Instructions: Yrc1000 Options

YRC1000 OPTIONS
INSTRUCTIONS
FOR FUNCTIONAL SAFETY FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
178949-1CD
4
MANUAL NO.
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DANGER
• This manual explains the functional safety function of the YRC1000
system. Read this manual carefully and be sure to understand its
contents before handling the YRC1000. Any matter, including
operation, usage, measures, and an item to use, not described in
this manual must be regarded as “prohibited” or “improper”.
• General information related to safety are described in “Chapter 1.
Safety” of the YRC1000 INSTRUCTIONS. To ensure correct and
safe operation, carefully read “Chapter 1. Safety” of the YRC1000
INSTRUCTIONS.
CAUTION
• In some drawings in this manual, protective covers or shields are
removed to show details. Make sure that all the covers or shields
are installed in place before operating this product.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids the
product warranty.
NOTICE
• 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
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.
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the YRC1000.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.
Indicates an imminently hazardous

DANGER situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.
Indicates a potentially hazardous

WARNING situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.
Indicates a hazardous situation,

CAUTION which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.
NOTICE is the preferred signal word

NOTICE to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.
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

NOTE to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION”.
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DANGER
• Before operating the manipulator, make sure the servo power is
turned OFF by performing the following operations. When the servo
power is turned OFF, the SERVO ON LED on the programming
pendant is turned OFF.
– Press the emergency stop buttons on the front door of the
YRC1000, on the programming pendant, on the external control
device, etc.
– Disconnect the safety plug of the safety fence.
(when in the play mode or in the remote mode)
If operation of the manipulator cannot be stopped in an emergency,
personal injury and/or equipment damage may result.
Fig. : Emergency Stop Button
• Before releasing the emergency stop, make sure to remove the

obstacle or error caused the emergency stop, if any, and then turn
the servo power ON.
Failure to observe this instruction may cause unintended movement of
the manipulator, which may result in personal injury.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing a teaching

operation within the manipulator's operating range:
– Be sure to perform lockout by putting a lockout device on the
safety fence when going into the area enclosed by the safety
fence. In addition, the operator of the teaching operation must
display the sign that the operation is being performed so that no
other person closes the safety fence.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind emergency response measures against the
manipulator’s unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may cause improper or unintended
movement of the manipulator, which may result in personal injury.
• Confirm that no person is present in the manipulator's operating
range and that the operator is in a safe location before:
– Turning ON the YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
Personal injury may result if a person enters the manipulator's
operating range during operation. Immediately press an emergency
stop button whenever there is a problem. The emergency stop buttons
are located on the front panel of the YRC1000 and on the right of the
programming pendant.
• Read and understand the Explanation of the Warning Labels before
operating the manipulator.
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WARNING
• Perform the following inspection procedures prior to conducting
manipulator teaching. If there is any problem, immediately take
necessary steps to solve it, such as maintenance and repair.
– Check for a problem in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the
YRC1000 cabinet after use.
If the programming pendant is left unattended on the manipulator, on a
fixture, or on the floor, the Enable Switch may be activated due to
surface irregularities of where it is left, and the servo power may be
turned ON. In addition, in case the operation of the manipulator starts,
the manipulator or the tool may hit the programming pendant left
unattended, which may result in personal injury and/or equipment
damage.
Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows.
Equipment Manual Designation
YRC1000 controller YRC1000
YRC1000 programming pendant Programming pendant
Cable between the manipulator and the controller Manipulator cable
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Descriptions of the programming pendant keys, buttons, and displays are

shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters or symbols
Pendant /Symbol Keys printed on them are denoted with [ ].
e.g. [ENTER]
Axis Keys [Axis Key] and [Numeric Key] are generic
/Numeric Keys names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a “+”
sign between them, e.g. [SHIFT]+[COORD].
Mode Switch Mode Switch can select three kinds of modes
that are denoted as follows: REMOTE, PLAY or
TEACH.
(The switch names are denoted as symbols)
Button The three buttons on the upper side of the
programming pendant are denoted as follows:
START, HOLD, or EMERGENCY STOP.
(The button names are denoted as symbols)
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
Start button* Hold button*
START HOLD
Mode switch*
P
EM
ER
O
T
GENCY S
REMOTE
Emergency stop button
PLAY
TEACH
Page key
Coordinate key
Axis keys
Shift key
Enter key
*The button/switch names
Numeric keys are denoted as symbols.
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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 [SELECT] is
pressed, or that the item is directly selected by touching the screen.
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.
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Contents
1 Overview of the Function ................................................................................................................ 1-1
1.1 Outline ............................................................................................................................... 1-1
1.2 List of Safety Functions...................................................................................................... 1-1
1.3 Structure of Configuration Files ......................................................................................... 1-2
2 System Configuration...................................................................................................................... 2-1
2.1 Outline ............................................................................................................................... 2-1
2.1.1 Safety Circuit Board (JANCD-ASF01-E)............................................................... 2-1
2.1.2 Expansion Safety I/O Board (JANCD-ASF02-E) .................................................. 2-1
2.1.3 Expansion Safety Terminal Block Board .............................................................. 2-2
2.1.4 Wiring Procedure of the Terminal Block ............................................................... 2-5
2.1.5 Functional Safety General-Purpose Input Signal 1 to 8........................................ 2-7
2.1.6 Functional Safety General-Purpose Output Signal 1 to 8..................................... 2-8
2.2 System Configuration for Dual-Arm Manipulator ............................................................. 2-11
3 Common Operation......................................................................................................................... 3-1
3.1 Security Mode When Using This Function......................................................................... 3-1
3.2 Readback Operation .......................................................................................................... 3-3
3.2.1 Readback Operation of the Configuration File...................................................... 3-3
3.2.2 Operations in Which the READBACK Window Is Shown ..................................... 3-5

3.2.2.1 Readback Operation of the Function Disable Mode................................ 3-6
3.2.2.2 Readback Operation of the Range Combination..................................... 3-8
3.3 External Memory Device (Saving/Loading)........................................................................ 3-9
4 Details of Functional Safety Function.............................................................................................. 4-1
4.1 Axis Range Limit Function ................................................................................................. 4-1
4.1.1 Outline .................................................................................................................. 4-1
4.1.2 Axis Range Limit Function Window ...................................................................... 4-3
4.1.3 Axis Range Limit Condition File Setting................................................................ 4-5
4.1.4 Confirming Method of Each Axis Operating Angle ............................................... 4-8
4.1.5 Confirmation of Safety Range............................................................................. 4-12
4.1.6 Start the Axis Range Limit Operation ................................................................. 4-13
4.1.7 Monitoring Status Confirmation Display.............................................................. 4-14
4.2 Axis Speed Monitor Function ........................................................................................... 4-17
4.2.1 Outline ................................................................................................................4-17
4.2.2 Axis Speed Monitor Function Window ................................................................ 4-18
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4.2.3 Axis Speed Monitor Condition File Setting ......................................................... 4-20
4.2.4 Start the Axis Speed Monitor Operation ............................................................. 4-22
4.3 Robot Range Limit Function ............................................................................................ 4-23
4.3.1 Outline ................................................................................................................ 4-23
4.3.2 Robot Range Limit Function Window ................................................................. 4-26
4.3.3 Robot Range Limit Function Condition File Setting Window .............................. 4-29
4.3.4 Confirmation of the Safety Range ...................................................................... 4-39
4.3.5 Starting the Robot Range Limit .......................................................................... 4-41
4.3.6 Switch the Monitoring Area................................................................................. 4-42
4.3.7 Safety Range and Manipulator Position ............................................................. 4-44
4.3.8 Proximity Warning Buzzer Setting ...................................................................... 4-48
4.3.9 Combining Function of Multiple Monitoring Areas .............................................. 4-50
4.4 Speed Limit Function ....................................................................................................... 4-53
4.4.1 Outline ................................................................................................................ 4-53
4.4.2 Speed Limit Function Window ............................................................................ 4-55
4.4.3 Speed Limit Function Condition File Setting Window......................................... 4-57
4.4.4 Starting the Speed Limit ..................................................................................... 4-60
4.4.5 Speed Limit in Teach Mode................................................................................ 4-60
4.5 Tool Angle Monitor Function............................................................................................ 4-62
4.5.1 Outline ................................................................................................................ 4-62
4.5.2 Tool Angle Monitor Function Window................................................................. 4-63
4.5.3 Tool Angle Monitor Condition File Setting .......................................................... 4-65
4.5.4 Confirmation of Tool Angle Limit Monitor ........................................................... 4-68
4.5.5 Starting the Tool Angle Monitor .......................................................................... 4-69
4.6 Tool Change Monitor Function ........................................................................................ 4-70
4.6.1 Outline ................................................................................................................ 4-70
4.6.2 Tool Change Monitor Function Window ............................................................. 4-71
4.6.3 Tool Change Monitor Condition File Setting....................................................... 4-73
4.6.4 Confirmation of Tool Change Monitor................................................................. 4-74
4.6.5 Starting the Tool Change Monitor....................................................................... 4-74
4.6.6 When Using the Tool Change Monitor Function................................................. 4-75
4.7 Tool Number Selection Function ..................................................................................... 4-80
4.7.1 Outline ................................................................................................................ 4-80
4.7.2 Tool Number Selection Function Window .......................................................... 4-82
4.7.3 Tool Number Selection Condition File Setting.................................................... 4-84
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Contents
4.7.4 Confirmation of Tool Number Selection.............................................................. 4-85
4.7.5 Starting the Tool Number Selection.................................................................... 4-85
4.7.6 When Using the Tool Number Selection Function.............................................. 4-86
4.8 Common Setting Item for the Condition File .................................................................... 4-91
5 Safety Signal ................................................................................................................................... 5-1
5.1 Allocation of Safety Logic Circuit Extended Signal ............................................................ 5-2
5.2 Allocation of Safety Fieldbus Signal................................................................................... 5-4
5.3 Settings of Safety Function Condition File ......................................................................... 5-6
5.4 File Switching to Valid/Invalid by the Safety Input Signal .................................................. 5-8
5.5 Safety Signal Output Value.............................................................................................. 5-11
6 Common Settings............................................................................................................................ 6-1
6.1 Function Disable Mode Setting .......................................................................................... 6-1
6.1.1 Restrictions While Function Disable Mode Is Enabled ......................................... 6-3
6.1.2 Security Level Setting for Function Disable Mode ................................................ 6-4
6.2 External Axis Coasting Value Setting ................................................................................ 6-5
6.3 Tool File Setting ................................................................................................................. 6-8
6.4 Tool Interference File Setting............................................................................................. 6-9
6.5 Security Level Setting for Tool File and Tool Interference Files ...................................... 6-13
6.6 Using the PMT Function Together with the Functional Safety Function .......................... 6-15
6.6.1 How to Use the PMT Function Together with the Functional Safety Function ... 6-15
6.6.2 Monitoring the Amount of Change in the Tool Files............................................ 6-19
6.6.3 Tool File Verification Check in a System Using the PMT Function Together
with the Functional Safety Function.................................................................... 6-22
6.7 Disabling Functional Safety by Changing Connection Settings ....................................... 6-23
7 Data Protection ............................................................................................................................... 7-1
7.1 Saving Dual Data ............................................................................................................... 7-1
7.2 FLASH Data Reset ............................................................................................................ 7-2
7.3 Change of Condition File by an External Device ............................................................... 7-4
7.3.1 Outputting the CRC Value to the External Memory Device .................................. 7-4
7.3.2 Confirming Method of the CRC Value .................................................................. 7-5
7.3.3 Register Output of the CRC Value........................................................................ 7-9
7.3.4 Data Monitor on the Total CRC Confirmation Window ....................................... 7-11
8 Specific Output Signal..................................................................................................................... 8-1
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9 Restriction ....................................................................................................................................... 9-1
9.1 Functions Cannot Be Used Concurrently with Functional Safety Function ....................... 9-1
9.1.1 Functions Which Modifies Parameter or File during Playback Operation ............ 9-1
9.2 Functions Conditionally Used Concurrently with Functional Safety Function.................... 9-2
9.2.1 Conveyor Synchronized Function, COMARC Function........................................ 9-2
9.2.2 Servo Float Function ............................................................................................ 9-2
9.2.3 Motor Gun Function.............................................................................................. 9-2
9.2.4 MotoPlus Function and MotoFit Function ............................................................. 9-2
9.2.5 T-axis Endless Function, External Axis Endless Function.................................... 9-2
9.2.6 Gun Change Function and Group Change Function ............................................ 9-3
9.2.7 Multi Layer Function ............................................................................................. 9-3
9.3 Restriction of Operation ..................................................................................................... 9-4
9.3.1 File/Parameter Loading ........................................................................................ 9-4
10 Error ............................................................................................................................................ 10-1
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1 Overview of the Function

1.1 Outline
1.1 Outline
By using the functional safety function, each of the two CPUs mounted on
the safety circuit board independently acquires the encoder feedback
pulse of the manipulator, and, based on this pulse, the position and speed
of the manipulator and the posture of its tool are monitored.
The data such as the result of safety monitoring is compared by each of
the two CPUs, and the power supply to the motor is suspended and the
manipulator is completely stopped when an error is detected.
With this function, improving of the safety of the manipulator’s motion and
minimizing of the equipment layouts when manipulators are installed are
realized.
1.2 List of Safety Functions

To the functional safety function, following six different functions for
monitoring purposes are equipped.
(1) Axis range limit function
Monitors each axis angle to be equal to or in the designated safety
area.
(2) Axis speed monitor function
Monitors each axis speed to be equal or slower than the desig-
nated speed.
(3) Robot range limit function
Monitors the manipulator arm or its tool to be in the designated
safety area.
(4) Speed limit function
Monitors the speed of manipulator TCP (Tool Center Point) and its
FCP (Flange Center Point) when the robot control group is moni-
tored.
If the station control group is monitored, it monitors the axis speed.
(5) Tool angle monitor function
Monitors the manipulator tool angle to be inside the range of lim-
ited angle when the angle is centered on the designated standard
posture.
(6) Tool change monitor function
Monitors the tool file used in the functional safety function to be
consistent with the user specified tool file. Cannot be used con-
currently with the tool number select function.
(7) Tool number select function
Selects the tool number used in the functional safety function.
Cannot be used concurrently with the tool change monitor func-
tion.
These safety functions conform to the following safety standards.

• EN ISO 13849-1: 2015 Cat.3 / PL d
• EN 62061(IEC 61508) SIL CL2
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1.3 Structure of Configuration Files
1.3 Structure of Configuration Files

Most of the configuration files for the functional safety are listed in the
{SAFETY FUNC.} menu under the main menu of the programming
pendant.
The files related to the functional safety shown below are expanded from
the {SAFETY FUNC.} menu.
Main Sub menu (1st layer) Sub menu (2nd layer)

menu
SAFETY AXIS RANGE LIMIT status list AXIS RANGE LIMIT condition file
FUNC. window (32 files/system)
AXIS SPEED MONITOR status AXIS SPEED MONITOR
list window condition file (32 files/system)
ROBOT RANGE LIMIT status list ROBOT RANGE LIMIT condition
window file (32 files/system)
SPEED LIMIT status list window SPEED LIMIT condition file
(32 files/system)
TEACH MODE SPEED LIMIT
condition file (32 files/system)
TOOL ANGLE MONITOR status TOOL ANGLE MONITOR
list window condition file (32 files/system)
TOOL CHANGE MONITOR TOOL CHANGE MONITOR
status list window condition file (16 files/robot group)
TOOL NUMBER SELECT status TOOL NUMBER SELECT
list window condition file (16 files/robot group)
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2 System Configuration
2.1 Outline
2.1 Outline
The functional safety function is performed by using the safety circuit
board. For details on the safety circuit board, refer to “YRC1000
INSTRUCTIONS (RE-CTO-A221)”.
2.1.1 Safety Circuit Board (JANCD-ASF01-E)

For details on the safety circuit board, refer to “YRC1000 INSTRUCTIONS
(RE-CTO-A221) 14.6.1 Safety Circuit Board (JANCD-ASF01-E)”.
2.1.2 Expansion Safety I/O Board (JANCD-ASF02-E)

The expansion safety I/O board (JANCD-ASF02-E) is an optional board
used to add 8 input points and 8 output points as the safety I/O signals,
and connected to the safety circuit board (JANCD-ASF01-E) by using a
communication cable.
Fig. 2-1: Expansion Safety I/O Board (JANCD-ASF02-E)
(CN221)
Connector for connection to the safety circuit board
(CN222)
Connector for connection to the expansion
safety terminal block board (IM-YR250/5-80P)
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2.1 Outline
2.1.3 Expansion Safety Terminal Block Board

Safety signals are connected to the expansion safety terminal block
board.
The type and main specifications of the expansion safety terminal block
board are shown below.
Item Specification
Unit type IM-YE250/5-80P
Function Connects the functional safety general I/O
signals.
Signal points Input: 8 points/station
Output: 8 points/station
The following is the external view of the expansion safety terminal block
board.
Fig. 2-2: Expansion Safety Terminal Block Board (IM-YE250/5-80P)
21 22 23 24 25 26 27 28 29 30
41 42 43 44 45 46 47 48 49 50
61 62 63 64 65 66 67 68 69 70
1
2
3
4
5
6
7
8
9
10
31 32 33 34 35 36 37 38 39 40
51 52 53 54 55 56 57 58 59 60
71 72 73 74 75 76 77 78 79 80
11
12
13
14
15
16
17
18
19
20
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2.1 Outline
The following table shows details of the connection terminals.
Table 2-1: Connection Terminals of IM-YE250/5-80P (Sheet 1 of 2)

Signal Name Connection No. Dual Signal Function Factory Setting
XIN1_1+
XIN1_1-
1
2 ○ Functional Safety
Universal Input 1
Open
(Corresponding FSBIN01)
XIN1_2+ 3
XIN1_2- 4
XIN2_1+
XIN2_1-
5
Universal Input 2
Open
XIN2_2+ 7
XIN2_2- 8
XOUT1_1+
XOUT1_1-
9
Universal Output 1
Open
(Corresponding FSBOUT01)
XOUT1_2+ 11
XOUT1_2- 12
XOUT2_1+
XOUT2_1-
13
Universal Output 2
Open
XOUT2_2+ 15
XOUT2_2- 16
XIN3_1+
XIN3_1-
21
Universal Input 3
Open
XIN3_2+ 23
XIN3_2- 24
XIN4_1+
XIN4_1-
25
Universal Input 4
Open
XIN4_2+ 27
XIN4_2- 28
XOUT3_1+
XOUT3_1-
29
Universal Output 3
Open
XOUT3_2+ 31
XOUT3_2- 32
XOUT4_1+
XOUT4_1-
33
Universal Output 4
Open
XOUT4_2+ 35
XOUT4_2- 36
XIN5_1+
XIN5_1-
41
Universal Input 5
Open
XIN5_2+ 43
XIN5_2- 44
XIN6_1+
XIN6_1-
45
Universal Input 6
Open
XIN6_2+ 47
XIN6_2- 48
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2.1 Outline
Table 2-1: Connection Terminals of IM-YE250/5-80P (Sheet 2 of 2)

Signal Name Connection No. Dual Signal Function Factory Setting
XOUT5_1+
XOUT5_1-
49
Universal Output 5
Open
XOUT5_2+ 51
XOUT5_2- 52
XOUT6_1+
XOUT6_1-
53
Universal Output 6
Open
XOUT6_2+ 55
XOUT6_2- 56
XIN7_1+
XIN7_1-
61
Universal Input 7
Open
XIN7_2+ 63
XIN7_2- 64
XIN8_1+
XIN8_1-
65
Universal Input 8
Open
XIN8_2+ 67
XIN8_2- 68
XOUT7_1+
XOUT7_1-
69
Universal Output 7
Open
XOUT7_2+ 71
XOUT7_2- 72
XOUT8_1+
XOUT8_1-
73
Universal Output 8
Open
XOUT8_2+ 75
XOUT8_2- 76
Refer to the connection diagram for the connection of each signal.
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2.1 Outline
2.1.4 Wiring Procedure of the Terminal Block

For your safety, appropriate work must be done by following the
instructions below.
NOTICE
• If the length of cable between the safety terminal block board and
the connected device is longer than 30 m, make sure to use the
shielded cable so that the electromagnetic resistant can be properly
performed. Then the shield of shielded cable must come into
contact with the controller's body.
 Tool: Screwdriver
For the connection, be sure to use a screwdriver of an applicable size and
configuration.
– WAGO standard screwdriver

