1 Safety
1.1 For Your Safety
1.2 Special Training
1.3 Motoman Manual List
1.4 Personnel Safety
1.5 Motoman Safety
1.5.1 Installation and Wiring Safety
1.5.2 Work Area Safety
1.5.3 Operation Safety
1.6 Notes for Moving and Transferring the MOTOMAN
1.7 Notes on MOTOMAN Disposal
2 Product Confirmation
2.1 Contents Confirmation
2.2 Order Number Confirmation
3 Installation
3.1 Handling Procedure
3.1.1 Using a Crane to Move the Controller
3.1.2 Using a Forklift to Move the Controller
3.2 Place of Installation
3.3 Location
3.4 Mounting the Controller
3.5 Procedure of Stacking the Controllers
4 Connection
4.1 Notes on Cable Junctions
4.2 Power Supply
4.2.1 Three-Phase Power Supply
4.2.2 Noise Filter Installation
4.2.3 Leakage Breaker Installation
4.2.4 Primary Power Supply Breaker Installation
4.3 Connection Methods
4.3.1 Connecting the Primary Power Supply
4.3.2 Connecting the Manipulator Cable
4.3.3 Connecting the Programming Pendant
4.3.4 User I/O Cable Connection
5 Turning ON and OFF the Power Supply
5.1 Turning ON the Main Power Supply
5.1.1 Initial Diagnosis
5.1.2 When Initial Diagnosis are Complete
5.2 Turning ON the Servo Power
5.2.1 During Play Mode
5.2.2 During Teach Mode
5.3 Turning OFF the Power Supply
5.3.1 Turning OFF the Servo Power (Emergency Stop)
5.3.2 Turning OFF the Main Power
5.3.3 The Method of Stopping Manipulator Operation
6 Test of Program Operation
6.1 Movement of the Axes
6.2 Manual Brake Release Function
7 Security System
7.1 Protection Through Security Mode Settings
7.1.1 Security Mode
7.1.1.1 Changing the Security Mode
7.1.2 User ID
7.1.2.1 Changing User ID
8 System Setup
8.1 Home Position Calibration
8.1.1 Home Position Calibration
8.1.2 Calibrating Operation
8.1.2.1 Registering All Axes at One Time
8.1.2.2 Registering Individual Axes
8.1.2.3 Changing the Absolute Data
8.1.2.4 Clearing Absolute Data
8.1.3 Home Position of the Robot
8.2 Setting the Second Home Position (Check Point)
8.2.1 Purpose of Position Check Operation
8.2.2 Procedure for the Second Home Position Setting (Check Point)
8.2.3 Procedure after the Alarm
8.3 Tool Data Setting
8.3.1 Registering Tool Files
8.3.1.1 Number of Tool Files
8.3.1.2 Registering Coordinate Data
8.3.1.3 Registering Tool Angle
8.3.1.4 Setting the Tool Load Information
8.3.2 Tool Calibration
8.3.2.1 Tool Calibration
8.3.2.2 Setting of Tool Calibration Method
8.3.2.3 Teaching of Calibration Point
8.3.2.4 Clearing Calibration Data
8.3.2.5 Checking the TCP
8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity
8.3.3.1 What is the Automatic Measurement of the Tool Load and the Center of Gravity?
8.3.3.2 Measurement of the Tool Load and the Center of Gravity
8.4 ARM Control
8.4.1 ARM Control
8.4.2 ARM CONTROL Window
8.4.2.1 Robot Setup Condition
8.4.3 Tool Load Information Setting
8.4.3.1 Tool Load Information
8.4.3.2 How to Calculate Tool Load Information
8.4.3.3 Tool Load Information Registering
8.5 Work Home Position
8.5.1 What is the Work Home Position?
8.5.2 Setting Work Home Position
8.5.2.1 Work Home Position Window
8.5.2.2 Registering/Changing the Work Home Position
8.5.2.3 Returning to the Work Home Position
8.5.2.4 Output of the Work Home Position Signal
8.6 Interference Area
8.6.1 Interference Area
8.6.2 Cubic Interference Area
8.6.2.1 Cubic Interference Area
8.6.2.2 Cube Setting Method
8.6.2.3 Setting Operation
8.6.3 Axis Interference Area
8.6.3.1 Axis Interference Area
8.6.3.2 Setting Operation
