Controlador DX100

YASKAWA
DX100
INSTRUCTIONS
FOR NORTH AMERICAN (ANSI/RIA) STANDARD
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.
Part Number: 155494-1CD

Revision: 1
YASKAWA MANUAL NO. RE-CTO-A217 1

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.
• 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.
ii
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 items listed under this heading.
Must never be performed.

PROHIBITED
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 “CAU-
TION” and “WARNING”.
iii
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 the emergency stop button
immediately if there are problems. The emergency stop button is
located on the right of 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.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on programming pendant is
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 button does 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
iv
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

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows.
Equipment Manual Designation
DX100 Controller DX100
DX100 Programming Pendant Programming Pendant
Cable between the manipulator and Manipulator Cable
the controller
v
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 “+”
sign between them, ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming

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

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

• The following warning labels are attached to DX100.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to
equipment.
WARNING
High Voltage DX100
TYPE
3PHASE
ERDR-
POWER SUPPLY
AC480V 50/60Hz
MAXIMUM RATED CURRENT A
SCCR
LARGEST LOAD
KA
A
PEAK
AVERAGE
DRAWING No.
SERIAL No.
DATE
kVA
kVA
Do not open the door

MADE IN JAPAN NJ2999-1
ON
with power ON. O

F
F
PROGRAMMING PENDANT
X 8 1
vii
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................................................................................................ 1-10
1.5.3 Operation Safety................................................................................................. 1-11
1.6 Notes for Moving and Transferring the MOTOMAN......................................................... 1-14
1.7 Notes on MOTOMAN Disposal ........................................................................................ 1-15
2 Product Confirmation ...................................................................................................................... 2-1
2.1 Contents Confirmation ....................................................................................................... 2-1
2.2 Order Number Confirmation............................................................................................... 2-2
3 Installation ....................................................................................................................................... 3-1
3.1 Handling Procedure ........................................................................................................... 3-1
3.1.1 Using a Crane to Move the Controller .................................................................. 3-1
3.1.2 Using a Forklift to Move the Controller ................................................................. 3-3
3.2 Place of Installation............................................................................................................ 3-4
3.3 Location ............................................................................................................................. 3-5
3.4 Mounting the Controller...................................................................................................... 3-6
4 Connection ...................................................................................................................................... 4-1
4.1 Notes on Cable Junctions .................................................................................................. 4-2
4.2 Power Supply..................................................................................................................... 4-3
4.2.1 Three-Phase Power Supply.................................................................................. 4-3
4.2.2 Noise Filter Installation ......................................................................................... 4-3
4.2.3 Leakage Breaker Installation ................................................................................ 4-4
4.2.4 Primary Power Supply Breaker/Fuse 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 ....................................................................... 4-9
4.3.3 Connecting the Programming Pendant............................................................... 4-10
viii
DX100 Contents
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
7 Security System .............................................................................................................................. 7-1
7.1 Protection Through Security Mode Settings ...................................................................... 7-1
7.1.1 Security Mode ...................................................................................................... 7-1

7.1.1.1 Changing the Security Mode ................................................................... 7-5
7.1.2 User ID ................................................................................................................. 7-7

7.1.2.1 Changing User ID.................................................................................... 7-7
8 System Setup.................................................................................................................................. 8-1
8.1 Home Position Calibration ................................................................................................. 8-2
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 ..................................................................... 8-6
8.1.2.3 Changing the Absolute Data ................................................................... 8-7
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 .......................................................................... 8-20

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 ................................................................................. 8-30
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 .................... 8-32
8.4 ARM Control .................................................................................................................... 8-37
8.4.1 ARM Control ....................................................................................................... 8-37
8.4.2 ARM CONTROL Window ................................................................................... 8-37

8.4.2.1 Robot Setup Condition .......................................................................... 8-37
8.4.3 Tool Load Information Setting............................................................................. 8-42

8.4.3.1 Tool Load Information ........................................................................... 8-42
8.4.3.2 How to Calculate Tool Load Information ............................................... 8-42
8.4.3.3 Tool Load Information Registering ........................................................ 8-48
8.5 Work Home Position ........................................................................................................ 8-51
8.5.1 What is the Work Home Position? ...................................................................... 8-51
8.5.2 Setting Work Home Position............................................................................... 8-51

8.5.2.1 Work Home Position Window ................................................................ 8-51
8.5.2.2 Registering/Changing the Work Home Position .................................... 8-52
8.5.2.3 Returning to the Work Home Position ................................................... 8-53
8.5.2.4 Output of the Work Home Position Signal ............................................. 8-54
8.6 Interference Area ............................................................................................................. 8-55
8.6.1 Interference Area ................................................................................................ 8-55
8.6.2 Cubic Interference Area...................................................................................... 8-55

8.6.2.1 Cubic Interference Area......................................................................... 8-55
8.6.2.2 Cube Setting Method............................................................................. 8-55
8.6.2.3 Setting Operation .................................................................................. 8-57
8.6.3 Axis Interference Area ........................................................................................ 8-63

8.6.3.1 Axis Interference Area ........................................................................... 8-63
8.6.3.2 Setting Operation .................................................................................. 8-63
8.6.4 Clearing the Interference Area Data ................................................................... 8-70
8.7 Shock Detection Function ................................................................................................ 8-72
8.7.1 Shock Detection Function................................................................................... 8-72
8.7.2 Shock Detection Function Setting....................................................................... 8-72

8.7.2.1 Shock Detection Level Setting............................................................... 8-72
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DX100 Contents
8.7.2.2 Tool Load Information Setting ............................................................... 8-75

8.7.2.3 Instruction of Shock Detection Function................................................ 8-75
8.7.2.4 Resetting the Shock Detected............................................................... 8-79
8.8 User Coordinate Setting .................................................................................................. 8-81
8.8.1 User Coordinates................................................................................................ 8-81
8.8.2 User Coordinate Setting ..................................................................................... 8-82

8.8.2.1 Selecting the User Coordinate File........................................................ 8-82
8.8.2.2 Teaching the User Coordinates............................................................. 8-83
8.8.2.3 Clearing the User Coordinates .............................................................. 8-85
8.9 Overrun / Tool Shock Sensor Releasing ......................................................................... 8-86
8.10 Soft Limit Release Function........................................................................................... 8-88
8.11 All Limit Release Function ............................................................................................. 8-89
8.12 Instruction Level Setting ................................................................................................ 8-91
8.12.1 Setting Contents ............................................................................................... 8-91

8.12.1.1 Instruction Set ..................................................................................... 8-91
8.12.1.2 Learning Function ............................................................................... 8-91
8.12.2 Setting the Instruction Set Level....................................................................... 8-92
8.12.3 Setting the Learning Function .......................................................................... 8-93
8.13 Setting the Controller Clock ........................................................................................... 8-95
8.14 Setting the Play Speed .................................................................................................. 8-96
8.15 Numeric Key Customize Function ................................................................................. 8-98
8.15.1 What is the Numeric Key Customize Function? ............................................... 8-98
8.15.2 Allocatable Functions ....................................................................................... 8-98

8.15.2.1 Key Allocation (EACH) ........................................................................ 8-98
8.15.2.2 Key Allocation (SIM)............................................................................ 8-98
8.15.3 Allocating an Operation .................................................................................... 8-99

8.15.3.1 Allocation Window ............................................................................... 8-99
8.15.3.2 Instruction Allocation ......................................................................... 8-100
8.15.3.3 Job Call Allocation............................................................................. 8-101
8.15.3.4 Display Allocation .............................................................................. 8-102
8.15.3.5 Alternate Output Allocation ............................................................... 8-103
8.15.3.6 Momentary Output Allocation ............................................................ 8-104
8.15.3.7 Pulse Output Allocation ..................................................................... 8-104
8.15.3.8 Group (4-bit/8-bit) Output Allocation.................................................. 8-105
8.15.3.9 Analog Output Allocation................................................................... 8-106
8.15.3.10 Analog Incremental Output Allocation ............................................. 8-106
8.15.4 Allocation of I/O Control Instructions .............................................................. 8-107
8.15.5 Execution of Allocation ................................................................................... 8-109

8.15.5.1 Executing the Instruction/Output Control Allocation .......................... 8-109
8.15.5.2 Executing the Job Call Allocation ...................................................... 8-109
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DX100 Contents
8.15.5.3 Executing the Display Allocation ....................................................... 8-109

8.15.5.4 Executing the I/O Control Allocation.................................................. 8-109
8.16 Changing the Output Status......................................................................................... 8-110
8.17 Changing the Parameter Setting.................................................................................. 8-112
8.18 File Initialization ........................................................................................................... 8-115
8.18.1 Initializing Job File .......................................................................................... 8-115
8.18.2 Initializing Data File......................................................................................... 8-115
8.18.3 Initializing Parameter File ............................................................................... 8-117
8.18.4 Initializing I/O Data.......................................................................................... 8-118
8.18.5 Initializing System Data .................................................................................. 8-119
8.19 Display Setting Function .............................................................................................. 8-121
8.19.1 Font Size Setting ............................................................................................ 8-121

8.19.1.1 Applicable Range for the Font Size Change ..................................... 8-121
8.19.1.2 Settable Font Size ............................................................................. 8-121
8.19.1.3 Setting the Font Size ......................................................................... 8-122
8.19.2 Operation Button Size Setting ........................................................................ 8-125

8.19.2.1 Applicable Range for the Button Size Change .................................. 8-125
8.19.2.2 Settable Button Size .......................................................................... 8-125
8.19.2.3 Setting the Button Size ...................................................................... 8-126
8.19.3 Initialization of Screen Layout......................................................................... 8-129

8.19.3.1 Initializing the Screen Layout............................................................. 8-129
8.19.4 Layout Storage ............................................................................................... 8-131
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
xii
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 ................................................... 9-13
9.3.2.4 Setting Examples .................................................................................. 9-15
9.4 Loading the Backup Data from the CompactFlash .......................................................... 9-16
9.4.1 Loading Procedure ............................................................................................. 9-16
9.5 Error List .......................................................................................................................... 9-19
9.5.1 Error Contents .................................................................................................... 9-19
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
10.3 Error Message ............................................................................................................... 10-4
11 Manual Brake Release Function................................................................................................. 11-1
11.1 Operating Conditions of Manual Brake Release............................................................ 11-1
11.2 Manual Brake Release Operation.................................................................................. 11-3
11.3 Warning Message Display ............................................................................................. 11-5
12 Modification of System Configuration ......................................................................................... 12-1
12.1 Addition of I/O Modules ................................................................................................. 12-1
12.2 Addition of Base and Station Axes ................................................................................ 12-3
12.2.1 Base Axis Setting ............................................................................................. 12-5

12.2.1.1 Selection of Base Axis Type................................................................ 12-5
12.2.1.2 Connection Setting .............................................................................. 12-8
12.2.1.3 Axis Configuration Setting ................................................................... 12-9
12.2.1.4 Mechanical Specification Setting....................................................... 12-10
12.2.1.5 Motor Specification Setting................................................................ 12-12
12.2.2 Station Axis Setting ........................................................................................ 12-13

12.2.2.1 Selection of Station Axis Type........................................................... 12-13
12.2.2.2 Connection Setting ............................................................................ 12-14
12.2.2.3 Axis Configuration Setting ................................................................. 12-16
12.2.2.4 Mechanical Specification Setting....................................................... 12-17
12.2.2.5 Motor Specification Setting................................................................ 12-20
13 DX100 Specification.................................................................................................................... 13-1
13.1 Specification List............................................................................................................ 13-3
13.2 Function List .................................................................................................................. 13-4
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DX100 Contents
13.3 Programming Pendant ................................................................................................... 13-5
13.4 Equipment Configuration ............................................................................................... 13-6
13.4.1 Arrangement of Units and Circuit Boards ......................................................... 13-6
13.4.2 Cooling System of the Controller Interior.......................................................... 13-8
14 Description of Units and Circuit Boards ...................................................................................... 14-1
14.1 Power Supply Contactor Unit......................................................................................... 14-4
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□) .................................................... 14-5
14.2.1 Major Axes Control Circuit Board (SRDA-EAXA01□) ....................................... 14-5
14.2.2 Connection for Tool Shock Sensor (SHOCK)................................................... 14-6

14.2.2.1 To connect the tool shock sensor directly to the tool shock sensor
signal line............................................................................................... 14-6
14.2.2.2 To connect the tool shock sensor with the cable that is built into
the manipulator...................................................................................... 14-7
14.2.3 Connection for Direct-in .................................................................................... 14-8
14.3 CPU Unit ........................................................................................................................ 14-9
14.3.1 CPU Unit Configuration .................................................................................... 14-9
14.3.2 Unit and Circuit Board in the CPU Unit........................................................... 14-10

14.3.2.1 Control Circuit Board (JANCD-YCP01-E).......................................... 14-10
14.3.2.2 Robot I/F Board (JANCD-YIF01-□E) ................................................. 14-10
14.4 CPS Unit (JZNC-YPS01-E).......................................................................................... 14-11
14.5 Brake Control Board (JANCD-YBK01-2E) ................................................................... 14-13
14.5.1 Brake Control Board (JANCD-YBK01-2E)...................................................... 14-13
14.6 Robot I/O Unit (JZNC-YIU01-E)................................................................................... 14-14
14.6.1 Robot I/O Unit (JZNC-YIU01-E)...................................................................... 14-14
14.7 Machine Safety Unit (JZNC-YSU01-1E) ...................................................................... 14-19
14.7.1 Machine Safety Unit (JZNC-YSU01-1E)......................................................... 14-19
14.7.2 Connection for Servo-ON Enable Input (ONEN1 and ONEN2) ...................... 14-20
14.7.3 Connection for External Axis Overrun (EXOT) ............................................... 14-21
14.8 WAGO Connector ........................................................................................................ 14-22
14.9 Robot Specific Input Terminal Block (MXT) ................................................................. 14-24
14.10 Contact Output of Emergency Stop Button................................................................ 14-35
14.11 SERVOPACK............................................................................................................. 14-36
14.11.1 Description of Each Unit ............................................................................... 14-36

14.11.1.1 Converter......................................................................................... 14-36
14.11.1.2 PWM Amplifier................................................................................. 14-36
14.11.2 SERVOPACK Configuration ......................................................................... 14-36
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DX100 Contents
14.12 Universal I/O Signal Assignment ............................................................................... 14-41
14.12.1 Arc Welding .................................................................................................. 14-41
14.12.2 Handling ....................................................................................................... 14-47
14.12.3 General Application ...................................................................................... 14-53
14.12.4 Spot Welding ................................................................................................ 14-59
14.12.5 JANCD-YEW01-E Circuit Board (Standard)................................................. 14-67

14.12.5.1 Arc Welding ..................................................................................... 14-67
xv
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
• Teaching maintenance of the robot must conform to:
– Industrial Safety and Health Law
– Enforcement Order of Industrial Safety and Health Law
– Ordinance of Industrial Safety and Health Law
Other related laws are:
– Occupational Safety and Health Act in USA
– Factory Act (Gewerbeordnung) in Germany
– Health and Safety at Work, etc. Act in UK
– EC Machinery Directive 98/37/EC
• Prepare
– SAFETY WORK REGULATIONS
based on concrete policies for safety management complying with
related laws.
• Observe the
– MANIPULATING INDUSTRIAL ROBOTS-SAFETY (ISO 10218)
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
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
• It is important to have and be familiar with all manuals concerning
the MOTOMAN.
You should have the four manuals listed below:
– MOTOMAN- INSTRUCTIONS
– DX100 INSTRUCTIONS
– DX100 OPERATOR’S MANUAL
Confirm that you have all these manuals on hand.
If any manuals are missing, contact your salesman from YASKAWA’s
local branch office.
The relevant telephone numbers are listed on the back cover.
1-2
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.
Failure to observe these cautions may result in fire, electric shock, or
injury due to contact with the manipulator and other equipment.
• Strictly observe the following items:
– Always wear approved work clothes (no loose-fitting clothes).
– Do not wear gloves when operating the MOTOMAN.
– Do not allow underwear, shirts, or neckties to hang out from the
work clothes.
– Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety
shoes (with slip-proof soles), face shields, safety glasses, and gloves
as necessary.
Improper clothing may result in injury.
• Unauthorized persons should not approach the manipulator or
associated peripheral equipment.
Failure to observe this caution may result in injury due to contact with
DX100, controller, the workpiece, the positioner, etc.
1-3
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.
• Never lean on DX100 or other controllers, and avoid inadvertently

pushing buttons.
Failure to observe this caution may result in injury or damage by
unexpected movement of the manipulator.
• 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
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.
Safeguarding
DX100
Door
1000 mm or more
1000 mm or more 1000 mm or more
P-point maximum envelope

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

codes.
Failure to observe this caution may result in fire or electric shock.
1-5
1 Safety
CAUTION
• Operation of the crane, sling, or forklift should only be performed by
authorized personnel.
Failure to observe this precaution may result in injury or equipment
damage.
MOTOMAN should be lifted with a crane using wire rope threaded
through the shipping bolts and positioners and the body should be lifted
in an upright posture as described in the manipulator instruction
manual.
Failure to observe these precautions may cause the manipulator to turn
downward, potentially causing injury or damage to equipment.
1-6
1 Safety
CAUTION
• 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.
Wire Rope
M16 Eye Bolt
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
3PHASE AC480V 50/60Hz AVERAGE kVA
MAXIMUM RATED CURRENT A DRAWING No.
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.
THE MANIPULATOR AND CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
PROGRAMMING PENDANT
X8 1
Table 1-1: Approx. Weight of DX100

Models Available for Approx.
DX100 Weight (kg)
small capacity:
MA1400, MA1900,
VA1400, MH5, MH5L,
MH6, HP20D, HP20D-6 250
middle/large capacity:
MH50,MS80,ES165D,
ES200D,VS50,SIA50D
• 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.
1-7
1 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.
500 500 800 500

800 650 500
650
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
1000
DOOR
PROGRAMMING PENDANT
X 8 1
782
890
DX100 Maintenance Area (Unit: mm) DX100 External Dimensions (Unit: mm)
• To ensure safety, be sure to operate the controller from a location

where the manipulator is easily visible.
Operation by unauthorized personnel may result in injury or equipment
damage.
• Install the DX100 outside the safeguarding of the manipulator’s
safety enclosure.
Failure to observe this precaution may result in injury or damage to
equipment resulting from contact with the manipulator.
• Install the manipulator using bolts of the size and type specified for
each MOTOMAN in the MOTOMAN INSTRUCTION MANUAL.
equipment.
1-8
1 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
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
40
12 dia. PROGRAMMING PENDANT
X81
(2 holes)
50
30
30
50
(Unit: mm)
Tapped Holes for
M10 Screws on
the DX100 Side
• Be familiar with the connection diagram before wiring the DX100,

and perform the wiring in accordance with the connection diagram.
There is a danger of equipment damage or injury due to miswiring and
unexpected movement of the equipment.
• 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.
1-9
1 Safety
1.5.2 Work Area Safety

Carelessness contributes to serious accidents in the work area.
To ensure safety, enforce the following precautions:
WARNING
• Install a safeguarding around the manipulator to prevent any
accidental contact with the manipulator while the power is ON.
Post a warning sign stating "Off-limits During Operation" at the
entrance of the enclosure. The gate of the safeguarding must be
equipped with a safety interlock. Be sure the interlock operates
correctly before use.
Failure to observe this caution may result in a serious accident due to
contact with the manipulator.
CAUTION
• Store tools and similar equipment in proper locations outside of the
enclosure.
Tools and loose equipment should not be left on the floor around the
manipulator, DX100, or welding fixture, etc., as injury or damage to
equipment can occur if the manipulator comes in contact with objects or
equipment left in the work area.
1-10
1 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
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O O
F
F
F
F WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
ENERGIZING
PROHIBITED PROGRAMMING PENDANT
X81
PADLOCK
Turning the power ON during tool installation may case electric shock
or injury due to unexpected movement of the manipulator.
• Never exceed the rated capacity of the manipulator (capacity can
be found in the specifications section of the manipulator manual.)
equipment.
• Teach jobs from outside the manipulator’s work area whenever
possible.
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.
1-11
1 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 right of 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
Injury may result from contact with the manipulator if persons enter the
P-point maximum envelope of the manipulator.
Press the emergency stop button immediately if there are problems.

