YASKAWA Motoman DX200 Instructions Manual

YASKAWA Motoman DX200 is an industrial robot controller designed for high-speed and precise handling of FPDs (flat panel displays). It offers exceptional accuracy, repeatability, and path performance, making it ideal for applications such as LCD, OLED, and touch panel handling. With its advanced motion control algorithms and powerful servo drives, the DX200 ensures smooth and efficient operation, resulting in increased productivity and reduced cycle times.

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DX200 OPTIONS

INSTRUCTIONS

SUPPLEMENT FOR FPD HANDLING USE

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN INSTRUCTIONS

DX200 INSTRUCTIONS

DX200 OPERATOR’S MANUAL (for each purpose)

DX200 MAINTENANCE MANUAL

The DX200 Operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

Part Number: 174117-1CD

Revision: 0

MANUAL No.

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All rights reserved. This manual is freely available as a service to Yaskawa customers to assist in the operation of Motoman robots, related equipment and software This manual is copyrighted property of

Yaskawa and may not be sold or redistributed in any way. You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF files to another website, blog, cloud storage site or any other means of storing or distributing online content.

Printed in the United States of America

First Printing, 2016

Yaskawa America, Inc.

Motoman Robotics Division

100 Automation Way

Miamisburg, OH 45342

Phone: 937-847-6200 www.motoman.com

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MANDATORY

• This manual explains the controller of the DX200. Read this manual carefully and be sure to understand its contents before handling the DX200.

 General items related to safety are listed in the Chapter 1: Safety of the DX200 instructions. To ensure correct and safe operation, carefully read the DX200 instructions before reading this manual.

CAUTION

• Some drawings in this manual are shown with the protective covers or shields removed for clarity. Be sure all covers and shields are replaced before operating this product.

• The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product.

• YASKAWA may modify this model without notice when necessary due to product improvements, modifications, or changes in specifications. If such modification is made, the manual number will also be revised.

• If your copy of a manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product’s warranty. iii

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We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial

Robots and Robot Systems (ANSI/RIA R15.06-2012). You can obtain this document from the Robotic

Industries Association (RIA) at the following address:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: (734) 994-6088

FAX: (734) 994-3338 www.roboticsonline.com

Ultimately, well-trained personnel are the best safeguard against accidents and damage that can result from improper operation of the equipment. The customer is responsible for providing adequately trained personnel to operate, program, and maintain the equipment. NEVER ALLOW UNTRAINED

PERSONNEL TO OPERATE, PROGRAM, OR REPAIR THE EQUIPMENT!

We recommend approved Yaskawa training courses for all personnel involved with the operation, programming, or repair of the equipment.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. iv

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the DX200. In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”,

“MANDATORY”, or “PROHIBITED”

DANGER

WARNING

Indicates an imminent hazardous situation which, if not avoided, could result in death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to personnel and damage to equipment. It may also be used to alert against unsafe practices.

Always be sure to follow explicitly the items listed under this heading.

MANDATORY

PROHIBITED

Must never be performed.

Even items described as “CAUTION” may result in a serious accident in some situations.

At any rate, be sure to follow these important items

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “DANGER”, “WARNING” and “CAUTION”.

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WARNING

• Before operating the manipulator, check that servo power is turned OFF pressing the emergency stop buttons on the front door of the DX200 and the programming pendant.

When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the manipulator during an emergency. The manipulator should not be used if the emergency stop buttons do not function.

Fig.: Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator.

Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Fig.: Release of Emergency Stop Button

• Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:

- Be sure to use a lockout device for safeguarding when going inside. Also, display a sign that an operation is being performed inside the safeguarding and make sure no one closes the safeguarding.

- View the manipulator from the front whenever possible.

- Always follow the predetermined operating procedure.

- Keep in mind the emergency response measures against the manipulator’s unexpected motion toward you.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no person is present in the P-point maximum envelope of the manipulator and that you are in a safe location before:

- Turning ON the power for the DX200.

- Moving the manipulator with the programming pendant.

- Running the system in the check mode.

- Performing automatic operations.

Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there is a problem.

The emergency stop buttons are located on the right of front door of the DX200 and the programming pendant.

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CAUTION

• Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.

– Check for problems in manipulator movement.

– Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the cabinet of the DX200 after use.

