Yaskawa Motoman DX100 Owner's Manual

DX100
INSTALLATION & WIRING
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number:
Revision:
165478-1CD
0
MANUAL NO. E1102000035GB 3
DX100-Controller
Installation and Wiring
Please read these instructions before operation and keep them for later
reference.
The operating instructions are only for internal use.
E1102000035GB03
DX100-Controller
Reference list:
List of modifications
Documentnumber
E1102000115DE01
E1102000035GB02
Creation of
original
document
Modification in the original document
In section
X
translate from
original
on Page
Date
Author
14.12.2009
WOE
28.05.2010
Rebec
E1102000035GB03
E1102000035GB03
2
DX100-Controller
Table of contents
1
General ........................................................................................................... 5
1.1
1.2
About this manual ....................................................................................................... 5
Intended use ............................................................................................................... 5
2
Safety.............................................................................................................. 6
2.1
2.2
2.3
2.4
2.5
For Your Safety........................................................................................................... 6
Special Training .......................................................................................................... 7
YASKAWA Manual List............................................................................................... 7
Personnel Safety ........................................................................................................ 8
YASKAWA Safety..................................................................................................... 10
2.5.1
2.5.2
2.5.3
2.6
2.7
Notes for Moving and Transferring the YASKAWA ..................................................19
Notes on YASKAWA Disposal..................................................................................20
3
Product Confirmation ................................................................................. 21
3.1
3.2
Contents Confirmation ..............................................................................................21
Order Number Confirmation .....................................................................................22
4
Installation ................................................................................................... 23
4.1
Handling Procedure .................................................................................................. 23
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
Using a Crane to Move the Controller ................................................................................... 23
Using a Forklift to Move the Controller .................................................................................. 24
Using a hand forklift to move the controller ........................................................................... 24
External axis cabinet ............................................................................................................. 25
Connecting two cabinets ....................................................................................................... 26
4.2
4.3
4.4
4.5
Location of Installation ..............................................................................................26
Location ....................................................................................................................27
Mounting the Controller ............................................................................................27
Opening the cabinet door ......................................................................................... 28
5
Controller specifications ............................................................................ 29
5.1
5.2
5.3
5.4
IP classification .........................................................................................................29
Internal wiring ........................................................................................................... 29
Noise level ................................................................................................................ 30
Technical specifications............................................................................................30
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.5
5.5.1
5.5.2
5.5.3
5.5.4
6
Control cabinet ...................................................................................................................... 30
Maintenance .......................................................................................................................... 31
Safety features ...................................................................................................................... 31
Programming ......................................................................................................................... 32
Programmin pendant ............................................................................................................. 33
Safety features..........................................................................................................34
External safety....................................................................................................................... 34
Emergency stop function ....................................................................................................... 34
Internal safety circuits............................................................................................................ 35
Combinations of safety functions related to speed................................................................ 37
Connection to safety circuit ....................................................................... 39
6.1
6.1.1
6.2
6.2.1
6.2.2
6.2.3
3
Installation and Wiring Safety ................................................................................................ 10
Work Area Safety .................................................................................................................. 15
Operation Safety.................................................................................................................... 16
Standard configuration..............................................................................................39
Safety circuit terminal ............................................................................................................ 39
Connect to basic safety ............................................................................................41
External emergency stop (EXESP) ....................................................................................... 41
External servo power ON (EXSVON) .................................................................................... 41
External hold (EXHOLD) ....................................................................................................... 42
E1102000035GB03
DX100-Controller
Table of contents
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.2.9
6.2.10
6.2.11
External safety circuit (SAF_F) .............................................................................................. 42
Full speed test (FST) ............................................................................................................. 43
Safety speed (SSP) ............................................................................................................... 43
Servo ON enable input (ON_EN)........................................................................................... 44
External axis overrun (EXOT) ................................................................................................ 44
Emergency stop button output ............................................................................................... 45
Enabeling device ................................................................................................................... 45
Shock sensor (SHOCK) ......................................................................................................... 46
7
Inspections .................................................................................................. 47
7.1
7.2
Regular Inspections.................................................................................................. 47
DX100 Inspections ................................................................................................... 48
7.2.1
7.2.2
Checking if the Doors are Firmly Closed ............................................................................... 48
Checking for Gaps or Damage in the Sealed Construction Section ...................................... 48
7.3
7.4
7.5
7.6
7.7
7.8
Cooling Fan Inspections ........................................................................................... 49
Emergency Stop Button Inspections ........................................................................ 50
Enable Switch Inspections ....................................................................................... 50
Battery Inspections ................................................................................................... 51
Power Supply Voltage Confirmation......................................................................... 52
Open Phase Check .................................................................................................. 53
8
Description of Units and Circuit Boards ................................................... 54
8.1
8.2
Power Supply Contactor Unit ................................................................................... 57
Major Axes Control Circuit Board (SRDA-EAXA01) ................................................. 58
8.2.1
8.2.2
8.2.3
8.3
8.3.1
8.3.2
8.4
8.5
8.5.1
8.6
8.6.1
8.7
8.7.1
8.7.2
8.7.3
8.8
8.9
8.10
8.10.1
8.10.2
8.11
8.11.1
8.11.2
8.11.3
8.11.4
8.11.5
Major Axes Control Circuit Board (SRDA-EAXA01) .............................................................. 58
Connection for Tool Shock Sensor (SHOCK) ........................................................................ 60
Connection for Direct-in ......................................................................................................... 62
CPU Unit .................................................................................................................. 63
CPU Unit Configuration ......................................................................................................... 63
Unit and Circuit Board in the CPU Unit .................................................................................. 64
CPS Unit (JZNC-YPS01-E) ...................................................................................... 65
Brake Control Board (JANCD-YBK01-E) ................................................................. 67
Brake Control Board (JANCD-YBK01-E) ............................................................................... 67
Robot I/O Unit (JZNC-YIU02-E) ............................................................................... 68
Robot I/O Unit (JZNC-YIU02-E)............................................................................................. 68
Machine Safety Unit (JZNC-YSU01-1E) .................................................................. 76
Machine Safety Unit (JZNC-YSU01-1E) ................................................................................ 76
Connection for Servo-ON Enable Input (ONEN1 and ONEN2) ............................................. 78
Connection for External Axis Overrun (EXOT) ...................................................................... 78
WAGO Connector .................................................................................................... 81
Contact Output of Emergency Stop Button .............................................................. 92
SERVOPACK ........................................................................................................... 93
Description of Each Unit ....................................................................................................... 94
SERVOPACK Configuration .................................................................................................. 94
Universal I/O Signal Assignment ............................................................................ 107
Arc Welding ......................................................................................................................... 107
Handling............................................................................................................................... 115
General Application ............................................................................................................. 122
Spot Welding ....................................................................................................................... 129
JANCD-YEW01 Circuit Board (Standard)............................................................................ 137
E1102000035GB03
4
DX100-Controller
1
General
1.1
About this manual
This manual covers the installation and system specification for the YASKAWA DX100 robot
controller
The manual explains the various components of the YASKAWA DX100 system and general
operations. Read this manual carefully and be sure tto understand its contents before
handling the YASKAWA DX100 controller
Information!

For programming and operation information refer to the DX100 Operator‘s manual.
Reference: E1102XXXXXXGBXX

For system setup information, refer to the DX100 System setup manual.
Reference: E1102XXXXXXGBXX

For Robot insatallation:
Reference: YASKAWA Instruction manual for the specific robot type.
Information!
1.2

This manual may not be copied without our written permission and the contents there of
must not be imparted to a third party nor be used for many unauthorized purpose.

Some drawings in this manual are show 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 diferences
may exist between them and the delivered product.
Intended use
YASKAWA DX100 robot controller is intended to control one or multiple YASKAWA robots.
The controller have possibillity to connect multiple additional external axis for a variety of different application types.
5
E1102000035GB03
DX100-Controller
2
Safety
2.1
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.
Read and understand the instruction manuals and related documents, and observe all precautions in order to avoid the risk of injury to personnel and damage to equipment.
It is the user’s responsibility to ensure that all local, state, and national codes, regulations,
rules, or laws relating to safety and safe operating conditions are met and followed.
MANDATORY
● Teaching maintenance of the robot must conform to:
- Industrial Safety and Health Law
- Enforcement Order of Industrial Safety and Health Law
- Ordinance of Industrial Safety and Health Law
Other related laws are:
- Occupational Safety and Health Act in USA
- EC Machinery Directive 2006/42/EC
● Prepare:
- SAFETY WORK REGULATIONS
based on concrete policies for safety management complying with
related laws.
● Observe the
- Robotic and robotic devices - Safety requirements (ISO10218)
for safe operation of the Industrial robot.
● Reinforce the
- SAFETY MANAGEMENT SYSTEM
by designating authorized workers and safety managers, as well as
giving continuing safety education.
● Teaching and maintaining the robot are specified as
"Hazardous Operations" in the Industrial Safety and Health Law
Workers employed in these above operations are requested to attend
special training offered by YASKAWA.
E1102000035GB03
6
DX100-Controller
2.2
Special Training
MANDATORY
● Persons who teach or inspect the manipulator must undergo required training before using the manipulator.
● For more information on training, inquire at the nearest YASKAWA
branch office.
The telephone numbers are listed on the back cover of this manual.
2.3
YASKAWA Manual List
MANDATORY
● It is important to have and be familiar with all manuals concerning
the YASKAWA.
You should have the YASKAWA robot four manuals listed below:
- For programming and operation information refer to the
DX100 Operator‘s manual.
Reference: E1102000066GB01 and higher
- For system setup information, refer to the
DX100 System setup manual.
Reference: E1102000125GB01 and higher
- For Robot insatallation:
Reference: YASKAWA Instruction manual
for the specific robot type.
Confirm that you have all these manuals on hand.
If any manuals are missing, contact your salesman from YASKAWA
local branch office.
The relevant telephone numbers are listed on the back cover.
7
E1102000035GB03
DX100-Controller
2.4
Personnel Safety
The entire manipulator P-point maximum envelope is potentially dangerous.
All personnel working with the YASKAWA Robot (safety administration, installation, operation,
and maintenance personnel) must always be prepared and "Safety First" minded, to ensure
the safety of all personnel.
CAUTION
● Avoid any dangerous actions in the area where the YASKAWA Robot is installed.
There is a danger of injury if there is contact with the robot or peripheral equipment.
● Please take strict safety precautions by placing signs such as
"Flammable", "High Voltage", "Waiting", and "Off-limits to Unauthorized Personnel" in necessary areas in the factory.
Failure to observe these cautions may result in fire, electric shock, or
injury due to contact with the robot and other equipment.
● Strictly observe the following items:
- Always wear approved work clothes (no loose-fitting clothes).
- Do not wear gloves when operating the YASKAWA Robot.
- Personal Protective Equipment (PPE) is controlled by
directive 89/656/EEC, called PPE-directive that is the
European law.
- Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety
shoes (with slip-proof soles), face shields, safety glasses, and gloves
as necessary.
Improper clothing may result in injury.
● Unauthorized persons should not approach the Robot or associated
peripheral equipment.
Failure to observe this caution may result in injury due to contact with
DX100 controller, the workpiece, the positioner, etc.
E1102000035GB03
8
DX100-Controller
CAUTION
● Never forcibly move the robot axes.
Failure to observe this caution may result in injury or equipment damage.
● Never lean on DX100 controller or other controllers, and avoid inadvertently pushing buttons.
Failure to observe this caution may result in injury or damage by unexpected movement of the robot.
● Never allow unauthorized personnel to touch the DX100 controller
during operation.
Failure to observe this caution may result in injury or damage resulting from unexpected movement of the robot.
9
E1102000035GB03
DX100-Controller
2.5
YASKAWA Safety
2.5.1
Installation and Wiring Safety
Refer to the YASKAWA- Instructions manual and DX100 controller Instructions for details on installation and wiring.
In planning installation, adapt an easy to observe arrangement to ensure safety. Take safety
into consideration when planning the installation. Observe the following when installing the
robot:
WARNING
● Select an area such as that described below to install the manipulator: Confirm that the area is large enough so that the fully extended
manipulator arm with tool will not reach a side wall, safeguarding, or
the controller.
Failure to observe this caution may result in injury or damage resulting from unexpected movement of the manipulator.
Safeguarding
500 mm or more
DX100 controller
Door
500 mm or more
1000 mm or more
P-point maximum envelope of robot
Maximum working envelope of robot
including tool or workpiece end
500 mm or more
● Perform grounding in accordance with all applicable electrical
codes.
Failure to observe this caution may result in fire or electric shock.
Equipotential bonding shall be performe up to IEC 60204-1:2005
(EN60204-1:2006)
E1102000035GB03
10
DX100-Controller
CAUTION
● Operation of the crane, sling, or forklift should only be performed by
authorized personnel.
Failure to observe this precaution may result in injury or equipment
damage.
YASKAWA should be lifted with a crane using wire rope threaded
through the shipping bolts and positioners and the body should be lifted
in an upright posture as described in the robot instruction manual.
Failure to observe these precautions may cause the robot to turn
downward, potentially causing injury or damage to equipment.
11
E1102000035GB03
DX100-Controller
CAUTION
● When lifting the DX100 controller, please check the following:
- As a rule, handling of DX100 controller must be performed using a
crane with wire rope threaded through attached eyebolts.
- Be sure to use wire that is strong enough to handle the weight of
the DX100 controller.
Wire rope
M16 Eye bolt
APPROX. WEIGHT OF DX100
CONTROLLER
Models Available for
DX100
small models:
MA1400, MA1900,
VA1400, MH5, MH5L,
MH6, HP20D, HP20D-6
Approx.
Weight (kg)
250
middle/large models:
MH50,MS80,ES165D,
ES200D,VS50, SIA50D
● Be sure the eyebolts are securely fastened.
Failure to observe this caution may result in injury or damage to
equipment.
E1102000035GB03
12
DX100-Controller
CAUTION
● If storing the robot temporarily before installation, be sure to place it
on a stable and flat surface and take precautions to prevent unauthorized personnel from touching it.
Failure to observe this precaution may result in injury of damage to
equipment.
CAUTION
● Be sure there is sufficient room for maintenance on the robot,
DX100 controller, and other peripheral equipment.
1000 mm
or more
Failure to observe this precaution could result in injury during maintenance.
Door
DX100 Maintenance Area (Unit: mm)
DX100 External Dimensions (Unit: mm)
● To ensure safety, be sure to operate the controller from a location
where the robot is easily visible.
Operation by unauthorized personnel may result in injury or equipment damage.
● Install the DX100 controller outside the safeguarding of the manipulator’s safety enclosure.
Failure to observe this precaution may result in injury or damage to
equipment resulting from contact with the robot.
● Install the robot using bolts of the size and type specified for each
YASKAWA in the YASKAWA INSTRUCTION MANUAL.
Failure to observe this caution may result in injury or damage to
equipment.
13
E1102000035GB03
DX100-Controller
CAUTION
● Secure the position of the DX100 controller after setting up.
Attach the DX100 controller to the floor or rack, etc., using the screw
holes on the bottom of the DX100 controller.
12 dia.
(2 holes)
(Unit: mm)
Tapped Holes for
M10 Screws on
the DX100 controller Side
Failure to observe this caution could lead to injury or equipment damage if the DX100 controller should shift or fall.
● Be familiar with the connection diagram before wiring the DX100
controller, and perform the wiring in accordance with the connection
diagram.
There is a danger of equipment damage or injury due to miswiring
and unexpected movement of the equipment.
E1102000035GB03
14
DX100-Controller
CAUTION
● Take precautions when wiring and piping between the DX100 controller, robot, and peripheral equipment. Run the piping, wiring, or
cables through a pit or use a protective cover, so that they are not
stepped on by personnel or run over by a forklift.
Lead
Piping
Cable channel
Operators and other personnel may stumble on exposed wiring or piping. Cable damage can cause unexpected manipulator motion resulting in injury or property damage.
2.5.2
Work Area Safety
Carelessness contributes to serious accidents in the work area.
To ensure safety, enforce the following precautions:
CAUTION
● Install a safeguarding around the manipulator to prevent any accidental contact with the robot while the power is ON.
Post a warning sign stating "Off-limits During Operation" at the
entrance of the enclosure. The gate of the safeguarding must be
equipped with a safety interlock. Be sure the interlock operates correctly before use.
Failure to observe this caution may result in a serious accident due to
contact with the robot.
15
E1102000035GB03
DX100-Controller
CAUTION
● Store tools and similar equipment in proper locations outside of the
enclosure.
Tools and loose equipment should not be left on the floor around the
manipulator, DX100 controller, or welding fixture, etc., as injury or damage to equipment can occur if the robot comes in contact with objects or equipment left in the work area.
2.5.3
Operation Safety
WARNING
● When attaching a tool such as the welding torch to the robot, be
sure to turn OFF the power supply of the DX100 controller and the
tool, lock the switch, and display a warning sign (reference to EN
60204-1).
OFF
ENERGIZING
PROHIBITED
PADLOCK
Turning the power ON during tool installation may case electric shock
or injury due to unexpected movement of the robot.
● Never exceed the rated capacity of the robot (capacity can be found
in the specifications section of the robot manual.)
Failure to observe this caution may result in injury or damage to
equipment.
E1102000035GB03
16
DX100-Controller
WARNING
● Teach jobs from outside the robot’s maximum workspace whenever
possible.
● Observe the following precautions when performing teaching operations within the P-point maximum envelope of the robot:
- Always view the robot from the front.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the
manipulator comes toward you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional robot operation can result in
injury.
WARNING
● Before operating the robot, check that the SERVO ON lamp on the
programming pendant goes out when the emergency stop buttons
on the right of the programming pendant and on an external control
device, etc. are pressed. And confirm that the servo lamp is turned
OFF.
Injury or damage to machinery may result if the robot cannot be stopped in case of an emergency.
17
E1102000035GB03
DX100-Controller
WARNING
● Prior to performing the following operations, be sure that no one is in
the restricted space up to EN ISO 10218-2 envelope of the robot
when:
- Turning ON the DX100 controller power.
- Moving the robot with the programming pendant.
- Running the system in the check mode.
- Performing automatic operations.
Injury may result from contact with the robot if persons enter the restricted space envelope of the robot.
Press the emergency stop button immediately if there are problems.
The emergency stop button is located on the right of the programming pendant.
Emergency Stop Button
Programming Pendant
E1102000035GB03
18
DX100-Controller
CAUTION
● Perform the following inspection procedures prior to teaching the robot. If problems are found, correct them immediately, and be sure
that all other necessary tasks have been performed.
- Check for problems in robot movement.
- Check for damage to the insulation and sheathing of external
wires.
● Always return the programming pendant to its hook on the DX100
controller cabinet after use.
If the programming pendant is inadvertently left on the robot, a fixture,
or on the floor, the robot or a tool could collide with it during robot movement, possibly causing injury or equipment damage.
MANDATORY
•
Persons operating or inspecting the robot should be trained as
required by applicable laws and company policies.
– Refer to chapter 2.2 Special Training
2.6
Notes for Moving and Transferring the YASKAWA
When moving or transferring the YASKAWA, observe the following safety precautions:
CAUTION
● Attach the instructions to the controller cabinet so that all users have
access to necessary manuals. See chapter 2.3 YASKAWA Manual
List for a complete list of manuals.
If any manuals are missing, contact your YASKAWA representative.
● If the warning labels on the robot and DX100 controller are illegible,
clean the labels so that they can be read clearly. Note that some local laws may prohibit equipment operation if safety labels are not in
place.
Contact your YASKAWA representative if you require new warning
labels.
19
E1102000035GB03
DX100-Controller
CAUTION
● When the YASKAWA is transferred, it is recommended to check with
YASKAWA which is listed on back cover of this manual.
Incorrect installation or wiring may result in personal injury and property damage.
2.7
Notes on YASKAWA Disposal
PROHIBITED
● Never modify the robot or DX100 controller.
Failure to observe this precaution could result in injury or damage resulting from fire, power failure, or operation error.
CAUTION
● When disposing of the robot, follow „directives“ new part after the
world applicable EC-directive, national/local laws and regulations.
● Anchor the robot well, even when temporarily storing it before disposal.
Failure to observe this precaution may result in injury due to the robot
falling down.
E1102000035GB03
20
DX100-Controller
3
Product Confirmation
3.1
Contents Confirmation
Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following five items (Information for the content of optional
goods is given separately):

