1CD

DX200
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATORS MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
The DX200 operators manuals above correspond to specific usage. Be sure to use the appropriate manual.
Part Number:
Revision:
165292-1CD
6
MANUAL NO.
RE-CTO-A220
165292-1CD
DX200 Controller
Copyright 2015, Yaskawa America, Inc.

Terms of Use and Copyright Notice
All rights reserved. This manual is freely available as a service to Yaskawa
customers to assist in the operation of Motoman robots, related equipment
and software This 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 copy the PDF files to another website, blog, cloud storage site or any
other means of storing or distributing online content.
Printed in the United States of America
First Printing, 2015
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200
www.motoman.com
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MANDATORY
This manual explains setup, diagnosis, maintenance, hardware,

etc. of the DX200 system. Read this manual carefully and be sure
to understand its contents before handling the DX200.
General items related to safety are listed in Section 1. To ensure

correct and safe operation, carefully read the section.
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
products warranty.
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We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer 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 approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200.
In this manual, the Notes for Safe Operation are classified as DANGER,
WARNING, CAUTION, MANDATORY or PROHIBITED.
DANGER
Indicates an imminent hazardous

situation which, if not avoided, could
result in death or serious injury to
personnel.
WARNING
Indicates a potentially hazardous

result in death or serious injury to
personnel.
CAUTION
MANDATORY
PROHIBITED
Indicates a potentially hazardous

result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the
items listed under this heading.
Must never be performed.
Even items described as CAUTION may result in a serious accident in

some situations.
At any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure

to follow all instructions, even if not designated as
DANGER, WARNING and CAUTION.
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WARNING
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 DX200 power
- 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 are problems.The emergency stop buttons are
located on the right of the front door of the DX200 and the programming
pendant.
Observe the following precautions when performing teaching

operations within the P-point 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 sure no one closes the
safeguarding.
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
Before operating the manipulator, check that servo power is

turned OFF when the emergency stop buttons on the front
door of the DX200 and programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned 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 buttons do 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
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CAUTION
Perform the following inspection procedures prior to

conducting manipulator teaching. If problems are found,
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.
Always return the programming pendant to the hook on the

DX200 cabinet after use.
The programming pendant can be damaged if it is left in the P-point

maximum envelope of the manipulators work area, on the floor, or near
fixtures.
Read and understand the Explanation of the Warning Labels

before operating the manipulator.
Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows:
Equipment
Manual Designation
DX200 Controller
DX200
DX200 Programming Pendant
Programming Pendant
Cable between the manipulator and

the controller
Manipulator Cable
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Descriptions of the programming pendant, buttons, and displays are

shown as follows:
Equipment
Manual Designation
Programming Character
Pendant
Keys
Symbol
Keys
The keys which have characters printed on

them are denoted with [ ].
ex. [ENTER]
Axis Keys
Number Keys
Axis Keys and Number Keys are generic

names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed

simultaneously simultaneously, the keys are shown with a +
sign between them, ex. [SHIFT]+[COORD]
Displays
The menu displayed in the programming

pendant is denoted with { }.
ex. {JOB}
Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select "
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
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Explanation of Warning Labels

The following warning labels are attached to the manipulator and DX200.
Fully comply with the precautions on the warning labels.
DANGER
The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
Failure to observe this caution may result in injury or damage to

equipment.
WARNING
WARNING
Do not enter
robot
work area.
Moving parts
may cause
injury
Refer to the manipulator manual for the warning label location.
The following warning labels are attached to DX200.
Observe the precautions on the warning labels.

Failure to observe this warning may result in injury or damage to
equipment.
WARNING
WARNING
High Voltage
Do not open the door
with power ON.
High Voltage
Do not open the cover.
WARNING
May cause
electric shock.
Ground the earth
terminal based on
local and national
electric code.
WARNING
High Voltage
Do not ope the cover.
WARNING
High Voltage
Do not open the door
with power ON.
WARNING
May cause
electric shock.
Ground the earth
terminal based on
local and national
electric code.
Internal Breaker
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Customer Support Information

If you need assistance with any aspect of your DX200 Controller system,
please contact Motoman Customer Support at the following
24-hour telephone number:
(937) 847-3200
For routine technical inquiries, you can also contact Motoman Customer
Support at the following e-mail address:
[email protected]
When using e-mail to contact Motoman Customer Support, please provide

a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
NOTE
Please use e-mail for routine inquiries only. If you have an

urgent or emergency need for service, replacement parts,
or information, you must contact Motoman Customer
Support at the telephone number shown above.
Please have the following information ready before you call:

System
DX200 Controller
Robots
Primary Application
Controller
DX200
Software Version
Access this information on the

Programming Pendants LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} {VERSION}
Robot Serial Number
Located on the robot data plate
Robot Sales Order Number
Located on the DX200 controller

data plate
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Table of Contents
Table of Contents
1 Safety.............................................................................................................................................. 1-1
1.1 For Your Safety.................................................................................................................. 1-1
1.2 Special Training ................................................................................................................. 1-2
1.3 Motoman Manual List ........................................................................................................ 1-2
1.4 Personnel Safety ............................................................................................................... 1-3
1.5 Motoman Safety................................................................................................................. 1-5
1.5.1 Installation and Wiring Safety ............................................................................... 1-5
1.5.2 Work Area Safety ................................................................................................. 1-9
1.5.3 Operation Safety ................................................................................................ 1-10
1.6 Notes for Moving and Transferring the MOTOMAN ........................................................ 1-13
1.7 Notes on MOTOMAN Disposal........................................................................................ 1-14
2 Product Confirmation ...................................................................................................................... 2-1
2.1 Contents Confirmation ....................................................................................................... 2-1
2.2 Order Number Confirmation .............................................................................................. 2-2
3 Installation....................................................................................................................................... 3-1
3.1 Handling Procedure ........................................................................................................... 3-1
3.1.1 Using a Crane to Move the Controller .................................................................. 3-1
3.1.2 Using a Forklift to Move the Controller ................................................................. 3-2
3.2 Place of Installation............................................................................................................ 3-3
3.3 Location ............................................................................................................................. 3-4
3.4 Mounting the Controller ..................................................................................................... 3-5
3.5 Procedure of Stacking the Controllers ............................................................................... 3-6
4 Connection...................................................................................................................................... 4-1
4.1 Notes on Cable Junctions.................................................................................................. 4-2
4.2 Power Supply..................................................................................................................... 4-3
4.2.1 Three-Phase Power Supply.................................................................................. 4-3
4.2.2 Noise Filter Installation ......................................................................................... 4-3
4.2.3 Leakage Breaker Installation ................................................................................ 4-4
4.2.4 Primary Power Supply Breaker Installation .......................................................... 4-5
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4.3 Connection Methods .......................................................................................................... 4-6

4.3.1 Connecting the Primary Power Supply ................................................................. 4-6
4.3.2 Connecting the Manipulator Cable ..................................................................... 4-11
4.3.3 Connecting the Programming Pendant............................................................... 4-12
4.3.4 User I/O Cable Connection................................................................................. 4-13
5 Turning ON and OFF the Power Supply ......................................................................................... 5-1
5.1 Turning ON the Main Power Supply .................................................................................. 5-1
5.1.1 Initial Diagnosis..................................................................................................... 5-2
5.1.2 When Initial Diagnosis are Complete.................................................................... 5-2
5.2 Turning ON the Servo Power............................................................................................. 5-3
5.2.1 During Play Mode ................................................................................................. 5-3
5.2.2 During Teach Mode .............................................................................................. 5-3
5.3 Turning OFF the Power Supply ......................................................................................... 5-5
5.3.1 Turning OFF the Servo Power (Emergency Stop)................................................ 5-5
5.3.2 Turning OFF the Main Power ............................................................................... 5-5
5.3.3 The Method of Stopping Manipulator Operation................................................... 5-6
6 Test of Program Operation.............................................................................................................. 6-1
6.1 Movement of the Axes ....................................................................................................... 6-3
6.2 Manual Brake Release Function........................................................................................ 6-4
7 Security System .............................................................................................................................. 7-1
7.1 Protection Through Security Mode Settings ...................................................................... 7-1
7.1.1 Security Mode....................................................................................................... 7-1
7.1.1.1 Changing the Security Mode ................................................................... 7-6
7.1.2 User ID.................................................................................................................. 7-9
7.1.2.1 Changing User ID .................................................................................... 7-9
8 System Setup.................................................................................................................................. 8-1
8.1 Home Position Calibration ................................................................................................. 8-2
8.1.1 Home Position Calibration .................................................................................... 8-4
8.1.2 Calibrating Operation............................................................................................ 8-5
8.1.2.1 Registering All Axes at One Time............................................................ 8-5
8.1.2.2 Registering Individual Axes ..................................................................... 8-8
8.1.2.3 Changing the Absolute Data ................................................................... 8-9
8.1.2.4 Clearing Absolute Data............................................................................ 8-9
8.1.3 Home Position of the Robot................................................................................ 8-11
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8.2 Setting the Second Home Position (Check Point) ........................................................... 8-12
8.2.1 Purpose of Position Check Operation ................................................................ 8-14
8.2.2 Procedure for the Second Home Position Setting (Check Point) ....................... 8-16
8.2.3 Procedure after the Alarm .................................................................................. 8-18
8.3 Tool Data Setting ............................................................................................................. 8-20
8.3.1 Registering Tool Files......................................................................................... 8-20
8.3.1.1 Number of Tool Files ............................................................................. 8-20
8.3.1.2 Registering Coordinate Data ................................................................. 8-20
8.3.1.3 Registering Tool Angle .......................................................................... 8-23
8.3.1.4 Setting the Tool Load Information ......................................................... 8-24
8.3.2 Tool Calibration .................................................................................................. 8-25
8.3.2.1 Tool Calibration ..................................................................................... 8-25
8.3.2.2 Setting of Tool Calibration Method ........................................................ 8-25
8.3.2.3 Teaching of Calibration Point ................................................................ 8-26
8.3.2.4 Clearing Calibration Data ...................................................................... 8-32
8.3.2.5 Checking the TCP ................................................................................. 8-34
8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity ................ 8-36
8.3.3.1 What is the Automatic Measurement of the Tool Load and
the Center of Gravity? ........................................................................... 8-36
8.3.3.2 Measurement of the Tool Load and the Center of Gravity .................... 8-36
8.4 ARM Control .................................................................................................................... 8-41
8.4.1 ARM Control ....................................................................................................... 8-41
8.4.2 ARM CONTROL Window ................................................................................... 8-41
8.4.2.1 Robot Setup Condition .......................................................................... 8-42
8.4.3 Tool Load Information Setting ............................................................................ 8-46
8.4.3.1 Tool Load Information ........................................................................... 8-46
8.4.3.2 How to Calculate Tool Load Information ............................................... 8-47
8.4.3.3 Tool Load Information Registering ........................................................ 8-52
8.5 Work Home Position ........................................................................................................ 8-55
8.5.1 What is the Work Home Position?...................................................................... 8-55
8.5.2 Setting Work Home Position............................................................................... 8-55
8.5.2.1 Work Home Position Window................................................................ 8-55
8.5.2.2 Registering/Changing the Work Home Position .................................... 8-57
8.5.2.3 Returning to the Work Home Position ................................................... 8-58
8.5.2.4 Output of the Work Home Position Signal............................................. 8-58
8.6 Interference Area ............................................................................................................. 8-59
8.6.1 Interference Area................................................................................................ 8-59
8.6.2 Cubic Interference Area...................................................................................... 8-59
8.6.2.1 Cubic Interference Area ........................................................................ 8-59
8.6.2.2 Cube Setting Method ............................................................................ 8-60
8.6.2.3 Setting Operation .................................................................................. 8-61
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8.6.3 Axis Interference Area ........................................................................................ 8-70

8.6.3.1 Axis Interference Area ........................................................................... 8-70
8.6.3.2 Setting Operation .................................................................................. 8-70
8.6.4 Clearing the Interference Area Data ................................................................... 8-79
8.7 Shock Detection Function ................................................................................................ 8-81
8.7.1 Shock Detection Function................................................................................... 8-81
8.7.2 Shock Detection Function Setting....................................................................... 8-81
8.7.2.1 Shock Detection Level Setting............................................................... 8-81
8.7.2.2 EACH AXIS LEVEL (CURRENT) Window ............................................ 8-86
8.7.2.3 Tool Load Information Setting ............................................................... 8-87
8.7.2.4 U-Arm Payload Setting .......................................................................... 8-87
8.7.2.5 Instruction of Shock Detection Function ................................................ 8-87
8.7.2.6 Resetting the Shock Detected ............................................................... 8-94
8.7.3 High-Sensitivity Shock Detection Function (For Arc Welding Application Only). 8-95
8.7.3.1 Manipulator Type for High-Sensitivity Shock Detection Function.......... 8-95
8.7.3.2 Setting for High-Sensitivity Shock Detection Function .......................... 8-96
8.7.3.3 Reading the Tool Load Information on the
MAKER INITIAL VALUE Window .......................................................... 8-96
8.7.3.4 Explanation of Maker Initial Value ......................................................... 8-99
8.7.3.5 Reading the U-Arm Payload................................................................ 8-100
8.7.3.6 Explanation of Maker Initial Value ....................................................... 8-103
8.8 User Coordinate Setting................................................................................................. 8-104
8.8.1 User Coordinates.............................................................................................. 8-104
8.8.2 User Coordinate Setting ................................................................................... 8-105
8.8.2.1 Selecting the User Coordinate File...................................................... 8-105
8.8.2.2 Teaching the User Coordinates........................................................... 8-106
8.8.2.3 Clearing the User Coordinates ............................................................ 8-108
8.9 Overrun/Tool Shock Sensor Releasing.......................................................................... 8-109
8.10 Soft Limit Release Function ......................................................................................... 8-111
8.11 All Limit Release Function ........................................................................................... 8-112
8.12 Instruction Level Setting............................................................................................... 8-114
8.12.1 Setting Contents ............................................................................................. 8-114
8.12.1.1 Instruction Set ................................................................................... 8-114
8.12.1.2 Learning Function.............................................................................. 8-115
8.12.2 Setting the Instruction Set Level ..................................................................... 8-115
8.12.3 Setting the Learning Function......................................................................... 8-117
8.13 Setting the Controller Clock ......................................................................................... 8-118
8.14 Setting the Play Speed ................................................................................................ 8-119
8.15 Numeric Key Customize Function................................................................................ 8-121
8.15.1 What is the Numeric Key Customize Function? ............................................. 8-121
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8.15.2 Allocatable Functions ..................................................................................... 8-121

8.15.2.1 Key Allocation (EACH) ...................................................................... 8-121
8.15.2.2 Key Allocation (SIM).......................................................................... 8-122
8.15.3 Allocating Operation ....................................................................................... 8-123
8.15.3.1 Allocation Window ............................................................................. 8-123
8.15.3.2 Instruction Allocation ......................................................................... 8-124
8.15.3.3 Job Call Allocation............................................................................. 8-126
8.15.3.4 Display Allocation .............................................................................. 8-127
8.15.3.5 Alternate Output Allocation ............................................................... 8-129
8.15.3.6 Momentary Output Allocation ............................................................ 8-130
8.15.3.7 Pulse Output Allocation ..................................................................... 8-131
8.15.3.8 Group (4-bit/8-bit) Output Allocation.................................................. 8-132
8.15.3.9 Analog Output Allocation................................................................... 8-132
8.15.3.10 Analog Incremental Output Allocation ............................................. 8-133
8.15.4 Allocation of I/O Control Instructions .............................................................. 8-134
8.15.5 Execution of Allocation ................................................................................... 8-136
8.15.5.1 Executing the Instruction/Output Control Allocation .......................... 8-136
8.15.5.2 Executing the Job Call Allocation ...................................................... 8-136
8.15.5.3 Executing the Display Allocation ....................................................... 8-136
8.15.5.4 Executing the I/O Control Allocation.................................................. 8-136
8.16 Changing the Output Status ........................................................................................ 8-137
8.17 Changing the Parameter Setting ................................................................................. 8-139
8.18 File Initialization ........................................................................................................... 8-142
8.18.1 Initializing Job File .......................................................................................... 8-142
8.18.2 Initializing Data File ........................................................................................ 8-143
8.18.3 Initializing Parameter File ............................................................................... 8-145
8.18.4 Initializing I/O Data ......................................................................................... 8-147
8.18.5 Initializing System Data .................................................................................. 8-149
8.19 Display Setting Function .............................................................................................. 8-151
8.19.1 Font Size Setting ............................................................................................ 8-151
8.19.1.1 Applicable Range for the Font Size Change ..................................... 8-151
8.19.1.2 Settable Font Size ............................................................................. 8-151
8.19.1.3 Setting the Font Size ......................................................................... 8-152
8.19.2 Operation Button Size Setting ........................................................................ 8-156
8.19.2.1 Applicable Range for the Button Size Change .................................. 8-156
8.19.2.2 Settable Button Size.......................................................................... 8-156
8.19.2.3 Setting the Button Size...................................................................... 8-157
8.19.3 Initialization of Screen Layout......................................................................... 8-161
8.19.3.1 Initializing the Screen Layout ............................................................ 8-161
8.19.4 Layout Storage ............................................................................................... 8-163
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8.20 Encoder Back-up Error Recovery Function ................................................................. 8-164

8.20.1 About Encoder Back-up Error Recovery Function.......................................... 8-164
8.20.2 Encoder Back-up Error Recovery Function Operation ................................... 8-164
8.21 Preventive Maintenance Function................................................................................ 8-167
8.21.1 Preventive Maintenance Function .................................................................. 8-167
8.21.2 Preventive Maintenance Function for the Speed Reducer ............................. 8-167
8.21.2.1 Diagnose by the Lifetime Calculation ................................................ 8-168
8.21.2.2 Diagnose by the Torque Average Value............................................ 8-172
8.21.2.3 After Replacement of the Speed Reducer......................................... 8-183
8.21.3 Inspection Notice Function ............................................................................. 8-184
8.21.3.1 Inspection Signal ............................................................................... 8-185
8.21.3.2 The Inspection Notice Window .......................................................... 8-187
8.21.4 Record of the Inspection Day the Replacement Day ................................... 8-188
8.21.5 Management of the Data ................................................................................ 8-189
8.21.6 Preventive Maintenance for the Hardware ..................................................... 8-191
8.21.6.1 Target Components for Diagnosis..................................................... 8-191
8.21.6.2 Replacement Time Display................................................................ 8-191
8.21.6.3 Replacement of Component.............................................................. 8-192
8.21.7 Setting of Preventive Maintenance for the Hardware ..................................... 8-193
8.21.7.1 Setting of Replacement Time Display ............................................... 8-193
8.21.7.2 Mask of Replacement Time Display (Signal Display)........................ 8-198
8.21.8 Display of the Numbers of Motor Revolution and Reverse Revolution........... 8-200
8.21.8.1 Display of the Numbers of Revolution and Reverse Revolution........ 8-200
8.21.8.2 Percent Display of the Number of Motor Revolution ......................... 8-200
8.21.8.3 Resetting the Number of Revolution.................................................. 8-201
8.21.8.4 Changing the Numbers of Revolution and Reverse Revolution ........ 8-202
8.22 Break Line Ground Judgement Function ..................................................................... 8-203
8.22.1 About the break Line Ground Judgement Function ........................................ 8-203
8.22.2 Operating Condition........................................................................................ 8-203
8.22.3 Operation ........................................................................................................ 8-204
8.22.3.1 Arising the DC 24V Power Supply Failure (SERVO)......................... 8-204
8.22.3.2 Break Line Ground Check ................................................................. 8-205
8.22.3.3 Initializing the Related Information .................................................... 8-207
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8.23 Safety Logic Circuit...................................................................................................... 8-209

8.23.1 Outline ............................................................................................................ 8-209
8.23.2 Set up the Safety Logic Circuit ....................................................................... 8-210
8.23.2.1 Changing the Security Mode ............................................................. 8-210
8.23.2.2 Allocating the Machine Safety Signal ............................................... 8-212
8.23.2.3 Allocating the Safety Signal Board .................................................... 8-215
8.23.2.4 Timer Delay ....................................................................................... 8-219
8.23.2.5 Safety Logic Circuit ........................................................................... 8-223
8.23.3 Performing the Safety Logic Circuit ................................................................ 8-236
8.23.4 Saving or Loading the File.............................................................................. 8-237
8.23.4.1 Saving the File .................................................................................. 8-237
8.23.4.2 Loading the File................................................................................. 8-238
8.23.5 Initializing the Safety Logic Circuit File ........................................................... 8-239
8.23.5.1 Initializing the Safety Logic Circuit File.............................................. 8-240
8.23.5.2 Machine Safety Flash Data Erase or Reset ...................................... 8-243
8.23.6 Example of Safety Logic Circuit...................................................................... 8-245
8.23.7 Alarm List of the Safety Logic Circuit.............................................................. 8-253
8.24 Robot Stop Factor Monitor Function............................................................................ 8-254
8.24.1 Outline ............................................................................................................ 8-254
8.24.1.1 The Robot Stop Factor ...................................................................... 8-254
8.24.1.2 The Robot Stop Factor Record Number............................................ 8-258
8.24.2 Operation........................................................................................................ 8-258
8.24.2.1 Displaying the Robot Stop Factor Monitor......................................... 8-258
8.24.2.2 Clear the Robot Stop Factor Information........................................... 8-260
8.25 Robot Detachment Function ........................................................................................ 8-261
8.25.1 Setting Maintenance Mode............................................................................. 8-261
8.25.2 Setting Robot Detachment Function............................................................... 8-263
8.26 Axes Detachment Function.......................................................................................... 8-267
8.26.1 Outline ............................................................................................................ 8-267
8.26.2 Setting Maintenance Mode............................................................................. 8-267
8.26.3 Setting Axes Detachment Function ................................................................ 8-267
8.26.4 Specific Output and Messages....................................................................... 8-270
8.26.5 Restrictions..................................................................................................... 8-271
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9 System Backup ............................................................................................................................... 9-1

9.1 System Backup with DX200............................................................................................... 9-1
9.1.1 Function Types of Data......................................................................................... 9-1
9.1.1.1 CMOS.BIN............................................................................................... 9-1
9.1.1.2 CMOSBK.BIN .......................................................................................... 9-1
9.1.2 Device................................................................................................................... 9-1
9.2 Backup by CMOS.BIN ....................................................................................................... 9-3
9.2.1 CMOS.BIN Save................................................................................................... 9-3
9.2.2 CMOS.BIN Load ................................................................................................... 9-5
9.3 Automatic Backup Function ............................................................................................... 9-7
9.3.1 Automatic Backup Function .................................................................................. 9-7
9.3.1.1 Objective ................................................................................................. 9-7
9.3.1.2 Outline ..................................................................................................... 9-7
9.3.2 Settings for Automatic Backup.............................................................................. 9-9
9.3.2.1 The CompactFlash of the Programming Pendant ................................... 9-9
9.3.2.2 The CompactFlash of the YCP21 Board ............................................... 9-10
9.3.2.3 RAMDISK on the YCP21 Board ............................................................ 9-11
9.3.2.4 DX200 Status and Automatic Backup ................................................... 9-11
9.3.2.5 Setting Examples .................................................................................. 9-13
9.3.2.6 AUTO BACKUP SET Display ................................................................ 9-14
9.3.2.7 AUTO BACKUP EXTENSION FUNCTION SET Window...................... 9-19
9.3.3 Limiting the Automatic Backup File Creation ...................................................... 9-25
9.3.3.1 Setting to Limit the Automatic Backup File Creation ............................. 9-25
9.4 Loading the Backup Data from the CompactFlash .......................................................... 9-26
9.4.1 Loading Procedure ............................................................................................. 9-26
9.5 Error List .......................................................................................................................... 9-32
9.5.1 Error Contents .................................................................................................... 9-32
10 Upgrade Function........................................................................................................................ 10-1
10.1 Functional Overview ...................................................................................................... 10-1
10.2 Upgrade Procedure........................................................................................................ 10-1
10.2.1 Confirmation of Software Version ..................................................................... 10-1
10.2.2 Automatic Upgrade of YPP............................................................................... 10-2
10.3 Error Message ............................................................................................................... 10-4
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11 Programming Pendant ................................................................................................................ 11-1

11.1 Disconnection Function ................................................................................................. 11-1
11.2 Reset Function............................................................................................................... 11-3
11.3 Touch Panel Invalidate Function ................................................................................... 11-4
12 Modification of System Configuration ......................................................................................... 12-1
12.1 Addition of I/O Modules ................................................................................................. 12-1
12.2 Allocating External I/O Signal ........................................................................................ 12-4
12.3 Addition of Base and Station Axes .............................................................................. 12-11
12.3.1 Base Axis Setting ........................................................................................... 12-13
12.3.1.1 Selection of Base Axis Type.............................................................. 12-13
12.3.1.2 Connection Setting ............................................................................ 12-16
12.3.1.3 Axis Configuration Setting ................................................................. 12-20
12.3.1.4 Mechanical Specification Setting....................................................... 12-21
12.3.1.5 Motor Specification Setting................................................................ 12-23
12.3.2 Station Axis Setting ........................................................................................ 12-25
12.3.2.1 Selection of Station Axis Type........................................................... 12-25
12.3.2.2 Connection Setting ............................................................................ 12-27
12.3.2.3 Axis Configuration Setting ................................................................. 12-30
12.3.2.4 Mechanical Specification Setting....................................................... 12-32
12.3.2.5 Motor Specification Setting................................................................ 12-35
13 DX200 Specification.................................................................................................................... 13-1
13.1 Specification List............................................................................................................ 13-3
13.2 Function List .................................................................................................................. 13-4
13.3 Programming Pendant................................................................................................... 13-5
13.4 Equipment Configuration ............................................................................................... 13-6
13.4.1 Arrangement of Units and Circuit Boards ......................................................... 13-6
13.4.2 Cooling System of the Controller Interior.......................................................... 13-8
14 Description of Units and Circuit Boards ...................................................................................... 14-1
14.1 Power ON Unit (JZRCR-YPU51- ) ............................................................................. 14-4
14.2 Axes Control Circuit Board ............................................................................................ 14-5
14.2.1 Major Axes Control Circuit Board (SRDA-EAXA21A)....................................... 14-5
14.2.2 External Axes Control Circuit Board (SRDA-EAXB21A) .................................. 14-6
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14.3 CPU Unit (JZNC-YRK21-1E) ......................................................................................... 14-7

14.3.1 CPU Unit Configuration .................................................................................... 14-7
14.3.2 Unit and Circuit Board in the CPU Unit............................................................. 14-8
14.3.2.1 CPU Circuit Board (JANCD-YCP21-E)................................................ 14-8
14.3.2.2 Robot I/F Circuit Board (JANCD-YIF01- E)...................................... 14-8
14.3.2.3 Machine Safety CPU Circuit Board ..................................................... 14-8
14.4 Control Power Supply Unit (JZNC-YPS21-E) ................................................................ 14-9
14.5 Machine Safety I/O Logic Circuit Board (JANCD-YSF22 -E) ................................... 14-11
14.5.1 Machine Safety I/O Logic Circuit Board (JANCD-YSF22 -E) ...................... 14-11
14.5.2 Connection for Tool Shock Sensor (SHOCK)................................................. 14-12
14.5.2.1 To connect the tool shock sensor directly
to the tool shock sensor signal line................................................... 14-12
14.5.2.2 To connect the tool shock sensor with
the cable that is built into the manipulator ......................................... 14-13
14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E) .............................. 14-14
14.6.1 Safety Plug ..................................................................................................... 14-20
14.6.2 External Emergency Stop ............................................................................... 14-22
14.6.3 External Enable Switch................................................................................... 14-23
14.6.4 Full-speed Test ............................................................................................... 14-24
14.6.5 Slow Speed Mode Selection........................................................................... 14-26
14.6.6 External Hold .................................................................................................. 14-27
14.6.7 External Servo ON.......................................................................................... 14-28
14.6.8 SYSRUN Signal Output .................................................................................. 14-29
14.6.9 Connection for Servo-ON Enable Input .......................................................... 14-30
14.6.10 External Axes Overrun.................................................................................. 14-31
14.6.11 Emergency Stop Output ............................................................................... 14-33
14.6.12 Universal Safety Input................................................................................... 14-34
14.6.13 Universal Safety Output................................................................................ 14-34
14.6.14 Connection for Direct-in ................................................................................ 14-36
14.6.15 Universal Input (Servo) ................................................................................. 14-37
14.6.16 Universal Output (Servo) .............................................................................. 14-37
14.7 Universal I/O Circuit Board (JANCD-YIO21-E) ............................................................ 14-38
14.7.1 Universal I/O Circuit Board (JANCD-YIO21-E)............................................... 14-38
14.8 break Control Circuit Board (JANCD-YBK21-3E) ........................................................ 14-44
14.8.1 break Control Circuit Board (JANCD-YBK21-3E) ........................................... 14-44
14.9 Converter (SRDA-COA30A21B-E) .............................................................................. 14-45
14.10 Capacitor Module (SRDA-CUA AA) ....................................................................... 14-46
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14.11 Amplifier Module (SRDA-SDA A01A-E) ................................................................. 14-47

14.12 WAGO Connector...................................................................................................... 14-48
14.13 Universal I/O Signal Assignment ............................................................................... 14-49
14.13.1 Arc Welding .................................................................................................. 14-49
14.13.2 Handling ....................................................................................................... 14-55
14.13.3 General Application ...................................................................................... 14-61
14.13.4 Spot Welding ................................................................................................ 14-67
14.13.5 JANCD-YEW01-E Circuit Board (Option)..................................................... 14-75
14.13.5.1 Arc Welding ..................................................................................... 14-75
14.14 The List of the Equipment Configuration by Model.................................................... 14-76
Appendix A DX200 North American Standard (NAS) ........................................................................A-1
A.1 Equipment Configuration...................................................................................................A-1
A.1.1 Arrangement of Units and Circuit Boards.............................................................A-1
A.1.2 Cooling System of the Controller Interior .............................................................A-2
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1 Safety
1.1 For Your Safety
Safety
1.1
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 users 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
Factory Act (Gewerbeordnung) in Germany
Health and Safety at Work, etc. Act in UK
EC Machinery Directive 98/37/EC
Prepare
SAFETY WORK REGULATIONS
based on concrete policies for safety management complying with

related laws.
Observe
JIS B 8433-1:2007
(ISO 10218-1:2006)
INDUSTRIAL ROBOT- SAFETY REQUIREMENTS
for safe operation of the robot. (Japan Only) (JIS B 8433)
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 (Japan only).
Workers employed in these above operations are requested to attend

special training offered by YASKAWA.
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1 Safety
1.2 Special Training
1.2
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.
1.3
Motoman Manual List
MANDATORY
It is important to have and be familiar with all manuals concerning

the MOTOMAN.
You should have the four manuals listed below:

MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATORS MANUAL
Confirm that you have all these manuals on hand.
If any manuals are missing, contact your salesman from YASKAWAs
local branch office.
The relevant telephone numbers are listed on the back cover.
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1 Safety
1.4 Personnel Safety
1.4
Personnel Safety
The entire manipulator P-point maximum envelope is potentially
dangerous.
All personnel working with the MOTOMAN (safety administration,
installation, operation, and maintenance personnel) must always be
prepared and "Safety First" minded, to ensure the safety of all personnel.
WARNING
Avoid any dangerous actions in the area where the MOTOMAN is

installed.
There is a danger of injury if there is contact with the manipulator 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 manipulator and other equipment.
Strictly observe the following items:

Always wear approved work clothes (no loose-fitting clothes).
Do not wear gloves when operating the MOTOMAN.
Do not allow underwear, shirts, or neckties to hang out from the
work clothes.
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 manipulator or

associated peripheral equipment.
Failure to observe this caution may result in injury due to contact with
DX200, controller, the workpiece, the positioner, etc.
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1 Safety
1.4 Personnel Safety
CAUTION
Never forcibly move the manipulator axes.
Failure to observe this caution may result in injury or equipment

damage.
Never sit or lean on DX200 controller.
Failure to observe this caution may result in injury or equipment

damage.
Never touch the buttons inadvertently on DX200 or other

controllers.
Failure to observe this caution may result in injury or damage by

unexpected movement of the manipulator.
Never allow unauthorized personnel to touch the DX200 during

operation.
Failure to observe this caution may result in injury or damage resulting

from unexpected movement of the manipulator.
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1 Safety
1.5 Motoman Safety
1.5
Motoman Safety
The followings are safty functions of MOTOMAN / DX200.
Emergency stop SW input (controller/programming pendant)
Enable SW input (programming pendant)
Safeguarding interlock signal input (safety plug)
External emergency stop SW input
External enable SW input
Servo power enable input
Overrun input (manipulator/external axis)
Universal safety input
These safety functions conform to the following safety standards.
EN ISO 13849-1:2008 + AC:2009 Cat.4 / PL e
EN 62061:2005 + AC:2010 + A1:2013 / IEC 61508 Part 1-7:2010 SIL3
The use frequency of each switch for safety functions is assumed as
below.
Emergency stop SW
500 times/ year
External emergency stop SW
500 times/ year
Enable SW (programming pendant) 2000 times/ year
External enable SW
2000 times/ year
1.5.1
Installation and Wiring Safety

Refer to the MOTOMAN- Instructions manual and DX200
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 manipulator:
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
DX200
Door
1000 mm or more
1000 mm or more
1000 mm or more
P-point maximum envelope

of Manipulator
Maximum Working Envelope of
Manipulator Including Tool or
Workpiece End
1000 mm or more
Perform grounding in accordance with all applicable electrical codes.

Failure to observe this caution may result in fire or electric shock.
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1 Safety
1.5 Motoman Safety
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.
MOTOMAN 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 manipulator instruction
manual.
Failure to observe these precautions may cause the manipulator to turn
downward, potentially causing injury or damage to equipment.
When lifting the DX200, please check the following:

As a rule, handling of DX200 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 DX200.
Wire Rope
Table 1-1: Approx. Weight of DX200

Models Available for Approx.
M12 Eye bolt
DX200
Weight (Kg)
Small capacity model
100
Medium /Large
capacity model
100
DX200
Be sure the eyebolts are securely fastened.

equipment.
If storing the manipulator 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.
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1.5 Motoman Safety
CAUTION
Be sure there is sufficient room for maintenance on the manipulator,

DX200, and other peripheral equipment.
520
500
Failure to observe this precaution could result in injury during

maintenance.
520
DX200
DX200
500
730
DX200 Maintenance Area

(Unit: mm)
600
DX200
586
690
DX200 Controller
DX200 External Dimensions (Unit: mm)
To ensure safety, be sure to operate the controller from a location

where the manipulator is easily visible.
Operation by unauthorized personnel may result in injury or equipment

damage.
Install the DX200 outside the safeguarding of the manipulators

safety enclosure.
Failure to observe this precaution may result in injury or damage to

equipment resulting from contact with the manipulator.
Install the manipulator using bolts of the size and type specified for
each MOTOMAN in the MOTOMAN INSTRUCTION MANUAL.

equipment.
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1.5 Motoman Safety
CAUTION
Secure the position of the DX200 after setting up.
Attach the DX200 to the floor or rack, etc., using the screw holes on the
bottom of the DX200.
Failure to observe this caution could lead to injury or equipment
damage if the DX200 should shift or fall.
DX200
40
14 dia.
(2 holes)
Tapped Holes for

M12 Screws on
the DX200 Side
60
40
DX200 Controller
30
50
(Unit: mm)
Recomended plate thickness : 6mm
Be familiar with the connection diagram before wiring the DX200,

and perform the wiring in accordance with the connection diagram.
There is a danger of equipment damage or injury due to mis-wiring and

unexpected movement of the equipment.
Take precautions when wiring and piping between the DX200,

manipulator, 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 the forklift.
SAFETY
FIRST
Piping
Lead
Cable Channnel
Operators and other personnel may stumble on exposed wiring or

piping. Cable damage can cause unexpected manipulator motion
resulting in injury or property damage.
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1 Safety
1.5 Motoman Safety
1.5.2
Work Area Safety

Carelessness contributes to serious accidents in the work area.
To ensure safety, enforce the following precautions:
WARNING
Install a safeguarding around the manipulator to prevent any

accidental contact with the manipulator 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 manipulator.
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, DX200, or welding fixture, etc., as injury or damage to
equipment can occur if the manipulator comes in contact with objects or
equipment left in the work area.
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1 Safety
1.5 Motoman Safety
1.5.3
Operation Safety
WARNING
When attaching a tool such as the welding torch to the manipulator,

be sure to turn OFF the power supply of the DX200 and the tool,
lock the switch, and display a warning sign.
DX200
ENERGING
PROHIBITED
PADLOCK
Turning the power ON during tool installation may case electric shock
or injury due to unexpected movement of the manipulator.
Never exceed the rated capacity of the manipulator (capacity can

be found in the specifications section of the manipulator manual.)

equipment.
Teach jobs from outside the manipulators work area whenever

possible.

manipulator:
Be sure to use a lockout device to the safeguarding when
going
performed inside the safeguarding and make sure no one
closes
the safeguarding.
Always view the manipulator 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 manipulator operation can result in injury.
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1 Safety
1.5 Motoman Safety
WARNING
Before operating the manipulator, check that the SERVO ON lamp

on the programming pendant goes out when the emergency stop
buttons on the front door of the DX200, on the programming
pendant, and on the external control device, etc. are pressed. And
confirm that the servo lamp is turned OFF.
Injury or damage to machinery may result if the manipulator cannot be

stopped in case of an emergency.
Prior to performing the following operations, be sure that no one is

in the P-point maximum envelope of the manipulator when:
Turning ON the DX200 power
Moving the manipulator with the programming pendant
Running the system in the check mode
Performing automatic operations
Injury may result from contact with the manipulator if persons enter the
P-point maximum envelope of the manipulator.
Press the emergency stop button immediately if there are problems.
The emergency stop buttons are located on the right of the front door of
the DX200 and the programming pendant.
Emergency Stop Button
Programming Pendant
DX200
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1 Safety
1.5 Motoman Safety
CAUTION
Perform the following inspection procedures prior to teaching the

manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.
Check for problems in manipulator movement.
Check for damage to the insulation and sheathing of external
wires.
Always return the programming pendant to its hook on the DX200

cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a

fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injury or equipment
damage.
MANDATORY
Persons operating or inspecting the manipulator should be trained

as required by applicable laws and company policies.
Refer to section 1.2 Special Training on page 1-2
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1 Safety
1.6 Notes for Moving and Transferring the MOTOMAN
1.6
Notes for Moving and Transferring the MOTOMAN

When moving or transferring the Motoman, observe the following safety
precautions:
CAUTION
Attach the instructions to the controller cabinet so that all users

have access to necessary manuals. See Section section 1.3
Motoman Manual List on page 1-2 for a complete list of manuals.
If any manuals are missing, contact your Yaskawa representative.
If the warning labels on the manipulator and DX200 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.
When the MOTOMAN is transferred, it is recommended to check

with Yaskawa Engineering Co. which is listed on back cover of this
manual.
Incorrect installation or wiring may result in personal injury and property

damage.
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1 Safety
1.7 Notes on MOTOMAN Disposal
1.7
Notes on MOTOMAN Disposal
PROHIBITED
Never modify the manipulator or DX200.
Failure to observe this precaution could result in injury or damage

resulting from fire, power failure, or operation error.
CAUTION
When disposing of the MOTOMAN, follow the applicable national/

local laws and regulations.
Anchor the manipulator well, even when temporarily storing it

before disposal.
Failure to observe this precaution may result in injury due to the

manipulator falling down.
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2 Product Confirmation
2.1 Contents Confirmation
Product Confirmation
2.1
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):
Manipulator
DX200
Programming Pendant
Manipulator Cable (Between Manipulator and DX200)
Complete Set of Manuals
Fig. 2-1: Standard Five Items
Programming
Pendant
Complete Set of Manuals
DX200
Manipulator
Manipulator Cable
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2 Product Confirmation
2.2 Order Number Confirmation
2.2
Order Number Confirmation

Confirm that the order number pasted on the manipulator and DX200 are
the same.
The order number plates are affixed to the figure below.
<Example>
THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE THE SAME ORDER NUMBER.
ORDER NO.
S78796-1
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3 Installation
3.1 Handling Procedure
Installation
3.1
Handling Procedure
CAUTION
Crane, sling, and forklift operations must be performed only by

authorized personnel.
Failure to observe this caution may result in injury or damage.
Avoid jarring, dropping, or hitting the controller during handling.
Excessive vibration or impacting the DX200 may adversely affect the

performance of the DX200.
3.1.1
Using a Crane to Move the Controller

Check the following before handling the DX200:
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.
Wire Rope
Table 3-1: Approx. Weight of DX200

M12 Eye bolt
Models Available for Approx.

DX200
Weight (Kg)
Small capacity model
100
Medium /Large
capacity model
100
DX200
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3 Installation
3.1 Handling Procedure
3.1.2
Using a Forklift to Move the Controller

Observe the following precautions when using a forklift to handle the
controller:
Confirm that there is a safe work environment and that the DX200
can be transported safely to the installation site.
Inform people along the forklift route that equipment is being moved
in their area.
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
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3 Installation
3.2 Place of Installation
3.2
Place of Installation
The conditions listed below must be met before installing the DX200:
Ambient temperature must be 0 to 45C (32 to 113F) during
operation and -10 to 60C (14 to 140F) during transportation and
maintenance.
Humidity must be low with no condensation (10~90%RH).
It must be a place with little dirt, dust, or water.
No flammable or corrosive liquids or gases, etc. in the area.
Little jarring or potential for striking of the DX200
(under 0.5 oscillation).
No large electric noise source (such as a TIG welding device, etc.)
nearby.
No potential for collision with moving equipment such as forklifts.
NOTE
If the external electric noise applies, the alarm occurs and

the manipulator may stop.
When the alarm occurs and the manipulator stops, refer to
DX200 maintenance manual and reset the alarm.
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3 Installation
3.3 Location
Location
1. Install the DX200 outside of the P-point maximum envelope of the
manipulator (outside of the safeguarding.)
Fig. 3-1: Location of DX200
Safeguarding
DX200
Door
1000 mm or more
1000 mm or more
1000 mm or more
P-point maximum envelope

of Manipulator
Maximum Working Envelope of
Manipulator Including Tool or
Workpiece End
1000 mm or more
2. Install the controller in a location from which the manipulator is easily

visible.
520
500
3. Install the controller in a location from which you can easily inspect it
when the door is open.
DX200
586
690
3.3
DOOR
3-4
RE-CTO-A220
165292-1CD
DX200 Controller
3 Installation
3.4 Mounting the Controller
4. Install the controller at least 500 mm from the nearest wall to allow
maintenance access.
520
DX200
DX200
500
730
600
Mounting the Controller
CAUTION
Do not climb on top of the DX200.
Failure to observe this caution could lead to injury or mechanical

failure.
Attach the controller to the floor using user-supplied brackets made
according to the specifications shown below.
DX200
40
60
14 dia.
(2 holes)
40
3.4
Tapped Holes for

M12 Screws on
the DX200 Side
30
50
(Unit: mm)
Recomended plate thickness : 6mm
NOTE
Refer to the Instruction Manual for information on

installation of the manipulator.
3-5
RE-CTO-A220
165292-1CD
DX200 Controller
3 Installation
3.5 Procedure of Stacking the Controllers
3.5
Procedure of Stacking the Controllers

It is possible to stack the DX200 controllers.
Note
There are restrictions to stack the DX200 controllers. Please read through
the following restrictions before installing the DX200.
* The following restrictions apply to both upper and lower controllers.
Restrictions: as for medium and large capacity controllers, the controllers
only for the spot welding are able to be stacked. Other controllers, such as
for handling, cannot be stacked. The controllers for the small capacity can
be stacked regardless of the uses.
Follow the procedures below when stacking the DX200 controllers.
1. Remove the four eyebolts (4 places) on the top of the DX200 to be
stacked lower level.
M12 eyebolts (4 places)
Top View
2. Lift the controller by using the crane, and stack the controllers. Refer
to section 3.1.1 Using a Crane to Move the Controller on page 3-1,
when use the crane.
Controller (upper)
Stacking
Controller (lower)
3-6
RE-CTO-A220
165292-1CD
DX200 Controller
3 Installation
CAUTION
Remove the crane after stacking and fixing the controllers.
Failure to observe this caution may cause the personal injury or the
equipment damage.
3. After stacking the controllers, remove the grommets inside (A-A
section a part) of the upper controller. Install the M12 bolts
(length:35 mm), spring washers and washers for temporally.
M12 (length:35mm)
Grommet (2 places)
Upper
Spring washer
Washer
a enlarged view
Lower
A-A Section View

4. Remove the back board and connector plate on the back of the upper
controller.
Back board
Connector plate
Back View
3-7
RE-CTO-A220
165292-1CD
DX200 Controller
3 Installation
CAUTION
When remove the connector plate from the controller, perform with
the great caution to avoid damaging the internal cables.
Failure to observe this caution may cause the cable damage.
5. After stacking the controllers, remove the grommets inside (A-A

section b part) of the upper controller. Install the M12 bolts
(length:35 mm), spring washers and washers for temporally.
M12 (length:35mm)
Grommet (2 places)
Upper
Spring washer
Washer
b enlarged view
Lower
A-A Section View

6. After confirming the stacking the controllers, tighten the temporally
M12 bolts firmly. (a,b parts: tighten the 4 places)
(tightening torque: 4.2N m)
7. Reinstall the removed back board and connector plate at procedure
No.4.
3-8
RE-CTO-A220
165292-1CD
DX200 Controller
3 Installation
8. Remove the wire lifting the controller by the crane, and stacking is
completed.
3-9
RE-CTO-A220
165292-1CD
DX200 Controller
Connection
Connection
WARNING
The system must be grounded.
Failure to ground equipment may result in injury from fire or electric

shock.
Before wiring, make sure to turn OFF the primary power supply, and
put up a warning sign. (ex. DO NOT TURN THE POWER ON)
Failure to observe this caution may result in injury and electric shock.
Do not touch any board inside the controller for five minutes after
turning OFF the power supply.
Capacitors inside the controller store electricity after power is turned

OFF. Exercise caution whenever handling circuit boards. Failure to
observe this caution may cause electrical shock.
Power cannot be turned ON unless the door is closed. Interlocks

prevent power from being turned ON.
Failure to observe this caution may result in fire and electric shock.
Any occurrence during wiring while the DX200 is in the emergency

stop mode is the users responsibility. Do an operation check once
the wiring is completed.
Failure to observe this caution could lead to injury or mechanical

failure.
Wiring must be performed only by authorized personnel.
Incorrect wiring may cause fire and electric shock.
Perform wiring in accordance with the rated capacity as specified in

the Instructions.
Incorrect wiring may cause fire or mechanical breakdown.
Be sure the power circuit screws are securely tightened.
Loose power circuit wires can cause fire and electric shock.
Do not handle the circuit board directly by hand.
The IC board may malfunction due to electrostatics.
4-1
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
4.1 Notes on Cable Junctions
4.1
Notes on Cable Junctions

The cables that connect the controller to peripheral device are low
voltage circuits. Keep controller signal cables away from the primary
power circuit. High voltage power lines should not be run in parallel
to controller signal cables. If running parallel cables is unavoidable,
use metal ducts or conduit to isolate electrical signal interference. If
cables must be crossed, run the power cables perpendicular across
the signal cables.
Confirm the connector and cable numbers to prevent mis-connection
and equipment damage. One connects the manipulator and DX200.
Another connects the DX200 and peripheral device. A wrong
connection can cause damage to electronic equipment.
Clear the area of all unauthorized personnel while making cable
connections. Place all cables in a covered cable channel in the floor.
Fig. 4-1: DX200 Cable Junction Diagram
SAFETY
FIRST
PIPING
LEAD
cable channel
4-2
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
4.2 Power Supply
4.2
4.2.1
Power Supply
Three-Phase Power Supply
NOTE
The power failure processing circuit operates when there is

a black out or drop in voltage, and the servo power turns
OFF.
Connect the power supply to a stable power source that is
not prone to power fluctuations.
The three-phase power supply consists of 200/220V AC at 60Hz and

200V AC at 50Hz.
Fig. 4-2: Input Power Connection
DX200
Contactor
(1KM)
Breaker
3-phase
200/220V AC at 60Hz
or
200V AC 50Hz
To the converter
Fuse
Noise Filter
To control
power supply
unit
4.2.2
Noise Filter Installation

Insert the three-phase noise filter into the primary station of the non-fuse
breaker filter if you hear noise coming from the power source.
Seal up each cable opening so that dust does not enter.
Fig. 4-3: Connection of Three-Phase Noise Filter
3-phase
Noise Filter
3-phase
200/220V AC at 60Hz
or
200V AC 50Hz
DX200
Contactor
-/
Breaker
To converter
Fuse
Noise Filter
To control
power supply
unit
4-3
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
4.2 Power Supply
4.2.3
Leakage Breaker Installation

When connecting the leakage breaker to the controller power supply
wiring, use a leakage breaker which can handle high frequencies from the
DX200 inverter. Leakage breakers which cannot handle high frequencies
may malfunction.
Table 4-1: Example of High Frequency Leakage Breaker
Maker
Model
Mitsubishi Electric Co., Ltd.
NV series (manufactured since 1988)
Fuji Electric Co., Ltd.
EG or SG Series (manufactured since 1984)
Even with a leakage breaker installed, there is still a possibility of some

high frequency current leakage from the DX200 inverter. However, this
current leakage presents no safety risks.
Fig. 4-4: Connection of the Leakage Breaker
3-phase
200/220V AC at 60Hz
or
200V AC 50Hz
Leakage
Breaker
DX200
Contactor
(1KM)
Breaker
To converter
Fuse
Noise Filter
To control
power supply
unit
4-4
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
4.2 Power Supply
4.2.4
Primary Power Supply Breaker Installation

Install the primary power supply breaker as shown below.
Fig. 4-5: Installation of the Primary Power Supply Breaker
Breaker
Breaker
Breaker
Controller
for Positioner
DX200
Power
Source
Table 4-2: DX200 Power Capacity, Cable Sizes, and Breaker Capacities
Manipulator
Power
capacity
(kVA)
Cable size (size of terminal)

(In case of Cabtyre cable
(three cores))
Capacity of
breaker in
DX200 (A)
(mm2)
MA1440
1.5
3.5 (M5)
15
MH12
1.5
3.5 (M5)
15
MS210
5.0
5.5 (M5)
30
The maximum load value (payload, operation speed, and frequency, etc.)
is displayed.
However, the power capacity is different depending on work conditions.
Inquire at the nearest branch office listed on the back cover for information
when selecting the transformer.
SUPPLEMENT
NOTE
For the models which are not in Table 4-2, refer to DX200
INSTRUCTIONS SUPPLEMENT FOR Controller
Specification List: ANSI Specification (171270-1CD).
The power capacity shown above is the continuous rating

value.
When the robot is rapidly accelerated, the power capacity of
several times the continuous rating value may be needed
instantly.
4-5
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
4.3 Connection Methods
4.3
Connection Methods
A connection diagram for the manipulator, manipulator cable, primary
power cable and programming pendant is shown below.
Fig. 4-6: Cable Connection
Manipulator
DX200
Primary Power
Supply Cable
Manipulator
Cable
Programming
Pendant Cable
4.3.1
Connecting the Primary Power Supply

1. Open the front door of the DX200.
(1) Using a flathead screwdriver, rotate the door locks on the front of
the DX200 (two places) 90 degrees clockwise.
Fig. 4-7: Rotating the Key Clockwise
door lock
clockwise
90
flathead screw d
4-6
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
(2) Rotate the main power supply switch to the "OFF" position and
open the door gently.
Fig. 4-8: Rotating the Main Power Supply Switch to the OFF Position
DX200
Main power supply switch
2. Confirm that the primary power supply is OFF.

