Page 1 /QVQOCP :4% %QPVTQNNGT /CPKRWNCVQT /CPWCN Part Number: 142104-1 Release Date: January 31, 2001 Document Version: Document Status: Final Motoman, Incorporated 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-Hour Service Hotline: (937) 847-3200...
Page 2 Motoman, Inc. ©2003 by MOTOMAN All Rights Reserved Because we are constantly improving our products, we reserve the right to change specifications without notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
Page 3: Table Of Contents
TABLE OF CONTENTS Section Page INTRODUCTION......................1-1 SAFETY ........................2-1 UP6 INSTRUCTIONS (R2)...................3-1 XRC INSTRUCTIONS — NORTH AMERICAN STANDARD (R1) ........4-1 XRC INSTRUCTIONS — GENERAL (R2)...............5-1 XRC TROUBLESHOOTING ..................6-1 UP6 ELEMENTARY DIAGRAMS ..................7-1 MOTO MAN UP6 Manipulator Manual...
Page 4 NOTES UP6 Manipulator Manual MOTO MAN...
Page 5: Introduction
SECTION 1 INTRODUCTION The Motoman UP6 and XRC controller represent state-of-the-art technology in robotics today. The UP6 has six individual axes: Sweep, Lower arm, Upper arm, Rotate, Bend, and Twist. The XRC controller coodinates the operation of the UP6 robot with external equipment such as power supply and positioning tables.
Page 6 INTRODUCTION Reference to Other Documentation For additional information refer to the following: • Concurrent I/O Parameters Manual (P/N 142102-1) • Operator’s Manual for General Purpose (P/N 142099-1) • Operator’s Manual for Handling (P/N 142100-1) • Operator’s Manual for Spot Welding (P/N 142101-1) •...
Page 7 SECTION 2 SAFETY Introduction It is the purchaser's responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed. We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems.
Page 8 SAFETY Standard Conventions This manual includes information essential to the safety of personnel and equipment. As you read through this manual, be alert to the four signal words: • DANGER • WARNING • CAUTION • NOTE Pay particular attention to the information provided under these headings which are deﬁned below (in descending order of severity).
Page 9 SAFETY General Safeguarding Tips All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot 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: •...
Page 10 SAFETY Installation Safety Safe installation is essential for protection of people and equipment. following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location.
Page 11 SAFETY • Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc. • Be sure that all safeguards are in place. • Check the E-STOP button on the teach pendant for proper operation before programming.
Page 12 SAFETY Maintenance Safety All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Maintenance tips are as follows: •...
Page 13 YASKAWA MOTOMAN-UP6 INSTRUCTIONS YR-UP6-A00 YR-UP6-A01 Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN-UP6 INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR’S MANUAL YASNAC XRC OPERATOR’S MANUAL for BEGINNERS The YASNAC XRC operator’s manuals above correspond to specific usage.
Page 14 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 rep- resentative to order a new copy. The representatives are listed on the back cover.
Page 15 NOTES FOR SAFE OPERATION Read this manual carefully before installation, operation, maintenance, or inspection of the YASNAC XRC. In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”. Indicates a potentially hazardous situation which, if not avoided, W A R N I N G could result in death or serious injury to personnel.
Page 16 WARNING • Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the playback panel or program- ming pendant are pressed. When the servo power is turned off, the SERVO ON READY lamp on the playback panel and the SERVO ON LED on the programming pendant are turned off.
Page 17 • Read and understand the Explanation of the Alarm Display in the Setup Manual before operating the manipulator: Definition of Terms Used Often in This Manual The MOTOMAN manipulator is the YASKAWA industrial robot product. The manipulator usually consists of the controller, the playback panel, the programming pen- dant, and supply cables.
Page 18 AN EXPLANATION OF WARNING LABELS The following warning labels are attached to the manipulator. Always follow the warnings on the labels. Also, an indentification label with important information is placed on the body of the manipula- tor. Prior to operating the manipulator, confirm the contents. WARNING WARNING M O T O M A N...
Page 19 Receiving 1.1 Checking Package Contents ....... .1-1 1.2 Checking the Order Number .
Page 20 System Application 7.1 Mounting Equipment ........7-1 7.1.1 Allowable Load .
Page 21: Receiving
1.1 Checking Package Contents 1 Receiving C A U T I O N • Confirm that the manipulator and the XRC have the same order number. Special care must be taken when more than one manipulator is to be installed. If the numbers do not match, manipulators may not perform as expected and cause injury or damage.
Page 22: Checking The Order Number
1.2 Checking the Order Number Checking the Order Number Check that the order number of the manipulator corresponds to the XRC. The order number is located on a label as shown below. Label(Enlarged view) THE MANIPULATOR AND THE CONTROLLER Check that the manipulator SHOULD HAVE SAME ORDER NUMBER.
Page 23: Transporting
2.1 Transporting Method 2 Transporting C A U T I O N • Sling applications and crane or forklift operations must be performed by authorized personnel only. Failure to observe this caution may result in injury or damage. • Avoid excessive vibration or shock during transporting. The system consists of precision components, so failure to observe this caution may adversely affect performance.
Page 24: Using The Forklift
2.2 Shipping Bolts and Jigs 2.1.2 Using the Forklift When using a forklift, the manipulator should be fixed on a pallet with shipping bolts and jigs as shown in " Fig. 3 Using the Forklift ". Insert claws under the pallet and lift it. The pallet must be strong enough to support the manipulator.
Page 25: Installation
3 Installation W A R N I N G • Install the safety guards. Failure to observe this warning may result in injury or damage. • Install the manipulator in a location where the fully extended arm and tool will not reach the wall, safety guards, or controller. Failure to observe this warning may result in injury or damage.
Page 26: Safety Guard Installation
3.1 Safety Guard Installation Safety Guard Installation To insure safety, be sure to install safety guards. They prevent unforeseen accidents with per- sonnel and damage to equipment. The following is quoted for your information and guidance. (ISO10218) Responsibility for Safeguarding The user of a manipulator or robot system shall ensure that safeguards are provided and used in accordance with Sections 6, 7, and 8 of this standard.
Page 27: When The Manipulator And Mounting Fixture Are
3.2 Mounting Procedures for Manipulator Baseplate 3.2.1 When the Manipulator and Mounting Fixture are Installed on a Common Flat Steel Plate The common base should be rugged and durable to prevent shifting of the manipulator or the mounting fixture. The thickness of the common base is 40mm or more and an M16 size or larger anchor bolt is recommended.
Page 28: When The Manipulator Is Mounted Directly On The Floor
3.2 Mounting Procedures for Manipulator Baseplate 3.2.2 When the Manipulator is Mounted Directly on the Floor The floor should be strong enough to support the manipulator. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the manipulator as shown in Table 1.
Page 29: Types Of Mounting
Refer to " Fig. 6 When Using Ceiling and Wall-Mounted Types " for details. Support 4 × M16 Hexagon Socket Head Cap Bolts Manipulator Base (Tensile Strength: 1200N/mm or Above) Fig. 6 When Using Ceiling and Wall-Mounted Types N OT E When using wall-mounted or ceiling mounted types, contact your Yaskawa representative.
Page 30: Location
3.4 Location Location When the manipulator is installed, it is necessary to satisfy the undermentioned environmental conditions: • 0° to +45°C (Ambient temperature) • 20 to 80%RH (no moisture) • Free from dust, soot, or water • Free from corrosive gases or liquid, or explosive gases •...
Page 31: Wiring
4 Wiring W A R N I N G • Ground resistance must be 100 Ω or less. Failure to observe this warning may result in fire or electric shock. • Before wiring, make sure to turn the primary power supply off, and put up a warning sign.
Page 32: Grounding
4.1 Grounding Grounding Follow local regulations for grounding line size. • Do not use this line in common with other ground lines or grounding electrodes for other N OT E electric power, motor power, welding devices, etc. • Where metal ducts, metallic conduits, or distributing racks are used for cable laying, ground in accordance with Electric Equipment Technical Standards.
Page 33: Connection To The Xrc
4.2 Cable Connection 4.2.2 Connection to the XRC Remove the two entrance cable covers on the XRC side. Pass the signal cable for detection (1BC) through one entrance, the power cable (2BC) through the other entrance, and then fas- ten bolts on the entrances. Connect each cable to the boards.
Page 34 4.2 Cable Connection Power Cable Signal Cable Connector No. XIU01-CN29 Connector No. XIU01-CN25 Signal Cable Connector No. WRCA01-CNPG456 (upper) WRCA01-CNPG123 (lower) Grounding plate for Signal and power line Terminal No.: E Power Cable Tighten the screws with screw driver(+). Connector 1PWM-1-CN1,2,3,4,5,6 (from left side) Fig.
Page 35: Basic Specifications
5.1 Basic Specifications 5 Basic Specifications Basic Specifications Table. 2 Basic Specifications Operation Mode Vertically Articulated Degree of Freedom Payload ±0.08mm Repetitive Positioning Accuracy S-Axis (turning) ±170° L-Axis (lower arm) +155°, -90° U-Axis (upper arm) +190°, -170° Motion Range R-Axis (wrist roll) ±180°...
Page 36: Part Names And Working Axes
5.2 Part Names and Working Axes Part Names and Working Axes Fig. 10 Part Names and Working Axes Baseplate Dimensions View A Fig. 11 Baseplate Dimensions (mm)
Page 37: Dimensions And Working Range
5.4 Dimensions and Working Range Dimensions and Working Range Point P WorkingRange Point P Fig. 12 Dimesions and Working Range...
Page 38: B-Axis Working Range
Alterable Working Range The working range of the S-Axis can be altered according to the operating conditions as shown in " Table. 3 S-Axis Working Range ". If alteration is necessary, contact your Yaskawa representative in advance. Table. 3 S-Axis Working Range...
Page 39: Allowable Load For Wrist Axis And Wrist Flange
The allowable total inertia is calculated when the moment is at the maximum. Contact your Yaskawa representative when only inertia moment, or load moment is small and inertia moment is large. Also, when the load mass is combined with an outside force, contact your Yaskawa representative.
Page 40: Wrist Flange
6.2 Wrist Flange Wrist Flange The wrist flange dimensions are shown in " Fig. 15 Wrist Flange ". In order to see the tram marks, it is recommended that the attachment be mounted inside the fitting. Fitting depth of inside and outside fittings must be 5mm or less. 4-M6 ×...
Page 41: System Application
7.1 Mounting Equipment 7 System Application Mounting Equipment When peripheral equipment is attached to the U-axis, the following conditions should be observed. 7.1.1 Allowable Load The allowable load on the U-Axis is a maximum of 15kg, including the wrist load. For instance, when the mass installed in the wrist point is 6kg, the mass which can be installed on the upper arm becomes 9kg.
Page 42: Incorporated Wire And Airduct
7.2 Incorporated Wire and Airduct Incorporated Wire and Airduct Wires and an air line are incorporated into the manipulator for user application. There are 16 wires and an air duct rating. The allowable current for wires must be 3A or below for each wire.
Page 43: Motoman Construction
8.1 Position of S-Axis Limit Switch 8 Motoman Construction Position of S-Axis Limit Switch The limit switches for the S-, L-, and U-Axes are located as shown in " Fig. 20 Location of Limit Switches ". The limit switch for the S-Axis is standard. The limit switch for the L- and U- Axes are optional (model UP6-A01).
Page 44: Internal Connections
8.2 Internal Connections Internal Connections High reliability connectors which can be easily removed are used with each connector part. For the number and location of connectors, see " Fig. 21 Location and Numbers of Connec- tors ". 3BC (For Internal Wire) 3BC (For Internal Wire) Fig.
Page 45 Feeder Cable Internal Wiring B and T Axes Internal wiring for Laxis L.S. YASNAC-XRC for Fan 1BC(6´6) No. 1CN WRCA01 CN 1- 1 DATA+1 DATA+ 1 CNPG123 CN 1-2 DATA-1 DATA- 1 S-AXIS CN 1-3 +5-1 CN 1-4 0V-1 FG 1 No.
Page 46 Feeder Cable Internal Wiring B and T Axes Internal wiring Casing Base 3BC(20-29) 3BC(20-29) 3BC-1 2BC-1 Incorporated wires 0.75 0.75 1.25 1.25 1.25 1.25 2BC(6X6) For FAN (OPTION) 1PWM-1-CN1 No.3CN CN 1- 1 3CN-1 CN 1-2 S-AXIS CN 1-3 CN 1-4 CN 1-5 CN 1-6 2PWM-1-CN1...
Page 47: Maintenance And Inspection
For any different or special applications, the inspection process should be developed on an case-by-case basis. For axes which are used very frequently (in handling applications, etc.), it is recom- mended that inspections be conducted at shorter Intervals. Contact your Yaskawa repre- sentative.
Page 48 9.1 Inspection Schedule Table. 6 Inspection Items Schedule Inspection Charge Operation Items Method 1000 6000 12000 24000 36000 Specified Service Daily Licensee Person Company Cycle Cycle Cycle Check tram mark • ¡ accordance and ¡ ¡ ¡ Tram mark Visual damage at the home position.
Page 49 9.1 Inspection Schedule Table. 6 Inspection Items Schedule Inspection Charge Operation Items Method 1000 6000 12000 24000 36000 Specified Service Daily Licensee Person Company Cycle Cycle Cycle Check for malfunc- tion. (Replace if nec- essary.) Supply grease (6000H cycle). See Par. " 9.2.2 Grease Replenishment/ Replacement for S-...
Page 50 Inspection No. correspond to the numbers in " Fig. 23 Inspection Parts and Inspection Numbers ". The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa representative. R-Axis...
Page 51 9.1 Inspection Schedule Table. 7 Inspection Parts and Grease Used Grease Used Inspected Parts Molywhite RE No. 00 S-, L-, and U-axis speed reducers 12, 13 Harmonic Grease SK-1A R-, B-, and T-axis speed reducers, 14, 15 T-axis gear Alvania EP Grease 2 R-axis cross roller bearings The numbers in the above table correspond to the numbers in "...
Page 52: Notes On Maintenance Procedures
9.2 Notes on Maintenance Procedures Notes on Maintenance Procedures 9.2.1 Battery Unit Replacement If the battery alarm occurs in the XRC, replace the battery according to the following proce- dure: Battery Unit Connector Base Connector Support Base Bolt Fig. 24 Battery Location Battery unit for SLU-axes HW9470917-A See Procedure 6...
Page 53: Grease Replenishment/Replacement For S-Axis Speed
9.2 Notes on Maintenance Procedures 6. Remove the old battery. Remove the old battery unit after connecting the new one so that the encoder absolute N OT E data does not disappear. 7. Protect the connection part of the battery unit in the manipulator with plastic tape (insu- lation tape).
Page 54: Grease Replenishment
9.2 Notes on Maintenance Procedures Grease Replenishment (Refer to " Fig. 26 S-Axis Speed Reducer Diagram ".) Replenish the grease according to the following procedure: 1. Remove the So exhaust plug. If grease is added without removing the exhaust plug, the grease will go inside the motor N OT E and may damage it.
Page 55: Grease Replenishment/Replacement For L-Axis Speed
9.2 Notes on Maintenance Procedures 9.2.3 Grease Replenishment/Replacement for L-Axis Speed Reducer Lo: Grease exhaust plug L-axis speed G Nipple A-MT6 × 1 reducer Li: Grease inlet G Nipple A-MT6 × 1 Fig. 27 L-Axis Speed Reducer Diagram N OT E For ceiling mounted manipulators, the exhaust port and the grease inlet are inverted.
Page 56: Grease Replacement (Refer To " Fig. 27 L-Axis Speed Reducer Diagram ".)
9.2 Notes on Maintenance Procedures Grease Replacement (Refer to " Fig. 27 L-Axis Speed Reducer Dia- gram ".) 1. Make the L-arm vertical for ground. 2. Remove the Lo exhaust plugs. If grease is added without removing the exhaust plugs, the grease will go inside the motor N OT E and may damage it.
Page 57 9.2 Notes on Maintenance Procedures Grease Replenishment (Refer to " Fig. 28 U-Axis Speed Reducer Diagram ".) 1. Make the U-arm horizontal for ground. 2. Remove the Uo exhaust plugs. If grease is added without removing the exhaust plugs, the grease will go inside the motor N OT E and may damage it.
Page 58: Grease Replenishment For R-Axis Speed Reducer
9.2 Notes on Maintenance Procedures 9.2.5 Grease Replenishment for R-Axis Speed Reducer Ro: Plug for air flow (Hexagon socket head M6) R-axis speed reducer Ri: Grease inlet G Nipple A-MT6 × 1 Section A-A Fig. 29 R-Axis Speed Reducer Diagram 1.
Page 59: Grease Replenishment For B- And T-Axis Speed Reducers
9.2 Notes on Maintenance Procedures 9.2.6 Grease Replenishment for B- and T-Axis Speed Reducers Bo: Plug for air flow T-axis speed reducer To: Plug for air flow B-axis speed reducer Bi: Grease inlet G Nipple A-MT6 × 1 Ti: Grease inlet G Nipple A-MT6 ×...
Page 60: Grease Replenishment For T-Axis Gear
9.2 Notes on Maintenance Procedures 9.2.7 Grease Replenishment for T-Axis Gear Bo: Plug for air flow Gear Grease Inlet (G Nipple A-MT6 × 1) Fig. 31 T-Axis Gear Diagram 1. Remove the Bo plug for air flow. 2. Inject grease into the gear grease inlet using a grease gun. (Refer to " Fig. 31 T-Axis Gear Diagram ".) Grease type: Harmonic grease SK-1A Amount of grease: 5cc...
Page 61: Grease Replenishment For R-Axis Cross Roller Bearing
9.2 Notes on Maintenance Procedures 9.2.8 Grease Replenishment for R-Axis Cross Roller Bear- Co plug for air flow R-axis cross roller bearing Ci: Grease Inlet (G Nipple A-MT6 × 1) Section A-A Fig. 32 R-Axis Cross Roller Bearing Diagram 1. Remove the Co plug for air flow. 2.
Page 62: Notes For Maintenance
9.2 Notes on Maintenance Procedures 9.2.9 Notes for Maintenance Wrist Axes The motor and encoder units are provided with the wrist unit. To prevent fumes from penetrat- ing into the wrist unit, the matched parts are sealed with silicon sealant. Therefore, if the wrist cover is disassembled, reseal with silicon sealant (modifier silicon caulk, refer to "...
Page 63: 10 Recommended Spare Parts
• Rank B: Parts for which replacement may be necessary as a result of frequent operation • Rank C: Drive unit N OT E For replacing parts in Rank B or Rank C, contact your Yaskawa representative. Table. 8 Spare Parts for the Motoman-UP6 Parts...
Page 64 Table. 8 Spare Parts for the Motoman-UP6 Parts Rank Name Type Manufacturer Remarks Unit R-Axis HW9381377-A Yaskawa Electric Speed Reducer Corporation B-Axis HW9381454-A Yaskawa Electric Speed Reducer Corporation T-Axis HW9381379-A Yaskawa Electric Speed Reducer Corporation Internal Wiring HW9171470-A Yaskawa Electric...
Page 65: 11 Parts List
11.1 S-Axis Parts List 11 Parts List 11.1 S-Axis Parts List 11-1...
Page 66 11.1 S-Axis Parts List DWG No. Name Pcs. DWG No. Name Pcs. 1001 HW9100881-1 Base M5 ×6 1057 Round head 1002 POC6-01M Union screw M6 × 8 1003 NB-0640-0.25 Tube 1058 APS bolt 1004 HW9100941-1 S head 1059 TA1-S10 Clamp 1005 HW9302222-1 M base...
