工控帮助教小舒QQ:2823408167

YASKAWA

DX100
INSTRUCTIONS

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

MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

YASKAWA MANUAL NO. RE-CTO-A215 1

 工控帮助教小舒QQ:2823408167

DX100

MANDATORY
• This manual explains setup, diagnosis, maintenance, hardware,
etc. of the DX100 system. Read this manual carefully and be sure
to understand its contents before handling the DX100.
• General items related to safety are listed in Section 1. 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.
•
司
The drawings and photos in this manual are representative
公
examples and differences may exist between them and the

•
delivered product.

有 限
YASKAWA may modify this model without notice when necessary

科 技
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will

• 教 育
also be revised.
If your copy of the manual is damaged or lost, contact a YASKAWA

控 帮
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual

沙 工•
number listed on the front cover.
YASKAWA is not responsible for incidents arising from unauthorized
长 modification of its products. Unauthorized modification voids your
product’s warranty.

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DX100

Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the DX100.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY” or ”PROHIBITED”.

Indicates a potentially hazardous

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

Indicates a potentially hazardous

CAUTION situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.

Always be sure to follow explicitly the

MANDATORY 司
items listed under this heading.
公
有 限
Must never be performed.
PROHIBITED
技
育 科
帮 教
Even items described as “CAUTION” may result in a serious accident in
some situations.

工 控
At any rate, be sure to follow these important items.

长 沙 NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “CAU-
TION” and “WARNING”.

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DX100

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 DX100 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 DX100 and the programming
pendant.
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
- View the manipulator from the front whenever possible.

公 司
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of
emergency.

有 限
Improper or unintended manipulator operation may result in injury.
• 技
Before operating the manipulator, check that servo power is turned
科
OFF when the emergency stop buttons on the front door of the

教 育
DX100 and programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the

控 帮
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit

沙 工cannot stop the manipulator during an emergency. The manipulator

should not be used if the emergency stop buttons do not function.
长 Fig. : 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.
Fig. : Release of Emergency Stop
TURN

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DX100

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 DX100
cabinet after use.
The programming pendant can be damaged if it is left in the P-point
maximum envelope of the manipulator’s 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 公 司

有 限
The MOTOMAN is the YASKAWA industrial robot product.

科 技
The MOTOMAN consists of the manipulator, the controller, the
programming pendant, and manipulator cables.

教 育
In this manual, the equipment is designated as follows.

帮
Equipment Manual Designation

工控
DX100 Controller DX100

长沙
DX100 Programming Pendant Programming Pendant
Cable between the manipulator and Manipulator Cable
the controller

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DX100

Descriptions of the programming pendant, buttons, and displays are

shown as follows:

Equipment Manual Designation

Programming Character The keys which have characters printed on
Pendant Keys them are denoted with [ ].
ex. [ENTER]
Symbol The keys which have a symbol printed on them
Keys are not denoted with [ ] but depicted with a small
picture.

ex. page key

The cursor key is an exception, and a picture is
not shown.

Axis Keys “Axis Keys” and “Number Keys” are generic

Number Keys 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 “+”
司
sign between them, ex. [SHIFT]+[COORD]
公
Displays
限
The menu displayed in the programming
有
pendant is denoted with { }.

科 技
ex. {JOB}

育
Description of the Operation Procedure
教
控 帮
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

沙 工
pressed, or that the item is directly selected by touching the screen.

Registered Trademark
长 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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DX100

Explanation of Warning Labels

The following warning labels are attached to the manipulator and DX100.
Fully comply with the precautions on the warning labels.

WARNING
• 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
Moving parts Do not enter
may cause robot
injury work area.

公 司
• 有 限
Refer to the manipulator manual for the warning label location.
The following warning labels are attached to DX100.

科 技
Observe the precautions on the warning labels.

教
equipment.
育
Failure to observe this warning may result in injury or damage to

控 帮
沙 工 WARNING
WARNING

长 High Voltage
Do not ope the cover.
May cause
electric shock.
Ground the earth
terminal based on
local and national
electric code.

WARNING
High Voltage
Internal Breaker Do not open the door
with power ON.

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DX100 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

司
2.1 Contents Confirmation ....................................................................................................... 2-1
公
限
2.2 Order Number Confirmation............................................................................................... 2-2

有
技
3 Installation ....................................................................................................................................... 3-1
科
教 育
3.1 Handling Procedure ........................................................................................................... 3-1

3.1.1 Using a Crane to Move the Controller .................................................................. 3-1

控 帮
3.1.2 Using a Forklift to Move the Controller ................................................................. 3-2

工
3.2 Place of Installation............................................................................................................ 3-3
沙
长
3.3 Location ............................................................................................................................. 3-4

3.4 Mounting the Controller...................................................................................................... 3-5

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

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

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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

6 Test of Program Operation ............................................................................................................. 6-1

6.1 Movement of the Axes ....................................................................................................... 6-2

司
7 Security System .............................................................................................................................. 7-1
公
限
7.1 Protection Through Security Mode Settings ...................................................................... 7-1

有
科 技
7.1.1 Security Mode ...................................................................................................... 7-1
7.1.1.1 Changing the Security Mode ................................................................... 7-5

教 育
7.1.2 User ID ................................................................................................................. 7-7
7.1.2.1 Changing User ID.................................................................................... 7-7

控 帮
8 System Setup.................................................................................................................................. 8-1

沙 工
8.1 Home Position Calibration ................................................................................................. 8-2
长
8.1.1 Home Position Calibration .................................................................................... 8-3

8.1.2 Calibrating Operation............................................................................................ 8-4

8.1.2.1 Registering All Axes at One Time ........................................................... 8-4
8.1.2.2 Registering Individual Axes ..................................................................... 8-7
8.1.2.3 Changing the Absolute Data ................................................................... 8-8
8.1.2.4 Clearing Absolute Data ........................................................................... 8-8

8.1.3 Home Position of the Robot................................................................................ 8-10

8.2 Setting the Second Home Position (Check Point) ........................................................... 8-11

8.2.1 Purpose of Position Check Operation ................................................................ 8-12

8.2.2 Procedure for the Second Home Position Setting (Check Point) ....................... 8-14

8.2.3 Procedure after the Alarm .................................................................................. 8-16

8.3 Tool Data Setting ............................................................................................................. 8-18

8.3.1 Registering Tool Files......................................................................................... 8-18

8.3.1.1 Number of Tool Files ............................................................................. 8-18
8.3.1.2 Registering Coordinate Data ................................................................. 8-18

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DX100 Contents

8.3.1.3 Registering Tool Angle .......................................................................... 8-21

8.3.1.4 Setting the Tool Load Information ......................................................... 8-22

8.3.2 Tool Calibration................................................................................................... 8-23

8.3.2.1 Tool Calibration ..................................................................................... 8-23
8.3.2.2 Setting of Tool Calibration Method ........................................................ 8-23
8.3.2.3 Teaching of Calibration Point ................................................................ 8-24
8.3.2.4 Clearing Calibration Data ...................................................................... 8-29
8.3.2.5 Checking the TCP ................................................................................. 8-31

8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity................. 8-32
8.3.3.1 What is the Automatic Measurement of the Tool Load and the
Center of Gravity? ................................................................................. 8-32
8.3.3.2 Measurement of the Tool Load and the Center of Gravity .................... 8-33

8.4 ARM Control .................................................................................................................... 8-38

8.4.1 ARM Control ....................................................................................................... 8-38

8.4.2 ARM CONTROL Window ................................................................................... 8-38

8.4.2.1 Robot Setup Condition .......................................................................... 8-38

司
8.4.3 Tool Load Information Setting............................................................................. 8-43
公
有 限
8.4.3.1 Tool Load Information ........................................................................... 8-43
8.4.3.2 How to Calculate Tool Load Information ............................................... 8-43

科 技
8.4.3.3 Tool Load Information Registering ........................................................ 8-49

8.5 Work Home Position ........................................................................................................ 8-52

教 育
8.5.1 What is the Work Home Position? ...................................................................... 8-52

控 帮
8.5.2 Setting Work Home Position............................................................................... 8-52

沙 工
8.5.2.1 Work Home Position Window ................................................................ 8-52
8.5.2.2 Registering/Changing the Work Home Position .................................... 8-54

长
8.5.2.3 Returning to the Work Home Position ................................................... 8-55
8.5.2.4 Output of the Work Home Position Signal ............................................. 8-55

8.6 Interference Area ............................................................................................................. 8-56

8.6.1 Interference Area ................................................................................................ 8-56

8.6.2 Cubic Interference Area...................................................................................... 8-56

8.6.2.1 Cubic Interference Area......................................................................... 8-56
8.6.2.2 Cube Setting Method............................................................................. 8-56
8.6.2.3 Setting Operation .................................................................................. 8-58

8.6.3 Axis Interference Area ........................................................................................ 8-64

8.6.3.1 Axis Interference Area ........................................................................... 8-64
8.6.3.2 Setting Operation .................................................................................. 8-65

8.6.4 Clearing the Interference Area Data ................................................................... 8-72

8.7 Shock Detection Function ................................................................................................ 8-74

8.7.1 Shock Detection Function................................................................................... 8-74

8.7.2 Shock Detection Function Setting....................................................................... 8-74

8.7.2.1 Shock Detection Level Setting............................................................... 8-74

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DX100 Contents

8.7.2.2 Tool Load Information Setting ............................................................... 8-77

8.7.2.3 Instruction of Shock Detection Function................................................ 8-77
8.7.2.4 Resetting the Shock Detected............................................................... 8-82

8.8 User Coordinate Setting .................................................................................................. 8-83

8.8.1 User Coordinates................................................................................................ 8-83

8.8.2 User Coordinate Setting ..................................................................................... 8-84

8.8.2.1 Selecting the User Coordinate File........................................................ 8-84
8.8.2.2 Teaching the User Coordinates............................................................. 8-85
8.8.2.3 Clearing the User Coordinates .............................................................. 8-87

8.9 Overrun / Tool Shock Sensor Releasing ......................................................................... 8-88

8.10 Soft Limit Release Function........................................................................................... 8-90

8.11 All Limit Release Function ............................................................................................. 8-91

8.12 Instruction Level Setting ................................................................................................ 8-93

8.12.1 Setting Contents ............................................................................................... 8-93

公 司
8.12.1.1 Instruction Set ..................................................................................... 8-93
8.12.1.2 Learning Function ............................................................................... 8-94

有 限
8.12.2 Setting the Instruction Set Level....................................................................... 8-94

技
8.12.3 Setting the Learning Function .......................................................................... 8-96
科
教 育
8.13 Setting the Controller Clock ........................................................................................... 8-97

8.14 Setting the Play Speed .................................................................................................. 8-98

控 帮
8.15 Numeric Key Customize Function ............................................................................... 8-100

沙 工
8.15.1 What is the Numeric Key Customize Function? ............................................. 8-100

长
8.15.2 Allocatable Functions ..................................................................................... 8-100
8.15.2.1 Key Allocation (EACH) ...................................................................... 8-100
8.15.2.2 Key Allocation (SIM).......................................................................... 8-101

8.15.3 Allocating an Operation .................................................................................. 8-102

8.15.3.1 Allocation Window ............................................................................. 8-102
8.15.3.2 Instruction Allocation ......................................................................... 8-103
8.15.3.3 Job Call Allocation............................................................................. 8-105
8.15.3.4 Display Allocation .............................................................................. 8-105
8.15.3.5 Alternate Output Allocation ............................................................... 8-107
8.15.3.6 Momentary Output Allocation ............................................................ 8-108
8.15.3.7 Pulse Output Allocation ..................................................................... 8-108
8.15.3.8 Group (4-bit/8-bit) Output Allocation.................................................. 8-109
8.15.3.9 Analog Output Allocation................................................................... 8-109
8.15.3.10 Analog Incremental Output Allocation ............................................. 8-110

8.15.4 Allocation of I/O Control Instructions .............................................................. 8-111

8.15.5 Execution of Allocation ................................................................................... 8-112

8.15.5.1 Executing the Instruction/Output Control Allocation .......................... 8-112
8.15.5.2 Executing the Job Call Allocation ...................................................... 8-112

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DX100 Contents

8.15.5.3 Executing the Display Allocation ....................................................... 8-112

8.15.5.4 Executing the I/O Control Allocation.................................................. 8-112

8.16 Changing the Output Status......................................................................................... 8-114

8.17 Changing the Parameter Setting.................................................................................. 8-116

8.18 File Initialization ........................................................................................................... 8-119

8.18.1 Initializing Job File .......................................................................................... 8-119

8.18.2 Initializing Data File......................................................................................... 8-120

8.18.3 Initializing Parameter File ............................................................................... 8-121

8.18.4 Initializing I/O Data.......................................................................................... 8-122

8.18.5 Initializing System Data .................................................................................. 8-124

8.19 Display Setting Function .............................................................................................. 8-126

8.19.1 Font Size Setting ............................................................................................ 8-126

8.19.1.1 Applicable Range for the Font Size Change ..................................... 8-126
8.19.1.2 Settable Font Size ............................................................................. 8-126

公 司
8.19.1.3 Setting the Font Size ......................................................................... 8-126

有 限
8.19.2 Operation Button Size Setting ........................................................................ 8-130
8.19.2.1 Applicable Range for the Button Size Change .................................. 8-130

科 技
8.19.2.2 Settable Button Size .......................................................................... 8-130
8.19.2.3 Setting the Button Size ...................................................................... 8-130

教 育
8.19.3 Initialization of Screen Layout......................................................................... 8-134
帮
8.19.3.1 Initializing the Screen Layout............................................................. 8-134
控
工
8.19.4 Layout Storage ............................................................................................... 8-136

沙
长
9 System Backup ............................................................................................................................... 9-1

9.1 System Backup with DX100............................................................................................... 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
9.1.1.3 CMOSxx.HEX.......................................................................................... 9-1
9.1.1.4 ALCMSxx.HEX ........................................................................................ 9-1

9.1.2 Device................................................................................................................... 9-2

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

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DX100 Contents

9.3.2.1 CompactFlash ......................................................................................... 9-9

9.3.2.2 AUTO BACKUP SET Display................................................................ 9-10
9.3.2.3 DX100 Status and Automatic Backup ................................................... 9-14
9.3.2.4 Setting Examples .................................................................................. 9-15

9.4 Loading the Backup Data from the CompactFlash .......................................................... 9-17

9.4.1 Loading Procedure ............................................................................................. 9-17

9.5 Error List .......................................................................................................................... 9-20

9.5.1 Error Contents .................................................................................................... 9-20

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 YPP01........................................................................... 10-2

司
10.3 Error Message ............................................................................................................... 10-4
公
限
11 Modification of System Configuration ......................................................................................... 11-1
有
科 技
11.1 Addition of I/O Modules ................................................................................................. 11-1

11.2 Addition of Base and Station Axes ................................................................................ 11-3

教 育
11.2.1 Base Axis Setting ............................................................................................. 11-5

控 帮
11.2.1.1 Selection of Base Axis Type................................................................ 11-5
11.2.1.2 Connection Setting .............................................................................. 11-8

沙 工
11.2.1.3 Axis Configuration Setting ................................................................... 11-9

长 11.2.1.4 Mechanical Specification Setting....................................................... 11-10

11.2.1.5 Motor Specification Setting................................................................ 11-12

11.2.2 Station Axis Setting ........................................................................................ 11-13

11.2.2.1 Selection of Station Axis Type........................................................... 11-13
11.2.2.2 Connection Setting ............................................................................ 11-15
11.2.2.3 Axis Configuration Setting ................................................................. 11-16
11.2.2.4 Mechanical Specification Setting....................................................... 11-18
11.2.2.5 Motor Specification Setting................................................................ 11-20

12 DX100 Specification.................................................................................................................... 12-1

12.1 Specification List............................................................................................................ 12-2

12.2 Function List .................................................................................................................. 12-3

12.3 Programming Pendant................................................................................................... 12-4

12.4 Equipment Configuration ............................................................................................... 12-5

12.4.1 Arrangement of Units and Circuit Boards ......................................................... 12-5

12.4.2 Cooling System of the Controller Interior.......................................................... 12-7

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DX100 Contents

13 Description of Units and Circuit Boards ...................................................................................... 13-1

13.1 Power Supply Contactor Unit......................................................................................... 13-3

13.2 Major Axes Control Circuit Board (SRDA-EAXA01□) .................................................... 13-4

13.2.1 Major Axes Control Circuit Board (SRDA-EAXA01□) ....................................... 13-4

13.2.2 Connection for Tool Shock Sensor (SHOCK)................................................... 13-5

13.2.2.1 To connect the tool shock sensor directly to the tool shock sensor
signal line............................................................................................... 13-5
13.2.2.2 To connect the tool shock sensor with the cable that is built into
the manipulator...................................................................................... 13-6

13.2.3 Connection for Direct-in .................................................................................... 13-7

13.3 CPU Unit ........................................................................................................................ 13-8

13.3.1 CPU Unit Configuration .................................................................................... 13-8

13.3.2 Unit and Circuit Board in the CPU Unit............................................................. 13-9

13.3.2.1 Control Circuit Board (JANCD-YCP01-E)............................................ 13-9
13.3.2.2 Robot I/F Board (JANCD-YIF01-1E) ................................................... 13-9

公 司
13.4 CPS Unit (JZNC-YPS01-E).......................................................................................... 13-10

限
13.5 Brake Control Board (JANCD-YBK01-□E)................................................................... 13-12
有
科 技
13.5.1 Brake Control Board (JANCD-YBK01-□E)...................................................... 13-12

13.6 Robot I/O Unit (JZNC-YIU01-E)................................................................................... 13-13

教 育
13.6.1 Robot I/O Unit (JZNC-YIU01-E)...................................................................... 13-13

控 帮
13.7 Machine Safety Unit (JZNC-YSU01-1E) ...................................................................... 13-18

工
13.7.1 Machine Safety Unit (JZNC-YSU01-1E)......................................................... 13-18
沙
长
13.7.2 Connection for Servo-ON Enable Input (ONEN1 and ONEN2) ...................... 13-19

13.7.3 Connection for External Axis Overrun (EXOT) ............................................... 13-20

13.8 WAGO Connector ........................................................................................................ 13-21

13.9 Robot Specific Input Terminal Block (MXT) ................................................................. 13-23

13.10 Contact Output of Emergency Stop Button................................................................ 13-34

13.11 SERVOPACK............................................................................................................. 13-35

13.11.1 Description of Each Unit ............................................................................... 13-35

13.11.1.1 Converter......................................................................................... 13-35
13.11.1.2 PWM Amplifier................................................................................. 13-35

13.11.2 SERVOPACK Configuration ......................................................................... 13-35

13.12 Universal I/O Signal Assignment ............................................................................... 13-40

13.12.1 Arc Welding .................................................................................................. 13-40

13.12.2 Handling ....................................................................................................... 13-46

13.12.3 General Application ...................................................................................... 13-52

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DX100 Contents

13.12.4 Spot Welding ................................................................................................ 13-58

13.12.5 JANCD-YEW01-E Circuit Board (Standard)................................................. 13-66

13.12.5.1 Arc Welding ..................................................................................... 13-66

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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1 Safety
DX100 1.1 For Your Safety

1 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 user’s 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
•
司
Teaching maintenance of the robot must conform to:
– Industrial Safety and Health Law
公
限
– Enforcement Order of Industrial Safety and Health Law
有
Other related laws are:
科 技
– Ordinance of Industrial Safety and Health Law

育
– Occupational Safety and Health Act in USA
教
控 帮
– Factory Act (Gewerbeordnung) in Germany
– Health and Safety at Work, etc. Act in UK

沙 工 – EC Machinery Directive 98/37/EC

长 • 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.

1-1
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1 Safety
DX100 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
公 司
•
限
It is important to have and be familiar with all manuals concerning
the MOTOMAN.
有
– MOTOMAN- 科 技
You should have the four manuals listed below:
INSTRUCTIONS

教 育
– DX100 INSTRUCTIONS

控 帮
– DX100 OPERATOR’S MANUAL

沙 工 Confirm that you have all these manuals on hand.

If any manuals are missing, contact your salesman from YASKAWA’s

长 local branch office.

The relevant telephone numbers are listed on the back cover.

1-2
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1 Safety
DX100 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.

CAUTION
• 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.

公 司
Failure to observe these cautions may result in fire, electric shock, or
injury due to contact with the manipulator and other equipment.
•
有
Strictly observe the following items: 限
科 技
– Always wear approved work clothes (no loose-fitting clothes).
– Do not wear gloves when operating the MOTOMAN.

教 育
– Do not allow underwear, shirts, or neckties to hang out from the

控 帮
work clothes.
– Do not wear large jewelry, such as earrings, rings, or pendants.

沙 工
Always wear protective safety equipment such as helmets, safety
shoes (with slip-proof soles), face shields, safety glasses, and gloves
长 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
DX100, controller, the workpiece, the positioner, etc.

1-3
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1 Safety
DX100 1.4 Personnel Safety

CAUTION
• Never forcibly move the manipulator axes.
Failure to observe this caution may result in injury or equipment
damage.

公 司
•
限
Never lean on DX100 or other controllers, and avoid inadvertently
pushing buttons.
有
科 技
Failure to observe this caution may result in injury or damage by
unexpected movement of the manipulator.

教 育
控 帮
沙 工
长

• Never allow unauthorized personnel to touch the DX100 during

operation.
Failure to observe this caution may result in injury or damage resulting
from unexpected movement of the manipulator.

1-4
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1 Safety
DX100 1.5 Motoman Safety

1.5 Motoman Safety

1.5.1 Installation and Wiring Safety

Refer to the MOTOMAN- Instructions manual and DX100
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.
公 司
限
Safeguarding
DX100

技有
Door
1000 mm or more

育 科
帮 教
1000 mm or more 1000 mm or more

工 控
长 沙 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.

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.

1-5
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1 Safety
DX100 1.5 Motoman Safety

CAUTION
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 DX100, please check the following:
– As a rule, handling of DX100 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 DX100.

公 司
Wire Rope
限
Table 1-1: Approx. Weight of DX100

技有
Models Available for Approx. Weight
DX100 (kg)

科
M16 Eye Bolt

育
small capacity:
MA1400, MA1900,
A-Type
(standard)

帮 教 VA1400, MH5, MH5L,

MH6, HP20D, HP20D-6
100

工控 middle/large capacity:
MH50, MS80, ES165D,
ES200D, VS50, SIA50D
A-Type
(standard)
100

长 沙

• Be sure the eyebolts are securely fastened.

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

1-6
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1 Safety
DX100 1.5 Motoman Safety

CAUTION
• Be sure there is sufficient room for maintenance on the manipulator,
DX100, and other peripheral equipment.
Failure to observe this precaution could result in injury during
maintenance.

500
425 425 450 500
DX100 DX100
E R GE N

EM

C
Y
DX100 S T
O P

PED
ON

TRIP
OFF
ET
RES
450

1200
PROGRAMMING PENDANT
X 8 1

DOOR
406
510

Kg

司
maintenance area

DX100 Maintenance Area (Unit: mm)

公
DX100 External Dimensions (Unit: mm)
A-Type (Standard)
限
•
有
To ensure safety, be sure to operate the controller from a location
技
where the manipulator is easily visible.

damage. 育 科
Operation by unauthorized personnel may result in injury or equipment

•
帮 教
Install the DX100 outside the safeguarding of the manipulator’s

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

长沙 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.
Failure to observe this caution may result in injury or damage to
equipment.

1-7
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1 Safety
DX100 1.5 Motoman Safety

CAUTION
• Secure the position of the DX100 after setting up.
Attach the DX100 to the floor or rack, etc., using the screw holes on the
bottom of the DX100.
Failure to observe this caution could lead to injury or equipment
damage if the DX100 should shift or fall.
DX100
R GE N
ME

CY
E
S T
O P
D ON
PE
IP
TR

SEOFF
T
RE
Tapped Holes for
M10 Screws on
the DX100 Side
40 PROGRAMMING PENDANT
X  8   1

12 dia.
(2 holes)

公 司
限
50
30

技有
概算質量：   Kg

30
50

育 科
(Unit: mm)

•
帮 教Be familiar with the connection diagram before wiring the DX100,
and perform the wiring in accordance with the connection diagram.

工控
There is a danger of equipment damage or injury due to miswiring and
unexpected movement of the equipment.

长 沙 • Take precautions when wiring and piping between the DX100,

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.

1-8
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1 Safety
DX100 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公司
• 有 限
Store tools and similar equipment in proper locations outside of the
enclosure.
科 技
教 育
Tools and loose equipment should not be left on the floor around the
manipulator, DX100, or welding fixture, etc., as injury or damage to

帮
equipment can occur if the manipulator comes in contact with objects or
equipment left in the work area.

工 控
长 沙

1-9
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1 Safety
DX100 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 DX100 and the tool,
lock the switch, and display a warning sign.

ON

D
PE
IP
TR
OFF
ENERGIZING

T
SE
RE
PROHIBITED

PADLOCK

公 司
有 限 DX100

技
Turning the power ON during tool installation may case electric shock
or injury due to unexpected movement of the manipulator.
科
•
育
Never exceed the rated capacity of the manipulator (capacity can

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

控 帮
Failure to observe this caution may result in injury or damage to
equipment.

沙 工 • Teach jobs from outside the manipulator’s work area whenever

长
possible.
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– 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.

1-10
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1 Safety
DX100 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 DX100, 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 DX100 power
– Moving the manipulator with the programming pendant
– Running the system in the check mode
– Performing automatic operations

P-point maximum envelope of the manipulator. 公 司

Injury may result from contact with the manipulator if persons enter the

有 限
科 技
Press the emergency stop button immediately if there are problems.
The emergency stop buttons are located on the right of the front door of
育
the DX100 and the programming pendant.
教
控 帮 Emergency Stop Button

沙 工 DX100

Programming Pendant

1-11
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1 Safety
DX100 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 DX100
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.

公 司
限
MANDATORY
有
•
科技
Persons operating or inspecting the manipulator should be trained

育
as required by applicable laws and company policies.

教
– Refer to chapter 1.2 “Special Training” at page 1-2

帮
工 控
长沙

1-12
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1 Safety
DX100 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 chapter 1.3
“Motoman Manual List” at 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 DX100 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.
• 司
When the MOTOMAN is transferred, it is recommended to check
公
with Yaskawa Engineering Co. which is listed on back cover of this
manual.
有 限
damage.
科 技
Incorrect installation or wiring may result in personal injury and property

教 育
控 帮
沙 工
长

1-13
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1 Safety
DX100 1.7 Notes on MOTOMAN Disposal

1.7 Notes on MOTOMAN Disposal

PROHIBITED
• Never modify the manipulator or DX100.
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.

公 司
Failure to observe this precaution may result in injury due to the
manipulator falling down.
有 限
科 技
教 育
控 帮
沙 工
长

1-14
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2 Product Confirmation
DX100 2.1 Contents Confirmation

2 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
• DX100
• Programming Pendant
• Manipulator Cable (Between Manipulator and DX100)
• Complete Set of Manuals
Fig. 2-1: Standard Five Items

Manipulator
DX100
Programming
Pendant
司
R GE N
ME
CY
E

S T
O P

公
D ON
PE
IP
TR
SEOFF
T
RE

有 限
科 技
育
PROGRAMMING PENDANT
X  8  1

帮 教
工 控
长 沙 概算質量：   Kg

MOTOMAN
安全マニュアル

Complete Set of Manuals

Manipulator Cable

2-1
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2 Product Confirmation
DX100 2.2 Order Number Confirmation

2.2 Order Number Confirmation

Confirm that the order number pasted on the manipulator and DX100
match.
The order number plates are affixed to the figure below.

<Example>
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.

ORDER NO. S78796-1

R GE N
ME
CY
E

S T
O P
D ON
PE
IP
TR
SEOFF
T
RE

公 司
有 限
技
PROGRAMMING PENDANT
X   8  1

育 科
帮 教
工 控
长 沙 概算質量：   Kg

2-2
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3 Installation
DX100 3.1 Handling Procedure

3 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 DX100 may adversely affect the
performance of the DX100.

3.1.1 Using a Crane to Move the Controller

Check the following before handling the DX100:

公 司
• 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.

有 限
• Install eyebolts for handling and confirm they are securely fastened
before hoisting.

科 技
教 育
控 帮
沙 工 Wire Rope

长 M16 Eye Bolt

Table 3-1: Approx. Weight of DX100
Models Available for Approx. Weight
DX100 (kg)
small capacity: A-Type
MA1400, MA1900, (standard)
VA1400, MH5, MH5L, 100
MH6, HP20D, HP20D-6
middle, large capacity: A-Type
MH50, MS80, ES165D, (standard)
ES200D, VS50, SIA50D 100

3-1
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3 Installation
DX100 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 DX100
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.

公司
Protective padding

有限
Tiedown straps

科 技
育
Palette

帮 教 Forklift

工 控
长 沙

3-2
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3 Installation
DX100 3.2 Place of Installation

3.2 Place of Installation

The conditions listed below must be met before installing the DX100:
• Ambient temperature must be 0 to 45° C (32 to 113°F) during opera-
tion and -10 to 60°C (14 to 140°F) during transportation and mainte-
nance.
• 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 DX100 (under 0.5 oscilla-
tion).
• No large electric noise source (such as a TIG welding device, etc.)
nearby.
• No potential for collision with moving equipment such as forklifts.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

3-3
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3 Installation
DX100 3.3 Location

3.3 Location
1. Install the DX100 outside of the P-point maximum envelope of the
manipulator (outside of the safeguarding.)
Fig. 3-1: Location of DX100

SAFEGUARD
DX100
DOOR
1000 mm or more

1000 mm or more 1000 mm or more

WORKING ENVELOPE
OF MANIPULATOR

公 司
MAXIMUM WORKING ENVELOPE OF
MANIPULATOR INCLUDING TOOL
OR WORKPIECE END

有 限
1000 mm or more

科 技
2. Install the controller in a location from which the manipulator is easily
visible.

教 育
3. Install the controller in a location from which you can easily inspect it

控 帮
when the door is open.

沙 工
长
500

425

DX100
450

DOOR
406
510

maintenance area

A-Type Standard

4. Install the controller at least 500mm from the nearest wall to allow
maintenance access.

3-4
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3 Installation
DX100 3.4 Mounting the Controller

425 450 500

DX100 DX100

1200
A-Type (Standard)

3.4 Mounting the Controller

CAUTION
公 司
•
有
Do not climb on top of the DX100.
限
failure. 科 技
Failure to observe this caution could lead to injury or mechanical

教 育
Attach the controller to the floor using user-supplied brackets made
帮
according to the specifications shown below.
控
沙 工 DX100

长
R GE N
ME
CY
E

S T
O P
D ON
PE
IP
TR
SEOFF
T
RE

Tapped Holes for

M10 Screws on
the DX100 Side
40 PROGRAMMING PENDANT
X 8 1

12 dia.
(2 holes)

50
30
概算質量：   Kg

30
50

(Unit: mm)

NOTE Refer to the Instruction Manual for information on installa-

tion of the manipulator.

3-5
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4 Connection
DX100

4 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.
• 司
Power cannot be turned ON unless the door is closed. Interlocks
prevent power from being turned ON.
公
限
Failure to observe this caution may result in fire and electric shock.
有
•
技
Any occurrence during wiring while the DX100 is in the emergency

科
stop mode is the user’s responsibility. Do an operation check once

教 育
the wiring is completed.
Failure to observe this caution could lead to injury or mechanical

控 帮
failure.

沙 工
长 CAUTION
• 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
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4 Connection
DX100 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 misconnection
and equipment damage. One connects the manipulator and DX100.
Another connects the DX100 and peripheral device. A wrong con-
nection can cause damage to electronic equipment.
• Clear the area of all unauthorized personnel while making cable con-
nections. Place all cables in a covered cable channel in the floor.
Fig. 4-1: DX100 Cable Junction Diagram

公 司
限
技有
SAFETY
FIRST

育 科 LEAD
教
PIPING
cable channel

控 帮
沙 工
长

4-2
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4 Connection
DX100 4.2 Power Supply

4.2 Power Supply

4.2.1 Three-Phase Power Supply

The power failure processing circuit operates when there is

a black out or drop in voltage, and the servo power turns
NOTE OFF.
Connect the power supply to a stable power source that is
not prone to power fluctuations.

The three-phase power supply consists of 200/220VAC at 60Hz and

200VAC at 50Hz.
Fig. 4-2: Input Power Connection
DX100

Contactor
Breaker
3-phase 1KM 2KM
200/220VAC at 60Hz

司
or SERVOPACK
200VAC 50Hz

限 公
Fuse

技有
Noise Filter

To control

育 科 power supply
unit

帮 教
4.2.2
控
Noise Filter Installation

沙工
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.
长 Seal up each cable opening so that dust does not enter.
Fig. 4-3: Connection of Three-Phase Noise Filter

DX100
3-phase
Noise Filter Contactor
Breaker
3-phase 1KM 2KM
200/220VAC at 60Hz
or SERVOPACK
200VAC 50Hz

Fuse

Noise Filter

To control
power supply
unit

4-3
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4 Connection
DX100 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
DX100 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 DX100 inverter. However, this
current leakage presents no safety risks.
Fig. 4-4: Connection of the Leakage Breaker

Leakage DX100
Breaker
Contactor
Breaker
1KM 2KM
3-phase

公司
200/220VAC at 60Hz
SERVOPACK
or
200VAC 50Hz

有 限
Fuse

技
Noise Filter

育 科 To control
power supply
unit

帮 教
工 控
长 沙

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4 Connection
DX100 4.2 Power Supply

4.2.4 Primary Power Supply Breaker Installation

Install the primary power supply breaker as shown.
Fig. 4-5: Installation of the Primary Power Supply Breaker

Breaker Breaker Breaker

Controller Power
DX100
for Positioner Source

Table 4-2: DX100 Power Capacity, Cable Sizes, and Breaker Capacities

公司
Manipulator Power capacity Cable size Capacity of breaker in
(size of terminal)
(kVA) DX100 (A)

(mm2)
有 限
(In case of Cabtyre cable (three cores))

MH5, MH5L 1 3.5 (M5)

科 技 15

育
MH6, MA1400N 1.5 3.5 (M5) 15
VA1400
HP20D, HP20D-6
MA1900
2.0
帮 教 3.5 (M5) 15

MH50, MS80 4.0

工 控 5.5 (M5) 30
VS50, SIA50D,
ES165D, ES200D
长 沙 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.

