YASKAWA Motoman DX200 User manual

MANUAL No.
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DX200 OPTIONS
INSTRUCTIONS
SUPPLEMENT FOR FPD HANDLING USE
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 manual above corresponds to specific usage. Be sure
to use the appropriate manual.
Part Number: 174117-1CD
Revision: 0
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Copyright © 2016, 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, 2016
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 a 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 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”.
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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 for safeguarding when going inside. Also, display a sign
that an 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 DX200
• Primary Application FPD Handling
• 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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Table of Contents
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Table of Contents
1 Introduction ................................................................................................................................... 1-1
2 Power Capacity............................................................................................................................. 2-1
3 Basic Specifications ...................................................................................................................... 3-1
3.1 Standard module ........................................................................................................................ 3-1
4 Controller Type List....................................................................................................................... 4-1
5 Dimension Diagram and Internal Arrangement Diagram.............................................................. 5-1
6 The List of the Equipment Configuration ...................................................................................... 6-1
7 Recommended Spare Parts List................................................................................................... 7-1
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Introduction
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1 Introduction
This manual is a supplementary instruction manual for the DX200.
The described contents are as follows;
i ) Power Capacity
ii ) Basic Specifications
iii ) Controller Type List
iv ) Dimension Diagram and Internal Arrangement Diagram
v) The List of the Equipment Configuration
vi ) Recommended Spare Parts List
For contents that are not described in this manual, refer to the “DX200 INSTRUCTIONS”, “DX200
MAINTENANCE MANUAL”, and all other related documents.
Before using this product, read this manual and all other documents carefully to
ensure knowledge about the product and safety, including all the cautions.
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2 Power Capacity
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2 Power Capacity
The power capacity of each model, and cable size of primary power supply cable are shown in Table
2-1: “Power capacity and Cable size”.
・The power capacity shown in table 2-1 is subject to change depending on the work
condition.
However, the maximum load value such as payload, operation speed, and
frequency etc. are taken into account to the value.
・When an external axis is added, the power capacity will also increase.
In that case, contact your YASKAWA representative, or check the rated value
shown on the label on the DX200 for the power capacity.
・When selecting a transformer, contact your YASKAWA representative.
The power capacity shown in table 2-1 is the continuous rating value.
When the robot is rapidly accelerated, the power capacity of
several times the continuous rating value may be needed instantly.
Table 2-1: Power Capacity and Cable Size
Model Power
capacity
[kVA]
Cable size（Terminal size）
[Cabtyre cable]mm2
MFL15D-875
MFL15DW-875
1.5 3.5（M5）
MFL15DW-1400
MFL15D-1600
2.0 3.5（M5）
MFL1200D-1200 2.5
3.5（M5）
MFL1200D-1600 2.5
3.5（M5）
MFL15DW-2400 3.0
5.5（M5）
MFL1200D-2400 3.0
5.5（M5）
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3 Basic Specifications
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3 Basic Specifications
3.1 Standard Module
Table 3-1: Standard Module Basic Specifications
Item Specification
Dust/Splash-proof
Construction
IP54（*Back fan part is IP2X）
Dimensions W800×H900×D550mm
Approx. Weight 200kg
Cooling System Indirect cooling
Power Supply 3-phase 200V/220V AC (+10 to -15%) at 60Hz (±2%)
200V AC (+10 to -15%) at 50Hz (±2%)
Grounding D class（Grounding resistor：100Ωor less）
Exclusive grounding
Noise Level Less than 62dB
Ambient Temperature 0℃to +25℃：During operation
-10℃to +60℃：During transit and storage
Relative Humidity 10% to 90%RH (non-condensing)
Vibration 0.5G or less
Others ・Free from corrosive gas or liquid, or explosive gas or liquid
・Free from exposure to water, oil or dust
・Free from excessive electrical noise (plasma)
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4 Controller Type List
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4 Controller Type List
Table 4-1: Controller Type List
Controller Type
ERER-
Model Dimension
Diagram ,
Internal
Arrangement
Diagram
Parts List Recommended
Spare Parts
List
MFL015D-A00 MFL15D-875
MFL15DW-875
Figure 5-1/5-2 Table 6-1 Table 7-1
MFL015D-A01 MFL15D-1600
MFL15DW-1400
Figure 5-1/5-2 Table 6-1 Table 7-1
MFL015D-A02 MFL15DW-2400 Figure 5-1/5-2 Table 6-1 Table 7-1
MFL020D-A01 MFL1200D-1200
MFL1200D-1600
Figure 5-1/5-2 Table 6-2 Table 7-2
MFL020D-A02 MFL1200D-2400 Figure 5-1/5-3 Table 6-3 Table 7-3
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5 Dimension Diagram and Internal Arrangement Diagram
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5 Dimension Diagram and Internal
Arrangement Diagram
Figure.5-1: Dimension Diagram
Figure.5-2: Internal Arrangement Diagram
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5 Dimension Diagram and Internal Arrangement Diagram
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* Only one cable inlet (door side) at left side of the main unit is available because an external servopack
is equipped.