The programming pendant can be damaged if it is left in the manipulator's work area, on the floor, or near fixtures.

• Read and understand the Explanation of Warning Labels in the DX200 Instructions before operating the manipulator:

Definitions of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables.

In this manual, the equipment is designated as follows

DX200 controller

DX200 programming pendant

Cable between the manipulator and the controller

DX200

Programming pendant

Manipulator cable

Registered Trademark

In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and TM are omitted.

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Customer Support Information

If you need assistance with any aspect of your system, please contact Motoman Customer Support at the following 24-hour telephone number:

(937)847-3200

For routine technical inquiries, you can also contact Motoman Customer Support at the following e-mail address: [email protected]

When using e-mail to contact Motoman Customer Support, please provide a detailed description of your issue, along with complete contact information. Please allow approximately 24 to 36 hours for a response to your inquiry.

Please use e-mail for routine inquiries only. If you have an urgent or emergency need for service, replacement parts, or information, you must contact Motoman Customer Support at the telephone number shown above.

Please have the following information ready before you call:

• System

DX200

• Primary Application

FPD Handling

• Controller

• Software Version

DX200

Access this information on the

Programming Pendant’s LCD display screen by selecting {MAIN

MENU} - {SYSTEM INFO} -

{VERSION}

• Robot Serial Number

• Robot Sales Order Number

Located on the robot data plate

Located on the DX200 controller data plate

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Table of Contents

3.1 Standard module ........................................................................................................................ 3-1

5 Dimension Diagram and Internal Arrangement Diagram .............................................................. 5-1

6 The List of the Equipment Configuration ...................................................................................... 6-1 ix

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Introduction

1 Introduction

This manual is a supplementary instruction manual for the DX200.

The described contents are as follows;

i ) Power Capacity

ii ) Basic Specifications iii ) Controller Type List iv ) Dimension Diagram and Internal Arrangement Diagram

v ) The List of the Equipment Configuration vi ) Recommended Spare Parts List

For contents that are not described in this manual, refer to the “DX200 INSTRUCTIONS”, “DX200

MAINTENANCE MANUAL”, and all other related documents.

Before using this product, read this manual and all other documents carefully to ensure knowledge about the product and safety, including all the cautions.

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2 Power Capacity

The power capacity of each model, and cable size of primary power supply cable are shown in Table

2-1: “Power capacity and Cable size”.

・ The power capacity shown in table 2-1 is subject to change depending on the work condition.

However, the maximum load value such as payload, operation speed, and frequency etc. are taken into account to the value.

・ When an external axis is added, the power capacity will also increase.

In that case, contact your YASKAWA representative, or check the rated value shown on the label on the DX200 for the power capacity.

・ When selecting a transformer, contact your YASKAWA representative .

The power capacity shown in table 2-1 is the continuous rating value.

When the robot is rapidly accelerated, the power capacity of several times the continuous rating value may be needed instantly.

Table 2-1: Power Capacity and Cable Size

Model Power capacity

[kVA]

1.5

Cable size

MFL15D-875

MFL15DW-875

3.5

（ M5 ）

MFL15DW-1400

MFL15D-1600

2.0 3.5

（ M5 ）

MFL1200D-1200 2.5 ）

（ Terminal size

[Cabtyre cable]mm 2

）

MFL1200D-1600 2.5 ）

MFL15DW-2400 3.0 ）

MFL1200D-2400 3.0 ）

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3 Basic Specifications

3.1

Standard Module

Table 3-1: Standard Module Basic Specifications

Item Specification

Dust/Splash-proof

Construction

IP54 （ *Back fan part is IP2X ）

Dimensions W800×H900×D550mm

Approx. Weight 200kg

Cooling System

Power Supply

Indirect cooling

Grounding

3-phase 200V/220V AC (+10 to -15%) at 60Hz (±2%)

200V AC (+10 to -15%) at 50Hz (±2%)

D class （ Grounding resistor ： 100 Ω or less ）

Noise Level

Ambient Temperature

Exclusive grounding

Less than 62dB

0 ℃ to +25 ℃ ： During operation

-10 ℃ to +60 ℃ ： During transit and storage

Relative Humidity

Vibration

Others

10% to 90%RH (non-condensing)

0.5G or less

・ Free from corrosive gas or liquid, or explosive gas or liquid

・ Free from exposure to water, oil or dust

・ Free from excessive electrical noise (plasma)