4-5
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4 Connection
DX100 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

Primary Power Supply Cable

DX100 DX100 Manipulator

Programming Manipulator
Pendant Cable Cable

4.3.1 Connecting the Primary Power Supply

公 司
1. Open the front door of the DX100.
有 限
(1) Using a flathead screwdriver, rotate the door locks on the front of
技
the DX100 (two places) 90 degrees clockwise.
科
育
Fig. 4-7: Rotating the Door Lock Clockwise

教
控 帮
沙 工
长
door lock
clockwise
90
flathead screw driv

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4 Connection
DX100 4.3 Connection Methods

(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

Main power supply switch

公 司
有 限
科 技
2. Confirm that the primary power supply is OFF.
育
3. Connect the primary power supply cable.
教
控 帮
– Draw the primary power supply cable in from the cable entrance on
top side of DX100 and fix it firmly with the cable clamp so that it

沙 工 won’t shift or slip out of place.

Fig. 4-9: Cable Clamp
长 DX100
Primary Power Supply Cable

CAUTION
Cable clamp must be used when connnecting 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 DX100.

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4 Connection
DX100 4.3 Connection Methods

(1) Pull off the primary cover of the switch which is on the upper right
side of the DX100.
Fig. 4-10: Pulling Off the Cover

司
(2) Connect a ground wire to reduce noise and prevent electric shock.
公
I)
限
Connect the ground wire to the ground terminal (screw) of the

有
switch which is on the upper left side of DX100.

技
Fig. 4-11: Connection of the Ground Wire
科
教育
Ground wire Ground terminal
(M6 screws)

控 帮
沙 工
长

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4 Connection
DX100 4.3 Connection Methods

II) 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 “DX100 Power Capacity, Cable
Sizes, and Breaker Capacities” at page 4-5.

NOTE The customer must prepare the ground wire.

Fig. 4-12: Exclusive Grounding

Exclusive Grounding
100 ohm maximum
ground resistance

Don’t connect the grounding wire with the wires for the elec-

NOTE 公 司
tric power source, the welder, etc.

有 限
Ground in accordance with all relevant governmental regu-
lations when using metallic ducts, metallic conduits, and

技
cable tray to construct the cable.

科
教 育
(3) Connect the primary power supply cable.

帮
Fig. 4-13: Connection of the Primary Power Supply Cable

控
沙 工
长

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4 Connection
DX100 4.3 Connection Methods

(4) Install the cover.

Fig. 4-14: Install the Cover

公 司
有 限
科 技
教 育
控 帮
沙 工
长

4-10
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4 Connection
DX100 4.3 Connection Methods

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 DX100.
Fig. 4-15: Connection of the Manipulator Cable

公 司
有 限
NOTE
科 技
For more information on connecting the manipulator cable,
please refer to the Instruction Manual which corresponds to

教 育 the particular DX100 model.

帮
2. Connect the manipulator to the DX100.

工控
– Confirm the shape and size of the cable connector, the key fitting,
and the position of the pins of the manipulator. Push the cable

长沙
connector into the manipulator side connector firmly, and tighten
securely.
3. Close the DX100 door.
(1) Close the door gently.
(2) Rotate the door lock counterclockwise 90 degrees.
Fig. 4-16: Rotating the Door Lock Counterclockwise

counterclockwise 90
door lock

flathead screw driver

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4 Connection
DX100 4.3 Connection Methods

CAUTION
Always close the door of the controller (DX100) except for mainte-
nance.
Make sure to rotate all the door locks counterclockwise.
If dust or water enter inside the controller, electric shock or breakdown
of DX100 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

公 司
有 限
科 技 Alignment mark

教 育
控 帮
沙 工
长
– The manipulator, DX100, and the programming pendant
connections are now complete.

4-12
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5 Turning ON and OFF the Power Supply

DX100 5.1 Turning ON the Main Power Supply

5 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 DX100 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 DX100 and on the right side of the programming pendant.

公 司
The main power supply is turned ON when the main power supply switch
on the front of the DX100 is turned to the "ON" position, and the initial
diagnosis and the current position setting begin.

有
Fig. 5-1: Turning ON the Main Power Supply
限
科 技
教 育
控 帮 Main power supply switch

沙 工 TR
IP
PE
D
ON

长
OFF
T
SE
RE

DX100

5-1
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5 Turning ON and OFF the Power Supply

DX100 5.1 Turning ON the Main Power Supply

5.1.1 Initial Diagnosis

The initial diagnosis are performed in the DX100 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

公 司
data, including:
有 限
When the power supply is turned OFF, the DX100 saves all condition

• Mode of operation

科 技
• Called job (active job if the DX100 is in the play mode; edit job if the
育
DX100 is in the teach mode) and the cursor position in the job.
教
帮
Fig. 5-3: Initial Window

控
沙 工
长

5-2
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5 Turning ON and OFF the Power Supply

DX100 5.2 Turning ON the Servo Power

5.2 Turning ON the Servo Power

5.2.1 During Play Mode

The worker’s 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 When the safeguarding is open, the servo power supply

cannot be turned ON.

公 司
5.2.2 During Teach Mode
有 限
科 技
1. Press [SERVO ON READY] on the programming pendant to turn ON
the servo power supply. [SERVO ON] lamp will flicker when the servo

育
power is turned ON.

教
控 帮 SERVO ON
READY

沙 工 Flicker

长 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
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5 Turning ON and OFF the Power Supply

DX100 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.

SUPPLE
-MENT Servo On

Release -> OFF Squeeze -> ON Squeeze Tightly -> OFF

When performing emergency stop on the front door of the

DX100, programming pendant, or external signal, the servo
NOTE
司
power-on operation from the Enable switch is cancelled.
公
When turning the power back ON, follow the previously
listed instructions.
有 限
科 技
教 育
控 帮
沙 工
长

5-4
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5 Turning ON and OFF the Power Supply

DX100 5.3 Turning OFF the Power Supply

5.3 Turning OFF the Power Supply

5.3.1 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
DX100 and on the right side of the programming pendant.
• The brake 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

公 司
有 限
Door upper side

5.3.2 Turning OFF the Main Power 科 技

教 育
After turning OFF the servo power, turn OFF the main power.

控 帮
• When the main power switch on the front of DX100 is turned to the
“OFF“ position, the main power is turned OFF.

沙 工
长
Main power supply switch
ON
D
PE
IP
TR
OFF
ET S
RE

DX100

5-5
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6 Test of Program Operation

DX100

6 Test of Program Operation

WARNING
• Press the emergency stop button on the right of the front door of the
DX100 and the programming pendant before operating the
manipulator. Confirm that the SERVO ON lamp is turned OFF.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency. The emergency stop buttons are
attached on the front door of the DX100 and right of the programming
pendant.
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– Always view the manipulator from the front.
– Always follow the predetermined operating procedure.

公 司
– Always have an escape plan in mind in case the manipulator
comes toward you unexpectedly.

有 限
– Ensure that you have a place to retreat to in case of emergency.

技
Improper or unintentional manipulator operation can result in injury.
科
•

教 育
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.

控 帮
– Turning ON the DX100 power

沙 工 – Moving the manipulator with the programming pendant

长 – Running the system in the check mode

– Performing automatic operations
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator.

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6 Test of Program Operation

DX100 6.1 Movement of the Axes

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.
– Check for problems in manipulator movement.
– Check for damage to the insulation and sheathing of external
wires.
• Always return the programming pendant to its specified position
after use.
If the programming pendant is inadvertently left on the manipulator,
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injuries or equipment
damage.

6.1 Movement of the Axes

公 司
有 限
Move each axis of the manipulator by pressing the axis keys on the
programming pendant.

科 技
This figure illustrates each axis of motion in the joint coordinates.

教 育 Be sure to remove all items from the area before moving the

控 帮
NOTE manipulator.
Refer to the INSTRUCTION MANUAL for the appropriate
position of the fixture.

沙 工
长
U-Axis
R-Axis

B-Axis

X- X+ X- X+
S- S+ R- R+ T-Axis
Y- Y+ Y- Y+
E-Axis
L- L+ B- B+

Z- Z+ Z- Z+
U- U+ T- T+ L-Axis
E- E+ 8- 8+

Axis Keys S-Axis

6-2
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6 Test of Program Operation

DX100 6.1 Movement of the Axes

Rotates main body Rotates upper arm

X- X+ X+
S- S+ R+

X-
R-

Moves lower arm forward/ Moves wrist up/down

backward
Y-
B-

Y- Y+
L- L+

Y+
B+

Moves upper arm up/ down Rotates wrist

Z+
U+ Z+
T+

Z-
T-
Z-
U-

E Rotates lower arm

司
E- E+

限 公
技 有
育 科
帮 教
工 控
长沙

6-3
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公 司
有 限
System
教 育 科Up
技

控 帮
沙 工
长
 工控帮助教小舒QQ:2823408167

7 Security System
DX100 7.1 Protection Through Security Mode Settings

7 Security System

7.1 Protection Through Security Mode Settings

The DX100 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 three security modes. Editing mode and management mode
require a user ID. The user ID consists of numbers and letters, and
contains no less than 4 and no more than 8 characters. (Significant
numbers and signs: ”0 to 9”, “-”, “.”.

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 司
This mode allows the operator to teach and edit jobs and
robot settings. 公
Management
Mode 有 限
This mode allows those authorized to set up and maintain
robot system: parameters, system time and modifying user
IDs.

科 技
教 育
控 帮
沙 工
长

7-1
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7 Security System
DX100 7.1 Protection Through Security Mode Settings

Table 7-2: Menu & Security Mode (Sheet 1 of 3)

Main Menu Sub Menu Allowed Security Mode
DISPLAY EDIT
JOB JOB Operation Edit
SELECT JOB Operation Operation
CREATE NEW JOB1) Edit Edit
MASTER JOB Operation Edit
JOB CAPACITY Operation -
1)
RES. START (JOB) Edit Edit
RES. STATUS2) Operation -
CYCLE Operation Operation
VARIABLE BYTE Operation Edit
INTEGER Operation Edit
DOUBLE Operation Edit
REAL Operation Edit
STRING Operation Edit

公司
POSITION (ROBOT) Operation Edit
POSITION (BASE) Operation Edit

有限
POSITION (ST) Operation Edit
LOCAL VARIABLE Operation -
IN/OUT
科 技
EXTERNAL INPUT Operation -

育
EXTERNAL OUTPUT Operation -

帮教
UNIVERSAL INPUT Operation Edit
UNIVERSAL OUTPUT Operation Edit

工控
SPECIFIC INPUT Operation -
SPECIFIC OUTPUT Operation -

长沙
RIN Operation -
CPRIN Operation -
REGISTER Operation -
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 Management Management
I/O MESSAGE Management Management

7-2
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7 Security System
DX100 7.1 Protection Through Security Mode Settings

Table 7-2: Menu & Security Mode (Sheet 2 of 3)

ROBOT CURRENT POSITION Operation -
COMMAND POSITION Operation -
SERVO MONITOR Management -
WORK HOME POS Operation Edit
SECOND HOME POS Operation Edit
DROP AMOUNT Management Management
POWER ON/OFF POS Operation -
TOOL Edit Edit
INTERFERENCE Management Management
SHOCK SENS LEVEL Operation Management
USER COORDINATE Edit Edit
HOME POSITION Management Management
MANIPULATOR TYPE Management -
ANALOG MONITOR Management Management
1)
OVERRUN&S-SENSOR Edit Edit
1)
LIMIT RELEASE Edit Edit
ARM CONTROL1)
SHIFT VALUE
公 司
Management
Operation
Management
-
SYSTEM INFO VERSION
限
Operation -

技有
MONITORING TIME Operation Management
ALARM HISTORY Operation Management

育 科
I/O MSG HISTORY Operation Management

帮教
SECURITY Operation Operation
FD/CF LOAD Edit -

工控
SAVE Operation -
VERIFY Operation -

长沙
DELETE Operation -
DEVICE Operation Operation
FOLDER Edit Management
2)
INITIALIZE Operation -
PARAMETER S1CxG Management Management
S2C Management Management
S3C Management Management
S4C Management Management
A1P Management Management
A2P Management Management
A3P Management Management
A4P Management Management
RS Management Management
S1E Management Management
S2E Management Management
S3E Management Management
S4E Management Management

7-3
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7 Security System
DX100 7.1 Protection Through Security Mode Settings

Table 7-2: Menu & Security Mode (Sheet 3 of 3)

SETUP TEACHING COND Edit Edit
OPERATE COND Management Management
DATE/TIME Management Management
3)
GRP COMBINATION Management Management
RESERVE JOB NAME Edit Edit
USER ID Edit Edit
SET SPEED Management Management
1)
KEY ALLOCATION Management Management
RES. START (CNCT) Management Management
AUTO BACK SET Management Management
WRONG DATA LOG Operation Management
ARC ARC START COND. Operation Edit
WELDING ARC END COND. Operation Edit
ARC AUX COND. Operation Edit
POWER SOURCE COND. Operation Edit
ARC WELD DIAG. Operation Edit

公司
WEAVING Operation Edit
4)
ARC MONITOR Operation -

有限
ARC MONITOR (SAMPL) Operation -
HANDLING HANDLING DIAGNOSIS Operation Edit

科技
SPOT WELD DIAGNOSIS Operation Edit
WELDING

育
I/O ALLOCATION Management Management

帮 教 GUN CONDITION
CLEARANCE SETTING
Management
Operation
Management
Edit

工 控
SPOT
POWER SOURCE COND
WELD DIAGNOSIS
Management
Operation
Management
Edit

长沙 WELDING
(MOTOR GUN)
GUN PRESSURE
PRESSURE
Edit
Edit
Edit
Edit
I/O ALLOCATION Management Management
GUN CONDITION Management Management
CLEARANCE SETTING Operation Edit
SPOT POWER Management Management
SOURCE COND
TIP INSTALLATION Operation Management
GENERAL WEAVING Operation Edit
GENERAL DIAG. Operation Edit
COMMON TO I/O VARIABLE CUSTOMIZE Operation Operation
ALL
APPLICATIONS
1 Displayed in the teach mode only.
2 It is possible to initialize a floppy at FC1/FC2.
3 Displayed only with two or more control groups.
4 Displayed in the teach mode only.
*Data is cleared in the edit mode or higher.

7-4
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7 Security System
DX100 7.1 Protection Through Security Mode Settings

7.1.1.1 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.

公 司
2. Select {SECURITY}.
有 限
技
– The selection window of security mode appears.

科
教 育
控 帮
沙 工
长

7-5
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7 Security System
DX100 7.1 Protection Through Security Mode Settings

3. Press [SELECT] .
– Select "SECURITY MODE".

4. Input the user ID.

– The user ID input window appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
The following user ID numbers are set by default.
SUPPLE • Editing Mode: [00000000]
-MENT
Management Mode: [99999999]

5. Press [ENTER].
– The input user ID is compared with the user ID of the selected
security mode. ]
– When the correct user ID is entered, the security mode is changed.

7-6
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7 Security System
DX100 7.1 Protection Through Security Mode Settings

7.1.2 User ID
User ID is requested when Editing Mode or Management Mode is
operated.
Create the user ID with four to eight numbers and symbols: the numbers 0
to 9; the symbols
"-" and ".".

7.1.2.1 Changing User ID

In order to change the user ID, the DX100 must be in Editing Mode or
Management Mode. Higher security modes can make changes the user
ID of to lower security modes.

1. Select {SETUP} under the main menu.

– The sub menu appears.

公 司
有 限
科 技
教 育
控 帮
沙 工 2. Select {USER ID}.

长 – The USER ID window appears.

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7 Security System
DX100 7.1 Protection Through Security Mode Settings

3. Select the desired ID.

– The character input line appears, and a message "Input current ID
no. (4 to 8 digits)" appears.

4. Input the current ID and press [ENTER].

公 司
– When the correct user ID is entered, a new ID is requested to be
input. "Input new ID no.(4 to 8 digits)" appears.

有 限
科 技
教 育
控 帮
沙 工
长
5. Input new ID and press [ENTER].
– User ID is changed.

7-8
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8 System Setup
DX100

8 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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

8-1
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8 System Setup
DX100 8.1 Home Position Calibration

8.1 Home Position Calibration

WARNING
• Before operating the manipulator, check that the SERVO ON lamp
goes out when the emergency stop buttons on the right of the front
door of the DX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency.
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always prepare your reactions to a manipulator’s unexpected
approach toward you.

公 司
– Ensure that you have a safe place to retreat in case of
emergency.

有 限
Improper or unintended manipulator operation may result in injury.
• 技
Prior to performing the following operations, be sure that no one is
科
in the P-point maximum envelope of the manipulator, and be sure

教 育
that you are in a safe place when:
– Turning ON the DX100 power.
帮
工控
– Operating the manipulator with the programming pendant.
Injury may result from contact with the manipulator if persons enter the

长沙
P-point maximum envelope of the manipulator.
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
DX100 and the programming pendant.

8-2
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8 System Setup
DX100 8.1 Home Position Calibration

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
DX100 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.

8.1.1 Home Position Calibration 公 司

有 限
科 技
Teaching and playback are not possible before the comple-
tion of the home position calibration.
NOTE
育
In a system with two or more manipulators, the home posi-
教
tion of all the manipulators must be calibrated before start-

控 帮
ing teaching or playback.

沙 工
Home position calibration is an operation in which the home position and
absolute encoder position coincide. Although this operation is performed

长 prior to shipment at the factory, the following cases require this operation
to be performed again.
• Change in the combination of the manipulator and DX100
• Replacement of the motor or absolute encoder
• Clearing stored memory (by replacement of NIF01 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 combina-
tion 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.

8-3
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8 System Setup
DX100 8.1 Home Position Calibration

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
SUPPLE The home position is the pulse value "0" for each axis and its
-MENT
posture. See chapter 8.1.3 “Home Position of the Robot”
at page 8-10.

8.1.2 Calibrating Operation

NOTE Home position calibration screen is displayed only in secu-

rity mode or management mode.

8.1.2.1 Registering All Axes at One Time

1. Select {ROBOT} under the main menu.
– The sub menu appears 公 司
有 限
科 技
教 育
控 帮
沙 工
长

2. Select {HOME POSITION}.

– The HOME POSITIONING window appears.

8-4
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8 System Setup
DX100 8.1 Home Position Calibration

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
4. Select the desired control group.
– Select the control group for HOME POSITIONING.
– The control group can also be selected by pressing page key .

8-5
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8 System Setup
DX100 8.1 Home Position Calibration

5. Select {EDIT} under the menu.

– The pull-down menu appears.

6. Select {SELECT ALL AXES}.

– The confirmation dialog box appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
7. Select {YES}.
– Displayed position data of all axes are registered as home position.
When {NO} is selected, the registration will be canceled.

8-6
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8 System Setup
DX100 8.1 Home Position Calibration

8.1.2.2 Registering Individual Axes

1. Select {ROBOT} under the main menu.
– The sub menu appears.
2. Select {HOME POSITION}.
3. Select the desired control group.
– 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.

公 司
有 限
科 技
育
– A confirmation dialog box appears.
教
控 帮
沙 工
长

5. Select {YES}.
– Displayed position data of the axis is registered as home position.
When {NO} is selected, the registration will be canceled.

8-7
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8 System Setup
DX100 8.1 Home Position Calibration

8.1.2.3 Changing the Absolute Data

To change the absolute data of the axis when home position calibration is
completed, perform the following:
1. Select {ROBOT} under the main menu.
2. Select {HOME POSITION}.
3. Select the desired control group.
– Perform the step 3 and 4 of the “Registering All Axes at One Time”
to select the desired control group.
4. Select the absolute data to be registered.
– The number can now be entered.

公 司
有 限
科 技
教 育
5. Enter the absolute data using the numeric keys.

控 帮
6. Press [ENTER].

沙 工 – Absolute data is modified.

8.1.2.4
长
Clearing Absolute Data
1. Select {ROBOT} under the main menu.
– The sub menu appears
2. Select {HOME POSITION}.
– Perform the step 3 and 4 of the “Registering All Axes at One Time”
to select the desired control group.
3. Select {DATA} under the main menu.

8-8
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8 System Setup
DX100 8.1 Home Position Calibration

– The pull-down menu appears

4. Select [CLEAR ALL DATA].

– A confirmation dialog box appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 5. Select {YES}.
– All absolute data are cleared.

– When {NO} is selected, the registration will be canceled.

8-9
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8 System Setup
DX100 8.1 Home Position Calibration

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°).

公 司
有 限
科 技
教 育 Other manipulator models have different positions. Always

控 帮
NOTE refer to "MANIPULATOR INSTRUCTIONS" for the correct
manipulator model.

沙 工
长

8-10
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8 System Setup
DX100 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.
• Before operating the manipulator, check that the SERVO ON lamp
goes out when the emergency stop buttons on the front door of
DX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency.
• Observe the following precautions when performing teaching

manipulator:
公 司
operations within the P-point maximum envelope of the

有 限
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.

科 技
– Ensure that you have a safe place to retreat in case of
emergency.

教 育
Improper or unintended manipulator operation may result in injury.
•
控 帮
Prior to performing the following operations, be sure that no one is
in the P-point maximum envelope of the manipulator, and be sure

沙 工 that you are in a safe place when:

长 – Turning ON the DX100 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 whenever there are
problems.
• Emergency stop buttons are attached on the front door of the
DX100 and the right side of the programming pendant.

8-11
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8 System Setup
DX100 8.2 Setting the Second Home Position (Check Point)

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 DX100
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.

8.2.1 Purpose of Position Check Operation

公 司
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

turned ON. 有 限
supply was turned OFF, an alarm is issued when the controller power is

科 技
There are two possible causes of this alarm:

教 育
• Error in the PG system
• The manipulator was moved after the power supply was turned OFF.

控 帮
If there is an error with the PG system, the manipulator may stall when

沙 工 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

长 checked.

8-12
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8 System Setup
DX100 8.2 Setting the Second Home Position (Check Point)

"OUT OF RANGE (ABSO DATA)" alarm occurs

Reset alarm

Turn ON servo power

Procedure After Alarm Occurs

Position confirmation
operation

Compare second home NG

position (check point)*
pulses with current
position pulses
公 司
Alarm occurs again

有 限
OK

科 技 Correct defective axis

教 育 • Replace PG system
• Home position calibration

∗ Position checking point

控 帮
沙 工
长 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, test runs, and FWD operation will not function
unless "CONFIRM POSITION" is performed.
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 chapter 8.2.2 “Procedure for the Sec-
ond Home Position Setting (Check Point)” at page 8-14.

8-13
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8 System Setup
DX100 8.2 Setting the Second Home Position (Check Point)

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.

• 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
brake, 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:
NOTE
• 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.
公 司
Regardless of cycle setting, the manipulator stops after

有 限
reaching to the step indicated by cursor. Starting the
manipulator again then moves it at the programmed
技
speed and cycle of the job.
科
教 育
8.2.2
帮
Procedure for the Second Home Position Setting (Check Point)

控 Apart from the "home position" of the manipulator, the second home

沙 工 position can be set up as a check point for absolute data. Use the
following steps to set the specified point.

长 If two or more manipulators or stations are controlled by one controller, the

second home position must be set for each manipulator or station.

1. Select {ROBOT} under the main menu.

– The sub menu appears.

8-14
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8 System Setup
DX100 8.2 Setting the Second Home Position (Check Point)

2. Select {SECOND HOME POS}.

– The SECOND HOME POS window appears.
A message “Available to move to and modify specified point” is
displayed.

3. Press the page key , or select {PAGE} to display the selection

window for the control group.
公 司
有 限
– When there are two or more group axes, select the group axes to
which the second home position is to be specified.

科 技
教 育
控 帮
沙 工
长

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.

8-15
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8 System Setup
DX100 8.2 Setting the Second Home Position (Check Point)

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.
公 司
限
The robot current position data when turning main power supply OFF and
ON can be confirmed in “POWER ON/OFF POS" window.
有
SUPPLE
科 技
For details on the “POWER ON/OFF POS" window, refer to "
7.7 Position Data When Power is Turned ON/OFF " in
育
-MENT
DX100 MAINTENANCE MANUAL.

帮 教
1. Select {ROBOT} under the main menu.

工控
– The sub menu appears.

长沙
2. Select {SECOND HOME POS}.
– The SECOND HOME POS window appears.

3. Press the page key , or select {PAGE} to display the selection

window for the control group.

8-16
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8 System Setup
DX100 8.2 Setting the Second Home Position (Check Point)

– 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.
公 司
6. Select {CONFIRM POSITION}.

有 限
– A message “Home position checked” appears.

科 技
– Pulse data of the second home position and current pulse data are

育
compared. If the compared error is in allowed range, playback
operation can be done.
教
控 帮
– If the error is beyond the allowed range, the alarm occurs again.

沙 工
长

8-17
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8 System Setup
DX100 8.3 Tool Data Setting

8.3 Tool Data Setting

8.3.1 Registering Tool Files

8.3.1.1 Number of Tool Files

There are 64 tool files numbered 0 to 63. Each file is called as a tool file.

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
SUPPLE
-MENT
司
one robot. Use the following parameter to set this function.
公
S2C333: TOOL NO. SWITCHING (1: enabled; 0: disabled)

TOR’S MANUAL.
有 限
For more details, refer to “ 8 Parameter ” in DX100 OPERA-

科 技
8.3.1.2 Registering Coordinate Data
教 育
控 帮
When the number input operation is used for registering the tool file, input
the TCP of the tool on the flange coordinates.

沙 工
长
XF

YF
Tool

TCP

ZF

1. Select {ROBOT} under the main menu.

8-18
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8 System Setup
DX100 8.3 Tool Data Setting

– The sub menu appears.

2. Select {TOOL}.
(1) Move the cursor to the number of the desired tool, and press
{SELECT} in the tool list window.
(2)
司
The tool coordinate window of the selected number appears.

公
– In the tool coordinate window, the tool number can be changed by
pressing the page key
有 限
or selecting {PAGE} .

科 技
教 育
控 帮
沙 工
长

– 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.
6. Press [ENTER].

8-19
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8 System Setup
DX100 8.3 Tool Data Setting

– The coordinate data is registered.

<Setting Example>

公 司
有 限
260 mm
科 技 260 mm 260 mm

教育
TCP TCP TCP
145 mm
ZF ZF
Tool A

控 帮 Tool B Tool C

沙 工 In case of Tool A, B
长

In case of Tool C

8-20
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8 System Setup
DX100 8.3 Tool Data Setting

8.3.1.3 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 XF
coordinates

YF

ZF
XT

Tool
coordinates YT

ZT

1. Select {ROBOT} under the main menu.

公 司
2. Select {TOOL}.
3. Select the desired tool number.
有 限
科 技
– In the same way as shown in Explanation 2, 3 in
chapter 8.3.1.2 “Registering Coordinate Data” at page 8-18,
育
display the desired tool coordinate window.
教
控 帮
4. Select the desired coordinate axis to modify.
– First, select Rz.

沙 工
5. Input the tool pose data.

长 – Input rotation angle around ZF of the flange coordinates.

XF

YF

ZF YF

X F Rz = 180

6. Press [ENTER].
– The rotation angle of Rz is registered.
In the same way, register the angle of Ry, Rx.

8-21
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8 System Setup
DX100 8.3 Tool Data Setting

Ry must be the input rotation angle around Y’F flange coordinates.

X F

ZF
Y F (Y F )
Z F
Ry = 90

– Rx must be the input rotation angle around X’F of flange

coordinates.
X F

YF

Z F Rx = 0

公 司
有 限
科 技
8.3.1.4 教 育
Setting the Tool Load Information

控 帮
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.

沙 工
长 SUPPLE
For more details on the tool load information, refer to
-MENT chapter 8.4.3 “Tool Load Information Setting” at page 8-43

8-22
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8 System Setup
DX100 8.3 Tool Data Setting

8.3.2 Tool Calibration

8.3.2.1 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 <Flange coordinates>
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 ZF: Direction perpendicular to the flange face

YF
YT
XT

公 司
限
Tool
coordinates

有
ZT

8.3.2.2 Setting of Tool Calibration Method

科 技
parameter.
教 育
There are three tool calibration methods, which are selected by setting

帮
S2C432: Designation of tool calibration method
控
沙 工 0: Calibrates only the coordinates.
“Coordinates” calculated from 5 calibration teaching points is
registered in the tool file.
长 In this case “Tool Posture Data” is all cleared to be 0.00.
1: Calibrates only the posture.
“Tool Posture Data” calculated from the first calibration
teaching point is registered in the tool file.
In this case, “Coodinates” 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.

8-23
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8 System Setup
DX100 8.3 Tool Data Setting

• In case of S2C432=0 (only coordiantes 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.)
NOTE
• 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.

8.3.2.3 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
公 司 TC3

有 限
科 技 TC4

教 育 TCP

帮
工控
TC5

长沙 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 calcurated with this TC1 posture.

8-24
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8 System Setup
DX100 8.3 Tool Data Setting

The X-axis of the tool coordinates is defined in the same direction as the
X-axis of the base coordinates.

Tool

TCP YT
Tool
XT Coordinates Z
Base
ZT Coordinates
X
Y

公 司
In case of calibrating with S2C432=2, teach TC1 with Z-axis
of the desired tool coordinates downward vertically to the

有 限
ground. Then teach the other calibration teaching points
(TC2~TC5) with the all tool points meet at the TC1’s tool

技
point as shown in the figure below.

科
教 育
控 帮
沙 工 SUPPLE

长
-MENT
If teaching in one place as the figure above is impossible
due to the interferance of peripheral equipments 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.

• There are 64 tool files numbered 0 to 63.

• In a basic system with one manipulator and one tool, the
SUPPLE
tool file for tool No.0 is used.
-MENT
• 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.

8-25
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8 System Setup
DX100 8.3 Tool Data Setting

1. Select {ROBOT} under the main menu.

2. Select {TOOL}.
3. Select the desired tool number.
– In the same way as shown in the instruction 2 and 3 of the
chapter 8.3.1.2 “Registering Coordinate Data” at page 8-18,
display the desired tool coordinate window.

公 司
有
4. Select {UTILITY} under the menu.
限
科 技
– The pull-down menu appears.

教 育
控 帮
沙 工
长

8-26
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8 System Setup
DX100 8.3 Tool Data Setting

5. Select {CALIBRATION}.
– The TOOL CALIBRATION window is shown.

6. Select the robot.

(1) Select the robot to calibrate.

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

有
robot in the shown selection dialog box.
(3) The robot is set.
科 技
教 育
控 帮
沙 工
长

8-27
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8 System Setup
DX100 8.3 Tool Data Setting

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. 公 司
有 限
Repeat 7 to 9 operation to teach TC1 to TC5.
" " indicates that teaching is completed and " " indicates that it is
not completed.
科 技
教 育
控 帮
沙 工
长

– 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.
10. Select “COMPLETE”.

8-28
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8 System Setup
DX100 8.3 Tool Data Setting

– Calibration data is registered in the tool file. Once the calibration is

completed, the tool coordinate window is displayed on the screen.

8.3.2.4 Clearing Calibration Data

calibration data.
公 司
Before the calibration of a new tool, clear the robot information and

1. Select {DATA} under the pull-down menu.

有 限
技
– The pull-down menue appears.

科
教 育
控 帮
沙 工
长

2. Select {CLEAR DATA}.

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8 System Setup
DX100 8.3 Tool Data Setting

– The confirmation dialog box is shown.

3. Select {YES}.
– All data is cleared.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
If tool angle data is required, input the data number in the
SUPPLE
tool coordinate window.
-MENT Refer to chapter 8.3.1.3 “Registering Tool Angle” at
page 8-21 for the operating instructions.

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8 System Setup
DX100 8.3 Tool Data Setting

8.3.2.5 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]. 公 司 JOINT” by pressing

有 限
科 技
教 育
控 帮
沙 工
长

2. Select desired tool number.

–Show the tool coordinate window of the desired tool by pressing the
page key or selecting it in the tool list window.

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8 System Setup
DX100 8.3 Tool Data Setting

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

SUPPLE
For details on the TCP fixed operation, see "2.8.1 Motion
-MENT about TCP" in OPERATOR’S MANUAL.

8.3.3
公
Automatic Measurement of the Tool Load and the Center of Gravity 司
8.3.3.1
有 限
What is the Automatic Measurement of the Tool Load and the Center of Gravity?

科 技
With this function, the user can register the load of tool and the position of
the tools center of gravity.

