YASKAWA Motoman UP6 Instructions Manual Download

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9.2 Notes on Maintenance Procedures

9-15

9.2.8

Grease Replenishment for R-Axis Cross Roller Bear-
ing

Fig. 32 R-Axis Cross Roller Bearing Diagram

Remove the Co plug for air flow.

Inject grease into the Ci grease inlet using a grease gun. (Refer to " Fig. 32 R-Axis

Cross Roller Bearing Diagram ").

Reinstall the Co plug.

Grease type: Alvania EP grease 2

Amount of grease: 3cc

(6cc for 1st supply)

The Co exhaust port is used for air flow. Do not inject excessive grease into the gear
grease inlet.

Co plug for air flow

R-axis cross
roller bearing

Ci: Grease Inlet

(G Nipple A-MT6

Section A-A

N OT E

Summary of Contents for Motoman UP6

Page 1: ...Lane West Carrollton OH 45449 TEL 937 847 6200 FAX 937 847 6277 24 Hour Service Hotline 937 847 3200 QVQOCP 4 QPVTQNNGT 72 CPKRWNCVQT CPWCN Part Number 142104 1 Release Date January 31 2001 Document...

Page 2: ...produced or transmitted to other parties without the expressed written authorization of Motoman Inc 2003 by MOTOMAN All Rights Reserved Because we are constantly improving our products we reserve the...

Page 3: ...Manipulator Manual Section Page 1 INTRODUCTION 1 1 2 SAFETY 2 1 3 UP6 INSTRUCTIONS R2 3 1 4 XRC INSTRUCTIONS NORTH AMERICAN STANDARD R1 4 1 5 XRC INSTRUCTIONS GENERAL R2 5 1 6 XRC TROUBLESHOOTING 6 1...

Page 4: ...UP6 Manipulator Manual ii MOTOMAN NOTES...

Page 5: ...troller and contains the following sections SECTION 1 INTRODUCTION Provides general information about the structure of this manual a list of reference documents and customer service information SECTIO...

Page 6: ...or s Manual for Arc Welding P N 142098 1 Vendor manuals for system components not manufactured by Motoman 1 3 Customer Service Information If you are in need of technical assistance contact the Motoma...

Page 7: ...and maintain the robot cell The robot must not be operated by personnel who have not been trained We recommend that all personnel who intend to operate program repair or use the robot system be traine...

Page 8: ...and imminent hazards that if not avoided will result in immediate serious personal injury or loss of life in addition to equipment damage WARNING Information appearing under the WARNING caption concer...

Page 9: ...nd Outputs The robot must be placed in Emergency Stop E STOP mode whenever it is not in use In accordance with ANSI RIA R15 06 section 6 13 4 and 6 13 5 use lockout tagout procedures during equipment...

Page 10: ...th the operation of the equipment must understand potential dangers of operation Programming tips are as follows Any modifications to PART 1 of the controller PLC can cause severe personal injury or d...

Page 11: ...ent for proper operation Repair or replace any non functioning safety equipment immediately Inspect the robot and work envelope to ensure no potentially hazardous conditions exist Be sure the area is...

Page 12: ...es are made A backup must always be made before any servicing or changes are made to options accessories or equipment to avoid loss of information programs or jobs Do not enter the robot cell while it...

Page 13: ...tion read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN UP6 INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR S MANUAL YASNAC X...

Page 14: ...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 modifi...

Page 15: ...a potentially hazardous situation which if not avoided could result in death or serious injury to personnel Indicates a potentially hazardous situation which if not avoided could result in minor or m...

Page 16: ...envelope to teach a job Operator injury can occur if the Teach Lock is not set and the manipulator is started from the playback panel Observe the following precautions when performing teaching operat...

Page 17: ...e that all other necessary processing has been performed Check for problems in manipulator movement Check for damage to insulation and sheathing of external wires Always return the programming pendant...

Page 18: ...e labels Also an indentification label with important information is placed on the body of the manipula tor Prior to operating the manipulator confirm the contents MOTOMAN TYPE ORDER NO PAYLOAD kg MAS...

Page 19: ...nted Directly on the Floor 3 4 3 3 Types of Mounting 3 5 3 3 1 S Axis Working Range 3 5 3 3 2 Affixing the Manipulator Base 3 5 3 3 3 Precautions to Prevent the Manipulator from Falling 3 5 3 4 Locati...

Page 20: ...er 9 9 n Grease Replenishment Refer to Fig 27 L Axis Speed Reducer Diagram 9 9 n Grease Replacement Refer to Fig 27 L Axis Speed Reducer Diagram 9 10 9 2 4 Grease Replenishment Replacement for U Axis...

Page 21: ...ions ordered should be checked as well Manipulator XRC Programming Pendant Feeder Cable Between Controller and Manipulator Confirm that the manipulator and the XRC have the same order number Special c...

Page 22: ...rresponds to the XRC The order number is located on a label as shown below Fig 1 Location of Order Number Labels a XRC Front View b Manipulator Top View Label Enlarged view THE MANIPULATOR AND THE CON...

Page 23: ...d with jigs before transporting and lift it in the posture as shown in Fig 2 Transporting Position Fig 2 Transporting Position Sling applications and crane or forklift operations must be performed by...

Page 24: ...X 3 B C M6 X 1 Check that the eyebolts are securely fastened The weight of the maniputator is approximately 150kg including the shipping bolts and jigs Use a wire rope strong enough to withstand the...

Page 25: ...amage When mounting the manipulator on the ceiling or wall the base section must have sufficient strength and rigidity to support the weight of the manipulator Also it is necessary to consider counter...

Page 26: ...eness signals 3 2 Mounting Procedures for Manipulator Baseplate The manipulator should be firmly mounted on a baseplate or foundation strong enough to sup port the manipulator and withstand repulsion...

Page 27: ...e and an M16 size or larger anchor bolt is recommended Affix the manipulator by fastening the plate with the M16 mm anchor bolts The plate is tapped for M16 50mm length bolts Tighten the bolts and anc...

Page 28: ...f the manipulator as shown in Table 1 As a rough standard when there is a concrete thickness floor is 150mm or more the base of the manipulator can be fixed directly to the floor with M16 anchor bolts...

Page 29: ...must be 30 3 3 2 Affixing the Manipulator Base When performing a wall or ceiling installation be sure to use four M16 hexagon socket head cap bolts Use a torque of 206N m when screwing in the bolts 3...

Page 30: ...ioned environmental conditions 0 to 45 C Ambient temperature 20 to 80 RH no moisture Free from dust soot or water Free from corrosive gases or liquid or explosive gases Free from excessive vibration l...

Page 31: ...e wiring make sure to turn the primary power supply off and put up a warning sign ex DO NOT TURN THE POWER ON Failure to observe this warning may result in fire or electric shock Wiring must be perfor...

Page 32: ...s to the manipulator verify the numbers 1BC and 2BC on both power supply cables and the manipulator base connectors When connecting adjust the cable connector positions to the main key positions of th...

Page 33: ...nnect each cable to the boards Be sure to verify the numbers on both the cable and board connectors before connecting and to fasten the bolts on 1BC connectors to prevent cables from loosening Fig 8 P...

Page 34: ...XIU01 CN25 Signal Cable Connector No XIU01 CN29 Power Cable Grounding plate for Signal and power line Terminal No E Signal Cable Connector No WRCA01 CNPG456 upper WRCA01 CNPG123 lower Power Cable Con...

Page 35: ...arm 190 170 R Axis wrist roll 180 B Axis wrist pitch yaw 225 45 T Axis wrist twist 360 Maximum Speed S Axis 2 44 rad s 140 s L Axis 2 79 rad s 160 s U Axis 2 97 rad s 170 s R Axis 5 85 rad s 335 s B...

Page 36: ...5 2 Part Names and Working Axes 5 2 5 2 Part Names and Working Axes Fig 10 Part Names and Working Axes 5 3 Baseplate Dimensions Fig 11 Baseplate Dimensions mm View A...

Page 37: ...5 4 Dimensions and Working Range 5 3 5 4 Dimensions and Working Range Fig 12 Dimesions and Working Range Point P WorkingRange Point P...

Page 38: ...e Fig 13 B Axis Working Range 5 6 Alterable Working Range The working range of the S Axis can be altered according to the operating conditions as shown in Table 3 S Axis Working Range If alteration is...

Page 39: ...olume load is small refer to the moment arm rating shown in Fig 14 Moment Arm Rating The allowable total inertia is calculated when the moment is at the maximum Contact your Yaskawa representative whe...

Page 40: ...arks it is recommended that the attachment be mounted inside the fitting Fitting depth of inside and outside fittings must be 5mm or less Fig 15 Wrist Flange Wash off anti corrosive paint solid color...

Page 41: ...nstance when the mass installed in the wrist point is 6kg the mass which can be installed on the upper arm becomes 9kg 7 1 2 Installation Position There is a limitation also on the installation positi...

Page 42: ...Fig 19 Detailed Drawing of Connector Pin Numbers The same pin number 1 16 of two connectors is connected in the lead line of single 0 2mm2 0 75mm2 or 1 25mm2 Cable connector provided on U axis is Type...

Page 43: ...shown in Fig 20 Location of Limit Switches The limit switch for the S Axis is standard The limit switch for the L and U Axes are optional model UP6 A01 The inspection and adjustment of the limit swit...

Page 44: ...and location of connectors see Fig 21 Location and Numbers of Connec tors Fig 21 Location and Numbers of Connectors Table 5 List of Connector Types Name Type of Connector Base Connector for Internal...

Page 45: ...6 CN5 4 CN5 3 CN6 1 CN6 5 CN6 3 CN6 4 CN6 2 LB1 BC2 0V 24V E SS2 CN2 6 CN3 6 CN4 6 CN5 6 CN6 6 24 19 47 21 45 22 16 14 37 11 39 13 WRCA01 CNPG123 8 3 FG 31 5 29 6 22 24 45 19 47 14 16 21 CNPG456 WRCA0...

Page 46: ...1 CN 1 2 CN 1 4 CN 1 3 CN 1 5 CN 1 6 CN2 4 CN2 3 CN2 5 CN2 2 CN2 1 MU3 MW3 ME3 BA3 MV3 MU4 BA4 ME4 MW4 MV4 CN3 4 CN3 3 CN3 5 CN3 2 CN3 1 CN4 4 CN4 3 CN4 5 CN4 2 CN4 1 MU5 MW5 ME5 BA5 MV5 MV6 MU6 BA6 M...

Page 47: ...ower sup ply off and put up a warning sign ex DO NOT TURN THE POWER ON Failure to observe this warning may result in electric shock or injury Maintenance and inspection must be performed by specified...

Page 48: ...s Spanner Wrench Tighten loose bolts Replace if necessary Cover mount ing screws Screw driver Wrench Tighten loose bolts Replace if necessary Base connec tors Manual Check for loose con nectors RBT ax...

Page 49: ...lace grease 3 12000H cycle See Par 9 2 3 Grease Replenishment Replacement for L Axis Speed Reducer RBT axes speed reduc ers Grease Gun Check for malfunc tion Replace if nec essary Supply grease 3 6000...

Page 50: ...ce of a grease leakage indicates the possibility that grease has seeped into the motor This can cause a motor breakdown Contact your Yaskawa representative Fig 23 Inspection Parts and Inspection Numbe...

Page 51: ...ers in Table 6 Inspection Items Table 7 Inspection Parts and Grease Used No Grease Used Inspected Parts 12 13 Molywhite RE No 00 S L and U axis speed reducers 14 15 Harmonic Grease SK 1A R B and T axi...

Page 52: ...4 Remove the plastic tape insulation tape protecting the connection part of the battery unit in the manipulator 5 Connect the new battery Battery Unit Connector Base Connector Base Bolt Support See Pr...

Page 53: ...e union and then mount the connector base 9 2 2 Grease Replenishment Replacement for S Axis Speed Reducer Fig 26 S Axis Speed Reducer Diagram Remove the old battery unit after connecting the new one s...

Page 54: ...The grease replacement is complete when new grease appears in the So exhaust port The new grease can be distinguished from the old grease by color 4 Move the S axis for for a few minutes to discharge...

Page 55: ...he L Axis for for a few minutes to discharge the excess grease 5 Wipe the Lo exhaust plugs with a cloth and reinstall the plugs For ceiling mounted manipulators the exhaust port and the grease inlet a...

Page 56: ...few minutes to discharge the excess grease 6 Wipe the Lo exhaust plugs with a cloth and reinstall the plugs 9 2 4 Grease Replenishment Replacement for U Axis Speed Reducer Fig 28 U Axis Speed Reducer...

Page 57: ...g a grease gun 4 The grease replacement is complete when new grease appears in the Uo exhaust ports The new grease can be distinguished from the old grease by color 5 Move the U Axes for a few minutes...

Page 58: ...grease inlet using a grease gun Refer to Fig 29 R Axis Speed Reducer Diagram 3 Reinstall the Ro plug Grease type Harmonic grease SK 1A Amount of grease 8cc 16cc for first supply The Ro exhaust port i...

Page 59: ...e U arm cover side of the B axis speed reducer Grease type Harmonic grease SK 1A Amount of grease For B axis Bi 10cc 20cc for 1st supply For T axis Ti 5cc 10cc for 1st supply The Bo and To exhaust por...

Page 60: ...ct grease into the gear grease inlet using a grease gun Refer to Fig 31 T Axis Gear Diagram 3 Reinstall the Bo plug Grease type Harmonic grease SK 1A Amount of grease 5cc 10cc for 1st supply The Bo ex...

Page 61: ...e into the Ci grease inlet using a grease gun Refer to Fig 32 R Axis Cross Roller Bearing Diagram 3 Reinstall the Co plug Grease type Alvania EP grease 2 Amount of grease 3cc 6cc for 1st supply The Co...

Page 62: ...or with CAUTION label Connect the battery unit with reference to the following figure before removing the encoder connector with CAUTION label Fig 34 Encoder Connector Diagram Cover Cover joining face...

