DX100 OPTIONS

INSTRUCTIONS
FOR FUNCTIONAL SAFETY UNIT (NSU01)

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.

YASKAWA ELECTRIC CORPORATION

MANUAL NO.

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DX100

MANDATORY
• This manual explains the functional safety unit (NSU01) of the
DX100 system. Read this manual carefully and be sure to
understand its contents before handling the DX100.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instructions before reading this manual.

CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
• If such modification is made, the manual number will also be
revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized modification
voids your product's warranty.

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DX100

Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

Indicates a potentially hazardous

WARNING situation which, if not avoided, could
result in death or serious injury to
personnel.

Indicates a potentially hazardous

CAUTION situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.

Always be sure to follow explicitly the

MANDATORY items listed under this heading.

Must never be performed.

PROHIBITED

Even items described as “CAUTION” may result in a serious accident in

some situations.
At any rate, be sure to follow these important items.

To ensure safe and efficient operation at all times, be sure to

NOTE follow all instructions, even if not designated as "CAUTION"
and "WARNING".

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DX100

WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN

• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.

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DX100

CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller

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DX100

Descriptions of the programming pendant, buttons, and displays are

shown as follows:

Equipment Manual Designation

Programming Character The keys which have characters printed on
Pendant Keys them are denoted with [ ].
ex. [ENTER]
Symbol The keys which have a symbol printed on them
Keys are not denoted with [ ] but depicted with a small
picture.
GO
GO
BACK
BACK

ex. page key PAGE

PAGE

The cursor key is an exception, and a picture is

not shown.

Axis Keys “Axis Keys” and “Number Keys” are generic

Number Keys names for the keys for axis operation and
number input.

Keys pressed When two keys are to be pressed

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

Displays The menu displayed in the programming

pendant is denoted with { }.
ex. {JOB}

Description of the Operation Procedure

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

Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.

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DX100

1 Function Overview .......................................................................................................................... 1-1

1.1 Preface .............................................................................................................................. 1-1

1.2 Function Overview ............................................................................................................. 1-1

2 System Configuration...................................................................................................................... 2-1

2.1 Outline ............................................................................................................................... 2-1

2.1.1 Functional Safety Unit........................................................................................... 2-1

2.1.2 Signal Distribution Board ...................................................................................... 2-2

2.1.3 Communication I/F Gateway Unit ......................................................................... 2-3

2.1.4 Power On Unit ...................................................................................................... 2-4

2.2 Overview of Unit Connection ............................................................................................. 2-5

2.3 Description of Unit Layout (Layout Drawing) ..................................................................... 2-6

2.4 Spare Parts ........................................................................................................................ 2-6

3 Setup (Safety Range Function for Robot) ....................................................................................... 3-1

3.1 Changing Security Mode.................................................................................................... 3-1

3.2 Preparation for Safety Range Function.............................................................................. 3-3

3.3 Setting Tool Interference File............................................................................................. 3-3

3.4 Setting Safety Range for Robot ......................................................................................... 3-7

3.5 Confirming Safety Range for Robot ................................................................................. 3-11

3.6 Switching Safety Range................................................................................................... 3-12

3.7 Starting Safety Range Function for Robot ....................................................................... 3-15

3.8 Confirming Safety Range and Robot Position ................................................................. 3-17

4 Setup (Safety Range Function for Each Axis)................................................................................. 4-1

4.1 Preparation for Safety Range Function.............................................................................. 4-1

4.2 Setting Expected Stop Value ............................................................................................. 4-1

4.3 Setting Safety Range for Each Axis................................................................................... 4-4

4.4 Confirming Safety Range for Each Axis............................................................................. 4-7

4.5 Starting Safety Range Function for Each Axis................................................................... 4-8

5 Stop Position Monitoring Function .................................................................................................. 5-1

5.1 Operating Condition Detection........................................................................................... 5-1

5.2 Turning Stop Position Monitoring Function VALID/INVALID.............................................. 5-1

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DX100

6 Data Protection ............................................................................................................................... 6-1

6.1 Saving Dual Data............................................................................................................... 6-1

6.2 Operation When VERIFY ERROR Occurs ........................................................................ 6-2

7 System Output Signal ..................................................................................................................... 7-1

8 Alarm............................................................................................................................................... 8-1

9 Restrictions ..................................................................................................................................... 9-1

9.1 Confirming Safety Range and Robot Position ................................................................... 9-1

9.2 Software Version of Machine Safety Unit .......................................................................... 9-1

9.3 Software Version of Functional Safety Unit ....................................................................... 9-2

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1 Function Overview
DX100 1.1 Preface

1 Function Overview

1.1 Preface
This function limits the operating range of the robot and monitors its
speed.
With this function, the software monitors the robot arm or each axis so that
its position does not exceed the preset safety range. If any monitoring
error is detected, the contactors are cut off to stop the robot. With this
function, it is possible to improve the safety for robot operation, and
reduce the facility space for the robot system.

1.2 Function Overview

(1) Range limit function (robot axis + servo track / unit)
This function is used to monitor the robot so that its position does
not exceed the preset safety range. Only one safety range can be
specified. The specified range can be applied to the following con-
figuration:
Robot (6 axes) + servo track (up to 3 axes)
or
Robot (7 axes) + servo track (up to 2 axes)
By the combination of 2 lines of dual input signals (range switch
signals) to the functional safety unit, 4 ranges (range: 1 to range:
4) can be set as the safety ranges.
To enable range switching, connect the range switch signals to the
functional safety system input terminal block shown in
chapter 2.1.2 “Signal Distribution Board” at page 2-2. When
range switching is not used, i.e. only one safety range is set, there
is no need to connect the signals. (In this case, range: 1 is set.)
For signal connection, refer to chapter 3.7 “Starting Safety Range
Function for Robot” at page 3-15.
(2) Each axis angle limit function (9 axes/unit)
(3) Stop position monitoring function
(4) Safety speed monitoring function
This function monitors the robot to see that it operates at the
safety speed of 250 mm/sec. The speed is monitored at the TCP
(Tool Center Point) and flange.
• Teach mode (manual high speed specification is OFF)

The safety speed monitoring function can monitor the

speed of one tool number per robot.
NOTE
The speed of R1 and R2 is monitored using the file with the
tool numbers 0 and 1, respectively.

(5) Logical verification of safety signals

This function detects the unmatch of the dual safety signals
converted into the functional safety unit.

1-1

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2 System Configuration
DX100 2.1 Outline

2 System Configuration

2.1 Outline
To achieve the functions described in this manual, the “functional safety
unit”, “signal distribution board”, “communication I/F gateway unit”, and
“power on unit” are added or replaced for the DX100.

2.1.1 Functional Safety Unit

The type and major specifications of functional safety unit are shown
below.

Item specification

Unit type JZNC-NSU01

Unit size W120×H300×D194 [mm]

Input power supply DC24V

Function (1) Safety range setting function (robot axis + servo track / unit)
(2) Safety speed monitoring function
(3) Safety signal logical verification function

The outline of the functional safety unit: JZNC-NSU01 is shown below.

2-1

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2 System Configuration
DX100 2.1 Outline

2.1.2 Signal Distribution Board

The signal distribution board is a special board equipped with an extended
function that distributes full-speed test signals to the functional safety unit
in addition to the standard functions of the robot system input terminal
block (MXT).

Item specification

Board type JARCR-YCU02

Function (1) Robot system input terminal block

(2) Signal distribution to the functional safety unit
(3) Spare terminal block (for future extension)

Robot system input termial block

For the connection to the robot system input terminal block,

NOTE refer to “13.9 Robot System Input Terminal Block (MXT)” in
DX100 INSTRUCTIONS MANUAL.

2-2

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2 System Configuration
DX100 2.1 Outline

2.1.3 Communication I/F Gateway Unit

The gateway unit for host communication I/F is added to convert the
communication signals to enable the communications between DX100
and the functional safety unit (JZNC-NSU01).
This unit converts the communication signals between the robot I/F board
(JANCD-YIF01-□) in DX100 and the functional safety unit (JZNC-
NSU01).