教 育
The tool load and the position of it’s center of gravity are measured and
registered in a tool file.

控 帮 This function can be used where the manipulator is installed

工NOTE level on the ground.

长沙
For the conditions required for manipulator installation, refer
to chapter 8.4 “ARM Control” at page 8-38.

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8 System Setup
DX100 8.3 Tool Data Setting

8.3.3.2 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
T+
L-axis
U- B- T- Home Position
(Horizontal to the U-,
B- and R-axes)

S-axis
公 司
有 限
科 技 Zero-degree Installation on the Ground

教 育
控 帮
沙 工 NOTE To correctly measure the tool load or the center of gravity,
remove the cables or wires connected to the tool.

长 1. Select {ROBOT} under the main menu.

2. Select {TOOL}.
– The tool list window appears.
– The tool list window is called up only when the file extension function
is valid.

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8 System Setup
DX100 8.3 Tool Data Setting

If the file extension function is invalid, the tool coordinate window appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 3. Select the desired tool number.
– 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 key or selecting {PAGE}.

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8 System Setup
DX100 8.3 Tool Data Setting

– To switch the tool list window and the tool coordinate window, press
{DISPLAY} {LIST} or {DISPLAY} {COORDINATE DATA}.

4. Select {UTILITY} under the menu.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 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 key .

– In a system with several manipulators, use the page key to
change the group to be controlled.

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8 System Setup
DX100 8.3 Tool Data Setting

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 “ “.

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

degrees +4.5 degrees 司

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

公
-4.5 degrees

•
有 限
The speed during measurement automatically changes
to “Medium”.
•
科 技
During the measurement, “HOME” or “U” blinks on the

教 育 •
screen.
During the measurement, the [FWD] button has to be

控
SUPPLE
-MENT
帮 kept pressed. If the button is released during the
measurement or if it is released before “ “changes into

沙 工 “ “, the measurement is aborted and the following

message appears: “Stopped measurement”

长 • The measurement starts again from the first home

position.

– When all the measurements are completed or when all the

“ “marks have changed into “ “, the measured data appears on the
screen.

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8 System Setup
DX100 8.3 Tool Data Setting

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.4 ARM Control

8.4 ARM Control

8.4.1 ARM Control

ARM Control, a control system originally developed by Yaskawa, achieves
an enhanced robot motion performance such as improved path accuracy
or educed cycle time.
The moment of inertia and the gravity moment etc. of each axis are
calculated by the ARM control function, and DX100 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

公 司
有 限
科 技CAUTION
•
教 育
Correctly set the robot setup condition.

控 帮
Make sure to avoid any mistake in setting the unit indication or
specifying positive and negative values. Failure to observe this caution

沙 工 may lead to improper control of the manipulator, resulting in error

occurrence or short life span of speed reducer.

长 • 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.

8.4.2.1 Robot Setup Condition

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

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8 System Setup
DX100 8.4 ARM Control

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.

Robot
installation +
Angle

公 司 -

有 限
<Example> 科 技
教 育
控 帮
沙 工
长
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 “-”.

Only rotation angle around Y axis of the robot coordinates

NOTE 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.

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.

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8 System Setup
DX100 8.4 ARM Control

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

公 司
有 限 (X position, Y position)

科 技 +X

教 育
控 帮
沙 工
长 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.
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.

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8 System Setup
DX100 8.4 ARM Control

Fig. 8-1: Load on the U-arm: Center of Gravity Position (Side View)

X (From U-Axis)

(-) (+)

U-axis
rotation Center of Gravity
center Position

HEIGHT
(From U-Axis)

公 司
有 限
科 技
NOTE
教 育
ARM CONTROL window is displayed only when the secu-
rity mode is set in the management mode.

控 帮
沙 工1. Select {ROBOT} under the main menu.

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8 System Setup
DX100 8.4 ARM Control

2. Select {ARM CONTROL}.

– The ARM CONTROL window appears.

3. Press the page key , or select {PAGE}.

– Select the desired control group when there are two or more group
axes.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
4. Select the desired item.
5. Input the value and press [ENTER].

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8 System Setup
DX100 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.
• 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.

公 司
8.4.3.1 Tool Load Information

有 限
Tool load information includes weight, a center of gravity position, and

These are registered in the tool file.科 技

moment of inertia at the center of gravity of the tool installed at the flange.

教 育
帮
XF' Moment of inertia around the Center of Gravity
Ix, Iy, Iz

工 控 XF

沙
Ix

YF'
Iy 长
YF

ZF' Iz
Weight:W

* Flange Coodinates
XF: It is a direction right above when T axis
ZF is 0 pulse position and the flange surface
of the manipulator turned to the front.
Center of Gravity Position YF: Y axis led by XF,ZF
( Xg, Yg, Zg ) ZF: Perpendicular direction from flange surface

8.4.3.2 How to Calculate Tool Load Information

Weight: W (Unit: kg)

The total weight of the installing tool 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 for small and medium size manipulator, and 1
to 5 kgs for large manipulator.)

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8 System Setup
DX100 8.4 ARM Control

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: kg·m2)

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.
It is not required to set a correct value, however, it is recommended to set
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

position.
公 司
moment of inertia calculated from weight and the center of gravity

有 限
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

center of gravity).
科 技
size is about more than 2-times the distance between the flange and the

教 育
控 帮
沙 工
长

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

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.

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8 System Setup
DX100 8.4 ARM Control

<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>

•W : 7.000 kg

• Xg : 100.000 mm

YF • Yg : 0.000 mm

• Zg : 70.000 mm

• Ix : 0.000 kg •m2
Center of Gravity Position
= (100, 0, 70) • Iy : 0.000 kg •m2
XF
70

• Iz : 0.000 kg •m2

公 司
Total Weight
有 限
Approx. 6.3 [kg]
7.00 [kg]
100

ZF
科 技
教 育
帮
工控
• The own moment of inertia calculation for hexahedron
and cylinder

长沙 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
r
Lx
Iz Iz
SUPPLE Iy Lz
-MENT Ix Y H Y

Ix Iy
X
X Weight:W Weight: W
2 2 2
Ly + Lz 3 r + H2
Ix = *W Ix = Iy = *W
12 12
2
Lx 2 + Lz 2 r
Iy = *W Iz = *W
12 2
* Unit of Weight : [kg]
Lx 2 + Ly 2
Iz = *W * Unit of Length : [m]
2
12 * Unit of Ix, Iy, Iz : [kgxm ]

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8 System Setup
DX100 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.

司
500 YF

限 公 Weight of tool:

有
Approx. 55 kg.
ZF
250

技
XF Weight of workpiece:

科
Approx. 40 kg.

400
教 育
帮
工控
1000

长沙
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

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8 System Setup
DX100 8.4 ARM Control

<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

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

approximated in construction of rough parts.

公 司
be roughly presumed. It is not necessary to divide in detail. The tool is

有 限
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

科 技
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

moment of inertia.)
教 育
inertia calculation for hexahedron and cylinder" for how to calculate the own

wi
(xi, yi, zi) 控 帮
: Weight of the i-th parts [kg]
: Center of gravity position of the i- th parts
工 (On flange coordinates)[mm]

长沙
Icxi, Icyi, Iczi : Own mome nts of inertia of the i-th parts [kg*m2]
SUPPLE
-MENT 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 System Setup
DX100 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 mothod 2.

(Top View)
Center of Flange

司
YF
YF

限 公 100

40
技 有 50 150
XF
科
教育
Gun 1
70 XF Gun 2

Gun 1

控 帮 ZF
(Gun 1)
Weight: w1 = 3 kg
Center of Gravity:
(Gun 2)
Weight: w2 = 6 kg
Center of Gravity:

沙 工 x1 = 100 mm
y1 = 50 mm
z1 = 40 mm
x2 = 100 mm
y2 = -150 mm
z2 = 70 mm

长
Gun 2
Weight : 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 System Setup
DX100 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 : 10.000 kg
• Xg : 100.000 mm

• Yg : -83.333 mm

• Zg : 60.000 mm

• Ix : 0.100 kg.m2
• Iy : 0.010 kg.m2
• Iz : 0.100 kg.m2

8.4.3.3 Tool Load Information Registering

公 司
1. Select {ROBOT} under the main menu.
有 限
Tool load information is registered in the tool file.

2. Select {TOOL}.
科 技
教 育
– The tool coordinate window appears.
– The tool coordinate window appears only when the file extension

控 帮
function is valid.
– When the file extension function is invalid, the tool list window

沙 工 appears.

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8 System Setup
DX100 8.4 ARM Control

3. Select the desired tool number.

(1) Move the cursor to the number of the desired tool, and press
[SELECT] in the tool list window.
(2)
司
The tool coordinate window of the selected number appears.

公
(3) Select the desired number in the tool coordinate window by press-
ing the page key
有 限
or clicking on the {PAGE} button.

press {DISPLAY}
技
(4) To switch the tool list window and the tool coordinate window,
科 {LIST} or {DISPLAY} {COORDINATE
DATA}.
教 育
4. Select the desired item to register and input the value.
帮
工控
– The window can be scrolled with the cursor.
– The menu enters the state of a numeric input if the cursor is on the

长沙
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 System Setup
DX100 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 using the standard parameter values
(vary according to each robot model) which were set by default.
Standard Value:
Weight: W = Payload
Center of gravity position:
(Xg, Yg, Zg) = (0, 0, Allowed value of B-axis for payload)
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
NOTE operating the manipulator with the standard value, a difference of 100 kg or more in the
load between the actual tool load and the standard 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.

公 司
Moreover, when the tool which an actual tool center of gravity position greatly offsets in

compensated.
有 限
X-direction or Y-direction is installed the generated moment by the tool cannot be

• Switch of the tool file

科 技
In case that two or more tool files are used, information on an effective tool file is referred

file.
教 育
for tool load information used by the ARM control at that time in according to switch tool

控 帮
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
工
entire tool installed in the flange is changed).
沙
长
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 System Setup
DX100 8.5 Work Home Position

8.5 Work Home Position

8.5.1 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 Setting Work Home Position

8.5.2.1 Work Home Position Window

1. Select {ROBOT} under the main menu.

公 司
有 限
科 技
教 育
控 帮
沙 工 2. Select {WORK HOME POS}.

长
– The WORK HOME POSITION window is appears.

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8 System Setup
DX100 8.5 Work Home Position

3. Press the page key .

– When two or more manipulators exist in the system, use the page
key to change the control group, or click on {PAGE} to select
the desired control group.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.5 Work Home Position

8.5.2.2 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
• The cube 63 is for ROBOT2
• The cube 62 is for ROBOT3
• The cube 61 is for ROBOT4
• The cube 60 is for ROBOT5
• The cube 59 is for ROBOT6
• The cube 58 is for ROBOT7
• The cube 57 is for ROBOT8
公 司
The work home position cube is a cube like the one shown
NOTE
有 限
in the figure below; the length of its sides is determined by a
parameter setting made by the user (units: µm).

科 技
By changing this parameter setting, the size of the cube
can be changed.

教 育Fig. 8-2: S3C805: The work home position cube length of

its sides (µm)

控 帮
沙 工 2

长
P 2
a a
2

a
a 2
2
Specify whether “COMMAND POSITION” or “FEEDBACK
POSITION” is to be set to the work home position cube
signal’s CHECK MEASURE in the interference area
settings. “COMMAND POSITION” is the default setting.

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8 System Setup
DX100 8.5 Work Home Position

8.5.2.3 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.

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 "Manipulator is moving to work
home position" 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 %.)

8.5.2.4 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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.6 Interference Area

8.6 Interference Area

8.6.1 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 DX100 judges whether the TCP of the manipulator is inside or outside
this area, and outputs this status as a signal.

8.6.2 Cubic Interference Area

8.6.2.1 Cubic Interference Area

This area is a rectangular parallelepiped which is parallel to the base
coordinate, robot coordinate, or user coordinate. The DX100 judges
whether the current position of the manipulator’s TCP is inside or outside
this area, and outputs this status as a signal.

公 司
有 限
Robot coordinate
Z-axis

科 技
教 育 Cubic

帮
interference
area

工 控
长 沙
Cubic
interference
User Coordinates area
Z-axis

X-axis
Y-axis Y-axis

X-axis

8.6.2.2 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.

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8 System Setup
DX100 8.6 Interference Area

Z-axis
Maximum
value

Cubic
interference X-axis
area 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

公 司
有 限 Minimum
value
Y-axis

科 技
教 育
3. After entering the lengths of the three faces of the cube (axial length)

控 帮
using the Numeric keys, move the manipulator to the center point of
the cube using the axis keys.

沙 工
长
Z-axis
Y X

Z X-axis
Center
point

Y-axis

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8 System Setup
DX100 8.6 Interference Area

8.6.2.3 Setting Operation

1. Select {ROBOT} under the main menu.

2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window is shown.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
3. Select the desired cube number.
– Select the desired cube number with the page key or by
number input.

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8 System Setup
DX100 8.6 Interference Area

– 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
司
INTERFERENCE” is selected, the window is changed.
公
有 限
科 技
教 育
控 帮
沙 工
长
5. Select “CONTROL GROUP”.
– A selection dialog box appears. Select the desired control group.

6. Select “REF COORDINATES”.

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8 System Setup
DX100 8.6 Interference Area

(1) A selection box appears.

(2) Select the desired coordinate.
(3) If the user coordinates are selected, the number input line is dis-
played. Input the user coordinate number and press [ENTER].

7. Select “CHECK MEASURE.”

公 司
– Each time [SELECT] is pressed, “COMMAND POSITION” and

限
“FEEDBACK POSITION” are displayed alternately.

有
科 技
教 育
控 帮
沙 工
长

To stop the manipulator movement using the interference

signal (use the cube interference signal for mutual interfer-
ence between robots), set CHECK MEASURE to “COM-
MAND 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.

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8 System Setup
DX100 8.6 Interference Area

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”.

公 司
2. Input number for “MAX” and “MIN” data and press [ENTER].
– The cubic interference area is set.

有 限
科 技
教 育
控 帮
沙 工
长

Teaching Corner
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “MAX/MIN”.
2. Press [MODIFY].

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8 System Setup
DX100 8.6 Interference Area

– 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.
The cursor only moves to either “<MIN>” or “<MAX>” at this time.

公
4. Move the manipulator using the axis keys.司
有
cube using the axis keys. 限
– Move the manipulator to the maximum or minimum position of the

5. Press [ENTER].
科 技
育
– The cubic interference area is registered.

教
控 帮
沙 工
长

Number Input of the Side of Cube and Teaching Center

1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.

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8 System Setup
DX100 8.6 Interference Area

(2) Select “CENTER POS”.

2. Input data for length of the cube, then press [ENTER].

– The length is set.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 3. Press [MODIFY].
– A message “Move to center point and teach” appears. The cursor
only moves to either “<MIN>” or “<MAX>” at this time.

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8 System Setup
DX100 8.6 Interference Area

4. Move the manipulator using the axis keys.

– 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.

公 司
8.6.3 Axis Interference Area
有 限
8.6.3.1 Axis Interference Area
科 技
教 育
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

控 帮
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

沙 工 is inside or outside this range is output. (ON: inside, OFF: outside)

Fig. 8-3: Axis Interference Signal for Station Axis
长 Max value
+ side
Min value
- side
ON

OFF

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8 System Setup
DX100 8.6 Interference Area

8.6.3.2 Setting Operation

1. Select {ROBOT} under the main menu.
2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window appears.

3. Select the desired interference signal number.

公 司
– Select the desired interference signal number using the page
key
有
or by number input. 限
科 技
– When selecting the desired interference signal number by number

育
input, select {PAGE} to input the desired signal number.

教
控 帮
沙 工
长

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8 System Setup
DX100 8.6 Interference Area

4. Select “METHOD”.
– ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are
displayed alternately every time [SELECT] is pressed. Select “AXIS
INTERFERENCE”.

5. Select “CONTROL GROUP”.

公 司
– A selection box appears. Select the desired control group.

有 限
科 技
教 育
控 帮
沙 工
长
6. Select “CHECK MEASURE”.
– Each time [SELECT] is pressed, “COMMAND POSITION” and
“FEEDBACK POSITION” switch alternately.

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8 System Setup
DX100 8.6 Interference Area

Number Input of the Axis Data Coordinates

1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.

(2) Select “MAX/MIN”.

公 司
2. Input number for “MAX” and “MIN” data and press [ENTER].
– The axis interference area is set.

有 限
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.6 Interference Area

Teaching Corner
1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “MAX/MIN”.

2. Press [MODIFY].
公 司
限
– A message “Teach max./min. position” appears.

有
科 技
教 育
控 帮
沙 工
长

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.

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DX100 8.6 Interference Area

5. Press [ENTER].
– The cubic interference area is registered.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.6 Interference Area

Number Imput of Center Position (WIDTH) and Teaching Center

1. Select “METHOD”.
(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “CENTER POS”.

公 司
2. Input number for “WIDTH” data and press [ENTER].
– “WIDTH” is set.

有 限
科 技
教 育
控 帮
沙 工
长

3. Press [MODIFY]
– A message “Move to the center point and teach” appears.

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8 System Setup
DX100 8.6 Interference Area

– 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 center position of the cube using the
axis keys.
5. Press [ENTER].

公 司
– The center position of the cube is registered.

有 限
科 技
教 育
控 帮
沙 工
长

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DX100 8.6 Interference Area

8.6.4 Clearing the Interference Area Data

1. Select {ROBOT} under the main menu.

2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window is shown.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
3. Select interference signal to be cleared.
– Select the desired interference signal number to be cleared using
the page key or by number input.

– When selecting the desired interference signal number by number

input, select {PAGE} to input the desired signal number.

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DX100 8.6 Interference Area

4. Select {DATA} under the menu.

– The pull-down menu appears.

5. Select {CLEAR DATA}.

– The confirmation dialog box appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
6. Select {YES}.
– All the data of the interference signal number are cleared.

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8 System Setup
DX100 8.7 Shock Detection Function

8.7 Shock Detection Function

8.7.1 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 user’s 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” at 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

公 司
有 限
The shock detection function is set not to mis-detect the shock even if
operating by the ratings load with the maximum speed when shipping from

科 技
the factory. If tool load information is set correctly, the detection sensitivity
can be improved. Moreover, it is possible to set the lower sensitivity of

教 育
detection only for a specific section where the contact work etc. The
sensitivity of detection is set by setting the detection level.

8.7.2.1
控 帮
Shock Detection Level Setting

沙 工 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
长 figure.
• Condition number 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 when playback opera-
tion.
• 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.
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.

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8 System Setup
DX100 8.7 Shock Detection Function

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

The detection level of condition number 8 (a standard in play

SUPPLE mode) is adopted in play mode excluding the range between
-MENT
SHCKSET and SHCKRST in the job.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

Detection Mode
Indicates the shock detection mode.
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.

Function Select
Specifies VALID/INVALID of the shock detection function. The shock
detection function is specified by each manipulator with this function.
1. Move the cursor to the manipulator of which function is to be enabled
or disabled; press [SELECT] to change the function to "VALID" or
"INVALID".
2. "VALID" and "INVALID" can be changed alternately whenever
[SELECT] is pressed. The change is available for all the condition
numbers.

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8 System Setup
DX100 8.7 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.
Refer to this value when inputting the detection level value in .
The maximum disturbance force can be cleared by selecting {DATA} à
{CLEAR MAX VALUE} in the menu.
Detection Level (Level range: 1 to 500)
Specifies the shock detection level. Set a value larger than the maxi-
mum 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 manipula-
tor, 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.

Method of Shock Detection Level File Setting

1. Select {ROBOT} under the main menu.
2. Select {SHOCK SENS LEVEL}.
公 司
限
– The SHOCK DETECT LEVEL window appears.
有
技
– Perform either of the following operations to display the page of
desired condition number:

育 科
(1) Select {PAGE} and input the desired condition number, then press

帮 教
[ENTER].
(2) Press the page key to change the page of condition number.

工 控
3. Select the desired condition number.

长沙 4. Select the desired item and perform setting.

To avoid false detection during the manipulator operation,

set the detection level greater than the maximum distur-
bance force by 20%.
An emergency stop of the manipulator due to the false
NOTE detection may become a factor to damage the speed reduc-
ers and tools.
<Example>
When the maximum disturbance force is 80, set the detec-
tion level at 96 or more.

NOTE "Detection level” can be modified only when the security

mode is set in management mode.

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8 System Setup
DX100 8.7 Shock Detection Function

8.7.2.2 Tool Load Information Setting

To increase the accuracy of shock detection, set the tool load information
in the tool file. Refer to chapter 8.4.3 “Tool Load Information Setting” at
page 8-43 for details of the tool load information setting.

8.7.2.3 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)

Robot Setting
Specifies the manipulator of which shock detection level is to be modified.

公 司
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

the slave axis group.

有 限
coordinated job, the modification is applied to the shock detection level of

科 技
Shock Detection Level Condition Number (1 to 7)
Specifies the shock detection level condition number in which the
育
detection level in playback mode is set.
教
控 帮
SHCKRST instruction
The shock detection level changed by the SHCKSET instruction is reset

沙 工
and returned to the detection level of the standard (value set in condition
number 8) by the SHCKRST instruction.

长 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 detec-
tion 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.

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8 System Setup
DX100 8.7 Shock Detection Function

1. Select {JOB} under the main menu.

Instruction
Address
Area

2. Select {JOB}.
3. Move the cursor in the address area.

SHCKSET

SHCKSET instruction is to be registered.

公 司
1. Move the cursor to the immediately preceding line where the

2. Press [INFORM LIST].

有 限
技
– The inform list dialog box is shown.

科
教 育
控 帮
沙 工3. Select SHCKSET instruction.

长 (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

I) When the value is input with the numeric key, press [SELECT]

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8 System Setup
DX100 8.7 Shock Detection Function

to display the input buffer line.

II) Press [ENTER] to change the number in the input buffer line.
• When robot specification is added
I) When robot specification is added, move the cursor to the
instruction in the input buffer line and press [SELECT] to dis-
play the DETAIL window.

公 司
有 限
II)
科 技
Move the cursor to "UNUSED" of "ROBOT/STATION", and
press [SELECT].
III)
教 育
The selection box appears.

控 帮
IV) Point the cursor to the robot to be added and press [SELECT].

沙 工
长

V) When the addition of robot is completed, press [ENTER].

VI) The DETAIL window closes and the JOB CONTENT window
appears.
5. Press [INSERT] then [ENTER].
– The instruction displayed in the input buffer line is registered.

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8 System Setup
DX100 8.7 Shock Detection Function

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.

公 司
有 限
科 技
教 育
帮
4. Change the value of the additional item.
控
沙 工 – < When registering the instruction as it is >
Operate the step 5 when registering the instruction in the input

长
buffer line as it is.
– < When adding or changing the additional item >
(1) When adding the robot specification, move the cursor to instruc-
tion 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].

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8 System Setup
DX100 8.7 Shock Detection Function

(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.
5. Press [INSERT] then [ENTER].
公 司
限
– The instruction displayed in the input buffer line is registered.
有
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.7 Shock Detection Function

8.7.2.4 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]. 公 司
有 限
– The alarm is reset when “RESET” is selected on the alarm display,

科 技
and the shock detection status is released.
2. Operation after resetting the detection status.

教 育
– In teach mode, the JOG operation of the manipulator is enabled by
resetting the status.
帮
工控
– In the play mode, move the manipulator once to the safety position
in the teach mode to check the damage though the playback

长沙
operation is possible after resetting the status.

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
NOTE
detected again after resetting.
In this case, set the collision detection function "INVALID",
or increase the detection level in teach mode and retreat
the manipulator to a safety position.

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8 System Setup
DX100 8.8 User Coordinate Setting

8.8 User Coordinate Setting

8.8.1 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
公 司
有 限
科 技
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

育
directions of Y- and Z-axes are determined by point XY.

教
帮
工控
NOTE It is important that the two points ORG and XX be taught
accurately.

长沙 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

User coordinate file 2
User coordinate file 3
User coordinate file 4

User coordinate file 63

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8 System Setup
DX100 8.8 User Coordinate Setting

8.8.2 User Coordinate Setting

8.8.2.1 Selecting the User Coordinate File

1. Select {ROBOT} under the main menu.
2. Select {USER COORDINATE}.
(1) The USER COORDINATE window appears.

公 司
有 限
(2) The " " mark indicates that the user coordinates is completed to
set and the " " mark indicates that it is not completed.

科 技
(3) To check the position of the user coordinates select {DISPLAY}
{COORDINATE DATA}.
育
(4) The following window appears.
教
控 帮
沙 工
长

3. Select the user coordinate number.

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8 System Setup
DX100 8.8 User Coordinate Setting

8.8.2.2 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”.

公 司
– Select the teaching point.

有 限
科 技
教 育
控 帮
沙 工
长

3. Move the manipulator to the desired position with the axis keys.
4. Press [MODIFY] then [ENTER].
– Taught position is registered.
– Repeat the steps 2 to 4 to teach ORG, XX and XY.

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8 System Setup
DX100 8.8 User Coordinate Setting

– “ “ 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.

公 司
– 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”. 有 限
科 技
– User coordinates are registered in the file.

教 育
– Once the user coordinate setting is completed, the following
window appears.

控 帮
沙 工
长

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8 System Setup
DX100 8.8 User Coordinate Setting

8.8.2.3 Clearing the User Coordinates

1. Select {DATA} under the pull-down menu.
2. Select {CLEAR DATA}.
– The confirmation dialog box appears.

3. Select {YES}.
– All data is cleared. 公 司
有 限
科 技
教 育
控 帮
沙 工
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8 System Setup
DX100 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.
1. Select {ROBOT} under the main menu.
2. Select {OVERRUN & S-SENSOR}.
– The OVERRUN & SHOCK SENSOR window appears.
– Select either "EMERGENCY STOP" or "HOLD" to set the item

公 司
"SHOCK SENSOR STOP COMMAND" which specifies the stop
condition in the current shock sensor detection.

有 限
– “E-STOP” and “HOLD” are displayed alternately every time
[SELECT] is pressed.

科 技
教 育
控 帮
沙 工
长

3. Select “RELEASE”.
– The control group in which overrun or shock sensor is detected is
indicated with “ ".

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8 System Setup
DX100 8.9 Overrun / Tool Shock Sensor Releasing

– 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.

公 司
NOTE 有 限
After releasing the overrun or tool shock sensor, if “CAN-
CEL” is selected or the window is changed to the other one,

celed.
科 技
the release of the overrun or tool shock sensor will be can-

教 育
控 帮
沙 工
长

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8 System Setup
DX100 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.
1. Select {ROBOT} under the main menu.
2. Select {LIMIT RELEASE}.
– The LIMIT RELEASE window appears.

公 司
有 限
科 技
3. Select “SOFT LIMIT RELEASE”.

教 育
– Each time [SELECT] is pressed, “VALID” and “INVALID” switch

帮
alternately.

工控
– When “SOFT LIMIT RELEASE” is set to “VALID”, a message “Soft
limits have been released” appears.

长沙

– When “SOFT LIMIT RELEASE” is set to “INVALID,” a message

"Softlimits off released" is displayed for a few seconds.

• The taught data cannot be registered when the soft limit

is being released.
NOTE
• The setting of "SOFT LIMIT RELEASE" becomes
"INVALID" when the mode is changed to the play mode.

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8 System Setup
DX100 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.
Failure to observe this caution may result in injury or damage to
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 manipulator’s range of motion.
L-U Interference Limit to check L- and U-axis interference area.
Soft Limit on Each Axis
motion.
公 司
Soft limit to check manipulator’s range of

Cube Interference
user.
有 限
Limit to check cube interference area set by

科 技
教 育
NOTE
控 帮
All limit release function is not available if the security mode
is not in the management mode. Refer to chapter 7 “Secu-
rity System” at page 7-1 for details on the security modes.

沙 工
1. Select {ROBOT} under the main menu.
长 2. Select {LIMIT RELEASE}.
– The LIMIT RELEASE window appears.

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8 System Setup
DX100 8.11 All Limit Release Function

3. Select “ALL LIMITS RELEASE”.

– “VALID” and “INVALID” are displayed alternately every time
[SELECT] is pressed.
– 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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.12 Instruction Level Setting

8.12 Instruction Level Setting

8.12.1 Setting Contents

8.12.1.1 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

and expansion instruction set. 公 司

items to be used in each instruction differ in the standard instruction set

有 限
In the standard instruction set, the following functions cannot be used.
However, operation becomes easier because the number of data items
技
decreases when registering an instruction.
科
教 育
• Use of local variables and arrangement variable
• Use of variables for additional items (Example: MOVJ VJ = I000)

控 帮
When instructions are executed, for example during playback, all the
instructions can be executed regardless of the instruction set used.

沙 工
长 Expanded instruction set
Standard instruction set

Subset instruction set

Frequency used
All instructions
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 System Setup
DX100 8.12 Instruction Level Setting

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.

公 司
8.12.2 Setting the Instruction Set Level

有
1. Select {SETUP} under the main menu.
限
2. Select {TEACHIG COND}.
科 技
育
– The TEACHING CONDITION window appears.

教
控 帮
沙 工
长

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8 System Setup
DX100 8.12 Instruction Level Setting

3. Select “LANGUAGE LEVEL”.

– The selection list appears.

4. Select desired language level.

– Language level is set.

公 司
有 限
科 技
教 育
控 帮
沙 工
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8 System Setup
DX100 8.12 Instruction Level Setting

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". 公 司

有 限
– VALID” and “INVALID” are displayed alternately every time

技
[SELECT] is pressed.

科
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.13 Setting the Controller Clock

8.13 Setting the Controller Clock

The clock inside the DX100 controller can be set as follows.
1. Select {SETUP} under the main menu.
2. Select {DATE/TIME}.
– The DATE/CLOCK SET window appears.

公 司
3. Select “DATE” or “CLOCK.

有
– ”The input buffer line appears.
限
4. Input the new date/time.
科 技
教 育
– For instance, to set the date to August 1, 2008, input "2008.8.1". To
set the time at twelve o’clock, enter "12.00".

帮
5. Press [ENTER].
控
沙 工– The date/time is changed.

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8 System Setup
DX100 8.14 Setting the Play Speed

8.14 Setting the Play Speed

1. Select {SETUP} under the main menu.
2. Select {SET SPEED}.
– The SPEED SET window is shown.

3. Press the page key .

公 司
use the page key 有 限
– When two or more manipulators and stations exist in the system,
to change the control group, or click on

科 技
{PAGE} to select the desired control group.

教 育
控 帮
沙 工
长

4. Select “JOINT” or “LNR/CIR”.

– The type of speed alternately changes from “JOINT” to “LNR/CIR”.

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8 System Setup
DX100 8.14 Setting the Play Speed

5. Select the speed to modify.

– The input buffer line appears.
6. Input the speed value.
7. Press [ENTER].
– The speed is modified.

公 司
有 限
科 技
教 育
控 帮
沙 工
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8 System Setup
DX100 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)

公 司
8.15.2.1 Key Allocation (EACH)
有 限
科 技
With key allocation (EACH), the manipulator operates according to the
allocated function when the numeric key is pressed. The allocatable

育
functions are listed below.

教
控
Function 帮 Description

沙 工 Manufacturer
allocation
Allocated by Yaskawa. Allocating another function
invalidates the function allocated by the manufacturer.

长 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 System Setup
DX100 8.15 Numeric Key Customize Function

8.15.2.2 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 Turns ON/OFF the specified user output signal when
allocation [INTERLOCK] and the allocated Numeric key are
pressed at the same time.
Momentary output Turns ON the specified user output signal user when
allocation [INTERLOCK] and the allocated user key are pressed at
the same time.
Pulse output Turns ON the specified user output signal only for the
allocation specified period when [INTERLOCK] and the allocated
Numeric key are pressed at the same time.
Group output Sends the specified output to the specified general group
allocation output signals when [INTERLOCK] and the allocated
(4-bit/8-bit) Numeric key are pressed at the same time.
Analog output Sends the specified voltage to the specified output port
allocation when [INTERLOCK] and the allocated Numeric key are
pressed at the same time.
Analog incremental
output allocation
公 司
Sends the voltage increased by the specified value to the
specified output port when [INTERLOCK] and the

限
allocated Numeric key are pressed at the same time.

有
科 技
In a system for multiple applications, a numeric key can be
育
SUPPLE
-MENT allocated for each application.

帮 教
工 控
长 沙

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8 System Setup
DX100 8.15 Numeric Key Customize Function

8.15.3 Allocating an Operation

8.15.3.1 Allocation Window

1. Select {SETUP} under the main menu.
2. Select {KEY ALLOCATION}.
– The KEY ALLOCATION (EACH) window appears.

公 司
3. Select {DISPLAY}.

有
– Pull-down menu appears.
限
科 技
– To call up the KEY ALLOCATION (SIM) window, select {ALLOCATE

育
SIM. KEY}.

教
控 帮
沙 工
长

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8 System Setup
DX100 8.15 Numeric Key Customize Function

4. Select {ALLOCATE SIM. KEY}.

– The KEY ALLOCATION (SIM) window appears.
– In a system multiple applications, press the page key to
change the window to the allocation window for each application, or
click on {PAGE} to select the desired application number.

公 司
8.15.3.2 Instruction Allocation
有 限
科 技
1. Set this function in the KEY ALLOCATION (EACH) window. Move the
cursor to “FUNCTION” of the key to be allocated and press [SELECT].

