Why Your Yaskawa DX100 Teach Pendant Might Be Failing (And How VICPAS Can Help)

The Yaskawa DX100 Teach Pendant (model JZRCR-YPP01-1) is the heart of your Motoman robot system—used for programming, jogging, and diagnostics. But issues like "Controller-Pendant connection failed", screen freezing, communication disconnected, or faulty E-stop/enable switch can halt production.

Common causes: Cable damage, version mismatches, network overload, battery failure, or hardware wear.

VICPAS Experience: We've helped thousands of factories restore Yaskawa DX100 Teach Pendant functionality with OEM-quality parts and fast global delivery. Skip downtime—get your quote in 24 hours!

Top 5 Yaskawa DX100 Teach Pendant Issues & Quick Fixes

Issue	Symptoms	Quick Fix
Connection Failed	"Controller-Pendant connection failed" on boot	Check cable/LEDs, match versions
Communication Disconnected	Intermittent drops, "Check DS1 LED"	Reduce network traffic, ping test
Screen Freezing	Pendant locks, TPS 1111 error	Reset via HMI or full restart
Unresponsive Buttons/E-stop	No servo ON, alarms 4381-4384	Inspect switch/wiring
Enable Switch Failure	Servo won't engage	Test grasp, replace if sticky

Step-by-Step: Troubleshoot Yaskawa DX100 Teach Pendant Issues Like a Pro

Step 1: Safety First (Official Motoman Protocol)

• Power OFF controller, wait 5 mins.
• Press E-stop on pendant/door—verify SERVO ON LED off.
• Clear robot envelope—no personnel!
• Backup CMOS.BIN via CF card.

Step 2: Basic Diagnostics & Reset

1. Power ON—watch HEX display (E=error, 8=no CF card).
2. Check backup battery (3.63V+), CF card for CMOS.bin.
3. Ping test: PC (10.0.0.3) → Controller (192.168.255.1).
4. Alarm Reset: {Main Menu} > {Alarm History} > [Reset].

Step 3: Fix Connection & Communication Problems

• LED Check: DS1 on YIF board (green=OK).
• Cable Test: Multimeter on pins, swap Ethernet switch.
• Version Match: DX100 pendant needs NS5.00+ software.
• Network Fix: Use managed switch to limit traffic.

Step 4: Hardware Deep Dive

• Enable/E-stop: Lightly grasp switch—test servo ON.
• Cables: Inspect for fraying (8m standard).
• Touchscreen/Keypad: Clean, test beeps in maintenance mode (hold [Main Menu] on boot).

Step 5: Key Alarms for Yaskawa DX100 Teach Pendant

Alarm Code	Cause	Fix
4381	Enable switch error	Check wiring CN209
4384	Signal mismatch	Verify E-stop pins
TPS 1111	External comms	HMI reset

When to Replace: Get Genuine Yaskawa DX100 Teach Pendant Parts from VICPAS

If resets fail, hardware replacement is key. Don't risk downtime with cheap knockoffs!

• Full Pendant: JZRCR-YPP01-1 (8m cable) – In Stock at VICPAS!
• Repair Kits: Touchscreen membrane, keypad, housing – From $15.90
• Why VICPAS? Custom fits, 360-day warranty, DHL same-day ship. Proven for Yaskawa DX100 Teach Pendant repairs worldwide.

VICPAS: Your Trusted Partner for Yaskawa DX100 Teach Pendant Solutions

With 20+ years specializing in HMI/robot parts, VICPAS delivers:

• Expert Support: Free troubleshooting via email/tel.
• Customization: Tailored kits for your DX100.
• Global Reach: Ships to 100+ countries.

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References

1. Yaskawa Motoman Knowledge Center – DX100 Error Message List
2. Yaskawa Motoman – DX100 Major Alarms
3. Motoman DX100 Controller / Programming Pendant Manual (PDF)
4. Robot-Forum – Controller ↔ Pendant Connection Failed
5. Robot-Forum – DX100 Communication Issue
6. Robot-Forum – DX100 Teach Pendant Freezing
7. DX100 Maintenance / Service Manual (PDF)
8. ROS motoman_driver Troubleshooting Wiki
9. inRobots – DX100 Teach Pendant Repair Parts
10. MRO Electric – JZRCR-YPP01-1 Pendant Specs

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Last Updated: October 29, 2025 | VICPAS – #1 in Robot HMI Parts