Figure.5-3: Internal Arrangement Diagram
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6 The List of the Equipment Configuration
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6 The List of the Equipment
Configuration
Table 6-1: List of the Equipment Configuration
Item Standard Remarks
Circuit breaker NF32-SVF 3P 20A
Control power supply unit JZNC-YPS21-E
CPU unit JZNC-YRK21-1E
CPU circuit board JANCD-YCP21-E
Back circuit board JANCD-YBB21-E
PCI riser circuit board JANCD-YBB22-E
Robot I/F circuit board JANCD-YIF01-□E
Machine safety CPU circuit board JANCD-YSF21-E
Machine safety I/O logic circuit board JANCD-YSF22□-E
Machine safety terminal block circuit board JANCD-YFC22-E
Universal I/O circuit board JANCD-YIO21-E
Power ON unit JZRCR-YPU51-1
Major axes control circuit board SRDA-EAXA21A
Brake control circuit board JANCD-YBK21-3E
Converter SRDA-COA30A21B-E
Capacitor module SRDA-CUA133AA
Amplifier module AMP1 - SRDA-SDA71A01A-E
AMP2 U SRDA-SDA71A01A-E
AMP3 - SRDA-SDA35A01A-E
AMP4 S SRDA-SDA06A01A-E
AMP5 L SRDA-SDA06A01A-E
AMP6 R SRDA-SDA06A01A-E
Regenerative
resistor
Type SMVK500W2R0J A5978 ×3
Rated value 1500W(500W×3)
Resistor value 6Ω(2Ω×3)
Circulation fan 4715MS-22T-B50-B00 ×2 or
11938MB-B2N-EA-01 ×2
Backside duct fan 4715MS-22T-B50-B00 ×3 or
11938MB-B2N-EA-01 ×3
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6 The List of the Equipment Configuration
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Table 6-2: List of the Equipment Configuration
Item Standard Remarks
Circuit breaker NF32-SVF 3P 20A
Control power supply unit JZNC-YPS21-E
CPU unit JZNC-YRK21-1E
CPU circuit board JANCD-YCP21-E
Back circuit board JANCD-YBB21-E
PCI riser circuit board JANCD-YBB22-E
Robot I/F circuit board JANCD-YIF01-□E
Machine safety CPU circuit board JANCD-YSF21-E
Machine safety I/O logic circuit board JANCD-YSF22□-E
Machine safety terminal block circuit board JANCD-YFC22-E
Universal I/O circuit board JANCD-YIO21-E
Power ON unit JZRCR-YPU51-1
Major axes control circuit board SRDA-EAXA21A
Brake control circuit board JANCD-YBK21-3E
Converter SRDA-COA30A21B-E
Capacitor module SRDA-CUA133AA
Amplifier module AMP1 - SRDA-SDA71A01A-E
AMP2 U SRDA-SDA71A01A-E
AMP3 - SRDA-SDA35A01A-E
AMP4 S SRDA-SDA14A01A-E
AMP5 L SRDA-SDA14A01A-E
AMP6 R SRDA-SDA14A01A-E
Regenerative
resistor
Type SMVK500W2R0J A5978 ×3
Rated value 1500W (500W×3)
Resistor value 6Ω(2Ω×3)
Circulation fan 4715MS-22T-B50-B00 ×2 or
11938MB-B2N-EA-01 ×2
Backside duct fan 4715MS-22T-B50-B00 ×3 or
11938MB-B2N-EA-01 ×3
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6 The List of the Equipment Configuration
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Table 6-3: List of the Equipment Configuration
Item Standard Remarks
Circuit breaker NF32-SVF 3P 20A
Control power supply unit JZNC-YPS21-E
CPU unit JZNC-YRK21-1E
CPU circuit board JANCD-YCP21-E
Back circuit board JANCD-YBB21-E
PCI riser circuit board JANCD-YBB22-E
Robot I/F circuit board JANCD-YIF01-□E
Machine safety CPU circuit board JANCD-YSF21-E
Machine safety I/O logic circuit board JANCD-YSF22□-E
Machine safety terminal block circuit board JANCD-YFC22-E
Universal I/O circuit board JANCD-YIO21-E
Power ON unit JZRCR-YPU51-1
Major axes control circuit board SRDA-EAXA21A
External axes control circuit board SRDA-EAXB21A
Brake control circuit board JANCD-YBK21-3E
Converter SRDA-COA30A21B-E
Capacitor module SRDA-CUA133AA
Amplifier module AMP1 - SRDA-SDA71A01A-E
AMP2 - SRDA-SDA71A01A-E
AMP3 - SRDA-SDA35A01A-E
AMP4 S SRDA-SDA14A01A-E
AMP5 L SRDA-SDA14A01A-E
AMP6 R SRDA-SDA14A01A-E
External axes servopack U SRDA-SDB95A01A-E
Regenerative
resistor
(For converter)
Type SMVK500W2R0J A5978 ×3
Rated value 1500W (500W×3)
Resistor value 6Ω(2Ω×3)
Regenerative
resistor
(For external axis
servopack)
Type SMVK500W2R0J A5978 ×3
Rated value 1500W (500W×3)
Resistor value 6Ω(2Ω×3)
Circulation fan 4715MS-22T-B50-B00 ×2 or
11938MB-B2N-EA-01 ×2
Backside duct fan 4715MS-22T-B50-B00 ×4 or
11938MB-B2N-EA-01 ×4
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7 Recommended Spare Parts List
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7 Recommended Spare Parts List
The recommended parts and components for DX200 are ranked as follows.
