YASKAWA Motoman DX200 User manual

MANUAL No.
HW1483491
DX200
INSTRUCTIONS FOR HOT PENDANT
REPLACEMENT FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-□□□ INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
The DX200 operator’s manuals above correspond to specific usage. Be sure to use the appropriate manual.
Part Number: 175386-1CD
Revision: 0
1 of 22

175386-1CD
- ii - - ii -ii
HW1482742
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
2 of 22

175386-1CD Safety
- iii –
HW1483491
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.
3 of 22

175386-1CD
Safety
- iv -
HW1483491
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.
4 of 22

175386-1CD Safety
- v –
HW1483491
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 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.
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”.
5 of 22

175386-1CD
Safety
- vi -
HW1483491
WARNING
•
Before operating the manipulator, check that servo power i
s 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.
6 of 22

175386-1CD Safety
- vii –
HW1483491
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
DX200 programming pendant cable Pendant cable
Cable between controller and the pendant
connection box
Relay cable
DX200 programming pendant extension cable Pendant extension cable
Cable between the manipulator and the controller
Manipulator cable
7 of 22

175386-1CD
Safety
- viii -
HW1483491
Descriptions of the programming pendant, buttons, and displays are shown as follows:
Equipment Manual Designation
Programming
Pendant
Character Keys/
Symbol Keys
The keys which have characters printed on them are denoted
with [ ].ex. [ENTER]
Axis Keys/
Number Keys
“Axis Keys” and “Number Keys” are generic names for the keys
for axis operation and number input.
Keys pressed
simultaneously
When two keys are to be pressed simultaneously, the keys are
shown with a “+” sign between them, ex. [SHIFT]+[COORD].
Displays The menu displayed in the programming pendant is denoted
with { }. ex. {JOB}
Description of the Operation Procedure
In the explanation of the operation procedure, the expression “Select • • •” means that the
cursor is moved to the object item and the SELECT key is pressed, or that the item is directly
selected by touching the screen.
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 ®and TM
are omitted.
8 of 22

175386-1CD Safety
- ix –
HW1483491
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:
[e-mail]
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
9 of 22

175386-1CD
Table of Contents
- x –
HW1483491
Table of Contents
1Introduction ....................................................................................................................1-1
2Hardware Specifications ................................................................................................2-1
2.1 Outline Drawing..........................................................................................................2-1
2.2 Length of Relay Cable................................................................................................2-2
3Procedures for Replacing Operation..............................................................................3-1
3.1 Procedures to Replace the Programming Pendant from the
DX200 to the Pendant Connection Box.............................................................................3-2
3.2 Procedures to Replace the Programming Pendant from the
Pendant Connection Box to the DX200.............................................................................3-4
10 of 22

175386-1CD 1 Introduction
- 1-1 –
HW1483491
1 Introduction
Hot pendant replacement function enables the standard length cable to be used for the
teaching operation near the manipulator by disconnecting the programming pendant and the
cable connected to the DX200 and connecting them to the box placed near the manipulator
even if there is long distance between the DX200 and the manipulator.
Fig. 1-1 Images of the DX200 Standard Specifications and
Specifications with Pendant Replacing Function
Pendant cable
DX200
Manipulator
Standard Specifications
DX200
Pendant
connection cover
Manipulator
Pendant cable
Pendant connection box
Relay cable
Specifications with Pendant Replacing Function
11 of 22

12 of 22

175386-1CD
2 Hardware Specifications
- 2-1 –
HW1483491
2 Hardware Specifications
2.1 Outline Drawing
Fig. 2-1 Outline Drawing of the Pendant Connection Cover
Pendant connection cover
Front View of the DX200 Right Side View of the DX200
13 of 22

175386-1CD
2 Hardware Specifications
- 2-2 –
HW1483491
2.2 Length of Relay Cable
The length of prepared standard cable between the DX200 and the pendant connection box is
8 m. If more length is needed, use the optional pendant extension cable.
Also, the pendant extension cable can be connected to the pendant cable.
For the length of the pendant extension cable for each type, refer to Table 1.
The total length of the cable should be within 36 m.
Length of pendant extension cable
Type
4 m
CBL-YRC062-1
8 m
CBL-YRC062-2
12 m
CBL-YRC062-3
16 m
CBL-YRC062-4
20 m
CBL-YRC062-5
Fig. 2-2 Outline Drawing of the Pendant Connection Box
Table 1 Pendant Extension Cable
14 of 22

175386-1CD
2 Hardware Specifications
- 2-3 –
HW1483491
Example) When the length of the pendant extension cable is 20 m:
Pendant cable: 8 m + Relay cable: 8 m + Pendant extension cable: 20 m = 36 m
Note 1) The relay cable and the pendant extension cable are connected with a connector.
Note 2) One extension cable can be connected at maximum.
15 of 22

