Page 1 MOTOMAN-MH900: INSTRUCTIONS DX200 CONTROLLER FOR THE MH900: INSTRUCTIONS DX200 CONTROLLER FOR THE MH900: MAINTENANCE DX200 CONTROLLER (for each purpose): OPERATOR’S The DX200 CONTROLLER operator’s manual above corresponds to a specific usage. Be sure to use the appropriate manual. Part Number: 182582-1CD...
Page 2 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...
Page 3 It is important that users operate the equipment in accordance with this instruction manual and any additional information which may be provided by Yaskawa. Address any questions regarding the safe and proper operation of the equipment to Yaskawa Customer Support.
Page 4 Make sure to follow these important items WARNING • This manual explains setup, diagnosis, maintenance, hardware, etc. of the MH900, DX200 Controller. Read this manual carefully and be sure to understand its contents before handling the MH900, DX200 Controller. •...
Page 5 182582-1CD Safety MH900, DX200 Controller Notes for Safe Operation WARNING • 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 controller power –...
Page 6 The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product. Yaskawa is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids the product warranty.
Page 7 • 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.
Page 8 182582-1CD Safety MH900, DX200 Controller Explanation of Warning Labels Explanation of Warning Labels The following warning labels are attached to the controller. Always follow the warnings on the labels. Also, an identification label with important information is placed on the body of the controller.
Page 9 Do not make any modifications to the controller unit. Making any changes without the written permission from Yaskawa will void the warranty. • Some operations require standard passwords and some require special passwords.
Page 10 182582-1CD Safety MH900, DX200 Controller Safeguarding Tips Safeguarding Tips All operators, programmers, maintenance personnel, supervisors, and anyone working near the system must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation.
Page 11 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.
Page 12 MH900, DX200 Controller Definition of Terms Used Often in This Manual Definition of Terms Used Often in This Manual The Yaskawa Motoman MH900, DX200 Controller is a Yaskawa industrial robot product. A Motoman usually consists of the manipulator, the controller, the programming pendant, and supply cables.
Page 13 MH900, DX200 Controller Customer Support Information Customer Support Information If assistance is needed with any aspect of the MH900, DX200 Controller system, please contact your local Yaskawa Customer Support (see back cover for details.) When contacting Yaskawa Customer Support please have the following information: •...
Page 14 182582-1CD Table of Contents MH900, DX200 Controller Table of Contents 1 Safety .............................. 1-1 1.1 For Your Safety........................1-1 1.2 Special Training ......................... 1-2 1.3 Motoman Manual List......................1-3 1.4 Personnel Safety........................ 1-4 1.5 Motoman Safety......................... 1-6 1.5.1 Installation and Wiring Safety ................1-6 1.5.2 Work Area Safety....................
Page 15 182582-1CD Table of Contents MH900, DX200 Controller 4.3.3 Connection to the Manipulator................4-13 4.3.4 Connection to the Controller................4-14 4.3.5 Connecting the Programming Pendant ............. 4-15 4.3.6 User I/O Cable Connection................. 4-16 5 Turning ON and OFF the Power Supply ..................5-1 5.1 Turning ON the Main Power Supply ..................
Page 16 182582-1CD Table of Contents MH900, DX200 Controller 8.1.2.4 Clearing ABSOLUTE DATA ..............8-10 8.1.3 Home Position of the Robot................8-11 8.2 Setting the Second Home Position (Check Point) ............8-12 8.2.1 Purpose of Position Check Operation..............8-14 8.2.2 Procedure for the Second Home Position Setting (Check Point) .......8-16 8.2.3 Procedure after the Alarm...................
Page 17 182582-1CD Table of Contents MH900, DX200 Controller 8.6.2.1 Cubic Interference Area ................ 8-57 8.6.2.2 Cube Setting Method................8-57 8.6.2.3 Setting Operation .................. 8-59 8.6.3 Axis Interference Area ..................8-69 8.6.3.1 Axis Interference Area................8-69 8.6.3.2 Setting Operation .................. 8-69 8.6.4 Clearing the Interference Area Data..............8-77 8.7 Shock Detection Function....................
Page 18 182582-1CD Table of Contents MH900, DX200 Controller 8.14 Setting the Play Speed ....................8-118 8.15 Numeric Key Customize Function................8-120 8.15.1 What is the Numeric Key Customize Function? ..........8-120 8.15.2 Allocatable Functions..................8-120 8.15.2.1 Key Allocation (EACH) ..............8-120 8.15.2.2 Key Allocation (SIM) ................
Page 19 182582-1CD Table of Contents MH900, DX200 Controller 8.19.3.1 Initializing the Screen Layout ............8-157 8.19.4 Layout Storage ....................8-159 8.20 Encoder Back-up Error Recovery Function ..............8-160 8.20.1 About Encoder Back-up Error Recovery Function.......... 8-160 8.20.2 Encoder Back-up Error Recovery Function Operation ........8-160 8.21 Preventive Maintenance Function ................
Page 20 182582-1CD Table of Contents MH900, DX200 Controller 8.23.2.3 Allocating the Safety Signal Board ............ 8-206 8.23.2.4 Timer Delay ..................8-209 8.23.2.5 Safety Logic Circuit................8-213 8.23.3 Performing the Safety Logic Circuit ..............8-226 8.23.4 The Safety Logic Circuit Expansion Function ..........8-226 8.23.4.1 Setting for the Safety Logic Circuit Expansion Function....8-226...
Page 21 182582-1CD Table of Contents MH900, DX200 Controller 8.26.1 Outline ......................8-295 8.26.2 Setting Maintenance Mode................8-295 8.26.3 Setting Axes Detachment Function ..............8-295 8.26.4 Specific Output and Messages............... 8-297 8.26.5 Restrictions..................... 8-298 9 System Backup ..........................9-1 9.1 System Backup with Controller..................9-1 9.1.1 Function Types of Data ..................
Page 22 12.3.2.2 Connection Setting ................12-30 12.3.2.3 Axis Configuration Setting ..............12-33 12.3.2.4 Mechanical Specification Setting............12-35 12.3.2.5 Motor Specification Setting..............12-38 13 DX200 Specification........................13-1 13.1 Specification List ......................13-3 13.2 Function List........................13-4 13.3 Programming Pendant ....................13-5 13.4 Equipment Configuration ....................13-6 13.4.1 Arrangement of Units and Circuit Boards ............
Page 23 182582-1CD Table of Contents MH900, DX200 Controller 14.3.2 Unit and Circuit Board in the CPU Unit............. 14-8 14.3.2.1 CPU Circuit Board (JANCD-YCP21-E) ..........14-8 14.3.2.2 Robot I/F Circuit Board (JANCD-YIF01- E) ........14-8 14.3.2.3 Machine Safety CPU Circuit Board ............. 14-8 14.4 Control Power Supply Unit (JZNC-YPS21-E) ..............
Page 24 182582-1CD Table of Contents MH900, DX200 Controller 14.13 Universal I/O Signal Assignment ................14-48 14.13.1 Arc Welding ....................14-48 14.13.2 Handling......................14-54 14.13.3 General Application ..................14-60 14.13.4 Spot Welding ....................14-66 14.13.5 JANCD-YEW01-E Circuit Board (Option) ............. 14-74 14.13.5.1 Arc Welding ..................14-74 14.14 List of the Equipment Configuration by Model ............
Page 25 182582-1CD Safety MH900, DX200 Controller 1.1 For Your Safety Safety For Your Safety Robots generally have requirements which are different from other manufacturing equipment, such as larger working areas, high-speed operation, rapid arm movements, etc., which can pose safety hazards.
Page 26 Teaching and maintaining the robot are specified as “Hazardous Operations” in the Industrial Safety and Health Law (Japan only). Workers employed in the above operations are requested to attend special training through Yaskawa. Special Training • Persons who teach or inspect the manipulator must undergo required training before using the manipulator.
Page 27 The following manuals are necessary to ensure proper operation. – MOTOMAN- INSTRUCTIONS – DX200 INSTRUCTIONS – DX200 OPERATOR’S MANUAL Ensure all manuals are on hand. If any manuals are missing, contact the local branch office. Telephone numbers are on the back cover of this manual.
Page 28 182582-1CD Safety MH900, DX200 Controller 1.4 Personnel Safety Personnel Safety The entire manipulator P-point maximum envelope is potentially dangerous. Everyone working with the MOTOMAN (safety administration, installation, operation, and maintenance personnel) are responsible for ensuring safety of all personnel WARNING •...
Page 29 182582-1CD Safety MH900, DX200 Controller 1.4 Personnel Safety • Never forcibly move the manipulator axes. Failure to observe this caution may result in injury or equipment damage. • Never sit or lean on the controller. Failure to observe this caution may result in injury or equipment damage.
Page 30 182582-1CD Safety MH900, DX200 Controller 1.5 Motoman Safety Motoman Safety The followings are safety functions of Motoman/controller. • Emergency stop SW input (controller/programming pendant) • Enable SW input (programming pendant) • Safeguarding interlock signal input (safety plug) • External emergency stop SW input •...
Page 31 182582-1CD Safety MH900, DX200 Controller 1.5 Motoman Safety WARNING • Ground per all applicable electrical codes. Failure to observe this caution may result in fire or electric shock. • Operation of the crane, sling, or forklift should only be performed by authorized personnel.
Page 32 Failure to observe this precaution can result in injury during maintenance. 1935 1058 DX200 Maintenance Area DX200 External Dimensions (Unit: mm) (Unit: mm) • Make sure to operate the controller from a location where the manipulator is easily visible. Operation by unauthorized personnel may result in injury or equipment damage.
Page 33 182582-1CD Safety MH900, DX200 Controller 1.5 Motoman Safety • Secure the position of the controller after setting up. – Attach the controller to the floor or rack, etc., using the screw holes on the bottom of the controller. Failure to observe this caution could lead to injury or equipment damage if the controller should shift or fall.
Page 34 182582-1CD Safety MH900, DX200 Controller 1.5 Motoman Safety 1.5.2 Work Area Safety Carelessness contributes to serious accidents in the work area. To ensure safety, enforce the following precautions: WARNING • Install safeguarding around the manipulator to prevent any accidental contact with the manipulator while the power is ON.
Page 35 182582-1CD Safety MH900, DX200 Controller 1.5 Motoman Safety 1.5.3 Operation Safety WARNING • When attaching a tool such as the welding torch to the manipulator, be sure to turn OFF the power supply of the controller and the tool, lock the switch, and display a warning sign.
Page 36 182582-1CD Safety MH900, DX200 Controller 1.5 Motoman Safety WARNING • Before operating the manipulator, check that the SERVO ON lamp on the programming pendant goes out when pressing the emergency stop button on the programming pendant and the external control device, etc. and confirm the servo lamp turns OFF.
Page 37 182582-1CD Safety MH900, DX200 Controller 1.5 Motoman Safety • Perform the following inspection procedures prior to teaching the manipulator. If there are any problems, correct the problem immediately and perform all other necessary tasks. – Check for problems with manipulator movement.
Page 38 See section 1.3 “Motoman Manual List” on page 1-3 for a complete list of manuals. If any manuals are missing, contact your Yaskawa representative. • Make sure warning labels are clean and are readable on the manipulator and the controller.
Page 39 MH900, DX200 Controller 2.1 Contents Confirmation Product Confirmation Contents Confirmation Confirm the contents of the delivery when the product arrives. Standard delivery includes the following five items (Yaskawa provides optional equipment information separately): • Manipulator • Controller • Programming Pendant •...
Page 40 182582-1CD Product Confirmation MH900, DX200 Controller 2.2 Order Number Confirmation Order Number Confirmation Confirm that the order number pasted on the manipulator and the controller are the same. See figure below for where the order number plates are located. ...
Page 41 182582-1CD Installation MH900, DX200 Controller 3.1 Handling Procedure Installation Handling Procedure • Authorized personnel are to operate the crane, sling, and forklift only. Failure to observe this caution may result in injury or damage. • Avoid jarring, dropping, or hitting the controller during handling.
Page 42 182582-1CD Installation MH900, DX200 Controller 3.1 Handling Procedure 3.1.2 Using a Forklift to Move the Controller Observe the following precautions when using a forklift to handle the controller: • Ensure installation site is a safe work environment. • Make sure of transportation of controller to installation location is possible.
Page 43 182582-1CD Installation MH900, DX200 Controller 3.2 Place of Installation Place of Installation The controller requires the following conditions for installation: • Ambient temperature: – During Operation: 0 to 45C (32 to 113F) during operation – During Transportation and Maintenance -10 to 60C(14 to 140F) –Temperature Change: 0.3C per minute or less...
Page 44 182582-1CD Installation MH900, DX200 Controller 3.3 Location Location When installing controller make sure controller is: • outside of the P-point maximum envelope of the manipulator (outside of the safeguarding.) Fig. 3-1: Location of Controller Safeguarding DX200 Door 1000mm or more...
Page 45 182582-1CD Installation MH900, DX200 Controller 3.4 Mounting the Controller Mounting the Controller • Do not climb on top of the controller. Failure to observe this caution could lead to injury or mechanical failure. Attach the controller to the floor using mounting holes on the bottom side of the controller.
Page 46 182582-1CD Connection MH900, DX200 Controller Connection WARNING • Ground the system. Failure to ground equipment may result in injury from fire or electric shock. • Before wiring, make sure to turn OFF the primary power supply, and put up a warning sign. (ex. DO NOT TURN THE POWER ON) Failure to observe this caution may result in injury and electric shock.
Page 47 182582-1CD Connection MH900, DX200 Controller 4.1 Notes on Cable Junctions Notes on Cable Junctions • The cables that connect the controller to peripheral device are low voltage circuits. Keep controller signal cables away from the primary power circuit. Do not run high voltage power lines in parallel to the controller signal cables.
Page 48 182582-1CD Connection MH900, DX200 Controller 4.2 Power Supply Power Supply 4.2.1 Three-Phase Power Supply The power failure processing circuit operates when there is a black out or drop in voltage, and the servo power turns OFF. Connect the power supply to a stable power source that is not prone to power fluctuations.
Page 49 182582-1CD Connection MH900, DX200 Controller 4.2 Power Supply 4.2.3 Leakage Breaker Installation When connecting the leakage breaker to the controller power supply wiring, use a leakage breaker which can handle high frequencies from the controller inverter. Leakage breakers which cannot handle high frequencies may malfunction.
Page 50 182582-1CD Connection MH900, DX200 Controller 4.2 Power Supply 4.2.4 Primary Power Supply Breaker Installation Install the primary power supply breaker as shown below. Fig. 4-5: Installation of the Primary Power Supply Breaker Breaker Breaker Breaker Controller Power DX200 for Positioner...
Page 51 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods Connection Methods The figure below shows a connection diagram for the manipulator, manipulator cable, primary power cable and programming pendant. Fig. 4-6: Cable Connection Manipulator DX200 Manipulator Cables 4.3.1 Connecting the Primary Power Supply 1.
Page 52 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods (2) Rotate the main power supply switch to the “OFF” position and open the door gently. Fig. 4-8: Rotating the Main Power Supply Switch to the OFF Position Main power supply switch 2.
Page 53 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods (2) Connect a ground wire to reduce noise and prevent electric shock. Connect the ground wire to the ground terminal (screw) of the switch in the bottom left side of the expansion cabinet.
Page 54 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods Fig. 4-11: Exclusive Grounding DX200 Exclusive Grounding 100 ohm maximum ground resistance • Do not connect the grounding wire with the wires for the electric power source, the welder, etc. Ground in accordance with all relevant governmental regulations when using metallic ducts, metallic conduits, and cable tray to construct the cable.
Page 55 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods Fig. 4-13: Rotating the Key Counterclockwise counterclockwise 90 door lock flathead screw driver 182582-1CD 4-10 55 of 552...
Page 56 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods 4.3.2 Connecting the Manipulator Cable The manipulator comes with seven manipulator cables; one encoder cable (Fig. 4-14(a)) and six power cables (Fig. 4-14(b)) In this manual, connection location identifies which cable to use.
Page 57 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods Fig. 4-14(b): Power Cables Manipulator Side Controller Side Manipulator Cable Part Number Connector Location Connector Location on Controller on Manipulator Mating Side Mating Side Length Table 4-4(a): Power Cable Part Numbers Connector Location on...
Page 58 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods 4.3.3 Connection to the Manipulator 1. Verify the numbers on the manipulator 2BC power cable with the connector number on the manipulator by referring to Fig. 4-14(b) and Fig. 4-15(a). Fig. 4-15(a): Manipulator Cable Connectors (Manipulator Side) FIELDBUS 2.
Page 59 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods 4.3.4 Connection to the Controller • Do not cover or tangle cables. • Keep cables as straight as possible. Failure to observe these cautions can result in minor or moderate injury from heat of cables.
