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
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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

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2 Indications on Explosion-Proof Devices
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Label
A
2 Indications on Explosion-Proof Devices
2.1 Label
Following warning labels are attached to the DX200.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the body of the
DX200. Prior to operating the DX200, confirm the contents.
Note 1:
Specifications of the standard unit vary depending on its function
or the manipulator to be connected.
Painting unit
Standard unit
Note1
Label B
Explosion-proof
indication
Label 1
Label D
Label A
Label C

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Fig: Explosion-Proof Indication
Name plate indications on explosion-proof specifications
Note 4: List of the Painting Unit Types
WARNINGS:
II(2)G
T
ype Rated Remarks Door opening
and closing direction
Painting unit Painting unit size Programing pendant
JZRCR-YCS21-P000
Single phase
AC200V 50/60Hz
AC220V 60Hz
W600XH330XD520 Non explosion-proof
Right
JZRCR-YCS21-P001 Explosion-proof
JZRCR-YCS21-P010 W600XH500XD520 Non explosion-proof
JZRCR-YCS21-P011 Explosion-proof
JZRCR-YCS21-P020 W800XH500XD658 Non explosion-proof
JZRCR-YCS21-P021 Explosion-proof
JZRCR-YCS21-PZ00 W600XH330XD520 Non explosion-proof
Left
JZRCR-YCS21-PZ01 Explosion-proof
JZRCR-YCS21-PZ10 W600XH500XD520 Non explosion-proof
JZRCR-YCS21-PZ11 Explosion-proof
JZRCR-YCS21-PZ20 W800XH500XD658 Non explosion-proof
JZRCR-YCS21-PZ21 Explosion-proof
JZRCR-YCS21-PY20
W800XH500XD658
Non explosion-proof Double door
Right door width:600mm
Left door width:200mm
JZRCR-YCS21-PY21 Explosion-proof
JZRCR-YCS21-PX20 Non explosion-proof
Double door
Right door width:200mm
Left door width:600mm
JZRCR-YCS21-PX21 Explosion-proof
1. Controller: Painting Unit
(Note 3)
(Note 4)
Note 2:
The place of production may be replaced with the
following address in case it is the ATEX-approved one.
YASKAWA ELECTRIC CORPORATION
2-1 Kurosaki shiroishi, Yahatanishi-ku
Kitakyushu 806-0004 Japan
Note 3:
This part may be replaced with the following one.
(Note 2)
Ⅱ(2)G [Exib] ⅡB Gb
Quality Number
Certificate Number

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Fig: Label 1 ( Indications on Rating) Fig: Label A: Caution Label
Fig: Label B: Type of Painting Unit
図：ラベルＢ：塗装ユニット型式銘板
Fig: Label D: Warning Label
Fig: Label C: Order Number Label

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2.2 Standards
The DX200 meets the following requirements:
・ Directive 94/9/EC for equipment and protective systems for proper use in hazardous
areas
・ IEC 60079-0:2011 for electrical apparatus for explosive gas atmospheres Part 0:
General requirements
・ IEC 60079-2:2007 for electrical apparatus for explosive gas atmospheres Part 2:
Pressurized enclosures “p”
・ IEC 60079-11:2011 for electrical apparatus for explosive gas atmospheres Part 11:
Intrinsic safety “ i ”
・ Machinery Directive 2006/42/EC
・ Low Voltage Directive 2006/95/EC
・ EMC Directive 2004/108/EC
・ EN 1127-1 and EN 13463-1 for hazardous areas
When classifying a manipulator environment as a hazardous area (zone),
observe the “Guidelines for the Avoidance of Dangers due to Explosive
Atmospheres with Collection of Examples - Explosion Protection
Guidelines - (EX-Directives)".
In special cases, or if you are not sure about the specification of areas
with the risk of explosion, contact the competent authorities or Yaskawa
and have them decide.
2.3 Use in Hazardous Areas
Following explosion-proof markings are attached on the painting unit.
Painting Unit [Exib] IIB Gb
Marking Description
EX Symbol for explosion-proof devices
ib Intrinsic safety type of explosion-proof
[ ] A marking when the unit is used with approved
devices such as barrier, and has conditional
parts for explosion-proof.
IIB Gas group

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3 System configuration
Fig 3-1:System Configuration(PMU3704-***)
(*) When using Explosion-proof programming pendant.
Note.1) The programming pendant is equipped with either non- explosion-proof
type or explosion-proof type.
（＊）