Robot

DX100 controller

Programming Pendant

Robot Cable (Between Manipulator and DX100)

Complete Set of Manuals
Robot
Programming Pendant
DX100 controller
Complete Set of Manuals
21
2 Robot Cables and
Equipotential boning cable
E1102000035GB03
DX100-Controller
3.2
Order Number Confirmation
Confirm that the order number pasted on the manipulator and DX100 controller match.
The order number plates are affixed as shown in the figure below.
<Example>
The robot and the DX100 controller
should have same order number.
Order NO.: S78796-1
E1102000035GB03
22
DX100-Controller
4
Installation
4.1
Handling Procedure
CAUTION
● Avoid jarring, dropping, or hitting the controller during handling.
Excessive vibration or impacting the DX100 controller may adversely
affect the performance of the DX100 controller.
4.1.1
Using a Crane to Move the Controller
Check the following before handling the DX100 controller:
23

Confirm the weight of the controller before handling, and use a wire rope with a rating
that is greater than the weight of the controller.

Install eyebolts for handling and confirm they are securely fastened before hoisting.
Controller
Approx.
weight
(KG)
DX100 cabinet
250 KG
E1102000035GB03
DX100-Controller
4.1.2
Using a Forklift to Move the Controller
Observe the following precautions when using a forklift to handle the controller:

Secure the controller so it cannot shift or fall during handling.

Transport the controller at the lowest possible height.

Avoid jarring, dropping, or hitting the controller during handling.

When carrying the controller, operate the forklift at a safe speed.
Protective padding
Tiedown straps
Palette
Forklift
4.1.3
Using a hand forklift to move the controller
By removing the lower front cover you will access to a tunnel under the cabinet. Normally this
tunnel is for hiding cables but can also be used for lifting the cabinet.
1.) Remove the lower front cover by grabbing it at left and right side.
2.) Pull it straight out.
E1102000035GB03
24
DX100-Controller
4.1.4
External axis cabinet
External axis cabinet may be mounted to the base cabinet in anumber of ways.
When mounting side by side, the cabinets are connected by four M12 bolts, wich is not
enough to withstand the lifting forces.
When top-mounting, the cabinets are tigthened by four M10 bolts.
When the cabinets are mounted side by side, they need to
be separated before lifting
25
E1102000035GB03
DX100-Controller
4.1.5
Connecting two cabinets
4x M10 x 35
4x M12 x 20
4.2
4x M12
Location of Installation
The conditions listed below must be met before installing the DX100 controller:

Ambient temperature must be 0 to 45 C (32 to 113F) during operation and -10 to 60C
(14 to 140F) during transportation and maintenance.

Humidity must be low with no condensation (10~90%RH).

It must be a place with little dirt, dust and water.

No flammable or corrosive liquids or gases, etc. in the area.

Vibrations and shaking of the DX100 controller shall be less than 0,5 Hz.

No large electric noise source (such as a TIG welding device, etc.) nearby.

No potential for collision with moving equipment such as forklifts.

Location shall fulfill the EMC directive 2004/108/EC.
E1102000035GB03
26
DX100-Controller
4.3
4.4
Location

Install the DX100 controller outside of the restricted space up to EN ISO 10218-1 envelope of the robot (outside of the safeguarding.)

Install the controller in a location from which the robot is easily visible.

Install the controller in a location from which you can easily inspect it when the door is
open.

It is recommended to have a free area around the controller of at least 500 mm to allow
maintenance acces. Minimum is 200 mm on the controllers backside for proper cooling.
Mounting the Controller
Attach the controller to the floor using user-supplied brackets made according to the specifications shown below.
12 dia.
12(2dia.
holes)
(2 holes)
(Unit: mm)
mm)
(Unit:
NOTE
27
Tapped Holes
Holes for
for M10 Screws on the DX100 Si
Tapped
M10 Screws on
the DX100 Side
Refer to the Instruction Manual for information on installation of the robot.
E1102000035GB03
DX100-Controller
4.5
Opening the cabinet door
Use the supplied key to open the cabinet door.