WAGO 210-119
WAGO 210-119SB (Short, delivered with the product)
 Applicable Wires
1. The length of the exposed conductor (L) must be as follows:
– The length of the exposed conductor for the terminal block (L)
WAGO series 250 (with 5.0 mm pitch): 9-10 mm
– Applicable wire conductor: 0.5 mm² to 1.5 mm² (AWG20-16)
– Applicable maximum wire outside diameter: 3.1 mm dia.
2. If the wire is bent or loose, make it straight as illustrated in the figure
above.
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2.1 Outline
 Wire Connection
Terminal block: screwless clamp

terminal WAGO series 250
1. Place the screwdriver on the lever upright as shown in the figure

above and push it straight down.
2. Insert the wire into the connection hole slowly until its leading end
touches the end of the hole.
For thin wires, never insert the wire with force, or the wire jacket may
get caught in.
3. Pull out the screwdriver to clamp the conductor with the spring.
4. Check if the wire is connected firmly by pulling the wire softly.
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2.1 Outline
2.1.5 Functional Safety General-Purpose Input Signal 1 to 8

When opening this connection terminal, corresponding FSBIN turns
ON(1).
When short circuiting this connection terminal, corresponding FSBIN turns
OFF(0).
For safety reasons, dual circuits are used for the functional
safety general-purpose input signals.
SUPPLE When state of the input mismatch continues for 500 ms or
-MENT
more, the following alarm occurs.
Alarm 4751: M-SAF GENERAL INPUT SIG. ERROR2
Fig. 2-3: Example of Connecting Functional Safety General-Purpose Input Signal
YRC1000
Expansion safety
terminal block board Expansion safety I/O board
(IM-YE250/5-80P) (JANCD-ASF02-E)
㻞
Functional safety
general-purpose input 1_1
Turn ON/OFF
at the same time
Functional safety
general-purpose input 1_2
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2.1 Outline
2.1.6 Functional Safety General-Purpose Output Signal 1 to 8

The output from the connection terminal differs depending on the status of
FSBOUT.
When FSBOUT is ON(1), the output is 24 VDC.
When FSBOUT is OFF(0), the output is 0 V.
• The rated output value is equal to or less than 24 VDC and

50 mA. Do not connect a load exceeding the rated output
value.
• When connecting an inductive load, such as a safety relay,
NOTE with the output circuit, suppress the surge voltage by
using an inductive load with a built-in protective circuit or
by connecting a flyback diode in parallel to the inductive
load.
Failure to observe this instruction may result in equipment
damage.
In case the other side of the duplicated functional safety

general-purpose output signal is not output normally due to
NOTE a board trouble, etc., the error is detected by the self-check
circuit and following alarm occurs.
Alarm 4923: M-SAF GENERAL OUT SELF CHECK ERR2
To conform with Safety Category 3 and PL-d at the whole

manipulator system, monitoring of the safety devices
(Safety PLC, etc.) in this system is required.
NOTE
For this reason, to detect malfunction of the safety relay or
disconnection of the signal line, etc., execute signal mis-
match detection to the functional safety general-purpose
output at the external safety device (Safety PLC, etc.) side.
Fig. 2-4: Example of Connecting Functional Safety General-Purpose Output Signal
YRC1000
Expansion safety
Expansion safety I/O board terminal block board
(JANCD-ASF02-E) (IM-YE250/5-80P)
CN222
XOUT1_1+
Functional safety
XOUT1_1- general-purpose output 1_1
XOUT1_2+
Functional safety
XOUT1_2- general-purpose output 1_2
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2.1 Outline
Fig. 2-5: Example Connection with an External Device (Safety PLC)

(Connect the functional safety general-purpose output signal to the Safety
PLC via the safety relay)
YRC1000
Expansion safety I/O board Expansion safety

terminal block board
CN222
XOUT1_1+
Safety PLC
XOUT1_1-
XOUT1_2+
XOUT1_2-
At the PLC side, monitor the contacting status of the dupli-

cated safety relay, which is for connecting the safety gen-
eral-purpose output signal with the Safety PLC, and
connecting status of the signal line.
NOTE
However, by using the general-purpose safety input signal
which is equipped to the YRC1000, the duplicated safety
relay can be monitored by the YRC1000.
(As for the connecting status of the signal line, monitor it at
the external device side.)
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2.1 Outline
Fig. 2-6: Example of Safety Relay Monitoring Circuit Board Using the
General-Purpose Safety Input Signal
(Example: GSIN signal is used)
YRC1000
Expansion safety
Expansion safety I/O board terminal block board
CN222
XOUT1_1+
External
XOUT1_1-
device
XOUT1_2+
XOUT1_2-
Expansion safety
Expansion safety circuit board terminal block board In case one safety relay out of two
welds, disaccord of the duplicated
GSIN1_1+ 41 GSIN1_1+ input signal (GSIN) is detected,
GSIN1_1- 42 GSIN1_1- and then the manipulator operation
is stopped.
GSIN1_2+ 43 GSIN1_2+
GSIN1_2- 44 GSIN1_2-
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2.2 System Configuration for Dual-Arm Manipulator
2.2 System Configuration for Dual-Arm Manipulator

Like dual-arm manipulator (SDA model) system, a system where the robot
group (arm) and the base group (base) exist separately and individually
arranged on the different servo board exists.
In this system, for the safety monitoring, the encoder feedback pulse
information of the axis which does not exist in its own station should be
acquired from other servo station. Thus, the following restrictions apply.
When using dual-arm type configuration manipulators, the

maximum number s of connecting axis for the servo station
at the encoder data receiving side decreases.
NOTE
Maximum numbers of connecting axis
= (9 axes - the number of axes whose encoder data was
acquired from other servo station)
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3 Common Operation
3.1 Security Mode When Using This Function
3 Common Operation
Common operations when using the functional safety function are
described in this chapter.

When using the functional safety function, settings of the condition file for
this function is necessary. And this settings must be performed when the
security mode is in the safety mode. For this reason, this file settings
must be performed by the person who has a safety license.
Followings are the procedures for changing the security mode.

1. Select {SYSTEM INFO} under the main menu, and then
select {SECURITY} in the sub menu.
2. Change the security mode to the SAFETY MODE.

– Press [SELECT], move the cursor to the SAFETY MODE, and press
[SELECT] again.
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3 Common Operation
3. Enter the password for the SAFETY MODE, and then press [ENTER].
– The security mode is changed to the SAFETY MODE.
Depending on the level of the security mode, available operations are

different as shown in the following table.
Security level Available operations

Operation, Only browsing of the data related to the functional safety is
Edit, available.
Management Editing is not available.
Safety Both browsing and editing of the data related to the functional
safety are available.
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3 Common Operation
3.2 Readback Operation

When the functional safety is enabled and if data are modified in the
condition file setting window or the tool file window of the functional safety,
the readback operation is performed.
The readback operation is used to check whether the data to be set in the
safety circuit board are correct.
3.2.1 Readback Operation of the Configuration File

The readback operation is performed for the configuration files in the
settings window of the submenus shown below.
Main menu Submenu
ROBOT TOOL
TOOL INTERFERENCE
HOME POSITIONING
SAFETY FUNCTION AXIS RANGE LIMIT
AXIS SPEED MONITOR
ROBOT RANGE LIMIT
SPEED LIMIT
TOOL ANGLE MONITOR
TOOL CHANGE MONITOR
TOOL NUBMER SELECT
1. Edit a file in the settings window of the data related to the functional
safety.
After editing the data, {READBACK} and {CANCEL} appear in the
lower part of the window.
{READBACK} : Transmits the settings of the edited file to the safety

circuit board.
{CANCEL} : Deletes the edited file and returns to the previous
settings.
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3 Common Operation
2. To set the data of the edited file, press {READBACK}. By pressing

{READBACK}, the data are transmitted to the safety circuit board, and
{WRITE} and {CANCEL} appear in the lower part of the window.
{WRITE} : Stores the settings of the edited file in the safety

circuit board.
{CANCEL} : Deletes the edited file and returns to the previous
settings.
3. To update the settings of the safety circuit board, press {WRITE}. By
pressing {WRITE}, a confirmation dialog “Update the file?” appears.
– Select “YES”, and if the data transmitted to the safety circuit board
match the data in the edited file, the settings of the edited file are
stored in the safety circuit board.
– Select “NO”, and the settings of the file are not stored in the safety
circuit board.
Note that the edited data will not be stored until {WRITE} is pressed
and “YES” is selected in the confirmation dialog “Update the file?”.
The data will be deleted if the {WRITE} procedure is not completed
in the following cases:
• When {CANCEL} is pressed
• When another menu is selected and its window is opened
• When the page is switched
• When the mode is switched
• When an alarm occurs
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3 Common Operation
3.2.2 Operations in Which the READBACK Window Is Shown

When one of the following items is edited, the READBACK window
appears immediately after the edition, and the readback is performed.
Window Setting item
AXIS RANGE LIMIT FUNCTION DISABLE MODE
ROBOT RANGE LIMIT FUNCTION DISABLE MODE
TOOL ANGLE MONITOR FUNCTION DISABLE MODE
TOOL CHANGE MONITOR FUNCTION DISABLE MODE
TOOL NUMBER SELECT FUNCTION DISABLE MODE
RANGE COMBINATION INPUT FILE 1
INPUT FILE 2
LOGIC
OUTPUT FILE
Only the readback operation is described here.

For the function disable mode, refer to chapter 6.1 “Function Disable
Mode Setting” .
For the range combination function, refer to chapter 4.3.9 “Combining
Function of Multiple Monitoring Areas” .
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3 Common Operation
3.2.2.1 Readback Operation of the Function Disable Mode

Perform settings of FUNCTION DISABLE MODE in the STATUS listing
window. In the following, the STATUS listing window of the axis range limit
function is shown.
1. Select {SAFETY FUNCTION} under the main menu, and then select
{AXIS RANGE LIMIT}. The STATUS listing window of AXIS RANGE
LIMIT appears.
2. Select “ON(1)” under FUNCTION DISABLE MODE.
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3 Common Operation
3. The READBACK window appears.

– The READBACK window is used to check whether the data to be set
in the safety circuit board are correct.
– Confirm the values in MODIFY VALUE and READBACK VALUE,

and then press {YES}. If {NO} is pressed, the settings return to the
previous values.
4. When {YES} is pressed, the settings are modified.
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3 Common Operation
3.2.2.2 Readback Operation of the Range Combination

After editing settings of INPUT FILE 1, INPUT FILE 2, LOGIC, or OUTPUT
FILE in the RANGE COMBINATION window, confirmation in the
READBACK window is necessary.
After the readback operation, {WRITE} and {CANCEL} appear in the lower
part of the window.
{WRITE} : Stores the settings of the edited file in the safety
circuit board.
{CANCEL} : Cancels the settings of the edited file and returns to
the previous settings.
When multiple setting items are modified, the readback operations are
performed multiple times; however, those data will not be stored until
{WRITE} is pressed. The data will be deleted if the {WRITE} procedure is
not completed in the following cases:
• When {CANCEL} is pressed
• When another menu is selected and its window is opened
• When the mode is switched
• When an alarm occurs
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3 Common Operation
3.3 External Memory Device (Saving/Loading)
3.3 External Memory Device (Saving/Loading)

The files related to the functional safety can be saved to or loaded from an
external memory device.
Saving of the files can be performed in any security mode.
Loading of the files can be performed only when the security mode is in
the safety mode.
File name Security mode for loading

AXIS RANGE LIMIT DATA Safety
AXIS SPEED MONITOR DATA Safety
ROBOT RANGE DATA Safety
SPEED LIMIT DATA Safety
TOOL ANGLE MONITOR DATA Safety
TOOL CHANGE MONITOR DATA Safety
(Common to TOOL NUMBER SELECT DATA)
APPR WARNING BUZZER DATA Safety
When a file related to the functional safety is loaded, a mes-

sage “Select ‘Safety Board FLASH Reset’ in the mainte-
NOTE nance mode.” appears.
For the details, please refer to chapter 7.2 “FLASH Data
Reset” .
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4 Details of Functional Safety Function

4.1 Axis Range Limit Function

In this chapter, details of the functional safety function are described.
4.1.1 Outline
Axis range limit function is a function which sets each axis range of motion
for the manipulator, base and station group and monitors whether each
axis is inside the already-fixed range of motion using a software.
This function specifies the upper limit and the lower limit of the range of
motion to those axes and the range inside the limits is defined as the
safety range.
While an axis is in operation, based on the axis motion speed, this
function calculates the coasting value in case of the immediate stop by the
alarm, and then, including this value, it monitors the safety range. With
this monitoring operation, the axes would not exceed the safety range
even if a motion error is detected.
In case an error is detected, the power supply to the motor is stopped
using the machine safety. And the error is notified using an alarm.
Thirty two files are prepared to this function and all axes motion range of
any one control group is set to one file. When a control group is set to
several files, the control group can be monitored by switching conditions.
Fig. 4-1: Limit of Motion Range at Each Axis
Safety range
Minimum value Maximum value
Maximum movable range
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Follow the procedures below when starting the axis range limit function.
1. Set the coasting value.
(Before using this function, set the coasting value by following the
procedures described in chapter 6.2 “External Axis Coasting Value
Setting” in case the base axis or the station axis exits in the system.)
2. Set the condition file of the axis range limit function.
3. Confirm the safety range.
4. Start the axis range limit function.
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4.1.2 Axis Range Limit Function Window

Followings are the setting procedures for the axis range limit function.
1. Set the security mode to the safety mode, and then select {SAFETY
FUNC.} under the main menu.
2. Select {AXIS RANGE LIMIT} in the sub menu.

– The list of the axis range limit status appears.
On the status list window, the 32 configuration files for the axis range limit
function are arranged so that their status can be confirmed. By scrolling
down the window, all the list can be seen.
Followings are the details of the item on the window.
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<Details of the Window>

1. FUNCTION DISABLE MODE
Valid/invalid the axis range limit function. When “ON” is selected, this
function becomes invalid temporarily.
Value Description
OFF The axis range limit function is valid.
ON The axis range limit function is invalid.
The play back, test run, forward/backward operation become
prohibited.
For the details, please refer to chapter 6.1 “Function Disable Mode Setting” .
2. FILE
The number of the condition file is displayed.
Move the cursor to any number and press [SELECT]. The individual
setting window for the selected condition file appears.
3. GROUP
The control group to be monitored specified by the condition file is indi-
cated.
4. STATUS
Monitoring status of the present condition file is indicated.
Value Description
SETTING The condition file is in the initial status or in the data setting status.
Monitoring is not performed.
CONFIR Confirming the area after the data is set. The status of the
MING monitoring operation depends on the valid condition of the condition
file.
VALID Data setting is completed and monitoring status of the file is in valid
(FILE) status.
INVALID Data setting is completed and monitoring status of the file is in
(FILE) invalid status.
(SIGNAL) status by the establishment of the safety signal condition.
(SIGNAL) invalid status by the disestablishment of the safety signal condition.
5. RANGE
Result of the present monitoring is displayed.
Value Description
SAFE Result of the object file monitoring is safe (inside the safety range).
NOT Result of the object file monitoring is not-safe (outside the safety
SAFE range)
- The object file is in monitoring invalid status.
6. COMMENT
The comment input is displayed.
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4.1.3 Axis Range Limit Condition File Setting

On the status list window, select a file number with the cursor, and then
press [SELECT].
– The settings window for the selected condition file of the axis range
limit function appears.
By scrolling down the window with the cursor, all the items can be seen.
In this section, only the items inherent to the axis range limit function are
explained. For the items not mentioned here, please refer to chapter 4.8
“Common Setting Item for the Condition File” .
1. AXIS
All the axis existing in a control group selected at {GROUP} item are
indicated. (8 axes at maximum)
2. SETTING
To one object axis, validating/invalidating of the monitoring can be set.
This setting is referred when the condition file is valid for monitoring, and
is not referred when it is invalid for monitoring.
Followings show the combination of conditions.
File monitoring Axis monitoring Result
status status
Valid Valid Monitoring of the object axis is valid.
Valid Invalid Monitoring of the object axis is invalid.
Invalid Valid Monitoring of the object axis is invalid.
Invalid Invalid Monitoring of the object axis is valid.
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3. MAX, MIN
Values for maximum/minimum range of motion can be input for the
object axis.
As their inputting range, with the axis’s home position defined as 0,
the position value limited by the soft limit switch of the manipulator can
be input.
When the axis is a rotating axis, it is measured in [deg], and is [mm]
when the axis is a direct acting axis.
Value Description
Minimum value Expresses the limited range in which an axis moves in the
negative direction.
In case the following inequality is true, adding an positive value
to the minimum value is possible.
The minimum value < The maximum value
Maximum value Expresses the limited range in which an axis moves in the
positive direction.
In case the following inequality is true, adding an negative
value to the minimum value is possible.
The minimum value < The maximum value
To a T-axis or to a positioner to which an mechanical stopper is not

equipped, there may be a case where an value which exceeds +-360
[deg] can be input.
In this case, the maximum/minimum range are limited by the basis of
numerical range but not by the basis of visual range.
For example, when 420 [deg] is set as the maximum value, the axis
positions at 60 [deg] and 420 [deg] visually look as they are at the same
position. However, even if the axis passed through the 60 [deg] position
it will not be defined as an error and an error is detected when the axis
reaches just before the 420 [deg] position.
Fig. 4-2: When the Axis Limit Value Exceeds ±360 [deg]
0 [deg] 60 [deg] No Alarm
420 [deg] Alarm !
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4. BOUNDARY
Specifies whether the range of motion of the axis includes or excludes
the maximum value and/or the minimum value.
The maximum value and the minimum value of each axis can be speci-
fied independently. To include the value in the range, select IN. To
exclude the value from the range, select EX.
Value Description
IN Range of motion is set including the maximum/minimum value of the axis.
• When including the maximum value:
(Range of motion of the axis ≤ Maximum value)
• When including the minimum value:
(Minimum value ≤ Range of motion of the axis)
EX Range of motion is set excluding the maximum/minimum value of the axis.
• When excluding the maximum value:
(Range of motion of the axis < Maximum value)
• When excluding the minimum value:
(Minimum value < Range of motion of the axis)
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4.1.4 Confirming Method of Each Axis Operating Angle

Each axis angle information can be confirmed on the CURRENT
POSITION window.
Follow the procedures below when confirming the manipulator’s present
angle.
1. Set the security mode to the management mode or higher.
Select {SETUP} under the main menu.
2. Select {FUNCTION ENABLE} in the sub menu.

– The FUNCTION ENABLE SETTING window appears.
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3. Set “VALID” to {ALL AXES ANGLE DISP FUNCTION}.
4. Select {ROBOT} under the main menu.
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5. Select {CURRENT POSITION} in the sub menu.

– CURRENT POSITION window opens.
6. While CURRENT POSITION window is appeared, select {DISPLAY}

tab at the upper left side of the window.
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7. Select {ABSOLUTE ANGLE} in the list under the {DISPLAY} tab.

– On {CURRENT POSITION} window, absolute angles of the axes
which exist in the present system is displayed.
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4.1.5 Confirmation of Safety Range

Confirmation of the monitoring operation to be appropriately performed
inside the specified safety range is required after values are set to both
{MAX} and {MIN} and {WRITE} is executed.
“CONFIRMING” is indicated to the status of the condition file on the axis
range limit window. Move the axes of the object group to confirm that they
stop within the specified safety range.
When confirming the safety range, move the axes of the object group into
the safety range, and then activate the monitoring operation of the
condition file by either setting “VALID” for the FILE VALID COND or by
inputting a selected safety signal to the condition file.
Fig. 4-3: Display When Confirming
In the functional safety function, the range of motion is mon-

itored by calculating the coasting values of the manipulator
NOTE or the external axis. (Refer to chapter 6.2 “External Axis
Coasting Value Setting” .) For this reason, the manipulator
stops just before exceeding the safety range in case it
moves to the teaching point near the safety range.
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4.1.6 Start the Axis Range Limit Operation

After confirming that the object axis moves to reach the edge of the
specified safety range, select {CONFIRM} on the window. “COMPLETE”
appears in “FILE SET STAUTS”, and the axis range limit can be
performed.
Execute playback operation to confirm the manipulator’s motion. An
alarm may occur in case the teaching point or the settings are
inappropriate.
When “Alarm 4780: F-SAFE AXIS RANGE LIMIT INTF” or
“Alarm 4781: AXIS RANGE LIMIT INTF” appeared
<Cause>
The position of the axis is out of the safety range or a range of motion
error is detected when the axis moved.
In the functional safety function, the axis position is monitored on the
basis of the feedback pulse from the motor. In this case, taking the axis
speed or coasting value into consideration, calculation of the movement
is executed so that the manipulator would not come out from the safety
range.
For this reason, in case a teaching point is set close to the edge of the
safety range, and when the teaching speed is high, this alarm occurs.
<Countermeasure>
Confirm the safety range.
Modify the teaching point so that it moves not to close to the safety
range border.
Decrease the manipulator’s teaching speed when it passes by the bor-
der of the safety range.
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4.1.7 Monitoring Status Confirmation Display

Settings of the configuration files (32 files) of the AXIS RANGE LIMIT can
be checked as the list of the set values for each axis of the specified
control group.
1. Select {SAFETY FUNC.} under the main menu, and then select {AXIS
RANGE LIMIT}.
2. Select {DISPLAY}, and then select {MONITOR}.
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3. The AXIS RANGE LIMIT MONITOR window appears.

