D1 3 SPMODCOM JANCD-NBB31 CNA4 CNB01 CNP CNB02 CARD EDGE CPS-320F FILTER FUSE MAIN SW (R-IN)CN02 (R-IN,R-OUT)CN03 (LINE)CN04 CN01 JANCD-NCP30 CNCF1 USB VGA2 Compact PARAREL PS/2 FLASH CN16 FUFAN1,2 TB1 SUP FILTER LAN1 AC FAN AC FAN COM1 LAND (EXON)CNPB SINGLE PHASE AC200/220V X41 X32 CPU RESET INPUT/OUTPUT FAN4 FAN5 X52 HOST RS-232C (UNDER DEVELOPMENT) X51 HOST ETHERNET (UNDER DEVELOPMENT) PROGRAMING PENDANT X81 PPESP (DUMMY (DUMMY HOST I/O DI01 DI12 DO0 DO13 CONNECTOR HB ) to HOST SAFETY CIRCUIT INPUT/OUTPUT CONNECTOR HB ) SVON,CHKOUT FST1,2/SSP SAFE1,2/FORCE1,2 EXSVON EXHOLD EXDSW EXESP1,2 X33 X61 CNA5 CNA6 CNB03 CNC CNB04 CNAP3 CNB16 CNB06 CNB05 CN5 CN4 JANCD-NIF30B-1 CN1 CNLED CND JANCD-NIO30B-1 CN1 OPTION PCI BOARD (OPTION) JANCD-NSP30 CN3 CNLED2 BAT CN1 CN6 CN2 CN3 PBESP 7SEG LED FUSE BATTERY EMERGENCY STOP SW X53 M-II(DISTRIBUTED I/O) X55 CERF to AXIS BOARD (UNPOPULATED) SON1,SON2 BON1,2 SPMOD1 3 SPMODCOM SON1,SON2 BON1,2 SPMOD1 3 SPMODCOM X63 X64 CNA1 CNA2 CNA7 CNB07 CNK2 CNB08 CNK1 CNB09 CNJS CNB10 CNB17 CN6 CNB17 CNB11 CN4 CNB12 CN15 DC FAN JANCD-NPA30 DC (OPTION) FAN DC LED FAN CN2 CN52A SGDR-AXC01B CNLED1 CN4 CN03A CNBT CN51A SGDR-AXD01A (OPTION) JANCD-NTU30B CN3 SGDR-COBCA01AB CN1 CN1B M-II CN2 CN1A +17V CN9 CN10 CN14 CN11 CN1 X71 X31 CM53A ANALOG MONITOR SIGNAL X54 CMO3B CERF TO AXIS BOARD CN02 BRAKE PG(EX AXIS) PG(6 AXES) SGDR-COBCB030GAB CN1CN4 CN3 CN8 100V/200V SWITCH SGDR-SDCCA02AAB AMP1 CN1 +17V CN2 CN3 CN4 CN7 CN5 PN CNB13 CN6 CN2 CN13 CN5 CN6 PN CN7 CN12 RF70 50kΩ SGDR-SDCCA01AAB AMP2 CN1 CN2 CN3 CN4 CN7 CN5 CNB14 CN6 +17V PN X72 ANALOG SENSOR OUTPUT X11 X12 X21 X22 JANCD-NCU31 CN1 CN2 CNB15 SGDR-SDCCA0 AAA AMP3 CN1 (OPTION) CN2 CN3 CN4 CN7 CN5 CNB18 CN6 +17V PN 6 AXES (MANIPULATOR) 24V SGDR-FBA02 5V S AXIS MOTOR L AXIS MOTOR U AXIS MOTOR R AXIS MOTOR B AXIS MOTOR T AXIS MOTOR /245

13 2.1 Protection Through Security Mode Settings 2 Security System 2.1 Protection Through Security Mode Settings The NXC100 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 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, -,.. Security Mode Descriptions Security Mode Operation Mode Editing Mode Management Mode Explanation This mode allows basic operation of the robot (stopping, starting, etc.) for people operating the robot work on the line. This mode allows the operator to teach and edit jobs and robot settings. This mode allows those authorized to set up and maintain robot system: parameters, system time and modifying user IDs /245