3. Connect the primary power supply cable.
Draw the primary power supply cable in from the cable entrance on
top side of DX200 and fix it firmly with the cable clamp so that it
wont shift or slip out of place.
Fig. 4-9: Cable Clamp
DX200
Primary Power
Supply Cable
WARNING
Cable clamp must be used when connecting primary power supply.
Make sure that the cable clamp is fastened tightly to prevent dust or
water from entering.
Failure to observe this caution may result in electric shock or
breakdown of DX200.
4-7
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
(1) Pull off the primary cover of the switch which is on the upper right
side of the DX200.
Fig. 4-10: Pulling Off the Cover
(2) Connect a ground wire to reduce noise and prevent electric shock.
I)
Connect the ground wire to the ground terminal (screw) of the

switch which is on the upper left side of DX200.
Fig. 4-11: Connection of the Ground Wire

Grounding wire
Groundig terminal
(M6 screws)
4-8
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
II)
NOTE
Perform grounding in accordance with all relevant local and

national electrical codes. The size of ground wire must the
same as listed on Table 4-2 "DX200 Power Capacity, Cable
Sizes, and Breaker Capacities" on page 4-5.
The customer must prepare the ground wire.
Fig. 4-12: Exclusive Grounding
DX200
Exclusive Grounding
100 ohm maximum
ground resistance
NOTE
Dont connect the grounding wire with the wires for the
electric power source, the welder, etc.
Ground in accordance with all relevant governmental
regulations when using metallic ducts, metallic conduits,
and cable tray to construct the cable.
(3) Connect the primary power supply cable.

Fig. 4-13: Connection of the Primary Power Supply Cable
4-9
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
(4) Install the cover.
Fig. 4-14: Install the Cover
4-10
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
4.3.2
Connecting the Manipulator Cable

1. Remove the package, and take out the manipulator cable. Connect
the cable to the connectors on the back side of DX200.
Fig. 4-15: Connection of the Manipulator Cable
NOTE
For more information on connecting the manipulator cable,

please refer to the Instruction Manual which corresponds to
the particular DX200 model.
2. Connect the manipulator to the DX200.

Confirm the shape and size of the cable connector, the key fitting,
and the position of the pins of the manipulator. Push the cable
connector into the manipulator side connector firmly, and tighten
securely.
3. Close the DX200 door.
(1) Close the door gently.
(2) Rotate the door lock counterclockwise 90 degrees.
Fig. 4-16: Rotating the Key Counterclockwise
counterclockwise 90
door lock
flathead screw driver
4-11
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
WARNING
Always close the door of the controller (DX200) except for
maintenance.
Make sure to rotate all the door locks counterclockwise.
If dust or water enter inside the controller, electric shock or breakdown
of DX200 may result.
4.3.3
Connecting the Programming Pendant

1. Connect the programming pendant cable to the connector on the door
lower right side of the controller cabinet.
Fig. 4-17: Connecting the Programming Pendant
Alignment mark
The manipulator, DX200, and the programming pendant

connections are now complete.
4-12
RE-CTO-A220
165292-1CD
DX200 Controller
4 Connection
4.3.4
User I/O Cable Connection

1. As for the wiring the cables from the I/O cable inlet on the back panel
of the DX200, perform the wiring by using the supplied cable support
in the accessory kit. Please do not cover the intake and exhaust area
of the back panel.
Fig. 4-18: User I/O Wiring Connection
I/O cable inlet
Cable support
Back View
4-13
RE-CTO-A220
165292-1CD
DX200 Controller
5 Turning ON and OFF the Power Supply

5.1 Turning ON the Main Power Supply
Turning ON and OFF the Power Supply

5.1
Turning ON the Main Power Supply
WARNING
Confirm that nobody is present in the P-point maximum envelope of

the manipulator when turning ON the DX200 power supply.
Failure to observe this caution could result in injury caused by

accidental contact with the manipulator.
Press the emergency stop button immediately if any problems occur.
The emergency stop buttons are located on the right side of the front
door of the DX200 and on the right side of the programming pendant.
The main power supply is turned ON when the main power supply switch
on the front of the DX200 is turned to the "ON" position, and the initial
diagnosis and the current position setting begin.
Fig. 5-1: Turning ON the Main Power Supply
DX200
5-1
RE-CTO-A220
165292-1CD
DX200 Controller

5.1 Turning ON the Main Power Supply
5.1.1
Initial Diagnosis
The initial diagnosis are performed in the DX200 when main power is
turned ON, and the startup window is shown on the programming pendant
screen.
Fig. 5-2: Startup Window
5.1.2
When Initial Diagnosis are Complete

When the power supply is turned OFF, the DX200 saves all condition data,
including:
Mode of operation
Called job (active job if the DX200 is in the play mode; edit job if the
DX200 is in the teach mode) and the cursor position in the job.
Fig. 5-3: Initial Window
CAUTION
Make sure that a system manager stores the key of the mode select
switch on the programming pendant.
After operation, the key should be removed and stored by the
system manager.

Also, the key or the mode select switch may be damaged if the
programming pendant is dropped with the key inserted.
5-2
RE-CTO-A220
165292-1CD
DX200 Controller

5.2 Turning ON the Servo Power
5.2
5.2.1
Turning ON the Servo Power

During Play Mode
The workers safety is secure if the safety plug is turned ON.
When the safeguarding is closed, press [SERVO ON READY] on the
programming pendant to turn ON the servo power supply. [SERVO
ON] lamp will light, when the servo power is turned ON.
SERVO ON
READY
Light
SERVO ON
NOTE
5.2.2
When the safeguarding is open, the servo power supply

cannot be turned ON.
During Teach Mode

1. Press [SERVO ON READY] on the programming pendant to turn ON
the servo power supply. [SERVO ON] lamp will flicker when the servo
power is turned ON.
SERVO ON
READY
Flicker
SERVO ON
2. The servo power is turned ON and [SERVO ON] lamp on the

programming pendant lights when the operator grips the Enable
switch.
5-3
RE-CTO-A220
165292-1CD
DX200 Controller

5.2 Turning ON the Servo Power
Servo Power ON/OFF --- Enable Switch

When the operator grips the Enable switch, the servo power
turns ON. However, if the operator squeezes the switch until
a click is heard, the servo power will turn OFF.
SUPPLEMENT
Servo On
Release -> OFF
NOTE
Squeeze -> ON
Squeeze Tightly -> OFF
When performing emergency stop on the front door of the

DX200, programming pendant, or external signal, the servo
power-on operation from the Enable switch is cancelled.
When turning the power back ON, follow the previously
listed instructions.
The Valid / Invalid setting of safety signals in operation modes.

Safety functions of the robotic system are switched to valid or invalid
depending on operation modes. Particularly in teach mode, be aware the
safeguarding(safety plug) signal input becomes invalid. Perform the
operation with great caution.
Operation Mode
Play Mode
Teach Mode
Controller Emergency Stop (PBESP)
Valid
Valid
External Emergency Stop (EXESP)
Valid
Valid
Programing Pendant Emergency Stop

(PPESP)
Valid
Valid
Safeguarding (safety plug)

(SAFF)
Valid
Invalid
Programing Pendant Enable SW (PPDSW)
Invalid
Valid
External Enable SW (EXDSW)
Invalid
Valid
Servo Power Enable (ONEN)
Valid
Valid
Manipulator Overrun (OT)
Valid
Valid
External Axis Overrun (EXOT)
Valid
Valid
Speed Limit
Invalid
Valid
Safety Signal
5-4
RE-CTO-A220
165292-1CD
DX200 Controller

5.3 Turning OFF the Power Supply
5.3
5.3.1
Turning OFF the Power Supply

Turning OFF the Servo Power (Emergency Stop)
The manipulator cannot be operated when the emergency stop button is
pressed and the servo power supply is turned OFF.
Press the emergency stop button and the servo power supply is
turned off.
The emergency stop buttons are located on the front door of the
DX200 and on the right side of the programming pendant.
The break operates once the servo power supply is turned OFF, and
the manipulator can no longer operate.
The emergency stop mode can be operated at any mode.
(Teach mode, Play mode, Remote mode)
Programming Pendant
EMERGENCY STOP
Door upper side
5.3.2
Turning OFF the Main Power

After turning OFF the servo power, turn OFF the main power.
When the main power switch on the front of DX200 is turned to the
OFF position, the main power is turned OFF.
DX200
When an hour glass pointer is appearing on the

programming pendant screen, the data writing is in process.
NOTE
If turn the DX200 power supply OFF during the data writing,
the data may be broken. Do not turn the power supply OFF
when the hour glass pointer is seen on the programming
pendant.
5-5
RE-CTO-A220
165292-1CD
DX200 Controller

5.3 Turning OFF the Power Supply
5.3.3
The Method of Stopping Manipulator Operation

The following 3 categories are stop functions of the manipulator.
Stop Category 0
The immediate insulation of the motor power source to servo motor
causes the stop.
After the motor power is insulated, the manipulator and the external
axis decelerate by the brake and stop.
The manipulator and the external axis may run off the operation path
(Path).
Stop Category 1
The manipulator and the external axis are controlled on the
operation path, decelerate and then stop.
After the stop, the manipulator and the external axis are locked by
the brake and the motor power is insulated.
Stop Category 2
The manipulator and the external axis are controlled on the
operation path, decelerate and then stop.
After the stop, the stop position is retained in a state that the motor
power is being supplied.
Besides the safety signals, the DX200 robotic system stops the
manipulator by the above three stop categories.
The method of stopping the manipulator by each stop signal is shown in
the following table.
Operation Mode
Safety Signal
Stop
Category 0
Stop
Category 1
External Emergency Stop (EXESP)
Programing Pendant Emergency Stop

(PPESP)
Safeguarding (safety plug)

(SAFF)
Controller Emergency Stop (PBESP)
Programing Pendant Enable SW

(PPDSW)
External Enable SW (EXDSW)
Servo Power Enable (ONEN)
Manipulator Overrun (OT)

External Axis Overrun (EXOT)
Programing Pendant (HOLD)
Stop
Category 2
5-6
RE-CTO-A220
165292-1CD
DX200 Controller
Test of Program Operation
WARNING
Press the emergency stop button on the right of the front door of the
DX200 and the programming pendant before operating the
manipulator. Confirm that the SERVO ON lamp is turned OFF.

stopped in case of an emergency. The emergency stop buttons are
attached on the front door of the DX200 and right of the programming
pendant.

manipulator:
going inside. Also, display the sign that the operation is
being performed inside the safeguarding and make sure no
one closes the safeguarding.
Always view the manipulator from the front.
Prior to performing the following operations, be sure that there is no

one within the P-point maximum envelope of the manipulator, and
be sure that you are in a safe place yourself.
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator.
6-1
RE-CTO-A220
165292-1CD
DX200 Controller
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.
wires.
Always return the programming pendant to its specified position

after use.
If the programming pendant is inadvertently left on the manipulator,

during manipulator movement, possibly causing injuries or equipment
damage.
system manager.

6-2
RE-CTO-A220
165292-1CD
DX200 Controller
6 Test of Program Operation

6.1 Movement of the Axes
6.1
Movement of the Axes

Move each axis of the manipulator by pressing the axis keys on the
programming pendant.
This figure illustrates each axis of motion in the joint coordinates.
NOTE
Be sure to remove all items from the area before moving the
manipulator.
Refer to the INSTRUCTION MANUAL for the appropriate
position of the fixture.
U-Axis
R-Axis
B-Axis
X-
X+
S-
X-
S+
Y-
Y+
L-
L+
Z-
U+
E-
R+
Y-
Y+
Z-
Z+
T-
T+
B-
Z+
U-
X+
R-
E+
T-Axis
E-Axis
B+
8-
L-Axis
8+
Axis Keys
S-Axis
Rotates main body
X-
Rotates upper arm
X+
S-
X+
S+
R+
XR-
Moves lower arm forward/

backward
Moves wrist up/down
Y-
B-
Y+
Y-
L+
L-
Y+
B+
Moves upper arm up/ down
Rotates wrist
Z+
U+
Z+
T+
ZT-
Z-
U-
Rotates lower arm

E-
E+
6-3
RE-CTO-A220
165292-1CD
DX200 Controller
6 Test of Program Operation

6.2 Manual Brake Release Function
6.2
Manual Brake Release Function

When the manipulator moves to unexpected places because of system or
operation errors and the operation can not be maintained, using the brake
release unit (optional) enables to release the brake of the arbitrary
working axis of the manipulator and operate manually.
Table 6-1: Brake Release Unit (Separate Unit Type)
Manipulator side
Brake release unit side

1CP
POWER
BRAKE RELEASE
4000
ON
(1CN)
(2CN)
2CN
OFF
2BC
Brake release unit cable

Power supply cable2 m (standard)
Weight: 3 kg
Manipularor type
Unitmm
This brake release unit can be used in a state that the motor servo ON can
not be executed from the DX200 controller.
Be very careful about the followings when using.
CAUTION
When releasing the brake, pay attention to surroundings.

The robot arm may move under its own weight, and personal injury
or equipment damage may result.
Release the brake for one axis at a time.

If the brakes of multiple axes are released out of necessity, the
robot arm may move in an unexpected way. Pay attention to
surroundings. Personal injury or equipment damage may result.
In case of purchase, inquire at the nearest Yaskawa branch office listed on

the back cover.
6-4
RE-CTO-A220
165292-1CD
DX200 Controller
7 Security System
7.1 Protection Through Security Mode Settings
Security System
7.1
Protection Through Security Mode Settings

The DX200 modes setting are protected by a security system. The system
allows operation and modification of settings according to operator
clearance. Be sure operators have the correct level of training for each
level to which they are granted access.
7.1.1
Security Mode
There are five security modes operation mode, editing mode,
management mode, safety mode and one time manage mode. Editing
mode, management mode and safety mode require a user ID.
For the editing mode and the management mode, the user ID should be 4
or more and 16 or less characters with number(s) and symbol(s). As for
the safety mode, it should be 9 or more and 16 or less characters with
number(s) and symbol(s).
(Significant numbers and symbols: 0 to 9, -, .. )
Operating the one time manage mode requires to enter the security code,
which is issued by YASKAWA sales representative.
Table 7-1: Security Mode Descriptions
Security Mode
Explanation
Operation Mode
This mode allows basic operation of the robot (stopping,

starting, etc.) for people operating the robot work on the line.
Editing Mode
This mode allows the operator to teach and edit jobs and
robot settings.
Management
Mode
This mode allows those authorized to set up and maintain

robot system: parameters, system time and modifying user
IDs.
Safety Mode
This mode allows the operator to setup the safety function,

and able to edit the files related to the safety function.
When the optional function functional safety is valid, the
security is changed to the safety mode to edit the some files,
such as the tool file.
Refer to DX200 OPTIONS INSTRUCTIONS FOR
FUNCTIONAL SAFETY BOARD OPERATION
(165988-1CD) for more details.
One Time
Manage Mode
This mode allows to operator to maintain the mode which is

higher than the management mode.
The loading limitation of the batch data (CMOS.BIN), the
parameter batch data (ALL.PRM) and the functional
definition parameter (FD.PRM) are removed.
7-1
RE-CTO-A220
165292-1CD
DX200 Controller
7 Security System
Table 7-2: Menu & Security Mode (Sheet 1 of 4)

Main Menu
Sub Menu
JOB
JOB
Allowed Security Mode

Edit
Operation
Operation
CREATE NEW JOB1)
Edit
Edit
MASTER JOB
Operation
Edit
JOB CAPACITY
Operation
Edit
Edit
Operation
(JOB)1)
RES. STATUS2)
IN/OUT
EDIT
Operation
SELECT JOB
RES. START
VARIABLE
DISPLAY
CYCLE
Operation
Operation
TRASH JOB LIST3)
Edit
Edit
JOB EDIT (PLAY)
Edit
Edit
PLAY EDIT JOB LIST
Edit
Edit
BYTE
Operation
Edit
INTEGER
Operation
Edit
DOUBLE
Operation
Edit
REAL
Operation
Edit
STRING
Operation
Edit
POSITION (ROBOT)
Operation
Edit
POSITION (BASE)
Operation
Edit
POSITION (ST)
Operation
Edit
LOCAL VARIABLE
Operation
TIMER
Operation
Edit
EXTERNAL INPUT
Operation
Edit
EXTERNAL OUTPUT
Operation
Edit
UNIVERSAL INPUT
Operation
Operation
UNIVERSAL OUTPUT
Operation
Operation
SPECIFIC INPUT
Operation
SPECIFIC OUTPUT
Operation
RIN
Operation
REGISTER
Operation
Management
AUXILIARY RELAY
Operation
CONTROL INPUT
Operation
PSEUDO INPUT SIG
Operation
Management
NETWORK INPUT
Operation
NETWORK OUTPUT
Operation
ANALOG OUTPUT
Operation
SV POWER STATUS
Operation
LADDER PROGRAM
Management Management
I/O ALARM
I/O MESSAGE
TERMINAL
Operation
Edit
I/O SIMULATION LIST
Operation
Operation
SERVO ON FACTOR
Management -
RB STOP FACTOR MONITOR
Operation
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7 Security System
Main Menu
Sub Menu
ROBOT
CURRENT POSITION
DISPLAY
EDIT
Operation
COMMAND POSITION
Operation
SERVO MONITOR
Management -
WORK HOME POS
Operation
Edit
SECOND HOME POS
Operation
Edit
DROP AMOUNT
POWER ON/OFF POS
Operation
TOOL
Edit
Edit
INTERFERENCE
SHOCK SENS LEVEL
Operation
Edit
USER COORDINATE
Edit
Edit
HOME POSITION
MANIPULATOR TYPE
Management -
ANALOG MONITOR
OVERRUN&S-SENSOR1)
Operation
Operation
Edit
Edit
LIMIT
RELEASE1)
ARM CONTROL1)
SYSTEM INFO
EX. MEMORY
PARAMETER
SHIFT VALUE
Operation
SOFTLIMIT SETTING
SHOCK SEN LV.(CURRENT)
Operation
VERSION
Operation
MONITORING TIME
Operation
Management
CONTROLLER INFORMATION Operation
ALARM HISTORY
Operation
Management
I/O MSG HISTORY
Operation
Management
LOGDATA
Operation
Management
USER DEFINITION MENU
Operation
Edit
QR CODE
Operation
Operation
SECURITY
Operation
Operation
LOAD
Edit
SAVE
Operation
VERIFY
Operation
DELETE
Operation
DEVICE
Operation
Operation
FOLDER
Operation
Management
INITIALIZE1)
Operation
S1CxG
S2C
S3C
S4C
A1P
A2P
A3P
A4P
A5P
A6P
A7P
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7 Security System
Main Menu
Sub Menu
PARAMETER
A8P
RS
S1E
S2E
S3E
S4E
S5E
S6E
S7E
DISPLAY
SETUP
S8E
TEACHING COND.
Edit
OPERATE ENABLE
FUNCTION ENABLE
JOG COND.
PLAYBACK COND.
FUNCTION COND.
DISPLAY COLOR COND.
Edit
LOGDATA COND.
Edit
DATE/TIME
GRP COMBINATION
SET WORD
Edit
Edit
RESERVE JOB NAME
Edit
Edit
USER ID
Edit
Edit
SET SPEED
KEY ALLOCATION
JOG KEY ALLOC.
Edit
RES. START (CNCT)
AUTO BACK SET
Management
WRONG DATA LOG
Edit
Management
ENERGY SAVING FUNCTION
Edit
Management
ENCODER MAINTENANCE
Edit
Management
SETTM SETUP
Edit
Management
TIMER DELAY SET
DISPLAY
SETUP
Edit
OPERATE COND.
SAFETY FUNC. M-SAFETY SIGNAL ALLOC
PM
EDIT
Operation
Safety
Operation
Safety
SAFETY LOGIC CIRCUIT
Operation
Safety
PM (REDUCER)
Operation
Management
PM (HARDWARE)
INSPECTION NOTICE
Operation
Edit
INSPECTION RECORD
Operation
Management
CHANGE FONT
Operation
Operation
CHANGE BUTTON
Operation
Operation
INITIALIZE LAYOUT
Operation
Operation
CHANGE WINDOW PATTERN
Operation
Operation
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7 Security System
Main Menu
Sub Menu
ARC WELDING ARC START COND.

DISPLAY
EDIT
Operation
Edit
ARC END COND.
Operation
Edit
ARC AUX COND.
Operation
Edit
POWER SOURCE COND.
Operation
Edit
ARC WELD DIAG.
Operation
Edit
WEAVING
Operation
Edit
ARC MONITOR
Operation
Edit
ARC MONITOR (SAMPL)
Operation
APPLI COND.
HANDLING
HANDLING DIAGNOSIS
Operation
Edit
SPOT
WELDING
WELD DIAGNOSIS
Operation
Edit
I/O ALLOCATION
GUN CONDITION
SPOT POWER SOURCE

COND.
APPLICATION CONDITION
SETTING
WELD DIAGNOSIS
Operation
Edit
GUN PRESSURE
Edit
Edit
PRESSURE
Edit
Edit
I/O ALLOCATION
GUN CONDITION
CLEARANCE SETTING
Operation
SPOT POWER SOURCE

COND.
TIP INSTALLATION
Operation
APPLICATION CONDITION
SETTING
WEAVING
Operation
Edit
GENERAL DIAG.
Operation
Edit
PAINT SYSTEM CONFIG.
PAINT SPECIAL
PAINT CONDITION
Operation
Edit
CALIBRATION CONFIG.
Operation
Edit
TIME CHART CONFIG.
TIME CHART
Operation
Edit
PAINT DATA CONFIG.
Operation
Edit
SPOT
WELDING
(MOTOR GUN)
GENERAL
PAINT
COMMON TO
ALL
APPLICATIONS
Edit
Management
PAINT OUTPUT TEST
I/O VARIABLE CUSTOMIZE
Operation
Operation
1 Displayed in the teach mode only.

2 Displayed in the play mode only.
3 Displayed when the job reconstruction function is valid.
*As for the menu and the security mode when the functional safety is valid, refer
to DX200 OPTIONS INSTRUCTIONS FOR FUNCTIONAL SAFETY BOARD
OPERATION (165988-1CD) for more details.
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7.1.1.1
7 Security System
Changing the Security Mode

1. Select {SYSTEM INFO} under the main menu.
The sub menu appears.
Note: Icons for the main menu, such as arc welding system, differ
depending on the system being used.
2. Select {SECURITY}.
The selection window of security mode appears.
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7 Security System
Security mode can be selected from OPERATION MODE,
EDITING MODE, MANAGEMENT MODE or SAFETY MODE.
3. Select the security mode to change.

If the selected security mode is lower than the current security level,
the password will be required.
4. Enter the password.

The following user ID numbers are set as default.
Editing Mode:
[0000000000000000]
Management Mode: [9999999999999999]
Safety Mode:
[5555555555555555]
5. Press [ENTER].
If the password is correct, the security mode will be changed.
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7 Security System
Procedures to Change the Mode to the One Time Management Mode

1. Change to the management mode.
When changing to the management mode, security mode can be
selected from OPERATION MODE, EDITING MODE,
MANAGEMENT MODE, SAFETY MODE or ONE TIME
MANAGE MODE.
2. Select ONE TIME MANAGE MODE.

A character string input keypad is displayed. Input the one time
security code, which is issued by YASKAWA sales representative.
If the password is correct, the security mode will be changed.
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7 Security System
7.1.2
User ID
User ID is requested when the editing mode, management mode or safety
mode is operated.
The user ID should be 4 or more and 16 or less characters with number(s)
and symbol(s) for the editing mode and the management mode. As for
the safety mode, it should be 9 or more and 16 or less characters with
number(s) and symbol(s).
(Significant numbers and symbols: 0 to 9, -, ..)
7.1.2.1
Changing User ID
In order to change the user ID, the DX200 must be in the editing mode,
the management mode or the safety mode. Higher security modes can
make changes the user ID of to lower security modes.
1. Select {SETUP} under the main menu.
2. Select {USER ID}.

The USER ID window appears.
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3. Select the desired ID.
The character input line appears, and a message "Input current ID
no. (4 or more digits)" appears.
(As for the safety mode, 9 or more digits)
4. Input the current ID and press [ENTER].

When the correct user ID is entered, a new ID is requested to be
input. "Input new ID no.(4 or more digits)" appears.
(As for the safety mode, 9 or more digits)
5. Input new ID and press [ENTER].

User ID is changed.
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System Setup
System Setup
WARNING
Various settings control system compatibility and manipulator

performance characteristics. Exercise caution when changing
settings that can result in improper manipulator operation.
Personal injury and/or equipment damage may result if incorrect

settings are applied by the user.
Observe the following precautions to safeguarding system settings:
Maintain supervisory control of user functions.
Retain data backups of control settings each time settings are

changed.
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8 System Setup
8.1 Home Position Calibration
8.1
Home Position Calibration
WARNING

goes out when the emergency stop buttons on the right of the front
door of the DX200 and the programming pendant are pressed.


manipulator:
going
closes
the safeguarding.
View the manipulator from the front whenever
possible.
Always prepare your reactions to a manipulators unexpected
approach toward you.
Ensure that you have a safe place to retreat in case of
emergency.

in the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place when:
Turning ON the DX200 power.
Operating the manipulator with the programming pendant.
Always press the emergency stop button immediately if there are
problems.
Emergency stop buttons are located on the right of the front door of the
DX200 and the programming pendant.
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8 System Setup
CAUTION

wires.
Always return the programming pendant to its hook on the
DX200 cabinet after use.

damage.
system manager.

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8 System Setup
8.1.1
Home Position Calibration
NOTE
Teaching and playback are not possible before the completion of the home position calibration.
In a system with two or more manipulators, the home
position of all the manipulators must be calibrated before
starting teaching or playback.
Home position calibration is an operation in which the home position and

absolute encoder position coincide. Although this operation is performed
prior to shipment at the factory, the following cases require this operation
to be performed again.
Change in the combination of the manipulator and DX200
Replacement of the motor or absolute encoder
Clearing stored memory (by replacement of YIF01-E circuit board,
weak battery, etc.)
Home position deviation caused by hitting the manipulator against a
workpiece, etc.
To calibrate the home position, use the axis keys to calibrate the home
position mark on each axis so that the manipulator can take its posture for
the home position. There are two operations for home position calibration:
All the axes can be moved at the same time: Recalibrate the home
position by moving all the axes
together if changing the
combination of manipulator and
circuit board.
Axes can be moved individually: Recalibrate the home position for
the individual axes that were
affected by the replacement, if
replacing the motor or absolute
encoder.
If the absolute data of its posture for the home position is already known,
set the absolute data again after completing home position registration.
Home Position
SUPPLEMENT
The home position is the pulse value "0" for each axis and its
posture. See section 8.1.3 Home Position of the Robot on
page 8-11.
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8 System Setup
8.1.2
Calibrating Operation
NOTE
8.1.2.1
Home position calibration screen is displayed only in the

security mode or the management mode.
Registering All Axes at One Time

1. Select {ROBOT} under the main menu.
The sub menu appears
2. Select {HOME POSITION}.

The HOME POSITIONING window appears.
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8 System Setup
3. Select {DISPLAY} under the menu.
The pull-down menu appears.
The same operation as the instruction 3 can also be performed by

selecting [PAGE], and selection box appears.
4. Select the desired control group.

Select the control group for HOME POSITIONING.
The control group can also be selected by pressing [PAGE].
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5. Select {EDIT} under the menu.
6. Select {SELECT ALL AXES}.

The confirmation dialog box appears.
7. Select {YES}.
Displayed position data of all axes are registered as home position.
When {NO} is selected, the registration will be canceled.
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8.1.2.2
8 System Setup
Registering Individual Axes

Perform the step 3 and 4 of the Registering All Axes at One Time
to select the desired control group.
4. Select the axis to be registered.
Move the cursor to the axis to be registered, and select it.
A confirmation dialog box appears.
5. Select {YES}.
Displayed position data of the axis is registered as home position.
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8.1.2.3
8 System Setup
Changing the Absolute Data

To change the absolute data of the axis when home position calibration is
completed, perform the following:
4. Select the absolute data to be registered.
The number can now be entered.
5. Enter the absolute data using the numeric keys.

6. Press [ENTER].
Absolute data is modified.
8.1.2.4
Clearing Absolute Data

The sub menu appears
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8 System Setup
3. Select {DATA} under the main menu.
The pull-down menu appears
4. Select [CLEAR ALL DATA].

5. Select {YES}.
All absolute data are cleared.
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8 System Setup
8.1.3
Home Position of the Robot

In case of VA1400, the home position are as follows.
B-axis center line angle against
U-axis center line (-0).
U-axis angle against horizontal
line on the ground (-0).
L-axis angle against vertical

line to the ground(-0).
NOTE
Other manipulator models have different positions. Always

refer to "MANIPULATOR INSTRUCTIONS" for the correct
manipulator model.
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8 System Setup
8.2 Setting the Second Home Position (Check Point)
8.2
Setting the Second Home Position (Check Point)
WARNING
Be aware of safety hazards when performing the position

confirmation of the second home position (check point).
When "OUT OF RANGE (ABSO DATA)" alarm occurs, abnormality of

the PG system may be a cause of the alarm. The manipulator may
operate in an unexpected manner, and there is a risk of damage to
equipment or injury to personnel.

goes out when the emergency stop buttons on the front door of
DX200 and the programming pendant are pressed.


manipulator:
going
closes
the safeguarding.
possible.
Ensure that you have a safe place to retreat in case of
emergency.

in the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place when:
Press the emergency stop button immediately whenever there are
problems.
Emergency stop buttons are attached on the front door of the

DX200 and the right side of the programming pendant.
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8 System Setup
CAUTION

wires.
Always return the programming pendant to its hook on the DX200

cabinet after use.

damage.
system manager.

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8 System Setup
8.2.1
Purpose of Position Check Operation

If the absolute number of rotation detected at power supply ON does not
match the data stored in the absolute encoder the last time the power
supply was turned OFF, an alarm is issued when the controller power is
turned ON.
There are two possible causes of this alarm:
Error in the PG system
The manipulator was moved after the power supply was turned OFF.
If there is an error with the PG system, the manipulator may stall when
playback is started. If the absolute data allowable range error alarm has
occurred, playback and test runs will not function and the position must be
checked.
"OUT OF RANGE (ABSO DATA)" alarm occurs
Reset alarm
Turn ON servo power

Procedure After Alarm Occurs
1
Position confirmation
operation
2
Compare second home
position (check point)*
pulses with current
position pulses
NG
Alarm occurs again
OK
3
Correct defective axis

Replace PG system
Home position calibration
Position checking point
Playback possible
Position Check
After the "OUT OF RANGE (ABSO DATA)" alarm occurs, move to the
second home position using the axis keys and perform the position
confirmation. Playback and test runs will not function unless "CONFIRM
POSITION" is performed.
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2
Pulse Difference Check
The pulse number at the second home position is compared with that at
the current position. If the difference is within the allowable range,
playback is enabled. If not, the alarm occurs again.
The allowable range pulse is the number of pulses per rotation of the
motor (PPR data).
The initial value of the second home position is the home position
(where all axes are at pulse 0). The second home position can be
changed. For details, refer to section 8.2.2 Procedure for the
Second Home Position Setting (Check Point) on page 8-16.
3
Alarm Occurrence
If the alarm occurs again, there may be an error in the PG system. Check
the system. After adjusting the erroneous axis, calibrate the home
position of the axis, then check the position again.
NOTE
Home position calibration of all the axes at the same

time enables playback operations without having to
check the position.
Sometimes in a system with a manipulator with no

break, it is possible to enable playback without position
checking after the alarm occurs. However, as a
rule, always perform "CONFIRM POSITION".
Under the above special conditions, the manipulator
moves as follows:
After the start, the manipulator moves at low speed (1/
10 of the maximum speed) to the step indicated by the
cursor. If it stops and restarts during this motion, the low
speed setting is retained until the step at cursor is
reached.
Regardless of cycle setting, the manipulator stops after
reaching to the step indicated by cursor. Starting the
manipulator again then moves it at the programmed
speed and cycle of the job.
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8 System Setup
8.2.2
Procedure for the Second Home Position Setting (Check Point)

Apart from the "home position of the manipulator, the second home
position can be set up as a check point for absolute data. Use the
following steps to set the specified point.
If two or more manipulators or stations are controlled by one controller, the
second home position must be set for each manipulator or station.
2. Select {SECOND HOME POS}.

The SECOND HOME POS window appears.
A message Available to move to and modify specified point is
displayed.
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8 System Setup
3. Press the [PAGE], or select [PAGE] to display the selection window for
the control group.
When there are two or more group axes, select the group axes to
which the second home position is to be specified.
4. Press the axis keys.

Move the manipulator to the new second home position.
5. Press [MODIFY], then [ENTER].
The second home position is changed.
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8 System Setup
8.2.3
Procedure after the Alarm
WARNING
Be aware of safety hazards when performing the position

confirmation of the specified point.
Abnormality of the PG system may be the cause of the alarm. The

manipulator may operate in an unexpected manner, and there is a risk
of damage to equipment or injury to personnel.
If the "OUT OF RANGE (ABSO DATA)" alarm occurs:
Reset the alarm;
Turn ON the servo power;
then confirm the second home position. After the confirmation, if the PG
system is found to be the cause of the alarm, perform the necessary
operation, such as replacing the PG, etc.
The robot current position data when turning main power supply OFF and
ON can be confirmed in POWER ON/OFF POS" window.
SUPPLEMENT
For details on the POWER ON/OFF POS" window, refer to

section 7.7 Position Data When Power is Turned ON/OFF
in DX200 MAINTENANCE MANUAL.

2. Select {SECOND HOME POS}.
The SECOND HOME POS window appears.
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8 System Setup
3. Press the [PAGE], or select [PAGE] to display the selection window for
the control group.
When there are two or more group axes, select the group axes to
which the second home position is to be specified.
4. Press [FWD].
TCP moves to the second home position. The robot moving speed is
set as selected manual speed.
5. Select {DATA} under the menu.
6. Select {CONFIRM POSITION}.
A message Home position checked appears.
Pulse data of the second home position and current pulse data are
compared. If the compared error is in allowed range, playback
operation can be done.
If the error is beyond the allowed range, the alarm occurs again.
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8.3.1.1
8 System Setup
8.3 Tool Data Setting
8.3
Tool Data Setting
8.3.1
Registering Tool Files
Number of Tool Files

There are 64 tool files numbered 0 to 63. Each file is called as a tool file.
TOOL FILE 0
TOOL FILE 63
SUPPLEMENT
8.3.1.2
Tool File Extension Function

Normally, one robot uses one kind of tool file. The tool file
extension function can change many tool files to be used by
one robot. Use the following parameter to set this function.
S2C333: TOOL NO. SWITCHING (1: enabled; 0: disabled)
For more details, refer to 8 Parameter in DX200
OPERATORS MANUAL.
Registering Coordinate Data

When the number input operation is used for registering the tool file, input
the TCP of the tool on the flange coordinates.
XF
YF
Tool
TCP
ZF
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8 System Setup
2. Select {TOOL}.
(1) Move the cursor to the number of the desired tool, and press
{SELECT} in the tool list window.
(2)
The tool coordinate window of the selected number appears.
In the tool coordinate window, the tool number can be changed by

pressing the [PAGE] or selecting [PAGE].
To switch the tool list window and the tool coordinate window, press
{DISPLAY} {LIST} or {DISPLAY} {COORDINATE DATA}.
3. Select the desired tool number.

4. Place the cursor in the part to register the desired coordinate data and
press [SELECT].
The number is ready to input.
5. Input the coordinate data.
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8 System Setup
6. Press [ENTER].
The coordinate data is registered.
<Setting Example>
260 mm
TCP
260 mm
TCP
ZF
Tool A
260mm
TCP
ZF
Tool B
145mm
Tool C
In case of Tool A, B
In case of Tool C
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8.3.1.3
8 System Setup
Registering Tool Angle

The tool pose data is angle data which shows the relation between the
flange coordinates and the tool coordinates. The angle when the flange
coordinates are rotated to meet to the tool coordinates becomes an input
value. Clockwise toward the arrow is the positive direction. Register in the
order of Rz Ry Rx.
In the following case, register Rz=180, Ry=90, Rx=0
Flange
coordinates
XF
YF
XT
ZF
Tool
coordinates
YT
ZT

2. Select {TOOL}.
In the same way as shown in Explanation 2, 3 in section 8.3.1.2
Registering Coordinate Data on page 8-20, display the desired tool
coordinate window.
4. Select the desired coordinate axis to modify.
First, select Rz.
5. Input the tool pose data.
Input rotation angle around ZF of the flange coordinates.
XF
YF
YF
ZF
X F
Rz = 180
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8 System Setup
6. Press [ENTER].
The rotation angle of Rz is registered.
In the same way, register the angle of Ry, Rx.
Ry must be the input rotation angle around YF flange coordinates.
X F
ZF
Y F (Y F )
Z F
Ry = 90
Rx must be the input rotation angle around XF of flange

coordinates.
X F
YF
Z F
8.3.1.4
Rx = 0
Setting the Tool Load Information

The tool load information includes weight, a center of gravity position, and
moment of inertia at the center of gravity of the tool installed at the flange.
Sets the tool load information by the design value of the tool.
SUPPLEMENT
For more details on the tool load information, refer to section

8.4.3 Tool Load Information Setting on page 8-46.
If the design value is uncertain, use of the Automatic Measurement of the

Tool Load and the Center of Gravity enable to set the tool load
information easily.
SUPPLEMENT
For more details on Automatic Measurement of the Tool

Load and the Center of Gravity, refer to section 8.3.3
Automatic Measurement of the Tool Load and the Center of
Gravity on page 8-36.
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8 System Setup
8.3.2
8.3.2.1
Tool Calibration
Tool Calibration
To ensure that the manipulator can perform motion type operations such
as linear and circular motion type correctly, accurate dimensional
information on tools such as torches, tools, and guns must be registered
and the position of the TCP must be defined.
Tool calibration is a function that enables this dimensional information to
be registered easily and accurately. When this function is used, the TCP is
automatically calculated and registered in the tool file.
What is registered in tool calibration is the coordinates of the TCP and the
tool posture data in the flange coordinates.
XF
Flange
coordinates
ZF
<Flange coordinates>
XF: Vertically upward direction when the current
position on the T-axis of the manipulator is "0"
YF: Y-axis complementing XF and ZF
ZF: Direction perpendicular to the flange face
XT
YT
YF
Tool
coordinates
8.3.2.2
ZT
Setting of Tool Calibration Method

There are three tool calibration methods, which are selected by setting
parameter.
S2C432: Designation of tool calibration method
0: Calibrates only the coordinates.
Coordinates calculated from 5 calibration teaching points is
registered in the tool file.
In this case Tool Posture Data is all cleared to be 0.
1: Calibrates only the posture.
Tool Posture Data calculated from the first calibration
teaching point is registered in the tool file.
In this case, Coordinates will not be changed. (the prior
value is maintained.)
2: Calibrates the coordinates and the posture.
Coordinates calculated from 5 calibration teaching points
and Tool Posture Data calculated from the first calibration
teaching point are registered in the tool file.
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NOTE
8.3.2.3
In case of S2C432=0 (only coordinates is calibrated),

tool posture data is overwritten with 0.
(When the coordinates calculated from tool calibration is
registered in the tool file in which the tool posture data is
already registered, the tool posture data will be deleted.)
In case of S2C432=1 (only posture is calibrated), the

coordinates are maintained.
In case of S2C432=1, 5 teaching points need to be

registered though only the first point is used for
calculation.
Teaching of Calibration Point
Teaching for defining coordinates

In order to calibrate coordinates, five different postures (TC1 to 5) must be
taught with the TCP as the reference point. The tool dimensions are
automatically calculated on the basis of these five points.
TC2
TC1
TC3
TC4
TCP
TC5
Each posture must be arbitrary. Accuracy may decrease when pose

setting is rotated in a constant direction
Teaching for defining posture

The calibration of tool posture data is performed with the first calibration
teaching point (TC1).
Teach TC1 with Z-axis of the desired tool coordinates downward vertically
to the ground. (the Z-axis of the tool coordinates is parallel to the Z-axis of
the base tool and points to the opposite direction.)
Tool posture data is automatically calculated with this TC1 posture.
The X-axis of the tool coordinates is defined in the same direction as the
X-axis of the base coordinates.
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TOOL
TCP
YT
XT
ZT
X
In case of calibrating with S2C432=2, teach TC1 with Z-axis

of the desired tool coordinates downward vertically to the
ground. Then teach the other calibration teaching points
(TC2~TC5) with the all tool points meet at the TC1s tool
point as shown in the figure below.
TC2
TC1
TC4
TC3
TC5
SUPPLEMENT
If teaching in one place as the figure above is impossible

due to the interference of peripheral equipment and so on,
perform calibration of coordinates with S2C432=0 or 2, and
then change to S2C432=1, teach only TC1 in a different
position and register the tool posture data.
TC1
TC2
TC1
TC4
TC3
TC5
[S2C432 = 0 or 2 ]
[S2C432 = 1 ]
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SUPPLEMENT
There are 64 tool files numbered 0 to 63.
In a basic system with one manipulator and one tool, the

tool file for tool No.0 is used.
If there is more than one tool, for example when using a

multihand, use the tool numbers in the order of 0, 1, 2,
etc.

2. Select {TOOL}.
In the same way as shown in the instruction 2 and 3 of the section
8.3.1.2 Registering Coordinate Data on page 8-20, display the
desired tool coordinate window.
4. Select {UTILITY} under the menu.

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5. Select {CALIBRATION}.
The TOOL CALIBRATION window is shown.
6. Select the robot.

(1) Select the robot to calibrate.
(When the robot has already been selected or there is only one of
robot, this operation should not be performed.)
(2)
Select ** in the TOOL CALIBRATION window and select the

robot in the shown selection dialog box.
(3) The robot is set.
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7. Select POSITION.
The selection dialog box is shown.
(1)
Select the teaching point for calibration.
8. Move the manipulator using the axis key.

9. Press [MODIFY] and [ENTER].
Taught position is registered.
Repeat 7 to 9 operation to teach TC1 to TC5.
"" indicates that teaching is completed and "" indicates that it is
not completed.
To check the taught positions, call up the required window among

TC1 to TC5 and press [FWD]. The manipulator moves to the set
position.
If there is a difference between the current position of the
manipulator and the shown position data, TC next to
POSITION in the window flashes.
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10. Select COMPLETE.
Calibration data is registered in the tool file. Once the calibration is
completed, the tool coordinate window is displayed on the screen.
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8.3.2.4
8 System Setup
Clearing Calibration Data

Before the calibration of a new tool, clear the robot information and
calibration data.
1. Select {DATA} under the pull-down menu.
2. Select {CLEAR DATA}.

The confirmation dialog box is shown.
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3. Select {YES}.
All data is cleared.
SUPPLEMENT
If tool angle data is required, input the data number in the

tool coordinate window.
Refer to section 8.3.1.3 Registering Tool Angle on page 823 for the operating instructions.
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8.3.2.5
8 System Setup
Checking the TCP

After registering the tool file, check if the TCP is correctly registered by
performing a TCP fixed operation like the one shown below, in any
coordinate system other than the joint.
Tool center
point
1. Press [COORD].
Select any coordinate system except
[COORD].
JOINT by pressing
2. Select desired tool number.

Show the tool coordinate window of the desired tool by pressing the
[PAGE] or selecting it in the tool list window.
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3. Move the R, B, or T axes using the axis key.
By pressing the axis keys for the R, B, and T axes, change the
manipulator pose without changing the TCP position.
If this operation shows a large TCP error, adjust the tool data.
TCP
SUPPLEMENT
For details on the TCP fixed operation, see "2.8.1 Motion

about TCP" in OPERATORS MANUAL.
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8.3.3
8.3.3.1
Automatic Measurement of the Tool Load and the Center of Gravity
What is the Automatic Measurement of the Tool Load and the Center of Gravity?
With this function, the user can register the load of tool and the position of
the tools center of gravity.
The tool load and the position of its center of gravity are measured and
registered in a tool file.
NOTE
8.3.3.2
This function can be used where the manipulator is installed

level on the ground.
For the conditions required for manipulator installation, refer
to section 8.4 ARM Control on page 8-41.
Measurement of the Tool Load and the Center of Gravity

To measure the tool load and the center of gravity, move the manipulator
to its home position (horizontal to the U-, B- and R-axes) and operate the
U-, B- and T-axes.
U-axis
U+
R-axis
B-axis
B+
T-axis
UL-axis
T+
B-
T-
Home Position
(Horizontal to the U-,
B- and R-axes)
Zero-degree Installation on the Ground
NOTE
To correctly measure the tool load or the center of gravity,

remove the cables or wires connected to the tool.
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2. Select {TOOL}.
The tool list window appears.
The tool list window is called up only when the file extension function
is valid.
If the file extension function is invalid, the tool coordinate window appears.
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Move the cursor to the desired number in the tool list window and
press [SELECT].
The tool coordinate window of the selected number is shown.
In the tool coordinate window, the number can be changed by
pressing the [PAGE] or selecting [PAGE].
To switch the tool list window and the tool coordinate window, press
{DISPLAY} {LIST} or {DISPLAY} {COORDINATE DATA}.
4. Select {UTILITY} under the menu.
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5. Select {W.GRAV.POS MEASURE}.
The window for the automatic measurement of the tool load and the
center of gravity is shown.
6. Press the [PAGE].

In a system with several manipulators, use the [PAGE] to change
the group to be controlled.
7. Press [FWD].
Press [FWD] once, and the manipulator moves to the home position
(horizontal to the U-, B- and R-axes).
8. Press [FWD] again.
Press [FWD] again, and measurement starts. Keep the button
pressed until measurement is completed.
The manipulator moves in the order listed below. Once measurement is
completed, changes to .
1
Measurement of the U-axis: U-axis home position +4.5 degrees

-4.5 degrees
Measurement of the B-axis: B-axis home position +4.5 degrees

-4.5 degrees
First measurement of the T-axis: T-axis home position +4.5 degrees

-4.5 degrees
Second measurement of the T-axis: T-axis home position +60

degrees +4.5 degrees -4.5 degrees
The speed during measurement automatically changes to
Medium.
During the measurement, HOME or U blinks on the
screen.
SUPPLEMENT
During the measurement, the [FWD] button has to be kept

pressed. If the button is released during the measurement
or if it is released before changes into , the
measurement is aborted and the following message
appears: Stopped measurement
The measurement starts again from the first home position.
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When all the measurements are completed or when all the
marks have changed into , the measured data appears on the
screen.
9. Select REGISTER.
The measured data is registered in the tool file, and the tool
coordinate window appears.
Select CANCEL to call up the tool list window without registering
the measured data in the tool file.
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8.4 ARM Control
8.4
8.4.1
ARM Control
ARM Control
ARM Control, a control system originally developed by Yaskawa, achieves
an enhanced robot motion performance such as improved path accuracy
or reduced cycle time.
The moment of inertia and the gravity moment etc. of each axis are
calculated by the ARM control function, and DX200 controls robot motion
according to the result. It is necessary to set the robot setup condition and
the tool load information to request these accurately.
The robot setup condition is robot installation angle relative to ground and
the weight and a center of gravity position of the load installed at each part
of robot, etc.
The tool load information is weight, a center of gravity position, and
moment of inertia at the center of gravity, of the tool installed at the flange.
It is necessary to set these information correctly to do a better operation
control by the ARM control.
8.4.2
ARM CONTROL Window
CAUTION
Correctly set the robot setup condition.
Make sure to avoid any mistake in setting the unit indication or

specifying positive and negative values. Failure to observe this caution
may lead to improper control of the manipulator, resulting in error
occurrence or short life span of speed reducer.
Confirm the operation path of robot of each job when modifying

settings.
Set the robot setup condition when setting up the manipulator.