Put the key in the key hole and tum clockwise.
As an option, a key lock can be mounted on the door to prevent unathorized personnel to
enter the cabinet.
E1102000035GB03
28
DX100-Controller
5
Controller specifications
YASKAWA DX100 is based on modules. All repairs are made by replacing the
brocken
unit / module. New options can be added to the System at any time to upgrade the performance. Boot software and system software can be upraded to
achieve new functions.
5.1
IP classification
The cabinet consist of three separate chambers. A totally enclosed chamber
for CPU, servopack, IO-boards, etc (IP54). One closed champer for the transformer and one open chamber for, cooling fans, etc.
5.2
Component
Standard classification
Optional
Cabinet
IP54
-
Cooling fans
not classifield
-
Motor and signal
cable
IP67
-
CEE power
connector
IP44
-
Robot
See robot manual
-
Programm pendant
IP65
-
Internal wiring
Electrial drawings (Elementary diagrams) for internal wiring of the DX100 cabinet.
Controller tybe
Drawing No.
Standard, all types
Twin, Triple, all types
29
E1102000035GB03
DX100-Controller
5.3
Noise level
Measuring point
Emitted noise *
Measured at 1m distance from the cabinet, infront of the door at 1,2 m over the floor.
64.4dB
Back ground noize: 62.6dB
Measured at 1m distance from the cabinet, behind the cabinet, at 1,6 m over the floor. 65.4dB
Back ground noize: 62.9dB
* Measured using standard cooling fans.
5.4
Technical specifications
5.4.1
Control cabinet
Dimensions
800 (W) x 1000 (H) x 650 (D)
Weight
Approx. 250 KG
Protection class
IP54
Cooling system
Indirect cooling
Ambient temperature
0° to +45° (operation)
-10° to +60° (transport and storage)
Relative humidity
Max. 90% non-condensating
Power supply
3-phase 400/415/440 VAC at 50/60 Hz
Digital I/O
40 inputs/40 outputs (standard)
(Expandable to 2048 inputs/2048 outputs)
Analogue in/outputs
40 channels (optional)
Positioning system
Absolute encoder / serial interface
Program memory
200.000 steps, 10.000 instructions and
15.000 PLC steps
Interface
RS-232C, Ethernet
E1102000035GB03
30
DX100-Controller
5.4.2
5.4.3
31
Maintenance
Functions
System monitor, internal maintenance clocks
(e.g. Servo power-on time)
Self-diagnosis
Classifies errors and major/minor alarms and
diplay the data
User alarm display
Alarm message for peripheral devices
Alarm display
Alarm messages and alarm history
I/O diagnosis
Simulated enable/disable outputs
TCP calibration
Automatic calibration on TCP
(Tool Center Piont)
Safety features
Specifications
SDual-channel safety system
(Emergency stop, safety interlock),
3-position Dead-man’s switch,
European safety standard (ISO10218)
Collision avoidance
Collision avoidance zones and radial
interference zones
Collision detection
Monitors robot axes’ torque levels
Machine lock
Test-run peripheral device without robot
motion possible
E1102000035GB03
DX100-Controller
Programming
Programming
INFORM III
Language
Robot motion control
Joint motion, linear, circular,spline
interpolation
Speed adjustement
Joint motion (% of maximum)
Interpolation (mm/sec; cm/min; inch/min)
80
Angular velocity (°/sec)
1
166
2
!
3
4
1000
Xxxxxxxxx Xxxxxx
XXX
11
5
12
A
A
6
800
7
9
Xxxxxxxxx Xxxxxx
XXX XXXXX
8
432BS6
13
14
X11
X21
10
15
16
75
5.4.4
35
A
A
570
20
Fig. 1: DX100 Cabinet
1
Main Power Supply Switch
9
CEE Connector 432BS6
2
Rating NAme Plate
10
Blind Panel
3
Waring Label
11
See Notes (1) min 500 mm
4
Key Handle
12
4-M16 Eye Bolts
5
Programming Pendant (P.P.)
13
Air in
6
Bottom Cover
14
Cable Entrance (a)
7
Mass Label
15
Cable Entrance (a)
8
Air Inlet
16
Air out
E1102000035GB03
32
DX100-Controller
5.4.5
Programmin pendant
The programming pendant is equipped with keys and buttons used to conduct
robot teaching operations and to edit jobs.
Dimensions
I169 (W) x 314.5 (H) x 50 (D)
Touchscreen display
5.7” colour LCD (640 x 480 pixels)
Weight
0.986 kg
Coordinate system
Joint, Rectangular/cylindrical, Tool,Usercoordinates
Speed adjustment
Fine adjustment possible during operationor
teach mode
Shortcuts
Direct access keys and user selectablescreen
keys possible
Language
Mostly spoken languages
available(worldwide)
Interface
Compact Flash card slot, USB port
Operating system
Windows CE
At the back of the programming pendant a three position enable device
(Dead-mans-switch (DSW) is placed. Function:
33
Released
No function (circuit open)
Middle positon
Operation (circuit closed)
Squeezed
No function (circuit open)
E1102000035GB03
DX100-Controller
To get from sqeezed position to middle position the deadman switch be completely released first.
When safety circuit is OK (all gates closed and reset), the DSW has no effect.
When safety circuit is down (gate open), servo power can be activated by
DSW.
See table for combinations:
Servo On
Released = OFF
Squeezed = ON
5.5
Safety features
5.5.1
External safety
Squeezed tightly = OFF
The robot and its auxiliary equipment must be surronded by a safetyguard.
Entrances (doors, gates, etc.) must be protected by interlockings, electro-sensitive devices or similar. Opening of the gates or entrance to the robot working
area must stop all motions inside the cell. Before taking the robot into operation, the complete machine must fulfill the “Essential health and safety requirements relating to the design and construction of machinery” according to the
EU Machinery Directive.
5.5.2
Emergency stop function
The emergency stop circuits are designed according to category 1 (EN 418
item 4.1.5) using power to the servo motor to achieve the stop and then removal of power when stop is achieved. If stop is not achieved after 0.8 seconds,
mechanical brakes are engaged automatically to support stopping.
E1102000035GB03
34
DX100-Controller
5.5.3
Internal safety circuits
The YASKAWA DX100 safety system is designed as a software controlled
system according to EN 61508. The system is through out a dual channel safety system according to
Category 4 (EN 954-1).
Dual CPUs in NIO01 (PLD1 and PLD2).
Dual CPUs in NTU01 (PLD3 and PLD4).
There are mainly two ways to build the safety system; with disconnection of
servo power to the external axes or without disconnection.
With disconnection
The servo power to each group of axes can be switched off independently of
each other. Each group is controlled by one NTU-unit. The servo power ON/
OFF is controlled by the ON_EN signal. The ON_EN signal is controlled by an
external safety system. The external safety system sets the condition for turning servo power ON/OFF by means of lightbeams, safety switches, etc.
This solution makes it possible to manually operate an external axis in PLAYmode (e.g. in a loading zone).
Without disconnection
The machine is built up as one control group. Servo power to an external axis
is not turned off. The servo power to the servo motor is always on. The motor
is monitored by external mechanical limit switches connected to an external
safety system. Conditions in the external safety system allow or prohibit the
motor to move. If the servo motor starts by any reason, the switches are affected and the safety system turns power off to the complete system.
By this solution it is not possible to manually operate an external axis in PLAYmode.
35
E1102000035GB03
DX100-Controller
Control group - robot
Control group - external axis
1 Servopack, controls each servo motor.
2 Converter, directs AC power to DC.
3 Contactor unit, turns power to converter ON/OFF.
4 NTU-unit, controls and monitors the contactor unit.
5 NIO-circuit board of the NIF-unit (CPU-rack)
6 External safety circuit control (safety-PLC or safety relays)
7 Emergency stop circuit
8 Dual channel monitoring of axis motion
E1102000035GB03
36
DX100-Controller
5.5.4
37
Combinations of safety functions related to speed
Mode
SAF_F
FORCE
FST
DSW
EXDSW
SSP2
Speed
SAF1
PLAY
OFF
ON
OFF
-
-
ON
16%
ON
PLAY
OFF
ON
OFF
-
-
OFF
2%
ON
PLAY
OFF
ON
ON
-
-
-
100%
ON
PLAY
ON
-
-
-
-
100%
ON
TEACH
-
OFF
OFF
ON
ON
ON
16%
ON
TEACH
-
OFF
OFF
ON
ON
OFF
2%
ON
TEACH
-
OFF
ON
ON
ON
-
100%
ON
TEACH
-
ON
OFF
-
-
ON
16%
ON
TEACH
-
ON
OFF
-
-
OFF
2%
ON
TEACH
-
ON
ON
-
-
-
100%
ON
(-)
Function has no effect
SAF_F
Safety circuit
SAF_1
Servo ON relay
FORCE
Force action overrule all safety functions
FST
Full speed test
DSW
Enable switch
EXDSW
External enable switch
SSP2
Speed select 2
Speed
Percent of maximum speed in PLAY-mode
100% is programmed speed
16% is about 240 mm/sec.
2% is about 30 mm/sec.
TEACH
Manual speed, set in (Fast, Medium, Slow, Inching)
E1102000035GB03
DX100-Controller
MANDATORY
●For programming, see operator‘s manual
1
17
START
REMOTE
16
15
2
3
HOLD
TEACH
PLAY
JOB
EDIT
DISPLAY
JOB CONTENT
,TEST01
CONTROL GROUP:R1
0000 NOP
0001 SET B000 1
0002 SET B001 0
0003 MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
UTILITY
S:0000
TOOL:
4
MOVJ VJ=0.78
Main Menu
TOOL SEL
LAYOUT
14
ENTRY
X+
Y-
Y+
Z-
Z+
E-
E+
SL-
U-
13
L+
INTER
LOCK
ROBOT
INFORM
LIST
EX.AXIS
WELD
ON/OFF
AUX
MOTION
TYPE
SELECT
X-
X+
Y-
Y+
Z-
Z+
8-
8+
R-
HIGH
SPEED
B+
T-
SLOW
7
T+
7
8
9
4
5
6
BWD
FWD
1
2
3
DELETE
INSERT
0
.
-
MODIFY
ENTER
12
6
R+
B-
FAST
MANUAL SPEED
U+
AREA
CANCEL
ASSIST
SERVO ON
S+
SHIFT
PAGE
SERVO
ON
READY
SIMPLE
MENU
X-
GO BACK
DIRECT
OPEN
COORD
Multi
MAIN
MENU
5
Turn on servo power
Short Cut
TEST
START
8
SHIFT
9
10
11
1
Start button
9
Enable switch (option)
2
Hold button
10
Enter key
3
Emergency stop button
11
Numeric keys / Function keys
4
Insertion slot for CF-Card
12
Motion type key
5
Page key
13
Enable switch
6
Select key
14
Cursor key
7
Manual speed keys
15
General purpose display area
8
Axis keys
16
Menu areat
17
Mode switch
E1102000035GB03
38
DX100-Controller
6
Connection to safety circuit
6.1
Standard configuration
As standard the YASKAWA DX100 controller is equipped with following safety
connections.
6.1.1
Safety circuit terminal
Connection to safety circuits are done at the terninal X18. The terminal is
placed on the inside of the cabinet door.
39
E1102000035GB03
DX100-Controller
Terminal
Description
Terminal
Description
Terminal
Description
-X5, 1
EXHOLD+
-X6, 1
+24V
-X2, 1
PPESP3
-X5, 2
EXHOLD-
-X6, 2
+24V
-X2, 2
PPESP3
-X5, 3
EXDSW1+
-X6, 3
SAFF1+
-X2, 3
PPESP4
-X5, 4
EXDSW1-
-X6, 4
SAFF1-
-X2, 4
PPESP4
-X5, 5
EXDSW2+
-X6, 5
SAFF2+
-X4, 1
PPDSW1+
-X5, 6
EXDSW2-
-X6, 6
SAFF2-
-X4, 2
PPDSW1-
-X5, 7
+24V2
-X6, 7
NC
-X4, 3
PPDSW2+
-X5, 8
024V
-X6, 8
NC
-X4, 4
PPDSW2-
-X5, 9
GSIN11+
-X6, 9
NC
-X4, 5
DSW1+
-X5, 10
GSIN11-
-X6, 10
NC
-X4, 6
DSW1-
-X5, 11
GSIN12+
-X6, 11
SYSRUN+
-X4, 7
DSW2+
-X5, 12
GSIN12-
-X6, 12
SYSRUN-
-X4, 8
DSW2-
-X5, 13
GSIN13+
-X6, 13
EXESP1+
-X5, 14
GSIN13-
-X6, 14
EXESP1-
-X5, 15
GSIN22+
-X6, 15
EXESP2+
-X5, 16
GSIN22-
-X6, 16
EXESP2-
-X5, 17
GSOUT1+
-X6, 17
FST1+
-X5, 18
GSOUT1-
-X6, 18
FST1-
-X5, 19
GSOUTFB1+
-X6, 19
FST2+
-X5, 20
GSOUTFB1-
-X6, 20
FST2-
-X5, 21
GSOUT2+
-X6, 21
SSP+
-X5, 22
GSOUT2-
-X6, 22
SSP-
-X5, 23
GSOUTFB2+
-X6, 23
EXSVON+
-X5, 24
GSOUTFB2-
-X6, 24
EXSVON-
-X5, 25
024V
-X5, 26
024V
E1102000035GB03
40
DX100-Controller
6.2
Connect to basic safety
Interconnections
At delivery, connectors for optional safety and external emergency stop are
short-circuited by jumpers, see below.
6.2.1
External emergency stop (EXESP)
This signal is used to connect the emergency stop switch of an external operation device. The servo power turns OFF and job execution stops when this
signal is input. Servo power can not be turned ON while this signal is OFF.
At delivery jumpers (J3 and J4) are placed on plug X18 between terminal X613 and X6-14 and between terminal X6-15 and X6-16. It is possible to connect
one external emergency stop circuit
X18
X6-13
X6-14
X6-15
X6-16
6.2.2
External servo power ON (EXSVON)
This signal is used to connect the servo ON switch of an external operation
device. The servo power turns ON when this signal is input. No jumpers are
placed in this circuit.
X18
X6-23
X6-24
41
E1102000035GB03
DX100-Controller
6.2.3
External hold (EXHOLD)
This signal is used to connect the HOLD switch of an external operation device. Job execution stops when this signal is input. Starting and axis operation
are disabled while this signal is OFF. As standard a jumper (J6) is connected,
which has to be removed to be able to use this function.
X18
X5-1
X5-2
6.2.4
External safety circuit (SAF_F)
This signal turns OFF the servo power when e.g. the door of the safety guardings is opened. The servo power turns OFF when the interlock signal is input. The servo power cannot be turned ON while this signal is OFF. However,
in Teach mode, this function is disabled.
At delivery jumpers (J1 and J2) are placed on plug X18 between terminal X63 and X6-4 and between terminal X6-5 and X6-6. It is possible to connect one
external safety circuit.
X18
X6-3
X6-4
X6-5
X6-6
E1102000035GB03
42
DX100-Controller
6.2.5
Full speed test (FST)
When both of FST1 and FST 2 input channels are put ON simultaneously, the
manipulator speed will be PLAY-mode speed when DX100 is in play mode,
and TEACH-mode speed when DX100 is in teach mode.
Note that 1st Safe Speed and 2nd Safe Speed can not be selected. If only one
channel is ON, an alarm will occur.
When FST is not activated, speed is limited by the SSP-circuit.
X18
X6-17
X6-18
X6-19
X6-20
6.2.6
Safety speed (SSP)
For conditions to engage SSP1 or SSP2.
●
Circuit closed: 1st safety speed is 16% of maximum play speed (about 240 mm/sec)
●
Circuit open: 2nd safety speed is 2% of maximum play speed (about 30 mm/sec)
At delivery a jumper (J5) is placed on plug X18 between terminal X6-21 and
X6-22 to set to 1st safety speed
X18
X6-21
X6-22
43
This short-circuit activates the 1st
safety speed.
If open = 2nd safety speed.
E1102000035GB03
DX100-Controller
6.2.7
Servo ON enable input (ON_EN)
Connect the ON_EN 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. Because these signals are not used for units of standard specifications, a jumper cable is connected as shown in figure below.
For safety reasons, dual circuits are used for the Servo_ON enable input signals. Remove the jumpers and connect the signal so that both input signals
are turned ON and OFF at the same time. If only one signal is turned ON, an
alarm occurs.
NTU-CN06
+24V
6.2.8
-1
ONEN1
-2
ONEN2
-3
024V
-4
External axis overrun (EXOT)
Used for overrun check of e.g. a servo track. Servo power is OFF and motor
brakes are ON while this signal is OFF.
For safety reasons, dual circuits are used for the EXOT input signals. Remove
the jumpers and connect the signal so that both input signals are turned ON
and OFF at the same time. If only one signal is turned ON, an alarm occurs.
NTU-CN06
+24V -5
EXOT1
-6
EXOT2
-7
024V
-8
E1102000035GB03
44
DX100-Controller
6.2.9
Emergency stop button output
The extra contact output terminals of the emergency stop button on the programming pendant are provided on the X18 terminal on the cabinet door. These contacts are always valid no matter if the DX100 power supply is ON or
OFF.
Programming pendant
-X18
X2-1
PPESP3+
X2-2
X2-3
PPESP3PPESP4+
X2-4
PPESP4-
6.2.10
Enabeling device
The extra contact output terminals of the enabeling device on the programming pendant are provided on the X18 terminal on the cabinet door. These
contacts are always valid no matter if the DX100 power supply is ON or OFF.
This function can be used for start/stopp of an other machine by means of the
enabling in the Programming pendant.
X18
X4-1
X4-3
X4-5
X4-7
Safety relay
X4-2
Output
X4-4
X4-6
X4-8
45
E1102000035GB03
DX100-Controller
6.2.11
Shock sensor (SHOCK)
To connect the tool shock sensor directly to the tool shock sensor signal line.
1 Disconnect the minus SHOCK (-) and 24 VU pin terminal from the NTUCN07 power supply contactor unit.
2 Connect the minus SHOCK (-) and 24VU pin terminals to the signal line of
the tool shock sensor.
To connect the tool shock sensor with the standard integrated cable.
1 Disconnect the minus SHOCK (-) and 24 VU pin terminal from the NTUCN07 power supply contactor unit.
Connect the minus SHOCK (-) pin terminals to the minus SHOCK (-) pin terminal of the robot.
Pin name terminal
Pin type
Sensor terminal type
SHOCK- (CN07-4)
PC-2005W
PC-2005M
24VU (CN07-3)
PC-2005M
PC-2005W
Mark: +24VU
NTU-CN07
-3
Optional limit switch for
shock sensor or collapsible torch holder.
+24VU
(option)
-4
SHOCK-
Default
Mark: SHOCKNTU-CN07
-1
+24VU
Inside robot
-3
(option)
Optional limit switch for
shock sensor or collapsible torch holder.
-4
Default
Mark: SHOCK-
E1102000035GB03
46
DX100-Controller
7
Inspections
7.1
Regular Inspections
CAUTION
● Do not touch the cooling fan or other equipment while the power is
turned ON.
Failure to observe this caution may result in electric shock or injury.
Carry out the following inspections.
47
Inspection
Equipment
Inspection Item
Inspection
Frequency
DX100 controller
Check that the doors
are completely
closed
Daily
Check for gaps or
damage to the
sealed construction
Monthly
Interior circulation
fan and backside
duct fan
Check operation
As required
While power ON
Emergency stop
button
Check operation
As required
While servo ON
Enable switch
Check operation
As required
In teach mode
Battery
Confirm battery
alarm or message is
displayed or not
As required
Power Supply
Check power supply
voltage is normal
As required
Lead Cables for
main power switch
Check falling out,
loosing or breaking
of the lead cables
Check the correlate
voltage
As required
E1102000035GB03
Comments
DX100-Controller
7.2
DX100 Inspections
7.2.1
Checking if the Doors are Firmly Closed
The DX100 controller has a fully sealed construction, designed to keep external air containing oil mist out of the DX100 controller.
Be sure to keep the DX100 controller doors fully closed at all times, even
when the controller is not operating.
When opening or closing the doors for maintenance, use the specific key for
this operation after the main power is turned OFF with the main power switch.
(CW: Open, CCW: Close).
Make sure to push the door and turn the door-lock with the specific key to
open or close the door. When closing the door, turn the door lock until it clicks.
1
DX100
TYPE
ERDRPOWER SUPPLY
3PHASE AC415V 50/60Hz
INTERRUPT CURRENT
SERIAL No.
DATE
PEAK
kVA
AVERAGE kVA
kA
MADE IN JAPAN
NJ3001-1
2
PROGRAMMING PENDANT
X‫ޓ‬8‫ޓ‬1
Fig. 2: DX100 controller Front View
Fig. 2:DX100 controller Front View
7.2.2
1
Main Power Switch
2
Door lock
Checking for Gaps or Damage in the Sealed Construction Section
●
Open the door and check that the seal around the door is undamaged.
●
Check that the inside of the DX100 controller is not stained badly. If it is, determine the
cause, take measures and immediately clean it.
E1102000035GB03
48
DX100-Controller
●
Firmly lock each door and check that no excessive gaps exist around the edge of the
door.
7.3
Cooling Fan Inspections
Inspect the cooling fans as required. A defective fan can cause the DX100 to
malfunction because of excessive high temperatures inside.
The interior circulation fan and backside duct fan normally operate while the
power is turned ON. Check if the fans are operating correctly by visual inspection and by feeling air moving into the air inlet and from the outlet.
2
2
3
1
1
3
MXT EXDSW1SYSRUN+
34
17
GSOUTFB2-50
EXDSW1+
33
16
GSOUTFB2+
49
EXHOLD32
15
GSOUT2-48
EXHOLD+
31
14
GSOUT2+47
EXSVON30
13
GSOUTFB1-46
EXSVON+
29SAFF2-12
GSOUTFB1+
45
SSP-28
SAFF2+
11
GSOUT1-44SSP+
27SAFF1-10
GSOUT1+43FST2SAFF1+9
26
024V2 42
GSIN22-8
25
+24V2 41FST2+
FST1-24
GSIN22+7
024V2 40FST1+
GSIN21-6
23
+24V2 39
EXESP2-22
GSIN21+5
024V2 38
EXESP2+
GSIN12-4
21
+24V2 37
EXESP1-20
GSIN12+3
EXDSW2-36
EXESP1+
GSIN11-2
19
EXDSW2+35
SYSRUNGSIN11+1
18
NJ2959-1
MXT EXDSW1SYSRUN+
34
17
GSOUTFB2-50
EXDSW1+
33
16
GSOUTFB2+
49
EXHOLD32
15
GSOUT2-48
EXHOLD+
31
14
GSOUT2+47
EXSVON30
13
GSOUTFB1-46
EXSVON+
29SAFF2-12
GSOUTFB1+
45
SSP-28
SAFF2+
11
GSOUT1-44SSP+
27SAFF1-10
GSOUT1+43FST2SAFF1+9
26
024V2 42
GSIN22-8
25
+24V2 41FST2+
FST1-24
GSIN22+7
024V2 40FST1+
GSIN21-6
23
+24V2 39
EXESP2GSIN21+5
22
024V2 38
EXESP2+
GSIN12-4
21
+24V2 37
EXESP1GSIN12+3
20
EXDSW2-36
EXESP1+
GSIN11-2
19
EXDSW2+35
SYSRUNGSIN11+1
18
NJ2959-1
BNL6
BNL6
BNL6
BNL6
BNL6
BNL6
4
4
Colling Fan Construction
(small Capacity DX100 controller)
Fig. 3:
Cooling Fan Construction
(Medium-, and Large Capacity DX100 controller)
Cooling Fan Construction DX100 controller
Fig. 3:Cooling Fan Construction DX100 controller
49
1
Air intake
2
Backside duct fan
3
Interior circulation fan
4
Air outlet
E1102000035GB03
DX100-Controller
NOTE
When the message of the "Cooling fan in YPS power supply stopped. Exchange fan" is displayed, it may be
caused by the error occurrence at the cooling fan (JZNCYZU01-E) inside CPU unit (JZNC-YPS01-E).
When the message of the "Cooling fan in YPS unit stopped, replace cooling fan" is displayed, carry out an inspection and the replacement of the cooling fan in the
CPS unit (JZNC-YPS01-E)as soon as possible.
7.4
Emergency Stop Button Inspections
The emergency stop button is located on the programming pendant. Before
operating the robot, confirm the servo power is OFF by pressing the
emergency stop button after the SERVO ON
7.5
Enable Switch Inspections
The programing pendant is equipped with a three-position enable switch. Perform the following operation to confirm the enable switch operates.
1.) Set the mode switch with key on the programming pendant to "TEACH."
Mode switch with key
TEACH
REMOTE
PLAY
2.) Press [Servo on READ] on the programming pendant. The [SERVO ON]
lamp blinks.
1
2
Blinking
Fig. 4: Servo on Blink
Fig. 4:Servo on Blink
1
Servo on Read
2
Servo ON
E1102000035GB03
50
DX100-Controller
3.) When the enable switch is grasped lightly, the servo power is turned ON.
When the enable switch is grasped firmly or released, the servo power is turned OFF.
NOTE
If the [SERVO ON] lamp does not light in previous operation (2), check the following:
● The emergency stop button on the programming pendant is being pressed.
● The emergency stop signal is input from external.
● If a major alarm is occurring.
7.6
Battery Inspections
The DX100 controller has a battery that backs up the important program files
for user data in the CMOS memory.
A battery alarm indicates when a battery has expired and must be replaced.
The programming pendant display and the message "Memory battery weak"
appears at the bottom of the display.
Please confirm that the above mentioned message is NOT indicated when inspecting.
51
E1102000035GB03
DX100-Controller
7.7
Power Supply Voltage Confirmation
Check the voltage of 1, 3, 5 terminal of the main power switch power switch
(Q1M) of with an electric tester.
Measuring Items
Terminals
Correct Value
Correlate voltage
Between
1 and 3(R-S),
3 and 5(S-T),
1 and 5(R-T)
400/415/440V +/- 10%
Voltage between earth
(phase ground)
Between
1 and E(R-E),
5 and E(R-E)
230/240/255V +/- 10%
Between
3 and E(S-G)
About 0V
WARNING
WARNING
May cause
electric shock.
May cause
electric shock.
Ground the earth terminal
based on local code.
Ground the earth terminal
based on local code.
1
3
5
2
4
6
Main power switch
part in the controller
Fig. 5: Main Power Switch
E1102000035GB03
52
DX100-Controller
7.8
Open Phase Check
Check Item
Contents
Lead Cable Check
Confirm if the lead cable for the power supply is wired as shown in the following
without any falling out, looseness or breaking from the connecting part.
Input Power Supply
Check
Check the open phase voltage of input power supply with an electric tester.
(Normal value: AC400/415/440V +10%, -15%)
Main power switch
(Q1M) Check
Turn ON the main power switch and check the open phase voltage of “2, 4, 6
of the main power switch (Q1M) with an electric tester. If abnormal, replace the
main power switch (Q1M).
1
1(R) 3(S) 5(T)
2
(Q1M)
2(U)
4(V) 6(W)
X9
1
4
7
2
3
5
6
V1
3
T1
AC400-415-440V/200V
TP1
5
4
㧔FS1㧕
CN555
1KM
2KM
AE2
6
Fig. 6: Open Phase Check
Fig. 6:Open Phase Check
53
1
Power Supply X4
2
Main Power Switch
3
Transfer
4
Circuit protector
5
Converter
6
Power supply contactor unit
7
Filter
E1102000035GB03
DX100-Controller
8
Description of Units and Circuit Boards
WARNING
● Before operating the robot, check that the SERVO ON lamp goes out
when the emergency stop at programming pendant is pressed.
Injury or damage to machinery may result if the robot cannot be stopped
in case of emergency. Always set the teach lock before starting teaching.The emergency stop at programming pendant.
● Observe the following precautions when performing teaching operations
within the restricted space up to EN ISO 10218-2 envelope of the robot:
- View the robot from the front whenever possible.
- Always follow the predetermined operating procedure.
- Always have an escape plan in mind in case the robot comes toward
you unexpectedly.
- Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional robot operation can result in injury.
● When turning ON the power to DX100 controller, be sure that there is no
one within the restricted space up to EN ISO 10218-2 envelope of the
robot, and that you are in a safe place.
Injury may result from collision with the robot to anyone entering the restricted space up to EN ISO 10218-2 envelope of the robot. Always press
the emergency stop button immediately if there are problems.
CAUTION
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 robot movement.
- Check for damage to insulation and sheathing of external wires.
● Always return the programming pendant to its specified position after
use.
If the programming pendant is inadvertently left on the robot or fixture, or
on the floor, the manipulator or a tool could collide with it during robot movement, possibly causing injuries or equipment damage.
●
Cautions for Connection of Dual Input Signals
E1102000035GB03
54
DX100-Controller
CAUTION
● Connect the switch (contact) that turns the dual signals ON and OFF
simultaneously.
● If the timing that turns the two signals ON and OFF is not right, a disagreement alarm occurs. Refer to the figure below.
DX100
1
JZNC-YSU01-1E
2
CN211
OT2_1+
OT2_1OT2_2+
OT2_2 -
55
-9
-10
3
4
-11
-12
1
Machine safety unit
2
Remove the jumper cable
3
External axis overun
4
Turn OFF/ON at the same time
E1102000035GB03
DX100-Controller
CAUTION
•
Do not connect two signals to the same contact point.
(Prepare two indivisual contact points)
•
Since the power supply for each signal is reversed, it will shortcircuit and may cause breakdown of DX100 controller Unit if the
signals are connected to the same contact point.
DX100
3
+24V2
4
-19
-20
1
5
-21
2
024V
-22
1
Input signal 1
2
Input signal 2
3
Input for the robot system
4
Switch
5
The same contact
E1102000035GB03
56
DX100-Controller
8.1
Power Supply Contactor Unit
The power supply contactor unit consists of the power supply contactor sequence circuit board (JARCR-YPC01-1). The contactor (1KM, 2KM) for servo
power and the line filter (1Z). It turns the contactor servo power ON and OFF
using the signal for servo power control from the power supply contactor sequence circuit board and supplies power
(3-phase AC200/220V) to the unit.
The power supply (single phase AC200/220V) is supplied to the control power
supply via the line filter.
Power Supply Contactor Unit Models
Model
Robot Type
JZRCRYPU01- □
MH5L, MH6, MA1400, VA1400, MA1900, HP20D, HP20D-6,
MH50, MS80, VS50, ES165D, ES200D
1
(CN601)
CN601
8
(2FU),(1FU)
0218010P(10A 250V)
CN601
CN610
CN611
CN610
1FU
2FU
10 A
(4FU),(3FU)
GP25(2.5A 200V)
3FU
4FU 2.5A
1 FU
10 A
4FU
CN607
SVMX1 SVMX2
CN601
SVMX2
CN609
NCM
SVMX1
SVMX2
CN605
CN604
CN604
CN603
CN603
CN608
CN612
CN605
CN608
CN612
CN606
(CN605,CN604,CN603)
2
(CN607)
CN606
5
CN611
CN607
SVMX1
6
(CN606)
2FU
3FU 2.5A
7
3
(CN608)
CN602
CN602
4
(CN602)
Fig. 7: Power Supply Contactor Unit
Fig. 7:Power Supply Contactor Unitt
57
1
Main power supply input
5
AC control power supply
2
Contactor control input
6
AC cooling fan
E1102000035GB03
DX100-Controller
Fig. 7:Power Supply Contactor Unitt
3
Brake interlock output
7
Fuse for AC cooling fan
4
Converter output
8
Fuse for AC control power supply
8.2
Major Axes Control Circuit Board (SRDA-EAXA01)
8.2.1
Major Axes Control Circuit Board (SRDA-EAXA01)
The major axes control circuit board (SRDA-EAXA01) controls the servomotors of the manipulator’s six axes. It also controls the converter, the PWM amplifiers, and the power supply contactor circuit board of the power supply
contactor unit. Mounting an external axes control circuit board option (SRDAEAXB01) makes it possible to control the servomotor of nine axes, including
the robot axes.
The major axes control circuit board (SRDA-EAXA01) also has the following
functions.
●
Brake Power Supply Control Circuit
●
Shock sensor (shock) input circuit
●
Direct-in circuit
E1102000035GB03
58
DX100-Controller
1
(CN510)
(CN513)
18
(CN512)
17
(CN509)
16
(CN508)
15
(CN518)
14
(CN517)
13
(CN516)
12
(CN515)
2
3
(CN511)
(CN514)
4
(CN507)
5
(CN502)
6
(CN501)
7
(CN504)
8
(CN503)
9
(CN506)
10
(CN505)
11
Fig. 8: Major Axes Control Circuit Board (SRDA-EAXA01)
Fig. 8:Major Axes Control Circuit Board (SRDA-EAXA01)
59
1
Converter power supply outputt
10
AMP6 PWM signal
2
Brake control signal
11
AMP5 PWMsignal
3
Safety unit I/F
12
Control communication
4
Direct-in
13
Control communication
5
Converter control signal
14
I/O communication
6
AMP2 PWM signal
15
I/O communication
7
AMP1 PWM signal
16
Encoder signal
8
AMP4 PWM signal
17
Control power supply input
9
AMP3 PWM signal
18
Shock signal input
E1102000035GB03
DX100-Controller
8.2.2
Connection for Tool Shock Sensor (SHOCK)
8.2.2.1
To connect the tool shock sensor directly to the tool shock sensor signal line
1.) Disconnect the minus SHOCK (-) and plus SHOCK (+) pin terminal from
the DINAMIC connector, the EAXA-CN512 major axes control circuit board.
2.)Connect the minus SHOCK (-) and plus SHOCK (+) pin terminals to the signal line of the tool shock sensor. Use the following pin terminals for preparing the end of the signal line.
Pin Terminal
Name
Pin Terminal Model Signal Line Terminal Model
SHOCK-
TMEDN-630809-MA
TMEDN-630809-FA
(manufactured by NICHIFU Co.,
Ltd.)
SHOCK+
TMEDN-630809-FA
TMEDN-630809-MA
(manufactured by NICHIFU Co.,
Ltd.)
3
1
TMEDN-630809-FA (NICHIFU)
SHOCK+
CN512
-3
+24V
SHOCK
2
F4
TMEDN-630809-MA
(NICHIFU)
TMEDN-630809-FA
(NICHIFU)
-4
4
F4
SHOCKTMEDN-630809-MA (NICHIFU)
5
Fig. 9: Direct Connection to Tool Shock Sensor Signal Line
Fig. 9:Direct Connection to Tool Shock Sensor Signal Line
8.2.2.2
1
Major axes control circuit board SRDA-EAXA01
2
Robot cable (signal)
3
robot
4
SHOCK sensor (Option)
5
Shock sensor signal cable
To connect the tool shock sensor with the cable that is built into the manipulator
E1102000035GB03
60
DX100-Controller
1.) Disconnect the minus SHOCK (-) and plus SHOCK (+) pin terminal from
the DYMAMIC connector, the EAXA-CN512 major axes control circuit board.
2.) Connect the minus SHOCK (-) pin terminal to the minus SHOCK (-) pin terminal of the robot
NOTE
Cable that is built into the robot is not connected to shocks
sensor because the tool shock sensor is a option. For connecting the tool shock sensor, refer to the wiring diagrams
in the INSTRUCTIONS for the robot.
1
2
SRDA-EAXA01
CN512
+24V2
-1
F4
SHOCK+
TMEDN-630809-FA (NICHIFU)
-3
SHOCKTMEDN-630809-FA (NICHIFU)
SHOCK
3
-4
SHOCKTMEDN-630809-MA (NICHIFU)
5
4
Fig. 10: Connection with Robot Cable
Fig. 10:Connection with Robot Cable
SUPPLE
-MENT
61
1
Major axes control circuit board SRDA-EAXA01
2
Robot
3
SHOK sensor (Option)
4
use the robot cable
5
Supply cables (PG)
When the tool shock sensor input signal is used, the
stopping method of the robot can be specified. The
stopping methods are hold stop and servo power supply
OFF. Selection of the stopping method is set in the display
of the programing pendant.
E1102000035GB03
DX100-Controller
8.2.3
Connection for Direct-in