Page 63: ...y Qty per Unit Remarks A 1 Grease Molywhite RE No 00 Yaskawa Electric Corporation 16kg A 2 Grease Harmonic Grease SK 1A Harmonic Drive System Co Ltd 2 5kg A 3 Grease Alvania EP Grease 2 Showa Oil Co L...

Page 64: ...ith brake with key lead terminal treatment comple tion C 19 L Axis AC Servomotor HW9381363 A Yaskawa Electric Corporation 1 1 With brake with key lead terminal treatment comple tion C 20 R B and T Axe...

Page 65: ...11 1 S Axis Parts List 11 1 11 Parts List 11 1 S Axis Parts List...

Page 66: ...2303 1 Cover 1 1024 M5 16 APS bolt 4 1025 HW9302270 1 Cover 1 1026 GT SA M6 15 Socket screw 2 1027 CD 31 Saddle 1 1028 M6 8 APS bolt 2 1029 TA1 S10 Clamp 1 1030 M5 10 APS bolt 1 1031 T50R Insulok tie...

Page 67: ...11 2 L U Axis Driving Unit 11 3 11 2 L U Axis Driving Unit...

Page 68: ...2010 2H 6 Spring washer 1 2011 HW9302190 1 Cover 1 2012 M6 8 APS bolt 4 2013 SGMDH 06A2A YR 24 Motor 1 2014 GT SA M8 30 Socket screw 4 2015 HW9280738 A Reduction Gear 1 2016 M4 50 Socket screw 1 2017...

Page 69: ...11 3 R Axis Driving Unit 11 5 11 3 R Axis Driving Unit...

Page 70: ...HW9301500 1 Stopper 1 3014 HW9405356 1 Plate 1 3015 M5 10 APS bolt 2 3016 HQE10 03 Union 1 3017 PT3 8 Plug 1 3018 HW9301976 1 Support 1 3019 GT SA M5 12 Socket screw 2 3020 HW9302409 1 Support 1 3021...

Page 71: ...11 4 Wrist Unit 11 7 11 4 Wrist Unit...

Page 72: ...A Gear 1 4023 6811LLU Bearing 1 4024 HW9482218 A Bearing 1 4025 6900ZZ NS7 Bearing 1 4026 6902ZZ NS7 Bearing 1 4027 HW9381454 A Reduction gear 1 4028 GT SA M4 12 Socket screw 7 4029 GT SA M4 12 Socke...

Page 73: ......

Page 74: ...IJING OFFICE Room No 301 Office Building of Beijing Intemational Club 21 Jianguomenwai Avenue Beijing 100020 China SHANGHAI OFFICE 27 Hui He Road Shanghai 200437 China YASKAWA JASON HK COMPANY LIMITED...

Page 75: ...eration read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR S MANUAL YASNAC XR...

Page 76: ...with the protective covers or shields removed for clarity Be sure all covers and shields are replaced before operating this product The drawings and photos in this manual are representative examples...

Page 77: ...a potentially hazardous situation which if not avoided could result in death or serious injury to personnel Indicates a potentially hazardous situation which if not avoided could result in minor or m...

Page 78: ...envelope to teach a job Operator injury can occur if the Teach Lock is not set and the manipulator is started from the playback panel Observe the following precautions when performing teaching operat...

Page 79: ...e that all other necessary processing has been performed Check for problems in manipulator movement Check for damage to insulation and sheathing of external wires Always return the programming pendant...

Page 80: ...th ex ENTER Symbol Keys The keys which have a symbol printed on them are not denoted with but depicted with a small picture ex page ke The cursor key is an exception and a picture is not shown Axis Ke...

Page 81: ...egular Inspections 3 1 3 2 XRC Inspections 3 2 3 2 1 Checking if the Doors are Firmly Closed 3 2 3 2 2 Checking for Gaps or Damage in the Sealed Construction Section 3 3 3 3 Cooling Fan Inspections 3...

Page 82: ...viii...

Page 83: ...hing operations within the working envelope of the manipulator Always view the manipulator from the front Always follow the predetermined operating procedure Always have an escape plan in mind in case...

Page 84: ...heck for problems in manipulator movement Check for damage to the insulation and sheathing of external wires Always return the programming pendant to its specified position after use If the programmin...

Page 85: ...0 V 208 V Switch built in transformer tap according to the supplied voltage on customer side 480 VAC is set before ship ment Grounding Grounding resistance 100 or less Exclusive grounding Digital I O...

Page 86: ...standard Running Speed Limit User definable Deadman Switch 3 position type Servo power can be turned on at the mid position only Located on programming pendant Collision proof Frames S axis frame dou...

Page 87: ...obot stop Execution of some instruc tions during robot motion Operation Instruc tions Preparing the operation instructions for each application Arc ON Arc OFF etc Variable Global variable Local variab...

Page 88: ...QS1 Transformer NETH1000AUL16 1 1KVA Servopack CACR SV3AAA JZNC XIU01 CN28 CN29 CN30 CN07 CN27 CN26 CN04 CN24 CN25 CN12 CN13 CN22 CN23 CN03 CN10 CN11 CN21 CN02 CN01 CN20 CN06 Power Supply Unit with p...

Page 89: ...S16 4 5kVA CACR SK16AAC SK16X 240 480 575V 208V JZNC XRK01 B 1 CPU Unit JZRCR XFL02 Sectional view A A JZRCR XPU09 A Fuse Class CC 5A UP6 Fues Class CC 10A Sk16X CP33FS 10D UP6 CP33FS 15D SK16X A UP6...

Page 90: ...lass CC 15A Disconnecting Switch 194R NC030P3 Servo Unit CACR SK45AAB SK45X CACR SK16MAAB SK16M CPU Unit JZNC XRK01B 1 Sectional view A A Class H Transformer NETH8000AULS16 8kVA 240 480 575V 208V CACR...

Page 91: ...r NETH8000AULS16 8kVA Converter JUSP ACP35JAA Huse Class CC 20A Disconnecting Switch 194R NC030P3 Servopack CACR UP130AAB UP130 and UP165 CACR UP130AABY18 UP200 and UP130R I O Power ON Unit JZNC XIU01...

Page 92: ...Unit JZNC XRK01B 1 Playback Panel ZY1C SS3152 Brake Release Operation Panel Brake Reliase Control Board JZRCR XFL02 Disconnecting Switch QS1 194R NC030P3 Fuse Class CC 30A No Fuse Breaker QF2 BU ECA3...

Page 93: ...tem of the Controller Interior Cooling System SV3X Cooling System Except for SV3X 1KM Servo Backside Duct Fan Air Inlet Servopack Air Outlet Servopack Natural heat radiation Air Output Backside Duct F...

Page 94: ...1 4 Equipment Configuration 1 12...

Page 95: ...ons within the working envelope of the manipulator Always view the manipulator from the front Always follow the predetermined operating procedure Always have an escape plan in mind in case the manipul...

Page 96: ...res prior to performing teach ing operations If problems are found correct them immediately and be sure that all other necessary processing has been performed Check for problems in manipulator movemen...

Page 97: ...y Unit Configuration JZRCR XPU07 for UP130 UP130R UP165 UP200 SK300X and SP100X 4X Contactor Output 1KM Contactor 1Z Noise Filter 5X Single 200 VAC Output Connector Contactor Output etc 1X Single phas...

Page 98: ...16MX NJ2096 3 DATE 1 1999 JAPAN YASKAWA ELECTRIC CORPORATION TYPE SER NO 1 2 3 4 1Z Noise Filter 1X Single phase Output Connector 1KM Contactor 1F 2F Fuse 5X Single phase Output Connector Connector Ou...

Page 99: ...U03 JAPAN TYPE SER NO YASKAWA ELECTRIC CORPORATION 1 1999 1Z Noise Filter 1KM Contactor 1F 2F Fuse 3X Triple phase 200 VAC input 5X Single phase 200 VAC Output Connector Contactor Output etc 4X Contac...

Page 100: ...ased as long as the button is pressed Watch on your feet and surroundings when releasing the brake When the brake is released the robot may move by its own weight which may cause a injury and damage t...

Page 101: ...XRC Controller Check that the doors are completely closed Daily Check for gaps or dam age to the sealed con struction Monthly Fan on upper part of Servo and backside duct fan Check operation As requir...

Page 102: ...ntenance after the main power is turned off CW Open CCW Close Make sure push the door closed and turn the door lock with the driver When the door is closed turn the door lock until the door clicks YAS...

Page 103: ...ock and check that no excessive gaps exist around the edge of the door 3 3 Cooling Fan Inspections Inspect the cooling fans as required A defective fan can cause the XRC to malfunction because of exce...

Page 104: ...3 Cooling Fan Inspections 3 4 Cooling Fan Construction Except for SV3X Servo pack Natural heat radiation Backside duct fan Air Inlrt In panel fan on Upper part of esrbo Air Outlrt Natural heat radiati...

Page 105: ...he TEACH lamp lights 2 Press SERVO ON READY on the playback panel The SERVO ON READY lamp blinks 3 Press TEACH LOCK on the programming pendant The TEACH LOCK LED blinks 4 When the deadman switch is gr...

Page 106: ...o replace the battery is described in 4 1 1 Replacing the Disconnecting Switch 3 7 Power Supply Voltage Confirmation Check the voltage of 1 R 3 S 5 T terminal of the disconnecting switch QS1 with an e...

Page 107: ...of input power supply with an electric tester Normal value 575 480 240V 10 15 Disconnecting Switch QS1 Check Turn on the control power supply and check the open phase volt age of U V W of the disconne...

Page 108: ...3 8 Open Phase Check 3 8...

Page 109: ...rning ON the power supply during maintenance put up a warning sign such as DO NOT TURN ON THE POWER at the primary power supply knife switch wiring circuit breaker etc and at the YASNAC XRC and relate...

Page 110: ...witch Configuration If a fuse appears to be blown remove each fuse shown above and check the continuity with an electric tester If the fuse is blown replace it with the same type of fuse supplied Part...

Page 111: ...thout transformer SV3X ATDR3 3A Class CC ATDR10 10A Class CC UP6 ATDR5 5A Class CC ATDR10 10A Class CC SK16X ATDR10 10A Class CC ATDR15 15A Class CC SK45X SK16MX ATDR15 15A Class CC ATDR20 20A Class C...

Page 112: ...use Locations in Power Supply Unit XPU07 for UP130 UP130R UP165 UP200 SK300X and SP100X Parts No Fuse Name Specification 1F 2F Control Power Supply Fuse 250V 10A Time Lag Fuse Std 326010 250V 10A LIT...

Page 113: ...rts 4 5 Fuse Locations in Power Supply Unit XPU08 for SK45X and SK16MX 1 1999 DATE NJ2096 3 SER NO TYPE JAPAN YASKAWA ELECTRIC CORPORATION 2F 4X 10A 250V JZRCR XPU 1F 10A 250V 5X 1X 1KM 1F 2F Fuse 250...

Page 114: ...ity with an electric tester If the fuse is blown replace it with the same type of fuse supplied Determine and correct the cause of the blown fuse If the problem is uncorrected the fuse may blow again...

Page 115: ...CPS 150F 3 I O Power ON unit JZNC XIU01 Power ON circuit board JANCD XTU01 Specific I O circuit board JANCD XIO01 General I O circuit board JANCD XIO02 4 Brake release operation board JARCR XFL02 5 Tr...

Page 116: ...k List Small Capacity Component SV3X UP6 SK16X Type Type Type Servopack CACR SV3AAA CACR UP6AAC CACR SK16AAC Converter JUSP WS05JAA JUSP ACP05JAA JUSP ACP05JAA Amplifier S JUSP WS02AA JUSP WS05AAY17 J...

Page 117: ...ontrol circuit board JASP WRCA01 JASP WRCA01 Converter JUSP ACP25JAA JUSP ACP25JAA Control power supply JUSP RCP01AAC JUSP RCP01AAC Component UP130 UP165 UP130R UP200 Type Type Servopack CACR UP130AAB...

Page 118: ...JUSP WS60AAY18 L JUSP WS60AAY18 JUSP WS60AAY18 U JUSP WS60AAY18 JUSP WS60AAY18 R JUSP WS30AAY18 B JUSP WS30AAY18 T JUSP WS30AAY18 JUSP WS20AAY19 Servo control circuit board JASP WRCA01 JASP WRCA01 Con...

Page 119: ...S16 8 0 kVA 575 480 240V 208V SK300X SP100X NETH012AULS16 12 0 kVA 575 480 240V 208V Robot Type Fuse Type With transformer built in Without transformer SV3X ATDR3 3A Class CC ATDR10 10A Class CC UP6 A...

Page 120: ...mensions Pcs Model Application 1 TIME DELAY CLASS CC FUSE Power supply fuse 2 1 Disconnecting switch 2 5A Glass Tube fuse 2 313005 5A 250V LITTEL JANCD XTU01 FU1 2 3 3A Glass Tube fuse 2 312003 3A 250...

Page 121: ...awa representative The spare parts are ranked as follows Rank A Expendable and frequently replaced parts Rank B Parts for which replacement may be necessary as a result of frequent operation Rank C Dr...

Page 122: ...atus 10 2 10 A Control Relay LY2 DC24V Omron 3 3 11 B Converter JUSP ACP05JAA Yaskawa 1 1 12 B Control Power Supply Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack Control Board JASP WRCA01 Ya...

Page 123: ...s 10 2 10 A Control Relay LY2 DC24V Omron 3 3 11 B Converter JUSP ACP05JAA Yaskawa 1 1 12 B Control Power Supply Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack Control Board JASP WRCA01 Yaska...

Page 124: ...V Daito Com munication Apparatus 10 2 10 A Control Relay LY2 DC24V Omron 3 3 11 B Converter JUSP ACP05JAA Yaskawa 1 1 12 B Control Power Supply Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack...

Page 125: ...Apparatus 10 2 10 A Control Relay LY2 DC24V Omron 3 3 11 B Converter JUSP ACP25JAA Yaskawa 1 1 12 B Control Power Supply Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack Control Board JASP WRCA...

