Fs100 Instructions Yaskawa

FS100
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
FS100 INSTRUCTIONS
FS100 OPERATOR’S MANUAL
FS100 MAINTENANCE MANUAL
YASKAWA ELECTRIC CORPORATION
MANUAL NO. RE-CTO-A218 6

FS100
MANDATORY
• This manual explains setup, diagnosis, maintenance, hardware,
etc. of the FS100 system. Read this manual carefully and be sure
to understand its contents before handling the FS100.
• General items related to safety are listed in chapter 1 “Safety” .
To ensure correct and safe operation, carefully read the chapter.
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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FS100
Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the FS100 .
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Indicates an imminent hazardous

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

NOTE to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION” .
iii
FS100
WARNING
• Confirm that no person is present in the manipulator’s operating
range and that you are in a safe location before:
– Turning ON the FS100 power.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the manipulator’s operating range
during operation. Always press the emergency stop button
immediately if there is a problem. The emergency stop button is
located on the right of the programming pendant.
• Observe the following precautions when performing teaching
operations within the manipulator’s operating range:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– 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.
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on the programming pendant
is pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop button does not function.
Fig. : Emergency Stop Button
• In the case of not using the programming pendant, be sure to

supply the emergency stop button on the equipment. Then before
operating the manipulator, check to be sure that the servo power is
turned OFF by pressing the emergency stop button.
Connect the external emergency stop button to the 5-6 pin and 16-
17 pin of the robot system signal connector (CN2).
• Upon shipment of the FS100, this signal is connected by a jumper
cable in the dummy connector. To use the signal, make sure to
supply a new connector, and then input it.
If the signal is input with the jumper cable connected, it does not
function, which may result in personal injury or equipment damage.
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FS100
WARNING
• 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 Button
TURN
CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If a problem is found, correct it and take all
other necessary actions immediately.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Return the programming pendant to a safe place after use.
If the programming pendant is inadvertently left on the manipulator, on
a fixture, or on the floor, the manipulator or a tool may collide with the
programming pendant during manipulator movement, which may result
in personal injury or equipment damage.
• Read and understand the Explanation of the Warning Labels 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 FS100 controller,
manipulator cables, the FS100 programming pendant (optional), and the
FS100 programming pendant dummy connector (optional).
In this manual, the equipment is designated as follows:
Equipment Manual Designation
FS100 controller FS100
FS100 programming pendant Programming pendant
Cable between the manipulator Manipulator Cable
and the controller
FS100 programming pendant Programming pendant
dummy connector dummy connector
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FS100
Descriptions of the programming pendant, buttons, and displays are

shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters printed on
Pendant them are denoted with [ ].
e.g. [ENTER]
Symbol Keys The keys which have a symbol printed on them
are not denoted with [ ] but depicted with a
small picture.
GO BACK
e.g. PAGE key PAGE

The cursor key is an exception, and a picture is
not shown.
Axis Keys “Axis keys” and “Numeric keys” are generic
Numeric 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.
TOOL SEL
COORD
e.g. SHIFT key SHIFT
+ COORD key
Mode Key Three kinds of modes that can be selected by
the mode key are denoted as follows:
REMOTE, PLAY, or TEACH
Button Three buttons on the upper side of the
programming pendant are denoted as follows:
HOLD button
START button
EMERGENCY STOP button
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
PC Keyboard The name of the key is denoted.
e.g. Ctrl key on the keyboard
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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FS100
Explanation of Warning Labels

The following warning labels are attached to the manipulator and FS100.
Fully comply with the precautions on the warning labels.
DANGER
• The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
• Failure to observe this caution may result in injury or damage to
equipment.
WARNING WARNING
Moving parts Do not enter
may cause robot
injury work area.
Refer to the manipulator manual for the warning label location.

• The following warning labels are attached to FS100.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to
equipment.
Heavy Object Warning NP
Top View
Electric Shock Warning NP
Front View Electric Shock Warning NP
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FS100 Contents
1 Safety .............................................................................................................................................. 1-1
1.1 For Your Safety.................................................................................................................. 1-1
1.2 Special Training ................................................................................................................. 1-2
1.3 Motoman Manual List......................................................................................................... 1-2
1.4 Personnel Safety................................................................................................................ 1-3
1.5 Motoman Safety................................................................................................................. 1-5
1.5.1 Installation and Wiring Safety ............................................................................... 1-5
1.5.2 Work Area Safety................................................................................................ 1-10
1.5.3 Operation Safety................................................................................................. 1-11
1.6 Notes for Moving and Transferring MOTOMAN............................................................... 1-15
1.7 Notes on MOTOMAN Disposal ........................................................................................ 1-16
2 Product Confirmation ...................................................................................................................... 2-1
2.1 Contents Confirmation ....................................................................................................... 2-1
2.2 Order Number Confirmation............................................................................................... 2-2
3 Installation ....................................................................................................................................... 3-1
3.1 Handling Procedure ........................................................................................................... 3-1
3.2 Place of Installation............................................................................................................ 3-2
3.3 Installation Location ........................................................................................................... 3-3
3.4 Installation Method............................................................................................................. 3-4
4 Connection ...................................................................................................................................... 4-1
4.1 Notes on Cable Connection ............................................................................................... 4-3
4.2 Power Supply..................................................................................................................... 4-4
4.2.1 Three-Phase Power Supply.................................................................................. 4-4
4.2.2 Noise Filter Installation ......................................................................................... 4-4
4.2.3 Leakage Breaker Installation ................................................................................ 4-5
4.2.4 Primary Power Supply Breaker Installation .......................................................... 4-6
4.3 Connection Methods .......................................................................................................... 4-8
4.3.1 Connecting Primary Power Supply ....................................................................... 4-8
4.3.2 Connecting Manipulator Cable ........................................................................... 4-10
4.3.3 Connecting Programming Pendant (Optional).................................................... 4-11
5 Turning ON and OFF Power Supply ............................................................................................... 5-1
5.1 Turning ON Main Power Supply ........................................................................................ 5-1
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FS100 Contents
5.1.1 Initial Diagnosis .................................................................................................... 5-2
5.1.2 When Initial Diagnosis Is Complete...................................................................... 5-4
5.2 Turning ON Servo Power................................................................................................... 5-5
5.2.1 During Play Mode ................................................................................................. 5-5
5.2.2 During Teach Mode .............................................................................................. 5-5
5.3 Turning OFF Power Supply ............................................................................................... 5-7
5.3.1 Turning OFF Servo Power (Emergency Stop)...................................................... 5-7
5.3.2 Turning OFF Main Power ..................................................................................... 5-7
6 Test of Program Operation ............................................................................................................. 6-1
6.1 Movement of Axes ............................................................................................................. 6-3
7 Security System .............................................................................................................................. 7-1
7.1 Protection Through Security Mode Settings ...................................................................... 7-1
7.1.1 Security Mode ...................................................................................................... 7-1

7.1.1.1 Changing Security Mode ......................................................................... 7-5
7.1.2 User ID ................................................................................................................. 7-7

7.1.2.1 Changing User ID.................................................................................... 7-7
8 System Setup.................................................................................................................................. 8-1
8.1 Home Position Calibration ................................................................................................. 8-2
8.1.1 Home Position Calibration .................................................................................... 8-4
8.1.2 Calibrating Operation............................................................................................ 8-5

8.1.2.1 Registering All Axes at One Time ........................................................... 8-5
8.1.2.2 Registering Individual Axes ..................................................................... 8-8
8.1.2.3 Changing Absolute Data ......................................................................... 8-9
8.1.2.4 Clearing Absolute Data ......................................................................... 8-10
8.1.3 Home Position of Robot...................................................................................... 8-12
8.2 Setting Second Home Position (Check Point) ................................................................. 8-13
8.2.1 Purpose of Position Check Operation ................................................................ 8-15
8.2.2 Procedure for Second Home Position Setting (Check Point) ............................. 8-17
8.2.3 Procedure After Alarm ........................................................................................ 8-19
8.3 Tool Data Setting ............................................................................................................. 8-21
8.3.1 Registering Tool Files......................................................................................... 8-21

8.3.1.1 Number of Tool Files ............................................................................. 8-21
8.3.1.2 Registering Coordinate Data ................................................................. 8-22
8.3.1.3 Registering Tool Angle .......................................................................... 8-24
8.3.1.4 Setting Tool Load Information ............................................................... 8-25
8.3.2 Tool Calibration .................................................................................................. 8-26
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FS100 Contents
8.3.2.1 Tool Calibration ..................................................................................... 8-26

8.3.2.2 Setting of Tool Calibration Method ........................................................ 8-27
8.3.2.3 Teaching of Calibration Point ................................................................ 8-28
8.3.2.4 Clearing Calibration Data ...................................................................... 8-34
8.3.2.5 Checking TCP ....................................................................................... 8-36
8.3.3 Automatic Measurement of Tool Load and Center of Gravity............................. 8-38

8.3.3.1 Description of Automatic Measurement of Tool Load and Center of Gravity
8-38
8.3.3.2 Measurement of Tool Load and Center of Gravity ................................ 8-38
8.4 ARM Control .................................................................................................................... 8-43
8.4.1 ARM Control ....................................................................................................... 8-43
8.4.2 ARM CONTROL Window ................................................................................... 8-43

8.4.2.1 Robot Setup Condition .......................................................................... 8-44
8.4.3 Setting Tool Load Information............................................................................. 8-48

8.4.3.1 Tool Load Information ........................................................................... 8-48
8.4.3.2 Calculating Tool Load Information......................................................... 8-49
8.4.3.3 Registering Tool Load Information ........................................................ 8-55
8.5 Work Home Position ........................................................................................................ 8-58
8.5.1 Description of Work Home Position .................................................................... 8-58
8.5.2 Setting Work Home Position............................................................................... 8-58

8.5.2.1 Work Home Position Window ................................................................ 8-58
8.5.2.2 Registering or Changing Work Home Position ...................................... 8-60
8.5.2.3 Returning to Work Home Position ......................................................... 8-61
8.5.2.4 Outputting Work Home Position Signal ................................................. 8-61
8.6 Interference Area ............................................................................................................. 8-62
8.6.1 Description of Interference Area ......................................................................... 8-62
8.6.2 Cubic Interference Area...................................................................................... 8-62

8.6.2.1 Description of Cubic Interference Area.................................................. 8-62
8.6.2.2 Cube Setting Method............................................................................. 8-63
8.6.2.3 Setting Operation .................................................................................. 8-64
8.6.3 Axis Interference Area ........................................................................................ 8-73

8.6.3.1 Description of Axis Interference Area .................................................... 8-73
8.6.3.2 Setting Operation .................................................................................. 8-74
8.6.4 Clearing Interference Area Data ......................................................................... 8-82
8.7 Shock Detection Function ................................................................................................ 8-84
8.7.1 Shock Detection Function................................................................................... 8-84
8.7.2 Shock Detection Function Setting....................................................................... 8-84

8.7.2.1 Shock Detection Level Setting............................................................... 8-84
8.7.2.2 Tool Load Information Setting ............................................................... 8-89
8.7.2.3 U-Arm Payload Setting .......................................................................... 8-89
8.7.2.4 Instruction of Shock Detection Function ................................................ 8-90
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FS100 Contents
8.7.2.5 Resetting Shock Detection Alarm.......................................................... 8-95
8.8 User Coordinate Setting .................................................................................................. 8-96
8.8.1 User Coordinates................................................................................................ 8-96

8.8.1.1 Definition of User Coordinates .............................................................. 8-96
8.8.1.2 Number of User Coordinate Files.......................................................... 8-96
8.8.2 User Coordinate Setting ..................................................................................... 8-97

8.8.2.1 Selecting User Coordinate File.............................................................. 8-97
8.8.2.2 Teaching User Coordinates................................................................... 8-98
8.8.2.3 Clearing User Coordinates .................................................................. 8-100
8.9 Releasing Overrun or Tool Shock Sensor ..................................................................... 8-101
8.10 Soft Limit Release Function......................................................................................... 8-103
8.11 All Limit Release Function ........................................................................................... 8-104
8.12 Instruction Level Setting .............................................................................................. 8-106
8.12.1 Setting Contents ............................................................................................. 8-106

8.12.1.1 Instruction Set ................................................................................... 8-106
8.12.1.2 Learning Function ............................................................................. 8-107
8.12.2 Setting Instruction Set Level........................................................................... 8-108
8.12.3 Setting Learning Function .............................................................................. 8-109
8.13 Setting Controller Clock ............................................................................................... 8-110
8.14 Setting Play Speed ...................................................................................................... 8-111
8.15 Numeric Key Customize Function ............................................................................... 8-113
8.15.1 Description of Numeric Key Customize Function ........................................... 8-113
8.15.2 Allocatable Functions ..................................................................................... 8-113

8.15.2.1 Key Allocation (EACH) ...................................................................... 8-113
8.15.2.2 Key Allocation (SIM).......................................................................... 8-114
8.15.3 Allocating Operation ....................................................................................... 8-115

8.15.3.1 Allocation Window ............................................................................. 8-115
8.15.3.2 Instruction Allocation ......................................................................... 8-116
8.15.3.3 Job Call Allocation............................................................................. 8-118
8.15.3.4 Display Allocation .............................................................................. 8-119
8.15.3.5 Alternate Output Allocation ............................................................... 8-120
8.15.3.6 Momentary Output Allocation ............................................................ 8-121
8.15.3.7 Pulse Output Allocation ..................................................................... 8-122
8.15.3.8 Group (4-bit/8-bit) Output Allocation.................................................. 8-123
8.15.3.9 Analog Output Allocation................................................................... 8-124
8.15.3.10 Analog Incremental Output Allocation ............................................. 8-125
8.15.4 Allocation of I/O Control Instructions .............................................................. 8-126
8.15.5 Execution of Allocation ................................................................................... 8-128

8.15.5.1 Executing Instruction/Output Control Allocation ................................ 8-128
8.15.5.2 Executing Job Call Allocation ............................................................ 8-128
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FS100 Contents
8.15.5.3 Executing Display Allocation ............................................................. 8-128

8.15.5.4 Executing I/O Control Allocation........................................................ 8-128
8.16 Changing Output Status............................................................................................... 8-129
8.17 Changing Parameter Setting........................................................................................ 8-131
8.18 File Initialization ........................................................................................................... 8-134
8.18.1 Initializing Job File .......................................................................................... 8-134
8.18.2 Initializing Data File......................................................................................... 8-135
8.18.3 Initializing Parameter File ............................................................................... 8-137
8.18.4 Initializing I/O Data.......................................................................................... 8-139
8.18.5 Initializing System Data .................................................................................. 8-141
8.19 Display Setting Function .............................................................................................. 8-143
8.19.1 Font Size Setting ............................................................................................ 8-143

8.19.1.1 Applicable Range for Font Size Change ........................................... 8-143
8.19.1.2 Settable Font Size ............................................................................. 8-143
8.19.1.3 Setting Font Size ............................................................................... 8-144
8.19.2 Operation Button Size Setting ........................................................................ 8-148

8.19.2.1 Applicable Range for Button Size Change ........................................ 8-148
8.19.2.2 Settable Button Size .......................................................................... 8-148
8.19.2.3 Setting Button Size ............................................................................ 8-149
8.19.3 Initialization of Screen Layout......................................................................... 8-153

8.19.3.1 Initializing Screen Layout................................................................... 8-153
8.19.4 Saving Layout ................................................................................................. 8-155
8.20 Hand Vibration Control Function.................................................................................. 8-156
8.20.1 Description of Hand Vibration Control Function.............................................. 8-156
8.20.2 Supported Models........................................................................................... 8-156
8.20.3 Setting Hand Vibration Control Function ........................................................ 8-157
8.21 Manual Brake Release Function.................................................................................. 8-159
8.21.1 Outline ............................................................................................................ 8-159
8.21.2 Manual Brake Release Procedure.................................................................. 8-160
8.21.3 Warning Message........................................................................................... 8-164
9 System Backup ............................................................................................................................... 9-1
9.1 System Backup with FS100 ............................................................................................... 9-1
9.1.1 Function Types of Data......................................................................................... 9-1

9.1.1.1 CMOS.BIN............................................................................................... 9-1
9.1.1.2 CMOSBK.BIN .......................................................................................... 9-1
9.1.1.3 CMOSxx.HEX.......................................................................................... 9-1
9.1.1.4 ALCMSxx.HEX ........................................................................................ 9-1
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FS100 Contents
9.1.2 Device .................................................................................................................. 9-2
9.2 Backup by CMOS.BIN ....................................................................................................... 9-3
9.2.1 CMOS.BIN Save................................................................................................... 9-4
9.2.2 CMOS.BIN Load................................................................................................... 9-6
9.3 Automatic Backup Function ............................................................................................... 9-9
9.3.1 Automatic Backup Function.................................................................................. 9-9

9.3.1.1 Objective ................................................................................................. 9-9
9.3.1.2 Outline ..................................................................................................... 9-9
9.3.2 Settings for Automatic Backup ........................................................................... 9-11

9.3.2.1 CompactFlash ....................................................................................... 9-11
9.3.2.2 USB Device of Main CPU Board ........................................................... 9-11
9.3.2.3 AUTO BACKUP SET Display................................................................ 9-12
9.3.2.4 FS100 Status and Automatic Backup.................................................... 9-16
9.3.2.5 Setting Examples .................................................................................. 9-18
9.4 Restoring Backup Data.................................................................................................... 9-19
9.4.1 Restoring Procedure........................................................................................... 9-19
9.5 Error List .......................................................................................................................... 9-22
9.5.1 Error Contents .................................................................................................... 9-22
9.6 Restoring FS100 Controller ............................................................................................. 9-23
9.6.1 Data Backup and Program Upload..................................................................... 9-23

9.6.1.1 Backup Medium Preparation ................................................................. 9-23
9.6.1.2 Data Backup.......................................................................................... 9-26
9.6.1.3 Program Upload .................................................................................... 9-29
9.6.2 Restoration Procedure........................................................................................ 9-31

9.6.2.1 Preparation of Programming Pendant................................................... 9-31
9.6.2.2 Preparation of Device for Writing System Program............................... 9-31
9.6.2.3 Writing System Program ....................................................................... 9-32
9.6.2.4 Writing Backup Data.............................................................................. 9-33
9.7 Error Indication ................................................................................................................ 9-35
10 Upgrade Function ....................................................................................................................... 10-1
10.1 Functional Overview ...................................................................................................... 10-1
10.2 Upgrade Procedure ....................................................................................................... 10-1
10.2.1 Confirmation of Software Version of Main CPU and Programming Pendant ... 10-1
10.2.2 Automatic Upgrade........................................................................................... 10-2
11 Modification of System Configuration ......................................................................................... 11-1
11.1 Addition of I/O Modules ................................................................................................. 11-1
11.2 Addition of Base and Station Axes ................................................................................ 11-4
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FS100 Contents
11.2.1 Base Axis Setting.............................................................................................. 11-6

11.2.1.1 Selection of Base Axis Type................................................................ 11-6
11.2.1.2 Connection Setting .............................................................................. 11-9
11.2.1.3 Axis Configuration Setting ................................................................. 11-12
11.2.1.4 Mechanical Specification Setting....................................................... 11-14
11.2.1.5 Motor Specification Setting................................................................ 11-16
11.2.2 Station Axis Setting......................................................................................... 11-18

11.2.2.1 Selection of Station Axis Type........................................................... 11-18
11.2.2.2 Connection Setting ............................................................................ 11-20
11.2.2.3 Axis Configuration Setting ................................................................. 11-22
11.2.2.4 Mechanical Specification Setting....................................................... 11-24
11.2.2.5 Motor Specification Setting................................................................ 11-27
12 FS100 Specification .................................................................................................................... 12-1
12.1 Specifications of FS100 ................................................................................................. 12-3
12.2 Functions of FS100........................................................................................................ 12-4
12.3 Specifications of Programming Pendant........................................................................ 12-6
12.4 Equipment Configuration of FS100................................................................................ 12-7
12.4.1 Arrangement of Units and Circuit Boards ......................................................... 12-7
13 Description of Units and Circuit Boards ...................................................................................... 13-1
13.1 CPU Unit ........................................................................................................................ 13-4
13.1.1 CPU Unit Configuration .................................................................................... 13-4
13.1.2 Circuit Board in CPU Unit ................................................................................. 13-5

13.1.2.1 Control Circuit Board
(JEPMC-CP3201R-E, Abbreviated as CPU-201R) ............................. 13-5
13.1.2.2 Power Relay Circuit Board (JEPMC-PSD3007R-E) ............................ 13-5
13.1.2.3 Circuit Board Rack (JEPMC-BUB3008R-E) ........................................ 13-5
13.2 Machine Safety Circuit Board (JAPMC-SF2300R-E, Abbreviated as SF2300) ............. 13-6
13.2.1 Machine Safety Circuit Board (JAPMC-SF2300R-E)........................................ 13-6
13.2.2 Connection for Robot System Input Signal....................................................... 13-7

13.2.2.1 Connection for Protection Stop (PSTOP) Signal ................................. 13-8
13.2.2.2 Connection for Safeguarding (Safety Plug) (SAFF) Signal ................. 13-9
13.2.2.3 Connection for External Emergency Stop (EXESP) Signal ............... 13-11
13.2.2.4 Connection for Emergency Stop Output (ESPOUT) Signal............... 13-12
13.2.3 Connection for External Axis Overrun ............................................................ 13-13
13.3 Converter Unit.............................................................................................................. 13-14
13.3.1 Converter Unit (CSTR-COB02AA).................................................................. 13-14
13.4 SERVOPACK............................................................................................................... 13-15
13.4.1 Description of Each Unit ................................................................................. 13-15

13.4.1.1 Mounting Base Unit (CSTR-MBB08AAA).......................................... 13-15
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FS100 Contents
13.4.1.2 PWM Amplifier Module (CSTR-SDB***AAA)..................................... 13-16

13.4.1.3 Major Axes Control Circuit Board (CSTR-IFBM3LB)......................... 13-16
13.4.1.4 Configuration of PWM Amplifier Module ........................................... 13-16
13.5 I/O Relay Circuit Board (CSTR-FBBCA8R03CAA)...................................................... 13-17
13.5.1 Connection for Direct-in Signal....................................................................... 13-18
13.6 User I/O Circuit Board for Japan and North America:
(JAPMC-IO2308R-E, Abbreviated as LIO-08R) ........................................................... 13-19
13.6.1 Connection for External Power Supply for Input/Output................................. 13-21
13.6.2 Protection by External Fuse ........................................................................... 13-22

13.6.2.1 Protection by External Fuse in Common Line of Output Signal ........ 13-22
13.6.3 Example of Servo ON Sequence Circuit from External Device ...................... 13-24
13.6.4 Example of Start Sequence Circuit from External Device .............................. 13-24
13.6.5 Input/Output Connector (CN1, CN2) .............................................................. 13-25

13.6.5.1 User Input/Output Connector (CN1).................................................. 13-25
13.6.5.2 System Input/Output Connector (CN2) ............................................. 13-25
13.6.6 Enabling External Hold ................................................................................... 13-29
13.7 User I/O Circuit Board for Europe: (JAPMC-IO2309R-E, Abbreviated as LIO-09R) ... 13-32
13.7.1 Connection for External Power Supply for Input/Output................................. 13-34
13.7.2 Protection by External Fuse ........................................................................... 13-35

13.7.2.1 Protection by External Fuse in Common Line of Output Signal ........ 13-35
13.7.3 Example of Servo ON Sequence Circuit from External Device ...................... 13-37
13.7.4 Example of Start Sequence Circuit from External Device .............................. 13-37
13.7.5 Input/Output Connector (CN1, CN2) .............................................................. 13-38

13.7.5.1 User Input/Output Connector (CN1).................................................. 13-38
13.7.5.2 System Input/Output Connector (CN2) ............................................. 13-38
13.7.6 Enabling External Hold ................................................................................... 13-42
xv
1 Safety
FS100 1.1 For Your Safety
1 Safety
1.1 For Your Safety

Robots generally have requirements which are different from other
manufacturing equipment, such as larger working areas, high-speed
operation, rapid arm movements, etc., which can pose safety hazards.
Read and understand the instruction manuals and related documents, and
observe all precautions in order to avoid the risk of injury to personnel and
damage to equipment.
It is the user’s responsibility to ensure that all local, state, and national
codes, regulations rules, or laws relating to safety and safe operating
conditions are met and followed.
MANDATORY
• Teaching maintenance of the robot must conform to:
– Industrial Safety and Health Law
– Enforcement Order of Industrial Safety and Health Law
– Ordinance of Industrial Safety and Health Law
Other related laws are:
– Occupational Safety and Health Act in USA
– Factory Act (Gewerbeordnung) in Germany
– Health and Safety at Work, etc. Act in UK
– EC Machinery Directive 98/37/EC
• Prepare
– Safety Work Regulations
based on concrete policies for safety management complying with
related laws.
• Observe
– Robots for Industrial Environments - Safety Requirements
(ISO 10218)
– Manipulating Industrial Robots - Safety (Japan only) (JIS B 8433)
for safe operation of the robot.
• Reinforce the
– Safety Management System
by designating authorized workers and safety managers, as well as
giving continuing safety education.
• Teaching and maintaining the robot are specified as “Hazardous
Operations” in the Industrial Safety and Health Law (Japan only).
Workers employed in these above operations are requested to attend
special training offered by YASKAWA.
1-1
1 Safety
FS100 1.2 Special Training
1.2 Special Training
MANDATORY
• Persons who teach or inspect the manipulator must undergo
required training before using the manipulator.
• For more information on training, inquire at the nearest YASKAWA
branch office.
The telephone numbers are listed on the back cover of this manual.
1.3 Motoman Manual List
MANDATORY
• It is important to have and be familiar with all manuals concerning
the MOTOMAN.
You should have the four manuals listed below:
– MOTOMAN- INSTRUCTIONS
– FS100 INSTRUCTIONS
– FS100 MAINTENANCE MANUAL
– FS100 OPERATOR’S MANUAL
Confirm that you have all these manuals on hand.
If any manuals are missing, contact your salesman from YASKAWA’s
local branch office.
The relevant telephone numbers are listed on the back cover.
1-2
1 Safety
FS100 1.4 Personnel Safety
1.4 Personnel Safety

The entire manipulator’s operating range is potentially dangerous.
All personnel working with the MOTOMAN (safety administration,
installation, operation, and maintenance personnel) must always be
prepared and “Safety First” minded, to ensure the safety of all personnel.
WARNING
• Avoid any dangerous actions in the area where the MOTOMAN is
installed.
Failure to observe this caution may result in personal injury due to
contact with the manipulator or peripheral equipment.
• Please take strict safety precautions by placing signs such as
“Flammable”, “High Voltage”, “Waiting”, and “Off-limits to
Unauthorized Personnel” in necessary areas in the factory.
Failure to observe this caution may result in fire, electric shock, or
personal injury due to contact with the manipulator and other
equipment.
• Strictly observe the following items:
– Always wear approved work clothes (no loose-fitting clothes).
– Do not wear gloves when operating the MOTOMAN.
– Do not allow underwear, shirts, or neckties to hang out from the
work clothes.
– Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety
shoes (with slip-proof soles), face shields, safety glasses, and gloves
as necessary.
Improper clothing may result in injury.
• Unauthorized persons should not approach the manipulator or
associated peripheral equipment.
Failure to observe this caution may result in personal injury due to
contact with the FS100, controller, workpiece, positioner, etc.
1-3
1 Safety
FS100 1.4 Personnel Safety
CAUTION
• Never forcibly move the manipulator axes.
Failure to observe this caution may result in personal injury or
equipment damage.
• Never lean on FS100 or other controllers, and avoid inadvertently

pushing buttons.
equipment damage due to unexpected movement of the manipulator.
START HOLD
REMOTE TEACH
PLAY
MULTI TOOL SEL GO BACK

LAYOUT COORD DIRECT PAGE AREA
OPEN
SELECT
ENTRY
MAIN SERVO
MENU SIMPLE ON ASSIST CANCEL
MENU READY !?
X- X+ SERVO ON
X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
Z- Z+ MANUAL SPEED Z- Z+
U- U+ T- T+
SLOW
E- E+ 8- 8+
SHIFT
INTER
LOCK 7SYNCRO 8 9 TEST
START SHIFT
SINGLE
ROBOT INFORM 4SMOV 5 6 BWD FWD

LIST
EX.AXIS USAGE 1 2 3 DELETE INSERT

TOOL ON TOOL ON
JOB
AUX
MOTION 0 TOOL OF TOOL OF
MODIFY ENTER
TYPE JOB
• Never allow unauthorized personnel to touch the FS100 during

operation.
1-4
1 Safety
FS100 1.5 Motoman Safety
1.5 Motoman Safety
1.5.1 Installation and Wiring Safety

Refer to the MOTOMAN- Instructions manual and FS100
Instructions for details on installation and wiring.
In planning installation, adapt an easy to observe arrangement to ensure
safety. Take safety into consideration when planning the installation.
Observe the following when installing the manipulator:
WARNING
• Select an area such as that described below to install the
manipulator:
Confirm that the area is large enough so that the fully extended
manipulator arm with tool will not reach a side wall, safeguarding, or
the controller.
Failure to observe this warning may result in personal injury or
Safeguarding
FS100
1000 mm or more
Front panel
1000 mm 1000 mm or more

or more
P-point maximum envelope

of manipulator
Maximum working envelope of manipulator

including tool or workpiece end
1000 mm or more
• Perform grounding in accordance with all applicable electrical

codes.
Failure to observe this warning may result in fire or electric shock.
CAUTION
• Operation of the crane, sling, or forklift should only be performed by
authorized personnel.
equipment damage.
1-5
1 Safety
CAUTION
• As a rule, the manipulator should be lifted by a crane.
– Make sure to fix the manipulator with the shipping bolts and
brackets, and lift it in the posture as shown in each manipulator’s
instruction manual.
– Use wire ropes threaded through the shipping bolts and brackets
or the attached eyebolts to lift up the manipulator.
Failure to observe this caution may cause the manipulator to fall, which
may result in personal injury or equipment damage.
• Lift, move, or install the FS100 by two or more persons.
– Approx. mass of FS100: 20 kg per unit
• Use a platform truck to carry the FS100.
– Avoid jarring, dropping, or hitting the FS100 during handling.
Failure to observe these cautions may cause the FS100 to fall down,
which may result in personal injury or equipment damage.
• If storing the manipulator temporarily before installation, make sure
to place it on a stable and flat surface, and take precautions to
prevent unauthorized personnel from touching it.
1-6
1 Safety
CAUTION
• Make sure that there is sufficient room for maintenance on the
manipulator, FS100, and other peripheral equipment.
Failure to observe this caution may result in personal injury during
maintenance.
Installation space for FS100 in horizontal position
Air Air
100
200
Air
150
Air
Air Air
100
200 150
Air
Unit: mm
Installation space for FS100 in vertical position
Air
200 150
Air
Air
100
Air
Air
Air
200
100
Air
150
Air
• To ensure safety, make sure to operate the controller from a

location where the manipulator is easily visible.
Operation by unauthorized personnel may result in personal injury or
equipment damage.
• Install the FS100 outside the safeguarding of the manipulator’s
safety enclosure.
equipment damage due to contact with the manipulator.
• Do not get on top of the FS100.
equipment damage.
1-7
1 Safety
CAUTION
• Install the manipulator using bolts of the size and type specified in
each manipulator’s instruction manual.
• After installation, fix the FS100 on the floor or base depending on its
way of installation by using the screws shown below.
Failure to observe this caution may cause the FS100 to fall, which may
result in personal injury or equipment damage.
Tapped hole M5
Tapped hole M5 (4 holes, thread depth: 5 mm)
(4 holes, thread depth: 5 mm)
15
15
170
170
15
15
20 380 20 20 380 20
Left Side View Front View Right Side View
• Up to 2 units of the FS100 can be stacked together on the flat floor.

Be sure to securely fix the upper and lower FS100s together by
using the screws on the left and right sides so that the FS100s do
not move apart.
Failure to observe this caution may cause the FS100 to drop or fall,
• Be familiar with the connection diagram before wiring the FS100,
and perform the wiring in accordance with the connection diagram.
equipment damage due to miswiring or unexpected movement of the
manipulator.
1-8
1 Safety
CAUTION
• Take precautions when wiring and piping between the FS100,
manipulator, and peripheral equipment. Run the piping, wiring, or
cables through a pit or use a protective cover, so that they are not
stepped on by personnel or run over by the forklift.
SAFETY
FIRST
Piping Lead
Cable Channnel
Operators and other personnel may stumble on exposed wiring or

piping. Cable damage may cause unexpected manipulator motion
resulting in personal injury or equipment damage.
1-9
1 Safety
1.5.2 Work Area Safety

Carelessness contributes to serious accidents in the work area.
To ensure safety, enforce the following precautions:
WARNING
• Install a safeguarding around the manipulator to prevent any
accidental contact with the manipulator while the power is ON.
Post a warning sign stating “Off-limits During Operation” at the
entrance of the enclosure. The gate of the safeguarding must be
equipped with a safety interlock. Be sure the interlock operates
correctly before use.
Failure to observe this warning may result in a serious accident due to
contact with the manipulator.
CAUTION
• Store tools and similar equipment in proper locations outside of the
enclosure.
Tools and loose equipment should not be left on the floor around the
manipulator, FS100, or welding fixture, etc., as injury or damage to
equipment can occur if the manipulator comes in contact with objects or
equipment left in the work area.
1-10
1 Safety
1.5.3 Operation Safety
MANDATORY
• Make sure to incorporate the robot system into the user’s system
which has lockout/tagout function.
That is to say, supply one or more devices to turn OFF the power
supply of the manipulator, servo track, and controller, and install
them outside the enclosure in which the manipulator and servo
track are installed. The devices must be able to be locked out and
tagged out.
Turning the power ON improperly during work may result in electric
shock or personal injury due to unexpected movement of the
manipulator.
WARNING
• Never exceed the rated capacity of the manipulator described in the
specifications section of the manipulator manual.
equipment damage.
• Teach jobs from outside the manipulator’s work area whenever
possible.
the safeguarding.
emergency.
Improper or unintentional manipulator operation may result in injury.
1-11
1 Safety
WARNING
• Before operating the manipulator, check that the SERVO ON lamp
on the programming pendant turns OFF when the emergency stop
button on the programming pendant or on the external control
device, etc. is pressed.
Personal injury or equipment damage may result if the manipulator
cannot be stopped in case of emergency.
1-12
1 Safety
WARNING
located on the top right of the programming pendant.
Emergency Stop Button
START HOLD
REMOTE TEACH
PLAY

OPEN
SELECT
ENTRY
MAIN SERVO
MENU SIMPLE ON ASSIST CANCEL
MENU READY !?
X- X+ SERVO ON
X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
U- U+ T- T+
SLOW
E- E+ 8- 8+
SHIFT
INTER
START SHIFT
SINGLE

LIST

TOOL ON TOOL ON
JOB
AUX
MODIFY ENTER
TYPE JOB
Programming Pendant

1-13
1 Safety
CAUTION
manipulator teaching. If a problem is found, correct it and
implement all other necessary measures immediately.
• Always return the programming pendant to its hook on the FS100
cabinet after use.
MANDATORY
• Persons operating or inspecting the manipulator should be trained
as required by applicable laws and company policies.
– Refer to chapter 1.2 “Special Training” at page 1-2.
1-14
1 Safety
FS100 1.6 Notes for Moving and Transferring MOTOMAN
1.6 Notes for Moving and Transferring MOTOMAN

When moving or transferring the Motoman, observe the following safety
precautions:
CAUTION
• Attach the instructions to the controller cabinet so that all users
have access to necessary manuals. See chapter 1.3 “Motoman
Manual List” at page 1-2 for a complete list of manuals.
If any manual is missing, contact your Yaskawa representative.
• If the warning labels on the manipulator and FS100 are illegible,
clean the labels so that they can be read clearly. Note that some
local laws may prohibit equipment operation if safety labels are not
in place.
Contact your Yaskawa representative if you require new warning
labels.
• When the MOTOMAN is transferred, it is recommended to check
with Yaskawa Engineering Co. which is listed on the back cover of
this manual.
Incorrect installation or wiring may result in personal injury or
equipment damage.
1-15
1 Safety
FS100 1.7 Notes on MOTOMAN Disposal
1.7 Notes on MOTOMAN Disposal
PROHIBITED
• Never modify the manipulator or FS100.
Failure to observe this may result in personal injury or equipment
damage due to fire, power failure, or operation error.
CAUTION
• When disposing of the MOTOMAN, follow the applicable national or
local laws and regulations.
• Anchor the manipulator well, even when temporarily storing it
before disposal.
Failure to observe this caution may result in injury due to the
manipulator falling down.
1-16
2 Product Confirmation
FS100 2.1 Contents Confirmation
2.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following four (five or six) items
(information for the content of optional goods is given separately):
• Manipulator
• FS100 (including spare parts)
• Manipulator cable (between manipulator and FS100)
• Complete set of manuals
• Programming pendant (optional)
• Programming pendant dummy connector (optional)
Fig. 2-1: Standard Four (Five or Six) Items
FS100
Programming
Pendant (optional)
START HOLD
REMOTE TEACH
PLAY
MULTI
LAYOUT
MAIN
TOOL SEL
COORD
ENTRY
DIRECT
OPEN
SERVO
GO BACK
PAGE
ASSIST
AREA
CANCEL
SELECT
Manipulator
MENU SIMPLE ON
MENU READY !?
X- X+ SERVO ON
X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
U- U+ T- T+
SLOW
E- E+ 8- 8+
SHIFT
INTER
START SHIFT
SINGLE

LIST

TOOL ON TOOL ON
JOB
AUX
MODIFY ENTER
TYPE JOB
Complete Set of Manuals
Programming Pendant
Dummy Connector (optional)
Manipulator Cable
2-1
FS100 2.2 Order Number Confirmation
2.2 Order Number Confirmation

Confirm that the order number pasted on the manipulator and FS100
match.
The order number plates are affixed to the figure below.
<Example>
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO. S78796-1
2-2
3 Installation
FS100 3.1 Handling Procedure
3 Installation
3.1 Handling Procedure
CAUTION
• Lift, move, or install the FS100 by two or more persons.
– Approx. mass of FS100: 20 kg per unit
• Use a platform truck to carry the FS100.
– Avoid jarring, dropping, or hitting the FS100 during handling.
Failure to observe these cautions may cause the FS100 to fall down,
The mass of the FS100 is indicated on the nameplate. The location and
content of the nameplate is shown below.
Unpack and move the FS100 by two or more persons.

