MOTOMAN-MS210,MS165,MH225,MH180

INSTRUCTIONS
FOR ZEROING FUNCTION
TYPE: YR-MS210/MH225-***, YR-MS165/MH180-***
(ZEROING (OPTIONAL))

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

MOTOMAN INSTRUCTIONS
MOTOMAN-MS210 INSTRUCTIONS
MOTOMAN-MS165 INSTRUCTIONS
MOTOMAN-MH225 INSTRUCTIONS
MOTOMAN-MH180 INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENACE MANUAL
The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

Part Number: 167777-1CD

Revision: 0

MANUAL NO.

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MANDATORY
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-MS210,
MS165, MH225, MH180
• General items related to safety are listed in Chapter 1: Safety of the
DX200 Instructions. To ensure correct and safe operation, carefully
read the DX200 Instructions before reading this manual.

CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
If such modification is made, the manual number will also be
revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200.
In this manual, the Notes for Safe Operation are classified as
“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 to

NOTE follow all instructions, even if not designated as "CAUTION"
and "WARNING".

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WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX200 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Figure 1: Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN

• 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.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX200.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX200 and the programming pendant.

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CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the DX200 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX200 Instructions before operating the manipulator:

Definition of Terms Used Often in This Manual

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

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Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Figure 3: Warning Label Locations

Nameplate

WARNING Label A
WARNING Label B
WARNING Label B

Nameplate: WARNING Label A:

WARNING
Moving parts
may cause
injury

WARNING Label B:

WARNING
Do not enter
robot
work area.

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Zeroing Function Table of Contents

Table of Contents

1 Zeroing Function ............................................................................................................................. 1-1

1.1 Outline ............................................................................................................................... 1-1

1.2 Details on Zeroing Function............................................................................................... 1-2

1.2.1 System Configuration ........................................................................................... 1-2

1.2.2 Operational Procedure and Cautions ................................................................... 1-3

1.2.2.1 Before the Zeroing Operation.................................................................. 1-3
1.2.2.2 Connection of the Zeroing Devices ......................................................... 1-3
1.2.2.3 Zeroing Procedure for S-Axis .................................................................. 1-5
1.2.2.4 Zeroing Procedure for L-Axis ................................................................ 1-10
1.2.2.5 Zeroing Procedure for U-Axis................................................................ 1-15
1.2.2.6 Zeroing Procedure for R-Axis................................................................ 1-20
1.2.2.7 Zeroing Procedure for B-Axis ................................................................ 1-25
1.2.2.8 Zeroing Procedure for T-Axis ................................................................ 1-30

1.3 Errors in the Zeroing Operation and Solutions ................................................................ 1-35

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Zeroing Function 1 Zeroing Function
1.1 Outline

1 Zeroing Function
Zeroing function automatically allows for the restoration of the home
position data when the manipulator’s home position data disappear.
(Optional function)

This function only applies to the manipulator which was ordered to be

equipped with the zeroing function and shipped.

1.1 Outline
The DX200 stores the manipulator home position based on the pulse
value of each axis encoder. Since the home position is already set and
registered before shipment, zeroing operation does not need to be
performed at the normal operation. However, zeroing operation needs to
be performed to restore the home position since the home position data
disappear when performing the following operations, or the followings
occur.
• Replacement of Motors
• Replacement of Encoders
• Backup Battery Exhaustion in the Manipulator

The home position data is stored by the backup battery.

If the battery is exhausted, the home position data
disappear again when turning OFF the DX200 power even
when the zeroing operation is performed.
NOTE
Be sure to replace the battery periodically. For the battery
replacement, refer to "Maintenance and Inspection" of
"MOTOMAN-MS210, MS165, MH225, MH180
INSTRUCTIONS"

The home positioning cannot be performed accurately by

NOTE the zeroing operation if the combination of the manipulator
and the DX200 are changed.

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1.2 Details on Zeroing Function

1.2 Details on Zeroing Function

1.2.1 System Configuration

The following Fig.1-1 "Zeroing System Configuration" shows the system
configuration of the zeroing function.

