Yamaha DRCX - Chapter 13 TROUBLESHOOTING

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13-1

TROUBLESHOOTING

Chapter 13 TROUBLESHOOTING

This chapter explains how to take corrective action when a problem or breakdown occurs, by categorizing it into

one of two cases depending on whether or not an alarm is output from the controller.

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Table of Contents4
Chapter 1 OVERVIEW10
Features of the DRCX Series Controller11
Setting up for Operation12
External View and Part Names13
DRCX Controller13
Tpb15
System Configuration16
Accessories and Options17
Accessories17
Peripheral Options17
Chapter 2 INSTALLATION and CONNECTION18
Installing the DRCX Controller19
Installation Method19
Installation Location19
Connecting the Power Supply20
Power Supply20
Connecting the Power Supply21
Installing an External Leakage Breaker21
Installing a Circuit Protector22
Installing Current Control Switches22
Insulation Resistance and Voltage Breakdown Tests22
Grounding23
Connecting the DRCX to the Control Unit23
Connecting to the Robot24
Robot I/O Connector and Signal Table24
Motor Connector and Signal Table24
Connecting to the I/O Connector25
Connecting to the Regenerative Unit26
Connecting the Absolute Battery27
Chapter 3 I/O INTERFACE28
I/O Signals29
Input Signal Description30
Dedicated Command Input30
General-Purpose Input (DI0 to DI15)33
SERVICE Mode Input (SVCE)34
Interlock (LOCK)34
Emergency Stop Inputs 1, 2 (EMG1, EMG2)34
Output Signal Description35
Dedicated Output35
General-Purpose Output (DO0 to DO12)36
I/O Circuits36
I/O Circuit Specifications36
I/O Circuit and Connection Example37
I/O Connection Diagram39
General Connections for Internal 24V Power Supply39
Connection to PLC Output Unit Using External 24V Power Supply40
Connection to PLC Input Unit Using External 24V Power Supply41
I/O Control Timing Charts42
When Turning the Power on42
When Executing a Dedicated Input Command43
When Interlock Signal Is Input47
When Emergency Stop Is Input48
When Alarm Is Issued48
When Executing a Point Movement Command49
I/O Assignment Change Function50
Changing the I/O Assignment50
I/O Signal Descripion52
Timing Chart56
Chapter 4 BASIC OPERATION of the TPB66
Connecting and Disconnecting the TPB67
Connecting the TPB to the DRCX Controller67
Disconnecting the TPB from the DRCX Controller68
Basic Key Operation69
Reading the Screen70
Program Execution Screen70
Program Edit Screen70
Point Edit Screen (Teaching Playback)71
DIO Monitor Screen71
Hierarchical Menu Structure72
Restricting Key Operation by Access Level73
Explanation of Access Level73
Changing an Access Level74
Chapter 5 PARAMETERS76
Setting the Parameters77
Parameter Description78
Common Parameters78
X-Axis Parameters90
Y-Axis Parameters97
Chapter 6 PROGRAMMING104
Basic Contents105
Robot Language and Point Data105
Using the TPB to Enter the Robot Language105
Program Specifications105
Editing Programs106
Creating Programs after Initialization107
Creating a New Program109
Adding a Step110
Correcting a Step112
Inserting a Step113
Deleting a Step114
Program Utility115
Copying a Program115
Deleting a Program116
Viewing the Program Information117
Chapter 7 EDITING POINT DATA118
Manual Data Input119
Teaching Playback120
Direct Teaching122
Manual Control of General-Purpose Output124
Manual Release of Holding Brake125
Deleting Point Data126
Editing the Pallet Data127
Tracing Points (Moving to a Registered Data Point)128
Chapter 8 ROBOT LANGUAGE130
Robot Language Table131
Robot Language Syntax Rules132
Command Statement Format132
Variables133
Program Function134
Multi-Task Function134
Limitless Movement Function135
Robot Language Description137
Mova137
Movi137
Movf138
Jmp138
Jmpf139
Jmpb140
Call141
Wait142
Timr142
Srvo144
Stop144
Mat145
Msel146
Movm147
Jmpc148
Jmpd148
Csel149
Orgn152
Acha153
Achi154
Drva155
Drvi156
Shft157
Ton158
