DX100 INSTALLATION & WIRING - Motoman€¦ · INSTALLATION & WIRING Upon receipt of the product and...
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MANUAL NO. 3 E1102000035GB Part Number: 165478-1CD Revision: 0 DX100 INSTALLATION & WIRING Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN INSTRUCTIONS DX100 INSTRUCTIONS DX100 OPERATOR’S MANUAL DX100 MAINTENANCE MANUAL The DX100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
Transcript of DX100 INSTALLATION & WIRING - Motoman€¦ · INSTALLATION & WIRING Upon receipt of the product and...
MANUAL NO. 3E1102000035GB
Part Number: 165478-1CDRevision: 0
DX100INSTALLATION & WIRING
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN INSTRUCTIONSDX100 INSTRUCTIONSDX100 OPERATOR’S MANUALDX100 MAINTENANCE MANUAL
The DX100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
DX100-Controller
Installation and Wiring
Please read these instructions before operation and keep them for later reference.The operating instructions are only for internal use.
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Reference list:
Documentnumber
List of modifications
Creation of original
document
Modification in the original document
In section on Page Date Author
E1102000115DE01 X 14.12.2009 WOE
E1102000035GB02translate from
original28.05.2010 Rebec
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Table of contents
1 General ...........................................................................................................51.1 About this manual .......................................................................................................51.2 Intended use...............................................................................................................5
2 Safety..............................................................................................................62.1 For Your Safety...........................................................................................................62.2 Special Training..........................................................................................................72.3 YASKAWA Manual List...............................................................................................72.4 Personnel Safety ........................................................................................................82.5 YASKAWA Safety.....................................................................................................10
2.5.1 Installation and Wiring Safety ................................................................................................ 102.5.2 Work Area Safety .................................................................................................................. 152.5.3 Operation Safety.................................................................................................................... 16
2.6 Notes for Moving and Transferring the YASKAWA ..................................................192.7 Notes on YASKAWA Disposal..................................................................................20
3 Product Confirmation .................................................................................213.1 Contents Confirmation ..............................................................................................213.2 Order Number Confirmation .....................................................................................22
4 Installation ...................................................................................................234.1 Handling Procedure..................................................................................................23
4.1.1 Using a Crane to Move the Controller ................................................................................... 234.1.2 Using a Forklift to Move the Controller .................................................................................. 244.1.3 Using a hand forklift to move the controller ........................................................................... 244.1.4 External axis cabinet ............................................................................................................. 254.1.5 Connecting two cabinets ....................................................................................................... 26
4.2 Location of Installation ..............................................................................................264.3 Location ....................................................................................................................274.4 Mounting the Controller ............................................................................................274.5 Opening the cabinet door .........................................................................................28
5 Controller specifications ............................................................................295.1 IP classification .........................................................................................................295.2 Internal wiring ...........................................................................................................295.3 Noise level ................................................................................................................305.4 Technical specifications............................................................................................30
5.4.1 Control cabinet ...................................................................................................................... 305.4.2 Maintenance .......................................................................................................................... 315.4.3 Safety features ...................................................................................................................... 315.4.4 Programming ......................................................................................................................... 325.4.5 Programmin pendant ............................................................................................................. 33
5.5 Safety features..........................................................................................................345.5.1 External safety....................................................................................................................... 345.5.2 Emergency stop function ....................................................................................................... 345.5.3 Internal safety circuits............................................................................................................ 355.5.4 Combinations of safety functions related to speed................................................................ 37
6 Connection to safety circuit .......................................................................396.1 Standard configuration..............................................................................................39
6.1.1 Safety circuit terminal ............................................................................................................ 396.2 Connect to basic safety ............................................................................................41
6.2.1 External emergency stop (EXESP) ....................................................................................... 416.2.2 External servo power ON (EXSVON) .................................................................................... 416.2.3 External hold (EXHOLD) ....................................................................................................... 42
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6.2.4 External safety circuit (SAF_F) .............................................................................................. 426.2.5 Full speed test (FST) ............................................................................................................. 436.2.6 Safety speed (SSP) ............................................................................................................... 436.2.7 Servo ON enable input (ON_EN)........................................................................................... 446.2.8 External axis overrun (EXOT)................................................................................................ 446.2.9 Emergency stop button output ............................................................................................... 456.2.10 Enabeling device ................................................................................................................... 456.2.11 Shock sensor (SHOCK)......................................................................................................... 467 Inspections .................................................................................................. 477.1 Regular Inspections.................................................................................................. 477.2 DX100 Inspections ................................................................................................... 48
7.2.1 Checking if the Doors are Firmly Closed ............................................................................... 487.2.2 Checking for Gaps or Damage in the Sealed Construction Section ...................................... 48
7.3 Cooling Fan Inspections........................................................................................... 497.4 Emergency Stop Button Inspections ........................................................................ 507.5 Enable Switch Inspections ....................................................................................... 507.6 Battery Inspections................................................................................................... 517.7 Power Supply Voltage Confirmation......................................................................... 527.8 Open Phase Check .................................................................................................. 53
8 Description of Units and Circuit Boards................................................... 548.1 Power Supply Contactor Unit ................................................................................... 578.2 Major Axes Control Circuit Board (SRDA-EAXA01)................................................. 58
8.2.1 Major Axes Control Circuit Board (SRDA-EAXA01) .............................................................. 588.2.2 Connection for Tool Shock Sensor (SHOCK)........................................................................ 608.2.3 Connection for Direct-in ......................................................................................................... 62
8.3 CPU Unit .................................................................................................................. 638.3.1 CPU Unit Configuration ......................................................................................................... 638.3.2 Unit and Circuit Board in the CPU Unit .................................................................................. 64
8.4 CPS Unit (JZNC-YPS01-E) ...................................................................................... 658.5 Brake Control Board (JANCD-YBK01-E) ................................................................. 67
8.5.1 Brake Control Board (JANCD-YBK01-E) ............................................................................... 678.6 Robot I/O Unit (JZNC-YIU02-E) ............................................................................... 68
8.6.1 Robot I/O Unit (JZNC-YIU02-E)............................................................................................. 688.7 Machine Safety Unit (JZNC-YSU01-1E) .................................................................. 76
8.7.1 Machine Safety Unit (JZNC-YSU01-1E) ................................................................................ 768.7.2 Connection for Servo-ON Enable Input (ONEN1 and ONEN2) ............................................. 788.7.3 Connection for External Axis Overrun (EXOT) ...................................................................... 78
8.8 WAGO Connector .................................................................................................... 818.9 Contact Output of Emergency Stop Button .............................................................. 928.10 SERVOPACK ........................................................................................................... 93
8.10.1 Description of Each Unit ....................................................................................................... 948.10.2 SERVOPACK Configuration .................................................................................................. 94
8.11 Universal I/O Signal Assignment............................................................................ 1078.11.1 Arc Welding ......................................................................................................................... 1078.11.2 Handling............................................................................................................................... 1158.11.3 General Application ............................................................................................................. 1228.11.4 Spot Welding ....................................................................................................................... 1298.11.5 JANCD-YEW01 Circuit Board (Standard)............................................................................ 137
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1 General
1.1 About this manual
This manual covers the installation and system specification for the YASKAWA DX100 robot controller
The manual explains the various components of the YASKAWA DX100 system and general operations. Read this manual carefully and be sure tto understand its contents before handling the YASKAWA DX100 controller
Information!
For programming and operation information refer to the DX100 Operator‘s manual.Reference: E1102XXXXXXGBXX
For system setup information, refer to the DX100 System setup manual.Reference: E1102XXXXXXGBXX
For Robot insatallation:Reference: YASKAWA Instruction manual for the specific robot type.
Information!
This manual may not be copied without our written permission and the contents there ofmust not be imparted to a third party nor be used for many unauthorized purpose.
Some drawings in this manual are show 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 diferences may exist between them and the delivered product.
1.2 Intended use
YASKAWA DX100 robot controller is intended to control one or multiple YASKAWA robots. The controller have possibillity to connect multiple additional external axis for a variety of dif-ferent application types.
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2 Safety
2.1 For Your Safety
Robots generally have requirements which are different from other manufacturing equipment, such as larger working areas, high-speed operation, rapid arm movements, etc., which can pose safety hazards.
Read and understand the instruction manuals and related documents, and observe all pre-cautions in order to avoid the risk of injury to personnel and damage to equipment.
It is the user’s responsibility to ensure that all local, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions are met and followed.
MANDATORY● Teaching maintenance of the robot must conform to:
- Industrial Safety and Health Law
- Enforcement Order of Industrial Safety and Health Law
- Ordinance of Industrial Safety and Health Law
Other related laws are:
- Occupational Safety and Health Act in USA
- EC Machinery Directive 2006/42/EC
● Prepare:
- SAFETY WORK REGULATIONS
based on concrete policies for safety management complying withrelated laws.
● Observe the
- Robotic and robotic devices - Safety requirements (ISO10218)
for safe operation of the Industrial robot.
● Reinforce the
- SAFETY MANAGEMENT SYSTEM
by designating authorized workers and safety managers, as well as giving continuing safety education.
● Teaching and maintaining the robot are specified as "Hazardous Operations" in the Industrial Safety and Health Law
Workers employed in these above operations are requested to attend special training offered by YASKAWA.
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2.2 Special Training
2.3 YASKAWA Manual List
● Persons who teach or inspect the manipulator must undergo re-quired training before using the manipulator.
● For more information on training, inquire at the nearest YASKAWA branch office.
The telephone numbers are listed on the back cover of this manual.
● It is important to have and be familiar with all manuals concerning the YASKAWA.
You should have the YASKAWA robot four manuals listed below:
- For programming and operation information refer to the DX100 Operator‘s manual. Reference: E1102000066GB01 and higher
- For system setup information, refer to the DX100 System setup manual. Reference: E1102000125GB01 and higher
- For Robot insatallation: Reference: YASKAWA Instruction manual for the specific robot type.
Confirm that you have all these manuals on hand.
If any manuals are missing, contact your salesman from YASKAWA local branch office.
The relevant telephone numbers are listed on the back cover.
MANDATORY
MANDATORY
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2.4 Personnel Safety
The entire manipulator P-point maximum envelope is potentially dangerous.
All personnel working with the YASKAWA Robot (safety administration, installation, operation, and maintenance personnel) must always be prepared and "Safety First" minded, to ensure the safety of all personnel.
● Avoid any dangerous actions in the area where the YASKAWA Ro-bot is installed.
There is a danger of injury if there is contact with the robot or periphe-ral equipment.
● Please take strict safety precautions by placing signs such as "Flammable", "High Voltage", "Waiting", and "Off-limits to Unauthori-zed Personnel" in necessary areas in the factory.
Failure to observe these cautions may result in fire, electric shock, or injury due to contact with the robot and other equipment.
● Strictly observe the following items:
- Always wear approved work clothes (no loose-fitting clothes).
- Do not wear gloves when operating the YASKAWA Robot.
- Personal Protective Equipment (PPE) is controlled by directive 89/656/EEC, called PPE-directive that is the European law.
- Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety shoes (with slip-proof soles), face shields, safety glasses, and gloves as necessary.
Improper clothing may result in injury.
● Unauthorized persons should not approach the Robot or associated peripheral equipment.
Failure to observe this caution may result in injury due to contact with DX100 controller, the workpiece, the positioner, etc.
CAUTION
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● Never forcibly move the robot axes.
Failure to observe this caution may result in injury or equipment da-mage.
● Never lean on DX100 controller or other controllers, and avoid inad-vertently pushing buttons.
Failure to observe this caution may result in injury or damage by un-expected movement of the robot.
● Never allow unauthorized personnel to touch the DX100 controller during operation.
Failure to observe this caution may result in injury or damage resul-ting from unexpected movement of the robot.
CAUTION
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2.5 YASKAWA Safety
2.5.1 Installation and Wiring Safety
Refer to the YASKAWA- Instructions manual and DX100 controller Instructions for de-tails on installation and wiring.
In planning installation, adapt an easy to observe arrangement to ensure safety. Take safety into consideration when planning the installation. Observe the following when installing the robot:
● Select an area such as that described below to install the manipula-tor: Confirm that the area is large enough so that the fully extended manipulator arm with tool will not reach a side wall, safeguarding, or the controller.
Failure to observe this caution may result in injury or damage resul-ting from unexpected movement of the manipulator.
● Perform grounding in accordance with all applicable electrical codes.
Failure to observe this caution may result in fire or electric shock.Equipotential bonding shall be performe up to IEC 60204-1:2005 (EN60204-1:2006)
WARNING
1000 mm or more 500 mm or more
DX100 controllerSafeguarding
500 mm or more
500 mm or more
P-point maximum envelope of robot
Maximum working envelope of robot
Door
including tool or workpiece end
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● Operation of the crane, sling, or forklift should only be performed by authorized personnel.
Failure to observe this precaution may result in injury or equipment damage.
YASKAWA should be lifted with a crane using wire rope threaded through the shipping bolts and positioners and the body should be lifted in an upright posture as described in the robot instruction manual.
Failure to observe these precautions may cause the robot to turn downward, potentially causing injury or damage to equipment.
CAUTION
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● When lifting the DX100 controller, please check the following:
- As a rule, handling of DX100 controller must be performed using a crane with wire rope threaded through attached eyebolts.
- Be sure to use wire that is strong enough to handle the weight of the DX100 controller.
● Be sure the eyebolts are securely fastened.
Failure to observe this caution may result in injury or damage to equipment.
CAUTION
Wire rope
M16 Eye bolt
APPROX. WEIGHT OF DX100 CONTROLLER
Models Available for DX100
Approx. Weight (kg)
small models:MA1400, MA1900, VA1400, MH5, MH5L, MH6, HP20D, HP20D-6 250
middle/large models:MH50,MS80,ES165D, ES200D,VS50, SIA50D
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● If storing the robot temporarily before installation, be sure to place it on a stable and flat surface and take precautions to prevent unaut-horized personnel from touching it.
Failure to observe this precaution may result in injury of damage to equipment.
● Be sure there is sufficient room for maintenance on the robot, DX100 controller, and other peripheral equipment.
Failure to observe this precaution could result in injury during mainte-nance.
● To ensure safety, be sure to operate the controller from a location where the robot is easily visible.
Operation by unauthorized personnel may result in injury or equip-ment damage.
● Install the DX100 controller outside the safeguarding of the manipu-lator’s safety enclosure.
Failure to observe this precaution may result in injury or damage to equipment resulting from contact with the robot.
● Install the robot using bolts of the size and type specified for each YASKAWA in the YASKAWA INSTRUCTION MANUAL.
Failure to observe this caution may result in injury or damage to equipment.
CAUTION
CAUTION
DX100 Maintenance Area (Unit: mm) DX100 External Dimensions (Unit: mm)
Door
10
00
mm
or
mo
re
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● Secure the position of the DX100 controller after setting up.
Attach the DX100 controller to the floor or rack, etc., using the screw holes on the bottom of the DX100 controller.
Failure to observe this caution could lead to injury or equipment da-mage if the DX100 controller should shift or fall.
● Be familiar with the connection diagram before wiring the DX100 controller, and perform the wiring in accordance with the connection diagram.
There is a danger of equipment damage or injury due to miswiring and unexpected movement of the equipment.
CAUTION
12 dia. (2 holes)
(Unit: mm)Tapped Holes for M10 Screws on the DX100 controller Side
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2.5.2 Work Area Safety
Carelessness contributes to serious accidents in the work area.
To ensure safety, enforce the following precautions:
● Take precautions when wiring and piping between the DX100 con-troller, robot, and peripheral equipment. Run the piping, wiring, or cables through a pit or use a protective cover, so that they are not stepped on by personnel or run over by a forklift.
Operators and other personnel may stumble on exposed wiring or pi-ping. Cable damage can cause unexpected manipulator motion re-sulting in injury or property damage.
● Install a safeguarding around the manipulator to prevent any acci-dental contact with the robot while the power is ON. Post a warning sign stating "Off-limits During Operation" at the entrance of the enclosure. The gate of the safeguarding must be equipped with a safety interlock. Be sure the interlock operates cor-rectly before use.
Failure to observe this caution may result in a serious accident due to contact with the robot.
CAUTION
PipingCable channel
Lead
CAUTION
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2.5.3 Operation Safety
● Store tools and similar equipment in proper locations outside of the enclosure.
Tools and loose equipment should not be left on the floor around the manipulator, DX100 controller, or welding fixture, etc., as injury or da-mage to equipment can occur if the robot comes in contact with ob-jects or equipment left in the work area.
● When attaching a tool such as the welding torch to the robot, be sure to turn OFF the power supply of the DX100 controller and the tool, lock the switch, and display a warning sign (reference to EN 60204-1).
Turning the power ON during tool installation may case electric shock or injury due to unexpected movement of the robot.
● Never exceed the rated capacity of the robot (capacity can be found in the specifications section of the robot manual.)
Failure to observe this caution may result in injury or damage to equipment.
CAUTION
WARNING
PADLOCK
OFF
ENERGIZINGPROHIBITED
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● Teach jobs from outside the robot’s maximum workspace whenever possible.