Item specification

Unit type JZNC-YGW01-E

Unit size W30×H230×D1 [mm]

Input power supply DC24V

Function Conversion of the communication signals between

DX100 robot I/F board (JANCD-YIF01-□) and the
functional safety unit (JZNC-NSU01)

Setting (rotary SW: S1) 1st robot: 0

2nd to 4th robot: 1 to 3 (Number consecutively.)

Connector CN902/CN903 For the connection of the robot I/F board (JANCD-
YIF01-□) and the functional safety unit (JZNC-
NSU01)

CN904 For the connection of the functional safety unit

(JZNC-NSU01)

CN901 For 24 VDC input

The outline of the communication I/F gateway unit: JZNC-YGW01-E is

shown below.

S1
Rotary SW

F1
Protection fuse

2-3

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2 System Configuration
DX100 2.1 Outline

2.1.4 Power On Unit

This power on unit is the unit to which an “auxiliary contact block” is added
in order to feed back the status of the built-in contactor to the functional
safety unit (JZNC-NSU01).
The standard power on unit should be replaced with this unit if needed.

Item specification

Unit type JZRCR-YPU0□-2

Unit size Same size as the standard power on unit

(interchangeable)

Function Contactor auxiliary contact signal output is added.

(for the functional safety unit (JZNC-NSU01))

Connector CN609 For the contactor auxiliary contact signal output

(added to the standard unit)

2-4

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2 System Configuration
DX100 2.2 Overview of Unit Connection

2.2 Overview of Unit Connection

The figure below shows a rough connection diagram where the functional
safety unit is added to the DX100 control panel.

(Current DX100 system)

Power
Teach pendant shutdown Primary
Position Machine safety control
Main CPU instruction Servo control Contactor control power
supply
(1) Target positioning CPU
(2) Current position Current
(1) Safety speed instruction
monitoring with Servo amplifier Motor
monitoring (*) Detector
soft limit Various types of
(3) Safety speed Current (2) Various types of
position error monitoring error monitoring
monitoring (*) Alarm & power shutdown
(4) Various types of information
error monitoring Current position

(DX100 system with the function added) Power

shutdown
Teach pendant Position Machine safety control Primary
Main CPU instruction Servo control (A) Contactor control power
supply
(1) Target positioning CPU
(2) Current position Current
(1) Safety speed
monitoring with instruction Servo amplifier Motor
monitoring (*) Detector
soft limit Various types of
Current (2) Various types of
(3) Safety speed error monitoring
position error monitoring
monitoring (*) Alarm & power shutdown
(4) Various types of information
error monitoring
(5) Safety range
control and monitoring Functional safety unit Current position
(1) Safety range monitoring
Dual safety signal (2) Safety speed monitoring (*) Current position
(3) Logical verification of
(*) Safety speed monitoring: safety signals (A)
Monitoring the speed of 250 mm/sec or slower Power
shutdown

2-5

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2 System Configuration
DX100 2.3 Description of Unit Layout (Layout Drawing)

2.3 Description of Unit Layout (Layout Drawing)

The figure below shows a layout drawing of the DX100 with which the
functional safety unit is added.
Fig. 2-1: Unit Layout Drawing (with the Door Open)

Power on unit (YPU)

JZRCR-YPU0†-2
A
CN601

(QF3)
COULD COULD
FUSE FUSE

CN610 CN611

1FU 2FU
CU
1 CU
3 CN607
O O
N N
L L
Y Y
3FU 4FU

BNL6
A
B

BNL6
C.B. R

C
489
40 C
480Y/277V ~
20A
NCM

CN609
SVMX1

SVMX2
CU CU

O
N
O
N
CN606
L
Y 2 L
Y 4

CN612

(QS2)

CN608
CN605

CN604

CN603

CN602

SOURCE
CN158/159
(+5V/ALM)
P-ON
+5V
+24V
FAN

Functional safety unit (YPU)

OHT

CN156/157
(+24V2)

CN154/155
YCU POWER SUPPLY (+24V1/V2)
CPS-520F
EXIN3_2+

EXIN3_1+

EXIN2_2+

EXIN2_1+

EXIN1_2+

EXIN1_1+
EXIN3_2-

EXIN3_1-

EXIN2_2-

EXIN2_1-

EXIN1_2-

EXIN1_1-

JZNC-NSU01
NO. C90AD XXXXX
DATE YYYY-MM
Fuji Electric Hi-Tech Corp.
MADE IN JAPAN
G
H

D
C
K

B
A
F
L

J
I

01 02 03 04 05 06 07 08 09 10
34 EXDSW1- 17 SYSRUN+ 11 12 13 14 15 16 17 18 19 20
50 GSOUTFB2- 21 22 23 24 25 26 27 28 29 30
33 EXDSW1+ 16 A B C D E F G H J K
49 GSOUTFB2+ L M N P Q R S T U V
48 GSOUT2-
32 EXHOLD- 15 CN153
47 GSOUT2+
31 EXHOLD+ 14 (+24V3)
30 EXSVON- 13
46 GSOUTFB1-
29 EXSVON+ 12 SAFF2-
45 GSOUTFB1+
44 GSOUT1-
28 SSP- 11 SAFF2+
CN151
43 GSOUT1+
27 SSP+ 10 SAFF1- (AC IN)
26 FST2- 9 SAFF1+
42 024V2 INPUT CN152
41 +24V2
25 FST2+ 8 GSIN22-
200-240V AC
24 FST1- 7 GSIN22+ 50/60Hz (REMOTE)
40 024V2
23 FST1+ 6 GSIN21- 3.4A-2.8A
39 +24V2
22 EXESP2- 5 GSIN21+
38 024V2
21 EXESP2+ 4 GSIN12-
37 +24V2
20 EXESP1- 3 GSIN12+
36 EXDSW2-
19 EXESP1+ 2 GSIN11-
35 EXDSW2+
18 SYSRUN- 1 GSIN11+
NJ3114-1

BNL6

A
1
CN214
CNEXT

CN207

A
1

CNNSUO CNYSUO
CN213
UL
94V-0

A
1
CN212

CN216
FRC5-C50S52T-OLS(D20)
MADE IN JAPAN

CN206
S/N
JARCR-YCU02 REV.A 0

CN202

CN211
HE0305598
CNC

CNB

CNA

Terminal unit for NSU

CN205

BNL6
FUSE

CN210

CN215
CN200 CN201

CN209
CN203 CN204

BNL6

JARCR-YCU02
CN208

Comm. I/F gateway unit

JZNC-YGW01-E†

Section A-A A

2.4 Spare Parts

To achieve the functions of range limit and speed monitoring for the
DX100 robot system, the recommended spare parts for the DX100 with
the functional safety unit are shown below.
Regarding the standard part of the DX100, refer to “DX100
INSTRUCTIONS (RE-CTO-A215)” and “DX100 MAINTENANCE
MANUAL (RE-CHO-A108)”.

Unit Name Model Qty. Manufacturer

Functional Safety Fuse 0217001P 2 Littelfuse

Unit (for F2 and F3)
(JZNC-NSU01)

Communication I/F Fuse (for F1) 0217001P 1 Littelfuse

Gateway Unit
(JZNC-YGW01-E)

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3 Setup (Safety Range Function for Robot)
DX100 3.1 Changing Security Mode

3 Setup (Safety Range Function for Robot)

3.1 Changing Security Mode

To limit the operating range of the robot, set the safety range.
To set the safety range, the security mode must be MANAGEMENT
MODE or higher. Thus, the administrator or a user with higher privilege
must set the range.
Change the security mode as follows:
1. Select {SYSTEM INFO} under the main menu.

2. Select {SECURITY} under the sub menu.

3-1

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3 Setup (Safety Range Function for Robot)

DX100 3.1 Changing Security Mode

3. Change the mode from EDITING MODE to MANAGEMENT MODE.

Press [ENTER] in the SECURITY screen. Move the cursor to
“MANAGEMENT MODE” and then press [ENTER] again.