育
– Selection list appears.
教
控 帮
沙 工
长

2. Select “INSTRUCTION”.
– The instruction is shown in the “ALLOCATION CONTENT”.

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DX100 8.15 Numeric Key Customize Function

(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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.15 Numeric Key Customize Function

8.15.3.3 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).

公 司
有 限
科 技
(1) To change the reserved job registration No. move the cursor to the

(2)
教 育
No. and press [SELECT]. Then input buffer line appears.
Input the number to be changed, and press [ENTER].

控 帮
8.15.3.4 Display Allocation
沙 工
长
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].
– Selection list appears.
2. Select [DISPLAY].
3. Move the cursor to “ALLOCATION CONTENT” and press [SELECT].
– Character input is available.

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8 System Setup
DX100 8.15 Numeric Key Customize Function

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.

公 司
6. Press [INTERLOCK] and the allocated key at the same time.
– A message “Reserved display registered” appears, and the window
is registered.

有 限
– In this case, the CURRENT POSITION window is registered by

科 技
pressing [INTERLOCK] + [0] with the CURRENT POSITION window
displayed on the screen.

教 育
控 帮
沙 工
长

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8 System Setup
DX100 8.15 Numeric Key Customize Function

8.15.3.5 Alternate Output Allocation

Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– Selection list appears.

2. Select “ALTERNATE OUTPUT”.

公 司
限
– The output No. is displayed in the “ALLOCATION CONTENT”.
有
科 技
教 育
控 帮
沙 工
长

(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 System Setup
DX100 8.15 Numeric Key Customize Function

8.15.3.6 Momentary Output Allocation

Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
2. Select “MOMENTARY OUTPUT”.
– The output No. is displayed in the “ALLOCATION CONTENT”.

公 司
有 限
科 技
(1) To change the output No., move the cursor to the No. and press
[SELECT]. Then numeric value can be entered.

育
(2) Input the number to be changed, and press [ENTER].
教
8.15.3.7 Pulse Output Allocation

控 帮
Set this function in the KEY ALLOCATION (SIM) window.

沙 工 1. Move the cursor to the “FUNCTION” of the key to be allocated and

长
press [SELECT].
– A selection list appears.
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

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8 System Setup
DX100 8.15 Numeric Key Customize Function

No. or time and press [SELECT]. Then numeric value can be

entered.
(2) Input the number or time to be changed, and press [ENTER].

8.15.3.8 Group (4-bit/8-bit) Output Allocation

Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.
2. Select “4 BIT OUTPUT” or “8 BIT OUTPUT”.
– The output No. and output value are displayed in the “ALLOCATION
CONTENT”.

公 司
有 限
科 技
教 育
控 帮
沙 工 (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
长 (2)
entered.
Input the number or value to be changed, and press [ENTER].

8.15.3.9 Analog Output Allocation

Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and
press [SELECT].
– A selection list appears.

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8 System Setup
DX100 8.15 Numeric Key Customize Function

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

(2)
numeric value can be entered.
公 司
Input the number or voltage value to be changed, and press
[ENTER]
有 限
8.15.3.10 Analog Incremental Output Allocation
科 技
教 育
Set this function in the KEY ALLOCATION (SIM) window.
1. Move the cursor to the “FUNCTION” of the key to be allocated and

帮
press [SELECT].

工控
– A selection list appears.

长沙
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 cur-
sor 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 System Setup
DX100 8.15 Numeric Key Customize Function

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
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].

– Selection list appears.

3. Select “OUTPUT CONTROL INST”.

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8 System Setup
DX100 8.15 Numeric Key Customize Function

– 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

公 司
allocated by the manufacturer with key allocation (SIM), the settings
for key allocation (EACH) remain the same.

有 限
8.15.5 Execution of Allocation

科 技
8.15.5.1
育
Executing the Instruction/Output Control Allocation

教
1. Press the key allocated for instruction allocation or output control

帮
allocation.

工控
– The allocated instruction is displayed in the input buffer line.

长沙 2. Press [INSERT] and [ENTER].

– The instruction displayed in the input buffer line is registered.

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.
2. Press [INSERT] then [ENTER].
– 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,

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8 System Setup
DX100 8.15 Numeric Key Customize Function

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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有 限
科 技
教 育
控 帮
沙 工
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8 System Setup
DX100 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.

A maximum of 64 output signals can be shown on the

NOTE 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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
3. Select the desired signal to change the output status.
– Select the status ( or ) of the desired signal.
4. Press [INTERLOCK] +[SELECT].
– The output status is changed. ( : status ON; : status OFF.)

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8 System Setup
DX100 8.16 Changing the Output Status

It is also possible to turn the relevant external output signal

SUPPLE
on only for the duration that [INTERLOCK]+[SELECT] are
-MENT pressed. This selection is made in advance by setting the
parameters (S4C391 to 454) to “1”.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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8 System Setup
DX100 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

公 司
有 限
3. Move the cursor to the desired parameter number.

科 技
教 育
控 帮
沙 工
长

– When the desired parameter number is not in the current window,

move the cursor in the following way:

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8 System Setup
DX100 8.17 Changing the Parameter Setting

(1) Move the cursor to a parameter number and press [SELECT].

(2) Enter the desired parameter number with the numeric keys.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 (3) Press [ENTER].
(4) The cursor moves to the selected parameter number.

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8 System Setup
DX100 8.17 Changing the Parameter Setting

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.

公 司
2. Enter the value.
有 限
numeric keys.
科 技
– If a decimal figure is selected, enter a decimal value with the

教 育
控 帮
– If a binary figure is selected, move the cursor to the binary figure
data in the input buffer line, and press [SELECT].

沙 工 – Each time [SELECT] is pressed, “0” and “1” alternate in the window.

长 – “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 System Setup
DX100 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.

公 司
有 限
科 技
5. Select {JOB}.
教 育
– A confirmation dialog box appears.

控 帮
沙 工
长

6. Select {YES}.
– The job data is initialized.

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8 System Setup
DX100 8.18 File Initialization

8.18.2 Initializing Data 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}.
5. Select {FILE/GENERAL DATA}.
– The INITIALIZE window appears.

公 司
有 限
科 技
6. Select the data file to be initialized.
育
– The selected data file/general data are marked with “ “.
教
控 帮
– The parameters marked with " " cannot be selected.

沙 工
长

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8 System Setup
DX100 8.18 File Initialization

7. Press [ENTER].
– A confirmation dialog box appears.

8. Select {YES}.
– The selected data file/general data are initialized.

公 司
8.18.3 Initializing Parameter File

有 限
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
科 技
教 育
2. Change the security mode to the management mode.
3. Select {FILE} under the main menu.

帮
4. Select {INITIALIZE}.
控
沙 工
5. Select {PARAMETER}.
– The parameter selection window appears.
长

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8 System Setup
DX100 8.18 File Initialization

6. Select the parameter to be initialized.

– The selected parameter is marked with “ “.
– The parameters marked with " " cannot be selected.

7. Press [ENTER].
– A confirmation dialog box appears.
公 司
有 限
科 技
教 育
控 帮
沙 工
长
8. Select {YES}.
– The selected parameter is initialized.

8.18.4 Initializing I/O Data

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}.
5. Select {I/O DATA}.

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8 System Setup
DX100 8.18 File Initialization

– 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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
7. Press [ENTER].
– A confirmation dialog box appears.

8. Select {YES}.
– The selected data is initialized.

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8 System Setup
DX100 8.18 File Initialization

8.18.5 Initializing System Data

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}.
5. Select {SYSTEM DATA}.
– The system data selection window appears.

公 司
有 限
科 技
6. Select the parameter to be initialized.
育
– The selected data is marked with “ “.
教
控 帮
– The system data marked with " " cannot be selected

沙 工
长

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8 System Setup
DX100 8.18 File Initialization

7. Press [ENTER].
– A confirmation dialog box appears.

8. Select {YES}.
– The selected data is initialized.

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有 限
科 技
教 育
控 帮
沙 工
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8 System Setup
DX100 8.19 Display Setting Function

8.19 Display Setting Function

8.19.1 Font Size Setting

DX100 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

公 司
有 限
科 技
8.19.1.2 Settable Font Size 教 育
控 帮
The following eight patterns of fonts are available in setting the size of

沙 工 fonts displayed on the screen.

Font Size Font Style

长 1
2
Small
Small
Regular
Bold
3 Regular Regular
4 Regular Bold
5 Large Regular
6 Large Bold
7 Extra large Regular
8 Extra large Bold

8.19.1.3 Setting the Font Size

To set the font size, first off display the font size setting dialog box as
follows.

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8 System Setup
DX100 8.19 Display Setting Function

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
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.

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8 System Setup
DX100 8.19 Display Setting Function

• Clear the {Bold Type} check box as follows to set the font to the reg-
ular style.

2. Specify the font size.

– Select a button from the four buttons in the dialog box.

公 司
有 限
科 技
教 育
控 帮
3. The font size setting dialog box is closed, and the screen displays the

沙 工 font specified in the dialog box.

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8 System Setup
DX100 8.19 Display Setting Function

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
Do not turn OFF the DX100 power supply when the font
NOTE size is being changed (when the font size setting dialog box
is on the screen).

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8 System Setup
DX100 8.19 Display Setting Function

8.19.2 Operation Button Size Setting

DX100 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

公 司
有 限
科 技
教 育
8.19.2.2 Settable Button Size

控 帮
The following three sizes of buttons are available in setting the size of

沙 工 each operation button; the font style of the character string on buttons can
also be specified.
长 Button Size Font Style
1 Small Regular
Bold
2 Regular Regular
Bold
3 Large Regular
Bold

8.19.2.3 Setting the Button Size

To set the button size, first off display the button size setting dialog box as
follows.

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8 System Setup
DX100 8.19 Display Setting Function

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
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.

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8 System Setup
DX100 8.19 Display Setting Function

• 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 reg-
ular style.

3. Specify the button size.

– Select a button from the three buttons in the dialog box.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
4. The font size setting dialog box is closed, and the screen displays the
buttons specified in the dialog box.

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8 System Setup
DX100 8.19 Display Setting Function

– 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.)

公 司
To cancel the setting of the button size, follow the procedure below.
1. Select {Cancel} in the button size setting dialog box.

有 限
科 技
教 育
控 帮
沙 工
长
– The dialog box closes without changing the button size.

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8 System Setup
DX100 8.19 Display Setting Function

Do not turn OFF the DX100 power supply when the button
NOTE 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).

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 – A confirmation dialog box appears on the center of the current
window.

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8 System Setup
DX100 8.19 Display Setting Function

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
To cancel the Initialized screen layout, follow the procedure below.
1. Select {CANCEL}.

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8 System Setup
DX100 8.19 Display Setting Function

– The dialog box closes without changing the current screen layout.

Do not turn OFF the DX100 power supply when the screen
NOTE 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).
公 司
有 限
8.19.4 Layout Storage
科 技
The settings of the font or button sizes are saved in the programming

教 育
pendant. The screen displays the font/button size specified last time with
the current programming pendant.

控 帮
沙 工
长

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9 System Backup
DX100 9.1 System Backup with DX100

9 System Backup
For the DX100, 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 DX100

For the DX100, four types of collective backup are available: CMOS.BIN,
CMOSBK.BIN, ALCMSxx.HEX, and CMOSxx.HEX.

9.1.1 Function Types of Data

9.1.1.1 CMOS.BIN
For the normal backup, use this data.
Save: Perform in the maintenance mode (the editing mode or higher.)
Load: Perform in the maintenance mode (the management mode.)
As for the load/save procedures, refer to chapter 9.2 “Backup by
CMOS.BIN” at page 9-3.

公 司
Target Area: All areas of the internally stored data. (Note that the

9.1.1.2 CMOSBK.BIN
monitoring time is not loaded.)

有 限
科 技
This data is used in the automatic backup function.

育
Save: Saves with the preset conditions in the normal mode.
教
控 帮
Load: Perform for the system restoration in the maintenance mode (the
management mode.)

沙 工
For details, refer to chapter 9.5 “Error List” at page 9-20.
Target Area: All areas of the internally stored data. (Note that the
长 monitoring time is not loaded.)

9.1.1.3 CMOSxx.HEX
This data is loaded/saved in the FD/CF menu in the normal mode.
Save: Perform in the normal mode (the editing mode or higher.)
Load: Perform in the normal mode (the management mode.)
For details, refer to "DX100 OPERATOR’S MANUAL."
Target Area: The collected data including "Job File," "Data File,"
"Parameter File," "System Data," and "I/O Data" which can
be individually loaded/saved in the FD/CF menu. Because
the setting information of robot etc. are not included in this
collected data, the system cannot be completely restored.

9.1.1.4 ALCMSxx.HEX
This data is for the manufacturer only. Users can save but cannot load
this data.

9-1
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9 System Backup
DX100 9.1 System Backup with DX100

9.1.2 Device
For the backup of the DX100 system, the CompactFlash can be used.
The following tables show the recommended CompactFlash.

<Recommended CompactFlash>
No. Manufacturer Model Remarks
1 Hagiwara Sys-Com MCF10P-256MS-YE2 (256MB)
2 Hagiwara Sys-Com MCF10P-512MS (512MB)
3 Hagiwara Sys-Com MCF10P-A01GS (1GB)
4 Hagiwara Sys-Com MCF10P-A02GS (2GB)
5 SiliconSystems, Inc. SSD-C25M3512 (2GB)

< Recommended USB Memory>

No. Manufacturer Model Remarks
1 Hagiwara Sys-Com UDG3-GA series (1GB, 2GB)

公 司
in the media.
有 限
In order to save the batch data, the following free space per file is needed

JZNC-NIF01-1: 18 MByte
科
JZNC-NIF01-2: 21 MByte
技
教 育
JZNC-NIF01-3: 21 MByte

控 帮
沙 工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.

长 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.
If USB memory is connected constantly, there is a risk it
NOTE drops off.
Use CompactFlash if there is no measures to maintain
water-proof function or to prevent USB memory from drop-
ping off.

9-2
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9 System Backup
DX100 9.2 Backup by CMOS.BIN

9.2 Backup by CMOS.BIN

Perform the backup by CMOS.BIN in the maintenance mode.
The chart below shows the availability of CMOS save/CMOS load in each
security mode in the maintenance mode.
Security CMOS Save CMOS Load
Operation Mode X X
Editing Mode O X
Management Mode O O
Yaskawa Mode O O

9.2.1 CMOS.BIN Save

Follow the procedures below to save CMOS.BIN.
1. Turn ON the DX100 power supply while pressing [MAIN MENU].
2. Insert a CompactFlash into the CompactFlash slot on the
programming pendant.
– when USB memory is used instead of CompactFlash, mount the

3. Select {FD/PC CARD} under the main menu. 公 司

USB memory and select {DEVICE} → ”USB: PENDANT”

– The sub menu appears.

有 限
科 技
教 育
控 帮
沙 工
长

4. Select {SAVE}.

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9 System Backup
DX100 9.2 Backup by CMOS.BIN

The save display appears.

The items marked with " " cannot be selected.

5. Select {CMOS SAVE}.
The confirmation dialog box appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 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.

9-4
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9 System Backup
DX100 9.2 Backup by CMOS.BIN

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.
1. Turn ON the DX100 power supply while pressing [MAIN MENU].
2. Change the security mode to the maintenance mode, or Yaskawa
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 {DEVICE} → “USB: PENDANT”.
4. Select {FD/PC CARD} under the main menu.
– The sub menu appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 5. Select {LOAD}.
The load display appears.

– The items marked with " " cannot be selected.

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9 System Backup
DX100 9.2 Backup by CMOS.BIN

6. Select {CMOS LOAD}.

– The comfirmation dialog box appears.

7. Select {YES}.
– The loaded CMOS.BIN file contents are reflected in the data inside
the robot,

公 司
限
CAUTION
有
育 科技
When the {CMOS LOAD} is performed, the current CMOS data is
replaced with the CMOS data (the contents of "CMOS.BIN") in the

教
CompactFlash. Therefore, before performing the load, make sure to
perform the {CMOS SAVE} of the CMOS data to be loaded.

控 帮
沙 工
长

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9 System Backup
DX100 9.3 Automatic Backup Function

9.3 Automatic Backup Function

9.3.1 Automatic Backup Function

9.3.1.1 Objective
With the automatic backup function, the data saved in the DX100 such as
system setting or operational condition are collectively backed up in the
CompactFlash which is inserted in the programming pendant.
In case of an unexpected trouble such as data loss, the backup data
saved in the CompactFlash by the automatic backup function can be
loaded to the DX100 memory to restore the file data.

The automatic backup function is enabled only while the

NOTE DX100 power supply is ON whereas it isn’t while in the
maintenance mode or the power supply is OFF.

9.3.1.2 Outline

公 司
The automatic backup function saves the internally stored data in a single
file in advance for the smooth restoration from unexpected troubles of the
DX100.

有 限
The teaching operation is one of the factors that changes the internally

科 技
stored data. Thus, a mode which backs up the latest data after the
teaching operation is prepared. To confirm the termination of the teaching

play mode.
教 育
operation, check the mode key whether it is changed from teach mode to

控 帮
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

沙 工
internally stored data. These data, however, are changed after each
operation and have very little need to be retained permanently.

长 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 DX100
and when inputting signals are also available for some specific versions.

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.

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9 System Backup
DX100 9.3 Automatic Backup Function

The automatic backup function has the following functions and features.
No Function/Feature Explanation
1 Cyclic backup This function backs up as much of
In the teach mode, the data in the latest data as possible during
memory is backed up in a specified editing. The backup data saved in
cycle from a specified starting time. the CompactFlash can be loaded to
the DX100 in case of data loss so
that the damage can be minimized.
2 Backup when switching modes The editing data is backed up when
When switching the mode from the editing is completed. The latest
teach mode to the play mode, the data is automatically backed up with
data in memory is backed up. this mode.
3 Backup when start-up When the DX 100 starts up, the
When the DX100 is start-up, the data data in memory is backed up. Since
in memory is backed up. the editing/playback operation is
usually completed when the DX100
power is turned OFF, the latest data
is automatically backed up with this
mode.
4 Backup when inputting specified The data in memory is backed up by
signals the signal from the host at the
The data in memory is backed up
when a specified signal(#40560) is
input.
司
intended timing. Although the
above mentioned items 1 to 3 are
公
designed to back up the data

有 限
automatically, this function backs up
the data in accordance with the

5
科 技
Backup while robot program is
instruction from the host.
Backs up the variables for essential

教 育
stopped
The backup during playback is
disabled. However, in the play mode,
data.

控 帮
the backup is enabled if the robot is
stopped. ("Cyclic backup" and

沙 工 "Backup when inputting specified

signals")

长 6 Backup and retry at low priority

The data in memory is backed up at
The backup operation hardly affects
the other operations so that the
low priority so that this operation programming pendant can be used
does not affect the other operations. even during the backup operation.
When other operations affect the
backup operation, the backup is
suspended and retried later.
7 Backup in binary Backup in binary allows the system
The data is saved as binary data. to be easily and speedily restored.
The range is same as that of the
"ALL CMOS AREA" in {FD/CF}, but
the data type is different.
8 Setting of items Unnecessary settings can be
Parameters can limit the settings of avoided with this setting.
the backup condition.

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9 System Backup
DX100 9.3 Automatic Backup Function

9.3.2 Settings for Automatic Backup

To set the automatic backup function, insert a CompactFlash in the
CompactFlash slot on the programming pendant, then set each item on
the AUTO BACKUP SET display.

Four ways to perform the automatic backup are available:

"Cyclic backup," "Backup when switching modes," "Backup
when start-up," and "Backup when inputting specified sig-
NOTE
nals."
The automatic backup can be performed only when the
robot is not during playback and the robot is stopped.

9.3.2.1 CompactFlash
To use the automatic backup function, insert CompactFlash in the
CompactFlash slot on the programming pendant. Only while the DX100
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,

公 司
an error message “Cannot backup CompactFlash” appears. At the same
time, the signal “occurrence of error” is output, but the robot program will

有 限
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

科 技
error occurs, the data cannot be saved.
Yaskawa recommends that the data be saved in two or more

damaged.
教 育
CompactFlash to minimize problems if the CompactFlash should be

控
auto backup.
帮
The products in the table below are recommended as Compact Flash for

沙 工
长 <Currently recommended products>
No. Manufacturer Model Remarks
1 Hagiwara Sys-Com MCF10P-256MS 256MB
(IOOAII-YE2)
2 SiliconSystems, Inc. SSD-C25M-3512 256MB

Storage capacities needed for CompactFlash are as follows:

When using JANCD-YIF01-1E, JANCD-YIF01-1EV:
(The number of stored files + 1) X 17.8MByte
When using JANCD-YIF01-2E, JANCD-YIF01-2EV, JANCD-YIF01-3E,
JANCD-IF01-3EV:
(The number of stored files + 1) X 20.8MByte
The number of storable files is automatically calculated and the MAX vlue
is shown when AUTO BACKUP SET display appears.

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9 System Backup
DX100 9.3 Automatic Backup Function

9.3.2.2 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
DX 100 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
公 司
• STORED FILE SETTING

有 限
科 技
With the version in which "STORED FILE SETTING" is set-

教 育 table, the capacity of a CompactFlash card inserted in the

programming pendant is checked when the setting window
appears. Therefore, a few seconds may be needed to open

控 帮 the setting window and an error may occur if no Compact-

Flash is inserted.

沙 工NOTE
When changing the settings of "STORED FILE SETTING"

长
or executing "ARRANGE", the files "CMOSBK.BIN" and
"CMOSBK??.BIN" (?? denotes figures) in the Compact-
Flash 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.

1. Turn ON the DX100.

– If the auto backup function is already set valid, insert a
CompactFlash.
2. Insert a CompactFlash in the CompactFlash slot on the programming
pendant.
3. Change the security mode to the management mode.
4. Select {SETUP} under the main menu.

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9 System Backup
DX100 9.3 Automatic Backup Function

5. Select {AUTO BACKUP SET}.

– The AUTO BACKUP SET display appears.

A
B
C
D
E
F
G
H
I
J
K
L
M

A. RESERVE TIME BACKUP

Set the backup function to valid or invalid in a specified cycle from a
specified starting time.

alternately. 公 司
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed

play. 有 限
The reserve time can be set by inputting values in B,C and D in the dis-

TIME BACKUP to VALID. 科 技

Every time values are set to these three items, reset the RESERVE

reset to VALID.教 育
If these settings are incorrect, the RESERVE TIME BACKUP cannot be

帮
If so, check and then change the values to the correct settings.
控
沙 工B. BASE TIME
Specify the reference time to start reserve time backup.

长 The time elapsed from the reference time for a BACKUP CYCLE period
is recognaized as the BACKUP TIME.
The first automatic backup is performed at the first BACKUP TIME after
the power of the DX 100 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.

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.

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9 System Backup
DX100 9.3 Automatic Backup Function

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.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.

F. STARTUP AUTO BACKUP

Set the backup function to be valid or invalid when the power of the DX
100 is turned ON.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
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).
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
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.

公 司
The term "automatic backup error" here means that the backup is not
performed successfully before the next backup (including retry opera-
tion) starts.
有 限
I. DISPLAY AT EMERGENCY

科 技
Set the method of notification of the automatic backup error to

教 育
"ERROR" or "MESSAGE."
Each time [SELECT] is pressed, "ERROR" and "MESSAGE" are dis-

帮
played alternately.
J. DURING ALARM OCCURENCE
控
沙 工 Set the backup function to be valid or invalid when an alarm is
occurred.

长 Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed

alternately.

K. 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)" indica-
tion is the maximum number of files that can be stored in the Compact-
Flash inserted when this window is displayed.
The settings range from 1 to (Max). When this setting value is changed,
the backup file arrangement starts.

L. BACKUP FILES
Indicates the existence of the files or the number of backup files stored
in the CompactFlash inserted when this window is displayed.

M. LATEST BACKUP FILE

Indicates the date of the latest file in the CompactFlash inserted when
this window is displayed.

N. 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.

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9 System Backup
DX100 9.3 Automatic Backup Function

6. Set the desired item, and press [ENTER].

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.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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9 System Backup
DX100 9.3 Automatic Backup Function

9.3.2.3 DX100 Status and Automatic Backup

Backup DX100 Status Automatic Backup

Timing Compact Absence or
Flash insufficient
ready to capacity of the
save the CompactFlash
data
From a Teach mode Editing Retry Retry
specified (Accessing to
starting time the memory)
When editing is Backup Error
interrupted
Play mode Executing jobs Disabled Disabled
Remote mode When stopped Backup Error
When a Teach mode Editing Error Error
specified (Accessing to
signal(#40560) the memory)
is input When editing is Backup Error
interrupted
Play mode
Remote mode 公 司
Executing jobs Disabled Disabled

限
When stopped Backup Error

技有
When - Backup Error
switching the

科
mode from the
teach mode to
the play mode
育
帮教
When the - Backup Error
DX100 starts

工 控 up

长 沙 * Retry is not performed when an error occurs.

* An error can be indicated by a message depending on setting.

Reserve Time Backup

While the data in the DX100 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.

Backup when the DX 100 starts up

Since the automatic backup process is added to the DX100 start-up
process, a few extra seconds are needed to start up the DX100.

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9 System Backup
DX100 9.3 Automatic Backup Function

Backup when Specific Signal is Input

While the DX100 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.

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.

9.3.2.4 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) 公 司
有 限
Power ON
科 技 BASE TIME

教 育
BACKUP CYCLE

RETRY CYCLE
控 帮
11:00
沙 工11:30 11:40 11:50 12:30

长
13:30
1st day 1st day 1st day 1st day

Backup Backup 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)

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9 System Backup
DX100 9.3 Automatic Backup Function

Power ON BASE TIME

BACKUP CYCLE

RETRY CYCLE

8:00 20:00 21:00 22:00 20:00 20:00

1st day 1st day 2nd day 3rd day

Backup Backup Backup

While a job is being executed, the automatic backup or retry

NOTE is not performed. Also, after an error occurs in writing into
the CompactFlash, the retry is not performed until the next
backup starting time.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

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9 System Backup
DX100 9.4 Loading the Backup Data from the CompactFlash

9.4 Loading the Backup Data from the CompactFlash

Restore the backup data saved in the CompactFlash to the DX100 in
maintenance mode.

9.4.1 Loading Procedure

1. Insert the CompactFlash with the backup data in the CompactFlash
slot on the programming pendant.
– The backup data is stored under the file name "CMOSBK.BIN" or
"CMOSBK??.BIN" (?? denotes figures.)
2. Turn ON the DX100 power supply while pressing [MAIN MENU].
3. Change the security mode to the management mode.
4. Select {EX. MEMORY} under the main menu.
– The sub menu appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
5. Select {CompactFlash}.

长 – The CompactFlash display appears.

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9 System Backup
DX100 9.4 Loading the Backup Data from the CompactFlash

6. Select {SYSTEM RESTORE} in the CompactFlash display.

– The Backup File list display appears.

7. Select the file to be loaded.

– The dialog box appears for the YIF/YCP01 board replacement
confirmation.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
– Select {YES} if the YIF/YCP01 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 system’s
monitoring time.

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9 System Backup
DX100 9.4 Loading the Backup Data from the CompactFlash

8. Select {YES} or {NO} for the message "Exchanged YIF/YCP01

board?"
– The dialog box appears for the loading confirmation.

公 司
– 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 DX100 CMOS.
9. Select {YES}.
有 限
科 技
教 育 CAUTION
控 帮
Note that executing "SYSTEM RESTORE" replaces the current CMOS

沙 工 data with the data of the file "CMOSBK.BIN" or "CMOSBK??.BIN" (??

denotes figures) in the CompactFlash.
长 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 System Backup
DX100 9.5 Error List

9.5 Error List

9.5.1 Error Contents

Error Data Message Cause

No.
0770 * The robot or the station is in The automatic backup would
motion. not work when the robot or a
manipulator is in motion.
3390 File not found The file to be loaded no longer
exists.
3460 * Cannot backup CompactFlash
1 Insufficient capacity of the
CompactFlash
2 Cannot access the
CompactFlash
3501 * Confirm the status of Cannot access the
CompactFlash. CompactFlash

司
3550 * The automatic backup is The automatic backup window
executed. Try it later. cannot be called to display while

限 公 the automatic backup is being

processed.

技有
3551 * The automatic backup is The file arrangement cannot be
executed. Arrange the file after operated during the automatic

3560 *
育 科
it is finished.
Failed to re-arrange the backup
backup operation.
Failed to re-arrange the backup

帮 教 file. file for another reason than the

access to CompactFlash.

工 控
3580 * Accessing to backup file. Try it
later.
To display another window and
then display the automatic

沙
backup window again after
"ARRANGE" operation,
长 “ARRANGE” process should be
completely finished.
3581 * Accessing to backup file. Try The previous "ARRANGE"
"ARRANGE"operation later. process should be completely
finished to perform the next
"ARRANGE" operation.

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10 Upgrade Function
DX100 10.1 Functional Overview

10 Upgrade Function

10.1 Functional Overview

DX100 applies two softwares for the CPU configuration: a software for
YCP01 (for the main CPU board) and a software for YPP01 (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,
DX100 can upgrade the software for YPP01 if the combination of the
softwares for YCP01 and YPP01 is invalid.

10.2 Upgrade Procedure

10.2.1 Confirmation of Software Version

The compatibility of the versions of YCP01 and YPP01 are automatically
checked in 20 seconds after the DX100 power supply is turned on.

公 司
有 限
科 技
教 育
控 帮
沙 工
长
• In case the versions of YCP01 and YPP01 matches.
1. Automatic upgrade process completes and the communication
process between YCP01 and YPP01is restarted.

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10 Upgrade Function
DX100 10.2 Upgrade Procedure

2. Initial window appears approx. 40 seconds later.

10.2.2 Automatic Upgrade of YPP01

In case that the pendant application version of YPP01 is older than the
one of YCP01 or the pendant appplication version of YPP01 is not

公 司
compatible to the one of YCP01, the YPP01 is automatically upgraded.
Not only the application software but the OS of the Programming Pendant
is also upgraded automatically.
(OS: Operating System) 有 限
科 技
教 育
控 帮
沙 工
长

1. Automatic upgrade process comletes and the communication process

between YCP01 and YPP01is restarted.
– Some upgraded softwares require restart.
In this case restart is done automatically and the communication
process between YPP01 and YCP01 starts again.
2. Initial window appears approx. 40 seconds later.

Every time the OS is upgraded automatically, restart is

NOTE done. There is no need of calibrating, for the calibration
data is taken over.

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10 Upgrade Function
DX100 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 DX100.
– Automatic upgrade might be exercised again.
• In case error occurs during automatic upgrade process.
(1) Prepare CF for upgrading or USB memory.
NOTE
(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 “DX100 Upgrade Procedure”
(HW0485193).
•
司
If no recovery is made with all the procedure above,
replace the pendant.
公
有 限
科 技
教 育
控 帮
沙 工
长

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10 Upgrade Function
DX100 10.3 Error Message

10.3 Error Message

If Error occurs while automatic upgrading, exercise the following
procedure.

公 司
•
限
Turn on the main power supply of DX100.

有
– Automatic upgrade might be exercised again.
•
科 技
In case error occurs during automatic upgrade process.

教 育
(1) Prepare CF for upgrading or USB memory.
(2) Press [2], [8] and [HIGH SPEED] at the same time.

控 帮-Upgrade of the OS of Programming Pendant

沙 工 (3) Press [INTERLOCK], [8] and [SELECT] at the same time.

(4) Exercise manual upgrading.
长 -Refer to “DX100 Upgrade Procedure” (HW0485193) for detail.

10-4
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11 Modification of System Configuration

DX100 11.1 Addition of I/O Modules

11 Modification of System Configuration

11.1 Addition of I/O Modules

To add I/O modules, turn OFF the power supply.

Addition operation must be performed in the management

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

1. Turn ON the power supply again while pressing [MAIN MENU]

simultaneously.
2. Change the "SECURITY MODE" to the "MANAGEMENT MODE".
3. Select {SYSTEM} under the main menu.
– The system window appears.

公 司
有 限
科 技
教 育
控 帮
沙 工
长 4. Select {SETUP}.
– The SETUP window appears.
– The items marked with " " cannot be selected.

11-1
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11 Modification of System Configuration

DX100 11.1 Addition of I/O Modules

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
module’s actual mounting status.

公 司
– The following information is shown for each station.
ST#
DI 有 限
Station address of I/O module
Number of contact input points1)
DO
科 技
Number of contact output points1)

教 育AI
AO
Number of analog input points1)
Number of analog output points1)

控 帮 BOARD Circuit board type2)

沙 工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

长 (*****) 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.

11-2
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

8. Press [ENTER].
– The confirmation dialog box is shown.

9. Select {YES}.
– The system parameters are then set automatically according to the

the I/O module is complete.

公 司
current mounted hardware status. The procedure for the addition of

NOTE 有 限
If there is a difference between the displayed contents and
the actual mounted status, confirm the status again. If the

科 技
status is correct, the I/O module may be defective: in such a
case, contact your Yaskawa representative.

教 育
11.2 控 帮
Addition of Base and Station Axes

沙 工
To add the base and station axes, mount all hardware correctly and then

长 execute maintenance mode.

Addition operation must be performed in the management

SUPPLE
mode.
-MENT 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 and the contactor which is used for the
SERVOPACK.

11-3
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

• 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]

公 司
• If axis type is rack & pinion type, set the following items.
限
技有
• MOTION RANGE (+) [mm]
• MOTION RANGE (-) [mm]

科
• REDUCTION RATIO (numerator)
育
帮 教
• REDUCTION RATIO (denominator)
• PINION DIAMETER [mm]

控
沙工
• If axis type is turn type, set the following items.

