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DX100 controller

Operator‘s Manual

Basic Programming

- Please read these instructions before operation and keep them for later reference.

- The operating instructions are only for internal use.

operation and keep them for later reference. - The operating instructions are only for internal use.

E1102000066GB01

DX100 controller

Edition

Version

Date

remark

changed by

0

1.00

02.03.2010

 

Woe

controller Edition Version Date remark changed by 0 1.00 02.03.2010   Woe E1102000066GB01

E1102000066GB01

controller Edition Version Date remark changed by 0 1.00 02.03.2010   Woe E1102000066GB01

DX100 controller

Table of contents

1

Safety

5

1.1

Notes for Safe operation

5

2

Introduction

9

2.1 DX100 overview

9

2.2 Programming pendant

10

2.2.1 Programming pendant overview

10

2.2.2 Key Description

11

2.2.3 Programmin pendant keys

12

2.2.4 Programming pendant display

18

2.2.5 Screen descriptions

25

2.2.6 Character input operation

26

2.3 Mode

28

2.3.1 Teach mode

28

2.3.2 Play mode

28

2.3.3 Remote mode

29

2.3.4 Teach mode priority

29

2.4 Security mode

30

 

2.4.1

Types of security modes

30

2.4.2

Changing Security Modes

34

3

Robot coordinate systems and operations

37

3.1

Control groups and coordinate systems

37

 

3.1.1

Control group

37

3.1.2

Types of coordinate systems

38

3.2 General operations

39

3.2.1 Check safety

39

3.2.2 Select teach mode

39

3.2.3 Select control group

39

3.2.4 Select coordinate system

39

3.2.5 Select manual speed

39

3.2.6 Servo on

40

3.2.7 Axis operation

40

3.2.8 High speed

40

3.3 Coordinate Systems and Axis Operation

3.3.1 Joint coordinates

41

41

3.4 Cartesian coordinates

43

3.5 Cylindrical coordinates

44

3.6 Toll coordinates

45

3.6.1 Axis motion

45

3.6.2 Selecting the tool number

46

3.7 User coordinates

47

3.7.1 Selecting user coordinates

48

3.7.2 Examples of user coordinate utilization

49

3.8 Tool tip operations

50

 

3.8.1

Control point operation

50

4

Simplified teaching and playback

51

4.1

Teaching

51

 

4.1.1

Preaparation for teaching

51

4.1.2

Teaching procedure

54

4.1.3

Path confirmation

62

4.1.4

Correcting a job

62

4.1.5

Chaning the position data

63

4.2 Playback

4.2.1 Preparation before playback

67

67

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4.2.2 Playback procedure

4.3 Example for arc welding application

67

68

4.3.1 Example job

68

4.3.2 Teaching procedure

69

4.3.3 Setting welding conditions

71

4.3.4 Welding test

72

4.4 Example for handling application

74

4.4.1 Example job

74

4.4.2 Hand instruction

75

4.4.3 Teaching procedure

76

4.4.4 Handling test

84

4.5 Example for general purpose application

85

4.5.1 Example job

85

4.5.2 Teaching procedure

86

4.5.3 Cutting test

88

4.6 Example for spot welding application

90

4.6.1 Example job

90

4.6.2 Setting welding conditions

91

4.6.3 Teaching procedure

92

4.6.4 Welding test

93

4.7 Example for painting application

95

 

4.7.1

Example job

95

4.7.2

Setting painting conditions

96

4.7.3

Teaching procedure

96

4.7.4

Painting test

99

5

Teaching

101

5.1

Preaparation for teaching

101

 

5.1.1

Checking emergency stop buttons

101

5.1.2

Setting the teach lock

101

5.1.3

Registering a job

101

5.2 Teaching operation

104

5.2.1 The teaching window

104

5.2.2 Interpolation type and play speed

104

5.2.3 Teaching steps

109

5.2.4 Overlapping the first and last steps

120

5.3 Checking Steps

5.3.1 FWD/BWD key operations

5.4 Modifying steps

122

122

128

5.4.1 Displaying the JOB CONTENT window for editing

132

5.4.2 Inserting MOV instructions

133

5.4.3 Deleting MOV instructions

135

5.4.4 Modifying MOV instructions

136

5.4.5 Undo operation after editing a MOV instruction

137

5.4.6 Modifying reference point instructions

138

5.4.7 Modifying timer instructions

139

5.5 Modifying jobs

140

5.5.1 Calling up a job

140

5.5.2 Windows related to job

141

5.6 Editing instructions

145

5.6.1 Instruction group

146

5.6.2 Inserting instructions

148

5.6.3 Deleting instructions

150

5.6.4 Modifying instructions

151

5.6.5 Undo operation after modifying instructions

154

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5.6.6 Modifying additional numeric data

154

5.6.7 Modifying additional items

155

5.6.8 Inserting additional items

156

5.6.9 Deleting additional items

157

5.6.10 Undo operation after modifying additional items

158

5.7 Editing jobs

159

5.7.1 Selecting the range

161

5.7.2 Copying

162

5.7.3 Cutting

162

5.7.4 Pasting

163

5.7.5 Reverse pasing

163

5.8 Test operations

5.8.1 Test Operation Procedures

5.9 Other job-editing functions

164

164

165

 

5.9.1

Editing play speed

165

5.9.2

Relative modification

165

5.9.3

Modification by TRT (Traverse time)

167

5.9.4

Editing condition files

169

5.9.5

Editing user variables

170

5.9.6

Editing local variables

186

5.9.7

Searching

189

6

Playback

195

6.1

Preparation for playback

195

 