● Observe the following precautions when performing teaching opera-tions within the P-point maximum envelope of the robot:
- Always view the robot from the front.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency. Improper or unintentional robot operation can result in injury.
● Before operating the robot, check that the SERVO ON lamp on the programming pendant goes out when the emergency stop buttons on the right of the programming pendant and on an external control device, etc. are pressed. And confirm that the servo lamp is turned OFF.
Injury or damage to machinery may result if the robot cannot be stop-ped in case of an emergency.
WARNING
WARNING
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● Prior to performing the following operations, be sure that no one is in the restricted space up to EN ISO 10218-2 envelope of the robot when:
- Turning ON the DX100 controller power.
- Moving the robot with the programming pendant.
- Running the system in the check mode.
- Performing automatic operations.
Injury may result from contact with the robot if persons enter the res-tricted space envelope of the robot.
Press the emergency stop button immediately if there are problems.The emergency stop button is located on the right of the program-ming pendant.
WARNING
Programming Pendant
Emergency Stop Button
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2.6 Notes for Moving and Transferring the YASKAWA
When moving or transferring the YASKAWA, observe the following safety precautions:
● Perform the following inspection procedures prior to teaching the ro-bot. If problems are found, correct them immediately, and be sure that all other necessary tasks have been performed.
- Check for problems in robot movement.
- Check for damage to the insulation and sheathing of external wires.
● Always return the programming pendant to its hook on the DX100 controller cabinet after use.
If the programming pendant is inadvertently left on the robot, a fixture, or on the floor, the robot or a tool could collide with it during robot mo-vement, possibly causing injury or equipment damage.
• Persons operating or inspecting the robot should be trained as required by applicable laws and company policies.
– Refer to chapter 2.2 Special Training
● Attach the instructions to the controller cabinet so that all users have access to necessary manuals. See chapter 2.3 YASKAWA Manual List for a complete list of manuals.
If any manuals are missing, contact your YASKAWA representative.
● If the warning labels on the robot and DX100 controller are illegible, clean the labels so that they can be read clearly. Note that some lo-cal laws may prohibit equipment operation if safety labels are not in place. Contact your YASKAWA representative if you require new warning labels.
CAUTION
MANDATORY
CAUTION
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2.7 Notes on YASKAWA Disposal
● When the YASKAWA is transferred, it is recommended to check with YASKAWA which is listed on back cover of this manual.
Incorrect installation or wiring may result in personal injury and pro-perty damage.
● Never modify the robot or DX100 controller.
Failure to observe this precaution could result in injury or damage re-sulting from fire, power failure, or operation error.
● When disposing of the robot, follow „directives“ new part after the world applicable EC-directive, national/local laws and regulations.
● Anchor the robot well, even when temporarily storing it before dispo-sal.
Failure to observe this precaution may result in injury due to the robot falling down.
CAUTION
PROHIBITED
CAUTION
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3 Product Confirmation
3.1 Contents Confirmation
Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following five items (Information for the content of optional goods is given separately):
Robot
DX100 controller
Programming Pendant
Robot Cable (Between Manipulator and DX100)
Complete Set of Manuals
Programming Pendant
DX100 controller
Robot
Complete Set of Manuals 2 Robot Cables andEquipotential boning cable
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3.2 Order Number Confirmation
Confirm that the order number pasted on the manipulator and DX100 controller match.
The order number plates are affixed as shown in the figure below.
<Example>The robot and the DX100 controller should have same order number.
Order NO.: S78796-1
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4 Installation
4.1 Handling Procedure
4.1.1 Using a Crane to Move the Controller
Check the following before handling the DX100 controller:
Confirm the weight of the controller before handling, and use a wire rope with a rating that is greater than the weight of the controller.
Install eyebolts for handling and confirm they are securely fastened before hoisting.
● Avoid jarring, dropping, or hitting the controller during handling.
Excessive vibration or impacting the DX100 controller may adversely affect the performance of the DX100 controller.
CAUTION
ControllerApprox. weight (KG)
DX100 cabinet 250 KG
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4.1.2 Using a Forklift to Move the Controller
Observe the following precautions when using a forklift to handle the controller:
Secure the controller so it cannot shift or fall during handling.
Transport the controller at the lowest possible height.
Avoid jarring, dropping, or hitting the controller during handling.
When carrying the controller, operate the forklift at a safe speed.
4.1.3 Using a hand forklift to move the controllerBy removing the lower front cover you will access to a tunnel under the cabinet. Normally this tunnel is for hiding cables but can also be used for lifting the cabinet.
1.) Remove the lower front cover by grabbing it at left and right side.
2.) Pull it straight out.
Forklift
Palette
Tiedown straps
Protective padding
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4.1.4 External axis cabinet
External axis cabinet may be mounted to the base cabinet in anumber of ways.When mounting side by side, the cabinets are connected by four M12 bolts, wich is not enough to withstand the lifting forces.When top-mounting, the cabinets are tigthened by four M10 bolts.
When the cabinets are moun-ted side by side, they need to be separated before lifting
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4.1.5 Connecting two cabinets
4.2 Location of Installation
The conditions listed below must be met before installing the DX100 controller:
Ambient temperature must be 0 to 45 C (32 to 113F) during operation and -10 to 60C(14 to 140F) during transportation and maintenance.
Humidity must be low with no condensation (10~90%RH).
It must be a place with little dirt, dust and water.
No flammable or corrosive liquids or gases, etc. in the area.
Vibrations and shaking of the DX100 controller shall be less than 0,5 Hz.
No large electric noise source (such as a TIG welding device, etc.) nearby.
No potential for collision with moving equipment such as forklifts.
Location shall fulfill the EMC directive 2004/108/EC.
4x M12 x 20 4x M124x M10 x 35
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4.3 Location
Install the DX100 controller outside of the restricted space up to EN ISO 10218-1 enve-lope of the robot (outside of the safeguarding.)
Install the controller in a location from which the robot is easily visible.
Install the controller in a location from which you can easily inspect it when the door is open.
It is recommended to have a free area around the controller of at least 500 mm to allow maintenance acces. Minimum is 200 mm on the controllers backside for proper cooling.
4.4 Mounting the Controller
Attach the controller to the floor using user-supplied brackets made according to the specifi-cations shown below.
Refer to the Instruction Manual for information on installa-tion of the robot.
12 dia. (2 holes)
(Unit: mm)Tapped Holes for M10 Screws on the DX100 Si
(2 holes)12 dia.
(Unit: mm)Tapped Holes for M10 Screws on the DX100 Side
NOTE
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4.5 Opening the cabinet door
Use the supplied key to open the cabinet door.
Put the key in the key hole and tum clockwise.
As an option, a key lock can be mounted on the door to prevent unathorized personnel to enter the cabinet.
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5 Controller specifications
YASKAWA DX100 is based on modules. All repairs are made by replacing the brockenunit / module. New options can be added to the System at any time to up-grade the performance. Boot software and system software can be upraded to achieve new functions.
5.1 IP classification
The cabinet consist of three separate chambers. A totally enclosed chamber for CPU, servopack, IO-boards, etc (IP54). One closed champer for the trans-former and one open chamber for, cooling fans, etc.
5.2 Internal wiring
Electrial drawings (Elementary diagrams) for internal wiring of the DX100 ca-binet.
Component Standard classification Optional
Cabinet IP54 -
Cooling fans not classifield -
Motor and signal cable
IP67 -
CEE power connector
IP44 -
Robot See robot manual -
Programm pendant IP65 -
Controller tybe Drawing No.
Standard, all types
Twin, Triple, all types
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5.3 Noise level
* Measured using standard cooling fans.
5.4 Technical specifications
5.4.1 Control cabinet
Measuring point Emitted noise *
Measured at 1m distance from the cabinet, infront of the door at 1,2 m over the floor. 64.4dB
Back ground noize: 62.6dB
Measured at 1m distance from the cabinet, behind the cabinet, at 1,6 m over the floor. 65.4dB
Back ground noize: 62.9dB
Dimensions 800 (W) x 1000 (H) x 650 (D)
Weight Approx. 250 KG
Protection class IP54
Cooling system Indirect cooling
Ambient temperature 0° to +45° (operation)-10° to +60° (transport and storage)
Relative humidity Max. 90% non-condensating
Power supply 3-phase 400/415/440 VAC at 50/60 Hz
Digital I/O 40 inputs/40 outputs (standard)(Expandable to 2048 inputs/2048 outputs)
Analogue in/outputs 40 channels (optional)
Positioning system Absolute encoder / serial interface
Program memory 200.000 steps, 10.000 instructions and 15.000 PLC steps
Interface RS-232C, Ethernet
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5.4.2 Maintenance
5.4.3 Safety features
Functions System monitor, internal maintenance clocks (e.g. Servo power-on time)
Self-diagnosis Classifies errors and major/minor alarms and diplay the data
User alarm display Alarm message for peripheral devices
Alarm display Alarm messages and alarm history
I/O diagnosis Simulated enable/disable outputs
TCP calibration Automatic calibration on TCP(Tool Center Piont)
Specifications SDual-channel safety system(Emergency stop, safety interlock),3-position Dead-man’s switch,European safety standard (ISO10218)
Collision avoidance Collision avoidance zones and radial interference zones
Collision detection Monitors robot axes’ torque levels
Machine lock Test-run peripheral device without robot motion possible
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5.4.4 Programming
Fig. 1: DX100 Cabinet
Programming
Language
INFORM III
Robot motion control Joint motion, linear, circular,spline interpolation
Speed adjustement Joint motion (% of maximum)
Interpolation (mm/sec; cm/min; inch/min)
Angular velocity (°/sec)
1 Main Power Supply Switch 9 CEE Connector 432BS6
2 Rating NAme Plate 10 Blind Panel
3 Waring Label 11 See Notes (1) min 500 mm
4 Key Handle 12 4-M16 Eye Bolts
5 Programming Pendant (P.P.) 13 Air in
6 Bottom Cover 14 Cable Entrance (a)
7 Mass Label 15 Cable Entrance (a)
8 Air Inlet 16 Air out
!
166
1000
80
AA
Xxxxxxxxx XxxxxxXXX
800
X21
X11
Xxxxxxxxx XxxxxxXXX XXXXX
432BS6
570 2035
AA75
1
2
3
4
5
6
7
8
9
10
11
12
13
16
14
15
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5.4.5 Programmin pendant
The programming pendant is equipped with keys and buttons used to conduct robot teaching operations and to edit jobs.
At the back of the programming pendant a three position enable device (Dead-mans-switch (DSW) is placed. Function:
Dimensions I169 (W) x 314.5 (H) x 50 (D)
Touchscreen display 5.7” colour LCD (640 x 480 pixels)
Weight 0.986 kg
Coordinate system Joint, Rectangular/cylindrical, Tool,User-coordinates
Speed adjustment Fine adjustment possible during operationor teach mode
Shortcuts Direct access keys and user selectablescreen keys possible
Language Mostly spoken languages available(worldwide)
Interface Compact Flash card slot, USB port
Operating system Windows CE
Released No function (circuit open)
Middle positon Operation (circuit closed)
Squeezed No function (circuit open)
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To get from sqeezed position to middle position the deadman switch be com-pletely released first.
When safety circuit is OK (all gates closed and reset), the DSW has no effect.
When safety circuit is down (gate open), servo power can be activated by DSW.
See table for combinations:
5.5 Safety features
5.5.1 External safety
The robot and its auxiliary equipment must be surronded by a safetyguard. Entrances (doors, gates, etc.) must be protected by interlockings, electro-sen-sitive devices or similar. Opening of the gates or entrance to the robot working area must stop all motions inside the cell. Before taking the robot into operati-on, the complete machine must fulfill the “Essential health and safety require-ments relating to the design and construction of machinery” according to the EU Machinery Directive.
5.5.2 Emergency stop function
The emergency stop circuits are designed according to category 1 (EN 418 item 4.1.5) using power to the servo motor to achieve the stop and then remo-val of power when stop is achieved. If stop is not achieved after 0.8 seconds, mechanical brakes are engaged automatically to support stopping.
Servo On
Released = OFF Squeezed = ON Squeezed tightly = OFF
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5.5.3 Internal safety circuits
The YASKAWA DX100 safety system is designed as a software controlled system according to EN 61508. The system is through out a dual channel sa-fety system according to Category 4 (EN 954-1).
Dual CPUs in NIO01 (PLD1 and PLD2).
Dual CPUs in NTU01 (PLD3 and PLD4).
There are mainly two ways to build the safety system; with disconnection of servo power to the external axes or without disconnection.
With disconnection
The servo power to each group of axes can be switched off independently of each other. Each group is controlled by one NTU-unit. The servo power ON/OFF is controlled by the ON_EN signal. The ON_EN signal is controlled by an external safety system. The external safety system sets the condition for tur-ning servo power ON/OFF by means of lightbeams, safety switches, etc.
This solution makes it possible to manually operate an external axis in PLAY-mode (e.g. in a loading zone).
Without disconnection
The machine is built up as one control group. Servo power to an external axis is not turned off. The servo power to the servo motor is always on. The motor is monitored by external mechanical limit switches connected to an external safety system. Conditions in the external safety system allow or prohibit the motor to move. If the servo motor starts by any reason, the switches are af-fected and the safety system turns power off to the complete system.
By this solution it is not possible to manually operate an external axis in PLAY-mode.
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1 Servopack, controls each servo motor.
2 Converter, directs AC power to DC.
3 Contactor unit, turns power to converter ON/OFF.
4 NTU-unit, controls and monitors the contactor unit.
5 NIO-circuit board of the NIF-unit (CPU-rack)
6 External safety circuit control (safety-PLC or safety relays)
7 Emergency stop circuit
8 Dual channel monitoring of axis motion
Control group - robot
Control group - external axis
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5.5.4 Combinations of safety functions related to speed
Mode SAF_F FORCE FST DSW EXDSW SSP2 Speed SAF1
PLAY OFF ON OFF - - ON 16% ON
PLAY OFF ON OFF - - OFF 2% ON
PLAY OFF ON ON - - - 100% ON
PLAY ON - - - - 100% ON
TEACH - OFF OFF ON ON ON 16% ON
TEACH - OFF OFF ON ON OFF 2% ON
TEACH - OFF ON ON ON - 100% ON
TEACH - ON OFF - - ON 16% ON
TEACH - ON OFF - - OFF 2% ON
TEACH - ON ON - - - 100% ON
( - ) Function has no effect
SAF_F Safety circuit
SAF_1 Servo ON relay
FORCE Force action overrule all safety functions
FST Full speed test
DSW Enable switch
EXDSW External enable switch
SSP2 Speed select 2
Speed Percent of maximum speed in PLAY-mode100% is programmed speed16% is about 240 mm/sec.2% is about 30 mm/sec.
TEACH Manual speed, set in (Fast, Medium, Slow, Inching)
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●For programming, see operator‘s manual
1 Start button 9 Enable switch (option)
2 Hold button 10 Enter key
3 Emergency stop button 11 Numeric keys / Function keys
4 Insertion slot for CF-Card 12 Motion type key
5 Page key 13 Enable switch
6 Select key 14 Cursor key
7 Manual speed keys 15 General purpose display area
8 Axis keys 16 Menu areat
17 Mode switch
MANDATORY
Short CutMain Menu
JOB CONTENT
000000010002000300040005000600070008000900100011
TEST01TOOL:CONTROL GROUP:R1S:0000
NOPSET B000 1SET B001 0MOVJ VJ=80.00MOVJ VJ=80.00DOUT OT#(10) ONTIMER T=3.00MOVJ VJ=80.00MOVJ VJ=100.00MOVJ VJ=100.00MOVJ VJ=100.00MOVJ VJ=100.00
Turn on servo power
JOB EDIT DISPLAY UTILITY
MOVJ VJ=0.78
S-
SELECT
X-S+
X+
L-Y-
L+Y+
U-Z-
U+Z+
R-X-
R+X+
B-Y-
B+Y+
T-Z-
T+Z+
TEACHPLAY
REMOTESTART HOLD
SLOW8- 8+
.
2
FAST
TESTSTART
HIGHSPEED
BWD FWD
INTERLOCK
WELDON/OFF
ASSIST
SERVO ONSERVO ON
CANCELCANCELSERVOSERVO
ONONREADYREADY
MAINMAINMENUMENU
AREAAREAPAGEPAGE
GO BACKGO BACKDIRECTDIRECTOPENOPEN
TOOL SELTOOL SEL
COORDCOORDMultiMulti
LAYOUTLAYOUT
Multi
MANUAL SPEED
TOOL SELLAYOUT
ENTRYENTRYENTRY
DELETE
MODIFY
SHIFT
ENTER
INSERT
9
6
3
-.
2
5
87
4
1
0MOTIONTYPE
INFORMLIST
ROBOT
EX.AXIS
AUX
MAINMENU
SIMPLESIMPLEMENUMENU
SIMPLEMENU
COORD
SERVOON
READY
PAGE AREA
CANCEL
DIRECTOPEN
GO BACK
SERVO ON
SHIFT
E- E+
1 2
3
4
5
6
7
8
9
10
1112
13
14
15
16
17
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6 Connection to safety circuit
6.1 Standard configuration
As standard the YASKAWA DX100 controller is equipped with following safety connections.