长
• MOTION RANGE (+) [deg]
• MOTION RANGE (-) [deg]
• REDUCTION RATIO (numerator)
• REDUCTION RATIO (denominator)
• 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.

11-4
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

11.2.1 Base Axis Setting

11.2.1.1 Selection of Base Axis Type

Select the type of base axis to be added/modified.
1. Turn ON the power supply again while pressing [MAIN MENU]
simultaneously.
2. Change the "SECURITY MODE" to the "MANAGEMENT MODE".
3. Select {SYSTEM} under the main menu.
– The system window appears.

公 司
有 限
科 技
教 育
4. Select {SETUP}.
– The SETUP window appears.

控 帮
– Note that the items marked with " " cannot be set.

沙 工
长

5. Select {CONTROL GROUP}.

11-5
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

– The current control group type is displayed.

6. Point the cursor to the type of control group to be modified, and press
[SELECT].
– The MACHINE LIST window is displayed.

公 司
有 限 RECT-X: traverse X-axis base
RECT-Y: traverse Y-axis base
RECT-Z: traverse Z-axis base

技
RECT-XZ: traverse XZ-axis base
RECT-XY: traverse XY-axis base

科
RECT-XYZ: traverse XYZ-axis base
(See the figures on the next page)

教 育
控 帮
沙 工
长
7. Select one in the type list.
– After the type selection, the window returns to the CONTROL
GROUP window.

8. Press [ENTER] in CONTROL GROUP window.

– The window moves to the CONNECTION window.

11-6
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

RECT-X RECT-Y RECT-Z

CARTESIAN
X-AXIS CARTESIAN CARTESIAN
Y-AXIS Z-AXIS
Base axis direction of travel coincides Base axis direction of travel coincides Base axis direction of travel coincides
with robot coordinate X-Axis. with robot coordinate Y-Axis. with robot coordinate Z-Axis.

RECT-XY RECT-YZ
司
RECT-XZ

公
有 限
科 技
教 育
帮
工控
CARTESIAN
Y-AXIS

长沙
CARTESIAN CARTESIAN CARTESIAN
CARTESIAN X-AXIS Z-AXIS CARTESIAN X-AXIS
Y-AXIS Z-AXIS
Base 1st and 2nd axes directions of Base 1st and 2nd axes directions of Base 1st and 2nd axes directions of
travel coincide with robot coordinate travel coincide with robot coordinate travel coincide with robot coordinate
X-Axis and Y-Axis, respecitively. Y-Axis and Z-Axis, respectively. X-Axis and Z-Axis,respectively.

RECT-XYZ CARTESIAN
Z-AXIS

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.

11-7
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

11.2.1.2 Connection Setting

In the CONNECT window, each axis in respective control groups is
specified to be connected to which connector of the SERVO board, or to
which brake of the contactor unit, or to which converter.
1. Confirm type of each control group in the CONNECTION window.
– The connection status of each control group is displayed.

the control group which

is set "NONE" in the
CONTROLGROUPE
window is not displayed.

公 司
有
– The settable items are displayed.
限
2. Select the connection item of desired control group.

科 技
– When the item is selected, the window returns to the CONNECTION

育
window.

教
控 帮
沙 工
长

– It is possible to change the connection freely between each axis

of each control group and each connector (CN) of a SERVO
board. The number in [ ] represents the axis number, and it
indicates which axis is to be connected with which connector.
– It is possible to change the connection freely between each axis
of each control group and each brake (BRK) of a contactor unit.
The number in [ ] represents the axis number, and it indicates
which axis is to be connected with which brake.
– It is possible to change the connection freely between each axis
of each control group and each converter (CV). The number in
[ ] represents the converter number, and it indicates which axis is
to be connected with which converter.

11-8
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

– In this example, B1 (Base) is to be connected as shown in the

following manner:

1st axis SERVO Board (SV #2), Connector (7CN),

Contactor Unit (TU #1), Brake Connector (BRK7),

Converter (CV #1)

2nd SERVO Board (SV #2), Connector (8CN)

axis

Contactor Unit (TU #1), Brake Connector (BRK8)

Converter (CV #2)

3rd SERVO Board (SV #2), Connector (9CN)

axis

Contactor Unit (TU #1), Brake Connector (BRK9)

Converter (CV #3)

3. Select the desired item.

4. Press [ENTER] in the CONNECTION window.
公 司
– The setting in the CONNECTION window is completed and the
window moves to the AXES CONFIG window.
有 限
科 技
11.2.1.3 Axis Configuration Setting

教 育
The axis type is specified in the AXES CONFIG window.

帮
1. Confirm axis type of each axis in the AXES CONFIG window.
控
沙 工 – The axis type of each axis is displayed.

2. Select the axis type to be modified.

11-9
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

(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 win-
dow.
(3) Select the axis type.
公 司
3. Press [ENTER] in the AXES CONFIG window.

有 限
4. The setting in the AXES CONFIG window is completed and the

技
window moves to the MECHANICAL SPEC window.

科
11.2.1.4
教 育
Mechanical Specification Setting

控 帮
The mechanical data is specified in the MECHANICAL SPEC window.

沙 工 1. Confirm specification of each axis in the MECHANICAL SPEC window.

– The mechanical specification of axis is shown.
长 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)

11-10
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

– 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 ball-
screw 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.

公 司
有 限
– MOTION RANGE
技
: Input maximum moving position (positive (+)

科
direction and negative (-) direction) from

教 育 home position when setting the home position

to 0. (Unit: mm)

控 帮
– REDUCTION RATIO: Input the numerator and the denominator.
<e.g.>If the reduction ratio is 1/120, the

沙 工 numerator should be set as 1.0 and the

denominator should be set as 120.0.

长 – 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.

11-11
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

11.2.1.5 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.

公 司
– When a numerical value is selected, the number input buffer line
appears.
有 限
科 技
– When MOTOR (or SERVO AMP or CONVERTER) is selected, the
list window of MOTOR (SERVO AMP, or CONVERTER) appears.

教 育
– ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The counterclockwise view from the

控 帮
loaded side is the normal rotation.)
Fig. 11-1: AC Servo Motor

沙 工
长
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.

11-12
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

– <Phenomenon2>
During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
3. Modify the settings.
4. Press [ENTER] in the MOTOR 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 MOTOR SPEC window for the last
axis, the setting in the MOTOR SPEC window is completed and the
confirmation dialog box appears.

公 司
有 限
科 技
教 育
– If {YES} is selected, the system parameter is set automatically.

11.2.2 Station Axis Setting

控 帮
11.2.2.1
沙 工
Selection of Station Axis Type

长 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.

11-13
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

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 STATIO
UNIV-2: UNIVERSAL 2 AXIS STATIO
...

3. Select desired type in the type list.

– After the type selection, the window returns to CONTROL GROUP
window.

公 司
有 限
– Select "UNIV" (universal) when using a mechanism other than the
registered type (such as a servo track) as a station axis. When

supported.
科 技
“UNIV” is selected, interpolation motion (linear, circular, etc.) is not

教 育
TURN-1

控 帮
沙 工
长 STATION 1ST AXIS

11-14
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

11.2.2.2 Connection Setting

In the CONNECTION window, each axis in respective control group is
specified to be connected to which connector of the SERVO board, or to
which brake of the contactor unit, or to which converter.
1. Confirm type of each control group in the CONNECTION window.
– Connection status of each control group is displayed.

the control group which

is set "NONE" in the
CONTROLGROUP
window is not displayed.

公 司
有
– The settable items are displayed.
限
2. Select the connection item of desired control group.

科 技
– When the item is selected, the window returns to the CONNECTION
window.

教 育
– It is possible to change the connection freely between each axis

控 帮
of each control group and each connector (CN) of a SERVO
board. The number in [ ] represents the axis number, and it

沙 工 indicates which axis is to be connected with which connector.

– It is possible to change the connection freely between each axis
长 of each control group and each brake (BRK) of a contactor unit.
The number in [ ] represents the axis number, and it indicates
which axis is to be connected with which brake.
– It is possible to change the connection freely between each axis
of each control group and each converter (CV). The number in
[ ] represents the converter number, and it indicates which axis is
to be connected with which converter.
– In this example, S1 (station) is to be connected as shown in the
following manner:
1st axis SERVO Board (SV #1), Connector (7CN),

Contactor Unit (TU #1), Brake Connector (BRK7),

Converter (CV #2)

2nd SERVO Board (SV #1), Connector (8CN),

axis

Contactor Unit (TU #1), Brake Connector (BRK8),

Converter (CV #3)

11-15
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

3. Select the desired item.

4. Press [ENTER] in the CONNECTION window.
– The setting in the CONNECTION window is completed and the
window moves to the AXES CONFIG window.

11.2.2.3 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

公 司
有 限
科 技
教 育
The AXES CONFIG window (in case of the UNIVERSAL type)

控 帮
沙 工 BALL- SCREW: Traverse axis (ball-screw)

长
RACK&PINION: Traverse axis (rack&pinion)
ROTATION: Rotation axis

11-16
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

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

公
window moves to the MECHANICAL SPEC window.
司
– The setting in the AXES CONFIG window is completed and the

有 限
科 技
教 育
控 帮
沙 工
长

11-17
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

11.2.2.4 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 公 司
: Input maximum moving position (positive (+)

有 限
direction and negative (-) direction) from home
position when setting the home position to 0.

科 技 (Unit: deg)

教 育
– REDUCTION RATIO: Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/120, the
numerator should be set as 1.0 and the

控 帮 denominator should be set as 120.0.

沙 工 – OFFSET : Offset should be specified at “TURN-2” type

only.

长
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)

11-18
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

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)

公 司
– REDUCTION RATIO : Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/2, the

有 限
numerator should be set as 1.0 and the
denominator should be set as 2.0.

科 技
– BALL-SCREW PITCH: Input the traveling length when the ball-
screw rotates once. (Unit: mm/r)

教 育
帮
The MECHANICAL SPEC window (In case of the RACK&PINION type)

控
沙 工
长
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 1/120, the
numerator should be set as 1.0 and the
denominator should be set as 120.0.
– PINION DIAMETER : Input the diameter of a pinion. (Unit: mm)

11-19
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

The MECHANICAL SPEC window (In case of the ROTATION 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: deg)
– REDUCTION RATIO: Input the numerator and the denominator.

公 司
<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.
2. Modify the settings.
有 限
科 技
3. Press [ENTER] in the MECHANICAL SPEC window.
– After the setting, the current window moves to the window for the

教 育
next axis setting. Complete the settings for all axes in the same
manner.When [ENTER] is pressed in the MECHANICAL SPEC

控 帮
window for the last axis, the setting in the MECHANICAL SPEC
window is completed and the window moves to the MOTOR SPEC

沙 工 window.

长
11.2.2.5 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.

Selected group,
type, axis no. and
axis type are shown.

11-20
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11 Modification of System Configuration

DX100 11.2 Addition of Base and Station Axes

2. Select 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.
– When the type is selected, the window returns to the AXES CONFIG
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. 11-2: AC Servo Motor

Normal direction

公 司
有 限
– MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)
– ACCELARATION SPEED: Input time between 0.01 and 1.00 to

(Unit: sec) 科 技
reach maximum speed from stopping status at 100% JOINT speed.

教 育
– INERTIA RATIO: The initial value is set at 300 in case of servo track;

帮
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with

工 控 the followed procedure.

长沙 – <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.
3. Modify the settings.

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 that case, the control axis configuration is not changed so
the job file data should not be initialized.

11-21
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12 DX100 Specification
DX100

12 DX100 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
DX100 power.
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator.
• Always set the teach lock before starting teaching.
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.

comes toward you unexpectedly.

公 司
– Always have an escape plan in mind in case the manipulator

限
– Ensure that you have a place to retreat to in case of emergency.
有
• 科 技
Improper or unintentional manipulator operation can result in injury.
Before operating the manipulator, check that the SERVO ON lamp

教 育
goes out when the emergency stop buttons on the right of the front
door of the DX100 and the programming pendant are pressed.

控 帮
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency.

沙 工 The emergency stop buttons are located on the right of the front door of

长 the DX100 and the programming pendant.

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.
– Check for problems in manipulator movement.
– Check for damage to the insulation and sheathing of external
wires.
• Always return the programming pendant to its specified position
after use.
If the programming pendant is inadvertently left on the manipulator,
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injuries or equipment
damage.

12-1
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12 DX100 Specification
DX100 12.1 Specification List

12.1 Specification List

Controller Construction Free-standing, enclosed type

Dimensions Refer to following
Cooling System Indirect cooling
Ambient 0°C to + 45°C (During operation)
-10°C to + 60°C (During transit and
Temperature
storage)
Relative Humidity 10% to 90%RH (non-condensing)
Power Supply 3-phase, 200/220 VAC (+10% to -15%)
at 60Hz(±2%)
200 VAC(+10% to -15%) at 50Hz(±2%)
Grounding Grounding resistance: 100Ω or less
Exclusive grounding
Digital I/O Specific signal (hardware)
23 inputs and 5 outputs
General signals (standard, max.)
40 inputs and 40 outputs
(Transistor: 32 outputs, Relay: 8 outputs)
Positioning System
司
By serial communication

公
(absolute encoder)
Drive Unit
Acceleration/ 有 限
SERVOPACK for AC servomotors
Software servo control
Deceleration
科 技
教育
Memory Capacity 200000 steps, 10000 instructions

控 帮
沙工
Small capacity MA1400, MA1900, VA1400, MH5L, MH6, HP20D, HP20D-6,
A-Type 425(W) × 1200(H) × 450(D) mm
(standard)
长 Medium and
Large capacity
MH50, MS80, ES165D, ES200D, VS50
425(W) × 1200(H) × 450(D) mm
A-Type
(standard)

12-2
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12 DX100 Specification
DX100 12.2 Function List

12.2 Function List

Programming Coordinate Joint, Rectangular/Cylindrical, Tool, User

Coordinates
Pendant System
Operation Modification of Adding, Deleting, Correcting (Robot axes
Teaching Points 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
Interface CF (Compact Flash) card slot, USB port
(USB1.1) (At Programming Pendant)
RS232C (At Control Circuit Board)
LAN (100 BASE-TX/10BASE-T) (At

Application
公 司
Control Circuit Board) (Option)
Arc welding, Spot welding, Handling,

限
General, Others

技有
Safety Essential JIS (Japanese Industrial Standard)
Measures
Feature

育 科
Running Speed
Limit
User definable

帮教
Enable Switch 3 position type. Servo power can be
turned on at the middle position only.

控
(Located on programming pendant)

沙 工 Collision proof
Frames
S-axis frame (doughnut-sector), Cubic
frame (user coordinate)

长 Self-Diagnosis Classifies error and two types of alarms

(major and minor) and displays the data
User Alarm Possible to display alarm messages for
Display 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.
Maintenance Operation Time Control power-on time, Servo power-on
Display time, Playback time, Operation time, Work
Function
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

12-3
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12 DX100 Specification
DX100 12.3 Programming Pendant

Programing Programming Interactive programming

Functions Language Robot language: INFORM II
Robot Motion Joint coordinates, Linear/Circular
Control 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
Instructions
manipulator motion
Operation Preparing the operation instructions for
Instructions each application Arc (ON), Arc (OFF), etc.
Variable Global variable, Local variable
Variable Type Byte type, Integer-type, Double precision-
type, Real type, Position type
I/O Instructions Discrete I/O, Pattern I/O processing

12.3 Programming Pendant

Material 公 司
Reinforced thermoplastic enclosure with a detachable

Dimensions
suspending strap
有 限
169(W) × 314.5(H) × 50(D) mm (excluding protrusions)
Displayed Units
科 技
TFT Color liquid crystal display, VGA (640 × 480)

Operated Units
教 育 Touch panel
Three-position Enable switch, Start switch, Hold switch,

帮 Mode select switch (with key, three mode)

工控
Others Provided with CF (Compact Flash) card slot
USB port (USB1.1) X 1

长沙

12-4
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12 DX100 Specification
DX100 12.4 Equipment Configuration

12.4 Equipment Configuration

The DX100 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 DX100 equipment.

12.4.1 Arrangement of Units and Circuit Boards

The arrangements of units and circuit boards in small-capacity, medium-
capacity, and large-capacity DX100s are shown.

Small Capacity
SERVOPACK Breaker Power Supply Contact Unit
Fig. 12-1: Configuration for Small-Capacity A-Type (Standard)

Breaker A Machine Safety Unit

(Refer to the following table) JZNC-YSU01-1E
Emergency Stop
Button (S1)
HW1B-V404R
Backside Duct Fan Brake Control Board Interior Circuration Fan
4715MS-22T-B50-B00 JANCD-YBK01-1E 4715MS-22T-B50-B00

Power Supply Contactor Unit

JZRCR-YPU01-1
公 司
限
I/O Unit
JZNC-YIU01-E

有
Converter
(Refer to the following table)
SERVOPACK
(Refer to the following table)

科 技
教育
Regenerative Resistor
SMRK220W12R5K A5979 MXT NP

(*for HP20D, HP20D-6

RDC50N12R5JI800ZZ
( (MXT)
Robot System Input

帮
Terminal Block
CPS Unit

工
JZNC-YPS01-E
控 Robot I/F Board
JANCD-YIF01-1E
CPU Unit

沙
A JZNC-YRK01-1E

长
Back View Inside Controller F Door Sectional View A-A’
(without cover) Front View Inside View

Table 12-1: Configuration for Small Capacity

Model DX100 SERVOPACK Breaker Power Supply
Contact Unit
Type (Converter integrated)
MH5 ERDR-MH00005-A00 JZRCR-YSV01-11 NF32-SW 3P 15A JZRCR-YPU01-1
MH5L
MH6 ERDR-MH00006-A00 JZRCR-YSV02-11 NF32-SW 3P 15A JZRCR-YPU01-1
MA1400 ERDR-MA01400-A00 JZRCR-YSV02-11 NF32-SW 3P 15A JZRCR-YPU01-1
VA1400 ERDR-VA01400-A00 JZRCR-YSV02-31 NF32-SW 3P 15A JZRCR-YPU01-1
MA1900 ERDR-MA01900-A00 JZRCR-YSV03-11 NF32-SW 3P 15A JZRCR-YPU01-1

HP20D ERDR-HP0020D-A00 JZRCR-YSV03-11 NF32-SW 3P 15A JZRCR-YPU01-1

HP20D-6

12-5
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12 DX100 Specification
DX100 12.4 Equipment Configuration

Medium and Large Capacity

Fig. 12-2: Configuration for Medium and Large Capacity A-Type (Standard)

Breaker A Machine Safety Unit Interior Circuration Fan

(Refer to the following table) JZNC-YSU01-1E 4715MS-22T-B50-B00
Emergency Stop
Backside Duct Fan Button (S1)
4715MS-22T-B50-B00 HW1B-V404R
Converter
(Refer to the following table)
Power Supply Contactor Unit
JZRCR-YPU01-1
SERVOPACK Brake Control Board
(Refer to the following table) JANCD-YBK01-1E
I/O Unit
JZNC-YIU01-E
Regenerative Resistor Interior Circuration Fan
SMVK500W2R0J A5978 4715MS-22T-B50-B00
(MXT)
Robot System Input
Terminal Block
MXT NP
CPS Unit Robot I/F Board
JZNC-YPS01-E JANCD-YIF01-1E
CPU Unit
A JZNC-YRK01-1E
Back View Inside Controller F Door Sectional View A-A’
(without cover)
司
Front View Inside View

限 公
Model DX100
Table 12-2(a): Configuration for Medium Capacity
SERVOPACK Converter
技 有 Breaker Power Supply
Type
科 Contact Unit

教育
MH50 ERDR-MH00050-A00 JZRCR- SRDA- NF32-SW 3P JZRCR-YPU01-1
YSV04-11 COA30A01A-E 30A
MS80 ERDR-MS00080-A00 JZRCR-
YSV05-11
控 帮 SRDA-
COA30A01A-E
NF32-SW 3P
30A
JZRCR-YPU01-1

沙工
VS50 ERDR-VS00050-A00 JZRCR- SRDA- NF32-SW 3P JZRCR-YPU01-1
YSV05-41 COA30A01A-E 30A
SIA50D
长
ERDR-SIA050D-A00 JZRCR-
YSV05-41
SRDA-
COA30A01A-E
NF32-SW 3P
30A
JZRCR-YPU01-1

Table 12-3(a): Configuration for Large Capacity

Model DX100 SERVOPACK Converter Breaker Power Supply
Contact Unit
Type
ES165D ERDR-ES0165D-A00 JZRCR- SRDA- NF32-SW 3P JZRCR-YPU01-1
YSV06-11 COA30A01A-E 30A
ES200D ERDR-ES0200D-A00 JZRCR- SRDA- NF32-SW 3P JZRCR-YPU01-1
YSV06-11 COA30A01A-E 30A

12-6
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12 DX100 Specification
DX100 12.4 Equipment Configuration

12.4.2 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 DX100. Make sure the door of the DX100 is closed when it’s
used to keep this cooling system effective.
Fig. 12-3: .Cooling System

Interior Circuration Fan

Air Intake

Backside Duct Fan

公 司
有 限 Air Outlet

科 技
教 育
控 帮
沙 工
长

12-7
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13 Description of Units and Circuit Boards

DX100

13 Description of Units and Circuit Boards

WARNING
• Before operating the manipulator, check that the SERVO ON lamp
goes out when the emergency stop buttons on the right of the front
door of DX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be
stopped in case of an emergency. The emergency stop buttons are
located on the right of the front door of DX100 and the programming
pendant.
• Always set the teach lock before starting teaching.
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
–
公 司
Always follow the predetermined operating procedure.
–
限
Always have an escape plan in mind in case the manipulator

有
comes toward you unexpectedly.

技
– Ensure that you have a place to retreat to in case of emergency.
科
•
教 育
Improper or unintentional manipulator operation can result in injury.
When turning ON the power to DX100, be sure that there is no one

控 帮
within the P-point maximum envelope of the manipulator, and that
you are in a safe place.

沙 工
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator. Always press the
长 emergency stop button immediately if there are problems.

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.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to its specified position
after use.
If the programming pendant is inadvertently left on the manipulator or
fixture, or on the floor, the manipulator or a tool could collide with it
during manipulator movement, possibly causing injuries or equipment
damage.

13-1
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13 Description of Units and Circuit Boards

DX100

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.

DX100

Input for the robot system

Switch

-19
+24V2
-20
Input signal 1
Turn ON/OFF
-21 at the same time
Input signal 2

024V
-22
公 司
有 限
科 技
教 育
控 帮
沙 工 CAUTION
长 • Do not connect two signals to the same contact point.
(Prepare two indivisual contact points)
• Since the power supply for each signal is reversed, it will short-
circuit and may cause breakdown of DX100 Unit if the signals are
connected to the same contact point.

DX100

Input for the robot system

Switch
-19
+24V2
-20
Input signal 1 The same contact
-21
Input signal 2
-22
024V

Short-circuit current

13-2
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13 Description of Units and Circuit Boards

DX100 13.1 Power Supply Contactor Unit

13.1 Power Supply Contactor Unit

The power supply contactor unit consists of the power supply contactor
sequence circuit board (JARCR-YPC01-1) and the contactor (1KM, 2KM)
for servo power and the line filter (1Z). It turns the contactor servo power
ON and OFF using the signal for servo power control from the power
supply contactor sequence circuit board and supplies power(3-phase
AC200/220V) to the unit.
The power supply (single phase AC200/220V) is supplied to the control
power supply via the line filter.

Table 13-1: Power Supply Contactor Unit Models

Model Robot Type
JZRCR- MH5, MH5L, MH6, MA1400, VA1400, MA1900, HP20D,
YPU01-□ HP20D-6, MH50, MS80, VS50, ES165D, ES200D, SIA50D

Fig. 13-1: Power Supply Unit Configuration (JZRCR-YPU01-□)

(CN601)

公 司 Main Power Supply Input

(2FU),(1FU)
Fuse for AC Control Power Supply
0218010P(10A 250V)
有
CN601 限
(4FU),(3FU)
科 技
CN610
CN601

CN611

教育
CN611
CN610
Fuse for AC Cooling Fan
2FU 1FU 2FU 1 FU
GP25(2.5A 200V) 10 A 10 A CN607

帮
3FU 4FU CN607 (CN607)

控
Contactor Control Input

沙工
4FU 2.5A

3FU 2.5A

(CN606)
AC Cooling Fan CN601 SVMX1 SVMX2

长
NCM
CN609
SVMX1

SVMX2

CN606
SVMX1 SVMX2
(CN605,CN604,CN603) CN606 CN612
AC Control Power Supply
CN608

CN612
(CN608)
CN608

CN605 CN605 Brake Interlock Output

CN604 CN604

CN603 CN603

CN602

CN602

(CN602)
Converter Output

13-3
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13 Description of Units and Circuit Boards

DX100 13.2 Major Axes Control Circuit Board (SRDA-EAXA01□)

13.2 Major Axes Control Circuit Board (SRDA-EAXA01□)

13.2.1 Major Axes Control Circuit Board (SRDA-EAXA01□)

The major axes control circuit board (SRDA-EAXA01□) controls the
servomotors of the manipulator’s six axes. It also controls the converter,
the PWM amplifiers, and the power supply contactor circuit board of the
power supply contactor unit. Mounting an external axes control circuit
board of an option (SRDA-EAXB01□) makes it possible to control the
servomotor of nine axes, including the robot axes.
The major axes control circuit board (SRDA-EAXA01□) also has the
following functions.
• Brake Power Supply Control Circuit
• Shock sensor (shock) input circuit
• Direct-in circuit

Fig. 13-2: Major Axes Control Circuit Board (SRDA-EAXA01□)

(CN510)

司
Converter Power Supply Output (CN513)
Brake Control Signal

公
(CN512)
SHOCK Signal Input
(CN509)
Control Power Supply Input
有 限 (CN511)
Safety Unit I/F

(CN508)
Encoder Signal
科 技 (CN514)
Direct-in

教育
(CN507)
Converter Control Signal

(CN518)
I/O Communication
控 帮
沙工
(CN502)
AMP2 PWM Signal
(CN517)

长
I/O Communication (CN501)
AMP1 PWM Signal
(CN516)
Control Communication (CN504)
AMP4 PWM Signal
(CN515)
Control Communication (CN503)
AMP3 PWM Signal
(CN506)
AMP6 PWM Signal
(CN505)
AMP5 PWM Signal

13-4
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13 Description of Units and Circuit Boards

DX100 13.2 Major Axes Control Circuit Board (SRDA-EAXA01□)

13.2.2 Connection for Tool Shock Sensor (SHOCK)

13.2.2.1 To connect the tool shock sensor directly to the tool shock sensor signal line
1. Disconnect the minus SHOCK (-) and plus SHOCK (+) pin terminal
from the DINAMIC connector, the EAXA-CN512 major axes control
circuit board.
2. Connect the minus SHOCK (-) and plus SHOCK (+) 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.)
SHOCK+ TMEDN-630809-FA TMEDN-630809-MA
(manufactured by NICHIFU Co.,
Ltd.)

Fig. 13-3: Direct Connection to Tool Shock Sensor Signal Line

Major Axes Control Circuit Board

公 司
SRDA-EAXA01

有 限 Manipulator

CN512 TMEDN-630809-FA
SHOCK+
NICHIFU

科 技
Manipulator cable (signal)

-3
教 育
+24V
帮
工控
TMEDN-630809-MA
NICHIFU Shock sensor

长沙
TMEDN-630809-FA (Option)
NICHIFU
-4
SHOCK

SHOCK-
TMEDN-630809-MA NICHIFU Shock sensor signal cable

13-5
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13 Description of Units and Circuit Boards

DX100 13.2 Major Axes Control Circuit Board (SRDA-EAXA01□)

13.2.2.2 To connect the tool shock sensor with the cable that is built into the manipulator
1. Disconnect the minus SHOCK (-) and plus SHOCK (+) pin terminal
from the DINAMIC connector, the EAXA-CN512 major axes control
circuit board.
2. Connect the minus SHOCK (-) pin terminal to the minus SHOCK (-) pin
terminal of the manipulator.

Cable that is built into the manipulator is not connected to

NOTE shocks sensor because the tool shock sensor is a option.
For connecting the tool shock sensor, refer to the wiring dia-
grams in the INSTRUCTIONS for the manipulator.

Fig. 13-4: Connection with Manipulator Cable

Power supply contactor unit

JZRCR-NTU†† Manipulator

CN07
-1
+24V2

-3
+24V
PC-2005M
公 司
限
(manufactured by NICHIFU Co., Ltd.)

技有
SHOCK-
PC2005M Shock sensor
(manufactured by (Option)

SHOCK
-4

育 科NICHIFU Co., Ltd.)

SHOCK-

帮
PC-2005W
教 Supply cables (PG) Use the manipulator cable

工 控
(manufactured by NICHIFU Co., Ltd.)

长 沙 When the tool shock sensor input signal is used, the

stopping method of the robot can be specified. The stopping
SUPPLE
methods are hold stop and servo power supply OFF.
-MENT Selection of the stopping method is set in the display of the
programing pendant. Refer to explanations in chapter 8
“System Setup” at page 8-1 for details.

13-6
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13 Description of Units and Circuit Boards

DX100 13.2 Major Axes Control Circuit Board (SRDA-EAXA01□)

13.2.3 Connection for Direct-in

Direct-in (Servo) 1 to 6
This signal is used to input a responsive signal in search functions.

Fig. 13-5: Connection for Direct-in (Servo) 1 to 6

JFA J2000 Series

Major Axes Control Circuit Board Applicable J21DF-20V-KX-L Maker JST
(SRDA-EAXA01 ) Connector SJ2F-01GF-P1.0(AWG20 24)

CN514
B1 B1
024V
AXDIN1 B3 B3
Direct-in (Servo) 1
AXDIN2 A4 A4
Direct-in (Servo) 2
AXDIN3 B4 B4
Direct-in (Servo) 3
AXDIN4 A5 A5
Direct-in (Servo) 4
AXDIN5 B5 B5
Direct-in (Servo) 5
AXDIN6 A6 A6
Direct-in (Servo) 6

司
AXINCOM A3 A3

+24V2
A1 A1

限 公
Connect the jumper cable.

技 有
育 科
Slave for the coordinated control side
Major Axes Control Circuit Board
帮 教
控
SRDA-EAXA01D
CN514
024V
沙 工
B1 B1

长
AXDIN1 B3 B3
AXDIN2 A4 A4
AXDIN3 B4 B4
AXDIN4 A5 A5
AXDIN5 B5 B5
AXDIN6 A6 A6
AXINCOM A3 A3
A1
+24V2 A1
Connect the jumper cable.

JFA J2000 Series

Applicable Connector J21DF-20V-KX-L JST
SJ2F-01GF-P1.0(AWG20 24)

The part of wiring is for the slave for the coordinated control side major axes control circuit board, SRDA-EAXA01

13-7
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13 Description of Units and Circuit Boards

DX100 13.3 CPU Unit

13.3 CPU Unit

13.3.1 CPU Unit Configuration

CPU unit consists of circuit board racks, control circuit boards, robot I/F
board. The JZNC-YRK01-E CPU unit contains only circuit board racks
and control circuit boards. It does not contain robot I/F board.
Fig. 13-6: CPU Unit Configuration (JZNC- YRK01-1E)

Robot I/F Circuit Board

PCI Slot for Sensor Board x 1 JANCD-YIF01- E

(CN114) Control Circuit Board

IO I/F( Communication with YIU) JANCD-YCP01-E

LED

(CN107)
Compact Flash

CN107
(CN113)
Drive I/F(Communication with EAXA)

公 司
(CN106)
USB

PCI Slot X2
有 限 (CN105)
For Programming Pendant

技
CN106

育 科 (CN104)
For LAN
CN105

帮 教
CN104

工 控
沙
CN103

长 (CN103)
Serial Port(RS232C)

Battery

13-8
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13 Description of Units and Circuit Boards

DX100 13.3 CPU Unit

13.3.2 Unit and Circuit Board in the CPU Unit

13.3.2.1 Control Circuit Board (JANCD-YCP01-E)

This board performs to control the entire system, display to the
programming pendant, control the operating keys, control operation and
calculate interpolation. This board has the Serial interface for RS-232C
and LAN (100BASE-TX/10BASE-T).

13.3.2.2 Robot I/F Board (JANCD-YIF01-1E)

The robot I/F board controls the entire robotic system. It is connected to
the control circuit board (JANCD-YCP01-E) with a PCI bus interface on
the backboard, and to the major axes control circuit board (SRDA-
EAXA01A-□) with high-speed serial transmissions.

公 司
有 限
科 技
教 育
控 帮
沙 工
长

13-9
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13 Description of Units and Circuit Boards

DX100 13.4 CPS Unit (JZNC-YPS01-E)

13.4 CPS Unit (JZNC-YPS01-E)

This unit (JZNC-YPS01-E)supplies the DC power (DC5V, DC24V) for
control (system, I/O, brake). It is also equipped with the input function for
turning the control power supply ON and OFF.