– Scroll the window to the right to see the rest of the items.
4. Items shown in the window are described below.

1. CTRL GROUP
Select the control group which includes the axis to be checked.
2. AXIS
Select the axis to be checked.
3. CURRENT POSITION
Indicates the manipulator’s current position.
4. FILE
Indicates the file number for the axis range limit function.
5. MAX/MIN
Indicates the maximum/minimum value set for the file.
6. VALID
Indicates the monitoring status of the file. ( : invalid, : valid)
7. RANGE
Indicates whether the axis is located within the range set in the file.
( : out of the range, : within the range)
WARNING
• This indication is not a safety signal. To confirm the safety status,
make sure to use the safety output signal.
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8. OUTPUT SIGNAL
Indicates the output signal set in the file.
9. COMMENT
Indicates the comment set in the file.
This window displays only the file(s) in which the selected axis is set as
“valid”. If no file for the axis range limit function is set, this window
displays nothing.
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4.2 Axis Speed Monitor Function
4.2.1 Outline
Axis speed monitor function is a function which sets the upper limit of the
speed to each axis motion speed for the manipulator, base and station
group, and then monitors whether each axis is inside the already-fixed
speed using a software. When “0” is set, it is called stop position
monitoring. This monitors the axis whether it does not move to exceed the
limit of specified range from the point where the monitoring is started.
any one control group is set to a file. When a control group is set to
Fig. 4-4: Monitoring of Motion Speed at Each Axis
Monitors each axis

motion speed
Follow the procedures below when starting the axis speed monitor
function.
1. Set the axis speed monitor condition file.
2. Start monitoring the axis speed.
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4.2.2 Axis Speed Monitor Function Window

Followings are the setting procedures for the axis speed monitor function.
2. Select {AXIS SPEED MONITOR} in the sub menu.

– The list of the axis speed monitor status appears.
On the status list window, the 32 configuration files for the axis speed limit
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1. FILE
2. GROUP
The control group to be monitored set by the condition file
3. STATUS
Monitoring status of the present condition file
Value Description
(FILE) status.
INVALID Data setting is completed and monitoring status of the file is in invalid
(FILE) status.
(SIGNAL) status by the disestablishment of the safety signal condition.
4. COMMENT
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4.2.3 Axis Speed Monitor Condition File Setting

press [SELECT].
– The settings window for the selected condition file of the axis speed
monitor function appears.
<When the unit of the speed is deg/sec>
<When the unit of the speed is %>
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In this section, only the items inherent to AXIS SPEED MONITOR are
1. AXIS
All the axis existing in a control group selected at {GROUP} item.
2. SETTING
To one objective axis, validating/invalidating of the monitoring can be
set.
This setting is referred when the condition file is valid for monitoring, and
is not referred when it is invalid for monitoring.
Followings show the combination of conditions.
File monitoring Axis monitoring Result
status status
Valid Valid Monitoring of the object axis is valid.
Valid Invalid Monitoring of the object axis is invalid.
Invalid Valid Monitoring of the object axis is invalid.
Invalid Invalid Monitoring of the object axis is valid.
3. Unit of the speed

The unit of the speed can be specified in the settings file.
When “deg/s” is set as the unit of the speed, [deg/sec] is used for a
rotating axis, and [mm/sec] is used for a linear-motion axis.
When “%” is set as the unit of the speed, percentage is used.
4. SPEED
To each object axis, set the upper limit of motion speed.
When “deg/s” is set as the unit of the speed, [deg/sec] is used for a
rotating axis, and [mm/sec] is used for a linear-motion axis.
When “%” is set as the unit of the speed, calculate and set the upper
limit by considering the maximum speed as 100%. This unit [%] is the
same as the unit of the set value used when the object axis is inde-
pendently operated by MOVJ=xx%.
5. ACCEP. RNG
When “0” is set to {SPEED}, setting a value to this item becomes possi-
ble.
This item is used when the axis is in the stop position monitoring status.
The stop position monitoring operation judges that the axis is not mov-
ing by monitoring the object axis position difference between the stop
position monitoring starting position and the present position.
To avoid any alarms from occurring due to tiny motions such as turning
ON of the servo during the monitoring, this item is set.
An alarm occurs when {ACCEP.RNG} is set in ± direction from the stop
position monitoring starting position and the axis moves to exceed the
position.
When the axis is a rotating axis, the unit is [deg], and when the axis is a
linear-motion axis, the unit is [mm].
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4.2.4 Start the Axis Speed Monitor Operation

After values are input to “SPEED” and {WRITE} on the window is selected,
“COMPLETED” appears in “FILE SET STATUS”. After that, the axis
speed monitor can be performed.
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4.3 Robot Range Limit Function
4.3.1 Outline
The robot range limit function is a function which carries out following
monitoring using software.
1. Define the manipulator’s range of motion with polygonal prism or
cuboid, and then monitors the manipulator arm or its tool to be inside
the range of motion.
→Inside the range monitoring
2. Define the manipulator’s approach-prohibited area with polygonal
prism or cuboid, and then monitors whether the manipulator arm or its
tool does not move inside the area.
→Outside the range monitoring
3. Limit the manipulator’s range of motion with a large enough plane
(wall), and then monitors the manipulator arm or its tool so as not to
interfere with the plane.
→Planar interference monitoring
<Inside the range monitoring>

The manipulator’s range of motion can be defined using the prism from
triangular prism to 16-prisms. The space inside the prism is defined as
the safety range.
There are two ways of specifying the prism as follows:
– A polygon on the XY plane with a height in Z-axis direction.
– A cuboid consists of two points on a diagonal line.
When the result of the monitoring is safe, the object arm and the tool of
the manipulator are inevitably inside the safety range.
Fig. 4-5: Inside the Range Monitoring
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<Outside the range monitoring>

The manipulator’s range of motion can be defined using the prism with
triangular prism and quadrangular prism. The space outside the prism
is defined as the safety range.
There are two ways of specifying the prism as follows.
-A polygon on the XY plane with a height in Z-axis direction.
-A cuboid consists of two points on a diagonal line.
When the result of the monitoring is safe, the object arm and tool of the
manipulator are inevitably outside the safety range.
Fig. 4-6: Outside the Range Monitoring
<Planar interference monitoring>

Draw a line on either XY, YZ or ZX coordinate plane, and then, along the
line, set a plane (wall) in the vertical direction. A plane, which is large
enough to the manipulator, is specified. Regarding the plane as a
boarder, the area where the manipulator exists is defined as the safety
range. The plane is defined by specifying a coordinate plane and two
points for drawing a line.
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While a manipulator is in operation, based on the manipulator motion

speed, this function calculates the coasting value in case of the immediate
stop by the alarm, and then, including this value, this function monitors the
safety range. With this monitoring operation, the axes would not exceed
the safety range even if a motion error is detected.
Thirty two files are prepared to this function and any one control group and
a safety range is set to a file. When a control group is set to several files,
the control group can be monitored by switching conditions.
Follow the procedures below when starting the robot range limit function.
1. Set the coasting value.

(Before using this function, set the coasting value by following the
procedures described in chapter 6.2 “External Axis Coasting Value
Setting” in case the base axis or the station axis exits in the system.)
2. Set the tool file.
(Before using this function, execute tool file setting by referring to
chapter 6.3 “Tool File Setting” .)
3. Set the tool interference file.
(Before using this function, execute tool interference file setting by
referring to chapter 6.4 “Tool Interference File Setting” .)
4. Set the robot range limit function.
6. Start the robot range limit function.
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4.3.2 Robot Range Limit Function Window

2. Select {ROBOT RANGE LIMIT} in the sub menu.

– The list of the robot range limit status appears.
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Valid/invalid the robot range limit function. When “ON” is selected, the
condition files of the 32 files of this function can be set to invalid tempo-
rarily.
Value Description
OFF The robot range limit function is valid.
ON The robot range limit function is invalid.
The play back, test run, forward/backward operation become prohibited.
For the details, please refer to chapter 6.1 “Function Disable Mode Setting” .
2. FILE
3. GROUP
The control group to be monitored specified by the condition file is indi-
cated.
4. STATUS
Value Description
CONFIR Confirming the area after the data is set. The status of the
MING monitoring operation depends on the valid condition of the condition
file.
(FILE) status.
(FILE) invalid status.
(SIGNAL) invalid status by the disestablishment of the safety signal condition.
5. RANGE
Result of the present monitoring is displayed.
Value Description
Safe Result of the object file monitoring is safe (inside the safety range) is
safe (inside the safety range)
Not-safe Result of the object file monitoring is not-safe (outside the safety
range)
- The object file is in monitoring invalid status.
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6. CPU LOAD
The robot range limit function can, to some extent, freely define the
shape as its range of motion. However, the time period needed for pro-
cessing the monitoring varies depending on the shape or the method of
monitoring.
Regard the allocated processing time for robot range limit function as
100%, the ratio of necessary processing time for the area created in the
object area is indicated to this item.
Followings are processing time for each area created in the object area.
Monitoring method Numbers of point Processing time
Inside the area 4 20%
8 23%
16 30%
Outside the area 3 18%
4 20%
4 (Cuboid) 18%
Plane (X-Y) - 8%
Plane (Y-Z) - 8%
Plane (X-Z) - 8%
7. TOTAL
Total {CPU LOAD} of the files to which monitoring is validated.
When executing the robot range limit function even after the
total cpu load exceeded over 100%, following alarms may
occur due to insufficient processing time.
Alarm 500 SEGMENT PROC NOT READY
NOTE
Alarm 1899 F-SAFE MONITOR EXECUTE TIMEOVER
When an alarm occurred, reduce the area where the moni-
toring is simultaneously validated to avoid the cpu load from
exceeding 100%.
8. COMMENT
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4.3.3 Robot Range Limit Function Condition File Setting Window

press [SELECT].
A setting window for the selected condition file of the ROBOT RANGE
LIMIT function appears.
On this window, the indication pattern on the window changes depending
on the selection of {MONITOR TARGET} or {SHAPE TYPE}. For the
details of the indication, please refer to the table below.
MONITOR TARGET SHAPE TYPE Indication

INSIDE, OUTSIDE PRISM Pattern A
CUBOID Pattern B
Plane (X-Y), (Y-Z), (X-Z) - Pattern C
 Pattern A
Following is the pattern A of the indication of condition file setting window.
By scrolling down the window with the cursor, all the indication can be
seen.
On this window, the polygonal prism is defined with the following two
steps.
STEP 1: Define a polygonal prism on the X-Y plane.
STEP 2: Specify 2 points on the Z-axis to define them as the height
for the polygonal prism on the X-Y plane.
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Fig. 4-8: Image of Robot Limit Range: Pattern A
Point1
Point2
Point6
Point3
Point5
Z Upper
Y
Point4
Z Lower

In this section, only the items inherent to robot range limit functions are
1. MONITOR TARGET
To the area of the object file, set the monitoring method.
Value Method
INSIDE Set the inside range monitoring.
OUTSIDE Set the outside range monitoring.
Plane (X-Y) Set the planar interference monitoring (X-Y)
Plane (Y-Z) Set the planar interference monitoring (Y-Z)
Plane (X-Z Set the planar interference monitoring (X-Z)
2. COORD
Specify the coordinates system to be monitored.
Value Method
ROBOT Define the monitoring area on the robot Cartesian coordinate
system.
BASE Define the monitoring area on the base Cartesian coordinate
system.
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Setting Example of Coordinate “Robot”: When setting the

area shown in fig. 4-9 “Area Setting (Robot)” .
Fig. 4-9: Area Setting (Robot)
For the area 1, as shown in fig. 4-10 “Example of Condition File Setting
(R1: Robot)” , select R1 to CTRL GROUP and ROBOT to COORD. Also,
to each POINT, set positions which are on the R1 Cartesian coordinates.
(R2: Robot)” , select R2 to CTRL GROUP and ROBOT to COORD. Also,
to each POINT, set each position which are on the R2 Cartesian
coordinates.
Fig. 4-10: Example of Condition File Fig. 4-11: Example of Condition File
Setting (R1: Robot) Setting (R2: Robot)
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When setting a position to a POINT, confirm the position following the

procedures below.
1. Select {ROBOT} → {CURRENT POSITION} under the main menu.
– The CURRENT POSITION window appears.
2. Select {ROBOT} at {COORDINATE}.
3. Set the Cartesian position indicated on the window to each POINT.
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Setting Example of Coordinate “Base”: When setting the

area shown in fig. 4-12 “Area Setting (Base)” .
Fig. 4-12: Area Setting (Base)
(R1: Base)” , select R1 to CTRL GROUP and ROBOT to COORD. Also,
to each POINT, set positions which are on the R1 Cartesian coordinates.
(R2:Base)” , select R2 to CTRL GROUP and ROBOT to COORD. Also, to
each POINT, set each position which are on the R2 Cartesian coordinates.
Fig. 4-13: Example of Condition File Fig. 4-14: Example of Condition File
Setting (R1: Base) Setting (R2:Base)
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When setting a position to a POINT, confirm the position following the

procedures below.
1. Select {ROBOT} → {CURRENT POSITION} under the main menu.
2. Select {ROBOT} at {COORDINATE}.
3. Add the Cartesian position indicated at <ORIGIN> to the Cartesian

position indicated on the window, and then set the sum of the position
to each POINT.
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3. SHAPE TYPE
Specify the creating method of the monitoring area.
If either Plane (X-Y), Plane (Y-Z) or Plane (X-Z) is set to {MONITOR
TARGET},
this item is invalid.
Value Method
PRISM Create lines between the created points to specify the area for
the range of motion.
For inside the range monitoring, up to 16 points can be specified.
For outside the range monitoring, up to 4 points can be specified.
CUBOID Specify two points, and then create a cuboid whose diagonal line
is created by those points.
This cuboid is specified as the area for the range of motion.
4. CPU LOAD
Please refer to “6. CPU LOAD” in chapter 4.3.2 “Robot Range Limit
Function Window” .
5. USED POINT NUM
Specify the numbers of points for creating a polygonal prism.
For the inside the range monitoring, from 3 to 16 can be input.
For the outside the range monitoring, from 3 to 4 can be input.
Ex. For triangular prism, input “3”.
For 16-prisms, input “16”.
6. POINT (X,Y)
Specify points on the X-Y plane to define a polygonal prism.
(Point 1 to 6 in fig. 4-8 “Image of Robot Limit Range: Pattern A” .)
The points are connected in ascending order like “POINT 1 →POINT
2→POINT3.....”. And the line of these points becomes the wall of the
range of motion. Take this procedures into consideration before speci-
fying the points.
The numbers of the points is specified by the settings of {USED POINT
NUM}. The last number of the point is connected to the first one.
7. Z UPPER, Z LOWER
Specify the height of the polygonal prism. (Z Upper and Z Lower in
fig. 4-8.
When “0 [mm]” is set to both the Z UPPER and the Z LOWER, the
height in the Z-axis direction is set to infinite (polygonal prism of infinite
height.
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 Pattern B
Following is the pattern B of the indication of condition file setting window.
seen.
On this window, the cuboid is defined with the following two steps.
STEP 1: Define two points (point 1 and point 2) on the X -Y - Z plane
to create a cuboid by regarding the connected line as its diagonal
line.
STEP 2: A cuboid area is automatically created based on the specified
two points.
Fig. 4-15: Image of Robot Limit Range: Pattern B
POINT 1
POINT 2

Please refer to ■ “Pattern A” or chapter 4.8 “Common Setting Item for
the Condition File” for the items not explained here in
■ “Pattern B” .
8. POINT (X, Y, Z)
Specify two points on a object coordinates system, and then a cuboid is
created whose diagonal line is specified by the points.
In case any two point values input in either X, Y or Z are overlapped, the
setting is regarded as an error.
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 Pattern C
Following is the pattern C of the indication of condition file setting window.
seen.
On this window, a plane is defined with the following two steps.

STEP 1: Define a straight line with two points (point 1 and point 2)
on any of the selected X-Y, Y-Z or X-Z plane.
STEP 2: In a vertical direction, a plane (wall) is specified along the
straight line which was defined in the STEP 1.
A plane, which is large enough to the manipulator, is specified.
Fig. 4-16: Image of Robot Limit Range: Pattern C (Area inside Dotted Line
Is Non-safety Area)
POINT 1
POINT 2
X-Y plane
POINT 1
POINT 2 POINT 2
X-Z plane Y-Z plane

POINT 1
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Please refer to ■ “Pattern A” or chapter 4.8 “Common Setting Item for
the Condition File” .
9. POINT (X,Y), (Y, Z) or (X,Z)
Specify two points to draw a straight line on a coordinate plane selected
at “MONITOR TARGET”.
In case the coordinates of these two points overlapped, the setting is
regarded as an error.
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4.3.4 Confirmation of the Safety Range

After the safety range is specified and {READ} is pressed, it is necessary
to confirm whether the monitoring is appropriately performed inside the
range.
“CONFIRMING” is indicated at “FILE SETSTATUS” on the robot range
limit window. Set “VALID” to the object file by the file setting or signal
condition.
Move the object manipulator or external axis to confirm whether it stops
inside the specified safety range.
Fig. 4-17: CONFIRMING Window
<Confirm Safety Range with Jog Operation>

With the jog operation, confirm whether the specified safety range is
appropriate.
○Inside the range monitoring
Move the manipulator inside the specified four walls and check that it
stops just in front of the wall. In case the area is not a cuboid, check
that it stops just in front of all walls.
Fig. 4-18: Inside the Range Monitoring
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○Outside the range monitoring

To the walls, move the manipulator toward all the direction where it can
make approach and check that it stops just in front of all each wall.
○Planar interference monitoring

To the specified plane, make the manipulator approach to it. And con-
firm that the manipulator stops at any three points on the plane.
Fig. 4-20: Planar Interference Monitoring
In the functional safety function, the range of motion is mon-

itored by calculating the coasting values of the manipulator
NOTE or the external axis. (Refer tochapter 6.2 “External Axis
Coasting Value Setting” .) For this reason, the manipulator
stops just short of the safety range in case it moves to the
teaching point near the safety range.
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4.3.5 Starting the Robot Range Limit

After the manipulator is confirmed that it moves to its robot range limit,
press {CONFIRMED} on the window. The robot range limit function
becomes valid.
Execute the play back operation of the practical movement. An alarms
may occur due to inappropriate settings or teaching point setting.
In case “Alarm 4783: F-SAFE ROBOT RANGE LIMIT INTF” or
“Alarm 4784: ROBOT RANGE LIMIT INTF” appeared
<Cause>
The positions of the robot and the tool are out of its safety area, or an
axis range limit error is detected when the manipulator started moving.
Inside the robot range limit, taking the feedback speed or the coasting
value which were detected by the functional safety function, into consid-
eration, calculation of the movement is executed so that the manipulator
would not come out from the safety range. For this reason, when a
manipulator moves close to the border of the range, this alarm occurs
because the higher its teaching speed becomes, the more its coasting
value increases.
<Countermeasure>
Check that the safety range is appropriately set.
Execute the teaching operation so that the manipulator dose not
approach close to the border of the range.
Decrease the teaching speed near the border of the range.
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4.3.6 Switch the Monitoring Area

When switching the monitoring area using the safety signal input, execute
the switching operation after moving the manipulator to be inside the next
monitoring area and stopping it completely.
When executing inside the range monitoring at multiple ranges, set the
overlapped range and execute the switching only when the manipulator is
inside the overlapped area.
Fig. 4-21: When Switching the Monitoring Area
First area
Second area
Area where the switching

peration is possible
When monitoring operation is validated to multiple areas at a time, the

overlapped area is regarded as the safety range.
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Inside the monitoring area + Inside the monitoring area

Fig. 4-22: Simultaneous Monitoring: Multiple Areas (Inside the Monitoring
Area + Inside the Monitoring Area)
Inside the monitoring area + Outside the monitoring area

Fig. 4-23: Simultaneous Monitoring: Multiple Areas (Inside the Monitoring
Area + Outside the Monitoring Area)
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4.3.7 Safety Range and Manipulator Position

On the operation area monitor window, the specified safety range and the
manipulator’s present position can be roughly depicted on the
programming pendant screen so that their position relation can be
confirmed.
Follow the procedures below to open the operation area monitor window.
The data to which {WRITE} button is not yet pressed would

not be reflected on the OPERATION AREA MONITOR win-
dow in case this window is opened while the robot range
NOTE
limit condition file is being edited.
Be sure to complete the editing operation before opening
the window.
The operation area can be displayed on the 3D graphic dis-

SUPPLE
play window. For further settings, refer to “YRC1000 GEN-
-MENT ERAL OPERATOR’S MANUAL (RE-CSO-A051) 6.19.1 3D
Graphic Display Function”.
1. Select {SAFETY FUNC.} under the main menu.
2. Select {OPERATION AREA MONITOR} under the sub menu.