6.1.1

The PLAYBACK window

198

6.1.2

Playback operation

199

6.1.3

Special playback operations

202

6.2 Stop and restart

205

6.2.1 Hold

205

6.2.2 Emergency stop

207

6.2.3 Restart After Emergency Stop

208

6.2.4 Stop by alarm

208

6.2.5 Others

209

6.3 Modifying play speed

6.3.1 Modifying with speed override

6.4 Playback with reserved start

209

209

213

6.4.1 Preparation for reserved start

213

6.4.2 Playback from reserved start

218

6.4.3 Hold operation

221

6.5 Displaying job stack

7 Editing

jobs

7.1 Copying jobs

223

224

225

7.1.1 Copying jobs on the JOB CONTENT window

225

7.1.2 Copying jobs on the JOB LIST window

226

7.2 Deleting jobs

227

7.2.1 Deleting jobs on the JOB CONTENT window

228

7.2.2 Deleting jobs on the JOB LIST window

229

7.3 Modifying job names

230

7.3.1 Modifying job names on the JOB CONTENT window

230

7.3.2 Modifying job names on the JOB LIST window

231

7.4 Editing comments

233

7.5 Setting edit lock on individual job units

234

7.6 Enabling the modification of position data only

235

8 Convenient functions

237

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8.1 One touch operation „direct open“

237

8.2 Parallel Shift Function

239

8.2.1 Function Overview

239

8.2.2 Setting the Shift Value

241

8.2.3 Registering shift instructions

243

8.2.4 Continuation of the Parallel Shift Function

249

8.2.5 Examples of Use

250

8.3 Parallel shift job conversion function

252

8.3.1 Function overview

252

8.3.2 Operating methods

257

8.4 PAM function

263

8.4.1 Function overview

263

8.4.2 Operating methods

264

8.5 Mirror shift function

268

 

8.5.1

Function overview

268

8.5.2

Pulse mirror shift function

268

8.5.3

Robot-coordinates mirror shift munction

269

8.5.4

User coordinates mirror shift function

270

8.5.5

Notes on the Mirror Shift Function

271

8.5.6

Operation procedures

272

9

Error messages

274

9.1

Error message list

274

 

9.1.1

System and general operation

275

9.1.2

Editing

280

9.1.3

Job Defined Data

280

9.1.4

External memory equipment

285

9.1.5

Concurrent I/O

291

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DX100 controller

1

Safety

1.1 Notes for Safe operation

Read this manual carefully before installation, operation, maintenance or in- spection of the MOTOMAN DX100.

In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.”

WARNINGIndicates a potentially hazardous situation which, if not avoided, could result in death or serious

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to per- sonnel.

CAUTIONIndicates a potentially hazardous situation which, if not avoided, could result in minor or moderate

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to per- sonnel and damage to equipment. It may also be used to alert against unsafe practices.

MANDATORYAlways be sure to follow explicitly the items listed under this heading.

Always be sure to follow explicitly the items listed under this heading.

PROHIBITEDMust never be performed.

Must never be performed.

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

NOTE
NOTE

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “CAUTION” and “WARNING.”

times, be sure to follow all instructions, even if not designated as “CAUTION” and “WARNING.” E1102000066GB01

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DX100 controller

 
  WARNING

WARNING

Before operating the robot, check that servo power is turned off when the emergency stop buttons on the front door of the DX100 and programing pendant are pressed. When the servo power is turned off, the SERVO ON LED on the

Injury or damage to machinery may result if the emergency stop circuit cannot stop the robot during an emergency. The robot should not be used if the emergency stop buttons do not function.

 
 

Fig 1: Emergency Stop Button

 

Once the emergency stop button is released, clear the cell of all items which could inter- fere with the operation of the robot. Then turn the servo power ON.

TURN Fig 2: Release of EM
TURN Fig 2: Release of EM

TURN

Fig 2: Release of EM

 

Observe the following precautions when performing teaching operations within the P- point maximum envelope of the robot:

- View the robot from the front whenever possible.

- Always follow the predetermined operating procedure.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended robot operation may result in injury.

Confirm that no person is present in the P-point maximum envelope of the robot and that you are in a safe location before:

- Turning on the power for the DX100.

 

- Moving the robot with the programming pendant.

- Running the system in the check mode.

 

- Performing automatic operations.

Injury may result if anyone enters the working envelope of the robot during operation. Always press an emergency stop button immediately if there are problems.

The emergency stop button is located on the right of the front door of the DX100 and programing pendant.

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The emergency stop button is located on the right of the front door of the DX100

DX100 controller

 
  CAUTION

CAUTION

Perform the following inspection procedures prior to conducting robot teaching. If pro- blems are found, repair them immediately, and be sure that all other necessary proces- sing 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 the hook on the cabinet of the DX100 after use.

The programming pendant can be damaged if it is left in the robot's work area, on the floor, or near fixtures.

Read and understand the Explanation of Warning Labels in the

DX100 Instructions before operating the robot.

Definition of terms used often in this manual

The MOTOMAN robot is the YASKAWA industrial robot product. The robot usually consists of the controller, the playback panel, the program- ming pendant and supply cables. In this manual, the equipment is designated as follows.

Equipment

Manual designation

DX100 Controller

DX100

DX100 Programming pendant

Programming pendant

Cable between the robot and the contrllere

Robot cable

Programming pendant Programming pendant Cable between the robot and the contrllere Robot cable E1102000066GB01 7

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DX100 controller

Descriptions of the programming pendant and playback panel keys, buttons and displays are shown as follows:

Equipment

 

Manual designation

Programming

 

The keys which have characters printed on them are de- noted with [ ] ex. [ENTER]

pendant

Character keys

 

The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture.

Symbol keys

ex. page key

GO BACK GO BACK PAGE PAGE
GO BACK
GO BACK
PAGE
PAGE

The cursor key is an exception and a picture is not shown.

Axis keys

“Axis keys” and “Number keys” are generic names for the keys for axis operation and number input.

Number keys

Keys pressed

When two keys are to be pressed simultaneously, the keys are shown with a “+” sign between them, ex. [SHIFT]+[COORD]

simultaneously

Displays

The menu displayed in the programming pendant is deno- ted with { }. ex. {JOB}

Description of the operation procedure

In the explanation of the operation procedure, the expression "Select • • • " means that the cursor is moved to the object item and the SELECT key is pressed, or that the item is directly selected by touching the screen.

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item and the SELECT key is pressed, or that the it em is directly selected by

DX100 controller

2

Introduction

2.1 DX100 overview

The main power switch and the door lock are located on the front of the DX100 controller. The emergency stop button is installed in the upper right corner of the cabinet door and the programming pendant hangs from a hook below the button. For information on setup, installation, and connection of the DX100 system, refer to the “DX100 INSTALLATION AND WIRING.”

