Up6 Manipulator System Manual PDF

UP6 MANIPULATOR
SYSTEM MANUAL
FOR XRC2001 CONTROLLER
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
Part Number: 172089-1CD

Revision: 1
MANUAL NO.S
RE-MTO-A211 4 RE-TA-A503 2
RE-CTO-A208 5 RE-CTO-A203 15
172089-1CD
UP6 Manipulator
Copyright 2015, Yaskawa America, Inc. All Rights Reserved.
RE-MTO-A211 RE-TA-A503
ii 2 of 656
RE-CTO-A208 RE-CTO-A203
172089-1CD
UP6 Manipulator
MANDATORY
This system manual provides an overview of the UP6 Manipulator
system. It gives general information about the system, a description
of its major components, and the procedures for installation, system
operation, and preventive and repair maintenance. Be sure to read
and understand this manual thoroughly before installing and
operating the UP6 Manipulator system.
General items related to safety are listed in Section 2 of the
XRC2001 Controller Manual. To ensure correct and safe operation,
carefully read the XRC2001 Controller Manual before reading this
manual.
CAUTION
Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure that 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 a modification is made, the manual number will also be
revised.
If your copy of the manual is damaged or lost, contact a YASKAWA
representative 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
product's warranty.
iii 3 of 656
172089-1CD
UP6 Manipulator
Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the UP6 Manipulator system.
In this manual, the Notes for Safe Operation are classified as
WARNING, CAUTION, MANDATORY, or PROHIBITED.
Indicates a potentially hazardous

WARNING situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous

CAUTION situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the

MANDATORY items listed under this heading.
PROHIBITED 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

NOTE follow all instructions, even if not designated as CAUTION.
and WARNING.
iv 4 of 656
172089-1CD
UP6 Manipulator
WARNING
Before operating the manipulator, check that servo
power is turned off when the emergency stop buttons
on the playback panel or programming 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.
TURN
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
manipulators 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 operation. 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.
v 5 of 656
172089-1CD
UP6 Manipulator
CAUTION
Perform the following inspection procedures prior to conducting
manipulator 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 cabinet
of the XRC2001 controller 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 Warning Labels in the
XRC2001 Controller Manual before operating the UP6 Manipulator
system.
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 Programming
Pendant, and supply cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
XRC2001 controller XRC
XRC2001 Programming Pendant Programming Pendant
XRC2001 Playback Panel Playback Panel
Cable between the manipulator and the Manipulator cable
controller
vi 6 of 656
172089-1CD
UP6 Manipulator
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 [ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on them are not
denoted with [ ] but depicted with a small picture.
ex. page key
The cursor key is an exception, and a picture is not shown.
Axis Keys Axis Keys and Number Keys are generic names for the
Number Keys keys for axis operation and number input.
Keys pressed When two keys are to be pressed simultaneously, the keys
simultaneously are shown with a + sign between them, ex.
[SHIFT]+[COORD]
Displays The menu displayed in the programming pendant is

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

ex. [TEACH] on the playback panel
Description of the Operation Procedure

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.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
vii 7 of 656
172089-1CD
UP6 Manipulator Table of Contents
Table of Contents
1 MOTOMAN-UP6 INSTRUCTIONS......................................................................................9
2 MOTOMAN SETUP MANUAL ...........................................................................................72
3 YASNAC XRC INSTRUCTIONS .....................................................................................127
4 YASNAC XRC INSTRUCTIONS .....................................................................................254
viii 8 of 656
MOTOMAN-UP6
INSTRUCTIONS
YR-UP6-A00
YR-UP6-A01
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
MOTOMAN INSTRUCTIONS
MOTOMAN SETUP MANUAL
MOTOMAN-UP6 INSTRUCTIONS
YASNAC XRC INSTRUCTIONS
YASNAC XRC OPERATORS MANUAL
YASNAC XRC OPERATORS MANUAL for BEGINNERS
The YASNAC XRC operators manuals above correspond to specific usage.
Be sure to use the appropriate manual.
YASKAWA ELECTRIC CORPORATION
9 of 656
MANUAL NO. RE-MTO-A211 4

MANDATORY
This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-UP6.
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
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.

modification of its products. Unauthorized modification voids your prod-
ucts warranty.
ii 10 of 656
NOTES FOR SAFE OPERATION
Read this manual carefully before installation, operation, maintenance, or inspection of the
YASNAC XRC.
In this manual, the Notes for Safe Operation are classified as WARNING, CAUTION,
MANDATORY, or PROHIBITED.
Indicates a potentially hazardous situation which, if not avoided,

WARNING could result in death or serious injury to personnel.

CAUTION 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

MANDATORY heading.
PROHIBITED 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.
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 11 of 656
WARNING
Before operating the manipulator, check that servo power is turned off
when the emergency stop buttons on the playback panel or program-
ming pendant are pressed.
When the servo power is turned off, the SERVO ON READY lamp on the
playback panel and the SERVO ON LED on the programming pendant are
turned off.
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.
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.

TURN
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.
- Ensure that you have a safe place to retreat in case of emergency.
Confirm that no persons are present in the manipulators work envelope

and that you are in a safe location before:
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 play-
back panel and programming pendant.
iv 12 of 656
CAUTION
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 manipulators 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:

The manipulator usually consists of the controller, the playback panel, the programming pen-
dant, and supply cables.
YASNAC XRC Controller XRC
YASNAC XRC Playback Panel Playback Panel
YASNAC XRC Programming Pendant Programming Pendant
v 13 of 656
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
vi 14 of 656
1 Receiving
1.1 Checking Package Contents . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2 Shipping Bolts and Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
3 Installation
3.1 Safety Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2 Mounting Procedures for Manipulator Baseplate . . . .3-2
3.2.1 When the Manipulator and Mounting Fixture are
Installed on a Common Flat Steel Plate . . . . . . . . . . . . . . . . . .3-3
3.2.2 When the Manipulator is Mounted Directly on the Floor . . . . . .3-4
3.3 Types of Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3.3.1 S-Axis Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3.3.2 Affixing the Manipulator Base . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3.3.3 Precautions to Prevent the Manipulator from Falling. . . . . . . . .3-5
3.4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
4 Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2 Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.1 Connection to the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.2 Connection to the XRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
5 Basic Specifications
5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . .5-2
5.3 Baseplate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.4 Dimensions and Working Range . . . . . . . . . . . . . . . . . . . .5-3
5.5 B-Axis Working Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
vii 15 of 656
5.6 Alterable Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7 System Application
7.1 Mounting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Allowable Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.2 Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Incorporated Wire and Airduct . . . . . . . . . . . . . . . . . . . . . . 7-2
8 Motoman Construction
8.1 Position of S-Axis Limit Switch . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9 Maintenance and Inspection

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-6
9.2.1 Battery Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.2 Grease Replenishment/Replacement for
S-Axis Speed Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Grease Replenishment (Refer to " Fig. 26 S-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Grease Replacement (Refer to " Fig. 26 S-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.2.3 Grease Replenishment/Replacement for L-Axis Speed
Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Grease Replenishment (Refer to " Fig. 27 L-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Grease Replacement (Refer to " Fig. 27 L-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.2.4 Grease Replenishment/Replacement for U-Axis Speed
Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Grease Replenishment (Refer to " Fig. 28 U-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Grease Replacement (Refer to " Fig. 28 U-Axis
Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . 9-11
viii 16 of 656
9.2.5 Grease Replenishment for R-Axis Speed Reducer . . . . . . . . .9-12
9.2.6 Grease Replenishment for B- and T-Axis Speed Reducers . .9-13
9.2.7 Grease Replenishment for T-Axis Gear . . . . . . . . . . . . . . . . .9-14
9.2.8 Grease Replenishment for R-Axis Cross Roller Bearing. . . . .9-15
9.2.9 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
Wrist Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
Encoder Connector (with CAUTION label) . . . . . . . . . . . . .9-16
10 Recommended Spare Parts
11 Parts List
11.1 S-Axis Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
11.2 L.U-Axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.3 R-Axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5
11.4 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7
ix 17 of 656
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 addi-
tional options ordered should be checked as well.):
Manipulator
XRC
Programming Pendant
Feeder Cable Between Controller and Manipulator
1-1 18 of 656
1.2 Checking the Order Number
1.2 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
ORDER. No. same order number.
YASNAC XRC UP6
YASNAC XRC
(a) XRC (Front View) (b) Manipulator (Top View)
Fig. 1 Location of Order Number Labels
1-2 19 of 656
2.1 Transporting Method
2 Transporting
CAUTION
Sling applications and crane or forklift operations must be performed by
authorized personnel only.
Failure to observe this caution may result in injury or damage.
Avoid excessive vibration or shock during transporting.
The system consists of precision components, so failure to observe this caution may
adversely affect performance.
2.1 Transporting Method
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 ".
ViewA
B
4 x M10 Eyebolts
(Provided at factory)
A
Fig. 2 Transporting Position
2-1 20 of 656
2.2 Shipping Bolts and Jigs
2.1.2 Using the Forklift

When using a forklift, the manipulator should be fixed on a pallet with shipping bolts and jigs
as shown in " Fig. 3 Using the Forklift ". Insert claws under the pallet and lift it. The pallet must
be strong enough to support the manipulator. Transporting of the manipulator must be per-
formed slowly in order to avoid overturning or slippage.
4 x M16 Bolts
Pallet
Forklift Claw Entry
Fig. 3 Using the Forklift
Check that the eyebolts are securely fastened.

NOTE The weight of the maniputator is approximately 150kg 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 exerting 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 Shipping Bolts and Jigs
The manipurator is provided with shipping bolts and jigs at points A, B, and C (" Fig. 2 Trans-
porting Position ").
The jigs are painted yellow.

The number of hexagon socket head cap screws are: A: M6 X 3, B,C: M6 X 1
Before turning on the power, check to be sure that the shipping bolts and jigs have been
NOTE removed. The shipping bolts and jigs then must be stored for future use, in the event that
the manipulator must be moved again.
2-2 21 of 656
3 Installation
WARNING
Install the safety guards.
Failure to observe this warning may result in injury or damage.
Install the manipulator in a location where the fully extended arm and
tool will not reach the wall, safety guards, or controller.
Failure to observe this warning may result in injury or damage.
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.
When mounting the manipulator on the ceiling or wall, the base section
must have sufficient strength and rigidity to support the weight of the
manipulator. Also, it is necessary to consider countermeasures to pre-
vent the manipulator from falling.
Failure to observe these warnings may result in 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
and jigs have been removed.
Failure to observe this caution may result in damage to the driving parts.
3-1 22 of 656
3.1 Safety Guard Installation
3.1 Safety Guard Installation
To insure safety, be sure to install safety guards. They prevent unforeseen accidents with per-
sonnel and damage to equipment. The following is quoted for your information and guidance.
(ISO10218)
Responsibility for Safeguarding

The user of a manipulator or robot system shall ensure that safeguards are provided and used
in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safeguard-
ing, including any redundancies, shall correspond directly to the type and level of hazard pre-
sented 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 Baseplate
The manipulator should be firmly mounted on a baseplate or foundation strong enough to sup-
port the manipulator and withstand repulsion forces during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand maximum repulsion
forces of the manipulator as shown in Table 1.
During installation, if out of the plane is not right, the manipulator shape may change and its
functional ability may be compromised. Out of the plane for installation must be kept at 0.5mm
or less. Mount the baseplate in either of the following ways: " 3.2.1 When the Manipulator and
Mounting Fixture are Installed on a Common Flat Steel Plate " or " 3.2.2 When the Manipula-
tor is Mounted Directly on the Floor ".
Table. 1 Maximum repulsion forces of the manipulator
Horizontal rotating maximum torque 2000N m

( S-axis moving direction)
Vertical rotating maximum torque 3500N m

(LU-axis moving direction)
3-2 23 of 656
3.2.1 When the Manipulator and Mounting Fixture are

Installed on a Common Flat Steel Plate
The common base should be rugged and durable to prevent shifting of the manipulator or the
mounting fixture. The thickness of the common base is 40mm or more and an M16 size or
larger anchor bolt is recommended. Affix the manipulator by fastening the plate with the M16
(mm) anchor bolts. The plate is tapped for M16 (50mm length) bolts. Tighten the bolts and
anchor bolts securely so that they will not work loose during operation. See " Fig. 4 Mounting
the Manipulator Baseplate " for the method.
4 x M16 Bolts
SpringWasher
Washer
Manipulator Base
Common
20 Base
40mm
or
More
Manipulator Base
Anchor Bolt (M16 or More)
Common Base
Fig. 4 Mounting the Manipulator Baseplate
3-3 24 of 656
3.2.2 When the Manipulator is Mounted Directly on the

Floor
The floor should be strong enough to support the manipulator. Construct a solid foundation
with the appropriate thickness to withstand maximum repulsion forces of the manipulator as
shown in Table 1. As a rough standard, when there is a concrete thickness (floor) is 150mm or
more, the base of the manipulator 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. Any thickness less than 150mm is insufficient for mounting, even if the floor is
concrete.
Concrete
4 x M16 Anchor Bolts
150mm or More
Fig. 5 Direct Mounting on the Floor
3-4 25 of 656
3.3 Types of Mounting
3.3 Types of Mounting
The manipulator can be mounted in three different ways: floor-mounted (standard), wall-
mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted types, the
three points listed below are different from the floor-mounted types.
S-Axis Working Range

Affixing the Manipulator Base
Precautions to Prevent the Manipulator from Falling
3.3.1 S-Axis Working Range

When performing a wall installation, the S-Axis movable range must be 30.
3.3.2 Affixing the Manipulator Base

When performing a wall or ceiling installation, be sure to use four M16 hexagon socket head
cap bolts. Use a torque of 206N m when screwing in the bolts.
3.3.3 Precautions to Prevent the Manipulator from Falling

When performing wall or ceiling installations, for safety purposes, take measures to keep the
manipulator from falling. Refer to " Fig. 6 When Using Ceiling and Wall-Mounted Types " for
details.
Support
Manipulator Base 4 x M16 Hexagon Socket Head Cap Bolts
(Tensile Strength: 1200N/mm2 or Above)
Fig. 6 When Using Ceiling and Wall-Mounted Types
NOTE When using wall-mounted or ceiling mounted types, contact your Yaskawa representative.
3-5 26 of 656
3.4 Location
3.4 Location
When the manipulator is installed, it is necessary to satisfy the undermentioned environmental

conditions:
0 to +45C (Ambient temperature)

20 to 80%RH (no moisture)
Free from dust, soot, or water
Free from corrosive gases or liquid, or explosive gases
Free from excessive vibration (less than 0.5G)
Free from large electrical noise (plasma)
Out of the plane for installation is 0.5mm or less
3-6 27 of 656
4 Wiring
WARNING
Ground resistance must be 100 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.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
4-1 28 of 656
4.1 Grounding
4.1 Grounding
Follow local regulations for grounding line size.
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.
A
5.5mm2or More
View A
M8 Bolt (For Grounding)
(Provided at Factory)
Fig. 7 Grounding Method
4.2 Cable Connection
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. Refer to
" Fig. 9 (a) Power Cable Connection to the Manipulator ", " Fig. 9 (b) Power Cable Connec-
tion to the XRC ".
4.2.1 Connection to the Manipulator

Before connecting two cables to the manipulator, verify the numbers: 1BC and 2BC on both
power supply 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, 1BC, and then set the lever until hearing a click.
4-2 29 of 656
4.2.2 Connection to the XRC

Remove the two entrance cable covers on the XRC side. Pass the signal cable for detection
(1BC) through one entrance, the power cable (2BC) through the other entrance, and then fas-
ten bolts on the entrances.
Connect each cable to the boards. Be sure to verify the numbers on both the cable and board
connectors before connecting, and to fasten the bolts on 1BC connectors to prevent cables
from loosening.
Connection to the XRC Connection to the manipulator
Connector Connector
A
WRCA01-CNPG123 1BC
1BC
Signal Cable
WRCA01-CNPG456 Terminal Manipulator Base Side
E
SHOCK
XIU01-CN25 1VU SHOCK
E 2BC
XIU01-CN29
2BC
Power Cable
1PWM-1-CN1 Manipulator Base Side
1PWM-1-CN2
1PWM-1-CN3
1PWM-1-CN4
1PWM-1-CN5
1PWM-1-CN6
Fig. 8 Power Cables
3BC
Connector details
Fig. 9 (a) Power Cable Connection to the Manipulator
4-3 30 of 656
Signal Cable Power Cable
Connector No.
XIU01-CN29
Connector No.
XIU01-CN25
Signal Cable
Connector No.
WRCA01-CNPG456 (upper)
WRCA01-CNPG123 (lower)
Grounding plate
for Signal and power line
Terminal No.: E
Power Cable
Tighten the screws with

screw driver(+).
Connector
1PWM-1-CN1,2,3,4,5,6
(from left side)
Fig. 9 (b) Power Cable Connection to the XRC
4-4 31 of 656
5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table. 2 Basic Specifications*1
MOTOMAN-UP6
Item Model
(YR-UP6-A00, -A01)
Operation Mode Vertically Articulated
Degree of Freedom 6
Payload 6kg
Repetitive Positioning Accuracy*2 0.08mm
S-Axis (turning) 170
L-Axis (lower arm) +155, -90
Motion U-Axis (upper arm) +190, -170

Range R-Axis (wrist roll) 180
B-Axis (wrist pitch/yaw) +225, -45
T-Axis (wrist twist) 360
S-Axis 2.44 rad/s, 140/s
L-Axis 2.79 rad/s, 160/s
Maximum U-Axis 2.97 rad/s, 170/s

Speed R-Axis 5.85 rad/s, 335/s
B-Axis 5.85 rad/s, 335/s
T-Axis 8.73 rad/s, 500/s
R-Axis 11.8Nm (1.2kgfm)

Allowable
B-Axis 9.8Nm (1.0kgfm)
Moment*3
T-Axis 5.9Nm (0.6kgfm)
R-Axis 0.24kgm2
Allowable
Inertia B-Axis 0.17kgm2
2/4)
(GD
T-Axis 0.06kgm2
Mass 130kg
Temperature 0 to 45 C
Humidity 20 to 80% RH (non-condensing)
Ambient Vibration Less than 0.5G

Conditions Free from corrosive gasses or liquids, or
explosive gasses
Others
Clean and dry
Free from excessive electrical noise (plasma)
Power Capacity 1.5kVA
*1 SI units are used in this table. However, gravitational unit is used in ( ).

*2 Conformed to ISO9283
*3 Refer to " 6.1 Allowable Wrist Load " for details on the permissible moment of inertia.
5-1 32 of 656
5.2 Part Names and Working Axes
5.2 Part Names and Working Axes
U+ R+ B+ T+
Wrist Flange
U- R- B- T-
(U) Arm
(L) Arm Wrist
L- L+
Rotary Head
S+
S- Manipulator Base
Fig. 10 Part Names and Working Axes
5.3 Baseplate Dimensions
300
260
18 dia. holes
(4 holes) 240
0.1
60
153
98
165
300
260
130 0.1
20
12 +0.018
0 dia. holes 100 0.1 153 0.1
View A
A
Fig. 11 Baseplate Dimensions (mm)
5-2 33 of 656
5.4 Dimensions and Working Range
5.4 Dimensions and Working Range
170
92
R3 3
R137
130
170
R285
1373
1073
392
188
0
Point P
1673 Working Range
80
150 640 95 320.5

173 147.5
22
130
Point P
80
1230
380
570
210 170
90
689 689
155
0
10
155
267
211
450
0 0
306
658
720
0
217
1028
309
346
667
Fig. 12 Dimesions and Working Range
5-3 34 of 656
5.5 B-Axis Working Range
5.5 B-Axis Working Range
The working range of the B-Axis maintaining a constant angle to the center of the U-arm is
shown in " Fig. 13 B-Axis Working Range ".
B-Axis
Rotation Center
Fig. 13 B-Axis Working Range
5.6 Alterable Working Range
The working range of the S-Axis can be altered according to the operating conditions as
shown in " Table. 3 S-Axis Working Range ". If alteration is necessary, contact your Yaskawa
representative in advance.
Table. 3 S-Axis Working Range
Item Specifications
170(standard)
150
S-Axis
120
Working
90
Range
60
30
5-4 35 of 656
6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist

Flange
6.1 Allowable Wrist Load
The allowable wrist load is 6kg. If force is applied to the wrist instead of the load, force on R-,
B-, and T-Axes should be within the value shown in " Table. 4 Moment and Total Inertia ".
Contact your Yaskawa representative for further information or assistance.
Table. 4 Moment and Total Inertia
Axis Moment Nm (kgfm)*1 GD2/4 Total Inertia kgm2
R-Axis 11.8 (1.2) 0.24

B-Axis 9.8 (1.0) 0.17
T-Axis 5.9 (0.6) 0.06
*1 ( ): Gravitational unit
When the volume load is small, refer to the moment arm rating shown in " Fig. 14 Moment
Arm Rating ".
The allowable total inertia is calculated when the moment is at the maximum. Contact your
Yaskawa representative when only inertia moment, or load moment is small and inertia
moment is large. Also, when the load mass is combined with an outside force, contact your
Yaskawa representative.
LB
Load Gravity
95 Position
200
LT
141
L T (mm)
W=3Kg
100
W=6Kg
B-Axis Rotaion
Center Line
0 100 167 200 238 300
L B (mm)
Fig. 14 Moment Arm Rating
6-1 36 of 656
6.2 Wrist Flange
6.2 Wrist Flange
The wrist flange dimensions are shown in " Fig. 15 Wrist Flange ". In order to see the tram
marks, it is recommended that the attachment be mounted inside the fitting. Fitting depth of
inside and outside fittings must be 5mm or less.
Tram Mark 4-M6 x P1.0 45

(Depth: 9 mm)
P.C
.D.
40
6 6 +0.018
0 dia. holes
(Depth: 9 mm)
6
50 dia. -0.027
25 dia.+0.018
0
0
Fig. 15 Wrist Flange
NOTE Wash off anti-corrosive paint (solid color) on the wrist flange surface with thinner or light oil
before mounting the tools.
6-2 37 of 656
7.1 Mounting Equipment
7 System Application
7.1 Mounting Equipment
When peripheral equipment is attached to the U-axis, the following conditions should be
observed.
7.1.1 Allowable Load

The allowable load on the U-Axis is a maximum of 15kg, including the wrist load.
For instance, when the mass installed in the wrist point is 6kg, the mass which can be
installed on the upper arm becomes 9kg.
7.1.2 Installation Position

There is a limitation also on the installation position.
" Fig. 17 Allowable Load on U-Axis " shows the distance between the U-Axis rotation center
and the load gravity.
A
W2 Z
14
Z-DirectionRestriction
Lerss than 350 W1
207
X 80
4-M6P1.0
Depth:10mm
U-Axis Rotation
Center
50
25
View A
Fig. 16 Installing Peripheral Equipment
X-Direction Restriction
20
W1=0kg
15
When Load Capacity W1
Weight W2<kg> 10 equals 6kg, Unbalanced
Moment is Not Permitted.
W1=3kg
5 W1=6kg
0
-200 -100 0 100 200 300 400
Distance Between U-Axis Rotation
Center And Load Gravity <mm>
Fig. 17 Allowable Load on U-Axis
7-1 38 of 656
7.2 Incorporated Wire and Airduct
7.2 Incorporated Wire and Airduct
Wires and an air line are incorporated into the manipulator for user application. There are 16
wires and an air duct rating. The allowable current for wires must be 3A or below for each
wire. (The total current value for pins 1 to 16 must be 40A or below). The maximum pressure
for the air duct is 490 kPa (5 kgf/cm2) and its inside diameter is 6.5mm.
Cable connector provided on U-axis

is Type JL05-2A20-29SC (with cap).
Mating plug type is JL05-6A20-29P.
Air outlet : PT3/8,

with pressure plug
Air inlet : PT3/8,
with pressure plug
Cable connector provided on S-axis

is Type JL05-2A20-29SC (with cap).
Mating plug type is JL05-6A20-29S.
A
View A
Fig. 18 Incorporated Wire and Airduct
1
2
Internal wires : 0.2mm 2,10 wires
3 : 0.75mm2 , 2 wires
4
: 1.25mm2, 4 wires
5
Pins used number 6
7 1
2 3
8
4 5
9 6
10 7 8 10
11 (0.75mm 2 ) 9
13 11 12
12 (0.75mm 2 ) 14
13 (1.25mm 2 ) 15 16
14 (1.25mm 2 )
15 (1.25mm 2 )
16 (1.25mm 2 )
Fig. 19 Detailed Drawing of Connector Pin Numbers
The same pin number (1-16) of two connectors is connected in the lead line of single 0.2mm2,
0.75mm2, or 1.25mm2.
7-2 39 of 656
8.1 Position of S-Axis Limit Switch
8 Motoman Construction
8.1 Position of S-Axis Limit Switch
The limit switches for the S-, L-, and U-Axes are located as shown in " Fig. 20 Location of
Limit Switches ". The limit switch for the S-Axis is standard. The limit switch for the L- and U-
Axes are optional (model UP6-A01). The inspection and adjustment of the limit switches
should be made after removing the cover.
LU-Axis Interference L.S.

(Option)
L-Axis Overrun L.S.

(Option)
S-Axis Overrun L.S.
Fig. 20 Location of Limit Switches
8-1 40 of 656
8.2 Internal Connections
High reliability connectors which can be easily removed are used with each connector part.
For the number and location of connectors, see " Fig. 21 Location and Numbers of Connec-
tors ".
3BC (For Internal Wire)
3BC (For Internal Wire)
Fig. 21 Location and Numbers of Connectors
Table. 5 List of Connector Types
Name Type of Connector
Base Connector JL05-2A20-29PC

for Internal Wire (JL05-6A20-29S: Optional)
U-arm Connector JL05-2A20-29SC

for Internal Wire (JL05-6A20-29P: Optional)
8-2 41 of 656
42 of 656
Feeder Cable Internal Wiring B and T Axes Internal wiring
LB1 LA2
YASNAC-XRC LB2 P LB2 for Laxis L.S. A3
AL1 AL1
AL2 P AL2 for Fan
1BC(66) BAT
No. 1CN OBT
WRCA01 CN 1- 1 DATA+1 -1 DATA+ 1
CNPG123 24 CN 1-2
22 P DATA-1 P -2 DATA- 1
-3 BAT
-4 OBT
19 PG S-AXIS
45 P CN 1-3 +5-1 -5 +5V
21
P CN 1-4 0V-1 P -6 0V
47 P -7 FG 1
BAT
No. 2CN OBT
16 CN2- 1 DATA+2 -1 DATA+2
14 P CN2-2 DATA-2 P -2 DATA-2
-3 BAT
-4 OBT
11 PG L-AXIS
37 P CN2-3 +5-2 -5 +5V
13
P CN2-4 0V-2 P -6 0V
39 CN2-5 FG2 -7 FG2
BATTERY BAT1 BAT1

P P OBT1
0BT1
BAT1
P
0BT1
BATTERY BAT4 BAT4
P P OBT4
0BT4
BAT4 BAT
P No.5CN OBT
CN3- 1 0BT4
8 DATA+3 -1 DATA+3
6 P CN3-2 DATA-3 P -2 DATA-3
-3 BAT
-4 OBT
3 PG U-AXIS
29 P CN3-3 +5-3 -5 +5V
5
P CN3-4 0V-3 P -6 0V
31 -7 FG3
FG
BAT
No. 6CN OBT
WRCA01 CN4- 1 DATA+4 -1 DATA+4
CNPG456 24 CN4-2
22 P DATA-4 P -2 DATA-4
-3 BAT
-4 OBT
19 PG R-AXIS
45 P CN4-3 +5-4 No.7CN
21
P CN4-4 0V-4 P -1 +5V
-2 0V
47 -3 FG4
P
BAT
No.8CN No.14CN OBT
16 CN5- 1 DATA+5 -1 DATA+5 -1 DATA+5
P CN5-2 DATA-5 P -2 DATA-5 P -2 DATA-5 B-AXIS
14 -3 BAT -3 BAT
-4 OBT P -4 OBT
11 PG
37 P CN5-3 +5-5 No.15CN
13
P CN5-4 0V-5 P -5 +5V -1 +5V
-6 0V P -2 0V
39 -3 FG5
P
BAT
No.9CN No.16CN OBT
8 CN6- 1 DATA+6 -1 DATA+6 -1 DATA+6
CN6-2 DATA-6 P -2 DATA-6 P -2 DATA-6 T-AXIS
6 -3 BAT
-4 OBT
3 PG
29 P CN6-3 +5-6 No.17CN
5
P CN6-4 0V-6 P -3 +5V -1 +5V
-4 0V P -2 0V
31 CN6-5 FG6 -5 FG6 -3 FG6
FG
No.20CN
XIU01-CN25 20CN-1 B1 B1 1 1
-2 SS1 SS1 2 P 2
-A1 -3 BC1 BC1 U
-B1 CN2-6 +24V -4 LA1 BC2 P V For LAMP (OPTION)
-D1 CN3-6 LB1 -5 LB1
-A3 CN4-6 BC2 -6 BC2 LB2 LA3
-C1 CN5-6 0V
-D2 B2 LB1 P LB3 for L,Uaxis interference L.S.
-C3 CN6-6 SS2 SS2
A1 LA1 A2
-D3 E LB1
E S-AXIS OVERRUN L.S.
Fig. 22 (a) Internal Connection Diagram
8-3 43 of 656
Feeder Cable Internal Wiring B and T Axes Internal wiring
E
Base Casing 3BC(20-29)
3BC(20-29)
E E E E E
3BC-1 1 1 1 1 1 1 2BC-1
-2 2 2 2 P 2 2 2 -2
-3 3 3 3 3 3 3 -3
-4 4 4 4 P 4 4 4 -4
-5 5 5 5 5 -5
-6 6 6 6 P 6 -6
-7 7 7 -7
-8
-9
8
9
P 8
9
-8
-9
Incorporated wires
-10 10 P 10 -10
-11 11 0.75 11 -11
-12 12 0.75 12 -12
-13 13 1.25 13 -13
-14 14 1.25 14 -14
-15 15 1.25 15 -15
-16 16 1.25 16 -16
2BC(6X6)
E E
AC1 AC1 For FAN (OPTION)
AC2 AC2
1PWM-1-CN1 No.3CN
-2 CN 1- 1 MU1 3CN-1 MU1
-3 CN 1-2 MV1 -2 MV1
SM S-AXIS
-4 CN 1-3 MW1 -3 MW1
-1 CN 1-4 ME1 -4 ME1
CN 1-5 BA1 -5 BA1
CN 1-6 BB1 -6 BB1 YB
2PWM-1-CN1 No.4CN
-2 CN2- 1 MU2 4CN-1 MU2
-3 CN2-2 MV2 -2 MV2
L-AXIS
CN2-3 SM
-4 MW2 -3 MW2
-1 CN2-4 ME2 -4 ME2
CN2-5 BA2 -5 BA2
-6 BB2 YB
3PWM-1-CN1 No.10CN
-2 CN3- 1 MU3 10CN-1 MU3
-3 CN3-2 MV3 -2 MV3
SM U-AXIS
-4 CN3-3 MW3 -3 MW3
-1 CN3-4 ME3 -4 ME3
CN3-5 BA3 -5 BA3
-6 BB3 YB
4PWM-1-CN1 No.11CN
-2 CN4- 1 MU4 11CN-1 MU4
-3 CN4-2 MV4 -2 MV4
SM R-AXIS
-4 CN4-3 MW4 -3 MW4
-1 CN4-4 ME4 -4 ME4
CN4-5 BA4 -5 BA4
CN4-6 BB4 -6 BB4 YB
5PWM-1-CN1 No.12CN No.18CN

-2 CN5- 1 MU5 12CN-1 MU5 18CN-1 MU5
CN5-2 MV5 -2 MV5 -2 MV5
1.000
10.000 1.890 0.000 0.000 0.000 0.000 0.000 3.150 12.000 0 )
(1.260
B-AXIS
4.000
-3 CN5-3 SM
-4 MW5 -3 MW5 -3 MW5
-1 CN5-4 ME5 -4 ME5 -4 ME5
CN5-5 BA5 -5 BA5 -5 BA5
-6 BB5 -6 BB5 YB
6PWM-1-CN1 No.13CN No.19CN
-2 CN6- 1 MU6 -1 MU6 19CN-1 MU6
-3 CN6-2 MV6 -2 MV6 -2 MV6
SM T-AXIS
-4 CN6-3 MW6 -3 MW6 -3 MW6
-1 CN6-4 ME6 -4 ME6
CN6-5 BA6 -4 BA6 -5 BA6
-6 BB6 YB
XIU01-CN29
-B1
-A1
-C1
-D1
-B2
-A2
-C2 LA1
-D2 LB1 LB1
S-AXIS OVERRUN L.S.
Notes LA2
LB2 LB2 L-AXIS OVERRUN L.S.
1 .These drawings are applicable to UP6-A00. LA3
PE
2. In case of UP6-A01, connection of part A LB3
L AND U-AXIS INTERFERENCE L.S.
was changed as shown in the right drawing. UP6-A01
Fig. 22 (b) Internal Connection Diagram
8-4 44 of 656
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.
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.
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 inter-
vals are displayed in six levels. Conduct periodical inspections according to the inspection
schedule in " Table. 6 Inspection Items ".
In " Table. 6 Inspection Items ", the inspection items are classified into three types of opera-
tion: operations which can be performed by personnel authorized by 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.
The inspection interval must be based on the servo power supply on time.
NOTE These inspections were developed for applications where the manipulator is used for arc
welding work. For any different or special applications, the inspection process should be
developed on an case-by-case basis.
For axes which are used very frequently (in handling applications, etc.), it is recom-
mended that inspections be conducted at shorter Intervals. Contact your Yaskawa repre-
sentative.
9-1 45 of 656
Table. 6 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

24000 36000 Specified Service
Daily H H H Person
Licensee
Company
H H
Cycle Cycle Cycle
Check tram mark

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

External lead Visual and deterioration of
leads.
Clean the work area

Working area if dust or spatter is
and Visual present. Check for
manipulator damage and outside
cracks.
S,L,U-axes Check for grease

Visual
motor leakage.*5
Baseplate Tighten loose bolts.

Spanner Replace if necessary.
mounting Wrench
bolts
Cover mount- Screw- Tighten loose bolts.

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

Manual nectors.
tors
RBT-axes Check for belt

Manual tension and wear.
timing belt
Check for conduc-

tion between the
main connecter of
Visual base and intermedi-
Wire harness
Multimeter ate connector with
in manipulator manually shaking the
(SLURBT- wire. Check for wear
axes leads)) of protective spring*1
Replace*2
Check for conduc-

Visual tion between termi-
Wire harness
Multimeter nals and wear of
In manipulator
protective spring.*1
(BT-axes
leads)
Replace*2
Replace the battery

Battery unit in unit when the battery
11 alarm occurs or the
manipulator manipulator drove for
36000H.
9-2 46 of 656

Daily H H H Person
Licensee
Company
H H
Cycle Cycle Cycle
Check for malfunc-

tion. (Replace if nec-
essary.) Supply
grease*3 (6000H
cycle). See Par. "
9.2.2 Grease
Replenishment/
S-axis speed Replacement for S-
Grease
12 Axis Speed Reducer
reducer Gun
"
Replace grease*3.
(12000H cycle)
See Par. " 9.2.2
Grease Replenish-
ment/Replacement
for S-Axis Speed
Reducer "
Check for malfunc-

essary.) Supply
grease*3 (6000H
cycle). See Par. "
9.2.3 Grease
Replenishment/
LU-axes Replacement for L-
Grease
13 speed reduc- Gun
Axis Speed Reducer
ers "
Replace grease*3
(12000H cycle). See
Par. " 9.2.3 Grease
Replenishment/
Replacement for L-
Axis Speed Reducer
"
Check for malfunc-

essary.) Supply
grease*3 (6000H
cycle).
RBT-axes See Par. " 9.2.4
Grease
14 speed reduc- Gun Grease Replenish-
ers ment/Replacement
for U-Axis Speed
Reducer ", " 9.2.5
Grease Replenish-
ment for R-Axis
Speed Reducer "
Check for malfunc-

essary.) Supply
grease*3 (6000H
Grease cycle).
15 T-axis gear Gun See Par. " 9.2.6
Grease Replenish-
ment for B- and T-
Axis Speed Reducers
"
9-3 47 of 656

Daily H H H Person
Licensee
Company
H H
Cycle Cycle Cycle
Check for malfunc-

essary.) Supply
grease*3 (6000H
cycle).
R-axis cross Grease See Par. " 9.2.7
16
roller bearing Gun Grease Replenish-
ment for T-Axis Gear
", " 9.2.8 Grease
Replenishment for R-
Axis Cross Roller
Bearing "
17 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 " 9.2.9 Notes for Maintenance ")
*2 Wire harness in manipulator to be replaced at 24000H inspection.
*3 For the grease, refer to " Table. 7 Inspection Parts and Grease Used ".
*4 Inspection No. correspond to the numbers in " Fig. 23 Inspection Parts and Inspection Numbers ".
*5 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can
cause a motor breakdown. Contact your Yaskawa representative.
5 14 R-Axis
4 8 T-Axis
8 B-Axis
8 R-Axis
1 S-Axis 14 T-Axis
10 15 16
1 B-Axis B-Axis 4 for ceiling-
mounted
2
13
1
1 R-Axis
T-Axis
1 U-Axis
4
1 L-Axis 4 for ceiling-
mounted
13
11 2 7
9
4
12
Fig. 23 Inspection Parts and Inspection Numbers
9-4 48 of 656
Table. 7 Inspection Parts and Grease Used
No. Grease Used Inspected Parts
12, 13 Molywhite RE No. 00 S-, L-, and U-axis speed reducers
Harmonic Grease SK-1A R-, B-, and T-axis speed reducers,

14, 15
T-axis gear
16 Alvania EP Grease 2 R-axis cross roller bearings
The numbers in the above table correspond to the numbers in " Table. 6 Inspection Items ".
9-5 49 of 656
9.2 Notes on Maintenance Procedures
9.2.1 Battery Unit Replacement

If the battery alarm occurs in the XRC, replace the battery according to the following proce-
dure:
Battery
Unit
2BC 1BC
3BC
Connector
Base
Connector Support
Base Bolt
Fig. 24 Battery Location
Battery unit for SLU-axes

See Procedure 6 before replacement HW9470932-A
(See " Table. 8
See Procedure 7 a: Insertion-type pin terminal(Pin)
b: Insertion-type pin terminal(Socket) Spare Parts for
0BT1 a b 0BT1 the Motoman-UP6 ")
BAT1 b a BAT1
b 0BT1
0BT1 a
a BAT1
BAT1 b
See Procedure 4 for RBT-axes before

See Procedure 6 replacement
See Procedure 7
See Procedure 5 New battery unit
0BT4 a b 0BT4
BAT4 b a BAT4
0BT4 a b 0BT4
BAT4 b a BAT4
See Procedure 4 Connector base Support

HW9470917-A
(See " Table. 8
Spare Parts for
the Motoman-UP6 ")
Fig. 25 Battery Connection
1. Turn the XRC main power supply off.

2. Remove the connector base, and grease tube from the union.
3. Remove the battery unit mounting screw on the support.
4. Remove the plastic tape (insulation tape) protecting the connection part of the battery
unit in the manipulator.
9-6 50 of 656
5. Connect the new battery.

6. Remove the old battery.
NOTE Remove the old battery unit after connecting the new one so that the encoder absolute
data does not disappear.
7. Protect the connection part of the battery unit in the manipulator with plastic tape (insu-
lation tape).
8. Mount the battery unit with the screws, connect the grease tube to the union, and then
mount the connector base.
9.2.2 Grease Replenishment/Replacement for S-Axis

Speed Reducer
So: Grease
exhaust plug
G Nipple
A-PT1/8
2BC 1BC
Si: Grease Inlet S-axis speed

reducer
G Nipple A-PT1/8
Fig. 26 S-Axis Speed Reducer Diagram
NOTE For ceiling mounted manipulators, the exhaust port and the grease inlet are inverted.
9-7 51 of 656
Grease Replenishment (Refer to " Fig. 26 S-Axis Speed Reducer

Diagram ".)
Replenish the grease according to the following procedure:
1. Remove the So exhaust plug.
NOTE If grease is added without removing the exhaust plug, the grease will go inside the motor
and may damage it. It is absolutely necessary to remove the plug.
2. Inject the grease into the Si grease inlet using a grease gun.
Grease type: Molywhite RE No. 00

Amount of grease: 30cc
(60cc for 1st supply)
3. Move the S-axis for for a few minutes to discharge the excess grease.
4. Reinstall the So exhaust plug.
Grease Replacement (Refer to " Fig. 26 S-Axis Speed Reducer

Diagram ".)
1. Remove the So exhaust plug.
NOTE If grease is added without removing the exhaust plug, the grease will go inside the motor
and may damage it. It is absolutely necessary to remove the plug.
2. Inject the grease into the Si grease inlet using a grease gun.

3. The grease replacement is complete when new grease appears in the So exhaust port.
The new grease can be distinguished from the old grease by color.
4. Move the S-axis for for a few minutes to discharge the excess grease.
5. Wipe the So exhaust port with a cloth and reinstall the plug.
9-8 52 of 656
9.2.3 Grease Replenishment/Replacement for L-Axis Speed

Reducer
L-arm Lo: Grease

exhaust plug
G Nipple A-MT6 x1
L-axis speed
reducer
Li: Grease inlet

G Nipple A-MT6 x 1
Fig. 27 L-Axis Speed Reducer Diagram
Grease Replenishment (Refer to " Fig. 27 L-Axis Speed Reducer

Diagram ".)
1. Make the L-arm vertical for ground.
2. Remove the Lo exhaust plugs.
NOTE If grease is added without removing the exhaust plugs, the grease will go inside the motor
and may damage it. It is absolutely necessary to remove the plugs.
3. Inject grease into the Li grease inlet using a grease gun.

