Operator'S Manual: Dx200 Options

DX200 OPTIONS
OPERATOR’S MANUAL
FOR WELDCOM FUNCTION:
ARC WELDING/DIGITAL I/F FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL (Volume 1) (Volume2)
The DX200 operator’s manuals above correspond to specific usage. Be sure to use the appropriate manual.
The DX200 maintenance manual above consists of "Volume1" and "Volume2".
YASKAWA ELECTRIC CORPORATION
MANUAL NO.
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DX200
MANDATORY
• This manual explains the various components of the DX200 system
and general operations. Read this manual carefully and be sure to
understand its contents before handling the DX200.
• General items related to safety are listed in the Chapter 1: Safety of
the DX200 Instructions. To ensure correct and safe operation,
carefully read the DX200 Instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.
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DX200
NOTES FOR SAFE OPERATION

Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Indicates a imminent hazardous
DANGER situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous
WARNING situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous situ-
CAUTION ation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equip-
ment. It may also be used to alert
against unsafe practices.
Always be sure to follow explicitly the

MANDATORY items listed under this heading.
PROHIBITED Must never be performed.
Even items described as “CAUTION” may result in a serious accident in

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

NOTE to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION”.
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DX200
WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop buttons on the front door of the
DX200 and programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
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
• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the DX200 power
– Moving the manipulator with the programming pendant
– Running the system in the check mode
– Performing automatic operations
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of the front door of
the DX200 and the programming pendant.
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DX200
CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the DX200
cabinet after use.
The programming pendant can be damaged if it is left in the
manipulator’s work area, on the floor, or near fixtures.
• Read and understand the Explanation of the Warning Labels in the
DX200 Instructions before operating the manipulator.
Definition of Terms Used Often in This Manual

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

DX200 Controller DX200
DX200 Programming Pendant Programming Pendant
Cable between the manipulator and the Manipulator Cable
controller
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DX200
Descriptions of the programming pendant keys, buttons, and displays are

shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters printed on
Pendant them are denoted with [ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on them
are not denoted with [ ] but depicted with a
small picture.
GO BACK
ex. page key PAGE

The cursor key is an exception, and a picture
is not shown.
Axis Keys “Axis Keys” and “Numeric Keys” are generic
Numeric 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 “+”
sign between them, ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}
Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • "
means that the cursor is moved to the object item and [SELECT] is
pressed.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
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Contents DX200
1 Functional Overview ....................................................................................................................... 1-1
1.1 Overview............................................................................................................................ 1-1
2 Setup .............................................................................................................................................. 2-1
2.1 Setup Flow......................................................................................................................... 2-1
2.2 DX200 System Software Upgrade..................................................................................... 2-1
2.2.1 Individual Data Backup......................................................................................... 2-1
2.2.2 System Upgrade................................................................................................... 2-1
2.3 Setting and Confirmation of Hardware Configuration ........................................................ 2-2
2.3.1 Removing Unnecessary EW Board ...................................................................... 2-2
2.3.2 Station Number when EW Board is Left ............................................................... 2-2
2.4 Connection of Welding Power Source and DX200 ............................................................ 2-3
2.4.1 Standard Connection

(When connecting one welding power source of digital interface to DX200) ....... 2-3
2.4.2 When Connecting to DX200 the Multiple Welding Power Sources

of Digital Interfaces and also Other Devices
with Data Transmission Function using Ethernet Function .................................. 2-4
2.5 System Configuration ........................................................................................................ 2-5
2.5.1 I/O Module Setting Check after Changing EW Board Station Number Setting .... 2-6
2.5.2 Setting of Optional Function “Network Function”.................................................. 2-7
2.5.3 Setting of Optional Function “WELDCOM Function” ............................................ 2-8
2.5.4 Detailed Setting of Welding Power Source......................................................... 2-10
2.5.5 I/O Module Setting Check after Adding Virtual EW Module ............................... 2-12
2.5.6 Setting of Optional Function "MotoPlus Function"

(When Welder is FroniusTPSi) ........................................................................... 2-14
2.5.7 Loading of MotoPlus Application (When Welder is FroniusTPSi)....................... 2-15
2.5.8 Setting of Parameter (When Welder is FroniusTPSi) ......................................... 2-16
2.5.9 Optional Parameters for FroniusTPS.................................... 2-18
2.5.10 Optional Parameter for FroniusTPSi ................................... 2-18
3 Operation of Welding Condition File Edit Window .......................................................................... 3-1
3.1 Overview............................................................................................................................ 3-1
3.2 Display of Welding Condition File Edit Window ................................................................. 3-1
3.3 MOTOWELD Type: Operation of Top Window.................................................................. 3-2
3.4 MOTOWELD Type: Operation of Weld type Window ........................................................ 3-3
3.5 MOTOWELD Type: Operation of Customize Window ....................................................... 3-4
3.6 MOTOWELD Type: Operation of Maintenance Window ................................................... 3-6
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DX200 Contents
3.7 MOTOWELD Type: Operation of Welder Parameter Window ........................................... 3-7
3.8 FroniusTPS Type: Operation of Top Window .................................................................... 3-9
3.9 FroniusTPS Type: Operation of Program No. setting Window ........................................ 3-10
3.10 FroniusTPS Type: Operation of Param. setting Window ............................................... 3-11
3.11 FroniusTPSi Type: Operation of Top Window ............................................................... 3-12
3.12 FroniusTPSi Type: Operation of Select Synergic Window............................................. 3-13
3.13 FroniusTPSi Type: Operation of Weld Parameter Setting Window ............................... 3-13
4 Job Preparation for Welding............................................................................................................ 4-1
4.1 Job Preparation for Welding .............................................................................................. 4-1
5 Alarm and Error............................................................................................................................... 5-1
5.1 Alarm.................................................................................................................................. 5-1
5.2 Error ................................................................................................................................. 5-22
5.3 Message .......................................................................................................................... 5-22
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1 Functional Overview
1.1 Overview DX200
1 Functional Overview
1.1 Overview
The WELDCOM function serves as a digital interface that communicates
via Ethernet with an arc welding power source. The function provides high
data rate transmission between DX200 and the welding power source,
enables the welding power source parameter to be set from the
programming pendant, and monitors graphically welding current and
voltage during welding.
 The WELDCOM function can use either of the following four welding
power sources for connection.
MOTOWELD-EL350-AJ2E (manufactured by YASKAWA
ELECTRIC CORPORATION)
(AJ2E indicates that an Ethernet interface is incorporated.)
MOTOWELD-RP500 (manufactured by YASKAWA ELECTRIC
CORPORATION)
(System version: DN1.00.00(□)-00 or newer)
(In the case of digital communication mode)
MOTOWELD-RL350 (manufactured by YASKAWA ELECTRIC
CORPORATION)
(System version: D1.00.00(□)-00 or newer)
(In the case of digital communication mode)
TPS4000 CMT (manufactured by Fronius International GMBH)
(Only the model that incorporates the WeldCom interface)
TPSi (manufactured by Fronius International GMBH)
(Only the model that incorporates the WeldCom interface)
 Programming a job is available using general arc welding commands.