Page 60 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods 4.3.5 Connecting the Programming Pendant WARNING • Always close the door of the controller except for maintenance. • Make sure to rotate all the door locks counterclockwise. If dust or water enter inside the controller, electric shock or breakdown of the controller may result.
Page 61 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods 4.3.6 User I/O Cable Connection User can choose one I/O cable connection method out of following three ways. Table 4-5: I/O Cable Connections Connect user I/O signal to I/O terminal User connects universal I/O signal using terminal blocks mounted on blocks that are connected to universal the bottom of the controller inside the controller's front door.
Page 62 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods Table 4-6: I/O Connections Connection Drawing Length Cable Terminal Process Connect user I/O signal to I/O terminal blocks Drawing length: 1m Unshielded connected to universal I/O circuit board (Cable length for terminal Refer to"Connection wire with Robot...
Page 63 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods 4. Route the system external signal cables for the external emergency stop, etc. drawn in step 2, to the right side of the controller from the bottom side of the controller as shown by the red line in the figure below.
Page 64 182582-1CD Connection MH900, DX200 Controller 4.3 Connection Methods 5. Route the universal I/O signal cables described above mentioned in step 2 to the bottom duct in front of the I/O terminal blocks. Then, connect them to each of the I/O terminal block that are connected to the universal I/O circuit board (JANCD-YIO21-E).
Page 65 182582-1CD Turning ON and OFF the Power Supply MH900, DX200 Controller 5.1 Turning ON the Main Power Supply Turning ON and OFF the Power Supply Turning ON the Main Power Supply WARNING • Confirm that nobody is present in the P-point maximum envelope of the manipulator when turning ON the controller power supply.
Page 66 182582-1CD Turning ON and OFF the Power Supply MH900, DX200 Controller 5.1 Turning ON the Main Power Supply 5.1.1 Initial Diagnosis The controller performs an initial diagnosis when turning ON the main power, and the startup window displays on the programming pendant screen.
Page 67 182582-1CD Turning ON and OFF the Power Supply MH900, DX200 Controller 5.2 Turning ON the Servo Power Turning ON the Servo Power 5.2.1 During Play Mode Turning ON the safety plug, workers safety is secure. • Close safeguards, press the [SERVO ON READY] button on the programming pendant to turn ON the servo power supply.
Page 68 182582-1CD Turning ON and OFF the Power Supply MH900, DX200 Controller 5.2 Turning ON the Servo Power Servo Power ON/OFF --- Enable Switch When the operator grips the Enable switch, the servo power turns ON. However, if the operator squeezes the switch until hearing a "click"...
Page 69 182582-1CD Turning ON and OFF the Power Supply MH900, DX200 Controller 5.3 Turning OFF the Power Supply Turning OFF the Power Supply 5.3.1 Turning OFF the Servo Power (Emergency Stop) The manipulator cannot be operated when the emergency stop button is pressed and the servo power supply is turned OFF.
Page 70 182582-1CD Turning ON and OFF the Power Supply MH900, DX200 Controller 5.3 Turning OFF the Power Supply 5.3.3 Stopping Manipulator Operation The following three categories are stop functions of the manipulator. • Stop Category 0 –Removes the motor power source to the servo motor causing the motor to stop –Once removing power, the manipulator and the external axis...
Page 71 182582-1CD Turning ON and OFF the Power Supply MH900, DX200 Controller 5.3 Turning OFF the Power Supply See Table 5-2 on the methods for stopping the manipulator by each stop signal. Table 5-2: Stopping the Manipulator by Stop Signal Safety Signal...
Page 72 182582-1CD Testing Program Operation MH900, DX200 Controller Testing Program Operation WARNING • Test the emergency stop button(s), confirming that the SERVO ON lamp turns OFF before operating the manipulator. Injury or damage to machinery may result if the manipulator does not stop in case of an emergency.
Page 73 182582-1CD Testing Program Operation MH900, DX200 Controller • Perform the following inspection procedures prior to teaching the manipulator. If there are any problems, correct the problem immediately and perform all other necessary tasks. – Check for problems with manipulator movement.
Page 74 182582-1CD Testing Program Operation MH900, DX200 Controller 6.1 Preparation for Startup Checklist Preparation for Startup Checklist Before startup, make sure the following items have been completed. Table 6-1: Checklist: Preparation for Startup Date Initials Item “Check List Before Applying Power” has been completed and main power has been turned on and tagged in.
Page 75 182582-1CD Testing Program Operation MH900, DX200 Controller 6.2 Troubleshooting at Startup Troubleshooting at Startup The following table lists actions to take for problems at startup. Table 6-2: Troubleshooting at Startup Condition Actions to Take Manipulator Make sure the tool file settings on the pendant are performance is correct.
Page 76 182582-1CD Testing Program Operation MH900, DX200 Controller 6.3 Movement of the Axes Movement of the Axes Move each axis of the manipulator by pressing the axis keys on the programming pendant. This figure illustrates each axis of motion in the joint coordinates.
Page 77 Use the brake release with the state that the motor servo is on and execution cannot occur with the controller. To purchase the Manual Brake Release function, contact the local Yaskawa branch office listed on the back cover. 182582-1CD 77 of 552...
Page 78 16 or less characters with number(s) and symbol(s). • Safety Mode: user ID needs to be nine or more but less than 16 or less characters with number(s) and symbol(s). • One Time Manage Mode: Requires security code from Yaskawa 182582-1CD 78 of 552...
Page 79 182582-1CD Security System MH900, DX200 Controller 7.1 Protection Through Security Mode Settings 7.1.1.2 Menus Table 7-2: Menu & Security Mode (Sheet 1 of 4) Main Menu Sub Menu Allowed Security Mode DISPLAY EDIT Operation Editing SELECT JOB Operation Operation CREATE NEW JOB...
Page 80 182582-1CD Security System MH900, DX200 Controller 7.1 Protection Through Security Mode Settings Table 7-2: Menu & Security Mode (Sheet 2 of 4) Main Menu Sub Menu Allowed Security Mode DISPLAY EDIT ROBOT CURRENT POSITION Operation COMMAND POSITION Operation SERVO MONITOR...
Page 81 182582-1CD Security System MH900, DX200 Controller 7.1 Protection Through Security Mode Settings Table 7-2: Menu & Security Mode (Sheet 3 of 4) Main Menu Sub Menu Allowed Security Mode DISPLAY EDIT PARAMETER Management Management Management Management Management Management Management Management...
Page 82 2 Displayed in the Play Mode only. 3 Displayed when the job reconstruction function is valid. * When the functional safety is valid, refer to the “DX200 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY BOARD OPERATION” (165988-1CD) for the Menu and Security Mode.
Page 83 182582-1CD Security System MH900, DX200 Controller 7.1 Protection Through Security Mode Settings 7.1.1.3 Changing the Security Mode 1. Select {SYSTEM INFO} under Main Menu. – The sub menu appears. Depending on the system icons for the Main Menu, such as arc welding system, differ.
Page 84 182582-1CD Security System MH900, DX200 Controller 7.1 Protection Through Security Mode Settings – Security mode allows the selection of “OPERATION MODE,” “EDITING MODE,” “MANAGEMENT MODE,” or “SAFETY MODE.” 3. Select the security mode to change. – Selecting a security mode lower than the current security level requires a password.
Page 85 182582-1CD Security System MH900, DX200 Controller 7.1 Protection Through Security Mode Settings  Changing the Mode to One Time Management Mode 1. Change to MANAGEMENT MODE. – When changing to the management mode, security mode is selectable from “OPERATION MODE,” “EDITING MODE,”...
Page 86 182582-1CD Security System MH900, DX200 Controller 7.1 Protection Through Security Mode Settings 7.1.2.1 Changing User ID To change the user ID, the controller must be in either editing mode, management mode or safety mode. Higher security modes can make changes the user ID of to lower security modes.
Page 87 182582-1CD Security System MH900, DX200 Controller 7.1 Protection Through Security Mode Settings 3. Select the desired ID. – The character input line appears, and a message “Input current ID no. (4 or more digits)” appears. (As for the safety mode, 9 or more digits) 4.
Page 88 182582-1CD System Setup MH900, DX200 Controller System Setup WARNING • Use caution when changing settings that can result in improper manipulator operation. Various setting may cause compatibility issues between the controller and the manipulator performance characteristics which may cause personal injury and/or equipment damage.
Page 89 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration Home Position Calibration WARNING • Before operating the manipulator, check that the SERVO ON lamp on the programming pendant goes out when pressing the emergency stop button on the programming pendant and the external control device, etc.
Page 90 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration • Perform the following inspection procedures prior to teaching the manipulator. If there are any problems, correct the problem immediately and perform all other necessary tasks. – Check for problems with manipulator movement.
Page 91 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration 8.1.1 Home Position Calibration • Teaching and playback are not possible before the completion of the home position calibration. In a system with two or more manipulators, calibrate the home position of all the manipulators before starting...
Page 92 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration 8.1.2 Calibrating Operation Home position calibration screen displays only in SECURITIY MODE or MANAGEMENT MODE. 8.1.2.1 Registering All Axes at One Time 1. Select {ROBOT} under the Main Menu. – The sub menu appears 2.
Page 93 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration 3. Select {DISPLAY} on the top of the window. – The pull-down menu appears. Selecting [PAGE] and a selection box appears, allowing the same operation as step 3. 4. Select the desired control group.
Page 94 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration 5. Select {EDIT} on top of the window. – The pull-down menu appears. 6. Select {SELECT ALL AXES}. – The confirmation dialog box appears. 7. Select {YES}. – Registers the position data of all axes as the home position.
Page 95 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration 8.1.2.2 Registering Individual Axes 1. Select {ROBOT} under the Main Menu. – The sub menu appears. 2. Select {HOME POSITION}. 3. Select the desired control group. – Perform step 3 and step 4 of section 8.1.2.1 “Registering All Axes at One Time”...
Page 96 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration 8.1.2.3 Changing the Absolute Data Perform the following to change the absolute data of the axis after completing the home position calibration: 1. Select {ROBOT} under the Main Menu. 2. Select {HOME POSITION}.
Page 97 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration 8.1.2.4 Clearing ABSOLUTE DATA 1. Select {ROBOT} under the Main Menu. – The sub menu appears 2. Select {HOME POSITION}. – Perform step 3 and step 4 of section 8.1.2.1 “Registering All Axes at One Time”...
Page 98 182582-1CD System Setup MH900, DX200 Controller 8.1 Home Position Calibration 8.1.3 Home Position of the Robot Refer to the “MANIPULATOR INSTRUCTIONS” for the correct Home Position. 182582-1CD 8-11 98 of 552...
Page 99 182582-1CD System Setup MH900, DX200 Controller 8.2 Setting the Second Home Position (Check Point) Setting the Second Home Position (Check Point) WARNING • Be aware of safety hazards when performing the position confirmation of the second home position (check point).
Page 100 182582-1CD System Setup MH900, DX200 Controller 8.2 Setting the Second Home Position (Check Point) • Perform the following inspection procedures prior to teaching the manipulator. If there are any problems, correct the problem immediately and perform all other necessary tasks.
Page 101 182582-1CD System Setup MH900, DX200 Controller 8.2 Setting the Second Home Position (Check Point) 8.2.1 Purpose of Position Check Operation If the absolute number of rotation detected at power supply ON does not match the data stored in the absolute encoder the last time the power supply was turned OFF, an alarm is issued when the controller power is turned ON.
Page 102 182582-1CD System Setup MH900, DX200 Controller 8.2 Setting the Second Home Position (Check Point) Pulse Difference Check The pulse number at the second home position is compared with that at the current position. If the difference is within the allowable range, playback is enabled.
Page 103 182582-1CD System Setup MH900, DX200 Controller 8.2 Setting the Second Home Position (Check Point) 8.2.2 Procedure for the Second Home Position Setting (Check Point) Apart from the “home position” of the manipulator, the second home position can be set up as a check point for absolute data. Use the following steps to set the specified point.
Page 104 182582-1CD System Setup MH900, DX200 Controller 8.2 Setting the Second Home Position (Check Point) – When there are two or more group axes, select the group axes to which the second home position is to be specified. 4. Press the axis keys.
Page 105 182582-1CD System Setup MH900, DX200 Controller 8.2 Setting the Second Home Position (Check Point) 8.2.3 Procedure after the Alarm WARNING • Be aware of safety hazards when performing the position confirmation of the specified point. Abnormality of the PG system may be the cause of the alarm. The manipulator may operate in an unexpected manner, and there is a risk of damage to equipment or injury to personnel.
Page 106 182582-1CD System Setup MH900, DX200 Controller 8.2 Setting the Second Home Position (Check Point) 3. Press the [PAGE], or select [PAGE] to display the selection window for the control group. – When there are two or more group axes, select the group axes to which the second home position is to be specified.
Page 107 Use the following parameter to set this function. S2C333: TOOL NO. SWITCHING (1: enabled; 0: disabled) For more details, refer to chapter 8 “Parameter” in DX200 OPERATOR’S MANUAL. 8.3.1.2 Registering Coordinate Data When the number input operation is used for registering the tool file, input the TCP of the tool on the flange coordinates.
Page 108 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting 1. Select {ROBOT} under the main menu. – The sub menu appears. 2. Select {TOOL}. (1) Move the cursor to the number of the desired tool, and press {SELECT} in the tool list window.
Page 109 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting – The coordinate data is registered. 260 mm 260 mm 260mm 145mm Tool A Tool B Tool C In case of Tool A, B In case of Tool C 8.3.1.3 Registering Tool Angle...
Page 110 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting Flange coordinates Tool coordinates 1. Select {ROBOT} under the main menu. 2. Select {TOOL}. 3. Select the desired tool number. – In the same way as shown in Explanation 2, 3 in section 8.3.1.2 “Registering Coordinate Data"...
Page 111 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting – Rx must be the input rotation angle around X’ of flange coordinates. Rx = 0 8.3.1.4 Setting the Tool Load Information The tool load information includes weight, a center of gravity position, and moment of inertia at the center of gravity of the tool installed at the flange.
Page 112 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting What is registered in tool calibration is the coordinates of the TCP and the tool posture data in the flange coordinates. Flange XF: Vertically upward direction when the current coordinates position on the T-axis of the manipulator is "0"...
Page 113 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting 8.3.2.3 Teaching of Calibration Point  Teaching for defining coordinates In order to calibrate coordinates, five different postures (TC1 to 5) must be taught with the TCP as the reference point. The tool dimensions are automatically calculated on the basis of these five points.
Page 114 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting In case of calibrating with S2C432=2, teach TC1 with Z-axis of the desired tool coordinates downward vertically to the ground. Then teach the other calibration teaching points (TC2~TC5) with the all tool points meet at the TC1’s tool point as shown in the figure below.
Page 115 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting – In the same way as shown in the instruction 2 and 3 of the section 8.3.1.2 “Registering Coordinate Data" on page 8-20, display the desired tool coordinate window. 4. Select {UTILITY} under the menu.
Page 116 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting (1) Select the robot to calibrate. (When the robot has already been selected or there is only one of robot, this operation should not be performed.) (2) Select “**” in the TOOL CALIBRATION window and select the robot in the shown selection dialog box.
Page 117 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting  indicates that teaching is completed and  indicates that it is not completed. – To check the taught positions, call up the required window among TC1 to TC5 and press [FWD]. The manipulator moves to the set position.
Page 118 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting – The pull-down menu appears. 2. Select {CLEAR DATA}. – The confirmation dialog box is shown. 3. Select {YES}. – All data is cleared. 182582-1CD 8-31 118 of 552...
Page 119 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting • If tool angle data is required, input the data number in the tool coordinate window. Refer to section 8.3.1.3 “Registering Tool Angle" on page 8- 22 for the operating instructions.
Page 120 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting – By pressing the axis keys for the R, B, and T axes, change the manipulator pose without changing the TCP position. If this operation shows a large TCP error, adjust the tool data.
Page 121 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting 8.3.3.2 Measurement of the Tool Load and the Center of Gravity To measure the tool load and the center of gravity, move the manipulator to its home position (horizontal to the U-, B- and R-axes) and operate the U-, B- and T-axes.
Page 122 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting 3. Select the desired tool number. – Move the cursor to the desired number in the tool list window and press [SELECT]. – The tool coordinate window of the selected number is shown.
Page 123 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting 4. Select {UTILITY} under the menu. 5. Select {W.GRAV.POS MEASURE}. – The window for the automatic measurement of the tool load and the center of gravity is shown. 6. Press the [PAGE].
Page 124 182582-1CD System Setup MH900, DX200 Controller 8.3 Tool Data Setting First measurement of the T-axis: T-axis home position +4.5 degrees  -4.5 degrees Second measurement of the T-axis: T-axis home position +60 degrees  +4.5 degrees  -4.5 degrees • The speed during measurement automatically changes to “Medium”.