Page 126: ...on Apparatus 10 2 10 A Control Relay LY2 DC24V Omron 3 3 11 B Converter JUSP ACP25JAA Yaskawa 1 1 12 B Control Power Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack Control Board JASP WRCA01 Y...

Page 127: ...ol Relay LY2 DC24V Omron 3 3 11 A Converter JUSP ACP35JAA Yaskawa 1 1 12 B Control Power Supply Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 14 B Ampli...

Page 128: ...3 11 A Converter JUSP ACP35JAA Yaskawa 1 1 12 B Control Power Supply Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 14 B Amplifier JUSP WS60AA Yaskawa 1...

Page 129: ...atus 10 2 10 A Control Relay LY2 DC24V Omron 3 3 11 A Converter JUSP ACP35JAA Yaskawa 1 1 12 B Control Power Supply Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack Control Board JASP WRCA01 Ya...

Page 130: ...paratus 10 2 10 A Control Relay LY2 DC24V Omron 3 3 11 A Converter JUSP ACP35JAA Yaskawa 1 1 12 B Control Power Supply Unit JUSP RCP01AAC SANRITZ 1 1 For Servo 13 B Servopack Control Board JASP WRCA01...

Page 131: ...20...

Page 132: ...aipei Taiwan BEIJING OFFIC Room No 301 Office Building of Beijing Intemational Club 21 Jianguomenwai Avenue Beijing 100020 China SHANGHAI OFFICE 27 Hui He Road Shanghai 200437 China YASKAWA JASON HK C...

Page 133: ...these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR S MANUAL YASNAC XRC OPERATOR S...

Page 134: ...this product The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product YASKAWA may modify this model without notice when neces...

Page 135: ...a potentially hazardous situation which if not avoided could result in death or serious injury to personnel Indicates a potentially hazardous situation which if not avoided could result in minor or m...

Page 136: ...envelope to teach a job Operator injury can occur if the Teach Lock is not set and the manipulator is started from the playback panel Observe the following precautions when performing teaching operat...

Page 137: ...e that all other necessary processing has been performed Check for problems in manipulator movement Check for damage to insulation and sheathing of external wires Always return the programming pendant...

Page 138: ...th ex ENTER Symbol Keys The keys which have a symbol printed on them are not denoted with but depicted with a small picture ex page ke The cursor key is an exception and a picture is not shown Axis Ke...

Page 139: ...Point Setting 3 11 3 2 3 Procedure After an Alarm 3 12 3 3 Setting the Controller Clock 3 13 3 4 Setting Play Speed 3 14 3 5 All Limits Releasing 3 16 3 6 Overrun Shock Sensor Releasing 3 18 3 7 Inter...

Page 140: ...ile 3 45 3 10 2 User Coordinates Setting 3 46 Selecting User Coordinates File 3 46 Teaching User Coordinates 3 47 Clearing User Coordinates 3 48 3 11 ARM Control 3 49 3 11 1 ARM Control 3 49 3 11 2 AR...

Page 141: ...3 86 3 14 4 Allocation of I O Control Instructions 3 86 3 14 5 Execution of Allocation 3 88 Executing the Instruction Output Control Allocation 3 88 Executing the Job Call Allocation 3 88 Executing th...

Page 142: ...8 5 2 4 Specific Output 5 9 Specific Output Display 5 9 Specific Output Detailed Display 5 9 5 2 5 RIN INPUT 5 10 RIN INPUT Display 5 10 5 3 System Monitoring Time 5 11 5 3 1 System Monitoring Time Di...

Page 143: ...Board JANCD XIO01 7 8 Safety Plug Input Signal 7 11 7 3 2 General I O Circuit Board JANCD XIO02 7 12 Connection wire with General I O CN10 11 12 13 7 13 Specific I O Signal Related to Start and Stop...

Page 144: ...8 4 8 6 Battery Inspections 8 5 8 7 Power Supply Voltage Confirmation 8 6 8 8 Open Phase Check 8 7 9 Replacing Parts 9 1 Replacing XRC Parts 9 1 9 1 1 Replacing Parts of the CPU Rack 9 2 Replacing the...

Page 145: ...10 5 10 4 I O Alarm Message List 10 51 Arc Welding Application 10 51 Handling Application 10 52 Spot Welding Application 10 53 General Application 10 54 11 Error 11 1 Error Message List 11 1 11 1 1 Sy...

Page 146: ...xiv...

Page 147: ...Setup Diagnosis...

Page 148: ......

Page 149: ...imizes the system to perform to its maximum potential in the chosen application Various settings control system compatibility and manipulator perfor mance characteristics Exercise caution when changin...

Page 150: ...1 2...

Page 151: ...ity modes Editing mode and management mode require a user ID The user ID consists of numbers and letters and contains no less than 4 and no more than 8 char acters Significant numbers and signs 0 to 9...

Page 152: ...on Edit DOUBLE Operation Edit REAL Operation Edit POSITION ROBOT Operation Edit POSITION BASE Operation Edit POSITION ST Operation Edit IN OUT EXTERNAL INPUT Operation EXTERNAL OUTPUT Operation UNIVER...

Page 153: ...TOOL Edit Edit INTERFERENCE Management Management USER COORDINATE Edit Edit HOME POSITION Management Management MANIPULATOR TYPE Management ANALOG MONITOR Management Management OVERRUN S SENSOR Edit E...

Page 154: ...gement RS Management Management S1E Management Management S2E Management Management S3E Management Management S4E Management Management SETUP TEACHING COND Edit Edit OPERATE COND Management Management...

Page 155: ...entered the operation mode is changed Select SECURITY under the top menu 1 Select the desired mode 2 Input the user ID Press ENTER 3 At the factory the following below user ID number is preset Editin...

Page 156: ...can make changes to lower security modes 1 User ID registration display is shown 2 The character input line is displayed and the message Input current ID no 4 to 8 digits is displayed Select SETUP un...

Page 157: ...s 2 7 3 When the correct user ID is entered a new ID is requested to be input Input new ID no 4 to 8 digits is displayed 4 User ID is changed DATA EDIT DISPLAY UTILITY USER ID EDITING MODE MANAGEMENT...

Page 158: ...2 1 Protection Through Security Mode Settings 2 8...

Page 159: ...ont whenever possible Always follow the predetermined operating procedure Ensure that you have a safe place to retreat in case of emergency Improper or unintended manipulator operation may resultin in...

Page 160: ...ally If the absolute data of the home position is already known set the absolute data again after completing home position registration Perform the following inspection procedures prior to teaching th...

Page 161: ...are specified as an angle in units of 1 1000 and vary for different manipulator types See 3 1 3 Home Position of the Robot Select ROBOT under the top menu Select HOME POSITION 1 Select DIS PLAY under...

Page 162: ...lay and select control group are shown Select ROBOT under the top menu Select HOME POSITION Select DIS PLAY under the menu Select the desired control group 1 Select the axis to be registered 2 Select...

Page 163: ...calibration display and select control group are shown 2 The number input buffer line is shown 3 Absolute data are modified Select ROBOT under the top menu Select HOME POSITION Select DIS PLAY Select...

Page 164: ...at once the home calibration display and select control group are shown 2 The all absolute data are cleared Select ROBOT under the top menu Select HOME POSITION 1 Select DATA under the menu Select CLE...

Page 165: ...n are as follows Other manipulator models have different positions Always consult the documentation for the correct manipulator model B axis center line angle against U axis center line 90 U axis angl...

Page 166: ...hen performing teaching oper ations within the working envelope of the manipulator View the manipulator from the front whenever possible Always follow the predetermined operating procedure Ensure that...

Page 167: ...Check for problems in manipulator movement Check for damage to the insulation and sheathing of external wires Always return the programming pendant to its hook on the XRC cabinet after use If the prog...

Page 168: ...tall when playback is started If the absolute data allowable range error alarm has occurred playback and test runs will not function and the position must be checked Position Check If the absolute dat...

Page 169: ...e control panel the specified point must be set for each manipulator or station 1 The specified point display is shown The message Available to move to any modify specified point is shown Home positio...

Page 170: ...eration such as replacing the PG etc The robot position data when turning power off and on are shown in Power ON OFF Position Display Be aware of safety hazards when performing the position confirma t...

Page 171: ...and playback operation can be done If the error is beyond the allowed band the alarm occurs again 3 3 Setting the Controller Clock The clock inside of the XRC controller can be set 1 The date and time...

Page 172: ...tations exist in the system the control group is changed by the page key Select SETUP under the top menu Select SET SPEED 1 Press the page key 2 Select JOINT or LNR CIR 3 Select desired speed value 4...

Page 173: ...isplayed 5 The speed value is modified SPEED SET LNR CIR R1 1 66 cm min 2 138 cm min 3 276 cm min 4 558 cm min 5 1122 cm min 6 2250 cm min 7 4500 cm min 8 9000 cm min R1 S C L DATA EDIT DISPLAY UTILIT...

Page 174: ...Type Contents Mechanical Limit Limit for checking manipulator s working envelope L U Interference Limit for checking L and U axes interference area Software Limit Every axis soft limit for checking m...

Page 175: ...been released is displayed When the setting changesto INVALID the message All limits release has been canceled is displayed for three seconds LIMIT RELEASE SOFT LIMIT RELEASE INVALID ALL LIMITS RELEA...

Page 176: ...AND E STOP and HOLD are displayed alternately every time SELECT is pressed 2 is displayed at the control group which detects overrun or shock sensor If RELEASE is selected overrun or shock sensor is r...

Page 177: ...s as a signal If the tool center point of the manipulator is inside the area the interference 1 inside signal or interference 2 inside signal come on and the manipulator automatically decelerates to a...

Page 178: ...n be set parallel to the base coordinate system or user coordinate system Setting Method There are three ways to set cubic interference areas as described in the following Number Input of Cube Coordin...

Page 179: ...ic interference area display is shown Select ROBOT under the top menu Select INTERFERENCE 1 Select the desired cube number 2 Select METHOD 3 Select CONTROL GROUP 4 Select REF COORDINATES 5 Select CHEC...

Page 180: ...ates are selected the number input line is displayed Input the user coordinate number and press ENTER INTERFERENCE AREA INTERFERENCE SIG 1 METHOD CUBIC INTERFERENCE CONTROL GROUP CHECK MEASURE COMMAND...

Page 181: ...the FEEDBACK POSITION setting so the timing of the output signal is more accurate Select METHOD 1 Input number for MAX and MIN data and press Enter 2 INTERFERENCE AREA INTERFERENCE SIG 1 METHOD CONTRO...

Page 182: ...he axis keys 5 The cubic interference area is registered Select METHOD 1 Press MODIFY 2 Move the cursor to MAX or MIN 3 Move the manipulator using the axis keys 4 Press ENTER 5 Operation Explanation I...

Page 183: ...e axis keys 4 Press Enter 5 Operation Explanation INTERFERENCE AREA INTERFERENCE SIG 1 METHOD CUBIC INTERFERENCE CONTROL GROUP R1 CHECK MEASURE COMMAND POSITION REF COORDINATE BASE TEACHING METHOD CEN...

Page 184: ...his range is output ON inside OFF outside Axis Interference Signal for Station Axis Setting Operation Number Input of Axis Data 1 The cubic interference area display is shown Select ROBOT under the to...

Page 185: ...rol group 5 Each time SELECT is pressed COMMAND POSITION and FEEDBACK POSI TION alternate 6 The interference area is set INTERFERENCE AREA INTERFERENCE SIG 1 METHOD AXIS INTERFERENCE CONTROL GROUP CHE...

Page 186: ...g the axis keys 4 The axis interference area is registered Select ROBOT under the top menu Select INTERFERENCE Select the desired interference signal number Select METHOD Select CONTROL GROUP 1 Press...

Page 187: ...dialog is displayed 3 All the data of the signal are cleared Select interference signal for clearing 1 Select DATA under the menu Select CLEARDATA 2 Select YES 3 Operation Explanation INTERFERENCE ARE...

Page 188: ...tion origin point the operation origin point signal turns ON 3 8 2 Setting Operation Origin Point Operation Origin Point Display 1 Operation origin point display is shown For spot application or handl...

Page 189: ...t position of the tool center point of the manipulator is checked and found to be within the operation origin cube When the operation origin point is changed the operation origin cube is automatically...

Page 190: ...When the tool extension function is invalid the coordinate display is shown Select ROBOT under the top menu Select TOOL 1 Select the desired tool number 2 Select the desired coordinate axis to modify...

Page 191: ...s DISPLAY LIST or DISPLAY COORDINATE DATA 3 The number input line is displayed 4 The tool data is registered TOOL COORDINATE NO NAME 00 TORCH1 01 TORCH2 02 03 04 05 06 07 DATA EDIT DISPLAY UTILITY R1...

Page 192: ...he order of Rz Ry Rx The following register Rz 90 Ry 90 Rx 0 Case of Tool A B Case ofTool C TOOL TOOL NO 00 NAME TORCH1 X 0 000 mm Rx 0 00 deg Y 0 000 mm Ry 0 00 deg Z 260 000 mm Rz 0 00 deg W 0 000 k...

Page 193: ...n includes weight a center of gravity position and moment of inertia at the center of gravity of the tool installed at the flange Select ROBOT under the top menu Select TOOL Select the desired tool nu...

Page 194: ...ration five different poses TC1 to 5 must be taught with the tool center point as the reference point The tool dimensions are automatically calculated on the basis of these five points Each pose must...

Page 195: ...on For details on how to register pose data refer to the preceding clause RegisteringTool Pose Select ROBOT under the top menu Select TOOL Select the desired tool number 1 Select UTILITY under the men...

Page 196: ...nd the dis played position data TC next to POSITION in the display flashes 6 Calibration data is registered in the tool file Once calibration is completed the tool coordinate display is shown TOOL CAL...

Page 197: ...ata number in the tool coordinate display Refer to RegisteringTool Pose for the operation R1 S C L TOOL TOOL NO 00 NAME TORCH1 X 0 000 mm Rx 0 00 deg Y 0 000 mm Ry 0 00 deg Z 300 000 mm Rz 0 00 deg W...