4. Input the password for MANAGEMENT MODE and press [ENTER].

The security mode is changed to MANAGEMENT MODE.

Security level Items that can be manipulated

OPERATION Data such as the operating range cannot be

edited or viewed.
NOTE EDITING

MANAGEMENT Data such as the operating range can be

edited or viewed. The “Safety Unit FLASH
Erase” can be performed in the
maintenance mode.

3-2

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3 Setup (Safety Range Function for Robot)
DX100 3.2 Preparation for Safety Range Function

3.2 Preparation for Safety Range Function

For the safety range function for the robot arm, set the safety range of the
robot arm as polygonal columns in advance. Then, the robot arm is
monitored so that it does not exceed the safety range.
If any monitoring error is detected, the servo power will be turned OFF.
The outline of the operating procedure is as follows:
(1) Setting tool interference file
È
(2) Setting safety range for robot
È
(3) Confirming safety range for robot
È
(4) Starting safety range function for robot

Each operating procedure is explained below.

3.3 Setting Tool Interference File

The safety unit also monitors that the robot tool does not exceed the
safety range. In this case, set the tool shape in the tool interference file.
To set the tool interference file, the security mode must be EDITING
MODE or higher.
<Tool interference file>
• Cylinders and spheres for up to 5 positions can be set.
• Both ends of a cylinder are set by POINT1 and POINT2.
The distance from the center of T axis flange should be set like tool
dimension setting.
• The radius of the spheres and cylinder between POINT1 and
POINT2 is set. The spheres are set to POINT1 and POINT2.
• The specified radius must have a margin of at least 10 mm com-
pared with the actual tool.

A single tool interference file can be used for a robot.

NOTE The safety range function is set to the data in the tool inter-
ference file #0 for R1 and that in the tool interference file #1
for R2.

3-3

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3 Setup (Safety Range Function for Robot)

DX100 3.3 Setting Tool Interference File

Set a tool interference file as instructed below.

1. Select {ROBOT} under the main menu.

2. Select {TOOL INTERFERE} under the sub menu.

– The TOOL INTERFERE screen is displayed.

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3 Setup (Safety Range Function for Robot)
DX100 3.3 Setting Tool Interference File

3. If the data is set in TOOL INTERFERE screen, the READBACK screen

is shown.

– In READBACK screen, you can check if the set data is correct.

– Compare MODIFY VALUE with READBACK VALUE.
• If the data is OK, press “YES” on the screen to fix the tool inter-
ference file setting.
• If the data is NG, press “NO” on the screen to restore to the value
before change.
4. After READBACK screen is displayed, [WRITE] and [CANCEL]
buttons are displayed in the lower position of the screen.

<Description of the screen>

WRITE: Robot controller records the setting of the tool interference file.
CANCEL: Cancel the tool interference file setting to restore the setting to
the previous status.

• Be sure to press [WRITE] after performing tool interfer-

NOTE ence file setting.
• A single tool interference file can be used for a robot.

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3 Setup (Safety Range Function for Robot)

DX100 3.3 Setting Tool Interference File

<Tool interference file setting example>

140

Robot 25

Model 2
Point 1

30
Tool coodinate origin X
(flange surface)

20

85
Model 1
Point 1

250
Model 1
Point 2

350
Tool

Model 3
Point 1 Model 2
Point 2

Model 3
Point 2
Z

Model 1: Set the flange surface as Point 1, and (X=140, Z=85) as Point 2.
Model 2: Set (X=140, Z=-30) as Point 1, and (X=140, Z=250) as Point 2.
This setting defines a model that is parallel to the Z direction of
the tool coordinates.
Model 3: Set (X=140, Z=250) as Point 1, and (X=25, Z=350) as Point 2.
Models 2 and 3 are defined at consecutive positions when point
2 of model 2 and point 1 of model 3 are set at the same position.

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3 Setup (Safety Range Function for Robot)
DX100 3.4 Setting Safety Range for Robot

3.4 Setting Safety Range for Robot

Set the safety range for the robot arm as follows:
1. Select {ROBOT} under the main menu.
2. Move the cursor and display the following sub menu.

3. Select {ROBOT RANGE} under the sub menu.

– The ROBOT RANGE screen is displayed.

<Description of the screen>

ROBOT: Selects a robot to be set in case the of a multiple robot system.
To set R1, move the cursor to “R1” and press [SELECT].
SETTING: Sets the safety range limit function status.

Status Detail

INVALID The safety range function can be disabled temporarily.

The system output signal “Range Monitoring” is turned OFF.
(Refer to chapter 7 “System Output Signal” at page 7-1.)

VALID The safety range function is enabled.

The system output signal “Range Monitoring” is turned ON.
(Refer to chapter 7 “System Output Signal” at page 7-1.)

3-7

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3 Setup (Safety Range Function for Robot)

DX100 3.4 Setting Safety Range for Robot

STATUS: Indicates the status: SETTING or CONFIRMING or

MONITORING.

Status Contents

SETTING “SETTING” is displayed when setting the data.

CONFIRMING “CONFIRMING” is displayed when confirming the range

after data setting.

MONITORING “MONITORING” is displayed after confirming the data.

While “MONITORING” is displayed, the safety range
function is performed.

4. Select “R1”. Then ROBOT RANGE screen is shown.

<Description of the screen>

COORD: Select a coordinate type; ROBOT or BASE.
STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING

Status Contents

SETTING “SETTING” is displayed when setting the data.

CONFIRMING “CONFIRMING” is displayed when confirming the range

after data setting.

MONITORING “MONITORING” is displayed after confirming the data.

While “MONITORING” is displayed, the safety range
function is performed.

LINE 1 to 16: Make line segments connecting <X1> and <Y1>, <X2> and
<Y2>, to set the safety range. Up to 16 line segments can be
used for setting.
Z TOP: Sets the safety range of Z-direction top surface.
Z BOTTOM: Sets the safety range of Z-direction bottom surface.

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DX100 3.4 Setting Safety Range for Robot

<Range setting example>

To set the range with the X direction + side: 3000 mm, X direction - side: -
2000 mm, Y direction + side: 2500 mm, and Y direction - side: -1500 mm,
enter the numbers as shown below.
X1 Y1 X2 Y2
Line 1 3000 2500 -2000 2500
Line 2 -2000 2500 -2000 -1500
Line 3 -2000 -1500 3000 -1500
Line 4 3000 -1500 3000 2500

X+: 3000 mm Line 4

Line 1 Line 3

Y+: 2500 mm Y-: 1500 mm

Line 2 X-: -2000 mm

5. If the data is set in ROBOT RANGE screen, the READBACK screen is

shown.

– In READBACK screen, you can check if the set data is correct.

Compare MODIFY VALUE with READBACK VALUE.
• If the data is OK, press [YES] on the screen to fix the setting in
ROBOT RANGE screen.
• If the data is NG, press [NO] on the screen to restore to the value
before change.

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3 Setup (Safety Range Function for Robot)

DX100 3.4 Setting Safety Range for Robot

6. After READBACK screen is displayed, [WRITE] and [CANCEL]

buttons are displayed in the lower position of the screen.

<Description of the screen>

WRITE: Robot controller records the setting of the safety range.
CANCEL: Cancel the safety range setting to restore the setting to the
previous status.

• Be sure to press [WRITE] after performing the safety

range setting.
• Unless the safety ranges are set and the status is set to
MONITORING for all the robots used in the system, robot
operations by the axis keys cannot be performed except
NOTE
for each axis operation.
Before performing the following operations, make sure to
complete the safety range setting.
– Job playback
– [FWD], [BWD], [TEST START] key operations
GO
BACK

7. When setting multiple ranges, press the page key PAGE and switch the
screen to make the settings.
For multiple ranges, set an overlap area. Switch between ranges only
when the robot is in the overlap area.
<Setting example>

Range 2

Range 1

Area where the ranges

can be switched.

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3 Setup (Safety Range Function for Robot)
DX100 3.5 Confirming Safety Range for Robot

3.5 Confirming Safety Range for Robot

After the completion of safety range setting, it is necessary to confirm if
the monitoring is performed according to the safety range set in the
chapter 3.4 “Setting Safety Range for Robot” at page 3-7.

