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

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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: 937-847-6200

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 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.

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Safety

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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: (734) 994-6088

FAX: (734) 994-3338

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 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.

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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

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

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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.

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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:

(937)847-3200

For routine technical inquiries, you can also contact Motoman Customer Support at the following

e-mail address:

techsupport@motoman.com

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

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Table of Contents

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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

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