YASKAWA Motoman DX200 User Manual Download

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ROBOTICS

Installation and Wiring

Robot controller

User manual

Summary of Contents for Motoman DX200

Page 1: ...ROBOTICS Installation and Wiring Robot controller User manual...

Page 2: ...d regularly and any necessary corrections will be made in subsequent editions Subject to technical modifications Created on 2015 10 Revision 06 Document number E1102000143GB06 Author WOE Changes made...

Page 3: ...method 25 3 1 1 Using a crane 26 3 1 2 Using a forklift 26 3 1 3 Using a lifting truck 27 4 Assembly and installation 28 4 1 Protection measures 28 4 2 Ambient conditions and installation location 29...

Page 4: ...59 8 7 External emergency stop signal 66 8 8 Safety plug 66 8 9 Installation of safety plug 68 8 10 External enable switch 68 8 11 Full speed test 70 8 12 Slow speed mode 72 8 13 External hold 72 8 1...

Page 5: ...e list of the Equipment configuration by model 105 9 Robot controller specification 108 9 1 Specification list 109 9 2 Function list 109 9 3 Programming Pendant 112 9 4 Device configuration 113 10 Rec...

Page 6: ...be used for property damage warnings 1 2 Frequently used terms The YASKAWA robot is a product of YASKAWA Electric Corporation and is provided by default with the robot control the programming pendant...

Page 7: ...system must receive training before they operate the robot For optimal use of our products we recommend our customers to take part in a training session at the YASKAWA Academy For more detailed infor...

Page 8: ...holes or similar modifications can damage parts This will be regarded as improper use i e use that deviates from the intended use and will lead to loss of warranty and liability claims as well as los...

Page 9: ...ices are listed on the last page Please mention the manual number in your order YASKAWA Europe GmbH is not responsible for damage caused due to unauthorized modification of the system If any impermiss...

Page 10: ...Stop button When the SERVO power is turned OFF the SERVO ON LED on the programming pendant goes off see Fig 1 2 LED SERVO ON Fig 1 2 LED SERVO ON Fig 1 3 Emergency Stop button Emergency Stop button 1...

Page 11: ...perations within the robot s working range View the Robot from the front whenever possible Always follow the prescribed operating procedure see the instructions on robot control as well as the operati...

Page 12: ...ing rules and regulations Industrial Safety and Health Law Enforcement Order of Industrial Safety and Health Law Ordinance of Industrial Safety and Health Law Other related laws are as follows Occupat...

Page 13: ...e the safety of all Safety management Assembly staff Operating staff Maintenance staff DANGER Death by electric shock serious injury from fire hazard Avoid dangerous actions in the area where the robo...

Page 14: ...foreseen movements Observe the following note Never forcibly move the robot axes Never lean against the robot control Avoid inadvertent pressing of the keys Do not allow unauthorised persons to touch...

Page 15: ...installation draw up easy to observe guidelines to ensure safety Take safety aspects into consideration when planning the installation Observe the following when installing the robot Select an area su...

Page 16: ...e eyebolts are securely fastened To lift the robot use a crane with wire rope threaded through the eyebolts and positioner s Lift the body in an upright position as described in the robot operator s m...

Page 17: ...lts specified in the operation and maintenance manual for each robot model Install the robot controller outside the safeguarding of the manipulator s safety enclosure CAUTION Danger of injury and mate...

Page 18: ...ith the wiring diagram and take notice thereof when establishing the connections Take precautions when wiring and piping between the robot controller robot and peripheral equipment Run the piping wiri...

Page 19: ...s 1 7 4 2 Operating safety DANGER Death and fire caused by short circuiting Switching on the power supply during tool installation may result in electric shock Before fixing a tool e g welding torch m...

Page 20: ...g 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 E...

Page 21: ...anufacturer Address YASKAWA ELECTRIC CORPORATION 2 1 KUROSAKISHIROISHI YAHATANISHI KU KITAKYUSHU JAPAN 1 9 Authorized representative Address YASKAWA Europe GmbH Robotics Division Yaskawastr 1 85391 Al...