ARCSET ASF#( ),
ARCON ASF#( ),
ARCOF AEF#( )
 Welding conditions are set in a welding start condition file or a
welding end condition file specified in an arc welding command.
 The welding start condition file or welding end condition file has the
edit window that provides the setting window for a digital interface,
enabling users to check or edit parameters to be set in welding
power source.
 The parameter to be set in the edit window of the welding condition

file is saved in the dedicated condition file, "Welding type file" and
"Digital welder condition file", where the data can be loaded and
saved with the external memory function.
 TCP Speed Function

This is the function only for TPS4000 CMT (Not available for MOTOWELD
EL350-AJ2E), welding with bead leg length kept constant by changing the
feeding rate according to the welding speed.
(NOTE)
• When using TCP Speed, you must add the ARATION and ARATIOF com-
mands to the welding section for the welding speed to be output in analog.
Ex. ARATION BV 7.00 SPD 512
• To use TCP Speed, special software must be installed on TPS4000 CMT.
• TCP Speed cannot be used with the TPS of the US specification.
1-1
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2 Setup
DX200 2.1 Setup Flow
2 Setup
2.1 Setup Flow

Setup the DX200 with the following procedure.
DX100 system software upgrade

DX200
Setting and confirmation of hardware configuration
Connection of welding power source and DX200

DX100
System configuration
2.2 DX200 System Software Upgrade

The WELDCOM function is incorporated into the system software version,
DN1.00.00()-00 or later. If DX200 has a version of earlier than DN1.00
installed, upgrade the version by following the procedure below. DX200
with DN1.00.00()-00 or later does not need to be upgraded.
FroniusTPSi is available for the version DN1.90.01()-78 or later. Also, it
needs the MotoPlus function (optional function).
2.2.1 Individual Data Backup

Save all the individual data including job and condition files to initialize the
system after the upgrade. Also, save the system configuration file in the
maintenance mode.
2.2.2 System Upgrade

Upgrade the version to DN1.00.00()-00 or later. (For detailed
information of the system software upgrade procedure, see "DX200
Upgrade Procedure" Manual number: HW1481995).
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2 Setup
2.3 Setting and Confirmation of Hardware Configuration DX200
2.3 Setting and Confirmation of Hardware Configuration
2.3.1 Removing Unnecessary EW Board

The WELDCOM is connected to the welding power source using the
digital interface via Ethernet communication. This does not require the EW
board (YEW01, XEW02, etc.) for an analog interface, so remove the EW
board.
In multiple robot systems, if some welding power source uses

SUPPLE digital interface and some uses analog interface, leave as
-MENT
many EW boards as the necessary analog interfaces.
2.3.2 Station Number when EW Board is Left

A digital interface requires a virtual EW module, not an actual EW board.
The virtual EW module also has a station number. If leaving an EW board
unremoved for other welding power sources, set the actual EW board
station number so that it does not duplicate the virtual EW module station
number.
(Setting Example)
 Replacing welding power source of analog interface with that of

digital interface
 Remove the actual EW board, which will be unnecessary. (The station
number of the virtual EW module is set at the time of configuration.)
X100
DX200
YEW01
Welder1
Station Number: 01 Digital I/F

Power Source
YCP21
YCP01
Station Number: 01 Virtual
EW
 When connecting welding power source of digital interface as

Welder 1, and analog interface as Welder 2
 Because the virtual EW module station number is set to the smallest
number at the time of configuration, set the EW board station number
to the second or later number.
DX200
Welder1
YEW01
Digital I/F
Station Number: 02
Power Source
Welder2
YCP21 Analog I/F
Station Number: 01 Virtual
EW Power Source
2-2
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2 Setup
DX200 2.4 Connection of Welding Power Source and DX200
 When applying digital interface to welder and using EW board as

general analog output board
 Because the EW board is automatically set as welding application due
to the configuration restrictions, set the arc application to Arc + Arc.
Specifically, set as follows:
• Set the application setting of [Initialization] to "Arc + Arc", and set Arc
2 as not for use.
• In [OPTION FUNCTION - WELDCOM FUNC.], set Arc 1 to digital
interface.
2.4 Connection of Welding Power Source and DX200
2.4.1 Standard Connection

(When connecting one welding power source of digital interface to DX200)
• Connect a LAN cable to YCP01 for LAN (CN104).
CAUTION
• Use the LAN cable that comes with our arc welding robot package
MOTOPAC. (The system may not properly work with a LAN cable
other than this, and we are not responsible for any problems that
may occur.)
When preparing a LAN cable other than the cable above

SUPPLE
-MENT • You can use either cross cable or straight cable.
• Use a cable with the connector that has a metal cover for
noise suppression and with the cable shield grounded to
the metal cover.
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2 Setup
2.4 Connection of Welding Power Source and DX200 DX200
2.4.2 When Connecting to DX200 the Multiple Welding Power Sources

of Digital Interfaces and also Other Devices
with Data Transmission Function using Ethernet Function
As shown in the following figure, connect the LAN cable to YCP21 for LAN
(CN104) using a switching hub.
DX200
Welder1
Digital I/F
YCP21
Power Source
CN104
for LAN Welder2
Digital I/F
Power Source
Welder3
Digital I/F
Power Source
HUB
(You can use either cross cable or straight cable.)
CAUTION
• Use the industrial switching hub that we recommend. (The system
may not properly work with a hub other than this, and we are not
responsible for any problems that may occur.)
• Our recommended switching hub: Model EDS-205 (manufactured
by MOXA)
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2 Setup
DX200 2.5 System Configuration
2.5 System Configuration

The following figure illustrates the configuration procedure outline. The
following and later pages explain the detailed procedure of each setting.
Note that the initialization processing after system upgrade is omitted.
Start
Did you upgrade

NO
system software?
YES
[Initialization] entry [SETUP] entry
Language, model, I/O module, ... [2.5.1] I/O Module Setting Check
Initialization processing of each items after Changing EW Board
: Station Number Setting
[SETUP] entry
For Fronius welding power source,

change the "ARC WELDING" setting
from "STANDARD" to "ENHANCED"
[2.5.2] Setting of Optional Function

"Network Function"
[2.5.3] Setting of Optional Function

"WELDCOM Function"
[2.5.4] Detailed Setting of

Welding Power Source
[2.5.5] I/O Module Setting Check

after Adding Virtual EW Module
* When the welder is FroniusTPSi;
[2.5.6] Setting of Optional

Function "MotoPlus Function"
[2.5.7] Loading of Dedicated

MotoPlus Application
[2.5.8] Setting of Parameter
End
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2.5 System Configuration DX200
2.5.1 I/O Module Setting Check after Changing EW Board Station Number Setting
The EW board removal and station number change performed in the
chapter 2.3 “Setting and Confirmation of Hardware Configuration”
changes the I/O module setting. The setting changes must be recognized
with [Setting] in the maintenance mode.
1. Start the DX200 while pressing [MAIN MENU]
– Start the DX200 in maintenance mode.
2. Select {SYSTEM} → {SECURITY} → “MANAGEMENT MODE”.
– A password must be entered after selecting “MANAGEMENT
MODE”.
3. Select {SYSTEM} → {SETUP} → “IO MODULE”.
4. Press the [ENTER] to check the I/O module connection status.

– If no EW board is connected, the board column displays “NONE” as
follows.
5. A confirmation dialog box appears. Select {YES}.
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2 Setup
2.5.2 Setting of Optional Function “Network Function”

The WELDCOM function uses the network function (optional function).
Set the network function by following the procedure below.
1. Select {SYSTEM} → {SETUP} → {OPTION FUNCTION}, and then
"DETAIL" of "NETWORK".
2. Change the setting of "DEVICE" from "NOT USED" to "Ethernet", and

select "DETAIL" of "HOST SETUP".
– Set the Network (Ethernet) function to enable.
3. After setting "IP ADDRESS SETTING" to "MANUAL SETTING",

change "IP ADDRESS" to "192.168.255.200".
• Set “SUBNET MASK” to “255.255.255.0”.