4. Move the L-Axis for for a few minutes to discharge the excess grease.
5. Wipe the Lo exhaust plugs with a cloth and reinstall the plugs.
9-9 53 of 656
Grease Replacement (Refer to " Fig. 27 L-Axis Speed Reducer Dia-

gram ".)
1. Make the L-arm vertical for ground.
2. Remove the Lo exhaust plugs.
3. Inject grease into the Li grease inlets using a grease gun.

Amount of grease: approx. 200cc
4. The grease replacement is complete when new grease appears in the Lo exhaust
ports. The new grease can be distinguished from the old grease by color.
5. Move the L-Axis for for a few minutes to discharge the excess grease.
6. Wipe the Lo exhaust plugs with a cloth and reinstall the plugs.
9.2.4 Grease Replenishment/Replacement for U-Axis

Speed Reducer
U-arm
Uo: Grease
exhaust plug
G Nipple A-MT6 x 1
U-axis speed
reducer
Ui: Grease Inlet

G Nipple A-MT6 x 1
Fig. 28 U-Axis Speed Reducer Diagram
9-10 54 of 656
Grease Replenishment (Refer to " Fig. 28 U-Axis Speed Reducer

Diagram ".)
1. Make the U-arm horizontal for ground.
2. Remove the Uo exhaust plugs.
3. Inject grease into the Ui grease inlet using a grease gun.

4. Move the U-Axes for a few minutes to discharge the excess grease.
5. Wipe the Uo exhaust plugs with a cloth and reinstall the plugs.
Grease Replacement (Refer to " Fig. 28 U-Axis Speed Reducer

Diagram ".)
1. Make the U-arm horizontal for ground.
2. Remove the Uo exhaust plugs.
3. Inject grease into the Ui grease inlets using a grease gun.

Amount of grease: approx. 200cc
4. The grease replacement is complete when new grease appears in the Uo exhaust
ports. The new grease can be distinguished from the old grease by color.
5. Move the U-Axes for a few minutes to discharge the excess grease.
6. Wipe the Uo exhaust plugs with a cloth and reinstall the plugs.
9-11 55 of 656
9.2.5 Grease Replenishment for R-Axis Speed Reducer
Ro: Plug for air flow

(Hexagon socket head M6)
A
R-axis speed
reducer
Ri: Grease inlet

G Nipple A-MT6 x1
Section A-A
Fig. 29 R-Axis Speed Reducer Diagram
1. Remove the Ro plug for air flow.

2. Inject grease into the Ri grease inlet using a grease gun. (Refer to " Fig. 29 R-Axis
Speed Reducer Diagram ".)
Grease type: Harmonic grease SK-1A

(16cc for first supply)
NOTE The Ro exhaust port is used for air flow. Do not inject excessive grease into the Ri grease
inlet.
3. Reinstall the Ro plug.
9-12 56 of 656
9.2.6 Grease Replenishment for B- and T-Axis Speed

Reducers
Bo: Plug for air flow
T-axis
speed
reducer
To: Plug for air flow
B-axis speed reducer

Bi: Grease inlet
G Nipple A-MT6 x 1
Ti: Grease inlet

G Nipple A-MT6 x 1
Fig. 30 B- and T-Axis Speed Reducers Diagram
1. Remove the Bo and To plugs for air flow.
NOTE Remove the U-arm cover side of the B-axis speed reducer.
2. Inject grease into the Bi and Ti grease inlets using a grease gun. (Refer to " Fig. 30 B-
and T-Axis Speed Reducers Diagram ".)

Amount of grease:
For B-axis (Bi): 10cc (20cc for 1st supply)
For T-axis (Ti): 5cc (10cc for 1st supply)
NOTE The Bo and To exhaust ports are used for air flow. Do not inject excessive grease into the
Bi and Ti grease inlets.
3. Reinstall the Bo and To plugs.
NOTE Mount the U-arm cover side of the B-axis speed reducer. (Refer to " 9.2.9 Notes for Main-
tenance ")
9-13 57 of 656
9.2.7 Grease Replenishment for T-Axis Gear
Bo: Plug for air flow
Gear Grease Inlet

(G Nipple A-MT6 x 1)
Fig. 31 T-Axis Gear Diagram
1. Remove the Bo plug for air flow.

2. Inject grease into the gear grease inlet using a grease gun. (Refer to " Fig. 31 T-Axis
Gear Diagram ".)

NOTE The Bo exhaust port is used for air flow. Do not inject excessive grease into the gear
grease inlet.
3. Reinstall the Bo plug.
9-14 58 of 656
9.2.8 Grease Replenishment for R-Axis Cross Roller Bear-

ing
Co plug for air flow
R-axis cross
roller bearing
Ci: Grease Inlet

(G Nipple A-MT6 x 1)
Section A-A
Fig. 32 R-Axis Cross Roller Bearing Diagram
1. Remove the Co plug for air flow.

2. Inject grease into the Ci grease inlet using a grease gun. (Refer to " Fig. 32 R-Axis
Cross Roller Bearing Diagram ").
Grease type: Alvania EP grease 2

NOTE The Co exhaust port is used for air flow. Do not inject excessive grease into the gear
grease inlet.
3. Reinstall the Co plug.
9-15 59 of 656
9.2.9 Notes for Maintenance

Wrist Axes
The motor and encoder units are provided with the wrist unit. To prevent fumes from penetrat-
ing into the wrist unit, the matched parts are sealed with silicon sealant. Therefore, if the wrist
cover is disassembled, reseal with silicon sealant (modifier silicon caulk, refer to " Table. 8
Spare Parts for the Motoman-UP6 ").
Cover
Cover joining face
Cover joining face

Cover
Fig. 33 Sealing Part of Wrist Unit
Encoder Connector (with CAUTION label)

Connect the battery unit with reference to the following figure before removing the encoder
connector (with CAUTION label).
Encoder
Motor
Motor cable etc
a: Insertion-type pin terminal(Pin)

b: Insertion-type pin terminal(Socket)
Internal Power connector
wire
Connection
b 0BT4
0BT a a BAT4
BAT b
removing connector.
to save the data before
Connect battery to encoder
CAUTION
Encoder connector battery unit
CAUTION label
Connection diagram
0BT a b 0BT4
BAT b a BAT4
CAUTION Label (Enlarged View)
Battery unit type:

CAUTION HW9470917-A
(See " Table. 8 Spare Parts for the
Motoman-UP6 ")
Connect battery to encoder
to save the data before
removing connector.
Fig. 34 Encoder Connector Diagram
9-16 60 of 656
10 Recommended Spare Parts
It is recommended that the following parts and components be kept in stock as spare parts for
the Motoman-UP6. The spare parts list for the Motoman-UP6 is shown below. Product perfor-
mance 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 For replacing parts in Rank B or Rank C, contact your Yaskawa representative.
Table. 8 Spare Parts for the Motoman-UP6
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
Grease Molywhite Yaskawa Electric

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

A 2 2.5kg -
SK-1A System Co., Ltd.
Grease Alvania EP Showa Oil Co.,

A 3 16kg -
Grease 2 Ltd.
Silicon Rubber Modifier Silicon Konishi Co., Ltd.

A 4
Compound Tube Caulk
Battery Unit HW9470932-A Yaskawa Electric for SLU-axes

A 5 1 1
Corporation
Battery Unit HW9470917-A Yaskawa Electric for RBT-axes

A 6 1 1
Corporation
R-Axis Timing Belt 60S4.5M338 Mitsuboshi Belt-

B 7 1 1
ing Limited
B-Axis Timing Belt 60S4.5M518 Mitsuboshi Belt-

B 8 1 1
ing Limited
T-Axis Timing Belt 60S4.5M387 Mitsuboshi Belt-

B 9 1 1
ing Limited
S-Axis HW9280729-A Yaskawa Electric

B 10 1 1
Speed Reducer Corporation
L-Axis HW9280732-A Yaskawa Electric

B 11 1 1
U-Axis HW9280738-A Yaskawa Electric

B 12 1 1
10-1 61 of 656
Table. 8 Spare Parts for the Motoman-UP6
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
R-Axis HW9381377-A Yaskawa Electric

B 13 1 1
B-Axis HW9381454-A Yaskawa Electric

B 14 1 1
T-Axis HW9381379-A Yaskawa Electric

B 15 1 1
Internal Wiring HW9171470-A Yaskawa Electric

B 16 1 1
Corporation
B- and T-Axes HW9371034-A Yaskawa Electric in U-arm

B 17 1 1
Internal Wiring Corporation
S-and U-Axes HW9381362-A Yaskawa Electric With brake, with

AC Servomotor Corporation key, lead terminal
C 18 1 2
treatment comple-
tion
L-Axis HW9381363-A Yaskawa Electric With brake, with

C 19 1 1
treatment comple-
tion
R-, B- and T-Axes HW9381370-A Yaskawa Electric With brake, no

C 20 1 3
treatment comple-
tion
Limit Switch Set HW9371069-A Yaskawa Electric Lead terminal

C 21 Corporation 1 1 treatment comple-
tion
Wrist Unit HW9170593-A Yaskawa Electric

C 22 1 1
Corporation
R-axis Driving Unit HW9370934-A Yaskawa Electric

C 23 1 1
Corporation
10-2 62 of 656
11.1 S-Axis Parts List
11 Parts List
11-1 63 of 656
No. DWG No. Name Pcs. No. DWG No. Name Pcs.
1001 HW9100881-1 Base 1
1057 M5 6 Round head 1
1002 POC6-01M Union 1 screw
1003 NB-0640-0.25 Tube 1 1058 M6 8 APS bolt 1
1004 HW9100941-1 S head 1 1059 TA1-S10 Clamp 1
1005 HW9302222-1 M base 1 1060 T50R Insulock tie 1
1006 A-MT6 1 G nipple 1 1061 M5 10 APS bolt 4
1007 M5 5 H set screw 1 1062 M10 I bolt 2
1008 GT-SA M8 30 Socket screw 4
1011 SDMDH-06A2A- Motor 1
YR24
1012 M8 50 Socket screw 3
1013 2H-8 Spring washer 3
1014 HW9230729-A Reduction gear 1
1018 HW9405026-1 Cover 1
1019 M5 10 APS bolt 2
1020 HW9405273-1 Dog 1
1023 HW9302303-1 Cover 1
1024 M5 16 APS bolt 4
1025 HW9302270-1 Support 1
1027 CD-31 Saddle 1
1028 M6 8 APS bolt 2
1029 TA1-S10 Clamp 1
1030 M5 10 APS bolt 1
1031 T50R Insulok tie 1
1032 HW9371069-A LS ASSY 1
1039 HW9405238-A Stopper 1
1041 M6 Washer 1
1042 HW9405284-A Stopper 1
1044 M6 Washer 1
1045 TA1-S10 Clamp 1
1046 M5 10 APS bolt 1
1047 T50R Insulock tie 1
1050 HW9405420-1 Support 1
1051 PMF6-01 Union 1
1052 KQE10-03 Union 1
1053 3/8-19 Plug 1
1054 A-PT1/8 G nipple 1
1055 CD-31 Saddle 1
screw
11-2 64 of 656
11.2 L.U-Axis Driving Unit
11-3 65 of 656
No. DWG No. Name Pcs.

1004 HW9100941-1 S head 1
2001 SGMDH-12A2A- Motor 1
YR12
2003 HW9100942-1 L arm 1
2005 GT-SH M14 Washer 6
2006 A-MT6 1 G nipple 1
2011 HW9302190-1 Cover 1
2012 M6 8 APS bolt 4
2013 SGMDH-06A2A- Motor 1
YR-24
2015 HW9280738-A Reduction 1
Gear
2019 HW9100943-1 Casing 1
2022 HW9405283-A Stopper 2
2026 HW9200893-1 Cover 1
2028 HW9405357-1 Cover 1
11-4 66 of 656
11.3 R-Axis Driving Unit
11-5 67 of 656
No. DWG No. Name Pcs.

2019 HW9100943-1 Casing 1
3004 HW9381397-A Cross rollar 1
bearing
3006 HW9301499-1 Housing 1
3008 SGMPH-01A1A- Motor 1
YR21
3010 HW9482235-A Pulley 1
3012 60S4.5M338 Timing belt 3
3013 HW9301500-1 Stopper 1
3014 HW9405356-1 Plate 1
3015 M5 10 APS bolt 2
3016 HQE10-03 Union 1
3017 PT3/8 Plug 1
3018 HW9301976-1 Support 1
3020 HW9302409-1 Support 1
3022 HW9482236-A Pulley 1
3024 6806ZZ Bearing 1
3025 6809ZZ Bearing 1
3026 IRTW-58 Retaining ring 1
3029 CD-12 Saddle 1
3030 M5 10 APS bolt 2
3031 TAI-S8 Clamp 1
screw
3034 M6 8 H set screw 1
3035 LP-M5 Plug 1
3036 HW9482408-A Seat 1
3037 T50R Insulok tie 1
4004 HW9100796-1 U arm 1
11-6 68 of 656
11.4 Wrist Unit
11.4 Wrist Unit
11-7 69 of 656
11.4 Wrist Unit
No. DWG No. Name Pcs. No. DWG No. Name Pcs.
3006 HW9301499-1 Housing 1
3028 GT-SA M6 40 Socket screw 8 screw
4001 SGMPH-01A1A- Motor 1 4051 T50R Insulok tie 1
YR21 4052 A-MT6 1 G nipple 2
4002 SGMPH-01A1A- Motor 1 4053 M6 6 H set screw 1
YR21
4054 LP-M5 Plug 1
4003 GT-SA M4 16 Socket scerw 6
4055 SP-0120** shim 1
4004 HW9100796-1 U arm 1
4056 HW9482404-A Seat 1
4005 HW9200780-1 Cover 2
4007 HW9405025-1 Support 1
4009 HW9482352-A Pulley 2
4013 HW9482220-A Pulley 1
4015 HW9482219-A Pulley 1
4017 HW9404986-1 B cover 1
4019 HW9404529-1 Housing 1
4021 HW9200713-1 Wrist base 1
4022 HW9381452-A Gear 1
4023 6811LLU Bearing 1
4024 HW9482218-A Bearing 1
4025 6900ZZ*NS7* Bearing 1
4026 6902ZZ*NS7* Bearing 1
4030 6812LLU Bearing 1
4031 HW9381384-A Gear 1
4033 HW9405199-1 B nut 1
4036 HW9481180-A Bearing 1
4037 HW9302037-1 Housing 1
4039 HW9403430-1 Housing 1
4041 HW9405200-1 B nut 1
4042 HW9481024-A Bearing 1
4043 HW9302220-1 Flange 1
4044 HW9404530-1 Housing 1
4047 CD-12 Saddle 1
4048 M5 10 APS bolt 2
4049 TA1-S8 Clamp 1
11-8 70 of 656
MOTOMAN-UP6
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan
Phone +81-93-645-7745 Fax +81-93-645-7746
YASKAWA America Inc. MOTOMAN Robotics Division

805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Nordic AB
Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden
Phone +46-480-417800 Fax +46-480-417999
YASKAWA Europe GmbH Robotics Division

Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Electric Korea Co., Ltd.

7F, Doore Bldg.; 24, Yeoido-Dong Youngdungpo-ku, Seoul, KOREA
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.

252/246, 4th Floor. Muang Thai-Phatra Office Tower II Rachadaphisek Road, Huaykwang Bangkok, 10320 Thailand
Phone +66-2-693-2200 Fax +66-2-693-4200
Shougang MOTOMAN Robot Co. Ltd.

No.7, Yongchang-North Road, Beijing E&T Development Area, China 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
MOTOMAN Motherson Robotics Ltd.

Plot No.195-196, 1st Floor, Sec.4 IMT Manesar, Gurgaon 122050, Haryana
Phone +91-124-475-8500 Fax +91-124-414-8016
Specifications are subject to change without notice

for ongoing product modifications and improvements.

MANUAL NO. RE-MTO-A211 4
C Printed in Japan December 2010 98-12
71 of 656
YASKAWA
MOTOMAN
SETUP MANUAL
Upon receipt of the product and prior to initial operation, read these instructions
thoroughly, and retain for future reference.
MOTOMAN- MANIPULATOR INSTRUCTION MANUAL
YASNAC XRC INSTRUCTION MANUAL
YASNAC XRC OPERATORS MANUAL FOR BEGINNERS
Please be sure to use the appropriate manual.
72 of 656
YASKAWA MANUAL NO. RE-TA-A503 2

MANDATORY
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.
CAUTION

product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.

on the front cover.

ucts warranty.
ii 73 of 656
YASNAC XRC.


practices.

MANDATORY heading.
PROHIBTED 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.
iii 74 of 656
WARNING
Before operating the manipulator, check that the servo power is turned
off when the emergency stop buttons on the playback panel or program-
turned off.
which could interfere with the operation of the manipulator. Then turn
the servo power ON

TURN
teach a job.
the playback panel.


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 75 of 656
CAUTION
ulator teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
after use.
Manual before operating the manipulator.

Manipulator Manipulator
Power Cable Power Cable
v 76 of 656
Descriptions of the programming pendant and playback panel keys, buttons, and displays are
shown as follows:
Pendant denoted with [ ]
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on them are
not denoted with [ ] but depicted with a small picture.
ex. 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,
ex. [SHIFT]+[COORD]

denoted with { }.
ex. {JOB}


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 77 of 656
Explanation of warning labels
The following warning labels are attached to the manipulator and XRC.
Fully comply with the precautions on the warning labels.
WARNING
The label described below is attached to the manipulator.
Observe the precations on the warning labels.

Failure to observe this caution may result in injury or damage to equipment.
WARNING WARNING
Donotenter Movingpartsmay
robotworkarea causeinjury
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.
!
! !
WARNING
WARNING WARNING
High Voltage
High Voltage
Do not open the door Do not open the cover. May cause
electric shock.
with power ON. Ground the earth
teminal based on
local and national
electrical code.
vii 78 of 656
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
viii 79 of 656
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
ix 80 of 656
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.
x 81 of 656
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 precau-
tions in order to avoid the risk of injury to personnel and damage to equipment.
It is the users 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 82 of 656
1.1 For Your Safety
MANDATORY
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 83 of 656
1.2 Special Training
1.2 Special Training
MANDATORY
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
MANDATORY
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- INSTRUCTIONS
-YASNAC XRC INSTRUCTIONS
-YASNAC XRC OPERATORS MANUAL FOR BEGINNERS
-YASNAC XRC OPERATORS MANUAL
Confirm that you have all these manuals on hand.

If any manuals are missing, contact your salesman from YASKAWAs local branch office.
The relevant telephone numbers are listed on the back cover.
1-3 84 of 656
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.
CAUTION
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 85 of 656
CAUTION
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 86 of 656
1.5 Motoman Safety
1.5 Motoman Safety
1.5.1 Installation and Wiring Safety

Refer to the MOTOMAN- 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:
WARNING
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
1000mmormore
1000mmormore 1000mmormore
WORKINGENVELOPE
OFMANIPULATOR
MAXIMUMWORKINGENVELOPEOF
MANIPULATORINCLUDINGTOOL
ORWORKPIECEEND
1000mmormore
Perform grounding in accordance with all applicable electrical codes.
Failure to observe this caution may result in fire or electric shock.
1-6 87 of 656
1.5 Motoman Safety
CAUTION
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.)

WIREROPE
Approx.
XRC equivalent
weight
model
(kg)
M16EYEBOLT
SV3X,UP6,SK16X 70
SK45X,SK16MX 90
UP130,UP165,
UP200,UP130R, 100
SP100X
XRC
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 88 of 656
1.5 Motoman Safety
CAUTION
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] [650] 20]

500 500 470 320 500
500
470
(550) (550) (420)
XRC
(420)
[420]
320
(860)
[860]
760
(550)
[650]
0]
(630)
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 manipulators 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 89 of 656
1.5 Motoman Safety
CAUTION
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.
TAPPEDHOLESFOR
XRC
M12SCREWSONTHE
XRCSIDE
(2)14mm
diameter
holes
MountingBrackets
PROVIDEDBYUSER
(mm)
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.
SAFETY
FIRST
PIPING LEAD
1-9 90 of 656
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:
WARNING
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.
CAUTION
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 91 of 656
1.5 Motoman Safety
1.5.3 Operation Safety
WARNING
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.
ENERGIZING
PROHIBITED
PADLOCK XRC
Turning the power on during tool installation may case electric shock or injury due to
unexpected movement of the manipulator.
Never exceed the the rated capacity of the manipulator (capacity can
be found in the specifications section of the manipulator manual.).

Teach jobs from outside the manipulators 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 92 of 656
1.5 Motoman Safety
WARNING
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 manipulators
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.
EMERGENCYSTOPBUTTON
MOTOMAN
MOTOMAN
X++ x
R- x
X-- S
R+
S
Y+ y y
Y- L+ B- YASNAC XRC
L- B+
Z- Z+ z z
U- U+ T- T+
7 8 9
4 5 6
1 2 3
0 . -
YASNAC XRC
PROGRAMMIMGPENDANT XRC
1-12 93 of 656
1.5 Motoman Safety
CAUTION
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.
MANDATORY
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 94 of 656
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:
CAUTION
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.
PROHIBTED
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 95 of 656
1.7 Notes on MOTOMAN Disposal
1.7 Notes on MOTOMAN Disposal
CAUTION
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 96 of 656
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
XRC Manipulator
Programming
Pendant
CompleteSetofManuals
PowerCable
2-1 97 of 656
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
OnlyconnecttheMOTOMANtothe
YASNACMRCwhichhassameorder
number.
ORDERNO. S 7 8 7 9 6 - 1
2-2 98 of 656
3.1 Handling Procedure
3 Installation
3.1 Handling Procedure
CAUTION
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 adversly 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)

WIREROPE
XRC equivalent Approx.
model weight (kg)
M16EYEBOLT SV3X,UP6, SK16X 70
SK16MX,SK45X 90
UP130,UP165, 100
UP200,UP130R,
SP100X
XRC
3-1 99 of 656
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.
Protectivepadding
Tiedownstraps
Palette
Forklift
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 113F) during operation and -10 to 60C
(14 to 140F) 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.
3-2 100 of 656

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
1000mmormore
1000mmormore 1000mmormore
WORKINGENVELOPE
OFMANIPULATOR
MAXIMUMWORKINGENVELOPEOF
MANIPULATORINCLUDINGTOOL
ORWORKPIECEEND
1000mmormore
IInstall 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
500
470
(550)
XRC
(420)
[420]
320
(550)
[650]
0]
(630)
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
3-3 101 of 656

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.
TAPPEDHOLESFOR
XRC
M12SCREWSONTHE
XRCSIDE
(2)14mm
diameter
holes
MountingBrackets
PROVIDEDBYUSER
(mm)
Attaching the XRC (mm) External Dimensions (mm)
NOTE Refer to the Instruction Manual for information on installation of the manipulator.
3-4 102 of 656

4 Connection
WARNING
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 users responsibility. Do an operation check once the wiring
is completed.
Failure to observe this caution could lead to injury or mechanical failure.
4-1 103 of 656

4.1 Notes on Cable Junctions
CAUTION
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.
4-2 104 of 656

4.2 Power Supply
SAFETY
FIRST
PIPING LEAD
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.
XRC
3-phase
AC200/220V SERVOPACK
50/60Hz
Noise
filter
To Control power supply unit
Input Power Source Connection
4-3 105 of 656

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.
XRC
3-phase
50/60Hz
3-phase Noise
filter
Noise
Filter
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 Electric Co., Ltd. NV series (manufactured since 1988)

Fuji Electric Co., Ltd. EG or SG Series (manufactured since 1984)
Recommended breaker (sensibility): 100 mA
CAUTION
If the XRC with European spec. is installed in Japan, the breaker of
which sensibility is 200 mA or 500 mA should be used.
If the primary power of delta connection (Japanese standard), instead of star connection
(EU standard), is applied to the XRC, the leakage becomes approximately twice, which
may activate the breaker occasionally.
XRC
3-phase
50/60Hz
Noise
Leakage filter
Breaker
Connection of the Leakage Breaker
4-4 106 of 656

4.2 Power Supply
4.2.4 Primary Power Supply Switch Installation

Install the primary power supply switch as shown.
Controller
XRC Welder
for jig
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.
4-5 107 of 656

4.3 Connection Methods
A connection diagram for the manipulator, controller power cable, primary power cable and
programming pendant is shown below.
Primarypower
supply
Connectionofprogramming
pendantcable
Powersupplycable
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.
doorlock
clockwise
90
screwdriver
Rotating the Door Handle Clockwise.
(2) Rotate the main switch to the "OPEN RESET" position and open the door gently.
4-6 108 of 656

PE
D ON
TRI
P
SET
OFF
RE
N
T
SE
RE
E
OP OP
EN
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 wont 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
4-7 109 of 656

(3) Connect a ground wire to reduce noise and prevent current leakage.
1) Connct the ground wire to the ground terminal (screw) of the switch which is on
the upper left side of XRC .
Groundwire
Crimpedterminal
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.
NOTE The customer must prepare the ground wire.
XRC
Exclusive grounding
(100 ohm maximum
groumd resistance)
Exclusive Grounding
Dont connect the grounding wire with the wires for the electric power source, the welder,
NOTE etc.
Ground in accordance with all relevant governmental regulations when using metallic
ducts, metallic conduits, and wiring hedges to construct the cable.
4-8 110 of 656

(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.
Cover
Detaching the Cable Hole Cover
4-9 111 of 656

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.
XRC
PowerCablefixbase
Cables Passed Through the Holes Tightening the Screws for the Cable
in the Side of the XRC
NOTE 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.
counterclockwise90
doorlock
(-)screwdriver
4-10 112 of 656

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.
4-11 113 of 656

5.1 Turning on the Main Power Supply
5 Turning on the Power Supply
WARNING
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
OFFSE
T
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.
5-1 114 of 656

5.2 Turning on the Servo Power
YASNAC XRC
PERFORMING SYSTEM DIAGNOSIS
Copyright(c):1998-
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 workers safety is secure if the safety plug is turned on.
1. When the safety guard is closed, press [SERVO ON READY] SERVO ON

READY
on the playback panel to turn on the servo power supply. This
button lights.
NOTE When the safety guard is open, the servo power supply cannot be turned on.
5-2 115 of 656

5.2.2 During Teach Mode

1. Press [SERVO ON READY] on the playback panel to turn on SERVO ON
READY
the servo power supply. The button will light when the servo
power is turned on.
2. Press [TEACH LOCK] to enter the teach mode. TEACH
3. The servo power is turned on and [SERVO ON READY] on

the playback panel lights when the operator grips the dead-
man switch.
Servo Power ON/OFF --- Deadman Switch

SUPPLE-
MENT
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.
ServoOn
Release->OFF Squeeze->ON SqueezeTightly->OFF
When using the playback panel, programming pendant, or external signal to perform emer-
NOTE gency stop, the servo power on operation from the deadmanswitch is cancelled. When
turning the power back on, follow the previously listed instructions.
5-3 116 of 656

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- Emergency Stop
dant or the playback box will turn off servo power.

The brake operates once the servo power supply is turned off, and the Programming Pendant
manipulator can no longer operate.
EMERGENCY STOP
The emergency stop mode can be operated at any time.
Playback Panel
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
OFFSE
T
RE
EN
OP
5-4 117 of 656

6 Test of Program Operation
WARNING
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 manipulators 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.
6-1 118 of 656

CAUTION
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.
6-2 119 of 656

6.1 Movement of the Axes
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.
NOTE 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.
U-Axis
R-Axis
B-Axis
X++ x
R- x
X-- S
R+ T-Axis
S
Y+ y y
Y- L+ B-
L- B+
Z- Z+ z z L-Axis
U- U+ T- T+
AxisKeys
S-Axis
S Rotatesmainbody R Rotatesupperarm
xx
R+
X- X+
S- S+
x
R-
L Moveslowerarmforward/ B Moveswristup/down
backward
y
Y- B+
L-
Y+
L+
y
B-
U Movesupperarmup/ T Rotateswrist
down
Z+
U+
z
T+
Z- z
U- T-
6-3 120 of 656

7 Home Position Confirmation
WARNING
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.
7-1 121 of 656

CAUTION
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.
7-2 122 of 656

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 .
NOTE 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.
DATA EDIT DISPLAY UTILITY

L
CUR POS R1 C S
COORDINATE:PULSE TOOL:00
R1:S -18402
L 45714
U -28450
R -287
B 8090
T -461
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.
7-3 123 of 656


L
CUR POS R1 C S
COORDINATE:PULSE TOOL:00
R1:S 0
L 0
U 0
R 0
B 0
T 0
Theangleofthecentrallineof
TheangleoftheL-axisperpendicularto theB-axisagainstthecentral
theground. lineoftheU-axisis90degrees.
B-AXIS
R-AXIS
U-AXIS T-AXIS
(oppositeside)
TheangleoftheU-axisagainst
thehorizonis0degrees.
L-AXIS
(oppositeside)
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.
NOTE Contact Customer Service if you encounter any problems performing home position cali-
bration.
7-4 124 of 656

8 Final Notes
Refer to the manuals listed below for additional information in work involving robot operations
such as teaching and playback.
Operators Manual For Beginners

Operating procedures are clarified for beginning users.
The operations are explained carefully in order.
Operators 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
8-1 125 of 656

MOTOMAN
SETUP MANUAL
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone 1-905-569-6686 Fax 1-905-813-5911
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone 46-480-417800 Fax 46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone 82-53-745-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone 60-3-6092-1377 Fax 60-3-6092-6377
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
SHOUGANG MOTOMAN ROBOT CO., LTD.
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-TA-A503 2

for ongoing product modifications and improvements. C Printed in Japan April 2005 98-12
126 of 656
YASNAC XRC
INSTRUCTIONS
SUPPLEMENTARY FOR NORTH AMERICAN (ANSI/RIA) STANDARD
MOTOMAN- INSTRUCTIONS
127 of 656
MANUAL NO. RE-CTO-A208 5

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.

ucts warranty.
ii 128 of 656
RE-CTO-A208

YASNAC XRC.


practices.

MANDATORY heading.
iii 129 of 656

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.


tion. Always press an emergency stop button immediately if there are problems.The
iv 130 of 656
RE-CTO-A208
CAUTION
after use.
Manual before operating the manipulator.

IIn this manual, the equipment is designated as follows.
v 131 of 656
RE-CTO-A208
shown as follows:
ex. [ENTER]
ex. page key

shown.

ex. [SHIFT]+[COORD]

denoted with { }.
ex. {JOB}


In this manual, names of companies, corporations, or products are trademarks, registered
trademarks, or brand names for each company or corporation. The indications of (R) and TM
are omitted.
vi 132 of 656
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 133 of 656

RE-CTO-A208
Servo Control Circuit board (JASP-WRCA01). . . . . . . . . 2-39

Servo Control Power Supply (JUSP-RCP01AA) . . . . . . . 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 134 of 656

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.

within the working envelope of the manipulator:

- 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.
1-1 135 of 656

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.
1-2 136 of 656

RE-CTO-A208
1.1 Specification List
Controller
Configuration Free-standing, enclosed type
Dimensions Refer to following
Cooling System Indirect cooling
Ambient Temperature 0C to + 45C (During operation)

-10C to + 60C (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

%) (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 %)
Grounding Grounding resistance : 100 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))
1-3 137 of 656

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
1-4 138 of 656

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
1-5 139 of 656

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-XRK01-1 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-
S
CN29
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
6XT
9 24V2 9 ON_EN2+
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
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

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

JAPAN NJ2096- JAPAN NJ2096-
(EV1) (EV2)
GRIP
Disconnect Switch
CNPB04 CNPB05 CNPB06
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
CN10
CONV
194RC-301753
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
Shaft
PWM
178323-2
CN50
PWM
CNPG123
FRC5-C14S52T-OL(D20)
1CN
10250-52A2JL
194RNHR1
CN30
CNE 3-175475-6
CN40
Handle
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
194RHS4 GRIP
Fuse:
Refer to the
following table. A
SERVOPACK: Sectional view A-A
Refer to the following table.
Transformer 1KVA Fuse
HB9480046 Type YASNAC XRC SERVOPACK
240-480-575V/208V QS1 QS2 QS3
Class H 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)
1-6 140 of 656

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-XRK01-1 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
6XT
9 24V2 9 ON_EN2+
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
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN NJ2096-
(EV1) (EV2)
GRIP
Disconnect Switch
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
CN10
CONV
194RC-301753
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
Shaft
PWM
178323-2
CN50
PWM
CNPG123
1CN
10250-52A2JL
194RNHR1
CN30
CNE 3-175475-6
Handle
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
194RHS4 GRIP
Fuse:
Refer to the
following table. A
SERVOPACK: Sectional view A-A
* Fuse
Type YASNAC XRC SERVOPACK
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
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
6XT
9 24V2 9 ON_EN2+
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
QS1
1 24V3 1 EXBRK+
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
QS2 QS3
TYPE TYPE
CN20

JAPAN
(EV1) (EV2)
Disconnect Switch
GRIP
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
194RC-301753
CN10
CONV
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
Shaft
PWM
178323-2
CN50
PWM
CNPG123
1CN
10250-52A2JL
194RNHR1
CN30
CNE 3-175475-6
CN40
Handle
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
194RHS4
GRIP
Fuse:
Refer to the
following table.
SERVOPACK:
Refer to the A
Sectional view A-A
following table.
* Fuse
Type
YASNAC XRC SERVOPACK QS1 QS2 QS3
SV3X ERCR-SV3-RB05 CACR-SV3AAA 3A 10A 5A
Transformer 4.5KVA UP6 ERCR-UP6-RB04 CACR-UP6AAC 5A 10A 10A
HB9480042 SK16X ERCR-SK16-RB05
240-480-575V/208V CACR-SK16AAC 10A 15A 15A
Class H UP20 ERCR-UP20-RB03 CACR-UP20AAA 10A 15A 15A
SV3X, UP6, SK16X, UP20 Configuration (With transformer built-in)
1-7 141 of 656

RE-CTO-A208
I/O unit Fuse holders

Power supply unit
(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-XRK01-1 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
6XT
9 24V2 9 ON_EN2+
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
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN JAPAN
(EV1) (EV2)
Disconnect Switch
GRIP
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
194RC-301753
CN10
CONV
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
Shaft
PWM
178323-2
CN50
PWM
CNPG123
1CN
10250-52A2JL
194RNHR1
CN30
CNE 3-175475-6
CN40
Handle
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
194RHS4
GRIP
Fuse:
Refer to the
following table.
A
Sectional view A-A
SERVOPACK: * Fuse
Refer to following Type YASNAC XRC SERVOPACK
QS1 QS2 QS3
table. 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-XPU05 JZNC-XRK01-1 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
6XT
9 24V2 9 ON_EN2+
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
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
QS2 QS3
TYPE TYPE
CN20

JAPAN JAPAN
(EV3)
Disconnect Switch
(EV1) (EV2)
GRIP
194RC-301753
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
CN10
Shaft
CNPG456
10220-6202JL
CN20
10250-52A2JL
178323-2
CN50
194RNHR1
CNPG123
FM31
MPC603EFE100L
10250-52A2JL
S1 KDS16-522
CNTEST
CN30
IMSA-9202B-1-03R-G
Handle
CNE 3-175475-6
BL02RN2-R62
U90 U126
PQ30RV21 PQ30RV21
105
FL9
C2
C176 C93
L2
CN40
20V68
20SAH68M TSL1110-101K1R0
680 680 CNPB01 CNPB02 CNPB03
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
194RHS4
Fuse:
Refer to the
following table.
Converter:
Refer to the
following table.
A
Sectional view A-A
SERVOPACK:
Refer to the * Fuse
following table. Type YASNAC XRC SERVOPACK Converter
QS1 QS2 QS3
UP50 ERCR-UP50-RB03 CACR-UP50AAB JUSP-ACP25JAAY11 15A 20A 20A
Transformer 8KVA UP20M ERCR-UP20M-RB02 CACR-UP20MAAB 15A 20A 20A
HB9480043 SK45X ERCR-SK45-RB02 CACR-SK45AAB JUSP-ACP25JAA 15A 20A 20A
240-480-575V/208V SK16MX ERCR-SK16M-RB02 CACR-SK16MAAB 15A 20A 20A
Class H SP70X ERCR-SP70-RB03 CACR-SP70AAB 15A 20A 20A
SK45X, SK16MX, UP50, UP20M, SP70 Configuration (With transformer built-in)
1-8 142 of 656

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-XPU05 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
6XT
9 24V2 9 ON_EN2+
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
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN JAPAN
(EV3)
(EV1) (EV2)
GRIP
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
102
DUSB-ARB8X-T11
CN10
Disconnect Switch
CNPG456
10220-6202JL
CN20
10250-52A2JL
178323-2
CN50
194RC-301753
CNPG123
FM31
MPC603EFE100L
10250-52A2JL
S1 KDS16-522
Shaft
CNTEST
CN30
IMSA-9202B-1-03R-G
CNE 3-175475-6
BL02RN2-R62
U90 U126
PQ30RV21 PQ30RV21
105
FL9
C2
C176 C93
L2
CN40
20V68
20SAH68M TSL1110-101K1R0
C178 C99
C166
194RNHR1
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
Handle
194RHS4
Fuse:
Refer to the
following table.
Converter: A
Refer to the Sectional view A-A
following table.
* Fuse
Type YASNAC XRC SERVOPACK Converter QS1 QS2 QS3
SERVOPACK: UP50 ERCR-UP50-RB04 CACR-UP50AAB JUSP-ACP25JAAY11 20A 20A
Refer to the UP20M ERCR-UP20M-RB03 CACR-UP20MAAB 20A 20A
following table. 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)
Power supply unit Fuse holders

(with protective cover) Playback Panel (QS2)(QS3)
JZRCR-XPU05 Power ON unit I/O unit ZY1C-SS3152 USCC3I
or JZRCR-XPU10 JZNC-XSU02 JZRCR-XCO02B Brake operation panel Fuse : Refer to the
CPU unit Brake release control board following table.
JZNC-XRK01-1
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
6XT
9 24V2 9 ON_EN2+
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
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
QS2 QS3
TYPE TYPE
CN20

JAPAN JAPAN
(EV3)
(EV1) (EV2)
G R I P
Disconnect Switch
8830-032-170SD 8830-032-170SD 8830-032-170SD
C249
13
14
TB4 102
DUSB-ARB8X-T11
FRC5-C14S52T
F4053A
CN10
-OL(D20)
REV.A
CN60
TB1 F4053A
2
1
A1
JASP-WRCF01
B1
B2
8830-032-170SD
194RC-301753
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
8830-032-170SD
CNPB09
Shaft
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
194RNHR1
PQ30RV21
PQ30RV21 PQ30RV21
105
FL9
U44
C2
25
24
49
50
C176 C93
L2
CN40
20V68
20SAH68M TSL1110-101K1R0
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
Handle
194RHS4
E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22 E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22
Fuse:
Refer to the
following table.
Converter
JUSP-ACP35JAA
A Sectional view A-A
SERVOPACK:
Refer to the * Fuse
following table. QS1 QS2 QS3
UP130 ERCR-UP130-RB04 CACR-UP130AAB 20A 30A 30A
UP165 ERCR-UP165-RB04 CACR-UP130AAB 20A 30A 30A
Transformer 8KVA 20A 30A 30A
HB9480043 UP165-100 ERCR-UP165-RB06 CACR-UP130AABY18
240-480-575V/208V UP200 ERCR-UP200-RB03 CACR-UP130AABY18 20A 30A 30A
Class H * : Time delay fuses of class CC are used for QS1, QS2, and QS3.
UP130, UP165, UP165-100, UP200 Configuration (With transformer built-in)
1-9 143 of 656

RE-CTO-A208
Power supply unit Playback Panel Fuse holders

(with protective cover) Power ON unit I/O unit ZY1C-SS3152 (QS3)
JZRCR-XPU05 JZNC-XSU02 JZRCR-XCO02B Brake operation panel
USCC3I
or JXRCR-XPU10 CPU unit Brake release control board Fuse : Refer to the
JZNC-XRK01-1 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
6XT
9 24V2 9 ON_EN2+
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
QS1
1 24V3 1 EXBRK+
CN26
CN04
CN03/RS232C
CN13
CN12
CN41
CN25
JZRCR-XSU02
OFF
CN02/PP
CN23
CN24
CN03
CN5
CN40
CN01/IO
CN02
CN21
CN22
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN NJ2096- JAPAN NJ2096-
(EV3)
(EV1) (EV2)
G R I P
Disconnect Switch
8830-032-170SD 8830-032-170SD 8830-032-170SD
C249
13
14
TB4 102
DUSB-ARB8X-T11
FRC5-C14S52T
F4053A
CN10
-OL(D20)
REV.A
CN60
TB1 F4053A
2
1
A1
JASP-WRCF01
B1
B2
8830-032-170SD
B16 CNPG456
CNPB07
194RC-301753
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
8830-032-170SD
CNPB09
Shaft
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
194RNHR1
PQ30RV21
PQ30RV21 PQ30RV21
105
FL9
U44
C2
25
24
49
50
C176 C93
L2
CN40
20V68
20SAH68M TSL1110-101K1R0
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
Handle
194RHS4
Fuse:
Refer to the
following table.
Converter A
Sectional view A-A
JUSP-ACP35JAA
* Fuse
QS1 QS2 QS3
SERVOPACK:
Refer to the UP130 ERCR-UP130-RB05 CACR-UP130AAB 30A 30A
following table. 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-XPU10 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
6XT
9 24V2 9 ON_EN2+
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
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM

CN01
QS2 QS3
TYPE TYPE
CN20

JAPAN NJ2096- JAPAN
(EV3)
Disconnect Switch
(EV1) (EV2)
G R I P
194RC-301753
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
13
14
TB4 102
DUSB-ARB8X-T11
FRC5-C14S52T
F4053A
CN10
-OL(D20)
REV.A
CN60
TB1 F4053A
Shaft
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
A1 A2 B1 B2
194RNHR1
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
Handle
10250-52A2JL
C27
CNE C28 3-175475-6

680
CNPG789
680
BL02RN2-R62
U90 U126
PQ30RV21
PQ30RV21 PQ30RV21
105
FL9
U44
C2
25
24
49
50
C176 C93
L2
CN40
20V68
20SAH68M TSL1110-101K1R0
C178 C99
C166
C89
680 680 8830-032-170SD 8830-032-170SD 8830-032-170SD
194RHS4
Fuse: E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22 E11 E12 U11 U12 V11 V12 W11 W12 E21 E22 U21 U22
Refer to the
following table.
Converter
JUSP-ACP35JAA
SERVOPACK:
Refer to the A
Sectional view A-A
following table.
* Fuse
QS1 QS2 QS3 Type YASNAC XRC SERVOPACK
Transformer 12KVA
HB9480044 UP130R ERCR-UP130R-RB02 CACR-UP130AABY18 30A 40A 40A
240-480-575V/208V UP130RL ERCR-UP130RL-RB02 CACR-UP130AABY21 30A 40A 40A
Class H 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)
1-10 144 of 656

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-XPU10
CPU unit Fuse : Refer to the
JZNC-XRK01-1 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
6XT
9 24V2 9 ON_EN2+
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
CN10
CN11
CN2 CN1 CN4 CN3
2KM 1KM 2KM 1KM
CN01
QS3
TYPE TYPE
CN20
JAPAN NJ2096- JAPAN
(EV3)
(EV1) (EV2)
Disconnect Switch G R I P
194RC-301753
8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
13
14
TB4 102
DUSB-ARB8X-T11
FRC5-C14S52T
F4053A
CN10
-OL(D20)
REV.A
CN60
TB1 F4053A
2
1
A1
JASP-WRCF01
Shaft
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
A1 A2 B1 B2
194RNHR1
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
Handle
BL02RN2-R62
U90 U126
PQ30RV21
PQ30RV21 PQ30RV21
105
FL9
U44
C2
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
194RHS4
Fuse:
Refer to the
following table.
A
Converter Sectional view A-A
JUSP-ACP35JAA
* Fuse
QS1 QS2 QS3 Type YASNAC XRC SERVOPACK
UP130R ERCR-UP130R-RB03 CACR-UP130AABY18 40A 40A
SERVOPACK: UP130RL ERCR-UP130RL-RB03 CACR-UP130AABY21 40A 40A
Refer to the SK300X ERCR-SK300-RB03 CACR-SK300AAB 40A 40A
following table. 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)
1-11 145 of 656

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)
1-12 146 of 656

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.
2-1 147 of 656

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-XPU05 UP50, UP20M, SK45X, SK16MX,

SP70X
JZRCR-XPU05 UP130, UP165, UP165-100,

or JZRCR-XPU10 UP200
JZRCR-XPU10 UP130R, UP130RL, SK300X,

SR200X, SP100X
2-2 148 of 656

RE-CTO-A208
(1Z)
Resister (RB) Noise filter
RB 1Z
(5X)
(4X) Single 200 VAC Output connector
Contactor output Contactor 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-XPU05, JZRCR-XPU06B, JZRCR-XPU10)
2-3 149 of 656

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.
2-4 150 of 656

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)
RS232C Connector
SW
0 1 2 3 4
BAT
CN03
(CN03)
CN03/RS232C
SOURCE
PWR ON
24 VDC Output
Battery
+5V
+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-XRK01-)
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 or JANCD-XIF04). 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.
2-5 151 of 656

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 65C
2-6 152 of 656

RE-CTO-A208
2.3 CPU Rack
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:
2-7 153 of 656

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.
2-8 154 of 656

RE-CTO-A208
2.3 CPU Rack
Wiring PHOENIX Connector

CN05, 06, 40 and 44 on the I/O unit (JZRCR-XCO02B) 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.
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
PHENIX 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.
2-9 155 of 656

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 (PHENIX connector)
(Refer to "Wiring PHENIX 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 (PHENIX connector) PPESPIN+ EXESP2+
(Refer to "Wiring PHENIX Connector".) JZRCR-XCO02B
PPESPIN- EXESP2-
PBESPOUT+ EXSVON1+
CN07
(CN44)
Direct IN (PHENIX connector) CN06 CN05
PBESPOUT- EXSVON1-
1 1
PPESPOUT+ EXESP1+ PBESPIN+ EXSVON2+
(Refer to "Wiring PHENIX 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
(PHENIX connector)
(Refer to "Wiring PHENIX 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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RE-CTO-A208
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 EXSVON1+
External Servo ON 1
6 EXSVON1-
7 EXSVON2+ External Servo ON 2
8 EXSVON2-
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
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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 PBESPOUT-
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
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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 PBESPOUT-
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-XCU01B 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 PBESPOUT-
7 PBESPIN+
+24VU +24V 8 PBESPIN-
9 DSWOUT+ External Power Supply
10 DSWOUT- (prepared by customer side)
11 RDY+ Remove
12 RDY-
13 024V
14 +24V 0V
15 EX0VIN
024VU
16 EX24VIN
+24VU +24V
024VU 024V
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RE-CTO-A208
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
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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-)
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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
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RE-CTO-A208
Specific Input List (XCO02B)
Factory
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
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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 R XRC
Teach Y Controller
Operating 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.
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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 unit
(JZRCR-XCO02B)
CN13 CN12 Connector A

I/O Cable (from XCO02B
to Peripheral Device)
CN11 CN10
I/O Cable (from XCO02B

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

AU (Fujitsu)
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
I/O Terminal Board (Terminal Size : M3)

Type: PX7DS-40V6-R (Yoshida Electric Industry)
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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
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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.
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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)
CN29
EX24VIN External Brake, External Direct IN, 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)
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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.
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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 dosnt 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
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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)
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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
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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
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RE-CTO-A208
2.6 SERVOPACK
UP50 UP20M
Component
SERVOPACK CACR-UP50AAB - CACR-UP20MAAB -
S JUSP-WS44AA 4.4kW JUSP-WS44AA 4.4kW
Amplifier
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-
-
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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
Servo control
JUSP-RCP01AA -
power supply
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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 -
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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
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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
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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
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RE-CTO-A208
2.6 SERVOPACK
Converter SERVOPACK
Speed Monitor Board Amplifier (4pcs)
Grip (top)
G R I P
CNS
2CN
+5V
JUSP-
RCP01AAB
CNE
1CN
6CN
G R I P
1GS
Grip (bottom)
SP100X SERVOPACK Configuration
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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.
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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-
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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 2
24VDC 2011 A1 - IN A1 1
8mA max. 2012 B2 Call Master Job IN B2 4
2013 A2 Alarm/Error Reset IN A2 3
JARCR-XCI03
2014 B3 Select Remote Mode IN B3 6

2015 A3 Select Play Mode IN A3 5
2016 B4 Select Teach Mode IN B4 8
2017 A4 IN192 IN A4 7
Interference1 Entrance
2020 B5 Prohibited IN B5 10
2021 A5 Prohibited IN A5 9
2022 B6 Work Prohibited IN B6 12
2023 A6 Work Response IN A6 11
B7 024VU B7 14
A7 024VU A7 13
3010 B8 Running OUT B8 16
3011 A8 Servo is ON OUT A8 15
3012 B9 Top of Master Job OUT B9 18
3013 A9 Alarm/Error Occurred OUT A9 17
3014 B10 Battery Alarm OUT B10 20
3015 A10 Remote Mode Selected OUT A10 19
3016 B11 Play Mode Selected OUT B11 22
3017 A11 Teach Mode Selected OUT A11 21
3020 B12 In Cube 1 OUT B12 24
3021 A12 In Cube 2 OUT A12 23
3022 B13 Operation Origin Point OUT B13 26
Intermediate Start OK
3023 A13 (continuousing Sequence) OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JARCR-XCI01
B16 024VU B16 32
CN06 Internal A16
Power Supply A16 024VU 31
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
A17 024VU
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19 +24VU A19 37
024 VE
B20 FG B20 40
A20 A20 39
* 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
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RE-CTO-A208
YASNAC-XRC
(Optional)
CN13 Connector
Logical Connector Terminal
NumberNumber Signal Number
Each Point 2024 B1 - IN B1 2

24VDC 2025 A1 - IN A1 1
8mA max. 2026 B2 Weaving Prohibited IN B2 4
2027 A2 Sensing Prohibited IN A2 3
JARCR-XCI03
2030 B3 - IN B3 6
2031 A3 - IN A3 5
2032 B4 - IN B4 8
2033 A4 - IN A4 7
2034 B5 - IN B5 10
2035 A5 - IN A5 9
2036 B6 - IN B6 12
2037 A6 - IN A6 11
B7 024 VU B7 14
A7 024 VU A7 13
3024 B8 Gas Shortage (Monitor) OUT B8 16
3025 A8 Wire Shortage (Monitor) OUT A8 15
3026 B9 Wire Sticking (Monitor) OUT B9 18
3027 A9 Arc Shortage (Monitor) OUT A9 17
3030 B10 - OUT B10 20
3031 A10 - OUT A10 19
3032 B11 - OUT B11 22
3033 A11 - OUT A11 21
3034 B12 - OUT B12 24
3035 A12 - OUT A12 23
3036 B13 - OUT B13 26
3037 A13 - OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JARCR-XCI01
B16 024 VU B16 32
CN06 Internal A16 31
A16 024 VU
-14 Power Supply
+24 V B17 024VU B17 34
-13 024 V A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19
A19 +24VU 37
024 VE
B20 FG B20 40
A20 A20 39

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RE-CTO-A208
YASNAC-XRC
(Optional)
CN10 Connector
Logical Co nnec t or Terminal
Number Nu m ber Signal
Number
Each Point 2040 B1 IN01 General Input IN B1 2

24VDC 2041 A1 IN02 IN A1 1
8mA max. 2042 B2 IN03 IN B2 4
2043 A2 IN04 IN A2 3
JARCR-XCI03
2044 B3 IN05 IN B3 6
2045 A3 IN06 IN A3 5
2046 B4 IN07 IN B4 8
2047 A4 IN08 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3040 B8 OUT01- General Output OUT B8 16
A8 OUT01+ OUT A8 15 RLY
3041 B9 OUT02- OUT B9 18
3042 B10 OUT03- OUT B10 20
3043 B11 OUT04- OUT B11 22
3044 B12 OUT05- OUT B12 24
3045 B13 OUT06- OUT B13 26
Each Point
24VDC
500mA max. 3046 B14 OUT07- OUT B14 28
3047 B15 OUT08- OUT B15 30
JARCR-XCI01 B16 024VU B16 32
Power Supply A16 024VU
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
A17 024VU
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19 +24VU A19 37 * means internal relay
024 VE
B20 FG B20 40 RLY means
A20 A20 39

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RE-CTO-A208
YASNAC-XRC
(Optional)
CN11 Connector
Number Number Signal
Number
Each Point 2050 B1 IN09 IN B1 2
24VDC 2051 A1 IN10 IN A1 1
8mA max. 2052 B2 IN11 IN B2 4
2053 A2 IN12 IN A2 3
JARCR-XCI03
2054 B3 IN13 IN B3 6
2055 A3 IN14 IN A3 5
2056 B4 IN15 IN B4 8
2057 A4 IN16 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3050 B8 OUT09- OUT B8 16
3051 B9 OUT10- OUT B9 18
3052 B10 OUT11- OUT B10 20
3053 B11 OUT12- OUT B11 22
3054 B12 OUT13- OUT B12 24
3055 B13 OUT14- OUT B13 26
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 28
3057 B15 OUT16- OUT B15 30
Power Supply
A16 024VU
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
A17 024VU
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024VU A19 +24VU A19 37
024 VE * means internal relay
A20 A20 39

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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.
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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.
2-46 192 of 656

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.
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RE-CTO-A208
2.8.2 Handling
YASNAC-XRC
(Optional)
CN12 Connector
NumberNumber Name Signal Number
24VDC 2011 A1 - IN A1 1
JARCR-XCI03

2017 A4 IN192 IN A4 7
2022 B6 - IN B6 12
2023 A6 - IN A6 11
B7 024VU B7 14
A7 024VU A7 13
3020 B12 In Cube 1 OUT B12 24
3021 A12 In Cube 2 OUT A12 23
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JARCR-XCI01
B16 024VU B16 32
CN06 Internal A16
Power Supply A16 024VU 31
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
(24V,1A)
A17 024VU
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19 +24VU A19 37
024 VE
B20 FG B20 40
A20 A20 39

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RE-CTO-A208
YASNAC-XRC
(Optional)
CN13 Connector
Logical Con nec t or Terminal
NumberNum ber Signal Number

24VDC 2025 A1 - IN A1 1
8mA max. 2026 B2
Shock Sensor (NC)
- Hold
IN B2 4
2027 A2 Low Air Pressure IN A2 3
JARCR-XCI03
2030 B3 IN01 General Input IN B3 6

2031 A3 IN02 IN A3 5
2032 B4 IN03 IN B4 8
2033 A4 IN04 IN A4 7
2034 B5 IN05 IN B5 10
2035 A5 IN06 IN A5 9
2036 B6 IN07 IN B6 12
2037 A6 IN08 IN A6 11
B7 024 VU B7 14
A7 024 VU A7 13
3024 B8 - OUT B8 16
3025 A8 - OUT A8 15
3026 B9 - OUT B9 18
3027 A9 - OUT A9 17
3030 B10 OUT01 General Output OUT B10 20
3031 A10 OUT02 OUT A10 19
3032 B11 OUT03 OUT B11 22
3033 A11 OUT04 OUT A11 21
3034 B12 OUT05 OUT B12 24
3035 A12 OUT06 OUT A12 23
3036 B13 OUT07 OUT B13 26
3037 A13 OUT08 OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JARCR-XCI01
B16 024 VU B16 32
Power Supply A16 024 VU
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
(24V,1A) A17 024VU
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19
A19 +24VU 37
024 VE
B20 FG B20 40
A20 A20 39
* Remove Jumper-pin between CN06-14 and -16, -13 and -15

2-49 195 of 656

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

24VDC 2041 A1 Sensor Input 2 IN A1 1
8mA max. 2042 B2 Sensor Input 3 IN B2 4
2043 A2 Sensor Input 4 IN A2 3
JARCR-XCI03
2044 B3 Sensor Input 5 IN B3 6

B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3040 B8 Hand Valve 1-1- OUT B8 16
A8 Hand Valve 1-1+ OUT A8 15 RLY
Each Point
24VDC A13 Hand Valve 3-2+ OUT A13 25 RLY
500mA max. 3046 B14 Hand Valve 4-1- OUT B14 28

-14
+24 V B17 024VU B17 34
-13 024 V A17 33
A17 024VU
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
024 VE
A20 A20 39

2-50 196 of 656

RE-CTO-A208
YASNAC-XRC
(Optional)
CN11 Connector
Number Num ber Signal
Number
24VDC 2051 A1 IN10 IN A1 1
8mA max. 2052 B2 IN11 IN B2 4
2053 A2 IN12 IN A2 3
JARCR-XCI03
2054 B3 IN13 IN B3 6
2055 A3 IN14 IN A3 5
2056 B4 IN15 IN B4 8
2057 A4 IN16 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3051 B9 OUT10- OUT B9 18
3052 B10 OUT11- OUT B10 20
3053 B11 OUT12- OUT B11 22
3054 B12 OUT13- OUT B12 24
3055 B13 OUT14- OUT B13 26
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 28
3057 B15 OUT16- OUT B15 30
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
(24V,1A) A17 024VU
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024VU A19 +24VU A19 37 * means internal relay
024 VE
A20 A20 39

2-51 197 of 656

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.
2-52 198 of 656

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
2-53 199 of 656

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.

2-54 200 of 656

RE-CTO-A208
2.8.3 General Application
YASNAC-XRC
(Optional)
CN12 Connector
NumberNum ber Name Signal Number
24VDC 2011 A1 - IN A1 1
JARCR-XCI03

2017 A4 IN192 IN A4 7
2023 A6 - IN A6 11
B7 024VU B7 14
A7 024VU A7 13
3020 B12 In Cube 1 OUT B12 24
3021 A12 In Cube 2 OUT A12 23
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JARCR-XCI01
B16 024VU B16 32
-14
+24 V B17 024VU B17 34
024 V
-13 A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19 +24VU A19 37
024 VE
B20 FG B20 40
A20 A20 39

2-55 201 of 656

RE-CTO-A208
YASNAC-XRC
(Optional)
CN13 Connector
NumberNumber Signal Number
Each Point 2024 B1 Prohibited IN B1 2
24VDC 2025 A1 Prohibited IN A1 1
8mA max. 2026 B2 - IN B2 4
2027 A2 - IN A2 3
JARCR-XCI03
2030 B3 - IN B3 6
2031 A3 - IN A3 5
2032 B4 - IN B4 8
2033 A4 - IN A4 7
2034 B5 - IN B5 10
2035 A5 - IN A5 9
2036 B6 - IN B6 12
2037 A6 - IN A6 11
B7 024 VU B7 14
A7 024 VU A7 13
3024 B8 In Cube 3 OUT B8 16
3025 A8 In Cube 4 OUT A8 15
3026 B9 Work Command OUT B9 18
3027 A9 - OUT A9 17
3030 B10 - OUT B10 20
3031 A10 - OUT A10 19
3032 B11 - OUT B11 22
3033 A11 - OUT A11 21
3034 B12 - OUT B12 24
3035 A12 - OUT A12 23
3036 B13 - OUT B13 26
3037 A13 - OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JARCR-XCI01
B16 024 VU B16 32
-14
+24 V B17 024VU B17 34
-13 024 V A17
A17 024VU 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19 37
A19 +24VU
024 VE
B20 FG B20 40
A20 A20 39

2-56 202 of 656

RE-CTO-A208
YASNAC-XRC
(Optional)
CN10 Connector
Logical Co nnec t or Terminal
Number Nu m ber Signal
Number

24VDC 2041 A1 IN02 IN A1 1
8mA max. 2042 B2 IN03 IN B2 4
2043 A2 IN04 IN A2 3
JARCR-XCI03
2044 B3 IN05 IN B3 6
2045 A3 IN06 IN A3 5
2046 B4 IN07 IN B4 8
2047 A4 IN08 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3041 B9 OUT02- OUT B9 18
3042 B10 OUT03- OUT B10 20
3043 B11 OUT04- OUT B11 22
3044 B12 OUT05- OUT B12 24
3045 B13 OUT06- OUT B13 26
Each Point
24VDC
500mA max. 3046 B14 OUT07- OUT B14 28
3047 B15 OUT08- OUT B15 30
A16 024VU
-14 Power Supply
+24 V B17 024VU B17 34
-13 024 V A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
024 VE
A20 A20 39

2-57 203 of 656

RE-CTO-A208
YASNAC-XRC
(Optional)
CN11 Connector
Number
24VDC 2051 A1 IN10 IN A1 1
8mA max. 2052 B2 IN11 IN B2 4
2053 A2 IN12 IN A2 3
JARCR-XCI03
2054 B3 IN13 IN B3 6
2055 A3 IN14 IN A3 5
2056 B4 IN15 IN B4 8
2057 A4 IN16 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3050 B8 OUT09- OUT B8 16
3051 B9 OUT10- OUT B9 18
3052 B10 OUT11- OUT B10 20
3053 B11 OUT12- OUT B11 22
3054 B12 OUT13- OUT B12 24
3055 B13 OUT14- OUT B13 26
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 28
3057 B15 OUT16- OUT B15 30
A16 024VU
-14 Power Supply
+24 V B17 024VU B17 34
-13 024 V A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
024 VE
A20 A20 39

2-58 204 of 656

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 doesnt 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.
2-59 205 of 656

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.
2-60 206 of 656

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.

2-61 207 of 656

RE-CTO-A208
2.8.4 Spot Welding
YASNAC-XRC
(Optional)
CN12 Connector
NumberNumber Name Signal Number
24VDC 2011 A1 - IN A1 1
JARCR-XCI03

2017 A4 IN192 (Fan Alarm) IN A4 7
2022 B6 Welding ON/OFF IN B6 12
2023 A6 Welding Pause IN A6 11
B7 024VU B7 14
A7 024VU A7 13
3020 B12 In Cube 1 OUT B12 24
3021 A12 In Cube 2 OUT A12 23
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JARCR-XCI01
B16 024VU B16 32
A16 024VU
-14 Power Supply
+24 V B17 024VU B17 34
-13 024 V A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19 +24VU A19 37
024 VE
B20 FG B20 40
A20 A20 39

2-62 208 of 656

RE-CTO-A208
YASNAC-XRC
(Optional)
CN13 Connector
Logical Con nec t or Terminal
NumberNum ber Signal Number
8mA max. 2026 B2 - IN B2 4
2027 A2 - IN A2 3
JARCR-XCI03
2030 B3 IN1 IN B3 6
2031 A3 IN2 IN A3 5
2032 B4 IN3 IN B4 8
2033 A4 IN4 IN A4 7
2034 B5 IN5 IN B5 10
2035 A5 IN6 IN A5 9
2036 B6 IN7 IN B6 12
2037 A6 IN8 IN A6 11
B7 024 VU B7 14
A7 024 VU A7 13
3026 B9 OUT B9 18
3027 A9 - OUT A9 17
3031 A10 OUT02 OUT A10 19
3032 B11 OUT03 OUT B11 22
3033 A11 OUT04 OUT A11 21
3034 B12 OUT05 OUT B12 24
3035 A12 OUT06 OUT A12 23
3036 B13 OUT07 OUT B13 26
3037 A13 OUT08 OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JARCR-XCI01
B16 024 VU B16 32
Power Supply
A16 024 VU
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
A17 024VU
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
+24 VE -15 024 VU A19
A19 +24VU 37
024 VE
B20 FG B20 40
A20 A20 39

2-63 209 of 656

RE-CTO-A208
YASNAC-XRC
(Optional)
CN10 Connector
Number
Timer Cooling Water
Each Point 2040 B1 Error (IN09) *** IN B1 2
Gun Cooling Water
24VDC 2041 A1 Error (IN10) *** IN A1 1
8mA max. 2042 B2 Transthermo Error (IN11)
*** IN B2 4
2043 A2 Low Air Pressure (IN12) *** IN A2 3
JARCR-XCI03
2044 B3 Weld Completion (IN13)

** IN B3 6
2045 A3 Weld Error (IN14)
** IN A3 5
Gun Short Open
2046 B4 Detection (IN15) ** IN B4 8
Tip Replacement
2047 A4 Completion (IN16) ** IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3040 B8 OUT B8 16
A8 Weld ON/OFF (OUT09)
*** OUT A8 15 RLY
3041 B9 OUT B9 18
A9 Weld Error Reset (OUT10) ** OUT A9 17 RLY
3042 B10 OUT B10 20
A10 Weld Condition 1 (OUT11) ** OUT A10 19 RLY
3043 B11 OUT B11 22
A11 Weld Condition 2 (OUT12)** OUT A11 21 RLY
3044 B12 OUT B12 24
3045 B13 OUT B13 26
Each Point
24VDC
500mA max. 3046 B14 OUT B14 28
Gun Pressure
A14 Instruction (OUT15) ** OUT A14 27 RLY
3047 B15 OUT B15 30
Tip Replacement
A15 Request (OUT16) ** OUT A15 29 RLY
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
A17 024VU
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
024 VE
A20 A20 39

** 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.
2-64 210 of 656

RE-CTO-A208
YASNAC-XRC
(Optional)
CN11 Connector
Number Num ber Signal
Number
24VDC 2051 A1 IN18 IN A1 1
8mA max. 2052 B2 IN19 IN B2 4
2053 A2 IN20 IN A2 3
JARCR-XCI03
2054 B3 IN21 IN B3 6
2055 A3 IN22 IN A3 5
2056 B4 IN23 IN B4 8
2057 A4 IN24 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3050 B8 OUT17- OUT B8 16
3051 B9 OUT18- OUT B9 18
3052 B10 OUT19- OUT B10 20
3053 B11 OUT20- OUT B11 22
3054 B12 OUT21- OUT B12 24
3055 B13 OUT22- OUT B13 26
Each Point
24VDC
500mA max. 3056 B14 OUT23- OUT B14 28
3057 B15 OUT24- OUT B15 30
-14
+24 V B17 024VU B17 34
-13 024 V A17 33
(24V,1A) A17 024VU
B18 +24VU B18 36
A18 +24VU A18 35
-16 +24VU
B19 +24VU B19 38
024 VE
A20 A20 39

2-65 211 of 656

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.
2-66 212 of 656

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 2042
signal is ON normally (NC) and an
2020 ON, the manipulator goes to wait alarm occurs when the signal is
*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.
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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 welders 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 welders 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
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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).
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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
*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
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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 Connector
Number Number
Name Signal
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
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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
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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
WARNING
S L U R B T
EDIT LOCK ALARM
(OFF) (ON) REMOTE 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
200/220V 50/60Hz 3PHASE KVA
SERIAL NO.
DATE P/N
MADE IN JAPAN NJ2063-1
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.
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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 feel-
ing 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)
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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 play-
back 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 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.
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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 dis-
play.
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)
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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
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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.
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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.
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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.
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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.
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4.1.2 Replacing Parts of Power Supply Unit

The power supply unit (JZRCR-XPU05, 06B, and 10) 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-XPU05 UP50, UP20M, SK45X, SK16MX, SP70X,
JZRCR-XPU05 or UP130, UP165, UP165-100, UP200

JZRCR-XPU10
JZRCR-XPU10 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.
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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-XRK01-
Backboard JANCD-XBB01
System control circuit board JANCD-XCP01
High speed serial interface JANCD-XIF03 or

circuit board JANCD-XIF04
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 4715S-22T-B0-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
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RE-CTO-A208
*1 The type of the SERVOPACK depends on the robot model. For details, see the Tables.
SERVOPACK List (Small Capacity) and SERVOPACKs 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 RCP01AA RCP01AA RCP01AA RCP01AA
supply
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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- RCP01AA RCP01AA RCP01AA
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-RCP01AA JUSP-RCP01AA
supply
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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-RCP01AA JUSP-RCP01AA JUSP-RCP01AA

supply
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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-RCP01AA JUSP-RCP01AA

power supply
Power Supply Unit Type
Type Robot Type
JZRCR-XPU05 SK45X, SK16MX, UP50, UP20M,

SP70X
JZRCR-XPU05 or UP130, UP165, UP165-100, UP200

JZRCR-XPU10
JZRCR-XPU10 UP130R, SK300X, SP100X, UP130RL,

SR200X
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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.
4-11 234 of 656

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
20
FU3, 4, 7, 8
fuse (LITTEL)
2183.15
3.15A
3.15A JARCR-XSU02
3 Glass-Tube 2
250V FU1, 2, 9, 10
fuse 20
(LITTEL)
326010 JZRCR-
10A 10A XPU05, 06B,
4 2
Ceramic fuse 250V 10
31.75
(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.
4-12 235 of 656

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.
4-13 236 of 656

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
4-14 237 of 656

RE-CTO-A208
Recommended Spare Parts of XRC for SV3X
Qty
No Rank Name Type Manufacturer Qty per Remark
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 or
4715MS-22T-
B50-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 250V Daito 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-RCP01AA SANRITZ 1 1 For Servo
15 B SERVOPACK Control JASP-WRCA01 Yaskawa 1 1
Board
16 B Control Power Supply Unit CPS-150F Fuji Electric 1 1 For CPU Unit
Hi-Tech
17 B System Control Board JANCD-XCP01 Yaskawa 1 1
18 B Communication Board JANCD-XIF03 or Yaskawa 1 1
JANCD-XIF04
19 B Specific I/O Board 1 JARCR-XCI01 Yaskawa 1 1
20 B Genenal I/O Board JARCR-XCI03 Yaskawa 1 1
21 B Specific I/O Board 2 JARCR-XCU01B Yaskawa 1 1
22 B Power On Board JARCR-XCT01 Yaskawa 1 1
23 C Servopack CACR-SV3AAA Yaskawa 1 1
24 C CPU Unit JZNC-XRK01-1 Yaskawa 1 1
25 C I/O Unit JZNC-XIU02B Yaskawa 1 1
26 C Power Supply Unit JZRCR-XPU06B Yaskawa 1 1
27 C Programming Pendant JZNC-XPP02B Yaskawa 1 1 With Cable
8m
*Specify application (Arc, General, Spot, Handling) of key sheet when No.27 Programming
Pendant is ordered.
4-15 238 of 656

RE-CTO-A208
Recommended Spare Parts of XRC for UP6

Qty per
No Rank Name Type Manufacturer Qty unit
Remark
Battery
B30-B00 or
4715MS-22T-
B50-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
Hi-Tech
JANCD-XIF04
22 C SERVOPACK CACR-UP6AAC Yaskawa 1 1
24 C I/O Power On Unit JZNC-XCO02B Yaskawa 1 1
25 C /O Power On Unit JZRCR-XSU02 Yaskawa 1 1
8m
Pendant is ordered.
4-16 239 of 656

RE-CTO-A208
Recommended Spare Parts of XRC for SK16X

Qty per
Remark
Battery
B30-B00 or
4715MS-22T-
B50-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
munication
Apparatus
Board
Hi-Tech
JANCD-XIF04
22 C SERVOPACK CACR-SK16AAC Yaskawa 1 1
24 C I/O Unit JZRCR-XCO02B Yaskawa 1 1
25 C I/O Power On Unit JZNC-XSU02 Yaskawa 1 1
8m
Pendant is ordered.
4-17 240 of 656

RE-CTO-A208

Qty per
Remark
Battery
B30-B00 or
4715MS-22T-
B50-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
Hi-Tech
JANCD-XIF04
22 C SERVOPACK CACR-UP20AAA Yaskawa 1 1
8m
Pendant is ordered.
4-18 241 of 656

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
Hi-Tech
JANCD-XIF04
22 C SERVOPACK CACR- Yaskawa 1 1
SK16MAAB
26 C Power Supply Unit JZRCR-XPU05 Yaskawa 1 1
8m
Pendant is ordered.
4-19 242 of 656

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-RCP01AA SANRITZ 1 1 For Servo
Hi-Tech
JANCD-XIF04
21 B Power ON Board JARCR-XCT01 Yaskawa 1 1
22 C SERVOPACK CACR-SK45AAB Yaskawa 1 1
25 C I/O Power On Unit JZRCR-XSU02 Yaskawa 1 1
8m
Pendant is ordered.
4-20 243 of 656

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
munication
Apparatus
12 B Converter JUSP- Yaskawa 1 1
ACP25JAAY11
Board
Hi-Tech
JANCD-XIF04
UP20MAAB
8m
Pendant is ordered.
4-21 244 of 656

RE-CTO-A208

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
Fuse
250V
munication
Apparatus
ACP25JAAY11
Board
Hi-Tech
JANCD-XIF04
22 C SERVOPACK CACR-UP50AAB Yaskawa 1 1
8m
Pendant is ordered.
4-22 245 of 656

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
Hi-Tech
JANCD-XIF04
22 C SERVOPACK CACR-SP70AAB Yaskawa 1 1
8m
Pendant is ordered.
4-23 246 of 656

RE-CTO-A208
Recommended Spare Parts of XRC for UP130, UP165

Qty per
Remark
Battery
B30-B00
of Servo B30-B00
transformer not
provided
7 A Control Power Supply Fuse 218005 5A 250V LITTEL 10 2
250V
9 A Control Power Supply Fuse 326010 10A LITTEL 2 2
in Power Supply Unit
munication
Apparatus
Board
Hi-Tech
JANCD-XIF04
21 B Power On Board JANCD-XCT01 Yaskawa 1 1
22 C SERVOPACK CACR-UP130AAB Yaskawa 1 1
26 C Power Supply Unit JZRCR-XPU05 or Yaskawa 1 1
JZRCR-XPU10
27 C Programming Pendant JZNC-XPP02B Yaskawa 1 1 With Cable 8m
Pendant is ordered.
4-24 247 of 656

RE-CTO-A208

Qty per
No Rank Name Type Manufacturer Qty unit 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
Hi-Tech
JANCD-XIF04
UP130AABY18
26 C Power Supply Unit JZRCR-XPU05 or Yaskawa 1 1
JZRCR-XPU10
8m
Pendant is ordered.
4-25 248 of 656

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
Hi-Tech
JANCD-XIF04
UP130AABY18
8m
Pendant is ordered.
4-26 249 of 656

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
Hi-Tech
JANCD-XIF04
UP130AABY21
8m
Pendant is ordered.
4-27 250 of 656

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
Hi-Tech
JANCD-XIF04
22 C SERVOPACK CACR-SK300AAB Yaskawa 1 1
8m
Pendant is ordered.
4-28 251 of 656

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
Hi-Tech
JANCD-XIF04
22 C SERVOPACK CACR-SP100AAB Yaskawa 1 1
8m
Pendant is ordered.
4-29 252 of 656

YASNAC XRC
INSTRUCTIONS
SUPPLEMENTARY FOR NORTH AMERICAN (ANSI/RIA) STANDARD
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan
Phone +81-93-645-7745 Fax +81-93-645-7746
YASKAWA America Inc. MOTOMAN Robotics Division

805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Nordic AB
Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden
Phone +46-480-417800 Fax +46-480-417999
YASKAWA Europe GmbH Robotics Division

Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Electric Korea Co., Ltd.

7F, Doore Bldg.; 24, Yeoido-Dong Youngdungpo-ku, Seoul, KOREA
Phone +82-2-784-7844 Fax +82-2-784-8495

Phone +65-6282-3003 Fax +65-6289-3003

252/246, 4th Floor. Muang Thai-Phatra Office Tower II Rachadaphisek Road, Huaykwang Bangkok, 10320 Thailand
Phone +66-2-693-2200 Fax +66-2-693-4200
Shougang MOTOMAN Robot Co. Ltd.

No.7, Yongchang-North Road, Beijing E&T Development Area, China 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
MOTOMAN Motherson Robotics Ltd.

Plot No.195-196, 1st Floor, Sec.4 IMT Manesar, Gurgaon 122050, Haryana
Phone +91-124-475-8500 Fax +91-124-414-8016


C Printed in Japan February 2011 01-03
253 of 656
YASNAC XRC
INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
254 of 656

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.

ucts warranty.
ii 255 of 656
RE-CTO-A203

YASNAC XRC.


practices.

MANDATORY heading.
iii 256 of 656

RE-CTO-A203
WARNING
Before operating the manipulator, check that servo power is turned OFF
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.
the servo power ON

TURN
teach a job.
the playback panel.


- Turning ON the YASNAC XRC power
tion. Always press an emergency stop button immediately if there are problems.The
iv 257 of 656
RE-CTO-A203
CAUTION
after use.
Read and understand the Explanation of the Alarm Display in the setup
manual before operating the manipulator.

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the programming pendant,
and the manipulator cables.
v 258 of 656
RE-CTO-A203
shown as follows:
ex. [ENTER]
ex. page key

shown.

ex. [SHIFT]+[COORD]

denoted with { }.
ex. {JOB}


In this manual, names of companies, corporations, or products are trademarks, registered
trademarks, or brand names for each company or corporation. The indications of (R) and TM
are omitted.
vi 259 of 656
RE-CTO-A203
Setup Diagnosis
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 and Backup

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 . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Changing the Absolute Data . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Clearing Absolute Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3.1.3 Home Position of the Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3.2 Specified Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.2.1 Purpose of Position Check Operation . . . . . . . . . . . . . . . . . . .3-11
3.2.2 Specified Point Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3.2.3 Procedure After an Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3.3 Setting the Controller Clock . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.4 Setting Play Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.5 All Limits Releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6 Overrun / Shock Sensor Releasing . . . . . . . . . . . . . . . 3-19
3.7 Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.7.1 Interference Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3.7.2 Cubic Interference Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Cubic Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Setting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Setting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3.7.3 Axis Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Axis Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Setting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3.7.4 Clearing Interference Area Data . . . . . . . . . . . . . . . . . . . . . . .3-31
3.8 Operation Origin Point Setting . . . . . . . . . . . . . . . . . . . . 3-32
vii 260 of 656

RE-CTO-A203
3.8.1 What is the Operation Origin Point? . . . . . . . . . . . . . . . . . . . . 3-32

3.8.2 Setting Operation Origin Point . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Operation Origin Point Display . . . . . . . . . . . . . . . . . . . . . . 3-32
Registering/Changing the Operation Origin Point. . . . . . . . 3-33
Returning to the Operation Origin Point . . . . . . . . . . . . . . . 3-34
Output of the Operation Origin Point Signal . . . . . . . . . . . . 3-34
3.9 Tool Data Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.9.1 Registering Tool Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Number of Tool Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Registering Coordinate Data . . . . . . . . . . . . . . . . . . . . . . . 3-35
Registering Tool Pose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Setting the Tool Load Information. . . . . . . . . . . . . . . . . . . . 3-39
3.9.2 Tool Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Tool Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Clearing Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Checking the Tool Center Point . . . . . . . . . . . . . . . . . . . . . 3-44
3.9.3 Automatic Measurement of the Tool Load and the Center of
Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
What is the Automatic Measurement of the Tool Load and
the Center of Gravity? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Measurement of the Tool Load and the Center of Gravity . 3-45
3.10 User Coordinates Setting . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.10.1 User Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Definition of User Coordinates . . . . . . . . . . . . . . . . . . . . . . 3-49
User Coordinates File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.10.2 User Coordinates Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Selecting User Coordinates File . . . . . . . . . . . . . . . . . . . . . 3-50
Teaching User Coordinates . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Clearing User Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.11 ARM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.11.1 ARM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.11.2 ARM CONTROL Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Robot Setup Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3.11.3 Tool Load Information Setting . . . . . . . . . . . . . . . . . . . . . . . 3-59
Tool Load Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
How to Calculate Tool Load Information. . . . . . . . . . . . . . . 3-60
Tool load Information registering . . . . . . . . . . . . . . . . . . . . 3-66
3.12 Shock Detection Function . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.12.1 Shock Detection Function . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.12.2 Shock Detection Function Setting . . . . . . . . . . . . . . . . . . . . 3-70
Shock Detection Level Setting . . . . . . . . . . . . . . . . . . . . . . 3-70
Tool load Information Setting . . . . . . . . . . . . . . . . . . . . . . . 3-73
Instruction of Shock Detection Function . . . . . . . . . . . . . . . 3-75
Reset Shock detected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
3.12.3 Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3.13 Instruction Level Setting . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
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3.13.1 Setting Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81

Instruction Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81
Learning Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82
3.13.2 Setting Instruction Set Level Operation. . . . . . . . . . . . . . . . .3-82
3.14 Number Key Customize Function . . . . . . . . . . . . . . . 3-84
3.14.1 What is the Number Key Customize Function? . . . . . . . . . .3-84
3.14.2 Allocatable Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-84
Key Allocation (EACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-84
Key Allocation (SIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-85
3.14.3 Allocating an Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86
Allocation Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86
Instruction Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-87
Job Call Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-88
Display Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-89
Alternate Output Allocation . . . . . . . . . . . . . . . . . . . . . . . . .3-90
Momentary Output Allocation . . . . . . . . . . . . . . . . . . . . . . .3-91
Pulse Output Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92
Group (4-bit/8-bit) Output Allocation . . . . . . . . . . . . . . . . . .3-93
Analog Output Allocation. . . . . . . . . . . . . . . . . . . . . . . . . . .3-94
Analog Incremental Output Allocation . . . . . . . . . . . . . . . . .3-95
3.14.4 Allocation of I/O Control Instructions. . . . . . . . . . . . . . . . . . .3-96
3.14.5 Execution of Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-97
Executing the Instruction/Output Control Allocation . . . . . .3-97
Executing the Job Call Allocation . . . . . . . . . . . . . . . . . . . .3-97
Executing the Display Allocation . . . . . . . . . . . . . . . . . . . . .3-97
Executing the I/O Control Allocation . . . . . . . . . . . . . . . . . .3-97
3.15 Changing the Output Status . . . . . . . . . . . . . . . . . . . . . 3-98
3.16 Temporary Release of Soft Limits . . . . . . . . . . . . . . 3-100
3.17 Changing the Parameter Setting . . . . . . . . . . . . . . . 3-101
3.18 File Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
3.18.1 Initialize Job File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103
3.18.2 Initialize Data File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-104
3.18.3 Initialize Parameter File. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-105
3.18.4 Initializing I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-106
3.18.5 Initializing System Data. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-107
3.19 System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3.19.1 Backup Data with XRC . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
CMOS.BIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
CMOSxx.HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
ALCMSxx.HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
3.19.2 Backup Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-109
After the Teaching Operation . . . . . . . . . . . . . . . . . . . . . .3-109
At Regular Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-109
3.19.3 Backup by CMOS.BIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-109
CMOS.BIN Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-110
CMOS.BIN Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112
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4 Modification of System Configuration

4.1 Addition of I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Addition of Base and Station Axis . . . . . . . . . . . . . . . . . . 4-4
4.2.1 Base Axis Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.2 Station Axis Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
5 System Diagnosis
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.4 System Monitoring Time. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.4.1 System Monitoring Time Display . . . . . . . . . . . . . . . . . . . . . . 5-14
5.4.2 Individual Display of the System Monitoring Time . . . . . . . . . 5-15
5.4.3 Clearing the System Monitoring Time. . . . . . . . . . . . . . . . . . . 5-16
5.5 Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.1 Alarm History Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
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
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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

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) . . . . . . . . . . . . . . . . . 7-8
7.3.1 Specific Input Circuit Board (JANCD-XIO01o) . . . . . . . . . . . . . 7-9
Safety Plug Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.3.2 General I/O Circuit Board (JANCD-XIO02). . . . . . . . . . . . . . . 7-12
Connection wire with General I/O (CN10, 11, 12, 13) . . . . 7-13
Specific I/O Signal Related to Start and Stop . . . . . . . . . . . 7-14
7.3.3 Power-ON Circuit Board (JANCD-XTU01) . . . . . . . . . . . . . . 7-15
Connection of Shock Sensor . . . . . . . . . . . . . . . . . . . . . . . 7-15
Connection of External Power Supply for I/O . . . . . . . . . . . 7-16
Method of Connecting External Axis Overrun Signal . . . . . 7-18
7.4 Playback Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.5 Contact Output of Emergency Stop Button . . . . . . . . 7-20
7.6 Servopack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.6.1 Servopack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.6.2 Description of Each Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Servo Control Circuit board (JASP-WRCA01). . . . . . . . . . 7-30
Servo Control Power Supply (JUSP-RCP01) . . . . . . . . . 7-30
Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7.7 General I/O Signal Assignment . . . . . . . . . . . . . . . . . . . . 7-31
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7.7.1 Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

7.7.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
7.7.3 General Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43
7.7.4 Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49
7.7.5 JANCD-XEW02 Circuit Board (Standard) . . . . . . . . . . . . . . . .7-57
For Arc Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57
7.7.6 JANCD-XEW01 Circuit Board (Option) . . . . . . . . . . . . . . . . . .7-58
Arc Welding Application . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
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Maintenance
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 . . . . . . . . . . . . . . . . 9-9
Checking and Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . 9-9
9.2 YASNAC XRC Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.3 Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.4 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . 9-16
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Alarm Error
10 Alarm
10.1 Outline of Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2.1 Displaying/Releasing Alarm . . . . . . . . . . . . . . . . . . . . . . . . .10-1
10.2.2 Special Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10.3 Alarm Message List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
10.4 I/O Alarm Message List . . . . . . . . . . . . . . . . . . . . . . . . 10-79
Arc Welding Application . . . . . . . . . . . . . . . . . . . . . . . . . .10-79
Handling Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80
Spot Welding Application . . . . . . . . . . . . . . . . . . . . . . . . .10-81
General Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-82
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. . . . . . . . . . . . . . . . . . . . . . . .11-11
11.1.5 Concurrent I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-17
11.1.6 Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-18
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Setup Diagnosis
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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.
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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. Of these three, editing mode and management mode require
a user ID. The user ID consists of numbers and letters, and contains no less than 4 and no
more than 8 characters. (Significant numbers and signs: 0 to 9, -, .. )
Security Mode Descriptions
Security Mode Explanation
This mode allows basic operation of the robot (stopping, start-

Operation Mode
ing 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

Management
robot system: parameters, system time and modifying user
Mode
IDs.
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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
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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
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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
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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
OPERATION MODE
L
EDITING MODE R1 C S
EDITING MODE
MANAGEMENT MODE
JOB ARC WELDING VARIABLE

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

SUPPLE
-MENT
Editing Mode:[00000000]
Management 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 possible to change.
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2.1.2 User ID
User ID is requested when Editing Mode or Management Mode is operated.
User ID must be between 4 and 8 characters, 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 Management 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.