Page 22: ...ecking the scope of delivery The standard delivery includes the following items Fig 2 1 Scope of supply Programming pendant The present assembly instructions Robot controller Cable Robot MOTOMAN MANUA...

Page 23: ...NOTICE Please contact the local YASKAWA branch office if the serial numbers do not match the information on the delivery note S N DX200 YASAKAW DX200 Part No Power Supply Peak kVA AC 400 415 440 Aver...

Page 24: ...Using a crane Adequate load handling devices must be used to transport the robot controller Make sure that the robot controller is lifted as shown in the diagram Transport by crane below Fig 3 1 Trans...

Page 25: ...s take due care when transporting the robot controller Fig 3 2 Using a forklift 3 1 3 Using a lifting truck By removing the lower front cover you will access to a tunnel under the cabinet Normally cab...

Page 26: ...t appropriate protective measures can lead to death of people serious bodily harm or material damage Implement the following protection measures Separating protection devices Non contact protection de...

Page 27: ...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 Must comply with the requirements of Directive...

Page 28: ...5 440 Average kVA Serial No Date Signature Type ERDR Robot Type Robot Order No Robot Serial No YASKAWA ELECTRIC CORPORATION 2 1 SHIROISHI KUROSAKI YAHATANISHILU KITAKYUSYU JAPAN YASKAWA Europe Robotic...

Page 29: ...OFF the main power supply Attach the required warning sign e g Do not energize Install a switch on guard as prescribed Do not touch any board inside the controller for five minutes after turning OFF t...

Page 30: ...connects the manipulator and robot controller Another connects the robot controller and peripheral device A wrong connection can cause damage to electronic equipment Clear the area of all unauthorize...

Page 31: ...ty of some high frequency current leakage from the robot controller However this current leakage presents no safety risks Fig 5 1 Connection of the Leakage Breaker Manufacturer Model Mitsubishi Electr...

Page 32: ...power capacity of several times the continuous rating value may be needed instantly 3 phase 200 220VAC at 60Hz or 200V AC 50Hz Connection of the Leakage Breaker Leakage Breaker Robot controller Breake...

Page 33: ...rogramming pendant cable Robot Front view Rear view All dimensions in mm Main switch at the front side of the robot controller 432BS6 ABB 1 2 3 4 5 6 7 DX200 YASAKAW DX200 Part No Power Supply Peak kV...

Page 34: ...ing 5 34 2 Connect the power supply cable to the CEE connector at the back side of the robot controller Connector type back side of robot controller Connector type cable side 1 432BS6 ABB 432C6 ABB 2...

Page 35: ...3 Connecting the programming pendant Connect the programming pendant cable to the connector connection X81 on the door of the robot controller see figure Connection programming pendant Fig 5 5 Connect...

Page 36: ...000 instructions and 20 000 PLC steps Interface RS 232C Ethernet Protection class Cabinet IP54 Cooling fan Not classified Motor and signal cable IP67 Robot See the operation and maintenance manual of...

Page 37: ...t axes Machine lock Test run of the peripheral device is possible without robot movement Programming functions Programming language INFORM III Robot motion control Joint coordinates linear circular in...

Page 38: ...lindrical Tool User Coordinates Speed setting Fine adjustment possible during OPERATION or TEACH mode Shortcuts Direct access keys and user selectable screen keys possible Language Most important lang...

Page 39: ...tions Start key Keys for movement types Hold key 3 position hold to run button Emergency stop button Optional position of the 3 position hold to run button Insertion slot for CF Card Cursor key Page k...

Page 40: ...Technical data 6 40 Released OFF Squeezed tightly OFF Squeezed ON Servo On 1 2 3 1 3 2...

Page 41: ...n Daily Check for gaps or damage to the sealed construction Visual inspec tion Monthly Power cable Check for damage and deterio ration of leads Visual inspec tion as required Interiorcirculation fan a...