Direct-in (Servo) 1 to 6
This signal is used to input a responsive signal in search functions.
MANDATORY
● PNP and NPN are possible. The standard in Europe is PNP
1
(SRDA-EAXA01‫)غ‬
AXDIN1
CN514
B1
024V
B3
3
(Servo) 1
AXDIN2
A4
A4
3
(Servo) 2
AXDIN3
B4
B4
3
(Servo) 3
AXDIN4
A5
A5
AXDIN5
B5
B5
AXDIN6
A6
A6
AXINCOM
A3
A3
A1
+24V2
A1
B1
B3
3
(Servo) 4
3
(Servo) 5
3
(Servo) 6
4
5
‫ޓޓޓޓޓޓޓޓޓ‬
2
8
㧔SRDA-EAXA01D㧕
CN514
B1
024V
AXDIN1
B3
B1
B3
AXDIN2
A4
A4
AXDIN3
B4
B4
AXDIN4
A5
A5
AXDIN5
B5
B5
AXDIN6
A6
A3
A6
+24V2 A1
A1
AXINCOM
A3
6
7
JFA J2000 Series
J21DF-20V-KX-L /CMGTJST
%QPVCEV㧦SJ2F-01GF-P1.0(AWG20㨪24)
The part of wiring is for the slave for the coordinated control
side major axes control circuit board, SRDA-EAXA01
Fig. 11: Connection for Direct-in (Servo) 1 to 6
Fig. 11:Connection for Direct-in (Servo) 1 to 6
1
Major axes control circuit board
2
DIN Adapter (Option) Order Nr.: 144475
3
Direct in (SERVO)
E1102000035GB03
62
DX100-Controller
Fig. 11:Connection for Direct-in (Servo) 1 to 6
4
Connect the jumper cable
5
Slave for the coordinated control side
6
Connect the jumper cable
7
Applicable connector
8
Major axes control circuit board
8.3
CPU Unit
8.3.1
CPU Unit Configuration
3
JANCD-YIF01-‫غ‬E
2
4
(CN114)
1
JANCD-YCP01-E
LED
(CN107)
Compact Flash
%0
(CN113)
5
(CN106)
USB
(CN105)
PCI Slot X2
6
%0
(CN104)
%0
8
%0
%0
(CN103)
Serial Port (RS232C)
7
Fig. 12: CPU Unit Configuration (JZNC- YRK01-1E)
Fig. 12:CPU Unit Configuration (JZNC- YRK01-1E)
63
1
IO I/F (Communication with YIU)
5
Drive I/F (Communication with EAXA)
2
PCI Slot for sensor board X1
6
for programming pendant
3
Robot I/F circuit board
7
Battery
4
Control circuit board
8
for LAN
E1102000035GB03
DX100-Controller
8.3.2
Unit and Circuit Board in the CPU Unit
8.3.2.1
Control Circuit Board (JANCD-NCP01)
This board performs to control the entire system, display to the programming
pendant, control the operating keys, control operation and calculate interpolation. This board has the Serial interface for RS-232C and LAN (100BASE-TX/
10BASE-T).
8.3.2.2
Robot I/F Unit (JZNC-YIF01-E)
The robot I/F Unit controls the entire robotic system. It is connected to the
control circuit board (JANCD-NCP01) with a PCI bus interface on the backboard, and to the major axes control circuit board (SRDA-EAXA01A) with
high-speed serial transmissions.
E1102000035GB03
64
DX100-Controller
8.4
CPS Unit (JZNC-YPS01-E)
This unit (JZNC-YPS01-E) supplies the DC power (DC5V, DC24V) for control
(system, I/O, brake). It is also equipped with the input function for turning the
control power supply ON and OFF.
8
(CN158)
(CN159)
CN159
(ALM)
SOURCE
P-ON
+5V
+24V
FAN
OHT
CN158
(+5V)
CN156/157
(+24V2)
CN155
(+24V1/+24V2)
POWER SUPPLY
CPS-520F
C90AD‫ޓ‬XXXXX
NO.
DATE YYYY-MM
Fuji Electric Hi-Tech Corp.
MADE IN JAPAN
01 02 03 04 05 06 07 08 09 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B C D E F G H J K
L M N P Q R S T U V
7
CN153
(+24V3)
(CN151)
CN151
(AC IN)
CN154
(+24V1/+24V2)
INPUT
200-240V AC
50/60Hz
3.4A-2.8A
1
2
(CN156/CN157)
3
(CN154/CN155)
4
(CN153)
5
(CN152)
6
CN152
(REMOTE)
Fig. 13: CPU Unit JZNC-YPS01-E
Fig. 13:CPU Unit JZNC-YPS01-E
65
1
Connection with CPU 1
2
Connection with CPU 2
3
+24V2 Power supply output
4
+24V1/+24V2 Power supply output
5
+24V3 Power supply output
6
Remote control
7
AC Power supply input
8
Monitor - Alarm display
E1102000035GB03
DX100-Controller
Items
Input
Specifications
Rating Input Voltage:
200/220VAC
Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)
Frequency:
Output Voltage
50/60Hz ± 2Hz (48 to 62Hz)
DC + 5V
DC +24V (24V1: System, 24V2: I/O, 24V3: Brake)
Indicator
Control Power
ON/OFF
DISPLAY
Color
Status
SOURCE
Green
Lights with power supply input.
Lights out when internal live part completes
discharge.
(Power supply status: being input)
POWER
ON
Green
Lights when PWR_OK output signal is ON.
(Power supply status: being output)
+5V
Red
Lights with +5V over-current
(ON when abnormal)
+24V
Red
Lights with +24V over-current
(ON when abnormal)
FAN
Red
Lights when FAN error occurs.
OHT
Red
Lights when unit interior overheats
To turn ON the DX100 controller power, turn the non-fuse breaker of controller to the
ON position then turning ON the control power supply. If the controller is not located
at the workplace, the non-fuse breaker of controller can be turned ON and OFF by
input from external device. It is operated by the external switch connected with CN
152 of control power supply as shown in the following figures. (CN152-1 and CN1522 is shortaged when shipment)
DX100
3
CPS-420F
1
CN152
R-IN
R-INCOM
-1
2
-2
Fig. 14: Connection to Control Power Supply Unit
See “WAGO Connector” for wiring of CN152 connector.
E1102000035GB03
66
DX100-Controller
Fig. 14:Connection to Control Power Supply Unit
1
Remove the short circuit positioner
2
Control power supply ON/OFF switch
3
Control power supply
8.5
Brake Control Board (JANCD-YBK01-E)
8.5.1
Brake Control Board (JANCD-YBK01-E)
Brake Control Board controls ON/OFF of the brakes of total nine axes (Robot
+ external axes) according to the command signal from Major Axes Control
Circuit Board (SRDA-EAXA01).
7
(CN405)
6
(CN404)
(CN403)
5
(CN402)
3.15 A/250 V
4
(CN401)
3
(CN400)
1
2
Fig. 15: Brake control Board (JANCD-YBK01-E)
Fig. 15:Brake control Board (JANCD-YBK01-E)
67
1
Brake power supply input
2
F1:Fuse
3
Brake Output
4
Brake release switch connection
5
Contactor interlock input
E1102000035GB03
DX100-Controller
Fig. 15:Brake control Board (JANCD-YBK01-E)
6
for switching external power supply
7
Brake command input
8.6
Robot I/O Unit (JZNC-YIU02-E)
8.6.1
Robot I/O Unit (JZNC-YIU02-E)
Four digital I/O connectors for the robot universal I/O are provided:
40 inputs and 40 outputs.The I/Os are divided into two types: universal I/O
and specific I/O.
The I/O assignment differs depending on the application. Specific I/O is a signal in which the part is decided in advance. Specific I/O is used when the external operation equipment such as positioner controller and centralized
controller control the manipulator and related equipment as a system. Universal I/O are mainly used as timing signals for the manipulator and peripheral
devices in jobs that require robot motion.
Refer to „Universal I/O signal assignment“for more details on signal allocation.
For the connection of the robot’s universal I/O signal connectors, and the I/O
signal related to start and stop to refer to „Connetion wire with universal I/O
Connector (CN306, 307, 308, 309) and „Specific I/O Signal Related to Start
and Stop.
E1102000035GB03
68
DX100-Controller
10
(CN305)
9
(CN304)
(CN309)
D1:24V2IN LED
8
(CN308)
1
(CN303)
F1,F2
7
6
1
(CN302)
(CN307)
1
(CN301)
(CN306)
5
1
4
3
(CN300)
2
Fig. 16: I/O Unit (JZNC-YIU02-E)
Fig. 16:I/O Unit (JZNC-YIU02-E)

1
Digital I/O
6
Direct-in (optional)
2
Communication Connector
7
Power supply protective fuse 3.15 A / 250 V
3
S1: Rotary Switch
8
For switching external power supply connector
4
D2: FUSE CUT LED
9
Power supply output
5
Panel I/O
10
Power supply input
Connection wire with 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 I/O unit
(JZNC-YIU0-E). Unshielded twisted pair cable must be used.(The cable
side connector and the I/O terminal block are the options).
69
E1102000035GB03
DX100-Controller
࡮'KP\GNJGKVGP5VGEMXGTDKPFWPIGP#
-CDGNUGKVG
B20
B1
A20
A1
࡮'KP\GNJGKVGP5VGEMXGTDKPFWPIGP%
-CDGNUGKVG
B20
B1
A20
A1
Steckverbinder Modell: FCN-361J040-AU (FUJITSU)
(gelöteter Pintyp)
Kappe Modell
: FCN-360C040-B (FUJITSU)
Steckverbinder Modell: 1903404-1
(Tyco Electronics Amp) (MT Typ㧕
E/A Einheit
(JZNC-YIU01-E)
Stecker A
CN309CN308
E-/A-Kabel (YIU ~ extern)
Stecker C
CN307 CN306
E-/A-Kabel (YIU ~ Klemmenblock)
Einzelheiten Steckverbindungen B
Stecker B
CN306,307,308,309
B1
B20
A1
A20
Steckverbinder Modell: 1747053-1
(Tyco Electronics Amp)
TIFS553YS
B1
A1
B2
A2
B3
A3
B4
A4
B5
A5
B6
A6
21-187-3201 R
024VU 024VU 024VU 024VU 024VU 024VU
024VU 024VU 024VU 024VU 024VU 024VU
E/A-Klemmenblock
B8
A8
B9
A9
B10
A10
B11
A11
+24VU +24VU
B12
A12
B13
A13
B14
A14
FG
B15 +24VU +24VU +24VU +24VU +24VU
A15 +24VU +24VU +24VU +24VU +24VU
Abstreiferlänge: 10mm
Anwendbares maximales Kabel Außendurchmesser: Ø 3mm
Modell: TIFS553YS (KASUGA ELECTRIC)
Fig. 17: CN306 bis CN309

Specific I/O Signal Related to Start and Stop
The following signals are specific I/O signals related to start and stop.
E1102000035GB03
70
DX100-Controller
●
Servo ON
(depending on application: JZNC-YIU02-E)
● External Servo ON
nal block X18)
(common to all application: Specific input termi-
●
External Start
(depending on application: JZNC-YIU02-E)
●
Operating
(depending on application: JZNC-YIU02-E)
● External Hold
nal block X18)
(common to all application: Specific input termi-
● External Emergency Stop (common to all application: Specific input terminal block X18)
8
1
RUN
STOP
2
ON
OFF
3
ON
OFF
4
ON
OFF
5
ON
OFF
6
ON
OFF
7
ON
OFF
T
T
T
Set T =
Fig. 18: Timing Chart
Fig. 18:Timing Chart
71
1
Robot
5
Operating
2
While servo on
6
External hold
3
Servo on
7
External E-Stop
4
External start
8
0,1 sec or more
E1102000035GB03
DX100-Controller

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
robot servo power supply. The set and reset timings are shown in the following.
DX100
2
1
3
X2
7
X1
6
X1
X1
+24VU
X18
X6:23
X6:14
9
(EXSVON)
5
4
(X18)
X3 (30011)
X2
8
X3
PL
10
JZNC-YIU02
+24VU
CN308
-A18
-A8
11
(30011)
Fig. 19: Servo on sequence circuit
NOTE
Number in ( ) means output signal number assigned to
YIU02. PL: Pilot Lamp
Fig. 19:Servo on sequence circuit
1
Servo on PB
2
Servo on confirmation
3
Servo on command
4
Servo power on
5
Servo on conformation
6
Servo on command
7
System input terminal
8
Servo power on
9
External servo on input
10
Robot I/O unit
11
Servo on output
E1102000035GB03
72
DX100-Controller

Example of Start Sequence Circuit from External Device
Only the rising edge of the external start signal is valid. This signal starts the
manipulator. Reset this signal with the interlock configuration that determines
if operation can start and with the playback (RUNNING) signal confirming that
the manipulator has actually started moving.
DX100
1
2
3
4
5
(30011)
(30016)
(30013)
X5
9
6
X4
8
X4
X3
7
CN308
-B1
-B18
PL
11
X6
Fig. 20: Start Sequence circuit
NOTE
10
(20010)
+24VU
X6 (30010)
X5
Number in ( ) means output signal number assigned to
YIU02.
Fig. 20:Start Sequence circuit
73
JZNC-YIU01
1
Run PB
2
While servo on
3
Play mode select
4
Alarm/Error occuring
5
Running confirmation
6
Start (command)
7
Running
8
External start command
9
Robot I/O unit
10
External strat input
11
Running, etc.
12
Running output (30010), etc.
E1102000035GB03
-B18
-B8
+24VU
12
DX100-Controller