The emergency stop button is located on the right of the programming
pendant.
Emergency Stop Button
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
PROGRAMMING PENDANT
X81
Programming Pendant DX100
1-12
1 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.
MANDATORY
• Persons operating or inspecting the manipulator should be trained
as required by applicable laws and company policies.
• Refer to chapter 1.2 “Special Training” at page 1-2
1-13
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 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.
• When the MOTOMAN is transferred, it is recommended to check
with Yaskawa Engineering Co. which is listed on back cover of this
manual.
Incorrect installation or wiring may result in personal injury and property
damage.
1-14
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.
Failure to observe this precaution may result in injury due to the
manipulator falling down.
1-15
2 Product Confirmation
DX100 2.1 Contents 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
Programming
Pendant DX100
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
PROGRAMMING PENDANT
X81
MOTOMAN
MANUAL
Complete Set of Manuals

Manipulator Cable
2-1
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
ORDER NO. S78796-1
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
PROGRAMMING PENDANT
X81
2-2
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:
• Confirm the weight of the controller before handling, and use a wire
rope with a rating that is greater than the weight of the controller.
• Install eyebolts for handling and confirm they are securely fastened
before hoisting.
3-1
3 Installation
Wire Rope
M16 Eye Bolt
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
PROGRAMMING PENDANT
X8 1
Table 3-1: Approx. Weight of DX100

Models Available for Approx.
DX100 Weight (kg)
small capacity:
MA1400, MA1900,
VA1400, MH5, MH5L,
MH6, HP20D, HP20D-6 250
middle/large capacity:
MH50,MS80,ES165D,
ES200D,VS50,SIA50D
3-2
3 Installation
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.
Protective padding
Tiedown straps
Palette
Forklift
3-3
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.
3-4
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
MAXIMUM WORKING ENVELOPE OF
MANIPULATOR INCLUDING TOOL
OR WORKPIECE END
1000 mm or more
2. Install the controller in a location from which the manipulator is easily

visible.
3. Install the controller in a location from which you can easily inspect it
when the door is open.
500
800
650
DOOR
782
890
4. Install the controller at least 500mm from the nearest wall to allow
maintenance access.
3-5
3 Installation
DX100 3.4 Mounting the Controller
800 650 500
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
1000
PROGRAMMING PENDANT
X81
3.4 Mounting the Controller
CAUTION
• Do not climb on top of the DX100.
Failure to observe this caution could lead to injury or mechanical
failure.
Attach the controller to the floor using user-supplied brackets made

according to the specifications shown below.
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
40
12 dia. PROGRAMMING PENDANT
X81
(2 holes)
50
30
30
50
(Unit: mm)
Tapped Holes for
M10 Screws on
the DX100 Side
NOTE Refer to the Instruction Manual for information on installa-

tion of the manipulator.
3-6
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.
• Power cannot be turned ON unless the door is closed. Interlocks
prevent power from being turned ON.
Failure to observe this caution may result in fire and electric shock.
• Any occurrence during wiring while the DX100 is in the emergency
stop mode is the user’s responsibility. Do an operation check once
the wiring is completed.
failure.
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
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
SAFETY
FIRST
PIPING LEAD
cable channel
4-2
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 as follows:

• With built-in transformer: 240/480/575 VAC at 50/60 Hz
• Without built-in transformer: 200 VAC at 50/60 Hz and 220 VAC at 60
Hz
Fig. 4-2: Input Power Connection
DX100
Fuse
(With built-in transformer) Transformer Fuse Contactor
disconnect switch
3-phase 1KM 2KM
240/480/575 VAC
at 50/60 Hz To SERVOPACK
(Without built-in transformer) N
3-phase
200 VAC at 50/60 Hz Fuse
220 VAC at 60 Hz Noise filter
This circuit is not applied To control
to the DX100 without built-in power supply
transformer. unit
4.2.2 Noise Filter Installation

Insert the three-phase noise filter into the primary station of the non-fuse
breaker filter if you hear noise coming from the power source.
Seal up each cable opening so that dust does not enter.
Fig. 4-3: Connection of Three-Phase Noise Filter
DX100
3-phase Fuse
noise filter Transformer Fuse Contactor
(With built-in transformer) disconnect switch
1KM 2KM
3-phase
240/480/575 VAC To SERVOPACK
at 50/60 Hz
N
(Without built-in transformer)
Fuse
3-phase
Noise filter
200 VAC at 50/60 Hz,
220 VAC at 60 Hz This circuit is not To control
applied to the DX100 power supply
without built-in transformer unit
4-3
4 Connection
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.
For the leakage breakers, select UL-approved products taking into
consideration SCCR (Short Circuit Current Rating.)
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
DX100
Leakage breaker Fuse
disconnect switch Transformer Fuse Contactor
(With built-in transformer) 1KM 2KM
3-phase
240/480/575 VAC To SERVOPACK
at 50/60 Hz
N
(Without built-in transformer)
3-phase Fuse
200 VAC at 50/60 Hz, Noise filter
220 VAC at 60 Hz
This circuit is not To control
applied to the DX100 power supply
without built-in transformer. unit
4-4
4 Connection
4.2.4 Primary Power Supply Breaker/Fuse Installation

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

(Protector) (Protector) (Protector)
Controller Power
DX100
for Positioner Source
Table 4-1: DX100 Power Capacity, Cable Sizes, and Breaker/Fuse Capacities
Manipulator Power Cable size Capacity of breaker/ Capacity of breaker/
capacity (size of terminal) fuse in DX100 fuse in DX100
(kVA) (In case of Cabtyre (With transformer) (Without transformer)
cable (three cores))
(A) (A)
(AWG)
MH5, MH5L 1 12 (M5) 10 15
MH6, 1.5 12 (M5) 10 15
MA1400,
VA1400
HP20D, 2.0 12 (M5) 10 15
HP20D-6,
MA1900
MH50, 4.0 10 (M5) 20 30
MS80
VS50, 5.0 10 (M5) 20 30
ES165D,
ES200D,
SIA50D
Select and utilize the breaker/fuse with appropriate breaking capacity in

consideration of the DX100 power capacity for the manipulator to be used.
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
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
DX100 Back View DX100 Front View Manipulator

Manipulator
Approx mass: Kg
Cable DX100
TYPE
POWER SUPPLY
3PHASE
ERDR-
AC200V
AC220V
INTERRUPT CURRENT
SERIAL No.
50/60Hz
60Hz
PEAK
AVERAGE
kVA
kVA
kA
DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
CHECK ALL THE DOOR LOCKS

PROPERLY.
NJ3005-1
PROGRAMMING PENDANT
X81
Programming
Pendant Cable
Primary Power Supply Cable
4.3.1 Connecting the Primary Power Supply

1. Open the front door of the DX100.
(1) Using a flathead screwdriver, rotate the door locks on the front of
the DX100 (two places) 90 degrees clockwise.
Fig. 4-7: Rotating the Door Lock Clockwise
door lock
clockwise
90
flathead screw driver
4-6
4 Connection
(2) Rotate the main power supply switch to the "OFF" position and
open the door gently.
Fig. 4-8: Rotating the Main Power Supply Switch to the OFF Position
Main power supply switch
(Fuse disconnect switch)
DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
2. Confirm that the primary power supply is OFF.

3. Remove the cover on the upper right side of the back of the DX100.
Run the primary power supply cable from the cable clamp below the
cover. Connect the cable to the terminal block ACINXT.
Connect a ground wire to the terminal block ACINXT to reduce noise
and prevent electric shock.
Fig. 4-9: Details for Running the Primary Power Supply Cable
Terminal block (ACINXT)

Refer to the details of
P2 terminal block (ACINXT)
Cover
Cable clamp
FGA26E-20B+SPR215-B
PG cable (X11)
PW cable (X21)
4-7
4 Connection
Perform grounding in accordance with all relevant local and national

electrical codes. The size of ground wire must the same as listed on
table 4-1 “DX100 Power Capacity, Cable Sizes, and Breaker/Fuse
Capacities” at page 4-5.
NOTE The customer must prepare the ground wire.
Fig. 4-10: Exclusive Grounding
DX100
Exclusive Grounding
100 ohm maximum ground resistance
Don’t connect the grounding wire with the wires for the elec-
tric power source, the welder, etc.
NOTE
Ground in accordance with all relevant governmental regu-
lations when using metallic ducts, metallic conduits, and
cable tray to construct the cable.
4-8
4 Connection
4.3.2 Connecting the Manipulator Cable

1. Remove the package, and take out the manipulator cable. Connect
the cable to the connectors on the back side of DX100.
Fig. 4-11: Connection of the Manipulator Cable
Approx mass: Kg
Manipulator Cable
Primary Power Supply Cable
For more information on connecting the manipulator cable,

NOTE please refer to the Instruction Manual which corresponds to
the particular DX100 model.
2. Connect the manipulator to the DX100.

– Confirm the shape and size of the cable connector, the key fitting,
and the position of the pins of the manipulator. Push the cable
connector into the manipulator side connector firmly, and tighten
securely.
3. Close the DX100 door.
(1) Close the door gently.
(2) Rotate the door locks (two places) 90 degrees counterclockwise.
Fig. 4-12: Rotating the Door Lock Counterclockwise
counterclockwise 90
door lock
(-)screwdriver
4-9
4 Connection
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. 4-13: Connecting the Programming Pendant
Alignment mark
– The manipulator, DX100, and the programming pendant

connections are now complete.
4-10
5 Turning ON and OFF the Power Supply
DX100 5.1 Turning ON the Main 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 button is located on the upper right side of the
programming pendant.
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.
Fig. 5-1: Turning ON the Main Power Supply

DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
MADE IN JAPAN
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
5-1
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

When the power supply is turned OFF, the DX100 saves all condition
data, including:
• Mode of operation
• Called job (active job if the DX100 is in the play mode; edit job if the
DX100 is in the teach mode) and the cursor position in the job.
Fig. 5-3: Initial Window
5-2
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.
5.2.2 During Teach Mode

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

programming pendant lights when the operator grips the Enable
switch.
5-3
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 by the programming pen-

NOTE dant or external signal, the servo power-on operation from
the Enable switch is cancelled. When turning the power
back ON, follow the previously listed instructions.
5-4
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 button is located on the right side of the pro-
gramming 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
5.3.2 Turning OFF the Main Power

After turning OFF the servo power, turn OFF the main power.
• When the main power switch on the front of DX100 is turned to the
“OFF” position, the main power is turned OFF.

DX100
TYPE ERDR-
POWER SUPPLY
PEAK kVA
SCCR KA SERIAL No.
LARGEST LOAD A DATE
MADE IN JAPAN
ON
O
F
F
WARNING
High Voltage
with power ON.

ORDER NO.
NJ1530
5-5
6 Test of Program Operation
DX100
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.
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.
manipulator:
– Always view the manipulator from the front.
• Prior to performing the following operations, be sure that there is no
one within the P-point maximum envelope of the manipulator, and
be sure that you are in a safe place yourself.
– Moving the manipulator with the programming pendant
Injury may result from collision with the manipulator to anyone entering
the P-point maximum envelope of the manipulator.
6-1
DX100 6.1 Movement of the Axes
CAUTION
• Perform the following inspection procedures prior to performing
teaching operations. If problems are found, correct them
been performed.
wires.
• Always return the programming pendant to its specified position
after use.
If the programming pendant is inadvertently left on the manipulator,
during manipulator movement, possibly causing injuries or equipment
damage.
6.1 Movement of the Axes

Move each axis of the manipulator by pressing the axis keys on the
This figure illustrates each axis of motion in the joint coordinates.
Be sure to remove all items from the area before moving the
NOTE manipulator.
Refer to the INSTRUCTION MANUAL for the appropriate
position of the fixture.
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
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
E- E+
6-3
System Up
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 This mode allows the operator to teach and edit jobs and
robot settings.
Management This mode allows those authorized to set up and maintain
Mode robot system: parameters, system time and modifying user
IDs.
7-1
7 Security System
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
POSITION (ROBOT) Operation Edit
POSITION (BASE) Operation Edit
POSITION (ST) Operation Edit
LOCAL VARIABLE Operation -
IN/OUT EXTERNAL INPUT Operation -
EXTERNAL OUTPUT Operation -
UNIVERSAL INPUT Operation Edit
UNIVERSAL OUTPUT Operation Edit
SPECIFIC INPUT Operation -
SPECIFIC OUTPUT Operation -
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
7 Security System

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) Management Management
SHIFT VALUE Operation -
SYSTEM INFO VERSION Operation -
MONITORING TIME Operation Management
ALARM HISTORY Operation Management
I/O MSG HISTORY Operation Management
SECURITY Operation Operation
FD/CF LOAD Edit -
SAVE Operation -
VERIFY Operation -
DELETE Operation -
DEVICE Operation Operation
FOLDER Edit Management
2)
INITIALIZE Operation -
PARAMETER S1CxG Management Management
S2C Management Management
A1P Management Management
RS Management Management
S1E Management Management
7-3
7 Security System

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
WEAVING Operation Edit
4)
ARC MONITOR Operation -
ARC MONITOR (SAMPL) Operation -
HANDLING HANDLING DIAGNOSIS Operation Edit
SPOT WELD DIAGNOSIS Operation Edit
WELDING I/O ALLOCATION Management Management
GUN CONDITION Management Management
CLEARANCE SETTING Operation Edit
POWER SOURCE COND Management Management
SPOT WELD DIAGNOSIS Operation Edit
WELDING GUN PRESSURE Edit Edit
(MOTOR GUN)
PRESSURE 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
7 Security System
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.
2. Select {SECURITY}.
– The selection window of security mode appears.
3. Press [SELECT].
7-5
7 Security System
– Select "SECURITY MODE".
4. Input the user ID.

– The user ID input window appears.
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
7 Security System
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.

2. Select {USER ID}.

– The USER ID window appears.
3. Select the desired ID.
7-7
7 Security System
– 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].

– When the correct user ID is entered, a new ID is requested to be
input. "Input new ID no.(4 to 8 digits)" appears.
5. Input new ID and press [ENTER].

– User ID is changed.
7-8
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.
8-1
8 System Setup
DX100 8.1 Home Position Calibration
8.1 Home Position Calibration
WARNING
goes out when the emergency stop buttons on the right of the front
door of the DX100 and the programming pendant are pressed.
manipulator:
– View the manipulator from the front whenever possible.
– Always prepare your reactions to a manipulator’s unexpected
approach toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
in the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place when:
– Turning ON the DX100 power.
– Operating the manipulator with the programming pendant.
Always press the emergency stop button immediately if there are
problems.
Emergency stop buttons are located on the right of the front door of the
DX100 and the programming pendant.
8-2
8 System Setup
CAUTION
wires.
– Always return the programming pendant to its hook on the
DX100 cabinet after use.
damage.
8.1.1 Home Position Calibration
Teaching and playback are not possible before the comple-

tion of the home position calibration.
NOTE
In a system with two or more manipulators, the home posi-
tion of all the manipulators must be calibrated before start-
ing teaching or playback.
Home position calibration is an operation in which the home position and

absolute encoder position coincide. Although this operation is performed
prior to shipment at the factory, the following cases require this operation
to be performed again.
• Change in the combination of the manipulator and 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
8 System Setup
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
2. Select {HOME POSITION}.

– The HOME POSITIONING window appears.
8-4
8 System Setup
3. Select {DISPLAY} under the menu.

– The pull-down menu appears.
– The same operation as the instruction 3 can also be performed by

selecting {PAGE}, and selection box appears.
4. Select the desired control group.

– Select the control group for HOME POSITIONING.
– The control group can also be selected by pressing page key .
5. Select {EDIT} under the menu.
8-5
8 System Setup
6. Select {SELECT ALL AXES}.

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

– Perform the step 3 and 4 of the “Registering All Axes at One Time”
to select the desired control group.
4. Select the axis to be registered.
8-6
8 System Setup
– Move the cursor to the axis to be registered, and select it.
– A confirmation dialog box appears.
5. Select {YES}.
– Displayed position data of the axis is registered as home position.
When {NO} is selected, the registration will be canceled.
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:
4. Select the absolute data to be registered.
8-7
8 System Setup
– The number can now be entered.
5. Enter the absolute data using the numeric keys.

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

– The sub menu appears
3. Select {DATA} under the main menu.
– The pull-down menu appears
4. Select [CLEAR ALL DATA].
8-8
8 System Setup
5. Select {YES}.
– All absolute data are cleared.
– When {NO} is selected, the registration will be canceled.
8-9
8 System Setup
8.1.3 Home Position of the Robot

In case of VA1400, the home position are as follows.
B-axis center line angle against

U-axis center line (-0°).
U-axis angle against horizontal

line on the ground (-0°).
L-axis angle against vertical

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

NOTE refer to "MANIPULATOR INSTRUCTIONS" for the correct
manipulator model.
8-10
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.
goes out when the emergency stop buttons on the front door of
DX100 and the programming pendant are pressed.
manipulator:
– Ensure that you have a safe place to retreat in case of
emergency.
in the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place when:
– Moving the manipulator with the programming pendant
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
8 System Setup
CAUTION
wires.
• Always return the programming pendant to its hook on the DX100
cabinet after use.
damage.
8.2.1 Purpose of Position Check Operation

If the absolute number of rotation detected at power supply ON does not
match the data stored in the absolute encoder the last time the power
supply was turned OFF, an alarm is issued when the controller power is
turned ON.
There are two possible causes of this alarm:
• Error in the PG system
• The manipulator was moved after the power supply was turned OFF.
If there is an error with the PG system, the manipulator may stall when
playback is started. If the absolute data allowable range error alarm has
occurred, playback and test runs will not function and the position must be
checked.
8-12
8 System Setup
"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 Alarm occurs again
OK
Correct defective axis
• Replace PG system
• Home position calibration
∗ Position checking point
Playback possible
Position Check
After the "OUT OF RANGE (ABSO DATA)" alarm occurs, move to the
second home position using the axis keys and perform the position
confirmation. Playback, 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
8 System Setup
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.
• Regardless of cycle setting, the manipulator stops after
reaching to the step indicated by cursor. Starting the
manipulator again then moves it at the programmed
speed and cycle of the job.
8.2.2 Procedure for the Second Home Position Setting (Check Point)
Apart from the "home position" of the manipulator, the second home
position can be set up as a check point for absolute data. Use the
following steps to set the specified point.
If two or more manipulators or stations are controlled by one controller, the
second home position must be set for each manipulator or station.

8-14
8 System Setup
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.
– When there are two or more group axes, select the group axes to
which the second home position is to be specified.
4. Press the axis keys.

– Move the manipulator to the new second home position.
5. Press [MODIFY], then [ENTER].
– The second home position is changed.
8-15
8 System Setup
8.2.3 Procedure after the Alarm
WARNING
• Be aware of safety hazards when performing the position
confirmation of the specified point.
Abnormality of the PG system may be the cause of the alarm. The
manipulator may operate in an unexpected manner, and there is a risk
of damage to equipment or injury to personnel.
If the "OUT OF RANGE (ABSO DATA)" alarm occurs:

• Reset the alarm;
• Turn ON the servo power;
then confirm the second home position. After the confirmation, if the PG
system is found to be the cause of the alarm, perform the necessary
operation, such as replacing the PG, etc.
The robot current position data when turning main power supply OFF and
ON can be confirmed in “POWER ON/OFF POS" window.
For details on the “POWER ON/OFF POS" window, refer to "

SUPPLE 7.7 Position Data When Power is Turned ON/OFF " in
-MENT
DX100 MAINTENANCE MANUAL.

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
8 System Setup
– When there are two or more group axes, select the group axes to
which the second home position is to be specified.
4. Press [FWD].
– TCP moves to the second home position. The robot moving speed is
set as selected manual speed.
5. Select {DATA} under the menu.
6. Select {CONFIRM POSITION}.
– A message “Home position checked” appears.
– Pulse data of the second home position and current pulse data are
compared. If the compared error is in allowed range, playback
operation can be done.
– If the error is beyond the allowed range, the alarm occurs again.
8-17
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 0
TOOL FILE 63
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 one robot. Use the following parameter to set this function.
-MENT
S2C333: TOOL NO. SWITCHING (1: enabled; 0: disabled)
For more details, refer to “ 8 Parameter ” in DX100 OPERA-
TOR’S MANUAL.
8.3.1.2 Registering Coordinate Data

When the number input operation is used for registering the tool file, input
the TCP of the tool on the flange coordinates.
XF
YF
Tool
TCP
ZF
8-18
8 System Setup
2. Select {TOOL}.
(1) Move the cursor to the number of the desired tool, and press
{SELECT} in the tool list window.
(2) The tool coordinate window of the selected number appears.
– In the tool coordinate window, the tool number can be changed by
pressing the page key or selecting {PAGE} .
– To switch the tool list window and the tool coordinate window, press
{DISPLAY} {LIST} or {DISPLAY} {COORDINATE DATA}.
3. Select the desired tool number.