• Set "DEFAULT GATEWAY" to "0.0.0.0".
4. After the setting above is completed, press the [ENTER]. When a

confirmation dialog appears, select {Yes} to confirm the setting.
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2.5.3 Setting of Optional Function “WELDCOM Function”

Set the WELDCOM function by following the procedure below.
1. Select {SYSTEM} → {SETUP} → {OPTION FUNCTION}, and then
"DETAIL" of "WELDCOM FUNC. (ARC DIGITAL I/F)".
* If "WELDCOM FUNC. (...)" is not displayed, the system software version
may be old (earlier than DN1.00.00-00) or the function parameter may be
disabled. Contact your Yaskawa representative.
2. The WELDER SETUP window appears.

When multiple applications (welders) are set, you can navigate among
welder numbers with the upper or lower cursor.
– When the application setting is arc and no actual EW board exists,
only one line is displayed with *** for the items.
<Explanation of each item>

• The window displays as many lines as the number of applications.
• ST#: The station number of EW module corresponding to the weld-
ers
• TYPE: Kind of EW module (EX: XEW02, XEW01-1, etc..)
• <Second board>: Displayed when two EW boards are used in the
enhanced mode.
• DIGITAL I/F TYPE: Displays the type of welding power source con-
nected. (Either MOTOWELD, Fronius TPS, or
Fronius TPSi)
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2 Setup
3. On the number of welder where you want to set a digital interface,

press the [SELECT] to select a digital interface type.
4. After specifying the digital interface above, pressing the [ENTER]

displays the confirmation dialog for initializing the related files. Select
{Yes} to confirm the initialization.
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2 Setup
2.5.4 Detailed Setting of Welding Power Source

After setting the digital interface in the WELDER SETUP window and
initializing the related files, “Type” shows VEW01, indicating that the
virtual EW module for the digital interface has been assigned. Perform
detailed setting for each welding power source by following the procedure
below.
Set the each welding power source by following the procedure below.
1. VEW01 (Virtual EW module) has been assigned. Move the cursor to
the “DETAIL” in the far right, and press the [SELECT].
– VEW01 for the digital interface has been assigned.
2. The WELDCOM function works with the default detailed settings. You
do not especially need to make settings. Press the [ENTER] to confirm
the setting.
To see the welding currents and voltages obtained and the error codes
in the concurrent IO ladder, specify the M register address of output
destination accordingly.
• Selecting “DETAIL” displays the following DETAILED SETUP win-
dow.
• The DETAILED SETUP window varies depending on a welding
power source type.
<MOTOWELD type>
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2 Setup
<Fronius TPS type, FroniusTPSi type>
3. A confirmation dialog box appears. Select {YES}.
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2 Setup
2.5.5 I/O Module Setting Check after Adding Virtual EW Module

Once the digital interface setting is confirmed, the virtual EW module
VEW01 is added as an I/O module.
The following explains the final checking process, not the setting
procedure, to add VEW01 as an I/O module at the time of completion of
the WELDCOM function setting.
1. In the WELDER SETUP and the DETAILED SETUP window, when the
settings are completed, the IO MODULE setting window automatically
appears.
– The virtual EW module, VEW01, is displayed.
2. Press [ENTER].
A confirmation dialog box appears. Select {YES}.
3. Select {AUTO} or {MANUAL} in the ALLOCATION MODE

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2 Setup
4. The window goes back to OPTION FUNCTION window.
The DX200 setup is now completed.

Turn OFF the main power and restart the system in the normal mode.
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2 Setup
2.5.6 Setting of Optional Function "MotoPlus Function"

(When Welder is FroniusTPSi)
When the welder is FroniusTPSi, use the MotoPlus function (optional
function). Set the MotoPlus function to enable by following the procedure
below.
1. In the maintenance mode, select {SYSTEM} → {SETUP} → {OPTION
FUNCTION} to display "MotoPlus FUNC.", and then set to "USED".
2. Press [ENTER] to confirm the setting.

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2 Setup
2.5.7 Loading of MotoPlus Application (When Welder is FroniusTPSi)

Load FroniusTPSi and a MotoPlus application for communication.
1. Select {MotoPlus APL.} → {LOAD(USER APPLICATION)}.
At this time, select a device and a folder in which the execution file of
MotoPlus application (FroniusXML.out) is saved.
2. Select "FroniusXML.out" in the displayed folder(s). (When selected,

is added at the left of it.)
Press [ENTER] to confirm the setting.

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2 Setup
2.5.8 Setting of Parameter (When Welder is FroniusTPSi)

When the welder is FroniusTPSi, the following parameters should be set.
Parameter Recommended value Name
AxP92 160 Status flag input register
The register number to be set allows to check the welder status.

Bit0:Heartbeat Powersource
Bit1:Power source ready
Bit2:Arc stable
Bit3:Current flow
Bit4:Main current signal
Bit5:Torch collision protection
Bit6:Wire stick control
Bit7:Wire available
Bit8:Touched
Bit9:Torchbody connected
Bit10:Command value out of range
Bit11:Correction out of range
Bit12:Process active
Bit13~15:Reserved (Do not change.)

AxP93 161 Control flag input register
The register number to be set allows to operate the signals to the welder.
Bit0:Welding start
Bit1:Robot ready
Bit2:Source error reset
Bit3:Gas on
Bit4:Wire inching
Bit5:Wire retract
Bit6:Torch blow out
Bit7:Welding simulation
Bit8:Touch sensing
Bit9:Reserved
Bit10:SFI ON
Bit11:Synchropulse ON
Bit12:WireBreake
Bit13:Torch XChange
Bit14:TeachMode
Bit15:Reserved (Do not change.)
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2 Setup

AxP103 192
AxP104 168 TPSi IP address for HTTP
AxP105 255 communication
AxP106 211
Set the IP address to be used to obtain the welding type database from TPSi.
(For the IP address for HTTP communication, check at the TPSi side.)
Example: When the IP address is "192.168.255.211";

AxP103=192, AxP104=168, AxP105=255, AxP106=211
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2 Setup
2.5.9 Optional Parameters for FroniusTPS
Parameter Name
-AxP91 RCU5000i Use Mode
0: It can set Job numbers from 0 to 99. (Initial setting)

1: It can set Job numbers from 0 to 999. (Only when RCU5000i is used.)
Parameter Name
-AxP92 Status flag input register
The register number to be set allows to check the welder status.

Bit0:Communication ready
Bit1:Power source ready
Bit2:Arc stable
Bit3:Process active
Bit4:Main current signal
Bit5:Torch collision protection
Bit6:Wire stick control
Bit7:Wire available
Parameter Name
-AxP93 Control flag input register
The register number to be set allows to operate the signals to the welder.
Bit7:Welding simulation
Bit9:Master selection Twin
Bit10~15 reserved (Do not change.)
Parameter Name
-AxP96 TPS panel type forcible designation
It can change the “Select Synergic” window.

0: auto (Initial setting)
1: Standard
2: CMT
3: US
5: CMT-L
Parameter Name
-RS380 Timeout lifecycle of welder
Unit:10 ms
Range: 5 (50 ms) - 30 (300 ms)
If it is out of range, 100 ms will be set (initial setting).
2.5.10 Optional Parameter for FroniusTPSi
Parameter Name
-RS380 Timeout lifecycle of welder
Unit:10 ms
Range: 5 (50 ms) - 30 (300 ms)
If it is out of range, 100 ms will be set (initial setting).
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3 Operation of Welding Condition File Edit Window

DX200 3.1 Overview
3.1 Overview
The WELDCOM function can set and obtain the parameter of the welding
power source in the edit window of an arc start condition file or an arc end
condition file.
3.2 Display of Welding Condition File Edit Window

1. Select {ARC WELDING} under the main menu.
2. Select {ARC START COND.} or {ARC END COND.}.
Fig. 3-1: E.g.) Edit window for arc start condition
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3.3 MOTOWELD Type: Operation of Top Window DX200
3.3 MOTOWELD Type: Operation of Top Window

1. Display {OTHER} tab of the welding condition file to specify the
number of a weld user file to be used.
2. Display {OTHER} tab of the welding condition file, and press {Welder
setting}.
3. Move the cursor to the weld user file number specified in 1.