Page 198: ...by pressing the page key or selecting it in the tool list 3 By pressing the axis keys for the R B and T axes change the manipulator pose with out changing the tool center point position If this opera...

Page 199: ...s home position horizontal to the U B and R axes and operate the U B and R axes This function is available for the models listed below Contact your Yaskawa representa tive for information on other mo...

Page 200: ...again 6 Select REGISTER 7 Tool File Extension Function Use the following parameter to set the Tool File Extension Function S2C261 TOOL NO SWITCHING 0 Tool switching prohibited 1 Can change 24 kinds o...

Page 201: ...button pressed until measure ment is completed The manipulator moves in the order listed below Once measure ment is completed changes to Measurement of the U axis U axis home position 4 5 degrees 4 5...

Page 202: ...d during measurement automatically changes to Medium During measurement HOME or U blinks on the screen During measurement the NEXT button has to be kept pressed If the button is released during measur...

Page 203: ...t on the X axis XY is a point on the Y axis side of the user coordinates that has been taught and the directions of Y and Z axes are determined by point XY User Coordinates File Up to 24 kinds of user...

Page 204: ...for setting in the user coordinate list display The user coordinate teaching display is shown Select ROBOT under the top menu Select USER COORDINATE 1 Select desired user coordinate number 2 Operation...

Page 205: ...icates that teaching is completed and indicates that it is not completed Select the robot 1 Select SET POS 2 Move the manipulator using the axis key Press MODIFY and ENTER 3 Select COMPLETE 4 Operatio...

Page 206: ...te list display is shown Clearing User Coordinates 1 The confirmation dialog is shown 2 All data is cleared Select DATA under the menu Select CLEAR DATA 1 Select YES 2 USER COORDINATE NO SET NAME 00 W...

Page 207: ...ter of gravity position and moment of inertia at the center of gravity of the tool installed at the flange It is necessary to set these information correctly to do a better operation control by the AR...

Page 208: ...ation from the home position posture of the manipulator becomes direction of of the robot installa tion angle Therefore the robot installation angle for a vertical downward wall mount specifi cation b...

Page 209: ...by a negative num ber when the position is in direction Load at S head Top View U arm payload Set the weight and the center of gravity position roughly when the equipment such as the wire supplying m...

Page 210: ...ty position Side View Setting 1 ARM CONTROL display is shown ARM CONTROL display is shown only when the security mode is set as management mode Select ROBOT under the top menu Select ARM CONTROL 1 Pre...

Page 211: ...load information basically before teaching the job after the tool is installed Confirm the operation path of each job which uses the tool file when the tool load informa tion is changed after teaching...

Page 212: ...rom specifica tions etc moment of inertia at the center of gravity lx ly lz Unit kg m2 It is an moment of inertia of the tool at the center of gravity position The value is calculated around each axis...

Page 213: ...y followings methods Method to approximate the entire tool in hexahedron or cylinder Method to calculate from each weight and center of gravity position of plural mass Refer to the following setting e...

Page 214: ...e and sets the center of gravity position on the flange coordinates There is no problem even if the moment of inertia at the center of gravity is not set because the size of the gun is not too large S...

Page 215: ...e next expression when the center of gravity is at the center Refer the expression when the calculation of the moment of inertia at the center of gravity SUPPLE MENT 3 r 2 H2 Ix Iy W 12 r 2 Iz W 2 Ly2...

Page 216: ...each workpiece and to switch the tool on each step according to the held workpiece Set the tool load information in the state to hold the heaviest workpiece when the tool is not switched Weight W 55 4...

Page 217: ...of the big parts If parts are small it is not necessary to calculate the own moments of inertia Refer to above mentioned supple ment The own moment of inertia calculation for hexahedron and cylinder...

Page 218: ...ate Center of gravity position and moment of inertia at the center of gravity for plural mass How by the method of 2 to calculate the value is shown here Weight W w1 w2 3 6 9 approx 10 kg Center of gr...

Page 219: ...function is invalid the tool coordinates dis play is shown W 10 000 kg Xg 100 000 mm Yg 83 333 mm Zg 60 000 mm Ix 0 100 kg m2 Iy 0 010 kg m2 Iz 0 100 kg m2 Select ROBOT under the top menu Select TOOL...

Page 220: ...state of a numeric input if the cursor is on the desired item to register and the SELECT is pressed 4 The input value is registered The servo power is automatically turned off when editing the value...

Page 221: ...er of gravity position greatly offsets in X direction or Y direction is installed the generated moment by the tool cannot be compen sated Switch of the tool file In case that two or more tool files ar...

Page 222: ...tion is set by setting the detection level Shock Detection Level Setting The shock detection level is set in the shock detection level file The shock detection set file are nine condition files as fol...

Page 223: ...ection level in play mode 9 For detection level in teach mode The detection level of condition number 8 which is a standard file in play mode is adopted in play mode excluding the range between SHCKSE...

Page 224: ...is shown here Refer to this value when the detection level in 5 is input The maximum disturbance force can be cleared by setting inmenu DATA CLEAR MAX VALUE Detection Level Level range 1 to 500 The s...

Page 225: ...red number with page key in the tool coordinates display Select DISPLAY LIST or DISPLAY COORDINATE DATA under the menu in order to switch between the tool list display and the tool coordinates display...

Page 226: ...nates and where the original point is the center of gravity position Input the moment of inertia by numeric key and press ENTER after the numeric input status is appeared by moving the cursor and pres...

Page 227: ...ch is desired to reset the shock detection level is specified here If nothing is specified the detection level of the control group of the job to which this instruction is registered is changed Howeve...

Page 228: ...aneously When the value is input with the numericalkey press SELECT to display the input buffer line And press ENTER to change the number in the input buffer line When robot station specification is a...

Page 229: ...e inform list dialog is shown Move the cursor to the line just before the location where SHCKRST instruction is desired to register Press INFORM LIST 1 Select SHCKRST instruction 2 Change the value of...

Page 230: ...the detail edit display Move the cursor to UNUSED of ROBOT STATION and press SELECT The selection dialog is shown Move the cursor to added robot or station and press SELECT When the addition of the ro...

Page 231: ...nfirm the damage after moving the manipulator to the safety position once with teach mode though the playback operation is possible after reset ting Press SELECT 1 Operation after resetting the detect...

Page 232: ...on level was small Remove the object after resetting the alarm or move the robot to the safety posi tion When the alarm cannot be reset because the robot comes in contact with the object invalidate th...

Page 233: ...ll the INFORM II instructions can be used The number of additional items to be used in each instruction differ in the standard instruction set and expansion instruction set In the standard instruction...

Page 234: ...layed An instructions are regis tered The next time an attempt is made to register the same instruction as in 1 the same additional items as were reg istered last time are also dis played in the input...

Page 235: ...ber of key operations reduces the teaching time 3 14 2 Allocatable Functions There are two allocation methods as follows Key Allocation EACH Key Allocation SIM The Number Key Customize Function is onl...

Page 236: ...the reserved display call function Function Description Alternate output allocation Turns ON OFF the specified general output signal when INTERLOCK and the allocated number key are pressed at the sam...

Page 237: ...der the menu Select KEY ALLOCATION 1 Select DIS PLAY 2 Select ALLOCATE SIM KEY 3 Operation Explanation KEY ALLOCATION EACH APPLI NO 1 KEY FUNCTION ALLOCATION CONTENT MAKER MAKER 0 MAKER 1 MAKER 2 MAKE...

Page 238: ...ey to be allocated Press SELECT 1 Select INSTRUCTION 2 Operation Explanation KEY ALLOCATION EACH APPLI NO 1 KEY FUNCTION ALLOCATION CONTENT MAKER MAKER 0 MAKER 1 MAKER 2 MAKER 3 MAKER 4 MAKER DATA EDI...

Page 239: ...gistration No move the cursor to the No and press SELECT Numeric values can now be entered Input the number to be changed and press ENTER Move the cursor to the FUNCTION of the key to be allocated Pre...

Page 240: ...key to be allocated Press SELECT 1 Select DISPLAY Move the cursor to ALLOCATION CONTENT Press SELECT 2 Input the name of the reserved display and press ENTER 3 Open the display for allocation Press I...

Page 241: ...ion dialog box is displayed Move the cursor to the FUNCTION of the key to be allocated Press SELECT 1 Select ALTERNATE OUTPUT 2 Move the cursor to the FUNCTION of the key to be allocated Press SELECT...

Page 242: ...the output No or output time move the cursor to the No or time and press SELECT Numeric values can now be entered Input the number or time to be changed and press ENTER Move the cursor to the FUNCTIO...

Page 243: ...t number and the output voltage value are displayed in the ALLOCA TION CONTENT Move the cursor to the FUNCTION of the key to be allocated Press SELECT 1 Select 4 BIT OUTPUT or 8 BIT OUTPUT 2 Move the...

Page 244: ...of I O Control Instructions With key allocation SIM output control instructions can be allocated to the number keys that have been allocated one of the following I O controls key allocation EACH Move...

Page 245: ...remain the same Move the cursor to the FUNCTION of the key that has been allocated with I O control with key allocation SIM Press SELECT 1 Select OUTPUT CONTROL INST 2 Operation Explanation KEY ALLOC...

Page 246: ...ay is shown At the same time the reserved display key lights up Press the allocated key again to turn off the reserved display key and return to the previous display Executing the I O Control Allocati...

Page 247: ...ies the operation for changing the status of signals that are used frequently 1 The relay on display is shown 2 Select the status or of the desired signal to change A maximum of 16 output signals can...

Page 248: ...le to turn the relevant external output signal on only for the duration that INTER LOCK SELECT are pressed This selection is made in advance by setting the parameters S2C229 244 to 1 RELAY ON OUTPUT N...

Page 249: ...operation area set parallel to the robot coordinate system These soft limits are continually monitored by the system When it is detected that the manip ulator tool center point has reached a soft limi...

Page 250: ...imits have been released is dis played When SOFT LIMIT RELEASE is set to INVALID the message Soft limits have been released is displayed for three seconds The teaching data cannot be entered while rel...

Page 251: ...while pressing TOP MENU simultaneously Change the security mode to management mode Select FILE under the top menu Select INI TIALIZE 1 Select JOB 2 Select YES 3 Operation Explanation INITIALIZE JOB FI...

Page 252: ...FRAME CND VARIABLE DATA VAR DAT ARC START COND DATA ARCSRT CND ARC END COND DATA ARCEND CND ARC AUXILIARY COND DATA ARCSUP DAT WELDER CONDITION DATA WELDER DAT Maintenance Mode INITIALIZE TOOL DATA TO...

Page 253: ...LIZE ROBOT MATCH PRMTR RC PRM SYS DEF PRMTR SD PRM COORD ORG PRMTR RO PRM SYS MATCH PRMTR SC PRM CIO PRMTR CIO PRM FCTN DEF PRMTR FD PRM APPLI PRMTR AP PRM TRANSMISSION UNIV RS PRM Maintenance Mode IN...

Page 254: ...LE under the top menu Select INITIALIZE Select I O DATA 1 Select data for initializing 2 Press ENTER 3 Select YES 4 Operation Explanation INITIALIZE C IO PRGM CIOPRG LST IO NAME DATA IONAME LST SIMULA...

Page 255: ...planation INITIALIZE USER WORD UWORD DAT SV MONITOR SIGNAL SVMON DAT VARIABLE NAME VARNAME DAT SECOND HOME POSITION HOME2 DAT HOME POS CALIB DATA ABSO DAT OPERATION ORG POS DATA OPEORG DAT Maintenance...

Page 256: ...3 17 File Initialize 3 98...

Page 257: ...de or editing mode only confirmation of status setting is possible Turn the power supply ON while pressing TOP MENU simultaneously Select SYS TEM under the top menu 1 Select SETUP 2 Select IO MODULE 3...

Page 258: ...the status again If the status is correct the I O module may be defective Contact your Yaskawa representative IO MODULE ST 01 DI 008 DO 008 AI 002 AO 002 ST 02 DI 016 DO 016 ST 03 NONE ST 04 NONE ST 0...

Page 259: ...nance mode 1 The system display is shown The additional operation must be done in the management mode In operation mode or editing mode only confirmation of status setting is possible Turn the power s...

Page 260: ...d with each axis group and the contactor which is used for the SERVOPACK AXIS TYPE Select one in the axis type list In case of TURN type No need to select The axis type is set as TURN type In case of...

Page 261: ...ollowing items MOTOR SERVO AMP CONVERTER ROTATION DIRECTION NORMAL REVERSE MAX RPM rpm ACCELERATION SPEED sec INERTIA RATIO Select MOTOR AMPLIFIER and CONVERTER from each type s list 4 2 1 Base Axis S...

Page 262: ...es CARTESIAN X AXIS Base axis advancing direction coincides with robot coordinate X Axis RECT X CARTESIAN Y AXIS Base axis advancing direction coincides with robot coordinate Y Axis RECT Y CARTESIAN Z...

Page 263: ...y 1 Select connection item of desired control group 2 Select desired item Press ENTER in the connection display 3 Direction of Base Axis CARTESIAN Y AXIS CARTESIAN X AXIS CARTESIAN Z AXIS Base 1st 2nd...

Page 264: ...is 1CN SERVOPACK 1 1st contactor is used 2nd axis 2CN SERVOPACK 1 1st contactor is used 3rd axis 3CN SERVOPACK 1 1st contactor is used 4th axis 4CN SERVOPACK 1 1st contactor is used 5th axis 5CN SERVO...

Page 265: ...he axes configuration display 3 The setting in the axes configuration display is completed and the display moves to the mechanical specification display Confirm axis type of each axis in the axes conf...

Page 266: ...UCTIONRATIO Input the numerator and the denominator e g If the reduction ratio is 1 120 the numerator should be set as 1 0 and the denominator should be set as 120 0 PINION DIAMETER Input the diameter...

