YASKAWA Motoman DX200 Quick start guide

MANUAL NO. R-AN-A307
Part Number: 165841-1CD
Revision: 2
5
DX200
NOTES FOR SAFE OPERATION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
DX200 NOTES FOR SAFE OPERATION
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
The operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

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DX200 Notes for Safe
Operation
Copyright © 2016, 2014, 2013 YASKAWA America, Inc.
Terms of Use and Copyright Notice
All rights reserved. This manual is freely available as a service to
YASKAWA customers to assist in the operation of Motoman robots,
related equipment and software This manual is copyrighted property of
YASKAWA and may not be sold or redistributed in any way. You are
welcome to copy this document to your computer or mobile device for
easy access but you may not copy the PDF files to another website, blog,
cloud storage site or any other means of storing or distributing online
content.
Printed in the United States of America
First Printing, 2016
YASKAWA America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com

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1 Safety Information
1.1 Definition of Terms Used Often in This Manual
DX200 Notes for Safe
Operation
1 Safety Information
1.1 Definition of Terms Used Often in This Manual
The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming
pendant, and manipulator cable.
In this manual, the equipment is designated as follows.
MANDATORY
• Read this manual and other related documents carefully before
installation, operation, maintenance, or inspection of the DX200.
• In this manual, the Notes for Safe Operation are classified as
"DANGER", "WARNING", "CAUTION", "MANDATORY" or
"PROHIBITED."
• Note, however, this instruction manual does not sufficiently provide
all the safety precautions. For your safety, be sure to ensure safety
measures or management before the operation.
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.
Equipment Manual Designation
DX200 Controller DX200
DX200 Programming Pendant Programming Pendant
Cable between the manipulator and the controller Manipulator Cable

1 Safety Information
1.2 Notes for Safe Operation
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DX200 Notes for Safe
Operation
1.2 Notes for Safe Operation
In this manual, the Notes for Safe Operation are classified as "DANGER",
"WARNING", "CAUTION", "MANDATORY" or "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.
DANGER
Indicates an imminent hazardous
situation which, if not avoided,
could result in death or serious
injury to personnel.
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury to personnel.
CAUTION
Indicates a potentially hazardous
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.
MANDATORY
Always be sure to follow explicitly
the items listed under this heading.
PROHIBITED
Must never be performed.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even
if not designated as “DANGER”, “WARNING” and
“CAUTION”.

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1 Safety Information
1.3 Safety
DX200 Notes for Safe
Operation
Explanation of Warning Labels
The following warning labels are attached to the manipulator and DX200.
Fully comply with the precautions on the warning labels.
1.3 Safety
1.3.1 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.
DANGER
• The label described below is attached to the manipulator.
Observe the precations on the warning labels.
Failure to observe this caution may result in injury or damage to
equipment.
• The following warning labels are attached to DX200.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to
equipment.
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
WARNING
High Voltage
Do not open the door
with power ON.
Internal Breaker
WARNING
High Voltage
Do not open the cover.
WARNING
May cause
electric shock.
Ground the earth
terminal based on
local and national
electric code.

1 Safety Information
1.3 Safety
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DX200 Notes for Safe
Operation
1.3.2 Special Training
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
– JIS B 8433-1:2007 (ISO 10218-1:2006)
– INDUSTRIAL ROBOT- SAFETY REQUIREMENTS
for safe operation of the robot. (Japan Only)
(JIS B 8433)
• 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.
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 instructions.

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1 Safety Information
1.3 Safety
DX200 Notes for Safe
Operation
1.3.3 Motoman Manual List
MANDATORY
• IIt is important to have and be familiar with all manuals concerning
the MOTOMAN.
You should have the four manuals listed below:
–MOTOMAN- INSTRUCTIONS
– DX200 INSTRUCTIONS
– DX200 MAINTENANCE MANUAL
– DX200 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 Safety Information
1.3 Safety
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DX200 Notes for Safe
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1.3.4 Personnel Safety
The entire manipulator P-point maximum envelope 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.
There is a danger of injury if there is 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 these cautions may result in fire, electric shock, or
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 injury due to contact with
DX200, controller, the workpiece, the positioner, etc.