14 2.1 Protection Through Security Mode Settings Menu & Security Mode Main Menu Menu Allowed Security Mode DISPLAY EDIT JOB JOB Operation Edit SELECT JOB Operation Operation CREATE NEW JOB *1 Edit Edit MASTER JOB Operation Edit JOB CAPACITY Operation - RES. START (JOB) *1 Edit Edit RES. STATUS *2 Operation - 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 - EXTERNAL OUTPUT Operation - UNIVERSAL INPUT Operation - UNIVERSAL OUTPUT Operation - SPECIFIC INPUT Edit - SPECIFIC OUTPUT Edit - RIN Edit - CPRIN Operation - REGISTER Edit - AUXILIARY RELAY Edit - CONTROL INPUT Edit - PSEUDO INPUT SIG Edit Management NETWORK INPUT Edit - NETWORK OUTPUT Operation - ANALOG OUTPUT Edit - SV POWER STATUS Edit - LADDER PROGRAM Management Management I/O ALARM Management Management I/O MESSAGE Management Management *1 Teach mode only *2 Play mode only /245

15 2.1 Protection Through Security Mode Settings Menu & Security Mode Main Menu 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 Management USER COORDINATE Edit Edit HOME POSITION Management Management MANIPULATOR TYPE Management - 3.ROBOT CALIBRATION Edit Edit ANALOG MONITOR Management Management OVERRUN&S-SENSOR *1 Edit Edit LIMIT RELEASE *1 Edit Management ARM CONTROL *1 Management Management SHIFT VALUE Operation - SYSTEM INFO VERSION Operation - MONITORING TIME Operation Management ALARM HISTORY Operation Management I/O MSG HISTORY Operation Management SECURITY Operation Operation FD/CF LOAD Edit - SAVE Operation - VERIFY Operation - DELETE Operation - DEVICE Operation Operation FOLDER Edit Management *1 Teach mode only /245

16 2.1 Protection Through Security Mode Settings Main Menu Menu & Security Mode 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 RS Management Management S1E Management Management S2E Management Management S3E Management Management S4E Management Management SETUP TEACHING COND Edit Edit OPERATE COND Management Management DATE/TIME Management Management GRP COMBINATION Management Management RESERVE JOB NAME Edit Edit USER ID Edit Edit SET SPEED Management Management KEY ALLOCATION *1 Management Management RES. START (CNCT) Management Management HANDLING HANDLING DIAGNOSIS Operation Edit GENERAL WEAVING Operation Edit COMMON TO ALL APPLI- CATIONS GENERAL DIAG. Operation Edit I/O VARIABLE CUSTOMIZE Operation Operation *1 Teach mode only /245

17 2.1 Protection Through Security Mode Settings Changing the Security Mode Operation Explanation 1 Select {SYSTEM INFO} under the main menu. The sub menu appears. T JOB DOUT MOVE END FD/CF CF ARC WELDING PARAMETER VARIABLE B001 IN/OUT In Out VERSION SETUP MONITORING TIME DISPLAY SETUP Aa ALARM HISTORY ROBOT I/O MSG HISTORY SYSTEM INFO SECURITY Main Menu Short Cut Turn on servo power 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. DATA EDIT DISPLAY UTILITY T JOB FD/CF SECURITY DOUT MOVE END CF ARC WELDING PARAMETER MODE EDITING MODE VARIABLE SETUP B001 IN/OUT In Out ROBOT SYSTEM INFO Main Menu Short Cut Turn on servo power 3 Press [SELECT] and select "SECURITY MODE". DOUT DATA EDIT DISPLAY UTILITY T FD/CF SECURITY JOB MOVE END CF ARC WELDING VARIABLE PARAMETER SETUP MODE OPERATING MODE EDITING MODE MANAGEMENT MODE B001 IN/OUT In Out ROBOT SYSTEM INFO Main Menu Short Cut Turn on servo power /245

18 2.1 Protection Through Security Mode Settings Operation Explanation 4 Input the user ID. The user ID input window appears. DATA EDIT DISPLAY UTILITY T JOB FD/CF SECURITY DOUT MOVE END CF ARC WELDING PARAMETER MODE Password = VARIABLE SETUP B001 IN/OUT In Out ROBOT SYSTEM INFO Main Menu Short Cut Turn on servo power SUPPLE -MENT At the factory, the following below user ID number is preset. Editing Mode:[ ] Management Mode:[ ] 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 /245