6.1.1 Safety circuit terminal
Connection to safety circuits are done at the terninal X18. The terminal is placed on the inside of the cabinet door.
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Terminal Description Terminal Description Terminal Description
-X5, 1 EXHOLD+ -X6, 1 +24V -X2, 1 PPESP3
-X5, 2 EXHOLD- -X6, 2 +24V -X2, 2 PPESP3
-X5, 3 EXDSW1+ -X6, 3 SAFF1+ -X2, 3 PPESP4
-X5, 4 EXDSW1- -X6, 4 SAFF1- -X2, 4 PPESP4
-X5, 5 EXDSW2+ -X6, 5 SAFF2+ -X4, 1 PPDSW1+
-X5, 6 EXDSW2- -X6, 6 SAFF2- -X4, 2 PPDSW1-
-X5, 7 +24V2 -X6, 7 NC -X4, 3 PPDSW2+
-X5, 8 024V -X6, 8 NC -X4, 4 PPDSW2-
-X5, 9 GSIN11+ -X6, 9 NC -X4, 5 DSW1+
-X5, 10 GSIN11- -X6, 10 NC -X4, 6 DSW1-
-X5, 11 GSIN12+ -X6, 11 SYSRUN+ -X4, 7 DSW2+
-X5, 12 GSIN12- -X6, 12 SYSRUN- -X4, 8 DSW2-
-X5, 13 GSIN13+ -X6, 13 EXESP1+
-X5, 14 GSIN13- -X6, 14 EXESP1-
-X5, 15 GSIN22+ -X6, 15 EXESP2+
-X5, 16 GSIN22- -X6, 16 EXESP2-
-X5, 17 GSOUT1+ -X6, 17 FST1+
-X5, 18 GSOUT1- -X6, 18 FST1-
-X5, 19 GSOUTFB1+ -X6, 19 FST2+
-X5, 20 GSOUTFB1- -X6, 20 FST2-
-X5, 21 GSOUT2+ -X6, 21 SSP+
-X5, 22 GSOUT2- -X6, 22 SSP-
-X5, 23 GSOUTFB2+ -X6, 23 EXSVON+
-X5, 24 GSOUTFB2- -X6, 24 EXSVON-
-X5, 25 024V
-X5, 26 024V
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6.2 Connect to basic safety
Interconnections
At delivery, connectors for optional safety and external emergency stop are short-circuited by jumpers, see below.
6.2.1 External emergency stop (EXESP)
This signal is used to connect the emergency stop switch of an external ope-ration device. The servo power turns OFF and job execution stops when this signal is input. Servo power can not be turned ON while this signal is OFF.
At delivery jumpers (J3 and J4) are placed on plug X18 between terminal X6-13 and X6-14 and between terminal X6-15 and X6-16. It is possible to connect one external emergency stop circuit
6.2.2 External servo power ON (EXSVON)
This signal is used to connect the servo ON switch of an external operation device. The servo power turns ON when this signal is input. No jumpers are placed in this circuit.
X18X6-13
X6-14
X6-15
X6-16
X18X6-23
X6-24
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6.2.3 External hold (EXHOLD)
This signal is used to connect the HOLD switch of an external operation de-vice. Job execution stops when this signal is input. Starting and axis operation are disabled while this signal is OFF. As standard a jumper (J6) is connected, which has to be removed to be able to use this function.
6.2.4 External safety circuit (SAF_F)
This signal turns OFF the servo power when e.g. the door of the safety guar-dings is opened. The servo power turns OFF when the interlock signal is in-put. The servo power cannot be turned ON while this signal is OFF. However, in Teach mode, this function is disabled.
At delivery jumpers (J1 and J2) are placed on plug X18 between terminal X6-3 and X6-4 and between terminal X6-5 and X6-6. It is possible to connect one external safety circuit.
X18X5-1
X5-2
X18X6-3
X6-4
X6-5
X6-6
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6.2.5 Full speed test (FST)
When both of FST1 and FST 2 input channels are put ON simultaneously, the manipulator speed will be PLAY-mode speed when DX100 is in play mode, and TEACH-mode speed when DX100 is in teach mode.
Note that 1st Safe Speed and 2nd Safe Speed can not be selected. If only one channel is ON, an alarm will occur.
When FST is not activated, speed is limited by the SSP-circuit.
6.2.6 Safety speed (SSP)
For conditions to engage SSP1 or SSP2.
● Circuit closed: 1st safety speed is 16% of maximum play speed (about 240 mm/sec)
● Circuit open: 2nd safety speed is 2% of maximum play speed (about 30 mm/sec)
At delivery a jumper (J5) is placed on plug X18 between terminal X6-21 and X6-22 to set to 1st safety speed
X18X6-17
X6-18
X6-19
X6-20
X18X6-21
X6-22
This short-circuit activates the 1st safety speed.If open = 2nd safety speed.
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6.2.7 Servo ON enable input (ON_EN)
Connect the ON_EN signal lines to enable the function to turn ON or OFF the servo power supply of an individual servo when a robotic system is divided into areas. Because these signals are not used for units of standard specifica-tions, a jumper cable is connected as shown in figure below.
For safety reasons, dual circuits are used for the Servo_ON enable input si-gnals. Remove the jumpers and connect the signal so that both input signals are turned ON and OFF at the same time. If only one signal is turned ON, an alarm occurs.
6.2.8 External axis overrun (EXOT)
Used for overrun check of e.g. a servo track. Servo power is OFF and motor brakes are ON while this signal is OFF.
For safety reasons, dual circuits are used for the EXOT input signals. Remove the jumpers and connect the signal so that both input signals are turned ON and OFF at the same time. If only one signal is turned ON, an alarm occurs.
NTU-CN06
-1
-2
-3
-4
+24V
ONEN1
ONEN2
024V
NTU-CN06-5
-6
-7
-8
+24V
EXOT1
EXOT2
024V
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6.2.9 Emergency stop button output
The extra contact output terminals of the emergency stop button on the pro-gramming pendant are provided on the X18 terminal on the cabinet door. The-se contacts are always valid no matter if the DX100 power supply is ON or OFF.
6.2.10 Enabeling device
The extra contact output terminals of the enabeling device on the program-ming pendant are provided on the X18 terminal on the cabinet door. These contacts are always valid no matter if the DX100 power supply is ON or OFF. This function can be used for start/stopp of an other machine by means of the enabling in the Programming pendant.
-X18
PPESP3+
PPESP3-
PPESP4+
PPESP4-
Programming pendant
X2-1
X2-2
X2-3
X2-4
X18X4-1
X4-3
X4-5
X4-7
X4-2
X4-4
X4-6
X4-8
Safety relay
Output
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6.2.11 Shock sensor (SHOCK)
To connect the tool shock sensor directly to the tool shock sensor si-gnal line.
1 Disconnect the minus SHOCK (-) and 24 VU pin terminal from the NTU-CN07 power supply contactor unit.
2 Connect the minus SHOCK (-) and 24VU pin terminals to the signal line of the tool shock sensor.
To connect the tool shock sensor with the standard integrated cable.
1 Disconnect the minus SHOCK (-) and 24 VU pin terminal from the NTU-CN07 power supply contactor unit.
Connect the minus SHOCK (-) pin terminals to the minus SHOCK (-) pin ter-minal of the robot.
Pin name terminal Pin type Sensor terminal type
SHOCK- (CN07-4) PC-2005W PC-2005M
24VU (CN07-3) PC-2005M PC-2005W
NTU-CN07
-3
-4
(option)
Optional limit switch for shock sensor or collapsi-ble torch holder.
Mark: SHOCK-
Mark: +24VU
+24VU
Default
NTU-CN07
-3
-4
Inside robot
(option)
Optional limit switch for shock sensor or collapsi-ble torch holder.
Mark: SHOCK-
+24VU
Default
-1
SHOCK-
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7 Inspections
7.1 Regular Inspections
Carry out the following inspections.
● Do not touch the cooling fan or other equipment while the power is turned ON.
Failure to observe this caution may result in electric shock or injury.
Inspection Equipment
Inspection Item Inspection Frequency
Comments
DX100 controller Check that the doors are completely closed
Daily
Check for gaps or damage to the sealed construction
Monthly
Interior circulation fan and backside duct fan
Check operation As required While power ON
Emergency stopbutton
Check operation As required While servo ON
Enable switch Check operation As required In teach mode
Battery Confirm battery alarm or message is displayed or not
As required
Power Supply Check power supply voltage is normal
As required
Lead Cables for main power switch
Check falling out, loosing or breaking of the lead cablesCheck the correlate voltage
As required
CAUTION
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7.2 DX100 Inspections
7.2.1 Checking if the Doors are Firmly Closed
The DX100 controller has a fully sealed construction, designed to keep exter-nal air containing oil mist out of the DX100 controller.Be sure to keep the DX100 controller doors fully closed at all times, even when the controller is not operating.
When opening or closing the doors for maintenance, use the specific key for this operation after the main power is turned OFF with the main power switch. (CW: Open, CCW: Close).
Make sure to push the door and turn the door-lock with the specific key to open or close the door. When closing the door, turn the door lock until it clicks.
Fig. 2: DX100 controller Front View
7.2.2 Checking for Gaps or Damage in the Sealed Construction Section
● Open the door and check that the seal around the door is undamaged.
● Check that the inside of the DX100 controller is not stained badly. If it is, determine the cause, take measures and immediately clean it.
Fig. 2:DX100 controller Front View
1 Main Power Switch
2 Door lock
X 8 1PROGRAMMING PENDANT
X 8 1PROGRAMMING PENDANT
kAINTERRUPT CURRENTAVERAGEPEAK kVA
ERDR-POWER SUPPLYTYPEDX100
kVA3PHASE
NJ3001-1
50/60Hz
SERIAL No.DATE
AC415V
MADE IN JAPAN
X 8 1PROGRAMMING PENDANT
1
2
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● Firmly lock each door and check that no excessive gaps exist around the edge of the door.
7.3 Cooling Fan Inspections
Inspect the cooling fans as required. A defective fan can cause the DX100 to malfunction because of excessive high temperatures inside.
The interior circulation fan and backside duct fan normally operate while the power is turned ON. Check if the fans are operating correctly by visual inspec-tion and by feeling air moving into the air inlet and from the outlet.
Fig. 3: Cooling Fan Construction DX100 controller
Fig. 3:Cooling Fan Construction DX100 con-troller
1 Air intake
2 Backside duct fan
3 Interior circulation fan
4 Air outlet
BNL6
BNL6
BNL6
BNL6
BNL6
BNL6
EXHOLD+
GSOUTFB2-GSOUTFB2+GSOUT2-GSOUT2+GSOUTFB1-GSOUTFB1+GSOUT1-GSOUT1+
+24V2
+24V2
+24V2
024V2
024V2
024V2
EXDSW2-EXDSW2+
EXDSW1-
EXHOLD-
EXSVON+
SSP+
EXDSW1+
EXSVON-
SSP-
FST2-FST2+FST1-FST1+
EXESP2-EXESP2+EXESP1-EXESP1+SYSRUN-
SYSRUN+
SAFF2-SAFF2+SAFF1-SAFF1+GSIN22-GSIN22+GSIN21-
GSIN12-GSIN12+GSIN11-
GSIN21+
GSIN11+
MXT
NJ2959-1
50494847464544434241403938373635
3433323130292827262524232221201918
1716151413121110987654321
EXHOLD+
GSOUTFB2-GSOUTFB2+GSOUT2-GSOUT2+GSOUTFB1-GSOUTFB1+GSOUT1-GSOUT1+
+24V2
+24V2
+24V2
024V2
024V2
024V2
EXDSW2-EXDSW2+
EXDSW1-
EXHOLD-
EXSVON+
SSP+
EXDSW1+
EXSVON-
SSP-
FST2-FST2+FST1-FST1+
EXESP2-EXESP2+EXESP1-EXESP1+SYSRUN-
SYSRUN+
SAFF2-SAFF2+SAFF1-SAFF1+GSIN22-GSIN22+GSIN21-
GSIN12-GSIN12+GSIN11-
GSIN21+
GSIN11+
MXT
NJ2959-1
50494847464544434241403938373635
3433323130292827262524232221201918
1716151413121110987654321
1 1
22
3
3
4 4
Colling Fan Construction(small Capacity DX100 controller)
Cooling Fan Construction(Medium-, and Large Capacity DX100 controller)
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7.4 Emergency Stop Button Inspections
The emergency stop button is located on the programming pendant. Before operating the robot, confirm the servo power is OFF by pressing the emergency stop button after the SERVO ON
7.5 Enable Switch Inspections
The programing pendant is equipped with a three-position enable switch. Per-form the following operation to confirm the enable switch operates.
1.) Set the mode switch with key on the programming pendant to "TEACH." Mode switch with key
2.) Press [Servo on READ] on the programming pendant. The [SERVO ON] lamp blinks.
Fig. 4: Servo on Blink
When the message of the "Cooling fan in YPS power sup-ply stopped. Exchange fan" is displayed, it may be caused by the error occurrence at the cooling fan (JZNC-YZU01-E) inside CPU unit (JZNC-YPS01-E).
When the message of the "Cooling fan in YPS unit stop-ped, replace cooling fan" is displayed, carry out an in-spection and the replacement of the cooling fan in the CPS unit (JZNC-YPS01-E)as soon as possible.
Fig. 4:Servo on Blink
1 Servo on Read
2 Servo ON
NOTE
REMOTE
PLAY
TEACH
1
2Blinking
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3.) When the enable switch is grasped lightly, the servo power is turned ON.When the enable switch is grasped firmly or released, the servo power is tur-ned OFF.
7.6 Battery Inspections
The DX100 controller 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 programming pendant display and the message "Memory battery weak" appears at the bottom of the display.
Please confirm that the above mentioned message is NOT indicated when in-specting.
If the [SERVO ON] lamp does not light in previous opera-tion (2), check the following:
● The emergency stop button on the programming pen-dant is being pressed.
● The emergency stop signal is input from external.
● If a major alarm is occurring.
NOTE
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7.7 Power Supply Voltage Confirmation
Check the voltage of 1, 3, 5 terminal of the main power switch power switch (Q1M) of with an electric tester.
Fig. 5: Main Power Switch
Measuring Items Terminals Correct Value
Correlate voltage Between 1 and 3(R-S), 3 and 5(S-T), 1 and 5(R-T)
400/415/440V +/- 10%
Voltage between earth(phase ground)
Between 1 and E(R-E), 5 and E(R-E)
230/240/255V +/- 10%
Between 3 and E(S-G)
About 0V
WARNING
based on local code.Ground the earth terminalelectric shock.May cause
WARNING
based on local code.Ground the earth terminalelectric shock.May cause
1 3 5
2 4 6
Main power switch part in the controller
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7.8 Open Phase Check
Fig. 6: Open Phase Check
Check Item Contents
Lead Cable Check Confirm if the lead cable for the power supply is wired as shown in the following without any falling out, looseness or breaking from the connecting part.
Input Power Supply Check
Check the open phase voltage of input power supply with an electric tester.(Normal value: AC400/415/440V +10%, -15%)
Main power switch (Q1M) Check
Turn ON the main power switch and check the open phase voltage of “2, 4, 6 of the main power switch (Q1M) with an electric tester. If abnormal, replace the main power switch (Q1M).
Fig. 6:Open Phase Check
1 Power Supply X4
2 Main Power Switch
3 Transfer
4 Circuit protector
5 Converter
6 Power supply contactor unit
7 Filter
2(U) 4(V) 6(W)
AC400-415-440V/200V
1KM
2KM
1(R) 3(S) 5(T)
1 2 3
4 5 6
CN555
T1
AE2
TP1
V1
(Q1M)
FS1
X9
1
2
3
4
5
6
7
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8 Description of Units and Circuit Boards
● Cautions for Connection of Dual Input Signals
● Before operating the robot, check that the SERVO ON lamp goes out when the emergency stop at programming pendant is pressed.
Injury or damage to machinery may result if the robot cannot be stopped in case of emergency. Always set the teach lock before starting tea-ching.The emergency stop at programming pendant.
● Observe the following precautions when performing teaching operations within the restricted space up to EN ISO 10218-2 envelope of the robot:
- View the robot from the front whenever possible.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the robot comes toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional robot operation can result in injury.
● When turning ON the power to DX100 controller, be sure that there is no one within the restricted space up to EN ISO 10218-2 envelope of the robot, and that you are in a safe place.
Injury may result from collision with the robot to anyone entering the res-tricted space up to EN ISO 10218-2 envelope of the robot. Always press the emergency stop button immediately if there are problems.
Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed.
- Check for problems in robot movement.
- Check for damage to insulation and sheathing of external wires.
● Always return the programming pendant to its specified position after use.
If the programming pendant is inadvertently left on the robot or fixture, or on the floor, the manipulator or a tool could collide with it during robot mo-vement, possibly causing injuries or equipment damage.
WARNING
CAUTION
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● Connect the switch (contact) that turns the dual signals ON and OFF simultaneously.
