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
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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
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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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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)