8.6.4 Clearing the Interference Area Data
8.7 Shock Detection Function
8.7.1 Shock Detection Function
8.7.2 Shock Detection Function Setting
8.7.2.1 Shock Detection Level Setting
8.7.2.2 EACH AXIS LEVEL (CURRENT) Window
8.7.2.3 Tool Load Information Setting
8.7.2.4 U-Arm Payload Setting
8.7.2.5 Instruction of Shock Detection Function
8.7.2.6 Resetting the Shock Detected
8.7.3 High-Sensitivity Shock Detection Function (For Arc Welding Application Only)
8.7.3.1 Manipulator Type for High-Sensitivity Shock Detection Function
8.7.3.2 Setting for High-Sensitivity Shock Detection Function
8.7.3.3 Reading the Tool Load Information on the MAKER INITIAL VALUE Window
8.7.3.4 Explanation of Maker Initial Value
8.7.3.5 Reading the U-Arm Payload
8.7.3.6 Explanation of Maker Initial Value
8.8 User Coordinate Setting
8.8.1 User Coordinates
8.8.2 User Coordinate Setting
8.8.2.1 Selecting the User Coordinate File
8.8.2.2 Teaching the User Coordinates
8.8.2.3 Clearing the User Coordinates
8.9 Overrun/Tool Shock Sensor Releasing
8.10 Soft Limit Release Function
8.11 All Limit Release Function
8.12 Instruction Level Setting
8.12.1 Setting Contents
8.12.1.1 Instruction Set
8.12.1.2 Learning Function
8.12.2 Setting the Instruction Set Level
8.12.3 Setting the Learning Function
8.13 Setting the Controller Clock
8.14 Setting the Play Speed
8.15 Numeric Key Customize Function
8.15.1 What is the Numeric Key Customize Function?
8.15.2 Allocatable Functions
8.15.2.1 Key Allocation (EACH)
8.15.2.2 Key Allocation (SIM)
8.15.3 Allocating Operation
8.15.3.1 Allocation Window
8.15.3.2 Instruction Allocation
8.15.3.3 Job Call Allocation
8.15.3.4 Display Allocation
8.15.3.5 Alternate Output Allocation
8.15.3.6 Momentary Output Allocation
8.15.3.7 Pulse Output Allocation
8.15.3.8 Group (4-bit/8-bit) Output Allocation
8.15.3.9 Analog Output Allocation
8.15.3.10 Analog Incremental Output Allocation
8.15.4 Allocation of I/O Control Instructions
8.15.5 Execution of Allocation
8.15.5.1 Executing the Instruction/Output Control Allocation
8.15.5.2 Executing the Job Call Allocation
8.15.5.3 Executing the Display Allocation
8.15.5.4 Executing the I/O Control Allocation
8.16 Changing the Output Status
8.17 Changing the Parameter Setting
8.18 File Initialization
8.18.1 Initializing Job File
8.18.2 Initializing Data File
8.18.3 Initializing Parameter File
8.18.4 Initializing I/O Data
8.18.5 Initializing System Data
8.19 Display Setting Function
8.19.1 Font Size Setting
8.19.1.1 Applicable Range for the Font Size Change
8.19.1.2 Settable Font Size
8.19.1.3 Setting the Font Size
8.19.2 Operation Button Size Setting
8.19.2.1 Applicable Range for the Button Size Change
8.19.2.2 Settable Button Size
8.19.2.3 Setting the Button Size
8.19.3 Initialization of Screen Layout
8.19.3.1 Initializing the Screen Layout
8.19.4 Layout Storage
8.20 Encoder Back-up Error Recovery Function
8.20.1 About Encoder Back-up Error Recovery Function
8.20.2 Encoder Back-up Error Recovery Function Operation
8.21 Preventive Maintenance Function
8.21.1 Preventive Maintenance Function
8.21.2 Preventive Maintenance Function for the Speed Reducer
8.21.2.1 Diagnose by the Lifetime Calculation
8.21.2.2 Diagnose by the Torque Average Value
8.21.2.3 After Replacement of the Speed Reducer
8.21.3 Inspection Notice Function
8.21.3.1 Inspection Signal
8.21.3.2 The Inspection Notice Window
8.21.4 Record of the Inspection Day ∙ the Replacement Day
8.21.5 Management of the Data