4. Place the cursor in the part to register the desired coordinate data and
press [SELECT].
– The number is ready to input.
5. Input the coordinate data.
6. Press [ENTER].
8-19
8 System Setup
– The coordinate data is registered.
<Setting Example>
260 mm 260 mm 260 mm
TCP TCP TCP

145 mm
ZF ZF
Tool A Tool B Tool C
In case of Tool A, B
In case of Tool C
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
8-20
8 System Setup
Flange XF
coordinates
YF
ZF
XT
Tool
coordinates YT
ZT

2. Select {TOOL}.
– In the same way as shown in Explanation 2, 3 in
chapter 8.3.1.2 “Registering Coordinate Data” at page 8-18,
display the desired tool coordinate window.
4. Select the desired coordinate axis to modify.
– First, select Rz.
5. Input the tool pose data.
– Input rotation angle around ZF of the flange coordinates.
XF
YF
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.
Ry must be the input rotation angle around Y’F flange coordinates.
X F
ZF
Y F (Y F )
Z F
Ry = 90
8-21
8 System Setup
– Rx must be the input rotation angle around X’F of flange

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

The tool load information includes weight, a center of gravity position, and
moment of inertia at the center of gravity of the tool installed at the flange.
SUPPLE
For more details on the tool load information, refer to
-MENT chapter 8.4.3 “Tool Load Information Setting” at page 8-42.
8-22
8 System Setup
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
XT
YT
YF
Tool
coordinates ZT
8.3.2.2 Setting of Tool Calibration Method

There are three tool calibration methods, which are selected by setting
parameter.
S2C432: Designation of tool calibration method
0: Calibrates only the coordinates.
“Coordinates” calculated from 5 calibration teaching points is
registered in the tool file.
In this case “Tool Posture Data” is all cleared to be 0.00.
1: Calibrates only the posture.
“Tool Posture Data” calculated from the first calibration
teaching point is registered in the tool file.
In this case, “Coordinates” will not be changed. (the prior
value is maintained.)
2: Calibrates the coordinates and the posture.
“Coordinates” calculated from 5 calibration teaching points
and “Tool Posture Data” calculated from the first calibration
teaching point are registered in the tool file.
8-23
8 System Setup
• In case of S2C432=0 (only coordinates is calibrated),

tool posture data is overwritten with 0.
(When the coordinates calculated from tool calibration is
registered in the tool file in which the tool posture data is
already registered, the tool posture data will be deleted.)
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 TC3
TC4
TCP
TC5
Each posture must be arbitrary. Accuracy may decrease when pose

setting is rotated in a constant direction
Teaching for defining posture

The calibration of tool posture data is performed with the first calibration
teaching point (TC1).
Teach TC1 with Z-axis of the desired tool coordinates downward vertically
to the ground. (the Z-axis of the tool coordinates is parallel to the Z-axis of
the base tool and points to the opposite direction.)
Tool posture data is automatically calculated with this TC1 posture.
8-24
8 System Setup
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
In case of calibrating with S2C432=2, teach TC1 with Z-axis

of the desired tool coordinates downward vertically to the
ground. Then teach the other calibration teaching points
(TC2~TC5) with the all tool points meet at the TC1’s tool
point as shown in the figure below.
SUPPLE
-MENT
If teaching in one place as the figure above is impossible
due to the interference of peripheral equipment and so on,
perform calibration of coordinates with S2C432=0 or 2, and
then change to S2C432=1, teach only TC1 in a different
position and register the tool posture data.
• 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
8 System Setup

2. Select {TOOL}.
– 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.
4. Select {UTILITY} under the menu.

5. Select {CALIBRATION}.
8-26
8 System Setup
– The TOOL CALIBRATION window is shown.
6. Select the robot.

(1) Select the robot to calibrate.
(When the robot has already been selected or there is only one of
robot, this operation should not be performed.)
(2) Select “**” in the TOOL CALIBRATION window and select the
robot in the shown selection dialog box.
(3) The robot is set.
7. Select “POSITION.”
– The selection dialog box is shown.
8-27
8 System Setup
(1) Select the teaching point for calibration.
8. Move the manipulator using the axis key.

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

TC1 to TC5 and press [FWD]. The manipulator moves to the set
position.
– If there is a difference between the current position of the
manipulator and the shown position data, “TC ” next to
“POSITION” in the window flashes.
10. Select “COMPLETE.”
8-28
8 System Setup
– 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

Before the calibration of a new tool, clear the robot information and
calibration data.
1. Select {DATA} under the pull-down menu.
2. Select {CLEAR DATA}.
8-29
8 System Setup
– The confirmation dialog box is shown.
3. Select {YES}.
– All data is cleared.
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 8-20 for the operating instructions.
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.
8-30
8 System Setup
Tool center
point
1. Press [COORD].
– Select any coordinate system except “ JOINT” by pressing
[COORD].
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.
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
8-31
8 System Setup
SUPPLE
For details on the TCP fixed operation, see "2.8.1 Motion
-MENT about TCP" in OPERATOR’S MANUAL.
8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity
8.3.3.1 What is the Automatic Measurement of the Tool Load and the Center of Gravity?
With this function, the user can register the load of tool and the position of
the tools center of gravity.
The tool load and the position of it’s center of gravity are measured and
registered in a tool file.
This function can be used where the manipulator is installed

NOTE level on the ground.
For the conditions required for manipulator installation, refer
to chapter 8.4 “ARM Control” at page 8-37.
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
Zero-degree Installation on the Ground
NOTE To correctly measure the tool load or the center of gravity,

remove the cables or wires connected to the tool.
8-32
8 System Setup
2. Select {TOOL}.
– The tool list window appears.
– The tool list window is called up only when the file extension function
is valid.
If the file extension function is invalid, the tool coordinate window appears.

– 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}.
8-33
8 System Setup
– To switch the tool list window and the tool coordinate window, press
{DISPLAY} {LIST} or {DISPLAY} {COORDINATE DATA}.
4. Select {UTILITY} under the menu.
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.
8-34
8 System Setup
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
Second measurement of the T-axis: T-axis home position +60
degrees +4.5 degrees -4.5 degrees
• The speed during measurement automatically changes

to “Medium”.
• During the measurement, “HOME” or “U” blinks on the
screen.
• During the measurement, the [FWD] button has to be
SUPPLE
-MENT kept pressed. If the button is released during the
measurement or if it is released before “ “changes into
“ “, the measurement is aborted and the following
message appears: “Stopped measurement”
• The measurement starts again from the first home
position.
– When all the measurements are completed or when all the

“ “marks have changed into “ “, the measured data appears on the
screen.
8-35
8 System Setup
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.
8-36
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
CAUTION
• Correctly set the robot setup condition.
Make sure to avoid any mistake in setting the unit indication or
specifying positive and negative values. Failure to observe this caution
may lead to improper control of the manipulator, resulting in error
occurrence or short life span of speed reducer.
• Confirm the operation path of robot of each job when modifying
settings.
Set the robot setup condition when setting up the manipulator.
Confirm the operation path of manipulator of each job afterwards when
the setting should be modified after the installation.
Modifying the settings of the ARM control may slightly change the
operation path. To avoid injury or damage to machinery caused by
collision between tool and positioner, make sure to check the operation
path before executing a job.
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
8-37
8 System Setup
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
<Example>
0 degrees -90 degrees +90 degrees 180 degrees
If the robot installation angle is not correctly set, the manipulator cannot be
properly controlled. Therefore, make sure to set the value correctly,
paying special attentions to the direction “+” or “-”.
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.
8-38
8 System Setup
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.
Fig. 8-1: Load on the S-head (Top View)
-X
S axis center
-Y +Y
(X position, Y position)
+X
U-arm payload
Set the weight and the center of gravity position roughly when the
equipment such as the wire supplying motors is installed on U arm.
A standard value is set when shipping from the factory.
Set the weight in “0” if there is no installing equipment on U arm.
WEIGHT (unit: kg)

The weight of the installing load is set here.
Set a little large value though it does not care by a rough value. (Rase to a
unit in each 0.5 to 1kg)
X (From U-Axis), HEIGHT (From U-Axis) (unit: mm)
The center of gravity position of the installing load is set here. It does not
care by a rough value.
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.
8-39
8 System Setup
Fig. 8-2: 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)
NOTE ARM CONTROL window is displayed only when the secu-

rity mode is set in the management mode.
2. Select {ARM CONTROL}.
8-40
8 System Setup
– 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.
4. Select the desired item.

5. Input the value and press [ENTER].
8-41
8 System Setup
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.
8.4.3.1 Tool Load Information

Tool load information includes weight, a center of gravity position, and
moment of inertia at the center of gravity of the tool installed at the flange.
These are registered in the tool file.
XF' Moment of inertia around the Center of Gravity

Ix, Iy, Iz
XF
Ix
YF'
Iy
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.
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.)
8-42
8 System Setup
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.
a value slightly larger than the actual value.
This setting is used to calculate the moment of inertia which loads to each
axis of the manipulator. However, the moment of inertia at the center of
gravity does not need to be set when this data is small enough for the
moment of inertia calculated from weight and the center of gravity
position.
However, the setting is required when the moment of inertia of the tool is
large (as a rough guide, the tool is considered to be large when the tool
size is about more than 2-times the distance between the flange and the
center of gravity).
The size of the tool is not too big. 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.
8-43
8 System Setup
<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
Total Weight
Approx. 6.3 [kg] 100
7.00 [kg] ZF
• The own moment of inertia calculation for hexahedron

and cylinder
The own moment of inertia of hexahedron and cylinder can
be calculated by the next expression when the center of
gravity is at the center.
Refer to the expression when the calculation of the moment
of inertia at the center of gravity.
Z Z
Ly
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]
12 * Unit of Ix, Iy, Iz : [kgxm 2 ]
8-44
8 System Setup
<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.
500 YF
Weight of tool:
Approx. 55 kg.
ZF
250
XF Weight of workpiece:
Approx. 40 kg.
400
1000
Weight: W = 55 + 40 = 95
= approx. 100[kg]
Center of gravity: Position at flange right under 250mm almost
(Xg, Yg, Zg) = (0,0,250)
Moment of inertia at the center of gravity:
The hexahedron of 0.500 x 0.400 x 1.000[m] which encloses the
entire tool + workpiece is assumed.
By the expression to calculate the own moment of inertia of
hexahedron,
Ix = ( Ly2 + Lz2 / 12) * W
= ( (0.4002 + 1.0002) / 12 ) * 100 = 9.667 = approx. 10.000
Iy = ( Lx2 + Lz2 / 12) * W = ( (0.5002 + 0.4002) / 12 ) * 100 = 3.417 =
approx. 3.500
Iz = ( Lx2 + Ly2 / 12) * W = ( (0.5002 + 1.0002) / 12 ) * 100 = 10.417 =
approx. 10.500
8-45
8 System Setup
<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 grav-
ity" for plural mass
The center of gravity position and the moment of inertia at the center of gravity of the
entire tool can be calculated by the weight and the center of gravity position of each
mass when the tool can be thought that the tool consists of two or more big mass like
the twin gun system etc.
1. Divide the tool into some parts as the weight and the center of gravity position can
be roughly presumed. It is not necessary to divide in detail. The tool is
approximated in construction of rough parts.
2. Calculate the weight and the center of gravity position of the each parts on flange
coordinates. It does not care by a rough value. Calculate the own moments of
inertia of the big parts. (If parts are small, it is not necessary to calculate the own
moments of inertia. Refer to above-mentioned supplement: "The own moment of
inertia calculation for hexahedron and cylinder" for how to calculate the own
moment of inertia.)
wi : Weight of the i-th parts [kg]
(xi, yi, zi) : Center of gravity position of the i- th parts
(On flange coordinates) [mm]
Icxi, Icyi, Iczi : Own moments of inertia of the i-th parts [kg*m2]
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}
8-46
8 System Setup
<Example 3>
When there are two or more big mass such as the twin gun system as
shown in the figure below, perform:
1. Set the center of gravity position when the center of gravity position of
the entire tool is roughly understood, and set the moment of inertia at
the center of gravity calculated by approximating the entire tool in the
shape of hexahedron or cylinder. (It is enough in this setting usually.);
or
2. When weight in each mass and the center of gravity position are
understood, the center of gravity position and the moment of inertia at
the center of gravity of the entire tool can be calculated. (Refer to
forementioned supplement column: "How to calculate "Center of
gravity position" and "moment of inertia at the center of gravity" for
plural mass".)
This example shows the calculation with the method 2.
(Top View)
Center of Flange
YF
YF
100
50 150
40
XF
Gun 1
70 XF Gun 2
(Gun 1) (Gun 2)
Gun 1
Weight: w1 = 3 kg Weight: w2 = 6 kg
ZF Center of Gravity: Center of Gravity:
x1 = 100 mm x2 = 100 mm
y1 = 50 mm y2 = -150 mm
Gun 2 z1 = 40 mm z2 = 70 mm
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
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

Tool load information is registered in the tool file.
2. Select {TOOL}.
– The tool coordinate window appears.
– The tool coordinate window appears only when the file extension
function is valid.
– When the file extension function is invalid, the tool list window
appears.
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8 System Setup

(1) Move the cursor to the number of the desired tool, and press
[SELECT] in the tool list window.
(2) The tool coordinate window of the selected number appears.
(3) Select the desired number in the tool coordinate window by press-
ing the page key or clicking on the {PAGE} button.
(4) To switch the tool list window and the tool coordinate window,
press {DISPLAY} {LIST} or {DISPLAY} {COORDINATE
DATA}.
4. Select the desired item to register and input the value.
– The window can be scrolled with the cursor.
– The menu enters the state of a numeric input if the cursor is on the
desired item to register and the [SELECT] is pressed.
5. Press [ENTER].
– The input value is registered.
– The servo power is automatically turned OFF when editing the value
while the servo power is ON, followed by a message "Servo off by
changing data" displayed for three seconds.
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8 System Setup
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 suffi-
ciently exert its function, (speed and acceleration / deceleration). Especially, when oper-
NOTE ating 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 manipu-
lator motion: it is therefore essential to correctly set the tool load information for the
proper operation of the manipulator.
Moreover, when the tool which an actual tool center of gravity position greatly offsets in
X-direction or Y-direction is installed the generated moment by the tool cannot be com-
pensated.
• Switch of the tool file
In case that two or more tool files are used, information on an effective tool file is referred
for tool load information used by the ARM control at that time in according to switch tool
file.
Set the same value of tool load information in each tool file when the tool file is switched
to change only TCP (when neither the weight nor the center of gravity position of the
entire tool installed in the flange is changed).
Moreover, set tool load information to the corresponding tool file respectively when total
weight and the center of gravity position etc. of the tool is changed (when the system
which exchange the tool by automatic tool changer).
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8 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

2. Select {WORK HOME POS}.

– The WORK HOME POSITION window is appears.
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8 System Setup
– 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.
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].
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8 System Setup
– New work home position is set.
When the work home position is changed, the cubic interfer-

ence area is automatically set as cube 64 to 57 in the base
coordinate system.
• The cube 64 is for ROBOT1
The work home position cube is a cube like the one shown
in the figure below; the length of its sides is determined by a
NOTE parameter setting made by the user (units: µm).
By changing this parameter setting, the size of the cube can
be changed.
Fig. 8-3: S3C805: The work home position cube length of
its sides (µm)
2
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 sig-
nal’s CHECK MEASURE in the interference area settings.
“COMMAND POSITION” is the default setting.
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 %.)
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8 System Setup
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.
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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.
Robot coordinate
Z-axis
Cubic
interference
area
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
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
Minimum
value
Y-axis
3. After entering the lengths of the three faces of the cube (axial length)
using the Numeric keys, move the manipulator to the center point of
the cube using the axis keys.
Z-axis
Y X
Z X-axis
Center
point
Y-axis
8-56
8 System Setup
8.6.2.3 Setting Operation

2. Select {INTERFERENCE}.
– The INTERFERENCE AREA window is shown.
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
– When selecting the cube number by number input, select {PAGE} to

input the desired signal number.
4. Select “METHOD”.
– ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are
displayed alternately every time [SELECT] is pressed. If “CUBIC
INTERFERENCE” is selected, the window is changed.
5. Select “CONTROL GROUP”.

– A selection dialog box appears. Select the desired control group.
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8 System Setup
6. Select “REF COORDINATES”.

(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.”

– Each time [SELECT] is pressed, “COMMAND POSITION” and
“FEEDBACK POSITION” are displayed alternately.
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
Number Input of the Cube Coordinates

(1) Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS”
switch alternately.
(2) Select “MAX/MIN”.
2. Input number for “MAX” and “MIN” data and press [ENTER].
– The cubic interference area is set.
Teaching Corner
switch alternately.
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8 System Setup
2. Press [MODIFY].
– A message “Teach max./min. position” appears.
3. Move the cursor to “<MAX>” or “<MIN>.”

– Move the cursor to “<MAX>” when changing the maximum value,
and move cursor to “<MIN>” when changing the minimum value.
The cursor only moves to either “<MIN>” or “<MAX>” at this time.
4. Move the manipulator using the axis keys.
– Move the manipulator to the maximum or minimum position of the
cube using the axis keys.
5. Press [ENTER].
– The cubic interference area is registered.
Number Input of the Side of Cube and Teaching Center

switch alternately.
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8 System Setup
(2) Select “CENTER POS”.
2. Input data for length of the cube, then press [ENTER].

– The length is set.
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

– 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.
8.6.3 Axis Interference Area
8.6.3.1 Axis Interference Area

The axis interference area is a function that judges the current position of
the each axis and outputs a signal. Once the maximum and minimum
values have been set at the plus and minus sides of the axis to define the
working range, a signal indicating whether the current position of the axis
is inside or outside this range is output. (ON: inside, OFF: outside)
Fig. 8-4: Axis Interference Signal for Station Axis
Max value Min value
+ side - side
ON
OFF
8.6.3.2 Setting Operation

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8 System Setup
– The INTERFERENCE AREA window appears.
3. Select the desired interference signal number.

– Select the desired interference signal number 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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8 System Setup
– ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are
displayed alternately every time [SELECT] is pressed. Select “AXIS
INTERFERENCE”.
5. Select “CONTROL GROUP”.

– A selection box appears. Select the desired control group.
6. Select “CHECK MEASURE”.

– Each time [SELECT] is pressed, “COMMAND POSITION” and
“FEEDBACK POSITION” switch alternately.
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8 System Setup
Number Input of the Axis Data Coordinates

switch alternately.

2. Input number for “MAX” and “MIN” data and press [ENTER].
– The axis interference area is set.
Teaching Corner
switch alternately.
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8 System Setup
2. Press [MODIFY].
– A message “Teach max./min. position” appears.
3. Move the cursor to “<MAX>” or “<MIN>.”

– Move the cursor to “<MAX>” when changing the maximum value,
and move cursor to “<MIN>” when changing the minimum value.
The cursor only moves to either “<MIN>” or “<MAX>” at this time.
– Move the manipulator to the maximum or minimum position of the
cube using the axis keys.
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8 System Setup
5. Press [ENTER].
– The cubic interference area is registered.
Number Input of Center Position (WIDTH) and Teaching Center

switch alternately.
(2) Select “CENTER POS”.
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8 System Setup
2. Input number for “WIDTH” data and press [ENTER].

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

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

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

– Select the desired interference signal number to be cleared using
the page 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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8 System Setup
4. Select {DATA} under the menu.


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

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
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
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 Shock Detection Level Setting

The shock detection level is set in the shock detection level set file.
The shock detection level set file are nine condition files as following
figure.
• Condition 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.
8-72
8 System Setup
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.
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
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}
{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

2. Select {SHOCK SENS LEVEL}.
– The SHOCK DETECT LEVEL window appears.
– Perform either of the following operations to display the page of
desired condition number:
(1) Select {PAGE} and input the desired condition number, then press
[ENTER].
(2) Press the page key to change the page of condition number.
3. Select the desired condition number.
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
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 8-42 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 modi-
fied. If nothing is specified, the modification is applied to the shock
detection level of the job control group in this instruction. However, in
case of coordinated job, the modification is applied to the shock detec-
tion level of the slave axis group.
Shock Detection Level Condition Number (1 to 7)
Specifies the shock detection level condition number in which the detec-
tion level in playback mode is set.
SHCKRST instruction
The shock detection level changed by the SHCKSET instruction is reset
and returned to the detection level of the standard (value set in condition
number 8) by the SHCKRST instruction.
The additional item of the SHCKRST instruction is as follows.
SHCKRST R1
Robot Setting
Specifies the manipulator of which shock detection level is to be reset.
If nothing is specified, the modification will be applied to the shock
detection level of the job control group of this instruction. However, in
case of coordinated job, the modification is applied to the shock 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
1. Select {JOB} under the main menu.
Instruction
Address
Area
2. Select {JOB}.
3. Move the cursor in the address area.
SHCKSET
1. Move the cursor to the immediately preceding line where the
SHCKSET instruction is to be registered.
2. Press [INFORM LIST].
– The inform list dialog box is shown.
3. Select SHCKSET instruction.

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

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

I) When the value is input with the numeric key, press [SELECT]
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8 System Setup
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.
II) Move the cursor to "UNUSED" of "ROBOT/STATION", and

press [SELECT].
III) The selection box appears.
IV) Point the cursor to the robot to be added and press [SELECT].
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.
SHCKRST
1. Move the cursor to the immediately preceding line where the
SHCKRST instruction is to be registered.
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8 System Setup
2. Press [INFORM LIST].

– The inform list appears.
3. Select SHCKRST instruction.

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

– < When registering the instruction as it is >
Operate the step 5 when registering the instruction in the input
buffer line as it is.
– < When adding or changing the additional item >
(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].
(3) The selection box appears.
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8 System Setup
(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.
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].
– The alarm is reset when “RESET” is selected on the alarm display,
and the shock detection status is released.
2. Operation after resetting the detection status.
– In teach mode, the JOG operation of the manipulator is enabled by
resetting the status.
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8 System Setup
– In the play mode, move the manipulator once to the safety position
in the teach mode to check the damage though the playback
operation is possible after resetting the status.
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
ORG is the home position, and XX is a point on the X-axis. XY is a point

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

accurately.
User Coordinate Files

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

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8 System Setup
8.8.2 User Coordinate Setting
8.8.2.1 Selecting the User Coordinate File

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

– Select the teaching point.
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
– “ “ indicates that teaching is completed and " " indicates that it is

not completed.
– To check the taught positions, call up the required window among

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

1. Select {DATA} under the pull-down menu.
3. Select {YES}.
– All data is cleared.
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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.
2. Select {OVERRUN & S-SENSOR}.
– The OVERRUN & SHOCK SENSOR window appears.
– Select either "EMERGENCY STOP" or "HOLD" to set the item
"SHOCK SENSOR STOP COMMAND" which specifies the stop
condition in the current shock sensor detection.
– “E-STOP” and “HOLD” are displayed alternately every time
[SELECT] is pressed.
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.
After releasing the overrun or tool shock sensor, if “CAN-

NOTE CEL” is selected or the window is changed to the other one,
the release of the overrun or tool shock sensor will be can-
celed.
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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.
2. Select {LIMIT RELEASE}.
– The LIMIT RELEASE window appears.
3. Select “SOFT LIMIT RELEASE”.