Page 67: 11.2 L.u-Axis Driving Unit
11.2 L.U-Axis Driving Unit 11.2 L.U-Axis Driving Unit 11-3...
Page 68 11.2 L.U-Axis Driving Unit DWG No. Name Pcs. 1004 HW9100941-1 S head 2001 SGMDH-12A2A- Motor YR12 GT-SA M8 × 30 2002 Socket screw 2003 HW9100942-1 L arm M14 × 35 2004 Socket screw 2005 GT-SH M14 Washer A-MT6 × 1 2006 G nipple 2007...
Page 69: 11.3 R-Axis Driving Unit
11.3 R-Axis Driving Unit 11.3 R-Axis Driving Unit 11-5...
Page 70 11.3 R-Axis Driving Unit DWG No. Name Pcs. 2019 HW9100943-1 Casing 3001 HW9331377-A Reduction gear GT-SA M6 × 40 3002 Socket screw GT-SA M4 × 12 3003 Socket screw 3004 AG3584A0 Cross rollar bearing GT-SA M5 × 12 3005 Socket screw 3006 HW9301499-1 Housing...
Page 71: 11.4 Wrist Unit
11.4 Wrist Unit 11.4 Wrist Unit 11-7...
Page 72 11.4 Wrist Unit DWG No. Name Pcs. DWG No. Name Pcs. 3006 HW9301499-1 Housing M4 × 8 4050 Round head GT-SA M6 × 40 3028 Socket screw screw 4001 SGMPH-01A1A- Motor 4051 T50R Insulok’ tie YR21 A-MT6 × 1 4052 G nipple 4002 SGMPH-01A1A-...
Page 74 TAIPEI OFFICE Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan Phone 886-2-2563-0010 Fax 886-2-2567-4677 BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD. 30 Xue Yuan Road, Haidian, B eijing P.R. China Post Code: 100083 Phone 86-10-6233-2782 Fax 86-10-6232-1536 SHOUGANG MOTOMAN ROBOT CO., LTD.
Page 75 YASKAWA YASNAC XRC INSTRUCTIONS FOR NORTH AMERICAN STANDARD Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN-!!! INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR’S MANUAL YASNAC XRC OPERATOR’S MANUAL for BEGINNERS...
Page 76 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 rep- resentative to order a new copy. The representatives are listed on the back cover.
Page 77 NOTES FOR SAFE OPERATION Read this manual carefully before installation, operation, maintenance, or inspection of the YASNAC XRC. In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,” “MANDATORY,” or ”PROHIBITED.” Indicates a potentially hazardous situation which, if not avoided, W A R N I N G could result in death or serious injury to personnel.
Page 78 W A R N I N G • Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the playback panel or program- ming pendant are pressed. When the servo power is turned off, the SERVO ON READY lamp on the playback panel and the SERVO ON LED on the programming pendant are turned off.
Page 79 • Read and understand the Explanation of the Alarm Display in the Setup Manual before operating the manipulator. Definition of Terms Used Often in This Manual The MOTOMAN manipulator is the YASKAWA industrial robot product. The manipulator usually consists of the controller, the playback panel, the programming pen- dant, and supply cables.
Page 80 Descriptions of the programming pendant and playback panel keys, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters printed on them are Pendant denoted with [ ]. ex. [ENTER] Symbol Keys The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture.
Page 81 YASNAC XRC Specification 1.1 Specification List ......... . . 1-3 1.2 Function List .
Page 82 viii...
Page 83 1 YASNAC XRC Specification WARNING • Before operating the manipulator, check that the SERVO ON lamp goes out when the emergency stop buttons on the playback panel and pro- gramming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.
Page 84 C A U T I O N • Perform the following inspection procedures prior to performing teach- ing operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed. - Check for problems in manipulator movement. - Check for damage to the insulation and sheathing of external wires.
Page 85 1.1 Specification List Specification List Controller Configuration Free-standing, enclosed type Dimensions Refer to following Cooling System Indirect cooling Ambient Temperature 0°C to + 45°C (During operation) -10°C to + 60°C (During transit and storage) Relative Humidity 90%RH max. (non-condensing) Power Supply 3-phase, 240/480/570 VAC(+10% to -15%) at 50/60Hz(±2 Hz) (Built-in transformer tap switchable) Built-in transformer 240 V - 480 V - 570 V/208 V ( -...
Page 86 1.2 Function List Function List Programming Coordinate System Joint, Rectangular/Cylindrical, Tool, User Coordinates Pendant Modification of Adding, Deleting, Correcting (Robot axes and external axes Operation Teaching Points can be independently corrected.) Inching Operation Possible Locus Confirmation Forward/Reverse step, Continuous feeding Speed Adjustment Fine adjustment possible during operating or pausing Timer Setting...
Page 87 1.3 Programming Pendant Programing Programming Interactive programming Functions Language Robot language: INFORM II Robot Motion Con- Joint coordinates, Linear/Circular interpolations, Tool coordi- trol nates Speed Setting Percentage for joint coordinates, 0.1mm/s units for interpola- tions, Angular velocity for T.C.P. fixed motion Program Control Jumps, Calls, Timer, Robot stop, Execution of some instruc- Instructions...
Page 88 1.4 Equipment Configuration Equipment Configuration The XRC is comprised of individual units and modules (circuit boards). Malfunctioning compo- nents can generally be easily repaired after a failure by replacing a unit or a module. This section outlines the XRC equipment configuration. 1.4.1 Arrangement of Units and Circuit Boards "...
Page 89 1.4 Equipment Configuration Playback Panel ZY1C-SS3152 Power Supply Unit I/O Power ON Unit Brake Release Operation Panel (with protective cover) CPU Unit JZNC-XIU01 JZRCR-XPU09 JZNC-XRK01 B-1 Brake Reliase Control Board JZRCR-XFL02 Disconnecting Switch 194R-NC030P3 Fuse: Class CC 5A (UP6) Fues: Class CC 10A (Sk16X) Servopack CACR-UP6AAC (UP6) CACR-SK16AAC (SK16X)
Page 90 1.4 Equipment Configuration Playback Panel ZY1C-SS3152 Power Supply Unit Brake Release Operation Panel I/O Power ON Unit CPU Unit (with protective cover) JZRCR-XPU08 JZNC-XIU01 JZNC-XRK01B-1 Brake Release Control Board JZRCR-XFL02 Disconnecting Switch 194R-NC030P3 Fuse: Class CC 15A Converter JUSP-ACP25JAA Servo Unit CACR-SK45AAB (SK45X) CACR-SK16MAAB (SK16M) (Front Door Rear Side)
Page 91 1.4 Equipment Configuration Playback panel ZYRCR-XFL02 Power Supply Unit Brake Release Operation Panel CPU Unit (with protective cover) I/O Power ON Unit JZNC-XRK01B-1 JZRCR-XPU07 JZNC-XIU01 Brake Release Control Board JZRCR-XFL02 Disconnecting Switch 194R-NC030P3 Huse: Class CC 20A Converter JUSP-ACP35JAA Servopack CACR-UP130AAB (UP130 and UP165) CACR-UP130AABY18 (UP200 and UP130R) (Front Door Rear Side)
Page 92 1.4 Equipment Configuration Playback Panel ZY1C-SS3152 Power Supply Unit CPU Unit I/O Power on Unit Brake Release Operation Panel (with protective cover) JZNC-XRK01B-1 JZNC-XIU01 JZRCR-XPU07 Brake Reliase Control Board JZRCR-XFL02 Disconnecting Switch (QS1) 194R-NC030P3 Fuse: Class CC 30A No Fuse Breaker (QF2) BU-ECA3040-L 40A 3P Converter JUSP-ACP35JAA...
Page 93 1.4 Equipment Configuration 1.4.2 Cooling System of the Controller Interior Servo Backside Duct Fan Air Inlet Servopack Air Outlet Cooling System (SV3X) Servo Top Fan Air Inlet Servopack Backside Duct Fan Air Output Natural heat radiation Natural heat radiation Cooling System (Except for SV3X) 1-11...
Page 94 1.4 Equipment Configuration 1-12...
Page 95 Description of Units and Circuit Boards W A R N I N G • Before operating the manipulator, check that the SERVO ON lamp goes out when the emergency stop buttons on the playback panel and pro- gramming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.
Page 96 2.1 Power Supply Unit C A U T I O N • Perform the following inspection procedures prior to performing teach- ing operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed. - Check for problems in manipulator movement.
Page 97 2.1 Power Supply Unit (1Z) Noise Filter (5X) Single 200 VAC Output Connector (4X) Contactor Output, etc. Contactor Output (1F, 2F) Fuse (1X) Single-phase 200 VAC Output Connector (1KM) Contactor Power Supply Unit Configuration (JZRCR-XPU07 for UP130, UP130R, UP165, UP200, SK300X and SP100X)
Page 98 2.1 Power Supply Unit (1Z) Noise Filter (5X) (4X) Single-phase Output Connector Connector Output, etc. 10A 250V 10A 250V Connector Output (1F, 2F) Fuse (1X) Single-phase Output Connector (1KM) Contactor Power Supply Unit Configuration (JZRCR-XPU08 for SK45X and SK16MX)
Page 99 2.1 Power Supply Unit (1Z) Noise Filter (5X) Single-phase 200 VAC Output Connector (4X) Contactor Output, etc. Contactor Output 10A 250V 10A 250V (1F, 2F) Fuse (3X) Triple-phase 200 VAC input (1KM) Contactor (2X) Triple-phase 200 VAC Output Connector (1X) Single-phase 200 VAC input Power Supply Unit Configuration (JZRCR-XPU09 for SV3X, UP6 and SK16X)
Page 100 2.2 Brake Release Unit Brake Release Unit Brake Release Switch Brake Release Operation Panel Display LED YASNAC XRC WARNING SERVO ON MODE READY PLAY TEACH BRAKE RELEASE WARNING EDIT LOCK ALARM (OFF) (ON) REMOTE HOLD START High Voltage Do not open the door with power ON Axis Selection Switch Door Surface...
Page 101 3.1 Regular Inspections 3 Inspections Regular Inspections C A U T I O N • Do not touch the cooling fan or other equipment while the power is turned ON. Failure to observe this caution may result in electric shock or injury. Carry out the following inspections.
Page 102 3.2 XRC Inspections XRC Inspections 3.2.1 Checking if the Doors are Firmly Closed • The YASNAC XRC has a fully sealed construction, designed to keep external air contain- ing oil mist out of the XRC. Be sure to keep the XRC doors fully closed at all times, even when the controller is not operating.
Page 103 3.3 Cooling Fan Inspections 3.2.2 Checking for Gaps or Damage in the Sealed Con- struction Section • Open the door and check that the seal around the door is undamaged. • Check that the inside of the XRC is not excessively dirty. If it is dirty, determine the cause, take measures to correct the problem and immediately clean up the dirt.
Page 104 3.3 Cooling Fan Inspections In-panel fan on Upper part of esrbo Air Inlrt Servo pack Backside duct fan Air Outlrt Natural heat radiation Natural heat radiation Cooling Fan Construction (Except for SV3X)
Page 105 3.4 Emergency Stop Button Inspections Emergency Stop Button Inspections The emergency stop buttons are located on both the playback panel and the programming pendant. Confir the servo power is off by pressing the emergency stop button on the play- back panel after the servo ON button, before the robot is operated. Deadman Switch Inspections The programing pendant is equipped with a three-position deadman switch.
Page 106 3.6 Battery Inspections Battery Inspections The XRC has a battery that backs up the important program files for user data in the CMOS memory. A battery alarm indicates when a battery has expired and must be replaced. The programming pendant display and the message "Memory battery weak" appears at the bottom of the dis- play.
Page 107 3.8 Open Phase Check Open Phase Check Open Phase Check List Check Item Contents Lead Cable Check Confirm if the lead cable for the power supply is wired as shown in the following. If the wiring is wrong or broken, repair it. Input Power Supply Check the open phase voltage of input power supply with an Check...
Page 108 3.8 Open Phase Check...
Page 109 4.1 Replacing XRC Parts 4 Replacing Parts Replacing XRC Parts W A R N I N G • Turn OFF the power supply before opening the XRC doors. Failure to observe this warning may result in electric shock. • After turning OFF the power supply, wait at least 5 minutes before replacing a servopack (including converter) or control power supply unit.
Page 110 4.1 Replacing XRC Parts 4.1.1 Replacing the Disconnecting Switch The disconnecting switch (QS1) is equipped with the following fuses. Parts No. Fuse Name Specification FU1, Power Supply Fuse 600 VAC * FU2, TIME DELAY/CLASS CC (GOULD) The type of fuse differs depending on the robot model. Refer to the table “Power Sup- ply Fuse List”.
Page 111 4.1 Replacing XRC Parts Power Supply Fuse List Fuse Type Robot Model With built-in transformer Without transformer SV3X ATDR3 3A (Class CC ATDR10 10A (Class CC) ATDR5 5A (Class CC ATDR10 10A (Class CC) SK16X ATDR10 10A (Class CC) ATDR15 15A (Class CC) SK45X, SK16MX ATDR15 15A (Class CC) ATDR20 20A (Class CC)
Page 112 4.1 Replacing XRC Parts 4.1.2 Replacing Parts of Power Supply Unit The power supply unit (JZRCR-XPU07, 08, and 09) is equipped with the following fuses. Parts No. Fuse Name Specification 1F, 2F Control Power Supply Fuse 250V, 10A, Time Lag Fuse (Std: 326010, 250V, 10A (LIT- TEL)) 10A 250V...
Page 113 4.1 Replacing XRC Parts 10A 250V 10A 250V (1F, 2F) Fuse 250V 10A 326010(LITTEL) Fuse Locations in Power Supply Unit XPU08 (for SK45X and SK16MX)
Page 114 4.1 Replacing XRC Parts 10A 250V 10A 250V (1F, 2F) Fuse 250V 10A 326010(LITTEL) Fuse Locations in Power Supply Unit XPU09 (for SV3X, UP6 and SK16X) If a fuse appears to be blown, remove each fuse shown above and check the continuity with an electric tester.
Page 115 4.2 YASNAC XRC Parts List YASNAC XRC Parts List YASNAC XRC Parts List Name Model Comment Servopack 6 Axis type CPU rack JZNC-XRK01B-$ Backboard JANCD-XBB01 System control circuit board JANCD-XCP01 High speed serial interface JANCD-XIF03 circuit board Control power supply CPS-150F I/O Power ON unit JZNC-XIU01...
Page 116 4.2 YASNAC XRC Parts List The type of the power supply unit depends on the robot model. For detail, see the " Table. Power Supply Unit Type ". The type of the fuse depends on the robot model. For detail, see the" Table. Power Supply Fuse "...
Page 117 4.2 YASNAC XRC Parts List Servopack List (Large Capacity) SK16MX SK45X Component Type Type Servopack CACR-SK16MAAB CACR-SK45AAB Amplifier JUSP-WS30AA JUSP-WS30AA JUSP-WS20AA JUSP-WS20AA JUSP-WS20AA JUSP-WS20AA JUSP-WS02AA JUSP-WS10AA JUSP-WS02AA JUSP-WS10AA JUSP-WS02AA JUSP-WS10AA Servo control JASP-WRCA01 JASP-WRCA01 circuit board Converter JUSP-ACP25JAA JUSP-ACP25JAA Control power JUSP-RCP01AAC JUSP-RCP01AAC supply...
Page 118 4.2 YASNAC XRC Parts List Servopack Configuration (Large Capacity Type) SK300X SP100X Component Type Type Servopack CACR-SK300AAB CACR-SP100AAB Amplifier JUSP-WS60AAY18 JUSP-WS60AAY18 JUSP-WS60AAY18 JUSP-WS60AAY18 JUSP-WS60AAY18 JUSP-WS60AAY18 JUSP-WS30AAY18 JUSP-WS30AAY18 JUSP-WS30AAY18 JUSP-WS20AAY19 Servo control JASP-WRCA01 JASP-WRCA01 circuit board Converter JUSP-ACP35JAA JUSP-ACP35JAA Control power JUSP-RCP01AAC JUSP-RCP01AAC supply...
Page 119 4.2 YASNAC XRC Parts List Transformer Type Robot Type Transformer Type SV3X NETB1000AULS18-1 1.0KVA 575-480-240V/208V UP6, SK16X NETH4500AULS16 4.5 kVA 575-480-240V/208V SK45X, UP130, UP130R, UP165, NETH8000AULS16 UP200 8.0 kVA 575-480-240V/208V SK300X, SP100X NETH012AULS16 12.0 kVA 575-480-240V/208V Power Supply Fuse Robot Type Fuse Type With transformer built-in Without transformer...
Page 120 4.3 Supplied Parts List Supplied Parts List The supplied parts of YASNAC XRC is as follows. Parts No.1 to 3 are used for fuse for replacement and No.4 is used as a tool for connecting the I/O. Parts Name Dimensions Model Application TIME DELAY/...
Page 121 XRC. The spare parts list for the XRC is shown below. Product performance can not be guaranteed when using spare parts from any company other than Yaskawa. To buy the spare parts which are ranked B or C, inform the manufacturing number (or order number) of XRC to Yaskawa representative.
Page 122 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP05JAA Yaskawa Control Power Supply Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP-WS02AA Yaskawa For S,L axis...
Page 123 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP05JAA Yaskawa Control Power Supply Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP- Yaskawa For S,U axis...
Page 124 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP05JAA Yaskawa Control Power Supply Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP- Yaskawa For S,L,U axis...
Page 125 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP25JAA Yaskawa Control Power Supply Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP-WS30AA Yaskawa For S axis...
Page 126 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP25JAA Yaskawa Control Power Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP-WS30AA Yaskawa For S axis...
Page 127 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP35JAA Yaskawa Control Power Supply Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP-WS60AA Yaskawa For S,L,U axis...
Page 128 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP35JAA Yaskawa Control Power Supply Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP-WS60AA Yaskawa For U axis...
Page 129 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP35JAA Yaskawa Control Power Supply Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP- Yaskawa For S, L, U...
Page 130 Fuse in Power Supply Unit Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Converter JUSP-ACP35JAA Yaskawa Control Power Supply Unit JUSP-RCP01AAC SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP- Yaskawa For S, L, U...
Page 132 TAIPEI OFFICE Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan Phone 886-2-2563-0010 Fax 886-2-2567-4677 BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD. 30 Xue Yuan Road, Haidian, B eijing P.R. China Post Code: 100083 Phone 86-10-6233-2782 Fax 86-10-6232-1536 SHOUGANG MOTOMAN ROBOT CO., LTD.
Page 133 YASKAWA YASNAC XRC INSTRUCTIONS Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN-!!! INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR’S MANUAL YASNAC XRC OPERATOR’S MANUAL for BEGINNERS The YASNAC XRC operator’s manuals above correspond to specific usage.
Page 134 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 rep- resentative to order a new copy. The representatives are listed on the back cover.
Page 135 NOTES FOR SAFE OPERATION Read this manual carefully before installation, operation, maintenance, or inspection of the YASNAC XRC. In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”, or ”PROHIBITED”. Indicates a potentially hazardous situation which, if not avoided, W A R N I N G could result in death or serious injury to personnel.
Page 136 W A R N I N G • Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the playback panel or program- ming pendant are pressed. When the servo power is turned off, the SERVO ON READY lamp on the playback panel and the SERVO ON LED on the programming pendant are turned off.
Page 137 • Read and understand the Explanation of the Alarm Display in the Setup Manual before operating the manipulator. Definition of Terms Used Often in This Manual The MOTOMAN manipulator is the YASKAWA industrial robot product. The manipulator usually consists of the controller, the playback panel, the programming pen- dant, and supply cables.
Page 138 Descriptions of the programming pendant and playback panel keys, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters printed on them are Pendant denoted with [ ]. ex. [ENTER] Symbol Keys The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture.
Page 139 Setup • Diagnosis 15 Outline of Setting and Diagnosis Security System 2.1 Protection Through Security Mode Settings ....2-1 2.1.1 Security Mode ......... . . 2-1 "...
Page 140 3.9 Tool Data Setting ......... 3-32 3.9.1 Registering Tool Files .
Page 141 3.14 Number Key Customize Function ......3-77 3.14.1 What is the Number Key Customize Function?....3-77 3.14.2 Allocatable Functions .
