YASKAWA MOTOMAN DX100 User manual

YASKAWA
YASKAWA MANUAL NO. RE-CHO-A108
DX100
MAINTENANCE MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for
future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
Part Number: 155492-1CD
Revision: 0

DX100
ii
MANDATORY
• This manual explains maintenance procedures of the DX100
system. Read this manual carefully and be sure to understand
its contents before handling the DX100.
• General items related to safety are listed in Section 1: Safety of
the DX100 INSTRUCTIONS. To ensure correct and safe
operation, carefully read the DX100 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.

DX100
iii
Notes for Safe Operation
Read this manual carefully before maintenance or inspection of the
DX100.
In this manual, the Notes for Safe Operation are classified as “WARNING,”
“CAUTION,” “MANDATORY,” or ”PROHIBITED.”
Even items described as “CAUTION” may result in a serious acci-
dent in some situations. At any rate, be sure to follow these impor-
tant items.
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.
NOTE To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “CAU-
TION” and “WARNING.”

DX100
iv
WARNING
• Before operating the manipulator, check that servo power is
turned off when the emergency stop buttons on the front door
of the DX 100 and programing pendant are pressed.
When the servo power is turned off, the SERVO ON LED on the
programing 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 EM
TURN
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– 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 DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the working envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there are problems.
The emergency stop button is located on the right of the front door of
the DX 100 and programing pendant.

DX100
v
Definition of Terms Used Often in This Manual
The MOTOMAN manipulator is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the controller, the programming
pendant, and supply cables.
In this manual, the equipment is designated as follows.
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
DX100 cabinet after use.
The programming pendant can be damaged if it is left in the P-point
maximum envelope of the manipulator, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator.
Equipment Manual Designation
DX100 Controller DX100
DX100 Programming Pendant Programming Pendant
Cable between the manipulator and the
controller Manipulator cable

DX100
vi
Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
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.
Equipment Manual Designation
Programmin
g Pendant Character
Keys The keys which have characters printed on them are denoted with [ ].
ex. [ENTER]
Symbol
Keys The keys which have a symbol printed on them are not denoted with [ ] but
depicted with a small picture.
ex. page key
The cursor key is an exception, and a
picture is not shown.
Axis Keys
Numeric
Keys
“Axis Keys” and “Numeric Keys” are
generic names for the keys for axis
operation and number input.
Keys
pressed
simultane-
ously
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 program-
ming pendant is denoted with { }.
ex. {JOB}
PAGE
GO BACK
PAGE
GO BACK

DX100
vii
Explanation of Warning Labels
WARNING
• The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
Failure to observe this caution may result in injury or damage to
equipment.
Fig. : Warning Labels
• The following warning labels are attached to DX100.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to
equipment.
Fig. : Location of Warning Labels
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
WARNING Label B:
WARNING Label A:
Internal Breaker
WARNING
High Voltage
Do not open the door
with power ON.
WARNING
May cause
electric shock.
Ground the earth
terminal based on
local and national
electric code.
X81
PROGRAMMINGPENDANT
Y
C
E
G
N
O
T
P
M
E
E
S
R
ON
TRIPPED
RESET
OFF
AVERAGE
PEAK
kVA
kA
INTERRUPTCURRENT
ERDR-
POWERSUPPLY
TYPE
DX100
kVA
3PHASE
NJ2960-1
60Hz
SERIALNo.
DATE
AC220V
MADEINJAPAN
50/60HzAC200V
ORDERNO.
NJ1529
Motoman No.
WARNING
High Voltage
Do not ope the cover.