Fig. 13-7: CPU Unit JZNC-YPS01-E

Connection with CPU 1 (CN158)

Monitor Alarm Display Connection with CPU 2 (CN159)

CN159
SOURCE (ALM)
P-ON
+5V (CN156/CN157)
+24V
FAN CN158 +24V2 Power Supply Output
OHT (+5V)

CN156/157 (CN154/CN155)
(+24V2)
+24V1/+24V2 Power Supply Output

POWER SUPPLY
CPS-520F
CN155 (CN153)
NO. C90AD XXXXX (+24V1/+24V2)
DATE YYYY-MM
Fuji Electric Hi-Tech Corp.
+24V3 Power Supply Output
01 02 03 04 05 06 07 08 09
MADE IN JAPAN
10
CN154
11 12 13 14 15 16 17 18 19 20 (+24V1/+24V2)
21 22 23 24 25 26 27 28 29 30

公司
A B C D E F G H J K
L M N P Q R S T U V
CN153 (CN152)
(CN151) (+24V3)
AC Power Supply Input Remote Control

限
CN151
(AC IN)

有
INPUT
200-240V AC CN152
50/60Hz (REMOTE)

技
3.4A-2.8A

育 科
帮 教
工 控
长 沙

13-10
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13 Description of Units and Circuit Boards

DX100 13.4 CPS Unit (JZNC-YPS01-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: Brake)
Indicator
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
OHT
Red
Red
公 司
Lights when FAN error occurs.
Lights when unit interior overheats

Control Power 有 限
To turn ON the DX100 controller power, turn ON the non-fuse breaker of the
ON/OFF
科 技
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

教 育
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 CPS unit as shown in
the following figure. (CN152-1 and CN152-2 is shortaged when shipment)

控 帮
Fig. 13-8: Connection to Control Power Supply Unit

沙 工 DX100

长 Control Power Supply

CPS-420F Remove the short-circuit positioner

CN152
-1 Control Power Supply ON/OFF Switch
R-IN

-2
R-INCOM

See chapter 13.8 “WAGO Connector” at page 13-21 for wiring of CN152 connector.

13-11
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13 Description of Units and Circuit Boards

DX100 13.5 Brake Control Board (JANCD-YBK01-□E)

13.5 Brake Control Board (JANCD-YBK01-□E)

13.5.1 Brake Control Board (JANCD-YBK01-□E)

Brake Control Board controls ON/OFF of the brakes of total nine axes
(Robot + external axes) according to the command signal from Major
Axes Control Circuit Board (SRDA-EAXA01□).

(CN405)
Brake Command Input

(CN404) (CN403)
For Switching External Power Supply Brake Power Supply Input

公 司
(CN402)
Contactor Interlock Input
有 限 F1:Fuse
3A/250V

科 技
教 育
帮
(CN400)
Brake Output

工 控
长 沙

13-12
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13 Description of Units and Circuit Boards

DX100 13.6 Robot I/O Unit (JZNC-YIU01-E)

13.6 Robot I/O Unit (JZNC-YIU01-E)

13.6.1 Robot I/O Unit (JZNC-YIU01-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 chapter 13.12 “Universal I/O Signal Assignment” at page 13-40
for more details on signal allocation.
For the connection of the robot’s universal I/O signal connectors, and the
I/O signal related to start and stop, refer to “Connection wire with
Universal I/O Connector (CN306, 307, 308, 309)” at page 13-14 and
“Specific I/O Signal Related to Start and Stop” at page 13-15
Fig. 13-9: I/O Unit (JZNC-YIU01-E)
(CN305)
Power Supply Input
公 司
(CN304)
有 限 (CN309)
Digital I/O
Power Supply Output

科 技
教育
D1:24V2IN LED
(CN308)
Digital I/O

控 帮
(CN303)
For Switching External Power Supply

沙 工 F1,F2

长
Power Supply Protective Fuse
3A/250V

(CN302) (CN307)
Direct-in Digital I/O
(optional)

(CN301)
Panel IO (CN306)
Digital I/O

D2:FUSE CUT LED

S1: Rotary Switch

(CN300)
Communication Connector

13-13
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13 Description of Units and Circuit Boards

DX100 13.6 Robot I/O Unit (JZNC-YIU01-E)

Connection wire with 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 I/O unit (JZNC-YIU01-E). Unshielded twisted pair cable must be
used.(The cable side connector and the I/O terminal block are the options)

Connector A detail (cable side)

B20 B1
Connector C detail (cable side)

B20 B1
A20 A1
Connector Model: FCN-361J040-AU (FUJITSU)
(Soldered Pin type) A20 A1
Hood Model : FCN-360C040-B (FUJITSU)
Connector Model: 1903404-1
(Tyco Electronics Amp)
(MT Type)
I/O Unit
(JZNC-YIU01-E)

CN309 CN308
Connector A

I/O Cable (YIU ~ external) 公 司

有 限
科 技
育
Connector C

教
CN307 CN306

帮
工控
I/O Cable (YIU ~ Terminal Block)

长沙

CN306,307,308,309 Connector B details

Connector B

B1 B20

A1 A20

Connector Model: 1747053-1 TIFS553YS 21-187-3201 R +24VU +24VU FG

(Tyco Electronics Amp)

B1 B2 B3 B4 B5 B6 024VU 024VU 024VU 024VU 024VU 024VU B8 B9 B10 B11 B12 B13 B14 B15 +24VU +24VU +24VU +24VU +24VU

A1 A2 A3 A4 A5 A6 024VU 024VU 024VU 024VU 024VU 024VU A8 A9 A10 A11 A12 A13 A14 A15 +24VU +24VU +24VU +24VU +24VU

Stripped length: 10mm

I/O Terminal Block Applicable max cable outside diameter: 3mm dia.

Model: TIFS553YS (KASUGA ELECTRIC)

13-14
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13 Description of Units and Circuit Boards

DX100 13.6 Robot I/O Unit (JZNC-YIU01-E)

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: JZNC-YIU01-E)

• External Servo ON (common to all application: Specific input
terminal block MXT)
• External Start (depending on application: JZNC-YIU01-E)
• Operating (depending on application: JZNC-YIU01-E)
• External Hold (common to all application:
Specific input terminal block MXT)
• External Emergency Stop (common to all application:
Specific input terminal block MXT)

<Timing Chart>

RUN
Manipulator
STOP
ON
While Servo ON OFF
公 司
Servo ON
ON
OFF
有 限
ON
T

科 技
育
External Start OFF T

Operating
ON
OFF
帮 教 T

工 控
External Hold ON
OFF

长 沙
Ext. E-Stop ON
OFF
Note: Set T=100msec or more

13-15
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13 Description of Units and Circuit Boards

DX100 13.6 Robot I/O Unit (JZNC-YIU01-E)

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.

DX100
Servo ON Servo ON
Servo ON PB Confirmation System Input Terminal
Command
X2 Servo ON Block (MXT)
X1 Command MXT +24VU
X1 -29
X1
External Servo
-30 ON Input
Servo ON
Servo Power ON Confirmation (EXSVON)
X3 (30011) Robot I/O Unit
X2 JZNC-YIU01
Servo Power ON CN308 +24VU

X3 -A18
PL
Servo ON
-A8 Output
(30011)

Note: Number in ( ) means output signal number assigned to YIU01.

公 司
限
PL: Pilot Lamp

技 有
育 科
Example of Start Sequence Circuit from External Device
Only the rising edge of the external start signal is valid. This signal starts

帮 教
the manipulator. Reset this signal with the interlock configuration that
determines if operation can start and with the playback (RUNNING) signal

工 控 confirming that the manipulator has actually started moving.

长
While
沙
Play mode Alarm/Error Running
DX100
Robot I/O Unit
Run PB Servo ON select Occuring Confirmation Start JZNC-YIU01
(30011) (30016) (30013) X5 (Command) Ex. Start
X4 Command CN308
X4 External Start
-B1
Input
X3
(20010)
-B7
Running
Running Confirmation OVU
X6 (30010)
X5
Running, etc.
-B18
X6 +24VU
PL
-B8
Running Output
(30010), etc.
Note: Number in ( ) means output signal number assigned to YIU01.

13-16
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13 Description of Units and Circuit Boards

DX100 13.6 Robot I/O Unit (JZNC-YIU01-E)

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 robot I/O unit.
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 chapter 13.8 “WAGO
Connector” at page 13-21.
Fig. 13-10: Connection of External Power Supply for I/O

Robot I/O unit (JZNC-YIU01-E) Robot I/O unit (JZNC-YIU01-E)

CN303 +24VU CN303 +24VU

External
F1 Power Supply F1
-1 (EX24VIN) -1 (EX24VIN)
3.15A +24V 3.15A
F2 F2
-2 (EX024VIN) -2 (EX024VIN)
0V

公司
3.15A 3.15A

024VU (Ready by Customer) 024VU

限
+24V +24V

-3 (+24V)
技 有
-3 (+24V)

-4 (024V)
育 科 -4 (024V)

帮 教
024V

工 控 024V

长 沙
In case of using internal power supply In case of using external power supply

• The internal power supply of 24V of about 1.5A of

DX100 can be used for I/O.
Use external 24V power supply for higher currents and
to isolate the circuit inside and outside the DX100.
• Power supply circuit for I/O (+24 VU, 024 VU) has 3.15A
fuses (F1, F2).
NOTE • Install the external power supply outside the DX100 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.

13-17
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13 Description of Units and Circuit Boards

DX100 13.7 Machine Safety Unit (JZNC-YSU01-1E)

13.7 Machine Safety Unit (JZNC-YSU01-1E)

13.7.1 Machine Safety Unit (JZNC-YSU01-1E)

This unit contains dual processing circuits for safety signal.
It processes external safety signals with the dual processing circuits and
control ON/OFF of the contactor for SERVO power supply of the contactor
unit (JZRCR-YPU) according to conditions.
Followings are the main functions of Machine Safety Unit.
• Robot specific I/O circuit (safety signal dual circuits)
• Servo-ON Enable (ONEN) Input Circuit (dual circuits)
• Overrun (OT, EXOT) Input Circuit (dual circuits)
• Programming Pendant Signal PPESP, PPDSW, etc. Input Circuit
(safety signal dual circuits)
• Contactor Control Signal Output Circuit (dual circuits)
• Emergency Stop Signal Input Circuit (dual circuits)

公 司 (CN214)

限
(CN207)
I/F for Machine Safety Unit Contactor Control 1

技 有 s (CN213)

科
B

Contactor Control 2
1
CN214

(CN206)
教 育
CN207

A
1

(CN212)
CN213

I/F-IN for Machine Safety Unit

帮
FANALM,FANCTL,LAMP

控
B

A
1
CN212

工
CN216

(CN202)
FRC5-C50S52T-OLS(D20)

(CN216)

长 沙
I/F for Major Axes Control Circuit Board - Communication
MXT Connection
CN206

(CN205)
I/F-OUT for Machine Safety Unit (CN211)
ONEN,EXONEN,EXOT
CN202

CN211

F1,F2: Fuse
3.15A/250V (CN210)
I/F between Major Axes
Control Circuit Boards
CN205
FUSE

(CN201)
CN210

Power Supply Output Connector

CN215

(CN215)
(CN200)
CN200 CN201

For Contactor Control 3 and 4

CN209

Power Supply Input Connector

CN203

(CN209)
CN208

PP I/F
(CN203)
OT Input Connector
(CN208)
Door Emergency Stop Button

13-18
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13 Description of Units and Circuit Boards

DX100 13.7 Machine Safety Unit (JZNC-YSU01-1E)

13.7.2 Connection for Servo-ON Enable Input (ONEN1 and ONEN2)

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 “8 Servo Power Supply Individual Control Function” of
“Independent/Coordinated Function Instructions Manual” for the usage of
the Servo-ON Enable signals.
For the connection of CN211 Connector, refer to chapter 13.8 “WAGO
Connector” at page 13-21
Fig. 13-11: Connection for Servo-ON Enable Input

DX100

Machine safety unit

JZNC-YSU01-1E
公 司
Remove the jumper cable

CN211

有 限
Servo-ON enable input signal

技
-1
ONEN1_1+

-2 科
教育
ONEN1_1-
Turn ON/OFF
-3 at the same time
ONEN1_2+

控
-4
帮
工
ONEN1_2-

沙
长

13-19
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13 Description of Units and Circuit Boards

DX100 13.7 Machine Safety Unit (JZNC-YSU01-1E)

13.7.3 Connection for External Axis Overrun (EXOT)

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, an alarm occurs.
1. Remove the jumper cable between the connectors CN211-9 and -10
and between the connectors CN211-11 and -12 of the JZNC-YSU01-
1E machine safety unit.
2. Connect the external axis overrun wiring between the connectors
CN211-9 and -10 and between the connectors CN211-11 and -12 of
the JZNC-YSU01-1E machine safety unit.
For the connection of CN211 Connector, refer to chapter 13.8 “WAGO
Connector” at page 13-21

公 司
有 限
CAUTION
科 技
•
育
Remove jumper cable installed on specific input signal before

教
connecting the input signal lines.

控 帮
Failure to observe this caution could lead to injury or mechanical
failure.

沙 工 Fig. 13-12: Connection for External Axis Overrun

长 DX100

Machine Safety Unit

JZNC-YSU01-1E Remove the jumper cable

CN211
-9
OT2_1+

-10 External axis overrun

OT2_1-
Turn ON/OFF
-11 at the same time
OT2_2+

-12
OT2_2 -

13-20
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13 Description of Units and Circuit Boards

DX100 13.8 WAGO Connector

13.8 WAGO Connector

CN211 on the machine safety unit (JZNC-YSU01-1E), CN152 on the CPS
unit (JZNC-YPS01-E), and CN303 on the robot I/O unit (JZNC-YIU01-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 DX100.
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

(Supplied parts - 2 types)
Hole for the wiring tool

公 司
有 限
Part A
科 技
教 育
控 帮 WAGO connector (e.g. 4 pins type)

沙 工 Wire

长 Connector to be applied Specification

Max cable outside diameter: 4.1mm dia.
CPS unit: (JZNC-YPS01-E) CN152
Stripped lentgh: 8-9mm
Machine safety unit: (JZNC-YSU01-1E) CN211 Max cable outside diameter: 3.4mm dia.
Robot I/O unit: (JZNC-YIU02-E) CN303 Stripped lentgh: 7mm

13-21
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13 Description of Units and Circuit Boards

DX100 13.8 WAGO Connector

2. Insert or pull out the wire while pushing the wiring tool downward
(Direction of the arrow).

Wiring tool for WAGO connector

Push

公 司
3. Remove the wiring tool from the connector. (Complete)
限
Keep this wiring tool for the future use.
有
科 技
教 育
控 帮
沙 工
长

13-22
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

13.9 Robot Specific Input Terminal Block (MXT)

The robot specific input termial block (MXT) is equipped at lower part of
the right side of DX100 as shown below. The input termilnal block (MXT) is
used for the input of robot system signals.
For connections, refer to connection diagrams for each corresponding
items.

Fig. 13-13: Robot Specific Input Terminal Block (MXT)

公 司
有 限
科 技 (MXT)

教 育
控 帮
沙 工
长
DX100 Inside Right Side

13-23
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

Wiring Procedure of the MXT Connector

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:
– * The length of the exposed conductor set for the terminal block (L)
司
WAGO series 250 (with 5.0 mm pitch): 9-10 mm
公
限
– * Applicable max cable outside diameter: 3.1 mm dia.

技有
L

育 科
帮 教
工控 (2) In case that the conductor is bent or feazed, make it straight as

长 沙 illustrated in the figure above.

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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

3. Wire Connection

Terminal block: screwless clamp

terminal WAGO series 250

250

250

250
209-188

(1) Place the screwdriver on the lever upright as shown in the figure
below and push straight down.

公 司
有 限
科 技
教 育
控 帮
沙 工 (2) Insert the wire into the connection hole slowly until its leading end
touches the end of the hole.
长 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.

13-25
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

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
• Always connect the signals after removing jumper cable.
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.

Fig. 13-14: Connection for External Emergency Stop

DX100
Robot system input
JZNC JANCD- terminal block
-YSU01-1E YSF03 MXT Remove the jumper cable

-19
EXESP1+

EXESP1-
-20

公 司
External emergency stop
Turn ON/OFF

EXESP2+
-21

有 限 at the same time

EXESP2-
-22

科 技
教 育
控 帮
沙 工
长

13-26
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

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
• Always connect the signals after removing jumper cable.
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.

Fig. 13-15: Connection for Safety Plug

DX100

司
Robot system input
JZNC JANCD terminal block
-YSU01-1E -YSF03 MXT

限 公
Remove the jumper cable

SAFF1+
-9

技 有
-10
科
Safety plug

教育
SAFF1-
Turn ON/OFF
-11 at the same time

帮
SAFF2+

SAFF2-
工
-12
控
长 沙

13-27
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

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.

Manipulator
Working Area
Safeguarding

Servo ON Lamp (Option)

DX100
公 司
Safety Plug
有 限
Safeguarding

Taked Plug
科 技
Emergency
Stop

教 育
控 帮
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

沙 工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
长 servo power can be turned ON while the interlock signal is input.

13-28
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

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 signal’s circuit is open, the status SSP input signal determines the
slow speed: The first slow speed (16%) or second slow speed (2%).
Fig. 13-16: Connection for Full-speed Test

D X100

Robot system input

JZNC JANCD terminal block
-YSU01-1E -YSF03 MXT

Full-speed test
-23
FST1+
-24
FST1-
-25 Turned ON/OFF
FST2+

-26
公 司 at the same time

限
FST2-

技 有
育 科
帮 教
工 控
长 沙

13-29
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

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%)
Fig. 13-17: Connection for Slow Speed Mode Selection

DX100

Robot system input

JZNC JANCD terminal block
-YSU01-1E -YSF03 MXT
Remove the jumper cable

-27 Slow speed mode selection

SSP+
-28
SSP-

公 司
有 限
External Servo ON
科 技
教 育
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

控
ON.
帮
Fig. 13-18: Connection for External Servo ON

沙 工 DX100

长
Robot system input
JZNC JANCD terminal block
-YSU01-1E -YSF03 MXT

External servo ON
-29
EXSVON+
-30
EXSVON-

13-30
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

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
• Always connect the signals after removing jumper cable.
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.

Fig. 13-19: Connection for External Hold

DX100

司
Robot system input
JZNC JANCD terminal block
-YSU01-1E -YSF03 MXT

限 公 Remove the jumper cable

-31
技 有
EXHOLD+
科
教育
-32 External Hold
EXHOLD-

控 帮
沙 工
长

13-31
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

External Enable Switch

This signal is used to connect Enable switch other than the one on the
programming pendant when two people are teaching.

CAUTION
• Always connect the signals after removing jumper cable.
Injury or damage to machinery may result because the external
emergency stop do not work even if the signal is input.

Fig. 13-20: Connection for External Enable Switch

DX100

Robot system input

JZNC JANCD terminal block
-YSU01-1E -YSF03 MXT Remove the jumper cable

-33
EXDSW1+

EXDSW1-
-34

公 司
External Enable Switch

EXDSW2+
-35

有 限 Turned ON/OFF
at the same time

EXDSW2-
-36

科 技
教 育
控 帮
沙 工
长

13-32
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13 Description of Units and Circuit Boards

DX100 13.9 Robot Specific Input Terminal Block (MXT)

Signal Name Connection Dual Function Factory Setting

No. (MXT)
input
EXESP1+ -19 Applicable External Emergency Stop Short-circuit with a
EXESP1- -20 jumper cable
Used to connect the emergency stop switch of an
external device.
EXESP2+ -21
If the signal is input, the servo power is turned
EXESP2- -22
OFF and the job is stopped.
While the signal is input, the servo power cannot
be turned ON.

SAFF1+ -9 Applicable Safety Plug Short-circuit with a

SAFF1- -10 Used to turn OFF the servo power if the door on jumper cable
the safeguarding is opened. Connect to the
SAFF2+ -11 interlock signal from the safety plug on the
SAFF2- -12 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.
FST1+ -23 Applicable Full-speed Test Open
FST1- -24
公 司
Used to reset the slow speed limit for the test run
FST2+
FST2-
-25
-26
in the teach mode.
限
If this signal input circuit is short-circuited, the
有
speed of the test run becomes 100% in the teach
mode.

科 技
If this signal’s circuit is open, the status SSP

教 育
input signal determines the safety speed: The
first slow speed (16%) or second slow speed
(2%).
SSP+
SSP-
-27
-28
-
控 帮
Slow Speed Mode Selection Short-circuit with a
jumper cable

沙 工 Used to determine the speed of the test run when

the FST (full-speed test) signal input circuit is
open.
长 Open: Second slow speed (2%)
Short-circuit: First slow speed (16%)
EXSVON+ -29 - External Servo ON Open
EXSVON- -30
Use to connect the servo ON switch of an
external operation device.
If the signal is input, the servo power supply is
turned ON.
EXHOLD+ -31 - External Hold Short-circuit with a
EXHOLD- -32 jumper cable
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.
EXDSW1+ -33 Applicable External Enable Switch Short-circuit with a
EXDSW1- -34 Used to connect a Enable switch other than the jumper cable
one on the programming pendant when two
EXDSW2+ -35 people are teaching.
EXDSW2- -36

13-33
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13 Description of Units and Circuit Boards

DX100 13.10 Contact Output of Emergency Stop Button

13.10 Contact Output of Emergency Stop Button

The contact output terminals for the emergency stop button on the pro-
gramming pendant and the door front are provided on the terminal block
2XT (screw size M3.5) at lower part of the right side of DX100.
These contact outputs are always valid no matter of the DX100 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. 13-21: Contact Output Terminal Block of Emergency Button (2XT)

Front door of DX100

司
Emergency stop button

2XT

限 公 EXT

技 有
PBESP3+
PBESP3+

科
教育
PBESP3−
PBESP3−

控 帮 PBESP4+
PBESP4+

沙 工 PBESP4−

长
PBESP4−

Programming pendant

Emergency stop button

PPESP3+
PPESP3+

PPESP3−
PPESP3−
PPESP4+
PPESP4+

PPESP4−
PPESP4−

13-34
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13 Description of Units and Circuit Boards

DX100 13.11 SERVOPACK

13.11 SERVOPACK
A SERVOPACK consists of a converter and a PWM amplifier of which
there are two types. One type is the SERVOPACK with a combined
converter and a PWM amplifier and the other type is one where both units
are separate. (Refer to attached table “SERVOPACK Configuration”).

13.11.1 Description of Each Unit

13.11.1.1 Converter
This exchanges the power supply (3-phase : AC200/220V) supplied by
the contactor unit for DC power supply and supplies the power to PWM
amplifiers for each axis.

13.11.1.2 PWM Amplifier

This exchanges the DC power supply supplied by a converter for a
3-phase motor power source and outputs to each servo motor.

13.11.2 SERVOPACK Configuration

Table 13-2:
公 司
Configuration Device MH5/MH5L MH6
限
MA1400 VA1400

技有
Model Model Model Model
SERVOPACK JZRCR-YSV01-11 JZRCR-YSV02-11 JZRCR-YSV02-11 JZRCR-YSV02-31
Converter SRDA-
COA12A01A-E
SRDA-

育 科
COA12A01A-E
SRDA-
COA12A01A-E
SRDA-
COA12A01A-E

帮教
PWM S SRDA- SRDA- SRDA- SRDA-
Amplifier SDA14A01A-E SDA14A01A-E SDA14A01A-E SDA14A01A-E

工控
L SRDA- SRDA- SRDA- SRDA-
SDA14A01A-E SDA14A01A-E SDA14A01A-E SDA14A01A-E

长沙
U SRDA- SRDA- SRDA- SRDA-
SDA06A01A-E SDA14A01A-E SDA14A01A-E SDA14A01A-E
R SRDA- SRDA- SRDA- SRDA-
SDA03A01A-E SDA06A01A-E SDA06A01A-E SDA06A01A-E
B SRDA- SRDA- SRDA- SRDA-
SDA03A01A-E SDA06A01A-E SDA06A01A-E SDA06A01A-E
T SRDA- SRDA- SRDA- SRDA-
SDA03A01A-E SDA06A01A-E SDA06A01A-E SDA06A01A-E
E SRDA-
SDA14A01A-E

13-35
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13 Description of Units and Circuit Boards

DX100 13.11 SERVOPACK

Table 13-3:
Configuration Device MA1900 HP20D
HP20D-6
Model Model
SERVOPACK JZRCR-YSV03-11 JZRCR-YSV03-11
Converter SRDA-COA12A01A-E SRDA-COA12A01A-E
PWM S SRDA-SDA14A01A-E SRDA-SDA14A01A-E
Amplifier L SRDA-SDA21A01A-E SRDA-SDA21A01A-E
U SRDA-SDA14A01A-E SRDA-SDA14A01A-E
R SRDA-SDA06A01A-E SRDA-SDA06A01A-E
B SRDA-SDA06A01A-E SRDA-SDA06A01A-E
T SRDA-SDA06A01A-E SRDA-SDA06A01A-E
E

Table 13-4:
Configuration Device MH50 MS80
公 司 VS50/SIA50D
Model
限
Model Model

技有
Converter SRDA-COA30A01A-E SRDA-COA30A01A-E SRDA-COA30A01A-E
SERVOPACK JZRCR-YSV04-11 JZRCR-YSV05-11 JZRCR-YSV05-41
PWM
Amplifier
S
L
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E 育 科 SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
SRDA-SDA71A01A-E
U
帮 教
SRDA-SDA35A01A-E SRDA-SDA71A01A-E SRDA-SDA71A01A-E
R
控
SRDA-SDA14A01A-E SRDA-SDA14A01A-E SRDA-SDA14A01A-E

沙工
B SRDA-SDA14A01A-E SRDA-SDA14A01A-E SRDA-SDA14A01A-E
T SRDA-SDA14A01A-E SRDA-SDA14A01A-E SRDA-SDA14A01A-E

长 E SRDA-SDA71A01A-E

Table 13-5:
Configuration Device ES165D ES200D
Model Model
Converter SRDA-COA30A01A-E SRDA-COA30A01A-E
SERVOPACK JZRCR-YSV06-11 JZRCR-YSV06-11
PWM S SRDA-SDA71A01A-E SRDA-SDA71A01A-E
Amplifier L SRDA-SDA71A01A-E SRDA-SDA71A01A-E
U SRDA-SDA71A01A-E SRDA-SDA71A01A-E
R SRDA-SDA35A01A-E SRDA-SDA35A01A-E
B SRDA-SDA21A01A-E SRDA-SDA21A01A-E
T SRDA-SDA21A01A-E SRDA-SDA21A01A-E
E

13-36
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13 Description of Units and Circuit Boards

DX100 13.11 SERVOPACK

Fig. 13-22: SERVOPACK Configuration for MH5, MH5L, MH6, MA1400, MA1900, HP20D, HP20D-6

Converter
(CN551) (CN552B)
Control Power Supply Input Control Power SupplyOutput
(CN554) (CN553) Monitor Alarm (CN552A) for External Axis Amplifier (AMP1,3,5-CN583) (AMP2,4,6-CN583)
Grounding Detection Input Converter Control Signal Display LED Control Power SupplyOutput (CN556) Amplifier Main Circuit Amplifier Main Circuit
Ground Terminal for 6-Axis Amplifier Control Power SupplyOutput for 6-Axis Amplifier Power Supply Power Supply
(CN558)
(CN557) Main Circuit Power Supply Output for External Axis Amplifier
Regenerative Resister
(CN555) Charge Lamp
Main Circuit Power Supply Input EAXA Base Fixing Screw (top)

EAXA Board (AMP1,3,5-CN581) (AMP2,4,6-CN584)

PWM Signal Motor Power Output
(CN513)
EAXA Base Fixing Screw (top) Brake Control Signal
(CN512) (CN511) AMP1
SHOCK Signal Input Safety Unit I/O
AMP2
(CN509) (CN514)
Control Power Supply Input Direct-in
(CN507) AMP3
Converter Control Signal AMP4
(CN508)
Encoder Signal (CN502)
AMP2 PWM Signal
(CN518) (CN501) AMP5 AMP6
I/O Communication AMP1 PWM Signal
(CN517) (CN504)
I/O Communication AMP4 PWM Signal
(AMP1,3,5-CN584) (AMP2,4,6-CN581)
(CN516) (CN503) PWM Signal
Control Communication Motor Power Output
AMP3 PWM Signal
(CN515)
Control Communication
EAXA Base (CN506)
Ground Terminal AMP6 PWM Signal

公司
(CN505)
EAXA Base Fixing AMP5 PWM Signal (AMP2,4,6-CN582)
Screw (bottom) (AMP1,3,5-CN582)
Amplifier Control
Amplifier Control Power Supply Power Supply

(EAXA Base is closed)

有 限 (EAXA Base is open)

Fig. 13-23: SERVOPACK Configuration for VA1400

科 技
育
帮教
(CN551) (AMP1,3,5,7-CN583)
Control Power Supply Input Amplifier Main Circuit
(CN552A) Converter Power Supply
(CN554) (CN553) Monitor Alarm (AMP2,4,6-CN583)

控
Converter Control Signal Display LED Control Power Supply Output (AMP1,3,5,7-CN581) Amplifier Main Circuit
Grounding Detection Input for 6-Axis Amplifier (CN552B) Control Power Supply Output
for External Axis Amplifier PWM Signal Power Supply

工
Ground Terminal
(CN556) Main Circuit Power Supply
(CN557) Output for 6-Axis Amplifier

沙
Regenerative Resister (CN558) Main Circuit Power Supply
(CN555) Output for External Axis Amplifier

长
Main Circuit Power Supply Input
Charge Lamp
EAXA Base Fixing Screw (top) (AMP2,4,6-CN584)
EAXA Base Fixing Screw (top)
(CN512) Motor Power Output
SHOCK Signal Input EAXA Board
(CN511) AMP1
Safety Unit I/O AMP2
(CN509) (CN513)
Control Power Supply Input Brake Control Signal
(CN508) (CN514)
Encoder Signal Direct-in AMP3
AMP4
(CN531) PWM Amplifier 7 Signal (CN507)
(back) Converter Control Signal
(CN532) PWM Amplifier 8 Signal (CN502) AMP5
AMP2 PWM Signal AMP6
(frond)
(CN517,CN518) (CN501)
I/O Communication AMP1 PWM Signal (AMP1,3,5,7-CN584)
(CN533) (CN504) Motor Power Output
PWM Amplifier 9 Signal AMP4 PWM Signal
(CN503)
(CN515,CN516) AMP3 PWM Signal
Control Communication AMP7
(CN506) (AMP2,4,6-CN581)
AMP6 PWM Signal PWM Signal
EAXA Base (CN505)
Ground Terminal AMP5 PWM Signal

EAXA Base Fixing (AMP2,4,6-CN582)

Screw (bottom) (AMP1,3,5,7-CN582) Amplifier Control
Amplifier Control Power Supply Power Supply

(EAXA Base is closed) (EAXA Base is open)

13-37
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13 Description of Units and Circuit Boards

DX100 13.11 SERVOPACK

Fig. 13-24: SERVOPACK Configuration for MH50, MS80

(CN551)
(CN553) Control Power Supply Input
Monitor Alarm Display LED
Converter Control Signal (CN552A) Control Power Supply
Output for 6-Axis Amplifier (AMP2,4,6-CN583)
(CN554) Upper Grip (AMP1,3,5-CN583) Amplifier Main Circuit Power Supply
Grounding Detection Input (CN552B) Control Power Supply
Output for External Axis Amplifier Amplifier Main Circuit (AMP2,4,6-CN582)
Power Supply Amplifier Control Power Supply
Ground Terminal Converter

(CN557) Charge Lamp

Regenerative Resister (CN556)
Main Circuit Power Supply Output
(CN555)
(CN558)
Main Circuit Power Supply Input
Main Circuit Output for External Axis
(CN510)
Control Power Supply Output Upper Grip
for Converter EAXA Base Fixing
EAXA Base Fixing Screw (top) AMP1
Screw (top) EAXA Board
(CN511) (AMP2,4,6-CN584)
(CN512) (AMP1,3,5-CN581)
SHOCK Signal Input Safety Unit I/F Motor Power Output
PWM Signal
(CN509) (CN513)
Control Power Supply Input Brake Control Signal
(CN514) AMP2
(CN508) AMP3
Direct-in
Encoder Signal
(CN507)
(CN518) Converter Control Signal
I/O Communication (CN502)
AMP2 PWM Signal AMP4
(CN517)
I/O Communication (CN501)
(CN516) AMP1 PWM Signal
Control Communication (CN504) AMP5 (AMP2,4,6-CN581)
AMP4 PWM Signal PWM Signal
(CN515) (CN506)
Control Communication AMP6 PWM Signal
(AMP1,3,5-CN584)
AMP6

司
(CN505) Motor Power Output
EAXA Base AMP5 PWM Signal
(CN503)

公
Ground Terminal
AMP3 PWM Signal
EAXA Base Fixing

限
Screw (bottom) (AMP1,3,5-CN582)
Amplifier Control

有
Power Supply

Lower Grip

科 技 Lower Grip

育
(EAXA Base is closed) (EAXA Base is open)

教
Fig. 13-25: SERVOPACK Configuration for VS50, SIA50D

帮
工控
Monitor Alarm
Display LED (CN551)
(CN553) Control Power Supply (AMP1,3,5,7-CN583) (AMP2,4,6-CN583)
I/O Signal Connecting Terminal Upper Grip (CN552A) (CN552B) Amplifier Main Circuit Power Supply Amplifier Main Circuit Power Supply