Page 125 8.4 ARM Control ARM Control 8.4.1 ARM Control ARM Control, a control system originally developed by Yaskawa, achieves an enhanced robot motion performance such as improved path accuracy or reduced cycle time. The moment of inertia and the gravity moment etc. of each axis are calculated by the ARM control function, and the controller controls robot motion according to the result.
Page 126 “+” or “-”. Only rotation angle around Y axis of the robot coordinates can be set in the robot installation angle. • Contact Yaskawa representative when robots is installed to incline Y axis of the robot coordinates relative to ground.
Page 127 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control  S-head payload Set the weight and the center of gravity position roughly when the equipment such as transformer is installed at the S-head. It is not necessary to set these values when there is no installed load on the S-head.
Page 128 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control X (From U-Axis) is horizontal distance from U axis rotation center to the center of gravity position of the load. Set negative number when there is mass side in the back from U-axis rotation center.
Page 129 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control 1. Select {ROBOT} under the main menu. 2. Select {ARM CONTROL}. – The ARM CONTROL window appears. 3. Press the page key BACK , or select [PAGE]. PAGE – Select the desired control group when there are two or more group axes.
Page 130 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control 8.4.3 Tool Load Information Setting • Set the tool load information correctly. The speed reducer longevity might decrease or the alarm might occur when the tool load information is not set correctly.
Page 131 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control 8.4.3.2 How to Calculate Tool Load Information  Weight: W (Unit: kg) The total weight of the installing tool is set. It is not required to set a correct value, however, it is recommended to set a value slightly larger than the actual load.
Page 132 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control Rough value of the moment of inertia at the center of gravity can be calculated by the following methods. • Method to approximate the entire tool in hexahedron or cylinder. • Method to calculate from each weight and center of gravity position of plural mass.
Page 133 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control • The own moment of inertia calculation for hexahedron and cylinder The own moment of inertia of hexahedron and cylinder can be calculated by the next expression when the center of gravity is at the center.
Page 134 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control It is necessary to set the moment of inertia at the center of gravity when the entire size of the tool and workpiece is large compared to the distance from the flange to the center of gravity position.
Page 135 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control How to calculate “Center of gravity position” and “moment of inertia at center of gravity” for plural mass The center of gravity position and the moment of inertia at the center of gravity of the entire tool can be calculated by...
Page 136 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control When there are two or more big mass such as the twin gun system as shown in the figure below, perform: 1. Set the center of gravity position when the center of gravity position of...
Page 137 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control Iz = 3 * ((100 - 100) + (50 - (-83)) ) * 10 6 * ((100 - 100) + ((-150) - (-83)) ) * 10 = 0.080 = approx. 0.100 * The own moment of inertia (Icxi, Icyi, Iczi) of the gun is disregarded in this example, since each gun is smaller than the entire tool.
Page 138 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control 3. Select the desired tool number. (1) Move the cursor to the number of the desired tool, and press [SELECT] in the tool list window. (2) The tool coordinate window of the selected number appears.
Page 139 182582-1CD System Setup MH900, DX200 Controller 8.4 ARM Control • When the data setting is not done It is considered that data is not set correctly in tool load information in the following cases. • When the weight (W) is “0”.
Page 140 182582-1CD System Setup MH900, DX200 Controller 8.5 Work Home Position Work Home Position 8.5.1 What is the Work Home Position? The Work Home Position is a reference point for manipulator operations. It prevents interference with peripheral device by ensuring that the manipulator is always within a set range as a precondition for operations such as starting the line.
Page 141 182582-1CD System Setup MH900, DX200 Controller 8.5 Work Home Position – When two or more manipulators exist in the system, use the [PAGE] to change the control group, or click on [PAGE] to select the desired control group. 8.5.2.2 Registering/Changing the Work Home Position 1.
Page 142 182582-1CD System Setup MH900, DX200 Controller 8.5 Work Home Position When the work home position is changed, the cubic interference area is automatically set as cube 64 to 57 in the base coordinate system. • The cube 64 is for ROBOT1 •...
Page 143 182582-1CD System Setup MH900, DX200 Controller 8.5 Work Home Position 8.5.2.4 Output of the Work Home Position Signal This signal is output any time the current position of the TCP of the manipulator is checked and found to be within the work home position cube.
Page 144 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area Interference Area 8.6.1 Interference Area The interference area is a function that prevents interference between multiple manipulators or the manipulator and peripheral device. The area can be set up to 32 area. There are two types of interference areas, as follows: •...
Page 145 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area Z-axis Maximum value Cubic X-axis interference area axis Minimum value Y-axis 2. Move the manipulator at the maximum and minimum value positions of the cube corner using the axis keys. Z-axis...
Page 146 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area 8.6.2.3 Setting Operation 1. Select {ROBOT} under the main menu. 2. Select {INTERFERENCE}. – The INTERFERENCE AREA window is shown. 3. Select the desired cube number. – Select the desired cube number with the [PAGE] or by number input.
Page 147 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area 4. Select “METHOD”. – ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are displayed alternately every time [SELECT] is pressed. If “CUBIC INTERFERENCE” is selected, the window is changed. 5. Select “CONTROL GROUP”. (1) A selection dialog box appears.
Page 148 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area displayed. Input the user coordinate number and press [ENTER]. 182582-1CD 8-61 148 of 552...
Page 149 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area 1. Select “CHECK MEASURE.” – Each time [SELECT] is pressed, “COMMAND POSITION” and “FEEDBACK POSITION” are displayed alternately. – “COMMAND POSITION”: When the command position (which is displayed on the current position window) is in the interference area, the signal is turned ON.
Page 150 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area 2. Select “ALARM OUTPUT.” – Each time [SELECT] is pressed, “OFF” and “ON” are displayed alternately. When selecting “ON” and if the manipulator’s TCP approaches inside the pre-defined interference area, the following alarm occurs and the manipulator stops immediately.
Page 151 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area – The cubic interference area is set. 182582-1CD 8-64 151 of 552...
Page 152 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area  Teaching Corner 1. Select “METHOD”. (1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS” switch alternately. (2) Select “MAX/MIN”. 2. Press [MODIFY]. – A message “Teach max./min. position” appears.
Page 153 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area – The cubic interference area is registered. 182582-1CD 8-66 153 of 552...
Page 154 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area  Number Input of the Side of Cube and Teaching Center 1. Select “METHOD”. (1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS” switch alternately. (2) Select “CENTER POS”. 2. Input data for length of the cube, then press [ENTER].
Page 155 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area – A message “Move to center point and teach” appears. The cursor only moves to either “” or “” at this time. 4. Move the manipulator using the axis keys. – Move the manipulator to the center point of the cube using the axis keys.
Page 156 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area 8.6.3 Axis Interference Area 8.6.3.1 Axis Interference Area The axis interference area is a function that judges the current position of the each axis and outputs a signal. Once the maximum and minimum...
Page 157 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area – When selecting the desired interference signal number by number input, select [PAGE] to input the desired signal number. 4. Select “METHOD”. – “AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are displayed alternately every time [SELECT] is pressed. Select “AXIS INTERFERENCE”.
Page 158 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area – Each time [SELECT] is pressed, “COMMAND POSITION” and “FEEDBACK POSITION” switch alternately. 7. Select “ALARM OUTPUT”. – Each time [SELECT] is pressed, “OFF” and “ON” are displayed alternately. When selecting “ON” and if the manipulator’s axes approach inside the pre-defined interference area, the following alarm occurs and the manipulator stops immediately.
Page 159 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area  Number Input of the Axis Data Coordinates 1. Select “METHOD”. (1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS” switch alternately. (2) Select “MAX/MIN”. 2. Input number for “MAX” and “MIN” data and press [ENTER].
Page 160 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area  Teaching Corner 1. Select “METHOD”. (1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS” switch alternately. (2) Select “MAX/MIN”. 2. Press [MODIFY]. – A message “Teach max./min. position” appears.
Page 161 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area – The cubic interference area is registered. 182582-1CD 8-74 161 of 552...
Page 162 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area  Number Input of Center Position (WIDTH) and Teaching Center 1. Select “METHOD”. (1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS” switch alternately. (2) Select “CENTER POS”. 2. Input number for “WIDTH” data and press [ENTER].
Page 163 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area 3. Press [MODIFY]. – A message “Move to the center point and teach” appears. The cursor only moves to either “” or “” at this time. 4. Move the manipulator using the axis keys.
Page 164 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area 8.6.4 Clearing the Interference Area Data 1. Select {ROBOT} under the main menu. 2. Select {INTERFERENCE}. – The INTERFERENCE AREA window is shown. 3. Select interference signal to be cleared. – Select the desired interference signal number to be cleared using the [PAGE] or by number input.
Page 165 182582-1CD System Setup MH900, DX200 Controller 8.6 Interference Area 5. Select {CLEAR DATA}. – The confirmation dialog box appears. 6. Select {YES}. – All the data of the interference signal number are cleared. 182582-1CD 8-78 165 of 552...
Page 166 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function Shock Detection Function 8.7.1 Shock Detection Function The shock detection function is a function to decrease damage due to the collision by stopping the manipulator without any external sensor when the tool or the manipulator collide with peripheral device.
Page 167 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function The detection level is changed by a job instruction SHCKSET. • After the instruction is executed, the shock will be detected by the specified detection level when the condition number is specified with the SHCKSET instruction.
Page 168 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function C o n d it io n N u m b e r (1 t o 9 ) 1 to 7: for changing detection level in play mode. 8: for standard detection level in play mode.
Page 169 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function  Method of Shock Detection Level File Setting 1. Select {ROBOT} under the main menu. 2. Select {SHOCK SENS LEVEL}. – The EACH AXIS LEVEL window appears. – Perform either of the following operations to display the page of desired condition number: (1) Press [PAGE] in the window.
Page 170 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function 4. Level setting for the condition number 9. The level setting for the condition number 9 is for the teach mode. This setting is made for each group. Refer to the max. disturbance force to set the DETECT LEVEL.
Page 171 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function • To adjust to the change in the grease viscosity at a cold start, the offset value is automatically added to DETECT LEVEL until the robot has operated for a certain period of time.
Page 172 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function • To adjust to the change in the grease viscosity at a cold start, the offset value is automatically added to DETECT LEVEL until the robot has operated for a certain period of time.
Page 173 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function If the non-existing axis in the system was specified to change the shock detection level for each axis, the its specified shock detection level is invalid. 182582-1CD 8-86 173 of 552...
Page 174 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function  SHCKRST instruction The shock detection level changed by the SHCKSET instruction is reset and returned to the detection level of the standard (value set in condition number 8) by the SHCKRST instruction.
Page 175 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function  SHCKSET 1. Move the cursor to the immediately preceding line where the SHCKSET instruction is to be registered. 2. Press [INFORM LIST]. – The inform list dialog box is shown.
Page 176 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function • When the robot specification is added (1) When the robot specification is added, move the cursor to the instruction in the input buffer line and press [SELECT] to display the DETAIL window.
Page 177 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function • When the shock detection level for the each axis change is added (1) Move the cursor over the instruction in the input buffer line, and select [Select] to display the DETAIL EDIT window.
Page 178 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function • When changing the shock detection level for the each axis (1) When changing the shock detection level for the each axis, move the cursor to the shock detection level; hold down [SHIFT] and press the up/down cursor key to change the level.
Page 179 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function DETAIL window. (2) Move the cursor to “UNUSED” of “ROBOT/STATION”, and press [SELECT]. (3) The selection box appears. (4) Point the cursor to the robot to be added and press [SELECT].
Page 180 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function 8.7.2.6 Resetting the Shock Detected When the collision of tool/manipulator and peripheral device is detected with the shock detection function, the manipulator stops instantaneously with alarm output. In this case, the shock detection alarm is displayed.
Page 181 8.7.3.1 Manipulator Type for High-Sensitivity Shock Detection Function The following manipulator types for arc welding support the high- sensitivity shock detection function. To enable this function, read the tool load information prepared by Yaskawa on the MAKER INITIAL VALUE window. Types for high-sensitivity shock detection function 8.7.3.2 Setting for High-Sensitivity Shock Detection Function...
Page 182 8.7 Shock Detection Function referring to section 8.4.2 “ARM CONTROL Window” on page 8-38. The U-arm payload prepared by Yaskawa can be read on the MAKER INITIAL VALUE window. Read the same data as the actual U-arm pay- load on the MAKER INITIAL VALUE window.
Page 183 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function 6. Select the number of the maker initial value to be read. – A confirmation dialog box appears. – Select a maker initial value other than the “STANDARD” to enable the high-sensitivity shock detection function.
Page 184 8.7.3.4 Explanation of Maker Initial Value N AME The name of tool load information prepared by Yaskawa is indicated. When using the tool in the following figure, select 300R BUILT MODEL, 308R BUILT MODEL, or 308RR UNIV MODEL.
Page 185 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function Fig. 8-4: Tool for High-Sensitivity Shock Detection (74.8) (116.5) 82.5 The high-sensitivity shock detection function works on the assumption that the tool file is correctly set. • To perform shock detection more accurately, read the tool load which is the same as the actual load on the MAKER INITIAL VALUE window.
Page 186 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function 3. Select {DATA} under the menu. – The pull-down menu appears. 182582-1CD 8-99 186 of 552...
Page 187 182582-1CD System Setup MH900, DX200 Controller 8.7 Shock Detection Function 4. Select {READING}. – The MAKER INITIAL VALUE window appears. 5. Select the number of the MAKER INITIAL VALUE to be read. – A confirmation dialog box appears. 182582-1CD 8-100...
Page 188 When {NO} is selected, the ARM CONTROL window appears without the U-arm payload being read into the ARM CONTROL window. U-arm payload information 8.7.3.6 Explanation of Maker Initial Value N AME The name of U-arm payload information prepared by Yaskawa is indi- cated. 182582-1CD 8-101 188 of 552...
Page 189 MAKER INITIAL VALUE window. 340MELC 310ELC 340ELC To perform shock detection more accurately, even when the U-arm payload information prepared by Yaskawa and the actual payload are the same, DO NOT read the payload information if the robot types are different. 182582-1CD 8-102...
Page 190 182582-1CD System Setup MH900, DX200 Controller 8.8 User Coordinate Setting User Coordinate Setting 8.8.1 User Coordinates  Definition of the User Coordinates User coordinates are defined by three points that have been taught to the manipulator through axis operations. These three defining points are ORG, XX, and XY, as shown in the diagram below.
Page 191 182582-1CD System Setup MH900, DX200 Controller 8.8 User Coordinate Setting 8.8.2 User Coordinate Setting 8.8.2.1 Selecting the User Coordinate File 1. Select {ROBOT} under the main menu. 2. Select {USER COORDINATE}. 3. Select the user coordinate number. (1) The USER COORDINATE window appears.
Page 192 182582-1CD System Setup MH900, DX200 Controller 8.8 User Coordinate Setting 8.8.2.2 Teaching the User Coordinates 1. Select the robot. – Select “**” on the upper left of the window to select the subject robot. (This operation can be omitted if the robot selection has already been made or if there is only one robot.)
Page 193 182582-1CD System Setup MH900, DX200 Controller 8.8 User Coordinate Setting – ““ indicates that teaching is completed and “” indicates that it is not completed. – To check the taught positions, call up the required window among ORG to XY and press [FWD]. The manipulator moves to the set position.
Page 194 182582-1CD System Setup MH900, DX200 Controller 8.8 User Coordinate Setting 8.8.2.3 Clearing the User Coordinates 1. Select {DATA} under the pull-down menu. 2. Select {CLEAR DATA}. – The confirmation dialog box appears. 3. Select {YES}. – All data is cleared.
Page 195 182582-1CD System Setup MH900, DX200 Controller 8.9 Overrun/Tool Shock Sensor Releasing Overrun/Tool Shock Sensor Releasing To operate the manipulator with the overrun or shock sensor released, pay extra attention to the safety of the surrounding operation environment. If the manipulator stops by overrun detection or tool shock sensor...
Page 196 182582-1CD System Setup MH900, DX200 Controller 8.9 Overrun/Tool Shock Sensor Releasing – If “RELEASE” is selected, overrun or tool shock sensor is released and “CANCEL” indication will be displayed. 4. Select “ALM RST”. – The alarm is reset and manipulator can be moved with the axis keys.
Page 197 182582-1CD System Setup MH900, DX200 Controller 8.10 Soft Limit Release Function 8.10 Soft Limit Release Function The switches that are set to detect the motion range of the manipulator are called limit switches. The operating range is monitored by the software in order to stop motion before these limit switches are reached.
Page 198 182582-1CD System Setup MH900, DX200 Controller 8.11 All Limit Release Function 8.11 All Limit Release Function To operate the manipulator with all limits released, pay extra attention to ensure the safety of the surrounding operation environment. Failure to observe this caution may result in injury or damage to equipment due to the unexpected manipulator motion exceeding its range of motion.