Page 267: ...increased The counterclockwise view from the loaded side is positioned normal Confirm specification of each axis in the motor specification display 1 Select desired item 2 Input the value and press E...

Page 268: ...atio in each 100 Phenomenon2 during pause the motor makes a lot of noise Confirm the motion with decreasing this ratio in each 100 3 After this motor specification setting the display moves to the nex...

Page 269: ...he control group construction is changed by addition a base axis or station axis the internal data of the job file are also changed so that the job file data should be initialized Initialize the job f...

Page 270: ...hen UNIVERSAL is selected interpolation motion linear circular etc is not supported If the number of axes is set beyond 27 error occurs MACHINE LIST NONE TURN 1 TURN 2 UNIV 1 UNIV 2 UNIV 3 UNIV 4 UNIV...

Page 271: ...nnects The example above means the following R1 Robot 1st axis 1CN SERVOPACK 1 1st contactor is used 2nd axis 2CN SERVOPACK 1 1st contactor is used 3rd axis 3CN SERVOPACK 1 1st contactor is used 4th a...

Page 272: ...is type of each axis is shown The axes form display In case of TURN type The axes form display In case of UNIVERSAL type Confirm axis type of each axis in the axes form display 1 Select desired axis 2...

Page 273: ...or and the denominator e g If the reduction ratio is 1 120 the numerator should be set as 1 0 and the denominator should be set as 120 0 OFFSET Offset should be specifiedat TURN 2 type only input leng...

Page 274: ...TION RANGE Input maximum moving position direction and direction from origin point Unit mm STATION 2ND AXIS ROTATION TABLE STATION 1ST AXIS INCLINATION AXIS OFFSET TURN 2 MECHANICAL SPEC S1 UNIV 3 AXI...

Page 275: ...ist of MOTOR SERVO AMP or CONVERTER is shown ROTATION DIRECTION Set the rotation direction to which the current pulse data is increased The counterclockwise from view from the loaded side is positione...

Page 276: ...in each 100 Phenomenon2 During pause the motor makes a lot of noise Confirm the motion with decreasing this ratio in each 100 3 After this motor specification setting the display moves to the next axi...

Page 277: ...In that case the control group construction is not changed so the job file data should not be initialized If the control group construction is changed by addition of a base axis or station axis the i...

Page 278: ...4 2 Addition of Base and Station Axis 4 22...

Page 279: ...Input The status of input signal from the external can be confirmed Universal Input Display Select SYSTEM INFO under the top menu Select VERSION 1 Select IN OUT under the top menu Select UNIVERSAL IN...

Page 280: ...Y under the menu Select DETAIL 1 Select IN OUT under the top menu Select UNIVERSAL OUTPUT 1 Explanation UNIVERSAL INPUT NO 7654 3210 001X 0111_1011 002X 0000_0000 003X 0000_0000 004X 1111_0000 005X 00...

Page 281: ...nder the menu Select DETAIL 1 Select the desired output signal number 1 Press INTER LOCK SELECT 2 Explanation UNIVERSAL OUTPUT NO 7654 3210 101X 0111_1011 102X 0000_0000 103X 0000_0000 104X 1111_0000...

Page 282: ...haracters on the input line by pressing CANCEL and then input a new name Select the desired output signal number in thedetailed display 1 Input the signal name 2 Press ENTER 3 UNIVERSAL OUTPUT GROUP O...

Page 283: ...GROUP IG 01 123 DEC 7b HEX IN 001 0010 TEST SIGNAL IN 002 0011 IN 003 0012 IN 004 0013 IN 005 0014 IN 006 0015 IN 007 0016 IN 008 0017 R1 S C L Operation Explanation DATA EDIT DISPLAY UTILITY UNIVERS...

Page 284: ...layed Select the signal number in the detailed display 1 Input the signal number 2 Press ENTER 3 Operation Explanation UNIVERSAL INPUT GROUP IG 01 123 DEC 7b HEX IN 001 0010 TEST SIGNAL IN 002 0011 IN...

Page 285: ...y Select EDIT under the menu 1 Select SEARCH 2 Input the signal number Press ENTER 3 Operation Explanation DATA EDIT DISPLAY UTILITY UNIVERSAL INPUT GROUP IG 01 123 DEC 7b HEX IN 001 0010 IN 002 0011...

Page 286: ...peration Explanation SPECIFIED INPUT NO 7654 3210 401X 0111_1011 402X 0000_0000 403X 0000_0000 404X 1111_0000 405X 0000_0000 406X 0000_1010 407X 0000_0000 408X 0000_0000 DATA EDIT DISPLAY UTILITY R1 S...

Page 287: ...ation SPECIFIED OUTPUT NO 7654 3210 501X 0111_1011 502X 0000_0000 503X 0000_0000 504X 1111_0000 505X 0000_0000 506X 0000_1010 507X 0000_0000 508X 0000_0000 DATA EDIT DISPLAY UTILITY R1 S C L Operation...

Page 288: ...NPUT RIN INPUT Display 1 RIN input display is shown Select IN OUT under the top menu Select RIN 1 Operation Explanation RIN INPUT RIN 001 DIRECT IN1 RIN 002 DIRECT IN2 RIN 003 DIRECT IN3 RIN 004 DIREC...

Page 289: ...G TIME Displays the cumulative time that the manipulator was in motion OPERATING TIME Displays the cumulative time spent in operation For example if the manipulator is used for arc welding it displays...

Page 290: ...show time as seen from the individual axes SERVO POWER TIME ROBOT1 1998 07 06 10 00 2 3 8 5 4 2 0 2 STATION1 1998 08 03 10 00 2 6 2 3 7 0 2 R1 S C L DATA EDIT DISPLAY UTILITY R1 S C L DATA EDIT DISPL...

Page 291: ...Select YE 2 Operation Explanation R1 S C L DATA EDIT DISPLAY UTILITY SYS MONITORING TIME CONTROL POWER TIME 1998 07 06 10 00 2 3 8 5 4 2 0 2 SERVO POWER TIME 1998 07 06 10 30 2 3 8 0 1 0 1 2 PLAYBACK...

Page 292: ...M MINOR ALARM USER ALARM SYSTEM USER ALARM USER OFF LINE 5 4 2 Clearing the Alarm History The history of the minor alarms and the user alarms system and user can be cleared Select SYSTEM INFO under th...

Page 293: ...Input the history number and press ENTER The search for the input history number begins and the I O mes sage that appeared on the screen is displayed Select SYSTEM INFO under the top menu Select I O M...

Page 294: ...the I O message history 1 The confirmation dialog box is displayed 2 The displayed I O message history is cleared Select EDIT under the menu Select SEARCH 1 Input the history No Press ENTER 2 Select D...

Page 295: ...wer was later turned on and the amount of difference between the two positions When alarm 4107 OUT OF RANGE ABSODATA occurs the error value of the faulty axes can be verified in this dis play 1 The po...

Page 296: ...5 6 Position Data When Power is Turned ON OFF 5 18...

Page 297: ...Hardware...

Page 298: ......

Page 299: ...hing operations within the working envelope of the manipulator Always view the manipulator from the front Always follow the predetermined operating procedure Always have an escape plan in mind in case...

Page 300: ...heck for problems in manipulator movement Check for damage to the insulation and sheathing of external wires Always return the programming pendant to its specified position after use If the programmin...

Page 301: ...2 Hz Grounding Grounding resistance 100 or less Exclusive grounding Digital I O Specific signal hardware 12 inputs and 2 outputs General signals standard max 40 inputs and 40 outputs Positioning Syst...

Page 302: ...Industrial Standard Running Speed Limit User definable Deadman Switch 3 position type Servo power can be turned on at the mid position only Located on programming pendant Collision proof Frames S axis...

Page 303: ...obot stop Execution of some instruc tions during robot motion Operation Instruc tions Preparing the operation instructions for each application Arc ON Arc OFF etc Variable Global variable Local variab...

Page 304: ...equipment configuration 6 4 1 Arrangement of Units and Circuit Boards Configuration SV3X UP6 SK16X Configuration Playback Panel ZY1C SS3152 I O Power On Unit JZNC XIU01 Sectional view A A No Fuse Bre...

Page 305: ...3P Servopack CACR SK45AAB SK45X CACR SK16MAAB SK16MX Sectional view A A TYPE SK16MX YASNAC XRC TYPE ERCR SK16M RA00 SK45X ERCR SK45 RA00 Power Supply Unit JZRCR XPU01 I O Power On Unit JZNC XIU01 CPU...

Page 306: ...large robots is equipped with a heat exchanger on the door to cool the interior of the XRC Section Unit Door Playback panel ZY1C SS3125 Heat exchange board Large type of robot Front section Servopack...

Page 307: ...on Small type Cooling Configuration Large type Servopack Ascending Fan Backside Duct Fan Air Intake Air Outlet Servopac Heat Exchange Air Intake Air Intake Air Outlet Air Outlet Air Outlet Servopack B...

Page 308: ...6 4 Equipment Configuration 6 10...

Page 309: ...ons within the working envelope of the manipulator Always view the manipulator from the front Always follow the predetermined operating procedure Always have an escape plan in mind in case the manipul...

Page 310: ...ures prior to performing teach ing operations If problems are found correct them immediately and be sure that all other necessary processing has been performed Check for problems in manipulator moveme...

Page 311: ...XPU01 JZRCR XPU02 1Z Line Filter 1KM Contactor 1X Single phase AC200V Output 2X 3 phase AC200V Output 3X 3 phase AC200V Input 4X Contactor Output 5X Single phase AC200V connector Contactor Coil etc 5...

Page 312: ...board has the PC card interface and Serial interface for RS 232C The JANCD XMM 01 board option can be installed when CMOS memory is expanded Control Power Supply Unit CPS 150F This unit supplies the...

Page 313: ...y can be turned ON and OFF by input from external device It is operated by the external switch connected with CN 04 of control power supply unit as shown in the fol lowing figures CN04 is shorted when...

Page 314: ...procedure is described as follows 1 Insert part A of the wiring tool into one of the holes designed for the tool 2 Insert or pull out the wire while pushing the wiring tool downward Direction of the a...

Page 315: ...GO Connector CN07 Input connector for Programming pendant Deadman switch Emergency stop CN29 Brake Output Connector CN25 Input connector for Power ON OFF WAGO connector See WAGO connector CN25 Output...

Page 316: ...man Switch Control Circuit JANCD XIO01 I O Allocation and Connection Diagram Before use remove any jumper leads from the specific input signals The unit may malfunction resulting in injury or damage t...

Page 317: ...bottom Size of terminal M3 5 Direct Output for emergency stop at Playback Panel Connect wire directly with the terminal of the play back panel emergency stop switch on the back of the door Terminal a...

Page 318: ...his signal is ON SAF P CN05 5 6 Safety plug Disabled by jumper lead This signal turns OFF the servo power when the door of the safe guard is opened Connect to the interlock signal from the safety plug...

Page 319: ...or is opened only during the TEACH mode In this case the servo power can be turned ON while the interlock signal is input DIN CN06 7 8 Direct in 4 Open Used for the search function FORCE CN06 9 10 For...

Page 320: ...cific I O IN OUT 24 points 24 points General I O IN OUT 16 points 16 points relay contact output The specific I O is a signal in which the part is decided in advance The specific I O is used when the...

Page 321: ...CN10 CN13 CN12 Connector Type FCN 361J040 AU Fujitsu Soldering pin type Food Type FCN 360C040 B Fujitsu Connector A CN10 CN11 CN12 CN13 Connector B detailed Connector Type FCN 365P040 AU Fujitsu 39 3...

Page 322: ...External Device Only the rising edge of the servo ON signal is valid This signal turns ON the manipulator servo power supply The set and reset timings are shown in the following Timing Chart RUN STOP...

Page 323: ...r I O circuit and emergency stop circuit Brake power supply circuit and its output Overrun OT shock sensor SHOCK and lamp light power supply output to robot Connection of Shock Sensor Remove SHOCK and...

Page 324: ...9 and CN26 8 to 10 of the I O con tactor unit JZNC XIU01 2 Connect 24V of the external power supply to CN26 7 and 0V to CN26 8 of the I O contactor unit JZNC XIU01 When the shock sensor input signal i...

Page 325: ...xternal power supply outside the XRC to avoid electric noise problems When the internal power supply is selected do not connect the line of the external power supply to the 24VU and 0VU terminals The...

Page 326: ...he manipulator 1 Remove wire jumper connected with CN26 1 2 of I O power on unit JZNC XIU01 2 The overrun input of an external axis is connected between CN26 1 and 2 of I O power on unit JZNC XIU01 as...

Page 327: ...nfiguration Servopack configuration Small Capacity Type Component SV3X UP6 Type Capacity Type Capacity Servopack CACR SV3AAA CACR UP6AAC Converter JUSP ACP05JAA 5A JUSP ACP05JAA 5A Amplifier S JUSP WS...

Page 328: ...wer supply JUSP RCP01AAB Servopack configuration Large Capacity Type Component SK16MX SK45X Type Capacity Type Capacity Servopack CACR UP16MAAB CACR SK45AAB Amplifier S JUSP WS30AA 3KW JUSP WS30AA 3KW...

Page 329: ...Y18 6KW L JUSP WS60AA 6KW JUSP WS60AAY18 6KW U JUSP WS60AA 6KW JUSP WS60AA 6KW R JUSP WS20AAY13 2KW JUSP WS20AAY13 2KW B JUSP WS15AAY13 1 5KW JUSP WS15AAY13 1 5KW T JUSP WS15AAY13 1 5KW JUSP WS15AAY13...

Page 330: ...6MX SK45 Servopack Dimensions for UP130 UP165 UP200 UP130R Servo Control Board Amplifier 6pcs Converte Servo cntrl Power Supply 5V Display LED Servopack Servo Control Board Amplifier 6pcs Converte Ser...

Page 331: ...ervo control board AC input Single phase AC200 220V is supplied by power supply unit Converter This exchanges the power source 3 phase AC200 220V supplied by the power supply unit for DC power source...