Use a lifter to lift the FS100 up to or put it down from the rack.
Also, use a platform truck to carry the FS100.
If the FS100 must be manually carried, lifted up, or put down, two persons
must hold the bottom of the FS100 firmly.
3-1
3 Installation
FS100 3.2 Place of Installation
3.2 Place of Installation

The conditions listed below must be met before installing the FS100.
• Ambient temperature: 0° to +40°C during operation, and
-10 to +60°C during transportation and maintenance
• Humidity: 10 to 90%RH (non-condensing)
• Free from exposure to dust, soot, oil, or water
• Free from corrosive gas or liquid, or explosive gas or liquid
• Free from excessive vibration
(Vibration acceleration: 4.9 m/s2 [0.5G] or less)
• Free from large electrical noise (plasma)
3-2
3 Installation
FS100 3.3 Installation Location
3.3 Installation Location

• Install the FS100 outside of the manipulator’s operating range (out-
side of the safeguarding).
Fig. 3-1: Installation Location of FS100
Safeguarding
FS100
1000 mm or more
Front panel
1000 mm 1000 mm or more

or more
P-point maximum envelope

of manipulator
Maximum working envelope of manipulator

including tool or workpiece end
1000 mm or more
• Install the FS100 where the manipulator can be clearly seen during
operation and can be operated safely.
• Install the FS100 where its front panel can be operated easily.
• Install the FS100 where it can be easily taken out of the rack for
maintenance.
• Install the FS100 where it can be inspected easily. (Make sure to
secure the maintenance area.)
• Do not place any obstacles in the following:
• within 200 mm from the rear panel (air inlet and air outlet) of the
FS100
• within 150 mm from the front panel (air outlet) of the FS100
• within 100 mm from the side panel (air outlet) of the FS100
Air Air
100
200 150
Air
Back Front Front
Space required for FS100 in horizontal position
Air
200 150
Air
Air
100
Air
Air
Back Front Front
Space required for FS100 in vertical position
3-3
3 Installation
FS100 3.4 Installation Method
3.4 Installation Method
CAUTION
• The length of the fixing screws for the FS100 must be equal to or
shorter than the thickness of the metal fitting + 5 mm.
If the length exceeds the above, the components inside the FS100 may
be damaged.
– Required screw size: M5 (length: equal to or shorter than the
thickness of the metal fitting + 5 mm)
– Required screw material: mild steel or higher-strength material
• Fix all the 8 fixing points to install the FS100.
• The FS100 is free-standing type. Avoid jarring, dropping, or hitting
the FS100 when installing it.
Failure to observe these cautions may result in personal injury or
equipment damage.
• The FS100 is not dust-proof, drip-proof, or explosion-proof.
Be sure to use it in the environment free from explosive gas,
combustible gas, corrosive gas, condensation, and dust.
Failure to observe this caution may result in equipment damage.
• Do not get on top of the FS100.
equipment damage.
 Fixing Method
For the FS100 in horizontal position, fix it to the rack by using the tapped
holes on the right and left side of it.
Tapped hole M5 (8 holes)
FS100 in vertical position FS100 in horizontal position
Tapped hole M5 Tapped hole M5

(4 holes, thread depth: 5 mm) (4 holes, thread depth: 5 mm)
15
15
170
200
210
170
15
10
15
20 380 20 470 20 380 20
Left Side View Front View Right Side View
3-4
4 Connection
FS100
4 Connection
MANDATORY
tagged out.
manipulator.
WARNING
• The system must be grounded.
Failure to ground equipment may result in fire or electric shock.
• Before wiring, make sure to turn OFF the primary power supply, and
put up a warning sign. (e.g. DO NOT TURN THE POWER ON)
Failure to observe this warning may result in injury or electric shock.
• Do not touch any board inside the controller for five minutes after
turning OFF the power supply.
Capacitors inside the controller store electricity after power is turned
OFF. Exercise caution whenever handling circuit boards. Failure to
observe this warning may result in injury or electric shock.
• Power cannot be turned ON unless the door is closed. Interlocks
prevent power from being turned ON.
Failure to observe this warning may result in fire or electric shock.
• Any occurrence during wiring while the FS100 is in the emergency
stop mode is the user’s responsibility. Do an operation check once
the wiring is completed.
mechanical failure.
4-1
4 Connection
FS100
WARNING
• Wiring must be performed only by authorized personnel.
Incorrect wiring may result in fire or electric shock.
• Perform wiring in accordance with the rated capacity as specified in
the Instructions.
Incorrect wiring may result in fire or mechanical failure.
• Do not handle the circuit board directly by hand.
The IC board may malfunction due to electrostatics.
4-2
4 Connection
FS100 4.1 Notes on Cable Connection
4.1 Notes on Cable Connection

• The cables that connect the FS100 and peripheral devices are low
voltage circuits. Keep the cables away from the primary power cir-
cuit.
Do not run high voltage power lines in parallel and close to the
cables.
If high voltage power lines must be run in parallel and close to the
cables due to unavoidable circumstances, use metal ducts or con-
duit to avoid electrical interference. If the lines and cables must
cross, ensure that they cross in a perpendicular fashion.
• Confirm the numbers of the connectors and cables so that there is no
misconnection between the manipulator and FS100, and the FS100
and peripheral devices.
Misconnection may result in damage to electronic devices.
• Make sure to put the cables in the cable channel. Do not leave the
cables uncovered while performing wiring between the manipulator
and FS100, or FS100 and peripheral devices. Uncovered cables
may get in the way of people, forklifts, etc, and may result in an acci-
dent or cable damage.
Fig. 4-1: FS100 Cable Connection Diagram
SAFETY
FIRST
Piping Wiring
Cable channel
4-3
4 Connection
FS100 4.2 Power Supply
4.2 Power Supply
4.2.1 Three-Phase Power Supply
The power failure processing circuit operates when there is

a black out or drop in voltage, and the servo power turns
NOTE OFF.
Connect the power supply to a stable power source that is
not prone to power fluctuations.
The three-phase power supply comprising 200/220 VAC at 50/60 Hz is

used.
The single-phase power supply comprising 200/230 VAC at 50/60 Hz can
also be used for the following models:
• MHJ, MH5F, MH5LF, SIA5F, SIA10F, SIA20F, SDA10F, SDA20F
Fig. 4-2: Connection of Input Power
FS100
Circuit Power relay
CN1 protector Noise filter MC1
3-phase
200/220 VAC at 50/60 Hz To converter
1-phase* (main circuit)
200/230 VAC at 50/60 Hz
To converter
(control circuit)
* Models for 1-phase power supply:

MHJ, MH5F, MH5LF, SIA5F, SIA10F, SIA20F, SDA10F, SDA20F
4.2.2 Noise Filter Installation

Insert the three-phase noise filter into the primary station of the non-fuse
breaker filter if you hear noise coming from the power source.
Seal up each cable opening so that dust does not enter.
Fig. 4-3: Connection of Three-Phase Noise Filter
FS100
3-phase Circuit Power relay
noise filter Noise
CN1 protector filter MC1
3-phase
(main circuit)
1-phase
noise filter
1-phase*
(control circuit)

4-4
4 Connection
4.2.3 Leakage Breaker Installation

When connecting the leakage breaker to the controller power supply
wiring, use a leakage breaker which can handle high frequencies from the
FS100 inverter. Leakage breakers which cannot handle high frequencies
may malfunction.
Table 4-1: Example of High Frequency Leakage Breaker
Maker Model
Mitsubishi Electric Co., Ltd. NV series (manufactured since 1988)
Fuji Electric Co., Ltd. EG or SG Series (manufactured since 1984)
Even with a leakage breaker installed, there is still a possibility of some

high frequency current leakage from the FS100 inverter. However, this
current leakage presents no safety risks.
Fig. 4-4: Connection of the Leakage Breaker
Leakage FS100
breaker
Circuit Noise Power relay
3-phase CN1 protector filter MC1
200/220 VAC at 50/60 Hz
To converter
(main circuit)
To converter
(control circuit)
Leakage FS100
breaker
Circuit Noise Power relay
1-phase * CN1 protector filter MC1
200/230 VAC at 50/60 Hz
To converter
(main circuit)
(for 1-phase)
To converter
(control circuit)

4-5
4 Connection
4.2.4 Primary Power Supply Breaker Installation

Install the primary power supply breaker as shown below.
MANDATORY
tagged out.
manipulator.
Fig. 4-5: Installation of Primary Power Supply Breaker
Breaker Breaker Breaker
Controller for Power

FS100
Positioner Source
Table 4-2: FS100 Power Capacity, Cable Size, and Circuit Protector
Manipulator Power Cable size Capacity of
capacity (with Cabtyre cable (three circuit
(kVA) cores)) protector
(mm2) in FS100
(A)
MHJ 0.5 3.5 15
MH5F, MH5LF, MH6F, 1.0 3.5 15
SIA5F
MPP3, 1.5 3.5 15
MH12,
HP20F, SIA20F,
SDA10F
MPK2F 2.0 3.5 15
SDA20F 3.0 3.5 15
The maximum load value (payload, operation speed, and frequency, etc.)
is displayed.
However, the power capacity is different depending on work conditions.
4-6
4 Connection
When selecting the transformer, contact your Yaskawa representative.
The power capacity shown above is the continuous rating

value.
NOTE When the robot is rapidly accelerated, the power capacity of
several times the continuous rating value may be needed
instantly.
4-7
4 Connection
FS100 4.3 Connection Methods
4.3 Connection Methods

A connection diagram for the manipulator, manipulator cable, primary
power cable and programming pendant is shown below.
Fig. 4-6: Connection of Cables
Manipulator
Programming FS100
pendant cable
Manipulator cable
Mounting base
4.3.1 Connecting Primary Power Supply
 Power Cable Connection
1. Prepare the power cable by using the power connector of the FS100.
Refer to table 4-3(a) “For Three-Phase Power Supply (CN1)” and
table 4-3(b) “For Single-Phase Power Supply (CN1) (Only for MHJ,
MH5F, MH5LF, SIA5F, SIA10F, SIA20F, SDA10F, SDA20F)” for the pin
assignment of the FS100 power connector (CN1), and prepare the
power cable.
2. Confirm that the circuit protector of the FS100 is turned OFF.
– CN1 INPUT AC (for AC power input)
– Controller-side connector:
CE05-2A18-10PD-B (manufactured by DDK Ltd.)
– Cable-side connector (supplied with controller):
CE05-6A18-10SD-B-BSS (manufactured by DDK Ltd.)
Table 4-3(a): For Three-Phase Power Supply (CN1)
Pin No. Signal Name Description
A L1 AC input (L1/R-phase)
B L2 AC input (L2/S-phase)
C L3 AC input (L3/T-phase)
D P.E. Protective grounding
Table 4-3(b): For Single-Phase Power Supply (CN1)

(Only for MHJ, MH5F, MH5LF, SIA5F, SIA10F, SIA20F, SDA10F, SDA20F)
A L1 AC input (L1/R-phase)
B N.C. Not available
C L3 AC input (L3/T-phase)
D P.E. Protective grounding
4-8
4 Connection
3. Confirm that the primary power supply is turned OFF.

4. Connect the primary power supply cable.
WARNING
• Make sure to use the supplied connector for the primary power
supply connection.
• Tighten the cable clamp to prevent the cable from breaking.
Failure to observe these cautions may result in electric shock or
equipment failure.
(1) Grounding method:

– Perform grounding as countermeasures against noise and electric
shock.
– Follow the steps below:
I) Connect the ground wire to the D terminal of the FS100 power
connector (CN1).
II) Perform grounding in accordance with all relevant local and
national electrical codes. The size of ground wire must the
same as listed on table 4-2 “FS100 Power Capacity, Cable
Size, and Circuit Protector” at page 4-6.
NOTE The ground wire must be supplied by the user.
Fig. 4-7: Exclusive Grounding
CN1
FS100
Exclusive grounding
(ground resistance: 100 ohms or less)
Do not connect the ground wire with the wires for the elec-
tric power source, the welder, etc.
NOTE
If using metallic ducts, metallic conduits, or cable trays for
cabling, perform grounding in accordance with all relevant
governmental regulations.
4-9
4 Connection
4.3.2 Connecting Manipulator Cable

1. Unpack the manipulator cable. Connect the cable to the connectors
on the back side of FS100.
Fig. 4-8: Connection of Manipulator Cable
X11/1BC encoder cable
X21/2BC power cable
2. Connect the manipulator to the FS100.

– Confirm the number of the manipulator cable connector. Push the
manipulator cable connector into the manipulator-side connector
firmly, and tighten it securely.
4-10
4 Connection
4.3.3 Connecting Programming Pendant (Optional)

1. Connect the programming pendant cable to the connector connection
(X81) on the front panel of the FS100.
Fig. 4-9: Connection of Programming Pendant Cables
X81
Alignment mark
The manipulator, FS100, and programming pendant connections are now

complete.
If the programming pendant is not used, connect the pro-

NOTE gramming pendant dummy connector (CBC-FRC063-1) to
the connector connection (X81).
4-11
5 Turning ON and OFF Power Supply
FS100 5.1 Turning ON Main Power Supply
5.1 Turning ON Main Power Supply
WARNING
• Confirm that nobody is present in the manipulator’s operating range
when turning ON the FS100 power supply.
Failure to observe this warning may result in injury caused by
accidental contact with the manipulator.
Press the emergency stop button immediately if any problem occurs.
The emergency stop button is located on the right of the programming
pendant.
The main power supply is turned ON when the main power supply switch
on the front of the FS100 is turned to the “ON” position, and the initial
diagnosis and the current position setting begin.
Fig. 5-1: Turning ON Main Power Supply
Main power supply

switch
5-1
5.1.1 Initial Diagnosis

When the programming pendant is connected and the main power is
turned ON, the initial diagnosis is performed in the FS100.
1. Turn ON the power supply.
– The screen switches.
2. Press the {Connect to FS100} button.

– The following “Pendant installation check” window appears.
5-2
3. Grip the enable switch.

– The following “Pendant installation check” window appears.
4. Release the enable switch.

– If the connection confirmation of the programming pendant is
successful, the communication between the FS100 and the
programming pendant is established.
– If the connection confirmation of the programming pendant is failed,
the following window appears.
For details of the messages displayed during the communi-

cation connection between the FS100 and the programming
SUPPLE
pendant, and the network configuration of the programming
-MENT pendant when connecting the FS100 via network, refer to
chapter 1.2 Programming Pendant of “FS100 Operator’s
Manual”.
5-3
5.1.2 When Initial Diagnosis Is Complete

When the power supply is turned OFF, the FS100 saves all condition data,
including:
• Operation mode
• Called job (active job if the FS100 is in the play mode; edit job if the
FS100 is in the teach mode) and cursor position in the job.
Fig. 5-2: Initial Window
CAUTION
• Make sure that a system manager stores the key of the mode select
switch on the programming pendant.
After operation, the key should be removed and stored by the

system manager.
Also, the key or the mode select switch may be damaged if the
programming pendant is dropped with the key inserted.
5-4
FS100 5.2 Turning ON Servo Power
5.2 Turning ON Servo Power
5.2.1 During Play Mode

If the safety plug of safeguarding is turned OFF, the FS100 determines
that the worker’s safety is not secure.
• When the safeguarding is closed, press [SERVO ON READY] on the
programming pendant to turn ON the servo power supply. [SERVO
ON] lamp lights when the servo power is turned ON.
SERVO
ON
READY
Light
SERVO ON
NOTE When the safeguarding is open, the servo power supply

cannot be turned ON.
5.2.2 During Teach Mode

1. Press [SERVO ON READY] on the programming pendant to turn ON
the servo power supply. [SERVO ON] lamp will blink when the servo
power is turned ON.
SERVO
ON
READY
Blink
SERVO ON
2. The servo power is turned ON and [SERVO ON] lamp on the

programming pendant lights when the operator grips the Enable
Switch.
5-5
FS100 5.2 Turning ON Servo Power
Servo Power ON/OFF --- Enable Switch

When the operator grips the Enable Switch, the servo power
turns ON. However, if the operator squeezes the switch until
a “click” is heard, the servo power will turn OFF.
SUPPLE SERVO ON
-MENT
Release -> OFF Squeeze -> ON Squeeze tightly -> OFF
When performing emergency stop on the front door of the

FS100, programming pendant, or external signal, the servo
NOTE power-on operation from the Enable switch is cancelled.
When turning the power back ON, follow the steps 1 and 2
on the previous page.
5-6
FS100 5.3 Turning OFF Power Supply
5.3 Turning OFF Power Supply
5.3.1 Turning OFF Servo Power (Emergency Stop)

The manipulator cannot be operated when the emergency stop button is
pressed and the servo power supply is turned OFF.
• Press the emergency stop button and the servo power supply is
turned off.
The emergency stop button is located on the right side of the pro-
gramming pendant.
• The brake operates once the servo power supply is turned OFF, and
the manipulator can no longer operate.
The emergency stop mode can be operated at any mode. (Teach
mode, Play mode, Remote mode)
Programming pendant
• In the case of not using the programming pendant, be sure to supply

the emergency stop button on the equipment. Then before operat-
ing the manipulator, check to be sure that the servo power is turned
OFF by pressing the emergency stop button.
cable in the dummy connector. To use the signal, make sure to sup-
ply a new connector, and then input it.
5.3.2 Turning OFF Main Power

After turning OFF the servo power, turn OFF the main power.
1. Turn the main power switch on the front of FS100 to the “OFF“ position
to turn OFF the main power.
Main power supply

switch
5-7
6 Test of Program Operation
FS100
WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on the programming pendant
is pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop button does not function.
• Press the emergency stop button immediately if any problem
occurs. The emergency stop button is located on the right of the
programming pendant.
the safeguarding.
emergency.
Improper or unintentional manipulator operation may result in injury.
6-1
FS100
CAUTION
• Always return the programming pendant to the hook on the FS100
cabinet after use.
system manager.
6-2
FS100 6.1 Movement of Axes
6.1 Movement of Axes

Move each axis of the manipulator by pressing the axis keys on the
This figure illustrates each axis of motion in the joint coordinates.
Be sure to remove all items from the area before moving the
NOTE manipulator.
Refer to the INSTRUCTION MANUAL for the appropriate
position of the fixture.
Z+
T+
T-Axis Z-
T-
Z+
U-Axis U+
R-Axis X+ B-Axis
R+
Y+
B+ B-Axis Y+
Y- B+
B-
X+
R+ X-
R-
R-Axis X-
R- Z+
Y- T+
Z+
Z-
U-
B- T-Axis
U+
Z- U-Axis Z-
X- X+ X- X+ U-
T-
S- S+ R- R+
E-
E-Axis L-Axis
Y- Y+ Y- Y+ E+
Y-
L- L+ B- B+ Y- L-
L-
Y+
L-Axis Y+ L+
Z- Z+ Z- Z+
L+
U- U+ T- T+
X+
S+ S-Axis
E- E+ 8- 8+ S-Axis X- X+
X- S- S+
S-
Axis Keys 7-axis robot 6-axis robot
S Rotates main body R Rotates upper arm

X+
R+
X-
R-
X- X+
S- S+
L Moves lower arm forward/backward B Moves wrist up/down
Y+
B+
Y-
L-
Y+
L+
Y-
B-
E Rotates lower arm U Moves upper arm up/down T Rotates wrist

Z+
U+
E-
Z+
E+ T+
L Z- Z-
U- T-
6-3
FS100
System Up
7 Security System
FS100 7.1 Protection Through Security Mode Settings
7 Security System
7.1 Protection Through Security Mode Settings

The FS100 modes setting are protected by a security system. The
system allows operation and modification of settings according to operator
clearance. Be sure operators have the correct level of training for each
level to which they are granted access.
7.1.1 Security Mode

There are three security modes. Editing mode and management mode
require a user ID. The user ID consists of numbers and letters, and
contains no less than 4 and no more than 8 characters. (Significant
numbers and signs: “0 to 9”, “-”, “.”.
Table 7-1: Security Mode Descriptions

Security Mode Explanation
Operation Mode This mode allows basic operation of the robot (stopping,
starting, etc.) for people operating the robot work on the line.
Editing Mode This mode allows the operator to teach and edit jobs and
robot settings.
Management This mode allows those authorized to set up and maintain
Mode robot system: parameters, system time and modifying user
IDs.
7-1
7 Security System
Table 7-2: Menu and Security Mode (Sheet 1 of 3)

Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT
JOB JOB Operation Edit
SELECT JOB Operation Operation
CREATE NEW JOB1) Edit Edit
MASTER JOB Operation Edit
JOB CAPACITY Operation -
CYCLE Operation Operation
VARIABLE BYTE Operation Edit
INTEGER Operation Edit
DOUBLE Operation Edit
REAL Operation Edit
STRING Operation Edit
POSITION (ROBOT) Operation Edit
POSITION (BASE) Operation Edit
POSITION (ST) Operation Edit
LOCAL VARIABLE1) Operation -
IN/OUT EXTERNAL INPUT Operation Edit
EXTERNAL OUTPUT Operation Edit
UNIVERSAL INPUT Operation Operation
UNIVERSAL OUTPUT Operation Operation
SPECIFIC INPUT Operation -
SPECIFIC OUTPUT Operation -
RIN Operation -
CPRIN Operation -
REGISTER Operation Management
AUXILIARY RELAY Operation -
CONTROL INPUT Operation -
PSEUDO INPUT SIG Operation Management
NETWORK INPUT Operation -
NETWORK OUTPUT Operation -
ANALOG OUTPUT Operation -
SV POWER STATUS Operation -
TERMINAL Operation -
LADDER PROGRAM Management Management
I/O ALARM Management Management
I/O MESSAGE Management Management
1) Displayed when “LANGUAGE LEVEL” is “EXPANDED”.
7-2
7 Security System

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 Edit
USER COORDINATE Edit Edit
HOME POSITION Management Management
MANIPULATOR TYPE Management -
ANALOG MONITOR Management Management
OVERRUN&S-SENSOR Edit Edit
LIMIT RELEASE Edit Edit
ARM CONTROL Management Management
SHIFT VALUE Operation -
HAND VIBRATION CONTROL Operation Management
SYSTEM INFO VERSION Operation -
MONITORING TIME Operation Management
ALARM HISTORY Operation Management
I/O MSG HISTORY Operation Management
NETWORK SERVICE Management -
USER DEFINITION MENU Operation Operation
SECURITY Operation Operation
FD/CF LOAD Edit -
SAVE Operation -
VERIFY Operation -
DELETE Operation -
DEVICE Operation Operation
FOLDER Edit Management
7-3
7 Security System

DISPLAY EDIT
PARAMETER S1CxG Management Management
S2C Management Management
A1P Management Management
A2P Management Management
RS Management Management
S1E Management Management
SETUP TEACHING COND. Edit Edit
OPERATE COND. Management Management
OPERATE ENABLE Management Management
FUNCTION ENABLE Management Management
JOG COND. Management Management
PLAYBACK COND. Management Management
FUNCTION COND. Management Management
DISPLAYING COLOR COND. Edit Edit
DATE/TIME Management Management
GRP COMBINATION Management Management
RESERVE JOB NAME Edit Edit
USER ID Edit Edit
SET SPEED Management Management
KEY ALLOCATION Management Management
JOG KEY ALLOC. Edit Management
RES. START (CNCT) Management Management
AUTO BACK SET Management Management
WRONG DATA LOG Edit Management
ENERGY SAVING FUNCTION Edit Management
ENCODER MAINTENANCE Edit Management
DISPLAY CHANGE FONT Operation Operation
SETUP CHANGE BUTTON Operation Operation
INITIALIZE LAYOUT Operation Operation
CHANGE WINDOW PATTERN Operation Operation
GENERAL GENERAL DIAG. Operation Edit
7-4
7 Security System
7.1.1.1 Changing Security Mode

1. Select {SYSTEM INFO} under the main menu.
– The sub menu appears.
2. Select {SECURITY}.
– The selection window of security mode appears.
7-5
7 Security System
3. Press [SELECT].
– Select “SECURITY MODE”.
4. Input the user ID.

– The user ID input window appears.
The following user ID numbers are set by default.

SUPPLE • Editing Mode: [00000000]
-MENT
Management Mode: [99999999]
5. Press [ENTER].
– The input user ID is compared with the user ID of the selected
security mode.
– When the correct user ID is entered, the security mode is changed.
7-6
7 Security System
7.1.2 User ID
User ID is requested when Editing Mode or Management Mode is
operated.
Create the user ID with four to eight numbers and symbols: the numbers 0
to 9; the symbols “-” and “.”.
7.1.2.1 Changing User ID

In order to change the user ID, the FS100 must be in Editing Mode or
Management Mode. Higher security modes can make changes the user
ID of to lower security modes.
1. Select {SETUP} under the main menu.

2. Select {USER ID}.

– The USER ID window appears.
7-7
7 Security System
3. Select the desired ID.

– The character input line appears, and a message “Input current ID
no. (4 to 8 digits)” appears.
4. Input the current ID and press [ENTER].

– When the correct user ID is entered, a new ID is requested to be
input. “Input new ID no. (4 to 8 digits)” appears.
5. Input new ID and press [ENTER].

– User ID is changed.
7-8
8 System Setup
FS100
8 System Setup
WARNING
• Data related to the system’s basic functions can be changed.
However, improper change may result in a fatal error or failure of
the manipulator or the whole system.
Observe the following warnings to safeguard system settings:
• Change the data under the supervision of the administrator.
• Make sure to save and manage the data each time you create or
change it.
(Supply a USB memory stick or CompactFlash (CF) card
recommended by Yaskawa.)
• Yaskawa is not responsible for accidents or failures caused by
incorrect data settings.
8-1
8 System Setup
FS100 8.1 Home Position Calibration
8.1 Home Position Calibration
WARNING
• Before operating the manipulator, check that the SERVO ON LED is
turned OFF when the emergency stop button on the programming
pendant is pressed.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency.
the safeguarding.
emergency.
8-2
8 System Setup
CAUTION
cabinet after use.
system manager.
8-3
8 System Setup
8.1.1 Home Position Calibration
Teaching and playback are not possible before the comple-

tion of the home position calibration.
NOTE In a system with two or more manipulators, the home posi-
tion of all the manipulators must be calibrated before start-
ing teaching or playback.
Home position calibration is an operation in which the home position and

absolute encoder position coincide. Although this operation is performed
prior to shipment at the factory, the following cases require this operation
to be performed again.
• Change in the combination of the manipulator and FS100
• Replacement of the motor or absolute encoder
• Clearing stored memory (by replacement of the main CPU board,
weak battery, etc.)
• Home position deviation caused by hitting the manipulator against a
workpiece, etc.
To calibrate the home position, use the axis keys to calibrate the home
position mark on each axis so that the manipulator can take its posture for
the home position. There are two operations for home position calibration:
• All the axes can be moved at the same time: Recalibrate the home
position by moving all the axes
together if changing the combina-
tion of manipulator and circuit
board.
• Axes can be moved individually: Recalibrate the home position for
the individual axes that were
affected by the replacement, if
replacing the motor or absolute
encoder.
If the absolute data of its posture for the home position is already known,
set the absolute data again after completing home position registration.
Home Position
SUPPLE The home position is the pulse value “0” for each axis and its
-MENT
posture. See chapter 8.1.3 “Home Position of Robot” at
page 8-12.
8-4
8 System Setup
8.1.2 Calibrating Operation
NOTE Home position calibration screen is displayed only when the

security mode is set to the management mode.
8.1.2.1 Registering All Axes at One Time

1. Select {ROBOT} under the main menu.
2. Select {HOME POSITION}.

– The HOME POSITIONING window appears.
8-5
8 System Setup
3. Select {DISPLAY} under the menu.

– The pull-down menu appears.
– The same operation as the instruction 3 can also be performed by

selecting {PAGE}, and selection box appears.
4. Select the desired control group.

– Select the control group for HOME POSITIONING.
GO BACK
– The control group can also be selected by pressing page key PAGE
.
8-6
8 System Setup
5. Select {EDIT} under the menu.

6. Select {SELECT ALL AXES}.

– The confirmation dialog box appears.
7. Select {YES}.
– Displayed position data of all axes are registered as home position.
When {NO} is selected, the registration will be canceled.
8-7
8 System Setup
8.1.2.2 Registering Individual Axes

– Perform the steps 3 and 4 of the “Registering All Axes at One Time”
to select the desired control group.
4. Select the axis to be registered.
– Move the cursor to the axis to be registered, and select it.
– A confirmation dialog box appears.
5. Select {YES}.
– Displayed position data of the axis is registered as home position.
When {NO} is selected, the registration will be canceled.
8-8
8 System Setup
8.1.2.3 Changing Absolute Data

To change the absolute data of the axis when home position calibration is
completed, perform the following:
– Perform the step 3 and 4 of the “Registering All Axes at One Time”
4. Select the absolute data to be registered.
– The number can now be entered.
5. Enter the absolute data using the numeric keys.

6. Press [ENTER].
– Absolute data is modified.
8-9
8 System Setup
8.1.2.4 Clearing Absolute Data

– The sub menu appears
– Perform the step 3 and 4 of the “Registering All Axes at One Time”
3. Select {DATA} under the main menu.
– The pull-down menu appears
4. Select [CLEAR ALL DATA].

8-10
8 System Setup
5. Select {YES}.
– All absolute data are cleared.
– When {NO} is selected, the registration will be canceled.
8-11
8 System Setup
8.1.3 Home Position of Robot

In the case of HP20F, the home position is as follows:
B-axis center line angle against

U-axis center line (-0°)
U-axis angle against horizontal

line on the ground (-0°)
L-axis angle against vertical

line to the ground (-0°)
Other manipulator models have different positions. Always

NOTE refer to “MANIPULATOR INSTRUCTIONS” for the correct
manipulator model.
8-12
8 System Setup
FS100 8.2 Setting Second Home Position (Check Point)
8.2 Setting Second Home Position (Check Point)
WARNING
• Be aware of safety hazards when performing the position
confirmation of the second home position (check point).
When “OUT OF RANGE (ABSO DATA)” alarm occurs, abnormality of
the PG system may be a cause of the alarm. The manipulator may
operate in an unexpected manner, and there is a risk of damage to
equipment or injury to personnel.
• Before operating the manipulator, check that the SERVO ON LED is
turned OFF when the emergency stop button on the programming
pendant is pressed.
the safeguarding.
emergency.
8-13
8 System Setup
CAUTION
cabinet after use.
system manager.
8-14
8 System Setup
8.2.1 Purpose of Position Check Operation

If the absolute number of rotation detected at power supply ON does not
match the data stored in the absolute encoder the last time the power
supply was turned OFF, an alarm is issued when the controller power is
turned ON.
There are two possible causes of this alarm:
• Error in the PG system
• The manipulator was moved after the power supply was turned OFF.
If there is an error with the PG system, the manipulator may stall when
playback is started. If the absolute data allowable range error alarm has
occurred, playback and test runs will not function and the position must be
checked.
"OUT OF RANGE (ABSO DATA)" alarm occurs
Reset alarm
Turn ON servo power
Procedure After Alarm Occurs
1 Position confirmation
operation
2
Compare second home NG
position (check point)*
pulses with current
position pulses Alarm occurs again
OK
3 Correct defective axis
Replace PG system
Home position calibration
Position checking point
Playback possible
1 Position Check
After the “OUT OF RANGE (ABSO DATA)” alarm occurs, move to the
second home position using the axis keys and perform the position con-
firmation. Playback, test runs, and FWD operation will not function
unless “CONFIRM POSITION” is performed.
2 Pulse Difference Check
The pulse number at the second home position is compared with that at
the current position. If the difference is within the allowable range, play-
back is enabled. If not, the alarm occurs again.
• The allowable range pulse is the number of pulses per rotation of the
motor (PPR data).
• The initial value of the second home position is the home position
(where all axes are at pulse 0). The second home position can be
changed. For details, refer to chapter 8.2.2 “Procedure for Second
Home Position Setting (Check Point)” at page 8-17.
8-15
8 System Setup
3 Alarm Occurrence
If the alarm occurs again, there may be an error in the PG system.
Check the system. After adjusting the erroneous axis, calibrate the
home position of the axis, then check the position again.
• Home position calibration of all the axes at the same

time enables playback operations without having to
check the position.
• Sometimes in a system with a manipulator with no
brake, it is possible to enable playback without position
checking after the alarm occurs. However, as a
rule, always perform “CONFIRM POSITION”.
Under the above special conditions, the manipulator
NOTE moves as follows:
After the start, the manipulator moves at low speed (1/
10 of the maximum speed) to the step indicated by the
cursor. If it stops and restarts during this motion, the low
speed setting is retained until the step at cursor is
reached.
Regardless of cycle setting, the manipulator stops after
reaching to the step indicated by cursor. Starting the
manipulator again then moves it at the programmed
speed and cycle of the job.
8-16
8 System Setup
8.2.2 Procedure for Second Home Position Setting (Check Point)

Apart from the “home position” of the manipulator, the second home
position can be set up as a check point for absolute data. Use the
following steps to set the specified point.
If two or more manipulators or stations are controlled by one controller, the
second home position must be set for each manipulator or station.
2. Select {SECOND HOME POS}.

– The SECOND HOME POS window appears.
A message “Available to move to and modify specified point” is
displayed.
8-17
8 System Setup
GO BACK
3. Press the page key PAGE

, or select {PAGE} to display the selection
window for the control group.
– When there are two or more group axes, select the group axes to
which the second home position is to be specified.
4. Press the axis keys.

– Move the manipulator to the new second home position.
5. Press [MODIFY], then [ENTER].
– The second home position is changed.
8-18
8 System Setup
8.2.3 Procedure After Alarm
WARNING
• Be aware of safety hazards when performing the position
confirmation of the specified point.
Abnormality of the PG system may be the cause of the alarm. The
manipulator may operate in an unexpected manner, and there is a risk
of damage to equipment or injury to personnel.
If the “OUT OF RANGE (ABSO DATA)” alarm occurs:

• Reset the alarm;
• Turn ON the servo power;
then confirm the second home position. After the confirmation, if the PG
system is found to be the cause of the alarm, perform the necessary
operation, such as replacing the PG, etc.
The robot current position data when turning main power supply OFF and
ON can be confirmed in “POWER ON/OFF POS” window.
SUPPLE For details on the “POWER ON/OFF POS” window, refer to “8.7 Position
-MENT Data When Power is Turned ON/OFF” in FS100 MAINTENANCE MANUAL.

2. Select {SECOND HOME POS}.
– The SECOND HOME POS window appears.
8-19
8 System Setup
GO BACK

, or select {PAGE} to display the selection
window for the control group.
– When there are two or more group axes, select the group axes to
which the second home position is to be specified.
4. Press [FWD].
– TCP moves to the second home position. The robot moving speed is
set as selected manual speed.
5. Select {DATA} under the menu.
6. Select {CONFIRM POSITION}.
– A message “Home position checked” appears.
– Pulse data of the second home position and current pulse data are
compared. If the compared error is in allowed range, playback
operation can be done.
– If the error is beyond the allowed range, the alarm occurs again.
8-20
8 System Setup
FS100 8.3 Tool Data Setting
8.3 Tool Data Setting
8.3.1 Registering Tool Files
8.3.1.1 Number of Tool Files

There are 16 tool files numbered 0 to 15. Each file is called as a tool file.
TOOL FILE 0
TOOL FILE 15
Tool File Extension Function

Normally, one robot uses one kind of tool file. The tool file
extension function can change many tool files to be used by
SUPPLE one robot. Use the following parameter to set this function.
-MENT
S2C333: TOOL NO. SWITCHING (1: enabled; 0: disabled)
For more details, refer to “8 Parameter” in FS100 OPERA-
TOR’S MANUAL.
8-21
8 System Setup
8.3.1.2 Registering Coordinate Data

When the number input operation is used for registering the tool file, input
the TCP of the tool on the flange coordinates.
XF
YF
Tool
TCP
ZF

2. Select {TOOL}.
(1) Move the cursor to the number of the desired tool, and press
{SELECT} in the tool list window.
(2) The tool coordinate window of the selected number appears.
– In the tool coordinate window, the tool number can be changed by
GO BACK
pressing the page key PAGE

or selecting {PAGE}.
8-22
8 System Setup
– To switch the tool list window and the tool coordinate window, press
{DISPLAY}  {LIST} or {DISPLAY}  {COORDINATE DATA}.
3. Select the desired tool number.