Connection of External Power Supply for I/O
At factory setting, the internal power supply for I/O is used. If the external
power supply for I/O is used, connect it with following procedure.
1.) Remove the wire connected between CN303-1 to -3 and CN303-2 to -4 of
the robot I/O unit.
2.) Connect +24V of the external power supply to CN303-1 and 0V to CN3032 of the robot I/O unit.
For the connection of the CN303 connector, refer to.
E1102000035GB03
74
DX100-Controller
(JZNC-YIU02)
1
(JZNC-YIU02)
+24VU
CN303
3A
0V
3A
024VU
+24V
-1 (EX24VIN)
F1
3.15A
+24V
F2
-2 (EX024VIN)
+24VU
CN303
2
F1
-1 (EX24VIN)
1
-2 (EX024VIN)
F2
3.15A
+24V
3
-3 (+24V)
-3 (+24V)
-4 (024V)
-4 (024V)
024VU
024V
024V
In case of using external power supply
In case of using internal power supply
Fig. 21: I/O Power Circuit
Fig. 21:I/O Power Circuit
1
Robot I/O unit
2
External power supply
3
Ready by customer
● The internal power supply of 24V of about 1.5A of
DX100 can be used for I/O.
Use external 24V power supply for higher currents and
to isolate the circuit inside and outside the DX100.
NOTE
● Power supply circuit for I/O (+24 VU, 024 VU) has 3A
fuses (F1, F2).
● If the internal power supply is selected and the external
power supply is connected to CN303-1 to -3 and CN3032 to -4, do not connect the line of the external power
supply to the +24VU and 0VU terminals. The unit may
malfunction if the external power supply is also connected.
75
E1102000035GB03
DX100-Controller
8.7
Machine Safety Unit (JZNC-YSU01-1E)
8.7.1
Machine Safety Unit (JZNC-YSU01-1E)
This unit contains dual processing circuits for safety signal.
It processes external safety signals with the dual processing circuits and control ON/OFF of the contactor for SERVO power supply of the contactor unit
(JZRCR-YPU) according to conditions.
Followings are the main functions of Machine Safety Unit.
●
Robot specific I/O circuit (safety signal dual circuits)
●
Servo-ON Enable (ONEN) Input Circuit (dual circuits)
●
Overrun (OT, EXOT) Input Circuit (dual circuits)
● Programming Pendant Signal PPESP, PPDSW, etc. Input Circuit (safety
signal dual circuits)
●
Contactor Control Signal Output Circuit (dual circuits)
●
Emergency Stop Signal Input Circuit (dual circuits)
E1102000035GB03
76
DX100-Controller
B
A
(CN214)
1
(CN213)
2
(CN212)
3
(CN216)
4
(CN211)
5
(CN210)
6
(CN215)
7
1
(CN205)
9
A
CN215
CN210
CN205
CN211
CN202
CN209
(CN200)
CN203
10
(CN209)
PP I/F
CN208
(CN201)
FUSE
11
CN200 CN201
F1,F2: Fuse
3.15A/250V
CN216
12
FRC5-C50S52T-OLS(D20)
(CN202)
CN206
13
CN212
1
B
(CN206)
CN213
14
CN207
CN214
1
s
A
(CN207)
B
15
(CN203)
(CN208)
8
Fig. 22: Machine safety unit (JZNC-YSU01-1E
Fig. 22:Machine safety unit (JZNC-YSU01-1E
77
1
Contactor control 1
2
Contactor control 2
3
FANALM, FANCTL, LAMP
4
X18 Connection
5
ONEN, EXONEN, EXOT
6
I/F between major axes control circuit boards
7
for contactor control 3 and 4
8
Door emergency stop button
9
OT input connector
10
Power supply input connector
11
Power supply output connector
12
I/F-OUT for machine safety unit
13
I/F for major axes control circuit board - communication
14
I/F-IN for machine safety unit
15
I/F for machine saftey unit
E1102000035GB03
DX100-Controller
8.7.2
Connection for Servo-ON Enable Input (ONEN1 and ONEN2)
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. Because these signals are not used for units of standard specifications, a jumper cable is connected as shown in the following figure.
For safety reasons, dual circuits are used for the Servo-ON Enable input signals. Connect the signal so that both input signals are turned ON or OFF at
the same time. If only one signal is turned ON, an alarm occurs.
Refer to “8 Servo Power Supply Individual Control Function” of “Independent/
Coordinated Function Instructions Manual” for the usage of the Servo-ON Enable signals.For the connection of CN211 Connector
DX100
1
2
CN06
+24V2
ONEN1
ONEN2
024V
3
-1
-2
Turn ON/OFF
at the same time
-3
-4
Fig. 23: Servo-ON enable input
Fig. 23:Servo-ON enable input
8.7.3
1
Power supply contactor unit JZNC-YSU01-1E
2
Remove the jumper cable
3
Servo-ON enable input signal
Connection for External Axis Overrun (EXOT)
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.
E1102000035GB03
78
DX100-Controller
If an overrun input signal for an axis other than manipulator axes, for example
the external axis, is required, connect the signal input circuit in the following
manner.
For safe reason, a dual circuits are used for the external axis overrun signal
input. Connect the external axis overrun signal so that both input signals are
turned ON or OFF at the same time. If only one signal is turned ON, an alarm
occurs.
1.) Remove the jumper cable between the connectors CN211-5 and -6 and
between the connectors CN211-7 and -8 of the JZRCR-YSU01-1E machine
safety unit.
2.) Connect the external axis overrun wiring between the connectors CN211-5
and -6 and between the connectors CN211-7 and -8 of the JZRCR-YSU01-1E
machine safety unit.
For the connection of CN211 Connector, refer to “7.8 WAGO Connector”
CAUTION
● Remove jumper cable installed on specific input signal before connecting the input signal lines.
Failure to observe this caution could lead to injury or mechanical failure.
79
E1102000035GB03
DX100-Controller
DX100
1
2
CN211
ONEN2_1+
ONEN2_1ONEN2_2+
ONEN2_2-
5
3
6
7
8
2
OT2_1+
OT2_1OT2_2+
OT2_2 -
Turn ON/OFF
at the same time
9
3
10
11
12
Fig. 24: External Axis Overrun
Fig. 24:External Axis Overrun
1
Power supply contactor unit JZNC-YSU01-1E
2
Remove the jumper cable
3
External axis overrun
E1102000035GB03
80
DX100-Controller
8.8
WAGO Connector
CN211 on the machine safety unit (JZNC-YSU01-1E), CN152 on the control
power supply (JZNC-YPS01-E), and CN303 on the robot I/O unit (JZNCYIU01-E) are equipped with a
connector made by WAGO.
The “wiring tool for the WAGO connector” is necessary to wire the WAGO
connector.
The tools (total 3, 2 types) are supplied with the DX100.
Use them with the appropriate sizes of connectors.
The wiring procedure is described as follows:
1.) Insert part A of the wiring tool into one of the holes designed for the tool.
1
2
3
Fig. 25: Wago Step1
CPS unit: (JZNC-YPS01-E) CN152
Max. cable outside diameter: 4.1 mm dia.
Stripped lentgh: 8-9 mm
Machine safety unit: (JZNC-YSU01-1E) CN211
Robot I/O unit:
(JZNC-YIU02-E) CN303
Max. cable outside diameter: 3.41 mm dia.
Stripped lentgh:7 mm
Fig. 25:Wago Step1
1
Part A
2
WAGO connector (e.g. 4 pins type)
3
Wire
2.) Insert or pull out the wire while pushing the wiring tool downward (Direction
of the arrow).
81
E1102000035GB03
DX100-Controller
Wiring fool for WAGO connector
Push
Fig. 26: Wago connector Step 2
3.) Remove the wiring tool from the connector. (Complete)
Keep this wiring tool for the future use.

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. While the signal is input, the servo power cannot be turned ON.
CAUTION
● Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external emergency stop will not work even if the signal is
input.
E1102000035GB03
82
DX100-Controller
DX100
JZNC
-YSU01-1E
JANCDYSF03
1
2
-X18
X6:13
EXESP1+
X6:14
EXESP1-
3
X6:15
Turn ON/OFF
at the same time
EXESP2+
X6:16
EXESP2-
Fig. 27: Connection for external emergency stop
Fig. 27:Connection for external emergency stop

1
Robot system input terminal block
2
Remove the jumper cable
3
External emergency stop
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. If the interlock signal is input, the servo power turns OFF.
While the signal is turned ON. The servo power cannot be turned ON. Note
that these signals are disabled in teach mode.
CAUTION
● Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external emergency stop will not work even if the signal is
input.
83
E1102000035GB03
DX100-Controller
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
1
-X18
2
X6:3
SAFF1+
X6:4
3
SAFF1-
Turn ON/OFF
at the same time
X6:5
SAFF2+
X6:6
SAFF2-
Fig. 28: Connection for safety plug
Fig. 28:Connection for safety plug
1
Robot system input terminal block
2
Remove the jumper cable
3
Safety plug
E1102000035GB03
84
DX100-Controller

Example of simple safety system
1
2
DX100
-X18
4
3
X6:13
X6:16
In A
In B
In A
A
A
B
B
In B
5
X6:15
X6:14
X6:4
X6:6
X6:5
X6:3
Fig. 29: Example of simple safety system
Fig. 29:Example of simple safety system
85
1
Safety door switch
2
Lightbean
3
Reset servicegate
4
Reset lightbeam
5
E. Stop
E1102000035GB03
DX100-Controller

High speed Test
This signal is used to reset the slow speed limit for the test run in the teach
mode.
If this signal input circuit is short-circuited, the speed of the test run becomes
100% in the teach mode.
If this signal’s circuit is open, the status SSP input signal determines the slow
speed:
– slow speed (250mm/sec)
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
1
-X18
X6:14
FST1+
FST1FST2+
FST2-
2
X6:18
Turned ON/OFF
at the same time
X6:19
X6:20
Fig. 30: High speed test
Fig. 30:High speed test
1
Robot system input terminal block
2
Full speed test
E1102000035GB03
86
DX100-Controller

Slow Speed Mode Selection
This signal is used to determine the speed of the test run when the FST (high
speed test) signal input circuit is open.
Open: slow speed (250mm/sec)
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
1
-X18
2
X6:21
3
SSP+
SSP-
X6:22
Fig. 31: Slow speed mode selection
Fig. 31:Slow speed mode selection
87
1
Robot system input terminal block
2
Remove the jumper cable
3
Slow speed mode selection
E1102000035GB03
DX100-Controller

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 ON.
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
1
X18
-X6:23
EXSVON+
2
-X6:24
EXSVON-
Fig. 32: External servo ON
Fig. 32:External servo ON
1
Robot system input terminal block
2
External servo ON
E1102000035GB03
88
DX100-Controller

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.
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
1
-X18
2
-X5:1
EXHOLD+
-X5:2
EXHOLD-
Fig. 33: External Hold
Fig. 33:External Hold
1
Robot system input terminal block
2
Remove the jumper cable
3
Slow speed mode selection
CAUTION
● Always connect the signals after removing jumper cable.
If the cables are not removed, injury or damage to machinery may result and the external emergency stop will not work even if the signal is
input.
89
E1102000035GB03
DX100-Controller

External Enable Switch
This signal is used to connect Enable switch other than the one on the programming pendant when two people are teaching.
CAUTION
● Always connect the signals after removing jumper cable.
Injury or damage to machinery may result because the external
emergency stop do not work even if the signal is input.
DX100
JZNC
-YSU01-1E
JANCD
-YSF03
1
-X18
2
-X5:3
EXDSW1+
-X5:4
3
EXDSW1-
Turned ON/OFF
at the same time
-X5:5
EXDSW2+
-X5:6
EXDSW2-
Fig. 34: External enable switch
Fig. 34:External enable switch
1
Robot system input terminal block
2
Remove the jumper cable
3
External enable switch
Signal
Name
Connection Dual
No. (X18)
input
Function
Factory
Setting
EXESP1
+
EXESP1-
-19
-20
External Emergency Stop
Short-circuit
with a jumper
cable
EXESP2
+
EXESP2-
-21
-22
Applicable
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.
While the signal is input, the servo
power cannot be turned ON.
E1102000035GB03
90
DX100-Controller
Signal
Name
Connection Dual
No. (X18)
input
Function
Factory
Setting
SAFF1+
SAFF1-
-9
-10
Safety Plug
Short-circuit
with a jumper
cable
SAFF2+
SAFF2-
-11
-12
FST1+
FST1-
-23
-24
FST2+
FST2-
-25
-26
SSP+
SSP-
-27
-28
Applicable
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. If
the interlock signal is input, the servo
power turns OFF. While the signal is
turned ON. The servo power cannot be
turned ON. Note that these signals are
disabled in teach mode.
Applicable
Full-speed Test
Used to reset the slow speed limit for the
test run in the teach mode.
If this signal input circuit is shortcircuited, the speed of the test run
becomes 100% in the teach mode.
If this signal’s circuit is open, the status
SSP input signal determines the safety
speed: The first slow speed (16%) or
second slow speed (2%).
-
Slow Speed Mode Selection
Used to determine the speed of the test
run when the FST (full-speed test) signal
input circuit is open.
Open: Second slow speed (2%)
Short-circuit: First slow speed (16%)
91
EXSVON
+
EXSVON
-
-29
-30
EXHOLD
+
EXHOLD-
-31
-32
Open
-
External Servo ON
Short-circuit
with a jumper
cable
Open
Use to connect the servo ON switch of
an external operation device.
If the signal is input, the servo power
supply is turned ON.
-
External Hold
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.
E1102000035GB03
Short-circuit
with a jumper
cable
DX100-Controller
Signal
Name
Connection Dual
No. (X18)
input
Function
Factory
Setting
EXDSW1
+
EXDSW1
-
-33
-34
External Enable Switch
Short-circuit
with a jumper
cable
-35
-36
Applicable
Used to connect a Enable switch other
than the one on the programming
pendant when two people are teaching.
EXDSW2
+
EXDSW2
-
8.9
Contact Output of Emergency Stop Button
The contact output terminals for the emergency stop button on the programming pendant and the door front are provided on the terminal block X18 terminal X5 (screw size M3.5) at lower part of the right side of DX100 controller.
E1102000035GB03
92
DX100-Controller
These contact outputs are always valid no matter of the DX100 controller
main power supply status ON or OFF. (Status output signal: normally closed
contact)
CAUTION
● Do not use the emergency stop button with 24 VAC, 0.5 A or more.
Failure to observe this instruction may result in damage to equipment.
EXT
1
-X18
2
PPESP3+
-X2:1
PPESP3+
-X2:2
PPESP3
PPESP4+
-X2:3
PPESP3
PPESP4+
-X2:4
PPESP4
PPESP4
Fig. 35: Emergency stop button
8.10
SERVOPACK
A SERVOPACK consists of a converter and a PWM amplifier of which there
are two types. One type is the SERVOPACK with a combined converter and a
PWM amplifier and the other type is one where both units are separate.
93
E1102000035GB03
DX100-Controller
8.10.1
Description of Each Unit
8.10.1.1 Converter
This exchanges the power supply (3-phase : AC200/220V) supplied by the
contactor unit for DC power supply and supplies the power to PWM amplifiers
for each axis.
8.10.1.2 PWM Amplifier
This exchanges the DC power supply supplied by a converter for a
3-phase motor power source and outputs to each servo motor.
8.10.2
SERVOPACK Configuration
Conficuration
Device
MH5L
MH6
MA1400
VA1400
Model
Model
Model
Model
SERVOPACK
SRDA-MH5
SRDA-MH6
SRDA-MH6
JZRCR-MH6-14/00
Converter
PWM
Amplifier
SRDA-COA12A01A SRDA-COA12A01A SRDA-COA12A01A SRDA-COA12A01A
S
SRDA-SDA06A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
L
SRDA-SDA06A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
U
SRDA-SDA06A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
R
SRDA-SDA03A01A
SRDA-SDA06A01A
SRDA-SDA06A01A
SRDA-SDA06A01A
B
SRDA-SDA03A01A
SRDA-SDA06A01A
SRDA-SDA06A01A
SRDA-SDA06A01A
T
SRDA-SDA03A01A
SRDA-SDA06A01A
SRDA-SDA06A01A
SRDA-SDA06A01A
AMP7
SRDA-SDA14A01A
Conficuration Device
MA1900
HP20D
HP20D-6
Model
Model
SRDA-MH20
SRDA-MH20
SRDA-COA12A01A
SRDA-COA12A01A
S
SRDA-SDA14A01A
SRDA-SDA14A01A
L
SRDA-SDA21A01A
SRDA-SDA21A01A
U
SRDA-SDA14A01A
SRDA-SDA14A01A
R
SRDA-SDA06A01A
SRDA-SDA06A01A
B
SRDA-SDA06A01A
SRDA-SDA06A01A
T
SRDA-SDA06A01A
SRDA-SDA06A01A
SERVOPACK
Converter
PWM
Amplifier
AMP7
E1102000035GB03
94
DX100-Controller
Conficuration Device
Converter
SERVOPACK
PWM
Amplifier
MH50
MS80
VS50
Model
Model
Model
SRDA-COA12A01AU
SRDA-COA12A01AU
SRDA-COA12A01AU
SRDA-MH50
SRDA-MS80
JZRCR-MS80-71/00
S
SRDA-SDA71A01A
SRDA-SDA71A01A
SRDA-SDA71A01A
L
SRDA-SDA71A01A
SRDA-SDA71A01A
SRDA-SDA71A01A
U
SRDA-SDA35A01A
SRDA-SDA71A01A
SRDA-SDA71A01A
R
SRDA-SDA14A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
B
SRDA-SDA14A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
T
SRDA-SDA14A01A
SRDA-SDA14A01A
SRDA-SDA14A01A
AMP7
SRDA-SDA71A01A
Conficuration Device
ES165D
ES200D
Model
Model
Converter
SRDA-COA30A01A
SRDA-COA30A01A
SERVOPACK
SRDA-MS165
SRDA-MS165
S
SRDA-SDA71A01A
SRDA-SDA71A01A
L
SRDA-SDA71A01A
SRDA-SDA71A01A
U
SRDA-SDA71A01A
SRDA-SDA71A01A
R
SRDA-SDA35A01A
SRDA-SDA35A01A
B
SRDA-SDA21A01A
SRDA-SDA21A01A
T
SRDA-SDA21A01A
SRDA-SDA21A01A
PWM
Amplifier
AMP7
95
E1102000035GB03
DX100-Controller