! Xxxxxxxxx Xxxxxx XXX Fig 3: DX100 front view
!
Xxxxxxxxx Xxxxxx
XXX
Fig 3: DX100 front view
refer to the “DX100 IN STALLATION AND WIRING.” ! Xxxxxxxxx Xxxxxx XXX Fig 3: DX100 front

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DX100 controller

2.2 Programming pendant

2.2.1 Programming pendant overview

The programming pendant is equipped with the keys and buttons used to con- duct robot teaching operations and to edit jobs.

1 2 3 START HOLD REMOTE TEACH PLAY JOB EDIT DISPLAY UTILITY JOB CONTENT TEST01
1
2
3
START
HOLD
REMOTE
TEACH
PLAY
JOB
EDIT
DISPLAY
UTILITY
JOB CONTENT
TEST01
S:0000
CONTROL GROUP:R1
TOOL:
0000
NOP
0001
SET B000 1
4
0002
SET B001 0
0003
MOVJ VJ=80.00
MOVJ VJ=80.00
0004
0005
DOUT OT#(10) ON
0006
TIMER T=3.00
0007
MOVJ VJ=80.00
0008
MOVJ VJ=100.00
0009
MOVJ VJ=100.00
0010
MOVJ VJ=100.00
0011
MOVJ VJ=100.00
MOVJ VJ=0.78
5
Main Menu
Short Cut
Turn on servo power
LAYOUTLAYOUT LAYOUT
TOOLTOOL SELSEL
TOOL SEL
GO BACK
GOGO BACKBACK
DIRECT
DIRECTDIRECT
COORDCOORD COORD
OPEN
OPENOPEN
14
PAGE
PAGEPAGE
Multi
MultiMulti
AREA
AREAAREA
SELECT
ENTRYENTRYENTRY
SERVOSERVO
SERVO
MAIN
MAINMAIN
SIMPLESIMPLE
SIMPLE
ON
ONON
CANCELCANCEL
CANCEL
6
MENUMENU
MENU
MENUMENU
MENU
READYREADY
READY
ASSIST
SERVO ON
SERVOSERVO ONON
X-
X+
X-
X+
S-
S+
R-
R+
HIGH
SPEED
Y-
Y+
Y-
Y+
L-
L+
B-
B+
7
FAST
Z-
Z+
Z-
Z+
MANUAL SPEED
U-
U+
T-
T+
SLOW
E-
E+
8-
8+
8
INTER
7
8
9
TEST
SHIFT
SHIFT
LOCK
START
13
4
5
6
INFORM
ROBOT
BWD
FWD
9
LIST
WELD
1
2
2
3
EX.AXIS
DELETE
INSERT
ON/OFF
.
.
-
0
MOTION
AUX
MODIFY
ENTER
10
TYPE
12
11

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

10

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General purpose display area 8 Axis keys 16 Menu areat     17 Mode switch 10

DX100 controller

2.2.2 Key Description

2.2.2.1 Character keys

The keys which have characters printed on them are denoted with [ ]. For ex-

ample,

tions along with their number values. Dual function keys are used in the

context of the operation being performed. For example:

bed in the text as [1] or [TIMER].

ENTER
ENTER

is shown as [ENTER]. The Numeric keys have additional func-

1 TIMER
1
TIMER

may be descri-

2.2.2.2 Symbol keys

The keys which have a symbol printed on them are not denoted with [ ] but de- picted with a small picture, with the exception of the cursor key, which is not shown with a picture.

Cursorof the cursor key, which is not shown with a picture. Emergency Stop button Direct Open

Emergency Stop buttonthe cursor key, which is not shown with a picture. Cursor Direct Open key Page key

Direct Open keyis not shown with a picture. Cursor Emergency Stop button Page key 2.2.2.3 Axis keys and

Page keywith a picture. Cursor Emergency Stop button Direct Open key 2.2.2.3 Axis keys and numeric keys

2.2.2.3 Axis keys and numeric keys

The keys pictured in the following are referred to as the axis keys and Nume- ric keys when described.

7 8 9 X- X+ SYNCRO X- X+ ARCON FEED SINGLE S- S+ R- R+
7
8
9
X- X+
SYNCRO
X- X+
ARCON
FEED
SINGLE
S- S+
R- R+
4
5 6
Y- Y+
Y- Y+
GAS
L- L+
SMOV
ARCOFF
RETRACT
B- B+
Z- Z+
1
2 3
Z- Z+
TOOL1
TOOL2
U- U+
T- T+
TIMER
ON
ON
.
-
0
E-
E+
8-
8+
TOOL1
TOOL2
REFP
OFF
OFF
Axis keys
Numeric keys

2.2.2.4 Keys pressed simulataneously

When two keys are to be pressed simultaneously, the keys are shown with a “+” sign between them, such as [SHIFT]+[COORD].

simultaneously, t he keys are shown with a “+” sign between them, su ch as [SHIFT]+[COORD].

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2.2.3 Programmin pendant keys

[START]

 

Starts the robot motion in playback operation.

 

• The lamp on this button is lit during the play operation.

  • The lamp also lights when the playback operation is started by the system
 

• The lamp also lights when the playback operation is started by the system input START signal. The lamp turns OFF when the playback operation is stopped by alarm occurrence, HOLD signal, or mode change.

[HOLD]

 

Holds the robot motion.

 

• This button is enabled in any mode.

  • The lamp on this button is lit only while the button is being
 

• The lamp on this button is lit only while the button is being pressed. Although the lamp turns OFF when the button is released, the robot stays stopped until a START command is input.

 

• The HOLD lamp automatically lights in the following cases to indicate that the system is in HOLD status. The start and axis operations are disabled while the lamp is lit.

1. The HOLD signal of system input is ON.

2. The HOLD request is being sent from an external de-

vice in remote mode.

3.

In the HOLD status caused by an error occurred in

working process such as wire sticking at arc welding.

E.STOP Button

Turns OFF the servo power.

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

• When the servo power is turned OFF, the SERVO ON LED on the programing pendant will extinguish.

• An emergency stop message is displayed on the screen.

[MODE]

 

Selects the Play mode, Teach mode, or Remote mode.

PLAY: Play Mode The playback of taught job is enabled. The START signal from an

PLAY: Play Mode The playback of taught job is enabled. The START signal from an external device is disabled.