Fig. 1-1: Zeroing System Configuration

4 Communication cable 5 Data communication card

2 Amplifier

3 Lead wire

Zeroing Devices

1 Sensor
Manipulator Controller (DX200)

Table 1-1: Items Making up the Zeroing System

Items Type Qty Manufacturer
1 Sensor HW0381863-A 1 Yaskawa
2 Amplifier HW0381864-A 1 Yaskawa
3 Lead wire HW0470652-A 1 Yaskawa
4 Communication cable KR-M2 1 Yaskawa
5 Data communication card REX-CF60 1 Yaskawa

The sensor, amplifier, and data communication card are

NOTE precision instruments.
Handle and store them with care.

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1.2 Details on Zeroing Function

1.2.2 Operational Procedure and Cautions

WARNING
• False zeroing operation may lead to the manipulator’s operation
error.
Be sure to follow the set procedures and perform the zeroing
operation upon ensuring the safety.
Injury may result from unintentional or unexpected manipulator motion,
or operation error.

The zeroing function is only valid when the security mode is

set to the management mode.
NOTE
For the security mode, refer to Chapter 7 “Security System"
in the "DX200 INSTRUCTIONS".

1.2.2.1 Before the Zeroing Operation

Remove the tool attached to the manipulator and perform the zeroing
operation for accurate home positioning by the zeroing function. If the
zeroing operation is performed with the tool attached to the manipulator,
the tool’s weight may affect positioning accuracy.

1.2.2.2 Connection of the Zeroing Devices

1. Insert the data communication card into the slot of the programming
pendant.
Fig. 1-2: Insertion of the Data Communication Card

2. Connect the data communication card and amplifier with the

communication cable.
3. Connect the lead wire to the amplifier.
(Do not connect the sensor yet.)

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1.2 Details on Zeroing Function

The installation locations of the zeroing sensors for each axis are shown in
Fig.1-3 "Installation Locations of the Zeroing Sensors".
Perform the zeroing operation every axis by referring to the zeroing
procedure for each axis.
The appearance of parts and installation locations may vary from each
model. In this manual, describe the details by using some figures of
MS210.
Fig. 1-3: Installation Locations of the Zeroing Sensors

R-axis T-axis

U-axis

B-axis L-axis S-axis

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1.2.2.3 Zeroing Procedure for S-Axis

Perform the zeroing operation for S-axis with the following procedure.
1. Remove the plug and cover from the attaching portion for the sensor.

S-axis: Cover on the sensor

attaching part

Plug

Cover

S-axis: Without cover on the

sensor attaching part

NOTE Be sure to remove the cover. If the zeroing operation is

performed with the cover on, the sensor may be damaged.

The plug, cover, and cover mounting screws are small

NOTE parts.
Be sure not to lose them during the operation.

Be sure that the servo power is OFF and no safety hazard

is around the manipulator when approaching the
NOTE manipulator.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

2. Perform the home position alignment by adjusting the alignment marks

on the S-axis of the manipulator in the "TEACH" mode.

NOTE Be sure to adjust the home position alignment marks and

perform the zeroing operation.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

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1.2 Details on Zeroing Function

3. Check that no spatter, fume or rust is attached in/on the sensor

mounting hole, or sensor detecting element after removing the plug
and cover.
– Remove the spatter, fume, and rust if they are found.
4. Install the sensor onto the mounting holes.
Sensor

When the sensor is equipped

Never use tools, or avoid excessive force on the sensor.

NOTE Failure to observe this instruction may result in damage to
the sensor.

5. Connect the lead wire to the sensor.

6. Turn ON the amplifier power.
– If the amplifier power has been turned ON for prolonged periods of
time, turn OFF the power once and turn ON the power again.
7. Set the mode selector switch on the programming pendant to
"TEACH".

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1.2 Details on Zeroing Function

8. Select {Robot}  {Zeroing} under the main menu.

Then, select "S: S-axis" on the touch panel.

9. Turn ON the servo power by the [SERVO ON READY] and Enable

Switch on the programming pendant.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

10. Press {Zeroing} on the touch panel, and pop-up window appears
displaying the CAUTION message.

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11. Press "OK" by following the message in the pop-up window, and the
manipulator starts automatically.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

The manipulator motion is hard to be detected due to its

NOTE slight motion.
Confirm that no persons approach the manipulator.

12. The programming pendant screen shows the message to confirm the
completion of the zeroing operation, then indicates the calculated
absolute data.

13. Turn OFF the servo power.

Be sure to turn OFF the servo power to approach the

manipulator.
NOTE
Injury may result from unintentional or unexpected
manipulator motion.