Page 142 System Diagnosis 5.1 System Version ..........5-1 5.2 Input/Output Status .
Page 143 Hardware 19 YASNAC XRC Specification 6.1 Specification List ......... . . 6-3 6.2 Function List .
Page 144 Maintenance 51 Inspections 8.1 Regular Inspections ........8-1 8.2 XRC Inspections .
Page 145 Alarm • Error 21 Alarm 10.1 Outline of Alarm ......... . 10-1 10.2 Alarm Display .
Page 147: Setup • Diagnosis
Setup • Diagnosis...
Page 149: Outline Of Setting And Diagnosis
1 Outline of Setting and Diagnosis W A R N I N G • Various settings control system compatibility and manipulator perfor- mance characteristics. Exercise caution when changing settings that can result in improper manipulator operation. Personal injury and/or equipment damage may result if incorrect settings are applied by the user.
Page 151: Security System
2.1 Protection Through Security Mode Settings 2 Security System Protection Through Security Mode Settings The XRC modes setting are protected by a security system. The system allows operation and modification of settings according to operator clearance. Be sure operators have the correct level of training for each level to which they are granted access.
Page 152 2.1 Protection Through Security Mode Settings Menu & Security Mode Allowed Security Mode Top Menu Sub Menu DISPLAY EDIT Operation Edit SELECT JOB Operation Operation CREATE NEW JOB Edit Edit MASTER JOB Operation Edit JOB CAPACITY Operation VARIABLE BYTE Operation Edit INTEGER Operation...
Page 153 2.1 Protection Through Security Mode Settings Menu & Security Mode Allowed Security Mode Top Menu Sub Menu DISPLA EDIT ROBOT CURRENT POSITION Operation COMMAND POSITION Operation SERVO MONITOR Management OPE ORIGIN POS Operation Edit SECOND HOME POS Operation Edit DROP AMOUNT Management Management POWER ON/OFF POS...
Page 154 2.1 Protection Through Security Mode Settings Menu & Security Mode Allowed Security Mode Top Menu Sub Menu DISPLA EDIT PARAMETER S1CxG Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management...
Page 155: Modification Of Security Mode
2.1 Protection Through Security Mode Settings " Modification of Security Mode Operation Select {SECURITY} under the top menu Select the desired mode Input the user ID Press [ENTER] Explanation The current security mode is displayed in menu title of the top menu. C Y C L E S E C U R I T Y EDITING MODE...
Page 156: User Id
2.1 Protection Through Security Mode Settings 2.1.2 User ID User ID is requested when Editing Mode or Management Mode is operated. User ID must be between 4 characters and 8, and they must be numbers and symbols (“0~9”,“-” and “.”). "...
Page 157 2.1 Protection Through Security Mode Settings When the correct user ID is entered, a new ID is requested to be input. "Input new ID no.(4 to 8 digits)" is displayed. D A T A E D I T D I S P L A Y U T I L I T Y U S E R I D E D I T I N G M O D E...
Page 158 2.1 Protection Through Security Mode Settings...
Page 159: System Setup
3.1 Home Position Calibration 3 System Setup Home Position Calibration W A R N I N G • Before operating the manipulator, check that the SERVO ON lamp goes out when the emergency stop buttons on the playback panel and pro- gramming pendant are pressed.
Page 160 3.1 Home Position Calibration C A U T I O N • Perform the following inspection procedures prior to teaching the manipulator. If problems are found, correct them immediately, and be sure that all other necessary tasks have been performed. - Check for problems in manipulator movement.
Page 161: Calibrating Operation
3.1 Home Position Calibration Home Position S U P P L E - M E N T The home position is the pulse value "0" for each axis. The relative values between the home position and the geometry position are set to parameters. The relative values are specified as an angle in units of 1/1000°, and vary for different manipulator types.
Page 162: Registering Individual Axes
3.1 Home Position Calibration The pull down menu appears. D A T A EDIT EDIT DISPLAY UTILITY SELECT ALL AXIS H O M E P O S I T I O N I N G SELECT ABSOLUTE DATA R1:S The confirmation dialog is displayed. D A T A E D I T D I S P L A Y...
Page 163: Changing The Absolute Data
3.1 Home Position Calibration The confirmation dialog is displayed. D A T A EDIT DISPLAY UTILITY H O M E P O S I T I O N I N G SELECT ABSOLUTE DATA R1:S -278 30154 Create home position? -217 Y E S Displayed position data of axis are registered as home position.
Page 164: Clearing Absolute Data
3.1 Home Position Calibration " Clearing Absolute Data Operation Select {ROBOT} under the top menu Select {HOME POSITION} Select {DATA} under the menu Select {CLEAR ALL DATA} Explanation In the same way shown in Explanation *1,*2 in ”Registering all axes at once”, the home calibration display and select control group are shown.
Page 165: Home Position Of The Robot
3.1 Home Position Calibration 3.1.3 Home Position of the Robot In case of UP6, the home position are as follows. U-axis angle against horizontal B-axis center line angle against line on the ground(0 ) U-axis center line(-90 ) L-axis angle against vertical line to the ground(0 ) Other manipulator models have different positions.
Page 166: Specified Point
3.2 Specified Point Specified Point W A R N I N G • Be aware of safety hazards when performing the position confirma- tion of the specified point. Abnormality of the PG system may be a cause for alarm. The manipulator may operate in an unexpected manner, and there is a risk of damage to equipment or injury to personnel.
Page 167 3.2 Specified Point C A U T I O N • Perform the following inspection procedures prior to teaching the manipulator. If problems are found, correct them immediately, and be sure that all other necessary tasks have been performed. - Check for problems in manipulator movement. - Check for damage to the insulation and sheathing of external wires.
Page 168: Purpose Of Position Check Operation
3.2 Specified Point 3.2.1 Purpose of Position Check Operation If the absolute number of rotation detected at power on does not match the data stored in the absolute encoder the last time the power was turned off, an alarm is issued when the control- ler power is turned on.
Page 169: Specified Point Setting
3.2 Specified Point & & & & Pulse Difference Check The pulse number at the specified point is compared with that at the current position. If the difference is within the allowable range, playback is enabled. If not, the error alarm occurs again.
Page 170: Procedure After An Alarm
3.2 Specified Point D A T A E D I T D I S P L A Y U T I L I T Y S P E C I F I E D P O I N T SPECIFIED CURRENT DIFFERENCE R1:S !Available to move to any modify specified point The group axes by which the specified point is set is selected when there are two or...
Page 171: Setting The Controller Clock
3.3 Setting the Controller Clock Operation Select {ROBOT} under the top menu Select {SECOND HOME POS} Press the pa Press [FWD] Select {DATA} under the menu Select {CONFIRM POSITION} Explanation The specified point display is shown. The group axes by which the specified point is set is selected when there are two or more group axes.
Page 172: Setting Play Speed
3.4 Setting Play Speed For instance, to make the date May 1, 1998, input [1998.5.1]. To set the time at exactly ten o’clock, enter [10.00]. > 1998.5.1 Date and time are modified. D A T A EDIT DISPLAY UTILITY D A T E / C L O C K S E T DATE 1998 .
Page 173 3.4 Setting Play Speed The type of speed alternately changes from “JOINT” to “LNR/CIR”. D A T A EDIT DISPLAY UTILITY S P E E D S E T LNR/CIR R1:1 66 cm/min 138 cm/min 276 cm/min 558 cm/min 1122 cm/min 2250 cm/min 4500 cm/min 9000 cm/min...
Page 174 3.5 All Limits Releasing All Limits Releasing C A U T I O N • To operate the manipulator with all limits released, pay extra attention to the operating environment around you. When all limits are released, the manipulator or equipment may be damaged. The following limits can be released by the operation explained in the following.
Page 175 3.5 All Limits Releasing D A T A EDIT DISPLAY UTILITY LIMIT RELEASE SOFT LIMIT RELEASE INVALID ALL LIMITS RELEASE INVALID “VALID” and “INVALID” are displayed alternately every time [SELECT] is pressed. When all limits release is changed to “VALID”, the message “All limits have been released”...
Page 176: Overrun / Shock Sensor Releasing
3.6 Overrun / Shock Sensor Releasing Overrun / Shock Sensor Releasing C A U T I O N • To operate the manipulator with overrun released or with shock sensor released, pay extra attention to the operating environment around you. If the manipulator stops by overrun detection or shock sensor detection, release the overrun or shock sensor by the following procedure and move the manipulator using the axis keys.
Page 177: Interference Area
3.7 Interference Area D A T A E D I T D I S P L A Y UTILITY O V E R R U N & S H O C K S E N S O R S H O C K S E N S O R S T O P C O M M A N D :E - S T O P OCCUR GRP OVERRUN...
Page 178: Cubic Interference Area
3.7 Interference Area 3.7.2 Cubic Interference Area " Cubic Interference Area This area is a rectangular parallelepiped which is parallel to the base coordinate system, robot coordinate system, or user coordinate system. The XRC judges whether the current position of the manipulator’s tool center point is inside or outside this area, and outputs this information as a signal.
Page 179: Setting Operation
3.7 Interference Area Z-axis Maximum value X-axis Minimum value Y-axis Number Input of the Side of Cube and Teaching Center After entering the lengths of the three faces of the cube (axial length) using the number keys, move the manipulator to the center point of the cube using the axis keys. Z-axis X-axis Center...
Page 180 3.7 Interference Area Select the desired cube number using the page key or by number input. The method for number input is as follows: Move cursor to “INTERFERENCE SIG” and press [ENTER] to display the number input line. Input desired signal number and press [ENTER].
Page 181 3.7 Interference Area Each time [SELECT] is pressed, “COMMAND POSITION” and “FEEDBACK POSI- TION” alternate. D A T A E D I T D I S P L A Y U T I L I T Y I N T E R F E R E N C E A R E A INTERFERENCE SIG : 1 METHOD CONTROL GROUP...
Page 182 3.7 Interference Area Teaching Corner Operation Select “METHOD” Press [MODIFY] Move the cursor to “<MAX>” or “<MIN>” Move the manipulator using the axis keys Press [ENTER Explanation Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS” alternate. Select “MAX/MIN”. The message “Teach max./min. position” is displayed. D A T A E D I T D I S P L A Y...
Page 183 3.7 Interference Area Number Input of the Side of Cube and Teaching Center Operation Select “METHOD” Input data for length of the cube and press [ENTER] Press [MODIFY] Move the manipulator using the axis keys Press [Enter] Explanation Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS” alternate. Select “CENTER POS”.
Page 184: Axis Interference Area
3.7 Interference Area 3.7.3 Axis Interference Area " Axis Interference Area The axis interference area is a function that judges the current position of the each axis and outputs a signal. Once the maximum and minimum values have been set at the plus and minus sides of the axis to define the operating range, a signal indicating whether the current position of the axis is inside or outside this range is output.
Page 185 3.7 Interference Area Select the desired interference signal number using the page key or by number input. The method for number input is as follows: Move cursor to “INTERFERENCE SIG” and press [ENTER] to display the number input line. Input desired signal number and press [ENTER].
Page 186 3.7 Interference Area Setting Axis Data by Moving Manipulator Using the Axis Key Operation Select {ROBOT} under the top menu Select {INTERFERENCE} Select the desired interference signal number Select “METHOD” Select “CONTROL GROUP” Press [MODIFY] Move the manipulator using the axis keys Press [ENTER] Explanation Operate in the same way as shown in Explanation *1~*4 in ”Number Input of Axis...
Page 187: Clearing Interference Area Data
3.7 Interference Area 3.7.4 Clearing Interference Area Data Operation Select interference signal for clearing Select {DATA} under the menu Select {CLEAR DATA} Select “YES” Explanation Select the desired signal number for clearing using the page key or by number input. The method for number input is as follows: Move cursor to the signal number and press [ENTER] to display the number input line.
Page 188: Operation Origin Point Setting
3.8 Operation Origin Point Setting Operation Origin Point Setting 3.8.1 What is the Operation Origin Point? The Operation Origin Point is a reference point for manipulator operations. It prevents interfer- ence with peripheral devices by ensuring that the manipulator is always within a set range as a precondition for operations such as starting the line.
Page 189: Returning To The Operation Origin Point
3.8 Operation Origin Point Setting New operation origin point is set. When the operation origin point is changed, the operation origin cube is automatically set N OT E as cube 24~22 in the base coordinate system. • The cube 24 is for ROBOT1 •...
Page 190: Tool Data Setting
3.9 Tool Data Setting Tool Data Setting 3.9.1 Registering Tool Files " Number of Tool Files There are 24 tool files numbered 0 to 23. Each file is called as a tool file. T O O L F I L E 0 T O O L F I L E 2 3 "...
Page 191 3.9 Tool Data Setting D A T A E D I T D I S P L A Y U T I L I T Y T O O L C O O R D I N A T E NAME [TORCH1 [TORCH2...
Page 192: Registering Tool Pose
3.9 Tool Data Setting D A T A EDIT DISPLAY UTILITY T O O L TOOL NO. : 00 NAME :TORCH1 0.000 mm 0.00 deg. 0.000 mm 0.00 deg. 260.000 0.00 deg. 0.000 kg 0.000 mm <Setting Example> 260 mm 260 mm 260 mm Control...
Page 193: Setting The Tool Load Information
3.9 Tool Data Setting Operation Select {ROBOT} under the top menu Select {TOOL} Select the desired tool number Select the desired coordinate axis to modify Input the tool pose data Press [ENTER Explanation In the same way shown in Explanation *1,*2 in ”Registering coordinate data”, the desired tool coordinate display is shown.
Page 194: Tool Calibration
3.9 Tool Data Setting For more details on the tool load information, refer to 3.11.3 “Tool Load Information Set- S U P P L E - ting.” M E N T 3.9.2 Tool Calibration " Tool Calibration To ensure that the manipulator can perform interpolation operations such as linear and circu- lar interpolation correctly, accurate dimensional information on tools such as torches, tools, and guns must be registered and the position of the tool center point must be defined.
Page 195 3.9 Tool Data Setting Tool pose data is not registered in tool calibration. For details on how to register pose data, S U P P L E - refer to the preceding clause " Registering Tool Pose ". M E N T Operation Select {ROBOT} under the top menu Select {TOOL}...
Page 196 3.9 Tool Data Setting D A T A E D I T D I S P L A Y U T I L I T Y T O O L C A L I B R A T I O N TOOL NO.
Page 197 3.9 Tool Data Setting D A T A E D I T D I S P L A Y U T I L I T Y T O O L TOOL NO. : 0 0 N A M E : T O R C H 1 0.000 0.00 deg.
Page 198: Checking The Tool Center Point
3.9 Tool Data Setting " Checking the Tool Center Point After registering the tool file, check if the tool center point is correctly registered by performing a TCP fixed operation like the one shown below, in any coordinate system other than the joint coordinates.
Page 199: Automatic Measurement Of The Tool Load And The Center Of Gravity
The tool load and the position of it’s center of gravity are measured and registered in a tool file. This function is available for the models listed below. Contact your Yaskawa representa- N OT E tive for information on other models.
Page 200 3.9 Tool Data Setting Operation Select {ROBOT} under the top menu Select {TOOL} Select the desired tool number Select {UTILITY} under the menu Select {W.GRAV.POS MEASURE} Press the page Press [NEXT] Press [NEXT] again Select “REGISTER” Explanation The tool list display is shown. The tool list is called up only when the file extension function is valid.
Page 201 3.9 Tool Data Setting Move the cursor to the desired number in the tool list and press [SELECT]. The tool coordinates of the selected number is shown. In the tool coordinates, change the desired number by pressing the page key .
Page 202 3.9 Tool Data Setting • The speed during measurement automatically changes to “Medium”. N OT E • During measurement, “HOME” or “U” blinks on the screen. • During measurement, the [NEXT] button has to be kept pressed. If the button is released during measurement or if it is released before “*“...
Page 203: 3.10 User Coordinates Setting
3.10 User Coordinates Setting 3.10 User Coordinates Setting 3.10.1 User Coordinates " Definition of User Coordinates User coordinates are defined by three points that have been taught to the manipulator through axis operations. These three defining points are ORG, XX, and XY, as shown in the diagram below.
Page 204: Selecting User Coordinates File
3.10 User Coordinates Setting 3.10.2 User Coordinates Setting " Selecting User Coordinates File Operation Select {ROBOT} under the top menu Select {USER COORDINATE} Select desired user coordinate number Explanation The user coordinate list display is shown. D A T A EDIT DISPLAY UTILITY...
Page 205: Teaching User Coordinates
3.10 User Coordinates Setting " Teaching User Coordinates Operation Select the robot Select “SET POS” Move the manipulator using the axis key Press [MODIFY] and [ENTER] Select “COMPLETE” Explanation Select the robot for teaching user coordinates. (When the robot has already been selected or there is only one robot, this operation should not be performed.) Select “**”...
Page 206: Clearing User Coordinates
3.10 User Coordinates Setting To check the taught positions, call up the required display among ORG to XY and press [FWD]. The manipulator moves to the set position. If there is a difference between the current position of the manipulator and the dis- played position data, “ORG”, “XX”, or “XY”...
Page 207: Arm Control
In XRC, the operation performance of the robot which satisfies various demands on the pro- duction site such as the improvement of the path accuracy and the cycle time shortening is achieved by adopting the ARM (Advanced Robot Motion) control which Yaskawa Electric Co., Ltd. originally developed.
Page 208: Robot Setup Condition
Only rotation angle around Y axis of the robot coordinates can be set in the robot installa- N OT E tion angle. Contact YASKAWA representative when robots is installed to incline Y axis of the robot coordinates relative to ground. 3-50...
Page 209 3.11 ARM Control S-head payload Set the mass and the center of gravity position roughly when the equipment such as trans- former is installed at the S-head. It is not necessary to set these value when there is no installed load at the S-head. WEIGHT (Unit:kg) The weight of the installed load is set.
Page 210: Setting
3.11 ARM Control HEIGHT (From U-Axis) is height of the vertical direction from U axis rotation center to the cen- ter of gravity position of the load. X (From U-Axis) ( - ) ( + ) U axis rotation Center of Gravity center Position EIGHT...
Page 211: Tool Load Information Setting
3.11 ARM Control D A T A EDIT DISPLAY UTILITY A R M C O N T R O L C O N T R O L G R O U P : R O B O T 1 < R O B O T S E T U P C O N D I T I O N > ANGLE REL.
Page 212: Tool Load Information
