YASKAWA

Simple Education System

INSTRUCTION MANUAL

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

Part Number: 155138-1CD

Revision: 0

YASKAWA
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Simple Education System

MANDATORY
• This manual explains the Simple Education System (SES). Read
this manual carefully and be sure to understand its contents before
operation.
• For detailed instructions on additional equipment, including the
Programming Pendant, NX100 Controller, and I/O box, refer to the
specific equipment manuals included with your documentation
package.

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.
• Software described in this manual is supplied against licensee only,
with permission to use or copy under the conditions stated in the
license. No part of this manual may be copied or reproduced in any
form without written consent of YASKAWA.

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Simple Education System

Notes for Safe Operation

Before using this product, read this manual and all other related
documents carefully to ensure knowledge about the product and safety,
including all cautions.
In this manual, the Notes for Safe Operation are classified as “WARNING,”
“CAUTION,” “MANDATORY,” or “PROHIBITED.”

Indicates a potentially hazardous

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

Indicates a potentially hazardous

situation which, if not avoided, could
result in minor or moderate injury to
CAUTION 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.

PROHIBITED Must never be performed.

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

some situations. Be sure to follow these important items.

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

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

CAUTION
Before operating the SES, read and understand the following:
• The Explanation of Warning Labels on Page vii of the NX100
Controller Manual.
• Section 2, “Safety,” of the NX100 Controller Manual, which provides
information on the safe use and operation of the NX100 Controller.

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Simple Education System Contents

1 Introduction ..................................................................................................................................... 1-1

1.1 About This Document ........................................................................................................ 1-1

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

1.3 Reference Documentation ................................................................................................. 1-2

1.4 Customer Service Information ........................................................................................... 1-3

2 SES Equipment............................................................................................................................... 2-1

2.1 NX100 Controller CPU....................................................................................................... 2-1

2.2 Programming Pendant....................................................................................................... 2-1

2.3 I/O Box............................................................................................................................... 2-3

2.4 Computer ........................................................................................................................... 2-3

2.5 MotoSim® EG Lite Software.............................................................................................. 2-3

3 SES Setup ...................................................................................................................................... 3-1

3.1 Setting Up the SES............................................................................................................ 3-2

3.1.1 Changing Cell Scenes .......................................................................................... 3-5

3.2 Programming Virtual Work-cell Scenes ............................................................................. 3-5

3.3 Shutting Down the SES ..................................................................................................... 3-5

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1 Introduction
Simple Education System 1.1 About This Document

1 Introduction

1.1 About This Document

This manual is delivered with the Simple Education System (SES) to
provide instructions on the setup and operation of the complete Motoman
Simple Education System. It is intended to help users set up the SES for
programming of ladder logic and jobs, self-training, or teaching others. To
perform these tasks, the SES software is used in conjunction with an
actual NX100 Controller, a Programming Pendant, and a computer
installed with MotoSim EG Lite software.
You should read and understand this manual before moving on to the
more detailed documentation that is included with your Simple Education
System. Although basic in content, this instruction manual is intended for
personnel who have received operator training from Motoman and who
are familiar with the operation of Motoman robotic systems.
For more detailed information on any specific component or peripheral of
the Simple Education System, please review the full documentation
package that is included with your Simple Education System (refer to
Section 1.3).
This instruction manual contains the following sections:
Section 1 – Introduction
This section provides general information about the Simple Education
System, a list of reference documents, and customer service contact
information.
Section 2 – SES Equipment
This section provides information about the major components of the SES.
Section 3 – SES Setup
This section provides detailed setup procedures for the Motoman SES.

1.2 Overview
The Motoman Simple Education System for the NX Controller is part of
the Motoman family of standardized solutions. The SES is a PC-based
robot simulator that helps customers learn to operate and program
Motoman robots in a virtual environment. This eliminates robot downtime
during training and helps with off-line programming of complex work cells.
The Motoman SES package, which comes with or without a computer
depending on the customer’s preference, includes the following features
(see Figure 1-1):
• Compact, robust, self-contained NX100 Controller CPU
• MotoSim® EG Lite software
• Standard NX100 robot Programming Pendant and cable
• Input/output (I/O) box
• 2.0 GHz laptop computer (optional), with Windows® XP platform, 2
GB SDRAM, and 512 MB video card
If you purchased the Motoman SES without the computer, Motoman
recommends using a computer that has the aforementioned
specifications.

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1 Introduction
Simple Education System 1.3 Reference Documentation

Because of the SES’s small, self-contained size, the unit can be moved to
wherever training is needed. See Section 2 for more information on the
equipment provided with the SES.

