YASKAWA Motoman DX200 User manual

MANUAL No.
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DX200
INSTRUCTIONS
FOR EXPLOSION-PROOF SPECIFICATIONS
(External Axis Motor Unit : PMU3704)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-
□□□ INSTRUCTIONS
MOTOMAN- □□□ INSTRUCTIONS FOR EXPLOSION-PROOF SPECIFICATION
PMU3704 EXTERNAL AXIS MOTOR UNIT FOR EXPLOSION-PROOF SPECIFICATION
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
DX200 INSTRUCTIONS SUPPLEMENTARY FOR □□□ CONTROLLER FOR PAINTING
The DX200 operator’s manuals above correspond to specific usage. Be sure to use the appropriate manual.
Part Number:174117-1CD
Revision:0
2

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Copyright © 2015, 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, 2015
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com

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MANDATORY
• This manual explains the controller of the DX200. Read this manual carefully and be
sure to understand its contents before handling the DX200.
General items related to safety are listed in the Chapter 1: Safety of the DX200
instructions. To ensure correct and safe operation, carefully read the DX200
instructions 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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We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial
Robots and Robot Systems (ANSI/RIA R15.06-2012). You can obtain this document from the Robotic
Industries Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: [phone]
FAX: [phone]
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against accidents and damage that can
result from improper operation of the equipment. The customer is responsible for providing adequately
trained personnel to operate, program, and maintain the equipment. NEVER ALLOW UNTRAINED
PERSONNEL TO OPERATE, PROGRAM, OR REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel involved with the operation,
programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.

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Notes for Safe Operation
Read this manual 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”
DANGER Indicates a 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.
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 to follow all
instructions, even if not designated as “DANGER”, “WARNING” and
“CAUTION”.

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WARNING
• Before operating the manipulator, check that servo power is turned OFF pressing the
emergency stop buttons on the front door of the DX200 and the programming pendant.
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 Button
• 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.
- 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 person is present in the P-point maximum envelope of the manipulator and
that you are in a safe location before:
- Turning ON the power for the DX200.
- 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 is a problem.
The emergency stop buttons are located on the right of front door of the DX200 and the
programming pendant.

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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 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.
• Read and understand the Explanation of Warning Labels in the DX200 Instructions
before operating the manipulator:
Definitions 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
DX200 controller DX200
DX200 programming pendant Programming pendant
Cable between the manipulator and the
controller
Manipulator cable
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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Customer Support Information
If you need assistance with any aspect of your system, please contact Motoman Customer Support at
the following 24-hour telephone number:
[phone]
For routine technical inquiries, you can also contact Motoman Customer Support at the following
e-mail address:
[email protected]
When using e-mail to contact Motoman Customer Support, 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, you must contact Motoman Customer Support at
the telephone number shown above.
Please have the following information ready before you call:
• System
• Primary Application
• Controller DX200
• Software Version Access this information on the
Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX200 controller
data plate

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1Introduction ....................................................................................................................1-1
2Indications on Explosion-Proof Devices.........................................................................2-1
2.1 Label ...........................................................................................................................2-1
2.2 Standards ...................................................................................................................2-4
2.3 Use in Hazardous Areas.............................................................................................2-4
3System configuration......................................................................................................3-1
4Basic Specifications .......................................................................................................4-1
5Installation ......................................................................................................................5-1
5.1 Place of Installation.....................................................................................................5-1
5.2 Location ......................................................................................................................5-2
5.3 Installation Method......................................................................................................5-3
6Connection .....................................................................................................................6-1
6.1 Connection Methods...................................................................................................6-1
6.2 Equipment Connection Diagram.................................................................................6-9
7Turning ON the Power Supply .......................................................................................7-1
7.1 Turning ON the Main Power Supply ...........................................................................7-1
7.2 Air purge .....................................................................................................................7-1
8Inspections .....................................................................................................................8-1
8.1 Regular Inspection Item..............................................................................................8-1
9Maintenance...................................................................................................................9-1
9.1 Maintenance for DX200 ..............................................................................................9-1

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1 Introduction
Before using this product, read this manual and all other documents
carefully to ensure knowledge about the product and safety, including all the
cautions.
As seen in the figure below, the DX200 consists of the painting unit part and
the standard unit part.
Hereinafter, the DX200 which consists of the painting unit part and the standard unit part
is referred to as “the DX200”.
“Manipulator” described in this manual contains the external axis motor unit.
Painting unit
Standard unit
DX200
Alarm lamp
Emergency Stop Switch
Breaker