4. Place the cursor in the part to register the desired coordinate data and
press [SELECT].
– The number is ready to input.
5. Input the coordinate data.
6. Press [ENTER].
– The coordinate data is registered.
<Setting Example>
260 mm 260 mm 260 mm
TCP TCP TCP

ZF 145 mm
ZF
Tool A Tool B Tool C
• In case of Tool A, B
• In case of Tool C
8-23
8 System Setup
8.3.1.3 Registering Tool Angle

The tool pose data is angle data which shows the relation between the
flange coordinates and the tool coordinates. The angle when the flange
coordinates are rotated to meet to the tool coordinates becomes an input
value. Clockwise toward the arrow is the positive direction. Register in the
order of Rz  Ry  Rx.
In the following case, register Rz=180, Ry=90, Rx=0
Flange XF
coordinates
YF
ZF
XT
Tool
coordinates YT
ZT

2. Select {TOOL}.
– In the same way as shown in Explanation 2, 3 in
chapter 8.3.1.2 “Registering Coordinate Data” at page 8-22,
display the desired tool coordinate window.
4. Select the desired coordinate axis to modify.
– First, select Rz.
5. Input the tool pose data.
– Input rotation angle around ZF of the flange coordinates.
XF
YF
ZF YF
X F Rz = 180
8-24
8 System Setup
6. Press [ENTER].
– The rotation angle of Rz is registered.
In the same way, register the angle of Ry, Rx.

Ry must be the input rotation angle around Y’F flange coordinates.
X F
ZF
Y F (Y F )
Z F
Ry = 90
– Rx must be the input rotation angle around X’F of flange

coordinates.
X F
YF
Z F Rx = 0
8.3.1.4 Setting Tool Load Information

The tool load information includes weight, a center of gravity position, and
moment of inertia at the center of gravity of the tool installed at the flange.
SUPPLE
For more details on the tool load information, refer to
-MENT chapter 8.4.3 “Setting Tool Load Information” at page 8-48.
8-25
8 System Setup
8.3.2 Tool Calibration
8.3.2.1 Tool Calibration

To ensure that the manipulator can perform motion type operations such
as linear and circular motion type correctly, accurate dimensional
information on tools such as hands must be registered and the position of
the TCP must be defined.
Tool calibration is a function that enables this dimensional information to
be registered easily and accurately. When this function is used, the TCP
is automatically calculated and registered in the tool file.
What is registered in tool calibration is the coordinates of the TCP and the
tool posture data in the flange coordinates.
XF
Flange <Flange coordinates>
coordinates XF: Vertically upward direction when the current
position on the T-axis of the manipulator is "0"
YF: Y-axis complementing XF and ZF
ZF ZF: Direction perpendicular to the flange face
XT
YT
YF
Tool
coordinates ZT
8-26
8 System Setup
8.3.2.2 Setting of Tool Calibration Method

There are three tool calibration methods, which are selected by setting
parameter.
S2C432: Designation of tool calibration method
0: Calibrates only the coordinates.
“Coordinates” calculated from 5 calibration teaching points is
registered in the tool file.
In this case “Tool Posture Data” is all cleared to be 0.
1: Calibrates only the posture.
“Tool Posture Data” calculated from the first calibration
teaching point is registered in the tool file.
In this case, “Coordinates” will not be changed. (the prior
value is maintained.)
2: Calibrates the coordinates and the posture.
“Coordinates” calculated from 5 calibration teaching points
and “Tool Posture Data” calculated from the first calibration
teaching point are registered in the tool file.
• In case of S2C432=0 (only coordinates is calibrated),

tool posture data is overwritten with 0.
(When the coordinates calculated from tool calibration is
registered in the tool file in which the tool posture data is
already registered, the tool posture data will be deleted.)
NOTE
• In case of S2C432=1 (only posture is calibrated), the
coordinates are maintained.
• In case of S2C432=1, 5 teaching points need to be
registered though only the first point is used for
calculation.
8-27
8 System Setup
8.3.2.3 Teaching of Calibration Point
 Teaching for defining coordinates

In order to calibrate coordinates, five different postures (TC1 to 5) must be
taught with the TCP as the reference point. The tool dimensions are
automatically calculated on the basis of these five points.
TC2
TC1 TC3
TC4
TCP
TC5
Each posture must be arbitrary. Accuracy may decrease when pose

setting is rotated in a constant direction
 Teaching for defining posture

The calibration of tool posture data is performed with the first calibration
teaching point (TC1).
Teach TC1 with Z-axis of the desired tool coordinates downward vertically
to the ground. (the Z-axis of the tool coordinates is parallel to the Z-axis of
the base tool and points to the opposite direction.)
Tool posture data is automatically calculated with this TC1 posture.
The X-axis of the tool coordinates is defined in the same direction as the
X-axis of the base coordinates.
Tool
TCP YT
Tool
XT Coordinates Z
Base
ZT Coordinates
X
Y
8-28
8 System Setup
In case of calibrating with S2C432=2, teach TC1 with Z-axis

of the desired tool coordinates downward vertically to the
ground. Then teach the other calibration teaching points
(TC2~TC5) with the all tool points meet at the TC1’s tool
point as shown in the figure below.
TC2 TC1
TC4
TC3
TC5
SUPPLE
-MENT If teaching in one place as the figure above is impossible
due to the interference of peripheral equipment and so on,
perform calibration of coordinates with S2C432=0 or 2, and
then change to S2C432=1, teach only TC1 in a different
position and register the tool posture data.
TC1
TC2
TC3 TC4 TC1
TC5
[S2C432 = 0 or 2 ]
[S2C432 = 1 ]
• There are 16 tool files numbered 0 to 15.

• In a basic system with one manipulator and one tool, the
SUPPLE
tool file for tool No. 0 is used.
-MENT
• If there is more than one tool, for example when using a
multihand, use the tool numbers in the order of 0, 1, 2,
etc.
8-29
8 System Setup

2. Select {TOOL}.
– In the same way as shown in the steps 2 and 3 of the
chapter 8.3.1.2 “Registering Coordinate Data” at page 8-22,
display the desired tool coordinate window.
4. Select {UTILITY} under the menu.

8-30
8 System Setup
5. Select {CALIBRATION}.
– The TOOL CALIBRATION window is shown.
6. Select the robot.

(1) Select the robot to calibrate.
(When the robot has already been selected or there is only one of
robot, this operation should not be performed.)
(2) Select “**” in the TOOL CALIBRATION window and select the
robot in the shown selection dialog box.
(3) The robot is set.
8-31
8 System Setup
7. Select “POSITION”.
– The selection dialog box is shown.
(1) Select the teaching point for calibration.
8. Move the manipulator using the axis key.

9. Press [MODIFY] and [ENTER].
– Taught position is registered.
Repeat 7 to 9 operation to teach TC1 to TC5.
“” denotes that teaching is completed and “” denotes that it is not
completed.
– To check the taught positions, call up the required window among

TC1 to TC5 and press [FWD]. The manipulator moves to the set
position.
– If there is a difference between the current position of the
manipulator and the shown position data, “TC” next to
“POSITION” in the window flashes.
8-32
8 System Setup
10. Select “COMPLETE”.

– Calibration data is registered in the tool file. Once the calibration is
completed, the tool coordinate window is displayed on the screen.
8-33
8 System Setup
8.3.2.4 Clearing Calibration Data

Before the calibration of a new tool, clear the robot information and
calibration data.
1. Select {DATA} under the pull-down menu.
2. Select {CLEAR DATA}.

– The confirmation dialog box is shown.
8-34
8 System Setup
3. Select {YES}.
– All data is cleared.
If tool angle data is required, input the data number in the

SUPPLE
tool coordinate window.
-MENT Refer to chapter 8.3.1.3 “Registering Tool Angle” at
page 8-24 for the operating instructions.
8-35
8 System Setup
8.3.2.5 Checking TCP

After registering the tool file, check if the TCP is correctly registered by
performing a TCP fixed operation like the one shown below, in any
coordinate system other than the joint.
Tool center
point
TOOL SEL
1. Press the COORD key COORD

.
– Select any coordinate system except “ JOINT” by pressing the

TOOL SEL
COORD key COORD

.
2. Select desired tool number.

–Show the tool coordinate window of the desired tool by pressing the
page key or selecting it in the tool list window.
GO BACK
PAGE
8-36
8 System Setup
3. Move the R, B, or T axes using the axis key.

– By pressing the axis keys for the R, B, and T axes, change the
manipulator pose without changing the TCP position.
If this operation shows a large TCP error, adjust the tool data.
TCP
SUPPLE
For details on the TCP fixed operation, see “2.3.7 Control
-MENT Point Operation” in FS100 OPERATOR’S MANUAL.
8-37
8 System Setup
8.3.3 Automatic Measurement of Tool Load and Center of Gravity
8.3.3.1 Description of Automatic Measurement of Tool Load and Center of Gravity

With this function, the user can register the load of tool and the position of
the tools center of gravity.
The tool load and the position of it’s center of gravity are measured and
registered in a tool file.
This function can be used where the manipulator is installed

NOTE level on the ground.
For the conditions required for manipulator installation, refer
to chapter 8.4 “ARM Control” at page 8-43.
8.3.3.2 Measurement of Tool Load and Center of Gravity

To measure the tool load and the center of gravity, move the manipulator
to its home position (with the U-, B- and R-axes horizontal to the ground)
and operate the U-, B- and T-axes.
U-axis
U+
R-axis
B-axis
B+ T-axis
T+
L-axis
U- Home Position
B- T- (with the U-, B- and R-axes
horizontal to the ground)
S-axis
Zero-degree installation on the ground
NOTE To correctly measure the tool load or the center of gravity,

remove the cables or wires connected to the tool.
8-38
8 System Setup

2. Select {TOOL}.
– The tool list window appears.
– The tool list window is called up only when the file extension function
is valid.
If the file extension function is invalid, the tool coordinate window appears.
8-39
8 System Setup

– Move the cursor to the desired number in the tool list window and
press [SELECT].
– The tool coordinate window of the selected number is shown.
– In the tool coordinate window, the number can be changed by
pressing the page key or selecting {PAGE}.
GO BACK
PAGE
– To switch the tool list window and the tool coordinate window, press
{DISPLAY}  {LIST} or {DISPLAY}  {COORDINATE DATA}.
4. Select {UTILITY} under the menu.
8-40
8 System Setup
5. Select {W.GRAV.POS MEASURE}.

– The window for the automatic measurement of the tool load and the
center of gravity is shown.
GO BACK

.
GO BACK
– In a system with several manipulators, use the page key PAGE

to
change the group to be controlled.
7. Press [FWD].
– Press [FWD] once, and the manipulator moves to the home position
(horizontal to the U-, B- and R-axes).
8. Press [FWD] again.
– Press [FWD] again, and measurement starts. Keep the button
pressed until measurement is completed.
The manipulator moves in the order listed below. Once measurement is
completed, “” changes to “”.
1 Measurement of the U-axis: U-axis home position +4.5 degrees 

-4.5 degrees
2 Measurement of the B-axis: B-axis home position +4.5 degrees 
-4.5 degrees
3 First measurement of the T-axis: T-axis home position +4.5 degrees
 -4.5 degrees
4 Second measurement of the T-axis: T-axis home position +60
degrees  +4.5 degrees  -4.5 degrees
• The speed during measurement automatically changes to

“Medium”.
• During the measurement, “HOME” or “U” blinks on the
screen.
SUPPLE • During the measurement, the [FWD] button has to be kept
-MENT
pressed. If the button is released during the measurement
or if it is released before “” changes into “”, the mea-
surement is aborted and the following message appears:
“Stopped measurement”
• The measurement starts again from the first home position.
8-41
8 System Setup
– When all the measurements are completed or when all the “”
marks have changed into “”, the measured data appears on the
screen.
9. Select “REGISTER”.
– The measured data is registered in the tool file, and the tool
coordinate window appears.
– Select “CANCEL” to call up the tool list window without registering
the measured data in the tool file.
8-42
8 System Setup
FS100 8.4 ARM Control
8.4 ARM Control
8.4.1 ARM Control

ARM Control, a control system originally developed by Yaskawa, achieves
an enhanced robot motion performance such as improved path accuracy
or reduced cycle time.
The moment of inertia and the gravity moment etc. of each axis are
calculated by the ARM control function, and FS100 controls robot motion
according to the result. It is necessary to set the robot setup condition and
the tool load information to request these accurately.
The robot setup condition is robot installation angle relative to ground and
the weight and a center of gravity position of the load installed at each part
of robot, etc.
The tool load information is weight, a center of gravity position, and
moment of inertia at the center of gravity, of the tool installed at the flange.
It is necessary to set these information correctly to do a better operation
control by the ARM control.
8.4.2 ARM CONTROL Window
CAUTION
• Correctly set the robot setup condition.
Make sure to avoid any mistake in setting the unit indication or
specifying positive and negative values. Failure to observe this caution
may lead to improper control of the manipulator, resulting in error
occurrence or short life span of speed reducer.
• Confirm the operation path of robot of each job when modifying
settings.
Set the robot setup condition when setting up the manipulator.
Confirm the operation path of manipulator of each job afterwards when
the setting should be modified after the installation.
Modifying the settings of the ARM control may slightly change the
operation path. To avoid injury or damage to machinery caused by
collision between tool and positioner, make sure to check the operation
path before executing a job.
8-43
8 System Setup
8.4.2.1 Robot Setup Condition

Fulfill the following robot setup condition to enable the ARM control.
• Robot installation angle
• S-head payload
• U-arm payload
 Robot installation angle

The angle of the manipulator installed relative to ground is set in ANGLE
REL. TO GROUND to calculate the gravity moment which loads to each
axis of the manipulator.
The robot installation angle sets how much X axis of the robot coordinates
has inclined with the ground around Y axis of the robot coordinates. The
direction of + in the U-axis operation from the home position posture of the
manipulator becomes direction of + of the robot installation angle.
Therefore, the robot installation angle for a vertical downward wall mount
specification becomes -90 degrees.
Robot
installation +
Angle
<Example>
0 degrees -90 degrees +90 degrees 180 degrees
If the robot installation angle is not correctly set, the manipulator cannot
be properly controlled. Therefore, make sure to set the value correctly,
paying special attentions to the direction “+” or “-”.
Only rotation angle around Y axis of the robot coordinates

can be set in the robot installation angle.
NOTE Contact Yaskawa representative when the robot is installed
to incline Y axis of the robot coordinates relative to the
ground.
8-44
8 System Setup
 S-head payload
Set the weight and the center of gravity position roughly when a device is
installed at the S-head.
It is not necessary to set these values when there is no installed load on
the S-head.
• WEIGHT (unit: kg)
The weight of the installed load is set.
It is not required to set a correct value, however, it is recommended
to set a value slightly larger than the actual load. (Round up the
value with each fraction between 0.5 to 1 kg.)
• X (from the S-axis), Y (from the S-axis) (unit: mm)
The center of gravity position of the installed load is set by the dis-
tance in the direction of X and the direction of Y from the S-axis cen-
ter here. It can be set with a rough value.
The direction of X and Y applies to the robot coordinates. The value
is set by a negative number when the position is in “-” direction.
Fig. 8-1: Load on S-Head (Top View)

-X
S axis center
-Y +Y
(X position, Y position)
+X
8-45
8 System Setup
 U-arm payload
Set the weight and the center of gravity position roughly when a device is
installed on the U-arm.
A standard value is set when shipping from the factory.
Set the weight in “0” if there is no installing equipment on the U-arm.
• WEIGHT (unit: kg)
The weight of the installed load is set.
It is not required to set a correct value, however, it is recommended
to set a value slightly larger than the actual load. (Round up the
value with each fraction between 0.5 to 1 kg.)
• X (from the U-axis), HEIGHT (from the U-axis) (unit: mm)
The center of gravity position of the installing load is set here. It
does not care by a rough value.
X (from the U-axis) is horizontal distance from the U-axis rotation
center to the center of gravity position of the load. Set negative num-
ber when there is mass side in the back from the U-axis rotation cen-
ter.
HEIGHT (from the U-axis) is height of the vertical direction from the
U-axis rotation center to the center of gravity position of the load.
Fig. 8-2: Load on U-Arm: Center of Gravity Position (Side View)
X (from U-axis)
(-) (+)
U-axis
rotation Center of gravity
center position
HEIGHT
(from U-axis)
NOTE ARM CONTROL window is displayed only when the secu-

rity mode is set to the management mode.
8-46
8 System Setup
2. Select {ARM CONTROL}.

– The ARM CONTROL window appears.
GO BACK

, or select {PAGE}.
– Select the desired control group when there are two or more group
axes.
4. Select the desired item.

5. Input the value and press [ENTER].
8-47
8 System Setup
8.4.3 Setting Tool Load Information
CAUTION
• Set the tool load information correctly.
The speed reducer longevity might decrease or the alarm might occur
when the tool load information is not set correctly.
To set the tool load information correctly, following message appears
when inputting the information.
“Input correct tool information. Using robot with wrong tool information
may result in premature failure of the robot.”
• Confirm the operation path of robot of each job which uses the tool
file after the tool load information is changed.
Set the tool load information before teaching the job after the tool is
installed.
Confirm the operation path of each job which uses the tool file when the
tool load information should be modified after teaching.
Modifying the tool load information may slightly change the operation
path. To avoid injury or damage to machinery caused by collision
between tool and positioner, make sure to check the operation path
before executing a job.
8.4.3.1 Tool Load Information

Tool load information includes weight, a center of gravity position, and
moment of inertia at the center of gravity of the tool installed at the flange.
These are registered in the tool file.
XF’ Moment of inertia around the Center of Gravity

Ix, Iy, Iz
XF
Ix
YF’
Iy
YF
ZF’
Iz
Weight:W
* Flange Coodinates
ZF XF: It is a direction right above when T axis
is 0 pulse position and the flange surface
of the manipulator turned to the front.
Center of Gravity Position YF: Y axis led by XF,ZF
( Xg, Yg, Zg ) ZF: Perpendicular direction from flange surface
8-48
8 System Setup
8.4.3.2 Calculating Tool Load Information
 Weight: W (Unit: kg)

The total weight of the installing tool is set.
It is not required to set a correct value, however, it is recommended to set
a value slightly larger than the actual load. (Round up the value with each
fraction between 0.5 to 1 kg.)
 Position of center of gravity: xg, yg, zg (Unit: mm)

The position of the center of gravity of the installed tool is set as the
position in the flange coordinates.
Since it is usually difficult to get a strict position of the center of gravity, it
can be set with a rough value. Presume and set a position of the center of
gravity roughly from outline of the tool.
Set the value when the position of the center of gravity of the installed tool
is clear from specifications, etc.
 Moment of inertia at the center of gravity: lx, ly, lz (Unit: kg·m2)

It is an moment of inertia of the tool at the position of the center of gravity.
The value is calculated around the each axis of the coordinates which is in
parallel to the flange coordinates and which home position is the position
of the center of gravity of the tool.
It is not required to set a correct value, however, it is recommended to set
a value slightly larger than the actual value.
This setting is used to calculate the moment of inertia which loads to each
axis of the manipulator. However, the moment of inertia at the center of
gravity does not need to be set when this data is small enough for the
moment of inertia calculated from weight and the position of the center of
gravity.
However, the setting is required when the moment of inertia of the tool is
large (as a rough guide, the tool is considered to be large when the tool
size is about more than 2-times the distance between the flange and the
center of gravity).
The size of the tool is not too big. The size of the tool is big.
Setting the moment of inertia at center Setting the moment of inertia at center
of gravity is not necessary. of gravity is necessary.
8-49
8 System Setup
Rough value of the moment of inertia at the center of gravity can be

calculated by the following methods.
• Method to approximate the entire tool in hexahedron or cylinder.
• Method to calculate from each weight and center of gravity position
of plural mass.
Refer to the following setting examples for details.
<Example 1>
For the example shown below, the center of gravity is set on the flange
coordinates assuming that the center of gravity is positioned slightly
inclined to the head from the center.
There is no need to set the moment of inertia at the center of gravity since
the size of the tool is not so large.
<Setting>
•W : 7.000 kg
• Xg : 100.000 mm
YF
• Yg : 0.000 mm
• Zg : 70.000 mm
Center of Gravity Position
= (100, 0, 70) • Ix : 0.000 kg •m2
XF
70
• Iy : 0.000 kg •m2
• Iz : 0.000 kg •m2
Total Weight
100
Approx. 6.3 [kg]
7.00 [kg] ZF
• The own moment of inertia calculation for hexahedron

and cylinder
The own moment of inertia of hexahedron and cylinder can
be calculated by the next expression when the center of
gravity is at the center.
Refer to the expression when the calculation of the moment
of inertia at the center of gravity.
Z Z
Ly
r
Lx
SUPPLE Iz Iz
-MENT Iy Lz
Ix Y H Y
Ix Iy
X
X Weight:W Weight: W
2 2 2
Ly + Lz 3 r + H2
Ix = *W Ix = Iy = *W
12 12
2
Lx 2 + Lz 2 r
Iy = *W Iz = *W
12 2
* Unit of Weight : [kg]
Lx 2 + Ly 2
Iz = *W * Unit of Length : [m]
2
12 * Unit of Ix, Iy, Iz : [kgm ]
8-50
8 System Setup
<Example 2>
It is necessary to set the moment of inertia at the center of gravity when
the entire size of the tool and workpiece is large compared to the distance
from the flange to the center of gravity position.
Calculate the moment of inertia at the center of gravity roughly from the
expression (refer to the forementioned supplement: “The own moment of
inertia calculation for hexahedron and cylinder”), by approximating the
entire tool in the shape of the hexahedron or the cylinder.
If the weight of held workpiece is greatly different, it is more effective to set
tool load information on each workpiece and to switch the tool on each
step according to the held workpiece. Set the tool load information in the
state to hold the heaviest workpiece when using the tools without
switching them.
500 YF
Weight of tool:
Approx. 55 kg.
ZF
250
XF Weight of workpiece:
Approx. 40 kg.
400
1000
Weight: W = 55 + 40 = 95
= approx. 100[kg]
Center of gravity: Position at flange right under 250mm almost
(Xg, Yg, Zg) = (0,0,250)
Moment of inertia at the center of gravity:
The hexahedron of 0.500 x 0.400 x 1.000[m] which encloses the
entire tool + workpiece is assumed.
By the expression to calculate the own moment of inertia of
hexahedron,
Ix = (Ly2 + Lz2 / 12) * W
= ((0.4002 + 1.0002) / 12) * 100 = 9.667 = approx. 10.000
Iy = (Lx2 + Lz2 / 12) * W = ((0.5002 + 0.4002) / 12) * 100 = 3.417
= approx. 3.500
Iz = (Lx2 + Ly2 / 12) * W = ((0.5002 + 1.0002) / 12) * 100 = 10.417
= approx. 10.500
<Setting>
•W : 100.000 kg
• Xg : 0.000 mm
• Yg : 0.000 mm
• Zg : 250.000 mm
• Ix : 10.000 kg.m2
• Iy : 3.500 kg.m2
• Iz : 10.500 kg.m2
8-51
8 System Setup
How to calculate “Center of gravity position” and “moment of inertia at center of grav-
ity” for plural mass
The center of gravity position and the moment of inertia at the center of gravity of the
entire tool can be calculated by the weight and the center of gravity position of each
mass when the tool can be thought that the tool consists of two or more big mass.
1. Divide the tool into some parts as the weight and the center of gravity position can
be roughly presumed. It is not necessary to divide in detail. The tool is
approximated in construction of rough parts.
2. Calculate the weight and the center of gravity position of the each parts on flange
coordinates. It does not care by a rough value. Calculate the own moments of
inertia of the big parts. (If parts are small, it is not necessary to calculate the own
moments of inertia. Refer to above-mentioned supplement: “The own moment of
inertia calculation for hexahedron and cylinder” for how to calculate the own
moment of inertia.)
wi : Weight of the i-th parts [kg]
(xi, yi, zi) : Center of gravity position of the i- th parts
(On flange coordinates) [mm]
Icxi, Icyi, Iczi : Own moments of inertia of the i-th parts [kg*m2]
SUPPLE 3. The center of gravity position of the entire tool is calculated by the next
-MENT
expression.
xg = {w1 * x1 + w2 * x2 + .... + wi * xi} / (w1 + w2 + .... + wi)
yg = {w1 * y1 + w2 * y2 + .... + wi * yi} / (w1 + w2 + .... + wi)
zg = {w1 * z1 + w2 * z2 + .... + wi * zi} / (w1 + w2 + .... + wi)
4. The moment of inertia at the center of gravity position of the entire tool is
calculated by the next expression.
Ix = {w1 * ((y1 - yg)2 + (z1 - zg)2) * 10-6 + Icx1} + {w2 * ((y2 - yg)2 +
(z2 - zg)2) * 10-6 + Icx2}
...................
+ {wi * ((yi - yg)2 + (zi - zg)2) * 10-6 + Icxi}
Iy = {w1 * ((x1 - xg)2 + (z1 - zg)2) * 10-6 + Icy1} + {w2 * ((x2 - xg)2 +
(z2 - zg)2) * 10-6 + Icy2}
.....................
+ {wi * ((xi - xg)2 + (zi - zg)2) * 10-6 + Icyi}
Iz = {w1 * ((x1 - xg)2 + (y1 - yg)2) * 10-6 + Icz1} + {w2 * ((x2 - xg)2 +
(y2 - yg)2) * 10-6 + Icz
.....................
+ {wi * ((xi - xg)2 + (yi - yg)2) * 10-6 + Iczi}
8-52
8 System Setup
<Example 3>
When there are two or more big mass as shown in the figure below,
perform:
1. Set the center of gravity position when the center of gravity position of
the entire tool is roughly understood, and set the moment of inertia at
the center of gravity calculated by approximating the entire tool in the
shape of hexahedron or cylinder. (It is enough in this setting usually.);
or
2. When weight in each mass and the center of gravity position are
understood, the center of gravity position and the moment of inertia at
the center of gravity of the entire tool can be calculated. (Refer to
forementioned supplement column: “How to calculate “Center of
gravity position” and “moment of inertia at the center of gravity” for
plural mass”.)
This example shows the calculation with the method 2.
(Top View)
Center of Flange
YF
YF
100
50 150
40
XF
Part 1
70 XF Part 2
(Part 1) (Part 2)
Part 1
Weight: w1 = 3 kg Weight: w2 = 6 kg
ZF Center of Gravity: Center of Gravity:
x1 = 100 mm x2 = 100 mm
y1 = 50 mm y2 = -150 mm
Part 2 z1 = 40 mm z2 = 70 mm
Weight: W = w1 + w2
= 3 + 6 = 9 = approx. 10[kg]
Center of gravity: Xg = (w1 * x1 + w2 * x2) / (w1 + w2)
= (3 * 100 + 6 * 100) / (3+6) = 100.0 [mm]
Yg = (3 * 50 + 6 * (-150)) / (3+6) = -83.333 [mm]
Zg = (3 * 40 + 6 * 70) / (3+6) = 60.0 [mm]
The moment of inertia at the center of gravity position:
Ix = {w1 * ((y1 - Yg)2 + (z1 - Zg)2) * 10-6 + Icx1}
+ {w2 * ((y2 - Yg)2 + (z2 - Zg)2) * 10-6 + Icx2}
= 3 * ((50 - (-83))2 + (40 - 60)2) * 10-6
+ 6 * (((-150) - (-83))2 + (70 - 60)2) * 10-6
= 0.082 = approx. 0.100
Iy = 3 * ((100 - 100)2 + (40 - 60)2) * 10-6
+ 6 * ((100 - 100)2 + (70 - 60)2) * 10-6
= 0.002 = approx. 0.010
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8 System Setup
Iz = 3 * ((100 - 100)2 + (50 - (-83))2) * 10-6

+ 6 * ((100 - 100)2 + ((-150) - (-83))2) * 10-6
= 0.080 = approx. 0.100
* The own moment of inertia (Icxi, Icyi, Iczi) of the part is disregarded in
this example, since each part is smaller than the entire tool.
<Setting>
•W : 10.000 kg
• Xg : 100.000 mm
• Yg : -83.333 mm
• Zg : 60.000 mm
• Ix : 0.100 kg.m2
• Iy : 0.010 kg.m2
• Iz : 0.100 kg.m2
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8 System Setup
8.4.3.3 Registering Tool Load Information

Tool load information is registered in the tool file.
2. Select {TOOL}.
– The tool coordinate list window appears.
– The tool coordinate list window appears only when TOOL NO.
SWITCH in the TEACHING CONDITION window is set to PERMIT.
– When TOOL NO. SWITCH in the TEACHING CONDITION window
is set to PROHIBIT, the tool window appears.

(1) Move the cursor to the number of the desired tool, and press
[SELECT] in the tool list window.
(2) The tool coordinate window of the selected number appears.
(3) Select the desired number in the tool coordinate window by press-
GO BACK
ing the page key PAGE

or clicking on the {PAGE} button.
(4) To switch the tool list window and the tool coordinate window,
press {DISPLAY}  {LIST} or {DISPLAY}  {COORDINATE
DATA}.
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8 System Setup
4. Select the desired item to register and input the value.

– The window can be scrolled with the cursor.
– The menu enters the state of a numeric input if the cursor is on the
desired item to register and the [SELECT] is pressed.
5. Press [ENTER].
– The input value is registered.
– The servo power is automatically turned OFF when editing the value
while the servo power is ON, followed by a message “Servo off by
changing data” displayed for three seconds.
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8 System Setup
• When the data setting is not done

It is considered that data is not set correctly in tool load
information in the following cases.
• When the weight (W) is “0”.
• When the center of gravity position (Xg, Yg, Zg) are all
“0”.
In these cases, the manipulator is controlled by the initial
setting values (vary according to each robot model) which
were set to the parameter before shipping.
Initial Setting Value:
Weight: W = Payload
Center of gravity position: (Xg, Yg, Zg) =
(0, 0, Allowed value of B-axis for payload)
In this case, when an actual tool load is not large enough,
the manipulator cannot sufficiently exert its function (speed
and acceleration or deceleration).
Especially, when operating the manipulator with the initial
setting value, a large difference in the load between the
actual tool load and the initial setting value may cause
vibrations in the manipulator motion. Thus, it is essential to
correctly set the tool load information for the proper opera-
NOTE tion of the manipulator.
Moreover, when the tool which an actual tool center of grav-
ity position greatly offsets in X-direction or Y-direction is
installed the generated moment by the tool cannot be com-
pensated.
To set the tool load information correctly, following message
appears when the playback operation is executed by using
the initial setting value.
“Using robot without setting tool info. may result in prema-
ture failure of the robot. Set W, Xg, Yg, and Zg in the tool
file.”
• Switch of the tool file
In case that two or more tool files are used, information on
an effective tool file is referred for tool load information used
by the ARM control at that time in according to switch tool
file.
Set the same value of tool load information in each tool file
when the tool file is switched to change only TCP (when
neither the weight nor the center of gravity position of the
entire tool installed in the flange is changed).
Moreover, set tool load information to the corresponding
tool file respectively when total weight and the center of
gravity position etc. of the tool is changed (when the system
which exchange the tool by automatic tool changer).
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8 System Setup
FS100 8.5 Work Home Position
8.5 Work Home Position
8.5.1 Description of Work Home Position

The work home position is a reference point for manipulator operations. It
prevents interference with peripheral device by ensuring that the
manipulator is always within a set range as a precondition for operations
such as starting the line. The manipulator can be moved to the set work
home position by operation from the programming pendant, or by signal
input from an external device. When the manipulator is in the vicinity of the
work home position, the work home position signal turns ON.
8.5.2 Setting Work Home Position
8.5.2.1 Work Home Position Window

2. Select {WORK HOME POS}.

– The WORK HOME POSITION window is appears.
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8 System Setup
GO BACK

.
– When two or more manipulators exist in the system, use the page
GO BACK
key PAGE
to change the control group, or click on {PAGE} to select
the desired control group.
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8 System Setup
8.5.2.2 Registering or Changing Work Home Position

1. Press the axis keys in the work home position display.
– Move the manipulator to the new work home position.
2. Press [MODIFY], [ENTER].
– New work home position is set.
When the work home position is changed, the cubic interfer-

ence area is automatically set as cube 64 and 63 in the
base coordinate system.
• The cube 64 is for ROBOT1
• The cube 63 is for ROBOT2
The work home position cube is a cube like the one shown
in the figure below; the length of its sides is determined by a
parameter setting made by the user (units: µm).
By changing this parameter setting, the size of the cube
can be changed.
NOTE Fig. 8-3: S3C1097: Length of Each Side of Work Home Position Cube (µm)
P
a a
2
a
a 2
2
Specify whether “COMMAND POSITION” or “FEEDBACK
POSITION” is to be set to the work home position cube sig-
nal’s CHECK MEASURE in the interference area settings.
“COMMAND POSITION” is the default setting.
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8 System Setup
8.5.2.3 Returning to Work Home Position
 In the teach mode

1. Press [FWD] in the work home position display.
– The manipulator moves to the new work home position. The moving
speed is the selected manual speed.
 In the play mode

When the work home position return signal is input (detected at leading
edge), the TCP of the manipulator is moved to the work home position.
When the manipulator moves, a message “Manipulator is moving to work
home position” is displayed. In this case, the move interpolation is MOVJ,
and the speed applied is the one set in the parameters. (S1CxG56; units:
0.01%.)
8.5.2.4 Outputting Work Home Position Signal

This signal is output any time the current position of the TCP of the
manipulator is checked and found to be within the work home position
cube.
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FS100 8.6 Interference Area
8.6 Interference Area
8.6.1 Description of Interference Area

The interference area is a function that prevents interference between
multiple manipulators or the manipulator and peripheral device.
The areas can be set up to 64 areas. There are two types of interference
areas, as follows:
• Cubic Interference Area
• Axis Interference Area
The FS100 judges whether the TCP of the manipulator is inside or outside
this area, and outputs this status as a signal.
8.6.2 Cubic Interference Area
8.6.2.1 Description of Cubic Interference Area

This area is a rectangular parallelepiped which is parallel to the base
coordinate, robot coordinate, or user coordinate.
The FS100 judges whether the current position of the manipulator’s TCP
is inside or outside this area, and outputs this status as a signal.
Robot coordinate
Z-axis
Cubic
interference
area
Cubic
interference
User coordinates area
Z-axis
X-axis
Y-axis Y-axis
X-axis
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8 System Setup
8.6.2.2 Cube Setting Method

There are three ways to set cubic a interference area as described in the
following sections:
1. Enter the maximum and minimum values for the cube coordinates.
Z-axis
Maximum
value
Cubic
interference X-axis
area axis
Minimum
value
Y-axis
2. Move the manipulator at the maximum and minimum value positions of

the cube corner using the axis keys.
Z-axis
Maximum
value
X-axis
Minimum
value
Y-axis
3. After entering the lengths of the three faces of the cube (axial length)
using the Numeric keys, move the manipulator to the center point of
the cube using the axis keys.
Z-axis
Y X
Z X-axis
Center
point
Y-axis
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8 System Setup
8.6.2.3 Setting Operation

2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window is shown.
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3. Select the desired cube number.

GO BACK
– Select the desired cube number with the page key PAGE
or by
number input.
– When selecting the cube number by number input, select {PAGE} to
input the desired signal number.
4. Select “METHOD”.
– ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are
displayed alternately every time [SELECT] is pressed. If “CUBIC
INTERFERENCE” is selected, the window is changed.
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5. Select “CONTROL GROUP”.

– A selection dialog box appears.
(1) Select the desired control group.
6. Select “REF COORDINATES”.

– A selection dialog box appears.
(1) Select the desired coordinate.
(2) If the user coordinates are selected, the number input line is dis-
played. Input the user coordinate number and press [ENTER].
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7. Select “CHECK MEASURE”.

– Press [SELECT] to alternate between “COMMAND POSITION” and
“FEEDBACK POSITION”.
To stop the manipulator movement using the interference

signal (use the cube interference signal for mutual interfer-
ence between robots), set CHECK MEASURE to “COM-
MAND POSITION”.
NOTE When set to the “FEEDBACK POSITION”, the manipulator

decelerates to a stop after entering the interference area.
When using the interference signal to inform an external
unit of the actual manipulator position, use the “FEEDBACK
POSITION” setting to enable the signal output in more
accurate timing.
8. Select “ALARM OUTPUT”.

– Press [ENTER] to alternate between “ON” and “OFF”.
– When “ALARM OUTPUT” is “ON”, the alarm below occurs if the

manipulator’s TCP enters the set interference area, and the
manipulator stops its motion immediately.
AL4902: CUBE INTERFERENCE (TCP)
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 Number input of cube coordinates

(1) Press [SELECT] to alternate between “MAX/MIN” and “CENTER
POS”.
(2) Select “MAX/MIN”.
2. Input number for “MAX” and “MIN” data and press [ENTER].
– The cubic interference area is set.
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8 System Setup
 Teaching corners
POS”.
2. Press [MODIFY].
– The message “Teach max./min. position” appears.
3. Move the cursor to “<MAX>” or “<MIN>”.

