YASKAWA Motoman DX200 User manual

Part Number 170294-1 Revision 2 March 2015 Page 1 of 2
READ FIRST!!
DX200
WELCOME…
…to the Yaskawa Motoman family of robotics. We take pride
in the work we do and would like to take this opportunity to
thank you for your business. This READ FIRST!! packet
familiarizes you with your new Motoman
®
robotic system.
Please review all the information contained here before
operating your system.
Contained in this READ FIRST!! packet you will find:
•Documentation Survey Card
•Customer Service Information
•Alarm Error Information
•Lithium Battery Safety Information
•System Drawings (if applicable)
•Door Key (if applicable)
•Additional Information
We continually strive to provide the highest quality systems
and service available. If you have any questions or
comments, please call us. We appreciate your business and
want Yaskawa Motoman to continue to be the best solution to
your automation needs.
ADDITIONAL INFORMATION
For additional information, refer to the following:
•Motoman Manipulator Manual for your robot model
•Motoman DX200 Controller Manual
(p/n 165292-1CD)
•Motoman Operator’s Manual for your application
•Motoman Concurrent I/O Parameter Manual
(p/n 165294-1CD)
•Equipment mounting guidelines refer to the installation
section of the manipulator manual and if applicable,
ArcWorld system manual. The installation section of
the manipulator manual contains the robot repulsion
forces. Contact your local concrete and masonry
supplier in order to meet equipment mounting and
anchoring requirements.
CUSTOMER SERVICE INFORMATION
If you are in need of technical assistance, contact the
Yaskawa Motoman service staff at 937.847.3200. Please
have the following information ready before you call.
•Robot type (MA1440, MH50II, MS165, etc.)
•Application type (arc and spot welding, handling, etc.)
•System type (ArcWorld
®
, FabWorld
®
, etc.)
•Software version (access using MAIN MENU,
SYSTEM INFO, VERSION on programming pendant)
•Robot serial number (located on the back side of robot
arm)
• Robot sales order number (located on front of the
DX200 controller)
ALARM ERRORS
We make every effort to ensure safe delivery of your robotic
system. However, occasionally a robotic system will
encounter problems with data loss and physical movement
caused during the shipping process. Therefore, when turning
on the system and a Minor Alarms occurs they are probably
ALARM:4692 and ALARM:4107. The following is a
description of each cause and remedy.
Alarm 4311 Encoder Backup Error
Should you receive a 4311 alarm, please contact the
Yaskawa Motoman Service Department. While not a major
cause for concern, there are several remedies for this error.
A Yaskawa Motoman service representative can help
determine the best solution for your system.
Alarm 4107 Out of Range (ABSO DATA)
A 4107 Out of Range alarm occurs at power ON if the robot’s
position has changed during shipment or since last
shutdown. The out of range axes will highlight in the alarm
display. After resetting the alarm and turning servo power
ON, a “Check Position” prompt occurs. The “Check Position”
procedure involves jogging the robot to a known pulse count
position (a specified point) and verifying that the robot is
physically at the proper position. This position called the
“Second Home.”
To check position:
1. Select ROBOT from the main menu.
2. Select SECOND HOME POS, the Second Home Position
window appears.
3. Press the Page key. The group axes by which the second
home position is set when there are two or more group axes.
4. Press FWD, and observe the robot moves to the second
home position. Robot speed is set as selected manual
operation speed.
5. Select DATA.
6. Select CONFIRM POSITION. The “Home Position
Checked” message appears.
A comparison of the current pulse data and second home
position to ensure allowable ranges, and resumes playback
operations. However, if outside the allowable range, the
alarm occurs again. Contact a Yaskawa Motoman Service
representative if this occurs.

Part Number 170294-1 Revision 2 March 2015 Page 2 of 2
LITHIUM BATTERY SAFETY
This section contains basic information regarding safe
storage, disposal, installation, and transportation of lithium
batteries used in your robotic system.