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

"Softlimits off released" is displayed for a few seconds.
• 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.
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 Soft limit to check manipulator’s range of motion.
Cube Interference Limit to check cube interference area set by user.
All limit release function is not available if the security mode

NOTE is not in the management mode. Refer to chapter 7 “Secu-
rity System” at page 7-1 for details on the security modes.

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
– When ALL LIMIT RELEASE is changed to “VALID”, a message “All
limits have been released” is displayed. When the setting changes
to “INVALID”, a message “All limits off released” is displayed for a
few seconds.
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8 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
items to be used in each instruction differ in the standard instruction set
and expansion instruction set.
In the standard instruction set, the following functions cannot be used.
However, operation becomes easier because the number of data items
decreases when registering an instruction.
• Use of local variables and arrangement variable
• Use of variables for additional items (Example: MOVJ VJ = I000)
When instructions are executed, for example during playback, all the
instructions can be executed regardless of the instruction set used.
Expanded instruction set

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

Use of variables for additional items
Job calls with arguments
Instruction set
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.
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8 System Setup
1. An instructions are registered.
2. The next time an attempt is made to register the same instruction as in

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

2. Select {TEACHIG COND}.
– The TEACHING CONDITION window appears.
3. Select “LANGUAGE LEVEL”.

– The selection list appears.
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8 System Setup
4. Select desired language level.

– Language level is set.
8.12.3 Setting the Learning Function

The learning function is set at "VALID" by default.
2. Select {TEACHIG COND}.
– The TEACHING CONDITION window appears.
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8 System Setup
3. Select "INSTRUCTION INPUT LEARNING".

– VALID” and “INVALID” are displayed alternately every time
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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.
2. Select {DATE/TIME}.
– The DATE/CLOCK SET window appears.
3. Select “DATE” or “CLOCK.

– ”The input buffer line appears.
4. Input the new date/time.
– For instance, to set the date to August 1, 2008, input "2008.8.1". To
set the time at twelve o’clock, enter "12.00".
5. Press [ENTER].
– 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

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

– When two or more manipulators and stations exist in the system,
use the page key to change the control group, or click on
{PAGE} to select the desired control group.
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.
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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)
8.15.2.1 Key Allocation (EACH)

With key allocation (EACH), the manipulator operates according to the
allocated function when the numeric key is pressed. The allocatable
functions are listed below.
Function Description
Manufacturer Allocated by Yaskawa. Allocating another function
invalidates the function allocated by the manufacturer.
allocation
Instruction Allocates any instructions assigned by the user.
allocation
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.
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.
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.
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8 System Setup
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 Sends the voltage increased by the specified value to the
output allocation specified output port when [INTERLOCK] and the
allocated Numeric key are pressed at the same time.
SUPPLE
In a system for multiple applications, a numeric key can be
-MENT allocated for each application.
8.15.3 Allocating an Operation
8.15.3.1 Allocation Window

2. Select {KEY ALLOCATION}.
– The KEY ALLOCATION (EACH) window appears.
3. Select {DISPLAY}.
– Pull-down menu appears.
– To call up the KEY ALLOCATION (SIM) window, select {ALLOCATE
SIM. KEY}.
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8 System Setup
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.
8.15.3.2 Instruction Allocation

1. Set this function in the KEY ALLOCATION (EACH) window. Move the
cursor to “FUNCTION” of the key to be allocated and press [SELECT].
– Selection list appears.
2. Select “INSTRUCTION”.
– The instruction is shown in the “ALLOCATION CONTENT”.
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8 System Setup
(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.
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.
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8 System Setup
2. Select “JOB CALL”.

– The reserved job registration No. is shown in the “ALLOCATION
CONTENT” (reserved job registration No.: 1 to 10).
(1) To change the reserved job registration No. move the cursor to the
No. and press [SELECT]. Then input buffer line appears.
(2) Input the number to be changed, and press [ENTER].
8.15.3.4 Display Allocation

Set this function in the KEY ALLOCATION (EACH) window.
press [SELECT].
2. Select [DISPLAY].
3. Move the cursor to “ALLOCATION CONTENT” and press [SELECT].
– Character input is available.
4. Input the name of the reserved window and press [ENTER].
– The reserved name input to the “ALLOCATION CONTENT” is
shown.
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8 System Setup
5. Open the window for allocation.

6. Press [INTERLOCK] and the allocated key at the same time.
– A message “Reserved display registered” appears, and the window
is registered.
– In this case, the CURRENT POSITION window is registered by
pressing [INTERLOCK] + [0] with the CURRENT POSITION window
displayed on the screen.
8.15.3.5 Alternate Output Allocation

Set this function in the KEY ALLOCATION (SIM) window.
press [SELECT].
2. Select “ALTERNATE OUTPUT”.
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8 System Setup
– The output No. is displayed in the “ALLOCATION CONTENT”.
(1) To change the output No., move the cursor to the No. and press
[SELECT]. Then numeric value can be entered.
8.15.3.6 Momentary Output Allocation

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

press [SELECT].
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8 System Setup
2. Select “PULSE OUTPUT”.

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

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

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

press [SELECT].
2. Select “ANALOG INC OUTPUT.”
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8 System Setup
– 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].
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
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8 System Setup
1. Allocation of I/O control instruction.

– Allocate the I/O control instruction with key allocation (SIM) following
the forementioned procedure.
2. Move the cursor to the “FUNCTION” of the key that has been allocated
with I/O control with key allocation (SIM) and press [SELECT].

3. Select “OUTPUT CONTROL INST”.
– The instruction corresponding to the I/O control allocated by key
allocation (SIM) is displayed in the “ALLOCATION CONTENT”.
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8 System Setup
– The allocated instruction changes automatically when

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

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

8.15.5.2 Executing the Job Call Allocation

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

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

Alternate output allocation, momentary output allocation, pulse output
allocation, group output allocation (4-bit/8-bit), analog output allocation,
analog incremental output allocation are executed by the following
operation.
1. Press [INTERLOCK] and the key allocated for I/O control allocation at
the same time.
– Allocated functions are executed.
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8 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.
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”.
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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
3. Move the cursor to the desired parameter number.
– When the desired parameter number is not in the current window,

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

(4) The cursor moves to the selected parameter number.
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].
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8 System Setup
(2) To enter a decimal setting, select the decimal figure.

(3) To enter a binary setting, select the binary figure.
2. Enter the value.

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

data in the input buffer line, and press [SELECT].
– Each time [SELECT] is pressed, “0” and “1” alternate in the window.
– “0” or “1” can also be entered with the numeric keys.
3. Press [ENTER].
– The new setting appears in the position where the cursor is located.
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8 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.
5. Select {JOB}.
6. Select {YES}.
– The job data is initialized.
8.18.2 Initializing Data File

simultaneously.
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8 System Setup
5. Select {FILE/GENERAL DATA}.

– The INITIALIZE window appears.
6. Select the data file to be initialized.

– The selected data file/general data are marked with “ “.
– The parameters marked with " " cannot be selected.
7. Press [ENTER].
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8 System Setup
8. Select {YES}.
– The selected data file/general data are initialized.
8.18.3 Initializing Parameter File

simultaneously.
5. Select {PARAMETER}.
– The parameter selection window appears.
6. Select the parameter to be initialized.

– The selected parameter is marked with “ “.
– The parameters marked with " " cannot be selected.
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8 System Setup
7. Press [ENTER].
8. Select {YES}.
– The selected parameter is initialized.
8.18.4 Initializing I/O Data

simultaneously.
5. Select {I/O DATA}.
– The I/O data selection window appears.
6. Select data to be initialized.

– The selected data is marked with “ “.
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8 System Setup
– The I/O data marked with " " cannot be selected.
7. Press [ENTER].
8. Select {YES}.
– The selected data is initialized.
8.18.5 Initializing System Data

simultaneously.
5. Select {SYSTEM DATA}.
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8 System Setup
– The system data selection window appears.
6. Select the parameter to be initialized.

– The selected data is marked with “ “.
– The system data marked with " " cannot be selected
7. Press [ENTER].
8. Select {YES}.
– The selected data is initialized.
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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
8.19.1.2 Settable Font Size

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

To set the font size, first off display the font size setting dialog box as
follows.
1. Select {DISPLAY SETUP} then {CHANGE FONT} under the main
menu.
2. The font size setting dialog box appears on the center of the current
window.
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.
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8 System Setup
• 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.
2. Specify the font size.

– Select a button from the four buttons in the dialog box.
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8 System Setup
3. The font size setting dialog box is closed, and the screen displays the
font specified in the dialog box.
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.
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8 System Setup
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).
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
8.19.2.2 Settable Button Size

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

To set the button size, first off display the button size setting dialog box as
follows.
1. Select {DISPLAY SETUP} then {CHANGE BUTTON} under the main
menu.
– The font size setting dialog box appears on the center of the current
window.
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.
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8 System Setup
2. Specify the font style.

– The {Bold Type} check box can be checked or unchecked
alternately each time the check box is selected.
• Check the {Bold Type} check box as follows to set the font to the bold
style.
• Clear the {Bold Type} check box as follows to set the font to the reg-
ular style.
3. Specify the button size.

– Select a button from the three buttons in the dialog box.
4. The font size setting dialog box is closed, and the screen displays the
buttons specified in the dialog box.
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8 System Setup
– 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.)
To cancel the setting of the button size, follow the procedure below.
1. Select {Cancel} in the button size setting dialog box.
– The dialog box closes without changing the button size.
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8 System Setup
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.
– A confirmation dialog box appears on the center of the current

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

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

1. Select {CANCEL}.
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8 System Setup
– 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).
8.19.4 Layout Storage

The settings of the font or button sizes are saved in the programming
pendant. The screen displays the font/button size specified last time with
the current programming pendant.
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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.
Target Area: All areas of the internally stored data. (Note that the
monitoring time is not loaded.)
9.1.1.2 CMOSBK.BIN
This data is used in the automatic backup function.
Save: Saves with the preset conditions in the normal mode.
Load: Perform for the system restoration in the maintenance mode (the
management mode.)
For details, refer to chapter 9.5 “Error List” at page 9-19.
Target Area: All areas of the internally stored data. (Note that the
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
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>

1 Hagiwara Sys-Com UDG3-GA series (1GB, 2GB)
In order to save the batch data, the following free space per file is needed
in the media.
JZNC-NIF01-1: 18 MByte
Note that the free space for one working file is needed in addition to the
free space for the stored files when using the automatic backup function.
Also, it is recommended to store the backup data in two or more media
cards to minimize problems if the media is damaged.
The water-proof function of the Pendant is not effective

while the USB memory is connected.
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
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
– when USB memory is used instead of CompactFlash, mount the
USB memory and select {DEVICE} → ”USB: PENDANT”
3. Select {FD/PC CARD} under the main menu.
4. Select {SAVE}.
9-3
9 System Backup
– The save display appears.
– The items marked with " " cannot be selected.

5. Select {CMOS SAVE}.
The confirmation dialog box appears.
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
9 System Backup
7. Select {YES}.
– The CMOS.BIN file is overwritten in the CompactFlash.
9.2.2 CMOS.BIN Load

Follow the procedures below to load CMOS.BIN.
2. Change the security mode to the maintenance mode, or 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.
5. Select {LOAD}.
The load display appears.
9-5
9 System Backup
6. Select {CMOS LOAD}.

7. Select {YES}.
– The loaded CMOS.BIN file contents are reflected in the data inside
the robot,
CAUTION
When the {CMOS LOAD} is performed, the current CMOS data is
replaced with the CMOS data (the contents of "CMOS.BIN") in the
CompactFlash. Therefore, before performing the load, make sure to
perform the {CMOS SAVE} of the CMOS data to be loaded.
9-6
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
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.
The teaching operation is one of the factors that changes the internally
stored data. Thus, a mode which backs up the latest data after the
teaching operation is prepared. To confirm the termination of the teaching
operation, check the mode key whether it is changed from teach mode to
play mode.
Other than the teaching operation, the present position of the robot or the
value of a variable can be pointed out as the factors to change the
internally stored data. These data, however, are changed after each
operation and have very little need to be retained permanently.
Accordingly, backing up these data at regular interval should be well
enough to operate and the mode to back up the data at regular interval is
also prepared.
Furthermore, the mode to back up the data when starting up the 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.
9-7
9 System Backup
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 intended timing. Although the
when a specified signal(#40560) is above mentioned items 1 to 3 are
input. designed to back up the data
automatically, this function backs up
the data in accordance with the
instruction from the host.
5 Backup while robot program is Backs up the variables for essential
stopped data.
The backup during playback is
disabled. However, in the play mode,
the backup is enabled if the robot is
stopped. ("Cyclic backup" and
"Backup when inputting specified
signals")
6 Backup and retry at low priority The backup operation hardly affects
The data in memory is backed up at 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.
9-8
9 System Backup
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,
an error message “Cannot backup CompactFlash” appears. At the same
time, the signal “occurrence of error” is output, but the robot program will
not be stopped. Check if CompactFlash is inserted and if it has enough
capacity, and take the necessary actions. If no actions are taken while the
error occurs, the data cannot be saved.
Yaskawa recommends that the data be saved in two or more
CompactFlash to minimize problems if the CompactFlash should be
damaged.
The products in the table below are recommended as Compact Flash for
auto backup.
<Currently recommended products>

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
value is shown when AUTO BACKUP SET display appears.
9-9
9 System Backup
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
• STORED FILE SETTING
With the version in which "STORED FILE SETTING" is set-

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
the setting window and an error may occur if no Compact-
Flash is inserted.
NOTE
When changing the settings of "STORED FILE SETTING"
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.
9-10
9 System Backup
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.
Each time [SELECT] is pressed, "INVALID" and "VALID" are displayed
alternately.
The reserve time can be set by inputting values in B,C and D in the dis-
play.
Every time values are set to these three items, reset the RESERVE
TIME BACKUP to VALID.
If these settings are incorrect, the RESERVE TIME BACKUP cannot be
reset to VALID.
If so, check and then change the values to the correct settings.
B. BASE TIME
Specify the reference time to start reserve time backup.
The time elapsed from the reference time for a BACKUP CYCLE period
is recognized as the BACKUP TIME.
The first automatic backup is performed at the first BACKUP TIME after
the power of the 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
9-11
9 System Backup
to 255, and is shorter than the BACKUP CYCLE.

When it is set to 0, retry will not be performed.
E. MODE CHANGE BACKUP

Set the automatic backup function to be valid or invalid when the mode
is switched from teach mode to play mode.
alternately.
F. STARTUP AUTO BACKUP

Set the backup function to be valid or invalid when the power of the DX
100 is turned ON.
alternately.
G. SPECIFIC INPUT BACKUP

Set the backup function to be valid or invalid when specific input signal
(# 40560) is input (rising edge from 0 to 1).
alternately.
H. UNIV.OUT NO. ON ERROR

Set "1" to the specified user output signal which was specified in this
chapter when the automatic backup error occurs.
The term "automatic backup error" here means that the backup is not
performed successfully before the next backup (including retry opera-
tion) starts.
I. DISPLAY AT EMERGENCY
Set the method of notification of the automatic backup error to
"ERROR" or "MESSAGE."
Each time [SELECT] is pressed, "ERROR" and "MESSAGE" are dis-
played alternately.
J. DURING ALARM OCCURENCE
Set the backup function to be valid or invalid when an alarm is
occurred.
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.
9-12
9 System Backup
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.
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.
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
9-13
9 System Backup
When a Teach mode Editing Error Error

specified (Accessing to
signal(#40560) the memory)
is input When editing is Backup Error
interrupted
Play mode Executing jobs Disabled Disabled
Remote mode When stopped Backup Error
When - Backup Error
switching the
mode from the
teach mode to
the play mode
When the - Backup Error
DX100 starts
up
* 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.
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.
9-14
9 System Backup
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)
Power ON BASE TIME
BACKUP CYCLE
RETRY CYCLE
11:00 11:30 11:40 11:50 12:30 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)
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.
9-15
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.)
4. Select {EX. MEMORY} under the main menu.
5. Select {CompactFlash}.
– The CompactFlash display appears.
9-16
9 System Backup
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.
– 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.
9-17
9 System Backup
8. Select {YES} or {NO} for the message "Exchanged YIF/YCP01

board?"
– The dialog box appears for the loading confirmation.
– Select {YES} in the loading confirmation dialog box to start loading

the contents of "CMOSBK.BIN" or "CMOSBK??.BIN" (?? denotes
figures) from the CompactFlash to the DX100 CMOS.
9. Select {YES}.
CAUTION
Note that executing "SYSTEM RESTORE" replaces the current CMOS
data with the data of the file "CMOSBK.BIN" or "CMOSBK??.BIN" (??
denotes figures) in the CompactFlash.
After "CMOSBK.BIN" has been loaded, check if the new data is the
same as the previously saved data in the CMOS, and call the master
job to confirm that the current manipulator position is correct and safe.
Then, start moving the manipulator.
9-18
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 not
motion. 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
3550 * The automatic backup is The automatic backup window
executed. Try it later. cannot be called to display while
the automatic backup is being
processed.
3551 * The automatic backup is The file arrangement cannot be
executed. Arrange the file after operated during the automatic
it is finished. backup operation.
3560 * Failed to re-arrange the Failed to re-arrange the backup
backup file. file for another reason than the
access to CompactFlash.
3580 * Accessing to backup file. Try it To display another window and
later. then display the automatic
backup window again after
"ARRANGE" operation,
“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.
9-19
10 Upgrade Function
DX100 10.1 Functional Overview
10 Upgrade Function
10.1 Functional Overview

DX100 applies two software 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
software 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.
• In case the versions of YCP01 and YPP01 matches.

1. Automatic upgrade process completes and the communication
process between YCP01 and YPP01is restarted.
10-1
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 application version of YPP01 is not
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)
1. Automatic upgrade process completes and the communication

process between YCP01 and YPP01is restarted.
– Some upgraded software 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.
10-2
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).
• If no recovery is made with all the procedure above,
replace the pendant.
10-3
10 Upgrade Function
DX100 10.3 Error Message
10.3 Error Message

If Error occurs while automatic upgrading, exercise the following
procedure.
• Turn on the main power supply of DX100.

– Automatic upgrade might be exercised again.
• In case error occurs during automatic upgrade process.
(1) Prepare CF for upgrading or USB memory.
(2) Press [2], [8] and [HIGH SPEED] at the same time.
-Upgrade of the OS of Programming Pendant
(3) Press [INTERLOCK], [8] and [SELECT] at the same time.
(4) Exercise manual upgrading.
-Refer to “DX100 Upgrade Procedure” (HW0485193) for detail.
10-4
11 Manual Brake Release Function
DX100 11.1 Operating Conditions of Manual Brake Release

The manual brake release function allows forcible release of each motor
brakes of the manipulator and external axes by programming pendant
operation.
The following operating conditions have to be met before performing the
manual brake release function since this function releases brakes by
software, which is different from the conventional brake release by
hardware.
The manual brake release is an optional function set by parameter.
11.1 Operating Conditions of Manual Brake Release

1. DX100 Status
The DX100 has to be launched correctly*1.
2. Mode: Mode switch on the programming pendant
The function can be used in all modes: Remote / Play / Teach.
3. Security Mode
The function can be used in all modes: Operation / Editing /
Management.
4. Others
• Servo power is OFF
• Emergency stop is OFF (programming pendant, DX100, external
signals)
• Power supply unit circuit board is JANCD-YBK01-2E
If the circuit board JANCD-YBK01-1E is used for any of the axes
in the control group of manipulator, base, or station, the manual
brake release function is not available for the group with an axis
using JANCD-YBK01-1E.
11-1
DX100 11.1 Operating Conditions of Manual Brake Release
*1 Basically, the manual brake release function is available even at alarm

occurrence.
However, the manual brake release function cannot be used if the
communication failure between each boards (YCP01, EAXA01, YIF01,
YSU01) occurs due to board failure, etc.
<Example>
The manual brake release cannot be performed at occurrence of the
alarm 1204 as shown in the following window, since the communica-
tion with the board YIF01 becomes unavailable.
In this case, reset IO modules in Maintenance mode, i.e. separate the
board, then perform the manual brake release.
Fig. 11-1: Alarm Window
If the power supply unit circuit board is JANCD-YBK01-1E and

[MANUAL BRAKE RELEASE] menu is selected, the message
"No axis for Manual Brake Release" is displayed as shown below.
Fig. 11-2: Brake Release Window
11-2
DX100 11.2 Manual Brake Release Operation
11.2 Manual Brake Release Operation

1. Select [ROBOT] under the main menu, then select [MANUAL BRAKE
RELEASE] under the submenu.
– [MANUAL BRAKE RELEASE] is shown under the submenu of the
main menu [ROBOT].
2. Select "YES".
– To avoid careless operation mistake, a warning message appears
when [MANUAL BRAKE RELEASE] menu is selected.
– Select "YES" to display [MANUAL BRAKE RELEASE] window.
– Select "NO" to return to the main menu.
11-3
DX100 11.2 Manual Brake Release Operation
3. Move a cursor to the axis of which the brake is to be released.