Toff158
Jmpp159
Movl160
Movc161
Sample Programs162
Moving between Two Points162
Moving at an Equal Pitch162
Picking up Workpieces Flowing on the Front Conveyor and Placing Them Sequentially on the Five Rear Conveyors165
Switching the Program from I/O167
Palletizing for Fixed Point Versus Pallet169
Palletizing for Pallet Versus Pallet170
Palletizing for Pallet Versus Pallet, Using a SHIFT Statement171
Palletizing for Special Pallets172
Changing the Placement Sequence for Palletizing173
Specifying a Position on a Pallet from I/O180
Picking up a Workpiece at P0 and Placing It at P1181
Picking up Workpieces at P0 and Placing Them Sequentially at P1, P2, P3 and P4181
Picking up Workpieces at P0 and Placing Them Sequentially on a 2×4 Pallet182
Axis Movement and I/O Multi-Task183
Multi-Robot Operation184
Synchronization in Multi-Robot Operation185
Turning on General-Purpose Outputs During Robot Movement after a Certain Time Has Elapsed186
Turning on a General-Purpose Output During Robot Movement When It Has Passed a Specified Position187
Sealing188
Limitless Movement at same Pitch189
Limitless Rotation190
Picking up Workpieces Supplied from an Index Table and Placing Them on a Conveyor191
Chapter 9 OPERATING the ROBOT192
Performing Return-To-Origin193
Return-To-Origin by the Search Method193
Return-To-Origin by the Mark Method195
Using Step Operation197
Using Automatic Operation200
Switching the Execution Program202
Emergency Stop Function203
Initiating an Emergency Stop203
Recovering from an Emergency Stop203
Displaying the Variables205
Displaying the Memory I/O Status206
Chapter 10 OTHER OPERATIONS208
Initialization209
DIO Monitor Display212
Display from the Monitor Menu212
Display from the DIO Key Operation213
System Information Display214
SERVICE Mode Function215
Safety Settings for SERVICE Mode216
Enabling/Disabling the SERVICE Mode Function218
Setting the SERVICE Mode Functions220
System Utilities222
Viewing Hidden Parameters222
Using a Memory Card223
Saving Controller Data to a Memory Card223
Loading Data from a Memory Card225
Formatting a Memory Card227
Viewing the ID Number for Memory Card Data229
Duty (Load Factor) Monitor230
Measuring the Duty (Load Factor)232
Chapter 11 COMMUNICATION with PC234
Communication Parameter Specifications235
Communication Cable Specifications236
Connecting to the Computer with a 25-Pin D-Sub Connector236
Connecting to the Computer with a 9-Pin D-Sub Connector236
Communication Command Specifications237
Communication Command List238
Communication Command Description241
Robot Movements241
Data Handling254
Utilities266
Chapter 12 MESSAGE TABLES272
Error Messages273
Error Message Specifications273
Command Error Message273
Operation Error Message274
Program Error Message275
System Error Message276
Multi-Task Error Message276
TPB Error Messages277
Stop Messages278
Message Specifications278
Displaying the Error History279
Chapter 13 TROUBLESHOOTING282
If a Trouble Occurs283
Alarm and Countermeasures284
Alarm Specifications284
Alarm Message List285
Troubleshooting for Specific Symptom288
Relating to the Robot Movement288
Relating to the I/O290
Other291
Displaying the Alarm History292
Chapter 14 MAINTENANCE and WARRANTY294
Warranty295
Warranty Description295
Warranty Period295
Exceptions to the Warranty295
Replacing the System Backup Battery296
Replacing the Absolute Battery296
Updating the System297
Chapter 15 SPECIFICATIONS298
DRCX Sereis299
Basic Specifications299
Robot Number List300
LED Display301
Absolute Battery Unit301
Tpb302
Basic Specifications302
Regenerative Unit (RGU-2)303
Basic Specifications303
Dimensions303
Chapter 16 APPENDIX304
Operation When Not Using Absolute Function305
How to Handle Options306
Memory Card306
Handling the I/O Checker308
POPCOM Communication Cable309

Yamaha DRCX - Chapter 13 TROUBLESHOOTING

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