Page 42: ...he internal cooling fan JZNC YZU01 E inside CPU unit JZNC YPS21 E When the message of the Cooling fan in YPS unit stopped replace cooling fan is displayed carry out an inspection and the replacement o...

Page 43: ...t The SERVO ON lamp will flashes Fig 7 3 Flashing light SERVO ON 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...

Page 44: ...battery weak appears at the bottom of the display Check that the message is NOT not displayed on the programming pendant 7 6 Check the power supply Check the voltage of 1 3 5 terminal of the main powe...

Page 45: ...lling out looseness or breaking from the connecting part Input Power Supply Check Check the open phase voltage of input power supply with an elec tric tester Normal value AC400 415 440V 10 15 Main swi...

Page 46: ...g 7 5 Open Phase Check Power Supply X4 Converter Main switch Power Supply Contactor Unit Transfer Filters Fuse 2 U 4 V 6 W AC400 415 440V 200V 1KM 2KM 1 R 3 S 5 T 1 2 3 4 5 6 CN555 T1 AE2 TP1 V1 Q1M F...

Page 47: ...larm occurs CAUTION Damage to property caused by short circuit As power supply is reversed for each signal a short circuit and thus a possible a robot control failure occurs Do not connect the two sig...

Page 48: ...d supplies power 3 phase AC200 220V to the converter The power supply single phase AC200 220V is supplied to the control power supply via the line filter Main power supply input connector 601 Configur...

Page 49: ...axes control circuit board also has the following functions Brake power supply control circuit Shock sensor shock input circuit Direct in circuit Machine safety I O I F CN511 Major axes control circu...

Page 50: ...l axes control circuit board STO control signal I F CN523 STO control signal I F CN522 PWM amplifier 9 I F CN533 PWM amplifier 7 I F Lower CN531 PWM amplifier 8 I F Upper CN532 Encoder distribution fo...

Page 51: ...ig 8 1 CPU Unit Configuration PCI Slot for Sensor Board x 1 Compact Flash CN107 Rotary switch S1 USB CN106 I O I F Communication with the op tional I O CN114 For Programming Pendant CN105 Drive I F co...

Page 52: ...hange the factory setting of S1 Factory setting is 0 8 3 1 3 CPU board machine safety This circuit board JANCD YSF21 E performs I O processing or diagnosis processing for the safety sequence and it is...

Page 53: ...with CN152 of the Control power supply unit as shown in the following figure CN152 1 and CN152 2 is shortaged when shipment See chapter 8 25 Brake control circuit board JANCD YBK21 3E at page 89 for...

Page 54: ...circuit for the robot system Machine safety terminal block circuit board I F NOTICE If the F1 fuse becomes blown it will cause a damage on the inner circuit of the board Replace the board instead of...

Page 55: ...terminals for the end of the signal line Fig 8 2 Direct Connection to Tool Shock Sensor Signal Line Pin terminal name Terminal model Signal line terminal model SHOCK TMEDN 630809 MA TMEDN 630809 FA m...

Page 56: ...shock sensor refer to the wiring diagrams in the INSTRUCTIONS for the robot Fig 8 3 Connection with robot cable NOTICE If the tool shock sensor input signal is used the method for stopping the robot...

Page 57: ...ircuit board JANCD YFC22 E is for the system external signal to connect with the safety I O signals For connection refer to the connection diagrams of each item Fig 8 4 Machine safety terminal block X...

Page 58: ...ith a jumper cable Used to connect the emer gency stop switch of an ex ternal device If the signal is input the ser vo power is turned OFF and the job is stopped As long as the signal input is active...

Page 59: ...o connect the tempo rary stop switch of an exter nal device If the signal is input the job is stopped As long as the signal is ON starting and axis move ments cannot be enabled EXSVON EXSVON 21 22 Ext...

