YASKAWA YRC1000 User manual

ROBOTICS
Instructions
Robot controller
User manual

© Copyright 2017
This documentation – also in part – may be reproduced or made available to third parties only with the
express approval of YASKAWA Europe GmbH „Robotics Division“.
We have checked the content of this publication for compliance with the hardware described.
Nevertheless, discrepancies cannot be ruled out. Therefore, we cannot guarantee full compliance.
However, the information given in this publication is checked regularly and any necessary corrections
will be made in subsequent editions.
Subject to technical modifications.
Created on: 2017-08
Revision: 04
Document number: E1102000214GB04 Author: WOE
Changes made in revision:
Rev. 01: Document created from the original RE-CTO-A221.1
Rev. 02: Revised version of the original RE-CTO-A221.2 (2017-02)
Rev. 03: Add the manual (document no.: ME00115EN-00) (2017-03)
Rev. 04: Revised version of the original RE-CTO-A221.3 and RE-CTO-A221.4 (Chapter:
2.4 "MOTOMAN Safety", 4.2.4 "Installation options", add a new chapters 9.26.3.1 "Full
speed mode", 9.26.3.2 "Switching display of system and user section", 9.26.11 "Output
signal", 9.26.20 "GP safety output monitoring signal" and 9.29.1 "Connecting the dummy
connector"

3
Table of contents
Table of contents
1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.8 Authorized representative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 YASKAWA manual list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Personal protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 MOTOMAN Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Safety during installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.3 Fixing the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.4 Safety in the work area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.5 Operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Checking the scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Product confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Position type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1 Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1.1 Transporting method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.1 Protection measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2.2 Ambient conditions and installation location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2.3 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2.4 Installation options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.5 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Notes on cable junctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2.1 3-phase power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.2 Leakage breaker installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.3 Installation of primary power supply breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Connection methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3.1 Connection to primary power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3.2 Connection of the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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5.3.4 User I/O cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Turning ON and OFF the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 Turning ON the main power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1.1 Initial diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1.2 When initial diagnosis are complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.2 Turning ON the SERVO power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.2.1 During PLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.2.2 During TEACH MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.3 Turning OFF the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.3.1 Turning OFF the SERVO power (emergency stop) . . . . . . . . . . . . . . . . . . . . . . . 61
6.3.2 Turning OFF the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.3.3 The method of stopping the robot operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7 Test of program operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.1 Movement of the axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.2 Manual brake release function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8 Security system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.1 Protection through security mode settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.2 Security mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.3 User ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.4 Main CPU SD card ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9 System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.1 Home position calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.1.1 Registering all axes at the time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.1.2 Registering individual axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.1.3 Changing the absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.1.4 Clearing absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.1.5 Home position posture of robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.2 Setting the second home position (check point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.2.1 Purpose of position check operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.2.2 Procedure for the second home position setting . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.2.3 Procedure after alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.3 Tool data setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.3.1 Number of tool files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.3.2 Registering coordinate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.3.3 Registering the posture data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.3.4 Setting the tool load information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.3.5 Tool calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.3.6 Automatic Measurement of the Tool Load and the center of gravity. . . . . . . . . . 103
9.4 ARM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..110
9.4.1 ARM control window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.4.2 Tool load information setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.5 Work home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.5.1 What is the work home position? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.5.2 Setting the work home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.5.3 Changing and registering the work home position . . . . . . . . . . . . . . . . . . . . . . . 126
9.5.4 Returning to the work home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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9.5.5 Output of the work home position signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.6 Interference area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9.6.1 Cubic interface area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9.6.2 Cube setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9.6.3 Axis interference area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.6.4 Deleting interference area data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
9.7 Shock detection function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9.7.1 Shock detection function setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9.7.2 High-sensitivity shock detection function (for Arc Welding application only) . . . 153
9.8 User coordinates setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9.8.1 Methods for user coordinates setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9.8.2 User coordinates setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.9 Overrun/Tool shock sensor releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
9.10 Soft limit release function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.11 All limit release function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
9.12 Instruction level setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9.12.1 Command set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9.12.2 Setting the instruction set level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
9.12.3 Setting the learning function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
9.13 Setting the controller clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.14 Setting play speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
9.15 Numeric key customize function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
9.15.1 About the numeric key customize function? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
9.15.2 Allocatable Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
9.15.3 Allocating operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
9.15.4 Allocation of I/O Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.15.5 Execution of allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
9.16 Changing output status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
9.17 Changing the parameter setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
9.18 File Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
9.18.1 Initializing JOB files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
9.18.2 Initialize data files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
9.18.3 Initializing parameter files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
9.18.4 Initializing the I/O data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
9.18.5 Initializing system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
9.18.6 Reset Safety Circuit Board FLASH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
9.19 Display Setting Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
9.19.1 Font size setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
9.19.2 Setting the button size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.19.3 Initialization screen layouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.19.4 Layout storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9.20 Encoder backup error recovery function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9.20.1 About encoder backup error recovery function. . . . . . . . . . . . . . . . . . . . . . . . . . 205
9.20.2 Encoder backup error recovery function operation. . . . . . . . . . . . . . . . . . . . . . . 205
9.21 Preventive maintenance function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9.21.1 Preventive maintenance function for the speed reducer . . . . . . . . . . . . . . . . . . 207
9.21.2 Inspection notice function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9.22 Operating status monitor function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