Safety
To ensure proper battery operation and to reduce personal
hazards:
•Use only for intended operation;
•Dispose of cells only according to recommended
procedures;
•Only ship using freight aircraft.
DANGER!
Excessive heat may cause batteries to burn or explode,
therefore:
•Do not charge batteries;
•Do not incinerate, solder, or expose to high
temperatures;
•Do not short positive & negative terminals
together.
Storage
Always store the lithium batteries in a cool and dry place,
typically 20 to 25°C (68.5 to 77°F) at 40% to 60% relative
humidity. Place batteries and a copy of these instructions
away from flammable materials.
Transportation
Each battery contains 0.23 grams of lithium. Two batteries
can ship together within the United States without restriction.
Transportation procedures for transferring three or more
batteries within the United States are in the Department of
Transportation (DOT), Code of Federal Regulations, CFR49,
“Transportation.” An exemption to these regulations,
DOT-E7052, covers transportation of certain hazardous
materials classified as flammable solids. This exemption
authorizes transport of lithium batteries by motor vehicle, rail
freight, cargo vessel, and cargo-only aircraft, providing
meeting certain conditions. Regulations governing shipment
to, or within, other countries may differ from those of the U.S.
A special provision of DOT-E7052 (11th Rev., October 21,
1982, par. 8-a) provides that: Persons who receive cells and
batteries covered by this exemption may reship them
pursuant to the provisions received.
The Code of Federal Regulations, 49 CRF 173.22a, relates
to the use of packaging authorized under exemptions. In part,
you must maintain a copy of the exemption at each facility
where the packaging is in connection with shipment under
the exemption. Shipment of depleted batteries intended for
disposal may be subject to specific regulations under the
IATA Restricted Articles of the International Air Transport
Association, Geneva, Switzerland. NOTE: Periodically
Regulations for transportation of lithium batteries are
changed.
Disposal
For disposal, batteries must be packaged and shipped in
accordance with transportation regulations to a disposal site.
For more information contact:
U. S. Department of Transportation
Research and Special Programs Administration
400 Seventh Street, S.W.
Washington, D.C. 20590
WARNING!
Do not incinerate or dispose of lithium batteries in
general trash collection. Explosion or violet rupture is
possible. Collect batteries for disposal in a manner to
prevent against short-circuiting, compacting, or
destruction of integrity and hermetic seal. Although the
Environmental Protection Agency has no specific lithium
battery regulations at this time, lithium may be
considered toxic, reactive, or corrosive. Persons
disposing of the material are responsible for any hazard
created in doing so. State and local regulations may
exist regarding the disposal of these materials.
BATTERY REPLACEMENT
Your lithium batteries provide memory backup for
approximately five years. Batteries are located in both the
robot base and controller.
DANGER!
Only qualified electricians familiar with high voltage
location within the controller should replace the battery.
Controller
A “Memory Battery Weak” error message appears on the
pendant screen, indicating battery replacement must occur
within 40 hours. If this message occurs within 30 minutes of
power-up following an extended power-off period of more
than two days, replace battery immediately as follows:
1. Set MAIN POWER switch on controller to ON.
2. Open cabinet and remove battery connector and fixing
screw on YIF01 board.
3. Unplug battery from CN110/BAT connection and remove.
4. Replace battery and plug connector into CN100/BAT
connection.
5. Close controller cabinet.
Robot
An “Encoder Battery Weak” error message appears on the
pendant screen, indicating battery replacement must occur
within 40 hours as follows.
NOTE: Connect new battery pack before removing old
one to avoid losing encoder absolute data.
1. Set the MAIN POWER switch on the controller to OFF.
2. Remove mounting screws for the battery pack on the
connector base.
3. Remove battery pack from holder.
4. Connect the new battery pack to the unoccupied
connector.
5. Remove the old battery pack from the connector.
6. Mount the new battery pack on the holder.
7. Securely fix the battery pack on the connector base with
the mounting screws.
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
TEL: [phone]
FAX: [phone]
24-HOURS HOTLINE: [phone]
www.motoman.com