REMOTE

PLAY

TEACH

TEACH: Teach Mode The axis operation and edition from the programming pendant are enabled. The START signal from an external device is disabled.

REMOTE: Remote Mode The operation by external signals is enabled. [START] is invalid during the remote mode.

Enable Switch

Turns ON the servo power. The Enable switch is active only when the SERVO ON LED is blinking, the safety plug is ON, and the Mode Switch is set to “TEACH.” When this switch is lightly squeezed, the power turns ON. When firmly squeezed, the power turns OFF.

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When this switch is lightly squeezed, the power turns ON. When firmly squeezed, the power turns

DX100 controller

[SELECT]

Works as described below.

SELECT
SELECT

• Selects menu items in the main menu area and the pull-down menu area.

• Makes the selected item ready to be set in the gene- ral-purpose display area.

• Displays multiple messages in the message area.

Cursor

Moves the cursor in the direction of the arrow.

The size of the cursor and the range/place where the cursor can move will vary depending on the window.

If the UP cursor button is pressed when the cursor is on the first line,

If the UP cursor button is pressed when the cursor is on the first line, the cursor will move to the last line of the job. Conversely, if the cursor is on the last line of the job and the DOWN cursor button is pressed, the cursor will jump to the first line of the job. [SHIFT] + UP Scrolls the screen upward. [SHIFT] + DOWN Scrolls the screen downward. [SHIFT] + RIGHT Scrolls the screen to the right. [SHIFT] + LEFT Scrolls the screen to the left.

[MAIN MENU]

Displays the main menu. If this button is pressed while the main menu is displayed, the main menu disappears.

[MAIN MENU] + UP Increases the brightness of the screen. [MAIN MENU] + DOWN Decreases the brightness of the screen.

MAINMAIN MAIN MENUMENU MENU
MAINMAIN
MAIN
MENUMENU
MENU

[SIMPLE MENU]

Displays the simple menu. If this button is pressed while the simple menu is displayed, the simple menu disappears.

ENTRENTRENTRYY SIMPLESIMPLE SIMPLE MENUMENU MENU
ENTRENTRENTRYY
SIMPLESIMPLE
SIMPLE
MENUMENU MENU

[SERVO ON READY]

Enables the servo power supply to be turned ON. Press this button to enable the servo power supply to be turned ON if the servo power supply is shut OFF by the emergency stop or overrun signal. When this button is pressed:

SERVO SERSERVOVO ON ONON READY READYREADY
SERVO SERSERVOVO
ON ONON
READY READYREADY

• In the play mode, the servo power supply is turned ON if the safeguarding is securely closed.

• In the teach mode, the SERVO ON lamp flashes and the servo power supply is turned ON when the Enable switch is ON.

• The SERVO ON lamp is lit while the servo power is ON.

turned ON when the Enable switch is ON. • The SERVO ON lamp is lit while

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DX100 controller

[ASSIST]

Displays the menu to assist the operation for the currently displayed window. Pressing this button with

ASSIST
ASSIST

• [SHIFT] or [INTERLOCK] displays the help guidance for the operation.

• [SHIFT] + [ASSIST] The function list of key combinations with [SHIFT] a pears.

 

• [INTERLOCK] + [ASSIST] The function list of key combinations with

• [INTERLOCK] appears.

[CANCEL]

Cancels the current status.

CANCELCANCELCANCEL
CANCELCANCELCANCEL

• Deletes the sub menu in the main menu area and the pull-down menu area.

• Cancels the input data or the input status in the general-purpose display area.

 

• Cancels the multiple views in the message area. Cancels the occurred error.

[MULTI]

Works for the multi mode. If this button is pressed when the multi mode is ON, the active window switches. [SHIFT] + [MULTI] Switches between the multi-window display and the single-window display when the multi mode is ON.

LALAYOUTYOUT LAYOUT MultiMulti Multi
LALAYOUTYOUT
LAYOUT
MultiMulti
Multi

[COORD]

Select the operation coordinate system when the robot is operated manually.

TOOLOOL SELSEL TOOL SEL COORDCOORD COORD
TOOLOOL SELSEL
TOOL SEL
COORDCOORD
COORD

Five coordinate systems (joint, cartesian, cylindrical, tool and user) can be used. Each time this key is pressed, the coordinate system is switched in the fol- lowing order:

"JOINT""WLD/CYL""TOOL""USER"

The selected coordinate system is displayed on the status display area. [SHIFT] + [COORD] The coordinate number can be changed when the "TOOL" or "USER" coordinate system is selected.

[DIRECT OPEN]

Displays the content related to the current line.

DIRECTDIRECT DIRECT OPENOPEN OPEN
DIRECTDIRECT
DIRECT
OPENOPEN
OPEN

To display the content of a CALL job or condition file, move the cursor to the next line and press [DIRECT OPEN]. The file will be displayed for the selected line. Display content will vary depending on the type of instruction used in the job. Example:

For a CALL instruction, the content of the called job will be displayed. For a work instruction, the content of the condition file will be displayed. For Input/output instructions, the input/output condition will be displayed.

The lamp on this button is lit while the direct open is ON. Press this button while the lamp is lit to return to the previous window.

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while the direct open is ON. Press this button while the lamp is lit to return

DX100 controller

[PAGE]

Displays the next page. The page can be switched only when the lamp on this button is lit. [SHIFT] + [PAGE] Switches to the previous page.

GOGO BACKBACK GO BACK PAGE PAGEAGE
GOGO BACKBACK
GO BACK
PAGE
PAGEAGE

[AREA]

Moves the cursor in the following order : “Menu Area””General-Purpose Display Area””Message Area””Main Menu Area”. If no item is displayed, the cursor does not move.

AREAAREAAREA
AREAAREAAREA

[SHIFT] + [AREA] The language can be switched when the bilingual func- tion is valid. (Bilingual function is optional.) [AREA] + DOWN Moves the cursor from the general-purpose display area to the operation button when the operation button is displayed. [AREA] + UP Moves the cursor to the general-purpose display area when the cursor is on the operation button.