14. Turn OFF the amplifier power.

15. Disconnect the lead wire from the sensor.
16. Remove the sensor from the manipulator.

After the zeroing operation, be sure to remove the sensor

from the manipulator before starting the manipulator.
NOTE
If the manipulator is operated with the sensor attached to
the manipulator, the sensor may be damaged.

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1.2 Details on Zeroing Function

17. Reinstall the plug and cover onto the manipulator.

Be sure to install the plug and cover to prevent any dirt on

the sensor mounting holes or sensor detecting element.
NOTE
The zeroing operation cannot be performed if any dirt is
attached on them.

18. Remove dust on the sensor for the sensor dust.

19. Confirm the manipulator position as follows:
Select {Robot} under the main menu  {Second Home Position}.
– The Second Home Position window appears.
– For safety reasons, automatic operations by playback cannot be
performed unless the position is confirmed.
20. Turn ON the servo power by the [SERVO ON READY] and Enable
Switch on the programming pendant.
Then, press [FWD] to move TCP to the second home position.
– Check for any position deviation of the manipulator’s second home
position.
21. Select {Data} under the main menu  {Confirm Position}.
– The message "Home position checked" appears.
22. Confirm the operation in the "TEACH" mode before restarting
automatic operation by playback.
– Check the followings to confirm the operation.
• Any deviation at each taught point by FWD operation in the
"TEACH" mode
• Test runs

Be sure to confirm the home position before starting

automatic operation.
NOTE
If false home position is input by the zeroing function, it may
lead to errors in the manipulator performance.

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1.2 Details on Zeroing Function

1.2.2.4 Zeroing Procedure for L-Axis

Perform the zeroing operation for L-axis with the following procedure.
1. Remove the plug and cover from the attaching portion for the sensor.

L-axis: Cover on the sensor

attaching part

Cover

Plug

Cover

L-axis: Without cover on the

sensor attaching part
Plug

View A

NOTE Be sure to remove the cover. If the zeroing operation is

performed with the cover on, the sensor may be damaged.

The plug, cover, and cover mounting screws are small

NOTE parts.
Be sure not to lose them during the operation.

Be sure that the servo power is OFF and no safety hazard

is around the manipulator when approaching the
NOTE manipulator.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

2. Perform the home position alignment by adjusting the alignment marks

on the L-axis of the manipulator in the "TEACH" mode.

NOTE Be sure to adjust the home position alignment marks and

perform the zeroing operation.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

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1.2 Details on Zeroing Function

3. Check that no spatter, fume or rust is attached in/on the sensor

mounting hole, or sensor detecting element after removing the plug
and cover.
– Remove the spatter, fume, and rust if they are found.
4. Install the sensor onto the mounting holes.

Sensor

When the sensor is equipped

Never use tools, or avoid excessive force on the sensor.

NOTE Failure to observe this instruction may result in damage to
the sensor.

5. Connect the lead wire to the sensor.

6. Turn ON the amplifier power.
– If the amplifier power has been turned ON for prolonged periods of
time, turn OFF the power once and turn ON the power again.
7. Set the mode selector switch on the programming pendant to
"TEACH".
8. Select {Robot}  {Zeroing} under the main menu.
Then, select "L: L-axis" on the touch panel.

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9. Turn ON the servo power by the [SERVO ON READY] and Enable

Switch on the programming pendant.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

10. Press {Zeroing} on the touch panel, and pop-up window appears
displaying the CAUTION message.

11. Press "OK" by following the message in the pop-up window, and the
manipulator starts automatically.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

The manipulator motion is hard to be detected due to its

NOTE slight motion.
Confirm that no persons approach the manipulator.

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1.2 Details on Zeroing Function

12. The programming pendant screen shows the message to confirm the
completion of the zeroing operation, then indicates the calculated
absolute data.

13. Turn OFF the servo power.

Be sure to turn OFF the servo power to approach the

manipulator.
NOTE
Injury may result from unintentional or unexpected
manipulator motion.

14. Turn OFF the amplifier power.

15. Disconnect the lead wire from the sensor.
16. Remove the sensor from the manipulator.

After the zeroing operation, be sure to remove the sensor

from the manipulator before starting the manipulator.
NOTE
If the manipulator is operated with the sensor attached to
the manipulator, the sensor may be damaged.