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)
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*3 When the correct user ID is entered, a new ID is requested to be input. The message
"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.
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3.1 Home Position Calibration
3 System Setup and Backup
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.
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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 cabinet
after use.
If the programming pendant is inadvertently left on the manipulator, a fixture, or on the

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.
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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. Refer to
" 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.

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

SELECT ALL AXIS
L
R1:S *
L *
U *
R *
B *
T *
*4 The confirmation dialog box 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.
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Registering Individual Axes

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

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.
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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-
tered*2 Enter the absolute data using the number keys Press [ENTER]*3
Explanation
*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.
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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
*2 The all absolute data are cleared.

L
R1:S *
L *
U *
R *
B *
T *
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3.1.3 Home Position of the Robot

In case of UP6, the home positions 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 refer to the instruction manual
for the correct manipulator model.
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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.
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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.
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3.2 Specified Point
3.2.1 Purpose of Position Check Operation

If the absolute rotation data in the absolute encoder vary while the power supply is turned ON
and while it is OFF, an alarm occurs after the controller 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 move in enexpected directions
when playback is started. When the absolute data allowablerange error alarm occured,
to secure improved safety, playback or test runs cannot be performed unless the position is
confirmed.
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
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3.2 Specified Point
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.
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 Occurrence
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.
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3.2 Specified Point
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
the page key Press the axis keys*3 Press [MODIFY] and [ENTER]*4
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 If there are several group axes, select a group axis which sets the specified point.
*3 Move the manipulator to the new specified point.
*4 The specified point position is modified.
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3.2 Specified Point
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 following operations:
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 Posi-
tion Display.
NOTE Refer to " 5.7 Position Data When Power is Turned ON/OFF " for details on the
Power ON/OFF Position Display.
Operation
Select {ROBOT} under the top menu Select {SECOND HOME POS}*1 Press
*2
the page key Press [FWD]*3 Select {DATA} under the menu Select
{CONFIRM POSITION}*4
Explanation
*1 The specified point display is shown.
*2 If there are several group axes, select a group axis which sets the specified point.
*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.
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3.3 Setting the Controller Clock
3.3 Setting the Controller Clock
The clock inside of the XRC controller can be set. Set the clock inside the XRC controller
with the correct time by the following operations.
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
The input buffer line is displayed.
*2 For instance, if you want to set the date to May 1, 1998, input [1998.5.1]. To set the
time at exactly ten oclock, enter [10.00].
> 1998.5.1
*3 Date and time are modified.

L
DATE/CLOCK SET R1 C S
DATE 1998 . 05 . 01
CLOCK 10 : 20
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3.4 Setting Play Speed
3.4 Setting Play Speed
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
the speed value Press [ENTER]*5
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 can
be alternated by pressing the page key .
*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 %
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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.
When all limits are released, the the following limit checks are also released.
Limit Type Contents
Mechanical Limit Limit for checking manipulators working envelope
L-U Interference Limit for checking L- and U-axes interference area
Software Limit Every axis soft limit for checking manipulators

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

user
NOTE If the security mode is not at management mode, all limits releasing is not allowed. Refer
to " 2 Security System " for details about security modes.
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Operation
Select {ROBOT} under the top menu Select {LIMIT RELEASE}*1 Select ALL
*2
LIMITS RELEASE
Explanation
*1 The limit release display is 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.
The message All limits have been released appears when VALID is set to ALL
LIMITS RELEASE, and the message All limits release has been canceled appears
for three seconds when INVALID is set..
L
ALL LIMITS RELEASE VALID
!All limits have been released
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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.
For your safety, it is recommended to operate the manipulator in low

speed or by inching upon the jog operation.
If the manipulator stops by overrun detection or shock sensor detection, release the overrun
or shock sensor by the following procedures 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 E-STOP
or HOLD with 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
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*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.
After overrun or shock sensor releasing, if CANCEL is selected or the display is changed
NOTE to the other one, overrun or shock sensor releasing is canceled.
The axis operation can be performed only in the joint coordinate system.
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3.7 Interference Area
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 of this
area, and outputs this status as a signal.
If the tool center point of the manipulator is inside of the area, inside the interference 1 signal
and inside the interference 2 signal are turned ON and the manipulator automatically deceler-
ates to stop. The manipulator stands by till these signals are turned OFF. When it is turned
OFF it automatically restarts.
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 manipulators 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
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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 coordinates.
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.
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
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Setting Operation
Operation
Select {ROBOT} under the top menu Select {INTERFERENCE}*1 Select the
*2 METHOD*3 Select CONTROL GROUP*4
desired cube number Select
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 >
*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 >
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*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
!
*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.
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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)
0
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 unlimber 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
*2 *3
{CLEAR DATA} Select YES
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 MEASUREInitialize?
: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 inter-
ference 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 .
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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.
*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: m). By changing this
parameter setting, the size of the cube can be changed.
S3C412: The operation origin cube length of its sides (m)
P
a
a
a
Specify whether COMMAND POSITION or FEEDBACK POSITION is to be set to the
operation origin cube signals CHECK MEASURE in the interference area settings. COM-
MAND POSITION is the default setting.
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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
For the double-arm type of MOTOMAN-CSL series, tool data can be set to the each tool
NOTE attached to the arm.
In this case, it is recommended to set hand data by even-numbered tool file to the L-arm,
and by odd-numbered tool file to the R-arm.
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]
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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/OParameter.

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}.
LISTR1
L
TOOL 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.
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*3 The number input line is displayed.
*4 The tool data is registered

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
<Setting Example>
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.
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Registering Tool Pose

The tool pose data is an 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
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 [ENTER]*4
data Press
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
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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.
SUPPLE For more details on the tool load information, refer to" 3.11.3 Tool Load Information Setting ".
-MENT
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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.
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 multi-hand, 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 ".
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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 robot, this operation should not be performed.) Select ** in the tool calibration
setting display and select the robot in the displayed selection dialog.
L
**:S * <STATUS>
L * TC1
R1:ROBOT1
U * TC2
R R2:ROBOT2
* TC3
B * TC4
T * TC5
COMPLETE CANCEL
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*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, TCnext 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.
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
!
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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 box 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 calibration. 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, refer to 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 its 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 its 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 REGIS-
TER*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.

LISTR1
L
TOOL 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 inter-
rupted 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 coordinate 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 coordinates 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
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*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
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 [ ]
!
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Clearing User Coordinates

Operation
Select {DATA} under the menu Select {CLEAR DATA}*1 Select YES*2
Explanation

L
R1:S 0 SET POS. :XY
L 10 <STATUS>
U Clear data? :ORG
1000
R 53 :XX
B YES
200 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 specifica-
tion 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
HEIGHT
(From U-Axis)
Load on U-arm: Center of gravity position (Side View)
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3.11 ARM Control
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]
Explanation
*1 ARM CONTROL display is shown.

ARM CONTROL
L
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.
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3.11 ARM Control
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.
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
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3.11 ARM Control
How to Calculate Tool Load Information

Weight: W (Unit: kg)
The total weight of the installed tool is set.
Set a rather large value even if it is a rough value. Round up the setting value by 0.5 to 1kg
for small and middle sized robots and by 1 to 5kg for large sized robots.
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 origin 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
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 a 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 10 0
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
r 2
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 comparing 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 supplement: "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")
Following is the method No. 2 for calculating the value:
(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 [ ]
!

TOOL
L
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 edit-
ing 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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3.11 ARM Control
When the data setting is not done:

NOTE When either of the following case, it is considered that data is not set correctly in tool load
information.
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 cant 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 the 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 urgently stops the manipulator to
decrease damages by detecting the shock 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, it sops the manipulator
instantaneously.
WARNING
This function cannot eliminate the damage to peripherals completely. Moreover, this func-
tion 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 for
details.
Injuries or damages to machinery may result by collision with the manipulator.
NOTE This function is equipped with the under mentioned models.

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

The shock detection function is set to detect the collision without any fasle positives
even if the manipulator is operated with the maximum speed by the ratings load 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 works are required, 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.
The detection level is changed by the SHCKSET instruction. After this instruction is executed,
the shock will be detected by the detection level of the specified file when the condition num-
ber 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.
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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.

SHOCK DETECTION LVL R1
L
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
Do either of the following operation 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 play 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}.
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Detection Level (Level range: 1 to 500)

The shock detection level is specified here. Bigger value than the maximum distur-
bance force is set here.
The values which would not falsely detect the shock (The detection level:100) even if
the robot is operated at the maximum speed are set here when shipped from the fac-
tory. The values which would not falsely detect the shock (The detection level:100)
even if the robot is operated at the maximum speed are set here when shipped from
the factory. Move the cursor to the robot or the station axis whose "Detection levelis
desired to be changed. Then press [SELECT] so that the numeric values are ready
to be input. 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 instantly stop of 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 management
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 cursor 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 cursor 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 coordi-
nates and which origin 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 cursor and pressing [SELECT].
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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.
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.
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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 cursor 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
SHCKSET
Operation
Move the cursor 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 additional 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 decrees the file number by pressing about
[SHIFT] and the cursor key simultaneously.
=> SHCKSET SSL#(2)
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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.
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.
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SHCKRST
Operation
Move the cursor to the line just before the location where SHCKRST instruction is desired
to register Press [INFORM LIST]*1 Select SHCKRST instruction*2 Change
the value of additional item*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 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
!
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When the addition of the robot/the station ends, press [ENTER]. The detail edit display
shuts and the job content display is shown.
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 occurred 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 interference Remove the object after
Robot/Station between robot and peripheral resetting the alarm or move
[Axis Data] device etc. was detected. the robot to the safety posi-
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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*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
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3.14 Number Key Customize Function
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 operations can be allocated to number keys on the programming
pendant, decreasing the number of key operations reduce the teaching time.
NOTE The Number Key Customize Function is only valid when the security mode is set to the
management mode.
3.14.2 Allocatable Functions

There are two allocation methods as follows:
Key Allocation (EACH)
Key Allocation (SIM)
Key Allocation (EACH)

With key allocation (EACH) function, the manipulator operates according to the allocated
function when the number key is pressed. The following shows the functions that can be allo-
cated.
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.
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Key Allocation (SIM)

With key allocation (SIM) function, the manipulator operates according to the allocated func-
tion when the [INTERLOCK] and the number key are pressed at the same time. The follow-
ings show 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
ALLOCATE
KEY ALLOCATION(EACH) R1 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.
*4 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 on 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

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
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 on 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].
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Momentary Output Allocation

Operation
Select MOMENTARY OUTPUT*2
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].
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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].
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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
!
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].
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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
incremental value and press [SELECT]. Numeric values can now be entered. Input
the number or incremental value to be changed, and press [ENTER].
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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
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 (refer to " 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.
*3 The status is changed. (: status ON, : status OFF)
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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
!
*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.
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3.17 Changing the Parameter Setting
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
S2C001 2 0000_0000
S2C002 4 1000_0000 Binary Data
S2C003 8 0000_0000
S2C004 16 0000_0000 Decimal Data
S2C005 32 0000_0000
S2C006 64 0000_0000
S2C007 89 0000_0000
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.
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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
*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 management mode Select {FILE} under the top menu Select {INI-
TIALIZE}*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
TIALIZE} Select {FILE/GENERAL DATA}*1 Select data file for initializing*2
Presenter]*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.
VARIABLE DATA VAR .DAT

!Maintenance Mode
INITIALIZE
TOOL DATA TOOL .CND

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

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

Operation
TIALIZE} 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 box 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
TIALIZE} 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
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
TIALIZE} 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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3.19 System Backup
3.19 System Backup
For the XRC, the system data can be collectively backed up in advance so that the data is
immediately loaded and restored in case of an unexpected trouble such as data loss.
3.19.1 Backup Data with XRC

For the XRC, three types of collective backup are available: CMOS.BIN, CMOSxx.HEX and
ALCMSxx.HEX.
CMOS.BIN
For the normal backup, use this data.
Save: Perform in the maintenance mode (the editing mode or higher).
Load: Perform in the maintenance mode (the management mode).
As for the load/save procedures, refer to " 3.19.3 Backup by CMOS.BIN ".
Target Area: All areas of the internally stored data.

(Note that the monitoring time is not loaded)
CMOSxx.HEX
This data is loaded/saved in the FD/CF menu in the normal mode.
Save: Perform in the normal mode (the editing mode or higher).
Load: Perform in the normal mode (the management mode).
For details, refer to "7-1 Floppy Disk Unit" in "YASNAC XRC Operators Manual"
Target Area: The collected data including "Job File", "Data File", "Parameter File", "System
Data" and "I/O Data" which can be individually loaded/saved in the FD/CF
menu.
Because the setting information of robot etc. are not included in this collected
data, the system cannot be completely restored.
ALCMSxx.HEX
This data is for the manufacturer only. Users can save but cannot load this data.
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3.19 System Backup
3.19.2 Backup Timing

It is recommended to save CMOS.BIN data at the following timings so that the data can be
immediately restored in case of an unexpected trouble such as data loss.
After the Teaching Operation

Backup the data after the operations such as modification of teaching, adding or deleting of
jobs or editing of a condition file.
At Regular Intervals
Backup the data at regular intervals even if the teaching operation is not performed.
3.19.3 Backup by CMOS.BIN

Perform the backup by CMOS.BIN in the maintenance mode.
The chart below shows the availability of CMOS save/CMOS load in each security mode in
the maintenance mode.
Security Save Load
Opearation Mode X X
Editing Mode O X
Management Mode O O
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3.19 System Backup
CMOS.BIN Save
When saving CMOS.BIN, follow the procedures below after inserting the PC card into the PC
card slot on XCP01 board.
Operation
Turn the power supply ON while pressing [TOP MENU] simultaneously Select {TOOL}
under the top menu*1 Select {PC CARD}*2 Select {CMOS SAVE}*3 Select
YES
Explanation
*1 The sub menu appears.
PC CARD
!Maintenance Mode
*2 PC card display appears.
PC CARD
Parameters marked by
CMOS SAVE
cannot be selected
CMOS LOAD
!Maintenance Mode
*3 The confirmation dialog box appears.
PC CARD
CMOS SAVE_____________________
CMOS LOAD SAVE ?
YES NO
!Maintenance Mode
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3.19 System Backup
Select {YES} to save the collective data in the PC card under the name of CMOS.BIN.
When saving the file, if CMOS.BIN file already exists in the PC card, the following
confirmation dialog box appears.
PC CARD
CMOS SAVE _____________________

CMOS LOADOVERWRITE?
CMOS.BIN
YES NO
!Maintenance Mode
Select {YES} to overwrite the collective data on CMOS.BIN file in the PC card.
The line pointed with the cursor becomes highlighted in reverse again when saving
operation is completed.
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3.19 System Backup
CMOS.BIN Load
When loading CMOS.BIN, follow the procedures below after inserting the PC card, in which
the CMOS.BIN (collective data) is written, into the PC card slot on XCP01 board.
Before performing the load, make sure the existing collective data is backed up by CMOS
save.
Operation
security mode to the maintenance mode Select {TOOL} under the top menu*1 Select
{PC CARD}*2 Select {CMOS LOAD}*3 Select YES
Explanation
*1 The sub menu appears.
PC CARD
!Maintenance Mode
*2 PC card display appears.
PC CARD
Parameters marked by
CMOS SAVE
cannot be selected
CMOS LOAD
!Maintenance Mode
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3.19 System Backup
*3 The confirmation dialog box appears.
PC CARD
CMOS SAVE_____________________
CMOS LOAD LOAD ?
YES NO
!Maintenance Mode
Select {YES}, to load the contents of CMOS.BIN file in the PC card.
The line pointed with the cursor becomes highlighted in reverse again when loading
operation is completed.
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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-
TEM} under the top menu*1 Select {SETUP}*2 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 modules 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 D ULE
S T# D I DO 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 D E :16byte)
!M aintenance M ode
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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.
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4.2 Addition of Base and Station Axis
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
*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 display moves to the control group display shown in the followings.
The following items must be set for base and station axes.
TYPE
Select one from the type list.
In case of base axis (B1,B2,B3)

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

Select one from 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 from 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.
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 types list.
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4.2.1 Base Axis Setting

First, select a 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 from 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
*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.
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Direction of Base Axis
RECT-X RECT-Y RECT-Z

Z Z
Z
Y Y Y
X X X
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

Z
Z Z
Y Y
Y
X CARTESIAN X
X
Y-AXIS
CARTESIAN
CARTESIAN Z-AXIS CARTESIAN CARTESIAN
CARTESIAN 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.
CARTESIAN
RECT-XYZ Z
Z-AXIS
X
Y
CARTESIAN
CARTESIAN
X-AXIS
Y-AXIS
Base 1st, 2nd, and 3rd axes advancing
directions coincide with robot coordinate
X-Axis, Y-Axis, and Z-Axis, respectively.
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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.
*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)
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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.
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
*2 Press [ENTER] in the axes configuration display*3
axis Select desired axis type
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
MOTION RANGE :Input maximum moving position (+ direction and - direction)

from origin point. (Unit: mm)
<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)
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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.)
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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 box 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.
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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-
trol group display*4
Explanation
*1 The control group display is shown.
CONTROL GROUP
R1 :UP6-A0*
B1 :NONE
R2 :NONE
S1 :TURN-2
S2 :NONE
!Maintenance Mode
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*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 The setting in the control group display is completed and the display moves to the con-
nection display.
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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)
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.
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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
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*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)
OFFSET :Offset should be specified at TURN-2 type only.
Input length between the center of bending axis (1st axis) and
the turning table (2nd axis). (Unit: mm)
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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
<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 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
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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.)
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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 setting
in this display is completed and the confirmation dialog box 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.
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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.
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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.

L
ROBOT AXIS CONFIG R1 C S
AXIS CONFIGURATION
R1 UP130-A* 0011_1111 B1:0000_0001
S1 TURN-1
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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 [ ]
!
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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
UNIVERSAL OUTPUT R1 C S
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 [ ]
!
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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)
UNIVERSAL OUTPUT
L
R1 C S
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 [ ]
!
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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.
SPECIFIED INPUT
L
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
!
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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
!
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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
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5.3.6 Modify the Signal Name

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

UNIVERSAL INPUT
L
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
!
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*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
EDIT DISPLAY UTILITY
L

SEARCH SIGNAL NO. R1 C S
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 [ ]
!
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5.3.7 Search the Signal Number

A signal number of universal input, universal output, specific input, or specific output can be
searched.
UNIVERSAL INPUT
L
R1 C S
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 *3
Press [ENTER] to start the search
Explanation
*1 Number input line is displayed.
L
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
!
*3 The page where the signal number exists is displayed.

L
UNIVERSALINPUT R1 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 [ ]
!
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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
DISPLAY UTILITY
L
SEARCH SIGNAL NO.
SIGNAL
SEARCH NO. R1 C S
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.
L
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 [ ]
!
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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.

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 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.
L
UNIVERSALINPUT R1 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 [ ]
!
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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
DISPLAY UTILITY
L
SIGNAL NO.
SEARCH R1 C S
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.
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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.
5-14 425 of 656

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

PLAYBACK TIME
L
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

OPERATING TIME
L
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.
5-15 426 of 656

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
L
SYS MONITORING TIME R1 C S
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.
SYS MONITORING TIME
L
R1 C S
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 )
!
5-16 427 of 656

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)
DISPLAY", 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."
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RE-CTO-A203
5.5 Alarm History
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
Select {CLEAR HISTORY}*1 Select YES*2
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.
5-18 429 of 656

RE-CTO-A203
5.6 I/O Message History
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.
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.
5-19 430 of 656

RE-CTO-A203
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.
5-20 431 of 656

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
5-21 432 of 656

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
CURRENT POSITION R1 C S
COORDINATE : PULSE TOOL : 00

R1 :S 0
L 0
U 0
R 0
B 0
T 0

L
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.

L
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
5-22 433 of 656

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
5-23 434 of 656

RE-CTO-A203
Explanation
*1 The servo monitor display appears.

L
SERVO MONITOR R1 C S
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
SPEED INST ERROR PULSE
R1 :S 4000 300
L 0 0
U 0 0
R 0 0
B 0 0
T 0 0
5-24 435 of 656

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.

L
CLEAR MAX TORQUE R1 C S
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.

L
MAX TORQUE FEEDBACK PULSE
R1 :S 0 0
L 0 0
U 0 0
R 0 0
B 0 0
T 0 0
5-25 436 of 656

Hardware
437 of 656
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.
6-1 438 of 656

RE-CTO-A203
CAUTION


use.
If the programming pendant is inadvertently left on the manipulator, fixture, or on the floor,
6-2 439 of 656

RE-CTO-A203
Controller
Configuration Free-standing, enclosed type
Dimensions Refer to following
Cooling System Indirect cooling
Ambient Temperature 0C to + 45C (During operation)

-10C to + 60C (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%)
Grounding Grounding resistance : 100 or less

Exclusive grounding
Digital I/O Specific signal (hardware) 11 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
6-3 440 of 656

RE-CTO-A203
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

B-type Small SV3X, UP6, or SK16X

panel capacity 700(W) 750(H) 420(D) mm
Medium SK45X, SK16MX, or SP70X

Large UP130, UP165, UP165-100, UP200, UP130R, SK300X, or SP100X

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
Large UP130, UP165, UP165-100, UP200, UP130T, SK300X, SP100X,

capacity SK506X, SR200X, UP130R, UP165R, UP200R, UP130RL
ES165,ES200,ES165R or ES200R
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, UP130RL
ES165,ES200,ES165R or ES200R
650(W) 1300(H) 450(D) mm
6-4 441 of 656

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 respectively can be corrected.)
Inching Operation Possible
Locus Confirmation Forward/Reverse step, Continuous feeding
Speed Adjustment Fine adjustment possible during operating or pausing
Timer Setting 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)
Collision-proof 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
6-5 442 of 656

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
6-6 443 of 656

RE-CTO-A203
The XRC is comprised of individual units and modules (circuit boards). Malfunctioning com-
ponents 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
A-type panel
Power Supply Unit

I/O-Power-On Unit CPU Rack Playback Panel Non-fuse Breaker (QF1)
JZRCR-XPU03 JZNC-XIU01 JZNC-XRK01- ZY1C-SS3152 SA33B 10A 3P
A
JZNC-XRK01
XCP01 CPS-150F
XCP01
CPS-150F
Back Duct Fan

SW
4715oS-22T
BAT
-Bo0-B00
(For air inlet) R R R T T T
1KM
1X
(EV1) (EV2)
Servopack
1
B 0 0
GRIP
Ascending Fan CNPB04
8830-032-170SD
CNPB05
8830-032-170SD
CNPB06
8830-032-170SD
C249
3610PS-22T
102
DUSB-ARB8X-T11
CN10
CONV
2CN
-B30-B00
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
(EV3) (EV4)
RCP01AAA
PWM
178323-2
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-XPU03
UP6 ERCR-UP6-RA00 CACR-UP6AAC JUSP-ACP05JAA SA33B 15A JZRCR-XPU03
ERCR-SK16-RA00 JZRCR-XPU03
SK16X CACR-SK16AAC JUSP-ACP05JAA SA33B 15A
ENCM-RX6003 JZNC-XPW03
Configuration for Small-Capacity XRC in A-Type Panel
6-7 444 of 656

RE-CTO-A203
2. B-type panel
Power Supply Unit I/O-Power-On Unit CPU Rack Playback Panel

JZRCR-XPU03 JZNC-XIU01A JZNC-XRK01- ZY1C-SS3152
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
Back Duct Fan
CN04/CARD
3X 3X
AN
CN06/SV
CN26
CN27
SER NO.
TYPE
CN24 CN25
4715S-22T-B0-B00
CN04
CN12
CN13
CN03/RS232C
CN23
CN22
(For air inlet)
CN02/PP
CN03
CN21
345
2X
67
CN02
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
102
DUSB-ARB8X-T11
CN10
CONV
2CN
Servopack
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
PWM
178323-2
CN50
Ascending Fan
CNPG123
PWM
1CN
10250-52A2JL
3610PS-22T
CN30
CNE 3-175475-6
CN40
-B30-B00
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
GRIP
(Air flows up)

A (Note 1)
Servopack
Welding Board
Sectional view A-A
JANCD-XEW01
SV3X ERCR-SV3-RA01 CACR-SV3AAA JUSP-ACP05JAA SA33B 15A JZRCR-XPU03
UP6 ERCR-UP6-RA01 CACR-UP6AAC JUSP-ACP05JAA SA33B 15A JZRCR-XPU03
SK16X ERCR-SK16-RA01 CACR-SK16AAC JUSP-ACP05JAA SA33B 15A JZRCR-XPU03
Configuration for Small-Capacity XRC in B Type Panel
3. New A-type panel

JZRCR-XPU03 JZNC-XIU01 A JZNC-XRK01- ZY1C-SS3152
JZNC-XRK01
XCP02/OPT CPS-150F
XCP01
5X 4X
CN05
DATE
YASNAC
3X POWER SUPPLY
CN05/SV
CPS-150F
JAPAN
SER NO.
TYPE
CN04
CN03
SOURCE
PWR ON
Back Duct Fan

+5V
CN02
+24V
OHT
CN01
4715S-22T-B0-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
102
DUSB-ARB8X-T11
CN10
CONV
2CN
CNPG456
10220-6202JL
+5V PWM
CN20
10250-52A2JL
JUSP-
RCP01AAA
PWM
178323-2
CN50
345
67
01 2
89 A
EF
BCD
(EV3) (EV4) Servopack

CNPG123
PWM
1CN
10250-52A2JL
Ascending Fan
CN30
CNE 3-175475-6
4715S-22T-B0-B00
CN40
8830-032-170SD 8830-032-170SD 8830-032-170SD
S L U R B T
(Air flows up) GRIP
Servopack (Note 1)
A Welding Board
JANCD-XEW01 Sectional view A-A
SV035X ERCR-SV035-RA10 CACR-SV035AAA JUSP-ACP05JAA SA33B/5A JZRCR-XPU03
ERCR-UP6-RA10 JZRCR-XPU03
UP6 CACR-UP6AAC JUSP-ACP05JAA SA33B/15A
SK16X ERCR-SK16-RA10 CACR-SK16AAC JUSP-ACP05JAA SA33B/15A JZRCR-XPU03
ERCR-UP20-RA10 JZRCR-XPU03
UP20 CACR-UP20AAA JUSP-ACP05JAA SA33B/15A
Configuration for Small-Capacity XRC in New A Type Panel
6-8 445 of 656

RE-CTO-A203
4. New B-type panel
Non-fuse Breaker (QF1) Playback Panel

Refer to the following table. A ZY1C-SS3152
I/O-Power-On Unit
JZNC-XIU01
Power Supply Unit
JZRCR-XPU03 CPU Rack
JZNC-XRK01-
Back Duct Fan Servopack
4715S-22T-B0-B00 Ascending Fan (Note1)
(For air inlet) 4715S-22T
-B0-B00 Welding Board
R R R T T T
1KM
(Air flows up) JANCD-XEW01
A Servopack
Refer to the following table. Sectional view A-A
UP6 ERCR-UP6-RA11 CACR-UP6AAC JUSP-ACP05JAA SA33B/15A JZRCR-XPU03
SK16X ERCR-SK16-RA11 CACR-SK16AAC JUSP-ACP05JAA SA33B/15A JZRCR-XPU03
UP20 ERCR-UP20-RA11 CACR-UP20AAA JUSP-ACP05JAA SA33B/15A JZRCR-XPU03
Configuration for Small-Capacity XRC in New B-Type Panel
6-9 446 of 656

RE-CTO-A203
Medium Capacity
1. A-type panel

JZNC-XRK01
Back Duct Fan

5915PC-22T-B30-B00
(For air inlet)
TYPE TYPE
JAPAN NJ2096-1 JAPAN NJ2096-1
(EV1) (EV2) (EV3)
(EV4) (EV5)
Non-fuse Breaker (QF1)
EA53B 30A
Servopack
Ascending Fan
3610PS-22T-B30-B00
(Air flows up)
Converter
JUSP-ACP25JAA
A Servopack
Model YASNAC XRC Servopack Converter (Separated) QF1 Power Supply Unit
SK45X ERCR-SK45-RA00 CACR-SK45AAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02
SK16MX ERCR-SK16M-RA00 CACR-SK16MAAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02
SP70X ERCR-SP70-RA00 CACR-SP70AAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02
Configuration for Medium-Capacity XRC in A-Type Panel
2. B-type panel

JZRCR-XPU02 JZNC-XIU01 JZNC-XRK01- ZY1C-SS3152
A
Back Duct Fan

5915PC-22T-B30-B00
(For air inlet) SER NO.
TYPE
DATE

JAPAN NJ2096-1
SER NO.
TYPE
DATE

JAPAN NJ2096-1
(EV7) (EV6) (EV5) (EV1) (EV2) (EV3) (EV4)

EA53B/30A
Servopack
Ascending Fan
3610PS-22T
-B30-B00
(Air flows up)
A Servopack
Sectional view A-A
Converter Refer to the following table.
JUSP-ACP25JAA
SK16MX ERCR-SK16M-RA01 CACR-SK16MAAB JUSP-ACP25JAA EA53B/30A JZRCR-XPU02
Configuration for Medium-Capacity XRC in B-type Panel
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RE-CTO-A203
3. New A-type panel

JZNC-XRK01
Back Duct Fan

5915PC-22T-B30-B00
TYPE
DATE

JAPAN NJ2096-1
DATE

JAPAN NJ2096-1
(EV1) (EV2) (EV3)

SA33B/20A
Servopack
Ascending Fan
4715oS-22T
-Bo0-B00
(Air flows up)
A
Converter Sectional view A-A
Servopack
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
A Playback Panel
ZY1C-SS3152
Non-fuse Breaker
(QF1) SA33B/20A
I/O-Power-On Unit
JZNC-XIU01
Power Supply Unit JZNC-XRK01 CPU Rack

JZRCR-XPU02 JZNC-XRK01-
Back Duct Fan
5915PC-22T-B30-B00
(For air inlet) Servopack SER NO.
TYPE
DATE

JAPAN NJ2096-1
Ascending Fan
4715S-22T (EV1) (EV2) (EV3)
-B0-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
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RE-CTO-A203
Large Capacity
1. A-type panel

Refer to the table below. JZNC-XIU01 A JZNC-XRK01- ZY1C-SS3152
JZNC-XRK01
4X 5X
1X
Back Duct Fan 1KM
5915PC-22T-B30-B00
TYPE
DATE

JAPAN NJ2096-1
SER NO.
TYPE
DATE

JAPAN NJ2096-1
(EV1) (EV2) (EV3) (EV4)
(EV5) (EV6) G R I P
Non-fuse Breaker(QF1)
EA53B/40A
Servopack
Ascending Fan
3610PS-22T
-B30-B00
(Air flows up)
A Heat Exchanger
Converter Servopack
JUSP-ACP35JAA Refer to the following table. YD5-1042A Sectional view A-A
UP130 ERCR-UP130-RA00 CACR-UP130AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 or JZRCR-XPU01
UP165 ERCR-UP165-RA00 CACR-UP130AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 or JZRCR-XPU01
UP165-100 ERCR-UP165-RA03 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 or JZRCR-XPU01
UP200 ERCR-UP200-RA00 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 or JZRCR-XPU01
UP130R ERCR-UP130R-RA00 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU01
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 JZNC-XRK01- ZY1C-SS3152
Refer to the following table. 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)
A Heat Exchanger
Converter Servopack YD5-1042A Sectional view A-A
JUSP-ACP35JAA Refer to the following table. Refer to the following table.
Model YASNAC XRC Servopack Converter (Separated) QF1 Power Supply Unit Heat Exchanger
UP130 ERCR-UP130-RA01 CACR-UP130AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 or JZRCR-XPU01 WIth
UP165 ERCR-UP165-RA01 CACR-UP130AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 or JZRCR-XPU01 With
UP165-100 ERCR-UP165-RA04 CACR-UP130Y18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 or JZRCR-XPU01 With
UP200 ERCR-UP200-RA01 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU02 or JZRCR-XPU01 With
UP130R ERCR-UP130R-RA01 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU01 With
SK300X ERCR-SK300-RA01 CACR-SK300AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU01 With
SK506X ERCR-SK506-RA01 CACR-UP130AABY18 JUSP-ACP35JAA EA53B/40A JZRCR-XPU01 With
SP100X ERCR-SP100-RA01 CACR-SP100AAB JUSP-ACP35JAA EA53B/40A JZRCR-XPU01 Without
Configuration for Large-Capacity XRC in B-Type Panel
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RE-CTO-A203
3. New A-type panel

I/O-Power-On Unit
JZNC-XIU01 CPU Rack Playback Panel
Power Supply Unit
Refer to the following table. A JZNC-XRK01- ZY1C-SS3152
JZNC-XRK01
Back Duct Fan

5915PC-22T-B30-B00
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
4715S-22T-B0-B00
(Air flows up)
Converter
JUSP-ACP35JAA A Servopack
UP130 ERCR-UP130-RA10 CACR-UP130AAB JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
UP165-100 ERCR-UP165-RA13 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
UP200 ERCR-UP200-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
UP130T ERCR-UP130T-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
ES165 ERCR-ES165-RA10 CACR-UP130AAB JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
ES200 ERCR-ES200-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
SK300X ERCR-SK300-RA10 CACR-SK300AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
SP100X ERCR-SP100-RA10 CACR-SP100AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
SK506X ERCR-SK506-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
SR200X ERCR-SR200-RA10 CACR-SK300AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
UP130R ERCR-UP130R-RA10 CACR-UP130AABY18 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
UP130RL ERCR-UP130RL-RA10 CACR-UP130AABY21 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
ES165R ERCR-ES165R-RA10 CACR-UP130AABY21 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
Configuration for Large-Capacity XRC in New A-Type Panel
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RE-CTO-A203
4. New B-type panel

Refer to the following table. A
QF1
I/O-Power-On Unit
ON
P
TRI
OFF
ET
RES
JZNC-XIU01
Power Supply Unit

Refer to the table CPU Rack
JZNC-XRK01-
JZNC-XRK01
below
Back Duct Fan Servopack
5915PC-22T-B30-B00 Ascending Fan
(For air inlet) 4715oS-22T
-B0-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-XPU02 or JZRCR-XPU01
UP200 ERCR-UP200-RA11 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
UP130T ERCR-UP130T-RA11 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
ES165 ERCR-ES165-RA11 CACR-UP130AAB JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
ES200 ERCR-ES200-RA11 CACR-UP130AABY18 JUSP-ACP35JAA SA33B/30A JZRCR-XPU02 or JZRCR-XPU01
SK300X ERCR-SK300-RA11 CACR-SK300AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
SP100X ERCR-SP100-RA11 CACR-SP100AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
SK506X ERCR-SK506-RA11 CACR-UP130AABY18 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
SR200X ERCR-SR200-RA11 CACR-SK300AAB JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
UP130RL ERCR-UP130RL-RA11 CACR-UP130AABY21 JUSP-ACP35JAA SA53B/40A JZRCR-XPU01
Configuration for Large-Capacity XRC in New B-Type Panel
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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-ACPJAA)
Front Amplifier (JUSP-WSAA)

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.
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RE-CTO-A203
Servopack
Ascending Fan
Backside Duct Fan
(X1)
(X2)
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)
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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)
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RE-CTO-A203
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 working 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.
7-1 455 of 656

RE-CTO-A203
CAUTION

- 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

The power supply unit consists of the contactor (1KM) for servo power and the line filter (1LF).
It turns the contactor servo power ON and OFF using the signal for servo power control from
the I/O contactor 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 and I/O
contactor unit and servopack (servo controlled power supply) via the line filter.
Power Supply Unit Models
Model Robot Type
JZNC-XPW03 or SV3X, SV035X, UP6, SK16X, UP20

JZRCR-XPU03
JZRCR-XPU02 SK16MX, SK45X, SP70X, UP50, UP20M
JZRCR-XPU02 or UP130, UP165, UP165-100, UP200,

JZRCR-XPU01 UP130T,ES165,ES200
JZRCR-XPU01 SK300X, SP100X, SK506X, SR200X, UP130R,

UP165R, UP200R, UP130RL,ES165R,ES200R
7-2 456 of 656

RE-CTO-A203
(5X)
Sigle-phase AC200V connector
(Contactor Coil, etc.)
(4X)
Contactor Output
(3X) (1Z)
3-phase AC200V Input Line Filter
(2X)
3-phase AC200V Output
(1KM)
Contactor
(1X)
Single-phase AC200V Output
Power Supply Unit Configuration (JZNC-XPW03, JZRCR-XPU03)
(5X) (4X)
Sigle-phase AC200V connector Contactor Output
(Contactor Coil, etc.)
5X 4X
(1X)
1X
Single-phase AC200V Output
(1Z)
Line Filter
(1KM)
Contactor
Power Supply Unit Configuration (JZRCR-XPU01, JZRCR-XPU02)
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RE-CTO-A203
7.2 CPU Rack
7.2 CPU Rack
7.2.1 CPU Rack Configuration

CPU rack consists of the control power unit, circuit board racks, and system control circuit
boards.
JZNC-XRK01
XCP01 CPS-150F
XCP01
CPS-150F (CN05)
(CN04) AC200V Input
CN05
PC Card (from Power Supply Unit)
Battery Alarm
CN04/CARD
(CN04)
CN05/SV
Control Power Supply

(CN03) CN04
ON/OFF Conection
RS232C
(WAGO connector)
SW
Connector
0 1 2 3 4
(See "WAGO Connector".)

BAT
CN03
CN03/RS232C
SOURCE
PWR ON
(CN03), (CN02)
+5V DC24V Output
Battery CN02
+24V
(to Programming Pendant)
OHT
CN02/PP
CN01 Monitor Alarm Display

CN01/IO
(CN01)
DC24V,DC5V Output
(to XIU)
System Control Board Control Power Supply Unit

7.2.2 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 or JANCD-XIF04). 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.
Control Power Supply Unit (CPS-150F)

This unit supplies the DC power (DC5V, 24V) to the I/O contactor unit (JZNC-XIU 01) and
the programming pendant. It is also equipped with the input function for turning the control
power supply ON and OFF.
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RE-CTO-A203
7.2 CPU Rack
Rated Input Voltage: AC200/220

Input Voltage Fluctuation Range: +10% to -15% (AC170 to 242V}
Frequency: 50/60Hz 2Hz (48 to 62Hz)
DC + 5V : 10A
Output Voltage
DC +24V : 4.0A
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)
It is detected when the temperature inside of the controller is about 65C

Overheat Detector
When the message of the "Cooling fan in control box stopped" is displayed, it may be
NOTE caused by the error occurrence at the cooling fan (JZNC-XZU02) on the CPU rack.
The playback operation (execution of the JOB) is not performed when the error is occurred
at the cooling fan. In this case, the alarm 4119 "FAN ERROR (IN CONTROL BOX)" is
appeared by 72 hours later.
The message of the "Cooling fan in control box stopped" is displayed, carry out an inspec-
tion and the replacement of the cooling fan on the CPU rack as soon as possible.
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RE-CTO-A203
7.2 CPU Rack
To turn ON the XRC controller power, turn the main switch to the ON
position 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 shortened when shipment)
Control Power Supply Unit
(CPS-150F)
Switch
Control Power CN04

ON/OFF -1
-2
*1
CN4:231-102/026-000 (WAGO)
Connection to Control Power Supply Unit
Refer to " WAGO Connector " for wiring of CN04 connector.
WAGO Connector
CN05, 06, 26 and 27 on the I/O contactor unit (JZNC-XIU01) and CN04 on the control
power supply unit are equipped with a connector made by WAGO.
The wiring tool for the WAGO connector is necessary to wire the WAGO connector.
Two of these tools are supplied with the XRC.
7-6 460 of 656

RE-CTO-A203
7.2 CPU Rack
1. Insert part A of the wiring tool into one of the holes designed for the tool.

