YASKAWA YRC1000 User manual

MANUAL NO. RE-CSO-A053 2
YRC1000
MATERIAL HANDLING, PRESS TENDING,
CUTTING, AND OTHER APPLICATIONS
OPERATOR’S MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”.
The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.
178647-1CD
1

ii
DANGER
• This manual describes the various components of the YRC1000
system and general operations. Read this manual carefully and be
sure to understand its contents before handling the YRC1000. Any
matter, including operation, usage, measures, and an item to use,
not described in this manual must be regarded as “prohibited” or
“improper”.
• General information related to safety are described in “Chapter 1.
Safety” of the YRC1000 INSTRUCTIONS. To ensure correct and
safe operation, carefully read “Chapter 1. Safety” of the YRC1000
INSTRUCTIONS.
CAUTION
• In some drawings in this manual, protective covers or shields are
removed to show details. Make sure that all the covers or shields
are installed in place before operating this product.
• YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized
modification voids the product warranty.
NOTICE
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.

iii
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the YRC1000.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
DANGER
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.
CAUTION
Indicates a hazardous situation,
which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.
NOTICE
NOTICE is the preferred signal word
to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION”.

iv
DANGER
• Before operating the manipulator, make sure the servo power is
turned OFF by performing the following operations. When the servo
power is turned OFF, the SERVO ON LED on the programming
pendant is turned OFF.
– Press the emergency stop buttons on the front door of the
YRC1000, on the programming pendant, on the external control
device, etc.
– Disconnect the safety plug of the safety fence.
(when in the play mode or in the remote mode)
If operation of the manipulator cannot be stopped in an emergency,
personal injury and/or equipment damage may result.
Fig. : Emergency Stop Button
• Before releasing the emergency stop, make sure to remove the
obstacle or error caused the emergency stop, if any, and then turn
the servo power ON.
Failure to observe this instruction may cause unintended movement of
the manipulator, which may result in personal injury.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing a teaching
operation within the manipulator's operating range:
– Be sure to perform lockout by putting a lockout device on the
safety fence when going into the area enclosed by the safety
fence. In addition, the operator of the teaching operation must
display the sign that the operation is being performed so that no
other person closes the safety fence.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind emergency response measures against the
manipulator’s unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may cause improper or unintended
movement of the manipulator, which may result in personal injury.
• Confirm that no person is present in the manipulator's operating
range and that the operator is in a safe location before:
– Turning ON the YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
Personal injury may result if a person enters the manipulator's
operating range during operation. Immediately press an emergency
stop button whenever there is a problem. The emergency stop buttons
are located on the front panel of the YRC1000 and on the right of the
programming pendant.
• Read and understand the Explanation of the Warning Labels before
operating the manipulator.

v
Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows.
WARNING
• Perform the following inspection procedures prior to conducting
manipulator teaching. If there is any problem, immediately take
necessary steps to solve it, such as maintenance and repair.
– Check for a problem in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the
YRC1000 cabinet after use.
If the programming pendant is left unattended on the manipulator, on a
fixture, or on the floor, etc., the Enable Switch may be activated due to
surface irregularities of where it is left, and the servo power may be
turned ON. In addition, in case the operation of the manipulator starts,
the manipulator or the tool may hit the programming pendant left
unattended, which may result in personal injury and/or equipment
damage.
Equipment Manual Designation
YRC1000 controller YRC1000
YRC1000 programming pendant Programming pendant
Cable between the manipulator and the
controller Manipulator cable

vi
Descriptions of the programming pendant keys, buttons, and displays are
shown as follows.
Description of the Operation Procedure
In the explanation of the operation procedure, the expression “Select • • • ”
means that the cursor is moved to the object item and [SELECT] is
pressed, or that the item is directly selected by touching the screen.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
Equipment Manual Designation
Programming
Pendant Character Keys Symbol Keys The keys which have characters or its
symbols printed on them are denoted with [ ].
ex. [ENTER]
Axis Keys
Numeric Keys [Axis Keys] and [Numeric Keys] are generic names for the keys for axis operation and
number input.
Keys pressed
simultaneously When two keys are to be pressed simultaneously, the keys are shown with a
“+” sign between them.
ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}