● If the timing that turns the two signals ON and OFF is not right, a dis-agreement alarm occurs. Refer to the figure below.
1 Machine safety unit
2 Remove the jumper cable
3 External axis overun
4 Turn OFF/ON at the same time
CAUTION
DX100
CN211
-9
-10
-11
-12
JZNC-YSU01-1E
OT2_1+
OT2_1-
OT2_2+
OT2_2 -
1
2
3
4
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• Do not connect two signals to the same contact point.(Prepare two indivisual contact points)
• Since the power supply for each signal is reversed, it will short-circuit and may cause breakdown of DX100 controller Unit if the signals are connected to the same contact point.
1 Input signal 1
2 Input signal 2
3 Input for the robot system
4 Switch
5 The same contact
CAUTION
DX100
-19
-20
-21
-22
+24V2
024V
1
2
34
5
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8.1 Power Supply Contactor Unit
The power supply contactor unit consists of the power supply contactor se-quence circuit board (JARCR-YPC01-1). The contactor (1KM, 2KM) for servo power and the line filter (1Z). It turns the contactor servo power ON and OFF using the signal for servo power control from the power supply contactor se-quence circuit board and supplies power (3-phase AC200/220V) to the unit.
The power supply (single phase AC200/220V) is supplied to the control power supply via the line filter.
Fig. 7: Power Supply Contactor Unit
Power Supply Contactor Unit Models
Model Robot Type
JZRCR-YPU01- □
MH5L, MH6, MA1400, VA1400, MA1900, HP20D, HP20D-6, MH50, MS80, VS50, ES165D, ES200D
Fig. 7:Power Supply Contactor Unitt
1 Main power supply input 5 AC control power supply
2 Contactor control input 6 AC cooling fan
(CN608)
(CN607)
GP25(2.5A 200V)(4FU),(3FU)
0218010P(10A 250V)
(CN602)
(2FU),(1FU)
(CN606)
(CN605,CN604,CN603)
(CN601)
A012FU FU
A011
CN601
CN610CN611
CN607
SVMX2SVMX1
CN601
CN606
CN612
CN60
8
CN602
CN603
CN604
CN605
SVMX2SVMX1
3FU
2.5
A
4FU
2.5
A
SVMX
2
SVMX
1
CN603
CN604
CN605
CN612
CN606
NCM
CN607
CN611
4FU3FU
CN610
CN601
CN60
9CN
608
CN602
2FU1FU
1
2
3
4
5
6
7
8
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8.2 Major Axes Control Circuit Board (SRDA-EAXA01)
8.2.1 Major Axes Control Circuit Board (SRDA-EAXA01)
The major axes control circuit board (SRDA-EAXA01) controls the servomo-tors of the manipulator’s six axes. It also controls the converter, the PWM am-plifiers, and the power supply contactor circuit board of the power supply contactor unit. Mounting an external axes control circuit board option (SRDA-EAXB01) makes it possible to control the servomotor of nine axes, including the robot axes.
The major axes control circuit board (SRDA-EAXA01) also has the following functions.
● Brake Power Supply Control Circuit
● Shock sensor (shock) input circuit
● Direct-in circuit
3 Brake interlock output 7 Fuse for AC cooling fan
4 Converter output 8 Fuse for AC control power supply
Fig. 7:Power Supply Contactor Unitt
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Fig. 8: Major Axes Control Circuit Board (SRDA-EAXA01)
Fig. 8:Major Axes Control Circuit Board (SRDA-EAXA01)
1 Converter power supply outputt 10 AMP6 PWM signal
2 Brake control signal 11 AMP5 PWMsignal
3 Safety unit I/F 12 Control communication
4 Direct-in 13 Control communication
5 Converter control signal 14 I/O communication
6 AMP2 PWM signal 15 I/O communication
7 AMP1 PWM signal 16 Encoder signal
8 AMP4 PWM signal 17 Control power supply input
9 AMP3 PWM signal 18 Shock signal input
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
(CN513)
(CN516)
(CN518)
(CN512)
(CN517)
(CN515)
(CN508)
(CN509)
(CN505)
(CN511)
(CN514)
(CN507)
(CN506)
(CN502)
(CN501)
(CN503)
(CN504)
(CN510)1
2
3
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8.2.2 Connection for Tool Shock Sensor (SHOCK)
8.2.2.1 To connect the tool shock sensor directly to the tool shock sensor signal line
1.) Disconnect the minus SHOCK (-) and plus SHOCK (+) pin terminal from the DINAMIC connector, the EAXA-CN512 major axes control circuit board.
2.)Connect the minus SHOCK (-) and plus SHOCK (+) pin terminals to the si-gnal line of the tool shock sensor. Use the following pin terminals for prepa-ring the end of the signal line.
Fig. 9: Direct Connection to Tool Shock Sensor Signal Line
8.2.2.2 To connect the tool shock sensor with the cable that is built into the manipulator
Pin Terminal Name
Pin Terminal Model Signal Line Terminal Model
SHOCK- TMEDN-630809-MA TMEDN-630809-FA(manufactured by NICHIFU Co., Ltd.)
SHOCK+ TMEDN-630809-FA TMEDN-630809-MA (manufactured by NICHIFU Co., Ltd.)
Fig. 9:Direct Connection to Tool Shock Sensor Signal Line
1 Major axes control circuit board SRDA-EAXA01
2 Robot cable (signal)
3 robot
4 SHOCK sensor (Option)
5 Shock sensor signal cable
TMEDN-630809-FA(NICHIFU)
SHOCK-
CN512
-3
-4
+24V
SHOCK
SHOCK+
TMEDN-630809-MA(NICHIFU)
1
TMEDN-630809-FA (NICHIFU)
TMEDN-630809-MA (NICHIFU)
2
3
4
5
F4
F4
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1.) Disconnect the minus SHOCK (-) and plus SHOCK (+) pin terminal from the DYMAMIC connector, the EAXA-CN512 major axes control circuit board.
2.) Connect the minus SHOCK (-) pin terminal to the minus SHOCK (-) pin ter-minal of the robot
Fig. 10: Connection with Robot Cable
Cable that is built into the robot is not connected to shocks sensor because the tool shock sensor is a option. For con-necting the tool shock sensor, refer to the wiring diagrams in the INSTRUCTIONS for the robot.
Fig. 10:Connection with Robot Cable
1 Major axes control circuit board SRDA-EAXA01
2 Robot
3 SHOK sensor (Option)
4 use the robot cable
5 Supply cables (PG)
When the tool shock sensor input signal is used, the stopping method of the robot can be specified. The stopping methods are hold stop and servo power supply OFF. Selection of the stopping method is set in the display of the programing pendant.
NOTE
SHOCK-TMEDN-630809-FA (NICHIFU)
CN512
-1
-3
-4
+24V2
SHOCK
SRDA-EAXA01�
SHOCK+TMEDN-630809-FA (NICHIFU)
SHOCK-TMEDN-630809-MA (NICHIFU)
12
3
45
F4
SUPPLE-MENT
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8.2.3 Connection for Direct-in
Direct-in (Servo) 1 to 6
This signal is used to input a responsive signal in search functions.
Fig. 11: Connection for Direct-in (Servo) 1 to 6
● PNP and NPN are possible. The standard in Europe is PNP
Fig. 11:Connection for Direct-in (Servo) 1 to 6
1 Major axes control circuit board
2 DIN Adapter (Option) Order Nr.: 144475
3 Direct in (SERVO)
MANDATORY
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
AXINCOM
+24V2
024VCN514
B1
B3
A4
B4
A5
B5
A6
A1
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
AXINCOM
(SRDA-EAXA01 )
A3
B1
B3
A4
B4
A5
B5
A6
A3
A1
AXDIN6
+24V2
024VCN514
B1
B3
A4
B4
A5
B5
A6
A1
A3
B1
B3
A4
B4
A5
B5A6A3
A1
JFA J2000 SeriesJ21DF-20V-KX-L JST
SJ2F-01GF-P1.0(AWG20 24)
SRDA-EAXA01D
AXDIN6
(Servo) 1
(Servo) 2
(Servo) 3
(Servo) 4
(Servo) 5
(Servo) 6
1
8
3
6
7
2
4
3
3
3
3
3
5
The part of wiring is for the slave for the coordinated control side major axes control circuit board, SRDA-EAXA01
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8.3 CPU Unit
8.3.1 CPU Unit Configuration
Fig. 12: CPU Unit Configuration (JZNC- YRK01-1E)
4 Connect the jumper cable
5 Slave for the coordinated control side
6 Connect the jumper cable
7 Applicable connector
8 Major axes control circuit board
Fig. 12:CPU Unit Configuration (JZNC- YRK01-1E)
1 IO I/F (Communication with YIU) 5 Drive I/F (Communication with EAXA)
2 PCI Slot for sensor board X1 6 for programming pendant
3 Robot I/F circuit board 7 Battery
4 Control circuit board 8 for LAN
Fig. 11:Connection for Direct-in (Servo) 1 to 6
Compact Flash(CN107)
(CN105)
USB(CN106)
(CN104)
Serial Port (RS232C)(CN103)
(CN114)
(CN113)
PCI Slot X2
JANCD-YCP01-E
JANCD-YIF01- E
LED
1
2
3
4
5
6
7
8
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8.3.2 Unit and Circuit Board in the CPU Unit
8.3.2.1 Control Circuit Board (JANCD-NCP01)
This board performs to control the entire system, display to the programming pendant, control the operating keys, control operation and calculate interpola-tion. This board has the Serial interface for RS-232C and LAN (100BASE-TX/10BASE-T).
8.3.2.2 Robot I/F Unit (JZNC-YIF01-E)
The robot I/F Unit controls the entire robotic system. It is connected to the control circuit board (JANCD-NCP01) with a PCI bus interface on the back-board, and to the major axes control circuit board (SRDA-EAXA01A) with high-speed serial transmissions.
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8.4 CPS Unit (JZNC-YPS01-E)
This unit (JZNC-YPS01-E) supplies the DC power (DC5V, DC24V) for control (system, I/O, brake). It is also equipped with the input function for turning the control power supply ON and OFF.
Fig. 13: CPU Unit JZNC-YPS01-E
Fig. 13:CPU Unit JZNC-YPS01-E
1 Connection with CPU 1
2 Connection with CPU 2
3 +24V2 Power supply output
4 +24V1/+24V2 Power supply output
5 +24V3 Power supply output
6 Remote control
7 AC Power supply input
8 Monitor - Alarm display
VUTSRQPNMLKJHGFEDCBA
302928272614
252423222120191817161513121110090807060504030201
C90AD XXXXX
MADE IN JAPANFuji Electric Hi-Tech Corp.
DATENO.
POWER SUPPLYCPS-520F
YYYY-MM
VUTSRQPNMLKJHGFEDCBA
302928272614
252423222120191817161513121110090807060504030201
CN154(+24V1/+24V2)
CN159
CN158(+5V)
CN155(+24V1/+24V2)
(+24V2)CN156/157
(+24V3)CN153
(REMOTE)CN152
(ALM)SOURCE
OHT
INPUT
FAN+24V+5VP-ON
50/60Hz
(AC IN)CN151
200-240V AC
3.4A-2.8A
1
2
3
4
5
67
8 (CN158)(CN159)
(CN156/CN157)
(CN154/CN155)
(CN153)
(CN152)(CN151)
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Items Specifications
Input Rating Input Voltage: 200/220VAC
Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)
Frequency: 50/60Hz ± 2Hz (48 to 62Hz)
Output Voltage DC + 5V
DC +24V (24V1: System, 24V2: I/O, 24V3: Brake)
Indicator
Control Power
ON/OFF
To turn ON the DX100 controller power, turn the non-fuse breaker of controller to the ON position then turning ON the control power supply. If the controller is not located at the workplace, the non-fuse breaker of controller can be turned ON and OFF by input from external device. It is operated by the external switch connected with CN 152 of control power supply as shown in the following figures. (CN152-1 and CN152-2 is shortaged when shipment)
Fig. 14: Connection to Control Power Supply Unit
See “WAGO Connector” for wiring of CN152 connector.
DISPLAY Color Status
SOURCE Green Lights with power supply input.Lights out when internal live part completes discharge.(Power supply status: being input)
POWER ON
Green Lights when PWR_OK output signal is ON. (Power supply status: being output)
+5V Red Lights with +5V over-current(ON when abnormal)
+24V Red Lights with +24V over-current(ON when abnormal)
FAN Red Lights when FAN error occurs.
OHT Red Lights when unit interior overheats
DX100
CPS-420F
CN152
R-IN
R-INCOM
-1
-2
1
2
3
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8.5 Brake Control Board (JANCD-YBK01-E)
8.5.1 Brake Control Board (JANCD-YBK01-E)
Brake Control Board controls ON/OFF of the brakes of total nine axes (Robot + external axes) according to the command signal from Major Axes Control Circuit Board (SRDA-EAXA01).
Fig. 15: Brake control Board (JANCD-YBK01-E)
Fig. 14:Connection to Control Power Supply Unit
1 Remove the short circuit positioner
2 Control power supply ON/OFF switch
3 Control power supply
Fig. 15:Brake control Board (JANCD-YBK01-E)
1 Brake power supply input
2 F1:Fuse
3 Brake Output
4 Brake release switch connection
5 Contactor interlock input
(CN405)
(CN404)
(CN400)
(CN402) 3.15 A/250 V
(CN403)
(CN401)
1
2
3
4
5
6
7
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8.6 Robot I/O Unit (JZNC-YIU02-E)
8.6.1 Robot I/O Unit (JZNC-YIU02-E)
Four digital I/O connectors for the robot universal I/O are provided: 40 inputs and 40 outputs.The I/Os are divided into two types: universal I/O and specific I/O. The I/O assignment differs depending on the application. Specific I/O is a si-gnal in which the part is decided in advance. Specific I/O is used when the ex-ternal operation equipment such as positioner controller and centralized controller control the manipulator and related equipment as a system. Univer-sal I/O are mainly used as timing signals for the manipulator and peripheral devices in jobs that require robot motion.
Refer to „Universal I/O signal assignment“for more details on signal allocation.
For the connection of the robot’s universal I/O signal connectors, and the I/O signal related to start and stop to refer to „Connetion wire with universal I/O Connector (CN306, 307, 308, 309) and „Specific I/O Signal Related to Start and Stop.
6 for switching external power supply
7 Brake command input
Fig. 15:Brake control Board (JANCD-YBK01-E)
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Fig. 16: I/O Unit (JZNC-YIU02-E)
Connection wire with Universal I/O connector (CN306, 307, 308, 309)
Please refer to the figure below when you manufacture the cable connecting with robot universal I/O connector (CN306, 307, 308, 309) of robot I/O unit (JZNC-YIU0-E). Unshielded twisted pair cable must be used.(The cable side connector and the I/O terminal block are the options).
Fig. 16:I/O Unit (JZNC-YIU02-E)
1 Digital I/O 6 Direct-in (optional)
2 Communication Connector 7 Power supply protective fuse 3.15 A / 250 V
3 S1: Rotary Switch 8 For switching external power supply connector
4 D2: FUSE CUT LED 9 Power supply output
5 Panel I/O 10 Power supply input
9
10
(CN301)
(CN303)
(CN302)
(CN309)
(CN306)
(CN307)
(CN308)
F1,F2
(CN304)
(CN305)
D1:24V2IN LED
(CN300)
2
1
1
1
1
3
4
5
6
7
8
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Fig. 17: CN306 bis CN309
Specific I/O Signal Related to Start and Stop
The following signals are specific I/O signals related to start and stop.
(JZNC-YIU01-E)
CN307 CN306
CN309CN308
B20
A20
B1
A1
B20
A20
B1
A1
: FCN-360C040-B (FUJITSU)
B20
A20
B1
A1
CN306,307,308,309
+24VU +24VU +24VU +24VU
+24VU +24VU +24VU +24VU
FG+24VU+24VU
+24VU
+24VU
024VU
024VU
024VU
024VU
024VU
024VU
024VU 024VU
024VU024VUB1 B2 B3 B4 B5 B6 024VU B8 B9 B10 B11 B12 B13 B14 B15
A15A14A13A12A11A10A9A8024VUA6A5A4A3A2A1
TIFS553YS 21-187-3201 R
E/A Einheit
Stecker A
E-/A-Kabel (YIU ~ extern)
Stecker C
E-/A-Kabel (YIU ~ Klemmenblock)
Stecker BEinzelheiten Steckverbindungen B
Steckverbinder Modell: FCN-361J040-AU (FUJITSU)
Steckverbinder Modell: 1747053-1 (Tyco Electronics Amp)
E/A-Klemmenblock Abstreiferlänge: 10mmAnwendbares maximales Kabel Außendurchmesser: Ø 3mm
Modell: TIFS553YS (KASUGA ELECTRIC)
(gelöteter Pintyp)
Steckverbinder Modell: 1903404-1(Tyco Electronics Amp) (MT Typ
Kappe Modell
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● Servo ON (depending on application: JZNC-YIU02-E)
● External Servo ON (common to all application: Specific input termi-nal block X18)
● External Start (depending on application: JZNC-YIU02-E)
● Operating (depending on application: JZNC-YIU02-E)
● External Hold (common to all application: Specific input termi-nal block X18)
● External Emergency Stop (common to all application: Specific input termi-nal block X18)
Fig. 18: Timing Chart
Fig. 18:Timing Chart
1 Robot 5 Operating
2 While servo on 6 External hold
3 Servo on 7 External E-Stop
4 External start 8 0,1 sec or more
RUNSTOP
ONOFF
ONOFF
ONOFF
ONOFF
ONOFF
ONOFF
T
T
T
1
3
4
5
6
7
8
2
Set T =
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Example of Servo ON Sequence Circuit from External Device
Only the rising edge of the servo ON signal is valid. This signal turns ON the robot servo power supply. The set and reset timings are shown in the fol-lowing.