DX100 Contents
viii
1 Equipment Configuration ................................................................................................................1-1
1.1 Arrangement of Units and Circuit Boards..........................................................................1-1
1.1.1 Arrangement.........................................................................................................1-1
1.1.1.1 Small-Capacity DX100 Controller............................................................1-1
1.1.1.2 Medium and Large-Capacity DX100 Controller.......................................1-2
1.2 Power Flow ......................................................................................................................................1-4
1.3 Signal Flow.......................................................................................................................................1-5
2 Security System..............................................................................................................................2-1
2.1 Protection Through Security Mode Settings......................................................................2-1
2.1.1 Security Mode ......................................................................................................2-1
2.1.1.1 Changing the Security Mode...................................................................2-6
2.1.2 User ID .................................................................................................................2-8
2.1.2.1 Changing a User ID.................................................................................2-8
3 Inspections......................................................................................................................................3-1
3.1 Regular Inspections...........................................................................................................3-1
3.2 DX100 Inspections.............................................................................................................3-2
3.2.1 Checking if the Doors are Firmly Closed..............................................................3-2
3.2.2 Checking for Gaps or Damage in the Sealed Construction Section.....................3-2
3.3 Cooling Fan Inspections...................................................................................................3-3
3.4 Emergency Stop Button Inspections..................................................................................3-4
3.5 Enable Switch Inspections.................................................................................................3-4
3.6 Battery Inspections............................................................................................................3-5
3.7 Power Supply Voltage Confirmation..................................................................................3-5
3.8 Open Phase Check............................................................................................................3-6
4 Preparation before Replacing Parts................................................................................................4-1
4.1 Creating a Check Program................................................................................................4-3
5 Replacing Parts...............................................................................................................................5-1
5.1 Replacing DX100 Parts .....................................................................................................5-1
5.1.1 Replacing Parts of the CPU Unit..........................................................................5-2
5.1.1.1 Replacing the Battery..............................................................................5-3
5.1.1.2 Replacing the Control Circuit Board (JANCD-YCP01-E) ........................5-3
5.1.1.3 Replacing the Control Power Supply (JZNC-YPS01-E)..........................5-5
5.1.1.4 Replacing the Robot I/F Circuit Board (JZNCD-YIF01-oE).....................5-6
5.1.1.5 Replacing the I/O Unit (JZNC-YIU0o-E)..................................................5-8
5.1.1.6 Replacing the Power Supply Contactor Unit (JZRCR-YPU01-o)............5-9

DX100 Contents
ix
5.1.1.7 Replacing the Brake Board (JZRCR-YBK01-oE) ..................................5-10
5.1.1.8 Replacing the Machine Safety Unit (JZNC-YSU01-1E).........................5-11
5.1.2 Replacing the SERVOPACK ..............................................................................5-12
5.1.3 Replacing the Converter.....................................................................................5-15
5.1.4 Replacing the Basic Axis Control Circuit Board (SRDA-EAXA01A)...................5-18
5.1.5 Checking and Replacing Fuses..........................................................................5-19
5.1.5.1 Power Supply Contactor Unit ................................................................5-19
5.1.5.2 I/O Unit ..................................................................................................5-20
5.1.5.3 Machine Safety Unit ..............................................................................5-21
5.1.5.4 Brake Board ..........................................................................................5-22
5.1.6 Interior Circulation Fan .......................................................................................5-23
5.1.6.1 Replacing the Interior Circulation Fan...................................................5-23
5.1.6.2 Replacing the Backside Duct Fan .........................................................5-25
5.2 DX100 Parts List..............................................................................................................5-26
5.3 Supplied Parts List...........................................................................................................5-28
5.4 Recommended Spare Parts.............................................................................................5-29
6 Operations After Replacing Parts....................................................................................................6-1
6.1 Home Position Calibration .................................................................................................6-2
6.1.1 Home Position Calibration....................................................................................6-2
6.1.2 Calibrating Operation............................................................................................6-4
6.1.2.1 Registering All Axes at One Time............................................................6-4
6.1.2.2 Registering Individual Axes.....................................................................6-5
6.1.2.3 Changing the Absolute Data ...................................................................6-7
6.1.2.4 Clearing Absolute Data............................................................................6-7
6.1.3 Manipulator Home Position...................................................................................6-9
6.2 Position Deviation Check Using the Check Program.......................................................6-10
6.3 Checking of the Check Program......................................................................................6-11
6.3.1 Motion of the Check Program.............................................................................6-11
6.3.2 Checking of the Check Program.........................................................................6-11
6.3.3 Home Position Data Correction..........................................................................6-12
6.4 Setting the Second Home Position (Check Point) ...........................................................6-13
6.4.1 Purpose of Position Check Operation.................................................................6-15
6.4.2 Procedure for the Second Home Position Setting (Check Point) .......................6-17
6.4.3 Procedure after the Alarm...................................................................................6-18
7 System Diagnosis ...........................................................................................................................7-1
7.1 System Version..................................................................................................................7-1