17. Reinstall the plug and cover onto the manipulator.

Be sure to install the plug and cover to prevent any dirt on

the sensor mounting holes or sensor detecting element.
NOTE
The zeroing operation cannot be performed if any dirt is
attached on them.

18. Remove dust on the sensor for the sensor dust.

19. Confirm the manipulator position as follows:
Select {Robot} under the main menu  {Second Home Position}.
– The Second Home Position window appears.
– For safety reasons, automatic operations by playback cannot be
performed unless the position is confirmed.

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1.2 Details on Zeroing Function

20. Turn ON the servo power by the [SERVO ON READY] and Enable
Switch on the programming pendant.
Then, press [FWD] to move TCP to the second home position.
– Check for any position deviation of the manipulator’s second home
position.
21. Select {Data} under the main menu  {Confirm Position}.
– The message "Home position checked" appears.
22. Confirm the operation in the "TEACH" mode before restarting
automatic operation by playback.
– Check the followings to confirm the operation.
• Any deviation at each taught point by FWD operation in the
"TEACH" mode
• Test runs

Be sure to confirm the home position before starting

automatic operation.
NOTE
If false home position is input by the zeroing function, it may
lead to errors in the manipulator performance.

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1.2 Details on Zeroing Function

1.2.2.5 Zeroing Procedure for U-Axis

Perform the zeroing operation for U-axis with the following procedure.
1. Remove the plug and cover from the attaching portion for the sensor.

U-axis: Cover on the sensor

attaching part

Plug

Cover

Cover Plug
A U-axis: Without cover on the
sensor attaching part

View A

NOTE Be sure to remove the cover. If the zeroing operation is

performed with the cover on, the sensor may be damaged.

The plug, cover, and cover mounting screws are small

NOTE parts.
Be sure not to lose them during the operation.

Be sure that the servo power is OFF and no safety hazard

is around the manipulator when approaching the
NOTE manipulator.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

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1.2 Details on Zeroing Function

2. Perform the home position alignment by adjusting the alignment marks

on the U-axis of the manipulator in the "TEACH" mode.

NOTE Be sure to adjust the home position alignment marks and

perform the zeroing operation.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

3. Check that no spatter, fume or rust is attached in/on the sensor

mounting hole, or indentation after removing the plug and cover.
– Remove the spatter, fume, and rust if they are found.
4. Install the sensor onto the mounting holes.

Sensor

When the sensor is equipped

Never use tools, or avoid excessive force on the sensor.

NOTE Failure to observe this instruction may result in damage to
the sensor.

5. Connect the lead wire to the sensor.

6. Turn ON the amplifier power.
– If the amplifier power has been turned ON for prolonged periods of
time, turn OFF the power once and turn ON the power again.
7. Set the mode selector switch on the programming pendant to
“TEACH".

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8. Select {Robot}  {Zeroing} under the main menu.

Then, select "U: U-axis" on the touch panel.

9. Turn ON the servo power by the [SERVO ON READY] and Enable

Switch on the programming pendant.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

10. Press {Zeroing} on the touch panel, and pop-up window appears
displaying the CAUTION message.

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1.2 Details on Zeroing Function

11. Press "OK" by following the message in the pop-up window, and the
manipulator starts automatically.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

The manipulator motion is hard to be detected due to its

NOTE slight motion.
Confirm that no persons approach the manipulator.

12. The programming pendant screen shows the message to confirm the
completion of the zeroing operation, then indicates the calculated
absolute data.

13. Turn OFF the servo power.

Be sure to turn OFF the servo power to approach the

manipulator.
NOTE
Injury may result from unintentional or unexpected
manipulator motion.

14. Turn OFF the amplifier power.

15. Disconnect the lead wire from the sensor.
16. Remove the sensor from the manipulator.

After the zeroing operation, be sure to remove the sensor

from the manipulator before starting the manipulator.
NOTE
If the manipulator is operated with the sensor attached to
the manipulator, the sensor may be damaged.

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17. Reinstall the plug and cover onto the manipulator.

Be sure to install the plug and cover to prevent any dirt on

the sensor mounting holes or sensor detecting element.
NOTE
The zeroing operation cannot be performed if any dirt is
attached on them.