Page 199 182582-1CD System Setup MH900, DX200 Controller 8.11 All Limit Release Function 3. Select “ALL LIMITS RELEASE”. – “VALID” and “INVALID” are displayed alternately every time [SELECT] is pressed. – When ALL LIMIT RELEASE is changed to “VALID”, a message “All limits have been released”...
Page 200 182582-1CD System Setup MH900, DX200 Controller 8.12 Instruction Level Setting 8.12 Instruction Level Setting 8.12.1 Setting Contents 8.12.1.1 Instruction Set There are three instruction sets that can be used when registering the instructions for the robot programming language (INFORM III): the subset instruction set, the standard instruction set, and the expanded instruction set.
Page 201 182582-1CD System Setup MH900, DX200 Controller 8.12 Instruction Level Setting 8.12.1.2 Learning Function When an instruction is entered from the instruction list, the additional items that were entered last time are also shown. This function can simplify instruction input. To register the same additional items as those in the former operation, register them without changing.
Page 202 182582-1CD System Setup MH900, DX200 Controller 8.12 Instruction Level Setting 3. Select “LANGUAGE LEVEL”. – The selection list appears. 4. Select desired language level. – Language level is set. 182582-1CD 8-115 202 of 552...
Page 203 182582-1CD System Setup MH900, DX200 Controller 8.12 Instruction Level Setting 8.12.3 Setting the Learning Function The learning function is set at “VALID” by default. 1. Select {SETUP} under the main menu. 2. Select {TEACHIG COND}. – The TEACHING CONDITION window appears.
Page 204 182582-1CD System Setup MH900, DX200 Controller 8.13 Setting the Controller Clock 8.13 Setting the Controller Clock The clock inside the controller can be set as follows. 1. Select {SETUP} under the main menu. 2. Select {DATE/TIME}. – The DATE/TIME SET window appears.
Page 205 182582-1CD System Setup MH900, DX200 Controller 8.14 Setting the Play Speed 8.14 Setting the Play Speed 1. Select {SETUP} under the main menu. 2. Select {SET SPEED}. – The SPEED SET window is shown. 3. Press the [PAGE]. – When two or more manipulators and stations exist in the system, use the [PAGE] to change the control group, or click on [PAGE] to select the desired control group.
Page 206 182582-1CD System Setup MH900, DX200 Controller 8.14 Setting the Play Speed 5. Select the speed to modify. – The input buffer line appears. 6. Input the speed value. 7. Press [ENTER]. – The speed is modified. 182582-1CD 8-119 206 of 552...
Page 207 The allocatable functions are listed below. Function Description Manufacturer Allocated by Yaskawa. Allocating another function invalidates the function allocated by the manufacturer. allocation Instruction Allocates any instructions assigned by the user. allocation Job call allocation Allocates job call instructions (CALL instructions).
Page 208 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 8.15.2.2 Key Allocation (SIM) With key allocation (SIM), the manipulator operates according to the allocated function when the [INTERLOCK] and the numeric key are pressed at the same time. The allocatable functions are listed below.
Page 209 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function – Pull-down menu appears. – To call up the KEY ALLOCATION (SIM) window, select {ALLOCATE SIM. KEY}. 4. Select {ALLOCATE SIM. KEY}. – The KEY ALLOCATION (SIM) window appears.
Page 210 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 2. Select “INSTRUCTION”. – The instruction is shown in the “ALLOCATION CONTENT”. (1) To change the instruction, move the cursor to the instruction and press [SELECT]. Then the instruction group list appears.
Page 211 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 2. Select “JOB CALL”. – The reserved job registration No. is shown in the “ALLOCATION CONTENT” (reserved job registration No.: 1 to 10). (1) To change the reserved job registration No. move the cursor to the No.
Page 212 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 5. Open the window for allocation. 6. Press [INTERLOCK] and the allocated key at the same time. – A message “Reserved display registered” appears, and the window is registered.
Page 213 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 2. Select “ALTERNATE OUTPUT”. – The output No. is displayed in the “ALLOCATION CONTENT”. (1) To change the output No., move the cursor to the No. and press [SELECT]. Then numeric value can be entered.
Page 214 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 8.15.2.9 Pulse Output Allocation Set this function in the KEY ALLOCATION (SIM) window. 1. Move the cursor to the “FUNCTION” of the key to be allocated and press [SELECT].
Page 215 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 8.15.2.10 Group (4-bit/8-bit) Output Allocation Set this function in the KEY ALLOCATION (SIM) window. 1. Move the cursor to the “FUNCTION” of the key to be allocated and press [SELECT].
Page 216 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 8.15.2.11 Analog Output Allocation Set this function in the KEY ALLOCATION (SIM) window. 1. Move the cursor to the “FUNCTION” of the key to be allocated and press [SELECT].
Page 217 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 8.15.2.12 Analog Incremental Output Allocation Set this function in the KEY ALLOCATION (SIM) window. 1. Move the cursor to the “FUNCTION” of the key to be allocated and press [SELECT].
Page 218 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 8.15.3 Allocation of I/O Control Instructions In key allocation (SIM), output control instructions can be allocated to the numeric keys that have been allocated one of the following I/O controls with key allocation (EACH).
Page 219 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 3. Select “OUTPUT CONTROL INST”. – The instruction corresponding to the I/O control allocated by key allocation (SIM) is displayed in the “ALLOCATION CONTENT”. – The allocated instruction changes automatically when “ALLOCATION CONTENT”...
Page 220 182582-1CD System Setup MH900, DX200 Controller 8.15 Numeric Key Customize Function 8.15.4.4 Executing the I/O Control Allocation Alternate output allocation, momentary output allocation, pulse output allocation, group output allocation (4-bit/8-bit), analog output allocation, analog incremental output allocation are executed by the following operation.
Page 221 182582-1CD System Setup MH900, DX200 Controller 8.16 Changing the Output Status 8.16 Changing the Output Status The status of external output signals can be changed from the programming pendant by using either of the following two methods. • On the user output status window •...
Page 222 182582-1CD System Setup MH900, DX200 Controller 8.16 Changing the Output Status 4. Press [INTERLOCK] +[SELECT]. – The output status is changed. (: status ON; : status OFF.) It is also possible to turn the relevant external output signal on only for the duration that [INTERLOCK]+[SELECT] are pressed.
Page 223 182582-1CD System Setup MH900, DX200 Controller 8.17 Changing the Parameter Setting 8.17 Changing the Parameter Setting The parameter settings can be changed only by the operator who has the correct user ID number for the management mode. 1. Select {PARAMETER} under the main menu.
Page 224 182582-1CD System Setup MH900, DX200 Controller 8.17 Changing the Parameter Setting (1) Move the cursor to a parameter number and press [SELECT]. (2) Enter the desired parameter number with the numeric keys. (3) Press [ENTER]. (4) The cursor moves to the selected parameter number.
Page 225 182582-1CD System Setup MH900, DX200 Controller 8.17 Changing the Parameter Setting Set the parameters in the following manner. 1. Select the parameter data to be set. (1) Move the cursor to the parameter number data (decimal or binary) in the PARAMETER window, and press [SELECT].
Page 226 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 8.18 File Initialization 8.18.1 Initializing Job File 1. Turn ON the power supply again while pressing [MAIN MENU] simultaneously. 2. Change the security mode to the management mode. 3. Select {FILE} under the main menu.
Page 227 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 6. Select {YES}. – The job data is initialized. When JOB is initialized, the following files are reset at the same time. Be careful when initializing JOB. • User coordinates • Memory play file •...
Page 228 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 6. Select the data file to be initialized. – The selected data file/general data are marked with ““.  – The parameters marked with “ ” cannot be selected. 7. Press [ENTER].
Page 229 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 8.18.3 Initializing Parameter File 1. Turn ON the power supply again while pressing [MAIN MENU] simultaneously. 2. Change the security mode to the management mode. 3. Select {FILE} under the main menu.
Page 230 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 7. Press [ENTER]. – A confirmation dialog box appears. 8. Select {YES}. – The selected parameter is initialized. 182582-1CD 8-143 230 of 552...
Page 231 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 8.18.4 Initializing I/O Data 1. Turn ON the power supply again while pressing [MAIN MENU] simultaneously. 2. Change the security mode to the management mode. 3. Select {FILE} under the main menu.
Page 232 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 7. Press [ENTER]. – A confirmation dialog box appears. 8. Select {YES}. – The selected data is initialized. 182582-1CD 8-145 232 of 552...
Page 233 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 8.18.5 Initializing System Data 1. Turn ON the power supply again while pressing [MAIN MENU] simultaneously. 2. Change the security mode to the management mode. 3. Select {FILE} under the main menu.
Page 234 182582-1CD System Setup MH900, DX200 Controller 8.18 File Initialization 7. Press [ENTER]. – A confirmation dialog box appears. 8. Select {YES}. – The selected data is initialized. 182582-1CD 8-147 234 of 552...
Page 235 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function 8.19 Display Setting Function 8.19.1 Font Size Setting The controller enables changing the font size displayed on the screen. The fonts displayed on the screen can be selected from eight patterns of fonts in the font size setting dialog box.
Page 236 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function 8.19.1.3 Setting the Font Size To set the font size, first off display the font size setting dialog box as follows. 1. Select {DISPLAY SETUP} then {CHANGE FONT} under the main menu.
Page 237 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function  To set the font size in the font size setting dialog box, follow the procedure below. 1. Specify the font style. – The {Bold Type} check box can be checked or unchecked alternately each time the check box is selected.
Page 238 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function 3. The font size setting dialog box is closed, and the screen displays the font specified in the dialog box.  To cancel the setting of the font size, follow the procedure below.
Page 239 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function Do not turn OFF the controller power supply when the font size is being changed (when the font size setting dialog box is on the screen). 8.19.2 Operation Button Size Setting The controller enables changing the size of operation buttons.
Page 240 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function 8.19.2.3 Setting the Button Size To set the button size, first off display the button size setting dialog box as follows. 1. Select {DISPLAY SETUP} then {CHANGE BUTTON} under the main menu.
Page 241 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function  To set the button size in the button size setting dialog box, follow the procedure below. 1. Specify the area to set the button size. (1) Select the desired area from the area setting buttons.
Page 242 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function 3. Specify the button size. – Select a button from the three buttons in the dialog box. 4. The font size setting dialog box is closed, and the screen displays the buttons specified in the dialog box.
Page 243 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function  To cancel the setting of the button size, follow the procedure below. 1. Select {Cancel} in the button size setting dialog box. – The dialog box closes without changing the button size.
Page 244 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function 8.19.3 Initialization of Screen Layout The font/button size changed with the font/button size setting function can be collectively changed back to the regular size. 8.19.3.1 Initializing the Screen Layout To initialize the screen layout, follow the procedure below.
Page 245 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function  To Initialize the screen layout, follow the procedure below. 1. select {OK}. – The dialog box is closed, and the font/button sizes are collectively changed to the regular size.
Page 246 182582-1CD System Setup MH900, DX200 Controller 8.19 Display Setting Function  To cancel the Initialized screen layout, follow the procedure below. 1. Select {CANCEL}. – The dialog box closes without changing the current screen layout. Do not turn OFF the controller power supply when the...
Page 247 182582-1CD System Setup MH900, DX200 Controller 8.20 Encoder Back-up Error Recovery Function 8.20 Encoder Back-up Error Recovery Function 8.20.1 About Encoder Back-up Error Recovery Function A motor of the robot, the travel axis or the rotation station which is controlled by the controller is connected with the back-up buttery in order to keep the position information even though the control power is disconnected.
Page 248 182582-1CD System Setup MH900, DX200 Controller 8.20 Encoder Back-up Error Recovery Function 7. Select {UTILITY} in the menu. – The pull-down menu appears. 8. Select {BACKUP ALM RECOVERY} in the menu. – The back-up alarm recovery display appears. 9. Select the axis to be fixed.
Page 249 – The absolute data of the selected axis is recovered. – Select {NO} to cancel the operation. 11. Select the current position. – To display the current position window, refer to DX200 MAINTENANCE MANUAL section 7.8.1 “Current Position Window”. 12. Confirm the current position.
Page 250 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 8.21 Preventive Maintenance Function 8.21.1 Preventive Maintenance Function The preventive maintenance function contains the function which provides the information of diagnosis the duration of life for the speed reducer and the function which informs the inspection time of the robot.
Page 251 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 2. Select {=PM} in the main menu. 3. Select {=RM(REDUCER)}. 4. Select {Display} in the menu. – {=SETUP CONDITION} appears under the pull down menu. 5. Select {=SETUP CONDITION}. – The condition setup window is appears.
Page 252 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 6. Move the cursor to over the {=REPLACEMENT SIGNAL}, and select. – Able to enter the values. 7. Enter the universal output signal. Lifetime Calculation Window  1. Select {=RM} in the main menu.
Page 253 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function For example, when setting with “100”, the message will be displayed 100 hours before the “TIME TO REPLACEMENT” becomes “0”, and the replacement signal will be turned ON as well.
Page 254 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 4. Move the cursor over the “=WARNING” to invalidate the desired axis, and select [Select]. [Invalid] and [Valid] will alternate each time when press the [Select]. 8.21.2.2 Diagnose by the Torque Average Value ...
Page 255 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function This function records the torque element arising from the deterioration of the speed reducer on a daily basis, and diagnoses the lifetime of the speed reducer by monitoring the change of the torque element.
Page 256 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function  Setting Procedures The setting procedures are described as follows. 1. Change the security mode to the management mode. 2. Select {=RM} in the main menu. 3. Select {=RM(REDUCER)}. – The lifetime calculation window appears.
Page 257 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 5. Select {=SETUP CONDITION}. – The setup window appears. – Modify the condition as necessary. 6. Select {End} button. Each item on the screen represents the following description. =TORQUE VARIATION ACCEPT RATE It is determined as accept OK when the measured value (the latest value - the average value) is smaller than the set value or the equal value.
Page 258 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function =CALCULATION DAYS Set the period to calculate the average value. The initial value of this item is “30” (days). =ELAPSED DAYS FROM CALC. START Set the period to calculate the average value from the day to diagnose.
Page 259 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function  Data Confirmation By operating a job in the play mode, a data (the torque element arising from the deterioration of the speed reducer) for each axis is recorded automatically on a daily basis, and the data is accumulated. It is unnecessary to prepare the job for this diagnosis.
Page 260 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function Each item on the screen represents the following description. =NG COUNT (IN A ROW) Shows the number of the variation days, which is higher than the value of the torque variation “HIGH”. The warning output signal, which is set by “...
Page 261 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function  Invalidate the Warning Output Signal Able to invalidate for each axis. Invalidate the warning output signal by the following procedures, in the case of the speed reducer seems to operate normally even though the warning output signal is turned ON.
Page 262 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 4. Select {=GRAPH}. – The graph appears. 5. Select {CLOSE}. – Return to the lifetime calculation window. Each item on the screen represents the following description. =Graph Select the {Graph}, and the pull down menu appears. Either “=Var” or “=Meas.”...
Page 263 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function In the case of the graph above, it shows a “variation” “Lo” of the T-axis, and the warning output signal, which is set by “torque variation low”, is • When selecting “=Meas.”, the measured value is displayed on the graph.
Page 264 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function =Torque The minimum value and the maximum value of the vertical axis can be set. “MIN” is the minimum value, and “MAX” is the maximum value. =Axis Removing the tick in the box hides the axis on the screen.
Page 265 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 4. Select {Display}, select the {=LIFE CALCULATION} or {=TORQUE MONITOR] in the pull down menu. – The lifetime calculation window or the torque monitor window appears. 5. Move the cursor over the “Reset” on the axis window of which speed reducer is replaced, and press {Select}.
Page 266 The inspection notice function turns the notice signal ON and displays the message when the inspection time has come. Perform the inspection by the authorized personnel or Yaskawa representative (the list on the back cover) when the notice signal is turned 8.21.3.1 Inspection Signal...
Page 267 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 6. Move the cursor over the “=INSPECTION SIGNAL”, and select. – It becomes the numeric value input status. 7. Enter the universal output number. 8.21.3.2 The Inspection Notice Window 1. Select {=RM} in the main menu.
Page 268 When the inspection signal is turned ON or the message is displayed, perform the inspection by an authorized personnel or the Yaskawa representative (listed on the back cover of this instruction manual). The message is displayed continuously until the controller is inspected.
Page 269 As for the external device menu, refer to Chapter 7 External Memory Devices of DX200 OPERATOR’S MANUAL for more details. 1. Select {External memory} in the main menu. – The external memory menu window appears.
Page 270 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 3. Select the {System data}. – The system data selection window appears. (The following is an example of a window.) 4. Select the system data to load or save. – For the speed reducer preventive maintenance data base, select “={PM(REDUCER)FILE}”.
Page 271 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 8.21.6 Preventive Maintenance for the Hardware This function estimates the life span of the controller components by calculating the consumed amount with considering the usage environment and the load, and outputs general signals to be the reference for the replacement time.