DX100 Contents
x
7.2 Manipulator Model.............................................................................................................7-1
7.3 Input/Output Status............................................................................................................7-2
7.3.1 Universal Input .....................................................................................................7-2
7.3.1.1 Universal Input Window...........................................................................7-2
7.3.1.2 Universal Input Simple Window...............................................................7-2
7.3.2 Universal Output...................................................................................................7-3
7.3.2.1 Universal Output Window........................................................................7-3
7.3.2.2 Universal Output Simple Window............................................................7-3
7.3.2.3 Modifying the Output Status....................................................................7-4
7.3.3 Specific Input........................................................................................................7-5
7.3.3.1 Specific Input Window.............................................................................7-5
7.3.3.2 Specific Input Simple Window.................................................................7-5
7.3.4 Specific Output.....................................................................................................7-6
7.3.4.1 Specific Output Window..........................................................................7-6
7.3.4.2 Specific Output Simple Window..............................................................7-6
7.3.5 RIN Input ..............................................................................................................7-7
7.3.5.1 RIN Input Window ...................................................................................7-7
7.3.6 Signal Number Search .........................................................................................7-7
7.3.6.1 Direct Search on the Universal/Specified
Input/Output Window.............................................................................................7-8
7.3.6.2 Search from the Menu.............................................................................7-9
7.3.7 Relay Number Search........................................................................................7-10
7.3.7.1 Direct Search on the Universal/Specified
Input/Output Window...........................................................................................7-10
7.3.7.2 Search from the Menu...........................................................................7-11
7.3.8 Modification of the Signal Name.........................................................................7-13
7.3.8.1 Direct Modification on the Universal/Specified
Input/Output Window...........................................................................................7-13
7.3.8.2 Modification from the Menu...................................................................7-13
7.4 System Monitoring Time Display.....................................................................................7-15
7.4.1 System Monitoring Time Display Window..........................................................7-15
7.4.2 Individual Window of the System Monitoring Time Display................................7-16
7.4.3 Clearing the System Monitoring Time Display....................................................7-17
7.5 Alarm History...................................................................................................................7-18
7.5.1 Alarm History Window........................................................................................7-18
7.5.2 Clearing the Alarm History..................................................................................7-19
7.6 I/O Message History........................................................................................................7-20
7.6.1 I/O Message History Window.............................................................................7-20
7.6.1.1 Search...................................................................................................7-20
7.6.2 Clearing the I/O Message History.......................................................................7-21

DX100 Contents
xi
7.7 Position Data When Power is Turned ON/OFF ...............................................................7-22
7.7.1 Power ON/OFF Position Window .......................................................................7-22
7.8 Current Position...............................................................................................................7-23
7.8.1 Current Position Window....................................................................................7-23
7.9 Servo Monitoring..............................................................................................................7-24
7.9.1 Servo Monitor Window........................................................................................7-24
7.9.1.1 Changing the Monitor Items ..................................................................7-24
7.9.1.2 Clearing Maximum Torque Data............................................................7-26
8 Alarm..............................................................................................................................................8-1
8.1 Outline of Alarm.................................................................................................................8-1
8.2 Alarm Display.....................................................................................................................8-2
8.2.1 Displaying and Releasing Alarm...........................................................................8-2
8.2.1.1 Releasing Alarms ....................................................................................8-2
8.2.2 Special Alarm Display...........................................................................................8-3
8.3 Alarm Message List ...........................................................................................................8-5
9 Error...............................................................................................................................................9-1
9.1 Error Message List.............................................................................................................9-1
9.1.1 System and General Operation............................................................................9-2
9.1.2 Editing...................................................................................................................9-6
9.1.3 Job Defined Data..................................................................................................9-7
9.1.4 External Memory Equipment ..............................................................................9-11
9.1.5 Concurrent I/O....................................................................................................9-16
9.1.6 Maintenance Mode.............................................................................................9-18
10 LED Indicator on Circuit Board...................................................................................................10-1
10.1 LED Indicator on YCP 01 Circuit Board.........................................................................10-1
10.2 LED Indicator on Robot I/F Circuit Board.......................................................................10-2
10.3 7 SEG-LED Indicator .....................................................................................................10-3
10.3.0.1 7 SEG-LED Indicator Status (1-digit indication)
of Each Unit at Error Occurrence ........................................................................10-4
10.3.0.2 7 SEG-LED Indicator Status (4 digit-indication)
of Each Unit at Error Occurrence ........................................................................10-5