18. Remove dust on the sensor for the sensor dust.

19. Confirm the manipulator position as follows:
Select {Robot} under the main menu  {Second Home Position}.
– The Second Home Position window appears.
– For safety reasons, automatic operations by playback cannot be
performed unless the position is confirmed.
20. Turn ON the servo power by the [SERVO ON READY] and Enable
Switch on the programming pendant.
Then, press [FWD] to move TCP to the second home position.
– Check for any position deviation of the manipulator’s second home
position.
21. Select {Data} under the main menu  {Confirm Position}.
– The message "Home position checked" appears.
22. Confirm the operation in the "TEACH" mode before restarting
automatic operation by playback.
– Check the followings to confirm the operation.
• Any deviation at each taught point by FWD operation in the
"TEACH" mode
• Test runs

Be sure to confirm the home position before starting

automatic operation.
NOTE
If false home position is input by the zeroing function, it may
lead to errors in the manipulator performance.

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1.2 Details on Zeroing Function

1.2.2.6 Zeroing Procedure for R-Axis

Perform the zeroing operation for R-axis with the following procedure.
1. Remove the plug and cover from the attaching portion for the sensor.

R-axis: Cover on the sensor

attaching part
Plug

Cover

A
Plug R-axis: Without cover on the
Cover
sensor attaching part

View A

NOTE Be sure to remove the cover. If the zeroing operation is

performed with the cover on, the sensor may be damaged.

The plug, cover, and cover mounting screws are small

NOTE parts.
Be sure not to lose them during the operation.

Be sure that the servo power is OFF and no safety hazard

is around the manipulator when approaching the
NOTE manipulator.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

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1.2 Details on Zeroing Function

2. Perform the home position alignment by adjusting the alignment marks

on the R-axis of the manipulator in the "TEACH" mode.

NOTE Be sure to adjust the home position alignment marks and

perform the zeroing operation.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

3. Check that no spatter, fume or rust is attached in/on the sensor

mounting hole, or sensor detecting element after removing the plug
and cover.
– Remove the spatter, fume, and rust if they are found.
4. Install the sensor onto the mounting holes.

Sensor

When the sensor is equipped

Never use tools, or avoid excessive force on the sensor.

NOTE Failure to observe this instruction may result in damage to
the sensor.

5. Connect the lead wire to the sensor.

6. Turn ON the amplifier power.
– If the amplifier power has been turned ON for prolonged periods of
time, turn OFF the power once and turn ON the power again.
7. Set the mode selector switch on the programming pendant to
"TEACH".

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

8. Select {Robot}  {Zeroing} under the main menu.

Then, select "R: R-axis" on the touch panel.

9. Turn ON the servo power by the [SERVO ON READY] and Enable

Switch on the programming pendant.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

10. Press {Zeroing} on the touch panel, and pop-up window appears
displaying the CAUTION message.

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

11. Press "OK" by following the message in the pop-up window, and the
manipulator starts automatically.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

The manipulator motion is hard to be detected due to its

NOTE slight motion.
Confirm that no persons approach the manipulator.

12. The programming pendant screen shows the message to confirm the
completion of the zeroing operation, then indicates the calculated
absolute data.

13. Turn OFF the servo power.

Be sure to turn OFF the servo power to approach the

manipulator.
NOTE
Injury may result from unintentional or unexpected
manipulator motion.

14. Turn OFF the amplifier power.

15. Disconnect the lead wire from the sensor.
16. Remove the sensor from the manipulator.

After the zeroing operation, be sure to remove the sensor

from the manipulator before starting the manipulator.
NOTE
If the manipulator is operated with the sensor attached to
the manipulator, the sensor may be damaged.

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

17. Reinstall the plug and cover onto the manipulator.

Be sure to install the plug and cover to prevent any dirt on

the sensor mounting holes or sensor detecting element.
NOTE
The zeroing operation cannot be performed if any dirt is
attached on them.

18. Remove dust on the sensor for the sensor dust.

19. Confirm the manipulator position as follows:
Select {Robot} under the main menu  {Second Home Position}.
– The Second Home Position window appears.
– For safety reasons, automatic operations by playback cannot be
performed unless the position is confirmed.
20. Turn ON the servo power by the [SERVO ON READY] and Enable
Switch on the programming pendant.
Then, press [FWD] to move TCP to the second home position.
– Check for any position deviation of the manipulator’s second home
position.
21. Select {Data} under the main menu  {Confirm Position}.
– The message "Home position checked" appears.
22. Confirm the operation in the "TEACH" mode before restarting
automatic operation by playback.
– Check the followings to confirm the operation.
• Any deviation at each taught point by FWD operation in the
"TEACH" mode
• Test runs

Be sure to confirm the home position before starting

automatic operation.
NOTE
If false home position is input by the zeroing function, it may
lead to errors in the manipulator performance.