(SuppliedParts)
Hole for the wiring tool
WAGO connector (e.g. 4 pins type)
Wire (Applicable size: 0.8mm2 to 3.5mm2 )

Stripped length: 8 to 9mm
2. Insert or pull out the wire while pushing the wiring tool downward (Direction of the
arrow).
Push
3. Remove the wiring tool from the connector. (Complete)

Keep this wiring tool for the future use.
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RE-CTO-A203
7.3 I/O Contactor Unit (JZNC-XIU01)
The I/O contactor unit consists of the Specific I/O circuit board (JANCD-XIO01), General I/O
circuit board (JANCD-XIO02) and Contactor circuit board (JANCD-XTU01) to control the
contactor sequence of the servo power supply.
(CN29)
Brake Output Connector (CN07)
Input connector for
Programming pendant,
Deadman switch,
Emergency stop
(CN25)
Input connector for Power ON/OFF (CN05,06)
(WAGO connector) Specific Input Connector
(See "WAGO connector") (WAGO connector)
(See "WAGO Connector".)
(CN25) (CN04)
Output connector for Overrun, I/O connector for
Shock Sensor, Lamp Power Supply Playback Panel
(CN10,11,12,13)
General I/O Connector
Power-on Circuit Board General I/O Circuit Board

JANCD-XTU01 JANCD-XIO02
Specific I/O Circuit Board

JANCD-XIO01
I/O Contatcor Unit Configuration (JZNC-XIU01)
SUPPLE Refer to " WAGO Connector ".

-MENT
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RE-CTO-A203
7.3.1 Specific Input Circuit Board (JANCD-XIO01)

The specific input circuit board is controlled by the system control circuit board (JANCD-XCP
01), and the main function of this board is as follows:
Specific I/O circuit, for instance I/O circuit for servo power supply contactor and emer-
gency stop circuit
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
JZNC-XIU01
JANCD-XIO01 CN05
+24VU
EXESP 1 EXESP+
External Emergency Stop
2 EXESP-
3 EXHOLD+
EXHOLD 4 EXHOLD- External Hold
SAF-F 5 SAF-F+
Safety Plug
6 SAF-F-
EXSVON 9 EXSVON+
External Servo On
10 EXSVON-
+24V +24VU
CN06
DIN 1 1 EXDIN 1+
2 EXDIN 1-
DIN 2 3 EXDIN 2+
4 EXDIN 2-
Direct Input
DIN 3 5 EXDIN 3+
6 EXDIN 3-
7
8
*Note
9 FORCE+ Switch with Key
FORCE 10 FORCE-
GND 024VU
JANCD-XIO01 I/O Allocation and Connection Diagram
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RE-CTO-A203
CAUTION
Do not use the FORCE (Forced release) input.
If the FORCE input should be used for an unavoidable reason, be sure to use a switch
with a key. The systems manager is responsible for storage of the key.
When FORCE is input, all the deadman switches become invalid, so handle with
extreme care.
Specific Input List (JANCD-XIO01)
Factory
Setting
EXESP External emergency stop
CN05 -1 Use to connect the emergency stop switch of an external operation Disabled by
CN05 -2 device. The servo power turns OFF and job execution stops when jumper lead
this signal is input. The servo power cannot be turned ON while this
signal is ON.
EXHOLD External hold

Disabled by
CN05 -3 Use to connect the HOLD switch of an external operation device. Job
jumper lead
CN05 -4 execution stops when this signal is input. Starting and axis opera-
tions are disabled while this signal is ON.
SAF-P Safety plug
CN05 -5 This signal turns OFF the servo power when the door of the safe-
Disabled by
CN05 -6 guard is opened. Connect to the interlock signal from the safety plug
jumper lead
attached to the door. The servo power turns OFF when the interlock
signal is input. The servo power cannot be turned ON while this sig-
nal is ON. However, in the teach mode, this function is disabled.
EXSVON Servo ON
Use to connect the servo On switch of an external operation device. Open

CN05 -9
CN05 -10 The servo power turns ON when this signal is input.
DIN1 Direct-in 1

CN06 -1
CN06 -2
DIN2 Direct-in 2

CN06 -3
CN06 -4
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RE-CTO-A203
Specific Input List (JANCD-XIO01)
Factory
Setting
DIN3 Direct-in 3

CN06 -5
CN06 -6
CN06 -7 For future expansion function Open

CN06 -8
FORCE Forced reset, input
CN06 -9 Do not use the FORCE (Forced release) input.

CN06 -10 If the FORCE input should be used for an unavoidable reason, be
Open
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.
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 Area

Safeguard
Servo ON Lamp
YASNAC
Controller XRC
Door
Safety Plug
Emergency
Taked Plug Stop
Receptacle for Teaching
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.
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RE-CTO-A203
7.3.2 General I/O Circuit Board (JANCD-XIO02)

The general I/O circuit board is controlled by the system control circuit board (JANCD-XCP
01) through the specific I/O circuit board (JANCD-XIO01).
I/O can be separated as specific I/O and general I/O allocated software as follows:
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 to which its role is divided 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 " 7.7 General I/O Signal Assignment ". The main
example using specific I/O is shown as follows.
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RE-CTO-A203
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

(JZNC-XIU01)
CN13 CN12 Connector A

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

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

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
I/O Terminal (Terminal size: M3)
Type: PX7DS-40V6-R (Yoshida Electric Industry)
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Specific I/O Signal Related to Start and Stop

The following signals are specific I/O signals related to start and stop.
Servo On (depending on application: JANCD-XIO02)

External Servo On (common to all application: JANCD-XIO01)
External Start (depending on application: JANCD-XIO02)
Operating (depending on application: JANCD-XIO02)
External Hold (common to all application: JANCD-XIO01)
External Emergency Stop (common to all application: JANCD-XIO01)
<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
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.
YASNAC XRC
Servo ON Servo ON
Servo ON PB Confirmation I/O Contactor Unit
Command
X2 Servo ON (JZNC-XIU01)
X1 Command CN05 +24VU
X1 -9
X1
External Servo
-10 ON Input
Servo ON
Servo Power ON Confirmation (EXSVON)
X3 (3011)
X2
Servo Power ON CN12 +24VU
X3 -A18
PL
Servo ON
-A8 Output
(3011)
Note: Number in ( ) means output signal number assigned to XIU01.

PL: Pilot Lamp
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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 Running
I/O Contactor Unit
Run PB Servo ON select Occuring Confirmation Start
(JZNC-XIU01o)
(3011) (3016) (3013) X5 (Command)
Ex. Start
Command CN12
X4 External Start
X4 -B1
Input
X3
(2011)
-B7
Running
Running Confirmation OVU
X6 (3010)
X5
Running, etc.
X6 +24VU
PL
Running Output
(3010), etc.
Note: Number in ( ) means output signal number assigned to XIU01o.
7.3.3 Power-ON Circuit Board (JANCD-XTU01)

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 XIU-CN25 (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
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I/O Contactor Unit

Manipulator JZNC-XIU01
XIU-CN25 +24VU
CN25
D1 +24VU
SHOCK24VU
D3
Shock Sensor
C3
SHOCK
Shock Sensor
(Option)
A3
Overrun Overrun
Connecting Cable
Shock Sensor Connection
When the shock sensor input signal is used, the stopping method of the robot can be
SUPPLE
-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 Releasing " for details.
Connection of External Power Supply for I/O

At factory setting, the internal power supply for I/O is used. If the external power supply for I/O
is used, connect it with following procedure.
1. Remove the wire connected between CN26-7 to -9 and CN26-8 to -10 of the I/O con-
tactor unit: JZNC-XIU01.
2. Connect +24V of the external power supply to CN26-7 and 0V to CN26-8 of the I/O
contactor unit: JZNC-XIU01.
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RE-CTO-A203
JZNC-XIU01 JZNC-XIU01
CN26 +24VU CN26 +24VU

External
FU4 Power Supply FU4
-7(EX24VIN) -7(EX24VIN)
3A +24V 3A
FU3 FU3
-8(EX024VIN) -8(EX024VIN)
0V
3A 3A
+24V 024VU (Ready by Customer) +24V 024VU
-9(+24V) -9(+24V)
-10(024V) -10(024V)
024V 024V
CN26: 231-110 / 026-000 (WAGO Connector)
(See "Wiring WAGO connector")
In case using internal power supply In case using external power supply
The internal power supply of 24V of about 1A of XRC can be used for I/O.
NOTE Use external 24V power supply for higher currents and to isolate the circuit inside and
outside the XRC.
The I/O power supply (+24 VU, 024 VU) has 3A fuses (FU3,FU4).
Install the external power supply outside the XRC to avoid electric noise problems.
When the internal power supply is selected, do not connect the line of the external power
supply to the +24VU and 0VU terminals. The unit may malfunction if the external power
supply is also connected.
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Method of Connecting External Axis Overrun Signal

In a standard specification, the external axis overrun input is unused.
Please connect the signal according to the following procedures when the overrun input for an
external axis is necessary, besides for the manipulator.
1. Remove wire (jumper) connected with CN26-1--2 of I/O power ON unit JZNC-XIU01.
2. The overrun input of an external axis is connected between CN26-1 and -2 of I/O
power ON unit JZNC-XIU01 as shown in below.
CAUTION
Remove a jumper when there is a jumper in the special input signal
used.
The injury and damage may result because it doesn't function even if the specific signal is
input.
YASNAC XRC
I/O Power on unit(JZNC-XIU01)
+24VU
CN26
-1
EXOT External Axis Overrun

-2
024VU
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RE-CTO-A203
7.4 Playback Panel
7.4 Playback Panel
Robot motion mode setting button, Servo ON button, playback hold/start button, emergency
stop button are provided on the playback panel.
ALARM lamp
Light up when an alarm
SERVO ON MODE EMERGENCY STOP or an error occurs.
READY
PLAY TEACH
SERVO ON READY
Turns on the servo
power supply. EMERGENCY
STOP button
MODE PLAY/ EDIT LOCK
TEACH (OFF) ALARM
Select the PLAY mode or the (ON) REMOTE HOLD START START button
Starts a playback
TEACH mode.
operation.
EDIT LOCK
(OPTION) HOLD button
Put a playback
Prohibits or enable editing.
REMOTE button on hold.
Select the remote mode.
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7.5 Contact Output of Emergency Stop Button
7.5 Contact Output of Emergency Stop Button
The contact output terminals for the emergency stop button on the programming pendant and
the playback panel are provided on the terminal board 2XT (screw size M3.5) on the bottom of
XRC.
These contact outputs are always valid no matter of the XRC main power supply status ON or
OFF. (Status output signal: normally closed contact)
Playback Panel
Emergency stop button
2XT EXT
PBESP1
PBESP1
PBESP2
PBESP2
Emergency stop button
PPESP1
PPESP1
PPESP2
PPESP2
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7.6 Servopack
7.6 Servopack
A Servopack consists of a servo control circuit board (JASP-WRCA01), a servo control

power supply (JUSP-RCP01), a converter and an amplifier (Refer to attached table
Servopack Configuration).
As for large capacity type, the converter and the servo power supply are separate.
7.6.1 Servopack Configuration
SV3X UP6
Component
Servopack CACR-SV3AAA - CACR-UP6AAC -
S JUSP-WS02AA 200W JUSP-WS05AAY17 500W
L JUSP-WS02AA 200W JUSP-WS10AAY17 1KW
U JUSP-WS01AA 100W JUSP-WS05AAY17 500W

Amplifier
R JUSP-WSA5AA 50W JUSP-WS01AA 100W
B JUSP-WSA5AA 50W JUSP-WS01AA 100W
T JUSP-WSA5AA 50W JUSP-WS01AA 100W
Servo control
circuit board
Servo control JUSP-RCP01 - JUSP-RCP01 -

power supply
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RE-CTO-A203
7.6 Servopack
SV035X
Component
Type Capacity
Servopack CACR-SV035AAA -
S JUSP-WS04AA 400W
L JUSP-WS04AA 400W
U JUSP-WS04AA 400W
Amplifier
R - -
B JUSP-WS01AA 100W
T JUSP-WS01AA 100W
Servo control
JASP-WRCA01 -
circuit board
Servo control
JUSP-RCP01 -
power supply
SK16X UP20
Component
Servopack CACR-SK16AAC - CACR-UP20AAA -
S JUSP-WS10AAY17 1kW JUSP-WS10AA 1kW
L JUSP-WS10AAY17 1kW JUSP-WS20AAY22 2kW
U JUSP-WS10AAY17 1kW JUSP-WS10AAY17 1kW

Amplifier
R JUSP-WS02AA 200W JUSP-WS02AA 200W
B JUSP-WS02AA 200W JUSP-WS02AA 200W
T JUSP-WS02AA 200W JUSP-WS02AA 200W
Servo control
circuit board
Servo control JUSP-RCP01 - JUSP-RCP01 -

power supply
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RE-CTO-A203
7.6 Servopack
SK45X SK16MX
Component
Servopack CACR-SK45AAB - CACR-SK16MAAB -
S JUSP-WS30AA 3kW JUSP-WS30AA 3kW

Amplifier
Servo control
circuit board
Servo control
JUSP-RCP01 - JUSP-RCP01 -
power supply
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RE-CTO-A203
7.6 Servopack
UP50 UP20M
Component
Servopack CACR-UP50AAB - CACR-UP20MAAB -
S JUSP-WS44AA 4.4kW JUSP-WS44AA 4.4kW

Amplifier
Servo control
circuit board
JUSP- JUSP-
Converter 25A 25A
ACP25JAAY11 ACP25JAAY11
Servo control
JUSP-RCP01 - JUSP-RCP01 -
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 -
circuit board
Servo control
JUSP-RCP01 -
power supply
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RE-CTO-A203
7.6 Servopack
UP130R, UP200, UP165-100,

UP130, UP165,ES165
UP130T, SK506K,ES200
Component
Servopack CACR-UP130AAB - CACR-UP130AABY18 -
S JUSP-WS60AA 6kW JUSP-WS60AAY18 6kW
L JUSP-WS60AA 6kW JUSP-WS60AAY18 6kW
U JUSP-WS60AA 6KW JUSP-WS60AA 6kW

Amplifier
R JUSP-WS20AAY13 2kW JUSP-WS20AAY13 2kW
B JUSP-WS15AAY13 1.5kW JUSP-WS15AAY13 1.5kW
T JUSP-WS15AAY13 1.5kW JUSP-WS15AAY13 1.5kW
Servo control
circuit board
Servo control JUSP-

- JUSP-RCP01 -
power supply RCP01
UP165R, UP200R, UP130RL

ES165R,ES200R
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 -
circuit board
Servo control
JUSP-RCP01 -
power supply
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RE-CTO-A203
7.6 Servopack

Component
Servopack CACR-SK300AAB - CACR-SP100AAB -
S JUSP-WS60AAY18 6kW JUSP-WS60AAY18 6kW
L JUSP-WS60AAY18 6kW JUSP-WS60AAY18 6kW
U JUSP-WS60AAY18 6KW JUSP-WS60AAY18 6kW

Amplifier
R JUSP-WS30AAY18 2kW - -
B JUSP-WS30AAY18 3kW - -
T JUSP-WS30AAY18 3kW JUSP-WS20AAY19 2kW
Servo control
circuit board
Servo control JUSP-

- JUSP-RCP01 -
power supply RCP01
Grip (Top)
Converter
Servo Control Amplifier 6pcs
Power Supply
Servo Control Board
G R I P 6AMP
+5 V Display LED
2CN
+5V
JUSP-
RCP01AAB
1CN
-OL(D20)
1CN 2CN 3CN 4CN 5CN 6CN
1GS 1CV 1AMP
G R I P
Grip (Bottom)
Servopack Configuration for SV3X, SV035X, UP6, SK16X
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RE-CTO-A203
7.6 Servopack
Grip (Top)
Converter
Amplifier 6pcs
Servo Control
Power Supply Servo Control Board
G R I P
8830-032-170SD 8830-032-170SD 8830-032-170SD

CNPB04 CNPB05 CNPB06 C249
+5V Display LED
CN10
2CN
CNPG456
10220-6202JL
CN20
+5V
JUSP-
RCP01AAA
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)
Servopack Configuration for UP20
Servopack
Converter
Grip (Top) Amplifier 6pcs
Servo Control G R I P
Servo Control Board
Power Supply
2CN
CNPG456
+5V Display LED +5V
JUSP-
RCP01AAB
CNPG123
1CN
CN1 CN2 CN3 GRIP CN4 CN5 CN6
Grip (Bottom)
Servopack Configuration for SK45X, SK16MX
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RE-CTO-A203
7.6 Servopack
Servopack
Converter
Grip (Top)
Amplifier 6pcs
Servo Control Board
Servo Control
Power Supply
2CN
+5V Display LED +5V
JUSP-
RCP01AAB
1CN
Grip (Bottom)
Servopack Configuration for UP50, UP20M
Servopack
Converter
Grip (Top) Amplifier 6pcs
Servo Control G R I P
Servo Control Board
Power Supply
2CN
CNPG456
+5V Display LED +5V
JUSP-
RCP01AAB
YASKAWA
CNPG123
1CN
CN1 CN2 CN3 GRIP CN4
Grip (Bottom)
Servopack Configuration for SP70X
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RE-CTO-A203
7.6 Servopack
Converter Servopack
Amplifier 6pcs Grip (Top)

Servo Control
Power Supply G R I P
Servo Control Board

+5V Display LED
2CN
+5V
JUSP-
RCP01AAB
CNE
1CN
4CN 5CN 6CN
G R I P
1GS
Grip (Bottom)
Servopack Configuration for UP130, UP165, UP200, UP130T, UP130R, UP165R, UP200R, UP130RL,
UP165-100, SK506X, SK300, SP200X, ES165, ES200, ES165R, ES200R
Converter Servopack
Servo Control Grip (Top)

Amplifier 6pcs
Power Supply
G R I P
2CN
+5V
JUSP-
RCP01AAB
CNE
1CN
6CN
G R I P
1GS
Grip (Bottom)
Servopack Configuration for SP100X
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7.6 Servopack
7.6.2 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 contactor circuit board (JANCD-XTU01) of
the I/O contactor unit. The power source is supplied by a servo control power supply.
Servo Control Power Supply (JUSP-RCP01)

This unit generates DC power (+5V, +7V, 15V) for the servo control board. AC input (Single
phase:AC200/220V) is supplied by power supply unit.
Items Specification
Rated Input AC200V to 220V

Voltage
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: AC200/220V) 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.
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7.7.1 Arc Welding
YASNAC-XRC
JZNC-XIU01 Connector Terminal Converter
(Optional)
CN12 Connector
Number Number Name Signal
Number
24VDC 2011 A1 - IN A1 1
JANCD-XIO02

2017 A4 IN192 IN A4 7
Interference2 Entrance 9
2021 A5 Prohibited IN A5
2023 A6 Work Response IN A6 11
B7 024VU B7 14
A7 024VU A7 13
3020 B12 In Cube 1 OUT B12 24
3021 A12 In Cube 2 OUT A12 23
Each Point 3023 A13 Intermediate Start OK

(continuousing Sequence) OUT A13 25
24VDC B14 B14 28

50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JANCD-XTU01
B16 024VU B16 32
CN26 A16 31
Internal
Power Supply
A16 024VU
-9
+24 V B17 024VU B17 34
-10 024V A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
External
-7 +24VU
Power Supply B19 +24VU B19 38
+24 VE -8 024 VU A19 37
A19 +24VU
024 VE
B20 FG B20 40
A20 A20 39

JANCD-XIO02 (CN12 Connector) I/O Allocation and Connection Diagram (For Arc Welding)
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RE-CTO-A203
YASNAC-XRC
(Optional)
CN13 Connector
Number Number
Name Signal
Number

24VDC 2025 A1 - IN A1 1
8mA max. 2026 B2 Weaving Prohibited IN B2 4
JANCD-XIO02
2027 A2 Sensing Prohibited IN A2 3

2030 B3 - IN B3 6
2031 A3 - IN A3 5
2032 B4 - IN B4 8
2033 A4 - IN A4 7
2034 B5 - IN B5 10
2035 A5 - IN A5 9
2036 B6 - IN B6 12
2037 A6 - IN A6 11
B7 024 VU B7 14
A7 024 VU A7 13
3024 B8 Gas Shortage (Monitor) OUT B8 16
3025 A8 Wire Shortage (Monitor) OUT A8 15
3026 B9 Wire Sticking (Monitor) OUT B9 18
3027 A9 Arc Shortage (Monitor) OUT A9 17
3030 B10 - OUT B10 20
3031 A10 - OUT A10 19
3032 B11 - OUT B11 22
3033 A11 - OUT A11 21
3034 B12 - OUT B12 24
3035 A12 - OUT A12 23
3036 B13 - OUT B13 26
3037 A13 - OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JANCD-XTU01
B16 024 VU B16 32
-9
+24 V B17 024VU B17 34
-10 0 24 V A17 024VU A17 33
(24 V,1A)
B18 +24VU B18 36
External A18 +24VU A18 35
-7 +24VU
+24 VE -8 024 VU A19
A19 +24VU 37
024 VE
B20 FG B20 40
A20 A20 39

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YASNAC-XRC
(Optional)
CN10 Connector
Number

24VDC 2041 A1 IN02 IN A1 1
8mA max. 2042 B2 IN03 IN B2 4
2043 A2 IN04 IN A2 3
JANCD-XIO02
2044 B3 IN05 IN B3 6
2045 A3 IN06 IN A3 5
2046 B4 IN07 IN B4 8
2047 A4 IN08 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3041 B9 OUT02- OUT B9 18
3042 B10 OUT03- OUT B10 20
3043 B11 OUT04- OUT B11 22
3044 B12 OUT05- OUT B12 24
3045 B13 OUT06- OUT B13 26
Each Point
24VDC
500mA max. 3046 B14 OUT07- OUT B14 28
3047 B15 OUT08- OUT B15 30
JANCD-XTU01 B16 024VU B16 32
CN26 Internal
A16 024VU A16 31
Power Supply
-9
+24 V B17 024VU B17 34
-10 0 24 V A17 024VU A17 33
(24 V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
External -7 +24VU
024 VE
A20 A20 39

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YASNAC-XRC
(Optional)
+24VU
CN11 Connector
Model:PX7DS-40V6-R
Number Number
Name Signal
Number
24VDC 2051 A1 IN10 IN A1 1
8mA max. 2052 B2 IN11 IN B2 4
2053 A2 IN12 IN A2 3
JANCD-XIO02
2054 B3 IN13 IN B3 6
2055 A3 IN14 IN A3 5
2056 B4 IN15 IN B4 8
2057 A4 IN16 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3050 B8 OUT09- OUT B8 16
3051 B9 OUT10- OUT B9 18
3052 B10 OUT11- OUT B10 20
3053 B11 OUT12- OUT B11 22
3054 B12 OUT13- OUT B12 24
3055 B13 OUT14- OUT B13 26
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 28
3057 B15 OUT16- OUT B15 30
CN26 Internal
A16 024VU A16 31
Power Supply
-9
+24 V B17 024VU B17 34
-10 0 24 V A17 024VU A17 33
(24 V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
External
-7 +24VU
+24 VE -8 024VU A19 37
A19 +24VU * means internal relay
024 VE
A20 A20 39

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RE-CTO-A203
Specific Input List XIU01 (Arc Welding)

Logical Logical
Number Number
2010 EXTERNAL START 2020 INTERFERENCE 1 ENTRANCE PROHIBITED
Functions the same as the [START] button in If the manipulator attempts to enter the cube
the playback panel. Only the rising edge of the 1*2 area while this signal is ON, the manipula-
signal is valid. It starts robot operation (play- tor goes to wait status (with servo power ON).
back). This signal is invalid if external start is During wait status, the manipulator operation
prohibited from the playback condition display. restarts if this signal turns OFF.
2012 CALL MASTER JOB 2021 INTERFERENCE 2 ENTRANCE PROHIBITED
Only the rising edge of the signal is valid. It If the manipulator attempts to enter the cube
calls up the top of the robot program, that is the 2*2 area while this signal is ON, the manipula-
top of the master job*1. This signal is invalid tor goes to wait status (with servo power ON).
during playback, during teach-lock and when During wait status, the manipulator operation
play master or call is prohibited (set from the restarts if this signal turns OFF.
playback operation condition display).
2013 ALARM/ERROR RESET 2022 WORK PROHIBITED (Arc Generation Prohib-
After an alarm or error has occurred and the ited)
cause been corrected, this signal resets the Arc generation is prohibited while this signal is
alarm or error. ON. Arc generation starts when this signal
turns OFF inside the arc-generation area. Use
this signal to confirm teaching.
2014 SELECT REMOTE MODE 2023 WORK RESPONSE (Pseudo Arc ON
Functions the same as [REMOTE] on the play- Response)
back panel. Valid only while the signal is ON. It This signal is used as a pseudo signal in cases
selects the REMOTE mode. that Arc Generation Confirmation signal is not
equipped on a welding power supply. Wire this
signal ON normally (short to OV).
2015 SELECT PLAY MODE 2026 WEAVING PROHIBITED
Functions the same as [MODE] on the play- Weaving is prohibited while this signal is ON.
back panel. Only the rising edge of the signal Use this signal to check taught steps and
is valid. It selects the PLAY mode. If desig- movements without performing the weaving
nated simultaneously with other modes, the operation.
TEACH mode takes priority. This signal is
invalid if external mode selection is prohibited
from the operation condition display.
2016 SELECT TEACH MODE 2027 SENSlNG PROHIBITED
The TEACH mode is selected if this signal Arc sensing is prohibited while this signal is
turns ON during PLAY mode. Switching to ON. Use this signal to check taught steps and
other modes is disabled while this signal is ON. movements if an arc sensor is mounted.
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 Refer to " 3.7 Interference Area ".
7-35 489 of 656

RE-CTO-A203
Specific Output List XIU01 (Arc Welding)

Logical Logical
Number Number
3010 RUNNING 3021 IN CUBE 2
This signal signifies that the job is running. This signal turns ON when the current tool cen-
(Signifies that the job is running, system status ter point lies inside a pre-defined space (Cube
is waiting reserved start, or test run is running.) 2). Use this signal to prevent interference with
This signal status is the same status as other manipulators and jigs.
[START] in the playback panel.
3011 SERVO IS ON 3022 OPERATION ORIGIN POINT (IN CUBE 24)*1
This signal signifies that the servo power is This signal turns ON when the current tool cen-
turned ON, internal processing such as current ter point lies inside a the operation origin area.
position creation is complete, and the system is Use this signal to evaluate whether the robot is
able to receive the START command. This sig- in the start position.
nal turns OFF when the servo power supply
turns OFF. It can be used for XRC status diag-
nosis for an external start.
3012 TOP OF MASTER JOB 3023 INTERMEDIATE START OK
This signal signifies that the execution position This signal turns ON when the manipulator
is the top of the master job. This signal can be operates. It turns OFF when the currently exe-
used to confirm that the master job has been cuted line is moved with the cursor or when
called.*2 editing operation is carried 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.
3013 ALARM/ERROR OCCURRED 3024 GAS SHORTAGE (MONITOR)
This signal signifies that an alarm or an error This signal stays ON while the gas shortage
occurred. If a major error occurs, this signal signal from the welding power supply is ON.
remains ON until the main power is turned
OFF.
3014 BATTERY ALARM 3025 WIRE SHORTAGE (MONITOR)
This signal turns ON to notify that the battery This signal status ON while the wire shortage
requires replacing when the voltage drops from signal from the welding power supply is ON.
the battery for backup memory of the encoder.
Major problems may result if memory data is
lost because of an expired battery. It is recom-
mended to avoid these problems by using this
signal as a warning signal.
3015 to REMOTE/PLAY/TEACH MODE SELECTED 3026 WIRE STICKING (MONITOR)
3017 This signal notifies the current mode setting. The sticking check is conducted automatically
These signals are synchronized with the lamps when the arc turns OFF. If wire sticking is
[REMOTE] and [MODE] in the playback panel. detected, this signal remains ON until the stick
The signal corresponding to the selected mode is released.
turns ON.
3020 IN CUBE 1 3027 ARC SHORTAGE (MONITOR)
This signal turns ON when the current tool cen- This signal stays ON while the arc shortage
ter point lies inside a pre-defined space (Cube signal from the welding power supply is ON.
1). Use this signal to prevent interference with
other manipulators and jigs.

7-36 490 of 656

RE-CTO-A203
7.7.2 Handling
YASNAC-XRC
(Optional)
CN12 Connector
Number Number Name Signal Number
24VDC 2011 A1 - IN A1 1
JANCD-XIO02

2017 A4 IN192 IN A4 7
2022 B6 - IN B6 12
2023 A6 - IN A6 11
B7 024VU B7 14
A7 024VU A7 13
3020 B12 In Cube 1 OUT B12 24
3021 A12 In Cube 2 OUT A12 23
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JANCD-XTU01
B16 024VU B16 32
CN26 A16 31
Internal A16 024VU
-9 Power Supply
+24 V B17 024VU B17 34
024 V
-10 A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
External
-7 +24VU
+24 VE -8 024 VU A19 37
A19 +24VU
024 VE
B20 FG B20 40
A20 A20 39

JANCD-XIO02 (CN12 Connector) I/O Allocation and Connection Diagram (For Handling)
7-37 491 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
CN13 Connector
Number

24VDC 2025 A1 - IN A1 1
8mA max. 2026 B2
Shock Sensor (NC)
- Hold
IN B2 4
2027 A2 Low Air Pressure IN A2 3
JANCD-XIO02
2030 B3 IN01 General Input IN B3 6

2031 A3 IN02 IN A3 5
2032 B4 IN03 IN B4 8
2033 A4 IN04 IN A4 7
2034 B5 IN05 IN B5 10
2035 A5 IN06 IN A5 9
2036 B6 IN07 IN B6 12
2037 A6 IN08 IN A6 11
B7 024 VU B7 14
A7 024 VU A7 13
3024 B8 - OUT B8 16
3025 A8 - OUT A8 15
3026 B9 - OUT B9 18
3027 A9 - OUT A9 17
3031 A10 OUT02 OUT A10 19
3032 B11 OUT03 OUT B11 22
3033 A11 OUT04 OUT A11 21
3034 B12 OUT05 OUT B12 24
3035 A12 OUT06 OUT A12 23
3036 B13 OUT07 OUT B13 26
3037 A13 OUT08 OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JANCD-XTU01
B16 024 VU B16 32
-9 +24 V B17 024VU B17 34
024 V
-10 (24V,1A) A17 024VU A17 33
B18 +24VU B18 36
-7 +24VU
+24 VE -8 024 VU A19
A19 +24VU 37
024 VE
B20 FG B20 40
A20 A20 39

7-38 492 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
CN10 Connector
Logical Terminal
Number
Connector
Number Name Signal
Number
Each Point 2040 B1 Sensor Input 1 IN B1 2

24VDC 2041 A1 Sensor Input 2 IN A1 1
8mA max. 2042 B2 Sensor Input 3 IN B2 4
JANCD-XIO02

B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
Each Point
24VDC A13 Hand Valve 3-2+ OUT A13 25 RLY
500mA max. 3046 B14 Hand Valve 4-1- OUT B14 28

Power Supply
A16 024VU
-9
+24 V B17 024VU B17 34
024 V
-10 (24V,1A) A17 024VU A17 33
B18 +24VU B18 36
A18 +24VU A18 35
External -7 +24VU
+24 VE -8 024 VU A19 +24VU A19 37
A20 A20 39

7-39 493 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
+24VU
CN11 Connector
Model:PX7DS-40V6-R
Number
24VDC 2051 A1 IN10 IN A1 1
8mA max. 2052 B2 IN11 IN B2 4
2053 A2 IN12 IN A2 3
JANCD-XIO02
2054 B3 IN13 IN B3 6
2055 A3 IN14 IN A3 5
2056 B4 IN15 IN B4 8
2057 A4 IN16 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3051 B9 OUT10- OUT B9 18
3052 B10 OUT11- OUT B10 20
3053 B11 OUT12- OUT B11 22
3054 B12 OUT13- OUT B12 24
3055 B13 OUT14- OUT B13 26
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 28
3057 B15 OUT16- OUT B15 30
CN26 A16 31
Internal A16 024VU
-9 Power Supply
+24 V B17 024VU B17 34
024 V
-10 A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
External
-7 +24VU
+24 VE
-8 024VU A19 +24VU A19 37
A20 A20 39

7-40 494 of 656

RE-CTO-A203
Specific Input List XIU01 (Handling)

Logical Logical
Number Number
2013 ALARM/ERROR RESET 2026 SHOCK SENSOR
After an alarm or error has occurred and the This is normally ON (NC) signal input. When it
cause been corrected, this signal resets the turns OFF, an XRC displays message "HAND
alarm or error. SHOCK SENSOR OPERATING" and a HOLD
is applied. 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 signal is not be used.
2014 SELECT REMOTE MODE 2027 LOW AIR PRESSURE
Functions the same as [REMOTE] on the play- This signal is normally OFF (NO). When it
back panel. Valid only while the signal is ON. turns ON, XRC displays user alarm in the
It selects the REMOTE mode. PLAY mode or displays user message in the
TEACH mode.
2015 SELECT PLAY MODE 2040 to SENSOR INPUT 1 - 8
Functions the same as [MODE] on the play- 2047 Inputs 1 to 8 are monitored with the HSEN han-
back panel. Only the rising edge of the signal is dling specific instructions. Sensor inputs 1 to 8
valid. It selects the PLAY mode. If designated correspond to HSEN 1 to 8.
simultaneously with other modes, the TEACH
mode takes priority. This signal is invalid if
external mode selection is prohibited from the
2016 SELECT TEACH MODE
The TEACH mode is selected if this signal
turns ON during PLAY mode. Switching to
other modes is disabled while this signal is ON.
master job.
7-41 495 of 656

RE-CTO-A203
Specific Output List XIU01 (Handling)

Logical Logical
Number Number
3013 ALARM/ERROR OCCURRED 3040 to HAND VALVE 1-4
This signal signifies that an alarm or an error 3047 These outputs are controlled by the HAND
occurred. If a major error occurs, this signal handling specific instructions.
remains ON until the main power is turned Hand valves 1 to 4 correspond to HAND 1 to 4.
OFF.
3014 BATTERY ALARM
This signal turns ON to notify that the battery
requires replacing when the voltage drops from
the battery for backup memory of the encoder.
3015 to REMOTE/PLAY/TEACH MODE SELECTED
3017 This signal notifies the current mode setting.
These signals are synchronized with the lamps
[REMOTE] and [MODE] in the playback panel.
The signal corresponding to the selected mode
turns ON.
3020 IN CUBE 1
This signal turns ON when the current tool cen-
ter point lies inside a pre-defined space (Cube

7-42 496 of 656

RE-CTO-A203
7.7.3 General Application
YASNAC-XRC
(Optional)
CN12 Connector
Number
24VDC 2011 A1 - IN A1 1
JANCD-XIO02

2017 A4 IN192 IN A4 7
2023 A6 - IN A6 11
B7 024VU B7 14
A7 024VU A7 13
3020 B12 In Cube 1 OUT B12 24
3021 A12 In Cube 2 OUT A12 23
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JANCD-XTU01
B16 024VU B16 32
CN26 A16 31
Internal A16 024VU
-9 Power Supply
+24 V B17 024VU B17 34
-10 024 V
A17 024VU A17 33
(24V,1A)
B18 +24VU B18 36
A18 +24VU A18 35
External
-7 +24VU
+24 VE -8 024 VU A19 37
A19 +24VU
024 VE
B20 FG B20 40
A20 A20 39

JANCD-XIO02 (CN12 Connector) I/O Allocation and Connection Diagram (For General Application)
7-43 497 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
CN13 Connector
Logical Connector
Signal
Terminal
Number Number Number
8mA max. 2026 B2 - IN B2 4
2027 A2 - IN A2 3
JANCD-XIO02
2030 B3 - IN B3 6
2031 A3 - IN A3 5
2032 B4 - IN B4 8
2033 A4 - IN A4 7
2034 B5 - IN B5 10
2035 A5 - IN A5 9
2036 B6 - IN B6 12
2037 A6 - IN A6 11
B7 024 VU B7 14
A7 024 VU A7 13
3026 B9 Work Command OUT B9 18
3027 A9 - OUT A9 17
3030 B10 - OUT B10 20
3031 A10 - OUT A10 19
3032 B11 - OUT B11 22
3033 A11 - OUT A11 21
3034 B12 - OUT B12 24
3035 A12 - OUT A12 23
3036 B13 - OUT B13 26
3037 A13 - OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JANCD-XTU01
B16 024 VU B16 32
CN26 A16 31
Internal
-9 +24 V
024 V B17 024VU B17 34
-10 (24V,1A)
A17 024VU A17 33
B18 +24VU B18 36
Power Supply -7 +24VU
B19 +24VU B19 38
+24 VE
-8 024 VU A19 +24VU A19 37
024 VE
B20 FG B20 40
A20 A20 39

7-44 498 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
CN10 Connector
Number

24VDC 2041 A1 IN02 IN A1 1
8mA max. 2042 B2 IN03 IN B2 4
2043 A2 IN04 IN A2 3
JANCD-XIO02
2044 B3 IN05 IN B3 6
2045 A3 IN06 IN A3 5
2046 B4 IN07 IN B4 8
2047 A4 IN08 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3041 B9 OUT02- OUT B9 18
3042 B10 OUT03- OUT B10 20
3043 B11 OUT04- OUT B11 22
3044 B12 OUT05- OUT B12 24
3045 B13 OUT06- OUT B13 26
Each Point
24VDC
500mA max. 3046 B14 OUT07- OUT B14 28
3047 B15 OUT08- OUT B15 30
-9 +24 V B17 024VU B17 34
024 V
-10 (24V,1A) A17 024VU A17 33
B18 +24VU B18 36
-7 +24VU
+24 VE -8 024 VU A19 +24VU A19 37
A20 A20 39

7-45 499 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
+24VU
CN11 Connector
Model:PX7DS-40V6-R
Number
24VDC 2051 A1 IN10 IN A1 1
8mA max. 2052 B2 IN11 IN B2 4
2053 A2 IN12 IN A2 3
JANCD-XIO02
2054 B3 IN13 IN B3 6
2055 A3 IN14 IN A3 5
2056 B4 IN15 IN B4 8
2057 A4 IN16 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3050 B8 OUT09- OUT B8 16
3051 B9 OUT10- OUT B9 18
3052 B10 OUT11- OUT B10 20
3053 B11 OUT12- OUT B11 22
3054 B12 OUT13- OUT B12 24
3055 B13 OUT14- OUT B13 26
Each Point
24VDC
500mA max. 3056 B14 OUT15- OUT B14 28
3057 B15 OUT16- OUT B15 30
-9 +24 V B17 024VU B17 34
024 V
-10 (24V,1A) A17 024VU A17 33
B18 +24VU B18 36
B19 +24VU B19 38
+24 VE
024 VE -8 024VU A19 +24VU A19 37 * means internal relay
A20 A20 39

7-46 500 of 656

RE-CTO-A203
Specific Input List XIU01 (General application)

Logical Logical
Number Number
2013 ALARM/ERROR RESET 2022 WORK PROHIBITED (Tool ON Prohibited)
After an alarm or error has occurred and the Even if TOOLON instruction is executed, XRC
cause been corrected, this signal resets the doesnt output to external while this signal is
alarm or error. ON.
2014 SELECT REMOTE MODE 2024 INTERFERENCE 3 ENTRANCE PROHIBITED
Functions the same as [REMOTE] on the play- If the manipulator attempts to enter the cube
back panel. Valid only while the signal is ON. 3*2 area while this signal is ON, the manipula-
It selects the REMOTE mode. tor goes to wait status (with servo power ON).
During wait status, the manipulator operation
2015 SELECT PLAY MODE 2025 INTERFERENCE 4 ENTRANCE PROHIBITED
Functions the same as [MODE] on the play- If the manipulator attempts to enter the cube
back panel. Only the rising edge of the signal is 4*2 area while this signal is ON, the manipula-
valid. It selects the PLAY mode. If designated tor goes to wait status (with servo power ON).
simultaneously with other modes, the TEACH During wait status, the manipulator operation
mode takes priority. This signal is invalid if restarts if this signal turns OFF.
2016 SELECT TEACH MODE
The TEACH mode is selected if this signal
turns ON during PLAY mode. Switching to
other modes is disabled while this signal is ON.
master job.
7-47 501 of 656

RE-CTO-A203
Specific Output List XIU01 (General application)

Logical Logical
Number Number
3013 ALARM/ERROR OCCURRED 3024 IN CUBE 3
This signal signifies that an alarm or an error This signal turns ON when the current tool cen-
occurred. If a major error occurs, this signal ter point lies inside a pre-defined space (Cube
remains ON until the main power is turned 3). Use this signal to prevent interference with
OFF. other manipulators and jigs.
3014 BATTERY ALARM 3025 IN CUBE 4