At that time, the “STATUS” in ROBOT RANGE screen indicates

“CONFIRMING”. Move the robot to check if the manipulator stops before
it exceeds the safety range.
When multiple ranges are set, change the range switch signals to check
for all the ranges.
<How to check the safety range with the jog operation>
Check that the specified safety range is correct with the jog operation.
Make the robot operate toward the specified four limits to see that the
robot stops operating within the range. If the range is not rectangular
solid, check that the robot stops before all the limits of the range.

CAUTION
Do not forget to move the robot to see that it stops within the specified
safety range.

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3 Setup (Safety Range Function for Robot)

DX100 3.6 Switching Safety Range

3.6 Switching Safety Range

Multiple safety ranges can be set/confirmed in advance, and the ranges
can be switched by external signals.
For multiple safety ranges, set an overlap area. Switch between ranges
only when the robot is in the overlap area.
Use the dual input signal of the functional safety unit to switch between
safety ranges. If the range is selected by the signal while the range is
being set, the following alarm occurs. Select another range already
confirmed to reset the alarm.
Alarm to occur:
Alarm 4691: “OPERATION AREA SET ERR (SAFETY)”
If the range is selected while it is being set or confirmed during the robot
program operation, the following alarm occurs. Select another range
already confirmed to reset the alarm.
Alarm to occur:
Alarm 4679: “SPECIFIED MOTION RANGE ERROR”
Selected safety range numbers are output to the following system output
signals. (Refer to chapter 7 “System Output Signal” at page 7-1.)
50940 to 50947: Selected RANGE NUMBER (d0)
50950 to 50957: Selected RANGE NUMBER (d1)

CAUTION
• Before using the safety range switching function, give due
consideration (risk assessment) to the potential danger by switching
between ranges.
• When performing the teaching operation of the robot program, the
operator should always check the range number before each
operation.
• Prepare a means to identify the selected range number, and check
the selected range number before performing operations.
• Check that the robot is stopped before switching between ranges.
Switching between ranges during the robot program operation may
result in the following risks.
– Risk of selecting a wrong range
– Risk that the robot may exceed the range after switch when the
ranges before and after switch are greatly different or the overlap
area of them are small

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3 Setup (Safety Range Function for Robot)
DX100 3.6 Switching Safety Range

The combinations of safety ranges and range switch signals are shown
below.

Table 3-1: Setting of Safety Range

Safety Welder 1 Welder 2 Notes
Range No. Status Terminal 1)
Status Terminal 1)

CLOSE A/B CLOSE E/F Default setting

1
CLOSE C/D CLOSE G/H
OPEN A/B CLOSE E/F
2
OPEN C/D CLOSE G/H
CLOSE A/B OPEN E/F
3
CLOSE C/D OPEN G/H
OPEN A/B OPEN E/F
4
OPEN C/D OPEN G/H
CLOSE A/B * E/F “SIGNAL COMPARISON ERROR
N/A (SAFETY)” alarm occurs.
OPEN C/D * G/H
OPEN A/B * E/F “SIGNAL COMPARISON ERROR
N/A (SAFETY)” alarm occurs.
CLOSE C/D * G/H
* A/B CLOSE E/F “SIGNAL COMPARISON ERROR
N/A (SAFETY)” alarm occurs.
* C/D OPEN G/H
* A/B OPEN E/F “SIGNAL COMPARISON ERROR
N/A (SAFETY)” alarm occurs.
* C/D CLOSE G/H
1 Terminal indicates the number of the functional safety system input terminal block on the JARCR-YCU02 board.

DX100 connection diagram

JARCR-YCU02
Functional safety system JZNC-NSU01
input terminal block Functional safety unit

A
EXIN1_1+
B
EXIN1_1-
Welder 1 C
EXIN1_2+
D
EXIN1_2-
E
EXIN2_1+
F
EXIN2_1-
Welder 2 G
EXIN2_2+
H
EXIN2_2-

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3 Setup (Safety Range Function for Robot)

DX100 3.6 Switching Safety Range

If the functional safety unit detects the safety signal inconsistency, the
following alarm occurs.
Alarm 4705: “SIGNAL COMPARISON ERROR (SAFETY)”
Subcode 5: Signal inconsistency of YCU02 board A to D
3: Signal inconsistency of YCU02 board E to H

CAUTION
• Connect an independent switch (dry contact) for the range switch
signal.
• The load current of 24 VDC/6.5 mA (typ) flows through each input
circuit.
For the connection, use a switching device capable of switching 24
VDC at 6.5 mA (typ).
• The dual input signals are checked whether they are synchronized.
Set the dual input signals as the signals which turn ON and OFF
simultaneously. If the dual input signal’s turning ON and OFF are
different in timings with 500 ms or more, the alarm of “INPUT
SIGNAL ERROR” occurs.
• For the details of wiring to the functional safety system input
terminal block, refer to “DX100 INSTRUCTIONS (RE-CTO-A215)
13.9 Robot System Input Terminal Block (MXT)”.

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3 Setup (Safety Range Function for Robot)
DX100 3.7 Starting Safety Range Function for Robot

3.7 Starting Safety Range Function for Robot

After confirming that the robot can move in the set safety range, press
[CONFIRM]. The STATUS indication is changed to “MONITORING” and
the safety unit starts the safety range function for the robot.

Check the following items with the actual job.

<How to check the safety range in the play mode>
1. Check the teaching point of job.
If an alarm occurs and the robot does not operate when the job is
played back, the following causes are possible:
• The specified range is inappropriate.
• Teaching is inappropriate.
In such a case, recalculate the range or modify teaching.
Alarm 4682: “MOTION RANGE LIMIT INTERFERENCE”
<Cause>
The teaching position is out of the specified range.
<Countermeasure>
Check that the specified range is correct.
Change the teaching position so that it falls in the range.

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3 Setup (Safety Range Function for Robot)

DX100 3.7 Starting Safety Range Function for Robot

2. Endurance running must be normally performed.

Try to move the actual job. If the robot moves near the specified
range, an alarm may occur. In such a case, modify teaching or slow
down the speed.
Alarm 1629: “OPERATION AREA MON. ERR(ROBOT)”
<Cause>
The range error was detected when the robot operated.
<Reason>
This alarm was detected by the safety unit. The safety unit monitors
the position based on the feedback pulse from the motor. The
speed and coasting value is considered during calculation so that
the robot does not move out of the range. Thus, this alarm occurs
when the teaching position is near the safety range or the teaching
speed is fast.
<Countermeasure>
Modify teaching so that the teaching position is not near the safety
range.
Reduce the teaching speed.

If the STATUS is “CONFIRMING”, PLAY mode operation is

NOTE disabled. Be sure to perform confirming operation and
press [CONFIRM] button on the screen.

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3 Setup (Safety Range Function for Robot)
DX100 3.8 Confirming Safety Range and Robot Position

3.8 Confirming Safety Range and Robot Position

The positional relation between the specified safety range and the actual
robot posture can be checked by showing them on the programming
pendant.
1. Select {ROBOT} under the main menu.
2. Move the cursor to display the following sub menu.

3. Select {OPERATION AREA MONITOR} under the sub menu.

– The Disp Operation Area screen is displayed.

1 2 3

5
4

<Description of the screen>

c The plane currently displayed
This is the plane currently displayed. The brown section indicates the
area out of the safety range.
• X-Y plane: The safety range is a white area enclosed with straight
lines.
• Y-Z and X-Z planes: The sides of the safety range.

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3 Setup (Safety Range Function for Robot)

DX100 3.8 Confirming Safety Range and Robot Position

d The number of the robot currently displayed

e The coordinate system of the safety range
f The correspondence table of the illustrated straight lines
The numbers of straight lines correspond to the straight line numbers
on ROBOT RANGE screen.
g [Change Plane] key
Each time pressed, the displayed plane is switched (X-Y, Y-Z, X-Z).
h [Exit] key
Closes the Disp Operation Area screen.