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

1.2.2.7 Zeroing Procedure for B-Axis

Perform the zeroing operation for B-axis with the following procedure.
1. Remove the plug and cover from the attaching portion for the sensor.

B-axis: Cover on the sensor

Plug attaching part

Cover

B-axis: Without cover on the

Plug sensor attaching part

Cover

View A

NOTE Be sure to remove the cover. If the zeroing operation is

performed with the cover on, the sensor may be damaged.

The plug, cover, and cover mounting screws are small

NOTE parts.
Be sure not to lose them during the operation.

Be sure that the servo power is OFF and no safety hazard

is around the manipulator when approaching the
NOTE manipulator.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

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1.2 Details on Zeroing Function

2. Perform the home position alignment by adjusting the alignment marks

on the B-axis of the manipulator in the "TEACH" mode.

NOTE Be sure to adjust the home position alignment marks and

perform the zeroing operation.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

3. Check that no spatter, fume or rust is attached in/on the sensor

mounting hole, or sensor detecting element after removing the plug
and cover.
– Remove the spatter, fume, and rust if they are found.
4. Install the sensor onto the mounting holes.

Sensor

When the sensor is equipped

Never use tools, or avoid excessive force on the sensor.

NOTE Failure to observe this instruction may result in damage to
the sensor.

5. Connect the lead wire to the sensor.

6. Turn ON the amplifier power.
– If the amplifier power has been turned ON for prolonged periods of
time, turn OFF the power once and turn ON the power again.
7. Set the mode selector switch on the programming pendant to
"TEACH".

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

8. Select {Robot}  {Zeroing} under the main menu.

Then, select "B: B-axis" on the touch panel.

9. Turn ON the servo power by the [SERVO ON READY] and Enable

Switch on the programming pendant.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

10. Press {Zeroing} on the touch panel, and pop-up window appears
displaying the CAUTION message.

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1.2 Details on Zeroing Function

11. Press "OK" by following the message in the pop-up window, and the
manipulator starts automatically.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

The manipulator motion is hard to be detected due to its

NOTE slight motion.
Confirm that no persons approach the manipulator.

12. The programming pendant screen shows the message to confirm the
completion of the zeroing operation, then indicates the calculated
absolute data.

13. Turn OFF the servo power.

Be sure to turn OFF the servo power to approach the

manipulator.
NOTE
Injury may result from unintentional or unexpected
manipulator motion.

14. Turn OFF the amplifier power.

15. Disconnect the lead wire from the sensor.
16. Remove the sensor from the manipulator.

After the zeroing operation, be sure to remove the sensor

from the manipulator before starting the manipulator.
NOTE
If the manipulator is operated with the sensor attached to
the manipulator, the sensor may be damaged.

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

17. Reinstall the plug and cover onto the manipulator.

Be sure to install the plug and cover to prevent any dirt on

the sensor mounting holes or sensor detecting element.
NOTE
The zeroing operation cannot be performed if any dirt is
attached on them.

18. Remove dust on the sensor for the sensor dust.

19. Confirm the manipulator position as follows:
Select {Robot} under the main menu  {Second Home Position}.
– The Second Home Position window appears.
– For safety reasons, automatic operations by playback cannot be
performed unless the position is confirmed.
20. Turn ON the servo power by the [SERVO ON READY] and Enable
Switch on the programming pendant.
Then, press [FWD] to move TCP to the second home position.
– Check for any position deviation of the manipulator’s second home
position.
21. Select {Data} under the main menu  {Confirm Position}.
– The message "Home position checked" appears.
22. Confirm the operation in the "TEACH" mode before restarting
automatic operation by playback.
– Check the followings to confirm the operation.
• Any deviation at each taught point by FWD operation in the
"TEACH" mode
• Test runs

Be sure to confirm the home position before starting

automatic operation.
NOTE
If false home position is input by the zeroing function, it may
lead to errors in the manipulator performance.

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

1.2.2.8 Zeroing Procedure for T-Axis

Perform the zeroing operation for T-axis with the following procedure.
1. Remove the plug and cover from the attaching portion for the sensor.

