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YASKAWA Motoman DX200 User manual

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Part Number: 182582-1CD
Revision: 0
MOTOMAN-MH900,
DX200 CONTROLLER
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MH900: INSTRUCTIONS
DX200 CONTROLLER FOR THE MH900: INSTRUCTIONS
DX200 CONTROLLER FOR THE MH900: MAINTENANCE
DX200 CONTROLLER (for each purpose): OPERATOR’S
The DX200 CONTROLLER operator’s manual above corresponds to a specific usage. Be sure to use the appropriate
manual.
TYPE:
YR-MH00900-A00 (
STANDARD SPECIFICATION)
1 of 552
ii
182582-1CD
182582-1CD
MH900, DX200 Controller
Copyright © 2018, 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, 2018
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200
www.motoman.com
2 of 552
iii
182582-1CD
182582-1CD
Safety
Summary of Warning Information
MH900, DX200 Controller
Summary of Warning Information
This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notice.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by Yaskawa. Address any questions regarding the safe and proper
operation of the equipment to Yaskawa Customer Support.
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the MH900, DX200 Controller.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
DANGER
Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury. Safety Signs
identified by the signal word DANGER
should be used sparingly and only for
those situations presenting the most
serious hazards.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, will result in death or
serious injury. Hazards identified by the
signal word WARNING present a lesser
degree of risk of injury or death than those
identified by the signal word DANGER.
Indicates a hazardous situation, which if
not avoided, could result in minor or
moderate injury. It may also be used
without the safety alert symbol as an
alternative to “NOTICE”.
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as
“DANGER”, “WARNING” and “CAUTION”.
Safety
3 of 552
Safety
Notes for Safe Operation
iv
182582-1CD
182582-1CD
MH900, DX200 Controller
Make sure to follow these important items
WARNING
• This manual explains setup, diagnosis, maintenance, hardware,
etc. of the MH900, DX200 Controller. Read this manual carefully
and be sure to understand its contents before handling the MH900,
DX200 Controller.
• General information related to safety are described in Chapter 1.
“Safety”. To ensure correct and safe operation, carefully read
Chapter 1. “Safety” of these instructions.
Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
4 of 552
v
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Safety
Notes for Safe Operation
MH900, DX200 Controller
WARNING
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the controller 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 button is
located on the right of the programming pendant.
• 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.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– 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 buttons 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
• Once the emergency stop button is released, clear the cell of all
items which can 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
5 of 552
Safety
Notes for Safe Operation
vi
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MH900, DX200 Controller
WARNING
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury. For
disassembly or repair, contact a Yaskawa representative.
• Read and understand the Explanation of Warning Labels in the
DX200 Instructions before operating the manipulator.
• In some drawings in this manual, protective covers or shields are
removed to show details. Make sure that all the covers or shields
are installed in place 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 is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids the
product warranty.
• 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 with 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 DX200 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
6 of 552
vii
182582-1CD
182582-1CD
Safety
Notes for Safe Operation
MH900, DX200 Controller
• 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.
• To ensure safe and efficient operation at all times, be
sure to follow all instructions, even if not designated as
“DANGER”, “WARNING” or “CAUTION”.
7 of 552
Safety
Explanation of Warning Labels
viii
182582-1CD
182582-1CD
MH900, DX200 Controller
Explanation of Warning Labels
The following warning labels are attached to the controller.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the controller. Prior to operating the controller, confirm the
contents.
Fig. : Warning Label Locations
WARNING
WARNING
HIGH VOLTAGE
DO NOT OPEN DOOR
WITH POWER ON
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
ENSURE DOOR LATCHES
WARNING
HIGH VOLTAGE
DO NOT OPEN DOOR
WITH POWER ON
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
ENSURE DOOR LATCHES ARE SECURELYLOCKED
Arc Flash Hazard
Appropriate PPE Required
Donot operate controls or open covers without
appropriatepersonal protectoin equipment.
Failureto comply may result in injury or death!.
WARNING
HIGH VOLTAGE
DO NOT OPEN DOOR
WITH POWER ON
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
ENSURE DOOR LATCHES
ARE SECURELY LOCKED
WARNING
HIGH VOLTAGE
DO NOT OPEN DOOR
WITH POWER ON
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
ENSURE DOOR LATCHES
ARE SECURELY LOCKED
WARNING
Arc Flash Hazard
Appropriate PPE Required
Do not operate controls or open covers without
appropriate personal protectoin equipment.
Failure to comply may result in injury or death!.
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$6(&7,21$$
8 of 552
ix
182582-1CD
182582-1CD
Safety
Programming, Operation, and Maintenance Safety
MH900, DX200 Controller
Programming, Operation, and Maintenance Safety
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the
operation of this equipment.
Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this equipment
should be permitted to program, or maintain the system. All personnel
involved with the operation of the equipment must understand potential
dangers of operation.
• Inspect the equipment to be sure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil,
debris, etc.
• Be sure that all safeguards are in place. Check all safety
equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Check the E-Stop button at the operator station for proper
operation before programming. The equipment must be in
Emergency Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before
program changes are made. To avoid loss of information,
programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to
options, accessories, or equipment.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot. Do not make any
modifications to the controller unit. Making any changes without
the written permission from Yaskawa will void the warranty.
• Some operations require standard passwords and some require
special passwords.
• The equipment allows modifications to the software for maximum
performance. Care must be taken when making modifications. All
modifications made to the software will change the way the
equipment operates and can cause severe personal injury or
death, as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of
the equipment.
9 of 552
Safety
Safeguarding Tips
x
182582-1CD
182582-1CD
MH900, DX200 Controller
Safeguarding Tips
Mechanical Safety Devices
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the
operation of this equipment. All personnel involved with the operation of
the equipment must understand potential dangers of operation.
General safeguarding tips are as follows:
Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this
equipment, the operator's manuals, the system equipment, and options
and accessories should be permitted to operate this equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources
of Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
The safe operation of this equipment is ultimately the users
responsibility. The conditions under which the equipment will be
operated safely should be reviewed by the user. The user must be
aware of the various national codes, ANSI/RIA R15.06-2012 safety
standards, and other local codes that may pertain to the installation and
use of this equipment.
Additional safety measures for personnel and equipment may be
required depending on system installation, operation, and/or location.
The following safety equipment is provided as standard:
Additional safety measures for personnel and equipment may be
required depending on system installation, operation, and/or location.
The following safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
10 of 552