– Select weld user file.
4. Select {Weld type}.

– Register a welding type in the weld user file selected.
→Go to Weld type window.
5. Select {Customize}.
– Change the parameter of the weld user file selected.
→Go to Customize window.
6. Select {Maintenance}.
– Perform maintenance. →Go to Maintenance window.
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DX200 3.4 MOTOWELD Type: Operation of Weld type Window
3.4 MOTOWELD Type: Operation of Weld type Window

1. At the top window, select a weld user file, and select {Weld type}.
2. Select welding condition.

– Select a value for "Wire type, Diameter, Shield Gas, and Pulse".
3. Select a welding type to be used, and press {SAVE}.
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3.5 MOTOWELD Type: Operation of Customize Window DX200
3.5 MOTOWELD Type: Operation of Customize Window

1. At the top window, select {Customize}.
2. Select {Start/End}.
– Change the parameter. For details on the parameters, see the user
manual of the welding power source.
3. Select {Short}.
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DX200 3.5 MOTOWELD Type: Operation of Customize Window
4. Select {End}.
5. Select {Curr. Character}.

6. Select {SAVE}.
– Apply the parameters changed.
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3.6 MOTOWELD Type: Operation of Maintenance Window DX200
3.6 MOTOWELD Type: Operation of Maintenance Window

1. At the top window, select Maintenance button.
2. Select {Maintenance}.
(1) {All write(DX200->welder)}: Send the parameters at a time to the

welding power source.
(2) {All read(welder->DX200)}: Receive the parameters at a time from
the welding power source.
(3) “CPU ver.,DSP ver.,DB ver.”: The versions of software and data-
base in the welding power source are
displayed.
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DX200 3.7 MOTOWELD Type: Operation of Welder Parameter Window
3.7 MOTOWELD Type: Operation of Welder Parameter

Window
1. At the top window, select {Welder prm.}.
2. Select {Gas/Wire}.
– Change the common parameter (C parameter).
• For details on the C parameters, see the user manual of the welding
power source.
3. Select {Other}.
power source.
4. Select {Other2}.
power source.
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3.7 MOTOWELD Type: Operation of Welder Parameter WindowDX200
5. Select {HAWC}.
• For details of the C parameter, see the user manual of the welding
power source.
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DX200 3.8 FroniusTPS Type: Operation of Top Window
3.8 FroniusTPS Type: Operation of Top Window

1. Display {OTHER} tab of the welding condition file to specify the
number of a weld user file to be used.
2. Display {OTHER} tab of the welding condition file, and press

{Welder setting}.
3. Select weld user file.
4. Select {Program No. setting}.

– Set a welding program in the weld user file selected.
→Go to the [Program No. setting] window.
5. Select {Param. setting}.
– Change the parameter setting of the weld user file selected.
→Go to the [Param. setting] window.
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3.9 FroniusTPS Type: Operation of Program No. setting WindowDX200
3.9 FroniusTPS Type: Operation of Program No. setting

Window
1. At the top window, select a weld user file, and select {Program No.
setting}.
2. Select welding condition.

– Select a value for "Diameter, Wire(Gas), and Operating mode".
3. Press {SAVE}.
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DX200 3.10 FroniusTPS Type: Operation of Param. setting Window
3.10 FroniusTPS Type: Operation of Param. setting Window

1. At the top window, select {Param. setting}.
(1) Gas preflow: Pre-flow that the robot performs as approaching the
welding start point.
(2) Gas postflow: Specify the time period of gas release performed at
the end of the welding.
(3) SFI: Select from “AUTO”, “MANUAL”, or “OFF”. Feeding rate
when the wire is approaching the base material at the touch start.
3. Select {Synchropulse}.
– Change the welding parameters for changing the feeding rate or arc
length in low-cycle pulses at the time of welding. For details, see the
user manual of the welding power source.
4. Select {SAVE}.
– Apply the parameters changed.
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3.11 FroniusTPSi Type: Operation of Top Window DX200
3.11 FroniusTPSi Type: Operation of Top Window

1. Display {OTHER} tab of the welding condition file, and then press
{Welder setting}.
– When the welding type database is not obtained yet, obtain the
database from the welder.
Open the Weld Parameter Setting window.
(When using Job mode of Fronius power source, put a check mark
in the check box of Job mode.)
2. Select a weld user file.
{Type:ISO/AWS}: Switches the display of materials.

{Unit:mm/inch}: Switches the unit of wire diameter.
{Refresh DataBase}:
Obtains the welding type database from the welder again.
3. Select {Select Synergic}.
– The welding type can be set to the selected weld user file.
→ Go to Select Synergic window.
4. Select {Set Parameter}.
– The parameter setting of the selected weld user file can be changed.
→ Go to Weld Parameter Setting window.
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DX200 3.12 FroniusTPSi Type: Operation of Select Synergic Window
3.12 FroniusTPSi Type: Operation of Select Synergic Window

1. At the top window, select a weld user file, and then select {Select Synergic}.
2. Select the welding condition.

– Select a value for "Mode", "Material type", "Diameter", and "Gas Type".
3. Select a welding program to be used, and then press {OK}.
3.13 FroniusTPSi Type: Operation of Weld Parameter Setting

Window
1. At the top window, select {Set Parameter}.
– The parameter of the selected weld user file can be changed.
2. Select {Weld Parameter}.
Penetration stabilizer: Sets the allowable value of speed fluctuation in
fluctuating the wire feeding speed in order to stabilize the welding current.
It is available only when the welding mode is PMC or LSC.
Arc length stabilizer: Stabilizes welding even if the amount of wire stickout
for short circuiting arc varies or there is interference from the outside.
It is available only when the welding mode is PMC.
For details, see the user manual of the welding power source.
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DX200
3.13 FroniusTPSi Type: Operation of Weld Parameter Setting Window
Gas preflow: Pre-flow that the robot performs as approaching the
welding start point.
Gas postflow: Specify the time period of gas release performed at the
end of the welding.
Inching speed: Wire feeding speed in perform inching manually by the
operator.
4. Select {Synchro Pulse}.

Changes the welding parameters for changing the feeding rate or arc
length in low-cycle pulses at the time of welding. For details, see the
user manual of the welding power source.
5. Select {OK}.
– The changed parameters are reflected.
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4 Job Preparation for Welding

DX200 4.1 Job Preparation for Welding
4.1 Job Preparation for Welding

1. Select {Job} under the main menu to create a job.
2. Select {INFORM} → {DEVICE}, and then select {ARCON}, {ARCSET},
and {ARCOF}.
– For the ARCON and ARCSET instructions, specify a welding start
condition file in the tag.
– For the ARCOF instruction, specify a welding end condition file in
the tag.
An example of a simple welding job
NOP
MOVJ VJ=30.00
MOVJ VJ=5.00
ARCON ASF#(1)
MOVL
ARCSET ASF#(10) ACOND=1
MOVL
ARCOF AEF#(5)
MOVJ VJ=50.00
MOVJ VJ=50.00
END
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4.1 Job Preparation for Welding DX200
3. When using a FroniusTPS-type welding power source, edit the

welding condition file so that the conditions are specified by using the
following physical quantity, not by welding current instruction or
welding voltage instruction.
• V1 (WFS): Wire feeding amount (m/min)
The range varies depending on a welding type.
• V2 (Arc Length): Arc length correction (%)
Set the value in the -30% to +30% range.
• V3 (CORR2): Correction 2
Set the value in the -5.0% to +5.0% range.
• V4 (CORR3): Correction 3
Set the value in the -0.2% to +0.2% range.
V2 (Arc Length): Arc length correction (%)