– Move the cursor to “<MAX>” when changing the maximum value,
and move cursor to “<MIN>” when changing the minimum value.
The cursor only moves to either “<MIN>” or “<MAX>” at this time.
4. Move the manipulator using the axis keys.
– Move the manipulator to the maximum or minimum position of the
cube using the axis keys.
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8 System Setup
5. Press [ENTER].
– The cubic interference area is registered.
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8 System Setup
 Number input of cube side length and teaching center

POS”.
(2) Select “CENTER POS”.
2. Input data for length of the cube, then press [ENTER].

– The length is set.
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8 System Setup
3. Press [MODIFY].
– The message “Move to center point and teach” appears. The cursor
only moves to either “<MIN>” or “<MAX>” at this time.

– Move the manipulator to the center point of the cube using the axis
keys.
5. Press [ENTER].
– The current position is registered as the center point of the cube.
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8 System Setup
8.6.3 Axis Interference Area
8.6.3.1 Description of Axis Interference Area

The axis interference area is a function that judges the current position of
the each axis and outputs a signal. Once the maximum and minimum
values have been set at the plus and minus sides of the axis to define the
working range, a signal indicating whether the current position of the axis
is inside or outside this range is output. (ON: inside, OFF: outside)
Fig. 8-4: Axis Interference Signal for Station Axis
Max value 0 Min value
+ side - side
ON
OFF
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8 System Setup
8.6.3.2 Setting Operation

– The INTERFERENCE AREA window appears.
3. Select the desired interference signal number.

– Select the desired interference signal number using the page key
GO BACK
PAGE
or by number input.
– When selecting the desired interference signal number by number

input, select {PAGE} to input the desired signal number.
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8 System Setup
– Press [SELECT] to alternate between ”AXIS INTERFERENCE” and
“CUBIC INTERFERENCE”. In this case, select “AXIS
INTERFERENCE”.
5. Select “CONTROL GROUP”.

– A selection box appears. Select the desired control group.
6. Select “CHECK MEASURE”.

– Press [SELECT] to alternate between “COMMAND POSITION” and
“FEEDBACK POSITION”.
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8 System Setup
7. Select “ALARM OUTPUT”.
– Press [SELECT] to alternate between “ON” and “OFF”.

– When “ALARM OUTPUT” is “ON”, the alarm below occurs if the
manipulator’s TCP enters the set interference area, and the
manipulator stops its motion immediately.
AL4901: AXIS INTERFERENCE
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8 System Setup
 Number input of axis data coordinates

POS”.

2. Input number for “MAX” and “MIN” data and press [ENTER].
– The axis interference area is set.
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8 System Setup
 Teaching corners
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
2. Press [MODIFY].
– A message “Teach max./min. position” appears.
3. Move the cursor to “<MAX>” or “<MIN>”.

– Move the cursor to “<MAX>” when changing the maximum value,
and move cursor to “<MIN>” when changing the minimum value.
– Move the manipulator to the maximum or minimum position of the
cube using the axis keys.
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8 System Setup
5. Press [ENTER].
– The cubic interference area is registered.
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8 System Setup
 Number input of center position (WIDTH) and teaching center

(1) Press [SELECT] to alternate “MAX/MIN” and “CENTER POS”.
(2) Select “CENTER POS”.
2. Input number for “WIDTH” data and press [ENTER].

– “WIDTH” is set.
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8 System Setup
3. Press [MODIFY].
– A message “Move to the center point and teach” appears.

– Move the manipulator to the center position of the cube using the
axis keys.
5. Press [ENTER].
– The center position of the cube is registered.
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8 System Setup
8.6.4 Clearing Interference Area Data

– The INTERFERENCE AREA window is shown.
3. Select interference signal to be cleared.

(1) Select the desired interference signal number to be cleared using
the page key or by number input.
GO BACK
PAGE
(2) When selecting the desired interference signal number by number

input, select {PAGE} to input the desired signal number.
4. Select {DATA} under the menu.
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8 System Setup

6. Select {YES}.
– All the data of the interference signal number are cleared.
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8 System Setup
FS100 8.7 Shock Detection Function
8.7 Shock Detection Function
8.7.1 Shock Detection Function

The shock detection function is a function to decrease damage due to the
collision by stopping the manipulator without any external sensor when
the tool or the manipulator collide with peripheral device.
When the shock is detected either in teach mode or in play mode, the
manipulator is stopped immediately.
WARNING
• This function does not completely avoid damage to the peripheral
devices; moreover, it does not guarantee the user’s safety.
• Make sure to supply the safety measures such as the safeguarding
etc. Refer to chapter 1 “Safety” to chapter 6 “Test of Program
Operation” for the safety measures in details.
Failure to observe this warning may result in Injury or damage to
machinery caused by contact with the manipulator.
8.7.2 Shock Detection Function Setting

At the factory default setting, the threshold value is set to detect a collision
without a miss even when the manipulator is operating at the maximum
speed, on the assumption that the tool file is correctly set. To detect a
collision during normal operation, check the following points:
• The tool’s load and moment do not exceed the rated values.
• The actual tool load and the tool file setting value are the same.
• The U-arm payload information and the set weight of U-arm payload
in the ARM CONTROL window are the same.
In addition, detection sensitivity can be decreased for only a specific
section where a contact task is performed.
The detection sensitivity is set by setting the detection level.
8.7.2.1 Shock Detection Level Setting

The shock detection level is set in the shock detection level set file.
The shock detection level set file are nine condition files as following
figure.
• Condition numbers 1 to 7 are used when the detection level is
changed in a specific section in play mode.
• Condition number 8 is used as standard in play mode: this function is
operated by the detection level set in this file during playback opera-
tion.
• Condition number 9 is for teach mode: the shock detection function
applies the detection level set here when the manipulator is operated
in teach mode.
• Condition numbers 1 to 8 are set for each axis and condition 9 is set
for each group.
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8 System Setup
The detection level is changed by a job instruction SHCKSET.

• After the instruction is executed, the shock will be detected by the
specified detection level when the condition number is specified with
the SHCKSET instruction.
• The detection level is returned to standard level when the SHCKRST
instruction is executed.
Setting in the specific section
in play mode
(Condition number 1 to 7)
Standard used
for play mode
(Condition
number 1 to 8)
Shock Detection
Level File
Condition number 1 Used for teach mode

(Condition number 9)
Condition number 7
Condition number 8
Condition number 9
The detection level of condition number 8 (a standard in play

SUPPLE mode) is adopted in play mode excluding the range between
-MENT
SHCKSET and SHCKRST in the job.
Teach Mode Each Axis Setting Function

Usually, the detection level setting of teach mode is set for
each group.
SUPPLE By using this function, the detection level can be set for each
-MENT
axis.
S2C869: Teach Mode Each Axis Setting Function
(1: VALID, 0: INVALID)
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8 System Setup
1 Condition Number (1 to 9)
1 to 7: for changing detection level in play mode.
8: for standard detection level in play mode.
9: for detection level in teach mode.
2 Robot Select
Select the manipulator whose detection level is to be changed.
3 Function Select
Specifies VALID/INVALID of the shock detection function. The shock
detection function is specified for each manipulator.
1. Select the manipulator whose function is to be enabled or disabled.
2. Move the cursor to “VALID” or “INVALID” and press [SELECT]. Each
time [SELECT] is pressed, “INVALID” and “VALID” are displayed
alternately. The change is available for all the condition numbers.
4 Max. Disturbance Force

Indicates the maximum disturbance force to the manipulator when the
manipulator is moved in play back operation or axis operation.
Refer to this value when inputting the detection level value in 5 .
The maximum disturbance force can be cleared by selecting {DATA} 
{CLEAR MAX VALUE} in the menu.
5 Detection Level (Level range: 1 to 500)
Specifies the shock detection level. Set a value larger than the maxi-
mum disturbance force.
The value set by default (the level 100) enables the function without
false detection even if the manipulator is operated at the maximum
speed.
To change DETECT LEVEL, move the cursor to the subject manipula-
tor, and press [SELECT] to display the numeric input status; input the
value with a numeric key and press [ENTER]. To increase the detection
sensitivity, set the level to small value, and to decrease the sensitivity,
set the level to large value.
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8 System Setup
 Method of shock detection level file setting

2. Select {SHOCK SENS LEVEL}.
– The EACH AXIS LEVEL window appears.
– Perform either of the following operations to display the page of
desired condition number:
(1) Press {PAGE} in the window. Enter the desired condition number
using numeric keys and press [ENTER]. Then the page of the
condition number appears.
GO BACK
(2) Press the page key PAGE

to change the condition number.
3. Level setting for the condition numbers 1 to 8.
Level setting values can be set for each axis on the EACH AXIS
LEVEL window.
Perform the following “Disturbance force measurement”, then perform
“Setting all levels at once”.
 Disturbance force measurement

1 Mount the tool, workpiece, external equipment, and equipment on
the arm to the manipulator.
2 Set the tool file correctly.
Set the load information (weight and center of gravity) of the tool.
3 Set the detection level values of all the axes to 100.
(1) Open the SHOCK DETECT LEVEL window.
(2) Select {DATA}, then {CLEAR MAX VALUE}.
4 Perform the JOB.
 Setting all levels at once

1 Open the SHOCK DETECT LEVEL window.
2 Select {DATA}, then {CHANGE EVERY LEVEL}.
3 Enter 120 in the coefficient (%) by which the max. disturbance force
is multiplied.
The following calculated value A or B, whichever is larger, is set to
the DETECT LEVEL.
A: (Max. disturbance force) x (coefficient = 120%)
B: (Max. disturbance force) + 15
<Example>
When the max. disturbance force is 80, the DETECT LEVEL is 96.
When the max. disturbance force is 10, the DETECT LEVEL is 25.
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8 System Setup
4. Level setting for the condition number 9.

The level setting for the condition number 9 is for the teach mode.
This setting is made for each group.
Refer to the max. disturbance force to set the DETECT LEVEL.
• Perform all the jobs to use for 5 to 6 hours.

• If a work job is performed both with holding a workpiece
and without holding a workpiece, measure both patterns.
• In the event of a collision while measuring the max. distur-
bance force, clear the max. disturbance force by selecting
{DATA}, then {CLEAR MAX VALUE}. Then try again.
• The max. disturbance force is cleared when the power is
turned ON/OFF. Therefore, DO NOT set the level based
NOTE
on the max. disturbance force immediately after turning
ON/OFF the power.
• When the teaching point, operation speed, operation posi-
tion, etc. of a job are greatly changed due to teaching
modification, etc., measure the max. disturbance force
and set the DETECT LEVEL again.
• When the load of tool or workpiece is greatly modified,
measure the max. disturbance force and set the DETECT
LEVEL again.
To avoid false detection during manipulator operation, set

the following calculated value A or B, whichever is larger, to
the DETECT LEVEL. An emergency stop of the manipula-
tor due to the false detection may become a factor to dam-
age the speed reducers and tools.
NOTE A: (Max. disturbance force) x (coefficient = 120%)

B: (Max. disturbance force) + 15
<Example>
When the max. disturbance force is 80, set the
DETECT LEVEL to 96 or more.
When the max. disturbance force is 10, set the
DETECT LEVEL to 25 or more.
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8 System Setup
To adjust to the change in the grease viscosity at a cold

start, the offset value is automatically added to DETECT
LEVEL until the robot has operated for a certain period of
NOTE time.
Thus, at a cold start, the shock detection will be performed
only when the value is more than or equal to the sum of
DETECT LEVEL and the offset value.
The offset value varies depending on the manipulator type.
NOTE DETECT LEVEL can be modified only when the security

mode is set to the management mode.
8.7.2.2 Tool Load Information Setting

To increase the accuracy of shock detection, set the tool load information
in the tool file. Refer to chapter 8.4.3 “Setting Tool Load Information” at
page 8-48 for details of the tool load information setting.
8.7.2.3 U-Arm Payload Setting

To perform shock detection more accurately, set the U-arm payload.
See chapter 8.4.2 “ARM CONTROL Window” at page 8-43 for details of
the U-arm payload setting.
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8 System Setup
8.7.2.4 Instruction of Shock Detection Function
 SHCKSET instruction
The SHCKSET instruction changes the shock detection level to the value
set in the shock detection level file during play back operation.
The additional items of the SHCKSET instruction are as follows.
SHCKSET R1 SSL#(1)
1 Robot Setting
Specifies the manipulator (R1, R2) or the station (ST1, ST2, ST3) of which
shock detection level is to be modified.
If nothing is specified, the modification is applied to the shock detection
level of the job control group in this instruction.
However, in the case of coordinated job, the modification is applied to the
shock detection level of the slave axis group.
2 Shock Detection Level Condition Number (1 to 7)

Specifies the shock detection level condition number in which the
detection level in playback mode is set.
 SHCKRST instruction
The shock detection level changed by the SHCKSET instruction is reset
and returned to the detection level of the standard (value set in condition
number 8) by the SHCKRST instruction.
The additional item of the SHCKRST instruction is as follows.
SHCKRST R1
1 Robot Setting
Specifies the manipulator (R1, R2) or the station (ST1, ST2, ST3) of
which shock detection level is to be reset.
If nothing is specified, the modification will be applied to the shock
detection level of the job control group of this instruction.
However, in the case of coordinated job, the modification is applied to
the shock detection level of the slave axis group.
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8 System Setup
 Instruction registration
The instruction is registered when the cursor is in the address area in the
JOB CONTENT window in teach mode.
1. Select {JOB} under the main menu.
Address area Instruction
2. Select {JOB}.
3. Move the cursor in the address area.
 SHCKSET
1. Move the cursor to the immediately preceding line where the
SHCKSET instruction is to be registered.
2. Press [INFORM LIST].
– The inform list dialog box is shown.
3. Select SHCKSET instruction.

(1) SHCKSET instruction is shown in the input buffer line.
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8 System Setup
4. Change the value of additional item and numerical data.

– < When registering the instruction as it is >
Operate the step 5 when registering the instruction in the input
buffer line as it is.
– < When adding or changing the additional item >
• When changing the shock detection level
(1) When changing the shock detection level, move the cursor to the
shock detection level condition number; hold down [SHIFT] and
press the up/down cursor key to change the condition number.
• When the value is input with the numeric key

I) When the value is input with the numeric key, press [SELECT]
to display the input buffer line.
II) Press [ENTER] to change the number in the input buffer line.
• When robot specification is added
I) When robot specification is added, move the cursor to the
instruction in the input buffer line and press [SELECT] to dis-
play the DETAIL window.
II) Move the cursor to “UNUSED” of “ROBOT/STATION”, and

press [SELECT].
III) The selection box appears.
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8 System Setup
IV) Point the cursor to the robot to be added and press [SELECT].
V) When the addition of robot is completed, press [ENTER].

VI) The DETAIL window closes and the JOB CONTENT window
appears.
5. Press [INSERT] then [ENTER].
– The instruction displayed in the input buffer line is registered.
 SHCKRST
1. Move the cursor to the immediately preceding line where the
SHCKRST instruction is to be registered.
2. Press [INFORM LIST].
– The inform list appears.
3. Select SHCKRST instruction.

– SHCKRST instruction appears in the input buffer line.
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8 System Setup
4. Change the value of the additional item.

– < When registering the instruction as it is >
Operate the step 5 when registering the instruction in the input
buffer line as it is.
– < When adding or changing the additional item >
(1) When adding the robot specification, move the cursor to instruc-
tion in the input buffer line and press [SELECT] to display the
DETAIL window.
(2) Move the cursor to “UNUSED” of “ROBOT/STATION”, and press

[SELECT].
(3) The selection box appears.
(4) Point the cursor to the robot to be added and press [SELECT].
(5) When the addition of robot is completed, press [ENTER].

(6) The DETAIL window closes and the JOB CONTENT window
appears.
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8 System Setup
8.7.2.5 Resetting Shock Detection Alarm

When the collision of tool/manipulator and peripheral device is detected
with the shock detection function, the manipulator stops instantaneously
with alarm output. In this case, the shock detection alarm is displayed.
The shock detection alarm in teach mode and play mode can be reset by
the following operation.
1. Press [SELECT].
– The alarm is reset when “RESET” is selected on the alarm display,
and the shock detection status is released.
2. Operation after resetting the detection status.
– In teach mode, the JOG operation of the manipulator is enabled by
resetting the status.
– In the play mode, move the manipulator once to the safety position
in the teach mode to check the damage though the playback
operation is possible after resetting the status.
When manipulator is stopped instantaneously while having

contact with the object and the detection alarm is tried to
reset on the alarm window, the situation in which the alarm
cannot be reset may occur since the collision may be
NOTE
detected again after resetting.
In this case, set the shock detection function “INVALID”, or
increase the detection level in teach mode and retreat the
manipulator to a safety position.
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FS100 8.8 User Coordinate Setting
8.8 User Coordinate Setting
8.8.1 User Coordinates
8.8.1.1 Definition of User Coordinates

User coordinates are defined by three points that have been taught to the
manipulator through axis operations. These three defining points are
ORG, XX, and XY, as shown in the diagram below. These three points of
positional data are registered in a user coordinate file.
Z-axis
X-axis
XX
XY
Y-axis ORG
User coordinate definition point

ORG: Home position
XX: Point on the X-axis
XY: Point on the Y-axis
ORG is the home position, and XX is a point on the X-axis. XY is a point

on the Y-axis side of the user coordinates that has been taught, and the
directions of Y- and Z-axes are determined by point XY.
NOTE It is important that the two points ORG and XX be taught

accurately.
8.8.1.2 Number of User Coordinate Files

Up to 16 kinds of user coordinates can be registered. Each coordinate
has a user coordinate No. and is called a user coordinate file.
User coordinate file 1

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8 System Setup
8.8.2 User Coordinate Setting
8.8.2.1 Selecting User Coordinate File

2. Select {USER COORDINATE}.
(1) The USER COORDINATE window appears.
(2) The “” denotes that the user coordinates is completed to set and
the “” denotes that it is not completed.
(3) To check the position of the user coordinates select {DISPLAY} 
{COORDINATE DATA}.
(4) The following window appears.
3. Select the user coordinate number.
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8 System Setup
8.8.2.2 Teaching User Coordinates

1. Select the robot.
– Select “**” on the upper left of the window to select the subject robot.
(This operation can be omitted if the robot selection has already
been made or if there is only one robot.)
2. Select “SET POS”.

– Select the teaching point.
3. Move the manipulator to the desired position with the axis keys.
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8 System Setup
4. Press [MODIFY] then [ENTER].

– Taught position is registered.
– Repeat the steps 2 to 4 to teach ORG, XX and XY.
– ““ denotes that teaching is completed and “” denotes that it is not
completed.
– To check the taught positions, call up the required window among

ORG to XY and press [FWD]. The manipulator moves to the set
position.
– If there is a difference between the current position of the
manipulator and the displayed position data, “ORG”, “XX”, or “XY”
flashes.
5. Select “COMPLETE”.
– User coordinates are registered in the file.
– Once the user coordinate setting is completed, the following
window appears.
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8 System Setup
8.8.2.3 Clearing User Coordinates

1. Select {DATA} under the pull-down menu.
3. Select {YES}.
– All data is cleared.
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8 System Setup
FS100 8.9 Releasing Overrun or Tool Shock Sensor
8.9 Releasing Overrun or Tool Shock Sensor
CAUTION
To operate the manipulator with the overrun or shock sensor released,
pay extra attention to the safety of the surrounding operation
environment.
If the manipulator stops by overrun detection or tool shock sensor

detection, release the overrun or tool shock sensor by the following
procedure and reset the alarm and move the manipulator with the axis
keys.
2. Select {OVERRUN & S-SENSOR}.
– The OVERRUN & SHOCK SENSOR window appears.
– Select either “EMERGENCY STOP” or “HOLD” to set the item
“SHOCK SENSOR STOP COMMAND” which specifies the stop
condition in the current shock sensor detection.
– “E-STOP” and “HOLD” are displayed alternately every time
[SELECT] is pressed.
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8 System Setup
FS100 8.9 Releasing Overrun or Tool Shock Sensor
3. Select “RELEASE”.
– The control group in which overrun or shock sensor is detected is
indicated with “”.
– If “RELEASE” is selected, overrun or tool shock sensor is released
and “CANCEL” indication will be displayed.
4. Select “ALM RST”.

– The alarm is reset and manipulator can be moved with the axis
keys.
After releasing the overrun or tool shock sensor, if “CAN-

NOTE CEL” is selected or the window is changed to the other one,
the release of the overrun or tool shock sensor will be can-
celed.
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8 System Setup
FS100 8.10 Soft Limit Release Function
8.10 Soft Limit Release Function

The switches that are set to detect the motion range of the manipulator
are called limit switches. The operating range is monitored by the software
in order to stop motion before these limit switches are reached. These
software limits are called “soft limits”. The operating range of the
manipulator is controlled by the following two soft limits.
• Maximum motion range for each axis
• Cubic operation area set parallel to the robot coordinate system
These soft limits are continually monitored by the system, and the
manipulator automatically stops when the its TCP reaches a soft limit.
When the manipulator is stopped at a soft limit, temporarily release the
soft limit by the following procedure, then move the manipulator away from
the soft limit in a direction opposite to the earlier operation direction.
2. Select {LIMIT RELEASE}.
– The LIMIT RELEASE window appears.
3. Select “SOFT LIMIT RELEASE”.

– Press [SELECT] to alternate between “VALID” and “INVALID”.
– When “SOFT LIMIT RELEASE” is set to “VALID”, the message “Soft
limits have been released” appears.
– When “SOFT LIMIT RELEASE” is set to “INVALID”, the message

“Softlimits off released” is displayed for a few seconds.
• The taught data cannot be registered when the soft limit is

being released.
NOTE
• The setting of “SOFT LIMIT RELEASE” becomes
“INVALID” when the mode is changed to the play mode.
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8 System Setup
FS100 8.11 All Limit Release Function
8.11 All Limit Release Function
CAUTION
To operate the manipulator with all limits released, pay extra attention
to ensure the safety of the surrounding operation environment.
Failure to observe this caution may result in injury or damage to
equipment due to the unexpected manipulator motion exceeding its
range of motion.
The following limits can be released with the all limit release function:
Limit Type Contents

Mechanical Limit Limit to check manipulator’s range of motion.
L-U Interference Limit to check L- and U-axis interference area.
Soft Limit on Each Axis Soft limit to check manipulator’s range of motion.
Cube Interference Limit to check cube interference area set by user.
The all limit release function is available only when the

NOTE security mode is set to the management mode. Refer to
chapter 7 “Security System” at page 7-1 for details on the
security modes.

2. Select {LIMIT RELEASE}.
– The LIMIT RELEASE window appears.
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8 System Setup
FS100 8.11 All Limit Release Function
3. Select “ALL LIMITS RELEASE”.

– When ALL LIMIT RELEASE is changed to “VALID”, the message
“All limits have been released” is displayed. When the setting
changes to “INVALID”, the message “All limits off released” is
displayed for a few seconds.
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8 System Setup
FS100 8.12 Instruction Level Setting
8.12 Instruction Level Setting
8.12.1 Setting Contents
8.12.1.1 Instruction Set

There are three instruction sets that can be used when registering the
instructions for the robot programming language (INFORM III): the subset
instruction set, the standard instruction set, and the expanded instruction
set.
• Subset Instruction Set:
The instructions displayed in the instruction list are limited to just
those that are most frequently used, reducing the number of instruc-
tions that can be registered. Since few instructions are shown,
selection and input are simple.
• Standard Instruction Set/Expanded Instruction Set:
All the INFORM III instructions can be used. The number of addi-
tional items to be used in each instruction differ in the standard
instruction set and expansion instruction set.
In the standard instruction set, the following functions cannot be
used. However, operation becomes easier because the number of
data items decreases when registering an instruction.
• Use of local variables and arrangement variable
• Use of variables for additional items (Example: MOVJ VJ = I000)
When instructions are executed, for example during playback, all the
instructions can be executed regardless of the instruction set used.
Fig. 8-5: Instruction Set
Expanded instruction set
Standard instruction set
Subset instruction set
Frequency used
All instructions
instructions
Use of local variables and arrangement variables

Use of variables for additional items
Job calls with arguments
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8 System Setup
8.12.1.2 Learning Function

When an instruction is entered from the instruction list, the additional
items that were entered last time are also shown. This function can
simplify instruction input.
To register the same additional items as those in the former operation,
register them without changing.
1. Register an instruction.
2. The next time an attempt is made to register the same instruction as in

1, the same additional items as were registered last time are also
shown in the input buffer line.
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8 System Setup
8.12.2 Setting Instruction Set Level

2. Select {TEACHING CONDITION SETTING}.
– The TEACHING CONDITION SETTING window appears.
3. Select “LANGUAGE LEVEL”.

– The selection list appears.
4. Select desired language level.

– Language level is set.
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8 System Setup
8.12.3 Setting Learning Function

The learning function is set at “VALID” by default.
2. Select {TEACHING CONDITION SETTING}.
– The TEACHING CONDITION SETTING window appears.
3. Select “INSTRUCTION INPUT LEARNING”.

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8 System Setup
FS100 8.13 Setting Controller Clock
8.13 Setting Controller Clock

To check the current date and time, follow the procedure below.
2. Select {DATE/TIME}.
– The DATE/TIME SET window appears.
To set the current date and time, follow the procedure below.
MAIN
1. While pressing the main menu key MENU
, turn the power OFF then back
ON.
2. Select {SYSTEM}, then {SETUP}. Then, select “DATE” or “TIME”.
– The DATE/TIME SET window appears.
3. Select “DATE” or “TIME”.
– The input buffer line appears.
4. Input the new date/time.
– For instance, to set the date to September 1, 2010, input “2010.9.1”.
To set the time at twelve o’clock, enter “12.00”.
5. Press [ENTER].
– The date or time is changed.
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8 System Setup
FS100 8.14 Setting Play Speed
8.14 Setting Play Speed

2. Select {SET SPEED}.
– The SPEED SET window is shown.
GO BACK

.
– When two or more manipulators and stations exist in the system,
GO BACK
use the page key PAGE

to change the control group, or click on
{PAGE} to select the desired control group.
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8 System Setup
FS100 8.14 Setting Play Speed
4. Select “JOINT” or “LNR/CIR”.

– The type of speed alternately changes from “JOINT” to “LNR/CIR”.
5. Select the speed to modify.

– The input buffer line appears.
6. Input the speed value.
7. Press [ENTER].
– The speed is modified.
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8 System Setup
FS100 8.15 Numeric Key Customize Function
8.15 Numeric Key Customize Function
8.15.1 Description of Numeric Key Customize Function

With this function, the user can set the function of an application that has
been allocated to the numeric keys of the programming pendant to the
other function.
Since any frequently used operation can be allocated to the numeric keys
on the programming pendant, decreased key operations reduce the
teaching time.
NOTE The Numeric Key Customize Function is allowed to set only

when the security mode is set to the management mode.
8.15.2 Allocatable Functions

There are two allocation methods as follows:
• Key Allocation (EACH)
• Key Allocation (SIM)
8.15.2.1 Key Allocation (EACH)

With key allocation (EACH), the manipulator operates according to the
allocated function when the numeric key is pressed. The allocatable
functions are listed below.
Function Description
Manufacturer Allocated by Yaskawa. Allocating another function
allocation invalidates the function allocated by the manufacturer.
Instruction Allocates any instructions assigned by the user.
allocation
Job call allocation Allocates job call instructions (CALL instructions). The
jobs to be called are only those registered in the reserved
job names. (Specified by the registration No.)
Display allocation Allocates any displays assigned by the user.
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8 System Setup
8.15.2.2 Key Allocation (SIM)

With key allocation (SIM), the manipulator operates according to the
INTER
allocated function when the interlock key and the numeric key are
LOCK
pressed at the same time. The allocatable functions are listed below.
Function Description
Alternate output Turns ON/OFF the specified user output signal when the
allocation INTER
interlock key LOCK and the allocated Numeric key are
pressed at the same time.
Momentary output Turns ON the specified user output signal user when the
allocation INTER
interlock key LOCK and the allocated user key are pressed
at the same time.
Pulse output Turns ON the specified user output signal only for the
allocation INTER
specified period when the interlock key LOCK and the
allocated Numeric key are pressed at the same time.
Group output Sends the specified output to the specified general group
allocation INTER
(4-bit/8-bit) output signals when the interlock key LOCK and the
Analog output Sends the specified voltage to the specified output port
allocation INTER
when the interlock key LOCK and the allocated Numeric key
are pressed at the same time.
Analog incremental Sends the voltage increased by the specified value to the
output allocation INTER
specified output port when the interlock key LOCK and the
SUPPLE
In a system for multiple applications, a numeric key can be
-MENT allocated for each application.
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8 System Setup
8.15.3 Allocating Operation
8.15.3.1 Allocation Window

2. Select {KEY ALLOCATION}.
– The KEY ALLOCATION (EACH) window appears.
3. Select {DISPLAY}.
– Pull-down menu appears.
– To call up the KEY ALLOCATION (SIM) window, select {ALLOCATE
SIM. KEY}.
4. Select {ALLOCATE SIM. KEY}.

– The KEY ALLOCATION (SIM) window appears.
GO BACK
PAGE
– In a system with multiple applications, press the page key to
change the window to the allocation window for each application, or
click on {PAGE} to select the desired application number.
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8 System Setup
8.15.3.2 Instruction Allocation

Set this function in the KEY ALLOCATION (EACH) window.
1. Move the cursor to “FUNCTION” of the key to be allocated and press
[SELECT].
– Selection list appears.
2. Select “INSTRUCTION”.
– The instruction is shown in the “ALLOCATION CONTENT”.
(1) To change the instruction, move the cursor to the instruction and
press [SELECT]. Then the instruction group list appears.
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8 System Setup
(2) Select the group which contains the instruction to modify.

(3) When the instruction list dialog box is shown, select the instruction
to be changed.
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8 System Setup
8.15.3.3 Job Call Allocation

1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
2. Select “JOB CALL”.
– The reserved job registration No. is shown in the “ALLOCATION
CONTENT” (reserved job registration No.: 1 to 10).
(1) To change the reserved job registration No. move the cursor to the
No. and press [SELECT]. Then input buffer line appears.
(2) Input the number to be changed, and press [ENTER].
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8 System Setup
8.15.3.4 Display Allocation

press [SELECT].
2. Select [DISPLAY].
3. Move the cursor to “ALLOCATION CONTENT” and press [SELECT].
– Character input is available.
4. Input the name of the reserved window and press [ENTER].
– The reserved name input to the “ALLOCATION CONTENT” is
shown.
5. Open the window for allocation.

INTER
6. Press the interlock key LOCK
and the allocated key at the same time.
– A message “Reserved display registered” appears, and the window
is registered.
– In this case, the CURRENT POSITION window is registered by
INTER
pressing the interlock key + [0] with the CURRENT POSITION
LOCK
window displayed on the screen.
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8 System Setup
8.15.3.5 Alternate Output Allocation

Set this function in the KEY ALLOCATION (SIM) window.
press [SELECT].
2. Select “ALTERNATE OUTPUT”.

– The output No. is displayed in the “ALLOCATION CONTENT”.
(1) To change the output No., move the cursor to the No. and press
[SELECT]. Then numeric value can be entered.
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8 System Setup
8.15.3.6 Momentary Output Allocation

press [SELECT].
2. Select “MOMENTARY OUTPUT”.
– The output No. is displayed in the “ALLOCATION CONTENT”.
(1) To change the output No., move the cursor to the No. and press
[SELECT]. Then numeric value can be entered.
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8 System Setup
8.15.3.7 Pulse Output Allocation

press [SELECT].
2. Select “PULSE OUTPUT”.
– The output No. and output time are displayed in the “ALLOCATION
CONTENT”.
(1) To change the output No. or output time, move the cursor to the
No. or time and press [SELECT]. Then numeric value can be
entered.
(2) Input the number or time to be changed, and press [ENTER].
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8 System Setup
8.15.3.8 Group (4-bit/8-bit) Output Allocation

press [SELECT].
2. Select “4 BIT OUTPUT” or “8 BIT OUTPUT”.
– The output No. and output value are displayed in the “ALLOCATION
CONTENT”.
(1) To change the output No. or output value, move the cursor to the
No. or value and press [SELECT]. Then numeric value can be
entered.
(2) Input the number or value to be changed, and press [ENTER].
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8 System Setup
8.15.3.9 Analog Output Allocation

press [SELECT].
2. Select “ANALOG OUTPUT”.
– The output port number and the output voltage value are displayed
in the “ALLOCATION CONTENT”.
(1) To change the output port No. or output voltage value, move the
cursor to the No. or voltage value and press [SELECT]. Then
numeric value can be entered.
(2) Input the number or voltage value to be changed, and press
[ENTER].
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8 System Setup
8.15.3.10 Analog Incremental Output Allocation

press [SELECT].
2. Select “ANALOG INC OUTPUT”.
– The output port No. and incremental value are displayed in the
“ALLOCATION CONTENT”.
(1) To change the output port No. or incremental value, move the cur-
sor to the No. or incremental value and press [SELECT]. Then
numeric values can be entered.
(2) Input the number or incremental value to be changed, and press
[ENTER].
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8 System Setup
8.15.4 Allocation of I/O Control Instructions

In key allocation (SIM), output control instructions can be allocated to the
numeric keys that have been allocated one of the following I/O controls
with key allocation (EACH).
Function Output Control Instruction allowed to be

Allocated
Alternate output allocation DOUT OT# (No.) ON
Momentary output allocation
Pulse output allocation PULSE OT# (No.) T = output time
Group output allocation (4-bit) DOUT OGH (No.) output value
Group output allocation (8-bit) DOUT OG# (No.) output value
Analog output allocation AOUT AO# (No.) output voltage value
1. Allocation of I/O control instruction.

– Allocate the I/O control instruction with key allocation (SIM) following
the forementioned procedure.
2. Move the cursor to the “FUNCTION” of the key that has been allocated
with I/O control with key allocation (SIM) and press [SELECT].
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8 System Setup
3. Select “OUTPUT CONTROL INST”.

– The instruction corresponding to the I/O control allocated by key
allocation (SIM) is displayed in the “ALLOCATION CONTENT”.
– The allocated instruction changes automatically when

“ALLOCATION CONTENT” is changed by key allocation (SIM).
Even if the I/O control allocation is changed to the default setting
allocated by the manufacturer with key allocation (SIM), the settings
for key allocation (EACH) remain the same.
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8 System Setup
8.15.5 Execution of Allocation
8.15.5.1 Executing Instruction/Output Control Allocation

1. Press the key allocated for instruction allocation or output control
allocation.
– The allocated instruction is displayed in the input buffer line.
2. Press [INSERT] and [ENTER].

8.15.5.2 Executing Job Call Allocation

1. Press the key allocated for the job call allocation.
– The CALL instruction is displayed in the input buffer line.
– The CALL instruction shown in the input buffer line is registered.
8.15.5.3 Executing Display Allocation

1. Press the key allocated for the display allocation.
– The allocated display appears.
8.15.5.4 Executing I/O Control Allocation

Alternate output allocation, momentary output allocation, pulse output
allocation, group output allocation (4-bit/8-bit), analog output allocation,
analog incremental output allocation are executed by the following
operation.
INTER
1. Press the interlock key and the key allocated for I/O control
LOCK
allocation at the same time.

– Allocated functions are executed.
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8 System Setup
FS100 8.16 Changing Output Status
8.16 Changing Output Status

The status of external output signals can be changed from the
programming pendant by using either of the following two methods.
• On the user output status window
• On the RELAY ON window
The method that uses the RELAY ON window, which is described here,
simplifies the operation for changing the status of signals that are used
frequently.
A maximum of 64 output signals can be shown on the

RELAY ON window and they must be set in advance to
NOTE parameters S4C327 to S4C390.
If they are not set, the sub menu in the RELAY ON window
will not be displayed.
1. Select {IN/OUT} under the main menu.

2. Select {RELAY ON}.
– The RELAY ON window appears.
3. Select the desired signal to change the output status.

– Select the status ( or ) of the desired signal.
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8 System Setup
FS100 8.16 Changing Output Status
INTER
4. Press the interlock key LOCK
+[SELECT].
– The output status is changed. (: status ON; : status OFF.)
It is also possible to turn the relevant external output signal

INTER
on only for the duration that the interlock key LOCK
+
SUPPLE
-MENT
[SELECT] are pressed.
This selection is made in advance by setting the parameters
(S4C391 to 454) to “1”.
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8 System Setup
FS100 8.17 Changing Parameter Setting
8.17 Changing Parameter Setting

The parameter settings can be changed only by the operator who has the
correct user ID number for the management mode.
1. Select {PARAMETER} under the main menu.
2. Select the parameter type.
– The PARAMETER window appears. Select the desired parameter.
3. Move the cursor to the desired parameter number.
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8 System Setup
– When the desired parameter number is not in the current window,

move the cursor in the following way:
(1) Move the cursor to a parameter number and press [SELECT].
(2) Enter the desired parameter number with the numeric keys.
(3) Press [ENTER].

(4) The cursor moves to the selected parameter number.
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8 System Setup
Set the parameters in the following manner.

1. Select the parameter data to be set.
(1) Move the cursor to the parameter number data (decimal or binary)
in the PARAMETER window, and press [SELECT].
(2) To enter a decimal setting, select the decimal figure.
(3) To enter a binary setting, select the binary figure.
2. Enter the value.