Confirm the operation path of manipulator of each job afterwards when
the setting should be modified after the installation.
Modifying the settings of the ARM control may slightly change the
operation path. To avoid injury or damage to machinery caused by
collision between tool and positioner, make sure to check the operation
path before executing a job.
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8.4.2.1
8 System Setup
8.4 ARM Control
Robot Setup Condition

Fulfill the following robot setup condition to enable the ARM control.
Robot installation angle
S-head payload
U-arm payload
Robot installation angle

The angle of the manipulator installed relative to ground is set in ANGLE
REL. TO GROUND to calculate the gravity moment which loads to each
axis of the manipulator.
The robot installation angle sets how much X axis of the robot coordinates
has inclined with the ground around Y axis of the robot coordinates. The
direction of + in the U axis operation from the home position posture of the
manipulator becomes direction of + of the robot installation angle.
Therefore, the robot installation angle for a vertical downward wall mount
specification becomes -90 degrees.
Z
X
Robot
installation
Angle
<Example>
0 degrees
-90 degrees
+90 degrees
180 degrees
If the robot installation angle is not correctly set, the manipulator cannot be
properly controlled. Therefore, make sure to set the value correctly,
paying special attentions to the direction + or -.
NOTE
Only rotation angle around Y axis of the robot coordinates

can be set in the robot installation angle.
Contact YASKAWA representative when robots is installed
to incline Y axis of the robot coordinates relative to ground.
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8.4 ARM Control
S-head payload
Set the weight and the center of gravity position roughly when the
equipment such as transformer is installed at the S-head.
It is not necessary to set these values when there is no installed load on
the S-head.
WEIGHT (unit: kg)
The weight of the installed load is set.
It is not required to set a correct value, however, it is recommended to set
a value slightly larger than the actual load. (Round up the value with each
fraction between 0.5 to 1 kg.)
X (From S-Axis), Y (From S-Axis) (unit: mm)
The center of gravity position of the installed load is set by the distance in
the direction of X and the direction of Y from S axis center here. It can be
set with a rough value.
The direction of X and Y applies to the robot coordinates. The value is set
by a negative number when the position is in - direction.
Load on the S-head (Top View)
-X
S axis center
-Y
+Y
(X position, Y position)
+X
U-arm payload
Set the weight and the center of gravity position roughly when the
equipment such as the wire supplying motors is installed on U arm.
A standard value is set when shipping from the factory.
Set the weight in 0 if there is no installing equipment on U arm.
WEIGHT (unit: kg)
The weight of the installing load is set here.
Set a little large value though it does not care by a rough value. (Rase to
a unit in each 0.5 to 1kg)
X (From U-Axis), HEIGHT (From U-Axis) (unit: mm)
The center of gravity position of the installing load is set here. It does not
care by a rough value.
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8.4 ARM Control
X (From U-Axis) is horizontal distance from U axis rotation center to the
center of gravity position of the load. Set negative number when there is
mass side in the back from U-axis rotation center.
HEIGHT (From U-Axis) is height of the vertical direction from U-axis
rotation center to the center of gravity position of the load.
Fig. 8-1: Load on the U-arm: Center of Gravity Position (Side View)
X (From U-Axis)
(-)
U-axis
rotation
center
(+)
Center of Gravity
Position
HEIGHT
(From U-Axis)
NOTE
ARM CONTROL window is displayed only when the

security mode is set in the management mode.
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8.4 ARM Control
2. Select {ARM CONTROL}.

The ARM CONTROL window appears.
3. Press the page key
GO
BACK
PAGE
, or select [PAGE].
Select the desired control group when there are two or more group
axes.
4. Select the desired item.

5. Input the value and press [ENTER].
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8.4 ARM Control
8.4.3
Tool Load Information Setting
CAUTION
Set the tool load information correctly.
The speed reducer longevity might decrease or the alarm might occur
when the tool load information is not set correctly.
To set the tool load information correctly, following message appears
when inputting the information.
Input correct tool information. Using robot with wrong tool information
may result in premature failure of the robot.
Confirm the operation path of robot of each job which uses the tool
file after the tool load information is changed.
Set the tool load information before teaching the job after the tool is
installed.
Confirm the operation path of each job which uses the tool file when the
tool load information should be modified after teaching.
Modifying the tool load information may slightly change the operation
path. To avoid injury or damage to machinery caused by collision
between tool and positioner, make sure to check the operation path
before executing a job.
8.4.3.1
Tool Load Information

Tool load information includes weight, a center of gravity position, and
moment of inertia at the center of gravity of the tool installed at the flange.
These are registered in the tool file.
Moment of inertia around the Center of Gravity
Ix, Iy, Iz
XF'
XF
Ix
YF'
Iy
YF
ZF'
Iz
Weight:W
ZF
Center of Gravity Position

( Xg, Yg, Zg )
* Flange Coodinates
XF: It is a direction right above when T axis
is 0 pulse position and the flange surface
of the manipulator turned to the front.
YF: Y axis led by XF,ZF
ZF: Perpendicular direction from flange surface
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8.4.3.2
8 System Setup
8.4 ARM Control
How to Calculate Tool Load Information
Weight: W (Unit: kg)

The total weight of the installing tool is set.
a value slightly larger than the actual load. (Round up the value with each
fraction between 0.5 to 1 kg for small and medium size manipulator, and 1
to 5 kgs for large manipulator.)
Center of gravity position: xg, yg, zg (Unit: mm)

The center of gravity position of the installed tool is set as the position in
the flange coordinates.
Since it is usually difficult to get a strict center of gravity position, it can be
set with a rough value. Presume and set a center of gravity position
roughly from outline of the tool.
Set the value when the center of gravity position of the installed tool is
clear from specifications, etc.
Moment of inertia at the center of gravity: lx, ly, lz (Unit: kgm2)

It is an moment of inertia of the tool at the center of gravity position.
The value is calculated around the each axis of the coordinates which is in
parallel to the flange coordinates and which home position is the center of
gravity position of the tool.
a value slightly larger than the actual value.
This setting is used to calculate the moment of inertia which loads to each
axis of the manipulator. However, the moment of inertia at the center of
gravity does not need to be set when this data is small enough for the
moment of inertia calculated from weight and the center of gravity
position.
However, the setting is required when the moment of inertia of the tool is
large (as a rough guide, the tool is considered to be large when the tool
size is about more than 2-times the distance between the flange and the
center of gravity).
The size of the tool is not too big.

Setting the moment of inertia at center
of gravity is not necessary.
The size of the tool is big.

Setting the moment of inertia at center
of gravity is necessary.
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8.4 ARM Control
Rough value of the moment of inertia at the center of gravity can be
calculated by the following methods.
Method to approximate the entire tool in hexahedron or cylinder.
Method to calculate from each weight and center of gravity position
of plural mass.
Refer to the following setting examples for details.
<Example 1>
In the example of sealing gun of the figure below, the center of gravity is
set on the flange coordinates assuming that the center of gravity is
positioned slightly inclined to the head from the center.
There is no need to set the moment of inertia at the center of gravity since
the size of the gun is not too large.
<Setting>
YF
Center of Gravity Position

= (100, 0, 70)
70
XF
Total Weight
Approx. 6.3 [kg]
7.00 [kg]
7.000 kg
Xg
: 100.000 mm
Yg
0.000 mm
Zg
70.000 mm
Ix
0.000 kg m2
Iy
0.000 kg m2
Iz
0.000 kg m2
100
ZF
The own moment of inertia calculation for hexahedron

and cylinder
The own moment of inertia of hexahedron and cylinder can

be calculated by the next expression when the center of
gravity is at the center.
Refer to the expression when the calculation of the moment
of inertia at the center of gravity.
Z
Z
Ly
Lx
Iz
Iz
SUPPLEMENT
Iy
Lz
Ix
Iy =
Iz =
Ly + Lz
Weight: W
12
Lx 2 + Lz 2
12
Lx 2 + Ly 2
12
Iy
Ix
Weight:W
2
Ix =
*W
*W
*W
Ix = Iy =
Iz =
r
2
3 r + H2
12
*W
*W
* Unit of Weight : [kg]

* Unit of Length : [m]
2
* Unit of Ix, Iy, Iz : [kgm ]
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8.4 ARM Control
<Example 2>
It is necessary to set the moment of inertia at the center of gravity when
the entire size of the tool and workpiece is large compared to the distance
from the flange to the center of gravity position.
Calculate the moment of inertia at the center of gravity roughly from the
expression (refer to the forementioned supplement: "The own moment of
inertia calculation for hexahedron and cylinder"), by approximating the
entire tool in the shape of the hexahedron or the cylinder.
If the weight of held workpiece is greatly different in the handling usage
etc., it is more effective to set tool load information on each workpiece and
to switch the tool on each step according to the held workpiece. Set the
tool load information in the state to hold the heaviest workpiece when
using the tools without switching them.
YF
500
XF
250
DX200 Controller
Weight of tool:
Approx. 55 kg.
ZF
Weight of workpiece:
Approx. 40 kg.
400
1000
Weight:
W = 55 + 40 = 95
= approx. 100[kg]
Center of gravity: Position at flange right under 250mm almost

(Xg, Yg, Zg) = (0,0,250)
Moment of inertia at the center of gravity:
The hexahedron of 0.500 x 0.400 x 1.000[m] which encloses the
entire tool + workpiece is assumed.
By the expression to calculate the own moment of inertia of
hexahedron,
Ix = (Ly2 + Lz2 / 12) * W
= ((0.4002 + 1.0002) / 12) * 100 = 9.667 = approx. 10.000
Iy = (Lx2 + Lz2 / 12) * W = ((0.5002 + 0.4002) / 12) * 100 = 3.417
= approx. 3.500
Iz = (Lx2 + Ly2 / 12) * W = ((0.5002 + 1.0002) / 12) * 100 = 10.417
= approx. 10.500
<Setting>
W
: 100.000 kg
Xg
0.000 mm
Yg
0.000 mm
Zg
: 250.000 mm
Ix
10.000 kg.m2
Iy
3.500 kg.m2
Iz
10.500 kg.m2
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8.4 ARM Control
How to calculate "Center of gravity position" and "moment of inertia at center of

gravity" for plural mass
The center of gravity position and the moment of inertia at the center of gravity of the
entire tool can be calculated by the weight and the center of gravity position of each
mass when the tool can be thought that the tool consists of two or more big mass like
the twin gun system etc.
1. Divide the tool into some parts as the weight and the center of gravity position can
be roughly presumed. It is not necessary to divide in detail. The tool is
approximated in construction of rough parts.
2. Calculate the weight and the center of gravity position of the each parts on flange
coordinates. It does not care by a rough value. Calculate the own moments of
inertia of the big parts. (If parts are small, it is not necessary to calculate the own
moments of inertia. Refer to above-mentioned supplement: "The own moment of
inertia calculation for hexahedron and cylinder" for how to calculate the own
moment of inertia.)
wi
: Weight of the i-th parts [kg]
(xi, yi, zi)
: Center of gravity position of the i- th parts

(On flange coordinates) [mm]
Icxi, Icyi, Iczi : Own moments of inertia of the i-th parts [kg*m2]
SUPPLEMENT
3. The center of gravity position of the entire tool is calculated by the next
expression.
xg = {w1 * x1 + w2 * x2 + .... + wi * xi} / (w1 + w2 + .... + wi)
yg = {w1 * y1 + w2 * y2 + .... + wi * yi} / (w1 + w2 + .... + wi)
zg = {w1 * z1 + w2 * z2 + .... + wi * zi} / (w1 + w2 + .... + wi)
4. The moment of inertia at the center of gravity position of the entire tool is
calculated by the next expression.
Ix = {w1 * ((y1 - yg)2 + (z1 - zg)2) * 10-6 + Icx1} + {w2 * ((y2 - yg)2 +
(z2 - zg)2) * 10-6 + Icx2}
...................
+ {wi * ((yi - yg)2 + (zi - zg)2) * 10-6 + Icxi}
Iy = {w1 * ((x1 - xg)2 + (z1 - zg)2) * 10-6 + Icy1} + {w2 * ((x2 - xg)2 +
(z2 - zg)2) * 10-6 + Icy2}
.....................
+ {wi * ((xi - xg)2 + (zi - zg)2) * 10-6 + Icyi}
Iz = {w1 * ((x1 - xg)2 + (y1 - yg)2) * 10-6 + Icz1} + {w2 * ((x2 - xg)2 +
(y2 - yg)2) * 10-6 + Icz
.....................
+ {wi * ((xi - xg)2 + (yi - yg)2) * 10-6 + Iczi}
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8.4 ARM Control
<Example 3>
When there are two or more big mass such as the twin gun system as
shown in the figure below, perform:
1. Set the center of gravity position when the center of gravity position of
the entire tool is roughly understood, and set the moment of inertia at
the center of gravity calculated by approximating the entire tool in the
shape of hexahedron or cylinder. (It is enough in this setting usually.);
or
2. When weight in each mass and the center of gravity position are
understood, the center of gravity position and the moment of inertia at
the center of gravity of the entire tool can be calculated. (Refer to
forementioned supplement column: "How to calculate "Center of
gravity position" and "moment of inertia at the center of gravity" for
plural mass".)
This example shows the calculation with the method 2.
(Top View)
Center of Flange
YF
YF
100
XF
50
40
150
Gun 1
70
XF
(Gun 1)
Weight: w1 = 3 kg
Center of Gravity:
x1 = 100 mm
y1 = 50 mm
z1 = 40 mm
Gun 1
ZF
Gun 2
Weight :
Gun 2
(Gun 2)
Weight: w2 = 6 kg
Center of Gravity:
x2 = 100 mm
y2 = -150 mm
z2 = 70 mm
W = w1 + w2
= 3 + 6 = 9 = approx. 10[kg]
Center of gravity Xg = (w1 * x1 + w2 * x2) / (w1 + w2)

= (3 * 100 + 6 * 100) / (3+6)
= 100.0 [mm]
Yg = (3 * 50 + 6 * (-150)) / (3+6) = -83.333 [mm]

Zg = (3 * 40 + 6 * 70) / (3+6)
= 60.0 [mm]
The moment of inertia at the center of gravity position:

Ix = {w1 * ((y1 - Yg)2 + (z1 - Zg)2) * 10-6 + Icx1}
+ {w2 * ((y2 - Yg)2 + (z2 - Zg)2) * 10-6 + Icx2}
= 3 * ((50 - (-83))2 + (40 - 60)2) * 10-6
+
6 * (((-150) - (-83))2 + (70 - 60)2) * 10-6
= 0.082 = approx. 0.100

Iy = 3 * ((100 - 100)2 + (40 - 60)2) * 10-6
+
6 * ((100 - 100)2 + (70 - 60)2) * 10-6
= 0.002
= approx. 0.010
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8.4 ARM Control
Iz = 3 * ((100 - 100)2 + (50 - (-83))2) * 10-6
+
6 * ((100 - 100)2 + ((-150) - (-83))2) * 10-6
= 0.080 = approx. 0.100

* The own moment of inertia (Icxi, Icyi, Iczi) of the gun is disregarded in
this example, since each gun is smaller than the entire tool.
<Setting>
W
8.4.3.3
10.000 kg
Xg
: 100.000 mm
Yg
: -83.333 mm
Zg
Ix
60.000 mm
0.100 kg.m2
Iy
0.010 kg.m2
Iz
0.100 kg.m2
Tool Load Information Registering

Tool load information is registered in the tool file.
2. Select {TOOL}.
The tool coordinate list window appears.
The tool coordinate list window appears only when TOOL NO.
SWITCH in the TEACHING CONDITION window is set to PERMIT.
When TOOL NO. SWITCH in the TEACHING CONDITION window
is set to PROHIBIT, the tool window appears.
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8.4 ARM Control

(1) Move the cursor to the number of the desired tool, and press
[SELECT] in the tool list window.
(2) The tool coordinate window of the selected number appears.
(3) Select the desired number in the tool coordinate window by pressing the [PAGE] or clicking on the [PAGE] button.
(4) To switch the tool list window and the tool coordinate window,
press {DISPLAY} {LIST} or {DISPLAY} {COORDINATE
DATA}.
4. Select the desired item to register and input the value.
The window can be scrolled with the cursor.
The menu enters the state of a numeric input if the cursor is on the
desired item to register and the [SELECT] is pressed.
5. Press [ENTER].
The input value is registered.
The servo power is automatically turned OFF when editing the value
while the servo power is ON, followed by a message "Servo off by
changing data" displayed for three seconds.
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8.4 ARM Control
When the data setting is not done

It is considered that data is not set correctly in tool load
information in the following cases.
When the weight (W) is "0".
When the center of gravity position (Xg, Yg, Zg) are all
0.
In these cases, the manipulator is controlled by the initial
setting values (vary according to each robot model) which
were set to the parameter before shipping.
Initial Setting Value:
Weight: W = Payload
Center of gravity position: (Xg, Yg, Zg) =
(0, 0, Allowed value of B-axis for payload)
NOTE
In this case, when an actual tool load is not large enough,

the manipulator cannot sufficiently exert its function, (speed
and acceleration / deceleration). Especially, when
operating the manipulator with the initial setting value, a
difference of 100 kg or more in the load between the actual
tool load and the initial setting value may cause vibrations in
the manipulator motion: it is therefore essential to correctly
set the tool load information for the proper operation of the
manipulator.
Moreover, when the tool which an actual tool center of
gravity position greatly offsets in X-direction or Y-direction is
installed the generated moment by the tool cannot be
compensated.
To set the tool load information correctly, following message
appears when the playback operation is executed by using
the initial setting value.
Using robot without setting tool info. may result in
premature failure of the robot. Set W, Xg, Yg, and Zg in the
tool file.
Switch of the tool file
In case that two or more tool files are used, information on
an effective tool file is referred for tool load information used
by the ARM control at that time in according to switch tool
file.
Set the same value of tool load information in each tool file
when the tool file is switched to change only TCP (when
neither the weight nor the center of gravity position of the
entire tool installed in the flange is changed).
Moreover, set tool load information to the corresponding
tool file respectively when total weight and the center of
gravity position etc. of the tool is changed (when the system
which exchange the tool by automatic tool changer).
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8.5 Work Home Position
8.5
8.5.1
Work Home Position

What is the Work Home Position?
The Work Home Position is a reference point for manipulator operations. It
prevents interference with peripheral device by ensuring that the
manipulator is always within a set range as a precondition for operations
such as starting the line. The manipulator can be moved to the set work
home position by operation from the programming pendant, or by signal
input from an external device. When the manipulator is in the vicinity of the
work home position, the work home position signal turns ON.
8.5.2
8.5.2.1
Setting Work Home Position
Work Home Position Window

2. Select {WORK HOME POS}.

The WORK HOME POSITION window is appears.
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When two or more manipulators exist in the system, use the [PAGE]
to change the control group, or click on [PAGE] to select the desired
control group.
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8 System Setup
Registering/Changing the Work Home Position

1. Press the axis keys in the work home position display.
Move the manipulator to the new work home position.
2. Press [MODIFY], [ENTER].
New work home position is set.
When the work home position is changed, the cubic

interference area is automatically set as cube 64 to 57 in
the base coordinate system.
The cube 64 is for ROBOT1
NOTE
The work home position cube is a cube like the one shown
in the figure below; the length of its sides is determined by a
parameter setting made by the user (units: m).
By changing this parameter setting, the size of the cube
can be changed.
Fig. 8-2: S3C1097: The work home position cube length of
its sides (m)
a
a
2
2
2
Specify whether COMMAND POSITION or FEEDBACK

POSITION is to be set to the work home position cube
signals CHECK MEASURE in the interference area
settings. COMMAND POSITION is the default setting.
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8.5.2.3
8 System Setup
Returning to the Work Home Position
In the teach mode

1. Press [FWD] in the work home position display.
The manipulator moves to the new work home position. The moving
speed is the selected manual speed.
8.5.2.4
In the play mode

When the work home position return signal is input (detected at leading
edge), the TCP of the manipulator is moved to the work home position.
When the manipulator moves, a message "Operation origin returning" is
displayed. In this case, the move interpolation is MOVJ, and the speed
applied is the one set in the parameters. (S1CxG56; units: 0.01 %.)
Output of the Work Home Position Signal

This signal is output any time the current position of the TCP of the
manipulator is checked and found to be within the work home position
cube.
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8.6 Interference Area
8.6
8.6.1
Interference Area
Interference Area
The interference area is a function that prevents interference between
multiple manipulators or the manipulator and peripheral device. The area
can be set up to 32 area. There are two types of interference areas, as
follows:
Cubic Interference Area
Axis Interference Area
The DX200 judges whether the TCP of the manipulator is inside or outside
this area, and outputs this status as a signal.
8.6.2
8.6.2.1

This area is a rectangular parallelepiped which is parallel to the base
coordinate, robot coordinate, or user coordinate. The DX200 judges
whether the current position of the manipulators TCP is inside or outside
this area, and outputs this status as a signal.
Robot coordinate
Z-axis
Cubic
interference
area
Cubic
interference
area
User Coordinates
Z-axis
Y-axis
X-axis
Y-axis
X-axis
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8.6.2.2
8 System Setup
Cube Setting Method

There are three ways to set cubic a interference area as described in the
following sections:
1. Enter the maximum and minimum values for the cube coordinates.
Z-axis
Maximum
value
Cubic
interference
area axis
X-axis
Minimum
value
Y-axis
2. Move the manipulator at the maximum and minimum value positions of

the cube corner using the axis keys.
Z-axis
Maximum
value
X-axis
Minimum
value
Y-axis
3. After entering the lengths of the three faces of the cube (axial length)
using the Numeric keys, move the manipulator to the center point of
the cube using the axis keys.
Center
point
Z-axis
X-axis
Y-axis
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8.6.2.3
8 System Setup
Setting Operation
2. Select {INTERFERENCE}.
The INTERFERENCE AREA window is shown.
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3. Select the desired cube number.
Select the desired cube number with the [PAGE] or by number input.
When selecting the cube number by number input, select [PAGE] to
input the desired signal number.
4. Select METHOD.
AXIS INTERFERENCE and CUBIC INTERFERENCE are
displayed alternately every time [SELECT] is pressed. If CUBIC
INTERFERENCE is selected, the window is changed.
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5. Select CONTROL GROUP.
A selection dialog box appears.
(1) Select the desired control group.
6. Select REF COORDINATES.

A selection box appears.
(2) Select the desired coordinate.
(3) If the user coordinates are selected, the number input line is displayed. Input the user coordinate number and press [ENTER].
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7. Select CHECK MEASURE.
Each time [SELECT] is pressed, COMMAND POSITION and

FEEDBACK POSITION are displayed alternately.
COMMAND POSITION : When the command position (which is

displayed on the current position window) is in the interference area,
the signal is turned ON.
FEEDBACK POSITION : When the actual position of the
manipulator is in the interference area, the signal is turned ON.
To stop the manipulator movement using the interference

signal (use the cube interference signal for mutual
interference between robots), set CHECK MEASURE to
COMMAND POSITION.
NOTE
When set to the FEEDBACK POSITION, the manipulator

decelerates to a stop after entering the interference area.
When using the interference signal to inform an external
unit of the actual manipulator position, use the "FEEDBACK
POSITION" setting to enable the signal output in more
accurate timing.
8. Select ALARM OUTPUT.
Each time [SELECT] is pressed, OFF and ON are displayed

alternately.
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When selecting ON and if the manipulators TCP approaches
inside the pre-defined interference area, the following alarm occurs
and the manipulator stops immediately.
AL4902 CUBE INTERFERENCE (TCP)
Number Input of the Cube Coordinates

1. Select METHOD.
(1) Each time [SELECT] is pressed, MAX/MIN and CENTER POS
switch alternately.
(2) Select MAX/MIN.
2. Input number for MAX and MIN data and press [ENTER].
The cubic interference area is set.
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Teaching Corner
1. Select METHOD.
switch alternately.
(2) Select MAX/MIN.
2. Press [MODIFY].
A message Teach max./min. position appears.
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3. Move the cursor to <MAX> or <MIN>.
Move the cursor to <MAX> when changing the maximum value,
and move cursor to <MIN> when changing the minimum value.
The cursor only moves to either <MIN> or <MAX> at this time.
4. Move the manipulator using the axis keys.
Move the manipulator to the maximum or minimum position of the
cube using the axis keys.
5. Press [ENTER].
The cubic interference area is registered.
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Number Input of the Side of Cube and Teaching Center

1. Select METHOD.
switch alternately.
(2) Select CENTER POS.
2. Input data for length of the cube, then press [ENTER].

The length is set.
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3. Press [MODIFY].
A message Move to center point and teach appears. The cursor
only moves to either <MIN> or <MAX> at this time.

Move the manipulator to the center point of the cube using the axis
keys.
5. Press [ENTER].
The current position is registered as the center point of the cube.
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8.6.3
8.6.3.1

The axis interference area is a function that judges the current position of
the each axis and outputs a signal. Once the maximum and minimum
values have been set at the plus and minus sides of the axis to define the
working range, a signal indicating whether the current position of the axis
is inside or outside this range is output. (ON: inside, OFF: outside)
Fig. 8-3: Axis Interference Signal for Station Axis
Max value
+ side
ON
Min value
- side
OFF
8.6.3.2
Setting Operation
The INTERFERENCE AREA window appears.
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3. Select the desired interference signal number.
Select the desired interference signal number using the [PAGE] or
by number input.
When selecting the desired interference signal number by number
input, select [PAGE] to input the desired signal number.
4. Select METHOD.
AXIS INTERFERENCE and CUBIC INTERFERENCE are
displayed alternately every time [SELECT] is pressed. Select AXIS
INTERFERENCE.
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5. Select CONTROL GROUP.
A selection box appears. Select the desired control group.
6. Select CHECK MEASURE.

Each time [SELECT] is pressed, COMMAND POSITION and
FEEDBACK POSITION switch alternately.
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7. Select ALARM OUTPUT.
Each time [SELECT] is pressed, OFF and ON are displayed

alternately.
When selecting ON and if the manipulators axes approach inside

the pre-defined interference area, the following alarm occurs and the
manipulator stops immediately.
AL4901 AXIS INTERFERENCE
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Number Input of the Axis Data Coordinates

1. Select METHOD.
switch alternately.
(2) Select MAX/MIN.

2. Input number for MAX and MIN data and press [ENTER].
The axis interference area is set.
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Teaching Corner
1. Select METHOD.
switch alternately.
(2) Select MAX/MIN.
2. Press [MODIFY].
A message Teach max./min. position appears.
3. Move the cursor to <MAX> or <MIN>.

Move the cursor to <MAX> when changing the maximum value,
and move cursor to <MIN> when changing the minimum value.
Move the manipulator to the maximum or minimum position of the
cube using the axis keys.
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5. Press [ENTER].
The cubic interference area is registered.
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Number Input of Center Position (WIDTH) and Teaching Center

1. Select METHOD.
switch alternately.
(2) Select CENTER POS.
2. Input number for WIDTH data and press [ENTER].

WIDTH is set.
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3. Press [MODIFY].
A message Move to the center point and teach appears.

Move the manipulator to the center position of the cube using the
axis keys.
5. Press [ENTER].
The center position of the cube is registered.
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8.6.4
Clearing the Interference Area Data

The INTERFERENCE AREA window is shown.
3. Select interference signal to be cleared.

Select the desired interference signal number to be cleared using
the [PAGE] or by number input.
When selecting the desired interference signal number by number
input, select [PAGE] to input the desired signal number.
4. Select {DATA} in the pull-down menu.
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6. Select {YES}.
All the data of the interference signal number are cleared.
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8.7 Shock Detection Function
8.7
8.7.1
Shock Detection Function

Shock Detection Function
The shock detection function is a function to decrease damage due to the
collision by stopping the manipulator without any external sensor when
the tool or the manipulator collide with peripheral device.
When the shock is detected either in teach mode or in play mode, the
manipulator is stopped immediately.
WARNING
This function does not completely avoid damage to the peripheral
devices; moreover, it does not guarantee the users safety.
Make sure to prepare the safety measures such as the safeguarding
etc. Refer to chapter 1 Safety at page 1-1 to chapter 6 Test of
Program Operation on page 6-1 for the safety measures in details.
Failure to observe this warning may result in Injury or damage to
machinery caused by contact with the manipulator.
8.7.2
Shock Detection Function Setting

At the factory default setting, the threshold value is set to detect a collision
without a miss even when the manipulator is operating at the maximum
speed, on the assumption that the tool file is correctly set. To detect a
collision during normal operation, check the following points:
The tools load and moment do not exceed the rated values.
The actual tool load and the tool file setting value are the same.
The U-arm payload information and the set weight of U-arm payload
in the ARM CONTROL window are the same.
In addition, detection sensitivity can be decreased for only a specific
section where a contact task is performed.
The detection sensitivity is set by setting the detection level.
8.7.2.1
Shock Detection Level Setting

The shock detection level is set in the shock detection level set file.
The shock detection level set file are nine condition files as following
figure.
Condition numbers 1 to 7 are used when the detection level is
changed in a specific section in play mode.
Condition number 8 is used as standard in play mode: this function is
operated by the detection level set in this file during playback
operation.
Condition number 9 is for teach mode: the shock detection function
applies the detection level set here when the manipulator is operated
in teach mode.
Condition numbers 1 to 8 are set for each axis and condition 9 is set
for each group.
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The detection level is changed by a job instruction SHCKSET.
After the instruction is executed, the shock will be detected by the
specified detection level when the condition number is specified with
the SHCKSET instruction.
The detection level is returned to standard level when the SHCKRST
instruction is executed.
Setting in the specific section
in play mode
(Condition number 1 to 7)
Standard used
for play mode
(Condition
number 1 to 8)
Shock Detection
Level File
Condition number 1
Used for teach mode

(Condition number 9)
Condition number 7
Condition number 8
Condition number 9
SUPPLEMENT
The detection level of condition number 8 (a standard in play

mode) is adopted in play mode excluding the range between
SHCKSET and SHCKRST in the job.
Teach Mode Each Axis Setting Function

Usually, the detection level setting of teach mode is set for
each group.
SUPPLEMENT
By using this function, the detection level can be set for each
axis.
S2C869: Teach Mode Each Axis Setting Function
(1: VALID, 0: INVALID)
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2
3
4
5
Condition Number (1 to 9)
1 to 7: for changing detection level in play mode.
8: for standard detection level in play mode.
9: for detection level in teach mode.
Robot Select
Select the manipulator whose detection level is to be changed.
Function Select
Specifies VALID/INVALID of the shock detection function. The shock
detection function is specified for each manipulator.
1. Select the manipulator whose function is to be enabled or disabled.
3
2. Move the cursor to VALID or INVALID and press [SELECT]. Each

time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately. The change is available for all the condition numbers.
Max. Disturbance Force
Indicates the maximum disturbance force to the manipulator when the
manipulator is moved in play back operation or axis operation.
Refer to this value when inputting the detection level value in 5 .

The maximum disturbance force can be cleared by selecting {DATA}
{CLEAR MAX VALUE} in the menu.
5
Detection Level (Level range: 1 to 500)
Specifies the shock detection level. Set a value larger than the maximum disturbance force.
The value set by default (the level 100) enables the function without
false detection even if the manipulator is operated at the maximum
speed.
To change DETECT LEVEL, move the cursor to the subject
manipulator, and press [SELECT] to display the numeric input status;
input the value with a numeric key and press [ENTER]. To increase the
detection sensitivity, set the level to small value, and to decrease the
sensitivity, set the level to large value.
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Method of Shock Detection Level File Setting

2. Select {SHOCK SENS LEVEL}.
The EACH AXIS LEVEL window appears.
Perform either of the following operations to display the page of
desired condition number:
(1) Press [PAGE] in the window. Enter the desired condition number
using numeric keys and press [ENTER]. Then the page of the
condition number appears.
(2) Press the [PAGE] to change the condition number.
3. Level setting for the condition numbers 1 to 8.
Level setting values can be set for each axis on the EACH AXIS
LEVEL window.
Perform the following Disturbance force measurement, then perform
Setting all levels at once.
Disturbance force measurement
1
Mount the tool, workpiece, external equipment, and equipment on

the arm to the manipulator.
Set the tool file correctly.

For spot welding
: Set the gun load information (weight and center
of gravity). To use the gun change function,
while removing the gun, switch to the tool file
with which the load information without a gun
is set.
For handling
: Set the total load information (weight and
center of gravity) of the hand and the maximum
load workpiece.
For other applications: Set the load information (weight and center of
gravity) of the tool.
Set the detection level values of all the axes to 100.

(1) Open the SHOCK DETECT LEVEL window.
(2) Select {DATA}, then {CLEAR MAX VALUE}.
Perform the JOB.
Setting all levels at once

1
Open the SHOCK DETECT LEVEL window.
Select {DATA}, then {CHANGE EVERY LEVEL}.
Enter 120 in the coefficient (%) by which the max. disturbance force
is multiplied.
The following calculated value A or B, whichever is larger, is set to
the DETECT LEVEL.
A: (Max. disturbance force) x (coefficient = 120%)
B: (Max. disturbance force) + 15
<Example>
When the max. disturbance force is 80, the DETECT LEVEL is 96.
When the max. disturbance force is 10, the DETECT LEVEL is 25.
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4. Level setting for the condition number 9.
The level setting for the condition number 9 is for the teach mode.
This setting is made for each group.
Refer to the max. disturbance force to set the DETECT LEVEL.
Perform all the jobs to use for 5 to 6 hours.

For handling application, if a work job is performed both
with holding a workpiece and without holding a workpiece,
measure both patterns.
In the event of a collision while measuring the max.
disturbance force, clear the max. disturbance force by
selecting {DATA}, then {CLEAR MAX VALUE}. Then try
again.
NOTE
The max. disturbance force is cleared when the power is

turned ON/OFF. Therefore, DO NOT set the level based
on the max. disturbance force immediately after turning
ON/OFF the power.
When the teaching point, operation speed, operation
position, etc. of a job are greatly changed due to teaching
modification, etc., measure the max. disturbance force
and set the DETECT LEVEL again.
When the load of tool or workpiece is greatly modified,
measure the max. disturbance force and set the DETECT
LEVEL again.
To avoid false detection during manipulator operation, set
the following calculated value A or B, whichever is larger, to
the DETECT LEVEL. An emergency stop of the
manipulator due to the false detection may become a factor
to damage the speed reducers and tools.
NOTE
A: (Max. disturbance force) x (coefficient = 120%)

B: (Max. disturbance force) + 15
<Example>
When the max. disturbance force is 80, set the
DETECT LEVEL to 96 or more.
When the max. disturbance force is 10, set the
DETECT LEVEL to 25 or more.
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8.7.2.2
8 System Setup
NOTE
To adjust to the change in the grease viscosity at a cold

start, the offset value is automatically added to DETECT
LEVEL until the robot has operated for a certain period of
time.
Thus, at a cold start, the shock detection will be performed
only when the value is more than or equal to the sum of
DETECT LEVEL and the offset value.
The offset value varies depending on the manipulator type.
NOTE
DETECT LEVEL can be modified only when the security

mode is set in the management mode.
EACH AXIS LEVEL (CURRENT) Window

Able to confirm the current detection level.
1
2
3
4
Robot Select
Select the manipulator to display the detection level.
Function Select
Displays the valid/invalid status of the shock detection function.
Max. Disturbance Force

Indicates the maximum disturbance force to the manipulator when the
manipulator is moved in play back operation or axis operation.
The maximum disturbance force can be cleared by selecting {DATA}
{CLEAR MAX VALUE} in the menu.
Detection Level
Displays the shock detection level.
When the maximum disturbance force exceeds this set value, the shock
is detected.
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NOTE
8.7.2.3
To adjust to the change in the grease viscosity at a cold

start, the offset value is automatically added to DETECT
LEVEL until the robot has operated for a certain period of
time.
Thus, at a cold start, the shock detection will be performed
only when the value is more than or equal to the sum of
DETECT LEVEL and the offset value.
The offset value varies depending on the manipulator type.
Tool Load Information Setting

To increase the accuracy of shock detection, set the tool load information
in the tool file. Refer to section 8.4.3 Tool Load Information Setting on
page 8-46 for details of the tool load information setting.
8.7.2.4
U-Arm Payload Setting

To perform shock detection more accurately, set the U-arm payload.
See section 8.4.2 ARM CONTROL Window on page 8-41 for details of
the U-arm payload setting.
8.7.2.5
Instruction of Shock Detection Function
SHCKSET instruction
The SHCKSET instruction changes the shock detection level to the value
set in the shock detection level file during play back operation.
The additional items of the SHCKSET instruction are as follows.
SHCKSET R1 SSL#(1) AXIS1=100 AXIS2=100 AXIS3=100 AXIS4=100

AXIS5=100 AXIS6=100 AXIS7=100 AXIS8=100
3
Robot Setting
Specifies the manipulator of which shock detection level is to be modified. If nothing is specified, the modification is applied to the shock
detection level of the job control group in this instruction. However, in
case of coordinated job, the modification is applied to the shock detection level of the slave axis group.
Shock Detection Level Condition Number (1 to 7)

Specifies the shock detection level condition number in which the detection level in playback mode is set.
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3
Changing the Shock Detection Level for Each Axis
(Setting range: 1 to 500)

Change the shock detection level specified in the changing the shock
detection level for the each axis.
If the shock detection level is not specified, the level will be the detection
level specified in the shock detection level condition number.
As for the manipulator with six axes, each axis indicates as follows.
AXIS1 AXIS2 AXIS3 AXIS4 AXIS5 AXIS6
S-axis L-axis
U-axis R-axis B-axis T-axis
If the non-existing axis in the system was specified to change the shock
detection level for each axis, the its specified shock detection level is
invalid.
SHCKRST instruction
The shock detection level changed by the SHCKSET instruction is reset
and returned to the detection level of the standard (value set in condition
number 8) by the SHCKRST instruction.
The additional item of the SHCKRST instruction is as follows.
SHCKRST R1
Robot Setting
Specifies the manipulator of which shock detection level is to be reset.
If nothing is specified, the modification will be applied to the shock
detection level of the job control group of this instruction. However, in
case of coordinated job, the modification is applied to the shock detection level of the slave axis group.
Instruction Registration
The instruction is registered when the cursor is in the address area in the
JOB CONTENT window in teach mode.
1. Select {JOB} under the main menu.
Address
Area
Instruction
2. Select {JOB}.
3. Move the cursor in the address area.
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SHCKSET
1. Move the cursor to the immediately preceding line where the
SHCKSET instruction is to be registered.
2. Press [INFORM LIST].
The inform list dialog box is shown.
3. Select SHCKSET instruction.

(1) SHCKSET instruction is shown in the input buffer line.
(2) Change the value of additional item and numerical data.

(3) Press [INSERT] then [ENTER].
4. Change the value of additional item and numerical data.
< When registering the instruction as it is >
Operate the step 5 when registering the instruction in the input
buffer line as it is.
< When adding or changing the additional item >
When changing the shock detection level
(1) When changing the shock detection level, move the cursor to the
shock detection level condition number; hold down [SHIFT] and
press the up/down cursor key to change the condition number.
When the value is input with the numeric key

(1) When the value is input with the numeric key, press [SELECT] to
display the input buffer line.
(2) Press [ENTER] to change the number in the input buffer line.
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When the robot specification is added
(1) When the robot specification is added, move the cursor to the
instruction in the input buffer line and press [SELECT] to display
the DETAIL window.
(2) Move the cursor to "UNUSED" of "ROBOT/STATION", and press

[SELECT].
(3)
The selection box appears.
(4) Point the cursor to the robot/station to be added and press

[SELECT].
(5) When the addition of robot/station is completed, press [ENTER].

(6)
The DETAIL window closes and the JOB CONTENT window

appears.
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When the shock detection level for the each axis change is
added
(1) Move the cursor over the instruction in the input buffer line, and
select [Select] to display the DETAIL EDIT window.
(2) Move the cursor to "UNUSED" of any SENS(AXIS)" to change the

detection level, and press [SELECT].
(3)
The selection box appears, and select AXIS=.
(4) Press [ENTER] after adding the items.

(5) The JOB CONTENT window appears, after closing the DETAIL
EDIT window.
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When changing the shock detection level for the each axis
(1) When changing the shock detection level for the each axis, move
the cursor to the shock detection level; hold down [SHIFT] and
press the up/down cursor key to change the level.
When the value is input with the numeric key

(1) When the value is input with the numeric key, press [SELECT] to
display the input buffer line.
(2) Input the numbers, and then press [ENTER]. The value in the
input buffers is changed.
5. Press [INSERT] then [ENTER].
The instruction displayed in the input buffer line is registered.
SHCKRST
1. Move the cursor to the immediately preceding line where the
SHCKRST instruction is to be registered.
2. Press [INFORM LIST].
The inform list appears.
3. Select SHCKRST instruction.

SHCKRST instruction appears in the input buffer line.
4. Change the value of the additional item.

< When registering the instruction as it is >
Operate the step 5 when registering the instruction in the input
buffer line as it is.
< When adding or changing the additional item >
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(1) When adding the robot specification, move the cursor to instruction in the input buffer line and press [SELECT] to display the
DETAIL window.
(2) Move the cursor to "UNUSED" of "ROBOT/STATION", and press

[SELECT].
(3) The selection box appears.
(4) Point the cursor to the robot to be added and press [SELECT].
(5) When the addition of robot is completed, press [ENTER].

(6)
The DETAIL window closes and the JOB CONTENT window

appears.

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8.7.2.6
8 System Setup
Resetting the Shock Detected

When the collision of tool/manipulator and peripheral device is detected
with the shock detection function, the manipulator stops instantaneously
with alarm output. In this case, the shock detection alarm is displayed.
The shock detection alarm in teach mode and play mode can be reset by
the following operation.
1. Press [SELECT].
The alarm is reset when RESET is selected on the alarm display,
and the shock detection status is released.
2. Operation after resetting the detection status.
In teach mode, the JOG operation of the manipulator is enabled by
resetting the status.
In the play mode, move the manipulator once to the safety position
in the teach mode to check the damage though the playback
operation is possible after resetting the status.
NOTE
When manipulator is stopped instantaneously while having

contact with the object and the detection alarm is tried to
reset on the alarm window, the situation in which the alarm
cannot be reset may occur since the collision may be
detected again after resetting.
In this case, set the shock detection function "INVALID", or
increase the detection level in teach mode and retreat the
manipulator to a safety position.
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8.7.3
High-Sensitivity Shock Detection Function (For Arc Welding

Application Only)
This function is designed to reduce the damage caused by a collision by
bringing the manipulator to an emergency stop when the tool or
manipulator collides with peripheral equipment. By increasing the
sensitivity to a collision, the damage caused by a collision can be reduced,
compared to the normal shock detection function.
To use this function, it is necessary to set the robot setup conditions and
the tool load information correctly.
The robot setup conditions include the weight and the center of gravity
position of the load installed at each part of robot, etc.
The tool load information includes the weight, the center of gravity
position, and the moment of inertia at the center of gravity, of the tool
installed at the flange.
WARNING
This function does not completely avoid damage to the peripheral
devices; moreover, it does not guarantee the users safety.
Make sure to prepare safety measures such as safeguarding etc.
Refer to chapter 1 Safety at page 1-1 to chapter 6 Test of Program
Operation on page 6-1 for the safety measures in details.
Failure to observe this warning may result in injury or damage to
machinery caused by contact with the manipulator.
8.7.3.1
Manipulator Type for High-Sensitivity Shock Detection Function

The following manipulator types for arc welding support the highsensitivity shock detection function. To enable this function, read the tool
load information prepared by Yaskawa on the MAKER INITIAL VALUE
window.
Types for high-sensitivity shock detection function
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8.7.3.2
8 System Setup
Setting for High-Sensitivity Shock Detection Function

To enable the high-sensitivity shock detection function, perform the
settings 1 and 2 as shown below. The function is enabled only with
the setting 1 , but perform both 1 and 2 to make the shock detection
more accurate.
Reading the tool load information from the MAKER INITIAL VALUE window
To enable the high-sensitivity shock detection function, read the tool
load information prepared by Yaskawa on the MAKER INITIAL VALUE
window. Since this function works on the assumption that the tool file is
correctly set, read the tool load which is the same as the actual load on
the MAKER INITIAL VALUE window. When the tool other than the tool
for high-sensitivity indicated in section 8.7.3.6 Explanation of Maker Initial Value on page 8-103 is used, DO NOT use this function.
Setting the U-arm payload

To perform shock detection more accurately, set the U-arm payload
referring to section 8.4.2 ARM CONTROL Window on page 8-41.
The U-arm payload prepared by Yaskawa can be read on the MAKER
INITIAL VALUE window. Read the same data as the actual U-arm payload on the MAKER INITIAL VALUE window.
8.7.3.3
Reading the Tool Load Information on the MAKER INITIAL VALUE Window
1. Change the SECURITY MODE to the MANAGEMENT MODE, then
select {ROBOT} under the main menu.
2. Select {TOOL}.
The TOOL window appears.
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5. Select {READING}.
The MAKER INITIAL VALUE window appears.
6. Select the number of the maker initial value to be read.

Select a maker initial value other than the STANDARD to enable
the high-sensitivity shock detection function.
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7. Select {YES}.
The tool load information is read into the tool file, and the TOOL
window appears.
When NO is selected, the tool load information is NOT read into
the tool file, and the TOOL window appears.
NOTE
NOTE
The high-sensitivity shock detection function is enabled

when a maker initial value other than the STANDARD is
selected. The read tool load information cannot be
changed because it is used for the high-sensitivity shock
detection function. When the standard torch is read, the
function is disabled and the tool load information becomes
editable.
In the case of using multiple tool files, when the tool file is
switched, the tool load information is also switched. When
switching the tool file only to switch the TCP (when the
weight or the center of gravity position, etc. of the whole tool
installed at the flange does not change), perform the same
settings to the tool load information of each file.
In addition, when the total weight or the center of gravity
position of the tool changes (with the system in which the
tool is exchanged by a tool changer, etc.), set the tool load
information for each tool file.
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Explanation of Maker Initial Value
NAME
The name of tool load information prepared by Yaskawa is indicated.
When using the tool in the following figure, select 300R BUILT MODEL,
308R BUILT MODEL, or 308RR UNIV MODEL.
397.7
(385.4)
395
Fig. 8-4: Tool for High-Sensitivity Shock Detection
325
(312.1)
8.7.3.4
8 System Setup
40
35
15
15
31
(116.5)
82.5
125
NOTE
15
(74.8)
The high-sensitivity shock detection function works on the

assumption that the tool file is correctly set.
To perform shock detection more accurately, read the tool
load which is the same as the actual load on the MAKER
INITIAL VALUE window.
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8.7.3.5
8 System Setup
Reading the U-Arm Payload

1. Change the SECURITY MODE to the MANAGEMENT MODE.
2. Select {ARM CONTROL}.
The ARM CONTROL window appears.

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4. Select {READING}.
The MAKER INITIAL VALUE window appears.
5. Select the number of the MAKER INITIAL VALUE to be read.

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6. Select {YES}.
The U-arm payload is read into the ARM CONTROL window, and
the ARM CONTROL window appears.
When {NO} is selected, the ARM CONTROL window appears
without the U-arm payload being read into the ARM CONTROL
window.
U-arm payload information
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8.7.3.6
8 System Setup
Explanation of Maker Initial Value
NAME
The name of U-arm payload information prepared by Yaskawa is indicated.
When using the U-arm payload in the following figure, select from the
MAKER INITIAL VALUE window.
340MELC
310ELC
NOTE
340ELC
To perform shock detection more accurately, even when the

U-arm payload information prepared by Yaskawa and the
actual payload are the same, DO NOT read the payload
information if the robot types are different.
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8.8 User Coordinate Setting
8.8
8.8.1
User Coordinate Setting

User Coordinates
Definition of the User Coordinates
User coordinates are defined by three points that have been taught to the
manipulator through axis operations. These three defining points are
ORG, XX, and XY, as shown in the diagram below. These three points of
positional data are registered in a user coordinate file.
Z-axis
X-axis
XX
XY
Y-axis
ORG
User coordinate definition point

ORG: Home position
XX: Point on the X-axis
XY: Point on the Y-axis
ORG is the home position, and XX is a point on the X-axis. XY is a point

on the Y-axis side of the user coordinates that has been taught, and the
directions of Y- and Z-axes are determined by point XY.
NOTE
It is important that the two points ORG and XX be taught

accurately.
User Coordinate Files

Up to 63 kinds of user coordinates can be registered. Each coordinate has
a user coordinate No. and is called a user coordinate file.
User coordinate file 1

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8.8.2
8.8.2.1
User Coordinate Setting
Selecting the User Coordinate File

2. Select {USER COORDINATE}.
3. Select the user coordinate number.
(1) The USER COORDINATE window appears.
(2) The "" mark indicates that the user coordinates is completed to
set and the "" mark indicates that it is not completed.
(3) To check the position of the user coordinates select {DISPLAY}
{COORDINATE DATA}.
(4) The following window appears.
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8.8.2.2
8 System Setup
Teaching the User Coordinates

1. Select the robot.
Select "**" on the upper left of the window to select the subject robot.
(This operation can be omitted if the robot selection has already
been made or if there is only one robot.)
2. Select SET POS.