8.21.6 Preventive Maintenance for the Hardware
8.21.6.1 Target Components for Diagnosis
8.21.6.2 Replacement Time Display
8.21.6.3 Replacement of Component
8.21.7 Setting of Preventive Maintenance for the Hardware
8.21.7.1 Setting of Replacement Time Display
8.21.7.2 Mask of Replacement Time Display (Signal Display)
8.21.8 Display of the Numbers of Motor Revolution and Reverse Revolution
8.21.8.1 Display of the Numbers of Revolution and Reverse Revolution
8.21.8.2 Percent Display of the Number of Motor Revolution
8.21.8.3 Resetting the Number of Revolution
8.21.8.4 Changing the Numbers of Revolution and Reverse Revolution
8.22 Break Line Ground Judgement Function
8.22.1 About the break Line Ground Judgement Function
8.22.2 Operating Condition
8.22.3 Operation
8.22.3.1 Arising the DC 24V Power Supply Failure (SERVO)
8.22.3.2 Break Line Ground Check
8.22.3.3 Initializing the Related Information
8.23 Safety Logic Circuit
8.23.1 Outline
8.23.2 Set up the Safety Logic Circuit
8.23.2.1 Changing the Security Mode
8.23.2.2 Allocating the Machine Safety Signal
8.23.2.3 Allocating the Safety Signal Board
8.23.2.4 Timer Delay
8.23.2.5 Safety Logic Circuit
8.23.3 Performing the Safety Logic Circuit
8.23.4 The Safety Logic Circuit Expansion Function
8.23.4.1 Setting for the Safety Logic Circuit Expansion Function
8.23.4.2 Outline of the Safety Logic Circuit Expansion Function
8.23.4.3 Setting the Comment
8.23.4.4 Adding Input and Output Signals and Instructions in Safety Logic Circuit Expansion Function
8.23.4.5 Output Signal
8.23.4.6 Message of Output Signals
8.23.4.7 Enable Switch Link Function
8.23.4.8 Signal List Window
8.23.4.9 Setting ON/OFF to the Input Signals
8.23.4.10 Setting for the Universal Safety Output Signals
8.23.4.11 Setting for the Safety Signal Allocation Board
8.23.4.12 Update and Execution of the Safety Logic Circuit
8.23.4.13 Sample of the Safety Logic Circuit Expansion Function
8.23.4.14 Saving or Loading the File
8.23.4.15 Alarm List of the Safety Logic Circuit
8.23.4.16 Specific Input Signals allocated to SPIN[xx]
8.23.4.17 Output to the Control Status Signal
8.23.5 Saving or Loading the File
8.23.5.1 Saving the File
8.23.5.2 Loading the File
8.23.6 Initializing the Safety Logic Circuit File
8.23.6.1 Initializing the Safety Logic Circuit File
8.23.6.2 Machine Safety Flash Data Erase or Reset
8.23.7 Example of Safety Logic Circuit
8.23.8 Alarm List of the Safety Logic Circuit
8.24 Robot Stop Factor Monitor Function
8.24.1 Outline
8.24.1.1 The Robot Stop Factor
8.24.1.2 The Robot Stop Factor Record Number
8.24.2 Operation
8.24.2.1 Displaying the Robot Stop Factor Monitor
8.24.2.2 Clear the Robot Stop Factor Information
8.25 Robot Detachment Function
8.25.1 Setting Maintenance Mode
8.25.2 Setting Robot Detachment Function
8.26 Axes Detachment Function
8.26.1 Outline
8.26.2 Setting Maintenance Mode
8.26.3 Setting Axes Detachment Function
8.26.4 Specific Output and Messages
8.26.5 Restrictions
8.27 Variable Allocation
9 System Backup
9.1 System Backup with DX200
9.1.1 Function Types of Data
9.1.1.1 CMOS.BIN
9.1.1.2 CMOSBK.BIN
9.1.2 Device
9.2 Backup by CMOS.BIN
9.2.1 CMOS.BIN Save
9.2.2 CMOS.BIN Load
9.3 Automatic Backup Function
9.3.1 Automatic Backup Function
9.3.1.1 Objective
9.3.1.2 Outline
9.3.2 Settings for Automatic Backup
9.3.2.1 The CompactFlash of the Programming Pendant
9.3.2.2 The CompactFlash of the YCP21 Board
9.3.2.3 RAMDISK on the YCP21 Board