Page 272 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function  Mask of Signal Output The general output signals can be masked for each component. If any of the components is judged as D, ON signal is output from the general output which is set as “Alarm signal”...
Page 273 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 8.21.7 Setting of Preventive Maintenance for the Hardware 8.21.7.1 Setting of Replacement Time Display 1. Select {PM} in the main menu. – The sub menu appears. – * The operation icons on the main menu vary depending on the system usage.
Page 274 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 3. Input the numerical value of the alarm signal. When any of components in this controller comes to the replacement time, the general output signal which is already set turns ON.
Page 275 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 5. The following information is displayed: Starting from the left, (1) “” is displayed when the replacement time is judged as D. (2) Component name (3) General output signal valid/invalid...
Page 276 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function – When {CONTACTOR} is selected: “ 6. When replaced with a new component, select ”. – A confirmation dialog box appears. When replaced with a new “ component, select YES”.
Page 277 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 8. When manually setting the approximate value to the leftover life, input the numerical value “0 - 100%”. 9. When the numerical value displayed in the confirmation dialog box is correct, select “YES”.
Page 278 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 2. The message is also displayed per component. Invalidate the output. – After checking the components, invalidate the output. 3. The general output signal turns OFF. And the message turns to be hidden.
Page 279 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 8.21.8 Display of the Numbers of Motor Revolution and Reverse Revolution 8.21.8.1 Display of the Numbers of Revolution and Reverse Revolution 1. Select {PM} in Main Menu  {PM(HARDWARE)}  {MOTOR}.
Page 280 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function 8.21.8.3 Resetting the Number of Revolution Used when the motor replaced with a new one. “ 1. Select ” of the axis to be reset by moving the cursor to it, and then select “YES”...
Page 281 182582-1CD System Setup MH900, DX200 Controller 8.21 Preventive Maintenance Function – * When changing the number of revolution. – * When changing the number of reverse revolution. 182582-1CD 8-194 281 of 552...
Page 282 182582-1CD System Setup MH900, DX200 Controller 8.22 Break Line Ground Judgment Function 8.22 Break Line Ground Judgment Function 8.22.1 About the break Line Ground Judgment Function If the current flowing through the break line exceeds the capacity of the control power supply unit, the DC 24V power supply will be disconnected by the protective circuit of the control power supply unit;...
Page 283 182582-1CD System Setup MH900, DX200 Controller 8.22 Break Line Ground Judgment Function 8.22.3 Operation 8.22.3.1 Arising the DC 24V Power Supply Failure (SERVO) – When detecting either the ground fault or the short circuit of the break line, the alarm “1683 DC24V POWER SUPPLY FAILURE(SV)”...
Page 284 182582-1CD System Setup MH900, DX200 Controller 8.22 Break Line Ground Judgment Function 2. Press “YES”. – The confirmation dialog appears due to prevent the mis-operation. – Select “YES”, then the break line ground check appears. – Select “NO”, the window returns to the previous window.
Page 285 182582-1CD System Setup MH900, DX200 Controller 8.22 Break Line Ground Judgment Function DETECTED GROUND: The ground fault or short circuit of the break line ABNORMAL END: The ground check is cancelled. (i.e. the dislocation of the axis is detected, and so on) 4.
Page 286 182582-1CD System Setup MH900, DX200 Controller 8.22 Break Line Ground Judgment Function 3. Select {CLEAR}. – The confirmation dialog appears. 4. Press “YES”. – The related information of the break line ground check is initialized. – {BREAK LINE GROUND CHECK} does not appear in the {Main Menu} until the alarm “1683 DC24V POWER SUPPLY...
Page 287 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23 Safety Logic Circuit 8.23.1 Outline The safety logic circuit is a function to create the safety logic circuit on the programming pendant. It enables to set up the logical operations, such as stopping the manipulator and outputting the servo ON signal.
Page 288 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.2 Set up the Safety Logic Circuit In order to set up the safety logic circuit, the security mode needs to be changed to safety mode. Before creating the safety logic circuit, the following procedures need to be set in the window as shown below.
Page 289 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit – Enter the password for the safety mode, and then press [ENTER]. – When the entered password is correct, the mode is changed to {SAFETY MODE}. After changing to the safety mode, the icon is displayed on the status area.
Page 290 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.2.2 Allocating the Machine Safety Signal 1. Displaying the window. – Select {M-SAFETY SIGNAL ALLOC} from {SAFETY FUNC.} in the main menu. 2. Set up the universal safety signal. – In the controller, the two points of the universal safety input signal...
Page 291 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Canceling the edit – To start over the editing, select {CANCEL EDIT} from {EDIT} in the pull-down menu. 4. Transferring or updating the file – After editing, select {WRITE} button.
Page 292 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit – Press “YES”, and then the file is updated. The file transferred to the machine safety circuit board (type:YSF21-E) is written in the FLASH ROM. The status becomes “DONE” from “NOT DONE”.
Page 293 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.2.3 Allocating the Safety Signal Board This window is displayed when the optional safety field bus is valid. 1. Displaying the window. – Select {SAFETY SIG. BOARD ALLOC} from {SAFETY FUNC.} in the main menu.
Page 294 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Canceling the edit – To start over the editing, select {CANCEL EDIT} from {EDIT} in the pull-down menu. 182582-1CD 8-207 294 of 552...
Page 295 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 4. Transferring or updating the file – After editing, select {WRITE} button. The file is transferred to the machine safety circuit board (type:YSF21-E). When the file transfer is done correctly, the confirmation dialog “Update the file?”...
Page 296 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit • If press “YES” on the confirmation dialog, the all window information, such as {M-SAFETY SIGNAL ALLOC}, {SAFETY SIG. BOARD ALLOC}, {TIMER DELAY SET}, and {SAFETY LOGIC CIRCUIT} are updated. The written file in the FLASH ROM of the machine safety circuit board is also updated.
Page 297 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit – Select {TIMER DELAY} from {SAFETY FUNC.} in the main menu. 2. Set up the delay time. – Set the value of the delay timer to use. After the setting, the status changes from “DONE” to “NOT DONE”.
Page 298 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Canceling the edit – To start over the editing, select {CANCEL EDIT} from {EDIT} in the pull-down menu. 4. Transferring or updating the file – After editing, select {WRITE} button.
Page 299 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit – Press “YES”, and then the file is updated. The file transferred to the machine safety circuit board (type:YSF21-E) is written in the FLASH ROM. The status becomes “DONE” from “NOT DONE”.
Page 300 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.2.5 Safety Logic Circuit 1. Displaying the window. – Select {SAFETY LOGIC CIRCUIT} from {SAFETY FUNC.} in the main menu. 2. Set up the safety logic circuit – Create the safety logic circuit. The setting items are “INPUT1”, “LOGIC”, “INPUT2”, “OUTPUT”...
Page 301 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit After the setting, the status changes from “DONE” to “NOT DONE”. The “WRITE” button is displayed on the left down corner of the screen. 3. Canceling the edit – To start over the editing, select {CANCEL EDIT} from {EDIT} in the pull-down menu.
Page 302 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 4. Line clear – To clear the one line, select {LINE CLEAR} from {EDIT} in the pull- down menu. 5. All line clear – To clear the all line, select {ALL LINE CLEAR} from {EDIT} in the pull-down menu.
Page 303 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 6. Copy – Choose the desired area to make a copy, and select {COPY} from {EDIT} in the pull-down menu. – Go to the area to paste, select {PASTE} from {EDIT} in the main menu to paste.
Page 304 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 7. Transferring or updating the file – After editing, select {WRITE} button. If there is a blank line in the safety logic board, it will be filled automatically. The file is transferred to the machine safety circuit board (type:YSF21-E).
Page 305 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit • If press “YES” on the confirmation dialog, the all window information, such as {M-SAFETY SIGNAL ALLOC}, {SAFETY SIG. BOARD ALLOC}, {TIMER DELAY SET}, and {SAFETY LOGIC CIRCUIT} are updated. The written file in the FLASH ROM of the machine safety circuit board is also updated.
Page 306 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit  Setup the Signal1 and Signal2 The signal 1 and signal 2 are the signals to be used by the safety logic circuit. The following table shows the usable input signals. When add “NOT”...
Page 307 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit In the case of teach mode, the manipulator stops immediately as the controller system when the one of the following signals, PPEST, PPDSW, PBESP, or EXDSW is inputted.  Logic The usable logical signals are shown below.
Page 308 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit When the manipulator is stopped by the safety logic circuit signal, the message “Robot is stopped by safety logic circuit” appears on the message area of the programming pendant. Also, the control status signal “#80343” is turned The same output signal cannot be used.
Page 309 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit  Timer Signal Name Abbreviation Note ON delay timer1 to ON TIMI1 ON DELAY ~ The value set in the timer delay. delay timer4 TIM4 ON DELAY OFF delay timer1 to...
Page 310 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit Whether the universal input signals (signal name: GSIN1, 2) are used, whether the universal output signals (signal name: GSOUT1, 2) are used, and the polarity of the universal output signals can be set.
Page 311 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit – Press [ENTER]. – The confirmation dialog box of parameter change appears. 2. Select {YES}. – If {YES} is selected, the system parameter is set automatically, and then the OPTION FUNCTION window appears.
Page 312 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit (2) Without feedback signal connection DX200 Machine Safety I/O Machine Safety Terminal Logic Circuit Board Block Circuit Board (JANCD-YSF22-E) (JANCD-YFC22-E) CN219 GSOUT1_1+ Universal Safety Output 1 GSOUT1_1- Dual Sianals GSOUT1_2+...
Page 313 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.3 Performing the Safety Logic Circuit The safety logic circuit is always performed except updating the file. Confirm that the status is “DONE”. When setting signal is turned ON, the mark “...
Page 314 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 2. Change the security. – Select {SYSTEM}-{SECURITY}-{SAFETY MODE}. 3. Change to the safety mode. – Enter the password for the safety mode and press [ENTER] on the programming pendant. 4. When the entered password is correct, the mode is changed to {SAFETY MODE}.
Page 315 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 5. After changing to the safety mode, select {SYSTEM}-{SETTING}- {OPTION FUNCTION}-{SAFETY LOGICAL EXPANSION}. 6. Press the select key on the programming pendant to enable {SAFETY LOGICAL EXPANSION}. If the general safety I/O board (type: YSF24-E) is connected to the controller, select “USED”.
Page 316 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 7. Press [Enter] on the programming pendant and select “YES” to update the data. 8. After the update, select {FILE}-{INITIALIZE}-{Machine Safety Board FLASH Reset}. The initialization is completed when a bleep sounds.
Page 317 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 9. Turn OFF/ON the controller. 8.23.4.2 Outline of the Safety Logic Circuit Expansion Function In the safety logic circuit expansion function, input and output signals and logic (instructions) available in the logic circuit are expanded.
Page 318 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit When using the safety PLC, enable the optional safety field bus function. WARNING • Compared to the hard-wired signal, the output signal from the safety PLC (optional) requires time to be transmitted to the machine safety board (type: YSF21-E) to stop the manipulator.
Page 319 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.4.3 Setting the Comment Comments (up to 32 characters) can be input in the following windows. 1. Select {SAFETY FUNC.}-{SAFETY LOGIC CIRCUIT} to display the safety logic circuit window on the programming pendant.
Page 320 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.4.4 Adding Input and Output Signals and Instructions in Safety Logic Circuit Expansion Function The following is the explanation of the expanded input and output signals and logic (instructions) available in the safety logic circuit.
Page 321 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 2. Input signal 1/ Input signal 2 No. Display Contents Standard Expansion Note Function Safety Safety Field Field Disabled Enabled EXDSW External enable switch signal ● : Servo OFF [release]/...
Page 322 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit R[x] Workpiece area 128 points ● :ON status/ :OFF status) ● ● REMOTE Remote mode ● :Remote mode/ :Not remote mode) ● S-EXDSW External enable switch signal ● :ON (servo ON enabled)/...
Page 323 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Output signal Display Contents Standard Expansion Function Note Safety Safety Field Bus Field Bus Disabled Enabled #n GSOUT[x] Machine safety universal output 2 points (YSF22B-E) ● :ON output/ :OFF output) ●...
Page 324 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 4. Timer No. Display Contents Standard Expansion Note Function Safety Safety Field Field Disabled Enabled ● ● TMR[8] One shot pulse width timer 8 timer TM[4] OFF DELAY OFF Delay timer 4 timer...
Page 325 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit S-FST This is the full speed signal and functions only in the teach mode. When this signal is ON in the teach mode, the manipulator operation speed can be switched to 100% output. The machine safety board does not check the status of the hard-wired FST signal if the S-FST signal is used in the safety logic circuit.
Page 326 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.4.7 Enable Switch Link Function This function is enabled only in the teach mode. Normally in the teach mode, the servo power is turned ON when the enable switch is gripped while the servo ON LED on the programming pendant is flashing.
Page 327 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit The Timing Chart When the Servo On Enable (S-SVON_EN) Signal is Enabled. WARNING Configure the optional safety PLC circuit so that the servo ON enable (S-SVON_EN) signal is turned OFF by releasing the enable switch on the programming pendant when this function is enabled.
Page 328 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 2. The signals used in the safety logic circuit are displayed. When the optional field bus function is enabled, its signals are also displayed. ...
Page 329 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 2. The ON/OFF status of input signals used in the safety logic circuit can be switched by pressing the select key on the programming pendant . Signal Normal Open Normal Close...
Page 330 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. For example, when the EXESP signal is changed from “Normal Open” ● to “Normal Close”, the mark “ ” indicates the external emergency stop signal is in the normal state (Normal Close) and the mark “...
Page 331 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.4.10 Setting for the Universal Safety Output Signals The general safety output signals (type: YSF24-E) that have been used only on the optional functional safety board can be also used in the safety logic circuit.
Page 332 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Select “WRITE” and then “CONFIRM” to enable the changed settings. When the data is updated correctly, the status on the title line is changed from NOT DONE to DONE.
Page 333 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 2. The default setting is “NOT USED”. Press the select key on the programming pendant and select one of “NOT USED”, “YSF21-E” and “YSF25-E #n”. When the functional safety board (optional) is disabled, “YSF25-E #n”...
Page 334 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. In the following setting, SFBOUT01 to SFBOUT04 are available in the safety logic circuit and SFBOUT05 to SFBOUT08 are available on the functional safety board as the first board. After changing the setting, the status in the title line becomes “NOT DONE”...
Page 335 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit • While the safety logic circuit is edited, all the output signals are OFF. • When updating any of the followings, 1. to 5. are also update. 1. “SAFETY LOGIC CIRCUIT”...
Page 336 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 2. After creating the safety logic circuit is completed, press “WRITE” to display “CONFIRM” as shown below. 3. After “CONFIRM” menu is displayed, press “CONFIRM” to display the following dialog. Then select “YES”. If “No” is selected, the window returns to the status in the 1.
Page 337 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 4. When the file update is completed, the status in the title line is changed to “DONE” and the safety logic circuit is executed. While the ● safety logic circuit is executed, the signal status (“...
Page 338 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 2. Select {PAGE}-{TIMER}. 3. Input “250” at TIMER1. 4. Create the following safety logic circuit. 001 DSU #1GSIN1 #1 GSOUT1 TMR1 182582-1CD 8-251 338 of 552...
Page 339 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit When #1 GSIN1 signal is ON, #1 GSOUT1 is ON for one second. 5. To enable the changed settings, press “WRITE” and then “CONFIRM”. When the data is updated correctly, the status in the title line is changed from “NOT DONE”...
Page 340 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit WARNING When the DSU or DSD instruction is used, the signal status only in 4ms ● where the condition is established is changed to “ ”. However, the changed status cannot be seen because it appears for a short time.
Page 341 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. When #1 GSIN1 signal and #1 GSIN2 are simultaneously turned ON, #1 GSOUT1 is ON for one second. #1 GSIN1 #1 GSIN2 #1 GSOUT1 1sec 4. When #1 GSIN1 signal and #1 GSIN2 are not simultaneously turned ON, #1 GSOUT1 remains OFF.
Page 342 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit c . Servo power individual control function by the safety PLC (optional) 1. While pressing the main menu key on the programming pendant, start the maintenance mode. 2. Select {SYSTEM}-{SETTING}-{CONTROL GROUP}. Then confirm which ON ENABLE signal each control group is allocated to.
Page 343 • For details on the servo power supply individual control function, refer to chapter 8 “Servo Power Supply Individual Control Function” of the DX200 OPTIONS INSTRUCTIONS FOR INDEPENDENT/ COORDINATED CONTROL FUNCTION manual. d . Output of the specific input signal to the safety PLC (optional) Create the logic circuit in which the specific input1 (#40780) signal is output to the safety PLC.