Fig. 19: Servo on sequence circuit
Number in ( ) means output signal number assigned to YIU02. PL: Pilot Lamp
Fig. 19:Servo on sequence circuit
1 Servo on PB
2 Servo on confirmation
3 Servo on command
4 Servo power on
5 Servo on conformation
6 Servo on command
7 System input terminal
8 Servo power on
9 External servo on input
10 Robot I/O unit
11 Servo on output
X1
DX100
(X18)
+24VU
+24VU
(30011)
(EXSVON)
JZNC-YIU02
X18
CN308
X6:23
-A8
-A18
X2
X1
X3 (30011)X2
PL X3
X1
1
2
3
4
5
6
8
7
9
10
11
X6:14
NOTE
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Example of Start Sequence Circuit from External Device
Only the rising edge of the external start signal is valid. This signal starts the manipulator. Reset this signal with the interlock configuration that determines if operation can start and with the playback (RUNNING) signal confirming that the manipulator has actually started moving.
Fig. 20: Start Sequence circuit
Number in ( ) means output signal number assigned to YIU02.
Fig. 20:Start Sequence circuit
1 Run PB
2 While servo on
3 Play mode select
4 Alarm/Error occuring
5 Running confirmation
6 Start (command)
7 Running
8 External start command
9 Robot I/O unit
10 External strat input
11 Running, etc.
12 Running output (30010), etc.
(20010)
+24VU
+24VU
-B18
-B1
-B8
-B18X6
X4CN308
DX100
JZNC-YIU01
PL
X5X6 (30010)
X3
X4
X5(30013)(30016)(30011)1 2 3 4 5
6
7
8
9
10
11
12
NOTE
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Connection of External Power Supply for I/O
At factory setting, the internal power supply for I/O is used. If the external power supply for I/O is used, connect it with following procedure.
1.) Remove the wire connected between CN303-1 to -3 and CN303-2 to -4 of the robot I/O unit.
2.) Connect +24V of the external power supply to CN303-1 and 0V to CN303-2 of the robot I/O unit.
For the connection of the CN303 connector, refer to.
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Fig. 21: I/O Power Circuit
Fig. 21:I/O Power Circuit
1 Robot I/O unit
2 External power supply
3 Ready by customer
● The internal power supply of 24V of about 1.5A of DX100 can be used for I/O. Use external 24V power supply for higher currents and to isolate the circuit inside and outside the DX100.
● Power supply circuit for I/O (+24 VU, 024 VU) has 3A fuses (F1, F2).
● If the internal power supply is selected and the external power supply is connected to CN303-1 to -3 and CN303-2 to -4, do not connect the line of the external power supply to the +24VU and 0VU terminals. The unit may malfunction if the external power supply is also con-nected.
(JZNC-YIU02)
CN303
-1 (EX24VIN)
-2 (EX024VIN)
-3 (+24V)
-4 (024V)
+24VU
024VU
(JZNC-YIU02)
CN303
-1 (EX24VIN)
-2 (EX024VIN)
-3 (+24V)
-4 (024V)
+24VU
024VU
+24V
0V
F1
F2
3A
3A
+24V
024V
F1
F2
3.15A
3.15A
+24V
024V
1 1
2
3
In case of using internal power supply In case of using external power supply
NOTE
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8.7 Machine Safety Unit (JZNC-YSU01-1E)
8.7.1 Machine Safety Unit (JZNC-YSU01-1E)
This unit contains dual processing circuits for safety signal.
It processes external safety signals with the dual processing circuits and cont-rol ON/OFF of the contactor for SERVO power supply of the contactor unit (JZRCR-YPU) according to conditions.
Followings are the main functions of Machine Safety Unit.
● Robot specific I/O circuit (safety signal dual circuits)
● Servo-ON Enable (ONEN) Input Circuit (dual circuits)
● Overrun (OT, EXOT) Input Circuit (dual circuits)
● Programming Pendant Signal PPESP, PPDSW, etc. Input Circuit (safety signal dual circuits)
● Contactor Control Signal Output Circuit (dual circuits)
● Emergency Stop Signal Input Circuit (dual circuits)
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Fig. 22: Machine safety unit (JZNC-YSU01-1E
Fig. 22:Machine safety unit (JZNC-YSU01-1E
1 Contactor control 1
2 Contactor control 2
3 FANALM, FANCTL, LAMP
4 X18 Connection
5 ONEN, EXONEN, EXOT
6 I/F between major axes control circuit boards
7 for contactor control 3 and 4
8 Door emergency stop button
9 OT input connector
10 Power supply input connector
11 Power supply output connector
12 I/F-OUT for machine safety unit
13 I/F for major axes control circuit board - communication
14 I/F-IN for machine safety unit
15 I/F for machine saftey unit
FU
SE
CN21
5CN
216
CN20
8CN
209
CN21
0CN
211
CN21
2CN
213
CN21
4
CN20
0CN
201
CN20
2
CN20
3CN
205
CN20
6CN
207
AB
1
AB
1
AB
1
FRC
5-C
50S
52T-
OLS
(D20
)
s
(CN202)
(CN203)
(CN200)
(CN201)
(CN205)
(CN206)
(CN207)
F1,F2: Fuse3.15A/250V
(CN208)
(CN209)PP I/F
(CN215)
(CN211)
(CN216)
(CN212)
(CN213)
(CN214)
(CN210)
1
2
3
4
5
6
7
8
10
11
12
13
14
15
9
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8.7.2 Connection for Servo-ON Enable Input (ONEN1 and ONEN2)
Connect the ONEN signal lines to enable the function to turn ON or OFF the servo power supply of an individual servo when a robotic system is divided into areas. Because these signals are not used for units of standard specifi-cations, a jumper cable is connected as shown in the following figure.
For safety reasons, dual circuits are used for the Servo-ON Enable input si-gnals. Connect the signal so that both input signals are turned ON or OFF at the same time. If only one signal is turned ON, an alarm occurs.
Refer to “8 Servo Power Supply Individual Control Function” of “Independent/Coordinated Function Instructions Manual” for the usage of the Servo-ON En-able signals.For the connection of CN211 Connector
Fig. 23: Servo-ON enable input
8.7.3 Connection for External Axis Overrun (EXOT)
With a unit of standard specifications without an external axis, the external axis overrun input signal is not used. In this case, a jumper cable is con-nected as shown in the following figure.
Fig. 23:Servo-ON enable input
1 Power supply contactor unit JZNC-YSU01-1E
2 Remove the jumper cable
3 Servo-ON enable input signal
DX100
CN06
-1
-2
-3
-4
+24V2
ONEN1
ONEN2
024V
1 2
3
Turn ON/OFFat the same time
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7
If an overrun input signal for an axis other than manipulator axes, for example the external axis, is required, connect the signal input circuit in the following manner.
For safe reason, a dual circuits are used for the external axis overrun signal input. Connect the external axis overrun signal so that both input signals are turned ON or OFF at the same time. If only one signal is turned ON, an alarm occurs.
1.) Remove the jumper cable between the connectors CN211-5 and -6 and between the connectors CN211-7 and -8 of the JZRCR-YSU01-1E machine safety unit.
2.) Connect the external axis overrun wiring between the connectors CN211-5 and -6 and between the connectors CN211-7 and -8 of the JZRCR-YSU01-1E machine safety unit.
For the connection of CN211 Connector, refer to “7.8 WAGO Connector”
● Remove jumper cable installed on specific input signal before con-necting the input signal lines.
Failure to observe this caution could lead to injury or mechanical fai-lure.
CAUTION
9 E1102000035GB03
DX100-Controller
Fig. 24: External Axis Overrun
Fig. 24:External Axis Overrun
1 Power supply contactor unit JZNC-YSU01-1E
2 Remove the jumper cable
3 External axis overrun
9
10
11
12
OT2_1+
OT2_1-
OT2_2+
OT2_2 -
2
3
DX100
CN211
5
6
7
8
ONEN2_1+
ONEN2_1-
ONEN2_2+
ONEN2_2-
1 2
3
Turn ON/OFFat the same time
E1102000035GB03 80
DX100-Controller
8
8.8 WAGO Connector
CN211 on the machine safety unit (JZNC-YSU01-1E), CN152 on the control power supply (JZNC-YPS01-E), and CN303 on the robot I/O unit (JZNC-YIU01-E) are equipped with a connector made by WAGO.
The “wiring tool for the WAGO connector” is necessary to wire the WAGO connector.
The tools (total 3, 2 types) are supplied with the DX100.
Use them with the appropriate sizes of connectors.
The wiring procedure is described as follows:
1.) Insert part A of the wiring tool into one of the holes designed for the tool.
Fig. 25: Wago Step1
2.) Insert or pull out the wire while pushing the wiring tool downward (Direction of the arrow).
CPS unit: (JZNC-YPS01-E) CN152 Max. cable outside diameter: 4.1 mm dia.Stripped lentgh: 8-9 mm
Machine safety unit: (JZNC-YSU01-1E) CN211Robot I/O unit: (JZNC-YIU02-E) CN303
Max. cable outside diameter: 3.41 mm dia.Stripped lentgh:7 mm
Fig. 25:Wago Step1
1 Part A
2 WAGO connector (e.g. 4 pins type)
3 Wire
1
2
3
1 E1102000035GB03
DX100-Controller
Fig. 26: Wago connector Step 2
3.) Remove the wiring tool from the connector. (Complete)Keep this wiring tool for the future use.
External Emergency Stop
This signal is used to connect the emergency stop switch of an external de-vice. If the signal is input, the servo power is turned OFF and the job is stop-ped. While the signal is input, the servo power cannot be turned ON.
● Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may re-sult and the external emergency stop will not work even if the signal is input.
Push
Wiring fool for WAGO connector
CAUTION
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DX100-Controller
8
Fig. 27: Connection for external emergency stop
Safety Plug
This signal is used to turn OFF the servo power if the door on the safeguar-ding is opened. Connect to the interlock signal from the safety plug on the sa-feguarding door. If the interlock signal is input, the servo power turns OFF. While the signal is turned ON. The servo power cannot be turned ON. Note that these signals are disabled in teach mode.
Fig. 27:Connection for external emergency stop
1 Robot system input terminal block
2 Remove the jumper cable
3 External emergency stop
● Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may re-sult and the external emergency stop will not work even if the signal is input.
X6:13
X6:14
X6:15
X6:16
EXESP1+
DX100
-X18JANCD-YSF03
JZNC-YSU01-1E
EXESP1-
EXESP2+
EXESP2-
12
3Turn ON/OFFat the same time
CAUTION
3 E1102000035GB03
DX100-Controller
Fig. 28: Connection for safety plug
Fig. 28:Connection for safety plug
1 Robot system input terminal block
2 Remove the jumper cable
3 Safety plug
SAFF1-
DX100
-X18JANCD-YSF03
JZNC-YSU01-1E
SAFF1+
SAFF2+
SAFF2-
2
3
1
X6:3
X6:4
X6:5
X6:6
Turn ON/OFFat the same time
E1102000035GB03 84
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8
Example of simple safety system
Fig. 29: Example of simple safety system
Fig. 29:Example of simple safety system
1 Safety door switch
2 Lightbean
3 Reset servicegate
4 Reset lightbeam
5 E. Stop
A
B
A
B
In AIn B
In AIn B
DX100
X6:13
-X18
1
2
34
5
X6:16
X6:15X6:14
X6:4
X6:6
X6:5
X6:3
5 E1102000035GB03
DX100-Controller
High speed Test
This signal is used to reset the slow speed limit for the test run in the teach mode.
If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the teach mode.
If this signal’s circuit is open, the status SSP input signal determines the slow speed:
– slow speed (250mm/sec)
Fig. 30: High speed test
Fig. 30:High speed test
1 Robot system input terminal block
2 Full speed test
FST1-
FST2+
DX100
-X18JZNC
-YSU01-1EJANCD-YSF03
FST1+
FST2-
1
2
X6:14
X6:18
X6:19
X6:20
Turned ON/OFFat the same time
E1102000035GB03 86
DX100-Controller
8
Slow Speed Mode Selection
This signal is used to determine the speed of the test run when the FST (high speed test) signal input circuit is open.
Open: slow speed (250mm/sec)
Fig. 31: Slow speed mode selection
Fig. 31:Slow speed mode selection
1 Robot system input terminal block
2 Remove the jumper cable
3 Slow speed mode selection
X6:21
-X18
DX100
JZNC-YSU01-1E
JANCD-YSF03
SSP-
SSP+
2
3
1
X6:22
7 E1102000035GB03
DX100-Controller
External Servo ON
This signal is used to connect the servo ON switch of an external operation device.If the signal is input, the servo power supply is turned ON.
Fig. 32: External servo ON
Fig. 32:External servo ON
1 Robot system input terminal block
2 External servo ON
EXSVON-
X18
DX100
JZNC-YSU01-1E
JANCD-YSF03
EXSVON+2
1
-X6:23
-X6:24
E1102000035GB03 88
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8
External Hold
This signal is used to connect the temporary stop switch of an external device. If the signal is input, the job is stopped. While the signal is input, starting and axis operations are disabled.
Fig. 33: External Hold
Fig. 33:External Hold
1 Robot system input terminal block
2 Remove the jumper cable
3 Slow speed mode selection
● Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may re-sult and the external emergency stop will not work even if the signal is input.
EXHOLD-
DX100
JZNC-YSU01-1E
JANCD-YSF03
EXHOLD+
-X181
2
-X5:1
-X5:2
CAUTION
9 E1102000035GB03
DX100-Controller
External Enable Switch
This signal is used to connect Enable switch other than the one on the pro-gramming pendant when two people are teaching.
Fig. 34: External enable switch
● Always connect the signals after removing jumper cable.
Injury or damage to machinery may result because the external emergency stop do not work even if the signal is input.
Fig. 34:External enable switch
1 Robot system input terminal block
2 Remove the jumper cable
3 External enable switch
Signal Name
ConnectionNo. (X18)
Dual
input
Function Factory Setting
EXESP1+EXESP1-
EXESP2+EXESP2-
-19-20
-21-22
Applicable External Emergency Stop Short-circuit with a jumper cableUsed to connect the emergency stop
switch of an external device.If the signal is input, the servo power is turned OFF and the job is stopped.While the signal is input, the servo power cannot be turned ON.
CAUTION
DX100
EXDSW2+
JZNC-YSU01-1E
JANCD-YSF03
EXDSW1+
EXDSW1-
EXDSW2-
-X181
2
3
-X5:3
-X5:4
-X5:5
-X5:6
Turned ON/OFFat the same time
E1102000035GB03 90
DX100-Controller
9
SAFF1+SAFF1-
SAFF2+SAFF2-
-9-10
-11-12
Applicable Safety Plug Short-circuit with a jumper cableUsed to turn OFF the servo power if the
door on the safeguarding is opened. Connect to the interlock signal from the safety plug on the safeguarding door. If the interlock signal is input, the servo power turns OFF. While the signal is turned ON. The servo power cannot be turned ON. Note that these signals are disabled in teach mode.
FST1+FST1-
FST2+FST2-
-23-24
-25-26
Applicable Full-speed Test Open
Used to reset the slow speed limit for the test run in the teach mode.If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the teach mode.If this signal’s circuit is open, the status SSP input signal determines the safety speed: The first slow speed (16%) or second slow speed (2%).
SSP+SSP-
-27-28
- Slow Speed Mode Selection Short-circuit with a jumper cableUsed to determine the speed of the test
run when the FST (full-speed test) signal input circuit is open.Open: Second slow speed (2%)Short-circuit: First slow speed (16%)
EXSVON+EXSVON-
-29-30
- External Servo ON Open
Use to connect the servo ON switch of an external operation device.If the signal is input, the servo power supply is turned ON.
EXHOLD+EXHOLD-
-31-32
- External Hold Short-circuit with a jumper cableUsed to connect the temporary stop
switch of an external device.If the signal is input, the job is stopped.While the signal is input, starting and axis operations are disabled.
Signal Name
ConnectionNo. (X18)
Dual
input
Function Factory Setting
1 E1102000035GB03
DX100-Controller
8.9 Contact Output of Emergency Stop Button
The contact output terminals for the emergency stop button on the program-ming pendant and the door front are provided on the terminal block X18 termi-nal X5 (screw size M3.5) at lower part of the right side of DX100 controller.