This signal turns ON to notify that the battery This signal turns ON when the current tool cen-
requires replacing when the voltage drops from ter point lies inside a pre-defined space (Cube
the battery for backup memory of the encoder. 4). Use this signal to prevent interference with
Major problems may result if memory data is other manipulators and jigs.
3015 to REMOTE/PLAY/TEACH MODE SELECTED 3026 WORK COMMAND
3017 This signal notifies the current mode setting. This signal provides the command for the gen-
These signals are synchronized with the lamps eral tool to operate. TOOL ON instruction exe-
[REMOTE] and [MODE] in the playback panel. cution or the [TOOL ON] key in the
The signal corresponding to the selected mode programming pendant turns this signal ON and
turns ON. TOOL OFF instruction 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.
3020 IN CUBE 1
This signal turns ON when the current tool cen-
ter point lies inside a pre-defined space (Cube

7-48 502 of 656

RE-CTO-A203
7.7.4 Spot Welding
YASNAC-XRC
(Optional)
CN12 Connector
Logical C o n n e c t o r Terminal
Number N u m b e r Name Signal
Number
24VDC 2011 A1 - IN A1 1
JANCD-XIO02

2017 A4 IN192 (Fan Alarm) IN A4 7
Interference2 Entrance 9
2021 A5 Prohibited IN A5
2022 B6 Welding ON/OFF IN B6 12
2023 A6 Welding Pause IN A6 11
B7 024VU B7 14
A7 024VU A7 13
3020 B12 In Cube 1 OUT B12 24
3021 A12 In Cube 2 OUT A12 23
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JANCD-XTU01
B16 024VU B16 32
CN26 A16 31
Internal
Power Supply
A16 024VU
-9
+24 V B17 024VU B17 34
024 V
-10 (24V,1A) A17 024VU A17 33
B18 +24VU B18 36
+24 VE B19 +24VU B19 38
024 VE -8 024 VU A19 +24VU A19 37
B20 FG B20 40
A20 A20 39

JANCD-XIO02 (CN12 Connector) I/O Allocation and Connection Diagram (For Spot Welding)
7-49 503 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
CN13 Connector
Number Number Name Signal Number
8mA max. 2026 B2 - IN B2 4
2027 A2 - IN A2 3
JANCD-XIO02
2030 B3 IN1 IN B3 6
2031 A3 IN2 IN A3 5
2032 B4 IN3 IN B4 8
2033 A4 IN4 IN A4 7
2034 B5 IN5 IN B5 10
2035 A5 IN6 IN A5 9
2036 B6 IN7 IN B6 12
2037 A6 IN8 IN A6 11
B7 024 VU B7 14
A7 024 VU A7 13
3026 B9 OUT B9 18
3027 A9 - OUT A9 17
3031 A10 OUT02 OUT A10 19
3032 B11 OUT03 OUT B11 22
3033 A11 OUT04 OUT A11 21
3034 B12 OUT05 OUT B12 24
3035 A12 OUT06 OUT A12 23
3036 B13 OUT07 OUT B13 26
3037 A13 OUT08 OUT A13 25
Each Point
24VDC B14 B14 28
50mA max. A14 A14 27
B15 B15 30
A15 A15 29
JANCD-XTU01
B16 024 VU B16 32
A16 024 VU
-9 Power Supply
+24 V B17 024VU B17 34
-10 024 V A17 33
A17 024VU
(24V,1A)
B18 +24VU B18 36
B19 +24VU B19 38
+24 VE
024 VE -8 024 VU A19 +24VU A19 37
B20 FG B20 40
A20 A20 39

7-50 504 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
CN10 Connector
Number
Timer Cooling Water
Each Point 2040 B1 Error (IN09) *** IN B1 2
Gun Cooling Water
24VDC 2041 A1 Error (IN10) *** IN A1 1
8mA max. 2042 B2 Transthermo Error (IN11)
*** IN B2 4
2043 A2 Low Air Pressure (IN12) *** IN A2 3
JANCD-XIO02
2044 B3 Weld Completion (IN13)

** IN B3 6
2045 A3 Weld Error (IN14) IN A3 5
**
Gun Short Open
2046 B4 Detection (IN15) ** IN B4 8
Tip Replacement
2047 A4 Completion (IN16) ** IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3040 B8 OUT B8 16
A8 Weld ON/OFF (OUT09)
*** OUT A8 15 RLY
3041 B9 OUT B9 18
A9 Weld Error Reset (OUT10) ** OUT A9 17 RLY
3042 B10 OUT B10 20
3043 B11 OUT B11 22
3044 B12 OUT B12 24
3045 B13 OUT B13 26
Each Point
24VDC
500mA max. 3046 B14 OUT B14 28
Gun Pressure
A14 Instruction (OUT15) ** OUT A14 27 RLY
3047 B15 OUT B15 30
Tip Replacement
A15 Request (OUT16) ** OUT A15 29 RLY
-9
+24 V B17 024VU B17 34
-10 024 V A17 33
(24V,1A) A17 024VU
B18 +24VU B18 36
Power Supply
-7 +24VU
B19 +24VU B19 38
+24 VE 024 VU
024 VE
-8 A19 +24VU A19 37 * means internal relay
A20 A20 39

** This assignment can be changed at the I/O assignment display. Refer to Specific Input List XIU01 and Specific Output List XIU01 for detail.
*** This assignment can be changed at the PSEDU input display. Refer to Specific Input List XIU01 and Specific Output List XIU01 for detail.
7-51 505 of 656

RE-CTO-A203
YASNAC-XRC
(Optional)
+24VU
CN11 Connector
Model:PX7DS-40V6-R
Number Number
Name Signal
Number
24VDC 2051 A1 IN18 IN A1 1
8mA max. 2052 B2 IN19 IN B2 4
2053 A2 IN20 IN A2 3
JANCD-XIO02
2054 B3 IN21 IN B3 6
2055 A3 IN22 IN A3 5
2056 B4 IN23 IN B4 8
2057 A4 IN24 IN A4 7
B5 B5 10
A5 A5 9
B6 B6 12
A6 A6 11
B7 024VU B7 14
A7 024VU A7 13
3050 B8 OUT17- OUT B8 16
3051 B9 OUT18- OUT B9 18
3052 B10 OUT19- OUT B10 20
3053 B11 OUT20- OUT B11 22
3054 B12 OUT21- OUT B12 24
3055 B13 OUT22- OUT B13 26
Each Point
24VDC
500mA max. 3056 B14 OUT23- OUT B14 28
3057 B15 OUT24- OUT B15 30
Power Supply
A16 024VU
-9
+24 V B17 024VU B17 34
-10 024 V A17 33
A17 024VU
(24V,1A)
B18 +24VU B18 36
B19 +24VU B19 38
+24 VE
024 VE -8 024VU A19 +24VU A19 37
* means internal relay
A20 A20 39

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Specific Input List XIU01 (Spot Welding)

Logical Logical
Number Number
2010 EXTERNAL START 2022 WELDING ON/OFF (From sequencer)
Functions the same as the [START] button in This signal inputs the welding ON/OFF selector
the playback panel. Only the rising edge of the switch status from the sequencer in the inter-
signal is valid. It starts robot operation (play- lock unit. The WELD ON/OFF signal is output
back). This signal is invalid if external start is to the welder according to this signal and the
prohibited from the playback condition display. manipulator status. Welding is not executed
when this signal is input (ON).
2012 CALL MASTER JOB 2023 WELDING PAUSE (From sequencer)
Only the rising edge of the signal is valid. It This signal is used to move the manipulator to
calls up the top of the robot program, that is the the origin point when an error occurs in the
top of the master job*1. This signal is invalid welder or the gun.
during playback, during teach-lock and when The robot neglects the spot welding instruction
play master or call is prohibited (set from the and operates playback motion.
2013 ALARM/ERROR RESET 2024 INTERFERENCE 3 ENTRANCE PROHIBITED
After an alarm or error has occurred and the If the manipulator attempts to enter the cube
cause been corrected, this signal resets the 3*2 area while this signal is ON, the manipula-
alarm or error. tor goes to wait status (with servo power ON).
2014 SELECT REMOTE MODE 2025 INTERFERENCE 4 ENTRANCE PROHIBITED
Functions the same as [REMOTE] on the play- If the manipulator attempts to enter the cube
back panel. Valid only while the signal is ON. It 4*2 area while this signal is ON, the manipula-
selects the REMOTE mode. tor goes to wait status (with servo power ON).
2015 SELECT PLAY MODE 2040 TIMER COOLING WATER ERROR
Functions the same as [MODE] on the play- *4 This signal monitors the status of timer cooling
back panel. Only the rising edge of the signal is water. The manipulator displays alarm and
valid. It selects the PLAY mode. If designated stops when this signal is input. The servo
simultaneously with other modes, the TEACH power remains ON.
mode takes priority. This signal is invalid if
2016 SELECT TEACH MODE 2041 GUN COOLING WATER ERROR
The TEACH mode is selected if this signal *4 This signal monitors the status of gun cooling
turns ON during PLAY mode. Switching to water. The manipulator displays alarm and
other modes is disabled while this signal is ON. stops when this signal is input. The servo
If this signal turns ON while the SELECT PLAY power supply remains ON.
2020 INTERFERENCE 1 ENTRANCE PROHIBITED 2042 TRANSTHERMO ERROR
If the manipulator attempts to enter the cube *4 Error signal is sent from the transformer in the
1*2 area while this signal is ON, the manipula- gun to the robot. This signal is ON normally
tor goes to wait status (with servo power ON). (NC) and an alarm occurs when the signal is
During wait status, the manipulator operation OFF. The servo power supply remains ON.
2021 INTERFERENCE 2 ENTRANCE PROHIBITED 2043 LOW AIR PRESSURE
If the manipulator attempts to enter the cube *4 When air pressure is reduced and this input is
2*2 area while this signal is ON, the manipula- turned ON, an alarm occurs. The servo power
tor goes to wait status (with servo power ON). supply remains ON.
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Specific Input List XIU01 (Spot Welding)

Logical Logical
Number Number
2044 WELD COMPLETION 2046 GUN SHORT OPEN DETECTION
*3 This signal indicates that the welder completed *3 This signal is connected with a single gun open
welding without error. This signal is used as a verification limit switch or a double stroke gun
confirmation signal for welding instruction exe- short open verification limit switch to verify the
cution and manual sp ot welding. gun open.
After this signal is input, the welding sequence
is completed and the next step is executed
when confirmation limit switch is not provided.
2045 WELDING ERROR GUN PRESSURE DETECTION
*3 This signal indicates an abnormal welding *3 This signal indicates that a gun is in pressing
result or welders error. Alarm occurs and the status.
manipulator stops if this signal is input during
welding.
STICK DETECTION 2047 TIP REPLACE COMPLETION
*3 This signal indicates an abnormal welding *3 When this signal is input after tip replacement,
result or welders error. Alarm occurs and the the TIP REPLACE REQUEST signal turns
manipulator stops if this signal is input during OFF, and the stored number of welding is
welding. cleared.
GUN FULL OPEN DETECTION
*3 This signal indicates that the stroke of the dou-
ble stroke gun is full open.
master job.
*3 This signal can be allocated to any general input signal at the I/O allocation display in
*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 the general I/O signal described in paren-
theses.
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 (or IN09)

Gun Cooling Water Error Validating (or IN10)
Transthermo Error Validating (or IN11)
Low Air Pressure Validating (or IN12)
Weld ON/OFF Validating (or OUT09)
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Specific Output List XIU01 (Spot Welding)

Logical Logical
Number Number
3010 RUNNING 3023 INTERMEDIATE START OK
This signal signifies that the job is running. This signal turns ON when the manipulator
(Signifies that the job is running, system status operates. It turns OFF when the currently exe-
is waiting reserved start, or test run is running.) cuted line is moved with the cursor or when
This signal status is the same status as editing operation is carried out after HOLD is
[START] in the playback panel. applied during operation. Therefore, this signal
3011 SERVO IS ON 3024 IN CUBE 3
turned ON, internal processing such as current ter point lies inside a pre-defined space (Cube
position creation is complete, and the system is 3). Use this signal to prevent interference with
able to receive the START command. This sig- other manipulators and jigs.
3012 TOP OF MASTER JOB 3025 IN CUBE 4
This signal signifies that the execution position This signal turns ON when the current tool cen-
is the top of the master job. This signal can be ter point lies inside a pre-defined space (Cube
used to confirm that the master job has been 4). Use this signal to prevent interference with
called.*2 other manipulators and jigs.
3013 ALARM/ERROR OCCURRED 3040 WELD ON/OFF
This signal signifies that an alarm or an error *4 Outputs a signal input from the interlock panel
occurred. If a major error occurs, this signal etc.considering the robot status.
remains ON until the main power is turned
OFF.
3014 BATTERY ALARM 3041 WELD ERROR RESET
This signal turns ON to notify that the battery *3 This signal commands the reset error status of
requires replacing when the voltage drops from the welder. This is operated with the program-
the battery for backup memory of the encoder. ing pendant operation.
3015 to REMOTE/PLAY/TEACH MODE SELECTED 3042 to WELD CONDITION (Level signals)
3017 This signal notifies the current mode setting. 3045 1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8)
These signals are synchronized with the lamps *3 Sets the welding conditions for the welder.
[REMOTE] and [MODE] in the playback panel. The output format can be selected as binary or
The signal corresponding to the selected mode discrete (bit number). It can handle up to 255
turns ON. conditions. Most-significant bit is the parity bit
(when specified).
3020 IN CUBE 1 WELDING COMMAND
This signal turns ON when the current tool cen- *3 This signal outputs execution command signal
ter point lies inside a pre-defined space (Cube to the welder. This signal is not necessary for
1). Use this signal to prevent interference with a welder which is executed using the WELD-
other manipulators and jigs. ING CONDITION signal.
3021 IN CUBE 2 STROKE CHANGE1
This signal turns ON when the current tool cen- *3 SINGLE SOLENOID
ter point lies inside a pre-defined space (Cube DOUBLE SOLENOID
2). Use this signal to prevent interference with This is a signal, when a double stroke gun is
other manipulators and jigs. used, to change the open stroke of the welding
gun.
3022 OPERATION ORIGIN POINT (IN CUBE 24)*1 3046 GUN PRESSURE INSTRUCTION
This signal turns ON when the current tool cen- *3 This outputs a gun pressure instruction.
ter point lies inside a the operation origin area.
Use this signal to evaluate whether the robot is
in the start position.
3047 TIP REPLACEMENT REQUEST
*3 This is output when the number of strokes
reaches the set value for tip replacement.
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*3 This signal can be allocated to any general output signal at the I/O allocation display in
*4 This signal can be select USE or NOT USE by pseudo input signal822x. If NOT
USE is selected, this signal can be used as the general I/O signal described in paren-
theses.
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 (or IN09)

Gun Cooling Water Error Validating (or IN10)
Transthermo Error Validating (or IN11)
Low Air Pressure Validating (or IN12)
Weld ON/OFF Validating (or OUT09)
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7.7.5 JANCD-XEW02 Circuit Board (Standard)

For Arc Welding
JANCD-XEW02 circuit board is provided with 2 points of analog output, 2 points of analog
input, and the welder status signal I/O.
YASNAC-XRC
Logical Connector Name

Number Pin No. Signal
CN03-1 1
Each point
24 VDC
5mA MAX CN03-3 -GASOF (Gas Shortage) IN 3 S
2303 CN03-6 +ARCACT (Arc Generation Confirm) IN 6
JANCD-XEW02

CN03-8 CH2 (Current Input) IN 8
A/D +5V CN03-9 9
CN03-10 10
A/D +5V CN03-11 CH1 (Voltage Input) IN 11
CN03-12 CH1-G IN 12
24 VDC 2302 CN03-13 +ARCOFF (Arc Shortage) IN 13
5mA MAX CN03-14 -ARCOFF (Arc Shortage) IN 14 R
24 VDC 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
CN03-21 21
CN03-22 22
CN03-23 23
CN03-24 24
CN03-25 25
Detector
CN03-28 CH2 -G IN 28
CN03-29 +24VU 29
CN03-30 024VU 30 E
D/A 14V
D/A 14V
CN03-34 CH2 -G OUT 34 D
CN02-1 +24VU
24 VDC 3305 CN02-2 Search Command A (Optional) OUT
0.5A MAX
CN02-5 024VU
MRP-34M01 Insulator
MRP-M112 Contactor MS3106 A, 20-29P
WAGO Connector (231-105/026-A0) RP-34 Casing MS3106 A, 20-29S
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7.7.6 JANCD-XEW01 Circuit Board (Option)

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
Logical Connector Name

Number Pin No. Signal
CN03-1 1
Each Point
24VDC
5mA MAX CN03-3 -GASOF (Gas Shortage) IN 3 S
JANCD-XEW01-1

2303 CN03-6 +ARCACT (Arc Generation Confirm) IN 6
CN03-8 8
CN03-9 CH3 (For extention) OUT 9
D/A 14V
CN03-10 CH3-G (For extention) OUT 10
CN03-11 11
24 VDC
5mA MAX CN03-12 12
2302 CN03-13 +ARCOFF (Arc Shortage) IN 13
CN03-14 -ARCOFF (Arc Shortage) IN 14 R
24 VDC 3301 CN03-15 ARCON (Arc ON) A OUT 15 K
0.5A MAX CN03-16 ARCON (Arc ON) B OUT 16 L Welder
3302 CN03-17 WIRINCH (Wire Inching) A OUT 17 F
3304 CN03-21 OUT1A (For extention) OUT 21
CN03-22 OUT1B (For extention) OUT 22
CN03-23 23
CN03-24 24
CN03-25 25
Detector
CN03-28 28
CN03-29 +24VU 29
CN03-30 024VU 30 E
D/A 14V
D/A 14V
CN03-34 CH2 -G OUT 34 D
CN02-1 +24VU
24 VDC 3305 CN02-2 Search Command A (Optional) OUT
0.5A MAX
CN02-5 024VU
MRP-34M01 Insulator
MRP-M112 Contactor MS3106 A, 20-29P
WAGO Connector (231-105/026-A0)
RP-34 Casing MS3106 A, 20-29S
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Maintenance
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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
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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.
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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.
When the message "Cooling fan in control box stopped" is displayed,

NOTE it may be caused by the error occurrence at the cooling fan (JZNC-XZU02) on the CPU
rack.
In the case an error occured in the cooling fan like this, the alarm 4119 with the message
"FAN ERROR (IN CONTROL BOX)" will appear in 72 hours and the playback operation
(execution of the JOB) will no longer be performed.
When the message "Cooling fan in control box stopped" is displayed, carry out an
inspection and the replacement of the cooling fan on the CPU rack as soon as possible.
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)
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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)
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Servo Ascending Fan
Backside Duct Fan
Air Intake
Air Outlet
Servopack
Cooling Fan Construction (New B type panel)
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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.
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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 program-
ming 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 ".
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)
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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
Check voltage 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
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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 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.
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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.
JZNC-XRK01
XCP01 CPS-150F
XCP01
CPS-150F
(CN05)
CN05
(CN04) AC200V Input Connector
PC Card (From Power Unit)
Battery Alarm
CN04/CARD
(CN04)
CN05/SV
Control Power ON/OFF
CN04
SW
(CN03)
0 1 2 3 4
RS232C Connector
BAT
CN03
(CN03), (CN02)
CN03/RS232C
SOURCE
PWR ON DC24V Output Connector
Battery
+5V
CN02 (To Programming Pendant)
+24V
OHT
CN02/PP
CN01 Monitor, Alarm Display

CN01/IO
(CN01)
DC24V, DC5V Output Connector
(To XIU unit)
System Control Board Control Power Unit

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 bat-
tery 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.
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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 circuit 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.
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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.
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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,
ES165, ES200, ES165R, ES200R
Before replacing a servopack, confirm the version number of the JASP-

NOTE WRCA01 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.
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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
lissted above.
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
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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 (P1, N1)
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 Servopack

3. Disconnect all the cables connected externally to the control board.
PG cable connectors (CNPG123, CNPG456)
Communication cable connector (CN10)
Motor cable connectors (CN1 to CN6)
Ground wire
4. Remove the four screws in the four corners of the servopack.
5. With the top and bottom grips, pull out the servopack.
6. Install the new servopack and reconnect the connectors in the reverse order of that
listed above.
.
Converter Servopack
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
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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 (P2, N2)
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 Servopack

3. Disconnect all the cables connected externally to the control board.
PG cable connectors(CNPG123, CNPG456)
Communication cable connector (CN10)
Motor cable terminal (EUVW), motor cable connectors (CN4 to CN6)
Ground wire
4. Remove the four screws in the four corners of the servopack.
5. With the top and bottom grips, pull out the servopack.
6. Install the new servopack and reconnect the connectors in the reverse order of that
listed above.
Converter Servopack
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
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RE-CTO-A203
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: 0313005 (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)
(FU1, 2)
Control power supply fuse
(FU5, 6) JANCD-XTU01 REV.B

DF9203040-B0
S/N Serial number
CN30
TS-01-SN
Brake fuse
F1
F2
XE0475
XX3
TS-01-SN
(FU3, 4)
250V 5A
250V 5A
F5 250V 4A
313005
313005
MADE IN JAPAN
CN29
GP40
94V-0
Holder: GPH-4V
DC24V fuse
TS-01-SN
TS-01-SN
CN28
GP40
Holder: GPH-4V
ERC20M-08
ERC20M-08
F6 250V 4A
D11
D6
K14
LY2-DC24V
D21
holding metal fittings: PYC-P

Z10D471F2
Z10D471F2
XX1
F4
F3
XX2
TS-01-SN
TS-01-SN
socket: PT08-0 D2 U05E

250V 3A
250V 3A
D3
312003
312003
ERC91-02L9
R3
TS-01-SN
TS-01-SN
R4
K15 K13
LY2-DC24V LY2-DC24V
D14
D22
holding metal fittings: PYC-P holding metal fittings: PYC-P
socket: PT08-0 socket: PT08-0

FL2
FL1
CN25
C7 R7
104
3.3K
R11 R8
680 680
R12 104 C4
3.3K
PC2 PC1
D8
D5
D9
CN24
PC450
2.2K
2.2K
2.2K
2.2K
R14
R23
R9
R5
RB104-DE
RB104-DE
RB104-DE
RB104-DE
RB104-DE
RB104-DE
RB104-DE
RB104-DE
RB104-DE
RB104-DE
RB104-DE
RB104-DE
K12
K11
K10
K9
K8
K7
K6
K5
K4
K3
K2
K1
3.3K
3.3K
3.3K
3.3K
3.3K
3.3K
3.3K
3.3K
R54
R52
R46
R43
R41
R38
R33
R30
3.3K
3.3K
R64
R62
C35 104
3.3K
R47
C26 104
R39
R55
R31
R24
C8 104
C25
ZD1
104
104
C21
C5
104
680
680
680
680
R66
R65
R49
R44
R42
R36
R27
R13
R10
C9 104
R25
C23
C16
C36
C44
104
104
104
104
104
104
D7
D4
680
680
680
680
680
680
1.8K
C39
C29
150
150
680
PC8 PC7 PC6 PC5

D20
D19
D18
D17
D16
D15
D13
D12
D10
PS2802-4 PC4
PS2801-4 PS2801-4 PS2801-4
C41
C40
C37
C32
C30
C27
C24
C22
C18
C17
PS2801-4
R71
R70
R69
R68
103
103
C10
C15
C12
R28
FL3
103
103
103
10K
PC450
R34
470
470
470
470
10K
10K
10K
R32
10K
FL5
10K
R26
10K
R50
R48
R45
R67
R53
R37
R40
R63
U2
R15
R16
R72 10K
HC165
R17
PC3
U11
U8
C38 C31
FM1
U14
HC165
HC165
470
VHC32
R74 10K 105 105

R18 47K
R51 4.7K
C13 102 L1
T1
R76
7705C
10K
U6
C19 105 3.3K R19

R77 0 M-614T
105 C42 105 3.3K R20
C48 C47
105
U3
VHC74
102
U12
C14
1
U9
VHC273
VHC08
OFF
U15
C33 105 R2
VHC32
R21
SW1
120
C51
75ALS1177
U7
47K
U1
ON
VHC14
22
C20 105
3
C43 105 R35 R29

C49 105
C45 105 470 470
U10
VHC244
R22
R56 10K 105 C34 C6

74F08
U13
105
FL4
VHC161
R57 10K
SG-636PCV
U5
Y1
48MHZ
U4
HC595
R58 10K
R6
R59
33
10K JL-012
R60
4.7K
10K
R61 10K
C46 105
C28 105 105
CN20
C11
B1
A1
JANCD-XTU01
Fuse Position
If a fuse appears to be blown (refer to " 10.3 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.
9-9 530 of 656

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 or
circuit board JANCD-XIF04
Control power supply CPS-150F
3 I/O Power-ON unit JZNC-XIU01
Power-ON circuit board JANCD-XTU01
Specific I/O circuit 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
4715S-22T-B0-B00 New A and new B type
panel
7 Backside duct fan 4715S-22T-B0-B00 Small capacity
5915PS-22T-B30-B00 Medium and large capacity
8 Heat exchanger YD5-1042A Only large capacity A and
B type panel
9 Contactor circuit board fuse 0313005 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, refer to " Table
Servopack List (Small Capacity) ", " Table Servopack List (Medium Capacity) ", and "
Table Servopack List (Medium Capacity) ".
*2 The type of the power supply unit depends on the robot model. For detail, refer to "
Table Power Supply Unit List ".
9-10 531 of 656

RE-CTO-A203
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
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
9-11 532 of 656

RE-CTO-A203
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
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
9-12 533 of 656

RE-CTO-A203
Servopack List (Large Capacity)
UP200, UP130R, UP130RL, UP165R,

UP130, UP165,
UP165-100, UP130T, UP200R,ES165R,
Component ES165
SK506X, ES200 ES200R
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

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
9-13 534 of 656

RE-CTO-A203
Power Supply Unit List
Type Robot Type

JZNC-XPW03 or SV3X, SV035X, UP6, SK16X, UP20
JZRCR-XPU03
JZRCR-XPU02 SK16MX, SK45X, SP70X, UP50, UP20M
JZRCR-XPU02 or UP130, UP165, UP165-100, UP200,
JZRCR-XPU01 UP130T,ES165,ES200
JZRCR-XPU01 SK300X, SP100X, SK506X, SR200X,
UP130R, UP165R, UUP200R,
UP130RL,ES165R,ES200R
9-14 535 of 656

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
6
JANCD-XTU01
5A 0313005 FU1, 2
1 2
Glass-Tube fuse (LITTEL)
3.0
6 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
9-15 536 of 656

RE-CTO-A203
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
9-16 537 of 656

RE-CTO-A203
Qty
Manufac-
No Rank Name Type Qty per Remark
turer
unit
Battery
2 A Rack Fan JZNC-XZU02 Yaskawa 2 1
B30-B00 or
4715MS-22T-B50-
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 or new B type
4715MS-22T-B50- panel
B00
5 A Control Power Fuse 0313005 Littel fuse 10 2
6 A 24VDC Fuse 312003 3A 250V Littel 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 Control Power Unit CPS-150F Fuji Electric 1 1 For CPU Unit
Hi-Tech
JANCD-XIF04
15 B Specific I/O Board JANCD-XIO01 Yaskawa 1 1
16 B Genenal I/O Board JANCD-XIO02 Yaskawa 1 1
17 B Power On Board JANCD-XTU01 Yaskawa 1 1
20 C I/O Power On Unit JZNC-XIU01 Yaskawa 1 1
21 C Power Unit JZRCR-XPU03 Yaskawa 1 1
22 C Programming Pendant JZNC-XPP02 Yaskawa 1 1 With Cable
8m
Pendant is ordered.
9-17 538 of 656

RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00 or
4715MS-22T-B50-
B00
4 A Servopack Ascending Fan 3610PS-22T- Minebea 2 2 New A and
B30-B00 new B type
4715PS-22T- panel
B30-B00 or
4715MS-22T-B50-
B00
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
8m
Pendant is ordered.
9-18 539 of 656

RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00 or
4715MS-22T-B50-
B00
B30-B00 panel
B00
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
18 C Servopack CACR-UP6AAC Yaskawa 1 1
8m
Pendant is ordered.
9-19 540 of 656

RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00 or
4715MS-22T-B50-
B00
B30-B00 panel
B00
munication
Apparatus
RCP01
12 B Control Power Unit CPS-150F Fuji Elec- 1 1 For CPU unit
tric Hi-Tech
JANCD-XIF04
18 C Servopack CACR-SK16AAC Yaskawa 1 1
8m
Pendant is ordered.
9-20 541 of 656

RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00 or
4715MS-22T-B50-
B00
B00
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
16 B General I/O Board JANCD-XIO02 Yaskawa 1 1
18 B Circuit Protection Board for JARCR-XFL01 Yaskawa 1 1
Brake Area
19 C Servopack CACR-UP20AAA Yaskawa 1 1
8m
Pendant is ordered.
9-21 542 of 656

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
B00
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
18 C Servopack CACR- Yaskawa 1 1
SK16MAAB
8m
Pendant is ordered.
9-22 543 of 656

RE-CTO-A203
Recommended Spare Parts of XRC for UP20M
Qty
Manufac-
turer
unit
Battery
B30-B00
B00
munication
Apparatus
ACP25JAAY11
RCP01
Hi-Tech
JANCD-XIF04
18 B Circuit Protection Board for JARCR-XFL01 Yaskawa 1 1
Brake Area
UP20MAAB
8m
Pendant is ordered.
9-23 544 of 656

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
B00
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
18 C Servopack CACR-SK45AAB Yaskawa 1 1
8m
Pendant is ordered.
9-24 545 of 656

RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00
B00
munication
Apparatus
ACP25JAAY11
RCP01
Hi-Tech
JANCD-XIF04
18 C Servopack CACR-UP50AAB Yaskawa 1 1
8m
Pendant is ordered.
9-25 546 of 656

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
B00
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
8m
Pendant is ordered.
9-26 547 of 656

RE-CTO-A203
Recommended Spare Parts of XRC for UP130, UP165, ES165
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
B00
5 A Heat Exchanger Fan 4710PS-22T-B30 Minebea 2 2 A and B type
panel
6 A Control Power Fuse 0313005 Little fuse 10 2
munication
Apparatus
9 A Control Relay LY2 DC24V OMRON 3 3
RCP01
Hi-Tech
JANCD-XIF04
19 C Servopack CACR-UP130AAB Yaskawa 1 1
22 C Power Unit JZRCR-XPU02or Yaskawa 1 1
JZRCR-XPU01
8m
Pendant is ordered.
9-27 548 of 656

RE-CTO-A203
Recommended Spare Parts of XRC for UP200, UP165-100, UP130T, ES200
Qty
Manufac-
turer
unit
Battery
B30-B00 new B type
panel
3 3 B type panel
B30-B00 panel
B00
panel
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
UP130AABY18
22 C Power Unit JZRCR-XPU02or Yaskawa 1 1
JZRCR-XPU01
8m
Pendant is ordered.
9-28 549 of 656

RE-CTO-A203
Recommended Spare Parts of XRC for UP130R, SK506X
Qty
Manufac-
turer
unit
Battery
B30-B00 new B type
panel
3 3 B type panel
B30-B00 panel
B00
panel
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
UP130AABY18
8m
Pendant is ordered.
9-29 550 of 656

RE-CTO-A203
Recommended Spare Parts of XRC for UP130RL, UP165R, UP200R, ES165R, ES200R
Qty
Manufac-
turer
unit
Battery
3 A Backside Duct Fan 5915PC-22T- Minebea 2 2 New A and
B30-B00 new B type
panel
B00
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
UP130AABY21
8m
Pendant is ordered.
9-30 551 of 656

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
B00
panel
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
8m
Pendant is ordered.
9-31 552 of 656

RE-CTO-A203
Qty
Manufac-
turer
unit
Battery
B30-B00 new B type
panel
3 3 B type panel
B30-B00 panel
B00
munication
Apparatus
RCP01
Hi-Tech
JANCD-XIF04
18 C Servopack CACR-SP100AAB Yaskawa 1 1
8m
Pendant is ordered.
9-32 553 of 656

Alarm Error
554 of 656
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 signal
0 Hardware diagnosis alarm) (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 signal
- (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).
10.2 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.
10-1 555 of 656

RE-CTO-A203
10.2 Alarm Display

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.
10.2.2 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
10-2 556 of 656

RE-CTO-A203
10.2 Alarm Display
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 Ser-
vopack number.
SV#1: Servopack 1 (WRCA01 board S1 switch: 0)
(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)
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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)
XCP02 circuit board (# -)
:Slot NO.
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RE-CTO-A203
Alarm Message List
Alarm
0021 COMMUNICATION Electric power is not supplied to the control Check FU1 and FU2
ERROR(SERVO) power unit. in the XIU01B
[Decimal Data] or check F1, F2 in the XSU01
The connection of communication cable or check F3, F4 in the XSU02
for servopack was not completed. Check the connection of communication
The connection of communication cable cable for servopack.
for servopack was not cut. (XCP01CN05 - WRCA(#*)CN10 cable,
The connection of terminal connector was WRCACN10(#*) - WRCA
not completed. CN10(#*) cable)
The terminal connector was unusual. Replace the communication connector
The WRCA01 circuit board was out of for servopack.
order. Check the connection of the terminal
(The terminal connector was equipped 1 connector (WRCACN10(#*)).
for a system). Replace the terminal connector.
Failure of the power supply (JUSP- Replace the circuit board.
RCP01AAA) for the WRCA01 circuit Check whether the fuse for the circuit
board. board power supply is cut out or not.
Replace the circuit board power supply.
50:WRCA01 circuit board (#1)
(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-
Data stands for an error circuit board tive.
1:XCP01 circuit board
2:XSP01 circuit board
(Note)
XCP02 circuit board (# - )
:Slot NO.
1 Sub-board1(connector CNSL side)
2 Sub-board2(connector CNET side)

(Note)
WRCA01 circuit board is ( -1).
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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)
XCP02 circuit board (# - )
:Slot NO.

(Note)
WRCA01 circuit board is ( -1)
0050 MEMORY A error occurred 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)
XCP02 circuit board (# -)
:Slot NO.
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RE-CTO-A203
Alarm Message List
Alarm
0060 COMMUNICATION An error occurred in communication of I/O Check the connection of the communica-
ERROR(I/O MOD- module. tion cable for I/O module. (XCP01CN01
ULE) Defective I/O module - XIU01CN03 cable,
[Decimal Data] WRCA01(#*)CN20 - XIU01CN21
Data stands for the error I/O module. cable)
1-15: I/O module connected with Replace the communication connector
XCP01circuit board for I/O module.
17-31:Contactor circuit board, speed detect
circuit board connected with
WRCA01 circuit board(#1)
(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.
Replace the circuit board.
ERROR (WRCA#2) sequence between the XCP01 circuit tions cable for the servopack. (XCP01 or
[Decimal Data] board and Servopack #2. CN05 to WRCA (#*) or CN10 cable,
(#*) cable)
the servopack.
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RE-CTO-A203
Alarm Message List
Alarm
ERROR (WRCA#3) sequence between the XCP01 circuit tions cable for the servopack. (XCP01or
(#*) 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
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.
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RE-CTO-A203
Alarm Message List
Alarm
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.
0240 MEMORY ERROR The devicenet assignment file is damaged. Reset the devicenet assignment on the
(MEMORY ERROR Data stands for the file No. maintenance mode.
(DeviceNet Allocation Load the devicenet assignment file
File) saved on the external memory unit, then
[Decimal Data] turn the power supply off once, and turn
it on again.
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 application on system setting was dif- Change the AP parameter to the correct
(APPLICATION SET- ferent than AP parameter. value.
TING)
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.
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RE-CTO-A203
Alarm Message List
Alarm
0350 VERIFY ERROR 1: The master station on the first page of the Set the devicenet allocation in the main-
(DeviceNet Allocation set file does not exist. tenance mode.
File) 2: MAC-ID which is on the first page of the
[No indication data] set file is different from the one which is
on the station.
3: The data which is over the range exists
on the first page of the set files.
10: There is no master station on the sec-
ond page of the set file.
11: MAC-ID which is on the second page of
the set file is different form the one which
is on the station.
12: The data which is over the range exists
on the second page of the set file.
0400 PARAMETER The connection of communication cable Check the connection of communication
TRANSMISSION for servopack was not completed. cable for servopack. (XCP01CN05 -
ERROR The connection of communication cable WRCA(#*)CN10 cable,
[Decimal Data] for servopack was not cut. WRCACN10(#*) - WRCACN10(#*)
The connection of terminal connector is cable)
not completed. Replace the communication connector
The terminal connector is unusual. for servopack.
The circuit board was out of order. Check the connection of the terminal
(The terminal connector is equipped 1 for a connector (WRCACN10(#*)).
system). Replace the terminal connector.
(Note)
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RE-CTO-A203
Alarm Message List
Alarm
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.
11:XCP02 circuit board (#1-1) <Data :50-55>
12:XCP02 circuit board (#1-2) Check the connection of communication
20:XCP02 circuit board (#2-0) cable for servopack. (XCP01CN05 -
21:XCP02 circuit board (#2-1) WRCA(#*)CN10 cable,
22:XCP02 circuit board (#2-2) WRCACN10(#*) - WRCACN10(#*)
cable)
(Note) Replace the communication connector
XCP02 circuit board (# - ) for servopack.
:Slot NO. Check the connection of the terminal
:0 XCP02 circuit board (main) connector (WRCACN10(#*)).
1 Sub-board1(connector CNSL side) Replace the terminal connector.
2 Sub-board2(connector CNET side) Replace the circuit board.
50:WRCA01 board (#1)

(Note)
The setting value of rotary switch on
0420 DeviceNet 1: An error occurs when the first setting file Set the devicenet assignment.
ALLOCATION FILE is sent.
TRANSMISSION 2: An error occurred when the second set-
ERROR ting file is sent.
[Decimal Data]
0500 SEGMENT PROC An error occurred in communication Turn the power OFF then back ON.
NOT READY between XCP01 circuit board and WRCA01 If the error occurs again, contact your
circuit board. YASKAWA representative.
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) Replace the circuit board.
[Decimal Data] If the error occurs again, contact your
YASKAWA representative.
0901 WATCHDOG TIMER An insertion error of the XCP02#1 circuit Insert the circuit board in the CPU rack
ERROR board or the circuit board failure. or the connector on the circuit board fast.
(XCP02#1) Replace the circuit board
0902 WATCHDOG TIMER An insertion error of the XCP02#2 circuit Insert the circuit board in the CPU rack
ERROR board or defective circuit board. or the connector on the circuit board fast.
(XCP02#2) Replace the circuit board.
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RE-CTO-A203
Alarm Message List
Alarm
0910 CPU ERROR(XCP01) An insertion error of the XCP01 circuit board Insert the circuit board in the CPU rack
[Decimal Data] or defective circuit board. fast.
If the error occurs again, contact your
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.
0912 CPU ERROR An insertion error of the XCP02#2 circuit Insert the circuit board in the CPU rack
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.
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
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.
0931 CPU HANG UP An insertion error of the XCP02#1 circuit Insert the circuit board in the CPU rack
0932 CPU HANG UP An insertion error of the XCP02#2 circuit Insert the circuit board in the CPU rack
0940 WATCHDOG TIMER An insertion error of theWRCA01#1 circuit Insert the circuit board in the CPU rack
(WRCA#1) 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) Replace the circuit board.
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RE-CTO-A203
Alarm Message List
Alarm
0942 WATCHDOG TIMER An insert error of the WRCA01#3 circuit Insert the circuit board in the CPU rack
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.
0960 CPU HANG UP An insertion error of the WRCA01#1 circuit Insert the circuit board in the CPU rack
10-13 567 of 656