Page 60: ...to input the overrun in the external axes other than the main body of the robot OT3_1 OT3_1 OT3_2 OT3_2 46 47 48 49 024V2 50 OT4_1 OT4_1 OT4_2 OT4_2 51 52 53 54 External axis overun Open Used to input...

Page 61: ...n The universal safety output signal is used in the safety logical circuit function Also inputs and uses the driven connection device status as the monitoring sig nal by the output signal GSEDM1 GSEDM...

Page 62: ...rgency stop will not work even with incoming signal Be sure to remove the jumper before using Fig 8 5 Connection external emergency stop signal AIN_COM AXIN1 AXIN2 95 96 97 Universal input SERVO Open...

Page 63: ...urned ON Note that these signals are disabled in teach mode CAUTION Injuries and machine damages caused by short circuit Jumpers are installed at the factory If the jumpers are not removed the externa...

Page 64: ...SERVO power turns OFF As long as the interlock signal is active the SERVO power cannot be turned ON However the servo power does not turn OFF when the door is opened only during the TEACH mode In this...

Page 65: ...pers are installed at the factory If the jumpers are not removed the external emergency stop will not work even with incoming signal Be sure to remove the jumper before using Fig 8 7 Connection extern...

Page 66: ...SSP input signal determines the slow speed The first slow speed 16 or second slow speed 2 Setting Method 1 Short circuit terminal numbers 13 and 14 of the machine safety terminal block circuit board...

Page 67: ...the table above are the ratio against the robot s maximum speed not against the taught speed The values are for restraining the operation speed not to exceed the limit values of operation speed agains...

Page 68: ...before using Fig 8 9 Connection for slow operation mode 8 13 External hold This signal is used to connect a stop switch of an external device If the signal is input the job is stopped As long as the s...

Page 69: ...the signal is input the servo power is turned ON Fig 8 11 Connection for external SERVO ON Robot controller Remove the jumper cable I O terminal machine safety External hold I O board machine safety R...

Page 70: ...d from the specific output signal 50911 to the external device for each 100ms it is also able to check whether the robot controller control circuit board is normal or abnormal Refer to Instructions fo...

Page 71: ...t 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...

Page 72: ...N OFF at the same time I O Terminal machine safety External axis overrun 2 line I O Platine machine safety External axis overrun 3 line External axis overrun 1 line 42 43 44 45 CN219 OT2_1 OT2_2 OT2_1...

Page 73: ...s shown in the following figure For safety reasons dual circuits are used for the SERVO ON enable input signals Connect the signal switch so that both input signals are turned ON or OFF at the same ti...

Page 74: ...CAUTION Damage to property caused by short circuit Do not use the emergency stop button with a voltage of 24 V AC 0 5 A or more Fig 8 17 Emergency stop button output Control cabinet door of the robot...

Page 75: ...afety logic circuit function universal safety input Fig 8 18 Universal safety input Robot controller Universal safety input Machine safety terminal block circuit board Turn ON OFF at the same time Mac...

Page 76: ...tput value is DC24V and less than 50mA Avoid excessive load when connect When connect the inductive load such as the safety relay with the output circuit use of the built in protective circuit for the...

Page 77: ...e main axles of the slave robot SRDA EAXA01 I O terminal board machine safety Direct in SERVO I O board machine safety Connect the jumper cable Connect the jumper cable 85 86 87 88 89 90 84 91 92 93 9...

Page 78: ...Machine safety terminal block circuit board Universal input SERVO Machine safety I O logic ciruit board Connect the jumper cable Robotcontroller Major axes control circuit board Machine safety termina...

Page 79: ...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...

Page 80: ...stor and the relay output circuits Specific I O signal related to start and stop The following signals are specific I O signals related to start and stop SERVO ON depending on application JANCD YIO22...

Page 81: ...E Number in means output signal number assigned to YIU21 PL Pilot lamp SERVO ON PB SERVO ON confirmation SERVO_ON command Robot controller Machine safety terminal block circuit board Machine safety I...