Controls the arc length.
+: Long arc-length, -: Short arc-length
V3 (CORR2): Correction 2
Parameter for the heat input control.
This varies depending on a welding type.
When the material is iron and the operating mode is CMT,
+: Small heat-input, -: Large heat-input
V4 (CORR3): Correction 3
This varies depending on a welding type.
– When TPS4000CMT is used for the welding power source,
This is a parameter for correction of burning-up.
– When CMTL is used for the welding power source, and
• the operating mode is CMT + P;
This is a parameter for changing the welding type ratio.
• the operating mode is one of the others;
This is a parameter for correction of burning-up.
Correction of burning-up
+: Increases burning-up time, -: Decreases burning-up time
Welding type ratio
+: Increases pulse ratio, -: Decreases pulse ratio
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DX200 4.1 Job Preparation for Welding
4. When using a FroniusTPSi-type welding power source, edit the

welding condition file so that the conditions are specified by using the
following physical quantity, not by welding current instruction or
welding voltage instruction.
• V1: Wire feeding speed (m/min)
The range varies depending on the welding type.
• V2: Arc Length
Set the value between -10.0% and +10.0%.
• V3: Pulse/Dynamic
Set the value between -10.0% and +10.0%.
• V4: Wire retraction
Set the value between 0.00 and 10.00.
V2: Arc Length

Controls the arc length.
+: Long arc-length, -: Short arc-length
V3: Pulse/Dynamic
V4: Wire retraction

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5 Alarm and Error
5.1 Alarm DX200
5 Alarm and Error
5.1 Alarm
Alarm Alarm Sub Meaning Remedy

No. Name Code
1 no Prg Select a pre-programmed program
Sub code[1**] shows the error code of Confirm the Fronius's manual
Fronius power source
1 :main error code
** :sub error code
2 ts1 Allow the machine to cool

2 :main error code
** :sub error code

3 :main error code
** :sub error code

4 :main error code
** :sub error code
TPS:
4290
ERROR 5 tp1 Allow the machine to cool
5 :main error code
** :sub error code
6 tp2 Allow the machine to cool

6 :main error code
** :sub error code

7 :main error code
** :sub error code

8 :main error code
** :sub error code
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5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
9 :main error code
** :sub error code

10 :main error code
** :sub error code
11 Errtf1 Change the thermo sensor on the

Sub code[11**] shows the error code of sec. side
Fronius power source Confirm the Fronius's manual
11 :main error code
** :sub error code
12 Errtf2 Change the thermo sensor on the

Sub code[12**] shows the error code of prim. side
12 :main error code
** :sub error code
13 Errtf3 Check cable tree of temperature

Sub code[13**] shows the error code of sensors
TPS: Fronius power source Confirm the Fronius's manual
4290
ERROR 13 :main error code
** :sub error code
14 Errtf4 Only for Magic Wave power source

14 :main error code
** :sub error code
15 Errtf5 Check cable tree of temperature

Sub code[15**] shows the error code of sensors
15 :main error code
** :sub error code
16 Errtf6 Change BPS PC-board

16 :main error code
** :sub error code
17 DSPE05 Update firmware, otherwise change

Sub code[17**] shows the error code of the UST board
17 :main error code
** :sub error code
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
18 ErrbPS Update firmware, otherwise change
Sub code[18**] shows the error code of the UST board or otherwise change
Fronius power source the BPS board
18 :main error code Confirm the Fronius's manual
** :sub error code
19 Err IP Change the BPS board

Sub code[19**] shows the error code of Change the secondary diode
Fronius power source Change the welding transformer
** :sub error code
20 DSPAxx Update firmware, otherwise change

20 :main error code
** :sub error code
21 DSPExx Update firmware, otherwise change

21 :main error code
** :sub error code
TPS:
4290
ERROR 22 ErrEPF Update firmware, otherwise change
22 :main error code
** :sub error code
23 Err23.x Update firmware, otherwise change

23 :main error code
** :sub error code

24 :main error code
** :sub error code

25 :main error code
** :sub error code
5-3
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5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
26 Err26.x Check whether the CfgMem has
Sub code[26**] shows the error code of good contact to the connecting
Fronius power source cables and in the plug.
26 :main error code Re-crimp if necessary.
** :sub error code If this does not help, remove and
send to Fronius Austria, together
with details of the series number of
the machine.
Confirm the Fronius's manual
27 Err027 Measure the +24VDC of NT 24

27 :main error code
** :sub error code
28 Err028 Change the cooling-unit temperature

Sub code[28**] shows the error code of sensor
28 :main error code
** :sub error code
29 DSPC Update firmware, otherwise change

29 :main error code
TPS: ** :sub error code
4290
ERROR
30 EFd Check wire feed system.

30 :main error code
** :sub error code
31 Err31 Update firmware, otherwise change

31 :main error code
** :sub error code
32 EcF Install correct primary BPS power

Sub code[32**] shows the error code of module
32 :main error code
** :sub error code
33 tSt Allow the machine to cool

33 :main error code
** :sub error code
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
34 Errtf7 Change the UST board
34 :main error code
** :sub error code
35 DSP KL Update firmware, otherwise change

35 :main error code
** :sub error code
36 DSPnSy Update firmware, otherwise change

36 :main error code
** :sub error code
37 US POL Change over the polarity of the two

Sub code[37**] shows the error code of cables otherwise change the UST
Fronius power source board
** :sub error code
38 -Stop- Deactivate the -Stop- by input -

Sub code[38**] shows the error code of RobotReady- and activate briefly -
Fronius power source SourceErrorReset-
TPS: 38 :main error code Confirm the Fronius's manual
4290 ** :sub error code
ERROR
39 NoH2O Check the coolant level and (if

Sub code[39**] shows the error code of appropriate) the coolant return-flow
Fronius power source rate
39 :main error code If necessary, clean the coolant filter.
** :sub error code Rate-of-flow watchdog may be
defective
40 ErrLic Confirm the Fronius's manual

Sub code[40**] shows the error code of
40 :main error code
** :sub error code
41 unknown OR NOT IN USE

41 :main error code
** :sub error code

42 :main error code
** :sub error code
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5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
43 :main error code
** :sub error code

44 :main error code
** :sub error code

45 :main error code
** :sub error code

46 :main error code
** :sub error code

TPS: Fronius power source
4290
** :sub error code

48 :main error code
** :sub error code
49 Err049 Check the mains power supply

Sub code[49**] shows the error code of Check all 3 phases
49 :main error code
** :sub error code
50 Err050 Disconnect NT60 or change/check

Sub code[50**] shows the error code of NT24/UST/BPS/intermediate circuit
Fronius power source capacitors
** :sub error code
51 Err051 Mains voltage too low or NT 24

Sub code[51**] shows the error code of defective
51 :main error code
** :sub error code
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
52 Err052 Mains voltage too high or NT 24
Sub code[52**] shows the error code of defective
52 :main error code
** :sub error code
53 ErrPE Low-resistance connection between

Sub code[53**] shows the error code of secondary and machine housing find
Fronius power source out the cause
** :sub error code
54 Err054 Increase the bbc (burn-back control)

Sub code[54**] shows the error code of Switch off "Wire stick " in the set-up
Fronius power source menu
54 :main error code After the end of welding, make sure
** :sub error code that the wire does not collide with the
workpiece when the torch is
retracted.
55 NoIGn Set a lower Ito value

Sub code[55**] shows the error code of Keep the torch stand-off distance
Fronius power source smaller before ignition.
TPS: ** :sub error code
4290
ERROR
56 Err056 Check how much wire is left on the