T-axis: Cover on the sensor

attaching part
Plug

Cover

T-axis: Without cover on the

sensor attaching part

Cover

Plug

View A

NOTE Be sure to remove the cover. If the zeroing operation is

performed with the cover on, the sensor may be damaged.

The plug, cover, and cover mounting screws are small

NOTE parts.
Be sure not to lose them during the operation.

Be sure that the servo power is OFF and no safety hazard

is around the manipulator when approaching the
NOTE manipulator.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

2. Perform the home position alignment by adjusting the alignment marks

on the T-axis of the manipulator in the "TEACH" mode.

NOTE Be sure to adjust the home position alignment marks and

perform the zeroing operation.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

3. Check that no spatter, fume or rust is attached in/on the sensor

mounting hole, or sensor detecting element after removing the plug
and cover.
– Remove the spatter, fume, and rust if they are found.
4. Install the sensor onto the mounting holes.

Sensor

When the sensor is equipped

Never use tools, or avoid excessive force on the sensor.

NOTE Failure to observe this instruction may result in damage to
the sensor.

5. Connect the lead wire to the sensor.

6. Turn ON the amplifier power.
– If the amplifier power has been turned ON for prolonged periods of
time, turn OFF the power once and turn ON the power again.

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1.2 Details on Zeroing Function

7. Set the mode selector switch on the programming pendant to

"TEACH".
8. Select {Robot}  {Zeroing} under the main menu.
Then, select "T: T-axis" on the touch panel.

9. Turn ON the servo power by the [SERVO ON READY] and Enable

Switch on the programming pendant.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

10. Press {Zeroing} on the touch panel, and pop-up window appears
displaying the CAUTION message.

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1.2 Details on Zeroing Function

11. Press "OK" by following the message in the pop-up window, and the
manipulator starts automatically.

Confirm that no persons are present in the P-point

maximum envelope of the manipulator, and the operator is
NOTE in a safe place.
Injury may result from unintentional or unexpected
manipulator motion, or operation error.

The manipulator motion is hard to be detected due to its

NOTE slight motion.
Confirm that no persons approach the manipulator.

12. The programming pendant screen shows the message to confirm the
completion of the zeroing operation, then indicates the calculated
absolute data.

13. Turn OFF the servo power.

Be sure to turn OFF the servo power to approach the

manipulator.
NOTE
Injury may result from unintentional or unexpected
manipulator motion.

14. Turn OFF the amplifier power.

15. Disconnect the lead wire from the sensor.
16. Remove the sensor from the manipulator.

After the zeroing operation, be sure to remove the sensor

from the manipulator before starting the manipulator.
NOTE
If the manipulator is operated with the sensor attached to
the manipulator, the sensor may be damaged.

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Zeroing Function 1 Zeroing Function
1.2 Details on Zeroing Function

17. Reinstall the plug and cover onto the manipulator.

Be sure to install the plug and cover to prevent any dirt on

the sensor mounting hoes or sensor detecting element.
NOTE
The zeroing operation cannot be performed if any dirt is
attached on them.

18. Remove dust on the sensor for the sensor dust.

19. Confirm the manipulator position as follows:
Select {Robot} under the main menu  {Second Home Position}.
– The Second Home Position window appears.
– For safety reasons, automatic operations by playback cannot be
performed unless the position is confirmed.
20. Turn ON the servo power by the [SERVO ON READY] and Enable
Switch on the programming pendant.
Then, press [FWD] to move TCP to the second home position.
– Check for any position deviation of the manipulator’s second home
position.
21. Select {Data} under the main menu  {Confirm Position}.
– The message "Home position checked" appears.
22. Confirm the operation in the "TEACH" mode before restarting
automatic operation by playback.
– Check the followings to confirm the operation.
• Any deviation at each taught point by FWD operation in the
"TEACH" mode
• Test runs

Be sure to confirm the home position before starting

automatic operation.
NOTE
If false home position is input by the zeroing function, it may
lead to errors in the manipulator performance.

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Zeroing Function 1 Zeroing Function
1.3 Errors in the Zeroing Operation and Solutions

1.3 Errors in the Zeroing Operation and Solutions

If errors occur during the zeroing operation, confirm the error contents and
perform the following operations.