Select the teaching point.
3. Move the manipulator to the desired position with the axis keys.
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4. Press [MODIFY] then [ENTER].
Taught position is registered.
Repeat the steps 2 to 4 to teach ORG, XX and XY.
indicates that teaching is completed and "" indicates that it is
not completed.
To check the taught positions, call up the required window among

ORG to XY and press [FWD]. The manipulator moves to the set
position.
If there is a difference between the current position of the
manipulator and the displayed position data, ORG, XX, or XY
flashes.
5. Select COMPLETE.
User coordinates are registered in the file.
Once the user coordinate setting is completed, the following
window appears.
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8.8.2.3
8 System Setup
Clearing the User Coordinates

1. Select {DATA} under the pull-down menu.
3. Select {YES}.
All data is cleared.
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8.9 Overrun/Tool Shock Sensor Releasing
8.9
Overrun/Tool Shock Sensor Releasing
CAUTION
To operate the manipulator with the overrun or shock sensor released,
pay extra attention to the safety of the surrounding operation
environment.
If the manipulator stops by overrun detection or tool shock sensor
detection, release the overrun or tool shock sensor by the following
procedure and reset the alarm and move the manipulator with the axis
keys.
2. Select {OVERRUN & S-SENSOR}.
The OVERRUN & SHOCK SENSOR window appears.
Select either "EMERGENCY STOP" or "HOLD" to set the item
"SHOCK SENSOR STOP COMMAND" which specifies the stop
condition in the current shock sensor detection.
E-STOP and HOLD are displayed alternately every time
[SELECT] is pressed.
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8.9 Overrun/Tool Shock Sensor Releasing
3. Select RELEASE.
The control group in which overrun or shock sensor is detected is
indicated with ".
If RELEASE is selected, overrun or tool shock sensor is released
and CANCEL indication will be displayed.
4. Select ALM RST.

The alarm is reset and manipulator can be moved with the axis
keys.
NOTE
After releasing the overrun or tool shock sensor, if

CANCEL is selected or the window is changed to the other
one, the release of the overrun or tool shock sensor will be
canceled.
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8.10 Soft Limit Release Function
8.10
Soft Limit Release Function

The switches that are set to detect the motion range of the manipulator
are called limit switches. The operating range is monitored by the software
in order to stop motion before these limit switches are reached. These
software limits are called "soft limits". The operating range of the
manipulator is controlled by the following two soft limits.
Maximum motion range for each axis
Cubic operation area set parallel to the robot coordinate system
These soft limits are continually monitored by the system, and the
manipulator automatically stops when the its TCP reaches a soft limit.
When the manipulator is stopped at a soft limit, temporarily release the
soft limit by the following procedure, then move the manipulator away from
the soft limit in a direction opposite to the earlier operation direction.
2. Select {LIMIT RELEASE}.
The LIMIT RELEASE window appears.
3. Select SOFT LIMIT RELEASE.

Each time [SELECT] is pressed, VALID and INVALID switch
alternately.
When SOFT LIMIT RELEASE is set to VALID, a message Soft
limits have been released appears.
When SOFT LIMIT RELEASE is set to INVALID, a message

"Softlimits off released" is displayed for a few seconds.
NOTE
The taught data cannot be registered when the soft limit is

being released.
The setting of "SOFT LIMIT RELEASE" becomes
"INVALID" when the mode is changed to the play mode.
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8.11 All Limit Release Function
8.11
All Limit Release Function
CAUTION
To operate the manipulator with all limits released, pay extra attention
to ensure the safety of the surrounding operation environment.
equipment due to the unexpected manipulator motion exceeding its
range of motion.
The following limits can be released with the All Limit Release function:
Limit Type
Contents
Mechanical Limit
Limit to check manipulators range of motion.
L-U Interference
Limit to check L- and U-axis interference area.
Soft Limit on Each Axis
Soft limit to check manipulators range of

motion.
Cube Interference
Limit to check cube interference area set by

user.
NOTE
All limit release function is not available if the security mode

is not in the management mode. Refer to chapter 7
Security System on page 7-1 for details on the security
modes.
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8.11 All Limit Release Function
2. Select {LIMIT RELEASE}.
The LIMIT RELEASE window appears.
3. Select ALL LIMITS RELEASE.

VALID and INVALID are displayed alternately every time
When ALL LIMIT RELEASE is changed to VALID, a message All
limits have been released is displayed. When the setting changes
to INVALID, a message All limits off released is displayed for a
few seconds.
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8.12 Instruction Level Setting
8.12
8.12.1
8.12.1.1
Instruction Level Setting

Setting Contents
Instruction Set
There are three instruction sets that can be used when registering the
instructions for the robot programming language (INFORM III): the subset
instruction set, the standard instruction set, and the expanded instruction
set.
Subset Instruction Set
The instructions displayed in the instruction list are limited to just those
that are most frequently used, reducing the number of instructions that
can be registered. Since few instructions are shown, selection and input
are simple.
Standard Instruction Set / Expanded Instruction Set
All the INFORM III instructions can be used. The number of additional
items to be used in each instruction differ in the standard instruction set
and expansion instruction set.
In the standard instruction set, the following functions cannot be used.
However, operation becomes easier because the number of data items
decreases when registering an instruction.
Use of local variables and arrangement variable
Use of variables for additional items (Example: MOVJ VJ = I000)
When instructions are executed, for example during playback, all the
instructions can be executed regardless of the instruction set used.
Expanded instruction set

Standard instruction set
Subset instruction set
All instructions
Frequency used
instructions
Use of local variables and arrangement variables

Use of variables for additional items
Job calls with arguments
Instruction set
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8.12.1.2 Learning Function

When an instruction is entered from the instruction list, the additional
items that were entered last time are also shown. This function can
simplify instruction input.
To register the same additional items as those in the former operation,
register them without changing.
1. An instructions are registered.
2. The next time an attempt is made to register the same instruction as in

1, the same additional items as were registered last time are also
shown in the input buffer line.
8.12.2 Setting the Instruction Set Level

2. Select {TEACHIG COND}.
The TEACHING CONDITION window appears.
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3. Select LANGUAGE LEVEL.
The selection list appears.
4. Select desired language level.

Language level is set.
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8.12.3 Setting the Learning Function
The learning function is set at "VALID" by default.
1.
Select {SETUP} under the main menu.
2. Select {TEACHIG COND}.

The TEACHING CONDITION window appears.
3. Select "INSTRUCTION INPUT LEARNING".

VALID and INVALID are displayed alternately every time
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8.13 Setting the Controller Clock
8.13
Setting the Controller Clock

The clock inside the DX200 controller can be set as follows.
2. Select {DATE/TIME}.
The DATE/TIME SET window appears.
3. Select DATE or TIME.

The input buffer line appears.
4. Input the new date/time.
For instance, to set the date to August 1, 2008, input "2008.8.1". To
set the time at twelve oclock, enter "12.00".
5. Press [ENTER].
The date/time is changed.
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8.14 Setting the Play Speed
8.14
Setting the Play Speed

2. Select {SET SPEED}.
The SPEED SET window is shown.

When two or more manipulators and stations exist in the system,
use the [PAGE] to change the control group, or click on [PAGE] to
select the desired control group.
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8.14 Setting the Play Speed
4. Select JOINT or LNR/CIR.
The type of speed alternately changes from JOINT to LNR/CIR.
5. Select the speed to modify.

The input buffer line appears.
6. Input the speed value.
7. Press [ENTER].
The speed is modified.
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8.15 Numeric Key Customize Function
8.15
Numeric Key Customize Function
8.15.1 What is the Numeric Key Customize Function?

With this function, the user can set the function of an application that has
been allocated to the numeric keys of the programming pendant to the
other function.
Since any frequently used operation can be allocated to the numeric keys
on the programming pendant, decreased key operations reduce the
teaching time.
NOTE
The Numeric Key Customize Function is allowed to set only

when the security mode is in the management mode.
8.15.2 Allocatable Functions

There are two allocation methods as follows:
Key Allocation (EACH)
Key Allocation (SIM)
8.15.2.1 Key Allocation (EACH)

With key allocation (EACH), the manipulator operates according to the
allocated function when the numeric key is pressed. The allocatable
functions are listed below.
Function
Description
Manufacturer
Allocated by Yaskawa. Allocating another function

invalidates the function allocated by the manufacturer.
allocation
Instruction
allocation
Allocates any instructions assigned by the user.
Job call allocation
Allocates job call instructions (CALL instructions). The

jobs to be called are only those registered in the reserved
job names. (Specified by the registration No.)
Display allocation
Allocates any displays assigned by the user.
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8.15.2.2
8 System Setup
Key Allocation (SIM)

With key allocation (SIM), the manipulator operates according to the
allocated function when the [INTERLOCK] and the numeric key are
pressed at the same time. The allocatable functions are listed below.
Function
Description
Alternate output
allocation
Turns ON/OFF the specified user output signal when

[INTERLOCK] and the allocated Numeric key are
pressed at the same time.
Momentary output
allocation
Turns ON the specified user output signal user when

[INTERLOCK] and the allocated user key are pressed at
the same time.
Pulse output
allocation
Turns ON the specified user output signal only for the

specified period when [INTERLOCK] and the allocated
Numeric key are pressed at the same time.
Group output
allocation
(4-bit/8-bit)
Sends the specified output to the specified general group

output signals when [INTERLOCK] and the allocated
Numeric key are pressed at the same time.
Analog output
allocation
Sends the specified voltage to the specified output port

when [INTERLOCK] and the allocated Numeric key are
pressed at the same time.
Analog incremental
output allocation
Sends the voltage increased by the specified value to the

specified output port when [INTERLOCK] and the
allocated Numeric key are pressed at the same time.
SUPPLEMENT
In a system for multiple applications, a numeric key can be

allocated for each application.
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8.15.3 Allocating Operation
8.15.3.1 Allocation Window

1. Select {SETUP} under the Main Menu.
2. Select {KEY ALLOCATION}.
The KEY ALLOCATION (EACH) window appears.
3. Select {DISPLAY}.
Pull-down menu appears.
To call up the KEY ALLOCATION (SIM) window, select {ALLOCATE
SIM. KEY}.
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4. Select {ALLOCATE SIM. KEY}.
The KEY ALLOCATION (SIM) window appears.
In a system multiple applications, press the [PAGE] to change the
window to the allocation window for each application, or click on
[PAGE] to select the desired application number.
8.15.3.2
Instruction Allocation
1. Set this function in the KEY ALLOCATION (EACH) window. Move the
cursor to FUNCTION of the key to be allocated and press [SELECT].
Selection list appears.
2. Select INSTRUCTION.
The instruction is shown in the ALLOCATION CONTENT.
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(1) To change the instruction, move the cursor to the instruction and
press [SELECT]. Then the instruction group list appears.
(2) Select the group which contains the instruction to modify.

(3) When the instruction list dialog box is shown, select the instruction
to be changed.
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8.15.3.3
8 System Setup
Job Call Allocation

Set this function in the KEY ALLOCATION (EACH) window.
1. Move the cursor to the FUNCTION of the key to be allocated and
press [SELECT].
A selection list appears.
2. Select JOB CALL.
The reserved job registration No. is shown in the ALLOCATION
CONTENT (reserved job registration No.: 1 to 10).
(1) To change the reserved job registration No. move the cursor to the
No. and press [SELECT]. Then input buffer line appears.
(2)
Input the number to be changed, and press [ENTER].
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8.15.3.4 Display Allocation

Set this function in the KEY ALLOCATION (EACH) window.
press [SELECT].
2. Select [DISPLAY].
3. Move the cursor to ALLOCATION CONTENT and press [SELECT].
Character input is available.
4. Input the name of the reserved window and press [ENTER].
The reserved name input to the ALLOCATION CONTENT is
shown.
5. Open the window for allocation.
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6. Press [INTERLOCK] and the allocated key at the same time.
A message Reserved display registered appears, and the window
is registered.
In this case, the CURRENT POSITION window is registered by
pressing [INTERLOCK] + [0] with the CURRENT POSITION window
displayed on the screen.
SUPPLEMENT
When allocate the display allocation to a key, key allocation

(SIM) will be set to the display set.
Unable to allocate the display allocation and the another
function to the same key.
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8.15.3.5 Alternate Output Allocation

Set this function in the KEY ALLOCATION (SIM) window.
press [SELECT].
2. Select ALTERNATE OUTPUT.

The output No. is displayed in the ALLOCATION CONTENT.
(1) To change the output No., move the cursor to the No. and press
[SELECT]. Then numeric value can be entered.
(2)
Input the number to be changed, and press [ENTER].
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8.15.3.6
8 System Setup
Momentary Output Allocation

press [SELECT].
2. Select MOMENTARY OUTPUT.
The output No. is displayed in the ALLOCATION CONTENT.
(1) To change the output No., move the cursor to the No. and press
[SELECT]. Then numeric value can be entered.
(2) Input the number to be changed, and press [ENTER].
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8.15.3.7 Pulse Output Allocation

press [SELECT].
2. Select PULSE OUTPUT.
The output No. and output time are displayed in the ALLOCATION
CONTENT.
(1) To change the output No. or output time, move the cursor to the
No. or time and press [SELECT]. Then numeric value can be
entered.
(2) Input the number or time to be changed, and press [ENTER].
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8.15.3.8
8 System Setup
Group (4-bit/8-bit) Output Allocation

press [SELECT].
2. Select 4 BIT OUTPUT or 8 BIT OUTPUT.
The output No. and output value are displayed in the ALLOCATION
CONTENT.
(1) To change the output No. or output value, move the cursor to the
No. or value and press [SELECT]. Then numeric value can be
entered.
(2)
8.15.3.9
Input the number or value to be changed, and press [ENTER].
Analog Output Allocation

press [SELECT].
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2. Select ANALOG OUTPUT.
The output port number and the output voltage value are displayed
in the ALLOCATION CONTENT.
(1) To change the output port No. or output voltage value, move the
cursor to the No. or voltage value and press [SELECT]. Then
numeric value can be entered.
(2)
8.15.3.10
Input the number or voltage value to be changed, and press

[ENTER]
Analog Incremental Output Allocation

press [SELECT].
2. Select ANALOG INC OUTPUT.
The output port No. and incremental value are displayed in the
ALLOCATION CONTENT.
(1) To change the output port No. or incremental value, move the cursor to the No. or incremental value and press [SELECT]. Then
numeric values can be entered.
(2)
Input the number or incremental value to be changed, and press

[ENTER].
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8.15.4
Allocation of I/O Control Instructions

In key allocation (SIM), output control instructions can be allocated to the
numeric keys that have been allocated one of the following I/O controls
with key allocation (EACH).
Function
Output Control Instruction allowed to be

Allocated
Alternate output allocation
DOUT OT# (No.) ON
Momentary output allocation

Pulse output allocation
PULSE OT# (No.) T = output time
Group output allocation (4-bit) DOUT OGH (No.) output value

Group output allocation (8-bit) DOUT OG# (No.) output value
Analog output allocation
AOUT AO# (No.) output voltage value
1. Allocation of I/O control instruction.

Allocate the I/O control instruction with key allocation (SIM) following
the forementioned procedure.
2. Move the cursor to the FUNCTION of the key that has been allocated
with I/O control with key allocation (SIM) and press [SELECT].
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3. Select OUTPUT CONTROL INST.
The instruction corresponding to the I/O control allocated by key
allocation (SIM) is displayed in the ALLOCATION CONTENT.
The allocated instruction changes automatically when

ALLOCATION CONTENT is changed by key allocation (SIM).
Even if the I/O control allocation is changed to the default setting
allocated by the manufacturer with key allocation (SIM), the settings
for key allocation (EACH) remain the same.
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8.15.5
8.15.5.1
Execution of Allocation
Executing the Instruction/Output Control Allocation

1. Press the key allocated for instruction allocation or output control
allocation.
The allocated instruction is displayed in the input buffer line.
2. Press [INSERT] and [ENTER].

8.15.5.2
Executing the Job Call Allocation

1. Press the key allocated for the job call allocation.
The CALL instruction is displayed in the input buffer line.
The CALL instruction shown in the input buffer line is registered.
8.15.5.3
Executing the Display Allocation

1. Press the key allocated for the display allocation.
The allocated display appears.
8.15.5.4
Executing the I/O Control Allocation

Alternate output allocation, momentary output allocation, pulse output
allocation, group output allocation (4-bit/8-bit), analog output allocation,
analog incremental output allocation are executed by the following
operation.
1. Press [INTERLOCK] and the key allocated for I/O control allocation at
the same time.
Allocated functions are executed.
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8.16 Changing the Output Status
8.16
Changing the Output Status

The status of external output signals can be changed from the
programming pendant by using either of the following two methods.
On the user output status window
On the RELAY ON window
The method that uses the RELAY ON window, which is described here,
simplifies the operation for changing the status of signals that are used
frequently.
NOTE
A maximum of 64 output signals can be shown on the

RELAY ON window and they must be set in advance to
parameters S4C327 to S4C390. If they are not set, the sub
menu in the RELAY ON window will not be displayed.
1. Select {IN/OUT} under the main menu.

2. Select {RELAY ON}.
The RELAY ON window appears.
3. Select the desired signal to change the output status.

Select the status ( or ) of the desired signal.
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8.16 Changing the Output Status
4. Press [INTERLOCK] +[SELECT].
The output status is changed. (: status ON; : status OFF.)
SUPPLEMENT
It is also possible to turn the relevant external output signal

on only for the duration that [INTERLOCK]+[SELECT] are
pressed. This selection is made in advance by setting the
parameters (S4C391 to 454) to 1.
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8.17 Changing the Parameter Setting
8.17
Changing the Parameter Setting

The parameter settings can be changed only by the operator who has the
correct user ID number for the management mode.
1. Select {PARAMETER} under the main menu.
2. Select the parameter type.
The PARAMETER window appears. Select the desired parameter.
Binary Data
Decimal Data
3. Move the cursor to the desired parameter number.
When the desired parameter number is not in the current window,

move the cursor in the following way:
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(1) Move the cursor to a parameter number and press [SELECT].
(2)
Enter the desired parameter number with the numeric keys.
(3) Press [ENTER].

(4) The cursor moves to the selected parameter number.
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Set the parameters in the following manner.
1. Select the parameter data to be set.
(1) Move the cursor to the parameter number data (decimal or binary)
in the PARAMETER window, and press [SELECT].
(2)
To enter a decimal setting, select the decimal figure.
(3)
To enter a binary setting, select the binary figure.
2. Enter the value.

If a decimal figure is selected, enter a decimal value with the
numeric keys.
If a binary figure is selected, move the cursor to the binary figure

data in the input buffer line, and press [SELECT].
Each time [SELECT] is pressed, 0 and 1 alternate in the window.
0 or 1 can also be entered with the numeric keys.
3. Press [ENTER].
The new setting appears in the position where the cursor is located.
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8.18 File Initialization
8.18
File Initialization
8.18.1
Initializing Job File

1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the security mode to the management mode.
3. Select {FILE} under the main menu.
4. Select {INITIALIZE}.
The INITIALIZE window appears.
5. Select {JOB}.
6. Select {YES}.
The job data is initialized.
When JOB is initialized, the following files are reset at the
same time.
Be careful when initializing JOB.
NOTE
User coordinates
Memory play file
Spot monitor data
Variable data
System definition parameter (S4D)
Robot calibration data
Conveyor calibration data
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8.18.2 Initializing Data File
simultaneously.
5. Select {FILE/GENERAL DATA}.
The INITIALIZE window appears.
6. Select the data file to be initialized.

The selected data file/general data are marked with .
The parameters marked with "" cannot be selected.
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7. Press [ENTER].
8. Select {YES}.
The selected data file/general data are initialized.
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8.18.3 Initializing Parameter File
simultaneously.
3. Select {FILE} under the Main Menu.
5. Select {PARAMETER}.
The parameter selection window appears.
6. Select the parameter to be initialized.

The selected parameter is marked with .
The parameters marked with "" cannot be selected.
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7. Press [ENTER].
8. Select {YES}.
The selected parameter is initialized.
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8.18.4 Initializing I/O Data
simultaneously.
5. Select {I/O DATA}.
The I/O data selection window appears.
6. Select data to be initialized.

The selected data is marked with .
The I/O data marked with "" cannot be selected.
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7. Press [ENTER].
8. Select {YES}.
The selected data is initialized.
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8.18.5 Initializing System Data
simultaneously.
5. Select {SYSTEM DATA}.
The system data selection window appears.
6. Select the parameter to be initialized.

The selected data is marked with .
The system data marked with "" cannot be selected
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7. Press [ENTER].
8. Select {YES}.
The selected data is initialized.
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8.19 Display Setting Function
8.19
Display Setting Function
8.19.1 Font Size Setting

DX200 enables changing the font size displayed on the screen.
The fonts displayed on the screen can be selected from eight patterns of
fonts in the font size setting dialog box.
8.19.1.1 Applicable Range for the Font Size Change
Changing the font size is allowed in the general display area indicated in
the following figure:
General display area
8.19.1.2 Settable Font Size

The following eight patterns of fonts are available in setting the size of
fonts displayed on the screen.
Font Size
Font Style
Small
Regular
Small
Bold
Regular
Regular
Regular
Bold
Large
Regular
Large
Bold
Extra large
Regular
Extra large
Bold
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8.19.1.3
8 System Setup
Setting the Font Size

To set the font size, first off display the font size setting dialog box as
follows.
1. Select {DISPLAY SETUP} then {CHANGE FONT} under the main
menu.
2. The font size setting dialog box appears on the center of the current
window.
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To set the font size in the font size setting dialog box, follow the
procedure below.
1. Specify the font style.
The {Bold Type} check box can be checked or unchecked
alternately each time the check box is selected.
Check the {Bold Type} check box as follows to set the font to the bold
style.
Clear the {Bold Type} check box as follows to set the font to the
regular style.
2. Specify the font size.

Select a button from the four buttons in the dialog box.
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3. The font size setting dialog box is closed, and the screen displays the
font specified in the dialog box.
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To cancel the setting of the font size, follow the procedure below.
1. Select {Cancel} in the font size setting dialog box.
2. The dialog box closes without changing the font size.
NOTE
Do not turn OFF the DX200 power supply when the font
size is being changed (when the font size setting dialog box
is on the screen).
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8.19.2
Operation Button Size Setting

DX200 enables changing the size of operation buttons.
The button size in the main menu area, menu area, and instruction list can
be respectively selected from three sizes.
8.19.2.1
Applicable Range for the Button Size Change

Changing the button size is allowed in the main menu, menu (pull-down
menu), and instruction list indicated in the following figure:
Menu area
(pull-down menu)
Instruction list
Main menu area
8.19.2.2
Settable Button Size

The following three sizes of buttons are available in setting the size of
each operation button; the font style of the character string on buttons can
also be specified.
1
Button Size
Font Style
Small
Regular
Bold
Regular
Regular
Bold
Large
Regular
Bold
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8.19.2.3 Setting the Button Size

To set the button size, first off display the button size setting dialog box as
follows.
1. Select {DISPLAY SETUP} then {CHANGE BUTTON} under the main
menu.
The font size setting dialog box appears on the center of the current
window.
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To set the button size in the button size setting dialog box, follow the
procedure below.
1. Specify the area to set the button size.
(1) Select the desired area from the area setting buttons.
(2) The buttons in the selected area is subject to size setting.
(3) Note that only the last-selected button determines the area subject
to size setting, even if settings are performed several times before
then.
2. Specify the font style.

The {Bold Type} check box can be checked or unchecked
alternately each time the check box is selected.
Check the {Bold Type} check box as follows to set the font to the bold
style.
Clear the {Bold Type} check box as follows to set the font to the
regular style.
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3. Specify the button size.
Select a button from the three buttons in the dialog box.
4. The font size setting dialog box is closed, and the screen displays the
buttons specified in the dialog box.
The modification is applied only to the buttons in the area selected
with the area setting button. (In this example, the change is applied
only to the pull-down menu buttons in the menu area.)
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To cancel the setting of the button size, follow the procedure below.
1.
Select {Cancel} in the button size setting dialog box.
The dialog box closes without changing the button size.
NOTE
Do not turn OFF the DX200 power supply when the button
size is being changed (when the button size setting dialog
box is on the screen, or when an hourglass is indicated in
the middle of the screen).
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8.19.3 Initialization of Screen Layout
The font/button size changed with the font/button size setting function can
be collectively changed back to the regular size.
8.19.3.1 Initializing the Screen Layout

To initialize the screen layout, follow the procedure below.
1. Select {DISPLAY SETUP} then {INITIALIZE LAYOUT} under the main
menu.
A confirmation dialog box appears on the center of the current

window.
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To Initialize the screen layout, follow the procedure below.

1. select {OK}.
The dialog box is closed, and the font/button sizes are collectively
changed to the regular size.
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To cancel the Initialized screen layout, follow the procedure below.

1. Select {CANCEL}.
The dialog box closes without changing the current screen layout.
NOTE
Do not turn OFF the DX200 power supply when the screen
layout is being initialized (when the confirmation dialog box
is on the screen, or when an hourglass is indicated in the
middle of the screen).
8.19.4 Layout Storage

The settings of the font or button sizes are saved in the programming
pendant. The screen displays the font/button size specified last time with
the current programming pendant.
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8.20 Encoder Back-up Error Recovery Function
8.20
8.20.1
Encoder Back-up Error Recovery Function

About Encoder Back-up Error Recovery Function
A motor of the robot, the travel axis or the rotation station which is
controlled by the DX200 is connected with the back-up buttery in order to
keep the position information even though the control power is
disconnected. This buttery consumes buttery power through time, and the
alarm 4312 ENCODER BATTERY ERROR occurs when the voltage
becomes lower than 2.8V. If the battery is not replaced and keep
consuming more battery power, it will cause the lost of the position
information. In addition, the alarm 4311 ENCODER BACK-UP ERROR
occurs. Meanwhile, there would be a gap between the manipulator
position and the position of the absolute encoder.
This function allows to recover the absolute data by moving the axis
operation to the home position from the position information where the
axis is lost.
8.20.2
Encoder Back-up Error Recovery Function Operation

1. Press {SELECT}.
When select the RESET in the alarm display, the alarm is reset.
The manipulator can be move by the axis operation key.
2. Adjust the alarm occurring axis to the home position mark of the each
manipulator axis by the axis operation key.
Refer to section 7.1.1 Security Mode on page 7-1 for the operation
of the changing the security mode.
4. Select {ROBOT} in the main menu.
5. Select {HOME POSITIONNING}.
The home positioning display appears. The absolute data of the axis
which is occurring the encoder back-up error appears with the
which indicates the undefined state.
6. Select the control group.
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7. Select {UTILITY} in the menu.
8. Select {BACKUP ALM RECOVERY} in the menu.

The back-up alarm recovery display appears.
9. Select the axis to be fixed.

Move the cursor over the axis to fix, and select it. The confirmation
dialog appears.
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10. Select {YES}.
The absolute data of the selected axis is recovered.
Select {NO} to cancel the operation.
11. Select the current position.
To display the current position window, refer to DX200
MAINTENANCE MANUAL section 7.8.1 Current Position Window.
12. Confirm the current position.
Confirm the recovered current position, and modify the followings
depending on its values.
(1) The pulse number is approximately 0.
Recovered normally.
(2) The pulse number is approximately 4096.
Move the recovered axis to the 4096 pulse position, and register
the individual axis to calibrate the home position.
(3) The pulse number is approximately -4096.
Move the recovered axis to the -4096 pulse position, and register
the individual axis to calibrate the home position.
As for the registering the individual axis, refer to DX200
INSTRUCTION section 8.1.2 Calibrating Operation on page 85.
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8.21 Preventive Maintenance Function
8.21
Preventive Maintenance Function
8.21.1 Preventive Maintenance Function

The preventive maintenance function contains the function which provides
the information of diagnosis the duration of life for the speed reducer and
the function which informs the inspection time of the robot. Furthermore, it
contains the function which provides the information of the life span of the
controller components. Use these functions for the preventive
maintenance for the robot.
The followings are the features.
Preventive maintenance function for the speed reducer
Inspection notice function
Preventive maintenance function for the hardware
8.21.2 Preventive Maintenance Function for the Speed Reducer
Diagnoses the duration of life for the speed reducer by using the both
methods of the lifetime calculation and the torque average value. The
diagnosis is executed by operating the job in the play mode. It is
unnecessary to prepare the job for this diagnosis.
The accuracy of the performance of the life diagnosis is

not guaranteed. Use this function as the one of the
methods to determine the duration of life for the speed
reducer.
If the periodic grease replenishment and grease

replacement are not performed, or the excessive
pressure is applied to the speed reducer, such as the
mechanical interference etc, it will be failed before
reaching to the diagnosis period.
The diagnosis is performed by executing the job in the

play mode. When operating the robot in the teach mode
(operation by the axis key, FWD operation and test
operation), the life diagnosis function is not performed.
NOTE
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8.21.2.1
8 System Setup
Diagnose by the Lifetime Calculation
Outline
This function calculates the torque and the speed of the each axis during
the job operation, and diagnoses the time to replace the speed reducer by
the lifetime calculation. The replacement time is informed by displaying
the message and turning the replacement signal ON.
Operating the job in the play mode performs the diagnosis automatically.
NOTE
This function is only available for the robot axes. As for the
external axes, this function is not available.
Set the Replacement Signal

Set the universal output signal to notify the replacement time by following
procedures.
2. Select {=PM} in the main menu.
3. Select {=RM(REDUCER)}.
4. Select {Display} in the menu.
{=SETUP CONDITION} appears under the pull down menu.
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5. Select {=SETUP CONDITION}.
The condition setup window is appears.
6. Move the cursor to over the {=REPLACEMENT SIGNAL}, and select.

Able to enter the values.
7. Enter the universal output signal.
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Lifetime Calculation Window

1. Select {=RM} in the main menu.
The lifetime calculation window appears. In the case of the another
window appears, select {Display}, and select the {=LIFE
CALCULATION} in the pull down menu to display the lifetime
calculation window.
Each item on the screen represents the following description.

=TIME TO REPLACEMENT
Displays the rest of the lifetime to replace the speed reducer. The
calculation of the subtraction of the number is operated automatically by
performing the job in the play mode.
=NOTICE TIME
By setting the time in this item, the replacement time is informed by
displaying the message and turning the replacement signal ON before the
TIME TO REPLACEMENT becomes 0.
For example, when setting with 100, the message will be displayed 100
hours before the TIME TO REPLACEMENT becomes 0, and the
replacement signal will be turned ON as well.
For example, when setting with -100, the message will be displayed 100
hours after the TIME TO REPLACEMENT became 0, and the
replacement signal will be turned ON as well.
=WARNING
Select this item to invalidate the notification signal and displaying the
message. [Invalid] and [Valid] will alternate each time when pressing the
[Select].
=RESET
Select this item after replacing the speed reducer.
Addition to the message is deleted, and the replacement signal is OFF,
TIME TO REPLACEMENT is reset.
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Invalidate the Replacement Signal and the Message Display

Able to invalidate the replacement signal and the message display in each
axis. Invalidate the replacement signal and the message display by the
following procedures, in the case of the speed reducer seems to operate
normally even though the replacement signal is turned ON.
The lifetime calculation window appears. In the case of the another
window appears, select {Display}, and select the {=LIFE
CALCULATION} in the pull down menu to display the lifetime
calculation window.
4. Move the cursor over the =WARNING to invalidate the desired axis,
and select [Select]. [Invalid] and [Valid] will alternate each time when
press the [Select].
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8.21.2.2
8 System Setup
Diagnose by the Torque Average Value
Diagnosis Element
Monitors the torque waveform during the job operation, and calculates the
average value of the vibration amplitude by extracting the waveform from
the torque arising from the speed reducer. This data is called the torque
average value, and it is the basis data to diagnose the lifetime. The
following chart shows the lifetime curved line according to the torque
average value and the operation hours.
Torque average value
Failure
Started operation
Lifetime curved line
Running in
Normal operation
Lifetime curved line
Deterioration
Operation hours
As the condition of the speed reducer is changing to deterioration from

normal operation, the torque element changes to increase from
normal. It is estimated that the speed reducer is in the deterioration
period as the number of the torque element is increasing by the
deterioration of the speed reducer.
This function records the torque element arising from the deterioration of
the speed reducer on a daily basis, and diagnoses the lifetime of the
speed reducer by monitoring the change of the torque element.
Torque
Speed
Torque
Speed
Torque and speed at the deterioration period
Torque and speed at the normal operation period
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By operating a job in the play mode, a data (the torque element arising
from the deterioration of the speed reducer) for each axis is recorded
automatically on a daily basis, and the data is accumulated.
When the difference value between the latest value the average value
from the measured result of the five days (the initial value) including the
day to diagnose and the average value the average of 30 days (the initial
value) between prior to 60 days from the day to diagnose and prior to 90
days from the day to diagnose becomes the threshold value or more, it
determines the speed reducer is almost failure, and outputs the warning.
The average value is indicated with%, and 100% indicates the standard
torque.
Latest period (5 days)

Latest value
(average of the nearest value)
Torque average value
When the measured value is greater

than the threshold value, it outputs the warning.
Average period (30 days)
Average value
(average value of the average period)
Prior to 60 days from the day to diagnose
Prior to 90 days
A day to diagnose
Prior to 60 days
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Setting Procedures
The setting procedures are described as follows.
The lifetime calculation window appears.
4. Select {Display} in the menu.

The {=SETUP CONDITION} appears in the pull down menu.
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The setup window appears.
Modify the condition as necessary.
1
3
4
5
6
7
8
9
6. Select {End} button.

=TORQUE VARIATION ACCEPT RATE
It is determined as accept OK when the measured value (the latest value the average value) is smaller than the set value or the equal value. It is
determined as accept NG when the measured value is greater than the
set value. The torque variation accept rate can be set as High, Medium
or Low. The initial value of each item is 50%, 40% and 20%.
=TORQUE VARIATION ALART OUTPUT
=ACCEPT RATE HIGH
The warning output signal is turned ON when the number of the day,
which is determined as accept NG (the latest value - the average
value > =ACCEPT RATE HIGH), is more than the number of the
consecutive days. If unnecessary to output the signal, set the item
0. The initial value of this item is 0.
=ACCEPT RATE MID, LOW
The universal output signal, which is set by =ACCEPT RATE MID
and =ACCEPT RATE LOW, is turned ON when it is determined as
follows.
The latest value - the average value > =ACCEPT RATE MID.
The latest value - the average value > =ACCEPT RATE LOW.
If unnecessary to output the signal, set the item 0. The initial value
of this item is 0.
=CONSECUTIVE DAYS (ACCEPT NG)
It is determined as the speed reducer is almost failure, when the number
of the day, which is determined as tolerance NG (the latest value - the
average value > =ACCEPT RATE HIGH), is more than the number of this
item. The initial value of this item is 3 (days).
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=CALCULATION DAYS
Set the period to calculate the average value. The initial value of this item
is 30 (days).
=ELAPSED DAYS FROM CALC. START
Set the period to calculate the average value from the day to diagnose.
The initial value of this item is 60 (days).
=LATEST MEASURED DAYS
Set the period to calculate the latest value. The initial value of this item is
5 (days).
=ERROR DELETE FILTER
Use to delete the error when calculate the average value. The following
values (torque average) are excepted from the calculation of the average
value.
The average from the previous day exists.
The average from the previous day / any measurement value of the
average period100 > filter setting value
The any measurement value of the average period / the average
from the previous day100 > filter setting value
The average from the previous day does not exist.
The latest value / any measurement value of the average
period100 > filter setting value
The any measurement value of the average period / the latest
value100 > filter setting value
The initial value of this item is 200 (%).
=GRAPH NAME
Able to register the name of the graph.
=REPLACEMENT SIGNAL
Use this item to calculate the lifetime. Refer to Set the Replacement
Notice Signal at page 8-165.
NOTE
Even though the initial value is set, the accuracy of the life
diagnosis is not guaranteed performance.
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Data Confirmation
By operating a job in the play mode, a data (the torque element arising
from the deterioration of the speed reducer) for each axis is recorded
automatically on a daily basis, and the data is accumulated. It is
unnecessary to prepare the job for this diagnosis.
Able to refer the data by following procedures.
3. Select {Display}.
The pull down menu appears.
4. Select {=TORQUE MONITOR}.

The torque monitor window appears.
1
2
3
5. Press [PAGE] key.

Able to refer the data of a date corresponding to the number by
pressing the [PAGE] key. Modify the number as necessary.
SUPPLEMENT
Unable to measure the torque average value because the

axis of the measured value indicating is not operating, or
the motion speed is less than the reference speed.
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=NG COUNT (IN A ROW)
Shows the number of the variation days, which is higher than the value of
the torque variation HIGH. The warning output signal, which is set by
=ACCEPT RATE HIGH, is turned ON when the number of the day above is
more than the number of the consecutive accept NG days.
=NG COUNT (ACCUM.)
Shows the total number of the variation days, which is higher than the
value of the torque variation HIGH. The number of =NG COUNT (IN A
ROW) is reset as 0, when a day does not exceed the torque variation.
However, this =NG COUNT (ACCM.) will not be reset.
=MEASURED DATE
Shows the date of the measurement or the updated speed reducer
diagnosis database.
=MEAS.
Shows the measured torque average.
=AVE.
Shows the arithmetic mean of the average period (certain number of the
days, which is calculated in the past, based on the MEASURED DATE).
However, the measured values excepted in the =ERROR DELETE
FILTER are not included.
=VARIATION (The Determining Value)
Shows the difference value between the latest value and the average
value. When this value exceeds the value, which is set at the torque
variation, it is determined as accept NG.
=LATEST
Shows the arithmetic mean of the latest period (certain number of the
days included the measured day).
=WARNING
Select this item to invalidate the warning output signal. [Invalid] and
[Valid] will alternate each time when press the [Select].
=RESET
Select this item after replacement of the speed reducer. The warning
output signal will be turned OFF, and the old data will not be used for the
lifetime diagnosis.
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Invalidate the Warning Output Signal

Able to invalidate for each axis. Invalidate the warning output signal by
the following procedures, in the case of the speed reducer seems to
operate normally even though the warning output signal is turned ON.

The lifetime calculation window appears.
4. Select {=TORQUE MONITOR}.
The torque monitor window appears.
Move the cursor over the =WARNING of the desired axis to invalidate,
and press [Select]. [Invalid] and [Valid] will alternate each time when
pressing the [Select].
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Graph Display
Able to confirm the variation by a graph after the measurement. The
graph is updated every 24 hours automatically. The measured value and
changes of the variation can be displayed on the programming pendant.
Thus, able to confirm the changes of the torque visually. Use the graph
display as the one of the methods to determine the duration of life for the
speed reducer.
The graph can be displayed by the following procedures.
4. Select {=GRAPH}.
The graph appears.
3
4
5
2
8
9
10
5. Select {CLOSE}.
Return to the lifetime calculation window.
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=Graph
Select the {Graph}, and the pull down menu appears. Either =Vari or
=Meas. can be selected.
When selectting =Vari.,
the variation (=latest value - average value) appears on the graph.
The line of each Hi, Midand Lo appears.
Hi means the torque variation accept high.
Mid means the torque variation accept mideum.
Lo means the torque variation accept low.
When changing the torque variation accept high, the torque
variation accept medium or the torque variation accept low on the
each setting window, the lines for Hi, Mid and Lo on the graph
also correspond to the setting values.
In the case of the graph above, it shows a variation > Lo of the T-axis,
and the warning output signal, which is set by torque variation low, is
ON.
When selecting =Meas.,
the measured value is displayed on the graph.
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=Group
Select {=Group}, and the pull down menu appears. Select the group to
display.
=Name
The names set in the each setting window are displayed.
=Renew
Pressing the =Renew button updates the latest data.
=Days
Set the number of the days between 5 and 150 days to be displayed. The
latest data is displayed on the right side of the graph, and the old data set
by =Days is displayed on the left side of the graph.
=Torque
The minimum value and the maximum value of the vertical axis can be
set. MIN is the minimum value, and MAX is the maximum value.
=Axis
Removing the tick in the box hides the axis on the screen.
=Save CSV
Pressing the CSV button saves the variation and measured value into
the external memory device as CSV format. As for the external device, it
can be saved into both CF card and USB, but the data is priory save into
the CF card. The followings are the name for a file and a folder to be
saved.
File name: the name which is set in the each setting window + year/
month/day + hour/minute/second. CSV
Folder name: SR LIFE DIAGNOSIS
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=Hard COPY
Pressing the =Hard COPY button saves the hard copy of the screen as
JPG format into the CF card.
The following is a name for the file.
File name: year/month/day + hour/minute/second. JPG
=CLOSE
Pressing =CLOSE button closes the graph window.
8.21.2.3 After Replacement of the Speed Reducer

The lifetime diagnosis does not perform correctly if use the old data after
replacement of the speed reducer. Thus, reset the data for the lifetime
diagnosis, and prevent using the data before replacement day.
Perform the following procedures after replacement of the speed reducer.
4. Select {Display}, select the {=LIFE CALCULATION} or {=TORQUE
MONITOR] in the pull down menu.
The lifetime calculation window or the torque monitor window
appears.
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5. Move the cursor over the Reset on the axis window of which speed
reducer is replaced, and press {Select}.
The confirmation dialog appears.
6. Select Yes.
The data of its axis is reset, and the replacement day is recorded
into the =INSPECTION RECORD window.
The operation is cancelled when select No.
The procedures above can be performed in the lifetime window or the
torque monitor window.
The replacement day is recorded into the INSPECTION RECORD
window by performing the procedures above.
8.21.3
Inspection Notice Function

The inspection notice function turns the notice signal ON and displays the
message when the inspection time has come.
Perform the inspection by the authorized personnel or Yaskawa
representative (the list on the back cover) when the notice signal is turned
ON.
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8.21.3.1 Inspection Signal

Set the universal output signal for the inspection time as the following
procedures.
3. Select {=INSPECTION NOTICE}.
The inspection notice window appears.
4. Select {Display} in the main menu.

{=SETUP CONDITION} is displayed in the pull down menu.
{=SETUP CONDITION} window appears.
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6. Move the cursor over the =INSPECTION SIGNAL, and select.
It becomes the numeric value input status.
7. Enter the universal output number.
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8.21.3.2 The Inspection Notice Window

2. Select {=INSPECTION NOTICE}.
The inspection notice window appears.

=TIME TO INSPECTION
The rest of the time to inspection is displayed. When the servo power is
turned ON, it calculates the subtraction automatically. When this item
become 0, the inspection notice signal is turned ON, and the message is
displayed.
=INTERVAL
The inspection interval is displayed.
NOTE
When the inspection signal is turned ON or the message is

displayed, perform the inspection by an authorized
personnel or the YASKAWA representative (listed on the
back cover of this instruction manual). The message is
displayed continuously until the DX200 is inspected.
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8.21.4
Record of the Inspection Day the Replacement Day

Able to confirm the inspection day and the replacement day by following
procedures.
2. Select {=INSPECTION RECORD}.
3. Select {Display}, and select {=INSPECTION DATE} in the pull down
menu.
Able to confirm the inspection day.
4. Select {Display}, and select {=REPLACEMENT DATE} in the pull down

menu.
Able to confirm the replacement day.
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8.21.5 Management of the Data
According to the torque average value, such as the speed reducer
preventive maintenance data base, the preventive maintenance elements,
the record of the inspection and replacement, can be loaded/saved by the
external memory device.
As for the external device menu, refer to Chapter 7 External Memory
Devices of DX200 OPERATORS MANUAL for more details.
1. Select {External memory} in the main menu.
The external memory menu window appears.
2. Select {Load} or {Save}.

The load window or the save window appears.
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3. Select the {System data}.
The system data selection window appears.
(The following is an example of a window.)
4. Select the system data to load or save.

For the speed reducer preventive maintenance data base, select
={PM(REDUCER)FILE}.
For the speed reducer preventive maintenance condition, select
={PM(REDUCER)CONDITION}.
For the record of the inspection and replacement date,
select={INSPECTION RECORD FILE}.
The selected system data is displayed with .
5. Press Enter.
6. Select Yes.
The selected system data is saved.
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8.21.6 Preventive Maintenance for the Hardware
This function estimates the life span of the controller components by
calculating the consumed amount with considering the usage environment
and the load, and outputs general signals to be the reference for the
replacement time.
The function overview is described below.
8.21.6.1 Target Components for Diagnosis

Regarding the following, calculations of the consumed amount and
outputs of the general signals to be the reference for the replacement time
are performed.
Cooling fan*
Capacitor
Amplifier IGBT
Contactor
Motor (numbers of revolution and reverse revolution are displayed)
*Even though a fan is an one of target components, some models do not

have the fan. Refer to the INSTRUCTIONS for the each manipulator to
confirm if it has the fan.
8.21.6.2 Replacement Time Display
Stepwise Display of Replacement Time

For each component, a judgement from A to D is displayed, and it can be
used as the reference for the replacement time.
Judgement
display
Status
New - Used about half of its life span
Used about half of its life span
Used about half of its life span - Time to replace (reference)
Time to replace (reference)
Signal Output of Replacement Time

If any of the components is judged as D, ON signal is output from the
general output which is set as "Alarm signal" of the file.
However, only one signal for this general signal can be output for one
controller.
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Mask of Signal Output
The general output signals can be masked for each component.

If any of the components is judged as D, ON signal is output from
the general output which is set as "Alarm signal" of the file. This
signal is output continuously, so the signal to inform the
replacement time of the component cannot output newly.
Therefore, the signal of the replacement time for other components
can be output by masking the signal output of the component which
is already judged as D and turning OFF the general output signal
temporarily.
Even if the masking is performed, D remains to be displayed for the
component judged that it should be replaced.
8.21.6.3
Replacement of Component
Record of Replacement Date of Component

When the component is replaced, the replacement date (year, month,
day) can be recorded. It can be used for the reference for the next
replacement time or for the estimation of the failure mode by the failure
time.
Life Span Setting at Replacement of Component

A new component or an used one, whichever it is replaced with, the life
span setting can be performed.
For the used component, after recording the replacement date, the value
1 - 100% can be set as the leftover life.
Display of the Numbers of Motor Revolution and Reverse Revolution

The accumulated values are displayed regarding the number of each
motor revolution and the number of reverse revolution of positive and
negative revolution. They can be used as the reference for the
replacement time of the speed reducer or motor.
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8.21.7 Setting of Preventive Maintenance for the Hardware
8.21.7.1 Setting of Replacement Time Display

1. Select {PM} in the main menu.
* The operation icons on the main menu vary depending on the

system usage.
2. Select {PM (HARDWARE)}.
Alarm signal setting and unit selection window appears.
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3. Input the numerical value of the alarm signal.
When any of components in this controller comes to the replacement
time, the general output signal which is already set turns ON.
* For example, 125 is input.

4. Select the unit.
Or select the unit from {DISPLAY} in the menu.
* For example, {COOLING FAN} is selected.
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5. The following information is displayed:
Starting from the left,
(1) is displayed when the replacement time is judged as D.
(2) Component name
(3) General output signal valid/invalid
(4) The first day of use
(5) Leftover life judgement
When {COOLING FAN} is selected:
(1
(2
(3
(4
(5
When {CAPACITOR} is selected:
When {AMPLIFIER IGBT} is selected:
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When {CONTACTOR} is selected:
6. When replaced with a new component, select .

A confirmation dialog box appears. When replaced with a new
component, select YES.
7. When replaced with an used component, select {BEGINNING}.

A window to input the numerical value appears. Input the
replacement date using half-width characters like {2009.3.14}.
After that, a following confirmation dialog box appears. When
replaced with an used component, select YES.
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8. When manually setting the approximate value to the leftover life, input
the numerical value 0 - 100%.
9. When the numerical value displayed in the confirmation dialog box is

correct, select YES.
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8.21.7.2
8 System Setup
Mask of Replacement Time Display (Signal Display)

Perform the masking of the replacement time display according to the
following procedures:
1. When any of the components comes to the replacement time, the
message is displayed per unit.
2. The message is also displayed per component.