Sub code[56**] shows the error code of spool
Fronius power source If necessary, change the spool
** :sub error code
57 NoGAS Check what volume of gas is still

Sub code[57**] shows the error code of available
57 :main error code
** :sub error code
58 NoArc Check the seam

58 :main error code
** :sub error code
59 Err059 Confirm the Fronius's manual

59 :main error code
** :sub error code
5-7
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5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
60 :main error code
** :sub error code
61 ErrArc Confirm the Fronius's manual

61 :main error code
** :sub error code
62 Err062 Allow the machine to cool

62 :main error code
** :sub error code
63 EIF Check interface configuration

63 :main error code
** :sub error code
64 Errtf8 Change the thermo sensor of the

Sub code[64**] shows the error code of cooling unit
4290
** :sub error code
65 hotH2O Cool down the cooling liquid

65 :main error code
** :sub error code
66 tJo Allow the JobMaster torch to cool

66 :main error code
** :sub error code
67 ErrtJo Change JobMaster PC-board

67 :main error code
** :sub error code

68 :main error code
** :sub error code
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
69 Err069 New welding start
69 :main error code
** :sub error code
70 Err70 Check gas

70 :main error code
** :sub error code
71 Err71 Check the welding seam

71 :main error code
** :sub error code
72 ErrCfg Check LHSB connection

72 :main error code
** :sub error code
73 noHost Check the connection between UST

Sub code[73**] shows the error code of and RCU and the firmware
4290
** :sub error code
74 Touch Touch sensing mode activated - no

Sub code[74**] shows the error code of error
74 :main error code
** :sub error code

75 :main error code
** :sub error code

76 :main error code
** :sub error code
77 Err77 Check the wire feeding alignment if it

Sub code[77**] shows the error code of is smooth
77 :main error code
** :sub error code
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5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
78 E-Stop Close the Safety circuit and activate
Sub code[78**] shows the error code of the Error reset
78 :main error code
** :sub error code
79 ErrU0 Confirm the Fronius's manual

79 :main error code
** :sub error code
80 Err080 Check the connection hose pack

Sub code[80**] shows the error code of between power source and wire
Fronius power source feeder
** :sub error code
81 tP7hot Allow the machine to cool

81 :main error code
** :sub error code
82 ErrEHF Allow the external HF to cool down

4290
** :sub error code
83 PHASE Check the mains supply cable of the

Sub code[83**] shows the error code of power source
83 :main error code
** :sub error code

84 :main error code
** :sub error code

85 :main error code
** :sub error code

86 :main error code
** :sub error code
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
87 :main error code
** :sub error code

88 :main error code
** :sub error code

89 :main error code
** :sub error code

90 :main error code
** :sub error code

4290
** :sub error code

92 :main error code
** :sub error code

93 :main error code
** :sub error code

94 :main error code
** :sub error code

Sub code[95*] shows the error code of Confirm the Fronius's manual
95 :main error code
** :sub error code
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5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
96 :main error code
** :sub error code

97 :main error code
** :sub error code

98 :main error code
** :sub error code

99 :main error code
** :sub error code
100 UndOpc Update firmware, otherwise change

4290
** :sub error code
101 PrtFlt Update firmware, otherwise change

101 :main error code
** :sub error code
102 IllOpa Update firmware, otherwise change

** :sub error code
103 IllIna Update firmware, otherwise change

** :sub error code
104 IllBus Update firmware, otherwise change

** :sub error code
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
105 Err105 Update firmware, otherwise change
** :sub error code
106 STKOVL Update firmware, otherwise change

** :sub error code
107 STKUVL Update firmware, otherwise change

** :sub error code
108 ErrDog Update firmware, otherwise change

** :sub error code
109 ASSErt Update firmware, otherwise change

4290
** :sub error code
110 EDg 1 Update firmware, otherwise change

** :sub error code

to Sub code[111**] shows the error code of Confirm the Fronius's manual
149 Fronius power source
** :sub error code
150 Err150 Check the power supply of the power

Sub code[150**] shows the error code of source
** :sub error code

to Sub code[151**] shows the error code of Confirm the Fronius's manual
200 Fronius power source
** :sub error code
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5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
4241 MOTOWELD 302 Sub Code: MOTOWELD's Err Code. When finish system reset, Shut
SYSTEM down the welding power source.
RESET
4242 MOTOWELD 107 Sub Code: MOTOWELD's Err Code. (1)Check if the output cable is short-
INPUT OVER- circuited or grounded.
CURRENT (2) The power circuit may be
broken . Contact your Yaskawa
representative.
4243 MOTOWELD 701 Sub Code: MOTOWELD's Err Code. Confirm the following content.
OUTPUT (1) Check that the torch cable or
OVER- power cable is not grounded?
CURRENT (2)Check that the contact tip does
not contact the welding work piece?
(3)Check that the encoder cable is
not damaged?
(4)Check if the screws of the
connector terminal block are
securely fastened. If the encoder
cable is disconnected or the screws
are loosened, the wire feeding speed
becomes excessively fast and an
error occurs in the wire feeding
amount. Replace the encoder cable
or fasten the screws of the connector
terminal block.
4244 MOTOWELD 001 Sub Code: MOTOWELD's Err Code. Confirm the input voltage.
INPUT OVER-
VOLTAGE
4245 MOTOWELD 102 Sub Code: MOTOWELD's Err Code. (1)Check the ambient temperature
EXCESSIVE (40 degrees centigrade or less) and
TEMPERAT- operational ratio (60%).
URE (2) Check if there are dust, dirt, and
clogging on the dust protective filter.
Clean or replace the dust protective
filter if necessary.
(3)In case of RL350, Check the
thermal guard (Item No.410).
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
103 Sub Code: MOTOWELD's Err Code. (1)Check the ambient temperature
(40 degrees centigrade or less) and
operational ratio (60%).
(2) Check if there are dust, dirt, and
thermal guard (Item No.318).
MOTOWELD (2) Check if there are dust, dirt, and
EXCESSIVE clogging on the dust protective filter.
4245 Clean or replace the dust protective
TEMPERAT-
URE filter if necessary.
thermal guard of DCL2 (Item
No.312).
(2) Check if there are dust, dirt, and
(3)Replace the Main board Pr (MB)-
030(Item No. 504).
4246 MOTOWELD 002 Sub Code: MOTOWELD's Err Code. Confirm the input voltage.
INPUT
UNDER-
VOLTAGE
4247 MOTOWELD 703 Sub Code: MOTOWELD's Err Code. (1)Fill up the cooling water.
WATER (2)Check the circuit of cooling water.
UNDER-
FLOW
DIGITAL I/F (1) The LAN cable has not
WDG.ERROR damaged.
(2) The Ethernet protocol address
setting is correct. (Check that C
parameter of the welding power
source and RS parameter of the
robot controller.)
(3) Welding power source is turn on.
(4) Please confirm the Ethernet
setting (Ethernet function is effective
and sets an IP address (RS
parameter ,AxP parameter)) of the
robot control unit.
4249 MOTOWELD 402 Sub Code: MOTOWELD's Err Code. Check the Node of the each welder
DIGITAL I/F power sources and robot controller.
NODE
ERROR
5-15
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5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
DIGITAL I/F (1) LAN cable is not damaged.
ERROR (2) Protocol type of the VEW01 is
correct. (is MOTOWELD type?)
4251 MOTOWELD 404 Sub Code: MOTOWELD's Err Code. Set the user file number 1...16.
DIGITAL I/F
FILE# ERROR
4252 MOTOWELD 405 Sub Code: MOTOWELD's Err Code. Replace the main board {Pr (MB) -
DIGITAL I/F 024}. Contact your Yaskawa
CHIP ERROR representative.
4253 MOTOWELD 304 Sub Code: MOTOWELD's Err Code. The setting of hardware or software
MACHINE may be not performed correctly.
TYP.ERROR1 Contact your YASKAWA
representative.
representative.
representative.
representative.
4257 MOTOWELD 303 Sub Code: MOTOWELD's Err Code. (1) Check the DIP switch setting of
PANEL SW WK-7036 board (Service parts
SETTING code:P00A0703600).
ERROR (2) WK-7036 board (Service parts
code:P00A0703600) may be broken.
Contact your YASKAWA
representative.
FEEDER (1)The encoder cable be not
ERROR damaged?
(2)Isn't there loosening of the screw
of the encoder cable connection
terminal block?
When there are a disconnection of
the encoder cable or loosening of the
screw, the wire feeding speed
quickens abnormally, and it becomes
an abnormal amount of feeding.
Replace the encoder cable or fasten
the screw of the terminal block.
(3)Check if the wire load becomes
heavy. Make sure that the torch
cable and conduit cable are not bent
excessively.
331 Sub Code: MOTOWELD's Err Code. (1)Confirm the feeder motor type.
(2)Check the C parameter for feeder
motor is correct.
(3)Check the dip switch SW700 on
the Main board (Service parts code:
UNIT-Pr (MB)-030).
5-16
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
4259 MOTOWELD 502 Sub Code: MOTOWELD's Err Code. Check if the wire load becomes
MOTOR heavy. Make sure that the torch
OVER- cable and conduit cable are not bent
CURRENT excessively.
4260 MOTOWELD 203 Sub Code: MOTOWELD's Err Code. The board may be broken. Contact
CPU ERROR1 your Yaskawa representative.
CPU ERROR2 your Yaskawa representative.
4262 MOTOWELD 205 Sub Code: MOTOWELD's Err Code. The data may not have been
MEMORY correctly saved when the welding
ERROR1 conditions are recorded because of
a power failure, etc. Reset the
system after saving the changed
parameters. (See the manual of
MOTOWELD "4.2.10 System
Reset")
If the error occurs again, the board
may be broken. Contact your
Yaskawa representative.
Reset")
Reset")
Reset")
5-17
HW1482771 46E/48
HW1482771
5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
Reset")
Reset")
Reset")
4269 MOTOWELD 601 Sub Code: MOTOWELD's Err Code. Check again the operation timing or
STARTING signal cable connections. The same
SIGNAL error may occur at momentary power
ERROR failure.
4270 MOTOWELD 602 Sub Code: MOTOWELD's Err Code. Select a correct welding process in
NO WELDING the using the welding user file.
TYPE
5-18
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5 Alarm and Error
5.1 Alarm DX200