– The brake is released by following the operation: Move a cursor to
the axis of which the brake is to be released and press
[INTERLOCK] + [SELECT] while gripping Enable switch. Then the
brake status is shown.
– The brake is locked under one of the following conditions:
• When [SELECT] is released.
Also, see the following CAUTION
• When the emergency stop button on the programming pendant,
DX100 or external device is pressed.
• When Enable switch is released or gripped further.
• When the window is switched from the Manual Brake Release win-
dow to another window.
Fig. 11-3: Manual Brake Release Window
Brake Status: : Brake locked : Brake released
4. Press [INTERLOCK] + [SELECT] while gripping Enable switch.
CAUTION
• Brake can be released by pressing [INTERLOCK] + [SELECT] while
gripping Enable switch.
Note that the brake remains released even though [INTERLOCK] is
released at this time.
11-4
DX100 11.3 Warning Message Display
11.3 Warning Message Display

If the manual brake release is performed under the following conditions,
the warning message appears in the message area bottom right of the
window as shown in fig. 11-2 “Brake Release Window” at page 11-2.
In this case, the brake release cannot be performed.
• Servo power is turned ON.
• Emergency stop button on the programming pendant is pressed.
• Emergency stop button on DX100 is pressed.
• External emergency stop signal is input.
11-5
12 Modification of System Configuration
DX100 12.1 Addition of I/O Modules
12.1 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 sta-
tus setting is possible.

simultaneously.
2. Change the "SECURITY MODE" to the "MANAGEMENT MODE".
3. Select {SYSTEM} under the main menu.
– The system window appears.
4. Select {SETUP}.
– The SETUP window appears.
12-1
DX100 12.1 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.
– The following information is shown for each station.
ST# Station address of I/O module

DI Number of contact input points1)
DO Number of contact output points1)
AI Number of analog input points1)
AO Number of analog output points1)
BOARD Circuit board type2)
1) A hyphen, -, indicates that the corresponding I/O section is not mounted.

2) If the system cannot recognize the circuit board type, a row of stars
(*****) are shown.　No problem will occur as long as the values
displayed in DI, DO, AI, and AO are correct.
7. Press [ENTER].
– Confirm the statuses of the mounted I/O modules for the other
stations.
12-2
DX100 12.2 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
current mounted hardware status. The procedure for the addition of
the I/O module is complete.
If there is a difference between the displayed contents and

NOTE the actual mounted status, confirm the status again. If the
status is correct, the I/O module may be defective: in such a
case, contact your Yaskawa representative.
12.2 Addition of Base and Station Axes

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

SUPPLE
mode.
-MENT In the operation mode or editing mode, only reference of sta-
tus 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.
12-3
• AXIS TYPE
Select from the axis type list.
• In case of TURN-* type
No need to select (The axis type is set as TURN type.)
• In case of RECT-* type
Select BALL-SCREW type or RACK & PINION type.
• In case of UNIV-* type
Select BALL-SCREW type, RACK & PINION type or TURN type.
• MECHANICAL SPECIFICATION
• If axis type is ball-screw type, set the following items:
• MOTION RANGE (+) [mm]
• MOTION RANGE (-) [mm]
• REDUCTION RATIO (numerator)
• REDUCTION RATIO (denominator)
• BALL-SCREW PITCH [mm/r]
• If axis type is rack & pinion type, set the following items.
• MOTION RANGE (+) [mm]
• MOTION RANGE (-) [mm]
• PINION DIAMETER [mm]
• If axis type is turn type, set the following items.

• MOTION RANGE (+) [deg]
• MOTION RANGE (-) [deg]
• OFFSET (1st and 2nd axis) [mm]
• MOTOR SPECIFICATION
Set the following items.
• MOTOR
• SERVO AMP
• CONVERTER
• ROTATION DIRECTION [normal/reverse]
• MAX. RPM [rpm]
• ACCELERATION SPEED [sec]
• INERTIA RATIO
* Select MOTOR, AMPLIFIER and CONVERTER from each type list on the
display.
12-4
12.2.1 Base Axis Setting
12.2.1.1 Selection of Base Axis Type

Select the type of base axis to be added/modified.
simultaneously.
2. Change the "SECURITY MODE" to the "MANAGEMENT MODE".
3. Select {SYSTEM} under the main menu.
– The system window appears.
4. Select {SETUP}.
– The SETUP window appears.
– Note that the items marked with " " cannot be set.
5. Select {CONTROL GROUP}.
12-5
– 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.
RECT-X: traverse X-axis base

RECT-Y: traverse Y-axis base
RECT-Z: traverse Z-axis base
RECT-XZ: traverse XZ-axis base
RECT-XY: traverse XY-axis base
RECT-XYZ: traverse XYZ-axis base
(See the figures on the next page)
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.
12-6
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 RECT-XZ
CARTESIAN
Y-AXIS
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.
12-7
12.2.1.2 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.
2. Select the connection item of desired control group.

– The settable items are displayed.
– When the item is selected, the window returns to the CONNECTION
window.
– 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.
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.
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.
12-8
– 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)

4. Press [ENTER] in the CONNECTION window.
– The setting in the CONNECTION window is completed and the
window moves to the AXES CONFIG window.
12.2.1.3 Axis Configuration Setting

The axis type is specified in the AXES CONFIG window.
1. Confirm axis type of each axis in the AXES CONFIG window.
– The axis type of each axis is displayed.
2. Select the axis type to be modified.
12-9
(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.
3. Press [ENTER] in the AXES CONFIG window.
4. The setting in the AXES CONFIG window is completed and the
window moves to the MECHANICAL SPEC window.
12.2.1.4 Mechanical Specification Setting

The mechanical data is specified in the MECHANICAL SPEC window.
1. Confirm specification of each axis in the MECHANICAL SPEC window.
– The mechanical specification of axis is shown.
The MECHANICAL SPEC window (in case of the BALL-SCREW type)
Selected group, type, axis no.

and axis type are shown.
– MOTION RANGE : Input maximum moving position (positive (+)

direction and negative (-) direction) from
home position when setting the home
position to 0. (Unit: mm)
12-10
– 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)


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
– 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.
12-11
12.2.1.5 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.

– When a numerical value is selected, the number input buffer line
appears.
– When MOTOR (or SERVO AMP or CONVERTER) is selected, the
list window of MOTOR (SERVO AMP, or CONVERTER) appears.
– ROTATION DIRECTION: Set the rotation direction to which the
current position is increased. (The counterclockwise view from the
loaded side is the normal rotation.)
Fig. 12-1: AC Servo Motor
Normal direction
– MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)

– ACCELARATION TIME: Input time between 0.01 and 1.00 to reach
maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
– INERTIA RATIO: The initial value is set at 300 in case of servo track;
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with
the followed procedure.
– <Phenomenon1>
During motion, the axis moves unsteady on advance direction.
Confirm the motion with increasing this ratio in each 100.
12-12
– <Phenomenon2>
During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
4. Press [ENTER] in the MOTOR SPEC window.
manner.
– When [ENTER] is pressed in the MOTOR SPEC window for the last
axis, the setting in the MOTOR SPEC window is completed and the
confirmation dialog box appears.
– If {YES} is selected, the system parameter is set automatically.
12.2.2 Station Axis Setting
12.2.2.1 Selection of Station Axis Type

Select the type of station axis to be added/modified.
1. Confirm the type of control group in CONTROL GROUP window.
– The CONTROL GROUP window appears.
2. Select the type of control group to be modified.
12-13
– 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.
– Select "UNIV" (universal) when using a mechanism other than the
registered type (such as a servo track) as a station axis. When
“UNIV” is selected, interpolation motion (linear, circular, etc.) is not
supported.
TURN-1
STATION 1ST AXIS
12.2.2.2 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.
12-14
– Connection status of each control group is displayed.
the control group which

is set "NONE" in the
CONTROLGROUP
window is not displayed.
2. Select the connection item of desired control group.

– The settable items are displayed.
– When the item is selected, the window returns to the CONNECTION
window.
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.
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.
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),
Converter (CV #2)
2nd SERVO Board (SV #1), Connector (8CN),

axis
Converter (CV #3)

4. Press [ENTER] in the CONNECTION window.
– The setting in the CONNECTION window is completed and the
window moves to the AXES CONFIG window.
12-15
12.2.2.3 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
The AXES CONFIG window (in case of the UNIVERSAL type)
BALL- SCREW: Traverse axis (ball-screw)

RACK&PINION: Traverse axis (rack&pinion)
ROTATION: Rotation axis
2. Select the axis type to be modified.

– The settable axis type is displayed.
12-16
3. Select the desired axis type.

4. Press [ENTER] in the AXES CONFIG window
– The setting in the AXES CONFIG window is completed and the
window moves to the MECHANICAL SPEC window.
12.2.2.4 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.

and axis type are shown
OFFSET is displayed on
the screen of the 1st axis
only when the TURN-2 type
is selected.

direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: deg)
– OFFSET : Offset should be specified at “TURN-2” type
only.
Input length between the center of bending
12-17
axis (1st axis) and the turning table (2nd axis).

(Unit: mm)
TURN-2
STATION 2ND AXIS

(ROTATION TABLE)
OFFSET
STATION 1ST AXIS

(INCLINATION AXIS)
The MECHANICAL SPEC window (In case of the BALL-SCREW type)


home position when setting the home
position to 0. (Unit: mm)
– REDUCTION RATIO : Input the numerator and the denominator.
– BALL-SCREW PITCH: Input the traveling length when the ball-
screw rotates once. (Unit: mm/r)
12-18
The MECHANICAL SPEC window (In case of the RACK&PINION type)


direction and negative (-) direction) from home
position when setting the home position to 0.
(Unit: mm)
<e.g.>If the reduction ratio is 1/120, the
– PINION DIAMETER : Input the diameter of a pinion. (Unit: mm)
The MECHANICAL SPEC window (In case of the ROTATION type)

– MOTION RANGE: Input maximum moving position (positive (+)

direction and negative (-) direction) from home position when setting
the home position to 0. (Unit: deg)
<e.g.> If the reduction ratio is 1/120, the numerator should be set as
1.0 and the denominator should be set as 120.0.
3. Press [ENTER] in the MECHANICAL SPEC window.
manner.When [ENTER] is pressed in the MECHANICAL SPEC
12-19
window for the last axis, the setting in the MECHANICAL SPEC
window is completed and the window moves to the MOTOR SPEC
window.
12.2.2.5 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.
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. 12-2: AC Servo Motor
Normal direction
– MAX. RPM: Input maximum rotation speed of a motor. (Unit: rpm)

– ACCELARATION TIME: Input time between 0.01 and 1.00 to reach
maximum speed from stopping status at 100% JOINT speed.
(Unit: sec)
– INERTIA RATIO: The initial value is set at 300 in case of servo track;
0 in case of rotation axis.
However, if the following phenomenon occurs in motion, deal with
the followed procedure.
12-20
– <Phenomenon1> During motion, the axis moves unsteady on

advance direction.
Confirm the motion with increasing this ratio in each 100.
– <Phenomenon2> During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
CAUTION
If the control axis configuration is changed by addition of a
base axis or station axis, the internal data of the job file are
also changed so that the job file data should be initialized.
Initialize the job file data with procedure “File Initialize” in this
manual after changing the construction.
When the data, motion range for example, should be changed
after the addition of a base axis or station axis, the change can
be done in the same procedure as shown above.
In that case, the control axis configuration is not changed so
the job file data should not be initialized.
12-21
13 DX100 Specification
DX100
WARNING
• When turning ON the power to DX100, be sure that there is no one
within the P-point maximum envelope of the manipulator, and that
you are in a safe place.
the P-point maximum envelope of the manipulator. Always press the
emergency stop button immediately if there are problems.
• Always set the teach lock before starting teaching.
manipulator:
goes out when the emergency stop button on the programming
pendant is pressed.
stopped in case of an emergency. The emergency stop button is
13-1
DX100
CAUTION
• Perform the following inspection procedures prior to performing
teaching operations. If problems are found, correct them
been performed.
wires.
after use.
If the programming pendant is inadvertently left on the manipulator,
damage.
13-2
DX100 13.1 Specification List
13.1 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, 240/480/575 VAC(+10% to -15%)
at 50/60Hz(±2%) (Built-in transformer tap
switchable)
Built-in transformer 240V-480V-575V/208V
(autotransformer - )
* Switch the built-in transformer tap
according to the supplied voltage on your
side. (480 VAC is set before shipment.)
Without a step-down transformer: 3-phase,
200 VAC (+10% to -15%) at 50/ 60Hz
220 VAC (+10% to -15%) at 60Hz
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 By serial communication
(absolute encoder)
Drive Unit SERVOPACK for AC servomotors
Acceleration/ Software servo control
Deceleration
Memory Capacity 200000 steps, 10000 instructions
Common to MA1400, MA1900, VA1400, MH5, MH5L, MH6, HP20D,

small, medium, HP20D-6, MH50, MS80, ES165D, ES200D, VS50, SIA50D
and large 800(W) × 1000(H) × 650(D) mm
capacities
13-3
DX100 13.2 Function List
13.2 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
Control Circuit Board) (Option)
Application Arc welding, Spot welding, Handling,
General, Others
Safety Essential JIS (Japanese Industrial Standard)
Measures
Feature
Running Speed User definable
Limit
Enable Switch 3 position type. Servo power can be
turned on at the middle position only.
(Located on programming pendant)
Collision proof S-axis frame (doughnut-sector), Cubic
Frames frame (user coordinate)
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
13-4
DX100 13.3 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
13.3 Programming Pendant
Material Reinforced thermoplastic enclosure with a detachable

suspending strap
Dimensions 169(W) × 314.5(H) × 50(D) mm (excluding protrusions)
Displayed Units TFT Color liquid crystal display, VGA (640 × 480)
Touch panel
Operated Units Three-position Enable switch, Start switch, Hold switch,
Mode select switch (with key, three mode)
Others Provided with CF (Compact Flash) card slot
USB port (USB1.1) X 1
13-5
DX100 13.4 Equipment Configuration
13.4 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.
13.4.1 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, Fuse (Disconnect Switch), Power Supply Unit
Fig. 13-1: Configuration for Small-Capacity
Disconnect Switch
194RF-NC030R14
Fuse Power Supply Unit
(Refer to the following table)
Backside Duct Fan JZRCR-YPU03-1
4715MS-22T-B50-B00 Regenerative Resistor Interior Circuration Fan
SMRK220W12R5K A5979 A 4715MS-22T-B50-B00
(*for HP20D, HP20D-6:
RDC50N12R5JI800ZZ) WARNING
May cause
electric shock.
Ground the earth terminal
based on local code.
PE
QS1
SERVOPACK
BNL6
BNL6
CU 1 CU 3
Robot I/F Board

O
N O
N
L
Y L
Y
40C
C.B. R
480Y/277V
~
489
20A
FAZ - 20
C /2-NA
(Refer to the
OFF
CU CU
O
N O
N
L
Y 2 L
Y 4
JANCD-YIF01-1E following table)

CPS Unit
JZNC-YPS01-E
CPU Unit
JZNC-YRK01-1E
B
A
1
CN214
CN207
B
A
1
CN213
B
A
1
CN212
FRC5-C50S52T-OLS(D20)
CN216
SAFETY UNIT
CN206
CN202
CN211
CN205
FUSE
JZNC-YSU01-1E
CN210
CN215
CN200 CN201
CN209
CN203 CN204
CN208
Brake Control Board (MXT)

JANCD-YBK01-2E Robot System Input
I/O Unit A Terminal Block
JZNC-YIU01-E
Back View Inside Controller F Door Sectional View A-A’

(without cover) Front View Inside View
Table 13-1: Configuration for Small Capacity

Model SERVOPACK Fuse Power Supply
DX100
Type (Converter integrated) (Disconnect Switch) Contact Unit
MH5 ERDR-MH00005-B00 JZRCR-YSV01-11 ATDR10 JZRCR-YPU03-1
MH5L
MH6 ERDR-MH00006-B00 JZRCR-YSV02-11 ATDR10 JZRCR-YPU03-1
MA1400 ERDR-MA01400-B00 JZRCR-YSV02-11 ATDR10 JZRCR-YPU03-1
VA1400 ERDR-VA01400-B00 JZRCR-YSV02-31 ATDR10 JZRCR-YPU03-1
MA1900 ERDR-MA01900-B00 JZRCR-YSV03-11 ATDR10 JZRCR-YPU03-1
HP20D ERDR-HP0020D-B00 JZRCR-YSV03-11 ATDR10 JZRCR-YPU03-1
HP20D-6
13-6
Medium and Large Capacity

Fig. 13-2: Configuration for Medium and Large Capacity
Disconnect Switch
194RF-NC030R14
Fuse CONVERTER
Backside Duct Fan (Refer to the following table) Power Supply Unit (Refer to the
4715MS-22T-B50-B00 Regenerative Resistor JZRCR-YPU03-1 following table) Interior Circuration Fan
SMVK500W2R0J A5978 (3 resistors) A 4715MS-22T-B50-B00
SERVOPACK
Robot I/F Board (Refer to the
JANCD-YIF01-1E EV1 EV2
following table)
CPS Unit
JZNC-YPS01-E
CPU Unit
JZNC-YRK01-1E
SAFETY UNIT
JZNC-YSU01-1E
Brake Control Board (MXT)
JANCD-YBK01-2E Robot System Input
I/O Unit A Terminal Block
JZNC-YIU01-E
Back View Inside Controller F Door Sectional View A-A’

(without cover) Front View Inside View
Table 13-2(a): Configuration for Medium Capacity

Model Fuse Power Supply
DX100 SERVOPACK Converter
Type (Disconnect Switch) Contact Unit
MH50 ERDR-MH00050-B00 JZRCR- SRDA- ATDR20 JZRCR-YPU03-1
YSV04-11 COA30A01A-E
MS80 ERDR-MS00080-B00 JZRCR- SRDA- ATDR20 JZRCR-YPU03-1
VS50 ERDR-VS00050-B00 JZRCR- SRDA- ATDR20 JZRCR-YPU03-1
SIA50D ERDR-SIA050D-B00 JZRCR- SRDA- ATDR20 JZRCR-YPU03-1
Table 13-2(b): Configuration for Large Capacity

Model Fuse
Power Supply
Type DX100 SERVOPACK Converter (Disconnect Contact Unit
Switch)
ES165D ERDR-ES0165D-B00 JZRCR- SRDA- ATDR20 JZRCR-YPU03-1
ES200D ERDR-ES0200D-B00 JZRCR- SRDA- ATDR20 JZRCR-YPU03-1
13-7
13.4.2 Cooling System of the Controller Interior

The backside duct fan draws in air from the air intake and expels it from
the air outlet to cool the SERVOPACK. The fan mounted inside the door
circulates the air to keep temperature even throughout the interior of the
DX100. Make sure the door of the DX100 is closed when it’s used to keep
this cooling system effective.
Fig. 13-3: .Cooling System
Air Intake
Circuration Fan
Backside Duct Fan
Air Outlet
13-8
14 Description of Units and Circuit Boards
DX100
WARNING
• When turning ON the power to DX100, be sure that there is no one
within the P-point maximum envelope of the manipulator, and that
you are in a safe place.
the P-point maximum envelope of the manipulator. Always press the
emergency stop button immediately if there are problems.
• Always set the teach lock before starting teaching.
manipulator:
goes out when the emergency stop button on the programming
pendant is pressed.
stopped in case of an emergency. The emergency stop button is
14-1
DX100
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 damage to insulation and sheathing of external wires.
after use.
If the programming pendant is inadvertently left on the manipulator or
damage.
14-2
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
-22
024V
CAUTION
• Do not connect two signals to the same contact point.
(Prepare two individual contact points)
• Since the power supply for each signal is reversed, it will 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
14-3
DX100 14.1 Power Supply Contactor Unit
14.1 Power Supply Contactor Unit

The power supply contactor unit consists of the power supply contactor
sequence circuit board (JARCR-YPC01-2) 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 14-1: Power Supply Contactor Unit Models

Model Robot Type
JZRCR- MH5, MH5L, MH6, MA1400, VA1400, MA1900, HP20D,
YPU03-□ HP20D-6, MH50, MS80, VS50, ES165D, ES200D, SIA50D
Fig. 14-1: Power Supply Unit Configuration (JZRCR-YPU03-□)
(1FU),(2FU)
Fuse for AC Control Power (CN601)
Supply ATDR10 (10A 250V) Main Power Supply Input
1FU CN601 2FU

10A600V 10A600V
COULD COULD
FUSE FUSE
JZRCR-YPU03-*
CN611
CN610
CN607
(CN606) Contactor Control Input

CN609
AC Cooling Fan CN601
(CN605,CN604,CN603) SVMX1 SVMX2
AC Control Power Supply CN606

CN608
CN612
(CN608)
CN605
CN604
Brake Interlock Output
CN603
CN602
(CN602)
Converter Output
14-4
DX100 14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
14.2 Major Axes Control Circuit Board (SRDA-EAXA01□)
14.2.1 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. 14-2: Major Axes Control Circuit Board (SRDA-EAXA01□)
(CN510)
Converter Power Supply Output (CN513)
(CN512) Brake Control Signal
SHOCK Signal Input
(CN511)
(CN509) Safety Unit I/F
Control Power Supply Input
(CN508) (CN514)
Encoder Signal Direct-in
(CN507)
Converter Control Signal
(CN518)
I/O Communication
(CN502)
AMP2 PWM Signal
(CN517)
I/O Communication (CN501)
AMP1 PWM Signal
(CN516)
Control Communication (CN504)
AMP4 PWM Signal
(CN515)
AMP3 PWM Signal
(CN506)
AMP6 PWM Signal
(CN505)
AMP5 PWM Signal
14-5
14.2.2 Connection for Tool Shock Sensor (SHOCK)
14.2.2.1 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. 14-3: Direct Connection to Tool Shock Sensor Signal Line
Major Axes Control Circuit Board