Page 332: ...2023 3010 3011 3012 3013 3014 3015 3016 3017 3020 3021 3022 3023 External Start Remove Jumper pin between CN26 9 and 7 CN26 10 and 8 when a external power supply is used 2 1 4 3 6 5 8 7 10 9 12 11 14...

Page 333: ...3027 3030 3031 3032 3033 3034 3035 3036 3037 024 VU 024 VU 024VU 024VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN IN IN 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18...

Page 334: ...3043 3044 3045 IN08 024VU 024VU 24VU 24VU 24VU 24VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT 3046 3047 IN01 GeneralInput IN02 IN03 IN04 IN05 IN06 IN07 OUT01 GeneralOu...

Page 335: ...24VU 24VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT 3056 3057 IN09 IN10 IN11 IN12 IN13 IN14 IN15 OUT09 OUT09 OUT10 OUT10 OUT11 OUT11 OUT12 OUT12 OUT13 OUT13 OUT14 OUT...

Page 336: ...on restarts if this signal turnsOFF 2013 ALARM ERROR RESET After an alarm or error has occurred and the cause been corrected this signal resets the alarm or error 2022 WORK PROHIBITED Arc Generation P...

Page 337: ...the cursor or when editing operation is carried out after HOLD is applied during operation Therefore this signal can be used as a restart interlock after a HOL is applied However it also turns ON in...

Page 338: ...23 3010 3011 3012 3013 3014 3015 3016 3017 3020 3021 3022 3023 External Start Remove Jumper pin between CN26 9 and 7 CN26 10 and 8 when a external power supply is used 2 1 4 3 6 5 8 7 10 9 12 11 14 13...

Page 339: ...3032 3033 3034 3035 3036 3037 024 VU 024 VU 024VU 024VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN IN IN 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 22 21...

Page 340: ...UT OUT OUT OUT OUT OUT 3046 3047 Sensor Input 1 Hand Valve 1 1 RLY RLY 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 22 21 24 23 26 25 28 30 27 29 32 34 31 33 36 35 38 37 40 39 OUT OUT OUT OUT 24...

Page 341: ...IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT 3056 3057 IN09 GeneralInput IN10 IN11 IN12 IN13 IN14 IN15 OUT09 GeneralOutput OUT09 OUT10 OUT10 OUT11 OUT11 OUT12 OUT12 OUT13 O...

Page 342: ...r ON During wait status the manipulator operation restarts if this signal turnsOFF 2013 ALARM ERROR RESET After an alarm or error has occurred and the cause been corrected this signal resets the alarm...

Page 343: ...o confirm that the master job has been called 2 3023 INTERMEDIATE START OK This signal turns ON when the manipulator operates It turns OFF when the currently exe cuted line is moved with the cursor or...

Page 344: ...3010 3011 3012 3013 3014 3015 3016 3017 3020 3021 3022 3023 External Start Remove Jumper pin between CN26 9 and 7 CN26 10 and 8 when a external power supply is used 2 1 4 3 6 5 8 7 10 9 12 11 14 13 1...

Page 345: ...4 3025 3026 3027 3030 3031 3032 3033 3034 3035 3036 3037 024 VU 024 VU 024VU 024VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN IN IN 2 1 4 3 6 5 8 7 10 9 12 11 14...

Page 346: ...3043 3044 3045 IN08 024VU 024VU 24VU 24VU 24VU 24VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT 3046 3047 IN01 GeneralInput IN02 IN03 IN04 IN05 IN06 IN07 OUT01 GeneralOu...

Page 347: ...24VU 24VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT 3056 3057 IN09 IN10 IN11 IN12 IN13 IN14 IN15 OUT09 OUT09 OUT10 OUT10 OUT11 OUT11 OUT12 OUT12 OUT13 OUT13 OUT14 OUT...

Page 348: ...servo power ON During wait status the manipulator operation restarts if this signal turnsOFF 2013 ALARM ERROR RESET After an alarm or error has occurred and the cause been corrected this signal resets...

Page 349: ...gnal can be used as a restart interlock after a HOL is applied However it also turns ON in the TEACH mode and TEACH MODE SELECTED signal must be referred together 3013 ALARM ERROR OCCURRED This signal...

Page 350: ...3013 3014 3015 3016 3017 3020 3021 3022 3023 External Start Remove Jumper pin between CN26 9 and 7 CN26 10 and 8 when a external power supply is used 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 1...

Page 351: ...4 3035 3036 3037 024 VU 024 VU 024VU 024VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN IN IN 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 22 21 24 23 26 25 2...

Page 352: ...6 25 28 30 27 29 32 34 31 33 36 35 38 37 40 39 OUT OUT OUT OUT 24VU RLY Each Point 24VDC 8mA max Each Point 24VDC 500mA max Internal Power Supply 24 V 024 V 24V 1A 24 VE 024 VE 024VU Logical Number Si...

Page 353: ...24VU 24VU FG IN IN IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT 3056 3057 IN17 IN18 IN19 IN20 IN21 IN22 IN23 OUT17 OUT17 OUT18 OUT18 OUT19 OUT19 OUT20 OUT20 OUT21 OUT21 OUT22 OUT...

Page 354: ...ts to enter the cub 4 2 area while this signal is ON the manipula tor goes to wait status with servo power ON During wait status the manipulator operation restarts if this signal turnsOFF 2015 SELECT...

Page 355: ...e next step is executed when confirmation limit switch is not provided 2046 3 GUN SHORT OPEN DETECTION This signal is connected with a single gun open verification limit switch or a double stroke gun...

Page 356: ...tc considering the robot status 3014 BATTERY ALAR This signal turns ON to notify that the battery requires replacing when the voltage drops from the battery for backup memory of the encoder Major prob...

Page 357: ...e I O allocation display in operation condition 4 This signal can be select USE or NOT USE by pseudo input signal 822x If NOT USE is selected this signal can be used as general input signal Timer Cool...

Page 358: ...2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 T P R K L F G H S J M N E A B C D MR Connector MS Connector Welder GASOF Gas Shortage GASOF Gas Shortage WIRC...

Page 359: ...Maintenance...

Page 360: ......

Page 361: ...ments XRC Controller Check that the doors are completely closed Daily Check for gaps or dam age to the sealed con struction Monthly Servo ascending fan and backside duct fan Check operation As require...

Page 362: ...power is turned off CW Open CCW Close Make sure push the door closed and turn the door lock with the driver When the door is closed turn the door lock until the door clicks YASNAC XRC Front View 8 2 2...

Page 363: ...xcessive high temperatures inside The servo ascending fan and backside duct fan normally operate while the power is turned ON Check if the fans are operating correctly by visual inspection and by feel...

Page 364: ...ncy stop button on the play back panel after the servo ON button before the robot is operated 8 5 Deadman Switch Inspections The programing pendant is equipped with a three position deadman switch Per...

Page 365: ...ndicates when a battery has expired and must be replaced The programming pendant display and the message Memory battery weak appears at the bottom of the dis play The way to replace the battery is des...

Page 366: ...of the circuit breaker QF1 with an electric tester Circuit Breaker QF1 Power Supply Voltage Confirmation Measuring Items Terminals CorrectValue Correlate voltage Between R and S S andT R and T 200 to...

Page 367: ...repair it Input Power Supply Check Check the open phase voltage of input power supply with an electric tester Normal value 200 220V 10 15 Circuit Breaker QF1 Check Turn on the control power supply and...

Page 368: ...8 8 Open Phase Check 8 8...

Page 369: ...ower supply during maintenance put up a warning sign such as DO NOT TURN ON THE POWER at the primary power supply knife switch wiring circuit breaker etc and at the YASNAC XRC and related controllers...

Page 370: ...ay and LED on the system con trol board is turned on Replacement Procedure 1 Disconnect the battery connector BAT and remove the battery 2 Mount the new battery and connect the battery connector Altho...

Page 371: ...the circuit board from the rack 5 Insert a new circuit board into the slot of the rack with the levers spread 6 Push the board until it is placed in the same position of other boards 7 Tighten upper a...

Page 372: ...ch is attached at the upper and lower side 4 Insert the new control power unit in to the slot of the rack 5 Push the new control power unit until it is placed in the same position of other boards 6 Ti...

Page 373: ...d externally to the servo control board PG cable connectors CNPB123 CNPB456 Communications cable connector CN10 Power ON signal cable connector CN20 Motor cable connectors CN1 to CN6 4 Remove the grou...

Page 374: ...above How to Replace PWM Amplifier 1 Turn OFF the primary power supply and wait at least 5 minutes before replacing Do not touch any terminals during this period 2 Verify that the converter CHARGE la...

Page 375: ...Turn OFF the primary power supply and wait at least 5 minutes before replacing Do not touch any terminals during this period 2 Verify that the converter CHARGE lamp red LED is unlit 3 Disconnect all t...

Page 376: ...he continuity with an electric tester If the fuse is blown replace it with the same type of fuse supplied Parts No Fuse Name Specification FU1 2 Control Power Supply Fuse 250V 5A Time Lag Fuse Std 313...

Page 377: ...oard JANCD XCP01 High speed serial interface circuit board JANCD XIF03 Control power supply CPS 150F 3 I O Power on unit JZNC XIU01 Power on circuit board JANCD XTU01 Specific I O circuit board JANCD...

Page 378: ...circuit board JASP WRCA01 JASP WRCA01 JASP WRCA01 Control power supply JUSP RCP01AAB JUSP RCP01AAB JUSP RCP01AAB Servopack List Large Capacity Component SK16MX SK45X UP130 UP165 Type Type Type Servopa...

Page 379: ...WS60AAY18 L JUSP WS60AAY18 U JUSP WS60AA R JUSP WS20AAY13 B JUSP WS15AAY13 T JUSP WS15AAY13 Servo control circuit board JASP WRCA01 Converter JUSP ACP35JAA Control power supply JUSP RCP01AAB Power Sup...

Page 380: ...o buy the spare parts which are ranked B or C inform the manufacturing number or order number of XRC to Yaskawa representative The spare parts are ranked as follows Rank A Expendable and frequently re...

Page 381: ...y LY2 DC24V Omron 3 3 9 B Convertor JUSP ACP05JAA Yaskawa 1 1 10 B Control Power Unit JUSP RCP01AAB SANRITZ 1 1 For Servo 11 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 12 B Amplifier JUSP WS02A...

Page 382: ...P ACP05JAA Yaskawa 1 1 10 B Control Power Unit JUSP RCP01AAB SANRITZ 1 1 For Servo 11 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 12 B Amplifier JUSP WS05AAY17 Yaskawa 1 2 For S U axes 13 B Ampl...

Page 383: ...3 3 9 B Convertor JUSP ACP05JAA Yaskawa 1 1 10 B Control Power Unit JUSP RCP01AAB SANRITZ 1 1 For Servo 11 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 12 B Amplifier JUSP WS10AAY17 Yaskawa 1 3...

Page 384: ...JUSP ACP25JAA Yaskawa 1 1 10 B Control Power Unit JUSP RCP01AAB SANRITZ 1 1 For Servo 11 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 12 B Amplifier JUSP WS30AA Yaskawa 1 1 For S axis 13 B Ampli...

Page 385: ...JUSP ACP25JAA Yaskawa 1 1 10 B Control Power Unit JUSP RCP01AAB SANRITZ 1 1 For Servo 11 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 12 B Amplifier JUSP WS30AA Yaskawa 1 1 For S U axes 13 B Amp...

Page 386: ...r JUSP ACP35JAA SANRITZ 1 1 11 B Control Power Unit JUSP RCP01AAB Yaskawa 1 1 For Servo 12 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 13 B Amplifier JUSP WS60AA Yaskawa 1 3 For S L U axes 14 B...

Page 387: ...1 11 B Control Power Unit JUSP RCP01AAB SANRITZ 1 1 For Servo 12 B Servopack Control Board JASP WRCA01 Yaskawa 1 1 13 B Amplifier JUSP WS60AAY18 Yaskawa 1 2 For S L axes 14 B Amplifier JUSP WS60AA Yas...

Page 388: ...9 4 Recommended Spare Parts 9 20...

Page 389: ...Alarm Error...

Page 390: ......

Page 391: ...m Then turn on the main power supply again 1 3 Level 1 3 Major alarm It is not possible to reset by RESET under the alarm display or the specific I O signal Alarm reset Turn off the main power supply...

Page 392: ...ency stop If the display is changed to the other during alar occurrence the alarm display can be shown again by selecting SYSTEM INFO and ALARM under the menu Release Alarms are classified by minor an...

Page 393: ...dinates when the alarm occurred are highlighted 123 data The data for the alarm that occurred is highlighted Control group data The control group where the alarm occurred is highlighted 2 Multiple Ser...

Page 394: ...independent control function multi task job the tasks that were being done when the alarm occurred are also displayed TASK 0 Master task job TASK 1 Sub task1 job SUB1 TASK 2 Sub task2 job SUB2 TASK 3...

Page 395: ...cuit board 1 0 11 XCP02 circuit board 1 1 12 XCP02 circuit board 1 2 20 XCP02 circuit board 2 0 21 XCP02 circuit board 2 1 22 XCP02 circuit board 2 2 Note XCP02 circuit board Slot NO 0 XCP02 circuit b...

Page 396: ...unication connector for servopack Check the connection of the terminal connector WRCA CN10 Replace the terminal connector Replace the circuit board 0030 ROM ERROR Decimal Data An error was found by su...

Page 397: ...it board 5 55 WRCA01 circuit board 6 Note WRCA01 circuit board The setting value of rotary switch on the WRCA01 circuit board is 1 Replace the circuit board When the XCP01 circuit board is replaced co...

Page 398: ...00 MEMORY ERROR PARAMETER FILE Decimal Data The parameter file was damaged Data stands for the damaged parameter file 0 RC 1 RO 2 SV 3 SVM 4 SC 5 SD 6 CIO 7 FD 8 AP 9 RS 10 SE 11 RMS 12 AMC 13 SVP 14...

