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