YASKAWA MOTOMAN DX100 Instruction manual

The YASKAWA MOTOMAN DX100 is a robotic arc welding controller designed for use with Miller® Auto-Axcess DI/E Digital power sources. It features a starting point detection function that helps to ensure accurate and reliable welds. The DX100 is compatible with various Motoman manipulators and welding equipment. It provides a user-friendly interface for programming and operating welding jobs, and includes error reporting features to help troubleshoot issues.

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Part Number: 166465-1CD
Revision: 1
MOTOMAN DX100 CONTROLLER
WITH ROBOTIC ARC WELDING
INSTRUCTIONS
FOR MILLER ® AUTO-AXCESS DI/E DIGITAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MANIPULATOR INSTRUCTIONS
MOTOMAN OPERATORS MANUAL FOR ARC WELDING
MOTOMAN CONCURRENT I/O MANUAL
DX100 CONTROLLER MANUAL
DX100 MAINTENANCE MANUAL
The operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
Vendor manuals for system components not manufactured by Motoman1/56

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166465-1CD
166465-1CD
Auto-Axcess DI/E Digital
MANDATORY
• This manual explains the starting point detecting function of the
DX100 system. Read this manual carefully and be sure to
understand its contents before handling the DX100.
• General items related to safety are listed in Section 1 of the DX100
instructions. To ensure correct and safe operation, carefully read
the section before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
• If such modification is made, the manual number will also be
revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.2/56

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166465-1CD
166465-1CD
Auto-Axcess DI/E Digital
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the Yaskawa Motoman robot.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
WARNING Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
MANDATORY Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED Must never be performed.
NOTE To ensure safe and efficient operation at all times, be sure to
follow all instructions, even if not designated as "CAUTION"
and "WARNING".3/56

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166465-1CD
166465-1CD
Auto-Axcess DI/E Digital
WARNING
• Before operating the manipulator, check that servo power is turned
OFF by pressing the emergency stop button on the programming
pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop button does not function.
Figure 1: Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that there is a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning on the power for the controller.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop button is located on the programming pendant.4/56

Key features

High-speed processing for fast and accurate control of the robot
Multiple robot control for increased productivity
Integrated safety features for operator protection
Easy-to-use programming interface for quick and efficient setup
Advanced motion control algorithms for smooth and precise robot movement
Built-in diagnostics for easy troubleshooting
Compact design for space-saving installation

Frequently asked questions

The YASKAWA MOTOMAN DX100 has a number of built-in safety features, including an emergency stop button, a power lockout feature, and a teach pendant with a dead-man switch.

The YASKAWA MOTOMAN DX100 can control up to 4 robots simultaneously.

The maximum payload capacity of the YASKAWA MOTOMAN DX100 is 12 kg.