Page 399: ...ard speed detect circuit board connected with WRCA01 circuit board 5 97 111 Contactor circuit board speed detect circuit board connected with WRCA01 circuit board 6 Note WRCA01 circuit board The setti...

Page 400: ...it board 1 1 12 XCP02 circuit board 1 2 20 XCP02 circuit board 2 0 21 XCP02 circuit board 2 1 22 XCP02 circuit board 2 2 Note XCP02 circuit board Slot NO 0 XCP02 circuit board main 1 Sub board1 connec...

Page 401: ...CPU ERROR XCP02 2 Decimal Data An insertion error of the XCP02 2 circuit board or defective circuit board Insert the circuit board in the CPU rack or the connector on the circuit board fast Replace th...

Page 402: ...error of the WRCA01 3 circuit board or defective circuit board Insert the circuit board in the CPU rack or the connector on the circuit board fast Replace the circuit board If the error occurs again...

Page 403: ...6 circuit board or defective circuit board Insert the circuit board in the CPU rack or the connector on the circuit board fast Replace the circuit board If the error occurs again contact you YASKAWA r...

Page 404: ...FC01 circuit board Replace the XFC01 circuit board ROM 1003 ROM XCP02 The error was found by sum check of sys tem program for the XCP02 circuit board Replace the XCP02 circuit board ROM 1030 MEMORY ER...

Page 405: ...le on maintenance mode Replace the XCP01 I O contactor unit I O module 1105 SYSTEM ERROR SERVO Decimal Data The error occurred in control check of th WACA01 WRCF01 circuit board Turn the power off the...

Page 406: ...tor WRCA CN10 Replace the terminal connector Replace the XCP01 circuit board WRCA01 circuit board If the error occurs again contact your YASKAWA representative 1302 COMMUNICATION ERROR SERVO I O Decim...

Page 407: ...o pack Error in external axis Check the type of servopack set by sys tem configuration is same as actual installed one If set data by system con figuration is correct replace installed servopack with...

Page 408: ...reducing the teaching speed on alarm There is a pos sibility that R B T axis move at a fast speed on liner interpolation according to teaching position In this case alter the teaching Error in robot...

Page 409: ...eck the breaking of the wire There is a possibility the robot moves by extra load Check the motion status of robot again and reduce the teaching speed Then confirm the reoccurrence Error in robot axis...

Page 410: ...aking of the wire There is a possibility the robot moves by extra load Check the motion status of robot again and reduce the teaching speed Then confirm the reoccurrence Error in robot axis Check that...

Page 411: ...tor again And check the breaking of the wire There is a possibility the robot moves by extra load Check the motion status of robot again and reduce the teaching speed Then confirm the reoccurrence Err...

Page 412: ...s tem configuration is the same as the actual installed one If set data by sys tem configuration is correct replace installed motor with correct one If set data by system configuration is not cor rect...

Page 413: ...01 and or WRCF01 circuit board Replace the amplifier motor for axis where the error occurred 1315 POSITION ERROR Robot Statio Axis Data The number of pulses generated by one rotation of the motor was...

Page 414: ...king the motor grounding There is a possibility the servopack is damaged when the servo turn on and off is repeat ing ground fault status Check the connection ofthe U V W E wires of motor again Remove...

Page 415: ...ier motor for the axis where the error occurred 1322 REGENERATIVE TROUBLE CONVERTER Bit Pattern Because the resurrection energy on reducing the motor speed was too high the resurrection circuit board...

Page 416: ...ing The no brake axes R B T axis for SK6 freely fell when the servo power supply was turned off by emergency stop When the power supply was turned back on this status this alarm occurred In case this...

Page 417: ...heck Check the connection cables of the I O contactor unit Replace the WRCA01 board 1338 SPEED MONITOR LEVEL ERROR The error occurred in the speed monitoring level signal signal error Check the connec...

Page 418: ...ype of motor is same as the one described in the manual If the type is not correct replace it with the correct motor Error in external axis Check that the type of motor set by sys tem configuration is...

Page 419: ...e Load the saved user coordinates file in the external memory unit and restore 4002 MEMORY ERROR SV MON SIGNAL FILE The servo monitor signal file of CMOS memory was damaged Initialize the servo monito...

Page 420: ...re 4017 MEMORY ERROR WELDER USER DEF FILE Decimal Data The welder user definition file of CMOS memory was damaged The data stands for the file No Initialize the welder user definition file in the main...

Page 421: ...4039 MEMORY ERROR FORM CUT FILE Decimal Data The form cut file of the CMOS memory was damaged The data stands for the file No Initialize the form cut file in the mainte nance mode Load the saved form...

Page 422: ...alarm 4104 WRONG EXECU TION OF LOAD INST Decimal Data When the installation was executed the error occurred in DCI function The data stands for the alarm factor Refer to the data transmission functio...

Page 423: ...sion timeout timer B Correct the error according to the data of the alarm factor after resetting the alarm 4116 TRANSMISSION SYSTEM ERROR Decimal Data When the data transmission function was used the...

Page 424: ...the alarm and repeat the opera tion Turn the power off then back on If the error occurs again contact your YASKAWA representative 4202 SYSTE ERROR JOB Decimal Data When access to the job was executed...

Page 425: ...l Data The error occurred in the safe circuit signal I O contactor unit Check the WRCA01 board duplication signal Check the safe circuit signal wiring of the cables connected to the I O contactor unit...

Page 426: ...the WRCA01 circuit board the converter 4304 CONVERTER INPUT POWER ERROR Bit Pattern There was no response ready 1 signal of primary power supply input from convertor at servo ON While turning servo ON...

Page 427: ...ter 4306 AMPLIFIER READY SIGNAL ERROR Bit Pattern There was no response amp ready signal of energizing completed from amplifier at servo ON While turning servo ON the amp ready signal was intercepted...

Page 428: ...R Robot Station Axis Data Because backup power supply voltage for encoder decreased less than 2 6V posi tion data of the encoder disappeared Whenever a new motor was used this error occurred Reset the...

Page 429: ...Data The error has occurred in job exec state ment part Data 1 255 stands for the alarm factor Reset the alarm and repeat the opera tion If the error occurs again contact you YASKAWA representative 44...

Page 430: ...or at specified speed Reset the alarm Reduce the speed of step Move instruction occurred the alarm or change the robot pose 4416 PULSE LIMIT MIN Robot Station Axis Data It exceeded pulse software limi...

Page 431: ...ONTROL GROUP Decimal Data The error occurs in information on the robot which uses for the job interpretation and the motion control Data 1 9 stands for the alarm factor Reset the alarm and repeat the...

Page 432: ...ion caused the alarm 4439 UNDEFINED LABEL Decimal Data No labels existed in the currently executing job Reset the alarm and register job Or Delete CALL JUMP instruction occurred the alarm 4440 UNDEFIN...

Page 433: ...g speed instruction was moving time instruction moving time was less than 0 5 Weaving speed instruction was frequency instruction frequency was less than 0 6 Weaving stopping time was negative 7 Verti...

Page 434: ...up the equation to reduce its length 4460 ZERO DIVIDED OCCURRENCE Decimal Data A division by zero was attempted Set not to divide by zero 4461 UNDEFINED AUTO WELD RELEASE COND Decimal Data Number of a...

Page 435: ...t correspond with reset process after the alarm occurred in arith metic section Reset the alarm and repeat the opera tion If the error occurs again contact you YASKAWA representative 4474 WRONG CONTR...

Page 436: ...nterpolation motion impropriety of end less function Linear motion impropriety This error occurred as follows When operating play back panel and programming pendant though continuous rotation was com...

Page 437: ...e the user coordinates 4501 OUT OF RANGE PARALLEL PROCESS Decimal Data The error occurred in task control process of independent control function Reset the alarm and repeat the opera tion If the error...

Page 438: ...do not lie on the straight line 4513 EXCESSIVE SEGMENT SAFETY 1 LOW Robot Station Axis Data The specified speed exceeded the safe speed After resetting the alarm reduce the speed of the step where the...

Page 439: ...ion unmatch Needs investigation Consult a YASKAWA representative 4529 TWIN COORDI NATED ERROR Decimal Data 1 The job started by SYNC was a job with out any robot axes job with station axes only or con...

Page 440: ...ng error and repeat the operation 4581 DEFECTIVE ANTICI PATION FILE Decimal Data A setting in the anticipation output file is set to an improper value The setting of the OT output or OG output is 1 OT...

Page 441: ...0 9010 01 MISSING ARC GENERATION CON FIRM 9020 02 ARC SHORTAGE 9030 03 9040 04 GAS SHORTAGE RESTART 9050 05 WIRE SHORTAGE RESTART 9060 06 9070 07 9080 08 9090 09 9100 10 9110 11 9120 12 9130 13 9140 1...

Page 442: ...tem Section 9000 00 AIR PRESSURE LOWERED 9010 01 9020 02 9030 03 9040 04 9050 05 9060 06 9070 07 9080 08 9090 09 9100 10 9110 11 9120 12 9130 13 9140 14 9150 15 9160 16 9170 17 9180 18 9190 19 9200 20...

Page 443: ...ING WATER 9010 01 ERROR OF GUN COOLING WATER 9020 02 ERROR IN TRANSTHERMO OF GUN 9030 03 AIR PRESSURE LOWERED 9040 04 9050 05 9060 06 9070 07 9080 08 9090 09 9100 10 9110 11 9120 12 9130 13 9140 14 91...

Page 444: ...essage System Section 9000 00 9010 01 9020 02 9030 03 9040 04 9050 05 9060 06 9070 07 9080 08 9090 09 9100 10 9110 11 9120 12 9130 13 9140 14 9150 15 9160 16 9170 17 9180 18 9190 19 9200 20 9210 21 92...

Page 445: ...r an external equipment com puter PLC etc accesses When an error occurs release it after the confirmation of the content of the error To release the error perform following the operation Press CANCEL...

Page 446: ...ORG XX XY Not registered user coordinates basic 3 points ORG XX XY 70 Program and current tool different The tool number registered with teaching position data didn t match the tool number selected at...

Page 447: ...ong specification of measure interval Wrong specification of measure interval for TRT function 410 Time could not be measured Time could not be measured 420 Incorrect number of taught points Taught po...

Page 448: ...t JOB robot 630 Not completed to load original tool file 640 Not specified tool file 650 Incorrect measured data 660 Wrong data type of position variable 670 Enter path number 680 Defined data XXX Fil...

Page 449: ...r instruction 860 Please release key registration mode 870 This key cannot be allocated 880 Same relay cannot be set 890 This key has already been registered Cannot register them once 900 Relay No not...

Page 450: ...me not entered 2030 Undefined JOB name 2040 Defined JOB name 2050 Address not found 2060 Select master 2070 Set robot exactly to taught position 2080 Press INSERT or MODIFY 2090 Only modifying move in...

Page 451: ...ction in JOB 2280 JOB memory is full 1 Lack of position file memories 2 Lack of JOB registering memories 3 Lack of instruction file memories 4 Lack of memory pool 5 Lack of pass condition file for mul...

Page 452: ...g 2410 When variable is used for speed set ting perform a line edit 2420 When variable is used for teach set ting perform a line edit 2430 Reverse data not found 2440 Move C and W axis to basic positi...

Page 453: ...orrect play speed in the JOB 2630 Conveyor position not reset 2640 Incorrect JOB name 2650 Defined JOB name 2660 Register MOVL inst after circular block 2670 Undefined target JOB 2680 Wrong designatio...

Page 454: ...070 Number of files on floppy disk 3080 I O error on floppy disk 3090 Transmission error with floppy disk drive 1 Framing error 2 Overrun error 3 Parity error 4 Data code error 5 Data read error 6 Dat...

Page 455: ...ror of channel No 5 Specification error of relay No 6 Timer value error 7 Specification error of timer No 3160 Cannot load illegal system data 3170 Condition file data error 1 Format error 2 Specified...

Page 456: ...e data ATTR record is wrong for the format 9 Control group GROUP record is wrong for the format 10 Local variable LVARS record is wrong for the format 11 JOB argument JARGS record is wrong for the for...

Page 457: ...ut format error 19 Date size over 20 MIN value over 21 MAX value over 22 Operation expression error 23 JOB call argument setting error 24 Macro JOB call argument setting error 25 Position vector setti...

Page 458: ...a error 49 COMMENT data error 58 Invalid instruction tag detection 3230 Syntax not matched 3240 Undefined application 3250 Cannot load this file 3260 Excess input data 3270 Cannot verify this file 328...

Page 459: ...80 Drive not ready 3390 File not found 3400 File already exists on the media 3410 Out of memory on the media 3420 Max number of files has been reached 3430 I O error on the drive 3440 Wrong media type...

Page 460: ...070 Excess AND OR STR instructions XXX Line No 4080 Syntax error in CNT instructions XXX Line No 4090 Enter STR NOT at head of block Need STR NOT XXX Line No 4100 Relay No duplicated in TMR and CNT Ti...

Page 461: ...ELETE keys 4190 Ladder program not found 4200 Cannot specify system variables 4210 Cannot edit line 4220 Excess TMR CNT or arithmetic instruc tions More than 100 TMR CNT or arithmetic instruction used...

Page 462: ...11 1 Error Message List 11 18...

Page 463: ......

Page 464: ...n BEIJING OFFIC Room No 301 Office Building of Beijing Intemational Club 21 Jianguomenwai Avenue Beijing 100020 China SHANGHAI OFFICE 27 Hui He Road Shanghai 200437 China YASKAWA JASON HK COMPANY LIMI...

Page 465: ...ese instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN ___ INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR S MANUAL YASNAC XRC OPERATOR...

Page 466: ......

Page 467: ...ngs 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 im...

Page 468: ...potentially hazardous situation which if not avoided could result in death or serious injury to personnel Indicates a potentially hazardous situation which if not avoided could result in minor or mode...

Page 469: ...envelope to teach a job Operator injury can occur if the Teach Lock is not set and the manipulator is started from the playback panel Observe the following precautions when performing teaching operati...

