Dx200 System Upgrade Procedure
Dx200 System Upgrade Procedure
Dx200 System Upgrade Procedure
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
MANUAL NO.
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Upgrade Procedure
www.motoman.com
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Upgrade Procedure
MANDATORY
• This manual explains the upgrading procedures of the DX200
system. Read this manual carefully and be sure to understand its
contents before handling the DX200.
• General items related to safety are listed in the Chapter 1: Safety of
the DX200 Instructions. To ensure correct and safe operation,
carefully read the DX200 Instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.
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Upgrade Procedure
We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved YASKAWA training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
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Upgrade Procedure Notes for Safe Operation
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WARNING
• Before operating the manipulator, check that servo power is turned
off when the emergency stop buttons on the front door of the DX
200 and programing pendant are pressed.
When the servo power is turned off, the SERVO ON LED on the
programing pendant is turned off.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN
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Upgrade Procedure Definition of Terms Used Often in This Manual
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.
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Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
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Upgrade Procedure Safeguarding Tips
Safeguarding Tips
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General
safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to
the equipment. Only trained personnel familiar with the operation of
this equipment, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this
equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
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Upgrade Procedure Maintenance Safety
Maintenance Safety
Turn the power OFF and disconnect and lockout/tagout all electrical
circuits before making any modifications or connections.
Perform only the maintenance described in this manual. Maintenance
other than specified in this manual should be performed only by
YASKAWA-trained, qualified personnel.
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(937) 847-3200
For routine technical inquiries, you can also contact YASKAWA Customer
Support at the following e-mail address:
Please have the following information ready before you call Customer
Support:
• Controller DX200
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Upgrade Procedure Table of Contents
Table of Contents
6.2 Reset Procedure for the Machine Safety Board Flash data in Maintenance Mode ........... 6-4
6.3 Initialize the Job Data (Only for Downgrade) ..................................................................... 6-6
7.2 How to Repair Programming Pendant when Fonts are Garbled ...................................... 7-4
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1 Outline
Upgrading Start
CompactFlash/USB Preparation
(Refer to Chapter 2)
Data Back Up
(Refer to Chapter 3)
No
Is the CMOS data compatible?
Upgrading Completed
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Upgrade Procedure 2 CompactFlash/USB Preparation
2.1 Prearrangements
2 CompactFlash/USB Preparation
To upgrade the DX200, it is required to set a CompactFlash memory card
(hereinafter referred to as “CompactFlash”) or a USB memory stick
(hereinafter referred to as “USB”) into the programming pendant.
This chapter describes on how to prepare the CompactFlash or USB for
upgrading the DX200.
2.1 Prearrangements
Prepare the following items when making the CompactFlash/USB for the
DX200 upgrade.
• Personal computer with Windows operating system, available to use
CompactFlash/USB. (Windows is a registered trademark of
Microsoft Corporation.)
• Data file for upgrade.
• CompactFlash
The following types are recommended for DX200.
<Recommended CompactFlash>
No. Manufacturer Model Remarks
1 Hagiwara Sys-Com MCF10P-256MS-YE 256MB
2 Hagiwara Sys-Com MCF10P-512MS 512MB
3 Hagiwara Sys-Com MCF10P-A01GS 1GB
4 Hagiwara Sys-Com MCF10P-A02GS 2GB
• USB
The following type is recommended for DX200.
< Recommended USB Memory>
No. Manufacturer Model Remarks
1 Hagiwara Sys-Com UDG4-xGDRJS 1GB,2GB or 4GB
SUPPLE-
The above mentioned CompactFlash with different capacity
MENT (xxMB) is also available to use.
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2. Run "MK_VX_CF.EXE".
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Upgrade Procedure 2 CompactFlash/USB Preparation
2.2 Preparing CompactFlash/USB for Upgrade
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Upgrade Procedure 2 CompactFlash/USB Preparation
2.2 Preparing CompactFlash/USB for Upgrade
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Upgrade Procedure 3 Data Back Up
3.1 Data Back Up
3 Data Back Up
Perform the following operation in advance so that the data can be
restored if upgrading is unsuccessful.
Example of CF
front surface
CF slot
Example of CF
front surface
Example of CF
back surface
Example of CF
back surface
– When inserting the USB, remove the rubber cap on the USB slot on
the back of the programming pendant.
USB
USB slot
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Upgrade Procedure 3 Data Back Up
3.1 Data Back Up
8. When the job is selected, it will be indicated with "" mark. Press
[ENTER] when all the jobs are selected.
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10. Each job data is saved individually when the figure on the display
changed as shown below.
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Upgrade Procedure 3 Data Back Up
3.2 Recording Other Information
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3. Select {SETUP} under the {SYSTEM}, then save the following data:
• LANGUAGE
• CONTROL GROUP (Data of axes configurations, data set for exter-
nal axis motor, SERVOPACK, etc.)
