Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters or symbols
Pendant /Symbol Keys printed on them are denoted with [ ].
e.g. [ENTER]
Axis Keys [Axis Key] and [Numeric Key] are generic
/Numeric Keys names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a “+”
sign between them, e.g. [SHIFT]+[COORD].
Mode Switch Mode Switch can select three kinds of modes
that are denoted as follows: REMOTE, PLAY or
TEACH.
Button The three buttons on the upper side of the
programming pendant are denoted as follows:
START, HOLD, or EMERGENCY STOP.
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
Start button Hold button
Mode switch
REMOTE Emergency stop button
PLAY
TEACH
START HOLD
REMOTE TEACH
PLAY
LAYOUT TOOL SEL GO BACK
Page key
Coordinate key
DIRECT
COORD OPEN
Multi PAGE AREA
ENTRY
SERVO
SELECT
MAIN
MENU
SIMPLE
MENU
ON
READY ASSIST
CANCEL
Axis keys
SERVO ON
X- X+ X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
Z- Z+ MANUAL SPEED
Z- Z+
U- U+ T- T+
SLOW
8- 8+
INTER 7 8 9 TEST
Shift key
SHIFT SHIFT
LOCK START
ROBOT INFORM 4 5 6 BWD FWD
LIST
EX.AXIS
WELD 1 2 3 DELETE INSERT
ON/OFF
.
AUX MOTION
TYPE
0 - MODIFY ENTER Enter key
Numeric keys
Description of the Operation Procedure
In the explanation of the operation procedure, the expression “Select • • • “
means that the cursor is moved to the object item and [SELECT] is
pressed, or that the item is directly selected by touching the screen.
vi
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.
Explanation of Warning Labels
The following warning labels are attached to the manipulator and DX200.
Fully comply with the precautions on the warning labels.
DANGER
• The label described below is attached to the manipulator.
Observe the precautions on the warning labels.
• Failure to observe this caution may result in injury or damage to
equipment.
WARNING WARNING
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 DX200.
Observe the precautions on the warning labels.
Failure to observe this warning may result in injury or damage to
equipment.
WARNING
WARNING WARNING
High Voltage
High Voltage
Do not open the door Do not open the cover. May cause
with power ON. electric shock.
Ground the earth
terminal based on
local and national
electric code.
WARNING
High Voltage
Do not ope the cover.
WARNING
High Voltage
Do not open the door
with power ON.
WARNING
May cause
electric shock.
Ground the earth
terminal based on
local and national
electric code.
Internal Breaker
vii
Contents
1 Safety .............................................................................................................................................. 1-1
1.1 For Your Safety.................................................................................................................. 1-1
1.2 Special Training ................................................................................................................. 1-2
1.3 Motoman Manual List......................................................................................................... 1-2
1.4 Personnel Safety................................................................................................................ 1-3
1.5 Motoman Safety................................................................................................................. 1-5
1.5.1 Installation and Wiring Safety ............................................................................... 1-5
1.5.2 Work Area Safety.................................................................................................. 1-9
1.5.3 Operation Safety................................................................................................. 1-10
1.6 Notes for Moving and Transferring the MOTOMAN......................................................... 1-13
1.7 Notes on MOTOMAN Disposal ........................................................................................ 1-14
2 Product Confirmation ...................................................................................................................... 2-1
2.1 Contents Confirmation ....................................................................................................... 2-1
2.2 Order Number Confirmation............................................................................................... 2-2
3 Installation ....................................................................................................................................... 3-1
3.1 Handling Procedure ........................................................................................................... 3-1
3.1.1 Using a Crane to Move the Controller .................................................................. 3-1
3.1.2 Using a Forklift to Move the Controller ................................................................. 3-2
3.2 Place of Installation............................................................................................................ 3-3
3.3 Location ............................................................................................................................. 3-4
3.4 Mounting the Controller...................................................................................................... 3-5
3.5 Procedure of Stacking the Controllers ............................................................................... 3-6
4 Connection ...................................................................................................................................... 4-1
4.1 Notes on Cable Junctions .................................................................................................. 4-2
4.2 Power Supply..................................................................................................................... 4-3
4.2.1 Three-Phase Power Supply.................................................................................. 4-3
4.2.2 Noise Filter Installation ......................................................................................... 4-3
4.2.3 Leakage Breaker Installation ................................................................................ 4-4
4.2.4 Primary Power Supply Breaker Installation .......................................................... 4-5
4.3 Connection Methods .......................................................................................................... 4-6
4.3.1 Connecting the Primary Power Supply ................................................................. 4-6
4.3.2 Connecting the Manipulator Cable ..................................................................... 4-11
viii
Contents
4.3.3 Connecting the Programming Pendant .............................................................. 4-12
4.3.4 User I/O Cable Connection................................................................................. 4-13
5 Turning ON and OFF the Power Supply ......................................................................................... 5-1
5.1 Turning ON the Main Power Supply .................................................................................. 5-1
5.1.1 Initial Diagnosis .................................................................................................... 5-2
5.1.2 When Initial Diagnosis are Complete ................................................................... 5-2
5.2 Turning ON the Servo Power............................................................................................. 5-3
5.2.1 During Play Mode ................................................................................................. 5-3
