Yaskawa Motoman DX100 communicstion issue.

    My programming pendent is giving this error

    Communication to controller is disconnected.

    Check LED(DS1) on YIF board in the controller before turning off the power.

    We already changed the Ethernet cable from pendent to controller and controller to robot.

    Can anyone help?

    thank you.

    You could try to ping the controller and the pendant. It is not really a solution but a way to pinpoint the fault.

    Add a network switch in between the controller board and the pendant. Set your computers IP address to 10.0.0.3 and the netmask to 255.255.255.0 and connect it to the switch. Then open a command prompt and type "ping 10.0.0.2" or "ping 10.0.0.4". When you can't reach 10.0.0.2, the problem is in the controller. When you can't reach 10.0.0.4, the problem resides in the PP, cable or connectors to it.

    In this, I presume that the IP addresses of the DX100 and the DX200 are the same. If you are not able to reach either one of the IP addresses, my presumption might be off.

    There are 2 rules for success:

    1. Never reveal everything you know,

    I believe that I saw in another post of yours that a "P" was showing up. That means that control power is not being provided from the CPS. Check the YPS CN154 and CN155 for voltage. Make sure there is not a red LED on the YPS. If the red LED is on there 24 Vdc is shorted and being pulled down.

    At least in the States, the default IP address for the DX controllers is 192.168.255.1. The 10 class is for the FS100 controllers. But almost any controller can be changed.

    I know a thing or two, because I’ve seen a thing or two. Don't even ask about a third thing. I won't know it.

    Thank you

    95devils and fester1981.

    I have tried with 10.0.0.3 none of the devices were responding.
    I will try with the other IP add tomorrow.
    also I will check whether it is having voltage or not.

    Will update here.

    Hello guys,

    on Friday I was trying to connect Ethernet switch between pendent and controller. but I realized that DX100 has its own switch why don't I try it? so i connected pendent to Ethernet switch and one cable from Ethernet switch to YCP01 board. robot was powered off at that time. I powered it on to connect the computer, and suddenly the error was gone. I was happy. but today morning my boss powered the robot on, he tried to manual move the robot, he was able to do that for few moments and the error came back. I tried changing Ethernet cable between switch and YCP01, tried changing Switch. nothing is working, error is keep coming back after some random amount of time every time. I did't get the chance to ping anyone of the devices because Friday after the error gone I did not found it necessary. well anyone have any idea about what is possibly happening here?

    Your controller has an ethernet switch inside? What was connected to it before you connected it in between the pendant and CN105?

    Do you happen to have a ethernet hub or switch with mirroring function available? Most managed Cisco switches (as does the relatively cheap Netgear ProSafe switches) have this option. This way you could monitor the traffic with Wireshark...

    In my experience, (in case of these non-fatal recurring faults) the parts that were moved the most, are the ones that are most likely to fail first. Being the cable between the controller and the pendant...

    Did you check both sides of the cables connectors for any bent/retracted pins or busses? The pins or busses of the controller and pendant connectors? The connection of the wires inside the connectors?

    There are 2 rules for success:

    1. Never reveal everything you know,

    Quote from Fester1981

    Your controller has an ethernet switch inside? What was connected to it before you connected it in between the pendant and CN105?

    Do you happen to have a ethernet hub or switch with mirroring function available? Most managed Cisco switches (as does the relatively cheap Netgear ProSafe switches) have this option. This way you could monitor the traffic with Wireshark...

    In my experience, (in case of these non-fatal recurring faults) the parts that were moved the most, are the ones that are most likely to fail first. Being the cable between the controller and the pendant...

    Did you check both sides of the cables connectors for any bent/retracted pins or busses? The pins or busses of the controller and pendant connectors? The connection of the wires inside the connectors?

    Yes My controller has an Ethernet switch inside. nothing was connected to it before I connected it between pendent and CN105. I have a netgear Switch that I tried using. It doesn't work as well .

    well we have changed the cable and the pendent, tried with all possible combination of two cables and two pendent that we have. what we haven't

    changed yet is X81 on ( the connector for CBL-YRC061) on the DX100. and the Ethernet cable connected to that connector. other pins and buses on the either side of cable and programming pendent - I have checked and it doesn't seems to be broken or bent.

    I only get to work on robot on Fridays and Sundays, when the production is stopped. so Please let me know if anyone have any idea about.

    I would like to change the X81 connector. Do anyone know how I can do that?

    Just for future reference to anyone,

    We finally had to call Yaskawa Tech support in to our facility.

    It turned out that everything inside the controller is good. CPU, X81-internal Harness, Cable and Pendent.

    our robot is connected to PLC and PLC is connected to an HMI. HMI is connected to plant network and that is causing issue.

    it's too much traffic for controller to handle. Once we disconnect the PLC from network, its running good with no error.

    at the same time we have to connect PLC to the network, we cannot take it out of it.

    We still need to figure out the solution. if anyone have any idea please let me know.

    Thank you,

    Quote from Robodoc

    You need a managed switch to limit the bits per second to the robot on your Ethernet network.

    I ran into this 15 years ago. Didn't prevent the controller from booting but caused a major alarm. Wrong switch was used. Like Doc said, we changed to a managed switch to keep the controller from being flooded with data.

    I know a thing or two, because I’ve seen a thing or two. Don't even ask about a third thing. I won't know it.

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