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1 Safety Information
1.3 Safety
DX200 Notes for Safe
Operation
CAUTION
• Never forcibly move the
manipulator axes.
Failure to observe this caution may
result in injury or equipment damage.
• Never lean on DX200 or other
controllers, and avoid inadvertently
pushing buttons.
Failure to observe this caution may
result in injury or damage by
unexpected movement of the
manipulator.
• Never allow unauthorized personnel to touch the DX200 during
operation.
Failure to observe this caution may result in injury or damage resulting
from unexpected movement of the manipulator.

1 Safety Information
1.4 Motoman Safety
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DX200 Notes for Safe
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1.4 Motoman Safety
1.4.1 Transporting
1.4.1.1 Transportation of the manipulator
CAUTION
• Crane, sling, and forklift operations must be performed only by
authorized personnel.
Failure to observe this caution may result in injury or damage.
• Avoid jarring, dropping, or hitting the controller during handling.
Excessive vibration or impacting the DX200 may adversely affect the
performance of the DX200.
• If storing the manipulator temporarily before installation, be sure to
place it on a stable and flat surface and take precautions to prevent
unauthorized personnel from touching it.
Failure to observe this precaution may result in injury of damage to
equipment.
CAUTION
• As a rule, when removing the manipulator from the package and
moving it, a crane should be used. The manipulator should be lifted
using wire rope threaded through attached eyebolts. Be sure the
manipulator is fixed with shipping bolts and brackets before
transporting, and lift it in the posture as shown in the figures below.
• Be sure to use wire that is strong enough to handle the weight of the
manipulator
• Transportation posture of the manipulator
Fig. : Transporting Position (An example: MOTOMAN-MA1440)

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1 Safety Information
1.4 Motoman Safety
DX200 Notes for Safe
Operation
1.4.1.2 Transportation of the DX200
1.4.2 Installation
Refer to the MOTOMAN- Instructions manual and DX200
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:
CAUTION
• When lifting the DX200, please check the following:
– As a rule, handling of DX200 must be performed using a crane
with wire rope threaded through attached eyebolts.
– Be sure to use wire that is strong enough to handle the weight of
the DX200.
Table : Approx. Weight of DX200
Models Available
for DX200 Approx. Weight (Kg)
Small capacity model 100
Medium /Large capacity
model 100
• Be sure the eyebolts are securely
fastened.
Failure to observe this caution may result in
injury or damage to equipment.
DX200
Wire Rope
M12 Eye bolt
4
NOTE
To insure safety, be sure to install the safeguarding. It
prevents unforeseen accidents with personnel and damage
to equipment. The following is quoted for your information
and guidance.(ISO10218)
Responsibility for Safeguarding
The user of a manipulator or robot system shall ensure that
the safeguarding is provided and used in accordance with
Sections 6, 7, and 8 of this standard. The means and
degree of safeguarding, including any redundancies, shall
correspond directly to the type and level of hazard
presented by the robot system consistent with the robot
application. Safeguarding may include but not be limited to
safeguarding devices, barriers, interlock barriers, perimeter
guarding, awareness barriers, and awareness signals.

