DX100 OPTIONS

INSTRUCTIONS
FOR PROFINET BOARD (PCU-ETHIO-PN MADE BY Molex)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.

MOTOMAN INSTRUCTIONS
MOTOMAN--……… INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 Operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.

Part Number: 158910-1CD

Revision: 1

YASKAWA ELECTRIC CORPORATION

MANUAL NO.

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DX100

MANDATORY
• This manual explains the Profinet board (For PCU-ETHIO-PN made
by Molex.) of the DX100 system and general operations. Read this
manual carefully and be sure to understand its contents before
handling the DX100.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instruction before reading this manual.

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

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DX100

Notes for Safe Operation

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

Indicates a potentially hazardous

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

Indicates a potentially hazardous

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

Always be sure to follow explicitly the

MANDATORY items listed under this heading.

Must never be performed.

PROHIBITED

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

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

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

NOTE to follow all instructions, even if not designated as "CAU-
TION" and "WARNING".

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DX100

PROHIBITED
• Do not use or keep the board in the following environmental
conditions.
– Where exposed to direct sunshine
– Where vibration or impact occurs
– Where high humidity exists
– Where a strong magnetic field exists
– Where much dust exists
– Where a sudden change in the temperature occurs
– Where corrosive gases occur
– Where condensation occurs
Improper usage of the board may damage the board.

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DX100

WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop buttons on the front door of the
DX100 and programming pendant are 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 buttons do not function.
Fig. : Emergency Stop Button

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

• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the manipulator
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the P-point maximum
envelope of the manipulator and that you are in a safe location
before:
– Turning ON the DX100 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 P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there are problems.The emergency stop buttons are
located on the right of the front door of the DX100 and the programming
pendant.
• Before wiring, be sure to turn OFF the power supply and put up a
warning sign, such as “DO NOT TURN ON THE POWER.”
Failure to observe this warning may result in an electric shock or an
injury.

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DX100

WARNING
• Do not touch the inside of the panel for 5 minutes after the power is
turned OFF.
The remaining charged voltage in the capacitor may cause an electric
shock or an injury.
• Be sure to close the door and install the protection cover while the
power is turned ON.
Failure to observe this warning may result in a fire or an electric shock.

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DX100

CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
Read and understand the Explanation of Warning Labels in the DX100
Instructions before operating the manipulator:
• The wiring and mounting must be performed by authorized and
qualified personnel.
Failure to observe this caution may result in a fire or an electric shock.
• Make sure that there is no foreign matter such as metal chips on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Make sure that there is no damage or deflection of parts on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Correctly connect each cable and connector.
Failure to observe this caution may result in a fire or damage the board.
• Set the switches, etc. correctly.
Malfunction, caused by an incorrect setting, may result in an injury or
damage the board.
• Never touch the mounting surfaces of the board parts directly with
fingers.
The generated static electricity may damage the IC.
• Never touch the soldered surfaces of the board directly with fingers.
Protrusions on the soldered surface may result in an injury.
• No shock to the board.
The shock may damage the board.

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DX100

Definition of Terms Used Often in This Manual

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

Descriptions of the programming pendant, buttons, and displays are

shown as follows:

Equipment Manual Designation

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

ex. page key

The cursor key is an exception, and a picture is
not shown.
Axis Keys “Axis Keys” and “Number Keys” are generic
Number Keys names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}

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DX100

Description of the Operation Procedure

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

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

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DX100 Contents

1 Outline............................................................................................................................................. 1-1

1.1 System Configuration......................................................................................................... 1-1

2 Hardware Specifications ................................................................................................................. 2-1

2.1 Board External View .......................................................................................................... 2-1

2.2 Board Specifications .......................................................................................................... 2-2

2.3 Communication Specifications........................................................................................... 2-2

3 Setting and attaching of the board .................................................................................................. 3-1

3.1 Attaching the board............................................................................................................ 3-2

3.1.1 Operating the Front Door of DX100 (controller).................................................... 3-2

3.1.2 Attaching the ETHIO-PN to the DX100................................................................. 3-3

3.1.3 Connecting the cable ............................................................................................ 3-3

3.1.4 Closing the Front Door of the DX100.................................................................... 3-4

4 Allocating I/O Signals ..................................................................................................................... 4-1

4.1 Setting ETHIO-PN communication conditions ................................................................... 4-1

4.2 ETHIO-PN GSDML file ......................................................................................................4-1

4.3 Optional board and I/O Module Settings............................................................................ 4-1

4.4 Transmission Data ............................................................................................................. 4-6

4.5 Example of I/O allocation ................................................................................................... 4-7

5 Error Indication................................................................................................................................ 5-1

5.1 LED Display ....................................................................................................................... 5-1

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1 Outline
DX100 1.1 System Configuration

1 Outline
This instruction manual describes settings and other information required
for the Profinet board PCU-ETHIO-PN (made by Molex, hereinafter
referred to as ETHIO-PN) to be used with DX100.
The use of this board enables DX100 general IO data to be transferred to
and from other Profinet communication stations.