When the Disp Operation Area screen is closed, other

opened screens are also closed. This means that data not
NOTE yet confirmed is discarded if the Disp Operation Area
screen is opened while editing the data. Thus, make sure
to confirm the editing data before opening the Disp Opera-
tion Area screen.

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4 Setup (Safety Range Function for Each Axis)
DX100 4.1 Preparation for Safety Range Function

4 Setup (Safety Range Function for Each Axis)

4.1 Preparation for Safety Range Function

For the safety range function for each axis, set the movement amount of
each axis of the robot in advance. Then, each axis is monitored so that it
does not exceed the safety range.
If any monitoring error is detected, the servo power will be turned OFF.
The outline of the operating procedure is as follows:
(1) Setting expected stop value
È
(2) Setting safety range for each axis
È
(3) Confirming safety range for each axis
È
(4) Starting safety range function for each axis

Each operating procedure is explained below.

4.2 Setting Expected Stop Value

When the servo power is turned OFF during robot operation, the robot
keeps moving due to inertia until it stops completely. The functional safety
unit predicts the movement distance (hereinafter called the coasting
value) according to the speed of each axis until the robot actually stops.
By predicting the coasting value, the robot does not exceed the safety
range even if an error, such as the robot’s exceeding the safety range, is
detected.
For example, when the robot is operating at 100% of its motion speed, the
functional safety unit starts to stop it from “the distance of the coasting
value of 100% motion speed”. When the robot is operating at 50% of its
motion speed, the functional safety unit starts to stop it from “the distance
of the coasting value of 50% motion speed”.
To perform the above predictive control, the robot may stop before the
safety range when it moves to the teaching point near the safety range.
To add an teaching point near the safety range, take the following
measures:
(1) Lower the teaching speed
(2) Change the teaching point
(3) Change the setting of the safety range to widen it
Regarding the coasting value of the external axis, settings must be made
by the user as instructed in the following.
If settings of the coasting value are not completed, the following error
occurs and playback cannot be performed.
Error 0384: “Coasting value setting of Ex-axis is not completed.”

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4 Setup (Safety Range Function for Each Axis)

DX100 4.2 Setting Expected Stop Value

1. Change the security mode to MANAGEMENT MODE, then select

{ROBOT} under the main menu.

2. Select {COASTING VALUE SETTING} under the sub menu.

– The COASTING VALUE SETTING screen is displayed.

The sub menu {COASTING VALUE SETTING} is not dis-

NOTE played when the system does not have any external axis. It
is not displayed either when the security mode is not MAN-
AGEMENT MODE.
GO
BACK

– When 2 or more external axes are used, press the page key PAGE
to
switch between the external axes.

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4 Setup (Safety Range Function for Each Axis)
DX100 4.2 Setting Expected Stop Value

3. Select the axis to set the coasting value, and edit the EXPECTED
STOP VALUE. Then the READBACK screen appears.

– Check that MODIFY VALUE and READBACK VALUE are the same,
then press [YES]. The COASTING VALUE SETTING screen is
displayed again, and the edited coasting value of axis is changed to
the input EXPECTED STOP VALUE. Press [NO] to cancel editing.

• The coasting value can be set from 0.000 to 999.999.

• When the coasting value is edited, the servo power is
turned OFF, and the robot and external axes cannot be
NOTE
operated until the control power is turned OFF and ON
again. Since the setting of the coasting value can be con-
tinued, turn OFF and ON the control power after setting
the coasting values of all axes.

„ How to Change the Stop Category

To measure the coasting value, the stop category can be changed.
In the COASTING VALUE SETTING screen, select IMMEDIATE STOP to
show INVALID and VALID. Select one of them to display the READBACK
screen in the same way when editing the coasting value. Check that the
READBACK VALUE is the same as the value shown right next to the
selected item of INVALID or VALID. Then press [YES] to switch between
INVALID and VALID.

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4 Setup (Safety Range Function for Each Axis)

DX100 4.3 Setting Safety Range for Each Axis

• When the IMMEDIATE STOP is set to VALID, the stop cat-

egory of the robot and external axes is set to 0. Be sure to
return the IMMEDIATE STOP to INVALID after measuring
the coasting value.
• If the start operation is performed when the IMMEDIATE
STOP is VALID, a confirmation dialog box appears.
Select [YES] and perform the start operation again to per-
form playback.

NOTE

4.3 Setting Safety Range for Each Axis

Set the safety range for each axis as instructed below.
1. Change the security mode to MANAGEMENT MODE, then select
{ROBOT} under the main menu.

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4 Setup (Safety Range Function for Each Axis)
DX100 4.3 Setting Safety Range for Each Axis

2. Select {AXIS RANGE} under the sub menu.

– The AXIS RANGE screen is displayed.

<Description of the screen>

CTRL GROUP: Selects a control group to be set in the case of a multiple
control group system.
To set S1, move the cursor to “S1” and press [SELECT].
SETTING: Sets the safety range limit function (for each axis) status.

Status Detail

INVALID The safety range function for each axis can be disabled
temporarily.

VALID The safety range function for each axis is enabled.

STATUS: Indicates the status: SETTING or CONFIRMING or

MONITORING.

Status Contents

SETTING “SETTING” is displayed when setting the data.

CONFIRMING “CONFIRMING” is displayed when confirming the range

after data setting.

MONITORING “MONITORING” is displayed after confirming the data.

While “MONITORING” is displayed, the safety range
function for each axis is performed.

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4 Setup (Safety Range Function for Each Axis)

DX100 4.3 Setting Safety Range for Each Axis

3. Select a control group. The AXIS RANGE screen of the selected

control group will be displayed.

<Description of the screen>

STATUS: Indicates the status: SETTING or CONFIRMING or
MONITORING.

Status Contents

SETTING “SETTING” is displayed when setting the data.

CONFIRMING “CONFIRMING” is displayed when confirming the range

after data setting.

MONITORING “MONITORING” is displayed after confirming the data.

While “MONITORING” is displayed, the safety range
function for each axis is performed.

MAX/MIN: The maximum and minimum values of the safety range are
shown for each axis of the selected control group.
4. When MAX/MIN data are set, the following READBACK screen is
displayed.

– Check that MODIFY VALUE and READBACK VALUE are the same,
then press [YES]. The selected data will be changed. Press [NO] to
cancel editing.

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4 Setup (Safety Range Function for Each Axis)
DX100 4.4 Confirming Safety Range for Each Axis

5. When the data are set, [WRITE] and [CANCEL] buttons are displayed
in the lower position of the screen.

<Description of the screen>

WRITE: Robot controller records the setting of MAX/MIN.
CANCEL: Cancel the MAX/MIN setting to restore the setting to the
previous status.

The functional safety unit predicts the coasting values of the

robot and external axes (see chapter 4.2 “Setting Expected
NOTE Stop Value” at page 4-1) when monitoring the safety range.
Therefore, the robot may stop before the safety range when
it moves to the teaching point near the safety range.

4.4 Confirming Safety Range for Each Axis

After the completion of safety range (for each axis) setting, it is necessary
to confirm if the monitoring is performed according to the safety range set
in the chapter 4.3 “Setting Safety Range for Each Axis” at page 4-4.

At that time, the “STATUS” in ROBOT RANGE screen indicates

“CONFIRMING”. Move the manipulator or the external axis to check if it
stops before it exceeds the safety range.