Servopack configuration for MH5, Mh6, Ma1400, Ma1800, Ma1900,
HP20D and HP20D-6
1
(CN551)
32
(CN554)
33
(CN553)
34
31
30
29
35
2
(CN552B)
(CN552A) 36
(CN557)
(CN556)
3
(CN558)
4
5
(CN555)
6
7
28
(CN513)
8
27 (CN512)
(CN511)
9
26
(CN514) 10
(CN509)
25 (CN508)
(CN507)
11
(CN502)
12
24 (CN518)
(CN501) 13
23 (CN517)
(CN504) 14
(CN516)
(CN503) 15
22
21
(CN515)
20
(CN506) 16
19
(CN505) 17
18
Fig. 36: EAXA base is closed
Fig. 36:EAXA base is closed
1
Converter
19
Ground terminal
2
Control power supply output for external
axis amplifier
20
EAXA Base
3
Control power supply output for 6-axis
amplifier
21
Control communication
4
Main circuit power supply output for
external axis amplifier
22
Control communication
5
Charge lamp
23
I/O Communication
6
EAXA Base fixing screw (top)
24
I/O Communication
7
EAXA Board
25
Encoder Signal
8
Brake control signal
26
Control power supply input
9
Safety unit I/O
27
SHOCK Signal input
10
Direct-in
28
EAXA Base fixing screw (top)
11
Converter control signal
29
Main circuit power supply input
E1102000035GB03
96
DX100-Controller
Fig. 36:EAXA base is closed
12
AMP2 PWM signal
30
Regenerative resister
13
AMP1 PWM signal
31
Ground Terminal
14
AMP4 PWM signal
32
Grounding detection input
15
AMP3 PWM signal
33
Converter control signal
16
AMP6 PWM signal
34
Monitor alarm display LED
17
AMP5 PWM signal
35
Control power supply input
18
EAXA Basae fixing screw (bottom)
36
Control power supply output for 6-axis
amplifier
1
(AMP1,3,5-CN583)
8
(AMP2,4,6-CN583)
(AMP2,4,6-CN584)
(AMP1,3,5-CN581)
7
2
AMP1
AMP2
AMP3
AMP4
AMP6
AMP5
6
(AMP2,4,6-CN581)
(AMP1,3,5-CN584)
5
(AMP1,3,5-CN582)
(AMP2,4,6-CN582)
3
4
Fig. 37: Servopack MH5, MH6, MA1800, MA1900, HP20D and HP20D-6
(EAXA Base is open)
Fig. 37:Servopack MH5, MH6, MA1800, MA1900, HP20D and HP20D-6 (EAXA Base is open)
97
1
Amplifier main circuit power supply
5
Amplifier control power supply
2
Motor power output
6
Motor power output
3
PWM Signal
7
PWM Signal
4
Amplifier control power supply
8
Amplifier main circuit power supply
E1102000035GB03
DX100-Controller

Servopack configuration for VA1400
(CN551)
36
1
(CN554)
33
34
(CN553)
35
(CN552A) 37
(CN552B)
32
31
(CN557)
30
(CN555)
2
(CN556)
3
(CN558)
4
5
29
6
28 (CN512)
7
(CN511) 8
27 (CN509)
(CN513)
26 (CN508)
(CN514) 10
(CN507)
25 (CN531)
11
(CN502) 12
24 (CN532)
(CN501) 13
23 (CN517,CN518)
22
9
(CN504) 14
(CN533)
(CN503) 15
21 (CN515,CN516)
20
(CN506) 16
19
(CN505) 17
18
Fig. 38: VA1400 EAXA Base is closed
Fig. 38:VA1400 EAXA Base is closed
1
Converter
19
Ground terminal
2
Control power supply output for external
axis amplifier
20
EAXA Base
3
Control power supply output for 6-axis
amplifier
21
Control communication
4
Main circuit power supply output for
external axis amplifier
22
PWM Amplifier 9 signal
5
Charge lamp
23
I/O Communication
6
EAXA Base fixing screw (top)
24
PWM Amplifier 8 signal (frond)
7
EAXA Board
25
PWM Amplifier 7 signal (back)
8
Safety unit I/O
26
Encoder signal
9
Brake control signal
27
Control power supply input
10
Direct-in
28
SHOCK Signal input
11
Converter control signal
29
EAXA Base fixing screw (top)
12
AMP2 PWM signal
30
Main circuit power supply input
13
AMP1 PWM signal
31
Regenerative resister
14
AMP4 PWM signal
32
Ground Terminal
15
AMP3 PWM signal
33
Grounding detection input
E1102000035GB03
98
DX100-Controller
Fig. 38:VA1400 EAXA Base is closed
16
AMP6 PWM signal
34
Converter control signal
17
AMP5 PWM signal
35
Monitor alarm display LED
18
EAXA Basae fixing screw (bottom)
36
Control power supply input
37
Control power supply output for 6-axis
amplifier
8
7
(AMP1,3,5,7-CN583)
(AMP2,4,6-CN583)
(AMP1,3,5,7-CN581)
1
2
(AMP2,4,6-CN584)
AMP1
AMP2
AMP3
AMP4
AMP5
AMP6
6
(AMP1,3,5,7-CN584)
AMP7
3
(AMP2,4,6-CN581)
5
(AMP1,3,5,7-CN582)
(AMP2,4,6-CN582)
4
Fig. 39: VA1400 EAXA Base is open
Fig. 39:VA1400 EAXA Base is open
99
1
Amplifier main circuit power supply
5
Amplifier control power supply
2
Motor power output
6
Motor power output
3
PWM Signal
7
PWM Signal
4
Amplifier control power supply
8
Amplifier main circuit power supply
E1102000035GB03
DX100-Controller

Servopack configuration for MH50, MS80
35
(CN553)
38
(CN551)
(CN552A)
37
(CN554)
34
36
39
(CN552B)
40
33
1
2
(CN557)
32
(CN556)
31
(CN555)
30
(CN510)
3
(CN558) 4
5
6
29
7
(CN512)
28
27
(CN509)
26
(CN508)
25
(CN518)
24
(CN517)
23
(CN516)
(CN511)
8
(CN513)
9
(CN514)
10
(CN507) 11
22 (CN515)
(CN502)
12
(CN501)
13
(CN504)
14
(CN506) 15
(CN505)
21
20
16
(CN503)
17
19
18
Fig. 40: Servopack MH50 and MS80 (EAXA Base is closed)
Fig. 40:Servopack MH50 and MS80 (EAXA Base is closed)
1
Converter
21
EAXA Base
2
Charge Lamp
22
Control communication
3
Main circuit power supply output
23
Control communication
4
Main circuit output for external axis
24
I/O Communication
5
Upper Grip
25
I/O Communication
6
EAXA Base fixing screw (top)
26
Encoder signal
7
EAXA Board
27
Control power supply input
8
Safety unit I/F
28
SHOCK Signal input
9
Brake control signal
29
EAXA Base fixing screw (top)
10
Direct-in
30
Control power supply output for converter
11
Converter control signal
31
Main circuit power supply input
E1102000035GB03
100
DX100-Controller
Fig. 40:Servopack MH50 and MS80 (EAXA Base is closed)
12
AMP2 PWM signal
32
Regenerative resister
13
AMP1 PWM signal
33
Ground Terminal
14
AMP4 PWM signal
34
Grounding detection input
15
AMP6 PWM signal
35
Converter control signal
16
AMP5 PWM signal
36
Upper Grip
17
AMP3 PWM signal
37
Monitor alarm display LED
18
Lower Grip
38
Control power supply input
19
EAXA Basae fixing screw (bottom)
39
Control power supply output for 6-axis
amplifier
20
Ground Terminal
40
Control power supply output for external
axis amplifier
(AMP2,4,6-CN583) 9
8
(AMP1,3,5-CN583)
(AMP2,4,6-CN582)
1
AMP1
7
(AMP2,4,6-CN584) 2
(AMP1,3,5-CN581)
AMP2
AMP3
AMP4
AMP5
6
(AMP2,4,6-CN581) 3
AMP6
(AMP1,3,5-CN584)
5
(AMP1,3,5-CN582)
4
Fig. 41: Servopack MH50 and MS80 (EAXA Base is open)
Fig. 41:Servopack MH50 and MS80 (EAXA Base is open)
101
1
Amplifier main circuit power supply
5
Amplifier control power supply
2
Motor power output
6
Motor power output
3
PWM Signal
7
PWM Signal
4
Lower Grip
8
Amplifier main circuit power supply
E1102000035GB03
DX100-Controller

Servopack Configuration for VS50
42
(CN553)
40
(CN552A) 44
(CN554)
39
(CN551) 43
41
(CN552B)
45
1
38
2
37
(CN557)
36
(CN555)
35
(CN510)
(CN556)
3
(CN558)
4
5
6
34
33
28
32
(CN512)
31
(CN508)
30
(CN531)
29
(CN532)
(CN511)
8
(CN513)
9
(CN514) 10
(CN507) 11
(CN502) 12
(CN517,CN518)
27
26
7
(CN509)
(CN501)
(CN533)
13
(CN504) 14
(CN515,CN516)
(CN506) 15
25
24
(CN505) 16
23
22
16
(CN503)
(CN534)
18
19
21 (CN535)
20
(CN536)
Fig. 42: Servopack configuration VS50 (EAXA base is closed)
Fig. 42:Servopack configuration VS50 (EAXA base is closed)
1
Converter
24
Ground terminal
2
Charge Lamp
25
EAXA base
3
Main circuit power supply output
26
Control communication
4
Main circuit output for external axis
27
PWM amplifier 9 signal
5
Upper Grip
28
I/O Communication
6
EAXA Base fixing screw (top)
29
PWM amplifier 8 signal (front)
7
EAXA Board
30
PWM amplifier 7 signal (back)
8
Safety unit I/F
31
Encoder signal
9
Brake control signal
32
SHOCK Signal input
10
Direct-in
33
Control power supply input
E1102000035GB03
102
DX100-Controller
Fig. 42:Servopack configuration VS50 (EAXA base is closed)
103
11
Converter control signal
34
EAXA Base fixing screw (top)
12
AMP2 PWM signal
35
Control power supply output for converter
13
AMP1 PWM signal
36
Main circuit power supply input
14
AMP4 PWM signal
37
Regenerative resister
15
AMP6 PWM signal
38
Ground Terminal
16
AMP5 PWM signal
39
Grounding detection input
17
EAXA Basae fixing screw (bottom)
40
I/O Signal connecting terminal
18
AMP3 PWM signal
41
Upper Gript
19
Lower Grip
42
Monitor alarm display LED
20
Encoder Signal (9th axis)
43
Control power supply
21
Encoder signal (8th axis)
44
Control power supply
22
Encoder signal (7th axis)
45
Control power supply
23
EAXA base fixing screw (bottom)
E1102000035GB03
DX100-Controller
8
7
(AMP1,3,5,7-CN583)
(AMP2,4,6-CN583)
9
(AMP2,4,6-CN582) 1
(AMP1,3,5,7-CN581)
AMP1
2
(AMP2,4,6-CN584)
AMP2
AMP3
AMP4
AMP5
(AMP2,4,6-CN581)
3
AMP6
6
(AMP1,3,5,7-CN584)
AMP7
5
(AMP1,3,5,7-CN582)
4
Fig. 43: Servopack configuration VS50 (EAXA Base is open)
Fig. 43:Servopack configuration VS50 (EAXA Base is open)
1
Amplifier control power supply
5
Amplifier control power supply
2
Motor power output
6
Motor power output
3
PWM Signal
7
PWM Signal
4
Lower Grip
8
Amplifier main circuit power supply
9
Amplifier main circuit power supply
E1102000035GB03
104
DX100-Controller

Servopack configuration for ES165D and ES200D
37
35
(CN551) 38
(CN553)
36
34
(CN554)
33
(CN552A)
39
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
40
(CN552B)
1
2
32
(CN557)
31
(CN555)
(CN556)
3
(CN558)
4
5
6
(CN510)
30
7
29
(CN513)
(CN512)
28
26
(CN514) 10
(CN508)
25
(CN518)
24
(CN517)
(CN507) 11
(CN502) 12
(CN501) 13
(CN504)
23 (CN516)
22
9
(CN511)
(CN509)
27
8
14
(CN503) 15
(CN515)
(CN506) 16
21
20
(CN505)
17
19
18
Fig. 44: Servopack for ES165D, ES200D (EAXA Base is closed
Fig. 44:Servopack for ES165D, ES200D (EAXA Base is closed
105
1
Converter
21
EAXA base
2
Charge Lamp
22
Control communication
3
Main circuit power supply output
23
Control communication
4
Main circuit output for external axis
24
I/O Communication
5
Upper Grip
25
I/O Communication
6
EAXA Base fixing screw (top)
26
Encoder signal
7
EAXA Board
27
Control power supply input
8
Brake control signal
28
SHOCK Signal input
9
Safety unit I/F
29
EAXA Base fixing screw (top)
10
Direct-in
30
Control power supply output for converter
11
Converter control signal
31
Main circuit power supply input
12
AMP2 PWM signal
32
Regenerative resister
E1102000035GB03
DX100-Controller
Fig. 44:Servopack for ES165D, ES200D (EAXA Base is closed
13
AMP1 PWM signal
33
Ground Terminal
14
AMP4 PWM signal
34
Grounding detection input
15
AMP3 PWM signal
35
I/O Signal connecting termina
16
AMP6 PWM signal
36
Monitor alarm display LED
17
AMP5 PWM signal
37
Upper Grip
18
Lower Grip
38
Control power supply
19
EAXA Basae fixing screw (bottom)
39
Control power supply
20
Ground terminal
40
Control power supply
(AMP2,4,6-CN583)
8
(AMP1,3,5-CN583)
9
(AMP2,4,6-CN582) 1
AMP1
AMP2
7
(AMP1,3,5-CN581)
(AMP2,4,6-CN584)
2
AMP3
AMP4
AMP5
3
(AMP2,4,6-CN581)
(AMP1,3,5-CN584)
6
AMP6
(AMP1,3,5-CN582)
5
4
Fig. 45: Servopack ES165D, ES200D (EAXA Base is open)
Fig. 45:Servopack ES165D, ES200D (EAXA Base is open)
1
Amplifier control power supply
5
Amplifier control power supply
2
Motor power output
6
Motor power output
3
PWM Signal
7
PWM Signal
4
Lower Grip
8
Amplifier main circuit power supply
9
Amplifier main circuit power supply
E1102000035GB03
106
DX100-Controller
8.11
Universal I/O Signal Assignment
8.11.1
Arc Welding
Connector terminal converter (optional)
Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
OUT
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
1
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
B12
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 46: JZNC-YIU02-E(CN308 Connector) I/O Allocation and
Connection Diagram (For Arc Welding)
Fig. 46:JZNC-YIU02-E(CN308 Connector) I/O Allocation and Connection Diagram (For
Arc Welding)
1
107
Each point
E1102000035GB03
DX100-Controller
Fig. 46:JZNC-YIU02-E(CN308 Connector) I/O Allocation and Connection Diagram (For
Arc Welding)
2
Internal power supply
3
External power supply
E1102000035GB03
108
DX100-Controller
Connector terminal converter (optional)
Order number: 105090
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
20020 B5
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
A8
30012 B9
Top of Master Job
OUT
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
OUT
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
B12
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 47: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram
(For Arc Welding)
FFig. 47:JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For
Arc Welding)
109
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
DX100-Controller
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter (optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
20010 B1
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
CN12
-3
-4
3
+24 VE
024 VE
OUT
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
24VDC
50mA max.
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
B4
20020 B5
20021 A5
B7
A7
1
Terminal
Number
Signal
A10
B12
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 48: JZNC-YIU02-E (CN306 Connector) I/O Allocation and
Connection Diagram (for arc welding)
Fig. 48:JZNC-YIU02-E (CN306 Connector) I/O Allocation and Connection Diagram (for arc welding)
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
110
DX100-Controller
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
Terminal
Number
Signal
20010 B1
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
A2
B3
A2
B3
IN
IN
A3
A3
B4
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
IN
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
20020 B5
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
A9
A9
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred OUT
OUT
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
30016 B11 Play Mode Selected OUT
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
1
24VDC
50mA max.
CN12
-3
2
+24 V
024 V
(24V,1A)
-4
3
+24 VE
024 VE
OUT
-1
+24VU
-2
024VU
A10
B12
A12
024VU
+24VU
+24VU
*
RLY
4
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 49: JZNC-YIU02-E (CN307 Connector) I/O allocation and
connection diagram (for arc welding)
Fig. 49:JZNC-YIU02-E (CN307 Connector) I/O allocation and connection diagram (for arc welding)
111
1
Each point
2
Internal power supply
3
External power supply
4
means internal relay
E1102000035GB03
DX100-Controller

Specific Input (Arc Welding)
Logical Input Name / Function
Logical Input Name / Function
Number
Number
20010
20012
20013
20015
20016
20020
EXTERNAL START
20022
Functions the same as the [START]
button in the programming pendant. Only
the rising edge of the signal is valid. It
starts robot operation (playback). This
signal is invalid if external start is
prohibited from the playback condition
display.
20023
CALL MASTER JOB
Only the rising edge of the signal is valid.
It calls up the top of the robot program,
that is the top of the master job*1. This
signal is invalid during playback, during
teach lock and when play master or call is
prohibited (set from the playback
operation condition display).
ALARM/ERROR RESET
20026
After an alarm or error has occurred and
the cause been corrected, this signal
resets the alarm or error.
SELECT PLAY MODE
20027
The play mode is selected when the
mode key on the programming pendant is
set at "REMOTE". Only the rising edge of
the signal is valid. When this selection
signal assigned concurrently with other
mode selection signal, the teach mode is
selected on a priority basis. The signal is
invalid while EXTERNAL MODE SWITCH
is prohibited.
SELECT TEACH MODE
The teach mode is selected when the
mode key of the programming pendant is
set at "REMOTE". The other mode
selection is unavailable when this signal
is ON; the signal is selected by priority
even when the other selection signal is
ON, enabling the teach mode selection.
INTERFERENCE 1 ENTRANCE
PROHIBITED
If the robot attempts to enter the cube
1area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
E1102000035GB03
WORK PROHIBITED (Arc Generation
Prohibited)
Arc generation is prohibited while this
signal is ON. Arc generation starts when
this signal turns OFF inside the arcgeneration area. Use this signal to
confirm teaching.
WORK RESPONSE (Pseudo Arc ON
Response)
This signal is used as a pseudo signal in
cases that “Arc Generation Confirmation”
signal is not equipped on a welding power
supply. Wire this signal ON normally
(short to OV).
WEAVING PROHIBITED
Weaving is prohibited while this signal is
ON. Use this signal to check taught steps
and movements without performing the
weaving operation.
SENSlNG PROHIBITED
Arc sensing is prohibited while this signal
is ON. Use this signal to check taught
steps and movements if an arc sensor is
mounted.
112
DX100-Controller
Logical Input Name / Function
Logical Input Name / Function
Number
Number
20021
INTERFERENCE 2 ENTRANCE
PROHIBITED
If the robot attempts to enter the cube 2
area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
*1 A master job is a job (program) which can be called by CALL MASTER
JOB.Other functions are the same as for normal jobs. Normally, the parent
job, which manages the child jobs called up immediately after the power is turned ON, is set as the master job.