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4 Controller Type List

Table 4-1: Controller Type List

Controller Type

ERER-

Model Dimension

Diagram ,

Internal

Parts List Recommended

Spare Parts

List

Arrangement

Diagram

Table 6-1 Table 7-1 MFL015D-A00 MFL15D-875

MFL15DW-875

Figure 5-1/5-2

MFL015D-A01 MFL15D-1600 Figure 5-1/5-2

MFL15DW-1400

MFL015D-A02 MFL15DW-2400 Figure 5-1/5-2

Table 6-1

Table 6-2

Table 7-1

Table 7-2

MFL020D-A02

MFL1200D-1600

MFL1200D-2400 Figure 5-1/5-3 Table 6-3 Table 7-3

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5 Dimension Diagram and Internal Arrangement Diagram

5 Dimension Diagram and Internal

Arrangement Diagram

Figure.5-1: Dimension Diagram

Figure.5-2: Internal Arrangement Diagram

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5 Dimension Diagram and Internal Arrangement Diagram

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* Only one cable inlet (door side) at left side of the main unit is available because an external servopack is equipped.

Figure.5-3: Internal Arrangement Diagram

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6 The List of the Equipment Configuration

6 The List of the Equipment

Configuration

Table 6-1: List of the Equipment Configuration

Circuit breaker

Control power supply unit

CPU unit

CPU circuit board

NF32-SVF 3P 20A

JZNC-YPS21-E

JZNC-YRK21-1E

JANCD-YCP21-E board JANCD-YBB21-E

PCI riser circuit board JANCD-YBB22-E

Robot I/F circuit board JANCD-YIF01□ E

Machine safety CPU circuit board JANCD-YSF21-E

Machine safety I/O logic circuit board JANCD-YSF22 □ -E

Machine safety terminal block circuit board JANCD-YFC22-E

Universal I/O circuit board

Power ON unit

Converter

Capacitor module

Major axes control circuit board

Brake control circuit board

JANCD-YIO21-E

JZRCR-YPU51-1

SRDA-EAXA21A

JANCD-YBK21-3E

SRDA-COA30A21B-E

SRDA-CUA133AA

Amplifier module AMP1 - SRDA-SDA71A01A-E

AMP2 U SRDA-SDA71A01A-E

AMP3 - SRDA-SDA35A01A-E

AMP4 S

AMP5 L SRDA-SDA06A01A-E

AMP6 R SRDA-SDA06A01A-E

Regenerative resistor

Type

Rated value

SMVK500W2R0J

1500W(500W×3)

×3

Resistor 6 Ω (2 Ω ×3)

Circulation fan

Backside duct fan

4715MS-22T-B50-B00 ×2 or

11938MB-B2N-EA-01 ×2

4715MS-22T-B50-B00 ×3 or

11938MB-B2N-EA-01 ×3

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6 The List of the Equipment Configuration

Table 6-2: List of the Equipment Configuration

Circuit breaker

Control power supply unit

NF32-SVF 3P 20A

JZNC-YPS21-E

CPU unit

CPU circuit board board

JZNC-YRK21-1E

JANCD-YCP21-E

JANCD-YBB21-E

PCI riser circuit board JANCD-YBB22-E

Robot I/F circuit board

Machine safety CPU circuit board

JANCD-YIF01□ E

JANCD-YSF21-E

Machine safety I/O logic circuit board JANCD-YSF22 □ -E

Machine safety terminal block circuit board JANCD-YFC22-E

Universal I/O circuit board

Power ON unit

Major axes control circuit board

JANCD-YIO21-E

JZRCR-YPU51-1

JANCD-YBK21-3E

SRDA-EAXA21A

Brake control circuit board

Converter

Capacitor module

Amplifier module AMP1

SRDA-COA30A21B-E

SRDA-CUA133AA

- SRDA-SDA71A01A-E

AMP2 U

AMP3 - SRDA-SDA35A01A-E

AMP4 S SRDA-SDA14A01A-E

AMP5 L

AMP6 R SRDA-SDA14A01A-E

Regenerative resistor

Type

SMVK500W2R0J ×3

Rated value 1500W (500W×3)

Resistor 6 Ω (2 Ω ×3)