NOTE This board is designed specifically for the DX100, and can-
not be used with general Profinet boards made by Molex.

NOTE Changing this board communication settings requires the

Molex "applicomIO Console" software application.

1.1 System Configuration

„ Example of system configuration when using as Profinet IO Device

Profinet IO Controller
PLC (sequencer) DX100 Controller

Profinet cable Profinet IO Device

ETHIO-PN
HUB

1-1

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1 Outline
DX100 1.1 System Configuration

„ Example of system configuration when using as Profinet IO

Controller

DX100 Controller

Profinet
IO Controller
ETHIO-PN

HUB

Profinet IO Device

1-2

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2 Hardware Specifications
DX100 2.1 Board External View

2 Hardware Specifications

2.1 Board External View

Profinet connector PCU-ETHIO-PN

(RJ45)

Discrete I/O allocation connector

cannot be used with the DX100
LED (Config Port Indicator. Trans) LED (Config Port Indicator. Recv)

Configration connector
(RS232C D-Sub 9 pin)
cannot be used with the DX100

LED (Network Status) LED (Module Status)

LED (Ethernet Link)

Profinet connector LED (Transmission speed)

(RJ45)

2-1

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2 Hardware Specifications
DX100 2.2 Board Specifications

2.2 Board Specifications

Items Specifications
Interface to Profinet
external devices
Board mounting DX100 PCI Slot in controller
position
Error display LED display
Maximum number Input: 250 Bytes, Output: 250 Bytes
of I/O However the Input Byte and Output Byte numbers cannot be
set individually.

The maximum I/O numbers above (Input: 250 Bytes/Output:

250 Bytes) only applies when this board is used as the
NOTE optional IO module. If optional IO modules other than this
board have been installed, the I/O number above may not
be possible.

2.3 Communication Specifications

Explanation
Connection type Star (connected via a HUB)
Communication speed 10Mbps/100Mbps (detected automatically during
startup)
Communication media Use a Profinet cable

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3 Setting and attaching of the board
DX100

3 Setting and attaching of the board

WARNING
• Before wiring, be sure to turn OFF the power supply and put up a
warning sign, such as “DO NOT TURN ON THE POWER.”
Failure to observe this warning may result in an electric shock or an
injury.
• Do not touch the inside of the panel for 5 minutes after the power is
turned OFF.
The remaining charged voltage in the capacitor may cause an electric
shock or an injury.
• Be sure to close the door and install the protection cover while the
power is turned ON.
Failure to observe this warning may result in a fire or an electric shock.

CAUTION
• The wiring and mounting must be performed by authorized and
qualified personnel.
Failure to observe this caution may result in a fire or an electric shock.
• Make sure that there is no foreign matter such as metal chips on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Make sure that there is no damage or deflection of parts on the
board.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Correctly connect each cable and connector.
Failure to observe this caution may result in a fire or damage the board.
• Set the switches, etc. correctly.
In case of malfunction, etc. it may result in an injury or damage the
board.
• Never touch the mounting surfaces and the soldered surfaces of the
board parts directly with fingers.
The generated static electricity may damage the IC, and protrusions on
the soldered surface may result in an injury.
• Never give any shock to the board.
The shock may damage the board.

3-1

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3 Setting and attaching of the board

DX100 3.1 Attaching the board

3.1 Attaching the board

Attach the ETHIO-PN using the following steps.

3.1.1 Operating the Front Door of DX100 (controller)

1. Open the front door of the DX100.
(1) Using a flathead screwdriver, rotate the door locks on the front of
the DX100 (two places) 90 degrees clockwise.
Fig. 3-1: Rotating the Door Lock Clockwise

door lock

clockwise
90°

flathed screw driver

(2) Rotate the main power supply switch to the "OFF" position and
open the door gently.
Fig. 3-2: Rotating the Main Power Supply Switch to the OFF Position）

ON
Main power supply switch
D
PE
IP
TR
OFF
T
SE
RE

DX100

3-2

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3 Setting and attaching of the board
DX100 3.1 Attaching the board

3.1.2 Attaching the ETHIO-PN to the DX100

1. Remove the riser card (JANCD-YBB02-E) from the CPU rack.
2. Insert the ETHIO-PN into the PCI slot of the riser card, and tighten the
support clamps to ensure it does not come lose.
3. Attach the riser card to the CPU rack.

When attaching the ETHIO-PN to the riser card, always do

NOTE so using slot1. Using the riser card with slot1 empty will
mean the board cannot be detected, and the card may not
operate correctly.