EXDSW1+EXDSW1-
EXDSW2+EXDSW2-
-33-34
-35-36
Applicable External Enable Switch Short-circuit with a jumper cableUsed to connect a Enable switch other
than the one on the programming pendant when two people are teaching.
Signal Name
ConnectionNo. (X18)
Dual
input
Function Factory Setting
E1102000035GB03 92
DX100-Controller
9
These contact outputs are always valid no matter of the DX100 controller main power supply status ON or OFF. (Status output signal: normally closed contact)
Fig. 35: Emergency stop button
8.10 SERVOPACK
A SERVOPACK consists of a converter and a PWM amplifier of which there are two types. One type is the SERVOPACK with a combined converter and a PWM amplifier and the other type is one where both units are separate.
● Do not use the emergency stop button with 24 VAC, 0.5 A or more.
Failure to observe this instruction may result in damage to equip-ment.
CAUTION
PPESP3+
PPESP3
PPESP3+
PPESP3
-X18
EXT
PPESP4+
PPESP4
PPESP4+
PPESP4
1
2
-X2:1
-X2:2
-X2:3
-X2:4
3 E1102000035GB03
DX100-Controller
8.10.1 Description of Each Unit
8.10.1.1 Converter
This exchanges the power supply (3-phase : AC200/220V) supplied by the contactor unit for DC power supply and supplies the power to PWM amplifiers for each axis.
8.10.1.2 PWM Amplifier
This exchanges the DC power supply supplied by a converter for a 3-phase motor power source and outputs to each servo motor.
8.10.2 SERVOPACK Configuration
Conficuration Device
MH5L MH6 MA1400 VA1400
Model Model Model Model
SERVOPACK SRDA-MH5 SRDA-MH6 SRDA-MH6 JZRCR-MH6-14/00
Converter SRDA-COA12A01A SRDA-COA12A01A SRDA-COA12A01A SRDA-COA12A01A
PWMAmplifier
S SRDA-SDA06A01A SRDA-SDA14A01A SRDA-SDA14A01A SRDA-SDA14A01A
L SRDA-SDA06A01A SRDA-SDA14A01A SRDA-SDA14A01A SRDA-SDA14A01A
U SRDA-SDA06A01A SRDA-SDA14A01A SRDA-SDA14A01A SRDA-SDA14A01A
R SRDA-SDA03A01A SRDA-SDA06A01A SRDA-SDA06A01A SRDA-SDA06A01A
B SRDA-SDA03A01A SRDA-SDA06A01A SRDA-SDA06A01A SRDA-SDA06A01A
T SRDA-SDA03A01A SRDA-SDA06A01A SRDA-SDA06A01A SRDA-SDA06A01A
AMP7 SRDA-SDA14A01A
Conficuration Device MA1900 HP20D
HP20D-6
Model Model
SERVOPACK SRDA-MH20 SRDA-MH20
Converter SRDA-COA12A01A SRDA-COA12A01A
PWMAmplifier
S SRDA-SDA14A01A SRDA-SDA14A01A
L SRDA-SDA21A01A SRDA-SDA21A01A
U SRDA-SDA14A01A SRDA-SDA14A01A
R SRDA-SDA06A01A SRDA-SDA06A01A
B SRDA-SDA06A01A SRDA-SDA06A01A
T SRDA-SDA06A01A SRDA-SDA06A01A
AMP7
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9
Conficuration Device MH50 MS80 VS50
Model Model Model
Converter SRDA-COA12A01AU SRDA-COA12A01AU SRDA-COA12A01AU
SERVOPACK SRDA-MH50 SRDA-MS80 JZRCR-MS80-71/00
PWMAmplifier
S SRDA-SDA71A01A SRDA-SDA71A01A SRDA-SDA71A01A
L SRDA-SDA71A01A SRDA-SDA71A01A SRDA-SDA71A01A
U SRDA-SDA35A01A SRDA-SDA71A01A SRDA-SDA71A01A
R SRDA-SDA14A01A SRDA-SDA14A01A SRDA-SDA14A01A
B SRDA-SDA14A01A SRDA-SDA14A01A SRDA-SDA14A01A
T SRDA-SDA14A01A SRDA-SDA14A01A SRDA-SDA14A01A
AMP7 SRDA-SDA71A01A
Conficuration Device ES165D ES200D
Model Model
Converter SRDA-COA30A01A SRDA-COA30A01A
SERVOPACK SRDA-MS165 SRDA-MS165
PWMAmplifier
S SRDA-SDA71A01A SRDA-SDA71A01A
L SRDA-SDA71A01A SRDA-SDA71A01A
U SRDA-SDA71A01A SRDA-SDA71A01A
R SRDA-SDA35A01A SRDA-SDA35A01A
B SRDA-SDA21A01A SRDA-SDA21A01A
T SRDA-SDA21A01A SRDA-SDA21A01A
AMP7
5 E1102000035GB03
DX100-Controller
Servopack configuration for MH5, Mh6, Ma1400, Ma1800, Ma1900, HP20D and HP20D-6
Fig. 36: EAXA base is closed
Fig. 36:EAXA base is closed
1 Converter 19 Ground terminal
2 Control power supply output for external axis amplifier
20 EAXA Base
3 Control power supply output for 6-axis amplifier
21 Control communication
4 Main circuit power supply output for external axis amplifier
22 Control communication
5 Charge lamp 23 I/O Communication
6 EAXA Base fixing screw (top) 24 I/O Communication
7 EAXA Board 25 Encoder Signal
8 Brake control signal 26 Control power supply input
9 Safety unit I/O 27 SHOCK Signal input
10 Direct-in 28 EAXA Base fixing screw (top)
11 Converter control signal 29 Main circuit power supply input
(CN505)
(CN508)
(CN506)
(CN507)
(CN511)
(CN514)
(CN502)
(CN501)
(CN503)
(CN504)
(CN513)
(CN552B)
(CN556)
(CN558)
(CN516)
(CN518)
(CN517)
(CN515)
(CN509)
(CN551)
(CN552A)(CN553)
(CN557)
(CN555)
(CN554)
(CN512)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1718
19
20
21
22
23
24
25
26
27
28
29
30
31
32 33 34
35
36
E1102000035GB03 96
DX100-Controller
9
Fig. 37: Servopack MH5, MH6, MA1800, MA1900, HP20D and HP20D-6 (EAXA Base is open)
12 AMP2 PWM signal 30 Regenerative resister
13 AMP1 PWM signal 31 Ground Terminal
14 AMP4 PWM signal 32 Grounding detection input
15 AMP3 PWM signal 33 Converter control signal
16 AMP6 PWM signal 34 Monitor alarm display LED
17 AMP5 PWM signal 35 Control power supply input
18 EAXA Basae fixing screw (bottom) 36 Control power supply output for 6-axis amplifier
Fig. 37:Servopack MH5, MH6, MA1800, MA1900, HP20D and HP20D-6 (EAXA Base is open)
1 Amplifier main circuit power supply 5 Amplifier control power supply
2 Motor power output 6 Motor power output
3 PWM Signal 7 PWM Signal
4 Amplifier control power supply 8 Amplifier main circuit power supply
Fig. 36:EAXA base is closed
1
2
3
45
6
7
8 (AMP1,3,5-CN583)
(AMP1,3,5-CN582)
(AMP1,3,5-CN581)
(AMP1,3,5-CN584)
AMP5
AMP3
AMP1
(AMP2,4,6-CN583)
(AMP2,4,6-CN582)
(AMP2,4,6-CN581)
(AMP2,4,6-CN584)
AMP2
AMP4
AMP6
7 E1102000035GB03
DX100-Controller
Servopack configuration for VA1400
Fig. 38: VA1400 EAXA Base is closed
Fig. 38:VA1400 EAXA Base is closed
1 Converter 19 Ground terminal
2 Control power supply output for external axis amplifier
20 EAXA Base
3 Control power supply output for 6-axis amplifier
21 Control communication
4 Main circuit power supply output for external axis amplifier
22 PWM Amplifier 9 signal
5 Charge lamp 23 I/O Communication
6 EAXA Base fixing screw (top) 24 PWM Amplifier 8 signal (frond)
7 EAXA Board 25 PWM Amplifier 7 signal (back)
8 Safety unit I/O 26 Encoder signal
9 Brake control signal 27 Control power supply input
10 Direct-in 28 SHOCK Signal input
11 Converter control signal 29 EAXA Base fixing screw (top)
12 AMP2 PWM signal 30 Main circuit power supply input
13 AMP1 PWM signal 31 Regenerative resister
14 AMP4 PWM signal 32 Ground Terminal
15 AMP3 PWM signal 33 Grounding detection input
(CN512)
(CN508)
(CN509)
(CN557)
(CN555)
(CN554)
(CN513)
(CN507)
(CN514)
(CN502)
(CN501)
(CN503)
(CN504)
(CN505)
(CN506)
(CN552B)
(CN556)
(CN558)
(CN511)
(CN533)
(CN515,CN516)
(CN532)
(CN517,CN518)
(CN531)
(CN553)
(CN551)
(CN552A)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33 34 35 37
36
E1102000035GB03 98
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9
Fig. 39: VA1400 EAXA Base is open
16 AMP6 PWM signal 34 Converter control signal
17 AMP5 PWM signal 35 Monitor alarm display LED
18 EAXA Basae fixing screw (bottom) 36 Control power supply input
37 Control power supply output for 6-axis amplifier
Fig. 39:VA1400 EAXA Base is open
1 Amplifier main circuit power supply 5 Amplifier control power supply
2 Motor power output 6 Motor power output
3 PWM Signal 7 PWM Signal
4 Amplifier control power supply 8 Amplifier main circuit power supply
Fig. 38:VA1400 EAXA Base is closed
(AMP1,3,5,7-CN583)
(AMP1,3,5,7-CN582)
(AMP1,3,5,7-CN581)
(AMP1,3,5,7-CN584)
AMP1
AMP3
AMP5
AMP7
(AMP2,4,6-CN583)
(AMP2,4,6-CN582)
(AMP2,4,6-CN581)
(AMP2,4,6-CN584)
AMP2
AMP4
AMP6
1
2
3
45
6
7
8
9 E1102000035GB03
DX100-Controller
Servopack configuration for MH50, MS80
Fig. 40: Servopack MH50 and MS80 (EAXA Base is closed)
Fig. 40:Servopack MH50 and MS80 (EAXA Base is closed)
1 Converter 21 EAXA Base
2 Charge Lamp 22 Control communication
3 Main circuit power supply output 23 Control communication
4 Main circuit output for external axis 24 I/O Communication
5 Upper Grip 25 I/O Communication
6 EAXA Base fixing screw (top) 26 Encoder signal
7 EAXA Board 27 Control power supply input
8 Safety unit I/F 28 SHOCK Signal input
9 Brake control signal 29 EAXA Base fixing screw (top)
10 Direct-in 30 Control power supply output for converter
11 Converter control signal 31 Main circuit power supply input
(CN502)
(CN501)
(CN503)
(CN504)
(CN505)
(CN506)
(CN516)
(CN518)
(CN512)
(CN510)
(CN513)
(CN551)
(CN507)
(CN511)
(CN514)
(CN517)
(CN515)
(CN508)
(CN509)
(CN556)
(CN558)
(CN557)
(CN555)
(CN554)
(CN553)(CN552A)
(CN552B)1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
3536
37
38
39
40
E1102000035GB03 100
DX100-Controller
1
Fig. 41: Servopack MH50 and MS80 (EAXA Base is open)
12 AMP2 PWM signal 32 Regenerative resister
13 AMP1 PWM signal 33 Ground Terminal
14 AMP4 PWM signal 34 Grounding detection input
15 AMP6 PWM signal 35 Converter control signal
16 AMP5 PWM signal 36 Upper Grip
17 AMP3 PWM signal 37 Monitor alarm display LED
18 Lower Grip 38 Control power supply input
19 EAXA Basae fixing screw (bottom) 39 Control power supply output for 6-axis amplifier
20 Ground Terminal 40 Control power supply output for external axis amplifier
Fig. 41:Servopack MH50 and MS80 (EAXA Base is open)
1 Amplifier main circuit power supply 5 Amplifier control power supply
2 Motor power output 6 Motor power output
3 PWM Signal 7 PWM Signal
4 Lower Grip 8 Amplifier main circuit power supply
Fig. 40:Servopack MH50 and MS80 (EAXA Base is closed)
9
1
2
8
7
(AMP2,4,6-CN583)
(AMP1,3,5-CN583) (AMP2,4,6-CN582)
(AMP1,3,5-CN582)
(AMP2,4,6-CN584)(AMP1,3,5-CN581)
(AMP1,3,5-CN584)
AMP1
AMP3
AMP5
AMP6
AMP2
AMP4
(AMP2,4,6-CN581) 3
4
5
6
01 E1102000035GB03
DX100-Controller
Servopack Configuration for VS50
Fig. 42: Servopack configuration VS50 (EAXA base is closed)
Fig. 42:Servopack configuration VS50 (EAXA base is closed)
1 Converter 24 Ground terminal
2 Charge Lamp 25 EAXA base
3 Main circuit power supply output 26 Control communication
4 Main circuit output for external axis 27 PWM amplifier 9 signal
5 Upper Grip 28 I/O Communication
6 EAXA Base fixing screw (top) 29 PWM amplifier 8 signal (front)
7 EAXA Board 30 PWM amplifier 7 signal (back)
8 Safety unit I/F 31 Encoder signal
9 Brake control signal 32 SHOCK Signal input
10 Direct-in 33 Control power supply input
(CN535) (CN536)
(CN534)
6
7
(CN533)
(CN531)
(CN510)
(CN552B)
(CN556)
(CN551)
(CN552A)(CN553)
(CN557)
(CN554)
(CN555)(CN558)
(CN532)
(CN512)
(CN508)
(CN509)
(CN515,CN516)
(CN517,CN518)
(CN513)
(CN511)
(CN514)
(CN507)
(CN501)
(CN504)
(CN503)
(CN506)
(CN505)
(CN502)
1
2
3
4
5
8
9
10
11
12
13
14
15
16
16
18
19
2021
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40 41
42
44
43
45
E1102000035GB03 102
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1
11 Converter control signal 34 EAXA Base fixing screw (top)
12 AMP2 PWM signal 35 Control power supply output for converter
13 AMP1 PWM signal 36 Main circuit power supply input
14 AMP4 PWM signal 37 Regenerative resister
15 AMP6 PWM signal 38 Ground Terminal
16 AMP5 PWM signal 39 Grounding detection input
17 EAXA Basae fixing screw (bottom) 40 I/O Signal connecting terminal
18 AMP3 PWM signal 41 Upper Gript
19 Lower Grip 42 Monitor alarm display LED
20 Encoder Signal (9th axis) 43 Control power supply
21 Encoder signal (8th axis) 44 Control power supply
22 Encoder signal (7th axis) 45 Control power supply
23 EAXA base fixing screw (bottom)
Fig. 42:Servopack configuration VS50 (EAXA base is closed)
03 E1102000035GB03
DX100-Controller
Fig. 43: Servopack configuration VS50 (EAXA Base is open)
Fig. 43:Servopack configuration VS50 (EAXA Base is open)
1 Amplifier control power supply 5 Amplifier control power supply
2 Motor power output 6 Motor power output
3 PWM Signal 7 PWM Signal
4 Lower Grip 8 Amplifier main circuit power supply
9 Amplifier main circuit power supply
2
1
3
45
6
7
8 9
(AMP2,4,6-CN582)
(AMP2,4,6-CN583)(AMP1,3,5,7-CN583)
(AMP1,3,5,7-CN582)
(AMP2,4,6-CN581)
(AMP2,4,6-CN584)
AMP2
AMP4
AMP6
(AMP1,3,5,7-CN581)
(AMP1,3,5,7-CN584)
AMP1
AMP3
AMP5
AMP7
E1102000035GB03 104
DX100-Controller
1
Servopack configuration for ES165D and ES200D
Fig. 44: Servopack for ES165D, ES200D (EAXA Base is closed
Fig. 44:Servopack for ES165D, ES200D (EAXA Base is closed
1 Converter 21 EAXA base
2 Charge Lamp 22 Control communication
3 Main circuit power supply output 23 Control communication
4 Main circuit output for external axis 24 I/O Communication
5 Upper Grip 25 I/O Communication
6 EAXA Base fixing screw (top) 26 Encoder signal
7 EAXA Board 27 Control power supply input
8 Brake control signal 28 SHOCK Signal input
9 Safety unit I/F 29 EAXA Base fixing screw (top)
10 Direct-in 30 Control power supply output for converter
11 Converter control signal 31 Main circuit power supply input
12 AMP2 PWM signal 32 Regenerative resister
(CN552B)
(CN502)
(CN513)
(CN507)
(CN511)
(CN514)
(CN501)
(CN503)
(CN504)
(CN505)
(CN506)
(CN556)
(CN558)
(CN552A)
(CN516)
(CN518)
(CN517)
(CN515)
(CN512)
(CN508)
(CN509)
(CN557)
(CN554)
(CN555)
(CN551)(CN553)
(CN510)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
37
36
38
3940
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
05 E1102000035GB03
DX100-Controller
Fig. 45: Servopack ES165D, ES200D (EAXA Base is open)
13 AMP1 PWM signal 33 Ground Terminal
14 AMP4 PWM signal 34 Grounding detection input
15 AMP3 PWM signal 35 I/O Signal connecting termina
16 AMP6 PWM signal 36 Monitor alarm display LED
17 AMP5 PWM signal 37 Upper Grip
18 Lower Grip 38 Control power supply
19 EAXA Basae fixing screw (bottom) 39 Control power supply
20 Ground terminal 40 Control power supply
Fig. 45:Servopack ES165D, ES200D (EAXA Base is open)
1 Amplifier control power supply 5 Amplifier control power supply
2 Motor power output 6 Motor power output
3 PWM Signal 7 PWM Signal
4 Lower Grip 8 Amplifier main circuit power supply
9 Amplifier main circuit power supply
Fig. 44:Servopack for ES165D, ES200D (EAXA Base is closed
(AMP1,3,5-CN583)
(AMP1,3,5-CN582)
(AMP1,3,5-CN581)
(AMP1,3,5-CN584)
AMP1
AMP3
AMP5
(AMP2,4,6-CN583)
(AMP2,4,6-CN582)
(AMP2,4,6-CN584)
AMP6
AMP2
AMP4
(AMP2,4,6-CN581)
9
1
3
4
5
7
8
2
6
E1102000035GB03 106
DX100-Controller
1
8.11 Universal I/O Signal Assignment
8.11.1 Arc Welding
Fig. 46: JZNC-YIU02-E(CN308 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
Fig. 46:JZNC-YIU02-E(CN308 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
1 Each point
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
Connector terminal converter (optional) Order number: 105090
07 E1102000035GB03
DX100-Controller
2 Internal power supply
3 External power supply
Fig. 46:JZNC-YIU02-E(CN308 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
E1102000035GB03 108
DX100-Controller
1
Fig. 47: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
FFig. 47:JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter (optional) Order number: 105090
09 E1102000035GB03
DX100-Controller
Fig. 48: JZNC-YIU02-E (CN306 Connector) I/O Allocation and Connection Diagram (for arc welding)
Fig. 48:JZNC-YIU02-E (CN306 Connector) I/O Allocation and Connection Diagram (for arc welding)
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter (optio-nal) Order number: 105090
E1102000035GB03 110
DX100-Controller
1
Fig. 49: JZNC-YIU02-E (CN307 Connector) I/O allocation and connection diagram (for arc welding)
Fig. 49:JZNC-YIU02-E (CN307 Connector) I/O allocation and connection diagram (for arc welding)
1 Each point
2 Internal power supply
3 External power supply
4 means internal relay
* RLY
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
4
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter (optional) Order number: 105090
11 E1102000035GB03
DX100-Controller
Specific Input (Arc Welding)
Logical
Number
Input Name / Function Logical
Number
Input Name / Function
20010 EXTERNAL STARTFunctions the same as the [START] button in the programming pendant. Only the rising edge of the signal is valid. It starts robot operation (playback). This signal is invalid if external start is prohibited from the playback condition display.