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4 Basic Specifications
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4 Basic Specifications
Note 1: Dimensions are subject to change depending on the type of the DX200.
Note 2: Mass is subject to change depending on the specifications of the DX200
Standard Unit Painting Unit
- ［Exib］ⅡBGb
Pressure detector/
flow switch circuit - Maximum voltage 13.2V Maximum current 14.2mA
Solenoid valve circuit - Maximum voltage 17.22V
Maximum current 220mA
Battery circuit -
Maximum voltage DC3.6V
Maximum current 81mA
（lithium thionyl chloride battery
（ER17500VLY）) (Note)
Note: mounted in the pressurized
enclosure which is in the manipulator.
600(W）×739(H)×520(D) 600(W）×330(H)×520(D)
Three-phase 200VAC 50/60Hz
220VAC 60Hz
ｓingle-phase 200VAC 50/60Hz
220VAC 60Hz
Supplied from the standard unit
Protective structure
Ambient Temperature
Ambient Temperature
Ambient Temperature
Ambient Temperature
Installation
Dimensions
Vibration
Others
Protective structure
Dimensions
IP54 (back side fan part: IP2X）
DX200
Non explosion-
proof programming
pendant
(JZRCR-YPP21)
Protective structure
Power Supply
Grounding
Noise
Installation
Ambient Temperature
Relative Humidity
D-class grounding with ground resistance of 100 or less
62db or less
Non-hazardous area
During operation: 0 to +45℃
During transportation or when stored: -10～+60℃
10％～90％ (Non-condensing)
0.5G or less
Free from corrosive gas or liquid, or explosive gas
Free from exposure to water, oil, or dust
Free from large electrical noise (plasma)
IP65
Dimensions (Note 1)
Explosion-proof marking
Intrinsic
safe circuit
IP54
Mass (Note 2) 150kg (total of Standard unit + paint unit)
169(W） × 314.5(H) × 50(D)
During operation: 0 to +45℃
During transportation or when stored: -10 to +60℃
10％～90％ (Non-condensing)
Non-hazardous area
Explosion-proof marking
Grounding A-class grounding with ground resistance of 10 or less
(Connected to the back side of the painting unit)
Explosion-proof
programming
pendant
(JZRCR-NPP07)
235(W） × 203(H) × 78(D)
Installation Hazardous area or non-hazardous area
During operation : 0 to +40℃ (Hazardous area）
During operation : 0 to +45℃ (Non-hazardous area）
During transportation or when stored:-10 to+60℃
10％～90％ (Non-condensing)
Ex ib ⅡBT4
Gb

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5 Installation
5.1 Place of Installation
The conditions listed below must be met before installing the DX200:
• Non-Hazardous area
• Ambient temperature must be 0 to 45° C (32 to 113°F) during operation
and -10 to 60°C (14 to 140°F) during transportation and maintenance.
• Humidity must be low with no condensation (10~90%RH).
• It must be a place with little dirt, dust, or water.
• No flammable or corrosive liquids or gases, etc. in the area.
• Little jarring or potential for striking of the DX200 (under 0.5G oscillation).
• No large electric noise source nearby.
• No potential for collision with moving equipment such as forklifts.
If the external electric noise applies, the alarm occurs and the
manipulator may stop.
When the alarm occurs and the manipulator stops, refer to
DX200 maintenance manual and reset the alarm.
WARNING
Devices that are not explosion proof must not be installed in hazardous area.
Failure to observe this warning may result in a fire.

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5.2 Location
・ Install the DX200 outside of the P-point maximum envelope of the manipulator and
outside of the safeguarding.
・ Install the DX200 in a location where the manipulator can be clearly seen during
operation and can be operated safely.
・ Install the DX200 in a location where it can be easily inspected with its door open.
(Make sure to keep the maintenance area.)
・ Install the DX200 at least 500 mm away from the nearest wall for maintenance access.
Front view Side view
Min.500mm

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5.3 Installation Method
CAUTION
• Do not climb on top of the DX200.
Failure to observe this caution may result in injury or damage.
Fix the DX200 to the floor or baseplate by using four user-supplied
brackets made according to the specifications shown below.
If casters are attached, fix the DX200 in the same way.
Specification ＡＢ
Standard, with transformer ４０ ６０
with caster １４５ １６５
40
40
A B
50
Recommended Controller fixing screw: M12 (length: 20 mm) Tightening torque (45N・m (4.6kgf・m2))
Recommended plate thickness :6 mm
Note.: Choose screw length in considering effective screw 14mm in depth of
the fixed screw in the side panel.
Anchor bolt: M12
(unit:mm)
φ14
(2 holes)
Tapped holes for
M12 screws on
The DX200 side
※1
※1 :Fixing JIG is different with specification.
For detail ,see the following.
40
30
50
A B
(unit: mm)

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6 Connection
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6 Connection
6.1 Connection Methods
A connection diagram for the manipulator, manipulator cable, primary
power cable, programming pendant, pressure switch unit, and Intrinsically safe cable is
shown below.
Fig. 6-1: Cable connection
(Non-explosion-proof programming pendant)
Fig. 6-2: Cable connection (Explosion-proof programming pendant)
Programming pendant
cable