No. Name Code
4271 MOTOWELD 702 Sub Code: MOTOWELD's Err Code. (1)Check if the voltage detection wire
VOLT.DETEC is connected. Check to confirm that
T WIRE the welding voltage sensing cable
ERROR select switch is set to "Base Metal".
The use of MOTOWELD-RP500:
Check to confirm that the voltage
sensing cable is connected between
the base metal and the terminal
block TB2 7.
The use of MOTOWELD-RL350:
Check to confirm that the base
metal-side welding voltage sensing
cable connects between the base
metal and the welding power source
via wire feeder cable.
(2)Check to confirm that the contact
chip and the welding work are not in
contact. Cancel the contact if any,
and weld them.
(3)Temporary power failure may
have occurred.
4272 MOTOWELD 101 Sub Code: MOTOWELD's Err Code. Contact your Yaskawa
SAFTY- representative.
CIRCUIT
ERROR
4273 MOTOWELD 104 Sub Code: MOTOWELD's Err Code. Replace the IGBT device (Part code
IGBT SHORT AJ0EL3870). Contact your Yaskawa
CIRCUIT representative.
VOLTAGE representative.
DETECTOR
ERROR
AUX. your Yaskawa representative.
CIRCUIT OV.
CURRENT
DSP ADC representative.
ERROR
4277 MOTOWELD 790 Sub Code: MOTOWELD's Err Code. (1)Check if the selection of motor is
OUTSIDE OF correct, or confirm the settings of C
CURR.SETTI parameter C09.
NG(H) (2)Check that the welding wire does
not slip, or the wire is fed as
instructed by the feeding command.
(3)Check that the wire stick out is not
excessively short or long.
(4)Check that the range set in C
parameter C29 is not too narrow.
(5)Check if the wire, shielding, etc.
are correctly set.
5-19
HW1482771 46G/48
HW1482771
5 Alarm and Error

DX200 5.1 Alarm

No. Name Code
4278 MOTOWELD 791 Sub Code: MOTOWELD's Err Code. (1)Check if the selection of motor is
OUTSIDE OF correct, or confirm the settings of C
CURR.SETTI- parameter C09.
NG(L) (2)Check that the welding wire does
not slip, or the wire is fed as
instructed by the feeding command.
(3)Check that the wire stick out is not
excessively short or long.
(4)Check that the range set in C
parameter C29 is not too narrow.
(5)Check if the wire, shielding, etc.
are correctly set.
4279 MOTOWELD 108 Sub Code: MOTOWELD's Err Code. (1)Check that short-circuit or the
MOMENTARY earth grounded of the output cable.
OVER-CURR (2)May be power circuit broken.
Contact your Yaskawa
representative.
OVER- representative.
VOLTAGE
4281 MOTOWELD 704 Sub Code: MOTOWELD's Err Code. The use of MOTOWELD-RP500:
+15V POWER Replace the switching power supply
SUPPLY unit (Service parts
ERROR code:35015612200) or the Main
board (Service parts
code:AJ0RP3024). Or, please
change two of them.
Replace the Interface board (Service
parts code: UNIT-Pr (IF)-008B) or
UNIT-Pr (MB)-030). Or, please
change two of them.
4282 MOTOWELD 705 Sub Code: MOTOWELD's Err Code. The use of MOTOWELD-RP500:
POWER Replace the switching power supply
SUPPLY unit (Service parts
ERROR code:35015612200) or the Main
board (Service parts
code:AJ0RP3024). Or, please
change two of them.
Replace the Interface board (Service
parts code: UNIT-Pr (IF)-008B) or
UNIT-Pr (MB)-030). Or, please
change two of them.
4283 MOTOWELD 406 Sub Code: MOTOWELD's Err Code. Confirm the welding process setting
ILLEGAL in the welding user file.
WELD TYPE
407 Sub Code: MOTOWELD's Err Code. Set a welding type to user file of
MOTOWELD. The user file can
setup in the editor screen for ARC
START CONDITION FILE or ARC
END CONDITION FILE of the robot
controller.
5-20
HW1482771 46H/48
HW1482771
5 Alarm and Error
5.1 Alarm DX200

No. Name Code
4284 MOTOWELD 310 Sub Code: MOTOWELD's Err Code. Load the suitable database.
SOFTWARE
MULFUNCT- 311 Sub Code: MOTOWELD's Err Code. Replace the main board (Service
ION parts code: UNIT-Pr (MB)-030).
representative.
312 Sub Code: MOTOWELD's Err Code. Replace the front panel (Service
parts code: UNIT-Pr (CR)-030).
representative.
316 Sub Code: MOTOWELD's Err Code. Replace the main board (Service
parts code: UNIT-Pr (MB)-030).
representative.
317 Sub Code: MOTOWELD's Err Code. Reboot the power source.
318 Sub Code: MOTOWELD's Err Code. (1)Do not turn off the power source
and reload the data.
(2)In case of turn off and reboot was
OK, reload the data.
(3)In case of turn off and reboot was
NG, load the data by special loading
tool.
(4)Other case of step 1,2,3, replace
the main board Pr (MB)-030.
4284 MOTOWELD 400 Sub Code: MOTOWELD's Err Code. (1)Movement abnormality of PLD
SOFTWARE occurred, and a welding power
MULFUNCT- supply rebooted..
ION (2)Replace the main board {Pr (MB)
-030}.
representative.
4285 MOTOWELD 320 Sub Code: MOTOWELD's Err Code. (1)Check the connection between
MACHINE front panel and main board.
SETTING (2)Check the status of dip switch
ERROR (SW301) on the front panel.
(3)Replace the front panel.
(4)Replace the main board.
4286 MOTOWELD 330 Sub Code: MOTOWELD's Err Code. (1)Confirm the power source class
CURRENT which of 350A or 500A.
CLASS (2)Switch a status of dip switch
ERROR SW600 which of 350A or 500A.
(3)Change the software which for
correct current class.
5-21
HW1482771 46I/48
HW1482771
5 Alarm and Error