19 2.1 Protection Through Security Mode Settings User ID 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. ). Changing a User ID In order to change the user ID, the NXC100 must be in Editing Mode or Management Mode. Higher security modes can make changes the user ID of to lower security modes. Operation 1 Select {SETUP} under the main menu. The sub menu appears. Explanation DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END FD/CF CF TEACHING COND KEY ALLOCATION ARC WELDING PARAMETER OPERATE COND VARIABLE SETUP DATE/TIME B001 IN/OUT DISPLAY SETUP GRP COMBINATION In Out ROBOT Aa RESERVE JOB NAME *** USER ID SYSTEM INFO SET SPEED Main Menu Short Cut 2 Select {USER ID}. The USER ID window appears. DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END FD/CF CF USER ID ARC WELDING PARAMETER EDITING MODE ******** VARIABLE B001 SETUP MANAGEMENT MODE ******** IN/OUT In Out ROBOT SYSTEM INFO Main Menu Short Cut /245

20 2.1 Protection Through Security Mode Settings Operation Explanation 3 Select the desired ID. The character input line appears, and the message "Input current ID no. (4 to 8 digits)" is shown. DATA EDIT DISPLAY UTILITY T JOB FD/CF USER ID DOUT MOVE END CF ARC WELDING PARAMETER EDITING MODE Password = VARIABLE B001 SETUP MANAGEMENT MODE ******** IN/OUT In Out ROBOT SYSTEM INFO Main Menu Short Cut Input current ID no. (4 to 8 digits) 4 Input current ID and press [ENTER]. When the correct user ID is entered, a new ID is requested to be input. "Input new ID no.(4 to 8 digits)" appears. DATA EDIT DISPLAY UTILITY T JOB FD/CF SECURITY DOUT MOVE END CF ARC WELDING PARAMETER EDITING MODE Password = VARIABLE B001 SETUP MANAGEMENT MODE ******** IN/OUT In Out ROBOT SYSTEM INFO Main Menu Short Cut Input current ID no. (4 to 8 digits) 5 Input new ID and press [ENTER]. User ID is changed /245

21 3.1 Inspection Schedule 3 Inspections WARNING Before conducting maintenance, inspection or wiring, turn OFF all supplied power (including the compressed air) to the robotic system, lock the switch in the "OFF" position and put up a warning sign, such as "DO NOT TURN ON THE POWER". The robotic system does not have the switch to turn OFF the power. Turn OFF the switch in the host system to which the robotic system is connected. Failure to observe this caution may result in electric shock or injury. CAUTION Maintenance and inspections must be performed by specified personnel. Failure to observe this caution may result in electric shock or injury. 3.1 Inspection Schedule Proper inspections are essential not only to assure that mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation. The inspection intervals should be based on the power supply ON time. Inspection intervals are displayed in the following three levels by taking it as a standard that the NXC100 is used for 6,000 hours per year. Weekly inspection Every 6-month inspection After 5-year inspection (overhaul) Weekly inspection and every 6-month inspection are essential mainly to assure safe operation and assure that the mechanism is able to function for a long period. These inspections can be conducted at the customer s facilities (on-site inspections). Conduct these on-site periodical inspections according to the inspection schedule in " 3.2 Inspection Items ". In addition, Yaskawa recommends the complete check (including the items which cannot be done on-site) at Yaskawa as a preventive maintenance after 5 years (30,000 hours) /245

22 3.2 Inspection Items 3.2 Inspection Items The inspection items are classified into three types of operations: The operation which can be performed by personnel authorized by the user. The operation which can be performed by personnel being trained. The operation which is performed by Yaskawa. Only specified personnel are to do the inspection work. Items *1 Daily Schedule 6-Month 3000H Cycle Overhaul 30,000H Cycle (Every 5 years) Method Operation Specified Personnel Inspection Charge Licensee Service Company Cables Visual Check for damage, etc. Replace if necessary. Working area and manipulator Visual Check for damage and outside cracks. Air filter Visual Check for damage, dirt, etc. Replace if necessary. Cable connection Visual Tighten loose screws. Replace if necessary. Cover mounting screws Screwdriver Tighten loose screws. Replace if necessary. Emergency stop button Function check Enable switch Function check Battery Visual NOTE Conduct inspections of the items No.1 to No.5 with the equipment fully de-energized. Conduct inspections of the items No.6 to No.8 with the equipment energized. 3.3 Cable Inspection Verify that no damage or deterioration is found on the power cables, programming pendant cables, and I/O cables connected to the NXC100. Cables with severe damage and deterioration may result in malfunction and failure. Replace with new cables /245