3.11 ARM Control " Tool Load Information Tool load information includes weight, a center of gravity position, and moment of inertia at the center of gravity of the tool installed at the flange. These are registered in the tool file. Inertia Moment around Center of Gravity Ix, Iy, Iz Weight:W...
Page 213 3.11 ARM Control case of about twice or more the distance from the flange to the center of gravity position), this setting is needed. The size of the tool is not too big. The size of the tool is big enough. Setting the inertia moment at center Setting the inertia moment at center of gravity is not necessary.
Page 214 3.11 ARM Control <Example1> In the example of sealing gun of the figure below, it is assumed that there is center of gravity in the position where inclined to head from the center a little, and sets the center of gravity position on the flange coordinates.
Page 215 3.11 ARM Control inertia • The own moment of calculation for hexahedron and cylinder S U P P L E - M E N T inertia The own moment of of hexahedron and cylinder can be calculated by the next expression when the center of gravity is at the center.
Page 216 3.11 ARM Control <Example 2> It is necessary to set the moment of inertia at the center of gravity when the entire size of the tool and workpiece is large enough comparing with the distance from the flange to the center of gravity position.
Page 217 3.11 ARM Control • How to calculate "Center of gravity position" and "moment of inertia at center of gravity" S U P P L E - for plural mass. M E N T The center of gravity position and the moment of inertia at the center of gravity of the entire tool can be calculated by the weight and the center of gravity position of each mass when the tool can be thought that the tool consists of two or more big mass like the twin gun sys- tem etc.
Page 218 3.11 ARM Control <Example 3> When there is two or more big mass like the twin gun system like the figure below, 1. Set the center of gravity position when the center of gravity position of the entire tool is roughly understood, and set the moment of inertia at the center of gravity calculated by approximating the entire tool in the shape of hexahedron or cylinder.
Page 219: Tool Load Information Registering
3.11 ARM Control * Here, the own moment of inertia (Icxi, Icyi, Iczi) of the gun is disregarded, because each gun are smaller enough than the entire tool. <Setting> • W 10.000 • Xg : 100.000 • Yg : -83.333 •...
Page 220 3.11 ARM Control Move the cursor to the number of the desired tool, and press [SELECT] in the tool list display. The tool coordinates display of the selected number is shown. Select the desired number with page key in the tool coordinates display. Select { DISPLAY} ) { LIST} or { DISPLAY} ) {COORDINATE DATA} under the menu in order to switch between the tool list display and the tool coordinates display.
Page 221 3.11 ARM Control • When the data setting is not done N OT E It is considered that data is not set correctly in tool load information in the following cases. • When the weight (W) is "0". • When the center of gravity position (Xg, Yg, Zg) are all “0”. In these cases, the robot is controlled by using the standard parameter value (Differ in each robot model) which were set when shipping.
Page 222: Shock Detection Function
Injury or damage to machinery may result by collision with the manipulator. N OT E This function is equipped with the undermentioned model. Applicable models: Motoman UP6, SK16X, UP20, SK45X, UP50, UP130 3.12.2 Shock Detection Function Setting The shock detection function is set not to mis-detect the shock even if operating by the ratings load with the maximum speed when shipping from the factory.
Page 223 3.12 Shock Detection Function The detection level is changed by the SHCKSET instruction. After this instruction is exe- cuted, the shock will be detected by the detection level of the specified file when the condition number is specified at SHCKSET instruction. The detection level is returned to standard level when the SHCKRST instruction is executed.
Page 224 3.12 Shock Detection Function Do either of the following operations to display the desired condition number. When the desired condition number is input with a numeric key and the [ENTER] is pressed after the cursor is moved on the condition number and [SELECT] is pressed, the file of the selected condition number is displayed.
Page 225: Tool Load Information Setting
3.12 Shock Detection Function " Tool load Information Setting To be the more accurate shock detection, the tool load information is set in the tool file. Refer to " 3.11.3 Tool Load Information Setting " for details concerning the tool load infor- S U P P L E - mation setting.
Page 226: Instruction Of Shock Detection Function
3.12 Shock Detection Function D A T A EDIT DISPLAY UTILITY T O O L TOOL NO. : 00 0.000 0.000 mm & 0.000 mm 0.000 mm 0.000 kg.m2 0.000 kg.m2 # # # # Weight This is total weight of the installed tool. Input weight by a numeric key and press [ENTER] after the numeric input status is appeared by moving the cursor and pressing [SELECT].
Page 227 3.12 Shock Detection Function Shock Detection Level File (1 to 7) & & & & The shock detection level file number is specified here. The detection level value when playback operation is set in the file. The detection level is changed by the condition of the file set here.
Page 228 3.12 Shock Detection Function SHCKSET Operation Move the cursor to the line just before the location where SHCKSET instruction is desired to register Press [INFORM LIST] Select SHCKSET instruction Change the value of additional item and numerical data Press [ADD] and [ENTER] Explanation The inform list dialog is shown.
Page 229 3.12 Shock Detection Function J O B U T I L I T Y E D I T D I S P L A Y D E T A I L E D I T S H C K S E T R O B O T / S T A T I O N U N U S E D S-DETECT.
Page 230 3.12 Shock Detection Function SHCKRST instruction is displayed in the input buffer line. => S H C K R S T < When register as it is > Operate *4 procedure when the instruction the input buffer line as it is should be regis- tered.
Page 231: Reset Shock Detected
3.12 Shock Detection Function " Reset Shock detected When the tool and the manipulator are collided with peripherals and it is detected by the shock detection function, the manipulator is stopped in the instantaneously with alarm output. At this time, the shock detection alarm is displayed. D A T A UTILITY EDIT...
Page 232: Alarm List
3.12 Shock Detection Function 3.12.3 Alarm List Alarm Message Cause Remedy Number 4315 COLLISION DETECT • A collision from interference • Remove the object after Robot/Station between robot and peripheral resetting the alarm or move [Axis Data] device etc. was detected. the robot to the safety posi- •...
Page 233: 3.13 Instruction Level Setting
3.13 Instruction Level Setting 3.13 Instruction Level Setting 3.13.1 Setting Contents " Instruction Set There are three instruction sets that can be used when registering the instructions for the robot language (INFORM II): the subset instruction set, the standard instruction set, and the expanded instruction set.
Page 234: Learning Function
3.13 Instruction Level Setting " Learning Function When an instruction is entered from the instruction list, the additional items that were entered last time are also displayed. This function can simplify instruction input. To register the same additional items as those in the former operation, register them without changing.
Page 235: 3.14 Number Key Customize Function
3.14 Number Key Customize Function D A T A EDIT DISPLAY UTILITY T E A C H I N G C O N D I T I O N RECT/CYLINDRICAL R E C T LANGUAGE LEVEL S U B S E T MOVE INSTRUCTION SET LINE S U B S E T...
Page 236: Key Allocation (Each)
The following shows the functions that can be allocated. Function Description Manufacturer Allocated by Yaskawa. Allocating another function invalidates the func- allocation tion allocated by the manufacturer. Instruction allocation Allocates any instructions assigned by the user.
Page 237: Allocating An Operation
3.14 Number Key Customize Function 3.14.3 Allocating an Operation " Allocation Display Operation Select {SETUP} under the menu Select {KEY ALLOCATION} Select {DIS- PLAY} Select {ALLOCATE SIM. KEY} Explanation The key allocation (EACH) display is shown. D A T A EDIT DISPLAY UTILITY...
Page 238: Instruction Allocation
3.14 Number Key Customize Function " Instruction Allocation Use this function in the key allocation (EACH) display. Operation Move the cursor to “FUNCTION” of the key to be allocated Press [SELECT] Select “INSTRUCTION” Explanation The selection dialog box is shown. D A T A E D I T D I S P L A Y...
Page 239: Job Call Allocation
3.14 Number Key Customize Function When the instruction list dialog box is displayed, select the instruction to be changed. D A T A E D I T D I S P L A Y U T I L I T Y K E Y A L L O C A T I O N ( E A C H ) APPLI.NO.:1 K E Y F U N C T I O N...
Page 240: Display Allocation
3.14 Number Key Customize Function " Display Allocation Use this function is used in the key allocation (EACH) display. Operation Move the cursor to the “FUNCTION” of the key to be allocated Press [SELECT] Select “DISPLAY” Move the cursor to “ALLOCATION CONTENT” Press [SELECT] Input the name of the reserved display and press [ENTER]...
Page 241: Alternate Output Allocation
3.14 Number Key Customize Function " Alternate Output Allocation Use this function is used in the key allocation (SIM) display. Operation Move the cursor to the “FUNCTION” of the key to be allocated Press [SELECT] Select “ALTERNATE OUTPUT” Explanation The selection dialog box is displayed. D A T A E D I T D I S P L A Y...
Page 242: Pulse Output Allocation
3.14 Number Key Customize Function The output No. is displayed in the “ALLOCATION CONTENT”. D A T A E D I T D I S P L A Y U T I L I T Y K E Y A L L O C A T I O N ( S I M ) APPLI.NO.:1 K E Y F U N C T I O N A L L O C A T I O N C O N T E N T...
Page 243: Group (4-Bit/8-Bit) Output Allocation
3.14 Number Key Customize Function " Group (4-bit/8-bit) Output Allocation Use this function in the key allocation (SIM) display. Operation Move the cursor to the “FUNCTION” of the key to be allocated Press [SELECT] Select “4 BIT OUTPUT” or “8 BIT OUTPUT” Explanation The selection dialog box is displayed.
Page 244: Analog Incremental Output Allocation
3.14 Number Key Customize Function To change the output port No. or output voltage value, move the cursor to the No. or voltage value and press [SELECT]. Numeric values can now be entered. Input the number or voltage value to be changed, and press [ENTER]. "...
Page 245 3.14 Number Key Customize Function Operation Move the cursor to the “FUNCTION” of the key that has been allocated with I/O control with key allocation (SIM) Press [SELECT] Select “OUTPUT CONTROL INST” Explanation The selection dialog box is displayed. D A T A E D I T D I S P L A Y U T I L I T Y...
Page 246: Execution Of Allocation
3.14 Number Key Customize Function 3.14.5 Execution of Allocation " Executing the Instruction/Output Control Allocation Operation Press the key allocated for instruction allocation or output control allocation Press [INSERT] and [ENTER] Explanation The allocated instruction is displayed in the input buffer line. =>...
Page 247: 3.15 Changing The Output Status
3.15 Changing the Output Status 3.15 Changing the Output Status The status of external output signals can be changed from the programming pendant by using either of the following two methods. • On the universal output status display (see " 5.2.2 Universal Output ") •...
Page 248 3.15 Changing the Output Status The status is changed. (': status ON, *: status OFF) D A T A EDIT DISPLAY UTILITY R E L A Y O N OUTPUT NO. STATUS NAME OUT#010 [HAND1 OUT#008 OUT#014 OUT#009 It is also possible to turn the relevant external output signal on only for the duration that S U P P L E - [INTER LOCK]+[SELECT] are pressed.
Page 249 3.16 Temporary Release of Soft Limits 3.16 Temporary Release of Soft Limits The switches that are set to detect the working envelope of the manipulator are called limit switches. The operating range is monitored by the software in order to stop motion before these limit switches are reached.
Page 250: 3.16 Temporary Release Of Soft Limits
3.16 Temporary Release of Soft Limits Each time [SELECT] is pressed, “VALID” and “INVALID” alternate. When “SOFT LIMIT RELEASE” is set to “VALID,” the message “Soft limits have been released” is dis- played. D A T A EDIT DISPLAY UTILITY LIMIT RELEASE SOFT LIMIT RELEASE VALID...
Page 251: 3.17 File Initialize
3.17 File Initialize 3.17 File Initialize 3.17.1 Initialize Job File Operation Turn the power supply ON while pressing [TOP MENU] simultaneously Change the security mode to management mode Select {FILE} under the top menu Select {INI- TIALIZE} Select “JOB” Select “YES” Explanation Initializing objects are shown.
Page 252: Initialize Data File
3.17 File Initialize 3.17.2 Initialize Data File Operation Turn the power supply ON while pressing [TOP MENU] simultaneously Change the security mode to management mode Select {FILE} under the top menu Select {INITIALIZE} Select {FILE/GENERAL DATA} Select data file for initializing Press [ENTER] Select “YES”...
Page 253: Initialize Parameter File
3.17 File Initialize 3.17.3 Initialize Parameter File Operation Turn the power supply ON while pressing [TOP MENU] simultaneously Change the security mode to management mode Select {FILE} under the top menu Select {INITIALIZE} Select {PARAMETER} Select parameter for initializing Press [ENTE Select “YES”...
Page 254: Initializing I/O Data
3.17 File Initialize 3.17.4 Initializing I/O Data Operation Turn the power supply ON while pressing [TOP MENU] simultaneously Change the security mode to management mode Select {FILE} under the top menu Select {INITIALIZE} Select {I/O DATA} Select data for initializing Press [ENTER] Select “YES”...
Page 255: Initializing System Data
3.17 File Initialize 3.17.5 Initializing System Data Operation Turn the power supply ON while pressing [TOP MENU] simultaneously Change the security mode to management mode Select {FILE} under the top menu Select {INITIALIZE} Select {SYSTEM DATA} Select the parameter to be initialized Press [ENTER] Select “YES”...
Page 256 3.17 File Initialize 3-98...
Page 257: Modification Of System Configuration
4.1 Addition of I/O Modules 4 Modification of System Configuration Addition of I/O Modules I/O modules,turn the power supply off. For addition of The additional operation must be done in the management mode. S U P P L E - In operation mode or editing mode, only confirmation of status setting is possible.
Page 258 If the slot display is different, check the status again. If the status is correct, the I/O module N OT E may be defective. Contact your Yaskawa representative. I O M O D U L E ST#08 NONE ST#09 NONE...
Page 259: Addition Of Base And Station Axis
4.2 Addition of Base and Station Axis The confirmation dialog is shown. I O M O D U L E S T # 0 8 N O N E S T # 0 9 N O N E Modify? S T # 1 0 N O N E S T # 1 1 N O N E Y E S S T # 1 2 N O N E...
Page 260 4.2 Addition of Base and Station Axis The setup display is shown. S E T U P Item marked by L A N G U A G E " can not be set. C O N T R O L G R O U P APPLICATION IO MODULE O P T I O N B O A R D...
Page 261: Base Axis Setting
4.2 Addition of Base and Station Axis MOTION RANGE (+) [mm] MOTION RANGE (-) [mm] REDUCTION RATIO (numerator) REDUCTION RATIO (denominator) PINION DIAMETER [mm] If axis type is turn type, set the following items. MOTION RANGE (+) [deg] MOTION RANGE (-) [deg] REDUCTION RATIO (numerator) REDUCTION RATIO (denominator)
Page 262 4.2 Addition of Base and Station Axis Machine type selection display is shown. MACHINE LIST RECT-X :TRAVEL X-AXIS BASE RECT-Y :TRAVEL Y-AXIS BASE NONE RECT-X RECT-Z :TRAVEL Z-AXIS BASE RECT-Y RECT-Z RECT-XY :TRAVEL XY-AXIS BASE RECT-XY RECT-XZ RECT-XZ :TRAVEL XZ-AXIS BASE RECT-YZ RECT-XYZ RECT-YZ :TRAVEL YZ-AXIS BASE...
Page 263 4.2 Addition of Base and Station Axis Direction of Base Axis RECT-XYZ CARTESIAN Z-AXIS CARTESIAN CARTESIAN X-AXIS Y-AXIS Base 1st, 2nd, and 3rd axes advancing directions coincide with robot coordinate X-Axis, Y-Axis, and Z-Axis, respectively. In the connection display, the SERVOPACK which is connected with each control group, and the contactor which is used for the SERVOPACK, are specified.
Page 264 4.2 Addition of Base and Station Axis The items which can be set are shown. When the item is selected the display returns to the connection display. C O N N E C T I O N CONTACT CN< 1 2 3 4 5 6 7 8 9 > R1 :#1 [ 1 2 3 4 5 6 - - - ] B1 :#1...
Page 265 4.2 Addition of Base and Station Axis In the axes configuration display, the axis type and motor type are specified. Operation Confirm axis type of each axis in the axes configuration display Select desired axis Select desired axis type Press [ENTER] in the axes configuration display Explanation The axis type of each axis is shown.
Page 266 4.2 Addition of Base and Station Axis In the mechanical specification display, mechanical data are specified. Operation Confirm specification of each axis in the mechanical specification display Select desired item Input the value Press [ENTER] Explanation The mechanical specification is shown. The mechanical specification display (In case of BALL-SCREW type) M E C H A N I C A L S P E C Group, Type, Axis Number...
Page 267 4.2 Addition of Base and Station Axis After this setting, the display moves to the next axis. Set them for all axes. When [ENTER] is pressed in the mechanical specification display for last axis the set- ting in the mechanical specification display is completed and the display moves to the motor specification display.
Page 268 4.2 Addition of Base and Station Axis Normal direction AC Servo Motor MAX. RPM Input maximum rotation speed of a motor. (Unit: mm) ACCELARATION SPEED: Input time between 0.01 and 1.00 to reach maximum speed from stopping status at 100% JOINT motion. (Unit: sec) INERTIA RATIO “300”...
Page 269 4.2 Addition of Base and Station Axis C A U T I O N If the control group construction is changed by addition a base axis or station axis, the internal data of the job file are also changed so that the job file data should be initialized. Initialize the job file data with the procedure “File Initialize”...
Page 270 4.2 Addition of Base and Station Axis Type selection display is shown. M A C H I N E L I S T TURN-1:TURN 1 AXIS STATION N O N E TURN-1 T U R N - 2 : T U R N 2 A X E S S T A T I O N UNIV-1:UNIVERSAL 1 AXIS STATION T U R N-2 UNIV-1...
Page 271 4.2 Addition of Base and Station Axis The setting in the control group display is completed and the display moves to the con- nection display. In the connection display, the SERVOPACK which is connected with each control group and the contactor which is used for the SERVOPACK are specified. Operation Confirm type of each control group in the connection display Select connection item...
Page 272 4.2 Addition of Base and Station Axis S1(Station) 1st axis ) 7CN (SERVOPACK #1, 2nd contactor is used) 2nd axis ) 8CN (SERVOPACK #1, 2nd contactor is used) 3rd axis ) 9CN (SERVOPACK #1, 2nd contactor is used) The setting in the connection display is completed and the display moves to the axes form display.
Page 273 4.2 Addition of Base and Station Axis The axis types which can be set are shown. A X E S C O N F I G : UNIV-3 AXIS AXIS TYPE B A L L - S C R E W : B A L L - S C R E W R A C K &...