[SHIFT]

Changes the functions of other keys by pressing toge- ther. Can be used with [MAIN MENU], [ASSIST], [COORD], [AREA], [MOTION TYPE], cursor key or Numeric key to access alternate functions. Refer to the description of each key for the alternate [SHIFT] functions.

SHIFT
SHIFT

[INTERLOCK]

Changes the functions of other keys by pressing toge- ther. Can be used with [ASSIST], [MULTI], [TEST START], [FWD], or Numeric key (Numeric key customize func- tion). Refer to the description of each key for the alternate [INTERLOCK] functions.

INTER LOCK
INTER
LOCK

[INFORM LIST]

Displays instruction lists of commands available for job editing.

INFORM LIST
INFORM
LIST

[ROBOT]

Enables the robot axis operation.

ROBOT
ROBOT

[ROBOT] is active for the system where multiple robots are controlled by one DX100 or the system with exter- nal axes.

[EX. AXIS]

Enables the external axis (base axis or station axis) operation.

[EX.AXIS] is active for the system with external axes.

EX.AXIS
EX.AXIS
axis or station axis) operation. [EX.AXIS] is active for the system with external axes. EX.AXIS E1102000066GB01

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15

DX100 controller

[MOTION TYPE]

Selects the interpolation type for playback operation. The selected interpolation type is shown in the status display area on the screen.

MOTION TYPE
MOTION
TYPE

Each time this key is pressed, the interpolation type changes in the following order:

"MOVJ"" MOVL""MOVC""MOVS"

[SHIFT] + [MOTION TYPE] The interpolation mode changes in the following order:

"STANDARD"" EXTERNAL REFERENCE POINT"*" CONVEYOR"*

Interpolation type can be changed in any mode.

*: These modes are purchased options.

[TEST START]

Moves the robot through taught steps in a continuous motion when [TEST START] and [INTERLOCK] are si- multaneously pressed. The robot can be moved to check the path of taught steps. Operation stops immediately when this key is released.

• The robot operates according to the currently selected operation cycle:

TEST START
TEST
START
 

"AUTO," "1CYCLE," or "STEP."

• The robot operates at the taught speed. However, if the taught speed exceeds the maximum teaching speed, the operation proceeds at the maximum tea- ching speed.

[FWD]

FWD
FWD

Moves the robot through the taught steps while this key is pressed.

Only move instructions are executed (one instruction at a time, no welding instructions).

 

[INTERLOCK] + [FWD] All instructions are executed. [REFP] + [FWD] Moves to the reference point of the cursor line. The robot operates at the selected manual speed. Make sure that the selected manual speed is the desired one before starting operation.

[BWD]

BWD
BWD

Moves the robot through the taught steps in the reverse direction while this key is pressed.

Only move instructions are executed (no weld com- mands). The robot operates at the selected manual speed. Make sure that the selected manual speed is the desired one before starting operation.

16

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speed. Make sure that the selected manual speed is the desired one before starting operation. •

DX100 controller

[DELETE]

Deletes the registered instruction.

 
DELETE
DELETE

Deletion completes when [ENTER] is pressed while this key lamp is lit.

[INSERT]

Inserts a new instruction.

 
INSERT
INSERT

Insertion completes when [ENTER] is pressed while this key lamp is lit.

[MODIFY]

Modifies the taught position data or instruction.

 
MODIFY
MODIFY

Modification completes when [ENTER] is pressed while this key lamp is lit.

[ENTER]

ENTER
ENTER

Registers instructions, data, current position of the ro- bot, etc.

When [ENTER] is pressed, the instruction or data dis- played in the input buffer line moves to the cursor position to complete a registration, insertion, or modi- fication.

MANUAL SPEED

Sets the speed for manual operation. This speed is also valid for operations with [FWD] and [BWD].

keys

There are four speed levels (slow, medium, fast, and inching). The speed changes as described below. The selected speed is displayed on the status area. Each time [FAST] is pressed, manual speed changes in the following order:

"INCH"" SLOW""MED""FST". Each time [SLOW] is pressed, manual speed changes in the following order:

FAST
FAST

MANUAL SPEED

SLOW
SLOW

"FST""MED""SLOW""INCH"

 

[HIGH SPEED]

Makes the robot move at high speed while this button and one of the axis keys are pressed simultaneously during manual operation. No need to change the set- ting of speed.

HIGH SPEED
HIGH
SPEED

The speed for [HIGH SPEED] is specified in advance.

Axis Key

Moves specified axes on robot.

 
X- X+ S- S+ Y- Y+ L- L+ Z- Z+ U- U+
X-
X+
S-
S+
Y-
Y+
L-
L+
Z-
Z+
U-
U+
X- X+ R- R+ Y- Y+ B- B+ Z- Z+ T- T+
X-
X+
R-
R+
Y-
Y+
B-
B+
Z-
Z+
T-
T+

• The robot axes only move while the key is pressed.

• Multiple axes can be operated simultaneously by

 

pressing two or more keys at the same time.

The robot operates in the selected coordinate system at the selected manual speed. Make sure that the se- lected coordinate system and the manual speed are the desired ones before starting the axis operation.

E- E+
E-
E+
8- 8+
8-
8+

Numeric Key

Enters the number or symbol when the ">" prompt ap-

7 SYNCRO SINGLE
7
SYNCRO
SINGLE
8 ARCON
8
ARCON
9 FEED
9
FEED

pears on the input line.

 

“.” is the decimal point. “-” is a minus sign or hyphen.

4 SMOV
4
SMOV
5 GAS ARCOFF
5
GAS
ARCOFF
6 RETRACT
6
RETRACT

The Numeric keys are also used as function keys.

fer to the explanation of each function for details.

Re-

1 TIMER
1
TIMER
2 TOOL1 ON
2
TOOL1
ON
3 TOOL2 ON
3
TOOL2
ON
0 REFP
0
REFP
. TOOL1 OFF
.
TOOL1
OFF
- TOOL2 OFF
-
TOOL2
OFF
 
TIMER 2 TOOL1 ON 3 TOOL2 ON 0 REFP . TOOL1 OFF - TOOL2 OFF  

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17

DX100 controller

2.2.4 Programming pendant display

The programming pendant display is a 5.7 inch color display. Alphanumeric characters can be used.