Page 344 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit e . Input of full speed test (S-FST) signal Set the safety logic circuit in which the full speed test output is turned ON after the machine safety universal safety signal (GSIN1) is ON in the teach mode.
Page 345 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit f. How to use MS-OUT signal The following is the explanation to use MS-OUT signal. 1. Create the following safety logic circuit. 01 #1 GSIN1 MS-OUT01 2. When GSIN1 signal is turned ON, MS-OUT01 signal is turned ON.
Page 346 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.4.16 Specific Input Signals allocated to SPIN[xx] 32 signals input in the SPIN[xx] are allocated to specific input signals #40780 to #40817. The signals input in the SPIN[xx] are available in the safety logic circuit.
Page 347 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.4.17 Output to the Control Status Signal The following signals used in the safety logic circuit can be confirmed in the control status signals. (1) SFBIN[64] (2) SFBOUT[64] (3) MS-OUT[64]...
Page 348 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 80607 80606 80605 80604 80603 80602 80601 80600 Safety Field Safety Field Safety Field Safety Field Safety Field Safety Field Safety Field Safety Field SFBOUT8 SFBOUT7 SFBOUT6 SFBOUT5 SFBOUT4 SFBOUT3...
Page 349 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 80707 80706 80705 80704 80703 80702 80701 80700 Functional Functional Functional Functional Functional Functional Functional Functional safety safety safety safety safety safety safety safety FSBIN8 FSBIN7 FSBIN6 FSBIN5 FSBIN4 FSBIN3...
Page 350 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 80787 80786 80785 80784 80783 80782 80781 80780 Functional Functional Functional Functional Functional Functional Functional Functional safety safety safety safety safety safety safety safety FSBIN8 FSBIN7 FSBIN6 FSBIN5 FSBIN4 FSBIN3...
Page 351 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 81357 81356 81355 81354 81353 81352 81351 81350 Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Circuit Circuit Circuit Circuit Circuit Circuit...
Page 352 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 81447 81446 81445 81444 81443 81442 81441 81440 Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Safety Logic Circuit Circuit Circuit Circuit Circuit Circuit...
Page 353 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.5 Saving or Loading the File 8.23.5.1 Saving the File In order to save the file, which is set in the safety logic circuit, select {I/O DATA} by going to {SAVE} from {EX. MEMORY} in the main menu.
Page 354 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.5.2 Loading the File In order to load the safety logic circuit file (file name: YSFLOGIC.DAT), select {I/O DATA} by going to {LOAD} from {EX. MEMORY} in the main menu. Perform the saving the file after confirming the either the CompactFlash or USB memory stick is inserting to the programming pendant.
Page 355 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit When loading the safety logic circuit file, the file is not transferred to the machine safety circuit board (type: YSF21-E). Thus, perform {WRITE} in the one of the following windows, such as {M-SAFETY SIGNAL ALLOC}, {TIMER DELAY SET}, {SAFETY LOGIC CIRCUIT} or {SAFETY SIG.
Page 356 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.6.1 Initializing the Safety Logic Circuit File 1. Displaying the window. – Select {SECURITY} from {SYSTEM} in the main menu. 2. Changing to the safety mode. – Select {SAFETY MODE}.
Page 357 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. When the entered password is correct, the mode is changed to {SAFETY MODE}. After changing to the safety mode, the icon displayed on the status area. 4. Select the file to be initialized.
Page 358 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 5. Perform the initialization. – Select {ENTER}. – The confirmation dialog appears. – Select {YES}. – The file written in the FLASH ROM of the machine safety circuit board (type: YSF21-E) is initialized.
Page 359 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit – The confirmation dialog appears, and select {YES}. – The safety logic circuit file(file name: YSFLOGIC.DAT) written in the FLASH ROM of the machine safety circuit board (type: YSF21-E) is erased.
Page 360 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.7 Example of Safety Logic Circuit The followings are the examples of the safety logic circuit. 1. The first universal input safety signal of the I/O circuit board (type:YSF22 -E) “1”...
Page 361 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Verifying the safety logic circuit. Switch ON the universal safety signal “1” and “2”. The mark “ ” becomes “ “. 182582-1CD 8-274 361 of 552...
Page 362 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 1. The emergency button of the programming pendant is pressed, and the first universal input safety signal of the I/O circuit board (type:YSF22 -E) “1” is OFF, and the I/O circuit board...
Page 363 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Verifying the safety logic circuit. Confirm that the mark “ ” becomes “ “ when pressing the programming pendant and switching the universal safety signal ON. The mark “...
Page 364 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 1. When the first universal input safety signal of the I/O circuit board (type:YSF22 -E) “1” is ON (#1 GSIN1) and under the teaching mode, the manipulator will decelerate and stop.
Page 365 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Verifying the safety logic circuit. Set up the teach mode, and turn the servo ON. When switching the universal safety signal ON, the mark “ ” of the universal safety output signal 1 becomes “...
Page 366 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 1. The setting example by using the auxiliary relay is described below. When the any one of the status of the programming pendant emergency stop, controller emergency stop or external emergency stop is stopped, the first universal output safety signal “1”...
Page 367 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 3. Verifying the safety logic circuit. When the one of the programming pendant emergency stop, controller emergency stop or the external emergency stop is inputted, the mark “ ” of the universal safety output signal 1 becomes “...
Page 368 182582-1CD System Setup MH900, DX200 Controller 8.23 Safety Logic Circuit 8.23.8 Alarm List of the Safety Logic Circuit Alarm Sub-code Message Remedy Number VERIFY ERROR (SYSTEM CONFIG-DATA) Machine Safety board save The safety logic circuit files in the file written in the Main...
Page 369 182582-1CD System Setup MH900, DX200 Controller 8.24 Robot Stop Factor Monitor Function 8.24 Robot Stop Factor Monitor Function 8.24.1 Outline The robot stop factor monitor function is a function to detect a robot stop, which is caused by the servo OFF or the hold and so on. The factors, which caused to stop the robot, are stored in chronological order and displayed on the screen.
Page 370 182582-1CD System Setup MH900, DX200 Controller 8.24 Robot Stop Factor Monitor Function Table 8-2: The List of the Servo OFF Factors by Machine Safety Circuit Board Instructions Displayed Item Secondary Indication Description of the Signal PP EMERGENCY STOP Programming pendant...
Page 371 182582-1CD System Setup MH900, DX200 Controller 8.24 Robot Stop Factor Monitor Function Table 8-2: The List of the Servo OFF Factors by Machine Safety Circuit Board Instructions Displayed Item Secondary Indication Description of the Signal CONTACTOR OR STO Circuit board No.
Page 372 182582-1CD System Setup MH900, DX200 Controller 8.24 Robot Stop Factor Monitor Function Table 8-3: The List of the Holding Factors Displayed Item Secondary Indication HOLD None EX.HOLD (SPECIFIC. IN TRMNL BLOCK) System input signal number #40067 EX.HOLD (SPECIFIC. IN SIGNAL)
Page 373 182582-1CD System Setup MH900, DX200 Controller 8.24 Robot Stop Factor Monitor Function 8.24.2 Operation 8.24.2.1 Displaying the Robot Stop Factor Monitor The RB STOP FACTOP MONITOR can be referred by following procedures. 1. Select {ROB STOP FACTOR MONITOR} under the {IN/OUT} in the main menu.
Page 374 182582-1CD System Setup MH900, DX200 Controller 8.24 Robot Stop Factor Monitor Function • The factor detected by the main CPU is displayed on the first line. • The factor(s) detected by the machine safety is (are) displayed from the second line on the screen.
Page 375 182582-1CD System Setup MH900, DX200 Controller 8.24 Robot Stop Factor Monitor Function 2. Select {CLEAR}, and the confirmation dialog “Initialize?” appears. Press “YES”, and the all information of the robot stop factor is cleared. The robot stop factor information is not saved when turning the power supply OFF.
Page 376 182582-1CD System Setup MH900, DX200 Controller 8.25 Robot Detachment Function 8.25 Robot Detachment Function 8.25.1 Setting Maintenance Mode This mode is used for setting up and maintenance of the robot system. 1. Turn the power ON while pressing {MAIN MENU} button.
Page 377 182582-1CD System Setup MH900, DX200 Controller 8.25 Robot Detachment Function 3. Select {SECURITY}. – Mode selection screen is shown. 4. Press [SELECT] to select the mode. – Mode selection list is shown. 5. Move the cursor to {SAFETY MODE} and select.
Page 378 182582-1CD System Setup MH900, DX200 Controller 8.25 Robot Detachment Function 6. Input the password for safety mode and press [ENTER]. – When the correct password is input, security mode is changed. 8.25.2 Setting Robot Detachment Function Operator can set or modify the setting items for robot detachment function in detail setting screen.
Page 379 182582-1CD System Setup MH900, DX200 Controller 8.25 Robot Detachment Function 2. Select {SETUP}. – “SETUP” screen is shown. 3. Move the cursor to {OPTION FUNCTION} and select. – “OPTION FUNCTION” screen is shown. 4. Move the cursor to {ROBOT DETACHMENT} and select.
Page 380 182582-1CD System Setup MH900, DX200 Controller 8.25 Robot Detachment Function 5. Change the setting contents. – Move the cursor to the target group and select to change the setting. – Select “ATTACHED” or “DETACHED”. 6. Change the setting item on JOB.
Page 381 182582-1CD System Setup MH900, DX200 Controller 8.25 Robot Detachment Function 7. Press [ENTER]. – Confirmation message for parameter change is shown. 8. Select “YES” to confirm the change. – System parameters are to be set automatically, then the screen returns to the option function screen.
Page 382 182582-1CD System Setup MH900, DX200 Controller 8.26 Axes Detachment Function 8.26 Axes Detachment Function 8.26.1 Outline The axes detachment function is to invalid the connection of specific axes by setting in maintenance mode. When the axes detachment function is set, the system can be started without any alarm even if some axes are not connected physically during setup or motor exchange.
Page 383 182582-1CD System Setup MH900, DX200 Controller 8.26 Axes Detachment Function 3. Move the cursor to {OPTION FUNCTION} and select. – “OPTION FUNCTION” screen is shown. 4. Move the cursor to {AXES DETACHMENT} and select. – Detail setting screen for axes detachment function is shown.
Page 384 182582-1CD System Setup MH900, DX200 Controller 8.26 Axes Detachment Function 6. Change the setting contents. – Move the cursor to the target axis and select to change the setting. – Select “ATTACHED” or “DETACHED”. 7. Press [ENTER]. – Confirmation message for parameter change is shown.
Page 385 182582-1CD System Setup MH900, DX200 Controller 8.26 Axes Detachment Function 8.26.5 Restrictions 1. Operation with restrictions When the axes detachment function is set, the following operations are restricted. If these operations are tried to be performed, an error or an alarm occurs.
Page 386 182582-1CD System Setup MH900, DX200 Controller 8.26 Axes Detachment Function 2. Operation without restrictions • While the axes detachment function is set, even if try to move the manipulator to the taught position, the manipulator may not be moved to the right position or operated in the right posture because the specific axes don’t operate.
Page 387 The loading/saving procedures in the maintenance mode, refer to chapter 9.2 “Backup by CMOS.BIN” at page 9-4. As for saving in the normal mode, refer to DX200 OPERATOR’S MANUAL section 7.3.0.2 “Saving Data”. Target Area: All areas of the internally stored data.
Page 388 182582-1CD System Backup MH900, DX200 Controller 9.1 System Backup with Controller < Recommended USB Memory> No. Manufacturer Model Remarks Hagiwara Solutions UBA2-xxxGSRB 1GB, 2GB, and 4GB are (TBAIA) available. “xxx” indicates “001” for “1GB”, “002” for “2GB” and “004” for “4GB”.
Page 389 182582-1CD System Backup MH900, DX200 Controller 9.1 System Backup with Controller insertion may cause the damage of the USB memory and the USB connector. The position to insert the USB memory. The upper surface USB memory * There are two USB connectors.
Page 390 182582-1CD System Backup MH900, DX200 Controller 9.2 Backup by CMOS.BIN Backup by CMOS.BIN Perform the backup by CMOS.BIN in the normal or maintenance mode. The chart below shows the availability of CMOS save/CMOS load in each security mode in the maintenance mode.
Page 391 182582-1CD System Backup MH900, DX200 Controller 9.2 Backup by CMOS.BIN 4. Select {SAVE}. – The save display appears.  – The items marked with “ ” cannot be selected. 5. Select {CMOS}. – The confirmation dialog box appears. 182582-1CD 391 of 552...
Page 392 182582-1CD System Backup MH900, DX200 Controller 9.2 Backup by CMOS.BIN 6. Select {YES}. – Select {YES} to save the CMOS data into the CompactFlash. – When saving the file, if the CMOS.BIN file already exists in the CompactFlash, the following confirmation dialog box appears.
Page 393 182582-1CD System Backup MH900, DX200 Controller 9.2 Backup by CMOS.BIN 5. Select {LOAD}. – The load display appears.  – The items marked with “ ” cannot be selected. 6. Select {CMOS}. – The confirmation dialog box appears. 7. Select {YES}.
Page 394 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function Automatic Backup Function 9.3.1 Automatic Backup Function 9.3.1.1 Objective With the automatic backup function, the data saved in the controller such as system setting or operational condition are collectively backed up in the CompactFlash, which is stored in the programming pendant, or the selected device at the automatic backup window.
Page 395 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function With the automatic backup function, all the part where the internal data is stored in the physical memory area is collectively saved. If there is any data which is in the middle of changing while executing the automatic backup function, the data might not be usable for restoration because of its inconsistency.
Page 396 If no actions are taken while the error occurs, the data cannot be saved. Yaskawa recommends that the data be saved in two or more CompactFlash to minimize problems if the CompactFlash should be damaged.
Page 397 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function 9.3.2.2 The CompactFlash of the YCP21 Board Set the following procedures in advance to back up to the CompactFlash of the YCP21 board. If the following procedures are not done, “CF: Controller”...
Page 398 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function 9.3.2.3 RAMDISK on the YCP21 Board RAMDISK will be shown when the high speed ethernet server function is effective. Refer to the controller’s HIGH-SPEED ETHERNET SERVER FUNCTION manual for more details.
Page 399 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function  Reserve Time Backup While the data in the controller memory is being edited or overwritten, the automatic backup is not performed at the specified backup starting time and is suspended and retried later. To start the backup at the reserved time, set to the time when the robot program is stopped and no job or file is edited.
Page 400 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function 9.3.2.5 Setting Examples  Setting Example 1 The following diagram shows a setting example with the following conditions: BASE TIME: 12:30 BACKUP CYCLE: 60 (minutes) RETRY CYCLE: 10 (minutes) BASE TIME...
Page 401 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function 9.3.2.6 AUTO BACKUP SET Display  Settings Select the following items on the AUTO BACKUP SET display and set values for the automatic backup. • RESERVE TIME BACKUP (VALID/INVALID of the cyclic backup) •...
Page 402 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function 1. Turn ON the controller. – Insert the CompactFlash to the programming pendant, when the backup is set on the CompactFlash of the programming pendant. 2. Change the security mode to the management or higher mode.
Page 403 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function D. R E T RY C YC LE Specify the length of time for a cycle to retry backing up when the backup operation is suspended. After being suspended, the backup is retried in the time specified in the RETRY CYCLE.
Page 404 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function K . DE VIC E Press {SELECT} to display the device list. The Device Name in Display Explanation CF: pendant Set the backup to the CompactFlash of the programming pendant.
Page 405 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function  Window Settings RS parameter can restrict the settings of some items in the automatic backup window. When setting the bit of RS096 parameter shown below to “1”, the corresponding items are restricted. The restricted items are indicated with “INVALID”...
Page 406 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function 9.3.2.7 AUTO BACKUP EXTENSION FUNCTION SET Window  Settings Automatic backup setting is performed by setting the following items on the AUTO BACKUP SET window: • RESERVE TIME BACKUP (Setting for performing the backup on what day of the week, every day, or in a specific cycle) •...
Page 407 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function 1. Turn ON the controller. – Insert the CompactFlash to the programming pendant, when the backup is set on the CompactFlash of the programming pendant. 2. Change the security mode to the management or higher mode.
Page 408 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function “INVALID” : RESERVE TIME BACKUP is not performed. “SET CYCLE” : The automatic backup is performed every BACKUP CYCLE based on the specified BASE TIME. “EVERY DAY” : The automatic backup is performed at the specified BASE TIME every day.
Page 409 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function D. R E T RY C YC LE Every time the automatic backup is implemented, the memory data in the controller is obtained, and the data is compared with the original memory data.
Page 410 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function K . DE VIC E Press {SELECT} to display the device list. The Device Name in Display Explanation CF: pendant Set the backup to the CompactFlash of the programming pendant.
Page 411 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function  Window Settings RS parameter can restrict the settings of some items in the automatic backup window. When setting the bit of RS096 parameter shown below to “1”, the corresponding items are restricted. The restricted items are indicated with “INVALID”...