1 Safety Information
1.4 Motoman Safety
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DX200 Notes for Safe
Operation
1.4.2.1 Installation of 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 caution may result in injury or damage resulting
from unexpected movement of the manipulator.
• Install a safeguarding around the manipulator to prevent any
accidental contact with the manipulator while the power is on.
• Equipped with a safety interlock. Be sure the interlock operates
correctly before use.
• Perform grounding in accordance with all applicable electrical
codes.
Failure to observe this caution may result in fire or electric shock.
• Do not start the manipulator or even turn ON the power before it is
firmly anchored.
The manipulator may overturn and cause injury or damage.
• When mounting the manipulator on the ceiling or wall, the base
section must have sufficient strength and rigidity to support the
mass of the manipulator. Also, it is necessary to consider
countermeasures to prevent the manipulator from falling.
Failure to observe these warning may result in injury or damage.
1000mm or more
1000mm or more
1000mm
or
more
1000mm
or
more
Door
DX200
Safeguarding
P-point maximum envelope of Manipulator
Maximum Working Envelope of Manipulator Including Tool or
Workpiece End

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1 Safety Information
1.4 Motoman Safety
DX200 Notes for Safe
Operation
CAUTION
• Do not install or operate the manipulator that is damaged or lacks
parts.
Failure to observe this caution may cause injury or damage.
• Before turning ON the power, check to be sure that the shipping
bolts and brackets are removed.
Failure to observe this caution may result in damage to the driving
parts.
• Install the manipulator using bolts of the size and type specified for
each MOTOMAN in the MOTOMAN INSTRUCTION MANUAL.
Failure to observe this caution may result in injury or damage to
equipment.

1 Safety Information
1.4 Motoman Safety
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DX200 Notes for Safe
Operation
1.4.2.2 Installation of the DX200
CAUTION
• Be sure there is sufficient room for maintenance on the
manipulator, DX200, and other peripheral equipment.
Failure to observe this precaution could result in injury during
maintenance.
• To ensure safety, be sure to operate the controller from a
location where the manipulator is easily visible.
Operation by unauthorized personnel may result in injury or
equipment damage.
• Install the DX200 outside the safeguarding of the
manipulator’s safety enclosure.
Failure to observe this precaution may result in injury or
damage to equipment resulting from contact with the
manipulator.
• Do not climb on top of the DX200.
Failure to observe this caution could lead to injury or
mechanical failure.
• Secure the position of the DX200 after setting up.
Attach the DX200 to the floor or rack, etc., using the screw
holes on the bottom of the DX200.
Failure to observe this caution could lead to injury or equipment
damage if the DX200 should shift or fall.
• Be familiar with the connection diagram before wiring the
DX200, and perform the wiring in accordance with the
connection diagram.
There is a danger of equipment damage or injury due to
miswiring and unexpected movement of the equipment.
DX200
586
520 500690
730
600 520 500
DX200 DX200
DX200 Maintenance Area
(Unit: mm)
DX200 External Dimensions
(Unit: mm)
40
60
40
50
30
14 dia.
(2 holes)
(Unit: mm)
Tapped Holes for
M12 Screws on
the DX200 Side
DX200
Recomended plate thickness : 6mm

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1 Safety Information
1.4 Motoman Safety
DX200 Notes for Safe
Operation
1.4.3 Work Area Safety
Carelessness contributes to serious accidents in the work area.
To ensure safety, enforce the following precautions:
CAUTION
• Take precautions when wiring and piping between the DX200,
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.
Operators and other personnel
may stumble on exposed wiring or
piping. Cable damage can cause
unexpected manipulator motion
resulting in injury or property
SAFETY
FIRST
Piping Cable Channel lead
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 caution 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, DX200, 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 Safety Information
1.4 Motoman Safety
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DX200 Notes for Safe
Operation
1.4.4 Operation Safety
MANDATORY
• Persons operating or inspecting the manipulator should be trained
as required by applicable laws and company policies. (chapter 1.3
“Safety” )
WARNING
• When attaching a tool such as the welding torch to the manipulator,
be sure to turn OFF the power supply of the DX200 and the tool,
lock the switch, and display a warning sign.
Turning the power ON during tool installation may case electric shock
or injury due to unexpected movement of the manipulator.
• Never exceed the rated capacity of the manipulator (capacity can
be found in the specifications section of the manipulator manual.)
Failure to observe this caution may result in injury or damage to
equipment.
• Teach jobs from outside the manipulator’s work area whenever
possible.
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– 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.
– Always view the manipulator from the front.
– Always follow the predetermined operating procedure.
– 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.
DX200
PADLOCK
ENERGING
PROHIBITED