2.2.4.1 Five display ares

The general-purpose display area, menu area, human interface display area, and main menu area among the following five areas can be moved by pres- sing [AREA], or can be selected by directly touching the screen.

1 2 5 3 4
1 2
5
3
4
be selected by directly touching the screen. 1 2 5 3 4 Fig 4: Five display

Fig 4: Five display area

Table 1: Five display area

1

Menu area

2

Status display area

3

General purpose display area

4

Human interface display area

5

Main menu area

Each window displayed during operations is provided with its name on the up- per left of the general-purpose display area.

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during operations is provided with its name on the up- per left of the general -purpose

DX100 controller

2.2.4.2 General purpose display area

2.2.4.2 General purpose display area Fig 5: General purpose display area On the general-purpose disp lay

Fig 5: General purpose display area

On the general-purpose display area, various settings and contents such as jobs and characteristics files can be displayed and edited.

The operation buttons are also displayed at the bottom of the window accor- ding to the window contents. To move the cursor to the operation button, press [AREA] + DOWN cursor key.

• To move the cursor to the general-purpose display area, press [AREA] + UP cursor key or press [CANCEL].

• To move the cursor between the operation but tons, use the RIGHT or LEFT cursor key.

• To execute the operation button, move the cursor to the button and press [SELECT].

EXECUTE :

Continues operation with the displayed contents.

CANCEL :

Cancels the displayed contents and returns to the

COMPLETE :

previouswindow. Completes the setting operation displayed on the

STOP :

general-purpose display area. Stops operation when loading, saving, or verifying with an

RELEASE :

external memory device. Releases the overrun and shock sensor function.

RESET :

Resets an alarm. (Cannot reset major alarms.)

PAGE :

Jumps to the appropriate page if the page can be switched. • When the page can be switched by specifying the page number, the following input box appears when

When the page can be switched by specifying the page number, the following i nput box

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19

DX100 controller

“DIRECT PAGE” is selected. Directly type the desired page number and press [ENTER].

JUMP TO PAGE
JUMP TO
PAGE

General-purpose

display area

Operation buttons

• When the page can be switched by selecting an item, the following selection list appears when “DIRECT PAGE” is selected. Select a desired item using the UP and DOWN cursor key and press [ENTER].

2.2.4.3 Main menu area

PAGE
PAGE

Each menu and submenu are displayed in the main menu area. Press [MAIN MENU] or touch {Main Menu} on the left bottom of the window to display the main menu.

Press [MAIN MENU] or touch {Main Menu} on the left bottom of the window to display
Press [MAIN MENU] or touch {Main Menu} on the left bottom of the window to display

Fig 6: Main menu area

20

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touch {Main Menu} on the left bottom of the window to display the main menu. Fig

DX100 controller

2.2.4.4 Status display area

The Status Display area shows controller status. The displayed information will vary depending on the controller mode (Play/Teach).

T 1 2 3 4 5 6 7 8 9 10 11
T
1
2
3
4
5
6
7
8
9
10
11

Fig 7: Status display area

Table 2: Status display area

1

Group operation axis

2

Operation coordinate system

3

Manual speed

4

Security mode

5

Operation cycle

6

State under execution

7

Mode

8

Page

9

Multi mode

10

Weak battery

11

Saving data

1. Control Group

Displays the active control group for systems equipped with station axes or several robot axes.

to to to
to
to
to

: Robot Axes

: Base Axes

: Station Axes

with station axes or several robot axes. to to to : Robot Axes : Base Axes

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21

DX100 controller

2. Operation Coordinate System

Displays the selected coordinate system. Switched by pressing [COORD].

:Joint Coordinates

: Cartesian Coordinates

: Cylindrical Coordinates

: Tool Coordinates

: User Coordinates

Manual Speed

Displays the selected speed.

: Inching

: Low Speed

: Medium Speed

: High Speed

Security Mode

: Operation Mode

: Edit Mode

: Management Mode

Operation Cycle

Displays the present operation cycle.

: Step

: Cycle

: Continuous

22

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Mode Operation Cycle Displays the present operation cycle. : Step : Cycle : Continuous 22 E1102000066GB01

DX100 controller

6. State Under Execution

Displays the present system status (STOP, HOLD, ESTOP, ALARM, or RUN).

Stop Statuspresent system status (STOP, HOLD, ES TOP, ALARM, or RUN). Hold Status Emergency Stop Status Alarm

Hold Statusstatus (STOP, HOLD, ES TOP, ALARM, or RUN). Stop Status Emergency Stop Status Alarm Status Operating

Emergency Stop Status(STOP, HOLD, ES TOP, ALARM, or RUN). Stop Status Hold Status Alarm Status Operating Status :

Alarm Statusor RUN). Stop Status Hold Status Emergency Stop Status Operating Status : : : : :

Operating StatusStop Status Hold Status Emergency Stop Status Alarm Status : : : : : 7. Mode

:

:

:

:

:

7. Mode

Teach modeStop Status Alarm Status Operating Status : : : : : 7. Mode Play mode :

Play modeAlarm Status Operating Status : : : : : 7. Mode Teach mode : : 8.

:

:

8. Page

Status : : : : : 7. Mode Teach mode Play mode : : 8. Page

: Displayed when the page can be switched.

9. Multi Mode

: Displayed when the page can be switched. 9. Multi Mode : Displayed when the mult

: Displayed when the multi window mode is set.

10. Weak Battery of Memory

the mult i window mode is set. 10. Weak Battery of Memory : Displayed when the

: Displayed when the battery of memory is weak.

11. Saving Data

Weak Battery of Memory : Displayed when the batter y of memory is weak. 11. Saving

: Displayed while saving the data.

: Displayed when the batter y of memory is weak. 11. Saving Data : Displayed while

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23

DX100 controller

2.2.4.5 Human interface area

An error(s) or a message(s) is displayed in the human interface display area.

Turn on servo power
Turn on servo power

When an error is displayed, operations cannot be performed until the error is canceled. Press [CANCEL] to allow for operations.

When two or more errors occur,

Activate the message display area and press [SELECT] to view the list of cur-

rent errors.

and press [SELECT] to view the list of cur- rent errors. appears in the message display

appears in the message display area.