1 Equipment Configuration
DX100 1.1 Arrangement of Units and Circuit Boards
1-1
1 Equipment Configuration
The DX100 is comprised of individual units and modules (circuit boards).
Malfunctioning components can generally be easily repaired after a failure
by replacing a unit or a module. This section explains the configuration of
the DX100 equipment.
1.1 Arrangement of Units and Circuit Boards
1.1.1 Arrangement
The arrangements of units and circuit boards in small-capacity, medium-
capacity, and large-capacity DX100s are shown.
1.1.1.1 Small-Capacity DX100 Controller
Fig. 1-1: Configuration of Small Capacity DX100 -A Controller (Standard)
FAN1
FAN2 FAN
CN152
1
R-IN
R-INCOM
2
R-OUT
3
R-OUTCOM
4
FAN1
FAN2 FAN
CN152
1
R-IN
R-INCOM
2
R-OUT
3
R-OUTCOM
4
A01
2FU FU
A01
1
5A125V
3FU
5A125V
4FU
CN601
CN610 CN611
CN607
CN107
SVMX2
CN601
CN606
CN612
CN608
CN602
CN603
CN604
CN605
V U T S R Q P N M L
K J H G F E DC BA
30 29282726
14
25242322 21
20 19181716151312 11
10 0908070605040302 01
C90AD XXXXX
MADEINJAPAN
FujiElectric Hi-Tech .
DATE
NO.
POWERSUPPLY
CPS-520F
YYYY-MM
V U T S R Q P N M L
K J H G F E DC BA
30 29282726
14
25242322 21
20 19181716151312 11
10 0908070605040302 01
CN158/159
CN154/155
(+24V1/V2)
(+24V2)
CN156/157
(+24V3)
CN153
(REMOTE)
CN152
(+5V/ALM)
SOURCE
OHT
INPUT
FAN
+24V
+5V
P-ON
50/60Hz
(ACIN)
CN151
200-240VAC
3.4A-2.8A
FUSE
CN215 CN216
CN208 CN209 CN210 CN211 CN212 CN213 CN214
CN200 CN201 CN202
CN203 CN204 CN205 CN206 CN207
A B
1
A B
1
FRC5-C50S52T-OLS(D20)
A B
1
PE
EXHOLD+
GSOUTFB2-
GSOUTFB2+
GSOUT2-
GSOUT2+
GSOUTFB1-
GSOUTFB1+
GSOUT1-
GSOUT1+
+24V2
+24V2
+24V2
024V2
024V2
024V2
EXDSW2-
EXDSW2+
EXDSW1-
EXHOLD-
EXSVON+
SSP+
EXDSW1+
EXSVON-
SSP-
FST2-
FST2+
FST1-
FST1+
EXESP2-
EXESP2+
EXESP1-
EXESP1+
SYSRUN-
SYSRUN+
SAFF2-
SAFF2+
SAFF1-
SAFF1+
GSIN22-
GSIN22+
GSIN21-
GSIN12-
GSIN12+
GSIN11-
GSIN21+
GSIN11+
MXT
NJ2959-1
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
A’
A
SVMX2 SVMX1
CN603
CN604
CN605
CN606
NCM
CN607
CN611
4FU3FU
2FU1FU
CN610
CN601
CN609CN608
CN602
A-A’ Section
Inside View of F Door
Front View
Inside the Controller
Brake board
JANCD-YBK01-1E
I/O Unit
JZNC-YIU01-E
Machine safety unit
JZNC-YSU01-1E
Robot I/Fcircuit board
JANCD-YIF01-1
JZNC-YRK01-1E
JZNC-YPS01-E
CPS Unit
NF32-SW
Breaker
SVMX1
CN612
Covering plate
Power supply
contractor unit
JZRCR-YPU01-1
Backside duct fan:
4715MS-22T-B50-B00
(For air inlet)
Regenerative resistor:
MRC22-125K-220W-12.5
(220W,12.5 )
SERVOPACK:
Refer to the
following table.
Back View
(without cover)
Emergency stop
button:
HW1B-V404R
CPU unit:
Interior circulation fan:
4715MS-22T-B50-B00
(For air inlet)
(MXT)
Robot system
specified input
terminal block
Model DX100 SERVOPACK (Converter Integrated)
MH5L ERDR-MH0005L-A00 SRDA-MH5
MH6 ERDR-MH00006-A00 SRDA-MH6
MA1400 ERDR-MA01400-A00 SRDA-MH6
VA1400 ERDR-VA01400-A00 JZRCR-MH6-14/00 1)
MA1900 ERDR-MA01900-A00 SRDA-MH20
HP20D ERDR-HP0020D-A00 SRDA-MH20
HP20D-6
1SRDA-MH6+SRDA-EAXB01A+SRDA-SDA14A01A-E