Message Contents Operation

There is little depth of the hole or it Error in the data on the hole depth  Check if dust or spatter is
is large. caught by the sensor present on the hole.
Investigate the hole.  Check for damage or cracks
ErrorCode:55550004 on the sensor exterior, or
deformation of the sensor
end.
 Perform the zeroing
operation again upon
confirming the procedures.
Switch mode to teach. The mode selector switch on the Set the mode selector switch to
Again, Execute zeroing. programming pendant is set to "PLAY" "TEACH" to perform the zeroing
mode at the start of the zeroing operation.
operation.
Keep servo on state in teach mode The servo power is not turned ON at Turn ON the servo power by the
between under zeroing execution. the start of the zeroing operation. operations as gripping the Enable
Again, Execute zeroing switch of the programming
pendant, etc.
Loop Error [The maximum Error in the zeroing processing Possible causes: False parameter
measurement point were settings for zeroing speed,
exceeded.] distance, radius, and etc., false
ErrorCode:55550005 starting point of the zeroing
operation and etc.
Contact the nearest YASKAWA
representative.
Loop Error [Acquiring a pulse went Error in communication Possible causes: Inconsistency in
wrong.] software version.
ErrorCode:55550006 Contact your nearest YASKAWA
Loop Error [The processing which representative.
starts robot operation went wrong.]
ErrorCode:55550008
Loop Error [The processing which
stops robot operation went wrong.]
ErrorCode:55550009
Loop Error [Acquiring the value of Error in communication Contact your nearest YASKAWA
the sensor went wrong.] representative for perceiving the
ErrorCode:55550010 details on the current state by the
particular numbers.
Error [Sensor Amp (Read():D1)] Contact your nearest YASKAWA
ErrorCode:55550044 representative.
Information Error in communication  Check if the alarm lamp is lit,
* Check the amp power supply of or cables and etc. are
the sensor. connected properly.
* Check connection of the RS-  Turn OFF the power to the
232C cable. amplifier, and turn ON again.
* Check Battery. Then perform the zeroing
operation.
Alarm : Sensor Amp (Battery) Amplifier battery exhaustion Replace the battery with the new
battery.
Alarm : Sensor Amp (Write Error Amplifier EEPROM writing error Contact your nearest YASKAWA
EEPROM) representative.

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Zeroing Function 1 Zeroing Function
1.3 Errors in the Zeroing Operation and Solutions

Message Contents Operation

Alarm : Sensor Amp (AD Over) AD Over Alarm of the amplifier Contact your nearest YASKAWA
representative.
Error [Sensor Amp (Auto Error in zeroing of the amplifier Contact your nearest YASKAWA
Zero:OK)] representative.
ErrorCode:55550046
Error [No CtrlGroup] Zeroing was performed with the DX200 Perform the zeroing operation by
ErrorCode:55550052 which has no manipulator control the DX200 with the manipulator
group. control group.
Error [No Axis] Zeroing was performed with the Specify the manipulator control
ErrorCode:55550056 manipulator control group which has no group with operable axes.
operable axes.
Not Found : RS-232C CF-Card CF-Card for the RS-232C is not Insert the CF-Card for the
ErrorCode:55550001 inserted into the slot of the RS-232C into the slot.
programming pendant.
Error [RS-232C Communication] Errors occur during the amplifier Contact your nearest YASKAWA
ErrorCode:55550017 communication representative.
Error [RS-232C Communication]
ErrorCode:55550018
Error RS-232C Communication]
ErrorCode:55550019
Error [RS-232C Communication]
ErrorCode:55550020
Error Occur The zeroing operation is terminated Confirm the error content and
Finish! (Error Occur) due to error occurrence. remove the error cause. Then,
perform the zeroing operation
again from the start.
Operator Stop The zeroing operation is terminated Perform the zeroing operation
Finish! (Operator Stop) with the stop button. again from the start.

The operator pushed the stop.

Error [Any axis don't set ABSO.] Error in the zeroing processing Contact your nearest YASKAWA
ErrorCode:55550088 representative.
Loop Error [The maximum moving Error in the zeroing processing Contact your nearest YASKAWA
pulse over.] representative.
ErrorCode:55550097

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MOTOMAN-MS210,MS165,MH225,MH180
INSTRUCTIONS
FOR ZEROING FUNCTION

Specifications are subject to change without notice

for ongoing product modifications and improvements.

MANUAL NO.

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