SRDA-EAXA01 Manipulator
CN512 TMEDN-630809-FA (NICHIFU)

SHOCK+
Manipulator cable (signal)
-3
+24V
TMEDN-630809-MA
(NICHIFU) Shock sensor
TMEDN-630809-FA (Option)
(NICHIFU)
-4
SHOCK
SHOCK-
TMEDN-630809-MA (NICHIFU) Shock sensor signal cable
14-6
14.2.2.2 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. 14-4: Connection with Manipulator Cable

SRDA-EAXA01 Manipulator
CN512
-1
+24V 2
SHOCK+
-3 TMEDN-630809-FA (NICHIFU)
SHOCK-
Shock sensor
TMEDN-630809-MA (NICHIFU)
(Option)
-4
SHOCK
SHOCK-
TMEDN-630809-MA (NICHIFU) Supply cables (PG) Use the manipulator cable
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.
14-7
14.2.3 Connection for Direct-in
Direct-in (Servo) 1 to 6
This signal is used to input a responsive signal in search functions.
Fig. 14-5: 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
AXINCOM A3 A3
A1 A1
+24V2
Connect the jumper cable.
Slave for the coordinated control side

SRDA-EAXA01D
CN514
B1 B1
024V
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
14-8
DX100 14.3 CPU Unit
14.3 CPU Unit
14.3.1 CPU Unit Configuration

CPU unit consists of circuit board racks, control circuit boards, robot I/F
board. The JZNC-YRK01-1E CPU unit contains only circuit board racks
and control circuit boards. It does not contain robot I/F board.
Fig. 14-6: 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)
(CN106)
USB
(CN105)
PCI Slot X2 For Programming Pendant
CN106
(CN104)
For LAN
CN105
CN104
CN103
(CN103)
Serial Port(RS232C)
Battery
14-9
DX100 14.3 CPU Unit
14.3.2 Unit and Circuit Board in the CPU Unit
14.3.2.1 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).
14.3.2.2 Robot I/F Board (JANCD-YIF01-□E)

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.
14-10
DX100 14.4 CPS Unit (JZNC-YPS01-E)
14.4 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. 14-7: CPS 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
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
CN151
(AC IN)
INPUT
200-240V AC CN152
50/60Hz (REMOTE)
3.4A-2.8A
14-11
DX100 14.4 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 Red Lights when FAN error occurs.
OHT Red Lights when unit interior overheats
Control Power To turn ON the DX100 controller power, turn ON the fuse disconnect switch of the
controller so that the control power supply is turned ON. If the controller is not located
ON/OFF
at the workplace, the control power supply can be turned ON/OFF by an external
device, etc. after the fuse disconnect switch 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)
Fig. 14-8: Connection to Control Power Supply Unit
DX100
CPS Unit
JZNC-YPS01-E Remove the short-circuit positioner
CN152
-1 Control Power Supply ON/OFF Switch
R-IN
-2
R-INCOM
See chapter 14.8 “WAGO Connector” at page 14-22 for wiring of CN152 connector.
14-12
DX100 14.5 Brake Control Board (JANCD-YBK01-2E)
14.5 Brake Control Board (JANCD-YBK01-2E)
14.5.1 Brake Control Board (JANCD-YBK01-2E)

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
(CN402) F1:Fuse
Contactor Interlock Input 3.15 A/250 V
(CN401)
Brake Release Switch Connection
(CN400)
Brake Output
14-13
DX100 14.6 Robot I/O Unit (JZNC-YIU01-E)
14.6 Robot I/O Unit (JZNC-YIU01-E)
14.6.1 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 14.12 “Universal I/O Signal Assignment” at page 14-41
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 14-15 and
“Specific I/O Signal Related to Start and Stop” at page 14-16
Fig. 14-9: I/O Unit (JZNC-YIU01-E)
(CN305)
Power Supply Input
(CN309)
(CN304) Digital I/O
Power Supply Output
D1:24V2IN LED
(CN308)
Digital I/O
(CN303)
For Switching External Power Supply
F1, F2
Power Supply Protective Fuse
3.15 A/250 V
(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
14-14
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 ( )
Connector Model: 1903404-1
(Tyco Electronics Amp)
(MT Type
I/O Unit
(JZNC-YIU01-E)
Connector A
CN309 CN308
I/O Cable (YIU ~ external)
Connector C
CN307 CN306
I/O Cable (YIU ~ Terminal Block)
Connector B
CN306,307,308,309 Connector B details
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: 3.3 mm dia.
Model: TIFS553YS (KASUGA ELECTRIC)
14-15
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
ON
Servo ON OFF
T
ON
External Start OFF T
ON
Operating OFF
T
External Hold ON
OFF
Ext. E-Stop ON
OFF
Note: Set T=100 msec or more
14-16
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.

PL: Pilot Lamp
Example of Start Sequence Circuit from External Device

Only the rising edge of the external start signal is valid. This signal starts
the manipulator. Reset this signal with the interlock configuration that
determines if operation can start and with the playback (RUNNING) signal
confirming that the manipulator has actually started moving.
DX100
While Play mode Alarm/Error Running 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.
14-17
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 14.8 “WAGO
Connector” at page 14-22.
Fig. 14-10: 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
3.15A 3.15A
+24V 024VU (Ready by Customer) +24V 024VU
-3 (+24V) -3 (+24V)
-4 (024V) -4 (024V)
024V 024V
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.
14-18
DX100 14.7 Machine Safety Unit (JZNC-YSU01-1E)
14.7 Machine Safety Unit (JZNC-YSU01-1E)
14.7.1 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)
(CN207) (CN214)
I/F for Machine Safety Unit Contactor Control 1
s (CN213)
B
Contactor Control 2
1
CN214
(CN206)
CN207
A
1
(CN212)
CN213
I/F-IN for Machine Safety Unit

FANALM,FANCTL,LAMP
B
A
1
CN212
CN216
(CN202)
FRC5-C50S52T-OLS(D20)
(CN216)
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
14-19
14.7.2 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 14.8 “WAGO
Connector” at page 14-22
Fig. 14-11: Connection for Servo-ON Enable Input
DX100
Machine safety unit

JZNC-YSU01-1E Remove the jumper cable
CN211
-1 Servo-ON enable input signal
ONEN1_1+
-2
ONEN1_1-
Turn ON/OFF
-3 at the same time
ONEN1_2+
-4
ONEN1_2-
14-20
14.7.3 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 14.8 “WAGO
Connector” at page 14-22.
CAUTION
• Remove jumper cable installed on specific input signal before
connecting the input signal lines.
failure.
Fig. 14-12: Connection for External Axis Overrun
DX100
Machine Safety Unit

JZNC-YSU01-1E Remove the jumper cable
CN211
-9
OT2_1+
-10 External axis overrun

OT2_1-
Turn ON/OFF
OT2_2+
-12
OT2_2-
14-21
DX100 14.8 WAGO Connector
14.8 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
Part A
WAGO connector (e.g. 4 pins type)
Wire
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
14-22
DX100 14.8 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
3. Remove the wiring tool from the connector. (Complete)

Keep this wiring tool for the future use.
14-23
DX100 14.9 Robot Specific Input Terminal Block (MXT)
14.9 Robot Specific Input Terminal Block (MXT)

The robot specific input terminal block (MXT) is equipped at lower part of
the right side of DX100 as shown below. The input terminal block (MXT) is
used for the input of robot system signals.
For connections, refer to connection diagrams for each corresponding
items.
Fig. 14-13: Robot Specific Input Terminal Block (MXT)
BNL6
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
10 11 12 13 14 15 16 17
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
9
8
7
6
5
4
3
2
1
BNL6
MXT EXDSW1- SYSRUN+
34 17
GSOUTFB2-50
EXDSW1+33 16
49
GSOUTFB2+ 32
EXHOLD- 15
GSOUT2-48 31
EXHOLD+ 14
GSOUT2+47 30
EXSVON- 13
GSOUTFB1-46 29SAFF2-12
EXSVON+
45
GSOUTFB1+ SSP-28
SAFF2+
11
(MXT)
GSOUT1-44SSP+ 27SAFF1-10
GSOUT1+43FST2- 26
SAFF1+9
024V2 42
+24V2 41FST2+ 25
GSIN22-8
FST1-24
GSIN22+7
024V2 40FST1+ 23
GSIN21-6
+24V2 39EXESP2-
22
GSIN21+5
024V2 38EXESP2+
21
GSIN12-4
+24V2 37EXESP1-
20
GSIN12+3
EXDSW2-36 EXESP1+
19
GSIN11-2
EXDSW2+35 SYSRUN-
18
GSIN11+1
NJ2959-1
BNL6
BNL6
BNL6
DX100 Inside Right Side
14-24
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)
WAGO series 250 (with 5.0 mm pitch): 9-10 mm
– * Applicable max cable outside diameter: 3.1 mm dia.
L
(2) In case that the conductor is bent or feazed, make it straight as

illustrated in the figure above.
14-25
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.
(2) Insert the wire into the connection hole slowly until its leading end
touches the end of the hole.
For thin wires, never insert the wire with force, or the wire
jacket may get caught in.
(3) Pull out the screwdriver to clamp the conductor with a spring.
(4) Check if the wire is connected firmly by pulling the wire softly.
14-26
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. 14-14: Connection for External Emergency Stop

DX100
Robot system input
JZNC JANCD- terminal block
-YSU01-1E YSF03 MXT Remove the jumper cable
-19
EXESP1+
-20 External emergency stop
EXESP1-
Turn ON/OFF
EXESP2+
-22
EXESP2-
14-27
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
is input.
Fig. 14-15: Connection for Safety Plug
DX100
Robot system input
JZNC JANCD terminal block
-YSU01-1E -YSF03 MXT
Remove the jumper cable
-9
SAFF1+
-10 Safety plug

SAFF1-
Turn ON/OFF
SAFF2+
-12
SAFF2-
14-28
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
Safeguarding
Safety Plug
Emergency
Taked Plug Stop
If the servo power is ON when the interlock signal is input, the servo
power turns OFF. The servo power cannot be turned ON while the
interlock signal is input. However, the servo power does not turn OFF
when the door is opened only during the teach mode. In this case, the
servo power can be turned ON while the interlock signal is input.
14-29
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. 14-16: Connection for Full-speed Test
D X100
Robot system input

Full-speed test
-23
FST1+
-24
FST1-
-25 Turned ON/OFF
FST2+ at the same time
-26
FST2-
14-30
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. 14-17: Connection for Slow Speed Mode Selection
DX100
Robot system input

-27 Slow speed mode selection

SSP+
-28
SSP-
External Servo ON
This signal is used to connect the servo ON switch of an external
operation device.If the signal is input, the servo power supply is turned
ON.
Fig. 14-18: Connection for External Servo ON
DX100
Robot system input

External servo ON
-29
EXSVON+
-30
EXSVON-
14-31
External Hold
This signal is used to connect the temporary stop switch of an external
device. If the signal is input, the job is stopped. While the signal is input,
starting and axis operations are disabled.
CAUTION
is input.
Fig. 14-19: Connection for External Hold

DX100
Robot system input

-31
EXHOLD+
-32 External Hold
EXHOLD-
14-32
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
Injury or damage to machinery may result because the external
emergency stop do not work even if the signal is input.
Fig. 14-20: Connection for External Enable Switch

DX100
Robot system input

-YSU01-1E -YSF03 MXT Remove the jumper cable
-33
EXDSW1+
-34 External Enable Switch
EXDSW1-
Turned ON/OFF
-35
at the same time
EXDSW2+
-36
EXDSW2-
14-33
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
Used to reset the slow speed limit for the test run
in the teach mode.
FST2+ -25
If this signal input circuit is short-circuited, the
FST2- -26
speed of the test run becomes 100% in the teach
mode.
If this signal’s circuit is open, the status SSP
input signal determines the safety speed: The
first slow speed (16%) or second slow speed
(2%).
SSP+ -27 - Slow Speed Mode Selection Short-circuit with a
SSP- -28 Used to determine the speed of the test run when jumper cable
the FST (full-speed test) signal input circuit is
open.
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
14-34
DX100 14.10 Contact Output of Emergency Stop Button
14.10 Contact Output of Emergency Stop Button

The contact output terminals for the emergency stop button on the
programming pendant is provided on the terminal block 2XT (screw size
M3.5) at lower part of the right side of DX100.
This contact output is always valid no matter whether the DX100 main
power supply status is ON or OFF. (Status output signal: normally closed
contact)
CAUTION
• Do not use the emergency stop button with 24 VAC, 0.5 A or more.
Failure to observe this instruction may result in damage to equipment.
Fig. 14-21: Contact Output Terminal Block of Emergency Button (2XT)

2XT EXT
Programming pendant
Emergency stop button
PPESP3+
PPESP3+
PPESP3−
PPESP3−
PPESP4+
PPESP4+
PPESP4−
PPESP4−
14-35
DX100 14.11 SERVOPACK
14.11 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.”)
14.11.1 Description of Each Unit
14.11.1.1 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.
14.11.1.2 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.
14.11.2 SERVOPACK Configuration
Table 14-2:
Configuration Device MH5/MH5L MH6 MA1400 VA1400
Model Model Model Model
SERVOPACK JZRCR-YSV01-11 JZRCR-YSV02-11 JZRCR-YSV02-11 JZRCR-YSV02-31
Converter SRDA- SRDA- SRDA- SRDA-
COA12A01A-E COA12A01A-E COA12A01A-E COA12A01A-E
PWM S SRDA- SRDA- SRDA- SRDA-
Amplifier SDA14A01A-E SDA14A01A-E SDA14A01A-E SDA14A01A-E
L SRDA- SRDA- SRDA- SRDA-
SDA14A01A-E SDA14A01A-E SDA14A01A-E SDA14A01A-E
U SRDA- SRDA- SRDA- SRDA-
R SRDA- SRDA- SRDA- SRDA-
B SRDA- SRDA- SRDA- SRDA-
T SRDA- SRDA- SRDA- SRDA-
E SRDA-
SDA14A01A-E
14-36
Table 14-3:
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 14-4:
Configuration Device MH50 MS80 VS50/SIA50D
Model Model Model
Converter SRDA-COA30A01A-E SRDA-COA30A01A-E SRDA-COA30A01A-E
SERVOPACK JZRCR-YSV04-11 JZRCR-YSV05-11 JZRCR-YSV05-41
PWM S SRDA-SDA71A01A-E SRDA-SDA71A01A-E SRDA-SDA71A01A-E
Amplifier L SRDA-SDA71A01A-E SRDA-SDA71A01A-E SRDA-SDA71A01A-E
U SRDA-SDA35A01A-E SRDA-SDA71A01A-E SRDA-SDA71A01A-E
R SRDA-SDA14A01A-E SRDA-SDA14A01A-E SRDA-SDA14A01A-E
B SRDA-SDA14A01A-E SRDA-SDA14A01A-E SRDA-SDA14A01A-E
T SRDA-SDA14A01A-E SRDA-SDA14A01A-E SRDA-SDA14A01A-E
E SRDA-SDA71A01A-E
Table 14-5:
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
14-37
Fig. 14-22: SERVOPACK Configuration for MH5, MH5L, MH6, MA1400,

MA1900, HP20D, HP20D-6
(CN551)
Monitor Alarm
Display LED (CN552A) Converter
(CN553) Control Power Supply
Converter Control Signal Output for 6-Axis Amplifier (CN552B)
(CN554) Control Power Supply Output (AMP1,3,5-CN583) (AMP2,4,6-CN583)
Grounding Detection Input for External Axis Amplifier Amplifier Main Circuit Amplifier Main Circuit
Power Supply Power Supply
Ground Terminal (CN556)
(CN557) Main Circuit Power Supply Output
Regenerative Resister for 6-Axis Amplifier
(CN555) Charge Lamp
Main Circuit Power (AMP1,3,5-CN581)
Supply Input (CN558) PWM Signal (AMP2,4,6-CN584)
Main Circuit Power Supply Output Motor Power Output
EAXA Base Fixing
Screw (top) for External Axis Amplifier
(CN512) EAXA Base Fixing Screw (top) AMP1
SHOCK Signal Input EAXA Board
AMP2
(CN509) (CN511)
Control Power Supply Input Safety Unit I/O AMP3
(CN508) (CN513)
Encoder Signal Brake Control Signal AMP4
(CN518) (CN514)
I/O Communication Direct-in AMP5 AMP6
(CN517) (CN507)
I/O Communication Converter Control Signal
(CN516) (CN502)
Control Communication AMP2 PWM Signal (AMP1,3,5-CN584) (AMP2,4,6-CN581)
Motor Power Output PWM Signal
(CN515) (CN504)
Control Communication AMP4 PWM Signal
(CN506)
EAXA Base AMP6 PWM Signal
AMP5 PWM Signal
EAXA Base Fixing (CN503)
Screw (bottom) (CN501) AMP3 PWM Signal (AMP2,4,6-CN582)
AMP1 PWM Signal (AMP1,3,5-CN582) Amplifier Control
Amplifier Control Power Supply Power Supply
(EAXA Base is closed) (EAXA Base is open)
Fig. 14-23: SERVOPACK Configuration for VA1400
(CN551)
Monitor Alarm Control Power Supply Input
Display LED Converter
(CN552A) (AMP1,3,5,7-CN583)
(CN553)
Control Power Supply (CN552B) Amplifier Main Circuit
(CN554) Output for 6-Axis Amplifier Control Power Supply Output Power Supply (AMP2,4,6-CN583)
for External Axis Amplifier (AMP1,3,5,7-CN581) Amplifier Main Circuit
Grounding Detection Input
(CN556) Main Circuit Power Supply PWM Signal Power Supply
Ground Terminal Output for 6-Axis Amplifier
(CN557)
Regenerative Resister (CN558) Main Circuit Power Supply
Output for External Axis Amplifier
(CN555)
Main Circuit Power Supply Input Charge Lamp
EAXA Base Fixing Screw (top) EAXA Base Fixing Screw (top) (AMP2,4,6-CN584)
(CN513) Motor Power Output
(CN512) Brake Control Signal
SHOCK Signal Input
(CN511) AMP1 AMP2
(CN509) Safety Unit I/O
Control Power Supply Input EAXA Board
(CN508) (CN514)
Encoder Signal AMP3 AMP4
Direct-in
(CN531) (CN507)
PWM Amplifier 7 Signal (back) Converter Control Signal
(CN532) (CN502) AMP5 AMP6
PWM Amplifier 8 Signal (front) AMP2 PWM Signal
(CN517,CN518)
I/O Communication (CN501) (AMP1,3,5,7-CN584)
AMP1 PWM Signal Motor Power Output
(CN533) (AMP2,4,6-CN581)
PWM Amplifier 9 Signal (CN504) AMP7
AMP4 PWM Signal PWM Signal
(CN515,CN516)
AMP6 PWM Signal
EAXA Base
AMP5 PWM Signal
EAXA Base Fixing Screw (bottom)
(CN534) (left) (CN503)
(CN535) (middle) AMP3 PWM Signal (AMP2,4,6-CN582)
(CN536) (right) (AMP1,3,5,7-CN582) Amplifier Control
Encoder Signal Amplifier Control Power Supply Power Supply
14-38
Fig. 14-24: SERVOPACK Configuration for MH50, MS80

(CN553) Monitor Alarm Display LED (CN551)
I/O Signal Connecting Terminal Control Power Supply
(AMP2,4,6-CN583)
(CN554) Upper Grip (CN552A) (AMP1,3,5-CN583) Amplifier Main Circuit Power Supply
Control Power (CN552B)
Grounding Detection Input Control Power Supply Amplifier Main Circuit (AMP2,4,6-CN582)
Supply Power Supply Amplifier Control Power Supply
Ground Terminal Converter
(CN557)
Charge Lamp
Regenerative Resister
(CN555) (CN556)
Main Circuit Power Main Circuit Power Supply Output
Supply Input (CN558)
(CN510) Main Circuit Output for External Axis
Control Power Supply Upper Grip
Output for Converter
EAXA Base Fixing AMP1
EAXA Base Fixing Screw (top)
Screw (top)
(CN513)
(CN512) Brake Control Signal (AMP1,3,5-CN581) (AMP2,4,6-CN584)
SHOCK Signal Input Motor Power Output
(CN511) PWM Signal
Control Power Supply Input EAXA Board AMP2
(CN508) (CN514) AMP3
Encoder Signal Direct-in
(CN518) (CN507)
I/O Communication Converter Control Signal
AMP4
(CN502)
(CN517) AMP2 PWM Signal
I/O Communication
(CN516) (CN504)
AMP4 PWM Signal AMP5 (AMP2,4,6-CN581)
Control Communication
(CN506) PWM Signal
Control Communication
(AMP1,3,5-CN584) AMP6
EAXA Base Motor Power Output
(CN505)
Ground Terminal AMP5 PWM Signal
EAXA Base Fixing EAXA Base Fixing Screw (bottom)
Screw (bottom) (CN503) (AMP1,3,5-CN582)
AMP3 PWM Signal Amplifier Control
Power Supply
(CN501)
AMP1 PWM Signal
Lower Grip Lower Grip
Fig. 14-25: SERVOPACK Configuration for VS50/SIA50D
Monitor Alarm (CN551)