Please do not use ETHIO-PN and PCU-ETHIO simultane-

NOTE ously.
Controller may fail to operate correctry.

Tighten the
screws

CN1 : CPU Optional Slot 1 CN2 : CPU Optional Slot 2

3.1.3 Connecting the cable

1. Connect the Profinet cable to the ETHIO-PN Profinet connector.

3-3

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3 Setting and attaching of the board

DX100 3.1 Attaching the board

3.1.4 Closing the Front Door of the DX100

Close the DX100 door.
(1) Close the door gently.
(2) Rotate the door lock counterclockwise 90 degrees.
Fig. 3-3: Rotating the Door Lock Counterclockwise

counterclockwise 90°
door lock

flathead screw driver

CAUTION
• Always close the door of the controller (DX100) except for
maintenance.
• Make sure to rotate all the door locks counterclockwise.
• If dust or water enter inside the controller, electric shock or
breakdown of DX100 may result.

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4 Allocating I/O Signals
DX100 4.1 Setting ETHIO-PN communication conditions

4 Allocating I/O Signals

4.1 Setting ETHIO-PN communication conditions

When using ETHIO-PN, network communication settings must first be
changed using the Molex applicomIO Console.
While pressing [MAIN MENU], turn the power to the DX100 on, change
the ETHIO-PN communication settings.
See the applicomIO Console instruction manual for more information on
communication settings.

4.2 ETHIO-PN GSDML file

When ETHIO-PN is used as a Profinet IO Device, the ETHIO-PN GSDML
file may be required to change network settings with the Profinet IO
Controller.
The GSDML file is generated automatically when applicomIO Console is
used to change communication settings. See the applicomIO Console
instruction manual for more information on the GSDML file.

4.3 Option board and I/O Module Settings

Set the option board and I/O Module, always do so in man-

agement mode after attaching the board.
NOTE
Settings cannot be changed if a board is not attached, or
from operating mode/editing mode.

To use the ETHIO-PN with the DX100, the option board and I/O module
settings must be changed using the following steps.
1. Turn the power supply ON again while pressing [MAIN MENU]
simultaneously.
– The maintenance mode will be displayed

2. Change security mode to management mode.

4-1

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4 Allocating I/O Signals

DX100 4.3 Option board and I/O Module Settings

3. Select [SYSTEM] under the main menu.

– The sub menu will be displayed

4. Select [SETUP].
– The SETUP window will be displayed

5. Select [OPTION BOARD].

– The option board screen will be displayed.

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4 Allocating I/O Signals
DX100 4.3 Option board and I/O Module Settings

6. Select [PCU-ETHIO-PN].
– The PCU-ETHIO-PN SETUP window will be displayed.

A
B

– (Description of each setting item)

A: PCU-ETHIO-PN
Set whether the PCU-ETHIO-PN will be used.
"Use" and "Do not use" can be selected and switched using
the toggle.
B: IO size
The communication byte number set with applicomIO
Console will be displayed. This screen cannot be used to
change the I/O size.
7. Change PCU-ETHIO-PN to "Use".

8. Press [ENTER].
– The confirmation dialog box will be disaplayed.

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4 Allocating I/O Signals

DX100 4.3 Option board and I/O Module Settings

9. Select [Yes].
– The I/O module screen will be displayed.

10. Press [ENTER].

– The next I/O module screen will be displayed, and the ETHIO-PN
I/O allocation results will be displayed.

11. Press [ENTER].

– The confirmation dialog box will be disaplayed.

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4 Allocating I/O Signals
DX100 4.3 Option board and I/O Module Settings

12. Select [Yes].

– Return to the setting screen.

4-5

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4 Allocating I/O Signals

DX100 4.4 Transmission Data

4.4 Transmission Data

Data transferred from the ETHIO-PN to within the DX100 includes I/O
data sent from other Profinet devices, as well as the ETHIO-PN board
status.
Accordingly, in addition to the area for contact point data within the
DX100, there are eight points (1 byte) for both input/output in the area for
the ETHIO-PN board status (the output area cannot be used).
ETHIO-PN board communication data is allocated as the external I/O
signal for the concurrent I/O signal.
Concurrent IO ETHIO-PN Profinet device

Input
20010~22567
(2048 points) Profinet
Communication Profinet
Output and forwarding Communication
to DX100
30010~32567
(2048 points)

If only the ETHIO-PN is installed as the 16Byte optional I/O board,

concurrent I/O allocation is as follows (20010 to 20057 used by the DX100
standard I/O unit).