– The OPERATION AREA MONITOR window appears.
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A. Plane X-Y, Y-Z, X-Z
The plane shown on the window now.
The manipulator and its tool are depicted in the approximate model
shape specified set to the robot parameter and to the tool interference
file.
When the manipulator is floor-mounted type, each figure indicates as
follows;
X-Y: top view of the manipulator
Y-Z: back side view of the manipulator
X-Z: left side view of the manipulator
B. ROBOT
The number of the manipulator is indicated.
C. TOOL
The tool number specified to the manipulator shown on the window is
indicated.
D. COORDINATES
The coordinates of the safety area shown on the window is indicated.
Value Description
Base Base coordinates
Tool Tool coordinates
E. Monitor
Monitoring method for the safety range shown on the window is indi-
cated.
Value Description
Inside Perform the inside range monitoring
Outside Perform the outside range monitoring
Plane (X-Y) Perform the plane interference monitoring
Plane (Y-Z)
Plane (X-Z)
F. FILE No.
The number of condition file of the robot range limit function. Inputting
value from 1 to 32 can switch the condition file.
G. Center X, Center Y, Center Z
Specifies the center point coordinates in the depictable range on the
plane. When the plane X-Y is shown on the window, the manipulator is
depicted on the plane with the center of the plane (X,Y) coordinates at
its center. Unit: [mm].
H. Size
Length of one side of the depicting area is specified. Unit: [mm].
I. Zoom
Scale the indicated plane. Magnification can be selected among 0.125,
0.25, 0.5, 1, 2, 4 and 8.
When 2 is selected as its magnification, the scale of the apparent size of
the plane becomes double and becomes half when 0.5 is selected.
In case the value of “CENTER” or “SIZE” is modified, the magnification
at “ZOOM” returns to 1.
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J. {Front/Back} button
It is indicated only when Y-X plane indication is set. The view of the
plane changes from manipulator front view to back view each time this
button is pressed.
K. {Left/Right} button
It is indicated only when Y-X plane indication is set. The view of the
plane changes from manipulator right side view to left side view each
time this button is pressed.
L. {CHANGE PLANE} button
The plane on the window alternates every time this button is pressed.
(X-Y → Y-Z→ X-Z→ X-Y)
However, this button is invalid when “Plane *-*” is specified for “Monitor”
because the plane view is fixed.
M. {Exit} button
Closes the operation area monitor window.
<Details of the Plane on the Window>

○ Example of X-Y plane (Indication of Y-Z and X-Z are also the same
when monitoring the plane.)
On the X-Y plane, the safety range is shown as the white area and not
safety area is shown as brown area. The borders between the areas
are indicated in colored lines and this lines are regarded as the wall.
The manipulator model and the tool model:
– contacting with the wall are indicated in red.
– inside the safety area are indicated in white.
– inside the not safety area are indicated in gray color.
The plane defined as Z upper or Z lower on the X-Y plane are not indi-
cated.
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○ Example of Y-Z and X-Z planes
Each Y-Z and X-Z plane indicates the side of the safety area. On the Y-
Z and X-Z planes, only the “wall” looked in the short from the view point
is indicated.
The manipulator model and the tool model:
– seen opposite side of the “wall” are indicated in gray color.
– seen in front of the “wall” are indicated in white.
– contacting to the “wall” are indicated in red.
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4.3.8 Proximity Warning Buzzer Setting

A warning buzzer sounds and a message “Approaching the non safety
area” when the manipulator approaches a certain distance to the
boundary of the non safety area. The distance object of detection can be
modified on the approach warning buzzer window. The default distance is
set to 50 [mm].
Also, the approaching status can be output as a user output signal. (The
signal is turned ON when the manipulator is detected to be in the specified
distance.) This output can be also specified on the approach warning
buzzer window. This is not set in the default settings (signal is not output).
Follow the procedures below for opening the approach warning buzzer
window.
1. Set the security mode to safety mode and then, select {SAFETY
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3. Select {UTILITY} → {APPR WARNING BUZZER}.

– The APPROACH WARNING BUZZAR window appears.

1. BUZZER DIST.
Specify a manipulator approaching distance to sound a buzzer.
Unit: [mm]
2. UNIV-OUT NO.
Specify an user output signal number for outputting the status of
detecting the approach. When “0” is set, “****” is displayed and no sig-
nal is output.
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4.3.9 Combining Function of Multiple Monitoring Areas

This function creates a new monitoring areas by combining two already-
specified monitoring areas.
Follow the procedures below for this operation.
1. Set the security mode to safety mode, and then select {SAFETY
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3. Select {UTILITY} → {RANGE COMBINATION}.

– The RANGE COMBINATION window appears.

1. INPUT FILE1, INPUT FILE2
Specify the file number of the range to combine.
Value Description
Range 1 to 32 Select the number of the range to be input from 1 to 32.
2. LOGIC
Logic for combining the areas.
Value Description
AND Combine the selected two areas with the logic of “AND”.
OR Combine the selected two areas with the logic of “OR”.
○Combination with “AND”

The overlapped area by the combination of two safety areas is created
as a new monitoring area.
Fig. 4-24: Image: Combined Area with “AND”
First area
Second area Combined area
AND
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○Combination with “OR”

The whole area consists of two safety areas is created as a new moni-
toring area.
Fig. 4-25: Image: Combined Area with “OR”
First area Combined area
Second area
OR
3. OUTPUT FILE
Specify the file number of the combined area.
For the file number to be output, choose a file to which the monitoring
operation is set invalid because the file number is overwritten.
In case choosing a file to which the monitoring operation is set valid, an
error occurs.
Value Description
Range 1 to 32 Select the number of the range to be output from 1 to 32.
<Combining restrictions>
Combination of the areas are not executed when:
• The two areas are not connected
• Inside the range monitoring and the outside the range monitoring are
selected.
• The robot coordinates and the base coordinates are selected.
• The height of each area is different and “OR” is selected as their
logic.
• Same file number is specified at {INPUT FILE} and {OUTPUT FILE}
• The shape of the range specified to the input file is not convex.
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4.4 Speed Limit Function
4.4.1 Outline
Speed limit function is a function which sets the upper limit of the robot
group control point (TCP: Tool Center Point) speed and flange center point
(FCP) speed, and then monitors whether the speed at each point dose not
exceed the already-fixed speed using a software.
When applying the function to a station group, the upper limit is set for the
motor rotating speed.
Fig. 4-26: TCP (Tool Center Point) and FCP (Flange Center Point)
When “0” is set to speed limit, it is called stop position monitoring. The
manipulator or the station group can be monitored by stop position
monitoring.
For the manipulator group, the stop position monitoring is performed to
TCP or FCP to confirm each point does not move.
For the station group, the stop position monitoring is performed to each
axis position to confirm each axis does not move.
When the function file of the speed limit function is validated and in case
the taught speed is faster than the limited speed, the speed is decreased
to the limited speed, and the monitoring starts.
The time for decreasing the speed varies depending on the manipulator
type or teaching conditions. For this reason, in the functional safety
function, the period of time from validating the condition file to complete
decreasing is regarded as the detection delay time and this can be set to
the condition file.
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Fig. 4-27: Outline of Speed Limit Function
Speed
Detection Delay Time
Reference
Speed
Limit
Speed Alarm Detection
Period Time
Condition File Enable Condition File Disable

䠄Signal ON䠅䠄Signal OFF䠅
Safety Input Signal ON

State
OFF
Along with the above mentioned monitoring, when it is in the teaching
mode, the speed is always monitored to be 250 mm/sec as the teach
mode safety speed.
Follow the procedures below when starting the speed limit function.

2. Set the speed limit condition file.
3. Start the speed limit function.
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4.4.2 Speed Limit Function Window

2. Select {SPEED LIMIT} in the sub menu.

– The list of the speed limit status appears.
function are listed so that their status can be confirmed. By scrolling down
the window, all the list can be seen.
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1. TEACH STANDARD
Move the cursor to this item and press [SELECT] to display the list of
speed limit for the teach mode.
2. FILE
Displays the file number for each condition.
Move the cursor to a desired file number and press [SELECT] to display
the settings window of the condition file of the file number.
3. GROUP
Displays the object group for the monitoring for the present condition
file.
4. STATUS
Displays the present monitoring status of the condition file.
Value Description
Not monitoring yet.
(FILE) status.
(FILE) status.
(SIGNAL) status by the disestablishment of the safety signal condition.
5. COMMENT
Displays the input comment.
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4.4.3 Speed Limit Function Condition File Setting Window

1. On the status list window, select a file number with the cursor, and then
press [SELECT].
– The individual setting window for the speed limit function opens.
The display on the window varies which group is to be monitored; robot
group or station group.
<When the robot group is monitored>
<When the station group is monitored>
seen.
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In this section, only the items to the axis range limit are explained. For the
items not mentioned here, please refer to chapter 4.8 “Common Setting
Item for the Condition File” .
1. LIMIT SPEED
Specify the speed limit to the motion speed in the object group.
When the robot group is monitored, the limit speed is specified with the
unit [mm/sec].
When the station group is monitored, the limit speed is specified with the
unit [%]. The unit [%] is same as the set value of target axis single oper-
ation with MOVJ=xx%. For example, the target axis stops when 0% is
specified and moves with maximum speed when 100% is specified.
During speed limit, all axis speeds in the group is controlled under spec-
ified limited value [%]. As for station group which has several axes, the
fastest motion speed ([%]) axis in the group are limited in specified
speed. Other axes speed in the same group are also limited in same
ratio.
The speed limit function limits the rotation speed of the

motor axis in the station group.
The speed 100% is equivalent to the maximum rotation
speed of a motor (unit: rpm) specified in the maintenance
mode. (For the maximum rotation speed of a motor, refer to
“YRC1000 INSTRUCTIONS (RE-CTO-A221) 12.3 Addition
of Base and Station Axes”.)
The motion speed of the load axis is calculated with the
rotation speed of the motor and reduction ration in the
mechanisms as follows.
Rotation speed of the motor axis x Reduction ratio
= Rotation speed of the load axis
Also, the load shape should be considered for the motion
speed. In the case of the disc-like load applied around the
load axis, the motion speed becomes faster as the load is
applied in the outer periphery.
When the station group has two or more motor axes, the
NOTE load may be moved by several motors. In this case, the load
motion speed is determined by the composite speed of the
motors. This speed can be faster than the single motor
motion speed.
The composite speed at this part
Before using this function, set the limit speed so that the tar-
get part in the load side becomes in the acceptable speed
range and perform enough risk assessment.
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WARNING
In case the customer performs the setting for the station group, refer to
“YRC1000 INSTRUCTIONS (RE-CTO-A221) 12.3.2 Station Axis
Setting” and set the axis mechanical specification (the motor type, the
maximum rotation speed, etc.) properly.
If using the manipulator in improper setting, the safety function does not
operate normally and a serious accident may occur.
When limiting speed with low speed (0.1~5[mm/sec] or

0.1~5[%]), even during speed limit, F-SAFETY SPEED
LIMIT ERROR alarms may occur due to tiny motions such
NOTE
as turning ON of the servo.
When the situation requires, take measures, for example,
review limit speed or limit section, or use stop monitoring.
2. DETECTION DELAY TIME

Specify a time frame from validating the condition file to start the alarm
detection.
Even if the set value is “0”, 1 [sec] is detected as the detection delay
time since the default value is set to this item.
For this reason, when a value is specified to this item,1 [sec] + the spec-
ified value is regarded as the detection delay time.
3. ACCEPTABLE RANGE
This item can be specified when “0” is set to “SPEED LIMIT”. Also, this
item is used when the stop position monitoring is performed. Although
the stop position monitoring monitors the difference between the stop
position monitoring start position and the present position, to avoid any
alarms from occurring due to tiny motions such as turning ON of the
servo during the monitoring, “ACCEPTABLE RANGE” is specified.
An alarm occurs when the axis moves to exceed the position where the
acceptable range is added to the stop position monitoring start position.
When the robot group is monitored, it is measured in [mm].
and when the station group is monitored and the axis is a rotating axis, it
is measured in [deg], and is [mm] when the axis is a linear-motion axis.
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4.4.4 Starting the Speed Limit

Specify the speed limit function and press {WRITE} button, the speed limit
function becomes valid.
4.4.5 Speed Limit in Teach Mode

While the teach mode is selected, to strictly observe the safety speed, the
speed monitoring of 250 [mm/sec] is performed in the functional safety
function. Unlike other speed limit function, this monitoring function cannot
be set invalid by the condition file setting.
However, only when the full speed test is input by the external signal and
when the manual brake is released, this monitoring function can be set
invalid and the speed can be increased faster than 250 [mm/sec] even
during the teach mode.
For the full speed test, refer to “YRC1000 INSTRUCTIONS (RE-CTO-
A221) 8.26 Safety Logic Circuit”.
For releasing the manual brake function, refer to “YRC1000 OPTIONS
INSTRUCTINS FOR MANUAL BRAKE RELEASE FUNCTION
(HW1483370)”.
When using the full speed test or manual brake release

NOTE functions, possible risks attributed to the speed limit release
should be sufficiently considered (risk assessment) before
operating the manipulator.
The condition file setting window for the speed limit function in the
teaching mode opens by the following procedures.
1. Set the security mode to safety mode, and then select {SAFETY
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2. Select {SPEED LIMIT} in the sub menu.
3. Select {TEACH STANDARD}.

– A list of condition file of the teach mode speed limit appears.

1. LIMIT SPEED
It is fixed to 250 [mm/sec] and not modified.

detection. It is set as the time for decreasing the speed slower than 250
[mm/sec] when the full speed test function is released. Even if the set
value is “0”, 1 [sec] is detected as the detection delay time since the
default value is set to this item. For this reason, when a value is speci-
fied to this item,1 [sec] + the specified value is regarded as the detection
delay time.
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4.5 Tool Angle Monitor Function
4.5.1 Outline
The tool angle monitor function is a function that monitors the angle of the
tool by specifying the standard value of manipulator tool tilting angle and
the limit of the tool angle, and then, using the software, monitors whether
the standard value-centered tool angle does not exceed the specified limit
angle. In case the tool file is not specified, it monitors the titling angle of
the flange.
To the object manipulator group, the tool tilting angle which is regarded as
the reference for the monitoring is defined as “REF. ANGLE”. At this time
the tool posture is calculated on the basis of the base coordinates as its
standard. While the condition file is validated, this function monitors
whether the “REF. ANGLE”-centered angle of the tool does not exceed the
specified limit of the tool angle.
using the machine safety.
Fig. 4-28: TOOL ANGLE MONITOR (EX: Laser Welding Application)
Follow the procedures below when starting the tool angle monitor function.

2. Set values to {REF. ANGLE} and {LIMIT ANGLE}.
4. Start the tool angle monitor function.
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4.5.2 Tool Angle Monitor Function Window

Followings are the setting procedures for the tool angle monitor function.
2. Select {TOOL ANGLE MONITOR} under the sub menu.

– The list of the tool angle monitor status appears.
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Specify ON/OFF of the tool angle monitor function. When ON is set to
this item, this function can be temporarily invalidated.
Value Description
OFF The tool angle monitor function is valid.
ON The tool angle monitor function is invalid.
At the same time, playback, test-run, forward/backward
operations are prohibited.
For the details, refer tochapter 6.1 “Function Disable Mode Setting” .
2. FILE
3. GROUP
The control group to be monitored specified by the condition file
4. STATUS
Value Description
Not monitoring yet.
CONFIR Confirming the area after the data is set. The status of the monitoring
MING operation depends on the valid condition of the condition file.
(FILE) status.
(FILE) status.
(SIGNAL) status by the establishment of the safety input signal condition.
(SIGNAL) status by the disestablishment of the safety input signal condition.
5. COMMENT
The input comment is displayed.
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4.5.3 Tool Angle Monitor Condition File Setting

press [SELECT].
– A setting window for the selected condition file of the axis range
monitor function appears.
In this section, only the items inherent to the tool angle monitor function
are explained. For the items not mentioned here, please refer to
chapter 4.8 “Common Setting Item for the Condition File” .
1. REF. ANGLE
Input a tool angle as a reference value for the tool angle monitor func-
tion.
Follow the procedures below to confirm the present tool tilting angle.
1. Select {ROBOT} under the main menu.
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2. Select {CURRENT POSITION} under the sub menu.

3. Select “BASE” in the selection box under {COORDINATE}.
4. In the system where more than two tools are used, select tools when
the monitoring is performed.
(For the details, refer to “YRC1000 GENERAL OPERATOR’S
MANUAL (RE-CSO-A051) 2.3.4.1 Selecting Tool”.
5. Move the manipulator to be in the reference posture.
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6. Record Rx, Ry and Rz values.
7. Set the recorded Rx, Ry and Rz values to {REF. ANGLE} on the tool
angle monitoring condition file window.
2. LIMIT ANGLE
Regard the REF.ANGLE-centered tool angle, which is the object of
monitoring, comprises of an appraising vector of the reference angle
and the present tool angle. The approaching vector is indicated in the
following ways.
• When the tool file is specified:
The vector of ZT direction in the tool coordinates.
• When the tool file is not specified:
The vector of ZF direction in the flange coordinates.
Fig. 4-29: Approaching Vector
Input the upper limit of the angle θa which consists of the approaching
vector of the reference angle over the approaching vector of the present
position as the limit angle. The value from 0Ο to 90Ο can be input.
Fig. 4-30: Limit Angle of the Approaching Vector
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4.5.4 Confirmation of Tool Angle Limit Monitor

After the tool angle monitor is specified and {READ} is pressed, it is
necessary to confirm whether the monitoring is appropriately performed
inside the specified angle.
“CONFIRMING” is indicated at “FILE SET STATUS” on the tool angle
monitor window. Move the object manipulator to confirm whether it stops
inside the specified angle.
Fig. 4-31: Window for in CONFIRMING Status
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4.5.5 Starting the Tool Angle Monitor

After the manipulator is confirmed that it moves to its angle limit, press
{CONFIRMED} on the window. The robot range limit function becomes
valid.
Execute the practical job movement to confirm the followings.
1. Confirmation of the limit angle in the play mode
There may be following causes, in case an alarm occurred during the
play back operation of the operating job.
• Specified REF. ANGLE is not appropriate
• Specified LIMIT ANGLE is not appropriate
• Teaching operation is not appropriate
Re-set REF. ANGLE or LIMIT ANGLE, or correct the teaching operation.
In case “Alarm4792: F-SAFE TOOL ANGL MONITOR ERR” or

“Alarm4793: TOOL ANGL MONITOR ERR” appeared
<Cause>
The manipulator’s present posture exceeds the limit angle.
<Countermeasure>
Confirm the reference angle or the limit angle.
Modify the teaching point so that it moves inside the specified limited
angle.
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4.6 Tool Change Monitor Function
4.6.1 Outline
When performing monitoring functions of the safety such as the robot
range limit function or the speed limit function in the functional safety
function, appropriate tool information is required to be selected. In the
system where the tool change is required, the function safety function
changes the tool number in accordance with the specified value from the
master CPU.
This tool change monitor function monitors whether the tool is
appropriately changed. The monitoring is performed comparing the
master CPU-specified tool number and the tool number which is specified
to a safety signal -specified condition file. It is judged as an error when a
manipulator operates when these numbers are not consistent.
Sixteen files are prepared to this function and one tool number is set to
one file. This means that, for a robot group, up to 16 files can be set to
monitor the tool change.
NOTE Tool change monitor function cannot be used concurrently

with the tool number select function.
Follow the procedures below when starting the tool change monitor
function.

2. Set the tool interference file.
(Before using this function, execute tool interference file setting by
referring tochapter 6.4 “Tool Interference File Setting” .)
3. Set the tool change monitor function.
4. Confirm the tool change.
5. Start the tool change monitor function.
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4.6.2 Tool Change Monitor Function Window

Followings are the setting procedures for the tool angle monitor function.
2. Select {TOOL CHANGE MONITOR} under the sub menu.