Page 82: ...can be started The playback signal RUNNING confirms that the robot is actually moving NOTICE Number in means output signal number assigned to YIU21 PL Pilot lamp Run PB While SERVO ON Selects PLAY mo...

Page 83: ...e the robot control Power supply circuit for I O 24 VU 024 VU has 3 15A fuses F1 F2 Install the external power supply outside the DX200 to avoid electric noise problems If the internal power supply is...

Page 84: ...xes Robot external axes according to the command signal from the major axes control circuit board SRDA EAXA21A Axes control cicuit board I F CN405 For external brake power supply CN404 Brake power sup...

Page 85: ...Converter control signal CN553 Monitor Alarm indication LED DC control power supply CN551 Control power supply output for six axes amplifier CN552A Control power supply output for external axes amplif...

Page 86: ...module smooth the DC voltage PN voltage created in the converter and also save the electric energy There are two type of the capacitors shown below Small capacity SRDA CUA662AA Medium Large capacity S...

Page 87: ...amplifier module exchanges the DC power supply supplied by a converter for a 3 phase motor power source and outputs to each servo motor Fig 8 25 Amplifier Position Main circuit power supply input CN5...

Page 88: ...8 A8 B9 A9 B10 A10 B11 A11 B12 A12 B13 A13 B14 A14 B15 A15 B16 A16 B17 A17 B18 A18 B19 A19 B20 A20 AE7 EFA 14 4 JANCD YIO22 E B1 20040 CN306 IN009 A1 20041 IN010 B2 20042 IN011 A2 20043 IN012 B3 20044...

Page 89: ...board Optocoupler Inputs Relay Outputs max 500mA 024VU AE7 EFA 14 4 B1 20050 CN307 IN017 A1 20051 IN018 B2 20052 IN019 A2 20053 IN020 B3 20054 IN021 A3 20055 IN022 B4 20056 IN023 A4 20057 IN024 B18 2...

Page 90: ...A6 B7 A7 B8 A8 B9 A9 B10 A10 B11 A11 B12 A12 B13 A13 B14 A14 B15 A15 B16 A16 B17 A17 B18 A18 B19 A19 B20 A20 assignment interface board AE7 EFA 14 4 B1 20010 CN308 A1 20011 B2 20012 A2 20013 B3 20014...

Page 91: ...B14 A14 B15 A15 B16 A16 B17 A17 B18 A18 B19 A19 B20 A20 assignment interface board AE7 EFA 14 4 B1 20024 CN309 A1 20025 B2 20026 A2 20027 B3 20030 IN001 A3 20031 IN002 B4 20032 IN003 A4 20033 IN004 B...

Page 92: ...nly the rising edge of the sig nal is valid When this selection signal assigned concurrently with other mode selection signal the teach mode is selected on a pri ority basis The signal is invalid whil...

Page 93: ...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 T...

Page 94: ...orming the weaving opera tion 20027 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 30010 RUNNING T...

Page 95: ...8 30050 to30057 HAND VALVE 1 4 These outputs are controlled by the HAND handling specific instruc tions Hand valves 1 to 4 correspond to HAND 1 to 4 Logical number I O Name Function 20024 INTERFERENC...

Page 96: ...signal turns OFF 200501 TIMER COOLING WATER ERROR This signal monitors the status of timer cooling water The robot dis plays alarm and stops when this signal is input The SERVO power sup ply remains O...

Page 97: ...IN CUBE 3 This signal is turned ON when the current TCP lies within a pre defined area cube 3 Use this signal to prevent faults due to other robots or positioners 30025 IN CUBE 4 This signal is turned...

Page 98: ...theses 2 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 3 This signal can be...

Page 99: ...14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 T P R K L F G H S J M N E A B C D MR Connector MS Connector GASOF Gas Shortage GASOF Gas Shortage WIRCUT Wire Shortage ARCACT ArcGenerat...