Page 412 182582-1CD System Backup MH900, DX200 Controller 9.3 Automatic Backup Function 9.3.3 Limiting the Automatic Backup File Creation 9.3.3.1 Setting to Limit the Automatic Backup File Creation It is applicable from version DN1.60-00 to limit the backup file creation executed by the automatic backup function to once a day.
Page 413 182582-1CD System Backup MH900, DX200 Controller 9.4 Loading the Backup Data from the CompactFlash Loading the Backup Data from the CompactFlash To restore the backup memory in the auto backup function is done in the maintenance mode. Otherwise, restore from the CompactFlash of the programming pendant or USB memory when backup is done at the optional high speed ethernet server function command.
Page 414 182582-1CD System Backup MH900, DX200 Controller 9.4 Loading the Backup Data from the CompactFlash – When set the {SYSTEM}- {SETUP}- {OPTIONAL FUNCTION}- {AUTO BACKUP (YCP21)} as “USE”, the following sub menu appears. 5. Select {SYSTEM RESTORE}. – The BACKUP FILE LIST display appears.
Page 415 182582-1CD System Backup MH900, DX200 Controller 9.4 Loading the Backup Data from the CompactFlash 6. Select the file to be loaded. – The dialog box appears for the YIF/YCP21 board replacement confirmation. – Select {YES} if the YIF/YCP21 board has been replaced, or select {NO} if it has not been replaced.
Page 416 182582-1CD System Backup MH900, DX200 Controller 9.4 Loading the Backup Data from the CompactFlash 9. Turn the power on, while pressing the [MAIN MENU]. 10. Change the security mode to the management or higher mode. 11. Select {External memory} in the main menu.
Page 417 182582-1CD System Backup MH900, DX200 Controller 9.4 Loading the Backup Data from the CompactFlash 13. Select desired date file. – The YIF/YCP21 board dialog will appear. – Select [YES] when exchanged the YIF/YCP21 board. If not, select [NO]. – When select [YES], cumulative time display will be initialized. For selecting [NO], cumulative time display will continue.
Page 418 182582-1CD System Backup MH900, DX200 Controller 9.4 Loading the Backup Data from the CompactFlash 15. Select [YES]. Note that executing “SYSTEM RESTORE” or “SYSTEM RESTORE (YCP21)” replaces the current CMOS data with the data of the file “CMOSBK.BIN” or “CMOSBK??.BIN” (?? denotes figures) in the CompactFlash.
Page 419 182582-1CD System Backup MH900, DX200 Controller 9.5 Error List Error List 9.5.1 Error Contents Error Data Message Cause 0770 The robot or the station is in The automatic backup would motion. not work when the robot or a manipulator is in motion.
Page 420 182582-1CD 10 Upgrade Function MH900, DX200 Controller 10.1 Functional Overview 10 Upgrade Function 10.1 Functional Overview The controller applies two software for the CPU configuration: a software for YCP21 (for the main CPU board) and a software for YPP (for programming pendant).
Page 421 182582-1CD 10 Upgrade Function MH900, DX200 Controller 10.2 Upgrade Procedure 10.2.2 Automatic Upgrade of YPP In case that the pendant application version of YPP is older than the one of YCP21 or the pendant application version of YPP is not compatible to the one of YCP21, the YPP is automatically upgraded.
Page 422 -Upgrade of the OS of Programming Pendant (3) Press [INTERLOCK], [8] and [SELECT] at the same time. (4) Exercise manual upgrading. - Refer to “DX200 Upgrade Procedure” (165560-1CD). • If no recovery is made with all the procedure above, replace the pendant.
Page 423 (2) Press [2], [8] and [HIGH SPEED] at the same time. -Upgrade of the OS of Programming Pendant (3) Press [INTERLOCK], [8] and [SELECT] at the same time. (4) Exercise manual upgrading. -Refer to “DX200 Upgrade Procedure” (165560-1CD) for details. 182582-1CD 10-4 423 of 552...
Page 424 182582-1CD 11 Programming Pendant MH900, DX200 Controller 11.1 Disconnection Function 11 Programming Pendant 11.1 Disconnection Function Disconnection function enables to cut off the communication between the programming pendant and the controller. 1. Long press [Simple Menu] key to show the pop-up menu.
Page 425 4. Press “OK” on the message dialog, otherwise the window is closed automatically after 10 seconds since the window appears on the screen, and then the programming pendant startup window is displayed. When connecting the controller and the programming pendant again, press “Connect to DX200” button. 182582-1CD 11-2 425 of 552...
Page 426 182582-1CD 11 Programming Pendant MH900, DX200 Controller 11.2 Reset Function 11.2 Reset Function Reset function enables to restart only the programming pendant while the main power supply of the controller is ON. If unable to operate the robot by the programming pendant causing from the communications error of the programming pendant, recover the programming pendant by following procedures.
Page 427 182582-1CD 11 Programming Pendant MH900, DX200 Controller 11.3 Touch Panel Invalidate Function 11.3 Touch Panel Invalidate Function The touch panel invalidate function enables to invalidate the touch panel operation of the programming pendant (key operation is still valid). Even if the touch panel is failure, it is able to prevent the mis-operation by using this function.
Page 428 182582-1CD 11 Programming Pendant MH900, DX200 Controller 11.3 Touch Panel Invalidate Function  Validate the Touch Panel 1. Push down the [INTER LOCK]+[AUX] keys at the same time. The confirmation dialog to validate the touch panel appears. 2. Move the focus area over the “YES” on the confirmation dialog by ←...
Page 429 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.1 Addition of I/O Modules 12 Modification of System Configuration 12.1 Addition of I/O Modules To add I/O modules, turn OFF the power supply. • Addition operation must be performed in the management mode.
Page 430 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.1 Addition of I/O Modules – The current status of the mounted I/O module is shown. 6. Confirm the status of mounted I/O module. – Confirm that each station (ST#) window is the same as the I/O module’s actual mounting status.
Page 431 If there is a difference between the displayed contents and the actual mounted status, confirm the status again. If the status is correct, the I/O module may be defective: in such a case, contact your Yaskawa representative. 182582-1CD 12-3 431 of 552...
Page 432  Allocation of the external I/O signal The DX200 exchanges I/O data with the I/O interface by using external I/O signal area (#2xxxxm #3xxxx). The allocation of the external-I/O signal area and I/O interface used to be unchangeable since they have been allocated to the signals from lower to higher numbers in bytes (8 points unit) by system software.
Page 433 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal 2. Select “AUTO” or “MANUAL” under the ALLOCATION MODE. – The selected menu appears. When the allocation mode is changed from “MANUAL” to “AUTO”, the set allocation data is discarded, and reallocation in the Auto mode takes place.
Page 434 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal 3. Select the allocation mode to set. – To operate the I/O signal allocation automatically, select the allocation mode “AUTO”. – To operate the I/O signal allocation manually, select the allocation mode “MANUAL”.
Page 435 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal 5. Select the external input signal number (at the change source) to be changed. (In the setting example, select “#20010”.) – The select menu appears. 6. Select “MODIFY”, and input the external input signal number (at the change destination) to be changed.
Page 436 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal 8. Press [ENTER]. – The External Output Signals Allocation window appears. 9. Like the case of the external input signal, select/modify the external output signal. – Repeat select/modify until it becomes the desired allocation.
Page 437 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal 11. Select {YES}. – The settings are confirmed, and the SETUP window reappears. 182582-1CD 12-9 437 of 552...
Page 438 I/O area, in the output signals #----- : Unallocated I/O area Indicates the DX200 station number allocated to each I/O board. The displayed contents include the following: : General I/O board (JANCD-YIO21) 1 to 13: Optional I/O board which is connected to the JANCD-YSF21...
Page 439 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal MAC ID Indicates the network communication station number set in the channel concerned on the board concerned. Regarding station numbers that cannot be displayed, or station numbers that do not need to be dis- played, ‘0’...
Page 440 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal  Allocation example of external I/O signal The following shows a system of setting example. I/O interface must be recognized in the I/O module setting window.
Page 441 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal < Setting example: Automatic setting > When the automatic setting is performed by external IO allocation, IO data is allocated to the external IO signals from lower to higher numbers.
Page 442 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.2 Allocating External I/O Signal < Setting example: Allocating the CC-Link board data only by manual setting > IO data of the CC-Link can be allocated from the top while data of the board status/system area allocated to different area.
Page 443 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3 Addition of Base and Station Axes To add the base and station axes, mount all hardware correctly and then execute maintenance mode. Addition operation must be performed in the management mode.
Page 444 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes • REDUCTION RATIO (denominator) • PINION DIAMETER [mm] • If axis type is turn type, set the following items. • MOTION RANGE (+) [deg] •...
Page 445 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3.1 Base Axis Setting 12.3.1.1 Selection of Base Axis Type Select the type of base axis to be added/modified. 1. Turn ON the power supply again while pressing [MAIN MENU] simultaneously.
Page 446 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 5. Select {CONTROL GROUP}. – The current control group type is displayed. 6. Move the cursor to the type of control group to be modified, and press [SELECT].
Page 447 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 7. Select one in the type list. – After the type selection, the window returns to the CONNECT window. RECT-Y RECT-Z RECT-X CARTESIAN CARTESIAN...
Page 448 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3.1.2 Connection Setting In the CONNECT window, it is specified that each axis of each control group is connected to which connector of the SERVO board, which break of the contactor unit, which converter, and which overrun signal.
Page 449 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 2. Select the connection item of a desired control group. – The settable items are displayed. – Select an item to change the setting. Select {Cancel} to return to the CONNECT window.
Page 450 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes [CONNECT (CONTACTOR) window] – Specify which connector (CN) of the SERVO board each axis of each control group is connected to. The numbers in [ ] represent axis numbers, and indicate which axis is connected to which connector.
Page 451 When the error message appears, invalid SPOT HIGH SPEED SPEC or review the configuration of the control group by referring to section 9.12 High Speed Spot Welding Function” at DX200 OPERATOR’S MANUAL FOR SPOT WELDING USING MOTOR GUN. 182582-1CD 12-23...
Page 452 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3.1.3 Axis Configuration Setting The axis type is specified in the AXES CONFIG window. 1. Confirm axis type of each axis in the AXES CONFIG window.
Page 453 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3.1.4 Mechanical Specification Setting The mechanical data is specified in the MECHANICAL SPEC window. 1. Confirm specification of each axis in the MECHANICAL SPEC window.
Page 454 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes – REDUCTION RATIO: Input the numerator and the denominator. If the reduction ratio is 1/120, the numerator should be set as 1.0 and the denominator should be set as 120.0.
Page 455 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 2. Select the desired item. – When a numerical value is selected, the number input buffer line appears. – When MOTOR (or SERVO AMP or CONVERTER) is selected, the list window of MOTOR (SERVO AMP, or CONVERTER) appears.
Page 456 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 4. Press [ENTER] in the MOTOR SPEC window. – After the setting, the current window moves to the window for the next axis setting. Complete the settings for all axes in the same manner.
Page 457 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3.2 Station Axis Setting 12.3.2.1 Selection of Station Axis Type Select the type of station axis to be added/modified. 1. Confirm the type of control group in CONTROL GROUP window.
Page 458 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 3. Select desired type in the type list. – After the type selection, the window returns to CONNECT window. – Select “UNIV” (universal) when using a mechanism other than the registered type (such as a servo track) as a station axis.
Page 459 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes – Specify which connector (CN) of the SERVO board each axis of each control group is connected to. The numbers in [ ] represent axis numbers, and indicate which axis is connected to which connector.
Page 460 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes – In this example, S1 (Station) is connected in the following manner: 1st axis  SERVO Board (SV #1), Connector (7CN), Contactor Unit (TU #1),...
Page 461 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3.2.3 Axis Configuration Setting The axis type and motor type are specified in the AXES CONFIG window. 1. Confirm axis type of each axis in the AXES CONFIG window.
Page 462 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 2. Select the axis type to be modified. – The settable axis type is displayed. 3. Select the desired axis type. 4. Press [ENTER] in the AXES CONFIG window –...
Page 463 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3.2.4 Mechanical Specification Setting The mechanical data is specified in the MECHANICAL SPEC window. 1. Confirm specification of each axis in the MECHANICAL SPEC window.
Page 464 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes • The MECHANICAL SPEC window (In case of the BALL-SCREW type) Selected group, type, axis no. and axis type are shown. – MOTION RANGE...
Page 465 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes • The MECHANICAL SPEC window (In case of the ROTATION type) Selected group, type, axis no. and axis type are shown. – MOTION RANGE: Input maximum moving position (positive (+) direction and negative (-) direction) from home position when setting the home position to 0.
Page 466 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes 12.3.2.5 Motor Specification Setting The motor data is specified in the MOTOR SPEC window. 1. Confirm specification of each axis in the MOTOR SPEC window.
Page 467 182582-1CD 12 Modification of System Configuration MH900, DX200 Controller 12.3 Addition of Base and Station Axes – During motion, the axis moves unsteady on advance direction.  Confirm the motion with increasing this ratio in each 100. – During pause, the motor makes a lot of noise.
Page 468 Before operating the manipulator, check that the SERVO ON lamp goes out when the emergency stop buttons on the right of the front door of the DX200 and the programming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.
Page 469 182582-1CD 13 DX200 Specification MH900, DX200 Controller • Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed. – Check for problems in manipulator movement.
Page 470 182582-1CD 13 DX200 Specification MH900, DX200 Controller 13.1 Specification List 13.1 Specification List Controller Dust/Splash-proof IP54 (The back fan is IP2X.) Construction 1935(W)  730(H) 520(D) mm Dimensions Cooling System Indirect cooling Power Supply 3-phase, 200V/220V AC (+10% to -15%) at 60Hz(2%)
Page 471 182582-1CD 13 DX200 Specification MH900, DX200 Controller 13.2 Function List 13.2 Function List Programming Coordinate Joint, Rectangular/Cylindrical, Tool, User System Coordinates Pendant Modification of Adding, Deleting, Correcting (Robot axes Operation Teaching Points and external axes respectively can be corrected.) Inching Operation...
Page 472 182582-1CD 13 DX200 Specification MH900, DX200 Controller 13.3 Programming Pendant Programing Programming Interactive programming Functions Language Robot language: INFORM II Robot Motion Joint coordinates, Linear/Circular Control interpolations, Tool coordinates Speed Setting Percentage for joint coordinates, 0.1mm/s units for interpolations, Angular velocity for T.C.P.
Page 473 13.4 Equipment Configuration 13.4 Equipment Configuration The DX200 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 DX200 equipment.
Page 474 182582-1CD 13 DX200 Specification MH900, DX200 Controller 13.4 Equipment Configuration Fig. 13-2: Inside Controller (Back and Doors) Backside Duct Fan Internal Circulation Fan Backside Resistor Fan 133614-4 133614-4 Capacitor Unit 165539-2 Regenerative Resistor 159422-1 Inside Controller (Doors) Inside Controller (Back) Fig.
Page 475 SERVOPACK. The fan mounted inside the door circulates the air to keep temperature even throughout the interior of the DX200. Make sure the door of the DX200 is closed when it’s used to keep this cooling system effective.
Page 476 Improper or unintentional manipulator operation can result in injury. • When turning ON the power to DX200, be sure that there is no one within the P-point maximum envelope of the manipulator, and that you are in a safe place.
Page 477 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller Perform the following inspection procedures prior to performing teaching operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed. – Check for problems in manipulator movement.
Page 478 Do not connect two signals to the same contact point. (Prepare two individual contact points) • Since the power supply for each signal is reversed, it will short- circuit and may cause breakdown of DX200 Unit if the signals are connected to the same contact point. DX200 Switch...
Page 479 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.1 Power ON Unit (JZRCR-YPU71- ) 14.1 Power ON Unit (JZRCR-YPU71- The power ON unit consists of the power ON control circuit board (JARCR-YPC21-1) and the main circuit contactor and the line filter. It turns...
Page 480 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.2 Axes Control Circuit Board 14.2 Axes Control Circuit Board 14.2.1 Major Axes Control Circuit Board (SRDA-EAXA21A) The major axes control circuit board controls the servomotors of the manipulator’s six axes. It also controls the converter and the PWM amplifiers.
Page 481 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.2 Axes Control Circuit Board 14.2.2 External Axes Control Circuit Board (SRDA-EAXB21A) An external axes control circuit board (SRDA-EAXB21A) is used to control the S, L, and U axes servomotors of the MH900 robot. It is mounted on the major axes control circuit board Fig.
Page 482 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.3 CPU Unit (JZNC-YRK21-1E) 14.3 CPU Unit (JZNC-YRK21-1E) 14.3.1 CPU Unit Configuration CPU unit consists of circuit board racks (flame, back circuit board, PCI riser circuit board), CPU circuit board, robot I/F circuit board and the machine safety CPU circuit board.