– The list of the tool change monitor status appears.
On the status list window, the 16 configuration files for the axis tool
change monitor function are arranged so that their status can be
confirmed. By scrolling down the window, all the list can be seen.
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Specify ON/OFF of the tool change monitor function. When ON is set to
this item, this function can be temporarily invalidated.
Value Description
OFF The tool change monitor function is valid.
ON The tool change monitor function is invalid.
For the details, refer to chapter 6.1 “Function Disable Mode Setting” .
2. GROUP
The robot group to be specified by the condition file us selected from R1
to R8 (however, only the groups set to the YRC1000).
3. FILE
The number of the individual condition file is displayed.
A robot group object file selected at “GROUP” is displayed.
4. STATUS
Value Description
Not monitoring yet.
CONFIR Confirming the area after the data is set. The status of the monitoring
MING operation depends on the valid condition of the condition file.
(FILE) status.
(FILE) status.
(SIGNAL) status by the establishment of the safety input signal condition.
(SIGNAL) status by the disestablishment of the safety input signal condition.
5. COMMENT
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4.6.3 Tool Change Monitor Condition File Setting

press [SELECT].
A setting window for the selected condition file of the AXIS CHANGE
MONITOR function appears.
In this section, only the items inherent to tool change monitor function are
1. TOOL NO.
For confirming the tool number, specify a tool number which is specified
to the functional safety function, when this file is selected.

detection. It is detected as an error in case a tool change monitor condi-
tion file is selected and one of the following conditions are met after the
time specified in {DETECTION DELAY TIME} is passed.
The followings are the error judging conditions in the tool change
monitoring function.
• All the condition files for one robot group are invalidated.
• Two or more condition files for one robot group are simultaneously
validated.
• The manipulator is in operation while a tool number specifying value
and the tool number specifying value of the validated condition files
are not consistent.
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4.6.4 Confirmation of Tool Change Monitor

After the setting of the condition file and {READ} is pressed, it is
necessary to confirm whether the monitoring is appropriately performed
by the specified tool.
“CONFIRM” is indicated on the tool change window. “VALID” the file and
change the tool, and then move the object manipulator to confirm whether
a alarm occurs.
An alarm for the tool change monitor function occurs only

when the manipulator is in motion. (If it is in stop status,
NOTE monitoring is still performed but the alarm does not occur.)
However, once an alarm occurs, it keeps sounding unless
the problem is solved even the manipulator stops.
CAUTION
• Make sure that the robot is in a stopped state when performing a
tool-file change.
If the tool-file change is performed during a robot program
operation, the following may result:
– Danger caused by selecting an incorrect tool
– The manipulator’s motion speed exceeding the speed limit if the
types of the tools before and after the change are significantly
different
4.6.5 Starting the Tool Change Monitor

After the tool change is confirmed, press {CONFIRMED} on the window.
The tool change monitor function becomes valid.
CAUTION
• By a tool change, an monitoring error may be detected in the robot
range limit function due to the change of tool model or TCP. For this
reason, when changing a tool, specify appropriate range of motions
for the object tool.
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4.6.6 When Using the Tool Change Monitor Function

When using the tool change monitor function, this function should be
validated in the maintenance mode.
Follow the procedures below.
1. Select {SYSTEM} under the main menu, and then select {SECURITY}
to change the security mode to the safety mode.
2. Select {SYSTEM} under the main menu, and then select {SET} under
the sub menu.
– The SETUP window appears.
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3. Select “OPTION FUNCTION”, “Functional safety” and “DETAIL”.

– The Functional safety window appears.
4. Change to set {USED (CHANGE MONITOR)} for the item at {Tool

change monitor/Tool number select}.
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5. Press [ENTER], and a dialog box asking “Modify?” appears.

– Select “YES”.
– After changing, a dialog box asking “Initialize related files?” may
appear.
– If the setting related to functional safety has already specified, select
“NO”, if not, select “YES”.
– Select “YES”, and a dialog box asking “Initialize related files?”

appears.
“NO”. (When “YES” is selected, the setting related to functional
safety will be initialized.)
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6. Select {FILE} under the main menu, and then select {INITIALIZE}
under the sub menu.
– The INITIALIZE window appears.
7. Move the cursor and select “Safety Board FLASH Reset” on the
window.
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8. Select “YES” when a window shown below appeared.

– Data of the safety circuit board is reset. When resetting is
completed, a beep sounds in a few seconds.
9. Turn ON the controller power supply.
The following alarm may occur at the first start-up and operation of the
manipulator after validating the tool change monitor function because all
the tool change files are not specified yet.
“Alarm 4789: F-SAFE TOOL CHANGE MONITOR ERR”
Perform the tool change condition file settings, validate the tool change
monitoring function and reset the alarm.
CAUTION
• The tool change monitoring function is set to invalid at the default
status. For the appropriate safety monitoring, be sure to validate
the function and perform the monitoring.
This monitoring should be set valid to monitor that the tool is not
changed even if the tool file is not changed.
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4.7 Tool Number Selection Function
4.7.1 Outline
When performing monitoring functions of the safety such as the robot
range limit function or the speed limit function in the functional safety
function, appropriate tool information is required to be selected. This tool
number selection function selects the tool number used in functional
safety based on the safety signal.
NOTE Tool number selection function cannot be used concurrently

with the tool change monitor function.
Functional safety uses the tool number set in the condition file specified by
the safety signal. It is judged as an error when a manipulator operates
over a certain distance when the tool number is not selected or multiple
tool numbers are selected.
Sixteen files are prepared to this function and one tool number is set to
one file. This means that, for a robot group, up to sixteen files can be set
to select the tool number. In case an error is detected, the power supply
to the motor is stopped using the machine safety board. And the error is
notified using an alarm.
To maintain Safety Category 3 and PL-d in the safety moni-

NOTE toring in the functional safety function, the safety signal to
be used must meet the requirements of Safety Level SIL2
and PL-d.
CAUTION
• Connect the safety signal used to select the tool number so that the
tool connected to the manipulator can be specified by the pattern of
the safety signal. When an alarm occurs, confirm the connection of
the safety signal.
• Also, consider sufficiently that the correct tool number is selected
based on the connection of the safety signal, and the robot range
limit function and the speed limit function operate properly.
If an incorrect tool number is selected, the safety of the robot range limit
function and the speed limit function may be impaired.
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Follow the procedures below when setting the tool number selection.
(1) Set the tool file.
(Before using this function, execute tool file setting to select by
referring to chapter 6.3 “Tool File Setting” .)
↓
(2) Set the tool interference file.
(The selected tool is necessary to perform the robot range limit
function. Before using this function, execute tool interference file
setting by referring to chapter 6.4 “Tool Interference File Setting” .)
↓
(3) Set the tool number selection condition file.
↓
(4) Confirm the tool number selection.
↓
(5) Start the tool number selection.
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4.7.2 Tool Number Selection Function Window

Followings are the setting procedures for the tool number selection
function.
1. Change the mode to the security mode, and then press {SAFETY
2. Press {TOOL NUBMER SELECTION} in the sub menu.

– The list of the tool number selection status appears.
On the status list window, the sixteen setting files for the tool number
selection function are arranged so that their status can be confirmed. By
scrolling down the window, all the list can be seen.
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1. {FUCTION DISABLE MODE}
Specify ON/OFF of the tool number selection function. When ON is set
to this item, this function can be temporarily invalidated.
Value Meaning
OFF The tool number selection function is valid.
ON The tool number selection function is invalid.
For the details, refer to chapter 6.1 “Function Disable Mode Setting” .
2. {GROUP}
The robot group to be specified by the condition file is selected from
R1to R8 (however, only the groups set to the YRC1000).
3. {FILE}
The number of the individual condition file is displayed. A robot group
object file selected at {GROUP} is displayed. Move the cursor to any
number and press [SELECT]. The individual setting window for the
selected condition file appears.
4. {STATUS}
Value Meaning
SETTING The condition file is in the initial status or in the data setting
status.
The tool number is not selected yet.
CONFIRMING Confirming the area after the data is set. The tool number to
be selected depends on the valid condition of the condition file.
VALID Data setting is completed and the tool number selection by
(FILE) using the condition file is in valid status.
INVALID Data setting is completed and the tool number selection by
(FILE) using the condition file is in invalid status.
VALID Data setting is completed and the tool number selection by
(SIGNAL) using the condition file is in valid status by the establishment of
the safety signal condition.
INVALID Data setting is completed and the tool number selection by
(SIGNAL) using the condition file is in invalid status by the
disestablishment of the safety signal condition.
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4.7.3 Tool Number Selection Condition File Setting

press [SELECT].
– A setting window for the selected condition file of the tool number
selection function appears.
By scrolling down the window with the cursor, items which are not
displayed on the window can be seen.
In this section, only the items inherent to the tool number selection
function are explained. For the items not mentioned here, please refer to
chapter 4.8 “Common Setting Item for the Condition File” .
1. {TOOL NO.}
Specify a tool number which is specified to the functional safety func-
tion, when this file is selected.
2. {DETECTION DELAY TIME}
detection. It is detected as an error in case a tool number selection con-
dition file is selected and one of the following conditions are met after
the time specified in {DETECTION DELAY TIME} is passed.
The followings are the error judging conditions in the tool number selec-
tion function.
• All the condition files for one robot group are invalidated.
• Two or more condition files for one robot group are simultaneously
validated.
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4.7.4 Confirmation of Tool Number Selection

After the setting of the condition file and {WRITE} is pressed, it is
necessary to confirm whether the tool is correctly selected. "CONFIRM" is
indicated on the tool number selection window. "VALID" the file and move
the object manipulator to confirm whether an alarm occurs.
An alarm for the tool number selection function occurs only

when the manipulator is in motion. (If it is in stop status, the
NOTE alarm does not occur.)
However, once an alarm occurs, it keeps sounding unless
the problem is solved even the manipulator stops.
CAUTION
• Perform selecting the tool number while the manipulator is stop
status or there may following dangers when it is performed while the
manipulator is in operating status.
– Wrong tool may be selected.
– The manipulator motion speed exceeds the speed limit in case
the tool before the change and after the change differs widely.
4.7.5 Starting the Tool Number Selection

After the tool number selection is confirmed, press {CONFIRMED} on the
window. The tool number selection function becomes valid.
CAUTION
• By a tool number selection, a monitoring error may be detected in
the robot range limit function due to the change of tool model or
TCP.
For this reason, when selecting a tool, specify appropriate range of
motions for the object tool.
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4.7.6 When Using the Tool Number Selection Function

When using the tool number selection function, this function should be
validated in the maintenance mode.
Follow the procedures below.
1. Press {SYSTEM} under the main menu, and then press {SECURITY}
to change the mode to the security mode.
2. Press {SYSTEM} under the main menu. And then, press {SET} in the
sub menu.
– SETUP window appears.
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3. Select {OPTION FUNCTION}, {Functional safety} and “DETAIL”.

– Functional safety window appears.
4. Change to set “USED (NUMBER SELECT)” for the item at {Tool

change monitor/Tool number select}.
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5. Press [ENTER], and a dialog box asking “Modify?” appears.

– After changing, a dialog box asking “Initialize related files?
Functional Safety Related Files” may appear.
“NO”, if not, select “YES”.
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6. Press {FILE} under the main menu. And then, press {INITIALIZE} in
the sub menu.
– A window for initialization appears.
7. Move the cursor and select "Functional Safety Board FLASH Reset"
on the window.
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8. Select “YES” when a window shown below appeared.

– Data of the functional safety board is reset. When resetting is
completed, a buzzer sounds in a few seconds.

Following alarm may occur at the first start-up and operation of the
manipulator after validating the tool number selection function because all
the tool number selection files are not specified yet.
“Alarm 4789: F-SAFE TOOL CHANGE MONITOR ERR”
Perform the tool number selection file settings, validate the tool number
selection function and reset the alarm.
CAUTION
• The tool number selection function is set to invalid at the default
status. For the appropriate safety monitoring, be sure to validate
either of the tool change monitor function or the tool number
selection function and perform the monitoring.
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4.8 Common Setting Item for the Condition File

Although the condition files of the functional safety function exist by
functions, there are common setting items to many files such as VALID/
INVALID of the file.
Here, in this chapter, details of the common items are explained. For the
safety signal settings, refer to chapter 5 “Safety Signal” .
The AXIS RANGE LIMIT window is used as an example.

1. COMMENT
COMMENT can be specified in the condition file of any function.
2. FILE SET STATUS

Status of the present condition file
Value Description
SETTING The condition file is in the initial status or in the updating
status. When the data is changed by the read back operation,
select {WRITE} in the window, the data writing to the safety
circuit board is completed, and then this changes to
“CONFIRMING” or “COMPLETED”.
CONFIRMING The data is appropriately set and the limit area can be
confirmed after the file validating conditions are met.
Select {COMFIRM} in the window after the area is confirmed.
“COMPLETED” is indicated when the data setting process in
the safety circuit board is completed.
In case the data is changed at this timing, the indication
changes to “CONFIRMING”.
Only the files mentioned below exist while “CONFIRMING” is
indicated.
• Axis range limit function
• Robot range limit function
• Tool angle monitor function
• Tool change monitor function
• Tool number select function
COMPLETED The condition file setting is completed. The safety monitoring
can be performed after the file validating conditions are met.
In case the data is changed at this timing, the indication
changes to “CONFIRMING”.
FILE SET STATUS is displayed in the condition file of any function.
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3. FILE VALID COND

Specify the conditions for validating the monitoring of the object files.
However, to validate the monitoring, condition file data should be appro-
priately specified. The settings at this item might be ignored in case
“SETTING” is indicated at “FILE SET STATUS”.
Value Description
INVALID Always invalidate the object file.
VALID Always validate the object file.
SIGNAL Judge valid/invalid by referring the safety input signal.
For the details of the safety signal usage, refer to chapter 5
“Safety Signal” .
{FILE VALID COND} can be specified in the condition file of any function.
In the tool change monitor function and the tool number select function,
only one condition file will be valid in the normal status. Therefore,
when setting {FILE VALID COND}, if the other condition file has been
set to “VALID”, a confirmation dialog box appears.
The confirmation dialog box can be displayed in the system software
version YAS2.82.00A(□)-00 or later.
4. ALARM
Select alarm or not alarm to the monitoring result of the object file.
Value Description
ON (MOVE Servo is turned OFF with an alarm when an error occurs under
STOP) the object file monitoring condition.
OFF Although monitoring is performed under the object file
(CONT MOVE) condition, alarm does not occur and the servo is not turned
OFF even if a monitoring error occurred.
The monitoring result can be obtained by the safety output
signal.
ALARM can be specified only in the condition file of the axis range limit
function, the robot range limit function, or the tool change monitor func-
tion. The tool change monitor function and the tool number select func-
tion can be displayed and set in the system software version
YAS2.82.00A(□)-00 or later.
DANGER
• When “OFF” is set to ALARM, the functional safety function does
not stop the manipulator operation even if a monitoring error is
detected in the object file. In this regard, before operating the
manipulator, sufficiently consider possible risks attributed to the
alarmless operation (risk assessment) and take necessary
measures to them.
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5. GROUP
Specify the control group to be monitored specified by the condition file.
Selectable control groups vary depending on the function.
Function Selectable control group
Axis range limit function Robot, Base, Station group
Axis speed monitor Robot, Base, Station group
function
Robot range limit function Robot group
Speed limit function Robot, Station group
Tool angle monitor function Robot group
Tool change monitor The group is fixed by files. When modifying the
function object group, change it on the list of tool change
monitor function window.
Tool number select The group is fixed by files. When modifying the
function object group, change it on the list of tool number
select function window.
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5 Safety Signal
5 Safety Signal
For the functional safety function, the safety monitoring condition files can
be switched by the safety input signal.
Also, this function corresponds the outputting of the monitoring result by
the safety output signal.
Followings are the safety signal available for the functional safety function.
Signal Signal point Note

Functional safety general-purpose (for JANCD-ASF02-E) The functional safety general-purpose signal is
signal Input: 8 points/terminal connected per safety circuit board.
Output: 8 points/terminal The number of the signals differ depending on
(for JANCD-ASF03-E) the board:
Input: 16 points/terminal  when connecting to “JANCD-ASF02-E”, 8 input
Output: 16 points/terminal points and 8 output points
 when connecting to “JANCD-ASF03-E”, 16
input points and 16 output points
Safety fieldbus signal Input: 64 points/system The safety fieldbus signal is connected per
Output: 64 points/system system.
Depending on the settings, up to 64 points can
be used from one safety circuit board.
The safety fieldbus is an optional function other
than the functional safety.
Safety logic circuit extended Input: 64 points/system The safety logic circuit extended signal (64 input
signal Output: 64 points/system points and 64 output points) is connected per
system.
The output of the safety logic circuit (MS-OUT)
can be used as the input of the functional safety.
The output of the functional safety (FS-OUT)
can be used as the input of the safety logic
circuit.
To maintain Safety Category 3 and PL-d in the safety moni-

NOTE toring using the functional safety function, the safety signal
to be used must meet the requirements of Safety Level SIL2
and PL-d.
If the safety fieldbus signal and the safety logic circuit signal are included,
up to 144 points can be used from one safety circuit board.
To condition files, as many safety signals as desired can be allocated
within the possible signal points, thus signals are flexibly used even if the
board has small numbers of signal points.
Follow the procedures below when using the safety signals:

1. Perform the allocation of the functional safety general-purpose signal.
2. Perform the allocation of the safety logic circuit signal.
(This is not necessary when using only the functional safety general-
purpose signal.)
3. Perform the allocation of the safety fieldbus signal.
(This is necessary when using the safety fieldbus signal.)
4. Set the condition file.
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5 Safety Signal
5.1 Allocation of Safety Logic Circuit Extended Signal

The safety logic circuit extended signal can be used as the input signal or
the output signal of the functional safety. The number of the signal points
are 64 input points and 64 output points. These signals are shared by the
whole system, and can be used from any board of the safety circuit board.
Regarding the FS-OUT (safety logic circuit functional safety output signal),
allocation of the signal and the board must be performed in advance.
For details of the safety logic circuit function, refer to “YRC1000
INSTRUCTIONS (RE-CTO-A221) 8.26 Safety Logic Circuit”.
2. Select {SLC EXT. SIGNAL ALLOC} under the submenu.

– The settings window of the safety logic circuit signal allocation
appears.
Allocation of FS-OUT (functional safety output signal)

1. SIGNAL
Indicates the signal number (FS-OUT01 to 64).
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2. UNIT
The destination of the FS-OUT is selected from the following:
I) Not used
II) One of the functional safety (F-SAFE) #1 to #8
To prevent the duplicate use of an output signal (FS-OUT), one signal is
allocated to one board in which the signal is used.
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5 Safety Signal
5.2 Allocation of Safety Fieldbus Signal

The safety fieldbus function is not a functional safety function but an
optional function. When it is valid, the safety fieldbus signal can be used
in the functional safety function.
Safety fieldbus signal transmits/receives the safety-guaranteed “safety
data” through the fieldbus communication path. It has 64 input signal
points and 64 output signal points.
These signals are commonly used in the whole system and thus they can
be referred from both machine safety board and functional safety board.
In this consequence, “SAFETY SIG. BOARD ALLOC” function is prepared
to define which signal is to be used in which board.
2. Select {SAFETY SIG. BOARD ALLOC} in the sub menu.

– The settings window of the safety signal board allocation appears.
Allocation of output signal
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5 Safety Signal

1. OUTPUT
Indicates the signal number.
2. UNIT
The destination of the safety fieldbus output signal is selected from the
following:
I) Not used
II) Machine safety (used in the safety logic circuit)
III) One of the functional safety (F-SAFE) #1 to #8
(used in the functional safety (specify the terminal to use))
IV) All of the functional safety
(used in the whole safety circuit board where the functional
safety is enabled)
To prevent the duplicate use of a safety signal, one signal is allocated to
one board basically.
Item Description
Not used The signal is not used.
Machine safety The signal can be used in the safety logic circuit.
One of the functional The signal can be used in the functional safety (one
safety #1 to #8 of the terminals from 1 to 8)
Functional safety The signal can be used in the whole safety circuit
ALL USE board where the functional safety is enabled.
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5 Safety Signal
5.3 Settings of Safety Function Condition File

A window for setting signals are prepared to all the condition files.
Axis range limit function window is shown below as an example of signal
setting window.

1. INPUT SIGNAL
To validate an object condition file, specify a safety input signal for refer-
ence.
Same input signal cannot be specified in the same condition file. The
already-specified signal does not appear in the selection list in the same
condition file.
Value Description
NO CONFIG Signal is not specified.
FSBIN01 to Specify the functional safety general-purpose input signal.
FSBIN16 The number of the signal points differs depending on the
safety I/O board to be connected.
When the ASF02 board is connected, the signals 1 to 8 are
used, and when the ASF03 board is connected, the signals
1 to 16 are used.
(# n): terminal number of the safety circuit board
SFBIN01 to Specify the safety fieldbus input signal. (signal 1 to 64)
SFBIN64
MS-OUT01 to Specify the machine safety output signal of the safety logic
MS-OUT64 circuit. (signal 1 to 64)
“INPUT SIGNAL” can be specified in the condition file of any function.