Contents
vii
1 Material Handling, Press Tending, Cutting, and Other Applications...............................................1-1
1.1 Simplified Teaching and Playback.....................................................................................1-1
1.1.1 Teaching...............................................................................................................1-1
1.1.1.1 Preparation for Teaching.........................................................................1-1
1.1.1.2 Teaching Procedure................................................................................1-4
1.1.1.3 Path Confirmation .................................................................................1-13
1.1.1.4 Correcting a Job....................................................................................1-14
1.1.1.5 Changing the Position Data ..................................................................1-15
1.1.2 Playback.............................................................................................................1-19
1.1.2.1 Preparation before Playback.................................................................1-19
1.1.2.2 Playback Procedure..............................................................................1-19
1.1.3 Example for General Purpose Application..........................................................1-20
1.1.3.1 Example Job .........................................................................................1-20
1.1.3.2 Teaching Procedure..............................................................................1-21
1.1.3.3 Confirmation of Cutting Operation (Speed Limitation Drive).................1-24
1.2 Operation for Tool Control..............................................................................................1-25
1.2.1 Function Keys.....................................................................................................1-25
1.2.2 Tool Control Settings..........................................................................................1-26
1.2.3 Work Instructions................................................................................................1-27
1.2.3.1 TOOLON/TOOLOF Instructions............................................................1-27
1.2.3.2 CALL Instruction....................................................................................1-28
1.2.3.3 WVON Instruction..................................................................................1-29
1.2.3.4 WVOF Instruction..................................................................................1-29
1.3 Weaving Operation..........................................................................................................1-30
1.3.1 Weaving Basic Coordinate System....................................................................1-30
1.3.1.1 Cases that Require the Registration of Reference Points.....................1-31
1.3.2 WVON ................................................................................................................1-33
1.3.2.1 Function ................................................................................................1-33
1.3.2.2 Syntax ...................................................................................................1-33
1.3.2.3 Explanation ...........................................................................................1-34
1.3.2.4 Registering the WVON Instruction ........................................................1-37
1.3.3 WVOF Instruction...............................................................................................1-39
1.3.3.1 Function ................................................................................................1-39
1.3.3.2 Syntax ...................................................................................................1-39
1.3.3.3 Explanation ...........................................................................................1-40
1.3.3.4 Registering the WVOF Instruction.........................................................1-41
1.3.4 WEAVING CONDITION Window........................................................................1-42
1.3.4.1 Displaying the Weaving File..................................................................1-49
1.3.4.2 Editing the Condition Data ....................................................................1-50
1.3.5 Prohibiting Weaving............................................................................................1-51
1.3.5.1 Method to Prohibit Weaving during a “CHECK” Operation ...................1-51
1.3.5.2
Method to Prohibit Weaving during a “TEST RUN” or FWD Operation ...1-52

Contents
viii
1.3.5.3 Method to Prohibit Weaving by Means of a System Input Signal..........1-52
1.4 Table of Work Instructions...............................................................................................1-53
2 Handling Application .......................................................................................................................2-1
2.1 Outlines..............................................................................................................................2-1
2.1.1 Function Keys.......................................................................................................2-1
2.1.2 HAND Instruction..................................................................................................2-2
2.1.2.1 Function...................................................................................................2-2
2.1.2.2 Instruction and Additional Items ..............................................................2-3
2.1.3 HSEN (Gripper Sensor) Instruction ......................................................................2-4
2.1.3.1 Function...................................................................................................2-4
2.1.3.2 Instruction and Additional Items ..............................................................2-4
2.1.3.3 Examples.................................................................................................2-5
2.1.4 Handling Window..................................................................................................2-6
2.1.5 Shock Sensor Function.........................................................................................2-8
2.1.6 Shock Sensor Input Signal ...................................................................................2-8
2.1.7 Shock Sensor Input Reset....................................................................................2-8
2.1.8 Low Air Pressure Input Signal..............................................................................2-8
2.2 Registering Instructions .....................................................................................................2-9
2.2.1 HAND Instruction..................................................................................................2-9
2.2.2 HSEN Instruction................................................................................................2-11
2.3 Table of Work Instructions...............................................................................................2-13