Logical Output Name / Function
Logical Output Name / Function
Number
Number
30010
30011
30012
30013
113
Specific Output (Arc Welding)
RUNNING
30021
This signal signifies that the job is
running. (Signifies that the job is running,
system status is waiting reserved start, or
test run is running.) This signal status is
the same status as [START] in the
programming pendant.
SERVO IS ON
30022
This signal signifies that the servo power
is turned ON, internal processing such as
current position creation is complete, and
the system is able to receive the START
command. This signal turns OFF when
the servo power supply turns OFF. It can
be used for DX100 status diagnosis for an
external start.
30023
TOP OF MASTER JOB
This signal signifies that the execution
position is the top of the master job. This
signal can be used to confirm that the
master job has been called.*1
ALARM/ERROR OCCURRED
This signal signifies that an alarm or an
error occurred. If a major error occurs,
this signal remains ON until the main
power is turned OFF.
30024
IN CUBE 2
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 2). Use this signal to prevent
interference with other robots and
positioners.
WORK HOME POSITION (IN CUBE
32)*2
This signal turns ON when the current
TCP lies inside the work home position
area. Use this signal to evaluate whether
the manipulator is in the start position.
INTERMEDIATE START OK
This signal turns ON when the
manipulator operates. It turns OFF when
the currently executed line is moved with
the cursor or when editing operation is
carried out after HOLD is applied during
operation. Therefore, this signal can be
used as a restart interlock after a HOLD is
applied. However, it also turns ON in the
teach mode and TEACH MODE
SELECTED signal must be referred
together.
GAS SHORTAGE (MONITOR)
This signal stays ON while the gas
shortage signal from the welding power
supply is ON.
E1102000035GB03
DX100-Controller
Logical Output Name / Function
Logical Output Name / Function
Number
Number
30014
BATTERY ALARM
30025
This signal turns ON to notify that the
battery requires replacing when the
voltage drops from the battery for backup
memory of the encoder. Major problems
may result if memory data is lost because
of an expired battery. It is recommended
to avoid these problems by using this
signal as a warning signal.
30015 to REMOTE/PLAY/TEACH MODE
30026
30017
SELECTED
This signal notifies the current mode
setting. These signals are synchronized
with the mode select switch in the
programming pendant. The signal
corresponding to the selected mode turns
ON.
30020
IN CUBE 1
30027
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 1). Use this signal to prevent
interference with other robots and
positioners.
WIRE SHORTAGE (MONITOR)
This signal status ON while the wire
shortage signal from the welding power
supply is ON.
WIRE STICKING (MONITOR)
The wire sticking check is conducted
automatically when the arc turns OFF. If
wire sticking is detected, this signal
remains ON until the wire sticking is
released.
ARC SHORTAGE (MONITOR)
This signal stays ON while the arc
shortage signal from the welding power
supply is ON.
1)This signal is not output during operation.
2) The work home position cube and Cube 32 are same.
E1102000035GB03
114
DX100-Controller
8.11.2
Handling
Connector terminal converter
(optional) Order number: 105090
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
A2
B3
A2
B3
IN
IN
A3
A3
B4
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
IN
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
20020 B5
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
A8
30012 B9
Top of Master Job
OUT
A8
B9
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
B7
A7
30010 B8
024VU
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
OUT
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
B9
A10
B12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
Fig. 50: JZNC-YIU02-E (CN308 Connector) I/O allocation and
connection diagram (for Handling
Fig. 50:JZNC-YIU02-E (CN308 Connector) I/O allocation and connection diagram (for Handling
115
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
DX100-Controller
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
Running
Servo is ON
OUT
B8
B8
30011 A8
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
30013 A9
Alarm/Error Occurred
30014 B10 Battery Alarm
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
30020 B12 In Cube 1
OUT
A11
B12
30021 A12 In Cube 2
OUT
A12
A12
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing
Sequence) OUT
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
B12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 51: JZNC-YIU02-E (CN309 Connector) I/O allocation and
connection diagram (for Handling
Fig. 51:JZNC-YIU02-E (CN309 Connector) I/O allocation and connection diagram (for Handling
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
116
DX100-Controller
Connector terminal converter
(optional) Order number: 105090
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
A8
30012 B9
Top of Master Job
OUT
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
+24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9
Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
24VDC
50mA max.
CN12
-3
3
+24 VE
024 VE
2
+24 V
024 V
(24V,1A)
-4
OUT
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
B12
A12
024VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 52: JZNC-YIU02-E (CN306 Connector) I/O allocation and
connection diagram (for Handling
Fig. 52:JZNC-YIU02-E (CN306 Connector) I/O allocation and connection diagram (for Handling
117
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
DX100-Controller
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
20020 B5
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
+24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9
Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
OUT
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
B12
A12
024VU
+24VU
*
RLY
4
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 53: JZNC-YIU02-E (CN307 Connector) I/O allocation and
connection diagram (for Handling
Fig. 53:JZNC-YIU02-E (CN307 Connector) I/O allocation and connection diagram (for Handling
1
Each point
2
Internal power supply
3
External power supply
4
means internal relay
E1102000035GB03
118
DX100-Controller

Logical
Specfic Input (Handling)
Input Name / Function
Logical
Number
119
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.
It starts robot operation (playback). This
signal is invalid if external start is
prohibited from the playback condition
display.
20021
INTERFERENCE 2 ENTRANCE
PROHIBITED
If the manipulator attempts to enter the
cube 2*2 area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
20012
CALL MASTER JOB
Only the rising edge of the signal is valid.
It calls up the top of the robot program,
that is the top of the master job*1. This
signal is invalid during playback, during
teach lock and when play master or call
is prohibited (set from the playback
operation condition display).
20026
TOOL SHOCK SENSOR
This is normally ON (NC) signal input.
When it turns OFF, an DX100 displays a
message "HAND TOOL SHOCK
SENSOR OPERATING" and a HOLD is
applied. The releasing in teach mode is
done on the handling application
diagnostic display. Set tool shock sensor
function “NOT USE” on the handling
applications diagnostic display if this
signal is not be used.
20013
ALARM/ERROR RESET
After an alarm or error has occurred and
the cause been corrected, this signal
resets the alarm or error.
20027
LOW AIR PRESSURE
This signal is normally OFF (NO). When
it turns ON, XRC displays user alarm in
the PLAY mode or displays user
message in the teach mode.
20015
SELECT PLAY MODE
The play mode is selected when the
mode key on the programming pendant
is set at "REMOTE". Only the rising
edge of the signal is valid. When this
selection signal assigned concurrently
with other mode selection signal, the
teach mode is selected on a priority
basis. The signal is invalid while
EXTERNAL MODE SWITCH is
prohibited.
20050 to
20057
SENSOR INPUT 1 - 8
Inputs 1 to 8 are monitored with the
HSEN handling specific instructions.
Sensor inputs 1 to 8 correspond to
HSEN 1 to 8.
20016
SELECT TEACH MODE
The teach mode is selected when the
mode key of the programming pendant
is set at "REMOTE". The other mode
selection is unavailable when this signal
is ON; the signal is selected by priority
even when the other selection signal is
ON, enabling the teach mode selection.
E1102000035GB03
DX100-Controller
20020
INTERFERENCE 1 ENTRANCE
PROHIBITED
If the robot attempts to enter the cube 1
area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
*1 A master job is a job (program) which can be called by CALL MASTER
JOB. Other functions are the same as for normal jobs. Normally, the parent
job, which manages the child jobs called up immediately after the power is turned ON, is set as the master job.

Specific Output (Handling)
Logical Output Name / Function
Logical Output Name / Function
Number
Number
30010
30011
30012
30013
RUNNING
30021
This signal signifies that the job is
running. (Signifies that the job is running,
system status is waiting reserved start, or
test run is running.) This signal status is
the same status as [START] in the
programming pendant.
SERVO IS ON
30022
This signal signifies that the servo power
is turned ON, internal processing such as
current position creation is complete, and
the system is able to receive the START
command. This signal turns OFF when
the servo power supply turns OFF. It can
be used for DX100 status diagnosis for an
external start.
TOP OF MASTER JOB
30023
This signal signifies that the execution
position is the top of the master job. This
signal can be used to confirm that the
master job has been called.*1
ALARM/ERROR OCCURRED
This signal signifies that an alarm or an
error occurred. If a major error occurs,
this signal remains ON until the main
power is turned OFF.
IN CUBE 2
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 2). Use this signal to prevent
interference with other robots and
positioners.
WORK HOME POSITION (IN CUBE
32)*2
This signal turns ON when the current
TCP lies inside the work home position
area. Use this signal to evaluate whether
the robot is in the start position.
INTERMEDIATE START OK
This signal turns ON when the
manipulator operates. It turns OFF when
the currently executed line is moved with
the cursor or when editing operation is
carried out after HOLD is applied during
operation. Therefore, this signal can be
used as a restart interlock after a HOLD is
applied. However, it also turns ON in the
teach mode and TEACH MODE
SELECTED signal must be referred
together.
30050 to HAND VALVE 1-4
30057
These outputs are controlled by the
HAND handling specific instructions.
Hand valves 1 to 4 correspond to HAND 1
to 4.
E1102000035GB03
120
DX100-Controller
Logical Output Name / Function
Logical Output Name / Function
Number
Number
30014
BATTERY ALARM
This signal turns ON to notify that the
battery requires replacing when the
voltage drops from the battery for backup
memory of the encoder. Major problems
may result if memory data is lost because
of an expired battery. It is recommended
to avoid these problems by using this
signal as a warning signal.
30015 to REMOTE/PLAY/TEACH MODE
30017
SELECTED
This signal notifies the current mode
setting. These signals are synchronized
with the mode select switch in the
programming pendant. The signal
corresponding to the selected mode turns
ON.
30020
IN CUBE 1
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 1). Use this signal to prevent
interference with other robots and
positioners.
*1 This signal is not output during operation.
*2 The work home position cube and Cube 32 are same.
121
E1102000035GB03
DX100-Controller
8.11.3
General Application
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
Terminal
Number
Signal
20010 B1
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
OUT
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
A10
B12
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 54: JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection
Diagram (For General Application)
Fig. 54:JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection Diagram (For General Application)
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
122
DX100-Controller
Connector terminal converter
(optional) Order number: 105090
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
30017 A11 Teach Mode Selected OUT
A11
A11
OUT
B12
A12
B12
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
30016 B11 Play Mode Selected OUT
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 55: JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection
Diagram (For General Application)
Fig. 55:JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection Diagram (For General Application)
123
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
DX100-Controller
Connector terminal converter
(optional) Order number: 105090
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
A2
B3
A2
B3
IN
IN
A3
A3
B4
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
IN
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
A8
A8
30012 B9
Top of Master Job
OUT
B9
B9
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
B7
A7
30010 B8
024VU
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
OUT
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
B12
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 56: JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection
Diagram (General Application)
Fig. 56:JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection Diagram (General Application)
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
124
DX100-Controller
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
OUT
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
B12
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 57: JZNC-YIU01-E (CN307 Connector ) I/O Allocation and
Connection Diagram (For General Application)
Fig. 57:JZNC-YIU01-E (CN307 Connector ) I/O Allocation and Connection Diagram (For General
Application)
125
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
DX100-Controller

Specific Input (General application)
Logical Input Name / Function
Logical Input Name / Function
Number
Number
20010
20012
20013
20015
20016
20020
EXTERNAL START
20021
Functions the same as the [START]
button in the programming pendant. Only
the rising edge of the signal is valid. It
starts robot operation (playback). This
signal is invalid if external start is
prohibited from the playback condition
display.
CALL MASTER JOB
20022
Only the rising edge of the signal is valid.
It calls up the top of the robot program,
that is the top of the master job *1. This
signal is invalid during playback, during
teach-lock and when play master or call is
prohibited (set from the playback
operation condition display).
ALARM/ERROR RESET
20024
After an alarm or error has occurred and
the cause been corrected, this signal
resets the alarm or error.
SELECT PLAY MODE
20025
The play mode is selected when the
mode key on the programming pendant is
set at "REMOTE". Only the rising edge of
the signal is valid. When this selection
signal assigned concurrently with other
mode selection signal, the teach mode is
selected on a priority basis. The signal is
invalid while EXTERNAL MODE SWITCH
is prohibited.
SELECT TEACH MODE
The teach mode is selected when the
mode key of the programming pendant is
set at "REMOTE". The other mode
selection is unavailable when this signal
is ON; the signal is selected by priority
even when the other selection signal is
ON, enabling the teach mode selection.
INTERFERENCE 1 ENTRANCE
PROHIBITED
If the manipulator attempts to enter the
cube 1 area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
robot operation restarts if this signal turns
OFF.
INTERFERENCE 2 ENTRANCE
PROHIBITED
If the manipulator attempts to enter the
cube 2*2 area while this signal is ON, the
robot goes to wait status (with servo
power ON). During wait status, the robot
operation restarts if this signal turns OFF.
WORK PROHIBITED (Tool ON
Prohibited)
Even if TOOLON instruction is executed,
XRC doesn’t output to external while this
signal is ON.
INTERFERENCE 3 ENTRANCE
PROHIBITED
If the manipulator attempts to enter the
cube 3*2 area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
INTERFERENCE 4 ENTRANCE
PROHIBITED
If the robot attempts to enter the cube 4*2
area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
*1 A master job is a job (program) which can be called by CALL MASTER
JOB.
E1102000035GB03
126
DX100-Controller
Other functions are the same as for normal jobs. Normally, the parent job,
which manages the child jobs called up immediately after the power is turned
ON, is set as the master job.

Logical Output Name / Function
Logical Output Name / Function
Number
Number
30010
30011
30012
127
Specific Output (General application)
RUNNING
30021
This signal signifies that the job is
running. (Signifies that the job is running,
system status is waiting reserved start, or
test run is running.) This signal status is
the same status as [START] in the
programming pendant.
SERVO IS ON
30022
This signal signifies that the servo power
is turned ON, internal processing such as
current position creation is complete, and
the system is able to receive the START
command. This signal turns OFF when
the servo power supply turns OFF. It can
be used for XRC status diagnosis for an
external start.
30023
TOP OF MASTER JOB
This signal signifies that the execution
position is the top of the master job. This
signal can be used to confirm that the
master job has been called.*1
30013
ALARM/ERROR OCCURRED
This signal signifies that an alarm or an
error occurred. If a major error occurs,
this signal remains ON until the main
power is turned OFF.
30024
30014
BATTERY ALARM
30025
This signal turns ON to notify that the
battery requires replacing when the
voltage drops from the battery for backup
memory of the encoder. Major problems
may result if memory data is lost because
of an expired battery. It is recommended
to avoid these problems by using this
signal as a warning signal.
IN CUBE 2
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 2). Use this signal to prevent
interference with other manipulators and
positioners.
WORK HOME POSITION (IN CUBE
32)*2
This signal turns ON when the current
TCP lies inside the work home position
area. Use this signal to evaluate whether
the robot is in the start position.
INTERMEDIATE START OK
This signal turns ON when the
manipulator operates. It turns OFF when
the currently executed line is moved with
the cursor or when editing operation is
carried out after HOLD is applied during
operation. Therefore, this signal can be
used as a restart interlock after a HOLD is
applied. However, it also turns ON in the
teach mode and TEACH MODE
SELECTED signal must be referred
together.
IN CUBE 3
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 3). Use this signal to prevent
interference with other manipulators and
positioners.
IN CUBE 4
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 4). Use this signal to prevent
interference with other manipulators and
positioners.
E1102000035GB03
DX100-Controller
Logical Output Name / Function
Logical Output Name / Function
Number
Number
30015 to REMOTE/PLAY/TEACH MODE
30026
30017
SELECTED
This signal notifies the current mode
setting. These signals are synchronized
with the mode select switch in the
programming pendant. The signal
corresponding to the selected mode turns
ON.
30020
WORK COMMAND
This signal provides the command for the
general tool to operate. TOOL ON
instruction execution or the [TOOL ON]
key in the programming pendant turns
this signal ON and TOOL OFF instruction
execution or the [TOOL OFF] key in the
programming pendant turns it OFF.
However, it remains OFF while the
WORK PROHIBITED signal (2022) is
input or while the robot is stopped.
IN CUBE 1
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 1). Use this signal to prevent
interference with other robots and
positioners.
*1 This signal is not output during operation.
*2 The work home position cube and Cube 32 are same.
E1102000035GB03
128
DX100-Controller
8.11.4
Spot Welding
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
IN
20014 B3
Alarm/Error Reset
-
A2
B3
A2
B3
20015 A3
Select Play Mode
Select Teach Mode
IN
IN
A3
20016 B4
A3
B4
IN
IN
A4
A4
B5
B5
20017 A4
-
IN
B4
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
20020 B5
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
B7
A7
30010 B8
024VU
024VU
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
30017 A11 Teach Mode Selected OUT
A11
A11
OUT
B12
A12
B12
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9
Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 58: JZNC-YIU01-E (CN308 Connector) I/O Allocation and
Connection Diagram (For Spot Welding)
Fig. 58:JZNC-YIU01-E (CN308 Connector) I/O Allocation and Connection Diagram (For
Spot Welding)
129
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
DX100-Controller
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
A2
B3
A2
B3
IN
IN
A3
A3
B4
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
IN
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
20020 B5
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
OUT
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
B12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 59: JZNC-YIU01-E (CN309 Connector) I/O Allocation and
Connection Diagram (For Spot Welding)
Fig. 59:JZNC-YIU01-E (CN309 Connector) I/O Allocation and Connection
Diagram (For Spot Welding)
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
130
DX100-Controller
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
30012 B9
Top of Master Job
OUT
A8
B9
A8
B9
30010 B8
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
OUT
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Start OK
30023 A13 Intermediate
(continuousing Sequence) OUT
1
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
Terminal
Number
Signal
20010 B1
A10
B12
A12
024VU
+24VU
+24VU
* Remove jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
Fig. 60: JZNC-YIU01-E (CN306 Connector) I/O Allocation and
Connection Diagram (For Spot Welding
Fig. 60:JZNC-YIU01-E (CN306 Connector) I/O Allocation and Connection
Diagram (For Spot Welding
131
1
Each point
2
Internal power supply
3
External power supply
E1102000035GB03
DX100-Controller
DX100
ROBOT I/O UNIT (JZNC-YIU02-E)
Connector terminal converter
(optional) Order number: 105090
CN308 Connector
Logical Connector
NumberNumber
1
24VDC
8mA max.
Name
Terminal
Number
Signal
20010 B1
External Start
IN
B1
B1
20011 A1
-
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
B4
IN
IN
A4
A4
B5
B5
20014 B3
20015 A3
Select Play Mode
20016 B4
Select Teach Mode
20017 A4
-
20020 B5
20021 A5
Interference1 Entrance
Prohibited
Interference2 Entrance
Prohibited
A5
Work Prohibited
IN
IN
A5
20022 B6
B6
B6
20023 A6
Work Response
IN
A6
A6
B7
A7
024VU
024VU
B7
A7
024VU
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
A8
A8
30012 B9
Top of Master Job
OUT
B9
B9
OUT
A9
A9
OUT
B10
A10
B10
B11
B11
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
A18 +24VU
B18
+24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
30010 B8
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT
OUT
30016 B11 Play Mode Selected
30017 A11 Teach Mode Selected OUT
30020 B12 In Cube 1
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
1
24VDC
50mA max.
CN12
-3
-4
3
+24 VE
024 VE
OUT
2
+24 V
024 V
(24V,1A)
-1
+24VU
-2
024VU
A10
B12
A12
024VU
+24VU
*
RLY
4
* Remove
jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used.
** This assignment can be changed at the I/O assignment display.
Refer to system input list YIU02 and system output list YIU02 for detail.
*** This assignment can be changed at the PSEDU input display
Refer to system input list YIU02 and sysrem output
Fig. 61: JZNC-YIU02-E (CN307 Connector) I/O allocation and
connection diagram (for spot welding)
Fig. 61:JZNC-YIU02-E (CN307 Connector) I/O allocation and connection
diagram (for spot welding)
1
Each point
3
External power supply
2
Internal power supply
4
means internal relay
E1102000035GB03
132
DX100-Controller