(CN553) Display LED Control Power Supply (AMP1,3,5,7-CN583) (AMP2,4,6-CN583)
I/O Signal Connecting Terminal (CN552B) Amplifier Main Circuit Power Supply Amplifier Main Circuit Power Supply
Upper Grip (CN552A) Control Power Supply
(CN554) Control Power Supply (AMP1,3,5,7-CN581) (AMP2,4,6-CN582)
Grounding Detection Input PWM Signal Amplifier Control Power Supply
Converter
Ground Terminal Charge Lamp
(CN557)
Regenerative Resister (CN556)
Main Circuit Power Supply Output
(CN555)
Main Circuit Power (CN558)
Supply Input Main Circuit Output for External Axis
(CN510) Upper Grip
Control Power Supply EAXA Base Fixing
Output for Converter Screw (top)
EAXA Base Fixing Screw (top) (CN513)
(CN512) Brake Control Signal AMP1 (AMP2,4,6-CN584)
SHOCK Signal Input (CN511) Motor Power Output
EAXA Board
(CN508) AMP2
Encoder Signal (CN514)
Direct-in AMP3
(CN531) PWM Amplifier 7
Signal (back) (CN507)
(CN532) PWM Amplifier 8
Signal (front) (CN502) AMP4
(CN517,CN518) AMP2 PWM Signal
(CN533) AMP4 PWM Signal AMP5 (AMP2,4,6-CN581)
PWM Amplifier 9 Signal (CN506) PWM Signal
(CN515,CN516) AMP6 PWM Signal
Control Communication (AMP1,3,5,7-CN584)
Motor Power Output AMP6
EAXA Base (CN505)
EAXA Base Fixing EAXA Base Fixing Screw (bottom)
Screw (bottom)
(CN503) AMP7
AMP3 PWM Signal
(CN534) (left) (CN501)
(CN535) (middle) AMP1 PWM Signal
(CN536) (right)
Encoder Signal
(AMP1,3,5,7-CN582)
Lower Grip Amplifier Control Power Supply Lower Grip
14-39
Fig. 14-26: SERVOPACK Configuration for ES165D, ES200D

Monitor Alarm (CN551)
Display LED Control Power Supply
(CN553) (AMP2,4,6-CN583)
I/O Signal Connecting Terminal (CN552B) (AMP1,3,5-CN583) Amplifier Main Circuit Power Supply
Upper Grip (CN552A)
(CN554) Control Power Supply Control Power Supply Amplifier Main Circuit (AMP2,4,6-CN582)
Grounding Detection Input Power Supply Amplifier Control Power Supply
Converter
Charge Lamp
Ground Terminal
(CN556)
(CN557) Main Circuit Power Supply Output
Regenerative Resister
(CN558)
(CN555) Main Circuit Output for External Axis
Main Circuit Power
Supply Input Upper Grip
(CN510) EAXA Base Fixing
Control Power Supply Screw (top)
Output for Converter AMP1
(CN513)
EAXA Base Fixing Brake Control Signal (AMP2,4,6-CN584)
Screw (top) (AMP1,3,5-CN581)
(CN511) Motor Power Output
(CN512) PWM Signal
Safety Unit I/F
SHOCK Signal Input
(CN509) EAXA Board
AMP2
Control Power Supply Input (CN514) AMP3
(CN508) Direct-in
Encoder Signal (CN507)
(CN518) AMP4
AMP4 PWM Signal AMP5 (AMP2,4,6-CN581)
(CN516)
Control Communication PWM Signal
(CN506)
(CN515) AMP6 PWM Signal (AMP1,3,5-CN584)
Control Communication AMP6
EAXA Base (CN505) Motor Power Output

EAXA Base Fixing
Screw (bottom) (CN503) (AMP1,3,5-CN582)
AMP3 PWM Signal Amplifier Control
(CN501) Power Supply
AMP1 PWM Signal
Lower Grip Lower Grip
14-40
DX100 14.12 Universal I/O Signal Assignment
14.12 Universal I/O Signal Assignment
14.12.1 Arc Welding

Fig. 14-27: 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
20021 A5 Prohibited IN A5 A5
20022 B6 Work Prohibited IN B6 B6
20023 A6 Work Response IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30010 B8 Running OUT B8 B8
30011 A8 Servo is ON OUT A8 A8
30012 B9 Top of Master Job OUT B9 B9
30013 A9 Alarm/Error Occurred OUT A9 A9
30014 B10 Battery Alarm OUT B10 B10
30015 A10 Remote Mode Selected OUT A10 A10
30016 B11 Play Mode Selected OUT B11 B11
30017 A11 Teach Mode Selected OUT A11 A11
30020 B12 In Cube 1 OUT B12 B12
30021 A12 In Cube 2 OUT A12 A12
30022 B13 Work Home Position OUT B13 B13
Each Point 30023 A13 Intermediate Start OK
(continuousing Sequence) OUT A13 A13
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 024VU A19
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
14-41
Fig. 14-28: JZNC-YIU01-E (CN309 Connector) I/O Allocation and

DX100
Connector Terminal Converter
Robot I/O Unit (JZNC-YIU01-E) (Optional)
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 B8 B8
30025 A8 Wire Shortage (Monitor) OUT A8 A8
30026 B9 Wire Sticking (Monitor) OUT B9 B9
A9 A9
30027 A9 Arc Shortage (Monitor) OUT
30030 B10 OUT01 User Output OUT B10 B10
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03 OUT B11 B11
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12
30035 A12 OUT06 OUT A12 A12

30036 B13 OUT07 OUT B13 B13
Each Point 30037 A13 OUT08 A13 A13
OUT
24VDC B14 B14
B14
50mA max. A14 A14
A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU
CN303 A16 024VU
Internal A16 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
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-42

DX100
(Optional)
+24VU Model: TIFS553YS
CN306 Connector
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 OUT09 User Input OUT B8 B8
30041 A8 OUT10 OUT A8 A8
30042 B9 OUT11 OUT B9 B9
30043 A9 OUT12 OUT A9 A9
30044 B10 OUT13 OUT B10 B10

30045 A10 OUT14 OUT A10 A10
30046 B11 OUT15 OUT B11 B11
30047 A11 OUT16 OUT A11 A11
B12 B12 B12
A12 A12 A12
Each Point B13 B13 B13

24VDC A13 A13
A13
50mA max. B14 B14
B14
A14 A14
A14
B15 B15 B15
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
+24 VE B19 +24VU
024 VE -2 024VU A19 +24VU
A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-43

DX100
(Optional)
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
A7 024VU A7 024VU
30050 B8 OUT17- OUT B8 B8
A8 OUT17+ OUT A8 A8 RLY
30051 B9 OUT18- OUT B9 B9
A9 OUT18+ A9 A9 RLY
OUT
30052 B10 OUT19- OUT B10 B10

30053 B11 OUT20- OUT B11 B11
30054 B12 OUT21- OUT B12 B12
30055 B13 OUT22- OUT B13 B13

Each Point A13 RLY
A13 OUT22+ OUT A13
24VDC
30056 B14 OUT23- OUT B14 B14
500mA max.
A14 A14 RLY
A14 OUT23+ OUT
OUT B15 B15
30057 B15 OUT24-
B16 024VU B16 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
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-44
Table 14-6: 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
a priority basis. The signal is invalid while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE
The teach mode is selected when the mode key of the programming pendant is set at
"REMOTE". The other mode selection is unavailable when this signal is ON; the
signal is selected by priority even when the other selection signal is ON, enabling the
teach mode selection.
20020 INTERFERENCE 1 ENTRANCE PROHIBITED
If the manipulator attempts to enter the cube 12) area while this signal is ON, the
manipulator goes to wait status (with servo power ON). During wait status, the
manipulator operation restarts if this signal turns OFF.
20022 WORK PROHIBITED (Arc Generation Prohibited)
Arc generation is prohibited while this signal is ON. Arc generation starts when this
signal turns OFF inside the arc-generation area. Use this signal to confirm teaching.
20023 WORK RESPONSE (Pseudo Arc ON Response)
This signal is used as a pseudo signal in cases that “Arc Generation Confirmation”
signal is not equipped on a welding power supply. Wire this signal ON normally (short
to OV).
20026 WEAVING PROHIBITED
Weaving is prohibited while this signal is ON. Use this signal to check taught steps
and movements without performing the weaving operation.
20027 SENSlNG PROHIBITED
Arc sensing is prohibited while this signal is ON. Use this signal to check taught steps
and movements if an arc sensor is mounted.
1 A master job is a job (program) which can be called by CALL MASTER JOB.Other functions are the same as for
normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is
turned ON, is set as the master job.
2 See chapter 8.6 “Interference Area” at page 8-55.
14-45
Table 14-7: 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
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 REMOTE/PLAY/TEACH MODE SELECTED
30017 This signal notifies the current mode setting. These signals are synchronized with the
mode select switch in the programming pendant. The signal corresponding to the
selected mode turns ON.
30020 IN CUBE 1
This signal turns ON when the current TCP lies inside a pre-defined space (Cube 1).
Use this signal to prevent interference with other manipulators and positioners.
30021 IN CUBE 2
30022 WORK HOME POSITION (IN CUBE 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.
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.
14-46
14.12.2 Handling
Connection Diagram (For Handling)
DX100
Model: TIFS553YS
+24VU
CN308 Connector
Logical Connector
Number
24VDC
20011 A1 - IN A1 A1
8mA max.
20012 B2 Call Master Job IN B2 B2
20014 B3 - IN B3 B3
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
A7 024VU A7 024VU
30012 B9 Top of Master Job OUT B9 B9
A9 A9
30013 A9 Alarm/Error Occurred OUT
30014 B10 Battery Alarm OUT B10 B10
30016 B11 Play Mode Selected OUT B11 B11
30017 A11 Teach Mode Selected OUT A11 A11
30020 B12 In Cube 1 OUT B12 B12
30021 A12 In Cube 2 OUT A12 A12

30022 B13 Work Home Position OUT B13 B13
Intermediate Start OK A13 A13
30023 A13 (continuousing Sequence) OUT
Each Point B14 B14
24VDC B14
A14 A14
50mA max. A14
B15 B15 B15
A15 A15 A15

B16 024VU B16 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
B19 +24VU
+24 VE A19 +24VU
024 VE
-2 024VU A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-47

DX100
(Optional)
+24VU
Model: TIFS553YS
CN309 Connector
Logical Connector
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
A7 024VU A7 024VU
30024 B8 - OUT B8 B8
30025 A8 - OUT A8 A8
30026 B9 - OUT B9 B9
- A9 A9
30027 A9 OUT
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03 OUT B11 B11
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12
30035 A12 OUT06 OUT A12 A12

30036 B13 OUT07 OUT B13 B13
30037 A13 OUT08 A13 A13
OUT
Each Point B14 B14
B14
24VDC A14 A14
50mA max. A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU
A16 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
+24 VE B19 +24VU
-2 024VU A19 +24VU
024 VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-48

DX100
(Optional)
CN306 Connector
Logical Connector
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
A7 024VU A7 024VU
30040 B8 OUT09 OUT B8 B8

30041 A8 OUT10 OUT A8 A8
30042 B9 OUT11 OUT B9 B9
30043 A9 OUT12 A9 A9
OUT
30044 B10 OUT13 OUT B10 B10
30045 A10 OUT14 OUT A10 A10
30046 B11 OUT15 OUT B11 B11
30047 A11 OUT16 OUT A11 A11
B12 B12 B12
A12 A12 A12

Each Point B13 B13
B13
24VDC A13 A13
A13
50mA max. B14 B14
B14
A14 A14
A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 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
B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-49

DX100
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
A7 024VU A7 024VU
Hand Value 1-1- OUT B8 B8

30050 B8
Hand Value 1-1+ A8 A8 RLY
A8 OUT
B9 B9
30051 B9 Hand Value 1-2- OUT
A9 A9 RLY
A9 Hand Value 1-2+ OUT
B10 B10
A10 A10 RLY
B11 B11
A11 A11 RLY
B12 B12
A12 A12 RLY
B13 B13
A13 A13 RLY
Each Point A13 Hand Value 3-2+ OUT
B14 B14
24VDC 30056 B14 Hand Value 4-1- OUT
A14 A14 RLY
500mA max. A14 Hand Value 4-1+ OUT
B15 B15
A15 A15 RLY
B16 024VU
B16 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
14-50
Table 14-8: Specific Input (Handling)

Number
is the top of the master job1). This signal is invalid during playback, during teach lock
display).
the alarm or error.
20026 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.
14-51
Table 14-9: Specific Output (Handling)

Number
30010 RUNNING
30011 SERVO IS ON
30014 BATTERY ALARM
30020 IN CUBE 1
30021 IN CUBE 2
Use this signal to evaluate whether the manipulator is in the start position.
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.
14-52
14.12.3 General Application

Connection Diagram (For General Application)
DX100
Model: TIFS553YS
+24VU
CN308 Connector
Logical Connector
Number
24VDC 20011 A1 - IN A1 A1
8mA max. Call Master Job IN B2 B2
20012 B2
20014 B3 - IN B3 B3

Select Teach Mode IN B4 B4
20016 B4
- IN A4 A4
20017 A4
IN B5 B5
20020 B5 Prohibited
B6 B6
20022 B6 Work Prohibited IN
A6 A6
20023 A6 - IN
B7 024VU B7 024VU
A7 024VU A7 024VU

B9 B9
30012 B9 Top of Master Job OUT
A9 A9
OUT B10 B10
30014 B10 Battery Alarm
B11 B11
30016 B11 Play Mode Selected OUT
A11 A11
30017 A11 Teach Mode Selected OUT
B12 B12
30020 B12 In Cube 1 OUT
A12 A12
30021 A12 In Cube 2 OUT
OUT B13 B13
30022 B13 Work Home Position
A13 A13
30023 A13 Intermediate Start OK
(continuousing Sequence) OUT
Each Point B14 B14
B14
24VDC A14 A14
50mA max. A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 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
B19 +24VU
+24 VE 024VU
A19 +24VU
-2 A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-53

DX100
CN309 Connector
Logical Connector
Number
Each Point 20024 B1 Interference3 Entrance
IN
Prohibited B1 B1
24VDC 20025 A1
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
A7 024VU A7 024VU
30024 B8 In Cube 3 OUT B8 B8
30025 A8 In Cube 4 OUT A8 A8
30026 B9 Work Instruction OUT B9 B9
A9 A9
30027 A9 - OUT
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03 OUT B11 B11
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12
30035 A12 OUT06 OUT A12 A12

30036 B13 OUT07 OUT B13 B13
30037 A13 OUT08 A13 A13
Each Point OUT
B14 B14
24VDC B14
A14 A14
50mA max. A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 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
External A18 +24VU
A18 +24VU
B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-54

Connection Diagram (General Application)
DX100
Model: TIFS553YS
+24VU
CN306 Connector
Name Signal
Each Point Number Number Number
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
A8 A8
30041 A8 OUT10 OUT
B9 B9
30042 B9 OUT11 OUT
A9 A9
30043 A9 OUT12 OUT
B10 B10
30044 B10 OUT13 OUT
A10 A10
30045 A10 OUT14 OUT
B11 B11
30046 B11 OUT15 OUT
A11 A11
30047 A11 OUT16 OUT
B12 B12
B12
A12 A12
A12
Each Point B13 B13
B13
24VDC A13 A13
A13
50mA max. B14 B14
B14
A14 A14
A14 B15
B15
B15
A15 A15
A15
B16 024VU
B16 024VU
A16 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
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-55
Fig. 14-38: JZNC-YIU01-E (CN307 Connector ) I/O Allocation and

DX100
Model: TIFS553YS
+24VU
CN306 Connector
Name Signal
Each Point Number Number Number
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
A8 A8
30041 A8 OUT10 OUT
B9 B9
30042 B9 OUT11 OUT
A9 A9
30043 A9 OUT12 OUT
B10 B10
30044 B10 OUT13 OUT
A10 A10
30045 A10 OUT14 OUT
B11 B11
30046 B11 OUT15 OUT
A11 A11
30047 A11 OUT16 OUT
B12 B12
B12
A12 A12
A12
Each Point B13 B13
B13
24VDC A13 A13
A13
50mA max. B14 B14
B14
A14 A14
A14 B15
B15
B15
A15 A15
A15
B16 024VU
B16 024VU
A16 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
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG 024VU
A20
A20 024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-56
Table 14-10: Specific Input (General Application)

Number
is the top of the master job1). This signal is invalid during playback, during teach-lock
display).
the alarm or error.
"REMOTE". The other mode selection is unavailable when this signal is ON; the signal
is selected by priority even when the other selection signal is ON, enabling the teach
mode selection.
20022 WORK PROHIBITED (Tool ON Prohibited)
Even if TOOLON instruction is executed, DX100 doesn’t output to external while this
signal is ON.
1 A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called
up immediately after the power is turned ON, is set as the master job.
14-57
Table 14-11: Specific Output (General Application)

Number
30010 RUNNING
30011 SERVO IS ON
can be used to confirm that the master job has been called.1)*1
30014 BATTERY ALARM
30020 IN CUBE 1
30021 IN CUBE 2
Use this signal to evaluate whether the robot is in the start position.
30024 IN CUBE 3
30025 IN CUBE 4
30026 WORK COMMAND
This signal provides the command for the general tool to operate. TOOL ON
instruction execution or the [TOOL ON] key in the programming pendant turns this
signal ON and TOOL OFF instruction execution or the [TOOL OFF] key in the
programming pendant turns it OFF. However, it remains OFF while the WORK
PROHIBITED signal (2022) is input or while the robot is stopped.
14-58
14.12.4 Spot Welding

Connection Diagram (For Spot Welding)
DX100
(Optional)
CN308 Connector
Logical Connector Signal Terminal
Number Number Name
Number
24VDC 20011 A1 - IN A1 A1
8mA max. 20012 B2 Call Master Job IN B2 B2
20014 B3 - IN B3 B3

Select Teach Mode IN B4 B4
20016 B4
- A4 A4
20017 A4 IN
IN B5 B5
20020 B5 Prohibited
B6 B6
20022 B6 Welding ON/OFF IN
A6 A6
20023 A6 Welding Pause IN
B7 024VU B7 024VU
A7 024VU A7 024VU
Running OUT B8 B8
30010 B8
Servo is ON OUT A8 A8
30011 A8
B9 B9
30012 B9 Top of Master Job OUT
A9 A9
B10 B10
30014 B10 Battery Alarm OUT
A10 A10
30015 A10 Remote Mode Selected OUT
B11 B11
30016 B11 Play Mode Selected OUT
A11 A11
30017 A11 Teach Mode Selected OUT
B12 B12
30020 B12 In Cube 1 OUT
A12 A12
30021 A12 In Cube 2 OUT
B13 B13
30022 B13 Work Home Position OUT
Intermediate Start OK A13 A13
Each Point 30023 A13 (continuousing Sequence) OUT
B14 B14
24VDC B14
A14 A14
50mA max. A14
B15 B15
B15
A15 A15
A15
B16 024VU
B16 024VU
A16 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
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-59

DX100
(Optional)
CN309 Connector
Number Number Name
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
A7 024VU A7 024VU
30024 B8 In Cube 3 OUT B8 B8
30025 A8 In Cube 4 OUT A8 A8

B9 B9
30026 B9 OUT
A9 A9
30027 A9 - OUT
B10 B10
30031 A10 OUT02 OUT A10 A10
OUT B11 B11
30032 B11 OUT03
A11 A11
30033 A11 OUT04 OUT
B12 B12
30034 B12 OUT05 OUT
A12 A12
30035 A12 OUT06 OUT
B13 B13
30036 B13 OUT07 OUT
A13 A13
30037 A13 OUT08 OUT
Each Point B14 B14
24VDC B14
A14 A14
50mA max. A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU

A16 024VU
+24 V B17 024VU
024 V A17 024VU
-4 (24V,1A) A17 024VU
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
+24 VE B19 +24VU
A19 +24VU
024 VE -2 024VU A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-60

DX100
(Optional)
CN306 Connector
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
A7 024VU
B8 B8
30040 B8 OUT17 OUT
A8 A8
30041 A8 OUT18 OUT
B9 B9
30042 B9 OUT19 OUT
A9 A9
30043 A9 OUT20 OUT
B10 B10
30044 B10 OUT21 OUT
A10 A10
30045 A10 OUT22 OUT
B11 B11
30046 B11 OUT23 OUT
A11 A11
30047 A11 OUT24 OUT
B12 B12
B12
A12 A12
A12
B13 B13
B13
A13 A13
Each Point A13
B14 B14
24VDC B14
A14 A14
50mA max. A14
B15
B15
B15
A15 A15
A15
B16 024VU
B16 024VU
A16 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
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
14-61

DX100
(Optional)
+24VU
Model: TIFS553YS
CN307 Connector
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
A7 024VU A7 024VU
30050 B8 OUT B8 B8
Weld ON/OFF (OUT09)*** OUT A8 A8 RLY
A8
B9 B9
30051 B9 OUT
A9 A9
A9 Weld Error Reset (OUT10)** OUT RLY
B10 B10
30052 B10 OUT
A10 Weld Condition 1 (OUT11)** OUT A10 A10 RLY
OUT B11 B11
30053 B11
A11 A11 RLY
A11 Weld Condition 2 (OUT12)** OUT
B12 B12
30054 B12 OUT
A12 A12 RLY
B13 B13
Each Point 30055 B13 OUT
A13 A13 RLY
24VDC A13 Weld Condition 4 (OUT14)** OUT
B14 B14
500mA max. 30056 B14 OUT
A14 A14 RLY
B15 B15
30057 B15 OUT
A15 Tip Change Request (OUT16)** OUT A15 A15 RLY
B16 024VU B16 024VU
CN303 A16 024VU
Internal A16 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 B19 +24VU RLY means
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
** 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
14-62
Table 14-12: Specific Input (Spot Welding) (Sheet 1 of 2)