Page 274 4.2 Addition of Base and Station Axis TURN-2 STATION 2ND AXIS (ROTATION TABLE) OFFSET STATION 1ST AXIS (INCLINATION AXIS) The mechanical specification display (In case of BALL-SCREW type) M E C H A N I C A L S P E C Group, Type, Axis Number :UNIV-3 AXIS:1...
Page 275 4.2 Addition of Base and Station Axis REDUCTION RATIO :Input the numerator and the denominator. <e.g.> If the reduction ratio is 1/120, the numerator should be set as 1.0 and the denominator should be set as 120.0. PINION DIAMETER :Input the diameter of a pinion. (Unit: mm) After this setting, the display moves to the next axis.
Page 276 4.2 Addition of Base and Station Axis Normal direction AC Servo Motor MAX. RPM Input maximum rotation speed of a motor. (Unit: mm) ACCELARATION SPEED: Input time between 0.01 and 1.00 to reach maximum speed from stopping status at 100% JOINT motion. (Unit: sec) INERTIA RATIO “300”...
Page 277 4.2 Addition of Base and Station Axis C A U T I O N If the control group construction is changed by addition of a base axis or station axis, the internal data of the job file are also changed so that the job file data should be initialized. Initialize the job file data with procedure “File Initialize”...
Page 278 4.2 Addition of Base and Station Axis 4-22...
Page 279: System Diagnosis
5.1 System Version 5 System Diagnosis System Version It is possible to check the system CPU version information as follows. Operation Select {SYSTEM INFO} under the top menu Select {VERSION} Explanation Version number display is shown. D A T A EDIT DISPLAY UTILITY...
Page 280: Universal Input Detailed Display
5.2 Input/Output Status Explanation Universal input display is shown. D A T A E D I T D I S P L A Y UTILITY U N I V E R S A L I N P U T 7654 3210 #001X 0111_1011 #002X...
Page 281: Universal Output Detailed Display
5.2 Input/Output Status Explanation Universal output display is shown. D A T A E D I T D I S P L A Y UTILITY U N I V E R S A L O U T P U T 7654 3210 #101X 0111_1011...
Page 282 5.2 Input/Output Status D A T A EDIT DISPLAY UTILITY U N I V E R S A L O U T P U T GROUP OG#01 122:DEC. 7a:HEX. OUT#001 #1010 OUT#002 #1011 OUT#003 #1012 OUT#004 #1013 OUT#005 #1014 OUT#006 #1015 OUT#007 #1016 OUT#008 #1017 "...
Page 283 5.2 Input/Output Status New signal name is registered. D A T A E D I T D I S P L A Y UTILITY U N I V E R S A L I N P U T GROUP IG#01 123:DEC.
Page 284: Search The Signal Number
5.2 Input/Output Status " Search the Signal Number The signal number can be searched in the following two ways. Direct Search on the Detailed Display Operation Select the signal number in the detailed display. Input the signal number Press [ENTER] Explanation Number input line is displayed.
Page 285 5.2 Input/Output Status Search from the Menu Operation Select the signal number in the detailed display. Select {EDIT} under the menu Select {SEARCH} Input the signal number Press [ENTER] Explanation The pull-down menu is shown. D A T A EDIT EDIT DISPLAY UTILITY...
Page 286: Specific Input
5.2 Input/Output Status 5.2.3 Specific Input " Specific Input Display Operation Select {IN/OUT} under the top menu Select {SPECIFIC INPUT} Explanation Specific input display is shown. D A T A EDIT DISPLAY UTILITY SPECIFIED INPUT 7654 3210 #401X 0111_1011 #402X 0000_0000 #403X 0000_0000...
Page 287: Specific Output
5.2 Input/Output Status 5.2.4 Specific Output " Specific Output Display Operation Select {IN/OUT} under the top menu Select {SPECIFIC OUTPUT} Explanation Specific output display is shown. D A T A EDIT DISPLAY UTILITY S P E C I F I E D O U T P U T 7654 3210 #501X 0111_1011...
Page 288: Rin Input
5.2 Input/Output Status 5.2.5 RIN INPUT " RIN INPUT Display Operation Select {IN/OUT} under the top menu Select {RIN} Explanation RIN input display is shown. D A T A EDIT DISPLAY UTILITY RIN INPUT RIN#001 DIRECT IN1 RIN#002 DIRECT IN2 RIN#003 DIRECT IN3 RIN#004...
Page 289: System Monitoring Time
5.3 System Monitoring Time System Monitoring Time 5.3.1 System Monitoring Time Display The status of system operation, e.g. power supply time, can be checked. Operation Select {SYSTEM INFO} Select {MONITORING TIME} Explanation The system monitoring time display is shown. D A T A EDIT DISPLAY UTILITY...
Page 290: Individual Display Of The System Monitoring Time
5.3 System Monitoring Time 5.3.2 Individual Display of the System Monitoring Time If the p age key is pressed, servo power time by each robot axis, playback time, moving time and operating time by each application, is individually displayed. D A T A E D I T D I S P L A Y U T I L I T Y...
Page 291: Clearing The System Monitoring Time
5.3 System Monitoring Time 5.3.3 Clearing the System Monitoring Time System monitoring times can be cleared and set back to 0 by following procedure. These operations can be performed in the system monitoring time display, or in the individual dis- plays.
Page 292: Alarm History
5.4 Alarm History Alarm History 5.4.1 Alarm History Display There are five types of alarm list displays: the "MAJOR ALARM DISPLAY," the "MINOR ALARM DISPLAY," the "USER ALARM(SYSTEM) DISPLAY," the "USER ALARM(USER) DIS- PLAY," and the "OFF-LINE DISPLAY." Each display shows the alarm code and the date and time.
Page 293: I/O Message History
5.5 I/O Message History Explanation The confirmation dialog is displayed. D A T A E D I T D I S P L A Y UTILITY M I N O R A L A R M CODE DATE CLOCK 4000 1998/05/12 12:00 Clear data?
Page 294: Search
5.5 I/O Message History " Search Use the following operation to search for the I/O message history. Operation Select {EDIT} under the menu Select {SEARCH} Input the history No. Press [ENTER] Explanation Character input line is displayed. The search for the input history number begins, and the I/O message is displayed. 5.5.2 Clearing the I/O Message History Use the following operation to clear the I/O message history.
Page 295: Position Data When Power Is Turned On/Off
5.6 Position Data When Power is Turned ON/OFF Position Data When Power is Turned ON/OFF 5.6.1 Power ON/OFF Position Display The Power ON/OFF position display shows the position of the manipulator when power was turned off the last time, the current position of the manipulator when power was later turned on, and the amount of difference between the two positions.
Page 296 5.6 Position Data When Power is Turned ON/OFF 5-18...
Page 297: Hardware
Hardware...
Page 299 6 YASNAC XRC Specification WARNING • Before operating the manipulator, check that the SERVO ON lamp goes out when the emergency stop buttons on the playback panel and pro- gramming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.
Page 300 C A U T I O N • Perform the following inspection procedures prior to performing teach- ing operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed. - Check for problems in manipulator movement. - Check for damage to the insulation and sheathing of external wires.
Page 301: Specification List
6.1 Specification List Specification List Controller Configuration Free-standing, enclosed type Dimensions Refer to following Cooling System Indirect cooling Ambient Temperature 0°C to + 45°C (During operation) -10°C to + 60°C (During transit and storage) Relative Humidity 90%RH max. (non-condensing) Power Supply 3-phase, 200/220 VAC(+10% to -15%) at 50/60Hz(2 Hz) Grounding resistance: 100 Ω...
Page 302: Function List
6.2 Function List Function List Programming Coordinate System Joint, Rectangular/Cylindrical, Tool, User Coordinates Pendant Modification of Adding, Deleting, Correcting (Robot axes and external axes Operation Teaching Points respectively can be corrected.) Inching Operation Possible Locus Confirmation Forward/Reverse step, Continuous feeding Speed Adjustment Fine adjustment possible during operating or pausing Timer Setting...
Page 303: Programming Pendant
6.3 Programming Pendant Programing Programming Interactive programming Functions Language Robot language: INFORM II Robot Motion Con- Joint coordinates, Linear/Circular interpolations, Tool coordi- trol nates Speed Setting Percentage for joint coordinates, 0.1mm/s units for interpola- tions, Angular velocity for T.C.P. fixed motion Program Control Jumps, Calls, Timer, Robot stop, Execution of some instruc- Instructions...
Page 304: Equipment Configuration
6.4 Equipment Configuration Equipment Configuration The XRC is comprised of individual units and modules (circuit boards). Malfunctioning compo- nents can generally be easily repaired after a failure by replacing a unit or a module. This section outlines the XRC equipment configuration. 6.4.1 Arrangement of Units and Circuit Boards "...
Page 305 6.4 Equipment Configuration I/O Power On Welding Board Power Supply Playback Panel Playback Panel Unit CPU Unit JANCD-XEW01 Unit ZY1C-SS3152 JZNC-XIU01 JZNC-XRK01B-. (Option) ZY1C-SS3152 JZRCR-XPU02 No Fuse Breaker EA53B 30A 3P Converter JUSP-ACP25JAA Servopack Sectional view A-A CACR-SK45AAB (SK45X) CACR-SK16MAAB (SK16MX) YASNAC XRC TYPE TYPE SK16MX...
Page 306: Location
6.4 Equipment Configuration " Location Section Unit Playback panel(ZY1C-SS3125) Door Heat exchange board (Large type of robot) Servopack Control circuit board (CACR- €..AA..) (JASP-WRCA01) (Large robot type uses Control power supply separated converter type.) (JUSP-RCP01AAB) Converter (JUSP-ACP..JAA) Front Amplifier (JUSP-WS..AA) section I/0, TU unit (JZNC-XIU01) CPU Rack...
Page 307 6.4 Equipment Configuration Servopack Ascending Fan Backside Duct Fan Air Intake Air Outle Servopac Cooling Configuration (Small type) Heat Exchange Servopack Ascending Fan Backside Duct Fan Air Intake Air Intake Air Outlet Air Outlet Air Outlet Air Outlet Servopack Cooling Configuration (Large type)
Page 308 6.4 Equipment Configuration 6-10...
Page 309: Description Of Units And Circuit Boards
Description of Units and Circuit Boards W A R N I N G • Before operating the manipulator, check that the SERVO ON lamp goes out when the emergency stop buttons on the playback panel and pro- gramming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.
Page 310: Power Supply Unit
7.1 Power Supply Unit C A U T I O N • Perform the following inspection procedures prior to performing teach- ing operations. If problems are found, correct them immediately, and be sure that all other necessary processing has been performed. - Check for problems in manipulator movement.
Page 311 7.1 Power Supply Unit (5X) Single-phase AC200V connector (Contactor Coil, etc.) (4X) Contactor Output (3X) (1Z) 3-phase AC200V Input Line Filter (2X) 3-phase AC200V Output (1KM) Contactor (1X) Single-phase AC200V Output Power Supply Unit Configuration ( JZNC-XPW03B, JZRCR-XPU03) (5X) Single-phase (4X) AC200V connector Contactor Output...
Page 312: Cpu Rack
7.2 CPU Rack CPU Rack 7.2.1 CPU Rack Configuration CPU rack consists of the control power unit, circuit board racks, and system control circuit boards. (CN05) AC200V Input (from Power Supply Unit) (CN04) PC Card (CN04) Control Power Supply Battery Alarm ON/OFF Connection (WAGO connector) (CN03)
Page 313 7.2 CPU Rack Items Specifications Rated Input Voltage: AC200/220 Input Voltage Fluctuation Range: +10% to -15% (AC170 to 242V} Frequency: 50/60Hz ± 2Hz (48 to 62Hz) DC + 5V: 10A Output Voltage DC +24V: 4.0A DISPLA Color Status SOURCE Green Lights when AC power supply input (Normally ON) POWER...
Page 314: Wago Connector
7.2 CPU Rack " WAGO Connector CN05, 06, 26 and 27 on the I/O contactor unit (JZNC-XIU01) and CN04 on the control power supply unit are equipped with a connector made by WAGO. The “wiring tool for the WAGO connector” is necessary to wire the WAGO connector. Two of these tools are supplied with the XRC.
Page 315: I/O Contactor Unit
7.3 I/O Contactor Unit I/O Contactor Unit The I/O contactor unit consists of the Specific I/O circuit board (JANCD-XIO01), General I/O circuit board (JANCD-XIO02) and Contactor circuit board (JANCD-XTU01) to control the con- tactor sequence of the servo power supply. (CN07) Input connector for Programming pendant,...
Page 316: Specific Input Circuit Board (Jancd-Xio01)
7.3 I/O Contactor Unit 7.3.1 Specific Input Circuit Board (JANCD-XIO01) The specific input circuit board is controlled by the system control circuit board (JANCD-XCP 01), and the main function of this board is as follows: • Specific I/O circuit, for instance I/O circuit for servo power supply contactor and emer- gency stop circuit •...
Page 317 7.3 I/O Contactor Unit C A U T I O N Do not use the “FORCE” (Forced release) input. If the “FORCE” input should be used for an unavoidable reason, be sure to use a switch with a key. The systems manager is responsible for storage of the key. When “FORCE”...
Page 318 7.3 I/O Contactor Unit Playback Panel Emergency Stop Switch : SA1 EXT. PBESP1 PBESP2 Specific Input List (XIO01) Factory Terminal Input Name / Function Setting EXESP External emergency stop Use to connect the emergency stop switch of an external operation Disabled by CN05 -1 device.
Page 319: Safety Plug Input Signal
7.3 I/O Contactor Unit Specific Input List (XIO01) Factory Terminal Input Name / Function Setting Direct-in 4 Open Used for the search function. CN06 -7 FORCE Forced reset, input Do not use the “FORCE” (Forced release) input. CN06 -9 If the “FORCE” input should be used for an unavoidable reason, be Open sure to use a switch with a key.
Page 320: General I/O Circuit Board (Jancd-Xio02)
7.3 I/O Contactor Unit 7.3.2 General I/O Circuit Board (JANCD-XIO02) The general I/O circuit board is controlled by the system control circuit board (JANCD-XCP 01) through the specific I/O circuit board (JANCD-XIO01). I/O can be separated as specific I/O and general I/O allocated software as follows: •...
Page 321: Connection Wire With General I/O (Cn10, 11, 12, 13)
7.3 I/O Contactor Unit " Connection wire with General I/O (CN10, 11, 12, 13) Please refer to the figure below when you manufacture the cable connecting with general I/O connector (CN10,11,12,13). (The cable side connector and the I/O terminal are the options) Connector A detailed (Cable side) Connector Type: FCN-361J040-AU (Fujitsu) (Soldering pin type)
Page 322: Specific I/O Signal Related To Start And Stop
7.3 I/O Contactor Unit " Specific I/O Signal Related to Start and Stop The following signals are specific I/O signals related to start and stop. • Servo On (depending on application: JANCD-XIO02) • External Servo On (common to all application: JANCD-XIO01) •...
Page 323: Power-On Circuit Board (Jancd-Xtu01)
7.3 I/O Contactor Unit Example of Start Sequence Circuit from External Device Only the rising edge of the external start signal is valid. This signal starts the manipulator. Reset this signal with the interlock configuration that determines if operation can start and with the playback (RUNNING) signal confirming that the robot has actually started moving.
Page 324: Connection Of External Power Supply For I/O
7.3 I/O Contactor Unit Shock Sensor Connection When the shock sensor input signal is used, the stopping method of the robot can be S U P P L E - specified. The stopping methods are hold stop and servo power supply off. Selection of the M E N T stopping method is set in the display of the programing pendant.
Page 325 7.3 I/O Contactor Unit JZNC-XIU01 JZNC-XIU01 +24VU +24VU CN26 CN26 -7(EX24VIN) -7(EX24VIN) +24V -8(EX024VIN) -8(EX024VIN) (Ready by Customer) 024VU 024VU +24V +24V -9(+24V) -9(+24V) -10(024V) -10(024V) 024V 024V CN26 • The internal power supply of 24V of about 1A of XRC can be used for I/O. N OT E Use external 24V power supply for higher currents and to isolate the circuit inside and outside the XRC.
Page 326: Method Of Connecting External Axis Overrun Signal
7.3 I/O Contactor Unit " Method of connecting external axis overrun signal In a standard specification, the external axis overrun input is unused. Please connect the signal according to the following procedures when the overrun input for an external axis is necessar , besides for the manipulator. 1.
Page 327: Servopack
7.4 Servopack Servopack A Servopack consists of a servo control circuit board (JASP-WRCA01), a servo control power supply (JUSP-RCP01AAB), a converter and an amplifier (Refer to attached table “Servopack Configuration”). As for large capacity type, the converter and the servo power supply are separate. 7.4.1 Servopack Configuration Servopack configuration (Small Capacity Type)
Page 328 7.4 Servopack Servopack configuration (Small Capacity Type) SK16X Component Type Capacity Servopack CACR-SK16AAC Converter JUSP-ACP05JAA JUSP-WS10AAY17 JUSP-WS10AAY17 JUSP-WS10AAY17 Amplifier JUSP-WS02AA 200W JUSP-WS02AA 200W JUSP-WS02AA 200W Servo control JASP-WRCA01 circuit board Servo control JUSP-RCP01AAB power supply Servopack configuration (Large Capacity Type) SK16MX SK45X Component...
Page 329 7.4 Servopack Servopack configuration (Large Capacity Type) UP130, UP165 UP200, UP130R Component Type Capacity Type Capacity Servopack CACR-UP130AAB CACR-UP130AABY18 JUSP-WS60AA JUSP-WS60AAY18 JUSP-WS60AA JUSP-WS60AAY18 JUSP-WS60AA JUSP-WS60AA Amplifier JUSP-WS20AAY13 JUSP-WS20AAY13 JUSP-WS15AAY13 1.5KW JUSP-WS15AAY13 1.5KW JUSP-WS15AAY13 1.5KW JUSP-WS15AAY13 1.5KW Servo control JASP-WRCA01 JASP-WRCA01 circuit board Converter JUSP-ACP35JAA...
Page 330 7.4 Servopack Converte Servopack Amplifier 6pcs Servo cntrl Power Supply Servo Control Board +5V Display LED Servopack Dimensions for SK16MX, SK45 Converte Servopack Servo cntrl Power Supply Amplifier 6pcs Servo Control Board +5V Display LED Servopack Dimensions for UP130, UP165, UP200, UP130R 7-22...
Page 331: Description Of Each Unit
7.4 Servopack 7.4.2 Description of Each Unit " Servo Control Circuit board (JASP-WRCA01) This is a circuit board which controls the servo motors of six axes of the manipulator. This board controls the converter, amplifiers and the contactor circuit board (JANCD-XTU01) of the I/O contactor unit.
Page 332: General I/O Signal Assignment
7.5 General I/O Signal Assignment General I/O Signal Assignment 7.5.1 Arc Weldin YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) Model:PX7D-40V6-R +24VU CN12 Connector Connector Logical Terminal Name Number Signal Number Number Each Point External Start 2010 24VDC 2011 8mA max. Call Master Job 2012 Alarm/Error Reset 2013...
Page 333 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN13 Connector Connector Terminal Logical Number Signal Number Number Each Point 2024 24VDC 2025 8mA max. Weaving Prohibited 2026 2027 Sensing Prohibited 2030 2031 2032 2033 2034 2035 2036 2037...
Page 334 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN10 Connector Logical Connector Signal Terminal Number Number Number General Input Each Point 2040 IN01 24VDC 2041 IN02 8mA max. IN03 2042 2043 IN04 2044 IN05 2045 IN06 IN07 2046...
Page 335 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN11 Connector Connector Logical Terminal Signal Number Number Number Each Point IN09 2050 24VDC IN10 2051 8mA max. IN11 2052 IN12 2053 2054 IN13 IN14 2055 IN15 2056 IN16 2057...
Page 336 7.5 General I/O Signal Assignment Specific Input List XIU01 (Arc Welding) Logical Logical Input Name / Function Input Name / Function Number Number 2010 EXTERNAL START 2020 INTERFERENCE 1 ENTRANCE PROHIBITED Functions the same as the [START] button in If the manipulator attempts to enter the cub the playback panel.