20022 WORK PROHIBITED (Arc Generation Prohibited)Arc generation is prohibited while this signal is ON. Arc generation starts when this signal turns OFF inside the arc-generation area. Use this signal to confirm teaching.
20012 CALL MASTER JOBOnly the rising edge of the signal is valid. It calls up the top of the robot program, that is the top of the master job*1. This signal is invalid during playback, during teach lock and when play master or call is prohibited (set from the playback operation condition display).
20023 WORK RESPONSE (Pseudo Arc ON Response)This signal is used as a pseudo signal in cases that “Arc Generation Confirmation” signal is not equipped on a welding power supply. Wire this signal ON normally (short to OV).
20013 ALARM/ERROR RESETAfter an alarm or error has occurred and the cause been corrected, this signal resets the alarm or error.
20026 WEAVING PROHIBITEDWeaving is prohibited while this signal is ON. Use this signal to check taught steps and movements without performing the weaving operation.
20015 SELECT PLAY MODEThe play mode is selected when the mode key on the programming pendant is set at "REMOTE". Only the rising edge of the signal is valid. When this selection signal assigned concurrently with other mode selection signal, the teach mode is selected on a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20027 SENSlNG PROHIBITEDArc sensing is prohibited while this signal is ON. Use this signal to check taught steps and movements if an arc sensor is mounted.
20016 SELECT TEACH MODEThe teach mode is selected when the mode key of the programming pendant is set at "REMOTE". The other mode selection is unavailable when this signal is ON; the signal is selected by priority even when the other selection signal is ON, enabling the teach mode selection.
20020 INTERFERENCE 1 ENTRANCE PROHIBITEDIf the robot attempts to enter the cube 1area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
E1102000035GB03 112
DX100-Controller
1
*1 A master job is a job (program) which can be called by CALL MASTER JOB.Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is tur-ned ON, is set as the master job.
Specific Output (Arc Welding)
20021 INTERFERENCE 2 ENTRANCE PROHIBITEDIf the robot attempts to enter the cube 2 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
Logical
Number
Output Name / Function Logical
Number
Output Name / Function
30010 RUNNINGThis signal signifies that the job is running. (Signifies that the job is running, system status is waiting reserved start, or test run is running.) This signal status is the same status as [START] in the programming pendant.
30021 IN CUBE 2This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2). Use this signal to prevent interference with other robots and positioners.
30011 SERVO IS ONThis signal signifies that the servo power is turned ON, internal processing such as current position creation is complete, and the system is able to receive the START command. This signal turns OFF when the servo power supply turns OFF. It can be used for DX100 status diagnosis for an external start.
30022 WORK HOME POSITION (IN CUBE 32)*2
This signal turns ON when the current TCP lies inside the work home position area. Use this signal to evaluate whether the manipulator is in the start position.
30012 TOP OF MASTER JOBThis signal signifies that the execution position is the top of the master job. This signal can be used to confirm that the master job has been called.*1
30023 INTERMEDIATE START OKThis signal turns ON when the manipulator operates. It turns OFF when the currently executed line is moved with the cursor or when editing operation is carried out after HOLD is applied during operation. Therefore, this signal can be used as a restart interlock after a HOLD is applied. However, it also turns ON in the teach mode and TEACH MODE SELECTED signal must be referred together.
30013 ALARM/ERROR OCCURREDThis signal signifies that an alarm or an error occurred. If a major error occurs, this signal remains ON until the main power is turned OFF.
30024 GAS SHORTAGE (MONITOR)This signal stays ON while the gas shortage signal from the welding power supply is ON.
Logical
Number
Input Name / Function Logical
Number
Input Name / Function
13 E1102000035GB03
DX100-Controller
1)This signal is not output during operation.
2) The work home position cube and Cube 32 are same.
30014 BATTERY ALARMThis signal turns ON to notify that the battery requires replacing when the voltage drops from the battery for backup memory of the encoder. Major problems may result if memory data is lost because of an expired battery. It is recommended to avoid these problems by using this signal as a warning signal.
30025 WIRE SHORTAGE (MONITOR)This signal status ON while the wire shortage signal from the welding power supply is ON.
30015 to30017
REMOTE/PLAY/TEACH MODE SELECTEDThis signal notifies the current mode setting. These signals are synchronized with the mode select switch in the programming pendant. The signal corresponding to the selected mode turns ON.
30026 WIRE STICKING (MONITOR)The wire sticking check is conducted automatically when the arc turns OFF. If wire sticking is detected, this signal remains ON until the wire sticking is released.
30020 IN CUBE 1This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1). Use this signal to prevent interference with other robots and positioners.
30027 ARC SHORTAGE (MONITOR)This signal stays ON while the arc shortage signal from the welding power supply is ON.
Logical
Number
Output Name / Function Logical
Number
Output Name / Function
E1102000035GB03 114
DX100-Controller
1
8.11.2 Handling
Fig. 50: JZNC-YIU02-E (CN308 Connector) I/O allocation and connection diagram (for Handling
Fig. 50:JZNC-YIU02-E (CN308 Connector) I/O allocation and connection diagram (for Handling
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
Connector terminal converter (optional) Order number: 105090
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
15 E1102000035GB03
DX100-Controller
Fig. 51: JZNC-YIU02-E (CN309 Connector) I/O allocation and connection diagram (for Handling
Fig. 51:JZNC-YIU02-E (CN309 Connector) I/O allocation and connection diagram (for Handling
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
Connector terminal converter (optional) Order number: 105090
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
E1102000035GB03 116
DX100-Controller
1
Fig. 52: JZNC-YIU02-E (CN306 Connector) I/O allocation and connection diagram (for Handling
Fig. 52:JZNC-YIU02-E (CN306 Connector) I/O allocation and connection diagram (for Handling
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
Connector terminal converter (optional) Order number: 105090
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
17 E1102000035GB03
DX100-Controller
Fig. 53: JZNC-YIU02-E (CN307 Connector) I/O allocation and connection diagram (for Handling
Fig. 53:JZNC-YIU02-E (CN307 Connector) I/O allocation and connection diagram (for Handling
1 Each point
2 Internal power supply
3 External power supply
4 means internal relay
Connector terminal converter (optional) Order number: 105090
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
* RLY
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
4
E1102000035GB03 118
DX100-Controller
1
Specfic Input (Handling)
Logical
Number
Input Name / Function Logical
Number
Input Name / Function
20010 EXTERNAL STARTFunctions the same as the [START] button in the programming pendant. Only the rising edge of the signal is valid. It starts robot operation (playback). This signal is invalid if external start is prohibited from the playback condition display.
20021 INTERFERENCE 2 ENTRANCE PROHIBITEDIf the manipulator attempts to enter the cube 2*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
20012 CALL MASTER JOBOnly the rising edge of the signal is valid. It calls up the top of the robot program, that is the top of the master job*1. This signal is invalid during playback, during teach lock and when play master or call is prohibited (set from the playback operation condition display).
20026 TOOL SHOCK SENSORThis is normally ON (NC) signal input. When it turns OFF, an DX100 displays a message "HAND TOOL SHOCK SENSOR OPERATING" and a HOLD is applied. The releasing in teach mode is done on the handling application diagnostic display. Set tool shock sensor function “NOT USE” on the handling applications diagnostic display if this signal is not be used.
20013 ALARM/ERROR RESETAfter an alarm or error has occurred and the cause been corrected, this signal resets the alarm or error.
20027 LOW AIR PRESSUREThis signal is normally OFF (NO). When it turns ON, XRC displays user alarm in the PLAY mode or displays user message in the teach mode.
20015 SELECT PLAY MODEThe play mode is selected when the mode key on the programming pendant is set at "REMOTE". Only the rising edge of the signal is valid. When this selection signal assigned concurrently with other mode selection signal, the teach mode is selected on a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20050 to20057
SENSOR INPUT 1 - 8Inputs 1 to 8 are monitored with the HSEN handling specific instructions. Sensor inputs 1 to 8 correspond to HSEN 1 to 8.
20016 SELECT TEACH MODEThe teach mode is selected when the mode key of the programming pendant is set at "REMOTE". The other mode selection is unavailable when this signal is ON; the signal is selected by priority even when the other selection signal is ON, enabling the teach mode selection.
19 E1102000035GB03
DX100-Controller
*1 A master job is a job (program) which can be called by CALL MASTER JOB. Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is tur-ned ON, is set as the master job.
Specific Output (Handling)
20020 INTERFERENCE 1 ENTRANCE PROHIBITEDIf the robot attempts to enter the cube 1 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
Logical
Number
Output Name / Function Logical
Number
Output Name / Function
30010 RUNNINGThis signal signifies that the job is running. (Signifies that the job is running, system status is waiting reserved start, or test run is running.) This signal status is the same status as [START] in the programming pendant.
30021 IN CUBE 2This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2). Use this signal to prevent interference with other robots and positioners.
30011 SERVO IS ONThis signal signifies that the servo power is turned ON, internal processing such as current position creation is complete, and the system is able to receive the START command. This signal turns OFF when the servo power supply turns OFF. It can be used for DX100 status diagnosis for an external start.
30022 WORK HOME POSITION (IN CUBE 32)*2
This signal turns ON when the current TCP lies inside the work home position area. Use this signal to evaluate whether the robot is in the start position.
30012 TOP OF MASTER JOBThis signal signifies that the execution position is the top of the master job. This signal can be used to confirm that the master job has been called.*1
30023 INTERMEDIATE START OKThis signal turns ON when the manipulator operates. It turns OFF when the currently executed line is moved with the cursor or when editing operation is carried out after HOLD is applied during operation. Therefore, this signal can be used as a restart interlock after a HOLD is applied. However, it also turns ON in the teach mode and TEACH MODE SELECTED signal must be referred together.
30013 ALARM/ERROR OCCURREDThis signal signifies that an alarm or an error occurred. If a major error occurs, this signal remains ON until the main power is turned OFF.
30050 to30057
HAND VALVE 1-4These outputs are controlled by the HAND handling specific instructions. Hand valves 1 to 4 correspond to HAND 1 to 4.
E1102000035GB03 120
DX100-Controller
1
*1 This signal is not output during operation.
*2 The work home position cube and Cube 32 are same.
30014 BATTERY ALARMThis signal turns ON to notify that the battery requires replacing when the voltage drops from the battery for backup memory of the encoder. Major problems may result if memory data is lost because of an expired battery. It is recommended to avoid these problems by using this signal as a warning signal.
30015 to30017
REMOTE/PLAY/TEACH MODE SELECTEDThis signal notifies the current mode setting. These signals are synchronized with the mode select switch in the programming pendant. The signal corresponding to the selected mode turns ON.
30020 IN CUBE 1This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1). Use this signal to prevent interference with other robots and positioners.
Logical
Number
Output Name / Function Logical
Number
Output Name / Function
21 E1102000035GB03
DX100-Controller
8.11.3 General Application
Fig. 54: JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection Diagram (For General Application)
Fig. 54:JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection Diagram (For General Application)
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter (optional) Order number: 105090
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
E1102000035GB03 122
DX100-Controller
1
Fig. 55: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For General Application)
Fig. 55:JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For General Application)
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter (optional) Order number: 105090
23 E1102000035GB03
DX100-Controller
Fig. 56: JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (General Application)
Fig. 56:JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (General Application)
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
Connector terminal converter (optional) Order number: 105090
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
E1102000035GB03 124
DX100-Controller
1
Fig. 57: JZNC-YIU01-E (CN307 Connector ) I/O Allocation and Connection Diagram (For General Application)
Fig. 57:JZNC-YIU01-E (CN307 Connector ) I/O Allocation and Connection Diagram (For General Application)
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
Connector terminal converter (optional) Order number: 105090
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
25 E1102000035GB03
DX100-Controller
Specific Input (General application)
*1 A master job is a job (program) which can be called by CALL MASTER JOB.
Logical
Number
Input Name / Function Logical
Number
Input Name / Function
20010 EXTERNAL STARTFunctions the same as the [START] button in the programming pendant. Only the rising edge of the signal is valid. It starts robot operation (playback). This signal is invalid if external start is prohibited from the playback condition display.
20021 INTERFERENCE 2 ENTRANCE PROHIBITEDIf the manipulator attempts to enter the cube 2*2 area while this signal is ON, the robot goes to wait status (with servo power ON). During wait status, the robot operation restarts if this signal turns OFF.
20012 CALL MASTER JOBOnly the rising edge of the signal is valid. It calls up the top of the robot program, that is the top of the master job *1. This signal is invalid during playback, during teach-lock and when play master or call is prohibited (set from the playback operation condition display).
20022 WORK PROHIBITED (Tool ON Prohibited)Even if TOOLON instruction is executed, XRC doesn’t output to external while this signal is ON.
20013 ALARM/ERROR RESETAfter an alarm or error has occurred and the cause been corrected, this signal resets the alarm or error.
20024 INTERFERENCE 3 ENTRANCE PROHIBITEDIf the manipulator attempts to enter the cube 3*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
20015 SELECT PLAY MODEThe play mode is selected when the mode key on the programming pendant is set at "REMOTE". Only the rising edge of the signal is valid. When this selection signal assigned concurrently with other mode selection signal, the teach mode is selected on a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20025 INTERFERENCE 4 ENTRANCE PROHIBITEDIf the robot attempts to enter the cube 4*2
area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
20016 SELECT TEACH MODEThe teach mode is selected when the mode key of the programming pendant is set at "REMOTE". The other mode selection is unavailable when this signal is ON; the signal is selected by priority even when the other selection signal is ON, enabling the teach mode selection.
20020 INTERFERENCE 1 ENTRANCE PROHIBITEDIf the manipulator attempts to enter the cube 1 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the robot operation restarts if this signal turns OFF.
E1102000035GB03 126
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1
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the master job.
Specific Output (General application)
Logical
Number
Output Name / Function Logical
Number
Output Name / Function
30010 RUNNINGThis signal signifies that the job is running. (Signifies that the job is running, system status is waiting reserved start, or test run is running.) This signal status is the same status as [START] in the programming pendant.
30021 IN CUBE 2This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2). Use this signal to prevent interference with other manipulators and positioners.