Invalidate the output.
After checking the components, invalidate the output.
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3. The general output signal turns OFF. And the message turns to be
hidden. However, the stepwise display remains D.
* Before the replacement, perform the above operation in order to

detect the multiple components because only one general
output of life diagnosis can be output for one controller.
That is, "Replacement time of component Turn ON the
general output Check the component and invalidate the
output Turn OFF the general output Replacement time of other
component Turn ON the general output".
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8.21.8
8.21.8.1
Display of the Numbers of Motor Revolution and Reverse

Revolution
Display of the Numbers of Revolution and Reverse Revolution

1. Select {PM} in Main Menu {PM(HARDWARE)} {MOTOR}.
8.21.8.2
Percent Display of the Number of Motor Revolution
At the motor rated number of revolution, it displays how many

percent it has operated with 100% representing the case it
operates 20000 hours.
1. After select {PM} in Main Menu {PM(HARDWARE)} {MOTOR},
select {DISPLAY} on the menu {REVOLUTION(%)}.
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8.21.8.3 Resetting the Number of Revolution

Used when the motor replaced with a new one.
1. Select of the axis to be reset by moving the cursor to it, and then
select "YES" on the dialog box.
The day of the first use (BEGINNING) is automatically changed.
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8.21.8.4
8 System Setup
Changing the Numbers of Revolution and Reverse Revolution

Used when the motor replaced with an used one.
1. Select the number of the axis to be reset by moving the cursor to it,
and then set the number.
To set the day of the first use (BEGINNING), select the date of the axis
to be reset by moving the cursor to it, and then set the date.
* When changing the number of revolution.
* When changing the number of reverse revolution.
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8.22 Break Line Ground Judgement Function
8.22
Break Line Ground Judgement Function
8.22.1 About the break Line Ground Judgement Function

If the current flowing through the break line exceeds the capacity of the
control power supply unit, the DC 24V power supply will be disconnected
by the protective circuit of the control power supply unit; then an alarm
1683 DC24V POWER SUPPLY FAILURE(SV) occurs.
This function identifies the position where the ground fault occurred after
arising the alarm 1683 DC24V POWER SUPPLY FAILURE(SV). It is
able to identify which axis break line does the ground fault occur by
inspecting the each axis from the programming pendant.
Identify the ground fault of the break line by the following methods.
(1) Turn the servo ON the group which the ground fault occurs.
(2) Discharge the any axis break, and then confirm if the DC 24V
power supply will be disconnected.
8.22.2 Operating Condition

1. Condition of the controller
The controller has restarted normally by restarting the controller after
arising the alarm 1683 DC24V POWER SUPPLY FAILURE(SV).
2. Mode
Only teach mode
3. Security
All security mode, such as Operation, Edit and Management mode
4. Others
Must be SERVO OFF
The emergency signal is not input (Pendant, controller, external
signal)
The servo power is not disconnected by the servo power supply
individual control function.
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8.22.3
8.22.3.1
Operation
Arising the DC 24V Power Supply Failure (SERVO)

When detecting either the ground fault or the short circuit of the
break line, the alarm 1683 DC24V POWER SUPPLY
FAILURE(SV) occurs.
Restart the control power, and perform the break line ground check.
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8.22.3.2 Break Line Ground Check

1. Select {BREAK LINE GROUND CHECK} in the sub-menu from
{ROBOT} in the main menu.
2. Press YES.
The confirmation dialog appears due to prevent the mis-operation.
Select YES, then the break line ground check appears.
Select NO, the window returns to the previous window.
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3. Move the cursor over the axis to perform the break line ground check,
and press [SERVO ON READY]. Grip the enable switch and long
press [SELECT] while pressing down the [INTER LOCK] to perform
the break line ground check.
Perform the break line ground check to the every single axis
The break line ground check is cancelled in the case of following
conditions.
[SELECT] is detached.
The emergency button of the programming pendant, controller or
external signal is pressed.
The servo power is disconnected by the servo power supply
individual control function.
The servo alarm occurs.
JUDGEMENT REQUIRED: The ground check is not performed

BREAKS LINE NORMAL: The break line is normal.
DETECTED GROUND: The ground fault or short circuit of the
break line
ABNORMAL END: The ground check is cancelled.
(i.e. the dislocation of the axis is detected, and so on)
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4. Detecting the Break Line Ground Fault
When the break line ground fault or the short circuit is detected, the
alarm 1694 GROUND FAULT (BRAKE LINE) occurs.
Inspect the break line of the axis which raised the alarm.
Restart the control power, and perform the break line ground check
to the rest of the axes.
8.22.3.3
Initializing the Related Information

1. The sub menu {BREAK LINE GROUND CHECK} appears after
selecting the {ROBOT} in the main menu.
2. Select {DATA} in the menu.
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3. Select {CLEAR}.
4. Press YES.
The related information of the break line ground check is initialized.
{BREAK LINE GROUND CHECK} does not appear in the {Main
Menu} until the alarm 1683 DC24V POWER SUPPLY
FAILURE(SV) occurs.
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8.23 Safety Logic Circuit
8.23
Safety Logic Circuit
8.23.1 Outline
The safety logic circuit is a function to create the safety logic circuit on the
programming pendant. It enables to set up the logical operations, such
as stopping the manipulator and outputting the servo ON signal.
The followings are the contents of this function.
(1) Executes the safety logic circuit by the machine safety logic circuit
board (type:YSF21-E) corresponded to the secure authentication.
(2) The safety logic circuit is composed by two inputs and one output
circuits, and can be set up the up to 128 circuits.
(3) The safety logic circuit is operated every 4 ms cycle.
(4) The safety logic circuit is referred by the all modes regardless the
security mode, and it can be edit only when the security mode is
higher than SAFETY MODE plus under the teach mode and the
servo is OFF.
(5) By using this safety logic circuit function, the hard-wired connection is no longer need to create the circuit, and becomes less wiring.
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8.23.2
Set up the Safety Logic Circuit

In order to set up the safety logic circuit, the security mode needs to be
changed to safety mode. Before creating the safety logic circuit, the
following procedures need to be set in the window as shown below.
M-SAFETY SIGNAL ALLOC
SAFETY SIG. BOARD ALLOC
(displayed when the optional safety field bus function is valid)
TIMER DELAY SET
(need to be set when using the timer delay)
These items above are displayed by selecting the {SAFETY FUNC.} in the
main menu. The setup information is written in the file.
8.23.2.1
Changing the Security Mode

1. Displaying the window.
Select {SECURITY} from {SYSTEM INFO} in the main menu.
2. Change to the safety mode.
Select {SAFETY MODE}.
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Enter the password for the safety mode, and then press [ENTER].
When the entered password is correct, the mode is changed to

{SAFETY MODE}. After changing to the safety mode, the icon
is displayed on the status area.
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8 System Setup
Allocating the Machine Safety Signal

Select {M-SAFETY SIGNAL ALLOC} from {SAFETY FUNC.} in the
main menu.
2. Set up the universal safety signal.

In the DX200, the two points of the universal safety input signal and
the two points of the universal safety output signal are present from
I/O board (type:YSF22 -E), and these signals can be used at the
safety logic circuit.
Set the USE for the input and output signal(s) to use.
After the setting, the status changes from DONE to NOT DONE.
The WRITE button is displayed on the left down corner of the
screen.
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3. Canceling the edit
To start over the editing, select {CANCEL EDIT} from {EDIT} in the
pull-down menu.
4. Transferring or updating the file

After editing, select {WRITE} button.
The file is transferred to the machine safety circuit board
(type:YSF21-E). When the file transfer is done correctly, the
confirmation dialog Update the file? appears.
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Press YES, and then the file is updated.
The file transferred to the machine safety circuit board
(type:YSF21-E) is written in the FLASH ROM.
The status becomes DONE from NOT DONE.
If press NO, the file will not be updated. The status remains NOT
DONE.
NOTE
If press YES on the confirmation dialog, the all window

information, such as {M-SAFETY SIGNAL ALLOC},
{SAFETY SIG. BOARD ALLOC}, {TIMER DELAY SET}, and
{SAFETY LOGIC CIRCUIT} are updated. The written file in
the FLASH ROM of the machine safety circuit board is also
updated.
NOTE
When performing {WRITE}, the universal safety and the

safety field bus output signals, which are sent from the
machine safety circuit board, are turned OFF till the writing
processing is finished.
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8.23.2.3 Allocating the Safety Signal Board

This window is displayed when the optional safety field bus is valid.
Select {SAFETY SIG. BOARD ALLOC} from {SAFETY FUNC.} in
the main menu.
2. Set up the safety field bus signal.

In the DX200, the 64 points of the safety input signal and the 64
points of the safety output signal are present from the safety PLC,
and these signals can be used at the safety logic circuit.
Set the USE for the input and output signal(s) to use.
screen.
<Input signal window>
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<Output signal window>

pull-down menu.
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The file transferred to the machine safety circuit board (type:YSF21E) is written in the FLASH ROM.
DONE.
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NOTE

updated.
NOTE

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8.23.2.4 Timer Delay

Set up the delay time of the output signal to use by the safety logic circuit.
In the TIMER DELAY, there are ON DELAY TIME to delay the ON output
and OFF DELAY TIME to delay the OFF output . It can be four timer
settings.
When setting the 500msec to ON DELAY TIME,
Safety logic output
Output
500msec
ON DELAY time
When setting the 300msec to OFF DELAY TIME,
Safety logic output
Output
300msec
OFF DELAY time
The initial value is 100(25 2)[msec]. It is able to set every 4msec up to

399,996 (99,999 25)[msec].
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Select {TIMER DELAY} from {SAFETY FUNC.} in the main menu.
2. Set up the delay time.

Set the value of the delay timer to use.
screen.
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pull-down menu.

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DONE.
NOTE

updated.
NOTE

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8.23.2.5 Safety Logic Circuit

Select {SAFETY LOGIC CIRCUIT} from {SAFETY FUNC.} in the
main menu.
2. Set up the safety logic circuit

Create the safety logic circuit. The setting items are INPUT1,
LOGIC, INPUT2, OUTPUT and TIMER.
The SIGNAL1 and SIGNAL2 must be set.
When setting the signal 1 or the signal 2, LOGIC also must to be set.
OUTPUT also must be set. The same output signal cannot be set to
the multiple logic circuit.
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screen.

pull-down menu.
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4. Line clear
To clear the one line, select {LINE CLEAR} from {EDIT} in the pulldown menu.
5. All line clear

To clear the all line, select {ALL LINE CLEAR} from {EDIT} in the
pull-down menu.
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6. Copy
Choose the desired area to make a copy, and select {COPY} from
{EDIT} in the pull-down menu.
Go to the area to paste, select {PASTE} from {EDIT} in the main

menu to paste.
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If there is a blank line in the safety logic board, it will be filled
automatically.

DONE.
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NOTE

updated.
NOTE

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Setup the Signal1 and Signal2

The signal 1 and signal 2 are the signals to be used by the safety logic
circuit. The following table shows the usable input signals. When add
NOT in the beginning of the signal name, it becomes a negative logic of
the input signal.
shows the status of the input signal during the safety logic circuit
operation.
No.
Signal Name
Abbreviation
Logic
OFF(0)
Note
ON (1)
Play mode
PLAY
Not play mode
Play mode
Teach mode
TEACH
Not teach
mode
Teach mode
Programming pendant PPEST

emergency stop
Not under
emergency
stop
[Short circuit]
Under
emergency
stop
(Emergency
stop button is
pressed)
[Release]
Programming pendant PPDSW

enable switch
Grip
[Short circuit]
Released
[Release]
Controller emergency
stop
PBESP
Not under
emergency
stop
[Short circuit]
Under
emergency
stop
(Emergency
stop button is
pressed)
[Release]
External emergency
stop
EXESP
Not under
emergency
stop
[Short circuit]
Under
emergency
stop
(Emergency
stop button is
pressed)
[Release]
External enable
switch
EXDSW
Grip
[Short circuit]
Released
[Release]
Safeguarding
SAFF
Close
[Short circuit]
Open
[Release]
Servo ON status
SVON
Servo OFF
Servo ON
10

signal 1,2
GSIN1,
GSIN2
OFF
[Short circuit]
ON
[Release]
Two points of the input signal

are present for each YSF22-E
circuit board. YSF22 -E circuit
board can be connected up to
eight boards.
11
Safety field bus input

1 to 64
SFBIN1 to
SFBIN64
OFF
ON
Can be used when the optional

safety field bus function is valid.
12
Auxiliary relay
R1 to R128
OFF
ON
Can be used as the work area.
NOTE
In the case of teach mode, the manipulator stops

immediately as the DX200 system when the one of the
following signals, PPEST, PPDSW, PBESP, or EXDSW is
inputted.
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Logic
The usable logical signals are shown below.
No. Signal Name
No.
Signal Name
Abbreviation
Logic OR
OR
Logic AND
AND
Note
Output Signal
The usable output signals are shown below.
Abbreviation
Logic
OFF(0)
Note
ON (1)

signal 1,2
GSIN1,
GSIN2
OFF
ON
Two points of the input signal

are present for each YSF22 -E
circuit board. YSF22 -E circuit
board can be connected up to
eight boards.
Manipulator stop
immediately
SVOFF CAT0
OFF
ON
Manipulator
deceleration to a stop
SVOFF CAT1
OFF
ON
Safety field bus input

1 to 64
SFBIN1 to
SFBIN64
OFF
ON
Can be used when the optional

safety field bus function is valid.
Auxiliary relay
R1 to R128
OFF
ON
Can be used as the work area.
SIGNAL1: Teach mode (TEACH)

SIGNAL2: Programming pendant enable switch (PPDSW)
LOGIC: AND
NOTE
OUTPUT: Manipulator deceleration to a stop

(SVOFF CAT1)
If create the safety logic circuit shown above, the
manipulator will stop immediately as the DX200 system.
(Manipulator does not decelerate.)
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NOTE
When the manipulator is stopped by the safety logic circuit

signal, the message Robot is stopped by safety logic
circuit appears on the message area of the programming
pendant. Also, the control status signal #80343 is turned
ON.
NOTE
The same output signal cannot be used.
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No.
Timer
Signal Name
Abbreviation
Note
ON delay timer1 to ON
delay timer4
TIMI1 ON DELAY ~
TIM4 ON DELAY
The value set in the timer delay.
OFF delay timer1 to

OFF delay timer4
TIM1 OFF DELAY ~

TIM4 OFF DELAY
Feedback Signal (Signal Name: GSEDM1, 2) of Universal Output Signal

The setting of whether to use or not to use the signal and the polarity
setting of the feedback signal (signal name: GSEDM1, 2) of the universal
output signal can be set in the following window.
1. Turn ON the power of DX200 while pressing Main Menu key of the
2. Select {SYSTEM} - {SECURITY} and change the security mode to the
safety mode.
3. Select {SYSTEM} - {SETTING} - {OPTION FUNCTION} - {Machine
Safety function}. Then the following window appears and the setting
change becomes possible.
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Whether the universal input signals (signal name: GSIN1, 2) are used,
whether the universal output signals (signal name: GSOUT1, 2) are used,
and the polarity of the universal output signals can be set.
1. Select {DETAIL} of Machine Safety.
The DETAIL settings window of the machine safety function
appears. If the two or more YSF22 boards exist in the robot
coordinated specifications, press [PAGE] on the pendant and
perform the settings of the second pages and the later.
It is possible to change the content of the setting each time the

The relation of the polarity of universal output signals (signal name:

GSOUT1, 2) and the universal output signals is as follows:
Polarity of GSOUT
Feedback signal
Output of GSOUT
signal
Feedback signal from

external devices
Synchronization is
performed
(SYNC.)
Synchronization is not
performed
(OUT OF SYNC.)
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2. Press [ENTER].
The confirmation dialog box of parameter change appears.
3. Select {YES}.
If {YES} is selected, the system parameter is set automatically, and
then the OPTION FUNCTION window appears.
Feedback Signal
(1) With feedback signal connection
DX200
Machine Safety I/O
Logic Circuit Board
(JANCD-YSF22-E)
CN219
Machine Safety Terminal

Block Circuit Board
(JANCD-YFC22-E)
GSOUT1_1+
69
GSOUT1_1-
70
GSOUT1_2+
71
GSOUT1_2-
72
GSEDM1+
77
GSEDM1-
78
Universal Safety Output 1
Dual Sianals
Safety Signal
Intaken as a feedback signal(*) of the devices driven by
the universal safety output signal(GSOUT) (safety relay,
contactor, etc.), and detects the wire sticking.
(*) It connects the contact B with forced guide nomally.
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(2) Without feedback signal connection
DX200
Machine Safety I/O
Logic Circuit Board
(JANCD-YSF22-E)
CN219

Block Circuit Board
(JANCD-YFC22-E)
GSOUT1_1+
69
GSOUT1_1-
70
GSOUT1_2+
71
GSOUT1_2-
72
GSEDM1+
77
GSEDM1-
78
Dual Sianals
When feedback signal is not intaken, errors (wire sticking, etc.)

of the devices driven by the universal safety output signal(GSOUT)
(safety relay, contactor, etc.) is not detected.
Perform the error detection (signal mismatch) with the receiving side
devices (safety PLC, etc.).
DX200
Machine Safety I/O
Logic Circuit Board
(JANCD-YSF22-E)
CN219

Block Circuit Board
(JANCD-YFC22-E)
GSOUT1_1+
69
GSOUT1_1-
70
GSOUT1_2+
71
GSOUT1_2-
72
GSEDM1+
77
GSEDM1-
78
Lamp
Universal output 1
It is possible to use either one of the dual safety output signals

and use it as a universal output signal. (cf. drive of lamp)
The 1ch and 2ch are controlled simultaneously, so they
cannot be used as different signals.
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8.23.3
Performing the Safety Logic Circuit

The safety logic circuit is always performed except updating the file.
Confirm that the status is DONE. When setting signal is turned ON, the
mark is displayed, and when setting signal is turned OFF, the mark
is displayed.
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8.23.4 Saving or Loading the File
8.23.4.1 Saving the File

In order to save the file, which is set in the safety logic circuit, select {I/O
DATA} by going to {SAVE} from {EX. MEMORY} in the main menu.
Perform the saving the file after confirming the either the CompactFlash or
USB memory stick is inserting to the programming pendant.
Select {I/O DATA}, by going to {SAVE} from {EX. MEMORY} in the
main menu.
The signal list relative to the I/O data is displayed, and then select
YSF LOGIC FILE.
The confirmation dialog appears, and select YES.
The safety logic circuit file (file name:YSFLOGIC.DAT) is saved in

the specified device.
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8.23.4.2
8 System Setup
Loading the File

In order to load the safety logic circuit file (file name: YSFLOGIC.DAT),
select {I/O DATA} by going to {LOAD} from {EX. MEMORY} in the main
menu. Perform the saving the file after confirming the either the
CompactFlash or USB memory stick is inserting to the programming
pendant.
Select {I/O DATA}, by going to {LOAD} from {EX. MEMORY} in the
main menu.
The signal list relative to the I/O data is displayed, and then select
YSF LOGIC FILE.
The confirmation dialog appears, and select YES.
The safety logic circuit file (file name:YSFLOGIC.DAT) is loaded

from the specified device.
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NOTE
When loading the safety logic circuit file, the file is not
transferred to the machine safety circuit board (type:
YSF21-E). Thus, perform {WRITE} in the one of the
following windows, such as {M-SAFETY SIGNAL ALLOC},
{TIMER DELAY SET}, {SAFETY LOGIC CIRCUIT} or
{SAFETY SIG. BOARD ALLOC}. The all display information
above are updated, and the file written in the FLASH ROM
of the machine safety circuit board is also updated.
8.23.5 Initializing the Safety Logic Circuit File

If the following alarm shown below appears when starting the DX200, it
will become the management mode. The alarm occurs when the file does
not match the file written in the FLASH ROM of the machine safety circuit
board (type: YSF21-E). For example, if the machine safety circuit board is
replaced the spared part, the alarm will occur.
When the alarm occurs, perform the following procedures to restore.
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8.23.5.1
8 System Setup
Initializing the Safety Logic Circuit File

Select {SECURITY} from {SYSTEM} in the main menu.
2. Changing to the safety mode.
Select {SAFETY MODE}.
Enter the password for the safety mode, and press {ENTER}.
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3. When the entered password is correct, the mode is changed to
{SAFETY MODE}. After changing to the safety mode, the icon
displayed on the status area.
is
4. Select the file to be initialized.

Select {I/O DATA} by going to {INITIALIZE} from {FILE} in the main
menu.
The I/O data file list is displayed, and then select YSF LOGIC FILE.
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5. Perform the initialization.
Select {ENTER}.
Select {YES}.
The file written in the FLASH ROM of the machine safety circuit
board (type: YSF21-E) is initialized.
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8.23.5.2 Machine Safety Flash Data Erase or Reset

Erase the safety logic circuit file (file name: YSFLOGIC.DAT) written in the
FLASH ROM of the machine safety circuit board (type: YSF21-E) by
selecting Machine Safety Board FLASH Erase.
By selecting the Machine Safety Board FLASH Reset, the machine
safety circuit board (type: YSF21-E) is transferred and saved in the
FLASH ROM of the machine safety circuit board (type: YSF21-E).
Machine Safety Board FLASH Erase

Select {Machine Safety Board FLASH Erase} by going to
{INITIALIZE} from {FILE} in the man menu.
The confirmation dialog appears, and select {YES}.

The safety logic circuit file (file name: YSFLOGIC.DAT) written in the
FLASH ROM of the machine safety circuit board (type: YSF21-E) is
erased.
NOTE
After performing the Machine Safety Board FLASH Erase,

and turning the DX200 power supply ON/OFF. Next time
when turning the power supply ON, the alarm 0300:
VERIFY ERROR (SYSTEM CONFIG-DATA) occurs.
Therefore, when performing the Machine Safety Board
FLASH Erase, the Machine Safety FLASH Restart needs
to be performed as well.
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Machine Safety FLASH Reset

Select {Machine Safety Board FLASH Reset} by going to
{INITIALIZE} from {FILE} in the man menu.
The confirmation dialog appears, and select {YES}.

The safety logic circuit file (file name: YSFLOGIC.DAT) is
transferred and written in the FLASH ROM of the machine safety
circuit board (type: YSF21-E).
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8.23.6 Example of Safety Logic Circuit
The followings are the examples of the safety logic circuit.
<The safety logic circuit: example 1>

1. The first universal input safety signal of the I/O circuit board
(type:YSF22 -E) 1 is ON (#1 GSIN1), and the first universal input
safety signal of the I/O circuit board (type:YSF22 -E) 2 is ON (#1
GSIN2). The signal is outputted from the I/O circuit board
(type:YSF22 -E) 1 (#1 GSOUT1) of the first universal output safety
signal.
Signal 1:
Universal safety input signal 1 (#1 GSIN1)
Signal 2:
Logic:
AND
Output signal: Universal output signal 1 (#1 GSOUT1)
2. Displays the time chart.
ON
#1 GSIN1
OFF
#1 GSIN1: ON
ON
#1 GSIN2
OFF
#1 GSIN2: ON
ON
#1 GSOUT1
OFF
#1 GSIN1 and #1 GSIN2 are ON,
so that #1 GSOUT1 will be ON.
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3. Verifying the safety logic circuit.
Switch ON the universal safety signal 1 and 2.
The mark becomes
.
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1. The emergency button of the programming pendant is pressed, and
the first universal input safety signal of the I/O circuit board
(type:YSF22 -E) 1 is OFF, and the I/O circuit board (type:YSF22 E) of the first universal output safety signal is ON after one second
passed.
Signal 1:
Programming pendant emergency button (PPESP)
Signal 2:
NOT machine safety universal input signal 1

(#1 GSIN1)
Logic:
AND
Output signal: Machine universal output signal 0 (#1 GSOUT0)

Delay timer:
ON delay timer1 (TM1 ON DELAY) 1 second

ON(press)
PPESP
OFF(release)
ON
PPESP(press)
#1 GSIN1
OFF
GSIN1: OFF
NOT
#1 GSIN1
ON
OFF
NOT GSIN1: ON
Setting value
TM1 ON
DELAY
0
Timer (start)
Timer (reaching the specified value)
ON
#1 GSOUT1
OFF
PPESP and NOT #1 GSIN1 are ON, and
ON DELAY TIM1 reached to the specified value
so that #1 GSOUT1will be ON
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Confirm that the mark becomes when pressing the
programming pendant and switching the universal safety signal ON.
The mark of the universal safety output signal 1 becomes
after one second passed.
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1. When the first universal input safety signal of the I/O circuit board
(type:YSF22-E) 1 is ON (#1 GSIN1) and under the teaching mode,
the manipulator will decelerate and stop.
Signal 1:
Teach mode (TEACH)
Signal 2:
Logic:
AND
Output signal: Manipulator deceleration to a stop

(SVOFF CAT1)

TEACH
Mode
PLAY
NOT
#1 GSIN1
ON
OFF
#1 GSIN1: ON
ON
Decelerating
processing
OFF
Starts decelerating
processing
Ends decelerating
processing
ON
Servo ON
OFF
Under the teach mode and #1 GSIN1 is ON,
so that the servo will be turned ON after
the decelerating processing
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Set up the teach mode, and turn the servo ON. When switching the
universal safety signal ON, the mark of the universal safety output
signal 1 becomes .
SIGNAL1: Teach mode (TEACH)

SIGNAL2: Programming pendant enable switch (PPDSW)
LOGIC: AND
NOTE
OUTPUT: Manipulator deceleration to a stop

(SVOFF CAT1)
If create the safety logic circuit shown above, the
manipulator will stop immediately as the DX200 system.
(Manipulator does not decelerate.)
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1. The setting example by using the auxiliary relay is described below.
When the any one of the status of the programming pendant
emergency stop, controller emergency stop or external emergency
stop is stopped, the first universal output safety signal 1 of the I/O
circuit board (type:YSF22 -E) is ON.
Signal 1:
Programming pendant emergency stop (PPESP)
Signal 2:
Controller emergency stop (PPESP)
Signal 3:
External emergency stop (EXESP)
Logic:
AND
Output signal: Universal safety output signal(#1 GSOUT1)

The display #1 GSOUT1 indicates the #1 GSOUT1 of the first
I/O circuit board (type:YSF22 -E).

ON(press)
P P ES P
OFF
(release)
ON(press)
P B ES P
OFF
(release)
ON
(release)
EX ES P
OFF
(short-circuit)
#1 G S O U T 1
One of these status is ON,

and turn #1GSOUT1 ON
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When the one of the programming pendant emergency stop, controller
emergency stop or the external emergency stop is inputted, the mark
of the universal safety output signal 1 becomes .
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8.23.7 Alarm List of the Safety Logic Circuit
Alarm
Number
Sub-code Message
300
Remedy
VERIFY ERROR (SYSTEM CONFIG-DATA)

20
Machine Safety board save data The safety logic circuit files in the file written in the Main
error
CPU circuit board (type: YCP21-E) and the machine
safety circuit board (type: YSF21-E) does not match.
Refer to section 8.23.5.2 Machine Safety Flash Data
Erase or Reset on page 8-243 for more details to
restore.
Start-up, in reading information

from the FlashROM of YSF21
board, YSF21 board has
detected an undefined signal.
The error of the safety logic circuit is detected when

startup. Check the safety logic circuit because an
invalid I/O signal is used by the safety logic signal.
In the receiving information on

safe logic circuit information,
YSF21 board has detected an
undefined signal.
The error is detected when updating the file. Check the

safety logic circuit because an invalid I/O signal is used
by the safety logic signal.
4776
M-SAFETY YSF LOGIC FILE SIGNAL ERR
4777
TRANSMISSION ERROR (M-SAF FILE)

1
Safe logic circuit information

transmission error was
detected.
An alarm occurred while transferring the safety logic

circuit file to the machine safety circuit board
(type:YSF21-E). Reset the alarm, and re-send the
safety logic circuit file.
Timer delay information

detected.

M-safety signal alloc information An alarm occurred while transferring the safety logic
detected.
Safety signal board alloc

information transmission error
was detected.

253
M-safety command reception

time out was detected.
No response from the machine safety circuit board

(type:YSF21-E) while transferring the safety logic
circuit file. Reset the alarm, and re-send (perform the
writing) the safety logic circuit file. If the alarm occurs
again, replace the machine safety circuit board (type:
YSF21-E).
254
Safe logic circuit write error was

detected.
Failure to transfer the safety logic circuit file to the

machine safety circuit board (type:YSF21-E). Please
re-send the safety logic circuit file. If the alarm occurs
again, refer to section 8.23.5.2 for more details.
255
Safe logic circuit cancel error

was detected.
Failure to sending the cancel command while

transferring the safety logic circuit file to the machine
safety circuit board (type:YSF21-E). Please re-send
the safety logic circuit file. If the alarm occurs again,
refer to section 8.23.5.2 for more details.
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8.24 Robot Stop Factor Monitor Function
8.24
8.24.1
Robot Stop Factor Monitor Function

Outline
The robot stop factor monitor function is a function to detect a robot stop,
which is caused by the servo OFF or the hold and so on. The factors,
which caused to stop the robot, are stored in chronological order and
8.24.1.1
The Robot Stop Factor

This function detects the servo OFF status caused by the machine safety
circuit board instructions or the main CPU instructions and the hold status
caused by programing pendant operations or signals. The detection items
are described as follows.
Table 8-1: The List of the Servo OFF Factors by Main CPU Instructions
Displayed Item
Secondary Indication
EX.SERVO OFF1 (HOLD STOP)
System input signal number

(#40065)
EX.SERVO OFF2 (CATEGORY0 STOP) System input signal number

(#40066)
EX.SERVO OFF3 (CATEGORY1 STOP) System input signal number
(#40064)
TEACH -> PLAY MODE CHANGE
None
PLAY -> TEACH MODE CHANGE
None
MAIN CPU ALARM
None
PARAMETER CHANGE
None
INST SVOFF
None
COMMAND SVON
None
HOME POSITIONING CHANGE
None
DATA FALSE RESTORE
None
TOOL FILE CHANGE
None
TOOL CALIBLATION
None
ENCODER RESET
None
ROBOT DETACHMENT
None
GROUND FAULT (BRAKE LINE)
None
MANUAL FULL SPEED
None
SERVO OFF QUE
None
SERVO ON ERROR
None
SERVO OFF ERROR
None
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Table 8-2: The List of the Servo OFF Factors by Machine Safety Circuit Board Instructions
Displayed Item
Description of the Signal
PP EMERGENCY STOP
Programming pendant
emergency stop
PP ENABLE SWITCH
Programming pendant enable

switch
PANEL BOX EMERGENCY

STOP
Controller emergency stop
EXTERNAL EMERGENCY
STOP
External emergency stop
EXTERNAL ENABLE
SWITCH
External enable switch
SAFETY FENCE
Safety guard
EXTERNAL SERVO ON
External servo ON
It is displayed only when the
level (S1D271=0) is specified
RDY0 OFF
RDY0OFF
Servo OFF request from the
main CPU
CATEGORY1 REQUEST
Category 1 stop request from

the main CPU
M3 COMMUNICATION
ERROR
Servo OFF by M3
communication error of the
main CPU or among the servo
circuit boards
CATEGORY0 SAFETY
LOGIC CIRCUIT

the safety logic circuit
CATEGORY0 FUNCTION
SAFETY

the machine safety
CATEGORY1 SAFETY
LOGIC CIRCUIT

the safety logic circuit
CATEGORY1 FUNCTION
SAFETY

the machine safety
YSF21 ALARM
Alarm of the machine safety
CATEGORY0 STOP
The time of the machine safety

category 0 stop timer is up, and
switch OFF the servo of the
machine safety.
CATEGORY1 STOP
The time of the machine safety

category 1 stop timer is up. The
machine safety servo category
0 stop timer must be started.
OVER TRAVEL1
Circuit board No.

SV#1 to SV#8
Servo OFF by the over travel

signal 1
OVER TRAVEL2
Circuit board No.

SV#1 to SV#8

signal 2
OVER TRAVEL3
Circuit board No.

SV#1 to SV#8

signal 3
OVER TRAVEL4
Circuit board No.

SV#1 to SV#8

signal 4
CONTACTOR OR STO OFF1 Circuit board No.

SV#1 to SV#8
Servo OFF of the contactor 1 or

STO1 from the main CPU
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Table 8-2: The List of the Servo OFF Factors by Machine Safety Circuit Board Instructions
Displayed Item
Description of the Signal

SV#1 to SV#8


SV#1 to SV#8


SV#1 to SV#8

ON ENABLE1
Circuit board No.

SV#1 to SV#8
Servo OFF of the control group

connected to ON_ENABLE1
ON ENABLE2
Circuit board No.

SV#1 to SV#8

ON ENABLE3
Circuit board No.

SV#1 to SV#8

ON ENABLE4
Circuit board No.

SV#1 to SV#8

CATEGORY ON ENABLE1
Circuit board No.

SV#1 to SV#8
The time of the category 0 is up

after inputting the
ON_ENABLE1 signal, then
machine safety.
CATEGORY ON ENABLE2
Circuit board No.

SV#1 to SV#8

after inputting the
machine safety.
CATEGORY ON ENABLE3
Circuit board No.

SV#1 to SV#8

after inputting the
machine safety.
CATEGORY ON ENABLE4
Circuit board No.

SV#1 to SV#8

after inputting the
machine safety.
2ND CONTACTOR1
Circuit board No.

SV#1 to SV#8
2NDSF1
The time of an auxiliary
contactor 1 in the secondary
contactor is up, and switch OFF
the servo of the machine safety.
2ND CONTACTOR2
Circuit board No.

SV#1 to SV#8
2NDSF2
2ND CONTACTOR3
Circuit board No.

SV#1 to SV#8
2NDSF3
2ND CONTACTOR4
Circuit board No.

SV#1 to SV#8
2NDSF4
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Table 8-3: The List of the Holding Factors

Displayed Item
HOLD
None
EX.HOLD (SPECIFIC. IN TRMNL BLOCK) System input signal number

#40067
EX.HOLD (SPECIFIC. IN SIGNAL)
None
INDIVIDUAL HOLD

#40270 to #40287
TASK#0 to TASK#15
HOLD (SHOCK SENSOR)
None
HOLD (DATA TRANSMISSION)
None
HOLD (API CTL)
None
HOLD (API)
None
HOLD (HIGH SPEED ES)
None
SKIP WAIT INST (STOP PLAYBACK)
Task number
TASK#0 to TASK#15
GUN TEACH SIG. OFF

(STOP PLAYBACK)

#41231
GUN TEACH STEPOVER

(STOP PLAYBACK)
None
ALARM STOP QUE
None
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8.24.1.2
8 System Setup
The Robot Stop Factor Record Number

One screen: maximum 37 factors
History number: 20 histories
If exceeds the number above, the old data will be deleted, and the new
data will be recorded.
8.24.2
8.24.2.1
Operation
Displaying the Robot Stop Factor Monitor

The RB STOP FACTOP MONITOR can be referred by following
procedures.
1. Select {RB STOP FACTOR MONITOR} under the {IN/OUT} in the
main menu.
The RB STOP FACTOR MONITOR window appears.
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The following items are displayed on the RB STOP FACTOR
MONITOR window.
DETECT TIME: Shows the time when the robot stop factor was
detected.
The factor detected by the main CPU is displayed on the first

line.
The factor(s) detected by the machine safety is (are) displayed

from the second line on the screen.
The data on the first page is the latest one, and the page 20 is the
oldest data.
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8.24.2.2
8 System Setup
Clear the Robot Stop Factor Information

1. Select {DATA} from the pull-down menu on the RB STOP FACTOR
MONITOR window when the security mode is the management or
higher mode. {CLEAR} is displayed.
2. Select {CLEAR}, and the confirmation dialog Initialize? appears.

Press YES, and the all information of the robot stop factor is cleared.
NOTE
The robot stop factor information is not saved when turning

the power supply OFF. Therefore, it will be initialized when
turning the power supply ON again. If it is necessary to
save the data, please store the data into the external
memory devices before turning the power supply OFF.
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8.25 Robot Detachment Function
8.25
Robot Detachment Function
8.25.1 Setting Maintenance Mode

This mode is used for setting up and maintenance of the robot system.
1. Turn the power ON while pressing {MAIN MENU} button.
Maintenance mode screen starts up.
2. Select {SYSTEM} under the main menu.

Sub menu is shown.
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3. Select {SECURITY}.
Mode selection screen is shown.
4. Press [SELECT] to select the mode.

Mode selection list is shown.
5. Move the cursor to {SAFETY MODE} and select.

Password input box is shown.
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6. Input the password for safety mode and press [ENTER].
When the correct password is input, security mode is changed.
8.25.2 Setting Robot Detachment Function

Operator can set or modify the setting items for robot detachment function
in detail setting screen.
The specified parameters are to be set automatically according to the
setting contents in detail setting screen.
1. Select {SYSTEM} under main menu.
Sub menu is shown.
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2. Select {SETUP}.
SETUP screen is shown.
3. Move the cursor to {OPTION FUNCTION} and select.

OPTION FUNCTION screen is shown.
4. Move the cursor to {ROBOT DETACHMENT} and select.

Detail setting screen for robot detachment function is shown.
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5. Change the setting contents.
Move the cursor to the target group and select to change the setting.
Select ATTACHED or DETACHED.
6. Change the setting item on JOB.

Move the cursor to the JOB setting item and select.
Every pressing the [SELECT] switches the indication between
and - .
Description for the setting items on JOB

When - is selected: The JOB including detached group cannot be
started up.
When is selected: The JOB including detached group can be
started up. However, the detached axes
cannot be operated.
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7. Press [ENTER].
Confirmation message for parameter change is shown.
8. Select YES to confirm the change.

System parameters are to be set automatically, then the screen
returns to the option function screen.
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8 System Setup
8.26 Axes Detachment Function
8.26
Axes Detachment Function
8.26.1 Outline
The axes detachment function is to invalid the connection of specific axes
by setting in maintenance mode. When the axes detachment function is
set, the system can be started without any alarm even if some axes are
not connected physically during setup or motor exchange.
8.26.2 Setting Maintenance Mode
Start the maintenance mode and set the security mode to the safety
mode. (Refer to section 8.25.1.)
8.26.3 Setting Axes Detachment Function
Operator can set or modify the setting items for axes detachment function
in detail setting screen.
The specified parameters are to be set automatically according to the
setting contents in detail setting screen.
Sub menu is shown.
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2. Select {SETUP}.
Setting selection screen is shown.
3. Move the cursor to {OPTION FUNCTION} and select.

OPTION FUNCTION screen is shown.
4. Move the cursor to {AXES DETACHMENT} and select.

Detail setting screen for axes detachment function is shown.
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5. By pressing [PAGE], the target group for setting is switched.
6. Change the setting contents.

Move the cursor to the target axis and select to change the setting.
Select ATTACHED or DETACHED.
7. Press [ENTER].
Confirmation message for parameter change is shown.
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8. Select YES to confirm the change.
System parameters are to be set automatically, then the screen
returns to the option function screen.
8.26.4
Specific Output and Messages

When the system is started in online mode and any axes (at least one
axis) are detached, the following specific output and message are output
all the time.
Specific output #50913 AXES DETACHMENT

Message is displayed
The following message is output in the bottom right message area on the
window of the programming pendant.
Axes deatchment has been set [sub code]
The control group including the detached axis is shown in [sub code].
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8.26.5 Restrictions
1. Operation with restrictions
When the axes detachment function is set, the following operations are
restricted. If these operations are tried to be performed, an error or an
alarm occurs.
Playback
Test run
Job registration (insert/modify/delete jobs in the target control group)
Variable registration
Second home position registration
Home position registration
Work home position registration
SUPPLEMENT
Use the robot detachment function (section 8.25) when

performing the playback operation in the state that the
specific manipulator, the base, or the station is detached.
Followings are the errors/alarms which may occur by the axes

detachment.
Operation
Alarm
Playback
ERROR 2762 This operation is not allowed, for axes

detachment has been set.
ALARM4916/4917 WRONG JOB EXEC OF
DETACHED AXIS
Test run
ERROR 2762 This operation is not allowed, for axes

detachment has been set.
Job registration
(insertion, modification,
deletion)
ERROR 2763 Cannot modify, for axes detachment

has been set.
Second home position

registration

has been set.
Home position
registration

has been set.
Work home position

registration

has been set.
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2. Operation without restrictions
CAUTION
While the axes detachment function is set, even if try to move the
manipulator to the taught position, the manipulator may not be
moved to the right position or operated in the right posture because
the specific axes dont operate. When performing the operations
mentioned below while the axes detachment function is set, be very
careful to the manipulators motion and the interference between
the manipulator and the peripheral devices.
The axes detachment function doesnt restrict the following operations,

though be careful when performing.
Jog operation (link, cartesian, user, tool, cylindrical, and I/O jog)
Next/Back operation
Variable movement
Second home position movement
Work home position return
3. Restriction in using with other function
Before using the following function, be sure to release the axes
detachment function.
Functional safety function

If there is any detached axis, safety monitoring cannot be performed.
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9 System Backup
9.1 System Backup with DX200
System Backup
For the DX200, the system data can be collectively backed up in advance
so that the data can be immediately loaded and restored in case of an
unexpected trouble such as data loss.
9.1
System Backup with DX200

For the DX200, two types of collective backup are available: CMOS.BIN
and CMOSBK.BIN.
9.1.1
9.1.1.1
Function Types of Data
CMOS.BIN
For the normal backup, use this data.
Save: Perform in the normal or maintenance mode.
Load: Perform in the maintenance mode.
(the management mode or higher mode)
The loading/saving procedures in the maintenance mode,
refer to section 9.2 Backup by CMOS.BIN on page 9-3.
As for saving in the normal mode, refer to DX200 OPERATORS
MANUAL section 7.3.0.2 Saving Data .
Target Area: All areas of the internally stored data.
(Note that the monitoring time is not loaded.)
9.1.1.2
CMOSBK.BIN
This data is used in the automatic backup function.
Save: Saves with the preset conditions in the normal mode.
Load: Perform for the system restoration in the maintenance mode
(the management mode or higher mode)
For details, refer to section 9.3 Automatic Backup Function on page 9-7.
Target Area: All areas of the internally stored data.
(Note that the monitoring time is not loaded.)
9.1.2
Device
For the backup of the DX200 system, the CompactFlash or the USB
memory is used. (The USB slot of the programming pendant is not
available in the automatic backup function.)
The following tables show the recommended CompactFlash and USB
memory.
<Recommended CompactFlash>
No. Manufacturer
Model
Remarks
Hagiwara Solutions
MCF10P-256MS-YE
256MB
Hagiwara Solutions
MCF10P-512MS
512MB
Hagiwara Solutions
MCF10P-A01GS
1GB
Hagiwara Solutions
MCF10P-A02GS
2GB
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9 System Backup
9.1 System Backup with DX200
< Recommended USB Memory>
No. Manufacturer
1
Hagiwara Solutions
Model
Remarks
UDG4-xGDRJ
1GB, 2GB, and 4GB are

available.
x indicates 1 for 1GB,
2 for 2GB and 4 for
4GB.
In order to save the batch data, the following free space per file is needed
in the media.
Approx. 26 MByte
Note that the free space for one working file is needed in addition to the
free space for the stored files when using the automatic backup function.
Also, it is recommended to store the backup data in two or more media
cards to minimize problems if the media is damaged.
The water-proof function of the Pendant is not effective
while the USB memory is connected.
NOTE
If USB memory is connected constantly, there is a risk it

drops off.
Use CompactFlash if there is no measures to maintain
water-proof function or to prevent USB memory from
dropping off.
When using the USB memory, insert it in the USB slot of the CPU circuit
board. Be careful about the insertion direction of the connector: The USB
memory should be inserted slowly with the upper surface right. Forcible
insertion may cause the damage of the USB memory and the USB
connector.
The position to insert the USB memory.
The upper surface
USB memory
* There are two USB connectors.

The left side is for USB1 and the right side is for USB2.
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9 System Backup
9.2 Backup by CMOS.BIN
9.2
Backup by CMOS.BIN
Perform the backup by CMOS.BIN in the normal or maintenance mode.
The chart below shows the availability of CMOS save/CMOS load in each
security mode in the maintenance mode.
9.2.1
Security
CMOS Save
CMOS Load
Operation Mode
Editing Mode
Management Mode
Safety Mode
CMOS.BIN Save
Follow the procedures below to save CMOS.BIN in the maintenance
mode.
1. Turn ON the DX200 power supply while pressing [MAIN MENU].
2. Insert a CompactFlash into the CompactFlash slot on the
when USB memory is used instead of CompactFlash, mount USB
memory and select one among USB: PENDANT, USB1:
CONTROLLER and USB2: CONTROLLER in the {DEVICE}.
3. Select {FD/PC CARD} under the main menu.
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4. Select {SAVE}.
The save display appears.
The items marked with "" cannot be selected.

5. Select {CMOS}.
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6. Select {YES}.
Select {YES} to save the CMOS data into the CompactFlash.
When saving the file, if the CMOS.BIN file already exists in the
CompactFlash, the following confirmation dialog box appears.
7. Select {YES}.
The CMOS.BIN file is overwritten in the CompactFlash.
9.2.2
CMOS.BIN Load
Follow the procedures below to load CMOS.BIN.
2. Change the security mode to the maintenance mode or higher mode.
3. Insert a CompactFlash into the CompactFlash on the programming
pendant.
When USB memory is used instead of CompactFlash, mount USB
memory and select one among USB: PENDANT, USB1:
CONTROLLER and USB2: CONTROLLER in the {DEVICE}.
4. Select {FD/PC CARD} under the main menu.
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5. Select {LOAD}.
The load display appears.

6. Select {CMOS}.
7. Select {YES}.
The loaded CMOS.BIN file contents are reflected in the data inside
the robot.
CAUTION
When the CMOS load is performed, the current CMOS data is
replaced with the CMOS data (the contents of "CMOS.BIN") in the
CompactFlash. Therefore, before performing the load, make sure to
perform the CMOS Save of the CMOS data to be loaded.
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9 System Backup
9.3 Automatic Backup Function
9.3
9.3.1
9.3.1.1
Automatic Backup Function

Automatic Backup Function
Objective
With the automatic backup function, the data saved in the DX200 such as
system setting or operational condition are collectively backed up in the
CompactFlash, which is stored in the programming pendant, or the
selected device at the automatic backup window.
speed ethernet server function is effective.)
DN1.50-00 or higher: The automatic backup function is expanded. In
order to use the automatic backup extension function, set the following
parameter.
For the setting of the automatic backup extension function, refer to section
9.3.2.7 AUTO BACKUP EXTENSION FUNCTION SET Window .
Parameter
Content
Initial Value
S2C737
Automatic backup extension

function
Able to back up to the following devices.

The CompactFlash of the programming pendant
The CompactFlash of the YCP21 board
The RAM AREA of the YCP21 board (It will display, when the high
speed ethernet server function is effective.)
NOTE
9.3.1.2
The automatic backup function is enabled only while the

DX200 power supply is ON whereas it isnt while in the
maintenance mode or the power supply is OFF.
Outline
The automatic backup function saves the internally stored data in a single
file in advance for the smooth restoration from unexpected troubles of the
DX200.
The teaching operation is one of the factors that changes the internally
stored data. Thus, a mode which backs up the latest data after the
teaching operation is prepared. To confirm the termination of the teaching
operation, check the mode key whether it is changed from teach mode to
play mode.
Other than the teaching operation, the present position of the robot or the
value of a variable can be pointed out as the factors to change the
internally stored data. These data, however, are changed after each
operation and have very little need to be retained permanently.
Accordingly, backing up these data at regular interval should be well
enough to operate and the mode to back up the data at regular interval is
also prepared.
Furthermore, the mode to back up the data when starting up the DX200
and when inputting signals are also available for some specific versions.
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9 System Backup
With the automatic backup function, all the part where the internal data is
stored in the physical memory area is collectively saved. If there is any
data which is in the middle of changing while executing the automatic
backup function, the data might not be usable for restoration because of
its inconsistency. Therefore, the function is terminated with an error
during the play back operation or while the manipulator is in motion so that
the automatic backup cannot be operated. Set the automatic backup
function to be executed while the manipulator is not in the playback status
and while the manipulator is stopped.
The automatic backup function has the following functions and features.
No Function/Feature
Explanation
Cyclic backup
In the teach mode, the data in
memory is backed up in a specified
cycle from a specified starting time.
This function backs up as much of

the latest data as possible during
editing. The backup data saved in
the CompactFlash can be loaded to
the DX200 in case of data loss so
that the damage can be minimized.
Backup when switching modes

When switching the mode from the
teach mode to the play mode, the
data in memory is backed up.
The editing data is backed up when

editing is completed. The latest
data is automatically backed up with
this mode.
Backup when start-up

When the DX200 is start-up, the data
in memory is backed up.
When the DX200 starts up, the data

in memory is backed up. Since the
editing/playback operation is
usually completed when the DX200
power is turned OFF, the latest data
is automatically backed up with this
mode.
Backup when inputting specified

signals
The data in memory is backed up
when a specified signal (#40560) is
input.
The data in memory is backed up by

the signal from the host at the
intended timing. Although the above
mentioned items 1 to 3 are
designed to back up the data
automatically, this function backs up
the data in accordance with the
instruction from the host.
Backs up the variables for essential

Backup while robot program is
stopped
data.
The backup during playback is
disabled. However, in the play mode,
the backup is enabled if the robot is
stopped. ("Cyclic backup" and
"Backup when inputting specified
signals")
Backup and retry at low priority

The data in memory is backed up at
low priority so that this operation
does not affect the other operations.
When other operations affect the
backup operation, the backup is
suspended and retried later.
The backup operation hardly affects

the other operations so that the
programming pendant can be used
even during the backup operation.
Backup in binary
The data is saved as binary data.
Backup in binary allows the system

to be easily and speedily restored.
Setting of items
Parameters can limit the settings of
the backup condition.
Unnecessary settings can be

avoided with this setting.
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9 System Backup
9.3.2
Settings for Automatic Backup

To set the automatic backup function, set each item at the automatic
backup display.
NOTE
Four ways to perform the automatic backup are available:

"Cyclic backup", "Backup when switching modes", "Backup
when start-up", and "Backup when inputting specified
signals".
The automatic backup can be performed only when the
robot is not during playback, and the robot is stopped.
Automatic backup function can be set from the command
of the optional high speed ethernet server function.
9.3.2.1
The CompactFlash of the Programming Pendant

To use the automatic backup function, insert CompactFlash in the
CompactFlash slot on the programming pendant. Only while the DX200
power supply is OFF, the CompactFlash can be inserted or removed.
When the data could not be saved in CompactFlash during an automatic
backup due to the absence or insufficient capacity of the CompactFlash,
an error message Cannot backup CompactFlash appears. At the same
time, the signal occurrence of error is output, but the robot program will
not be stopped. Check if CompactFlash is inserted and if it has enough
capacity, and take the necessary actions. If no actions are taken while the
error occurs, the data cannot be saved.
Yaskawa recommends that the data be saved in two or more
CompactFlash to minimize problems if the CompactFlash should be
damaged.
Regarding the Compact Flash for auto backup, refer to Recommended
CompactFlash in section 9.1.2 Device on page 9-1.
Storage capacities needed for CompactFlash are as follows:
(The number of stored files + 1) X approx. 26MByte
The number of storable files is automatically calculated and the MAX
value is shown when AUTO BACKUP SET display appears.
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9.3.2.2
9 System Backup
The CompactFlash of the YCP21 Board

Set the following procedures in advance to back up to the CompactFlash
of the YCP21 board. If the following procedures are not done, CF:
Controller would not be shown on the device list of the auto backup set
display.
1. Turn ON the Power supply while pressing the {MAIN MENU} on the
2. After starting maintenance mode, change the security mode to the
management or higher mode.
3. Select {SYSTEM} in the main menu.
When the sub menu will appear, select {SETTING}-{OPTION
FUNCTION}. The list of the optional function will appear.
4. Select {Automatic backup (YCP21)}, and change the UNUSE to
USE.
Select {YES}, when the confirmation dialog appears.
Select {YES}, when the confirmation dialog appears, and ask
initialized related files? or CMOSBK. BIN?
It will allocate automatic backup to the CompactFlash of the YCP21.
During allocating, the massage of do not turn the power off appears.
The message of the maintenance mode will appear, when finished
allocating.
5. Turn ON the power supply again.
6. The online window appears on the programming pendant.
8. Select {CONTROLLER SET}-{SET AUTO BACKUP}.
9. It would be error without inserting the CompactFlash in the
programming pendant, when the device is set on the CompactFlash in
the programming pendant. Push down the [cancel], when the error
occurs.
10. Select the device, and change to CF: Controller.
Backup setting to the CompactFlash of the YCP21 board
should be done while the robot is not operating.
NOTE
When access to CompactFlash of the YCP21 by using

other than the auto backup function, the auto backup
function and the exclusive process would be run.
Therefore, the save time of the auto backup will extend.
(Normally, it takes about three minutes to finish backing-up.
However, duplication access to the CompactFlash of the
YCP21 board takes three to ten minutes.)
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9.3.2.3
9 System Backup
RAMDISK on the YCP21 Board

RAMDISK will be shown when the high speed ethernet server function is
effective. Refer to the instruction of the DX200 HIGH-SPEED
ETHERNET SERVER FUNCTION for more details.
9.3.2.4
DX200 Status and Automatic Backup
Backup Timing DX200 Status
From a
specified
starting time
When a
specified signal
(#40560) is
input
Teach mode
Automatic Backup
Editing
(Accessing to
the memory)
Compact
Flash
ready to
save the
data
Absence or
insufficient
capacity of the
CompactFlash
Retry
Retry
When editing is Backup

interrupted
Error
Play mode
Remote mode
Executing jobs
Disabled
Disabled
When stopped
Backup
Error
Teach mode
Editing
(Accessing to
the memory)
Error
Error
When editing is Backup

interrupted
Error
Executing jobs
Disabled
Disabled
When stopped
Backup
Error
When switching the mode from

the teach mode
to the play
mode
Backup
Error
When the
DX200 starts
up
Backup
Error
Play mode
Remote mode
* Retry is not performed when an error occurs.