• APPLICATION
• OPTION BOARD (Detailed settings of expansion boards, etc.)
• OPTION FUNCTION (Detailed settings of optional functions, etc.)
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Upgrade Procedure 3 Data Back Up
3.3 Recording Information in Maintenance Mode
5. Turn OFF the main power of the DX200 after the CMOS save is
completed.
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Example of CF
front surface
CF slot
Example of CF
front surface
Example of CF
back surface
Example of CF
back surface
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Upgrade Procedure 4 System Software Upgrade
4.1 System Software Upgrade
Bitmap image
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5. When the message “Turn off controller power supply” appears, turn
OFF the main power of the DX200.
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Upgrade Procedure 4 System Software Upgrade
4.1 System Software Upgrade
USB
USB slot
Bitmap image
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Upgrade Procedure 4 System Software Upgrade
4.1 System Software Upgrade
5. When the message “Turn off controller power supply” appears, turn
OFF the main power of the DX200.
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Bitmap image
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Upgrade Procedure 5 Programming Pendant Upgrade
5.1 Programming Pendant Upgrade
Data reading from CompactFlash to SDRAM: Data writing from SDRAM to FlashRom:
4 LED indications blink clockwise. 3 LED indications blink clockwise.
The blink interval is irregular. The blink interval is 1 to 2 seconds.
(The interval may be 1 to 2 seconds or The time required for writing is approx.
4 to 5 seconds.) 4 minutes.
The time required for reading is approx.
3 minutes.
SUPPLE-
The total time required for data transfer and writing from
MENT CompactFlash to FlashRom is approx. 7 minutes.
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Upgrade Procedure 5 Programming Pendant Upgrade
5.1 Programming Pendant Upgrade
(3) After turning OFF the main power of the DX200, be sure to
remove the CompactFlash from the CF slot or the USB from the
USB slot of the programming pendant.
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7. Select {SYSTEM INFO} and then {VERSION} under the main menu to
confirm the version data.
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Upgrade Procedure 6 Procedure when Data Incompatibility Occurs after Upgrading
1863 10 M-SAF SETUP ERROR A failure occurs in the Perform the procedure in section
machine safety data 6.2 “Reset Procedure for the
consistency check. Machine Safety Board Flash data in
11 Maintenance Mode”.
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Upgrade Procedure 6 Procedure when Data Incompatibility Occurs after Upgrading
6.1 Data Rebuild Procedure in Maintenance Mode
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6.2 Reset Procedure for the Machine Safety Board Flash data
in Maintenance Mode
Follow the procedure below if the following alarms occur after the
upgrade.
• ALARM 1863: M-SAF SETUP ERROR
1. Select {File} then {INITIALIZE} in SAFETY MODE in the Maintenance
mode.
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6 Procedure when Data Incompatibility Occurs after Upgrading
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When the control power is turned ON after the downgrade which meets
the requirements above is executed, there is a case that the alarm below
occurs. At the same time, the SETUP INITIALIZE ERROR accompanies.
• Alarm 4203 System Error (Position Data) Sub Code [-3] or [-9]
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Upgrade Procedure 6 Procedure when Data Incompatibility Occurs after Upgrading
6.3 Initialize the Job Data (Only for Downgrade)
When this alarm occurs, execute the operations below in the Maintenance
mode.
If the alarm doesn’t occur, none of the operations need to be done.
3. Download the CMOS.BIN which was saved in the version earlier than
DN 1.70.00A()-00.
4. Start up the DX200 in the normal mode again, and download each file
saved before the downgrade as necessary.
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7 Troubleshooting
Perform the following operation if the DX200 does not start up normally or
does not operate correctly.
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Upgrade Procedure 7 Troubleshooting
7.1 Back Up the CompactFlash
(2) Then, click the [Tools] tab and click "Check Now" in the [Error-
checking] box.
(3) Tick the check boxes in the [Check disk options] and click [Start].
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5. After the files are copied into the CompactFlash, return it to the YCP21
board.
6. Perform initialization in the Maintenance mode.
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Upgrade Procedure 7 Troubleshooting
7.2 How to Repair Programming Pendant when Fonts are Garbled
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Window 4
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Upgrade Procedure 7 Troubleshooting
7.2 How to Repair Programming Pendant when Fonts are Garbled
6. When Window 5 appeared, turn OFF the main power of the DX200.
Insert the CompactFlash for upgrading the DX200, then turn ON the
main power again by pressing [INTERLOCK] + [8] + [SELECT].
The window for upgrade appears, then, select {Software Upgrade} to
execute upgrade.
Window 5
7. When upgrade operation is completed, turn OFF the main power of the
DX200.
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UPGRADE PROCEDURE MANUAL
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800 Fax +46-486-414-10
MANUAL NO.
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