To perform settings of “INPUT SIGNAL”, set “SIGNAL” for “FILE VALID
COND”.
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2. SET
To the input value of the signal selected at “INPUT SIGNAL”, specify
either ON or OFF for satisfying the condition to set valid.
Value Description
OFF The valid condition is satisfied when the value set at
“INPUT SIGNAL” becomes OFF.
ON The valid condition is satisfied when the value set at
“INPUT SIGNAL” becomes ON.
“SET” can be specified in the condition file of any function.

To perform settings of “SET”, set “SIGNAL” for “FILE VALID COND”.
3. STATUS
The present input value of the signal input at “INPUT SIGNAL”
Value Description
○ The present input value of the signal set at “INPUT

SIGNAL” is OFF.
● The present input value of the signal set at “{INPUT

SIGNAL” is ON.
“STATUS” can be displayed in the condition file of any function.

To display “STATUS”, set “SIGNAL” for “FILE VALID COND”.
4. OUTPUT SIGNAL
Specify a signal to output the object condition file monitoring result.
To avoid a redundant output result, two of the same output signal cannot
be specified in one system. The already-specified signal does not
appear in the selection list in the same condition file.
Regarding the safety fieldbus output signals and the functional safety
output signals, only the ones allocated as usable in the safety circuit
board appear in the selection list.
Value Description
NO CONFIG Signal is not specified
FSBOUT01 to Specify the functional safety general-purpose output signal.
FSBOUT16 The number of the signal points differs depending on the
safety I/O board to be connected.
When the ASF02 board is connected, the signals 1 to 8 are
used, and when the ASF03 board is connected, the signals 1
to 16 are used.
(# n): terminal number of the safety circuit board
SFBOUT01 to Specify the safety fieldbus output signal. (signal 1 to 64)
SFBOUT64
FS-OUT01 to Specify the functional safety output signal to the safety logic
FS-OUT64 circuit. (signal 1 to 64)
“OUTPUT SIGNAL” can be specified in the condition file of any function.
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5 Safety Signal
5.4 File Switching to Valid/Invalid by the Safety Input Signal

Judging method for switching the condition file using the safety input
signal is explained here.
Fig. 5-1: Signal Setting Window
The input signal is judged line-by line.

As shown in fig. 5-1 “Signal Setting Window” , when performing a setting
as marked with the red square, the condition of bit 0 line is defined as
satisfied because “ON” is set to {SET} at the input signal {FSBIN01}, and
● (=ON)} is set to {STATUS}.
Up to 5 signals can be set to a condition file (up to 4 for the tool change
monitor function and the tool number select function).
Conditions of the lines from bit0 line to bit4 line are judged by the safety
input signal respectively, the object condition file is validated only when all
the conditions are satisfied.
For the line “****” (undefined) is indicated at {SET} is disregarded for this
judgement.
Fig. 5-2: When the Conditions for File Validation is Satisfied
All conditions satisfied
Ignored
Fig. 5-3: When the Condition for File Validation is Not Satisfied
Condition not satisfied
Ignored
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5 Safety Signal
There can be a time difference after the first signal and

before the last signal. In the functional safety function, an
interval of 32 [ms] is equipped to the system to be totally
switched to internally settled after the last signal change.
For this reason, please take this into consideration when
performing the following operations.
NOTE
• When switching several signals, do not take more than 32
[ms].
→The signals may be settled with half-specified values.
• Do not use signals that continue shifting ON/OFF within
the interval of less than 32 [ms].
→Signals will not be settled.
On the basis of above mentioned judging methods, following patterns can

be conceived when switching files using three signals.
Pattern 1: When switching one file using one signal

Operate more than two files respectively.
Simultaneous monitoring is available.
The number of the object file: 3
Condition file Signal and setting Setting Conditions for

validating the file
File 1 Signal A ON ●(Signal A)
File 2 Signal B OFF ○(Signal B)
File 3 Signal C ON ●(Signal C)
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5 Safety Signal
Pattern 2: When switching one file using more than two signals
Select one file out of several files.
Many files can be managed with less signals. This pattern is effective
when simultaneous monitoring is not necessary.
The number of the object file: 8
Condition file Signal and setting Setting Conditions for

validating the file
File 1 Signal A OFF ○(Signal A)
Signal B OFF ○(Signal B)
Signal C OFF ○(Signal C)
Signal B ON ●(Signal B)
File4 Signal A ON ●(Signal A)
Signal C ON ●(Signal C)
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5 Safety Signal
5.5 Safety Signal Output Value

The output signal outputs the status of safety or not safety over the
monitoring conditions when the object condition file is validated.
Followings show the meanings of output result for each safety function.
Basically, output signal ON is defined as safety side and OFF is defined as
not safety side in preparation for the disconnection of the hard signals, etc.
In case the status becomes not safety and OFF is output during the
monitoring, the OFF signal is kept outputting unless the error alarm is re-
set.
If the alarm is set to be out of occurring by a condition file, the signal keeps
outputting OFF while in not safety status and becomes ON when it returns
to the safety status.
CAUTION
In case a major alarm occurred in the functional safety function, all the
output signals are turned OFF.
• Axis range limit function

Object file Monitoring result Output
status value
Invalid - OFF
Valid All the axes monitoring is validated are inside the ON
safety range.
Some of the axes monitoring are validated are OFF
detected to be outside the safety range
For some of the axes monitoring are validated, the OFF
stop position to which coasting value is included
are detected to be in error status when moving
close to the border of the safety range.
• Axis speed monitor function

status value
Invalid - OFF
Valid All the axes monitoring is validated are inside the ON
safety range.
Some of the axes monitoring are validated are OFF
detected to be outside the safety range
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5 Safety Signal
• Robot range limit function

status value
Invalid - OFF
Valid Object manipulator or tool is inside the safety ON
range.
Object manipulator or tool is detected to be outside OFF
the safety range
For the object manipulator or tool, the stop position OFF
to which coasting value is included are detected to
be in error status when moving close to the border
of the safety.
• Speed limit function

Object file Monitoring result Output value
status
Invalid - OFF
Valid Object groups for monitoring are inside the ON
limited speed.
Object groups for monitoring detected the OFF
limited speed error.
• Tool angle monitor function

status
Invalid - OFF
Valid The tool angle of the object group for ON
monitoring is inside the limited angle.
An error is detected to the tool angle of the OFF
object group for monitoring.
• Tool change monitor function

status
Invalid There is no valid file OFF
Valid One condition file is specified as valid and the ON
value is inconsistent with the master CPU.
One condition file is specified as valid but the OFF the valid
value is not consistent with the master CPU. file signal
Several condition files are specified as valid OFF all the
valid file signal
• Tool number select function

status
Invalid There is no valid file. OFF
Valid One condition file is specified as valid. ON
Several condition files are specified as valid. OFF all the
valid file signal
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6 Common Settings
6.1 Function Disable Mode Setting
6 Common Settings

When the function disable mode (temporary disablement) is used, all the
object condition files of the safety monitoring function (32 files) can be set
invalid.
This mode is used in the following functions marked with ○.
Function Availability
Axis range limit function ○
Axis speed monitor function X
Robot range limit function ○
Speed limit function X
Tool angle monitor function ○
Tool change monitor function ○
Tool number select function ○
Use this mode mainly to recover from the status when an out-of-range
alarm of the range limit function occurred.
Although the alarm activated by the safety monitoring is a re-settable
alarm, the same alarm occurs again if the manipulator or the external axis
is located outside of the safety range.
Follow the procedures below when recovering from the alarm.
1. Temporarily disable the safety function which is detecting the alarm.
2. Reset the alarm.
3. Jog operate to move the manipulator or the external axis inside the
safety range.
4. Release the function disable mode.
The function disable mode can be specified on the status list window.
The AXIS RANGE LIMIT window is used as an example below.
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6 Common Settings
Set “ON” for “FUNCTION DISABLE MODE”. The window changes as

shown below to indicate that the function is temporarily disabled.
Also, in the message area at the lower right of the window, a message
showing that the object function is being temporarily disabled appears.
<Message>
“Axis range limit function is temporarily disable”
“Robot range limit function is temporarily disable”
“Tool angle monitor function is temporarily disable”
“Tool change monitor function / Tool number select function is
temporarily disable”
To an specific output signal, a signal for the disabled function is output.

<Specific output signal>
-Axis range limit is temporarily disabled
-Robot range limit is temporarily disabled
-Tool angle monitor is temporarily disabled
-Tool change monitor / Tool number select is temporarily disabled
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6 Common Settings
6.1.1 Restrictions While Function Disable Mode Is Enabled

Restrictions are set to the following operations while the function disable
mode is enabled because this mode also disables monitoring operations.
When moving the manipulator or the external axis while the restrictions
are set, only the jog operation using the programming pendant is
available. And an error occurs when one of the following operations is
executed.
• Play back operation
• Forward and Backward operations
• Test-run operation
• I/O Jog operation
• Execution of motor gun auto tuning
<Error Message>
Error 1191: Axis range limit function is temporarily disable
Error 1192: Robot range limit function is temporarily disable
Error 1193: Tool angle monitor function is temporarily disable
Error 1194: Tool change monitor function / Tool number select function is
temporarily disable
Following error codes are returned when executing the data transmission
or start commands of the high-speed Ethernet server, or when executing
jobs of MotoPlus or Pendant customization functions.
<Error Message>
3061: “Axis range limit function is temporarily disable”
3062: “Robot range limit function is temporarily disable”
3063: “Tool angle monitor function is temporarily disable”
3064: “Tool change monitor function / Tool number select function is temporarily
disable”
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6 Common Settings
6.1.2 Security Level Setting for Function Disable Mode

For the functions in which the function disable mode exists, the security
level to use this mode can be selected.
Follow the procedures below to open the settings window of the function
disable mode.
1. Set the security mode to the safety mode, and then select {SETUP}
under the main menu.
2. Select {OPERATE COND.} in the sub menu.

– The OPERATE CONDITION SETTING window appears.
– When the security mode is higher than the safety mode and the
functional safety function is enabled, “FUNC DISABLE MODE
SECURITY(FSU)” appears on this window.

FUNC DISABLE MODE SECURITY (FSU)
Value Description
EDITING MODE Switching of FUNCTION DISABLE MODE is permitted
in the editing mode or higher.
MANAGEMENT MODE Switching of FUNCTION DISABLE MODE is permitted
in the management mode or higher.
SAFETY MODE Switching of FUNCTION DISABLE MODE is permitted
in the safety mode. (Default)
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6 Common Settings
6.2 External Axis Coasting Value Setting

This setting can be referred by the following safety functions. When using
○
the safety function marked with in the following table, an advanced
setting is required.
Function Reference
Axis range limit function ○
Tool angle monitor function X
Tool change monitor function X
Tool number select function X
In case the power supply to the servo is turned OFF while the manipulator
is in operation, it may move a little bit before completely stops because of
the force of inertia. The functional safety function functions by estimating
the moving value (coasting value) of the manipulator from the servo OFF
position to the completely stopped position in accordance with each axis
speed.
By setting the manipulator to stop just before it exceeds the safety range
including its coasting distance on the basis of the estimated coasting
value, the stop position of the manipulator does not exceed the safety
range.
For example, when the manipulator is operating with 100% of operating
speed, the functional safety function starts instructing the manipulator to
stop “the coasting value when the manipulator is operating with 100% of
operating speed” before the border of its limited area.
Also, when the manipulator is operating with 50% of operating speed, the
functional safety function starts instructing the manipulator to stop “the
coasting value when the manipulator is operating with 50% of operating
speed” before the border of its limited area.
For the coasting value of the manipulator, it is already set before
shipment. However, for that of an external axis, it should be set by the
customer.
When the monitoring operations in the axis range limit function or the
robot range limit function is valid but its coasting value is not set, an error
may occur and following operations will be restricted.
• Play back operation
• Forward and Backward operations
• Test-run operation
• I/O Jog operation
• Execution of motor gun at tuning
The coasting value is difficult to obtain by calculation. Do

not use values using in other systems because the value
varies largely depending on the structure or shape of the
NOTE
external axis.
When inputting a temporary value, set a large value enough
to avoid the risk.
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6 Common Settings
<Error message>
“Error 0384: Coasting value setting of Ex-axis is not completed”
Following error code is returned when executing the data transmission,
the starting system command by the high-speed Ethernet server or the
play back operations from the programming pendant customization
function or MotoPlus before setting of the coasting value is not completed.
<Error codes>
3065 “Coasting value setting of Ex-axis is not completed”
Setting of the coasting value is not necessary for the sys-

NOTE tem to which the external axis does not exist. Also, follow-
ing sub menu is not displayed.
Open the external axis coasting value setting window by the following
procedures.
2. Select {COASTING VALUE SETTING} in the sub menu.

– The COASTING VALUE SETTING window appears.
– When several external axes exist, press [PAGE] to alternate the
external axes.
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6 Common Settings

1. IMMEDIATE STOP
The value input to “COASTING VALUE” must be measured in the cate-
gory 0 status. For the coasting value measurement, the category can
be modified.
Value Description
OFF Category 1 is set for the stop of the robot and the external axis
(Default)
ON Category 0 is set for the stop of the robot and the external axis
• “OFF” should be set to “IMMEDIATE STOP” again after

the coasting value measurement.
• When the starting operation is executed while “ON” is set,
a dialog box notifying that “Immediate stop” is already set
appears.
If performing the coasting value measurement, the play
back operation can be executed after selecting “YES” and
NOTE re-start the starting operation.
2. COASTING VALUE
Set the coasting value to a object axis. The inputting range is from
0.000 to 999.999.
A message “Select ‘Safety Board FLSH Reset’ in the main-

tenance mode.” appears when the coasting value is edited.
NOTE
Re-set the data by following the procedures in chapter 7.2
“FLASH Data Reset” .
While modifying the coasting value, the power supply to the

servo is stopped and the operation of the manipulator or the
SUPPLE
axis is disabled. However the modification is continuously
-MENT available. For this reason, it is recommended to turn ON
the power supply to the controller after completing the mod-
ification of all the coasting value.
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6 Common Settings
6.3 Tool File Setting
6.3 Tool File Setting

○
Function Reference
Axis range limit function X
Speed limit function ○
Tool angle monitor function ○
The tool file must be appropriately specified for the precise monitoring of
the safety function.
Make sure to perform the tool file setting properly by referring to
“YRC1000 INSTRUCTIONS (RE-CTO-A221) 8.3 Tool Data Setting”.
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6 Common Settings
6.4 Tool Interference File Setting

○
Function Reference
Axis range limit function X
Tool angle monitor function X
In the robot range limit function, monitoring of the manipulator as well as

its tool is executed. In this case, register the tool shape to the tool
interference file as an approximate model.
Set a tool interference file as instructed below.
1. Set the security mode to the safety mode, and then select {ROBOT}
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6 Common Settings
2. Select {TOOL INTERFERE} under the sub menu.

– The TOOL INTERFERE window appears.
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6 Common Settings

1. 1 to 5
Cylinders and spheres for up to 5 positions can be set.
2. POINT1 to POINT5
Input the coordinate value of XYZ, and set both ends of a cylinder.
The distance from the center of T axis flange should be set like tool
dimension setting.
3. RADIUS
The radius of the spheres and cylinder between POINT 1 and POINT 2
is set. The spheres are set to POINT 1 and POINT 2.
It is measured in [mm]
The specified radius must have a margin of at least 10 mm compared
with the actual tool.
<Tool interference file setting example>

Fig. 6-1: Tool Interference File Setting Example
140
Robot 25
Model 2
Point 1
30
Tool coodinate origin X
(flange surface)
20
85
Model 1
Point 1
250
Model 1
Point 2
350
Tool
Model 3
Point 1 Model 2
Point 2
Model 3
Point 2
Z
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6 Common Settings
Model 1: Set the flange surface to Point 1, and (X=140, Z=85) to Point 2.
Model 2: Set (X=140, Z=-30) to Point 1, and (X=140, Z=250) to Point 2.
This setting defines a model that is parallel to the Z direction of
the tool coordinates.
Model 3: Set (X=140, Z=250) to Point 1, and (X=25, Z=350) to Point 2.
By setting the point 2 of model 2 and the point 1 of model 3 at the
same position, model 2 and 3 are defined at consecutive
positions.
Following window shows the result of the setting model shown in fig. 6-1
“Tool Interference File Setting Example” .
CAUTION
When setting a radius to a tool model, set a little larger radius
corresponding to the distance from the flange surface as shown below.
Distance from the flange surface Recommended radius

0 mm 55 mm
100 mm 58 mm
200 mm 60 mm
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6 Common Settings
6.5 Security Level Setting for Tool File and Tool Interference Files
In the system where the functional safety function is not used, both tool file
and tool interference files can be operated in the editing or higher mode.
On the other hand, in the system where the function is used, in the default
setting, they can be operated only in the safety mode because these files
influence the safety monitoring operation.
The person who has a safety license can select one out of three security
level for operating the tool file or tool interference file.
The setting window opens by the following procedures.
1. Set the security mode to the safety mode, and then select {SETUP}
2. Select {OPERATE COND.} under the sub menu.

– The OPERATE CONDITION SETTING window appears.
– When the security level is higher than the safety mode and the
functional safety function is enabled, “TOOL (INTF)FILE OPE
SECURITY(FSU)” appears on this window
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6 Common Settings

TOOL (INTF)FILE OPE SECURITY(FSU)
Value Description
EDITING MODE Operation of the tool file and tool interference file is
permitted in the editing mode or higher.
MANAGEMENT MODE Operation of the tool file and tool interference file is
permitted in the management mode or higher.
SAFETY MODE Operation of the tool file and tool interference file is
permitted in the safety mode. (Default)
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6 Common Settings
6.6 Using the PMT Function Together with the Functional Safety Function
6.6 Using the PMT Function Together with the Functional

Safety Function
6.6.1 How to Use the PMT Function Together with the Functional Safety Function
For system version YAS2.80.00A(*)-00 or later, the tool file that was last
saved on the safety board is stored inside the system separately from the
tool file (TOOL.CND) that is used normally.
The tool file to verify against the tool file that was saved on the safety
board can be specified with the following parameter.
If S2C450 is set to 1, the PMT function can be used with the functional
safety function. The setting of this parameter can be changed only if the
security mode is safety mode. For this reason, the setting must be
performed by the person who has a safety license.
Parameter Details Default

No. Value
S2C450 Specify the target for verifying the tool file to use in the safety functions. 0
0: Verify the tool file to use normally against the tool file that was
saved on the safety board (the PMT function will not be used
together with the functional safety function).
1: Verify the tool file that was last saved on the safety board against
the tool file that was saved on the safety board (the PMT function
will be used together with the functional safety function).
WARNING
When the tool file is changed with the SETTOOL instruction, only the
TCP to control the robot path is changed. The TCP to monitor with the
safety function is not changed. Therefore, the robot will operate in a
state where the TCPs do not match.
For the safety functions that use the tool file, refer to chapter 6.3 “Tool
File Setting” .
When changing the parameter for this function, first conduct a sufficient
risk assessment and carefully check the impact on the safety functions.
If S2C450 is set to 0, "Alarm 0300: VERIFY ERROR (SYSTEM CONFIG-

DATA) [10]" may occur when the control power is turned ON. For details,
refer to chapter 6.6.3 “Tool File Verification Check in a System Using the
PMT Function Together with the Functional Safety Function” .
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Since this parameter is related to the safety function, if the parameter

S2C450 is edited in management mode, the following error message will
appear.
If a parameter file is loaded in management mode, the parameter S2C450

will be checked to see if it has changed before/after loading.
If the parameter has changed, the following error message will appear,
and the parameter file will not be loaded.
A parameter file in which the parameter S2C450 has been changed must
be loaded in safety mode.
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The tool file that was saved on the safety board stored inside the system
can be confirmed in the tool window.
Press {DISPLAY}, and then select {MONITORING COND.}.
The window is changed to the “MONITORING COND.” window to indicate

the details of the tool file that was last saved on the safety board.
The tool file cannot be edited in this window. The value of the tool file
displayed in this window will be updated when the tool file is saved on the
safety board with the readback operation by the person who has a safety
license.
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To show the current tool file or to edit the value of the tool file, press
{DISPLAY}, and then select {TOOL FILE (CURRENT)}.
When verifying the current tool file against the tool file that was saved on
the safety board, the comparison result of the following two tool files: the
tool file that was last saved on the safety board and the tool file to use
normally (TOOL.CND) is output to a concurrent I/O signal (specific output
signal).
• 52585:
The comparison result of two tool files is output. ON is for the
mismatch, and OFF is for the match.
Value Details
OFF The tool file that was last saved on the safety board and the tool file to
use normally match.
ON The tool file that was last saved on the safety board and the tool file to
use normally do not match.
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6.6.2 Monitoring the Amount of Change in the Tool Files

For system version YAS2.80.00A(*)-00 or later, the amount of change in
tool files is monitored by checking the difference between the tool file that
was last saved on the safety board and the tool file that is set with the
SETTOOL instruction.
The amount of change in the above two tool files is checked when the
SETTOOL instruction is executed, and the following alarm will occur if the
threshold is exceeded.
Alarm 4605: SETTOOL ERROR [2]
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The threshold for the amount of change in tool files can be specified with
the following parameter.
The setting of this parameter can be changed only if the security mode is
safety mode. For this reason, the setting must be performed by the
person who has a safety license.
Parameter Details Unit Default

No. Value
S3C1193 The maximum allowable deviation from the tool file that 0.001 mm 20000
was last saved on the safety board when the tool data is
automatically set (SETTOOL instruction is executed).
0: Do not monitor the amount of change in tool files.