DX200 5.2 Error
5.2 Error
Error No. Message Cause Remedy
1110 TPS: SELECTED A welding program unprepared for Select again a welding program.
UNREGISTERED the welding power source was
PROGRAM selected.
1111 TPS: FEEDING A wire was clogged or so in the The most problems automatically
SYSTEM FAILURE feeding system, leading to improper solve when inching retract is
feeding. performed on the wire for a short
For the CMT welding power source, time at the time of error reset.
the possibilities are high that the If the problem persists, try to
wire buckled in the wire buffer and perform manual wire inching or
this caused a problem with the wire retract.
sensor in the buffer. Adjust manually the sensor of the
wire buffer to the proper position.
If the problem frequently occurs,
first check the feeding system for
abnormally high feeding load, and
replace parts as needed.
1112 TPS: ABNORMAL The water flow sensor was Check if water flows. If water flows
WATER FLOW activated. and the error still occurs, replace
the sensor because the sensor
possibly has failed.
5.3 Message
Message Cause Remedy
TPS: TOUCH SENSOR The touch sensor was activated and This is only a notification. It does not
IN OPERATION the status flag bit turned ON. indicate any problem.
TPS: ARC IGNITION When welding started, timeout Remove the slag or other objects at the
FAILURE occurred while waiting for arc to be wire tip or in the base material. For CO2
generated that produces current flow. welding especially, because slag tends to
An insulator such as slag prevented prevent conduction, take some action
current from flowing, thus arc was not whenever possible so that welding starts
generated. Or the wire took long time from other than welding bead edge. Adjust
to contact the base material, being the crater conditions for welding ending
determined as arc ignition failure. time so that some short length of wire
comes out from the chip (so that the wire
can immediately contact the base
material).
TPS: ROBOT NOT The welding power source received Check if the digital interface type of
READY the notification that the "Robot ready" VEW01 is FroniusTPS.
bit turned OFF, which was sent from
the robot side, and issued the error.
WELDING POWER The Ethernet communication was Check if the LAN cable is connected. If
SOURCE: Ethernet disconnected. using a HUB, check if the HUB is turned
COMMUNICATION ON.
ERROR
TPS: WELDING The welding power source notified This phenomenon may temporarily occur
POWER SOURCE NOT that it is not ready for welding. when the welding power source is turned
READY ON or OFF, but it has no problem.
However, if the error persists, restart the
welding power source.
TPS: OUTSIDE THE Welding is performed with the feeding When welding with the TCP speed
RANGE OF FEEDING amount exceeding the maximum function, decrease the welding rate to
AMOUNT value set for welding programs. reduce the feeding amount.
5-22
HW1482771 47/48
DX200 OPTIONS
OPERATOR’S MANUAL
FOR WELDCOM FUNCTION:
ARC WELDING/DIGITAL I/F FUNCTION
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Europe GmbHRobotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800 Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.

22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542
YASKAWA Electric Korea Co., Ltd

9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513
YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199
PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741
Specifications are subject to change without notice

for ongoing product modifications and improvements.
YASKAWA ELECTRIC CORPORATION
C Printed in Japan February 2016 14-06
MANUAL NO.
HW1482771 2 48/48

Operator'S Manual: Dx200 Options

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DX200 OPTIONS

YASKAWA ELECTRIC CORPORATION

NOTES FOR SAFE OPERATION

Always be sure to follow explicitly the

PROHIBITED Must never be performed.

Even items described as “CAUTION” may result in a serious accident in

To ensure safe and efficient operation at all times, be sure

• Observe the following precautions when performing teaching

Definition of Terms Used Often in This Manual

Equipment Manual Designation

Descriptions of the programming pendant keys, buttons, and displays are

ex. page key PAGE

Description of the Operation Procedure

1 Functional Overview ....................................................................................................................... 1-1

1.1 Overview............................................................................................................................ 1-1

2 Setup .............................................................................................................................................. 2-1

2.1 Setup Flow......................................................................................................................... 2-1

2.2 DX200 System Software Upgrade..................................................................................... 2-1

2.2.1 Individual Data Backup......................................................................................... 2-1

2.2.2 System Upgrade................................................................................................... 2-1

2.3 Setting and Confirmation of Hardware Configuration ........................................................ 2-2

2.3.1 Removing Unnecessary EW Board ...................................................................... 2-2

2.3.2 Station Number when EW Board is Left ............................................................... 2-2

2.4 Connection of Welding Power Source and DX200 ............................................................ 2-3

2.4.1 Standard Connection

2.4.2 When Connecting to DX200 the Multiple Welding Power Sources

2.5 System Configuration ........................................................................................................ 2-5

2.5.2 Setting of Optional Function “Network Function”.................................................. 2-7

2.5.3 Setting of Optional Function “WELDCOM Function” ............................................ 2-8

2.5.4 Detailed Setting of Welding Power Source......................................................... 2-10

2.5.6 Setting of Optional Function "MotoPlus Function"

2.5.7 Loading of MotoPlus Application (When Welder is FroniusTPSi)....................... 2-15

2.5.8 Setting of Parameter (When Welder is FroniusTPSi) ......................................... 2-16

2.5.9 Optional Parameters for FroniusTPS.................................... 2-18

2.5.10 Optional Parameter for FroniusTPSi ................................... 2-18

3 Operation of Welding Condition File Edit Window .......................................................................... 3-1

3.1 Overview............................................................................................................................ 3-1

3.2 Display of Welding Condition File Edit Window ................................................................. 3-1

3.3 MOTOWELD Type: Operation of Top Window.................................................................. 3-2

3.4 MOTOWELD Type: Operation of Weld type Window ........................................................ 3-3

3.5 MOTOWELD Type: Operation of Customize Window ....................................................... 3-4

3.6 MOTOWELD Type: Operation of Maintenance Window ................................................... 3-6

3.7 MOTOWELD Type: Operation of Welder Parameter Window ........................................... 3-7

3.8 FroniusTPS Type: Operation of Top Window .................................................................... 3-9

3.10 FroniusTPS Type: Operation of Param. setting Window ............................................... 3-11

3.11 FroniusTPSi Type: Operation of Top Window ............................................................... 3-12

3.12 FroniusTPSi Type: Operation of Select Synergic Window............................................. 3-13

4 Job Preparation for Welding............................................................................................................ 4-1

4.1 Job Preparation for Welding .............................................................................................. 4-1

5 Alarm and Error............................................................................................................................... 5-1

5.1 Alarm.................................................................................................................................. 5-1

5.2 Error ................................................................................................................................. 5-22

5.3 Message .......................................................................................................................... 5-22

 Programming a job is available using general arc welding commands.

 The parameter to be set in the edit window of the welding condition

 TCP Speed Function

2.1 Setup Flow

DX100 system software upgrade

Setting and confirmation of hardware configuration