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-1
1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1.1.1 Teaching
1.1.1.1 Preparation for Teaching
Perform the following tasks before starting to teach.
• Set the operation mode to teach mode.
• Enter the job name.
1. Confirm that the mode switch on the programming pendant is set to
“TEACH”. If not, set the switch to “TEACH”.
2. Press [SERVO ON READY].
The SERVO ON lamp will blink. If [SERVO ON READY] is not
pressed, the servo power supply cannot be turned ON using the
Enable switch.
3. Select {JOB} under the main menu, and select {CREATE NEW JOB} in
the sub menu.
4. After the NEW JOB CREATE window appears, press [SELECT].

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-2
5. After the following window appears, input the job name. The word
“TEST” is used in this example job name.
6. Move the active window to software keypad by pressing the [AREA].
Move the cursor to “T” and press [SELECT]. Enter “E,” “S,” and “T” in
the same manner. The characters can also be entered by directly
touching each character on the screen.
7. Press [ENTER] to register.

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-3
8. Move the cursor to “EXECUTE” and press [SELECT]. The job “TEST”
is registered and the job is displayed. The NOP and END instructions
are automatically registered.
SUPPLE
-MENT
Characters which can be Used for Job Names
Job names can be created from numbers and the alphabeti-
cal letters. The input display can be switched between
upper-case characters, lower-case characters, and symbols
by pressing [PAGE] during the operation 5. Up to 32 charac-
ters can be used.

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-4
1.1.1.2 Teaching Procedure
To playback the manipulator, the instruction to move the manipulator must
be written in a job. This instruction is called a move instruction. The
destination position, the interpolation method, the play speed, etc. are
registered in the move instruction.
Main move instructions begin with “MOV” in the INFORM III language
used by the DX200.
<Example>
MOVJ VJ=50.00
MOVL V=1122 PL=1
<Example>
Refer to the following JOB CONTENT window. When executing playback,
the manipulator moves to the position of Step 1 with the interpolation type
and play speed registered in Step 1’s move instruction. Then, the
manipulator moves between Steps 1 and 2 with the interpolation type and
play speed registered in Step 2’s move instruction. Then, the manipulator
moves between Steps 2 and 3 with the interpolation type and play speed
registered in Step 3’s move instruction. After the manipulator reaches the
position of Step 3, the manipulator then executes the TIMER instruction
followed by the DOUT instruction, and then continues on to Step 4.
Line No.
Step 1
Step 2
Step 3
Step 4
Step 5
MOVJ VJ=50.00
MOVJ VJ=50.00
Step 1
Step 2 Step 3
To Step 4
MOVL V=1122

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-5
Teaching a Job
A job is a work program that describes the tasks that the manipulator will
execute. Jobs are created using a robot programming language called
INFORM III.
The following example will instruct you how to teach the manipulator all of
the steps from Point A to Point B of the following workpiece. This job can
be completed in 6 steps.
Fig. 1-1: Teaching a Job
Actual work is not performed here.
Step 4
Step 5
Step 6
Step 1
New Step
Step 6
Step Confirmation
AB
Step 6
+
TEACHING
Register
each step.
Step 1
Step 2
Step 3
Overlap
the first step
and last step.
CAUTION
Make sure that the teach lock is set.
Make sure to keep a safe distance between the operator and the manipulator.