1 or higher: Set the value of the parameter to the
threshold and perform monitoring.
WARNING
For system versions before YAS2.80.00A(*)-00, the default value of
S3C1193 is 0. For this reason, the amount of change in the tool files will
not be monitored simply by upgrading from a system version before
YAS2.80.00A(*)-00 to system version YAS2.80.00A(*)-00 or later.
To monitor the amount of change in tool files, first upgrade the system
version, and then conduct a sufficient risk assessment and set the
value of S3C1193.
Since this parameter is related to the safety function, if the parameter

S3C1193 is edited in management mode, the following error message will
appear.
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If a parameter file is loaded in management mode, the parameter

S3C1193 will be checked to see if it has changed before/after loading.
If the parameter has changed, the following error message will appear,
and the parameter file will not be loaded.
A parameter file in which the parameter S3C1193 has been changed must
be loaded in safety mode.
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6.6.3 Tool File Verification Check in a System Using the PMT Function Together with the
Functional Safety Function
When changing parameters and condition files, such as the tool file to be
used in the safety functions (TOOL.CND), the following items must be
checked by the person who has a safety license.
• Visually confirm that setting values are correct by using the readback
operation.
• Perform an operation check using the newly set parameters and con-
dition files and confirm that the safety functions work as intended.
The changed tool file is saved on the safety board by the above readback
operation.
For a system that changes tool files using the PMT function, the tool file
(TOOL.CND) is automatically changed by the PMT function. Changing
the tool file with the PMT function is not accompanied with the above
checks by the person who has a safety license, so the tool file on the
safety board is not updated.
When the control power is turned ON, a verification check is performed on
the tool file that was saved on the safety board and the tool file in the
system, and if the files do not match, the following alarm occurs.
Alarm 0300: VERIFY ERROR (SYSTEM CONFIG-DATA) [10]
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6.7 Disabling Functional Safety by Changing Connection Settings
6.7 Disabling Functional Safety by Changing Connection

Settings
If functional safety must be disabled for some reason, such as a failure of
the safety board, it can be disabled by changing the functional safety
connection setting in maintenance mode.
Use the following procedure to disable functional safety.
2. Select {SYSTEM} under the main menu, and then select {SETUP}
under the sub menu.
– The SETUP window appears.
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3. Select “OPTION FUNCTION”, “Functional safety” and “DETAIL”.

– The Functional safety window appears.
4. Select "Connection setting".

– The Connect setting window appears.
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5. Change to set “NOT USED” for the functional safety board to

invalidate.
6. Press [ENTER] twice, and a dialog box asking “Modify?” appears.

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6 Common Settings
– Select “YES”, and a dialog box asking “Initialize related files?"

appears.
“NO”. (When “YES” is selected, the setting related to functional
safety will be initialized.)
under the sub menu.
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6 Common Settings
8. Move the cursor and select “Safety Board FLASH Reset” on the
window.
9. Select “YES” when a dialog box asking "Reset?" appears.

– Data of the safety circuit board is reset. A few seconds later, a beep
will sound, indicating that the data of the safety circuit board has
been reset.
When validating the functional safety again, perform setting

NOTE in the same procedures as described in this chapter, and
change the functional safety to validate to "USED" in step 5.
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7 Data Protection
7.1 Saving Dual Data
7 Data Protection
7.1 Saving Dual Data

The data related to the safety function is saved in the safety circuit board
memory in a duplicated manner for safety.
When the control power is turned ON, check is performed to see that dual
data sets are the same.
If they are different when the control power is turned ON, the following
alarm occurs.
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]”
In the system with the functional safety function, a message “Select

‘Safety Board FLASH Reset’ in the maintenance mode” is displayed after
the following operations.
Turning ON or OFF causes error in verification.
• The data related to the safety function is loaded from an external
storage.
• A parameter related to the safety function is rewrote by setting
operations in maintenance mode.
• The zeroing function is performed.
• Encoder is reset
In case one of the above mentioned operations is performed, re-set the

data following the procedures shown in chapter 7.2 “FLASH Data Reset” .
In the maintenance mode, there are cases when parameters related to the
safety function are rewritten by several setting operations.
For this reason, the message “Select ‘Safety Board FLASH Reset’” may
be displayed.
Perform the safety board FLASH reset operation by following the
procedure shown in chapter 7.2.
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7.2 FLASH Data Reset

If the following alarm occurs when the control power supply is turned ON,
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]”
perform the following operations to re-set the data of the function safety
board.
1. When the controller power is turned ON,
Alarm 0300: “VERIFY ERROR(SYSTEM CONFIG-DATA)[10]” occurs
and the maintenance mode is started up.
under the sub menu.
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4. Move the cursor to “Safety Board FLASH Reset” and press [ENTER].
5. The dialog box “Reset?” is displayed. Select “YES”.

– The data of the safety circuit board is re-set. A few seconds later, a
beep sounds and the data setting is completed.
6. When the data reset is completed, turn the control power OFF and
then turn the power ON again.
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7.3 Change of Condition File by an External Device

When using the functional safety function, the data used for the setting of
safety monitoring must not be modified by an external device. Therefore,
when loading the condition file from the external memory device, loading
is allowed only when it is confirmed that the contents of the saved file have
not been modified.
7.3.1 Outputting the CRC Value to the External Memory Device

When the file (shown in table 7-1) referred to for the functional safety is
saved in the external memory device, the CRC value is added into the file.
The CRC value, which is created based on the file data, is a fixed value
unless the contents of the file are modified. When the CRC value created
from the contents of the data which is read during file loading and the CRC
value added into the file are different, an alarm 4796: “Functional Safety
Data CRC Error” occurs.
(e.g.)Tool file
//TOOL 0
///CRC 4294967294 (CRC value)
///NAME standard tool
0.000, 0. 000, 0. 000, 0. 0000, 0.0000, 0. 0000
0.000, 0. 000, 0. 000
0.000.
0.000, 0. 000, 0. 000
0.000, 0, 1
Table 7-1: Files to which the CRC Value is output while Functional Safety is Valid
File File name of the external memory device
Tool file TOOL.CND
Tool interference protection file TOOLINTF.DAT
Home position calibration data ABSO.DAT
Axis range limit data AXRNGLMT.DAT
Axis speed monitor data AXSPDMON.DAT
Robot range limit data RBRNGLMT.DAT
Speed limit data SPDLMT.DAT
Tool angle monitor data TLANGMON.DAT
Tool change monitor data / TLCHGMON.DAT
Tool number select data
Functional definition parameter FD.PRM
System definition parameter SD.PRM
Servo parameter SV.PRM
Servo motor parameter SVM.PRM
Robot match parameter RC.PRM
Coordinate origin parameter RO.PRM
Motion function parameter MF.PRM
Robot expand parameter RE.PRM
Safety function parameter FMS.PRM
System match parameter SC.PRM
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Since the CRC value has not been added to the file saved
NOTE in the system in which functional safety is invalid, the file
cannot be loaded in the system in which functional safety is
valid.
7.3.2 Confirming Method of the CRC Value

The CRC value of each data can be confirmed in the TOTAL CRC
CONFIRM window. The TOTAL CRC CONFIRM window appears when
selecting {SAFETY FUNC.} and then selecting {TOTAL CRC CONFIRM}
In this window the CRC value and the date of the last update of each data
are shown.
CRC value: the CRC value calculated from the file data.
The same value is shown as the value which is output to the
file when the file is saved in the external memory device.
The file is usually updated simultaneously when modifying the
data. However, when performing the modification in which the
Functional Safety Board FLASH Reset is necessary, an
asterisk appears, and then the value is shown after resetting
the Functional Safety Board Flash.
Last update date: The last date and time when the file was modified
(edited, loaded, or initialized) are shown.
In case that the data has not been modified since the
system started operating, an asterisk is shown.
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The indication method of the TOTAL CRC CONFIRM win-

NOTE dow changes in the system software version
YAS2.80.00A(□)-00 or later.
This window shows the last update of the total safety number derived from
the CRC value of each data to be monitored by "monitoring target setting".
The CRC of each data can be sorted by data type by pressing {PAGE}.
For the data monitoring in the TOTAL CRC CONFIRM window, refer to
chapter 7.3.4 “Data Monitor on the Total CRC Confirmation Window” .
“TOTAL SAFETY NUMBER” window shows the following items.
Item Description
TOTAL SAFETY NUMBER “LAST UPDATE” when pressing {START}
(LATCH)
TOTAL SAFETY NUMBER The last update value of CRC for each data
(LAST UPDATE) included in the “monitoring target setting”
MONITOR START The last date and time when pressing {START}
RESULT OK: The latch and the last update of the TOTAL
SAFETY NUMBER are equal, and the data
included in “monitoring target setting” is not
changed.
NG: The latch and the last update of the TOTAL
SAFETY NUMBER are different, and the
data included in “monitoring target setting” is
changed.
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“Each data” window shows below. The window when “SAFETY LOGIC
CIRCUIT” included in “monitoring target setting” is selected is shown as
an example.
The descriptions of the items to be displayed are as follows.
Item Description
CRC (LATCH) “LAST UPDATE” is reflected when pressing
{START}.
If not included in “monitoring target setting”,
asterisks are displayed.
LAST UPDATE (LATCH) “LAST UPDATE” is reflected when pressing
{START}.
If not included in “monitoring target setting”,
CRC (LAST UPDATE) The last update CRC value is displayed.
However, in the functional safety function-relevant
files, asterisks are displayed and the value is
updated after the functional safety FLASH reset.
Also, this value is consistent with the CRC value
output to the file when saving to the external
memory.
LAST UPDATE The last update date and time is displayed.
(LAST UPDATE) When never changed since the system started,
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The data types that the CRC can be displayed, corresponding to the valid/
invalid of the optional function, are shown in the following table.
○: Display ×: Non-Display
Valid/Invalid of Optional Function
Safety logic circuit expanded Invalid Valid Valid Valid
function
Safety fieldbus Invalid Invalid Valid Valid
Functional safety Invalid Invalid Invalid Valid
Data Type Display Possible / Impossible
Total safety number ○ ○ ○ ○
Safety logic circuit ○ ○ ○ ○
Machine safety signal ○ × × ×
allocation
Timer delay ○ ○ ○ ○
Safety signal board allocation × × ○ ○
Functional safety signal × × × ○ (*)
allocation
Safety circuit expanded signal × × × ○ (*)
allocation
Timer × ○ ○ ○
Safety circuit signal display × ○ ○ ○
setting
Tool × × × ○
Tool interference × × × ○
Home position calibration × × × ○
Axis range limit × × × ○
Axis speed monitor × × × ○
Robot range limit × × × ○
Speed limit × × × ○
Tool angle monitor × × × ○
Tool change monitor × × × ○
Functional definition × × × ○
parameter
System definition parameter × × × ○
Servo parameter × × × ○
Servo motor parameter × × × ○
Robot match parameter × × × ○
Coordinate origin parameter × × × ○
Motion function parameter × × × ○
Robot expand parameter × × × ○
Safety function parameter × × × ○
(*) The functional safety signal allocation and the safety circuit expanded signal
allocation are displayed when both the safety logic circuit expanded function and
the functional safety are valid.
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7.3.3 Register Output of the CRC Value

By outputting the CRC value which is shown in the TOTAL CRC
CONFIRM window to the general-purpose register, an external device can
confirm that the file has been modified. By setting the parameter
S4C1180 to S4C1207 shown in table 7-2 “Allocation of Parameter for
Register output of the CRC Value” , the user can output the CRC value to
the register.
Parameter setting value
0, 559 or more: The CRC value is not output to the general-purpose
register.
1 to 558: The CRC value is output to the general-purpose register.
For the target files, refer to table 7-2. The two low-order bytes of
the CRC value are output to the general-purpose register of
specified number, and the two high-order bytes of the CRC value
are output to the next general-purpose register.
Table 7-2: Allocation of Parameter for Register output of the CRC Value
Parameter CRC value output file
S4C1180 Tool file
S4C1181 Tool interference protection file
S4C1182 Home position calibration data
S4C1183 Axis range limit data
S4C1184 Axis speed monitor data
S4C1185 Robot range limit data
S4C1186 Speed limit data
S4C1187 Tool angle monitor data
S4C1188 Tool change monitor data / Tool number select data
S4C1189 Functional definition parameter
S4C1190 System definition parameter
S4C1191 Servo parameter
S4C1192 Servo motor parameter
S4C1193 Robot match parameter
S4C1194 Coordinate origin parameter
S4C1195 Motion function parameter
S4C1196 Robot expand parameter
S4C1197 Safety function parameter
S4C1198 System match parameter
S4C1199 Machine safety signal allocation
S4C1200 Timer delay setting
S4C1201 Safety signal board allocation
S4C1202 Functional safety signal allocation
S4C1203 Safety circuit expanded signal allocation
S4C1204 Timer setting
S4C1205 Safety circuit signal display setting
S4C1206 Safety logic circuit
S4C1207 Safety logic circuit (System)
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• When the general-purpose register which is specified as

the output destination is used as the output destination
(the current value of TMR/CNT instruction or the destina-
tion of the operating instruction) by the ladder program,
the CRC value is not output. When setting, the register
number must not be duplicated.
NOTE
• When the Functional Safety Board FLASH Reset is
required (the CRC value is shown as an asterisk on the
TOTAL CRC CONFIRM window), the CRC value before
updating is output to the general-purpose register.
• The CRC value of both the safety logic circuit and the
safety logic circuit (system part) cannot be output.
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7.3.4 Data Monitor on the Total CRC Confirmation Window

On the total CRC confirmation window, the data to monitor can be
selected and monitored.
The procedure of the data monitor on the total CRC confirmation window
is as follows.
1. Change the mode to the security mode, and then select {SAFETY
FUNC.} → {TOTAL CRC CONFIRM} under the main menu.
– TOTAL CRC CONFIRM window appears.
2. Select {EDIT} → {SET CRC MONITOR}, and set the MONITOR to the
Include/Not include.
– If “STOP” is displayed on “TOTAL CRC CONFIRM” window, press
“STOP” before setting.
– When returning to “TOTAL CRC CONFIRM” window from “SET CRC
MONITOR” window, press {RETURN}.
– After setting, press {START}. Monitoring will start.
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3. RESULT can be confirmed on the page of “Total safety number” on the

TOTAL CRC CONFIRM window, on “SET CRC MONITOR” window,
and by the specific output signal.
– The page of total safety number
“TOTAL SAFETY NUMBER” window shows the following items.

Item Meaning
TOTAL SAFETY NUMBER “LAST UPDATE” when pressing {START}
(LATCH)
TOTAL SAFETY NUMBER The last update value of CRC for each data
(LAST UPDATE) included in “MONITOR”
MONITOR START The last date and time when pressing {START}
RESULT OK: The latch and the last update of the TOTAL
SAFETY NUMBER are equal, and the data
included in “MONITOR” is not changed.
NG: The latch and the last update of the TOTAL
SAFETY NUMBER are not equal, and the
data included in “MONITOR” is changed.
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– SET MONITOR window

When the data set to “Include” on “MONITOR” is changed, NG is
displayed on “RESULT”.
Only the items that included in the MONITOR during data monitor
are displayed on the RESULT.
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– Specific output signal

For the monitoring result of each item, output to the specific output
signal. For the item included in the MONITOR, when the CRC
(LATCH) and the CRC (LAST UPDATE) are same, ON is output,
and when not same, OFF is output. For the item not included in the
MONITOR, OFF is output.
Item Specific output signal Output value

Total safety number #52590
Safety logic circuit #52591
Machine safety signal allocation #52592
Timer delay #52593
Safety signal board allocation #52594
Functional safety signal allocation #52595
Safety circuit expanded signal allocation #52596
Timer #52597
Safety circuit signal display setting #52600
Tool #52601
Tool interference #52602
Home position calibration #52603
Axis range limit #52604
Axis speed monitor #52605 ON: RESULT OK
Robot range limit #52606 OFF: RESULT NG or Out of a
Speed limit #52607 Monitoring target
Tool angle monitor #52610
Tool change monitor / Tool number select #52611
Functional definition parameter #52612
System definition parameter #52613
Servo parameter #52614
Servo motor parameter #52615
Robot match parameter #52616
Coordinate origin parameter #52617
Motion function parameter #52620
Robot expand parameter #52621
Safety function parameter #52622
Safety logic circuit (System) #52623
System match parameter #52624
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8 Specific Output Signal

Signals shown below are output to the concurrent I/O while the functional
safety is used.
Signals output to the concurrent I/O are auxiliary signals

only to check the status of the functional safety.
NOTE
To implement the safety monitoring, use the safety output
signal. (Refer to chapter 5 “Safety Signal” .)
• 52010 to 52047
Outputs the monitoring status (valid/invalid) of each condition file of
the axis range limit function.
ON: Monitoring is valid
OFF: Monitoring is invalid
52017 52016 52015 52014 52013 52012 52011 52010

SOUT#1608 SOUT#1607 SOUT#1606 SOUT#1605 SOUT#1604 SOUT#1603 SOUT#1602 SOUT#1601
Axis range Axis range Axis range Axis range Axis range Axis range Axis range Axis range
limit limit limit limit limit limit limit limit
Condition file Condition file Condition file Condition file Condition file Condition file Condition file Condition file
8 7 6 5 4 3 2 1
Valid/Invalid Valid/Invalid Valid/Invalid Valid/Invalid Valid/Invalid Valid/Invalid Valid/Invalid Valid/Invalid
52027 52026 52025 52024 52023 52022 52021 52020

16 15 14 13 12 11 10 9
52037 52036 52035 52034 52033 52032 52031 52030

24 23 22 21 20 19 18 17
52047 52046 52045 52044 52043 52042 52041 52040

32 31 30 29 28 27 26 25
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• 52050 to 52087
the axis speed monitor function.
52057 52056 52055 52054 52053 52052 52051 52050

Axis speed Axis speed Axis speed Axis speed Axis speed Axis speed Axis speed Axis speed
monitor monitor monitor monitor monitor monitor monitor monitor
8 7 6 5 4 3 2 1
52067 52066 52065 52064 52063 52062 52061 52060

16 15 14 13 12 11 10 9
52077 52076 52075 52074 52073 52072 52071 52070

24 23 22 21 20 19 18 17
52087 52086 52085 52084 52083 52082 52081 52080

32 31 30 29 28 27 26 25
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• 52090 to 52127
the robot range limit function.
52097 52096 52095 52094 52093 52092 52091 52090

Robot range Robot range Robot range Robot range Robot range Robot range Robot range Robot range
8 7 6 5 4 3 2 1
52107 52106 52105 52104 52103 52102 52101 52100

16 15 14 13 12 11 10 9
52117 52116 52115 52114 52113 52112 52111 52110

24 23 22 21 20 19 18 17
52127 52126 52125 52124 52123 52122 52121 52120

32 31 30 29 28 27 26 25
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• 52130 to 52167
the speed limit function.
52137 52136 52135 52134 52133 52132 52131 52130

Speed limit Speed limit Speed limit Speed limit Speed limit Speed limit Speed limit Speed limit
8 7 6 5 4 3 2 1
52147 52146 52145 52144 52143 52142 52141 52140

16 15 14 13 12 11 10 9
52157 52156 52155 52154 52153 52152 52151 52150

24 23 22 21 20 19 18 17
52167 52166 52165 52164 52163 52162 52161 52160

32 31 30 29 28 27 26 25
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• 52130 to 52167
the tool angle monitor function.
52177 52176 52175 52174 52173 52172 52171 52170

Tool angle Tool angle Tool angle Tool angle Tool angle Tool angle Tool angle Tool angle
8 7 6 5 4 3 2 1
52187 52186 52185 52184 52183 52182 52181 52180

16 15 14 13 12 11 10 9
52197 52196 52195 52194 52193 52192 52191 52190

24 23 22 21 20 19 18 17
52207 52206 52205 52204 52203 52202 52201 52200

32 31 30 29 28 27 26 25
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• 52210 to 52367
the tool change monitor function.
52217 52216 52215 52214 52213 52212 52211 52210

Tool change Tool change Tool change Tool change Tool change Tool change Tool change Tool change
monitor(R1) monitor(R1) monitor(R1) monitor(R1) monitor(R1) monitor(R1) monitor(R1) monitor(R1)
8 7 6 5 4 3 2 1
52227 52226 52225 52224 52223 52222 52221 52220