Page 337 7.5 General I/O Signal Assignment Specific Output List XIU01 (Arc Welding) Logical Logical Output Name / Function Output Name / Function Number Number 3010 RUNNING 3021 IN CUBE 2 This signal signifies that the job is running. This signal turns ON when the current tool cen- (Signifies that the job is running, system status ter point lies inside a pre-defined space (Cube is waiting reserved start, or test run is running.)
Page 338: Handling
7.5 General I/O Signal Assignment 7.5.2 Handling YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) Model:PX7D-40V6-R +24VU CN12 Connector Connector Terminal Logical Name Number Signal Number Number Each Point External Start 2010 24VDC 2011 8mA max. Call Master Job 2012 2013 Alarm/Error Reset 2014 Select Remote Mode Select Play Mode...
Page 339 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN13 Connector Logical Connector Terminal Signal Number Number Number Each Point 2024 24VDC 2025 Shock Sensor (NC) 8mA max. 2026 - Hold Low Air Pressure 2027 General Input IN01 2030 IN02...
Page 340 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN10 Connector Connector Logical Terminal Signal Number Number Number Each Point 2040 Sensor Input 1 24VDC Sensor Input 2 2041 8mA max. Sensor Input 3 2042 Sensor Input 4 2043 Sensor Input 5 2044...
Page 341 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN11 Connector Logical Connector Signal Terminal Number Number Number General Input Each Point IN09 2050 24VDC IN10 2051 8mA max. IN11 2052 IN12 2053 IN13 2054 IN14 2055 IN15 2056...
Page 342 7.5 General I/O Signal Assignment Specific Input List XIU01 (Handling) Logical Logical Input Name / Function Input Name / Function Number Number 2010 EXTERNAL START 2020 INTERFERENCE 1 ENTRANCE PROHIBITED Functions the same as the [START] button in If the manipulator attempts to enter the cub the playback panel.
Page 343 7.5 General I/O Signal Assignment Specific Output List XIU01 (Handling) Logical Logical Output Name / Function Output Name / Function Number Number 3010 RUNNING 3021 IN CUBE 2 This signal signifies that the job is running. This signal turns ON when the current tool cen- (Signifies that the job is running, system status ter point lies inside a pre-defined space (Cube is waiting reserved start, or test run is running.)
Page 344: General Application
7.5 General I/O Signal Assignment 7.5.3 General Application YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN12 Connector Connector Terminal Logical Name Signal Number Number Number Each Point 2010 External Start 24VDC 2011 8mA max. Call Master Job 2012 2013 Alarm/Error Reset 2014 Select Remote Mode...
Page 345 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN13 Connector Connector Terminal Logical Number Signal Number Number Interference3 Entrance Each Point 2024 Prohibited Interference4 Entrance 24VDC 2025 Prohibited 8mA max. 2026 2027 2030 2031 2032 2033 2034 2035...
Page 346 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN10 Connector Logical Connector Signal Terminal Number Number Number General Input Each Point 2040 IN01 24VDC 2041 IN02 8mA max. IN03 2042 2043 IN04 2044 IN05 IN06 2045 2046 IN07...
Page 347 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN11 Connector Connector Terminal Logical Number Signal Number Number Each Point IN09 2050 24VDC IN10 2051 8mA max. IN11 2052 IN12 2053 IN13 2054 IN14 2055 IN15 2056 IN16 2057...
Page 348 7.5 General I/O Signal Assignment Specific Input List XIU01 (General application) Logical Logical Input Name / Function Input Name / Function Number Number 2010 EXTERNAL START 2020 INTERFERENCE 1 ENTRANCE PROHIBITED Functions the same as the [START] button in If the manipulator attempts to enter the cub the playback panel.
Page 349 7.5 General I/O Signal Assignment Specific Output List XIU01 (General application) Logical Logical Output Name / Function Output Name / Function Number Number 3010 RUNNING 3021 IN CUBE 2 This signal signifies that the job is running. This signal turns ON when the current tool cen- (Signifies that the job is running, system status ter point lies inside a pre-defined space (Cube is waiting reserved start, or test run is running.)
Page 350: Spot Welding
7.5 General I/O Signal Assignment 7.5.4 Spot Welding YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) Model:PX7D-40V6-R +24VU CN12 Connector Connector Terminal Logical Name Number Signal Number Number Each Point External Start 2010 24VDC 2011 8mA max. Call Master Job 2012 Alarm/Error Reset 2013 2014 Select Remote Mode...
Page 351 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN13 Connector Logical Connector Terminal Signal Number Number Number Interference3 Entrance Each Point 2024 Prohibited Interference4 Entrance 24VDC 2025 Prohibited 8mA max. 2026 2027 2030 2031 2032 2033 2034 2035...
Page 352 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN10 Connector Connector Logical Terminal Signal Number Number Number Timer Cooling Water Each Point 2040 Error (IN09) Gun Cooling Water 24VDC 2041 Error (IN10) 8mA max. Transthermo Error (IN11) 2042 2043 Low Air Pressure (IN12)
Page 353 7.5 General I/O Signal Assignment YASNAC-XRC JZNC-XIU01 Connector Terminal Converter (Optional) +24VU Model:PX7D-40V6-R CN11 Connector Connector Terminal Logical Signal Number Number Number Each Point IN17 2050 24VDC IN18 2051 8mA max. IN19 2052 IN20 2053 IN21 2054 IN22 2055 IN23 2056 IN24 2057...
Page 354 7.5 General I/O Signal Assignment Specific Input List XIU01 (Spot Welding) Logical Logical Input Name / Function Input Name / Function Number Number 2010 EXTERNAL START 2022 WELDING ON/OFF (From sequencer) Functions the same as the [START] button in This signal inputs the welding ON/OFF selector the playback panel.
Page 355 7.5 General I/O Signal Assignment Specific Input List XIU01 (Spot Welding) Logical Logical Input Name / Function Input Name / Function Number Number 2044 WELD COMPLETION 2046 GUN SHORT OPEN DETECTION This signal indicates that the welder completed This signal is connected with a single gun open welding without error.
Page 356 7.5 General I/O Signal Assignment Specific Output List XIU01 (Spot Welding) Logical Logical Output Name / Function Output Name / Function Number Number 3010 RUNNING 3023 INTERMEDIATE START OK This signal signifies that the job is running. This signal turns ON when the manipulator (Signifies that the job is running, system status operates.
Page 357 7.5 General I/O Signal Assignment The operation origin cube and Cube 24 are same. This signal is not output during operation. This signal can be allocated to any general output signal at the I/O allocation display in operation condition. This signal can be select “USE” or “NOT USE” by pseudo input signal ”822x”. If “NOT USE”...
Page 358: Jancd-Xew01 Circuit Board
7.5 General I/O Signal Assignment 7.5.5 JANCD-XEW01 Circuit Board " Arc Welding Application There are two types of XEW01 circuit board as follows; XEW01-01: Analog Outputs x 3 ports + Status Signal Input of a Welder XEW01-02: Analog Outputs x 3 ports only YASNAC-XRC MS Connector MR Connector...
Page 359 Maintenance...
Page 361 8.1 Regular Inspections 8 Inspections Regular Inspections C A U T I O N • Do not touch the cooling fan or other equipment while the power is turned ON. Failure to observe this caution may result in electric shock or injury. Carry out the following inspections.
Page 362 8.2 XRC Inspections XRC Inspections 8.2.1 Checking if the Doors are Firmly Closed • The YASNAC XRC has a fully sealed construction, designed to keep external air contain- ing oil mist out of the XRC. Be sure to keep the XRC doors fully closed at all times, even when the controller is not operating.
Page 363 8.3 Cooling Fan Inspections Cooling Fan Inspections Inspect the cooling fans a . A defective fan can cause the XRC to malfunction s required because of excessive high temperatures inside. The s ervo ascending fan and backside duct fan normally operate while the power is turned ON. Check if the fans are operating correctly by visual inspection and by feeling air moving into the air inlet and from the outlet.
Page 364 8.4 Emergency Stop Button Inspections Servo Ascending Fan Heat Exchanger Backside Duct Fan Air Intake Air Intake Air Outlet Air Outlet Servopack Cooling Fan Construction (Large type) Emergency Stop Button Inspections The emergency stop buttons are located on both the playback panel and the programming pendant.
Page 365 8.6 Battery Inspections 2. Press [SERVO ON READY] on the playback panel. The [SERVO ON READY] lamp blinks. S E R V O O N R E A D Y 3. Press [TEACH LOCK] on the programming pendant. The [TEACH LOCK] LED blinks. T E A C H L O C K 4.
Page 366 8.7 Power Supply Voltage Confirmation Power Supply Voltage Confirmation Check the voltage of R, S, T terminal of the circuit breaker (QF1) with an electric tester. Power Supply Voltage Confirmation Measuring Items Terminals Correct Value Correlate voltage Between R and S, S 200 to 220V (+10%, -15%) and T, R and T Voltage between earth...
Page 367 8.8 Open Phase Check Open Phase Check Open Phase Check List Check Item Contents Lead Cable Check Confirm if the lead cable for the power supply is wired as shown in the following. If the wiring is wrong or broken, repair it. Input Power Supply Check the open phase voltage of input power supply with an Check...
Page 368 8.8 Open Phase Check...
Page 369 9.1 Replacing XRC Parts 9 Replacing Parts Replacing XRC Parts W A R N I N G • Turn OFF the power supply before opening the XRC doors. Failure to observe this warning may result in electric shock. • After turning OFF the power supply, wait at least 5 minutes before replacing a servopack or power supply unit.
Page 370 9.1 Replacing XRC Parts 9.1.1 Replacing Parts of the CPU Rack CPU rack (JZNC-XRK01B-.) is comprised of the control power supply unit, the rack for the various circuit boards and system control boards. (CN05) AC200V Input Connector (CN04) (From Power Unit) PC Card (CN04) Battery Alarm...
Page 371 9.1 Replacing XRC Parts " Replacing the JANCD-XCP01 Circuit Board Turn off the power before replacing a circuit board. Replacement Procedure 1. Disconnect all cables connected to the circuit board. 2. Undo 2 screws fixing the circuit board and rack. 3.
Page 372 9.1 Replacing XRC Parts " Replacing the Control Power Unit (CPS-150F) C A U T I O N • After turning OFF the power supply, wait at least 5 minutes before replacing a control power unit. Do not touch any terminals during this period.
Page 373 9.1 Replacing XRC Parts 9.1.2 Replacing the Servopack There are two kinds of Servopacks depending on capacity. Type Manipulator Integrated Type SV3X, UP6, SK16X Separated Type SK16MX, SK45X, UP130, UP165, UP200, UP130R Replacement Procedure (Integrated Type) 1. Turn OFF the primary power supply and wait at least 5 minutes before replacing. Do not touch any terminals during this period.
Page 374 9.1 Replacing XRC Parts Replacement Procedure (Separated Type) a) SK16MX, SK45X • How to Replace Converter 1. Turn OFF the primary power supply and wait at least 5 minutes before replacing. Do not touch any terminals during this period. 2. Verify that the converter CHARGE lamp (red LED) is unlit. 3.
Page 375 9.1 Replacing XRC Parts b) UP130, UP165, UP200, UP130R • How to Replace Converter 1. Turn OFF the primary power supply and wait at least 5 minutes before replacing. Do not touch any terminals during this period. 2. Verify that the converter CHARGE lamp (red LED) is unlit. 3.
Page 376 9.1 Replacing XRC Parts 9.1.3 Replacing the parts of I/O Power-on Unit " Checking and Replacing Fuses The types of fuses on the I/O power-on unit (JZNC-XIU01) and power-on unit (JANCD- XTU01) are as follows. Parts No. Fuse Name Specification FU1, 2 Control Power Supply Fuse 250V, 5A, Time Lag Fuse...
Page 377 9.2 YASNAC XRC Parts List YASNAC XRC Parts List YASNAC XRC Parts List Name Model Comment Servopack 6 Axis type CPU rack JZNC-XRK01B-. Backboard JANCD-XBB01 System control circuit board JANCD-XCP01 High speed serial interface JANCD-XIF03 circuit board Control power supply CPS-150F I/O Power-on unit JZNC-XIU01...
Page 378 9.2 YASNAC XRC Parts List Servopack List (Small Capacity) SV3X SK16X Component Type Type Type Servopack CACR-SV3AAA CACR-UP6AAC CACR-SK16AAC Converter JUSP-ACP05JAA JUSP-ACP05JAA JUSP-ACP05JAA Amplifier JUSP-WS02AA JUSP-WS05AAY17 JUSP-WS10AAY17 JUSP-WS02AA JUSP-WS10AAY17 JUSP-WS10AAY17 JUSP-WS01AA JUSP-WS05AAY17 JUSP-WS10AAY17 JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA Servo control...
Page 379 9.2 YASNAC XRC Parts List Servopack List (Large Capacity) UP200, UP130R Component Type Servopack CACR-UP130AABY18 Amplifier JUSP-WS60AAY18 JUSP-WS60AAY18 JUSP-WS60AA JUSP-WS20AAY13 JUSP-WS15AAY13 JUSP-WS15AAY13 Servo control JASP-WRCA01 circuit board Converter JUSP-ACP35JAA Control power JUSP-RCP01AAB supply Power Supply Unit List Type Robot Type JZNC-XPW03B or SV3X, UP6, SK16X JZRCR-XPU03...
Page 380 XRC. The spare parts list for the XRC is shown below. Product performance can not be guaranteed when using spare parts from any company other than Yaskawa. To buy the spare parts which are ranked B or C, inform the manufacturing number (or order number) of XRC to Yaskawa representative.
Page 381 9.4 Recommended Spare Parts N OT E For replacing parts in Rank B or Rank C, contact your Yaskawa representative. Recommended Spare Parts of XRC for SV3X No Rank Name Type Mfr. Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack Fan...
Page 382 312003 3A 250V Littel fuse Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Convertor JUSP-ACP05JAA Yaskawa Control Power Unit JUSP-RCP01AAB SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP- Yaskawa For S,U axes...
Page 383 312003 3A 250V Littel fuse Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Convertor JUSP-ACP05JAA Yaskawa Control Power Unit JUSP-RCP01AAB SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP- Yaskawa For S,U axes...
Page 384 312003 3A 250V Littel fuse Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Convertor JUSP-ACP25JAA Yaskawa Control Power Unit JUSP-RCP01AAB SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP-WS30AA Yaskawa For S axis...
Page 385 312003 3A 250V Littel fuse Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Convertor JUSP-ACP25JAA Yaskawa Control Power Unit JUSP-RCP01AAB SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP-WS30AA Yaskawa For S,U axes...
Page 386 312003 3A 250V Daito Com- munication Apparatus Brake Fuse GP40 4.0A 250V Omron Control Relay LY2 DC24V Yaskawa Convertor JUSP-ACP35JAA SANRITZ Control Power Unit JUSP-RCP01AAB Yaskawa For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP-WS60AA Yaskawa For S,L,U axes Amplifier JUSP- Yaskawa...
Page 387 312003 3A 250V Littel fuse Brake Fuse GP40 4.0A 250V Daito Com- munication Apparatus Control Relay LY2 DC24V Omron Convertor JUSP-ACP35JAA Yaskawa Control Power Unit JUSP-RCP01AAB SANRITZ For Servo Servopack Control Board JASP-WRCA01 Yaskawa Amplifier JUSP- Yaskawa For S,L axes...
Page 388 9.4 Recommended Spare Parts 9-20...
Page 389 Alarm • Error...
Page 391 10.1 Outline of Alarm 10 Alarm 10.1 Outline of Alarm When the alarm of level 0-3(major alarm) occurs, the servo power supply is interrupted. Alarm Code classification. Alarm Code Alarm Level Alarm Reset Method Level 0 (Major alarm) It is not possible to reset by [RESET] under (Off line alarm: Initial diagnosis/ the alarm display or the specific I/O signal 0...
Page 392 10.2 Alarm Display 10.2 Alarm Display 10.2.1 Displaying/Releasing Alarm If an alarm occurs during operation, the manipulator stops immediately, the alarm/error lamp on the playback panel lights and the alarm display appears on the programming pendant indi- cating that the machine was stopped by an alarm. J O B E D I T D I S P L A Y...
Page 393 10.2 Alarm Display 10.2.2 Special Alarm Display (1) Sub Data Sub data such as data for the axis where the alarm occurred, may also be displayed for some alarms. • Decimal data Without signs: 0 to 65535 With signs: -32768 to 32767 •...
Page 394 10.2 Alarm Display (3) Independent Control Function (Optional) In the independent control function (multi-task job), the tasks that were being done when the alarm occurred are also displayed. TASK#0: Master-task job TASK#1: Sub-task1 job (SUB1) TASK#2: Sub-task2 job (SUB2) TASK#3: Sub-task3 job (SUB3) TASK#4: Sub-task4 job (SUB4) TASK#5: Sub-task5 job (SUB5) 10-4...
Page 395 JANCD-XCP01 back up very important file data for the user program with a battery. Care- less operation may delete registered data. If repairs for JANCD-XCP01 are necessary, consult YASKAWA representative before performing any repairs. Alarm Message List Alarm...
Page 396 An error was found by sum check of syste • Replace the circuit board. [Decimal Data] program. • When the XCP01 circuit board is replaced, consult YASKAWA representa- Data stands for an error circuit board tive. 1:XCP01 circuit board 2:XSP01 circuit board...
Page 397 • Replace the circuit board. (CPU BOARD RAM) • When the XCP01 circuit board is [Decimal Data] Data stands for an error circuit board replaced, consult a YASKAWA represen 1:XCP01 circuit board tative. 2:XSP01 circuit board 10:XCP02 circuit board (#1-0)
Page 398 *:System paramete 0210 MEMORY ERROR The system configuration data informatio Needs investigation. (SYSTEM CONFIG- on setting system initialization was Consult a YASKAWA representative. DATA) damaged. 0220 MEMORY ERROR The job control data was damaged. • Initialize the job on maintenance mode (JOB MNG DATA) The whole job data is deleted.
Page 399 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0320 VERIFY ERROR • The status of the I/O module on initializing • Check the I/O module is same as when it (I/O MODULE system or modifying was different than the was initialized or modified.
Page 400 NOT READY between XCP01 circuit board and WRCA01 • If the error occurs again, contact your circuit board. YASKAWA representative. 0900 WATCHDOG TIMER An insertion error of the XCP01 circuit board • Insert the circuit board in the CPU rack ERROR or defective circuit board.
Page 401 (XCP02#1) • Replace the circuit board [Decimal Data] • If the error occurs again, contact you YASKAWA representative. 0902 WATCHDOG TIMER An insertion error of the XCP02#2 circuit • Insert the circuit board in the CPU rack ERROR board or defective circuit board.
Page 402 (XCP02#1) • Replace the circuit board. [Decimal Data] • If the error occurs again, contact your YASKAWA representative. 0932 CPU HANG UP An insertion error of the XCP02#2 circuit • Insert the circuit board in the CPU rack ERROR board or defective circuit board.
Page 403 [Decimal Data] • Replace the circuit board. • If the error occurs again, contact you YASKAWA representative. 0952 CPU ERROR An insertion error of the WRCA01#3 circuit • Insert the circuit board in the CPU rack (WRCA#3) board or defective circuit board.
Page 404 (WRCA#5 • Replace the circuit board. [Decimal Data] • If the error occurs again, contact your YASKAWA representative. 0965 CPU HANG UP An insertion error of the WRCA01#6 circuit • Insert the circuit board in the CPU rack ERROR board or defective circuit board.
Page 405 • Don't operate the overrun recovery SWITCH RELEASED playback. switch on playback. • It is thought that the overrun recovery switch is failed. Consult YASKAWA rep- resentative. 1202 FAULT CPU motion impossibility caused by 0 divi- • Turn the power off then back on.