16 of 22

175386-1CD 3 Procedures for Replacing Operation
- 3-1 –
HW1483491
3 Procedures for Replacing Operation
CAUTION
• When performing the replacement of the programming pendant, pay careful
attention to steps and surroundings.
• When turning ON the power of the DX200, check that no person is present in the
maximum envelope of the manipulator, and then perform the operation in a safe
location.
If anyone carelessly enters the maximum envelope of the manipulator, injury may result due
to the contact with the manipulator.
• When a trouble occurs, press the emergency stop button immediately.
The emergency stop buttons are located on the front door of the DX200 and at the right side
of the programming pendant one by one.
(Caution)
The emergency stop button of the programming pendant only works when the programming
pendant is connected to the DX200 or to the pendant connection box.
Make sure to use the programming pendant with connecting to either the DX200 or the
pendant connection box.
• During the automatic operation, the pendant cannot be replaced. Make sure to
turn OFF the servo for replacement.
When the programming pendant cable is disconnected without pressing the
emergency stop button, the servo is turned OFF.
• If the pendant is disconnected while the programming pendant is accessing the
Compact Flash or the USB memory (during saving to the external memory or
automatic backup), the media may be damaged or the backup data may not be
stored correctly. Do not disconnect the pendant while accessing the Compact
Flash or the USB memory.
• When using the spare programming pendant for the first time, connect it to the
DX200 and turn OFF/ON the power with the main breaker to perform the update
confirmation of the software installed on the pendant. In case the software
installed on the programming pendant and the DX200 system software are not the
same, the software of the programming pendant is updated automatically when the
power is turned ON.
If the spare programming pendant is connected by pressing the illuminated
pushbutton switch of the hot pendant replacement function without turning OFF/ON
the DX200 power, software update confirmation is not performed. Therefore, the
programming pendant software may not work properly. Make sure to connect it to
the DX200 and turn OFF/ON the power with the main breaker to perform the
software update confirmation.
Attach the protection caps to the unconnected connectors of the pendant
connection cover and the pendant connection box. The protection caps are
included in the DX200. If used without the protection caps, connection failure may
be caused by foreign objects etc. Make sure to attach the protection caps.
17 of 22

175386-1CD
3 Procedures for Replacing Operation
- 3-2 –
HW1483491
3.1 Procedures to Replace the Programming Pendant
from the DX200 to the Pendant Connection Box
Following is the operation procedures to replace the programming pendant from the DX200 to
the pendant connection box. Replacement can be performed even if the main power switch
is ON.
[Operation at the DX200 Side]
1. Confirm that the mode selecting switch of the programming pendant is in the teach mode.
When not, stop the movement of the manipulator once, and then switch it to the teach
mode.
2. Press the emergency stop button of the DX200 or the programming pendant.
3. Turn OFF (extinguish) the illuminated pushbutton switch by pressing it.
4. Disconnect the pendant cable connected to the connector (X81).
5. Connect the relay cable to the connector (X81) at the DX200 side.
6. Turn ON (lighten up) the illuminated pushbutton switch, which is operated at the step 3,
by pressing it.
Fig. 3-1 Configuration of the Pendant Replacing Function
(After Replacing to Manipulator Side)
Programming
pendant (P.P.)
Illuminated pushbutton
switch (for turning OFF
programming pendant
power)
Connector
(PENDANT CABLE X81)
Connector (EX. CABLE)
Connector (X81)
Pendant
connection box
Pendant cable
Illuminated pushbutton
switch (for turning OFF
programming pendant
power)
Connector
(EX. CABLE X82).
Relay cable
Main power switch
18 of 22

175386-1CD 3 Procedures for Replacing Operation
- 3-3 –
HW1483491
[Operation at Pendant Connection Box Side]
7. Turn OFF (extinguish) the illuminated pushbutton switch by pressing it.
8. Connect the relay cable to the connector (EX. CABLE X82).
9. Connect the pendant cable which is disconnected at the step 4 to the connector
(PENDANT CABLE X81) of the pendant connection box.
10. Turn ON (lighten up) the illuminated pushbutton switch, which is operated at the step 7,
by pressing it.
Confirm that the initial window is displayed after the start up window is displayed on the
programming pendant screen. Confirm that the programming pendant started up
properly, and then perform the ordinary operations.
11. Pay careful attention to surroundings, and restore the emergency stop button of the
DX200 or the programming pendant.
19 of 22

175386-1CD
3 Procedures for Replacing Operation
- 3-4 –
HW1483491
3.2 Procedures to Replace the Programming Pendant
from the Pendant Connection Box to the DX200
Following is the operation procedures to replace the programming pendant from the pendant
connection box to the DX200. Replacement can be performed even the main power switch
is ON.
[Operation at Pendant Connection Box Side]
1. Confirm that the mode selecting switch of the programming pendant is in the teach mode.
When not, stop the movement of the manipulator once, and then switch it to the teach
mode.
2. Restore the emergency stop button of the DX200 or the programming pendant.
3. Turn OFF (extinguish) the illuminated pushbutton switch by pressing it.
4. Disconnect the pendant cable connected to the connector at the pendant connection box
(PENDANT CABLE X81).
5. Turn ON (lighten up) the illuminated pushbutton switch, which is operated at the step 3,
by pressing it.
Fig. 3-2 Configuration of the Pendant Replacing Function (After
Replacing to the DX200 Side)
Illuminated pushbutton
switch (for turning OFF
programming pendant
power)
Connector
(EX. CABLE X82).
Connector (EX. CABLE)
Connector (X81)
Illuminated pushbutton
switch (for turning OFF
programming pendant
power)
Pendant cable
Pendant
connection box
Programming
pendant (P.P.)
Relay cable
Main power switch
20 of 22