23 ON OFF FU1 FU2 SOURCE AC FUSE : F1, F2 I/O FUSE : F1, F2, F3, F4 15A / 250V 3.15A / 250V SLOW BLOW FAST BLOW when removing or replacing Can cause muscle strain or 3.4 Inspection of Whole Exterior 3.4 Inspection of Whole Exterior Conduct inspections of the exterior of the NXC100 and programming pendant. If any damage is found on the switches and connectors, replace them with new ones promptly. Furthermore, if the rated nameplates and warning labels are hard to be seen due to dirt on them, remove the dirt so that the contents of the nameplates and warning labels can be confirmed. 3.5 Inspection of Air Filter The NXC100 has air filters in seven positions as shown below. Verify extent of dust and dirt of air filters. Replace the air filter with new one as necessary. X52 X31 NXC100 F1 SOURCE BATTERY BAT FUSE F2 X51 X81 WARNING HEAVY OBJECT back injury. Use lifting aids & proper lifting technjques WARNING HAZAARDOUS VOLTAGE 208/110 VAC PRESENT Contact may cause electric shock or burn Turn off and lock out system power before servicing X72 X11 FAN3 FAN2 X54 X53 X21 X12 X55 X71 X62 PPESP PPESP X64 - X63 Air Filter Positions /245

24 3.6 Inspection of Cover Mounting Screws 3.6 Inspection of Cover Mounting Screws Check for loose screws that fastens covers and connectors. Tighten the loose screws as necessary. 3.7 Inspection of Emergency Stop Button The emergency stop buttons are located on both the front face of the NXC100 and the programming pendant. Before operating the manipulator, confirm that the servo power turns OFF by pressing each emergency stop button on the front face of the NXC100 and programming pendant after the servo ON. 3.8 Inspection of Enable Switch 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 on the programming pendant to "TEACH". REMOTE PLAY TEACH 2. Press [SERVO ON READY] on the programming pendant. The [SERVO ON] lamp blinks. SERVO ON READY Blinking SERVO ON 3. When the enable switch is squeezed lightly, the servo power is turned ON. When the enable switch is squeezed tightly or released, the servo power is turned OFF /245

25 3.9 Battery Inspection NOTE If the [SERVO ON] lamp does not light in previous operation (2), check the following: The emergency stop button on the front face of the NXC100 is pressed. The emergency stop button on the programming pendant is pressed. The emergency stop signal is input from external. If the servo is not turned ON in a previous operation (3), check the following: A major alarm is occurring. 3.9 Battery Inspection The NXC100 has a battery that backs up the important program files for user data in the CMOS memory. A battery alarm indicates when a battery has expired and must be replaced. The message "Memory battery weak" appears at the bottom of the programming pendant display. The way to replace the battery is described in " Replacing the Battery " /245

26 4 Preparation before Replacing Parts WARNING Before operating the manipulator, check that the SERVO ON lamp turns OFF when the emergency stop buttons on the front face of the NXC100 and the programming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency. 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 NXC100 power. - Moving the manipulator with the programming pendant Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press the emergency stop button immediately if there are problems. Emergency stop buttons are located at the upper right corner of the front face of the NXC100 and on the upper right of the programming pendant /245

27 CAUTION 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 user s designated place 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 /245

28 The following flowchart shows the operations for replacing parts. Start Creating a check program : Chapter 4 Replacing parts : Chapter 5 Home position calibration : Chapter 6 Position deviation check using the check program No OK? Yes End This chapter describes how to create a check program as a preparation for replacing parts. The check program is a program to check the position deviation. If positions are deviated, home position calibration is required. For the calibration, this program data is used to correct the home position data. In the following cases particularly, the home position calibration using the check program is needed. Be sure to create a check program referring to " 4.1 Creating a Check Program ". Change in the combination of the manipulator and NXC100 Replacement of the motor or absolute encoder Clearing stored memory (by replacement of weak battery, etc.) Home position deviation caused by hitting the manipulator against a workpiece, etc. Furthermore, in case that the NXC100 itself is replaced due to controller failure, etc., all the data need to be saved and loaded. When replacing the NXC100, make sure to perform saving and loading of the data /245