Page 406 • Replace the contactor unit. • If the error occurs again, contact your YASKAWA representative. 1303 ARITHMETIC The error occurred on check of interior con- Needs investigation. Consult a YASKAWA ERROR trol for the WRCA circuit board. representative. (SERVO) [Decimal Data]...
Page 407 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1305 POWER ON UNIT • The contactor unit was set on system con- <The system with external axis> NOT INSTALLED • Check the installation of the external axis figuration, but the contactor unit was not [Bit Pattern] circuit board(WRCF01 board).
Page 408 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1308 OVER SPEED The motor speed displayed by axis data • Check the connection of motor. Robot/Station exceeded allowable max speed. • Check the robot motion on alarm and [Axis Data] •...
Page 409 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1309 OVERLOAD The motor torque displayed by axis data • Check whether the robot interferes with (CONTINU exceeded rated torque for a long time (a fe the outside equipment. If the robot inter Robot/Statio seconds - a few minutes).
Page 410 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1310 OVERLOAD The motor torque displayed by axis data • Check whether the robot interferes with (MOMENT) exceeded rated torque for a long time. It the outside equipment. If the robot inter- Robot/Station may have burned the motor.
Page 411 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1311 AMPLIFIER OVER- The servopack (amplifier) current displayed • Check whether the robot interferes with LOAD by axis data exceeded rated current for a the outside equipment. If the robot inter (CONTINU long time (a few seconds - a few minutes).
Page 412 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1312 AMPLIFIER OVER- The servopack (amplifier) current displayed • Check whether the robot interferes with LOAD by axis data exceeded rated current for a the outside equipment. If the robot inter- (MOMENT) long time (a few seconds - a few minutes).
Page 413 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1314 SERVO TRACKING The servo deflection of the axis displayed by • Check whether the robot interferes with ERROR axis data became excessive, the robot was the outside equipment. If the robot inter Robot/Statio shifted from instructed motion position or feres, remove the cause.
Page 414 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1317 SPEED WATCHER The error occurred in the speed detective • Turn the power off then back on. BOARD ERROR circuit board. • If the error occurs again, replace the •...
Page 415 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1321 OVERCURRENT One of the U,V,W wires of the motor dis- This alarm does not occur by turning off (AMP) played on the axis data was grounded at the controlled power supply.
Page 416 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1325 COMMUNICATION The communication error between the • Check the connection of the encoder dis- ERROR encoder and the WRCA01 circuit board. played on axis data. (ENCODER) • The wrong wiring of the encoder wire •...
Page 417 Reset was not completed though encoder • Connect the battery with the encoder. RESET backup error reset was requested. It may Contact your YASKAWA representative Robot/Statio be possible that the battery is not connected because the breakdown of the encoder [Axis Data] with the encoder.
Page 418 • Faulty connection between the WRCA01 • Replace the WRCA01 board and the Robot/Station board and the XFC01 circuit board. XFC01 circuit board. [Axis Data] • Defective WRCA01 boar • If the error occurs again, contact your • Defective XFC01 circuit board YASKAWA representative. 10-28...
Page 419 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1344 COMMUNICATION The communication error occurred between • Check the encoder connection displayed the encoder and the XFC01 circuit board. in the axis data. (ENCODER) (XFC01) • Improper wiring of encoder cables •...
Page 420 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4008 MEMORY ERROR The arc end condition file of CMOS memory Initialize the arc end condition file in the (ARC END COND was damaged. maintenance mode. Load the saved arc FILE) The data stands for the file No.
Page 421 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4033 MEMORY ERROR The servo gun pressure file of CMOS mem- Initialize the servo gun pressure file in the (GUN PRESSURE ory was damaged. maintenance mode. Load the saved servo FILE) The data stands for the file No.
Page 422 • Check whether fuse for I/O contactor unit SUPPLY FAILURE put. is cut or not. • Check the external 24V power supply. • Check the connection of communication cable for I/O module. (XCP0 (CN01- XIU01(CN03 cable • If the error occurs again, contact your YASKAWA representative. 10-32...
Page 423 (robot and external ERROR axis) • If the error occurs again, contact you YASKAWA representative. 4119 FAN ERROR The axis was instructed to turn servo on and Make the condition so as to be able to turn (IN CONTROL BOX) off separately.
Page 424 [Binary Data] reduced. Contact your Yaskawa representative to replace the cooling fan 1. 4122 COOLING FAN 2 The number of revolutions of cooling fan 2...
Page 425 4300 VERIFY ERROR A mistake was found in the paramete Needs investigation. (SERVO PARAM related to servo control. Consult a YASKAWA representative. TER) [Decimal Data]] 4301 CONTACTOR • The contactor of the contactor unit was not • Turn servo ON again after resetting the ERROR turned ON at servo ON.
Page 426 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4303 CONVERTER • There was no response (servo ready sig • Reset the alarm and turn servo ON READY SIGNAL nal) of charge completion from convertor at again. ERROR servo ON.
Page 427 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4305 CONVERTER CIR- • There was no response (ready 2 signal) of • Check that primary power supply is more CUIT CHARGE charge completed from convertor at servo than 170V.
Page 428 Robot/Station the motor (encoder) for axis occurred the [Axis Data] error. • If the error occurs again, consult with a YASKAWA representative. 4310 ENCODER OVER- The encoder has overheated to 100 • Check that the ambient temperature is HEAT degrees.
Page 429 Data (1-5) stands for the alarm factor. • If the error occurs again, contact you YASKAWA representative. 4401 SEQUENCE TASK The error has occurred in job exec state- • Reset the alarm and repeat the opera- CONTR ERROR ment part.
Page 430 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4409 TWO STEPS SAME Among three taught points, there was the Reset the alarm. Teach the different 3 POSITION same point of two points or more. (User points again. (3 POINTS) coordinates, robots calibration, etc.) 4410...
Page 431 & Delete the job that cause the alarm and register again and start execution. • If the error occurs again, contact you YASKAWA representative. 4433 UNDEFINED GLO- The global variable range was undefined. Needs investigation at YASKAWA. Con- BAL VARIABLE sult a YASKAWA representative. [Decimal Data] 10-41...
Page 432 & Delete the job that cause the alarm and register again and start execution. • If the error occurs again, contact your YASKAWA representative. 4435 UNDEFINED LOCAL- The local variable was undefined. Set the local variable used for sub header VARIABLE of job.
Page 433 • In case the phenomenon occurs again without any external force, try to insert the XCP01 circuit board again. • If the error occurs again, contact you YASKAWA representative. 4445 DATA PRESET When the interpretation process section of • Reset the alarm. Select the job and...
Page 434 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4454 UNDEFINED The welder condition data file was not set. Set the welder condition data file. WELDER CONDI- TION FILE [Decimal Data] 4455 UNDEFINED ARC The arc start condition file was not set. Set the arc start condition file.
Page 435 4477 SELECT ERROR When executing operation instruction, the Needs investigation. (APPLICATION) selection parameter (parameter specified Consult a YASKAWA representative. [Decimal Data] for maker) for first application and applica- tion parameter (AP) was not adjusted. 4480 SELECT When executing sensor instruction, the Needs investigation.
Page 436 Number 4485 WRONG SELEC- When executing sensor instruction, robot Needs investigation. TION (SENSOR) designation (system parameter) uses sen- Consult a YASKAWA representative. [Decimal Data] sor application and robot designation (sys tem parameter) uses application was not corresponded. 4486 PASS OVER The path went outside the designated pass •...
Page 437 [Bit pattern] 4496 PARAMETER Parameter settings caused division by zero. Needs investigation. ERROR Consult a YASKAWA representative. [Decimal Data] 4497 DEFECTIVE TAUGHT There was a problem with the taught points. Teach the points again. POINT(CALIB)
Page 438 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4508 PECIFIED ERROR Position confirmation was not possible Reset the alarm and change the coordi- (COORDINATE) because the position variable (P) desig- nates. [Decimal Data] nates coordinates as tool coordinates, mas- ter tool coordinates.
Page 439 (CONCUR JOB) concurrent job. 4526 SYNTAX ERROR IN Internal data of equation inst was abnormal. Needs investigation. EQUATION INST Consult a YASKAWA representative. [Decimal Data] 4527 UNDEFINED PORT Designation of port No.for job was abnor- Needs investigation. mal. Consult a YASKAWA representative.
Page 440 4576 ERR IN SERVO GUN The error occurred in control process of ser- Needs investigation. CONT MODE vogun. Consult a YASKAWA representative. 4577 ERR IN SERVO GUN The error occurred in control process of ser- Needs investigation. MODE RLSE vogun.
Page 441 10.4 I/O Alarm Message List 10.4 I/O Alarm Message List " Arc Welding Application Alarm No. Registration No. I/O Alarm Message System Section 9000 9010 MISSING ARC GENERATION CON- FIRM 9020 ARC SHORTAGE 9030 9040 GAS SHORTAGE (RESTART) 9050 WIRE SHORTAGE (RESTART) 9060 9070 9080...
Page 442 10.4 I/O Alarm Message List " Handling Application Alarm No. Registration No. I/O Alarm Message System Section 9000 AIR PRESSURE LOWERED 9010 9020 9030 9040 9050 9060 9070 9080 9090 9100 9110 9120 9130 9140 9150 9160 9170 9180 9190 9200 9210 9220...
Page 443 10.4 I/O Alarm Message List " Spot Welding Application Alarm No. Registration No. I/O Alarm Message System Section 9000 ERR OF WELD TIMER COOLING WATER 9010 ERROR OF GUN COOLING WATER 9020 ERROR IN TRANSTHERMO OF GUN 9030 AIR PRESSURE LOWERED 9040 9050 9060...
Page 444 10.4 I/O Alarm Message List " General Application Alarm No. Registration No. I/O Alarm Message System Section 9000 9010 9020 9030 9040 9050 9060 9070 9080 9090 9100 9110 9120 9130 9140 9150 9160 9170 9180 9190 9200 9210 9220 9230 User Section 9240...
Page 445 11.1 Error Message List 11 Error 11.1 Error Message List Error warns the operator not to advance to the next operation caused by a wrong operation and the access method when programing pendant operation or an external equipment (com- puter, PLC, etc.)accesses. When an error occurs, release it after the confirmation of the content of the error.
Page 446 11.1 Error Message List 11.1.1 System and General Operation Error NO. Data Message Contents Turn off servo power and perform cor- It cannot be operated on servo rective action power supply. Depress TEACH Out of specified mode operation Illegal setting for number of variables Parameter setting error Illegal setting for number of variables Limit of variables name is 64...
Page 447 11.1 Error Message List Error NO. Data Message Contents Undefined file Undefined gun condition file Lack of number of I/O points Cannot set same No. Undefined user frame Cannot register Master JOB Cannot operate CHECK-RUN Cannot operate MACHINE LOCK Cannot operate Master JOB Cannot initialize Teach point not specified No SYNCHRO operation...
Page 448 11.1 Error Message List Error NO. Data Message Contents Not start reservation mode Start reserved JOB change prohibit is Cannot teach position while soft limit released Turn on all contactor's servo power Connect group axis to one contactor Register group axis combination [SYNCHRO] key for coordinated job which was not registered as group was pressed.
Page 449 11.1 Error Message List Error NO. Data Message Contents Servo power supply is limited Modification range over Cannot move while modifying speed Unregistered key Cannot register instruction Please release key registration mode This key cannot be allocated Same relay cannot be set This key has already been registered.
Page 450 11.1 Error Message List 11.1.2 Editing Error No. Data Message Contents 1010 EDIT LOCK mode 1020 Enter correct value 1030 Unauthorized ID No. 1040 1050 Enter correct date 1060 Enter correct clock 1070 Enter a number in 8 figures 11.1.3 Job Defined Data Error No.
Page 451 11.1 Error Message List Error No. Data Error Message Error Contents 2190 Cannot delete data 2200 Cannot modify data 2210 Illegal data setting 2220 Display edit instruction 2230 Illegal instruction equation 2240 Excessive instruction equation Unmatched number of parentheses in 2250 equation 2260...
Page 452 11.1 Error Message List Error No. Data Error Message Error Contents Cannot teach JOB without group-axis 2300 specification Same label exists 2310 2320 Cannot create coordinated JOB Line No. 2330 Cannot edit coordinated instruction Calibration not complete 2340 Pasted data not found 2350 Editing data not found 2360...
Page 453 11.1 Error Message List Error No. Data Error Message Error Contents 2570 The step does not contain speed 2580 The step dose not contain PL/CONT 2590 Soft limit range over Cannot teach position in concurrent 2600 2610 Wrong JOB kind 2620 Cannot correct play speed in the JOB 2630...
Page 454 11.1 Error Message List 11.1.4 External Memory Equipment Error No. Data Message Contents 3010 Floppy disk cable not connected Floppy disk not inserted into floppy 3020 disk drive 3030 Floppy disk protection is ON 3040 File not saved on floppy disk 3050 File saved on floppy disk 3060...
Page 455 11.1 Error Message List Error No. Data Message Contents Concurrent I/O record error Format error Ladder program is too long Exceed the range of the data 3150 Specification error of channel No. Specification error of relay No. Timer value error Specification error of timer No.
Page 456 11.1 Error Message List Error No. Data Message Contents Error in JOB data record The number of position data (NPOS) record wrong for the format Record on the user coordinate No. is wrong for the format Tool record is wrong for the format Record on the position data section is wrong for the format Robot type of XYZ data (RCONF)
Page 457 11.1 Error Message List Error No. Data Message Contents Invalid instruction Invalid tag Invalid character Undefined intermediate code Intermediate code shortage Syntax stack overflow Syntax stack underflow Array type tag incomplete Tag [ARRAY] Element type tag incomplete Tag [ELEMENT] Macro JOB unregistered Input format error Date size over MIN value over...
Page 458 11.1 Error Message List Error No. Data Message Contents [BINARY/HEXADECIMAL WORD TYPE] data error [DOUBLE PRECISION TYPE] [DECIMAL DWORD TYPE] data error [BINARY/HEXADECIMAL WORD TYPE] data error [REAL TYPE] data error [LADDER SPECIAL TYPE] data error 3220 JCL text Invalid text [LABEL NAME] data error [JOB NAME] data error [STRING] data error...
Page 459 11.1 Error Message List Error No. Data Message Contents 3380 Drive not ready 3390 File not found 3400 File already exists on the media 3410 Out of memory on the media 3420 Max number of files has been reached 3430 I/O error on the drive 3440 Wrong media type...
Page 460 11.1 Error Message List 11.1.5 Concurrent I/O Error No. Data Message Contents Illegal relay No. 4010 Line No. Illegal block No. 4020 Line No. Illegal instruction 4030 Line No. Relay/register No. duplicated in OUT/ Plural output are instructed to GOUT or arithmetic instruction the relay or register 4040 Line No.
Page 461 11.1 Error Message List Error No. Data Message Contents 4170 Cannot modify/delete 4180 Press INSERT/MODIFY/DELETE keys 4190 Ladder program not found 4200 Cannot specify system variables ($) 4210 Cannot edit line Excess TMR/CNT or arithmetic instruc- More than 100 TMR, CNT or 4220 tions arithmetic instruction used...
Page 462 11.1 Error Message List 11-18...
Page 464 TAIPEI OFFICE Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan Phone 886-2-2563-0010 Fax 886-2-2567-4677 BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD. 30 Xue Yuan Road, Haidian, Beijing 100083, China Phone 86-10-6233-2782 Fax 86-10-6232-1536 SHOUGANG MOTOMAN ROBOT CO., LTD.
Page 465 YASKAWA YASNAC XRC TROUBLESHOOTING Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN-___ INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR’S MANUAL YASNAC XRC OPERATOR’S MANUAL for BEGINNERS The YASNAC XRC operator’s manuals above correspond to specific usage.
Page 467 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 rep- resentative to order a new copy. The representatives are listed on the back cover.
Page 468 NOTES FOR SAFE OPERATION Read this manual carefully before installation, operation, maintenance, or inspection of the YASNAC XRC. In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”,or ”PROHIBITED”. Indicates a potentially hazardous situation which, if not avoided, WARNING could result in death or serious injury to personnel.
Page 469 WARNING • Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the playback panel or program- ming pendant are pressed. When the servo power is turned off, the SERVO ON READY lamp on the playback panel and the SERVO ON LED on the programming pendant are turned off.
Page 470 • Read and understand the Explanation of the Alarm Display in the setup manual before operating the manipulator. Definition of Terms Used Often in This Manual The MOTOMAN manipulator is the YASKAWA industrial robot product. The manipulator usually consists of the controller, the playback panel, the programming pen- dant, and supply cables.
Page 471 Table of Contents Alarm/Error Code Page AL-0010 (CPU BOARD INSERTION ERROR) ..................8 AL-0020 (CPU COMMUNICATION ERROR)..................9 AL-0030 (ROM ERROR) ........................10 AL-0040 (MEMORY ERROR (CPU BOARD RAM))................10 AL-0050 (MEMORY ERROR (PCI-BUS COMMON RAM)) ..............11 AL-0060 (COMMUNICATION ERROR (I/O MODULE) ................ 12 AL-0200 (MEMORY ERROR (PARAMETER FILE) ................
Page 472: Alarm/Error Code Page
Alarm/Error Code Page AL-1325 (COMMUNICATION ERROR (ENCODER)) ................44 AL-1326 (DEFECTIVE ENCODER ABSOLUTE DATA) ............... 45 AL-1327 (ENCODER OVER SPEED) ....................46 AL-1328 (DEFECTIVE SERIAL ENCODER) ..................47 AL-1329 (DEFECTIVE SERIAL ENCODER COMMAND)..............48 AL-1330 (MICRO PROGRAM TRANSMIT ERROR)................49 AL-1331 (CURRENT FEEDBACK ERROR (U PHASE))..............
Page 473 Alarm/Error Codes Scope This manual lists troubleshooting procedures for specific XRC alarm/error codes. It is intended to help you understand and rectify the alarm/error codes you may encounter while using the Motoman XRC controller. How to Use this Manual Alarm/error codes are listed numerically in the Table of Contents. Locate, and turn to, the page number of the alarm/error code displayed on your controller.
Page 474: Al-0010 (Cpu Board Insertion Error)