Circulation fan

Backside duct fan

4715MS-22T-B50-B00 ×2 or

11938MB-B2N-EA-01 ×2

4715MS-22T-B50-B00 ×3 or

11938MB-B2N-EA-01 ×3

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6 The List of the Equipment Configuration

Table 6-3: List of the Equipment Configuration

Circuit breaker

Control power supply unit

NF32-SVF 3P 20A

JZNC-YPS21-E

CPU unit

CPU circuit board board

JZNC-YRK21-1E

JANCD-YCP21-E

JANCD-YBB21-E

PCI riser circuit board JANCD-YBB22-E

Robot I/F circuit board

Machine safety CPU circuit board

JANCD-YIF01□ E

JANCD-YSF21-E

Machine safety I/O logic circuit board JANCD-YSF22 □ -E

Machine safety terminal block circuit board JANCD-YFC22-E

Universal I/O circuit board

Power ON unit

JANCD-YIO21-E

JZRCR-YPU51-1

Major axes control circuit board SRDA-EAXA21A

External axes control circuit board SRDA-EAXB21A

Brake control circuit board

Converter

Capacitor module

Amplifier module AMP1

JANCD-YBK21-3E

SRDA-COA30A21B-E

SRDA-CUA133AA

- SRDA-SDA71A01A-E

AMP2 - SRDA-SDA71A01A-E

AMP3 -

AMP4 S SRDA-SDA14A01A-E

AMP5 L SRDA-SDA14A01A-E

AMP6 R

External axes servopack

Regenerative resistor

(For converter)

Type

Rated value

U SRDA-SDB95A01A-E

SMVK500W2R0J

1500W (500W×3)

×3

Resistor 6 Ω (2 Ω ×3)

Regenerative resistor

(For external axis servopack)

Type

Rated value

Resistor value

SMVK500W2R0J

1500W (500W×3)

6 Ω (2 Ω

×3

×3)

Circulation fan

Backside duct fan

4715MS-22T-B50-B00 ×2 or

11938MB-B2N-EA-01 ×2

4715MS-22T-B50-B00 ×4 or

11938MB-B2N-EA-01 ×4

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7 Recommended Spare Parts List

The recommended parts and components for DX200 are ranked as follows.

It is recommended that the following parts and components be kept in stock as spare parts for DX200.

• Rank A: Expendable and frequently replaced parts

• Rank B: Boards and sub-units

• Rank C: Units

When purchasing of spare parts, please inform YASKAWA representative of the manufacturing number (or order number) and controller type (refer to chapter 4 “Controller Type List” –Table 4-1

“Controller Type List”).

Product performance cannot be guaranteed when using spare parts from any company other than

YASKAWA.

For replacing parts in Rank A, refer to the “DX200 MAINTENANCE MANUAL”.

For replacing parts in Rank B or Rank C, be sure to contact your YASKAWA representative.

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7 Recommended Spare Parts List

Table 7-1: Recommended Spare Parts List

Rank Parts

No.

Name Type Manufacturer

TOSHIBA

BATTERY CO.,LTD

Qty Qty per unit

Remarks

1 1 A 1 Battery

A 2

Control Power Supply

Cooling Fan

4715MS-22T-B50-B00 or 11938MB-B2N-EA-01

Minebea Co., Ltd 5 5

A 4

AC Control Power

Supply Fuse

Daito

Communication

Apparatus Co., Ltd

2 2 A 5 AC Cooling Fan Fuse GP25 2.5A, 250V

A 6

24VDC Fuse for I/O

Brake Power Supply

Fuse

A 7

PG Power Supply

Fuse

02173.15P 3.15A,

250V

HM10 1A, 250V

A 8 24VDC Fuse for I/O 0217002P 2A, 250V

Daito

Communication

Apparatus Co., Ltd

Littelfuse

1 1

B 9 AMP1,2 YASKAWA 2

B 10 AMP3

B 11 AMP4,5,6

B 12

Major Axes Control

Circuit Board

B 13 CPU Circuit Board

B 14

Robot I/F Circuit

Board

B 15

Machine safety CPU

Circuit Board

B 16

Machine safety I/O

Logic Circuit Board

B 17

Universal I/O Circuit

Board

B 18

Brake control Circuit

Board

C 19 Converter

SRDA-EAXA21A YASKAWA 1

JANCD-YCP21-E YASKAWA

JANCD-YIF01 E YASKAWA

1 1

JANCD-YSF21-E YASKAWA 1

JANCD-YSF22  -E YASKAWA 1 1

JANCD-YIO21-E YASKAWA 1

JANCD-YBK21-3E YASKAWA 1 1

C 21 Power ON Unit

JZNC-YRK21-1E YASKAWA

JZRCR-YPU51-1 YASKAWA

YASKAWA

1 1 Standard

1 1

C 24

Programming

Pendant

JZRCR-YPP26-1 YASKAWA 1

With

Cable(8M)