Figure 1-1: Motoman Simple Education System

1.3 Reference Documentation

For additional information on individual components of the Simple
Education System, refer to the following documentation that is included
with your delivered system:
• Motoman MotoSim EG Instructions (P/N 152002-1CD)
• Motoman NX100 Controller Manual (P/N 149201-1CD)
• Motoman Maintenance Manual for NX100 (P/N 150133-1CD)
• Motoman NX100 Operator's Manual for Arc Welding (P/N 149235-
1CD)
• Motoman NX100 Concurrent I/O Manual (P/N 149230-1CD)
• Motoman INFORM (programming language) User’s Manual (P/N
150078-1CD)
• Vendor manuals for system components not manufactured by
Motoman

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1 Introduction
Simple Education System 1.4 Customer Service Information

1.4 Customer Service Information

For professional training assistance on the use of the SES product, please
contact the Training Coordinator at (937) 847-3307 during normal
business hours (8 a.m. to 5 p.m. EST, Monday through Friday).
If you need other assistance with any aspect of your Simple Education
System, please call Motoman Customer Service’s 24-hour support
number: (937) 847-3200. For routine technical inquiries, you can also
contact Motoman Customer Service at the following e-mail address:

techsupport@motoman.com

When using e-mail to contact Motoman Customer Service, please provide

a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
Please use e-mail for routine inquiries only. If you have an urgent or
emergency need for service, replacement parts, or information, please call
the Customer Service telephone number shown above.
Please have the following information ready before you call:

• System Simple Education System

• Primary Application Training

• Controller NX100 CPU

• Software Version Access this information on the

Programming Pendant LCD display
screen by selecting {MAIN MENU} -
{SYSTEM INFO} - {VERSION}

• Serial Number Located on the label on top of the

NX100 Controller CPU

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2 SES Equipment
Simple Education System 2.1 NX100 Controller CPU

2 SES Equipment

2.1 NX100 Controller CPU

The Simple Education System includes an NX100 Controller central
processing unit (CPU; see Figure 2-1). The NX100 Controller CPU
represents state-of-the-art technology in robotics today. It processes input
and output signals, maintains variable data, and performs numeric
processing to convert to and from different coordinate systems. It also
provides main logic functions, program and constant data memory, and
power distribution. The NX100 Controller CPU features a real-time
operating system (RTOS) and is programmed with the Motoman INFORM
programming language.
For more detailed information on the NX100 Controller CPU, refer to the
NX100 Controller Manual that is included with your Simple Education
System (see Section 1.3).

CAUTION
Do not re-initialize the NX100 Controller CPU after setup or the SES
will not function. Re-initialization should be performed only by Motoman
personnel.

Figure 2-1: NX100 Controller CPU

2.2 Programming Pendant

The Programming Pendant (see Figure 2-2) provides the primary means
of programmer/operator interaction with the Simple Education System.
The pendant features the Windows® CE operating system and displays

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2 SES Equipment
Simple Education System 2.2 Programming Pendant

information on a 6½-inch, color LCD, touch-screen display (640 X 480

VGA). The pendant also incorporates a Compact Flash card slot for
program backups. The pendant provides icon-driven system
programming. By using the pendant, the operator can teach the virtual
robot motion and perform programming, editing, and diagnostic functions.
For detailed information on the pendant’s programming keys,
programming functions, and display functions, please refer to the NX100
Operator’s Manual for Arc Welding that is included with your Simple
Education System (see Section 1.3).

Figure 2-2: NX100 Programming Pendant

START Button

HOLD Button

Mode
Select Switch EMERGENCY
STOP Button
REMOTE TEACH
PLAY START HOLD

Menu Area JOB EDIT DISPLAY UTILITY Status Display Area

JOB CONTENT
JOB NAME: TEST01 STEP NO: 0003
CONTROL GROUP: R1 TOOL: 00
General-purpose 0000 NOP Insertion Slot for
Compact Flash™
0001 SET B000 0
Display Area 0002
0003
SET B001 1
MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OGH#(13) B002
0006 DOUT OT#(41) ON
0007 MOVL C00002 V=880.0 CV#(1) CTP=0.662
0008 DOUT OT#(44) ON
0009 TIMER T=3.0
0010 MOVL V=880.0
0011 MOVL V=880.0
0012 MOVL V=880.0
0013 MOVL V=880.0

