YASKAWA Motoman DX200 Operator'S Manual Download Page 1

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MANUAL NO.

HW1482771

Part Number:

169861-1CD

Revision:

DX200 OPTIONS

OPERATOR’S MANUAL

FOR WELDCOM FUNCTION:
ARC WELDING/DIGITAL I/F FUNCTION

MOTOMAN INSTRUCTIONS

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

MOTOMAN-



INSTRUCTIONS

DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL

The DX200 operator’s manuals above correspond to specific usage. Be sure to use the appropriate manual.

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Summary of Contents for Motoman DX200

Page 1: ...STRUCTIONS Upon receipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS DX200 INSTRUCTIONS DX200 OPERATOR S MANUAL...

Page 2: ...is manual is copyrighted property of YASKAWA and may not be sold or redistributed in any way You are welcome to copy this document to your computer or mobile device for easy access but you may not cop...

Page 3: ...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...

Page 4: ...stomer is responsible for providing adequately trained personnel to operate program and maintain the equipment NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE PROGRAM OR REPAIR THE EQUIPMENT We recommend a...

Page 5: ...jury 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 ag...

Page 6: ...maximum envelope of the manipulator Be sure to use a lockout device to the safeguarding when going inside Also display the sign that the operation is being performed inside the safeguarding and make s...

Page 7: ...repair them immediately and be sure that all other necessary processing has been performed Check for problems in manipulator movement Check for damage to insulation and sheathing of external wires Al...

Page 8: ...ration The indications of R and TM are omitted Equipment Manual Designation Programming Pendant Character Keys The keys which have characters printed on them are denoted with ex ENTER Symbol Keys The...

Page 9: ...mode whenever it is not in use In accordance with ANSI RIA R15 06 2012 section 4 2 5 Sources of Energy use lockout tagout procedures during equipment maintenance Refer also to Section 1910 147 29CFR...

Page 10: ...grams or jobs a backup must always be made before any service procedures are done and before any changes are made to options accessories or equipment Any modifications to the controller unit can cause...

Page 11: ...AWA trained qualified personnel Summary of Warning Information This manual is provided to help users establish safe conditions for operating the equipment Specific considerations and precautions are a...

Page 12: ...llow approximately 24 to 36 hours for a response to your inquiry Please have the following information ready before you call Customer Support techsupport motoman com NOTE Please use e mail for routine...

Page 13: ...2 5 1 I O Module Setting Check after Changing EW Board Station Number Setting 2 6 2 5 2 Setting of Optional Function Network Function 2 6 2 5 3 Setting of Optional Function WELDCOM Function 2 7 2 5 4...

Page 14: ...roniusTPS Type Operation of Program No setting Window 3 10 3 10 FroniusTPS Type Operation of Param setting Window 3 11 3 11 FroniusTPSi Type Operation of Top Window 3 12 3 12 FroniusTPSi Type Operatio...

Page 15: ...the case of digital communication mode MOTOWELD X350 manufactured by YASKAWA ELECTRIC CORPORATION System version DN2 10 00 00 or newer In the case of digital communication mode TPS4000 CMT manufactur...

Page 16: ...ing with bead leg length kept constant by changing the feeding rate according to the welding speed NOTE When using TCP Speed you must add the ARATION and ARATIOF commands to the welding section for th...

Page 17: ...usTPSi is available for the version DN1 90 01 78 DN1 91 00 78 and DN2 15 00 00 or newer Also it needs the MotoPlus function 2 2 1 Individual Data Backup Save all the individual data including job and...

Page 18: ...ion number Setting Example Replacing welding power source of analog interface with that of digital interface Remove the actual EW board which will be unnecessary The station number of the virtual EW m...

Page 19: ...DCOM FUNC set Arc 1 to digital interface 2 4 Connection of Welding Power Source and DX200 2 4 1 Standard Connection When connecting one welding power source of digital interface to DX200 Connect a LAN...