Number
is the top of the master job1). This signal is invalid during playback, during teach-lock
display).
the alarm or error.
20022 WELDING ON/OFF (From sequencer)
This signal inputs the welding ON/OFF selector switch status from the sequencer in
the interlock unit. The WELD ON/OFF signal is output to the Power Source according
to this signal and the manipulator status.
20023 WELDING PAUSE (From sequencer)
This signal is used to move the manipulator to the home position when an error
occurs in the Power Source or the gun.
The robot ignores the spot welding instruction and operates playback motion.
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.
14-63
Table 14-12: Specific Input (Spot Welding) (Sheet 2 of 2)

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
occurs and the manipulator stops if this signal is input during welding.
4)
GUN FULL OPEN DETECTION
This signal indicates that the stroke of the double stroke gun is full open.
4) GUN SHORT OPEN DETECTION
This signal is connected with a single gun open verification limit switch or a double
stroke gun short open verification limit switch to verify the gun open.
4)
GUN PRESSURE DETECTION
This signal indicates that a gun is in pressing status.
4) TIP REPLACE COMPLETION
When this signal is input after tip replacement, the TIP REPLACE REQUEST signal
turns OFF, and the stored number of welding is cleared.
1 A master job is a job (program) which can be called by CALL MASTER JOB.
Other functions are the same as for normal jobs. Normally, the parent job, which manages the child jobs called
up immediately after the power is turned ON, is set as the master job.
3 This signal can be set as “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is selected, this
signal can be used as the universal I/O signal described in parentheses.
4 This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
Pseudo Input 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)
14-64
Table 14-13: Specific Output (Spot Welding) (Sheet 1 of 2)

Number
30010 RUNNING
30011 SERVO IS ON
30014 BATTERY ALARM
30020 IN CUBE 1
30021 IN CUBE 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.
30024 IN CUBE 3
30025 IN CUBE 4
30050 WELD ON/OFF
3) Outputs a signal input from the interlock panel, etc.considering the robot status.
14-65
Table 14-13: Specific Output (Spot Welding) (Sheet 2 of 2)

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.
3 This signal can be select “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is selected, this
signal can be used as the universal I/O signal described in parentheses.
4 This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
Pseudo Input 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)
14-66
14.12.5 JANCD-YEW01-E Circuit Board (Standard)
14.12.5.1 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
CN322-10 10
A/D +5V CN322-11 CH1 (Voltage Input) IN 11
CN322-12 CH1-G IN 12
DC24V 22552 CN322-13 +ARCOFF (Arc Shortage) IN 13
5mA MAX CN322-14 -ARCOFF (Arc Shortage) IN 14 R
DC24V 32551 CN322-15 ARCON (Arc ON) A OUT 15 K
0.5A MAX CN322-16 ARCON (Arc ON) B OUT 16 L
Power
32552 CN322-17 WIRINCH (Wire Inching) A OUT 17 F
Source
CN322-18 WIRINCH (Wire Inching) B OUT 18 G
32553 CN322-19 WIRINCH (Wire Retract) A OUT 19 H
CN322-20 WIRINCH (Wire Retract) B OUT 20 J
32567 CN322-21 GAS Checking OUT A OUT 21
CN322-22 GAS Checking OUT B OUT 22
CN322-23 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
14-67
DX100 Index
absolute data ........................................................................................ 8-4

absolute encoder ................................................................................... 8-3
AC Servo Motor ....................................................................... 12-12, 12-20
ACCELARATION TIME ............................................................ 12-12, 12-20
acceleration/deceleration...................................................................... 13-3
Addition of Base and Station Axes ........................................................ 12-3
Addition of I/O Modules ........................................................................ 12-1
alarm display ....................................................................................... 13-4
ALARM HISTORY ................................................................................. 7-3
All Limit Release Function .................................................................... 8-89
allocating an operation ......................................................................... 8-99
allocation of I/O control instructions ..................................................... 8-107
allocation window ................................................................................ 8-99
alternate output allocation .......................................................... 8-98, 8-103
ambient temperature ............................................................................ 13-3
analog incremental output allocation............................................ 8-99, 8-106
ANALOG MONITOR .............................................................................. 7-3
analog output allocation ............................................................. 8-99, 8-106
application .......................................................................................... 13-4
ARC SHORTAGE (MONITOR) ........................................................... 14-46
ARM CONTROL .................................................................................... 7-3
ARM control ........................................................................................ 8-37
automatic measurement of the tool load and the center of gravity ............ 8-32
AXES CONFIG window .............................................................. 12-9, 12-16
axis interference area........................................................................... 8-63
Axis keys .............................................................................................. 6-2
BALL-SCREW ................................................................................... 12-10

BALL-SCREW PITCH .............................................................. 12-11, 12-18
base coordinate ................................................................................... 8-55
B-Axis................................................................................................... 6-2
cable junctions ...................................................................................... 4-2

changing the absolute data ..................................................................... 8-7
changing the output status.................................................................. 8-110
changing the parameter setting ........................................................... 8-112
checking the TCP ................................................................................ 8-30
circuit board racks ............................................................................... 14-9
clearing absolute data ............................................................................ 8-8
clearing calibration data ....................................................................... 8-29
clearing the interference area data ........................................................ 8-70
clearing the user coordinates ................................................................ 8-85
collision proof frames ........................................................................... 13-4
COMMAND POSITION .......................................................................... 7-3
connecting the manipulator cable ............................................................ 4-9
connecting the primary power supply ....................................................... 4-6
connecting the programming pendant .................................................... 4-10
connection ............................................................................................ 4-1
construction ........................................................................................ 13-3
contents confirmation ............................................................................. 2-1
control circuit board (JANCD-YCP01-E) ............................................... 14-10
Index-1
DX100 Index
control circuit boards ............................................................................ 14-9

CONTROL GROUP ........................................................................... 12-14
control group ....................................................................................... 12-6
CONVERTER .................................................................................... 12-12
converter ........................................................................................... 14-36
cooling system ..................................................................................... 13-3
coordinate system ................................................................................ 13-4
CPU unit configuration.......................................................................... 14-9
CREATE NEW JOB ............................................................................... 7-2
cube ................................................................................................... 8-56
cube interference ................................................................................. 8-89
cube number ....................................................................................... 8-57
cubic interference area ......................................................................... 8-55
CURRENT POSITION ............................................................................ 7-3
DATE/TIME ........................................................................................... 7-4

definition of the user coordinates ........................................................... 8-81
DELETE................................................................................................ 7-3
detection level (level range:1 to 500)...................................................... 8-74
detection mode .................................................................................... 8-73
DEVICE ................................................................................................ 7-3
digital I/O ............................................................................................ 13-3
dimensions .......................................................................................... 13-3
display allocation ....................................................................... 8-98, 8-102
door interlock ....................................................................................... 13-4
drive unit ............................................................................................. 13-3
DROP AMOUNT .................................................................................... 7-3
E-Axis ................................................................................................... 6-2

editing mode.......................................................................................... 7-1
emergency stop ..................................................................................... 5-5
enable switch ............................................................................... 5-4, 13-4
essential measures .............................................................................. 13-4
executing the display allocation ........................................................... 8-109
executing the I/O control allocation ...................................................... 8-109
executing the instruction/output control allocation.................................. 8-109
executing the job call allocation ........................................................... 8-109
execution of allocation ........................................................................ 8-109
expanded instruction set ....................................................................... 8-91
external emergency stop ................................................ 14-16, 14-27, 14-34
external enable switch .............................................................. 14-33, 14-34
external hold.................................................................. 14-16, 14-32, 14-34
external servo ON .......................................................... 14-16, 14-31, 14-34
external start ..................................................................................... 14-16
eyebolt .................................................................................................. 1-7
FD/CF ................................................................................................... 7-3

file initialization .................................................................................. 8-115
full-speed test .......................................................................... 14-30, 14-34
Index-2
DX100 Index
function list.......................................................................................... 13-4

fuse (disconnect switch) ....................................................................... 13-6
GAS SHORTAGE (MONITOR) ........................................................... 14-46

grounding ..................................................................................... 1-5, 13-3
group (4-bit/8-bit) output allocation ...................................................... 8-105
group output allocation (4-bit/8-bit) ........................................................ 8-99
GRP CONBINATION ............................................................................. 7-4
GUN COOLING WATER ERROR ....................................................... 14-63
GUN FULL OPEN DETECTION .......................................................... 14-64
GUN PRESSURE DETECTION .......................................................... 14-64
GUN SHORT OPEN DETECTION ...................................................... 14-64
HAND VALVE ................................................................................... 14-52

handling procedure ................................................................................ 3-1
HOME POSITION.................................................................................. 7-3
home position ........................................................................................ 8-4
home position calibration ........................................................................ 8-2
home position of the robot .................................................................... 8-10
how to calculate tool load information .................................................... 8-42
I/O diagnosis ....................................................................................... 13-4

I/O instructions .................................................................................... 13-5
I/O modules ........................................................................................ 12-1
I/O MSG HISTORY ................................................................................ 7-3
IN/OUT ................................................................................................. 7-2
inching operation ................................................................................. 13-4
INERTIA RATIO ...................................................................... 12-12, 12-20
initial diagnosis ...................................................................................... 5-2
initializing data file ............................................................................. 8-115
initializing I/O data ............................................................................. 8-118
initializing job file ............................................................................... 8-115
initializing parameter file ..................................................................... 8-117
initializing system data ....................................................................... 8-119
installation and wiring safety ................................................................... 1-5
instruction allocation .................................................................. 8-98, 8-100
instruction level setting ......................................................................... 8-91
instruction of shock detection function ................................................... 8-75
instruction set ...................................................................................... 8-91
interface ............................................................................................. 13-4
INTERFERENCE................................................................................... 7-3
interference area ................................................................................. 8-55
JANCD-YEW01-E circuit board (standard) ........................................... 14-67
Index-3
DX100 Index
JOB ...................................................................................................... 7-2

job call allocation ....................................................................... 8-98, 8-101
JOB CAPACITY ..................................................................................... 7-2
KEY ALLOCATION ................................................................................ 7-4

key allocation (EACH) .......................................................................... 8-98
key allocation (SIM).............................................................................. 8-98
language ............................................................................................. 13-5

L-axis.................................................................................................... 6-2
leakage breaker installation .................................................................... 4-4
learning function .................................................................................. 8-91
lifting the DX100 .................................................................................... 1-7
LIMIT RELEASE .................................................................................... 7-3
limit switch .......................................................................................... 8-88
LOAD ................................................................................................... 7-3
LOW AIR PRESSURE.............................................................. 14-51, 14-64
L-U interference ................................................................................... 8-89
machine lock ....................................................................................... 13-4

major axes control circuit board (SRDA-EAXA01□) ................................. 14-5
management mode ................................................................................ 7-1
MANIPULATOR TYPE ........................................................................... 7-3
manufacturer allocation ........................................................................ 8-98
MASTER JOB ....................................................................................... 7-2
max. disturbance force ......................................................................... 8-74
MAX. RPM .............................................................................. 12-12, 12-20
measurement of the tool load and the center of gravity ............................ 8-32
mechanical limit ................................................................................... 8-89
MECHANICAL SPEC window ............................... 12-10, 12-11, 12-18, 12-19
memory capacity.................................................................................. 13-3
modification of system configuration ...................................................... 12-1
modification of teaching points .............................................................. 13-4
momentary output allocation ....................................................... 8-98, 8-104
MONITORING TIME .............................................................................. 7-3
MOTION RANGE ....................................... 12-10, 12-11, 12-17, 12-18, 12-19
MOTOR ............................................................................................ 12-12
MOTOR SPEC window ...................................................................... 12-12
moving the MOTOMAN ........................................................................ 1-14
noise filter ............................................................................................. 4-3

number of tool files ............................................................................... 8-18
numeric key customize function ............................................................. 8-98
Index-4
DX100 Index
OPERATE COND .................................................................................. 7-4

operating .......................................................................................... 14-16
operation instructions ........................................................................... 13-5
operation mode ..................................................................................... 7-1
operation time display .......................................................................... 13-4
order number ........................................................................................ 2-2
ORG................................................................................................... 8-81
output of the work home position signal ................................................. 8-54
overrun releasing ................................................................................. 8-86
OVERRUN&S-SENSOR ........................................................................ 7-3
PARAMETER ........................................................................................ 7-3

path confirmation ................................................................................. 13-4
PINION DIAMETER ................................................................. 12-11, 12-19
positioning system ............................................................................... 13-3
POWER ON/OFF POS........................................................................... 7-3
power supply ................................................................................. 4-3, 13-3
power supply contactor unit .................................................................. 14-4
power supply unit................................................................................. 13-6
primary power supply breaker/fuse installation ......................................... 4-5
program control instructions.................................................................. 13-5
programming ....................................................................................... 13-5
programming pendant .......................................................................... 13-5
pulse output allocation ............................................................... 8-98, 8-104
PWM amplifier ................................................................................... 14-36
RACK&PINION ................................................................................. 12-10

R-Axis .................................................................................................. 6-2
REDUCTION RATIO............................................ 12-11, 12-17, 12-18, 12-19
registering tool angle............................................................................ 8-20
registering/changing the work home position .......................................... 8-52
relative humidity .................................................................................. 13-3
RES. STARG (CNCT) ............................................................................ 7-4
RES. START (JOB) ............................................................................... 7-2
RES. STATUS....................................................................................... 7-2
RESERVE JOB NAME ........................................................................... 7-4
resetting the shock detected ................................................................. 8-79
returning to the work home position ....................................................... 8-53
ROBOT ................................................................................................ 7-3
robot coordinate .................................................................................. 8-55
robot I/F board..................................................................................... 14-9
robot I/O unit (JZNC-YIU01-E) .................................................. 14-14, 14-15
robot installation angle ......................................................................... 8-38
robot motion control ............................................................................. 13-5
robot programming language (INFORM III) ............................................ 8-91
robot setup condition............................................................................ 8-37
ROTATION DIRECTION .................................................................... 12-20
running speed limit............................................................................... 13-4
Index-5
DX100 Index
safeguarding ......................................................................................... 5-3

safety.................................................................................................... 1-3
safety plug .............................................................................. 14-28, 14-34
SAVE.................................................................................................... 7-3
S-Axis ................................................................................................... 6-2
SECOND HOME POS ............................................................................ 7-3
security mode ........................................................................................ 7-1
security system ...................................................................................... 7-1
SELECT JOB ........................................................................................ 7-2
selecting user coordinates file ............................................................... 8-82
self-diagnosis ...................................................................................... 13-4
SENSOR INPUT ................................................................................ 14-51
SERVO AMP ..................................................................................... 12-12
SERVO MONITOR ................................................................................ 7-3
SERVO ON ................................................................................. 5-3, 14-16
SERVO ON READY ............................................................................... 5-3
servo-ON enable input........................................................................ 14-20
SERVOPACK ............................................................................ 13-6, 14-36
SET SPEED .......................................................................................... 7-4
setting contents ................................................................................... 8-91
setting play speed ................................................................................ 8-96
setting shock detection function ............................................................. 8-72
setting the controller clock .................................................................... 8-95
setting the tool load information ............................................................. 8-22
setting work home position.................................................................... 8-51
SETUP ................................................................................................. 7-4
SHCKRST instruction ........................................................................... 8-75
SHCKSET instruction ................................................................... 8-72, 8-75
S-head payload ................................................................................... 8-38
shock detection function ....................................................................... 8-72
shock sensor ....................................................................................... 14-6
short-cut function ................................................................................. 13-4
slow speed mode selection ....................................................... 14-31, 14-34
soft limit on each axis ........................................................................... 8-89
software limit ....................................................................................... 8-88
special training ...................................................................................... 1-2
specification list ................................................................................... 13-3
speed adjustment ................................................................................ 13-4
speed setting ....................................................................................... 13-5
standard instruction set ........................................................................ 8-91
station axis setting ............................................................................. 12-13
STICK DETECTION ........................................................................... 14-64
subset instruction set............................................................................ 8-91
switch of the tool file ............................................................................. 8-50
SYSTEM INFO ...................................................................................... 7-3
T.C.P. calibration ................................................................................. 13-4

T-Axis ................................................................................................... 6-2
TEACHING COND ................................................................................. 7-4
teaching user coordinates ..................................................................... 8-83
temporary release of soft limits .............................................................. 8-88
three-phase noise filter ........................................................................... 4-3
three-phase power supply ....................................................................... 4-3
TIMER COOLING WATER ERROR ..................................................... 14-63
timer setting ........................................................................................ 13-4
TIP REPLACE COMPLETION ............................................................ 14-64
Index-6
DX100 Index
TIP REPLACE REQUEST .................................................................. 14-65

TOOL ................................................................................................... 7-3
tool calibration ..................................................................................... 8-23
tool data setting ................................................................................... 8-18
tool file ................................................................................................ 8-18
tool load information............................................................................. 8-42
tool load information registering ............................................................ 8-48
tool load information setting .......................................................... 8-42, 8-75
tool shock sensor................................................................................. 14-6
tool shock sensor releasing .................................................................. 8-86
transferring the MOTOMAN .................................................................. 1-14
TRANSTHERMO ERROR .................................................................. 14-64
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..................................................................................... 8-39

U-Axis .................................................................................................. 6-2
user alarm display ............................................................................... 13-4
USER COORDINATE ............................................................................ 7-3
user coordinate ................................................................................... 8-55
user coordinate files ............................................................................. 8-81
user coordinate setting ......................................................................... 8-81
user coordinates .................................................................................. 8-81
user ID .......................................................................................... 7-4, 7-6
VARIABLE ............................................................................................ 7-2

variable............................................................................................... 13-5
variable type ....................................................................................... 13-5
VERIFY ................................................................................................ 7-3
VERSION ............................................................................................. 7-3
WEAVING PROHIBITED.................................................................... 14-45

WELD COMPLETION ........................................................................ 14-64
WELD CONDITION ........................................................................... 14-66
WELD ERROR RESET ...................................................................... 14-66
WELD ON/OFF ................................................................................. 14-65
WELDING COMMAND....................................................................... 14-66
WELDING ERROR ............................................................................ 14-64
WELDING ON/OFF (from sequencer).................................................. 14-63
WELDING PAUSE (from sequencer) ................................................... 14-63
WIRE SHORTAGE (MONITOR).......................................................... 14-46
WIRE STICKING (MONITOR)............................................................. 14-46
WORK COMMAND............................................................................ 14-58
WORK HOME POS ............................................................................... 7-3
work home position .............................................................................. 8-51
work home position cube length of its sides............................................ 8-53
WORK PROHIBITED (arc generation prohibited).................................. 14-45
Index-7
DX100 Index
WORK RESPONSE (pseudo arc ON response) .................................... 14-45
XX ...................................................................................................... 8-81
XY ...................................................................................................... 8-81
Index-8
DX100
INSTRUCTIONS
FOR NORTH AMERICAN (ANSI/RIA) STANDARD
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.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
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.
252/246, 4th Floor. Muang Thai-Phatra office Tower II Rechadapisek Road, Huaykwang Bangkok 10320, Thailand
Phone +66-2-693-2200 Fax +66-2-693-4200
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 Fax +86-10-6788-0542
MOTOMAN MOTHERSON ROBOTICS LTD.
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-A217 1

for ongoing product modifications and improvements. C Printed in Japan May 2009 09-04

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YASKAWA

Part Number: 155494-1CD

YASKAWA MANUAL NO. RE-CTO-A217 1

Notes for Safe Operation

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly the

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

Definition of Terms Used Often in This Manual

Descriptions of the programming pendant, buttons, and displays are

Equipment Manual Designation

ex. page key

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

Keys pressed When two keys are to be pressed

Displays The menu displayed in the programming

Description of the Operation Procedure

Explanation of Warning Labels

Refer to the manipulator manual for the warning label location.

Do not open the door

with power ON. O

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................................................................................................ 1-10

1.5.3 Operation Safety................................................................................................. 1-11

1.6 Notes for Moving and Transferring the MOTOMAN......................................................... 1-14

1.7 Notes on MOTOMAN Disposal ........................................................................................ 1-15

2 Product Confirmation ...................................................................................................................... 2-1

2.1 Contents Confirmation ....................................................................................................... 2-1

2.2 Order Number Confirmation............................................................................................... 2-2

3 Installation ....................................................................................................................................... 3-1

3.1 Handling Procedure ........................................................................................................... 3-1

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

3.1.2 Using a Forklift to Move the Controller ................................................................. 3-3

3.2 Place of Installation............................................................................................................ 3-4

3.3 Location ............................................................................................................................. 3-5

3.4 Mounting the Controller...................................................................................................... 3-6

4 Connection ...................................................................................................................................... 4-1

4.1 Notes on Cable Junctions .................................................................................................. 4-2

4.2 Power Supply..................................................................................................................... 4-3

4.2.1 Three-Phase Power Supply.................................................................................. 4-3

4.2.2 Noise Filter Installation ......................................................................................... 4-3

4.2.3 Leakage Breaker Installation ................................................................................ 4-4

4.2.4 Primary Power Supply Breaker/Fuse 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 ....................................................................... 4-9

4.3.3 Connecting the Programming Pendant............................................................... 4-10

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