Logical Input Name / Function
Logical Input Name / Function
Number
Number
20010
20012
20013
20015
20016
20020
133
Specific Input (Spot Welding)
EXTERNAL START
20023
Functions the same as the [START]
button in the programming pendant. Only
the rising edge of the signal is valid. It
starts robot operation (playback). This
signal is invalid if external start is
prohibited from the playback condition
display.
20024
CALL MASTER JOB
Only the rising edge of the signal is valid.
It calls up the top of the robot program,
that is the top of the master job *1. This
signal is invalid during playback, during
teach-lock and when play master or call is
prohibited (set from the playback
operation condition display).
ALARM/ERROR RESET
20025
After an alarm or error has occurred and
the cause been corrected, this signal
resets the alarm or error.
SELECT PLAY MODE
The play mode is selected when the
mode key on the programming pendant is
set at "REMOTE". Only the rising edge of
the signal is valid. When this selection
signal assigned concurrently with other
mode selection signal, the teach mode is
selected on a priority basis. The signal is
invalid while EXTERNAL MODE SWITCH
is prohibited.
SELECT TEACH MODE
The teach mode is selected when the
mode key of the programming pendant is
set at "REMOTE". The other mode
selection is unavailable when this signal
is ON; the signal is selected by priority
even when the other selection signal is
ON, enabling the teach mode selection.
INTERFERENCE 1 ENTRANCE
PROHIBITED
If the manipulator attempts to enter the
cube 1*2 area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
20050
*4
WELDING PAUSE (From sequencer)
This signal is used to move the
manipulator to the home position when an
error occurs in the Power Source or the
gun.
The robot ignores the spot welding
instruction and operates playback motion.
INTERFERENCE 3 ENTRANCE
PROHIBITED
If the manipulator attempts to enter the
cube 3*2 area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
INTERFERENCE 4 ENTRANCE
PROHIBITED
If the manipulator attempts to enter the
cube 4*2 area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
TIMER COOLING WATER ERROR
This signal monitors the status of timer
cooling water. The manipulator displays
alarm and stops when this signal is input.
The servo power remains ON.
20051
*4
GUN COOLING WATER ERROR
This signal monitors the status of gun
cooling water. The manipulator displays
alarm and stops when this signal is input.
The servo power supply remains ON.
20052
*4
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. The servo power
supply remains ON.
E1102000035GB03
DX100-Controller
Logical Input Name / Function
Logical Input Name / Function
Number
Number
20021
INTERFERENCE 2 ENTRANCE
20053
PROHIBITED
*4
If the manipulator attempts to enter the
cube 2 area while this signal is ON, the
manipulator goes to wait status (with
servo power ON). During wait status, the
manipulator operation restarts if this
signal turns OFF.
WELDING ON/OFF (From sequencer)
*3
This signal inputs the welding ON/OFF
selector switch status from the sequencer
in the interlock unit. The WELD ON/OFF
signal is output to the Power Source
according to this signal and the
manipulator status.
20022

LOW AIR PRESSURE
When air pressure is reduced and this
input is turned ON, an alarm occurs. The
servo power supply remains ON.
WELD COMPLETION
This signal indicates that the Power
Source completed welding without error.
This signal is used as a confirmation
signal for welding instruction execution
and manual spot welding.
After this signal is input, the welding
sequence is completed and the next step
is executed when confirmation limit switch
is not provided.
Specific Input List YIU02 (Spot Welding)
Logical Input Name / Function
Logical Input Name / Function
Number
Number
*3
*3
*3
WELDING ERROR
*3
This signal indicates an abnormal welding
result or Power Source’s error. Alarm
occurs and the manipulator stops if this
signal is input during welding.
STICK DETECTION
*3
This signal indicates an abnormal welding
result or Power Source’s error. Alarm
occurs and the manipulator stops if this
signal is input during welding.
GUN FULL OPEN DETECTION
*3
This signal indicates that the stroke of the
double stroke gun is full open.
GUN SHORT OPEN DETECTION
This signal is connected with a single gun
open verification limit switch or a double
stroke gun short open verification limit
switch to verify the gun open.
GUN PRESSURE DETECTION
This signal indicates that a gun is in
pressing status.
TIP REPLACE COMPLETION
When this signal is input after tip
replacement, the TIP REPLACE
REQUEST signal turns OFF, and the
stored number of welding is cleared.
* 1) A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages
the child jobs called up immediately after the power is turned ON, is set as the master job.
*2) This signal can be allocated to any universal I/O signal at the I/O allocation display in
operation condition.
E1102000035GB03
134
DX100-Controller
*3) This signal can be set as “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT
USE” is selected, this signal can be used as the universal I/O signal described in parentheses.
Pseudo Input
Signal 8202x
7 6 5 4 3 2 1 0
0 0 0 1_1 1 1 1
Timer cooling water error validating ( or IN09)
Gun cooling water error validating (or IN10)
Transthermo error validating (or IN11)
Low air pressure validating (or IN12)
Weld ON/OFF validating (or OUT09

Logical Output Name / Function
Logical Output Name / Function
Number
Number
30010
RUNNING
30023
This signal signifies that the job is
running. (Signifies that the job is running,
system status is waiting reserved start, or
test run is running.) This signal status is
the same status as [START] in the
programming pendant.
30011
SERVO IS ON
30024
This signal signifies that the servo power
is turned ON, internal processing such as
current position creation is complete, and
the system is able to receive the START
command. This signal turns OFF when
the servo power supply turns OFF. It can
be used for DX100 status diagnosis for an
external start.
30025
TOP OF MASTER JOB
This signal signifies that the execution
position is the top of the master job. This
signal can be used to confirm that the
master job has been called.*1
30012
30013
135
Specific output list YIU02 (Spot welding)
ALARM/ERROR OCCURRED
This signal signifies that an alarm or an
error occurred. If a major error occurs,
this signal remains ON until the main
power is turned OFF.
30050
*4
INTERMEDIATE START OK
This signal turns ON when the
manipulator operates. It turns OFF when
the currently executed line is moved with
the cursor or when editing operation is
carried out after HOLD is applied during
operation. Therefore, this signal can be
used as a restart interlock after a HOLD is
applied. However, it also turns ON in the
teach mode and TEACH MODE
SELECTED signal must be referred
together.
IN CUBE 3
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 3). Use this signal to prevent
interference with other manipulators and
positioners.
IN CUBE 4
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 4). Use this signal to prevent
interference with other manipulators and
positioners.
WELD ON/OFF
Outputs a signal input from the interlock
panel, etc.considering the robot status.
E1102000035GB03
DX100-Controller
Logical Output Name / Function
Logical Output Name / Function
Number
Number
30014
30051
*3
BATTERY ALARM
This signal turns ON to notify that the
battery requires replacing when the
voltage drops from the battery for backup
memory of the encoder. Major problems
may result if memory data is lost because
of an expired battery. It is recommended
to avoid these problems by using this
signal as a warning signal.
30015 to REMOTE/PLAY/TEACH MODE
30017
SELECTED
This signal notifies the current mode
setting. These signals are synchronized
with the mode select switch in the
programming pendant. The signal
corresponding to the selected mode turns
ON.
30020
30021
30022
30057
IN CUBE 1
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 1). Use this signal to prevent
interference with other manipulators and
positioners.
IN CUBE 2
This signal turns ON when the current
TCP lies inside a pre-defined space
(Cube 2). Use this signal to prevent
interference with other manipulators and
positioners.
WORK HOME POSITION (IN CUBE
32)*2
This signal turns ON when the current
TCP lies inside a the work home position
area. Use this signal to evaluate whether
the robot is in the start position.
TIP REPLACE REQUEST
This signal is output when the stored
number of welding reaches the number of
welding set for the tip replacement.
WELD ERROR RESET
This signal commands the reset error
status of the Power Source. This is
operated with the programing pendant
operation.
30052 to WELD CONDITION (Level signals)
30056
1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7),
*3
128(8)
Sets the welding conditions for the Power
Source.
The output format can be selected as
binary or discrete (bit number). It can
handle up to 255 conditions. Mostsignificant bit is the parity bit (when
specified).
WELDING COMMAND
*3
This signal outputs execution command
signal to the Power Source. This signal is
not necessary for a Power Source which
is executed using the WELDING
CONDITION signal.
STROKE CHANGE1
*3
SINGLE SOLENOID
DOUBLE SOLENOID
This is a signal, when a double stroke gun
is used, to change the open stroke of the
welding gun.
GUN PRESSURE INSTRUCTION
*3
This outputs a gun pressure instruction.
*1.) This signal is not output during operation.
*2.) The work home position cube and Cube 32 are same.
*3.) This signal can be allocated to any universal I/O signal at the I/O allocation display in operation
condition.
E1102000035GB03
136
DX100-Controller
*4.) This signal can be select “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is
selected, this signal can be used as the universal I/O signal described in parentheses.
Pseudo Input
Signal 8202x
7654 3210
0 0 0 1_1 1 1 1
Timer cooling water error validating ( or IN09)
Gun cooling water error validating (or IN10)
Transthermo error validating (or IN11)
Low air pressure validating (or IN12)
Weld ON/OFF validating (or OUT09
8.11.5
JANCD-YEW01 Circuit Board (Standard)
8.11.5.1 Arc Welding
DX100
Logical Connector
Number
Pin No.
1
Name
2
Signal
CN322-1
24 VDC
5mA MAX
A/D +5V
A/D +5V
22550 CN322-2 +GASOF㧔Gas Shortage㧕
IN
CN322-3 -GASOF㧔Gas Shortage㧕
IN
4
22553 CN322-6 +ARCACT (Arc Generation Confirm㧕 IN
6
5
CN322-7 -ARCACT㧔Arc Generation Confirm㧕 IN
7
CN322-8 CH2㧔Current Input㧕
8
IN
CN322-9
9
CN322-10
10
CN322-12 CH1-G
IN
IN
11
12
13
T
P
22552 CN322-13 +ARCOFF㧔Arc Shortage㧕
CN322-14 -ARCOFF㧔Arc Shortage㧕
IN
IN
14
DC24V
0.5A MAX
32551 CN322-15 ARCON㧔Arc ON㧕A
OUT
15
K
CN322-16 ARCON㧔Arc ON㧕B
OUT
16
L
32552 CN322-17 WIRINCH㧔Wire Inching㧕A OUT
17
F
CN322-18 WIRINCH㧔Wire Inching㧕B OUT
18
G
32553 CN322-19 WIRINCH (Wire Retract) A
OUT
19
H
CN322-20 WIRINCH (Wire Retract) B
J
OUT
20
32567 CN322-21 GAS Checking OUT A
OUT
CN322-22 GAS Checking OUT B
OUT
21
22
CN322-23
23
CN322-24
24
22554 CN322-26 STICK㧔Wire Sticking㧕
IN
CN322-27 *STICK㧔Wire Sticking㧕
IN
CN322-28 CH2 -G
IN
D/A ±14V
17BYTE 32BYTE
DC24V
0.5A MAX
M
27
N
28
30
E
CN322-31 CH1㧔Voltage Command㧕
OUT
31
A
CN322-32 CH1-G
OUT
32
B
CN322-33 CH2㧔Current Command㧕
OUT
33
C
CN322-34 CH2 -G
OUT
34
D
CN322-30 024VU
3
26
29
CN322-29 +24VU
D/A ±14V
R
25
CN322-25
CN321-1 +24VU
32555 CN321-2 Search Command A (Optional)
OUT
CN321-4 Search Command B (Optional㧕 OUT
CN321-5 024VU
5
6
MS3106 A, 20-29P
MS3106 A, 20-29S
Fig. 62: JANCD-YEW01 Circuit Board
137
S
DC24V
5mA MAX
Detector
SW2
1
1
2
3
22551 CN322-4 +WIRCUT㧔Wire Shortage㧕 IN
CN322-5 -WIRCUT㧔Wire Shortage㧕 IN
CN322-11 CH1㧔Voltage Input㧕
3
E1102000035GB03
4
DX100-Controller
JANCD-YEW01 Circuit Board: Analog outputs x2 ports, Analog inputs x2
ports + Status signal I/O of a Welder.
Fig. 62:JANCD-YEW01 Circuit Board
1
Each point
4
Power Souce
2
MR Connector
5
WAGO Connector (321-105/026-A0) t
3
MS Connector
6
MRP-34M01 Insulator
MRP-M112 Contactor
RP-34 Casing
E1102000035GB03
138
DX100-Controller
139
E1102000035GB03
DX100-Controller
E1102000035GB03
140
DX100-Controller
141
E1102000035GB03
YASKAWA in Ihrer Nähe / YASKAWA near You
YASKAWA Electric Corporation
JP
2-1, Kuroskai-shiroishi
Yahatanishi-ku
Kitakyushu-shi 806-0004
+093-645-8801
MOTOMAN EU
Distributors
A
BG Kammarton Bulgaria Ltd.
Yaskawa Europe GmbH
Wien +43-1-707-9324-15
CZ Yaskawa Czech s.r.o
Prag +420-257-941-718
D
Yaskawa Europe GmbH
Allershausen +49-8166-90-0
Yaskawa Europe GmbH
Eschborn +49-6169-777250
DK Motoman Robotics Europe AB
Løsning +45-7022-2477
Yaskawa Iberica S.L
E
Barcelona +34-93-6303478
Yaskawa France SARL
F
Nantes +33-2-4131919
FIN Yaskawa Finland Oy
Turku +358-403000600
GB Yaskawa UK Ltd.
Banbury +44-1295-272755
Yaskawa Italia s.r.l.
I
Modena +39-059-280496
Turin +39-011-9005833
NL Yaskawa Benelux B.V
Son +31-40-2895500
P
Yaskawa Iberica S.L
Aveiro +351-234-9430 900
SE Yaskawa Nordic AB
Kalmar +46-480-417800
Toras +46-480-417800
SI
Sofia +359-02-926-6060
CH Messer Eutectic Castolin Switzerland S.A.
Dällikon +41-44-847-17-17
CZ Hadyna International spol s.r.o.
Ostrava-Marianske Hory +420-596-622-636
Sp-Tech s.r.o.
Nymburk +420-325-515105
H Flexman Robotics Kft
Budapest +36-30-9510065
Rehm Hegesztéstechnika Kft
Budapest +36-53-380-078
IL Yaskawa Europe Technology LTD.
Rosh Ha´ayin +972-3-9004114
N Optimove AS
Lierstranda +47-32240600
PL Integrator RHC Sp. z o.o.
Torun +48-56-6519710
RUS Weber Comechanics
Torun +7-495-105-8887
TR Teknodrom Robotik
Otomasyon San. Tic. Ltd. pti
Gebze/Kocaeli +90-262-678-88-18
ZA Robotic Systems SA PT Y Ltd
Johannesburg +27-11-6083182
Yaskawa Slovenia d.o.o
Ribnica +386-1-8372-410
Yaskawa Ristro d.o.o
Ribnica +386-1-8372-410
Standort/ Yaskawa Europe GmbH
Location Robotics Division
Standort Allershausen
Kammerfeldstraße 1
85391 Allershausen
Fon +49 -81 66 -90 -0
Fax: +49 -81 66 -90 -103
Schulungszentrum
und Vertriebsniederlassung /
Training centre and sales office
Yaskawa Europe GmbH
Drives + Motion Division
Hauptstraße 185
65760 Eschborn
Fon +49-61 96 -7 77 25 -0
Fax: +49-61 96 -7 77 25 -39
www.yaskawa.eu
e-Mail: [email protected]
Änderungen, welche dem technischen Fortschritt dienen, vorbehalten.
Alterations in the course of technical progress, are reserved, without separate information.
DX100
INSTALLATION & WIRING
Specifications are subject to change without notice
for ongoing product modifications and improvements.
MANUAL NO. E1102000035GB 3
">