Page 20: ...owing figure connect the LAN cable to YCP21 for LAN CN104 using a switching hub CAUTION Use the industrial switching hub that we recommend The system may not properly work with a hub other than this a...

Page 21: ...u upgrade system software End 2 5 1 I O Module Setting Check after Changing EW Board Station Number Setting SETUP entry SETUP entry Language model I O module Initialization processing of each items N...

Page 22: ...he maintenance mode 1 Start the DX200 while pressing MAIN MENU Start the DX200 in maintenance mode 2 Select SYSTEM SECURITY MANAGEMENT MODE A password must be entered after selecting MANAGEMENT MODE 3...

Page 23: ...enable 3 After setting IP ADDRESS SETTING to MANUAL SETTING change IP ADDRESS to 192 168 255 200 Set SUBNET MASK to 255 255 255 0 Set DEFAULT GATEWAY to 0 0 0 0 4 After the setting above is completed...

Page 24: ...hen the application setting is arc and no actual EW board exists only one line is displayed with for the items Explanation of each item The window displays as many lines as the number of applications...

Page 25: ...welding power source by following the procedure below Set the each welding power source by following the procedure below 1 VEW01 Virtual EW module has been assigned Move the cursor to the DETAIL in th...

Page 26: ...1 Weldcom Function Arc Welding Digital I F Fronius TPS type Fronius TPSi type HTTP POWER SOURCE IP ADDRESS Set the IP address to be used to obtain the welding type database from TPSi For the IP addres...

Page 27: ...odule The following explains the final checking process not the setting procedure to add VEW01 as an I O module at the time of completion of the WELDCOM function setting 1 In the WELDER SETUP and the...

Page 28: ...he main power and restart the system in normal mode 2 5 6 Setting of Optional Function MotoPlus Function When Welder is FroniusTPSi When the welder is FroniusTPSi use the MotoPlus function optional fu...

Page 29: ...7 Loading of MotoPlus Application When Welder is FroniusTPSi Load FroniusTPSi and a MotoPlus application for communication 1 Select MotoPlus APL LOAD USER APPLICATION At this time select a device and...

Page 30: ...low Bit4 Main current signal Bit5 Torch collision protection Bit6 Wire stick control Bit7 Wire available Bit8 Touched Bit9 Torchbody connected Bit10 Command value out of range Bit11 Correction out of...

Page 31: ...status Bit0 Communication ready Bit1 Power source ready Bit2 Arc stable Bit3 Process active Bit4 Main current signal Bit5 Torch collision protection Bit6 Wire stick control Bit7 Wire available The reg...

Page 32: ...ng mode 0 Switch to the mode selected by welding condition Initial setting 1 Switch the mode with following rule Executing a job Switch to the mode selected by welding condition NOT Executing a job IN...

Page 33: ...t Window 3 1 Overview The WELDCOM function can set and obtain the parameter of the welding power source in the edit window of an arc start condition file or an arc end condition file 3 2 Display of We...

Page 34: ...number of a weld user file to be used 2 Display OTHER tab of the welding condition file and press Welder setting 3 Move the cursor to the weld user file number specified in 1 Select weld user file 4...

Page 35: ...type Window Weldcom Function Arc Welding Digital I F 3 4 MOTOWELD Type Operation of Weld type Window 1 At the top window select a weld user file and select Weld type 2 Select welding condition Select...

Page 36: ...of Customize Window 1 At the top window select Customize Change the parameter of the weld user file selected 2 Select Start End Change the parameter For details on the parameters see the user manual o...

Page 37: ...ow Weldcom Function Arc Welding Digital I F Case Selected weld type is Pulse 4 Select End Change the parameter For details on the parameters see the user manual of the welding power source 5 Select Cu...

Page 38: ...ype Operation of Customize Window 3 6 169861 1CD HW1482771 Weldcom Function Arc Welding Digital I F 6 Select HAWC Change the parameter For details on the parameters see the user manual of the welding...