29 4.1 Creating a Check Program 4.1 Creating a Check Program To check position deviation whenever necessary, create a program in which a check point is taught (the job for the check point). In the job for the check point, teach two points; one as a check point and the other as the point to approach the check point. This program checks for any deviation between the tool tip position and the check point. Enlarged View /245

30 REMOTE PLAY TEACH START!? HOLD 4.2 Saving of the NXC100 Data 4.2 Saving of the NXC100 Data Before replacing the NXC100, make sure to follow the instructions below to save data. The saved data are used in" 6.5 Loading the NXC100 Data ". The Compact Flash cards are used to save and load the NXC100 data. The following listed below are Yaskawa s recommended Compact Flash cards. Product performance cannot be guaranteed when using Compact Flash cards other than those listed below. NOTE Type : SDCFBI-64-EPP-80 (By SanDisk, Inc., 64MB) Type : CFI-064MBA (By Hagiwara Sys-Com Co., Ltd., 64MB) Type : CFC-064MBA (By Hagiwara Sys-Com Co., Ltd, 64MB) 128MB Compact Flash cards of the above types can also be used. Operation Explanation 1 Turn OFF the power supply to the NXC Open the Compact Flash slot cover of the programming pendant and insert the Compact Flash card. Then close the cover. Compact Flash slot Make sure the inserting direction of the Compact Flash card before inserting it into the slot. 3 Turn ON the power supply to the NXC100 while pressing MAIN MENU the [MAIN MENU] key. Release your finger from the [MAIN MENU] key three seconds. MAIN MENU after X- S- Y- LAYOUT MULTI MAIN MENU X+ S+ Y+ COORD SHORT CUT DIRECT OPEN SERVO ON READY SERVO ON HIGH SPEED GO BACK PAGE!? ASSIST X- R- Y AREA CANCEL X+ R+ Y /245

31 4.2 Saving of the NXC100 Data Operation Explanation 3 (cont d) The main menu window of the maintenance mode appears on the programming pendant display approximately after forty seconds. SYSTEM FILE TOOL CF Main Menu Short Cut Maintenance mode If the above window is not displayed, turn OFF the power supply to the NXC100 and try the step 3 again. 4 Select {TOOL} under the main menu. The sub menu appears. SYSTEM FILE TOOL CF CompactFlash Main Menu Short Cut Maintenance mode 5 Select {CompactFlash}. The CMOS SAVE/LOAD display appears. SYSTEM FILE CMOS SAVE CMOS LOAD TOOL CF Main Menu Short Cut Maintenance mode /245

32 4.2 Saving of the NXC100 Data Operation 6 Move the cursor to "CMOS SAVE" and press [SELECT]. Explanation The confirmation dialog box appears. SYSTEM FILE CMOS SAVE CMOS LOAD TOOL CF Save? YES NO Main Menu Short Cut Maintenance mode 7 Select "YES". The CMOS data are saved in the Compact Flash card in the programming pendant slot. CAUTION If the CMOS data are already saved in the Compact Flash card in the programming pendant slot, the following display appears. If the data need to be saved, move the data to the different location or change the Compact Flash card with a different one, and save the data. Select "YES" on the touch panel if the CMOS data can be overwritten. SYSTEM FILE CMOS SAVE CMOS LOAD TOOL CF Overwrite? CMOS.BIN YES NO Main Menu Short Cut Maintenance mode PROHIBITED Do not turn OFF the power supply to the NXC100 while the CMOS data are saved. The CMOS data cannot be saved normally in the Compact Flash card in the programming pendant slot /245

33 4.2 Saving of the NXC100 Data Operation Explanation 8 Saving is completed. If the programming pendant blips approximately after forty seconds from the start of data saving, saving of CMOS data is completed. Turn OFF the power supply to the NXC /245

34 5.1 Replacing NXC100 Parts 5 Replacing Parts 5.1 Replacing NXC100 Parts WARNING Before conducting maintenance, inspection or wiring, turn OFF all supplied power (including the compressed air) to the robotic system, lock the switch in the "OFF" position and put up a a warning sign, such as "DO NOT TURN ON THE POWER". CAUTION Maintenance and inspections must be performed by specified personnel. Failure to observe this caution may result in electric shock or injury /245