Page 470: ...ir them immediately and be sure that all other necessary processing has been performed Check for problems in manipulator movement Check for damage to insulation and sheathing of external wires Always...

Page 471: ...CPU HANG UP ERROR 22 AL 0940 to 0945 WATCHDOG TIMER ERROR 19 AL 0950 to 0955 CPU ERROR 20 AL 0960 to 0965 CPU HANG UP ERROR 22 AL 0999 NMI ERROR 22 AL 0021 COMMUNICATION ERROR SERVO 23 AL 0030 ROM ERR...

Page 472: ...ERROR V PHASE 50 AL 4100 OVERRUN IN ROBOT AXIS 51 AL 4301 CONTACTOR ERROR 52 AL 4302 BRAKE CIRCUIT ERROR 53 AL 4303 CONVERTER READY SIGNAL ERROR 54 AL 4304 CONVERTER INPUT POWER ERROR 55 AL 4305 CONV...

Page 473: ...controller How to Use this Manual Alarm error codes are listed numerically in the Table of Contents Locate and turn to the page number of the alarm error code displayed on your controller Answer the...

Page 474: ...alarm Contact your Yaskawa representative An error occurs during the check of the CPU board No Yes Yes No No Yes Yes No No Yes Alarm Alarm Alarm AL 0010 CPU BOARD INSERTION ERROR Alarm Remove the corr...

Page 475: ...XCP01 circuit board caused the alarm Continue normal operation The defective XBB01 circuit board caused the alarm Contact your Yaskawa representative No Yes Yes No No Yes Yes No No Yes Alarm Alarm Al...

Page 476: ...rm Remove the corresponding RAM board and remount it Replace the board Continue normal operation An alarm occurs Turn the power OFF and then ON AL 0030 ROM ERROR An error occurs during the ROM s total...

Page 477: ...skawa representative Continue normal operation The defective RAM board caused the alarm No Yes Yes No No Yes Alarm Alarm Alarm Remove the corresponding RAM board and remount it Replace the board Conti...

Page 478: ...Yes No Alarm No Yes Check the cable connected to the corresponding I O Module Turn the power OFF and then ON No Yes Continue normal operation The defective I O Module caused the alarm Contact your Yas...

Page 479: ...AL 0210 MEMORY ERROR SYSTEM CONFIG DATA An alarm occurs An error occurs during the system configuration data s total check Yes No Alarm Replace the XCP01 circuit board Contact your Yaskawa representat...

Page 480: ...ective XCP01 circuit board caused the alarm Replace the XCP01 circuit board Initialize the CIO ladder data AL 0220 MEMORY ERROR JOB MNG DATA An alarm occurs No Yes Alarm Continue normal operation The...

Page 481: ...tive Replace the expansion CMOS board AL 0300 VERIFY ERROR SYSTEM CONFIG DATA An error occurs during the check of the system configuration data and the parameter file An alarm occurs No Yes Alarm Cont...

Page 482: ...ON AL 0320 VERIFY ERROR I O MODULE The system configuration setting differs from the actual status of the hardware An alarm occurs Continue normal operation No Yes Remove the corresponding I O Module...

Page 483: ...No Replace the corresponding sensor board Alarm Continue normal operation The defective sensor board caused the alarm Alarm Initialize the parameter file Reset the option board AL 0400 PARAMETER TRANS...

Page 484: ...ing communications between the XCP01 circuit board and the WRCA01 circuit board Continue normal operation No Yes Alarm Contact your Yaskawa representative An alarm occurs Turn the power OFF and then O...

Page 485: ...ation The defective board caused the alarm Contact your Yaskawa representative No Yes Yes No No Yes Alarm Alarm Alarm Check the connection of the corresponding board See the table below Replace the bo...

Page 486: ...e board Continue normal operation An alarm occurs Turn the power OFF and then ON An error occurs during the internal control check AL0910 XCP01 circuit board AL095 0 AL0953 AL091 1 XCP02 1 circuit boa...

Page 487: ...tative No Yes Yes No No Yes Alarm Alarm Alarm Check the connection of the corresponding board See the table below Replace the board Continue normal operation An alarm occurs Turn the power OFF and the...

Page 488: ...on An alarm occurs Turn the power OFF and then ON An error occurs during the internal control check AL0930 AL096 0 AL0963 AL093 1 AL096 1 AL093 2 AL096 2 AL0964 AL0965 Continue normal operation No Yes...

Page 489: ...onnector 2CN on the RCP01AAA unit and re insert it Alarm Yes No Is the LED on the RCP01AAA unit lit Yes No Remove connector 1CN on the RCP01AAA unit and re insert it Alarm Yes No Check the fuse for th...

Page 490: ...it board caused the alarm Turn the control power supply OFF and then ON Alarm Yes No Continue normal operation AL 1001 ROM ERROR WRCA01 An alarm occurs Replace the WRCA01 circuit board Alarm Yes No Co...

Page 491: ...gun with the power cable Alarm Yes No Does the alarm occur the first time the servo is turned ON after turning ON the control power supply No Yes Is the servo gun at the stroke end the first time the...

Page 492: ...operation Remove connector CN05 on the XCP01 circuit board and re insert it Alarm Yes No Continue normal operation Replace the WRCA01 circuit board Alarm Yes No Contact your Yaskawa representative Con...

Page 493: ...Alarm Yes No Is the LED on the RCP01AAA unit lit Yes No Remove connector 1CN on the RCP01AAA unit and re insert it Alarm Yes No Check the fuse for the RCP01AAA unit Blown out Normal Remove the connec...

Page 494: ...n the control power supply OFF and then ON Alarm Yes No Replace the WRCA01 circuit board Alarm Yes No Continue normal operation The defective WRCA01 circuit board caused the alarm Replace the XIU01 un...

Page 495: ...the specified range AL 1304 EX AXIS BOARD NOT INSTALLED An alarm occurs Remove the WRCF01 circuit board and re mount it Alarm Yes No Is a WRCF01 circuit board mounted No Yes Replace the WRCA01 circui...

Page 496: ...t them See Fig 1 Alarm Yes No Replace the WRCA01 circuit board Alarm Yes No Replace the SERVOPACK Alarm Yes No Contact your Yaskawa representative The capacity of the amplifier 1 0 kW or less or 1 5 k...

Page 497: ...56 on the WRCA01 circuit board The connection of CNPG 123 and CNPG 456 See Fig 2 Alarm Yes No Replace the encoder or motor Alarm Yes No The serial encoder type 16 bit or 17 bit is selected according t...

Page 498: ...o Was MOVJ the move instruction at the position Yes No Does the robot axis move at the same time with any other axes Yes No Reduce the motion speed Alarm Yes No Does the alarm occur during operation Y...

Page 499: ...s at a specific position Yes No Close the opening of the gun a little Alarm Yes No Does the alarm occur during operation Yes No Replace the WRCF01 circuit board Alarm Yes No Replace the motor Alarm Ye...

Page 500: ...Does 90 V flow between the motor brake terminals BA and BB No Yes Continue normal operation Check the conductivity of the internal lead brake wires Abnormal Normal Replace the internal leads Alarm Yes...

Page 501: ...a specific position Yes No Was MOVJ the move instruction at the position where the alarm occurred Yes No Does the robot axis move at the same time with any other axes Yes No Reduce the motion speed Al...

Page 502: ...ard Alarm Yes No Replace the WRCF01 circuit board Alarm Yes No Replace the cable between the WRCF01 circuit board and the XEI01 circuit board Alarm Yes No A miscount of the feedback pulses is detected...

Page 503: ...connecotor CN20 on the XIU01 unit and re insert it Alarm Yes No Check the power supply for the XEI01 board Check the power supply for the XEI01 board Replace the XEI01 circuit board Alarm Yes No Repla...

Page 504: ...voltage of the breaker to the specified voltage Alarm Yes No Converter SERVOPACK CN30 CN1 Fig 3 Is the primary voltage of the breaker 200 V 10 to 15 Yes No Is the regenerative resistor disconnected D...

Page 505: ...e motor power cable of the axis where the alarm occurred turn ON the servo power supply Alarm No Yes Replace the SERVOPACK Alarm No Yes Contact your Yaskawa representative Continue normal operation Tu...

Page 506: ...and T all 200 V 10 to 15 Yes No Change the breaker s primary voltage to the specified voltage Alarm Yes No Continue normal operation Continue normal operation Replace the converter Alarm No Yes Is the...

Page 507: ...Measure the resistance between E11 and U11 U12 V11 V12 W11 and W12 and between E12 and U11 U12 V11 V12 W11 and W12 to confirm that all the contacts are open Disconnect CN29 on the XIU01 unit After dis...

Page 508: ...on the converter and re insert it See Fig 8 Alarm Yes No Continue normal operation Replace the converter Alarm No Yes Change the breaker s primary voltage to the specified voltage Alarm Yes No Convert...

Page 509: ...city is discharged Remove connector CN30 on the WRCA01 circuit board and re insert it See Fig 10 Alarm Yes No Remove connector CN1 on the converter and re insert it See Fig 10 Alarm Yes No Continue no...

Page 510: ...XEI circuit board See Fig 12 Yes No The serial encoder type 16 bit or 17 bit is selected according to the motor type A 16 bit encoder for the motor type SGM A1A A 17 bit encoder for SGM A2A A 12 bit...

Page 511: ...hem Alarm Yes No Turn the control power supply OFF and then ON Alarm Yes No Replace the motor encoder Alarm Yes No This alarm is sent from the encoder This alarm is often caused by a defective encoder...

Page 512: ...nnected See Fig 15 Contact your Yaskawa representative Remove connectors CNPG123 and CNPG456 on the corresponding WRCA01 circuit board and re insert them Alarm Yes No Continue normal operation The def...

Page 513: ...larm Yes No Turn the control power supply OFF and then ON Alarm Yes No Replace the motor encoder Alarm Yes No This alarm is sent from the encoder This alarm is often caused by a defective encoder CNPG...

Page 514: ...A01 circuit board and re insert them Alarm Yes No Turn the control power supply OFF and then ON Alarm Yes No Replace the motor encoder Alarm Yes No CNPG456 CNPG123 SERVOPACK Fig 17 Continue normal ope...

Page 515: ...e between the WRCA01 circuit board and the amplifier Alarm Yes No Replace the WRCA01 cirucit board Alarm Yes No Replace the SERVOPACK Alarm Yes No SERVOPACK CNPB4 Fig 19 CNPB5 CNPB6 CNPB1 CNPB2 CNPB3...

Page 516: ...cable between the WRCA01 circuit board and the amplifier Alarm Yes No Replace the WRCA01 cirucit board Alarm Yes No Replace the SERVOPACK Alarm Yes No Continue normal operation A faulty connection ca...

Page 517: ...Alarm Yes No Remove connector CN1 of the converter and re insert it Alarm Yes No Continue normal operation Replace the converter Alarm No Yes Contact your Yaskawa representative Replace the WRCA01 ci...

Page 518: ...istance r s t R S T Non fuse breaker K14 K15 K13 Confirm that relay K15 of the XTU01 circuit board is not stuck or disconnected See Fig 22 Alarm Yes No XIU01 XTU01 Fig 21 Fig 22 After turning OFF the...

Page 519: ...tive Confirm that relay K15 of the XTU01 circuit board is not stuck or disconnected See Fig 23 Alarm Yes No XIU01 XTU01 Fig 23 Continue normal operation The defective WRCA01 circuit board caused the a...

Page 520: ...confirm that all the LEDs on the SERVOPACK and converter are unlit and that no charged electricity remains It may take a few minutes until all the electricity is discharged K14 K15 K13 Alarm Yes No C...

Page 521: ...larm Yes No Contact your Yaskawa representative Replace the converter Alarm Yes No Continue normal operation Alarm Yes No Converter SERVOPACK Tester Measure the resistance XIU01 XTU01 Fig 27 Fig 28 Fi...

Page 522: ...Replace the WRCA01 circuit board Alarm Yes No Contact your Yaskawa representative Replace the converter Alarm Yes No Replace the SERVOPACK Alarm Yes No CN30 CN1 CN7 Converter SERVOPACK Fig 30 Continue...

Page 523: ...larm Yes No Replace the amplifier Alarm Yes No Replace the WRCA01 circuit board Alarm Yes No CNPB4 CNPB5 CNPB6 CNPB1 CNPB2 CNPB3 SERVOPACK Fig 31 Continue normal operation The wrong operation of the W...

Page 524: ...nnected See Fig 32 Contact your Yaskawa representative Remove connectors CNPG123 and CNPG456 on the corresponding WRCA01 circuit board and re insert them Alarm Yes No Check the connector of the amplif...

Page 525: ...WRCA01 circuit board and re insert them See Fig 33 Alarm Yes No Turn the control power supply OFF and then ON Alarm Yes No Replace the motor encoder Alarm Yes No SERVOPACK CNPG456 CNPG123 Fig 33 Conti...

Page 526: ...FF the control power supply and wait 10 minutes Alarm Yes No Replace the motor encoder Alarm Yes No Operate the encoder at 80 C or less Alarm Yes No Continue normal operation The overheated encoder ca...

Page 527: ...Alarm Yes No CNPG456 CNPG123 When this alarm occurs the data for the accumulated rotation is lost To restart an operation after removing the cause of the error perform the zero point positioning payin...

Page 528: ...e data for the accumulated rotation is lost perform zero point positioning paying attention to the robot s working envelope before restarting the operation SERVOPACK Fig 35 AL 4313 SERIAL ENCODER OVER...

Page 529: ...ttention to the robot s working envelope before restarting the operation An alarm occurs Contact your Yaskawa representative Replace the battery Alarm Yes No Check the battery cable disconnection etc...

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Page 532: ...EIJING OFFICE Room No 301 Office Building of Beijing Intemational Club 21 Jianguomenwai Avenue Beijing 100020 China SHANGHAI OFFICE 27 Hui He Road Shanghai 200437 China YASKAWA JASON HK COMPANY LIMITE...

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