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4 Setup (Safety Range Function for Each Axis)

DX100 4.5 Starting Safety Range Function for Each Axis

4.5 Starting Safety Range Function for Each Axis

After confirming that the manipulator/external axis can move in the set
safety range, press [CONFIRM]. The STATUS indication is changed to
“MONITORING” and the safety unit starts the safety range function for
each axis.
Check the following items with the actual job.
<How to check the safety range in the play mode>
1. Check the teaching point of job.
If an alarm occurs and the robot does not operate when the job is
played back, the following causes are possible:
• The specified range is inappropriate.
• Teaching is inappropriate.
In such a case, recalculate the range or modify teaching.
Alarm 4683: “AXIS MOTION RANGE LIMIT”
<Cause>
The teaching position is out of the specified range.
<Countermeasure>
Check that the specified range is correct.
Change the teaching position so that it falls in the range.
2. Endurance running must be normally performed.
Try to move the actual job. If the robot moves near the specified
range, an alarm may occur. In such a case, modify teaching or slow
down the speed.
Alarm 1625: “OPERATION AREA MON. ERR(AXIS)”
<Cause>
The range error was detected when the robot operated.
<Reason>
This alarm was detected by the safety unit. The safety unit monitors
the position based on the feedback pulse from the motor. The
speed and coasting value is considered during calculation so that
the robot does not move out of the range. Thus, this alarm occurs
when the teaching position is near the safety range or the teaching
speed is fast.
<Countermeasure>
Make the safety range setting INVALID, move the robot within the
safety range, then make the setting VALID again.
Modify teaching so that the teaching position is not near the safety
range.
Reduce the teaching speed.

If the STATUS is “CONFIRMING”, PLAY mode operation is

NOTE disabled. Be sure to perform confirming operation and
press [CONFIRM] button on the screen.

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5 Stop Position Monitoring Function
DX100 5.1 Operating Condition Detection

5 Stop Position Monitoring Function

5.1 Operating Condition Detection

The stop position monitoring function is one of the functions of the
functional safety unit. With this function, the encoder information of the
robot or external axis is monitored. If the robot or external axis moves
when the function is valid, the power supply to the servo is shut off
immediately to turn the servo power OFF.
The VALID/INVALID setting of the stop position monitoring function is
performed by the turning ON/OFF of the external dual signal (e.g. area
sensor, mat switch).
When using this function, refer to chapter 5.2 “Turning Stop Position
Monitoring Function VALID/INVALID” and connect the dual signal.
If the movement of each axis is detected, the following alarm occurs and
the servo power is turned OFF.
Alarm 4704: “STOPPING POS. MON. ERR (SAFETY)
Countermeasure:
(1) Short-circuit the GSIN signal.
(2) Reset the alarm.

If the system consists of multiple control groups (e.g. robot

NOTE + external axis), the stop position monitoring cannot be per-
formed for each axis separately. The monitoring is per-
formed only for the whole controller.

5.2 Turning Stop Position Monitoring Function VALID/INVALID

The combination of the VALID/INVALID status of the stop position
monitoring function and the ON/OFF status of the signal is shown in
table 5-1 “VALID/INVALID Setting of Stop Position Monitoring Function”
at page 5-2 and the connection diagram is shown in chapter Fig. 5-1:
“Connection Diagram Example” at page 5-2.
If the functional safety unit detects the inconsistency of GSIN signal, the
following alarm occurs:
Alarm 4705: “SIGNAL COMPARISON ERROR (SAFETY)”
Subcode 40, 41: GSIN SIGNAL INCONSISTENT

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5 Stop Position Monitoring Function

DX100 5.2 Turning Stop Position Monitoring Function VALID/INVALID

Table 5-1: VALID/INVALID Setting of Stop Position Monitoring Function

Status Signal Terminal Remarks
INVALID ON GSI01+/GSI01-
Default setting
ON GSI02+/GSI02-
VALID OFF GSI01+/GSI01-
OFF GSI02+/GSI02-
VALID OFF GSI01+/GSI01- Input signal
ON GSI02+/GSI02- inconsistent alarm
occurs
VALID ON GSI01+/GSI01- Input signal
OFF GSI02+/GSI02- inconsistent alarm
occurs

Fig. 5-1: Connection Diagram Example

Remove the jumper cable.

Functional safety unit

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5 Stop Position Monitoring Function
DX100 5.2 Turning Stop Position Monitoring Function VALID/INVALID

CAUTION
• Connect an independent switch (dry contact) for the signal.
If the semiconductor output (*periodic OFF check diagnosis) is
directly connected, the input circuit may malfunction.
The signal must be received by a control device such as a safety
relay unit before connecting the contact signal.
Note that an appropriate control device must be used to achieve the
safety function.
• The load current of 24 VDC/8.5 mA (typ) flows through each input
circuit.
For the connection, use a switching device capable of switching 24
VDC at 8.5 mA (typ).
• The dual input signals are checked whether they are synchronized.
Set the dual input signals as the signals which turn ON and OFF
simultaneously. If the dual input signal’s turning ON and OFF are
different in timings with 500 ms or more, the alarm of “INPUT
SIGNAL ERROR” occurs.
• A screwless terminal block is used as the terminal block 151XT.
See below for the applicable wire and wire termination.
Applicable wire: 0.3 to 1.0 mm dia. (AWG 28 to 18)
0.08 to 1.25 mm2 (AWG 28 to 16)
* When using a ferrule, a wire of up to 0.5 mm2
(AWG20) is applicable.

* Wire strip size (mm)

8

Solid wire

Stranded wire

Ferrule

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6 Data Protection
DX100 6.1 Saving Dual Data

6 Data Protection

6.1 Saving Dual Data

The data related to this function is saved in a duplicated manner for safety.
When the control power is turned ON, check is performed to see that dual
data sets are the same.
If they are different when the control power is turned ON, the following
alarm occurs.
When the following alarm occurs, set up data according to the procedure
described in chapter 6.2 “Operation When VERIFY ERROR Occurs” at
page 6-2.

Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]”

If the alarm occurs, the following causes are possible:

• The data related to this function is loaded from an external storage.
• The home position calibration or the home position change operation
is performed.
• The tool calibration operation is performed.
• The data saving has not been performed correctly.

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6 Data Protection
DX100 6.2 Operation When VERIFY ERROR Occurs

6.2 Operation When VERIFY ERROR Occurs

If the following alarm occurs when the control power is turned ON,
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]”
perform the following operations to re-set the data of the functional safety
unit.
1. When the controller power is turned ON,
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]” occurs
and the maintenance mode is started up.

– Select {SYSTEM} under the main menu. Then, change the security
mode from EDIT MODE to MANAGEMENT MODE with the
procedure described in chapter 3.1 “Changing Security Mode” at
page 3-1.
2. Select {FILE} under the main menu. Then, select {INITIALIZE} under
the sub menu.

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6 Data Protection
DX100 6.2 Operation When VERIFY ERROR Occurs

3. Move the cursor to “Safety Unit FLASH Reset” and press [ENTER].

4. The dialog box “Reset?” is displayed. Select [YES].

– The data of the safety unit is re-set. A few seconds later, the buzzer
sounds and the data setting is completed.

5. When the data reset is completed, turn the control power OFF and
then turn the power ON again.

To set the safety unit data, the security mode must be MAN-
NOTE AGEMENT MODE or higher. Thus, the administrator or a
user with higher privilege must perform these settings.

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7 System Output Signal
DX100

7 System Output Signal

The signals output while using the functional safety unit are shorn below.

50917 50916 50915 50914 50913 50912 50911 50910

SOUT#728 SOUT#727 SOUT#726 SOUT#725 SOUT#724 SOUT#723 SOUT#722 SOUT#721
SF. UNIT
CONNECT

• 50910: SF. UNIT CONNECT

When one or more functional safety units (NSU01) are connected
with the system, this signal turns ON.

50937 50936 50935 50934 50933 50932 50931 50930

SOUT#744 SOUT#743 SOUT#742 SOUT#741 SOUT#740 SOUT#739 SOUT#738 SOUT#737
MONITOR MONITOR MONITOR MONITOR MONITOR MONITOR MONITOR MONITOR
RANGE RANGE RANGE RANGE RANGE RANGE RANGE RANGE
(R8) (R7) (R6) (R5) (R4) (R3) (R2) (R1)

• 50930 to 50937: MONITOR RANGE (R1 to 8)

This signal shows the operation status of the safety range function
for each robot. Set VALID/INVALID to turn ON/OFF this signal on
the ROBOT RANGE window. (Refer to chapter 3.4 “Setting Safety
Range for Robot” at page 3-7.)