35 ON OFF FU1 FU2 SOURCE AC FUSE : F1, F2 I/O FUSE : F1, F2, F3, F4 15A / 250V 3.15A / 250V SLOW BLOW FAST BLOW 5.1 Replacing NXC100 Parts Replacing the Battery Replace the battery immediately if a battery alarm occurs. Replace the battery within two hours after the main switch turns OFF. (The battery alarms appear on the programing pendant display.) Replacement Procedure 1. Remove the battery cover on the front face of the NXC100. Remove the battery connector (CN2) to uninstall the battery. 2. Mount a new battery and connect the battery connector (CN2). X31 NXC100 ON(I) F1 X52 SOURCE BATTERY FUSE BAT OFF(O) F2 X51 X81 Position of Battery Cover I/O fuse Battery 5 1 Battery connector: CN2 The View after Battery Cover is Removed /245

36 ON OFF FU1 FU2 SOURCE 5.1 Replacing NXC100 Parts Checking and Replacing Fuses The types of fuses on power supply contactor unit (JZRCR-NTUoo) are as follows. Fuse Name Position Type Manufacturer Main Fuse for Power Supply Protection Front of the NXC , 250V, 10A, φ 6 32 mm, Time lag fuse Littelfuse, Inc. I/O Protection Fuse Inside of the battery cover , 250V, 3.15A, φ 5 20 mm, Fast-Acting fuse Littelfuse, Inc. Brake Protection Fuse Inside of the battery cover SMP50, 5A, Time lag fuse Daito Communication Apparatus Co., Ltd. Fuse for Fan Front of the NXC , 250V, 1A, φ 5 20 mm, Time lag fuse Littelfuse, Inc. Main fuse for power supply protection Fuse for fans Brake protection fuse (Inside of the battery cover) I/O protection fuse (Inside of the battery cover) X31 NXC100 ON(I) F1 X52 SOURCE BATTERY BAT FUSE OFF(O) F2 X51 X81 AC FUSE : F1, F2 I/O FUSE : F1, F2, F3, F4 15A / 250V 3.15A / 250V SLOW BLOW FAST BLOW Fuse Position If a fuse appears to be blown (see " 8.3 List "), remove each fuse shown above and check the continuity with an electric tester. If the fuse is blown, replace it with the same type of fuse (supplied). NOTE Determine and correct the cause of the blown fuse. If the problem is uncorrected, the fuse may blow again Replacing the Air Filter If an air filter is covered with dust and dirt, replace the air filter with new one promptly. Remove knurled screws to uninstall the filter cover, and replace the air filter /245

37 5.2 Replacing the NXC Replacing the NXC100 WARNING Before conducting maintenance, inspection or wiring, turn OFF all supplied power (including the compressed air) to the robotic system, lock the switch in the "OFF" position and put up a a warning sign, such as "DO NOT TURN ON THE POWER". CAUTION Maintenance and inspections must be performed by specified personnel. Failure to observe this caution may result in electric shock or injury. If the NXC100 itself is replaced due to controller failure, etc., refer to " NXC100 CONTROLLER REPLACEMENT MANUAL" (HW ) to perform the replacement. Replacement must be performed by specified personnel /245

38 5.3 Supplied Parts List 5.3 Supplied Parts List The following list shows the supplied parts of the NXC100 No. Item Qty Type Remarks 1 10A Ceramic fuse A Glass-Tube fuse 3 1A Glass-Tube fuse 4 5A fuse 5 WAGO Connector wiring tool , 250V, 10A, Time lag fuse, φ 6 32 mm (Littelfuse, Inc.) , 250V, 3.15A, Fast-Acting fuse, φ 5 20 mm (Littelfuse, Inc.) , 250V, 1A, Time lag fuse, φ 5 20 mm (Littelfuse, Inc.) 2 SMP50, 5A, Time lag fuse (Daito Communication Apparatus Co., Ltd.) (WAGO Corporation) For power supply protection F1, F2 For I/O protection F1 to F4 For fans FUFAN1, FUFAN2 For brake protection X32, PPESP, PBESP Wiring tool 6 Dummy connector 1 HB (Yaskawa Electric Corporation) 7 Dummy connector 1 HB (Yaskawa Electric Corporation) 8 Terminal connector 1 HB (Yaskawa Electric Corporation) 9 Connector / (WAGO Corporation) 10 Connector / (WAGO Corporation) 11 Connector / (WAGO Corporation) For X33 For X61 For X54 For X32 For PPESP For PBESP /245