Table 4-1: Example of concurrent I/O allocation

Kind of Input Output
data
I/O Data 20060 ~ 20067 board status (1) 30060 ~ 30067 not available
20070 ~ 20077 input data (1) 30070 ~ 30077 output data (1)
20080 ~ 20087 input data (2) 30080 ~ 30087 output data (2)
20090 ~ 20097 input data (3) 30090 ~ 30097 output data (3)
··· ···
20220 ~ 20227 input data (16) 30220 ~ 30227output data (16)

[ETHIO-PN board status]

The first 1 byte of the input data of ETHIO-PN allocated to the external
input signal (20060 to 20067 in the allocation example above) represents
the ETHIO-PN board status.

Signal Details
2xxx0 ~ 2xxx5 Reservation area with manufacturer
2xxx6 Represents the Profinet communication status.
0: Nomal status
1: Communication error
2xxx7 Represents the operating status of the board.
0: Nomal status
1: Communication error

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4 Allocating I/O Signals
DX100 4.5 Example of I/O allocation

4.5 Example of I/O allocation

Examples of external I/O signal allocation is shown below.

Example1. Only for ETHIO-PN (16Byte communication settings)

Input Output
20010 ~ 20057 : JZNC-YIU01-E 30010 ~ 30057 : JZNC-YIU01-E
20060 ~ 20227 : ETHIO-PN 30060 ~ 30227 : ETHIO-PN

Example 2. For XOI01 + ETHIO-PN (16Byte communication settings)

Input Output
20010 ~ 20057 : JJZNC-YIU01-E 30010 ~ 30057 : JJZNC-YIU01-E
20060 ~ 20107 : JJANCD-XOI01 30060 ~ 30107 : JJANCD-XOI01
20110 ~ 20277 : JETHIO-PN 30110 ~ 30277 : JETHIO-PN

4-7

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5 Error Indication
DX100 5.1 LED Display

5 Error Indication

5.1 LED Display

The ETHIO-PN has six LEDs, each of which is used to display the
following information.
• Configuration port Indicator: Trans
Status with the serial cable connected for changing board settings.
(cannot be used with the DX100)
• Configuration port Indicator: Recv
Status with the serial cable connected for changing board settings.
(cannot be used with the DX100)
• Network Status
Displays the Profinet communication status.
• Module Status
Displays the ETHIO-PN board status.
• Ethernet Link
Displays the Ethernet Link status.
• Transmission speed
Displays the Ethernet transmmsion speed.

The position of each LED and detailed information are shown below.

Configration port Indicator: Trans Configration port Indicator: Recv

Network Status Module Status

Ethernet Link

Transmission speed

5-1

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5 Error Indication
DX100 5.1 LED Display

„ Network Status

Network Status Status Details and Solutions

Off The communication target The presence of the station
cannot be identified. specified as the
communication target cannot
be identified.
• Check the Profinet cable,
HUB, connector wiring and
connection status.
• Check the communication
speed of each device.
• Check the operating status
of the target communica-
tion station.
Green light The communication target The device is online,
flashing was identified, however a however communication
communication connection cannot be established.
could not be established. • Check the Profinet cable,
HUB, connector wiring and
connection status.
• Check the communication
speed of each device.
• Check the operating status
of the target communica-
tion station.
• Check that the number of I/
O allocation matches that
set at the communication
target station.
Green light on Communication connection Normal status
was established.
Red light flashing One or more communication Communications have been
connections have timed out. established with online
status, however there are
stations with a
communication error.
• Check the operating status
of the target communica-
tion station.
• Check that the number of I/
O allocation matches that
set at the communication
target station.

5-2

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5 Error Indication
DX100 5.1 LED Display

„ Module Status

Module Status Status Details and Solutions

Off The power has not been This board has not been
turned on, or this board has installed correctly, or settings
not started. may mean this board cannot
be used.
• Check the installation status
of this board.
• Check the setting status of
this board.
Green light This board settings could not Cannot start normally as this
flashing be changed correctly. board has not been set
correctly.
• Check the connection sta-
tus of this board.
• Check the setting status of
this board.
Green light on This board is operating Normal status
normally.
Red light flashing A minor problem has Check whether the alarm has
occurred. been output by the DX100
side.
Red light on A major problem has Replace the ETHIO-PN
occurred. board.

„ Ethernet Link

Module Status Status Details and Solutions

Off The Ethernet communication (Physical) signals are not
link has not been being sent or received at the
established. Ethernet level.
Check the installation status
of this board.
• Check the Profinet cable,
HUB, connector wiring and
connection status.
• Check the communication
speed of each device.
Light on The Ethernet communication Normal status
link is operating normally.

„ Transmission Speed

Transmission Speed Status

Light on Communication at 100Mbps
Off Communication at 10Mbps

5-3

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DX100 OPTIONS
INSTRUCTIONS
FOR PROFINET BOARD (PCU-ETHIO-PN MADE BY Molex)

Specifications are subject to change without notice

for ongoing product modifications and improvements.

C Printed in Japan October 2011 11-01

YASKAWA ELECTRIC CORPORATION

MANUAL NO.

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