– If a decimal figure is selected, enter a decimal value with the
numeric keys.
– If a binary figure is selected, move the cursor to the binary figure

data in the input buffer line, and press [SELECT].
– Each time [SELECT] is pressed, “0” and “1” alternate in the window.
– “0” or “1” can also be entered with the numeric keys.
3. Press [ENTER].
– The new setting appears in the position where the cursor is located.
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FS100 8.18 File Initialization
8.18 File Initialization
8.18.1 Initializing Job File

MAIN
ON.
2. Change the security mode to the management mode.
3. Select {FILE} under the main menu.
4. Select {INITIALIZE}.
– The INITIALIZE window appears.
5. Select {JOB}.
6. Select {YES}.
– The job data is initialized.
When JOB is initialized, the following files are reset at the

same time.
Be careful when initializing JOB.
NOTE • User coordinates
• Variable data
• System definition parameter (S4D)
• Robot calibration data
• Conveyor calibration data
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8 System Setup
8.18.2 Initializing Data File

MAIN
ON.
5. Select {FILE/GENERAL DATA}.
– The INITIALIZE window appears.
6. Select the data file to be initialized.

– The selected data file/general data are marked with “”.
– The parameters marked with “” cannot be selected.
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8 System Setup
7. Press [ENTER].
8. Select {YES}.
– The selected data file/general data are initialized.
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8 System Setup
8.18.3 Initializing Parameter File

MAIN
ON.
5. Select {PARAMETER}.
– The parameter selection window appears.
6. Select the parameter to be initialized.

– The selected parameter is marked with “”.
– The parameters marked with “” cannot be selected.
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8 System Setup
7. Press [ENTER].
8. Select {YES}.
– The selected parameter is initialized.
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8 System Setup
8.18.4 Initializing I/O Data

MAIN
ON.
5. Select {I/O DATA}.
– The I/O data selection window appears.
6. Select data to be initialized.

– The selected data is marked with “”.
– The I/O data marked with “” cannot be selected.
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8 System Setup
7. Press [ENTER].
8. Select {YES}.
– The selected data is initialized.
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8 System Setup
8.18.5 Initializing System Data

MAIN
ON.
5. Select {SYSTEM DATA}.
– The system data selection window appears.
6. Select the parameter to be initialized.

– The selected data is marked with “”.
– The system data marked with “” cannot be selected.
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8 System Setup
7. Press [ENTER].
8. Select {YES}.
– The selected data is initialized.
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8 System Setup
FS100 8.19 Display Setting Function
8.19 Display Setting Function
8.19.1 Font Size Setting

FS100 enables changing the font size displayed on the screen.
The fonts displayed on the screen can be selected from eight patterns of
fonts in the font size setting dialog box.
8.19.1.1 Applicable Range for Font Size Change

Changing the font size is allowed in the general display area indicated in
the following figure:
General
display area
8.19.1.2 Settable Font Size

The following eight patterns of fonts are available in setting the size of
fonts displayed on the screen.
Font Size Font Style
1 Small Regular
2 Small Bold
3 Regular Regular
4 Regular Bold
5 Large Regular
6 Large Bold
7 Extra large Regular
8 Extra large Bold
8-143
8 System Setup
8.19.1.3 Setting Font Size

To set the font size, first off display the font size setting dialog box as
follows.
1. Select {DISPLAY SETUP} then {CHANGE FONT} under the main
menu.
2. The font size setting dialog box appears on the center of the current
window.
8-144
8 System Setup
 To set the font size in the font size setting dialog box, follow the
procedure below.
1. Specify the font style.
– The {Bold Type} check box can be checked or unchecked
alternately each time the check box is selected.
• Check the {Bold Type} check box as follows to set the font to the bold
style.
• Clear the {Bold Type} check box as follows to set the font to the reg-
ular style.
8-145
8 System Setup
2. Specify the font size.

– Select a button from the four buttons in the dialog box.
3. The font size setting dialog box is closed, and the screen displays the
font specified in the dialog box.
 To cancel the setting of the font size, follow the procedure below.
1. Select {Cancel} in the font size setting dialog box.
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8 System Setup
2. The dialog box closes without changing the font size.
When the general display area is in the multi-window mode,

the font size for each window can be set by using the font
size setting dialog box. To change the font size, select one
of the windows and set the font size.
SUPPLE
-MENT
Do not turn OFF the FS100 power supply when the font size
NOTE is being changed (when the font size setting dialog box is
on the screen).
8-147
8 System Setup
8.19.2 Operation Button Size Setting

FS100 enables changing the size of operation buttons.
The button size in the main menu area, menu area, and instruction list can
be respectively selected from three sizes.
8.19.2.1 Applicable Range for Button Size Change

Changing the button size is allowed in the main menu, menu (pull-down
menu), and instruction list indicated in the following figure:
Menu area (pull-down menu)
Main menu Instruction

area list
8.19.2.2 Settable Button Size

The following three sizes of buttons are available in setting the size of
each operation button; the font style of the character string on buttons can
also be specified.
Button Size Font Style
1 Small Regular
Bold
2 Regular Regular
Bold
3 Large Regular
Bold
8-148
8 System Setup
8.19.2.3 Setting Button Size

To set the button size, first off display the button size setting dialog box as
follows.
1. Select {DISPLAY SETUP} then {CHANGE BUTTON} under the main
menu.
– The font size setting dialog box appears on the center of the current
window.
8-149
8 System Setup
 To set the button size in the button size setting dialog box, follow the
procedure below.
1. Specify the area to set the button size.
(1) Select the desired area from the area setting buttons.
(2) The buttons in the selected area is subject to size setting.
(3) Note that only the last-selected button determines the area subject
to size setting, even if settings are performed several times before
then.
2. Specify the font style.

– The {Bold Type} check box can be checked or unchecked
alternately each time the check box is selected.
• Check the {Bold Type} check box as follows to set the font to the bold
style.
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8 System Setup
• Clear the {Bold Type} check box as follows to set the font to the reg-
ular style.
3. Specify the button size.

– Select a button from the three buttons in the dialog box.
4. The font size setting dialog box is closed, and the screen displays the
buttons specified in the dialog box.
– The modification is applied only to the buttons in the area selected
with the area setting button. (In this example, the change is applied
only to the pull-down menu buttons in the menu area.)
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8 System Setup
 To cancel the setting of the button size, follow the procedure below.
1. Select {Cancel} in the button size setting dialog box.
– The dialog box closes without changing the button size.
Do not turn OFF the FS100 power supply when the button
NOTE size is being changed (when the button size setting dialog
box is on the screen, or when an hourglass is indicated in
the middle of the screen).
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8 System Setup
8.19.3 Initialization of Screen Layout

The font/button size changed with the font/button size setting function can
be collectively changed back to the regular size.
8.19.3.1 Initializing Screen Layout

To initialize the screen layout, follow the procedure below.
1. Select {DISPLAY SETUP} then {INITIALIZE LAYOUT} under the main
menu.
– A confirmation dialog box appears on the center of the current

window.
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8 System Setup
 To initialize the screen layout, follow the procedure below.

1. select {OK}.
– The dialog box is closed, and the font/button sizes are collectively
changed to the regular size.
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8 System Setup
 To cancel the initialized screen layout, follow the procedure below.

1. Select {CANCEL}.
– The dialog box closes without changing the current screen layout.
Do not turn OFF the FS100 power supply when the screen
NOTE layout is being initialized (when the confirmation dialog box
is on the screen, or when an hourglass is indicated in the
middle of the screen).
8.19.4 Saving Layout

The settings of the font size and button size are saved. The screen is
displayed with the font size and button size specified last time by the
current controller.
In the maintenance mode, the screen is displayed with the

NOTE standard font size and button size regardless of the settings
of them. The font size and button size can be changed in
the maintenance mode, but the settings are not saved.
8-155
8 System Setup
FS100 8.20 Hand Vibration Control Function
8.20 Hand Vibration Control Function
8.20.1 Description of Hand Vibration Control Function

With this function, vibration caused by the hand or workpiece can be
reduced.
The reduction of vibration eliminates the need to improve the accuracy of
and to reduce the speed of picking-up or placing motion for handling
application, which reduces cycle time.
Make correct settings to make the best of the hand vibration

control function.
NOTE
For settings, refer to chapter 8.20.3 “Setting Hand Vibra-
tion Control Function” at page 8-157.
CAUTION
• The path and cycle time of the robot changes depending on the
settings of the hand vibration control function. Make sure to check
operation after changing the settings.
8.20.2 Supported Models

The following high-speed handling models support the hand vibration
control function:
• MPK2
• MPP3
The hand vibration control function can be supported by the

NOTE system with one manipulator.
It cannot be supported by the system with an external axis
and/or station.
8-156
8 System Setup
8.20.3 Setting Hand Vibration Control Function

2. Select {HAND VIBRATION CONTROL}.
– The HAND VIBRATION CONTROL window appears.
1 FUNCTION
Specifies VALID or INVALID of the hand vibration control
function.
Move the cursor to “VALID/INVALID”, then press [SELECT].
Press [SELECT] to alternate between VALID and INVALID.
2 NATURAL FREQUENCY [Hz]
Specifies the natural frequency of the hand or workpiece.
Move the cursor to “NATURAL FREQUENCY” and press
[SELECT] to enter a numeric value. Enter a setting value by
using the numeric keys, then press [ENTER].
3 EFFICIENCY [%] (Range: 1 to 100)
Specifies the efficiency of the hand vibration control function.
Move the cursor to “EFFICIENCY” and press [SELECT] to
enter a numeric value. Enter a setting value by using the
numeric keys, then press [ENTER].
3. Enable the function by setting “FUNCTION” to “VALID”.

4. Set the natural frequency.
– If the natural frequency of the hand or workpiece is known, set the
value.
If the natural frequency of the hand or workpiece is not known, set
the value with which vibration is minimized when the manipulator
operates. It is acceptable to set this value even if the natural
frequency of the hand or workpiece is known.
8-157
8 System Setup
Any object vibrates with its own frequency and with its own
waveform, and the frequency is called “natural frequency”.
Natural frequency is expressed by the number of vibration
repeated in one second.
With the waveform below, the natural frequency is “5 Hz”.
SUPPLE
-MENT
5. Set the efficiency.

– Set the efficiency of the hand vibration control function.
Normally, there is no need to change it from 100%.
However, by changing the value, the efficiency of hand vibration
control and the cycle time can be adjusted.
The efficiency of hand vibration control and the cycle time

are changed according to the adjustment of the efficiency as
shown below.
SUPPLE Efficiency 1% 100%

-MENT
Efficiency of hand Low High

vibration control
Cycle time Short Long
The settings of the hand vibration control function can be

NOTE changed only when the security mode is set to the manage-
ment mode.
8-158
8 System Setup
FS100 8.21 Manual Brake Release Function
8.21 Manual Brake Release Function
8.21.1 Outline
With this function, the brake of each motor of the manipulator and the
external axis can be forcibly released by using the programming pendant.
Note that the following operating conditions must be met:
• Operating conditions
(1)FS100 condition
The FS100 must be started up normally.
(2)Mode
All modes (REMOTE, PLAY, TEACH)
(3)Security
All security modes (Operation, Edit, Management)
(4)Others
• The servo is not turned ON.
• The emergency stop is not incoming. (programming pendant,
external signal, controller (optional))
• The interlock connector is connected.
Also, observe the following restrictions on the axis whose brake is to be
released:
• Restrictions
Due to the hardware configuration, the brake release can be per-
formed only by the following units:
• Group of the S-, L-, and U-axes (the first, second, and third axes)
• Group of the R-, B-, and T-axes (the fourth, fifth, and sixth axes)
• The E-axis or the first external axis, etc. (the seventh axis)
• The first or the second external axis, etc. (the eighth axis)
CAUTION
• Use great caution when manually releasing the brake because the
brakes of up to 3 axes are released.
8-159
8 System Setup
8.21.2 Manual Brake Release Procedure

1. Select {ROBOT} under the main menu, then select the submenu
{MANUAL BRAKE RELEASE}.
– The submenu {MANUAL BRAKE RELEASE} is displayed under the
main menu {ROBOT}.
2. Select {YES}.
– When the manual brake release menu is selected, a warning

message appears to prevent improper operation.
– Select {YES} to display the MANUAL BRAKE RELEASE window.
8-160
8 System Setup
– If there is no axis whose brake can be released in such a case when

the interlock connector is not connected, the following window
appears.
– Select {NO} to display the following window. The same window is

displayed if the interlock connector is removed while the MANUAL
BRAKE RELEASE window is being displayed.
8-161
8 System Setup
3. Move the cursor to the axis whose brake is to be released. Then press
INTER
the interlock key LOCK
+ [SELECT] while gripping the enable switch.
– Since the brakes of multiple axes will be released if the S-, L-, or U-
axis (the first, second, or third axis) or the R-, B-, or T-axis (the
fourth, fifth, or sixth axes) is selected, one of the following
confirmation dialog boxes appears. Proceed to the step 4.
8-162
8 System Setup
– If the E-axis, the first external axis, or the second external axis (the
seventh or eighth axis) is selected, the brake is released and the
BRAKE STATUS is displayed.
BRAKE STATUS : Brake locked :Brake released

– The brake is locked with one of the following conditions:
• [SELECT] is released. (See the CAUTION box below.)
• The emergency stop button on the programming pendant, the FS100
(optional), or the external device is pressed.
• The enable switch is released, or gripped more tightly to press it fur-
ther.
• The window is switched from the MANUAL BRAKE RELEASE win-
dow to another.
• The interlock connector is removed.
CAUTION
INTER
• The brake is released by pressing the interlock key + [SELECT]
LOCK
while gripping the enable switch. At this time, note that the brake
INTER
remains released when only the interlock key LOCK
is released.
4. Select {YES} in the selection dialog box.

– Select {NO} or press [CANCEL] to close the confirmation dialog box
without releasing the brake.
INTER
After that, press the interlock key + [SELECT] while gripping the
LOCK
enable switch to display the confirmation dialog box again. Proceed

to the step 4.
8-163
8 System Setup
– When {YES} is selected, the brake is not released immediately. Do

INTER
not move the cursor, and press the interlock key + [SELECT]
LOCK
while gripping the enable switch again to release the brakes of the 3
axes including the axis at which the cursor points.
BRAKE STATUS : Brake locked :Brake released

– When the axis whose brake is to be released is changed by moving
the cursor, proceed to the step 3.
– The brake is locked with one of the following conditions:
• [SELECT] is released. (See the CAUTION box below.)
• The emergency stop button on the programming pendant, the FS100
(optional), or the external device is pressed.
• The enable switch is released, or gripped more tightly to press it fur-
ther.
• The window is switched from the MANUAL BRAKE RELEASE win-
dow to another.
• The interlock connector is removed.
CAUTION
INTER
• The brake is released by pressing the interlock key + [SELECT]
LOCK
while gripping the enable switch. At this time, note that the brake
INTER
remains released when only the interlock key LOCK
is released.
8.21.3 Warning Message

If the manual brake release is performed under one of the following
conditions, a warning message appears in the message area on the
screen.
In this case, note that the brake cannot be released.
• The servo is turned ON.
• The emergency stop button on the programming pendant is pressed.
• The emergency stop button on the FS100 (optional) is pressed.
• The external emergency stop signal is incoming.
• The interlock connector is not connected.
8-164
9 System Backup
FS100 9.1 System Backup with FS100
9 System Backup
For the FS100, the system data can be collectively backed up in advance
so that the data can be immediately loaded and restored in case of an
unexpected trouble such as data loss.
9.1 System Backup with FS100

For the FS100, four types of collective backup are available: CMOS.BIN,
CMOSBK.BIN, ALCMSxx.HEX, and CMOSxx.HEX.
9.1.1 Function Types of Data
9.1.1.1 CMOS.BIN
For the normal backup, use this data.
Save: Perform in the maintenance mode (the editing mode or higher.)
Load: Perform in the maintenance mode (the management mode.)
As for the load/save procedures, refer to chapter 9.2 “Backup by
CMOS.BIN” at page 9-3.
Target Area: All areas of the internally stored data.
9.1.1.2 CMOSBK.BIN
This data is used in the automatic backup function.
Save: Saves with the preset conditions in the normal mode.
Load: Perform for the system restoration in the maintenance mode (the
management mode.)
For details, refer to chapter 9.3 “Automatic Backup Function” at page 9-9.
Target Area: All areas of the internally stored data.
9.1.1.3 CMOSxx.HEX
This data is loaded/saved in the FD/CF menu in the normal mode.
Save: Perform in the normal mode (the editing mode or higher.)
Load: Perform in the normal mode (the management mode.)
For details, refer to “FS100 OPERATOR’S MANUAL”.
Target Area: The collected data including “Job File”, “Data File”,
“Parameter File”, “System Data”, and “I/O Data” which can
be individually loaded/saved in the FD/CF menu. Because
the setting information of robot etc. are not included in this
collected data, the system cannot be completely restored.
9.1.1.4 ALCMSxx.HEX
This data is for the manufacturer only. Users can save but cannot load
this data.
9-1
9 System Backup
FS100 9.1 System Backup with FS100
9.1.2 Device
For the backup of the FS100 system, a CompactFlash card or a USB
memory stick can be used.
(For the automatic backup function, USB memory cannot be used.)
The following tables show the recommended CompactFlash and USB
memory.
<Recommended CompactFlash>
No. Manufacturer Model Remarks
1 Hagiwara Solutions Co., Ltd. MCF10P-256MS 256MB
2 Hagiwara Solutions Co., Ltd. MCF10P-512MS 512MB
3 Hagiwara Solutions Co., Ltd. MCF10P-A01GS 1GB
4 Hagiwara Solutions Co., Ltd. MCF10P-A02GS 2GB
< Recommended USB Memory>

No. Manufacturer Model Remarks
1 Hagiwara Solutions Co., Ltd. UDG4-*GDRJ * denotes the
capacity: 1GB, 2GB,
4GB
In order to save the batch data, 8 MBytes per file is needed in the medium.
Note that the free space for one working file is needed in addition to the
free space for the stored files when using the automatic backup function.
Also, it is recommended to store the backup data in two or more media to
minimize problems if the medium is damaged.
The water-proof function of the programming pendant is not

effective while a USB memory stick is connected to the pro-
gramming pendant.
Also, if a USB memory stick is connected constantly, it may
drop off.
NOTE
Use a CompactFlash card instead if there is no means to
maintain the water-proof function or to prevent a USB mem-
ory stick from dropping off.
To use a USB memory stick, connect it to the USB device of
the main CPU board.
9-2
9 System Backup
FS100 9.2 Backup by CMOS.BIN
9.2 Backup by CMOS.BIN

Perform the backup by CMOS.BIN in the maintenance mode.
The chart below shows the availability of CMOS save and CMOS load in
each security mode in the maintenance mode.
Security CMOS Save CMOS Load
Operation Mode Not available Not available
Editing Mode Available Not available
Management Mode Available Available
Yaskawa Mode Available Available
9-3
9 System Backup
9.2.1 CMOS.BIN Save

Follow the procedures below to save CMOS.BIN.
MAIN
, turn ON the FS100 power
supply.
2. Insert a CompactFlash card into the CompactFlash slot on the
– When using USB memory instead of CompactFlash, mount a USB
memory stick to the programming pendant, select {DEVICE}, then
select ”USB: PENDANT”.
To connect a USB memory stick to the USB device of the main CPU
board, mount a USB memory stick to the USB device, select
{DEVICE}, then select ”USB: CONTROLLER”.
3. Select {EX. MEMORY} under the main menu.
4. Select {SAVE}.
– The save display appears.
– The items marked with “” cannot be selected.
9-4
9 System Backup
5. Select {CMOS}.
6. Select {YES}.
– Select {YES} to save the CMOS data into a CompactFlash card.
– When saving the file, if the CMOS.BIN file already exists in the
CompactFlash card, the following confirmation dialog box appears.
7. Select {YES}.
– The CMOS.BIN file is overwritten in the CompactFlash card.
9-5
9 System Backup
9.2.2 CMOS.BIN Load

Follow the procedures below to load CMOS.BIN.
MAIN
supply.
2. Change the security mode to the maintenance mode.
– When using USB memory instead of CompactFlash, mount a USB
memory stick to the programming pendant, select {DEVICE}, then
select ”USB: PENDANT”.
To connect a USB memory stick to the USB device of the main CPU
board, mount a USB memory stick to the USB device, select
{DEVICE}, then select ”USB: CONTROLLER”.
5. Select {LOAD}.
– The load display appears.
9-6
9 System Backup
6. Select {CMOS}.
7. Select {YES}.
– The dialog box “Overwrite network configuration?” appears.
8. Select {YES} or {NO}.

– If {YES} is selected, the network configuration in the controller is
overwritten and the contents of the loaded “CMOS.BIN” file are
reflected to the CMOS in the controller.
– If {NO} is selected, the network configuration in the controller is not
updated and the other data are reflected to the CMOS in the
controller.
9-7
9 System Backup
CAUTION
When the “CMOS load” is performed, the current CMOS data is
replaced with the CMOS data (the contents of “CMOS.BIN”) in the
selected device. Therefore, before performing the load, make sure to
perform the “CMOS Save” of the CMOS data to be loaded.
After the “CMOS load”, check if the contents written in the FS100 are
the same as before, and check to be sure that safety is confirmed with
the current manipulator position. After that, start the manipulator’s
operation.
CAUTION
When the network configuration is updated, the IP address in the
controller is also updated. After the update, the settings of IP address
and subnet mask are changed, which may make it impossible to
communicate with the programming pendant or computer. Make sure
to record the network configuration of the programming pendant,
computer, etc. in advance.
9-8
9 System Backup
FS100 9.3 Automatic Backup Function
9.3 Automatic Backup Function
9.3.1 Automatic Backup Function
9.3.1.1 Objective
With the automatic backup function, the data saved in the FS100 such as
system setting or operational condition are collectively backed up in the
specified device.
In case of an unexpected trouble such as data loss, the backup data
saved in the CompactFlash card by the automatic backup function can be
loaded to the FS100 memory to restore the file data.
The automatic backup function is enabled only while the

NOTE FS100 power supply is ON whereas it isn’t while in the
maintenance mode or the power supply is OFF.
9.3.1.2 Outline
The automatic backup function saves the internally stored data in a single
file in advance for the smooth restoration from unexpected troubles of the
FS100.
The teaching operation is one of the factors that changes the internally
stored data. Thus, a mode which backs up the latest data after the
teaching operation is prepared. To confirm the termination of the teaching
operation, check the mode key whether it is changed from teach mode to
play mode.
Other than the teaching operation, the present position of the robot or the
value of a variable can be pointed out as the factors to change the
internally stored data. These data, however, are changed after each
operation and have very little need to be retained permanently.
Accordingly, backing up these data at regular interval should be well
enough to operate and the mode to back up the data at regular interval is
also prepared.
Furthermore, the mode to back up the data when starting up the FS100
and when inputting signals are also available for some specific versions.
With the automatic backup function, all the part where the internal data is
stored in the physical memory area is collectively saved. If there is any
data which is in the middle of changing while executing the automatic
backup function, the data might not be usable for restoration because of
its inconsistency. Therefore, the function is terminated with an error
during the play back operation or while the manipulator is in motion so that
the automatic backup cannot be operated. Set the automatic backup
function to be executed while the manipulator is not in the playback status
and while the manipulator is stopped.
9-9
9 System Backup
The automatic backup function has the following functions and features.
No. Function/Feature Explanation
1 Cyclic backup This function backs up as much of
In the teach mode, the data in the latest data as possible during
memory is backed up in a specified editing. The backup data saved in
cycle from a specified starting time. the CompactFlash card can be
loaded to the FS100 in case of data
loss so that the damage can be
minimized.
2 Backup when switching modes The editing data is backed up when
When switching the mode from the editing is completed. The latest
teach mode to the play mode, the data is automatically backed up with
data in memory is backed up. this mode.
3 Backup when start-up When the FS100 starts up, the data
When the FS100 starts up, the data in memory is backed up. Since the
in memory is backed up. editing/playback operation is
usually completed when the FS100
power is turned OFF, the latest data
is automatically backed up with this
mode.
4 Backup when inputting specified The data in memory is backed up
signals by the signal from the host at the
The data in memory is backed up intended timing. Although the
when a specified signal (#40560) is above mentioned items 1 to 3 are
input. designed to back up the data
automatically, this function backs up
the data in accordance with the
instruction from the host.
5 Backup while robot program is Backs up the variables for essential
stopped data.
The backup during playback is
disabled. However, in the play mode,
the backup is enabled if the robot is
stopped. (“Cyclic backup” and
“Backup when inputting specified
signals”)
6 Backup and retry at low priority The backup operation hardly affects
The data in memory is backed up at the other operations so that the
low priority so that this operation programming pendant can be used
does not affect the other operations. even during the backup operation.
When other operations affect the
backup operation, the backup is
suspended and retried later.
7 Backup in binary Backup in binary allows the system
The data is saved as binary data. to be easily and speedily restored.
The range is same as that of the “ALL
CMOS AREA” in {FD/CF}, but the
data type is different.
8 Setting of items Unnecessary settings can be
Parameters can limit the settings of avoided with this setting.
the backup condition.
9-10
9 System Backup
9.3.2 Settings for Automatic Backup

To set the automatic backup function, insert a CompactFlash card into the
CompactFlash slot on the programming pendant or connect a USB
memory stick to the USB device of the main CPU board, then set each
item on the AUTO BACKUP SET display.
Four ways to perform the automatic backup are available:

“Cyclic backup”, “Backup when switching modes”, “Backup
when start-up”, and “Backup when inputting specified sig-
NOTE
nals”.
The automatic backup can be performed only when the
robot is not during playback and the robot is stopped.
To use the automatic backup function, insert a CompactFlash card into

the CompactFlash slot on the programming pendant or insert a USB
memory stick into chapter 9.3.2.2 “USB Device of Main CPU Board” .
9.3.2.1 CompactFlash
When the data could not be saved in a CompactFlash card during an
automatic backup due to the absence or insufficient capacity of the
CompactFlash card, an error message “Cannot backup the media”
appears.
(At the same time, the signal “occurrence of error” is output, but the robot
program will not stop.)
Check if the CompactFlash card is inserted and if it has enough capacity,
and take the necessary measures.
Yaskawa recommends that the data be saved in two or more
CompactFlash cards to minimize problems if the CompactFlash card is
damaged.
Regarding CompactFlash card, refer to <Recommended CompactFlash>
in chapter 9.1.2 “Device” at page 9-2.
Storage capacity needed for the CompactFlash card is as follows:
(The number of stored files + 1) X 8 MByte
The number of storable files is automatically calculated and the MAX
value is shown when AUTO BACKUP SET display appears.
9.3.2.2 USB Device of Main CPU Board

When the data could not be saved in a USB memory stick during an
automatic backup due to the absence or insufficient capacity of the USB
memory stick, an error message “Cannot backup the media” appears.
(At the same time, the signal “occurrence of error” is output, but the robot
program will not stop.)
Check if the USB memory stick is inserted and if it has enough capacity,
and take the necessary measures.
Yaskawa recommends that the data be saved in two or more USB
memory sticks to minimize problems if the USB memory stick is damaged.
Regarding USB memory stick, refer to < Recommended USB Memory> in
chapter 9.1.2 “Device” at page 9-2.
Storage capacity needed for the USB memory stick is as follows:
(The number of stored files + 1) X 8 MByte
The number of storable files is automatically calculated and the maximum
number is shown when AUTO BACKUP SET display appears.
9-11
9 System Backup
9.3.2.3 AUTO BACKUP SET Display
 Settings
Select the following items on the AUTO BACKUP SET display and set
values for the automatic backup.
• RESERVE TIME BACKUP (VALID/INVALID of the cyclic backup)
• BASE TIME
• BACKUP CYCLE
• RETRY CYCLE
• MODE CHANGE BACKUP (VALID/INVALID of the backup when
switching the mode from teach mode to play mode)
• STARTUP AUTO BACKUP (VALID/INVALID of the backup when the
FS100 starts up)
• SPECIFIC INPUT BACKUP (VALID/INVALID of the backup when
inputting specified signals)
• UNIV.OUT NO. ON ERROR
• DISPLAY AT EMERGENCY
• DURING ALARM OCCURENCE
• STORED FILE SETTING
• DEVICE
• With the version in which “STORED FILE SETTING” is

settable, the capacity of a CompactFlash card inserted
into the programming pendant is checked when the set-
ting window appears. Therefore, a few seconds may be
needed to open the setting window and an error may
occur if no CompactFlash card is inserted.
NOTE
• When changing the settings of “STORED FILE SETTING”
or executing “ARRANGE”, the files “CMOSBK.BIN” and
“CMOSBK??.BIN” (? is a number) in the CompactFlash
card are changed in name or deleted. If a certain file of
this type is needed to be saved before changed in name
or deleted, evacuate it into a PC, etc. beforehand.
NOTE Each item’s setting cannot be changed in the AUTO

BACKUP SET display during alarm occurrence.
9-12
9 System Backup
1. Turn ON the FS100.

– If the auto backup function is already set valid, insert a
CompactFlash card.
5. Select {AUTO BACKUP SET}.
– The AUTO BACKUP SET display appears.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1 RESERVE TIME BACKUP

Sets the backup function to valid or invalid in a specified cycle from a
specified starting time.
Press [SELECT] to alternate between “INVALID” and “VALID”.
The reserve time can be set by inputting values in 2 , 3 , and 4 in
the display.
Every time values are set to these three items, reset the RESERVE
TIME BACKUP to VALID.
If these settings are incorrect, the RESERVE TIME BACKUP cannot be
reset to VALID.
If so, check and then change the values to the correct settings.
2 BASE TIME
Specifies the reference time to start reserve time backup.
The time elapsed from the reference time for a BACKUP CYCLE period
is recognized as the BACKUP TIME.
The first automatic backup is performed at the first BACKUP TIME after
the power of the FS100 is turned ON.
The automatic backup after the first time, is performed at the interval of
BACKUP CYCLES.
The reference time ranges from 0:00 to 23:59.
3 BACKUP CYCLE
Specifies the length of time for a cycle to back up.
After the first backup, the next backup is performed automatically in the
time specified in the BACKUP CYCLE.
Set the backup cycle in minutes. The cycle setting ranges from 10 to
9999 minutes, and is longer than the RETRY CYCLE.
9-13
9 System Backup
4 RETRY CYCLE
Specifies the length of time for a cycle to retry backing up when the
backup operation is suspended.
After being suspended, the backup is retried in the time specified in the
RETRY CYCLE.
Set the retry cycle in minutes. The cycle setting ranges from 0 to 255,
and is shorter than the BACKUP CYCLE.
When it is set to 0, retry will not be performed.
5 MODE CHANGE BACKUP
Sets the automatic backup function to be valid or invalid when the mode
is switched from teach mode to play mode.
6 STARTUP AUTO BACKUP
Sets the backup function to be valid or invalid when the power of the
FS100 is turned ON.
7 SPECIFIC INPUT BACKUP
Sets the backup function to be valid or invalid when specific input signal
(# 40560) is input (rising edge from 0 to 1).
8 UNIV.OUT NO. ON ERROR
Outputs “1” to the specified user output signal which was specified in
this chapter when the automatic backup error occurs.
The term “automatic backup error” here means that the backup is not
performed successfully before the next backup (including retry opera-
tion) starts.
9 DISPLAY AT EMERGENCY
Sets the method of notification of the automatic backup error to
“ERROR” or “MESSAGE”.
Press [SELECT] to alternate between “ERROR” and “MESSAGE”.
10 DURING ALARM OCCURENCE
Sets the backup function to be valid or invalid when an alarm occurs.
11 DEVICE
Specifies the device to store data.
Press [SELECT] to specify the device.
When the device is set to “CF: PENDANT”, the automatic backup is per-
formed only if communication is established between the programming
pendant and the FS100, and one of the four settings (RESERVE TIME
BACKUP, MODE CHANGE BACKUP, STARTUP AUTO BACKUP, and
SPECIFIC INPUT BACKUP) in the AUTO BACKUP SET display is set
to “VALID”.
12 STORED FILE SETTING
Sets the number of files to be stored by the automatic backup function.
The number mentioned on the right side of this item with “(Max)” indica-
tion is the maximum number of files (up to 100) that can be stored in the
CompactFlash card inserted when this window is displayed.
The settings range from 1 to (Max). When this setting value is changed,
the backup file arrangement starts.
9-14
9 System Backup
13 BACKUP FILES
Indicates the existence of the files or the number of backup files stored
in the CompactFlash card inserted when this window is displayed.
14 LATEST BACKUP FILE
Indicates the date of the latest file in the CompactFlash card inserted
when this window is displayed.
15 ARRANGE
When the setting of maximum number of stored files is changed, the file
arrangement of the backup files in the CompactFlash card is executed.
With this operation, the file arrangement can be performed without
changing the maximum number of stored files.
6. Set the desired item, and press [ENTER].
 Window setting restrictions

RS parameter can restrict the settings of some items in the automatic
backup window.
When setting the bit of RS096 parameter shown below to “1”, the
corresponding items are restricted. The restricted items are indicated with
“INVALID” in the display and input and modification to the item become
impossible. Also, the automatic backup does not function with the
restricted items.
<RS096>
D7 D6 D5 D4 D3 D2 D1 D0
RESERVE TIME BACKUP

MODE CHANGE BACKUP
STARTUP BACKUP
RETRY CYCLE
DURING ALARM BACKUP
SPECIFIC INPUT BACKUP
9-15
9 System Backup
9.3.2.4 FS100 Status and Automatic Backup
Backup Timing FS100 Status Automatic Backup

Compact Absence or
Flash insufficient
ready to capacity of the
save the CompactFlash
data
From a Teach mode Editing Retry Retry
specified (Accessing to
starting time the memory)
When editing is Backup Error
interrupted
Play mode Executing jobs Disabled Disabled
Remote mode When stopped Backup Error
When a Teach mode Editing Error Error
specified signal (Accessing to
(#40560) is the memory)
input When editing is Backup Error
interrupted
Play mode Executing jobs Disabled Disabled
Remote mode When stopped Backup Error
When switching - Backup Error
the mode from
the teach mode
to the play
mode
When the - Backup Error
FS100 starts up
* Retry is not performed when an error occurs.

* An error can be indicated by a message depending on setting.
 Reserve time backup

While the data in the FS100 memory is being edited or overwritten, the
automatic backup is not performed at the specified backup starting time
and is suspended and retried later. To start the backup at the reserved
time, set to the time when the robot program is stopped and no job or file
is edited.
 Backup when switching from teach mode to play mode

When the mode is repeatedly switched from the teach mode to the play
mode or vice versa within 1 to 2 seconds, backup starts after the last time
the mode is switched.
 Backup when FS100 starts up

Since the automatic backup process is added to the FS100 start-up
process, a few extra seconds are needed to start up the FS100.
9-16
9 System Backup
 Backup when specific signal is input

While the FS100 memory is edited such as overwriting, the backup
operation becomes an error even if there is an input to a specific signal
(#40560). To start the specific input backup, perform it while the robot
program is stopped and a job or file is not being modified.
Also, since the signal input is executed at rising detection, turn the signal
to “0” if it is already “1”, then return to “1” again.
 Overwriting limit in CompactFlash

The number of times to overwrite the CompactFlash card is limited.
Because frequent backup operations may shorten the life of
CompactFlash card, minimize the number of backup times.
 Overwriting limit in USB memory

The number of times to overwrite the USB memory stick is limited.
Because frequent backup operations may shorten the life of USB memory
stick, minimize the number of backup times.
9-17
9 System Backup
9.3.2.5 Setting Examples
 Setting Example 1
The following diagram shows a setting example with the following
conditions:
BASE TIME: 12:30
BACKUP CYCLE: 60 (minutes)
RETRY CYCLE: 10 (minutes)
Power ON BASE TIME
BACKUP CYCLE
RETRY CYCLE
11:00 11:30 11:40 11:50 12:30 13:30

1st day 1st day 1st day 1st day
Backup Backup Backup
 Setting Example 2
The following diagram shows a setting example with the following
conditions:
BASE TIME: 20:00
BACKUP CYCLE: 1440 (minutes) (24 hours)
RETRY CYCLE: 60 (minutes)
Power ON BASE TIME
BACKUP CYCLE
RETRY CYCLE
8:00 20:00 21:00 22:00 20:00 20:00

1st day 1st day 2nd day 3rd day
Backup Backup Backup
While a job is being executed, the automatic backup or retry

NOTE is not performed. Also, after an error occurs in writing into
the selected device, the retry is not performed until the next
backup starting time.
9-18
9 System Backup
FS100 9.4 Restoring Backup Data
9.4 Restoring Backup Data

Restore the backup data saved in the CompactFlash card to the FS100 in
the maintenance mode.
9.4.1 Restoring Procedure

1. Insert the CompactFlash card with the backup data into the
CompactFlash slot on the programming pendant.
– The backup data is stored under the file name “CMOSBK.BIN” or
“CMOSBK??.BIN” (? is a number).
MAIN
supply.
5. Select {SYSTEM RESORE}.

– The SYSTEM RESTORE display appears.
6. Select {SYSTEM RESTORE}.
– The BACKUP FILE LIST display appears.
9-19
9 System Backup
7. Select the file to be loaded.

– The confirmation dialog box “Initialize monitoring time?” appears.
– Select {YES} to initialize the system monitoring time.