长沙
(CN554) Control Power Supply Control Power Supply (AMP1,3,5,7-CN581) (AMP2,4,6-CN582)
Grounding Detection Input PWM Signal Amplifier Control Power Supply
Converter
Ground Terminal
(CN557) Charge Lamp
Regenerative Resister (CN556)
Main Circuit Power Supply Output
(CN555) Main Circuit
Power Supply Input (CN558)
Main Circuit Output for External Axis
(CN510) Control Power Supply Upper Grip
Output for Converter
EAXA Base Fixing
EAXA Base Fixing Screw (top) Screw (top)
(CN509) EAXA Board
Control Power Supply Input (CN511) AMP1 (AMP2,4,6-CN584)
(CN512) Safety Unit I/F
SHOCK Signal Input Motor Power Output
(CN508) (CN513)
Encoder Signal Brake Control Signal
(CN531) PWM Amplifier 7 (CN514) AMP2
Signal (back) Direct-in AMP3
(CN532) PWM Amplifier 8 (CN507)
Signal (front) Converter Control Signal
(CN502)
(CN517,CN518) AMP2 PWM Signal AMP4
I/O Communication
(CN501)
(CN533) AMP1 PWM Signal
PWM Amplifier 9 Signal (CN504) AMP5 (AMP2,4,6-CN581)
(CN515,CN516) AMP4 PWM Signal PWM Signal
Control Communication (CN506)
AMP6 PWM Signal
EAXA Base
AMP6
(AMP1,3,5,7-CN584)
Ground Terminal Motor Power Output
(CN505)
AMP5 PWM Signal
EAXA Base Fixing
Screw (bottom) EAXA Base Fixing AMP7
Screw (bottom)
(CN534) (CN503)
Encoder Signal AMP3 PWM Signal
(7th Axis)
(CN535) (CN536) (AMP1,3,5,7-CN582)
Lower Grip Lower Grip
Encoder Signal Encoder Signal Amplifier Control Power Supply
(8th Axis) (9th Axis)

(EAXA Base is closed) (EAXA Base is open)

13-38
 工控帮助教小舒QQ:2823408167

13 Description of Units and Circuit Boards

DX100 13.11 SERVOPACK

Fig. 13-26: SERVOPACK Configuration for ES165D, ES200D

Monitor Alarm Display LED (CN551)
Control Power Supply (AMP2,4,6-CN583)
(CN553) I/O Signal Connecting Terminal (AMP1,3,5-CN583) Amplifier Main Circuit Power Supply
(CN552B)
(CN554) Upper Grip (CN552A) Control Power Supply Amplifier Main Circuit
Control Power Supply (AMP2,4,6-CN582)
Grounding Detection Input Power Supply Amplifier Control Power Supply
Ground Terminal Converter
Charge Lamp
(CN557) (CN556)
Regenerative Resister Main Circuit Power Supply Output
(CN558)
(CN555) Main Circuit Main Circuit Output for External Axis
Power Supply Input
Upper Grip
(CN510) EAXA Base
Control Power Supply Fixing Screw (top)
Output for Converter
EAXA Base EAXA Board AMP1
Fixing Screw (top) (CN513) AMP2
(CN512) Brake Control Signal
(AMP1,3,5-CN581) (AMP2,4,6-CN584)
SHOCK Signal Input (CN511) PWM Signal Motor Power Output
Safety Unit I/F
(CN509)
Control Power Supply Input (CN514)
Direct-in
(CN508) AMP3
(CN507)
Encoder Signal Converter Control Signal
(CN502)
(CN518) AMP2 PWM Signal
I/O Communication (CN501)
(CN517) AMP4
AMP1 PWM Signal
I/O Communication (CN504)
(CN516) AMP4 PWM Signal AMP5
Control Communication (CN503)
(CN515) AMP3 PWM Signal (AMP2,4,6-CN581)
Control Communication (AMP1,3,5-CN584) PWM Signal

公司
Motor Power Output
(CN506)
EAXA Base AMP6 PWM Signal AMP6
Ground Terminal
(CN505)

限
AMP5 PWM Signal (AMP1,3,5-CN582)
EAXA Base Fixing Amplifier Control

有
Screw (bottom) Power Supply

科 技
育
Lower Grip
Lower Grip

帮教
(EAXA Base is closed) (EAXA Base is open)

工 控
长 沙

13-39
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

13.12 Universal I/O Signal Assignment

13.12.1 Arc Welding

Fig. 13-27: JZNC-YIU01-E (CN308 Connector) I/O Allocation and
Connection Diagram (For Arc Welding)

DX100
Robot I/O Unit (JZNC-YIU01-E) Connector Terminal Converter
(Optional)
+24VU Model:TIFS553YS
CN308 Connector
Logical Connector Name Signal Terminal
Number Number Number

Each Point 20010 B1 External Start IN B1 B1

24VDC 20011 A1 - IN A1 A1
8mA max. 20012 B2 Call Master Job IN B2 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 - IN B3 B3
20015 A3 Select Play Mode IN A3 A3
20016 B4 Select Teach Mode IN B4 B4
20017 A4 - IN A4 A4
Interference1 Entrance
20020 B5 Prohibited IN B5 B5
Interference2 Entrance
20021 A5 Prohibited IN A5 A5

公司
20022 B6 Work Prohibited IN B6 B6
20023 A6 Work Response IN A6 A6
B7 024VU B7 024VU

有限
A7 024VU A7 024VU
30010 B8 Running OUT B8 B8
30011 A8 Servo is ON OUT A8 A8

科技
30012 B9 Top of Master Job OUT B9 B9
30013 A9 Alarm/Error Occurred OUT A9 A9

教育
30014 B10 Battery Alarm OUT B10 B10
30015 A10 Remote Mode Selected OUT A10 A10
30016 B11 Play Mode Selected OUT B11 B11

帮 30017 A11 Teach Mode Selected OUT A11 A11

控
30020 B12 In Cube 1 OUT B12 B12
30021 A12 In Cube 2 OUT A12 A12

沙工
30022 B13 Work Home Position OUT B13 B13
Each Point 30023 A13 Intermediate Start OK
(continuousing Sequence) OUT A13 A13

长
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3
+24 V B17 024VU B17 024VU
-4 024 V A17 024VU A17 024VU
(24V,1A)
B18 +24VU B18 +24VU
External A18 +24VU A18 +24VU
Power Supply -1 +24VU
B19 +24VU B19 +24VU
+24 VE -2 A19
024VU A19 +24VU +24VU
024 VE
B20 FG B20 FG
A20 A20 024VU
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
024VU
when a external power supply is used.
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-40
 工控帮助教小舒QQ:2823408167

13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-28: JZNC-YIU01-E (CN309 Connector) I/O Allocation and

Connection Diagram (For Arc Welding)

DX100
Connector Terminal Converter
Robot I/O Unit (JZNC-YIU01-E) (Optional)
+24VU Model:TIFS553YS
CN309 Connector
Logical Connector
Number Number
Name Signal Terminal
Number
Each Point 20024 B1 - IN B1 B1
24VDC 20025 A1 - IN A1 A1
8mA max.
20026 B2 Weaving Prohibited IN B2 B2
20027 A2 Sensing Prohibited IN A2 A2
20030 B3 IN01 User Output IN B3 B3
20031 A3 IN02 IN A3 A3
20032 B4 IN03 IN B4 B4
20033 A4 IN04 IN A4 A4
20034 B5 IN05 IN B5 B5
20035 A5 IN06 IN A5 A5

20036 B6 IN07 IN B6 B6

20037 A6 IN08 IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30024 B8 Gas Shortage (Monitor) OUT
30025 A8 Wire Shortage (Monitor) OUT
B8
A8
公 司 B8
A8

限
30026 B9 Wire Sticking (Monitor) OUT B9 B9
A9 A9

有
30027 A9 Arc Shortage (Monitor) OUT
30030 B10 OUT01 User Output OUT B10 B10
30031 A10 OUT02
30032 B11 OUT03
OUT

科
OUT技 A10
B11
A10
B11

教育
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12

30035 A12 OUT06 OUT A12 A12

Each Point
24VDC
帮
30036 B13 OUT07

控
30037 A13 OUT08
OUT
OUT
B13
A13
B13
A13

沙工
B14 B14
B14
50mA max. A14 A14
A14
B15 B15
B15

CN303
Internal
长 A15
B16 024VU
A16 024VU
A15
B16
A16
A15
024VU
024VU
-3 Power Supply
024VU
+24 V B17 024VU B17
024 V 024VU
-4 (24V,1A) A17 024VU A17
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24 VE
B19 +24VU
-2 024VU A19 +24VU
024 VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
+24VU
when a external power supply is used.
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-41
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-29: JZNC-YIU01-E (CN306 Connector) I/O Allocation and

Connection Diagram (For Arc Welding)

DX100
Robot I/O Unit JZNC-YIU01-E Connector Terminal Converter
(Optional)
+24VU Model: TIFS553YS
CN306
Logical Connector
Number Name Signal Terminal
Number
Number

Each Point 20040 B1 IN09 User Input IN B1 B1

24VDC 20041 A1 IN10 IN A1 A1
8mA max. IN11 IN
20042 B2 B2 B2
20043 A2 IN12 IN A2 A2
20044 B3 IN13 IN B3 B3
20045 A3 IN14 IN A3 A3
20046 B4 IN15 IN B4 B4
20047 A4 IN16 IN A4 A4
B5 B5 B5
A5 A5 A5

B6 B6 B6

A6 A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30040 B8
30041 A8
OUT09 User Input OUT
OUT10 OUT
B8

公
A8
B9
司 B8
A8
B9

限
30042 B9 OUT11 OUT
30043 A9 OUT12 OUT A9 A9

30044 B10 OUT13

30045 A10 OUT14

技 有 OUT
OUT
B10
A10
B10
A10

科
30046 B11 OUT15 OUT B11 B11
30047 A11 OUT16 OUT A11 A11

教育
B12 B12 B12
A12 A12 A12

帮
Each Point B13 B13 B13
24VDC A13 A13
A13
50mA max.
控 B14
B14 B14

沙工
A14 A14
A14
B15 B15 B15

长
A15 A15 A15
B16 024VU B16 024VU
CN303 A16 024VU
Internal A16 024VU
-3 Power Supply
+24 V B17 024VU B17 024VU
024 V
-4 (24V,1A) A17 024VU
A17 024VU
B18 +24VU B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24 VE B19 +24VU
024 VE -2 024VU A19 +24VU
A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
024VU
when a external power supply is used.
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-42
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-30: JZNC-YIU01-E (CN307 Connector) I/O Allocation and

Connection Diagram (For Arc Welding)

DX100
Robot I/O Unit JZNC-YIU01-E Connector Terminal Converter
(Optional)
+24VU Model: TIFS553YS
CN307 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point IN17
20050 B1 IN B1 B1
24VDC
20051 A1 IN18 IN A1 A1
8mA max.
20052 B2 IN19 IN B2 B2
20053 A2 IN20 IN A2 A2
20054 B3 IN21 IN B3 B3
20055 A3 IN22 IN A3 A3
20056 B4 IN23 IN B4 B4
20057 A4 IN24 IN A4 A4

B5 B5 B5
A5 A5 A5
B6 B6
B6
A6 A6
A6
B7 024VU B7 024VU

司
A7 024VU A7 024VU

公
30050 B8 OUT17- OUT B8 B8
A8 OUT17+ OUT A8 A8 RLY
30051 B9
A9
OUT18-
OUT18+
OUT
OUT
有
B9
A9 限 B9
A9 RLY

技
30052 B10 OUT19- OUT B10 B10

科
A10 OUT19+ OUT A10 A10 RLY
30053 B11 OUT20- OUT B11 B11

教育
A11 OUT20+ OUT A11 A11 RLY
30054 B12 OUT21- OUT B12 B12

帮
A12 OUT21+ OUT A12 A12 RLY

30055 B13 OUT22- B13 B13

控
OUT
Each Point A13 RLY
A13 OUT22+ OUT A13
24VDC

沙工
30056 B14 OUT23- OUT B14 B14
500mA max.
A14 A14 RLY
A14 OUT23+ OUT

长
OUT B15 B15
30057 B15 OUT24-
A15 OUT24+ OUT A15 A15 RLY
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply
A16 024VU
-3 +24 V B17 024VU
B17 024VU
024 V 024VU
-4 (24V,1A) A17 024VU A17
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU * means internal relay
+24 VE B19 +24VU RLY means
-2 024VU A19 +24VU
024 VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-43
 工控帮助教小舒QQ:2823408167

13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-6: 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

司
a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE

限 公
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

teach mode selection.

技 有
signal is selected by priority even when the other selection signal is ON, enabling the

20020
科
INTERFERENCE 1 ENTRANCE PROHIBITED

育
If the manipulator attempts to enter the cube 12) area while this signal is ON, the

帮 教
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021

工 控INTERFERENCE 2 ENTRANCE PROHIBITED

If the manipulator attempts to enter the cube 22) area while this signal is ON, the

沙
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20022 长 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 chapter 8.6 “Interference Area” at page 8-56.

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 工控帮助教小舒QQ:2823408167

13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-7: 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 DX100 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

problems by using this signal as a warning signal.

公 司
if memory data is lost because of an expired battery. It is recommended to avoid these

30015 to
30017
REMOTE/PLAY/TEACH MODE SELECTED
限
This signal notifies the current mode setting. These signals are synchronized with the
有
mode select switch in the programming pendant. The signal corresponding to the

30020
selected mode turns ON.
IN CUBE 1
科 技
教 育
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

控 帮
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2).

30022
沙 工
Use this signal to prevent interference with other manipulators and positioners.
WORK HOME POSITION (IN CUBE 32)2)

长
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 32 are same.

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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

13.12.2 Handling
Fig. 13-31: JZNC-YIU01-E (CN308 Connector) I/O Allocation and
Connection Diagram (For Handling)

DX100
Connector Terminal Converter
Robot I/O Unit (Optional)
Model: TIFS553YS
+24VU
CN308
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20010 B1 External Start IN B1 B1
24VDC
20011 A1 - IN A1 A1
8mA max.
20012 B2 Call Master Job IN B2 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 - IN B3 B3
20015 A3 Select Play Mode IN A3 A3
20016 B4 Select Teach Mode IN B4 B4
20017 A4 - IN A4 A4
Interference1 Entrance B5 B5
20020 B5 Prohibited IN
Interference2 Entrance A5 A5
20021 A5 Prohibited IN
20022 B6 - IN B6 B6

20023 A6 - IN A6 A6
B7 024VU B7 024VU

公司
A7 024VU A7 024VU
30010 B8 Running OUT B8 B8
30011 A8 Servo is ON OUT A8 A8

有限
30012 B9 Top of Master Job OUT B9 B9
A9 A9
30013 A9 Alarm/Error Occurred OUT

科技
30014 B10 Battery Alarm OUT B10 B10
30015 A10 Remote Mode Selected OUT A10 A10
30016 B11 Play Mode Selected OUT B11 B11

教育
30017 A11 Teach Mode Selected OUT A11 A11
30020 B12 In Cube 1 OUT B12 B12

帮
30021 A12 In Cube 2 OUT A12 A12
30022 B13 Work Home Position OUT B13 B13

控 Intermediate Start OK
30023 A13 (continuousing Sequence) OUT A13 A13

沙工
Each Point B14 B14
24VDC B14
A14 A14
50mA max. A14

长
B15 B15 B15

A15 A15 A15

B16 024VU B16 024VU
CN303 Internal A16 024VU
A16 024VU
-3 Power Supply
+24 V B17 024VU B17 024VU
-4 024 V A17 024VU
(24V,1A) A17 024VU
B18 +24VU B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24 VE A19 +24VU
024 VE
-2 024VU A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-46
 工控帮助教小舒QQ:2823408167

13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-32: JZNC-YIU01-E (CN309 Connector) I/O Allocation and

Connection Diagram (For Handling)

DX100
Robot I/O Unit JZNC-YIU01-E Connector Terminal Converter
(Optional)
+24VU
Model: TIFS553YS
CN309 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point
20024 B1 - IN B1 B1
24VDC
20025 A1 - IN A1 A1
8mA max. Shock Sensor (NC)
20026 B2 - Hold IN B2 B2
20027 A2 Low Air Pressure IN A2 A2
20030 B3 IN01 IN B3 B3
20031 A3 IN02 IN A3 A3
20032 B4 IN03 IN B4 B4
20033 A4 IN04 IN A4 A4
20034 B5 IN05 IN B5 B5
20035 A5 IN06 IN A5 A5

20036 B6 IN07 IN B6 B6

20037 A6 IN08 IN A6 A6
B7 024VU B7 024VU

司
A7 024VU A7 024VU
30024 B8 - OUT B8 B8
30025 A8
30026 B9
-
-
OUT
OUT
A8
B9

限 公 A8
B9

有
- A9 A9
30027 A9 OUT
30030 B10 OUT01 User Output B10 B10

技
OUT
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03
科
OUT B11 B11

教育
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12

30035 A12 OUT06 OUT A12 A12

Each Point
控 帮
30036 B13 OUT07
30037 A13 OUT08
OUT
OUT
B13
A13
B13
A13

沙工
B14 B14
B14
24VDC A14 A14
50mA max. A14
B15 B15
B15

CN303 Internal
长 A15
B16 024VU
A16 024VU
A15
B16
A16
A15
024VU
024VU
-3 Power Supply
+24 V B17 024VU B17 024VU
024 V A17 024VU
-4 (24V,1A) A17 024VU
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24 VE B19 +24VU
-2 024VU A19 +24VU
024 VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
024VU
when a external power supply is used.
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-47
 工控帮助教小舒QQ:2823408167

13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-33: JZNC-YIU01-E (CN306 Connector) I/O Allocation and

Connection Diagram (For Handling)

DX100
Robot I/O Unit Connector Terminal Converter
JZNC-YIU01-E (Optional)
+24VU Model: TIFS553YS
CN306 Connector
Logical Connector
NumberNumber Name Signal Terminal
Number
Each Point 20040 B1 IN09 IN B1 B1
24VDC 20041 A1 IN10 IN A1 A1
8mA max. IN11 IN B2
20042 B2 B2
20043 A2 IN12 IN A2 A2
20044 B3 IN13 IN B3 B3
20045 A3 IN14 IN A3 A3
20046 B4 IN15 IN B4 B4

20047 A4 IN16 IN A4 A4

B5 B5 B5
A5 A5
A5
B6 B6
B6
A6 A6
A6
B7 024VU B7 024VU

公司
A7 024VU A7 024VU

30040 B8 OUT09 OUT B8 B8

30041 A8 OUT10 OUT A8 A8

有限
30042 B9 OUT11 OUT B9 B9

30043 A9 OUT12 A9 A9
OUT

科技
30044 B10 OUT13 OUT B10 B10
30045 A10 OUT14 OUT A10 A10
30046 B11 OUT15 OUT B11 B11

教育
30047 A11 OUT16 OUT A11 A11

B12 B12 B12

A12 A12

帮
A12
Each Point B13 B13
B13

控
24VDC A13 A13
A13
50mA max.

沙工
B14 B14
B14
A14 A14
A14
B15 B15

长
B15
A15 A15 A15

B16 024VU B16 024VU

CN303 Internal A16 024VU
A16 024VU
-3 Power Supply 024VU
+24 V B17 024VU B17
-4 024 V A17 024VU
(24V,1A) A17 024VU
B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-48
 工控帮助教小舒QQ:2823408167

13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-34: JZNC-YIU01-E (CN307 Connector) I/O Allocation and

Connection Diagram (For Handling)

DX100
Connector Terminal Converter
Robot I/O Unit JZNC-YIU01-E (Optional)
Model: TIFS553YS
+24VU
CN307 Connector
Logical Connector Terminal
Number Number Name Signal
Number
Each Point 20050 B1 Sensor Input 1 IN B1 B1
24VDC 20051 A1 Sensor Input 2 IN A1 A1
8mA max. Sensor Input 3 B2 B2
20052 B2 IN
20053 A2 Sensor Input 4 IN A2 A2
20054 B3 Sensor Input 5 B3 B3
IN
20055 A3 Sensor Input 6 IN A3 A3
Sensor Input 7 B4 B4
20056 B4 IN
Sensor Input 8 A4 A4
20057 A4 IN
B5 B5
B5
A5 A5
A5
B6 B6
B6
A6 A6
A6
B7 024VU B7 024VU

司
A7 024VU A7 024VU
B8

公
30050 B8 Hand Value 1-1- OUT B8
Hand Value 1-1+ A8 A8 RLY
OUT

限
A8
B9 B9
30051 B9 Hand Value 1-2- OUT

有
A9 A9 RLY
A9 Hand Value 1-2+ OUT

技
B10 B10
30052 B10 Hand Value 2-1- OUT
A10 A10 RLY

科
A10 Hand Value 2-1+ OUT
B11 B11
30053 B11 Hand Value 2-2- OUT

育 A11 A11 RLY

A11 Hand Value 2-2+ OUT

教
B12 B12
30054 B12 Hand Value 3-1- OUT
A12 A12 RLY

帮
A12 Hand Value 3-1+ OUT
B13 B13
30055 B13 Hand Value 3-2- OUT

控 A13 A13 RLY

Each Point A13 Hand Value 3-2+ OUT

工
B14 B14
24VDC 30056 B14 Hand Value 4-1- OUT
A14 A14 RLY

沙
500mA max. A14 Hand Value 4-1+ OUT
B15 B15

长
30057 B15 Hand Value 4-2- OUT
A15 A15 RLY
A15 Hand Value 4-2+ OUT
B16 024VU
B16 024VU
CN303 Internal A16 024VU
A16 024VU
-3 Power Supply B17 024VU
+24 V B17 024VU
024 V A17 024VU
-4 A17 024VU
(24V,1A) B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU * means internal relay
-1 +24VU B19 +24VU
Power Supply RLY means
B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. +24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-49
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-8: Specific Input (Handling)

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

司
a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE

限 公
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

teach mode selection.

技 有
signal is selected by priority even when the other selection signal is ON, enabling the

20020
科
INTERFERENCE 1 ENTRANCE PROHIBITED

育
If the manipulator attempts to enter the cube 12) area while this signal is ON, the

帮 教
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021

工 控INTERFERENCE 2 ENTRANCE PROHIBITED

If the manipulator attempts to enter the cube 22) area while this signal is ON, the

沙
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20026 长 TOOL SHOCK SENSOR
This is normally ON (NC) signal input. When it turns OFF, an DX100 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, DX100 displays user alarm in the
PLAY mode or displays user message in the teach mode.
20050 to SENSOR INPUT 1 - 8
20057 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.
2 See chapter 8.6 “Interference Area” at page 8-56.

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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-9: Specific Output (Handling)

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 DX100 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

公 司
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

限
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
技 有
This signal notifies the current mode setting. These signals are synchronized with the

selected mode turns ON.

育 科
mode select switch in the programming pendant. The signal corresponding to the

30020 IN CUBE 1

帮 教
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1).

30021
工 控
Use this signal to prevent interference with other manipulators and positioners.
IN CUBE 2

长 沙
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2).
Use this signal to prevent interference with other manipulators and positioners.
30022 WORK HOME POSITION (IN CUBE 32)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.
30050 to HAND VALVE 1-4
30057 These outputs are controlled by the HAND handling specific instructions.
Hand valves 1 to 4 correspond to HAND 1 to 4.
1 This signal is not output during operation.
2 The work home position cube and Cube 32 are same.

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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

13.12.3 General Application

Fig. 13-35: JZNC-YIU01-E (CN308 Connector) I/O Allocation and
Connection Diagram (For General Application)

DX100
Connector Terminal Converter
Robot I/O Unit JZNC-YIU01-E (Optional)
Model: TIFS553YS
+24VU
CN308 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20010 B1 External Start IN B1 B1
24VDC 20011 A1 IN A1 A1
8mA max. Call Master Job IN B2 B2
20012 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 IN B3 B3

20015 A3 Select Play Mode IN A3 A3

Select Teach Mode IN B4 B4
20016 B4
IN A4 A4
20017 A4
Interference1 Entrance
IN B5 B5
20020 B5 Prohibited
Interference2 Entrance A5 A5
20021 A5 Prohibited IN
B6 B6
20022 B6 Work Prohibited IN
A6 A6
20023 A6 IN
B7 024VU B7 024VU

30010 B8
A7 024VU
Running OUT
A7

公
B8司 024VU
B8

限
30011 A8 Servo is ON OUT A8 A8
B9 B9
30012 B9 Top of Master Job OUT
30013 A9 Alarm/Error Occurred
30014 B10 Battery Alarm
技 有 OUT
OUT
A9
B10
A9
B10

科
30015 A10 Remote Mode Selected OUT A10 A10
B11 B11

教育
30016 B11 Play Mode Selected OUT
A11 A11
30017 A11 Teach Mode Selected OUT
B12 B12
30020 B12 In Cube 1 OUT

帮
A12 A12
30021 A12 In Cube 2 OUT
B13

控
30022 B13 Work Home Position OUT B13
A13 A13
30023 A13 Intermediate Start OK
OUT

沙工
(continuousing Sequence)
Each Point B14 B14
B14
24VDC A14 A14
50mA max. A14

长
B15 B15
B15
A15 A15 A15

B16 024VU B16 024VU

CN303 Internal A16 024VU
A16 024VU
-3 Power Supply 024VU
+24 V B17 024VU B17
-4 024 V A17 024VU
(24V,1A) A17 024VU
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24 VE 024VU
A19 +24VU
-2 A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
024VU
when a external power supply is used.
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-52
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-36: JZNC-YIU01-E (CN309 Connector) I/O Allocation and

Connection Diagram (For General Application)

DX100
Robot I/O Unit JZNC-YIU01-E Connector Terminal Converter
(Optional)
+24VU Model: TIFS553YS
CN309 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20024 B1 Interference3 Entrance
IN
Prohibited B1 B1
24VDC 20025 A1
Interference4 Entrance
IN
Prohibited A1 A1
8mA max. IN
20026 B2 B2 B2
20027 A2 IN A2 A2
20030 B3 IN01 User Input IN B3 B3
20031 A3 IN02 IN A3 A3
20032 B4 IN03 IN B4 B4
20033 A4 IN04 IN A4 A4
20034 B5 IN05 IN B5 B5
20035 A5 IN06 IN A5 A5

20036 B6 IN07 IN B6 B6

20037 A6 IN08 IN A6 A6
B7 024VU B7 024VU

司
A7 024VU A7 024VU
30024 B8 In Cube 3 OUT B8 B8
30025 A8
30026 B9
In Cube 4
Work Instruction
OUT
OUT
A8
B9

限 公 A8
B9

有
A9 A9
30027 A9 OUT
B10 B10

技
30030 B10 OUT01 User Output OUT
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03
科
OUT B11 B11

教育
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12

30035 A12 OUT06 OUT A12 A12

Each Point
控 帮
30036 B13 OUT07
30037 A13 OUT08
OUT
OUT
B13
A13
B13
A13

沙工
B14 B14
24VDC B14
A14 A14
50mA max. A14
B15 B15
B15

CN303 Internal
长 A15
B16 024VU
A16 024VU
A15
B16
A16
A15
024VU
024VU
-3 Power Supply
+24 V B17 024VU B17 024VU
-4 024 V A17 024VU
(24V,1A) A17 024VU
B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-53
 工控帮助教小舒QQ:2823408167

13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-37: JZNC-YIU01-E (CN306 Connector) I/O Allocation and

Connection Diagram (General Application)

DX100
Connector Terminal Converter
Robot I/O Unit JZNC-YIU01-E (Optional)
Model: TIFS553YS
+24VU
CN306 Connector
Logical Connector Terminal
Name Signal
Each Point Number Number Number
20040 B1 IN09 User Input IN B1 B1
24VDC
A1 A1
8mA max. 20041 A1 IN10 IN
B2 B2
20042 B2 IN11 IN
20043 A2 A2 A2
IN12 IN
B3 B3
20044 B3 IN13 IN
A3 A3
20045 A3 IN14 IN
B4 B4
20046 B4 IN15 IN
A4 A4
20047 A4 IN16 IN
B5 B5
B5
A5 A5
A5
B6 B6
B6 A6 A6
A6
B7 024VU
B7 024VU
A7 024VU
A7 024VU
B8 B8
30040 B8 OUT09 User Output OUT

司
A8 A8
30041 A8 OUT10 OUT

公
B9 B9
30042 B9 OUT11 OUT
A9 A9

限
30043 A9 OUT12 OUT
B10 B10
30044 B10 OUT13

技有
OUT
A10 A10
30045 A10 OUT14 OUT
B11 B11
30046 B11 OUT15 OUT
A11

科
A11
30047 A11 OUT16 OUT
B12 B12

育
B12
A12 A12
A12

教
Each Point B13 B13
B13
24VDC A13 A13
50mA max.

控 帮 A13
B14
B14
A14
B14
A14

沙工
A14 B15
B15
B15
A15 A15
A15

长
B16 024VU
B16 024VU
CN303 Internal A16 024VU
A16 024VU
-3 Power Supply B17 024VU
+24 V B17 024VU
024 V A17 024VU
-4 (24V,1A) A17 024VU
B18 +24VU
B18 +24VU +24VU
A18
External A18 +24VU +24VU
-1 +24VU B19
Power Supply B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG 024VU
A20
A20 024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. +24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-54
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-38: JZNC-YIU01-E (CN307 Connector ) I/O Allocation and

Connection Diagram (For General Application)

DX100
Connector Terminal Converter
Robot I/O Unit JZNC-YIU01-E (Optional)
Model: TIFS553YS
+24VU
CN306 Connector
Logical Connector Terminal
Name Signal
Each Point Number Number Number
20040 B1 IN09 User Input IN B1 B1
24VDC
A1 A1
8mA max. 20041 A1 IN10 IN
B2 B2
20042 B2 IN11 IN
20043 A2 A2 A2
IN12 IN
B3 B3
20044 B3 IN13 IN
A3 A3
20045 A3 IN14 IN
B4 B4
20046 B4 IN15 IN
A4 A4
20047 A4 IN16 IN
B5 B5
B5
A5 A5
A5
B6 B6
B6 A6 A6
A6
B7 024VU
B7 024VU
A7 024VU
A7 024VU

司
B8 B8
30040 B8 OUT09 User Output OUT
A8 A8

公
30041 A8 OUT10 OUT
B9 B9
30042 B9 OUT11 OUT

限
A9 A9
30043 A9 OUT12 OUT

技有
B10 B10
30044 B10 OUT13 OUT
A10 A10
30045 A10 OUT14 OUT
B11 B11
30046 B11 OUT15

科
OUT
A11 A11
30047 A11 OUT16 OUT

育
B12 B12
B12
A12 A12

帮教
A12
Each Point B13 B13
B13
24VDC A13 A13
A13

工控
50mA max. B14 B14
B14
A14 A14
A14 B15
B15

长沙
B15
A15 A15
A15
B16 024VU
B16 024VU
CN303 Internal A16 024VU
A16 024VU
-3 Power Supply B17 024VU
+24 V B17 024VU
024 V A17 024VU
-4 (24V,1A) A17 024VU
B18 +24VU
B18 +24VU +24VU
A18
External A18 +24VU +24VU
-1 +24VU B19
Power Supply B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG 024VU
A20
A20 024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. +24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-55
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-10: Specific Input (General Application)

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

司
a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE

限 公
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

mode selection.
技 有
is selected by priority even when the other selection signal is ON, enabling the teach

20020
科
INTERFERENCE 1 ENTRANCE PROHIBITED

育
If the manipulator attempts to enter the cube 12) area while this signal is ON, the

帮 教
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021

工 控INTERFERENCE 2 ENTRANCE PROHIBITED

If the manipulator attempts to enter the cube 22) area while this signal is ON, the

沙
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20022 长 WORK PROHIBITED (Tool ON Prohibited)
Even if TOOLON instruction is executed, DX100 doesn’t output to external while this
signal is ON.
20024 INTERFERENCE 3 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 32) 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.
20025 INTERFERENCE 4 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 42) 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.
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 chapter 8.6 “Interference Area” at page 8-56.

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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-11: Specific Output (General Application)

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 DX100 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)*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

problems by using this signal as a warning signal.

公 司
if memory data is lost because of an expired battery. It is recommended to avoid these

30015 to
30017
REMOTE/PLAY/TEACH MODE SELECTED

有 限
This signal notifies the current mode setting. These signals are synchronized with the

selected mode turns ON.

科 技
mode select switch in the programming pendant. The signal corresponding to the

30020 IN CUBE 1

教 育
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
控
IN CUBE 2 帮
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2).

30022 沙 工
Use this signal to prevent interference with other manipulators and positioners.
WORK HOME POSITION (IN CUBE 32)2)
长 This signal turns ON when the current TCP lies inside the work home position area.
Use this signal to evaluate whether the robot 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 IN CUBE 3
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 3).
Use this signal to prevent interference with other manipulators and positioners.
30025 IN CUBE 4
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 4).
Use this signal to prevent interference with other manipulators and positioners.
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.
1 This signal is not output during operation.
2 The work home position cube and Cube 32 are same.