PAGE Key
COORD Key Main Menu ShortCut !Turn on servo power

Cursor Key SERVO ON READY Key

LAYOUT GO BACK
DIRECT
OPEN
COORD
Multi PAGE AREA

MAIN SHORT
SERVO
!? CANCEL
SELECT SELECT Key
ON
MENU CUT
READY ASSIST

SERVO ON
X- X+
S- S+ X- X+
HIGH R- R+
SPEED
Y-. Y+
L- L+ Y- Y+
.
FAST
B- B+
MANUAL SPEED Keys
MANUAL SPEED
Z- Z+
U- U+ Z- Z+
SLOW T- T+

Axis Keys
INTER 7 8 9 TEST
SHIFT LOCK START SHIFT

ROBOT INFORM 4 5. 6 BWD FWD

LIST

EX.AXIS 1 2 3 DELETE INSERT

BACK MOTION 0 . - MODIFY ENTER

SPACE
TYPE ENTER Key
MOTOMAN

Motion Numeric Keys / Function Keys

Type Key

The Programming Pendant’s LCD display goes dark after a

NOTE few minutes of inactivity. Press any key to restore the
screen.

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2 SES Equipment
Simple Education System 2.3 I/O Box

2.3 I/O Box

The input/output (I/O) box (see Figure 2-3) allows the user to interact with
the SES in order to configure the inputs and outputs of its virtual I/O
devices, such as proximity switches, conveyor relays, motors, safety
devices, and programmable logic controllers (PLC). The SES is
configured for the use of up to 8 inputs and 8 outputs [IG#(1) and OG#(1)]
on the I/O box. For more information on the I/O box, refer to the NX100
Concurrent I/O Manual that is part of your SES documentation package
(see Section 1.3).

Figure 2-3: I/O Box

2.4 Computer
An optional 2.0 GHz laptop computer with a Windows® XP platform, 2 GB
of SDRAM, and 512 MB video card is available with the SES. If you
purchased the Motoman SES without the computer, Motoman
recommends using a computer that has these specifications.
The computer is installed with the MotoSim® EG Lite software, which was
developed as an offline teaching tool for Motoman robots. See Section 2.5
for more information on this software. For more information about the
computer, refer to the vendor manual that is included as part of your SES
documentation package (see Section 1.3).

2.5 MotoSim® EG Lite Software

The MotoSim® EG Lite software provides the following:
• Collision detection through the use of sensors on the virtual robot,
• Cycle time calculations, which help to ascertain how long it takes to
complete a virtual robotic job, and
• Reach analysis, which enables users to determine how to lay out the
virtual work cell, where to position the robot relative to the part being
built, and whether or not the correct size of the robot has been spec-
ified for the job.
Refer to the MotoSim EG Instructions manual for detailed information
about this software (see Section 1.3).

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3 SES Setup
Simple Education System

3 SES Setup
This section provides detailed procedures for setting up, operating, and
shutting down the SES. These procedures should be performed only by
personnel familiar with computer setup. Read this section thoroughly
before beginning setup.

CAUTION
The SES weighs approximately 36.3 kg. Handle the system with care.
Do not drop it. Use proper lifting techniques to prevent injury to
personnel.

When unpacking the SES, remove the protective plastic covering and
other packaging material and put aside. Then carefully inspect the
components of the SES for shipping damage.

• Do not discard or recycle any parts or material until setup

of the SES is complete.
NOTE
• Notify your shipping contractor if you notice any shipping
damage.

CAUTION
The customer is responsible for providing trained operators to run the
equipment. The customer is also responsible for making sure that the
equipment is operated in accordance with the ANSI/RIA R15.06-1999
Robot Safety standard, as well as any other local or state standards.

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3 SES Setup
Simple Education System 3.1 Setting Up the SES

3.1 Setting Up the SES

Perform the following steps to set up the Motoman SES and ensure its
proper functioning:
1. Connect the Programming Pendant cable to the NX100 Controller
CPU by connecting the cable to the connector on the left side of the
CPU’s enclosure (see Figure 3-4).
Fig. 3-4: Programming Pendant Cable to NX100 Controller CPU

2. Connect the other end of the Programming Pendant cable to the

pendant (see Figure 3-5).
Fig. 3-5: Connection of Programming Pendant Cable to Pendant

3. Locate the gray Ethernet cable that is attached to the NX100

Controller CPU and connect its other end to the computer (see
Figure 3-6 and Figure 3-7).

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3 SES Setup
Simple Education System 3.1 Setting Up the SES

Fig. 3-6: Ethernet Cable (P/N 704148-7)

Fig. 3-7: Ethernet Connection

4. Plug the SES power cord into a grounded wall outlet.

CAUTION
Do not use an adaptor that converts a three-prong plug into a two-
prong.

5. Unlatch the door of the CPU’s enclosure and locate the power ON/
OFF switch on its upper left-hand side (see Figure 3-8).