39 5.4 Recommended Spare Parts 5.4 Recommended Spare Parts CAUTION Make sure to use the recommended spare parts and components as listed below. Product performance cannot be guaranteed when using spare parts other than those listed below. [Ranking of Spare Parts] Rank A: Expendable and frequently replaced parts Rank B: Parts for which replacement may be necessary as a result of frequent operation Rank C: Drive unit Recommended Spare Parts Rank Parts No. Name Type Manufacturer Qty Qty per Unit Remarks C 1 Fan HB Minebea Co., Ltd. 3 1 Fan type: 2406KL-05W-B59- L00 C 2 Fan HB Royal Electric Co., Ltd. 2 1 Fan type: S40E7R C 3 Fan Minebea Co., Ltd. 3 1 Fan type: 4710PS-22T-B30- B00 A 4 Fuse SMP50, 5A Daito Communication Apparatus Co., Ltd. 2 1 For brake A 5 A 6 A 7 Fuse Littelfuse Inc V, 3.15A For I/O Fuse Littelfuse Inc V, 10A For power supply Fuse Littelfuse Inc V, 1A For fans A 8 Battery ER6VC3N Toshiba Corporation 1 1 Air filter Japan Vilene Company, Ltd. 7 7 PS/ mm 130 mm 18 mm, 90 mm 33 mm t8 mm, 40 mm 23 mm t8 mm, A 9 65 mm 13 mm t8 mm, 77 mm 103 mm t8 mm, 112 mm 57 mm t8 mm, 120 mm 60 mm t8 mm, one for each /245

40 6 Operations after Replacing Parts WARNING Before operating the manipulator, check that the SERVO ON lamp turns OFF when the emergency stop buttons on the front face of the NXC100 and the programming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency. 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 NXC100 power. - Moving the manipulator with the programming pendant Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press the emergency stop button immediately if there are problems. Emergency stop buttons are located on the front face of the NXC100 and on the upper right of the programming pendant /245

41 6.1 Home Position Calibration CAUTION 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 user s designated place 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. 6.1 Home Position Calibration Home Position Calibration NOTE Teaching and playback are not possible before home position calibration is completed. In a system with two or more manipulators, the home position of all the manipulators must be calibrated before starting teaching or playback. Set the security mode to the management mode to perform home position calibration. Home position calibration is an operation in which the home position and absolute encoder position coincide. Although this operation is performed prior to shipment at the factory, the following cases require this operation to be performed again. Change in the combination of the manipulator and NXC100 Replacement of the motor or absolute encoder Clearing stored memory (by replacement of NCP30 circuit board, weak battery, etc.) Home position deviation caused by hitting the manipulator against a workpiece, etc. To calibrate the home position, use the axis keys to calibrate the mark for the home position on each axis so that the manipulator can take its posture for the home position. There are two operations for home position calibration: All the axes can be moved at the same time Axes can be moved individually If the absolute data of the home position is already known, set the absolute data again after /245

42 6.1 Home Position Calibration completing home position registration. SUPPLE -MENT Home Position The home position is the position with the pulse value "0" for each axis. The deviation values between the home position and the control reference position are set to parameters. The deviation values are specified as an angle in units of 1/1000, and vary depending on manipulator types. See " Manipulator Home Position " /245

43 6.1 Home Position Calibration Calibrating Operation Registering All Axes at One Time Operation Explanation 1 Select {ROBOT} under the main menu. 2 Select {HOME POSITION}. The HOME POSITIONING window appears. DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT FD/CF CF PARAMETER SETUP DISPLAY SETUP HOME POSITIONING SELECT R1: S L U R B T ABSOLUTE DATA In Out Aa ROBOT SYSTEM INFO PAGE Main Menu Short Cut 3 Select {DISPLAY} under the menu, or select "PAGE" to display the selection window for the control group, GO BACK PAGE or press. The pull-down menu appears. DATA EDIT DISPLAY UTILITY JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT FD/CF HOME POSITIONING ROBOT 1 CF SELECT R1: S ROBOT 2 PARAMETER L U STATION 1 SETUP R B T DISPLAY SETUP ABSOLUTE DATA T In Out Aa ROBOT SYSTEM INFO PAGE Main Menu Short Cut DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT FD/CF CF PARAMETER SETUP DISPLAY SETUP HOME POSITIONING SELECT R1: S L U R B T ABSOLUTE DATA In Out Aa ROBOT SYSTEM INFO R1 :ROBOT1 R2 :ROBOT2 S1 :STATION1 PAGE Main Menu Short Cut 4 Select the desired control group /245