RE-CTO-A203
Alarm Message List
Alarm
0999 NMI ERROR NMI (interruption CPU signal of unknown Insert the circuit board in the CPU rack
[Decimal Data] origin) occurred because of the motion error or the connector on the circuit board fast.
of hardware, circuit board and rack or con- Replace the circuit board.
trol error of software. If the error occurs again, contact your
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*, floppy disk and restore.
6:CIO*, 7:FD*, 8:AP, 9:RS, 10:SE, 11:RMS*,
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.
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RE-CTO-A203
Alarm Message List
Alarm
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 board failure.
1050 SET-UP PROCESS The error occurred 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 occurred in the setup process of Turn the power OFF then back ON.
ERROR motion instruction when the main power If the error occurs again, contact your
(MOTION) was turned ON. YASKAWA representative.
[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 occurred in the control check of Turn the power OFF then back ON.
(SYSTEM1) system. If the error occurs again, contact your
[Decimal Data] YASKAWA representative.
1102 SYSTEM ERROR The error occurred in the control check of Turn the power OFF then back ON.
(SYSTEM2) system. If the error occurs again, contact your
1103 SYSTEM ERROR The error occurred in the event data check If the error occurs again, contact your
(EVENT) of system. YASKAWA representative.
[Decimal Data]
1104 SYSTEM ERROR The error occurred in the I/O control check Check the connector, cable for transmis-
(CIO) of 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 mode.
module or setting error of I/O module Replace the XCP01, I/O contactor unit, I/
O module.
1105 SYSTEM ERROR The error occurred in control check of the Turn the power OFF then back ON.
(SERVO) WACA01/WRCF01 circuit board. If the error occurs again, contact your
1106 SYSTEM ERROR The error occurred in control check of the Turn the power OFF then back ON.
(SPEED MONITOR) XFC01 circuit board. If the error occurs again, contact your
1109 SYSTEM ERROR The error occurs in control check. Turn the power off then back on.
(CONVEYER) If the error occurs again, contact your
1110 SYSTEM ERROR The error occurs in control check. Turn the power off then back on.
(CONTROLNET) If the error occurs again, contact your
1200 HIGH TEMPERA- The temperature in the controller raised Check whether interior fan of controller is
TURE (IN CNTL BOX) abnormally. working or not.
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RE-CTO-A203
Alarm Message List
Alarm
1201 OVERRUN LIMIT Overrun recovery switch was operated on Don't operate the overrun recovery
SWITCH RELEASED playback. switch on playback.
It is thought that the overrun recovery
switch is failed. Consult YASKAWA rep-
resentative.
1202 FAULT CPU motion impossibility caused by 0 divi- Turn the power OFF then back ON.
[Decimal Data] sion etc. If the error occurs again, contact your
Data stands for the factor of alarm. YASKAWA representative.
1:Calculation
2:Floating point
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 If the error occurs again, contact your
*: 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 power
[Binary Data] 0000_0000_0000_0010: ST#1 ON unit, and I/O module)
0000_0000_0000_0100: ST#2 Set the I/O module to maintenance
0000_0000_0000_1000: ST#3 mode again.
: Take countermeasures against noise.
1000_0000_0000_0000: ST#15 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 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 linear
interpolation. If so, reconsider the teach-
ing.
<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 con-
figuration. If not, correct the setting in
the system configuration.
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RE-CTO-A203
Alarm Message List
Alarm
1300 SERVO CPU SYN- The communication between the XCP01 cir- Check the connection of communication
CHRONIZING cuit board and the WRCA01 circuit board cable for servopack.
ERROR was abnormal. (XCP01CN05 - WRCA(#*)CN10 cable,
The cable between the XCP01 circuit WRCACN10(#*) - WRCACN10(#*)
board and WRCA01 circuit board was cable)
defective. Replace the communication cable for
The connection of the terminal connector servopack.
was incomplete. Check the connection of the terminal
Defective XCP01 circuit board connector (WRCA CN10(#*)).
Defective WRCA01 circuit board Replace the terminal connector.
Replace the XCP01 circuit board,
WRCA01 circuit board.
1301 COMMUNICATION The communication between the XCP01 Check the connection of communication
ERROR circa board and the WRCA01 circuit board cable for servopack.
(SERVO) was abnormal. (XCP01CN05 - WRCA(#*)CN10 cable,
[Decimal Data] The cable between the XCP01 circuit WRCACN10(#*) - WRCACN10(#*)
board and WRCA01 circuit board was cable)
defective. Replace the communication cable for
The connection of the terminal connector servopack.
was incomplete. Check the connection of the terminal
Defective XCP01 circuit board connector (WRCA CN10(#*)).
Defective WRCA01 circuit board Replace the terminal connector.
Replace the XCP01 circuit board,
1302 COMMUNICATION The communication between WRCA01 cir- Check the connection for communication
ERROR cuit board and the I/O Power-ON unit cable between the WRCA01 circuit
(SERVO I/O) (for I/O, robot, external axis) was abnormal. board and I/O Power-ON unit.
[Decimal Data] (WRCA01(#*)CN20 - XIU01CN21
cable)
Replace the WRCA01 circuit board.
Replace the I/O Power-ON unit.
Check the settings of the shorting pins
(SW1 and SW2) of the I/O Power-ON
unit.
1303 ARITHMETIC The error occurred on check of interior con- Needs investigation. Consult a YASKAWA
ERROR trol for the WRCA circuit board. representative.
(SERVO)
[Decimal Data]
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>
Defective WRCF01 circuit board Check the system is not included exter-
Defective WRCA01 circuit board nal axis.
Execute the system configuration again
on system without external axis.
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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 I/O Power-ON unit was Check the installation of the external axis
[Bit Pattern] not installed. circuit board(WRCF01 board).
The system was not installed I/O Power- If the WRCF01 circuit board is installed,
ON unit, but the system was set as though replace it.
a <The system without external axis>
I/O Power-ON unit installed. Check the system is not included exter-
Defective I/O Power-ON unit nal axis.
Defective WRCA circuit board 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 ser-
Defective amplifier vopack.
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
system 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>
Check that the type of motor set by sys-
(Note) tem configuration is same as actual
The encoder is accessories of motor, check installed one. If the set data by system
the type of motor to check the type of configuration is correct, replace installed
encoder motor with correct one. If set data by sys-
tem configuration is not correct, set the
correct system configuration.
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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 reoccurrence by reducing 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.
<Error in robot axis>
Check that the type of motor is same as
the one described in the manual. If the
type is not correct, replace it with the cor-
rect motor.
<Error in external axis>
installed one. If the set data by system
configuration is correct, replace installed
motor with correct one. If set data by sys-
If the error occurs again, replace WRC01
and/or WRCF01 circuit board.
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 UVW motor again. And check the breaking of
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 <Error in robot axis>
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 servopack, motor for axis
where the error occurred.
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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 Check the connection of UVW wire of
UVW wire for the motor motor again. And check the breaking of
The type of motor was not correct. the wire.
The motor was moved by external power. There is a possibility the robot moves by
It interfered with an outside equipment. extra load. Check the motion status of
Defective WRCA01, WRCF01 circuit board robot again and reduce the teaching
Defective amplifier speed. Then confirm the reoccurrence.
Defective (encoder) <Error in robot axis>
Check that the type of motor is the same
correct motor.
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. Check the connection of UVW wire of
[Axis Data] The wrong wiring, the breaking of the UVW motor again. And check the breaking of
correct motor.
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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. Check the connection of UVW wire of
[Axis Data] The wrong wiring, the breaking of the UVW motor again. And check the breaking of
correct motor.
1313 MOTOR ERROR The motor was driven recklessly. This error Check the connection of UVW wire of
Robot/Station occurred when the motor moved in reverse motor again.
[Axis Data] for the forward instruction. <Error in robot axis>
Incorrect wiring of the UVW wire for the Check that the type of motor is same as
motor the one described in the manual. If the
The type of motor was not correct. type is not correct, replace it with correct
Defective WRCA01, WRCF01 circuit board motor.
installed one. If set data by system con-
figuration is correct, replace installed
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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 Check the connection of UVW wire of
The wrong wiring, the breaking of the wire motor again. And check the breaking of
of UVW wire for the motor the wire.
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 error occurred at external axis,
occurred simultaneously with the alarm set the ferrite core on the encoder cable
related to the encoder, it was thought this for noise measure.
alarm accompanied the encoder alarm.) If the error occurs again, replace
Noise of outside equipment WRCA01 and/or WRCF01 circuit board.
Defective WRCA01, WRCF01 circuit board Replace the motor for axis occurred the
Down of the power supply voltage for the error.
encoder
Defective motor (encoder)
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 posi- WRCA01, WRCF circuit board to the
[Axis Data] tion error alarm, the alarm related to the motor (encoder).
encoder.) Check whether there is equipment gen-
Noise of outside equipment erating loud noise.
Defective WRCA01, WRCF01 circuit board Check the grounding of controller is cor-
Decrease of the power supply voltage for rect.
the encoder If the error occurs again, replace
Defective motor (encoder) WRCA01 and/or WRCF01 circuit board.
Replace the motor for the axis where the
error occurred.
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.
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RE-CTO-A203
Alarm Message List
Alarm
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 occurrence 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
Defective WRCA01 circuit board WRCA01 circuit board and the converter.
1319 GROUND FAULT One of U,V,W wires of the motor displayed This alarm does not occur 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 that the servopack is damaged
Defective amplifier when the servo turn-ON and OFF is
repeated 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.
If the error occurs again, replace the
Replace the servopack, motor for the
axis where the error occurred.
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. If the error occurs again, replace the
The decrease of the primary side power WRCA01,WRCF01 circuit board.
supply voltage(170V or less) Replace the converter for the axis where
Defective WRCA01, WRCF01 circuit board the error occurred.
Defective converter
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RE-CTO-A203
Alarm Message List
Alarm
1321 OVERCURRENT One of the U,V,W wires of the motor dis- This alarm does not occur by turning OFF
(AMP) played on the axis data was grounded at the controlled power supply. 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
Defective amplifier repeated during ground fault status.
Overheating of amplifier Check the connection of the U,V,W,E
wires of motor again.
Remove the U,V,W,E wires of the motor
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.
Replace the servopack, motor for the
axis where the error occurred.
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 occurrence step about 30% and
[Bit Pattern] The load installed on robot was too heavy. check the reoccurrence. 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,
Defective converter +10%).
Defective WRCA01, WRCF01 circuit board If the error occurs again, replace the
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) If the error occurs again, replace the
[Bit Pattern] WRCA01 circuit board.
Replace the converter of the concerned
axis.
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%).
the error occurred.
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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 system config-
uration is not correct, set the correct sys-
tem configuration.
1326 DEFECTIVE The error occurred 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 error occurred.
[Axis Data]
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 sup- If the error occurs when the control
[Axis Data] ply can not be done when the motor is power supply is turned in a stopped
rotating. 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 occurred.
In case this alarm occurred in 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 repeating
Robot/Station error of the encoder. this operation several times, replace the
[Axis Data] 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 repeating
MAND the data of the encoder. But, this was the this operation several times, replace the
Robot/Station case there was no response of the reset 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 repeating
Robot/Station this operation several times, replace the
[Axis Data] WRCA01 circuit board for the axis where
the error occurred.
1331 CURRENT FEED- When the phase balance of the motor cur- Turn the power OFF then back ON. If the
BACK ERROR rent was automatically adjusted, the read U phenomenon occurs again after repeating
(U PHASE) phase current value was abnormal. this operation several times, replace the
Robot/Station Defective WRCA01 circuit board WRCA01 circuit board, servopack for the
[Axis Data] Defective amplifier axis where the error occurred.
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RE-CTO-A203
Alarm Message List
Alarm
1332 CURRENT FEED- When the phase balance of the motor cur- Turn the power OFFthen back ON. If the
BACK ERROR rent was automatically adjusted, the read V phenomenon occurs again after repeating
(V PHASE) phase current value was abnormal. this operation several times, replace the
Robot/Station Defective WRCA01 circuit board WRCA01 circuit board, servopack for axis
[Axis Data] Defective amplifier the error occurred.
1333 Collision Detection The servo deflection of the axis displayed in Check the robot arm is interfered with
(play mode) the axis data becomes excessive, the robot the eternal devices or the robot body. If
is shifted from instructed motion position of the robot interferes, remove the causes.
tracks more than tolerance. Check the connection of the UVW wire
The wiring of the UVW wire of the motor is of the motor, and check the breaking of
not correct or cut. the wire.
The type of the motor used is different. The robot might be worked with heavy
The motor is moved by the external force. load.
It interferes with an outside equipment Review the robot operation and set the
Defective WRCA01, WRCF01 circuit board teaching speed lower.
Defective motor (encoder) Check the type of the motor is same as
described one on the manual. If the type
is not correct, replace it with correct motor.
Check the type of the motor set in the
system configuration is same as actual
installed one. If set data in the system
motor with correct one. If set data in the
If error occurs again, replace the
Replace the amplifier or the motor of the
error axis.
1334 Resurrection It is too much energy of the resurrection at Check the load again. Reduce the teach-
Overload the motor deceleration for the resurrection ing speed of four steps by about 30%
circuit of the servopack to control. before and behind the alarm generation
The load installed on robot is too heavy. step. If the alarm does not reoccur, alter
The primary power supply voltage is too the load.
high. (more than 242 V) Check the primary power supply
Defective converter (220V+10%)
Defective WRCA01, WRCF01 circuit board If the error occurs again, replace the
WRCA01, WRCF01 circuit board.
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.
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RE-CTO-A203
Alarm Message List
Alarm
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.
ductor 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
ductor 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.
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.
Defective XFC01 circuit board 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.
rect motor.
XFC01 circuit board.
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. XFC01 circuit board.
[Axis Data] Defective WRCA01 board If the error occurs again, contact your
Defective XFC01 circuit board YASKAWA representative.
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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>
rect motor.
XFC01 circuit board.
1345 SAFETY CIRCUIT There is an improper signal in the double Check the wiring.
SIGNAL UNMATCH check for the receive data from the Replace the power-on unit circuit board.
power-on unit.
1346 LINEAR SERVO The servo deflection of the axis displayed in Check the robot arm is interfered with
FLOAT TRACKING the axis data becomes excessive, the robot the eternal devices or the robot body. If
ERROR is shifted from instructed motion position of the robot interferes, remove the causes.
[XYZ] tracks more than tolerance. Check the connection of the UVW wire
The wiring of the UVW wire of the motor is of the motor, and check the breaking of
not correct or cut. the wire.
The type of the motor used is different. The robot might be worked with heavy
The motor is moved by the external force. load. Review the robot operation and set
It interferes with an outside equipment the teaching speed lower.
Defective WRCA01, WRCF01 circuit board <Error in robot axis>
Defective amplifier Check the type of the motor is same as
Defective motor (encoder) described one on the manual. If the type
error axis.
1347 CONVERTER Total loads of the all motors connected with There is a possibility to be operated at
OVERLOAD the converter exceed the rated value for a overload.
long time. Ensure the operation of the robot, then
reduce the teaching speed and check
whether the error occurs again.
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RE-CTO-A203
Alarm Message List
Alarm
1348 POSITION ERROR The bit error is detected in the serial Check the connection of the encoder dis-
(Serial Encoder) encoder. played on the axis data.
Robot/Station Check whether there is the equipment of
device generating big noise around.
Check the ground of the controller is cor-
rect.
Check the type of the motor is same as
1349 POWER LOST Power lost is detected Verify the state of primary power supply.
DETECTION Verify the CPS power supply.
(WRCA01) If the error occurs again, contact your
Yaskawa representative.
1350 POWR ON UNIT The type of the power-on circuit board is Turn the power off then back on.
TYPE improper.(ex. The standard TU is used If the error occurs again, contact your
UNMATCH though the safety specification is set.) YASKAWA representative.
1351 SPEED MONITORING The speed monitoring circuit board is Turn the power off then back on.
BOARD installed though the speed monitoring circuit If the error occurs again, contact your
SPECIFICATION board is invalidly specified in the S1D YASKAWA representative.
parameter.
1352 SERIAL ENCODER The correction mistake is detected by the bit Check the connection of the encoder dis-
CORRECTION deviation correction check. played on the axis data.
MISSING Check whether there is the equipment of
Check the ground of the controller is
correct.
1353 SPEED MONITORING Defective XFC01 circuit board Replace the I/O power-on unit and the
BOARD WATCHDOG XFC01 circuit board.
ERROR If the error occurs again, contact your
1354 COMMAND TIMEOUT The command execution time of the speed Replace the I/O power-on unit and the
(XFC01) monitoring circuit board exceeds allowable XFC01 circuit board.
time. If the error occurs again, contact your
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RE-CTO-A203
Alarm Message List
Alarm
1355 SERIAL ENCODER The internal parameter of the serial encoder Turn off the power supply then back on.
MULTI TURNING is abnormal. It is thought to be an error of If the error occurs again, replace the
RANGE ERROR the encoder. motor(encoder) for the axis where the
error occurred.
1356 INVALID AXIS A group axis is required of processing Turn the power off then back on.
SPECIFICATION though the group is specified to invalidity at If the error occurs again, contact your
ERROR the group cutting-off function. YASKAWA representative.
1400 CONVEYER The encoder is abnormal. Replace the encoder or the encoder
ENCODER ERROR Sub Code 1-6 : The conveyor No. that the cable.
[123] abnormal encoder is set.
1401 ENCODER The encoder mode "Encoder / Virtual Do not switch "Encoder / Virtual encoder"
OPERATION MODE encoder" was switched by the general input with the general signal while performing
CHANGE DISABLE while performing conveyor synchronized the conveyor synchronized function.
[123] function.
1402 CONVEYER QUE The error occurs when the signal of con- Check the workplace interval that there
OVER FLOW veyer home position L.S. is input and all of are 6 or less of workplaces which passed
[123] the six conveyer cues are used. by the conveyer synchronization L.S.
There are 6 or more work which are Check whether there are any chattering
passed by the conveyer synchronization etc. when the workplace interval is cor-
LS. rect. (The conveyer home position L.S
The conveyer home position LS is may work incorrectly.)
operating incorrectly.
<There is no function for the moment.>
1403 CONVEYER QUE The CVQUW command is executed though Check the timing of the CVQUE command
NO DATA all conveyer cue has not been used. Or, the execution or the timing of input signal for
[123] clear signal for the conveyer que is input. the conveyer cue clear.
<There is no function for the moment.>
1410 CONTROLNET The error occurs in the CONTROLNET Replace the XCP03 circuit board.
MODULE ERROR communication module connected to the
XCP03 circuit board.
1411 CONTROLNET The data for the CONTROLNET communi- Set up the CONTROLNET communication
SETTING ERROR cation is abnormal. correctly.
1: Setting address is abnormal.
2: Output signal allocation is abnormal.
1412 CONTROLNET The error occurs in the system of the sensor Turn off the power supply then back on.
PROCESS ERROR part of the CONTROLNET function. If error occurs again, contact your
1500 SGDB PARAMETER The contents of the parameter writing value Turn the power off then back on.
ERROR for the SGDx is illegal. If the error occurs again, contact your
1501 SGDB COMMAND The sending data is different from the Turn the power off then back on.
ERROR receiving data when the mechatro link com- If the error occurs again, contact your
mand is received. YASKAWA representative.
1502 SGDB PARAMETER The writing data is different from the reading Turn the power off then back on.
VERIFICATION data at the mechatro link parameter. If the error occurs again, contact your
ERROR YASKAWA representative.
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RE-CTO-A203
Alarm Message List
Alarm
1503 COMMUNICAITON The alarm code from the SGDx at the Check the connection of the encoder
ERROR(Encoder) mechatro link communication. displayed on the axis data.
(SGDB) (CODE:00) Check whether there is the equipment of
correct.
1504 CONSTANTDE- The alarm code from the SGDx at the Replace the SGDB.
STRUCTION mechatro link communication.
(SGDB) (CODE:02)
1505 POSITION ERROR The alarm code from the SGDx at the Check the connection of the encoder
(SGDB) mechatro link communication. displayed on the axis data.
(CODE:80) Check whether there is the equipment of
correct.
1506 ENCODER ABSO An error occurs in the position detect circuit Turn off the power supply then back on.
ERROR(SGDB) board of the encoder. If the error occurs again, replace the
* This error occurs during the low speed motor(encoder) for the axis where the
operations such as the welding operation error occurred.
and the teaching because the alarm check * There is a possibility of the mis-detection
is onducted only when the encoder drives by the dust adhesion, etc. on the LED,
at 200 rpm or less. This alarm does not the lens, and the slit of the detector due
occur at high speed motion. to the encoder internal abnormality.
1507 PARAMETER The alarm code from the SGDx at the Replace the SGDB.
WRITING ERROR mechatro link communication.
(SGDB) (CODE:94)
1508 COMMAND ERROR The alarm code from the SGDx at the Replace the SGDB.
(SGDB) mechatro link communication.
(CODE:95)
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Alarm Message List
Alarm
1509 COMMUNICATION The alarm code from the SGDx at the Replace the SGDB.
ERROR WARNING mechatro link communication.
(SGDB) (CODE:96)
1510 GATE ARRAY 1 The alarm code from the SGDx at the Replace the SGDB.
ERROR(SGDB) mechatro link communication.
(CODE:B1)
1511 GATE ARRAY 2 The alarm code from the SGDx at the Replace the SGDB.
(CODE:B2)
1512 ENCODER PHASE An error occurs in the position detect circuit Turn off the power supply then back on.
MISDETETION board of the encoder. If the error occurs again, replace the
(SGDB) * This error occurs during the low speed motor(encoder) for the axis where the
operations such as the welding operation error occurred.
and the teaching because the alarm check * There is a possibility of the mis-detection
is onducted only when the encoder drives by the dust adhesion, etc. on the LED,
at 200 rpm or less. This alarm does not the lens, and the slit of the detector due
occur at high speed motion. to the encoder internal abnormality.
1513 PG LINE CUT-A/B The alarm code from the SGDx at the Check the connection of the encoder dis-
PHASE(SGDB) mechatro link communication. played on the axis data.
(CODE:C3) Check whether there is the equipment of
correct.
1514 PG LINE CUT-C The alarm code from the SGDx at the Check the connection of the encoder dis-
PHASE(SGDB) mechatro link communication. played on the axis data.
(CODE:C4) Check whether there is the equipment of
correct.
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Alarm Message List
Alarm
1515 SYNCHRONIZING The alarm code from the SGDx at the Replace the SGDB.
ERROR mechatro link communication.
(SGDB) (CODE:E5)
1516 COMMUNICATION The alarm code from the SGDx at the Replace the SGDB.
(CODE:E6)
1517 OVER CURRENT One of the U,V, W wires of the motor dis- This alarm is reset by turning off the
(SGDB) played on the axis data is grounded at least. control power supply. But do not turn on
Defective motor the servo power supply before checking
Ground fault of the motor, lead wire the motor grounding. There is a possibility
Defective WRCA01, WRCF01 circuit board the servopack is damaged when the servo
Defective amplifier turn-on and off is repeated during ground
Overheating of the amplifier fault status.
Check the connection of the U, V, W and
E wire of the motor.
Remove the U,V, W, E wires of the motor
check the conduction of U-E, V-E, W-E.
If the 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.
Replace the motor.
If an error is not found by the above
check, turn off the power supply and
leave them for a while. (self-cooling).
If the error is not found after that, the
overheat may be a cause. Review the
load and the ambient temperature.
Replace the amplifier and the motor of
the error axis.
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Alarm Message List
Alarm
1518 GROUND FAULT One of U,V and W wires of the motor dis- This alarm is reset by turning off the
(SGDB) played on axis data is grounded at least. control power supply. But do not turn on
Defective motor the servo power supply before checking
Ground fault of the motor and lead wire the motor grounding. There is a possibility
Defective WRCA01, WRCF01 circuit board the servopack is damaged when the servo
Defective amplifier turn-on and off is repeated during ground
fault status.
Check the connection of the U, V, W and
E wire of the motor.
Remove the U,V, W, E wires of the motor
check the conduction of U-E, V-E, W-E.
If the error is found by the above check,
remove the connector of the motor side
and check again. If the wires are con-
ducted, it is thought to be a defective
lead wire. Specify the error point and
replace the lead wire.
Replace the motor.
Replace the amplifier and the motor of
the error axis.
1519 RESURRECTION The alarm code from the SGDx at the Replace the SGDB.
ERROR mechatro link communication.
(SGDB) (CODE:30)
1520 OVERVOLTAGE The alarm code from the SGDx at the Replace the SGDB.
(SGDB) mechatro link communication.
(CODE:40)
1521 SPEED The motor speed displayed in the axis data Check the connection wire of the motor.
ERROR(SGDB) exceeds allowable max speed. Check the operation of the robot when
The wiring of UVW wire of the motor is not the alarm is occurred, and confirm
correct. whether the external force adds.
The type of the motor is not correct. Check the connection of the UVW wire
The motor is moved by the external force. of the motor. If it is wrong, correct it up.
Defective WRCA01, WRCF01 circuit board Drop the teaching speed when the alarm
Defective motor (encoder) is occurred. Moreover, R, B, and T axes
operate at a fast speed according to the
teaching pose at the linear motion type
occasionally. In this case, review
teaching.
<Generated axis is a robot axis>
<Generated axis is external axis>
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Alarm Message List
Alarm
1522 OVERLOAD The motor torque displayed in the axis Check the robot arm is interfered with
(CONTINUE)(SGDB) data exceeds rated torqued for a long time. the eternal devices or the robot body. If
It may have burned the motor. the robot interferes, remove the causes.
The wiring of the UVW wire of the motor is Check the connection of the UVW wire
not correct or cut. of the motor, and check the breaking of
The type of the motor used is different. the wire.
The motor is moved by the external force. The robot might be worked with heavy
It interferes with an outside equipment. load. Review the robot operation and set
Defective WRCA01, WRCF01circuit board the teaching speed lower.
error axis.
1523 OVERLOAD The motor torque several times rated torque Check the robot arm is interfered with
(MOMENT) is generated for a long time at the axis dis- the eternal devices or the robot body. If
(SGDB) played in the axis data. the robot interferes, remove the causes.
The wiring of the UVW wire of the motor is Check the connection of the UVW wire
not correct or cut. of the motor, and check the breaking of
The type of the motor used is different. the wire.
The motor is moved by the external force. The robot might be worked with heavy
It interferes with an outside equipment. load. Review the robot operation and set
Defective WRCA01, WRCF01circuit board the teaching speed lower.
error axis.
1524 TEMPERATURE The alarm code from the SGDx at the Replace the SGDB.
(CODE:7A)
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Alarm Message List
Alarm
1525 ENCODER BACKUP The position data inside the encoder is Reset the alarm then perform the
ERROR missing because that the back-up power homeposition calibration again of the
(SGDB) supply voltage has decreased to 2.6 V or alarm axis
less. Check the voltage of battery in the
The above error always occurs when pur- encoder.(2.8 V or more)
chased motor is used at first time. Replace the battery.
(The alarm occurs when the control power If the error occurs again, replace the
supply has just been turned on, and it does encoder.
not occur in operating.) Do not turn the power supply off while
the backup capacitor is charging.
(For a few minutes)
1526 ENCODER INTER- The internal parameter of the serial encoder Turn off the power supply then back on.
NAL is abnormal. It is thought to be an error of If the error occurs again, replace the
DATA the encoder. motor(encoder) for the axis where the
ERROR(SGDB) error occurred.
1527 ENCODER SPEED The control power supply is turned on Check the timing of the turning on the
ERROR when the encoder is driving at 400 rpm or control power supply.
(SGDB) more. The control power supply should not If the error occurs when the control
be turned on when the motor is rotating. power supply is turned on at the robot
The axis without the brakes such as the R, geostatioary state, replace the motor
B and T axis of the SK6 falls freely when (encoder) for the axis data where is the
the servo power supply is turned off by the error occurred.
emergency stop etc. If the error occurs during the operation,
If the power supply is turned on above stat- contact your YASKAWA representative.
ues, the alarm occurs.
If the alarm occurs in the robot geostation-
ary state, it is thought that the encoder
caused the error. (This alarm occurs when
the control power supply starts turning on
and this does not occur during the opera-
tion.)
1528 CURRENT FEED The alarm code from the SGDx at the Replace the SGDB.
BACK U PHASE mechatro link communication.
ERROR(SGDB) (CODE:B3)
1529 CURRENT FEED The alarm code from the SGDx at the Replace the SGDB.
BACK V PHASE mechatro link communication.
(SGDB) (CODE:B4)
1530 WATCHDOG The alarm code from the SGDx at the Replace the SGDB.
DETECTOR ERROR mechatro link communication.
(SGDB) (CODE:B5)
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Alarm Message List
Alarm
1531 MOTOR ERROR The motor is out of control. This alarm Check the connection of the U,V,W lines
(SGDB) occurs when the motor is operated revers- of the motor.
ing to the instruction of the correct turning <Generated axis is a robot axis>
direction. Check the type of the motor is same as
Mis-wiring of the U,V,W, lines of the motor. described one on the manual. If the type
Improper type of the motor is not correct, replace it with correct motor.
External force <Generated axis is external axis>
Defective WRCA01,WRCF01 circuit Check the type of the motor set in the
boards system configuration is same as actual
1532 SERVO TRACKING The servo deviation displayed in the axis Check whether the robot interferes with
ERROR(SGDB) data is excessive and the specified active the external device or with robot body.
position and path is deviated over the toler- Remove the cause if interference.
ance. Check the connection of the U,V,W lines
Mis-wiring and disconnection of the U,V,W, of the motor, and check the disconnec-
lines of the motor tion as well.
Improper type of the motor The robot may run with overload. Review
External force the state of robot working, then reduce
Interfering with external devices the teaching speed and so on.
Defective WRCA01,CWRCF01 <Error in robot axis>
Defective amplifier Check the type of the motor is same as
Defective motor (Encoder) described one on the manual. If the type
error axis.
1533 OPEN PHASE The alarm code from SGDx at the mechatro Review the primary connecting wires of
(SGDB) link communication. the R,S, and T lines of the servopack.
(CODE:F1) Ensure the power supply voltage is 170V
or more.
WRCA01 and WRCF01 circuit boards.
Replace the SGDB of the error axis.
1534 SGDB Received watch dog data is abnormal. Replace the SGDB.
WATCHDOG ERROR
1535 SGDB COMMAND The execution time of the command Replace the SGDB.
TIMEOUT exceeds the permissible time.
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.
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Alarm Message List
Alarm
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.
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.
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RE-CTO-A203
Alarm Message List
Alarm
4015 MEMORY The welding start condition guide file of the Initialize the welding start condition
ERROR(Welding start CMOS memory is damaged. guide file in the maintenance mode.
condition guide file) Load the welding start condition guide
file in the external memory unit and
restore.
4016 MEMORY The welding end condition guide file of the Initialize the welding end condition guide
ERROR(Welding end CMOS memory is damaged. file in the maintenance mode.
condition guide file) Load the welding end condition guide 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.
4019 MEMORY ERROR The cutting condition file of the CMOS mem- Initialize the cutting condition file in the
(Cutting condition file) ory is damaged. maintenance mode.
[Decimal Data] Data stands for the file number. Load the saved cutting condition 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.
4024 MEMORY ERROR The wrist weaving amplitude characteristic Initialize the wrist weaving amplitude
(Wrist weaving file of the CMOS memory is damaged. characteristic file in the maintenance
amplitude characteristic mode.
file) Load the saved wrist weaving amplitude
characteristic file in the external memory
unit and 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.
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
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Alarm Message List
Alarm
4030 MEMORY ERROR The press characteristic file of the CMOS Initialize the press characteristic file in
(Press characteristic file) memory is damaged. the maintenance mode.
[Decimal Data] Data stands for the file number. Load the saved press characteristic con-
dition file in the external memory unit
and restore.
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 form cut 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
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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.
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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
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Alarm Message List
Alarm
4103 PARALLEL START The error occurred in the independent 1:Complete the sub task by PWAIT com-
INSTRUCTION control start operation. mand.
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 command 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 command 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 command 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 occurred in DCI function. the alarm factor after reset the alarm.
[Decimal Data] The data stands for the alarm factor.
Refer to the data transmission function
manual for details.
4105 WRONG EXECU- When the installation was executed, an Correct the error according to the data of
TION OF SAVE INST error occurred 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 occurred 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 current value 0 position and check the
Robot/Station ON exceeded tolerance for the robot / sta- original mark (arrow).
[Axis Data] tion. If not matched, there is an error of PG
system for the axis where the error
occurred. Please check.
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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. (XCP01CN01-
XIU01CN03 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 time out 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 time out (timer A)
2:Reception time out (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 time out (timer A)
5:Transmission time out (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]
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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)
4118 RESURRECTION The cycle of the cooling fan for the resurrec- Move the manipulator to a safe position in
RESISTANCE tion resistance has decreased. the teaching mode after resetting the
COOLING FAN alarm.
ERROR Replace the cooling fan for the resurrec-
tion resistance.
Contact your YASKAWA representative.
4119 FAN ERROR The axis was instructed to turn servo ON Make the condition so as to be able to turn
(IN CONTROL BOX) and OFF separately. servo ON and OFFafter 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 I/O Power-ON unit was ulator in the teach mode to a safe place.
[Binary Data] reduced. Contact your Yaskawa representative to
replace the cooling fan 1.
10-45 599 of 656

RE-CTO-A203
Alarm Message List
Alarm
4124 VISION INSTRUCTION 1: There is a wrong number in the desig- 1:Set the correct file number.
EXECUTION ERROR nated file. 2:Set the correct setting value.
[Decimal Data] 2: There is a wrong setting number in the 3:
designated file. Set the robot coordinates value and the
3: The calibration is unable to be executed. pixel coordinates value for the calibration
4: The communication port for the vision in the user variable.
system are unable to be initialized. Set the user variable number in calibration
5: The time-out occurs when the data is file correctly.
sent. 4:Set the parameter for the communication
6: The time-out occurs when the data is port correctly.
received. 5:
7: There is a mistake at the data which is Set the cable between the vision system
received from the vision system. and the XRC correctly.
8: It is unable to convert from the pixel coor- Set up the vision system to communicate.
dinates value to the robot coordinates 6:
value. Set the cable between the vision system
9: A position variable (P variable) was and the XRC correctly.
unable to be read or written. Set up the vision system to communi-
cate.
Set the cable between vision system and
the XRC correctly.
7:
Set the cable between the vision system
and the XRC correctly.
Set up the vision system to communicate
Set up the vision system to be detectable.
8:
Set up the vision system to detect the
correct position.
Use proper calibration file.
9:Do not use the designated positional
variable at the same time by other jobs.
4125 WELDING PULSE The error occurs when the instruction is 1:Check set file number.
CONDITION executed in the welding pulse condition 2:Check setting value of the file.
TRANSMISSION transmission function. 4:Check setting value of the RS parame-
ERROR 1: File access abnormality. ter.
[Decimal Data] 2: File setting data abnormality. 5,6,7:Check setting value of the RS
4: Port initialization abnormality. parameter.
5: Data sending time-out.
6: Data receiving time-out.
7: Received data abnormality.
4126 AUTOMATIC PMT The error occurs when the automatic PMT 1:Contact your YASKAWA representative.
EXECUTION ERROR function is executed. 2:Check the editing prohibition key of the
[Decimal Data] 1: System abnormality. P panel.
2: P panel editing prohibition 3,4:Check the job headers.
3: Conversion object job editing prohibition 5,7:Delete unnecessary jobs.
4: Saved job editing prohibition 6:Check the name of the PMT conversion
5: Job area memory lack. object job.
6: None conversion object job
7: Position area memory lack
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.
10-46 600 of 656

RE-CTO-A203
Alarm Message List
Alarm
4128 ARC MONITOR 1: One ARCMONON instruction is started 1:Do not carry out an ARCMONON
ERROR while another is being carried out. instruction while another is being car-
[Decimal data] 10: The settings for the XEW02 analog input ried out. After an ARCMONON instruc-
board have not been made. tion, be sure to issue an ARCMONOF
11: A time-over error occurs while sampling. instruction to end the arc monitoring
function.
10:Make the settings for the XEW02
analog input board.
11:Shorten the monitoring distance.
4200 SYSTEM ERROR When accessing to the file data was exe- Reset the alarm and repeat the opera-
(FILE DATA) cuted, the error occurred. (File edition, tion.
[Decimal Data] Operation of external memory unit) Turn the power OFFthen back ON.
4201 SYSTEM When accessing to the job was executed, Reset the alarm and repeat the opera-
ERROR(JOB) the error occurred. tion.
[Decimal Data] (During robot is being playback and opera- Turn the power OFF then back ON.
tion) If the error occurs again, contact your
4202 SYSTEM When accessing to the job was executed, Reset the alarm and repeat the opera-
ERROR(JOB) the error occurred. tion.
[Decimal Data] (Job edition, Operation of external memory Turn the power OFFthen back ON.
unit) If the error occurs again, contact your
4203 SYSTEM ERROR When accessing to the position data was Reset the alarm and repeat the opera-
(POSITION DATA) executed, the error occurred. tion.
[Bit Pattern] (During playback and operation) Turn the power OFF then back ON.
4204 SYSTEM ERROR When access to the position data was exe- Reset the alarm and repeat the opera-
(POSITION DATA) cuted, the error occurred. tion.
[Decimal Data] (Job/position variable edition, Operation of Turn the power OFF then back ON.
external memory unit) If the error occurs again, contact your
4206 SYSTEM ERROR When the data transmission function was Needs investigation.
(TRANSMISSION) used, the error occurred. Consult a YASKAWA representative.
[Decimal Data] The error of internal procedure for transmis-
sion system.
4207 SYSTEM The system error occurred in MOTION. Reset the alarm and repeat the opera-
ERROR(MOTION) tion.
[Decimal Data] Turn the power OFF then back ON.
4208 SYSTEM ERROR The system error occurred in ARITH. Reset the alarm and repeat the opera-
(ARITH) tion.
[Decimal Data] Turn the power OFF then back ON.
4209 OFFLINE SYSTEM The system error occurred in ARITH offline. Reset the alarm and repeat the opera-
ERROR tion.
(ARITH) Turn the power OFF then back ON.
10-47 601 of 656

RE-CTO-A203
Alarm Message List
Alarm
4210 SYSTEM ERROR -1: Unused local variable Reset the alarm then try again.
-2: Local variable area lack Turn the power supply off once then
-3: None empty handle value back on.
-4: LVMT semaphore error If the error occurs again, contact your
-5: Invalid specification handle YASKAWA representative.
(LVMD.flag=0)
-6: Handle value abnormality
-7: Failure of the DMM_free
-8: Failure of the DMM_new
-9: LVMT unconstruction (it has not be ini-
tialized.)
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 turn 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
4224 MEMORY PLAY FILE Return value (negative value) from the Reset the alarm then try again.
ERROR memory play file manager Turn the power supply off once then
-1: File system bug back on.
-2: Control information default (allocation If the error occurs again, contact your
address information) YASKAWA representative.
-3: Control information default (save control
information)
-4: Undefined file No.
-5: Used file No.
-6: Verification at writing to the CMOS
-7: Unused memory play file
-8: Memory play file destruction
-9: Sampling data area full
-10: Sampling data destruction
-11: Parameter error
-12: Sampling data end or head
-13: File system uninitialization
-14: MEMOP_sample_seek() illegal offset
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]]
10-48 602 of 656

RE-CTO-A203
Alarm Message List
Alarm
4301 CONTACTOR The contactor of the Power Supply Unit Turn servo ON again after resetting the
ERROR was not 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. Power Supply Unit, WRCA01 circuit
The contactor signal was not intercepted at board.
servo OFF (at emergency stop).
While turning servo OFF (at emergency
stop), the contactor signal was turned ON.
Reasons are as follows:
Defective Power Supply Unit
Defective WRCA01 circuit board
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 I/O
signal was intercepted. Power-ON 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 I/O Power-ON unit
Defective WRCA01 circuit board
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
Defective converter
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).
ON.
Defective converter
10-49 603 of 656

RE-CTO-A203
Alarm Message List
Alarm
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 servopack.
[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).
ON.
Defective converter
Defective amplifier (There is a possibility
that power circuit was short-circuited inter-
nally.)
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, servopack, the
signal was intercepted. converter.
The amp ready signal was not intercepted
at servo OFF (at emergency stop).
stop), the amp ready signal was turned
ON.
Defective converter
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 power supply again.
Robot/Station to turn ON control power supply in the rota-
[Axis Data] tion
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 occurred.
4308 VOLTAGE DROP Direct current power supply voltage sup- Check the connection for primary side
(CONVERTER) plied to amplifier for servopack has wiring R,S,T, wire.
[Bit Pattern] become less than143V. 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
10-50 604 of 656

RE-CTO-A203
Alarm Message List
Alarm
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 the motor (encoder) for axis occurred the
[Axis Data] 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] Check the primary power supply voltage
(220V+10%).
WRCA01 circuit board, the encoder.
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 disappeared. 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 interference between robot Remove the object after resetting the
Robot/Station and peripheral device etc. was detected. alarm or move the robot to the safety
[Axis Data] The collision was mis-detected by the nor- position.
mal movement of the robot, because the When the alarm cannot be reset
detection level was small. because the robot comes in contact with
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.
10-51 605 of 656

RE-CTO-A203
Alarm Message List
Alarm
4317 PRE-LOAD ERROR The motor does not operate in the pre-load Adjust the gun opening.
process.
4318 SERIAL ENCODER DLTPG exceeds the tolerance. Check the connection of the encoder dis-
CORRECTION played on the axis data.
LIMITATION Check whether there is the equipment of
OVER device generating big noise around.
Check the ground of the controller is cor-
rect.
4345 LINK SERVO FLOAT The link servo float execution is demanded Turn the power off then back on.
CANNOT EXUCUTE to the linear servo float execution axis. If the error occurs again, contact your
4346 LINK SERVO FLOAT The control torque specified in the link servo Turn the power off then back on.
LIMITATION float condition file exceeds the limited range If the error occurs again, contact your
TORQUE RANGE specified by the CMOS parameter. YASKAWA representative.
ERROR
4347 LINEAR SERVO The control torque specified the linear servo Turn the power off then back on.
FLOAT float condition file exceeds the limited range If the error occurs again, contact your
LIMITATION specified by the CMOS parameter. YASKAWA representative.
TORQUE RANGE
[XYZ]
4348 LINEAR SERVO A linear servo float indicates other coordi- Turn the power off then back on.
FLOAT nates type of the linear servo float. If the error occurs again, contact your
COORDINATES YASKAWA representative.
TYPE
UNMATCH
4349 LINEAR SERVO Tool pose control specification indicates as Turn the power off then back on.
FLOAT TOOL POSE no existence though the tool pose control If the error occurs again, contact your
CONTROL specification exists. YASKAWA representative.
SPECIFICATION
ERROR
4350 LINEAR SERVO The linear servo float execution is Turn the power off then back on.
FLOATCANNOT EXU demanded to the link servo float execution If the error occurs again, contact your
CUTE axis. YASKAWA representative.
[XYZ]
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.
4401 SEQUENCE TASK The error has occurred in job exec state- Reset the alarm and repeat the opera-
CONTR ERROR ment part. tion.
10-52 606 of 656

RE-CTO-A203
Alarm Message List
Alarm
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 occurred in the path opera- Reset the alarm and repeat the opera-
ERROR tion process. tion.
4405 SELECT ERROR The control error occurred 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 occurred in the path operation tion.
[Decimal Data] process. If the error occurs again, contact your
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]
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.
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RE-CTO-A203
Alarm Message List
Alarm
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]
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. If the error occurs again, contact your
10-54 608 of 656

RE-CTO-A203
Alarm Message List
Alarm
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. If the error occurs again, contact your
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 The global variable range was undefined. Needs investigation at YASKAWA. Con-
GLOBAL 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 consec-
STEPS(SPLINE) contain a minimum of 3 consecutive points. utive points for the spline interpolation
designation step.
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 occurred
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]
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RE-CTO-A203
Alarm Message List
Alarm
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 abnormal. If the error occurs again, contact your
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 If the error occurs again, contact your
data were attempted to be initialized. At the YASKAWA representative.
time, a disagreement of data occurred.
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 A straight line linked the three points. Reset the alarm and teach again.
TAUGHT POINT
(CIRC)
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 6:Set a positive value in the stopping
time instruction, moving time was less time of weaving file.
than 0. 7:Set 1mm or more in the vertical direc-
5:Weaving speed instruction was frequency tion, horizontal direction distance of
instruction, frequency was less than 0. weaving file.
6.Weaving stopping time was negative If the error occurs again, contact your
7:Vertical direction distance at or horizontal YASKAWA representative.
direction distance was 0 in triangular
wave, L type weaving.
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 occurred during file No. check. Reset the alarm. Select the job and
[Decimal Data] repeat the operation.
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RE-CTO-A203
Alarm Message List
Alarm
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, uni-
[Decimal Data] fied).
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 procedure:
alarm and register again.
Delete the job that caused the alarm
and register again.
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 occurring.
10-57 611 of 656

RE-CTO-A203
Alarm Message List
Alarm
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. If the error occurs again, contact your
4467 USER COORDI- An error occurred at user coordinate Be sure that the number of steps will be
NATES creation by a job. three or more.
GENERATION STEP The number of steps was lacking for a job
SHORTAGE for user coordinate creation.
4468 ROBOT CALIBRA- The error occurred in the process of making Reset the alarm and repeat the opera-
TION DATA ERROR robot calibration data. tion.
4469 ROBOT CALIBRA- The error occurred 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
4470 ROBOT An error occurred at calibration data cre- Correct the number of steps for a job.
CALIBRATION STEP ation between manipulators.
SHORTAGE The number of steps was lacking for a job
for calibration data creation between
manipulators.
4471 CALIBRATION DATA The error occurred in the process of making Reset the alarm and repeat the opera-
ERROR calibration data. tion.
4472 TOOL CALIBRATION The error occurred in the process of making Reset the alarm and repeat the opera-
DATA ERROR calibration data. tion.
4473 ARITHMETIC ALARM System data didn't correspond with reset Reset the alarm and repeat the opera-
RESET ERROR process after the alarm occurred in arithme- tion.
[Decimal Data] tic 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.
10-58 612 of 656

RE-CTO-A203
Alarm Message List
Alarm
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 Consult a YASKAWA representative.
[Decimal Data] for maker) for first application and applica-
tion parameter (AP) was not adjusted.
4480 SELECT When executing sensor instruction, the Needs investigation.