* An error can be indicated by a message depending on setting.
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9 System Backup
Reserve Time Backup

While the data in the DX200 memory is being edited or overwritten, the
automatic backup is not performed at the specified backup starting time
and is suspended and retried later. To start the backup at the reserved
time, set to the time when the robot program is stopped and no job or file
is edited.
Backup when Switching from Teach Mode to Play Mode

When the mode is repeatedly switched from the teach mode to the play
mode or vice versa within 1 to 2 seconds, backup starts after the last time
the mode is switched.
Execute the job after three second since starting the back-up.
Backup when the DX200 starts up

Since the automatic backup process is added to the DX200 start-up
process, a few extra seconds are needed to start up the DX200.
Backup when Specific Signal is Input

While the DX200 memory is edited such as overwriting, the backup
operation becomes an error even if there is an input to a specific signal
(#40560). To start the specific input backup, perform it while the robot
program is stopped and a job or file is not being modified.
Also, since the signal input is executed at rising detection, turn the signal
to "0" if it is already "1", then return to "1" again.
Execute the job after three second since starting the back-up.
Overwriting Limit in CompactFlash

The number of times that the CompactFlash can be overwritten is limited
to approx. 100,000 times. Because frequent backup operations may
shorten the life of CompactFlash, the number of backup times should be
minimized as much as possible.
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9.3.2.5
9 System Backup
Setting Examples
Setting Example 1
The following diagram shows a setting example with the following
conditions:
BASE TIME: 12:30
BACKUP CYCLE: 60 (minutes)
RETRY CYCLE: 10 (minutes)
BASE TIME
Power ON
BACKUP CYCLE
RETRY CYCLE
11:00
1st day
11:30 11:40
1st day
11:50
12:30
1st day
Backup
Backup
13:30
1st day
Backup
Setting Example 2
The following diagram shows a setting example with the following
conditions:
BASE TIME: 20:00
BACKUP CYCLE: 1440 (minutes) (24 hours)
RETRY CYCLE: 60 (minutes)
Power ON
BASE TIME
BACKUP CYCLE
RETRY CYCLE
8:00
1st day
20:00 21:00
1st day
22:00
20:00
2nd day
Backup
NOTE
Backup
20:00
3rd day
Backup
While a job is being executed, the automatic backup or retry

is not performed. Also, after an error occurs in writing into
the CompactFlash, the retry is not performed until the next
backup starting time.
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9.3.2.6
9 System Backup
AUTO BACKUP SET Display
Settings
Select the following items on the AUTO BACKUP SET display and set
values for the automatic backup.
RESERVE TIME BACKUP (VALID/INVALID of the cyclic backup)
BASE TIME
BACKUP CYCLE
RETRY CYCLE
MODE CHANGE BACKUP (VALID/INVALID of the backup when
switching the mode from teach mode to play mode)
STARTUP AUTO BACKUP (VALID/INVALID of the backup when the
DX200 is started up)
SPECIFIC INPUT BACKUP (VALID/INVALID of the backup when
inputting specified signals)
UNIV.OUT NO. ON ERROR
DISPLAY AT EMERGENCY
DURING ALARM OCCURENCE
STORED FILE SETTING (It is possible to set when CF:pendant is
set on the device.)
When the CF: pendant or CF:Controller is selected on
the auto backup display, the capacity of the CompactFlash
card in the specified device will be checked. Therefore, a
few seconds may be needed to open the setting window.
For the CF: Pendant, an error may occur without seting in
the CompactFlash card.
NOTE
When changing the settings of "STORED FILE SETTING"

or executing "ARRANGE", the files "CMOSBK.BIN" and
"CMOSBK??.BIN" (?? denotes figures) in the
CompactFlash card are changed in name or deleted. If a
certain file of this type is needed to be saved before
changed in name or deleted, evacuate it into a PC, etc.
beforehand.
While an error occurring, the setting of the each item on the
auto backup set display cannot be changed.
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9 System Backup
1. Turn ON the DX200.
Insert the CompactFlash to the programming pendant, when the
backup is set on the CompactFlash of the programming pendant.
2. Change the security mode to the management or higher mode.
4. Select {AUTO BACKUP SET}.
The AUTO BACKUP SET display appears.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
A. RESERVE TIME BACKUP

Set the backup function to valid or invalid in a specified cycle from a
specified starting time.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
The reserve time can be set by inputting values in B,C and D in the display.
Every time values are set to these three items, reset the RESERVE
TIME BACKUP to VALID.
If these settings are incorrect, the RESERVE TIME BACKUP cannot be
reset to VALID.
If so, check and then change the values to the correct settings.
B. BASE TIME
Specify the reference time to start reserve time backup.
The time elapsed from the reference time for a BACKUP CYCLE period
is recognized as the BACKUP TIME.
The first automatic backup is performed at the first BACKUP TIME after
the power of the DX200 is turned ON.
The automatic backup after the first time, is performed at the interval of
BACKUP CYCLES.
The reference time ranges from 0:00 to 23:59.
C. BACKUP CYCLE
Specify the length of time for a cycle to back up. After the first
backup, the next backup is performed automatically in the time specified
in the BACKUP CYCLE.
Set the backup cycle in units of minutes. The cycle setting ranges from
10 to 9999 minutes, and is longer than the RETRY CYCLE.
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9 System Backup
D. RETRY CYCLE
Specify the length of time for a cycle to retry backing up when the
backup operation is suspended.
After being suspended, the backup is retried in the time specified in the
RETRY CYCLE.
Set the retry cycle in units of minutes. The cycle setting ranges from 0
to 255, and is shorter than the BACKUP CYCLE.
When it is set to 0, retry will not be performed.
E. MODE CHANGE BACKUP
Set the automatic backup function to be valid or invalid when the mode
is switched from teach mode to play mode.
alternately.
F. STARTUP AUTO BACKUP
Set the backup function to be valid or invalid when the power of the
DX200 is turned ON.
alternately.
G. SPECIFIC INPUT BACKUP
Set the backup function to be valid or invalid when specific input signal
(# 40560) is input (rising edge from 0 to 1).
alternately.
H. UNIV.OUT NO. ON ERROR
Set "1" to the specified user output signal which was specified in this
chapter when the automatic backup error occurs.
The term "automatic backup error" here means that the backup is not
performed successfully before the next backup (including retry operation) starts.
I. DISPLAY AT EMERGENCY
Set the method of notification of the automatic backup error to
"ERROR" or "MESSAGE."
Each time [SELECT] is pressed, "ERROR" and "MESSAGE" are displayed alternately.
J. DURING ALARM OCCURENCE
Set the backup function to be valid or invalid when an alarm occurs.
alternately.
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9 System Backup
K.DEVICE
Press {SELECT} to display the device list.
The Device Name in Display
Explanation
CF: pendant
Set the backup to the CompactFlash

of the programming pendant.
CF: controller

of the YCP21 board. When the CF:
controller of the device name is not
shown, refer to 9.3.2.2 the
CompactFlash of the YCP21.
RAMDISK
It will be shown when the optional

function of High Speed Ethernet
Server function is effective. It can
back up by the DX200 high speed
ethernet server function command.
Refer to the [DX200 Instruction
HIGH-SPEED ETHERNET SERVER
FUNCTION].
USB1: controller
Set the backup to the USB memory of

the YCP21 board.
USB2: controller

the YCP21 board.
L. STORED FILE SETTING

Set the number of files to be stored by the automatic backup function.
The number mentioned on the right side of this item with "(Max)" indication is the maximum number of files that can be stored in the CompactFlash inserted when this window is displayed.
The settings range from 1 to (Max). When this setting value is changed,
the backup file arrangement starts. (Max is 100.)
M. BACKUP FILES
Indicates the existence of the files or the number of backup files stored
in the CompactFlash inserted when this window is displayed.
N. LATEST BACKUP FILE
Indicates the date of the latest file in the CompactFlash inserted when
this window is displayed.
O. ARRANGE
When the setting of maximum number of stored files is changed, the file
arrangement of the backup files in the CompactFlash is executed.
With this operation, the file arrangement can be performed without
changing the maximum number of stored files.
ARRANGE will not be displayed when the device of the CF: controller is
set on.
5. Set the desired item, and press [ENTER].
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9 System Backup
Window Settings
RS parameter can restrict the settings of some items in the automatic
backup window.
When setting the bit of RS096 parameter shown below to "1", the
corresponding items are restricted. The restricted items are indicated with
"INVALID" in the display and inputting/modification to the item becomes
impossible. Also, the automatic backup does not function with the
restricted items.
D7 D6 D5 D4 D3 D2 D1 D0
RESERVE TIME BACKUP

MODE CHANGE BACKUP
STARTUP BACKUP
RETRY CYCLE
DURING ALARM BACKUP
SPECIFIC INPUT BACKUP
Output the Backup Processing Status

Able to confirm the backup processing status by the system output signal.
<#50766> It is creating the auto backup data.
When this signal is turned ON, it is creating the backup data.
Some operations are limited. For example, the start signal is not accepted.
<#50767> It is transferring the backup data.
When this signal is turned ON, writes the data to the CompactFlash after
creating the backup data. Do not remove the CompactFlash from the
programming pendant during this period.
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9.3.2.7
9 System Backup
AUTO BACKUP EXTENSION FUNCTION SET Window
Settings
Automatic backup setting is performed by setting the following items on
the AUTO BACKUP SET window:
RESERVE TIME BACKUP
(Setting for performing the backup on what day of the week, every
day, or in a specific cycle)
BASE TIME
BACKUP CYCLE
RETRY CYCLE
MODE CHANGE BACKUP
(VALID/INVALID of the backup when switching the mode from the
teach mode to the play mode)
STARTUP AUTO BACKUP
(VALID/INVALID of the backup when the DX200 is started up)
(VALID/INVALID of the backup when inputting specified signals)
UNIV.OUT NO. ON ERROR
DISPLAY AT EMERGENCY
DURING ALARM OCCURENCE
DEVICE
(Setting of the device to store the automatic backup file)
STORED FILE SETTING
(It is possible to set when CF:Pendant is set in DEVICE.)
When the CF: pendant or CF:Controller is selected on

the auto backup display, the capacity of the CompactFlash
card in the specified device will be checked. Therefore, a
few seconds may be needed to open the setting window.
For the CF: Pendant, an error may occur without seting in
the CompactFlash card.
NOTE
When changing the settings of "STORED FILE SETTING"

or executing "ARRANGE", the files "CMOSBK.BIN" and
"CMOSBK??.BIN" (?? denotes figures) in the
CompactFlash card are changed in name or deleted. If a
certain file of this type is needed to be saved before
changed in name or deleted, evacuate it into a PC, etc.
beforehand.
While an error occurring, the setting of the each item on the
auto backup set display cannot be changed.
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9 System Backup
1.
Turn ON the DX200.

Insert the CompactFlash to the programming pendant, when the
backup is set on the CompactFlash of the programming pendant.

3. Select {PARAMETER} in the main menu.
4. Select {S2C}.
The parameter setting window appears. Set the value of S2C737 to "1".
6. Select {AUTO BACKUP SET}.
The AUTO BACKUP SET display appears.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
A. RESERVE TIME BACKUP

Pressing [SELECT] displays the following list. Select the item from
"SET CYCLE", "EVERY DAY", or the day of the week ("MONDAY" to
"SUNDAY").
Please note that after setting the base time, the backup cycle, and the
retry cycle, select the item from "SET CYCLE", "EVERY DAY", or the
day of the week ("MONDAY" to "SUNDAY").
If "SET CYCLE", "EVERY DAY", or the day of the week ("MONDAY" to
"SUNDAY") is set before setting one of the base time, the backup cycle,
and the retry cycle, "INVALID" is selected for RESERVE TIME BACKUP.
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9 System Backup
"INVALID"
"SET CYCLE"
: RESERVE TIME BACKUP is not performed.

: The automatic backup is performed every
BACKUP CYCLE based on the specified
BASE TIME.
"EVERY DAY"
: The automatic backup is performed at the
specified BASE TIME every day.
"MONDAY" to "SUNDAY" : The automatic backup is performed at the
specified BASE TIME every week.
Setting example for the automatic backup at 11:29 every day
Setting example for the automatic backup at 11:29 on every

Thursday
B. BASE TIME
Specify the reference time to start the automatic backup.
The reference time ranges from 0:00 to 23:59.
C. BACKUP CYCLE
Specify the backup cycle to perform the cyclic back up.
Set the backup cycle in units of minutes. The cycle setting ranges from
10 to 9999 minutes. After the first backup, the following backups are
performed automatically in every BACKUP CYCLE.
When "EVERY DAY" or the day of the week ("MONDAY" to "SUNDAY")
for RESERVE TIME BACKUP is selected, BACKUP CYCLE cannot be
input.
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9 System Backup
D. RETRY CYCLE
Every time the automatic backup is implemented, the memory data in
the controller is obtained, and the data is compared with the original
memory data. If they are not the same, the retry of the automatic
backup is implemented. However, please note that when the device is
not inserted and the automatic backup is failed, for example, the retry is
not executed.
Set the retry cycle in units of minutes. The cycle setting ranges from 0
to 255, and should be shorter than the BACKUP CYCLE. If the value is
the same as or longer than the BACKUP CYCLE, RESERVE TIME
BACKUP cannot set to "VALID".
When it is set to 0, retry will not be performed.
E. MODE CHANGE BACKUP
Set the automatic backup function to be valid or invalid when the mode
is switched from teach mode to play mode.
alternately.
F. STARTUP AUTO BACKUP
Set the backup function to be valid or invalid when the power of the
DX200 is turned ON.
alternately.
G. SPECIFIC INPUT BACKUP
Set the backup function to be valid or invalid when specific input signal
(# 40560) is input (rising edge from 0 to 1).
alternately.
H. UNIV.OUT NO. ON ERROR
Set "1" to the specified user output signal which was specified in this
chapter when the automatic backup error occurs.
The term "automatic backup error" here means that the backup is not
performed successfully before the next backup (including retry operation) starts.
I. DISPLAY AT EMERGENCY
Set the method of notification of the automatic backup error to
"ERROR" or "MESSAGE."
Each time [SELECT] is pressed, "ERROR" and "MESSAGE" are displayed alternately.
J. DURING ALARM OCCURENCE
Set the backup function to be valid or invalid when an alarm occurs.
alternately.
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9 System Backup
K.DEVICE
Press {SELECT} to display the device list.
The Device Name in Display
Explanation
CF: pendant

of the programming pendant.
CF: controller

of the YCP21 board. When the CF:
controller of the device name is not
shown, refer to 9.3.2.2 the
CompactFlash of the YCP21.
RAMDISK
It will be shown when the optional

function of High Speed Ethernet
Server function is effective. It can
back up by the DX200 high speed
ethernet server function command.
Refer to the [DX200 Instruction
HIGH-SPEED ETHERNET SERVER
FUNCTION].
USB1: controller

the YCP21 board.
USB2: controller

the YCP21 board.
L. STORED FILE SETTING

Set the number of files to be stored by the automatic backup function.
The number mentioned on the right side of this item with "(Max)" indication is the maximum number of files that can be stored in the CompactFlash inserted when this window is displayed.
The settings range from 1 to (Max). When this setting value is changed,
the backup file arrangement starts. (Max is 100.)
M. BACKUP FILES
Indicates the existence of the files or the number of backup files stored
in the CompactFlash inserted when this window is displayed.
N. LATEST BACKUP FILE
Indicates the date of the latest file in the CompactFlash inserted when
this window is displayed.
O. ARRANGE
When the setting of maximum number of stored files is changed, the file
arrangement of the backup files in the CompactFlash is executed.
With this operation, the file arrangement can be performed without
changing the maximum number of stored files.
ARRANGE will not be displayed when the device of the CF: controller is
set on.
7. Set the desired item, and press [ENTER].
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9 System Backup
Window Settings
RS parameter can restrict the settings of some items in the automatic
backup window.
When setting the bit of RS096 parameter shown below to "1", the
corresponding items are restricted. The restricted items are indicated with
"INVALID" in the display and inputting/modification to the item becomes
impossible. Also, the automatic backup does not function with the
restricted items.
D7 D6 D5 D4 D3 D2 D1 D0
RESERVE TIME BACKUP

MODE CHANGE BACKUP
STARTUP BACKUP
RETRY CYCLE
DURING ALARM BACKUP
Output the Backup Processing Status

Able to confirm the backup processing status by the system output signal.
<#50766> It is creating the auto backup data.
When this signal is turned ON, it is creating the backup data.
Some operations are limited. For example, the start signal is not accepted.
<#50767> It is transferring the backup data.
When this signal is turned ON, writes the data to the CompactFlash after
creating the backup data. Do not remove the CompactFlash from the
programming pendant during this period.
NOTE
When the value of the parameter S2C737 is changed from

"0" to "1" or "1" to "0", the setting details of RESERVE TIME
BACKUP are not taken over, but the others are.
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9 System Backup
9.3.3
9.3.3.1
Limiting the Automatic Backup File Creation
Setting to Limit the Automatic Backup File Creation

It is applicable from version DN1.60-00 to limit the backup file creation
executed by the automatic backup function to once a day.
To limit the backup file creation to once a day, set the following parameter.
Parameter number
Contents
Setting value
S0C682
Limits the backup file creation

executed by the automatic backup
function to once a day.
0 (Invalid)
1 (Valid)
When the automatic backup function is requested to start in

the state of limiting the automatic backup file to once a day,
an error occurs to notify that the backup has not been
processed.
NOTE
To avoid the above error, set DISPLAY AT EMERGENCY to

message.
For the setting of DISPLAY AT EMERGENCY, refer to
section 9.3.2.6 AUTO BACKUP SET Display and section
9.3.2.7 AUTO BACKUP EXTENSION FUNCTION SET
Window.
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9 System Backup
9.4 Loading the Backup Data from the CompactFlash
9.4
Loading the Backup Data from the CompactFlash

To restore the backup memory in the auto backup function is done in the
maintenance mode. Otherwise, restore from the CompactFlash of the
programming pendant or USB memory when backup is done at the
optional high speed ethernet server function command. Prepare either of
the CompactFlash or the USB memory to make copies.
9.4.1
Loading Procedure
To restore from the CompactFlash of the programming pendant, perform
the following procedures No.1 to 8. To restore from the CompactFlash on
the YCP21 board, perform the following procedures from No.9.
For the USB memory, select one among the USB: pendant, USB1:
controller and USB2: controller in the {EX. MEMORY} -{DEVICE} to
restore.
1. Insert the CompactFlash with the backup data in the CompactFlash
slot on the programming pendant.
(When selecting USB1: controller or USB2: controller, insert it in the
YCP21 board.)
The backup data is stored under the file name "CMOSBK.BIN" or
"CMOSBK??.BIN" (?? denotes figures.)
4. Select {EX. MEMORY} under the main menu.
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9 System Backup
When set the {SYSTEM}- {SETUP}- {OPTIONAL FUNCTION}{AUTO BACKUP (YCP21)} as USE, the following sub menu
appears.
5. Select {SYSTEM RESTORE}.

The BACKUP FILE LIST display appears.
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9 System Backup
6. Select the file to be loaded.
The dialog box appears for the YIF/YCP21 board replacement
confirmation.
Select {YES} if the YIF/YCP21 board has been replaced, or select

{NO} if it has not been replaced.
Selecting {YES} initializes the system monitoring time.
Selecting {NO} continues the counting of the current systems
monitoring time.
7. Select from the confirmation dialog box.
The dialog box appears for the loading confirmation.
Select {YES} in the loading confirmation dialog box to start loading

the contents of "CMOSBK.BIN" or "CMOSBK??.BIN" (?? denotes
figures) from the CompactFlash to the DX200 CMOS.
8. Select {YES}.
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9 System Backup
9. Turn the power on, while pressing the [MAIN MENU].
11. Select {External memory} in the main menu.
The sub menu will appear. .
12. Select {SYSTEM RESTORE (YCP21)}.

The backup-file list display will appear.
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9 System Backup
13. Select desired date file.
The YIF/YCP21 board dialog will appear.
Select [YES] when exchanged the YIF/YCP21 board. If not, select

[NO].
When select [YES], cumulative time display will be initialized. For
selecting [NO], cumulative time display will continue.
14. Select from the confirmation dialog box.
The dialog box appears for the loading confirmation.
Selecting [YES] in the confirmation dialog starts loading the content

of [CMOSBK.BIN] to CMOS of the YCP21 board.
15. Select [YES].
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9 System Backup
CAUTION
Note that executing "SYSTEM RESTORE" or SYSTEM RESTORE
(YCP21) replaces the current CMOS data with the data of the file
"CMOSBK.BIN" or "CMOSBK??.BIN" (?? denotes figures) in the
CompactFlash.
After "CMOSBK.BIN" has been loaded, check if the new data is the
same as the previously saved data in the CMOS, and call the master
job to confirm that the current manipulator position is correct and safe.
Then, start moving the manipulator.
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9.5 Error List
9.5
9.5.1
Error List
Error Contents
Error Data Message
Cause
No.
0770
3390
The robot or the station is in

motion.
The automatic backup would

not work when the robot or a
manipulator is in motion.
File not found
The file to be loaded no longer

exists.
The capacity of the
CompactFlash is 128MB.
Change the CompactFlash to
256MB.
3430
I/O error on the drive
3460
Cannot backup CompactFlash
Insufficient capacity of the

CompactFlash
Cannot access the

CompactFlash
3501
Confirm the status of

CompactFlash.
Cannot access the

CompactFlash
3550
The automatic backup is

executed. Try it later.
The automatic backup window

cannot be called to display while
the automatic backup is being
processed.
3551
The automatic backup is

executed. Arrange the file after
it is finished.
The file arrangement cannot be

operated during the automatic
backup operation.
3560
Failed to re-arrange the backup

file.
Failed to re-arrange the backup

file for another reason than the
access to CompactFlash.
3580
Accessing to backup file. Try it

later.
To display another window and

then display the automatic
backup window again after
"ARRANGE" operation,
ARRANGE process should be
completely finished.
3581
Accessing to backup file. Try

"ARRANGE"operation later.
The previous "ARRANGE"

process should be completely
finished to perform the next
"ARRANGE" operation.
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10 Upgrade Function
10.1 Functional Overview
10 Upgrade Function
10.1
Functional Overview
DX200 applies two software for the CPU configuration: a software for
YCP21 (for the main CPU board) and a software for YPP (for
programming pendant). The system works only with the combination of
certain versions due to a compatibility problem of each software.
Therefore, with the system version NS3.00 and the subsequent versions,
DX200 can upgrade the software for YPP if the combination of the
software for YCP21 and YPP is invalid.
10.2
Upgrade Procedure
10.2.1 Confirmation of Software Version

The compatibility of the versions of YCP21 and YPP are automatically
checked in 20 seconds after the DX200 power supply is turned on.
In case the versions of YCP21 and YPP matches.

1. Automatic upgrade process completes and the communication
process between YCP21 and YPP is restarted.
2. Initial window appears approx. 45 seconds later.
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10 Upgrade Function
10.2 Upgrade Procedure
10.2.2
Automatic Upgrade of YPP

In case that the pendant application version of YPP is older than the one
of YCP21 or the pendant application version of YPP is not compatible to
the one of YCP21, the YPP is automatically upgraded.
Not only the application software but the OS of the Programming Pendant
is also upgraded automatically.
(OS: Operating System)
1. After the automatic upgrade process is completed, the communication

process between YCP21 and YPP is restarted.
Some upgraded software require restart.
In this case restart is done automatically and the communication
process between YPP and YCP21 starts again.
2. Initial window appears approx. 45 seconds later.
NOTE
Every time the OS is upgraded automatically, restart is

done. There is no need of calibrating because the
calibration data is taken over.
NOTE
If start the DX200 without the auto upgrade process, press

all of the [Interlock]+[5]+[Select] keys at the same time to
start.
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10 Upgrade Function
10.2 Upgrade Procedure
DO NOT turn off the main power supply during automatic

upgrade process.
In case the main power supply is turned off, exercise the
following process.
Turn on the main power supply of DX200.
Automatic upgrade might be exercised again.
In case error occurs during automatic upgrade process.
NOTE
(1) Prepare CF for upgrading or USB memory.

(2) Press [2], [8] and [HIGH SPEED] at the same time.
-Upgrade of the OS of Programming Pendant
(3) Press [INTERLOCK], [8] and [SELECT] at the same
time.
(4) Exercise manual upgrading.
- Refer to DX200 Upgrade Procedure
(165560-1CD).
If no recovery is made with all the procedure above,
replace the pendant.
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10 Upgrade Function
10.3 Error Message
10.3
Error Message
If Error occurs while automatic upgrading, exercise the following
procedure.
Turn on the main power supply of DX200.

Automatic upgrade might be exercised again.
In case error occurs during automatic upgrade process.

(1) Prepare CF for upgrading or USB memory.
(2) Press [2], [8] and [HIGH SPEED] at the same time.
-Upgrade of the OS of Programming Pendant
(3) Press [INTERLOCK], [8] and [SELECT] at the same time.
(4) Exercise manual upgrading.
-Refer to DX200 Upgrade Procedure (165560-1CD) for detail.
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11 Programming Pendant
11.1 Disconnection Function
11.1
Disconnection Function
Disconnection function enables to cut off the communication between the
programming pendant and the controller.
1. Long press [Simple Menu] key to show the pop-up menu.
2. Select Disconnect button, and the confirmation dialog appears.
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11.1 Disconnection Function
3. Select YES to disconnect the communication between the controller
and the programming pendant. After disconnecting the
communication, the message is displayed.
4. Press OK on the message dialog, otherwise the window is closed

automatically after 10 seconds since the window appears on the
screen, and then the programming pendant startup window is
displayed.
When connecting the controller and the programming pendant again,
press Connect to DX200 button.
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11.2 Reset Function
11.2
Reset Function
Reset function enables to restart only the programming pendant while the
main power supply of the controller is ON.
If unable to operate the robot by the programming pendant causing from
the communications error of the programming pendant, recover the
programming pendant by following procedures.
5. Confirmation of the LED (DS1) display on the JANCD-YIF01- E
Check the LED display on the JANCD-YIF01- E.
Check that an alphabet letter or a number is displayed on

the LED display.
SUPPLEMENT
Check that a dot is displayed at the lower right of the LED.

If it is, check that the dot is blinking or lighted.
If the displayed alphabet or the number is continuously
changing, write down them in order.
6. Reset the programming pendant

Open the CF slot cover on the programming pendant.
There is a small hole below the CF insertion slot. Insert a spit to
press inside the hole.
The programming pendant is rebooted and it starts connecting to the
controller again.
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11.3 Touch Panel Invalidate Function
11.3
Touch Panel Invalidate Function

The touch panel invalidate function enables to invalidate the touch panel
operation of the programming pendant (key operation is still valid).
Even if the touch panel is failure, it is able to prevent the mis-operation by
using this function.
Operate the following procedures to valid/invalid the touch panel.
Invalidate the Touch Panel

1. Push down the [INTER LOCK]+[AUX] keys at the same time.
The confirmation dialog to invalidate the touch panel appears.
2. Move the focus area over the YES on the confirmation dialog by
using [] key.
3. Press [Select] key. The touch panel becomes invalid.
When the touch panel is invalid, an icon, which shows the invalidating
the touch panel, is displayed on the status area, and the message
Touch operation is invalid is displayed on the message area.
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11.3 Touch Panel Invalidate Function
Validate the Touch Panel

1. Push down the [INTER LOCK]+[AUX] keys at the same time.
The confirmation dialog to validate the touch panel appears.
2. Move the focus area over the YES on the confirmation dialog by
using [] key.
3. Press [Select].
The touch panel become valid.
NOTE
In the case of invalidating the touch panel, the touch

panel invalidating status continues even though the
power supply is turned ON/OFF.
To validate the touch panel again, push down the

[INTER LOCK]+[AUX] keys at the same time, and then
validate the touch panel on the confirmation dialog.
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12 Modification of System Configuration

12.1 Addition of I/O Modules

12.1
Addition of I/O Modules

To add I/O modules, turn OFF the power supply.
SUPPLEMENT
Addition operation must be performed in the management

mode.
In the operation mode or editing mode, only reference of
status setting is possible.

simultaneously.
2. Change the "SECURITY MODE" to the "MANAGEMENT MODE".
The system window appears.
4. Select {SETUP}.
The SETUP window appears.
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5. Select {IO MODULE}.
The current status of the mounted I/O module is shown.
6. Confirm the status of mounted I/O module.

Confirm that each station (ST#) window is the same as the I/O
modules actual mounting status.
The following information is shown for each station.
ST#
Station address of I/O module
DI
Number of contact input points1)
DO
Number of contact output points1)
AI
Number of analog input points1)
AO
Number of analog output points1)
BOARD
Circuit board type2)
1) A hyphen, -, indicates that the corresponding I/O section is not mounted.

2) If the system cannot recognize the circuit board type, a row of stars (*****) are
shown. No problem will occur as long as the values displayed in DI, DO, AI, and
AO are correct.
7. Press [ENTER].
Confirm the statuses of the mounted I/O modules for the other
stations.
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8. Press [ENTER].
The confirmation dialog box is shown.
9. Select {YES}.
The system parameters are then set automatically according to the
current mounted hardware status, and the window will be changed
to the external I/O setup window.
NOTE
If there is a difference between the displayed contents and

the actual mounted status, confirm the status again. If the
status is correct, the I/O module may be defective: in such a
case, contact your Yaskawa representative.
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12.2 Allocating External I/O Signal
12.2
Allocating External I/O Signal

1. The EXTERNAL IO SETUP window appears.
2. Select AUTO or MANUAL under the ALLOCATION MODE.

The selected menu appears.
NOTE
When the allocation mode is changed from MANUAL to

AUTO, the set allocation data is discarded, and reallocation in the Auto mode takes place.
If it is necessary to save the set allocation data, save it
using the external memory menu in advance.
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3. Select the allocation mode to set.
To operate the I/O signal allocation automatically, select the
allocation mode AUTO.
To operate the I/O signal allocation manually, select the allocation
mode MANUAL.
Selected allocation mode appears.
4. Select DETAIL under the EXTERNAL IO ALLOCATION.

The External Input Signals Allocation window appears.
When select the AUTO, skip the following procedures from No. 5
to No. 7. Operate from the procedure No. 8.
S for the allocation mode MANUAL, operate the following
procedures.
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5. Select the external input signal number (at the change source) to be
changed. (In the setting example, select #20010.)
The select menu appears.
6. Select MODIFY, and input the external input signal number (at the
change destination) to be changed. (In the setting example, enter
20190.)
The external I/O signal is changed.
7. Likewise, select/modify the number of the external input signal.

Repeat select/modify until it becomes the desired allocation.
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8. Press [ENTER].
The External Output Signals Allocation window appears.
9. Like the case of the external input signal, select/modify the external
output signal.
Repeat select/modify until it becomes the desired allocation.
10. Press [ENTER].
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11. Select {YES}.
The settings are confirmed, and the SETUP window reappears.
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Explanation about the External I/O Signal Allocation Window
The details of the window are explained using the window example. The
range over which the cursor can move is the hatched area of the figure.
EXTERNAL IO ALLOCATION(INPUT)
ST# CH MAC ID ADDRBYTE NAME
#20010
14
16
16
YSF21
#20060
#20070
0
0
254
1
0
1
1
5
DN4-PCU-1
DN4-PCU-1
#20120
16
DN4-PCU-1
#20160
#20190
16
17
0
0
3
254
10
0
3
1
DN4-PCU-1
CCS-PCU
#20200
17
CCS-PCU
External I/O signal numbers

Indicates the beginning number of the external I/O signals allocated to
each I/O area. On the allocation window, the set values of these items
are used and displayed in ascending order. The following contents are
displayed.
#20010 to #25120: The number of the signal allocated to the beginning
of each I/O area, in the input signals
#30010 to #35120: The number of the signal allocated to the beginning
of each I/O area, in the output signals
#----: Unallocated I/O area
ST#
Indicates the DX200 station number allocated to each I/O board. The
displayed contents include the following:
0
: General I/O board (JANCD-YIO21)
1 to 13: Optional I/O board which is connected to the JANCD-YSF21

using a serial communication cable (The serial communication
station number is determined by the rotary switch setting on
each board.)
16
17
: The first field bus board

(Normally, optional board inserted into CN1 of the riser card in
the CPU rack.)
: The second field bus board
(Normally, optional board inserted into CN2 of the riser card in
the CPU rack.)
CH
Indicates the channel number (network communication system) on the
board. The following contents are displayed.
0: I/O area for channel 1
1: I/O area for channel 2
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MAC ID
Indicates the network communication station number set in the channel
concerned on the board concerned. Regarding station numbers that
cannot be displayed, or station numbers that do not need to be displayed, 0 is displayed. The following contents are displayed.
0
: No station number, or network communication station number 0
Scanner station of EtherNet/IP board (PCU-ETHIO)
1 to 251 : Network communication station number 1 to 251
Adapter station of EtherNet/IP board (PCU-ETHIO)
(Scanner allocation number sequence)
252
: Unallocated I/O area of channel 1
253
: Unallocated I/O area of channel 2
254
: Communication status area of channel 1
255
: Communication status area of channel 2
ADDR
Indicates the offset address from the beginning of each I/O area when
the inside of each I/O area is further divided into multiple parts.
BYTE
Indicates the size (number of bytes) inside each I/O area.
NAME
Indicates the name of each I/O board.
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12.3 Addition of Base and Station Axes
12.3
Addition of Base and Station Axes

To add the base and station axes, mount all hardware correctly and then
execute maintenance mode.
SUPPLEMENT
Addition operation must be performed in the management

mode.
In the operation mode or editing mode, only reference of
status setting is possible.
When adding a base and a station axis, set the following items:
TYPE
Select one in the type list.
In case of base axis (B1,B2,B3...B8)
Select one of RECT-X, -Y, -Z, -XY, -XZ, -YZ or -XYZ.
In case of station axis (S1,S2,S3,S4,S5... S24)
Select UNIV-* ("*" represents the number of axes) when using a
mechanism other than the registered type as a station axis.
CONNECTION
In the CONNECTION window, specify the SERVOPACK which is
connected with each axis group, the contactor which is used for the
SERVOPACK, and the overrun signal (OT).
AXIS TYPE
Select from the axis type list.
In case of TURN-* type
No need to select (The axis type is set as TURN type.)
In case of RECT-* type
Select BALL-SCREW type or RACK & PINION type.
In case of UNIV-* type
Select BALL-SCREW type, RACK & PINION type or TURN type.
MECHANICAL SPECIFICATION
If axis type is ball-screw type, set the following items:
MOTION RANGE (+)
[mm]
MOTION RANGE (-)
[mm]
REDUCTION RATIO (numerator)

REDUCTION RATIO (denominator)
BALL-SCREW PITCH
[mm/r]
If axis type is rack & pinion type, set the following items.
MOTION RANGE (+)
[mm]
MOTION RANGE (-)
[mm]

PINION DIAMETER
[mm]
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If axis type is turn type, set the following items.
MOTION RANGE (+)
[deg]
MOTION RANGE (-)
[deg]

OFFSET (1st and 2nd axis)
[mm]
MOTOR SPECIFICATION
Set the following items.
MOTOR
SERVO AMP
CONVERTER
ROTATION DIRECTION
[normal/reverse]
MAX. RPM
[rpm]
ACCELERATION SPEED [sec]

INERTIA RATIO
* Select MOTOR, AMPLIFIER and CONVERTER from each type list on the
display.
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12.3.1
12.3.1.1
Base Axis Setting
Selection of Base Axis Type

Select the type of base axis to be added/modified.
simultaneously.
2. Change the "SECURITY MODE" to the "MANAGEMENT MODE".
The system window appears.
4. Select {SETUP}.
The SETUP window appears.
Note that the items marked with "" cannot be set.
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5. Select {CONTROL GROUP}.
The current control group type is displayed.
6. Move the cursor to the type of control group to be modified, and press
[SELECT].
The MACHINE LIST window is displayed.
RECT-X: traverse X-axis base
RECT-Y: traverse Y-axis base
RECT-Z: traverse Z-axis base
RECT-XZ: traverse XZ-axis base
RECT-XY: traverse XY-axis base
RECT-XYZ: traverse XYZ-axis base
(See the figures on the next page)
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7. Select one in the type list.
After the type selection, the window returns to the CONNECT
window.
RECT-Y
RECT-X
RECT-Z
Y
X
Y
X
CARTESIAN
Y-AXIS
CARTESIAN
X-AXIS
Base axis direction of travel coincides
with robot coordinate X-Axis.
RECT-XY

with robot coordinate Y-Axis.
RECT-YZ
Y
X
CARTESIAN
Y-AXIS
CARTESIAN
Z-AXIS
CARTESIAN CARTESIAN
X-AXIS
Y-AXIS
Base 1st and 2nd axes directions of
travel coincide with robot coordinate
X-Axis and Y-Axis, respecitively.

with robot coordinate Z-Axis.
RECT-XZ
Z
CARTESIAN
Z-AXIS

Y-Axis and Z-Axis, respectively.
RECT-XYZ
CARTESIAN
X-AXIS
CARTESIAN
Z-AXIS
X-Axis and Z-Axis,respectively.
CARTESIAN
Z-AXIS
Y
X
CARTESIAN CARTESIAN
Y-AXIS
X-AXIS
Base 1st, 2nd, and 3rd axes directions

of travel coincide with robot coordinate
X-Axis, Y-Axis, and Z-Axis, respectively.
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12.3.1.2 Connection Setting

In the CONNECT window, it is specified that each axis of each control
group is connected to which connector of the SERVO board, which break
of the contactor unit, which converter, and which overrun signal.
1. Confirm the type of each control group in the CONNECT window.
The connection status of each control group is displayed.
[CONNECT(STO) window]
[CONNECT (CONTACTOR) window]
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2. Select the connection item of a desired control group.
The settable items are displayed.
Select an item to change the setting. Select {Cancel} to return to the
CONNECT window.
[CONNECT (STO) window]
Specify which connector (CN) of the SERVO board each axis of

each control group is connected to.
The numbers in [ ] represent axis numbers, and indicate which axis
is connected to which connector.
Specify which break (BRK) of the each control group is connected
to.
The numbers in [ ] represent the axis numbers, and indicate which
axis is connected to which break.
Specify which converter (CV) each axis of each control group is
connected to.
The numbers in [ ] represent the converter numbers, and indicate
which axis is connected to which converter.
Specify which on enable signal (ON_EN) each control group is
connected to.
Specify which overrun signal (OT) each control group is connected
to.
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Specify which break (BRK) of the contactor unit each axis of each
control group is connected to.
connected to.
to.
In this example, B1 (Base) is connected in the following manner:
1st axis
SERVO Board (SV #2),
Connector (7CN),
Contactor Unit (TU #1),
break Connector (BRK7),
Converter (CV #1)

2nd axis
Connector (8CN)
break Connector (BRK8)
Converter (CV #2)

3rd axis
Connector (9CN)
break Connector (BRK9)
Converter (CV #3)

Overrun
(OT2)
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3. Therefore, when an overrun alarm occurs, the subcode is indicated by
the control group.
However, select NOT CONNECT if an overrun switch is not installed
to the control group or the allocation of the external axis overrun signal
is not needed.
Regarding the connection of the external axis overrun signal, refer to
section 14.7 Universal I/O Circuit Board (JANCD-YIO21-E) on page
14-38.
4. Select a desired item.
5. Press [ENTER] in the CONNECT window.
The setting in the CONNECT window is completed and the window
moves to the AXES CONFIG window.
An error massage Error 8217 Cannot change setting.

Check the setting of spot high speed spec. may appear
when press [ENTER] in the CONNECT window.
SUPPLEMENT
When the error massage appears, invalid SPOT HIGH

SPEED SPEC or review the configuration of the control
group by referring to section 9.12 High Speed Spot Welding
Function at DX200 OPERATORS MANUAL FOR SPOT
WELDING USING MOTOR GUN.
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12.3.1.3 Axis Configuration Setting

The axis type is specified in the AXES CONFIG window.
1. Confirm axis type of each axis in the AXES CONFIG window.
The axis type of each axis is displayed.
2. Select the axis type to be modified.

(1) The settable axis type is displayed.
(2) Select "BALL-SCREW" when the servo track is ball-screw type,

and "RACK&PINION" when the servo track is rack & pinion type.
After the selection, the window returns to the AXES CONFIG window.
(3) Select the axis type.
3. Press [ENTER] in the AXES CONFIG window.
4. The setting in the AXES CONFIG window is completed and the
window moves to the MECHANICAL SPEC window.
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12.3.1.4

Mechanical Specification Setting

The mechanical data is specified in the MECHANICAL SPEC window.
1. Confirm specification of each axis in the MECHANICAL SPEC window.
The mechanical specification of axis is shown.
The MECHANICAL SPEC window (in case of the BALL-SCREW type)
Selected group,
type, axis no.,
and axis type
are shown.
MOTION RANGE
: Input maximum moving position (positive (+)

direction and negative (-) direction) from
home position when setting the home
position to 0. (Unit: mm)
REDUCTION RATIO : Input the numerator and the denominator.

<e.g.> If the reduction ratio is 1/2, the
numerator should be set as 1.0 and the
denominator should be set as 2.0.
BALL-SCREW PITCH: Input the traveling length when the ballscrew rotates once. (Unit: mm/r)
The MECHANICAL SPEC window (in case of the RACK&PINION type)
Selected group,
type, axis no.,
and axis type
are shown.
MOTION RANGE

home position when setting the home position
to 0. (Unit: mm)
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REDUCTION RATIO: Input the numerator and the denominator.
<e.g.>If the reduction ratio is 1/120, the
PINION DIAMETER : Input the diameter of a pinion. (Unit: mm)
2. Select the item to be modified.
Point the cursor to the item subject for setting value modification,
and press [SELECT].
3. Modify the settings.
The selected item is in the input status.
Input the setting value, and press [ENTER].
4. Press [ENTER] in the MECHANICAL SPEC window.
After the setting, the current window moves to the window for the
next axis setting. Complete the settings for all axes in the same
manner.
When [ENTER] is pressed in the MECHANICAL SPEC window for
the last axis, the setting in the MECHANICAL SPEC window is
completed and the window moves to the MOTOR SPEC window.
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12.3.1.5

Motor Specification Setting

The motor data is specified in the MOTOR SPEC window.
1. Confirm specification of each axis in the MOTOR SPEC window.
The motor specification of each axis is displayed.
2. Select the desired item.

When a numerical value is selected, the number input buffer line
appears.
When MOTOR (or SERVO AMP or CONVERTER) is selected, the
list window of MOTOR (SERVO AMP, or CONVERTER) appears.
ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The counterclockwise view from the
loaded side is the normal rotation.)
Fig. 12-1: AC Servo Motor
Normal direction
MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)

ACCELARATION TIME: Input time between 0.01 and 1.00 to reach
maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
INERTIA RATIO: The initial value is set at 300 in case of servo track;
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with
the followed procedure.
<Phenomenon1>
During motion, the axis moves unsteady on advance direction.
Confirm the motion with increasing this ratio in each 100.
<Phenomenon2>
During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
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4. Press [ENTER] in the MOTOR SPEC window.
manner.
When [ENTER] is pressed in the MOTOR SPEC window for the last
axis, the setting in the MOTOR SPEC window is completed and the
confirmation dialog box appears.
If {YES} is selected, the system parameter is set automatically.

5. Initialize the related files.
To add and modify the base axis in completed.
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12.3.2
12.3.2.1
Station Axis Setting
Selection of Station Axis Type

Select the type of station axis to be added/modified.
1. Confirm the type of control group in CONTROL GROUP window.
The CONTROL GROUP window appears.
2. Select the type of control group to be modified.

The MACHINE LIST window appears.
TURN-1: TURN 1 AXIS STATION
TURN-2: TURN 2 AXIS STATION
UNIV-1: UNIVERSAL 1 AXIS STATION
UNIV-2: UNIVERSAL 2 AXIS STATION
...
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3. Select desired type in the type list.
After the type selection, the window returns to CONNECT window.
Select "UNIV" (universal) when using a mechanism other than the
registered type (such as a servo track) as a station axis. When
UNIV is selected, interpolation motion (linear, circular, etc.) is not
supported.
TURN-1
STATION 1ST AXIS
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12.3.2.2

Connection Setting
In the CONNECT window, it is specified that each axis of each control
group is connected to which connector of the SERVO board, which break
of the contactor unit, which converter, and which overrun signal.
1. Confirm the type of each control group in the CONNECT window.

2. Connection status of each control group is displayed.Select the
connection item of desired control group.
The settable items are displayed.
Select an item to change the setting. Select {Cancel} to return to the
CONNECT window.
[CONNECT (STO) window]

Specify which break (BRK) of the each control group is connected
to.
connected to.
Specify which on enable signal (ON_EN) each control group is
connected to.
to.
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DX200 Controller


Specify which break (BRK) of the contactor unit each axis of each
control group is connected to.
connected to.
to.
In this example, S1 (Station) is connected in the following manner:
1st axis
Connector (7CN),
Converter (CV #2)

2nd axis
Connector (8CN),
Converter (CV #3)

Overrun
(OT2)
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3. An overrun signal is allocated to a control group. Therefore, when an
overrun alarm occurs, the subcode is indicated by the control group.
However, select NOT CONNECT if an overrun switch is not installed
to the control group or the allocation of the external axis overrun signal
is not needed.
Regarding the connection of the external axis overrun signal, refer to
section 14.7.1 Universal I/O Circuit Board (JANCD-YIO21-E) on
page 14-38.
5. Press [ENTER] in the CONNECT window.
The setting in the CONNECT window is completed and the window
moves to the AXES CONFIG window.
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12.3.2.3 Axis Configuration Setting

The axis type and motor type are specified in the AXES CONFIG window.
1. Confirm axis type of each axis in the AXES CONFIG window.
The axis type of each axis is displayed.
The AXES CONFIG window (in case of the TURN type)
when axis type is

"ROTATION",
the axis type cannot
be changed.
The AXES CONFIG window (in case of the UNIVERSAL type)
BALL- SCREW: Traverse axis

(ball-screw)
RACK&PINION: Traverse axis
(rack&pinion)
ROTATION: Rotation axis
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2. Select the axis type to be modified.
The settable axis type is displayed.
3. Select the desired axis type.

4. Press [ENTER] in the AXES CONFIG window
The setting in the AXES CONFIG window is completed and the
window moves to the MECHANICAL SPEC window.
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12.3.2.4 Mechanical Specification Setting

The mechanical data is specified in the MECHANICAL SPEC window.
1. Confirm specification of each axis in the MECHANICAL SPEC window.
The mechanical specification of axis is shown.
Selected group, type, axis no.

and axis type are shown.
OFFSET is displayed on
the screen of the 1st axis
only when the TURN-2 type
is selected.
MOTION RANGE

direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: deg)

OFFSET
: Offset should be specified at TURN-2 type

only.
Input length between the center of bending
axis (1st axis) and the turning table (2nd axis).
(Unit: mm)
TURN-2
STATION 2ND AXIS

(ROTATION TABLE)
OFFSET
STATION 1ST AXIS
(INCLINATION AXIS)
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The MECHANICAL SPEC window (In case of the BALL-SCREW type)

MOTION RANGE

home position when setting the home
position to 0. (Unit: mm)
REDUCTION RATIO : Input the numerator and the denominator.