44 6.1 Home Position Calibration Operation 5 Select {EDIT} under the menu. The pull-down menu appears. Explanation DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT In Out FD/CF SELECT ALL AXIS CF PARAMETER SETUP DISPLAY SETUP Aa HOME POSITIONING SELECT R1: S L U R B T ABSOLUTE DATA ROBOT SYSTEM INFO PAGE Main Menu Short Cut 6 Select {SELECT ALL AXES}. The confirmation dialog box appears. DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT In Out FD/CF CF PARAMETER SETUP DISPLAY SEUTP Aa HOME POSITIONING SELECT ABSOLUTE DATA R1: S L U R B Create home position? T YES NO ROBOT SYSTEM INFO Main Menu Short Cut PAGE 7 Select YES. Displayed position data of all axes are registered as home position. When NO is selected, the registration will be canceled /245

45 6.1 Home Position Calibration Registering Individual Axes Operation Explanation 1 Select {ROBOT} under the main menu. 2 Select {HOME POSITION}. 3 Select the desired control group. Perform steps 3 and 4 which have been described in " Registering All Axes at One Time " to select the desired control group. 4 Select the axis to be registered. DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT FD/CF CF PARAMETER SETUP DISPLAY SETUP HOME POSITIONING SELECT R1: S L U R B T ABSOLUTE DATA In Out Aa ROBOT SYSTEM INFO PAGE Main Menu Short Cut The confirmation dialog box appears. DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT In Out FD/CF CF PARAMETER SETUP DISPLAY SETUP Aa HOME POSITIONING SELECT ABSOLUTE DATA R1: S -278 L U R B Create home position? -217 T YES NO ROBOT SYSTEM INFO Main Menu Short Cut PAGE 5 Select "YES". Displayed position data of the axis are registered as home position. When NO is selected, the registration will be canceled /245

46 6.1 Home Position Calibration Changing the Absolute Data To change the absolute data of the axis when home position calibration is completed, perform the following: Operation Explanation 1 Select {ROBOT} under the main menu. 2 Select {HOME POSITION}. 3 Select the desired control group. 4 Select the absolute data to be registered. Perform steps 3 and 4 which have been described in " Registering All Axes at One Time " to select the desired control group. The number can now be entered. DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT FD/CF CF PARAMETER SETUP DISPLAY SETUP HOME POSITIONING SELECT R1: S L U R B T ABSOLUTE DATA In Out Aa ROBOT SYSTEM INFO PAGE Main Menu Short Cut 5 Enter the absolute data using the numeric keys. 6 Press [ENTER]. Absolute data are modified /245

47 6.1 Home Position Calibration Clearing Absolute Data Operation Explanation 1 Select {ROBOT} under the main menu. 2 Select {HOME POSITION}. Perform steps 2, 3, and 4 which have been described in " Registering All Axes at One Time " to display the HOME POSITIONING window and select the desired control group. 3 Select {DATA} under the menu. The pull-down menu appears. DATA EDIT DISPLAY UTILITY T JOB CLEAR ALL DATA DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT FD/CF CF PARAMETER SETUP DISPLAY SETUP HOME POSITIONING SELECT R1: S L U R B T ABSOLUTE DATA In Out Aa ROBOT SYSTEM INFO PAGE Main Menu Short Cut 4 Select {CLEAR ALL DATA}. The confirmation dialog box appears. DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT In Out FD/CF CF PARAMETER SETUP DISPLAY SETUP Aa HOME POSITIONING SELECT ABSOLUTE DATA R1: S L U R B T Clear data? YES NO ROBOT SYSTEM INFO Main Menu Short Cut PAGE 5 Select "YES". The all absolute data are cleared. When "NO" is selected, the operation will be canceled. DATA EDIT DISPLAY UTILITY T JOB DOUT MOVE END ARC WELDING VARIABLE B001 IN/OUT FD/CF CF PARAMETER SETUP DISPLAY SETUP HOME POSITIONING SELECT R1: S L U R B T ABSOLUTE DATA In Out Aa ROBOT SYSTEM INFO PAGE Main Menu Short Cut /245