Select {NO} to continue counting the current system’s monitoring
time.
8. Select {YES} in the confirmation dialog box.
– The confirmation dialog box “Overwrite network configuration?”

appears.
9-20
9 System Backup
9. Select {YES}.
– The network configuration set in the FS100 is overwritten, and the
loaded contents of “CMOS.BIN” or “CMOSBK??.BIN” (? is a
number) are loaded.
– When the load of “CMOSBK.BIN” or “CMOSBK??.BIN” (? is a
number) starts, the message “Loading system data. Don’t turn the
power off.” appears.
CAUTION
When “SYSTEM RESTORE” is performed, the internally stored data in
the FS100 is replaced with the contents of “CMOSBK.BIN” or
“CMOSBK??.BIN” (? is a number).
Give due consideration to it before performing “SYSTEM RESTORE”.
After “SYSTEM RESTORE”, check if the contents written in the FS100
are the same as before, and check to be sure that safety is confirmed
with the current manipulator position. After that, start the manipulator’s
operation.
9-21
9 System Backup
FS100 9.5 Error List
9.5 Error List
9.5.1 Error Contents
Error Data Message Cause

No.
0770 * The robot or the station is in The automatic backup would
motion. not work when the robot or a
manipulator is in motion.
3390 File not found The file to be loaded no longer
exists.
3460 * Check storage medium
1 Insufficient capacity of the
storage medium.
Check the medium.
2 Cannot access to the storage
medium.
Check the medium.
3501 * Cannot backup to medium Cannot access to the storage
medium.
Check the medium.
3550 * The automatic backup is The automatic backup window
executed. Try it later. cannot be called to display while
the automatic backup is being
processed.
3551 * The automatic backup is The file arrangement cannot be
executed. Arrange the file after operated during the automatic
it is finished. backup operation.
3560 * Failed to re-arrange the backup Failed to re-arrange the backup
file. file in the storage medium for a
reason other than access.
3580 * Accessing to backup file. Try it To display another window and
later. then display the automatic
backup window again after
“ARRANGE” operation,
“ARRANGE” process must be
completely finished.
3581 * Accessing to backup file. Try The previous “ARRANGE”
“ARRANGE” operation later. process must be completely
finished to perform the next
“ARRANGE” operation.
9-22
9 System Backup
FS100 9.6 Restoring FS100 Controller
9.6 Restoring FS100 Controller

Acquire the FS100 system program and the FS100 batch data (file name:
CMOS.BIN) in advance by following the procedures below.
This enables rapid and easy restoration of the system in case of system
failure.
9.6.1 Data Backup and Program Upload

By the program upload function of the FS100, the FS100 system program
can be saved in the CompactFlash card or USB memory stick inserted
into the programming pendant, or the USB memory stick inserted into the
main CPU board.
9.6.1.1 Backup Medium Preparation

For saving the FS100 system program, supply a CompactFlash card or a
USB memory stick with free space of 50 MB or more, and follow the
procedure below.
1. Connect the prepared device (CompactFlash card or USB memory
stick) to the PC.
2. Delete all data in the device by using Windows Explorer, etc.
3. Remove the device from the PC, then insert it into the programming
pendant or the main CPU board.
Fig. 9-1: Inserting CompactFlash Card into Programming Pendant
START HOLD
REMOTE TEACH
PLAY
CompactFlash card slot

Insertion direction
OPEN
SELECT
ENTRY
MAIN
Top
SERVO ASSIST
MENU SIMPLE ON CANCEL
MENU READY !?
X- X+ SERVO ON
X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
U- U+ T- T+
SLOW
E- E+ 8- 8+
SHIFT
INTER
LOCK 7SYNCRO 8
SINGLE
9 TEST
START SHIFT
Notch Tip
LIST

TOOL ON TOOL ON
JOB
AUX
MODIFY ENTER
TYPE JOB
Make sure to insert a CompactFlash card to the correct direction.

Make the programming pendant face up, and make the center notches of
both sides and the tip of the CompactFlash card face down, then insert it
slowly.
If the CompactFlash card is inserted forcibly, the card or the CF card slot
may be damaged.
After inserting the card into the slot, make sure to close the cover of the
slot before use.
9-23
9 System Backup
Fig. 9-2: Inserting USB Memory Stick into Programming Pendant
USB connector
Insert part
Top
USB memory stick
Make sure to insert a USB memory stick to the correct direction.

Make the programming pendant face down, and make the top of the USB
memory stick face up and make the connector point upward, then insert it
slowly.
If the USB memory stick is inserted forcibly, the stick or the USB
connector may be damaged.
After removing the stick from the connector, make sure to close the cover
of the connector before use.
Fig. 9-3: Inserting USB Memory Stick into Main CPU Board
Top
Make sure to insert a USB memory stick to the correct direction.

Make the top of the USB memory stick face to the left, then insert it slowly.
If the USB memory stick is inserted forcibly, the stick or the USB
connector may be damaged.
After removing the stick from the connector, make sure to close the cover
of the connector before use.
9-24
9 System Backup
 File system of device

Use an FAT 16 or FAT 32 formatted USB memory stick.
 Precautions for handling device

• Do not subject the device to excessive force or shock by dropping it,
bending it, etc.
• Do not subject it to water, oil, organic solvent, dust, or soot.
• Do not use or store it in a location where excessive static electricity
or electrical noise is present.
• During data writing or reading, do not remove or insert the device
and do not turn the power OFF.
• Backup the data regularly to another medium for data protection.
This can minimize the impact of data damage or loss in case of
improper operation or accident.
 Recommended device
It is recommenced to use the CompactFlash cards or USB memory sticks
listed in chapter 9.1.2 “Device” at page 9-2.
9-25
9 System Backup
9.6.1.2 Data Backup

Backup the FS100 batch data (file name: CMOS.BIN) by following the
procedure below.
When using the programming pendant, perform the steps 1 to 6, and
when not using the programming pendant, perform the steps 7 to 9.
MAIN
supply.
– The maintenance mode starts.
2. Select {DEVICE}.
– Select the device to save data.

9-26
9 System Backup
4. Select {SAVE}.
– The following menu appears.
5. Select {CMOS}.
6. Select {YES}.
– CMOS save starts.
– The process is completed when the message “Saving system data.
Don’t turn the power off.” at the human interface display area
disappears.
9-27
9 System Backup
7. Open the door of the FS100 controller. Turn the RSW1 of the main
CPU board from “0” to “E” by using a precision screwdriver (flathead, 2
mm), and insert a USB memory stick into the main CPU board.
RSW1
Top
8. Turn ON the FS100 power supply.

– CMOS save starts.
– While saving data, “J” lights up on the 7SegLED of the main CPU
board, and the LED of RUN blinks.
– When data save is finished, the LED of RUN of the main CPU board
lights up.
7SegLED RUN
CAUTION
• If CMOS data exists in the root directory of the USB memory stick, it
will be forcibly overwritten.
• Do not remove the USB memory stick while saving data.
Failure of the stick may result if it is removed while saving data.
9. After data save is finished, turn OFF the FS100 power supply.
– Turn the RSW1 of the main CPU board from “E” to “0”.
– Remove the USB memory stick.
9-28
9 System Backup
9.6.1.3 Program Upload

After finishing data backup, subsequently upload the program.
When using the programming pendant, perform the steps 1 to 8, and
when not using the programming pendant, perform the steps 9 to 11.
MAIN
supply.
2. Select {DEVICE}.
– Select the device to save the system program.
4. Select {SAVE}.
5. Select {SYSTEM UPLOAD}.
6. Select {YES}.
– The confirmation dialog box “Overwrite?” appears.
Select {YES} to overwrite.
Select {NO} to change the device to another.
9-29
9 System Backup
7. Select {YES}.
– Program upload starts.
– The process is completed when the message “Program uploading.
Don’t turn the power off.” at the human interface display area
disappears.
8. Turn OFF the FS100 power supply, and remove the device.
– For restoration, make sure to store the device to which the FS100
batch data (file name: CMOS.BIN) is backed up and the program is
uploaded by following the procedures above.
When a job is created, added, or modified, or a parameter, etc. is
changed, perform chapter 9.6.1.2 “Data Backup” at page 9-26.
When the system software is upgraded, perform
chapter 9.6.1.3 “Program Upload” at page 9-29.
<Procedure without using the programming pendant>
9. Open the door of the FS100 controller. Turn the RSW1 of the main
CPU board from “0” to “F” by using a precision screwdriver (flathead, 2
mm), and insert a USB memory stick into the main CPU board.
10. Turn ON the FS100 power supply.
– Program upload starts.
– While uploading the program, “u (lowercase)” lights up on the
7SegLED of the main CPU board, and the LED of RUN blinks.
– When program upload is finished, the LED of RUN of the main CPU
board lights up.
11. After program upload is finished, turn OFF the FS100 power supply.
– Turn the RSW1 of the main CPU board from “F” to “0”.
– Remove the USB memory stick from the main CPU board.
CAUTION
• The root folder of the USB memory stick is forcibly overwritten.
• Do not remove the USB memory stick while uploading the program.
Failure of the stick may result if it is removed while uploading the
program.
9-30
9 System Backup
9.6.2 Restoration Procedure

Check whether the replacement of the main CPU board is necessary. If
the replacement is necessary, follow the procedure below to restore the
FS100.
Failure of the FS100 is suspected when
• The 7SegLED of the main CPU board does not light up after turning
ON the FS100 power supply.
• The 7SegLED of the main CPU board fully lights up after turning ON
the FS100 power supply, but it does not count up after that.
• After turning ON the FS100 power supply, the programming pendant
keeps showing the startup window (showing the robot) for more than
one minute, and the 7SegLED of the main CPU board stays turned
off or fully lit up.
7SegLED
• After turning ON the FS100 power supply, an error described in

chapter 9.7 “Error Indication” at page 9-35 occurs, and the error
occurs again even after a retry.
CAUTION
• After the main CPU board is replaced, it is impossible to operate the
manipulator normally before writing the system program, and
loading the batch file or performing initialization in the maintenance
mode.
Give due consideration to it before replacing the main CPU board.
The restoration cannot be performed by using the optional

NOTE software pendant (PC version).
Make sure to use the programming pendant.
9.6.2.1 Preparation of Programming Pendant

For the FS100 in which a dummy connector inserted, prepare the
9.6.2.2 Preparation of Device for Writing System Program

Insert the device used in chapter 9.6.1 “Data Backup and Program
Upload” at page 9-23 into the programming pendant.
9-31
9 System Backup
9.6.2.3 Writing System Program

INTER
1. While pressing the interlock key LOCK
+ [8] + [SELECT], turn ON the
FS100 power supply.
– The upgrading tool starts.
2. Select {Software Upgrade}.

– Upgrade starts.
– The upgrade is completed when the message “Turn off controller
power supply” appears at the bottom of the screen.
9-32
9 System Backup
9.6.2.4 Writing Backup Data

Write the data by following the procedure below.
MAIN
supply.
4. Select {LOAD}.
– The LOAD window appears.
5. Select {CMOS}.
9-33
9 System Backup
6. Select {YES}.
– The confirmation dialog box “Overwrite network configuration?”
appears. If this step is performed after replacing the main CPU
board, select {YES}.
7. Select {YES}.
– Load starts, and the data inside FS100 is updated.
– The loading process is completed when the message “Loading
system data. Don’t turn the power off.” at the human interface
display area disappears.
Turn the FS100 power supply OFF then back ON to start it normally.
9-34
9 System Backup
FS100 9.7 Error Indication
9.7 Error Indication

If an error number is indicated on the 7SegLED of the main CPU board,
check the error content and correct the error. The error number is
repeatedly indicated.
<Example of repeated indication>

The indication repeats every second in the order of [] -> [0] -> [0] ->
[0] -> [,].
: The alphabet (“J”, “L”, “u”, or “b”) of the selected function is indicated.
J: System batch data save process
L: Language file load/save process
u: Program upload process
b: Boot program executing process
7SegLED Error content and countermeasure

indication
 0001. No USB memory stick.
Insert a USB memory stick, and retry.
 0010. The RC_SETUP.INI file needed for upgrading does not exist.
Retry according to chapter 9.6 “Restoring FS100 Controller”
at page 9-23.
If the error occurs again, replace the USB memory stick, then
retry according to chapter 9.6 “Restoring FS100 Controller” at
page 9-23.
 0011. The file needed for upgrading does not exist.
at page 9-23.
page 9-23.
 0012. The system file does not exist.
at page 9-23.
page 9-23.
 0013. The language file does not exist.
Copy the language file to the USB memory stick, then retry.
 0020. CRC error occurred.
Turn the FS100 power supply OFF then back ON.
If the error occurs again, replace the main CPU board.
 0021. Expanded in memory, but verification error occurred.
 0022. Writing failed because the maximum writing size was
exceeded.
Replace the USB memory stick to a new one, or delete files in
it.
 0024. The USB memory stick does not have enough free space.
Replace the USB memory stick to a new one, or delete files in
it.
 0030. Failed to ERASE or format the Flash Rom.
9-35
9 System Backup

indication
 0041. File open error occurred in a file stored in the USB memory
stick.
page 9-23.
 0042. File read error occurred in a file stored in the USB memory
stick.
page 9-23.
 0043. File write error occurred in a file stored in the USB memory
stick.
page 9-23.
 0044. File close error occurred in a file stored in the USB memory
stick.
page 9-23.
 0045. File creation failed in a file stored in the USB memory stick.
page 9-23.
 0046. File directory creation failed in a file stored in the USB memory
stick.
page 9-23.
 0047. File directory deletion failed in a file stored in the USB memory
stick.
page 9-23.
 0048. File deletion failed in a file stored in the USB memory stick.
page 9-23.
 0049. File rename failed in a file stored in the USB memory stick.
page 9-23.
 004F. File open error occurred in a file stored in the USB memory
stick.
page 9-23.
9-36
9 System Backup

indication
 0051. Access error occurred in a file stored in the Flash Rom.
 0052. File read error occurred in a file stored in the Flash Rom.
 0053. File write error occurred in a file stored in the Flash Rom.
 0054. File close error occurred in a file stored in the Flash Rom.
 0055. File creation error occurred in a file stored in the Flash Rom.
 0056. File directory creation error occurred in a file stored in the
Flash Rom.
 0057. File directory deletion error occurred in a file stored in the
Flash Rom.
 0058. File deletion error occurred in a file stored in the Flash Rom.
 0059. File rename error occurred in a file stored in the Flash Rom.
 005F. Access error occurred in a file stored in the Flash Rom.
 0090. Error code only for the manufacturer.
 0999. An error other than the above occurred.
9-37
10 Upgrade Function
FS100 10.1 Functional Overview
10 Upgrade Function
10.1 Functional Overview

For the CPU configuration, the FS100 has two pieces of software: the
software for the main CPU board and the software for the programming
pendant. Due to the compatibility of each software’s version, the system
runs only with the specified combination of the software versions.
Thus, the FS100 can upgrade the software for the programming pendant if
the combination of the software for the main CPU and the programming
pendant is invalid.
10.2 Upgrade Procedure
10.2.1 Confirmation of Software Version of Main CPU and Programming Pendant

The combination of the software versions for the main CPU and the
programming pendant is automatically checked in 25 seconds after the
FS100 power supply is turned on.
Only if the combination is invalid, automatic upgrade will be performed.
If the combination is compatible, automatic upgrade will not be performed.
• If the software versions of the main CPU and the programming pen-
dant are compatible:
– The initial window appears.
10-1
10 Upgrade Function
FS100 10.2 Upgrade Procedure
10.2.2 Automatic Upgrade

If the programming pendant software is older than the one stored in the
main CPU memory, or if the software version is incompatible, automatic
upgrade will be performed.
Note that the OS of the programming pendant will not be upgraded.
(OS: operating system)
1. After the automatic upgrade process is completed, the programming

pendant reboots and the main CPU stops communication processing.
2. After the programming pendant reboots, the main CPU restarts the
communication processing and the initial window appears on the
programming pendant screen.
To avoid the automatic upgrade, turn ON the FS100 power

INTER
SUPPLE
-MENT supply while pressing the interlock key LOCK
+ [5] +
[SELECT].
DO NOT turn off the main power supply during automatic

upgrade process.
In case the main power supply is turned off, exercise the fol-
lowing process.
• Turn on the main power supply of FS100.
– Automatic upgrade might be exercised again.
• In case error occurs during automatic upgrade process.
NOTE
(1) Supply CF for upgrading or USB memory.
(2) Press [2] + [8] + [HIGH SPEED].
-Upgrade of the OS of Programming Pendant
INTER
(3) Press the interlock key LOCK
+ [8] + [SELECT].
(4) Exercise manual upgrading.
- Refer to “FS100 Upgrade Procedure”
• If no recovery is made with all the procedure above,
replace the pendant.
10-2
11 Modification of System Configuration
FS100 11.1 Addition of I/O Modules
11.1 Addition of I/O Modules

To add I/O modules, turn OFF the power supply.
Addition operation must be performed in the management

SUPPLE
mode.
-MENT In the operation mode or editing mode, only reference of sta-
tus setting is possible.
MAIN
, turn the FS100 power supply
OFF then back ON.
3. Select {SYSTEM} under the main menu.
– The system window appears.
4. Select {SETUP}.
– The SETUP window appears.
11-1
5. Select {IO MODULE}.

– The current status of the mounted I/O module is shown.
6. Confirm the status of mounted I/O module.

– Confirm that each station (ST#) window is the same as the I/O
module’s actual mounting status.
– The following information is shown for each station.
ST# Station address of I/O module
DI Number of contact input points1)
DO Number of contact output points1)
BOARD Circuit board type2)
1) A hyphen, -, indicates that the corresponding I/O section is not mounted.

2) If the system cannot recognize the circuit board type, a row of stars (*****) are
shown. No problem will occur as long as the values displayed in DI and DO
are correct.
7. Press [ENTER].
– Confirm the statuses of the mounted I/O modules for the other
stations.
11-2
8. Press [ENTER].
9. Select {YES}.
– The system parameters are then set automatically according to the
current mounted hardware status. The procedure for the addition of
the I/O module is complete.
If there is a difference between the displayed contents and

NOTE the actual mounted status, confirm the status again. If the
status is correct, the I/O module may be defective: in such a
case, contact your Yaskawa representative.
11-3
FS100 11.2 Addition of Base and Station Axes
11.2 Addition of Base and Station Axes

To add the base and station axes, mount all hardware correctly and then
execute maintenance mode.
Addition operation must be performed in the management

SUPPLE
mode.
-MENT In the operation mode or editing mode, only reference of sta-
tus setting is possible.
When adding a base and a station axis, set the following items:
• TYPE
Select one in the type list.
• In case of base axis (B1, B2)
Select one of RECT-X, -Y, -Z, -XY, -XZ, -YZ or -XYZ.
• In case of station axis (S1, S2, S3)
Select UNIV-* (“*” represents the number of axes) when using a
mechanism other than the registered type as a station axis.
• CONNECTION
In the CONNECTION window, specify the SERVOPACK which is
connected with each axis group, the contactor which is used for the
SERVOPACK, and the overrun signal (OT).
• AXIS TYPE
Select from the axis type list.
• In case of TURN-* type
No need to select (The axis type is set as TURN type.)
• In case of RECT-* type
Select BALL-SCREW type or RACK & PINION type.
• In case of UNIV-* type
Select BALL-SCREW type, RACK & PINION type or TURN type.
• MECHANICAL SPECIFICATION
• If axis type is ball-screw type, set the following items:
• MOTION RANGE (+) [mm]
• MOTION RANGE (-) [mm]
• REDUCTION RATIO (numerator)
• REDUCTION RATIO (denominator)
• BALL-SCREW PITCH [mm/r]
• If axis type is rack & pinion type, set the following items.
• MOTION RANGE (+) [mm]
• MOTION RANGE (-) [mm]
• PINION DIAMETER [mm]
11-4
• If axis type is turn type, set the following items.

• MOTION RANGE (+) [deg]
• MOTION RANGE (-) [deg]
• OFFSET (1st and 2nd axis) [mm]
• MOTOR SPECIFICATION
Set the following items.
• MOTOR
• SERVO AMP
• CONVERTER
• ROTATION DIRECTION [normal/reverse]
• MAX. RPM [rpm]
• ACCELERATION SPEED [sec]
• INERTIA RATIO
* Select MOTOR, AMPLIFIER and CONVERTER from each type list on the
display.
11-5
11.2.1 Base Axis Setting
11.2.1.1 Selection of Base Axis Type

Select the type of base axis to be added or modified.
MAIN
, turn the FS100 power supply
OFF then back ON.
3. Select {SYSTEM} under the main menu.
– The system window appears.
4. Select {SETUP}.
– The SETUP window appears.
– Note that the items marked with “” cannot be set.
11-6
5. Select {CONTROL GROUP}.

– The current control group type is displayed.
6. Move the cursor to the type of control group to be modified, and press
[SELECT].
– The MACHINE LIST window is displayed.
RECT-X: traverse X-axis base

RECT-Y: traverse Y-axis base
RECT-Z: traverse Z-axis base
RECT-XZ: traverse XZ-axis base
RECT-XY: traverse XY-axis base
RECT-YZ: traverse YZ-axis base
RECT-XYZ: traverse XYZ-axis base
(See the figures on the next page)
7. Select one in the type list.

– After the type selection, the window changes to the CONNECTION
window.
11-7
RECT-X RECT-Y RECT-Z

Z Z Z
Y Y Y
X X
X
CARTESIAN CARTESIAN
Y-AXIS CARTESIAN
X-AXIS
Z-AXIS
Base axis direction of travel coincides Base axis direction of travel coincides Base axis direction of travel coincides
with robot coordinate X-Axis. with robot coordinate Y-Axis. with robot coordinate Z-Axis.
RECT-XY RECT-YZ RECT-XZ

Z Z
Z
Y
Y Y
X X
CARTESIAN X
Y-AXIS
CARTESIAN CARTESIAN
CARTESIAN CARTESIAN
Z-AXIS CARTESIAN X-AXIS
Y-AXIS X-AXIS Z-AXIS
Base 1st and 2nd axes directions of Base 1st and 2nd axes directions of Base 1st and 2nd axes directions of
travel coincide with robot coordinate travel coincide with robot coordinate travel coincide with robot coordinate
X-Axis and Y-Axis, respecitively. Y-Axis and Z-Axis, respectively. X-Axis and Z-Axis,respectively.
RECT-XYZ CARTESIAN
Z-AXIS
Z
Y
X
CARTESIAN CARTESIAN
Y-AXIS X-AXIS
Base 1st, 2nd, and 3rd axes directions

of travel coincide with robot coordinate
X-Axis, Y-Axis, and Z-Axis, respectively.
11-8
11.2.1.2 Connection Setting

In the CONNECT window, it is specified that each axis of each control
group is connected to which connector of the SERVO board, which brake
of the contactor unit, which converter, and which overrun signal.
1. Confirm the type of each control group in the CONNECT window.
– The connection status of each control group is displayed.
2. Select the connection item of a desired control group.

– The settable items are displayed.
– Select an item to change the setting. Select {Cancel} to return to the
CONNECT window.
– Specify which connector (CN) of the SERVO board each axis of

each control group is connected to.
The numbers in [ ] represent axis numbers, and indicate which axis
is connected to which connector.
– Specify which brake (BRK) each axis of each control group is
connected to.
The numbers in [ ] represent the axis numbers, and indicate which
axis is connected to which brake.
– Specify which converter (CV) each axis of each control group is
connected to.
The numbers in [ ] represent the converter numbers, and indicate
which axis is connected to which converter.
11-9
– Specify which overrun signal (OT) each control group is connected

to.
– In this example, B2 (Base) is connected in the following manner:
1st axis  SERVO Board (SV #2), Connector (7CN),
Brake Connector (BRK7), Converter (CV #1)
2nd axis  SERVO Board (SV #2), Connector (8CN)
Brake Connector (BRK8) Converter (CV #2)
Overrun  (OT2)
3. An overrun signal is allocated to a control group. Thus, when an

overrun alarm occurs, the subcode is indicated by the control group.
(With software of a version before DS1.20.00(A)-00, the subcode is
indicated in binary.)
However, select “NOT CONNECT” if an overrun switch is not installed
to the control group or the allocation of the external axis overrun signal
is not needed.
Regarding the connection of the external axis overrun signal, refer to
chapter 13.2.3 “Connection for External Axis Overrun” at
page 13-13.
4. Select a desired item.
5. Press [ENTER] in the CONNECT window.
– The setting in the CONNECT window is completed, the window
changes to the CONTROL GROUP window, and a confirmation
dialog box appears.
– Select {YES} to set the system parameters automatically according

to the selected items in the windows so far.
11-10
6. Initialize related files.
11-11
11.2.1.3 Axis Configuration Setting

Select “DETAIL” in the CONTROL GROUP window to select “INIT
(initialization)”, “MODIFY”, “DELETE”, or “DETAIL”.
– Select “INIT” to initialize parameters according to the current

settings.
– Select “MODIFY” to see the MACHINE LIST window.
– Select “DELETE” to delete the selected axis’s type.
– Select “DETAIL” to move to the AXIS CONFIG window.
The axis type is specified in the AXES CONFIG window.

1. Confirm axis type of each axis in the AXES CONFIG window.
– The axis type of each axis is displayed.
11-12
2. Select the axis type to be modified.

(1) The settable axis type is displayed.
(2) Select “BALL-SCREW” when the servo track is ball-screw type,

and “RACK&PINION” when the servo track is rack-and-pinion
type. After the selection, the window returns to the AXES CON-
FIG window.
(3) Select the axis type.
3. Press [ENTER] in the AXES CONFIG window.
4. The setting in the AXES CONFIG window is completed and the
window moves to the MECHANICAL SPEC window.
11-13
11.2.1.4 Mechanical Specification Setting

The mechanical data is specified in the MECHANICAL SPEC window.
1. Confirm specification of each axis in the MECHANICAL SPEC window.
– The mechanical specification of axis is shown.
MECHANICAL SPEC window (BALL-SCREW type)
Selected group,
type, axis no.,
and axis type
are shown.
– MOTION RANGE : Input maximum moving position (positive (+)

direction and negative (-) direction) from
home position when setting the home
position to 0. (Unit: mm)
– REDUCTION RATIO : Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/2, the
numerator should be set as 1.0 and the
denominator should be set as 2.0.
– BALL-SCREW PITCH: Input the traveling length when the ball-
screw rotates once. (Unit: mm/r)
MECHANICAL SPEC window (RACK & PINION type)
Selected group,
type, axis no.,
and axis type
are shown.

home position when setting the home position
to 0. (Unit: mm)
11-14
– REDUCTION RATIO: Input the numerator and the denominator.

<e.g.>If the reduction ratio is 1/120, the
– PINION DIAMETER : Input the diameter of a pinion. (Unit: mm)
2. Select the item to be modified.
– Point the cursor to the item subject for setting value modification,
and press [SELECT].
3. Modify the settings.
– The selected item is in the input status.
Input the setting value, and press [ENTER].
4. Press [ENTER] in the MECHANICAL SPEC window.
– After the setting, the current window moves to the window for the
next axis setting. Complete the settings for all axes in the same
manner.
– When [ENTER] is pressed in the MECHANICAL SPEC window for
the last axis, the setting in the MECHANICAL SPEC window is
completed and the window moves to the MOTOR SPEC window.
11-15
11.2.1.5 Motor Specification Setting

The motor data is specified in the MOTOR SPEC window.
1. Confirm specification of each axis in the MOTOR SPEC window.
– The motor specification of each axis is displayed.
2. Select the desired item.

– When a numerical value is selected, the number input buffer line
appears.
– When MOTOR (or SERVO AMP or CONVERTER) is selected, the
list window of MOTOR (SERVO AMP, or CONVERTER) appears.
– ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The counterclockwise view from the
loaded side is the normal rotation.)
Fig. 11-1: AC Servo Motor
Normal direction
– MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)

– ACCELARATION TIME: Input time between 0.01 and 1.00 to reach
maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
– INERTIA RATIO: The initial value is set at 300 in case of servo track;
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with
the followed procedure.
– <Phenomenon 1>
During motion, the axis moves unsteadily to the direction of travel.
 Check the motion by increasing this ratio in increments of 100.
– <Phenomenon 2>
During pause, the motor makes a strange noise.
 Check the motion by decreasing this ratio in increments of 100.
11-16

4. Press [ENTER] in the MOTOR SPEC window.
manner.
– When [ENTER] is pressed in the MOTOR SPEC window for the last
axis, the setting in the MOTOR SPEC window is completed and the
confirmation dialog box appears.

– Addition or modification of the base axis is completed.
11-17
11.2.2 Station Axis Setting
11.2.2.1 Selection of Station Axis Type

Select the type of station axis to be added or modified.
1. Confirm the type of control group in CONTROL GROUP window.
– The CONTROL GROUP window appears.
2. Select the type of control group to be modified.

– The MACHINE LIST window appears.
TURN-1: TURN 1 AXIS STATION

TURN-2: TURN 2 AXIS STATION
UNIV-1: UNIVERSAL 1 AXIS STATION
UNIV-2: UNIVERSAL 2 AXIS STATION
...
11-18
3. Select desired type in the type list.

– After the type selection, the window changes to the CONNECT
window.
– Select “UNIV” (universal) when using a mechanism other than the
registered type (such as a servo track) as a station axis. When
“UNIV” is selected, interpolation motion (linear, circular, etc.) is not
supported.
TURN-1
STATION 1ST AXIS
11-19
11.2.2.2 Connection Setting

In the CONNECT window, it is specified that each axis of each control
group is connected to which connector of the SERVO board, which brake,
which converter, and which overrun signal.
Note that the software version should be DS1.20.00(A)-00 or higher to set
the overrun signal.
1. Confirm the type of each control group in the CONNECT window.
– Connection status of each control group is displayed.
2. Select the connection item of desired control group.

– The settable items are displayed.
– Select an item to change the setting. Select {Cancel} to return to the
CONNECT window.
– Specify which connector (CN) of the SERVO board each axis of
each control group is connected to.
The numbers in [ ] represent axis numbers, and indicate which axis
is connected to which connector.
– Specify which brake (BRK) each axis of each control group is
connected to.
The numbers in [ ] represent the axis numbers, and indicate which
axis is connected to which brake.
– Specify which converter (CV) each axis of each control group is
connected to.
The numbers in [ ] represent the converter numbers, and indicate
which axis is connected to which converter.
– Specify which overrun signal (OT) each control group is connected
to.
– In this example, S1 (Station) is connected in the following manner:
1st axis  SERVO Board (SV #1), Connector (7CN),
2nd axis  SERVO Board (SV #1), Connector (8CN),
Overrun  (OT2)
11-20
3. In software of the version DS1.20.00(A)-00 or higher, an overrun

signal is allocated to a control group. Therefore, when an overrun
alarm occurs, the subcode is indicated by the control group. (With
software of a version before DS1.20.00(A)-00, the subcode is
indicated in binary.)
However, select “NOT CONNECT” if an overrun switch is not installed
to the control group or the allocation of the external axis overrun signal
is not needed.
Regarding the connection of the external axis overrun signal, refer to
chapter 13.2.3 “Connection for External Axis Overrun” at
page 13-13.
5. Press [ENTER] in the CONNECT window.
– The setting in the CONNECT window is completed, the window
changes to the CONTROL GROUP window, and the confirmation
dialog box appears.
11-21
11.2.2.3 Axis Configuration Setting

Select “DETAIL” in the CONTROL GROUP window to select “INIT
(initialization)”, “MODIFY”, “DELETE”, or “DETAIL”.
– Select “INIT” to initialize parameters according to the current
settings.
– Select “MODIFY” to see the MACHINE LIST window.
– Select “DELETE” to delete the selected axis’s type.
– Select “DETAIL” to move to the AXIS CONFIG window.
The axis type and motor type are specified in the AXES CONFIG window.
1. Confirm axis type of each axis in the AXES CONFIG window.
– The axis type of each axis is displayed.
• AXES CONFIG window (TURN type)
when axis type is

"ROTATION",
the axis type cannot
be changed.
• AXES CONFIG window (UNIVERSAL type)
BALL- SCREW: Traverse axis

(ball-screw)
RACK&PINION: Traverse axis
(rack&pinion)
ROTATION: Rotation axis
11-22
2. Select the axis type to be modified.

– The settable axis type is displayed.
3. Select the desired axis type.

4. Press [ENTER] in the AXES CONFIG window.
– The setting in the AXES CONFIG window is completed and the
window moves to the MECHANICAL SPEC window.
11-23
11.2.2.4 Mechanical Specification Setting

The mechanical data is specified in the MECHANICAL SPEC window.
1. Confirm specification of each axis in the MECHANICAL SPEC window.
– The mechanical specification of axis is shown.
Selected group, type, axis no.

and axis type are shown.
OFFSET is displayed on
the screen of the 1st axis
only when the TURN-2 type
is selected.

direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: deg)
– OFFSET : Offset should be specified at “TURN-2” type
only.
Input length between the center of bending
axis (1st axis) and the turning table (2nd axis).
(Unit: mm)
TURN-2
STATION 2ND AXIS

(ROTATION TABLE)
OFFSET
STATION 1ST AXIS

(INCLINATION AXIS)
11-24
• MECHANICAL SPEC window (BALL-SCREW type)


home position when setting the home
position to 0. (Unit: mm)
– REDUCTION RATIO : Input the numerator and the denominator.
– BALL-SCREW PITCH: Input the traveling length when the ball-
screw rotates once. (Unit: mm/r)
• MECHANICAL SPEC window (RACK & PINION type)


direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: mm)
<e.g.>If the reduction ratio is 1/120, the
– PINION DIAMETER : Input the diameter of a pinion. (Unit: mm)
11-25
• MECHANICAL SPEC window (ROTATION type)

– MOTION RANGE: Input maximum moving position (positive (+)

direction and negative (-) direction) from home position when setting
the home position to 0. (Unit: deg)
<e.g.> If the reduction ratio is 1/120, the numerator should be set as
1.0 and the denominator should be set as 120.0.
3. Press [ENTER] in the MECHANICAL SPEC window.
manner.When [ENTER] is pressed in the MECHANICAL SPEC
window for the last axis, the setting in the MECHANICAL SPEC
window is completed and the window moves to the MOTOR SPEC
window.
11-26
11.2.2.5 Motor Specification Setting

The motor data is specified in the MOTOR SPEC window.
1. Confirm specification of each axis in the MOTOR SPEC window.
– The motor specification of each axis is displayed.


