Download Print this page

Motoman SK300X Manual

Motoman SK300X Manual

Manipulator

page of 553

/ 553
Contents
Table of Contents
Bookmarks

Table of Contents

Advertisement

Quick Links

Download this manual

XRC 2001 Controller

SK300X

Manipulator Manual

Part Number 146524-1

September 21, 2001

MOTO MAN

805 Liberty Lane

West Carrollton, OH 45449

TEL: (937) 847-6200

FAX: (937) 847-6277

24-HOUR SERVICE HOTLINE: (937) 847-3200

The information contained within this document is the proprietary property of Motoman, Inc., and may

not be copied, reproduced or transmitted to other parties without the expressed written authorization of

Motoman, Inc.

©2001 by MOTO MAN

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.

Table of Contents

Advertisement

Chapters

Table of Contents

Need help?

Need help?

Do you have a question about the SK300X and is the answer not in the manual?

Questions and answers

Summary of Contents for Motoman SK300X

Page 1 FAX: (937) 847-6277 24-HOUR SERVICE HOTLINE: (937) 847-3200 The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman, Inc.
Page 3: Table Of Contents
TABLE OF CONTENTS Section Page INTRODUCTION .......................... 1-1 SAFETY ............................2-1 XRC SETUP ..........................3-1 SK300X INSTRUCTIONS ......................4-1 XRC INSTRUCTIONS (NAS 2001) ....................5-1 XRC INSTRUCTIONS-GENERAL (R2) ..................6-1 SK300X ELEMENTARY DIAGRAMS .................... 7-1 MOTO MAN SK300X Manipulator Manual (XRC 2001)
Page 4 NOTES SK300X Manipulator Manual (XRC 2001) MOTO MAN...
Page 5: Introduction
The Motoman SK300X has six individual axes: Sweep, Lower arm, Upper arm, Rotate, Bend, and Twist. The XRC 2001 controller coodinates the operation of the SK300X robot with external equipment such as power supply and positioning tables. The XRC 2001 processes input and output signals, maintains variable data, and performs numeric processing to convert to and from different coordinate systems.
Page 6 • Vendor manuals for system components not manufactured by Motoman. Customer Service Information If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200. Please have the following information ready before you call: • Robot Type (SV3X, etc.) •...
Page 7 INTRODUCTION NOTES MOTO MAN SK300X Manipulator Manual (XRC 2001)
Page 8 We recommend that all personnel who intend to operate, program, repair, or use the robot system be trained in an approved Motoman training course and become familiar with the proper operation of the system. This safety section addresses the following: •...
Page 9 NOTE: Information appearing in a NOTE caption provides additional information which is helpful in understanding the item being explained. SK300X Manipulator Manual (XRC 2001) MOTO MAN...
Page 10 Safety fences and barriers • Light curtains • Door interlocks • Safety mats • Floor markings • Warning lights Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately. MOTO MAN SK300X Manipulator Manual (XRC 2001)
Page 11 Do not make any modiﬁcations to PART 1. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY! • Some operations require standard passwords and some require special passwords.
Page 12 This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modiﬁcations. Check and test all changes at slow speed. MOTO MAN SK300X Manipulator Manual (XRC 2001)
Page 13 (Input and Output) modiﬁcations. Check and test all changes at slow speed. • Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs). SK300X Manipulator Manual (XRC 2001) MOTO MAN...
Page 14 MOTOMAN SETUP MANUAL 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- ooo MANIPULATOR INSTRUCTION MANUAL YASNAC XRC INSTRUCTION MANUAL YASNAC XRC OPERATOR’S MANUAL YASNAC XRC OPERATOR’S MANUAL FOR BEGINNERS...
Page 15 • This manual explains the various components of the YASNAC XRC sys- tem and general operations. Read this manual carefully and be sure to understand its contents before handling the YASNAC XRC. • General items related to safety are listed in Section 1: Safety of the Setup Manual.
Page 16 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,” “MAN- DATORY,” or “PROHIBITED.” Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.
Page 17 • Before operating the manipulator, check that the 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 18 • 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 19 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 [ ], e.g., [ENTER]. Symbol Keys The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture.
Page 20 Explanation of warning labels The following warning labels are attached to the manipulator and XRC. Fully comply with the precautions on the warning labels. • The label described below is attached to the manipulator. Observe the precautions on the warning labels. Failure to observe this caution may result in injury or damage to equipment.
Page 21 viii...
Page 22 1.5.3 Operation Safety ........1-11 1.6 Notes for Moving and Transferring the MOTOMAN .
Page 23 Turning on the Power Supply 5.1 Turning on the Main Power Supply ......5-1 5.1.1 Startup Diagnostics ........5-1 5.1.2 When Startup Diagnostics are Complete .
Page 24 This manual is arranged as follows: Chapter 1 includes general notes for safe and proper operation of the MOTOMAN. Chapter 2 explains how to receive the manipulator and its support equipment. Chapter 3 explains XRC installation, location, and setup.
Page 26: Safety
1.1 For Your Safety 1 Safety For Your Safety Robots generally have requirements which are different from other manufacturing equipment, such as larger working areas, high-speed operation, rapid arm movements, etc., which can pose safety hazards. Read and understand the instruction manuals and related documents, and observe all pre- cautions in order to avoid the risk of injury to personnel and damage to equipment.
Page 27 1.1 For Your Safety • Teaching maintenance of the robot must conform to: -Industrial Safety and Health Law -Enforcement Order of Industrial Safety and Health Law -Ordinance of Industrial Safety and Health Law Other related laws are: -Occupational Safety and Health Act in USA -Factory Act (Gewerbeordnung) in Germany -Health and Safety at Work, etc.
Page 28: Special Training
• For more information on training, inquire at the nearest YASKAWA branch ofﬁce. The telephone numbers are listed on the back cover of this manual. Motoman Manual List • It is important to have and be familiar with all manuals concerning the MOTOMAN.
Page 29: Personnel Safety
"Safety First" minded, to ensure the safety of all personnel. • Avoid any dangerous actions in the area where the MOTOMAN is installed. There is a danger of injury if there is contact with the manipulator or peripheral equip- ment.
Page 30 1.4 Personnel Safety • Never forcibly move the manipulator axes. Failure to observe this caution may result in injury or equipment damage. • Never lean on XRC or other controllers, and avoid inadvertently pushing buttons. Failure to observe this caution may result in injury or damage by unexpected movement of the manipulator.
Page 31: Motoman Safety
1.5 Motoman Safety Motoman Safety 1.5.1 Installation and Wiring Safety Refer to the MOTOMAN-ooo Instructions manual and XRC Instructions for details on instal- lation and wiring. In planning installation, adapt an easy to observe arrangement to ensure safety. Take safety into consideration when planning the installation.
Page 32 Failure to observe this precaution may result in injury or equipment damage. MOTOMAN should be lifted with a crane using wire rope threaded through the shipping bolts and jigs and the body should be lifted in an upright posture as described in the manipulator instruction manual.
Page 33 Failure to observe this precaution may result in injury or damage to equipment resulting from contact with the manipulator. • Install the manipulator using bolts of the size and type speciﬁed for each MOTOMAN in the MOTOMAN INSTRUCTION MANUAL. Failure to observe this caution may result in injury or damage to equipment.
Page 34 1.5 Motoman Safety • Secure the position of the XRC after setting up. Attach the XRC to the ﬂoor or rack, etc., using the screw holes on the bottom of the XRC. Failure to observe this caution could lead to injury or equipment damage if the XRC should shift or fall.
Page 35: Work Area Safety
1.5 Motoman Safety 1.5.2 Work Area Safety Carelessness contributes to serious accidents in the work area. To ensure safety, enforce the following precautions: • Install an enclosure around the manipulator to prevent any accidental contact with the manipulator while the power is on.
Page 36: Operation Safety
1.5 Motoman Safety 1.5.3 Operation Safety • When attaching a tool such as the welding torch to the manipulator, be sure the power supply of the XRC and the tool is off, lock the switch, and display a warning sign.
Page 37 1.5 Motoman Safety • Before operating the manipulator, conﬁrm that the emergency stop cir- cuit is functioning by pressing the emergency stop button on the play- back panel and programming pendant, and conﬁrm that the servo lamp is turned off.
Page 38 1.5 Motoman Safety • Inspect all equipment before turning on power to the controller. Correct problems before operating. -Check for problems in manipulator motion -Check for damage to insulation and sheathing of cables. • Always return the programming pendant to the hook on the front of the controller after use.
Page 39: Notes For Moving And Transferring The Motoman
Contact your YASKAWA representative if you require new warning labels. • When the MOTOMAN is transferred, it is recommended to check with Yaskawa Engineering Co. which is listed on back cover of this manual.
Page 40: Notes On Motoman Disposal
1.7 Notes on MOTOMAN Disposal Notes on MOTOMAN Disposal • When disposing of the MOTOMAN, follow the applicable national/local laws and regulations. • Anchor the manipulator well, even when temporarily storing it before disposal. Failure to observe this precaution may result in injury due to the manipulator falling down.
Page 41 1.7 Notes on MOTOMAN Disposal 1-16...
Page 42: Product Confirmation
2.1 Contents Confirmation 2 Product Conﬁrmation Contents Conﬁrmation Conﬁrm the contents of the delivery when the product arrives. Standard delivery includes the following ﬁve items (Information for the content of optional goods is given separately): • Manipulator • XRC • Programming Pendant •...
Page 43: Order Number Confirmation
2.2 Order Number Confirmation Order Number Conﬁrmation Conﬁrm that the order number pasted on the manipulator and XRC match. The order number plates are afﬁxed to the ﬁgure below. Example...
Page 44: Installation
3.1 Handling Procedure 3 Installation Handling Procedure • Crane, sling, and forklift operations must be performed only by autho- rized personnel. Failure to observe this caution may result in injury or damage. • Avoid jarring, dropping, or hitting the controller during handling. Excessive vibration or impacting the XRC may adversely affect the performance of the XRC.
Page 45: Using A Forklift To Move The Controller
3.2 Place of Installation 3.1.2 Using a Forklift to Move the Controller Observe the following precautions when using a forklift to handle the controller: • Conﬁrm that there is a safe work environment and that the XRC can be transported safely to the installation site.
Page 46: Location
3.3 Location Location • Install the XRC outside of the working envelope of the manipulator (outside of the enclo- sure) ENCLOSURE DOOR 1000 mm or more 1000 mm or more 1000 mm or more WORKING ENVELOPE OF MANIPULATOR MAXIMUM WORKING ENVELOPE OF MANIPULATOR INCLUDING TOOL OR WORKPIECE END 1000 mm or more...
Page 47: Mounting The Controller
3.4 Mounting the Controller Mounting the Controller Attach the controller to the ﬂoor using user-supplied brackets made according to the speciﬁca- tions shown below. External Dimensions (mm) Attaching the XRC (mm) Refer to the Instruction Manual for information on installation of the manipulator.
Page 48: Connection
4 Connection • The system must be grounded. Failure to ground equipment may result in injury from ﬁre or electric shock. • Before grounding the system, turn off the power supply and lock the main power switch. Failure to observe this caution may result in injury and electric shock. •...
Page 49: Notes On Cable Junctions
4.1 Notes on Cable Junctions • Wiring must be performed only by authorized personnel. Incorrect wiring may cause ﬁre and electric shock. • Perform wiring in accordance with the rated capacity as speciﬁed in the Instructions. Incorrect wiring may cause ﬁre or mechanical breakdown. •...
Page 50: Power Supply
4.2 Power Supply XRC Cable Junction Diagram Power Supply 4.2.1 Three-Phase Power Supply The three-phase power supply consists of AC200/220V(+10/-15%) and 50/60Hz(+2Hz/-2Hz). The power failure processing circuit operates when there is a temporary power frequency black out or drop in voltage, and the servo power turns off. Connect the power supply to a stable power source that is not prone to power ﬂuctuations.
Page 51: Noise Filter Installation
4.2 Power Supply 4.2.2 Noise Filter Installation Insert the three-phase noise ﬁlter if you hear noise coming from the power source. Seal up each cable opening so that dust does not enter. Connection of Three-Phase Noise Filter 4.2.3 Leakage Breaker Installation When connecting the leakage breaker to the controller power supply wiring, use a leakage breaker which can handle high frequencies.
Page 52: Primary Power Supply Switch Installation
4.2 Power Supply 4.2.4 Primary Power Supply Switch Installation Install the primary power supply switch as shown. Installation of the Primary Power Supply Switch Cable Sizes and Switch Capacities Voltage Switch Cable size (size of terminal) source Manipulator capacity capacity (In case of Cabtyre cable (four wicks)) mm (kVA) SV3X...
Page 53: Connection Methods
4.3 Connection Methods Connection Methods A connection diagram for the manipulator, controller power cable, primary power cable and programming pendant is shown below. 4.3.1 Connecting the Primary Power Supply Open the front door of the XRC. (1) Insert the door handle in the door lock on the front of XRC (two places), and rotate it 90 degrees clockwise.
Page 54 4.3 Connection Methods Rotating the main switch to the OPEN RESET position. 2. Conﬁrm that the main power supply is OFF. 3. Make a hole in the plate and run the primary power supply cable through it. It is located on the top or on the left side of the XRC.
Page 55 4.3 Connection Methods (3) Connect a ground wire to reduce noise and prevent current leakage. 1) Connect the ground wire to the ground terminal (screw) of the switch which is on the upper left side of XRC. Ground wire Crimped terminal Connection of the Ground Wire 2) Perform grounding in accordance with all relevant local and national electrical codes.
Page 56: Connecting The Power Supply
4.3 Connection Methods (4) Install the cover. Install the Switch Cover 4.3.2 Connecting the Power Supply 1. Remove the cover from the left side of the controller cabinet. Detaching the Cable Hole Cover...
Page 57 4.3 Connection Methods 2. Remove the package, and take out the cable. Once you have run the cables through the cable holes on each side of XRC, tighten the screws. Tightening the Screws for the Cable Cables Passed Through the Holes in the Side of the XRC For more information on connecting the power cables, please refer to the Instruction Man- ual which corresponds to the particular XRC model.
Page 58: Connecting The Programming Pendant
4.3 Connection Methods 4.3.3 Connecting the Programming Pendant Connect the programming pendant cable to the connector on the left side of the controller cabinet. Connecting the Programming Pendant The manipulator, XRC, and the programming pendant connections are now complete. 4-11...
Page 59 4.3 Connection Methods 4-12...
Page 60: Turning On The Power Supply
5.1 Turning on the Main Power Supply 5 Turning on the Power Supply • Conﬁrm that nobody is present in the working envelope of the manipula- tor when turning on XRC power supply. Failure to observe this caution could result in injury caused by accidental contact with the manipulator.
Page 61: When Startup Diagnostics Are Complete
5.2 Turning on the Servo Power 5.1.2 When Startup Diagnostics are Complete When the power is turned off, the XRC saves all condition data, including: • Mode of operation • Cycle • Called job (active job if the XRC is in the play mode; edit job if the XRC is in the teach mode) and the cursor position in the job.
Page 62: During Teach Mode
5.2 Turning on the Servo Power 5.2.2 During Teach Mode 1. Press [SERVO ON READY] on the playback panel to turn on the servo power supply. The button will light when the servo power is turned on. 2. Press [TEACH LOCK] to enter the teach mode. 3.
Page 63: Turning The Power Off
5.3 Turning the Power Off Turning the Power Off 5.3.1 Turning the Servo Power Off (Emergency Stop) The manipulator cannot be operated when the emergency stop button is pressed and the servo power supply is turned off. Turning the Servo Power Off •...
Page 64: Test Of Program Operation
6 Test of Program Operation • Press the emergency stop button on the playback panel and the pro- gramming pendant before operating the manipulator. Conﬁrm that the servo on lamp is turned off. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.
Page 65 • Inspect the system before teaching jobs. If problems are found, correct them before resuming operation. Speciﬁcally check for: -Problems in manipulator motion -Damage to cables • Always return the programming pendant to its speciﬁed position after use. The programming pendant can be damaged if it is left in the manipulator work area or on the ﬂoor.
Page 66: Movement Of The Axes
6.1 Movement of the Axes Movement of the Axes Move each axis of the manipulator by pressing the axis keys on the programming pendant. This ﬁgure illustrates each axis of motion in the joint coordinate system. Be sure to remove all items from the area before moving the manipulator. Refer to the Instruction Manual for the appropriate position of the ﬁxture.
Page 67 6.1 Movement of the Axes...
Page 68: Home Position Confirmation
7 Home Position Conﬁrmation • Press each emergency stop button on the playback panel and the pro- gramming pendant before operating the manipulator. Be sure the servo on lamp is turned off. There is a danger of injury and equipment damage if the manipulator cannot be stopped in the event of an emergency.
Page 69 • Perform the following inspection procedures before starting to teach. If problems are found, repair them immediately and be sure all necessary processing has been performed: -Check for problems in manipulator movement. -Check for damage to insulation and sheathing of external wires. •...
Page 70: Operating Procedure
7.1 Home Position Confirmation Home Position Conﬁrmation It is necessary to register the home position (each axis has a position of 0 pulse) correctly so that the manipulator will work accurately. The home position for the UP6 is shown. Other manipulator models have different positions. Always consult the documentation for the correct manipulator model.
Page 71 7.1 Home Position Confirmation The angle of the central line of The angle of the L-axis perpendicular to the B-axis against the central the ground. line of the U-axis is 90 degrees. B-AXIS R-AXIS T-AXIS U-AXIS (opposite side) The angle of the U-axis against the horizon is 0 degrees.
Page 72: Final Notes
Composed of several sections, each corresponding to operation of the system. Work involving setting and diagnosis of the controller, alarm explanations, setting of the home position, etc. • MOTOMAN-***** Instruction manual Covers manipulator topics • INFORM Manual Covers the INFORM robot programming language •...
Page 75 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. 7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area, Beijing 100076, P.R. China Phone 86-10-6788-0551...
Page 76 YASKAWA MOTOMAN-SK300X,SK300X-170 SK300X-400 INSTRUCTIONS YR-SK300-J0 (SK300X) YR-SK300-J1(SK300X-170) YR-SK300-J2(SK300X-400) 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-SK300X,SK300X-170,SK300X-400 INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR’S MANUAL YASNAC XRC OPERATOR’S MANUAL FOR BEGINNERS...
Page 77 M A N D A T O R Y • This instruction manual is intended to explain operating instructions and maintenance procedures primarily for the MOTOMAN- SK300X,SK300X-170, and SK300X-400. • General items related to safety are listed in the Safety Manual Section 1: Safety.
Page 78 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 79 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 80 • 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 81 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 82 Receiving 1.1 Checking Package Contents ....... .1-1 1.2 Checking the Order Number .
Page 83 Motoman Construction 8.1 Position of S-Axis Limit Switch ......8-1 8.2 Internal Connections .
Page 84: 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 85: 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 86: 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 87: Shipping Bolts And Jigs
2.2 Shipping Bolts and Jigs • Check that the eyebolts are securely fastened. N OT E • The weight of the manipulator is approximately 2300kg including the shipping bolts and jigs. Use a wire rope strong enough to withstand the weight. •...
Page 88: 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 89: 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. (ISO 10218) 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 90: When The Manipulator And Mounting Fixture Are Installed On A Common
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 50mm or more and a size of the anchor bolt of M20 or larger is recommended.
Page 91: 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 92: Location
3.3 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 93 3.3 Location...
Page 94: Wiring
4.1 Grounding 4 Wiring WARNING • 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 95: Cable Connection
4.2 Cable Connection Fig. 5 Grounding Method Cable Connection There are three cables for the power supply; a signal cable for detection (1BC), a power cable (2BC), and an I/O cable (3BC). Connect these cables to the manipulator base connectors and the XRC.
Page 96 4.2 Cable Connection Connection to the manipulator Connection to the XRC WRCA01-CNPG123 Signal cable WRCA01-CNPG456 XIU01-CN25 Power cable Fig. 6 (a) Power Cables (1BC, 2BC)
Page 97 4.2 Cable Connection Connection to the XRC Connection to the manipulator CACR-SK300AAB Power cable Fig. 6 (b) Power Cables (3BC) Fig. 7 (a) Power Connection to the Manipulator...
Page 98 4.2 Cable Connection Signal Cable Power Cable Connector No. XIU01-CN25 Tighten the screws with screw driver(+). Signal Cable Grounding plate Connector No. for signal and power line WRCA01-CNPG456 (upper) Terminal No.: E WRCA01-CNPG123 (lower) Power Cable BB1 to BA6 Power Cable Connector No.
Page 99 4.2 Cable Connection...
Page 100: Basic Specifications
5.1 Basic Specifications 5 Basic Specifications Basic Specifications Table. 2 Basic Specifications MOTOMAN-SK300X-400 MOTOMAN-SK300X MOTOMAN-SK300X-170 Item Model (YR-SK300-J2) (YR-SK300-J0) (YR-SK300-J1) Operation Mode Vertically Articulated Degree of Freedom Payload 400kg 300kg 170kg ±0.5mm Repetitive Positioning Accuracy S-Axis (turning) ±150° L-Axis (lower arm) +60°, -55°...
Page 101: Part Names And Working Axes
5.2 Part Names and Working Axes Part Names and Working Axes Fig. 8 Part Names and Working Axes Baseplate Dimensions 28 Hole View A Fig. 9 Baseplate Dimensions (mm)
Page 102: Dimensions And Working Range
5.4 Dimensions and Working Range Dimensions and Working Range Fig. 10 (a) Dimesions and Working Range (YR-SK300-J0)
Page 103 5.4 Dimensions and Working Range Fig. 10 (b) Dimesions and Working Range (YR-SK300-J1)
Page 104 5.4 Dimensions and Working Range Fig. 10 (c) Dimesions and Working Range (YR-SK300-J2)
Page 105: B-Axis Working Range
5.5 B-Axis Working Range B-Axis Working Range The working range of the B-Axis maintaining a constant angle to the center of U-axis is shown in " Fig. 11 B-Axis Working Range ". Fig. 11 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 "...
Page 106: Allowable Load For Wrist Axis And Wrist Flange
6.1 Allowable Wrist Load 6 Allowable Load for Wrist Axis and Wrist Flange Allowable Wrist Load The allowable wrist load including the weight of the mount/gripper is: • YR-SK300-J0 : 300kg maximum • YR-SK300-J1 : 170kg maximum • YR-SK300-J2 : 400kg maximum If force is applied to the wrist instead of the load, force on R-, B-, and T-axes should be within the value shown in "...
Page 107 6.1 Allowable Wrist Load T-,B-Axes Rotation Center Line Point P B-Axis Rotation Center Line T-,B-Axes Rotation Center Line Point P B-Axis Rotation Center Line T-,B-Axes Rotation Center Line Point P B-Axis Rotation Center Line Fig. 12 Moment Arm Rating...
Page 108: Wrist Flange
6.2 Wrist Flange Wrist Flange The wrist flange dimensions are shown in " Fig. 13 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 8mm or less. Fig.
Page 109 6.2 Wrist Flange...
Page 110: 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. Fig. 14 Clamp and Tapped Holes Table. 5 Constraint for Attaching Application Note Cable Processing Attaching load weight is: 300kg max.
Page 111: 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 17 wires and air duct rating. The allowable current for wires must be 2.7A or below for each wire. (The total current value for pins 1 to 17 must be 2.7A or below).
Page 112: 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-Axis are located as shown in " Fig. 16 Location of Limit Switches ". Fig. 16 Location of Limit Switches...
Page 113: 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. 17 Location and Numbers of Connec- tors " and " Table. 6 List of Connector Types ". Fig.
Page 114 BATTERY BAT-1 0BT-1 YASNAC-XRC 0BT-1 BAT-1 1BC(6X6) No.1CN CN1-1 DATA+1 1CN-C DATA+1 CN1-2 DATA-1 DATA-1 S-AXIS CN1-3 +5V-1 CN1-4 0V-1 No.2CN 2CN- No.3CN CN2-1 DATA+2 3CN-C DATA+2 CN2-2 DATA-2 DATA-2 L-AXIS CN2-3 +5V-2 CN2-4 0V-2 CN2-5 No.4CN 4CN- No.5CN CN3-1 DATA+3 5CN-C DATA+3...
Page 115 2BC(8X6) Mounted line CN1-1 CN1-2 CN1-3 CN1-7 No.13CN CN1-5 13CN-A CN1-6 CN2-1 S-AXIS CN2-2 CN2-3 CN2-7 CN2-5 CN2-6 CN1-4 CN1-8 CN3-1 CN3-2 CN3-3 CN3-4 CN3-5 No.14CN CN3-6 14CN-A CN3-7 CN3-8 L-AXIS CN4-1 A terminal CN4-2 CN4-3 1.25-4 CN4-4 CN4-5 CN4-6 CN4-7 CN4-8 CN2-4...
Page 116: Maintenance And Inspection
9.1 Inspection Schedule 9 Maintenance and Inspection W A R N I N G • Before maintenance or inspection, be sure to turn the main power sup- ply off, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.) Failure to observe this warning may result in electric shock or injury.
Page 117 9.1 Inspection Schedule • The inspection interval must be based on the servo power supply on time. N OT E • 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 118 9.1 Inspection Schedule Table. 7 Inspection Items Schedule Inspection Charge Operation Items Method 1000 6000 12000 24000 36000 Specified Service Daily Licensee Person Company Cycle Cycle Cycle Check for conduc- tion between the main connecter of base and intermedi- ¡ ¡...
Page 119 9.1 Inspection Schedule Table. 7 Inspection Items Schedule Inspection Charge Operation Items Method 1000 6000 12000 24000 36000 Specified Service Daily Licensee Person Company Cycle Cycle Cycle S-, L- and U- Check for malfunc- tion. (Replace if nec- axes cross essary.) Supply roller bearings ¡...
Page 120 B-and T-axis Gears 10,14,20 Alvania EP Grease 2 • S-, L- and R-Axis Cross Roller Bearing (SK300X-J2 :R-Axis Link Taper Roller Bearings) • Link Taper Roller Bearings • L-Axis Balancer The numbers in the above table correspond to the numbers in " Table. 7 Inspection Items ".
Page 121: Notes On Maintenance Procedures
9.2 Notes on Maintenance Procedures Notes on Maintenance Procedures 9.2.1 Battery Unit Replacement If a battery alarm occurs in the XRC, replace the battery according to the following procedure: Fig. 20 (a) Battery Location (Back View) Fig. 20 (b) Battery Location (Top View)
Page 122 9.2 Notes on Maintenance Procedures Battery unit for SLU-axes See Procedure 6 before replacement See Procedure 7 Internal wires for SLU-axes New battery unit See Procedure 4 a: Insertion-type pin terminal (Male) See Procedure 5 b: Insertion-type pin terminal (Female) Fig.
Page 123: Grease Replenishment/Replacement For S-Axis Speed Reducer
9.2 Notes on Maintenance Procedures 9.2.2 Grease Replenishment/Replacement for S-Axis Speed Reducer Fig. 22 S-Axis Speed Reducer Diagram Grease Replenishment (Refer to " Fig. 22 S-Axis Speed Reducer Diagram ".) 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 124: Speed Reducer Diagram.")
9.2 Notes on Maintenance Procedures The new grease can be distinguished from the old grease by color. 4. Wipe the So exhaust port with a cloth and reinstall the plug.(Spread the Modifier silicon Caulk on the screw of the plug.) If the plug is installed when the grease is being exhausted, the grease will go inside the N OT E motor and may damage it.
Page 125: Grease Replacement (Refer To "Fig. 23 L-Axis And U-Axis Speed Reducer Diagram.")
9.2 Notes on Maintenance Procedures Grease Replacement (Refer to " Fig. 23 L-Axis and U-Axis Speed Reducer Diagram ".) 1. Remove the Lo and Uo exhaust plugs. N OT E If grease is added without removing the exhaust plugs, the grease will go inside the motor and may damage it.
Page 126: Grease Replacement
9.2 Notes on Maintenance Procedures 3. Move the R-Axis for a few minutes to discharge the excess grease. 4. Wipe the Ro exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier sil- icon Caulk on the screw of the plug.) 5.
Page 127: Grease Replenishment (Refer To "Fig. 25 B-Axis And T-Axis Speed Reducer Diagra.")
9.2 Notes on Maintenance Procedures Grease Replenishment(Refer to " Fig. 25 B-Axis and T-Axis Speed Reducer Diagram ".) 1. Make the robot wrist posture as shown in Fig.25. 2. Remove Bo exhaust plug: G-Nipple A-M6F. If grease is added without removing the exhaust plugs, the grease will go outside the N OT E grease box and may damage it.
Page 128 9.2 Notes on Maintenance Procedures 9.2.6 Grease Replenishment for S-Axis Cross Roller Bear- Fig. 26 S-Axis Cross Roller Bearing 1. Inject grease into the Sc grease inlet using a grease gun. Grease type: Alvania EP grease 2 Amount of grease: 130cc 9.2.7 Grease Replenishment for L-Axis Cross Roller Bear- Plug To Air Flow (Hexagon Socket Haed A-PT1/8)
Page 129: 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- (YR-SK300-J1) (YR-SK300-J0) Fig. 28 R-Axis Cross Roller Bearing 1. Remove the plug (A-PT1/8) for air flow . (" Fig. 28 R-Axis Cross Roller Bearing ") 2. Inject grease Lc grease inlet using a grease gun. Grease type: Alvania EP grease 2 Amount of grease: 19cc 3.
Page 130: Grease Replenshment For Link Taper Roller Bearings
9.2 Notes on Maintenance Procedures 2. Inject grease Rc grease inlet using a grease gun. Grease type: Alvania EP grease 2 Amount of grease: 12cc 3. Reinstall the plug for air flow. 9.2.10 Grease Replenshment for Link Taper Roller Bearings ´...
Page 131: Grease Replenishment For Balancer Connection Part
9.2 Notes on Maintenance Procedures 9.2.11 Grease Replenishment for Balancer Connection Part × Vc : Grease Inlet Balancer × G Nipple A-PT1/8 Fig. 31 Balancer Connection Part 1. Remove the plug for air flow. (4ps, refer to " Fig. 31 Balancer Connection Part ") Grease type: Alvania EP grease 2 Amount of grease: 5cc (10cc for 1st supply)
Page 132: Notes For Maintenance
9.2 Notes on Maintenance Procedures 9.2.12 Notes for Maintenance Remove the old battery unit after connecting the new one so that the encoder absolute data does not disappear. Battery Unit Connection for S-, L-, U-, R-, B- and T-Axis Motors The connector for the battery unit connection is attached to the main body of the S-, L-, U-, R-, B- and T-axis motors.
Page 133 9.2 Notes on Maintenance Procedures 9-18...
Page 134: 10 Recommended Spare Parts
It is recommended that the following parts and components be kept in stock as spare parts for the Motoman-UP130, -UP165. The spare parts list for the Motoman-UP130, -UP165 is shown below. Product performance can not be guaranteed when using spare parts from any com- pany other than Yaskawa.
Page 135 Table. 9 Spare Parts for the Motoman-SK300X, -SK300X-170,SK300X-400 Parts Rank Name Type Manufacturer Remarks Unit R-Axis HW9381008-A Yaskawa Speed Reducer (SK300X) Electric (SK300X-400) Corporation HW9381009-A (SK300X-170) B-Axis HW9380851-A Yaskawa Speed Reducer (SK300X) Electric (SK300X-400) Corporation HW9380850-A (SK300X-170) T-Axis HW9381000-A Yaskawa...
Page 136 11.1 S-Axis Driving Unit 11 Parts List 11.1 S-Axis Driving Unit 11-1...
Page 137 11.1 S-Axis Driving Unit 0065 HW9301493-1 Stopper DWG No. Name Pcs. 0066 M16x75 Socket screw 0006 HW9100726-1 Base 0067 2H-16 Spring washer 0007 HW9381006-A RV redution 0068 HW9403786-1 Stopper gear 0069 M6x30 Socket screw 0007AA HW9481457-A Shaft 0070 2H-6 Spring washer 0007AB HW9481367-A Shaft...
Page 138 11.2 L.U-Axis Driving Unit(1) 11.2 L.U-Axis Driving Unit(1) 11-3...
Page 139 11.2 L.U-Axis Driving Unit(1) 0113 M16x150 Socket screw DWG No. Name Pcs. 0114 2H-16 Spring washer 0021 SGMDH-45A2B AC Servo Motor 0115 O ring 0029 Eyebolt 0116 A-PT1/8 Grease nipple 0033 HW9403731-1 Cover 0118 G300 O ring 0034 M5x16 Screw 0119 POC6 -01M Union...
Page 140 11.3 L.U-Axis Driving Unit(2) 11.3 L.U-Axis Driving Unit(2) 11-5...
Page 141 11.3 L.U-Axis Driving Unit(2) DWG No. Name Pcs. 0309 HW9403750-1 Cover 0310 M5 x 8 Socket screw 0311 2H-5 Spring washer 0312 HW9403751-1 Cover 0313 M5x8 Socket screw 0314 2H-5 Spring washer 03l5 300S8M824 Belt 0316 300S8M920 Belt 0317 HW9403752-1 Cover 0318 M5x8...
Page 142 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. 7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area, Beijing 100076, P.R. China Phone 86-10-6788-0551...
Page 143 !"##$%&%'()$*+,-.+'-.(/+)&%.01)'+23.1+45567+!()'8).8 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 144 C A U T I O N 9+(:;<+=>?@>A+BCDA>;?<+E:B+'FGE:+)=BG;H>?+<DBH;I;H>E;F?<+J:;H:+K;IIBG+ IGF=+E:B+<E>?K>GK+3.1+<DBH;I;H>E;F?<L 9+(:B+;EB=<+J:;H:+>GB+?FE+BCDA>;?BK+;?+E:B+=>?@>A+>GB+E:B+<>=B+><+E:B+ <E>?K>GK+<DBH;I;H>EG;F?<L+"<B+E:B+<E>?K>GK+3.1+;?<EG@HE;F?<+J;E:+E:;<+ =>?@>AL M A N D A T O R Y 9+(:;<+=>?@>A+BCDA>;?<+<BE@DM+K;>N?F<;<M+=>;?EB?>?HBM+:>GKJ>GB+>?K+<F+ F?+FI+E:B+*)!')1+3.1+<O<EB=L+.B>K+E:;<+=>?@>A+H>GBI@AAO+>?K+PB+<@GB+ EF+@?KBG<E>?K+;E<+HF?EB?E<+PBIFGB+:>?KA;?N+E:B+*)!')1+3.1L 9+QB?BG>A+;EB=<+GBA>EBK+EF+<>IBEO+>GB+A;<EBK+;?+E:B+!BE@D+&>?@>A+!BHE;F?+6R+ !>IBEO+FI+!BE@D+&>?@>AL+(F+B?<@GB+HFGGBHE+>?K+<>IB+FDBG>E;F?M+H>GBI@AAO+ GB>K+E:B+!BE@D+&>?@>A+PBIFGB+GB>K;?N+E:;<+=>?@>AL C A U T I O N 9+!F=B+KG>J;?N<+;?+E:;<+=>?@>A+>GB+<:FJ?+J;E:+E:B+DGFEBHE;SB+HFSBG<+FG+ <:;BAK<+GB=FSBK+IFG+HA>G;EOL+TB+<@GB+>AA+HFSBG<+>?K+<:;BAK<+>GB+GBDA>HBK+ PBIFGB+FDBG>E;?N+E:;<+DGFK@HEL 9+(:B+KG>J;?N<+>?K+D:FEF<+;?+E:;<+=>?@>A+>GB+GBDGB<B?E>E;SB+BC>=DAB<+ >?K+K;IIBGB?HB<+=>O+BC;<E+PBEJBB?+E:B=+>?K+E:B+KBA;SBGBK+DGFK@HEL 9+*)!U)V)+=>O+=FK;IO+E:;<+=FKBA+J;E:F@E+?FE;HB+J:B?+?BHB<<>GO+K@B+EF+ DGFK@HE+;=DGFSB=B?E<M+=FK;I;H>E;F?<M+FG+H:>?NB<+;?+<DBH;I;H>E;F?<L+0I+ <@H:+=FK;I;H>E;F?+;<+=>KBM+E:B+=>?@>A+?@=PBG+J;AA+>A<F+PB+GBS;<BKL 9+0I+OF@G+HFDO+FI+E:B+=>?@>A+;<+K>=>NBK+FG+AF<EM+HF?E>HE+>+*)!U)V)+GBDW...
Page 145 '-(%!+,-.+!),%+-#%.)(0-' 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 146 W A R N I N G 9+TBIFGB+FDBG>E;?N+E:B+=>?;D@A>EFGM+H:BHX+E:>E+<BGSF+DFJBG+;<+E@G?BK+FII+ J:B?+E:B+B=BGNB?HO+<EFD+P@EEF?<+F?+E:B+DA>OP>HX+D>?BA+FG+DGFNG>=W =;?N+DB?K>?E+>GB+DGB<<BKL V:B?+E:B+<BGSF+DFJBG+;<+E@G?BK+FIIM+E:B+!%.[-+-'+.%)8*+A>=D+F?+E:B+ DA>OP>HX+D>?BA+>?K+E:B+!%.[-+-'+$%8+F?+E:B+DGFNG>==;?N+DB?K>?E+>GB+ E@G?BK+FIIL Injury or damage to machinery may result if the emergency stop circuit cannot stop the manipulator during an emergency. The manipulator should not be used if the emergency stop buttons do not function.
Page 147 9+.B>K+>?K+@?KBG<E>?K+E:B+%CDA>?>E;F?+FI+E:B+)A>G=+8;<DA>O+;?+E:B+!BE@D+ &>?@>A+PBIFGB+FDBG>E;?N+E:B+=>?;D@A>EFGL 8BI;?;E;F?+FI+(BG=<+"<BK+-IEB?+;?+(:;<+&>?@>A 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. IIn this manual, the equipment is designated as follows.
Page 148 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 149 YASNAC XRC Specification 6L6 Specification List ........1-3 6L4 Function List .
Page 150 4L`L4 Description of Each Unit ......2-40 " Servo Control Circuit board (JASP-WRCA01) ..2-40 "...
Page 151: Yasnac Xrc Specification
1 YASNAC XRC Specification WARNING 9+TBIFGB+FDBG>E;?N+E:B+=>?;D@A>EFGM+H:BHX+E:>E+E:B+!%.[-+-'+A>=D+NFB<+ F@E+J:B?+E:B+B=BGNB?HO+<EFD+P@EEF?<+F?+E:B+DA>OP>HX+D>?BA+>?K+DGFW NG>==;?N+DB?K>?E+>GB+DGB<<BKL Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency. The emergency stop buttons are attached on upper-right of the playback panel and right of the programming pendant. 9+)AJ>O<+<BE+E:B+EB>H:+AFHX+PBIFGB+<E>GE;?N+EB>H:;?NL Failure to observe this caution may result in injury from inadvertent operation of the play- back panel.
Page 152 C A U T I O N 9+#BGIFG=+E:B+IFAAFJ;?N+;?<DBHE;F?+DGFHBK@GB<+DG;FG+EF+DBIFG=;?N+EB>H:;?N+ FDBG>E;F?<L+0I+DGFPAB=<+>GB+IF@?KM+HFGGBHE+E:B=+;==BK;>EBAOM+>?K+PB+ <@GB+E:>E+>AA+FE:BG+?BHB<<>GO+DGFHB<<;?N+:><+PBB?+DBGIFG=BKL W+1:BHX+IFG+DGFPAB=<+;?+=>?;D@A>EFG+=FSB=B?EL W+1:BHX+IFG+K>=>NB+EF+E:B+;?<@A>E;F?+>?K+<:B>E:;?N+FI+BCEBG?>A+J;GB<L 9+)AJ>O<+GBE@G?+E:B+DGFNG>==;?N+DB?K>?E+EF+;E<+<DBH;I;BK+DF<;E;F?+>IEBG+ @<BL If the programming pendant is inadvertently left on the manipulator, fixture, or on the floor, the manipulator or a tool could collide with it during manipulator movement, possibly causing injuries or equipment damage.
Page 153: 6L6 Specification List
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, 240/480/575 VAC(+10% to -15%) at 50/60Hz(±2 Hz) (Built-in transformer tap switchable) Built-in transformer 240 V - 480 V - 575 V/208 V ( -...
Page 154: 6L4 Function List
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 155: Programming Pendant
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 156: Equipment Configuration
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. 6L^L6 Arrangement of Units and Circuit Boards "...
Page 157 1.4 Equipment Configuration Fuse holders I/O unit Playback Panel Power supply unit Power ON unit (QS3) JZRCR-XCO02B Brake operation panel ZY1C-SS3152 JZRCR-XPU06B JZNC-XSU02 USCC3I CPU unit Fuse: Refer to the JZNC-XRK01B-1 Brake release control board follwing table. JZRCR-XFL02B JARCR-XCO02B JZNC-XRK01 XCP01 CPS-150F XCP01...
Page 158 1.4 Equipment Configuration Fuse holders Power supply unit I/O unit (QS3) (with protective cover) JZRCR-XCO02B Playback Panel Power ON unit USCC3I JZNC-XSU02 ZY1C-SS3152 JZRCR-XPU06B Brake operation panel CPU unit Fuse : Refer to the Brake release control board JZNC-XRK01B-1 following table. JZRCR-XFL02B JARCR-XCO02 JZNC-XRK01...
Page 159 1.4 Equipment Configuration Fuse holders I/O unit Playback Panel Power supply unit Power ON unit (QS3) Brake operation panel JZRCR-XCO02B ZY1C-SS3152 (with protective cover) JZNC-XSU02 USCC3I JZRCR-XPU05B CPU unit Fuse : Refer to the Brake release control board JZNC-XRK01B-1 JZRCR-XFL02B following table.
Page 160 CACR-SK300AAB SR200X ERCR-SR200-RB02 SP100X ERCR-SP100-RB02 CACR-SP100AAB * : Time delay fuses of class CC (30A or less) or class J (40A or more) are used for QS1, QS2, and QS3. UP130R, UP130RL, SK300X, SR200X, SP100X Configuration (With transformer built-in) 1-10...
Page 161 ERCR-SK300-RB03 CACR-SK300AAB SR200X ERCR-SR200-RB03 CACR-SK300AAB SP100X ERCR-SP100-RB03 CACR-SP100AAB * : Time delay fuses of class CC (30A or less) or class J (40A or more) are used for QS1, and QS3 UP130R, UP130RL, SK300X, SR200X, SP100X Configuration (Without transformer) 1-11...
Page 162: L4 Cooling System Of The Controller Interior
1.4 Equipment Configuration 6L^L4 Cooling System of the Controller Interior Servo Top Fan Backside Duct Fan Air Inlet Servopack Air Outlet Cooling System (SV3X (Small Capacity type))(Right side view) Servo Top Fan Air Inlet Servopack Backside Duct Fan Air Output Natural heat raditation Natural heat raditation Cooling System (Except for SV3X (Small Capacity type))(Right side view)
Page 163: Description Of Units And Circuit Boards
Description of Units and Circuit Boards W A R N I N G 9+TBIFGB+FDBG>E;?N+E:B+=>?;D@A>EFGM+H:BHX+E:>E+E:B+!%.[-+-'+A>=D+NFB<+ F@E+J:B?+E:B+B=BGNB?HO+<EFD+P@EEF?<+F?+E:B+DA>OP>HX+D>?BA+>?K+DGFW NG>==;?N+DB?K>?E+>GB+DGB<<BKL Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency. 9+)AJ>O<+<BE+E:B+EB>H:+AFHX+PBIFGB+<E>GE;?N+EB>H:;?NL Failure to observe this caution may result in injury due to inadvertent operation on the playback panel.
Page 164: 4L6 Power Supply Unit
I/O power ON unit and servopack (servo control power supply) via the line filter. Power Supply Unit Models Model Robot Type JZRCR-XPU06B SV3X, UP6, SK16X, UP20 JZRCR-XPU05B UP50, UP20M, SK45X, SK16MX, SP70, UP130, UP165, UP165-100, UP200 JZRCR-XPU10B UP130R, UP130RL, SK300X, SR200X, SP100X...
Page 165 2.1 Power Supply Unit (1Z) Resister (RB) Noise filter (5X) Single 200 VAC Output connector (4X) Conector output, etc. Contactor output 10A 250V 10A 250V (1F,2F) (1X) Fuse Single-phase 200 VAC Output connector (2KM) (1KM) Contactor Contactor SER NO. DATE TYPE YASKAWA ELECTRIC CORPORATION JAPAN...
Page 166: 4L4 Brake Release Unit
2.2 Brake Release Unit Brake Release Unit A Switch to release the robot brake is provided on the door of the XRC for North America (ANSI) spesification. Brake Release Switch Brake Release Operation Panel Display LED Axis Selection Switch Door Surface 4L4L6 Operation Methods 1.
Page 167: Cpu Rack
2.3 CPU Rack CPU Rack 4L]L6 CPU Rack Configuration CPU rack consists of the control power supply unit, circuit board racks, and system control cir- cuit boards. JZNC-XRK01 XCP01 CPS-150F (CN05) XCP01 200 VAC Input CPS-150F (from Power Supply Unit) (CN04) CN05 PC Card...
Page 168: Control Power Supply Unit (Cps-150F)
2.3 CPU Rack " Control Power Supply Unit (CPS-150F) This unit supplies the DC power (5VDC, 24VDC) to the I/O unit (JZRCR-XCO02B) , the power ON unit (JZRCR-XSU02) and the programming pendant. It is also equipped with the input function for turning the control power supply on and off. Items Specifications Rated Input Voltage:...
Page 169: Wiring Wago Connector
2.3 CPU Rack Items Specifications To turn on the XRC controller power, turn the main switch to the ON posi- tion then turning on the control power supply. If the controller is not located at the workplace, the control power supply can be turned ON and OFF by input from external device.
Page 170 2.3 CPU Rack 1. Insert the A part of the wiring tool into a attachment hole. Wiring tool WAGO connector (Supplied part) Attachment hole A part WAGO connector Wire (Applicable size AWG28 to AWG12) Wire (Bare length 8 to 9 mm) 2.
Page 171: Wiring Phoenix Connector
2.3 CPU Rack " Wiring PHOENIX Connector CN05, 06, 40 and 44 on the I/O unit (JZRCR-XCO01) and CN27 and 28 of the power ON unit (JZRCR-XSU02) are equipped with a connector produced by PHOENIX. The “small size flat tipped screwdriver” is necessary to wire to PHOENIX connector. The wiring procedure is described as follows: 1.
Page 172 2.4 I/O Unit (JZRCR-XCO02B) I/O Unit (JZRCR-XCO02B) The I/O unit consists of the specific I/O circuit board 1 (JARCR-XCI01), the specific I/O circuit board 2 (JARCR-XCU01B) and the general I/O circuit board (JARCR-XCI03). (CN05) External Emergency Stop External Servo ON, External Hold Safeguard Specific Output Connector (PHENIX connector) (Refer to "Wiring PHENIX Connector.")
Page 173 2.4 I/O Unit (JZRCR-XCO02B) 4L^L6 Specific I/O Circuit Board 1 (JARCR-XCI01) and Spe- cific I/O Circuit Board 2 (JARCR-XCU01B) The specific I/O circuit board consists of the specific I/O circuit board 1 (JARCR-XCI01) and the specific I/O circuit board 2 (JARCR-XCU01B) both of which have a control function. The main functions are as follows.
Page 174: Direct In
2.4 I/O Unit (JZRCR-XCO02B) " Direct IN The signals can be directly and externally connected. YASNAC XRC JZRCR-XCO02B (JARCR-XCU01B) +24V +24VU CN44 EXDIN1+ DIN1 EXDIN1- EXDIN2+ Direct IN DIN2 EXDIN2- EXDIN3+ DIN3 EXDIN3- EXDIN4+ DIN4 EXDIN4- Note: EXDIN4 is for future use. 024VU JZRCR-XCO02B Specific I/O Circuit Board Allocation and Connection Diagram 2-12...
Page 175: Connected Jumper Leads Before Shipment
2.4 I/O Unit (JZRCR-XCO02B) " Connected Jumper Leads Before Shipment CN06 of the I/O unit (JZRCR-XCO02B) is connected with jumper leads as shown in the figure below before shipment. The short-circuit pins SW1, 8, and 9 on the specific input circuit board (JARCR-XCI01) are set across 2 and 3 of SW 1, 1 and 2 of SW8 , and 1 and 2 of SW9.
Page 176: Deadman Switch Signal Output
2.4 I/O Unit (JZRCR-XCO02B) " Deadman Switch Signal Output A deadman switch signal is output from CN06-9 and -10. YASNAC XRC JZRCR-XCO02B JARCR-XCI01 CN06 PPESPOUT+ PPESPOUT- PPESPIN+ PPESPIN- PBESPOUT+ PPESPOUT- PBESPIN+ PBESPIN- Deadman Switch DSWOUT+ DSWOUT- Signal Output RDY+ +24VU RDY- 024VU 024VU 024V...
Page 177: Connection To I/O External Power Supply
2.4 I/O Unit (JZRCR-XCO02B) " Connection to I/O External Power Supply In the standard specification, the I/O power supply is installed internally. When an external power supply is used, proceed as follows. 1. Remove the jumper lead between CN6-13 and -15, and between CN06-14 and -16 of I/ O unit (JZRCR-XCO02B).
Page 178: Force (Forced Reset)
2.4 I/O Unit (JZRCR-XCO02B) " FORCE (Forced Reset) The signals are input externally to FORCE1 (Forced Reset 1) (CN40-1 and -2) and FORCE2 (Forced Reset 2) (CN40-3 and -4). When both of FORCE1 and FORCE2 are turned ON, the deadman switch is invalidated. When only one is input, an alarm occurs. YASNAC XRC JZRCR-XCO02B (JARCR-XCU01B)
Page 179: Fst (Full-Speed Test)
2.4 I/O Unit (JZRCR-XCO02B) " FST (Full-speed Test) When both of FST1 (Full-speed Test 1) input (CN40-5 and -6) and FST2 (Full-speed Test 2) input (CN40-7 and -8) are turned ON, the manipulator motion speed will be a PLAY-mode speed when XRC is in play mode, and a TEACH-mode speed when XRC is in teach mode. Note that 1st Safe Speed and 2nd Safe Speed can not be selected.
Page 180: Hanger Switch (Hsw)
2.4 I/O Unit (JZRCR-XCO02B) " Hanger Switch (HSW) Short-circuiting the S-SP1 (CN40-9 and -10) validates the hanger switch (HSW). At this time, the deadman switch (DSW) is invalidated. (Before shipment, the S-SP1 is set open, therefore, the deadman switch (DSW) is set valid while the hanger switch (HSW) is set invalid).
Page 181: 1St Safety Speed And 2Nd Safety Speed
2.4 I/O Unit (JZRCR-XCO02B) " 1st Safety Speed and 2nd Safety Speed When either the deadman switch (DSW) or the hanger switch (HSW) is turned ON, the speed is limited to safety speeds. With the S-SP2 (CN40-11 and -12) open, the speed is limited to 1st Safety Speed, with the S-SP2 (CN40-11 and -12) short-circuited, the speed is limited to 2nd Safety Speed.
Page 182 2.4 I/O Unit (JZRCR-XCO02B) Specific Input List (XCO02B) Factory Terminal Input Name / Function Setting EXESP1 External emergency stop Use to connect the emergency stop switch of an external operation CN05 -1 device. The servo power turns OFF and job execution stops when Disabled by this signal is input.
Page 183 2.4 I/O Unit (JZRCR-XCO02B) Specific Input List (XCO02B) Factory Terminal Input Name / Function Setting Direct-in 4 Open Direct-in4 is for future use. CN44 -7 FORCE1 Forced reset input Do not use the “FORCE” (Forced release) input. CN40 -1 If the “FORCE” input should be used for an unavoidable reason, be sure to use a switch with a key.
Page 184: Safety Plug Input Signal
2.4 I/O Unit (JZRCR-XCO02B) " Safety Plug Input Signal The manipulator must be surrounded by a safeguard and a door protected by an interlock function. The door must be opened by the technician to enter and the interlock function stops the robot operation when the door is open.
Page 185: Connection Wire With General I/O (Cn10, 11, 12, 13)
2.4 I/O Unit (JZRCR-XCO02B) " 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) B 2 0 A 2 0...
Page 186: Specific I/O Signal Related To Start And Stop
2.4 I/O Unit (JZRCR-XCO02B) " 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:JARCR-XCI03) • External Servo On (common to all application:JARCR-XCI01) • External Start (depending on application:JARCR-XCI03) •...
Page 187 2.4 I/O Unit (JZRCR-XCO02B) Example of Servo ON Sequence Circuit from External Device Only the rising edge of the servo ON signal is valid. This signal turns ON the manipulator servo power supply. The set and reset timings are shown in the following. Servo Power ON Confirmation YASNAC XRC Servo ON...
Page 188 2.5 Power ON Unit (JZRCR-XSU02) Power ON Unit (JZRCR-XSU02) The power ON unit consists of the power ON circuit board (JARCR-XCT01) to control the servo power ON sequence. (CN32) Brake Resistance AC Input (CN31) Brake Output Connector CN28 CN27 (CN30) ON_EN2- FAN, AC Output +24V...
Page 189: 4L_L6 Power On Circuit Board (Jarcr-Xct01)
2.5 Power ON Unit (JZRCR-XSU02) 4L_L6 Power ON Circuit Board (JARCR-XCT01) The power ON circuit board is controlled by the servo control circuit board (JASP-WRCA01). The main functions are as follows: • Specific I/O circuit, for instance, servo power supply contactor I/O circuit and emergency stop circuit •...
Page 190: Method Of Connecting External Axis Overrun Signal
2.5 Power ON Unit (JZRCR-XSU02) " Method of Connecting External Axis Overrun Signal In a standard specification, the external axis overrun input is unused. (It is set invalid by a jumper lead.) Please connect the signal according to the following procedures when the overrun input for an external axis is necessary, besides for the manipulator.
Page 191: Servo On Enable Input (On_En1 And 2)
2.5 Power ON Unit (JZRCR-XSU02) " Servo ON Enable Input (ON_EN1 and 2) This function divides the system into multiple servo areas and turns ON the servo power for each area. In the standard specification, this is short-circuited by a jumper lead. 1.
Page 192: Servopack
2.6 SERVOPACK SERVOPACK A SERVOPACK consists of a servo control circuit board (JASP-WRCA01), a servo control power supply (JUSP-RCP01AA!), a converter and an amplifier (Refer to the following tables “SERVOPACK Configuration”). As for large capacity type, the converter and the servo power supply are separate. 4L`L6 SERVOPACK Configuratio SERVOPACK Configuration (Small Capacity Type)
Page 193 2.6 SERVOPACK SERVOPACK Configuration (Small Capacity Type) SK16X UP20 Component Type Capacity Type Capacity SERVOPACK CACR-SK16AAC CACR-UP20AAA Converter JUSP-ACP05JAA JUSP-ACP05JAA JUSP- JUSP-WS10AA WS10AAY17 JUSP- JUSP- WS10AAY17 WS20AAY22 JUSP- JUSP- Amplifier WS10AAY17 WS10AAY17 JUSP-WS02AA 200W JUSP-WS02AA 200W JUSP-WS02AA 200W JUSP-WS02AA 200W JUSP-WS02AA 200W JUSP-WS02AA...
Page 194 2.6 SERVOPACK SERVOPACK Configuration (Medium Capacity Type) UP50 UP20M Component Type Capacity Type Capacity SERVOPACK CACR-UP50AAB CACR-UP20MAAB JUSP-WS44AA 4.4kW JUSP-WS44AA 4.4kW JUSP-WS60AA JUSP-WS60AA JUSP-WS20AA JUSP-WS20AA Amplifier JUSP-WS10AA JUSP-WS02AA 200W JUSP-WS10AA JUSP-WS02AA 200W JUSP-WS10AA JUSP-WS02AA 200W Servo control JASP-WRCA01 JASP-WRCA01 curcuit board Speed monitor JANCD-XFC01 JANCD-XFC01...
Page 195 2.6 SERVOPACK SERVOPACK Configuration (Large Capacity Type) UP130R, UP200 UP130, UP165 UP165-100 Component Type Capacity Type Capacity SERVOPACK CACR-UP130AAB CACR-UP130AABY18 JUSP-WS60AA JUSP-WS60AAY18 JUSP-WS60AA JUSP-WS60AAY18 JUSP-WS60AA JUSP-WS60AA JUSP- JUSP-WS20AAY13 Amplifier WS20AAY13 JUSP- 1.5kW JUSP-WS15AAY13 1.5kW WS15AAY13 JUSP- 1.5kW JUSP-WS15AAY13 1.5kW WS15AAY13 Servo control JASP-WRCA01 JASP-WRCA01...
Page 196 2.6 SERVOPACK SERVOPACK Configuration (Large Capacity Type) SK300X, SR200X SP100X Component Type Capacity Type Capacity SERVOPACK CACR-SK300AAB CACR-SP100AAB JUSP- JUSP-WS60AAY18 WS60AAY18 JUSP- JUSP-WS60AAY18 WS60AAY18 JUSP- JUSP-WS60AAY18 WS60AAY18 Amplifier JUSP- WS30AAY18 JUSP- WS30AAY18 JUSP- JUSP-WS20AAY19 WS30AAY18 Servo control JASP-WRCA01 JASP-WRCA01 curcuit board...
Page 197 2.6 SERVOPACK Grip (top) Converter Amplifier (6 pcs) Servo Control Power Supply Servo Control Board 6AMP +5 V Display LED Speed Monitor Board JUSP- RCP01AAB 1CN 2CN 3CN 4CN 5CN 6CN 1AMP Grip (bottom) SV3X, UP6, SK16X SERVOPACK Configuration Grip (top) Converter Amplifier (6 pcs) Servo Control Power Supply...
Page 198 2.6 SERVOPACK SERVOPACK Speed Monitor Board Grip (top) Amplifier (6 pcs) Converter Servo Control Power Supply Servo Control Board +5V Display LED JUSP- RCP01AAB G R I P Grip (bottom) SK45X, SK16MX SERVOPACK Configuration SERVOPACK Speed Monitor Board Grip (top) Converter Amplifier (6 pcs) Servo Control Board...
Page 199 2.6 SERVOPACK SERVOPACK Speed Monitor Board Amplifier (4pcs) Grip (top) Converter Servo Control Power Supply Servo Control Board +5V Display LED JUSP- RCP01AAB YASKAWA G R I P Grip (bottom) SP70X SERVOPACK Configuration Converter SERVOPACK Speed Monitor Board Amplifier (6 pcs) Servo Control Power Supply Grip (top) Servo Control Board...
Page 200 2.6 SERVOPACK Converter SERVOPACK Speed Monitor Board Amplifier (4pcs) Servo Control Power Supply Grip (top) Servo Control Board +5V Display LED JUSP- RCP01AAB E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22 V21 V22 W21 W22 E31 E32 U31 U32 V31 V32 W31 W32 Grip (bottom) SP100X SERVOPACK Configuration 2-38...
Page 201: L4 Description Of Each Unit
2.6 SERVOPACK 4L`L4 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 power ON unit (JZRCR-XSU02). The power source is supplied by a servo control power supply.
Page 202: 4La Playback Panel
2.7 Playback Panel Playback Panel The playback panel is equipped with the buttons used to play back the manipulator. ALARM Lights when an SERVO ON alarm occurs. MODE EMERGENCY STOP SERVO ON READY READY PLAY TEACH Turns ON the servo power.
Page 203: 4Lb General I/O Signal Assignment
2.8 General I/O Signal Assignment General I/O Signal Assignment 4LbL6 Arc Welding YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) Model:PX7DS-40V6-R +24VU CN12 Connector C o n n e c t o r Terminal Logical Name Signal N u m b e r Number Number Each Point...
Page 204 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN13 Connector C o n n e c t o r Terminal Logical N u m b e r Signal Number Number Each Point 2024 24VDC 2025 8mA max.
Page 205 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN10 Connector Logical C o n n e c t o r Signal Terminal Number N u m b e r Number General Input Each Point 2040 IN01 24VDC 2041...
Page 206 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN11 Connector C o n n e c t o r Logical Terminal Signal N u m b e r Number Number Each Point IN09 2050 24VDC IN10 2051 8mA max.
Page 207 2.8 General I/O Signal Assignment Specific Input List XCO02B (Arc Welding) Logical Logical Input Name / Function Input Name / Function Number Number EXTERNAL START INTERFERENCE 1 ENTRANCE Functions the same as the [START] PROHIBITED button in the playback panel . Only If the manipulator attempts to enter the rising edge of the signal is valid.
Page 208 2.8 General I/O Signal Assignment Specific Input List XCO02B (Arc Welding) Logical Logical Input Name / Function Input Name / Function Number Number SELECT TEACH MODE SENSlNG PROHIBITED The TEACH mode is selected if this Arc sensing is prohibited while this signal turns ON during PLAY mode.
Page 209 2.8 General I/O Signal Assignment Specific Output List XCO02B (Arc Welding) Logical Logical Output Name / Function Output Name / Function Number Number ALARM/ERROR OCCURRE GAS SHORTAGE (MONITOR) This signal signifies that an alarm or an This signal stays ON while the gas short- 3013 error occurred.
Page 210: 4Lbl4 Handling
2.8 General I/O Signal Assignment 4LbL4 Handling YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) Model:PX7DS-40V6-R +24VU CN12 Connector C o n n e c t o r Terminal Logical Name Signal N u m b e r Number Number Each Point 2010 External Start 24VDC...
Page 211 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN13 Connector Logical C o n n e c t o r Terminal Signal Number N u m b e r Number Each Point 2024 24VDC 2025 Shock Sensor (NC) 8mA max.
Page 212 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN10 Connector C o n n e c t o r Logical Terminal Signal N u m b e r Number Number Each Point 2040 Sensor Input 1 24VDC Sensor Input 2 2041...
Page 213 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN11 Connector Logical C o n n e c t o r Signal Terminal Number N u m b e r Number General Input Each Point IN09 2050 24VDC IN10...
Page 214 2.8 General I/O Signal Assignment Specific Output List XCO02B (Handling) Logical Logical Output Name / Function Output Name / Function Number Number EXTERNAL START INTERFERENCE 1 ENTRANCE PRO- Functions the same as the [START] but- HIBITED ton in the playback panel . Only the ris- If the manipulator attempts to enter the ing edge of the signal is valid.
Page 215 2.8 General I/O Signal Assignment A master job is a job (program) which can be called by CALL MASTER JOB. Other functions are the same as for normal jobs. Normally, the parent job, which man- ages the child jobs called up immediately after the power is turned ON, is set as the master job.
Page 216 2.8 General I/O Signal Assignment Specific Output List XCO02B (Handling) Logical Logical Output Name / Function Output Name / Function Number Number REMOTE/PLAY/TEACH MODE SELECTED This signal notifies the current mode set- 3015 to ting. These signals are synchronized 3017 with the lamps [REMOTE] and [MODE] in the playback panel.
Page 217: 4Lbl] General Application
2.8 General I/O Signal Assignment 4LbL] General Application YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) Model:PX7DS-40V6-R +24VU CN12 Connector C o n n e c t o r Logical Terminal Name Signal N u m b e r Number Number Each Point 2010 External Start 24VDC...
Page 218 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN13 Connector C o n n e c t o r Terminal Logical N u m b e r Signal Number Number Interference3 Entrance Each Point 2024 Prohibited Interference4 Entrance 24VDC...
Page 219 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN10 Connector Logical C o n n e c t o r Signal Terminal Number N u m b e r Number General Input Each Point 2040 IN01 24VDC 2041...
Page 220 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN11 Connector C o n n e c t o r Terminal Logical Signal N u m b e r Number Number Each Point IN09 2050 24VDC 2051 IN10 8mA max.
Page 221 2.8 General I/O Signal Assignment Specific Input List XCO02B (General Application) Logical Logical Input Name / Function Input Name / Function Number Number EXTERNAL START INTERFERENCE 1 ENTRANCE Functions the same as the [START] PROHIBITED button in the playback panel . Only If the manipulator attempts to enter the rising edge of the signal is valid.
Page 222 2.8 General I/O Signal Assignment Specific Input List XCO02B (General Application) Logical Logical Input Name / Function Input Name / Function Number Number SELECT TEACH MODE The TEACH mode is selected if this signal turns ON during PLAY mode. Switching to other modes is disabled 2016 while this signal is ON.
Page 223 2.8 General I/O Signal Assignment Specific Output List XCO02B (General Application) Logical Logical Output Name / Function Output Name / Function Number Number ALARM/ERROR OCCURRING IN CUBE 3 This signal signifies that an alarm or an This signal turns ON when the current error occurred.
Page 224: 4Lbl^ Spot Welding
2.8 General I/O Signal Assignment 4LbL^ Spot Welding YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN12 Connector C o n n e c t o r Logical Terminal Name N u m b e r Signal Number Number Each Point External Start 2010 24VDC...
Page 225 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN13 Connector Logical C o n n e c t o r Terminal Signal Number N u m b e r Number Interference3 Entrance Each Point 2024 Prohibited Interference4 Entrance 24VDC...
Page 226 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN10 Connector C o n n e c t o r Logical Terminal Signal N u m b e r Number Number Timer Cooling Water Each Point 2040 Error (IN09) Gun Cooling Water...
Page 227 2.8 General I/O Signal Assignment YASNAC-XRC JZRCR-XCO02B Connector Terminal Converter (Optional) +24VU Model:PX7DS-40V6-R CN11 Connector C o n n e c t o r Logical Terminal Signal N u m b e r Number Number Each Point IN17 2050 24VDC IN18 2051 8mA max.
Page 228 2.8 General I/O Signal Assignment Specific Input List XCO02B (Spot Welding) Logical Logical Input Name / Function Input Name / Function Number Number EXTERNAL START WELDING ON/OFF (From Functions the same as the [START] sequencer) button in the playback panel . Only This signal inputs the welding ON/ the rising edge of the signal is valid.
Page 229 2.8 General I/O Signal Assignment Specific Input List XCO02B (Spot Welding) Logical Logical Input Name / Function Input Name / Function Number Number SELECT TEACH MODE GUN COOLING WATER ERROR The TEACH mode is selected if this This signal monitors the status of signal turns ON during PLAY mode.
Page 230 2.8 General I/O Signal Assignment Specific Input List XCO02B (Spot Welding) Logical Logical Input Name / Function Input Name / Function Number Number WELD COMPLETIO GUN SHORT OPEN DETECTION This signal indicates that the welder This signal is connected with a sin- completed welding without error.
Page 231 2.8 General I/O Signal Assignment Specific Output List XCO02B (Spot Welding) Logical Logical Output Name / Function Output Name / Function Number Number RUNNING INTERMEDIATE START OK (Sequence This signal signifies that the job is run- continues) ning. (Signifies that the job is running, This signal turns ON when the manipula- system status is waiting reserved start, tor operates.
Page 232 2.8 General I/O Signal Assignment Specific Output List XCO02B (Spot Welding) Logical Logical Output Name / Function Output Name / Function Number Number IN CUBE 1 WELDING COMMAND This signal turns ON when the current This signal outputs execution command tool center point lies inside a pre-defined signal to the welder.
Page 233: Arc Welding Application
2.8 General I/O Signal Assignment 4LbL_ JANCD-XEW01 Circuit Boar " 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 234 2.8 General I/O Signal Assignment 2-72...
Page 235: Inspections
3.1 Regular Inspections 3 Inspections Regular Inspections C A U T I O N 9+8F+?FE+EF@H:+E:B+HFFA;?N+I>?+FG+FE:BG+Bc@;D=B?E+J:;AB+E:B+DFJBG+;<+ E@G?BK+-'L Failure to observe this caution may result in electric shock or injury. Carry out the following inspections. Inspection Inspection Equipment Inspection Item Comments Frequency Check that the doors are Daily completely closed.
Page 236: L4 Xrc Inspections
3.2 XRC Inspections XRC Inspections ]L4L6 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 237: L] Cooling Fan Inspections
3.3 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 in-panel fan on the upper part of door and backside duct fan normally operate while the power is turned ON.
Page 238: L^ Emergency Stop Button Inspections
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. Confirm 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 239: L` Battery Inspections
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 240 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 241: Replacing Parts
4.1 Replacing XRC Parts 4 Replacing Parts Replacing XRC Parts W A R N I N G 9+(@G?+-,,+E:B+DFJBG+<@DDAO+PBIFGB+FDB?;?N+E:B+3.1+KFFG<L Failure to observe this warning may result in electric shock. 9+)IEBG+E@G?;?N+-,,+E:B+DFJBG+<@DDAOM+J>;E+>E+AB><E+_+=;?@EB<+PBIFGB+ GBDA>H;?N+>+<BGSFD>HX+2;?HA@K;?N+HF?SBGEBG7+FG+HF?EGFA+DFJBG+<@DDAO+ @?;EL+8F+?FE+EF@H:+>?O+EBG=;?>A<+K@G;?N+E:;<+DBG;FKL Failure to observe this warning may result in electric shock. C A U T I O N 9+(F+DGBSB?E+>?OF?B+;?>KSBGEB?EAO+E@G?;?N+-'+E:B+DFJBG+<@DDAO+K@G;?N+ =>;?EB?>?HBM+D@E+@D+>+J>G?;?N+<;N?+<@H:+><+d8-+'-(+(".'+-'+(/%+...
Page 242: L6L6 Replacing The Disconnecting Switch
4.1 Replacing XRC Parts ^L6L6 Replacing the Disconnecting Switch The disconnecting switch (QS1) is equiped with the following fuses. Parts No. Fuse Name Specification FU1, Power Supply Fuse 600 VAC * FU2, TIME DELAY/CLASS CC (30A or less) TIME DELAY/CLASS J (40A or more) The type of fuse differs depencing on the robot model.
Page 243 4.1 Replacing XRC Parts Fuse holders The fuse holders (QS2,QS3) are equiped with the following fuses. Fuse holders Parts No. Fuse Name Specification FU4,FU5,FU6 Power Supply 600VAC Fuse TIME DELAY/CLASS CC (30A or less) TIME DELAY/CLASS J (40A or more) FU7,FU8,FU9 Power Supply 600VAC...
Page 244 UP130, UP165, UP165-100, UP200 Without trans- former With built-in transformer UP130R, UP130RL, SK300X, SP100X, SR200X Without trans- former Time delay fuses of class CC (30A or less) or class J (40A or more) are used for QS1, QS2, and QS3.
Page 245: L6L4 Replacing Parts Of Power Supply Unit
UP130, UP165, UP165-100, UP200 JZRCR-XPU10B UP130R, UP130RL, SK300X, SR200X, SP100X If a fuse appears to be blown, remove each fuse shown above and check the continuity with an electric tester.If the fuse is blown, replace it with the same type of fuse (supplied).
Page 246: L4 Yasna Xrc Parts List
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 unit JZRCR-XCO02B...
Page 247 4.2 YASNAC XRC Parts List The type of the SERVOPACK depends on the robot model. For details, see the Tables. “ SERVOPACK List (Small Capacity)” and “SERVOPACKz List (Large Capacity)”. The type of the power supply unit depends on the robot model. For details, see the Table “Power Supply Unit List”.
Page 248 4.2 YASNAC XRC Parts List SERVOPACK List (Medium Capacity) SK16MX SK45X UP50 Component Type Type Type SERVOPACK CACR- CACR-SK45AAB CACR-UP50AAB SK16MAAB Amplifier S JUSP-WS30AA JUSP-WS30AA JUSP-WS44AA L JUSP-WS20AA JUSP-WS20AA JUSP-WS60AA U JUSP-WS20AA JUSP-WS20AA JUSP-WS20AA R JUSP-WS02AA JUSP-WS10AA JUSP-WS10AA B JUSP-WS02AA JUSP-WS10AA JUSP-WS10AA T JUSP-WS02AA...
Page 249 4.2 YASNAC XRC Parts List SERVOPACK List (Large Capacity) UP130R, UP200 UP130, UP165 UP130RL UP165-100 component Type Type Type SERVOPACK CACR-UP130AAB CACR- CACR- UP130AABY18 UP130AABY21 Amplifier JUSP-WS60AA JUSP- JUSP- WS60AAY18 WS60AAY18 JUSP-WS60AA JUSP- JUSP- WS60AAY18 WS60AAY18 JUSP-WS60AA JUSP-WS60AA JUSP- WS60AAY18 JUSP- JUSP- JUSP-...
Page 250 Converter JUSP-ACP35JAA JUSP-ACP35JAA Control JUSP-RCP01AAC JUSP-RCP01AAC power supply Power Supply Unit Type Type Robot Type JZRCR-XPU06B SV3X, UP6, SK16X, UP20 JZRCR-XPU05B SK45X, SK16MX, UP50, UP20M, SP70X, UP130, UP165, UP165-100, UP200 JZRCR-XPU10B UP130R, SK300X, SP100X, UP130RL, SR200X 4-10...
Page 251 1.0KVA 575-480-240V/208V UP6, SK16X, UP20 HB9480042 4.5KVA 575-480-240V/208V SK45X, SK16MX, UP50, HB9480043 UP20M, SP70X, UP130, 8.0KVA 575-480-240V/208V UP165, UP165-100, UP200 UP130R, UP130RL, SK300X, HB9480044 SP100X, SR200X 12.0KVA 575-480-240V/208V Power Supply Fuse List Fuse Type Robot Type With trans- former built-in...
Page 252: L] Supplied Parts List
4.3 Supplied Parts List Supplied Parts List The supplied parts of YASNAC XRC is as follows. Parts No.1 to 5 are used for fuse for replacement and No.6 is used as a tool for connecting the I/O. Parts Name Dimensions Model Application Class CC...
Page 253 UP130, UP165, UP165-100, UP200 Without trans- former With built-in transformer UP130R, UP130RL, SK300X, SP100X, SR200X Without trans- former Time delay fuses of class CC (30A or less) or class J (40A or more) are used for QS1, QS2, and QS3.
Page 254: L^ Recommended Spare Parts
4.4 Recommended Spare Parts Recommended Spare Parts It is recommended that the following parts and components be kept in stock as spare parts for the 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.
Page 255 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for SV3X Manufa No Rank Name Type Remark cturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 4715PS-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo B30-B00...
Page 256 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP6 Manufa Qty per No Rank Name Type Remark unit cturer Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 4715PS-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 257 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for SK16X Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 4715PS-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 258 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP20 Qty per No Rank Name Type Manufacturer Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 4715PS-22T- Minebea B30-B00 Servo Top Fan 3610PS-22T- Minebea B30-B00 Power Supply Fuse ATDR10 10A...
Page 259 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for SK16MX Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 260 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for SK45X Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 261 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP20M Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PS-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 262 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP50 Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 263 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for SP70X Qty per No Rank Name Type Manufacturer Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 264 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP130, UP165 Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 265 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP200 Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 266 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP130R Qty per No Rank Name Type Manufacturer Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 267 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP130RL Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 268 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for SR200X, SK300X Qty per No Rank Name Type Manufacturer Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part...
Page 269 4.4 Recommended Spare Parts Recommended Spare Parts of XRC for SP100X Qty per No Rank Name Type Remark Manufacturer unit Battery ER6VC3N 3.6V Toshiba Battery Rack fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 In-panel Fan on upper part 3610PS-22T- Minebea of Servo...
Page 270 4.4 Recommended Spare Parts 4-30...
Page 271 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. 7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area, Beijing 100076, P.R. China Phone 86-10-6788-0551...
Page 272 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 273 M A N D A T O R Y • This manual explains setup, diagnosis, maintenance, hardware and so on of the YASNAC XRC system. Read this manual carefully and be sure to understand its contents before handling the YASNAC XRC. •...
Page 274 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 275 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 276 • 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 277 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 278 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 279 3.9 Tool Data Setting ......... 3-32 3.9.1 Registering Tool Files .
Page 280 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 281 System Diagnosis 5.1 System Version ..........5-1 5.2 Input/Output Status .
Page 282 Hardware 19 YASNAC XRC Specification 6.1 Specification List ......... . . 6-3 6.2 Function List .
Page 283 Maintenance 51 Inspections 8.1 Regular Inspections ........8-1 8.2 XRC Inspections .
Page 284 Alarm • Error 21 Alarm 10.1 Outline of Alarm ......... . 10-1 10.2 Alarm Display .
Page 286: Setup • Diagnosis
Setup • Diagnosis...
Page 288: Outline Of Setting And Diagnosis
- Retain floppy disk backups of control settings each time settings are changed. The XRC controller for the Motoman industrial robot provides a full range of advanced and practical functions. It can meet the industry demands for more flexible and more sophisticated robotics systems.
Page 290: 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 291 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 292 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 293 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 294: 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 295: 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 296 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 297 2.1 Protection Through Security Mode Settings...
Page 298: 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 299 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 300: 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 301: 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 302: 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 303: 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 304: 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 305: 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 306 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 307: 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 308: 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 309: 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 310: 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 311: 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 312 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 313 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 314 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 315: 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 316: 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 317: 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 318: 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 319 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 320 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 321 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 322 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 323: 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 324 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 325 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 326: 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 327: 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 328: 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 329: 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 330 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 331: 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 332: 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 333: 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 334 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 335 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 336 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 337: 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 338: Automatic Measurement Of The Tool Load And The Center Of Gravity
N OT E tive for information on other models. Applicable models: MOTOMAN UP6, SK16X, SK45X, and UP130 This function can be used where the manipulator is installed level on the ground. For the conditions required for manipulator installation, refer to 3.11 “ARM Control”.
Page 339 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 340 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 341 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 342: 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 343: 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 344: 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 345: 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 346: Arm Control
3.11 ARM Control 3.11 ARM Control 3.11.1 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.
Page 347: Robot Setup Condition
3.11 ARM Control " Robot Setup Condition It is necessary to set the following robot setup condition to execute the ARM control appropri- ately. • Robot installation angle • S-head payload • U-arm payload Robot installation angle The angle of the manipulator installed relative to ground is set in ANGLE REL. TO GROUND to calculate the gravity moment which loads to each axis of the manipulator.
Page 348 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 349: 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 350: 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 351: 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 352 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 353 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 354 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 355 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 356 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 357 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 358 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 359 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 360 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 361: 3.12 Shock Detection Function
This function cannot do away with the damage to peripherals completely. Moreover, this function does not guarantee safety to the person. Prepare the safety measures such as the safety fence etc. Refer to "MOTOMAN Setup Manual" for the safety measures in detail.
Page 362 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 363 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 364: 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 365: 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 366 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 367 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 368 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 369 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 370 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 371: 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 372: 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 373: 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 374: 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 375: Key Allocation (Each)
3.14 Number Key Customize Function " Key Allocation (EACH) With key allocation (EACH), the manipulator operates according to the allocated function when the number key is pressed. 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.
Page 376: 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 377: 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 378: 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 379: 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 380: 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 381: 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 382: 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 383: 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 384 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 385: 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 386: 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 387 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 388: 3.16 Temporary Release Of Soft Limits
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 389 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 390: 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 391: 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 392: 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 393: 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 394: 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 395 3.17 File Initialize 3-98...
Page 396: 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 397 4.1 Addition of I/O Modules The current status of the mounted I/O module is displayed. I O M O D U L E ST#01 DI-008 DO-008 AI-002 AO-002 ST#02 DI-016 DO-016 ST#03 NONE ST#04 NONE ST#05 NONE ST#06 NONE ST#07 NONE ST#08 NONE !Maintenance Mode Confirm that each station (ST#) is the correct status.
Page 398: 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 399 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 400: 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 401 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 402 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 403 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 404 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 405 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 406 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 407 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 408 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 409 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 410 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 411 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 412 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 413 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 414 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 415 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 416 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 417 4.2 Addition of Base and Station Axis 4-22...
Page 418: 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 419: 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 420: 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 421: Modify The Signal Name
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 422 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 423: 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 424 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 425: 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 426: 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 427: 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 428: 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 429: 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 430: 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 431: 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 432: 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 433: 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 434: 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 435 5.6 Position Data When Power is Turned ON/OFF 5-18...
Page 436: Hardware
Hardware...
Page 438: Yasnac Xrc Specification
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 439 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 440: 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 441: 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 442: 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 443: 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 444 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 445: 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 446 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 447 6.4 Equipment Configuration 6-10...
Page 448: Description Of Units And Circuit Boards
Description of Units and Circuit Boards Refer to XRC 2001 Supplement, section 2, for description of units and circuit boards.
Page 449 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 450 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 451 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 452 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 453 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 454 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 455 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 456 8.8 Open Phase Check...
Page 457 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 458 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 459 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 460 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 461 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 462 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 463 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 464 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 465: Power Supply Unit
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 466 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 467: Servopack
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 468 9.3 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 313005...
Page 469 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 JZNC-XZU02 Yaskawa Backside Duct Fan...
Page 470 9.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP6 No Rank Name Type Mfr. Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack Fan JZNC-XZU02 Yaskawa Backside Duct Fan 4715PS-22T- Minebea B30-B00 Servopack Ascending Fan 3610PS-22T- Minebea B30-B00 Control Power Fuse 313005 5A 250V Littel fuse 24VDC Fuse...
Page 471 9.4 Recommended Spare Parts Recommended Spare Parts of XRC for SK16X No Rank Name Type Mfr. Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack Fan JZNC-XZU02 Yaskawa Backside Duct Fan 4715PS-22T- Minebea B30-B00 Servopack Ascending Fan 3610PS-22T- Minebea B30-B00 Control Power Fuse 313005 5A 250V Littel fuse 24VDC Fuse...
Page 472 9.4 Recommended Spare Parts Recommended Spare Parts of XRC for SK16MX No Rank Name Type Mfr. Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack Fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 Servopack Ascending Fan 3610PS-22T- Minebea B30-B00 Control Power Fuse 313005 5A 250V Littel fuse 24VDC Fuse...
Page 473 9.4 Recommended Spare Parts Recommended Spare Parts of XRC for SK45X No Rank Name Type Mfr. Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack Fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 Servopack Ascending Fan 3610PS-22T- Minebea B30-B00 Control Power Fuse 313005 5A 250V Littel fuse 24VDC Fuse...
Page 474 9.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP130, UP165 No Rank Name Type Mfr. Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack Fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 Servopack Ascending Fan 3610PS-22T- Minebea B30-B00 Heat Exchanger Fan 4710PS-22T-B30 Littel fuse Control Power Fuse...
Page 475 9.4 Recommended Spare Parts Recommended Spare Parts of XRC for UP200, UP130R No Rank Name Type Mfr. Remark unit Battery ER6VC3N 3.6V Toshiba Battery Rack Fan JZNC-XZU02 Yaskawa Backside Duct Fan 5915PC-22T- Minebea B30-B00 Servopack Ascending Fan 3610PS-22T- Minebea B30-B00 Heat Exchanger Fan 4710PS-22T-B30 Minebea Control Power Fuse...
Page 476 9.4 Recommended Spare Parts 9-20...
Page 477: Alarm • Error
Alarm • Error...
Page 479: 10 Alarm
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 480: 10.2 Alarm Display
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 481: Special Alarm Display
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 482 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 483 10.3 Alarm Message List 10.3 Alarm Message List C A U T I O N Pay special attention when performing any repairs for system control circuit board “JANCD-XCP01”. Personnel must be appropriately skilled in maintenance mode opera- tion to carry out repairs. JANCD-XCP01 back up very important file data for the user program with a battery.
Page 484 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0021 COMMUNICATION • The connection of communication cable • Check the connection of communication ERROR(SERVO for servopack was not completed. cable for servopack. [Decimal Data] • The connection of communication cable •...
Page 485 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0040 MEMORY ERROR Memory (RAM) error • 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.
Page 486: Maintenance Mode
10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0060 COMMUNICATION • An error occurred in communication of I/O • Check the connection of the communica- ERROR(I/O MOD- module. tion cable for I/O module. (XCP01(CN01 ULE) • Defective I/O module - XIU01(CN03 cable, [Decimal Data] WRCA01(#*)(CN20 - XIU01(CN21...
Page 487 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 488 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0400 PARAMETER • The connection of communication cable • Check the connection of communication TRANSMISSION for servopack was not completed. cable for servopack. (XCP01(CN05 - ERROR • The connection of communication cable WRCA(#*)(CN10 cable, [Decimal Data] for servopack was not cut.
Page 489 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0901 WATCHDOG TIMER An insertion error of the XCP02#1 circuit • Insert the circuit board in the CPU rack ERROR board or the circuit board failed. or the connector on the circuit board fast. (XCP02#1) •...
Page 490 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0931 CPU HANG UP An insertion error of the XCP02#1 circuit • Insert the circuit board in the CPU rack ERROR board or defective circuit board. or the connector on the circuit board fast. (XCP02#1) •...
Page 491 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0951 CPU ERROR An insertion error of the WRCA0#21 circuit • Insert the circuit board in the CPU rack (WRCA#2) board or defective circuit board. or the connector on the circuit board fast. [Decimal Data] •...
Page 492 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 0964 CPU HANG UP An insertion error of the WRCA01#5 circuit • Insert the circuit board in the CPU rack ERROR board or defective circuit board. or the connector on the circuit board fast. (WRCA#5 •...
Page 493 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1051 SETUP INITIALIZE The error occurred in the setup process of • Turn the power off then back on. ERROR motion instruction when the main power • If the error occurs again, contact you (MOTION) was turned on.
Page 494 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1300 SERVO CPU SYN The communication between the XCP01 • Check the connection of communication CHRONIZING circ board and the WRCA01 circuit board cable for servopack. ERROR was abnormal. (XCP01(CN05 - WRCA(#*)(CN10 cable, •...
Page 495 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 496 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 497 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 498 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 499 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 500 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 501 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 502 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 503 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 504 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 505 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1331 CURRENT FEED- When the phase balance of the motor cur Turn the power off then back on. If the BACK ERROR rent was automatically adjusted, the read U phenomenon occurs again after repeating (U PHASE) phase current value was abnormal.
Page 506 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 1342 OVER SPEED The motor speed displayed in the axis data • Check the motor wiring. (XFC01) exceeded the allowable maximum motor • Check the robot movement when the Robot/Station speed.
Page 507 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 508 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 509 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 510 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4102 SYSTEM DATA An attempt was made to change data which Turn off the power once and back on. CHANGING exerted the influence on the system and [Decimal Data] turned on the servo power supply.
Page 511 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4110 SHOCK SENSOR The shock sensor was operated. Check the factor of shock sensor opera- ACTION tion. [Bit Pattern] 4111 BRAKE FUSE The brake fuse was melted. Replace the fuse. BLOWN [Bit Pattern] 4112...
Page 512 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4121 COOLING FAN 1 The number of revolutions of cooling fan 1 After resetting the alarm, move the manip- ERROR connected to the contactor unit was ulator in the teach mode to a safe place. [Binary Data] reduced.
Page 513 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4208 SYSTEM ERROR The system error occurred in ARITH. • Reset the alarm and repeat the opera- (ARITH) tion. [Decimal Data] • Turn the power off then back on. •...
Page 514 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 515 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 516 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4308 VOLTAGE DROP • Direct current power supply voltage sup- • Check the connection for primary side (CONVERTER) plied to amplifier for servopack has wiring R,S,T, wire. [Bit Pattern] become less than143V.
Page 517 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4315 COLLISION DETECT • A collision from interference between robot • Remove the object after resetting the Robot/Statio and peripheral device etc. was detected. alarm or move the robot to the safety [Axis Data] •...
Page 518 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 519 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4423 MECHANICAL An abnormal (reverse) axis interfered mutu- Reset the alarm. Release the interference INTERFERENCE ally. and teach again. (MAX.) Robot/Statio [Axis Data] 4424 SPECIAL MECHANI- An abnormal (reverse) axis interfered mutu- Reset the alarm.
Page 520 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4434 VAR-SCOREBOARD The error occurred in variable scoreboard • Reset the alarm. Select job and repeat CONTROL ERROR control. the operation. [Decimal Data] • If the error occurs again, operate by the following procedure: # Delete the command that caused the alarm and register again and start exe-...
Page 521 10.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number 4444 UNSUCCESSFUL • When executing PL=0 or interrupting • Reset the alarm. In case an external FINE POSITIONING external servo, the servo deflection was force is affecting the robot, move the [Binary Data] not put within time.
Page 522 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.

This manual is also suitable for:

Xrc 2001