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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

13.12.4 Spot Welding

Fig. 13-39: JZNC-YIU01-E (CN308 Connector) I/O Allocation and
Connection Diagram (For Spot Welding)

DX100
Robot I/O Unit JZNC-YIU01-E Connector Terminal Converter
(Optional)
+24VU Model: TIFS553YS
CN308
Logical Connector Signal Terminal
Number Number Name
Number
Each Point 20010 B1 External Start IN B1 B1
24VDC 20011 A1 - IN A1 A1
8mA max. 20012 B2 Call Master Job IN B2 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 - IN B3 B3

20015 A3 Select Play Mode IN A3 A3

Select Teach Mode IN B4 B4
20016 B4
- A4 A4
20017 A4 IN
Interference1 Entrance
IN B5 B5
20020 B5 Prohibited
Interference2 Entrance A5 A5
20021 A5 Prohibited IN
B6 B6
20022 B6 Welding ON/OFF IN
A6 A6
20023 A6 Welding Pause IN
B7 024VU B7 024VU

公司
A7 024VU A7 024VU

Running OUT B8 B8
30010 B8
A8

限
30011 A8 Servo is ON OUT A8
B9 B9
30012 B9 Top of Master Job OUT
30013 A9
30014 B10 Battery Alarm
Alarm/Error Occurred OUT
OUT
技 有 A9
B10
A9
B10

科
A10 A10
30015 A10 Remote Mode Selected OUT
B11 B11

育
30016 B11 Play Mode Selected OUT
A11 A11
30017 A11 Teach Mode Selected OUT

帮教
B12 B12
30020 B12 In Cube 1 OUT
A12 A12
30021 A12 In Cube 2 OUT
B13 B13

工控
30022 B13 Work Home Position OUT
Intermediate Start OK A13 A13
Each Point 30023 A13 (continuousing Sequence) OUT
B14 B14
24VDC B14

长沙
A14 A14
50mA max. A14
B15 B15
B15
A15 A15
A15
B16 024VU
B16 024VU
CN303 Internal A16 024VU
A16 024VU
-3 Power Supply B17 024VU
+24 V B17 024VU
024 V A17 024VU
-4 A17 024VU
(24V,1A) +24VU
B18
B18 +24VU
A18 +24VU
External A18 +24VU
-1 +24VU B19 +24VU
Power Supply B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
024VU
when a external power supply is used.
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-58
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-40: JZNC-YIU01-E (CN309 Connector) I/O Allocation and

Connection Diagram (For Spot Welding)

DX100
I/O JZNC-YIU01-E Connector Terminal Converter
(Optional)
+24VU Model:TIFS553YS
CN309 Connector
Logical Connector Signal Terminal
Number Number Number
Each Point 20024 B1 Interference3 Entrance IN B1 B1
Prohibited
24VDC Interference4 Entrance
20025 A1 Prohibited IN A1 A1
8mA max.
20026 B2 IN B2 B2
20027 A2 IN A2 A2
20030 B3 IN1 USER INPUT IN B3 B3

20031 A3 IN2 IN A3 A3
IN3 IN B4 B4
20032 B4
IN A4 A4
20033 A4 IN4
IN5 IN B5 B5
20034 B5
A5 A5
20035 A5 IN6 IN
B6 B6
20036 B6 IN7 IN
A6 A6
20037 A6 IN8 IN
B7 024VU B7 024VU

司
A7 024VU A7 024VU

In Cube 3 B8 B8

公
30024 B8 OUT
30025 A8 In Cube 4 OUT A8 A8

限
B9 B9
30026 B9 OUT

有
A9 A9
30027 A9 OUT
B10 B10

技
30030 B10 OUT01 User Output OUT
30031 A10 OUT02 OUT A10 A10

30032 B11 OUT03

科
OUT B11 B11

教育
A11 A11
30033 A11 OUT04 OUT
B12 B12
30034 B12 OUT05 OUT
A12 A12

帮
30035 A12 OUT06 OUT
B13 B13
30036 B13 OUT07 OUT

控 A13 A13
30037 A13 OUT08 OUT
Each Point

沙工
B14 B14
24VDC B14
A14 A14
50mA max. A14
B15 B15

长
B15
A15 A15 A15

B16 024VU B16 024VU

CN303 Internal A16 024VU
A16 024VU
-3 Power Supply B17 024VU
+24 V B17 024VU
024 V A17 024VU
-4 (24V,1A) A17 024VU
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24 VE B19 +24VU
A19 +24VU
024 VE -2 024VU A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-59
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-41: JZNC-YIU01-E (CN306 Connector) I/O Allocation and

Connection Diagram (For Spot Welding)

DX100
Robot I/O Unit JZNC-YIU01-E Connector Terminal Converter
(Optional)
+24VU Model: TIFS553YS
CN306 Connector
Logical Connector Signal Terminal
Number Number Name Number

Each Point 20040 B1 IN17 IN B1 B1

24VDC 20041 A1 IN18 IN A1 A1

8mA max. IN19 IN B2 B2

20042 B2
20043 A2 IN A2 A2
IN20
B3 B3
20044 B3 IN21 IN
IN22 A3 A3
20045 A3 IN
B4 B4
20046 B4 IN23 IN
A4 A4
20047 A4 IN24 IN
B5 B5
B5
A5 A5
A5
B6 B6
B6
A6 A6
A6
024VU B7 024VU
B7
A7 024VU

公司
A7 024VU
B8 B8
30040 B8 OUT17 OUT
A8 A8
30041 A8 OUT18 OUT

限
B9 B9
30042 B9 OUT19 OUT
A9 A9

有
30043 A9 OUT20 OUT
B10 B10

技
30044 B10 OUT21 OUT
A10 A10
30045 A10 OUT22 OUT

科
B11 B11
30046 B11 OUT23 OUT

育
A11 A11
30047 A11 OUT24 OUT
B12 B12

帮教
B12
A12 A12
A12
B13 B13
B13

工控
A13 A13
Each Point A13
B14 B14
24VDC B14
A14 A14

长沙
50mA max. A14
B15
B15
B15
A15 A15
A15
B16 024VU
B16 024VU
CN303 Internal A16 024VU
A16 024VU
-3 Power Supply B17 024VU
+24 V B17 024VU
A17 024VU
-4 024 V A17 024VU
(24V,1A) B18 +24VU
B18 +24VU +24VU
A18
External A18 +24VU
-1 +24VU B19 +24VU
Power Supply
B19 +24VU A19 +24VU
+24 VE
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG 024VU
A20
A20 024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
024VU
when a external power supply is used.
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

13-60
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Fig. 13-42: JZNC-YIU01-E (CN307 Connector) I/O Allocation and

Connection Diagram (For Spot Welding)

DX100
Robot I/O Unit JZNC-YIU01-E Connector Terminal Converter
(Optional)
+24VU
Model: TIFS553YS
CN307
Logical Connector Signal
Number Number Name Terminal
Number
Each Point 20050 B1 Timer Cooling Water
IN B1 B1
Error (IN09)
24VDC Gun Cooling Water
A1
20051 A1 Error (IN10) IN A1
8mA max.
20052 B2 Transthermo Error (IN11) IN B2 B2
20053 A2 Low Air Pressure (IN12) IN A2 A2
20054 B3 IN13 IN B3 B3

20055 A3 IN14 IN A3 A3
IN15 IN B4 B4
20056 B4
IN16 IN A4 A4
20057 A4
B5 B5
B5
A5 A5
A5
B6 B6
B6
A6 A6
A6
B7 024VU B7 024VU

司
A7 024VU A7 024VU
B8

公
30050 B8 OUT B8
Weld ON/OFF (OUT09)*** OUT A8 A8 RLY
A8
30051 B9 OUT B9
限 B9

技有
A9 A9
A9 Weld Error Reset (OUT10)** OUT RLY
B10 B10
30052 B10 OUT
A10 A10 RLY

科
A10 Weld Condition 1 (OUT11)** OUT
OUT B11 B11
30053 B11

育 A11 A11 RLY

A11 Weld Condition 2 (OUT12)** OUT

帮教
B12 B12
30054 B12 OUT
A12 A12 RLY
A12 Weld Condition 3 (OUT13)** OUT
B13 B13
30055 B13 OUT

工控
Each Point A13
A13 RLY
24VDC A13 Weld Condition 4 (OUT14)** OUT
B14 B14
500mA max. 30056 B14 OUT
A14 A14

长沙
RLY
A14 Weld Condition 5 (OUT15)** OUT
B15 B15
30057 B15 OUT
A15 Tip Change Request (OUT16)** OUT A15 A15 RLY
B16 024VU B16 024VU
CN303 A16 024VU
Internal A16 024VU
-3 Power Supply B17 024VU
+24 V B17 024VU
024 V A17 024VU
-4 A17 024VU
(24V,1A)
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU * means internal relay
-1 +24VU B19 +24VU means
Power Supply B19 +24VU RLY
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. +24VU
** This assignment can be changed at the I/O assignment display. +24VU
Refer to System Input List YIU01 and System Output List YIU01 for detail.
+24VU
*** This assignment can be changed at the PSEDU input display.
+24VU
Refer to System Input List YIU01 and System Output List YIU01 for detail.
+24VU
+24VU
+24VU
+24VU

13-61
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-12: Specific Input (Spot Welding) (Sheet 1 of 2)

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

司
a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE

限 公
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

teach mode selection.

技 有
signal is selected by priority even when the other selection signal is ON, enabling the

20020
科
INTERFERENCE 1 ENTRANCE PROHIBITED

育
If the manipulator attempts to enter the cube 12) area while this signal is ON, the

帮 教
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20021

工 控INTERFERENCE 2 ENTRANCE PROHIBITED

If the manipulator attempts to enter the cube 22) area while this signal is ON, the

沙
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20022 长 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 INTERFERENCE 3 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 32) 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.
20025 INTERFERENCE 4 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 42) 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.
20050 TIMER COOLING WATER ERROR
3) 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
3)
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.

13-62
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-12: Specific Input (Spot Welding) (Sheet 2 of 2)

Logical Input Name / Function
Number
20052 TRANSTHERMO ERROR
3)
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
3)
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 Source’s 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 Source’s error. Alarm

4)
GUN FULL OPEN DETECTION 公 司
occurs and the manipulator stops if this signal is input during welding.

4) GUN SHORT OPEN DETECTION 有 限

This signal indicates that the stroke of the double stroke gun is full open.

科 技
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

教 育
This signal indicates that a gun is in pressing status.
4)
帮
TIP REPLACE COMPLETION

控
When this signal is input after tip replacement, the TIP REPLACE REQUEST signal

沙 工
turns OFF, and the stored number of welding is cleared.
1 A master job is a job (program) which can be called by CALL MASTER JOB.

长
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 chapter 8.6 “Interference Area” at page 8-56.
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 7 6 5 4 3 2 1 0
Signal 8202x 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)

13-63
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-13: Specific Output (Spot Welding) (Sheet 1 of 2)

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 DX100 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

公 司
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

限
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
技 有
This signal notifies the current mode setting. These signals are synchronized with the

育
selected mode turns ON.
科
mode select switch in the programming pendant. The signal corresponding to the

30020 IN CUBE 1

帮 教
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1).

30021
工 控Use this signal to prevent interference with other manipulators and positioners.
IN CUBE 2

长 沙 This signal turns ON when the current TCP lies inside a pre-defined space (Cube 2).
Use this signal to prevent interference with other manipulators and positioners.
30022 WORK HOME POSITION (IN CUBE 32)2)
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
3)
This signal is output when the stored number of welding reaches the number of
welding set for the tip replacement.
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 IN CUBE 3
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 3).
Use this signal to prevent interference with other manipulators and positioners.
30025 IN CUBE 4
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 4).
Use this signal to prevent interference with other manipulators and positioners.
30050 WELD ON/OFF
3) Outputs a signal input from the interlock panel, etc.considering the robot status.

13-64
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

Table 13-13: Specific Output (Spot Welding) (Sheet 2 of 2)

Logical Output Name / Function
Number
30051 WELD ERROR RESET
4)
This signal commands the reset error status of the Power Source. This is operated
with the programing pendant operation.
30052 to WELD CONDITION (Level signals)
30056 1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8)
4)
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.
1 This signal is not output during operation. 公 司
2 The work home position cube and Cube 32 are same.
有 限
3 This signal can be select “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is selected, this

科 技
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.

教 育
控 帮
Pseudo Input
Signal 8202x
沙 工 7 6 5 4 3 2 1 0
0 0 0 1 1 1 1 1

长 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)

13-65
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13 Description of Units and Circuit Boards

DX100 13.12 Universal I/O Signal Assignment

13.12.5 JANCD-YEW01-E Circuit Board (Standard)

13.12.5.1 Arc Welding

JANCD-YEW01-E Circuit Board: Analog outputs ×2 ports, Analog inputs ×
2 ports + Status signal I/O of a Welder.

DX100
MR Connector MS Connector

Logical Connector Signal

Number Pin No.
Name

CN322-1 1
Each point
24 VDC 22550 CN322-2 +GASOF Gas Shortage IN 2
5mA MAX CN322-3 -GASOF Gas Shortage IN 3 S
22551 CN322-4 +WIRCUT Wire Shortage IN 4
CN322-5 -WIRCUT Wire Shortage IN 5 T
22553 CN322-6 +ARCACT (Arc Generation Confirm IN 6
CN322-7 -ARCACT Arc Generation Confirm IN 7 P
CN322-8 CH2 Current Input IN 8
A/D +5V CN322-9 9

A/D +5V
CN322-10
CN322-11 CH1 Voltage Input IN
10

公
11
司
CN322-12 CH1-G IN
限12

技有
DC24V 22552 CN322-13 +ARCOFF Arc Shortage IN 13
5mA MAX CN322-14 -ARCOFF Arc Shortage IN 14 R
DC24V
0.5A MAX
32551 CN322-15 ARCON Arc ON A

育
CN322-16 ARCON Arc ON B科 OUT
OUT
15
16
K
L

教
Power
32552 CN322-17 WIRINCH Wire Inching A OUT 17 F
Source

控 帮
CN322-18 WIRINCH Wire Inching B OUT
32553 CN322-19 WIRINCH (Wire Retract) A OUT
18
19
G
H

沙工
CN322-20 WIRINCH (Wire Retract) B OUT 20 J
32567 CN322-21 GAS Checking OUT A OUT 21

长 CN322-22 GAS Checking OUT B

CN322-23
OUT 22
23
CN322-24 24
CN322-25 25
22554 CN322-26 STICK Wire Sticking IN 26 M
Detector
CN322-27 *STICK Wire Sticking IN 27 N
CN322-28 CH2 -G IN 28
CN322-29 +24VU 29
CN322-30 024VU 30 E
CN322-31 CH1 Voltage Command OUT 31 A
D/A –14V
CN322-32 CH1-G OUT 32 B

SW2 CN322-33 CH2 Current Command OUT 33 C

D/A –14V
1 3 CN322-34 CH2 -G OUT 34 D

17BYTE 32BYTE
CN321-1 +24VU
DC24V 32555 CN321-2 Search Command A (Optional) OUT
0.5A MAX
CN321-4 Search Command B (Optional OUT
CN321-5 024VU

MRP-34M01 Insulator
MRP-M112 Contactor MS3106 A, 20-29P
WAGO Connector(231-105/026-A0) RP-34 Casing MS3106 A, 20-29S

13-66
 工控帮助教小舒QQ:2823408167

DX100 Index

absolute data ......................................................................................... 8-4

absolute encoder ................................................................................... 8-3
ACCELARATION SPEED ................................................................... 11-21
ACCELARATION TIME ...................................................................... 11-12
Acceleration/Deceleration ..................................................................... 12-2
Addition of Base and Station Axes ......................................................... 11-3
Addition of I/O Modules ........................................................................ 11-1
Alarm Display ...................................................................................... 12-3
ALARM HISTORY.................................................................................. 7-3
All Limit Release Function .................................................................... 8-91
Allocating an Operation ...................................................................... 8-102
Allocation of I/O Control Instructions .................................................... 8-111
Allocation Window.............................................................................. 8-102
Alternate Output Allocation ................................................................. 8-107
alternate output allocation ................................................................... 8-101
Ambient Temperature ........................................................................... 12-2
Analog Incremental Output Allocation .................................................. 8-110
analog incremental output allocation .................................................... 8-101
ANALOG MONITOR .............................................................................. 7-3
analog output allocation ............................................................ 8-101, 8-109
Application .......................................................................................... 12-3

公 司
ARC SHORTAGE (MONITOR)............................................................ 13-45
ARM CONTROL .................................................................................... 7-3

限
ARM control ........................................................................................ 8-38
Automatic Measurement of the Tool Load and the Center of Gravity ......... 8-32
有
AXES CONFIG window ........................................................................ 11-9

科 技
Axis Interference Area .......................................................................... 8-64
Axis keys .............................................................................................. 6-2

教 育
B
控 帮
沙 工 BALL-SCREW PITCH .............................................................. 11-11, 11-19
base coordinate ................................................................................... 8-56
长 B-Axis ................................................................................................... 6-2

Cable Junctions ..................................................................................... 4-2

Cautions for Connection of Dual Input Signals ........................................ 13-2
Changing the Absolute Data ................................................................... 8-8
Changing the Output Status ................................................................ 8-114
Changing the Parameter Setting.......................................................... 8-116
Checking the TCP ................................................................................ 8-31
circuit board racks ................................................................................ 13-8
Clearing Absolute Data ........................................................................... 8-8
Clearing Calibration Data ...................................................................... 8-29
Clearing the Interference Area Data ....................................................... 8-72
Clearing the User Coordinates .............................................................. 8-87
Collision proof Frames.......................................................................... 12-3
COMMAND POSITION .......................................................................... 7-3
Condition Number ................................................................................ 8-75
Connecting the Manipulator Cable ......................................................... 4-11
Connecting the Primary Power Supply ..................................................... 4-6
Connecting the Programming Pendant ................................................... 4-12
Connection ............................................................................................ 4-1

Index-1
 工控帮助教小舒QQ:2823408167

DX100 Index

Construction........................................................................................ 12-2
Contents Confirmation ........................................................................... 2-1
Control Circuit Board (JANCD-YCP01-E) ............................................... 13-9
control circuit boards ............................................................................ 13-8
control group ....................................................................................... 11-6
Converter.......................................................................................... 13-35
Cooling System ................................................................................... 12-2
Coordinate System .............................................................................. 12-3
CPU Unit Configuration ........................................................................ 13-8
CREATE NEW JOB ............................................................................... 7-2
cube ................................................................................................... 8-57
Cube Interference ................................................................................ 8-91
cube number ....................................................................................... 8-58
Cubic Interference Area ....................................................................... 8-56
CURRENT POSITION ........................................................................... 7-3

DATE/TIME........................................................................................... 7-4
Definition of the User Coordinates ......................................................... 8-83
DELETE ............................................................................................... 7-3

公 司
detection level (level range: 1 to 500) ............................................... 8-76
Detection Mode ................................................................................... 8-75

有 限
DEVICE ................................................................................................ 7-3
Digital I/O ............................................................................................ 12-2
Dimensions ......................................................................................... 12-2

科 技
display allocation ..................................................................... 8-100, 8-105
Door Interlock...................................................................................... 12-3

教 育
Drive Unit ............................................................................................ 12-2
DROP AMOUNT ................................................................................... 7-3

控 帮
沙 工E

长 E-Axis................................................................................................... 6-2
Editing Mode ......................................................................................... 7-1
emergency stop ..................................................................................... 5-5
Enable Switch ............................................................................... 5-4, 12-3
Essential Measures ............................................................................. 12-3
Executing the Display Allocation ......................................................... 8-112
Executing the I/O Control Allocation .................................................... 8-112
Executing the Instruction/Output Control Allocation ............................... 8-112
Executing the Job Call Allocation ........................................................ 8-112
Execution of Allocation ....................................................................... 8-112
Expanded Instruction Set ..................................................................... 8-93
External Emergency Stop ............................................... 13-15, 13-26, 13-33
External Enable Switch ............................................................ 13-32, 13-33
External Hold ................................................................ 13-15, 13-31, 13-33
External Servo ON ......................................................... 13-15, 13-30, 13-33
External Start .................................................................................... 13-15
eyebolt ................................................................................................. 1-6

FD/CF .................................................................................................. 7-3

File Initialization ................................................................................. 8-119

Index-2
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DX100 Index

Full-speed Test ........................................................................ 13-29, 13-33

Function List ........................................................................................ 12-3
Function Select .................................................................................... 8-75

GAS SHORTAGE (MONITOR)............................................................ 13-45

Grounding .................................................................................... 1-5, 12-2
Group (4-bit/8-bit) Output Allocation ..................................................... 8-109
group output allocation (4-bit/8-bit) ...................................................... 8-101
GRP CONBINATION.............................................................................. 7-4
GUN COOLING WATER ERROR........................................................ 13-62
GUN FULL OPEN DETECTION .......................................................... 13-63
GUN PRESSURE DETECTION .......................................................... 13-63
GUN SHORT OPEN DETECTION ....................................................... 13-63

公 司
HAND VALVE.................................................................................... 13-51
Handling Procedure ............................................................................... 3-1

限
HOME POSITION .................................................................................. 7-3
Home Position ....................................................................................... 8-4
有
Home Position Calibration ...................................................................... 8-2
技
How to Calculate Tool Load Information ................................................. 8-43
科
教 育
I
控 帮
沙 工 I/O Diagnosis ....................................................................................... 12-3
I/O Instructions .................................................................................... 12-4

长 I/O modules ......................................................................................... 11-1

I/O MSG HISTORY ................................................................................ 7-3
I/O Unit (JZNC-YIU01-E) .................................................................... 13-13
IN/OUT ................................................................................................. 7-2
Inching Operation ................................................................................ 12-3
INERTIA RATIO ...................................................................... 11-12, 11-21
Initial Diagnosis ..................................................................................... 5-2
Initializing Data File ............................................................................ 8-120
Initializing I/O Data ............................................................................. 8-122
Initializing Job File.............................................................................. 8-119
Initializing Parameter File.................................................................... 8-121
Initializing System Data ...................................................................... 8-124
Installation and Wiring Safety .................................................................. 1-5
Instruction Allocation ................................................................ 8-100, 8-103
Instruction of Shock Detection Function ................................................. 8-77
Instruction Set ..................................................................................... 8-93
Interface.............................................................................................. 12-3
INTERFERENCE ................................................................................... 7-3
Interference area ................................................................................. 8-56

JANCD-YEW01-E Circuit Board (Standard) .......................................... 13-66

Index-3
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DX100 Index

JOB...................................................................................................... 7-2
Job Call Allocation ................................................................... 8-100, 8-105
JOB CAPACITY .................................................................................... 7-2

KEY ALLOCATION ................................................................................ 7-4

Key Allocation (EACH) ....................................................................... 8-100
Key Allocation (SIM) .......................................................................... 8-100

Language ........................................................................................... 12-4

L-axis ................................................................................................... 6-2
Leakage Breaker Installation .................................................................. 4-4
Learning Function ................................................................................ 8-94
lifting the DX100 .................................................................................... 1-6
LIMIT RELEASE.................................................................................... 7-3

公 司
limit switch .......................................................................................... 8-90
LOAD ................................................................................................... 7-3

限
LOW AIR PRESSURE ............................................................. 13-50, 13-63
L-U Interference .................................................................................. 8-91
有
科 技
M
教 育
控 帮 ......................................................................................
Machine Lock
Management Mode ................................................................................ 7-1
12-3

沙 工 MANIPULATOR TYPE ........................................................................... 7-3

Manufacturer allocation ...................................................................... 8-100

长 MASTER JOB ....................................................................................... 7-2

Max. Disturbance Force ....................................................................... 8-76
MAX. RPM .............................................................................. 11-12, 11-21
Measurement of the Tool Load and the Center of Gravity ........................ 8-33
Mechanical Limit .................................................................................. 8-91
MECHANICAL SPEC window ............................... 11-10, 11-11, 11-19, 11-20
Memory Capacity................................................................................. 12-2
Modification of System Configuration ..................................................... 11-1
Modification of Teaching Points ............................................................ 12-3
momentary output allocation ..................................................... 8-101, 8-108
MONITORING TIME .............................................................................. 7-3
MOTION RANGE ...................................... 11-10, 11-11, 11-18, 11-19, 11-20
MOTOR SPEC window ...................................................................... 11-12
Moving the MOTOMAN ........................................................................ 1-13

Noise Filter ........................................................................................... 4-3

Number of Tool Files............................................................................ 8-18
Numeric Key Customize Function ....................................................... 8-100

Index-4
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DX100 Index

OPERATE COND .................................................................................. 7-4

Operating .......................................................................................... 13-15
Operation Instructions .......................................................................... 12-4
Operation Mode ..................................................................................... 7-1
Operation Time Display ........................................................................ 12-3
Order Number ....................................................................................... 2-2
ORG ................................................................................................... 8-83
Output of the Work Home Position Signal ............................................... 8-55
Overrun .............................................................................................. 8-88
OVERRUN&S-SENSOR ......................................................................... 7-3

PARAMETER ........................................................................................ 7-3

Path Confirmation ................................................................................ 12-3
PINION DIAMETER ................................................................. 11-11, 11-19
Positioning System .............................................................................. 12-2
POWER ON/OFF POS ........................................................................... 7-3

公 司
Power Supply ............................................................................... 4-3, 12-2
Power Supply Contactor Unit ................................................................ 13-3
Primary Power Supply Breaker Installation ............................................... 4-5

有 限
Program Control Instructions ................................................................. 12-4
Programming ....................................................................................... 12-4

科 技
Programming Pendant.......................................................................... 12-4
pulse output allocation .............................................................. 8-101, 8-108

育
PWM Amplifier ................................................................................... 13-35

教
控
R
帮
工
沙 ...................................................................................................
长
R-Axis 6-2
REDUCTION RATIO ............................................ 11-11, 11-18, 11-19, 11-20
Registering/Changing the Work Home Position ....................................... 8-54
Relative Humidity ................................................................................. 12-2
RES. STARG (CNCT) ............................................................................ 7-4
RES. START (JOB)................................................................................ 7-2
RES. STATUS ....................................................................................... 7-2
RESERVE JOB NAME ........................................................................... 7-4
Resetting the Shock Detected ............................................................... 8-82
Returning to the Work Home Position .................................................... 8-55
ROBOT ................................................................................................. 7-3
robot coordinate ................................................................................... 8-56
robot I/F board ..................................................................................... 13-8
Robot I/F Board (JANCD-YIF01-1E) ...................................................... 13-9
robot I/O unit (JZNC-YIU01-E) ............................................................ 13-14
Robot installation angle ........................................................................ 8-39
Robot Motion Control ........................................................................... 12-4
robot programming language (INFORM III) ............................................. 8-93
Robot Setup Condition ......................................................................... 8-38
Running Speed Limit ............................................................................ 12-3

Index-5
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DX100 Index

safeguarding ......................................................................................... 5-3

Safety ................................................................................................... 1-3
Safety Plug ............................................................................. 13-27, 13-33
SAVE ................................................................................................... 7-3
S-Axis................................................................................................... 6-2
SECOND HOME POS ........................................................................... 7-3
Security Mode ....................................................................................... 7-1
SELECT JOB ........................................................................................ 7-2
Selecting the User Coordinate File ........................................................ 8-84
Self-Diagnosis ..................................................................................... 12-3
SENSOR INPUT ............................................................................... 13-50
SERVO MONITOR ................................................................................ 7-3
SERVO ON ................................................................................. 5-3, 13-15
SERVO ON READY............................................................................... 5-3
Servo-ON Enable Input ...................................................................... 13-19
SERVOPACK............................................................................ 12-5, 13-35
SET SPEED.......................................................................................... 7-4
Setting Contents .................................................................................. 8-93
Setting the Controller Clock .................................................................. 8-97
Setting the Play Speed ......................................................................... 8-98
Setting the Tool Load Information.......................................................... 8-22

公 司
Setting Work Home Position ................................................................. 8-52
SETUP ................................................................................................. 7-4

限
SHCKRST instruction........................................................................... 8-77
SHCKSET........................................................................................... 8-74
有
SHCKSET instruction ........................................................................... 8-77

科 技
S-head payload ................................................................................... 8-39
Shock Detection Function ..................................................................... 8-74

教 育
Shock Detection Function Setting.......................................................... 8-74
Shock Sensor...................................................................................... 13-5
Short-cut Function ............................................................................... 12-3

控 帮
Slow Speed Mode Selection ..................................................... 13-30, 13-33
Soft Limit on Each Axis ........................................................................ 8-91

沙 工 Soft Limit Release Function .................................................................. 8-90

software limit ....................................................................................... 8-90

长 Special Training..................................................................................... 1-2

Specification List ................................................................................. 12-2
Speed Adjustment ............................................................................... 12-3
Speed Setting ..................................................................................... 12-4
Standard Instruction Set ....................................................................... 8-93
Station Axis Setting............................................................................ 11-13
STICK DETECTION........................................................................... 13-63
Subset Instruction Set .......................................................................... 8-93
Switch of the tool file ............................................................................ 8-51
SYSTEM INFO ...................................................................................... 7-3

T.C.P. Calibration ................................................................................ 12-3

T-Axis ................................................................................................... 6-2
TEACHING COND................................................................................. 7-4
Teaching the User Coordinates ............................................................. 8-85
three-phase noise filter ........................................................................... 4-3
Three-Phase Power Supply .................................................................... 4-3
TIMER COOLING WATER ERROR .................................................... 13-62
Timer Setting....................................................................................... 12-3
TIP REPLACE COMPLETION ............................................................ 13-63
TIP REPLACE REQUEST .................................................................. 13-64

Index-6
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DX100 Index

TOOL ................................................................................................... 7-3

Tool Calibration ................................................................................... 8-23
Tool Data Setting ................................................................................. 8-18
Tool File .............................................................................................. 8-18
Tool Load Information .......................................................................... 8-43
Tool Load Information Registering ......................................................... 8-49
Tool Load Information Setting ....................................................... 8-43, 8-77
Tool Shock Sensor ............................................................................... 13-5
Tool Shock Sensor Releasing ............................................................... 8-88
Transferring the MOTOMAN ................................................................. 1-13
TRANSTHERMO ERROR .................................................................. 13-63
Turning OFF the Main Power .................................................................. 5-5
Turning OFF the Servo Power ................................................................. 5-5
Turning ON the Main Power Supply ......................................................... 5-1
Turning ON the Servo Power .................................................................. 5-3

U-arm payload ..................................................................................... 8-40

U-Axis ................................................................................................... 6-2
User Alarm Display .............................................................................. 12-3

公 司
USER COORDINATE ............................................................................ 7-3
User Coordinate .......................................................................... 8-56, 8-83

有 限
User Coordinate Files ........................................................................... 8-83
User Coordinate Setting ....................................................................... 8-83
user ID ........................................................................................... 7-4, 7-6

科 技
V 教 育
控 帮
VARIABLE ............................................................................................ 7-2

沙 工 Variable .............................................................................................. 12-4

Variable Type ...................................................................................... 12-4

长 VERIFY ................................................................................................ 7-3

VERSION.............................................................................................. 7-3

WEAVING PROHIBITED .................................................................... 13-44

WELD COMPLETION ........................................................................ 13-63
WELD CONDITION............................................................................ 13-65
WELD ERROR RESET ...................................................................... 13-65
WELD ON/OFF.................................................................................. 13-64
WELDING COMMAND ....................................................................... 13-65
WELDING ERROR ............................................................................ 13-63
WELDING ON/OFF (from sequencer) .................................................. 13-62
WELDING PAUSE (from sequencer) ................................................... 13-62
WIRE SHORTAGE (MONITOR) .......................................................... 13-45
WIRE STICKING (MONITOR) ............................................................. 13-45
WORK COMMAND ............................................................................ 13-57
WORK HOME POS................................................................................ 7-3
Work Home Position ............................................................................ 8-52
work home position cube length of its sides ............................................ 8-54
WORK PROHIBITED (arc generation prohibited) .................................. 13-44
WORK RESPONSE (pseudo arc ON response) .................................... 13-44

Index-7
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DX100 Index

XX...................................................................................................... 8-83
XY...................................................................................................... 8-83

公 司
有 限
科 技
教 育
控 帮
沙 工
长

Index-8
 工控帮助教小舒QQ:2823408167

DX100
INSTRUCTIONS

HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone +81-93-645-7745 Fax +81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 10, Box 4004, SE-390 04 Kalmar, Sweden
Phone +46-480-417800 Fax +46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA ELECTRIC KOREA CORPORATION
1F, Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone +82-53-382-7844 Fax +82-53-382-7845
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.

司
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.

限 公
Unit 47-1 and 2. Jalan PJU 5/9, Dataran Sunway, Kota Damansara, 47810, Petailng Jaya Selangor, Malaysia
Phone +60-3614-08919 Fax +60-3614-08929
YASKAWA ELECTRIC (THAILAND) CO., LTD.
技 有
Phone +66-2-693-2200
育
Fax +66-2-693-4200 科
252/246, 4th Floor. Muang Thai-Phatra office Tower II Rechadapisek Road, Huaykwang Bangkok 10320, Thailand

教
SHOUGANG MOTOMAN ROBOT CO., LTD.
No.7,Yongchang-North Road, Beijing Economic and Technological and Development Area, Beijing 100076, China
Phone +86-10-6788-0541

控
MOTOMAN MOTHERSON ROBOTICS LTD.
帮
Fax +86-10-6788-0542

沙 工
Plot Number 195-196, First Floor, Imt Manesar -Sector 4, Gurgaon (Haryana),Pin-122050, India
Phone +91-124-475-8500 Fax +91-124-475-8542

YASKAWA ELECTRIC CORPORATION

YASKAWA

Specifications are subject to change without notice MANUAL NO. RE-CTO-A215 1

for ongoing product modifications and improvements. C Printed in Japan April 2009 08-12