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1 Safety Information
1.4 Motoman Safety
DX200 Notes for Safe
Operation
• Before operating the manipulator, check that the SERVO ON lamp
on the programming pendant goes out when the emergency stop
buttons on the front door of the DX200, on the programming
pendant, and on the external control device, etc. are pressed. And
confirm that the servo lamp is turned OFF.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency.
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
• Prior to performing the following operations, be sure that no one is
in the P-point maximum envelope of the manipulator when:
– Turning ON the DX200 power
– Moving the manipulator with the programming pendant
– Running the system in the check mode
– Performing automatic operations
Injury may result from contact with the manipulator if persons enter the
P-point maximum envelope of the manipulator. Press the emergency
stop button immediately if there are problems.
The emergency stop buttons are located on the right of the front door of
the DX200 and the programming pendant.
WARNING
DX200Programming Pendant
Emergency Stop Button

1 Safety Information
1.4 Motoman Safety
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DX200 Notes for Safe
Operation
CAUTION
• Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.
– Check for problems in manipulator movement.
– Check for damage to the insulation and sheathing of external
wires.
• Always return the programming pendant to its hook on the DX200
cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injury or equipment
damage.

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1 Safety Information
1.4 Motoman Safety
DX200 Notes for Safe
Operation
1.4.5 Connection
1.4.5.1 Connecting the Primary Power Supply
WARNING
• The system must be grounded.
Failure to ground equipment may result in injury from fire or electric
shock.
• Before wiring, make sure to turn OFF the primary power supply, and
put up a warning sign.
(ex. DO NOT TURN THE POWER ON)
Failure to observe this caution may result in injury and electric shock.
• Do not touch the inside of the panel for 5 minutes after the power is
tuned OFF. The remaining changed 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 or tuned on.
Failure to observe this warning may result in fire or an electric shock.
• Any occurrence during wiring while the DX200 is in the emergency
stop mode is the user’s responsibility. Do an operation check once
the wiring is completed.
Failure to observe this caution could lead to injury or mechanical
failure.
• Wiring must be performed only by authorized personnel.
Incorrect wiring may cause fire and electric shock.
• Perform wiring in accordance with the rated capacity as specified in
the Instructions.
Incorrect wiring may cause fire or mechanical breakdown.
• Be sure the power circuit screws are securely tightened.
Loose power circuit wires can cause fire and electric shock.
• Do not handle the circuit board directly by hand.
The IC board may malfunction due to electrostatics.
NOTE
• Don’t connect the grounding wire with the wires for the
electric power source, the welder, etc.
• Ground in accordance with all relevant governmental
regulations when using metallic ducts, metallic conduits,
and cable tray to construct the cable.

1 Safety Information
1.4 Motoman Safety
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DX200 Notes for Safe
Operation
1.4.5.2 Connecting the Manipulator Cable
1.4.6 Turning ON the Main Power Supply
NOTE
For more information on connecting the manipulator cable,
please refer to the Instruction Manual which corresponds to
the particular DX200 model.
NOTE
Close the door of the controller (DX200) securely to
prevent dust from entering.
WARNING
• Confirm that nobody is present in the P-point maximum envelope of
the manipulator when turning ON the DX200 power supply.
Failure to observe this caution could result in injury caused by
accidental contact with the manipulator.
Press the emergency stop button immediately if any problems occur.
The emergency stop buttons are located on the right side of the front
door of the DX200 and on the right side of the programming pendant.
NOTE
Be sure to remove all items from the area before moving
the manipulator.
Refer to the INSTRUCTION MANUAL for the appropriate
position of the fixture.