50947 50946 50945 50944 50943 50942 50941 50940

SOUT#752 SOUT#751 SOUT#750 SOUT#749 SOUT#748 SOUT#747 SOUT#746 SOUT#745
RANGE RANGE RANGE RANGE RANGE RANGE RANGE RANGE
NO.: d0 (R8) NO.: d0 (R7) NO.: d0 (R6) NO.: d0 (R5) NO.: d0 (R4) NO.: d0 (R3) NO.: d0 (R2) NO.: d0 (R1)

50957 50956 50955 50954 50953 50952 50951 50950

SOUT#760 SOUT#759 SOUT#758 SOUT#757 SOUT#756 SOUT#755 SOUT#754 SOUT#753
RANGE RANGE RANGE RANGE RANGE RANGE RANGE RANGE
NO.: d1 (R8) NO.: d1 (R7) NO.: d1 (R6) NO.: d1 (R5) NO.: d1 (R4) NO.: d1 (R3) NO.: d1 (R2) NO.: d1 (R1)

• 50940 to 50947: RANGE NO.: d0 (R1 to 8)

• 50950 to 50957: RANGE NO.: d1 (R1 to 8)
When the safety range switch function is used (refer to chapter 3.6
“Switching Safety Range” at page 3-12), the monitored safety range
number for each robot is shown. The ranges 1 to 4 are indicated by
the combination of 2 bits, d0 and d1.
Selected safety range d1 d0
No.
1 OFF OFF
2 OFF ON
3 ON OFF
4 ON ON

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8 Alarm
DX100

8 Alarm

Alarm Message Explanation

No.
0020 CPU COMMUNICATION The connected board’s presence was not confirmed.
ERROR This alarm also occurs when an error is detected in the serial
communication between YIF01 and EAXA01 or YIF01 and NSU01.
Subcode 1: YCP01 (main CPU board)
50 to 57: EAXA01
60 to 67: NSU01
0021 COMMUNICATION ERROR An error is detected in the serial communication between YIF01 and
(SERVO) EAXA01 or YIF01 and NSU01.
Subcode 50 to 57: EAXA01
60 to 67: NSU01
0110 COMMUNICATION ERROR An error is detected in the serial communication between YIF01 and
to (SU#1 to 8) NSU01. The last digit of the alarm number indicates the node
0117 number.
Alarm 0110: NSU 1st node
Alarm 0111: NSU 2nd node
0300 VERIFY ERROR (SYSTEM The DX100 has detected an error in the validity check on the data
CONFIG-DATA) files between YCP01 and the safety unit (NSU) when the power is
turned ON. Execute “Safety Unit FLASH Erase” in the maintenance
mode.
This alarm also occurs when the functional safety unit is replaced with
the unit whose data has not been set.
0400 PARAMETER An error is detected in the parameter transmission between YIF01
TRANSMISSION ERROR and EAXA board or YIF and NSU.
Subcode: same as the alarm 0021
0410 MODE CHANGE ERROR The DX100 changes its operation modes during a startup process
from the power-on operation until the startup process completion. An
unsuccessful mode change was detected.
Subcode: same as the alarm 0021
0510 SOFTWARE VERSION The combination of software is incorrect.
UNMATCH Subcode 60: The software version of the functional safety unit
(NSU01) is incorrect.
1610 SAFETY UNIT CPU The DX100 has detected an error in the communication between
SYNCHRO ERROR YCP01 and the safety unit (NSU) when the power is turned ON.
Check the cables and connectors between these boards, then turn
the power OFF and ON again.
1612 COMMUNICATION ERROR There is a communication error between YIF01 and NSU. There may
(SAFETY) be poor contact of connectors. Check the cables and connectors
between these boards, then turn the power OFF and ON again.
1613 ENCODER COMM. ERR 1 The DX100 has detected an error in the communication between the
(SAFETY) encoder (each axis) and the safety unit (NSU). Check the encoder
cables, then turn the power OFF and ON again.
1614 ENCODER COMM. ERR 2 The DX100 has detected an error in the communication between the
(SAFETY) encoder (all axes) and the safety unit (NSU). Check the encoder
cables and connectors, then turn the power OFF and ON again.
1615 SYSTEM ERROR (SAFETY) NSU01 could not execute the process successfully.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1616 SYSTEM ERROR 1 NSU01 could not execute the process successfully.
(SAFETY) Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.

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8 Alarm
DX100

Alarm Message Explanation

No.
1618 ARITHMETIC ERROR NSU01 detected an arithmetic error.
(SAFETY) Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1619 PARAMETER ERROR NSU01 detected an error in the setting value of parameter or file.
(SAFETY) Check for an error in the setting of the safety range, then turn the
power OFF and ON again. If this alarm occurs frequently, replace
NSU01 unit.
1622 DEFECTIVE ENCODER NSU01 detected an error in the encoder data.
(SAFETY) Check the encoder cables, then turn the power OFF and ON again.
1623 ENCODER CORR. NUM Reading encoder data failed multiple times in a row.
OVER (SAFETY) Turn the power OFF and ON again.
If this alarm occurs again, replace NSU01 unit.
1625 OPERATION AREA MON. The safety unit (NSU) has detected the manipulator motion exceeding
ERR (AXIS) the safety range of each axis. Check the teaching points and range
setting.
1629 OPERATION AREA MON. The safety unit (NSU) has detected the manipulator motion exceeding
ERR (ROBOT) the safety range. Check the teaching points, range setting, and
motion speed near the end of the range.
1630 MUTUAL DIAGNOSIS ERR Data inconsistency occurred in the duplicated monitoring by the
(WDT) safety unit (NSU). One CPU detected an error in the timing check of
the other.
This alarm may be accompanied by the alarm 1610 and 1615.
Turn the power OFF and ON again.
1631 MUTUAL DIAGNOSIS ERR Data inconsistency occurred in the duplicated monitoring by the
(HW SETTING) safety unit (NSU). The hardware setting failure of one of the dual
systems was detected.
This alarm may occur due to the failure of the rotary switch. Turn the
power OFF and ON again.
Subcode 1: rotary switch setting error
2: other errors
1632 MUTUAL DIAGNOSIS ERR Data inconsistency occurred in the duplicated monitoring by the
(MONITOR) safety unit (NSU). Turn the power OFF and ON again. This alarm
occurs when an error was detected in one of the CPUs.
1634 FEEDBACK SIGNAL ERROR Data inconsistency occurred in the feedback monitoring of the safety
(SAFETY) signal outputs. Check the safety signal cables, then turn the power
ON again.
<Check point> Connectors and cables of NSU01: CNLO, CNSF 1 to 4
1635 LOW VOLTAGE (SAFETY) The internally-generated voltage of NSU fell below the low voltage
threshold. The failure of the unit may have occurred. Replace
NSU01 unit.
1636 OVER VOLTAGE (SAFETY) The internally-generated voltage of NSU exceeded the over voltage
threshold. The failure of the unit may have occurred. Replace
NSU01 unit.
1637 RAM DIAGNOSIS ERROR An error was detected by the hardware diagnosis of NSU.
(SAFETY) Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1639 RAM AREA CONVERSION An error was detected by the hardware diagnosis of NSU.
ERR (SAFETY) Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1640 REAL TIME MONITOR An error was detected by the hardware diagnosis of NSU.
ERROR (SAFETY) Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.