Continue normal operation. Replace the XCP01 circuit board. The defective CPU board caused the alarm. Alarm? Continue normal operation. Replace the XBB01 circuit board. Alarm? Continue normal operation. Contact your Yaskawa The defective XBB01 circuit representative. board caused the alarm.
Page 475: Al-0020 (Cpu Communication Error)
The defective CPU board caused the alarm. Alarm? Continue normal operation. Replace the XBB01 circuit board. The defective XCP01 circuit board caused the alarm. Alarm? Contact your Yaskawa representative. Continue normal operation. The defective XBB01 circuit board caused the alarm.
Page 476: Al-0030 (Rom Error)
Remove the corresponding ROM board and Continue normal operation. remount it. Alarm? Continue normal operation. Contact your Yaskawa representative. The defective ROM board caused the alarm. AL-0040 (MEMORY ERROR (CPU BOARD RAM)) An error occurs during the local RAM's reading/writing check. An alarm occurs.
Page 477: Al-0050 (Memory Error (Pci-Bus Common Ram))
Turn the power OFF and then ON. Alarm? Remove the corresponding RAM board and Continue normal operation. remount it. Alarm? Replace the board. Continue normal operation. Alarm? Contact your Yaskawa representative. Continue normal operation. The defective RAM board caused the alarm.
Page 478: Al-0060 (Communication Error (I/O Module)
XIO01 circuit board. Alarm? Continue normal operation. Confirm the setting of the I/O Module. Alarm? Replace the I/O Module. Continue normal operation. Alarm? Continue normal operation. Contact your Yaskawa representative. The defective I/O Module caused the alarm.
Page 479: Al-0200 (Memory Error (Parameter File)
Replace the XCP01 circuit board. Continue normal operation. The destructured parameter file caused the alarm. Alarm? Contact your Yaskawa representative. Continue normal operation. The defective XCP01 circuit board caused the alarm. AL-0210 (MEMORY ERROR (SYSTEM CONFIG-DATA)) An error occurs during the system configuration data's total check.
Page 480: Al-0220 (Memory Error (Job Mng Data)
Continue normal operation. The destructured job file caused the alarm. Alarm? Continue normal operation. Contact your Yaskawa representative. The defective XCP01 circuit board caused the alarm. AL-0230 (MEMORY ERROR (LADDER PRG FILE)) An error occurs during the CIO ladder data's total check.
Page 481: Al-0300 (Verify Error (System Config-Data)
The destructured parameter file caused the alarm. Alarm? Continue normal operation. Contact your Yaskawa representative. The defective XCP01 circuit board caused the alarm. AL-0310 (VERIFY ERROR (CMOS MEMORY SIZE)) The system settings for the CMOS memory capacity differ from the actual capacity.
Page 482: Al-0320 (Verify Error (I/O Module)
Confirm the setting of the I/O Module. Alarm? Replace the I/O Module. Continue normal operation. Alarm? Continue normal operation. Contact your Yaskawa representative. The defective I/O Module caused the alarm. AL-0330 (VERIFY ERROR (APPLICATION)) An error occurs in the parameter setting. An alarm occurs.
Page 483: Al-0340 (Verify Error (Sensor Function)
Continue normal operation. Reset the option board. The defective sensor board caused the alarm. Alarm? Contact your Yaskawa representative. Continue normal operation. The destructured system configurations data caused the alarm. AL-0400 (PARAMETER TRANSMISSION ERROR ) An error occurs during the internal control check.
Page 484: Al-0410 (Mode Change Error)
An alarm occurs. Turn the power OFF and then ON. Alarm? Continue normal operation. Contact your Yaskawa representative. AL-0500 (SEGMENT PROC NOT READY) An error occurs during communications between the XCP01 circuit board and the WRCA01 circuit board. An alarm occurs.
Page 485: Al-0900 To 0906 (Watchdog Timer Error)
Continue normal operation. the corresponding board. (See the table below.) Alarm? Replace the board. Continue normal operation. Alarm? Continue normal operation. Contact your Yaskawa The defective board caused the alarm. representative. AL090 XCP02 (#2-2) WRCA01 #6 AL0900 XCP01 circuit board AL0945...
Page 486: Al-0910 To 0912 (Cpu Error)
Continue normal operation. the corresponding board. (See the table below.) Alarm? Replace the board. Continue normal operation. Alarm? Contact your Yaskawa Continue normal operation. The defective board caused the alarm. representative. AL095 WRCA01 #1 WRCA01 #4 AL0910 XCP01 circuit board...
Page 487: Al-0920 To 0922 (Bus Error)
(See the table below.) Alarm? Replace the board. Continue normal operation. Alarm? Continue normal operation. Contact your Yaskawa The defective board caused the alarm. representative. AL0920 XCP01 circuit board AL092 XCP02 #1 circuit board AL092 XCP02 #2 circuit board...
Page 488: Al-0930 To 0932 (Cpu Hang Up Error)
AL-0999 (NMI ERROR) An NMI error (origin unknown) occurs. An alarm occurs. Turn the power OFF and then ON. Alarm? Check the connections of all the boards. Continue normal operation. Alarm? Contact your Yaskawa representative. Continue normal operation.
Page 489: Al-0021 (Communication Error (Servo))
Continue normal RCP01AAA unit lit? operation. Replace the WRCA01 circuit board. Remove connector 1CN on the RCP01AAA unit and re-insert it. Alarm? Alarm? Contact your Yaskawa Check the fuse for the Continue normal representative. RCP01AAA unit. operation. Normal Blown out Continue normal operation.
Page 490: Al-0030 (Rom Error)
Turn the control power supply OFF and then ON. Alarm? Continue normal operation. Replace the WRCA01 circuit board. Alarm? Contact your Yaskawa Continue normal operation. representative. The defective WRCA01 circuit board caused the alarm. AL-1001 (ROM ERROR (WRCA01)) An alarm occurs.
Page 491: Al-1105 (System Error (Servo))
Is the decimal data set to "13"? Continue normal operation. Replace the WRCA01 circuit board. Alarm? Contact your Yaskawa Continue normal operation. representative. The defective WRCA01 circuit board caused the alarm. Does the alarm occur the first time the servo is turned ON after turning...
Page 492: Al-1300 (Servo Cpu Synchronizing Error)
Alarm? Remove connector CN05 on the Continue normal operation. XCP01 circuit board and re-insert it. Alarm? Continue normal operation. Replace the WRCA01 circuit board. Alarm? Continue normal operation. Contact your Yaskawa The defective WRCA01 circuit representative. board caused the alarm.
Page 493: Al-1301(Communication Error (Servo))
Replace the XCP01 circuit board . Alarm? Remove the connector 1CN on the RCP01AAA unit and re-insert it. Continue normal operation. Alarm? The defective XCP01 circuit board caused the alarm. Continue normal Contact your Yaskawa Contact your Yaskawa operation. representative. representative.
Page 494: Al1302 (Communication Error (Servo I/O))
Continue normal operation. The defective XIU01 unit caused the alarm. Replace the cable between CN21 on the XIU01 unit and CN20 on the WRCA01 circuit board. Alarm? Continue normal operation. The defective cable caused the alarm. Contact your Yaskawa representative.
Page 495: Al-1303 (Arithmetic Error (Servo))
Check the tool file. (Check the units and positive/ negative of the setting values.) Continue normal operation. Alarm? A parameter settings error caused the alarm. Contact your Yaskawa representative. AL-1304 (EX-AXIS BOARD NOT INSTALLED) An alarm occurs. Is a WRCF01 circuit board mounted? Mount a WRCF01 board.
Page 496: Al-1306 (Amplifier Type Mismatch)
A faulty connection caused the alarm. Replace the WRCA01 circuit board. Continue normal operation. Alarm? The defective WRCA01 circuit board caused the alarm. Replace the SERVOPACK. Continue normal operation. Alarm? The defective SERVOPACK caused the alarm. Contact your Yaskawa representative.
Page 497: Al-1307 (Encoder Type Mismatch)
CNPG456 on the corresponding WRCA01 circuit board and re-insert them. (See Fig. 2.) Continue normal operation. Alarm? A faulty connection caused the alarm. Replace the encoder (or motor). Continue normal operation. Alarm? The defective encoder caused the alarm. Contact your Yaskawa representative.
Page 498: Al-1308 (Over Speed (Error In Robot Axis))
Replace the WRCA01 circuit board. Alarm? Reduce the motion speed. Continue normal operation. Alarm? The defective WACA01 circuit board caused the alarm. Replace the motor. Alarm? Continue normal operation. The defective motor caused the alarm. Contact your Yaskawa representative.
Page 499: Al-1308 (Over Speed (Error In Servo-Gun Axis))
Close the opening of the gun a little. Alarm? Replace the WRCF01 circuit board. Alarm? Continue normal operation. The defective WACF01 circuit board caused the alarm. Replace the motor. Alarm? Contact your Yaskawa Continue normal operation. representative. The defective motor caused the alarm.
Page 500: Al-1309 (Overload (Continue))
D o e s t h e a l a r m o c c u r when the servo is OFF? Does the alarm occur while Contact your Yaskawa the robot is stopped? representative. Decrease the weight of the tool or Reduce the motion speed.
Page 501: Al-1314 (Servo Tracking Error)
Does the robot axis move at the same time with any other axes? Continue normal operation. Reduce the motion speed. Alarm? Replace the servo unit. Alarm? Contact your Yaskawa representative. Continue normal operation.
Page 502: Al-1315 (Position Error)
Remove CN2 on the XEI01 circuit board and re-insert it. Alarm? Replace the XEI01 circuit board. Alarm? Replace the WRCF01 circuit board. Alarm? Replace the cable between the WRCF01 circuit board and the XEI01 circuit board. Alarm? Contact your Yaskawa Continue normal representative. operation.
Page 503: Al-1316 (Broken
XIU01 unit and re-insert it. XEI01 board. Alarm? Replace the XEI01 circuit board. Alarm? Replace the WRCF01 circuit board. Alarm? Replace the cable between the WRCF01 circuit board and the XEI01 circuit board. Alarm? Contact your Yaskawa Continue normal representative. operation.
Page 504: Al-1318 (Overvoltage (Converter))
Replace the WRCA01 circuit board. cable for the B1 and B2 terminals Alarm? of the converter to measure the Alarm? resistance.) (See Fig. 4.) Continue normal operation. Contact your Yaskawa Replace the regenerative resistor. representative. Alarm? Continue normal operation. Continue normal Replace the converter.
Page 505: Al-1319 (Ground Fault)
Replace the SERVOPACK. Is there a ground fault? Alarm? (See Fig. 5.) Protection against the axis falling Contact your Yaskawa Disconnect CN29 on the representative. XIU01 unit. Turn ON the servo power supply with Continue normal the 2BC and 3BC base connectors After disconnecting the motor power cable operation.
Page 506: Al-1320 (Open Phase (Converter))
Replace the WRCA01 circuit board. Alarm? Are the breaker's primary voltages at R, S, and T all 200 V (+10% to 15%)? Contact your Yaskawa representative. Change the breaker's primary voltage to the specified voltage. Alarm? Turn OFF the control power supply.
Page 507: Al-1321 (Overcurrent (Amp))
Replace the SERVOPACK. operation. Is there any ground fault? Alarm? (See Fig. 7.) Protection against the axis falling Contact your Yaskawa Disconnect CN29 on the representative. XIU01 unit. Turn ON the servo power supply with Continue normal 2BC and 3BC base connectors After disconnecting the motor power cable operation.
Page 508: Al-1323 (Input Power Overvoltage (Conv))
Change the breaker's primary voltage to the specified voltage. Replace the WRCA01 circuit board. Alarm? Alarm? Continue normal operation. Replace the converter. Contact your Yaskawa Alarm? representative. Continue normal Replace the WRCA01 circuit board. operation. Alarm? Contact your Yaskawa Continue normal representative.
Page 509: Al-1324 (Temperature Error(Converter))
(See Fig. 10.) CN30 Alarm? Remove connector CN1 on the Fig. 10 converter and re-insert it. (See Fig. 10.) Alarm? Replace the converter. Alarm? Continue normal operation. Replace the WRCA01 circuit board. Alarm? Contact your Yaskawa Continue normal representative. operation.
Page 510: Al-1325 (Communication Error (Encoder))
Does the alarm always occur? Replace the motor (encoder). Continue normal operation. Alarm? The defective encoder caused the alarm. Take a corrective measure against noise from the communications line. Continue normal operation. Alarm? The noise caused the alarm. Contact your Yaskawa representative.
Page 511: Al-1326 (Defective Encoder Absolute Data)
Remove the connectors CNPG123 and CNPG456 on the corresponding WRCA01 circuit board and re-insert them. Alarm? Continue normal operation. A faulty connection caused the alarm. Replace the motor (encoder). Continue normal operation. Alarm? The defective encoder caused the alarm. Contact your Yaskawa representative.
Page 512 CNPG456 on the corresponding WRCA01 circuit board and re-insert them. Continue normal operation. Alarm? A faulty connection caused the alarm. Fig. 15 Replace the motor (encoder). Alarm? Continue normal operation. The defective encoder caused the alarm. Contact your Yaskawa representative.
Page 513: Al-1328 (Defective Serial Encoder)
CNPG456 on the corresponding WRCA01 circuit board and re-insert them. Alarm? CNPG123 Continue normal operation. Fig. 16 A faulty connection caused the alarm. Replace the motor (encoder). Alarm? Continue normal operation. Contact your Yaskawa representative. The defective encoder caused the alarm.
Page 514: Al-1329 (Defective Serial Encoder Command)
A faulty connection caused the alarm. Replace the corresponding WRCA01 circuit board. Alarm? Continue normal operation. The defective WRCA01 circuit board caused the alarm. Replace the motor (encoder). Alarm? Continue normal operation. The defective encoder caused the alarm. Contact your Yaskawa representative.
Page 515: Al-1330 (Micro Program Transmit Error)
The poor contact caused the alarm. Fig. 18 Replace the WRCA01 circuit board. Alarm? Continue normal operation. The defective WRCA01 circuit board caused the alarm. Contact your Yaskawa representative. AL-1331 (CURRENT FEEDBACK ERROR (U PHASE)) An alarm occurs. SERVOPACK Turn the control power supply OFF...
Page 516 The defective cable caused the alarm. Replace the WRCA01 cirucit board. Alarm? Continue normal operation. The defective WRCA01 circuit board caused the alarm. Replace the SERVOPACK. Alarm? Continue normal operation. The defective SERVOPACK caused the alarm. Contact your Yaskawa representative.
Page 517: Al-4100 (Overrun In Robot Axis)
Continue normal WRCA01 circuit board and re-insert it. operation. Alarm? Remove connector CN1 of the converter and re-insert it. Alarm? Replace the converter. Alarm? Continue normal operation. Replace the WRCA01 circuit board. Alarm? Contact your Yaskawa Continue normal representative. operation.
Page 518: Al-4301 (Contactor Error)
Alarm? (Measure the resistance.) Continue normal operation. The defective WRCA01 circuit board caused the alarm. Contact your Yaskawa representative. Converter L1 L2 L3 B1 B2 After turning OFF the non-fuse breaker, measure the resistance between the non-fuse breaker's secondary terminals and the converter's input power supply terminals to confirm that all are open.
Page 519 The defective relay caused the alarm. Replace the XTU01 circuit board. Alarm? Continue normal operation. The defective XTU01 circuit board caused the alarm. Replace the WRCA01 circuit board. Alarm? Continue normal operation. The defective WRCA01 circuit board caused the alarm. Contact your Yaskawa representative.
Page 520 The defective XTU01 circuit Replace the WRCA01 circuit board. board caused the alarm. Alarm? Continue normal operation. Continue normal The defective WRCA01 circuit operation. board caused the alarm. Contact your Yaskawa representative. Non-fuse breaker Converter SERVOPACK Tester (Measure the resistance.) CN30...
Page 521: Al-4304 (Converter Input Power Error)
Alarm? Continue normal operation. The defective WRCA01 circuit board caused the alarm. Non-fuse breaker Contact your Yaskawa representative. Tester (Measure the resistance.) After turning OFF the non-fuse breaker, measure the resistance between the non-fuse breaker's secondary...
Page 522: Al-4305 (Converter Circuit Charge Error)
The defective SERVOPACK caused the alarm. Replace the converter. Alarm? Continue normal operation. The defective converter caused the alarm. Replace the WRCA01 circuit board. Alarm? Continue normal operation. The defective WRCA01 circuit board caused the alarm. Contact your Yaskawa representative.
Page 523: Al-4306 (Amplifier Ready Signal Error)
The poor contact caused the alarm. Replace the amplifier. Alarm? Continue normal operation. The defective amplifier caused the alarm. Replace the WRCA01 circuit board. Alarm? Continue normal operation. The defective WRCA01 circuit board caused the alarm. Contact your Yaskawa representative.
Page 524: Al-4307 (Servo On Difective Speed)
Alarm? Check the connector of the amplifier's power line. Alarm? Check the connector of the power supply cable on the robot. Alarm? Continue normal operation. A faulty connection caused the alarm. Contact your Yaskawa representative.
Page 525 WRCA01 circuit board and re-insert them. (See Fig. 33.) Alarm? Continue normal operation. A faulty connection caused the alarm. Replace the motor (encoder). Alarm? Continue normal operation. The defective encoder caused the alarm. Contact your Yaskawa representative.
Page 526 10 minutes. Alarm? Operate the encoder at 80°C or less. Alarm? Continue normal operation. The overheated encoder caused the alarm. Replace the motor (encoder). Alarm? Continue normal operation. The defective encoder caused the alarm. Contact your Yaskawa representative.
Page 527 Continue normal operation. The diconnected battery cable caused the alarm. Remove connectors CNPB123 and CNPB456 of the WRCA01 circuit board and re-insert them. (See Fig. 34.) Alarm? Continue normal operation. A faulty connection caused the alarm. Contact your Yaskawa representative.
Page 528 CNPB456 of the WRCA01 circuit board Fig. 35 and re-insert them. (See Fig. 35.) Alarm? Continue normal operation. A faulty connection caused the alarm. Contact your Yaskawa representative. AL-4313 (SERIAL ENCODER OVERHEAT) An alarm occurs. Turn OFF the control power supply and wait until the encoder cools.
Page 529 Alarm? Continue normal operation. Remove connectors CNPB123 and The disconnected cable caused the alarm. CNPB456 of the WRCA01 circuit board and re-insert them. (See Fig. 36.) Alarm? Continue normal operation. A faulty connection caused the alarm. Contact your Yaskawa representative.
Page 532 TAIPEI OFFICE Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan Phone 886-2-2563-0010 Fax 886-2-2567-4677 BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD. 30 Xue Yuan Road, Haidian, Beijing 100083, China Phone 86-10-6233-2782 Fax 86-10-6232-1536 SHOUGANG MOTOMAN ROBOT CO., LTD.

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Yasnac xrc Yr-up6-a00 Yr-up6-a01

YASKAWA Motoman UP6 Instructions Manual

Table of Contents

Receiving

1 Receiving

2 Transporting

3 Installation

4 Wiring

5 Basic Specifications

6 Allowable Load for Wrist Axis and Wrist Flange

7 System Application

8 Motoman Construction

9 Maintenance and Inspection

10 Recommended Spare Parts

11 Parts List

Setup • Diagnosis 15

1 Outline of Setting and Diagnosis

2 Security System

3 System Setup

4 Modification of System Configuration

5 System Diagnosis

7 Description of Units and Circuit Boards

Alarm/Error Code Page

Quick Links

Chapters

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Summary of Contents for YASKAWA Motoman UP6