Page 483 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.3 CPU Unit (JZNC-YRK21-1E) 14.3.2 Unit and Circuit Board in the CPU Unit 14.3.2.1 CPU Circuit Board (JANCD-YCP21-E) This circuit board (JANCD-YCP21-E) performs to control the entire system, display to the programming pendant, control the operating keys, control operation and calculate interpolation.
Page 484 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.4 Control Power Supply Unit (JZNC-YPS21-E) 14.4 Control Power Supply Unit (JZNC-YPS21-E) This unit (JZNC-YPS21-E) supplies the DC power (DC5V, DC24V) for control (system, I/O, break). It is also equipped with the input function for turning the control power supply ON and OFF.
Page 485 Lights when FAN error occurs. Lights when unit interior overheats Control Power To turn ON the DX200 controller power, turn ON the non-fuse breaker of the controller so that the control power supply is turned ON. If the controller is not located ON/OFF at the workplace, the control power supply can be turned ON/OFF by an external device, etc.
Page 486 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.5 Machine Safety I/O Logic Circuit Board (JANCD-YSF22 -E) 14.5 Machine Safety I/O Logic Circuit Board (JANCD-YSF22 14.5.1 Machine Safety I/O Logic Circuit Board (JANCD-YSF22 This circuit board contains dual processing circuits for safety signal and the I/O circuit for the un-safety signal.
Page 487 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.5 Machine Safety I/O Logic Circuit Board (JANCD-YSF22 -E) 14.5.2 Connection for Tool Shock Sensor (SHOCK) 14.5.2.1 To Connect the Tool Shock Sensor Directly to the Tool Shock Sensor Signal Line 1.
Page 488 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.5 Machine Safety I/O Logic Circuit Board (JANCD-YSF22 -E) 14.5.2.2 To Connect the Tool Shock Sensor with the Cable that is Built into the Manipulator 1. Disconnect the minus SHOCK (-) and +24V2 pin terminal from the...
Page 489 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) The machine safety terminal block circuit board (JANCD-YFC22-E) is for the system external signal to connect with the safety I/O signals.
Page 490 Use to connect the servo ON switch of an external operation device. If the signal is input, the servo power supply is turned ON. SYSRUN+ SYSRUN signal Open SYSRUN- Use to determine the normal/abnormal condition of the DX200 controller by SYSRUN signal. 182582-1CD 14-15 490 of 552...
Page 491 Used to output a contact point of the emergency stop button on the programing pendant. PPESP4+ PPESP4- PBESP3+ Used to output a contact point of the emergency PBESP3- stop button on the front door of the DX200 Control panel. PBESP4+ PBESP4- 182582-1CD 14-16 491 of 552...
Page 492 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E)  Wiring Procedure of the Terminal Block For your safety, appropriate work must be done by following the instructions below. 1. Tool: Screwdriver –...
Page 493 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) below and push straight down. (2) Insert the wire into the connection hole slowly until its leading end touches the end of the hole.
Page 494 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.1 Safety Plug This signal is used to turn OFF the servo power if the door on the safeguarding is opened. Connect to the interlock signal from the safety plug on the safeguarding door.
Page 495 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E)  Installation of Safety Plug The manipulator must be surrounded by a safeguarding and a door protected by an interlock function. The door must be opened by the technician to enter and the interlock function stops the robot operation when the door is open.
Page 496 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.2 External Emergency Stop This signal is used to connect the emergency stop switch of an external device. If the signal is input, the servo power is turned OFF and the job is stopped.
Page 497 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.3 External Enable Switch This signal is used to connect Enable switch other than the one on the programming pendant when two people are teaching. In the condition of the external enable switch ON, when turn the enable switch ON/OFF by the programming pendant, the servo power is also turned ON/OFF.
Page 498 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.4 Full-speed Test This signal is used to reset the slow speed limit for the test run in the teach mode.
Page 499 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 2. The message “Full-speed test mode” is displayed as follows when the setting is finished. • Operation Speed When the full-speed test mode is set, operation speed is set depending on the setting of manual speed as follows.
Page 500 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.5 Slow Speed Mode Selection This signal is used to determine the speed of the test run when the FST (full-speed test) signal input circuit is open.
Page 501 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.6 External Hold This signal is used to connect the temporary stop switch of an external device. If the signal is input, the job is stopped. While the signal is input, starting and axis operations are disabled.
Page 502 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.7 External Servo ON This signal is used to connect the servo ON switch of an external operation device. If the signal is input, the servo power supply is turned Fig.
Page 503 MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.8 SYSRUN Signal Output This signal is used to check whether the DX200’s status is normal or abnormal. This signal is output on the following conditions. Primary power supply...
Page 504 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.9 Connection for Servo-ON Enable Input Connect the ONEN signal lines to enable the function to turn ON or OFF the servo power supply of an individual servo when a robotic system is divided into areas.
Page 505 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.10 External Axes Overrun With a unit of standard specifications without an external axis, the external axis overrun input signal is not used. In this case, a jumper cable is connected as shown in the following figure.
Page 506 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) The following figure shows the external axis overrun wiring of the factory default setting when the external axes are connected to the DX200. Please refer to the following figure to connect the external axes overrun signal to wire in the another route.
Page 507 Outputs the contact output terminals for both emergency stop buttons on the programming pendant and on the front door. These contact outputs are always valid regardless of the DX200 main power supply status ON or OFF. (Status output signal: normally closed contact) •...
Page 508 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.12 Universal Safety Input The universal safety input signal is used in the safety logic circuit function. Fig. 14-24: Universal Safety Input...
Page 509 It may cause the damage on the output circuit. • The feedback signal must be inputted to the DX200 when use the universal safety output signal. 182582-1CD 14-34...
Page 510 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.14 Connection for Direct-in  Direct-in (Servo) 1 to 6 This signal is used to input a responsive signal in search functions.
Page 511 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) 14.6.15 Universal Input (Servo) Connect when use the universal signal. Fig. 14-27: Universal Input (Servo) DX200 Machine safety terminal Major axes control...
Page 512 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.7 Universal I/O Circuit Board (JANCD-YIO21-E) 14.7 Universal I/O Circuit Board (JANCD-YIO21-E) 14.7.1 Universal I/O Circuit Board (JANCD-YIO21-E) Four digital I/O connectors for the robot universal I/O are provided: 40 inputs and 40 outputs.
Page 513 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.7 Universal I/O Circuit Board (JANCD-YIO21-E)  Connection wire with Robot Universal I/O Connector (CN306, 307, 308, 309) Please refer to the figure below when you manufacture the cable connecting with robot universal I/O connector (CN306, 307, 308, 309) of robot universal I/O circuit board (JANCD-YIO21-E).
Page 514 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.7 Universal I/O Circuit Board (JANCD-YIO21-E) When connecting an inductive load to the output circuit, connect a flyback (snubber) diode in parallel to the inductive load to suppress the surge voltage. Not using the flyback (snubber) diode may damage the output circuit.
Page 515 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.7 Universal I/O Circuit Board (JANCD-YIO21-E)  Specific I/O Signal Related to Start and Stop The following signals are specific I/O signals related to start and stop. • Servo ON (depending on application: JANCD-YIO21-E) •...
Page 516 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.7 Universal I/O Circuit Board (JANCD-YIO21-E)  Example of Servo ON Sequence Circuit from External Device Only the rising edge of the servo ON signal is valid. This signal turns ON the manipulator servo power supply.
Page 517 In case of using internal power supply In case of using external power supply (The factory default settings) • The internal power supply of 24V of about 1.5A of DX200 can be used for I/O. Use external 24V power supply for higher currents and to isolate the circuit inside and outside the DX200.
Page 518 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.8 Control Circuit Board (JANCD-YBK21-3E) 14.8 Control Circuit Board (JANCD-YBK21-3E) 14.8.1 Control Circuit Board (JANCD-YBK21-3E) The break control circuit board controls ON/OFF of the breaks of total nine axes (Robot + external axes) according to the command signal from the major axes control circuit board (SRDA-EAXA21A).
Page 519 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.9 Converter (SRDA-COA A21 -E) 14.9 Converter (SRDA-COA The converter (SRDA-COA -E) exchanges the power supply (3-phase: AC200/220V) supplied by the power ON unit for DC power supply and supplies the power to the amplifier module (PWM amplifiers).
Page 520 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.10Capacitor Module (SRDA-CUA AA) 14.10 Capacitor Module (SRDA-CUA The capacitor module smooth the DC voltage (PN voltage) created in the converter and also save the electric energy. There are two type of the capacitors shown below.
Page 521 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.11Amplifier Module (SRDA-SDA A01A-E) 14.11 Amplifier Module (SRDA-SDA A01A-E) The amplifier module exchanges the DC power supply supplied by a converter for a 3-phase motor power source and outputs to each servo motor.
Page 522 The “wiring tool for the WAGO connector” is necessary to wire the WAGO connector. The tools (total 3, 2 types) are supplied with the DX200. Use them with the appropriate sizes of connectors. The wiring procedure is described as follows: 1.
Page 523 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment 14.13 Universal I/O Signal Assignment 14.13.1 Arc Welding Fig. 14-38: JANCD-YIO21-E (CN308 (8TX) Connector) I/O Allocation and Connection Diagram (For Arc Welding) DX200 Universal I/O circuit board (JANCD-YIO21-E)
Page 524 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-39: JANCD-YIO21-E (CN309 (9TX) Connector) I/O Allocation and Connection Diagram (For Arc Welding) DX200 Connector Terminal Converter Universal I/O circuit board (JANCD-YIO21-E) (Optional) +24VU...
Page 525 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-40: JANCD-YIO21-E (CN306 (6TX) Connector) I/O Allocation and Connection Diagram (For Arc Welding) DX200 (JANCD-YIO21-E) Universal I/O circuit board Connector Terminal Converter (Optional) Model:...
Page 526 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-41: JANCD-YIO21-E (CN307 (7TX) Connector) I/O Allocation and Connection Diagram (For Arc Welding) DX200 (JANCD-YIO21-E) Universal I/O circuit board Connector Terminal Converter (Optional) TIFS553YS...
Page 527 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Table 14-2: Specific Input (Arc Welding) Logical Input Name / Function Number 20010 EXTERNAL START Functions the same as the [START] button in the programming pendant. Only the rising edge of the signal is valid.
Page 528 START command. This signal turns OFF when the servo power supply turns OFF. It can be used for DX200 status diagnosis for an external start. 30012 TOP OF MASTER JOB This signal signifies that the execution position is the top of the master job.
Page 529 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment 14.13.2 Handling Fig. 14-42: JANCD-YIO21-E (CN308 (8TX) Connector) I/O Allocation and Connection Diagram (For Handling) DX200 Connector Terminal Converter Universal I/O circuit board (JANCD-YIO21-E) (Optional)
Page 530 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-43: JANCD-YIO21-E (CN309 (9TX) Connector) I/O Allocation and Connection Diagram (For Handling) DX200 Universal I/O circuit board (JANCD-YIO21-E) Connector Terminal Converter (Optional) Model: TIFS553YS...
Page 531 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-44: JANCD-YIO21-E (CN306 (6TX) Connector) I/O Allocation and Connection Diagram (For Handling) DX200 Universal I/O circuit board (JANCD-YIO21-E) Connector Terminal Converter (Optional) TIFS553YS Model:...
Page 532 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-45: JANCD-YIO21-E (CN307 (7TX) Connector) I/O Allocation and Connection Diagram (For Handling) DX200 Connector Terminal Converter Universal I/O circuit board (JANCD-YIO21-E) (Optional) Model: TIFS553YS...
Page 533 20027 LOW AIR PRESSURE This signal is normally OFF (NO). When it turns ON, DX200 displays user alarm in the PLAY mode or displays user message in the teach mode. 20050 to SENSOR INPUT 1 - 8 20057 Inputs 1 to 8 are monitored with the HSEN handling specific instructions.
Page 534 START command. This signal turns OFF when the servo power supply turns OFF. It can be used for DX200 status diagnosis for an external start. 30012 TOP OF MASTER JOB This signal signifies that the execution position is the top of the master job.
Page 535 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment 14.13.3 General Application Fig. 14-46: JANCD-YIO21-E (CN308 (8TX) Connector) I/O Allocation and Connection Diagram (For General Application) DX200 Connector Terminal Converter Universal I/O circuit board...
Page 536 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-47: JANCD-YIO21-E (CN309 (9TX) Connector) I/O Allocation and Connection Diagram (For General Application) DX200 Universal I/O circuit board Connector Terminal Converter (JANCD-YIO21-E) (Optional) TIFS553YS...
Page 537 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-48: JANCD-YIO21-E (CN306 (6TX) Connector) I/O Allocation and Connection Diagram (General Application) DX200 Universal I/O circuit board (JANCD-YIO21-E) Connector Terminal Converter (Optional) Model: TIFS553YS...
Page 538 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-49: JANCD-YIO21-E (CN307 (7TX) Connector) I/O Allocation and Connection Diagram (For General Application) DX200 Universal I/O circuit board (JANCD-YIO21-E) Connector Terminal Converter (Optional) Model: TIFS553YS...
Page 539 (with servo power ON). During wait status, the manipulator operation restarts if this signal turns OFF. 20022 WORK PROHIBITED (Tool ON Prohibited) Even if TOOLON instruction is executed, DX200 doesn’t output to external while this signal is ON. 20024 INTERFERENCE 3 ENTRANCE PROHIBITED...
Page 540 START command. This signal turns OFF when the servo power supply turns OFF. It can be used for DX200 status diagnosis for an external start. 30012 TOP OF MASTER JOB This signal signifies that the execution position is the top of the master job.
Page 541 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment 14.13.4 Spot Welding Fig. 14-50: JANCD-YIO21-E (CN308 (8TX) Connector) I/O Allocation and Connection Diagram (For Spot Welding) DX200 Connector Terminal Converter Universal I/O circuit board...
Page 542 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-51: JANCD-YIO21-E (CN309 (9TX) Connector) I/O Allocation and Connection Diagram (For Spot Welding) DX200 Universal I/O circuit board (JANCD-YIO21-E) Connector Terminal Converter (Optional) TIFS553YS...
Page 543 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-52: JANCD-YIO21-E (CN306 (6TX) Connector) I/O Allocation and Connection Diagram (For Spot Welding) DX200 (JANCD-YIO21-E) Universal I/O circuit board Connector Terminal Converter (Optional) Model:...
Page 544 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Fig. 14-53: JANCD-YIO21-E (CN307 (7TX) Connector) I/O Allocation and Connection Diagram (For Spot Welding) DX200 Connector Terminal Converter Universal I/O circuit board (JANCD-YIO21-E) (Optional) TIFS553YS...
Page 545 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Table 14-8: Specific Input (Spot Welding) (Sheet 1 of 2) Logical Input Name / Function Number 20010 EXTERNAL START Functions the same as the [START] button in the programming pendant. Only the rising edge of the signal is valid.
Page 546 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Table 14-8: Specific Input (Spot Welding) (Sheet 2 of 2) Logical Input Name / Function Number 20052 TRANSTHERMO ERROR Error signal is sent from the transformer in the gun to the robot. This signal is ON normally (NC) and an alarm occurs when the signal is OFF.
Page 547 START command. This signal turns OFF when the servo power supply turns OFF. It can be used for DX200 status diagnosis for an external start. 30012 TOP OF MASTER JOB This signal signifies that the execution position is the top of the master job.
Page 548 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.13Universal I/O Signal Assignment Table 14-9: Specific Output (Spot Welding) (Sheet 2 of 2) Logical Output Name / Function Number 30052 to WELD CONDITION (Level signals) 30056 1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8) Sets the welding conditions for the Power Source.
Page 549 14.13.5.1 Arc Welding This circuit board is a welder I/F circuit board for the welding, and it is an optional for the DX200. It is necessary to use this circuit board when operating the instructions by the analog instruction to the welder.
Page 550 List of the Equipment Configuration by Model For the models which are not in Table 14-10 and Table 14-11, refer to “DX200 INSTRUCTIONS SUPPLEMENT FOR Controller Specification List. Table 14-10: DX200 Parts List for the MH900 Name Model Comment Amplifier Module...
Page 551 182582-1CD 14 Description of Units and Circuit Boards MH900, DX200 Controller 14.14List of the Equipment Configuration by Model Table 14-11: Amplifier Module List Component MH900 Amplifier AMP1 SRDA-SDA71A01A-E module AMP2 SRDA-SDA71A01A-E AMP3 SRDA-SDA71A01A-E AMP4 SRDA-SDA14A01A-E AMP5 SRDA-SDA14A01A-E AMP6 SRDA-SDA14A01A-E Middle...
Page 552 INSTRUCTIONS MANUAL HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802 YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Europe GmbH Robotics Divsion ) Yaskawastrasse 1, 85391 Allershausen, Germany...

YASKAWA DX200 Instructions Manual

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