It is recommended that the following parts and components be kept in stock as spare parts for DX200.
• Rank A: Expendable and frequently replaced parts
• Rank B: Boards and sub-units
• Rank C: Units
When purchasing of spare parts, please inform YASKAWA representative of the manufacturing
number (or order number) and controller type (refer to chapter 4 “Controller Type List” –Table 4-1
“Controller Type List”).
Product performance cannot be guaranteed when using spare parts from any company other than
YASKAWA.
For replacing parts in Rank A, refer to the “DX200 MAINTENANCE MANUAL”.
For replacing parts in Rank B or Rank C, be sure to contact your YASKAWA
representative.
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7 Recommended Spare Parts List
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Table 7-1: Recommended Spare Parts List
Rank Parts
No.
Name Type Manufacture
r
Qty Qty
per
unit
Remarks
A 1 Battery ER6VC3N 3.6V TOSHIBA
BATTERY CO.,LTD 1 1
A 2 Control Power Supply
Cooling Fan JZNC-YZU21-E YASKAWA 1 1
A 3 Cooling Fan 4715MS-22T-B50-B00
or 11938MB-B2N-EA-01 Minebea Co., Ltd 5 5
A 4 AC Control Power
Supply Fuse 0215010MXP Littelfuse 2 2
A 5 AC Cooling Fan Fuse GP25 2.5A, 250V
Daito
Communication
Apparatus Co., Ltd
2 2
A 6
24VDC Fuse for I/O
Brake Power Supply
Fuse
02173.15P 3.15A,
250V Littelfuse 3 3
A 7 PG Power Supply
Fuse HM10 1A, 250V
Daito
Communication
Apparatus Co., Ltd
1 1
A 8 24VDC Fuse for I/O 0217002P 2A, 250V Littelfuse 1 1
B 9 AMP1,2 SRDA-SDA71A01A-E YASKAWA 2 2
B 10 AMP3 SRDA-SDA35A01A-E YASKAWA 1 1
B 11 AMP4,5,6 SRDA-SDA06A01A-E YASKAWA 3 3
B 12
Major Axes Control
Circuit Board SRDA-EAXA21A YASKAWA 1 1
B 13 CPU Circuit Board JANCD-YCP21-E YASKAWA 1 1
B 14
Robot I/F Circuit
Board JANCD-YIF01-E YASKAWA 1 1
B 15
Machine safety CPU
Circuit Board JANCD-YSF21-E YASKAWA 1 1
B 16
Machine safety I/O
Logic Circuit Board JANCD-YSF22-E YASKAWA 1 1
B 17
Universal I/O Circuit
Board JANCD-YIO21-E YASKAWA 1 1
B 18
Brake control Circuit
Board JANCD-YBK21-3E YASKAWA 1 1
C 19 Converter SRDA-COA30A21B-E YASKAWA 1 1
C 20 CPU Unit JZNC-YRK21-1E YASKAWA 1 1
C 21 Power ON Unit JZRCR-YPU51-1 YASKAWA 1 1 Standard
C 22 Control Power Supply JZNC-YPS21-E YASKAWA 1 1
C 23 Capacitor Module SRDA-CUA133AA YASKAWA 1 1
C 24
Programming
Pendant JZRCR-YPP26-1 YASKAWA 1 1
With
Cable(8M)
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