30011 SERVO IS ONThis signal signifies that the servo power is turned ON, internal processing such as current position creation is complete, and the system is able to receive the START command. This signal turns OFF when the servo power supply turns OFF. It can be used for XRC status diagnosis for an external start.
30022 WORK HOME POSITION (IN CUBE 32)*2
This signal turns ON when the current TCP lies inside the work home position area. Use this signal to evaluate whether the robot is in the start position.
30012 TOP OF MASTER JOBThis signal signifies that the execution position is the top of the master job. This signal can be used to confirm that the master job has been called.*1
30023 INTERMEDIATE START OKThis signal turns ON when the manipulator operates. It turns OFF when the currently executed line is moved with the cursor or when editing operation is carried out after HOLD is applied during operation. Therefore, this signal can be used as a restart interlock after a HOLD is applied. However, it also turns ON in the teach mode and TEACH MODE SELECTED signal must be referred together.
30013 ALARM/ERROR OCCURREDThis signal signifies that an alarm or an error occurred. If a major error occurs, this signal remains ON until the main power is turned OFF.
30024 IN CUBE 3This signal turns ON when the current TCP lies inside a pre-defined space (Cube 3). Use this signal to prevent interference with other manipulators and positioners.
30014 BATTERY ALARMThis signal turns ON to notify that the battery requires replacing when the voltage drops from the battery for backup memory of the encoder. Major problems may result if memory data is lost because of an expired battery. It is recommended to avoid these problems by using this signal as a warning signal.
30025 IN CUBE 4This signal turns ON when the current TCP lies inside a pre-defined space (Cube 4). Use this signal to prevent interference with other manipulators and positioners.
27 E1102000035GB03
DX100-Controller
*1 This signal is not output during operation.
*2 The work home position cube and Cube 32 are same.
30015 to30017
REMOTE/PLAY/TEACH MODE SELECTEDThis signal notifies the current mode setting. These signals are synchronized with the mode select switch in the programming pendant. The signal corresponding to the selected mode turns ON.
30026 WORK COMMANDThis signal provides the command for the general tool to operate. TOOL ON instruction execution or the [TOOL ON] key in the programming pendant turns this signal ON and TOOL OFF instruction execution or the [TOOL OFF] key in the programming pendant turns it OFF. However, it remains OFF while the WORK PROHIBITED signal (2022) is input or while the robot is stopped.
30020 IN CUBE 1This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1). Use this signal to prevent interference with other robots and positioners.
Logical
Number
Output Name / Function Logical
Number
Output Name / Function
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1
8.11.4 Spot Welding
Fig. 58: JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection Diagram (For Spot Welding)
Fig. 58:JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection Diagram (For Spot Welding)
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
Connector terminal converter (optional) Order number: 105090
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
29 E1102000035GB03
DX100-Controller
Fig. 59: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For Spot Welding)
Fig. 59:JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For Spot Welding)
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter (optional) Order number: 105090
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
E1102000035GB03 130
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1
Fig. 60: JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (For Spot Welding
Fig. 60:JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (For Spot Welding
1 Each point
2 Internal power supply
3 External power supply
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12
-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.
Connector terminal converter (optional) Order number: 105090
31 E1102000035GB03
DX100-Controller
Fig. 61: JZNC-YIU02-E (CN307 Connector) I/O allocation and connection diagram (for spot welding)
Fig. 61:JZNC-YIU02-E (CN307 Connector) I/O allocation and connection diagram (for spot welding)
1 Each point 3 External power supply
2 Internal power supply 4 means internal relay
* RLY
A20B20A19B19
A18B18A17B17A16
B16A15B15A14
B14A13B13A12B12
A11B11A10B10
A9B9A8
B8
A7B7A6B6A5B5
A4B4A3B3A2B2A1
B1
CN308 Connector
B1A1B2
A2B3
A3B4A4B5A5B6A6B7A7B8A8B9A9
B10A10B11
A11B12A12
B13A13B14
B15A14
A15
B16
B17
A16
A17
B18A18B19A19B20
A20
2001020011
200122001320014
20015200162001720020200212002220023
300103001130012
300133001430015300163001730020
300213002230023
A1B2
A2B3
A3B4A4B5A5B6A6
024VU
B8A8B9A9
B10A10B11A11B12A12B13A13B14
B15A14
A15
024VU
024VU
024VU
024VU
FG024VU
ININININININININ
OUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUTOUT
024VU024VU024VU024VU+24VU+24VU+24VU+24VUFG
ININININ
B1
024VU
+24VU
+24VU
+24VU
+24VU
Name Signal Terminal Number
LogicalNumber
ConnectorNumber
External Start-Call Master JobAlarm/Error Reset-
-Interference1 Entrance Prohibited
Work ProhibitedWork Response024VU024VURunningServo is ON
Top of Master JobAlarm/Error OccurredBattery Alarm
Remote Mode SelectedPlay Mode SelectedTeach Mode SelectedIn Cube 1In Cube 2Work Home Position
Intermediate Start OK(continuousing Sequence)
Interference2 Entrance Prohibited
Select Play Mode
Select Teach Mode
1
1
2
3
CN12-3
-4
-1
-2
+24VU
024VU
24VDC8mA max.
24VDC50mA max.
+24 VE 024 VE
+24 V 024 V(24V,1A)
4
DX100ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter (optional) Order number: 105090
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4 when a external power supply is used.** This assignment can be changed at the I/O assignment display. Refer to system input list YIU02 and system output list YIU02 for de-tail.*** This assignment can be changed at the PSEDU input display Refer to system input list YIU02 and sysrem output
E1102000035GB03 132
DX100-Controller
1
Specific Input (Spot Welding)
Logical
Number
Input Name / Function Logical
Number
Input Name / Function
20010 EXTERNAL STARTFunctions the same as the [START] button in the programming pendant. Only the rising edge of the signal is valid. It starts robot operation (playback). This signal is invalid if external start is prohibited from the playback condition display.
20023 WELDING PAUSE (From sequencer)This signal is used to move the manipulator to the home position when an error occurs in the Power Source or the gun.The robot ignores the spot welding instruction and operates playback motion.
20012 CALL MASTER JOBOnly the rising edge of the signal is valid. It calls up the top of the robot program, that is the top of the master job *1. This signal is invalid during playback, during teach-lock and when play master or call is prohibited (set from the playback operation condition display).
20024 INTERFERENCE 3 ENTRANCE PROHIBITEDIf the manipulator attempts to enter the cube 3*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
20013 ALARM/ERROR RESETAfter an alarm or error has occurred and the cause been corrected, this signal resets the alarm or error.
20025 INTERFERENCE 4 ENTRANCE PROHIBITEDIf the manipulator attempts to enter the cube 4*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
20015 SELECT PLAY MODEThe play mode is selected when the mode key on the programming pendant is set at "REMOTE". Only the rising edge of the signal is valid. When this selection signal assigned concurrently with other mode selection signal, the teach mode is selected on a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20050*4
TIMER COOLING WATER ERRORThis signal monitors the status of timer cooling water. The manipulator displays alarm and stops when this signal is input. The servo power remains ON.
20016 SELECT TEACH MODEThe teach mode is selected when the mode key of the programming pendant is set at "REMOTE". The other mode selection is unavailable when this signal is ON; the signal is selected by priority even when the other selection signal is ON, enabling the teach mode selection.
20051*4
GUN COOLING WATER ERRORThis signal monitors the status of gun cooling water. The manipulator displays alarm and stops when this signal is input. The servo power supply remains ON.
20020 INTERFERENCE 1 ENTRANCE PROHIBITEDIf the manipulator attempts to enter the cube 1*2 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
20052*4
TRANSTHERMO ERRORError signal is sent from the transformer in the gun to the robot. This signal is ON normally (NC) and an alarm occurs when the signal is OFF. The servo power supply remains ON.
33 E1102000035GB03
DX100-Controller
Specific Input List YIU02 (Spot Welding)
* 1) A master job is a job (program) which can be called by CALL MASTER JOB. Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is turned ON, is set as the master job.
*2) This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
20021 INTERFERENCE 2 ENTRANCE PROHIBITEDIf the manipulator attempts to enter the cube 2 area while this signal is ON, the manipulator goes to wait status (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF.
20053*4
LOW AIR PRESSUREWhen air pressure is reduced and this input is turned ON, an alarm occurs. The servo power supply remains ON.
20022 WELDING ON/OFF (From sequencer)This signal inputs the welding ON/OFF selector switch status from the sequencer in the interlock unit. The WELD ON/OFF signal is output to the Power Source according to this signal and the manipulator status.
*3 WELD COMPLETIONThis signal indicates that the Power Source completed welding without error. This signal is used as a confirmation signal for welding instruction execution and manual spot welding.After this signal is input, the welding sequence is completed and the next step is executed when confirmation limit switch is not provided.
Logical
Number
Input Name / Function Logical
Number
Input Name / Function
*3 WELDING ERRORThis signal indicates an abnormal welding result or Power Source’s error. Alarm occurs and the manipulator stops if this signal is input during welding.
*3 GUN SHORT OPEN DETECTIONThis signal is connected with a single gun open verification limit switch or a double stroke gun short open verification limit switch to verify the gun open.
*3 STICK DETECTIONThis signal indicates an abnormal welding result or Power Source’s error. Alarm occurs and the manipulator stops if this signal is input during welding.
*3 GUN PRESSURE DETECTIONThis signal indicates that a gun is in pressing status.
*3 GUN FULL OPEN DETECTIONThis signal indicates that the stroke of the double stroke gun is full open.
*3 TIP REPLACE COMPLETIONWhen this signal is input after tip replacement, the TIP REPLACE REQUEST signal turns OFF, and the stored number of welding is cleared.
Logical
Number
Input Name / Function Logical
Number
Input Name / Function
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1
*3) This signal can be set as “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is selected, this signal can be used as the universal I/O signal described in parentheses.
Specific output list YIU02 (Spot welding)
Logical
Number
Output Name / Function Logical
Number
Output Name / Function
30010 RUNNINGThis signal signifies that the job is running. (Signifies that the job is running, system status is waiting reserved start, or test run is running.) This signal status is the same status as [START] in the programming pendant.
30023 INTERMEDIATE START OKThis signal turns ON when the manipulator operates. It turns OFF when the currently executed line is moved with the cursor or when editing operation is carried out after HOLD is applied during operation. Therefore, this signal can be used as a restart interlock after a HOLD is applied. However, it also turns ON in the teach mode and TEACH MODE SELECTED signal must be referred together.
30011 SERVO IS ONThis signal signifies that the servo power is turned ON, internal processing such as current position creation is complete, and the system is able to receive the START command. This signal turns OFF when the servo power supply turns OFF. It can be used for DX100 status diagnosis for an external start.
30024 IN CUBE 3This signal turns ON when the current TCP lies inside a pre-defined space (Cube 3). Use this signal to prevent interference with other manipulators and positioners.
30012 TOP OF MASTER JOBThis signal signifies that the execution position is the top of the master job. This signal can be used to confirm that the master job has been called.*1
30025 IN CUBE 4This signal turns ON when the current TCP lies inside a pre-defined space (Cube 4). Use this signal to prevent interference with other manipulators and positioners.
30013 ALARM/ERROR OCCURREDThis signal signifies that an alarm or an error occurred. If a major error occurs, this signal remains ON until the main power is turned OFF.
30050*4
WELD ON/OFFOutputs a signal input from the interlock panel, etc.considering the robot status.
7 6 5 4 3 2 1 00 0 0 1 _ 1 1 1 1
Pseudo InputSignal 8202x
Timer cooling water error validating ( or IN09)Gun cooling water error validating (or IN10)Transthermo error validating (or IN11)Low air pressure validating (or IN12)Weld ON/OFF validating (or OUT09
35 E1102000035GB03
DX100-Controller
*1.) This signal is not output during operation.
*2.) The work home position cube and Cube 32 are same.
*3.) This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
30014 BATTERY ALARMThis signal turns ON to notify that the battery requires replacing when the voltage drops from the battery for backup memory of the encoder. Major problems may result if memory data is lost because of an expired battery. It is recommended to avoid these problems by using this signal as a warning signal.
30051*3
WELD ERROR RESETThis signal commands the reset error status of the Power Source. This is operated with the programing pendant operation.
30015 to30017
REMOTE/PLAY/TEACH MODE SELECTEDThis signal notifies the current mode setting. These signals are synchronized with the mode select switch in the programming pendant. The signal corresponding to the selected mode turns ON.
30052 to30056*3
WELD CONDITION (Level signals) 1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8) Sets the welding conditions for the Power Source. The output format can be selected as binary or discrete (bit number). It can handle up to 255 conditions. Most-significant bit is the parity bit (when specified).
30020 IN CUBE 1This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1). Use this signal to prevent interference with other manipulators and positioners.
*3WELDING COMMANDThis signal outputs execution command signal to the Power Source. This signal is not necessary for a Power Source which is executed using the WELDING CONDITION signal.
30021 IN CUBE 2This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2). Use this signal to prevent interference with other manipulators and positioners.
*3STROKE CHANGE1SINGLE SOLENOIDDOUBLE SOLENOIDThis is a signal, when a double stroke gun is used, to change the open stroke of the welding gun.
30022 WORK HOME POSITION (IN CUBE 32)*2
This signal turns ON when the current TCP lies inside a the work home position area. Use this signal to evaluate whether the robot is in the start position.
*3GUN PRESSURE INSTRUCTION This outputs a gun pressure instruction.
30057 TIP REPLACE REQUESTThis signal is output when the stored number of welding reaches the number of welding set for the tip replacement.
Logical
Number
Output Name / Function Logical
Number
Output Name / Function
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1
*4.) This signal can be select “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is selected, this signal can be used as the universal I/O signal described in parentheses.
8.11.5 JANCD-YEW01 Circuit Board (Standard)
8.11.5.1 Arc Welding
Fig. 62: JANCD-YEW01 Circuit Board
7 6 5 4 3 2 1 00 0 0 1 _ 1 1 1 1
Timer cooling water error validating ( or IN09)Gun cooling water error validating (or IN10)Transthermo error validating (or IN11)Low air pressure validating (or IN12)Weld ON/OFF validating (or OUT09
Pseudo InputSignal 8202x
D/A ±14V
D/A ±14V
A/D +5V
CH2 Current Input
CH1 Voltage Input
DC24V0.5A MAX
DX100
ININININININ
OUTOUTOUTOUTOUTOUT
OUTOUT
OUT
OUT
CN322-1
WIRINCH (Wire Retract) A
CN322-2
CN322-3
CN322-4
CN322-5
CN322-6
CN322-7
CN322-8
CN322-9
CN322-10
CN322-11
CN322-12
CN322-13
CN322-14
CN322-15
CN322-16
CN322-17
CN322-18
CN322-19
CN322-20
CN322-21
CN322-22
CN322-23
CN322-24
CN322-25
CN322-26
CN322-27
CN322-28
CN322-29
CN322-30
CN322-31
CN322-32
CN322-33
CN322-34
CN321-2
CN321-4
DC24V5mA MAX
DC24V0.5A MAX
1234
5678 9101112 13
1415161718
1920 21
22 23
242526272829303132 33
34
T
P
RK
LFG H
S
J
MN
EAB
C D
+GASOF Gas Shortage
-GASOF Gas Shortage+WIRCUT Wire Shortage
+ARCACT (Arc Generation Confirm
-ARCACT Arc Generation Confirm
-WIRCUT Wire Shortage
+ARCOFF Arc Shortage-ARCOFF Arc Shortage
ARCON Arc ON A
ININ
ARCON Arc ON B
WIRINCH Wire Inching A
WIRINCH Wire Inching B
WIRINCH (Wire Retract) B
STICK Wire Sticking*STICK Wire Sticking
+24VU024VUCH1 Voltage CommandCH1 G-CH2 Current CommandCH2 G-
Search Command A (Optional)
Search Command B (Optional
OUTOUT
ININ
22550
22551
22553
22552
32551
32552
32553
22554
MS3106 A, 20-29PMS3106 A, 20-29S
32555+24VUCN321-1
CN321-5 024VU
IN
CH1 G-
ININ
CH2 G- IN
A/D +5V
SW21 3
17BYTE 32BYTE
GAS Checking OUT A OUTOUT
32567GAS Checking OUT B
LogicalNumber
ConnectorPin No. Name Signal
24 VDC5mA MAX
Detector
1
2 3
5 6
4
37 E1102000035GB03
DX100-Controller
JANCD-YEW01 Circuit Board: Analog outputs x2 ports, Analog inputs x2 ports + Status signal I/O of a Welder.
Fig. 62:JANCD-YEW01 Circuit Board
1 Each point 4 Power Souce
2 MR Connector 5 WAGO Connector (321-105/026-A0) t
3 MS Connector 6 MRP-34M01 InsulatorMRP-M112 Contactor
RP-34 Casing
E1102000035GB03 138
1
DX100-Controller
39 E1102000035GB03
DX100-Controller
E1102000035GB03 140
1
DX100-Controller
41 E1102000035GB03
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3E1102000035GBMANUAL NO.
Specifications are subject to change without noticefor ongoing product modifications and improvements.
DX100INSTALLATION & WIRING