ERROR(SENSOR) selection parameter (parameter specified Consult a YASKAWA representative.
[Decimal Data] for maker) for first sensor application and
sensor 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 sen- Consult a YASKAWA representative.
[Decimal Data] sor application and robot designation (sys-
tem parameter) uses application was not
corresponded.
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.
4489 DEFECTIVE Impossible to execute cutting motion. 1:Set C,W axis position of cutting start
TAUGHT Data stands for the alarm factor. position zero(0).
POINT(CUTTING) 1:CW axis CUT pulse error 2:Set the radius zero(0) or more.
[Decimal Data] C,W axis position on cutting start is not
zero(0) pulse.
2:Cutting(edge) radius 0
Cutting (edge) radius is zero(0).
4490 DEFECTIVE Impossible to execute endless motion. 1:In case this alarm occurs when operat-
TAUGHT Data stands for the alarm factor ing programing pendant, reset the alarm
POINT(ENDLESS) 1:Interpolation motion impropriety of end- and execute the MRESET operation.
[Decimal Data] less function. In case this alarm occurs when operat-
Linear motion impropriety. 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 rotation was com- 4:Check the teaching position again. Set
pleted, MRESET instruction was not exe- C,W axis position of cutting start posi-
cuted but linear interpolation was tion zero(0).
executed.
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 Teach reference points again.
DIRECTION ERROR occurred in the process of making a correc- If the error occurs again, contact your
[Decimal Data] tion in the direction for path arithmetic. YASKAWA representative.
4:Referrence points were the same.
10-59 613 of 656

RE-CTO-A203
Alarm Message List
Alarm
4492 POSITION CORREC- When correcting a motion, the error Reset the alarm and repeat the opera-
TION ERROR occurred in making process of making a cor- tion.
[Decimal Data] rection in the volume for path arithmetic. If the error occurs again, contact your
4493 OVER TOOL FILE The error occurred in the tool file control Reset the alarm and repeat the opera-
NO. process. tion.
4494 DEFECTIVE 1:Weaving start point and end point were Check the position of the start point, end
TAUGHT the same. point and reference point. Teach again.
POINT(WEAV) In case there was no instruction of stop
[Decimal Data] weaving, the position of weaving start point
and end point was the same point or the
position of weaving start point and refer-
ence point is the same point.
In case there is instruction to stop weav-
ing, the position of the weaving start point
and reference 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 There was a problem with the taught points. Teach the points again.
TAUGHT
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]
4501 OUT OF The error occurred 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
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. YASKAWA representative.
4503 CONTROL GROUP The error occurs in the process of the job Contact your YASKAWA representative.
JOB EXECUTION control.
IMPOSSIBILITY
4504 MEASURE INST When executing the measure instruction, Reset the alarm and repeat the opera-
EXECUTE ERROR the error occurred. tion.
[Decimal Data] Data stands for the alarm factor. If the error occurs again, contact your
2:MEASON instruction YASKAWA representative.
3:MEASOF instruction
10-60 614 of 656

RE-CTO-A203
Alarm Message List
Alarm
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 calculate the root Correct the job.
INSTRUCTION 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 cocoa- Teach again such that the three points do
LINE(3 STEPS) nuts or three or more taught points for robot not lie on the straight line.
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]
(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]
10-61 615 of 656

RE-CTO-A203
Alarm Message List
Alarm
4517 SEARCH MONITOR The error occurred in the interface with Check the system version of the XCP01,
SET ERROR servo on feedback latch mode. WRCA circuit board.
(SERVO)
[Decimal Data]
4518 SEARCH MON The error occurred in the interface with Check the system version of the XCP01,
RELEASE ERROR servo on feedback latch 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 occurred 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.
4525 SPECIFIED JOB The error occurs in the job control process- Contact your YASKAWA representative.
EXECUTION ingpart.
IMPOSSIBILITY
4526 SYNTAX ERROR IN Internal data of equation installation was Needs investigation.
EQUATION INST abnormal. 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 unmatched) Consult a YASKAWA representative.
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.
10-62 616 of 656

RE-CTO-A203
Alarm Message List
Alarm
4530 CONVEYER Data stands for the alarm factor. Reset the alarm then try again.
SYNCHRONIZING 1: The base axis in the conveyer character- If the error occurs again, contact your
ERROR istic file is specified to the value excepted YASKAWA representative.
for 0, 1, and 2.
2: The job which follow up the robot axis
does not have the robot axis.
3: The job which follow up the base axis
does not have the base axis.
4: CV selection <-> CVF# number unmatch
5: No conveyer starting point data at pre-
reading
6: Conveyer position latch error at pre-
reading
7: No synchronization starting signal input
8: Conveyer position reset prohibited
9: Conveyer correction amount read error
4531 CONVEYER Use state of the conveyer characteristic Set Use state to 1:Use at the conveyer
CHARACTERISTIC file set up by the job is not specified to characteristic file set by the job.
FILE UNSET 1:Use.
4532 CONVEYER SPEED The conveyer speed drops into under Check the speed specified at Conveyer
DOWN Conveyer Lowest Speed in the conveyer Lowest Speed of the conveyer character-
characteristic file when Mode When istic file.
Conveyer Decreases of the conveyer
characteristic file is selected as 1:Mode
When the Alarm Occurs.
4533 CONVEYER Data stands for the alarm factor. Reset the alarm then try again.
SYNCHRONIZATION 1: Conveyer synchronization control group If the error occurs again, contact your
CALCULATION specification error YASKAWA representative.
ERROR 2: Conveyer synchronization user coordi-
nate specification error
3: Conveyer synchronization cooperation
slave error
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.
4535 PSEND ERROR Data stands for the alarm factor. Check the destination.
1: PRECV is instructed to its own task.
2: Mail data type unmatch
3: Mail box number error
4536 PRECV ERROR Data stands for the alarm factor. Check the destination.
1: PRECV is likely to be instructed by itself
to its task.
2: Unmatched mail data type
3: Mail box number error
4537 OFFLINE MAIL BOX Data stands for the alarm factor. Reset the alarm then try again.
PROCESSING 1: Mail box number error f the error occurs again, contact your
ERROR The error of the mail box number from the YASKAWA representative.
SYSCON CPU
2: Undefined mail box operation command
The error of the mail box number from the
SYSCON CPU
3: OFF_MB_IFS pointer improper
MOTION CPU internal data error
10-63 617 of 656

RE-CTO-A203
Alarm Message List
Alarm
4538 ROBOT AXIS SYMOVJ is executed for following up the Check the job.
TRACKING robot.
IMPOSIBILITY SYMOVJ is only able to use for the base
axis follow-up.
4539 CORNER R Unable to use the corner R during the Do not use the corner R in the coordinated
CONTROL ERROR cooperative operation motion.
No reference point Teach it again.
Permissible angle over Adjust the set value of the corner R
Circular path inscribed by the specified operation specification.
radius cannot be generated.
1: Corner R cooperated control slave
specification error
2: Corner R pass refinement reference point
error
3: Corner R pass angle error
4: Corner R operating radius data error
5: Corner R operating group specification
error
6: Corner R master side command error
7: Corner R operation prohibition during the
weaving function execution
8: Corner R operation prohibition during the
conveyer synchronization function
execution
17: Corner R operation
prohibition during the conveyer synchro-
nization execution
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.
4541 UNDEFINED "SET" in the painting characteristic file Select Completed at SET at the
PAINT specified by the job has not been painting characteristic file specified by the
CHARACTERISTIC Completed. job.
FILE
4542 MRESET ERROR The MRESET instruction is executed Reset the alarm then try again.
though the endless axis is not speci- If the error occurs again, contact your
fied.Data stands for the alarm factor. YASKAWA representative.
1: Endless axis specification error.
4543 STACK LESS THAN 0 The error occurred in internal data when Reset the alarm and repeat the operation.
(JOB CALL) returning job. If the error occurs again, contact your
4544 MULTI LAYER JOB Incorrect job attribute (reverse attribute) The Check the attribute of the job specified
ATTRIBUTE cause is as following: by the MLTSMPL.
UNMATCH The sampling reverse job specified by the Check the sampling reverse job is gener-
MLTSMPL instruction is not the reverse ated.
attribute. Correct the attribute of the job specified
First layer job specified by the MLTSMPL by the MLTSCAL.
instruction or sampling forward job is
reverse attribute.
The attribute of the sampling job specified
by the MLTSCAL is different from the attri-
bute of the Nth job.
(MLTSMPL, MLTSCAL)
4545 MULTI LAYER JOB The control group between the specified Select the job which matches with the
CONTROL GROUP jobs are not same. (MLTSMPL, MLTSCAL) control group.
UNMATCH
10-64 618 of 656

RE-CTO-A203
Alarm Message List
Alarm
4546 MULTI LAYER JOB The number of total steps is not equal Match the number of the steps between
STEP NUMBER between specified jobs. jobs.
UNMATCH (MLTSMPL,MLTSCAL)
4547 MULTI LAYER JOB Unmatch number of the reference point Match the number of the reference point
REFERENCE POINT between specified jobs (MLTSMPL, between the jobs.
NUMBER UNMATCH MLTSCAL)
4548 MULTI LAYER JOB The sample job and the jobs after the sec- Create the sample job and the jobs after
POSITION DATA ond layer are pulse type. (MLTSMPL, the second layer according to the instruc-
COORDINATES MLTSCAL) tion of "Multi Layer Function".
UNMATCH
4549 MULTI LAYER The tool file of the move instruction corre- Match the tool file of the move instruction
TEACHING TOOL sponded between specified jobs is corresponded between jobs.
UNMATCH unmatched.(MLTSMPL, MLTSCAL)
4550 MULTI LAYER The welding section as follow are not regis- Register the welding section on the each
WELDING SECTION tered at the specified job. job.
UNREGISTERED (SENSON COMARC - SENSOF COMARC,
SENSON SCOMARC - SENSOF SCO-
MARC, ARCON - ARCOF)
(MLTSMPL,MLTSCAL)
4551 MULTI LAYER The number of the move instruction in the Match the number of the move instruction
WELDING SECTION welding section between specified jobs is in the welding section between jobs.
MOVE INSTRUC- unmatched. (MLTSMPL, MLTSCAL)
TION
NUMBER UNMATCH
4552 MULTI LAYER Data stands for the alarm factor. Reset alarm then try again.
EXECUTION ERROR 1: Multi layer sampling cue underflow The If the error occurs again, contact your
internal cue for sampling is underflow at YASKAWA representative.
the MLTSMPL instruction execution.
(MLTSMPL)
2: Multi-layer sampling cue overflow The
internal cue for sampling is overflow at
the MLTSMPL instruction execution.
(MLTSMPL)
3: Multi layer sampling cue fatal error The
job name of the internal cue for sampling
is not registered at the MLTSMPL instruc-
tion execution. (MLTSMPL)
4: Multi layer sampling cue / job name unset
5: Multi layer scaling calculation error
(approach point)
(sensing start point)
(sensing start reference point)
(sensing execution point)
(sensing end point)
10: MLTWSET file pointer Illegality
11: Scaling shift calculation answer point
number over
4553 MLTSMPL The MLTSMPL instruction is executed again Check the contents of the job.
INSTRUCTION while the MLTSMPL is executed. Check if the MLTSMPL instruction is exe-
DUPLICATION (MLTSMPL) cuted doubly by the problems such as the
EXECUTION JUMP instruction makes the flow change,
IMPOSSIBLE and so on.
10-65 619 of 656

RE-CTO-A203
Alarm Message List
Alarm
4554 UNDEFINED MULTI The setting of the multi-layer condition file is Set the multi-layer condition file com-
LAYER CONDITION not completely. pletely.
FILE (MLTSSET, MLTWSET)
4555 UNDEFINED MULTI The multi-layer condition file which is no Check the specified multi-layer condition
LAYER CONDITION used is specified. file.
FILE (MLTSSET, MLTWSET)
4556 MULTI LAYER The number of the welding section as follow Equate the number of the welding section
WELDING SECTION is not equal in the specified job. between jobs.
NUMBER UNMATCH (SENSON COMARC - SENSOF COMARC,
SENSON SCOMARC - SENSOF SCO-
MARC, ARCON - ARCOF)
(MLTSMPL,MLTSCAL)
4557 MULTI LAYER There are SENSON instruction and ARCON Register it with pairs as SENSON
WELDING START instruction between the welding sections at COMARC and SENSOF COMARC,
INSTRUCTION the specified job. (MLTSMPL, MLTSCAL) SENSON SCOMARC and SENSOF
DUPLICATION SCOMARC, ARCON and ARCOF.
EXECUTION Do not register SENSON and ARCON in
IMPOSSIBILITY structions in that sections.
(MLTSMPL, MLTSCAL)
4558 MULTI LAYER The number of the welding section exceeds Adjust the number of the welding sections
WELDING SECTION 10. (MLTSMPL, MLTSCAL) in the job to 1-10.
NUMBER OVER
4559 MULTI LAYER MOVE The type of the move instruction which Equate type of the move instruction which
INSTRUCTION corresponds between the jobs is not equal. corresponds between the jobs.
UNMATCH (MLTSCAL)
4560 SCALING SHIFT Same three points of the MOVL instruction Same point must be two or less.
SAME POINT are registered in the scaling shift section.
ERROR (MLTSCAL)
(MOVL3 POINTS)
4561 SCALING SHIFT The REFP instruction is registered with the Re-teach the same points of the REFP.
SAME POINT same point in the scaling shift section.
ERROR (MLTSCAL)
(REFP)
4562 SCALING SHIFT The start point and the end point in the scal- Teach the start point and the end point at
SAME POINT ing shift sections are registered at the same the different point.
ERROR point. (MLTSCAL)
(Start point/End point)
4563 SCALING SHIFT Data stands for the alarm factor. Reset the alarm then try again.
ERROR 1: Scaling shift internal processing error 1 If the error occurs again, contact your
2: Scaling shift internal processing error 2 YASKAWA representative.
3: Scaling shift calculation processing error
(MLTSCAL)
4564 INTERNAL STATUS When execution of start point detecting Reset the alarm and repeat the opera-
ERR function (SRCH), search function for gen- tion.
(SEARCH HALT) eral sensor (ASRCH), force detecting func- If the error occurs again, contact your
[Decimal Data] tion (TSRCH) was completed, the process YASKAWA representative.
error occurred.
4565 SOFTWARE Operating function didn't correspond to sys- Need the investigation.
UNMATCH tem. Consult YASKAWA representative.
[Decimal Data]
10-66 620 of 656

RE-CTO-A203
Alarm Message List
Alarm
4566 USER COORDI- 1: The teaching points are incorrect. 2: Among three taught points in the
NATES 2: The teaching points for user coordinate teaching position. Teach the three
GENERATION turning are incorrect. points again so that they do not lie in
ERROR 3: The robot axis is not specified for the con- the straight line.
trol group of the job to prepare the user Except 2:
coordinates. (1)Reset the alarm, and then try again.
5: Position data error Software operation (2)If the alarm occurs again, save the
error occurred CMOS.BIN in maintenance mode,
6: Setting error of the slave group for user and then contact your Yaskawa
coordinate conversion representative about occurrence
status (operating procedure).
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.
4568 UNDEFINED PRESS "Unused" is specified in the press character- Set Used State in the press characteris-
CHARACTERISTIC istic file used in the job. tic file.
FILE
4569 PRESS RESOLUTION The resolution of the press characteristic file Please set the resolution of the press
DATA UNSET specified by the job is not set. characteristic file.
4570 SERVO FLOAT MODE The float mode can not be specified at the Check the proper ROM version for the
SETTING ERROR FLOATON instruction execution. WRCA circuit board.
It is necessary to replace the SL circuit
board and investigate the problem by
YASKAWA if the error occurs again.
4571 SERVO FLOAT MODE The float mode can not be canceled at the Check the proper ROM version for the
RELEASE ERROR FLOATOF instruction execution time. WRCA circuit board.
It is necessary to replace the SL circuit
board and investigate the problem by
YASKAWA if the error occurs again.
4572 UNDEFINED MOTOR There was no group setting controlled as Configured 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.
10-67 621 of 656

RE-CTO-A203
Alarm Message List
Alarm
4579 ANTICIPATION The error occurs at the processing of the Register the move instruction between
CONTROL ERROR participation function. The alarm may occur work instructions.
when the work instructions are registered PAINTON PAINTON
consecutively. PAINTOF MOVL
PAINTOF
MOVL
4580 ANTICIPATION There is no return step at the re-painting Reset the alarm then try again
DISTANCE function after the emergency stop. The error Refer to the Painting System Additional
SHORTAGE occurs at restart after the emergency stop is Function Manual for details.
performed during the movement to the top
step of the job called in the painting section.
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
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 Confirmation signal designated by stroke Correct the factor, defective LS etc., and
LIMIT 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 Encoders power is not on when the control Check the cable connection of the motor
ERROR power supply is turned ON. guns encoder.
4587 MOTOR GUN The error occurred 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 guns motor is OFF.
uration in which the gun change function 3: Execute 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 guns motor was on. ATC is chucked.
3: GUNCHG PICK was issued when the 5: Check the cable connection of the
ATC was unchecked. motor guns encoder.
4: GUNCHG PLACE was issued when the 6: Check the cable connection of the
ATC was unchecked. motor guns encoder.
5: The encoders power could not be turned 7: Check the gun number in the gun con-
ON when GONCHG PLACE was issued. dition data file for GUNCHG. And,
6: The encoders power could not be turned check the guns 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
10-68 622 of 656

RE-CTO-A203
Alarm Message List
Alarm
4591 SERVO PART The error occurs in control check. (1)Reset the alarm, and then try again.
SPEED CONTROL (2)If the alarm occurs again, save the
MODE CMOS.BIN in maintenance mode, and
SETTING ERROR then contact your Yaskawa representa-
tive about occurrence status (operating
procedure).
4592 SERVO PART The error occurs in control check. (1)Reset the alarm, and then try again.
SPEED (2)If the alarm occurs again, save the
CONTROL MODE CMOS.BIN in maintenance mode, and
RELEASE ERROR then contact your Yaskawa representa-
procedure).
4593 SERVO HAND The error occurs in control check. (1)Reset the alarm, and then try again.
CONTROL MODE (2)If the alarm occurs again, save the
SETTING ERROR CMOS.BIN in maintenance mode, and
then contact your Yaskawa representa-
procedure).
4594 SERVO HAND The error occurs in control check. (1)Reset the alarm, and then try again.
CONTROL MODE (2)If the alarm occurs again, save the
RELEASE ERROR CMOS.BIN in maintenance mode, and
procedure).
4595 FORM CUTTING 1: Radius data set defect 1: Check the value of the radius.
MOTION 2: Horizontal data set defect 2: Check the value of the horizontal.
IMPOSSIBILITY 3: Vertical data set defect 3: Check the value of the vertical.
4: Corner radius data set defect 4: Check the radius value of the corner.
5: Overlap data set defect 5: Check the value of the overlap amount.
6: Speed data set defect 6: Check the value of the cutting speed.
7: Cooperative control slave specified 7: Execute FORMCUT instruction at the
8: From cutting operation minimum radius independent job.
not specified 8: Check the set value of the minimum
9: Form cutting operation maximum radius radius.
not specified 9: Check the set value of the maximum
10: FORMAPR unexecution. radius.
(The FORMAPR is not performed at the 10:
previous step though the starting point -Execute the FORMAPR instruction.
is specified to Starting Point or -Do not register any move instruction
Automatic.) between the FORMAPR and FROMCUT
instructions.
-To execute the FORMCUT instrucion
by pressing PLAYBACK, TEST RUN,
or INTERLOCK and FWD at the same
time after a FWD or BACK operation,
be sure to execute the FWD or BACK
operation several steps before the
FORMCUT instrucion. All the instruc-
tions between the instruction carried
out by pressing the FWD or BACK
and the FORMCUT instruction must
be executed by pressing PLAYBACK,
TEST RUN, or INTERLOCK and FWD
at the same time.
4596 FORMCUT ERROR An attempt was made to reexecute the Re-execute the move instruction executed
FORMCUT instruction after interrupting it. before the FORMCUT instruction, and
then execute the FORMCUT instruction
again.
10-69 623 of 656

RE-CTO-A203
Alarm Message List
Alarm
4597 OFFLINE POSITION 1: Error of the original position data tag for 4: The variable position may be out of the
DATA CONVERSION the off-line position data conversion robot motion range. Check if the vari-
ERROR 2: Error of the original position data user able position is within the robot motion
coordinates number for the off-line range.
position data conversion Except 4:
3: Defect of the position data for the (1)Reset the alarm, and then try again.
reference for the off-line position data (2)If the alarm occurs again, save the
conversion CMOS.BIN in maintenance mode,
4: Error of the original position data order and then contact your Yaskawa rep-
and the inversion for the off-line position resentative about occurrence status.
data conversion (operating procedure).
5: Defect of the pulse increment for the
offline position data conversion
6: Conversion failure after the pulse
increment for the off-line position data
conversion
7: Defect of the XYZ incremental value for
the off-line position data conversion
8: Conversion failure after the XYZ
conversion
9: Conversion error by the conversion
information for the off-line position data
conversion
10: Defect of the angle incremental value for
11:Conversion failure after the angle
conversion
12: Reverse shift data creation failure of the
3D shift for the off-line position data
conversion
13: Reverse shift data addition failure of the
3D shift for the off-line position data
conversion
14: Reverse shift data creation failure of the
shift data for the off-line position data
conversion
15: Reverse shift data addition failure of the
shift data for the off-line position data
conversion
16: Addition failure of the 3D shift data for
17: Addition failure of the shift data for the
offline position conversion
4598 PAINTOUT ERROR 1: The parameter setting for the universal Check the settings for the AxP011.
input group number is incorrect.
4599 SERVO COMMAND An attempt was made to issue the (1)Reset the alarm, and then try again.
ERROR command while the servo control (2)If the alarm occurs again, save the
processing has not completed. CMOS.BIN in maintenance mode, and
procedure).
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
10-70 624 of 656

RE-CTO-A203
Alarm Message List
Alarm
4604 DESIGNATED AXIS The home position correction data is not Registration for the home position correc-
HOME POSITION registered. tion data.
CORRECTION DATA
NON-EXISTING
4605 SETTOOL ERROR The different value between a present tool Check whether the setting value is cor-
constant and the setting value exceeds a rect.
permissible range (parameter setting value). Check whether the parameter setting is
1: Maximum deviation permissible rang correct.
over.
4606 GLOBAL VARIABLE The value of the number setting parameter Reset the global variable (user variable)
AREA OVERFLOW of the global variable (user variable) is number and the position variable setting
defective. parameter.
User variable setting condition
The maximum rows are 4:(below 999)
The maximum memory are below 2816
byte.
S1D190*4*1+S1D191*4*2+S1D192*4*4+S1
D193*4*4 2816
S1D190(B variable) 1block: 4 numbers

S1D191(I variable) 1block: 4 numbers
S1D192(D variable)1block: 4 numbers
S1D193(R variable) 1block: 4 numbers
Position variable setting condition<X3.76>
Maximum numbers are 4992.
S1D187(P variable) 1 block:64 numbers
Setting value 0-78
S1D188(B variable)1 block: 64 numbers
Setting value0-78
S1D189(EX variable)1 block: 64 numbers
Setting value 0-78
* It is necessary initialize the job when the
position variable number is expanded.
Standard CMOS is able to correspond the
P variable with the maximum numbers of
4992 at the one robot system. However,
the number of the P variable is limited
within the ranges of the number of
teaching step at the system of the base or
station.
4607 MACRO COMMAND 1: Macro execution job unset (1)Check the following settings.
EXECUTION ERROR 2: Macro interruption job unset Check the settings for execution macro
3: Unstartable job from the specified macro job.
command (attribute)
4: Macro execution cancel error1
5: Macro execution cancel error2
4608 JOB ARGUMENT 1: Job argument unset (1)Check the following settings.
GET ERROR 2: No specific argument numbers Check the settings for jobs.
3: Argument data type unmatch
4609 MEMORY PLAY FILE 1: Memory play has already executed. (1)Check the following settings.
(task itself) Check the setting of the used memory
2: Memory play is in use at the other task play file number.
3: Re-record of the record completion file Check the control group setting of the
4: Replay of the record incompletion file used memory play file.
5: Memory play file control group is different
from the execution job control group.
10-71 625 of 656

RE-CTO-A203
Alarm Message List
Alarm
4610 MEMORY PLAY 1: Memory play sampling data reading (1)Reset the alarm, and then try again.
SAMPLING ERROR failure (2)Check the following settings.
2: Memory play sampling data writing failure Check the settings for the memory play
3: Memory play sampling data seeking mode.
failure Check the number of the memory play
4: Memory play mode setting error at the file for use.
memory play sampling (3)If the alarm occurs again, save the
5: Memory play sampling data control group CMOS.BIN in maintenance mode, and
error then contact your Yaskawa representa-
6: Ki/Ni in the sampling section of the mem- tive about occurrence status (operating
ory play sampling data is lower than 0. procedure).
7: Undetection at the memory play sampling
data back play mode.
4611 OPTON It exceeds the limitation numbers of the (1)Check the following settings.
INSTRUCTION execution. Check the settings for the OPTON
EXECUTION instruction. OPTON instruction can use
NUMBER OVER only the function to five simultaneously.
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.
4613 SERVO SEALING 1: The set up of the Sealing Gun Charac- (1)Check the following settings.
GUN CONTROL teristic File is not completed. Check the settings for the function
ERROR 2: Sealing guns does not exist at the job designation parameter.
which executes the sealing gun control. Check the settings for the control-group
3: Robot does not exist at the job which of the job.
executes the sealing gun control. Set either "1" or "2" for PRM1 control
4:The specification of the control method for method designation of the OPTON
the servo sealing control is not correct. instruction.
(PRM1 of the OPTON instruction must be If "1" is set for PRM1 of the OPTON
specified to 1 or 2.) instruction, set the PRM2 needle position
5: The specification value of the needle designation to a value between 0 and
position is not correct. (PRM2 must be 100.
specified to 0-100 when PRM=1 in the If "2" is set for PRM1 of the OPTON
OPTON instruction.) instruction, set PRM2 sealing width des-
6: The specification value of the painting ignation to a value between 0 and 30.
width is not correct. (PRM2 must be
specified to 0-30 when PRM1=2 in the
OPTON instruction.)
4614 SEALING GUN Sealing gun characteristic file unset Complete the sealing gun characteristic
CHARACTERISTIC file.
FILE
UNSET
4615 I/O AXIS OPERATING An attempt was made to command a job Check the following settings.
whose control group was in I/O axis motion. Does not the I/O axis motion executed
for the control group that executing the
job?
Does not the job executed for the control
group that operating by the I/O axis
motion?
The control group where the I/O axis is
operating cannot execute the job.
Moreover, the I/O axis motion cannot
perform for the control group where the
job is executing.
10-72 626 of 656

RE-CTO-A203
Alarm Message List
Alarm
4616 AXIS SHIFT ERROR An internal control error occurred when (1)Reset the alarm, and then try again.
shifting the axis. (2)Check the following settings.
1: The file could not be switched because of Correct the settings for the OPTON
incorrect start point designation. instruction tag so that value of the file
2: The control group with which the axis number specification is 1 to 32.
shifting is performed disagrees with the (3)If the alarm occurs again, save the
control group set for the axis shifting CMOS.BIN in maintenance mode, and
function in the calibration file. then contact your Yaskawa representa-
3: The calibration file number for axis tive about occurrence status (operating
shifting function is out of the applicable procedure).
range.
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.
4618 SHIFT INSTRUCTION 1: At the tool shift in Eulerian angles 90 (1)Check the following settings.
EXECUTION ERROR degrees, the shift value is specified Check if the shift value is setting for
besides Y axis. Y-axis only.
4619 JOB REGISTRATION An error occurred in job registration table. (1)Check the following settings.
ON TABLE UNSET The job registration table is not set. Check the settings for the job registration
Sub Code: Designated registration number table.
4620 ARM(TOOL) Parts and tool of manipulators were about to (1)Check the following settings.
INTERFERENCE interfere with each other. Change the teaching so that the manipula-
Sub Code: Group(Interferening)&Axis(Inter- tors specified by sub code will not interfere
fering)&Group(Interfered)&Axis(Interfered) with each other.
Check if the tool model (Tool interference
file) of the manipulator specified by sub
code is correctly set.
Check if calibration between the manipulors
are correctly set.
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.
4809 ENCODER BATTERY The voltage of the encoder backup battery Check the battery voltage of the
ERROR(SGDB) decreased to 2.8V or less. encoder. (2.8V or more)
Leaving above situation makes the abnor- Replace the battery.
mal backup, and the home position data
disappears.
(This alarm only occurs when the control
power supply is started to turn on, and this
does not occur in operating)
4811 MAIN POWER Alarm code (Code:B6) from SGDx at the Replace the SGDB.
SUPPLY CIRCUIT mechatro link communication
ERROR(SGDB)
4816 SGDB MAIN POWER The main power supply signal is not turned Replace the SGDB.
SUPPLY READY on in the servo ON sequence.
ERROR The main power supply signal is not on
during the servo on.
The main power supply signal is not on in
the servo OFF sequence.
The main power supply signal is not off
during the servo OFF. (emergency stop).
10-73 627 of 656

RE-CTO-A203
Alarm Message List
Alarm
4817 SGDB BASE BLOCK The base block signal is not released in Replace the SGDB.
SIGNAL ERROR the servo ON sequence.
The base block signal is not released dur-
ing the servo ON.
The base block signal is released in the
servo OFF sequence.
The base block signal is released during
the servo OFF. (emergency stop)
4818 SGDB EXECUTION Processing which cannot be used in the Replace the SGDB.
IMPOSSIBILITY mechatro link mode is specified for execu-
tion.
(X3.90)
4901 CUBE/ Cube/Axis interference 1 (1)Check the following settings.

AXIS INTERFERENCE Perform the teaching again to correct
positions for manipulators so that the
step where the alarm occurred is out of
interference area.
Change the settings for interference
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.
10-74 628 of 656

RE-CTO-A203
Alarm Message List
Alarm

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.
10-75 629 of 656

RE-CTO-A203
Alarm Message List
Alarm

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.

interference area.
area.
10-76 630 of 656

RE-CTO-A203
Alarm Message List
Alarm

interference area.
area.

interference area.
area.
5000 IP ADDRESS The setting of the I P address of the local Ensure the setting value and change to an
SETTING ERROR station or server is (0,0,0,0) or appropriate numerical value in the system
(255,255,255,255). configuration.
5001 SUBNET MASK The setting of the sub net mask is (0,0,0,0) Ensure the setting value and change to an
SETTING ERROR or (255,255,255,255). appropriate numerical value in the system
configuration.
5002 GATEWAY SETTING The setting of the IP address of the gateway Ensure the setting value and change to
ERROR does not exist in the same local station and the correct gateway IP address in the
the same network. network specified by the sub-net mask in
the system configuration.
5003 ETHERNET XIF02 circuit board initialization error. Turn on the control power again.
PROCESSING If the error occurs again, contact your
ERROR YASKAWA representative.
5010 ANALOG INPUT The value of the analogue input on the Check the cable.
ERROR(XCP02) XCP02 circuit board can not be readable Replace the XCP02 circuit board.
correctly.
Data stands for the channel where an input
error has occurred.
5011 TRANSMISSION An error occurs in the serial transmission of Check the receiving and sending
ERROR(XCP02) the XCP02 circuit board. communication parameter.
Data stands for the defective contents. Check the communication cable.
d0: Receiving FIFO error
d1: Framing error
d2: Parity error
d3: Overrun error
d4: Check sum error
d5: NAK receiving error
d6: Sending time over
d7: Receiving time over
5012 SYSTEM An error occurs in the system on the sensor Reset the alarm then try again.
ERROR(COMARC) part of the COMARC function. If the error occurs again, contact your
Data stands for the contents of the errors. YASKAWA representative.
5013 COMARC An error occurs in the system on the sensor Reset the alarm then try again.
PROCESSING part of the COMARC function. If the error occurs again, contact your
ERROR Data stands for the contents of the errors. YASKAWA representative.
5020 SENSOR The value of the sensor (SE) is abnormal. Review the sensor (SE) parameter.
PARAMETER
ERROR
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Alarm Message List
Alarm
5021 CONVEYER Data of the conveyer characteristic file is Correct the data of the conveyer charac-
CHARACTERISTIC abnormal. teristic file.
FILE ERROR Date stands for the conveyer characteristic
number.
5022 CONVEYER The position of the corrected conveyer Review the synchronization motion
POSITION LIMIT exceeds the limited value of 21m. section.
OVER Date stands for the conveyer characteristic This alarm does not require the update of
number. the conveyer position, therefore re-
synchronization motion after the alarm
reset is not necessary.
Perform at the conveyer position where
the alarm occurs.
5023 CONVEYER The counter pulse of the conveyer position Review the conveyer resolution or the
COUNTER is overflowed. section of synchronization. This alarm does
LIMIT OVER Date stands for the conveyer characteristic not require the update of the conveyer
number. position, therefore re-synchronization
motion after the alarm reset is not
necessary.
Perform at the conveyer position where the
alarm occurs.
5030 SYSTEM ERROR An error occurs in the system of the sensor Turn the power off then back on.
(General Sensor) part of the general sensor function. If the error occurs again, contact your
Data stands for the alarm factor. YASKAWA representative.
5031 GENERAL SENSOR An error occurs in the system of the sensor Turn the power off then back on.
PROCESSING part of the general sensor function. If the error occurs again, contact your
ERROR Data stands for the alarm factor. YASKAWA representative.
5040 CONTROLNET Communication error occurs. Check the function and the connection of
COMMUNICATION the network devices such as the cables.
ERROR
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RE-CTO-A203
10.4 I/O Alarm Message List
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
10-79 633 of 656

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
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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
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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
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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-
puter, 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).
11-1 637 of 656

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 tool number.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 combination
220 - Taught by other robot
230 - While releasing soft limit
11-2 638 of 656

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 operation
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
11-3 639 of 656

RE-CTO-A203
Cannot select two coordinated 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
11-4 640 of 656

RE-CTO-A203
FWD/BWD dont 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
I/O axis mode requesting Start the job after completing JOG
960 -
motion.
ERRSVCPU signal error Servo ON request during WRCA

circuit board alarm. Turn the
power OFF then back ON.
If the error occurs again, turn the
power OFF and disconnect the
WRCA01 circuit board, XIU
970 -
(XCO) unit, and XST (XSU) unit.
Or disconnect the cables that are
connected to those units. If the
problem is not resolved, replace
those circuit boards, units, and
cables.
TIMER DATA TRANSMISSION ERROR Error in timer setting. Correct the

980 -
timer setting.
11-5 641 of 656

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
1080 - Negative value can't be set
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
Cannot insert/alter/delete with servo

2120 -
OFF
Only modifying move instruction possi-

2130 -
ble
2150 - Inserting is not possible from this point
2160 - Cannot modify or delete this position
11-6 642 of 656

RE-CTO-A203
Press INSERT to record same step as

2170 -
previous step
2180 - Cannot insert data
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
11-7 643 of 656

RE-CTO-A203
* 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
Cannot teach JOB without group-axis

2300 -
specification
* Same label exists

2310
XXX Line No.
2320 - Cannot create 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 Laser 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
11-8 644 of 656

RE-CTO-A203
2510 - Cannot correct position in the JOB
2520 - Enter JOB name
2530 - Illegal step number
2540 - Enter step number
2550 - Duplicated step number
2551 - Duplicated line number
Cannot correct steps of position vari-

2560 -
ables and REFP
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 cant 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
11-9 645 of 656

RE-CTO-A203
Axis is separated.
2761 -
Cannot add, modify, or delete.
Cannot reverse data of SVSPOTMOV

2770 -
instruction
2780 - Arithmetic error
11-10 646 of 656

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
3090 4 Data code error
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
11-11 647 of 656

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
11-12 648 of 656

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
format
3190
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 coordinates do not

13
match relative job coordinates
14 Correct the format of the job file.
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
11-13 649 of 656

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 uncompleted

15
Tag [ARRAY]
Element type tag uncompleted

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
11-14 650 of 656

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
11-15 651 of 656

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
3530 - Cannot load at current security mode Raise the security level.
11-16 652 of 656

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

*
4040 GOUT or arithmetic instruction the relay or register
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
*
4100 twice
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
*
4150 together
XXX Line No.
4160 - Cannot edit system section
11-17 653 of 656

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))
8031 - Too many boards(MSC01B)
Memory error (ControlNet) output condi-

8040 -
tion
Memory error (UNIWIRE CONNECT DAT) Initialize the UNIWIRE setting

8041 -
file in the maintenance mode.
8050 - Robot model is not registered
Cannot get UNIWIRE connection data Connection data cannot be

obtained due to communication
8060 -
error.
Verify the network connection.
11-18 654 of 656

YASNAC XRC
INSTRUCTIONS


C Printed in Japan July 2013 98-12
655 of 656
UP6 MANIPULATOR
SYSTEM MANUAL
FOR XRC2001 CONTROLLER
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Europe GmbH

Robotics Divsion )
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 vn. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800 Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.

22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542
YASKAWA Electric Korea Co., Ltd

9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513

Phone +65-6282-3003 Fax +65-6289-3003

252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek RoadHuaykwang, Bangkok 10320, Thailand
Phone +66-2693-2200 Fax +66-2693-4200
PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741

RE-MTO-A211 4 RE-TA-A503 2
RE-CTO-A208 5 RE-CTO-A203 15

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What components does the system include?

What components does the system include?

What safety items are discussed?

What safety items are discussed?

UP6 MANIPULATOR

Part Number: 172089-1CD

Copyright 2015, Yaskawa America, Inc. All Rights Reserved.

Notes for Safe Operation

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly the

PROHIBITED Must never be performed

Even items described as CAUTION may result in a serious accident in

To ensure safe and efficient operation at all times, be sure to

Emergency Stop Button

Release of Emergency Stop

Definition of Terms Used Often in This Manual

Descriptions of the programming pendant and playback panel keys,

Equipment Manual Designation

Displays The menu displayed in the programming pendant is

Playback Panel Buttons Playback panel buttons are enclosed in brackets.

Description of the Operation Procedure

2 MOTOMAN SETUP MANUAL ...........................................................................................72

3 YASNAC XRC INSTRUCTIONS .....................................................................................127

4 YASNAC XRC INSTRUCTIONS .....................................................................................254

YASKAWA ELECTRIC CORPORATION

MANUAL NO. RE-MTO-A211 4

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

PROHIBITED 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 manipulators work envelope

Definition of Terms Used Often in This Manual

Equipment Manual Designation

YASNAC XRC Controller XRC

YASNAC XRC Playback Panel Playback Panel

YASNAC XRC Programming Pendant Programming Pendant

MOTOMAN WARNING WARNING

YASKAWA ELECTRIC CORPORATION JAPAN

Moving parts may Do not enter

6 Allowable Load for Wrist Axis and Wrist Flange

9 Maintenance and Inspection

10 Recommended Spare Parts

1.1 Checking Package Contents

1.2 Checking the Order Number

THE MANIPULATOR AND THE CONTROLLER

YASNAC XRC UP6

YASKAWA ELECTRIC CORPORATION

(a) XRC (Front View) (b) Manipulator (Top View)

Fig. 1 Location of Order Number Labels

Failure to observe this caution may result in injury or damage.