Page 100: ...21 E Machine safety I O logic circuit board JANCD YSF22 E Machine safety terminal block JANCD YFC22 E Universal I O circuit board JANCD YIO22 E Power ON unit JZRCR YPU51 1 Major axes control circuit b...

Page 101: ...ic circuit board JANCD YSF22 E Machine safety terminal block JANCD YFC22 E Universal I O circuit board JANCD YIO22 E Power ON unit JZRCR YPU51 1 Major axes control circuit board SRDA EAXA21A Brake con...

Page 102: ...ic circuit board JANCD YSF22 E Machine safety terminal block JANCD YFC22 E Universal I O circuit board JANCD YIO22 E Power ON unit JZRCR YPU51 1 Major axes control circuit board SRDA EAXA21A Brake con...

Page 103: ...essed Injury or damage to machinery may result if the robot cannot be stopped in case of an emergency The emergency stop buttons are located on the right of the front door of the robot controller and...

Page 104: ...esistance 0 1 Noise Level Less than 62 dB Digital I O General signals standard max 40 inputs and 40 outputs Transistor 32 outputs Relay 8 outputs Specific signal hardware 25 inputs and 7 outputs Posit...

Page 105: ...endant RS 232C RS 232C RS 422 Exclusion use USB port USB1 1 2 ports LAN 100 BASE TX 10BASE T 2 ports At CPU circuit board Application Arc welding Spot welding Handling General Others Essential Measure...

Page 106: ...I Robot Motion Control Joint coordinates Linear Circular interpolations Tool coordinates Speed Setting Percentage for joint coordinates 0 1mm s units for interpolations Angular velocity for T C P fixe...

Page 107: ...layed Units TFT Color liquid crystal display VGA 640 x 480 Touch panel Operated Units 3 position enable switch start switch hold switch and mode select switch with key three mode Type of the key for t...

Page 108: ...I O BOARD AE7 DSW 1 2 X810 OPTION FUNCTIONAL SAFETY X181 OPTION MACHINE SAFETY TERMINAL BOARD X18 I O TERMINAL X12A X13B OPTION EX AXIS CONTROL BOARD AE6 1 OPTION BRAKE CONTROL BOARD AE5 BACKSIDE OF...

Page 109: ...n throughout the interior of the robot controller Make sure the door of the robot controller is closed when it s used to keep this cooling system effective Fig 9 3 Cooling System Front view Door Inter...

Page 110: ...Brake control board AE5 backside of axis control board CPU unit AE1 Axis control board AE6 0 I O Terminal X12A X13B option Ex axis control board AE6 1 Machine Safety I O logic board AE4 Safety functio...

Page 111: ...Recommended spare parts list 10 111 Fig 10 1 SERVOPACK TA1 to TA9 The SERVOPACK types is different depending on robot model TA7 Option TA8 Option TA9 Option TA4 TA6 TA3 TA2 TA1 TA5...

Page 112: ...ption Ex axis control board AE6 1 Machine Safety I O logic board AE4 Safety functional board AE6 2 Functional safety X181 option Terminal X9 Machine safety terminal board X18 Circuit breaker FS1 Funct...

Page 113: ...circuit board JZNC YRK21 1E master 164756 YEC I F board JANCD YIF01 2E master E145855 YEC Safety CPU board JANCD YSF21 E master 164757 YEC Safety I O board JANCD YSF22 E Master Slave 164758 YEC I O bo...

Page 114: ...YIF01 2E master E145855 YEC Safety CPU board JANCD YSF21 E master 164757 YEC Safety I O board JANCD YSF22 E Master Slave 164758 YEC I O board PNP type JANCD YIO22 E master 164762 YEC Power supply unit...

Page 115: ...E Slave E147571 YEC Rack circuit board JZNC YRK21 1E master 164756 YEC I F board JANCD YIF01 2E master E145855 YEC Safety CPU board JANCD YSF21 E master 164757 YEC Safety I O board JANCD YSF22 E Mast...

Page 116: ...YASKAWA Headquarter...

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YASKAWA Motoman DX200, User Manual

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