9.3.2.4 DX200 Status and Automatic Backup
9.3.2.5 Setting Examples
9.3.2.6 AUTO BACKUP SET Display
9.3.2.7 AUTO BACKUP EXTENSION FUNCTION SET Window
9.3.3 Limiting the Automatic Backup File Creation
9.3.3.1 Setting to Limit the Automatic Backup File Creation
9.4 Loading the Backup Data from the CompactFlash
9.4.1 Loading Procedure
9.5 Error List
9.5.1 Error Contents
10 Upgrade Function
10.1 Functional Overview
10.2 Upgrade Procedure
10.2.1 Confirmation of Software Version
10.2.2 Automatic Upgrade of YPP
10.3 Error Message
11 Programming Pendant
11.1 Disconnection Function
11.2 Reset Function
11.3 Touch Panel Invalidate Function
12 Modification of System Configuration
12.1 Addition of I/O Modules
12.2 Allocating External I/O Signal
12.3 Addition of Base and Station Axes
12.3.1 Base Axis Setting
12.3.1.1 Selection of Base Axis Type
12.3.1.2 Connection Setting
12.3.1.3 Axis Configuration Setting
12.3.1.4 Mechanical Specification Setting
12.3.1.5 Motor Specification Setting
12.3.2 Station Axis Setting
12.3.2.1 Selection of Station Axis Type
12.3.2.2 Connection Setting
12.3.2.3 Axis Configuration Setting
12.3.2.4 Mechanical Specification Setting
12.3.2.5 Motor Specification Setting
13 DX200 Specification
13.1 Specification List
13.2 Function List
13.3 Programming Pendant
13.4 Equipment Configuration
13.4.1 Arrangement of Units and Circuit Boards
13.4.2 Cooling System of the Controller Interior
14 Description of Units and Circuit Boards
14.1 Power ON Unit (JZRCR-YPU51-☐)
14.2 Axes Control Circuit Board
14.2.1 Major Axes Control Circuit Board (SRDA-EAXA21A)
14.2.2 External Axes Control Circuit Board (SRDA-EAXB21A)
14.3 CPU Unit (JZNC-YRK21-1E)
14.3.1 CPU Unit Configuration
14.3.2 Unit and Circuit Board in the CPU Unit
14.3.2.1 CPU Circuit Board (JANCD-YCP21-E)
14.3.2.3 Machine Safety CPU Circuit Board
14.3.2.2 Robot I/F Circuit Board (JANCD-YIF01-☐E)
14.4 Control Power Supply Unit (JZNC-YPS21-E)
14.5 Machine Safety I/O Logic Circuit Board (JANCD-YSF22☐-E)
14.5.1 Machine Safety I/O Logic Circuit Board (JANCD-YSF22☐-E)
14.5.2 Connection for Tool Shock Sensor (SHOCK)
14.5.2.1 To Connect the Tool Shock Sensor Directly to the Tool Shock Sensor Signal Line
14.5.2.2 To Connect the Tool Shock Sensor with the Cable that is Built into the Manipulator
14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E)
14.6.1 Safety Plug
14.6.2 External Emergency Stop
14.6.3 External Enable Switch
14.6.4 Full-speed Test
14.6.5 Slow Speed Mode Selection
14.6.6 External Hold
14.6.7 External Servo ON
14.6.8 SYSRUN Signal Output
14.6.9 Connection for Servo-ON Enable Input
14.6.10 External Axes Overrun
14.6.11 Emergency Stop Output
14.6.12 Universal Safety Input
14.6.13 Universal Safety Output
14.6.14 Connection for Direct-in
14.6.15 Universal Input (Servo)
14.6.16 Universal Output (Servo)
14.7 Universal I/O Circuit Board (JANCD-YIO21-E)
14.7.1 Universal I/O Circuit Board (JANCD-YIO21-E)
14.8 break Control Circuit Board (JANCD-YBK21-3E)
14.8.1 break Control Circuit Board (JANCD-YBK21-3E)
14.9 Converter (SRDA-COA☐A21☐-E)
14.10 Capacitor Module (SRDA-CUA☐AA)
14.11 Amplifier Module (SRDA-SDA☐A01A-E)
14.12 WAGO Connector
14.13 Universal I/O Signal Assignment
14.13.1 Arc Welding
14.13.2 Handling
14.13.3 General Application
14.13.4 Spot Welding
14.13.5 JANCD-YEW01-E Circuit Board (Option)
14.13.5.1 Arc Welding
14.14 The List of the Equipment Configuration by Model
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