1 Equipment Configuration
DX100 1.1 Arrangement of Units and Circuit Boards
1-2
1.1.1.2 Medium and Large-Capacity DX100 Controller
Fig. 1-2: Configuration of Medium Capacity DX100 -A Controller
(Standard)
Covering plate
(1000W 12.0 )
NF32-SW
RDC50N6ROJIX800ZZ X2
Regenerative registor
Breaker
JZNC-YPS01-E
I/O Unit
JZNC-YIU01-E
Robot I/F circuit board
JANCD-YIF01-1
CPU Unit
JZNC-YRK01-E
Converter
Refer to the
following table.
Emergency stop
button:
HW1B-V404R
Brake board
JANCD-YBK01-1E
Machine safety unit
JZNC-YSU01-1E
JZRCR-YPU01-1
CPS Unit
Power supply
contactor unit
(MXT)
Robot system
specified input
terminal block
SERVOPACK:
Refer to the
following table.
Interior circulation fan:
4715MS-22T-B50-B00
(For air inlet)
Backside duct fan:
4715MS-22T-B50-B00
(For air inlet)
A-A’ Section Inside View of F Door Inside the Controller Front View
Back View
(without cover)
Model DX100 SERVOPACK Converter
MH50 ERDR-
MH00050-A00 SRDA-MH50 SRDA-COA12A01AU-E
MS80 ERDR-
MS00080-A00 SRDA-MS80 SRDA-COA12A01AU-E
VS50 ERDR-
VS00050-A00 JZRCR-MS80-71/001) SRDA-COA12A01AU-E
1SRDA-MH80+SRDA-EAXB01A+SRDA-SDA71A01A-E

1 Equipment Configuration
DX100 1.1 Arrangement of Units and Circuit Boards
1-3
Fig. 1-3: Configuration of Large Capacity DX100 -A Controller (Standard)
A’
(1500W 6.0 )
SMVK500W2R0J
A5978 X3
JZNC-YPS01-E
CPS Unit Robot I/Fcircuit board
JANCD-YIF01-1
CPU Unit
JZNC-YRK01-E
NF32-SW JZNC-YSU01-1E
JZRCR-YPU01-1
A-A’ Section
Inside View of F Door
Front View
Inside the Controller
Back View
(without cover)
Interior circulation fan:
4715MS-22T-B50-B00
(For air inlet)
I/O Unit
JZNC-YIU01-E
Converter
Refer to the
following table.
Emergency stop
button:
HW1B-V404R
Brake board
JANCD-YBK01-1E
Machine safety unit
(MXT)
Robot system
specified input
terminal block
Regenerative
registor
Backside duct fan:
4715MS-22T
-B50-B00
(For air inlet)
Breaker
Power supply
contactor unit
SERVOPACK:
Refer to the
following table.
Model DX100 SERVOPACK Converter
ES165D ERDR-
ES0165D-A00 SRDA-MS165 SRDA-COA30A01A-E
ES200D ERDR-
ES0200D-A00 SRDA-MS165 SRDA-COA30A01A-E