BALL-SCREW PITCH: Input the traveling length when the ballscrew rotates once. (Unit: mm/r)
The MECHANICAL SPEC window (In case of the RACK&PINION type)

MOTION RANGE

direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: mm)

<e.g.>If the reduction ratio is 1/120, the
PINION DIAMETER : Input the diameter of a pinion. (Unit: mm)
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The MECHANICAL SPEC window (In case of the ROTATION type)

MOTION RANGE: Input maximum moving position (positive (+)

direction and negative (-) direction) from home position when setting
the home position to 0. (Unit: deg)
<e.g.> If the reduction ratio is 1/120, the numerator should be set as
1.0 and the denominator should be set as 120.0.
3. Press [ENTER] in the MECHANICAL SPEC window.
manner.When [ENTER] is pressed in the MECHANICAL SPEC
window for the last axis, the setting in the MECHANICAL SPEC
window is completed and the window moves to the MOTOR SPEC
window.
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12.3.2.5

Motor Specification Setting

The motor data is specified in the MOTOR SPEC window.
1. Confirm specification of each axis in the MOTOR SPEC window.
The motor specification of each axis is displayed.


When a numerical value is selected, the number input buffer line
appears.
When MOTOR (or SERVO AMP or CONVERTER) is selected, the
list window of MOTOR (SERVO AMP or CONVERTER) appears.
When the type is selected, the window returns to the MOTOR SPEC
window.
ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The counterclockwise view from the
loaded side is the normal rotation.)
Fig. 12-2: AC Servo Motor
Normal direction
MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)

ACCELARATION SPEED: Input time between 0.01 and 1.00 to
reach maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
INERTIA RATIO: The initial value is set at 300 in case of servo track;
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with
the followed procedure.
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<Phenomenon1> During motion, the axis moves unsteady on
advance direction.
Confirm the motion with increasing this ratio in each 100.
<Phenomenon2> During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
CAUTION
If the control axis configuration is changed by addition of a base

axis or station axis, the internal data of the job file are also changed
so that the job file data should be initialized.
Initialize the job file data with procedure File Initialize in this
manual after changing the construction.
When the data, motion range for example, should be changed after
the addition of a base axis or station axis, the change can be done
in the same procedure as shown above.
In this case, the control axis configuration is not changed so the job
file data should not be initialized.
12-36
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13
DX200 Specification
13 DX200 Specification
WARNING
Make sure that there is no one within the P-point maximum envelope of
the manipulator and that you are in a safe place before turning ON the
DX200 power.
the P-point maximum envelope of the manipulator.
Always set the teach lock before starting teaching.

manipulator:
going
closes
the safeguarding.
View the manipulator from the front whenever possible.

door of the DX200 and the programming pendant are pressed.

The emergency stop buttons are located on the right of the front door of
the DX200 and the programming pendant.
13-1
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DX200 Controller
13
DX200 Specification
CAUTION

teaching operations. If problems are found, correct them
immediately, and be sure that all other necessary processing has
been performed.
wires.

after use.
If the programming pendant is inadvertently left on the manipulator,

damage.
system manager.

13-2
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DX200 Controller
13.1 Specification List
13.1
Specification List
Controller Dust/Splash-proof
Construction
IP54 (The back fan is IP2X.)
Dimensions
Refer to the following table
Cooling System
Indirect cooling
Power Supply
3-phase,
200V/220V AC (+10% to -15%) at
60Hz(2%)
200V AC (+10% to -15%) at 50Hz(2%)
Grounding
Grounding resistance: 100 or less

Exclusive grounding
Noise Level
Less than 62 dB
Digital I/O
Specific signal (hardware)

25 inputs and 7 outputs
General signals (standard, max.)
40 inputs and 40 outputs
(Transistor: 32 outputs, Relay: 8 outputs)
Positioning System
By serial communication
(absolute encoder)
Drive Unit
SERVOPACK for AC servomotors
Acceleration/
Software servo control
Deceleration
Memory Capacity
Ambient
Ambient
Conditions
Temperature
200,000 steps, 10,000 instructions

0C to + 45C (During operation)
-10C to + 60C
(During transit and storage)
Relative Humidity
10% to 90%RH (non-condensing)
Vibration
Acceleration
0.5G or less
Others
Free from corrosive gas or liquid, or

explosive gas
Free from exposure to water, oil, or dust
Free from excessive electrical noise
(plasma)
Type
Dimension
Small capacity
600(W) 730(H) 520(D) mm
Medium and Large capacity
600(W) 730(H) 520(D) mm
13-3
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13.2 Function List
13.2
Function List
Programming Coordinate
System
Pendant
Modification of
Operation
Teaching Points
Joint, Rectangular/Cylindrical, Tool, User

Coordinates
Adding, Deleting, Correcting (Robot axes
and external axes respectively can be
corrected.)
Inching Operation
Possible
Path
Forward/Reverse step, Continuous

feeding
Confirmation
Speed Adjustment Fine adjustment possible during operating

or pausing
Timer Setting
Possible every 0.01 s
Short-cut Function Direct-open function, Multi-window
Safety
Feature
Maintenance
Function
Interface
CF card slot, USB port (USB1.1) (At

Programming Pendant)
Application
Arc welding, Spot welding, Handling,

General, Others
Essential
Measures
JIS (Japanese Industrial Standard)
Running Speed
Limit
User definable
Enable Switch
3 position type. Servo power can be

turned on at the middle position only.
(Located on programming pendant)
Collision proof
Frames
S-axis frame (doughnut-sector), Cubic

frame (user coordinate)
Self-Diagnosis
Classifies error and two types of alarms

(major and minor) and displays the data
User Alarm
Display
Possible to display alarm messages for

peripheral device
Machine Lock
Test-run of peripheral devices without

robot motion
Door Interlock
A door can be opened only when a circuit

breaker is OFF.
Operation Time
Display
Control power-on time, Servo power-on

time, Playback time, Operation time, Work
time
Alarm Display
Alarm message, troubleshooting, previous

alarm records
I/O Diagnosis
Simulated enabled/disabled output

possible
T.C.P. Calibration
Automatically calibrates parameters for

end effectors using a master positioner
13-4
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13.3 Programming Pendant
Programing
Functions
Programming
Interactive programming
Language
Robot language: INFORM II
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. fixed motion
Program Control
Jumps, Calls, Timer, Robot stop,

Execution of some instructions during
manipulator motion
Instructions
13.3
Operation
Instructions
Preparing the operation instructions for

each application Arc (ON), Arc (OFF), etc.
Variable
Global variable, Local variable
Variable Type
Byte type, Integer-type, Double precisiontype, Real type, Position type, String type
I/O Instructions
Discrete I/O, Pattern I/O processing
Programming Pendant
Material
Reinforced thermoplastic enclosure with a detachable

suspending strap
Dimensions
169(W) 314.5(H) 50(D) mm (excluding protrusions)
Displayed Units
TFT Color liquid crystal display, VGA (640 480)

Touch panel
Operated Units
Three-position enable switch, start switch, hold switch, and

mode select switch (with key, three mode)
Type of the key for the mode select switch: AS6-SK-132
(manufactured by IDEC Corp.)
* Two keys are shipped with the programming pendant.
Others
Provided with CF (Compact Flash) card slot

USB port (USB1.1) X 1
13-5
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DX200 Controller
13.4 Equipment Configuration
13.4
Equipment Configuration
.
If using a standard DX200 NAS built in the United States

Appendix A replaces this section.
NOTE
The DX200 is comprised of individual units and modules (circuit boards).

Malfunctioning components can generally be easily repaired after a failure
by replacing a unit or a module.
This section explains the configuration of the DX200 equipment.
13.4.1 Arrangement of Units and Circuit Boards
The arrangements of units and circuit boards in small-capacity, mediumcapacity, and large-capacity DX200s are shown.
Small Capacity
Fig. 13-1: Configuration for Small-Capacity
Machine safety
CPU circuit board
JANCD-YSF21-E
Backside duct fan

4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
Machine safety I/O
logic circuit board
Machine safety terminal

block circuit board
JANCD-YFC22-E
Robot I/F
circuit board
Major axes control

circuit board
SRDA-EAXA21A
Brake control
circuit board
JANCD-YBK21-3E
Amplifier module
(Refer to the chap 14.14)
Universal I/O
circuit board
JANCD-YIO21-E
CPU unit
JZNC-YRK21-1E
Control power
supply unit
JZNC-YPS21-E
Emergency stop
button
HW1B-V404R
A
Breaker
NF32-SVF
Power ON unit
JZRCR-YPU51-1
Capacitor module
SRDA-CUA662AA
Regenerative resistor
SMVK500W6R0J A6103
Inside Controller
Back View
Converter
SRDA-COA30A21B-E
Inside Controller
Front View
Sectional View A-A'
Internal air circulation fan

4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
Front Door
Inside View
CPU Unit
CPU Circuit Board
Robot I/F Circuit Board
13-6
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DX200 Controller
Medium and Large Capacity

Fig. 13-2: Configuration for Medium and Large Capacity
Backside duct fan

4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
Machine safety
I/O logic circuit board
Robot I/F
Machine safety
circuit board
terminal block circuit board
JANCD-YFC22-E
Universal I/O
circuit board
JANCD-YIO21-E
CPU unit
JZNC-YRK21-1E
Control power
supply unit
JZNC-YPS21-E
Amplifier module
(Refer to the chap14.14)
Emergency stop
button
XW1E-BV404MR
Breaker
NF32-SVF
Power ON unit
JZRCR-YPU51-1
Capacitor module
SRDA-CUA133AA
SMVK500W2R0J A5978
Inside Controller
Back View
Converter
SRDA-COA30A21B-E
Inside Controller
Front View
Sectional View A-A'
Heat exchanger
TCSIP-16A4Y-OC
Front Door
Inside View
CPU Unit
CPU Circuit Board
Robot I/F Circuit Board
Control Power Supply Unit
Machine Safety I/O Logic Circuit Board
Machine Safety Terminal Block Circuit Board
Universal I/O Circuit Board
Converter
Capacitor Module
Amplifier Module
Breaker
13-7
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13.4.2 Cooling System of the Controller Interior
The backside duct fan draws in air from the air intake and expels it from
the air outlet to cool the SERVOPACK. The fan mounted inside the door
circulates the air to keep temperature even throughout the interior of the
DX200. Make sure the door of the DX200 is closed when its used to keep
this cooling system effective.
Fig. 13-3: .Cooling System for Small Capacity
Circulation HCP
Backside Duct Fan
Air Intake
Air Outlet
Fig. 13-4: Cooling System for Medium and Large Capacity
Heat exchanger
Backside Duct Fan
Air Intake
Air Intake
Air Outlet
Air Outlet
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14
Description of Units and Circuit Boards
14 Description of Units and Circuit Boards
WARNING

door of DX200 and the programming pendant are pressed.

stopped in case of an emergency. The emergency stop buttons are
located on the right of the front door of DX200 and the programming
pendant.
Always set the teach lock before starting teaching.

manipulator:
going inside. Also, display the sign that the operation is
being performed inside the safeguarding and make sure no
one closes the safeguarding.
possible.
When turning ON the power to DX200, be sure that there is no one

within the P-point maximum envelope of the manipulator, and that
you are in a safe place.
the P-point maximum envelope of the manipulator. Always press the
emergency stop button immediately if there are problems.
14-1
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14
CAUTION
teaching operations. If problems are found, correct them immediately,
and be sure that all other necessary processing has been performed.
Check for damage to insulation and sheathing of external wires.

after use.
If the programming pendant is inadvertently left on the manipulator or

damage.
system manager.

14-2
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DX200 Controller
14
Cautions for Connection of Dual Input Signals
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.
DX200
Switch
Input for the robot system

1
-24V2
Turn ON/OFF
at the same time
Input signal 1
Input signal 2
024V
CAUTION
Do not connect two signals to the same contact point.

(Prepare two individual contact points)
Since the power supply for each signal is reversed, it will shortcircuit and may cause breakdown of DX200 Unit if the signals are
connected to the same contact point.
DX200
Switch
Input for the robot system

1
2
The same contact
3
4
-24V2
Input signal 1
Input signal 2
024V
Short-circuit current
14-3
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14.1 Power ON Unit (JZRCR-YPU51- )
14.1
Power ON Unit (JZRCR-YPU51- )

The power ON unit consists of the power ON control circuit board
(JARCR-YPC21-1) and the main circuit contactor and the line filter. It
turns the main circuit control contactor ON and OFF using the signal for
the servo power control from the machine safety I/O logic circuit board,
and supplies power (3-phase AC200/220V) to the converter.
The power supply (single phase AC200/220V) is supplied to the control
power ON unit via the line filter.
Fig. 14-1: Power ON unit Configuration (JZRCR-YPU51- )
(CN607)
Contactor control input connector
(CN608)
Brake interlock output connector
(1FU), (2FU)
Fuse for AC control
power supply
0218010P(10A 250V)
(CN603,CM604,CN605)
AC control power
supply connector
(3FU), (4FU)
Fuse for AC cooling fan
GP25(2.5A 250V)
(CN601)
Main power supply
Input connector
(CN606)
AC cooling fan connector
(CN602)
Main power supply output connector
14-4
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14.2 Axes Control Circuit Board
14.2
14.2.1
Axes Control Circuit Board

Major Axes Control Circuit Board (SRDA-EAXA21A)
The major axes control circuit board controls the servomotors of the
manipulators six axes. It also controls the converter and the PWM
amplifiers. Mounting an external axes control circuit board of an option
(SRDA-EAXB21A) makes it possible to control the servomotor of nine
axes, including the robot axes.
The major axes control circuit board (SRDA-EAXA21A) also has the
following functions.
break power supply control circuit
Shock sensor (shock) input circuit
Direct-in circuit
Fig. 14-2: Major Axes Control Circuit Board (SRDA-EAXA21A)

(CN511)
Machine safety I/O I/F
(CN509)
Control power supply input
(CN513)
Brake control signal
(CN515)
Control communication
(CN507)
Converter I/F
(CN516)
Control communication
(CN510)
DC control power supply
(F1)
PG power supply protective fuse
(CN502)
PWM amplifier 2 I/F
(CN508)
Encoder signal
(CN504)
PWM amplifier 4 I/F
(CN519)
Analog monitor I/F
(CN506)
PWM amplifier 6 I/F
(CN501)
PWM amplifier 1 I/F
(CN503)
PWM amplifier 3 I/F
(CN505)
PWM amplifier 5 I/F
14-5
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DX200 Controller

14.2 Axes Control Circuit Board
14.2.2 External Axes Control Circuit Board (SRDA-EAXB21A)
An external axes control circuit board (SRDA-EAXB21A) is an optional,
and it can control the additional three axes. It can be mounted on the
external axes control circuit board.
Fig. 14-3: External Axes Control Circuit Board (SRDA-EAXB21A)
(CN522)
STO control signal I/F
(CN523)
(CN524)
(CN533)
PWM amplifier 9 I/F
CN531(Lower)
PWM amplifier 7 I/F
CN532(Upper)
PWM amplifier 8 I/F
(CN542) Encorder distribution for
the machine safety system (9th axis)
(CN536)
Encoder I/F (9th axis)
(CN535)
(CN534)
14-6
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14.3 CPU Unit (JZNC-YRK21-1E)
14.3
CPU Unit (JZNC-YRK21-1E)
14.3.1
CPU Unit Configuration

CPU unit consists of circuit board racks (flame, back circuit board, PCI
riser circuit board), CPU circuit board, robot I/F circuit board and the
machine safety CPU circuit board. The JZNC-YRK21-1E CPU unit
contains only circuit board racks and CPU circuit boards. Be sure that it
does not contain robot I/F circuit board and the machine safety CPU circuit
board.
Fig. 14-4: CPU Unit Configuration (JZNC- YRK21-1E)
Robot I/F circuit board
PCI slot for sensor circuit board x 1

(S1) Rotary switch
Machine safety CPU

circuit board
JANCD-YSF21-E
LED
(CN114)
I/O I/F
(Communication with
the optional I/O)
CPU circuit board

JANCD-YCP21-E
(CN107)
Compact flash
(CN106)
USB
(CN113)
(CN105)
For Programming pendant
DriveI/F
(Communication with the
major axes control circuit board)
PCI Slot X2
Battery
Connction terminal for

the grounding
(CN201)
I/O I/F
machine safety I/O logic
circuit board: 1ch side)
(CN203)
I/O I/F
functional safety circuit board)
(CN202)
I/O I/F
machine safety I/O logic
circuit board: 2ch side)
14-7
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DX200 Controller

14.3 CPU Unit (JZNC-YRK21-1E)
14.3.2
14.3.2.1
Unit and Circuit Board in the CPU Unit
CPU Circuit Board (JANCD-YCP21-E)

This circuit board (JANCD-YCP21-E) performs to control the entire
system, display to the programming pendant, control the operating keys,
control operation and calculate interpolation.
14.3.2.2 Robot I/F Circuit Board (JANCD-YIF01- E)

The robot I/F circuit board (JANCD-YIF01- E) controls the entire robotic
system. It is connected to the CPU circuit board (JANCD-YCP21-E) with
a PCI bus interface on the back circuit board, and to the major axes
control circuit board (SRDA-EAXA21A) with high-speed serial
transmissions.
NOTE
Please do not change the factory setting of S1.

(Factory setting is [0] )
14.3.2.3 Machine Safety CPU Circuit Board

This circuit board (JANCD-YSF21-E) performs I/O processing or
diagnosis processing for the safety sequence, and it is connected with the
CPU circuit board (JANCD-YCP21-E) by the PCI Express bus I/F in the
back circuit board.
It is also connected with the machine safety I/O logic circuit board by the
high speed serial communications (two lines).
14-8
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DX200 Controller

14.4 Control Power Supply Unit (JZNC-YPS21-E)
14.4
Control Power Supply Unit (JZNC-YPS21-E)

This unit (JZNC-YPS21-E) supplies the DC power (DC5V, DC24V) for
control (system, I/O, break). It is also equipped with the input function for
turning the control power supply ON and OFF.
Fig. 14-5: Control Power Supply Unit JZNC-YPS21-E

Connection with CPU 1 (CN158)
Connection with CPU 2 (CN159)
(CN156/CN157)
+24V2 Power Supply Output
MonitorAlarm Display
(CN154/CN155)
+24V1/+24V2 Power Supply Output
(CN153)
+24V3 Power Supply Output
(CN151)
AC Power Supply Input
(CN152)
Remote Control
14-9
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14.4 Control Power Supply Unit (JZNC-YPS21-E)
Items
Specifications
Input
Rating Input Voltage:

200/220VAC
Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)
Frequency:
50/60Hz 2Hz (48 to 62Hz)
Output Voltage
DC + 5V
DC +24V (24V1: System, 24V2: I/O, 24V3: break)
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 DX200 controller power, turn ON the non-fuse breaker of the controller
so that the control power supply is turned ON. If the controller is not located at the
workplace, the control power supply can be turned ON/OFF by an external device,
etc. after the non-fuse breaker of the controller is turned ON. It is operated by the
external switch connected with CN152 of the Control power supply unit as shown in
the following figure. (CN152-1 and CN152-2 are short-circuited when shipment)
Fig. 14-6: Connection to Control Power Supply Unit

DX200
Control power supply unit
(JZNC-YPS21-E)
Control Power Supply ON/OFF Switch
CN152
1
R-IN
2
R-INCOM
Remove the short-circuit positioner
See section 14.8 break Control Circuit Board (JANCD-YBK21-3E) on page 14-44
for wiring of CN152 connector.
14-10
RE-CTO-A220
165292-1CD
DX200 Controller

14.5 Machine Safety I/O Logic Circuit Board (JANCD-YSF22 -E)
14.5
14.5.1
Machine Safety I/O Logic Circuit Board (JANCD-YSF22 -E)

Machine Safety I/O Logic Circuit Board (JANCD-YSF22 -E)
This circuit board contains dual processing circuits for safety signal and
the I/O circuit for the un-safety signal.
It processes external safety signals with the dual processing circuits and
control ON/OFF of the main circuit control contactor of the power ON unit
according to conditions.
Followings are the main functions of Machine Safety I/O Logic Unit.
System safety input circuit (dual circuits)
User safety input circuit (dual circuits)
User safety output circuit (dual circuits)
Emergency stop signal input circuit (dual circuits)
Servo power control signal output circuit (dual circuits)
Anti-safety I/O circuit for the robot system
Machine safety terminal block circuit board I/F
Fig. 14-7: Machine Safety I/O Logic Board (JANCD-YSF22 -E)
(F1)
Fuse for protecting
the power supply
1A/250V
(F2)
Fuse for protecting
the power supply
2A/250V
(CN213)
Power supply input connector
(S1/S2)
Rotary switch
(CN211)
I/O I/F
CPU unit: 1ch side)
(CN219)
Machine safety terminal circuit
board I/F connector
(CN212)
I/O I/F
CPU unit: 2ch side)
Connction terminal for

the grounding
(CN214)
Major axes control circuit
board I/F connector
(CN218)
PP I/F connector
(CN217)
Contactor control
output connector
NOTE
(CN215)
OT,SHOCK,LAMP
(CN216)
FANALM,FANCTL
If the F1 fuse becomes blown, it will cause a damage on the

inner circuit of the board. Replace the board instead of
replacing the fuse.
(There is no attached spare of the fuse.)
14-11
RE-CTO-A220
165292-1CD
DX200 Controller

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
1. Disconnect the minus SHOCK (-) and +24V2 pin terminal from the
DINAMIC connector, the machine safety I/O logic circuit board
(YSF22 -CN215). The pin terminal for the shock sensor is attached
on the right side of the controller.
2. Connect the minus SHOCK (-) and +24V2 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.)
+24V2
TMEDN-630809-FA
TMEDN-630809-MA
(manufactured by NICHIFU Co.,
Ltd.)
Fig. 14-8: Direct Connection to Tool Shock Sensor Signal Line

Manipulator
DX200
Machine safety I/O logic
circuit board
TMEDN-630809-FA (NICHIFU)
+24V2
CN215
A3
SHOCK+
TMEDN-630809-MA (NICHIFU)
Shock sensor
(Option)
B3
Shock sensor signal cable
SHOCK-
SHOCKTMEDN-630809-MA (NICHIFU)
The pin terminal for the shock sensor is

attached on the right side of the controller.
14-12
RE-CTO-A220
165292-1CD
DX200 Controller
14.5.2.2

To connect the tool shock sensor with the cable that is built into the manipulator
1. Disconnect the minus SHOCK (-) and +24V2 pin terminal from the
DINAMIC connector, the machine safety I/O logic circuit board
(YSF22 -CN215). The pin terminal for the shock sensor is attached
on the right side of the controller.
2. Connect the minus SHOCK (-) pin terminal to the plus SHOCK(+) pin
terminal of the manipulator.
Cable that is built into the manipulator 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 manipulator.
NOTE
Fig. 14-9: Connection with Manipulator Cable

Manipulator
DX200
circuit board
CN215
A3
+24V2
Shock sensor
(Option)
SHOCK+
B3
SHOCK+
SHOCK-
SHOCKTMEDN-630809-MA (NICHIFU)
Supply cables (PG)
The pin terminal for the shock sensor is

attached on the right side of the controller.
SUPPLEMENT
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. Refer to explanations in chapter 8
System Setup on page 8-1 for details.
14-13
RE-CTO-A220
165292-1CD
DX200 Controller

14.6 Machine Safety Terminal Block Circuit Board (JANCD-YFC22-E)
14.6
Machine Safety Terminal Block Circuit Board

(JANCD-YFC22-E)
The machine safety terminal block circuit board (JANCD-YFC22-E) is for
the system external signal to connect with the safety I/O signals.
For connections, refer to connection diagrams for each corresponding
items.
Fig. 14-10: Machine Safety Terminal Block

(CN219)
circuit board I/F connector
14-14
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-1(a): JANCD-YFC22-E Details for the Connection Terminal

Signal Name Connection Dual
No. (MXT)
input
Function
Factory Setting
SAFF1+
SAFF1-
-1
-2
Safety Plug
Short-circuit with a
jumper cable
SAFF2+
SAFF2-
-3
-4
EXESP1+
EXESP1-
-5
-6
EXESP2+
EXESP2-
-7
-8
EXDSW1+
EXDSW1-
-9
-10
EXDSW2+
EXDSW2-
-11
-12
FST1+
FST1-
-13
-14
FST2+
FST2-
-15
-16
SSP+
SSP-
-17
-18
EXHOLD+
EXHOLD-
-19
-20
EXSVON+
EXSVON-
-21
-22
SYSRUN+
SYSRUN-
-23
-24
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
External Emergency Stop

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.
Applicable
External Enable Switch
jumper cable
Used to connect a Enable switch other than the

one on the programming pendant when two
people are teaching.
Applicable
jumper cable
Full-speed Test
Open
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 signals 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%)
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.
External Servo ON
jumper cable
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.
SYSRUN signal
Open
Use to determine the normal/abnormal condition

of the DX200 controller by SYSRUN signal.
14-15
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-1(b): JANCD-YFC22-E Details for the Connection Terminal

Signal Name
Connection Dual
Function
Factory Setting
No. (MXT)
input
ONEN11+
ONEN11-
-25
-26
Applicable Servo ON Enable
ONEN12+
ONEN12-
-27
-28
ONEN21+
ONEN21-
-29
-30
ONEN22+
ONEN22-
-31
-32
ONEN31+
ONEN31-
-33
-34
ONEN32+
ONEN32-
-35
-36
ONEN41+
ONEN41-
-37
-38
ONEN42+
ONEN42-
-39
-40
OT21+
OT21-
-41
-42
OT22+
OT22-
-43
-44
OT31+
OT31-
-45
-46
OT32+
OT32-
-47
-48
OT41+
OT41-
-49
-50
OT42+
OT42-
-51
-52
PPESP3+
PPESP3-
-53
-54
PPESP4+
PPESP4-
-55
-56
PBESP3+
PBESP3-
-57
-58
PBESP4+
PBESP4-
-59
-60
jumper cable
Connected to use a function which distributes the

robot system to the multiple servo areas, and
turns the servo power ON/OFF.
Applicable
Applicable
Applicable
External Axes Overrun
Open
Used to input the overrun in the external axes

other than the main body of the manipulator.
Emergency Stop Button Contact Output
Open
Used to output a contact point of the emergency

stop button on the programing pendant.
Used to output a contact point of the emergency

stop button on the front door of the DX200 Control
panel.
14-16
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-1(c): JANCD-YFC22-E Details for the Connection Terminal

Signal Name
Connection
Dual
No. (MXT)
input
GSIN11+
GSIN11-
-61
-62
Applicable Universal Safety Input
GSIN12+
GSIN12-
-63
-64
GSIN21+
GSIN21-
-65
-66
GSIN22+
GSIN22-
-67
-68
GSOUT11+
GSOUT11-
-69
-70
GSOUT12+
GSOUT12-
-71
-72
GSOUT21+
GSOUT21-
-73
-74
GSOUT22+
GSOUT22-
-75
-76
GSEDM1+
GSEDM1-
-77
-78
GSEDM2+
GSEDM2-
-79
-80
+24V2U3
-81
-82
-92
-93
-83
-84
-94
-95
AXDIN_COM
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
AXDIN6
-85
-86
-87
-88
-89
-90
-91
AIN_COM
AXIN1
AXIN2
-96
-97
-98
AXOUT1
AXOUT2
-99
-100
024V2
Function
Factory
Setting
Open
The universal safety input signal is used in the safety

logical circuit function.
Applicable
Universal Safety Output
Open
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 signal by the output signal.
-
DC +24V2 output terminal
Open
DC024V2 output terminal
Open
Direct -in (Servo)
Open
Used to input the quick responding signals in the

search function etc.
Universal input (Servo)
Open
Used to input the universal signal from the external

device.
Universal output (Servo)
Open
Used to output the universal signal to the external

device.
14-17
RE-CTO-A220
165292-1CD
DX200 Controller

Wiring Procedure of the Terminal Block

For your safety, appropriate work must be done by following the
instructions below.
1. Tool: Screwdriver
For the connection, be sure to use a screwdriver of an applicable
size and configuration.
* WAGO standard screwdriver
WAGO 210-119
WAGO 210-119SB (Short,
delivered with the product)
2. Applicable Wires
(1) The length of the exposed conductor (L) should be as follows:
L
* The length of the exposed conductor set for the terminal block (L)
WAGO series 250 (with 5.0 mm pitch): 9-10 mm
* Applicable max cable outside diameter: 3.1 mm dia.
(2) In case that the conductor is bent or frayed, make it straight as
illustrated in the figure above.
14-18
RE-CTO-A220
165292-1CD
DX200 Controller

3. Wire Connection
Terminal block: screwless clamp
terminal WAGO series 250
(1) Place the screwdriver on the lever upright as shown in the figure
below and push straight down.
(2) Insert the wire into the connection hole slowly until its leading end
touches the end of the hole.
For thin wires, never insert the wire with force, or the wire
jacket may get caught in.
(3) Pull out the screwdriver to clamp the conductor with a spring.
(4) Check if the wire is connected firmly by pulling the wire softly.
14-19
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.1 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
Jumper cables are installed at the factory. Be sure to remove the

jumper cables before using.
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.
SUPPLEMENT
Because of the its dual circuits signal to input, the alarm

occurs if the signal does not much. However, in the teach
mode, even though the signal does not much, the alarm is
not detected. The alarm is detected only in the play mode.
Fig. 14-11: Connection for Safety Plug

DX200
block circuit board
(JANCD-YFC22-E)
CN219
Safety plug
SAFF_1+
SAFF_1-
SAFF_2+
SAFF_2-
Turn ON/OFF
at the same time
Remove the jumper cable
14-20
RE-CTO-A220
165292-1CD
DX200 Controller

Installation of Safety Plug

The manipulator must be surrounded by a safeguarding and a door
protected by an interlock function. The door must be opened by the
technician to enter and the interlock function stops the robot operation
when the door is open. The safety plug input signal is connected to the
interlock signal from the gate.
Fig. 14-12: Installation of Safety Plug

Manipulator
Working Area
Safeguarding
Servo ON Lamp (Option)
DX200
Safeguarding
Safety Plug
Taked Plug
Emergency
Stop
If the servo power is ON when the interlock signal is input, the servo
power turns OFF. The servo power cannot be turned ON while the
interlock signal is input. However, the servo power does not turn OFF
when the door is opened only during the teach mode. In this case, the
servo power can be turned ON while the interlock signal is input.
14-21
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.2 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


is input.
Fig. 14-13: Connection for External Emergency Stop

DX200

block circuit board
(JANCD-YFC22-E)
CN219
External emergency stop
EXESP_1+
EXESP_1-
EXESP_2+
EXESP_2-
Turn ON/OFF
at the same time
14-22
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.3

This signal is used to connect Enable switch other than the one on the
programming pendant when two people are teaching. In the condition of
the external enable switch ON, when turn the enable switch ON/OFF by
the programming pendant, the servo power is also turned ON/OFF.
However, when turn the external enable switch ON after turning the
enable switch ON by the programming pendant, the servo power is not
turned ON.
CAUTION

Injury or damage to machinery may result because the external

emergency stop do not work even if the signal is input.
Fig. 14-14: Connection for External Enable Switch

DX200
block circuit board
(JANCD-YFC22-E)
CN219
EXDSW1+
10
EXDSW1-
11
EXDSW2+
12
EXDSW2-
Turned ON/OFF
at the same time
14-23
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.4 Full-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 play mode.
If this signals circuit is open, the status 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 (JANCD-YFC22-E), and 15 and 16 as well.
(Normally, each terminal is unwired.)
Fig. 14-15: Connection for Full-speed Test

DX200
block circuit board
(JANCD-YFC22-E)
CN219
Full-speed test
13
FST_1+
14
FST_1-
15
FST_2+
16
FST_2-
Turned ON/OFF
at the same time
14-24
RE-CTO-A220
165292-1CD
DX200 Controller

2. The message "Full-speed test mode" is displayed as follows when the
setting is finished.
Operation Speed
When the full-speed test mode is set, operation speed is set depending on
the setting of manual speed as follows.
At the time of setting the full-speed mode, the setting of manual speed
shifts to Inching automatically.
When changing the setting of manual speed, make sure that there is no
person around the manipulator and pay great attention to perform the
operation.
Manual
speed
Limit of operation speed

(default value)
Parameter (Unit: 0.01%)
Inching
20%
S1CxG60 (default value: 2000)
Slow
50%
Medium
75%
Fast
100% (fixed value)
NOTE
The limit values of operation speed described in the table

above are the ratio against the manipulator'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 against the manipulator's
maximum speed during the test run or FWD/BWD
operation.
Manual full-speed function allows the manipulator to
perform the test run or FWD/BWD operation at the taught
speed by a job during the teach mode. Perform the
operation outside the motion range.
If the full-speed test mode is set or released while a servo
power is ON, the servo power turns OFF.
14-25
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.5 Slow Speed Mode Selection
This signal is 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%)
CAUTION


is input.
Fig. 14-16: Connection for Slow Speed Mode Selection

DX200

Slow speed mode selection

block circuit board
(JANCD-YFC22-E)
CN219
17
SSP+
18
SSP-
14-26
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.6
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.
CAUTION


is input.
Fig. 14-17: Connection for External Hold

DX200

block circuit board
(JANCD-YFC22-E)
CN219
External Hold
19
EXHOLD+
20
EXHOLD-
14-27
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.7 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.
Fig. 14-18: Connection for External Servo ON

DX200
block circuit board
(JANCD-YFC22-E)
CN219
External servo ON
21
EXSVON+
22
EXSVON-
14-28
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.8
SYSRUN Signal Output

This signal is used to check whether the DX200s status is normal or
abnormal.
This signal is output on the following conditions.
ON
Primary power supply OFF

Normal
DX200 status Abnormal

ON
SYSRUN OFF
Fig. 14-19: Connection for SYSRUN Signal Output

DX200
block circuit board
(JANCD-YFC22-E)
CN219
SYSRUN+
23
SYSRUN-
24
SYSRUN+
SYSRUN-
Because the pulse signal is outputted from the specific output signal
(#50911) to the external device for each 100ms, it is also able to check
whether the DX200s control circuit board is normal or abnormal.
Refer to section 4.12 Specific Output Signals of DX200 OPTIONS
INSTRUCTIONS FOR CONCURRENT I/O (165294-1CD) for more
details.
14-29
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.9 Connection for Servo-ON Enable Input
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 Chapter 8 Servo Power Supply Individual Control Function of
Independent/Coordinated Function Instructions Manual for the usage of
the Servo-ON Enable signals.
Fig. 14-20: Connection for Servo-ON Enable Input
DX200
block circuit board
(JANCD-YFC22-E)
CN219
Servo-ON enable input signal
25
ONEN1_1+
26
ONEN1_1-
27
ONEN1_2+
28
ONEN1_2-
Turn ON/OFF
at the same time
14-30
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.10
External Axes Overrun

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.
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, the machine safety signal error occurs.
For the setting of the external axis overrun, refer to section 12.3.1.2
Connection Setting on page 12-16.
CAUTION


is input.
Fig. 14-21: Connection for External Axis Overrun
DX200
block circuit board
(JANCD-YFC22-E)
CN219
External axis overrun
41
OT2_1+
42
OT2_1-
43
OT2_2+
44
OT2_2-
Turn ON/OFF
at the same time
14-31
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165292-1CD
DX200 Controller

The following figure shows the external axis overrun wiring of the factory
default setting when the external axes are connected to the DX200.
Please refer to the following figure to connect the external axes overrun
signal to wire in the another route. On that occasion, confirm the external
axes overrun setting to connect. (Refer to section 12.3.1.2 Connection
Setting on page 12-16. )
Fig. 14-22: Connection for External Axis Overrun (Multiple Lines)
DX200
block circuit board
(JANCD-YFC22-E)
The first line
CN219
41
OT2_1+
42
OT2_1-
Turn ON/OFF
at the same time

The second line
43
OT2_2+
44
OT2_2-
45
OT3_1+
46
OT3_1-
47
OT3_2+
48
OT3_2-
Turn ON/OFF
at the same time

The third line
49
OT4_1+
50
OT4_1-
51
OT4_2+
52
OT4_2-
Turn ON/OFF
at the same time
14-32
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DX200 Controller

14.6.11
Emergency Stop Output

Outputs the contact output terminals for both emergency stop buttons on
the programming pendant and on the front door.
These contact outputs are always valid regardless of the DX200 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.
Fig. 14-23: Output of Emergency Button

DX200
Front door of DX200
block circuit board
(JANCD-YFC22-E)
Emergency
stop button
CN219
PBESP3+
57
PBESP3-
58
PBESP4+
59
PBESP4-
60
PPESP3+
53
PPESP3-
54
PPESP4+
55
PPESP4-
56
PBESP3+
PBESP3PBESP4+
PBESP4-
Programming pendant
Emergency
stop button
PPESP3+
PPESP3PPESP4+
PPESP4-
14-33
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165292-1CD
DX200 Controller

14.6.12
Universal Safety Input

The universal safety input signal is used in the safety logic circuit function.
Fig. 14-24: Universal Safety Input
DX200
block circuit board
(JANCD-YFC22-E)
CN219
61
GSIN1_1+
62
GSIN1_1-
63
GSIN1_2+
64
GSIN1_2-
Turn ON/OFF
at the same time
14.6.13
Universal Safety Output

The universal safety output signal is used in the safety logic circuit
function.
For example, composing the circuit to output the status signal, such as the
servo ON signal or the emergency stop button by the safety logic circuit
function enables to output the signals to the external device.
The signal is outputted as the dual signals, and inputs the status of the
driven devices by the output signal as the monitoring signal.
For the example of use of the universal safety output signal, refer to
section 8.23 Safety Logic Circuit.
Fig. 14-25: Example of Use of Universal Safety Output Signal
DX200
block circuit board
(JANCD-YFC22-E)
Universal safety output 1
Universal safety output 2
Monitoring signal
14-34
RE-CTO-A220
165292-1CD
DX200 Controller

Rated output 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 surge suppressor or connect the flyback
diode in parallel to the inductive load to suppress the
surge voltage.
It may cause the damage on the output circuit.
The feedback signal must be inputted to the DX200

when use the universal safety output signal.
NOTE
14-35
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.14
Connection for Direct-in

Direct-in (Servo) 1 to 6
This signal is used to input a responsive signal in search functions.
Fig. 14-26: Connection for Direct-in (Servo) 1 to 6

Major Axes Control
Circuit Board
(SRDA-EAXA21A)

block circuit board
(JANCD-YFC22-E)
CN219
83,84
Direct-in (Servo) 1
Direct-in (Servo) 2
Direct-in (Servo) 3
Direct-in (Servo) 4
Direct-in (Servo) 5
Direct-in (Servo) 6
024V2
86
AXDIN1
87
AXDIN2
88
AXDIN3
89
AXDIN4
90
AXDIN5
91
AXDIN6
85
AXDIN_COM
81,82
+24V2
Connect the jumper cable.

block circuit board
(JANCD-YFC22-E)
Major Axes Control

Circuit Board
(SRDA-EAXA21A)
CN219
83,84
024V2
86
AXDIN1
87
AXDIN2
88
AXDIN3
89
AXDIN4
90
AXDIN5
91
AXDIN6
85
AXDIN_COM
81,82
+24V2
The
part of wiring is that if there is a slave for the coordinated control side
major axes control circuit board (SRDA-EAXA21A).
14-36
RE-CTO-A220
165292-1CD
DX200 Controller

14.6.15
Universal Input (Servo)

Connect when use the universal signal.
Fig. 14-27: Universal Input (Servo)
DX200
block circuit board
(JANCD-YFC22-E)
Major axes control

circuit board
(SRDA-EAXA21A)
CN219
94,95
024V2
97
Universal input (Servo) 1

AXIN1
98
AXIN2
96
AXIN_COM
92,93
+24V2
14.6.16
Universal Output (Servo)

Connect when use the universal signal.
Fig. 14-28: Universal Output (Servo)
DX200
Major axes control

circuit board
(SRDA-EAXA21A)
Machine safety
terminal block
circuit board
(JANCD-YFC22-E)
CN219
AXOUT1
99

AXOUT2
100
+24V2
92,93
14-37
RE-CTO-A220
165292-1CD
DX200 Controller

14.7 Universal I/O Circuit Board (JANCD-YIO21-E)
14.7
Universal I/O Circuit Board (JANCD-YIO21-E)
14.7.1 Universal I/O Circuit Board (JANCD-YIO21-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 section 14.13 Universal I/O Signal Assignment on page 14-49
for more details on signal allocation.
For the connection of the robots universal I/O signal connectors, and the
I/O signal related to start and stop, refer to Connection wire with Robot
Universal I/O Connector (CN306, 307, 308, 309) on page 14-39 and
Specific I/O Signal Related to Start and Stop on page 14-41.
Fig. 14-29: Universal I/O Circuit Board (JANCD-YIO21-E)
(CN303)
For Switching External Power Supply
F1,F2
Power Supply Protective Fuse
3.15A/250V
(CN304)
Power Supply Output
(CN307)
Digital I/O
(CN309)
Digital I/O
(CN306)
Digital I/O
(CN308)
Digital I/O
14-38
RE-CTO-A220
165292-1CD
DX200 Controller

Connection wire with Robot 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 universal I/O circuit board (JANCD-YIO21-E). Unshielded twisted
pair cable must be used.(The cable side connector and the I/O terminal
block are the options)
Fig. 14-30: Robot Universal I/O Connector (CN306, 307, 308, 309) Connection
Connector A detail (cable side)

B20
B1
A20
A1
Connector C detail (cable side)

B20
B1
A20
A1
Connector Model: FCN-361J040-AU (FUJITSU)

(Soldered Pin type)
Hood Model : FCN-360C040-B (FUJITSU)

Connector Model: 1903404-1
(Tyco Electronics Amp)
(MT Type)
Universal I/O circuit board

(JANCD-YIO21-E)
Connector A
CN309 CN308
I/O Cable (YIO ~ external)
Connector C
CN307 CN306
I/O Cable (YIO ~ Terminal Block)
Connector B
CN306,307,308,309 Connector B details

B1
B20
A1
A20
Connector Model: 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
I/O Terminal block
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
Stripped length: 10mm

Applicable max cable outside diameter: 3mm dia.
Model: TIFS553YS
14-39
RE-CTO-A220
165292-1CD
DX200 Controller

When connecting an inductive load to the output circuit,

connect a flyback (snubber) diode in parallel to the inductive
load to suppress the surge voltage. Not using the flyback
(snubber) diode may damage the output circuit.
When connecting the load with a large inrush current such
as the lamp, connect the current limiting resistor in series to
the load, so that the output current does not exceed its
maximum value. Exceeding the maximum output current
value may damage the output circuit.

(JANCD-YIO21-E)
+24VU
NOTE
Inductive load
Flyback Diode
Current limiting
resistor
Lamp
024VU
Refer to section 14.13 Universal I/O Signal

Assignmentfrom page14-44 to 14-70 about the maximum
current of the transistor and the relay output circuits.
14-40
RE-CTO-A220
165292-1CD
DX200 Controller

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-YIO21-E)
External Servo ON
(common to all application: JANCD-YFC22-E)
External Start
Operating
External Hold
External Emergency Stop

<Timing Chart>
Manipulator
RUN
STOP
ON
While Servo ON OFF
Servo ON
ON
OFF
External Start
ON
OFF
Operating
ON
OFF
External Hold
ON
OFF
Ext. E-Stop
ON
OFF
Note: Set T=100msec or more
14-41
RE-CTO-A220
165292-1CD
DX200 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 manipulator servo power supply. The set and reset timings are shown
in the following.
Fig. 14-31: Example of the Servo ON Sequence Circuit from the External Device
Servo ON PB
Servo ON
confirmation
X2
DX200
Servo ON
command
Servo ON
command

block circuit board
(JANCD-YFC22-E)
Servo power ON
X3 (30011)
Servo ON
confirmation

JANCD-YIO21-E
Note: Number in ( ) means the output signal

number assigned to YIO21.
PL: Pilot Lamp
Servo power ON
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.
Fig. 14-32: Example of Start Sequence Circuit from the External Device
While
Servo ON
Run PB (30011)
Selecting
play mode
(30016)
Alarm/Error
occuring
(30013)
Running
confirmation
X5
DX200
Running
X6 (30010)
Start
(Command)
Ex. Start
Command

(JANCD-YIO21-E)
Running
Confirmation
Running, etc.
External Start
Input
(20011)
Running Output
(30010), etc.
Note: Number in ( ) means the output signal number assigned to YIO21.