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7 Recommended Spare Parts List

Table 7-2: Recommended Spare Parts List

Rank Parts

No.

A 1 Battery

TOSHIBA

BATTERY CO.,LTD

Qty per

Remarks unit

1 1

A 2

Control Power Supply

Cooling Fan

4715MS-22T-B50-B00 or 11938MB-B2N-EA-01

Minebea Co., Ltd 5 5

A 4

A 5

AC Control Power

Supply Fuse

AC Cooling Fan Fuse

A 6

24VDC Fuse for I/O

Brake Power Supply

Fuse

A 7

PG Power Supply

Fuse

0215010MXP Littelfuse 2

GP25 2.5A, 250V

02173.15P 3.15A,

250V

HM10 1A, 250V

Daito Communication

Apparatus Co., Ltd

Daito Communication

Apparatus Co., Ltd

2 2

1 1

A 8 24VDC Fuse for I/O 0217002P 2A, 250V Littelfuse 1 1

B 9 AMP1,2 2 2

B 10 AMP3

B 11 AMP4,5,6

C 19 Converter

CPU Circuit Board

Power ON Unit

1 1

3 3

SRDA-EAXA21A YASKAWA 1

JANCD-YCP21-E YASKAWA

JANCD-YIF01 E YASKAWA

1 1

JANCD-YSF21-E YASKAWA

JANCD-YSF22  -E YASKAWA

JANCD-YBK21-3E YASKAWA

1 1

JANCD-YIO21-E YASKAWA 1

1 1

JZNC-YRK21-1E YASKAWA

JZRCR-YPU51-1 YASKAWA

YASKAWA

1 1

1 1 Standard

1 1

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7 Recommended Spare Parts List

Table 7-3: Recommended Spare Parts List

Rank Parts

No.

A 1 Battery

A 2

Control Power Supply

Cooling Fan

TOSHIBA

BATTERY CO.,LTD

Qty per

Remarks unit

1 1

JZNC-YZU21-E YASKAWA 1

4715MS-22T-B50-B00 or 11938MB-B2N-EA-01

Minebea Co., Ltd 6 6

A 4

AC Control Power

Supply Fuse

0215010MXP Littelfuse 2

Daito Communication

Apparatus Co., Ltd

2 2 A 5 AC Cooling Fan Fuse GP25 2.5A, 250V

A 6

24VDC Fuse for I/O

Brake Power Supply

Fuse

A 7

PG Power Supply

Fuse

02173.15P 3.15A,

250V

HM10 1A, 250V

Daito Communication

Apparatus Co., Ltd

1 1

A 8 24VDC Fuse for I/O 0217002P 2A, 250V Littelfuse 1 1

B 9 AMP1,2 2 2

B 10 AMP3

B 11 AMP4,5,6

C 21 Converter

CPU Circuit Board

Power ON Unit

1 1

3 3

SRDA-EAXA21A YASKAWA 1

SRDA-EAXB21A YASKAWA 1

SRDA-SDB95A01A-E YASKAWA 1 1

1 1 JANCD-YCP21-E YASKAWA

JANCD-YIF01 E YASKAWA

JANCD-YSF21-E YASKAWA

JANCD-YSF22  -E YASKAWA 1 1

JANCD-YIO21-E YASKAWA 1

JANCD-YBK21-3E YASKAWA 1 1

1 1

JZNC-YRK21-1E YASKAWA

JZRCR-YPU51-1 YASKAWA

YASKAWA

1 1

1 1 Standard

1 1

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DX200 OPTIONS

INSTRUCTIONS

SUPPLEMENT FOR FPD HANDLING USE

Specifications are subject to change without notice for ongoing modifications and improvements.

MANUAL No.

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