Cannot load macro job at current security modeCannot insert/modify/delete for group axis detachment Cannot insert/modify/delete for axis detachment 5 / 9 HELP

Cannot insert/modify/delete for group axis detachmentCannot load macro job at current security mode Cannot insert/modify/delete for axis detachment 5 / 9

Cannot insert/modify/delete for axis detachment
Cannot insert/modify/delete for axis detachment
5 / 9 HELP CLOSE
5 / 9
HELP
CLOSE

To close the error list, select "CLOSE" or press [CANCEL].

2.2.4.6 Menu area

The menu area is used to edit a job, manage jobs, and execute various utili- ties.

or press [CANCEL]. 2.2.4.6 Menu area The menu area is used to edit a job, manage

24

E1102000066GB01

Menu area The menu area is used to edit a job, manage jobs, and exec ute

DX100 controller

2.2.5 Screen descriptions

• The menu displayed in the programming pendant is denoted with { }

displayed in the program ming pendant is denoted with { } The above menu items are

The above menu items are denoted with {DATA}, {EDIT}, {DISPLAY}, AND {UTILITY}.

• The window can be displayed according to the view desired.

The window can be displayed a ccording to the view desired. Fig 8: Full window view

Fig 8: Full window view

a ccording to the view desired. Fig 8: Full window view Fig 9: Upper window view

Fig 9: Upper window view

to the view desired. Fig 8: Full window view Fig 9: Upper window view Fig 10:

Fig 10: Middle window view

to the view desired. Fig 8: Full window view Fig 9: Upper window view Fig 10:

Fig 11: Lower window view

8: Full window view Fig 9: Upper window view Fig 10: Middle window view Fig 11:

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25

DX100 controller

2.2.6 Character input operation

Move the cursor to the data for which characters are to be input, and press [SELECT] to display the software keypad.

2.2.6.1 Character Input

To input characters, the software keypad is shown on the programming

pendant display.

There are three types of software keypads: the alphanumeric keypads each for upper-case and lower-case characters and the symbol keypad. To switch between the alphanumeric keypads and the symbol keypad, touch the button tab on the screen or press [PAGE]. To switch t he alphanumeric keypads between upper-case and lower-case characters, touch “CapsLock OFF” or “CapsLock ON.”

2.2.6.2 Operation

Keypad

Button on the Programming Pendant

Explanation

Cursor

Cursor Moves the cursor (focus).

Moves the cursor (focus).

[SELECT]

SELECT
SELECT

Selects a character.

[CANCEL]

CANCELCANCELCANCEL
CANCELCANCELCANCEL

Clears all the characters being ty- ped. Pressing this second time cancels the software keypad.

[ENTER]

ENTER
ENTER

Enters the input characters.

Button Tab

GOGO BACKBACK GO BACK PAGEAGE PAGE
GOGO BACKBACK
GO BACK
PAGEAGE
PAGE

Switches the keypads displayed on the programming pendant.

 
MAINMAIN MAIN MENUMENU MENU
MAINMAIN
MAIN
MENUMENU MENU

Closes the software keypad.

26

E1102000066GB01

on the programming pendant.   MAINMAIN MAIN MENUMENU MENU Closes the software keypad. 26 E1102000066GB01

DX100 controller

Keypad

Button on the Programming Pendant

Explanation

 
0
0

Enters numbers.

Numeric Keys

to

9
9

2.2.6.3 Alphanumeric input

Number input is performed with the Numeric keys or on the following alphanu- meric input window. Numbers include 0 to 9, the decimal point (.), and the mi- nus sign/hyphen (-).

Note however, that the decimal point cannot be used in job names.

Press the page key

cursor to the desired letter and press [SELECT] to enter the letter.

GOGO BACKBACK GO BACK PAGEAGE PAGE
GOGO BACKBACK
GO BACK
PAGEAGE
PAGE

to display the alphanumeric input window. Move the

PAGE to display the alphanumeric input window. Move the Fig 12: For numbers and upper-case characters

Fig 12: For numbers and upper-case characters

input window. Move the Fig 12: For numbers and upper-case characters Fig 13: For numbers and

Fig 13: For numbers and lower-case characters

the Fig 12: For numbers and upper-case characters Fig 13: For numbers and lower-case characters E1102000066GB01

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27

DX100 controller

2.2.6.4 Symbol input

GOGO BACKBACK GO BACK PAGEAGE PAGE
GOGO BACKBACK
GO BACK
PAGEAGE
PAGE

Press the page key

Move the cursor to the desired symbol and press [SELECT] to enter the symbol.

Note that only some symbols are available for naming jobs.

to display the symbol input window.

able for naming jobs. to disp lay the symbol input window. Fig 14: For symbols 2.3

Fig 14: For symbols

2.3

Mode

The following three modes are available for DX100.

• Teach Mode

• Play Mode

• Remote Mode

2.3.1 Teach mode

In the teach mode, the following can be done.

• Preparation and teaching of a job

• Modification of a registered job

• Setting of various characteristic files and parameters

2.3.2 Play mode

In the play mode, the following can be done.

• Playback of a taught job

• Setting, modification, or deletion of various condition files

28

E1102000066GB01

• Playback of a taught job • Setting, modificati on, or deletion of va rious condition

DX100 controller

2.3.3 Remote mode

In the remote mode, the operations such as Servo ON Ready, Start, Cycle Change, Call Master Job can be commanded by external input signals.

The operations by external input signals become enabled in the remote mode, while [START] on the programming pendant becomes disabled.

The data transmission function (optional function) is also available in the re- mote mode.

The following table shows how each operation is input in each mode.

 

Mode

     

Operation

Teach Mode

Play Mode

Remote Mode

Servo ON Ready

PP

PP

External input signal

Start

Invalid

PP

External input signal

Cycle Change

PP

PP

External input signal

Call Master Job

PP

PP

External input signal

Note: “PP” indicates the programming pendant.

2.3.4 Teach mode priority

In the teach mode, following operations are disabled:

1. Playback using [START].

2. Playback from external input signals.

g operations are disabled: 1. Playback using [START]. 2. Playback from ex ternal input signals. E1102000066GB01

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29

DX100 controller

2.4 Security mode

2.4.1 Types of security modes

The following three types of security modes are available for DX100.