Condition file Condition file Condition file Condition file Condition file Condition file Condition Condition file
16 15 14 13 12 11 file10 9
52237 52236 52235 52234 52233 52232 52231 52230

8 7 6 5 4 3 2 1
52247 52246 52245 52244 52243 52242 52241 52240

16 15 14 13 12 11 10 9
52257 52256 52255 52254 52253 52252 52251 52250

8 7 6 5 4 3 2 1
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52267 52266 52265 52264 52263 52262 52261 52260

Condition file Condition file Condition file Condition file Condition file Condition file Condition Condition file
16 15 14 13 12 11 file10 9
52277 52276 52275 52274 52273 52272 52271 52270

8 7 6 5 4 3 2 1
52287 52286 52285 52284 52283 52282 52281 52280

16 15 14 13 12 11 10 9
52297 52296 52295 52294 52293 52292 52291 52290

8 7 6 5 4 3 2 1
52307 52306 52305 52304 52303 52302 52301 52300

16 15 14 13 12 11 10 9
52317 52316 52315 52314 52313 52312 52311 52310

8 7 6 5 4 3 2 1
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52327 52326 52325 52324 52323 52322 52321 52320

16 15 14 13 12 11 10 9
52347 52346 52345 52344 52343 52342 52341 52340

8 7 6 5 4 3 2 1
52357 52356 52355 52354 52353 52352 52351 52350

16 15 14 13 12 11 10 9
52357 52356 52355 52354 52353 52352 52351 52350

8 7 6 5 4 3 2 1
52367 52366 52365 52364 52363 52362 52361 52360

16 15 14 13 12 11 10 9
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• 52370 to 52407
Outputs the monitoring result for each condition file of the axis range
limit function.
For details of the output value, refer to chapter 5.5 “Safety Signal
Output Value” .
52377 52376 52375 52374 52373 52372 52371 52370

8 7 6 5 4 3 2 1
Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring Monitoring
result result result result result result result result
52387 52386 52385 52384 52383 52382 52381 52380

16 15 14 13 12 11 10 9
52397 52396 52395 52394 52393 52392 52391 52390

24 23 22 21 20 19 18 17
52407 52406 52405 52404 52403 52402 52401 52400

32 31 30 29 28 27 26 25
8-9 HW1483576 188/203

HW1483576
• 52410 to 52447
Outputs the monitoring result for each condition file of the axis speed
monitor function.
Output Value” .
52417 52416 52415 52414 52413 52412 52411 52410

8 7 6 5 4 3 2 1
52427 52426 52425 52424 52423 52422 52421 52420

16 15 14 13 12 11 10 9
52437 52436 52435 52434 52433 52432 52431 52430

24 23 22 21 20 19 18 17
52447 52446 52445 52444 52443 52442 52441 52440

32 31 30 29 28 27 26 25
8-10 HW1483576 189/203

HW1483576
• 52450 to 52487
Outputs the monitoring result for each condition file of robot range
limit function.
Output Value” .
52457 52456 52455 52454 52453 52452 52451 52450

8 7 6 5 4 3 2 1
52467 52466 52465 52464 52463 52462 52461 52460

16 15 14 13 12 11 10 9
52477 52476 52475 52474 52473 52472 52471 52470

24 23 22 Monitoring 21 20 19 18 17
Monitoring Monitoring result Monitoring Monitoring Monitoring Monitoring Monitoring
result result result result result result result
52487 52486 52485 52484 52483 52482 52481 52480

32 31 30 Monitoring 29 28 27 26 25
Monitoring Monitoring result Monitoring Monitoring Monitoring Monitoring Monitoring
result result result result result result result
8-11 HW1483576 190/203

HW1483576
• 52490 to 52527
Outputs the monitoring result for each condition file of speed limit
function.
Output Value” .
52497 52496 52495 52494 52493 52492 52491 52490

8 7 6 5 4 3 2 1
52507 52506 52505 52504 52503 52502 52501 52500

16 15 14 13 12 11 9 8
52517 52516 52515 52514 52513 52512 52511 52510

24 23 22 21 20 19 18 17
52527 52526 52525 52524 52523 52522 52521 52520

32 31 30 29 28 27 26 25
8-12 HW1483576 191/203

HW1483576
• 52530 to 52567
Outputs the monitoring result for each condition file of tool angle
monitor function.
Output Value” .
52537 52536 52535 52534 52533 52532 52531 52530

8 7 6 5 4 3 2 1
52547 52546 52545 52544 52543 52542 52541 52540

16 15 14 13 12 11 10 9
52557 52556 52555 52554 52553 52552 52551 52550

24 23 22 21 20 19 18 17
52567 52566 52565 52564 52563 52562 52561 52560

32 31 30 29 28 27 26 25
8-13 HW1483576 192/203

HW1483576
• 52570 to 52577
For R1 to R8, outputs the monitoring result of the tool change moni-
tor function.
ON: Normal
OFF: Abnormal
52577 52576 52575 52574 52573 52572 52571 52570

(R8) (R7) (R6) (R5) (R4) (R3) (R2) (R1)
• 52580 to 52583
Outputs the status of the settings of the function disable mode.
• 52585
The comparison result of the following two tool files: the tool file that
was last saved on the safety board and the tool file to use normally is
output (TOOL.CND). ON is for the mismatch, and OFF is for the
match.
52585 52583 52582 52581 52580

SOUT#2062 SOUT#2060 SOUT#2059 SOUT#2058 SOUT#2057
Tool file Tool change Tool angle Robot range Axis speed
monitor monitor limit monitor
Comparison Function Function Function Function

mismatch disable mode disable mode disable mode disable mode
8-14 HW1483576 193/203

HW1483576
• 52590 to 52645
The result of the data monitoring in the total CRC confirmation win-
dow is output. If the item is included in the monitoring target and is
normal, ON is output, if it is abnormal, OFF is output, if it is not
included in the monitoring target, OFF is output.
52597 52596 52595 52594 52593 52592 52591 52590

Timer setting Safety logic Functional Safety signal Timer delay Machine Safety logic Total safety
Monitoring circuit safety signal board setting safety signal circuit number
result expanded allocation allocation Monitoring allocation Monitoring Monitoring
signal Monitoring Monitoring result Monitoring result result
allocation result result result
Monitoring
result
52607 52606 52605 52604 52603 52602 52601 52600

Speed limit Robot range Axis speed Axis range Home Tool Tool file Safety logic
Monitoring limit monitor limit position interference Monitoring circuit signal
result Monitoring Monitoring Monitoring calibration file result display
result result result Monitoring Monitoring setting
result result Monitoring
result
52617 52616 52615 52614 52613 52612 52611 52610

Coordinate Robot match Servo motor Servo System Functional Tool change Tool angle
origin parameter parameter parameter definition definition monitor/ Tool monitor
parameter Monitoring Monitoring Monitoring parameter parameter number Monitoring
Monitoring result result result Monitoring Monitoring select result
result result result Monitoring
result
52622 52621 52620

SOUT#2091 SOUT#2090 SOUT#2089
Safety Robot Motion
function expand function
parameter parameter parameter
Monitoring Monitoring Monitoring
result result result
8-15 HW1483576 194/203

HW1483576
52635 52634 52633 52632 52631 52630

SOUT#2102 SOUT#2101 SOUT#2100 SOUT#2099 SOUT#2098 SOUT#2097
Tool change Tool angle Speed limit Robot range Axis speed Axis range
monitor/Tool monitor All files are limit monitor limit
number All files are invalid. All files are All files are All files are
select invalid. invalid. invalid. invalid.
All files are
invalid.
52645 52644 52643 52642 52641 52640

SOUT#2110 SOUT#2109 SOUT#2108 SOUT#2107 SOUT#2106 SOUT#2105
Tool change Tool angle Speed limit Robot range Axis speed Axis range
monitor/Tool monitor All files are limit monitor limit
number All files are set to default. All files are All files are All files are
select set to default. set to default. set to default. set to default.
All files are
set to default.
8-16 HW1483576 195/203

HW1483576
9 Restriction
9.1 Functions Cannot Be Used Concurrently with Functional Safety Function
9 Restriction
9.1 Functions Cannot Be Used Concurrently with Functional

Safety Function
9.1.1 Functions Which Modifies Parameter or File during Playback Operation

As explained in chapter 7 “Data Protection” , data of parameters or files
are saved in a duplicated manner in the safety circuit board, and are
verified for safety.
When modifying these data, special procedures such as read back
operations or re-setting of the FLASH data are required.
For this reason, functions that modify parameters or file when executing
the play back operation cannot be used concurrently with the functional
safety function.
• Speed control function
• PMT function (SETTOOL instruction) (Can be used for
YAS2.80.00A(*)-00 or later.)
To use the functional safety and PMT function (SETTOOL instruction)
concurrently, refer to chapter 6.6 “Using the PMT Function Together with
the Functional Safety Function” .
9-1 HW1483576 196/203

HW1483576
9 Restriction
9.2 Functions Conditionally Used Concurrently with Functional Safety Function
9.2 Functions Conditionally Used Concurrently with

Functional Safety Function
9.2.1 Conveyor Synchronized Function, COMARC Function

To the conveyor synchronized function and COMARC function, the speed
for other purposes are added along with the normal operation speed in
this consequence, there may be a case where the TCP speed or the
flange speed cannot be controlled as specified.
Alarms and their countermeasures

Alarm 4785: F-SAFE SPEED MONITOR ERROR
Countermeasure: Set the limit value on the condition file with the
calculated value on the basis of the speed added by
each function.
Alarm 4786: F-SAFE TEACH SAFETY SPEED ERROR
Countermeasure: The operation speed of the manipulator exceeds the
speed limited for the teach mode (250 [mm/sec]). Input a full speed test
signal and disable the teach mode speed limit.
For the details, refer to chapter 4.4.5 “Speed Limit in Teach Mode” .
9.2.2 Servo Float Function

The manipulator position/speed and feedback position/speed may widely
differ while the servo float function is executed. At this time, results of
instruction monitoring and feed back monitoring vary.
The safety monitoring starts alarming at the earliest monitoring condition
error in the instruction monitoring or feedback monitoring.
The monitoring is normally executed even in the system where the servo
float function is available if this function is not executed (FLOATOF).
9.2.3 Motor Gun Function

The safety monitoring for the motor gun axis is not available. Functions
such as the robot range limit function for the manipulator with the motor
gun are available.
9.2.4 MotoPlus Function and MotoFit Function

When using the path correction function or the increment level movement
function in the MotoPlus function or the Motofit function, the speed limit
function is not available.
9.2.5 T-axis Endless Function, External Axis Endless Function

Safety monitoring cannot be performed for the axis which performs
endless operation. For the axis which does not perform endless operation,
safety monitoring is possible.
9-2 HW1483576 197/203

HW1483576
9 Restriction
9.2 Functions Conditionally Used Concurrently with Functional Safety Function
9.2.6 Gun Change Function and Group Change Function

With the functional safety, the position and the motion speed of the
manipulator are calculated based on the feedback from the encoder, to
perform a safety monitoring operation.
Thus, safety monitoring for a gun-change axis or a group-change axis
whose communication with the encoder is temporarily disconnected
cannot be performed.
However, the robot range monitoring, etc. for the manipulator which
includes a gun-change axis or a group-change axis can be performed.
9.2.7 Multi Layer Function

When using the multi layer function, the tool angle monitor function cannot
be used.
When the angle of the ground installation of the manipulator is except for
0°, the functional safety function is not available.
0
9-3 HW1483576 198/203

HW1483576
9 Restriction
9.3 Restriction of Operation
9.3 Restriction of Operation

When the functional safety function is available, operable security mode
for the following data varies.
Data Operation Security Security

(When functional (When functional
safety function is safety function is
available) not available)
Tool file Editing on the tool file window Safety1) Editing
Tool calibration Safety Editing
Automatic measurement of the tool load and Safety Editing
the center of gravity
Loading from the external memory device Safety Editing
File initialization in the maintenance mode Safety Editing
1)
Tool interference file Editing on the tool interference file window Safety Editing
Loading from the external memory device Safety Editing
File initialization in the maintenance mode Safety Editing
Home position Edit on the home position window Safety Management
Loading from the external memory device Safety Management
File initialization in the maintenance mode Safety Management
Zeroing function Safety Management
2)
Each parameter Loading from the external memory device Safety Management
File initialization in the maintenance mode Safety Management
1 This setting can be changed. For the details, refer to chapter 6.5 “Security Level Setting for Tool File and Tool
Interference Files” .
2 Object parameters: ALL, RC, SD, RO, FD, SV, SVM, MF, RE, FMS
9.3.1 File/Parameter Loading

After loading the data related to the functional safety, re-set the data by
following the procedures described in chapter 7.2 “FLASH Data Reset” .
(After loading the data related to the functional safety, the message
“Select ‘Safety Board FLASH Reset’ in the maintenance mode.” appears.)
The following restrictions apply until the power supply to the YRC1000 is
turned OFF.
• The servo cannot be turned ON.
• All of the safety monitoring functions of the functional safety are
disabled.
9-4 HW1483576 199/203

HW1483576
10 Error
10 Error
Errors related to the settings of the functional safety are listed in the
following.
These errors warn the operator that it is impossible to advance to the next
operation due to an incorrect operation or setting.
Error No. Data Error Message Contents
1140 - No input signals are set.

1141 - Overlapped input signals exist.
1142 - Overlapped output signals exist.
1143 - The signal which cannot be used is set up.
1150 * There are abnormal values in the file.
1 FILE NO.
2 FILE SET STATUS
3 FILE VALID CONDITION
4 ALARM SET
5 STOP METHOD
6 Control GROUP
7 Robot range limit:
MONITOR TARGET
8 Robot range limit: COORDINATE
SHAPE TYPE
10 Range combination: INPUT FILE1, INPUT
FILE2 and OUTPUT FILE
11 Range combination: LOGIC
1151 * Check the numeric value settings.
1 Axis range limit: the valid axis can be set by
maximum < minimum.
set the “Z UPPER < Z LOWER“ when the
creating method is the prism.
set the same coordinate at the two vertices
of the plane monitoring.
10-1 HW1483576 200/203

HW1483576
10 Error
1152 * The set values are out of range.

1 Axis range limit: maximum value and
minimum value
2 Axis speed monitor: speed
3 Axis speed monitor: acceptable range
4 Speed limit: limit speed (Robot)
5 Speed limit: limit speed (Station)
6 Speed limit: detection delay time
7 Speed limit: acceptable range
8 Robot range limit: used point number
9 Robot range limit: X and Y coordinates
10 Robot range limit: Z coordinate
11 Approach warning buzzer: buzzer occurring
distance
12 Approach warning buzzer: universal output
number
13 Tool angle monitor: reference angle
14 Tool angle monitor: limit angle
16 Tool change monitor: tool number
17 Tool change monitor: detection delay time
1160 * The selected control group cannot be
applied to functional safety.
2 The target group of the group change
3 The target group of the gun change
4 The group with the endless axis
5 The group with the speed control axis
6 The group with unsetting of the current
position set up parameter
7 The group with unsetting of the
approximation model
8 The group is not the monitoring target of the
functional safety.
9 The group with the functional safety
monitoring invalid axis
1161 * The axis that cannot be applied to functional
safety exist.
10 to 17 The axis motion range limit and the axis
speed monitor are valid, and the axes are
endless axes (10+axis number).
speed control axes (20+axis number).
functional safety monitoring invalid axes
(30+axis number).
1162 * The axis to which coasting distance is not
set cannot be set to VALID.
0 to 7 The coasting values are not set when the
axis is valid (axis number).
10-2 HW1483576 201/203

HW1483576
10 Error
1163 * The group to which coasting distance is not

set cannot be set to VALID.
1170 * Range cannot be configured with this
setting.
1 Invalid robot range limit file number
2 Inequality of the neighboring lines in the
initial and terminal node
3 There is the same point at the specified
vertex.
4 Lack of the setting vertex number
5 The setting range lines are interfering each
other.
8 Inappropriate height setting
9 Detected the non-convex range
12 The exceeded number of the vertices
13 Failure to create the data for the monitoring
the outside of the range.
14 Failure to create the plane surface range.
1180 - Same file cannot be set.
1181 - The specified output file is under monitoring.
1182 - Monitor type differs between INPUT1 and
INPUT2.
1183 - Coord type differs between INPUT1 and
INPUT2.
1184 - The height in Z-direction differs between
INPUT1 and INPUT2.
1185 * Range combination cannot be performed.
1 Inappropriate specified combination
2 The exceeded number of the point of the
intersection
3 Failure to combine the range “AND”
4 Failure to combine the range “OR”
1186 - The combination use of the files where plane
monitoring is set is not permitted.
1190 - Cannot modify this parameter.
1191 - Axis range limit function is temporally
disabled.
1192 - Robot range limit function is temporally
disabled.
1194 - Tool range limit function is temporally
disable.
1195 * The tool No. must be the same as the
registered tool No.
xxx The control group for the operation target.
1196 - Select “Safety Board FLASH Reset”.
10-3 HW1483576 202/203

YRC1000 OPTIONS
INSTRUCTIONS
FOR FUNCTIONAL SAFETY FUNCTION
C 2016 YASKAWA ELECTRIC CORPORATION

Published by YASKAWA
October 2019 16-12
MANUAL NO.
HW1483576 5
203/203

Instructions: Yrc1000 Options

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YRC1000 OPTIONS

Notes for Safe Operation

Indicates an imminently hazardous

Indicates a potentially hazardous

Indicates a hazardous situation,

NOTICE is the preferred signal word

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

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

iii HW1483576 3/203

• Before releasing the emergency stop, make sure to remove the

• Observe the following precautions when performing a teaching

Definition of Terms Used Often in This Manual

Descriptions of the programming pendant keys, buttons, and displays are

Start button* Hold button*

Description of the Operation Procedure

vii HW1483576 7/203

1 Overview of the Function ................................................................................................................ 1-1

1.1 Outline ............................................................................................................................... 1-1

1.2 List of Safety Functions...................................................................................................... 1-1

1.3 Structure of Configuration Files ......................................................................................... 1-2

2 System Configuration...................................................................................................................... 2-1

2.1 Outline ............................................................................................................................... 2-1

2.1.1 Safety Circuit Board (JANCD-ASF01-E)............................................................... 2-1

2.1.2 Expansion Safety I/O Board (JANCD-ASF02-E) .................................................. 2-1

2.1.3 Expansion Safety Terminal Block Board .............................................................. 2-2

2.1.4 Wiring Procedure of the Terminal Block ............................................................... 2-5

2.1.5 Functional Safety General-Purpose Input Signal 1 to 8........................................ 2-7

2.1.6 Functional Safety General-Purpose Output Signal 1 to 8..................................... 2-8

2.2 System Configuration for Dual-Arm Manipulator ............................................................. 2-11

3 Common Operation......................................................................................................................... 3-1

3.1 Security Mode When Using This Function......................................................................... 3-1

3.2 Readback Operation .......................................................................................................... 3-3

3.2.1 Readback Operation of the Configuration File...................................................... 3-3

3.2.2 Operations in Which the READBACK Window Is Shown ..................................... 3-5

3.3 External Memory Device (Saving/Loading)........................................................................ 3-9

4 Details of Functional Safety Function.............................................................................................. 4-1

4.1 Axis Range Limit Function ................................................................................................. 4-1

4.1.1 Outline .................................................................................................................. 4-1

4.1.2 Axis Range Limit Function Window ...................................................................... 4-3

4.1.3 Axis Range Limit Condition File Setting................................................................ 4-5

4.1.4 Confirming Method of Each Axis Operating Angle ............................................... 4-8

4.1.5 Confirmation of Safety Range............................................................................. 4-12

4.1.6 Start the Axis Range Limit Operation ................................................................. 4-13

4.1.7 Monitoring Status Confirmation Display.............................................................. 4-14

4.2 Axis Speed Monitor Function ........................................................................................... 4-17

4.2.1 Outline ................................................................................................................4-17

4.2.2 Axis Speed Monitor Function Window ................................................................ 4-18

viii HW1483576 8/203

4.2.3 Axis Speed Monitor Condition File Setting ......................................................... 4-20

4.2.4 Start the Axis Speed Monitor Operation ............................................................. 4-22

4.3 Robot Range Limit Function ............................................................................................ 4-23

4.3.1 Outline ................................................................................................................ 4-23

4.3.2 Robot Range Limit Function Window ................................................................. 4-26

4.3.4 Confirmation of the Safety Range ...................................................................... 4-39

4.3.5 Starting the Robot Range Limit .......................................................................... 4-41

4.3.6 Switch the Monitoring Area................................................................................. 4-42

4.3.7 Safety Range and Manipulator Position ............................................................. 4-44

4.3.8 Proximity Warning Buzzer Setting ...................................................................... 4-48