– When a numerical value is selected, the number input buffer line
appears.
When MOTOR (or SERVO AMP or CONVERTER) is selected, the
list window of MOTOR (SERVO AMP or CONVERTER) appears.
– When the type is selected, the window returns to the AXES CONFIG
window.
– ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The counterclockwise view from the
loaded side is the normal rotation.)
Fig. 11-2: AC Servo Motor
Normal direction
– MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)

– ACCELARATION SPEED: Input time between 0.01 and 1.00 to
reach maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
– INERTIA RATIO: The initial value is set at 300 in case of servo track;
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with
the followed procedure.
11-27
– <Phenomenon 1>
During motion, the axis moves unsteadily to the direction of travel.
 Check the motion by increasing this ratio in increments of 100.
– <Phenomenon 2>
During pause, the motor makes a strange noise.
 Check the motion by decreasing this ratio in increments of 100.
CAUTION
• If the control axis configuration is changed by addition of a base
axis or station axis, the internal data of the job file are also changed
so that the job file data should be initialized.
Initialize the job file data with procedure “File Initialize” in this
manual after changing the construction.
• When the data, motion range for example, should be changed after
the addition of a base axis or station axis, the change can be done
in the same procedure as shown above.
In this case, the control axis configuration is not changed so the job
file data should not be initialized.
11-28
12 FS100 Specification
FS100
WARNING
• Make sure that there is no one within the manipulator’s operating
range and that you are in a safe place before turning ON the FS100
power.
Injury may result from collision with the manipulator to anyone entering
the manipulator’s operating range.
• Always set the teach lock before starting teaching.
the safeguarding.
– Always have an escape plan in mind in case the manipulator
comes toward you unexpectedly.
– Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional manipulator operation can result in injury.
goes out when the emergency stop button on the programming
pendant is pressed.
The emergency stop button is located on the right of the programming
pendant.
12-1
FS100
CAUTION
• Perform the following inspection procedures prior to performing
teaching operations. If problems are found, correct them
immediately, and be sure that all other necessary processing has
been performed.
– Check for damage to the insulation and sheathing of external
wires.
• Always return the programming pendant to its specified position
after use.
If the programming pendant is inadvertently left on the manipulator,
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injuries or equipment
damage.

system manager.
12-2
FS100 12.1 Specifications of FS100
12.1 Specifications of FS100
Item For Japan and North America For Europe

Structure Free-standing, open type
Dimensions 470 (W) × 200 (H) × 420 (D) mm
Approximate 20 kg (except options such as an additional external axis)
mass
45 kg (SDA5F, SDA10F, SDA20F)
(except options such as an additional external axis)
Cooling system Direct cooling
Grounding Grounding resistance: 100 Ω or less, exclusive grounding1)
Digital I/O NPN PNP
Specific signals (hardware): 10 inputs and 1 outputs
General signals (standard, maximum): 28 inputs, 28 outputs
(transistor: 28 outputs)
Positioning By serial communication (absolute encoder)
system
Drive unit SERVOPACK for AC servomotors
Acceleration/ Software servo control
deceleration
Memory 10000 steps, 1000 instructions
capacity
CIO ladder Max. 1500 step
Built-in None
transformer
Brake release The brake of each system can be released individually by the
1 Perform grounding in accordance with all relevant local and national electrical
codes.
The size of the ground wire must be equal to or larger than the size listed in
table 4-2 “FS100 Power Capacity, Cable Size, and Circuit Protector” at
page 4-6.
12-3
FS100 12.2 Functions of FS100
12.2 Functions of FS100
Programming Coordinate Joint, Rectangular/Cylindrical, Tool, User

System Coordinates
Pendant
Modification of Adding, Deleting, Correcting (Robot axes
Operation
Teaching Points and external axes respectively can be
corrected.)
Inching Operation Possible
Path Forward/Reverse step, Continuous
feeding
Confirmation
Speed Adjustment Fine adjustment possible during operating
or pausing
Timer Setting Possible every 0.01 s
Short-cut Function Direct-open function, Multi-window
Interface CF (CompactFlash) card slot, USB port
(USB1.1) (on programming pendant),
USB port (2.0) (on control circuit board),
RS232C (on control circuit board),
LAN (100 BASE-TX/10BASE-T) (on
control circuit board) (optional)
Safety Essential JIS (Japanese Industrial Standard)
Measures
Feature
Running Speed User definable
Limit
Enable Switch 3 position type. Servo power can be
turned on at the middle position only.
(Located on programming pendant)
Collision proof Cubic frame,
Frames Axis frame
Self-Diagnosis Classifies error and two types of alarms
(major and minor) and displays the data
User Alarm Possible to display alarm messages for
Display peripheral device
Machine Lock Test-run of peripheral devices without
robot motion
Door Interlock A door can be opened only when a circuit
breaker is OFF.
Maintenance Operation Time Control power-on time, Servo power-on
Display time, Playback time, Operation time, Work
Function
time
Alarm Display Alarm message, troubleshooting, previous
alarm records
I/O Diagnosis Simulated enabled/disabled output
possible
T.C.P. Calibration Automatically calibrates parameters for
end effectors using a master positioner
12-4
FS100 12.2 Functions of FS100
Programming Programming Interactive programming

Type
Language Robot language: INFORM II
Robot Motion Joint coordinates, Linear/Circular
Control interpolations, Tool coordinates
Speed Setting Percentage for joint coordinates, 0.1mm/s
units for interpolations, Angular velocity
for T.C.P. fixed motion
Program Control Jumps, Calls, Timer, Robot stop,
Execution of some instructions during
Instructions
manipulator motion
Variable Global variable, Local variable
Variable Type Byte type, Integer-type, Double precision-
type, Real type, Position type, String type
I/O Instructions Discrete I/O, Pattern I/O processing
12-5
FS100 12.3 Specifications of Programming Pendant
12.3 Specifications of Programming Pendant
Item Specifications
Type JZRCR-YPP03-1
or JZRCR-YPP13-1
Dimensions 169 (W) × 314.5 (H) × 50 (D) mm
(excluding protrusions)
Approximate 990 g
mass 5
4 START HOLD
Material Reinforced plastic

REMOTE TEACH
PLAY
8
Control (1) Select key
device (2) Axis keys 7
(3) Numeric/application keys
(4) Mode switch with a key
(mode: teach, play, remote)
OPEN
SELECT
1
ENTRY
MAIN SERVO ASSIST
Key type: AS6-SK-132

MENU SIMPLE ON CANCEL
MENU READY !?
X- X+ SERVO ON
X- X+
(manufactured by IDEC) 1)
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
(5) Emergency stop button

U- U+ T- T+
SLOW
2
E- E+ 8- 8+
(6) Enable switch SHIFT

INTER
LOCK 7SYNCRO 8
SINGLE
9 TEST
START SHIFT
(7) CompactFlash card slot

4SMOV 5 6
6
INFORM BWD FWD
ROBOT
LIST

TOOL ON TOOL ON
(CompactFlash is optional.)
JOB
AUX
MODIFY ENTER
TYPE JOB
(8) USB port (1 port)

Display 640 × 480 pixel color LCD, 3
touch panel (Alphanumeric
characters, Chinese characters,
Japanese letters, etc.)
IEC IP65
protection
class
Cable length Standard: 8 m,
Max.: 20 m (optional)
Key sheet General (1 sheet only)
1 Two keys are supplied with the programming pendant.
12-6
FS100 12.4 Equipment Configuration of FS100
12.4 Equipment Configuration of FS100

The equipment configuration of the FS100 is described below.
12.4.1 Arrangement of Units and Circuit Boards
Fig. 12-1: Equipment Configuration of FS100
Mounting base unit

CSTR-MBB08AAA
PWM amplifier module
CSTR-SDB***AAA
Converter unit
CSTR-COB02AA Major axes control circuit board
CSTR-IFBM3LB
I/O relay circuit board

CSTR-FBBCA8R03CAA
User I/O circuit board

Power relay circuit board for Japan and North America: JAPMC-IO2308R-E
JEPMC-PSD3007R-E (abbreviated as LIO-08R)
Control circuit board for Europe: JAPMC-IO2309R-E
JEPMC-CP3201R-E (abbreviated as LIO-09R)
(abbreviated as CPU-201R) Machine safety circuit board
JAPMC-SF2300R-E
(abbreviated as SF2300R)
Top view
(without top cover)
12-7
13 Description of Units and Circuit Boards
FS100
WARNING
• When turning ON the power to FS100, be sure that there is no one
within the manipulator’s operating range, and that you are in a safe
place.
Injury may result from collision with the manipulator to anyone entering
the manipulator’s operating range. Always press the emergency stop
button immediately if there are problems.
• Always set the teach lock before starting teaching.
the safeguarding.
emergency.
goes out when the emergency stop button on the programming
pendant is pressed.
stopped in case of an emergency. The emergency stop button is
13-1
FS100
CAUTION
Perform the following inspection procedures prior to performing
teaching operations. If problems are found, correct them immediately,
and be sure that all other necessary processing has been performed.
• Always return the programming pendant to its specified position
after use.
If the programming pendant is inadvertently left on the manipulator or
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injuries or equipment
damage.

system manager.
13-2
FS100
 Cautions on Connection for Dual Input Signals
CAUTION
• Connect the switch (contact) that turns the dual signals ON and
OFF simultaneously.
• If the timing that turns the two signals ON and OFF is not right, a
disagreement alarm occurs. Refer to the figure below.
FS100
Front panel
Machine safety circuit board
CN3 CN2 Switch
A1 1
+24V
B1 2
Input signal 1
Turn ON/OFF
A6 11 simultaneously
Input signal 2
B6 12
024V
CAUTION
• Do not connect two signals to the same contact point.
(Prepare two individual contact points)
• Since the power supply for each signal is reversed, it will short-
circuit and may cause breakdown of FS100 Unit if the signals are
connected to the same contact point.
FS100
Front panel
CN3 CN2 Switch
A1 1
+24V
The same contact
B1 2
Input signal 1
A6 11
Input signal 2
B6 12
024V
Short-circuit current
13-3
FS100 13.1 CPU Unit
13.1 CPU Unit
13.1.1 CPU Unit Configuration

CPU unit consists of a power relay circuit board, control circuit board,
circuit board rack, machine safety circuit board, and user I/O circuit board.
The machine safety circuit board and user I/O circuit board are mounted
on the circuit board rack.
The power relay circuit board, control circuit board, and circuit board rack
are connected by using the connectors on the back.
Fig. 13-1: CPU Unit Configuration
CP3201R
RSW1(Right side)
RSW2(Left side)
JAPMC-SF2300R-E
(abbreviated as SF2300)
Control circuit board
JEPMC-CP3201R-E
for Japan and North America: JAPMC-IO2308R-E
(abbreviated as CPU-201R)
(abbreviated as LIO-08R)
Power relay circuit board for Europe: JAPMC-IO2309R-E
JEPMC-PSD3007R-E (abbreviated as LIO-09R)
LI0-08R
CP3201R
7-seg LED
Status indication LED
CP3201R SW2
CP3201R SW1
CP3201R
(CN4) USB
CP3201R
(CN1) RS232C
CP3201R
(CN5) High-speed Circuit board rack
serial communication JEPMC-BUB3008R-E
CP3201R (8 slots in total: 3 slots used, 5 slots available)
(CN2) Ethernet
(CN3) Programming pendant connection
13-4
FS100 13.1 CPU Unit
13.1.2 Circuit Board in CPU Unit
13.1.2.1 Control Circuit Board (JEPMC-CP3201R-E, Abbreviated as CPU-201R)

This board performs to control the entire system, display to the
programming pendant, control the operating keys, control operation, and
calculate interpolation.
The operation status of the FS100 is indicated by the 7-seg LED and
status indication LED.
(For details of the 7-seg LED and status indication LED, refer to chapter
11 “LED Indicator on Each Circuit Board” of “FS100 MAINTENANCE
MANUAL”.)
This board is connected with the major axes control circuit board (CSTR-
IFBM3LB) via high-speed serial communication, and has a USB port (2.0)
and Ethernet (100BASE-TX/10-BASE-TX).
Please do not change the factory setting of RSW1 except

NOTE operations which are described at chapter 9.
(Factory setting is [0] )
Please do not change the factory setting of RSW2.

NOTE
(Factory setting is [0])
Please do not change the DIP switch settings of SW1 and

NOTE SW2.
(Factory settings are all "OFF")
13.1.2.2 Power Relay Circuit Board (JEPMC-PSD3007R-E)

This is the relay board to receive the control power supply for the entire
CPU rack from the converter unit (CSTR-COB02AA).
13.1.2.3 Circuit Board Rack (JEPMC-BUB3008R-E)

This is the rack to mount the circuit boards including optional circuit
boards.
This rack is connected with the control circuit board (JEPMC-CP3201R-E)
by using the connectors on the back.
The total number of slots is 8, but the circuit boards (machine safety circuit
board and user I/O circuit board) are mounted as standard. Thus, the
number of available slots is 5, i.e., 5 optional circuit boards can be
mounted.
13-5
FS100 13.2 Machine Safety Circuit Board (JAPMC-SF2300R-E, Abbreviated as
SF2300)
13.2 Machine Safety Circuit Board (JAPMC-SF2300R-E,
Abbreviated as SF2300)
13.2.1 Machine Safety Circuit Board (JAPMC-SF2300R-E)

This unit contains dual processing circuits for safety signal.
It processes external safety signals with the dual processing circuits and
control ON/OFF of the output of the PWM amplifier module according to
conditions.
The functions of the machine safety circuit board include the following:
• Robot system input circuit (safety signal dual circuits)
• Servo-ON enable (ONEN) input circuit (dual circuits)
• Protection stop (PSTOP) input circuit (dual circuits)
• Programming pendant signal PPESP, PPDSW input circuit
(dual circuits)
For details of the status indication LED, refer to chapter 10 “LED Indicator
on Each Circuit Board” of “FS100 MAINTENANCE MANUAL”.
Status indication LED
(CN2)
PPESP/PPDSW
(CN3)
Front panel CN2 cable connection
(safety signal)
(CN4)
PWM module control signal output
(CN5)
Overrun OT1, OT2
(CN6)
24 V input for safety signal I/O
13-6
SF2300)
13.2.2 Connection for Robot System Input Signal
A connector to input the robot system signal is prepared on the lower right
of the front panel of the FS100. (Connector number: CN2)
For connection, refer to the connection diagram of each item.
(CN2)
Robot system signal
input connector
Table 13-1: Pin Assignment of Robot System Signal Input Connector (CN2)
Controller-side connector: 17JE-13250-02(D4A)A, manufacturer: DDK
Note: fitting stud M2.6
Mating connector: 17JE-43250-02(D8A1)-CG (connector with hood), manufacturer: DDK
* Upon shipment of the FS100, a dummy connector which short-circuits each
system signal is attached.
1 SAFF_1+ Safeguarding (safety plug) (first system)
2 SAFF_1- * Upon shipment of the FS100, this is short-circuited
with a jumper cable in the dummy connector.
3 PSTOP_1+ Protection stop (first system)
4 PSTOP_1- * Upon shipment of the FS100, this is short-circuited
5 EXESP_1+ External emergency stop (first system)
6 EXESP_1- * Upon shipment of the FS100, this is short-circuited
7 ESPOUT_1+ Do not short-circuit.
8 ESPOUT_1-
9 PPESP3+ Programming pendant emergency stop output
10 PPESP3- (first system)
11 SAFF_2+ Safeguarding (safety plug) (second system)
12 SAFF_2- * Upon shipment of the FS100, this is short-circuited
13 Not used
14 PSTOP_2+ Protection stop (second system)
15 PSTOP_2- * Upon shipment of the FS100, this is short-circuited
16 EXESP_2+ External emergency stop (second system)
17 EXESP_2- * Upon shipment of the FS100, this is short-circuited
18 ESPOUT_2+ Do not short-circuit.
19 ESPOUT_2-
20 PPESP4+ Programming pendant emergency stop
21 PPESP4- output(second system)
22 Not used
23 Not used
24 Not used
25 Not used
* To input a system signal, supply a new connector for the signal.

To a signal not used, connect a jumper cable similarly to when the
FS100 is shipped.
13-7
SF2300)
13.2.2.1 Connection for Protection Stop (PSTOP) Signal
Connect this signal line when using the function to immediately turn OFF
the servo power for safety protection when the servo power of the FS100
robot system is turned ON.
This signal is not used as standard, and a jumper cable is connected in
the dummy connector.
To use this signal, supply a new connector and perform wiring.
To a robot system signal which is not used, connect a jumper cable
similarly to when the FS100 is shipped.
The dual inputs of the protection stop signal are used for safety. Thus,
connect the switch (contact) that turns the dual signals ON and OFF
simultaneously.
If only one of the signals is turned ON, an alarm occurs.
Fig. 13-2: Connection for Protection Stop Signal

FS100
Front panel
CN3 CN2
Protection stop signal
A2 3
PSTOP_1+
B2 4
PSTOP_1-
Turn ON/OFF
PSTOP_2+
B7 15
PSTOP_2-
13-8
SF2300)
13.2.2.2 Connection for Safeguarding (Safety Plug) (SAFF) Signal
This is the signal to turn OFF the servo power when the safeguarding
opens.
Connect the interlock signal of the safety plug, etc. mounted on the door of
safeguarding.
When the interlock signal is input, the servo power turns OFF, and the
servo power cannot be turned ON after that.
This is disabled in the teach mode.
Upon shipment of the FS100, a jumper cable is connected in the dummy

connector.
To use the robot, supply a new connector and perform wiring of the
safeguarding signal.
CAUTION
Fig. 13-3: Connection for Safeguarding (Safety Plug) Signal

FS100
Front panel
CN3 CN2
Safeguarding (safety plug) signal
A1 1
SAFF_1+
B1 2
SAFF_1-
Turn ON/OFF
SAFF_2+
B6 12
SAFF_2-
13-9
SF2300)
 Installation example of safety plug
Install a safeguarding and a door with the interlock function around the
manipulator so that an operator must open the door to enter and the
interlock function stops the robot operation when the door opens.
The safety plug input signal is the signal to connect this interlock signal.
Fig. 13-4: Installation Example of Safety Plug
Manipulator’s
Safeguarding
range of motion
Servo ON lamp
(optional)
FS100
Safety door
Safety plug
Emergency
stop button
Portable plug
When the servo power is ON, input the interlock signal to turn OFF the
servo power.
(The servo power cannot be turned ON while the interlock signal is input.)
Note that the servo power does not turn OFF in the teach mode.
(The servo power can be turned ON even while the interlock signal is
input.)
13-10
SF2300)
13.2.2.3 Connection for External Emergency Stop (EXESP) Signal
This signal is used to connect the emergency stop switch of an external
device, etc.
If the signal is input, the servo power is turned OFF and the job is stopped.
While the signal is input, the servo power cannot be turned ON.
Upon shipment of the FS100, a jumper cable is connected in the dummy

connector.
To use the this signal, supply a new connector and perform wiring of the
external emergency stop signal.
CAUTION
Fig. 13-5: Connection for External Emergency Stop Signal
FS100
Front panel
CN3 CN2
External emergency stop signal
A3 5
EXESP_1+
B3 6
EXESP_1-
Turn ON/OFF
EXESP_2+
B8 17
EXESP_2-
13-11
SF2300)
13.2.2.4 Connection for Emergency Stop Output (ESPOUT) Signal
This signal outputs, as dual signals, the signal status of the emergency
stop of the programming pendant, the external emergency stop, and the
safeguarding (safety plug) in the automatic operation mode.
This signal can be used to check the signal status of the emergency stop
of the programming pendant, the external emergency stop, and the
safeguarding (safety plug) in the automatic operation mode by using an
external safety device, etc. (for monitor use only)
To use this signal, supply a new connector and perform wiring.
Fig. 13-6: Connection for Emergency Stop Output Signal
FS100
Front panel
CN3 CN2
Emergency stop
A4 7 output signal External device
ESPOUT_1+
B4 8
ESPOUT_1-
A9 18
ESPOUT_2+
ESPOUT_2- B9 19
* Output capacity: 24 VDC, 50 mA max.
13-12
SF2300)
13.2.3 Connection for External Axis Overrun
If the overrun input of an external axis, etc. other than the manipulator is
needed, perform connection as shown in fig. 13-7 “Connection for
External Axis Overrun Signal” .
If the signal is input, the servo power is turned OFF and the job is stopped.
While the signal is input, the servo power cannot be turned ON.
The dual inputs of the external axis overrun signal are used for safety.
Thus, connect the switch (contact) that turns the dual signals ON and OFF
simultaneously.
If only one of the signals is turned ON, an alarm occurs.
For the standard specification (without external axis), this signal cannot be
used because the connectors for input (EX-X11, EX-X12) are not
mounted.
Fig. 13-7: Connection for External Axis Overrun Signal

FS100
Rear panel
CN5 EX-X11
External axis overrun signal
A2 25
OT2_1+
B2 26
OT2_1-
Turn ON/OFF
OT2_2+
B4 28
OT2_2-
13-13
FS100 13.3 Converter Unit
13.3 Converter Unit
13.3.1 Converter Unit (CSTR-COB02AA)

The converter unit (CSTR-COB02AA) has the following functions:
1. Supplies the DC power (5 V, 24 V) for control (system, I/O, brake)
2. Converts the main power supply (three-phase 200/220 VAC at 50/60
Hz for all manipulator models, single-phase 200/230 VAC at 50/60 Hz
for MHJ, MH5F, MH5LF, SIA5F, SIA10F, SIA20F, SDA10F, SDA20F) to
DC power, and supplies it to the PWM amplifier module for each axis.
Use the converter unit (CSTR-COB02AA) with the capacitor circuit board
(CSTR-CRBCC22AAA).
(CN304)
Control power supply input
Status indication LED (CN305)

SOURCE/+5VC PWM amplifier module
Control power supply output
(CN301)
DC power supply output (CN306)
Regenerative resistor connection Brake power supply
(24 V) output
(CN302)
Capacitor circuit (CN307)
board connection Control power supply
(24 V) output
(CN303) (CN308)
Main power supply input Control power supply
(5 V) output
(CN309)
Major axes control circuit board I/F
(CN310)
I/O power supply (24 V) output
Item Specifications
Input power Main power supply: three-phase 200/220 VAC at 50/60 Hz for
supply all manipulator models
single-phase 200/230 VAC at 50/60 Hz for
MHJ, MH5F, MH5LF, SIA5F, SIA10F,
SIA20F, SDA10F, SDA20F
Control power supply: single-phase 200 to 230 VAC at 50/60 Hz
Range of voltage regulation: +10% to -15%
Output voltage DC power supply for PWM amplifier module: Input voltage × 2
Control power supply: 16.5 V (for PWM amplifier module)
: 5 V (for CPU rack control power supply)
: 24 V (24V1: for system, 24V3: for I/O,
24V4: for brake)
Monitor and
alarm function
Indication Color Status
SOURCE Green Lights up with the input of
control power supply.
+5VC Green Lights up with the output of
+5VC.
13-14
FS100 13.4 SERVOPACK
13.4 SERVOPACK
A SERVOPACK consists of a mounting base unit, PWM amplifier module,
and major axes control circuit board. The configuration of PWM amplifier
module differs depending on the manipulator model.
13.4.1 Description of Each Unit
(CN52)
Converter unit control
signal connection
Major axes control circuit board
(CN120) CSTR-IFBM3LB
I/O relay circuit board control
signal connection
(CN53)
control power supply input
(CN54)
main power supply input
Mounting base unit

CSTR-MBB08AAA
(CN6A)
PWM amplifier module High-speed serial communication
(up to 8 modules can be mounted) (connected to control circuit board)
CSTR-SDB***AAA
(CN8)
output ON/OFF control signal input
(connected to machine safety circuit board)
13.4.1.1 Mounting Base Unit (CSTR-MBB08AAA)

A mounting base unit consists of a base circuit board (CSTR-
MBBCA08AAA) and a motherboard (CSTR-MBBCB08AAA). The major
axes control circuit board (CSTR-IFBM3LB) and up to 8 PWM amplifier
modules (CSTR-SDB∗∗∗AAA) can be mounted to the mounting base unit.
The main power supply (280 VDC) and the control power supply (16.5 V,
5 V, 24 V) of the PWM amplifier module are received from the converter
unit (CSTR-COB02AA).
Also, the mounting base unit receives the output ON/OFF signal of the
PWM amplifier module from the machine safety circuit board (JAPMC-
SF2300R-E), and distributes it to each PWM amplifier module.
13-15
FS100 13.4 SERVOPACK
13.4.1.2 PWM Amplifier Module (CSTR-SDB∗∗∗AAA)

This module converts the main power supply (DC, input voltage × √2)
supplied from the converter to three-phase motor current, and outputs to
each servomotor.
13.4.1.3 Major Axes Control Circuit Board (CSTR-IFBM3LB)

This is the circuit board to control the servomotor for the manipulator.
It controls the converter unit and the PWM amplifier modules.
Also, it connects to the I/O relay circuit board (CSTR-FBBCA8R03CAA),
and controls the brake of each servomotor.
In addition to the control of the manipulator’s major axes, this circuit board
has the following functions:
• Can be used by connecting the brake power supply control circuit to
the I/O relay circuit board (CSTR-FBBCA8R03CAA)
• Can be used by connecting the direct-in circuit to the I/O relay circuit
board (CSTR-FBBCA8R03CAA)
13.4.1.4 Configuration of PWM Amplifier Module

The configurations of the PWM amplifier module for each manipulator are
shown below.
Table 13-2: Configurations of PWM Amplifier Module
S-axis(AMP1) L-axis(AMP2) U-axis(AMP3) R-axis(AMP4) B-axis(AMP5) T-axis(AMP6) E-axis(AMP7) Rotation-axis(AMP8)
MHJ CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 㧙㧙
MH3F CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 㧙㧙
MH5F CSTR-SDB3R8 CSTR-SDB3R8 CSTR-SDB1R6 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 㧙㧙
MH6F CSTR-SDB5R5 CSTR-SDB5R5 CSTR-SDB3R8 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 㧙㧙
MH12 CSTR-SDB5R5 CSTR-SDB5R5 CSTR-SDB3R8 CSTR-SDBR90 CSTR-SDBR90 CSTR-SDBR90 㧙㧙
HP20F CSTR-SDB5R5 CSTR-SDB120 CSTR-SDB5R5 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 㧙㧙
MPP3 CSTR-SDB120 CSTR-SDB120 CSTR-SDB120 㧙㧙 CSTR-SDBR90 㧙㧙
MPK2F CSTR-SDB120 CSTR-SDB120 CSTR-SDB5R5 㧙 CSTR-SDB1R6 CSTR-SDB1R6 㧙㧙
SIA5F CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 㧙
CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB3R8

SDA5F
CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 CSTR-SDB1R6 㧙

SDA10F

SDA20F
Note: AMP7 and AMP8 are also used for external axes. Used amplifier types:
R90, 1R6, 3R8, 5R5, 120 (5 types in total)
13-16
FS100 13.5 I/O Relay Circuit Board (CSTR-FBBCA8R03CAA)
13.5 I/O Relay Circuit Board (CSTR-FBBCA8R03CAA)

This circuit board transmits and receives the encoder signals and the
control I/O signals to and from the SERVOPACK.
Also, it controls the ON/OFF of brake relay by the control signal from the
major axes control circuit board (CSTR-IFBM3LB).
(CN205) (CN204) (CN206)

Encoder signal input Manipulator I/O connection
(for external axis) (CN202)
(CN203) Brake power supply input
Encoder signal input (CN207)
(for manipulator) Brake control output
(CN200)
SERVOPACK I/F
(servo control signal)
(CN208)
Programming pendant
connection
(CN209)
Power relay connection
for converter main circuit
(CN201)
Control power supply input
(CN210)
Brake release enable (CN211)
(optional) Direct-in signal input
FS100 Front View
13-17
FS100 13.5 I/O Relay Circuit Board (CSTR-FBBCA8R03CAA)
13.5.1 Connection for Direct-in Signal

This signal is used to input responsive signals when using the search
function, etc. An example connection is shown in fig. 13-8 “Example
Connection for Direct-in Signal (AXDIN1 to AXDIN6)” .
Fig. 13-8: Example Connection for Direct-in Signal (AXDIN1 to AXDIN6)
FS100
Front panel Mating connector:
I/O relay circuit board 17JE-23150-02(D8A)-CG
CN211 (manufacturer: DDK)
13 (14 and 15 are also available)
024V
AXDIN1 1
Direct-in 1
AXDIN2 2
Direct-in 2
AXDIN3 3
Direct-in 3
AXDIN4 4
Direct-in 4
AXDIN5 5
Direct-in 5
AXDIN6 6
Direct-in 6
AXDINCOM 7
10
+24V
(11 and 12
are also Connect a jumber cable.
available)
FS100 (slave for coodinated control)

Front panel
I/O relay circuit board
CN211
13
024V
AXDIN1 1
AXDIN2 2
AXDIN3 3
AXDIN4 4
AXDIN5 5
AXDIN6 6
AXDINCOM 7
10
+24V
Connect a jumber cable.
Connect the part inside when the I/O relay circuit board (CSTR-FBBCA8R03CAA)
of the slave for coodinated control is present.
13-18
FS100 13.6 User I/O Circuit Board for Japan and North America: (JAPMC-
IO2308R-E, Abbreviated as LIO-08R)
13.6 User I/O Circuit Board for Japan and North America:
(JAPMC-IO2308R-E, Abbreviated as LIO-08R)
Regarding the user I/O circuit board for the FS100 for
Europe (JAPMC-IO2309R-E, abbreviated as LIO-09R),
NOTE refer to chapter 13.7 “User I/O Circuit Board for Europe:
(JAPMC-IO2309R-E, Abbreviated as LIO-09R)” at
page 13-32.
The FS100 has one user I/O circuit board (JAPMC-IO2308R-E) in its CPU
unit as standard.
The user I/O circuit board (JAPMC-IO2308R-E) has 2 connectors for
digital input/output (robot user input/output).
28 inputs and 28 outputs are available.
System input/output and user input/output can be used when allocating
these inputs and outputs.
The system input/output is the signal with a function specified in advance.
It is mainly used to control the manipulator and related devices as a
system from the external control device such as a fixturing controller or a
integrated controller, etc.
The user input/output is mainly used in the job of manipulator motion as
the timing signal between the manipulator and peripheral devices.
For the details of allocation, refer to fig. 13-11(a) “Connection Diagram of
User Input/Output Connector (CN1) of User I/O Circuit Board (JAPMC-
IO2308R-E) for Japan and North America” at page 13-26 and
fig. 13-11(b) “Connection Diagram of System Input/Output Connector
(CN2) of User I/O Circuit Board (JAPMC-IO2308R-E) for Japan and North
America” at page 13-27.
(CN1)
User input/output connector:
16 inputs and 16 outputs
(CN2)
System input/output connector:
(CN3)
Power supply for I/O (+24V) input
13-19
In addition to user input/output, status of LIO-08R can be entered to the
external input signal.
Logical number Signal name Description

Bit content ‘1’ ‘0’
20050 24V_CHK 1) DC24V Normal Abnormal
Low voltage ditection （Voltage drop or
disconnection of
external fuse）
20051 1 (FIXED) 1 (FIXED)
20056 MOST1 Module status1 Normal Abnormal
20057 OSC_CHK Oscillator stop Abnormal Normal
detection
20060 MOST Module status Abnormal Normal
1 DC24There is an lower voltage detection for the blown detection of DC24V power supply external fuse. When
the input voltage is lower than 15V, DC24V lower voltage detection of the status input signal would be an error.
13-20
13.6.1 Connection for External Power Supply for Input/Output
As standard, the input/output power supply is the internal power supply.
The FS100 can use the internal power supply of approx. 0.5 A, 24 VDC for
input/output.
This internal power supply is protected by the fuse (F1: 0.6 A) on the front
panel.
To use the FS100 with an external power supply, perform connection as
follows:
1. Remove the cable connected to the power supply connector (CN3) of
the user I/O circuit board from the connector.
Make sure to insulate the removed cable.
2. Connect the external power supply to the power supply connectors of
the user I/O circuit board by connecting +24V to CN3-2 and 0V to
CN3-1.
To prevent burnout at short circuit of the 24V power supply or short circuit
of the output, use an external fuse in the 24V line.
For the details of external fuse, refer to chapter 13.6.2 “Protection by
External Fuse” at page 13-22.
Fig. 13-9: Connection for Power Supply for Input/Output
FS100 FS100
Converter unit Front panel Converter unit Front panel

(CSTR-COB02AA) (CSTR-COB02AA)
CN307 +24V CN307
0.5 A max. F1: 0.6 A Not used
Remove the pre-connected

cable from CN3 of the user
I/O circuit board, and insulate it.
024V
User I/O circuit board User I/O circuit board

(JAPMC-IO2308R-E) (JAPMC-IO2308R-E)
CN3 CN3 External power supply

024V
+24V
+24V/1 A
(User supplied)
Internal Power Supply External Power Supply

(factory-set)
13-21
• The FS100 can use the internal power supply of approx.

0.5 A, 24 VDC for input/output.
To use current exceeding the above, or to insulate
between the inside and the outside, use the external 24 V
power supply.
• Install the external power supply outside the controller to
prevent external noise from entering the inside of the con-
NOTE troller.
Do not connect the power lines from the external power
supply to the terminals CN3-1 and CN3-2 if the connection
is set for using the internal power supply (with the pre-con-
nected cable connected).
The internal power supply and the external power supply
interfere with each other, which may result in equipment fail-
ure.
13.6.2 Protection by External Fuse

The user I/O circuit board (JAPMC-IO2308R-E) does not have a built-in
protection device (fuse) for short circuit of the 24 VDC power supply or
short circuit of the output, etc.
To prevent burnout, use an external fuse (rated current: 1 A, fast-acting
fuse) in the +24V line of external power supply.
The user I/O circuit board has a built-in circuit to detect if the external fuse
for the 24 VDC power supply is blown.
Voltage drop of the 24 VDC power supply or a blown external fuse, etc. is
detected as an error.
13.6.2.1 Protection by External Fuse in Common Line of Output Signal

If the output current is too large for the rated current (1 A) of the external
fuse for the 24 VDC power supply, perform either or both of the following:
• Increase the capacity of the external fuse for the 24 VDC power sup-
ply up to the maximum of 2 A. (Use a fast-acting fuse.)
• Add an external fuse in the common line of the output signal.
For CN1, connect an external fuse (fast-acting fuse) with the rated current
of 1 A for every 8 outputs.
13-22
Fig. 13-10: Example Connection for External Fuse in Common Line of Output Signal
FS100
Front panel
(JAPMC-IO2308R-E)
CN2
1 A (fast-acting)
13
Output common fuse
OUT0 10
Load
OUT5 32
Load
1 A (fast-acting)
16
Output common fuse
OUT6 15
Load
OUT11 36
Load
CN3 External power supply

1 024V
024V
2 +24V
+24V
2 A (fast-acting)
13-23
13.6.3 Example of Servo ON Sequence Circuit from External Device
Only the rising edge of the servo ON signal is valid. This signal turns ON
the manipulator servo power supply. The set and reset timings are shown
in the following.
FS100
Servo ON Servo ON
Servo ON PB Confirmation Command User I/O Circuit Board
X2 Servo ON
X1 Command CN2 +24V
X1 -19
X1
External Servo
-4 ON Input
Servo ON
Servo Power ON Confirmation (EXSVON)
X3 (30011)
X2
Servo Power ON CN2 +24V
X3 -13
PL
Servo ON
-28 Output
(30011)
Note: Number in ( ) means output signal number assigned to YIU01.