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DX100

Alarm Message Explanation

No.
1641 SAFETY OUTPUT FB An error was detected in the connection between NSU and another
ERROR (SAFETY) unit. Check the safety signal cables, then turn the power OFF and
ON again.
<Check point 1> communication cable between NSU (CNSF1
connector) and YSU (CN207 connector)
<Check point 2> communication cable between NSU (CNSF1
connector) and YPU (CN609 connector)
1642 WATCHDOG SIGNAL An error was detected by the hardware diagnosis of NSU.
ERROR (SAFETY) Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1643 SIGNAL SETTING ERROR When a multiple robot system (with 2 or more manipulators) is used,
(SAFETY) the DX100 has detected an error in the link signal between the safety
units (NSU01) or in the jumper cable setting of NSF02 board. Turn
the power OFF and then ON again.
<Check point> CNMA connector of NSU01 of the first robot, CNMB
connector of NSU01 of the second robot, and the cables between the
connectors
<Check point> CNLO connector of NSU01 of the first robot, CNLI
connector of NSU01 of the second robot, and the cables between the
connectors
<Check point> The jumper cable setting of NSF02 board of the rotary
switch
1644 24V LOW VOLTAGE The externally supplied 24V voltage for NSU is not supplied.
(SAFETY) Check the fuse, power supply connector, and cables of NSU01.
<Check point> F2, F3 fuses, CN01 connector, and power cable of
NSU01
1645 CRC ERROR (SAFETY) An error was detected in the stored data of NSU01.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
1646 COMM. SETTING ERROR An error was detected by the hardware diagnosis of NSU.
(SAFETY) Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.

4208 SYSTEM ERROR (ARITH) A teaching point is set outside the range. Check the teaching points
and range setting.
4679 SPECIFIED MOTION RANGE Upper YCP01 detected that the range whose setting and confirmation
ERROR are not completed is selected.
Check the status of range selection signal and the setting of the safety
range.
4680 SAFETY UNIT COMMAND An error is detected in the serial communication between NIF01 and
ERROR NSU01. This alarm may be accompanied by the alarm 0020 or 0100.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4682 MOTION RANGE LIMIT Upper YCP01 detected the manipulator motion exceeding the safety
INTERFERENCE range. Check the teaching points and range setting.
4683 AXIS MOTION RANGE LIMIT Upper YCP01 detected the motion of each axis exceeding the safety
range. Check the teaching points and range setting.
4685 WRITE ERROR (SAFETY) Data was not recorded successfully in the functional safety unit.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4687 OPERATION AREA MON. The safety unit (NSU) detected the motion of each axis exceeding the
ERR 2 (AXIS) safety range. Check the teaching points and range setting.
4689 OPERATION AREA MON. The safety unit (NSU) detected the manipulator motion exceeding the
ERR 2 (ROBOT) safety range. Check the teaching points and range setting.

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8 Alarm
DX100

Alarm Message Explanation

No.
4691 OPERATION AREA SET ERR The safety unit (NSU) detected that the range whose setting is not
(SAFETY) completed is selected.
Check the status of range selection signal and the setting of the safety
range.
4692 ENCODER BACKUP ERROR This alarm occurs when the voltage of encoder battery drops.
(SAFETY) Replace the encoder battery.
<Check point> CN03A connector and connection cables of NSU01
4693 READBACK PROC. ERROR An error was detected in the readback process at the data change
(SAFETY) between NSU01 and the programming pendant.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4694 SPEED MONITOR ERROR 1 The speed at TCP exceeded the safety speed. Lower the operation
(SAFETY) speed.
4695 SPEED MONITOR ERROR 2 The speed at the manipulator flange exceeded the safety speed.
(SAFETY) Lower the operation speed.
4703 OPERATION MODE ERROR An error was detected by the internal diagnosis of NSU.
Turn the power OFF and ON again.
If this alarm occurs frequently, replace NSU01 unit.
4704 STOPPING POS. MON. ERR NSU01 detected that the robot moved when the stop position
(SAFETY) monitoring function was enabled.
Check the status of GSIN signal, set GSIN signal to the short-circuit
status, then reset the alarm.
4705 SIGNAL COMPARISON Data inconsistency occurred in the duplicated monitoring of the safety
ERROR (SAFETY) signals. Check the safety signal cables, then turn the power ON
again.
<Check point> Connectors and cables of NSU01: CNMA, CNMB,
CNIFA, CNIFB, and CNSF 1 to 4
Subcode 1: Signal inconsistency in PPDSW
5: Signal inconsistency in YCU02 board A to D
3: Signal inconsistency in YCU02 board E to H
40: Signal inconsistency in GSIN signal
41: Signal inconsistency in GSIN signal

NOTE Investigation is required If the error occurs again. Contact

your Yaskawa representative.

„ 7 segment LED indication of safety unit NSU01

7 segment LED indication of safety unit NSU01 are as follows.

(Left side LED: CPU1, Right side LED: CPU2)
7 seg. LED indication Status
All Lit After power on
[0] to [C] Under boot up
[d] Normal status
[E] Error status

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DX100

When an error occurs in safety unit, 5 digits LED are indicated with 7 seg.
LED.
Each digit is indicated for 1.0sec and all turning off status is for 0.3sec.
Following is the example of “F001.” error.
Sequence 7 seg. LED indication Indication time Total time
1 [F] 1.0 [sec] 1.0 [sec]
2 Turning off 0.3 [sec] 1.3 [sec]
3 [0] 1.0 [sec] 2.3 [sec]
4 Turning off 0.3 [sec] 2.6 [sec]
5 [0] 1.0 [sec] 3.6 [sec]
6 Turning off 0.3 [sec] 3.9 [sec]
7 [1] 1.0 [sec] 4.9 [sec]
8 Turning off 0.3 [sec] 5.2 [sec]
9 [.] 1.0 [sec] 6.2 [sec]
10 Turning off 0.3 [sec] 6.5 [sec]

Meaning of 7 segment LED indication are as follows.

5 digits Error meaning Cause
indication
code
F001. Communication Data communication error occurs.Check cable
F002. error wiring and a terminator then power on again.

F003.
F004.
F010.
0100. CPU error CPU internal error occurs.
0200. Power on again.

0210.
0300.
0400.
0500.
0600.
0700.
0800.
0900.
0C00.
0D00.
1000.
1100.
1200.
1300.
1400.

NOTE Investigation is required If the error occurs again. Contact

your Yaskawa representative.

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9 Restrictions
DX100 9.1 Confirming Safety Range and Robot Position

9 Restrictions

9.1 Confirming Safety Range and Robot Position

This function also records parameters, files and other data in the safety
unit.
Therefore, this function cannot be used with a function that changes
parameters or files during playback.
• T axis endless function and external axis endless function
• PMT function
• Gun change function and group change function
• System for painting
• Tool file number change

9.2 Software Version of Machine Safety Unit

This function checks the signals from the functional safety unit in the
machine safety unit (YSU01-1E). The machine safety unit must have the
following version:
YSU01-1: 1.08-00 or later
If the YSU version is earlier than the above version, ALARM 510
“SOFTWARE VERSION UNMATCH [70]” occurs.

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9 Restrictions
DX100 9.3 Software Version of Functional Safety Unit

9.3 Software Version of Functional Safety Unit

The functional safety unit (NSU01) must have the following version:
NSU01: V3.00-00 or later
If the NSU version is earlier than the above version, ALARM 510
“SOFTWARE VERSION UNMATCH [70]” occurs.

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DX100 OPTIONS
INSTRUCTIONS
FOR FUNCTIONAL SAFETY UNIT (NSU01)

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan
Phone +81-93-645-7745 Fax +81-93-645-7746

YASKAWA America Inc. MOTOMAN Robotics Division

805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Nordic AB
Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden
Phone +46-480-417800 Fax +46-480-417999

YASKAWA Europe GmbH Robotics Division

Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Electric Korea Co., Ltd.

7F, Doore Bldg.; 24, Yeoido-Dong Youngdungpo-ku, Seoul, KOREA
Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

252/246, 4th Floor. Muang Thai-Phatra Office Tower II Rachadaphisek Road, Huaykwang Bangkok, 10320 Thailand
Phone +66-2-693-2200 Fax +66-2-693-4200

Shougang MOTOMAN Robot Co. Ltd.

No.7, Yongchang-North Road, Beijing E&T Development Area, China 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878

MOTOMAN Motherson Robotics Ltd.

Plot No.195-196, 1st Floor, Sec.4 IMT Manesar, Gurgaon 122050, Haryana
Phone +91-124-475-8500 Fax +91-124-414-8016

Specifications are subject to change without notice

for ongoing product modifications and improvements.

C Printed in Japan July 2010 10-07

YASKAWA ELECTRIC CORPORATION

MANUAL NO.

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