1 Equipment Configuration
DX100 1.2 Power Flow
1-4
1.2 Power Flow
(2.5A)4FU
(2.5A)3FU
(10A)
(10A) 2FU
1FU
Manipulator
(SRDA-EAXA01A)
Basic axis control board
Brake
Power
T-axis motor
B-axis motor
R-axis motor
U-axis motor
L-axis motor
Programming pendant
(JZRCR-YPP01- )
DC24V(Brake)
DC24V
DC24V
DC24V
DC24V
DC24V
Backside duct fan
Interior circulation fan
SERVOPACK
(SRDA- )
Converter
(SRDA-COA )
CPS Unit
(JZNC-YPS01-E)
CPU Unit
(JZNC-YRK01-1E)
I O Unit
(JZNC-YIU -E)
Safety unit
(JZNC-YSU01-1E)
Brake board
(JANCD-YBK01- E)
Power contactor - )
Three phase
AC 220/200V 60Hz
A
C 200V 50Hz
PE
L1
L2
L3
X81
+24V1
CN209
+24V3
CN400
+24V2
S-axis motor
CN584
CN583
CN584
CN583
CN584
CN583
CN584
CN583
CN584
CN583
CN404
+24VU
+24V3
CN403
+24V1
24V1/
CN510
CN509
AMP6
AMP5
AMP4
AMP3
AMP2
CN551
CN556CN552
CN555
CN554
AMP1
CN584
CN583
+24VU
+24V2/
+24V2
CN304
CN303
CN305
(+24V1/+24V2)
CN200
+24V2) CN158
+24V2
+24V1/
CN5
CN2
CN1
CPU UNIT
BACK BOARD
JANCD-YBB01
BATTERY
CN110
JANCD-YIF01- E
CNBUS
ROBOT I F BOARD
JANCD-YCP01-E
CN1A 1B
+5V
+24V2
+24V1/
CN157
CN154
AC200V IN
CN151
+24V3 CN153
CN155
+24V2 CN156
CN159
CN604
CN603
CN606
CN602
CN601
2KM
2KM1KM
Filter
10A
AC250V
1KM
E
E
E
CN582
CN582
CN582
CN582
CN582
CN582
12
34
56
EV1
EV2
EV3
QF1
Brake
Power
Brake
Power
Brake
Power
Brake
Power
Brake
Power

1 Equipment Configuration
DX100 1.3 Signal Flow
1-5
1.3 Signal Flow
(SRDA-EAXA01A)
Basic axis control board
(Specified input terminal block
Emergency stop external output
Manipulator
SERVOPACK
(SRDA- )
Converter
(SRDA-COA )
Break board
(JANCD-YBK01- E)
Safety unit
(JZNC-YSU01-1E)
CPU Unit
(JZNC-YRK01-1E)
CPS Unit
(JZNC-YPS01-E)
Power contactor unit(JZRCR-YPU - )
Programming pendant
(JZRCR-YPP01- )
Emergency stop switch
(Universal I/O)
IO=8 8
IO=8 8
IO=12 12
IO=12 12
I/O Unit
(JZNC-YIU -E)
Terminal register
Terminal register
Terminal register
CN607
CN608
RY1 RY2
CN602
1KM
CN601 2KM
CN203CN202
P.P. Emergency stop signal
CN209
Specified I/O
CN216
Lump
External axis overrun
Emergency stop signal
(Overrun)
CN212
CN211
CN210
CN214
CN208
MXT
CN103
RS232C
CN101
RS422
CN102
RS232C
CN105
LAN:PP
LAN:Ethernet
CN104
CN581
CN581
CN581
CN581
CN581
CN405
CN402
PBESP
S-axis
motor
L-axis
motor
U-axis
motor
R-axis
motor
B-axis
motor
Optional
SHOCK.LAMP
OT
T-axis
motor
SGDR-FBA A
24V IN
5V OUT
X81
2XT
(Shock sensor)
CN512
CN518
CN517
CN516
CN515
CN511
CN513
AMP6
AMP5
AMP4
AMP3
AMP2
AMP1
CN581
CN553CN507
CN502
CN504
CN506
CN501
CN503
CN505
CN508
I O I F
CN300
CN309
CN308
CN307
CN306
CN5
CN2
CN1
CPU UNIT
BACK BOARD
JANCD-YBB01
BATTERY
CN110
CN113
JANCD-YIF01- E
CN114
CNBUS
ROBOT I F BOARD
JANCD-YCP01-E
CN1A 1B
CN159

2 Security System
DX100 2.1 Protection Through Security Mode Settings
2-1
2 Security System
2.1 Protection Through Security Mode Settings
The DX100 modes setting are protected by a security system. The system
allows operation and modification of settings according to operator
clearance. Be sure operators have the correct level of training for each
level to which they are granted access.
2.1.1 Security Mode
There are three security modes. Editing mode and management mode
require a user ID. The user ID consists of numbers and letters, and
contains no less than 4 and no more than 8 characters. (Significant
numbers and signs: ”0 to 9”, “-”, “.”.
Table 2-1: Security Mode Descriptions
Security Mode Explanation
Operation Mode This mode allows basic operation of the robot (stopping,
starting, etc.) for people operating the robot work on the
line.
Editing Mode This mode allows the operator to teach and edit jobs and
robot settings.
Management
Mode This mode allows those authorized to set up and maintain robot system: parameters, system time and modifying user
IDs.