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3 SES Setup
Simple Education System 3.1 Setting Up the SES

Fig. 3-8: NX100 Controller CPU’s Power ON/OFF Switch

6. Turn the CPU ON, then close and latch the door of the enclosure.
7. Turn ON the computer to start up Windows®.
8. Connect the MotoSim EG Lite hardware key to the USB port on the
computer (see Figure 3-9).

NOTE Your MotoSim EG Lite hardware key may differ from the
one shown in the picture.

Fig. 3-9: Connecting MotoSim EG Lite Key to USB Port

9. On the Programming Pendant, use the Mode Select Switch to select

the TEACH mode (see Figure 2-2).
10. Verify that the EMERGENCY STOP (E-STOP) button on the pendant
is released by turning it clockwise (see Figure 2-2).
11. On the computer, select [Start] > [All Programs] > [Motoman] >
[MotoSim EG].
12. When the MotoSimEG dialog box appears, select [OK].

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3 SES Setup
Simple Education System 3.2 Programming Virtual Work-cell Scenes

13. Select [File] > [Open].

14. Select a virtual work-cell scene file that you have already
programmed, or begin creating a work-cell scene file. (Refer to
Section 3.2 for information on programming virtual work-cell scenes.)
15. Select [Open] or double-click on the file to open it.
16. From the menu, select [RemoteMonitor] then [Connect].
17. Press the SERVO ON READY button on the Programming Pendant
(see Figure 2-2).
18. Press COORD on the Programming Pendant until the desired
coordinate system is displayed in the Status Display Area (see
Figure 2-2). For detailed information on coordinate systems, refer to
the NX100 Operator’s Manual for Arc Welding that is included with
your Simple Education System (see Section 1.3).
19. Press the MANUAL SPEED Fast key on the Programming Pendant to
set the SES to high manual speed (see Figure 2-2).
20. Press the coordinate Axis Keys on the Programming Pendant to verify
that the robot moves and thus simulates operation from the pendant
(see Figure 2-2).

3.1.1 Changing Cell Scenes

To go to another cell scene, proceed as follows:
1. Select [Disconnect] from the Remote Monitoring dialog box.
2. Select [File] > {Close} to close only the scene, not MotoSim EG.
3. Continue from Step 13 in Section 3.1 above.

3.2 Programming Virtual Work-cell Scenes

For detailed instructions on how to program the SES with work-cell scenes
pertinent to your job applications, refer to the MotoSim EG Instructions
manual that is included as part of your SES documentation package (see
Section 1.3).

3.3 Shutting Down the SES

Perform the following steps to shut down the SES:
1. On the Remote Monitoring dialog box, select [Disconnect].
2. Select [File] > [Close].
3. Close the MotoSimEG window and, if desired, shut down the
computer.
4. Unlatch the door of the CPU’s enclosure and press OFF on the ON/
OFF switch to shut down the SES.
5. Close and latch the door of the enclosure.

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INSTRUCTION MANUAL

HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone +81-93-645-7745 Fax +81-93-645-7746
MOTOMAN INC. HEADQUARTERS
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Phone +1-937-847-6200 Fax +1-937-847-6277
MOTOMAN ROBOTICS EUROPE AB
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Phone +46-480-417800 Fax +46-480-417999
MOTOMAN ROBOTEC GmbH
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Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA ELECTRIC KOREA CORPORATION
1F, Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone +82-53-382-7844 Fax +82-53-382-7845
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
Unit 47-1 and 2. Jalan PJU 5/9, Dataran Sunway, Kota Damansara, 47810, Petailng Jaya Selangor, Malaysia
Phone +60-3614-08919 Fax +60-3614-08929
YASKAWA ELECTRIC (THAILAND) CO., LTD.
252/246, 4th Floor. Muang Thai-Phatra office Tower II Rechadapisek Road, Huaykwang Bangkok 10320, Thailand
Phone +66-2-693-2200 Fax +66-2-693-4200
SHOUGANG MOTOMAN ROBOT CO., LTD.
No.7,Yongchang-North Road, Beijing Economic and Technological and Development Area, Beijing 100076, China
Phone +86-10-6788-0541 Fax +86-10-6788-0542
MOTOMAN MOTHERSON ROBOTICS LTD.
910, DLF Galleria, DLF City Phase IV, Gurgaon - 122002 Haryama, india
Phone +91-124-414-8514 Fax +91-124-414-8016

YASKAWA ELECTRIC CORPORATION

YASKAWA

Specifications are subject to change without notice

for ongoing product modifications and improvements.

MANUAL NO.

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