Any operation in the edit mode and the management mode requires a pass- word. The password must contain between 4 and 8 letters, numbers, or sym- bols.

• Operation Mode The operator can monitor the line operation and start and stop the robot. Repairs, etc. can be performed if any abnormalities are detected.

• Edit Mode Teaching, robot jog operations, and editing of jobs and various condition files can be performed in addition to the operations enabled in the operation mode.

• Management Mode The operator who performs setup and maintenance for the system can set the machine control parameter, set the time, change the password, etc. in addition to the operations enabled in the edit mode.

Table 3: Menu & Security Mode (Continued)

Main Menu

Sub Menu

Security Mode

DISPLAY

EDIT

JOB

JOB

Operation

Edit

SELECT JOB

Operation

Operation

CREATE NEW JOB a)

Edit

Edit

MASTER JOB

Operation

Edit

JOB CAPACITY

Operation

-

RES. START(JOB) a)

Edit

Edit

RES. STATUS a)

Operation

-

CYCLE

Operation

Operation

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a ) Edit Edit RES. STATUS a ) Operation - CYCLE Operation Operation 30 E1102000066GB01

DX100 controller

Table 3: Menu & Security Mode (Continued)

Main Menu

Sub Menu

Security Mode

DISPLAY

EDIT

VARIABLE

BYTE

Operation

Edit

INTEGER

Operation

Edit

DOUBLE

Operation

Edit

REAL

Operation

Edit

STRING

Operation

Edit

POSITION(ROBOT)

Operation

Edit

POSITION(BASE)

Operation

Edit

POSITION(ST)

Operation

Edit

LOCAL VARIABLE

Operation

-

IN/OUT

EXTERNAL INPUT

Operation

-

EXTERNAL OUTPUT

Operation

-

UNIVERSAL INPUT

Operation

Edit

UNIVERSAL OUTPUT

Operation

Edit

SPECIFIC INPUT

Operation

-

SPECIFIC OUTPUT

Operation

-

RIN

Operation

-

CPRIN

Operation

-

REGISTER

Operation

-

AUXILIARY RELAY

Operation

-

CONTROL INPUT

Operation

-

PSEUDO INPUT SIG

Operation

Management

NETWORK INPUT

Operation

-

NETWORK OUTPUT

Operation

-

ANALOG OUTPUT

Operation

-

SV POWER STATUS

Operation

-

LADDER PROGRAM

Management

Management

I/O ALARM

Management

Management

I/O MESSAGE

Management

Management

Management I/O ALARM Management Management I/O MESSAGE Management Management E1102000066GB01 31

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31

DX100 controller

Table 3: Menu & Security Mode (Continued)

Main Menu

Sub Menu

Security Mode

DISPLAY

EDIT

ROBOT

CURRENT POSITION

Operation

-

COMMAND POSITION

Operation

-

SERVO MONITOR

Management

-

WORK HOME POS

Operation

Edit

SECOND HOME POS

Operation

Edit

DROP AMOUNT

Management

Management

POWER ON/OFF POS

Operation

-

TOOL

Edit

Edit

INTERFERENCE

Management

Management

SHOCK SENS LEVEL

Operation

Management

USER COORDINATE

Edit

Edit

HOME POSITION

Management

Management

robot TYPE

Management

-

ANALOG MONITOR

Management

Management

OVERRUN&S-SENSOR a)

Edit

Edit

LIMIT RELEASE a)

Edit

Edit

ARM CONTROL a)

Management

Management

SHIFT VALUE

Operation

-

SYSTEM INFO

VERSION

Operation

-

MONITORING TIME

Operation

Management

ALARM HISTORY

Operation

Management

I/O MSG HISTORY

Operation

Management

SECURITY

Operation

Operation

FD/CF

LOAD

Edit

-

SAVE

Operation

-

VERIFY

Operation

-

DELETE

Operation

-

DEVICE

Operation

Operation

FOLDER

Edit

Edit

FORMAT a)

Operation

Operation

32

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DEVICE Operation Operation FOLDER Edit Edit FORMAT a ) Operation Operation 32 E1102000066GB01

DX100 controller

Table 3: Menu & Security Mode (Continued)

Main Menu

Sub Menu

Security Mode

DISPLAY

EDIT

PARAMETER

S1CxG

Management

Management

S2C

Management

Management

S3C

Management

Management

S4C

Management

Management

A1P

Management

Management

A2P

Management

Management

A3P

Management

Management

A4P

Management

Management

RS

Management

Management

S1E

Management

Management

S2E

Management

Management

S3E

Management

Management

S4E

Management

Management

SETUP

TEACHING COND

Edit

Edit

OPERATE COND

Management

Management

DATE/TIME

Management

Management

GRP COMBINATION b)

Management

Management

RESERVE JOB NAME

Edit

Edit

USER ID

Edit

Edit

SET SPEED

Management

Management

KEY ALLOCATION

Management

Management

RES. START(CNCT)

Management

Management

AUTO BACKUP SET

Management

Management

WRONG DATA LOG

Operation

Management

ARC WELDING

ARC START COND.

Operation

Edit

ARC END COND.

Operation

Edit

ARC AUX COND.

Operation

Edit

POWER SOURCE COND.

Operation

Edit

ARC WELD DIAG.

Operation

Edit

WEAVING

Operation

Edit

ARC MONITOR

Operation

-

ARC MONITOR (SAMPLING)

Operation

-

HANDLING

HANDLING DIAG.

Operation

Edit

- ARC MONITOR (SAMPLING) Operation - HANDLING HANDLING DIAG. Operation Edit E1102000066GB01 33

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33

DX100 controller

Table 3: Menu & Security Mode (Continued)

Main Menu

Sub Menu

Security Mode

DISPLAY

EDIT

SPOT WEL-

WELD DIAGNOSIS

Operation

Edit

DING

I/O ALLOCATION

Management

Management

GUN CONDITION

Management

Management

CLEARANCE SETTING

Operation

Edit

SPOT POWER SOURCE

Management

Management

SPOT WEL-

WELD DIAGNOSIS

Operation

Edit

DING

GUN PRESSURE

Edit

Edit

(MOTOR GUN)

PRESSURE

Edit

Edit

I/O ALLOCATION

Management

Management

GUN CONDITION

Management

Management