5.2.2 During Teach Mode .............................................................................................. 5-3
5.3 Turning OFF the Power Supply ......................................................................................... 5-5
5.3.1 Turning OFF the Servo Power (Emergency Stop)................................................ 5-5
5.3.2 Turning OFF the Main Power ............................................................................... 5-5
5.3.3 The Method of Stopping Manipulator Operation................................................... 5-6
6 Test of Program Operation ............................................................................................................. 6-1
6.1 Movement of the Axes ....................................................................................................... 6-3
6.2 Manual Brake Release Function........................................................................................ 6-4
7 Security System .............................................................................................................................. 7-1
7.1 Protection Through Security Mode Settings ...................................................................... 7-1
7.1.1 Security Mode ...................................................................................................... 7-1
7.1.1.1 Changing the Security Mode ................................................................... 7-6
7.1.2 User ID ................................................................................................................. 7-9
7.1.2.1 Changing User ID.................................................................................... 7-9
8 System Setup.................................................................................................................................. 8-1
8.1 Home Position Calibration ................................................................................................. 8-2
8.1.1 Home Position Calibration .................................................................................... 8-4
8.1.2 Calibrating Operation............................................................................................ 8-5
8.1.2.1 Registering All Axes at One Time ........................................................... 8-5
8.1.2.2 Registering Individual Axes ..................................................................... 8-8
8.1.2.3 Changing the Absolute Data ................................................................... 8-9
8.1.2.4 Clearing Absolute Data ........................................................................... 8-9
8.1.3 Home Position of the Robot................................................................................ 8-11
8.2 Setting the Second Home Position (Check Point) ........................................................... 8-12
8.2.1 Purpose of Position Check Operation ................................................................ 8-14
8.2.2 Procedure for the Second Home Position Setting (Check Point) ....................... 8-16
ix
Contents
8.2.3 Procedure after the Alarm................................................................................... 8-18
8.3 Tool Data Setting ............................................................................................................. 8-20
8.3.1 Registering Tool Files ......................................................................................... 8-20
8.3.1.1 Number of Tool Files ............................................................................. 8-20
8.3.1.2 Registering Coordinate Data ................................................................. 8-20
8.3.1.3 Registering Tool Angle .......................................................................... 8-23
8.3.1.4 Setting the Tool Load Information ......................................................... 8-24
8.3.2 Tool Calibration................................................................................................... 8-25
8.3.2.1 Tool Calibration ..................................................................................... 8-25
8.3.2.2 Setting of Tool Calibration Method ........................................................ 8-25
8.3.2.3 Teaching of Calibration Point ................................................................ 8-26
8.3.2.4 Clearing Calibration Data ...................................................................... 8-32
8.3.2.5 Checking the TCP ................................................................................. 8-34
8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity................. 8-36
8.3.3.1 What is the Automatic Measurement of the Tool Load and
the Center of Gravity? ........................................................................... 8-36
8.3.3.2 Measurement of the Tool Load and the Center of Gravity .................... 8-36
8.4 ARM Control .................................................................................................................... 8-41
8.4.1 ARM Control ....................................................................................................... 8-41
8.4.2 ARM CONTROL Window ................................................................................... 8-41
8.4.2.1 Robot Setup Condition .......................................................................... 8-42
8.4.3 Tool Load Information Setting............................................................................. 8-46
8.4.3.1 Tool Load Information ........................................................................... 8-46
8.4.3.2 How to Calculate Tool Load Information ............................................... 8-47
8.4.3.3 Tool Load Information Registering ........................................................ 8-52
8.5 Work Home Position ........................................................................................................ 8-55
8.5.1 What is the Work Home Position? ...................................................................... 8-55
8.5.2 Setting Work Home Position............................................................................... 8-55
8.5.2.1 Work Home Position Window ................................................................ 8-55
8.5.2.2 Registering/Changing the Work Home Position .................................... 8-57
8.5.2.3 Returning to the Work Home Position ................................................... 8-58
8.5.2.4 Output of the Work Home Position Signal ............................................. 8-58
8.6 Interference Area ............................................................................................................. 8-59
8.6.1 Interference Area ................................................................................................ 8-59
8.6.2 Cubic Interference Area...................................................................................... 8-59
8.6.2.1 Cubic Interference Area......................................................................... 8-59
8.6.2.2 Cube Setting Method............................................................................. 8-60
8.6.2.3 Setting Operation .................................................................................. 8-61
8.6.3 Axis Interference Area ........................................................................................ 8-72
8.6.3.1 Axis Interference Area ........................................................................... 8-72
8.6.3.2 Setting Operation .................................................................................. 8-72