2 Security System
DX100 2.1 Protection Through Security Mode Settings
2-2
Table 2-2: Menu & Security Mode (Sheet 1 of 4)
Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT
JOB JOB Operation Edit
SELECT JOB Operation Operation
CREATE NEW JOB1) Edit Edit
MASTER JOB Operation Edit
JOB CAPACITY Operation -
RES. START (JOB)1) Edit Edit
RES. STATUS2) Operation -
CYCLE Operation Operation
VARIABLE BYTE Operation Edit
INTEGER Operation Edit
DOUBLE Operation Edit
REAL Operation Edit
STRING Operation Edit
POSITION (ROBOT) Operation Edit
POSITION (BASE) Operation Edit
POSITION (ST) Operation Edit
LOCAL VARIABLE Operation -
IN/OUT EXTERNAL INPUT Operation -
EXTERNAL OUTPUT Operation -
UNIVERSAL INPUT Operation -
UNIVERSAL OUTPUT Operation -
SPECIFIC INPUT Edit -
SPECIFIC OUTPUT Edit -
RIN Edit -
CPRIN Operation -
REGISTER Edit -
AUXILIARY RELAY Edit -
CONTROL INPUT Edit -
PSEUDO INPUT SIG Edit Management
NETWORK INPUT Edit -
NETWORK OUTPUT Operation -
ANALOG OUTPUT Edit -
SV POWER STATUS Edit -
LADDER PROGRAM Management Management
I/O ALARM Management Management
I/O MESSAGE Management Management

2 Security System
DX100 2.1 Protection Through Security Mode Settings
2-3
ROBOT CURRENT POSITION Operation -
COMMAND POSITION Operation -
SERVO MONITOR Management -
WORK HOME POS Operation Edit
SECOND HOME POS Operation Edit
DROP AMOUNT Management Management
POWER ON/OFF POS Operation -
TOOL Edit Edit
INTERFERENCE Management Management
SHOCK SENS LEVEL Operation Management
USER COORDINATE Edit Edit
HOME POSITION Management Management
MANIPULATOR TYPE Management -
ROBOT CALIBRATION Edit Edit
ANALOG MONITOR Management Management
OVERRUN&S-SENSOR1) Edit Edit
LIMIT RELEASE1) Edit Management
ARM CONTROL1) Management Management
SHIFT VALUE Operation -
SYSTEM INFO VERSION Operation -
MONITORING TIME Operation Management
ALARM HISTORY Operation Management
I/O MSG HISTORY Operation Management
SECURITY Operation Operation
FD/CF LOAD Edit -
SAVE Operation -
VERIFY Operation -
DELETE Operation -
DEVICE Operation Operation
FOLDER Edit Management
Table 2-2: Menu & Security Mode (Sheet 2 of 4)
Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT

2 Security System
DX100 2.1 Protection Through Security Mode Settings
2-4
PARAMETER S1CxG Management Management
S2C Management Management
S3C Management Management
S4C Management Management
A1P Management Management
A2P Management Management
A3P Management Management
A4P Management Management
RS Management Management
S1E Management Management
S2E Management Management
S3E Management Management
S4E Management Management
SETUP TEACHING COND Edit Edit
OPERATE COND Management Management
DATE/TIME Management Management
GRP COMBINATION Management Management
RESERVE JOB NAME Edit Edit
USER ID Edit Edit
SET SPEED Management Management
KEY ALLOCATION1) Management Management
RES. START (CNCT) Management Management
ARC WELDING ARC START COND. Operation Edit
ARC END COND. Operation Edit
ARC AUX COND. Operation Edit
POWER SOURCE COND. Operation Edit
ARC WELD DIAG. Operation Edit
WEAVING Operation Edit
HANDLING HANDLING DIAGNOSIS Operation Edit
SPOT WELDING WELD DIAGNOSIS Operation Edit
I/O ALLOCATION Management Management
GUN CONDITION Management Management
POWER SOURCE COND Management Management
Table 2-2: Menu & Security Mode (Sheet 3 of 4)
Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT