Manual Motoman

XRC 2001 Controller
CSL10
Manipulator Manual
Part Number 148266-1
June 11, 2003
MOTOMAN
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.
©2003 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without notice.
MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
TABLE OF CONTENTS
Section Page
1 INTRODUCTION .......................................................................................................................... 1-1
2 SAFETY ....................................................................................................................................... 2-1
3 XRC SETUP ................................................................................................................................. 3-1
4 CSL10 INSTRUCTIONS ............................................................................................................... 4-1
5 CSL10 SUPPLEMENT ................................................................................................................. 5-1
6 XRC INSTRUCTIONS (NAS 2001) ............................................................................................... 6-1
7 XRC INSTRUCTIONS-GENERAL (R2) .......................................................................................... 7-1
8 SV3X/CSL10 ELEMENTARY DIAGRAMS .................................................................................... 8-1
MOTOMAN i CSL10 Manipulator Manual (XRC 2001)

NOTES
CSL10 Manipulator Manual (XRC 2001) ii MOTOMAN

SECTION 1
INTRODUCTION
The Motoman CSL10 clean room robot and XRC 2001 controller represent state-
of-the-art technology in robotics today. The Motoman CSL10 has a 3 kg payload
and six individual axes: Sweep, Lower arm, Upper arm, Rotate, Bend, and Twist.
The XRC 2001 controller coodinates the operation of the CSL10 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. Furthermore, it
provides main logic functions, servo control, program and constant data memory,
and power distribution. Please read this manual thoroughly to familiarize yourself
with the many aspects of the CSL10 robot and XRC 2001 controller.
1.1 About this Document

This manual provides system information for CSL10 robot and XRC 2001
controller and contains the following sections:
SECTION 1 – INTRODUCTION
Provides general information about the structure of this manual, a list of reference
documents, and customer service information.
SECTION 2 – SAFETY
Provides information regarding the safe use and operation of the CSL10 robot.
SECTION 3 — CSL10 INSTRUCTIONS
Provides detailed information about the CSL10, including installation, wiring,
specifications, and maintenance.
SECTION 4 — CSL10 SUPPLEMENT
Provides information specific to the CSL10 clean room robot and the XRC 2001
controller. Use this section as a supplement for information contained in Sections 6
and 7.
SECTION 5 — XRC SETUP
Provides basic information about the installation, connection, initial operation, and
home calibration of your Motoman robot and XRC 2001 controller.
SECTION 6 — XRC INSTRUCTIONS–NORTH AMERICAN STANDARD 2001
Provides detailed information about the NAS XRC 2001 controller, including
descriptions, inspections, and parts replacement.
SECTION 7— XRC INSTRUCTIONS–GENERAL
Provides general information about the XRC 2001 controller, including system
setup, inspections, diagnosis, and configuration, as well as specifications,
maintenance, and alarm/error message lists.
SECTION 8 — SV3X/CSL10 ELEMENTARY DIAGRAMS
Provides detailed information about XRC wiring and system configuration with
regard to the CSL10 robot.
MOTOMAN 1-1 CSL10 Manipulator Manual (XRC 2001)

INTRODUCTION
1.2 Reference to Other Documentation

For additional information refer to the following:
• Concurrent I/O Parameters Manual for XRC 2001 (P/N 147626-1)
• Operator’s Manual for General Purpose (P/N 142099-1)
• Operator’s Manual for Handling (P/N 142100-1)
• Operator’s Manual for Spot Welding (P/N 142101-1)
• Operator’s Manual for Arc Welding (P/N 142098-1)
• Vendor manuals for system components not manufactured by Motoman.
1.3 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 (UP20, UP130, etc.)
• Application Type (assembly, handling, etc.)
• Software Version (5.101A, etc.)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of XRC controller)
CSL10 Manipulator Manual (XRC 2001) 1-2 MOTOMAN

SECTION 2
SAFETY
2.1 Introduction
.
It is the purchaser's responsibility to ensure that all local, county,

state, and national codes, regulations, rules, or laws relating to
safety and safe operating conditions for each installation are met
and followed.
We suggest that you obtain and review a copy of the ANSI/RIA National Safety
Standard for Industrial Robots and Robot Systems. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not been
trained!
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:
• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)

SAFETY
2.2 Standard Conventions

This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
• DANGER
• WARNING
• CAUTION
• NOTE
Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE: Information appearing in a NOTE caption provides additional information which is helpful in
understanding the item being explained.

SAFETY
2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General safeguarding
tips are as follows:
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the robot cell.
• 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).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use
lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health
Standards for General Industry (OSHA).
2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is
ultimately the user's responsibility. The conditions under which the equipment
will be operated safely should be reviewed by the user. The user must be aware of
the various national codes, ANSI/RIA R15.06 safety standards, and other local
codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following safety
measures are available:
• 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.

SAFETY
2.5 Installation Safety

Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace, existing federal,
local, and state laws and regulations. Additional safety measures for personnel and
equipment may be required depending on system installation, operation, and/or
location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
• Identify the work envelope of each robot with floor markings, signs, and
barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry
into the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot
and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and
maintenance procedures.
2.6 Programming Safety

equipment must understand potential dangers of operation. Programming tips are
as follows:
• Any modifications to PART 1 of the controller PLC can cause severe
personal injury or death, as well as damage to the robot! 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. Special passwords are for Motoman use only. YOUR
WARRANTY WILL BE VOID if you use these special passwords.
• Back up all programs and jobs onto a floppy disk whenever program changes
are made. To avoid loss of information, programs, or jobs, a backup must
always be made before any service procedures are done and before any
changes are made to options, accessories, or equipment.
• The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.

SAFETY
• Inspect the robot and work envelope to be sure no potentially hazardous

conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place.
• Check the E-STOP button on the teach pendant for proper operation before
programming.
• Carry the teach pendant with you when you enter the workcell.
• Be sure that only the person holding the teach pendant enters the workcell.
• Test any new or modified program at low speed for at least one full cycle.
2.7 Operation Safety

equipment must understand potential dangers of operation. Operation tips are as
follows:
• Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Inspect the robot and work envelope to ensure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
must have the teach pendant when they enter the cell.
not in use.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.

SAFETY
2.8 Maintenance Safety

equipment must understand potential dangers of operation. Maintenance tips are
as follows:
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Back up all your programs and jobs onto a floppy disk whenever program
changes are made. A backup must always be made before any servicing or
changes are made to options, accessories, or equipment to avoid loss of
information, programs, or jobs.
must have the teach pendant when they enter the cell.
not in use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(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).

YASKAWA
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
The YASNAC XRC operator’s manuals above correspond to specific usage.
Please be sure to use the appropriate manual.
YASKAWA MANUAL NO. RE-TA-A503 1

• 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. To ensure correct and safe operation, carefully read the
Setup Manual before reading this manual.
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
• The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.
• YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA rep-

resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-
uct’s warranty.
ii
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.

could result in minor or moderate injury to personnel and dam-
age to equipment. It may also be used to alert against unsafe
practices.
Always be sure to follow explicitly the items listed under this

heading.
Must never be performed.
Even items described as “CAUTION” may result in a serious accident in some situations. At
any rate, be sure to follow these important items.
To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING.”
iii
• 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.
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.
Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator. Then turn
the servo power ON
Injury may result from unintentional or unexpected manipulator motion.
Release of Emergency Stop
• Always set the Teach Lock before entering the robot work envelope to
teach a job.
Operator injury can occur if the Teach Lock is not set and the manipulator is started from
the playback panel.
• Observe the following precautions when performing teaching operations

within the working envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the manipulator’s work envelope

and that you are in a safe location before:
- Turning on the YASNAC XRC power
- Moving the manipulator with the programming pendant
- Running check operations
- Performing automatic operations
Injury may result if anyone enters the working envelope of the manipulator during opera-
tion. Always press an emergency stop button immediately if there are problems. The
emergency stop button is located on the right side of both the YASNAC XRC playback
panel and programming pendant.
iv
• Perform the following inspection procedures prior to conducting manip-
ulator teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the XRC cabinet
after use.
The programming pendant can be damaged if it is left in the manipulator’s work area, on
the floor, or near fixtures.
• Read and understand the Explanation of 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.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
Manipulator Manipulator
Power Cable Power Cable
YASNAC XRC Controller XRC
YASNAC XRC Playback Panel Playback Panel
YASNAC XRC Programming Pendant Programming Pendant
v
Descriptions of the programming pendant and playback panel keys, buttons, and displays are
shown as follows:
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.
e.g., page key

The cursor key is an exception, and a picture is not
shown.
Axis Keys “Axis Keys” and “Number Keys” are generic names
Number Keys for the keys for axis operation and number input.
Keys pressed When two keys are to be pressed simultaneously,

simultaneously the keys are shown with a “+” sign between them,
e.g., [SHIFT]+[COORD].
Displays The menu displayed in the programming pendant is

denoted with { }, e.g., {JOB}.
Playback Panel Buttons Playback panel buttons are enclosed in brackets,

e.g., [TEACH] on the playback panel.
Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • " means that the cur-
sor is moved to the object item and the SELECT key is pressed.
vi
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.
Refer to the manipulator manual for the warning label location.

• The following warning labels are attached to XRC.
Fully comply with the precautions on the warning labels.

Failure to observe this warning may result in injury or damage to equipment.
vii
viii
1 Safety
1.1 For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Special Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3 Motoman Manual List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.4 Personnel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.5 Motoman Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.5.1 Installation and Wiring Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.5.2 Work Area Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.5.3 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1.6 Notes for Moving and Transferring the MOTOMAN . . . . . . . .1-14
1.7 Notes on MOTOMAN Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
2 Product Confirmation
2.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
3 Installation
3.1 Handling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.1 Using a Crane to Move the Controller . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.2 Using a Forklift to Move the Controller . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2 Place of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.4 Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
4 Connection
4.1 Notes on Cable Junctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.1 Three-Phase Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.2 Noise Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.2.3 Leakage Breaker Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.2.4 Primary Power Supply Switch Installation . . . . . . . . . . . . . . . . . . . . . .4-5
4.3 Connection Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.3.1 Connecting the Primary Power Supply . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.3.2 Connecting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.3.3 Connecting the Programming Pendant . . . . . . . . . . . . . . . . . . . . . . .4-11
ix
5 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 . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Turning on the Servo Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 During Play Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.2 During Teach Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Turning the Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 Turning the Servo Power Off (Emergency Stop) . . . . . . . . . . . . . . . . 5-4
5.3.2 Turning the Main Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
6 Test of Program Operation

6.1 Movement of the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
7 Home Position Confirmation

7.1 Home Position Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.1 Operating Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
8 Final Notes
x
About Setup Manual Configuration
Thank you very much for purchasing Yaskawa Electric Mfg. Co., Ltd.’s manipulator .
This Setup Manual contains instructions for the safe use of the manipulator, and safe installa-
tion and wiring.
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.
Chapter 4 explains how to connect the primary power supply and power cables.
Chapter 5 explains how to turn the power supply on/off.
Chapter 6 explains the check operation and manipulator handling.
Chapter 7 explains home position registration and confirmation.
Chapter 8 lists all the manuals and their relevant uses.
xi
xii
1.1 For Your Safety
1 Safety
1.1 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.
It is the user’s responsibility to ensure that all local, state, and national codes, regulations
rules, or laws relating to safety and safe operating conditions are met and followed.
1-1
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. Act in UK
-EC Directive 89/392 Machinery and 91/368 EEC
• Prepare
-SAFETY WORK REGULATIONS
based on concrete policies for safety management complying with related laws.
• Observe the
-MANIPULATING INDUSTRIAL ROBOTS-SAFETY (ISO 10218)
for safe operation of the robot. (Japan Only) (JIS B 8433)
• Reinforce the
-SAFETY MANAGEMENT SYSTEM
by designating authorized workers and safety managers, as well as giving continuing

safety education.
• Teaching and maintaining the robot are specified as

"Hazardous Operations" in the Industrial Safety and Health Law
(Japan only).
Workers employed in these above operations are requested to attend special training
offered by YASKAWA.
1-2
1.2 Special Training
1.2 Special Training
• Persons who teach or inspect the manipulator must undergo required

training before using the manipulator.
• For more information on training, inquire at the nearest YASKAWA

branch office.
The telephone numbers are listed on the back cover of this manual.
1.3 Motoman Manual List
• It is important to have and be familiar with all manuals concerning the

MOTOMAN.
You should have the four manuals listed below:
-MOTOMAN SETUP MANUAL

-MOTOMAN-ooo INSTRUCTIONS
-YASNAC XRC INSTRUCTIONS
-YASNAC XRC OPERATOR’S MANUAL FOR BEGINNERS
-YASNAC XRC OPERATOR’S MANUAL
Confirm that you have all these manuals on hand.

If any manuals are missing, contact your salesman from YASKAWA’s local branch office.
The relevant telephone numbers are listed on the back cover.
1-3
1.4 Personnel Safety
The entire manipulator working envelope is potentially dangerous.

All personnel working with the MOTOMAN (safety administration, installation, operation, and
maintenance personnel) must always be prepared and "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.
• Please take strict safety precautions by placing signs such as "Flamma-
ble," "High Voltage," "Waiting," and "Off-limits to Unauthorized Person-
nel" in necessary areas in the factory.
Failure to observe these cautions may result in fire, electric shock, or injury due to contact
with the manipulator and other equipment.
• Strictly observe the following items:
-Always wear approved work clothes (no loose-fitting clothes).

-Do not wear gloves when operating the MOTOMAN.
-Do not allow underwear, shirts, or neckties to hang out from the work
clothes.
-Do not wear large jewelry, such as earrings, rings, or pendants.
Always wear protective safety equipment such as helmets, safety shoes (with slip-proof
soles),face shields, safety glasses, and gloves as necessary.
Improper clothing may result in injury.

• Unauthorized persons should not approach the manipulator or associ-
ated peripheral equipment.
Failure to observe this caution may result in injury due to contact with XRC, playback
panel, the workpiece, the positioner, etc.
1-4
• 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.
• Never allow unauthorized personnel to touch the XRC during operation.
Failure to observe this caution may result in injury or damage resulting from unexpected
movement of the manipulator.
1-5
1.5 Motoman Safety
1.5 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. Observe the following when installing the
manipulator:
• Select an area such as that described below to install the manipulator:

Confirm that the area is large enough so that the fully extended manipu-
lator arm with tool will not reach a side wall, safeguards, or the control-
ler.
Failure to observe this caution may result in injury or damage resulting from unexpected
movement of the manipulator.
ENCLOSURE XRC
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
• Perform grounding in accordance with all applicable electrical codes.
Failure to observe this caution may result in fire or electric shock.
1-6
1.5 Motoman Safety
• Operation of the crane, sling, or forklift should only be performed by

authorized personnel.
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.
Failure to observe these precautions may cause the manipulator to turn downward,
potentially causing injury or damage to equipment.
• When lifting the XRC, please check the following:
-As a rule, handling of XRC must be performed using a crane with wire
rope threaded through attached eyebolts.
-Be sure to use wire that is strong enough to handle the weight of the
XRC.
THE WEIGHT OF XRC (approx.)
Approx.
XRC equivalent
weight
model
(kg)
SV3X,UP6,SK16X 70
SK45X,SK16MX 90
UP130,UP165,
UP200,UP130R, 100
SP100X
• Be sure the eyebolts are securely fastened.

• If storing the manipulator temporarily before installation, be sure to
place it on a stable and flat surface and take precautions to prevent
unauthorized personnel from touching it.
Failure to observe this precaution may result in injury of damage to equipment.
1-7
1.5 Motoman Safety
• Be sure there is sufficient room for maintenance on the manipulator,

XRC, and other peripheral equipment.
Failure to observe this precaution could result in injury during maintenance.
[650] 20]
[650]
500
500 470 500 470 320 500
(550) (550) (420)
(420)
[420]
XRC
320
(860)
[860]
760
(550)
[650]
(630)
0]
470
550
DOOR
XRC
Securing (mm) SV3X,UP6,SK16X, External Dimensions (mm) SV3X,UP6,SK16X

( )SK16MX,SK45X, ( )SK16MX,SK45X,
[ ]UP130,UP165,UP200,UP130R,SP100X [ ]UP130,UP165,UP200,UP130R,SP100X
• The manipulator is controlled by the XRC or the welding fixture control-

ler.
To ensure safety, be sure to operate the controller from a location where the manipulator
is easily visible.
Operation by unauthorized personnel may result in injury or equipment damage.

• Install the XRC outside the safeguard of the manipulator’s safety enclo-
sure.
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.
1-8
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.
• Be familiar with the connection diagram before wiring the XRC, and per-
form the wiring in accordance with the connection diagram.
There is a danger of equipment damage or injury due to miswiring and unexpected move-
ment of the equipment.
• Take precautions when wiring and piping between the XRC, manipula-
tor, and peripheral equipment. Run the piping, wiring, or cables through
a pit or use a protective cover, so that they are not stepped on by per-
sonnel or run over by the forklift.
Operators and other personnel may stumble on

exposed wiring or piping. Cable damage can
cause unexpected manipulator motion resulting
in injury or property damage.
1-9
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.
Post a warning sign stating "Off-limits During Operation" at the
entrance of the enclosure. The gate of the enclosure must be equipped
with a safety interlock. Be sure the interlock operates correctly before
use.
Failure to observe this caution may result in a serious accident due to contact with
the manipulator.
• Store tools and similar equipment in proper locations outside of the

enclosure.
Tools and loose equipment should not be left on the floor around the manipulator, XRC,
or welding fixture, etc., as injury or damage to equipment can occur if the manipulator
comes in contact with objects or equipment left in the work area.
1-10
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.
ON
IP
TR
OFF
T
SE
RE
PADLOCK
Turning the power on during tool installation may case electric shock or injury due to
unexpected movement of the manipulator.
• Never exceed the rated capacity of the manipulator (capacity can be
found in the specifications section of the manipulator manual.).

• Teach jobs from outside the manipulator’s work area whenever possi-
ble.
• When teaching within the working envelope of the manipulator, please
observe the following:
- Always view the manipulator from the front.

- Follow the predetermined operating procedure.
- Always have an escape plan in mind in case the manipulator comes
toward you unexpectedly.
Failure to observe these precautions may result in injury due to unexpected manipulator
motion.
1-11
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.
If the manipulator cannot be stopped in the event of an emergency, there is a risk of injury
or damage to equipment.
• Always press Teach Lock before starting to teach.
Failure to observe this precaution may result in injury due to unauthorized personnel
operating the manipulator from the playback panel.
• Prior to operation, be sure there are no personnel in the manipulator’s
working envelope. The following operations should always be per-
formed from a safe location.
-Turning on the XRC power supply

-Moving the manipulator using the programming pendant
-The check operation
-Automatic operation
Failure to observe this caution may result in injury from contact with the manipulator.
Press the emergency stop button immediately in the event any problems occur.
The emergency stop button is on the upper right side of the playback panel on the con-
troller and on the right side of the programming pendant.
MOTOMAN
MOTOMAN
YASNAC XRC
YASNAC XRC
1-12
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.
The programming pendant can be damaged if it is left on the floor or in the manipulator
work area.
• Persons operating or inspecting the manipulator should be trained as

required by applicable laws and company policies.
(Refer to the 1.2 Special Training)
1-13
1.6 Notes for Moving and Transferring the MOTOMAN
1.6 Notes for Moving and Transferring the MOTOMAN
When moving or transferring the Motoman, observe the following safety precautions:
• Attach the instructions to the controller cabinet so that all users have
access to necessary manuals. See Section 1.3 for a complete list of
manuals.
If any manuals are missing, contact your Yaskawa representative.

• If the warning labels on the manipulator and YASNAC XRC are illegible,
clean the labels so that they can be read clearly. Note that some local
laws may prohibit equipment operation if safety labels are not in place.
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.
Incorrect installation or wiring may result in personal injury and property damage.
• Never modify the manipulator or XRC.
Failure to observe this precaution could result in injury or damage resulting from fire,
power failure, or operation error.
1-14
1.7 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.
1-15
1-16
2.1 Contents Confirmation
2 Product Confirmation
2.1 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
• Power Cable (Between Manipulator and XRC)
• Complete Set of Manuals
2-1
2.2 Order Number Confirmation
2.2 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
2-2
3.1 Handling Procedure
3 Installation
3.1 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.
3.1.1 Using a Crane to Move the Controller
Check the following before handling the XRC:

• Confirm the weight of the controller before handling, and use a wire rope with a rating that
is greater than the weight of the controller.
• Install eyebolts for handling and make sure they are securely fastened before hoisting.
THE WEIGHT OF YASNAC XRC (approx.)
XRC equivalent Approx.

model weight (kg)
SV3X,UP6, SK16X 70
SK16MX,SK45X 90
UP130,UP165, 100
UP200,UP130R,
SP100X
3-1
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.
• Inform people along the forklift route that equipment is being moved in their area.
• Secure the controller so it cannot shift or fall during handling.
• Transport the controller at the lowest possible height.
• Avoid jarring, dropping, or hitting the controller during handling.
3.2 Place of Installation
The conditions listed below must be met before installing the XRC:
• Ambient temperature must be 0 to 45° C (32 to 113°F) during operation and -10 to 60°C
(14 to 140°F) during transportation and maintenance.
• Humidity must be low with no condensation (under 20%RH).
• It must be a place with little dirt, dust, or water.
• No flammable or corrosive liquids or gases, etc. in the area.
• Little jarring or potential for striking of the XRC (under 0.5 oscillation).
• No large electric noise source (such as a TIG welding device, etc.) nearby.
• No potential for collision with moving equipment such as forklifts.
3-2
3.3 Location
3.3 Location
• Install the XRC outside of the working envelope of the manipulator (outside of the enclo-
sure)
ENCLOSURE XRC
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
• Install the controller in a location from which the manipulator is easily visible.
• Install the controller in a location from which you can easily inspect it when the door is
open.
[650]
500
500 470 500

(550)
(420)
[420]
XRC
320
(550)
[650]
(630)
0]
470
550
DOOR
• Install the controller at least 500mm from the nearest wall to allow maintenance access.
Shows the external dimensions.
[650] 20]
470 320 500
(550) (420)
(860)
[860]
760
XRC
3-3
3.4 Mounting the Controller
3.4 Mounting the Controller
Attach the controller to the floor using user-supplied brackets made according to the specifica-
tions shown below.
Attaching the XRC (mm) External Dimensions (mm)
Refer to the Instruction Manual for information on installation of the manipulator.
3-4
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.
• Do not touch any board inside the controller for five minutes after turn-
ing off the power supply.
Capacitors inside the controller store electricity after power is turned off. Exercise caution
whenever handling circuit boards. Failure to observe this caution may cause electrical
shock.
• Power cannot be turned on unless the door is closed. Interlocks pre-

vent power from being turned on.
Failure to observe this caution may result in fire and electric shock.
• Any occurrence during wiring while the XRC is in the emergency stop
mode is the user’s responsibility. Do an operation check once the wiring
is completed.
Failure to observe this caution could lead to injury or mechanical failure.
4-1
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.
• Be sure the power circuit screws are securely tightened.
Loose power circuit wires can cause fire and electric shock.
• Do not handle the circuit board directly by hand.
The IC board may malfunction due to static electricity.
4.1 Notes on Cable Junctions
• The cables that connect the controller to peripheral equipment are low voltage circuits.
Keep controller signal cables away from the primary power circuit. High voltage power
lines should not be run in parallel to controller signal cables. If running parallel cables is
unavoidable, use metal ducts or conduit to isolate electrical signal interference. If cables
must be crossed, run the power cables perpendicular across the signal cables.
• Confirm the connector and cable numbers to prevent misconnection and equipment dam-
age. One connects the manipulator and XRC. Another connects the XRC and peripheral
equipment. A wrong connection can cause damage to electronic equipment.
• Clear the area of all unauthorized personnel while making cable connections. Place all
cables in a covered cable channel in the floor.
4-2
4.2 Power Supply
XRC Cable Junction Diagram
4.2 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.
Input Power Source Connection
4-3
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. Leakage breakers which cannot handle high fre-
quencies may malfunction.
Example of High Frequency Leakage Breakers
Maker Model
Mitsubishi NV series (manufactured since 1988)

Electric Co.,
Ltd.
Fuji Electric EG or SG Series (manufactured since 1984)

Co., Ltd.
Even with a leakage breaker installed, there is still a possibility of some high frequency current
leakage (small capacity 60-80 mA or large capacity 80-200 mA) from the XRC inverter. This
current leakage presents no safety risks.
Connection of the Leakage Breaker
4-4
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
Cable size (size of terminal) Switch
source
Manipulator capacity
capacity (In case of Cabtyre cable (four wicks)) mm2 (A)
(kVA)
SV3X 1 2.0 (M5) 10
UP6 2 3.5 (M5) 15
SK16X 2 3.5 (M5) 15
SK16MX,
5 5.5 (M5) 30
SK45X
UP130,UP165,
7.5 5.5(M5) 40
UP200
UP130R 10 5.5(M5) 40
SP100X 11 5.5(M5) 40
The maximum load value (payload, operation speed, and frequency, etc.) is displayed.
However, the voltage source capacity is different depending on work conditions.
Inquire at the nearest branch office listed on the back cover for information when selecting the
transformer.
4-5
4.3 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

1. 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.
Rotating the Door Handle Clockwise.
(2) Rotate the main switch to the "OPEN RESET" position and open the door gently.
4-6
PED ON
TRIP
ET
OFF
RES
N
SET
E
RE
OP OPE
N
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.
Attach the plate and cable firmly so that it won’t shift or slide out of place.
(1) Pull off the top cover of the switch which is on the upper left side of the XRC.
Pulling Off the Cover
(2) Connect the primary power supply cable.
Connection to the Terminal
4-7
(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. Grounding wire must be 8.0 mm2 or larger.
The customer must prepare the ground wire.
Exclusive Grounding
• Don’t connect the grounding wire with the wires for the electric power source, the welder,
etc.
• Ground in accordance with all relevant governmental regulations when using metallic
ducts, metallic conduits, and wiring hedges to construct the cable.
4-8
(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
4-9
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.
Cables Passed Through the Holes Tightening the Screws for the Cable
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.
3. Connect the manipulator to the XRC.

Check the shape and size of the cable connector, the key fitting, and the position of the
pins of the manipulator. Push the cable connector into the manipulator side connector
firmly, and tighten securely.
4. Close the XRC door.
(1) Close the door gently.
(2) Rotate the door handle counterclockwise 90 degrees.
4-10
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
4-12
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.
Push the emergency stop button immediately if any problems occur.

The emergency stop button is located on the upper right side of XRC playback panel and
on the right side of the programming pendant.
5.1 Turning on the Main Power Supply
The main power supply is turned on when the main power supply switch on the front of the
XRC is turned to the "ON" position, and the initial diagnosis and the current position begin.
PP
ED ON
I
TR
OFF
T
SE
RE
EN
OP
5.1.1 Startup Diagnostics

The startup diagnostics are performed when the XRC main power is turned on, and the star-
tup display is shown on the programming pendant screen.
5-1
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.
5.2.1 During Play Mode

The worker’s safety is secure if the safety plug is turned on.
1. When the safety guard is closed, press [SERVO ON READY]

on the playback panel to turn on the servo power supply. This
button lights.
When the safety guard is open, the servo power supply cannot be turned on.
5-2
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. The servo power is turned on and [SERVO ON READY] on the

playback panel lights when the operator grips the deadman
switch.
Servo Power ON/OFF --- Deadman Switch
When the operator squeezes the deadman switch, the servo power turns ON. However, if
the operator squeezes the switch until a “click” is heard, the servo power will turn OFF.
When using the playback panel, programming pendant, or external signal to perform emer-
gency stop, the servo power on operation from the deadman switch is cancelled. When
turning the power back on, follow the previously listed instructions.
5-3
5.3 Turning the Power Off
5.3 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

• Pressing the emergency stop button on either the programming pen-
dant or the playback box will turn off servo power.
• The brake operates once the servo power supply is turned off, and the
manipulator can no longer operate.
• The emergency stop mode can be operated at any time.
5.3.2 Turning the Main Power Off

After turning off the servo power, turn off the main power.
When the main power switch on the front of XRC is turned off, the main
power is cut off.
PP
ED ON
I
TR
OFF
T
SE
RE
EN
OP
5-4
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.
• Set the teach lock before starting to teach.
Injury can occur if unauthorized personnel operate the playback panel during operation.
• Observe the following when teaching in the working envelope:
-View the manipulator from the front at all times.

-Follow the predetermined operating procedure.
-Always have an escape plan in mind in case the manipulator comes
Improper or unintentional manipulator movement can result in injury.
• Ensure no persons are present in the manipulator work area before:
-Turning on the power supply to XRC

-Moving the manipulator using the programming pendant
-Doing a check operation
-Performing automatic operation
Persons who enter the manipulator’s work area while the manipulator is in operation may
be injured if they come in contact with the manipulator.
Push the emergency stop button immediately if any problems occur.

The emergency stop button is located on the upper right of the playback panel of the
XRC and on the right side of the programming pendant.
6-1
• 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.
6-2
6.1 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.
6-3
6-4
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.
• Set the teach lock before starting to teach.
There is a danger of injury when unauthorized personnel operate the playback panel dur-
ing operation.
• Strictly observe the following when teaching in the working envelope:
-View the manipulator from the front at all times.

-Follow the predetermined operating procedure.
-Always have an escape plan in mind in case the manipulator comes
-Ensure that you have a safe place to retreat in the event of an emer-
gency.
Improper or unintentional manipulator operation can result in injury.
• Prior to performing the following operations, be sure that there is no

one within the working envelope of the manipulator, and be sure that
you are in a safe area from which to operate:
- When turning on the power supply to the XRC

-When moving the manipulator using the programming pendant
-When doing a check operation
-When performing automatic operation
Injury may result from contact with the manipulator if anyone carelessly enters the work-
ing envelope of the manipulator.
Push the emergency stop button at once if any problems occur.

The emergency stop button is located on the upper right of the playback panel of the XRC
and on the right side of the programming pendant.
7-1
• 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:

• Return the programming pendant to its specified position after use.
If the programming pendant is left carelessly on the floor, manipulator, or positioner etc.
the manipulator or a tool could collide with it during manipulator movement, possibly
causing injury and equipment damage.
7-2
7.1 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.
7.1.1 Operating Procedure
Operation
Select{ROBOT} Select {CURRENT POSITION}*1
Explanation
*1 The position display is shown.
Operation
Press the AXIS KEY Press {E. STOP]*2
Explanation
*1 Move each manipulator axis using the programming pendant axis key. Adjust each axis
to the position of 0 pulse. Make sure the manipulator servo power supply is off and that
the axis home position calibration is accurate.
7-3
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.
L-AXIS
(opposite side)
S-AXIS
Home positions for the UP6
Confirm whether the home position calibration mark (of each axis of the manipulator) are
accurately matched with each other.
The home position is correctly registered if home position mark for each axis is matched
accurately.
Contact Customer Service if you encounter any problems performing home position cali-
bration.
7-4
8 Final Notes
Refer to the manuals listed below for additional information in work involving robot operations
such as teaching and playback.
• Operator’s Manual For Beginners

Operating procedures are clarified for beginning users.
The operations are explained carefully in order.
• Operator’s Manual
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
• Concurrent I/O and Parameter Manual

Covers concurrent I/O and parameters
8-1
8-2
MOTOMAN
SETUP MANUAL
TOKYO OFFICE
New Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo 105-0022, Japan
Phone 81-3-5402-4511 Fax 81-3-5402-4580
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
MOTOMAN INC. TROY FACILITY
1050 S. Dorset, Troy, OH 45373, U.S.A.
Phone 1-937-440-2600 Fax 1-937-440-2626
MOTOMAN INC. COLUMBUS OFFICE
Dublin Tech Mart 5000 Blazer Memonal Parkway Dublin, OH 43017-3359, U.S.A.
Phone 1-614-718-4200 Fax 1-614-718-4222
YASKAWA ELECTRIC EUROPE GmbH
Am Kronberger Hang 2, 65824 Schwalbach,Germany.
Phone 49-6196-569-300 Fax 49-6196-888-301
Motoman Robotics AB
Box 504 S38525 Torsås, Sweden
Phone 46-486-48800 Fax 46-486-41410
Motoman Robotec GmbH
Kammerfeldstraβe1,85391 Allershausen, Germany
Phone 49-8166-900 Fax 49-8166-9039
YASKAWA ELECTRIC KOREA CORPORATION
Kfpa Bldg #1201, 35-4 Youido-dong, Yeongdungpo-Ku, Seoul 150-010, Korea
Phone 82-2-784-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park Singapore 556741, Singapore
Phone 65-282-3003 Fax 65-289-3003
YATEC ENGINEERING CORPORATION
Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road, Taipei, Taiwan
Phone 886-2-2563-0010 Fax 886-2-2567-4677
BEIJING OFFICE
Room No. 301 Office Building of Beijing Intemational Club, 21 Jianguomenwai Avenue, Beijing 100020, China
Phone 86-10-6532-1850 Fax 86-10-6532-1851
SHANGHAI OFFICE
27 Hui He Road Shanghai 200437 China
Phone 86-21-6553-6600 Fax 86-21-6531-4242
YASKAWA JASON (HK) COMPANY LIMITED
Rm. 2909-10, Hong Kong Plaza, 186-191 Connaught Road West, Hong Kong
Phone 852-2803-2385 Fax 852-2547-5773
TAIPEI OFFICE
Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan
Phone 886-2-2563-0010 Fax 886-2-2567-4677
BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD.
30 Xue Yuan Road, Haidian, B eijing P.R. China Post Code: 100083
Phone 86-10-6233-2782 Fax 86-10-6232-1536
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area,
Beijing 100076, P.R. China
Phone 86-10-6788-0551 Fax 86-10-6788-2878
YASKAWA ELECTRIC CORPORATION
YASKAWA
Specifications are subject to change without notice MANUAL NO. RE-TA-A503 1

for ongoing product modifications and improvements. C Printed in Japan August 1999 98-12
YASKAWA
MOTOMAN-CSL10
INSTRUCTIONS
YR-CSL10-A00 (570ST)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN-CSL10 INSTRUCTIONS
YASNAC XRC INSTRUCTIONS
YASNAC XRC OPERATOR’S MANUAL For BEGINNERS
Be sure to use the appropriate manual.
YASKAWA MANUAL NO. RE-MTO-A225 1

RE-MTO-A225
MANDATORY
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-CSL10.
• General items related to safety are listed in the Safety Manual Section
1: Safety. To ensure correct and safe operation, carefully read the Setup
Manual before reading this manual.
CAUTION


on the front cover.

uct’s warranty.
ii
RE-MTO-A225

YASNAC XRC.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.

WARNING could result in death or serious injury to personnel.

CAUTION could result in minor or moderate injury to personnel and dam-
practices.

MANDATORY heading.
PROHIBITED Must never be performed.
NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING”.
iii
RE-MTO-A225
WARNING
• Before operating the manipulator, check that servo power is turned OFF
when the emergency stop buttons on the playback panel or program-
When the servo power is turned OFF, the SERVO ON READY lamp on the
turned OFF.
the servo power ON.

TURN
teach a job.
the playback panel.

within the working envelope of the manipulator :

- Turning ON the YASNAC XRC power
tion. Always press an emergency stop button immediately if there are problems.The
iv
RE-MTO-A225
WARNING
• Install the safeguards.
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 XRC.
• Do not start the manipulator or even turn ON the power before it is

firmly anchored.
The manipulator may overturn and cause injury or damage.
• 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. (ex. DO NOT TURN THE POWER ON.)
• 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.
CAUTION
after use.
v
RE-MTO-A225
CAUTION
• 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.
• Sling applications and crane or forklift operations must be performed by

authorized personnel only.
• Avoid excessive vibration or shock during transporting.
The system consists of precision components, so failure to observe this caution may
adversely affect performance.
• Do not install or operate a manipulator that is damaged or lacking parts.
Failure to observe this caution may cause injury or damage.
• Before turning ON the power, check to be sure that the shipping bolts
(two hexagon socket head bolts M6×40 and jigs have been removed.
Failure to observe this caution may result in damage to the driving parts.
• Wiring must be performed by authorized or certified personnel.
• Maintenance and inspection must be performed by specified personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact your Yaskawa representative.
• The battery unit must be connected before removing detection connec-

tor when maintenance and inspection.
Failure to observe this caution may result in the loss of home position data.
vi
RE-MTO-A225

dant, and feeder cables.
In this manual, the equipment is designated as follows:
vii
RE-MTO-A225
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.
MOTOMAN WARNING WARNING

TYPE
PAYLOAD MASS
kg kg
ORDER NO. DATE
SERIAL NO.
YASKAWA ELECTRIC CORPORATION JAPAN
Moving parts may Do not enter
cause injury robot work area
viii
RE-MTO-A225
1 Receiving
1.1 Checking Package Contents . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Precautions when Unpacking . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Checking the Order Number . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 Transporting
2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Using the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.2 Using the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Shipping Bolts and Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3 Installation
3.1 Safeguard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . 3-2
3.2.1 When the Manipulator and Mounting Fixture are Installed on a
Common Installation Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.2.2 When the Manipulator is Mounted Directly on the Floor . . . . . .3-3
3.3 After Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Mounted Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.5 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
4 Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 Connection to the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.2 Connection to the XRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
5 Basic Specifications
5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Manipulator Clean Specifications . . . . . . . . . . . . . . . . . . 5-1
5.3 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Manipulator Base Dimensions . . . . . . . . . . . . . . . . . . . . . 5-3
5.5 Dimensions and Working Envelope . . . . . . . . . . . . . . . . 5-4
ix
RE-MTO-A225
6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7 System Application
7.1 Use Cables and Air Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8 MOTOMAN Construction
8.1 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9 Maintenance and Inspection

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-5
9.2.1 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.2 Grease Replenishment for U-axis Ball Screw, Linear Guide . . 9-7
Grease Replenishment (Refer to " Fig. 21 U-axis Ball Screw and
Linear Guide Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.2.3 Grease Replenishment for S-Axis Speed Reducer . . . . . . . . . 9-8
Grease Replenishment (Refer to " Fig. 22 S-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.2.4 Grease Replenishment for L-Axis Speed Reducer . . . . . . . . . . 9-9
Grease Replenishment (Refer to " Fig. 23 L-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.2.5 Grease Replenishment for R-Axis Speed Reducer . . . . . . . . 9-10
Grease Replenishment ( Refer to " Fig. 24 R-Axis Speed
Reducer Diagram ") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.2.6 Grease Replenishment for R-Axis Gears . . . . . . . . . . . . . . . . 9-11
Grease Replenishment(Refer to " Fig. 25 R-Axis Gears
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.2.7 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
10 Recommended Spare Parts
x
RE-MTO-A225
1.1 Checking Package Contents
1 Receiving
CAUTION
• 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.
1.1 Checking Package Contents
When the package arrives, check the contents for the following standard items (Any
additional options ordered should be checked as well.):
• Manipulator
• XRC
• Programming pendant
• Power supply cable between the XRC and the manipulator
1.2 Precautions when Unpacking
Unpack the equipment in a clean room. If in any place other than a clean room, unpack the
manipulator after removing dust with an air blower.
NOTE When operating the manipulator in an environmental clean room of a lower class, the
cleanliness class may be lower.
1-1
RE-MTO-A225
1.3 Checking the Order Number
1.3 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

SHOULD HAVE SAME ORDER NUMBER. Check that the manipulator
and the XRC have the same
ORDER. No. order number.
YASNAC XRC CSL10
ON
IP
TR
OFF
T
SE
RE
XS++ X
XS--
R-
R+
X
Y- Y+
L+
y
B- y
L- B+
Z-
U-
Z+
U+
z
T-
z
T+
7 8 9
4 5 6
1 2 3
0 . -
ORDER NO.
NJ1530
TYPE ERCR-
POWER SUPPLY
200/220V 50/60Hz 3PHASE KVA
SERIAL NO.
DATE P/N
MADE IN JAPAN NJ2063-1
(a) XRC(Front View) (b) Manipulator (Back-side View)
Fig. 1 Location of Order Number Labels
1-2
RE-MTO-A225
2.1 Transporting Method
2 Transporting
CAUTION
• Sling applications and crane or forklift operations must be performed by
authorized personnel only.
• Avoid excessive vibration or shock during transporting.
The system consists of precision components, so failure to observe this caution may
adversely affect performance.
2.1.1 Using the Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be
used. The manipulator should be lifted using wire rope threaded through attached eyebolts.
Be sure the manipulator is fixed with jigs before transporting, and lift it in the posture as shown
in " Fig. 2 Transporting Position ". Be sure to use the urethane washers to protect the paint.
S-arm
A Shipping bolts and jigs
Hexagon socket head cap bolts M6 × 15mm
(4 bolts) (anti-corrosive)
Spring washers
(4 washers) (anti-corrosive)
Plate
Urethane washers (4 washers)
Details of Section A
Fig. 2 Transporting Position
2.1.2 Using the Forklift

When using a forklift, the manipulator on a pallet should be fixed with shipping bolts and jigs
2-1
RE-MTO-A225
as shown in " Fig. 3 When Using the Forklift ". Insert claws under the pallet and lift it.
The pallet should be strong enough to support the manipulator. Handling of the manipulator
should be performed slowly to avoid overturning or slipping.
Pallet
Hexagon socket head cap bolts M16
Forklift claw entry (4 bolts)
Fig. 3 When Using the Forklift
• Check that the eyebolts are securely fastened.

NOTE • The weight of the manipulator is approximately Approx.120kg including the shipping
bolts and jigs. Use a wire rope strong enough to withstand the weight.
• Attached eyebolts are designed to support the manipulator weight. Do not use them for
anything other than transporting the manipulator.
• Mount the shipping bolts and jigs for transporting the manipulator.
• Avoid external force on the arm or motor unit when transporting, use caution when using
transporting equipment other than a crane or forklift, as injury may occur.
2-2
RE-MTO-A225
2.2 Shipping Bolts and Jigs
2.2 Shipping Bolts and Jigs
The manipulator is provided with shipping bolts and jigs as shown in " Fig. 4 Shipping Bolts
and Jigs ".
• The jigs are mounted with hexagon socket head cap bolts M6 (4 bolts).
• Be sure to use the urethane washer to protect the paint.
Before turning ON the power, check to be sure that the shipping bolts and jigs have been
NOTE removed. For the removing method, refer to “3 INSTALLATION”. The shipping bolts and
jigs then must be stored for future use, in the event that the robot must be moved again.
S-arm
Shipping bolts and jigs
A
Spring washers
(4 washers) (anti-corrosive)
Plate
Urethane washers (4 washers)
Details of Section A
Fig. 4 Shipping Bolts and Jigs
2-3
RE-MTO-A225
3 Installation
WARNING
• Install the safeguards.
• Install the manipulator in a location where the fully extended arm and
tool will not reach the wall, safeguards, or the XRC.
• Do not start the manipulator or even turn ON the power before it is

firmly anchored.
The manipulator may overturn and cause injury or damage.
CAUTION
• Do not install or operate a manipulator that is damaged or lacking parts.
Failure to observe this caution may cause injury or damage.
• Before turning ON the power, check to be sure that the shipping bolts
(hexagon socket head cap bolts M6 × 15mm (4 bolts) and jigs have been
removed.
Failure to observe this caution may result in damage to the driving parts.
3-1
RE-MTO-A225
3.1 Safeguard Installation
3.1 Safeguard Installation
To insure safety, be sure to install safeguards. They prevent unforeseen accidents with
personnel 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. The means and degree of
safeguarding, including any redundancies, shall correspond directly to the type and level of
hazard presented by the robot system consistent with the robot application. Safeguarding may
include but not be limited to safeguarding devices, barriers, interlock barriers, perimeter
guarding, awareness barriers, and awareness signals.
3.2 Mounting Procedures for Manipulator Base
The manipulator should be firmly mounted on a base or foundation strong enough to support
the manipulator and jigs, and withstand repulsion forces during acceleration and deceleration.
During installation, if the flatness is not right, the manipulator shape may change and its
functional ability may be compromised. The flatness for installation must be kept at 0.5mm or
less. Mount the manipulator base in either of the following ways: "3.2.1 When the Manipulator
and Mounting Fixture are Installed on a Common Installation Base" or "3.2.2 When the
Manipulator is Mounted Directly on the Floor".
3-2
RE-MTO-A225
3.2 Mounting Procedures for Manipulator Base
3.2.1 When the Manipulator and Mounting Fixture are

Installed on a Common Installation Base
The common installation base should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. The thickness of the common installation base is 30mm
or more is recommended. There are 4 mounting holes in the manipulator base. Affix the
manipulator securely with hexagon socket head cap bolts M16 (50 mm long recommended).
Tighten the bolts securely so that they will not work loose during operation. See " Fig. 5
Mounting on the Common Installation Base " for the method. The flatness for the manipulator
installation face must be 0.5 mm or less.
(provided at factory)
Disc spring 2H-16 (anti-corrosive)
Washer WSSM25-16-5
Manipulator base
Common installation base
Fig. 5 Mounting on the Common Installation Base
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 a
rough standard, when there is a concrete thickness (floor) of 150mm or more, the manipulator
base can be fixed directly to the floor with M16 anchor bolts. Before mounting the manipulator,
however, check that the floor is level and that all cracks, etc. are repaired. A non-concrete
floor or a floor less than 150mm thick is insufficient for mounting, even if the floor is concrete.
The flatness for the manipulator installation face must be 0.5 mm or less.
Grating
Anchor bolts M16 (4 bolts)
Concrete floor
More than
150mm
Fig. 6 Direct Mounting on the Floor
3-3
RE-MTO-A225
3.3 After Installation
3.3 After Installation
After installing the manipulator, remove the eyebolts M12 and the spacers, then mount the cap
bolts as shown in " Fig. 7 Cap Bolt Mounting ".
Eyebolts M12 (2 eyebolts)
Spacers (2 spacers)
Cap bolts (2 bolts)
Note: Operating the manipulator with the eyebolts M12 on results in interference
between the eyebolts and the manipulator, causing a failure.
Fig. 7 Cap Bolt Mounting
NOTE Operating the manipulator with the eyebolts on may cause a failure. Be sure to replace
the eyebolts M12 with the cap bolts.
3.4 Mounted Type
The MOTOMAN-CSL10 is floor-mounted type.
3.5 Location
The MOTOMAN-CSL10 is used in the clean room.

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, non-condensing)
• Free from corrosive gases or liquid, or explosive gases
• Free from water
• Free from excessive impact or vibration (less than 4.9m/s2 (0.5G))
• Free from large electrical noise
• The flatness for installation is 0.5mm or less.
3-4
RE-MTO-A225
4.1 Grounding
4 Wiring
WARNING
• Ground resistance must be 100 Ω or less.
• Before wiring, make sure to turn the primary power supply OFF, and put
up a warning sign. (ex. DO NOT TURN THE POWER ON.)
CAUTION
• Wiring must be performed by authorized or certified personnel.
4.1 Grounding
Follow the local regulations for ground line size. A line of 5.5mm2 or more is recommended.
Refer to “Fig. 8 Grounding Method” to connect the ground line directly to the manipulator.
• Do not use this line in common with other ground lines or grounding electrodes for other
NOTE electric power, motor power, welding devices, etc.
• Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
ground in accordance with Electric Equipment Technical Standards.
4-1
RE-MTO-A225
4.2 Cable Connection
Bolt M8 (for grounding)
provided at factory
View A
5.5mm or more
Fig. 8 Grounding Method
There are two cables for the power supply; a signal cable for detection (1BC) and a power
cable (2BC). Connect these cables to the manipulator base connectors and the XRC,
respectively. For the connection method, refer to " Fig. 10 (a) Power Supply Cable
Connection to the Manipulator " and " Fig. 10 (b) Power Supply Cable Connection to the XRC ".
4.2.1 Connection to the Manipulator

Before connecting the cables to the manipulator, verify the numbers on both cables and the
manipulator base connectors. When connecting, adjust the cable connector positions to the
main key positions of the manipulator, and insert cables in the order of 2BC and 1BC, and
then push down the lever until hearing a “click”. To fix the cables, tighten the hexagon socket
head cap bolts M3 (attached to the product).
4.2.2 Connection to the XRC

Remove the cover on the XRC side. Pass the signal cable for detection (1BC) and the power
cable (2BC), through the opening for the cables, and then fasten bolts on the opening.
Connect each cable to the board. Be sure to verify the numbers on both the cable and board
connectors before connecting, and to fasten the bolts on connectors to prevent cables from
loosening.
4-2
RE-MTO-A225
Connection to the XRC Connection to the Manipulator
A
WACA01-CNPC123
1BC
1 BC
WACA01-CNPC456 Signal cable
SHOCK
E E
Hexagon socket head cap bolt M3
XIU01-CN25 24VU SHOCK Connector
E E 2BC
X1U01-CN29
Power cable
1PWM-1-CN1
Manipulator base
1PWM-1-CN2
1PWM-1-CN3
1PWM-1-CN4
Fig. 9 Power Supply Cables
1BC 2BC
A B
3BC
1BC 2BC
3BC
Fig. 10 (a) Power Supply Cable Connection to the Manipulator
4-3
RE-MTO-A225
Power Cable
Signal Cable
Connector No.
Connector No. XIU01-CN29
XIU01-CN25
Signal Cable
Grounding plate
for signal and power cable Connector No.
Terminal No.: E WRCA01-CNPG456 (upper)
WRCA01-CNPG123 (lower)
Power Cable
Connector No. (from the left)

Tighten the screws with
IPWM-1-CN1
screw driver(+).
IPWM-1-CN2
IPWM-1-CN3
IPWM-1-CN4
IPWM-1-CN5
IPWM-1-CN6
Fig. 10 (b) Power Supply Cable Connection to the XRC
4-4
RE-MTO-A225
5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table. 1 Basic Specifications*1
Type YR-CSL10-A00 YR-CSL10-A10 YR-CSL10-A20
Operation Mode Horizontally Articulated
Degree of Freedom 4
Payload 10kg
Repetitive Positioning Accuracy*2 ±0.1mm
U-Axis (upper/lower) 570mm 460mm 650mm
Motion S-Axis (first arm) ±175°

Range L-Axis (second arm) ±175°
R-Axis (rotation) ±300°
U-Axis 400mm/s
Maximum S-Axis 3.05 rad/s, 175°/s

Speed L-Axis 3.49 rad/s, 200°/s
R-Axis 4.36 rad/s, 250°/s
R-Axis Allowable
R-Axis 2.1kg•m2
Inertia (GD2/4)
Mass Approx. 110kg Approx. 98kg Approx. 120kg

Temperature 0° to 45C°
Humidity 20 to 80% RH (non-condensing)

Ambient Vibration Less than 4.9m/s2 (0.5G)
Conditions
• Free from corrosive gasses or liquids, or explosive gasses
Others • Free from water
• Free from excessive electrical noise
Power Capacity 1.5kVA
*1 SI units are used in this table. However, gravitational unit is used in ().
*2 Conformed to ISO9283
5.2 Manipulator Clean Specifications
The MOTOMAN-CSL10 has the FEDERAL STANDARD 209E, cleanliness class 10*1.
*1 Under the condition that the manipulator is in the downflow of 0.4 m/s or more (verti-
cally rectified state) and exhausted (exhausted amount of 3.3 m3/min. and more)
inside.
The parts higher than the wrist flange are applicable.
5-1
RE-MTO-A225
5.3 Part Names and Working Axes
5.3 Part Names and Working Axes
Wrist flange
Wrist R- R+ L- L+
U+
U- Second arm
(L-arm)
S- S+
First arm
(S-arm)
Base
Fig. 11 Part Names and Working Axes
5-2
RE-MTO-A225
5.4 Manipulator Base Dimensions
5.4 Manipulator Base Dimensions
A
140 ±0.1
Dimensions in mm
198 ±0.1
416
380
198 ±0.1
140 ±0.1 Tapped holes M12 (4 holes)
17 dia. holes (4 holes)
320 10 dia. holes (2 holes)
0.015
0
375
Base Dimensions (View A)
Fig. 12 Manipulator Base Dimensions
5-3
RE-MTO-A225
5.5 Dimensions and Working Envelope
175
9
83
R
Tapped holes M5 × 10mm 175° 20
R4
4
D7
(P1.0) (6 holes)
C.
(equally divided into 6)
P. P.C
.D60
175°
Point P
5 dia. holes × 7mm
+0.012
0 Point P working
(2 holes) envelope
175°
45°
420
Wrist Flange Home Position
570ST
R-axis L-axis
Point P
U-axis
1520
S-axis
950
Fig. 13 (a) Dimesions and Working Envelope (570ST)
5-4
RE-MTO-A225
175°
9
83
R
175° 20
Tapped holes M5 × 10mm R4
4
D7
(P1.0) (6 holes)
C.
P.
.D60
P.C 175
Point P
+0.012
5 dia. holes × 7mm
0 Point P working
(2 holes) envelope
175°
45°
420
460st
Point P
R-axis L-axis
U-axis
1300
S-axis
840
Fig. 13 (b) Dimesions and Working Envelope (460ST)
5-5
RE-MTO-A225
175
9
83
R
Tapped holes M5 × 10mm
175° 20
4
(P1.0) (6 holes) R4
D7
C.
P.
.D60
P.C
175°
Point P
5 dia. holes × 7mm
+0.012
0
(2 holes) Point P working
envelope
175°
45°
420
650st
Point P
R-axis L-axis
U-axis
1680
S-axis
1030
Fig. 13 (c) Dimesions and Working Envelope (650ST)
5-6
RE-MTO-A225
6.1 Wrist Flange
6 Allowable Load for Wrist Axis and Wrist

Flange
6.1 Wrist Flange
The wrist flange dimensions are shown in " Fig. 14 Wrist Flange ". The hole positions of the 5
0 dia. holes (2 holes) in " Fig. 14 Wrist Flange " are the same as the “Wrist Flange Home
+0.012
Position” in “Fig.13 Dimensions and Working Envelope”. Fitting depth of inside and outside
fittings must be 6mm or less.
6 Tapped holes M5 (P1.0)
(6 holes)
4
D7
C.
P.
.D60
20 dia. hollow hole
P.C
35 dia. hole
85 dia. hole
-0.019
+0.025
0
0
+0.012
5 dia. holes × 7mm
0
(2 holes)
45°
6
Fig. 14 Wrist Flange
NOTE Dust may be generated from the 20 dia. hollow hole. Therefore, it should be covered with
the units such as tool to be mounted on the wrist flange.
6-1
RE-MTO-A225
7.1 Use Cables and Air Duct
7 System Application
User cables (0.2 mm2, 12 cables) are used in the manipulator for the drives of the peripheral
devices mounted on the upper arm as shown in " Fig. 15 User Cables and Air Duct ".
The connector pins (1 to 12) are assigned as shown in " Fig. 16 Detailed Drawing of
Connector Pin Numbers ". Wiring must be performed by user.
Air supply inlets are in two locations on the upper arm. The air supply holes are tapped holes
PT1/8 with cover plugs. The followings are the conditions required.
• The allowable current for cables: 2.5 A or less for each cable
• The maximum pressure for the air hose: 490 kPa (5 kgf/cm2) or less
20 dia. hollow hole

A Reserved cable connector: HR10-10R-12S
The other HR10A-10P-12P
will not be supplied.
A B
A'
Air supply inlets
Section A-A' Tapped holes PT1/8
with cover plugs
Robot in-air absorption port (outer dia. 32)

(Prepare an air duct with an inner dia. 32
for robot in-air absorption.)
(Air absorption amount: 1.2m3 /min)
Air inlet
Tapped holes PT3/8
with cover plugs
1BC 2BC
A B
Reserved cable connector: JL05-2A20-29PC
1BC 2BC
3BC
The other JL05-6A20-29S
3BC
will not be supplied.
Fig. 15 User Cables and Air Duct
7-1
RE-MTO-A225
1
2
3
4
1 5
2 Key position 6 Key position
3 7
4 Used pins 8 1
3
Used pins 9 1 number 6 5 2
5 9
number 8 2 8 7 4
6 10 10
7 7 3 11 10 12 11 9
12 11
8 6 4 12 14 13
5 16 15
9 13 Not used
10 14 Not used
11 15 Not used
12 16 Not used
Detailed Drawing of Connector Pin No. Detailed Drawing of Connector Pin No.
(R-Axis Section) (Base Section)
Fig. 16 Detailed Drawing of Connector Pin Numbers
7-2
RE-MTO-A225
8.1 Internal Connections
8 MOTOMAN Construction
8.1 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
Connectors ". “Figs. 18 (a) and 18 (b) Internal Connection Diagram” show the internal
connections between the inside of the manipulator and the XRC.
No.15 to 17
No.5, No6, No.11, No12
No.3, No4, No.10
2BC 3BC (for user cable)
1BC
No.1, No2, No.9
Fig. 17 Location and Numbers of Connectors
Table. 2 List of Connector Types
Name Type of Connector
Connector for user cable on base JL05-2A20-29PC

(JL05-6A20-29S: Optional)
Connector for user cable on U-arm HR10A-10R-12S

(HR10A-10P-12P: Optional)
8-1
YASNAC XRC
1BC(6´ 6)
BAT
No.1CN
WRCA01 CN3- 1
OBT
CNPG123 8 DATA+3 1CN-1 DATA+3
6 P CN3-2 DATA-3 P -2 DATA-3
-3 BAT
P -4 OBT
3 PG U-axis
29 P CN3-3 +5-3 No.2CN
5
P CN3-4 0V-3 P 2CN-1 +5V
-2 0V
31
-3 FG3
BAT
No. 3CN OBT
24 CN1- 1 DATA+1 3CN-1 DATA+1
-3 BAT
P -4 OBT
19 PG S-axis
45 P CN1-3 +5-1 No. 4CN
21
P CN1-4 0V-1 4CN-1 +5V
P -2 0V
47 P
-3 FG1
BAT
No. 5CN OBT
16 CN2- 1 DATA+2 5CN-1 DATA+2
-3 BAT
P -4 OBT
11 PG L-axis
37 P CN2-3 +5-2 No. 6CN
13
P CN2-4 0V-2 6CN-1 +5V
P -2 0V
39 CN2-5 FG2
FG P -3 FG2
BAT
No. 7CN No.15CN OBT
WRCA01 CN4- 1 DATA+4 7CN-1 DATA+4 DATA+4 15CN-1 DATA+4
CNPG456 24 CN4-2
22 P DATA-4 P -2 DATA-4 P DATA-4 P -2 DATA-4
-3 BAT BAT -3 BAT R-axis
-4 OBT P OBT P -4 OBT
19 PG
45 P CN4-3 +5-4 No.8CN No.16CN
21
P CN4-4 0V-4 P 8CN-1 +5V +5V 16CN-1 +5V
-2 0V P 0V P -2 0V
47 -3 FG4 FG4 -3 FG4
CN5- 1
Terminal A 2-3.5 P CN5-2
2-3.5
Battery
BAT1
11 P CN5-3
BAT1
37 P P OBT1
13
P CN5-4 0BT1
39
BAT1
P
Battery 0BT1
BAT4
8 CN6- 1 BAT4
CN6-2 P P OBT4
6 0BT4
BAT4
3 P
P CN6-3 0BT4
29 P CN6-4
5
31 CN6-5
FG FG
XIU01-CN25
-A1
-B1 CN2-6
178214-1 -D1 CN3-6
-A3 CN4-6
(AMP) -C1
-D2 CN5-6
-C3 CN6-6
-D3 E
1.25-4 E
Fig. 18 (a) Internal Connection Diagram

8-2
E
Bace
E E
2BC(6X6)
1.25-4 E E
3PWM-1-CN1 No.9CN
-2 CN 3- 1 MU3 9CN-1 MU3
-3 CN 3-2 MV3 -2 MV3
SM U-aixs
-4 CN 3-3 MW3 -3 MW3
-1 CN 3-4 ME3 -4 ME3
CN 3-5 BA3 -5 BA3
CN 3-6 BB3 -6 BB3 YB
1PWM-1-CN1 No.10CN
-2 CN1- 1 MU1 10CN-1 MU1
-3 CN1-2 MV1 -2 MV1
SM S-axis
-4 CN1-3 MW1 -3 MW1
-1 CN1-4 ME1 -4 ME1
CN1-5 BA1 -5 BA1
-6 BB1 YB
2PWM-1-CN1 No.11CN
-2 CN2- 1 MU2 11CN-1 MU2
-3 CN2-2 MV2 -2 MV2
SM L-axis
-4 CN2-3 MW2 -3 MW2
-1 CN2-4 ME2 -4 ME2
CN2-5 BA2 -5 BA2
-6 BB2 YB
4PWM-1-CN1 No.12CN No.17CN R-axis
-2 CN4- 1 MU4 12CN-1 MU4 MU4 17CN-1 MU4
-3 CN4-2 MV4 -2 MV4 MV4 -2 MV4
SM
-4 CN4-3 MW4 -3 MW4 MW4 -3 MW4
-1 CN4-4 ME4 -4 ME4 ME4 -4 ME4
CN4-5 BA4 -5 BA4 BA4 -5 BA4
CN4-6 BB4 -6 BB4 BB4 -6 BB4 YB
Terminal A
2-4 40XT-AC1 CN5- 1
2-4 40XT-AC2 CN5-2
CN5-3
CN5-4
CN6- 1
CN6-2
CN6-3
CN6-4
XIU01-CN29
-D1
-A1
-B1 3BC(20-29)
-C1 E
-B2 No.13CN
-A2 1 13CN-1 1
3BC-1 2 P -2 P P 2 3BC-1
-2 -2
3 -3 3
-3 -3
4 P -4 P P 4
-4 -4
5 -5 5
-5 -5
6 P -6 P P 6
-6 -6
PE
No.14CN
-7 7
8 P
14CN-1
-2 P P
7
8
-7 Reserved cable
-8 -8
9 -3 9
-9 -9
10 P -4 P P 10
-10 -10
11 -5 11
-11 -11
12 P -6 P P 12
-12 -12
Fig. 18 (b) Internal Connection Diagram

8-3
RE-MTO-A225
9.1 Inspection Schedule
9 Maintenance and Inspection
WARNING
• 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.
CAUTION
• Maintenance and inspection must be performed by specified personnel.
• For disassembly or repair, contact your Yaskawa representative.
• The battery unit must be connected before removing detection connec-

tor when maintenance and inspection.
Failure to observe this caution may result in the loss of home position data.
Proper inspections are essential not only to assure that the mechanism will be able to function
for a long period, but also to prevent malfunctions and assure safe operation. Inspection
intervals are displayed in the levels shown in “Table 3 Inspection Items”. Conduct periodical
inspections according to the inspection schedule in “Table 3 Inspection Items”.
In “Table 3 Inspection Items”, the inspection items are classified into three types of operation:
operations which can be performed by personnel authorized of the user, operations which can
be performed by personnel being trained, and operations which can be performed by service
company personnel. Only specified personnel are to do inspection work.
NOTE The inspection interval must be based on the servo power supply on time.
9-1
RE-MTO-A225
Table. 3 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

18000 24000 Specified Service
Daily H H H Person
Licensee
Company
H H
Cycle Cycle Cycle
Check tram mark

accordance and
1 Tram mark Visual
damage at the home
position.
Working area Check for damage

2 and Visual and outside cracks.
manipulator
Base mount- Spanner Tighten loose bolts.

3 Wrench Replace if necessary.
ing bolts
Cover mount- Screw- Tighten loose bolts.

4 driver, Replace if necessary.
ing screws Wrench
Base connec- Check for loose con-

5 Manual nectors.
tors
USLR-axes Check for belt

6 Manual
timing belt tension and wear.*2
Check for conduc-

tion between the
main connecter of
base and intermedi-
Visual, ate connector with
USLR-axes tester manually shaking the
7 internal cable. Check for
cables wear of protective
spring.*1
Replace.*2
Check for conduc-

Visual, tion between termi-
Multi- nals and wear of
LR-axes inter- meter
8 protective spring.*1
nal cables
Replace.*2
Check for conduc-

Visual, tion between termi-
Multi- nals and wear of
R-axis inter- meter
9 protective spring.*1
nal cables
Replace.*2
Replace the battery

Battery in when the battery
10 alarm occurs or the
manipulator manipulator drove for
36000H.
Check for malfunc-

tion. (Replace if nec-
U-axis ball Grease essary.) Supply
11 Gun
screw grease*3 (12000H
cycle). See Par.9.2.2.
9-2
RE-MTO-A225
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

18000 24000 Specified Service
Daily H H H Person
Licensee
Company
H H
Cycle Cycle Cycle
Check for malfunc-

U-axis linear Grease essary.) Supply
12 Gun
guide grease*3 (12000H
cycle). See Par.9.2.2.
U-axis ball Check for malfunc-

Screw- tion. (Replace if nec-
screw sup- essary.) Supply
13 driver,
porting bear- Wrench grease*3 (1200H
ing unit cycle).
Check for malfunc-

S-axis speed Grease essary.) Supply
14
reducer Gun grease*3 (12000H
cycle). See Par.
9.2.3.
Check for malfunc-

L-axis speed Grease essary.) Supply
15
cycle). See Par.
9.2.4.
Check for malfunc-

R-axis speed Grease essary.) Supply
16
cycle). See Par.
9.2.5.
Check for malfunc-

Grease essary.) Supply
17 R-axis gears Gun grease*3 (12000H
cycle). See Par.
9.2.6.
18 Overhaul
*1 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the
motor side for each axis, and then remove connectors on detecter side for each axis from the motor. Other-
wise, the home position may be lost. (Refer to 9.2.8.)
*2 The S-, L-, and U-axes internal cables and the S-, L-, U-, and R-axes timing belts to be replaced at 24000H
inspection.
*3 For the grease, refer to Table 4.
*4 Inspection No. correspond to the numbers in Fig.19.
9-3
RE-MTO-A225
1
R-axis
1 9 1
S-axis
17 6 15
L-axis
R-axis
16
1
U-axis
6
L-axis
8
7
14 12 11
6
S-axis
5
10 6
U-axis
13
Fig. 18 Inspection Parts and Inspection Numbers
Table. 4 Inspection Parts and Grease Used
No. Grease Used Inspected Parts
11, 12 CG2 grease U-axis ball screw

U-axis linear guide
14, 15 Molywhite RE No.00 S-, L-axes speed reducers
16, 17 Harmonic grease R-axis speed reducer, gears

SK-1A
The numbers in the above table correspond to the numbers in " Table. 3 Inspection Items ".
9-4
RE-MTO-A225
9.2 Notes on Maintenance Procedures
9.2.1 Battery Replacement

If a battery alarm occurs in the XRC, replace the battery according to the following procedure:
Sems round head screws M4 (6 screws)

Clamp TA1-S8
Insulok'tie T50R
Battery set
Sems round head screws M4

(6 screws)
Clamp TA1-S8
Insulok'tie T50R
1BC 2BC
Battery set
3BC
1BC 2BC
Connector base
3BC
Fig. 19 Battery Location
9-5
RE-MTO-A225
Battery for U,S-axes

See step 6 below before replacement
To internal
cables See step 7 below
a: Insertion-type pin terminal (male)
0BT1 a b 0BT1 b: Insertion-type pin terminal (female)
BAT1 b a BAT1
b 0BT1
0BT1 a
a BAT1
BAT1 b
See step 4 below Battery for L,R-axes

See step 6 below before replacement
See step 7 below

See step 5 below New battery
0BT4 a b 0BT4
BAT4 b a BAT4
0BT4 a b 0BT4
BAT4 b a BAT4
See step 4 below
Fig. 20 Battery Connection
1. Turn the XRC main power supply OFF.

2. Remove the connector base.
3. Remove the battery mounting screw on the connector base.
4. Remove the plastic tape (insulation tape) protecting the connection part of the battery
in the manipulator.
5. Connect the new battery.
6. Remove the old battery and the washer.
NOTE Remove the old battery after connecting the new one so that the encoder absolute data
does not disappear.
7. Protect the connection part of the battery in the manipulator with plastic tape (insulation
tape).
8. Mount the battery and the washer with the screw, and then mount the connector base.
9-6
RE-MTO-A225
9.2.2 Grease Replenishment for U-axis Ball Screw, Linear

Guide
Note: This grease inlet is for the

S-axis speed reducer.
U BI : Grese inlet
Plug G nipple A-PT1/8
Grease supply hole cover
U-axis ball screw
U-axis linear guide
Fig. 21 U-axis Ball Screw and Linear Guide Diagram
Grease Replenishment (Refer to " Fig. 21 U-axis Ball Screw and

Linear Guide Diagram ".)
1. Remove the M4 mounting bolt for the grease supply hole cover in the manipulator side
face, and remove the cover.
2. Move the U-axis to a position where the G nipple A-PT 1/8 in the UBI grease inlet can
be seen.
3. Inject the grease into the G nipple A-PT1/8 in the UBI grease inlet .
Grease type: CG2 grease

Amount of grease: Approx. 20 cc
(Approx. 30 cc for 1st supply)
The amount of grease above includes grease in the ball
screw and linear guide due to centralized lubrication.
9-7
RE-MTO-A225
• Since the lubrication of the ball screw and the linear guide is centralized, grease can be
NOTE injected from one grease inlet to the ball screw or slide block.
• Grease cannot be discharged from the ball screw and the linear guide. Do not inject too
much grease.
• Do not inject the CG2 grease into the SI grease inlet. Injecting the incorrect type of
grease may cause product failure.
9.2.3 Grease Replenishment for S-Axis Speed Reducer
S 0 : Grease exhaust port

Hexagon socket head plug PT1/8
SI : Grase inlet
Plug G nipple A-PT1/8
Note: This grease inlet is for the

ball screw and linear guide.
S-axis speed reducer
Grease supply hole cover
Fig. 22 S-Axis Speed Reducer Diagram
Grease Replenishment (Refer to " Fig. 22 S-Axis Speed Reducer

Diagram ".)
1. Remove the hexagon socket head plug PT1/8 in the So exhaust port.
2. Remove the M4 mounting bolt for the grease supply hole cover in the manipulator side
face, and remove the cover.
3. Move the U-axis to a position where the G nipple A-PT 1/8 in the SI grease inlet can be
seen.
4. Inject the grease into the G nipple A-PT 1/8 in the SI grease inlet.
Grease type: Molywhite RE No.00

Amount of grease: Approx. 400cc
9-8
RE-MTO-A225
5. The grease replenishment is completed when new grease appears in the So exhaust
port. The new grease can be distinguished from the old grease by color.
6. Move the S-axis for a few minutes to discharge the excess grease.
7. Wipe the So exhaust port with a cloth and reinstall the hexagon socket head plug PT1/
8 on the So exhaust port after degreasing the tapped hole PT1/8 in the So exhaust
port. Spread the sealing agent (Three Bond 1211) on the screw section of the hexagon
socket head plug PT1/8.
• The grease injection with the hexagon socket head plug PT1/8 on the exhaust port
NOTE increases the internal pressure to cause a failure. Be sure to remove the hexagon socket
head plug PT1/8.
• Do not inject the Molywhite RE No.00 into the UBI grease inlet. Injiecting the incorrect
type of grease may cause product failure.
9.2.4 Grease Replenishment for L-Axis Speed Reducer
L-axis speed reducer
L 0: Grease exhaust port

L I : Grease inlet
Fig. 23 L-Axis Speed Reducer Diagram
Grease Replenishment (Refer to " Fig. 23 L-Axis Speed Reducer

Diagram ".)
1. Remove the hexagon socket head plug PT1/8 in the Lo exhaust port.
2. Replace the hexagon socket head plug PT1/8 in the LI grease inlet with the G nipple A-
PT1/8, and inject the grease.
Grease type: Molywhite RE No.00

3. The grease replenishment is completed when new grease appears in the So exhaust
port. The new grease can be distinguished from the old grease by color.
9-9
RE-MTO-A225
4. Remove the G nipple A-PT1/8 in the LI grease inlet, and reinstall the hexagon socket
head plug PT1/8 on the LI grease inlet after degreasing the tapped hole PT1/8 in the LI
grease inlet. Spread the sealing agent (Three Bond 1211) on the screw section of the
hexagon socket head plug PT1/8.
5. Move the L-axis for a few minutes to discharge the excess grease.
6. Wipe the Lo exhaust port with a cloth and reinstall the hexagon socket head plug PT1/
8 on the Lo exhaust port after degreasing the tapped hole PT1/8 in the Lo exhaust port.
Spread the sealing agent (Three Bond 1211) on the screw section of the hexagon
socket head plug PT1/8.
The grease injection with the hexagon socket head plug PT1/8 on the exhaust port
NOTE increases the internal pressure to cause a failure. Be sure to remove the hexagon socket
head plug PT1/8.
9.2.5 Grease Replenishment for R-Axis Speed Reducer
R0 : Air flow
R1 : Grease inlet
Fig. 24 R-Axis Speed Reducer Diagram
Grease Replenishment ( Refer to " Fig. 24 R-Axis Speed Reducer

Diagram ")
1. Remove the hexagon socket head plug PT1/8 in the RO air flow.
2. Replace the hexagon socket head plug PT1/8 in the RI grease inlet with the G nipple A-
PT1/8, and inject the grease.
Grease type: Harmonic grease SK-1A

3. Remove the G nipple A-PT1/8 in the RI grease inlet, and reinstall the hexagon socket
head plug PT1/8 on the RI grease inlet after degreasing the tapped hole PT1/8 in the
RI grease inlet. Spread the sealing agent (Three Bond 1211) on the screw section of
the hexagon socket head plug PT1/8.
9-10
RE-MTO-A225
4. Reinstall the hexagon socket head plug PT1/8 on the Ro air flow. Spread the sealing
agent (Three Bond 1211) on the screw section of the hexagon socket head plug PT1/8.
The grease injection with the hexagon socket head plug PT1/8 on the air flow increases
NOTE the internal pressure to cause a failure. Be sure to remove the hexagon socket head plug
PT1/8.
9.2.6 Grease Replenishment for R-Axis Gears
RGO: Air flow

RGI : Grease inlet

View A
R-axis gears
Fig. 25 R-Axis Gears Diagram
Grease Replenishment(Refer to " Fig. 25 R-Axis Gears Diagram ".)
1. Remove the hexagon socket head plug PT1/8 in the RGO air flow.
2. Replace the hexagon socket head plug PT1/8 in the RGI grease inlet with the G nipple
A-PT1/8, and inject the grease.
Grease type: Harmonic grease SK-1A

(Approx. 10cc for 1st supply)
3. Remove the G nipple A-PT1/8 in the RGI grease inlet, and reinstall the hexagon socket
head plug PT1/8 on the RGI grease inlet after degreasing the tapped hole PT1/8 in the
RGI grease inlet. Spread the sealing agent (Three Bond 1211) on the screw section of
the hexagon socket head plug PT1/8.
4. Reinstall the hexagon socket head plug PT1/8 on the RGO air flow. Spread the sealing
agent (Three Bond 1211) on the screw section of the hexagon socket head plug PT1/8.
9-11
RE-MTO-A225
The grease injection with the hexagon socket head plug PT1/8 on the air flow increases
NOTE the internal pressure to cause a failure. Be sure to remove the hexagon socket head plug
PT1/8.
9.2.7 Notes for Maintenance

Refer to the following diagram to connect the battery before removing the detector connectors
(with caution labels).
Detector
Motor
Motor cables, etc.
Internal cables Power connector
b 0BT4
0BT a a BAT4
BAT b
Detector connector Battery

a: Insertion-type pin terminal (male)
Caution lavel b: Insertion-type pin terminal (female)
Connection Status Diagram
0BT a b 0BT4
BAT b a BAT4
WARNING
Connect Battery to encoder
to save the data before
removing connector
Fig. 26 Encoder Connector Diagram
9-12
RE-MTO-A225
10 Recommended Spare Parts
It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOMAN-CSL10. The spare parts list for the MOTOMAN-CSL10 is shown below.
Product performance can not be guaranteed when using spare parts from any company other
than Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation
• Rank C: Drive Unit
NOTE To replace parts in Rank B or Rank C, contact your Yaskawa representative.
Table 5 Spare Parts for the MOTOMAN-CSL10
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
Grease Molywhite Yaskawa

A 1 RE No. 00 Electric 16kg -
Corporation
Grease Harmonic grease Harmonic Drive

A 2 SK-1A Systems Co., 2.5kg -
Ltd.
A 3 Grease CG2 grease IKO Co., Ltd. 120g -
Battery Unit HW9470917-A Yaskawa 1 1 For SU-axes

A 4 Electric For LR-axes
HW9470917-B Corporation
1 1
S-Axis Timing Belt B150-S5M-550 Mitsuboshi Belt-

B 5 1 1
ing Limited
L-Axis Timing Belt 120-S4.5M-387 Mitsuboshi Belt-

B 6 1 1
ing Limited
U-Axis Timing Belt B150-5M-475 Mitsuboshi Belt-

B 7 1 1
ing Limited
R-Axis Timing Belt B60-S4.5M-329 Mitsuboshi Belt-

B 8 1 1
ing Limited
S-Axis HW9381607-A Yaskawa

B 9 Speed Reducer Electric 1 1
Corporation
L-Axis HW9280707-A Yaskawa

Corporation
R-Axis HW9381648-A Yaskawa

Corporation
10-1
RE-MTO-A225
Table 5 Spare Parts for the MOTOMAN-CSL10
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
U-Axis HW9381639-A Yaskawa

Ball Screw (for CSL10-A00) Electric
HW9381820-A Corporation
B 12 1 1
(for CSL10-A10)
HW9381819-A
(for CSL10-A20)

Linear Guide (for CSL10-A00) Electric
HW9381822-A Corporation
B 13 1 1
(for CSL10-A10)
HW9381821-A
(for CSL10-A20)

Ball Screw Electric
B 14 1 1
Supporting Bearing Corporation
(Upper Part)

Ball Screw Electric
B 15 1 1
Supporting Bearing Corporation
(Lower Part)
N-base Internal HW9171652-A Yaskawa

Cable (for CSL10-A00) Electric
HW9171652-E Corporation
B 16 1 1
(for CSL10-A10)
HW9171652-D
(for CSL10-A20)
L-Axis Internal HW9371133-A Yaskawa For LR-axes

B 17 Cable Electric 1 1 For user cables
Corporation
Internal Cable HW9471030-A Yaskawa For R-axis motor

B 18 Electric 1 1 signal
Corporation
Internal Cable HW9471031-A Yaskawa For R-axis motor

B 19 Electric 1 1 power
Corporation
Internal Cable HW9471029-A Yaskawa For user cables

B 20 Electric 1 1
Corporation
AC Servomotor for HW9381838-A Yaskawa With brake, no

C 21 S-Axis Electric 1 1 key, lead termi-
Corporation nated

C 22 L-Axis Electric 1 1 key, lead termi-
Corporation nated

C 23 U-Axis Electric 1 1 key, lead termi-
Corporation nated

C 24 R-Axis Electric 1 1 key, lead termi-
Corporation nated
10-2
MOTOMAN-CSL10
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
Phone 1-937-847-6200 Fax 1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
2280 Argentia Road, Mississauga, Ontario, L5N 6H8, Canada
Phone 1-905-813-5900 Fax 1-905-813-5911
YASKAWA ELECTRIC AMERICA, INC.
2121 Norman Drive South Waukegan, IL 60085, U.S.A.
Phone 1-847-887-7000 Fax 1-847-887-7370
Am Kronberger Hang 2, 65824 Schwalbach,Germany
Phone 49-6196-569-300 Fax 49-6196-888-301
MOTOMAN ROBOTICS EUROPE AB
Box 504 S38525 Torsas, Sweden
Phone 46-486-48800 Fax 46-486-41410
MOTOMAN ROBOTEC GmbH
Kammerfeldstr.1,D-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
KFPA Bldg #1201, 35-4 Yeoido-dong, Youngdungpo-Ku, Seoul 150-010, Korea
Phone 82-2-784-7844 Fax 82-2-784-8495
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD. MALAYSIA REPRESENTATIVE OFFICE
B615, 6th Floor, East Wing, Wisma Tractors, No.7, Jalan SS 16/1, Subang Jaya, 47500 Petaling Jaya, Selangor D.E. Malaysia
Phone 60-3-5031-5311 Fax 60-3-5031-5312
YASKAWA ELECTRIC (SHANGHAI) CO., LTD.
4F No Aona Road, Waigaoqiao Free Trade Zone, Pudong New Area, Shanghai 200131, China
Phone 86-21-5866-3470 Fax 86-21-5866-3869
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16, Nanking E. RD., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
YASKAWA ELECTRIC (HK) COMPANY LIMITED
Phone 852-2803-2385 Fax 852-2547-5773
BEIJING OFFICE
Room No. 301 Office Building Intemational Club, 21 Jianguomenwai Avenue, Beijing 100020, China
Phone 86-10-6532-1850 Fax 86-10-6532-1851
30 Xue Yuan Road, Haidian, Beijing P.R. China Post Code: 100083, China
Phone 86-10-6234-5003 Fax 86-10-6234-5002
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541 Fax 86-10-6788-2878
YASKAWA
Specifications are subject to change without notice MANUAL NO. RE-MTO-A225 1

for ongoing product modifications and improvements. C Printed in Japan March 2002 99-12
YASKAWA
YASNAC XRC
INSTRUCTIONS
SUPPLEMENTARY FOR CLEAN ROBOT
FOR MOTOMAN-CSL10
MOTOMAN-CSL10 INSTRUCTIONS
YASNAC XRC OPERATOR’S MANUAL FOR BEGINNERS
YASKAWA MANUAL NO. HW0480165

MANDATORY
• This manual explains the operations of the YASNAC XRC system for
passing over a singular point.
• General items related to safety are listed in the Safety Manual Section
1: Safety. To ensure correct and safe operation, carefully read the Setup
Manual before reading this manual.
CAUTION


on the front cover.

uct’s warranty.
ii
1. INTRODUCTION
These supplementary instructions describe the YASNAC XRC for the MOTOMAN-CSL10 clean
robot.
Read this manual thoroughly together with the following:
"MOTOMAN SETUP MANUAL" (Manual No.: RE-TA-A503)
"YASNAC XRC INSTRUCTIONS" (Manual No.: RE-CTO-A203)
This manual only describes the information for this particular type. For any information other
than that described in this manual, refer to the aforementioned instruction manuals.
1
2. SPECIFICATIONS
Table 1 Specifications of the CSL10

Manipulator MOTOMAN SETUP YASNAC XRC
Type MANUAL INSTRUCTIONS
CSL10
XRC Type ERCR- - -
CSL10-RA00
Approx. Mass 70 kg 1.5 "Motoman Safety" 6.1 "Specification List"
3.1 "Handling Procedure"
Power Supply 2.0 kVA 4.2 "Power Supply" -
Capacity
Primary Power 2.0 mm2 4.2 "Power Supply" -
Supply Cable Size (M5)
(Terminal Size)
Switching Device 15 A 4.2 "Power Supply" -
Capacity
External Dimensions 470 × 760 × 1.5 "Motoman Safety" 6.1 "Specification List"
(W×H×D) [mm] 320
Unit and Board Refer to Fig. - 6.4 "Equipment
Locations 1. Configuration"
Cooling Configuration Refer to Fig. - 6.4.2 "Cooling System of
2. * the Controller Interior"
Power Supply Unit JZNC-XPU03 - 6.4 "Equipment
Configuration"
2
(Cont'd)
Servo Unit
SERVOPACK CACR-CSL10AAA - 6.4 "Equipment
(for 4 axes) Configuration"
Converter JUSP-ACP05JAA
Control power supply JUSP-RCP01AA
S-axis amplifier JUSP-WS05AA
L-axis amplifier JUSP-WS02AA
U-axis amplifier JUSP-WS05AA
R-axis amplifier JUSP-WS01AA
Control board JASP-WRCA01
*: There are three types of XRCs for the MOTOMAN-CSL10 clean robot, depending on the form
of the air discharging section at the rear as shown in Fig. 2 (1), (2), and (3). Refer to the
figure of the type of machine you ordered.
For types (2) and (3), the user must provide the exhaust duct.
3
Power ON unit CPU unit Playback panel
Power supply unit JZNC-XIU01 JZNC-XRK01B-1 ZY1C-SS3152
JZNC-XPU03
A
JZNC-XRK01
XCP01 CPS-150F
XCP01
CPS-150F
1 2
3 4
5 6
7 8
1 2
9 10
3 4
5 6
11 12
ＱＦ１
CN04/CARD
13 14
7 8
CN06/SV
15 16
9 10
17 18
11 12 20
19
13 14
15 16
17 18
20
SW
0 1 2 3 4
19
BAT
CN03/RS232C
CN02/PP
CN01/IO
1 2
3 4
5 6
7 8
9 10
11 12
(EV1) (EV2)
GRIP
CNPB04 CNPB05 CNPB06
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
DUSB-ARB8X-T11
102
CN10
CONV
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
178323-2
PWM
CN50
CNPG123
PWM
FRC5-C14S52T-OL(D20)
1CN
10250-52A2JL
CN30
CNE 3-175475-6
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
GRIP
A
Sectional view A-A
SERVOPACK
CACR-CSL10AAA
Fig.1 CSL10 Configuration

(43)
Playback panel
Power supply cable inlet A
(P Panel)
概算質量：Ｋｇ
70
YASNAC XRC CSL10
非常停止
SERVO ON MODE
READY PLAY TEACH
ＱＦ１
EDIT LOCK ALARM
(OFF) (ON) REMOTE HOLD START
ON
IP
TR
OFF
T
SE
RE
751
760
760
Air トップティーチ

メニューロック
座標
Air
サーボオン
χ
inlet
X+
χ
inlet
R-
S+
X-
S-
R+
Y- Y+
L+
y
B- y
L- B+
手動速度
Z-
U-
Z+
U+ T-
z z
T+
インタ
シフトロックウィービング
7 8シフト 9
開始溶接開始送給テスト運転
ロボット切替
補助ウィービング
4 5
バックネクスト
6
終了溶接終了リトラクト
外部軸切替
補助タイマ電圧
1 2 3 消去追加
電流
キャンセル 0 . -
補間参照点電圧電流変更
ＯＲＤＥＲＮＯ．
NJ1530
TYPE ERCR-
POWER SUPPLY
SERIAL NO.
DATE P/N
Air
outlet A Air
9
470 outlet
(40) 320 470
Sectional view A-A
(1) Standard
(43)
Power supply cable inlet Playback panel
A (P panel)
70
YASNAC XRC CSL10
非常停止
SERVO ON MODE
READY PLAY TEACH
ＱＦ１
EDIT LOCK ALARM
ON
IP
TR
OFF
T
SE
RE
Air
751
760
Air
760
座標
トップティーチ
inlet
inlet χ
サーボオン
X+
X- S+
R-
R+
χ
S-
Y- Y+
L+
y
B- y
L- B+
手動速度
Z-
U-
Z+
U+ T-
z z
T+
インタ
7 8シフト 9
ロボット切替
4 5
6
外部軸切替
1 2 3 消去追加
電流
NJ1530
TYPE ERCR-
POWER SUPPLY
SERIAL NO.
DATE P/N
Air
194.5 A
outlet
9
470
(140) 320 470 Pipe provided by the user
Air
Sectional view A-A outlet
(2) With Projecting Pipe on the Bottom
(43)
Power supply cable inlet Playback panel

A (P panel)
70
YASNAC XRC CSL10

非常停止
SERVO ON MODE
READY PLAY TEACH
ＱＦ１
EDIT LOCK ALARM
ON
IP
TR
OFF
T
SE
RE
760
751
Air Air
760
座標
トップティーチ
inlet X-
S-
Y-
L-
X+
S+
Y+
L+
サーボオン
y
B-
χ
R-
y
R+
B+
χ
inlet
手動速度
Z-
U-
Z+
U+ T-
z z
T+
インタ
7 8シフト 9
ロボット切替
4 5
6
外部軸切替
1 2 3 消去追加
電流
Air
f100 outlet
Air outlet
f90
NJ1530
113.5
TYPE ERCR-
POWER SUPPLY
SERIAL NO.
DATE P/N
194.5
A
9
470
(97) 320
470 Pipe provided by the user
Sectional view A-A

(3) With Projecting Pipe on the Rear
Fig.2 Cooling Configuration
YASNAC XRC
INSTRUCTIONS
SUPPLEMENTARY FOR CLEAN ROBOT
TOKYO OFFICE
New Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo 105-6891, Japan
Phone 81-3-5402-4511 Fax 81-3-5402-4580
Phone 1-937-847-6200 Fax 1-937-847-6277
MOTOMAN INC. TROY FACILITY
1050 S. Dorset, Troy, OH 45373, U.S.A.
Phone 1-937-440-2600 Fax 1-937-440-2626
Phone 1-905-813-5901 Fax 1-905-813-5911
Phone 49-6196-569-300 Fax 49-6196-888-301
Motoman Robotics Europe AB
Box 504 S38525 Torsås, Sweden
Phone 46-486-48800 Fax 46-486-41410
Motoman Robotec GmbH
Kammerfeldstraβe1,85391 Allershausen, Germany
Phone 49-8166-900 Fax 49-8166-9039
Kfpa Bldg #1201, 35-4 Youido-dong, Yeongdungpo-Ku, Seoul 150-010, Korea
Phone 82-2-784-7844 Fax 82-2-784-8495
Phone 65-282-3003 Fax 65-289-3003
YATEC ENGINEERING CORPORATION
Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road, Taipei, Taiwan
Phone 886-2-2563-0010 Fax 886-2-2567-4677
BEIJING OFFICE
Room No. 301 Office Building of Beijing Intemational Club, 21 Jianguomenwai Avenue, Beijing 100020, China
Phone 86-10-6532-1850 Fax 86-10-6532-1851
SHANGHAI OFFICE
27 Hui He Road Shanghai 200437 China
Phone 86-21-6553-6600 Fax 86-21-6531-4242
YASKAWA JASON (HK) COMPANY LIMITED
Phone 852-2803-2385 Fax 852-2547-5773
TAIPEI OFFICE
Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan
Phone 886-2-2563-0010 Fax 886-2-2567-4677
30 Xue Yuan Road, Haidian, Beijing 100083, China
Phone 86-10-6233-2782 Fax 86-10-6232-1536
7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area,
Beijing 100076, P.R. China
Phone 86-10-6788-0551 Fax 86-10-6788-2878
YASKAWA
Specifications are subject to change without notice MANUAL NO. HW0480165

for ongoing product modifications and improvements. C Printed in Japan August 2000 00-8
YASKAWA
YASNAC XRC
INSTRUCTIONS
SUPPLEMENTARY FOR NORTH AMERICAN (ANSI/RIA) STANDARD
MOTOMAN- INSTRUCTIONS
YASNAC XRC OPERATOR’S MANUAL for BEGINNERS
YASKAWA MANUAL NO. RE-CTO-A208 1

RE-CTO-A208
CAUTION
• This manual explains the North American specifications which differ
from the standard XRC specifications.
• The items which are not explained in the manual are the same as the
standard specificatrions. Use the standard XRC instructions with this
manual.
MANDATORY
• 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.
• General items related to safety are listed in the Setup Manual Section 1:
Safety of Setup Manual. To ensure correct and safe operation, carefully
read the Setup Manual before reading this manual.
CAUTION


on the front cover.

uct’s warranty.
ii
RE-CTO-A208

YASNAC XRC.
“MANDATORY”, or ”PROHIBITED”.


practices.

MANDATORY heading.
iii
RE-CTO-A208
WARNING
• Before operating the manipulator, check that servo power is turned off
turned off.
the servo power ON.

TURN
teach a job.
the playback panel.


iv
RE-CTO-A208
CAUTION
after use.

IIn this manual, the equipment is designated as follows.
v
RE-CTO-A208
shown as follows:
Pendant denoted with [ ].
ex. [ENTER]
ex. page key

shown.

ex. [SHIFT]+[COORD]

denoted with { }.
ex. {JOB}
Playback Panel Buttons Playback panel buttons are enclosed in brackets.

ex. [TEACH] on the playback panel

In the explanation of the operation procedure, the expression "Select • • • " means that the
cursor is moved to the object item and the SELECT key is pressed.
vi
RE-CTO-A208
1 YASNAC XRC Specification

1.1 Specification List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.2 Function List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.3 Programming Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.4 Equipment Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.4.1 Arrangement of Units and Circuit Boards . . . . . . . . . . . . . . . . .1-6
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.4.2 Cooling System of the Controller Interior . . . . . . . . . . . . . . . .1-12
2 Description of Units and Circuit Boards

2.1 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2 Brake Release Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.2.1 Operation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.3 CPU Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3.1 CPU Rack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3.2 Circuit Board in the CPU Rack . . . . . . . . . . . . . . . . . . . . . . . . .2-5
System Control Circuit Board (JANCD-XCP01) . . . . . . . . . .2-5
Control Power Supply Unit (CPS-150F) . . . . . . . . . . . . . . . .2-6
Wiring WAGO Connector . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Wiring PHOENIX Connector . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.4 I/O Unit (JZRCR-XCO02B) . . . . . . . . . . . . . . . . . . . . . . . .2-10
2.4.1 Specific I/O Circuit Board 1 (JARCR-XCI01) and Specific I/O
Circuit Board 2 (JARCR-XCU01B) . . . . . . . . . . . . . . . . . . . . .2-11
Direct IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Connected Jumper Leads Before Shipment . . . . . . . . . . . .2-13
Deadman Switch Signal Output . . . . . . . . . . . . . . . . . . . . .2-14
Connection to I/O External Power Supply . . . . . . . . . . . . . .2-15
FORCE (Forced Reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
FST (Full-speed Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Hanger Switch (HSW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
1st Safety Speed and 2nd Safety Speed . . . . . . . . . . . . . .2-19
Safety Plug Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2.4.2 General I/O Circuit Board (JARCR-XCI03). . . . . . . . . . . . . . .2-22
Connection wire with General I/O (CN10, 11, 12, 13) . . . . .2-23
Specific I/O Signal Related to Start and Stop . . . . . . . . . . .2-24
2.5 Power ON Unit (JZRCR-XSU02) . . . . . . . . . . . . . . . . . . .2-26
2.5.1 Power ON Circuit Board (JARCR-XCT01) . . . . . . . . . . . . . . .2-27
Connection of Shock Sensor . . . . . . . . . . . . . . . . . . . . . . . .2-27
Method of Connecting External Axis Overrun Signal . . . . .2-28
Servo ON Enable Input (ON_EN1 and 2) . . . . . . . . . . . . . .2-29
2.6 SERVOPACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
2.6.1 SERVOPACK Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
2.6.2 Description of Each Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
vii
RE-CTO-A208
Servo Control Circuit board (JASP-WRCA01) . . . . . . . . . . 2-39

Servo Control Power Supply (JUSP-RCP01AAo) . . . . . . . 2-39
Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Speed Monitor Board (JANCD-XFC01) . . . . . . . . . . . . . . . 2-39
2.7 Playback Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Contact Output for Emergency Stop Button . . . . . . . . . . . . 2-40
2.8 General I/O Signal Assignment . . . . . . . . . . . . . . . . . . . . 2-41
2.8.1 Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.8.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.8.3 General Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
2.8.4 Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
2.8.5 JANCD-XEW01 Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Arc Welding Application . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
3 Inspections
3.1 Regular Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 XRC Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Checking if the Doors are Firmly Closed . . . . . . . . . . . . . . . . . 3-2
3.2.2 Checking for Gaps or Damage in the Sealed Construction
Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Cooling Fan Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Emergency Stop Button Inspections . . . . . . . . . . . . . . . . 3-4
3.5 Deadman Switch Inspections . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6 Battery Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.7 Power Supply Voltage Confirmation . . . . . . . . . . . . . . . . 3-5
3.8 Open Phase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4 Replacing Parts
4.1 Replacing XRC Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Replacing the Disconnecting Switch. . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Replacing Parts of Power Supply Unit . . . . . . . . . . . . . . . . . . . 4-5
4.2 YASNAC XRC Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3 Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.4 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . 4-14
viii
RE-CTO-A208
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.
an emergency. The emergency stop buttons are attached on upper-right of the playback
panel and right of the programming pendant.
• Always set the teach lock before starting teaching.
Failure to observe this caution may result in injury from inadvertent operation of the play-
back panel.


- Ensure that you have a place to retreat to in case of emergency.
• Prior to performing the following operations, be sure that there is no one

within the working envelope of the manipulator, and be sure that you are
in a safe place yourself.
- Turning the power ON to the YASNAC XRC.

- Moving the manipulator with the programming pendant.
- Running check operation.
- Performing automatic operation.
Injury may result from collision with the manipulator to anyone entering the working enve-
lope of the manipulator.
1-1
RE-CTO-A208
CAUTION
• Perform the following inspection procedures prior to peforming teaching
operations. If problems are found, correct them immediately, and be
- Check for problems in manipulator movement.

- Check for damage to the insulation and sheathing of external wires.

use.
If the programming pendant is inadvertently left on the manipulator, fixture, or on the floor,
causing injuries or equipment damage.
1-2
RE-CTO-A208
1.1 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 ( - )
Switch built-in transformer tap according to the supplied
voltage on customer side. (480 VAC is set before ship-
ment.)
If the transformer is not used, the specification is three
phase AC200/220V(+10% ～ -15%) at 50/60Hz(±2 Hz)
Grounding Grounding resistance : 100 Ω or less

Exclusive grounding
Digital I/O Specific signal (hardware) 15 inputs and 2 outputs

General signals (standard, max.) 40 inputs and 40 outputs
Positioning System By serial communication (absolute encoder)
Drive Unit SERVOPACK for AC servomotors
Acceleration/ Software servo control

Deceleration
Programming 5000 steps, 3000 instructions

Capacity
Playback Panel*1
Dimensions 190(W) × 120(H) × 50(D) mm
Buttons Provided Mode change

Start / Hold, Emergency stop
*1 An optional remote playback panel is available
750(W) × 1100(H) × 550(D) mm (Except for SV3X (Small capacity

type))
Dimensions
750(W) × 860(H) × 550(D) mm (SV3X (Small capacity type))
1-3
RE-CTO-A208
1.2 Function List
1.2 Function List
Programming Coordinate System Joint, Rectangular/Cylindrical, Tool, User Coordinates

Pendant
Operation Modification of Adding, Deleting, Correcting (Robot axes and external axes
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 Possible every 0.01 s
Short-cut Function Direct-open function, Screen reservation function
Interface RS-232C × 1 port for FC 1/FC2

(At Programming Pendant)
Application Arc welding, Spot welding, Handling, General, Others
Safety Running Speed User definable

Feature Limit
Deadman Switch 3 position type. Servo power can be turned on at the mid
position only. (Located on programming pendant)
Collisionproof S-axis frame (doughnut-sector), Cubic frame (user coordi-

Frames nate)
Self-Diagnosis Classifies error and two types of alarms (major and minor)
and displays the data
User Alarm Display Possible to display alarm messages for peripheral device
Machine Lock Test-run of peripheral devices without robot motion
Door Interlock A door can be opened only when a circuit breaker is off.
Maintenance Operation Time Control power-on time, Servo power-on time, Playback time,
Function Display Operation time, Work time
Alarm Display Alarm message and previous alarm records
I/O Diagnosis Simulated enabled/disabled output possible
T.C.P. Calibration Automatically calibrates parameters for end effectors using a

master jig
1-4
RE-CTO-A208
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 tions during robot motion
Operation Instruc- Preparing the operation instructions for each application

tions (Arc-ON, Arc-OFF, etc...)
Variable Global variable, Local variable
Variable Type Byte type, Integer type, Double precision type, Real number
type, Position type
I/O Instructions Discrete I/O, Pattern I/O processing
Material Reinforced thermoplastic enclosure with a detachable sus-

pending strap
Dimensions 200(W) × 348(H) × 61.8(D) mm
Displayed 40 characters 12 lines

Units
Multilingual function (English, Japanese, Hankul)
Backlight
Others 3 position deadman switch, RS-232C × 1 port
1-5
RE-CTO-A208
1.4 Equipment Configuration
The XRC is comprised of individual units and modules (circuit boards). Malfunctioning compo-
nents can generally be easily repaired after a failure by replacing a unit or a module.
This section outlines the XRC equipment configuration.
1.4.1 Arrangement of Units and Circuit Boards

Configuration
I/O unit Playback panel

JZRCR-XCO02B ZY1C-SS3152 Brake operation panel Fuse holders
Power supply unit Power ON unit (QS2),(QS3)
JZRCR-XPU06B JZNC-XSU02
CPU unit USCC3I
JZNC-XRK01B-1 Brake release control board Fuse : Refer to the
A JZRCR-XFL02B following table.
JARCR-XCO02 JZNC-XRK01
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
1 EXESP1+ 1 PPESPOUT+
1FU 2FU 1FU 2FU 2 EXESP1- 2 PPESPOUT-
10A 250V 10A 250V 10A 250V 10A 250V
3 EXESP-2 3 PPESPIN+
CN44
4 EXESP2- 4 PPESPIN-
5 EXSVON1+ 5 PPESPOUT+
6 EXSVON1- 6 PPESPOUT-
CN29
S
7 EXSVON2+ 7 PPESPIN+
8 EXSVON2- 8 PPESPIN-
CN04/CARD
9 EXHOLD1+ 9 DSWOUT+
10 EXHOLD1- 10 DSWOUT-
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
1X 12 EXHOLD2- 12 RDY-
CN43
9 24V2 9 ON_EN2+
6XT
13 SAF_F1+ 13 GND2/G
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
QS1
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
SER NO. DATE SER NO. DATE
QS2 QS3
TYPE TYPE
CN20
YASKAWA ELECTRIC CORPORATION YASKAWA ELECTRIC CORPORATION

JAPAN NJ2096- JAPAN NJ2096-
(EV1) (EV2)
GRIP
No fuse breaker(QS1)
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
CN10
CONV
194R-NC030P3
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
PWM
178323-2
Fuse : Refer to the

CN50
CNPG123
PWM
1CN
10250-52A2JL
following table.
CN30
CNE 3-175475-6
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
Transformer 1KVA
GRIP
HB9480046
240-480-575V/208V
Class H A'
SERVOPACK Sectional view A-A'
Refer to the follwing table.
Fuse
Type YASNAC XRC SERVOPACK
QS1 QS2 QS3
SV3X ERCR-SV3-RB07 CACR-SV3AAA 3A 10A 5A
* : Time delay fuses of class CC are used for QS1, QS2, and QS3.
SV3X Configuration (With transformer built-in)
1-6
RE-CTO-A208
I/O unit Fuse holders

Power supply unit Power ON unit Playback Panel Brake operation panel (QS3)
JZRCR-XCO02B ZY1C-SS3152
JZRCR-XPU06B JZNC-XSU02 USCC3I
CPU unit
JZNC-XRK01B-1 Fuse: Refer to the
A Brake release control board
JZRCR-XFL02B follwing table.
JARCR-XCO02B JZNC-XRK01
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
CN26
CN04
CN03/RS232C
QS1
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN NJ2096-
(EV1) (EV2)
GRIP
No fuse breaker (QS1)

8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
DUSB-ARB8X-T11
102
CN10
CONV
194R-NC030P3
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
Fuse : Refer to the following

PWM
178323-2
CN50
CNPG123
PWM
1CN
10250-52A2JL
table.
CN30
CNE 3-175475-6
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
GRIP
A'
SERVOPACK Sectional view A-A'
Refer to the follwing table
* Fuse
QS1 QS2 QS3
SV3X ERCR-SV3-RB08 CACR-SV3AAA 10A 5A
* : Time delay fuses of class CC are used for QS1, and QS3.
SV3X Configuration (Without transformer)
I/O unit
Power supply unit JZRCR-XCO02B
(with protective cover) Power ON unit Playback panel Fuse holders
JZRCR-XPU06B JZNC-XSU02 ZY1C-SS3152 Brake operation panel (QS2)(QS3)
CPU unit USCC3I
A JZRCR-XFL02B Following table.
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
QS1
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
QS2 QS3
TYPE TYPE
CN20

JAPAN
(EV1) (EV2)
GRIP
Disconnecting switch
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
CN10
CONV
194R-NC030P3 2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
Fuse : Refer to the

PWM
178323-2
CN50
CNPG123
PWM
1CN
10250-52A2JL
following table.
CN30
CNE 3-175475-6
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
SERVOPACK GRIP
Refer to the
following table.
A'
Sectional view A-A'
Transformer 4.5KVA
HB9480042 * Fuse
240-480-575V/208V Type YASNAC XRC SERVOPACK QS1 QS2 QS3
Class H
SV3X ERCR-SV3-RB05 CACR-SV3AAA 3A 10A 5A
UP6 ERCR-UP6-RB04 CACR-UP6AAC 5A 10A 10A
SK16X ERCR-SK16-RB05 CACR-SK16AAC 10A 15A 15A
UP20 ERCR-UP20-RB03 CACR-UP20AAA 10A 15A 15A
SV3X, UP6, SK16X, UP20 Configuration (With transformer built-in)
1-7
RE-CTO-A208
Power supply unit I/O unit Fuse holders

(with protective cover) Power ON unit JZRCR-XCO02B Playback Panel (QS3)
JZRCR-XPU06B JZNC-XSU02 ZY1C-SS3152 Brake operation panel USCC3I
CPU unit Fuse : Refer to the
JZNC-XRK01B-1 Brake release control board following table.
A JZRCR-XFL02B
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
QS1
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN JAPAN
(EV1) (EV2)
GRIP
Disconnecting switch CNPB04
8830-032-170SD
CNPB05
8830-032-170SD
CNPB06
8830-032-170SD
C249
102
DUSB-ARB8X-T11
194R-NC030P3
CN10
CONV
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
Fuse : Refer to the

RCP01AAA
PWM
178323-2
CN50
CNPG123
PWM
1CN
following table.
10250-52A2JL
CN30
CNE 3-175475-6
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
SERVOPACK GRIP
Refer to following
table.
A'
Sectional view A-A'
* Fuse
QS1 QS2 QS3
SV3X ERCR-SV3-RB06 CACR-SV3AAA 10A 5A
UP6 ERCR-UP6-RB05 CACR-UP6AAC 10A 10A
SK16X ERCR-SK16-RB06 CACR-SK16AAC 15A 15A
UP20 ERCR-UP20-RB04 CACR-UP20AAA 15A 15A
SV3X, UP6, SK16X, UP20 Configuration (Without transformer)
Playback Panel
Power ON unit I/O unit ZY1C-SS3152 Brake operation panel Fuse holders
Power supply unit JZNC-XSU02 JZRCR-XCO02B (QS2)(QS3)
(with protective cover) CPU unit Brake release control board USCC3I
JZRCR-XPU05B JZNC-XRK01B-1 JZRCR-XFL02B Fuse : Refer to the
A following table.
JZNC-XRK01
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
QS1
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
QS2 QS3
TYPE TYPE
CN20

JAPAN JAPAN
(EV3)
Disconnecting switch (EV1) (EV2)

GRIP
194R-NC030P3
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
CN10
Fuse : Refer to the

CNPG456
10220-6202JL
CN20
10250-52A2JL
178323-2
folloeing table.
CN50
CNPG123
FM31
MPC603EFE100L
10250-52A2JL
S1 KDS16-522
CNTEST
CN30
IMSA-9202B-1-03R-G
CNE 3-175475-6
Converter
BL02RN2-R62
U90 U126
105
PQ30RV21 PQ30RV21
FL9
C2
C176 C93
CN40
20V68 L2
20SAH68M TSL1110-101K1R0
680 680 CNPB01 CNPB02 CNPB03
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
Refer to the
folloeing table.
SERVOPACK
Refer to the
folloeing table.
A'
Sectional view A-A'
Transformer 8KVA
HB9480043 * Fuse
240-480-575V/208V Type YASNAC XRC SERVOPACK Converter
QS1 QS2 QS3
Class H ERCR-UP50-RB03 CACR-UP50AAB JUSP-ACP25JAAY11 15A
UP50 20A 20A
UP20M ERCR-UP20M-RB02 CACR-UP20MAAB 15A 20A 20A
SK45X ERCR-SK45-RB02 CACR-SK45AAB JUSP-ACP25JAA 15A 20A 20A
SK16MX ERCR-SK16M-RB02 CACR-SK16MAAB 15A 20A 20A
SP70X ERCR-SP70-RB03 CACR-SP70AAB 15A 20A 20A
SK45X, SK16MX, UP50, UP20M, SP70 Configuration (With transformer built-in)
1-8
RE-CTO-A208
I/O unit Playback Panel Fuse holders

Power supply unit Power ON unit (QS3)
(with protective cover) JZNC-XSU02 JZRCR-XCO02B ZY1C-SS3152 Brake operation panel
USCC3I
JZRCR-XPU05B CPU unit
JZNC-XRK01
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
QS1
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN JAPAN
(EV3)
Disconnecting switch(QS1)
(EV1) (EV2)
GRIP
194R-NC030P3
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
CN10
Fuse : Refer to the
CNPG456
10220-6202JL
CN20
10250-52A2JL
following table. CN50
178323-2
CNPG123
FM31
MPC603EFE100L
10250-52A2JL
Converter
S1 KDS16-522
CNTEST
CN30
IMSA-9202B-1-03R-G
CNE 3-175475-6
U90 U126
BL02RN2-R62
PQ30RV21 PQ30RV21 105

FL9
C2
Refer to the
C176 C93
CN40
20V68 L2
20SAH68M TSL1110-101K1R0
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
following table.
SERVOPACK
Refer to the
following table.
A'
Sectional view A-A'
* Fuse
Type YASNAC XRC SERVOPACK Converter QS1 QS2 QS3
UP50 ERCR-UP50-RB04 CACR-UP50AAB JUSP-ACP25JAAY11 20A 20A
UP20M ERCR-UP20M-RB03 CACR-UP20MAAB 20A 20A
SK45X ERCR-SK45-RB03 CACR-SK45AAB JUSP-ACP25JAA 20A 20A
SK16MX ERCR-SK16M-RB03 CACR-SK16MAAB 20A 20A
SP70X ERCR-SP70-RB04 CACR-SP70AAB 20A 20A
SK45X, SK16MX, UP50, UP20M, SP70 Configuration (Without transformer)
Fuse holders
Playback Panel (QS2)(QS3)
Power supply unit ZY1C-SS3152
(with protective cover) Power ON unit I/O unit USCC3I
JZNC-XSU02 JZRCR-XCO02B Brake operation panel Fuse : Refer to the
JZRCR-XPU05B
CPU unit Brake release control board following table.
JZNC-XRK01B-1
A JZRCR-XFL02B
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
CN26
QS1
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
QS2 QS3
TYPE TYPE
CN20

JAPAN JAPAN
(EV3)
Disconnecting switch(QS1)
(EV1) (EV2)
G R I P
194R-NC030P3
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
13
14
TB4 102
DUSB-ARB8X-T11
FRC5-C14S52T
CN10
F4053A
-OL(D20)
Fuse : Refer to the

REV.A
CN60
TB1 F4053A
2
1
A1
JASP-WRCF01
B1
B2
8830-032-170SD
B16 CNPG456
CNPB07
10220-6202JL
CN20
B15
A2
B2
B1
A1
10250-52A2JL
TB2
following table.
F4053A
CNPB08
8830-032-170SD
TB3
178323-2
F4053A
CN50
A1 A2 B1 B2
8830-032-170SD
CNPB09
CNPG123
FM31
MPC603EFE100L
DF9203369-A0
10250-52A2JL
26
27
2
1
S1 KDS16-522
CNTEST
681MPH
681MPH
CN30
UPL1C
UPL1C
IMSA-9202B-1-03R-G
10250-52A2JL
C27
CNE C28 3-175475-6
680
CNPG789
680
BL02RN2-R62
U90 U126
PQ30RV21
105
PQ30RV21 PQ30RV21
FL9
U44
C2
Converter
25
24
49
50
C176 C93
CN40
20V68 L2
20SAH68M TSL1110-101K1R0
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
JUSP-ACP35JAA E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22 E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22
SERVOPACK
Refer to the
following table.
A' Sectional view A-A'

Transformer 8KVA
HB9480043 * Fuse
240-480-575V/208V Type YASNAC XRC SERVOPACK
Class H QS1 QS2 QS3
UP130 ERCR-UP130-RB04 CACR-UP130AAB 20A 30A 30A
UP165 ERCR-UP165-RB04 CACR-UP130AAB 20A 30A 30A
UP165-100 ERCR-UP165-RB06 CACR-UP130AABY18 20A 30A 30A
UP200 ERCR-UP200-RB03 CACR-UP130AABY18 20A 30A 30A
UP130, UP165, UP165-100, UP200 Configuration (With transformer built-in)
1-9
RE-CTO-A208
Power supply unit Playback Panel Fuse holders

(with protective cover) Power ON unit I/O unit ZY1C-SS3152 (QS3)
JZNC-XSU02 JZRCR-XCO02B Brake operation panel
JZRCR-XPU05B USCC3I
CPU unit Brake release control board Fuse : Refer to the
JZNC-XRK01B-1 following table.
A JZRCR-XFL02B
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
QS1
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN NJ2096- JAPAN NJ2096-
(EV3)
(EV1) (EV2)
Disconnecting switch(QS1) CNPB04

G R I P
CNPB05 CNPB06
194R-NC030P3
8830-032-170SD 8830-032-170SD 8830-032-170SD
C249
13
14
TB4 102
DUSB-ARB8X-T11
FRC5-C14S52T
CN10
F4053A
-OL(D20)
REV.A
CN60
TB1 F4053A
2
1
A1
JASP-WRCF01
Fuse : Refer to the

B1
B2
8830-032-170SD
B16 CNPG456
CNPB07
10220-6202JL
CN20
B15
A2
B2
B1
A1
10250-52A2JL
TB2
F4053A
CNPB08
8830-032-170SD
TB3
178323-2
F4053A
CN50
following table.
A1 A2 B1 B2
8830-032-170SD
CNPB09
CNPG123
FM31
MPC603EFE100L
DF9203369-A0
10250-52A2JL
26
27
2
1
S1 KDS16-522
CNTEST
681MPH
681MPH
CN30
UPL1C
UPL1C
IMSA-9202B-1-03R-G
10250-52A2JL
C27
CNE C28 3-175475-6
680
CNPG789
680
BL02RN2-R62
U90 U126
PQ30RV21
105
PQ30RV21 PQ30RV21
FL9
U44
C2
25
24
49
50
Converter
C176 C93
CN40
20V68 L2
20SAH68M TSL1110-101K1R0
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
SERVOPACK
Refer to the
following table.
A'
Sectional view A-A'
* Fuse
QS1 QS2 QS3
UP130 ERCR-UP130-RB05 CACR-UP130AAB 30A 30A
UP165 ERCR-UP165-RB05 CACR-UP130AAB 30A 30A
UP165-100 ERCR-UP165-RB07 CACR-UP130AABY18 30A 30A
UP200 ERCR-UP200-RB04 CACR-UP130AABY18 30A 30A
UP130, UP165, UP165-100, UP200 Configuration (Without transformer)
Power supply unit I/O unit Fuse holders

(with protective cover) Power ON unit Playback Panel (QS2)(QS3)
JZNC-XSU02 JZRCR-XCO02B ZY1C-SS3152 Brake operation panel
JZRCR-XPU10B USCC3I
CPU unit
JZNC-XRK01
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
CN26
QS1
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
QS2 QS3
TYPE TYPE
CN20

JAPAN NJ2096- JAPAN
(EV3)
(EV1) (EV2)
Disconnecting switch (QS1) G R I P
194R-NC030P3
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
13
14
TB4 102
DUSB-ARB8X-T11
FRC5-C14S52T
CN10
F4053A
-OL(D20)
REV.A
CN60
TB1 F4053A
Fuse : Refer to the

2
1
A1
JASP-WRCF01
B1
B2
8830-032-170SD
B16 CNPG456
CNPB07
10220-6202JL
CN20
B15
A2
B2
B1
A1
10250-52A2JL
TB2
F4053A
CNPB08
8830-032-170SD
TB3
178323-2
F4053A
CN50
following switch
A1 A2 B1 B2
8830-032-170SD
CNPB09
CNPG123
FM31
MPC603EFE100L
DF9203369-A0
10250-52A2JL
26
27
2
1
S1 KDS16-522
CNTEST
681MPH
681MPH
CN30
UPL1C
UPL1C
IMSA-9202B-1-03R-G
10250-52A2JL
C27
CNE C28 3-175475-6
680
CNPG789
680
BL02RN2-R62
U90 U126
PQ30RV21
105
PQ30RV21 PQ30RV21
FL9
U44
C2
25
24
49
50
C176 C93
Converter
CN40
20V68 L2
20SAH68M TSL1110-101K1R0
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
SERVOPACK
Refer to the
following table.
A'
Sectional view A-A'
Transformer 12KVA
HB9480044 * Fuse
240-480-575V/208V QS1 QS2 QS3 Type YASNAC XRC SERVOPACK
Class H
UP130R ERCR-UP130R-RB02 CACR-UP130AABY18 30A 40A 40A
UP130RL ERCR-UP130RL-RB02 CACR-UP130AABY21 30A 40A 40A
SK300X ERCR-SK300-RB02 CACR-SK300AAB 30A 40A 40A
SR200X ERCR-SR200-RB02 CACR-SK300AAB 30A 40A 40A
SP100X ERCR-SP100-RB02 CACR-SP100AAB 30A 40A 40A
* : 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
RE-CTO-A208
Power supply unit Playback Panel Fuse holders

I/O unit (QS3)
(with protective cover) Power ON unit JZRCR-XCO02B
ZY1C-SS3152
JZNC-XSU02 Brake operation panel USCC3I
JZRCR-XPU10B
CPU unit Fuse : Refer to the
JZNC-XRK01B-1 Brake release control board following table.
A JZRCR-XFL02B
JZNC-XRK01
CN32
XCP01 CPS-150F
CN07
XCP01
CN31
CPS-150F 1XT
4X 5X 4X 5X
CN06 CN05
CN30
10A 250V 10A 250V 10A 250V 10A 250V
CN44
CN29
CN04/CARD
CN27 CN28
CN06/SV
11 EXHOLD2+ 11 RDY+
10 G2 10 ON_EN2-
CN43
9 24V2 9 ON_EN2+
6XT
8 EX0VIN 8 ON_EN1-
14 SAF_F1- 14 24VIN
7 EX24VIN 7 ON_EN1+
6 G3 6 EXTUDIN
16 SAF_F2- 16 24V3
5 24V3 5 G3
SW
4 EXOT2- 4 EXNCM-
0 1 2 3 4
CN42
3 24V3 3 EXNCM+
2 EXOT1- 2 EXBRK-
BAT
1 24V3 1 EXBRK+
QS1
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN11
CN10
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN NJ2096- JAPAN
(EV3)
(EV1) (EV2)
Disconnect switch(QS1) CNPB04

G R I P
CNPB05 CNPB06
194R-NC030P3
8830-032-170SD 8830-032-170SD 8830-032-170SD
C249
13
14
TB4 102
DUSB-ARB8X-T11
FRC5-C14S52T
CN10
F4053A
-OL(D20)
REV.A
CN60
TB1 F4053A
2
1
A1
JASP-WRCF01
B1
B2
Fuse : Refer to the
8830-032-170SD
B16 CNPG456
CNPB07
10220-6202JL
CN20
B15
A2
B2
B1
A1
10250-52A2JL
TB2
F4053A
CNPB08
8830-032-170SD
TB3
178323-2
F4053A
CN50
A1 A2 B1 B2
following table.
8830-032-170SD
CNPB09
CNPG123
FM31
MPC603EFE100L
DF9203369-A0
10250-52A2JL
26
27
2
1
S1 KDS16-522
CNTEST
681MPH
681MPH
CN30
UPL1C
UPL1C
IMSA-9202B-1-03R-G
10250-52A2JL
FRC5-C14S52T-OL(D20) C27
CNE C28 3-175475-6
680
CNPG789
680
BL02RN2-R62
U90 U126
PQ30RV21
105
PQ30RV21 PQ30RV21
FL9
U44
C2
25
24
49
50
Converter
C176 C93
CN40
20V68 L2
20SAH68M TSL1110-101K1R0
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
SERVOPACK
Refer to the
following table.
A'
Sectional view A-A'
* Fuse
Type QS1 QS2 QS3 YASNAC XRC SERVOPACK
UP130R ERCR-UP130R-RB03 CACR-UP130AABY18 40A 40A
UP130RL ERCR-UP130RL-RB03 CACR-UP130AABY21 40A 40A
SK300X ERCR-SK300-RB03 CACR-SK300AAB 40A 40A
SR200X ERCR-SR200-RB03 CACR-SK300AAB 40A 40A
SP100X ERCR-SP100-RB03 CACR-SP100AAB 40A 40A
* : 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
RE-CTO-A208
1.4.2 Cooling System of the Controller Interior
Servo Top Fan
1KM
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)
1-12
RE-CTO-A208
WARNING
an emergency.
Failure to observe this caution may result in injury due to inadvertent operation on the
playback panel.


• When turning the power on to the YASNAC XRC, be sure that there is no
one within the worklng envelope of the manipulator, and be sure that
you are in a safe place yourself.
lope of the manipulator. Always press the emergency stop button immediately if there are
problems.
2-1
RE-CTO-A208
2.1 Power Supply Unit
CAUTION
• Perform the following inspection procedures prior to performing teach-
ing operations. If problems are found, correct them immediately, and be

- Check for damage to insulation and sheathing of external wires.

use.
If the programming pendant is inadvertently left on the manipulator or fixture, or on the

floor, the manipulator or a tool could collide with it during manipulator movement, possibly
The power supply unit consists of the contactors (1KM, 2KM) for servo power and the line filter
(1Z). It turns the contactor servo power on and off using the signal for servo power control
from the I/O power ON unit, and supplies power(3-phase AC200/220V) to the unit.
The power supply (single phase AC200/220V) is supplied to the control 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
2-2
RE-CTO-A208
(1Z)
Resister (RB) Noise filter
RB 1Z
(5X)
(4X) Single 200 VAC Output connector
Contactor output Conector output, etc.
4X 5X
1FU 2FU
10A 250V 10A 250V
(1X) 1X (1F,2F)
Single-phase 200 VAC Output connector Fuse
(2KM) (1KM)
Contactor Contactor
2KM SER NO.

TYPE
DATE
1KM
JAPAN NJ2096-1
Power Supply Unit Configuration (JZRCR-XPU05B, JZRCR-XPU06B, JZRCR-XPU10B)
2-3
RE-CTO-A208
2.2 Brake Release Unit
2.2 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
2.2.1 Operation Methods

1. Make sure that the XRC is in the status of Servo OFF (the lamp “SERVO ON READY”
on the P.PANEL is unlit).
2. Press the button “BRAKE RELEASE” of the brake release unit on the XRC door sur-
face. The lamp “BRAKE RELEASE” is lit. (The lamp is unlit when the button “BRAKE
RELEASE” is released.)
3. With the button “BRAKE RELEASE” held pressed, press the button of axis for which
the brake is to be released. The brake for the corresponding axis is released as long
as the button is pressed.
CAUTION
• Watch on your feet and surroundings when releasing the brake.
When the brake is released, the robot may move by its own weight, which may cause a
injury and damage to the equipment.
• Release the axis brake one by one.
In the case that simultaneous release of brakes of multiple number of axes is necessary,
pay full attetion for an unexpected motion of robot. Otherwise, an injury or damage to the
equipment may be resulted.
2-4
RE-CTO-A208
2.3 CPU Rack
2.3 CPU Rack
2.3.1 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
XCP01 (CN05)
CPS-150F 200 VAC Input
(CN04) (from Power Supply Unit)
CN05
PC Card
(CN04)
Battery Alarm Control Power Supply
CN04/CARD
ON/OFF Conection
CN05/SV
(WAGO connector)
CN04
(See "Wiring WAGO Connector")
(CN03)
SW
RS232C Connector
0 1 2 3 4
BAT
CN03
(CN03)
CN03/RS232C
SOURCE
PWR ON
24 VDC Output
+5V
Battery +24V
CN02 (to Programing Pendant)
OHT
CN02/PP
CN01
Monitor Alarm Display
CN01/IO
(CN01)
24 VDC, 5VDC
(to XCO)
System Control Board Control Power Supply Unit

JANCD-XCP01 CPS-150F
CPU Rack Configuration (JZNC-XRK01B-)
2.3.2 Circuit Board in the CPU Rack

System Control Circuit Board (JANCD-XCP01)
This board performs to control the entire system, display to the programming pendant, control
the operating keys, control operation, calculate interpolation, and interface the servo control
circuit board (with a serial communication board JANCD-XIF03). This board has the PC card
interface and Serial interface for RS-232C. The JANCD-XMM 01 board (option) can be
installed when CMOS memory is expanded.
2-5
RE-CTO-A208
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: 200/220VAC

Input Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)
Frequency: 50/60Hz ± 2Hz (48 to 62Hz)
+5VDC : 10A
Output Voltage
+24VDC : 4.0A
DISPLAY Color Status
SOURCE Green Lights when AC power supply input

(Normally ON)
POWER Green Lights when DC power supply input

ON (Normally ON)
Indicator
+5V Red Lights when +5V supply overvoltage or
overcurrent (ON when abnormal)
+24V Red Lights when +24V supply overcurrent

(ON when abnormal)
OHT Red Lights when units interior overheats

(ON when abnormal)
Overheat Detector It is detected when the temperature inside of the controller is about 65°C
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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. It is operated by the external switch
connected with CN 04 of control power supply unit as shown in the fol-
lowing figures. (CN04 is shortaged when shipment)
Control Power Supply Unit
(CPS-150F)
Switch
Control Power CN04

-1
ON/OFF
-2
*1
CN4:231-102/026-000 (WAGO)
Connection to Control Power Supply Unit
GO “Wiring WAGO Connector” for wiring of CN04 connector.
Wiring WAGO Connector

CN04 on the control power supply unit (CPS-150F) is equipped with a connector produced by
WAGO. The “wiring tool for WAGO connector” is necessary to wire with WAGO connector.
Two wiring tools are provided with the XRC as supplied parts.
The wiring procedure is described as follows:
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RE-CTO-A208
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. Insert or pull out the wire while pushing the wiring tool downward (Direction of the
arrow).
Wiring tool for WAGO connector
Push
3. Remove the wiring tool from the connector. (Complete)

The wiring tool for WAGO connector should be kept for future use.
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RE-CTO-A208
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. Loosen the screw on A part of the connector by using “small size flat tipped screw-
driver”.
A part
Screw (M2.5) for wire connection
PHOENIX connector (example with 10-pin type)
Small size flat tripped screwdriver
B part Connecting terminal
Wire (Applicable size AWG24 to AWG12)

Wire (Bare length: 10mm)
2. Insert a wire into the B part of connector, and tigten the A part screw by using a “small
size flat tipped screwdriver”. (Recommended tighitening torque: 0.8 Nm)
NOTE Make sure that the screw is securely tightened so that the wire will not come out.
Make sure that each connector is securely inserted into the unit.
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RE-CTO-A208
2.4 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 (PHOENIX connector)
(Refer to "Wiring PHOENIX Connector.")
(CN06)
For fetch of emergency stop direct output CN06 CN05
1 1
For fetch of deadman signal PPESPOUT+ EXESP1+
Power Supply ON/OFF
PPESPOUT- EXESP1-
Specific Output Connector (PHOENIX connector) PPESPIN+ EXESP2+
(Refer to "Wiring PHOENIX Connector".) JZRCR-XCO02B
PPESPIN- EXESP2-
PBESPOUT+ EXSVON1+
CN07
(CN44)
Direct IN (PHOENIX connector) CN06 CN05
PBESPOUT- EXSVON1-
1 1
PPESPOUT+ EXESP1+ PBESPIN+ EXSVON2+
(Refer to "Wiring PHOENIX Connector".) PPESPOUT- EXESP1-
PPESPIN+ EXESP2+ PBESPIN- EXSVON2-
PPESPIN- EXESP2-
CN44
(CN43) PBESPOUT+ EXSVON1+ DSWOUT+ EXHOLD1+

PBESPOUT- EXSVON1-
Deadman Switch and Input Connector PBESPIN+ EXSVON2+ DSWOUT- EXHOLD1-

PBESPIN- EXSVON2-
for Emergency Stop from programming pendant DSWOUT+ EXHOLD1+ RDY+ EXHOLD2+
DSWOUT- EXHOLD1-
RDY+ EXHOLD2+ RDY- EXHOLD2-
(CN42) RDY- EXHOLD2-
024V SAF_F1+
CN43
0 24 V SAF_F1+
Input Connector for Emergency Stop +24V SAF_F1-

EX0VIN SAF_F2+ +24V SAF_F1-
from the playback panel EX24VIN SAF_F2-
16 16
EX0VIN SAF_F2+
EX24VIN SAF_F2-
CN42
(CN41)
16 16
For connection to Power ON unit
Expanded view
CN04
(CN40)
CN13
CN12
Forced Reset, Full-speed Set, (CN04)

CN41
Switch to Safe Speed, Hanger Switch Specific I/O Connector for Playback Panel
(PHOENIX connector)
(Refer to "Wiring PHOENIX connector".)
CN03
(CN10, 11, 12, and 13)

CN40
General I/O Signal Connector

CN02
CN11
CN10
CN01
(CN01)
Power Supply Input
I/O Unit Configuration (JZRCR-XCO02B)
SUPPLE- Refer to “Wiring PHOENIX Connector”.

MENT
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2.4.1 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.
• Safety circuit control (depulexing + cross-diagnosis) function

• Specific I/O for playback panel (IN / OUT = 8 points / 8 points)
• Direct input (3 points)
• Deadman Switch Control Circuit
CAUTION
• Before use, remove any jumper leads from the specific input signals.
The unit may malfunction resulting in injury or damage to equipment.
YASNAC XRC
JZRCR-XCO02B
(JARCR-XCI01)
+24VU
CN05
1 EXESP1+ External Emergency Stop 1
2 EXESP1-
3 EXESP2+
4 EXESP2- External Emergency Stop 2
5 EXVON1+
External Servo ON 1
6 EXVON1-
7 EXVON2+ External Servo ON 2
8 EXVON2-
9 EXHOLD1+ External Hold 1
10 EXHOLD1-
11 EXHOLD2+
External Hold 2
12 EXHOLD2-
13 SAF-F1+
Safety Plug 1
14 SAF-F1-
15 SAF-F2+
Safety Plug 2
16 SAF-F2-
024VU
JZRCR-XCO02B Specific Input Circuit Board Allocation and Connection Diagram
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RE-CTO-A208
Direct IN
The signals can be directly and externally connected.
YASNAC XRC
JZRCR-XCO02B
(JARCR-XCU01B)
+24V +24VU
CN44
1 EXDIN1+
DIN1 2 EXDIN1-
3 EXDIN2+ Direct IN
DIN2 4 EXDIN2-
5 EXDIN3+
DIN3 6 EXDIN3-
7 EXDIN4+
DIN4 8 EXDIN4-
Note: EXDIN4 is for future use.
024VU
JZRCR-XCO02B Specific I/O Circuit Board Allocation and Connection Diagram
2-12
RE-CTO-A208
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.
YASNAC XRC
JZRCR-XCO02B
(JARCR-XCI01)
SW8 CN06
1 1 PPESPOUT+
2 2 PPESPOUT-
3 3 PPESPIN+
4 PPESPIN-
SW9 5 PBESPOUT+
1 6 PPESPOUT-
2 7 PBESPIN+
8 PBESPIN-
3 9 DSWOUT+
10 DSWOUT-
SW1 11 RDY+
1 12 RDY-
2 13 024V
14 +24V
3 15 EX0VIN
16 EX24VIN
JZRCR-XCO02B Specific I/O Circuit Board Allocation and Connection Diagram
2-13
RE-CTO-A208
Deadman Switch Signal Output

A deadman switch signal is output from CN06-9 and -10.
YASNAC XRC
JZRCR-XCO02B
JARCR-XCI01
CN06
1 PPESPOUT+
2 PPESPOUT-
3 PPESPIN+
4 PPESPIN-
5 PBESPOUT+
6 PPESPOUT-
7 PBESPIN+
8 PBESPIN-
9 DSWOUT+ Deadman Switch
10 DSWOUT- Signal Output
11 RDY+
+24VU 12 RDY-
024VU 024VU
13 024V
14 +24V
15 EX0VIN
16 EX24VIN
+24VU PP
CN43
B1 DSW1+
2 DSW1-
3 Deadman Switch
4 DSW2+
5 DSW2-
JARCR-XCU01 024VU
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RE-CTO-A208
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).
2. Connect CN06-16 and -15 of the I/O unit (JZRCR-XCO02B) to +24 V and 0V of the
external power supply respectively.
YASNAC XRC
JZRCR-XCO02B
(JARCR-XCI01) CN06
1 PPESPOUT+
2 PPESPOUT-
3 PPESPIN+
4 PPESPIN-
5 PBESPOUT+
6 PPESPOUT-
7 PBESPIN+
+24VU +24V 8 PBESPIN-
9 DSWOUT+
10 DSWOUT- External Power Supply
11 RDY+ Remove (prepared by customer side)
12 RDY-
13 024V
14 +24V 0V
15 EX0VIN
024VU
16 EX24VIN
+24VU +24V
024VU 024V
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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)
+24VU
CN40
1 FORCE1+ Turn ON simultaneously
2 FORCE1- Switch with key
3 FORCE2+ *CAUTION
4 FORCE2-
024VU 5 FST1+
6 FST1-
+24VU 7 FST2+
024VU 8 FST2-
9 S-SP1+
10 S-SP1-
11 S-SP2+
12 S-SP2-
13 HSW1+(TEACH1+)
14 HSW1-(TEACH1-)
15 HSW2+(TEACH2+)
16 HSW2-(TEACH2-)
CAUTION
Do not use the “FORCE” (Forced release) input.
It the “FORCE” input should be used for an unavoidable reason, be sure to use a switch
with a key. The systems manager is responsible for storage of the key.
When “FORCE” is input, all the deadman switches become invalid, so handle with
extreme care.
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RE-CTO-A208
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. When only one is input,
an alarm occurs.
YASNAC XRC
JZRCR-XCO02B
(JARCR-XCU01B)
CN40
+24VU 1 FORCE1+
2 FORCE1-
3 FORCE2+
4 FORCE2-
5 FST1+
6 FST1- Turn ON
7 FST2+ simultaneously.
8 FST2-
024VU 9 S-SP1+
10 S-SP1-
+24VU 11 S-SP2+
024VU 12 S-SP2-
13 HSW1+(TEACH1+)
14 HSW1-(TEACH1-)
15 HSW2+(TEACH2+)
16 HSW2-(TEACH2-)
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RE-CTO-A208
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).
For HSW, there are HSW1 (CN40-13 and -14) and HSW2 (CN40-15 and -16). Use two-con-
tact type input switch so that both of HSW1 and HSW2 turn ON/OFF simultaneously. If only
one is input, an alarm occurs.
YASNAC XRC
JZRCR-XCO02B
(JARCR-XCU01B)
CN40
1 FORCE1+
2 FORCE1-
3 FORCE2+
4 FORCE2-
5 FST1+
6 FST1-
7 FST2+
8 FST2-
+24VU 9 S-SP1+ Hanger switch (HSW) input validated
10 S-SP1- when short-circuited
11 S-SP2+
12 S-SP2-
13 HSW1+(TEACH1+)
14 HSW1-(TEACH1-) Turn ON simultaneously
15 HSW2+(TEACH2+)
024VU
+24VU
16 HSW2-(TEACH2-)
024VU
JZRCR-XCO02B Specific Input Circuit Board Allocation and Connecition Diagram
2-18
RE-CTO-A208
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.
• 1st Safety Speed: limited to 16 % of the play maximum speed.
• 2nd Safety Speed: limited to 2 % of the play maximum speed.
YASNAC XRC
JZRCR-XCO02B
(JARCR-XCU01B)
CN40
1 FORCE1+
2 FORCE1-
3 FORCE2+
4 FORCE2-
5 FST1+
6 FST1-
+24VU 7 FST2+
8 FST2-
9 S-SP1+
10 S-SP1-
11 S-SP2+ Open, 1st Safety Speed
12 S-SP2- Short-circuited, 2nd Safety Speed
13 HSW1+(TEACH1+)
14 HSW1-(TEACH1-)
024VU 15 HSW2+(TEACH2+)
16 HSW2-(TEACH2-)
2-19
RE-CTO-A208
Specific Input List (XCO02B)
Factory
Terminal Input Name / Function
Setting
EXESP1 External emergency stop
CN05 -1 Use to connect the emergency stop switch of an external operation

-2 device. The servo power turns OFF and job execution stops when
this signal is input. The servo power cannot be turned ON while this Disabled by
signal is ON. jumper lead
EXESP2
CN05 -3
-4
EXSVON1 Servo ON
CN05 -5 Use to connect the servo ON switch of an external operation device.

-6 The servo power turns ON when this signal is input.
Open
EXSVON2
CN05 -7
-8
EXHOLD1 External hold
CN05 -9 Use to connect the HOLD switch of an external operation device. Job
-10 execution stops when this signal is input. Starting and axis opera-
tions are disabled while this signal is ON. Disabled by
jumper lead
EXHOLD2
CN05-11
-12
SAF-F1 Safety plug
CN05-13 This signal turns OFF the servo power when the door of the safe-
-14 guard is opened. Connect to the interlock signal from the safety plug
attached to the door. The servo power turns OFF when the interlock Disabled by
signal is input. The servo power cannot be turned ON while this sig- jumper lead
SAF-F2
nal is ON. However, in the teach mode, this function is disabled.
CN05-15
-16
DIN1 Direct-in 1
Used for the search function. Open

CN44 -1
-2
DIN2 Direct-in 2

CN44 -3
-4
DIN3 Direct-in 3

CN44 -5
-6
2-20
RE-CTO-A208
Specific Input List (XCO02B)
Factory
Terminal Input Name / Function
Setting
DIN4 Direct-in 4
Direct-in4 is for future use. Open

CN44 -7
-8
FORCE1 Forced reset input
CN40 -1 Do not use the “FORCE” (Forced release) input.

-2 If the “FORCE” input should be used for an unavoidable reason, be
sure to use a switch with a key. The systems manager is responsible Open
FORCE2 for storage of the key.
When “FORCE” is input, all the deadman switches become invalid,
CN40 -3 so handle with extreme care.
-4
RDY Optional board Ready signal Disabled by

Jumper lead
CN06-11 Use to add safety circuit conditions.
-12
FST1 Full-speed test Open
CN40 -5 PLAY normal speed is selected in PLAY mode, and TEACH normal
-6 speed is selected in TEACH mode.
FST2
CN40 -7
-8
S-SP1 Switches Valid/Invalid of HSW/DSW. Open
CN40 -9 When open, DSW valid

-10 When short-circuited, HSW valid
S-SP2 Switches between 1st Safety Speed and 2nd Safety Speed. Open
CN40-11 1st Safety Speed: the speed is limited to 16 % of PLAY maximum

-12 speed.
2nd Safety Speed: the speed is limited to 2 % of PLAY maximum
speed.
When open, 1st Safety Speed is selected
Whe short-circuited, 2nd Safety Speed is selected.
HSW1 Hanger switch Open
CN40-13 Validates the hanger switch with S-SP1 short-circuited.

-14 When open, a normal speed
When short-circuited, a safety speed (according to the setting of S-
HSW2 SP2)
CN40-15
-16
2-21
RE-CTO-A208
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. The safety plug input signal is connected to the
interlock signal from the gate.
Manipulator Working
Envelope
Safeguard
Servo ON Lamp
YASNAC
Abnormal Æ R XRC
Teach Æ Y Controller
Operating Æ G Door
Safety Plug
Signal Tower Emergency
R: Red Taked Plug Stop
Y: Yellow Receptacle for Teaching
G: Green
Safeguard
If the servo power is ON when the interlock signal is input, the servo power turns OFF. The
servo power cannot be turned ON while the interlock signal is input. However, the servo power
does not turn OFF when the door is opened only during the TEACH mode. In this case, the
servo power can be turned ON while the interlock signal is input.
2.4.2 General I/O Circuit Board (JARCR-XCI03)

The general I/O circuit board is controlled by the system control circuit board (JANCD-XCP
01) through the specific I/O circuit board (JARCR-XCI01).
I/O can be separated as specific I/O and general I/O allocated software as follows:
• Specific I/O : IN/OUT = 24 points / 24 points

• General I/O : IN/OUT= 16 points / 16 points (relay contact output)
The specific I/O is a signal in which the part is decided in advance. The specific I/O is used
when the external operation equipment, jig controller and centralized controller control the
manipulator and related equipment as a system. The assignment of the general input signal
depends on the applications as shown in " 2.8 General I/O Signal Assignment ". The main
example using specific I/O is shown as follows.
2-22
RE-CTO-A208
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)
B20 B1
A20 A1
Connector Type: FCN-361J040-AU (Fujitsu)

(Soldering pin type)
Food Type: FCN-360C040-B (Fujitsu)

I/O Power-ON unit
(JZRCR-XCO02B)
CN13 CN12 Connector A

I/O Cable (form XIU01
to Peripheral Device)
CN11 CN10
I/O Cable (from XIU01 to

Terminal)
CN10,CN11,CN12,CN13,
Connector B detailed Connector B
B1 B20
A1 A20
Connector Type: FCN-365P040-

AU (Fujitsu)
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20
I/O Terminal Board (Terminal Size : M3)

Type: PX7DS-40V6-R (Yoshida Denki)
2-23
RE-CTO-A208
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)
• Operating (depending on application:JARCR-XCI03)
• External Hold (common to all application:JARCR-XCI01)
• External Emergency Stop (common to all application:JARCR-XCI01)
<Timing Chart>
RUN
Manipulator
STOP
ON
While Servo ON OFF
ON
Servo ON OFF
T
ON
External Start OFF T
ON
Operating OFF
T
ON
External Hold
OFF
ON
Ext. E-Stop OFF
Note: Set T=100msec or more
2-24
RE-CTO-A208
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
Command I/O Unit
Servo ON PB (JZRCR-XCO02B)
X4 X1
CN05 +24VU
X1 Servo ON
Servo ON Command X1
-5
Command
-6
X4 X2
Servo ON X2 -7
Command
X2 -8
Servo Power ON
Servo Power ON Confirmation 024VU
X3 X4 +24VU
CN12
-A18
X3
PL
-A8
Servo ON Output 3011
Note: Number in ( ) means output signal number assigned to XCO02B.

PL: Pilot Lamp
Example of Start Sequence Circuit from External Device

Only the rising edge of the external start signal is valid. This signal starts the manipulator.
Reset this signal with the interlock configuration that determines if operation can start and with
the playback (RUNNING) signal confirming that the robot has actually started moving.
YASNAC XRC
While Play mode Alarm/Error Runnig
Servo ON select Occuring Confirmation Start I/O Unit
Run PB
(3011) (3016) (3013) X6 (Command) (JZRCR-XCO02B)
Ex. Start
X5 Command CN12
X5 External Start
-B1
Input
X5
(2011)
-B7
Ruunig
Running OVU
Confirmation
X7 (3010)
X6
Running, etc.
+24VU
X7
PL
Running Output
(3010), etc.
Note: Number in ( ) means output signal number assigned to XCO02B.
2-25
RE-CTO-A208
2.5 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
CN32
CN31
CN27 CN28
CN30
10 (CN30) 10
024V FAN, AC Output ON_EN2-
+24V (CN27, CN28) ON_EN2+
EX0VIN Overrun, Switch to External Power Supply, ON_EN1-
CN29
External Brake, External Direct IN, (CN29)
EX24VIN ON_EN1+
Servo Area Input Contactor Control
024VU CN27
10 10
CN28 EXTUDIN
024V ON_EN2-
+24VU +24V ON_EN2+ 024VU
EX0VIN ON_EN1-
EXOT2- EX24VIN ON_EN1+ EXNCM-
024VU EXTUDIN
EXOT2+ +24VU 024VU EXNCM+
EXOT2- EXNCM-
EXOT1- EXBRK-
EXOT2+
EXOT1-
EXNCM+
EXBRK-
(CN26)
EXOT1+ EXOT1+ EXBRK+ Shock Sensor, Lamp EXBRK+
1 1
1 1
CN26
(CN23) (CN25)
CN25
Interface to I/O Unit Interface to Speed Monitor Board

JZRCR-XSU02
(JZRCR-XCO02B) (JANCD-XFC01), Fan Alarm

CN23
CN24
(CN22, CN24)
(CN21) Back-stage, Interface to Power ON Unit
Interface to Servo Control
CN21
CN22
Circuit Board (JASP-WRCA01)
CN20
+24VU 0VU
CN20
+24V 0V
+24VU 0VU
+24V 0V
(CN20)
Power Supply Input
Power ON Unit Configuration (JZRCR-XSU02)
2-26
RE-CTO-A208
2.5.1 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
• Brake power supply circuit and its output
• Overrun(OT) shock sensor(SHOCK) and lamp light power supply output to robot
Connection of Shock Sensor

Remove “SHOCK-” and “+24VU” from XSU-CN26 (Dynamic Connector) , and connect the
shock sensor signal “SHOCK-” to the robot.
Shock Sensor Connection Terminal
Terminal Type Factory Setting Use Shock Sensor
SHOCK- PC-2005W
+24VU PC-2005M
SHOCK- PC-2005M
Power ON Unit
Manipulator JZRCR-XSU02
XSU-CN26 24VU
CN26
D1 24VU
SHOCK +24VU
D3
Shock Sensor
C3
SHOCK
Shock Sensor
(Option)
A3
Overrun Overrun
Connecting Cable
Shock Sensor Connection
SUPPLE-
When the shock sensor input signal is used, the stopping method of the robot can be
MENT specified. The stopping methods are hold stop and servo power supply off. Selection of the
stopping method is set in the display of the programing pendant. Refer to Explanation *1 in
“3.6 Overrun / Shock Sensor Reliasing” of the YASNAC XRC Instructions for details.
2-27
RE-CTO-A208
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.
1. Remove jumper leads connected between CN27-1 and -2 , and CN27-3 and -4 of
power ON unit (JZRCR-XSU02).
2. Connect the overrun input of an external axis between CN27-1 and -2 , and CN27-3
and -4 of power ON unit (JZRCR-XSU02) as shown in the figure below. The input
switch for external axis overrun should be of 2-contact type so that both signals are
turned ON/OFF simultaneously.
CAUTION
• Remove a jumper when there is a jumper in the specific input signal to
be used.
The injury and damage may result because it dosn’t function even if the soecific signal is
input.
YASNAC XRC
Power ON Unit (JZRCR-XSU02)
+24VU
CN27
-1
EXOT1 External Axis

Overrun
-2
+24VU
Turn ON/OFF
EXOT2 simultaneously.
-3
024VU
-4
024VU
2-28
RE-CTO-A208
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. Remove jumper leads between CN28-7 and -8, and between CN28-9 and -10 of the
power ON unit (JZRCR-XSU02).
2. Connect the switch 1 for servo area to the servo ON enable input (ON_EN1) across
CN28-7 and -8, the switch 2 to the servo ON enable input (ON_EN2) across CN28-9
and -10. Make a connection so that both of these switches turn ON/OFF simulta-
neously. When both of ON_EN1 and 2 are ON, the servo power supply turns ON.
When only one is ON, an alarm occurs.
JZRCR-XSU02 JZRCR-XSU02
+24VU +24VU
CN28 CN28
-7 -7
-8 ON_EN1 Switch 1 -8 ON_EN1
024VU 024VU
+24VU +24VU
Turn ON
simultaneously
-9 -9
-10 ON_EN2 Switch 2 -10 ON_EN2
024VU 024VU
Standard (Setting before shipment) Servo ON for an area
Servo ON Enable Input (ON_EN1 and 2)
2-29
RE-CTO-A208
2.6 SERVOPACK
2.6 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.
2.6.1 SERVOPACK Configuration
SERVOPACK Configuration (Small Capacity Type)
SV3X UP6
Component
Type Capacity Type Capacity
SERVOPACK CACR-SV3AAA - CACR-UP6AAC -
Converter JUSP-ACP05JAA 5A JUSP-ACP05JAA 5A
JUSP-
S JUSP-WS02AA 200W 500W
WS05AAY17
JUSP-
L JUSP-WS02AA 200W 1kW
WS10AAY17
Amplifier JUSP-
U JUSP-WS01AA 100W 500W
WS05AAY17
R JUSP-WSA5AA 50W JUSP-WS01AA 100W
B JUSP-WSA5AA 50W JUSP-WS01AA 100W
T JUSP-WSA5AA 50W JUSP-WS01AA 100W
Servo control
JASP-WRCA01 - JASP-WRCA01 -
curcuit board
Servo control
JUSP-RCP01AA - JUSP-RCP01AA -
power supply
Speed monitor
JANCD-XFC01 - JANCD-XFC01 -
board
2-30
RE-CTO-A208
2.6 SERVOPACK
SERVOPACK Configuration (Small Capacity Type)
SK16X UP20
Component
SERVOPACK CACR-SK16AAC - CACR-UP20AAA -
JUSP-
S 1kW JUSP-WS10AA 1kW
WS10AAY17
JUSP- JUSP-
L 1kW 2kW
WS10AAY17 WS20AAY22
Amplifier JUSP- JUSP-

U 1kW 1kW
WS10AAY17 WS10AAY17
R JUSP-WS02AA 200W JUSP-WS02AA 200W
B JUSP-WS02AA 200W JUSP-WS02AA 200W
T JUSP-WS02AA 200W JUSP-WS02AA 200W
Servo control
curcuit board
Servo control
power supply
Speed monitor
board
SERVOPACK Configuration (Medium Capacity Type)
SK45X SK16MX
Component
SERVOPACK CACR-SK45AAB - CACR-SK16MAAB -

S JUSP-WS30AA 3kW JUSP-WS30AA 3kW
L JUSP-WS20AA 2kW JUSP-WS20AA 2kW
U JUSP-WS20AA 2kW JUSP-WS20AA 2kW
Amplifier
R JUSP-WS10AA 1kW JUSP-WS02AA 200W
B JUSP-WS10AA 1kW JUSP-WS02AA 200W
T JUSP-WS10AA 1kW JUSP-WS02AA 200W
Servo control
curcuit board
Speed monitor
board
Servo control JUSP-
- JUSP-RCP01AA -
power supply RCP01AA
2-31
RE-CTO-A208
2.6 SERVOPACK
UP50 UP20M
Component
SERVOPACK CACR-UP50AAB - CACR-UP20MAAB -
S JUSP-WS44AA 4.4kW JUSP-WS44AA 4.4kW
L JUSP-WS60AA 6kW JUSP-WS60AA 6kW
Amplifier
R JUSP-WS10AA 1kW JUSP-WS02AA 200W
B JUSP-WS10AA 1kW JUSP-WS02AA 200W
T JUSP-WS10AA 1kW JUSP-WS02AA 200W
Servo control
curcuit board
Speed monitor
board
JUSP-
Converter 25A JUSP-ACP25JAAY11 25A
ACP25JAAY11
Servo control
power supply
SP70X
Component
Type Capacity
SERVOPACK CACR-SP70AAB -
S JUSP-WS20AA 2kW
L JUSP-WS15AA 1.5kW
U JUSP-WS44AA 4.4kW
Amplifier
R JUSP-WS05AA 500W
B - -
T - -
Servo control
JASP-WRCA01 -
curcuit board
Speed monitor
JANCD-XFC01 -
board
Converter JUSP-ACP25JAA 25A
Servo control JUSP-
-
2-32
RE-CTO-A208
2.6 SERVOPACK
SERVOPACK Configuration (Large Capacity Type)
UP130R, UP200
UP130, UP165
Component UP165-100

SERVOPACK CACR-UP130AAB - CACR-UP130AABY18 -
S JUSP-WS60AA 6kW JUSP-WS60AAY18 6kW
L JUSP-WS60AA 6kW JUSP-WS60AAY18 6kW
JUSP-
Amplifier R 2kW JUSP-WS20AAY13 2kW
WS20AAY13
JUSP-
B 1.5kW JUSP-WS15AAY13 1.5kW
WS15AAY13
JUSP-
T 1.5kW JUSP-WS15AAY13 1.5kW
WS15AAY13
Servo control
curcuit board
Speed monitor
board
Servo control JUSP-
- JUSP-RCP01AA -
UP130RL
Component
Type Capacity
SERVOPACK CACR-UP130AABY21 -
S JUSP-WS60AAY18 6kW
L JUSP-WS60AAY18 6kW
U JUSP-WS60AAY18 6kW
Amplifier
R JUSP-WS20AAY13 2kW
B JUSP-WS15AAY13 1.5kW
T JUSP-WS15AAY13 1.5kW
Servo control
JASP-WRCA01 -
curcuit board
Speed monitor
JANCD-XFC01 -
board
Converter JUSP-ACP35JAA 35A
Servo control
JUSP-RCP01AA -
power supply
2-33
RE-CTO-A208
2.6 SERVOPACK
SK300X, SR200X SP100X

Component
SERVOPACK CACR-SK300AAB - CACR-SP100AAB -
JUSP-
S 6kW JUSP-WS60AAY18 6kW
WS60AAY18
JUSP-
L 6kW JUSP-WS60AAY18 6kW
WS60AAY18
JUSP-
U 6kW JUSP-WS60AAY18 6kW
WS60AAY18
Amplifier
JUSP-
R 3kW - -
WS30AAY18
JUSP-
B 3kW - -
WS30AAY18
JUSP-
T 3kW JUSP-WS20AAY19 2kW
WS30AAY18
Servo control
curcuit board
Speed monitor
board
Servo control JUSP-
- JUSP-RCP01AA -
2-34
RE-CTO-A208
2.6 SERVOPACK
Grip (top)
Converter
Amplifier (6 pcs)
Servo Control Power Supply
Servo Control Board
G R I P 6AMP
+5 V Display LED
2CN
CNS
+5V
JUSP-
RCP01AAB
Speed Monitor Board
1CN
-OL(D20)
1CN 2CN 3CN 4CN 5CN 6CN
1GS 1CV 1AMP
G R I P
Grip (bottom)
SV3X, UP6, SK16X SERVOPACK Configuration
Grip (top)
Converter
Amplifier (6 pcs)
Servo Control Board
G R I P
8830-032-170SD 8830-032-170SD 8830-032-170SD

CNPB04 CNPB05 CNPB06 C249
+5V Display LED

CN10
CNS
2CN
CNPG456
10220-6202JL
CN20
+5V
JUSP-
RCP01AAA Speed Monitor Board
178323-2
CN50
CNPG123
1CN
CN30
CNE 3-175475-6
CN40

8830-032-170SD 8830-032-170SD 8830-032-170SD
CN1 CN2 CN3 CN4 CN5 CN6
G R I P
Grip (bottom)
UP20 SERVOPACK Configuration
2-35
RE-CTO-A208
2.6 SERVOPACK
SERVOPACK
Speed Monitor Board
Grip (top) Amplifier (6 pcs)
Converter
Servo Control Power Supply G R I P

Servo Control Board
CNS
2CN
CNPG456
+5V Display LED +5V
JUSP-
RCP01AAB
CNPG123
1CN
CN1 CN2 CN3 GRIP CN4 CN5 CN6
Grip (bottom)
SK45X, SK16MX SERVOPACK Configuration
Speed Monitor Board SERVOPACK
Grip (top)
Converter
Amplifier (6 pcs)
Servo Control Board
CNS
2CN
+5V Display LED +5V
JUSP-
RCP01AAB
1CN
Grip (bottom)
UP50, UP20M SERVOPACK Configuration
2-36
RE-CTO-A208
2.6 SERVOPACK
SERVOPACK
Speed Monitor Board
Converter Grip (top) Amplifier (4pcs)
Servo Control Power Supply G R I P

Servo Control Board
CNS
2CN
CNPG456
+5V Display LED +5V
JUSP-
RCP01AAB
YASKAWA
CNPG123
1CN
CN1 CN2 CN3 GRIP CN4
Grip (bottom)
SP70X SERVOPACK Configuration
Converter SERVOPACK
Speed Monitor Board Amplifier (6 pcs)
Servo Control Power Supply Grip (top)
G R I P
+5V Display LED Servo Control Board

CNS
2CN
+5V
JUSP-
RCP01AAB
CNE
1CN
4CN 5CN 6CN
G R I P
E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22 V21 V22 W21 W22 E31 E32 U31 U32 V31 V32 W31 W32
1GS
Grip (bottom)
UP130, UP165, UP200, UP130R, UP130RL, UP165-100, SK300, SR200X SERVOPACK Configuration
2-37
RE-CTO-A208
2.6 SERVOPACK
Converter SERVOPACK
Speed Monitor Board Amplifier (4pcs)
Grip (top)
G R I P
+5V Display LED Servo Control Board
CNS
2CN
+5V
JUSP-
RCP01AAB
CNE
1CN
6CN
G R I P
E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22 V21 V22 W21 W22 E31 E32 U31 U32 V31 V32 W31 W32
1GS
Grip (bottom)
SP100X SERVOPACK Configuration
2-38
RE-CTO-A208
2.6 SERVOPACK
2.6.2 Description of Each Unit

Servo Control Circuit board (JASP-WRCA01)
This is a circuit board which controls the servo motors of six axes of the manipulator. This
board controls the converter, amplifiers and the power ON unit (JZRCR-XSU02). The power
source is supplied by a servo control power supply.
Servo Control Power Supply (JUSP-RCP01AA)

This unit generates DC power (+5V, +7V, ±15V) for servo control. AC input (Single
phase:200/220VAC) is supplied by power supply unit.
Items Specification
Rated Input Volt- 200 to 220VAC

age
AC input Voltage Fluctua- +10% to -15% (AC170V to 242V)

tion Range
Frequency 50/60Hz (48Hz to 62Hz)
+ 5V 5A
Output + 7V 2.5A
±15V 1.3A(+15V), 0.6A(-15V)
This lights when +5V power supply is

Indicator +5V
output. (Color : Green)
Converter
This exchanges the power source (3-phase : 200/220VAC) supplied by the power supply unit
for DC power source and supplies the power to amplifiers for each axis.
Amplifier
This exchanges the DC power source supplied by a converter for a 3-phase motor power
source and outputs to each servo motor.
Speed Monitor Board (JANCD-XFC01)

This monitors the robot motion speed and outputs a speed error signal to the servo control
board (JASP-WRCA01) if the speed exceeds the set value.
2-39
RE-CTO-A208
2.7 Playback Panel
2.7 Playback Panel
The playback panel is equipped with the buttons used to play back the manipulator.
ALARM
Lights when an
SERVO ON MODE EMERGENCY STOP alarm occurs.
SERVO ON READY READY
PLAY TEACH
Turns ON the servo
power.
EMERGENCY
PLAY and TEACH STOP Button
Sets controller to Play EDIT LOCK
(OFF) ALARM
or Teach mode. (ON) REMOTE HOLD START START Button
Starts playback.
EDIT LOCK
Enables and disables HOLD Button
editing. (Option) Stops playback and
REMOTE Button holds at the present
Switches to remote
step in the job.
mode.
Contact Output for Emergency Stop Button

The contact output for the emergency stop button is on terminal block 2XT (Screw size: M3.5)
at the bottom of the panel.
This emergency stop output is always valid, regardless of whether the main power supply of
the XRC is ON or OFF. (Status output signal: NC contact)
Emergency
stop button
2XT EXT
PBESP3+
PBESP3+
PBESP3-
PBESP3-
PBESP4+
PBESP4+
PBESP4-
PBESP4-
2-40
RE-CTO-A208
2.8 General I/O Signal Assignment
2.8.1 Arc Welding
YASNAC-XRC
JZRCR-XCO02B Connector Terminal Converter
(Optional)
+24VU Model:PX7DS-40V6-R
CN12 Connector
Logical Connec t or Terminal
NumberNum ber Name Signal Number
Each Point 2010 B1 External Start IN B1 B1
24VDC 2011 A1 - IN A1 A1
8mA max. 2012 B2 Call Master Job IN B2 B2
2013 A2 Alarm/Error Reset IN A2 A2
JARCR-XCI03
2014 B3 Select Remote Mode IN B3 B3

2015 A3 Select Play Mode IN A3 A3
2016 B4 Select Teach Mode IN B4 B4
2017 A4 IN192 IN A4 A4
Interference1 Entrance
2020 B5 Prohibited IN B5 B5
2021 A5 Prohibited IN A5 A5
2022 B6 Work Prohibited IN B6 B6
2023 A6 Work Response IN A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3010 B8 Running OUT B8 B8
3011 A8 Servo is ON OUT A8 A8
3012 B9 Top of Master Job OUT B9 B9
3013 A9 Alarm/Error Occurred OUT A9 A9
3014 B10 Battery Alarm OUT B10 B10
3015 A10 Remote Mode Selected OUT A10 A10
3016 B11 Play Mode Selected OUT B11 B11
3017 A11 Teach Mode Selected OUT A11 A11
3020 B12 In Cube 1 OUT B12 B12
3021 A12 In Cube 2 OUT A12 A12
3022 B13 Operation Origin Point OUT B13 B13
Intermediate Start OK
3023 A13 (continuousing Sequence) OUT A13 A13
Each Point
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
JARCR-XCI01
B16 024VU B16 B16
CN06 Internal A16
Power Supply A16 024VU A16
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
A17 024VU
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19 +24VU A19 A19
024 VE
B20 FG B20 B20
A20 A20 A20
* Remove Jumper-pin between CN06-14 and -16, CN06-13 and -15

when a external power supply is used.
JARCR-XCI03 (CN12 Connector) I/O Allocation and Connection Diagram
2-41
RE-CTO-A208
YASNAC-XRC
(Optional)
CN13 Connector
Logical Connector Terminal
NumberNumber Signal Number
Each Point 2024 B1 - IN B1 B1

24VDC 2025 A1 - IN A1 A1
8mA max. 2026 B2 Weaving Prohibited IN B2 B2
2027 A2 Sensing Prohibited IN A2 A2
JARCR-XCI03
2030 B3 - IN B3 B3
2031 A3 - IN A3 A3
2032 B4 - IN B4 B4
2033 A4 - IN A4 A4
2034 B5 - IN B5 B5
2035 A5 - IN A5 A5
2036 B6 - IN B6 B6
2037 A6 - IN A6 A6
B7 024 VU B7 B7
A7 024 VU A7 A7
3024 B8 Gas Shortage (Monitor) OUT B8 B8
3025 A8 Wire Shortage (Monitor) OUT A8 A8
3026 B9 Wire Sticking (Monitor) OUT B9 B9
3027 A9 Arc Shortage (Monitor) OUT A9 A9
3030 B10 - OUT B10 B10
3031 A10 - OUT A10 A10
3032 B11 - OUT B11 B11
3033 A11 - OUT A11 A11
3034 B12 - OUT B12 B12
3035 A12 - OUT A12 A12
3036 B13 - OUT B13 B13
3037 A13 - OUT A13 A13
Each Point
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
JARCR-XCI01
B16 024 VU B16 B16
CN06 Internal A16 A16
A16 024 VU
-14 Power Supply
+24 V B17 024VU B17 B17
-13 024 V A17 024VU A17 A17
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19
A19 +24VU A19
024 VE
B20 FG B20 B20
A20 A20 A20

2-42
RE-CTO-A208
YASNAC-XRC
(Optional)
CN10 Connector
Number Num ber Signal
Number
Each Point 2040 B1 IN01 General Input IN B1 B1

24VDC 2041 A1 IN02 IN A1 A1
8mA max. 2042 B2 IN03 IN B2 B2
2043 A2 IN04 IN A2 A2
JARCR-XCI03
2044 B3 IN05 IN B3 B3
2045 A3 IN06 IN A3 A3
2046 B4 IN07 IN B4 B4
2047 A4 IN08 IN A4 A4
B5 B5 B5
A5 A5 A5
B6 B6 B6
A6 A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3040 B8 OUT01- General Output OUT B8 B8
A8 OUT01+ OUT A8 A8 RLY
3041 B9 OUT02- OUT B9 B9
3042 B10 OUT03- OUT B10 B10
3043 B11 OUT04- OUT B11 B11
3044 B12 OUT05- OUT B12 B12
3045 B13 OUT06- OUT B13 B13
Each Point
24VDC
500mA max. 3046 B14 OUT07- OUT B14 B14
3047 B15 OUT08- OUT B15 B15
JARCR-XCI01 B16 024VU B16 B16
Power Supply
A16 024VU
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
A17 024VU
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19 +24VU A19 A19 * means internal relay
024 VE
B20 FG B20 B20 RLY means
A20 A20 A20

2-43
RE-CTO-A208
YASNAC-XRC
(Optional)
CN11 Connector
Number Number Signal
Number
Each Point 2050 B1 IN09 IN B1 B1
24VDC 2051 A1 IN10 IN A1 A1
2053 A2 IN12 IN A2 A2
JARCR-XCI03
2054 B3 IN13 IN B3 B3
2055 A3 IN14 IN A3 A3
2056 B4 IN15 IN B4 B4
2057 A4 IN16 IN A4 A4
B5 B5 B5
A5 A5 A5
B6 B6 B6
A6 A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3050 B8 OUT09- OUT B8 B8
3051 B9 OUT10- OUT B9 B9
3052 B10 OUT11- OUT B10 B10
3053 B11 OUT12- OUT B11 B11
3054 B12 OUT13- OUT B12 B12
3055 B13 OUT14- OUT B13 B13
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 B14
3057 B15 OUT16- OUT B15 B15
Power Supply
A16 024VU
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
A17 024VU
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024VU A19 +24VU A19 A19
024 VE * means internal relay
A20 A20 A20

2-44
RE-CTO-A208
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. It the cube 1*2 area while this signal is
2010 starts robot operation (playback). This 2020
ON, the manipulator goes to wait sta-
signal is invalid if external start is pro- tus (with servo power ON). During
hibited from the playback condition wait status, the manipulator operation
display. restarts if this signal turns OFF.
CALL MASTER JOB INTERFERENCE 2 ENTRANCE

Only the rising edge of the signal is PROHIBITED
valid. It calls up the top of the robot If the manipulator attempts to enter
program, that is the top of the master the cube 2*2 area while this signal is
2012 job *1. This signal is invalid during 2021 ON, the manipulator goes to wait sta-
playback, during teach-lock and when tus (with servo power ON). During
play master or call is prohibited (set wait status, the manipulator operation
from the playback operation condi- restarts if this signal turns OFF.
tion display).
ALARM/ERROR RESET WORK PROHIBITED (Arc Genera-

After an alarm or error has occurred tion Prohibited)
and the cause been corrected, this Arc generation is prohibited while this
2013 signal resets the alarm or error. 2022 signal is ON. Arc generation starts
when this signal turns OFF inside the
arc-generation area. Use this signal
to confirm teaching.
SELECT REMOTE MODE WORK RESPONSE (Pseudo Arc ON

Functions the same as [REMOTE] on Response)
the playback panel. Valid only while This signal is used as a pseudo signal
2014 the signal is ON. It selects the 2023 in cases that “Arc Generation Confir-
REMOTE mode. mation” signal is not equiped on a
welding power supply. Wire this sig-
nal ON normally (short to OV).
SELECT PLAY MODE WEAVING PROHIBITED

Functions the same as [MODE] on Weaving is prohibited while this sig-
the playback panel. Only the rising nal is ON. Use this signal to check
edge of the signal is valid. It selects taught steps and movements without
the PLAY mode. If designated simul- performing the weaving operation.
2015 2026
taneously with other modes, the
TEACH mode takes priority. This sig-
nal is invalid if external mode selec-
tion is prohibited from the operation
condition display.
2-45
RE-CTO-A208
Specific Input List XCO02B (Arc Welding)
Logical Logical
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. signal is ON. Use this signal to check
Switching to other modes is disabled taught steps and movements if an arc
2016 while this signal is ON. If this signal 2027 sensor is mounted.
turns ON while the SELECT PLAY
MODE signal is ON, this signal takes
priority and the TEACH mode is
selected.
*1 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.
*2 See “ 3.7 Interfarence Area “of the YASNAC XRC Instructions.
Specific Output List XCO02B (Arc Welding)
Logical Logical
Output Name / Function Output Name / Function
Number Number
RUNNING IN CUBE 2
This signal signifies that the job is run- This signal turns ON when the current
ning. (Signifies that the job is running, tool center point lies inside a pre-defined
3010 system status is waiting reserved start, 3021 space (Cube 2). Use this signal to pre-
or test run is running.) This signal status vent interference with other manipulators
is the same status as [START] in the and jigs.
playback panel.
SERVO IS ON OPERATION ORIGIN POINT (IN CUBE
This signal signifies that the servo power 24)*1
is turned ON, internal processing such This signal turns ON when the current
as current position creation is complete, tool center point lies inside a the opera-
3011 and the system is able to receive the 3022 tion origin area. Use this signal to evalu-
START command. This signal turns OFF ate whether the robot is in the start
when the servo power supply turns OFF. position.
It can be used for XRC status diagnosis
for an external start.
TOP OF MASTER JOB INTERMEDIATE START OK (Sequence
This signal signifies that the execution Continues)
position is the top of the master job. This This signal turns ON when the manipula-
signal can be used to confirm that the tor operates. It turns OFF when the cur-
master job has been called.*2 rently executed line is moved with the
cursor or when editing operation is car-
3012 3023 ried out after HOLD is applied during
operation. Therefore, this signal can be
used as a restart interlock after a HOLD
is applied. However, it also turns ON in
the TEACH mode and TEACH MODE
SELECTED signal must be referred
together.
2-46
RE-CTO-A208
Specific Output List XCO02B (Arc Welding)
Logical Logical
Number Number
ALARM/ERROR OCCURRED GAS SHORTAGE (MONITOR)
This signal signifies that an alarm or an This signal stays ON while the gas short-
3013 error occurred. If a major error occurs, 3024 age signal from the welding power sup-
this signal remains ON until the main ply is ON.
power is turned OFF.
BATTERY ALARM WIRE SHORTAGE (MONITOR)
This signal turns ON to notify that the This signal status ON while the wire
battery requires replacing when the volt- shortage signal from the welding power
age drops from the battery for backup supply is ON.
3014 memory of the encoder. Major problems 3025
may result if memory data is lost
because of an expired battery. It is rec-
ommended to avoid these problems by
using this signal as a warning signal.
REMOTE/PLAY/TEACH MODE WIRE STICKING (MONITOR)
SELECTED The sticking check is conducted auto-
This signal notifies the current mode set- matically when the arc turns off. If wire
3015 to
ting. These signals are synchronized 3026 sticking is detected, this signal remains
3017
with the lamps [REMOTE] and [MODE] ON until the stick is released.
in the playback panel. The signal corre-
sponding to the selected mode turns ON.
IN CUBE 1 ARC SHORTAGE (MONITOR)
This signal turns ON when the current This signal stays ON while the arc short-
tool center point lies inside a pre-defined age signal from the welding power sup-
3020 2027
space (Cube 1). Use this signal to pre- ply is ON.
vent interference with other manipulators
and jigs.
*1 The operation origin cube and Cube 24 are same.

*2 This signal is not output during operation.
2-47
RE-CTO-A208
2.8.2 Handling
YASNAC-XRC
(Optional)
CN12 Connector
NumberNumber Name Signal Number
24VDC 2011 A1 - IN A1 A1
JARCR-XCI03

2017 A4 IN192 IN A4 A4
2022 B6 - IN B6 B6
2023 A6 - IN A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
Each Point
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
JARCR-XCI01
B16 024VU B16 B16
CN06 Internal A16
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
(24V,1A)
A17 024VU
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19 +24VU A19 A19
024 VE
B20 FG B20 B20
A20 A20 A20

2-48
RE-CTO-A208
YASNAC-XRC
(Optional)
CN13 Connector
NumberNum ber Signal Number
Each Point 2024 B1 - IN B1 B1

24VDC 2025 A1 - IN A1 A1
8mA max. 2026 B2
Shock Sensor (NC)
- Hold
IN B2 B2
2027 A2 Low Air Pressure IN A2 A2
JARCR-XCI03
2030 B3 IN01 General Input IN B3 B3

2031 A3 IN02 IN A3 A3
2032 B4 IN03 IN B4 B4
2033 A4 IN04 IN A4 A4
2034 B5 IN05 IN B5 B5
2035 A5 IN06 IN A5 A5
2036 B6 IN07 IN B6 B6
2037 A6 IN08 IN A6 A6
B7 024 VU B7 B7
A7 024 VU A7 A7
3024 B8 - OUT B8 B8
3025 A8 - OUT A8 A8
3026 B9 - OUT B9 B9
3027 A9 - OUT A9 A9
3030 B10 OUT01 General Output OUT B10 B10
3031 A10 OUT02 OUT A10 A10
3032 B11 OUT03 OUT B11 B11
3033 A11 OUT04 OUT A11 A11
3034 B12 OUT05 OUT B12 B12
3035 A12 OUT06 OUT A12 A12
3036 B13 OUT07 OUT B13 B13
3037 A13 OUT08 OUT A13 A13
Each Point
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
JARCR-XCI01
B16 024 VU B16 B16
Power Supply A16 024 VU
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
(24V,1A) A17 024VU
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19
A19 +24VU A19
024 VE
B20 FG B20 B20
A20 A20 A20
* Remove Jumper-pin between CN06-14 and -16, -13 and -15

2-49
RE-CTO-A208
YASNAC-XRC
(Optional)
CN10 Connector
Number
Each Point 2040 B1 Sensor Input 1 IN B1 B1

24VDC 2041 A1 Sensor Input 2 IN A1 A1
8mA max. 2042 B2 Sensor Input 3 IN B2 B2
2043 A2 Sensor Input 4 IN A2 A2
JARCR-XCI03
2044 B3 Sensor Input 5 IN B3 B3

2046 B4 Sensor Input 7 IN B4 B4
B5 B5 B5
A5 A5 A5
B6 B6 B6
A6 A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3040 B8 Hand Valve 1-1- OUT B8 B8
A8 Hand Valve 1-1+ OUT A8 A8 RLY
Each Point
24VDC A13 Hand Valve 3-2+ OUT A13 A13 RLY
500mA max. 3046 B14 Hand Valve 4-1- OUT B14 B14
Power Supply A16 024VU
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
A17 024VU
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
024 VE
A20 A20 A20

2-50
RE-CTO-A208
YASNAC-XRC
(Optional)
CN11 Connector
Number
24VDC 2051 A1 IN10 IN A1 A1
2053 A2 IN12 IN A2 A2
JARCR-XCI03
2054 B3 IN13 IN B3 B3
2055 A3 IN14 IN A3 A3
2056 B4 IN15 IN B4 B4
2057 A4 IN16 IN A4 A4
B5 B5 B5
A5 A5 A5
B6 B6 B6
A6 A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3051 B9 OUT10- OUT B9 B9
3052 B10 OUT11- OUT B10 B10
3053 B11 OUT12- OUT B11 B11
3054 B12 OUT13- OUT B12 B12
3055 B13 OUT14- OUT B13 B13
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 B14
3057 B15 OUT16- OUT B15 B15
Power Supply A16 024VU
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
(24V,1A) A17 024VU
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024VU A19 +24VU A19 A19 * means internal relay
024 VE
A20 A20 A20

2-51
RE-CTO-A208
Specific Output List XCO02B (Handling)
Logical Logical
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. It starts *2
2010 robot operation (playback). This signal is 2020 cube 1 area while this signal is ON, the
manipulator goes to wait status (with
invalid if external start is prohibited from servo power ON). During wait status, the
the playback condition display. manipulator operation restarts if this sig-
nal turns OFF.
CALL MASTER JOB INTERFERENCE 2 ENTRANCE PRO-
Only the rising edge of the signal is valid. HIBITED
It calls up the top of the robot program, If the manipulator attempts to enter the
2012 that is the top of the master job *1. This *2
2021 cube 2 area while this signal is ON, the
signal is invalid during playback, during manipulator goes to wait status (with
teach-lock and when play master or call servo power ON). During wait status, the
is prohibited (set from the playback manipulator operation restarts if this sig-
operation condition display). nal turns OFF.
ALARM/ERROR RESET SHOCK SENSOR
After an alarm or error has occurred and This is normally ON (NC) signal input.
the cause been corrected, this signal When it turns OFF, an XRC displays
resets the alarm or error. message "HAND SHOCK SENSOR
OPERATING" and a HOLD is applied.
2013 2026 The releasing in TEACH mode is done
on the handling application diagnostic
display. Set hand shock sensor function
“NOT USE” on the handling applications
diagnostic display if this siganl is not be
used.
SELECT REMOTE MODE LOW AIR PRESSURE
Functions the same as [REMOTE] on This signal is normally OFF (NO). When
2014 the playback panel. Valid only while the 2027 it turns ON, XRC displays user alarm in
signal is ON. It selects the REMOTE the PLAY mode or displays user mes-
mode. sage in the TEACH mode.
SELECT PLAY MODE SENSOR INPUT 1 - 8
Functions the same as [MODE] on the Inputs 1 to 8 are monitored with the
playback panel. Only the rising edge of HSEN handling specific instructions.
the signal is valid. It selects the PLAY Sensor inputs 1 to 8 correspond to
2040 to
2015 mode. If designated simultaneously with HSEN 1 to 8.
2047
other modes, the TEACH mode takes
priority. This signal is invalid if external
mode selection is prohibited from the
operation condition display.
SELECT TEACH MODE
The TEACH mode is selected if this sig-
nal turns ON during PLAY mode. Switch-
ing to other modes is disabled while this
2016
signal is ON. If this signal turns ON while
the SELECT PLAY MODE signal is ON,
this signal takes priority and the TEACH
mode is selected.
2-52
RE-CTO-A208
master job.
*2 See “ 3.7 Interference Area “ of the YASNAC XRC Instructions.
Logical Logical
Number Number
RUNNING IN CUBE 2
playback panel.
TOP MASTER JOB INTERMEDIATE START OK (Sequence
This signal signifies that the execution continues)
together.
ALARM/ERROR OCCURRING HAND VALVE 1-4
This signal signifies that an alarm or an These outputs are controlled by the
3040 to
3013 error occurred. If a major error occurs, HAND handling specific instructions.
3047
this signal remains ON until the main Hand valves 1 to 4 correspond to HAND
power is turned OFF. 1 to 4.
BATTERY ALARM
This signal turns ON to notify that the
battery requires replacing when the volt-
age drops from the battery for backup
3014 memory of the encoder. Major problems
2-53
RE-CTO-A208
Logical Logical
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. The signal corre-
sponding to the selected mode turns ON.
IN CUBE 1
This signal turns ON when the current
tool center point lies inside a pre-defined
3020
space (Cube 1). Use this signal to pre-
and jigs.

2-54
RE-CTO-A208
2.8.3 General Application
YASNAC-XRC
(Optional)
CN12 Connector
NumberNum ber Name Signal Number
24VDC 2011 A1 - IN A1 A1
JARCR-XCI03

2017 A4 IN192 IN A4 A4
2022 B6 Work Prohibited IN B6 B6
2023 A6 - IN A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
Each Point
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
JARCR-XCI01
B16 024VU B16 B16
Power Supply
A16 024VU
-14
+24 V B17 024VU B17 B17
024 V
-13 A17 024VU A17 A17
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19 +24VU A19 A19
024 VE
B20 FG B20 B20
A20 A20 A20

2-55
RE-CTO-A208
YASNAC-XRC
(Optional)
CN13 Connector
NumberNumber Signal Number
Each Point 2024 B1 Prohibited IN B1 B1
24VDC 2025 A1 Prohibited IN A1 A1
8mA max. 2026 B2 - IN B2 B2
2027 A2 - IN A2 A2
JARCR-XCI03
2030 B3 - IN B3 B3
2031 A3 - IN A3 A3
2032 B4 - IN B4 B4
2033 A4 - IN A4 A4
2034 B5 - IN B5 B5
2035 A5 - IN A5 A5
2036 B6 - IN B6 B6
2037 A6 - IN A6 A6
B7 024 VU B7 B7
A7 024 VU A7 A7
3026 B9 Work Command OUT B9 B9
3027 A9 - OUT A9 A9
3030 B10 - OUT B10 B10
3031 A10 - OUT A10 A10
3032 B11 - OUT B11 B11
3033 A11 - OUT A11 A11
3034 B12 - OUT B12 B12
3035 A12 - OUT A12 A12
3036 B13 - OUT B13 B13
3037 A13 - OUT A13 A13
Each Point
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
JARCR-XCI01
B16 024 VU B16 B16
Power Supply A16 024 VU
-14
+24 V B17 024VU B17 B17
-13 024 V A17
A17 024VU A17
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19 A19
A19 +24VU
024 VE
B20 FG B20 B20
A20 A20 A20

2-56
RE-CTO-A208
YASNAC-XRC
(Optional)
CN10 Connector
Number

24VDC 2041 A1 IN02 IN A1 A1
2043 A2 IN04 IN A2 A2
JARCR-XCI03
2044 B3 IN05 IN B3 B3
2045 A3 IN06 IN A3 A3
2046 B4 IN07 IN B4 B4
2047 A4 IN08 IN A4 A4
B5 B5 B5
A5 A5 A5
B6 B6 B6
A6 A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3041 B9 OUT02- OUT B9 B9
3042 B10 OUT03- OUT B10 B10
3043 B11 OUT04- OUT B11 B11
3044 B12 OUT05- OUT B12 B12
3045 B13 OUT06- OUT B13 B13
Each Point
24VDC
500mA max. 3046 B14 OUT07- OUT B14 B14
3047 B15 OUT08- OUT B15 B15
A16 024VU
-14 Power Supply
+24 V B17 024VU B17 B17
-13 024 V A17 024VU A17 A17
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
024 VE
A20 A20 A20

2-57
RE-CTO-A208
YASNAC-XRC
(Optional)
CN11 Connector
Number
24VDC 2051 A1 IN10 IN A1 A1
2053 A2 IN12 IN A2 A2
JARCR-XCI03
2054 B3 IN13 IN B3 B3
2055 A3 IN14 IN A3 A3
2056 B4 IN15 IN B4 B4
2057 A4 IN16 IN A4 A4
B5 B5 B5
A5 A5 A5
B6 B6 B6
A6 A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3050 B8 OUT09- OUT B8 B8
3051 B9 OUT10- OUT B9 B9
3052 B10 OUT11- OUT B10 B10
3053 B11 OUT12- OUT B11 B11
3054 B12 OUT13- OUT B12 B12
3055 B13 OUT14- OUT B13 B13
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 B14
3057 B15 OUT16- OUT B15 B15
A16 024VU
-14 Power Supply
+24 V B17 024VU B17 B17
-13 024 V A17 024VU A17 A17
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
024 VE
A20 A20 A20

2-58
RE-CTO-A208
Specific Input List XCO02B (General Application)
Logical Logical
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. It the cube 1*2 area while this signal is
2010 starts robot operation (playback). This 2020
signal is invalid if external start is pro- tus (with servo power ON). During
hibited from the playback condition wait status, the manipulator operation
display. restarts if this signal turns OFF.
CALL MASTER JOB INTERFERENCE 2 ENTRANCE

Only the rising edge of the signal is PROHIBITED
valid. It calls up the top of the robot If the manipulator attempts to enter
program, that is the top of the master the cube 2*2 area while this signal is
2012 job *1. This signal is invalid during 2021 ON, the manipulator goes to wait sta-
playback, during teach-lock and when tus (with servo power ON). During
play master or call is prohibited (set wait status, the manipulator operation
from the playback operation condi- restarts if this signal turns OFF.
tion display).
ALARM/ERROR RESET WORK PROHIBITED (Tool ON Pro-

After an alarm or error has occurred hibited)
2013 and the cause been corrected, this 2022 Even if TOOLON instruction is exe-
signal resets the alarm or error. cuted, XRC doesn’t output to external
while this signal is ON.
SELECT REMOTE MODE INTERFERENCE 3 ENTRANCE

Functions the same as [REMOTE] on PROHIBITED
the playback panel. Valid only while If the manipulator attempts to enter
the signal is ON. It selects the the cube 3*2 area while this signal is
2014 REMOTE mode. 2024
tus (with servo power ON). During
wait status, the manipulator operation
restarts if this signal turns OFF.
SELECT PLAY MODE INTERFERENCE 4 ENTRANCE

Functions the same as [MODE] on PROHIBITED
the playback panel. Only the rising If the manipulator attempts to enter
edge of the signal is valid. It selects the cube 4*2 area while this signal is
the PLAY mode. If designated simul- ON, the manipulator goes to wait sta-
2015 2025
taneously with other modes, the tus (with servo power ON). During
TEACH mode takes priority. This sig- wait status, the manipulator operation
nal is invalid if external mode selec- restarts if this signal turns OFF.
tion is prohibited from the operation
condition display.
2-59
RE-CTO-A208
Specific Input List XCO02B (General Application)
Logical Logical
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. If this signal
turns ON while the SELECT PLAY
MODE signal is ON, this signal takes
priority and the TEACH mode is
selected.
master job.
*2 See “ 3.7 Interfarence Area “ of the YASNAC XRC Instructions.
Specific Output List XCO02B (General Application)
Logical Logical
Number Number
RUNNING IN CUBE 2
playback panel.
TOP MASTER JOB INTERMEDIATE START OK (Sequence
This signal signifies that the execution continues)
together.
2-60
RE-CTO-A208
Specific Output List XCO02B (General Application)
Logical Logical
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. If a major error occurs, tool center point lies inside a pre-defined
this signal remains ON until the main space (Cube 3). Use this signal to pre-
3013 3024
power is turned OFF. vent interference with other manipulators
and jigs.
BATTERY ALARM IN CUBE 4

This signal turns ON to notify that the This signal turns ON when the current
battery requires replacing when the volt- tool center point lies inside a pre-defined
age drops from the battery for backup space (Cube 4). Use this signal to pre-
3014 memory of the encoder. Major problems 3025 vent interference with other manipulators
may result if memory data is lost and jigs.
REMOTE/PLAY/TEACH MODE WORK COMMAND
SELECTED This signal provides the command for
This signal notifies the current mode set- the general tool to operate. TOOL ON
ting. These signals are synchronized instruction execution or the [TOOL ON]
with the lamps [REMOTE] and [MODE] key in the programming pendant turns
3015 to
in the playback panel. The signal corre- 3026 this signal ON and TOOL OFF instruc-
3017
sponding to the selected mode turns ON. tion execution or the [TOOL OFF] key in
the programming pendant turns it OFF.
However, it remains OFF while the
WORK PROHIBITED signal (2022) is
input or while the robot is stopped.
IN CUBE 1
This signal turns ON when the current
tool center point lies inside a pre-defined
3020
space (Cube 1). Use this signal to pre-
and jigs.

2-61
RE-CTO-A208
2.8.4 Spot Welding
YASNAC-XRC
(Optional)
CN12 Connector
NumberNumber Name Signal Number
24VDC 2011 A1 - IN A1 A1
JARCR-XCI03

2017 A4 IN192 (Fan Alarm) IN A4 A4
2022 B6 Welding ON/OFF IN B6 B6
2023 A6 Welding Pause IN A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
Each Point
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
JARCR-XCI01
B16 024VU B16 B16
A16 024VU
-14 Power Supply
+24 V B17 024VU B17 B17
-13 024 V A17 024VU A17 A17
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19 +24VU A19 A19
024 VE
B20 FG B20 B20
A20 A20 A20

2-62
RE-CTO-A208
YASNAC-XRC
(Optional)
CN13 Connector
NumberNum ber Signal Number
Each Point 2024 B1 Prohibited IN B1 B1
24VDC 2025 A1 Prohibited IN A1 A1
8mA max. 2026 B2 - IN B2 B2
2027 A2 - IN A2 A2
JARCR-XCI03
2030 B3 IN1 IN B3 B3
2031 A3 IN2 IN A3 A3
2032 B4 IN3 IN B4 B4
2033 A4 IN4 IN A4 A4
2034 B5 IN5 IN B5 B5
2035 A5 IN6 IN A5 A5
2036 B6 IN7 IN B6 B6
2037 A6 IN8 IN A6 A6
B7 024 VU B7 B7
A7 024 VU A7 A7
3026 B9 OUT B9 B9
3027 A9 - OUT A9 A9
3030 B10 OUT01 General Output OUT B10 B10
3031 A10 OUT02 OUT A10 A10
3032 B11 OUT03 OUT B11 B11
3033 A11 OUT04 OUT A11 A11
3034 B12 OUT05 OUT B12 B12
3035 A12 OUT06 OUT A12 A12
3036 B13 OUT07 OUT B13 B13
3037 A13 OUT08 OUT A13 A13
Each Point
24VDC B14 B14 B14
50mA max. A14 A14 A14
B15 B15 B15
A15 A15 A15
JARCR-XCI01
B16 024 VU B16 B16
Power Supply
A16 024 VU
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
A17 024VU
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
+24 VE -15 024 VU A19
A19 +24VU A19
024 VE
B20 FG B20 B20
A20 A20 A20

2-63
RE-CTO-A208
YASNAC-XRC
(Optional)
CN10 Connector
Number
Timer Cooling Water
Each Point 2040 B1 Error (IN09) *** IN B1 B1
Gun Cooling Water
24VDC 2041 A1 Error (IN10) *** IN A1 A1
8mA max. 2042 B2 Transthermo Error (IN11)
*** IN B2 B2
2043 A2 Low Air Pressure (IN12) *** IN A2 A2
JARCR-XCI03
2044 B3 Weld Completion (IN13)

** IN B3 B3
2045 A3 Weld Error (IN14) IN A3 A3
**
Gun Short Open
2046 B4 Detection (IN15) ** IN B4 B4
Tip Replacement
2047 A4 Completion (IN16) ** IN A4 A4
B5 B5 B5
A5 A5 A5
B6 B6 B6
A6 A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3040 B8 OUT B8 B8
A8 Weld ON/OFF (OUT09)
*** OUT A8 A8 RLY
3041 B9 OUT B9 B9
A9 Weld Error Reset (OUT10) ** OUT A9 A9 RLY
3042 B10 OUT B10 B10
A10 Weld Condition 1 (OUT11) ** OUT A10 A10 RLY
3043 B11 OUT B11 B11
A11 Weld Condition 2 (OUT12)** OUT A11 A11 RLY
3044 B12 OUT B12 B12
A12 Weld Condition 3 (OUT13)** OUT A12 A12 RLY
3045 B13 OUT B13 B13
Each Point
A13 Weld Condition 4 (OUT14) ** OUT A13 A13 RLY
24VDC
500mA max. 3046 B14 OUT B14 B14
Gun Pressure
A14 Instruction (OUT15) ** OUT A14 A14 RLY
3047 B15 OUT B15 B15
Tip Replacement
A15 Request (OUT16) ** OUT A15 A15 RLY
Power Supply
A16 024VU
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
A17 024VU
(24V,1A)
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
024 VE
A20 A20 A20

** This assignment can be changed at the I/O assignment display. Refer to Specific Input List XCO02B and Specific Output List XCO02B for detail.
*** This assignment can be changed at the pseudo input display. Refer to Specific Input List XCO02B and Specific Output List XCO02B for detail.
2-64
RE-CTO-A208
YASNAC-XRC
(Optional)
CN11 Connector
Number
24VDC 2051 A1 IN18 IN A1 A1
2053 A2 IN20 IN A2 A2
JARCR-XCI03
2054 B3 IN21 IN B3 B3
2055 A3 IN22 IN A3 A3
2056 B4 IN23 IN B4 B4
2057 A4 IN24 IN A4 A4
B5 B5 B5
A5 A5 A5
B6 B6 B6
A6 A6 A6
B7 024VU B7 B7
A7 024VU A7 A7
3050 B8 OUT17- OUT B8 B8
3051 B9 OUT18- OUT B9 B9
3052 B10 OUT19- OUT B10 B10
3053 B11 OUT20- OUT B11 B11
3054 B12 OUT21- OUT B12 B12
3055 B13 OUT22- OUT B13 B13
Each Point
24VDC
500mA max. 3056 B14 OUT23- OUT B14 B14
3057 B15 OUT24- OUT B15 B15
CN06 Internal A16
-14
+24 V B17 024VU B17 B17
-13 024 V A17 A17
(24V,1A) A17 024VU
B18 +24VU B18 B18
A18 +24VU A18 A18
-16 +24VU
B19 +24VU B19 B19
024 VE
A20 A20 A20

2-65
RE-CTO-A208
Specific Input List XCO02B (Spot Welding)
Logical Logical
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. OFF selector switch status from the
It starts robot operation (playback). sequencer in the interlock unit. The
2010 2022
This signal is invalid if external start WELD ON/OFF signal is output to
is prohibited from the playback the welder according to this signal
condition display. and the manipulator status. Welding
is not wxecuted when this signal is
input (ON).
CALL MASTER JOB WELDING PAUSE (From

Only the rising edge of the signal is sequencer)
valid. It calls up the top of the robot This signal is used to move the
program, that is the top of the mas- manipulator to the origin point when
2012 ter job *1. This signal is invalid dur- 2023 an error occurs in the welder or the
ing playback, during teach-lock and gun.
when play master or call is prohib- The robot neglects the spot welding
ited (set from the playback opera- instruction and operates playback
tion condition display). motion.
ALARM/ERROR RESET INTERFERENCE 3 ENTRANCE

After an alarm or error has occurred PROHIBITED
and the cause been corrected, this If the manipulator attempts to enter
signal resets the alarm or error. the cube 3*2 area while this signal is
2013 2024 ON, the manipulator goes to wait
status (with servo power ON). Dur-
ing wait status, the manipulator
operation restarts if this signal turns
OFF.
SELECT REMOTE MODE INTERFERENCE 4 ENTRANCE

Functions the same as [REMOTE] PROHIBITED
on the playback panel. Valid only If the manipulator attempts to enter
while the signal is ON. It selects the the cube 4*2 area while this signal is
2014 REMOTE mode. 2025 ON, the manipulator goes to wait
OFF.
SELECT PLAY MODE TIMER COOLING WATER ERROR

Functions the same as [MODE] on This signal monitors the status of
the playback panel. Only the rising timer cooling water. The manipula-
edge of the signal is valid. It selects tor displays alarm and stops when
the PLAY mode. If designated 2040 this signal is input. The servo power
2015
simultaneously with other modes, *4 remains ON.
the TEACH mode takes priority.
This signal is invalid if external
mode selection is prohibited from
the operation condition display.
2-66
RE-CTO-A208
Logical Logical
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. gun cooling water. The manipulator
Switching to other modes is dis- displays alarm and stops when this
2041
2016 abled while this signal is ON. If this signal is input. The servo power
*4
signal turns ON while the SELECT supply remains ON.
PLAY MODE signal is ON, this sig-
nal takes priority and the TEACH
mode is selected.
INTERFERENCE 1 ENTRANCE TRANSTHERMO ERROR

PROHIBITED Error signal is sent from the transfo-
If the manipulator attempts to enter mer in the gun to the robot. This
the cube 1*2 area while this signal is signal is ON normally (NC) and an
2042 alarm occurs when the signal is
2020 ON, the manipulator goes to wait *4 OFF. The servo power supply
ing wait status, the manipulator remains ON.
OFF.
INTERFERENCE 2 ENTRANCE LOW AIR PRESSURE

PROHIBITED When air pressure is reduced and
If the manipulator attempts to enter this input is turned ON, an alarm
the cube 2*2 area while this signal is occurs. The servo power supply
2043 remains ON.
2021 ON, the manipulator goes to wait *4
OFF.
2-67
RE-CTO-A208
Logical Logical
Number Number
WELD COMPLETION GUN SHORT OPEN DETECTION

This signal indicates that the welder This signal is connected with a sin-
completed welding without error. gle gun open verification limit switch
This signal is used as a confirma- or a double stroke gun short open
2044 tion signal for welding instruction 2046 verifrcation limit switch to verify the
*3 execution and manual spot welding. *3 gun open.
After this signal is input, the welding
sequence is completed and the
next step is executed when confir-
mation limit switch is not provided.
WELDING ERROR GUN PRESSURE DETECTION

This signal indicates an abnormal This siganl indicates that a gun is in
2045 welding result or welder’s error. pressing status.
*3 Alarm occurs and the manipulator *3
stops if this signal is input during
welding.
STICK DETECTION TIP REPLACE COMPLETION

This signal indicates an abnormal When this signal is input after tip
welding result or welder’s error. 2047 replacement, the TIP REPLACE
*3 Alarm occurs and the manipulator *3 REQUEST signal turns OFF, and
stops if this signal is input during the stored number of welding is
welding. cleared.
GUN FULL OPEN DETECTION

This signal indicates that the stroke
*3 of the double stroke gun is full
open.
master job.
*2 See “ 3.7 Interference Area “ of the YASNAC XRC Instructions.
*3 This signal can be allocated to any general input signal at the I/O allocation display in
operation condition.
*4 This signal can be set as “USE” or “NOT USE” by pseudo input signal ”822x”. If “NOT
USE” is selected, this signal can be used as general input signal.
Pseudo Input 7 6 5 4 3 2 1 0
Signal 822x 0 0 0 1 1 1 1 1
Timer Cooling Water Error Validating

Gun Cooling Water Error Validating
Transthermo Error Validating
Low Air Pressure Validating
Weld ON/OFF Validating
2-68
RE-CTO-A208
Specific Output List XCO02B (Spot Welding)
Logical Logical
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. It turns OFF when the cur-
or test run is running.) This signal status rently executed line is moved with the
is the same status as [START] in the cursor or when editing operation is car-
3010 playback panel. 3023 ried out after HOLD is applied during
togather.
SERVO IS ON IN CUBE 3
This signal signifies that the servo power This signal turns ON when the current
is turned ON, internal processing such tool center point lies inside a pre-defined
as current position creation is complete, space (Cube 3). Use this signal to pre-
3011 and the system is able to receive the 3024 vent interference with other manipulators
START command. This signal turns OFF and jigs.
when the servo power supply turns OFF.
TOP MASTER JOB IN CUBE 4
This signal signifies that the execution This signal turns ON when the current
position is the top of the master job. This tool center point lies inside a pre-defined
3012 3025
signal can be used to confirm that the space (Cube 4). Use this signal to pre-
master job has been called.*2 vent interference with other manipulators
and jigs.
ALARM/ERROR OCCURRING WELD ON/OFF
This signal signifies that an alarm or an Outputs a signal input from the interlock
3040
3013 error occurred. If a major error occurs, panel, etc.considering the robot status.
*4
this signal remains ON until the main
power is turned OFF.
BATTERY ALARM WELD ERROR RESET
This signal turns ON to notify that the This signal commands the reset error
battery requires replacing when the volt- status of the welder. This is operated
age drops from the battery for backup with the programing pendant operation.
3041
3014 memory of the encoder. Major problems
*3
REMOTE/PLAY/TEACH MODE WELD CONDITION (Level signals)
SELECTED 1(1), 2(2), 4(3) , 8(4), 16(5), 32(6), 64(7),
This signal notifies the current mode set- 128(8)
ting. These signals are synchronized 3042 to Sets the welding conditions for the
3015 to
with the lamps [REMOTE] and [MODE] 3045 welder.
3017
in the playback panel. The signal corre- *3 The output format can be selected as
sponding to the selected mode turns ON. binary or discrete (bit number). It can
handle up to 255 conditions. Most-signif-
icant bit is the parity bit (when specified).
2-69
RE-CTO-A208
Specific Output List XCO02B (Spot Welding)
Logical Logical
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. This signal is not
3020
space (Cube 1). Use this signal to pre- *3 necessary for a welder which is exe-
vent interference with other manipulators cuted using the WELDING CONDITION
and jigs. signal.
IN CUBE 2 STROKE CHANGE1
This signal turns ON when the current SINGLE SOLENOID
tool center point lies inside a pre-defined DOUBLE SOLENOID
3021
space (Cube 2). Use this signal to pre- *3 This is a signal, when a double stroke
vent interference with other manipulators gun is used, to change the open stroke
and jigs. of the welding gun.
OPERATION ORIGIN POINT (IN CUBE GUN PRESSURE INSTRUCTION
24)*1 This outputs a gun pressure instruction.
This signal turns ON when the current 3046
3022 tool center point lies inside a the opera- *3
tion origin area. Use this signal to evalu-
ate whether the robot is in the start
position.
TIP REPLACEMENT REQUEST
3047 This is output when the number of
*3 strokes reaches the set value for tip
replacement.

*3 This signal can be allocated to any general output signal at the I/O allocation display in
operation condition.
*4 This signal can be select “USE” or “NOT USE” by pseudo input signal ”822x”. If “NOT
USE” is selected, this signal can be used as general input signal.
Pseudo Input 7 6 5 4 3 2 1 0
Signal 822x 0 0 0 1 1 1 1 1
Timer Cooling Water Error Validating

Gun Cooling Water Error Validating
Transthermo Error Validating
Low Air Pressure Validating
Weld ON/OFF Validating
2-70
RE-CTO-A208
2.8.5 JANCD-XEW01 Circuit Board

Arc Welding Application
There are two types of XEW01 circuit board as follows;
XEW01-01 : Analog Outputs x 3 ports + Status Signal Input of a Welder
XEW01-02 : Analog Outputs x 3 ports only
YASNAC-XRC
MR Connector MS Connector
Logical Conn e cto r Signal

NumberNumb e r
Name
CN03-1 1
Each Point
2300 CN03-2 +GASOF (Gas Shortage) IN 2
24VDC
5mA max. CN03-3 -GASOF (Gas Shortage) IN 3 S
JANCD-XEW01-1
2301 CN03-4 +WIRCUT (Wire Shortage) IN 4

CN03-5 -WIRCUT (Wire Shortage) IN 5 T
2303 CN03-6 +ARCACT (Arc Generation Confirm)IN 6
CN03-7 -ARCACT (Arc Generation Confirm) IN 7 P
CN03-8 8
CN03-9 CH3 (For extension) OUT 9
D/A ±14V
CN03-10 CH3-G (For extension) OUT 10
CN03-11 11
24VDC
5mA max. CN03-12 12
2302 CN03-13 +ARCOFF (Arc Shortage) IN 13
CN03-14 -ARCOFF (Arc Shortage) IN 14 R
24VDC 3301 CN03-15 ARCON (Arc ON) A OUT 15 K
0.5A max. CN03-16 ARCON (Arc ON) B OUT 16 L
3302 CN03-17 WIRINCH (Wire Inching) A OUT 17 F
Welder
CN03-18 WIRINCH (Wire Inching) B OUT 18 G
3303 CN03-19 WIRINCH (Wire Retract) A OUT 19 H
CN03-20 WIRINCH (Wire Retract) B OUT 20 J
3304 CN03-21 OUT1A (For extension) OUT 21
CN03-22 OUT1B (For extension) OUT 22
CN03-23 23
CN03-24 24
Detector CN03-25 25
2304 CN03-26 STICK (Wire Sticking) IN 26 M
CN03-27 *STICK (Wire Sticking) IN 27 N
CN03-28 28
CN03-29 +24VU 29
CN03-30 024VU 30 E
CN03-31 CH1 (Voltage Command) OUT 31 A
D/A ±14V
CN03-32 CH1-G OUT 32 B
CN03-33 CH2 (Current Command) OUT 33 C
D/A ±14V
CN03-34 CH2 -G OUT 34 D
24VDC 3305 CN02-2 Search Command A (Optional) OUT

0.5A max.
CN02-4 Search Command B (Optional) OUT
WAGO Connector MS3106 A, 20-29P

(231-105/026-A0) MRP-34M01 Insulator
MRP-M112 Contacts
RP-34 Casing MS3106 A, 20-29S
2-71
RE-CTO-A208
3.1 Regular Inspections
3 Inspections
CAUTION
• Do not touch the cooling fan or other equipment while the power is
turned ON.
Carry out the following inspections.
Inspection
Inspection Equipment Inspection Item Comments
Frequency
Check that the doors are Daily

completely closed.
XRC Controller
Check for gaps or dam- Monthly
age to the sealed con-
struction.
Fan on the upper part Check operation As required While power ON

of door
and backside duct fan
Emergency stop Check operation As required While servo ON

button
Deadman switch Check operation As required On teach mode
Confirm battery alarm or As required

Battery message is displayed or
not
3-1
RE-CTO-A208
3.2 XRC Inspections
3.2 XRC Inspections
3.2.1 Checking if the Doors are Firmly Closed

• The YASNAC XRC has a fully sealed construction, designed to keep external air contain-
ing oil mist out of the XRC.
Be sure to keep the XRC doors fully closed at all times, even when the controller is not
operating.
• Open or close the two locks in each door with the minus driver when opening or closing
the doors for maintenance after the main power is turned off. (CW:Open, CCW:Close)
Make sure push the door closed and turn the door lock with the driver. When the door is
closed, turn the door lock until the door clicks.
Door Lock
YASNAC XRC
WARNING SERVO ON MODE
READY PLAY TEACH
BRAKE RELEASE
S L U R B T
WARNING EDIT LOCK
(OFF) (ON) REMOTE
ALARM
HOLD START
High Voltage
Do not open the door
with power ON
ON
O
F
F
Main Switch
Handle X-
S-
Y-
X+
S+
Y+
L+ B-
R-
R+
y
L- B+
Z-
U-
Z+
U+
z
T-
z
T+
7 8 9
4 5 6
1 2 3
0 . -
Door Lock
NJ1530
TYPE ERCR-
POWER SUPPLY
SERIAL NO.
DATE P/N
YASNAC XRC Front View
3.2.2 Checking for Gaps or Damage in the Sealed Con-

struction Section
• Open the door and check that the seal around the door is undamaged.
• Check that the inside of the XRC is not excessively dirty. If it is dirty, determine the cause,
take measures to correct the problem and immediately clean up the dirt.
• Fully close each door lock and check that no excessive gaps exist around the edge of the
door.
3-2
RE-CTO-A208
3.3 Cooling Fan Inspections
Inspect the cooling fans as required. A defective fan can cause the XRC to malfunction
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. Check if the fans are operating correctly by visual inspection and by
feeling air moving into the air inlet and from the outlet.
Servo Top Fan
Air Inlet
SERVOPACK
Backside Duct Fan
Air Outlet
Cooling System (SV3X (Small Capacity Type))(Right side view)
Servo Top Fan
Air Inlet
SERVOPACK
Backside Duct Fan
Air Outlet
Natural Heat Natural Heat

Radiation Radiation
Cooling System (Except for SV3X (Small Capacity Type))(Right side view)
3-3
RE-CTO-A208
3.4 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
playback panel after the servo ON button, before the robot is operated.
3.5 Deadman Switch Inspections
The programing pendant is equipped with a three-position deadman switch. Perform the
following operation to confirm the deadman switch operates.
1. Press [TEACH] on the playback panel to switch to teach mode. The [TEACH] lamp
lights.
TEACH
2. Press [SERVO ON READY] on the playback panel. The [SERVO ON READY] lamp
blinks.
SERVO ON
READY
3. Press [TEACH LOCK] on the programming pendant. The [TEACH LOCK] LED blinks.
TEACH
LOCK
4. When the deadman switch is grasped lightly, the servo power is turned ON.
When the deadman switch is grasped firmly or released, the servo power is turned
OFF.
If the [SERVO ON READY] lamp does not light in previous operation (2), check the follow-
NOTE ing:
• The emergency stop button on the playback panel is pressed.
• The emergency stop button on the programming pendant is pressed.
• The emergency stop signal is input from external.
If the servo is not turned on in a previous operation 4, check the following:
• The overrun LS is operating.
• If a major alarm is occurring.
3-4
RE-CTO-A208
3.6 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
display.
The way to replace the battery is described in “9.1.1 Replacing Parts of the CPU Rack” of the
YASNAC XRC Instructions.
3.7 Power Supply Voltage Confirmation
Check the voltage of 1 (R), 3 (S), 5 (T) terminal of the disconnecting switch (QS1) with an
electric tester.
Power Supply Voltage Confirmation
Measuring Items Terminals Correct Value
Correlate voltage Between 1 and 3 (R and S), 575/480/240 V (+10%, -15%)

3 and 5 (S and T), 1 and 5
(R and T)
Voltage between earth Between 1 and E (R and E), 575/480/240 V (+10%, -15%)
(S phase ground) 5 and E (T and E)
Between 3 and E (S and E) About 0V
1(R) 3(S) 5(T) E

OFF
2(U) 4(V) 6(W) E
Disconnecting Switch (QS1)
3-5
RE-CTO-A208
3.8 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 electric tester.
(Normal value: 575/480/240 VAC (+10%, -15%))
The voltage differs depending on the built-in transformer tap
selection.
Disconnecting Switch Turn on the control power supply and check the open phase volt-
(QS1) Check age of “U,V,W” of the disconnecting switch (QS1) with an electric
tester. If abnormal, replace the disconnecting switch (QS1).
575/480/240 VAC Input

R S T
1 3 5
Disconnecting Switch
QS1
2 4 6
U V W
Transfomer (575-480-240V/208V)
T1
U V W
Fuse Holder
QS2
1KM
Power Supply Unit Converter

2KM
Fuse Holder
QS3
L1 L2 L3
3-6
RE-CTO-A208
4.1 Replacing XRC Parts
4 Replacing Parts
WARNING
• Turn OFF the power supply before opening the XRC doors.
Failure to observe this warning may result in electric shock.
• After turning OFF the power supply, wait at least 5 minutes before
replacing a servopack (including converter) or control power supply
unit. Do not touch any terminals during this period.
CAUTION
• To prevent anyone inadvertently turning ON the power supply during
maintenance, put up a warning sign such as "DO NOT TURN ON THE
POWER" at the primary power supply (knife switch, wiring circuit
breaker, etc.) and at the YASNAC XRC and related controllers and use
accepted lockout/tagout procedures.
• Do not touch the regeneration resistors. They are very hot.
Failure to observe this caution may result in burn injuries.
• After maintenance is completed, carefully check that no tools are left

inside the YASNAC XRC and that the doors are securely closed.
4-1
RE-CTO-A208
4.1.1 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 *1

FU2, TIME DELAY/CLASS CC (30A or less)
FU3 TIME DELAY/CLASS J (40A or more)
*1 The type of fuse differs depencing on the robot model. Refer to the table “Power Sup-
ply Fuse List”.
FU2
FU1 FU3
OFF
Direction for mounting fuse
ATDR
Disconnecting Switch Configuration
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).
NOTE Determine and correct the cause of the blown fuse. If the problem is uncorrected, the fuse
may blow again.
4-2
RE-CTO-A208
Fuse holders
The fuse holders (QS2,QS3) are equiped with the following fuses.
Fuse holders Parts No. Fuse Name Specification
QS2 FU4,FU5,FU6 Power Supply 600VAC *1

Fuse TIME DELAY/CLASS CC (30A or
less)
TIME DELAY/CLASS J (40A or
more)
QS3 FU7,FU8,FU9 Power Supply 600VAC *1

Fuse TIME DELAY/CLASS CC (30A or
less)
TIME DELAY/CLASS J (40A or
more)
*1 The type of fuse differs depencing on the robot model. Refer to the table “Power Sup-
ply Fuse List”.
Fuse Holders Configuration

an electric tester.
If the fuse is blown, replace it with the same type of fuse (supplied).
may blow again.
4-3
RE-CTO-A208
Power Supply Fuse List
Fuse Type
Robot Model
QS1 QS2 QS3
With built-in
3A 10A 5A
transformer
SV3X
Without trans-
10A - 5A
former
With built-in
5A 10A 10A
transformer
UP6
Without trans-
10A - 10A
former
With built-in
10A 15A 15A
transformer
SK16X, UP20
Without trans-
15A - 15A
former
With built-in
15A 20A 20A
transformer
SK45X, SK16MX, UP50, UP20M,
SP70X Without trans-
20A - 20A
former
With built-in
20A 30A 30A
transformer
UP130, UP165, UP165-100, UP200
Without trans-
30A - 30A
former
With built-in
30A 40A 40A
transformer
UP130R, UP130RL, SK300X,
SP100X, SR200X
Without trans-
40A - 40A
former
Time delay fuses of class CC (30A or less) or class J (40A or more) are used for QS1, QS2, and
QS3.
4-4
RE-CTO-A208
4.1.2 Replacing Parts of Power Supply Unit

The power supply unit (JZRCR-XPU05B, 06B, and 10B) is equipped with the following fuses.
1F, 2F Control Power Supply Fuse 250V, 10A, Time Lag Fuse
(Std: 326010, 250V, 10A (LITTEL))
4X 5X
1FU 2FU
10A 250V 10A 250V
(1F,2F)
1X
Fuse
250V 10A
326010 (LITTEL)
2KM SER NO.

TYPE
DATE
1KM
JAPAN NJ2096-1
Fuse Lcations in Power Supply Unit
Power Supply Unit Type
Type Applicable Robot Model

JZRCR-XPU05B UP50, UP20M, SK45X, SK16MX, SP70X,
UP130, UP165, UP165-100, UP200
JZRCR-XPU10B UP130R, UP130RL, SK300X, SR200X, SP100X
an electric tester.If the fuse is blown, replace it with the same type of fuse (supplied).
may blow again.
4-5
RE-CTO-A208
4.2 YASNAC XRC Parts List
YASNAC XRC Parts List
No. Name Model Comment
1 SERVOPACK *1 6 Axis type
2 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
3 I/O unit JZRCR-XCO02B
Specific I/O circuit board 1 JARCR-XCI01
Specific I/O circuit board 2 JARCR-XCU01B
General I/O circuit board JARCR-XCI03
4 Power ON unit JZRCR-XSU02
Power ON circuit board JARCR-XCT01
5 Break release control board JARCR-XFL02B
6 Transformer *4
7 Power supply unit *2
8 Playback pannel ZY1C-SS3152
9 Servo ascending fan 3610PS-22T-B30-B00
10 4715PS-22T-B30-B00 Small capacity only

Backside duct fun
5915PS-22T-B30-B00 Large capacity only
11 218005, 5A, 250V Time lag fuse
Power ON circuit board fuse 2183.15, 3.15A, 250V Time lag fuse
GP40, 4.0A, 250V Alarm fuse
12 Power ON circuit board relay LY2 24 VDC
13 Battery ER6VC3N 3.6V
14 Power supply fuse *3 Time deray / class cc
4-6
RE-CTO-A208
*1 The type of the SERVOPACK depends on the robot model. For details, see the Tables.
“ SERVOPACK List (Small Capacity)” and “SERVOPACKz List (Large Capacity)”.
*2 The type of the power supply unit depends on the robot model. For details, see the
Table “Power Supply Unit List”.
*3 The type of the fuse depends on the robot model. For details, refer to the table “ Fuse
List “.
*4 The type of transformer depends on the robot model. For details, see the table “Trans-
former List.”
SERVOPACK List (Small Capacity)
SV3X UP6 SK16X UP20

Component
Type Type Type Type
Servopack CACR-SV3AAA CACR-UP6AAC CACR-SK16AAC CACR-UP20AAA
Amplifier S JUSP-WS02AA JUSP- JUSP- JUSP-WS10AA

WS05AAY17 WS10AAY17
L JUSP-WS02AA JUSP- JUSP- JUSP-

WS10AAY17 WS10AAY17 WS20AAY22
U JUSP-WS01AA JUSP- JUSP- JUSP-

R JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA JUSP-WS02AA
B JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA JUSP-WS02AA
T JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA JUSP-WS02AA
Servo con- JASP-WRCA01 JASP-WRCA01 JASP-WRCA01 JASP-WRCA01

trol circuit
board
Converter JUSP-ACP05JAA JUSP-ACP05JAA JUSP-ACP05JAA JUSP-ACP05JAA
Control JUSP- JUSP- JUSP- JUSP-

power RCP01AAC RCP01AAC RCP01AAC RCP01AAC
supply
4-7
RE-CTO-A208
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 JUSP-WS10AA JUSP-WS10AA
Servo con- JASP-WRCA01 JASP-WRCA01 JASP-WRCA01

torol circuit
board
Converter JUSP-ACP25JAA JUSP-ACP25JAA JUSP-

ACP25JAAY11
Control JUSP- JUSP- JUSP-

power sup- RCP01AAC RCP01AAC RCP01AAC
ply
SERVOPACK List (Medium Capacity)
UP20M SP70X
Component
Type Type
SERVOPACK CACR- CACR-SP70AAB

UP20MAAB
Amplifier S JUSP-WS44AA JUSP-WS20AA
L JUSP-WS60AA JUSP-WS15AA
U JUSP-WS20AA JUSP-WS44AA
R JUSP-WS02AA JUSP-WS05AA
B JUSP-WS02AA -
T JUSP-WS02AA -
Servo control JASP-WRCA01 JASP-WACA01
circuit board
Converter JUSP- JUSP-ACP25JAA
ACP25JAAY11
Control power JUSP-RCP01AAC JUSP-RCP01AAC
supply
4-8
RE-CTO-A208
SERVOPACK List (Large Capacity)
UP130R, UP200
UP130, UP165 UP130RL
UP165-100
component
Type Type Type
SERVOPACK CACR-UP130AAB CACR- CACR-

UP130AABY18 UP130AABY21
Amplifier S JUSP-WS60AA JUSP- JUSP-

WS60AAY18 WS60AAY18
L JUSP-WS60AA JUSP- JUSP-

WS60AAY18 WS60AAY18
U JUSP-WS60AA JUSP-WS60AA JUSP-

WS60AAY18
R JUSP- JUSP- JUSP-

B JUSP- JUSP- JUSP-

T JUSP- JUSP- JUSP-

Servo control JASP-WRCA01 JASP-WRCA01 JAS-WRCA01

circuit board
Converter JUSP-ACP35JAA JUSP-ACP35JAA JUSP-ACP35JAA
Control power JUSP-RCP01AAC JUSP-RCP01AAC JUSP-RCP01AAC

supply
4-9
RE-CTO-A208
SERVOPACK List (Large Capacity)

Component
Type Type
SERVOPACK CACR-SK300AAB CACR-SP100AAB
Amplifier S JUSP- JUSP-

WS60AAY18 WS60AAY18
L JUSP- JUSP-
WS60AAY18 WS60AAY18
U JUSP- JUSP-
WS60AAY18 WS60AAY18
R JUSP- -
WS30AAY18
B JUSP- -
WS30AAY18
T JUSP- JUSP-
WS30AAY18 WS20AAY19
Servo con- JASP-WRCA01 JASP-WRCA01

trol circuit
board
Converter JUSP-ACP35JAA JUSP-ACP35JAA
Control JUSP-RCP01AAC JUSP-RCP01AAC

power supply
Power Supply Unit Type
Type Robot Type
JZRCR-XPU05B SK45X, SK16MX, UP50, UP20M,

SP70X, UP130, UP165, UP165-100,
UP200
JZRCR-XPU10B UP130R, SK300X, SP100X, UP130RL,

SR200X
4-10
RE-CTO-A208
Transformer Type
Robot Type Transformer Type
SV3X HB9480046
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
Fuse Type
Robot Type
QS1 QS2 QS3
With trans-
3A 10A 5A
former built-in
SV3X
Without trans-
10A - 5A
former
With trans-
5A 10A 10A
former built-in
UP6
Without trans-
10A - 10A
former
With trans-
10A 15A 15A
former built-in
SK16X, UP20
Without trans-
15A - 15A
former
With trans-
15A 20A 20A
SK45X, SK16MX, UP50, UP20M, former built-in
20A - 20A
former
With trans-
20A 30A 30A
former built-in
UP130, UP165, UP165-100, UP200
Without trans-
30A - 30A
former
With trans-
30A 40A 40A
UP130R, UP130RL, SK300X, former built-in
SP100X, SR200X
Without trans-
40A - 40A
former
QS3.
4-11
RE-CTO-A208
4.3 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.
No Parts Name Dimensions Pcs Model Application
Class CC
2 *1
(30 or less)
Time Delay
Disconnecting
Fuse
1 switch
Power Supply
Fuse holders
Fuse
Class J
2 *1
(40 or more)
5A 218005
JARCR-XSU02
2 Glass-Tube 2 5A 250V
FU3, 4, 7, 8
fuse 30 (LITTEL)
2183.15
3.15A
3.15A JARCR-XSU02
3 Glass-Tube 2
250V FU1, 2, 9, 10
fuse 30
(LITTEL)
326010 JZRCR-
10A 10A XPU05B, 06B,
4 2
Ceramic fuse 250V 10B
30
(LITTEL) 1F,2F
GP40
4.0A
4.0A 32 JANCD-XSU02
5 2 250V
Alarm fuse FU5, 6
20.5
(Daito
11.5 Tsushin)
WAGO 2 231-131
Connector wir- (WAGO) CPS-150F
6
ing CN04
tool
*1 The type of the fuse depends on the robot type. See the table “Power Supply Fuse”.
4-12
RE-CTO-A208
Fuse Type
Robot Model
QS1 QS2 QS3
With built-in
3A 10A 5A
transformer
SV3X
Without trans-
10A - 5A
former
With built-in
5A 10A 10A
transformer
UP6
Without trans-
10A - 10A
former
With built-in
10A 15A 15A
transformer
SK16X, UP20
Without trans-
15A - 15A
former
With built-in
15A 20A 20A
transformer
SK45X, SK16MX, UP50, UP20M,
20A - 20A
former
With built-in
20A 30A 30A
transformer
UP130, UP165, UP165-100, UP200
Without trans-
30A - 30A
former
With built-in
30A 40A 40A
transformer
UP130R, UP130RL, SK300X,
SP100X, SR200X
Without trans-
40A - 40A
former
QS3.
4-13
RE-CTO-A208
4.4 Recommended Spare Parts
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. To buy the spare
parts which are ranked B or C, inform the manufacturing number (or order number ) of XRC to
Yaskawa representative. The spare parts are ranked as follows:

• Rank C: Drive unit
NOTE For replacing parts in Rank B or Rank C, contact your Yaskawa representative.
4-14
RE-CTO-A208
Recommended Spare Parts of XRC for SV3X
Qty
Manufa
No Rank Name Type Qty per Remark
cturer
unit
1 A Battery ER6VC3N 3.6V Toshiba 1 1
Battery
2 A Rack fan JZNC-XZU02 Yaskawa 2 2
3 A Backside Duct Fan 4715PS-22T- Minebea 2 2
B30-B00
4 A In-panel Fan on upper part 3610PS-22T- Minebea 2 2
of Servo B30-B00
5 A Power Supply Fuse ATDR3 3A GOULD 3 3 Not used when
transformer not
provided
6 A Power Supply Fuse ATDR 5 5A GOULD 3 3
7 A Power Supply Fuse ATDR 10 10A GOULD 3 3
8 A Control Power Fuse 218005 5A 250V LITTEL 10 2
9 A 24VDC Fuse 2183.15 3.15A LITTEL 10 2
250V
10 A Control Power Supply 326010 10A 250V LITTEL 2 2
Fuse in Power Supply Unit
11 A Brake Fuse GP40 4.0A 250VDaito Com- 10 2
munication
Apparatus
12 A Control Relay LY2 DC24V Omron 3 3
13 B Converter JUSP-ACP05JAA Yaskawa 1 1
14 B Control Power Supply Unit JUSP-RCP01AAC SANRITZ 1 1 For Servo
15 B SERVOPACK Control JASP-WRCA01 Yaskawa 1 1
Board
16 B Amplifier JUSP-WS02AA Yaskawa 1 2 For S, L axes
17 B Amplifier JUSP-WS01AA Yaskawa 1 1 For U axis
18 B Amplifier JUSP-WS05AA Yaskawa 1 3 For R, B, T
axes
19 B Control Power Supply Unit CPS-150F Fuji Electric 1 1 For CPU Unit
Hi-Tech
20 B System Control Board JANCD-XCP01 Yaskawa 1 1
21 B Communication Board JANCD-XIF03 Yaskawa 1 1
22 B Specific I/O Board 1 JARCR-XCI01 Yaskawa 1 1
23 B Genenal I/O Board JARCR-XCI03 Yaskawa 1 1
24 B Specific I/O Board 2 JARCR-XCU01B Yaskawa 1 1
25 B Power On Board JARCR-XCT01 Yaskawa 1 1
26 C Servopack CACR-SV3AAA Yaskawa 1 1
27 C CPU Unit JZNC-XRK01B-1 Yaskawa 1 1
28 C I/O Unit JZNC-XIU02B Yaskawa 1 1
29 C Power Supply Unit JZRCR-XPU06B Yaskawa 1 1
30 C Programming Pendant JZNC-XPP02B Yaskawa 1 1 With Cable
8m
*Specify application (Arc, General, Spot, Handling) of key sheet when No.30 “ Programming
Pendant” is ordered.
4-15
RE-CTO-A208
Recommended Spare Parts of XRC for UP6
Manufa Qty per

No Rank Name Type Qty unit Remark
cturer
Battery
B30-B00
of Servo B30-B00
transformer not
provided
6 A Power Supply Fuse ATDR10 10A GOULD 3 6
7 A Control Power Fuse 218005 5A 250V LITTEL 10 2
8 A DC24V Fuse 2183.15 3.15A LITTEL 10 2
250V
munication
Apparatus
Board
15 B Amplifier JUSP- Yaskawa 1 2 For S,U axes
WS05AAY17
16 B Amplifier JUSP- Yaskawa 1 1 For L axis
WS10AAY17
17 B Amplifier JUSP-WS01AA Yaskawa 1 3 For R,B,T
axes
Hi-Tech
25 C SERVOPACK CACR-UP6AAC Yaskawa 1 1
27 C I/O Power On Unit JZNC-XCO02B Yaskawa 1 1
28 C /O Power On Unit JZRCR-XSU02 Yaskawa 1 1
8m
4-16
RE-CTO-A208
Recommended Spare Parts of XRC for SK16X

Qty per
No Rank Name Type Manufacturer Qty unit
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
munication
Apparatus
Board
15 B Amplifier JUSP- Yaskawa 1 3 For S,L,U
WS10AAY17 axes
axes
Hi-Tech
24 C SERVOPACK CACR-SK16AAC Yaskawa 1 1
26 C I/O Unit JZRCR-XCO02B Yaskawa 1 1
27 C I/O Power On Unit JZNC-XSU02 Yaskawa 1 1
8m
4-17
RE-CTO-A208

Qty per
Remark
Battery
B30-B00
4 A Servo Top Fan 3610PS-22T- Minebea 2 2
B30-B00
transformer not
provided
Fuse
8 A 24VDC Fuse 2183.15 3.15A LITTEL 10 2
250V
munication
Apparatus
Board
15 B Amplifier JUSP-WS10AA Yaskawa 1 1 For S axis
WS20AAY22
17 B Amplifier JUSP- Yaskawa 1 1 For U axis
WS10AAY17
axes
Hi-Tech
26 C SERVOPACK CACR-UP20AAA Yaskawa 1 1
8m
4-18
RE-CTO-A208
Recommended Spare Parts of XRC for SK16MX

Qty per
Remark
Battery
3 A Backside Duct Fan 5915PC-22T- Minebea 2 2
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
munication
Apparatus
14 B Servopack Control Board JASP-WRCA01 Yaskawa 1 1
16 B Amplifier JUSP-WS20AA Yaskawa 1 2 For L,U axes
axes
Hi-Tech
25 C SERVOPACK CACR- Yaskawa 1 1
SK16MAAB
8m
4-19
RE-CTO-A208

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
munication
Apparatus
13 B Control Power Unit JUSP-RCP01AAC SANRITZ 1 1 For Servo
16 B Amplifier JUSP-WS20AA Yaskawa 1 2 For L,U axes
axes
Hi-Tech
24 B Power ON Board JARCR-XCT01 Yaskawa 1 1
25 C SERVOPACK CACR-SK45AAB Yaskawa 1 1
28 C I/O Power On Unit JZRCR-XSU02 Yaskawa 1 1
8m
4-20
RE-CTO-A208
Recommended Spare Parts of XRC for UP20M

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
10 A Brake Fuse GP40 4.0A 250V Daito Com- 10 2
munication
Apparatus
12 B Converter JUSP- Yaskawa 1 1
ACP25JAAY11
Board
16 B Amplifier JUSP-WS60AA Yaskawa 1 1 For L axis
17 B Amplifier JUSP-WS20AA Yaskawa 1 1 For Uaxis
axes
Hi-Tech
UP20MAAB
8m
4-21
RE-CTO-A208

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
munication
Apparatus
ACP25JAAY11
Board
17 B Amplifier JUSP-WS20AA Yaskawa 1 2 For Uaxis
axes
Hi-Tech
26 C SERVOPACK CACR-UP50AAB Yaskawa 1 1
8m
4-22
RE-CTO-A208
Recommended Spare Parts of XRC for SP70X

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
munication
Apparatus
Board
18 B Amplifier JUSP-WS05AA Yaskawa 1 3 For R axis
Hi-Tech
26 C SERVOPACK CACR-SP70AAB Yaskawa 1 1
8m
4-23
RE-CTO-A208
Recommended Spare Parts of XRC for UP130, UP165

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
9 A Control Power Supply 326010 10A LITTEL 2 2
munication
Apparatus
Board
15 B Amplifier JUSP-WS60AA Yaskawa 1 3 For S, L, U
axes
16 B Amplifier JUSP- Yaskawa 1 1 For R axis
WS20AAY13
17 B Amplifier JUSP- Yaskawa 1 2 For B, T axes
WS15AAY13
Hi-Tech
24 B Power On Board JANCD-XCT01 Yaskawa 1 1
UP130AAB
8m
4-24
RE-CTO-A208

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
munication
Apparatus
Board
16 B Amplifier JUSP- Yaskawa 1 2 For S, L axes
WS60AAY18
WS20AAY13
WS15AAY13
Hi-Tech
UP130AABY18
8m
4-25
RE-CTO-A208
Recommended Spare Parts of XRC for UP130R

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
6 A Power Supply Fuse LPJ-40SP 40A BUSSMAN 3 6
Fuse
250V
munication
Apparatus
Board
16 B Amplifier JUSP- Yaskawa 1 2 For S, L axes
WS60AAY18
WS20AAY13
WS15AAY13
Hi-Tech
UP130AABY18
8m
4-26
RE-CTO-A208
Recommended Spare Parts of XRC for UP130RL

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
6 A Power Supply Fuse LPJ-40SP 40A BUSSMAN 3 6
Fuse
250V
munication
Apparatus
Board
15 B Amplifier JUSP- Yaskawa 1 2 For S, U, L
WS60AAY18 axes
WS20AAY13
WS15AAY13
Hi-Tech
UP130AABY21
8m
4-27
RE-CTO-A208
Recommended Spare Parts of XRC for SR200X, SK300X

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
6 A Power Supply Fuse LPJ-40SP BUSSMAN 3 6
Fuse
250V
munication
Apparatus
Board
15 B Amplifier JUSP- Yaskawa 1 3 For S, L, U
WS60AAY18 axes
16 B Amplifier JUSP- Yaskawa 1 3 For R, B, T
WS30AAY13 axes
Hi-Tech
24 C SERVOPACK CACR-SK300AAB Yaskawa 1 1
8m
4-28
RE-CTO-A208

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
6 A Power Supply Fuse LPJ-40SP BUSSMAN 3 6
Fuse
250V
munication
Apparatus
Board
15 B Amplifier JUSP- Yaskawa 1 3 For S, L, U
WS60AAY18 axes
16 B Amplifier JUSP- Yaskawa 1 1 For T axis
WS30AAY13
Hi-Tech
24 C SERVOPACK CACR-SP100AAB Yaskawa 1 1
8m
4-29
YASNAC XRC
INSTRUCTIONS
SUPPLEMENTARY FOR NORTH AMERICAN (ANSI/RIA) STANDARD
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
Phone 1-937-847-6200 Fax 1-937-847-6277
Phone 1-905-813-5900 Fax 1-905-813-5911
YASKAWA ELECTRIC AMERICA, INC.
2121 Norman Drive South Waukegan, IL 60085, U.S.A.
Phone 1-847-887-7000 Fax 1-847-887-7370
Phone 49-6196-569-300 Fax 49-6196-888-301
MOTOMAN ROBOTICS EUROPE AB
Box 504 S38525 Torsas, Sweden
Phone 46-486-48800 Fax 46-486-41410
MOTOMAN ROBOTEC GmbH
Kammerfeldstr.1,D-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
KFPA Bldg #1201, 35-4 Yeoido-dong, Youngdungpo-Ku, Seoul 150-010, Korea
Phone 82-2-784-7844 Fax 82-2-784-8495
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD. MALAYSIA REPRESENTATIVE OFFICE
B615, 6th Floor, East Wing, Wisma Tractors, No.7, Jalan SS 16/1, Subang Jaya, 47500 Petaling Jaya, Selangor D.E. Malaysia
Phone 60-3-5031-5311 Fax 60-3-5031-5312
YASKAWA ELECTRIC (SHANGHAI) CO., LTD.
4F No Aona Road, Waigaoqiao Free Trade Zone, Pudong New Area, Shanghai 200131, China
Phone 86-21-5866-3470 Fax 86-21-5866-3869
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16, Nanking E. RD., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
YASKAWA ELECTRIC (HK) COMPANY LIMITED
Phone 852-2803-2385 Fax 852-2547-5773
BEIJING OFFICE
Room No. 301 Office Building Intemational Club, 21 Jianguomenwai Avenue, Beijing 100020, China
Phone 86-10-6532-1850 Fax 86-10-6532-1851
30 Xue Yuan Road, Haidian, Beijing P.R. China Post Code: 100083, China
Phone 86-10-6234-5003 Fax 86-10-6234-5002
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541 Fax 86-10-6788-2878
YASKAWA
Specifications are subject to change without notice MANUAL NO.RE-CTO-A208 1

for ongoing product modifications and improvements. C Printed in Japan July 2002 01-03
YASKAWA
YASNAC XRC
INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
YASNAC XRC OPERATOR’S MANUAL for BEGINNERS
YASKAWA MANUAL NO. RE-CTO-A203 4

RE-CTO-A203
MANDATORY
• 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.
• General items related to safety are listed in the Setup Manual Section 1:
Safety of Setup Manual. To ensure correct and safe operation, carefully
read the Setup Manual before reading this manual.
CAUTION


on the front cover.

uct’s warranty.
ii
RE-CTO-A203

YASNAC XRC.
“MANDATORY”,or ”PROHIBITED”.


practices.

MANDATORY heading.
iii
RE-CTO-A203
WARNING
• Before operating the manipulator, check that servo power is turned off
turned off.
the servo power ON

TURN
teach a job.
the playback panel.


iv
RE-CTO-A203
CAUTION
after use.
• Read and understand the Explanation of the Alarm Display in the setup
manual before operating the manipulator.

In this manual, the equipment is designated as follows.
v
RE-CTO-A203
shown as follows:
Pendant denoted with [ ].
ex. [ENTER]
ex. page key

shown.

ex. [SHIFT]+[COORD]

denoted with { }.
ex. {JOB}
Playback Panel Buttons Playback panel buttons are enclosed in brackets.

ex. [TEACH] on the playback panel

In the explanation of the operation procedure, the expression "Select • • • " means that the
cursor is moved to the object item and the SELECT key is pressed.
vi
RE-CTO-A203
Setup • Diagnosis xv
1 Outline of Setting and Diagnosis
2 Security System
2.1 Protection Through Security Mode Settings . . . . . .2-1
2.1.1 Security Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Modification of Security Mode . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.1.2 User ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Changing a User ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
3 System Setup
3.1 Home Position Calibration . . . . . . . . . . . . . . . . . . . .3-1
3.1.1 Home Position Calibration . . . . . . . . . . . . . . . 3-2
3.1.2 Calibrating Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Registering All Axes at On Time . . . . . . . . . . . . . . . . . . . . . .3-3
Registering Individual Axes . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Changing the Absolute Data . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Clearing Absolute Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3.1.3 Home Position of the Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3.2 Specified Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3.2.1 Purpose of Position Check Operation . . . . . . . . . . . . . . . . . . .3-10
3.2.2 Specified Point Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3.2.3 Procedure After an Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3.3 Setting the Controller Clock . . . . . . . . . . . . . . . . . .3-13
3.4 Setting Play Speed . . . . . . . . . . . . . . . . . . . . . . . .3-14
3.5 All Limits Releasing . . . . . . . . . . . . . . . . . . . . . . . .3-16
3.6 Overrun / Shock Sensor Releasing . . . . . . . . . . . .3-18
3.7 Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3.7.1 Interference Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3.7.2 Cubic Interference Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Cubic Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Setting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Setting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3.7.3 Axis Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Axis Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Setting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3.7.4 Clearing Interference Area Data . . . . . . . . . . . . . . . . . . . . . . .3-29
3.8 Operation Origin Point Setting . . . . . . . . . . . . . . . .3-30
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3.8.1 What is the Operation Origin Point? . . . . . . . . . . . . . . . . . . . . 3-30

3.8.2 Setting Operation Origin Point . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Operation Origin Point Display . . . . . . . . . . . . . . . . . . . . . . 3-30
Registering/Changing the Operation Origin Point. . . . . . . . 3-30
Returning to the Operation Origin Point . . . . . . . . . . . . . . . 3-31
Output of the Operation Origin Point Signal . . . . . . . . . . . . 3-31
3.9 Tool Data Setting . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.9.1 Registering Tool Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Number of Tool Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Registering Coordinate Data . . . . . . . . . . . . . . . . . . . . . . . 3-32
Registering Tool Pose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Setting the Tool Load Information. . . . . . . . . . . . . . . . . . . . 3-35
3.9.2 Tool Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Tool Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Clearing Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Checking the Tool Center Point . . . . . . . . . . . . . . . . . . . . . 3-40
3.9.3 Automatic Measurement of the Tool Load and the Center of Gravity
3-41
What is the Automatic Measurement of the Tool Load and the
Center of Gravity? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Measurement of the Tool Load and the Center of Gravity . 3-41
3.10 User Coordinates Setting . . . . . . . . . . . . . . . . . . 3-45
3.10.1 User Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Definition of User Coordinates . . . . . . . . . . . . . . . . . . . . . . 3-45
User Coordinates File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3.10.2 User Coordinates Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Selecting User Coordinates File . . . . . . . . . . . . . . . . . . . . . 3-46
Teaching User Coordinates . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Clearing User Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.11 ARM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.11.1 ARM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.11.2 ARM CONTROL Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Robot Setup Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3.11.3 Tool Load Information Setting . . . . . . . . . . . . . . . . . . . . . . . 3-53
Tool Load Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
How to Calculate Tool Load Information. . . . . . . . . . . . . . . 3-54
Tool load Information registering . . . . . . . . . . . . . . . . . . . . 3-61
3.12 Shock Detection Function. . . . . . . . . . . . . . . . . . 3-64
3.12.1 Shock Detection Function . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3.12.2 Shock Detection Function Setting . . . . . . . . . . . . . . . . . . . . 3-64
Shock Detection Level Setting . . . . . . . . . . . . . . . . . . . . . . 3-64
Tool load Information Setting . . . . . . . . . . . . . . . . . . . . . . . 3-67
Instruction of Shock Detection Function . . . . . . . . . . . . . . . 3-68
Reset Shock detected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3.12.3 Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.13 Instruction Level Setting . . . . . . . . . . . . . . . . . . . 3-75
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3.13.1 Setting Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75

Instruction Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75
Learning Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
3.13.2 Setting Instruction Set Level Operation. . . . . . . . . . . . . . . . .3-76
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
Key Allocation (EACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78
Key Allocation (SIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78
3.14.3 Allocating an Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-79
Allocation Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-79
Instruction Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-80
Job Call Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81
Display Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82
Alternate Output Allocation . . . . . . . . . . . . . . . . . . . . . . . . .3-83
Momentary Output Allocation . . . . . . . . . . . . . . . . . . . . . . .3-83
Pulse Output Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-84
Group (4-bit/8-bit) Output Allocation . . . . . . . . . . . . . . . . . .3-85
Analog Output Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-85
Analog Incremental Output Allocation . . . . . . . . . . . . . . . . .3-86
3.14.4 Allocation of I/O Control Instructions. . . . . . . . . . . . . . . . . . .3-86
3.14.5 Execution of Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-88
Executing the Instruction/Output Control Allocation . . . . . .3-88
Executing the Job Call Allocation . . . . . . . . . . . . . . . . . . . .3-88
Executing the Display Allocation . . . . . . . . . . . . . . . . . . . . .3-88
Executing the I/O Control Allocation . . . . . . . . . . . . . . . . . .3-88
3.15 Changing the Output Status . . . . . . . . . . . . . . . .3-89
3.16 Temporary Release of Soft Limits . . . . . . . . . . . .3-91
3.17 Changing the Parameter Setting . . . . . . . . . . . . .3-92
3.18 File Initialize. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-95
3.18.1 Initialize Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-95
3.18.2 Initialize Data File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-96
3.18.3 Initialize Parameter File. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-97
3.18.4 Initializing I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-98
3.18.5 Initializing System Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-99
4 Modification of System Configuration

4.1 Addition of I/O Modules . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Addition of Base and Station Axis . . . . . . . . . . . . . .4-3
4.2.1 Base Axis Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.2.2 Station Axis Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
5 System Diagnosis
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5.1 System Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Robot Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Input/Output Status . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.1 Universal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Universal Input Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Universal Input Detailed Display. . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.2 Universal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Universal Output Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Universal Output Detailed Display . . . . . . . . . . . . . . . . . . . . 5-3
Modify the Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.3 Specific Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Specific Input Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Specific Input Detailed Display . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.4 Specific Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Specific Output Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Specific Output Detailed Display . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.5 RIN INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
RIN INPUT Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.6 Modify the Signal Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.7 Search the Signal Number . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.3.8 Relay Number Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.4 System Monitoring Time . . . . . . . . . . . . . . . . . . . . 5-15
5.4.1 System Monitoring Time Display . . . . . . . . . . . . . . . . . . . . . . 5-15
5.4.2 Individual Display of the System Monitoring Time . . . . . . . . . 5-16
5.4.3 Clearing the System Monitoring Time. . . . . . . . . . . . . . . . . . . 5-17
5.5 Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.5.1 Alarm History Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.5.2 Clearing the Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.6 I/O Message History . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.6.1 I/O Message History Display . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.6.2 Clearing the I/O Message History . . . . . . . . . . . . . . . . . . . . . . 5-20
5.7 Position Data When Power is Turned ON/OFF. . . 5-21
5.7.1 Power ON/OFF Position Display . . . . . . . . . . . . . . . . . . . . . . 5-21
5.8 Current Position Display . . . . . . . . . . . . . . . . . . . . 5-22
5.8.1 Current Position Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.9 Servo Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.9.1 Servo Monitor Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Changing the Monitor Items . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Clearing Maximum Torque Data. . . . . . . . . . . . . . . . . . . . . 5-25
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Hardware 26

6.1 Specification List . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6.2 Function List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6.3 Programming Pendant. . . . . . . . . . . . . . . . . . . . . . .6-6
6.4 Equipment Configuration . . . . . . . . . . . . . . . . . . . . .6-7
6.4.1 Arrangement of Units and Circuit Boards . . . . . . . . . . . . . . . . .6-7
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6.4.2 Cooling System of the Controller Interior. . . . . . . . . . . . . . . . .6-15

7.1 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.2 CPU Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.2.1 CPU Rack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.2.2 Circuit Board in the CPU Rack . . . . . . . . . . . . . . . . . . . . . . . . .7-4
System Control Circuit Board (JANCD-XCP01o) . . . . . . . . .7-4
Control Power Supply Unit (CPS-150F) . . . . . . . . . . . . . . . .7-4
WAGO Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
7.3 I/O Contactor Unit (JZNC-XIU01o) . . . . . . . . . . . . .7-7
7.3.1 Specific Input Circuit Board (JANCD-XIO01o) . . . . . . . . . . . . .7-8
Safety Plug Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
7.3.2 General I/O Circuit Board (JANCD-XIO02) . . . . . . . . . . . . . .7-11
Connection wire with General I/O (CN10, 11, 12, 13) . . . . .7-12
Specific I/O Signal Related to Start and Stop . . . . . . . . . . .7-13
7.3.3 Power-on Circuit Board (JANCD-XTU01®) . . . . . . . . . . . . . . .7-14
Connection of Shock Sensor . . . . . . . . . . . . . . . . . . . . . . . .7-14
Connection of External Power Supply for I/O . . . . . . . . . . .7-15
Method of connecting external axis overrun signal . . . . . . .7-17
7.4 Playback Panel . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
7.5 Contact Output of Emergency Stop Button . . . . . .7-19
7.6 Servopack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
7.6.1 Servopack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
7.6.2 Description of Each Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
Servo Control Circuit board (JASP-WRCA01). . . . . . . . . . .7-29
Servo Control Power Supply (JUSP-RCP01®®®) . . . . . . .7-29
Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
7.7 General I/O Signal Assignment . . . . . . . . . . . . . . .7-30
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7.7.1 Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7.7.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.7.3 General Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7.7.4 Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
7.7.5 JANCD-XEW02 Circuit Board (Standard). . . . . . . . . . . . . . . . 7-56
For Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
7.7.6 JANCD-XEW01 Circuit Board (Option). . . . . . . . . . . . . . . . . . 7-57
Arc Welding Application . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
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Maintenance 59
8 Inspections
8.1 Regular Inspections . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.2 XRC Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
8.2.1 Checking if the Doors are Firmly Closed . . . . . . . . . . . . . . . . . .8-2
8.2.2 Checking for Gaps or Damage in the Sealed Construction Section
8-2
8.3 Cooling Fan Inspections . . . . . . . . . . . . . . . . . . . . .8-3
8.4 Emergency Stop Button Inspections . . . . . . . . . . . .8-6
8.5 Deadman Switch Inspections . . . . . . . . . . . . . . . . .8-6
8.6 Battery Inspections . . . . . . . . . . . . . . . . . . . . . . . . .8-7
8.7 Power Supply Voltage Confirmation . . . . . . . . . . . .8-7
8.8 Open Phase Check . . . . . . . . . . . . . . . . . . . . . . . . .8-8
9 Replacing Parts
9.1 Replacing XRC Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1 Replacing Parts of the CPU Rack . . . . . . . . . . . . . . . . . . . . . . .9-2
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2
Replacing the JANCD-XCP01o Circuit Board . . . . . . . . . . . .9-3
Replacing the Control Power Unit (CPS-150F) . . . . . 9-4
9.1.2 Replacing the Servopack . . . . . . . . . . . . . . . 9-5
9.1.3 Replacing the parts of I/O Power-on Unit . . . . . . . . . . . . . . . . .9-8
Checking and Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . .9-8
9.2 YASNAC XRC Parts List . . . . . . . . . . . . . . . . . . . .9-10
9.3 Supplied Parts List. . . . . . . . . . . . . . . . . . . . . . . . .9-15
9.4 Recommended Spare Parts . . . . . . . . . . . . . . . . .9-15
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Alarm • Error 32
10 Alarm
10.1 Outline of Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2.1 Displaying/Releasing Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2.2 Special Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.3 Alarm Message List . . . . . . . . . . . . . . . . . . . . . . 10-5
10.4 I/O Alarm Message List . . . . . . . . . . . . . . . . . . 10-57
Arc Welding Application . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
Handling Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
Spot Welding Application . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
General Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
11 Error
11.1 Error Message List . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1.1 System and General Operation . . . . . . . . . . . . . . . . . . . . . . 11-2
11.1.2 Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.1.3 Job Defined Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.1.4 External Memory Equipment . . . . . . . . . . . . . . . . . . . . . . . 11-10
11.1.5 Concurrent I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
11.1.6 Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
xiv
RE-MTO-A203
Setup • Diagnosis
-xv
RE-MTO-A203
1 Outline of Setting and Diagnosis
WARNING
• Various settings control system compatibility and manipulator perfor-
mance characteristics. Exercise caution when changing settings that
can result in improper manipulator operation. Personal injury and/or
equipment damage may result if incorrect settings are applied by the
user.
• Observe the following precautions to safeguard system settings:
- Maintain supervisory control of user functions.

- 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. The following must be performed to create a more powerful system.
• Home Position Calibration

• Second Home Position
• IO Status Display
• Time Setting
Making these settings optimizes the system to perform to its maximum potential in the chosen
application.
NOTE These functions can be operated in the teach mode.
1-1
RE-CTO-A203
2.1 Protection Through Security Mode Settings
2 Security System
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.
2.1.1 Security Mode

There are three security modes. Editing mode and managememt mode require a user ID. The
user ID consists of numbers and letters, and contains no less than 4 and no more than 8 char-
acters. (Significant numbers and signs: ”0 to 9”, “-”, “.”.
Security Mode Descriptions
Security Mode Explanation
This mode allows basic operation of the robot (stopping,

Operation Mode
starting, etc.) for people operating the robot work on the line.
This mode allows the operator to teach and edit jobs and
Editing Mode
robot settings.
This mode allows those authorized to set up and maintain

Managememt
robot system: parameters, system time and modifying user
Mode
IDs.
2-1
RE-CTO-A203
Menu & Security Mode
Allowed Security Mode

Top Menu Sub Menu
DISPLAY EDIT
JOB JOB Operation Edit
SELECT JOB Operation Operation
CREATE NEW JOB Edit Edit
MASTER JOB Operation Edit
JOB CAPACITY Operation -
RESERVED START (JOB) Edit Edit
RESERVATION STATUS Operation -
VARIABLE BYTE Operation Edit
INTEGER Operation Edit
DOUBLE Operation Edit
REAL Operation Edit
POSITION (ROBOT) Operation Edit
POSITION (BASE) Operation Edit
POSITION (ST) Operation Edit
IN/OUT EXTERNAL INPUT Operation -
EXTERNAL OUTPUT Operation -
UNIVERSAL INPUT Operation -
UNIVERSAL OUTPUT Operation -
SPECIFIC INPUT Edit -
SPECIFIC OUTPUT Edit -
RIN Edit -
REGISTER Edit -
AUXILIARY RELAY Edit -
CONTROL INPUT Edit -
PSEUDO INPUT SIGNAL Edit Management
NETWORK INPUT Edit -
ANALOG OUTPUT Edit -
SV POWER STATUS Edit -
LADDER PROGRAM Management Management
I/O ALARM Management Management
I/O MESSAGE Management Management
2-2
RE-CTO-A203

Top Menu Sub Menu
DISPLAY 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 Operation -
TOOL Edit Edit
INTERFERENCE Management Management
SHOCK SENS LEVEL Operation Management
USER COORDINATE Edit Edit
HOME POSITION Management Management
MANIPULATOR TYPE Management -
ROBOT CALIBRATION Edit Edit
ANALOG MONITOR Management Management
OVERRUN&S-SENSOR Edit Edit
LIMIT RELEASE Edit Management
ARM CONTROL Management Management
SHIFT VALUE Operation -
SYSTEM INFO MONITORING TIME Operation Management
ALARM HISTORY Operation Management
I/O MSG HISTORY Operation Management
VERSION Operation -
FD/PC CARD LOAD Edit -
SAVE Operation -
VERIFY Operation -
DELETE Operation -
FORMAT Operation Operation
DEVICE Operation Operation
FOLDER Operation Management
2-3
RE-CTO-A203

Top Menu Sub Menu
DISPLAY EDIT
PARAMETER S1CxG Management Management
S2C Management Management
A1P Management Management
RS Management Management
S1E Management Management
SETUP TEACHING COND Edit Edit
OPERATE COND Management Management
DATE/TIME Management Management
GRP COMBINATION Management Management
SET WORD Edit Edit
RESERVE JOB NAME Edit Edit
USER ID Edit Edit
SET SPEED Management Management
KEY ALLOCATION Management Management
RESERVED START (CONNECT) Management Management
ARC WELDING ARC START CONDITION Operation Edit
ARC END CONDITION Operation Edit
ARC AUXILIARY CONDITION Operation Edit
WELDER CONDITION Operation Edit
ARC WELD DIAGNOSIS Operation Edit
WEAVING Operation Edit
HANDLING HANDLING DIAGNOSIS Operation Edit
SPOT WELDING WELD DIAGNOSIS Operation Edit
I/O ALLOCATION Management Management
GUN CONDITION Management Management
WELDER CONDITION Management Management
SPOT WELDING WELD DIAGNOSIS Operation Edit
(MOTOR GUN)
GUN PRESSURE Edit Edit
PRESSURE Edit Edit
I/O ALLOCATION Management Management
GUN CONDITION Management Management
2-4
RE-CTO-A203

Top Menu Sub Menu
DISPLAY EDIT
GUN CONDITION AUX Management Management
WELDER CONDITION Management Management
GENERAL GENERAL DIAGNOSIS Operation Edit
Modification of Security Mode

Operation
Select {SECURITY} under the top menu*1 Select the desired mode*2 Input the
*3
user ID Press [ENTER]
Explanation
*1 The current security mode is displayed in menu title of the top menu.
CYCLE SECURITY
L
EDITING MODE R1 C S
JOB ARC WELDING VARIABLE

OUT
IN
IN/OUT ROBOT SYSTEM INFO
!Turn on servo power
*2 When the selected security mode is a higher level than the current settings, a user ID
must be input.
.
CYCLE SECURITY
L
OPERATION
EDITING MODE
MODE R1 C S
EDITING MODE
MANAGEMENT MODE
JOB ARC WELDING VARIABLE

OUT
IN
IN/OUT ROBOT SYSTEM INFO
At the factory, the following below user ID number is preset.

SUPPLE
-MENT
• Editing Mode:[00000000]
• Managememt Mode:[99999999]
*3 The input user ID is compared with the user ID of the selected security mode. When the
correct user ID is entered, the operation mode is changed.
2-5
RE-CTO-A203
2.1.2 User ID
User ID is requested when Editing Mode or Managememt Mode is operated.
User ID must be between 4 characters and 8, and they must be numbers and symbols
(“0~9”,“-” and “.”).
Changing a User ID
In order to change the user ID, the XRC must be in Editing Mode or Managememt Mode.
Higher security modes can make changes to lower security modes.
Operation
Select {SETUP} under the top menu Select {USER ID}*1 Select the desired ID*2
Input current ID and press [Enter]*3 Input new ID and press [Enter]*4
Explanation
*1 User ID registration display is shown.
DATA EDIT DISPLAY UTILITY

L
USER ID R1 C S
EDITING MODE
∗∗∗∗∗∗∗∗
MANAGEMENT MODE
∗∗∗∗∗∗∗∗
*2 The character input line is displayed, and the message "Input current ID no. (4 to 8 dig-
its)" is displayed.

L
USER ID R1 C S
EDITING MODE
∗∗∗∗∗∗∗∗
MANAGEMENT MODE
∗∗∗∗∗∗∗∗
>
!Input current ID no.(4 to 8 digits)
2-6
RE-CTO-A203
*3 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.

L
USER ID R1 C S
EDITING MODE
∗∗∗∗∗∗∗∗
MANAGEMENT MODE
∗∗∗∗∗∗∗∗
>
!Input new ID no.(4 to 8 digits)
*4 User ID is changed.
2-7
RE-CTO-A203
3.1 Home Position Calibration
3 System Setup
WARNING
an emergency.
• Always set the teach lock before starting to teach.
Failure to observe this warning may result in injury when operating the playback panel.


• Prior to performing the following operations, be sure that no one is in

the working envelope of the manipulator, and be sure that you are in a
safe place when:
- Turning the power on to the XRC.

- Running check operations.
- Performing automatic operations.
Injury may result from contact with the manipulator if persons enter the working envelope
of the manipulator.
• Always press the emergency stop button immediately if there are prob-
lems.
Emergency stop buttons are located at the upper right corner of the
XRC playback panel and on the upper right of the programming pendant.
3-1
RE-CTO-A203
CAUTION
• 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.

- Always return the programming pendant to its hook on the XRC cabi-
net after use.
If the programming pendant is inadvertently left on the manipulator, a fixture, or on the

floor, the manipulator or a tool could collide with it during manipulator movement, possibly
causing injury or equipment damage.
3.1.1 Home Position Calibration
Teaching and playback are not possible before home position calibration is complete.
NOTE In a system with two or more manipulators, the home position of all the manipulators must
be calibrated before starting teaching or playback.
Home position calibration is an operation in which the home position and encoder zero posi-
tion coincide. Although this operation is performed prior to shipment at the factory, the follow-
ing cases require this operation to be performed again.
• Change in the combination of the manipulator and XRC

• Replacement of the motor or encoder
• Clearing stored memory (by replacement of XCP01 board, weak battery, etc.)
• Home position deviation caused by hitting the manipulator against a workpiece, etc.
To calibrate the home position, use the axis keys to calibrate the mark for the home position
on each axis so that the manipulator can take its posture for the home position. There are two
operations for home position calibration:
• All the axes can be moved at the same time

• Axes can be moved individually
If the absolute data of the home position is already known, set the absolute data again after
completing home position registration.
3-2
RE-CTO-A203
Home Position
SUPPLE
-MENT
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. See "
3.1.3 Home Position of the Robot ".
3.1.2 Calibrating Operation

Registering All Axes at On Time
Operation
Select {ROBOT} under the top menu Select {HOME POSITION}*1 Select {DIS-
*2
PLAY} under the menu Select the desired control group Select {EDIT} under
the menu*3 Select {SELECT ALL AXES}*4 Select “YES”*5
Explanation
*1 The home position calibration display is shown.

L
HOME POSITIONING R1 C S
SELECT ABSOLUTE DATA
R1:S *
L *
U *
R *
B *
T *
*2 The pull down menu appears.

L
HOME POSITIONING ROBOT1
R1 C S
SELECT STATION1
ABSOLUTE DATA
R1:S *
L *
U *
R *
B *
T *
3-3
RE-CTO-A203
*3 The pull down menu appears.

L
SELECT ALL AXIS
R1:S *
L *
U *
R *
B *
T *
*4 The confirmation dialog is displayed.

L
R1:S *
L *
Create home position?
U *
R *
B YES NO *
T *
*5 Displayed position data of all axes are registered as home position.

When “NO” is selected, the registration will be canceled.
Registering Individual Axes

Operation
Select {ROBOT} under the top menu Select {HOME POSITION} Select {DIS-
PLAY} under the menu Select the desired control group*1 Select the axis to be
*2 *3
registered Select “YES”
Explanation
*1 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.

L
R1:S -278
L 30154
U *
R -217
B *
T *
3-4
RE-CTO-A203

L
R1:S -278
L 30154
Create home position?
U *
R -217
B YES NO *
T *
*3 Displayed position data of axis are registered as home position.

When “NO” is selected, the registration will be canceled.
Changing the Absolute Data

To change the absolute data of the axis when home position calibration is completed, perform
the following:
Operation
Select {ROBOT} under the top menu Select {HOME POSITION} Select {DIS-
PLAY} Select the desired control group*1 Select the absolute data to be regis-
*2
tered Enter the absolute data using the number keys Press [ENTER]*3
Explanation
*1 By the same way shown in Explanation *1,*2 in ”Registering all axes at once”, the
home calibration display and select control group are shown.
*2 The number input buffer line is shown.

L
R1:S -278
L 30154
U -29912
R -217
B 7745
T 15881
>3000
!
*3 Absolute data are modified.
3-5
RE-CTO-A203
Clearing Absolute Data

Operation
Select {ROBOT} under the top menu Select {HOME POSITION}*1 Select
*2
{DATA} under the menu Select {CLEAR ALL DATA}
Explanation
*1 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.
*2 The all absolute data are cleared.

L
R1:S *
L *
U *
R *
B *
T *
3-6
RE-CTO-A203
3.1.3 Home Position of the Robot

In case of UP6, the home position are as follows.
U-axis angle against horizontal

line on the ground(-0°) B-axis center line angle against
U-axis center line(-90°)
L-axis angle against vertical

line to the ground(-0°)
NOTE Other manipulator models have different positions. Always consult the documentation for
the correct manipulator model.
3-7
RE-CTO-A203
3.2 Specified Point
3.2 Specified Point
WARNING
• 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.
• Before operating the manipulator, check that the SERVO ON lamp

goes out when the emergency stop buttons on the playback panel
and programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in

case of an emergency.
• Always set the teach lock before starting to teach.
Failure to observe this warning may result in injury when operating the playback
panel.
• Observe the following precautions when performing teaching oper-

ations within the working envelope of the manipulator :

• Prior to performing the following operations, be sure that no one is

in the working envelope of the manipulator, and be sure that you
are in a safe place when:
- Turning the power on to the XRC.

- Running check operations.
- Performing automatic operations.
Injury may result from contact with the manipulator if persons enter the working
envelope of the manipulator.
• Always press the emergency stop button immediately if there are

problems.
Emergency stop buttons are located at the upper right corner of the XRC playback
panel and at the upper right of the programming pendant.
3-8
RE-CTO-A203
3.2 Specified Point
CAUTION
• 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 damage to the insulation and sheathing of external
wires.
- Always return the programming pendant to its hook on the XRC
cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a fixture, or on

the floor, the manipulator or a tool could collide with it during manipulator move-
ment, possibly causing injury or equipment damage.
3-9
RE-CTO-A203
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.
There are two possible causes of this alarm:
• Error in the PG system

• The manipulator was moved after the power was turned OFF.
If there is an error with the PG system, the manipulator may stall when playback is started. If
the absolute data allowable range error alarm has occurred, playback and test runs will not
function and the position must be checked.
After absolute data allowable range alarm occurs
Reset alarm
Turn ON servo power
Procedure After Alarm Occurs
Position checking
Compare second home NG

position pulses with
current position pulses
Alarm occurs again
OK
Correct defective axis
• Replace PG system
• Home position calibration
Playback possible
Position Check
If the absolute data allowable range alarm occurs, move to the specified point using the axis
keys and check the position. Playback, test runs, and other operation will not function.
3-10
RE-CTO-A203
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.
• The allowable range is the number of pulses per rotation of the motor (PPR data).
• The initial value of the specified point is the home position (where all axes are at pulse 0).
The specified point can be changed. For details, refer to " 3.2 Specified Point ".
Alarm Occurence
If the error alarm occurs again, there may be an error in the PG system. Check the system.
After adjusting the erroneous axis, calibrate the home position of the axis, then check the
position again.
• Home position calibration of all the axes at the same time enables playback operations
NOTE without having to check the position.
• Sometimes in a system with a manipulator that has no brake, it is possible to enable

playback without position checking after the absolute data allowable range error alarm
occurs. However, as a rule, always check the position.
Under the above special conditions, the manipulator moves as follows:
After starting, the manipulator moves at low speed (1/10 of the maximum speed) to the
step indicated by the cursor. If it is stopped and restarted during this motion, the low
speed setting is retained until the step at cursor is reached. Regardless of cycle setting,
the manipulator stops after the cursor step is reached. Starting the manipulator again
then moves it at the programmed speed and cycle of the job.
3.2.2 Specified Point Setting

Apart from the normal home position of the manipulator, the specified point can be set up as a
check point for absolute data. Use the following steps to set the specified point.
If two or more manipulators or stations are controlled by one control panel, the specified point
must be set for each manipulator or station.
Operation
Select {ROBOT} under the top menu Select {SECOND HOME POS}*1 Press
*2 Press the axis keys*3 Press [MODIFY] and [ENTER]*4
the page key
3-11
RE-CTO-A203
3.2 Specified Point
Explanation
*1 The specified point display is shown.
The message “Available to move to any modify specified point” is shown.

L
SPECIFIED POINT R1 C S
SPECIFIED CURRENT DIFFERENCE
R1:S 0 0 0
L 0 0 0
U 0 0 0
R 0 0 0
B 0 0 0
T 0 0 0
!Available to move to any modify specified point
*2 The group axes by which the specified point is set is selected when there are two or
more group axes.
*3 Move the manipulator to the new specified point.
*4 The specified point is modified.
3.2.3 Procedure After an Alarm
WARNING
• Be aware of safety hazards when performing the position confirma-
tion of the specified point.
Abnormality of the PG system may be cause for alarm. The manipulator may oper-
ate in an unexpected manner, and there is a risk of damage to equipment or injury.
If the absolute data allowable range alarm occurs, perform the followings
• Reset the alarm
• Turn Servo power on
and confirm the specified point. After the confirmation, if the PG is found to be the cause of the
alarm, perform the necessary operation, such as replacing the PG, etc.
The robot position data when turning power off and on are shown in “Power ON/OFF Position
Display”.
NOTE Refer to " 5.7 Position Data When Power is Turned ON/OFF " for details on the
“Power ON/OFF Position Display”.
3-12
RE-CTO-A203
3.3 Setting the Controller Clock
Operation
Select {ROBOT} under the top menu Select {SECOND HOME POS}*1 Press
the page key *2 Press [FWD]*3 Select {DATA} under the menu Select
{CONFIRM POSITION}*4
Explanation
*1 The specified point display is shown.
*2 The group axes by which the specified point is set is selected when there are two or
more group axes.
*3 Move the manipulator to the new specified point.The robot moving speed is set as
selected manual operation speed.
*4 The message “Home position checked” is shown.

Pulse data of specified point and current pulse data are compared. If the compared
error is in allowed band, playback operation can be done.
If the error is beyond the allowed band, the alarm occurs again.
3.3 Setting the Controller Clock
The clock inside of the XRC controller can be set.
Operation
Select {SETUP} under the top menu Select {DATE/TIME}*1 Select “DATE” or
“CLOCK”*2 Input the new date or time*3 Press [ENTER]*4
Explanation
*1 The date and time set display is shown.

L
DATE/CLOCK SET R1 C S
DATE 1998 . 10 . 20
CLOCK 10 : 20
*2 The input buffer line is displayed.
3-13
RE-CTO-A203
3.4 Setting Play Speed
*3 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
*4 Date and time are modifed.

L
DATE/CLOCK SET R1 C S
DATE 1998 . 05 . 01
CLOCK 10 : 20
Operation
Select {SETUP} under the top menu Select {SET SPEED}*1 Press the page key
*2 Select “JOINT” or “LNR/CIR”*3 Select desired speed value*4 Input
*5
the speed value Press [ENTER]
Explanation
*1 The play speed display is shown.

L
SPEED SET R1 C S
JOINT R1:1 0.78 %
2 1.56 %
3 3.12 %
4 6.25 %
5 12.50 %
6 25.00 %
7 50.00 %
8 100.00 %
*2 When two or more manipulators and stations exist in the system, the control group is
changed by the page key .
3-14
RE-CTO-A203
*3 The type of speed alternately changes from “JOINT” to “LNR/CIR”.

L
SPEED SET R1 C S
LNR/CIR R1:1 66 cm/min
2 138 cm/min
3 276 cm/min
4 558 cm/min
5 1122 cm/min
6 2250 cm/min
7 4500 cm/min
8 9000 cm/min
*4 The input buffer line is displayed.
*5 The speed value is modified.

L
SPEED SET R1 C S
JOINT R1:1 0.78 %
2 1.56 %
3 3.12 %
4 40.00 %
5 12.50 %
6 25.00 %
7 50.00 %
8 100.00 %
3-15
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3.5 All Limits Releasing
CAUTION
• 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.
Limit Type Contents
Mechanical Limit Limit for checking manipulator’s working envelope
L-U Interference Limit for checking L- and U-axes interference area
Software Limit Every axis soft limit for checking manipulator’s

working envelope
Cube Interference Limit for checking cube interference area set by

user
NOTE If the security mode is not at managememt mode, all limits releasing is not allowed. Refer
to " 2 Security System " for details about security modes.
Operation
Select {ROBOT} under the top menu Select {LIMIT RELEASE}*1 Select “ALL
*2
LIMITS RELEASE”
3-16
RE-CTO-A203
Explanation
*1 The limit release display ia shown.

L
LIMIT RELEASE R1 C S
SOFT LIMIT RELEASE INVALID
ALL LIMITS RELEASE INVALID
*2 “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” is displayed. When the setting changes to “INVALID”, the message “All limits
release has been canceled” is displayed for three seconds.

L
ALL LIMITS RELEASE VALID
!All limits have been released
3-17
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3.6 Overrun / Shock Sensor Releasing
3.6 Overrun / Shock Sensor Releasing
CAUTION
• 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.
Operation
Select {ROBOT} under the top menu Select {OVERRUN & S-SENSOR}*1
Select “RELEASE”*2 Select “ALM RST”*3
Explanation
*1 The overrun & shock sensor release display is shown.
The stopping condition when the shock sensor is detected can be selected “EMER-
GENCY STOP” or “HOLD” at the “SHOCK SENSOR STOP COMMAND”. “E-STOP”
and “HOLD” are displayed alternately every time [SELECT] is pressed.

L
OVERRUN&SHOCK SENSOR R1 C A
SHOCK SENSOR STOP COMMAND :E-STOP
OCCUR GRP OVERRUN S-SENSOR
ROBOT1
RELEASE ALM RST
3-18
RE-CTO-A203
3.7 Interference Area
*2 “ " is displayed at the control group which detects overrun or shock sensor. If
“RELEASE” is selected, overrun or shock sensor is released and “CANCEL” is dis-
played.

L
OVERRUN&SHOCK SENSOR R1 C A
SHOCK SENSOR STOP COMMAND :E-STOP
OCCUR GRP OVERRUN S-SENSOR
ROBOT1
CANCEL ALM RST
*3 Alarm is reset and manipulator can be moved using the axis keys.
• During overrun or shock sensor releasing, the manipulator can be moved using the axis
NOTE keys with low speed or inching motion only.
• After overrun or shock sensor releasing, if “CANCEL” is selected or the display is changed
to the other one, overrun or shock sensor releasing is canceled.
• The axis operation can be performed only in the joint coordinate system.
3.7.1 Interference Area

The interference area is a function that prevents interference between multiple manipulators
or the manipulator and peripheral devices. The area can be set up to 24 area. There are two
types of interference areas, as follows:
• Cubic Interference Area
• Axis Interference Area
The XRC judges whether the tool center point of the manipulator is inside or outside this area,
and outputs this status as a signal.
If the tool center point of the manipulator is inside the area, the interference 1 inside signal or
interference 2 inside signal come on and the manipulator automatically decelerates to a stop.
The manipulator stands by until these signals are turned off, whereupon it automatically
restarts.
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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. The cubic interference areas can be set, parallel to the base coordinate system or
user coordinate system.
Robot coordinates
Z-axis
Cubic
interference
area
Cubic
interference Cubic
User Coordinates area interference
Z-axis area
X-axis
Y-axis Y-axis
X-axis
Setting Method
There are three ways to set cubic interference areas, as described in the following:
Number Input of Cube Coordinates

Enter the maximum and minimum values for the cube coodinates.
Z-axis
Maximum
value
Cubic
interference X-axis
area
Minimum
value
Y-axis
Teaching Corner
Move the manipulator at the maximum and minimum value positions of the cube corner using
the axis keys.
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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
Y X
Z X-axis
Center
point
Y-axis
Setting Operation
Operation
Select {ROBOT} under the top menu Select {INTERFERENCE}*1 Select the
desired cube number*2 Select “METHOD”*3 Select “CONTROL GROUP”*4
Select “REF COORDINATES” *5 Select “CHECK MEASURE”*6
Explanation
*1 The cubic interference area display is shown.

L
INTERFERENCE AREA R1 C S
INTERFERENCE SIG : 1
METHOD :AXIS INTERFERENCE
CONTROL GROUP :**
CHECK MEASURE :COMMAND POSITION
< MAX > < MIN >
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*2 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].
*3 ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are displayed alternately

every time [SELECT] is pressed. If “CUBIC INTERFERENCE” is selected, the display
is changed.

L
METHOD : CUBIC INTERFERENCE
CONTROL GROUP :**
CHECK MEASURE : COMMAND POSITION
REF COORDINATE : BASE
TEACHING METHOD : MAX/MIN
< MAX > < MIN >
*4 The selection dialog is displayed. Select desired control group.

L
METHOD :CUBIC INTERFERENCE
R1:ROBOT1
CONTROLR1:ROBOT1
GROUP :**
R2:ROBOT2
REF COORDINATE :BASE
TEACHING METHOD :MAX/MIN
< MAX > < MIN >
*5 The selection dialog is displayed. Select desired coordinate.

If the user coordinates are selected, the number input line is displayed. Input the user
coordinate number and press [ENTER].

L
INTERFERENCE SIG: 1
BASE
CONTROLBASE
GROUP :**
ROBOT
USER
< MAX > < MIN >
X 0.000 0.000
Y 0.000 0.000
!
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*6 Each time [SELECT] is pressed, “COMMAND POSITION” and “FEEDBACK POSI-

TION” alternate.

L
METHOD :
CONTROL GROUP :**
< MAX > < MIN >
To stop the manipulator movement using the interference signal (use the cube interference
NOTE signal for mutual interference between robots), set CHECK MEASURE to “COMMAND
POSITION”.
When set to the “FEEDBACK POSITION”, the manipulator decelerates to a stop after
entering the interference area.
When informing an external unit of the actual manipulator position, use the “FEEDBACK
POSITION” setting so the timing of the output signal is more accurate.
Number Input of Cube Coordinates

Operation
Select “METHOD”*1 Input number for “MAX” and “MIN” data and press [Enter]*2
Explanation
*1 Each time [SELECT] is pressed, “MAX/MIN” and “CENTER POS” alternate.
Select “MAX/MIN” .

L
CONTROL GROUP : R1
< MAX > < MIN >
X 0.000 0.000
Y 0.000 0.000
!
*2 The cubic interference area is set.

L
CONTROL GROUP : R1
< MAX > < MIN >
X 100.000 0.000
Y 50.000 0.000
!
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Teaching Corner
Operation
Select “METHOD”*1 Press [MODIFY]*2 Move the cursor to “<MAX>” or

“<MIN>”*3 Move the manipulator using the axis keys*4 Press [ENTER]*5
Explanation
Select “MAX/MIN”.
*2 The message “Teach max./min. position” is displayed.

L
CONTROL GROUP : R1
< MAX > < MIN >
X 0.000 0.000
Y 0.000 0.000
!Teach max./min. position
*3 Move cursor to “<MAX>” for changing maximum value and move cursor to “<MIN>” for
changing minimum value. The cursor moves to only either “<MIN>” or “<MAX>” at this
time. The cursor moves freely when this operation is canceled by pressing [CANCEL].
*4 Move the manipulator to the maximum or minimum position of the cube using the axis
keys.
*5 The cubic interference area is registered.

L
CONTROL GROUP : R1
< MAX > < MIN >
X 100.000 0.000
Y 50.000 0.000
!
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Number Input of the Side of Cube and Teaching Center

Operation
Select “METHOD”*1 Input data for length of the cube and press [ENTER]*2
Press [MODIFY]*3 Move the manipulator using the axis keys*4 Press [Enter]*5
Explanation
Select “CENTER POS”.
L
CONTROL GROUP : R1
TEACHING METHOD : CENTER POS
< MAX > < MIN > <LENGTH>
X 0.000 0.000 0.000
Y 0.000 0.000 0.000
!
*2 The length is set.

L
CONTROL GROUP : R1
TEACHING METHOD : CENTER POS
X 0.000 0.000 0.000
Y 0.000 0.000 50.000
!
*3 The message “Move to center point and teach” is displayed.

The cursor moves to only either “<MIN>” or “<MAX>” at this time. The cursor moves
freely when this operation is canceled by pressing [CANCEL].

L
CONTROL GROUP :R1
TEACHING METHOD :CENTER POS
X 0.000 0.000 0.000
Y 0.000 0.000 50.000
!Move to center point and teach
*4 Move the manipulator to the center point of the cube using the axis keys.
*5 The current position is registered as the center point of the cube.
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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. (ON: inside, OFF: outside)
Max value Min value
+ side - side
ON
OFF
Axis Interference Signal for Station Axis
Setting Operation
Number Input of Axis Data
Operation
Select {ROBOT} under the top menu Select {INTERFERENCE}*1 Select the
desired interference signal number*2 Select “METHOD”*3 Select “CONTROL
*4 *5
GROUP” Select “CHECK MEASURE” Input data for desired axis and press
[Enter]*6
Explanation
*1 The cubic interference area display is shown.

L
CONTROL GROUP :**
< MAX > < MIN >
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*2 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].
*3 ”AXIS INTERFERENCE” and “CUBIC INTERFERENCE” are displayed alternately

every time [SELECT] is pressed. Select “AXIS INTERFERENCE”.
*4 The selection dialog is displayed. Select desired control group.

L
INTERFERENCE SIG: 1
R1:ROBOT1
CONTROL GROUP :**
R1:ROBOT1
R2:ROBOT2
< MAX > < MIN >
*5 Each time [SELECT] is pressed, “COMMAND POSITION” and “FEEDBACK POSI-

TION” alternate.

L
METHOD : AXIS INTERFERENCE
CONTROL GROUP : R1
CHECK MEASURE : FEEDBACK POSITION
< MAX > < MIN >
S 0 0
L 0 0
U 0 0
R 0 0
!
*6 The interference area is set.

L
CONTROL GROUP : R1
CHECK MEASURE : FEEDBACK POSITION
< MAX > < MIN >
S 300 0
L 0 0
U 0 0
R 0 0
!
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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”*1 Press [MODIFY]*2 Move the manipulator using the axis keys*3
Press [ENTER]*4
Explanation
*1 Operate in the same way as shown in Explanation *1~*4 in ”Number Input of Axis
Data”.
*2 Move cursor to “<MAX>” for changing maximum value and move cursor to “<MIN>” for
changing minimum value. The cursor moves to only either “<MIN>” or “<MAX>” at this
time. The cursor moves freely when this operation is canceled by pressing [CANCEL].

L
CONTROL GROUP : R1
< MAX > < MIN >
S 0 0
L 0 0
U 0 0
R 0 0
!
*3 Move the manipulator to the desired position using the axis keys.
*4 The axis interference area is registered.

L
CONTROL GROUP :R1
< MAX > < MIN >
S 510 0
L 1004 0
U 213 0
R 10 0
!
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3.7.4 Clearing Interference Area Data

Operation
Select interference signal for clearing*1 Select {DATA} under the menu Select
{CLEAR DATA}*2 Select “YES”*3
Explanation
*1 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. Input desired signal number and press
[ENTER].

L
INTERFERENCE SIG: 1
CONTROL GROUP :R1
CHECK MEASURE Initialize?
:FEEDBACK POSITION
< MAX
YES > < NO
MIN >
S 510 0
L 1004 0
U 213 0
R 10 0
!
*3 All the data of the signal are cleared.

L
CONTROL GROUP : **
< MAX > < MIN >
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3.8 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. The manipulator can be moved to the
set operation origin point by operation from the programming pendant, or by signal input from
an external device. When the manipulator is in the vicinity of the operation origin point, the
operation origin point signal turns ON.
3.8.2 Setting Operation Origin Point

Operation Origin Point Display
Operation
Select {ROBOT} under the top menu Select {OPE ORIGIN POS}*1 Press the
page key *2
Explanation
*1 Operation origin point display is shown. For spot application or handling application.
L
OPERATION ORIGIN R1 C S
[APPL 1] HOME POS CUR POS
S 0 2240
L 0 32
U 0 342
R 0 -21
B 0 0
T 0 -3239
*2 When two or more manipulators exist in the system, the control group is changed using
the page key
Registering/Changing the Operation Origin Point

Operation
Press the axis keys in the operation origin point display*1 Press [MODIFY] and
[ENTER]*2
Explanation
*1 Move the manipulator to the new operation origin point.
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*2 New operation origin point is set.
When the operation origin point is changed, the operation origin cube is automatically set
NOTE as cube 24 to 21 in the base coordinate system.
• The cube 24 is for ROBOT1
The operation origin cube is a cube like the one shown in the figure below; the length of its
sides is determined by a parameter setting made by the user (units: µm). By changing this
parameter setting, the size of the cube can be changed.
S3C412 : The operation origin cube length of its sides( µm)
P
a
a
a
Specify whether “COMMAND POSITION” or “FEEDBACK POSITION” is to be set to the
operation origin cube signal’s CHECK MEASURE in the interference area settings. “COM-
MAND POSITION” is the default setting.
Returning to the Operation Origin Point

In the teach mode
Operation
Press [FWD] in the operation origin point display*1
Explanation
*1 The manipulator moves to the new operation origin point. During movement, the mes-
sage “Manipulator is moving to operation origin point” is shown. The moving speed is
the selected manual operation speed.
In the play mode

When the operation origin point return signal is input (detected at leading edge), the tool cen-
ter point of the manipulator is moved to the operation origin point using the same operation as
the teach mode. However, the speed for this is set in the parameters.
Output of the Operation Origin Point Signal

This signal is output any time the current position of the tool center point of the manipulator is
checked and found to be within the operation origin cube.
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3.9 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.
TOOL FILE 0
TOOL FILE 23
Registering Coordinate Data

When the number input operation is used for registering the tool file, input the control point of
the tool on the flange coordinates.
XF
YF
Tool
Control point
ZF
Operation
Select {ROBOT} under the top menu Select {TOOL}*1 Select the desired tool
number*2 Select the desired coordinate axis to modify*3 Input the tool data
*4
Press [ENTER]
Explanation
*1 The tool list display is shown. When the tool extension function is valid, the list is
shown. When the tool extension function is invalid, the coordinate display is shown.
Tool File Extension Function

SUPPLE
-MENT
Normally, one robot uses one kind of tool file. The tool file extension function can change
many tool files to be used by one robot. Use the following parameter to set this function.
S2C261: TOOL NO. SWITCHING (1: enabled, 0: disabled)
For more details, refer to “Concurrent I/O Parameter”.
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L
TOOL COORDINATE R1 C S
NO. NAME
00 [TORCH1 ]
01 [TORCH2 ]
02 [ ]
03 [ ]
04 [ ]
05 [ ]
06 [ ]
07 [ ]
!

L
TOOL R1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
!
*2 When the tool list display is shown, move the cursor and press [SELECT]. The coordi-
nate display of the selected tool is shown. If the tool coordinate display is shown, press
the page key to select the desired tool.

To switch the tool list display and the tool coordinate display, press {DISPLAY}
{LIST} or {DISPLAY} {COORDINATE DATA}.

L
TOOL LISTR1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 0.00 deg.
*3 The number input line is displayed.
*4 The tool data is registered.
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L
TOOL R1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 260.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
<SettingExample>
260 mm 260 mm 260 mm
Control Control Control

Point Point Point 145 mm
ZF ZF
Tool A Tool B Tool C
Case of Tool A, B Case of Tool C
X 0.000 mm Rx 0.00 deg. X 0.000 mm Rx 0.00 deg.

Y 0.000 mm Ry 0.00 deg. Y 145.000 mm Ry 0.00 deg.
Z 260.000 mm Rz 0.00 deg. Z 260.000 mm Rz 0.00 deg.
Registering Tool Pose

The tool pose data is angle data which shows the relation between the flange coordinates
and the tool coordinates. The angle when the flange coordinates are rotated to meet to the
tool coordinates becomes an input value. Clockwise toward the arrow is the positive direction.
Register in the order of Rz Ry Rx.
The following, register Rz=180, Ry=90, Rx=0
Flange XF
coordinates
YF
ZF XT
Tool
coordinates YT
ZT
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Operation
Select {ROBOT} under the top menu Select {TOOL} Select the desired tool
number*1 Select the desired coordinate axis to modify*2 Input the tool pose
*3 *4
data Press [ENTER]
Explanation
*1 In the same way shown in Explanation *1,*2 in ”Registering coordinate data”, the
desired tool coordinate display is shown.
*2 First, select Rz.
*3 Input rotation angle around ZF of the flange coordinates.

XF
YF X 0.000 mm Rx 0.00 deg.

Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 180.00 deg.
ZF YF
X F Rz = 180
*4 The rotation angle of Rz is registered.

In the same way, register the angle of Ry,Rx.
Ry must be the input rotation angle around YF flange coordinates.
X F
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 90.00 deg.
ZF Y F (Y F ) Z 0.000 mm Rz 180.00 deg.
Z F
Ry = 90
Rx must be the input rotation angle around XF of flange coordinates.
X F
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 90.00 deg.
YF Z 0.000 mm Rz 180.00 deg.
Z F Rx = 0
NOTE If tool data is registered in the tool file by tool calibration, the old data will be deleted.
Setting the Tool Load Information

The 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.
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SUPPLE
For more details on the tool load information, refer to 3.11.3 “Tool Load Information Set-
-MENT ting.”
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. Tool
calibration is a function that enables this dimensional information to be registered easily and
accurately. When this function is used, the tool center point is automatically calculated and
registered in the tool file. What is registered in tool calibration is the coordinates of the tool
center point in the flange coordinates.
XF
Flange <Flange coordinates>
coordinates XF: Vertically upward direction when the current
position on the T-axis of the manipulator is "0"
YF: Y-axis complementing XF and ZF
ZF ZF: Direction perpendicular to the flange face
XT
YT
YF
Tool
coordinates ZT
Teaching
In order to perform tool calibration, five different poses (TC1 to 5) must be taught with the tool
center point as the reference point. The tool dimensions are automatically calculated on the
basis of these five points.
Control
point
Each pose must be arbitrary. Accuracy may decrease when pose setting is rotated in a con-
stant direction.
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There are 24 tool files numbered 0 to 23. In a basic system with one manipulator and one
SUPPLE
-MENT
tool, the tool file for tool No.0 is used. If there is more than one tool, for example when
using a multihand, use the tool numbers in the order 0, 1, 2, .... etc.
SUPPLE
Tool pose data is not registered in tool calibration. For details on how to register pose data,
-MENT refer to the preceding clause " Registering Tool Pose ".
Operation
Select {ROBOT} under the top menu Select {TOOL} Select the desired tool
number*1 Select {UTILITY} under the menu Select {CALIBRATION}*2
Select the robot*2 Select “POSITION”*4 Move the manipulator using the axis key
Press [MODIFY] Press [MODIFY] and [ENTER]*5 Select “COMPLETE”*6
Explanation
*1 In the same way shown in Explanation *1,*2 in " Registering Coordinate Data ", the
desired tool coordinate display is shown.

L
TOOL R1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
*2 The tool calibration setting display is shown.

L
TOOL CALIBRATION R1 C S
TOOL NO. : 00 POSITION : TC1
**:S * <STATUS>
L * TC1
U * TC2
R * TC3
B * TC4
T * TC5
COMPLETE CANCEL
*3 Select the robot to calibrate. (When the robot has already been selected or there is only
one of robot, this operation should not be performed.) Select “**” in the tool calibration
setting display and select the robot in the displayed selection dialog.
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L
**:S * <STATUS>
L * TC1
U R1:ROBOT1
* TC2
R R2:ROBOT2
* TC3
B * TC4
T * TC5
COMPLETE CANCEL
*4 The selection dialog is displayed. Select the teaching point for calibration.

L
R1:S * <STATUS>
L TC1 * TC1
U TC2 * TC2
R TC3 * TC3
B TC4 * TC4
T * TC5
COMPLETE CANCEL
*5 Taught position is registered.

Repeat *4~*5 operation to teach TC1 to TC5.
indicates that teaching is completed and indicates that it is not completed.

L
R1:S 0 <STATUS>
L 10 TC1
U 1000 TC2
R 53 TC3
B 200 TC4
T 8 TC5
COMPLETE CANCEL
To check the taught positions, call up the required display among TC1 to TC5 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, “TC “ next to “POSITION” in the display flashes.
*6 Calibration data is registered in the tool file. Once calibration is completed, the tool
coordinate display is shown.
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L
TOOL R1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 300.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
!
Clearing Calibration Data

Before the calibration of a new tool, clear the robot information and calibration data.
Operation
Select {DATA} under the menu Select {CLEAR DATA}*1 Select “YES”*2
Explanation
*1 The confirmation dialog is shown.

L
R1:S 0 <STATUS>
L 10 TC1
U Clear
* data?
TC2
R * TC3
B YES* NO
TC4
T * TC5
COMPLETE CANCEL
*2 All data is cleared.

L
**:S * <STATUS>
L * TC1
U * TC2
R * TC3
B * TC4
T * TC5
COMPLETE CANCEL
Only tool coordinate data are calculated using tool calibraton. If tool pose data is required,
NOTE input the data number in the tool coordinate display.
Refer to " Registering Tool Pose " for the operation.
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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.
Control
point
Operation
Press [COORD]*1 Select desired tool number*2 Move the R, B, or T axes using
*3
the axis key
Explanation
*1 Select any coordinate type except “ JOINT” by pressing [COORD].

L
TOOL R1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
*2 Show the tool coordinate display of the desired tool by pressing the page key or
selecting it in the tool list.
*3 By pressing the axis keys for the R, B, and T axes, change the manipulator pose with-
out changing the tool center point position.
If this operation shows a large tool center point error, adjust the tool data.
Control point
error
SUPPLE For details on TCP fixed operation, see the Operator's Manual (Application)
-MENT
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3.9.3 Automatic Measurement of the Tool Load and the

Center of Gravity
What is the Automatic Measurement of the Tool Load and the Cen-
ter of Gravity?
With this function, the user can register the load of tool and the position of the tools center of
gravity.
The tool load and the position of it’s center of gravity are measured and registered in a tool
file.
This function is available for the models listed below. Contact your Yaskawa representa-
NOTE 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”.
Measurement of the Tool Load and the Center of Gravity

To measure the tool load and the center of gravity, move the manipulator to it’s home position
(horizontal to the U-, B- and R-axes) and operate the U-, B- and R-axes.
U-axis
U+
R-axis
B-axis
B+ T-axis
T+
L-axis U- B- T- Home Position
(Horizontal to the U-,
B- and R-axes)
S-axis
Zero-degree Installation on the Ground
NOTE To measure the tool load or the center of gravity, remove the cables or wires connected to
the tool. Otherwise, the measurements may not be correct.
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Operation
number*2 Select {UTILITY} under the menu Select {W.GRAV.POS MEASURE}*3
*4
Press the page key Press [NEXT]*5 Press [NEXT] again*6 Select
“REGISTER”*7
Explanation
*1 The tool list display is shown. The tool list is called up only when the file extension
function is valid. If the file extension function is invalid, the tool coordinates is shown.
Tool File Extension Function

SUPPLE
-MENT
Use the following parameter to set the Tool File Extension Function.
S2C261: TOOL NO. SWITCHING
“0”: Tool switching prohibited.
“1”: Can change 24 kinds of tools numbering from 0 to 23.

L
NO. NAME
00 [TORCH1 ]
01 [TORCH2 ]
02 [ ]
03 [ ]
04 [ ]
05 [ ]
06 [ ]
07 [ ]
!

L
TOOL R1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
!
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*2 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 . To alternate between the tool list and
the tool coordinates, select {DISPLAY} and {LIST}, or {DISPLAY} and {COORDINATE
VALUE} under the menu.

L
TOOL LISTR1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
!
*3 The display for the automatic measurement of the tool load and the center of gravity is
shown.

L
W.GRAV.POS MEASURE R1 C S
TOOL :00
R1:W *.*** kg < STATUS >
HOME
Xg *.*** mm U
Yg *.*** mm B
Zg *.*** mm T(1)
T(2)
REGISTER CANCEL
*4 In a system with several manipulators, use the page key to change the group to
be controlled.
*5 Press [NEXT] once, and the manipulator moves to the home position (horizontal to the
U-, B- and R-axes).
*6 Press [NEXT] again, and measurement starts. Keep the button pressed until measure-
ment is completed. The manipulator moves in the order listed below. Once measure-
ment is completed, “ “ changes to “ “.
Measurement of the U-axis: U-axis home position + 4.5 degrees -4.5 degrees
Measurement of the B-axis: B-axis home position + 4.5 degrees -4.5 degrees
First measurement of the T-axis: T-axis home position + 4.5 degrees -4.5 degrees
Second measurement of the T-axis: T-axis home position +60 degrees + 4.5
degrees -4.5 degrees
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• The speed during measurement automatically changes to “Medium”.

NOTE • 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 “ “ changes into “ “, measurement is
interrupted and the following message appears.
“Stopped measurement”
Measurement starts again from the first home position.
When all measurements are completed or when all the “ “ marks have changed into
“ “, the measurements are displayed on the screen.

L
W.GRAV.POS MEASURE R1 C S
TOOL :00
R1:W 4.513 kg < STATUS >
HOME
Xg 10.112 mm U
Yg 10.435 mm B
Zg 55.123 mm T(1)
T(2)
REGISTER CANCEL
*7 The measurements are registered in the tool file, and the tool coordinates are shown.
Select “CANCEL” to call up the tool coordinates without registering the measurements
in the tool file.
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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. These three points of positional data are registered in a user coordinate file.
Z-axis
X-axis
XX
XY
Y-axis
ORG
User coordinate definition point
ORG: Home position
XX: Point on the X-axis
XY: Point on the Y-axis
ORG is the home position, and XX is a point on the X-axis. XY is a point on the Y-axis side of
the user coordinates that has been taught, and the directions of Y- and Z-axes are determined
by point XY.
NOTE It is important that the two points ORG and XX be taught accurately.
User Coordinates File

Up to 24 kinds of user coordinates can be registered. Each coordinate has a user coordinate
No. and is called a user coordinate file.
User coordinate file 1
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3.10.2 User Coordinates Setting

Selecting User Coordinates File
Operation
Select {ROBOT} under the top menu Select {USER COORDINATE}*1 Select
*2
desired user coodinate number
Explanation
*1 The user coordinate list display is shown.

L
USER COORDINATE R1 C S
NO. SET NAME
00 [WORK1 ]
01 [WORK2 ]
02 [ ]
03 [ ]
04 [ ]
05 [ ]
06 [ ]
07 [ ]
!
indicates that the user coordinates is completed to set and indicates that it is not
completed.
To check the position of the user coodinates select {DISPLAY} {COORDINATE
DATA}. The user coordinate display is shown.

L
USER COORD NO.:01
NAME :WORK2
X 50.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 30.000 mm Rz 0.00 deg.
*2 Select the desired user coordinate number for setting in the user coordinate list display.
The user coordinate teaching display is shown.

L
USER COORD NO.: 03 TOOL :00
**:S * SET POS. :ORG
L * <STATUS>
U * :ORG
R * :XX
B * :XY
T *
COMPLETE CANCEL
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Teaching User Coordinates

Operation
Select the robot*1 Select “SET POS”*2 Move the manipulator using the axis key
*3 Select “COMPLETE”*4
Press [MODIFY] and [ENTER]
Explanation
*1 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 “**”
in the user coordinates setting display and select the robot in the displayed selection
dialog. The robot is registered.

L
**:S * SET POS. :ORG
L * <STATUS>
U R1:ROBOT1* :ORG
R S1:STATION1
* :XX
B * :XY
T *
COMPLETE CANCEL
*2 The selection dialog is displayed. Select the teaching point.

L
R1:S * SET POS. :ORG
L ORG
ORG * <STATUS>
U XX * :ORG
R XY * :XX
B * :XY
T *
COMPLETE CANCEL
*3 Taught position is registered.

Repeat *2~*3 operation to teach ORG, XX and XY.
indicates that teaching is completed and indicates that it is not completed.

L
R1:S 0 SET POS. :XY
L 10 <STATUS>
U 1000 :ORG
R 53 :XX
B 200 :XY
T 8
COMPLETE CANCEL
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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” flashes.
*4 User coordinates are registered in the file. Once the user coordinate setting is com-
pleted, the user coordinate list display is shown.

L
NO. SET NAME
00 [WORK1 ]
01 [WORK2 ]
02 [ ]
03 [WORK3 ]
04 [ ]
05 [ ]
06 [ ]
07 [ ]
!
Clearing User Coordinates

Operation
Select {DATA} under the menu Select {CLEAR DATA}*1 Select “YES”*2
Explanation
*1 The confirmation dialog is shown.

L
R1:S 0 SET POS. :XY
L 10 <STATUS>
U Clear data? :ORG
1000
R 53 :XX
B 200
YES NO
:XY
T 8
COMPLETE CANCEL
*2 All data is cleared.

L
R1:S * SET POS. :ORG
L * <STATUS>
U * :ORG
R * :XX
B * :XY
T *
COMPLETE CANCEL
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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. originally developed.
The moment of inertia and the gravity moment etc. of each axis are calculated in the ARM
control, and XRC controls robot motion according to it. It is necessary to set the Robot setup
condition and the tool load information to request these accurately.
The robot setup condition is robot installation angle relative to ground and the weight and a
center of gravity position of the load installed at each part of robot, etc.
The tool load information is weight, a center of gravity position, and moment of inertia at the
center of gravity, of the tool installed at the flange.
It is necessary to set these information correctly to do a better operation control by the ARM
control.
3.11.2 ARM CONTROL Display

In ARM CONTROL display, the robot setup condition etc. are set.
CAUTION
• Set the robot setup condition exactly.
Set the robot setup condition very noting of mistake the unit, the value or the positive and
negative of number.
An appropriate operation control cannot be done, decrease the speed reducer longevity,
or occur the alarm when these are not correctly set.
• Confirm the operation path of robot of each job when you change set-
ting.
Set the robot setup condition when you basically set up the robot.
Confirm the operation path of robot of each job afterwards when you change the setting
unavoidably.
Injury or damage to machinery may result by collision between tool and jig because the
operation path might be changed slightly when the setting about the ARM control is
changed.
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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.
The robot installation angle sets how much X axis of the robot coordinates has inclined with
the earth around Y axis of the robot coordinates. The direction of + in the U axis operation
from the home position posture of the manipulator becomes direction of + of the robot installa-
tion angle. Therefore, the robot installation angle for a vertical downward wall mount specifi-
cation becomes -90 degrees.
Robot
installation +
Angle
<Example>
0 degrees -90 degrees +90 degrees 180 degrees
Because the gravity moment which loads to each axis can't be calculated correctly when this
value is not correctly set, it can not be possible to control the manipulator appropriately. Set
the value correctly. Especially, note the direction “+” or “-”.
Only rotation angle around Y axis of the robot coordinates can be set in the robot installa-
NOTE tion angle.
Contact YASKAWA representative when robots is installed to incline Y axis of the robot
coordinates relative to ground.
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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.
Set a little large value though it does not care by a rough value. (Rase to a unit in each 0.5 to
1kg)
X (From S-Axis), Y (From S-Axis) (unit: mm)
The center of gravity position of the installed load is set by the distance in the direction of X
and the direction of Y from S axis center here. It does not care by a rough value.
The direction of X and Y applies to the robot coordinates. The value is set by a negative num-
ber when the position is in “-” direction.
-X
S axis center
-Y +Y
(X position, Y position)
+X
Load at S-head (Top View)
U-arm payload
Set the weight and the center of gravity position roughly when the equipment such as the wire
supplying motors is installed on U arm.
A standard value is set when shipping from the factory.
Set the weight in “0” if there is no installing equipment on U arm.
WEIGHT (Unit:kg)
The weight of the installing load is set here.
Set a little large value though it does not care by a rough value. (Rase to a unit in each 0.5 to
1kg)
X (From U-Axis), HEIGHT (From U-Axis) (unit: mm)
The center of gravity position of the load installed is set here. It does not care by a rough
value.
X (From U-Axis) is horizontal distance from U axis rotation center to the center of gravity posi-
tion of the load. Set negative number when there is mass side in the back from U axis rotation
center.
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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 Center of Gravity
Position
EIGHT
From U-Axis)
Load on U arm : Center of gravity position (Side View )
Setting
NOTE ARM CONTROL display is shown only when the security mode is set as management
mode.
Operation
Select {ROBOT} under the top menu Select {ARM CONTROL}*1 Press the page
*2
key Select the desired item Input the value and press [ENTER]
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3.11 ARM Control
Explanation
*1 ARM CONTROL display is shown.

L
ARM CONTROL R1 C S
CONTROL GROUP:ROBOT1
<ROBOT SETUP CONDITION>
ANGLE REL. TO GROUND : 0.000 deg.
S-HEAD PAYLOAD
WEIGHT : 0.000 kg
X(FROM S-AXIS) : 0.000 mm
Y(FROM S-AXIS) : 0.000 mm
U-ARM PAYLOAD
WEIGHT : 20.000 kg
!
*2 Select the desired group axis when there are two or more group axes.
3.11.3 Tool Load Information Setting
CAUTION
• Set the tool load information correctly.
The speed reducer longevity might decrease or the alarm might occur when the tool load
information is not set correctly.
• Confirm the operation path of robot of each job which uses the tool file
after the tool load information is changed.
Set the tool load information basically before teaching the job after the tool is installed.
Confirm the operation path of each job which uses the tool file when the tool load informa-
tion is changed after teaching, unavoidably.
Injury or damage to machinery may result by collision between tool and jig because the
operation path might be changed slightly when the tool load information is changed.
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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.
XF' Inertia Moment around Center of Gravity

Ix, Iy, Iz
XF
Ix
YF'
Iy
YF
ZF' Iz
Weight:W
* Flange Coodinates
XF: It is a direction right above when T axis
ZF is 0 pulse position and the flange surface
of the manipulator turned to the front.
Center of Gravity Position YF: Y axis led by XF,ZF
( Xg, Yg, Zg ) ZF: Perpendicular direction from flange surface
How to Calculate Tool Load Information

Weight : W (Unit:kg)
The total weight of the installing tool is set.
Set a little large value though it does not care by a rough value. Rase to a unit in each 0.5 to
1kg for small or middle robot and rase to a unit in each 1 to 5kg for large robot.
Center of gravity : xg, yg, zg (Unit : mm)

The center of gravity position of the installed tool is set as the position in the flange coordi-
nates.
It does not care by setting a rough value because it is usually difficult to get a strict center of
gravity position. Presume and set a center of gravity position roughly from outline of the tool.
Set the value when the center of gravity position of the installed tool is clear from specifica-
tions etc.
moment of inertia at the center of gravity: lx, ly, lz (Unit : kg.m2)

It is an moment of inertia of the tool at the center of gravity position.
The value is calculated around the each axis of the coordinates which is in parallel to the
flange coordinates and which origine position is the center of gravity position of the tool.
Set a little large value though it does not care by a rough value.
This setting is used to calculate the moment of inertia which loads to each axis of the manipu-
lator. However, the moment of inertia at the center of gravity need not usually set because
this data is small enough to the moment of inertia calculated from weight and the center of
gravity position.
Only when the moment of inertia of the tool is large (The size of the tool is, as a standard, in
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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 m om ent at center of Setting the inertia m om ent at center of
gravity is not necessary. gravity is necessary.
Rough value of the moment of inertia at the center of gravity can be calculated by followings
methods.
- Method to approximate the entire tool in hexahedron or cylinder.
- Method to calculate from each weight and center of gravity position of plural mass.
Refer to the following setting examples for details.
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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.
There is no problem even if the moment of inertia at the center of gravity is not set because
the size of the gun is not too large.
YF
C enter of G ravity P osition

= (100, 0, 70)
XF
70
Total W eight 100

A pprox. 6.3 [kg]
7.00 [kg]
ZF
<Setting>
•W : 7.000 kg
• Xg : 100.000 mm
• Yg : 0.000 mm
• Zg : 70.000 mm
• Ix : 0.000 kg.m2
• Iy : 0.000 kg.m2
• Iz : 0.000 kg.m2
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3.11 ARM Control
• The own moment of inertia calculation for hexahedron and cylinder

SUPPLE
-MENT The own moment of inertia of hexahedron and cylinder can be calculated by the next
expression when the center of gravity is at the center.
Refer the expression when the calculation of the moment of inertia at the center of gravity.
Z Z
Ly
r
Lx
Iz Iz
Iy Lz
Ix Y H Y
Ix Iy
X
X Weight:W Weight: W
Ly2 + Lz2 3 r 2 + H2
Ix = *W Ix = Iy = *W
12 12
r2
Lx2 + Lz2 Iz = *W
Iy = *W 2
12
Lx2 + Ly2 * Unit of Weight : [kg]

Iz = *W * Unit of Length : [m]
12
* Unit of Ix, Iy, Iz : [kg.m2]
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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 compareing with the distance from the flange to the center
of gravity position.
Calculate the moment of inertia at the center of gravity roughly from the expression (Refer to
the above-mentioned supplemen:"The own moment of inertia calculation for hexahedron and
cylinder"), by approximating the entire tool in the shape of the hexahedron or the cylinder.
If the weight of held workpiece is greatly different like in the handling usage etc, it is more
effective to set tool load information on each workpiece and to switch the tool on each step
according to the held workpiece. Set the tool load information in the state to hold the heaviest
workpiece when the tool is not switched.
0 YF
50
Weight of Hand :
Approx. 55kg
ZF
250
XF
Weight of Workpiece :
Approx. 40kg
400
1000
Weight : W = 55 + 40 = 95
= approx. 100[kg]
Center of gravity : Position at flange right under 250mm almost
(Xg, Yg, Zg) = (0,0,250)
Moment of inertia at the center of gravity :
The hexahedron of 0.500 x 0.400 x 1.000[m] which encloses the entire
hand + workpiece is assumed.
By the expression to calculate the own moment of inertia of hexahedron,
Ix = ( Ly2 + Lz2 / 12) * W
= ( (0.4002 + 1.0002) / 12 ) * 100 = 9.667 = approx. 10.000
Iy = ( Lx2 + Lz2 / 12) * W = ( (0.5002 + 0.4002) / 12 ) * 100 = 3.417 = approx. 3.500
Iz = ( Lx2 + Ly2 / 12) * W = ( (0.5002 + 1.0002) / 12 ) * 100 = 10.417 = approx. 10.500
<Setting>
•W : 100.000 kg
• Xg : 0.000 mm
• Yg : 0.000 mm
• Zg : 250.000 mm
• Ix : 10.000 kg.m2
• Iy : 3.500 kg.m2
• Iz : 10.500 kg.m2
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3.11 ARM Control
• How to calculate "Center of gravity position" and "moment of inertia at center of gravity"
SUPPLE
-MENT for plural mass
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.
1. Divide the tool into some parts as the weight and the center of gravity posi-
tion can be roughly presumed. It is not necessary to divide in detail. The
tool is approximated in construction of rough parts.
2. Calculate the weight and the center of gravity position of the each parts on
flange coordinates. It does not care by a rough value. Calculate the own
moments of inertia of the big parts. (If parts are small, it is not necessary to
calculate the own moments of inertia. Refer to above-mentioned supple-
ment : "The own moment of inertia calculation for hexahedron and cylinder"
for how to calculate the own moment of inertia.)
wi : Weight of the i-th parts [kg]
(xi, yi, zi) : Center of gravity of the i-th parts (On flange coordinates)[mm]
Icxi, Icyi, Iczi : Own moments of inertia of the i-th parts [kg*m2]
3. The center of gravity position of the entire tool is calculated by the next
expression.
xg = {w1 * x1 + w2 * x2 + .... + wi * xi} / (w1 + w2 + .... + wi)
yg = {w1 * y1 + w2 * y2 + .... + wi * yi} / (w1 + w2 + .... + wi)
zg = {w1 * z1 + w2 * z2 + .... + wi * zi} / (w1 + w2 + .... + wi)
4. The moment of inertia at the center of gravity position of the entire tool is
calculated by the next expression.
Ix = { w1 * ((y1 - yg)2 + (z1 - zg)2) * 10-6 + Icx1}
+ { w2 * ((y2 - yg)2 + (z2 - zg)2) * 10-6 + Icx2}
.....................
+ { wi * ((yi - yg)2 + (zi - zg)2) * 10-6 + Icxi}
Iy = { w1 * ((x1 - xg)2 + (z1 - zg)2) * 10-6 + Icy1}

+ { w2 * ((x2 - xg)2 + (z2 - zg)2) * 10-6 + Icy2}
.....................
+ { wi * ((xi - xg)2 + (zi - zg)2) * 10-6 + Icyi}
Iz = { w1 * ((x1 - xg)2 + (y1 - yg)2) * 10-6 + Icz1}
+ { w2 * ((x2 - xg)2 + (y2 - yg)2) * 10-6 + Icz2}
.....................
+ { wi * ((xi - xg)2 + (yi - yg)2) * 10-6 + Iczi}
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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. (It is enough in
this setting usually)
2. Or, when weight in each mass and the center of gravity position are understood, the
center of gravity position and the moment of inertia at the center of gravity of the entire
tool can be calculated. (Refer to above-mentioned supplement: "How to calculate
"Center of gravity position" and "moment of inertia at the center of gravity" for plural
mass")
How by the method of 2 to calculate the value is shown here.
(Top View)
Center of Flange
YF
YF
100
50 150
40
X F
Gun 1
70
XF Gun 2
(Gun 1) (Gun 2)
Gun 1
Weight: w1 = 3 kg Weight: w2 = 6 kg
ZF Center of Gravity: Center of Gravity:
x1 = 100 mm x2 = 100 mm
y1 = 50 mm y2 = -150 mm
Gun 2 z1 = 40 mm z2 = 70 mm
Weight : W = w1 + w2
= 3 + 6 = 9 = approx. 10[kg]
Center of gravity Xg = (w1 * x1 + w2 * x2) / (w1 + w2)
= (3 * 100 + 6 * 100) / (3+6) = 100.0 [mm]
Yg = (3 * 50 + 6 * (-150)) / (3+6) = -83.333 [mm]
Zg = (3 * 40 + 6 * 70) / (3+6) = 60.0 [mm]
The moment of inertia at the center of gravity position :
Ix = { w1 * ((y1 - Yg)2 + (z1 - Zg)2) * 10-6 + Icx1}
+ { w2 * ((y2 - Yg)2 + (z2 - Zg)2) * 10-6 + Icx2}
= 3 * ((50 - (-83))2 + (40 - 60)2) * 10-6
+ 6 * (((-150) - (-83))2 + (70 - 60)2) * 10-6
= 0.082 = approx. 0.100
Iy = 3 * ((100 - 100)2 + (40 - 60)2) * 10-6
+ 6 * ((100 - 100)2 + (70 - 60)2) * 10-6
= 0.002 = approx. 0.010
Iz = 3 * ((100 - 100)2 + (50 - (-83))2) * 10-6
+ 6 * ((100 - 100)2 + ((-150) - (-83))2) * 10-6
= 0.080 = approx. 0.100
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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 kg
• Xg : 100.000 mm
• Yg : -83.333 mm
• Zg : 60.000 mm
• Ix : 0.100 kg.m2
• Iy : 0.010 kg.m2
• Iz : 0.100 kg.m2
Tool load Information registering

Tool load Information is registered in the tool file.
Operation
*2 Select the desired item to register and input the value*3
number Press
[ENTER]*4
Explanation
*1 The tool list display is shown. Only when the file expansion function is valid, the tool list
display is shown. When the file expansion function is invalid, the tool coordinates dis-
play is shown.

L
NO. NAME
00 [TORCH1 ]
01 [TORCH2 ]
02 [ ]
03 [ ]
04 [ ]
05 [ ]
06 [ ]
07 [ ]
!

L
TOOL R1 C S
TOOL NO. : 00
NAME:TOACH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
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3.11 ARM Control
*2 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.

TOOL LIST
TOOL NO. : 00
NAME:TOACH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
*3 The display can be scrolled by the cursor. The menu enters the state of a numeric
input if the cursor is on the desired item to register and the [SELECT] is pressed.

L
TOOL R1 C S
TOOL NO. : 00
Weight W 0.000 kg
Center of Xg 0.000 mm
Gravity Yg 0.000 mm
Position Zg 0.000 mm
Inertia Moment at Ix 0.000 kg.m2

Center of Gravity Iy 0.000 kg.m2
!
*4 The input value is registered. The servo power is automatically turned off when editing
the value during the servo power turned on, and the message "Servo off by changing
data " is displayed for three seconds.
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• When the data setting is not done

NOTE 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.
Standard Value.....Weight : W = Payload
Center of gravity position :
(Xg, Yg, Zg) = (0, 0, Allowed value of B axis for rated
payload)
In this case, when an actual tool load is not too heavy, the manipulator can’t be performed
enough.
Moreover, when the tool which an actual tool center of gravity position greatly offsets in X
direction or Y direction is installed the generated moment by the tool cannot be compen-
sated.
• Switch of the tool file

In case that two or more tool files are used, Information on an effective tool file is referred
for tool load information used by the ARM control at that time in according to switch tool
file.
Set the same value of tool load information in each tool file when the tool file is switched to
change only tool center point (when neither the weight nor the center of gravity position of
the entire tool installed in the flange is changed).
Moreover, set tool load information to the corresponding tool file respectively when total
weight and the center of gravity position etc. of the tool is changed (when the system which
exchange the tool by automatic tool changer).
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3.12 Shock Detection Function
3.12.1 Shock Detection Function

The shock detection function is a function to decrease damage because of the collision by
instantaneously detecting the shock and stopping the manipulator without any external sensor
when the tool or the manipulator collide with peripherals.
When the shock is detected either in teach mode and in play mode, the manipulator is
stopped instantaneously.
WARNING
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.
Injury or damage to machinery may result by collision with the manipulator.
NOTE This function is equipped with the undermentioned model.

Applicated model: Motoman UP6, SK16X, UP20, SK45X, UP50, UP130
3.12.2 Shock Detection Function Setting

The shock detection function is set not to mis-detect the shock even if operating by the ratings
load with the maximum speed when shipping from the factory. If tool load information is set
correctly, the detection sensitivity can be improved. Moreover, it is possible to set the lower
sensitivity of detection only for a specific section where the contact work etc. The sensitivity of
detection is set by setting the detection level.
Shock Detection Level Setting

The shock detection level is set in the shock detection level file.
The shock detection set file are nine condition files as following figure.
Condition number 1 to 7 are used when the detection level is changed in a specific section in
play mode.
Condition number 8 is a file used as standard in play mode. This function is operated by the
detection level set in this file when playback operation.
Condition number 9 is a file for teach mode. The shock is detected by the detection level set in
this file when the robot is operated in teach mode.
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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.
Files for specific

section in play mode
Standard file
for play mode
Shock Detection
Level File
Condition number 1
File for teach mode
Condition number 7
Condition number 8
Condition number 9
SUPPLE
The detection level of condition number 8 which is a standard file in play mode is adopted
-MENT in play mode excluding the range between SHCKSET and SHCKRST in the job.
Method of Shock Detection Level File Setting

Operation
Select {ROBOT} under the top menu Select {SHOCK SENS LEVEL}*1 Select
the desired condition number Select the desired item and set it
Explanation
*1 The shock detection level display is shown.

L
SHOCK DETECTION LVL R1 C S
DETECTION MODE: PLAY
COND. NO. : 8 (STANDARD)
FUNC. MAX.DISTURBANCE DETECTION LVL
R1 VALID 80 100
R2 VALID 80 100
S1 VALID 80 100
S2 VALID 80 100
S3 VALID 80 100
Detection Mode
The shock detection mode is indicated.
Condition Number (1 to 9)
1 to 7 : For changing detection level in play mode
8 : For standard detection level in play mode
9 : For detection level in teach mode
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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.
When page key is pressed the condition number file is changed.
Function Select
VALID/INVALID of the shock detection function is specified here. The shock detec-
tion function is specified by each manipulator or each station axes which has this
function.
The cursor is moved to the robot or the station axis which is desired to change the
function "VALID" or "INVALID" and [SELECT] is pressed. "VALID" and "INVALID" is
changed alternately whenever [SELECT] is pressed. The change of "VALID" or
"INVALID" is effective for all the condition number files.
Max. Disturbance Force

The maximum disturbance force to the manipulator when the manipulator is moved
in paly back operation or axis operation is shown here.
Refer to this value when the detection level in (5) is input.
The maximum disturbance force can be cleared by setting in menu {DATA}
{CLEAR MAX VALUE }.
Detection Lebel (Level range : 1 to 500)

The shock detection level is specified here. Bigger value than the maximum distur-
bance force should be set.
The value (The detection level:100) not mis-detected the shock even if robot is oper-
ated at the maximum speed is set when shipping from the factory.
To change "Detection level", move the cursor to the robot or the station axis which is
desired to change to appear the numeric input status and press [SELECT] moreover
input the value by a numeric key and press [ENTER]. Set the level to small value to
raise the detection sensitivity or set the level to large value to lower sensitivity.
Set the level 20% or more greatly than the maximum disturbance force for the mis-detec-
NOTE tion prevention when the manipulator works.
An instaneously stopping the manipulator by the mis-detection may become a factor to
damage the speed reducer or the tool.
<Example>
When the maximum disturbance force is 80, set the detection level 96 or more.
NOTE "Detection level” can be changed only when the security mode is set as managememt
mode.
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Tool load Information Setting

To be the more accurate shock detection, the tool load information is set in the tool file.
SUPPLE
Refer to " 3.11.3 Tool Load Information Setting " for details concerning the tool load infor-
-MENT mation setting.
Method of the Tool load Information Setting

Operation
number*2 Select the desired item and set it
Explanation
*1 Tool list display is shown. Only when the file expansion function is valid, the tool list
display is shown. When the file expansion function is invalid, the tool coordinates dis-
play is shown.

L
NO. NAME
00 [TORCH1 ]
01 [TORCH2 ]
02 [ ]
03 [ ]
04 [ ]
05 [ ]
06 [ ]
07 [ ]
!

L
TOOL R1 C S
TOOL NO. : 00
NAME :TORCH1
X 0.000 mm Rx 0.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 0.000 mm Rz 0.00 deg.
W 0.000 kg
Xg 0.000 mm
!
*2 Move the cursor to the number of the desired tool and press [ENTER] in the tool list dis-
play. 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.
The tool coordinates display is scrolled by the cursor.
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L
TOOL R1 C S
TOOL NO. : 00
W 0.000 kg
Xg 0.000 mm
Yg 0.000 mm
Zg 0.000 mm
Ix 0.000 kg.m2
Iy 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 cursole and pressing [SELECT].
Center of Gravity Position

This is center of gravity position of the installed tool. The value are specified by the
coordinates value on each axis of the flange coordinates. Input the center of gravity
position by a numeric key and press [ENTER] after the numeric input status is
appeared by moving the cursole and pressing [SELECT].
Moment of inertia at the Center of Gravity

This is Moment of inertia of the tool at the Center of Gravity in (2). The value are
specified around each axis of the coordinates which is in parallel to the flange coor-
dinates and which origine point is the center of gravity position.
Input the moment of inertia by a numeric key and press [ENTER] after the numeric
input status is appeared by moving the cursole and pressing [SELECT].
Instruction of Shock Detection Function

SHCKSET instruction
The SHCKSET instruction changes the shock detection level to the value set in the shock
detection level file during play back operation.
The additional items of the SHCKSET instruction are as follows.
SHCKSET R1 SSL#(1)
Robot / Station Setting

The robot or the station axis which is desired to change the shock detection level is speci-
fied. If nothing is specified, the detection level of the control group of the job to which this
instruction is registered is changed.
However, if the job is coordinated job, the detection level of the slave axis group is
changed.
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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.
SHCKRST instruction
The shock detection level changed by the SHCKSET instruction is reset and returned to the
detection level of the standard (value set in condition number 8) by the SHCKRST instruction.
The additional item of the SHCKRST instruction is as follows.
SHCKRST R1
Robot / Station Setting

The robot or the station axis which is desired to reset the shock detection level is specified
here. If nothing is specified, the detection level of the control group of the job to which this
instruction is registered is changed.
However, if the job is coordinated job, the detection level of the slave axis group is
changed.
Instruction Registration
The instruction is registered when the cursor is in the address area in the job content display
in teach mode.
Operation
Select {JOB} under the top menu Select {JOB} Move the cursole in the address
area
JOB EDIT DISPLAY UTILITY

L
JOB CONTENT R1 C S
J:TEST S:003 R1 TOOL:00
0000 NOP
0001 'THIS JOB IS TEST JOB
0002 MOVJ VJ=50.00
Address Area 0003 MOVJ VJ=12.50 Instruction Area
0004 MOVL V=276
0005 TIMER T=1.00
0006 DOUT OT#(1) ON
=>MOVJ VJ=100.00
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SHCKSET
Operation
Move the cursole to the line just before the location where SHCKSET instruction is desired
to register Press [INFORM LIST]*1 Select SHCKSET instruction*2 Change
the value of additianal item and numerical data*3 Press [ADD] and [ENTER]*4
Explanation
*1 The inform list dialog is shown.
IN/OUT ..
CONTROL SHCKSET
DEVICE SHCKRST
MOTION
ARITH
SHIFT
OTHER
*2 SHCKSET instruction is displayed in the input buffer line.
=> SHCKSET SSL#(1)
*3 < When register as it is >

Operate *4 procedure when the instruction the input buffer line as it is should be regis-
tered.
< When add or change the additional item >

• When the shock detection level file is changed, move the cursor to the shock detec-
tion level file number, and increase or decrese the file number by pressing about
[SHIFT] and the cursor key simultaneously.
=> SHCKSET SSL#(2)
When the value is input with the numerical key, press [SELECT] to display the input
buffer line.
=>SHCKSET SSL#(1)
>Shock_sens_file_no.=
And press [ENTER] to change the number in the input buffer line.
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• When robot/station specification is added, move the cursor to the instruction in the
input buffer line and press [SELECT] to show the detail edit display.

L
DETAIL EDIT R1 C S
SHCKSET
ROBOT/STATION UNUSED
S-DETECT. FILE SSL#( ) 1
=> SHCKSET SSL#(1)

!
Move the cursor to "UNUSED" of "ROBOT/STATION", and press [SELECT]. The

selection dialog is shown. Move the cursor to added robot or station and press
[SELECT].

L
DETAIL EDIT R1 C S
SHCKSET
S-DETECT. FILE R1:ROBOT1
SSL#(%) 1
R1:ROBOT1
S1:STATION1
UNUSED
=> SHCKSET SSL#(1)

!
When the addition of robot/station ends, press [ENTER]. The detail edit display shuts
and the job content display is shown.
*4 The instruction displayed in the input buffer line is registered.
SHCKRST
Operation
Move the cursole to the line just before the location where SHCKRST instruction is desired
to register Press [INFORM LIST]*1 Select SHCKRST instruction*2 Change
*3 *4
the value of additianal item Press [ADD] and [ENTER]
Explanation
*1 The inform list dialog is shown.
IN/OUT ..
CONTROL SHCKSET
DEVICE SHCKRST
MOTION
ARITH
SHIFT
OTHER
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*2 SHCKRST instruction is displayed in the input buffer line.
=> SHCKRST
*3 < When register as it is >

Operate *4 procedure when the instruction the input buffer line as it is should be regis-
tered.
< When add or change the additional item >

When robot/station specification is added, move the cursor to the instruction in the
input buffer line and press [SELECT] to show the detail edit display.

L
DETAIL EDIT R1 C S
SHCKRST
=> SHCKRST
!
Move the cursor to "UNUSED" of "ROBOT/STATION", and press [SELECT]. The

selection dialog is shown. Move the cursor to added robot or station and press
[SELECT].

L
DETAIL EDIT R1 C S
SHCKRST
R1:ROBOT1
R1:ROBOT1
S1:STATION1
UNUSED
=> SHCKRST
!
When the addition of the robot/the station ends, press [ENTER]. The detail edit dis-
play shuts and the job content display is shown.
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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.
L
ALARM R1 C A
ALARM 4315
COLLISION DETECT
ROBOT1[SLURBT]
OCCUR TIMES : 1 RESET
The shock detection alarm in teach mode and play mode can be reset by the following opera-
tion.
Operation
Press [SELECT]*1 Operation after resetting the detection status*2
Explanation
*1 The alarm is reset when "RESET" is selected on the alarm display, and the shock
detection status is released.
*2 In teach mode, the JOG operation of the manipulator becomes possible again after
resetting. In play mode, confirm the damage after moving the manipulator to the safety
position once with teach mode though the playback operation is possible after reset-
ting.
When manipulator was stopped instantaneously while having contact with the object and
NOTE the detection alarm is tried to reset on the alarm display, the situation in which the alarm
cannot be reset might be occured because the collision might be detected again after
resetting.
In this case, set the collision detection function "INVALID" with the shock detection level
file or enlarge the detection level in teach mode and move the manipulator to safety posi-
tion.
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3.12.3 Alarm List
Alarm
Message Cause Remedy
Number
4315 COLLISION DETECT • A collision from interferrence • 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-
• The collision was mis-detected tion.
by the normal movement of the • When the alarm cannot be
robot, because the detection reset because the robot
level was small. comes in contact with the
object, invalidate this func-
tion in the collision detec-
tion level set file or enlarge
the detection level and
move the robot to the
safety position.
• Enlarge the detection level
so as not to mis-detect the
collision detection by the
normal movement of the
robot. Moreover, set accu-
rate information of the
weight of the tool.
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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.
Subset Instruction Set

The instructions displayed in the instruction list are limited to just those that are most fre-
quently used, reducing the number of instructions that can be registered. Since few instruc-
tions are displayed, selection and input are simple.
Standard Instruction Set / Expanded Instruction Set

All the INFORM II instructions can be used. The number of additional items to be used in each
instruction differ in the standard instruction set and expansion instruction set.
In the standard instruction set, the following functions cannot be used. However, operation
becomes easier because the number of data items decreases when registering an instruction.
• Use of local variables and arrangement variables

• Use of variables for additional items (Example: MOVJ = 1000)
When instructions are executed, for example during playback, all the instructions can be exe-
cuted regardless of the instruction set used.
Expanded instruction set

Standard instruction set
Subset instruction set
Frequency used
All instructions
instructions
Use of local variables and arrangement variables

Use of variables for additional items
Job calls with arguments
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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.
Register an An instructions are regis-

0003 WAIT IN#(1)=ON
instruction 0004 END tered
The instruction and The next time an attempt is

the additional items made to register the same
that were entered => WAIT IN#(1)=ON
last time are ! instruction as in 1, the same
displayed additional items as were reg-
istered last time are also dis-
played in the input buffer
line.
3.13.2 Setting Instruction Set Level Operation

Operation
Select {SETUP} under the top menu Select {TEACHIG COND}*1 Select “LAN-
GUAGE LEVEL”*2 Select desired language level*3
Explanation
*1 The teaching condition display is shown.

L
TEACHING CONDITION R1 C S
RECT/CYLINDRICAL RECT
LANGUAGE LEVEL SUBSET
MOVE INSTRUCTION SET LINE
STEP ONLY CHANGING PROHIBIT
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3.14 Number Key Customize Function
*2 The selection dialog is displayed.

L
LANGUAGE LEVEL SUBSET
MOVE INSTRUCTION
SUBSET SET LINE
STEP ONLY CHANGING
STANDARD PROHIBIT
EXPANDED
*3 Language level is set.

L
LANGUAGE LEVEL STANDARD
MOVE INSTRUCTION SET LINE
STEP ONLY CHANGING PROHIBIT
3.14.1 What is the Number Key Customize Function?

With this function, the user can change the function of an application that has been allocated
to the number keys of the programming pendant.
Since any frequently used operation can be allocated to a number keys on the programming
pendant, decreasing the number of key operations reduces the teaching time.
NOTE The Number Key Customize Function is only valid when the security mode is set to the
managememt mode.
3.14.2 Allocatable Functions

There are two allocation methods as follows:
• Key Allocation (EACH)
• Key Allocation (SIM)
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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.
Instruction allocation Allocates any instructions assigned by the user.
Job call allocation Allocates job call instructions (CALL instructions). The jobs to be called
are only those registered in the reserved job names. (Specify it by the
registration No.)
Display allocation Allocates any displays assigned by the user. It functions the same as
the reserved display call function.
Key Allocation (SIM)

With key allocation (SIM), the manipulator operates according to the allocated function when
the [INTERLOCK] and the number key are pressed at the same time. The following shows
the functions that can be allocated.
Function Description
Alternate output Turns ON/OFF the specified general output signal when [INTERLOCK]
allocation and the allocated number key are pressed at the same time.
Momentary output Turns ON the specified general output signal when [INTERLOCK] and
allocation the allocated number key are pressed at the same time.
Pulse output Turns ON the specified output signal only for the specified period when
allocation [INTERLOCK] and the allocated number key are pressed at the same
time.
Group output Sends the specified output to the specified general group output signals
allocation (4-bit/8- when [INTERLOCK] and the allocated number key are pressed at the
bit) same time.
Analog output Sends the specified voltage to the specified output port when [INTER-
allocation LOCK] and the allocated number key are pressed at the same time.
Analog incremental Sends the voltage increased by the specified value to the specified out-
output allocation put port when [INTERLOCK] and the allocated number key are pressed
at the same time.
SUPPLE In a system for multiple applications, a number key can be allocated for each application.
-MENT
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3.14.3 Allocating an Operation

Allocation Display
Operation
Select {SETUP} under the menu Select {KEY ALLOCATION}*1 Select {DIS-
PLAY}*2 Select {ALLOCATE SIM. KEY}*3
Explanation
*1 The key allocation (EACH) display is shown.

L
KEY ALLOCATION(EACH) R1 C S
APPLI.NO.:1
KEY FUNCTION ALLOCATION CONTENT
- MAKER
. MAKER
0 MAKER
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
*2 The pull-down menu is displayed. To call up the key allocation (SIM) display, select
{ALLOCATE SIM. KEY}.

L
KEY ALLOCATION(EACH) R1
ALLOCATE EACH
C KEY
ALLOCATE EACH S
KEY
APPLI.NO.:1 ALLOCATE SIM. KEY
- MAKER
. MAKER
0 MAKER
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
*3 The key allocation (SIM) display is shown.
In a system multiple applications, press the page key to change the display to the
allocation display for each application.

L
KEY ALLOCATION(SIM) R1 C S
APPLI.NO.:1
- MAKER
. MAKER
0 MAKER
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
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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]*1

Select “INSTRUCTION”*2
Explanation
*1 The selection dialog box is shown.

L
APPLI.NO.:1
- MAKER
MAKER
. MAKER MAKER
INSTRUCTION
0 MAKER
JOB CALL
1 MAKER DISPLAY
2 MAKER
3 MAKER
4 MAKER
!
*2 The instruction is displayed in the “ALLOCATION CONTENT”.

L
APPLI.NO.:1
- INSTRUCTION DOUT
. MAKER
0 MAKER
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
To change the instruction, move the cursor to the instruction and press [SELECT].
Then the instruction group list dialog box is displayed. Select the group containing the
instruction to be changed.

L
APPLI.NO.:1
- INSTRUCTION DOUT IN/OUT
. MAKER CONTROL
0 MAKER DEVICE
1 MAKER MOTION
2 MAKER ARITH
3 MAKER SHIFT
4 MAKER OTHER
!
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When the instruction list dialog box is displayed, select the instruction to be changed.

L
APPLI.NO.:1
- INSTRUCTION WAIT
. MAKER
0 MAKER
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
Job Call Allocation

Use this function in the key allocation (EACH) display.
Operation
Move the cursor to the “FUNCTION” of the key to be allocated Press [SELECT]*1
Select “JOB CALL”*2
Explanation
*1 The selection dialog box is displayed.
*2 The reserved job registration No. is displayed in the “ALLOCATION CONTENT”

(reserved job registration No.: 1 to 10).

L
APPLI.NO.:1
- INSTRUCTION DOUT
. JOB CALL 1
0 MAKER
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
To change the reserved job registration No., move the cursor to the No. and press
[SELECT]. Numeric values can now be entered. Input the number to be changed, and
press [ENTER].
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Display Allocation
Use this function is used in the key allocation (EACH) display.
Operation
Select “DISPLAY” Move the cursor to “ALLOCATION CONTENT” Press
[SELECT]*2 Input the name of the reserved display and press [ENTER]*3 Open the
display for allocation Press [INTERLOCK] and the allocated key at the same time*4
Explanation
*2 The character input status is entered.
*3 The reserved name input to the “ALLOCATION CONTENT” is displayed.

L
APPLI.NO.:1
- INSTRUCTION DOUT
. JOB CALL 1
0 DISPLAY WORK POSITION DISP
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
*4 A message “Reserved display registered” is displayed, and the display is registered.
NOTE The display allocation functions the same as the reserved display call function. Only one
display can be allocated to a key.
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Alternate Output Allocation

Use this function is used in the key allocation (SIM) display.
Operation
Select “ALTERNATE OUTPUT”*2
Explanation

L
APPLI.NO.:1
- MAKER MAKER
MAKER
. MAKER ALTERNATE OUTPUT
0 MAKER MOMENTARY OUTPUT
PULSE OUTPUT
1 MAKER
4 BIT OUTPUT
2 MAKER
3 MAKER
4 MAKER
!
*2 The output No. is displayed in the “ALLOCATION CONTENT”.

L
APPLI.NO.:1
- ALTERNATE NO. : 1
. MAKER
0 MAKER
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
To change the output No., move the cursor to the No. and press [SELECT]. Numeric
values can now be entered. Input the number to be changed, and press [ENTER].
Momentary Output Allocation

Use this function in the key allocation (SIM) display.
Operation
Select “MOMENTARY OUTPUT”*2
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Explanation
*2 The output No. is displayed in the “ALLOCATION CONTENT”.

L
APPLI.NO.:1
- ALTERNATE NO. : 1
. MOMENTARY NO. : 1
0 MAKER
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
To change the output No., move the cursor to the No. and press [SELECT]. Numeric
values can now be entered. Input the number to be changed, and press [ENTER].
Pulse Output Allocation

Operation
Select “PULSE OUTPUT”*2
Explanation
*2 The output No. and output time are displayed in the “ALLOCATION CONTENT”.

L
APPLI.NO.:1
- ALTERNATE NO. : 1
. MOMENTARY NO. : 1
0 PULSE NO. : 1 TIME: 0.01 SEC
1 MAKER
2 MAKER
3 MAKER
4 MAKER
!
To change the output No. or output time, move the cursor to the No. or time and press
[SELECT]. Numeric values can now be entered. Input the number or time to be
changed, and press [ENTER].
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Group (4-bit/8-bit) Output Allocation

Operation
Select “4 BIT OUTPUT” or “8 BIT OUTPUT”*2
Explanation
*2 The output No. and output value are displayed in the “ALLOCATION CONTENT”.
L
APPLI.NO.:1
- ALTERNATE NO. : 1
. MOMENTARY NO. : 1
1 4BIT OUTPUT NO. : 1 OUT : 0
2 MAKER
3 MAKER
4 MAKER
!
To change the output No. or output value, move the cursor to the No. or value and
press [SELECT]. Numeric values can now be entered. Input the number or value to be
changed, and press [ENTER].
Analog Output Allocation

Operation
Select “ANALOG OUTPUT”*2
Explanation
*2 The output port number and the output voltage value are displayed in the “ALLOCA-
TION CONTENT”.

L
APPLI.NO.:1
- ALTERNATE NO. : 1
. MOMENTARY NO. : 1
2 ANALOG OUT NO. : 1 OUT : 0.00
3 MAKER
4 MAKER
!
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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].
Analog Incremental Output Allocation

Operation
Select “ANALOG INC OUTPUT”*2
Explanation
*2 The output port No. and incremental value are displayed in the “ALLOCATION CON-
TENT”.

L
APPLI.NO.:1
- ALTERNATE NO. : 1
. MOMENTARY NO. : 1
2 ANALOG OUT NO. : 1 OUT : 0.00
3 ANALOG INC NO. : 1 INC : 1.00
4 MAKER
!
To change the output port No. or incremental value, move the cursor to the No. or incre-
mental value and press [SELECT]. Numeric values can now be entered. Input the
number or incremental value to be changed, and press [ENTER].
3.14.4 Allocation of I/O Control Instructions

With key allocation (SIM), output control instructions can be allocated to the number keys that
have been allocated one of the following I/O controls key allocation (EACH).
Function Output Control Instruction To Be Allocated
Alternate output allocation DOUT OT# (No.) ON
Momentary output allocation
Pulse output allocation PULSE OT# (No.) T = output time
Group output allocation (4-bit) DOUT OGH (No.) output value
Group output allocation (8-bit) DOUT OG# (No.) output value
Analog output allocation AOUT AO# (No.) output voltage value
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Operation
Move the cursor to the “FUNCTION” of the key that has been allocated with I/O control with
key allocation (SIM) Press [SELECT]*1 Select “OUTPUT CONTROL INST”*2
Explanation

L
APPLI.NO.:1
MAKER
- INSTRUCTION
MAKERDOUT
. JOB CALLINSTRUCTION
1
0 DISPLAY JOB CALL
WORK POSITION DISP
1 MAKER OUTPUT CONTROL INST
DISPLAY
2 MAKER
3 MAKER
4 MAKER
!
*2 The instruction corresponding to the I/O control allocated by key allocation (SIM) is dis-
played in the “ALLOCATION CONTENT”.

L
APPLI.NO.:1
- INSTRUCTION DOUT
. JOB CALL 1
0 DISPLAY WORK POSITION DISP
1 INSTRUCTION DOUT OGH#(1) 0
2 MAKER
3 MAKER
4 MAKER
!
The allocated instruction changes automatically when “ALLOCATION CONTENT” is

changed by key allocation (SIM).
Even if the I/O control allocation is changed to the default setting allocated by the man-
ufacturer, the settings for key allocation (EACH) remain the same.
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3.14.5 Execution of Allocation

Executing the Instruction/Output Control Allocation
Operation
Press the key allocated for instruction allocation or output control allocation*1 Press
*2
[INSERT] and [ENTER]
Explanation
*1 The allocated instruction is displayed in the input buffer line.
=> WAIT IN#(1) =ON
Executing the Job Call Allocation

Operation
Press the key allocated for the job call allocation*1 Press [INSERT] and [ENTER]*2
Explanation
*1 The CALL instruction is displayed in the input buffer line.
=> CALL JOB: ARCON
*2 The CALL instruction displayed in the input buffer line is registered.
Executing the Display Allocation

Operation
Press the key allocated for the display allocation*1
Explanation
*1 The allocated display is shown. At the same time, the reserved display key
lights up. Press the allocated key again to turn off the reserved display key and
return to the previous display.
Executing the I/O Control Allocation

Operation
Press [INTERLOCK] and the key allocated for I/O control allocation at the same time*1
Explanation
*1 Allocated functions are executed.
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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 " 5.3.2 Universal Output ")
• On the relay on display
The method that uses the relay on display, which is described here, simplifies the operation
for changing the status of signals that are used frequently.
NOTE A maximum of 16 output signals can be displayed on the relay on display and they must be
set in advance with parameter settings S2C213 to S2C228.
Operation
Select {IN/OUT} under the top menu Select {RELAY ON}*1 Select the desired
*2 *3
signal for changing Press [INTER LOCK]+[SELECT]
Explanation
*1 The relay on display is shown.

L
RELAY ON R1 C S
OUTPUT NO. STATUS NAME
OUT#010 [HAND1 ]
OUT#008 [ ]
OUT#014 [ ]
OUT#009 [ ]
*2 Select the status ( or ) of the desired signal to change.
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*3 The status is changed. ( : status ON, : status OFF)

L
RELAY ON R1 C S
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
SUPPLE
-MENT
[INTER LOCK]+[SELECT] are pressed. This selection is made in advance by setting the
parameters S2C229 ~ 244 to “1”.
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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. These software limits are called "soft limits." The operating
range of the manipulator is controlled by the following two soft limits.
• Maximum working range for each axis

• Cubic operation area set parallel to the robot coordinate system
These soft limits are continually monitored by the system. When it is detected that the manip-
ulator (tool center point) has reached a soft limit, the manipulator automatically stops.
When the manipulator is stopped at a soft limit, temporarily release the soft limit by following
the procedure below, then move the manipulator away from that which exceeded the soft limit.
Operation
Select {ROBOT} under the top menu Select {LIMIT RELEASE}*1 Select “SOFT
LIMIT RELEASE”*2
Explanation
*1 The limit release display is shown.

L
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3.17 Changing the Parameter Setting
*2 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.

L
SOFT LIMIT RELEASE VALID
!Softlimits have been released
When “SOFT LIMIT RELEASE” is set to “INVALID,” the message “Soft limits have been
released" is displayed for three seconds.
NOTE The teaching data cannot be entered while releasing software limit.
The parameter settings can be changed only by the operator who has the correct user ID
number for the management mode.
Operation
Select {PARAMETER} under the top menu Select the parameter type *1 Move
*2
the cursor to the parameter number whose setting is to be changed
Explanation
*1 The parameter display is shown. Select the desired parameter.

L
PARAMETER R1 C S
S2C000 1 0000_0000
パ S2C001 2 0000_0000
ラ S2C002 4 1000_0000 Binary Data
メ S2C003 8 0000_0000
ー S2C004 16 0000_0000 Decimal Data
タ S2C005 32 0000_0000
S2C006 64 0000_0000
S2C007 89 0000_0000
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When the desired parameter number is not in the present display, move the cursor to a
parameter number and press [SELECT]. Enter the desired parameter number with the
number keys and press [ENTER]. The cursor moves to the selected parameter num-
ber.

L
PARAMETER R1 C S
The cursor moves S2C055 128 1000_0000
to the selected S2C056 256 0000_1000
parameter number. S2C057 512 1100_0000
S2C058 875 0000_0000
Set the parameters in the following manner.
Operation
Select a parameter setting *1 Enter the value *2 Press [ENTER]
Explanation
*1 Move the cursor to the parameter number in the parameter display, and press
[SELECT].
- To enter a decimal setting, select the decimal figure.
- To enter a binary setting, select the binary figure.

L
PARAMETER R1 C S
S2C055 128 1000_0000
S2C056 256 0000_1000
S2C057 512 0000_0000
S2C058 0 0000_0000
S2C059 0 0000_0000
S2C060 0 0000_0000
S2C061 0 0000_0000
S2C062 0 0000_0000
S2C063 0 0000_0000
!
*2 If a decimal figure is selected, enter a decimal value with the number keys.
S2C056 　0 0000_0000_0000_0000
> 256
If a binary figure is selected, move the cursor to the numbers in the input buffer line,
and press [SELECT]. Each time [SELECT] is pressed, “0” and “1” alternate in the dis-
play. “0” or “1” can also be entered with the number keys.
S2C056 　0 0000_0000_0000_0000
> 0000_0000_1100_0000
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*3 The new setting appears in the position where the cursor is located.

L
PARAMETER R1 C S
S2C055 192 1000_0000
S2C056 256 0000_1000
S2C057 512 0000_0000
S2C058 0 0000_0000
S2C059 0 0000_0000
S2C060 0 0000_0000
S2C061 0 0000_0000
S2C062 0 0000_0000
S2C063 0 0000_0000
!
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3.18 File Initialize
NOTE The teaching data cannot be entered while releasing software limit.
3.18.1 Initialize Job File

Operation
Turn the power supply ON while pressing [TOP MENU] simultaneously Change the
security mode to managememt mode Select {FILE} under the top menu Select
{INITIALIZE}*1 Select “JOB”*2 Select “YES”*3
Explanation
*1 Initializing objects are shown.
INITIALIZE
JOB Item marked by can not be

FILE/GENERAL DATA selected.
PARAMETER
I/O DATA
SYSTEM DATA
!Maintenance Mode
INITIALIZE
JOB
FILE/GENERAL DATA
Initialize?
PARAMETER
I/O DATA
SYSTEM DATAYES NO
!Maintenance Mode
*3 Job data is initialized.
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3.18.2 Initialize Data File

Operation
security mode to managememt mode Select {FILE} under the top menu Select
{INITIALIZE} Select {FILE/GENERAL DATA}*1 Select data file for initializing*2
Press[ENTER]*3 Select “YES”*4
Explanation
*1 Data files are shown.
INITIALIZE
TOOL DATA TOOL .CND

WEAVING DATA WEAV .CND
USER COODINATE DATA UFRAME .CND
VARIABLE DATA VAR .DAT
ARC START COND DATA ARCSRT .CND
ARC END COND DATA ARCEND .CND
ARC AUXILIARY COND DATA ARCSUP .DAT
WELDER CONDITION DATA WELDER .DAT

!Maintenance Mode
*2 The selected data file is marked with “ “.
INITIALIZE
TOOL DATA TOOL .CND

WEAVING DATA WEAV .CND File/Data marked by
USER COODINATE DATA UFRAME .CND can not be selected.

!Maintenance Mode
INITIALIZE
TOOL DATA TOOL .CND

WEAVING DATA Initialize? WEAV .CND
USER COODINATE DATA UFRAME .CND
YES NO

!Maintenance Mode
*4 Selected data file is initialized.
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3.18.3 Initialize Parameter File

Operation
security mode to management mode Select {FILE} under the top menu Select
{INITIALIZE} Select {PARAMETER}*1 Select parameter for initializing*2
Press [ENTER]*3 Select “YES”*4
Explanation
*1 Parameters are shown.
INITIALIZE
ROBOT MATCH PRMTR RC .PRM

SYS DEF PRMTR SD .PRM
COORD ORG PRMTR RO .PRM
SYS MATCH PRMTR SC .PRM
CIO PRMTR CIO .PRM
FCTN DEF PRMTR FD .PRM
APPLI PRMTR AP .PRM
TRANSMISSION(UNIV) RS .PRM
!Maintenance Mode
*2 The selected parameter is marked with “ “.
INITIALIZE
ROBOT MATCH PRMTR RC .PRM Parameter marked by

SYS DEF PRMTR SD .PRM can not be selected.
CIO PRMTR CIO .PRM
APPLI PRMTR AP .PRM
!Maintenance Mode
*3 The confirmation dialog is displayed

.
INITIALIZE
ROBOT MATCH PRMTR RC .PRM

SYS DEF PRMTR SD .PRM
Initialize?
CIO PRMTRYES NO CIO .PRM
APPLI PRMTR AP .PRM
!Maintenance Mode
*4 Selected parameter is initialized.
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3.18.4 Initializing I/O Data

Operation
{INITIALIZE} Select {I/O DATA}*1 Select data for initializing*2 Press
[ENTER]*3 Select “YES” *4
Explanation
*1 The I/O data is shown.
INITIALIZE
C IO PRGM CIOPRG .LST

IO NAME DATA IONAME .LST
SIMULATED IN DATA PSEUDOIN.DAT
!Maintenance Mode
*2 The selected data is marked with “ “.
INITIALIZE
C IO PRGM CIOPRG .LST Parameters marked by

IO NAME DATA IONAME .LST can not be selected.
!Maintenance Mode
*3 The confirmation dialog box is displayed.
INITIALIZE
C IO PRGM CIOPRG .LST

IO NAME DATAInitialize? IONAME .LST
YES NO
!Maintenance Mode
*4 The selected data is initialized.
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3.18.5 Initializing System Data

Operation
{INITIALIZE} Select {SYSTEM DATA}*1 Select the parameter to be initialized*2
Press [ENTER]*3 Select “YES”*4
Explanation
*1 The system data is shown.
INITIALIZE
USER WORD UWORD .DAT

SV MONITOR SIGNAL SVMON .DAT
VARIABLE NAME VARNAME .DAT
SECOND HOME POSITION HOME2 .DAT
HOME POS CALIB DATA ABSO .DAT
OPERATION ORG POS DATA OPEORG .DAT
!Maintenance Mode
*2 The selected data is marked with “ “.
INITIALIZE
USER WORD UWORD .DAT Parameter marked by

SV MONITOR SIGNAL SVMON .DAT can not be selected.
HOME POS CALIB DATA ABSO .DAT
!Maintenance Mode
INITIALIZE
USER WORD UWORD .DAT

SV MONITOR SIGNAL SVMON .DAT
Initialize?
HOME POS CALIB
YES DATA NO ABSO .DAT
!Maintenance Mode
*4 The selected data is initialized.
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4.1 Addition of I/O Modules
4 Modification of System Configuration
For addition of I/O modules,turn the power supply off.
SUPPLE
The additional operation must be done in the management mode.
-MENT In operation mode or editing mode, only confirmation of status setting is possible.
Operation
Turn the power supply ON while pressing [TOP MENU] simultaneously Select {SYS-
*1 *2
TEM} under the top menu Select {SETUP} Select {IO MODULE}*3
Confirm the status of mounted I/O module*4 Press [ENTER]*5 Press [ENTER]*6
Select “YES”*7
Explanation
*1 System display is shown.
SETUP VERSION
!Maintenance Mode
*2 The setup display is shown.
SETUP
LANGUAGE Item marked by

CONTROL GROUP can not be set.
APPLICATION
IO MODULE
OPTION BOARD
CMOS MEMORY
DATE CLOCK
!Maintenance Mode
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*3 The current status of the mounted I/O module is displayed.
IO MODULE
ST# DI DO AI AO BOARD
01 008 008 002 002
02 016 016 - -
03 - - - - NONE
04 - - - - NONE
05 - - - - NONE
06 - - - - NONE
07 - - - - NONE
08 - - - - NONE
!Maintenance Mode
*4 Confirm that each station (ST#) displays the I/O module’s actual mounting status.
The following information is displayed for each station.
ST# Station number of I/O module

DI Number of contact input points (*1)
DO Number of contact output points (*1)
AI Number of analog input points (*1)
AO Number of analog output points (*1)
BOARD Board type (*2)
*1 A hyphen, -, indicates that the corresponding I/O section is not mounted.

*2 If the system cannot recognize the board type, a row of stars (****) are
displayed.
No problem will occur as long as the values displayed in DI, DO, AI, and AO
are correct.
*5 Confirm the statuses of the mounted I/O modules for the other stations.
NOTE If the slot display is different, check the status again. If the status is correct, the I/O module
may be defective. Contact your Yaskawa representative.
IO M O DU LE
S T# D I D O A I A O B O A RD
08 - - - - NO NE
09 - - - - NO NE
10 - - - - NO NE
11 - - - - NO NE
12 - - - - NO NE
13 - - - - NO NE
14 - - - - NO NE
15 040 040 - - XIO 01(M O DE :16byte)
! M aintenance M ode
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4.2 Addition of Base and Station Axis
*6 The confirmation dialog box is shown.
For the XIO01 circuit board, the communication mode is displayed in parentheses.
In the following example, the communication mode is set to 16 bytes.
IO MODULE
ST# DI DO AI AO BOARD
08 - - - - NONE
09 - - - - NONE Modify?
10 - - - - NONE
11 - - - - NONE
YES
12 - - - - NONE NO
13 - - - - NONE
14 - - - - NONE
15 040 040 - - XIO01(MODE:16byte)
!Maintenance Mode
*7 The system parameters are then set automatically according to the current mounted
hardware status. The procedure for the addition of the I/O module is complete.
For addition of base and station axis, mount all hardware correctly and then execute mainte-
nance mode.
SUPPLE
The additional operation must be done in the management mode.
-MENT In operation mode or editing mode, only confirmation of status setting is possible.
Operation
Turn the power supply ON while pressing [TOP MENU] simultaneously Select {SYS-
TEM} under the top menu*1 Select {SETUP}*2 Select {CONTROL GROUP}*3
(Display moves to the control group display.)
Explanation
*1 The system display is shown.
SETUP VERSION
!Maintenance Mode
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*2 The setup display is shown.
SETUP
LANGUAGE Item marked by

CONTROL GROUP can not be set.
APPLICATION
IO MODULE
OPTION BOARD
CMOS MEMORY
DATE CLOCK
!Maintenance Mode
*3 The display moves to the control group display shown in the followings pages.
The following items must be set for base and station axes.
-TYPE
Select one in the type list.
In case of base axis (B1,B2,B3)

Select one of RECT-X, -Y, -Z, -XY, -XZ, -YZ or -XYZ.
In case of station axis (S1,S2,S3,S4,S5,S6)

Select one of TURN-1, -2.
In case of other type, select one of UNIV-1, -2, -3, -4, -5, -6
-CONNECTION
In the connection display, specify the SERVOPACK which is connected with each axis
group and the contactor which is used for the SERVOPACK.
-AXIS TYPE
Select one in the axis type list.
In case of TURN-* type

No need to select (The axis type is set as TURN type.)
In case of RECT-* type

Select BALL-SCREW type or RACK & PINION type.
In case of UNIV-* type

Select BALL-SCREW type, RACK & PINION type or TURN type.
-MECHANICAL SPECIFICATION
If axis type is ball-screw type, set the following items.
MOTION RANGE (+) [mm]

MOTION RANGE (-) [mm]
REDUCTION RATIO (numerator)
REDUCTION RATIO (denominator)
BALL-SCREW PITCH [mm/r]
If axis type is rack & pinion type, set the following items.
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MOTION RANGE (+) [mm]

MOTION RANGE (-) [mm]
PINION DIAMETER [mm]
If axis type is turn type, set the following items.
MOTION RANGE (+) [deg]

MOTION RANGE (-) [deg]
OFFSET (1st and 2nd axis) [mm]
-MOTOR SPECIFICATION
Set the following items.
MOTOR
SERVO AMP
CONVERTER
ROTATION DIRECTION [NORMAL/REVERSE]
MAX. RPM [rpm]
ACCELERATION SPEED [sec]
INERTIA RATIO
* Select MOTOR, AMPLIFIER and CONVERTER from each type’s list.
4.2.1 Base Axis Setting

First, select control group type
Operation
Confirm the type of control group in control group display*1 Select type of control
group for changing*2 Select one in the machine list*3 Press [ENTER] in control
group display
Explanation
*1 The control group display is shown.
CONTROL GROUP
R1 :UP6-A0*
B1 :RECT-XYZ
R2 :NONE
S1 :NONE
!Maintenance Mode
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*2 Machine type selection display is shown.
MACHINE LIST
RECT-X :TRAVEL X-AXIS BASE
NONE RECT-X RECT-Y :TRAVEL Y-AXIS BASE
RECT-Y RECT-Z RECT-Z :TRAVEL Z-AXIS BASE
RECT-XY RECT-XZ RECT-XY :TRAVEL XY-AXIS BASE
RECT-XZ :TRAVEL XZ-AXIS BASE
RECT-YZ RECT-XYZ RECT-YZ :TRAVEL YZ-AXIS BASE
RECT-XYZ:TRAVEL XYZ-AXIS
BASE
(See following pages)
!Maintenance Mode
*3 After the type selection, the display returns to control group display.
*4 The display moves to the connection display.
Direction of Base Axis
RECT-X RECT-Y RECT-Z
CARTESIAN CARTESIAN
CARTESIAN
X-AXIS Z-AXIS
Y-AXIS
Base axis advancing direction coincides
Base axis advancing direction coincides
with robot coordinate X-Axis. Base axis advancing direction
with robot coordinate Y-Axis.
coincides with robot coordinate
Z-Axis.
RECT-XY RECT-YZ RECT-XZ
CARTESIAN
Y-AXIS
CARTESIAN
CARTESIAN CARTESIAN CARTESIAN
CARTESIAN Z-AXIS
X-AXIS Z-AXIS X-AXIS
Y-AXIS
Base 1st and 2nd axes advancing directions Base 1st and 2nd axes advancing directions Base 1st and 2nd axes advancing directions
coincide with robot coordinate X-Axis and Y-Axis, coincide with robot coordinate Y-Axis and coincide with robot coordinate X-Axis and
respecitively. Z-Axis, respectively. Z-Axis,respectively.
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Direction of Base Axis
RECT-XYZ CARTESIAN
Z-AXIS
CARTESIAN CARTESIAN
Y-AXIS X-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.
Operation
Confirm type of each control group in the connection display*1 Select connection item
of desired control group*2 Select desired item Press [ENTER] in the connection
*3
display
Explanation
*1 The connection status of each control group is shown.
CONNECTION
SV CONTACT CN< 1 2 3 4 5 6 7 8 9 >
R1 :#1 1 [123456- - -] Control group which is set as
B1 :#1 2 [- - -- - -123] "NONE" in the control group
display is not shown.
!Maintenance Mode
Note: # is the SERVOPACK number. This number is set by the rotary switch on the
WRCA01 board.
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*2 The items which can be set are shown.

When the item is selected the display returns to the connection display.
CONNECTION
SV CONTACT CN< 1 2 3 4 5 6 7 8 9 >
R1 :#1 1 [123456- - -]
B1 :#1 2
#1
#1 [- - - - - -123]
#2
#3
#4
#5
#6
!Maintenance Mode
It is possible to change freely the connection between each axis of each control group
and each connector (CN) of a SERVOPACK. The number in [ ] means axis number,
and it indicates the connector number to which each axis connects.
The example above meaning is as follows,
R1(Robot)
1st axis 1CN (SERVOPACK #1, 1st contactor is used)
2nd axis 2CN (SERVOPACK #1, 1st contactor is used)
3rd axis 3CN (SERVOPACK #1, 1st contactor is used)
4th axis 4CN (SERVOPACK #1, 1st contactor is used)
B1(Base)
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)
*3 The setting in the connection display is completed and the display moves to the axes
form display.
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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*1 Select desired
axis*2 Select desired axis type Press [ENTER] in the axes configuration display*3
Explanation
*1 The axis type of each axis is shown.
AXES CONFIG
B1 : RECT-XYZ
AXIS AXIS TYPE
1 : BALL-SCREW
2 : BALL-SCREW
3 : BALL-SCREW
!Maintenance Mode
*2 The axis type which can be set is shown.
AXES CONFIG
B1 : RECT-XYZ
AXIS AXIS TYPE
BALL-SCREW
1 : BALL-SCREW
RACK&PINION
2 : BALL-SCREW
3 : BALL-SCREW
!Maintenance Mode
The traveling axis of ball-screw type should be selected as “ BALL-SCREW ”, the one
of rack & pinion type should be selected as “ RACK & PINION ”. Then the display
returns to the axes configuration display.
*3 The setting in the axes configuration display is completed and the display moves to the
mechanical specification display.
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In the mechanical specification display, mechanical data are specified.
Operation
Confirm specification of each axis in the mechanical specification display*1 Select

desired item Input the value Press [ENTER]*2
Explanation
*1 The mechanical specification is shown.
The mechanical specification display (In case of BALL-SCREW type)
MECHANICAL SPEC Group, Type, Axis Number and

B1 :RECT-XYZ AXIS:1 Axis Type are displayed.
AXIS TYPE:BALL-SCREW
MOTION RANGE (+) 0.000 mm The cursor is reversed.
MOTION RANGE (-) 0.000 mm
REDUCTION RATIO(NUMER) 1.000
REDUCTION RATIO(DENOM) 2.000
BALL-SCREW PITCH 10.000 mm/r
!Maintenance Mode
MOTION RANGE :Input maximum moving position (+ direction and - direction) from
origin point. (Unit: mm)
REDUCTION RATIO :Input the numerator and the denominator.
<e.g.> If the reduction ratio is 1/2, the numerator should be set
as 1.0 and the denominator should be set as 2.0.
BALL-SCREW PITCH :Input the traveling length when the ball-screw rotates once.
(Unit: mm/r)
The mechanical specification display (In case of RACK & PINION type)
MECHANICAL SPEC
B1 :RECT-XYZ AXIS:2 Group, Type, Axis Number and
AXIS TYPE:RACK&PINION Axis Type are displayed.
PINION DIAMETER 100.000 mm
!Maintenance Mode
PINION DIAMETER :Input the diameter of a pinion. (Unit: mm)
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*2 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.
In the motor specification display, motor data are specified.
Operation
Confirm specification of each axis in the motor specification display*1 Select desired
*2
item Input the value and press [ENTER] (Or move cursor to alternative and press
[ENTER].)*3
Explanation
*1 The motor specification of each axis is shown.
MOTOR SPEC Group, Type, Axis Number and

B1 :RECT-XYZ AXIS:1 Axis Type are displayed.
MOTOR SGMP-15AW-YR1∗ The cursor is reversed.
SERVO AMP JUSP-WSA3AB
CONVERTER JUSP-ACP35JAB
ROTATION DIRECTION NORMAL
MAX RPM 2000 rpm
ACCELARATION TIME 0.300 sec
INERTIA RATIO 300
!Maintenance Mode
*2 When an item which is input by number is selected the number input buffer line is dis-
played.
When MOTOR (or SERVO AMP or CONVERTER) is selected, the list of MOTOR
(SERVO AMP, or CONVERTER) is shown.
MOTOR LIST
Group, Type, Axis Number and
B1 :RECT-XYZ AXIS:1
Axis Type are displayed.
USAREM-01YRW1* USADED -22YRW1* The type list registered in
USAREM-02YRW1* USADED -32YRW1* ROM is displayed.
USAREM-05YRW1* USADED -40YRW1*
USAREM-08YRW1* USADED -45YRW1*
USADED-13YRW1* SGMP -01AWYR2*
USAREM-18YRW1* SGMP -02AWYR1*
!Maintenance Mode
ROTATION DIRECTION : Set the rotation direction to which the current pulse data is
increased. (The counterclock wise view from the loaded side is positioned normal.)
4-11
RE-CTO-A203
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 ” when in case of traveling axis or ” 0 ” when in case
of rotation axis is set as initial value.
But if the following phenomenon occurs in motion,
deal with the followed procedure.
<Phenomenon1> During motion, the axis moves unsteady on advance direction.
Confirm the motion with increasing this ratio in each 100.
<Phenomenon2> during pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
*3 After this motor specification setting, the display moves to the next axis. Set them for all
axes.
When [ENTER] is pressed at the motor specification display for last axis, the setting in
this display is completed and the confirmation dialog is shown.
MOTOR SPEC
B1 :RECT-XYZ AXIS:3
MOTOR SGMP-15AWYR1
Modify?
AMP JUSP-WSA3AB
ROTATION DIRECTION
YES NO FORWARD
MAX RPM 2000 rpm
INERTIA RATIO 300
!Maintenance Mode
If “ YES ” is selected, the system parameter is modified automatically.
The addition of the base axis setting is complete.
4-12
RE-CTO-A203
CAUTION
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” in this manual after changing
the construction.
When the data, for example motion range, must be changed after the addition of a
base axis or station axis, the change can be done with the same procedure shown
above.
In that case, the control group construction is not changed so the job file data should
not be initialized.
4.2.2 Station Axis Setting

Operation
Confirm the type of control group in control group display*1 Select type of control
group for changing*2 Select desired type in the type list*3 Press [ENTER] in con-
*4
trol group display
Explanation
*1 The control group display is shown.
CONTROL GROUP
R1 :UP6-A0*
B1 :NONE
R2 :NONE
S1 :TURN-2
S2 :NONE
!Maintenance Mode
4-13
RE-CTO-A203
*2 Type selection display is shown.
MACHINE LIST
TURN-1:TURN 1 AXIS STATION
NONE TURN-1 TURN-2:TURN 2 AXES STATION
TURN-2 UNIV-1 UNIV-1:UNIVERSAL 1 AXIS STATION
UNIV-2 UNIV-3 UNIV-2:UNIVERSAL 2 AXES STATION
UNIV-4 UNIV-5 .....
UNIV-6
!Maintenance Mode
*3 After the type selection, the display returns to control group display.
When the station type is not “TURN-1” and “TURN-2” (like a traveling axis) “UNIVER-
SAL” should be selected. When “UNIVERSAL” is selected, interpolation motion (linear,
circular, etc.) is not supported.
TURN-1
STATION 1ST AXIS
TURN-2
STATION 2ND AXIS (ROTATION TABLE)
OFFSET
STATION 1ST AXIS (INCLINATION AXIS)
If the number of axes is set beyond 27, error occurs.
4-14
RE-CTO-A203
*4 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*1 Select connection item
of desired control group*2 Select desired item Press [ENTER] in the connection
*3
display
Explanation
*1 Connection status of each control group is shown.
CONNECTION
SV CONTACT CN< 1 2 3 4 5 6 7 8 9 > Control group which is set as
R1 :#1 1 [123456 - - -] "NONE" in the control group
S1 :#1 2 [- - - - - -12 -] display is not shown.
!Maintenance Mode
*2 The items which can be set are shown.
CONNECTION
SV CONTACT CN< 1 2 3 4 5 6 7 8 9 >
R1 :#1 1 [123456 - - -]
S1 :#1 2
#1 [- - - - - -12 -]
#2
#3
#4
#5
#6
!Maintenance Mode
It is possible to freely change the connection between each axis of each control group
and each connector(CN) of a SERVOPACK. The number in [ ] is the axis number, and
it indicates the connector number to which each axis connects.
The example above means the following:
R1(Robot)
1st axis 1CN (SERVOPACK #1, 1st contactor is used)
2nd axis 2CN (SERVOPACK #1, 1st contactor is used)
3rd axis 3CN (SERVOPACK #1, 1st contactor is used)
4-15
RE-CTO-A203
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.
In the axes form display, the axis type and motor type are specified.
Operation
Confirm axis type of each axis in the axes form display*1 Select desired axis*2
Select desired axis type Press [ENTER] in the axes form display*3
Explanation
*1 The axis type of each axis is shown.
The axes form display (In case of TURN type)
AXES CONFIG
S1 : TURN-2
AXIS AXIS TYPE
1 : TURN When axis type is "TURN-*" the
2 : TURN axis type can not be changed.
!Maintenance Mode
The axes form display (In case of UNIVERSAL type)
AXES CONFIG
S1 : UNIV-3
AXIS AXIS TYPE
1 : BALL-SCREW BALL-SCREW :TRAVEL
2 : RACK&PINION (BALL-SCREW)
3 : TURN RACK&PINION:TRAVEL
(RACK&PINION)
TURN :TURN
!Maintenance Mode
4-16
RE-CTO-A203
*2 The axis types which can be set are shown.
AXES CONFIG
S1 : UNIV-3
AXIS AXIS TYPE
BALL-SCREW
1 : BALL-SCREW
RACK&PINION
2 : RACK&PINION
ROTATION
3 : ROTATION
!Maintenance Mode
The traveling axis for the ball-screw type should be selected as “ BALL-SCREW ”, the
one for rack & pinion type should be selected as “ RACK & PINION ”. Then the display
returns to the axes form display.
*3 The setting in the axes form display is completed and the display moves to the
mechanical specification display.
In the mechanical specification display, mechanical data are specified.
Operation
Confirm specification of each axis in the mechanical specification display*1 Select

desired item Input the value Press [ENTER]*2
Explanation
*1 The mechanical specification is shown.
The mechanical specification display (In case of ROTATION type)
MECHANICAL SPEC
Group, Type, Axis Number and
S1 :TURN-2 AXIS:1
Axis Type are displayed.
AXIS TYPE :ROTATION
MOTION RANGE (+) 0.000 deg The cursor is reversed.
MOTION RANGE (-) 0.000 deg
OFFSET (AXIS#1-2) 10.000 mm OFFSET is shown at 1st axis
when the type is TURN-2 only.
!Maintenance Mode
origin point. (Unit: deg)
<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.
OFFSET :Offset should be specified at “ TURN-2 ” type only.
nput length between the center of bending axis (1st axis) and
the turning table (2nd axis). (Unit: mm)
4-17
RE-CTO-A203
TURN-2
STATION 2ND AXIS (ROTATION TABLE)
OFFSET
STATION 1ST AXIS (INCLINATION AXIS)
The mechanical specification display (In case of BALL-SCREW type)
MECHANICAL SPEC Group, Type, Axis Number

S1 :UNIV-3 AXIS:1 and Axis Type are displayed.
BALL-SCREW PITCH 10.000 mm/r
!Maintenance Mode
BALL-SCREW PITCH :Input the traveling length when the ball-screw rotates once.
(Unit: mm/r)
The mechanical specification display (In case of RACK&PINION type)
MECHANICAL SPEC Group, Type, Axis Number

S1 :UNIV-3 AXIS:2 and Axis Type are displayed.
AXIS TYPE :RACK&PINION
PINION DIAMETER 100.000 mm
!Maintenance Mode
4-18
RE-CTO-A203

<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)
*2 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 the last axis, the
setting in the mechanical specification display is completed and the display moves to
the motor specification display.
In the motor specification display, motor data are specified.
Operation
Confirm specification of each axis in the motor specification display*1 Select desired
item*2 Input the value Press [ENTER] in the motor specification display*3
Explanation
*1 The motor specification of each axis is shown.
MOTOR SPEC
Group, Type, Axis Number
S1 :TURN-2 AXIS:1
and Axis Type are displayed.
AXIS TYPE:ROTATION
MOTOR SGMP-15AW-YR1∗ The cursor is reversed.
ROTATION DIRECTION NORMAL
MAX RPM 2000 rpm
INERTIA RATIO 300
!Maintenance Mode
*2 When an item which is input by number is selected, the number input buffer line is dis-
played.
And when MOTOR (or SERVO AMP or CONVERTER) is selected the list of MOTOR
(SERVO AMP or CONVERTER) is shown.
MOTOR LIST Group, Type, Axis Number

S1 :TURN-2 AXIS:1 and Axis Type are displayed.
AXIS TYPE:ROTATION
The type list registered in
USAREM-01YRW1* USADED-22YRW1* ROM is displayed.
USAREM-02YRW1* USADED-32YRW1*
USADED-13YRW1* SGMP-01AWYR2*
USAREM-18YRW1* SGMP-02AWYR1*
!Maintenance Mode
ROTATION DIRECTION : Set the rotation direction to which the current pulse data is
increased. (The counterclock wise from view from the loaded side is positioned nor-
mal.)
4-19
RE-CTO-A203
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 ” when in case of traveling axis or “ 0 ” when in case
of rotation axis is set as initial value.
But if the following phenomenon occurs in motion,
deal with the followed procedure.
<Phenomenon1> During motion, the axis moves unsteady on advance direction.
Confirm the motion with increasing this ratio in each 100.
<Phenomenon2> During pause, the motor makes a lot of noise.
Confirm the motion with decreasing this ratio in each 100.
*3 After this motor specification setting, the display moves to the next axis. Set them for all
axes.
When [ENTER] is pressed at the motor specification display for the last axis, the set-
ting in this display is completed and the confirmation dialog is shown.
MOTOR SPEC
S1 :TURN-2 AXIS:2
AXIS TYPE:TURN
MOTOR SGMP-15AWYR1
Modify?
ROTATION DIRECTION
YES NOFORWARD
MAX RPM 2000 rpm
INERTIA RATIO 300
!Maintenance Mode
If “ YES ” is selected, the system parameters are modified automatically.
Then addition of the station axis setting is complete.
4-20
RE-CTO-A203
CAUTION
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” in this manual after changing the
construction.
When the data, motion range for example, should be changed after the addition of a
base axis or station axis, the change can be done in the same procedure as shown
above.
In that case, the control group construction is not changed so the job file data should
not be initialized.
4-21
RE-CTO-A203
5.1 System Version
5 System Diagnosis
5.1 System Version
It is possible to check the system CPU version information as follows.
Operation
Select {SYSTEM INFO} under the top menu Select {VERSION}*1
Explanation
*1 Version number display is shown.

L
VERSION R1 C S
SYSTEM :X1.00A(US)-00
PARAM :1.00 A
MODEL :UP130-A
APPLI :SPOT WELD
CPU SYSTEM ROM BOOT ROM

XCP01 1.00 1.00
XSP01 1.00 1.00
WRCA#0 1.00-00 1.00
!
5.2 Robot Model
Operation
Select {ROBOT} under the top menu Select {MANIPULATOR TYPE}*1
Explanation
*1 The robot axis configuration display is shown.

ROBOT AXIS CONFIG 　 R1 L C S
AXIS CONFIGURATION
　R1： UP130-A* 0011_1111 B1:0000_0001
　S1： TURN-1
5-1
RE-CTO-A203
5.3 Input/Output Status
5.3.1 Universal Input

The status of input signal from the external can be confirmed.
Universal Input Display

Operation
Select {IN/OUT} under the top menu Select {UNIVERSAL INPUT}*1
Explanation
*1 Universal input display is shown.

L
UNIVERSAL INPUT R1 C S
NO. 7654 3210
#001X 0111_1011
#002X 0000_0000
#003X 0000_0000
#004X 1111_0000
#005X 0000_0000
#006X 0000_1010
#007X 0000_0000
#008X 0000_0000
!
Universal Input Detailed Display

Operation
Select {DISPLAY} under the menu Select {DETAIL}*1
Explanation
*1 Universal input detailed display is shown.

L
GROUP IG#01 123:DEC. 7b:HEX.
IN#001 #0010 [ ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
5-2
RE-CTO-A203
5.3.2 Universal Output

The status of the output signal set by the output instruction can be confirmed and modified.
Universal Output Display

Operation
Select {IN/OUT} under the top menu Select {UNIVERSAL OUTPUT}*1
Explanation
*1 Universal output display is shown.

L
UNIVERSAL OUTPUT R1 C S
NO. 7654 3210
#101X 0111_1011
#102X 0000_0000
#103X 0000_0000
#104X 1111_0000
#105X 0000_0000
#106X 0000_1010
#107X 0000_0000
#108X 0000_0000
!
Universal Output Detailed Display

Operation
Explanation
*1 Universal output detailed display is shown.

L
GROUP OG#01 123:DEC. 7b: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 [ ]
!
5-3
RE-CTO-A203
Modify the Output Status

Operation
Select the desired output signal number*1 Press [INTER LOCK] + [SELECT]*2
Explanation
*1 Select the status of the desired output signal, “ ” or “ ”, in the universal output
detailed display.
*2 The status is changed. ( :ON status, :OFF status)

L
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 [ ]
!
5-4
RE-CTO-A203
5.3.3 Specific Input

Specific Input Display
Operation
Select {IN/OUT} under the top menu Select {SPECIFIC INPUT}*1
Explanation
*1 Specific input display is shown.

L
SPECIFIED INPUT R1 C S
NO. 7654 3210
#401X 0111_1011
#402X 0000_0000
#403X 0000_0000
#404X 1111_0000
#405X 0000_0000
#406X 0000_1010
#407X 0000_0000
#408X 0000_0000
!
Specific Input Detailed Display

Operation
Explanation
*1 Specific input detailed display is shown.

L
SPECIFIED INPUT R1 C S
GROUP 123:DEC. 7b:HEX.
SIN#001 #4010 SYSTEM ALM REQ
SIN#002 #4011 SYSTEM MSG REQ
SIN#003 #4012 USER ALM REQ
SIN#004 #4013 USER MSG REQ
SIN#005 #4014 ALM/ERR RESET
SIN#006 #4015
SIN#007 #4016 SPEED LIMIT
SIN#008 #4017
!
5-5
RE-CTO-A203
5.3.4 Specific Output

Specific Output Display
Operation
Select {IN/OUT} under the top menu Select {SPECIFIC OUTPUT}*1
Explanation
*1 Specific output display is shown.

L
SPECIFIED OUTPUT R1 C S
NO. 7654 3210
#501X 0111_1011
#502X 0000_0000
#503X 0000_0000
#504X 1111_0000
#505X 0000_0000
#506X 0000_1010
#507X 0000_0000
#508X 0000_0000
!
Specific Output Detailed Display

Operation
Explanation
*1 Specific output detailed display is shown.

L
SPECIFIED OUTPUT R1 C S
GROUP 123:DEC. 7b:HEX.
SOUT#001 #5010 MAJOR ALM OCCUR
SOUT#002 #5011 MINOR ALM OCCUR
SOUT#003 #5012 SYSTEM ALM OCCUR
SOUT#004 #5013 USER ALM OCCUR
SOUT#005 #5014 ERROR OCCUR
SOUT#006 #5015 MEMORY BTRY WEAK
SOUT#007 #5016 ENCDR BTRY WEAK
SOUT#008 #5017
!
5-6
RE-CTO-A203
5.3.5 RIN INPUT

RIN INPUT Display
Operation
Select {IN/OUT} under the top menu Select {RIN}*1
Explanation
*1 RIN input display is shown.

L
RIN INPUT R1 C S
RIN#001 DIRECT IN1
RIN#002 DIRECT IN2
RIN#003 DIRECT IN3
RIN#004 DIRECT IN4
5-7
RE-CTO-A203
5.3.6 Modify the Signal Name

The name of the universal input or output signal can be modified.

L
UNIVERSAL INPUT 　　　　 R1 C S
IN#001 #0010 [ ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ] SIGNAL NAME
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
The name can be modified in two ways.
Direct Modify on the Detailed Display

Operation
Move the cursor to the signal name to be modified in the detailed display, and press
[SELECT].*1 Input the signal name*2 Press [ENTER]*3
Explanation
*1 Character input line is displayed.

L
IN#001 #0010 [ ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
>
!
*2 If the signal name has already been registered, the current name is displayed on the
input line.
If you wish to change the name, delete the characters on the input line by pressing
[CANCEL], and then input a new name.
IN#007 #0016 [ ]
>TEST SIGNAL
!
5-8
RE-CTO-A203
*3 New signal name is registered.

L

IN#001 #0010 [ TEST SIGNAL ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
Modify from the Menu

Operation
Move the cursor to the signal name to be modified in the detailed display. Select
{EDIT} under the menu*1 Select {RENAME}*2 Input the signal name Press
*3
[ENTER]
Explanation
*1 The pull-down menu is shown.
DATA 編集
EDIT DISPLAY UTILITY
L
汎用入力　　　　
SEARCH SIGNAL NO. R1 C S
グループ IG#01 NO.
SEARCH RELAY 123:DEC. 7b:HEX.
IN#001
RENAME
RENAME #0010 [ ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
*3 New signal name is registered.

L

IN#001 #0010 [ TEST SIGNAL ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
5-9
RE-CTO-A203
5.3.7 Search the Signal Number

A signal number of universal input, universal output, specific input, or specific output can be
searched.

L
IN#001 #0010 [ ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
SIGNAL NO. IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
The signal number can be searched in the following two ways.
Direct Search on the Detailed Display

Operation
Move the cursor to a signal number in the detail display, and press [SELECT]*1 Type
the number of the signal *2 Press [ENTER] to start the search*3
Explanation
*1 Number input line is displayed.

UNIVERSAL INPUT 　　　　R1 L C S
IN#001 #0010 [TEST SIGNAL ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
>
!
*2 Input the signal number in the number input line.
IN#007 #0016 [ ]
>41
!
5-10
RE-CTO-A203
*3 The page where the signal number exists is displayed.

UNIVERSALINPUT 　　　　 R1 L C S
GROUP IG#06 128:DEC 80:HEX.
IN#041 #0060 [ ]
IN#042 #0061 [ ]
IN#043 #0062 [ ]
IN#044 #0063 [ ]
IN#045 #0064 [ ]
IN#046 #0065 [ ]
IN#047 #0066 [ ]
IN#048 #0067 [ ]
!
5-11
RE-CTO-A203
Search from the Menu

Operation
Select {EDIT} under the menu in the detail display*1 Select {SEARCH SIGNAL NO.}*2
Type the number of the signal Press [ENTER] to start the search*3
Explanation
*1 The pull-down menu is shown.
DATA EDIT
編集 DISPLAY UTILITY
SEARCH SIGNAL NO.
　　　　SIGNAL NO. L C S
SEARCH R1
GROUP
SEARCH RELAY NO. IG#01 123:DEC. 7b:HEX.
RENAME#0010
IN#001 [ ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
*2 Number input line is displayed.
*3 Input the signal number to be searched in the number input line, and press [ENTER].
The page where the signal number exists is displayed.
5.3.8 Relay Number Search

A search can be done for a relay number of a universal input or output signal or a specific
input or output signal.

IN#001 #0010 [ ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
RELAY NO. IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
5-12
RE-CTO-A203
Direct Search on the Detail Display

Operation
Move the cursor to a relay number in the detail display, and press [SELECT]*1 Type
*2 *3
the number of the relay Press [ENTER] to start the search
Explanation
*1 A number input line is displayed.

IN#001 #0010 [TEST SIGNAL ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
>
!
*2 In the number input line, type the relay number.
IN#007 #0016 [ ]
>60
!
*3 The page where the input relay number can be found is displayed.

UNIVERSALINPUT 　　　　 R1 L C S
GROUP IG#06 128:DEC 80:HEX.
IN#041 #0060 [ ]
IN#042 #0061 [ ]
IN#043 #0062 [ ]
IN#044 #0063 [ ]
IN#045 #0064 [ ]
IN#046 #0065 [ ]
IN#047 #0066 [ ]
IN#048 #0067 [ ]
!
5-13
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Search using the Menu

Operation
Select {EDIT} under the menu in the detail display*1 Select {SEARCH RELAY NO.}*2
Type the number of the relay Press [ENTER] to start the search*3
Explanation
*1 A pull-down menu appears.
DATA EDIT
編集 DISPLAY UTILITY
　　　　SIGNAL NO. L C S
SEARCH R1
GROUP
SEARCH RELAY NO. IG#01 123:DEC. 7b:HEX.
IN#001
RENAME#0010 [ ]
IN#002 #0011 [ ]
IN#003 #0012 [ ]
IN#004 #0013 [ ]
IN#005 #0014 [ ]
IN#006 #0015 [ ]
IN#007 #0016 [ ]
IN#008 #0017 [ ]
!
*2 A number input line is displayed.
*3 In the number input line, type the relay number and press [ENTER] to start the search.
The page where the relay number can be found is displayed.
5-14
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5.4 System Monitoring Time
5.4.1 System Monitoring Time Display

The status of system operation, e.g. power supply time, can be checked.
Operation
Select {SYSTEM INFO} Select {MONITORING TIME}*1
Explanation
*1 The system monitoring time display is shown.

L
SYS MONITORING TIME R1 C S
CONTROL POWER TIME (1998/07/06 10:00 )
2385:42'02
SERVO POWER TIME (1998/07/06 10:30 )
2380:10'12
PLAYBACK TIME (1998/10/22 11:12 )
2210:00'20
MOVING TIME (1998/10/22 15:30 )
1875:15'30
OPERATING TIME (1998/10/22 16:12 )
!
CONTROL POWER TIME

Displays the cumulative time that the main power supply has been ON.
SERVO POWER TIME

Displays the cumulative time that the servo power supply has been ON.
PLAYBACK TIME
Displays the cumulative time during which playback was executed.
MOVING TIME
Displays the cumulative time that the manipulator was in motion.
OPERATING TIME
Displays the cumulative time spent in operation. For example, if the manipulator is
used for arc welding, it displays the amount of time spent in arc welding; if the
manipulator is used for handling, it displays the time spent in handling.
5-15
RE-CTO-A203
5.4.2 Individual Display of the System Monitoring Time
If the page key is pressed, servo power time by each robot axis, playback time, moving
time and operating time by each application, is individually displayed.

L
SERVO POWER TIME R1 C S
ROBOT1 (1998/07/06 10:00 )
2385:42'02
STATION1 (1998/08/03 10:00 )
262:37'02

L
PLAYBACK TIME R1 C S
ROBOT1 (1998/07/06 10:00 )
2385:42'02
STATION1 (1998/08/03 10:00 )
262:37'02

L
MOVING TIME R1 C S
ROBOT1 (1998/07/06 10:00 )
2385:42'02
STATION1 (1998/08/03 10:00 )
262:37'02

L
OPERATING TIME R1 C S
APPLI1 (1998/07/06 10:00 )
2385:42'02
APPLI2 (1998/08/03 10:00 )
262:37'02
NOTE The total axes times here are not always the same as the time in the system monitoring
time display because these displays show time as seen from the individual axes.
5-16
RE-CTO-A203
5.4.3 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.
Operation
Select the time to be cleared*1 Select “YES”*2
Explanation
*1 Confirmation dialog is displayed.

L
2385:42'02
SERVO POWER TIME (1998/07/06 10:30 )
Initialize?
2 3MOVING
8 0 : 1 0 TIME
'12
PLAYBACK TIME (1998/10/22 11:12 )
2YES
210:00'20 NO
MOVING TIME (1998/10/22 15:30 )
1875:15'30
OPERATING TIME (1998/10/22 16:12 )
!
*2 The cumulative time value at the cursor line is reset to 0, and a new time measurement
begins.

L
2385:42'02
SERVO POWER TIME (1998/07/06 10:30 )
2380:10'12
PLAYBACK TIME (1998/10/22 11:12 )
2210:00'20
MOVING TIME (1998/10/22 15:30 )
0:00'00
OPERATING TIME (1998/10/22 16:12 )
!
5-17
RE-CTO-A203
5.5 Alarm History
5.5 Alarm History
5.5.1 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.
Operation
Select {SYSTEM INFO} under the top menu Select {ALARM HISTORY}*1 Press
the page key to change the display*2
Explanation
*1 The alarm history display is shown.

L
MAJOR ALARM R1 C S
CODE DATE CLOCK
01 1030 1998/05/12 12:00
02 0060 1998/06/15 15:25
03
04
05
MEMORY ERROR(PARAMETER FILE)
[5]
JOB:TEST0001 LINE:0010 STEP:010
!
*2 Each time the page key is pressed, the display changes "MAJOR
ALARM" "MINOR ALARM" "USER ALARM(SYSTEM)” "USER
ALARM(USER)" "OFF-LINE."
5.5.2 Clearing the Alarm History

The history of the minor alarms and the user alarms (system and user ) can be cleared.
Operation
Display the alarm history display to be cleared Select {DATA} under the menu
*1 *2
Select {CLEAR HISTORY} Select “YES”
5-18
RE-CTO-A203
5.6 I/O Message History
Explanation

L
MINOR ALARM R1 C S
CODE DATE CLOCK
01 4000 1998/05/12 12:00
02
Clear data?
03
04
05 YES NO
MEMORY ERROR(TOOL FILE)
[5]
JOB:TEST0001 LINE:0010 STEP:010
!
*2 The alarm history displayed is reset.
5.6.1 I/O Message History Display

The I/O message history display shows the date and time, job name, line number, and step
number of the I/O message that appeared on the screen.
Operation
Select {SYSTEM INFO} under the top menu Select {I/O MSG HISTORY}*1
Explanation
*1 The I/O message history display is shown.

L
I/O MESSAGE HISTORY R1 C S
0001 GAS SHORTAGE
0002 WIRE STICKING
0003
0004
0005
0006
0007
DATE/TIME:1999/06/16 12:00
JOB NAME :ARCON LINE:0006 STEP:004
!
Press [SELECT], and numeric values can now be entered. Input the history number,
and press [ENTER]. The search for the input history number begins, and the I/O mes-
sage that appeared on the screen is displayed.
5-19
RE-CTO-A203
Search
Use the following operation to search for the I/O message history.
Operation
Select {EDIT} under the menu Select {SEARCH}*1 Input the history No.
Press [ENTER]*2
Explanation
*2 The search for the input history number begins, and the I/O message is displayed.
5.6.2 Clearing the I/O Message History

Use the following operation to clear the I/O message history.
Operation
Select {DATA} under the menu Select {CLEAR HISTORY}*1 Select “YES”*2
Explanation

L
I/O MESSAGE HISTORY R1 C S
0001 GAS SHORTAGE
0002 WIRE STICKING
0003 Clear data?
0004
0005 YES NO
0006
0007
DATE/TIME:1999/06/16 12:00
JOB NAME :ARCON LINE:0006 STEP:004
!
*2 The displayed I/O message history is cleared.
5-20
RE-CTO-A203
5.7 Position Data When Power is Turned ON/OFF
5.7 Position Data When Power is Turned ON/OFF
5.7.1 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. When alarm 4107, "OUT OF
RANGE (ABSO DATA)" occurs, the error value of the faulty axes can be verified in this dis-
play.
Operation
Select {ROBOT} under the top menu Select {POWER ON/OFF POS}*1
Explanation
*1 The power ON/OFF position display is shown.

L
POWER ON/OFF POSITION R1 C S
OFF POS ON POS DIFFERENCE
R1:S 4775 4120 665
L 8225 8225 0
U 960 960 0
R -336 -336 0
B -202 -203 1
T -10 -11 1
5-21
RE-CTO-A203
5.8 Current Position Display
5.8 Current Position Display
5.8.1 Current Position Display

Operation
Select {ROBOT} under the top menu Select {CURRENT POSITION} under the sub
menu*1 Select the types of coordinates to be displayed *2 Select the desired
coordinate system*3
Explanation
*1 The current position display is shown.

L C S
CURRENT POSITION R1
COORDINATE : PULSE TOOL : 00
R1 :S 0
L 0
U 0
R 0
B 0
T 0

L C S
CURRENT POSITION R1
COORDINATE : PULSE TOOL : 00
R1 :S PULSE 0
L BASE 0
U ROBOT0
R USER 0
B 0
T 0
*3 The type of coordinates being displayed is changed.

CURRENT POSITION L C S
R1
COORDINATE : BASE TOOL : 00
R1 : X 915.000 mm Rx 180.00 deg.
Y 0.000 mm Ry 0.00 deg.
Z 765.000 mm Rz 0.00 deg.
<ROBOT TYPE>
FRONT S< 180
UP R< 180
FLIP T< 180
5-22
RE-CTO-A203
5.9 Servo Monitoring
5.9.1 Servo Monitor Display

The servo monitor display shows the servo-related data of each axis.
Monitor Items Description
FEEDBACK PULSE Feedback position (actual position) of each axis

“0” at the home position.
ERROR PULSE Difference between the command position and

the feedback position of each axis.
SPEED DEVIATION Difference between the command speed and the

feedback speed of each axis.
SPEED INST Speed reference of each axis.
FEEDBACK SPEED Feedback speed (actual speed) of each axis.
TORQUE SPEC Torque reference of each axis.
MAX. TORQUE Keeps the maximum value of the torque refer-

ence of each axis.
“0” when the maximum torque is cleared or the
control power supply is turned on or off.
ENCODER ROTATE SUM Position after one rotation of the encoder when
the control power supply of each axis is turned
on.
MOTOR ABSOLUTE Absolute value of the motor is calculated by add-

ing the position in one rotation to the sum of the
accumulated rotations when the control power
supply of each axis is turned on.
Changing the Monitor Items

Operation
Set the security mode to Management mode Select {ROBOT} under the top menu
Select {SERVO MONITOR}*1 Select {DISPLAY} under the menu *2 Select
MONITOR ITEM 1 or 2, and view the sub-menu choices by pressing the RIGHT ARROW
KEY [ →] *3 Select a menu *4
5-23
RE-CTO-A203
Explanation
*1 The servo monitor display appears.

L C S
SERVO MONITOR R1
FEEDBACK PULSE ERROR PULSE
R1 :S 1805 300
L 234 0
U 995 0
R 123 0
B 237 0
T 2432 0

MONITOR ITEM 1 is the data on the left, and MONITOR ITEM 2 is the data on the
right.

SERVO MONITOR MONITOR ITEM1　　 >
FEEDBACK PULS MONITOR ITEM2　　 >
R1 :S 1805 300
L 234 0
U 995 0
R 123 0
B 237 0
T 2432 0
*3 The sub-menu choices are displayed.

SERVO MONITOR FEEDBACK PULSE
FEEDBACK PULSE ERROR PULSE
R1 :S 1805 SPEED DEVIATION
300
L SPEED INST
234 SPEED INST 0
U 995 ▼ 0
R 123 0
B 237 0
T 2432 0
*4 The type of monitor-related information is changed.

L C S
SERVO MONITOR R1
SPEED INST ERROR PULSE
R1 :S 4000 300
L 0 0
U 0 0
R 0 0
B 0 0
T 0 0
5-24
RE-CTO-A203
Clearing Maximum Torque Data

The data for the maximum torque can be cleared when the maximum torque-related informa-
tion is being displayed.
Operation
Select {DATA} under the menu *1 Select {MAX. TORQUE} *2
Explanation
*1 {CLEAR MAX TORQUE} is displayed.

CLEAR MAX TORQUE L C S
R1
MAX TORQUE ERROR PULSE
R1 :S 30 0
L 70 0
U 80 0
R 20 0
B 40 0
T 30 0
*2 The maximum torque data is cleared.

SERVO MONITOR L C S
R1
MAX TORQUE FEEDBACK PULSE
R1 :S 0 0
L 0 0
U 0 0
R 0 0
B 0 0
T 0 0
5-25
Hardware
RE-CTO-A203
WARNING
an emergency. The emergency stop buttons are attached on upper-right of the playback
panel and right of the programming pendant.
Failure to observe this caution may result in injury from inadvertent operation of the play-
back panel.


• Prior to performing the following operations, be sure that there is no one

within the working envelope of the manipulator, and be sure that you are
in a safe place yourself.
- Turning the power ON to the YASNAC XRC.

- Running check operation.
- Performing automatic operation.
lope of the manipulator.
6-1
RE-CTO-A203
CAUTION
• Perform the following inspection procedures prior to peforming teaching
operations. If problems are found, correct them immediately, and be


use.
If the programming pendant is inadvertently left on the manipulator, fixture, or on the floor,
6-2
RE-CTO-A203
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 Grounding resistance : 100 Ω or less

Exclusive grounding
Digital I/O Specific signal (hardware) 12 inputs and 2 outputs

General signals (standard, max.) 40 inputs and 40 outputs
Positioning System By serial communication (absolute encoder)
Drive Unit SERVOPACK for AC servomotors
Acceleration/ Software servo control

Deceleration
Programming 5000 steps, 7000 instructions (including steps)

Capacity
Playback Panel*1
Dimensions 190(W) × 120(H) × 50(D) mm
Buttons Provided Mode change

Start / Hold, Emergency stop
*1 An optional remote playback panel is available
External Dimensions
A-type Small SV3X, UP6, or SK16X

panel capacity 470(W) × 760(H) × 320(D) mm
Medium SK45X, SK16MX, or SP70X

capacity 550(W) × 860(H) × 420(D) mm
Large UP130, UP165, UP165-100, UP200, UP130R, SK300X, or SP100X

capacity 650(W) × 860(H) × 420(D) mm
6-3
RE-CTO-A203
External Dimensions
B-type Small SV3X, UP6, or SK16X

panel capacity 700(W) × 750(H) × 420(D) mm
Medium SK45X, SK16MX, or SP70X

capacity 900(W) × 860(H) × 420(D) mm
Large UP130, UP165, UP165-100, UP200, UP130R, SK300X, or SP100X

capacity 900(W) × 860(H) × 420(D) mm
New A- Small SV3X, SV035X, UP6, SK16X, or UP20

type capacity 500(W) × 900(H) × 420(D) mm
panel
Medium UP50, SK45X, SK16MX, SP70X, or UP20M
capacity 650(W) × 900(H) × 420(D) mm
Large UP130, UP165, UP165-100, UP200, UP130T, SK300X, SP100X,

capacity SK506X, SR200X, UP130R, UP165R, UP200R, or UP130RL
650(W) × 900(H) × 420(D) mm
New B- Small SV3X, SV035X, UP6, SK16X, or UP20

type capacity 500(W) × 1300(H) × 450(D) mm
panel
Medium UP50, SK45X, SK16MX, SP70X, or UP20M
capacity 650(W) × 1300(H) × 450(D) mm
Large UP130, UP165, UP165-100, UP200, UP130T, SK300X, SP100X,

capacity SK506X, SR200X, UP130R, UP165R, UP200R, or UP130RL
650(W) × 1300(H) × 450(D) mm
6-4
RE-CTO-A203
6.2 Function List
6.2 Function List
Programming Coordinate System Joint, Rectangular/Cylindrical, Tool, User Coordinates

Pendant
Operation Modification of Adding, Deleting, Correcting (Robot axes and external axes
Teaching Points espectively can be corrected.)
Inching Operation Possible
Locus Confirmation Forward/Reverse step, Continuous feeding
Speed Adjustment Fine adjustment possible during operating or pausing
Timer Setting Possible every 0.01 s
Short-cut Function Direct-open function, Screen reservation function
Interface RS-232C × 1 port for FC 1/FC2

(At Programming Pendant)
Application Arc welding, Spot welding, Handling, General, Others
Safety Essential Measures JIS (Japanese Industrial Standard)

Feature
Running Speed User definable
Limit
Deadman Switch 3 position type. Servo power can be turned on at the mid
position only. (Located on programming pendant)
Collisionproof S-axis frame (doughnut-sector), Cubic frame (user coordi-

Frames nate)
Self-Diagnosis Classifies error and two types of alarms (major and minor)
and displays the data
User Alarm Display Possible to display alarm messages for peripheral device
Machine Lock Test-run of peripheral devices without robot motion
Door Interlock A door can be opened only when a circuit breaker is off.
Maintenance Operation Time Control power-on time, Servo power-on time, Playback time,
Function Display Operation time, Work time
Alarm Display Alarm message and previous alarm records
I/O Diagnosis Simulated enabled/disabled output possible
T.C.P. Calibration Automatically calibrates parameters for end effectors using a

master jig
6-5
RE-CTO-A203
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 tions during robot motion
Operation Instruc- Preparing the operation instructions for each application

tions (Arc-ON, Arc-OFF, etc...)
Variable Global variable, Local variable
Variable Type Byte type, Integer type, Double precision type, Real number
type, Position type
I/O Instructions Discrete I/O, Pattern I/O processing
Material Reinforced thermoplastic enclosure with a detachable sus-

pending strap
Dimensions 200(W) × 348(H) × 61.8(D) mm
Displayed 40 characters 12 lines

Units
Multilingual function (English, Japanese, Hankul)
Backlight
Others 3 position deadman switch, RS-232C × 1 port
6-6
RE-CTO-A203
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 explains the configuration of the XRC equipment.
6.4.1 Arrangement of Units and Circuit Boards

Configuration
The arrangements of units and circuit boards in the A-type, the B-type, the new A-type, and
the new B-type panels for small-capacity, medium-capacity, and large-capacity XRCs are
shown.
Small Capacity
1. A-type panel
Power Supply Unit I/O-Power-On Unit CPU Rack Playback Panel Non-fuse Breaker (QF1)
JZRCR-XPU03 o JZNC-XIU01 o JZNC-XRK01 - oo ZY1C-SS3152 SA33B 10A 3P
A
JZNC-XRK01
XCP01 CPS-150F
XCP01
CPS-150F
NJ2096-1
DATE
JAPAN
Back Duct Fan

SER NO.
TYPE
SW
4715PS-22T
BAT
-B30-B00
(For air inlet) 2X
R R R T T T
1KM
1X 1X
(EV1) (EV2) 1
Servopack
B 0 0
GRIP
Ascending Fan CNPB04
8830-032-170SD
CNPB05
8830-032-170SD
CNPB06
8830-032-170SD
C249
DUSB-ARB8X-T11
102
3610PS-22T
CN10
CONV
2CN
CNPG456
10220-6202JL
-B30-B00
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
(EV3) (EV4)
178323-2
PWM
CN50
(Air flows up)

CNPG123
PWM
1CN
10250-52A2JL
345
67
012
89A
EF
BCD
CN30
CNE 3-175475-6
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
GRIP
Servopack A' Welding Board

(Note 1)
Refer to the following table. JANCD-XEW02 Sectional view A-A'

Note 1: Standard feature only for UP6 (welding specifications). Available as an option for other models.
Model YASNAC XRC Servopack Converter (Integrated) QF1 Power Supply Unit
SV3X ERCR-SV3-RA00 CACR-SV3AAA JUSP-ACP05JAA SA33B 15A JZRCR-XPU03o
UP6 ERCR-UP6-RA00 CACR-UP6AAC JUSP-ACP05JAA SA33B 15A JZRCR-XPU03o
ERCR-SK16-RA00 JZRCR-XPU03o
SK16X CACR-SK16AAC JUSP-ACP05JAA SA33B 15A
ENCM-RX6003 JZNC-XPW03o
Configuration for Small-Capacity XRC in A-Type Panel
6-7
RE-CTO-A203
2. B-type panel
Power Supply Unit I/O-Power-On Unit CPU Rack Playback Panel
JZRCR-XPU03 o JZNC-XIU01 o JZNC-XRK01 - oo ZY1C-SS3152
A
JZNC-XRK01
XCP01 CPS-150F
CN30
CN07
XCP01 1
B 0 0
CPS-150F
CN29
5X 4X 5X 4X
NJ2096-1
SKAWA ELECTRIC CORPORATION
CN28
DATE
DATE
CN05
CN06
CN04/CARD
3X 3X
Back Duct Fan
AN
CN06/SV
CN26
CN27
SER NO.
TYPE
CN24 CN25
CN04
CN12
CN13
4715PS-22T-B30-B00
CN03/RS232C
CN23
CN22
CN02/PP
CN03
(For air inlet)
CN21
345
67
CN02
2X
01 2
CN01/IO
89 A
CN10
CN11
EF
BCD
R R R T T T
1KM
1X 1X
CN20
CN01
(EV1) (EV2)
(EV3) (EV4)
Non-fuse Breaker (QF1) GRIP
SA33B 15A 3P
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
DUSB-ARB8X-T11
102
CN10
CONV
2CN
CNPG456
10220-6202JL
Servopack
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
178323-2
PWM
CN50
Ascending Fan
CNPG123
PWM
1CN
10250-52A2JL
CN30
CNE 3-175475-6
3610PS-22T
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
-B30-B00
S L U R B T
GRIP
(Air flows up)

A' Welding Board (Note 1)
Servopack Sectional view A-A'
Refer to the following table. JANCD-XEW01
SV3X ERCR-SV3-RA01 CACR-SV3AAA JUSP-ACP05JAA SA33B 15A JZRCR-XPU03 o
UP6 ERCR-UP6-RA01 CACR-UP6AAC JUSP-ACP05JAA SA33B 15A JZRCR-XPU03 o
SK16X ERCR-SK16-RA01 CACR-SK16AAC JUSP-ACP05JAA SA33B 15A JZRCR-XPU03 o
Configuration for Small-Capacity XRC in B Type Panel
3. New A-type panel

A
JZNC-XRK01
XCP02/OPT CPS-150F
XCP01
5X 4X
NJ2096-
CN05
DATE
YASNAC
3X POWER SUPPLY
CN05/SV
JAPAN
CPS-150F
SER NO.
TYPE
CN04
CN03
SOURCE
PWR ON
+5V
CN02
Back Duct Fan

+24V
OHT
CN01
4715PS-22T-B30-B00
2X
R R R T T T
1KM
1X
(For air inlet)

1
B 0 0
(EV1) (EV2)
Non-fuse Breaker (QF1) CNPB04
GRIP
CNPB05 CNPB06
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
Refer to the following table.

DUSB-ARB8X-T11
102
CN10
CONV
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
178323-2
PWM
CN50
345
67
01 2
89 A
EF
BCD
(EV3) (EV4) Servopack

CNPG123
PWM
1CN
10250-52A2JL
Ascending Fan
CN30
CNE 3-175475-6
4715PS-22T-B30-B00
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
(Air flows up) GRIP
Servopack Welding Board

(Note 1)
Refer to the following table. A'
JANCD-XEW01 Sectional view A-A'
SV035X ERCR-SV035-RA10 CACR-SV035AAA JUSP-ACP05JAA SA33B/5A JZRCR-XPU03o
SV3X ERCR-SV3-RA10 CACR-SV3AAA JUSP-ACP05JAA SA33B/5A JZRCR-XPU03o
ERCR-UP6-RA10 JZRCR-XPU03o
JZNC-XPW03o
UP6 CACR-UP6AAC JUSP-ACP05JAA SA33B/15A
ENCM-RX6006
SK16X ERCR-SK16-RA10 CACR-SK16AAC JUSP-ACP05JAA SA33B/15A JZRCR-XPU03o
ERCR-UP20-RA10 JZRCR-XPU03o
JZNC-XPW03o
UP20 CACR-UP20AAA JUSP-ACP05JAA SA33B/15A
ENCM-RX6005
Configuration for Small-Capacity XRC in New A Type Panel
6-8
RE-CTO-A203
4. New B-type panel
Non-fuse Breaker (QF1) Playback Panel

Refer to the following table. ZY1C-SS3152
A
I/O-Power-On Unit
JZNC-XIU01 o
Power Supply Unit CPU Rack
JZRCR-XPU03 o JZNC-XRK01 - oo
Back Duct Fan Servopack
4715PS-22T-B30-B00 Ascending Fan
(For air inlet) 4715PS-22T Welding Board (Note 1)
-B30-B00 JANCD-XEW01
R R R T T T
1KM
(Air flows up)
2
A' Servopack
Refer to the following table. Sectional view A-A'
SV035X ERCR-SV035-RA11 CACR-SV035AAA JUSP-ACP05JAA SA33B/5A JZRCR-XPU03 o
SV3X ERCR-SV3-RA11 CACR-SV3AAA JUSP-ACP05JAA SA33B/5A JZRCR-XPU03 o
UP6 ERCR-UP6-RA11 CACR-UP6AAC JUSP-ACP05JAA SA33B/15A JZRCR-XPU03 o
SK16X ERCR-SK16-RA11 CACR-SK16AAC JUSP-ACP05JAA SA33B/15A JZRCR-XPU03 o
UP20 ERCR-UP20-RA11 CACR-UP20AAA JUSP-ACP05JAA SA33B/15A JZRCR-XPU03 o
Configuration for Small-Capacity XRC in New B-Type Panel
6-9
RE-CTO-A203
Medium Capacity
1. A-type panel
A
Back Duct Fan

5915PC-22T-B30-B00
(For air inlet)
Non-fuse Breaker (QF1)

EA53B 30A
Servopack
Ascending Fan
3610PS-22T-B30-B00
(Air flows up)
Converter
JUSP-ACP25JAA
A' Servopack Sectional view A-A'

Model YASNAC XRC Servopack Converter (Separated) QF1 Power Supply Unit
SK45X ERCR-SK45-RA00 CACR-SK45AAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02 o
SK16MX ERCR-SK16M-RA00 CACR-SK16MAAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02 o
SP70X ERCR-SP70-RA00 CACR-SP70AAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02o
Configuration for Medium-Capacity XRC in A-Type Panel
2. B-type panel
I/O-Power-On Unit CPU Rack Playback Panel
Power Supply Unit o oo
o
JZNC-XIU01 JZNC-XRK01 - ZY1C-SS3152
JZRCR-XPU02
A
Back Duct Fan

5915PC-22T-B30-B00
(For air inlet)

EA53B/30A
Servopack
Ascending Fan
3610PS-22T
-B30-B00
(Air flows up)
A' Servopack
Converter Refer to the following table. Sectional view A-A'
JUSP-ACP25JAA
SK45X ERCR-SK45-RA01 CACR-SK45AAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02 o
SK16MX ERCR-SK16M-RA01 CACR-SK16MAAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02 o
SP70X ERCR-SP70-RA01 CACR-SP70AAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02 o
Configuration for Medium-Capacity XRC in B-type Panel
6-10
RE-CTO-A203
3. New A-type panel

A
Back Duct Fan

5915PC-22T-B30-B00
(For air inlet)

SA33B/20A
Servopack
Ascending Fan
4715PS-22T
-B30-B00
(Air flows up)
A' Servopack
Converter Refer to the following table. Sectional view A-A'
Refer to the follwing table.
UP50 ERCR-UP50-RA10 CACR-UP50AAB JUSP-ACP25JAAY11 SA33B/20A JZRCR-XPU02
SK45X ERCR-SK45-RA10 CACR-SK45AAB JUSP-ACP25JAAY SA33B/20A JZRCR-XPU02
SK16MX ERCR-SK16M-RA10 CACR-SK16MAAB JUSP-ACP25JAAY SA33B/20A JZRCR-XPU02
SP70X ERCR-SP70-RA10 CACR-SP70AAB JUSP-ACP25JAAY SA33B/20A JZRCR-XPU02
UP20M ERCR-UP20M-RA10 CACR-UP20MAAB JUSP-ACP25JAAY11 SA33B/20A JZRCR-XPU02
Configuration for Medium-Capacity XRC in New A-Type Panel
4. New B-type panel

Playback Panel
ZY1C-SS3152
A
Non-fuse Breaker
(QF1) SA33B/20A
I/O-Power-On Unit
JZNC-XIU01 o
Power Supply Unit
o
CPU Rack
JZRCR-XPU02 JZNC-XRK01
JZNC-XRK01 - oo
Back Duct Fan
5915PC-22T-B30-B00
(For air inlet) Servopack SER NO.
TYPE
DATE

JAPAN NJ2096-1
Ascending Fan
4715PS-22T (EV1) (EV2) (EV3)
-B30-B00
(Air flows up)
Converter A' Servopack

Refer to the following table. Refer to the following table. Sectional view A-A'
Model YASNAC XRC Servopack Converter (Separated ) QF1 Power Supply Unit
UP50 ERCR-UP50-RA11 CACR-UP50AAB JUSP-ACP25JAAY11 SA33B/20A JZRCR-XPU02
SK45X ERCR-SK45-RA11 CACR-SK45AAB JUSP-ACP25JAAY SA33B/20A JZRCR-XPU02
SK16MX ERCR-SK16M-RA11 CACR-SK16MAAB JUSP-ACP25JAAY SA33B/20A JZRCR-XPU02
SP70X ERCR-SP70-RA11 CACR-SP70AAB JUSP-ACP25JAAY SA33B/20A JZRCR-XPU02
UP20M ERCR-UP20M-RA11 CACR-UP20MAAB JUSP-ACP25JAAY11 SA33B/20A JZRCR-XPU02
Configuration for Medium-Capacity XRC in New B-Type Panel
6-11
RE-CTO-A203
Large Capacity
1. A-type panel
Refer to the table below. JZNC-XIU01 o JZNC-XRK01 - oo ZY1C-SS3152
A
Back Duct Fan

5915PC-22T-B30-B00
(For air inlet)

EA53B/40A
Servopack
Ascending Fan
3610PS-22T
-B30-B00
(Air flows up)
Converter A' Servopack Heat Exchanger
JUSP-ACP35JAA Refer to the following table. YD5-1042A Sectional view A-A'
UP130 ERCR-UP130-RA00 CACR-UP130AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU02o
UP165 ERCR-UP165-RA00 CACR-UP130AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU02o
UP165-100 ERCR-UP165-RA03 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU02o
UP200 ERCR-UP200-RA00 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU02o
UP130R ERCR-UP130R-RA00 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU01o
SK300X ERCR-SK300-RA00 CACR-SK300AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU01o
SP100X ERCR-SP100-RA00 CACR-SP100AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU01o
Configuration for Large-Capacity XRC in A-type Panel
2. B-type panel
I/O Power On Unit CPU Rack Playback Panel
Power Supply Unit JZNC-XIU01 o JZNC-XRK01 - oo ZY1C-SS3152
A
Back Duct Fan

5915PC-22T-B30-B00
(For air inlet) SER NO. DATE
SER NO. DATE
TYPE
TYPE
JAPAN NJ2096-1
JAPAN NJ2096-1
(EV7) (EV6) (EV5) (EV1) (EV2) (EV3) (EV4)

EA53B/40A
Servopack
Ascending Fan
3610PS-22T
-B30-B00
(Air flows up)
Servopack Heat Exchanger
Converter A' Refer to the following table. Sectional view A-A'
JUSP-ACP35JAA YD5-1042A
Model YASNAC XRC Servopack Converter (Separated) QF1 Power Supply Unit Heat Exchanger
UP130 ERCR-UP130-RA01 CACR-UP130AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 o WIth
UP165 ERCR-UP165-RA01 CACR-UP130AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 o With
UP165-100 ERCR-UP165-RA04 CACR-UP130Y18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 o With
UP200 ERCR-UP200-RA01 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 o With
UP130R ERCR-UP130R-RA01 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU01 o With
SK300X ERCR-SK300-RA01 CACR-SK300AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU01 o With
SK506X ERCR-SK506-RA01 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU01 o With
SP100X ERCR-SP100-RA01 CACR-SP100AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU01 o Without
Configuration for Large-Capacity XRC in B-Type Panel
6-12
RE-CTO-A203
3. New A-type panel

I/O-Power-On Unit CPU Rack Playback Panel
Power Supply Unit
Refer to the following table. JZNC-XIU01 o JZNC-XRK01 - oo ZY1C-SS3152
A
JZNC-XRK01
Back Duct Fan

5915PC-22T-B30-B00
(For air inlet) SER NO.
TYPE
DATE

JAPAN NJ2096-1
DATE

JAPAN NJ2096-1
Non-fuse Breaker (QF1) (EV1) (EV2) (EV3)

Refer to the table below.
G R I P
Servopack
Ascending Fan
4715PS-22T-B30-B00
(Air flows up)
Converter
JUSP-ACP35JAA
A' Servopack
Refer to the following table. Sectional view A-A'
UP130 ERCR-UP130-RA10 CACR-UP130AAB JUSP-ACP35JAA SA33B/30A JZRCR-XPU02o
UP165-100 ERCR-UP165-RA13 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02o
UP200 ERCR-UP200-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02o
UP130T ERCR-UP130T-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02o
SK300X ERCR-SK300-RA10 CACR-SK300AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
SP100X ERCR-SP100-RA10 CACR-SP100AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
SK506X ERCR-SK506-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
SR200X ERCR-SR200-RA10 CACR-SK300AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
UP130R ERCR-UP130R-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
UP130RL ERCR-UP130RL-RA10 CACR-UP130AABY21 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
Configuration for Large-Capacity XRC in New A-Type Panel
6-13
RE-CTO-A203
4. New B-type panel

A
I/O-Power-On Unit
o
QF1
ON
JZNC-XIU01
P
TRI
OFF
ET
RES
Power Supply Unit CPU Rack
JZRCR-XPU01 o JZNC-XRK01
JZNC-XRK01 -oo
Back Duct Fan Servopack
5915PC-22T-B30-B00 Ascending Fan
(For air inlet) 4715PS-22T
-B30-B00 SER NO.
TYPE
DATE

JAPAN NJ2096-1
(Air flows up) (EV1) (EV2) (EV3)

G R I P
A' Servopack
Converter
JUSP-ACP35JAA Sectional view A-A'
UP165-100 ERCR-UP165-RA14 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02o
UP200 ERCR-UP200-RA11 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02o
UP130T ERCR-UP130T-RA11 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02o
SK300X ERCR-SK300-RA11 CACR-SK300AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
SP100X ERCR-SP100-RA11 CACR-SP100AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
SK506X ERCR-SK506-RA11 CACR-UP130AABY18 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
SR200X ERCR-SR200-RA11 CACR-SK300AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
UP130RL ERCR-UP130RL-RA11 CACR-UP130AABY21 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01o
Configuration for Large-Capacity XRC in New B-Type Panel
6-14
RE-CTO-A203
Location
Section Unit
Playback panel(ZY1C-SS3125)
Door Heat exchange board (Large capacity XRC in A and B type
panel)
Servopack Control circuit board

(CACR- AA ) (JASP-WRCA01)
(Separated type converter
for medium and large Control power supply
capacity XRC) (JUSP-RCP01 )
Converter(JUSP-ACP JAA)
Front Amplifier(JUSP-WS AA)

section
I/0, TU unit (JZNC-XIU01 )
CPU Rack System control circuit board

(JZNC-XRK01 - ) (JANCD-XCP01 )
CPU power supply(CPS-150F)
Power Supply unit (JZNC-XPW03 , JZRCR-XPU )
6.4.2 Cooling System of the Controller Interior

The backside duct fan draws in air from the air intake and expels it from the air outlet to cool the
Servopack. The servopack ascending fan circulates the air to keep temperature even throughout the
interior of the XRC. Large capacity XRC in A and B type panel are equipped with a heat exchanger on
the door to cool the interior of the XRC.
6-15
RE-CTO-A203
Servopack
Ascending Fan
Backside Duct Fan
Air Intake
Air Outlet
Servopack
Cooling Configuration (Small and medium capacity XRC in A and B type panel)
Heat Exchange Servopack Ascending Fan
Backside Duct Fan
Air Intake
Air Intake
Air Outlet
Air Outlet
Servopack
Cooling Configuration (Large capacity XRC in A and B type panel)
6-16
RE-CTO-A203
Servopack Ascending Fan
Backside Duct Fan
Air Intake
Air Outlet
Servopack
Cooling Configuration (New A type panel)
Servopack Ascending Fan
Backside Duct Fan
Air Intake
Air Outlet
Servopack
Cooling Configuration (New B type panel)
6-17
Refer to XRC 2001 Supplement, section 2, for description of units and circuit boards.
7-1
7-2
Maintenance
RE-CTO-A203
8 Inspections
CAUTION
• Do not touch the cooling fan or other equipment while the power is
turned ON.
Carry out the following inspections.
Inspection
Inspection Equipment Inspection Item Comments
Frequency
Check that the doors are Daily

completely closed.
XRC Controller
Check for gaps or dam- Monthly
age to the sealed con-
struction.
Servo ascending fan Check operation As required While power ON

and backside duct fan
Heat exchange fan Check operation As required While servo ON

(Inside, Outside)
(Large type only)
Emergency stop Check operation As required While servo ON

button
Deadman switch Check operation As required On teach mode
Confirm battery alarm or As required

Battery message is displayed or
not
8-1
RE-CTO-A203
8.2 XRC Inspections
8.2 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.
• Open or close the two locks in each door with the minus driver when opening or closing
the doors for maintenance after the main power is turned off. (CW:Open, CCW:Close)
Make sure push the door closed and turn the door lock with the driver. When the door is
closed, turn the door lock until the door clicks.
Door Lock
Main Switch
Handle
Door Lock
YASNAC XRC Front View
8.2.2 Checking for Gaps or Damage in the Sealed Con-

struction Section
• Open the door and check that the seal around the door is undamaged.
• Check that the inside of the XRC is not excessively dirty. If it is dirty, determine the cause,
take measures to correct the problem and immediately clean up the dirt.
• Fully close each door lock and check that no excessive gaps exist around the edge of the
door.
8-2
RE-CTO-A203
Inspect the cooling fans as required. A defective fan can cause the XRC to malfunction
because of excessive high temperatures inside.
The servo 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.
Servo Ascending Fan
Backside Duct Fan
Air Intake
Air Outlet
Servopack
Cooling Fan Construction (Small- or medium-capacity XRC, in A- or B-type panels)
8-3
RE-CTO-A203
Servo Ascending Fan

Heat Exchanger
Backside Duct Fan
Air Intake
Air Intake
Air Outlet
Air Outlet
Servopack
Cooling Fan Construction (Large capacity XRC in A and B type panel)
Servo Ascending Fan
Backside Duct Fan
Air Intake
Air Outlet
Servopack
Cooling Fan Construction (New A type panel)
8-4
RE-CTO-A203
Servo Ascending Fan
Backside Duct Fan
Air Intake
Air Outlet
Servopack
Cooling Fan Construction (New B type panel)
8-5
RE-CTO-A203
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.
8.5 Deadman Switch Inspections
The programing pendant is equipped with a three-position deadman switch. Perform the fol-
lowing operation to confirm the deadman switch operates.
1. Press [TEACH] on the playback panel to switch to teach mode. The [TEACH] lamp
lights.
TEACH
2. Press [SERVO ON READY] on the playback panel. The [SERVO ON READY] lamp
blinks.
SERVO ON
READY
3. Press [TEACH LOCK] on the programming pendant. The [TEACH LOCK] LED blinks.
TEACH
LOCK
4. When the deadman switch is grasped lightly, the servo power is turned ON.
When the deadman switch is grasped firmly or released, the servo power is turned
OFF.
If the [SERVO ON READY] lamp does not light in previous operation (2), check the follow-
NOTE ing:
• The emergency stop button on the playback panel is pressed.
• The emergency stop button on the programming pendant is pressed.
• The emergency stop signal is input from external.
If the servo is not turned on in a previous operation (4), check the following:
• The overrun LS is operating.
• If a major alarm is occurring.
8-6
RE-CTO-A203
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.
The way to replace the battery is described in “9.1.1 Replacing Parts of the CPU Rack”.
8.7 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, T and R
Voltage between earth Between R and G, T 200 to 220V (+10%, -15%)

(S phase ground) and G
Between S and G About 0V
R S T
G
ON
OFF
U V W
Circuit Breaker (QF1)
8-7
RE-CTO-A203
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 electric tester.
(Normal value: 200-220V (+10%, -15%))
Circuit Breaker (QF1) Turn on the control power supply and check the open phase volt-
Check age of “U,V,W” of the circuit breaker (QF1) with an electric tester.
If abnormal, replace the circuit breaker (QF1).
Input 200/220VAC
R S T
CIRCUIT
BREAKER CONVERTER
(QF1)
U V W CONTACTER
(1KM)
R S T
U V W
8-8
RE-CTO-A203
9 Replacing Parts
WARNING
• Turn OFF the power supply before opening the XRC doors.
replacing a servopack or power supply unit. Do not touch any terminals
during this period.
CAUTION
• To prevent anyone inadvertently turning ON the power supply during
maintenance, put up a warning sign such as "DO NOT TURN ON THE
POWER" at the primary power supply (knife switch, wiring circuit
breaker, etc.) and at the YASNAC XRC and related controllers and use
accepted lockout/tagout procedures.
• Do not touch the regeneration resistors. They are very hot.
Failure to observe this caution may result in burn injuries.
• After maintenance is completed, carefully check that no tools are left

inside the YASNAC XRC and that the doors are securely closed.
9-1
RE-CTO-A203
9.1.1 Replacing Parts of the CPU Rack

CPU rack (JZNC-XRK01 - ) 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
Battery Alarm (CN04)

Control Power ON/OFF
(CN03)
RS232C Connector
(CN03), (CN02)
DC24V Output Connector
Battery (To Programming Pendant)
Monitor, Alarm Display
(CN01)
DC24V, DC5V Output Connector
(To XIU unit)
System Control Board Control Power Unit

JANCD-XCP01 CPS-150F
CPU Rack Configuration (JZNC-XRK01 - )
Replacing the Battery

Replace the battery within 40 hours if a battery alarm occurs. If it is within 30 minute after tur-
ing on the electricity after the power was turned off for more than 2 days, replace the battery
immediately.
(The battery alarms appear on the programing pendant display and LED on the system con-
trol board is turned on.)
Replacement Procedure
1. Disconnect the battery connector (BAT) and remove the battery.
2. Mount the new battery and connect the battery connector.
Although the CMOS memory is backed up by super capacitor, the battery must be
NOTE replaced as soon as the battery alarm occurs. The job data and other data may be lost if
the battery is left for more than 40 hours.
9-2
RE-CTO-A203
Replacing the JANCD-XCP01 Circuit Board

Turn off the power before replacing a circuit board.
1. Disconnect all cables connected to the circuit board.
2. Undo 2 screws fixing the circuit board and rack.
3. Spread the levers attached to the upper and lower side of circut board up and down
respectively and pull out the circuit board forward
To Remove
To Fix
JANCD-XCP01 Lever
To Fix
To Remove
4. Pull out the circuit board from the rack.

5. Insert a new circuit board into the slot of the rack with the levers spread.
6. Push the board until it is placed in the same position of other boards.
7. Tighten upper and lower screws.
8. Connect all disconnected cables.
The JANCD-XCP01 circuit board contains important file data (CMOS memory) for the
NOTE user programs, which is backed up by the battery. Incorrect operations can cause this
stored file data to be lost.
For more information about the replacement procedure of the JANCD-XCP01 circuit
board, refer to “YASNAC XRC INSTRUCTIONS for CPU Circuit Board Replacement Pro-
cedure.” If you have not received a copy of this instruction manual, contact your Yaskawa
representative.
9-3
RE-CTO-A203
Replacing the Control Power Unit (CPS-150F)
CAUTION
replacing a control power unit. Do not touch any terminals during this
period. Confirm all monitor lights are turned off.
1. Disconnect all cables connected to the control power unit.
2. Undo four upper and lower screws attaching the control power unit and the rack. (two
screws on each side).
3. Pull out the control power unit from the rack holding the lever which is attached at the
upper and lower side.
4. Insert the new control power unit in to the slot of the rack.
5. Push the new control power unit until it is placed in the same position of other boards.
6. Tighten upper and lower screws.
7. Connect all disconnected cables.
9-4
RE-CTO-A203
9.1.2 Replacing the Servopack
WARNING
replacing a servopack. Do not touch any terminals during this period.
There are two kinds of Servopacks depending on capacity.
Type Manipulator
Integrated Type Small capacity SV3X, SV035X, UP6, SK16X, UP20
Separated Type Medium capacity SK16MX, SK45X, UP50, UP20M, SP70X
Large capacity UP130, UP130R, UP165, UP200, UP130T,

SK300X, SR200X, UP200R, SK506X,
UP165-100, UP165R, UP130RL, SP100X
• Before replacing a servopack, confirm the version number of the JASP-WRCA01

NOTE board and be sure to backup the data. (Refer to YASNAC XRC INSTRUCTION
For CPU Circuit Board Replacement Procedure.)
• After having replaced the servopack, load the backup data to the JASP-WRCA01
board.
Replacement Procedure (Integrated Type Small Capacity)

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 Servopack CHARGE lamp (red LED) is unlit.
3. Disconnect all the cables connected externally to the Servopack.
Main circuit power supply connector (CN7)
Regenerative resistor connector (CN8)
Servo control power supply connector (1CN)
Cables connected externally to the servo control board
• PG cable connectors (CNPG123, CNPG456)
• Communications cable connector (CN10)
• Power ON signal cable connector (CN20)
• Motor cable connectors (CN1 to CN6)
4. Remove the ground wiring connected to the Servopack.
5. Remove the four screws in the four corners of the Servopack.
6. With the top and bottom grips, pull out the Servopack.
7. Install the new Servopack and reconnect the connectors in the reverse order of that lis-
sted above.
9-5
RE-CTO-A203
Servo Control Servo Control

Power Supply Board
Ground Top Grip
Wiring
CN10
CN20 CNPG456
Red LED
CNPG123
1CN
Bottom
CN7 CN8 Grip CN1 to CN6
Configuration of Integrated Type (Small Capacity) Servopack
Replacement Procedure (Separated Type Medium Capacity)
• How to Replace Converter

2. Verify that the converter CHARGE lamp (red LED) is unlit.
3. Disconnect all the cables connected externally to the converter.
Main circuit power supply connector (CN7)
Regenerative resistor connector (CN8)
Servo control power supply connectors (1CN and 2CN)
PN power supply terminals (P×1, N×1)
4. Remove the ground wiring connected to the converter.
5. Remove the four screws in the four corners of the converter.
6. With the top and bottom grips, pull out the converter.
7. Install the new converter and reconnect the connectors in the reverse order of that
listed above.
• How to Replace PWM Amplifier

3. Disconnect all the cables connected externally to the control board.
PG cable connectors (CNPG123, CNPG456)
Communication cable connector (CN10)
Power ON signal cable connector (CN20)
Motor cable connectors (CN1 to CN6)
4. Remove the ground wiring connected to the PWM amplifier.
5. Remove the four screws in the four corners of the PWM amplifier.
9-6
RE-CTO-A203
6. With the top and bottom grips, pull out the PWM amplifier.
7. Install the new PWM amplifier and reconnect the connectors in the reverse order of
that listed above.
Converter PWM Amplifier
Top Grip 20CN Top Grip Ground Wiring
10CN
2CN
CNPG456
Servo Control Red
Power Supply LED
P CNPG123
1CN N
PN
Wiring
Servo Control
Board
Bottom Grip
Ground
Bottom Wiring 4CN to 6CN
7CN 8CN 1CN to 3CN
Grip
Configuration of Separated Type (Medium Capacity) Servopack
Replacement Procedure (Separated Type Large Capacity)
• How to Replace Converter

3. Disconnect all the cables connected externally to the converter.
Main circuit power supply terminals (TM1: L1, L2, L3)
Regenerative resistor terminals (TM1: B1, B2)
Servo control power supply connectors (1CN and 2CN)
PN power supply terminals (P×2, N×2)
4. Remove the ground wiring connected to the converter.
5. Remove the four screws in the four corners of the converter.
6. With the top and bottom grips, pull out the converter.
7. Install the new converter and reconnect the connectors in the reverse order of that
listed above.
• How to Replace PWM Amplifier

3. Disconnect all the cables connected externally to the control board.
PG cable connectors(CNPG123, CNPG456)
Communication cable connector (CN10)
Power ON signal cable connector (CN20)
Motor cable terminal (EUVW), motor cable connectors (CN4 to CN6)
4. Remove the ground wiring connected to the PWM amplifier.
9-7
RE-CTO-A203
5. Remove the four screws in the four corners of the PWM amplifier.
6. With the top and bottom grips, pull out the PWM amplifier.
7. Install the new PWM amplifier and reconnect the connectors in the reverse order of
that listed above.
Converter PWM Amplifier
Top Grip 20CN Top Grip Ground Wiring

Ground
Wiring 10CN
2CN
CNPG456
Servo Control Red
Power Supply LED CNPG123
P
1CN
N
Servo Control
PN Board
Wiring
4CN to
6CN
Bottom Grip Bottom Grip
TM1 L1L2L3B1B2 EUVW11-12 EUVW21-22 EUVW31-32

Configuration of Separated Type Servopack for Large Size Robot
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.
FU1, 2 Control Power Supply Fuse 250V, 5A, Time Lag Fuse
(Std: 313005, 250V, 5A (LITTEL))
FU3, 4 DC24V Fuse 250V, 3A Rapid Cut Fuse

(Std : 312003 250V, 3A (LITTEL))
FU5, 6 Brake Fuse GP40, 4.0A, 250V (Daito Tsushin)
9-8
RE-CTO-A203
(FU1, 2)
Control power supply fuse
(FU5, 6)
Brake fuse
(FU3, 4)
DC24V fuse
JANCD-XTU01
Fuse Position
If a fuse appears to be blown (see “10.2 Alarm Message List”), 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).
may blow again.
9-9
RE-CTO-A203
YASNAC XRC Parts List
No. Name Model Comment
1 Servopack *1 6 Axis type
2 CPU rack JZNC-XRK01 -
Backboard JANCD-XBB01
System control circuit board JANCD-XCP01
High speed serial interface JANCD-XIF03

circuit board
Control power supply CPS-150F
3 I/O Power-on unit JZNC-XIU01
Power-on circuit board JANCD-XTU01
Specific I/O curcuit board JANCD-XIO01
General I/O circuit board JANCD-XIO02
4 Power supply unit *2
5 Playback panel ZY1C-SS3152
6 Servo ascending fan 3610PS-22T-B30-B00 A and B type panel
4715PS-22T-B30-B00 New A and new B type

panel
7 Backside duct fan 4715PS-22T-B30-B00 Small capacity
5915PS-22T-B30-B00 Medium and large capac-

ity
8 Heat exchanger YD5-1042A Only large capacity A and

B type panel
9 Contactor circuit board fuse 313005, 5A, 250V Time lag fuse
312003, 3A, 250V Rapid cut fuse
GP40, 4.0A, 250V Alarm fuse
10 Contactor circuit board relay LY2 DC24V
11 Battery ER6VC3N 3.6V
*1 The type of the servopack depends on the robot model. For details, see the " Table.
Servopack List (Small Capacity) ", “Table. Servopack List (Medium Capacity)”, and "
9-10
RE-CTO-A203
Table. Servopack List (Medium Capacity) " .

*2 The type of the power supply unit depends on the robot model. For detail, see the "
Table. Power Supply Unit List ".
Servopack List (Small Capacity)
SV3X UP6 SK16X

Component
Type Type Type
Servopack CACR-SV3AAA CACR-UP6AAC CACR-SK16AAC
Amplifier S JUSP-WS02AA JUSP-WS05AAY17 JUSP-WS10AAY17
L JUSP-WS02AA JUSP-WS10AAY17 JUSP-WS10AAY17
U JUSP-WS01AA JUSP-WS05AAY17 JUSP-WS10AAY17
R JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA
B JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA
T JUSP-WSA5AA JUSP-WS01AA JUSP-WS02AA
Servo control JASP-WRCA01 JASP-WRCA01 JASP-WRCA01

circuit board
Control power JUSP-RCP01 JUSP-RCP01 JUSP-RCP01

supply
9-11
RE-CTO-A203
SV035X UP20
Component
Type Type
Servopack CACR-SV035AAA CACR-UP20AAA
L JUSP-WS04AA JUSP-WS20AAY22
U JUSP-WS04AA JUSP-WS10AAY17
R - JUSP-WS02AA
B JUSP-WS01AA JUSP-WS02AA
T JUSP-WS01AA JUSP-WS02AA
Servo control JASP-WRCA01 JASP-WRCA01

circuit board
Control power JUSP-RCP01 JUSP-RCP01

supply
Servopack List (Medium Capacity)
SK16MX SK45X UP50

Component
Type Type Type
Servopack CACR-SK16MAAB CACR-SK45AAB CACR-UP50AAB
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 JUSP-WS10AA JUSP-WS10AA

circuit board
Converter JUSP-ACP25JAA JUSP-ACP25JAA JUSP-ACP25JAAY11

supply
9-12
RE-CTO-A203
UP20M SP70X
Component
Type Type
Servopack CACR-UP20MAAB CACR-SP70AAB
L JUSP-WS60AA JUSP-WS15AA
U JUSP-WS20AA JUSP-WS44AA
R JUSP-WS02AA JUSP-WS05AA
B JUSP-WS02AA -
T JUSP-WS02AA -

circuit board
Converter JUSP-ACP25JAAY11 JUSP-ACP25JAA

supply
Servopack List (Large Capacity)
UP200, UP130R,
UP130RL, UP165R,
UP165-100, UP130T, UP130, UP165
UP200R
Component SK506X
Type Type Type
Servopack CACR-UP130AABY18 CACR-UP130AAB CACR-UP130AABY21
Amplifier S JUSP-WS60AAY18 JUSP-WS60AA JUSP-WS60AAY18
L JUSP-WS60AAY18 JUSP-WS60AA JUSP-WS60AAY18
U JUSP-WS60AA JUSP-WS60AA JUSP-WS60AAY18
R JUSP-WS20AAY13 JUSP-WS20AAY13 JUSP-WS20AAY13
B JUSP-WS15AAY13 JUSP-WS15AAY13 JUSP-WS15AAY13
T JUSP-WS15AAY13 JUSP-WS15AAY13 JUSP-WS15AAY13

circuit board

supply
9-13
RE-CTO-A203

Component
Type Type
Servopack CACR-SK300AAB CACR-SP100AAB
Amplifier S JUSP-WS60AAY18 JUSP-WS60AAY18
L JUSP-WS60AAY18 JUSP-WS60AAY18
U JUSP-WS60AAY18 JUSP-WS60AAY18
R JUSP-WS30AAY18 -
B JUSP-WS30AAY18 -
T JUSP-WS30AAY18 JUSP-WS20AAY19

circuit board

supply
Power Supply Unit List
Type Robot Type
JZNC-XPW03 or SV3X, SV035X, UP6, SK16X, UP20

JZRCR-XPU03
JZRCR-XPU02 SK16MX, SK45X, SP70X, UP50, UP20M,

UP130, UP165, UP165-100, UP200,
UP130T
JZRCR-XPU01 SK300X, SP100X, SK506X, SR200X,

UP130R, UP165R, UUP200R, UP130RL
9-14
RE-CTO-A203
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.
No Parts Name Dimensions Pcs Model Application
Φ6
313005 JANCD-XTU01
5A FU1, 2
1 2 5A 250V
Glass-Tube fuse
3.0 (LITTEL)
Φ6
312003
3A JANCD-XTU01
2 2 3A 250V
Glass-Tube fuse FU3, 4
3.0 (LITTEL)
32 GP40
4.0A JANCD-XTU01
3 2 4.0A 250V
Alarm fuse FU5, 6
20.5 (Daito Tsushin)
11.5
2 231-131 JANCD-XI001
(WAGO) CN05, 06
WAGO
JANCD-XTU01
4 Connector wiring
CN26, 27
tool
CPS-150F
CN04
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. To buy the spare
parts which are ranked B or C, inform the manufacturing number (or order number ) of XRC to
Yaskawa representative. The spare parts are ranked as follows:

• Rank C: Drive unit
9-15
RE-CTO-A203
NOTE For replacing parts in Rank B or Rank C, contact your Yaskawa representative.
Qty
Manufac-
turer
unit
Battery
2 A Rack Fan JZNC-XZU02 Yaskawa 2 2
B30-B00
4 A Servopack Ascending Fan 3610PS-22T- Minebea 2 2 A and B type
B30-B00 panel
4715PS-22T- Minebea 2 2 New A and
B30-B00 new B type
panel
5 A Control Power Fuse 313005 5A 250VLittel fuse 10 2
6 A 24VDC Fuse 312003 3A 250VLittel fuse 10 2
munication
Apparatus
8 A Control Relay LY-2-DC24V OMRON 3 3
10 B Control Power Unit JUSP- SANRITZ 1 1 For Servo
RCP01
12 B Amplifire JUSP-WS02AA Yaskawa 1 2 For S,L axes
13 B Amplifire JUSP-WS01AA Yaskawa 1 1 For U axis
14 B Amplifire JUSP-WSA5AA Yaskawa 1 3 For R,B,T
axes
15 B Control Power Unit CPS-150F Fuji Electric 1 1 For CPU Unit
Hi-Tech
18 B Specific I/O Board JANCD-XIO01 Yaskawa 1 1
19 B Genenal I/O Board JANCD-XIO02 Yaskawa 1 1
20 B Power On Board JANCD-XTU01 Yaskawa 1 1
22 C CPU Unit JZNC-XRK01 -1 Yaskawa 1 1
23 C I/O Power On Unit JZNC-XIU01 Yaskawa 1 1
24 C Power Unit JZRCR-XPU03 Yaskawa 1 1
25 C Programming Pendant JZNC-XPP02 Yaskawa 1 1 With Cable
8m
9-16
RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00
4 A Servopack Ascending Fan 3610PS-22T- Minebea 2 2 New A and
B30-B00 new B type
4715PS-22T- panel
B30-B00
5 A Control Power Fuse 313005 5A 250V Littel fuse 10 2
6 A 24VDC Fuse 312003 3A 250V Littel fuse 10 2
munication
Apparatus
RCP01
12 B Amplifire JUSP-WS04AA Yaskawa 1 3 For S,L,U
axes
13 B Amplifire JUSP-WS01AA Yaskawa 1 2 For B, T axes
Hi-Tech
8m
9-17
RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00
B30-B00 panel
B30-B00 new B type
panel
munication
Apparatus
RCP01
12 B Amplifire JUSP- Yaskawa 1 2 For S,U axes
WS05AAY17
13 B Amplifire JUSP- Yaskawa 1 1 For L axis
WS10AAY17
14 B Amplifire JUSP-WS01AA Yaskawa 1 3 For R,B,T
axes
Hi-Tech
21 C Servopack CACR-UP6AAC Yaskawa 1 1
8m
9-18
RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00
B30-B00 panel
B30-B00 new B type
panel
munication
Apparatus
RCP01
12 B Amplifire JUSP- Yaskawa 1 3 For S,L,U
WS10AAY17 axes
axes
14 B Control Power Unit CPS-150F Fuji Elec- 1 1 For CPU unit
tric Hi-Tech
20 C Servopack CACR-SK16AAC Yaskawa 1 1
8m
9-19
RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00
B30-B00 new B type
panel
munication
Apparatus
RCP01
WS20AAY22
14 B Amplifier JUSP- Yaskawa 1 1 For U axis
WS10AAY17
axes
Hi-Tech
19 B Specific I/O Board JANCD-XIO01B Yaskawa 1 1
20 B General I/O Board JANCD-XIO02 Yaskawa 1 1
21 B Power On Board JANCD-XTU01B Yaskawa 1 1
22 B Circuit Protection Board for JARCR-XFL01 Yaskawa 1 1
Brake Area
23 C Servopack CACR-UP20AAA Yaskawa 1 1
25 C I/O Power On Unit JZNC-XIU01B Yaskawa 1 1
8m
9-20
RE-CTO-A203
Recommended Spare Parts of XRC for SK16MX
Qty
Manufac-
turer
unit
Battery
3 A Backside Duct Fan 5915PC-22T- Minebea 2 2 A, new A, new
B30-B00 B type panel
3 3 B type panel
4 A Servopack Ascending Fan 3610PS-22T- Minebea 3 3 A type panel
B30-B00 4 4 B type panel
B30-B00 new B type
panel
munication
Apparatus
RCP01
12 B Amplifire JUSP-WS30AA Yaskawa 1 1 For S axis
13 B Amplifire JUSP-WS20AA Yaskawa 1 2 For L,U axes
axes
Hi-Tech
21 C Servopack CACR- Yaskawa 1 1
SK16MAAB
8m
9-21
RE-CTO-A203
Recommended Spare Parts of XRC for UP20M
Qty
Manufac-
turer
unit
Battery
B30-B00
B30-B00 new B type
panel
munication
Apparatus
ACP25JAAY11
RCP01
13 B Amplifire JUSP-WS60AA Yaskawa 1 1 For L axis
axes
Hi-Tech
22 B Circuit Protection Board for JARCR-XFL01 Yaskawa 1 1
Brake Area
UP20MAAB
8m
9-22
RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
3 A Backside Duct Fan 5915PC-22T- Minebea 2 2 A type, new A
B30-B00 type, and new
B type panel
3 3 B type panel
B30-B00 new B type
panel
munication
Apparatus
RCP01
13 B Amplifire JUSP-WS20AA Yaskawa 1 2 For L, U axes
axes
Hi-Tech
21 C Servopack CACR-SK45AAB Yaskawa 1 1
8m
9-23
RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00
B30-B00 new B type
panel
munication
Apparatus
ACP25JAAY11
RCP01
axes
Hi-Tech
19 B Specific I/O Board JANCD-XIO01B Yaskawa 1 1
21 B Power On Board JANCD-XTU01B Yaskawa 1 1
22 C Servopack CACR-UP50AAB Yaskawa 1 1
24 C I/O Power On Unit JZNC-XIU01B Yaskawa 1 1
8m
9-24
RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
3 A Backside Duct Fan 5915PC-22T- Minebea 2 2 A, new A, and
B30-B00 new B type
panel
3 3 B type panel
B30-B00 new B type
panel
munication
Apparatus
RCP01
axes
Hi-Tech
8m
9-25
RE-CTO-A203
Recommended Spare Parts of XRC for UP130, UP165
Qty
Manufac-
turer
unit
Battery
3 A Backside Duct Fan 5915PC-22T- Minebea 2 2 A, new A,
B30-B00 new B type
panel
3 3 B type panel
B30-B00 panel
B30-B00 new B type
panel
5 A Heat Exchanger Fan 4710PS-22T-B30 Minebea 2 2 A and B type
panel
6 A Control Power Fuse 313005 5A 250VLittle fuse 10 2
munication
Apparatus
9 A Control Relay LY2 DC24V OMRON 3 3
RCP01
13 B Amplifire JUSP-WS60AA Yaskawa 1 3 For S,L,U
axes
14 B Amplifire JUSP- Yaskawa 1 1 For R axis
WS20AAY13
15 B Amplifire JUSP- Yaskawa 1 2 For B,T axes
WS15AAY13
Hi-Tech
UP130AAB
8m
9-26
RE-CTO-A203
Recommended Spare Parts of XRC for UP200, UP165-100
Qty
Manufac-
turer
unit
Battery
B30-B00 new B type
panel
3 3 B type panel
B30-B00 panel
B30-B00 new B type
panel
panel
munication
Apparatus
RCP01
13 B Amplifire JUSP- Yaskawa 1 2 For S,L axes
WS60AAY18
WS20AAY13
WS15AAY13
Hi-Tech
UP130AABY18
8m
9-27
RE-CTO-A203
Recommended Spare Parts of XRC for UP130R, UP130T, SK506X
Qty
Manufac-
turer
unit
Battery
B30-B00 new B type
panel
3 3 B type panel
B30-B00 panel
B30-B00 new B type
panel
panel
munication
Apparatus
RCP01
13 B Amplifire JUSP- Yaskawa 1 2 For S,L axes
WS60AAY18
WS20AAY13
WS15AAY13
Hi-Tech
UP130AABY18
8m
9-28
RE-CTO-A203
Recommended Spare Parts of XRC for UP130RL, UP165R, UP200R
Qty
Manufac-
turer
unit
Battery
3 A Backside Duct Fan 5915PC-22T- Minebea 2 2 New A and
B30-B00 new B type
panel
B30-B00 new B type
panel
munication
Apparatus
RCP01
12 B Amplifire JUSP- Yaskawa 1 3 For S, L, U
WS60AAY18 axes
WS20AAY13
14 B Amplifire JUSP- Yaskawa 1 2 For B, T axes
WS15AAY13
Hi-Tech
UP130AABY21
8m
9-29
RE-CTO-A203
Recommended Spare Parts of XRC for SK300X, SR200X
Qty
Manufac-
turer
unit
Battery
B30-B00 new B type
panel
3 3 B type panel
B30-B00 panel
B30-B00 new B type
panel
panel
munication
Apparatus
RCP01
WS60AAY18 axes
14 B Amplifire JUSP- Yaskawa 1 3 For R,B,T
WS30AAY18 axes
Hi-Tech
8m
9-30
RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00 new B type
panel
3 3 B type panel
B30-B00 panel
B30-B00 new B type
panel
munication
Apparatus
RCP01
WS60AAY18 axes
13 B Amplifire JUSP- Yaskawa 1 1 For T axis
WS20AAY19
Hi-Tech
20 C Servopack CACR-SP100AAB Yaskawa 1 1
8m
9-31
Alarm • Error
RE-CTO-A203
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 sig-
0 Hardware diagnosis alarm) nal(Alarm reset). Turn off the main power sup-
ply and correct the cause of the alarm. Then
turn on the main power supply again.
Level 1-3 (Major alarm) It is not possible to reset by [RESET] under

1 the alarm display or the specific I/O sig-
- nal(Alarm reset). Turn off the main power sup-
3 ply and correct the cause of the alarm. Then
turn on a main power supply again.
4 Level 4-8 (Minor alarm) After correcting the cause, it is possible to

- reset by [RESET] under the alarm display or
8 the specific I/O signal(Alarm reset).
Level 9 (Minor alarm) After correcting the cause that the specific
(I/O Alarm) input signal for the system or user alarm
9 request is input, it is possible to reset by
[RESET] under the alarm display or the spe-
cific I/O signal(Alarm reset).
10-1
RE-CTO-A203
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.

L
ALARM R1 C A
ALARM 4000
MEMORY ERROR(TOOL FILE)
[1]
OCCUR TIMES:1 RESET
If more than one alarm occurs simultaneously, the first four alarms are displayed. The fifth
and subsequent alarms are not displayed, but they can be checked on the alarm history dis-
play. The following operations are available in the alarm status: display change, mode
change, alarm reset, and emergency stop. If the display is changed to the other during alarm
occurrence, the alarm display can be shown again by selecting {SYSTEM INFO} and
{ALARM} under the menu.
Release
Alarms are classified by minor and major alarms.
Minor Alarms
Operation
Press [SELECT]*1
Explanation
*1 Select [RESET] under the alarm display to release the alarm status. When using an
external input signal, turn on the “ALARM RESET” setting.
Major Alarms
Operation
Turn off the main power supply and remove the cause of the alarm*1
Explanation
*1 If a severe alarm, such as hardware failure occurs, servo power is automatically shut
off and the manipulator stops. If releasing does not work, turn off the main power and
correct the cause of the alarm.
10-2
RE-CTO-A203
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
• Binary data
The alarm occurrence data becomes “1”.
With 8 bits: 0000_0001
With 16 bits: 00000001_00000001
• Axis data
The axis where the alarm occurred is highlighted.
With robot axis: Robots 1 to 3 [SLURBT]
With base axis: Robots 1 to 3 [123]
With station axis: Stations 1 to 6 [ 1 2 3 ]
• XYZ coordinate data

The coordinates when the alarm occurred are highlighted.
[XYZ]
[ X Y Z Tx Ty Tz ]
• 123 data
The data for the alarm that occurred is highlighted.
[123]
• Control group data

The control group where the alarm occurred is highlighted.
[ R1 R2 S1 S2 S3 ]
(2) Multiple Servopack System

In a system using more than one Servopack, the number of the Servopack where the
alarm occurred is also displayed. The S1 switch of the WRCA01 board shows the Servo-
pack number.
SV#1: Servopack 1 (WRCA01 board S1 switch: 0)
10-3
RE-CTO-A203
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)
10-4
RE-CTO-A203
10.3 Alarm Message List
CAUTION
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. Care-
less operation may delete registered data. If repairs for JANCD-XCP01 are necessary,
consult YASKAWA representative before performing any repairs.
Alarm Message List
Alarm
Number Message Cause Remedy
0010 CPU BOARD INSER- • Insertion of the circuit board was not com- • Check whether the circuit board is cor-
TION ERROR pleted rectly inserted.
[Decimal Data] • Defective circuit board • Replace the circuit board.
Data stands for error circuit board

10:XCP02 circuit board (#1-0)
(Note)
XCP02 circuit board (# - )
:Slot NO.
:0 XCP02 circuit board(main)
1 Sub-board1(connector CNSL side)
2 Sub-board2(connector CNET side)
0020 CPU • Insertion of the circuit board was not com- • Check whether the circuit board is cor-
COMMUNICATION pleted rectly inserted.
ERROR
• Defective circuit board • Replace the circuit board.
[Decimal Data]
Data stands for an error circuit board
(Note)
:Slot NO.
10-5
RE-CTO-A203
Alarm Message List
Alarm
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 • (XCP01 CN05 - WRCA(#*) CN10 cable,
for servopack was not cut.
WRCA CN10(#*) - WRCA
• The connection of terminal connector was
not completed. • CN10(#*) cable)
• The terminal connector was unusual. • Replace the communication connector
• The circuit board was out of order. for servopack.
• (The terminal connector was equipped 1 • Check the connection of the terminal
for a system).
connector(WRCA CN10(#*)).
Data stands for an error circuit board • Replace the terminal connector.
50:WRCA01 circuit board (#1) • Replace the circuit board.
51:WRCA01 circuit board (#2)
(Note)
WRCA01 circuit board (# )
The setting value of rotary switch on the
WRCA01 circuit board is ( -1).
0030 ROM ERROR An error was found by sum check of system • Replace the circuit board.
[Decimal Data] program. • When the XCP01 circuit board is
replaced, consult YASKAWA representa-
tive.
1:XCP01 circuit board
2:XSP01 circuit board
(Note)
:Slot NO.

(Note)
WRCA01 circuit board is ( -1).
10-6
RE-CTO-A203
Alarm Message List
Alarm
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.
2:XSP01 circuit board
(Note)
:Slot NO.

(Note)
WRCA01 circuit board is ( -1)
0050 MEMORY A error occured in PCI bus shared RAM of • Insert the circuit board securely in the
ERROR(PCI-BUS the CPU rack or shared RAM between cir- CPU rack or in the connector on the
COMMON RAM) cuit boards.
board.
[Decimal Data]
• Replace the circuit board.
(Note)
:Slot NO.
10-7
RE-CTO-A203
Alarm Message List
Alarm
0060 COMMUNICATION • An error occured 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
Data stands for the error I/O module.
1-15: I/O module connected with cable)
XCP01circuit board • Replace the communication connector
17-31:Contactor circuit board, speed detect for I/O module.
circuit board connected with
WRCA01 circuit board(#1)
33-47:Contactor circuit board, speed detect
(Note)
WRCA circuit board is ( -1)
0100 COMMUNICATION • An error occurred in the communications • Check the connection of the communica-
ERROR (WRCA#1) sequence between the XCP01 circuit tions cable for the servopack. (XCP01
[Decimal Data] board and Servopack #1.
or CN05 to WRCA (#*) or CN10 cable,
WRCA (#*) or CN10 to WRCA or CN10
(#*) cable)
• Replace the communications cable for
the servopack.
• Check the connection of the terminal
connector (WRCA (#*) and CN10).
• Replace the terminal connector.
ERROR (WRCA#2) sequence between the XCP01 circuit tions cable for the servopack. (XCP01 or
CN05 to WRCA (#*) or CN10 cable,
(#*) cable)
the servopack.
10-8
RE-CTO-A203
Alarm Message List
Alarm
ERROR (WRCA#3) sequence between the XCP01 circuit tions cable for the servopack. (XCP01or
[Decimal Data] board and Servopack #3. CN05 to WRCA (#*) or CN10 cable,
(#*) cable)
the servopack.
(#*) cable)
the servopack.
(#*) cable)
the servopack.
(#*) cable)
the servopack.
0200 MEMORY ERROR The parameter file was damaged. • Initialize the parameter file damaged on
(PARAMETER FILE) Data stands for the damaged parameter file. maintenance mode.
[Decimal Data] 0:RC*, 1:RO*, 2:SV, 3:SVM, 4:SC, 5:SD*,
• Load the saved parameter file in the
6:CIO*, 7:FD*, 8:AP, 9:RS, 10:SE, 11:RMS*,
external memory unit.
12:AMC*, 13:SVP*, 14:MF*,15:PCD*
*:System parameter
10-9
RE-CTO-A203
Alarm Message List
Alarm
0210 MEMORY ERROR The system configuration data information Needs investigation.
(SYSTEM CONFIG- on setting system initialization was Consult a YASKAWA representative.
DATA) damaged.
0220 MEMORY ERROR The job control data was damaged. • Initialize the job on maintenance mode
(JOB MNG DATA) The whole job data is deleted.
• Load the job saved on the external mem-
ory unit.
0230 MEMORY ERROR The concurrent I/O ladder program was • Initialize the ladder program on mainte-
(LADDER PRG FILE) damaged. nance mode.
• Load the ladder program saved on the
external memory unit.
0300 VERIFY ERROR The system parameter was modified ille- Needs investigation.
(SYSTEM CONFIG- gally. Consult a YASKAWA representative.
DATA)
[Decimal Data]
0310 VERIFY ERROR CMOS memory capacity on system setting Check the connection status of CMOS
(CMOS MEMORY was different than the current one. memory circuit board (XMM01) for expan-
SIZE) sion.
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.
[Decimal Data]
current. • Modify the I/O module on maintenance
• The communication mode (16/17 bytes) mode.
does not coincide with the XIO01 due to • Verity the communication mode (16/17
replacement of the I/O module. bytes) of the new I/O module.
Data stands for the I/O module.

1-15: I/O module connected with XCP01 cir-
cuit board
(Note)
0330 VERIFY ERROR The applicatoion on system setting was dif- Change the AP parameter to the correct
(APPLICATION SET- ferent than AP parameter. value.
TING)
10-10
RE-CTO-A203
Alarm Message List
Alarm
0340 VERIFY ERROR • The sensor function on system initializing • Set the function of the sensor circuit
(SENSOR FUNC- was different than the function of the sen- board on maintenance mode again.
TION) sor circuit board mounted now. • Change SE parameter for the correct
• The sensor setting on system setting was value.
different than SE parameter.
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.
• The connection of terminal connector is WRCA CN10(#*) - WRCA CN10(#*)
not completed. cable)
• The terminal connector is unusual. • Replace the communication connector
• The circuit board was out of order. (The for servopack.
terminal connector is equipped 1 for a sys-
tem).
Data stands for an error circuit board • Replace the terminal connector.
50:WRCA01 circuit board (#1) • Replace the circuit board.
(Note)
0410 MODE CHANGE An error occurred in process of change to <Data :10-21>

ERROR normal operation mode. • Insert the circuit board in the CPU rack
[Decimal Data] fast.
Data stands for an error circuit board • Replace the circuit board.
<Data :50-55>
• Check the connection of communication
21:XCP02 circuit board (#2-1) cable for servopack. (XCP01 CN05 -
22:XCP02 circuit board (#2-2) WRCA(#*) CN10 cable,
WRCA CN10(#*) - WRCA CN10(#*)
(Note)
cable)
• Replace the communication connector
:Slot NO.
:0 XCP02 circuit board(main) for servopack.
1 Sub-board1(connector CNSL side) • Check the connection of the terminal
2 Sub-board2(connector CNET side) connector(WRCA CN10(#*)).
50:WRCA01 board (#1)
(Note)
The setting value of rotary switch on
0500 SEGMENT PROC An error occured in communication between • Turn the power off then back on.
NOT READY XCP01 circuit board and WRCA01 circuit • If the error occurs again, contact your
board.
YASKAWA representative.
10-11
RE-CTO-A203
Alarm Message List
Alarm
0510 SOFTWARE VER- The software version of the XCP01 circuit • Contact your Yaskawa representative.
SION UNMATCH board does not agree with that of the WRCA
[Decimal Data] circuit board.
0900 WATCHDOG TIMER An insertion error of the XCP01 circuit board • Insert the circuit board in the CPU rack
ERROR or defective circuit board. fast.
(XCP01)
[Decimal Data]
• If the error occurs again, contact your
0901 WATCHDOG TIMER An insertion error of the XCP02#1 circuit • Insert the circuit board in the CPU rack
ERROR board or the circuit borad failer. or the connector on the circuit board fast.
(XCP02#1) • Replace the circuit board
[Decimal Data]
0902 WATCHDOG TIMER An insertion error of the XCP02#2 circuit • Insert the circuit board in theCPU rack or
ERROR board or defective circuit board. the connector on the circuit board fast.
(XCP02#2)
[Decimal Data]
0910 CPU ERROR(XCP01) An insertion error of the XCP01 circuit board • Insert the circuit board in theCPU rack
[Decimal Data] or defective circuit board. fast.
0911 CPU ERROR An insertion error of the XCP02#1 circuit • Insert the circuit board in the CPU rack
(XCP02#1) board or defective circuit board. or the connector on the circuit board fast.
[Decimal Data] • Replace the circuit board.
0912 CPU ERROR An insertion error of the XCP02#2 circuit • Insert the circuit board in the CPU rack
[Decimal Data]
0920 BUS ERROR An insertion error of the XCP01 circuit board • Insert the circuit board in the CPU rack
(XCP01) or defective circuit board. fast.
0921 BUS ERROR An insertion error of the XCP02#1 circuit • Insert the circuit board in the CPU rack
(XCP02#1) board or defective circuit board. fast.
[Decimal Data]
0922 BUS ERROR An insertion error of the XCP02#2 circuit • Insert the circuit board in the CPU rack
[Decimal Data]
• Replace the circuit board
10-12
RE-CTO-A203
Alarm Message List
Alarm
0930 CPU HANG UP An insertion error of the XCP01 circuit board • Insert the circuit board in the CPU rack
ERROR or defective circuit board. fast.
(XCP01) • Replace the circuit board.
[Decimal Data]
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)
[Decimal Data]
0932 CPU HANG UP An insertion error of the XCP02#2 circuit • Insert the circuit board in the CPU rack
(XCP02#2)
[Decimal Data]
0940 WATCHDOG TIMER An insertion error of theWRCA01#1 circuit • Insert the circuit board in the CPU rack
ERROR board or defective circuit board. or the connector on the circuit board
(WRCA#1) fast.
[Decimal Data]
• Replace the circuit board
0941 WATCHDOG TIMER An insertion error of the WRCA01#2 circuit • Insert the circuit board in the CPU rack
(WRCA#2)
[Decimal Data]
0942 WATCHDOG TIMER An insert error of the WRCA01#3 circuit • Insert the circuit board in the CPU rack
(WRCA#3) • Replace the circuit board.
[Decimal Data]
(WRCA#4)
[Decimal Data]
(WRCA#5)
[Decimal Data]
[Decimal Data]
10-13
RE-CTO-A203
Alarm Message List
Alarm
0950 CPU ERROR An insertion error of the WRCA01#1 circuit • Insert the circuit board in the CPU rack
(WRCA#1) board or defective circuit board. or the connector on the circuit board fast.
[Decimal Data]
[Decimal Data]
(WRCA#4) board or defective circuit board. or the connector on the circuit board
[Decimal Data] fast.
[Decimal Data]
0960 CPU HANG UP An insertion error of the WRCA01#1 circuit • Insert the circuit board in the CPU rack
(WRCA#1)
[Decimal Data]
(WRCA#2)
[Decimal Data]
[Decimal Data]
10-14
RE-CTO-A203
Alarm Message List
Alarm
[Decimal Data]
(WRCA#5)
[Decimal Data]
(WRCA#6)
[Decimal Data]
0999 NMI ERROR NMI(interruption CPU signal of unknown ori- • Insert the circuit board in theCPU rack or
[Decimal Data] gin) occured because of the motion error of the connector on the circuit board fast.
hardware, circuit board and rack or control • Replace the circuit board.
error of software.
1000 ROM ERROR The error was found by sum check of sys- Replace the XCP01 circuit board (ROM).
(XCP01) tem program for the XCP01 circuit board.
1001 ROM The error was found by sum check of sys- Replace the WRCA circuit board (ROM).
ERROR(WRCA01) tem program for the XCP01 circuit board.
[Decimal Data]
1002 ROM ERROR The error was found by sum check of sys- Replace the XFC01 circuit board (ROM).
(XFC01) tem program for the XFC01 circuit board.
1003 ROM (XCP02) The error was found by sum check of sys- Replace the XCP02 circuit board (ROM).
tem program for the XCP02 circuit board.
1030 MEMORY ERROR The parameter file of CMOS memory was • Initialize the parameter file damaged on
(PARAMETER FILE) damaged. maintenance mode.
[Decimal Data] Data stands for the damaged parameter file.
• Load the saved parameter from the
0:RC*, 1:RO*, 2:SV, 3:SVM, 4:SC, 5:SD*,
6:CIO*, 7:FD*, 8:AP, 9:RS, 10:SE, 11:RMS*, floppy disk and restore.
12:AMC*, 13:SVP*, 14:MF*, 15:PCD*
*:System parameter
1031 MEMORY ERROR The saved each file on CMOS memory used • Initialize the file damaged on mainte-
(MOTION1) by motion instruction was damaged. nance mode.
[Decimal Data]
• Load the saved file from the floppy disk
and restore.
1032 MEMORY ERROR • The saved each file on XCP01 circuit • Turn the power off then back on.
(MOTION2) board memory used by motion instruction • Insert the XCP01 circuit board in CPU
[Decimal Data] was damaged. rack fast.
• An insertion error of the XCP01 circuit • Replace the XCP01 circuit board.
board or the circuit borad failer. • If the error occurs again, contact your
10-15
RE-CTO-A203
Alarm Message List
Alarm
1050 SET-UP PROCESS The error occured in the setup process of • Turn the power off then back on.
ERROR system when the main power was turned • If the error occurs again, contact your
(SYSCON) on. YASKAWA representative.
[Decimal Data] 1: The set up of motion instruction was not
completed. The set up of the WRCA01,
XCP02 circuit board was not completed.
1051 SETUP INITIALIZE The error occured 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 your
(MOTION) was turned on.
[Decimal Data]
1100 SYSTEM ERROR The alarm of unknown origin was detected • Needs investigation. Consult a
C: B: C: by noise and control error. YASKAWA representative.
[Decimal Data]
1101 SYSTEM ERROR The error occured in the control check of • Turn the power off then back on.
(SYSTEM1) system. • If the error occurs again, contact your
[Decimal Data]
1102 SYSTEM ERROR The error occured in the control check of • Turn the power off then back on.
(SYSTEM2) system. • If the error occurs again, contact your
[Decimal Data] YASKAWA representative.
1103 SYSTEM ERROR The error occured in the event data check of • If the error occurs again, contact your
(EVENT) system. YASKAWA representative.
[Decimal Data]
1104 SYSTEM ERROR The error occured in the I/O control check of • Check the connector, cable for transmis-
(CIO) system sion path of I/O signal(XCP01I/O contac-
[Bit Pattern] tor unit , I/O module)
Data stands for the cause of alarm.
• Reset the I/O module on maintenance
0001_0000:Communication error with I/O
module or seting error of I/O module mode.
• Replace the XCP01, I/O contactor unit, I/
O module.
1105 SYSTEM ERROR The error occured in control check of the • Turn the power off then back on.
(SERVO) WACA01/WRCF01 circuit board. • If the error occurs again, contact your
[Decimal Data]
1106 SYSTEM ERROR The error occured in control check of the • Turn the power off then back on.
(SPEED MONITOR) XFC01 circuit board. • If the error occurs again, contact your
[Decimal Data] YASKAWA representative.
1200 HIGH TEMPERA- The temperature in the controller raised Check whether interior fan of controller is
TURE (IN CNTL BOX) abnormally. working or not.
1201 OVERRUN LIMIT Overrun recovery switch was operated on • Don't operate the overrun recovery
SWITCH RELEASED playback. switch on playb\ack.
• It is thought that the overrun recovery
switch is failed. Consult YASKAWA rep-
resentative.
1202 FAULT CPU motion impossibility caused by 0 divi- • Turn the power off then back on.
[Decimal Data] sion etc. • If the error occurs again, contact your
Data stands for the factor of alarm.
1:Calculation
2:Floating point
10-16
RE-CTO-A203
Alarm Message List
Alarm
1203 SAFETY CIRCUIT The error occurred in the safe circuit pro- • Turn the power off then back on.
ERROR (XCI01) cessing of the XCI01 circuit board. • Check the connection cable of the I/O
[Binary Data] 00000000_********: CPU1 error contactor unit.
********_00000000: CPU2 error
*: Data of 0 or 1
Yaskawa representative.
1204 COMMUNICATION An error occurred in the communications of • Check the connector and cable for the I/
ERROR (I/O Module) the I/O module. O signal transmission (XCP01-I/O
[Binary Data] 0000_0000_0000_0010: ST#1
power on unit, and I/O module)
0000_0000_0000_0100: ST#2
0000_0000_0000_1000: ST#3 • Set the I/O module to maintenance
: mode again.
1000_0000_0000_0000: ST#15 • Take countermeasures against noise.
• Replace the XCP01 circuit board, the I/
O-power on unit, and/or the I/O module.
1206 SPEED ERROR The motor speed displayed in the axis data • Check the connection of the motor.
(XCP01) exceeds the maximum motor speed. • Check the robot motion for when the
Robot/Station • Incorrect wiring of motor U,V,W lines
alarm occurs and if any external force is
[Axis Data} • Incorrect motor type
being applied to the motor.
• The motor was rotated by an external
• Check if the the U, V, and W lines of the
force.
motor are connected correctly. If not,
• Motor (encoder) fault
reconnect them.
• Check if the alarm occurs at a teaching
speed lower than the speed when the
alarm occurred. Depending on the
teaching posture, the R, B, or T axis
may move at a higher speed during lin-
ear interpolation. If so, reconsider the
teaching.
<When the alarm occurs in the robot
axis>
Check if the motor type specified in the
instruction manual is used. If not, use
the specified type of motor.
<When the alarm occurs in the external
axis>
Check if the motor type set in the sys-
tem configuration is the same as that is
actually connected. If the setting in the
system configuration is correct, replace
the motor with one set in the system
configuration. If not, correct the setting
in the system configuration.
10-17
RE-CTO-A203
Alarm Message List
Alarm
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,
• The cable between the XCP01 circuit
board and WRCA01 circuit board was
cable)
defective.
• Replace the communication cable for
• The connection of the terminal connector
servopack.
was imcomplete.
• Defective XCP01 circuit board
• Defective WRCA01 circuit board
• Replace the XCP01 circuit board,
WRCA01 circuit board.
1301 COMMUNICATION The communication between the XCP01 • Check the connection of communication
ERROR circ board and the WRCA01 circuit board cable for servopack.
(SERVO) was abnormal.
(XCP01 CN05 - WRCA(#*) CN10 cable,
[Decimal Data] • The cable between the XCP01 circuit
board and WRCA01 circuit board was
cable)
defective.
• Replace the communication cable for
• The connection of the terminal connector
servopack.
was incomplete.
• Defective XCP01 circuit board
• Replace the terminal conector.
• Replace the XCP01 circuit board,
1302 COMMUNICATION The communication between WRCA01 cir- • Check the connection for communication
ERROR cuit board and the contactor unit(for I/O, cable between the WRCA01 circuit
(SERVO I/O) robot, external axis)was abnormal. board and contactor unit.
[Decimal Data]
(WRCA01(#*) CN20 - XIU01 CN21
cable)
• Replace the WRCA01 circuit board.
• Replace the contactor unit.
1303 ARITHMETIC The error occured on check of interior con- Needs investigation. Consult a YASKAWA
ERROR trol for the WRCA circuit board. representative.
(SERVO)
[Decimal Data]
1304 EX-AXIS BOARD • The system included the external axis, but <The system with external axis>
NOT INSTALLED the external axis circuit board (WRCF01 • Check the installation of the external axis
board) was not installed. circuit board(WRCF01 board).
• The system did not include the external • If the WRCF01 circuit board is installed,
axis, but the system with external axis was replace it.
set. <The system without external axis>
• Check the system is not included exter-
• Defective WRCF01 circuit board
nal axis.
• Execute the system configuration again
on system without external axis.
10-18
RE-CTO-A203
Alarm Message List
Alarm
1305 POWER ON UNIT • The contactor unit was set on system con- <The system with external axis>
NOT INSTALLED figuration, but the contactor unit was not • Check the installation of the external axis
[Bit Pattern] installed. circuit board(WRCF01 board).
• The system was not installed contactor • If the WRCF01 circuit board is installed,
unit, but the system was set as though a replace it.
contactor unit installed. <The system without external axis>
• Defective contactor unit • Check the system is not included exter-
• Defective WRCA circuit borad nal axis.
• Execute the system configuration again
on system without external axis.
1306 AMPLIFIER TYPE • The type of amplifier displayed by axis • Check the type of servopack displayed
MISMATCH data was different than the type set by sys- by axis data.
Robot/Station
tem configuration. <Error in robot axis>
[Axis Data]
• The type of amplifier was not correct. Check the type of servopack is same as
• The type of amplifier was different than the described one on manual. If the type is
type set by system configuration. not correct, replace it with correct servo-
• Defective amplifier pack.
• Defective WRCA01 circuit board <Error in external axis>
Check the type of servopack set by sys-
tem configuration is same as actual
installed one. If set data by system con-
figuration is correct, replace installed ser-
vopack with correct one. If set data by
sytem configuration is not correct, set the
correct system configuration.
• If the error occurs again, replace
1307 ENCORDER TYPE The type of encoder displayed by axis data • Check the type of motor displayed by
MISMATCH was different than the type set by system axis data.
Robot/Station configuration.
<Error in robot axis>
[Axis Data] • The type of encoder was not correct.
Check that the type of motor is same as
• The system configuration setting of
the one described in the manual. If the
encoder was not correct.
type is not correct, replace it with the cor-
• Defective encoder
rect motor.
• Defective WRCA circuit board
<Error in external axis>
(Note) Check that the type of motor set by sys-
The encoder is accessories of motor, check tem configuration is same as actual
the type of motor to check the type of installed one. If the set data by system
encoder configuration is correct, replace installed
motor with correct one. If set data by sys-
tem configuration is not correct, set the
10-19
RE-CTO-A203
Alarm Message List
Alarm
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] • The wiring of UVW wire of motor was not check whether external power is oper-
correct. ated or not.
• The type of motor was not correct. • Check the connection of UVW wire of
• The motor was moved by external power. motor again. If the error is found, alter
• Defective WRCA01, WRCF01 circuit board the connection.
• Defective motor(encoder) • Check the reoccurence by reducting the
teaching speed on alarm.There is a pos-
sibility that R,B,T axis move at a fast
speed on liner interpolation according to
teaching position. In this case, alter the
teaching.
type is not correct, replace it with the cor-
rect motor.
Check that the type of motor set by sys-
installed one. If the set data by system
configuration is correct, replace installed
• If the error occurs again, replace WRC01
and/or WRCF01 circuit board.
10-20
RE-CTO-A203
Alarm Message List
Alarm
1309 OVERLOAD The motor torque displayed by axis data • Check whether the robot interferes with
(CONTINUE) exceeded rated torque for a long time(a few the outside equipment. If the robot inter-
Robot/Station seconds - a few minutes). It may have feres, remove the cause.
[Axis Data] burned the motor.
• Check the connection of UVW wire of
• The wrong wiring, the breaking of the
motor again. And check the breaking of
UVW wire for the motor
the wire.
• The type of motor was not correct.
• There is a possibility the robot moves by
• The motor was moved by external power.
extra load. Check the motion status of
• It interfered with an outside equipment.
robot again and reduce the teaching
• Defective WRCA01, WRCF01 circuit board
speed. Then confirm the reoccurrence.
• Defective amplifier
• Defective motor(encoder)
Check that the type of motor is the same
as the one described in the manual. If
the type is not correct, replace it with the
correct motor.
tem configuration is the same as the
actual installed one. If set data by system
WRCA01 and/or WRCF01 circuit board.
• Replace the amplifier, motor for axis
where the error occurred.
10-21
RE-CTO-A203
Alarm Message List
Alarm
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. feres, remove the cause.
[Axis Data] • The wrong wiring, the breaking of the wire
the wire.
correct motor.
10-22
RE-CTO-A203
Alarm Message List
Alarm
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-
(CONTINUE) long time(a few seconds - a few minutes). It feres, remove the cause.
Robot/Station may have burned the servopack.
[Axis Data] • The wrong wiring, the breaking of the
the wire.
correct motor.
10-23
RE-CTO-A203
Alarm Message List
Alarm
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). It feres, remove the cause.
Robot/Station may have burned the servopack.
[Axis Data] • The wrong wiring, the breaking of the
the wire.
correct motor.
1313 MOTOR ERROR The motor was driven recklessly. This error • Check the connection of UVW wire of
Robot/Station occured when the motor moved in reverse motor again.
[Axis Data] for the forward instruction.
• Incorrect wiring of the UVW wire for the
motor
type is not correct, replace it with correct
motor.
installed one. If set data by system con-
figuration is correct, replace installed
10-24
RE-CTO-A203
Alarm Message List
Alarm
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/Station shifted from instructed motion position or feres, remove the cause.
[Axis Data] tracks more than tolerance and operated
• The wrong wiring, the breaking of the wire
of UVW wire for the motor
the wire.
• Defective WRCA01, WRCF01 cir cuit
board
correct motor.
1315 POSITION ERROR The number of pulses generated by one • Check whether there is a equipment
Robot/Station rotation of the motor was not a regulated generating loud noise.
[Axis Data] pulse numbers. There is a possibility the
• Check the ground of controller is correct.
position was shifted. (But, if this alarm
• When the errror occurred at external
occured simultaneously with the alarm
related to the encoder, it was thought this axis, set the ferritecore on the encoder
alarm accompanied the encoder alarm.) cable for noise measure.
• Noise of outside equipment • If the error occurs again, replace
• Down of the power supply voltage for the
• Replace the motor for axis occured the
encoder
error.
1316 BROKEN PG LINE The break of the signal wire from encoder • Check the conduction of cable from the
Robot/Station (But, this alarm may accompany the position WRCA01, WRCF circuit board to the
[Axis Data] error alarm, the alarm related to the
motor(encoder).
encoder.)
• Noise of outside equipment • Check whether there is equipment gen-
• Defective WRCA01, WRCF01 circuit board erating loud noise.
• Decrease of the power supply voltage for • Check the grounding of controller is cor-
the encoder rect.
• Defective motor(encoder) • If the error occurs again, replace
• Replace the motor for the axis where
the error occurred.
10-25
RE-CTO-A203
Alarm Message List
Alarm
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
• Defective speed detective circuit board speed detective circuit board and
• Defective WRCA circuit board WRCA01 circuit board.
1318 OVERVOLTAGE The power supply voltage of direct current • Check the primary power supply (220V,
(CONVERTER) supplied to the amplifier of servopack +10%).
[Bit Pattern] exceeded 420V.
• Lower the teaching speed of the fore and
• The primary power supply voltage was too
aft steps for alarm occurence step about
high.(220V,+10%)
30% and check the reoccurrence. If the
• It was too much load.
alarm doesn't reoccur, alter the load.
• Defective converter
• If the error occurs again, replace the
WRCA01 circuit board and the converter.
1319 GROUND FAULT One of U,V,W wires of the motor displayed This alarm does not occured by turning off
Robot/Station on axis data was grounded at least. the controlled power supply. But never fail
[Axis Data] • Defective the motor to turn on the servo power supply after
• Ground fault of the motor, lead wire checking the motor grounding. There is a
• Defective WRCA01, WRCF01 circuit board possibility the servopack is damaged
when the servo turn-on and off is repeate-
during ground fault status.
• Check the connection of the U,V,W,E
wires of motor again.
• Remove the U,V,W,E wires of the motor
from the terminal of the controller and
check the conduction of U-E, V-E, W-E. If
the wires are conducted, it's abnormal.
• In case an error is found by the above
check, remove the connector of the
motor side and check again. If the wires
are conducted, it is thought to be a
defective lead wire. Specify the error
point and replace the lead wire.
• If the error is not caused by the lead
wire, it is thought to be a defective motor.
• Replace the amplifier, motor for the axis
1320 OPEN PHASE Any of the three-phase current for primary • Check the connection of the primary side
(CONVERTER) side power supply of servopack was open- wiring R,S,T wires of servopack.
[Bit Pattern] phase. • Check that the power supply voltage is
• The wrong wiring of the primary side
more than 170V.
power supply connection.
• The decrease of the primary side power
WRCA01,WRCF01 circuit board.
supply voltage(170V or less)
• Replace the converter for the axis where
the error occurred.
10-26
RE-CTO-A203
Alarm Message List
Alarm
1321 OVERCURRENT One of the U,V,W wires of the motor dis- This alarm does not occured by turning off
(AMP) played on the axis data was grounded at the controlled power supply. But never fail
Robot/Station least. to turn on the servo power supply after
[Axis Data] • Defective motor checking the motor grounding. There is a
• Ground fault of the motor, lead wire possibility the servopack is damaged
• Defective WRCA01, WRCF01 circuit board when the servo turn-on and off is repeate-
during ground fault status.
• Check the connection of the U,V,W,E
• Overheating of amplifier
wires of motor again.
• Remove the U,V,W,E wires of the motor
from the terminal of the controller and
check the conduction of U-E, V-E, W-E. If
the wires are conducted, it's abnormal.
• In case an error is found by the above
check, remove the connector of the
motor side and check again. If the wires
are conducted, it is thought to be a
defective lead wire. Specify the error
point and replace the lead wire.
• If the error is not caused by the lead
wire, it is thought to be a defective motor.
• Replace the amplifier, motor for the axis
1322 REGENERATIVE Because the resurrection energy on • Check the load again. Lower the teach-
TROUBLE reducing the motor speed was too high, the ing speed of the fore and aft steps for
(CONVERTER) resurrection circuit board didn't work. alarm occurence step about 30% and
[Bit Pattern] • The load installed on robot was too heavy.
check the reoccurence. If the alarm
• The primary side power supply voltage
doesn't reoccur, alter the load.
was too high.(242V or more)
• Check the primary power supply(220V,
+10%).
WRCA01, WRCF01 circuit board.
• Replace the converter for the axis where
the error occurred.
1323 INPUT POWER The primary side power supply voltage of • Check the primary power supply(220V,
OVER VOLTAGE servopack was too high.(more than 242V) +10%).
(CONV)
[Bit Pattern]
• Replace the converter for axis occured
the error.
1324 TEMPERATURE The temperature of servopack(converter) • Check whether the ambient temperature
ERROR was too high. is too high or not.
(CONVERTER) • Check the primary power supply(220V,
[Bit Pattern]
+10%).
• Replace the converter for axis occured
the error.
10-27
RE-CTO-A203
Alarm Message List
Alarm
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 • Check whether there is equipment gen-
Robot/Station • The type of motor was not correct. erating big noise around or not.
[Axis Data]
• Defective WRCA01 circuit board • Check the ground of controller is correct.
• Defective encoder <Error in robot axis>
Check the type of motor is same as
described one on manual. If the type is
not correct, replace it with correct motor.
Check the type of motor set by system
configuration is same as actual installed
one. If set data by system configuration
is correct, replace installed motor with
correct one. If set data by sytem configu-
ration is not correct, set the correct sys-
tem configuration.
1326 DEFECTIVE The error occured in the position detect • Turn the power off then back on.
ENCODER ABSO- circuit board of encoder. • If the error occurs again, replace the
LUTE DATA
motor(encoder) for the axis where the
Robot/Station
[Axis Data] error occurred.
1327 ENCODER OVER • The control power supply was turned on • Check the timing of turning on the con-
SPEED when the encoder was rotating(400rpm or trol power supply.
Robot/Station
more). Turning on the control power supply • If the error occurs when the control
[Axis Data]
can not be done when the motor is rotat- power supply is turned in a stopped
ing. state, replace the motor(encoder) dis-
• The no brake axes, R,B,T axis for SK6, played on axis data.
freely fell when the servo power supply
was turned off by emergency stop. When
the power supply was turned back on this
status, this alarm occured.
• In case this alarm occuredin a stop state, it
is thought that the encoder caused the
error.
1328 DEFECTIVE SERIAL The internal parameter of the serial encoder Turn the power off then back on. If the
ENCODER became abnormal. It is thought to be an phenomenon occurs again after repeat-
Robot/Station error of the encoder. ing this operation several times, replace
[Axis Data] the motor(encoder) for the axis where the
error occurred.
1329 DEFECTIVE SERIAL When the encoder backup error occurred, Turn the power off then back on. If the
ENCODER COM- normally the controller automatically resets phenomenon occurs again after repeat-
MAND the data of the encoder. But, this was the ing this operation several times, replace
Robot/Station case there was no response of the reset the motor(encoder) for the axis where the
[Axis Data] completion from the encoder. It is thought error occurred.
that the encoder was abnormal.
1330 MICRO PROGRAM Defective WRCA01 circuit board Turn the power off then back on. If the
TRANSMIT ERROR phenomenon occurs again after repeat-
Robot/Station ing this operation several times, replace
[Axis Data] the WRCA01 circuit board for the axis
10-28
RE-CTO-A203
Alarm Message List
Alarm
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 repeat-
(U PHASE) phase current value was abnormal. ing this operation several times, replace
Robot/Station • Defective WRCA01 circuit board the WRCA01 circuit board, amplifier for
[Axis Data] • Defective amplifier the axis where the error occurred.
1332 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 V phenomenon occurs again after repeat-
(V PHASE) phase current value was abnormal. ing this operation several times, replace
Robot/Station • Defective WRCA01 circuit board the WRCA01 circuit board, amplifier for
[Axis Data] • Defective amplifier axis the the error occurred.
1335 ENCODER NOT Reset was not completed though encoder • Connect the battery with the encoder.
RESET backup error reset was requested. It may Contact your YASKAWA representative
Robot/Station be possible that the battery is not connected
because the breakdown of the encoder
[Axis Data] with the encoder.
is thought when the alarm occurs again
even if the battery is connected.
1336 XFC01 NOT The speed monitoring board (XFC01) is not Mount the speed monitoring board
INSTALLED mounted although it has been specified. (XFC01).
1337 SPEED MONITOR The error occurred in the speed monitoring • Check the connection cables of the I/O
LEVEL NOT SAME level signal (duplicated signal check). contactor unit.
• Replace the WRCA01 board.
1338 SPEED MONITOR The error occurred in the speed monitoring • Check the connection cables of the I/O
LEVEL ERROR level signal (signal error). contactor unit.
1339 SPEED MONITOR The error occurred in the speed monitoring • Check the cable connection between the
LEVEL ERR (XFC01) level signal. I/O contactor unit and the XFC01 circuit
• Disconnected cable between the I/O con-
board.
tactor unit and the XFC01 circuit board
• Check the cable connection between the
• Disconnected cable between the I/O con- I/O contactor unit and the XCI01 circuit
tactor unit and the XCI01 circuit board board.
• Defective I/O contactor unit • Replace the I/O contactor unit and the
• Defective XFC01 circuit board XFC01 circuit board.
1340 BROKEN SPEED The speed monitoring command cable is • Check the connection cable of the I/O
MONITOR LINE disconnected. contactor unit.
1341 BROKEN SPEED The error occurred in the speed monitoring • Check the cable connection between the
MONITOR LINE level signal. I/O contactor unit and the XFC01 circuit
(XFC01) • Disconnected cable between the I/O con-
board.
tactor unit and the XFC01 circuit board
• Check the cable connection between the
• Disconnected cable between the I/O con-
I/O contactor unit and the XCI01 circuit
tactor unit and the XCI01 circuit board
board.
• Defective I/O contactor unit
• Replace the I/O contactor unit and the
• Defective XFC01 circuit board
XFC01 circuit board.
10-29
RE-CTO-A203
Alarm Message List
Alarm
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. alarm occurred to make sure that no
[Axis Data] • Improper wiring of motor lines U, V and W.
external force has been applied.
• Wrong type of motor was used .
• Check the wiring of motor lines U, V and
• Motor was moved by an external force.
W.
• Reduce the teaching speed from the
• Defective motor (encoder)
speed when the alarm occurred to
check if the same error will occur. With
some taught postures, the R-, B-, or T-
axis may operate at a high speed during
linear interpolation. In this case, review
the teaching.
type is not correct, replace it with the
correct motor.
motor with correct one. If set data by
system configuration is not correct, set
the correct system configuration.
1343 COMMUNICATION The communication error occurred between • Check the connection of the WRCA01
ERROR the WRCA01 and the XFC01 circuit board. board and the XFC01 circuit board.
(XFC01) • Faulty connection between the WRCA01
• Replace the WRCA01 board and the
Robot/Station board and the XFC01 circuit board.
[Axis Data] • Defective WRCA01 board
10-30
RE-CTO-A203
Alarm Message List
Alarm
1344 COMMUNICATION The communication error occurred between • Check the encoder connection displayed
ERR the encoder and the XFC01 circuit board. in the axis data.
(ENCODER) (XFC01) • Improper wiring of encoder cables • Check that there is no device generating
Robot/Station • Noise from external devices excessive noise.
[Axis Data]
• Incorrect motor type • Check that the grounding of the control
• Defective XFC01 circuit board panel is correct.
• Defective encoder <Error in robot axis>
type is not correct, replace it with the
correct motor.
motor with correct one. If set data by
system configuration is not correct, set
the correct system configuration.
4000 MEMORY ERROR The tool file of CMOS memory was dam- Initialize the tool file in the maintenance
(TOOL FILE) aged. mode. Load the saved tool file in the
[Decimal Data] The data stands for the file No. external memory unit and restore.
4001 MEMORY ERROR The user coordinates file of CMOS memory Initialize the user coordinates file in the
(USER COORD FILE) was damaged. maintenance mode. Load the saved user
The data stands for the file No. coordinates file in the external memory
unit and restore.
4002 MEMORY ERROR The servo monitor signal file of CMOS Initialize the servo monitor signal file in the
(SV MON SIGNAL memory was damaged. maintenance mode. Load the saved servo
FILE) monitor signal file in the external memory
unit and restore.
4003 MEMORY ERROR The weaving condition file of CMOS mem- Initialize the weaving condition file in the
(WEAVING FILE) ory was damaged. maintenance mode. Load the saved
weaving condition file in the external
memory unit and restore.
4004 MEMORY The home position calibration file of CMOS Reset the home position calibration (abso-
ERROR(HOME POS memory was damaged. lute data) after reset the alarm. Load the
FILE) home position calibration file (absolute
data)in the external memory unit and
restore.
4005 MEMORY ERROR The specified point file of CMOS memory Load the specified point file in the external
(SPEC POINT DATA) was damaged. memory unit and restore.
4006 MEMORY ERROR The welder condition data file of CMOS Initialize the welder condition data file in
(WELDER COND memory was damaged. the maintenance mode. Load the saved
FILE) The data stands for the file No. welder condition data file in the external
[Decimal Data] memory unit and restore.
4007 MEMORY ERR The arc start condition file of CMOS mem- Initialize the arc start condition file in the
(ARC START COND ory was damaged. The data stands for the maintenance mode. Load the saved arc
FILE) file No. start condition file in the external memory
[Decimal Data] unit and restore.
10-31
RE-CTO-A203
Alarm Message List
Alarm
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. end condition file in the external memory
4009 MEMORY ERROR The welding condition assistance file of Initialize the welding condition assistance
(ARC AUX COND CMOS memory was damaged. file in the maintenance mode. Load the
FILE) The data stands for the file No. saved welding condition assistance file in
[Decimal Data] the external memory unit and restore.
4010 MEMORY ERROR The COM-ARC condition file of CMOS Initialize the COM-ARC condition file in
(COM-ARC COND memory was damaged. the maintenance mode. Load the saved
FILE) The data stands for the file No. COM-ARC condition file in the external
4012 MEMORY ERROR The link servo float condition file of CMOS Initialize the link servo float condition file
(LINK memory was damaged. in the maintenance mode. Load the
SERVOFLOAT ) The data stands for the file No. saved link servo float condition file in the
[Decimal Data] external memory unit and restore.
4013 MEMORY ERROR The linear servo float condition file of CMOS Initialize the linear servo float condition file
(LINEAR memory was damaged. in the maintenance mode. Load the
SERVOFLOAT) The data stands for the file No. saved linear servo float condition file in
4014 MEMORY ERROR The robot calibration file of CMOS memory Initialize the robot calibration file in the
(ROBOT CALIB FILE) was damaged. maintenance mode. Load the saved robot
[Decimal Data] The data stands for the file No. calibration file in the external memory unit
and restore.
4017 MEMORY ERROR The welder user definition file of CMOS Initialize the welder user definition file in
(WELDER memory was damaged. the maintenance mode. Load the saved
USER-DEF FILE) The data stands for the file No. welder user definition file in the external
4018 MEMORY ERR The ladder program file of CMOS memory Initialize the ladder program file in the
(LADDER PRG FILE) was damaged. maintenance mode. Load the saved
[Decimal Data] ladder program file in the external memory
unit and restore.
4020 MEMORY ERROR The operation origin file of CMOS memory Initialize the operation origin file in the
(OPERATION ORI- was damaged. maintenance mode.
GIN FILE) The data stands for the file No.
[Decimal Data]
4021 MEMORY ERROR The conveyor condition file of CMOS mem- Initialize the conveyor condition file in the
(CONVEYOR COND ory was damaged. maintenance mode. Load the saved con-
FILE) The data stands for the file No. veyor condition file in the external memory
4022 MEMORY ERROR The paint color condition file in the CMOS Initialize the paint color condition file in the
(PAINT SPECIAL memory was damaged. maintenance mode. Load the saved file in
FILE) The the data stands for the file number. the external memory unit and restore.
[Decimal Data]
4023 MEMORY ERROR The painting condition file in the CMOS Initialize the painting condition file in the
(PAINTING COND memory was damaged. maintenance mode. Load the saved con-
FILE) The data stands for the file number. dition file in the external memory unit and
[Decimal Data] restore.
4025 MEMORY ERROR The interrupt jog file in the CMOS memory Initialize the interrupt jog file in the mainte-
(INTERRUPT JOB was damaged. nance mode.
FILE) The data stands for the file number.
10-32
RE-CTO-A203
Alarm Message List
Alarm
4028 MEMORY ERROR The sensor monitoring condition file of Initialize the sensor monitoring condition
(SENSOR MON CMOS memory was damaged. file in the maintenance mode. Load the
COND FILE) The data stands for the file No. saved sensor monitoring condition file in
4031 MEMORY ERROR The spot gun condition data file of Initialize the spot gun condition data file in
(GUN COND FILE) CMOS memory was damaged. the maintenance mode. Load the saved
[Decimal Data] The data stands for the file No. spot gun condition data file in the external
4032 MEM ERROR The spot welder condition data file of CMOS Initialize the spot welder condition data file
(SPOT WELDER memory was damaged. in the maintenance mode. Load the saved
COND FILE) The data stands for the file No. spot welder condition data file in the exter-
[Decimal Data] nal memory unit and restore.
4033 MEMORY ERROR The gun pressure file of CMOS memory Initialize the gun pressure file in the main-
(GUN PRESSURE was damaged. tenance mode. Load the saved servo gun
FILE) The data stands for the file No. pressure file in the external memory unit
[Decimal Data] and restore.
4034 MEMORY ERROR The anticipation output file of CMOS mem- Initialize the anticipation output file in the
(ANTICIPATION OT ory was damaged. maintenance mode.
FILE) The data stands for the file No. Load the saved anticipation output file in
4035 MEMORY ERROR The anticipation output file of CMOS mem- Initialize the anticipation output file in the
(ANTICIPATION OG ory was damaged. maintenance mode.
FILE) The data stands for the file No. Load the saved anticipation output file in
4036 MEMORY ERROR The wearing file of CMOS memory was Initialize the wearing file in the mainte-
(WEARING FILE) damaged. nance mode. Load the saved wearing file
[Decimal Data] The data stands for the file No. in the external memory unit and restore.
4037 MEMORY ERROR The stroke position file of CMOS memory Initialize the stroke position file in the
(STROKE POSITION) was damaged. maintenance mode. Load the saved
[Decimal Data] The data stands for the file No. stroke position file in the external memory
unit and restore.
4038 MEMORY ERROR The pressure file of CMOS memory was Initialize the pressure file in the mainte-
(PRESSURE FILE) damaged. nance mode. Load the saved pressure file
[Decimal Data] The data stands for the file No. in the external memory unit and restore
4039 MEMORY ERROR The form cut file of the CMOS memory was Initialize the form cut file in the mainte-
(FORM CUT FILE) damaged. The data stands for the file No. nance mode. Load the saved formcut file
[Decimal Data] in the external memory unit and restore
4040 MEMORY ERROR The shock level file of the CMOS memory Initialize the shock level file in the mainte-
(SHOCK LEVEL was damaged. The data stands for the file nance mode.
FILE) No. Load the saved shock level file in the
4041 MEMORY ERROR The spot IO allocate file of the CMOS mem- Initialize the spot IO allocate file in the
(SPOT IO ALLOCTE ory was damaged. maintenance mode.
FL) Load the saved spot IO allocate file in the
4042 MEMORY ERROR The vision file of the CMOS memory was Initialize the vision file in the maintenance
(VISION FILE) damaged. mode.
[Decimal Data] The data stands for the file No. Load the saved vision file in the external
10-33
RE-CTO-A203
Alarm Message List
Alarm
4043 MEMORY ERROR The vision calibration of the CMOS memory Initialize the vision calibration in mainte-
(VISION CALIBRA- was damaged. nance mode.
TION) The data stands for the file No. Load the saved vision calibration in the
4044 MEMORY ERROR The welding pulse condition file in the Initialize the welding pulse condition file in
(WELDING PULSE CMOS memory was damaged. maintenance mode.
COND FILE) The data stands for the file number. Load the saved condition file in the exter-
4045 MEMORY ERROR The welding pulse selection file in the Initialize the welding pulse selection file in
(WELDING PULSE CMOS memory was damaged. maintenance mode.
SELECTION FILE) The data stands for the file number. Load the saved selection file in the exter-
[Decimal Data} nal memory unit and restore.
4046 MEMORY ERROR The conveyor calibration in the CMOS Initialize the conveyor calibration in main-
(CONVEYOR CALI- memory was damaged. tenance mode.
BRATION) The data stands for the file number. Load the saved calibration in the external
4047 MEMORY ERROR The macro definition file in the CMOS mem- Initialize the macro definition file in main-
(MACRO DEFINI- ory was damaged. tenance mode.
TION FILE) The data stands for the file number. Load the saved definition file in the exter-
4048 MEMORY ERROR The sealer gun condition file in the CMOS Initialize the sealer gun condition file in the
(SERVO S-GUN memory was damaged. maintenance mode.
FILE) Load the saved condition file in the exter-
nal memory unit and restore.
4049 MEMORY ERROR The seal amount correction condition file in Initialize the seal amount correction condi-
(PASTE QUAN COM- the CMOS memory was damaged. tion file in maintenance mode.
PENSATION FILE) Load the saved condition file in the exter-
4050 MEMORY ERROR The axis motion I/O allocation file in the Initialize the axis motion I/O allocation file
(AXIS I/O ALLOCA- CMOS memory was damaged. in maintenance mode.
TION FILE) Load the saved I/O allocation file in the
external memory unit and restore.
4051 MEMORY ERROR The gun condition auxiliary file in the CMOS Initialize the gun condition auxiliary file in
(GUN COND AUX memory was damaged. maintenance mode.
FILE The data stands for the file number. Load the saved file in the external mem-
[Decimal Data] ory unit and restore.
4052 MEMORY ERROR The tool interference file in the CMOS mem- Initialize the tool interference file in main-
(TOOL INTERFER- ory was damaged. tenance mode.
ENCE FILE) The data stands for the file number. Load the saved file in the external mem-
4053 MEMORY ERROR The painting system setting file in the Initialize the painting system setting file in
(PAINTING SYSTEM CMOS memory was damaged. maintenance mode.
CONFIGURATION) The data stands for the file number. Load the saved setting file in the external
4054 MEMORY ERROR The painting device condition file in the Initialize the painting device condition file
(PAINTING SPECIAL) CMOS memory was damaged. in maintenance mode.
[Decimal Data] The data stands for the file number. Load the saved file in the external mem-
ory unit and restore.
4055 MEMORY ERROR The painting CCV file in the CMOS memory Initialize the painting CCV file in mainte-
(CCV-PAINT TABLE) was damaged. nance mode.
10-34
RE-CTO-A203
Alarm Message List
Alarm
4056 MEMORY ERROR The painting filling file in the CMOS memory Initialize the painting filling file in mainte-
(PLUG VOLUME was damaged. nance mode.
FILE) The data stands for the file number. Load the saved file in the external mem-
4057 MEMORY ERROR The EVB gun file in the CMOS memory was Initialize the EVB gun file in maintenance
(EVB GUN SPECIAL damaged. mode.
4058 MEMORY ERROR The EVB turbine file in the CMOS memory Initialize the EVB turbine file in mainte-
(EVB TURBINE was damaged. nance mode.
SPECIAL FILE) The data stands for the file number. Load the saved file in the external mem-
4059 MEMORY ERROR The EVB paint file in the CMOS memory Initialize the EVB paint file in maintenance
(EVB PAINT was damaged. mode.
SPECIAL FILE) The data stands for the file number. Load the saved file in the external mem-
4060 MEMORY ERROR The clearance file in the CMOS memory Initialize the clearance file in maintenance
(CLEARANCE FILE) was damaged. mode.
4061 MEMORY ERROR The gaging sensor file in the CMOS mem- Initialize the gaging sensor file in mainte-
(GAGING SENSOR ory was damaged. nance mode.
4062 MEMORY ERROR The linear scale condition file in the CMOS Initialize the linear scale condition file in
(LINEAR SCALE memory was damaged. maintenance mode.
4063 MEMORY ERROR The conveyor condition auxiliary file in the Initialize the conveyor condition auxiliary
(CONVEYOR COND CMOS memory was damaged. file in maintenance mode.
SUPP.) The data stands for the file number. Load the saved auxiliary file in the exter-
4064 MEMORY ERROR The weaving synchronizing welding condi- Initialize the weaving synchronizing weld-
(WEAVING SYN- tion file in the CMOS memory was dam- ing condition file in maintenance mode.
CHRONIZING WELD aged. Load the saved condition file in the exter-
FILE) The data stands for the file number. nal memory unit and restore.
[Decimal Data]
4100 OVERRUN IN One of the robot axis overrun limit switches Reset the overrun.
ROBOT AXIS was operated.
[Bit Pattern]
4101 OVERRUN IN One of the external axis overrun limit Reset the overrun.
EXTERNAL AXIS switches was operated.
[Bit Pattern]
4102 SYSTEM DATA HAS An attempt was made to change data which Turn off the power once and back on.
BEEN CHANGED exerted the influence on the system and
[Decimal Data] turned on the servo power supply.
The data stands for the alarm factor.
1:System parameter change
10-35
RE-CTO-A203
Alarm Message List
Alarm
4103 PARALLEL START The error occured in the independent 1:Complete the sub task by PWAIT
INSTRUCTION control start operation. comand.
ERROR The data stands for alarm factor. 2:Check that the job started and the timing
[Decimal Data] 1:The sub task is being executed. of execution for start comand again.
The job was executed by instructed sub 3:Check that the job started and the timing
task, but another job was being started in of execution for start comand again.
the sub task. 4:Register the master job for sub task.
2:The group axis is being used 5:Check that the job started and the timing
The job operated by other sub task used of execution for start comand again.
same group axis. 6:Start after reset the alarm.
3:Multiple start of same job 7: Check the PSTART command again.
The job tried to start was executed by 8: Check the PSTART command again.
other sub task.
4:Master job unregistration
Though master job was not registered,
The attempt was made to execute
PSTART SUB(job name omitted)
5:Synchronization instruction error
When restarted by PSTART, synchroniza
tion instruction status of sub task under
interruption was different than the status
to restart.
6:The alarm is stopping
The attempt was made to start sub task
under stop by alarm.
7: SYNC synchronized task designation
omit error
The start sub-task omits the synchronized
task designation between SUB3 and
SUB5.
8: SYNC synchronized task designation
error
The same task is designated in SYNC.
4104 WRONG EXECU- When the installation was executed, the Correct the error according to the data of
TION OF LOAD INST error occured in DCI function. the alarm factor after reset the alarm.
[Decimal Data] The data stands for the alarm factor.
Refer to the data transmission functionman-
ual for details.
4105 WRONG EXECU- When the installation was executed, an Correct the error according to the data of
TION OF SAVE INST error occured in DCI function. the alarm factor after resetting the alarm.
Refer to the data transmission function
manual for details.
4106 WRONG EXECU- When the installation was executed, the Correct the error according to the data of
TION OF DELETE error occured in DCI function. the alarm factor after resetting the alarm.
INST The data stands for the alarm factor.
[Decimal Data] Refer to the data transmission function
manual for details.
4107 OUT OF RANGE The difference between the position of the Operate axis for robot /station to set the
(ABSO DATA) power supply off and the power supply on current value 0 position and check the
Robot/Station exceeded tolerance for the robot / station. original mark (arrow).
[Axis Data] If not matched, there is an error of PG
system for the axis where the error
occurred. Please check.
10-36
RE-CTO-A203
Alarm Message List
Alarm
4109 DC 24V POWER The external 24V power supply was not out- • Check whether fuse for I/O contactor unit
SUPPLY FAILURE put. is cut or not.
• Check the external 24V power supply.
• Check the connection of communication
cable for I/O module. (XCP01 CN01-
XIU01 CN03 cable)
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 DATA SENDING When the data transmission function was Correct the error according to the data of
ERROR used, the error occurred. the alarm factor after resetting the alarm.
1:Retryover of NAK
2:Retryover of timeout in timer A
3:Retryover of mutual response error
4113 DATA RECEIVING When the data transmission function was Correct the error according to the data of
ERROR used, the error occurred. the alarm factor after resetting the alarm.
1:Reception timeout (timer A)
2:Reception timeout (timer B)
3:Heading length is short.
4:Heading length is long.
5:The heading No. error.
6:The text length exceeds 256 characters.
4114 TRANSMISSION When the data transmission function was Correct the error according to the data of
HARDWARE ERROR used, the error occurred. the alarm factor after resetting the alarm.
1:Overrun error
2:Parity error
3:Flaming error
4:Transmission timeout (timer A)
5:Transmission timeout (timer B)
4115 TRANSMISSION When the data transmission function was Correct the error according to the data of
SYSTEM BLOCK used, the error occurred. (Though the trans- the alarm factor after resetting the alarm.
[Decimal Data] mission procedure is correct, there is a
reception that irrationality is caused in sys-
tem. This error is mainly caused by PC
breached the rule or abnormal communica-
tion.)
The data stands for the alarm factor.
1:Received EOT when waiting ACK.
2:Received EOT when waiting ENQ.
3:Received EOT before last block reception
4:Received codes for except EOT after last
block reception.
4116 TRANSMISSION An error occurs in the internal processing of An investigation is required. Contact your
SYSTEM ERROR the transmission system. Yaskawa representative.
[Decimal Data]
10-37
RE-CTO-A203
Alarm Message List
Alarm
4117 SERVO POWER It is thought that the CPU rack, circuit board • Check whether the setting is the same
INPUT SIGNAL was abnormal. as the system or not(robot and external
ERROR axis)
4119 FAN ERROR The axis was instructed to turn servo on and Make the condition so as to be able to turn
(IN CONTROL BOX) off separately. servo on and off after resetting the alarm.
4120 IMPOSSIBLE TO Some axes were instructed and cannot turn After resetting the alarm, adjust the axes
DISCONNECT the servo on or off. so that the servo power can be turned on
SERVO and off.
[Control Group]
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. Contact your Yaskawa representative to
replace the cooling fan 1.
4127 U-AXIS TIMING BELT An error was detected in the drive belt of the Perform an overrun release, move the
BLOWN U-axis. robot to the posture for replacement, and
replace the belt.
4200 SYSTEM ERROR When acess to the file data was executed, • Reset the alarm and repeat the opera-
(FILE DATA) the error occured. (File edition, Operation of tion.
[Decimal Data] external memory unit)
• Turn the power off then back on.
4201 SYSTEM When access to the job was executed, the • Reset the alarm and repeat the opera-
ERROR(JOB) error occured. tion.
[Decimal Data] (During robot is being playback and opera- • Turn the power off then back on.
tion)
4202 SYSTEM When acess to the job was executed, the • Reset the alarm and repeat the opera-
ERROR(JOB) error occured. tion.
[Decimal Data] (Job edition, Operation of external memory
unit)
4203 SYSTEM ERROR When acess to the position data was exe- • Reset the alarm and repeat the opera-
(POSITION DATA) cuted, the error occured. tion.
[Bit Pattern] (During playback and operation)
10-38
RE-CTO-A203
Alarm Message List
Alarm
4204 SYSTEM ERROR When access to the position data was exe- • Reset the alarm and repeat the opera-
(POSITION DATA) cuted, the error occured. tion.
[Decimal Data] (Job/position variable edition, Operation of • Turn the power off then back on.
external memory unit)
4206 SYSTEM ERROR When the data transmission function was Needs investigation.
(TRANSMISSION) used, the error occured. Consult a YASKAWA representative.
[Decimal Data] The error of internal procedure for transmis-
sion system.
4207 SYSTEM The system error occured in MOTION. • Reset the alarm and repeat the opera-
ERROR(MOTION) tion.
[Decimal Data]
4208 SYSTEM ERROR The system error occured in ARITH. • Reset the alarm and repeat the opera-
(ARITH) tion.
[Decimal Data] • Turn the power off then back on.
4209 OFFLINE SYSTEM The system error occured in ARITH offline. • Reset the alarm and repeat the opera-
ERROR tion.
(ARITH)
[Decimal Data]
4220 SERVO POWER OFF The servo power supply was not turned on Intercept the servo power supply once
FOR JOB for the job group axis which was to be oper- and turn on the servo power supply to the
[Control Group] ated. group axis to be operated.
4221 SERVO POWER OFF The servo power supply was not turned on Intercept the servo power supply once
FOR JOB for the job group axis which was to be oper- and trun on the servo power supply to the
[Control Group] ated. group axis to be operated.
4222 SAFE CIRCUIT SIG The error occurred in the safe circuit signal • Check the safe circuit signal wiring of the
NOT SAME (I/O contactor unit). (Check the XCI01 cir- cables connected to the I/O contactor
(XCI01) cuit board duplication signal.)
unit.
[Binary Data]
• Replace the I/O contactor unit.
4223 SAFE CIRCUIT SIG- The error occurred in the safe circuit signal • Check the safe circuit signal wiring of the
NAL NOT SAME (I/O contactor unit). (Check the WRCA01 cables connected to the I/O contactor
(SV) board duplication signal.)
unit.
[Decimal Data] The data stands for the following error sig-
• Replace the I/O contactor unit.
nals:
1: IORDY
2: ON_EN
3: OVSPD
4: SVMAIN
5: EXOT
6: SVMX
7: KMMB
8: KMMA
4300 VERIFY ERROR A mistake was found in the parameter Needs investigation.
(SERVO PARAME- related to servo control. Consult a YASKAWA representative.
TER)
[Decimal Data]]
10-39
RE-CTO-A203
Alarm Message List
Alarm
4301 CONTACTOR • The contactor of the contactor unit was not • Turn servo ON again after resetting the
ERROR turned ON at servo ON. alarm.
[Bit Pattern] • While turning servo ON, the signal from • If the error occurs again, replace the
the contactor was intercepted .
contactor unit, WRCA01 circuit board.
• The contactor signal was not intercepted at
servo OFF(at emergency stop).
• While turning servo OFF(at emergency
stop), the contactor signal was turned ON.
Reasons are as follows:
• Defective contactor unit
4302 BRAKE CIRCUIT • The brake relay signal unit was not turned • Reset the alarm and turn servo ON
ERROR ON at servo ON. again.
[Bit Pattern] • While turning servo ON, the brake relay • If the error occurs again, replace the
signal was intercepted .
contactor unit, WRCA01 circuit board.
• The brake relay signal was not intercepted
at servo OFF(at emergency stop).
stop), the brake relay signal was turned
ON.
• Defective contactor unit
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. • Check the primary power supply voltage
[Bit Pattern]
• While turning servo ON, the servo ready (220V+10%).
signal was intercepted . • If the error occurs again, replace the
• The servo ready signal was not inter- WRCA01 circuit board, the converter.
cepted at servo OFF(at emergency stop).
stop), the servo ready signal was turned
ON.
• Primary side power supply voltage was too
low.
• Because the power supply cable of pri-
mary side was too fine or its cable was too
long, the voltage drop occurred at servo
ON.
• Defective WRCA01,WRCF01 circuit board
10-40
RE-CTO-A203
Alarm Message List
Alarm
4304 CONVERTER INPUT • There was no response(ready 1 signal) of • Check the connection for primary side
POWER ERROR primary power supply input from convertor wiring R,S,T, wire.
[Bit Pattern] at servo ON. • Check that the power supply voltage is
• While turning servo ON, the ready 1 signal more than 170V.
was intercepted . • If the error occurs again, replace the
• The ready 1 signal was not intercepted at WRCA01 circuit board, WRCF01 circuit
servo OFF(at emergency stop). board, the converter.
stop), the ready 1 signal was turned ON .
• Mistaken wiring of connection for primary
side power supply.
• The drop of primary side power supply
(less than170V).
long, the voltage drop occurred at servo
ON.
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.
ERROR
ON. • Replace the amplifier.
[Bit Pattern]
• While turning servo ON, the ready 2 signal • If the error occurs again, replace the
was intercepted . WRCA01 circuit board, WRCF01 circuit
• The ready 2 signal was not intercepted at board, the converter.
servo OFF(at emergency stop).
stop), the ready 2 signal was turned ON .
• Mistaken wiring of connection for primary
side power supply.
• The drop of primary side power supply
(less than170V).
long, the voltage drop occured at servo
ON.
• Defective amplifier(There is a possibility
that power circuit was short-circuited inter-
nally.)
10-41
RE-CTO-A203
Alarm Message List
Alarm
4306 AMPLIFIER READY • There was no response(amp ready signal) • Reset the alarm and turn servo ON
SIGNAL ERROR of energizing completed from amplifier at again.
[Bit Pattern] servo ON. • If the error occurs again, replace the
• While turning servo ON, the amp ready WRCA01 circuit board, WRCF01 circuit
signal was intercepted. board, the converter.
• The amp ready signal was not intercepted
at servo OFF(at emergency stop).
stop), the amp ready signal was turned
ON.
• Defective amplifier(There is a possibility
that power circuit was short-circuited inter-
nally.)
4307 SERVO ON DEFEC- • While encoder was rotating, the servo Check the timing of turning on servo
TIVE SPEED power supply was turned on. Impossible to power supply again.
Robot/Station
turn on control power supply in the rotation
[Axis Data]
• The no brake axes, R,B,T axis for SK6,
freely fell when the servo power supply
was turned off by emergency stop. When
the servo control power supply was turned
back on this status, this alarm occured.
4308 VOLTAGE DROP • Direct current power supply voltage sup- • Check the connection for primary side
(CONVERTER) plyed to amplifier for servopack has wiring R,S,T, wire.
[Bit Pattern]
become less than143V. • Check that power supply voltage is more
Reason is follows: than 170V.
• Primary power supply voltage was too low. • If the error occurs again, replace the
• There was open phase. WRCA01, WRCF01 circuit board, the
• Defective converter converter.
• Defective WRCA01circuit board
4309 DEFECTIVE The internal parameter error for serial • Turn the power off then back on. If a
ENCODER INTER- encoder. It is thought the encoder was phenomenon occurs again after repeat-
NAL DATA abnormal.
ing this operation several times, replace
Robot/Station
[Axis Data] the motor(encoder) for axis occured the
error.
• If the error occurs again, consult with a
4310 ENCODER OVER- The encoder has overheated to 100 • Check that the ambient temperature is
HEAT degrees. not too high.
Robot/Station
• Check the load again.
[Axis Data]
• Chech the primary power supply voltage
(220V+10%).
WRCA01 circuit board, the encoder.
10-42
RE-CTO-A203
Alarm Message List
Alarm
4311 ENCODER BACK-UP • Because backup power supply voltage for • Reset the alarm. Adjust the home posi-
ERROR encoder decreased(less than 2.6V), position again.
Robot/Station tion data of the encoder disappered. • Check the battery voltage for encoder.
[Axis Data]
• Whenever a new motor was used, this (more than 2.8V)
error occurred. • Replace the battery.
encoder.
• Because it is charged the backup con-
denser, don't turn off power supply for a
few minutes.
4312 ENCODER BAT- Voltage of backup battery for encoder has • Check the battery voltage for encoder.
TERY ERROR decreased.(less than 2.8V) (more than 2.8V)
Robot/Station (In case leaving this voltage as it is, the
• Replace the battery.
[Axis Data] backup error occurs and position data dis-
appears.)
4313 SERIAL ENCODER The encoder has overheated to 100 • Check that the ambient temperature is
OVER HEAT degrees. not too high.
Robot/Station
• Check the load again.
[Axis Data]
• Check the primary power supply voltage
(220V+10%).
WRCA01 circuit board, the encoder.
4314 SERIAL ENCODER Voltage of backup battery for encoder has • Check the battery voltage for encoder.
BATTERY ERROR decreased.(less than 2.8V)(In case leaving (more than 2.8V)
Robot/Station this voltage as it is, the backup error occurs
• Replace the battery.
[Axis Data] and position data disappears.)
4315 COLLISION DETECT • A collision from interferrence between • Remove the object after resetting the
Robot/Station robot and peripheral device etc. was alarm or move the robot to the safety
[Axis Data]
detected. position.
• The collision was mis-detected by the nor- • When the alarm cannot be reset
mal movement of the robot, because the because the robot comes in contact with
detection level was small. the object, invalidate this function in the
collision detection level set file or enlarge
the detection level and move the robot to
the safety position.
• Enlarge the detection level so as not to
mis-detect the collision detection by the
normal movement of the robot. More-
over, set accurate information of the
weight of the tool.
4316 PRESSURE DATA The value of pressure in the "GUN PRES- Change the value of pressure in the
LIMIT SURE" file or the "PRESSURE" file exceeds "GUN PRESSURE" file or the "PRES-
the maximum pressure in the "GUN CONDI- SURE" file below the maximum pressure.
TION" file.
4400 NOT READY (ARITH) The operation process of motion control • Reset the alarm and repeat the opera-
[Decimal Data] does not end in regulated time. tion.
10-43
RE-CTO-A203
Alarm Message List
Alarm
4401 SEQUENCE TASK The error has occured in job exec statement • Reset the alarm and repeat the opera-
CONTR ERROR part. tion.
[Decimal Data] • If the error occurs again, contact your
4402 UNDEFINED COM- The instruction not defined was demanded • Reset the alarm and repeat the opera-
MAND(ARITH) of the path operation process. tion.
4404 ARITHMETIC The control error occured in the path opera- • Reset the alarm and repeat the opera-
ERROR tion process. tion.
[Decimal Data]
4405 SELECT ERROR The control error occured in the path opera- • Reset the alarm and repeat the opera-
(PARAMETER) tion process. tion.
4406 GROUP AXIS CON- When operating cooperative control, the • Reset the alarm and repeat the opera-
TROL ERROR control error occured in the path operation tion.
[Decimal Data] process.
4407 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. points again.
(CIRC)
POSITION same point of two points or more. points again.
(SPLINE)
POSITION same point of two points or more. (User points again.
(3 POINTS) coordinates, robots calibration, etc.)
4410 TWO STEPS SAME The weaving base point was the same as Reset the alarm. Teach the different 3
POSITION the wall point. points again.
(WEAV)
4411 TEACH ERROR It was not an equidistant distance between Teach again to be an even distance
(SPLINE) teaching points. between teaching point
4412 IMPOSSIBLE LINEAR In case the form of L,U axis for start point Make the form of L,U axis same and teach
MOTION and end point were different in interpolation again.
(L/U) motion except MOJV, it was not possible to
operate.
4413 IMPOSSIBLE LINEAR In case the form of S, L axis for start point Make the form of S, L axis the same and
MOTION and end point were different in interpolation teach again.
(S/L) motion except MOJV, it was not possible to
operate.
4414 EXCESSIVE SEG- It exceeded rated speed of the motor at a Reset the alarm. Reduce the speed of the
MENT specified speed. step (Move instruction) occurred the alarm
(LOW SPEED) or change the robot pose.
Robot/Station
[Axis Data]
10-44
RE-CTO-A203
Alarm Message List
Alarm
4415 EXCESSIVE SEG- It exceeded rated speed of the motor at a Reset the alarm. Reduce the speed of
MENT specified speed. step (Move instruction) occurred the alarm
(HIGH SPEED) or change the robot pose.
Robot/Station
[Axis Data]
4416 PULSE LIMIT (MIN.) It exceeded pulse software limit. Release the alarm and teach again
Robot/Station according to the release method when
[Axis Data] software limit range is exceeded.
4417 PULSE LIMIT (MAX.) It exceeded pulse software limit. Release the alarm and teach again
Robot/Station according to the release method when
[Axis Data] software limit range is exceeded.
4418 CUBE LIMIT (MIN.) The tool control point exceeded cube soft- Release the alarm and teach again
Robot/Station ware limit. according to the release method when
[XYZ] software limit range is exceeded.
4419 CUBE LIMIT (MAX.) The tool control point exceeded cube soft- Release the alarm and teach again
Robot/Station ware limit. according to the release method when
[XYZ] software limit range is exceeded.
4420 SPECIAL SOFTLIMIT It exceeded pulse software limit. Release the alarm and teach again
(MIN.) according to the release method when
Robot/Station software limit range is exceeded.
[Axis Data]
4421 SPECIAL SOFTLIMIT It exceeded pulse software limit. Release the alarm and teach again
(MAX.) according to the release method when
[Axis Data]
4422 MECHANICAL An abnormal (reverse) axis interfered mutu- Reset the alarm. Release the interference
INTERFERENCE ally. and teach again.
(MIN.)
Robot/Station
[Axis Data]
4423 MECHANICAL An abnormal (reverse) axis interfered mutu- Reset the alarm. Release the interference
INTERFERENCE ally. and teach again.
(MAX.)
Robot/Station
[Axis Data]
4424 SPECIAL MECHANI- An abnormal (reverse) axis interfered mutu- Reset the alarm. Release the interference
CAL INTRF (MIN.) ally. and teach again
Robot/Station
[Axis Data]
4425 SPECIAL MECHANI- An abnormal (reverse) axis interfered mutu- Reset the alarm. Release the interference
CAL INTRF (MAX.) ally. and teach again.
Robot/Station
[Axis Data]
4426 PULSE MECHANI- It exceeded pulse software limit. Release the alarm and teach again
CAL LIMIT (MIN.) according to the release method when
[Axis Data]
4427 PULSE MECHANI- It exceeded pulse software limit. Release the alarm and teach again
CAL LIMIT (MAX.) according to the release method when
[Axis Data]
10-45
RE-CTO-A203
Alarm Message List
Alarm
4428 SEGMENT CON- The error occurred in data and the timing of • Reset the alarm and repeat the opera-
TROL ERROR the processing part where the operation part tion.
[Decimal Data] was controlled. • If the error occurs again, contact your
4429 WRONG SPECIFIED The error occurs in information on the robot • Reset the alarm and repeat the opera-
CONTROL GROUP which uses for the job interpretation and the tion
[Decimal Data] motion control.
4430 CPU COMMUNICA- When interrupting various circuit board from • Reset the alarm and repeat the opera-
TION ERROR the XCP01 circuit board, interrupted boards tion.
[Decimal Data] were not prepared or didn't respond.
4431 JHM ERROR The data was abnormal in the job control • Reset the alarm and repeat the opera-
[Decimal Data] process. tion.
4432 INSTRUCTION The error occurred in the job interpretation • Reset the alarm. Select job and repeat
INTERPRETER exec statement part. the operation.
ERROR
• If the error occurs again, operate by the
[Decimal Data]
following procedure:
Delete the command that caused the
alarm and register again and start exe-
cution.
Delete the job that cause the alarm and
register again and start execution.
4433 UNDEFINED GLO- The global variable range was undefined. Needs investigation at YASKAWA. Con-
BAL VARIABLE sult a YASKAWA representative.
[Decimal Data]
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:
cution.
Delete the job that cause the alarm and
register again and start execution.
4435 UNDEFINED LOCAL- The local variable was undefined. Set the local variable used for sub header
VARIABLE of job.
[Bit Pattern]
4436 LESS THAN 3 A circle step didn't contain a minimum of 3 Reset the alarm. Teach at least 3 consec-
STEPS(CIRCULAR) consecutive points. utive points for the circle step.
[Decimal Data]
4437 LESS THAN 3 A spline interpolation designation step didn't Reset the alarm. Teach at least 3 onsecu-
STEPS(SPLINE) contain a minimum of 3 consecutive points. tive points for the spline interpolation des-
ignation step.
10-46
RE-CTO-A203
Alarm Message List
Alarm
4438 UNDEFINED JOB Job was not registered. Reset the alarm and register job. Or
[Decimal Data] Delete CALL, JUMP instruction caused
the alarm.
4439 UNDEFINED LABEL No labels existed in the currently executing Reset the alarm and register job . Or
[Decimal Data] job. Delete CALL, JUMP instruction occured
the alarm.
4440 UNDEFINED The job call stack contained no return. Reset the alarm and start execution from
RETURN JOB the master job. Or delete RET instruction.
[Decimal Data]
4441 LACK OF LOCAL- Too many local variables used in the job. Reset the alarm and reduce the use num-
VARIABLE AREA ber of the local variables
[Decimal Data]
4442 LOCAL-VARIABLE When job was executed, the error occurred • Reset the alarm. Select job and repeat
CONTROL ERROR in control process of local variable. the operation.
[Decimal Data]
• If the error occurs again, operate by fol-
lowing procedure:
cution.
Delete the job that caused the alarm
and register again and start execution.
4443 JOB CALL STACK At the job CALL, RET, END instruction, • Reset the alarm. Select the job again
ERROR when operating the job call stack, internal and repeat the operation.
[Decimal Data] control data of inside was abnomal.
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. robot to remove the external force and
• Excessive external force repeat the operation.
• The servopack, the motor were abnormal. • In case the phenomenon occurs again
without any external force, try to insert
the XCP01 circuit board again.
4445 DATA PRESET When the interpretation process section of • Reset the alarm. Select the job and
ERROR job annuled the content of interpretation and repeat the operation.
[Decimal Data] started to interpret again, various kinds of
data were attempted to be initialized. At the
time,a disagreement of data occured.
4446 OVER VARIABLE The range of the numerical value of the vari- Increase the variable range at the storage
LIMIT able for storage destination was exceeded. destination or rewrite the job to bring the
[Decimal Data] number of variables in range.
4447 DEFECTIVE TAUGHT A straight line linked the three points. Reset the alarm and teach again.
POINT
(CIRC)
10-47
RE-CTO-A203
Alarm Message List
Alarm
4448 WEAVING CON- When executing the weaving motion control, • 4:Set 0.1 seconds or more in the moving
TROL ERROR the control error occurred in the path opera- time of weaving file.
[Decimal Data] tion process. • 5:Set 0.1 hertz or more in the frequency
Data stands for the alarm factor.
of weaving file.
4:Weaving speed instruction was moving
time instruction, moving time was less • 6:Set a positive value in the stopping
than 0. time of weaving file.
5:Weaving speed instruction was frequency • 7:Set 1mm or more in the vertical direc
instruction, frequency was less than 0. tion, horizontal direction distance of
6.Weaving stopping time was negative
weaving file.
7:Vertical direction distance at or horizontal
direction distance was 0 in triangular • If the error occurs again, contact your
wave, L type weaving. YASKAWA representative.
9:Distance between P point and control
point was less than 0 in the wrist weaving
Except above:Control error
4449 UNMATCHED POSN The data types(pulse, Cartesian) of the Match the data types(pulse, Cartesian) of
VAR DATA TYPE stored data and the storage destination are the stored data and the storage destina-
[Bit Pattern] different. tion.
4450 FILE NO. ERROR The error occured during file No. check. • Reset the alarm. Select the job and
[Decimal Data] repeat the operation.
4451 UNDEFINED REFER- No reference point was registered or insuffi- Correctly register reference points.
ENCE POINT cient reference points were registered.
[Bit Pattern]
4452 STACK MORE THAN The job call stack overflowed. Reset the alarm and modify the job to
8 (JOB CALL) reduce the jobs in the job call stack.
[Decimal Data]
4453 OVER VARIABLE A variable number was out-of-range. Modify the job by using the permitted vari-
NO. able number.
[Bit Pattern]
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.
START COND FILE
[Decimal Data]
4456 UNDEFINED ARC The arc end condition file was not set. Set the arc end condition file.
END COND FILE
[Decimal Data]
4457 WRONG WELDER The arc voltage command units didn't match Match the arc voltage command units.
SELECTION the welder power supply (individual,unified).
[Decimal Data]
4458 EQUATION EXCEP- When executing equation of SET instruc- • Reset the alarm and repeat the opera-
TION ERROR tion, the item of the equation which couldn't tion.
[Decimal Data] be executed was attempted. • If the error occurs again, operate the fol-
lowing procdure:
alarm and register again.
Delete the job that caused the alarm
and register again.
10-48
RE-CTO-A203
Alarm Message List
Alarm
4459 EXCESSIVE An equation was too long. Divide up the equation to reduce its
INSTRUCTION length.
EQUATION
[Decimal Data]
4460 ZERO DIVIDED A division by zero was attempted. Set not to divide by zero.
OCCURRENCE
[Decimal Data]
4461 UNDEFINED AUTO Number of automatic sticking release Set the number of automatic sticking
WELD RELEASE attempts was set to zero in the arc auxiliary release attempts and repeat the opera-
COND file. tion.
[Decimal Data]
4462 UNDEFINED POSI- Arc retry was set but no move instruction Set a move instruction after ARCON.
TION FOR ARC exists after ARCON.
RETRY
[Decimal Data]
4463 PARITY ERROR General I/O group parity error. Stop parity error from occuring.
4464 OVER BCD RANGE • An attempt was made to output a value • Reset the data in the permitted range.
which exceeded the maximum BCD value • Check the designated data (BCD/binary)
limit of 99 (decimal) without parity or 79 and parity check.
(decimal) with parity.
• An attempt was made to read data which
couldn't be represented as BCD (most-or
least-significant 4 bits are 9 or above) to a
variable.
4465 OVER BINARY An attempt was made to output a value • Reset the data in the permitted range.
RANGE exceeding 127(decimal) while the parity • Review the parity check.
(PARITY CHECK) check was designated.
4466 OFFLINE UNDE- Undefined instruction was required for soft- • Reset the alarm and repeat the opera-
FINED COM- ware for off-line path arithmetic of the tion.
MAND(ARITH) XCP01 circuit board.
[Decimal Data]
4468 ROBOT CALIBRA- The error occured in the process of making • Reset the alarm and repeat the opera-
TION DATA ERROR robot calibration data. tion.
[Decimal Data]
4469 ROBOT CALIBRA- The error occured in frame conversion pro- • Reset the alarm and repeat the opera-
TION FRAME cess of robot calibration data tion.
ERROR • If the error occurs again, contact your
[Decimal Data]
4471 CALIBRATION DATA The error occured in the process of making • Reset the alarm and repeat the opera-
ERROR calibration data. tion.
[Decimal Data]
4472 TOOL CALIBRATION The error occured in the process of making • Reset the alarm and repeat the opera-
DATA ERROR calibration data. tion.
[Decimal Data]
10-49
RE-CTO-A203
Alarm Message List
Alarm
4473 ARITHMETIC ALARM System data didn't corrspond with reset pro- • Reset the alarm and repeat the opera-
RESET ERROR cess after the alarm occurred in arithmetic tion.
[Decimal Data] section. • If the error occurs again, contact your
4474 WRONG CONTROL An instruction such as a job call (CALL) or Include the call source job control group in
GROUP AXIS job jump (JUMP) was used for a call or jump the control group used by the current call
[Bit Pattern] to a job in a group outside the currently used destination job.
job control group.
4475 CANNOT EXECUTE When executing ARCON, WVON instruc- Add a robot to the job control group.
JOB(NO ROBOT) tion, the robot was not in the prescribed job
[Decimal Data] control group.
4476 CANNOT EDIT (EDIT An attempt was made to overwrite an edit- Cancel the edit lock.
LOCK JOB) locked job.
[Decimal Data]
4477 SELECT ERROR When executing operation instruction, the Needs investigation.
(APPLICATION ) selection parameter(parameter specified for Consult a YASKAWA representative.
[Decimal Data] maker) for first application and application
parameter(AP) was not adjusted.
4480 SELECT When executing sensor instruction, the Needs investigation.

ERROR(SENSOR ) selection parameter(parameter specified for Consult a YASKAWA representative.
[Decimal Data] maker) for first sensor application and sen-
sor parameter(SE) is not adjusted.
4484 WRONG PORT NO. Parameter(AxP010) showed the head of Change the parameter to a normal value.
(ANALOG OUTPUT) analog port used for arc, sealing was incor-
[Decimal Data] rect.
4485 WRONG SELEC- When executing sensor instruction, robot Needs investigation.
TION (SENSOR) designation(system parameter) uses sensor Consult a YASKAWA representative.
[Decimal Data] application and robot designation(system
parameter) uses application was not corre-
sponded.
4486 PATH OVER The path went outside the designated pass- • Correct the cause of the pass-over.
[Decimal Data] over monitoring area. • Set the pass-over radius inside the per-
mitted range.
4487 WRONG MECH Path arithmetic process section control • Reset the alarm and repeat the opera-
PARAMETER FILE error. tion.
4488 INCOMPLETE PT Path arithmetic process section control • Reset the alarm and repeat the opera-
FRAME error. tion.
[Decimal Data]
4489 DEFECTIVE TAUGHT Impossible to execute cutting motion. 1:Set C,W axis position of cutting start
POINT(CUTTING) Data stands for the alarm factor. position zero(0).
[Decimal Data] 1:CW axis CUT pulse error 2:Set the radius zero(0) or more.
C,W axis position on cutting start is not
zero(0) pulse.
2:Cutting(edge) radius 0
Cutting(edge) radius is zero(0).
10-50
RE-CTO-A203
Alarm Message List
Alarm
4490 DEFECTIVE TAUGHT Impossible to execute endless motion. 1:In case this alarm occurs when operat-
POINT(ENDLESS) Data stands for the alarm factor ing programing pendant, reset the alarm
[Decimal Data] 1:Interpolation motion impropriety of end- and execute the MRESET operation.
less function. In case this alarm occurs when operat-
Linear motion inpropriety. This error ing playback, set the MRESET instruc-
occurred as follows. When operating play- tion before executing the MOVL, MOVC
back panel and programming pendant, instruction.
though continuous rotaion was completed, 4:Check the teaching position again. Set
MRESET instruction was not executed but C,W axis position of cutting start posi-
linear interpolation was executed. tion zero(0).
4:Instruction position of step has permitted
pulse over cursor for endless axis
exceeded 2,147,483,647 pulse.
4491 CORRECTIONAL When correcting a motion, the error occured • Teach reference points again.
DIRECTION ERROR in the process of making a correction in the • If the error occurs again, contact your
[Decimal Data] direction for path arithmetic.
4:Referrence points were the same.
4492 POSITION CORREC- When correcting a motion, the error occured • Reset the alarm and repeat the opera-
TION ERROR in making process of making a correction in tion.
[Decimal Data] the volume for path arithmetic.
4493 OVER TOOL FILE The error occurred in the tool file control • Reset the alarm and repeat the opera-
NO. process. tion.
4494 DEFECTIVE TAUGHT 1:Weaving start point and end point were Check the position of the start point, end
POINT(WEAV) the same. point and referrence point. Teach again.
[Decimal Data] • In case there was no instruction of stop
weaving, the position of weaving start point
and end point was the same point or the
position of weaving start point and refer-
rence point is the same point.
• In case there is instruction to stop weav-
ing, the position of the weaving start point
and referrence point is the same point.
4495 UNDEFINED ROBOT Robot calibration was incomplete when a Conduct robot calibration.
CALIBRATION coordinated move instruction was executed.
[Bit pattern]
4496 PARAMETER Parameter settings caused division by zero. Needs investigation.

ERROR Consult a YASKAWA representative.
[Decimal Data]
4497 DEFECTIVE TAUGHT There was a problem with the taught points. Teach the points again.
POINT(CALIB)
[Decimal Data]
4498 CANNOT EXECUTE An illegal instruction was executed in a job Register the instruction in a job with con-
JOB(NO GRP AXIS) with no control group. trol axis.
[Decimal Data]
4499 UNDEFINED POSI- Undefined position data was used. Define the position data.
TION VARIABLE
[Bit Pattern]
4500 UNDEFINED USER Undefined user coordinates were used. Define the user coordinates.
FRAME
[Decimal Data]
10-51
RE-CTO-A203
Alarm Message List
Alarm
4501 OUT OF The error occured in task control process of • Reset the alarm and repeat the opera-
RANGE(PARALLEL independent control function. tion.
PROCESS) • If the error occurs again, contact your
[Decimal Data]
4502 SL BOARD ON-LINE When turning on power supply, detected in • Insert the XCP02 circuit board again.
ERROR the XCP01 circuit board that the XCP02 • If the error occurs again, contact your
didn't normally work.
4504 MEASURE INST When executing the measure instruction, • Reset the alarm and repeat the opera-
EXECUTE ERROR the error occured. tion.
[Decimal Data] Data stands for the alarm factor.
2:MEASON instruction
3:MEASOF instruction
4505 UNDEFINED POSI- Retry was possible with ARC RETRY exe- Register a step in front of the ARCON
TION FOR ARC ON cution only if a step existed before the instruction.
[Decimal Data] ARCON instruction.
4506 UNDEFINED POS No restart-return step existed in the job Reset the alarm and correct the job.
FOR RESTART when a restart was attemted.(Eg.,a retry
RETURN request was received during 1-step execu-
[Decimal Data] tion of CALL destination job.)
4507 REFP POS ERROR The distance between the search start point Reset the alarm and increase the distance
(SEARCH MOTION) and aimed point was too short to determine between the search start point and aimed
the search direction. point.
4508 PECIFIED ERROR Position confirmation was not possible Reset the alarm and change the coordi-
(COORDINATE) because the position variable (P) desig- nates.
[Decimal Data] nates coordinates as tool coordinates, mas-
ter tool coordinates.
Data stands for the alarm factor.
0:No coordinates
1:Designation error for master tool coordi-
nates system
2:Designation error for tool coordinates sys-
tem
4509 MFRAME ERROR Impossible to create user coordinates Register the position file(variable).
[Decimal Data] 8:No position file registered.
4510 CANNOT EXECUTE The attempt was made to caluculate the Correct the job.
INSTRUCTION root of a negative number
(SQRT) (Second argument is a negative.)
[Decimal Data]
4511 OUT OF RANGE When turning on servo, the difference in Reset the alarm and repeat the operation.
(DROP-VALUE) robot position pulse at servo ON and the
[Control Group] previous servo OFF exceeded the permitted
range.
(Permitted pulse is normally 100pulse.)
4512 TWO STEPS SAME The three points for creating the user coodi- Teach again such that the three points do
LINE(3 STEPS) nates or three or more taught points for not lie on the straight line.
robot calibration lie on the same line.
4513 EXCESSIVE The specified speed exceeded the safe After resetting the alarm, reduce the
SEGMENT speed. speed of the step where the alarm
(SAFETY 1): LOW occurred (move instruction) or change the
Robot/Station robot posture.
[Axis Data]
10-52
RE-CTO-A203
Alarm Message List
Alarm
(SAFETY 1): HIGH occurred (move instruction) or change the
Robot/Station [Axis robot posture.
Data]
(SAFETY 2): LOW occurred (move instruction) or change the
[Axis Data]
(SAFETY 2): HIGH occurred (move instruction) or change the
[Axis Data]
4517 SEARCH MONITOR The error occurred in the interface with Check the system version of the XCP01,
SET ERROR servo on feedback ratch mode. WRCA circuit board.
(SERVO)
[Decimal Data]
4518 SEARCH MON The error occured in the interface with servo Check the system version of the XCP01,
RELEASE ERROR on feedback ratch mode. WRCA circuit board.
(SERVO)
[Decimal Data]
4519 SPHERE INTRF Robot calibration was not executed. Execute robot calibration.
ERR(ROBOT)
[Decimal Data]
4520 AXIS BLOCKING Operation was instructed to group axis out • Reset the alarm and repeat the opera-
[Control Group] of axis blocking on play mode. tion.
• In case operating robot after reset the
alarm, turn on the general input signal
set in the parameter.
4521 WRONG JOB TYPE 0000_0001:Robot job was started from con- Check the starting job.
[Bit Pattern] current job by CALL or JUMP instruction.
0000_0001:Concurrent job was started from
robot job by CALL or JUMP instruction.
4522 TAG DATA CHANGE The error occured when welding conditions Correct the job.
PROCESS ERROR were changed in a job or file.
[Decimal Data]
4524 CANNOT EXECUTE A concurrent job contained an instruction Correct the job.
INST (MOV,etc.) which couldn't be executed in a
(CONCUR JOB) concurrent job.
4526 SYNTAX ERROR IN Internal data of equation inst was abnormal. Needs investigation.
EQUATION INST Consult a YASKAWA representative.
[Decimal Data]
4527 UNDEFINED PORT Designation of port No.for job was abnor- Needs investigation.
NO. mal. Consult a YASKAWA representative.
(AOUT)
[Decimal Data]
4528 SYNTAX ERROR Internal data was abnormal in instruction. Needs investigation.
[Decimal Data] (System function unmatch) Consult a YASKAWA representative.
10-53
RE-CTO-A203
Alarm Message List
Alarm
4529 TWIN COORDI- 1: The job started by SYNC was a job with- Set the R +S job to the job that is
NATED ERROR out any robot axes (job with station axes started by SYNC.
[Decimal Data] only, or concurrent job, etc.).
2: The job started by SYNC was a job with
robot axes only.
4534 TORQUE INTERFER- During operation at the designated speed, • Check if the tool weight information is
ENCE there is axis that the robot axis or motor load correctly set in the tool file.
torque exceeded the permitted torque. • Reset the alarm. Reduce the step (for
moving instruction) speed that caused
the alarm or change pose of robot.
4540 JOB QUE EMPTY [QUE] was called by CALL instruction and Set data in the job queue and call [QUE].
ERROR JUMP instruction when all job queue was
not used.
4543 STACK LESS THAN 0 The error occurred in internal data when • Reset the alarm and repeat the opera-
(JOB CALL) returning job. tion.
4564 INTERNAL STATUS When execution of start point detecting • Reset the alarm and repeat the opera-
ERR function(SRCH), search function for general tion.
(SEARCH HALT) sensor(ASRCH), force detecting func-
[Decimal Data] tion(TSRCH) was completed, the process
error occured. YASKAWA representative.
4565 SOFTWARE Operating function didn't correspond to sys- Need the investigation.
UNMATCH tem. Consult YASKAWA representative.
[Decimal Data]
4567 CANNOT MONITOR The attempt was made to execute MOVJ, Set not to operate ARC retry, restart or,
DISTANCE MOVS when operating ARC retry, restart. change the instruction(interpolation) to
MOVL, MOVC.
4572 UNDEFINED MOTOR There was no group setting controlled as Configulate again on customer mainte-
GUN CONTROL GRP motor gun. nance mode, set the motor gun axis cor-
rectly.
4574 SPOT WELD COM- Welding completed signal from timer con- • Correct the factor, no turning on power
PLETE TIME LIMIT ductor or welding error signal doesn't enter supply of timer conductor etc., and
even if waiting set time.
repeat the operation.
• In case that it takes time to response
from the timer, lengthen set time.
4575 ERROR IN WELD When there was no set of second pressure Set the second pressure or, change the
START TIMING SET at servogun, welding timing was set [After start timing.
first pressure].
4576 ERR IN SERVO GUN The error occurred in control process of ser- Needs investigation.
CONT MODE vogun. Consult a YASKAWA representative.
4577 ERR IN SERVO GUN The error occurred in control process of ser- Needs investigation.
MODE RLSE vogun. Consult a YASKAWA representative.
4578 SPOT WELD ERROR The error occurred in timer conductor of Reset the timer conductor that caused the
[Decimal Data] system designated by data. welding error and repeat the operation.
4581 DEFECTIVE ANTICI- A setting in the anticipation output file is set After resetting the alarm, set to the proper
PATION FILE to an improper value. The setting of the OT value .
[Decimal Data] output or OG output is “-”
1: OT output No. failure
2: OG output No. failure
10-54
RE-CTO-A203
Alarm Message List
Alarm
4583 CANNOT EXECUTE Set gun was set by operation mode of con- Change to the mode applied to the gun.
GUN TYPE trol impossible.
4584 STRWAIT TIME LIMIT Confirmation signal designated by stroke • Correct the factor, defective LS etc., and
switch confirmation instruction doesn't enter repeat the operation.
even if waiting set time. • If the error occurs again, contact your
4585 SERVO PG ON Encoder’s power is not on when the control Check the cable connection of the motor
ERROR power supply is turned on. gun’s encoder.
4587 MOTOR GUN The error occured when the gun was 1: Reconnect the motor gun on the station
CHANGE ERROR changed. The number shown indicates the axis in maintenance mode.
cause of the alarm. 2: Execute GUNCHG PICK when the
1: GUNCHG was issued in a system config- servo of the motor gun’s motor is off.
uration in which the gun change function 3: Exceute GUNCHG PICK when the ATC
cannot be used. is chucked.
2: GUNCHG PICK was issued while the 4: Execute GUNCHG PLACE when the
servo of the motor gun’s motor was on. ATC is chucked.
3: GUNCHG PICK was issued when the 5: Check the cable connection of the
ATC was unchucked. motor gun’s encoder.
4: GUNCHG PLACE was issued when the 6: Check the cable connection of the
ATC was unchucked. motor gun’s encoder.
5: The encoder’s power could not be turned 7: Check the gun number in the gun con-
on when GONCHG PLACE was issued. diton data file for GUNCHG. And,
6: The encoder’s power could not be turned check the gun’s serial number.
off when GUNCHG PLACE was issued.
7: The serial number of the motor gun does
not correspond to the gun number speci-
fied in GUNCHG.
4588 COMPENSATION When correction direction of fix side chip for Set the correction direction of fix side chip
DIRECTION UNSET- gun condition data file was except 1, 2, to apply the gun.
TING [Contact Teaching],[Abrasion Correction]
etc. was intended to used.
4589 ABRASION BASIS When using abrasion correction function at Register a required standard position.
POS UNSETTING servogun, various standard position was not
[Decimal Data] registered.
1: Standard position A
2: Standard position B
3: Standard position C
4601 UNDEFINED GUN Gun condition data file was not set. Set the gun condition data file completely.
COND FILE
[Decimal Data]
4603 WIRE STICKING The sticking was detected by the welder. Determine the sticking factor of the
[Decimal Data] 1 : Welder 1 welder.
2 : Welder 2
3 : Welder 3
4 : Welder 4
4612 TSYNC ERROR The number of synchronizations in the Check the number of synchronizations in
[Decimal Data] TSYNC command disagree. the TSYNC command again.
The data indicates the number of synchroni-
zation that were first executed.
4617 SU AXIS MOTION With L- and R-axes in the present positions, Add a teaching position or change the
DISABLED (LR AXIS the S- and U-axes cannot be moved. teaching position before the move com-
POSITION ERROR) mand where the error occurred so that the
[Decimal Data] L- and R-axes move to the home position.
10-55
RE-CTO-A203
Alarm Message List
Alarm
4623 GETPOS COM- 1: Cannot get the step of the local position Check the GETPOS command again.
MAND ERROR variable.
[Decimal Data] Ex.) MOVJ LP000 VJ=25.00
2: Cannot get the step of the arrangement
variable.
Ex.) MOVJ P[0] VJ=25.00
3: This step does not exist.
10-56
RE-CTO-A203
10.4 I/O Alarm Message List
Arc Welding Application
Alarm No. Registration No. I/O Alarm Message

System Section
9000 00
9010 01 MISSING ARC GENERATION CON-
FIRM
9020 02 ARC SHORTAGE
9030 03
9040 04 GAS SHORTAGE (RESTART)
9050 05 WIRE SHORTAGE (RESTART)
9060 06
9070 07
9080 08
9090 09
9100 10
9110 11
9120 12
9130 13
9140 14
9150 15
9160 16
9170 17
9180 18
9190 19
9200 20
9210 21
9220 22
9230 23
User Section
9240 24
9250 25
9260 26
9270 27
9280 28
9290 29
9300 30
9310 31
10-57
RE-CTO-A203
Handling Application

System Section
9000 00 AIR PRESSURE LOWERED
9010 01
9020 02
9030 03
9040 04
9050 05
9060 06
9070 07
9080 08
9090 09
9100 10
9110 11
9120 12
9130 13
9140 14
9150 15
9160 16
9170 17
9180 18
9190 19
9200 20
9210 21
9220 22
9230 23
User Section
9240 24
9250 25
9260 26
9270 27
9280 28
9290 29
9300 30
9310 31
10-58
RE-CTO-A203
Spot Welding Application

System Section
9000 00 ERR OF WELD TIMER COOLING
WATER
9010 01 ERROR OF GUN COOLING WATER
9020 02 ERROR IN TRANSTHERMO OF GUN
9030 03 AIR PRESSURE LOWERED
9040 04
9050 05
9060 06
9070 07
9080 08
9090 09
9100 10
9110 11
9120 12
9130 13
9140 14
9150 15
9160 16
9170 17
9180 18
9190 19
9200 20
9210 21
9220 22
9230 23
User Section
9240 24
9250 25
9260 26
9270 27
9280 28
9290 29
9300 30
9310 31
10-59
RE-CTO-A203
General Application

System Section
9000 00
9010 01
9020 02
9030 03
9040 04
9050 05
9060 06
9070 07
9080 08
9090 09
9100 10
9110 11
9120 12
9130 13
9140 14
9150 15
9160 16
9170 17
9180 18
9190 19
9200 20
9210 21
9220 22
9230 23
User Section
9240 24
9250 25
9260 26
9270 27
9280 28
9290 29
9300 30
9310 31
10-60
RE-CTO-A203
11.1 Error Message List
11 Error
Error warns the operator not to advance to the next operation caused by a wrong operation
and the access method when programing pendant operation or an external equipment(com-
putor, PLC, etc.)accesses.
When an error occurs, release it after the confirmation of the content of the error.
To release the error perform following the operation.

• Press [CANCEL] on programming pendant.
• Input alarm/error reset signal (specific input).
NOTE An error is different than an alarm because it does not stop the robot even if it occurred
while the robot was operated (during playback).
11-1
RE-CTO-A203
11.1.1 System and General Operation
Error NO. Data Message Contents
Turn off servo power and perform cor- It cannot be operated on servo
10 -
rective action power supply.
20 - Depress TEACH Out of specified mode operation
30 - Illegal setting for number of variables Parameter setting error
Illegal setting for number of variables

31 -
name
Undefined robot position variables Position type variable cannot be

40 -
used
50 - Depress MODIFY
Undefined points (ORG, XX, XY) Not registered user coordinates

60 -
basic 3 points(ORG, XX, XY)
Program and current tool different The tool number registered with
teaching position data didn't
70 - match the the tool num-
ber.selected at the programing
pendant.
80 - Same position in the 3 points
90 - Set robot exactly to taught position
100 - On overrun recovery status
110 - Turn ON servo power
120 - Set to PLAY mode
130 - No start using external signal
140 - No start using P.BOX
150 - TEACH-LOCK mode
170 - Servo off signal ON
180 - TEACH mode select signal ON
190 - Set variable number
200 - Defined group axis
210 - Undefined coordinated robots
211 - Cannot register between stations
212 Cannot register group conbination
220 - Taught by other robot
230 - While releasing soft limit
11-2
RE-CTO-A203
240 - Undefined robot
250 - Defined condition No.
260 - Undefined file
270 - Undefined gun condition file
280 - Lack of number of I/O points
290 - Cannot set same No.
300 - Undefined user frame
310 - Cannot register Master JOB
320 - Cannot operate CHECK-RUN
330 - Cannot operate MACHINE LOCK
340 - Cannot operate Master JOB
350 - Cannot initialize
360 - Teach point not specified
370 - No SYNCHRO operatrion
Position not checked Second home position was not

380 -
checked
390 - Can specify servo off by safety relay
Wrong specification of measure interval Wrong specification of measure

400 -
interval for TRT function.
410 - Time could not be measured Time could not be measured
Incorrect number of taught points Taught points for tool calibration

420 -
were incorrect.
430 - Register start reserved JOB
Clear data to teach at the tool because

440 -
other tool is set
450 - Wrong JOB for measuring
460 - Excess time for measuring
470 - Calibration at another file
480 - Calibration at another robot combination
490 - Cannot calibrate at this combination
500 - Undefined robot calibration data
510 - Undefined axis
11-3
RE-CTO-A203
Cannot select two coorditated combina-

520 -
tion
530 - Start reservation mode
540 - Not start reservation mode
Start reserved JOB change prohibit is

550 -
set
Cannot teach position while soft limit

560 -
released
570 - Turn on all contactor's servo power
580 - Connect group axis to one contactor
Register group axis combination [SYNCHRO] key for coordinated

590 - job which was not registered as
group was pressed.
600 - Out of setting data range
610 - Cannot use the user coordinate
620 - Select JOB (robot)
630 - Not completed to load original tool file
640 - Not specified tool file
650 - Incorrect measured data
660 - Wrong data type of position variable
670 - Enter path number
- Defined data
680
XXX File No.
690 - Illegal path number
700 - Wrong CMOS memory board type
710 - Enter path number
720 - Defined file name
730 - Undefined Name Position file
740 - This name cannot be defined
750 - Undefined Name Position
760 - Error in start condition set
770 - During robot operation
780 - Quit operation by mini operation pendant
11-4
RE-CTO-A203
FWD/BWD don’t work in the handle

790 -
operation
800 - The gun of designation is not connected
810 - Servo power supply is limited
820 - Modification range over
830 - Cannot move while modifying speed
840 - Unregistered key
850 - Cannot register instruction
860 - Please release key registration mode
870 - This key cannot be allocated
880 - Same relay cannot be set
This key has already been registered.

890 -
Cannot register them once
900 - Relay No. not set
Cannot be registered because job con-

910 -
trol group not same
920 - Cannot modify this setting
930 - Undefined conveyor calibration data
940 - Forced pressure signal ON
950 - Negative correction distance
11-5
RE-CTO-A203
11.1.2 Editing
Error No. Data Message Contents
1010 - EDIT LOCK mode
1020 - Enter correct value
1030 - Unauthorized ID No.
1040 - -
1050 - Enter correct date
1060 - Enter correct clock
1070 - Enter a number in 8 figures
11.1.3 Job Defined Data
Error No. Data Error Message Error Contents
2010 - Incorrect character
2020 - Name not entered
2030 - Undefined JOB name
2040 - Defined JOB name
2050 - Address not found
2060 - Select master
2070 - Set robot exactly to taught position
2080 - Press INSERT or MODIFY
Only modifying move instruction possi-

2090 -
ble
2100 - JOB cannot be edited.
2110 - Over soft limit
2120 - Cannot insert/alter/delete with servo off
Only modifying move instruction possi-

2130 -
ble
2150 - Inserting is not possible from this point
2160 - Cannot modify or delete this position
Press INSERT to record same step as

2170 -
previous step
2180 - Cannot insert data
11-6
RE-CTO-A203
2190 - Cannot delete data
2200 - Cannot modify data
2210 - Illegal data setting
2220 - Display edit instruction
2230 - Illegal instruction equation
2240 - Excessive instruction equation
Unmatched number of parentheses in

2250 -
equation
2260 - Wrong group axis selection
Cannot insert any more instruction in

2270 -
JOB
* JOB memory is full
1 Lack of position file memories
2 Lack of JOB registering memories

2280 3 Lack of instruction file memories
4 Lack of memory pool
Lack of pass condition file for multi-

5
layer
2290 - Undefined master JOB
* Undefined SUB Master JOB
1 Sub-master 1
2 Sub-master 2
2291
3 Sub-master 3
4 Sub-master 4
5 Sub-master 5
2292 - Undefined MASTER START JOB
* Undefined SUB START JOB
1 Sub-master 1
2 Sub-master 2
2293
3 Sub-master 3
4 Sub-master 4
5 Sub-master 5
11-7
RE-CTO-A203
Cannot teach JOB without group-axis

2300 -
specification
* Same label exists

2310
XXX Line No.
2320 - Cannot creat coordinated JOB
2330 - Cannot edit coordinated instruction Calibration not complete
2340 - Pasted data not found
2350 - Editing data not found
2360 - Cannot create editing area
Cannot cut/copy NOP and END

2370 -
instructions
2380 - Wiring JOB selection
2390 - Wrong group axis selection
2400 - Cannot move in cut & paste editing
When variable is used for speed set-

2410 -
ting, perform a line-edit
When variable is used for teach set-

2420 -
ting, perform a line-edit
2430 - Reverse data not found
2440 - Move C-and W-axis to basic position Lazer cutting
2450 - Relative JOB not permitted
2460 - Specified JOB is already converted
2470 - Wrong JOB type
2480 - Wrong JOB coordinates setting
2490 - Execute NEXT/BACK operation once
2500 - Cannot convert the JOB
2510 - Cannot correct position in the JOB
2520 - Enter JOB name
2530 - Illegal step number
2540 - Enter step number
2550 - Duplicated step number
Cannot correct steps of position vari-

2560 -
ables and REFP
11-8
RE-CTO-A203
2570 - The step does not contain speed
2580 - The step dose not contain PL/CONT
2590 - Soft limit range over
Cannot teach position in concurrent

2600 -
JOB
2610 - Wrong JOB kind
2620 - Cannot correct play speed in the JOB
2630 - Conveyor position not reset
2640 - Incorrect JOB name
2650 - Defined JOB name
2660 - Register MOVL inst. after circular block
2670 - Undefined target JOB
2680 - Wrong designation of welding section
2690 - Defined same kind JOB
2700 - Press position not reset
Relative job can’t be shifted with pulse

2710 -
type
2720 - Cannot correct position variables
2730 - Cannot use robot macro JOB
2740 - Cannot use concurrent macro JOB
Cannot use JOB with group-axis speci-

2750 -
fication
Cannot insert/modify/delete for group

2760 -
axis detachment
Axis is separated.
2761 -
Cannot add, modify, or delete.
Cannot reverse data of SVSPOTMOV

2770 -
instruction
2780 - Arithmetic error
11-9
RE-CTO-A203
11.1.4 External Memory Equipment
3010 - Floppy disk drive cable not connected
Floppy disk not inserted into floppy

3020 -
disk drive
3030 - Floppy disk protection is ON
3040 - File not saved on floppy disk
3050 - File saved on floppy disk
3060 - Out of memory on floppy disk
3070 - Number of files on floppy disk is full
3080 - I/O error on floppy disk
Transmission error with floppy disk

*
drive
1 Framing error
2 Overrun error
3 Parity error
4 Data code error

3090
5 Data read error
6 Dat write error
7 Data time out
8 Serial I/O error
9 Error other than described above
3100 - Total checksum error
3110 - Syntax error
* HEX code error
1 Specification error of data record
3120 2 Specification error of FEO record
3 Record type error
4 Total check error of record
3130 - Verify error
3140 - Wrong pseudo instruction
11-10
RE-CTO-A203
* Concurrent I/O record error
1 Format error
2 Ladder program is too long
3 Exceed the range of the data

3150
4 Specification error of channel No.
5 Specification error of relay No.
6 Timer value error
7 Specification error of timer No.
3160 - Cannot load illegal system data
* Condition file data error
1 Format error
3170 2 Specified file No. is omitted
3 Specified tool No. is omitted
4 User file is not registered
3180 - Concurrent I/O data transmission error
11-11
RE-CTO-A203
* Error in JOB data record
The number of position data

1
(NPOS) record wrong for the format
Record on the user coordinate No.

2
is wrong for the format
3 Tool record is wrong for the format
Record on the position data section

4
is wrong for the format
Robot type of XYZ data (RCONF)

5
record is wrong for the format
6 Date record is wrong for the format
Comment record is wrong for the

7
3190 format
JOB attribute data (ATTR) record is

8
wrong for the format
Control group (GROUP)record is

9
Local variable (LVARS)record is

10
JOB argument (JARGS) record is

11
Teaching coordinates for relative

12 JOB (FRAME) record is wrong for
the format
Position data corrdinates do not

13
match relative job coordinates
3200 - NOP or END instruction not found
3210 - Position No. storage area not found
* Syntax error in instruction data
2 Interior control error
3 Undefined instruction/tag
3220 4 Instruction/tag shortage
5 Disuse instruction/tag
6 Sub instruction
7 Non instruction
11-12
RE-CTO-A203
8 Invalid instruction
9 Invalid tag
10 Invalid character
11 Undefined intermediate code
12 Intermediate code shortage
13 Syntax stack overflow
14 Syntax stack underflow
Array type tag incompleted

15
Tag [ARRAY]
Element type tag incompleted

16
Tag [ELEMENT]
17 Macro JOB unregistered
18 Input format error
19 Date size over
20 MIN value over
21 MAX value over

3220
22 Operation expression error
23 JOB call argument setting error
Macro JOB call argument setting

24
error
25 Position vector setting error
26 System error
27 Soft key designate error
28 Numerical input buffer overflow
29 Real type data precision error
30 Element format error
35 [BOOL TYPE] data error
36 [CHAR] data error
[BYTETYPE] [BINARY] / HEXA-

37
DECIMAL BYTE TYPE] data error
[INTEGER TYPE] [DECIMAL

38
EORD TYPE] data error
11-13
RE-CTO-A203
[BINARY/HEXADECIMAL WORD
39
TYPE] data error
[DOUBLE PRECISION TYPE]

40 [DECIMAL DWORD TYPE] data
error
[BINARY/HEXADECIMAL WORD
41
TYPE] data error
42 [REAL TYPE] data error
[LADDER SPECIAL TYPE] data

43
3220 error
44 JCL text
45 Invalid text
46 [LABEL NAME] data error
47 [JOB NAME] data error
48 [STRING] data error
49 [COMMENT] data error
58 Invalid instruction/tag detection
3230 - Syntax not matched
3240 - Undefined application
3250 - Cannot load this file
3260 - Excess input data
3270 - Cannot verify this file
Wrong welding condition (STANDARD/

3280 -
ENHANCED)
3290 - Serial port not defined
3300 - Serial port being used
3310 - Protocol being used
3320 - Wrong GUN type
3330 - Undefined multilayer data
3340 - Illegal number of multilayer data
3350 - Not enough memory
3360 - Invalid directory
3370 - Incorrect directory name
11-14
RE-CTO-A203
3380 - Drive not ready
3390 - File not found
3400 - File already exists on the media
3410 - Out of memory on the media
3420 - Max number of files has been reached
3430 - I/O error on the drive
3440 - Wrong media type
Cannot load macro JOB at current Load in management mode.

3450 -
security mode
* Cannot backup to PC card
3460 1 Insufficient PC card memory.
2 Not accessible to PC card.
3470 - Database not found
3480 - Database access error
3490 - Same database exists
3500 - Check PC card insertion
Cannot delete folder. Check attribute

3510 -
and inside file
3520 - Same folder exists
11-15
RE-CTO-A203
11.1.5 Concurrent I/O
* Illegal relay No.

4010
XXX Line No.
* Illegal block No.

4020
XXX Line No.
* Illegal instruction
4030
XXX Line No.
Relay/register No. duplicated in OUT/ Plural output are instructed to

*
GOUT or arithmetic instruction the relay or register
4040
XXX Line No.
* The relay is not used

4050
XXX Line No.
* Excess STR-[-NOT] instructions

4060
XXX Line No.
* Excess AND [OR] STR instructions

4070
XXX Line No.
* Syntax error in CNT instructions

4080
XXX Line No.
* Enter STR [-NOT] at head of block Need STR [-NOT]

4090
XXX Line No.
Relay No. duplicated in TMR and CNT Timer and counter are used
*
twice
4100
XXX Line No.
4110 - Excessive ladder scan-time Ladder scan time is too long
4120 - Concurrent I/O memory is full Exceeds memory capacity
4130 - END instruction not found END instruction not found
Wrong ladder program Position and number of PART

4140 -
instruction are wrong
Wrong use of GSTR, GOUT commands GSTR and GOUT is not used
*
together
4150
XXX Line No.
4160 - Cannot edit system section
11-16
RE-CTO-A203
4170 - Cannot modify/delete
4180 - Press INSERT/MODIFY/DELETE keys
4190 - Ladder program not found
4200 - Cannot specify system variables ($)
4210 - Cannot edit line
Excess TMR/CNT or arithmetic instruc- More than 100 TMR, CNT or

4220 -
tions arithmetic instruction used
4230 - Syntax error in TMR/CNT instructions
11.1.6 Maintenance Mode
8010 - Too many axes
8020 - Too many I/O points
8030 - Too many boards (XFB01B (MASTER))
Memory error (ControlNet) output condi-

8040 -
tion
8050 - Robot model is not registered
11-17
Dwg.No.
1
Revisions:
CUSTOMER :
HE0300332-1/31
2
MACHINE : (PAGE2)
3 ELEMENTARY DIAGRAM OF YASNAC XRC FOR NORTH AMERICAN SPEC.(ANSI/RIA)
4 PAGE NOTE NAME REVISION

1/ CONTENTS
5
2/ LIST OF REFERENCE
3/ SYSTEM CONNECTION DIAGRAM
6
4
/ MAIN POWER : QS1,T1,QS2
7 5/ MAIN POWER :JZRCR-XPU06B,QS3
6/ BRAKE RELEASE:JARCR-XFL02B
8
7/ JZRCR-XSU02(1/4) : JARCR-XCT01(1/4)
9
10 10/ JZRCR-XSU02(4/4) : JARCR-XCT01(4/4)
11/ 1SV(1/8):1CV(CONVERTER),1GS(DC POWER SUPPLY)
11
12/ 1SV(2/8):S-AXIS 1AMP,JASP-WRCA01(1/7)
13/ 1SV(3/8):L-AXIS 2AMP,JASP-WRCA01(2/7)
12
14 / 1SV(4/8):U-AXIS 3AMP,JASP-WRCA01(3/7)
13 15/ 1SV(5/8):R-AXIS 4AMP,JASP-WRCA01(4/7)
Check.
Appr.
Draw.
16/ 1SV(6/8):B-AXIS 5AMP,JASP-WRCA01(5/7)

14 1SV(7/8):T-AXIS 6AMP,JASP-WRCA01(6/7)
17 /
18/ 1SV(8/8):JASP-WRCA01(7/7),JANCD-XFC01
15
19/ JZNC-XRK01B-1(1/2):JANCD-XBB01(1/2),XCP01(1/2),2GS
16 20 / JZNC-XRK01B-1(2/2):JANCD-XBB01(2/2),XCP01(2/2)
21 / JZRCR-XCO02 (1/8) : JARCR-XCI01(1/3)
17 22 / JZRCR-XCO02 (2/8) : JARCR-XCI01(2/3),XCI03(1/5)
23 / JZRCR-XCO02 (3/8) : JARCR-XCI01(3/3);SAFTY CIRCUIT:CPU1,CPU2
18
YASNAC XRC
24 / JZRCR-XCO02 (4/8) : JARCR-XCU01

19 25 / JZRCR-XCO02 (5/8) : JARCR-XCI03(2/5)
20
CONTENTS
21
29 / PLAYBACK PANEL (ZY1C-SS3152)
22 30 / PROGRAMMING PENDANT (JZNC-XPP02 )
ELEMENTARY DIAGRAM
31 / JANCD-XEW01-1(OPTION)
23
24
LIST OF ADDED PAGE
25 PAGE NOTE NAME REVISION

/
26
/
HE0300332
27 /
/
28 /
/
29
/
30 /
/
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
1
Dwg.No.
1
Revisions:
HE0300332-2/31
TABLE OF REFERENCE DIAGRAMS
2
No. DRAW No. NAME REVISION

3 1 HB9280 MAIN CONTROL BOX DIMENSION DIAGRAM
2
4
3
5 4
5
6
6
7
7
8
8 9
10
9
10 OPTION LIST
11 No. NAME PAGE

1
12 2
3
13
4
Check.
Appr.
Draw.
5
14
6
15 7
8
16
9
10
17
18
YASNAC XRC
TYPE LIST
19
No. XRC TYPE(ERCR-) ROBOT TYPE AC POWER QS1 FU1 3 QS2 FU4 6 QS3 FU7 9 1KM,2KM SERVO PACK NOTE
LIST OF REFERENCE
SC-5-1 Z845 INPUT POWER SOURCE

20 1 SV3-RB10 SV3X 1 kVA 194R-NC030P3 3A USCC3I 10A USCC3I 5A SZ-A11 CACR-SV3AAA AC480V
2 SC-5-1 Z845 INPUT POWER SOURCE
SV3-RB11 SV3X 1 kVA 194R-NC030P3 10A - - USCC3I 5A SZ-A11 CACR-SV3AAA AC200/220V
21
3
22 4
ELEMENTARY DIAGRAM
23
24
25
26
HE0300332
27
28
29
30
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
2
IN CASE OF INPUT POWER SOURCE
AC200/220V.
Dwg.No.
AC 480V AC 200/220V
1 50/60Hz 50/60Hz
Revisions:
L1 L2 L3 PE L1 L2 L3 PE
HE0300332-4/31
(R) (S) (T) (R) (S) (T)
2 EXT. EXT.
PE PE
1 3 5 1 3 5
3
QS1 (PAGE2) QS1 (PAGE2)
FU1 FU2 FU3 FU1-3 FU1 FU2 FU3 FU1-3
4
(PAGE2) (PAGE2)
U V W
5
T1
3 1kVA
PRIMARY:575/480/240V
6 SECONDARY:208V
N
7
u v w
8 1 3 5
9 FU4 FU5 FU6 QS2 (PAGE2)

2 4 6
10 L1 L2 L3
XPU06B-1KM
11 5
1
12
r1 XFL02B 6
13 CN4 25
t1
Check.
Appr.
Draw.
14
15
16
17
18
YASNAC XRC ELEMENTARY DIAGRAM
MAIN POWER : QS1,T1,QS2
19
20
21
22
23
L1 L2 L3
XPU06B-1KM
24
5
1
25
26
HE0300332
27
28
29
30
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
4
QS2
Dwg.No.
4 NOTE
1 24
Revisions:
FU1,FU2
HE0300332-5/31
AC250V 10A
L1 L2 L3
2 TIME LAG FUSE
JZRCR-XPU06B
3
FN2010-10/06
(SCHAFFNER) 1XT 5X
FU1
P P’ 1 -B2
1Z r XSU02 7
4 N’ 2 -A2
FU2 AC250V t CN32 12
N 10A E
-B1
5
PS1 2GS(CPS) 19
-A1 3
1KM PS2 CN05
A2 A1 3 -B3
AC1
6
1FV 2KM XSU02 7
SZ-Z5 4 CN30 27
A1 A2 -A3
7
AC2
2FV -B5
SVM1A
SZ-Z5
-A5
8 SVM1B XSU02 10
-B6 CN29 11
SVM2A
-A6
9 SVM2B
23 24 23 24 -B8
SVM2 XSU02 7
-A8 P CN32 22
SVM1
10 4X
54 53 -B2
2KMMA+
11 -A2 P
2KMMA-
54 53 -B1
1 3 5 1KMMA+
-A1 P
12 1KM 1KMMA-
(PAGE2) 62 61 -B4 XSU02 10
2 4 6 2KMMB+ CN29 19
-A4 P
2KMMB-
13 62 61 -B3
1KMMB+
Check.
Appr.
Draw.
-A3 P
1KMMB-
14 5X
-B4
RKFAN1
-A4 P XSU02 7
15 1 3 5 RKFAN2 CN30 26
2KM
(PAGE2)
16 2 4 6
17
1X
18 -B1
MAIN POWER:JZRCR-XPU06B,QS3
YASNAC XRC
2XT
-A1
19
R -B2 RKFAN1
20 EV1
T -A2 RKFAN2 4715PS-22T-B30-B00 X1
(MINEBEA)
-B3 RKFAN1 1
21
EV2
r2 -A3 RKFAN2 2
XFL02B
22 t2 CN3 R -B4
3
ELEMENTARY DIAGRAM
6
21 EV3
T -A4
23 4
1 3 5 -B5
6XT 4715PC-22T-B30-B00 X2
24 QS3 -A5
(MINEBEA)
FU7 FU8 FU9 (PAGE2)
2 4 6
R -B6
25
T -A6
26
RB
-B7
HE0300332
27 -A7
L1 L2 L3 -B8
L1C(r)
28 1GS
1CV 1CN
-A8
11 L2C(t) 11
9 24
29
30 FG RB:MF20N3R5JU(MICRON)
3.5 20W
(FRAME to FRAME CONNECTION)
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
5
1.000
(1.260 1.890 0.000 0.000 0.000 0.000 0.000 3.150 12.000 0 )
10.000
JARCR-XFL02B
Dwg.No.
CN1
1
1 CN6
Revisions:
BA4
HE0300332-6/31
2 1 9 -1
2 BA1
3 [K2]
XSU02 BR
CN31 4 -2
BRCOM
3 7 5
17 BB4
6
BB1
4
D10 D11 D12 D13 D14 D15 D16
NOTE
5 FOR EXTERNAL AXIS. 6
(NOT MOUNT)
CN2 TM1
SB8 10 [K2]
6
1 2 10 1
BA7
13 14 [K2]
7 EXTERNAL
7SUP AXIS
MOTOR
BRAKE
8 2
BB7
7 8 5 6 7 8
9
11 12 9 10 11 12
[K2] [K2] [K1] [K1] [K1] [K1]
10 CN2
SB2 CN5
2 3 11 -B1
BA1
11 13 14 [K2]
SB3 1SUP
3 4 12 -C1
BA2
13 14 [K2]
12 SB4 2SUP
4 1 9 -D1
BA3
13 14 [K1]
13 SB5 3SUP
5 2 10 -B2
Check.
Appr.
Draw.
BA4
13 14 [K1]
14 SB6 4SUP
6 3 11 -C2
BA5
13 14 [K1]
SB7 5SUP
15
7 4 12 -D2
BA6
13 14 [K1]
6SUP
16 8
NOTE
17
FU1,2,3
SERVO
AC250V 3.15A MOTOR 2BC
BRAKE
18 K1,K2
YASNAC XRC ELEMENTARY DIAGRAM
BRAKE RELEASE:JARCR-XFL02B
MY4Z-CR (OMRON) 12 13 14
AC200V 9 9 9
15 16 17
19 K3 9 9 9
MY2ZN-CR (OMRON)
AC200V CN3
FU3 [K1]
20 1
r2
13 14
21 QS3 [K2]
5 2
22 t2
22 13 14
[K3]
23
13 14
24
1BA
CN4
25
SB1
FU1 D1
1 1 9
26 r1
13 14 [K3] 2BA
QS2 FU2 D2
HE0300332
4 2 4 12 -A1
27 13 t1 23 24
BB1
[K3]
-A2
HL1 BB4
28 WHITE 3
1 2
29
4
30
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
6
1.000
JZRCR-XSU02(1/4)
Dwg.No.
1 NOTE
JARCR-XCT01(1/4)
CN20 I/O DC SUPPLY
Revisions:
HE0300332-7/31
+5V DUMMY CONNECTION
CN20
2 B1 6
2GS +24V Z(L) NEXT I/O
PS 5
(CPS150F) A1
19 024V 4 DUMMY
3 7 B2 3 CONNECTOR
+24VU +24V
GND
A2 2
4 024VU
1
-B3
DUMMY NCM NCM B A
-A3
5 CONNECTOR [K25] [K24]
-B4
NOTE
-A4
4P F9,F10
6
B5 AC250V 3.15A
NEXT +24V TIME LAG FUSE
XSU02 A5 +24VU 024V
024V F9
7 B6 NCM [K25]
+24VU Z(L) LY2-DC24V
250V 3.15A D1
NCM (OMRON)
(GREEN)
8 F10
A6
024VU Z(L) CN27
250V 3.15A 024VU 7
9 EX24VIN
8
EX0VIN DC
+24V SELECT
10
9
+24V
10
024V
11
024V
CN32
12 -D1 CN30 -D1
r PS1
XPU06B -C1 -C1
5X t PS2
13 5
4 F3 F4
Check.
Appr.
Draw.
+24V
14 BRK BRK-R CN31
250V 250V F5
NOTE 5A 5A -B1
BA1
F3.F4 250V -C1
15 [K7] [K3]
AC250V 5A 4A -D1
TIME LAG FUSE -A1
XX3 BB1
16 F5,F6 -B2
XE475 BA4
AC250V 4A
-C2
GP40(DAITO) F6
17 INDICATION FUSE -D2
250V XFL02B
4A -A2 CN1
NOTE BB4
18 6
YASNAC XRC
+24V SYSTEM
JZRCR-XSU02(1/4 ):JARCR-XCT01(1/4 )
024V +24V 3
-C3
FUCUT BR
19 (INDATA) -D3
+24VU USER -A3
024VU +24V BRCOM
20 XX4 -B3
NCM XE475 KEYIN PLUG KEYIN PLUG
[K25] CN32
21 -D3
SVM1 XPU06B 5
-C3
SVM2 5X 9
22 -D2
RBRAKE1
ELEMENTARY DIAGRAM
-C2
RBRAKE2
-A1
23
-B1
-A3
24 KEYIN PLUG KEYIN PLUG
SVM-1 CN30
25 -B1
FAN1
[K14] -A1
FAN2
26 -B3
RKFAN1 XPU06B 5
-A3
HE0300332
RKFAN2 5X 15
-D3
27 AC1 XPU06B
-C3 5
AC2 5X 6
-B2
28
KEYIN PLUG KEYIN PLUG
29
30
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
7
JZRCR-XSU02(2/4)
Dwg.No.
1
JARCR-XCT01(2/4)
CBL-RC007 +24V
Revisions:
CN21
HE0300332-8/31
-4 FU1
2 S_ON1+ ON_EN1 OVER_SPEED1 OT EXOT1 SVMAIN1 SVMX1 SVM-1
-14 250V 3.15A
S_ON1-
[K9] [K10] [K11] [K12] [K13] [K5]
INDATA [K1]
3 S_ON1
[K14]
4 [K15] 024V GND
024V
9
S_ON1+ +24V
7
5 [K16]
9 024V INDATA
S_ON1- +24V
14
6 FU2
GND 250V 3.15A

7
CN21
ON_EN2 OVER_SPEED2 OT EXOT2 SVMAIN2 SVMX2 SVM-2
-5
S_ON2+
8 -13 [K17] [K18] [K19] [K20] [K21] [K8] [K2]
S_ON2- S_ON2
1KMMA
10
9 18 [K22]
S_ON2+ 9 10
8 2KMMA
19
1KMMMA 2KMMMA SW2 SVMXOK1 SVMXOK2 [K23]
10 9
+24V S_ON2- 1-2 ON OFF
13 ON ON +5V
2-3 OFF ON
CN21 SW2
-1 ON OFF OFF OFF 3 CN22
11 024V +5V OFF ON OFF OFF
+24V 2 -1
-2 OFF OFF OFF OFF
SVMXOK1 1 -2
-3
12 -3
SVMXOK1 GND S_ON1
-4
+24V +24VU S_ON11+
024V [K15]
13 S_ON2
-6 -5
Check.
Appr.
Draw.
DINCOM S_ON21+
[K22] -6
-7 10
14 TUDIN EXTUDIN
15 -7
TUDIN 9
WRCA01
CN20 -8 CN24 9 -8
DIN3 DIN3
15 18 -9 9 -9
22 DIN2 DIN2 15
-10 -10
DIN1 DIN1
-11 -11
16 +24V SVMXOK21+
+5V
-12
-12 SVMXOK21-
17 SVMXOK2
024V
SVMXOK2
NEXT
JZRCR-XSU02(2/4):JARCR-XCT01(2/4)
18 -13 XSU02
YASNAC XRC
024V S_ON21-
+5V -14
024V S_ON11-
19 -15
SVMAIN11+
-16
SVMAIN11-
20 OVSPD1
9
18
-17
21 SVMAIN21+
-18
SVMAIN21-
OVSPD2
22 9
ELEMENTARY DIAGRAM
20 INDATA
23
024V 0V
-19
TUSIG
24 -20
TUSIC*
CN21 +24V
25 -15
SVMAIN1+ SVMAIN1
-16
SVMAIN1-
-17
26 SVMAIN2+ [K13]
SVMAIN2
HE0300332
-18
27 SVMAIN2-
[K21]
024V
28
-19
TUSIG JL012 INDATA
-20
29 TUSIG* OUTDATA
SW1
120 3 SERIAL
30 2 TERMINATOR
1
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
8
Dwg.No.
JZRCR-XSU02(3/4)
1
JARCR-XCT01(3/4)
Revisions:
HE0300332-9/31
2
+24V
CBL-RC007 CN23
3 -1 +24V
SPMOD1
4 CN24
-2 -1
SPMOD2 SPMOD1OUT
5
-3 -2
6 SPMOD3 SPMOD2OUT
7 -4 8 -3
S_ON1+ S_ON1+ 4 SPMOD3OUT
-5 8 S_ON1
S_ON2+ S_ON2+ -4
-6 9 S_ON12+
8 [K16]
XCO02 DINCOM
CN41 -7 S_ON2
-5
24 -8 S_ON22+
9 DIN3 8 TUDIN [K23]
24 14 -6
DIMCOM NEXT
-7 XSU02
TUDIN
10 -9 -8
DIN2 DIN3OUT
11
-10 -9
DIN1 DIN2OUT
12 -11
SPMOD COM
-12
-10
13 -13 8 DIN1OUT
S_ON2- S_ON2- 10 -11
-14 SPMODCOM
Check.
Appr.
Draw.
S_ON1- S_ON1- 8 -12

-15 5 024V
14 -13
-16 S_ON22+
-14
-17 S_ON12+
DIN3 -15
15 -18 8
15 DIN2 -16
-19
DIN1 -17
16 -20
-18
CBL-RC031 +24V -19
CN25
17 -A1 -20
+24V OVER_SPEED1
-A2
OVSPD1
18 8 [K10]
YASNAC XRC
OVSPD1 20 024V
OVER_SPEED2
19 -A3
OVSPD2
XFC01 8
CNSCU OVSPD2 22 [K18]
20 18
27
-A4
SPMODE1
-A5
21 SPMODE2
-B1
SPMODE3
-B2
024V
22 -B3
ELEMENTARY DIAGRAM
-B4
23 -B5
-C1
FANALM1
-C2
24 FANALM2 INDATA
-C3
FANALM3
-C4
25
-C5
26 -D1
024VU
-D2
HE0300332
024VU
-D3
27 024VU
-D4
-D5
28
024VU 024V
29
30
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
9
JZRCR-XSU02(4/4)
Dwg.No.
1
JARCR-XCT01(4/4)
Revisions:
HE0300332-10/31
+24VU +24VU
OT_R CN26
2
CN27 -A1 024VU
[K4]
-1
EXOT1+ -B1 LP2 1BC (OPTION)
3 EXOT1
-2 SVM-1 SVM-2 CN5 CN5 LAMP
EXOT1- -C1 LP1 -6 -4
[K12] [K1] [K2] CN4 CN4
4 -D1 +24VU P -6 -4 +24VU
EXOT2
-3
EXOT2+ OT_R -A2
5 [K20] INDATA
(BATTERY ALARM) -B2
-4 [K4]
EXOT2-
-5
6 24VUT
-6 CN3 CN3
024VUT INDATA -D2
OT 024VU -6 -4 SPARE
7 +24VU -A3 (0V)
OT-
024VU
INDATA [K11]
-B3
8
-C2 P
KEYIN PLUG KEYIN PLUG
[K19]
GND
9 024VU 024VU
SHOCK- CN6 CN6
INDATA -C3 -6 -4 SHOCK-
INDATA
SHOCK1 -D3 (OPTION)
10 SHOCK2
SVM-1 CN29
024VU GND F7
250V 5A -A1
SVM1A
11 [K1] -B1
SVM1B
SVM-2 XPU06B
250V 5A F8 -C1 5X 5
12 CN28 BRK SVM2A
-1 +24V [K2] 8
-D1
EXBRK+ SVM2B
-2 [K6]
EXBRK- -A2
13 SVM-1 SVM-2
NCM INDATA -B2
-3
Check.
Appr.
Draw.
[K1] [K2] (SVMX_ER)

EXNCM+ KEYIN PLUG KEYIN PLUG
-4 [K24]
-C2
14 EXNCM-
-5 024V GND -D2
024VU
-6 8 +24VU -A3
15 EXTUDINE
EXTUDIN 14
-7 -B3
ON_EN1+ ON_EN1
-8 -C3
ON_EN1-
16 [K9] -D3
ON_EN2
+24V
-9
ON_EN2+ 024VU
17 -A4
[K17] 1KMMB+
-10 -B4
ON_EN2- INDATA INDATA 1KMMB-
-C4
18 1KMMA+
1KMMA -D4
YASNAC XRC
8 INDATA 1KMMA-
-A5 XPU06B
GND 8 2KMMB+ 4X
19 -B5 5
INDATA INDATA 2KMMB- 12
2KMMA -C5
8 2KMMA+
20 -D5
9 INDATA 2KMMA-
GND
024VU +24V
21
Z(L)
+5V
22 BRK-R
NOTE
[K3] BRK-R [K3]
ELEMENTARY DIAGRAM
23 BRK [K7]
OT_R
LY2-DC24V
(OMRON)
24
[K4]
SVM 1
25
[K5]
BRK
26
OUTDATA
HE0300332
[K6]
27 BRK
28 [K7]
SVM
29
[K8]
30
024V
31
10
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
1
Revisions:
HE0300332-11/31
2
4
1SV(1/8) SERVO PACK (PAGE2)
5
6 CONVERTER
JUSP-ACP05JAA (5A)
7
1 CV
8 CN7 CN3,4
-1 R -A3
L1 P
9 5 -2 S
QS3 L2
28 + CHARGE 1AMP 6AMP
-3 T JUSP-WS**AA
L3
10 CN3,4
-A1 12 15
FG N 2 2
11
CN1
12 CN8 CONRDY1* -1
-1 CONRDY1*
CONRDY2* -2
CONRDY2*
13 CONRDY* -3
CONRDY*
Check.
Appr.
Draw.
R1 OVFLT* -4
OVFLT*
14 OPHFLT* -5
OPHFLT*
-2 REGFLT* -6
REGFLT*
15 UVFLT* -7
REGENERATIVE UVFLT* WRCA01
RESISTOR COM -8 CN30
220W 12.5 COM
18
16 AXRUN -9
AXRUN 5
AXRUN* -10
AXRUN*
17 REGON* -11
REGON*
ACOVFLT* -12
ACOVFLT*
1SV(1/8):1CV(CONVERTER),1GS
18 THM -13
YASNAC XRC
THM
THMCOM -14
THMCOM
19
20
21 DC POWER SUPPLY
JUSP-RCP01AAC
22
1 GS
ELEMENTARY DIAGRAM
2CN
23
1CN GND -A1
-3 GND
L1C(r) NOISE +5V -B1
5 XPU06B +5V
24 1X -2 FILTER
28 L2C(t) ALM -A2
+ POWER LOST WRCA01
CHARGE
-1 +7V -B2
FG PG7V CN50
25
-15V -A3 18
-15V
13
+15V -B3
26 +15V
HE0300332
27
28
29
30
31
11
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
SERVO PACK 1SV(2/8)
1
MANIPULATOR
Revisions:
HE0300332-12/31
CN6 S-AXIS
2 A3 2BC
11 1CV-CN3 P P 1AMP
CASE FG
9 A1
N N S-AXIS
3 B3 1CN CN1
13 P CN1
2AMP-CN6 B1 MU1 -2 -1 -3 MU1 -1
2 -2
N
4 JASP-WRCA01(1/7) MV1 -3 -2 -2 MV1 -2
-3 SM
CNPB01 CN3
5 PU_1* B7 A7 PU* MW1 -4 -3 -1 MW1 -3
-4
PU_1 B8 A8 PU
ME1 -1 -4 -6 ME1 -4
6 NU_1* B1 A1 NU* -1
B2 A2 BRAKE
NU_1 NU -5 -5 BA1 -1
7 PV_1* B9 A9 PV*
P
PV_1 B10 A10 PV -6 -4 BB1 -2
NV_1* B3 A3 NV*
8
NV_1 B4 A4 NV
BA1 BB1 BB1
PW_1* B11 A11 PW* 13 14
9 PW_1 B12 A12 PW XFL02B 8 8
CN5
NW_1* B5 A5 NW*
6
10 NW_1 B6 A6 NW 17
POS15V B15 A15 +15V
GND B14 A14 GND
11
IUCT_1 A5 B5 IU
GND A6 B6 GND
12 CN2
IVCT_1 A7 B7 IV
-1
GND A8 B8 GND
13 IPMFLT_1* A1 B1 IPMFLT*
GND A2 B2
Check.
GND
Appr.
Draw.
-2
DBON_1 A9 B9 DBON
14
GND A10 B10 GND
PBRDY_1* A3 B3 RDY* -3
15 GND A4 B4 GND
AXEN_1* A11 B11 GND
16 ID1_1 A12 B12 ID1
ID2_1 A13 B13 ID2
ID3_1 A14 B14 ID3
17
ID4_1 A15 B15 ID4
ID5_1 A16 B16 ID5
18
1SV(2/8): S-AXIS 1AMP,JASP-WRCA01(1/7)
YASNAC XRC
(NC) B13 A13 (NC)

NFG15V B16 A16 -15V
19 ROBOT 1AMP(JUSP-) DB-RESISTOR(R1,R2) MOTOR S-AXIS W
SV3X WS02AA - (SHORT) SGMPH-02A1A-YR1*200
20
21
1BC
22
CNPG123
ELEMENTARY DIAGRAM
(1/3) CN1 S-AXIS

23 PS_1 24 -1 -3 DATA+ -1
22 P -2 -2 P DATA- -2
PS_1* PG
BAT -3
24 P OBT -4
25 PG5V_1 45 -3 -1 +5V -1
19 P
PG5V_1 P P -2
21 -4 -6 0V
26 GND
47 FG -3
GND
HE0300332
27 CASE
FG FG
17 BATTERY
28 27
E
13 14 15
28 28 28
29 16 17
28 28
30
BAT 0BT
13 14
30 30
31
12
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
SERVO PACK 1SV(3/8)
1
MANIPULATOR
Revisions:
L-AXIS
HE0300332-13/31
CN6 P 2AMP
2 A3
12 1AMP-CN6 P P
N
3 A1 2BC
N N L-AXIS
3 B3 2CN CN2
14 P CN1 -1 -3
3AMP-CN6 B1 MU2 -2 MU2 -1
2 -2
N
4 -3 -2
JASP-WRCA01(2/7) -3
MV2 -2 MV2 -2
SM
CNPB02 CN3
MW2 -4 -3 -1 MW2 -3
5 PU_2* B7 A7 PU*
-4
PU_2 B8 A8 PU
ME2 -1 -4 -6 ME2 -4
6 NU_2* B1 A1 NU* -1
NU_2 B2 A2 NU -5 BA2
-5 -1 BRAKE
7 PV_2* B9 A9 PV*
P
PV_2 B10 A10 PV -2
NV_2* B3 A3 NV*
8
NV_2 B4 A4 NV
BA2 BB1
PW_2* B11 A11 PW* 12
9 PW_2 B12 A12 PW XFL02B 8
CN5
NW_2* B5 A5 NW* 6
B6 A6 NW 17
10 NW_2
POS15V B15 A15 +15V
GND B14 A14 GND
11
IUCT_2 A5 B5 IU
GND A6 B6 GND
12
CN2
IVCT_2 A7 B7 IV -1
GND A8 B8 GND
GND A2 B2 -2
Check.
GND
Appr.
Draw.
DBON_2 A9 B9 DBON
14
GND A10 B10 GND
PBRDY_2* RDY* -3
A3 B3
15 GND A4 B4 GND
AXEN_2* A11 B11 GND
16 ID1_2 A12 B12 ID1
ID2_2 A13 B13 ID2
ID3_2 A14 B14 ID3
17
ID4_2 A15 B15 ID4
ID5_2 A16 B16 ID5
18
1SV(2/7): L-AXIS 2AMP,JASP-WRCA01(2/7)
YASNAC XRC
(NC) B13 A13 (NC)

NFG15V B16 A16 -15V
19
20 ROBOT 2AMP(JUSP-) DB-RESISTOR(R1,R2) MOTOR L-AXIS W

SV3X WS02AA - (SHORT) SGMPH-02A1A-YR1* 200
21
22
CNPG123 1BC
ELEMENTARY DIAGRAM
(2/3) CN2 L-AXIS

23 PS_2 16 -1 -3 DATA+ 1
14 P -2 -2 P DATA- 2
PS_2* PG
BAT 3
24 P OBT 4
25 37 -3 -1 +5V 1
PG5V_2
11
PG5V_2 P
13 P P -4 -6 0V 2
GND
26 39
GND
-5 -5 FG 3
HE0300332
CASE FG
27
FG
17
28 27
E
29 12
28
30 BAT1 0BT1
12
30
31
13
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
1 SERVO PACK 1SV(4/8) MANIPULATOR
Revisions:
HE0300332-14/31
CN6
2 A3 U-AXIS
13 P P 3AMP 2BC
2AMP-PN A1
3 N N
3 B3 3CN CN3 U-AXIS
CN1 MU3 -2 -1 -3 MU3 -1
B1 -2
4 JASP-WRCA01(3/7) MV3 -3 MV3 -2
-2 -2 SM
-3
CNPB03 CN3
5 PU_3* B7 A7 PU* MW3 -4 -3 -1 MW3 -3
-4
PU_3 B8 A8 PU
ME3 -1 -4 -6 ME3 -4
6 NU_3* B1 A1 NU* -1
B2 A2 BRAKE
NU_3 NU -5 -5 BA3 -1
7 PV_3* B9 A9 PV*
P
PV_3 B10 A10 PV -2
NV_3* B3 A3 NV*
8
NV_3 B4 A4 NV
BA3 BB1
PW_3* B11 A11 PW* 12
9 PW_3 B12 A12 PW XFL02B 8
CN5
NW_3* B5 A5 NW* 6
NW_3 B6 A6 NW 17
10
POS15V B15 A15 +15V
GND B14 A14 GND
11
IUCT_3 A5 B5 IU
GND A6 B6 GND
12 A7 B7 IV
IVCT_3
GND A8 B8 GND CN2
13 IPMFLT_3* A1 B1 IPMFLT* -1
GND A2 B2
Check.
GND
Appr.
Draw.
DBON_3 A9 B9 DBON
14
GND A10 B10 GND -2
PBRDY_3* A3 B3 RDY*
15 GND A4 B4 GND
-3
AXEN_3* A11 B11 GND
16 ID1_3 A12 B12 ID1
ID2_3 A13 B13 ID2
ID3_3 A14 B14 ID3
17
ID4_3 A15 B15 ID4
ID5_3 A16 B16 ID5
18
1SV(4/8): U-AXIS 3AMP,JASP-WRCA01(3/7)
YASNAC XRC
(NC) B13 A13 (NC)

NFG15V B16 A16 -15V
19
ROBOT 3AMP(JUSP-) DB-RESISTOR(R1,R2) MOTOR U-AXIS W
SV3X WS01AA - (SHORT) SGMPH-01A1A-YR1*100
20
21
22
1BC
ELEMENTARY DIAGRAM
CNPG123
(3/3) CN3
U-AXIS
23 8 -1 -3 DATA+ -1
PS_3
6 P -2 -2 P DATA- -2
PS_3* PG
BAT -3
24
P OBT -4
29 -3 -1 +5V -1
25 PG5V_3
3
PG5V_3 P
P P
5 -4 -6 0V -2
26 GND
31 FG -3
GND
HE0300332
27
FG
17
28 27
E
12
29 28
30 BAT 0BT
12
30
31
14
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
Revisions:
HE0300332-15/31
CN6
2 A3
R-AXIS
11 P P 4AMP
1CV-CN4 A1 2BC
9 N N R-AXIS
3 B3 4CN CN4
P CN1
16 5AMP-CN6 MU4 -2 -1 -3 MU4 -1
2 B1 -2
N
4 JASP-WRCA01(4/7) MV4 -3
-3 -2 -2 MV4 -2
SM
CNPB04 CN3
5 PU_4* B7 A7 PU* MW4 -4 -3 -1 MW4 -3
-4
PU_4 B8 A8 PU
ME4 -1 -4 -6 ME4 -4
6 NU_4* B1 A1 NU* -1
NU_4 B2 A2 NU -5 -5 BA4 -1 BRAKE
7 PV_4* B9 A9 PV*
P
PV_4 B10 A10 PV BB5 -2
NV_4* B3 A3 NV*
8
NV_4 B4 A4 NV
BA4 BB5
PW_4* B11 A11 PW* 16
9 PW_4 B12 A12 PW XFL02B 9
CN5
NW_4* B5 A5 NW* 6
NW_4 B6 A6 NW 17
10
POS15V B15 A15 +15V
GND B14 A14 GND
11
IUCT_4 A5 B5 IU
GND A6 B6 GND
12 A7 B7 IV
IVCT_4
GND A8 B8 GND
(CN2)
-1
GND A2 B2
Check.
GND
Appr.
Draw.
DBON_4 A9 B9 DBON
14
GND A10 B10 GND -2
PBRDY_4* A3 B3 RDY*
15 GND A4 B4 GND
AXEN_4* A11 B11 GND -3
16 ID1_4 A12 B12 ID1
ID2_4 A13 B13 ID2
ID3_4 A14 B14 ID3
17
ID4_4 A15 B15 ID4
ID5_4 A16 B16 ID5
1SV(5/8): R-AXIS 4AMP,JASP-WRCA01(4/7)
18
YASNAC XRC
(NC) B13 A13 (NC)

NFG15V B16 A16 -15V
19 ROBOT 4AMP(JUSP-) DB-RESISTOR(R1,R2) MOTOR R-AXIS W
SV3X WSA5AA -(SHORT) SGMPH-A5A1A-YR2* 50
20
21
22
1BC
ELEMENTARY DIAGRAM
CNPG456
(1/3) CN4
R-AXIS
23 24 -1 -3 DATA+ -1
PS_4
22 P -2 -2 P DATA- -2
PS_4* PG
BAT -3
24
P 0BT -4
25 PG5V_4 45 -3 -1 +5V -1
19 P
PG5V_4
P P
26 21 -4 -6 0V -2
GND
47 FG -3
HE0300332
GND
27
FG BATTERY
17
28 E 27
12
28
29
30
BAT 0BT
16 17
30 30
31
15
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
Revisions:
HE0300332-16/31
CN6
2 A3 B-AXIS
15 4AMP-CN6 P P 5AMP
3 A1
N N 2BC
3 B3
17 P B-AXIS
6AMP-CN6 B1 5CN CN5
2 N CN1 -2 -1 -3 MU5 -1
MU5
4 JASP-WRCA01(5/7) -2
CNPB05 CN3 MV5 -3 -2 -2 MV5 -2

-3 SM
5 PU_5* B7 A7 PU*
PU_5 B8 A8 PU MW5 -4 -3 -1 MW5 -3
-4
6 NU_5* B1 A1 NU*
B2 A2 ME5 -1 -4 -6 ME5 -4
NU_5 NU -1
7 PV_5* B9 A9 PV*
-5 -5 BA5 -1 BRAKE
PV_5 B10 A10 PV
NV_5* B3 A3 NV* P
8 -6 -4 BB5 -2
NV_5 B4 A4 NV
PW_5* B11 A11 PW*
9 PW_5 B12 A12 PW BA5 BB5 BB5
15 17
NW_5* B5 A5 NW* XFL02B 8 8
10 NW_5 B6 A6 NW CN5
POS15V B15 A15 +15V 6
17
GND B14 A14 GND
11
IUCT_5 A5 B5 IU
GND A6 B6 GND
12 A7 B7 IV
IVCT_5
GND A8 B8 GND (CN2)
-1
GND A2 B2
Check.
GND
Appr.
Draw.
DBON_5 A9 B9 DBON
14 -2
GND A10 B10 GND
PBRDY_5* A3 B3 RDY*
15 GND A4 B4 GND -3
AXEN_5* A11 B11 GND
16 ID1_5 A12 B12 ID1
ID2_5 A13 B13 ID2
ID3_5 A14 B14 ID3
17
ID4_5 A15 B15 ID4
ID5_5 A16 B16 ID5
18
1SV(6/8): B-AXIS 5AMP,JASP-WRCA01(5/7)
YASNAC XRC
(NC) B13 A13 (NC)

NFG15V B16 A16 -15V
19
ROBOT 5AMP(JUSP-) DB-RESISTOR(R1,R2) MOTOR B-AXIS W

20
SV3X WSA5AA -(SHORT) SGMAH-A5A1A-YR2* 50
21
22 CNPG456 1BC
ELEMENTARY DIAGRAM
(2/3) CN5 B-AXIS

23 PS_5 16 -1 -3 DATA+ -1
14 P -2 -2 P DATA- -2
PS_5* PG
BAT -3
24 P 0BT -4
PG5V_5 37 -3 -1 +5V -1
25
11
PG5V_5 P
P P
13 -4 -6 0V -2
26 GND
39 FG -3
GND
HE0300332
27
FG
17
28 E 27
12
28
29
30 BAT 0BT
15
30
31
16
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
1
SERVO PACK 1SV(7/8) MANIPULATOR
Revisions:
HE0300332-17/31
CN6
2 A3 T-AXIS
16 P P
5AMP-CN6 6AMP
3 A1
N N 2BC
3 B3
B1 6CN CN6 T-AXIS
CN1 -1 -3 MU6 -1
MU6 -2
4 JASP-WRCA01(6/7) -2
CNPB06 CN3 MV6 -3 -2 -2 MV6 -2

-3 SM
5 PU_6* B7 A7 PU*
PU_6 B8 A8 PU MW6 -4 -3 -1 MW6 -3
-4
6 NU_6* B1 A1 NU*
B2 A2 ME6 -1 -4 -6 ME6 -4
NU_6 NU -1
7 PV_6* B9 A9 PV*
-5 -5 BA6 -1 BRAKE
PV_6 B10 A10 PV
NV_6* B3 A3 NV* P
8 -2
NV_6 B4 A4 NV
PW_6* B11 A11 PW*
BA6 BB5
9 PW_6 B12 A12 PW
16
NW_6* B5 A5 NW* XFL02B 8
NW_6 B6 A6 NW CN5
10 6
POS15V B15 A15 +15V 17
GND B14 A14 GND
11
IUCT_6 A5 B5 IU
GND A6 B6 GND
12 A7 B7 IV
IVCT_6
GND A8 B8 GND (CN2)
13 IPMFLT_6* A1 B1 IPMFLT* -1
GND A2 B2
Check.
GND
Appr.
Draw.
DBON_6 A9 B9 DBON
14
GND A10 B10 GND -2
PBRDY_6* A3 B3 RDY*
15 GND A4 B4 GND
-3
AXEN_6* A11 B11 GND
16 ID1_6 A12 B12 ID1
ID2_6 A13 B13 ID2
ID3_6 A14 B14 ID3
17
ID4_6 A15 B15 ID4
ID5_6 A16 B16 ID5
18
YASNAC XRC
(NC) B13 A13 (NC)

1SV(7/8): T-AXIS 6AMP,JASP-WRCA01(6/7)
NFG15V B16 A16 -15V

19 ROBOT 6AMP(JUSP-) DB-RESISTOR(R1,R2) MOTOR T-AXIS W
SV3X WSA5AA -(SHORT) SGMAH-A5A1A-YR2* 50
20
21
CNPG456 1BC
22 (3/3)
CN6
ELEMENTARY DIAGRAM
T-AXIS
PS_6 8 -1 -3 DATA+ -1
23 6 P -2 -2 P DATA- -2
PS_6* PG
PG5V_6 29 -3 -1 BAT -3
3 P 0BT -4
24 PG5V_6 P
5 -4 -6
GND
25
31 +5V -1
GND
P 0V -2
-5 -5 FG -3
26 CASE FG
HE0300332
27
FG
12 13 14
27 27 27
28 E 15 16
12 27 27
28
29
30 BAT 0BT
15
30
31
17
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
SERVO PACK 1SV(8/8)
Dwg.No.
1 JASP-WRCA01(7/7) CBL-RC001
Revisions:
CN10
HE0300332-18/31
SIG* -A2
2 INDATA SIG*
JL040 SIG -A3 P
CN30 OUTDATA SIG XCP01
-1 CN05
3 CONRDY1* 20
-2 CASE FG FG 4
CONRDY2*
-3
4 CONRDY* CBL-RC015-1
-4 -B2
OVFLT* SIG*
120
-5
5 OPHFLT* SIG -B3
1 CV -6
RGFLT*
CN1 -7 TERMINATION
6 11 UVFLT* CONNECTOR
15 -8
COM NOTE
7 -9
AXRUN IN CASE OF CONNECTED NEXT SERVO UNIT
-10
AXRUN*
-11 CBL-RC001
8 REGON* CN10
-12 -A2
ACOVFLT* SIG*
SIG*
9 -13 P
THM SIG -A3 XCP01 20
-14 SIG
CN05 4
THMCOM
10 CASE FG FG
SIG* -B2
SIG*
P NEXT
11 SIG -B3
SIG SERVO UNIT
+5V -5V FOR EXTERNAL
CN50 AXES CONTROL
12
CASE FG FG
-A1
GND
-B1 REGULATOR
+5V
3.3V
13 -A2
1 GS POWER LOST GND JASP-WRCF01 (OPTION)
Check.
Appr.
Draw.
2CN -B2 REGULATOR

PG7V (EXTERNAL MOTOR AXIS)
14 11 -A3
25 -15V -15V
-B3 REGULATOR PG_5V
+15V +15V
15
CNPB07
CNE CNE
CBL-RC007
CN20
16
-1 CNPB08
+24V
P -2
17 SVMXOK1
-3 CNPB09
(024V)
1SV(8/8):JASP-WRCA01(7/7),JANCD-XFC01
18 P -4
YASNAC XRC
(S_ON+)
-5
(NC) CNPG789
19 P -6
DINCOM
-7
20 TUDIN
P -8
DIN3
21 -9
DIN2
P -10
DIN1
22 XSU02 -11
CN21 +24V JANCD-XFC01
P -12
8 SVMXOK2
ELEMENTARY DIAGRAM
23 14
-13
(024V)
P -14 CBL-RC031
24 (S_ON-) CNSCU
CNS CNS -1
-15 +24V +24V
SVMAIN1+
25 P -16 -2
SVMAIN1- SVMAIN1 OVSPD1
-17 -3
SVMAIN2+ SVMAIN2 OVSPD2
26
P -18 -4
SVMAIN2- SPMODE1 SPMODE1 XSU02
HE0300332
-5 CN25
27 SPMODE2 SPMODE2 9
-6 19
SPMODE3 SPMODE3
28 -19 TUSIG -7
TUSIG INDATA 024V 024V
P -20 TUSIG*
JL012
TUSIG* OUTDATA
29
CASE FG
30
31
18
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
JZNC-XRK01B-1(1/2)
1
2GS
Revisions:
HE0300332-19/31
CPS-150F
2
CN05 CN01
XPU06B PS1 -4 -5 XCO02
+5V +5V
3 5X P CN01
PS2 -3 -4 21
5 0V 0V
5 6
-1 -2
+24V +24V XCO02
4
-1 P CN01
024V 024V 21
JANCD-XBB01(1/2) 4
5 CN03
-3
CNP CNP +24V 30
P X81 7
+5V -2
6 024V
CBL-RC032
0V CN02
-3 XSU02
7
+24V +24V
P CN20
-2 7
024V 024V
2
8 CN04
EOF -1
POWER ON/OFF
9 CONTROL PCOM -2
DC POWER ON/OFF
10
JANCD-XCP01(1/2)
11
CNS2 CNJ2 CN01

12 IOSIG* -1 IOSIG*
INDATA
JL012 IOSIG -2 P IOSIG
OUTDATA
13 ERRCPU* -5 ERRCPU+
Check.
Appr.
Draw.
ERRCPUCOM -6 P ERRCPU-
14
DINCOM -10 DINCOM
P XCO02
DIN4 -11 DIN4 CN03
15
DIN2 DIN2 21
-12
5
DIN3 -13 P DIN3
16
DIN1 -14 DIN1
17
CASE
18 FG
JZNC-XRK01B-1(1/2):JANCD-XBB01(1/2),XCP01(1/2),2GS
YASNAC XRC
CBL-RC006
19 CN02
PPSIG* -2
INDATA PPSIG*
20 JL012 PPSIG -3 P
OUTDATA PPSIG
X81 30
CASE FG 10
21 FG
CNS1 CNJ1
CN03 CBL-RC032
22
CD -1
CD
ELEMENTARY DIAGRAM
RD -2 P
RD
23 SD -3
SD
ER -4 P
ER
24 RS232C
232SG -5
232SG
DR -6 P
25 DR
RS -7
+5V RS
26 +5V2 CS -8 P
LED4:BETTERY
CS
ALARM(RED)
HE0300332
27 -5V
CNBAT
BATTERY BAT -3
28
BATALM* VOLTAGE ER6VC3N
CHECK 3.6V
PWOFF GND/G -1 (TOSHIBA)
29
+5V -5
GND/G
30
+ GND
GND
31
19
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
1
JANCD-XBB01(2/2) JANCD-XCP01(2/2) JZNC-XRK01B-1 (2/2)
Revisions:
HE0300332-20/31
2
JANCD-XIF03
3 CNIF CNIF CN05
SIG*-2
SIG*
4 JL040 SIG -3 P
SIG WRCA01
CN10
18
5
INDATA OUTDATA CASE FG 3
FG
6 CBL-RC001
8
CN04
PCMCIA
9
(PC CARD)
10
11
CNMM CNMM
12 JANCD-XMM01
(OPTION)
13
Check.
Appr.
Draw.
14
15
16
17 JANCD-XCP02
(OPTION)
18
YASNAC XRC
JZNC-XRK01B-1(2/2):JANCD-XBB01(2/2),XCP01(2/2)
CNT1-1 CNS1
19
20
21
22
ELEMENTARY DIAGRAM
23
+24V
CNFAN1 DC FAN (JZNC-XZU02)

24
FANALM1 FAN
25 CNFAN2 FG
FANALM2 FAN
FRAME to FRAME
26
CONNECTION
HE0300332
024V
27
28
29
30
31
20
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
JZRCR-XCO02 (1/8)
Dwg.No.
JARCR-XCI01(1/3)
1 CN03
CN02
Revisions:
HE0300332-21/31
IOSIG* -2 IOSIG* IOSIG* -1
(OPTION) IOSIG*
2 XEW01 IOSIG P -3 IOSIG IOSIG -2 P
CN01 IOSIG
31 ERR_CPU- -3
CBL-RC001 +24V +5V +24VU 22 23
3 -4
3 CN01 10 5 +24V
-A1
024V JL012 -5
2GS P ERRCPU ERRCPU+
-B1 P
4 (CPS-150F) +24V -6
-A2 ERRCPU-
CN01 K8 -7
19 KEYIN PLUG KEYIN PLUG XCP01
4 P/S P/S -8
5 -B2 024V CN01
-9 19
-A3 15
0V INDATA OUTDATA
-10
6 -B3 024V
2GS P
(CPS-150F) -A4
CN01 +5V 024V
7 -B4 -11
19 DIN4
3 KEYIN PLUG KEYIN PLUG -12 P
GND DIN2
-A5 -13
8 024V DIN3
-B5 -14 P
(OPTION) +24V DIN1
XEW01 -A6 +24VU +5V +24V CBL-RC006
9 CN04 024VU
31 -B6 CND1
22 +24VU
-A1,B1
+24V
10 CN04 -A3,B3
1,3,5,7 024V 024VU +5V
9,11,13 -A5,B5
024VU +24VU
11 -2 -A2,B2
OPTION INDATA 024V
-4 -A4,B4
PLAY INDATA 0V
024VU
12 -6
INDATA -A6,B6
TEACH 024VU
-8
START INDATA
13 HOLD -10 INDATA 024VU GND 024V
-A7
DIN4
Check.
Appr.
Draw.
-12 INDATA
REMOTE
-A8
-14 DIN3
14 EDITLOCK INDATA +24VU
-A9
15,17,19,21,23 DIN2
P.PANEL 25,27,29,31,33 -A10
CN1 +24VU DIN1
15 -16 22 23
SVON- SVON- 11 8
29 22 23 -A11
15 -18 FORCE1- FORCE1-
(PBESP-) 12 7
16 23 -A12
-20 FORCE2+ FORCE2+
OPTIONLED OUTDATA 5
23 -A13
-22 FST1- FST1-
PLAYLED OUTDATA 8
17 23 -A14
-24 FST2+ FST2+
TEACHLED OUTDATA 5
23 -A15
-26 S_SP1- S_SP1-
STARTLED OUTDATA 9
JZRCR-XCO02 (1/8):JARCR-XCI01(1/3)HE0300332
23 -A16
18 -28 S_SP2+ S_SP2+
HOLDLED OUTDATA 6
YASNAC XRC
-30 22 23 XCU01
OUTDATA -A17
REMOTELED 9 10 HSW1- HSW1- CND1
19 -32 DSW 23 24
ALMLED OUTDATA -A18 14
7 HSW2+ HSW2+
-34
SVONLED OUTDATA 22 23 -A19
K12 9 6 DSW1- DSW1-
20 PPESP 23
CBL-RC018 -A20
4 DSW2+ DSW2+
024VU
22 23 -A21
21 K5 4 2 PPESP1- PPESP1-
-A22
22 PPESP2+ PPESP2+
024V 14 -A23
PPESP2- PPESP2-
22
-B 7
ELEMENTARY DIAGRAM
LED1 LED1
+24V
-B 8
LED2 LED2
23 PPESP PBESP EXESP ERRCPU SYSRDY -B 9
LED3 LED3
-B10
LED4 LED4
24 K5 K6 K7 K8 K9 -B11
LED5 LED5
-B12
+24V K4 SPMOD1 SPMOD1
25 +5V
-B13
IORDY1 024V SPMOD2 SPMOD2
-B14
SYSRDY IORDY1 RDY SPMOD3 SPMOD3
26 23 -B15
SAF1 K10 S_ON1+
18 K9 K10 K11 -B16 S_ON1-
IORDY2 SYSRDY IORDY2 RDY
27 -B17
S_ON2+
K4 K3 K2 -B18
23 S_ON2-
SAF2 K3 -B19
27 PBESP2+ PBESP2+
28 22
-B20
17 PBESP2- PBESP2-
024V
PBESP
29
K6 -B21
PBESP1- PBESP1-
22 23
30 024VU 4 1 CBL-RC034-1
31
21
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
JZRCR-XCO02 (2/8)
Dwg.No.
JARCR-XCI01(2/3)
1 CN07
Revisions:
+24VU
HE0300332-22/31
CN05 -A1
024V
2 EXESP1+ -1 -A2
EXESP 024VU
EXESP1- -2 024V
23 K7
3 EXESP1- 3 024VU
EXESP2+ -3 -A3
EXESP2+ 23 EXESP-
2
-4 21 -A4
EXESP2-
4 21 PPESP1- PPESP1-
21 PBESP1- -A5
-5 29 PBESP1-
EXSVON1+
-B1
5 -6 23 SAF_F1-
EXSVON1- EXSVON1- 5 23 -B2
10 TLK TLK
-7 23 23 -B3
6 EXSVON2+ EXSVON2+ 3 8 PM PM
-8 23 -B4
EXSVON2- 9 TM TM
-B5 XSR01
EXHOLD1+ -9
7 +24V KEYIN PLUG KEYIN PLUG (OPTION)
EXHOLD1- -10 23
EXHOLD1- 11 +24VU
-C1
-11 23 +24V
8 EXHOLD2+ EXHOLD2+ 7
-C2
-12 +24VU
EXHOLD2-
21 -C3
-13 19
HSW1- HSW1-
9 SAF_F1+
21 -C4
-14 23 20 DSW1- DSW1-
SAF_F1- SAF_F1- 4
21 -C5
10 SAF_F2+ -15 23 ERR_CPU- ERRCPU-
SAF_F2+ 2 3
-16 21 -D1
SAF_F2- 15 SVON- SVON-
11 -D2
EXSVON1-
024VU -D3
EXHOLD1-
12 21 -D4
15 FORCE1- FORCE1-
-D5
13 CN06
-1
Check.
Appr.
Draw.
PPESPOUT+ PPESP2+ SW9

21
-2 21
14 PPESPOUT- PPESP2- 23 3
2 PPESP1 2 23
PPESP2 23
+24VU
1
15
INDATA
PPESPIN+ -3
16
GND
PPESPIN- -4
17 PBESPOUT+ -5
PBESP2+
21 SW8
PBESPOUT- -6 28
PBESP2- 23 3
1 PBESP1
JZRCR-XCO02 (2/8):JARCR-XCI01(2/3),XCI03(1/5) HE0300332
18 2
PBESP2 23
YASNAC XRC
+24VU 23
1
19 INDATA
-7
PBESPIN+
-8 JARCR-XCI03(1/5)
PBESPIN- DSW
20 GND CBL-RC011-1 CNA2
-9 CNA2
DSWOUT+
K12 +24VU -3 -18
-10 GND GND
DSWOUT- -4 -17
21 IO2 IO2
-5 -16
-11 GND GND
RDY+ -6 -15
IO1 IO1
-7 -14
22 RDY GND GND
-12 -8 -13
ELEMENTARY DIAGRAM
RDY- OE0* OE0*

K2
-9 -12
GND GND
024V -13 -10 -11
23 +24V LC0* LC0*
-11 -10
K11 GND GND
SCLKO -12 -9
SCLKO
-14 -13 -8
24 DC +24V GND GND
INDATA31 -14 -7
SELECT INDATA31
-15 -15 -6
024VU GND GND
OUTDATA20 -16 -5
25 OUTDATA20
-17 -4
-16 GND GND
+24VU SAMPO* -18 -3
SAMPO*
-19 -2
GND GND
26 -20 -1
RSTO* RSTO*
024V 024VU RDY 23 23
21 30
27 FG
CNA1 CBL-RC011-1 CNA1
INDATA
024VU GND 2,4,6 15,17,19
5V 5V
1,3,5 16,18,20
28 GND GND FRAME to
10,12,14 7,9,11
+24V +24V FRAME
9,11,13 8,10,12
024V 024V CONNECTION
16,18,20 1,3,5
29 +24VU +24VU
15,17,19 2,4,6
024VU 024VU
30
31
22
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
JZRCR-XCO02 (3/8)
JARCR-XCI01(3/3)
Dwg.No.
Revisions: 1 +24VU
21 23 22 23
HE0300332-23/31
PBESP1- PBESP1 EXESP2
29 14 18 22 24
2 INDATA EXESP2+
21 23 22 3 23
PPESP1- PPESP1 SAF_F2 26
21 14 14 22
INDATA 10 SAF_F2+ 23
3 22 23 EXSVON2
EXESP1- EXESP1 22 27
3 15
INDATA 6 EXSVON2+ 23
22 23 DSW2
SAF_F1- SAF_F1 21 25
4 9 16
INDATA 20 DSW2+ 23
21 23 23 FORCE2 27
ERR_CPU- ERR_CPU 21
3 15 24 FORCE2+
5 INDATA 16 23
22 23 FST2 29
EXSVON1- EXSVON1 21
5 17 FST2+
INDATA 17 23
6 21 23 S_SP2 29
DSW1- DSW1 21
20
INDATA
16 18 S_SP2+ 23
21 23 HSW2 30
FORCE1- FORCE1 21
7 15 18 HSW2+
INDATA 19 23
EXHOLD2 30
21 23 23 22
SVON- SVON EXHOLD2+
15 17 26 8
8 INDATA
21 23 +5V
FST1- FST1 GND
17 19 22
INDATA PM
9 21 23 6
S_SP1- S_SP1 PM*
18 20 22
INDATA TM
21 23 7
10 HSW1- HSW1 OUTDATA* TM*
19 20 22
INDATA TLK
22 23 5
EXHOLD1- EXHOLD1 TLK*
7 21
11 INDATA 23 23
TLK* 19 28 024VU
23 23
12 024V 024VU GND TM* 15 25
23 23
PM* 18 27
13 CPU1
Check.
Appr.
Draw.
23
2
PPESP1 SAFETY CIRCUIT
23 PBESP1 TM* SYSRDY1
14
1
23 EXESP1
3
23 ERR_CPU
15 5 PPESP1 PBESP1 EXESP1 ERRCPU DSW1 SVON SYSRDY1
23 TM*
12
23 DSW1
16 6
23 SAF_F1 SAF_F1 EXSVON1 IORDY1
4 FORCE1 SAFRDY1
23 SVON
17 8 SYSRDY1
23 EXSVON1
5 21
SAF_F1 SAF1
23 FORCE1 26
18 7
YASNAC XRC
JZRCR-XCO02 (3/8):JARCR-XCI01(3/3);SAFTY CIRCUIT:CPU1,CPU2
23 PM* PM* SAFRDY1

13
23 TLK* DSW1
19 11
23 FST1
8
23 S_SP1
TM* TLK* DSW1
20 9
23 HSW1
10
23 EXHOLD1
21 11
22 RDY
27
22 CPU2
ELEMENTARY DIAGRAM
PPESP2
22
14
SAFETY CIRCUIT
23 22 PBESP2
18 TM* SYSRDY2
23 EXESP2
1
24 23 ERR_CPU
5
23 TM* PPESP2 PBESP2 EXESP2 ERRCPU DSW2 SVON SYSRDY2
12
25 23 DSW2
JZRCR-XCO02 (4/8)
JARCR-XCU01
Dwg.No.
1 CN40 +24VU +24V CND1 CBL-RC034-1
Revisions:
HE0300332-24/31
-1 -A1,B1
FORCE1+ +24V
2 -2
FORCE1- -A2,B2
024V
-3 +5V
FORCE2+
-4 024V
3 FORCE2- -A3,B3
-5 +5V
FST1+ -A4,B4
-6 +24VU
0V
4 FST1-
-7 0V
FST2+ -A5,B5
-8 +24VU
SAFETY FST2- -A6,B6
5 SIGNAL -9 024VU
S_SP1+
-10 024VU
S_SP1- -A 7
6 -11 DIN4
S_SP2+ -A 8
-12 DIN3
S_SP2- -A 9
7 -13 DIN2
HSW1+ -A10
-14 DIN1
HSW1- -A11
-15 FORCE1
8 HSW2+ -A12
-16 FORCE2
HSW2- -A13
+24VU FST1
9 CBL-RC032 CN43 -A14
FST2
-B1 024VU -A15
DSW1+ S_SP1
-B2 -A16
10 DSW1- S_SP2
-A17
-B3 HSW1
-A18
X81 HSW2
11 -A19
30 DSW1
2 -B4 -A20
DSW2+ DSW2
12 -B5 -A21
DSW2- PPESP1-
-A22
-A1 PPESP2+
13 PPESP1+ 024VU -A23
PPESP2-
-A2 -A24
PPESP1-
Check.
Appr.
Draw.
-A3 -A25 XCI01

14 X81
30 CND1
-A4 21
12 PPESP2+
-A5 18
15 PPESP2-
+24VU +24V
16 CN44
-1
EXDIN1+
-2
EXDIN1-
17 EXDIN2+ -3
EXT. -4 +5V
EXDIN2-
DIN -5
EXDIN3+
18 EXDIN3- -6 -B 7
LED1
YASNAC XRC
-7 LED
JZRCR-XCO02 (4/8):JARCR-XCU01
EXDIN4+ YELLOW
EXDIN4- -8 -B 8
LED
LED2
19 YELLOW
-B 9
024VU +5V LED
LED3
YELLOW
-B10
20 +24V LED
LED4
YELLOW
CBL-RC007 -B11
CN41 LED
LED5
YELLOW
21 -1 -B12
SPMOD1 SPMOD01
-2 -B13
SPMOD2 SPMOD02
22 -3 -B14
SPMOD3 SPMOD03
ELEMENTARY DIAGRAM
-4 -B15
S_ON1+ S_ON1+
23 -5 -B16
S_ON2+ S_ON1-
-6 -B17
DINCOM S_ON2+
XSU02 -7 -B18
24 CN23 -8 024V S_ON2-
9 DIN3 -B19
8 -9 PBESP2+
DIN2 -B20
-10 PBESP2-
25 DIN1 -B21
-11 PBESP1-
SPMODCOM
-12 -B22
26 -13 024V -B23
S_ON2-
-14 -B24
HE0300332
S_ON1-
-15 -B25
27
-16
-17 CN42
28 -18 -A 1
PBESP2+
+24VU -A 2
-19 P.PANEL
-A 3 SA1(PBESP)
29 NOTE -20 PBESP2- 29
-B 1 16
+24V PBESP1+
SYSTEM +24V -B 2
024V
30 -B 3
+24VU PBESP1-
USER +24V
024VU
24
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
1 JZRCR-XCO02 (5/8)
Revisions:
HE0300332-25/31
2
JARCR-XCI03(2/5)
+24VU CN10
3 IN00 B1
INDATA
IN01 A1
4
GND IN02 B2
5 IN03 A2
IN04 B3
6
IN05 A3
7 IN06 B4
024VU IN07 A4
8
024VU B7
+24V 024VU A7
9
OUT00 OUT00- B8
+5V
10 OUT00+ A8
OUTDATA OUT01 OUT01- B9

11
024V OUT01+ A9
12 OUT02 OUT02- B10
OUT02+ A10
13
OUT03 OUT03- B11
Check.
Appr.
Draw.
14 OUT03+ A11
OUT04 OUT04- B12
15 OUT04+ A12
OUT05 OUT05- B13
16
OUT05+ A13
17 OUT06 OUT06- B14
OUT06+ A14
18
JZRCR-XCO02 (5/8):JARCR-XCI03(2/5)
YASNAC XRC
OUT07 OUT07- B15
19 OUT07+ A15
024VU B16
20
024VU A16
21 024VU B17
024VU A17
22 +24VU
+24VU B18
ELEMENTARY DIAGRAM
024VU
23 +24VU A18
+24VU B19
24
+24VU A19
FG B20
25
26
HE0300332
27
28
29
30
25
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
1 JZRCR-XCO02 (6/8)
Revisions:
HE0300332-26/31
2
JARCR-XCI03(3/5)
+24VU CN11
3 IN10 B1
INDATA
IN11 A1
4
GND IN12 B2
5 IN13 A2
IN14 B3
6
IN15 A3
7 IN16 B4
024VU IN17 A4
8
024VU B7
+24V 024VU A7
9
OUT10 OUT10- B8
+5V
10 OUT10+ A8
OUTDATA OUT11 OUT11- B9

11
024V OUT11+ A9
12 OUT12 OUT12- B10
OUT12+ A10
13
OUT13 OUT13- B11
Check.
Appr.
Draw.
14 OUT13+ A11
OUT14 OUT14- B12
15 OUT14+ A12
OUT15 OUT15- B13
16
OUT15+ A13
17 OUT16 OUT16- B14
OUT16+ A14
18
YASNAC XRC
OUT17 OUT17- B15
19 OUT17+ A15
024VU B16
20
024VU A16
21 024VU B17
024VU A17
22 +24VU
+24VU B18
ELEMENTARY DIAGRAM
024VU
23 +24VU A18
+24VU B19
24
+24VU A19
FG B20
25
26
27
28
29
30
26
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
JZRCR-XCO02 (7/8)
Dwg.No.
1 JARCR-XCI03(4/5)
Revisions:
HE0300332-27/31
+24VU
2 CN12
INDATA EXIN00 -B1
3 EXIN01 -A1
GND
EXIN02 -B2
4
EXIN03 -A2
5 EXIN04 -B3
EXIN05 -A3
6
EXIN06 -B4
7 EXIN07 -A4
EXIN10 -B5
8
EXNI11 -A5
EXIN12 -B6
9
EXNI13 -A6
10 024VU -B7
+5V
024VU -A7
11
EXOUT00 -B8
12 OUTDATA EXOUT01 -A8

024VU EXOUT02 -B9
13
EXOUT03 -A9
Check.
Appr.
Draw.
EXOUT04 -B10
14
EXOUT05 -A10
15 EXOUT06 -B11
EXOUT07 -A11
16
EXOUT10 -B12
17 EXOUT11 -A12
+24VU EXOUT12 -B13

18
JZRCR-XCO02 (7/8):JARCR-XCI03(4/5)
YASNAC XRC
EXOUT13 -A13
19 024VU -B16
024VU -A16
20
024VU -B17
21 024VU -A17
+24VU -B18
22
+24VU -A18
ELEMENTARY DIAGRAM
024VU
+24VU -B19
23
+24VU -A19
24
FG -B20
JZRCR-XCO02 (8/8)
Dwg.No.
1 JARCR-XCI03(5/5)
Revisions:
HE0300332-28/31
+24VU
2 CN13
INDATA EXIN14 -B1
3 EXIN15 -A1
GND
EXIN16 -B2
4
EXIN17 -A2
5 EXIN20 -B3
EXIN21 -A3
6
EXIN22 -B4
7 EXIN23 -A4
EXIN24 -B5
8
EXNI25 -A5
EXIN26 -B6
9
EXNI27 -A6
10 024VU -B7
+5V
024VU -A7
11
EXOUT14 -B8
12 OUTDATA EXOUT15 -A8

024VU EXOUT16 -B9
13
EXOUT17 -A9
Check.
Appr.
Draw.
EXOUT20 -B10
14
EXOUT21 -A10
15 EXOUT22 -B11
EXOUT23 -A11
16
EXOUT24 -B12
17 EXOUT25 -A12
+24VU EXOUT26 -B13

18
YASNAC XRC
EXOUT27 -A13
19 024VU -B16
024VU -A16
20
024VU -B17
21 024VU -A17
+24VU -B18
22
+24VU -A18
ELEMENTARY DIAGRAM
024VU
+24VU -B19
23
+24VU -A19
24
FG -B20
25
26
27
28
29
30
28
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
ZY1C-SS3152(IZUMI)
1
Revisions:
PLAYBACK PANEL(P.PANEL)
HE0300332-29/31
CBL-RC018
2 CN1
15
+24VU
3 33
+24VU SA4
16 SERVO ON READY
4 SVON- GREEN
34 SVON LED
SVONLED LED
3
5 024VU
21
+24VU
SA3
6
4 PLAY
PLAY WHITE
7 22 PLAY_LED
PLAYLED LED
5
024VU
8 23
+24VU SA2
6 TEACH
9 TEACH WHITE
24 TEACH_LED
TEACHLED LED
7
10 024VU
25
+24VU
SA5
11
8 START
START WHITE
26 START_LED
12 STARTLED LED
9
024VU
13
27
+24VU
SA6
Check.
Appr.
Draw.
10 HOLD
14 HOLD
GREEN
28 HOLD_LED
HOLDLED LED
21 XCO02 31
15 15 CN04 +24VU HL1 EMERGENCY STOP
32 ALARM_LED ORANGE
L11 PBESP1+
ALARMLED LED
11 SA1 L12
16 024VU PBESP1-
29 XCO02
+24VU R11 PBESP2+ CN42
SA7
17 24
12 REMOTE 28
REMOTE WHITE R12 PBESP2-
30 REMOTE_LED
18 REMOTELED LED 2XT
YASNAC XRC
PLAYBACK PANEL(ZY1C-SS3152)
CN2
17 ESP_COM 1 L21 PBESP3+
19
+24VU
18 ESP1 2 L22 PBESP3-
PBESP- EXPBESP
20 R21 PBESP4+
(024VU) 1 (024VU)
R22 PBESP4-
21 OPTION 2 OPTION
3 (OPTION)
(+24VU) 19 (+24VU)
22 RED
4
ELEMENTARY DIAGRAM
OPTIONLED 20 OPTION_LED LED
23
CN3
13 EDIT_LOCK_COM 1 SA8
24 024VU
14 EDIT_LOCK 2
EDITLOCK
NC(3) EDIT LOCK(OPTION)
25
NC(4)
NC(5)
26 FG
NC(6)
HE0300332
NC(7)
27
28
29
30
29
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
YASNAC-XRC JZNC-XPP02
Dwg.No.
1 CBL-RC032
Revisions:
DEADMAN SWITCH FUNCTION
HE0300332-30/31
X81 X82 1CN
GRIP GRIP SERVOPACK GRIP POSITION
-5 -5 -1
2 DSW1+ DSW1 POSITION STRENGTH BEHAVIOR CYCLE
-4 -4 -2 SB2 FREE MAIN POWER SHUTOFF
XCO02 DSW1- HA1B-M1(IZUMI)
1
(GRIP RELEASED) (CANNOT POWER ON) 1
CN43 -1 -1 -3 SOFT GRIP
2 MAIN POWER ON
3 24 DSW2+ DSW2 (1CLICK)
11 -2 -2 -4 SB3 HARD GRIP
DSW2- HA1B-M1(IZUMI) MAIN POWER SHUTOFF
3 PANIC OR
EMERGENCY (CANNOT POWER ON) 2 3
SHUTOFF
4
5
JANCD-XSP01
CNKEY SHEET KEYBOARD
6 +24V WITH CABLE
(NC) -1 (NC)
X81 X82 CNIF
-9 -9 -3 +24V +5V -2 KEYD0
7 2GS +24V
(CPS-150F) -24V -3 KEYD1
DC/DC
CN03 -10 -10 -4 -4 KEYD2
024V
8 19 024V
6 -5 KEYD3
024V GND -6 KEYD4
9
-7 KEYD5
-12 -12 -1
PPSIG* INDATA -8 KEYD6 FP5-YKD4-A
10 XCP01 -13 -13 -2 JL012
PPSIG OUTDATA -9 KEYD7 (JAE)
CN02
-11 -11
19 FG -10 KEYL0
11 20
-3 -3 -5 (PPESP+) -11 KEYL1
PPESP1+
-6 -6 -6 (PPESP-) -12 KEYL2
12 PPESP1-
XCO02 -13 KEYL3
CN43 -14 KEYL4
13 24 -7 -7 -7 (EXPPESP+)
PPESP2+
14 -15 KEYL5
-8 -8 -8 (EXPPESP-)
Check.
Appr.
Draw.
PPESP2-
-16 KEYL6
14
-17 LEDD0
-18 LEDD1
15
-19
-20 3
16
CBL-XRO05-1 FG
17
CNLCD
18
FLM
YASNAC XRC
-1
PROGRAMMING PENDANT : JZNC-XPP02
LCD MODULE
-2 CL1
19 +5V -3 CL2
CN01 LU4833
-2 -4 VCC G
20 RD RD (STANLAY)
-3 -5 GND G
SD SD
-7 -6 D_OFF*
21 RS-232C RS RS
-8 GND -7 VD3
(FC2) CS CS
-5 -8 VD2
22 GND
-9 VD1
ELEMENTARY DIAGRAM
FG
HOOD -10 VD0
23 CASE GND
FG -11 LCNEG24V
-12 VCON
24
CNCFL
-2 CFL5V
25 BACK
-1 GND/G
LIGHT
26 CNESP SB1
-1 PPESP+ NC1 NC1
HE0300332
-2 PPESP-
27
-3 EXPPESP+ NC2 NC2
-4 EXPPESP-
28
CNBZ
BUZZ+ HA1
-1
29
BUZZ- BUZZER
-2
30
30
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
Dwg.No.
1 JANCD-XEW01-1 (OPTION)
Revisions:
HE0300332-31/31
2 CBL-RCO01 CN03
CN01
-2
-A2 IOSIG* GASOF_A
XCO02 IOSIG* INDATA
P JL012 -3
3 -A3 IOSIG GASOF_B
CN02 IOSIG OUTDATA
21 -4
WIRCUT_A
2
-5
4 CBL-RC015-1 WIRCUT_B
-B2 IOSIG* -6
120 ARCACT_A
5 -B3 IOSIG -7
ARCACT_B
TERMINATION -13
CONNECTOR ARCOFI_A
6 -14
ARCOFI_B
NOTE
IN CASE OF CONNECTED NEXT I/O CONNECTION
/WELDING ARCON*
7 CBL-RC001
(INDATA) -26
CN01 STICK
STICK
-2 IOSIG* DETECTOR
8 IOSIG* -27
P STICK*
XCO02 -3 IOSIG
-23
IOSIG CUP SENSOR
CN02 CUP14V
9 21 +24VU -25
FG CASE FG CUP14*
2
Z( L)
-2 IOSOG* +5V ARCON*
IOSOG*
10
NEXT P -3 IOSIG
I/O IOSIG
(XEW01) TO
11 FG CASE FG ARCON ARCON WELDER
-15
ARCON_A
12 -16 ARCON_B
WIRINCH WIRINCH
-17
13 WIRINCH_A
-18
Check.
Appr.
Draw.
WIRINCH_B
WIRRTR WIRRTR
14 -19
WIRRTR_A
-20
WIRRTR_B
15 FLOW FLOW
-21
OUT1_A
16 -22
OUT1_B
+24VU
17 -29
+24VU
-30
024VU
18 OUT DATA
WELDING I/F BOARD:JANCD-XEW01-1 (OPTION)
YASNAC XRC
024VU
19 12bit -31 CH1_A

D/A (ANALOG OUT)
-32
CH1_G
20
12bit -33 CH2_A
D/A (ANALOG OUT)
CN04 -34
21 CH2_G
-B1
+24V +24V
P -A1 12bit -9 CH3_A
22 XCO02 024V 024V D/A (ANALOG OUT)
-B2 FU1 -10
CN01 CH3_G
ELEMENTARY DIAGRAM
+24VU +24VU
21 P FU2
-A2
23 9 024VU 024VU 024VU -1
FG
-B5
+24
24 P -A5
024V +24VU CN02
NEXT
-B6 -1
I/O +24VU +24VU
25 P -A6
024VU SEARCH SEARCH
-2
26
SEARCH_A TO
-4 WELDER
SEARCH_B
HE0300332
+24VU -5
27 NOTE 024VU
FU1,FU2
250V 1A 024VU 024VU
28 QUICK ACTING
FG
29
FRAME to FRAME
CONNECTION
30
31
31
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31

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XRC 2001 Controller

Part Number 148266-1

June 11, 2003

MOTOMAN i CSL10 Manipulator Manual (XRC 2001)

CSL10 Manipulator Manual (XRC 2001) ii MOTOMAN

1.1 About this Document

MOTOMAN 1-1 CSL10 Manipulator Manual (XRC 2001)

1.2 Reference to Other Documentation

1.3 Customer Service Information

CSL10 Manipulator Manual (XRC 2001) 1-2 MOTOMAN

It is the purchaser's responsibility to ensure that all local, county,

MOTOMAN 2-1 CSL10 Manipulator Manual (XRC 2001)

2.2 Standard Conventions

CSL10 Manipulator Manual (XRC 2001) 2-2 MOTOMAN

2.3 General Safeguarding Tips

2.4 Mechanical Safety Devices

MOTOMAN 2-3 CSL10 Manipulator Manual (XRC 2001)

2.5 Installation Safety

2.6 Programming Safety

CSL10 Manipulator Manual (XRC 2001) 2-4 MOTOMAN

• Inspect the robot and work envelope to be sure no potentially hazardous

2.7 Operation Safety

MOTOMAN 2-5 CSL10 Manipulator Manual (XRC 2001)

2.8 Maintenance Safety

CSL10 Manipulator Manual (XRC 2001) 2-6 MOTOMAN

YASKAWA MANUAL NO. RE-TA-A503 1

• General items related to safety are listed in Section 1: Safety of the

• The drawings and photos in this manual are representative examples

• If your copy of the manual is damaged or lost, contact a YASKAWA rep-

• YASKAWA is not responsible for incidents arising from unauthorized

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Always be sure to follow explicitly the items listed under this

Must never be performed.

Emergency Stop Button

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Stop

• Observe the following precautions when performing teaching operations

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the manipulator’s work envelope

Definition of Terms Used Often in This Manual

Equipment Manual Designation

Power Cable Power Cable

YASNAC XRC Controller XRC

YASNAC XRC Playback Panel Playback Panel

YASNAC XRC Programming Pendant Programming Pendant

Equipment Manual Designation

e.g., page key

Keys pressed When two keys are to be pressed simultaneously,

Displays The menu displayed in the programming pendant is

Playback Panel Buttons Playback panel buttons are enclosed in brackets,

Description of the Operation Procedure

• The label described below is attached to the manipulator.

Observe the precautions on the warning labels.

Refer to the manipulator manual for the warning label location.

Fully comply with the precautions on the warning labels.

6 Test of Program Operation

7 Home Position Confirmation

Chapter 3 explains XRC installation, location, and setup.

Chapter 5 explains how to turn the power supply on/off.