Page 39: ...aintenance 1 Welder update Update Welder s data Select Data type and Device in which welder s data is put Select Upload starting and send update data to the welding power source 2 All write Controller...

Page 40: ...ndow select Welder prm 2 Select Gas Wire Change the common parameter C parameter For details on the C parameters see the user manual of the welding power source 3 Select Other Change the common parame...

Page 41: ...of the welding condition file to specify the number of a weld user file to be used 2 Display OTHER tab of the welding condition file and press Welder setting 3 Select weld user file 4 Select Program...

Page 42: ...w 3 10 169861 1CD HW1482771 Weldcom Function Arc Welding Digital I F 3 9 FroniusTPS Type Operation of Program No setting Window 1 At the top window select a weld user file and select Program No settin...

Page 43: ...as preflow Pre flow that the robot performs as approaching the welding start point 2 Gas postflow Specify the time period of gas release performed at the end of the welding 3 SFI Select from AUTO MANU...

Page 44: ...r Open the Weld Parameter Setting window When using Job mode of Fronius power source put a check mark in the check box of Job mode 2 Select a weld user file Type ISO AWS Switches the display of materi...

Page 45: ...Weldcom Function Arc Welding Digital I F 3 12 FroniusTPSi Type Operation of Select Synergic Window 1 At the top window select a weld user file and then select Select Synergic 2 Select the welding con...

Page 46: ...of speed fluctuation in fluctuating the wire feeding speed in order to stabilize the welding current It is available only when the welding mode is PMC or LSC Arc length stabilizer Stabilizes welding e...

Page 47: ...rc Welding Digital I F Inching speed Wire feeding speed in perform inching manually by the operator 4 Select Synchro Pulse Changes the welding parameters for changing the feeding rate or arc length in...

Page 48: ...main menu to create a job 2 Select INFORM DEVICE and then select ARCON ARCSET and ARCOF For the ARCON and ARCSET instructions specify a welding start condition file in the tag For the ARCOF instructio...

Page 49: ...orrection Controls the arc length Long arc length Short arc length V3 CORR2 Correction 2 Parameter for the heat input control This varies depending on a welding type When the material is iron and the...

Page 50: ...instruction or welding voltage instruction V1 Wire feeding speed m min The range varies depending on the welding type V2 Arc Length Set the value between 10 0 and 10 0 V3 Pulse Dynamic Set the value...

Page 51: ...ine to cool Confirm the Fronius s manual 4 ts3 Sub code 4 shows the error code of Fronius power source 4 main error code sub error code Allow the machine to cool Confirm the Fronius s manual 5 tp1 Sub...

Page 52: ...m side Confirm the Fronius s manual 13 Errtf3 Sub code 13 shows the error code of Fronius power source 13 main error code sub error code Check cable tree of temperature sensors Confirm the Fronius s m...

Page 53: ...e 21 shows the error code of Fronius power source 21 main error code sub error code Update firmware otherwise change the UST board Confirm the Fronius s manual 22 ErrEPF Sub code 22 shows the error co...

Page 54: ...ling unit temperature sensor Confirm the Fronius s manual 29 DSPC Sub code 29 shows the error code of Fronius power source 29 main error code sub error code Update firmware otherwise change the UST bo...

Page 55: ...d Confirm the Fronius s manual 38 Stop Sub code 38 shows the error code of Fronius power source 38 main error code sub error code Deactivate the Stop by input RobotReady and activate briefly SourceErr...

Page 56: ...known Sub code 47 shows the error code of Fronius power source 47 main error code sub error code OR NOT IN USE Confirm the Fronius s manual 48 unknown Sub code 48 shows the error code of Fronius power...

Page 57: ...he torch is retracted Confirm the Fronius s manual 55 NoIGn Sub code 55 shows the error code of Fronius power source 55 main error code sub error code Set a lower Ito value Keep the torch stand off di...