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-6
Step 1 -- Standby Position
Always be sure the manipulator is in a safe work area before operation.
1. Grip the Enable switch and the servo power will turn ON. The
manipulator can then be operated.
2. Move the manipulator to the standby position using [Axis Keys]. Be
sure the position is safe and that the work area is appropriate for the
job to be programmed.
3. Select joint interpolation by pressing [MOTION TYPE]. Joint
instruction “MOVJ...” will be displayed in the input buffer line.
4. Move the cursor to the line number 0000 and press [SELECT].
5. The input buffer line appears. Move the cursor to the right to VJ=*.**,
which shows the speed. While pressing [SHIFT] simultaneously, move
the cursor up and down (to higher and lower play speeds) until the
desired speed is specified.
Set the speed to 50%.
6. Press [ENTER]. Step1 (Line 0001) is registered.
Step 1

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-7
Step 2 -- Near the Work Start Position
Define the manipulator’s working posture.
1. Move the manipulator to the working position using [Axis Keys].
2. Press [ENTER]. Step 2 (Line 0002) is registered.
Step 1
Step 2

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-8
Step 3 -- Work Start Position
Move the manipulator to the work start position with the pose as shown in
Step 2.
1. Change to medium speed by pressing [FAST] or [SLOW] until is
displayed in the status area.
2. Do not release the pose in Step 2. Press [COORD] to select the
Cartesian coordinates. Move the manipulator to the welding start
position using [Axis Keys].
3. With the cursor located on the line number 0002, press [SELECT].
4. The input buffer line appears. Move the cursor to the right to VJ=*.**,
which shows the speed. While pressing [SHIFT] simultaneously, move
the cursor up and down (to higher and lower play speeds) until the
desired speed is specified.
Set the speed to 12.50%.
5. Press [ENTER]. Step 3 (Line 0003) is registered.
Step 1
Step 2
Step 3

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-9
Step 4 -- Work End Position
Specify the work end position.
1. Move the manipulator to the work end position with [Axis Keys]. While
the manipulator is moving, keep a wide enough distance to ensure it
will not strike the workpiece. There is no need to follow the work line
too closely.
2. Press [MOTION TYPE] to select linear interpolation (MOVL).
3. With the cursor located on the line number 0003, press [SELECT].
4. The input buffer line appears. Move the cursor tothe right to V= 100.0,
which shows the speed. While pressing [SHIFT] simultaneously, move
the cursor up and down (to higher and lower play speeds) until the
desired speed is specified.
Set the speed to 200.0 cm/min.
5. Press [ENTER]. Step 4 (Line 0004) is registered.
Step 1
Step 2
Step 3
Step 4

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-10
Step 5 -- Clear Position
Move the manipulator to a position where it will not strike the workpiece or
fixture.
1. Change the speed to high speed by pressing [FAST].
2. Move the manipulator with [Axis Keys] to a position where it will not
strike the fixture.
3. Press [MOTION TYPE] to set to the joint interpolation type (MOVJ).
4. With the cursor located on line number 0004, press [SELECT].
5. The input buffer line appears. Move the cursor to the right to
VJ=12.50, which shows the speed. While pressing [SHIFT]
simultaneously, move the cursor up and down (to higher and lower
play speeds) until the desired speed is specified.
Set the speed to 50%.
6. Press [ENTER]. Step 5 (Line 0005) is registered.
NOTE
This button only affects teaching speed. When the job is
played, the job will execute at the speed defined in Step 4.
Step1
Step2
Step3
Step4
Step5

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-11
Step 6 -- Near the Standby Position
Move the manipulator near the standby position.
1. Move the manipulator near the standby position with [Axis Keys].
2. Press [ENTER]. Step 6 (Line 0006) is registered.
Step1
Step2
Step3
Step4
Step5
Step6

1 Material Handling, Press Tending, Cutting, and Other Applications
1.1 Simplified Teaching and Playback
1-12
Ensuring the First and Last Step are Identical
The manipulator has stopped at Step 6, which should be very close to
Step1.
It is possible to move directly from the job end position of Step 5 to Step1,
so the manipulator can begin the next job quickly and efficiently.
The following operation will make Step 6 (end position) and Step1
(standby position) identical.
1. Move the cursor to Step1 (Line 0001).
2. Press [FWD]. The manipulator will move to Step1.
3. Move the cursor to Step 6 (Line 0006).
4. Press [MODIFY].
5. Press [ENTER]. This will change the position of Step 6 to be the same
as Step1.
Step 2
Step 3 Step 4
Step 5
Corrent Step 6
Modified Step 6
Step 1