PL: Pilot Lamp
14-42
RE-CTO-A220
165292-1CD
DX200 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 universal I/O circuit board.
2. Connect +24V of the external power supply to CN303-1 and 0V to
CN303-2 of the robot I/O unit.
For the connection of the CN303 connector, refer to section 14.12 WAGO
Connector on page 14-48.
Fig. 14-33: Connection of External Power Supply for I/O

(JANCD-YIO21-E)

(JANCD-YIO21-E)
External
Power Supply
CN303
+24VU
1(EX+24VIN) F1
2(EX024VIN) F2
3.15A
CN303
+24VU
+24V
1(EX+24VIN) F1
0V
2(EX024VIN) F2
3.15A
3.15A
3.15A
(Ready by Customer)
024VU
024VU
+24V
+24V
3(+24V)
3(+24V)
4(024V)
4(024V)
024V
024V
In case of using internal power supply

(The factory default settings)
In case of using external power supply
The internal power supply of 24V of about 1.5A of DX200

can be used for I/O.
Use external 24V power supply for higher currents and to
isolate the circuit inside and outside the DX200.
NOTE
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 selected and the external
power supply is connected to CN303-1 to -3 and CN303-2
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.
14-43
RE-CTO-A220
165292-1CD
DX200 Controller

14.8 break Control Circuit Board (JANCD-YBK21-3E)
14.8
break Control Circuit Board (JANCD-YBK21-3E)
14.8.1
break Control Circuit Board (JANCD-YBK21-3E)

The break control circuit board controls ON/OFF of the breaks of total nine
axes (Robot + external axes) according to the command signal from the
major axes control circuit board (SRDA-EAXA21A).
Fig. 14-34: break Control Circuit Board (JANCD-YBK21-3E)

(CN404)
For extenal brake power supply
(CN405)
Axes control circuit board I/F
(CN403)
Brake power supply input
(F1:For external axes)

Brake power supply fuse
3.15A/250V
(CN402)
Brake interlock
(CN401)
Handbrake release unit I/F
(CN400)
Brake I/F
14-44
RE-CTO-A220
165292-1CD
DX200 Controller

14.9 Converter (SRDA-COA30A21B-E)
14.9
Converter (SRDA-COA30A21B-E)
The converter (SRDA-COA30A21B-E) exchanges the power supply (3phase: AC200/220V) supplied by the power ON unit for DC power supply
and supplies the power to the amplifier module (PWM amplifiers).
Fig. 14-35: Converter (SRDA-COA30A21B-E)

(CN555)
Main circuit power
supply input
(CN557)
(CN556)
Main circuit power
supply output
(CN554)
Grounding detection input
(CN553)
Converter control signal
Monitor/Alarm indication LED

(CN551)
DC control power supply
(CN559)
Power supply regenerative
unit connection
(CN558)
External axes main
circuit connection
(CN552A)
Control power supply output
for six axes amplifier
(CN552B)
Control power supply output
for external axes amplifier
Charge lamp
Grounding terminal
14-45
RE-CTO-A220
165292-1CD
DX200 Controller

14.10 Capacitor Module (SRDA-CUA AA)
14.10
Capacitor Module (SRDA-CUA AA)

The capacitor 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: SRDA-CUA133AA
Fig. 14-36: Capacitor Module (SRDA-CUA AA)
Small capacity
SRDA-CUA662AA
Large capacity
SRDA-CUA133AA
14-46
RE-CTO-A220
165292-1CD
DX200 Controller

14.11 Amplifier Module (SRDA-SDA A01A-E)
14.11
Amplifier Module (SRDA-SDA A01A-E)

The 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. 14-37(a): Amplifier Module
(CN583)
Main circuit power supply input
(CN583)
Main circuit power supply input
(CN582)
(CN582)
(CN581)
PWM signal
(CN581)
PWM signal
(CN584)
Motor power output
(CN584)
Motor power output
54&#5&###'
54&#5&###'
54&#5&###'
54&#5&###'
54&#5&###'
54&#5&###'
Fig. 14-37(b): Amplifier Module Arrangement Example
AMP8
AMP7
AMP9
AMP5
AMP4
AMP6
AMP1
AMP3
AMP2
14-47
RE-CTO-A220
165292-1CD
DX200 Controller

14.12 WAGO Connector
14.12
WAGO Connector
The control power supply unit: CN152 on (JZNC-YPS21-E), and CN303
on the universal I/O circuit board (JANCD-YIO21-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 DX200.
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.
Wiring tool for WAGO connector

(DX200 Supplied parts - 2 types)
Hole for the wiring tool
Part A
WAGO connector (e.g. 4 pins type)
Wire
Specification
Connector to be applied
Max cable outside diameter:
Control power supply unit:
(JANC-YPS21-E) CN152 Stripped lentgh:
Max cable outside diameter:
Universal I/O unit:
(JANCD-YIO21-E) CN303 Stripped lentgh:
4.1mm dia.
8-9mm
3.4mm dia.
7mm
2. Insert or pull out the wire while pushing the wiring tool downward
(Direction of the arrow).
Wiring tool for WAGO connector
Push
3. Remove the wiring tool from the connector. (Complete)

Keep this wiring tool for the future use.
14-48
RE-CTO-A220
165292-1CD
DX200 Controller

14.13 Universal I/O Signal Assignment
14.13
Universal I/O Signal Assignment
14.13.1
Arc Welding
Fig. 14-38: JANCD-YIO21-E (CN308 Connector) I/O Allocation and
Connection Diagram (For Arc Welding)
DX200
Universal I/O circuit board (JANCD-YIO21-E)
+24VU
CN308 Connector
Logical Connector
Number Number
Each Point
24VDC
6.9 mA (TYP)
Name
External Start
IN
B1
IN
A1
B1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
-
IN
A2
B3
A2
B3
20015 A3
Select Play Mode
20016 B4
20017 A4
Select Teach Mode

-
024VU
A3
B4
IN
IN
A4
A4
B5
B5
A5
A5
B6
B6
A6
A6
B7
024VU
024VU
Work Prohibited
20023 A6
Work Response
IN
024VU
A7
024VU
OUT
B8
B8
30011 A8
Running
Servo is ON
OUT
A8
30012 B9
Top of Master Job
OUT
B9
A8
B9
OUT
A9
A9
OUT
B10
B10
30015 A10 Remote Mode Selected OUT

OUT
30016 B11 Play Mode Selected
A10
A10
B11
B11
30017 A11 Teach Mode Selected OUT
A11
A11
OUT
B12
B12
OUT
A12
A12
30022 B13 Work Home Position OUT

Start OK
30023 A13 Intermediate
(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
B20
FG
A20
A20
024VU
30020 B12 In Cube 1

30021 A12 In Cube 2
+24VU
B4
20022 B6
Alarm/Error Occurred
30014 B10 Battery Alarm
-1
A3
IN
IN
30013 A9
-2
IN
IN
Interference1 Entrance
Prohibited
Prohibited
30010 B8
External
Power Supply
+24 VE
024 VE
IN
20020 B5
20021 A5
B7
A7
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
Signal
20011 A1
20010 B1
20014 B3
Each Point
24VDC
50mA (max.)
Connector Terminal Converter

(Optional)
Model:TIFS553YS
024VU
+24VU
+24VU
+24VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4

when a external power supply is used.
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-49
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
CN309 Connector
Logical
Number
Each Point
24VDC
6.9mA (TYP)
Connector
Number
Name
Signal
IN
B1
B1
IN
A1
A1
20026 B2
20027 A2
Weaving Prohibited
IN
B2
B2
Sensing Prohibited
IN
20030 B3
IN01 User Output
IN
A2
B3
A2
B3
20025 A1
20031 A3
IN02
IN03
IN
IN
A3
B4
A3
20032 B4
20033 A4
IN04
IN
A4
A4
20034 B5
20035 A5
IN05
IN
B5
IN06
A5
B5
A5
20036 B6
20037 A6
IN07
IN
IN
IN08
IN
024VU
A7 024VU
30024 B8 Gas Shortage (Monitor) OUT
30025 A8 Wire Shortage (Monitor) OUT
30026 B9 Wire Sticking (Monitor) OUT
-4
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
B6
A6
B6
B7
A7
024VU
024VU
B8
B8
A8
B9
A8
B9
A6
A9
A9
OUT
B10
B10
OUT
A10
A10
30032 B11 OUT03

30033 A11 OUT04
OUT
B11
B11
OUT
A11
30034 B12 OUT05
OUT
A11
B12
30035 A12 OUT06

30036 B13 OUT07
30037 A13 OUT08
OUT
A12
A12
OUT
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
A19 +24VU
B19
+24VU
A19
+24VU
Arc Shortage (Monitor) OUT
OUT
B14
A14
Internal
Power Supply
+24 V
024 V
(24V,1A)
B4
30030 B10 OUT01 User Output

30031 A10 OUT02
30027 A9
CN303
-3
Terminal
Number
20024 B1
B7
Each Point
24VDC
50mA (max.)

(Optional)
Model:TIFS553YS
A17 024VU
B18 +24VU
B20 FG
A20
B12
024VU
B20
FG
A20
024VU
024VU
024VU
024VU
024VU

024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-50
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
CN306 Connector
Logical
Number
Each Point
24VDC
6.9mA (TYP)
Connector
Number
Name
20040 B1
IN09
20041 A1
20042 B2
20043 A2
20044 B3
IN13
20045 A3
IN14
20046 B4
20047 A4
B1
IN10
IN
A1
A1
IN11
IN
B2
B2
IN12
IN
IN
A2
B3
A2
B3
IN
IN
A3
B4
A3
IN15
IN16
IN
A4
A4
B5
B5
A5
A5
B5
A5
B6
A6
B6
A6
B6
B7
A7
024VU
024VU
024VU
024VU
-4
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
B4
A6
30040 B8
OUT09 User Input OUT
B8
B8
30041 A8
OUT10
OUT
30042 B9
OUT11
OUT
A8
B9
A8
B9
30043 A9
OUT12
OUT
A9
A9
30044 B10 OUT13

30045 A10 OUT14
30046 B11 OUT15
OUT
B10
B10
OUT
A10
A10
OUT
B11
B11
30047 A11 OUT16
OUT
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
B14
A14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
B16
A16
024VU
A17 024VU
B17
A17
024VU
024VU
B18 +24VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
B19
+24VU
A19
+24VU
A12
Internal
Power Supply
+24 V
024 V
(24V,1A)
Terminal
Number
B1
User Input
B12
CN303
-3
Signal
IN
B7
A7
Each Point
24VDC
50mA (max.)

(Optional)
Model: TIFS553YS
B13
A13
A16 024VU
B17 024VU
A19 +24VU
B20 FG
A20
B12
A12
024VU
B20
FG
A20
024VU
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-51
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
Each Point
24VDC
6.9mA (TYP)
CN307 Connector
Logical Connector
Number Number
-4
024 V
(24V,1A)
IN
B1
B1
20051 A1
IN18
IN
A1
A1
20052 B2
20053 A2
IN19
IN
B2
B2
IN20
IN
20054 B3
IN21
IN
A2
B3
A2
B3
20055 A3
IN22
IN23
IN
IN
A3
20056 B4
20057 A4
B4
A3
B4
IN24
IN
A4
A4
B5
B5
A5
A5
B5
A5
B6
A6
B6
A6
B6
B7
A7
024VU
024VU
024VU
024VU
OUT17-
OUT
B8
B8
A8
OUT17+
OUT
A8
OUT18-
OUT
B9
A8
B9
RLY
30051 B9
A9
RLY
OUT18+
OUT
A9
A9
30052 B10 OUT19A10 OUT19+
OUT
B10
B10
OUT
A10
A10
30053 B11 OUT20A11 OUT20+
OUT
B11
B11
OUT
OUT
A11
B12
A12
A11
30054 B12 OUT21A12 OUT21+
A12
RLY
B13
A13
B13
A13
RLY
B14
B14
30055 B13 OUT22A13 OUT22+

30056 B14 OUT23-
+24VU
-2
024VU
OUT
OUT
OUT
OUT
OUT
A14
A14
OUT
B15
B15
A15 OUT24+
OUT
A15
A15
B16
A16
024VU
B17
A17
024VU
024VU
B18
A18
+24VU
B19
A19
+24VU
A16 024VU
B17 024VU
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
RLY
RLY
B12
A14 OUT23+
30057 B15 OUT24-
A17 024VU
-1
A6
30050 B8
B18 +24VU
External
Power Supply
+24 VE
024 VE
Terminal
Number
IN17
B16 024VU
CN303 Internal
Power Supply
-3
+24 V
Signal
20050 B1
B7
A7
Each Point
24VDC
500mA (max.)
Name

(Optional)
Model: TIFS553YS
RLY
RLY
024VU
+24VU
+24VU
B20
FG
A20
024VU
means internal relay

RLY means
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-52
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-2: Specific Input (Arc Welding)

Logical
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.
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 job1). This signal is invalid during playback, during teach lock
and when play master or call is prohibited (set from the playback operation condition
display).
20013
ALARM/ERROR RESET
After an alarm or error has occurred and the cause been corrected, this signal resets
the alarm or error.
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.
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.
20020
INTERFERENCE 1 ENTRANCE PROHIBITED

If the manipulator attempts to enter the cube 12) 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.
20021

20022
WORK PROHIBITED (Arc Generation Prohibited)

Arc generation is prohibited while this signal is ON. Arc generation starts when this
signal turns OFF inside the arc-generation area. Use this signal to confirm teaching.
20023
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).
20026
WEAVING PROHIBITED
Weaving is prohibited while this signal is ON. Use this signal to check taught steps
and movements without performing the weaving operation.
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.
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 See section 8.6 Interference Area on page 8-59.
14-53
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-3: Specific Output (Arc Welding)

Logical
Output Name / Function
Number
30010
RUNNING
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
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 DX200 status diagnosis for an external start.
30012
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.
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
30017
REMOTE/PLAY/TEACH MODE 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 manipulators and positioners.
30021
IN CUBE 2
30022
WORK HOME POSITION (IN CUBE 64)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.
30023
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.
30024
GAS SHORTAGE (MONITOR)

This signal stays ON while the gas shortage signal from the welding power supply is
ON.
30025
WIRE SHORTAGE (MONITOR)

This signal status ON while the wire shortage signal from the welding power supply is
ON.
30026
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.
30027
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 64 are the same.
14-54
RE-CTO-A220
165292-1CD
DX200 Controller

14.13.2
Handling
Connection Diagram (For Handling)
DX200
Universal I/O circuit board(JANCD-YIO21-E)
+24VU
Each Point
24VDC
6.9mA (TYP)
CN308 Connector
Logical Connector
Number Number
Name
IN
B1
B1
20011 A1
IN
A1
A1
20012 B2
20013 A2
Call Master Job
IN
B2
B2
Alarm/Error Reset
IN
20014 B3
IN
A2
B3
A2
B3
20015 A3
Select Play Mode

Select Teach Mode
IN
IN
A3
20016 B4
20017 A4
B4
A3
B4
B7
A7
IN
A4
A4
IN
B5
A5
B5
A5
IN
IN
IN
Prohibited
Prohibited
024VU
024VU
-4
External
Power Supply
+24 VE
024 VE
-1
+24VU
-2
024VU
B6
A6
B6
B7
A7
024VU
024VU
A6
30010 B8
Running
OUT
B8
B8
30011 A8
Servo is ON
OUT
A8
30012 B9
Top of Master Job
OUT
B9
A8
B9
30013 A9
Alarm/Error Occurred
OUT
A9
A9
OUT
B10
B10

OUT
A10
A10
B11
B11
30017 A11 Teach Mode Selected
OUT
A11
30020 B12 In Cube 1
OUT
A11
B12
30021 A12 In Cube 2

30022 B13 Work Home Position
Intermediate Start OK
30023 A13 (continuousing Sequence)
OUT
A12
A12
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
+24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
+24VU
A19
+24VU
B20
FG
A20
A20
024VU
+24 V
024 V
(24V,1A)
Terminal
Number
External Start
20022 B6
20023 A6
CN303 Internal
Power Supply
-3
Signal
20010 B1
20020 B5
20021 A5
Each Point
24VDC
50mA (max.)

(Optional)
Model: TIFS553YS
OUT
B12
024VU
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-55
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
Each Point
24VDC
6.9mA (TYP)
CN309 Connector
Logical Connector
Number Number
Name
-4
External
Power Supply
+24 VE
024 VE
+24 V
024 V
(24V,1A)
IN
B1
B1
20025 A1
IN
A1
A1
Shock Sensor (NC)

- Hold
IN
B2
B2
Low Air Pressure
IN
A2
B3
A2
B3
20026 B2
20027 A2
20030 B3
IN01
IN
20031 A3
IN02
A3
IN03
IN
IN
A3
20032 B4
20033 A4
B4
B4
IN04
IN
A4
A4
20034 B5
20035 A5
IN05
IN06
IN
B5
A5
B5
A5
20036 B6
20037 A6
IN07
IN
IN
IN08
IN
024VU
024VU
+24VU
-2
024VU
B6
A6
B6
B7
A7
024VU
024VU
A6
30024 B8
OUT
B8
B8
30025 A8
OUT
30026 B9
OUT
A8
B9
A8
B9
30027 A9
OUT
A9
A9
OUT
B10
B10
30031 A10 OUT02

30032 B11 OUT03
OUT
A10
A10
OUT
B11
B11
OUT
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU
OUT
30035 A12 OUT06

30036 B13 OUT07
OUT
30037 A13 OUT08
OUT
OUT
B14
A14
A17 024VU
B18 +24VU
-1
Terminal
Number
30033 A11 OUT04

30034 B12 OUT05
CN303 Internal
Power Supply
-3
Signal
20024 B1
B7
A7
Each Point
24VDC
50mA (max.)

(Optional)
Model: TIFS553YS
B12
A12
024VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
A19
+24VU
B20
FG
A20
A20
024VU
+24VU
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-56
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
CN306 Connector
Logical Connector
Number Number
Each Point
24VDC
6.9mA (TYP)
Name
IN
B1
B1
20041 A1
IN10
IN
A1
A1
20042 B2
20043 A2
IN11
IN
B2
B2
IN12
IN13
IN
A2
B3
A2
B3
IN
20045 A3
IN14
A3
IN15
IN
IN
A3
20046 B4
20047 A4
B4
B4
IN16
IN
A4
A4
B5
A5
B5
B5
A5
B6
A6
B6
A6
B6
B7
A5
024VU
A7
024VU
024VU
30040 B8
30041 A8
OUT09
OUT10
OUT
B8
B8
OUT
A8
30042 B9
30043 A9
OUT11
OUT12
OUT
B9
A8
B9
OUT
A9
A9
30044 B10 OUT13

30045 A10 OUT14
30046 B11 OUT15
30047 A11 OUT16
OUT
B10
B10
024VU
OUT
A10
A10
OUT
B11
B11
OUT
A11
B12
A11
B12
A12
A12
A12
B13
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
+24VU
A19
+24VU
A13
A16 024VU
B17 024VU
A17 024VU
B18 +24VU
-1
+24VU
-2
024VU
A6
B7
A7
A14
External
Power Supply
+24 VE
024 VE
Terminal
Number
IN09
B14
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Signal
20040 B1
20044 B3
Each Point
24VDC
50mA (max.)

(Optional)
Model: TIFS553YS
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
B12
024VU
B20
FG
A20
024VU
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-57
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
Each Point
24VDC
6.9mA (TYP)
CN307 Connector
Logical Connector
Number Number
20050 B1
Name
IN
B1
B1
20051 A1
IN
A1
A1
20052 B2
20053 A2
Sensor Input 3
IN
B2
B2
Sensor Input 4
IN
20054 B3
Sensor Input 5
IN
A2
B3
A2
B3
20055 A3
Sensor Input 6
A3
20056 B4
IN
IN
A3
Sensor Input 7
B4
B4
20057 A4
Sensor Input 8
IN
A4
A4
B5
B5
A5
A5
A5
B6
A6
B7
024VU
A7
024VU
-2
+24VU
024VU
B7
A7
024VU
024VU
A6
OUT
B8
B8
A8
Hand Value 1-1+
OUT
A8
A8
30051 B9
A9
Hand Value 1-2-
OUT
B9
B9
Hand Value 1-2+

30052 B10 Hand Value 2-1-
OUT
OUT
A10
B11
B11
OUT
A11
B12
A11
A12
A12
RLY
B13
A13
B13
A13
RLY
B14
B14
A14
A14
B15
B15
OUT
OUT
A14 Hand Value 4-1+

OUT
OUT
A15 Hand Value 4-2+
OUT
A17 024VU
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
RLY
A10
B17 024VU
A9
B10
OUT
OUT
A16 024VU
A9
B10
RLY
OUT
A12 Hand Value 3-1+

30055 B13 Hand Value 3-2A13 Hand Value 3-2+
B18 +24VU
-1
B6
Hand Value 1-1-
B16 024VU
External
Power Supply
+24 VE
024 VE
B6
A6
30050 B8
A10 Hand Value 2-1+

30053 B11 Hand Value 2-2A11 Hand Value 2-2+
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
Signal
Sensor Input 1
Sensor Input 2
B5
Each Point
24VDC
500mA (max.)

(Optional)
Model: TIFS553YS
OUT
OUT
RLY
RLY
B12
A15
A15
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
RLY
RLY
024VU
+24VU
B20
FG
A20
024VU

RLY means
024VU
024VU
024VU
024VU

024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-58
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-4: Specific Input (Handling)

Logical
Number
20010
EXTERNAL START
20012
CALL MASTER JOB

is the top of the master job1). This signal is invalid during playback, during teach lock
display).
20013
ALARM/ERROR RESET
the alarm or error.
20015
SELECT PLAY MODE

20016
SELECT TEACH MODE

20020

20021

20026
TOOL SHOCK SENSOR

This is normally ON (NC) signal input. When it turns OFF, an DX200 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.
20027
LOW AIR PRESSURE

This signal is normally OFF (NO). When it turns ON, DX200 displays user alarm in the
PLAY mode or displays user message in the teach mode.
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.
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.
14-59
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-5: Specific Output (Handling)

Logical
Number
30010
RUNNING
30011
SERVO IS ON
30012
TOP OF MASTER JOB

30013
30014
BATTERY ALARM
30015 to
30017

30020
IN CUBE 1
30021
IN CUBE 2
30022

Use this signal to evaluate whether the manipulator is in the start position.
30023
30050 to
30057
HAND VALVE 1-4

These outputs are controlled by the HAND handling specific instructions.
Hand valves 1 to 4 correspond to HAND 1 to 4.

14-60
RE-CTO-A220
165292-1CD
DX200 Controller

14.13.3
General Application
Connection Diagram (For General Application)
DX200
+24VU
CN308 Connector
Logical Connector
Number Number
Each Point
24VDC
6.9mA (TYP)
Name
20010 B1
20011 A1
Signal
B1
B1
IN
A1
A1
Call Master Job
IN
B2
B2
Alarm/Error Reset
IN
A2
B3
A2
B3
External Start
IN
20015 A3
Select Play Mode

Select Teach Mode
IN
IN
A3
20016 B4
20017 A4
B4
A3
B4
IN
A4
A4
Prohibited
IN
B5
Prohibited
IN
IN
A5
B5
A5
20020 B5
20021 A5
Work Prohibited
20022 B6
20023 A6
IN
+24VU
-2
024VU
B7
A6
A7
Running
OUT
B8
B8
30011 A8
Servo is ON
OUT
A8
A8
30012 B9
Top of Master Job
OUT
B9
B9
A9
A9
OUT
B10
B10

OUT
A10
A10
B11
B11
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
024VU
30020 B12 In Cube 1

30021 A12 In Cube 2
30022 B13 Work Home Position
Start OK
30023 A13 Intermediate
(continuousing Sequence)
OUT
OUT
OUT
OUT
OUT
B14
A14
B15
-1
B6
30010 B8
024VU
30013 A9 Alarm/Error Occurred

External
Power Supply
+24 VE
024 VE
B6
A6
024VU
024VU
B7
A7
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
IN
20012 B2
20013 A2
20014 B3
Each Point
24VDC
50mA (max.)

(Optional)
Model: TIFS553YS
B12
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
A19
+24VU
B19 +24VU
A19 +24VU
B20 FG
A20
024VU
+24VU
B20
FG
A20
024VU
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-61
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
CN309 Connector
Logical Connector
Number Number
Each Point
24VDC
6.9mA (TYP)
20024 B1
20025 A1
Name
Prohibited
Prohibited
-1
+24VU
-2
024VU
B1
B1
IN
A1
A1
IN
B2
B2
IN
20030 B3
IN01 User Input
IN
A2
B3
A2
B3
20031 A3
IN02
A3
IN03
IN
IN
A3
20032 B4
B4
B4
20033 A4
IN04
IN
A4
A4
20034 B5
20035 A5
IN05
IN
B5
IN06
IN07
IN
IN
A5
B5
A5
IN08
IN
B7
024VU
A7
024VU
B6
A6
B6
B7
A6
A7
024VU
024VU
30024 B8
In Cube 3
OUT
B8
B8
30025 A8
In Cube 4
OUT
A8
A8
30026 B9
30027 A9
Work Instruction
OUT
B9
B9
OUT
A9
A9
OUT
B10
B10
OUT
A10
A10
30032 B11 OUT03

30033 A11 OUT04
OUT
B11
B11
OUT
A11
30034 B12 OUT05
OUT
A11
B12
30035 A12 OUT06

30036 B13 OUT07
OUT
A12
A12
OUT
30037 A13 OUT08
OUT
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B15
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU

30031 A10 OUT02
External
Power Supply
+24 VE
024 VE
Terminal
Number
IN
20037 A6
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Signal
20026 B2
20027 A2
20036 B6
Each Point
24VDC
50mA (max.)

(Optional)
Model: TIFS553YS
B14
A14
A17 024VU
B18 +24VU
B12
024VU
B18
+24VU
A18 +24VU
A18
+24VU
B19 +24VU
A19 +24VU
B20 FG
B19
+24VU
A19
+24VU
B20
FG
A20
A20
024VU
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-62
RE-CTO-A220
165292-1CD
DX200 Controller

Connection Diagram (General Application)
DX200
+24VU
Each Point
24VDC
6.9m A (TYP)

(Optional)
Model: TIFS553YS
CN306 Connector
Name
Logical Connector
Number Number
Terminal
Number
Signal
IN
B1
B1
IN10
IN
A1
A1
IN11
IN
B2
B2
A2
B3
A2
B3
A3
A3
B4
B4
A4
A4
B5
B5
A5
20040 B1
IN09
20041 A1
20042 B2
20043 A2
General Input
IN12
IN
20044 B3
IN13
IN
20045 A3
IN14
20046 B4
IN15
IN
IN
20047 A4
IN16
IN
B5
A5
A5
B6
B6
A6
B6
B7
A7
024VU
024VU
B8
B8
A8
A8
A6
B7
A7
024VU
30040 B8
OUT09
30041 A8
OUT10
OUT
30042 B9
30043 A9
OUT11
OUT
024VU
General Output
OUT12
OUT
30044 B10 OUT13

30045 A10 OUT14
30046 B11 OUT15
OUT
OUT
OUT
30047 A11 OUT16
OUT
B12
A12
B13
A13
Each Point
24VDC
50mA (max.)
B14
A14
B15
A15
B16 024VU
CN303 Internal
Power Supply
-3
+24V
024V
-4
(24V, 1A)
A16 024VU
B17 024VU
A17 024VU
B18 +24VU
External
Power Supply
+24VE
024VE
-1
-2
+24VU
024VU
OUT
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
A6
B9
B9
A9
A9
B10
B10
A10
A10
B11
B11
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
B12
A15
A15
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
+24VU
A19
+24VU
024VU
B20
FG
A20
024VU
024VU
024VU
024VU
024VU

024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-63
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
Each Point
24VDC
6.9mA (TYP)
CN307 Connector
Logical
Number
Connector
Number
Name
IN17
IN
B1
B1
20051 A1
IN18
IN
A1
A1
20052 B2
20053 A2
IN19
IN
B2
B2
IN20
IN
20054 B3
IN21
IN
A2
B3
A2
B3
20055 A3
IN22
A3
IN23
IN
IN
A3
20056 B4
B4
B4
20057 A4
IN24
IN
A4
A4
B5
B5
A5
A5
A5
B6
B6
A6
B6
B7
A6
A7
30050 B8
OUT17-
OUT
B8
B8
A8
OUT17+
OUT
A8
OUT18-
OUT
A8
B9
RLY
B9
OUT18+
OUT
RLY
30051 B9
A9
024VU
024VU
-1
+24VU
-2
024VU
A9
A9
B10
30052 B10 OUT19A10 OUT19+
OUT
B10
OUT
A10
A10
30053 B11 OUT20A11 OUT20+
OUT
B11
B11
OUT
OUT
A11
B12
A11
30054 B12 OUT21A12 OUT21+
A12
A12
RLY
30055 B13 OUT22A13 OUT22+
OUT
B13
A13
B13
A13
RLY
30056 B14 OUT23-
OUT
B14
B14
A14 OUT23+
30057 B15 OUT24-
A14
A14
OUT
B15
B15
A15 OUT24+
OUT
A15
A15
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
OUT
OUT
OUT
B16 024VU
External
Power Supply
+24 VE
024 VE
A6
024VU
024VU
B7
A7
CN303 Internal
Power Supply
-3
+24 V
-4
024 V
(24V,1A)
Terminal
Number
Signal
20050 B1
B5
Each Point
24VDC
500mA (max.)

(Optional)
Model: TIFS553YS
A16 024VU
B17 024VU
A17 024VU
B18 +24VU
A18 +24VU
B19 +24VU
A19 +24VU
B20 FG
A20
RLY
RLY
B12
RLY
RLY
024VU
+24VU
B20
FG
A20
024VU
*
RLY
means
024VU
024VU
024VU
024VU

024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-64
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-6: Specific Input (General Application)

Logical
Number
20010
EXTERNAL START
20012
CALL MASTER JOB

is the top of the master job1). This signal is invalid during playback, during teach-lock
display).
20013
ALARM/ERROR RESET
the alarm or error.
20015
SELECT PLAY MODE

20016
SELECT TEACH MODE

20020

20021

20022
WORK PROHIBITED (Tool ON Prohibited)

Even if TOOLON instruction is executed, DX200 doesnt output to external while this
signal is ON.
20024

20025

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.
14-65
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-7: Specific Output (General Application)

Logical
Number
30010
RUNNING
30011
SERVO IS ON
30012
TOP OF MASTER JOB

can be used to confirm that the master job has been called.1)*1
30013
30014
BATTERY ALARM
30015 to
30017

30020
IN CUBE 1
30021
IN CUBE 2
30022

Use this signal to evaluate whether the robot is in the start position.
30023
30024
IN CUBE 3
30025
IN CUBE 4
30026
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.

14-66
RE-CTO-A220
165292-1CD
DX200 Controller

14.13.4
Spot Welding
Connection Diagram (For Spot Welding)
DX200
+24VU
CN308 Connector
Logical Connector
Number Number
Each Point
24VDC
6.9mA (TYP)
Name
20010 B1
20011 A1
IN
B1
B1
IN
A1
A1
Call Master Job
IN
B2
B2
Alarm/Error Reset
IN
A2
B3
A2
B3
IN
IN
A3
A3
B4
B4
IN
A4
A4
Prohibited
IN
B5
Prohibited
IN
IN
B5
A5
External Start
IN
20015 A3
Select Play Mode
20016 B4
20017 A4
Select Teach Mode
20020 B5
20021 A5
20022 B6
20023 A6
Welding ON/OFF
Welding Pause
IN
-1
-2
+24VU
024VU
B6
A6
B6
B7
A6
A7
OUT
B8
B8
30011 A8
Servo is ON
OUT
A8
A8
30012 B9
30013 A9
Top of Master Job
OUT
024VU
024VU
30010 B8
Running
B9
B9
A9
A9
OUT
OUT
B10
B10
A10
A10
B11
B11

OUT
30020 B12 In Cube 1
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
Alarm/Error Occurred OUT
OUT
30021 A12 In Cube 2
30022 B13 Work Home Position OUT
Intermediate Start OK
30023 A13 (continuousing Sequence) OUT
B14
A14
B15
External
Power Supply
+24 VE
024 VE
A5
024VU
024VU
B7
A7
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
Signal
20012 B2
20013 A2
20014 B3
Each Point
24VDC
50mA (max.)

(Optional)
Model: TIFS553YS
B12
A12
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
B19 +24VU
A19 +24VU
B20 FG
A20
024VU
B20
FG
A20
024VU
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-67
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
CN309 Connector
Logical Connector
Number Number
Each Point
24VDC
6.9mA (TYP)
Name
IN
B1
B1
20025 A1
IN
A1
A1
20026 B2
20027 A2
IN
B2
B2
IN
20030 B3
IN1 USER INPUT
IN
A2
B3
A2
B3
20031 A3
IN2
A3
IN3
IN
IN
A3
20032 B4
20033 A4
B4
B4
IN
A4
A4
IN
B5
A5
B5
A5
IN4
IN5
20034 B5
20035 A5
IN6
20036 B6
IN7
IN
IN
IN8
IN
External
Power Supply
+24 VE
024 VE
A7
024VU
In Cube 3
A7
OUT
B8
B8
30025 A8
In Cube 4
OUT
A8
30026 B9
30027 A9
A8
B9
A9
A9
OUT
B10
B10
OUT
A10
A10
OUT
B11
B11
OUT
A11
B12
A12
A11
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
OUT
OUT
30034 B12 OUT05

30035 A12 OUT06
OUT
30036 B13 OUT07

30037 A13 OUT08
OUT
OUT
OUT
B14
A14
-2
024VU
B9
B12
A12
A15
A15
A15
B16 024VU
A16 024VU
B16
A16
024VU
B17 024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
A19
+24VU
A18 +24VU
+24VU
A6
30024 B8
A17 024VU
B18 +24VU
-1
B7
024VU
024VU
B15
+24 V
024 V
(24V,1A)
B6
024VU
30031 A10 OUT02

30032 B11 OUT03
30033 A11 OUT04
-4
B6
A6
B7
CN303 Internal
Power Supply
-3
Terminal
Number
Signal
Prohibited
Prohibited
20024 B1
20037 A6
Each Point
24VDC
50mA (max.)

(Optional)
Model:TIFS553YS
B19 +24VU
A19 +24VU
B20 FG
A20
024VU
+24VU
B20
FG
A20
024VU
024VU
024VU
024VU
024VU

024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-68
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
CN306 Connector
Logical Connector
Number Number
Each Point
24VDC
6.9mA (TYP)
Name
IN17
IN
B1
B1
20041 A1
IN18
IN
A1
A1
20042 B2
20043 A2
IN19
IN
B2
B2
IN
20044 B3
IN20
IN21
A2
B3
A2
B3
20045 A3
IN22
A3
A3
B4
B4
A4
A4
B5
B5
A5
IN
IN
IN
IN23
IN24
IN
B5
A5
A5
B6
A6
B7
A7
024VU
30040 B8
OUT17
OUT
30041 A8
OUT18
OUT
30042 B9
OUT19
OUT
024VU
30043 A9
OUT
OUT20
30044 B10 OUT21
30045 A10 OUT22
30046 B11 OUT23
OUT
OUT
OUT
30047 A11 OUT24
OUT
B12
A12
B13
A13
B14
A14
B15
-2
024VU
A7
024VU
024VU
B8
B8
A8
B9
A8
A9
A9
B10
B10
A10
A10
B11
B11
A11
B12
A11
A12
A12
B13
A13
B13
A13
B14
B14
A14
A14
B15
B15
A6
B9
B12
A15
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
+24VU
B19 +24VU
B19
A19
A19 +24VU
B20 FG
B20
FG
A20
024VU
A16 024VU
B17 024VU
A17 024VU
A18 +24VU
+24VU
B7
024VU
B18 +24VU
-1
B6
B16
A16
B16 024VU
External
Power Supply
+24 VE
024 VE
B6
A6
A15
A15
CN303 Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
Signal
20040 B1
20046 B4
20047 A4
Each Point
24VDC
50mA (max.)

(Optional)
Model: TIFS553YS
A20
024VU
+24VU
024VU
024VU
024VU

024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-69
RE-CTO-A220
165292-1CD
DX200 Controller

DX200
+24VU
Each Point
24VDC
6.9mA (TYP)
CN307 Connector
Logical Connector
Number Number
20050 B1
Name
Timer Cooling Water
Error (IN09)
Gun Cooling Water
Error (IN10)
Signal
B1
B1
IN
A1
A1
20052 B2
20053 A2
Transthermo Error (IN11) IN
B2
B2
Low Air Pressure (IN12)
IN
20054 B3
IN13
IN
A2
B3
A2
B3
20055 A3
IN14
20056 B4
IN
IN
A3
IN15
B4
A3
B4
20057 A4
IN16
IN
A4
A4
B5
B5
A5
20051 A1
A5
B6
A6
B7
A7
A8
30051 B9
A9
A7
B8
B8
OUT
A8
A8
OUT
B9
B9
A9
OUT
A10 Weld Condition 1 (OUT11)** OUT

OUT
30053 B11
A10
A10
B11
B11
A11
B12
A11
A12
A12
RLY
B13
A13
B13
A13
RLY
B14
B14
A14
A14
B15
B15
OUT
OUT
30055 B13

30056 B14
OUT
OUT
30057 B15
A15
A15
B16 024VU
B16
A16
024VU
B17
A17
024VU
024VU
B18
+24VU
A18
+24VU
B19
+24VU
A19
+24VU
A16 024VU
B17 024VU
A17 024VU
A18 +24VU
024VU
B19 +24VU
A19 +24VU
B20 FG
A20
RLY
RLY
RLY
B12
A15 Tip Change Request (OUT16)** OUT
B18 +24VU
-2
RLY
B10
OUT
+24VU
A6
A9
30054 B12
-1
B7
B10
Weld Error Reset (OUT10)**
30052 B10
External
Power Supply
+24 VE
024 VE
B6
OUT
024VU
Weld ON/OFF (OUT09)***
B6
A6
024VU
024VU
024VU
30050 B8
CN303
Internal
Power Supply
-3
+24 V
024 V
-4
(24V,1A)
Terminal
Number
IN
B5
A5
Each Point
24VDC
500mA (max.)

(Optional)
Model: TIFS553YS
RLY
RLY
024VU
B20
FG
A20
024VU

RLY means
024VU
024VU
024VU
024VU

** This assignment can be changed at the I/O assignment display.
Refer to System Input List YIU01 and System Output List YIU01 for detail.
*** This assignment can be changed at the PSEDU input display.
Refer to System Input List YIU01 and System Output List YIU01 for detail.
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-70
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-8: Specific Input (Spot Welding) (Sheet 1 of 2)

Logical
Number
20010
EXTERNAL START
20012
CALL MASTER JOB

is the top of the master job1). This signal is invalid during playback, during teach-lock
display).
20013
ALARM/ERROR RESET
the alarm or error.
20015
SELECT PLAY MODE

20016
SELECT TEACH MODE

20020

20021

20022
WELDING ON/OFF (From sequencer)

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.
20023
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.
20024

20025

20050
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
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.
3)
3)
14-71
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-8: Specific Input (Spot Welding) (Sheet 2 of 2)

Logical
Number
20052
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.
20053
LOW AIR PRESSURE

When air pressure is reduced and this input is turned ON, an alarm occurs. The servo
power supply remains ON.
4)
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.
4)
WELDING ERROR
This signal indicates an abnormal welding result or Power Sources error. Alarm
occurs and the manipulator stops if this signal is input during welding.
4)
STICK DETECTION
This signal indicates an abnormal welding result or Power Sources error. Alarm
occurs and the manipulator stops if this signal is input during welding.
4)
GUN FULL OPEN DETECTION

This signal indicates that the stroke of the double stroke gun is full open.
4)
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.
4)
GUN PRESSURE DETECTION

This signal indicates that a gun is in pressing status.
4)
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.
3)
3)
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.
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.
4 This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
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)
14-72
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-9: Specific Output (Spot Welding) (Sheet 1 of 2)

Logical
Number
30010
RUNNING
30011
SERVO IS ON
30012
TOP OF MASTER JOB

30013
30014
BATTERY ALARM
30015 to
30017

30020
IN CUBE 1
30021
IN CUBE 2
30022

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.
30057
TIP REPLACE REQUEST

This signal is output when the stored number of welding reaches the number of
welding set for the tip replacement.
30023
30024
IN CUBE 3
30025
IN CUBE 4
30050
WELD ON/OFF
Outputs a signal input from the interlock panel, etc.considering the robot status.
3)
14-73
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-9: Specific Output (Spot Welding) (Sheet 2 of 2)

Logical
Number
30051
WELD ERROR RESET

This signal commands the reset error status of the Power Source. This is operated
with the programing pendant operation.
30052 to
30056
WELD CONDITION (Level signals)

1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 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. Most-significant bit is the parity bit (when specified).
4)
WELDING COMMAND
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.
4)
STROKE CHANGE1
SINGLE SOLENOID
DOUBLE SOLENOID
This is a signal, when a double stroke gun is used, to change the open stroke of the
welding gun.
4)
GUN PRESS COMMAND

This outputs gun press command.
4)
4)

3 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.
4 This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
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)
14-74
RE-CTO-A220
165292-1CD
DX200 Controller

14.13.5
14.13.5.1
JANCD-YEW01-E Circuit Board (Option)
Arc Welding
This circuit board is a welder I/F circuit board for the welding, and it is an
optional for the DX200. It is necessary to use this circuit board when
operating the instructions by the analog instruction to the welder.
DX200
MR Connector
Logical Connector
Number
Pin No.
Name
Signal
25110 CN322-2 +GASOF (Gas Shortage)
IN
CN322-3 -GASOF (Gas Shortage)
IN
1
2
3
IN
CN322-1
Each point
24 VDC
5mA MAX
25111 CN322-4 +WIRCUT (Wire Shortage)

CN322-5 -WIRCUT (Wire Shortage)
25113 CN322-6 +ARCACT (Arc Generation Confirm)
CN322-7 -ARCACT (Arc Generation Confirm)
CN322-8 CH2 (Current Input)
A/D +5V
IN
IN
IN
IN
CN322-9
8
10
CN322-11 CH1 (Voltage Input)

CN322-12 CH1-G
IN
IN
11
12
IN
13
DC24V
5mA MAX
25112 CN322-13 +ARCOFF (Arc Shortage)
IN
14
DC24V
0.5A MAX
35111 CN322-15 ARCON (Arc ON) A

CN322-16 ARCON (Arc ON) B
OUT
15
OUT
16
35112 CN322-17 WIRINCH (Wire Inching) A
OUT
17
CN322-18 WIRINCH (Wire Inching) B
OUT
18
35113 CN322-19 WIRINCH (Wire Retract) A
OUT
19
CN322-20 WIRINCH (Wire Retract) B
OUT
20
35127 CN322-21 GAS Checking OUT A
OUT
CN322-22 GAS Checking OUT B
OUT
21
22
CN322-14 -ARCOFF (Arc Shortage)
CN322-23
Detector
24
CN322-25
25
25114 CN322-26 STICK (Wire Sticking)
IN
26
CN322-27 *STICK (Wire Sticking)
IN
27
CN322-28 CH2 -G
IN
28
D/A 14V
3
17BYTE 32BYTE
DC24V
0.5A MAX
Welder
29
30
CN322-31 CH1 (Voltage Command)
OUT
31
CN322-32 CH1-G
OUT
32
CN322-33 CH2 (Current Command)
OUT
33
CN322-34 CH2 -G
OUT
34
CN322-30 024VU
D/A 14V
23
CN322-24
CN322-29 +24VU
SW2
1
CN322-10
A/D +5V
MS Connector
CN321-1 +24VU
35115 CN321-2 Search Command A (Optional)
OUT
CN321-4 Search Command B (Optional)
OUT
CN321-5 024VU
WAGO Connector(231-105/026-A0)
MRP-34M01 Housing
MRP-M113 Contactor
MR-34L+ Casing
MS3106 A, 20-29P
MS3106 A, 20-29S
14-75
RE-CTO-A220
165292-1CD
DX200 Controller

14.14 The List of the Equipment Configuration by Model
14.14
The List of the Equipment Configuration by Model
SUPPLEMENT
For the models which are not in Table 14-10, Table 14-11(a)
and Table 14-11(b), refer to DX200 INSTRUCTIONS
SUPPLEMENT FOR Controller Specification List: ANSI
Specification (171270-1CD).
Table 14-10: Small Capacity Model

Model
MA1440/MH12
Type
ERER-MA1440/MH12-A00
Dimension(W) x (H) x (D)
600mm730mm520mm
Breaker
NF32-SVF 3P 15A
JZNC-YPS21-E
CPU unit
JZNC-YRK21-1E
CPU circuit board
JANCD-YCP21-E
Back circuit board
JANCD-YBB21-E
PCI raiser Circuitboard JANCD-YBB22-E

JANCD-YIF01- E
Machine safety CPU circuit board
JANCD-YSF21-E
Machine safety I/O logic circuit board
JANCD-YSF22 -E
Machine safety terminal block circuit board JANCD-YFC22-E

JANCD-YIO21-E
Power ON unit
JZRCR-YPU51-1
Major axes control circuit board
SRDA-EAXA21A
Break control circuit board
JANCD-YBK21-3E
Converter
SRDA-COA30A21B-E
Capacitor module
SRDA-CUA662AA
Amplifier module
Regenerative
resistor
AMP1
SRDA-SDA14A01A-E
AMP2
SRDA-SDA21A01A-E
AMP3
SRDA-SDA14A01A-E
AMP4
SRDA-SDA06A01A-E
AMP5
SRDA-SDA06A01A-E
AMP6
SRDA-SDA06A01A-E
Type
SMVK500W6R0J A6103
Rated value
500W
Resister value
6
4715MS-22T-B50-B00 or
11938MB-B2N-EA-01
4715MS-22T-B50-B00 x3 or
11938MB-B2N-EA-01 x3
Circulation fan
Cooling fan
14-76
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-11(a): Medium/Large Capacity Robot

Model
MS210/MH225
Type
ERER-MS210/MH225-A00
600mm730mm520mm
Breaker
NF32-SVF 3P 30A
JZNC-YPS21-E
CPU unit
JZNC-YRK21-1E
CPU circuit board
JANCD-YCP21-E
Back circuit board
JANCD-YBB21-E
PCI raiser circuit board
JANCD-YBB22-E
JANCD-YIF01- E
JANCD-YSF21-E
JANCD-YSF22 -E
Machine safety terminal block
JANCD-YFC22-E
JANCD-YIO21-E
Power ON unit
JZRCR-YPU51-1
SRDA-EAXA21A
JANCD-YBK21-3E
Converter
SRDA-COA30A21B-E
Capacitor module
SRDA-CUA133AA
Amplifier module
Regenerative
resistor
AMP1
SRDA-SDA71A01A-E
AMP2
SRDA-SDA71A01A-E
AMP3
SRDA-SDA71A01A-E
AMP4
SRDA-SDA35A01A-E
AMP5
SRDA-SDA35A01A-E
AMP6
SRDA-SDA35A01A-E
Type
SMVK500W2R0J A5978 x3
Rated value
1500W
Resister value
Heat exchanger
TCSIP-16A4Y-0C
Cooling fan
4715MS-22T-B50-B00 x3 or
11938MB-B2N-EA-01 x3
14-77
RE-CTO-A220
165292-1CD
DX200 Controller

Table 14-11(b): Medium/Large Capacity Robot
Model
MS165/MH180
Type
ERER-MS165/MH180-A00
600mm730mm520mm
Breaker
NF32-SVF 3P 30A
JZNC-YPS21-E
CPU unit
JZNC-YRK21-1E
CPU circuit board
JANCD-YCP21-E
Back circuit board
JANCD-YBB21-E
PCI raiser circuit board
JANCD-YBB22-E
JANCD-YIF01- E
JANCD-YSF21-E
JANCD-YSF22 -E
Machine safety terminal block
JANCD-YFC22-E
JANCD-YIO21-E
Power ON unit
JZRCR-YPU51-1
SRDA-EAXA21A
JANCD-YBK21-3E
Converter
SRDA-COA30A21B-E
Capacitor module
SRDA-CUA133AA
Amplifier module
Regenerative
resistor
AMP1
SRDA-SDA71A01A-E
AMP2
SRDA-SDA71A01A-E
AMP3
SRDA-SDA71A01A-E
AMP4
SRDA-SDA35A01A-E
AMP5
SRDA-SDA35A01A-E
AMP6
SRDA-SDA35A01A-E
Type
SMVK500W2R0J A5978 x3
Rated value
1500W
Resister value
Heat exchanger
TCSIP-16A4Y-0C
Cooling fan
4715MS-22T-B50-B00 x3 or
11938MB-B2N-EA-01 x3
14-78
RE-CTO-A220
165292-1CD
DX200 Controller

14-79
RE-CTO-A220
165292-1CD
DX200 Controller
Appendix A
Appendix A DX200 North American Standard (NAS)

A.1 Equipment Configuration
DX200 North American Standard (NAS)

The DX200 NAS is the standard DX200 built in the United States. This
Appendix replaces section 13.4 Equipment Configuration on page 13-6 if
your DX200 is built in the United States.
A.1
Equipment Configuration
The DX200 NAS is comprised of individual units and modules (circuit
boards). Malfunctioning components can generally be easily repaired after
a failure by replacing a unit or a module.
This section explains the configuration of the DX200 NAS equipment.
A.1.1 Arrangement of Units and Circuit Boards

The arrangements of units and circuit boards in small-capacity, mediumcapacity, and large-capacity DX200 NASes are shown in the following
figures.
Small Capacity
Fig. A-1: Configuration for Small-Capacity

Backside duct fan
133614-4
Capacitor unit
165539-1
Machine PC
safety board
166927-1
Disconnect
Switch
166702-1
ServoPack
167284-1
Converter module
164291-1
Contactor
Power On/Off
164288-1
Machine CPU
safety board
164282-1
Power supply
164279-1
I/O NPN board
164287-1
CPU & Rack

164280-1
I/O machine
safety board
164283-1
Transformer
159437-1
149500-3
Inside Controller
Back View
Inside Controller
Right Side
Inside Controller
Front View
A-1
RE-CTO-A220
165292-1CD
DX200 Controller
Appendix A DX200 North American Standard (NAS)

A.1 Equipment Configuration
Medium and Large Capacity
Fig. A-2: Configuration for Medium and Large Capacity

Backside duct fan
133614-4
Capacitor unit
165539-2
Machine PC
safety board
166927-1
Disconnect
Switch
166702-1
ServoPack
167284-2
Converter module
164291-1
Contactor
Power On/Off
164288-1
Machine CPU
safety board
164282-1
Power supply
164279-1
I/O NPN board
164287-1
CPU & Rack

164280-1
I/O machine
safety board
164283-1
Transformer
159437-2
152661-1
Inside Controller
Back View
A.1.2
Inside Controller
Right Side
Inside Controller
Front View
Cooling System of the Controller Interior

The fans in the back draws air from the outside to cool the SERVOPACK.
The fans mounted inside the door circulates the air to keep temperature
even throughout the interior of the DX200. Make sure the door of the
DX200 is closed when it is used to keep this cooling system effective.
Fig. A-3: .Cooling System
Back Side
Air Intake
A-2
RE-CTO-A220
DX200
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703
Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200
Fax +1-937-847-6277
YASKAWA Europe GmbH
Robotics Divsion )
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100
Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 vn. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800
Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.
22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200
Fax 86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858
Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)
#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500
Fax +91-124-475-8542
YASKAWA Electric Korea Co., Ltd
9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844
Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333
Fax +886-2-8913-1513
YASKAWA Electric (Singapore) PTE Ltd.
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003
Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.
252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek RoadHuaykwang, Bangkok 10320, Thailand
Phone +66-2693-2200
Fax +66-2693-4200
PT. YASKAWA Electric Indonesia
Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470
Fax +62-21-2982-6741
Specifications are subject to change without notice

for ongoing product modifications and improvements.
MANUAL NO.
RE-CTO-A220

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DX200

Copyright 2015, Yaskawa America, Inc.

This manual explains setup, diagnosis, maintenance, hardware,

General items related to safety are listed in Section 1. To ensure

The drawings and photos in this manual are representative

YASKAWA may modify this model without notice when necessary

If your copy of the manual is damaged or lost, contact a YASKAWA

YASKAWA is not responsible for incidents arising from unauthorized

Notes for Safe Operation

Indicates an imminent hazardous

Indicates a potentially hazardous

Indicates a potentially hazardous

Must never be performed.

Even items described as CAUTION may result in a serious accident in

To ensure safe and efficient operation at all times, be sure

Confirm that no person is present in the P-point maximum

Observe the following precautions when performing teaching

Improper or unintended manipulator operation may result in injury.

Before operating the manipulator, check that servo power is

Injury or damage to machinery may result if the emergency stop circuit

Once the emergency stop button is released, clear the cell of

Injury may result from unintentional or unexpected manipulator

Perform the following inspection procedures prior to

Always return the programming pendant to the hook on the

The programming pendant can be damaged if it is left in the P-point

Read and understand the Explanation of the Warning Labels

Definition of Terms Used Often in This Manual

DX200 Programming Pendant

Cable between the manipulator and

Descriptions of the programming pendant, buttons, and displays are

The keys which have characters printed on

Axis Keys and Number Keys are generic

Keys pressed When two keys are to be pressed

The menu displayed in the programming

Description of the Operation Procedure

Explanation of Warning Labels

The label described below is attached to the manipulator.

Observe the precautions on the warning labels.

Failure to observe this caution may result in injury or damage to

Refer to the manipulator manual for the warning label location.

The following warning labels are attached to DX200.

Observe the precautions on the warning labels.

Customer Support Information

When using e-mail to contact Motoman Customer Support, please provide

Please use e-mail for routine inquiries only. If you have an

Please have the following information ready before you call:

Access this information on the

Robot Serial Number

Located on the robot data plate

Robot Sales Order Number

Located on the DX200 controller

4.3 Connection Methods .......................................................................................................... 4-6

8.6.3 Axis Interference Area ........................................................................................ 8-70

8.15.2 Allocatable Functions ..................................................................................... 8-121

8.20 Encoder Back-up Error Recovery Function ................................................................. 8-164

8.23 Safety Logic Circuit...................................................................................................... 8-209

9 System Backup ............................................................................................................................... 9-1

11 Programming Pendant ................................................................................................................ 11-1