Page 58: ...rm the Fronius s manual 64 Errtf8 Sub code 64 shows the error code of Fronius power source 64 main error code sub error code Change the thermo sensor of the cooling unit Confirm the Fronius s manual 6...

Page 59: ...he Fronius s manual 73 noHost Sub code 73 shows the error code of Fronius power source 73 main error code sub error code Check the connection between UST and RCU and the firmware Confirm the Fronius s...

Page 60: ...de sub error code Allow the machine to cool Confirm the Fronius s manual 82 ErrEHF Sub code 82 shows the error code of Fronius power source 82 main error code sub error code Allow the external HF to c...

Page 61: ...b error code OR NOT IN USE Confirm the Fronius s manual 91 unknown Sub code 91 shows the error code of Fronius power source 91 main error code sub error code OR NOT IN USE Confirm the Fronius s manual...

Page 62: ...he error code of Fronius power source 100 main error code sub error code Update firmware otherwise change the UST board Confirm the Fronius s manual 101 PrtFlt Sub code 101 shows the error code of Fro...

Page 63: ...mware otherwise change the UST board Confirm the Fronius s manual 109 ASSErt Sub code 109 shows the error code of Fronius power source 109 main error code sub error code Update firmware otherwise chan...

Page 64: ...Check if the screws of the connector terminal block are securely fastened If the encoder cable is disconnected or the screws are loosened the wire feeding speed becomes excessively fast and an error o...

Page 65: ...onal ratio 60 2 Check if there are dust dirt and clogging on the dust protective filter Clean or replace the dust protective filter if necessary 3 Replace the Main board Pr MB 030 Item No 504 4246 MOT...

Page 66: ...ntative 4256 MOTOWELD MACHINE TYP ERROR4 307 Sub Code MOTOWELD s Err Code The setting of hardware or software may be not performed correctly Contact your YASKAWA representative 4257 MOTOWELD PANEL SW...

Page 67: ...OTOWELD s Err Code The data may not have been correctly saved when the welding conditions are recorded because of a power failure etc Reset the system after saving the changed parameters See the manua...

Page 68: ...rameters See the manual of MOTOWELD section 4 2 10 System Reset If the error occurs again the board may be broken Contact your YASKAWA representative 4268 MOTOWELD MEMORY ERROR7 210 Sub Code MOTOWELD...

Page 69: ...occurred 4 When the welding voltage sensing cable is used please connect the welding voltage sensing cable to the base metal 5 When the AC unit used a weldingpower source output cable please confirm w...

Page 70: ...set 4279 MOTOWELD MOMENTARY OVER CURR 108 Sub Code MOTOWELD s Err Code 1 Check that short circuit or the earth grounded of the output cable 2 May be power circuit broken Contact your YASKAWA represent...

Page 71: ...the PLD on the main board Pr MB is wrong Replace the main board Service parts code UNIT Pr MB 030 Contact your YASKAWA representative 317 The program or data base was load by the ethernet Reboot the...

Page 72: ...AC UNIT ERROR 126 AC unit temperature anomaly 1 Check the ambient temperature 45 degrees or below and the usage rate 60 2 Check for no dirt or clogging in the dust proof filter Check or replace as ne...

Page 73: ...vo motor main circuit cable failure Please replace the servo motor main circuit cable There is a possibility of servo pack failure Please replace the servo pack 3 A b33 Current detection abnormality T...

Page 74: ...urred while waiting for arc to be generated that produces current flow An insulator such as slag prevented current from flowing thus arc was not generated Or the wire took long time to contact the bas...

Page 75: ...124 475 8542 Phone 91 124 475 8500 YASKAWA India Private Ltd Robotics Division YASKAWA Electric China Co Ltd 22F One Corporate Avenue No 222 Hubin Road Huangpu District Shanghai 200021 China Phone 86...

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