PL: Pilot Lamp
13.6.4 Example of Start Sequence Circuit from External Device

Only the rising edge of the external start signal is valid. This signal starts
the manipulator. Reset this signal with the interlock configuration that
determines if operation can start and with the playback (RUNNING) signal
confirming that the manipulator has actually started moving.
FS100
While Play mode Alarm/Error Running
Run PB Servo ON select Occuring Confirmation Start User I/O Circuit Board
(30011) (30016) (30013) X5 (Command) Ex. Start
X4 Command CN2
X4 -19 +24V
X3
-2 External Start
Running Input
Running Confirmation
X6 (30010) (20010)
X5
Running, etc.
-13
X6 +24V
PL
-10
Running Output
(30010), etc.
13-24
13.6.5 Input/Output Connector (CN1, CN2)
When wiring, refer to the types of the input/output connectors (CN1, CN2)
of the user I/O circuit board (JAPMC-IO2308R-E) shown below.
13.6.5.1 User Input/Output Connector (CN1)
Item Description
Used connector 10250-52A3PL (manufacturer: Sumitomo 3M Limited)
Mating connector 10150-3000PE (manufacturer: Sumitomo 3M Limited) Connector body
10350-52A0-008 (manufacturer: Sumitomo 3M Limited) Shell, thumbscrew lock type
10350-52F0-008 (manufacturer: Sumitomo 3M Limited) Shell, quick-release latching type
13.6.5.2 System Input/Output Connector (CN2)
Item Description
13-25
Fig. 13-11(a): Connection Diagram of User Input/Output Connector (CN1) of
User I/O Circuit Board (JAPMC-IO2308R-E) for Japan and North America
FS100
User I/O circuit board (JAPMC-IO2308R-E)
Each point
24 VDC CN1
4.1 mA max. Logical Connector Pin No. Name Signal
No. pin No.
1 DICOM3 Input common 3
20030 2 DI_16 User input IN01 IN
GND 20032 3 DI_18 User input IN03 IN
+24V 20044 9 DI_28 User input IN13 IN
11 DICOM3_24V Input common 3_24V
GND 36 DICOM4_24V Input common 4_24V
15 CN1_+24V +24V for output load
Each point 22 CN1_+24V +24V for output load
24 VDC 25 CN1_+24V +24V for output load
100 mA max. 40 CN1_+24V +24V for output load
Buffer 30030 12 DO_16 User output OT01 OUT Load
30031 37 DO_17 User output OT02 OUT Load
024V 024V
CN3
+24V
024V
External
power supply
Converter unit (CSTR-COB02AA)
CN307
+24V
024V
Internal
power supply
* To use the external power supply, remove the cable connected to

the power supply connector (CN3) of the user I/O circuit board
from the connector.
13-26
Fig. 13-11(b): Connection Diagram of System Input/Output Connector (CN2) of
User I/O Circuit Board (JAPMC-IO2308R-E) for Japan and North America
FS100
Each point
24 VDC CN2
No. pin No.
20010 2 DI_00 External start IN
20011 20 DI_01 External hold IN
GND 20012 3 DI_02 Call master job IN
20013 21 DI_03 Alarm/error reset IN
20014 4 DI_04 External servo ON IN
20015 22 DI_05 Select play mode IN
20016 6 DI_06 Select teach mode IN
20017 24 DI_07 Digital input 7 IN
+24V 20021 25 DI_09 Digital input 9 IN
20022 8 DI_10 Work prohibited IN
GND 27 DICOM2_24V Input common 2_24V
Each point 23 DICOM2_0V Input common 2_0V
24 VDC
100 mA max.
Buffer 30010 10 DO_00 Running OUT Load
30011 28 DO_01 Servo in ON OUT Load
30012 11 DO_02 Top of master job OUT Load
30013 29 DO_03 Alarm/error occurred OUT Load
30014 14 DO_04 Battery alarm OUT Load
30015 32 DO_05 Remote mode selected OUT Load
30016 15 DO_06 Play mode selected OUT Load
30017 33 DO_07 Teach mode selected OUT Load
30020 17 DO_08 In cube 1 OUT Load
30021 35 DO_09 Digital output 9 OUT Load
30022 18 DO_10 Work home position OUT Load
30023 36 DO_11 Intermediate start OK OUT Load
024V 024V
CN3
+24V
024V
External
power supply
CN307
+24V
024V
Internal
power supply

from the connector.
13-27
Table 13-3: System Input

Logical Number Input Name/Function
20010 EXTERNAL START
Functions the same as the [START] button on the programming pendant. Only the
rising edge of the signal is valid. It starts robot operation (playback). This signal is
invalid if external start is prohibited from the playback condition display.
20011 EXTERNAL HOLD
Functions the same as the [HOLD] button on the programming pendant, and is used
when connecting a temporary stop switch of an external control device, etc. Connect
a break-contact switch to this signal.
When this signal is input (OFF), the JOB is stopped. During the input, the operation
cannot be started and the axes cannot be operated. Also, while this signal is OFF, the
[HOLD] button on the programming pendant lights up.
Note that this signal is disabled as the default setting. To enable this signal, enable
“EXTERNAL HOLD” in the {OPERATE ENABLE} under the main menu {SETUP} of
the programming pendant in the management mode. For details, refer to
chapter 13.6.6 “Enabling External Hold” at page 13-29.
20012 CALL MASTER JOB
Only the rising edge of the signal is valid. It calls up the top of the robot program, that
is the top of the master job1). This signal is invalid during playback, during teach-lock
and when play master or call is prohibited (set from the playback operation condition
display).
20013 ALARM/ERROR RESET
After an alarm or error has occurred and the cause been corrected, this signal resets
the alarm or error.
20014 EXTERNAL SERVO ON
Turns ON the servo power supply. Only the rising edge of the signal is valid.
20015 SELECT PLAY MODE
The play mode is selected when the mode key on the programming pendant is set at
“REMOTE”. Only the rising edge of the signal is valid. When this selection signal
assigned concurrently with other mode selection signal, the teach mode is selected on
a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE
The teach mode is selected when the mode key of the programming pendant is set at
“REMOTE”. The other mode selection is unavailable when this signal is ON; the
signal is selected by priority even when the other selection signal is ON, enabling the
teach mode selection.
1 A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called
up immediately after the power is turned ON, is set as the master job.
13-28
13.6.6 Enabling External Hold
The external hold signal is disabled as the default setting so that the
manipulator can be operated without the I/O cable connected. To enable
the external hold signal, follow the procedure below.
1. In the management mode, select {OPERATE ENABLE} under the
main menu {SETUP}.
2. Switch “EXTERNAL HOLD” from “PROHIBIT” to “PERMIT”. By doing

so, the pseudo input signal #82011 “EXT HOLD ENABLE” changes
from “OFF” to “ON.
13-29
The initial value of the concurrent I/O is as shown below, so the system
input #40067 can be controlled by the break-contact switch connected to
#20011.
#20011 #82011 #40067 (External hold)

()
• Be sure to use the break-contact switch for the external

hold switch.
NOTE • After the setting of the external hold, check to be sure that
the external hold functions properly. While the external
hold switch is in operation, the [HOLD] button on the pro-
gramming pendant lights up.
13-30
Table 13-4: System Output

Logical Number Output Name/Function
30010 RUNNING
This signal signifies that the job is running. (Signifies that the job is running, system
status is waiting reserved start, or test run is running.) This signal status is the same
status as [START] in the programming pendant.
30011 SERVO IS ON
This signal signifies that the servo power is turned ON, internal processing such as
current position creation is complete, and the system is able to receive the START
command. This signal turns OFF when the servo power supply turns OFF. It can be
used for FS100 status diagnosis for an external start.
30012 TOP OF MASTER JOB
This signal signifies that the execution position is the top of the master job. This signal
can be used to confirm that the master job has been called.1)*1
30013 ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error occurred. If a major error occurs, this
signal remains ON until the main power is turned OFF.
30014 BATTERY ALARM
This signal turns ON to notify that the battery requires replacing when the voltage
drops from the battery for backup memory of the encoder. Major problems may result
if memory data is lost because of an expired battery. It is recommended to avoid these
problems by using this signal as a warning signal.
30015 to REMOTE/PLAY/TEACH MODE SELECTED
30017 This signal notifies the current mode setting. These signals are synchronized with the
mode select switch in the programming pendant. The signal corresponding to the
selected mode turns ON.
30020 WORK COMMAND
This signal provides the command for the general tool to operate. TOOL ON
instruction execution or the [TOOL ON] key in the programming pendant turns this
signal ON and TOOL OFF instruction execution or the [TOOL OFF] key in the
programming pendant turns it OFF. However, it remains OFF while the WORK
PROHIBITED signal (2022) is input or while the robot is stopped.
30022 WORK HOME POSITION (IN CUBE 64)2)
This signal turns ON when the current TCP lies inside the work home position area.
Use this signal to evaluate whether the robot is in the start position.
30023 INTERMEDIATE START OK
This signal turns ON when the manipulator operates. It turns OFF when the currently
executed line is moved with the cursor or when editing operation is carried out after
HOLD is applied during operation. Therefore, this signal can be used as a restart
interlock after a HOLD is applied. However, it also turns ON in the teach mode and
TEACH MODE SELECTED signal must be referred together.
1 This signal is not output during operation.
2 The work home position cube and Cube 64 are the same.
13-31
FS100 13.7 User I/O Circuit Board for Europe: (JAPMC-IO2309R-E, Abbreviated
as LIO-09R)
13.7 User I/O Circuit Board for Europe: (JAPMC-IO2309R-E,
Abbreviated as LIO-09R)
Regarding the user I/O circuit board for the FS100 for Japan
and North America (JAPMC-IO2308R-E, abbreviated as
NOTE LIO-08R), refer to chapter 13.6 “User I/O Circuit Board for
Japan and North America: (JAPMC-IO2308R-E, Abbrevi-
ated as LIO-08R)” at page 13-19.
The FS100 has one user I/O circuit board (JAPMC-IO2309R-E) in its CPU
unit as standard.
The user I/O circuit board (JAPMC-IO2309R-E) has 2 connectors for
digital input/output (robot user input/output).
28 inputs and 28 outputs are available.
System input/output and user input/output can be used when allocating
these inputs and outputs.
The system input/output is the signal with a function specified in advance.
It is mainly used to control the manipulator and related devices as a
system from the external control device such as a fixturing controller or a
integrated controller, etc.
The user input/output is mainly used in the job of manipulator motion as
the timing signal between the manipulator and peripheral devices.
For the details of allocation, refer to fig. 13-14(a) “Connection Diagram of
User Input/Output Connector (CN1) of User I/O Circuit Board (JAPMC-
IO2309R-E) for Europe” at page 13-39 and fig. 13-14(b) “Connection
Diagram of System Input/Output Connector (CN2) of User I/O Circuit
Board (JAPMC-IO2309R-E) for Europe” at page 13-40.
(CN1)
User input/output connector:
(CN2)
System input/output connector:
(CN3)
Power supply for I/O (+24V) input
13-32
as LIO-09R)
In addition to user input/output, status of LIO-09R can be entered to the
external input signal.
Logical number Signal name Description

Bit content ‘1’ ‘0’
20050 24V_CHK 1) DC24V Normal Abnormal
Low voltage ditection （Voltage drop or
disconnection of
external fuse）
20056 MOST1 Module status1 Normal Abnormal
20057 OSC_CHK Oscillator stop Abnormal Normal
detection
20060 MOST Module status Abnormal Normal
1 DC24There is an lower voltage detection for the blown detection of DC24V power supply external fuse. When
the input voltage is lower than 15V, DC24V lower voltage detection of the status input signal would be an error.
13-33
as LIO-09R)
13.7.1 Connection for External Power Supply for Input/Output
As standard, the input/output power supply is the internal power supply.
The FS100 can use the internal power supply of approx. 0.5 A, 24 VDC for
input/output.
This internal power supply is protected by the fuse (F1: 0.6 A) on the front
panel.
To use the FS100 with an external power supply, perform connection as
follows:
1. Remove the cable connected to the power supply connector (CN3) of
the user I/O circuit board from the connector.
2. Connect the external power supply to the power supply connectors of
the user I/O circuit board by connecting +24V to CN3-2 and 0V to
CN3-1.
To prevent burnout at short circuit of the 24V power supply or short circuit
of the output, use an external fuse in the 24V line.
For the details of external fuse, refer to chapter 13.6.2 “Protection by
External Fuse” at page 13-22.
Fig. 13-12: Connection for Power Supply for Input/Output
FS100 FS100
Converter unit Front panel Converter unit Front panel

(CSTR-COB02AA) (CSTR-COB02AA)
CN307 +24V CN307
0.5 A max. F1: 0.6 A Not used
Remove the pre-connected

cable from CN3 of the user
I/O circuit board, and insulate it.
024V
User I/O circuit board User I/O circuit board

(JAPMC-IO2309R-E) (JAPMC-IO2309R-E)
CN3 CN3 External power supply

024V
+24V
+24V/1 A
(User supplied)
Internal Power Supply External Power Supply

(factory-set)
13-34
as LIO-09R)
• The FS100 can use the internal power supply of approx.

0.5 A, 24 VDC for input/output.
To use current exceeding the above, or to insulate
between the inside and the outside, use the external 24 V
power supply.
• Install the external power supply outside the controller to
prevent external noise from entering the inside of the con-
NOTE troller.
Do not connect the power lines from the external power
supply to the terminals CN3-1 and CN3-2 if the connection
is set for using the internal power supply (with the pre-con-
nected cable connected).
The internal power supply and the external power supply
interfere with each other, which may result in equipment fail-
ure.
13.7.2 Protection by External Fuse

The user I/O circuit board (JAPMC-IO2309R-E) does not have a built-in
protection device (fuse) for short circuit of the 24 VDC power supply or
short circuit of the output, etc.
To prevent burnout, use an external fuse (rated current: 1 A, fast-acting
fuse) in the +24V line of external power supply.
The user I/O circuit board has a built-in circuit to detect if the external fuse
for the 24 VDC power supply is blown.
Voltage drop of the 24 VDC power supply or a blown external fuse, etc. is
detected as an error.
13.7.2.1 Protection by External Fuse in Common Line of Output Signal

If the output current is too large for the rated current (1 A) of the external
fuse for the 24 VDC power supply, perform either or both of the following:
• Increase the capacity of the external fuse for the 24 VDC power sup-
ply up to the maximum of 2 A. (Use a fast-acting fuse.)
• Add an external fuse in the common line of the output signal.
13-35
as LIO-09R)
Fig. 13-13: Example Connection for External Fuse in Common Line of Output Signal
FS100
Front panel
(JAPMC-IO2309R-E)
CN2
OUT0 10
Load
OUT5 32
Load
1 A (fast-acting)
12
Output common fuse
OUT6 15
Load
OUT11 36
Load
1 A (fast-acting)
30
Output common fuse
024V CN3 External power supply
1 024V
024V
2 +24V
+24V
2 A (fast-acting)
13-36
as LIO-09R)
13.7.3 Example of Servo ON Sequence Circuit from External Device
Only the rising edge of the servo ON signal is valid. This signal turns ON
the manipulator servo power supply. The set and reset timings are shown
in the following.
FS100
Servo ON Servo ON
Servo ON PB Confirmation Command User I/O Circuit Board
X2 Servo ON
X1 Command CN2 +24V
X1 -27
X1
External Servo
-4 ON Input
Servo ON
Servo Power ON Confirmation (EXSVON)
X3 (30011)
X2
Servo Power ON CN2 +24V
X3 -28
PL
Servo ON
-12 Output
(30011)

PL: Pilot Lamp
13.7.4 Example of Start Sequence Circuit from External Device

Only the rising edge of the external start signal is valid. This signal starts
the manipulator. Reset this signal with the interlock configuration that
determines if operation can start and with the playback (RUNNING) signal
confirming that the manipulator has actually started moving.
FS100
While Play mode Alarm/Error Running
Run PB Servo ON select Occuring Confirmation Start User I/O Circuit Board
(30011) (30016) (30013) X5 (Command) Ex. Start
X4 Command CN2
X4 -27 +24V
X3
-2 External Start
Running Input
Running Confirmation
X6 (30010) (20010)
X5
Running, etc.
-10
X6 +24V
PL
-12
Running Output
(30010), etc.
13-37
as LIO-09R)
13.7.5 Input/Output Connector (CN1, CN2)
When wiring, refer to the types of the input/output connectors (CN1, CN2)
of the user I/O circuit board (JAPMC-IO2309R-E) shown below.
13.7.5.1 User Input/Output Connector (CN1)
Item Description
13.7.5.2 System Input/Output Connector (CN2)
Item Description
13-38
as LIO-09R)
Fig. 13-14(a): Connection Diagram of User Input/Output Connector (CN1) of
User I/O Circuit Board (JAPMC-IO2309R-E) for Europe
FS100
Each point
24 VDC CN1
4.1 mA max. Logical Connector
No. pin No. Pin No. Name Signal
GND 20032 3 DI_18 User input IN03 IN
+24V 20044 9 DI_28 User input IN13 IN
+24V 11 DICOM3_24V Input common 3_24V
GND Each point 36 DICOM4_24V Input common 4_24V
24 VDC 26 DICOM3_0V Input common 3_0V
100 mA max. 31 DICOM4_0V Input common 4_0V
Buffer 30031 37 DO_17 User output OT02 OUT Load
Buffer 14 CN1_0V 0V for output load
39 CN1_0V 0V for output load
024V 024V
CN3
+24V
024V
External
power supply
CN307
+24V
024V
Internal
power supply

from the connector.
13-39
as LIO-09R)
Fig. 13-14(b): Connection Diagram of System Input/Output Connector
(CN2) of User I/O Circuit Board (JAPMC-IO2309R-E) for Europe
FS100
Each point
24 VDC CN2
No. pin No.
20010 2 DI_00 External start IN
20011 20 DI_01 External hold IN
GND 20012 3 DI_02 Call master job IN
20013 21 DI_03 Alarm/error reset IN
20014 4 DI_04 External servo ON IN
20015 22 DI_05 Select play mode IN
20016 6 DI_06 Select teach mode IN
+24V 20021 25 DI_09 Digital input 9 IN
20022 8 DI_10 Work prohibited IN
+24V 9 DICOM1_24V Input common 1_24V
GND Each point 27 DICOM2_24V Input common 2_24V
24 VDC 19 DICOM1_0V Input common 1_0V
100 mA max. 23 DICOM2_0V Input common 2_0V
30010 10 DO_00 Running OUT Load
Buffer
30011 28 DO_01 Servo in ON OUT Load
30012 11 DO_02 Top of master job OUT Load
30013 29 DO_03 Alarm/error occurred OUT Load
30014 14 DO_04 Battery alarm OUT Load
30015 32 DO_05 Remote mode selected OUT Load
30016 15 DO_06 Play mode selected OUT Load
30017 33 DO_07 Teach mode selected OUT Load
30020 17 DO_08 In cube 1 OUT Load
30021 35 DO_09 Digital output 9 OUT Load
30022 18 DO_10 Work home position OUT Load
30023 36 DO_11 Intermediate start OK OUT Load
Buffer 12 CN2_0V 0V for output load
024V 024V
CN3
+24V
024V
External
power supply
CN307
+24V
024V
Internal
power supply

from the connector.
13-40
as LIO-09R)
Table 13-5: System Input

Logical Number Input Name/Function
20010 EXTERNAL START
Functions the same as the [START] button in the programming pendant. Only the
rising edge of the signal is valid. It starts robot operation (playback). This signal is
invalid if external start is prohibited from the playback condition display.
20011 EXTERNAL HOLD
Functions the same as the [HOLD] button on the programming pendant, and is used
when connecting a temporary stop switch of an external control device, etc. Connect
a break-contact switch to this signal.
When this signal is input (OFF), the JOB is stopped. During the input, the operation
cannot be started and the axes cannot be operated. Also, while this signal is OFF, the
[HOLD] button on the programming pendant lights up.
Note that this signal is disabled as the default setting. To enable this signal, enable
“EXTERNAL HOLD” in the {OPERATE ENABLE} under the main menu {SETUP} of
the programming pendant in the management mode. For details, refer to
chapter 13.7.6 “Enabling External Hold” at page 13-42.
20012 CALL MASTER JOB
Only the rising edge of the signal is valid. It calls up the top of the robot program, that
is the top of the master job1). This signal is invalid during playback, during teach-lock
and when play master or call is prohibited (set from the playback operation condition
display).
20013 ALARM/ERROR RESET
After an alarm or error has occurred and the cause been corrected, this signal resets
the alarm or error.
20014 EXTERNAL SERVO ON
Turns ON the servo power supply. Only the rising edge of the signal is valid.
20015 SELECT PLAY MODE
The play mode is selected when the mode key on the programming pendant is set at
“REMOTE”. Only the rising edge of the signal is valid. When this selection signal
assigned concurrently with other mode selection signal, the teach mode is selected on
a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE
The teach mode is selected when the mode key of the programming pendant is set at
“REMOTE”. The other mode selection is unavailable when this signal is ON; the
signal is selected by priority even when the other selection signal is ON, enabling the
teach mode selection.
1 A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called
up immediately after the power is turned ON, is set as the master job.
13-41
as LIO-09R)
13.7.6 Enabling External Hold
The external hold signal is disabled as the default setting so that the
manipulator can be operated without the I/O cable connected. To enable
the external hold signal, follow the procedure below.
1. In the management mode, select {OPERATE ENABLE} under the
main menu {SETUP}.
2. Switch “EXTERNAL HOLD” from “PROHIBIT” to “PERMIT”. By doing

so, the pseudo input signal #82011 “EXT HOLD ENABLE” changes
from “OFF” to “ON.
13-42
as LIO-09R)
The initial value of the concurrent I/O is as shown below, so the system
input #40067 can be controlled by the break-contact switch connected to
#20011.
#20011 #82011 #40067 (External hold)

()
• Be sure to use the break-contact switch for the external

hold switch.
NOTE • After the setting of the external hold, check to be sure that
the external hold functions properly. While the external
hold switch is in operation, the [HOLD] button on the pro-
gramming pendant lights up.
13-43
as LIO-09R)
Table 13-6: System Output

Logical Number Output Name/Function
30010 RUNNING
This signal signifies that the job is running. (Signifies that the job is running, system
status is waiting reserved start, or test run is running.) This signal status is the same
status as [START] in the programming pendant.
30011 SERVO IS ON
This signal signifies that the servo power is turned ON, internal processing such as
current position creation is complete, and the system is able to receive the START
command. This signal turns OFF when the servo power supply turns OFF. It can be
used for FS100 status diagnosis for an external start.
30012 TOP OF MASTER JOB
This signal signifies that the execution position is the top of the master job. This signal
can be used to confirm that the master job has been called.1)*1
30013 ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error occurred. If a major error occurs, this
signal remains ON until the main power is turned OFF.
30014 BATTERY ALARM
This signal turns ON to notify that the battery requires replacing when the voltage
drops from the battery for backup memory of the encoder. Major problems may result
if memory data is lost because of an expired battery. It is recommended to avoid these
problems by using this signal as a warning signal.
30015 to REMOTE/PLAY/TEACH MODE SELECTED
30017 This signal notifies the current mode setting. These signals are synchronized with the
mode select switch in the programming pendant. The signal corresponding to the
selected mode turns ON.
30020 WORK COMMAND
This signal provides the command for the general tool to operate. TOOL ON
instruction execution or the [TOOL ON] key in the programming pendant turns this
signal ON and TOOL OFF instruction execution or the [TOOL OFF] key in the
programming pendant turns it OFF. However, it remains OFF while the WORK
PROHIBITED signal (2022) is input or while the robot is stopped.
30022 WORK HOME POSITION (IN CUBE 64)2)
This signal turns ON when the current TCP lies inside the work home position area.
Use this signal to evaluate whether the robot is in the start position.
30023 INTERMEDIATE START OK
This signal turns ON when the manipulator operates. It turns OFF when the currently
executed line is moved with the cursor or when editing operation is carried out after
HOLD is applied during operation. Therefore, this signal can be used as a restart
interlock after a HOLD is applied. However, it also turns ON in the teach mode and
TEACH MODE SELECTED signal must be referred together.
1 This signal is not output during operation.
2 The work home position cube and Cube 64 are the same.
13-44
FS100 Index
absolute data ......................................................................................... 8-4

absolute encoder ................................................................................... 8-4
ACCELARATION SPEED ................................................................... 11-27
ACCELARATION TIME ...................................................................... 11-16
acceleration/deceleration ...................................................................... 12-3
Addition of Base and Station Axes ......................................................... 11-4
Addition of I/O Modules ........................................................................ 11-1
Alarm Display ...................................................................................... 12-4
ALARM HISTORY.................................................................................. 7-3
All Limit Release Function .................................................................. 8-104
Allocating an Operation ...................................................................... 8-115
Allocation of I/O Control Instructions .................................................... 8-126
Allocation Window.............................................................................. 8-115
Alternate Output Allocation ................................................................. 8-120
alternate output allocation ................................................................... 8-114
Analog Incremental Output Allocation .................................................. 8-125
analog incremental output allocation .................................................... 8-114
ANALOG MONITOR .............................................................................. 7-3
analog output allocation ............................................................ 8-114, 8-124
approximate mass................................................................................ 12-3
ARM CONTROL .................................................................................... 7-3
ARM control ........................................................................................ 8-43
Automatic Measurement of the Tool Load and the Center of Gravity ......... 8-38
AXES CONFIG window ...................................................................... 11-12
Axis Interference Area .......................................................................... 8-73
Axis keys .............................................................................................. 6-3
BALL-SCREW PITCH .............................................................. 11-14, 11-25

base coordinate ................................................................................... 8-62
B-Axis ................................................................................................... 6-3
Brake release ...................................................................................... 12-3
Built-in transformer ............................................................................... 12-3
Cable Junctions ..................................................................................... 4-3

Cautions for Connection of Dual Input Signals ........................................ 13-3
Changing the Absolute Data ................................................................... 8-9
Changing the Output Status ................................................................ 8-129
Changing the Parameter Setting.......................................................... 8-131
Checking the TCP ................................................................................ 8-36
CIO ladder .......................................................................................... 12-3
circuit board rack ......................................................................... 13-4, 13-5
Clearing Absolute Data ......................................................................... 8-10
Clearing Calibration Data ...................................................................... 8-34
Clearing the Interference Area Data ....................................................... 8-82
Clearing the User Coordinates ............................................................ 8-100
Collision proof Frames.......................................................................... 12-4
COMMAND POSITION .......................................................................... 7-3
Condition Number ................................................................................ 8-86
Connecting the Manipulator Cable ......................................................... 4-10
Connecting the Primary Power Supply ..................................................... 4-8
Connecting the Programming Pendant ................................................... 4-11
Index-1
FS100 Index
Connection ........................................................................................... 4-1

Contents Confirmation ........................................................................... 2-1
control circuit board ..................................................................... 13-4, 13-5
control group ....................................................................................... 11-7
converter unit .................................................................................... 13-14
cooling system .................................................................................... 12-3
Coordinate System .............................................................................. 12-4
CPU Unit Configuration ........................................................................ 13-4
CPU-201R .......................................................................................... 13-5
CREATE NEW JOB ............................................................................... 7-2
cube ................................................................................................... 8-63
Cube Interference .............................................................................. 8-104
cube number ....................................................................................... 8-65
Cubic Interference Area ....................................................................... 8-62
CURRENT POSITION ........................................................................... 7-3
DATE/TIME........................................................................................... 7-4
Definition of the User Coordinates ......................................................... 8-96
DELETE ............................................................................................... 7-3
detection level (level range1 to 500) ...................................................... 8-86
DEVICE ................................................................................................ 7-3
digital I/O ............................................................................................ 12-3
dimensions ......................................................................................... 12-3
direct-in signal ................................................................................... 13-18
display allocation ..................................................................... 8-113, 8-119
Door Interlock...................................................................................... 12-4
drive unit ............................................................................................. 12-3
DROP AMOUNT ................................................................................... 7-3
E-Axis................................................................................................... 6-3
Editing Mode ......................................................................................... 7-1
emergency stop ..................................................................................... 5-7
emergency stop output (ESPOUT) signal ............................................. 13-12
Enable Switch ............................................................................... 5-6, 12-4
Essential Measures ............................................................................. 12-4
Executing the Display Allocation ......................................................... 8-128
Executing the I/O Control Allocation .................................................... 8-128
Executing the Instruction/Output Control Allocation ............................... 8-128
Executing the Job Call Allocation ........................................................ 8-128
Execution of Allocation ....................................................................... 8-128
Expanded Instruction Set ................................................................... 8-106
external axis overrun.......................................................................... 13-13
external emergency stop (EXESP) signal ............................................. 13-11
external power supply for input/output ....................................... 13-21, 13-34
FD/CF .................................................................................................. 7-3

File Initialization ................................................................................. 8-134
Function List ....................................................................................... 12-4
Function Select ................................................................................... 8-86
Index-2
FS100 Index
Grounding ............................................................................................. 1-5

grounding ............................................................................................ 12-3
Group (4-bit/8-bit) Output Allocation ..................................................... 8-123
group output allocation (4-bit/8-bit) ...................................................... 8-114
GRP COMBINATION ............................................................................. 7-4
HAND VIBRATION CONTROL................................................................ 7-3

Handling Procedure ............................................................................... 3-1
HOME POSITION .................................................................................. 7-3
Home Position ....................................................................................... 8-4
Home Position Calibration ...................................................................... 8-2
How to Calculate Tool Load Information ................................................. 8-49
I/O Diagnosis ....................................................................................... 12-4

I/O Instructions .................................................................................... 12-5
I/O modules ......................................................................................... 11-1
I/O MSG HISTORY ................................................................................ 7-3
I/O relay circuit board ......................................................................... 13-17
IN/OUT ................................................................................................. 7-2
Inching Operation ................................................................................ 12-4
INERTIA RATIO ...................................................................... 11-16, 11-27
Initial Diagnosis ..................................................................................... 5-2
Initializing Data File ............................................................................ 8-135
Initializing I/O Data ............................................................................. 8-139
Initializing Job File.............................................................................. 8-134
Initializing Parameter File.................................................................... 8-137
Initializing System Data ...................................................................... 8-141
Installation and Wiring Safety .................................................................. 1-5
Instruction Allocation ................................................................ 8-113, 8-116
Instruction of Shock Detection Function ................................................. 8-90
Instruction Set ................................................................................... 8-106
Interface.............................................................................................. 12-4
INTERFERENCE ................................................................................... 7-3
Interference area ................................................................................. 8-62
JOB ...................................................................................................... 7-2

Job Call Allocation ................................................................... 8-113, 8-118
JOB CAPACITY ..................................................................................... 7-2
KEY ALLOCATION ................................................................................ 7-4

Key Allocation (EACH) ....................................................................... 8-113
Key Allocation (SIM) ........................................................................... 8-113
Index-3
FS100 Index
Language ........................................................................................... 12-5

L-axis ................................................................................................... 6-3
Leakage Breaker Installation .................................................................. 4-5
Learning Function .............................................................................. 8-107
LIMIT RELEASE.................................................................................... 7-3
limit switch ........................................................................................ 8-103
LIO-08R............................................................................................ 13-19
LIO-09R............................................................................................ 13-32
LOAD ................................................................................................... 7-3
L-U Interference ................................................................................ 8-104
Machine Lock ...................................................................................... 12-4

machine safety circuit board ......................................................... 13-4, 13-6
major axes control circuit board........................................................... 13-16
Management Mode ................................................................................ 7-1
MANIPULATOR TYPE ........................................................................... 7-3
Manufacturer allocation ...................................................................... 8-113
MASTER JOB ....................................................................................... 7-2
Max. Disturbance Force ....................................................................... 8-86
MAX. RPM .............................................................................. 11-16, 11-27
Measurement of the Tool Load and the Center of Gravity ........................ 8-38
Mechanical Limit ................................................................................ 8-104
MECHANICAL SPEC window ......................................... 11-14, 11-25, 11-26
memory capacity ................................................................................. 12-3
Modification of System Configuration ..................................................... 11-1
Modification of Teaching Points ............................................................ 12-4
momentary output allocation ..................................................... 8-114, 8-121
MONITORING TIME .............................................................................. 7-3
MOTION RANGE ................................................ 11-14, 11-24, 11-25, 11-26
MOTOR SPEC window ...................................................................... 11-16
mounting base unit ............................................................................ 13-15
Moving the MOTOMAN ........................................................................ 1-15
Noise Filter ........................................................................................... 4-4

Number of Tool Files............................................................................ 8-21
Numeric Key Customize Function ....................................................... 8-113
OPERATE COND .................................................................................. 7-4

Operation Mode..................................................................................... 7-1
Operation Time Display ........................................................................ 12-4
Order Number ....................................................................................... 2-2
ORG................................................................................................... 8-96
Output of the Work Home Position Signal .............................................. 8-61
Overrun ............................................................................................ 8-101
OVERRUN&S-SENSOR ........................................................................ 7-3
Index-4
FS100 Index
PARAMETER ........................................................................................ 7-4

Path Confirmation ................................................................................ 12-4
PINION DIAMETER ................................................................. 11-15, 11-25
positioning system ............................................................................... 12-3
POWER ON/OFF POS ........................................................................... 7-3
power relay circuit board ............................................................... 13-4, 13-5
Power Supply ........................................................................................ 4-4
Primary Power Supply Breaker Installation ............................................... 4-6
Program Control Instructions ................................................................. 12-5
Programming ....................................................................................... 12-5
Programming Pendant.......................................................................... 12-6
protection stop (PSTOP) signal ............................................................. 13-8
pulse output allocation .............................................................. 8-114, 8-122
PWM amplifier module ....................................................................... 13-16
R-Axis ................................................................................................... 6-3

REDUCTION RATIO .................................. 11-14, 11-15, 11-24, 11-25, 11-26
Registering/Changing the Work Home Position ....................................... 8-60
RES. START (CNCT) ............................................................................. 7-4
RESERVE JOB NAME ........................................................................... 7-4
Resetting the Shock Detected ............................................................... 8-95
Returning to the Work Home Position .................................................... 8-61
ROBOT ................................................................................................. 7-3
robot coordinate ................................................................................... 8-62
Robot installation angle ........................................................................ 8-44
Robot Motion Control ........................................................................... 12-5
robot programming language (INFORM III) ........................................... 8-106
Robot Select........................................................................................ 8-86
Robot Setup Condition ......................................................................... 8-44
Running Speed Limit ............................................................................ 12-4
safeguarding ......................................................................................... 5-5

safeguarding (safety plug) (SAFF) signal................................................ 13-9
Safety ................................................................................................... 1-3
safety plug ........................................................................................ 13-10
SAVE.................................................................................................... 7-3
S-Axis ................................................................................................... 6-3
SECOND HOME POS ............................................................................ 7-3
Security Mode ....................................................................................... 7-1
SELECT JOB ........................................................................................ 7-2
Selecting the User Coordinate File ........................................................ 8-97
Self-Diagnosis ..................................................................................... 12-4
SERVO MONITOR ................................................................................ 7-3
SERVO ON ........................................................................................... 5-5
SERVO ON READY ............................................................................... 5-5
SERVOPACK .................................................................................... 13-15
SET SPEED .......................................................................................... 7-4
Setting Contents ................................................................................ 8-106
Setting the Controller Clock ................................................................ 8-110
Setting the Play Speed ....................................................................... 8-111
Setting the Tool Load Information .......................................................... 8-25
Index-5
FS100 Index
Setting Work Home Position ................................................................. 8-58

SETUP ................................................................................................. 7-4
SF2300............................................................................................... 13-6
SHCKRST instruction........................................................................... 8-90
SHCKSET........................................................................................... 8-85
SHCKSET instruction ........................................................................... 8-90
S-head payload ................................................................................... 8-45
Shock Detection Function ..................................................................... 8-84
Shock Detection Function Setting.......................................................... 8-84
SHOCK SENS LEVEL ........................................................................... 7-3
Short-cut Function ............................................................................... 12-4
Soft Limit on Each Axis ...................................................................... 8-104
Soft Limit Release Function ................................................................ 8-103
software limit ..................................................................................... 8-103
Special Training..................................................................................... 1-2
Specification List ................................................................................. 12-3
Speed Adjustment ............................................................................... 12-4
Speed Setting ..................................................................................... 12-5
Standard Instruction Set ..................................................................... 8-106
Station Axis Setting............................................................................ 11-18
structure ............................................................................................. 12-3
Subset Instruction Set ........................................................................ 8-106
Switch of the tool file ............................................................................ 8-57
SYSTEM INFO ...................................................................................... 7-3
T.C.P. Calibration ................................................................................ 12-4

T-Axis ................................................................................................... 6-3
TEACHING COND................................................................................. 7-4
Teaching the User Coordinates ............................................................. 8-98
three-phase noise filter ........................................................................... 4-4
Three-Phase Power Supply .................................................................... 4-4
Timer Setting....................................................................................... 12-4
TOOL ................................................................................................... 7-3
Tool Calibration ................................................................................... 8-26
Tool Data Setting ................................................................................. 8-21
Tool File ............................................................................................. 8-21
Tool Load Information .......................................................................... 8-48
Tool Load Information Registering ......................................................... 8-55
Tool Load Information Setting ....................................................... 8-48, 8-89
Tool Shock Sensor Releasing ............................................................. 8-101
Transferring the MOTOMAN ................................................................. 1-15
Turning OFF the Main Power .................................................................. 5-7
Turning OFF the Servo Power ................................................................ 5-7
Turning ON the Main Power Supply......................................................... 5-1
Turning ON the Servo Power .................................................................. 5-5
U-arm payload..................................................................................... 8-46

U-Axis .................................................................................................. 6-3
User Alarm Display .............................................................................. 12-4
USER COORDINATE ............................................................................ 7-3
User Coordinate .......................................................................... 8-62, 8-96
User Coordinate Files .......................................................................... 8-96
User Coordinate Setting ....................................................................... 8-96
user I/O circuit board........................................................ 13-4, 13-19, 13-32
Index-6
FS100 Index
user ID ........................................................................................... 7-4, 7-6
VARIABLE ............................................................................................ 7-2

Variable .............................................................................................. 12-5
Variable Type ...................................................................................... 12-5
VERIFY ................................................................................................ 7-3
VERSION.............................................................................................. 7-3
WORK COMMAND .................................................................. 13-31, 13-44

WORK HOME POS................................................................................ 7-3
Work Home Position ............................................................................ 8-58
work home position cube length of its sides ............................................ 8-60
XX ...................................................................................................... 8-96
XY ...................................................................................................... 8-96
Index-7
FS100
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Europe GmbH

Robotics Divsion )
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800 Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.

22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㧗86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542
YASKAWA Electric Korea Co., Ltd

9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513
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.

252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek Road㧘Huaykwang, Bangkok 10320, Thailand
Phone +66-2693-2200 Fax +66-2693-4200
PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741
Specifications are subject to change without notice

for ongoing product modifications and improvements.
YASKAWA ELECTRIC CORPORATION

MANUAL NO. RE-CTO-A218 6
C Printed in Japan December 2014 11-09

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What safety precautions should be followed when handling the FS100?

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What are the different types of notes classified in the manual?

FS100

YASKAWA ELECTRIC CORPORATION

MANUAL NO. RE-CTO-A218 6

Notes for Safe Operation

Indicates an imminent hazardous

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly the

Must never be performed.

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

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

• In the case of not using the programming pendant, be sure to

Definition of Terms Used Often in This Manual

Descriptions of the programming pendant, buttons, and displays are

e.g. PAGE key PAGE

Description of the Operation Procedure

Explanation of Warning Labels

Refer to the manipulator manual for the warning label location.

Heavy Object Warning NP

Front View Electric Shock Warning NP

1 Safety .............................................................................................................................................. 1-1

1.1 For Your Safety.................................................................................................................. 1-1

1.2 Special Training ................................................................................................................. 1-2

1.3 Motoman Manual List......................................................................................................... 1-2

1.4 Personnel Safety................................................................................................................ 1-3

1.5 Motoman Safety................................................................................................................. 1-5

1.5.1 Installation and Wiring Safety ............................................................................... 1-5

1.5.2 Work Area Safety................................................................................................ 1-10

1.5.3 Operation Safety................................................................................................. 1-11

1.6 Notes for Moving and Transferring MOTOMAN............................................................... 1-15

1.7 Notes on MOTOMAN Disposal ........................................................................................ 1-16

2 Product Confirmation ...................................................................................................................... 2-1

2.1 Contents Confirmation ....................................................................................................... 2-1

2.2 Order Number Confirmation............................................................................................... 2-2

3 Installation ....................................................................................................................................... 3-1

3.1 Handling Procedure ........................................................................................................... 3-1

3.2 Place of Installation............................................................................................................ 3-2

3.3 Installation Location ........................................................................................................... 3-3

3.4 Installation Method............................................................................................................. 3-4

4 Connection ...................................................................................................................................... 4-1

4.1 Notes on Cable Connection ............................................................................................... 4-3

4.2 Power Supply..................................................................................................................... 4-4

4.2.1 Three-Phase Power Supply.................................................................................. 4-4

4.2.2 Noise Filter Installation ......................................................................................... 4-4

4.2.3 Leakage Breaker Installation ................................................................................ 4-5

4.2.4 Primary Power Supply Breaker Installation .......................................................... 4-6

4.3 Connection Methods .......................................................................................................... 4-8

4.3.1 Connecting Primary Power Supply ....................................................................... 4-8

4.3.2 Connecting Manipulator Cable ........................................................................... 4-10

4.3.3 Connecting Programming Pendant (Optional).................................................... 4-11

5 Turning ON and OFF Power Supply ............................................................................................... 5-1

5.1 Turning ON Main Power Supply ........................................................................................ 5-1

5.1.1 Initial Diagnosis .................................................................................................... 5-2

5.1.2 When Initial Diagnosis Is Complete...................................................................... 5-4

5.2 Turning ON Servo Power................................................................................................... 5-5