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Table of contents
9.23 JOB monitor function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
9.24 Robot monitor function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.25 Break line ground judgment function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
9.25.1 About the break line ground judgement function . . . . . . . . . . . . . . . . . . . . . . . . 242
9.25.2 Operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9.25.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9.26 Safety logic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
9.26.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
9.26.2 Changing the SECURITY mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
9.26.3 Available I/O signals and instructions in safety logic circuit . . . . . . . . . . . . . . . . 248
9.26.4 Safety logic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
9.26.5 Signal list window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
9.26.6 Setting ON/OFF to the input signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
9.26.7 Setting for the general purpose safety I/O signals . . . . . . . . . . . . . . . . . . . . . . . 262
9.26.8 Safety signal board allocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
9.26.9 Timer delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
9.26.10 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
9.26.11 Output signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
9.26.12 Display of the message on the programming pendant . . . . . . . . . . . . . . . . . . . 271
9.26.13 Enable switch link function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
9.26.14 Specific Input Signals Allocated to SPIN[xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
9.26.15 Output to the control status signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.26.16 Saving or loading the file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
9.26.17 Initializing the safety logic circuit file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
9.26.18 Example of safety logic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
9.26.19 Alarm list of the safety logic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
9.26.20 GP safety output monitoring signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
9.27 Robot stop factor monitor function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
9.27.1 The robot stop factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
9.27.2 The robot stop factor record number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
9.28 Robot detachment function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
9.28.1 Setting MAINTENANCE mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
9.28.2 Setting robot detachment function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
9.29 Axes detachment function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
9.29.1 Connecting the dummy connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
9.29.2 Setting MAINTENANCE mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
9.29.3 Setting axes detachment function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
9.29.4 Specific output and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
9.29.5 Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
9.30 User group input and output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
9.30.1 User group input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
9.30.2 User group output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
9.31 Variable Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
9.32 Controller information display function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
10 System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
10.1 System Backup with robot controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
10.1.1 Function types of data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

7
Table of contents
10.1.2 Storage medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
10.2 Backup by CMOS.BIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
10.2.1 CMOS.BIN save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
10.2.2 CMOS.BIN load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
10.3 Automatic Backup function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
10.3.1 Objective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
10.3.2 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
10.3.3 Settings for automatic Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
10.3.4 Limiting the automatic backup file creation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
10.4 Loading the backup data from the Memory medium. . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
10.5 Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
11 Upgrade function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
11.1 Functional overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
11.2 Upgrade procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
11.3 Error message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
12 Programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
12.1 Disconnection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
12.2 Reset function of the programming pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
12.3 Touch panel invalidate function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
12.4 Reboot robot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
13 Modification of System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
13.1 Addition of I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
13.2 Allocating External I/O Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
13.3 Addition of base and station axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
13.3.1 Base Axis Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
13.3.2 Station axis setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
14 Robot controller specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
14.1 Specification list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
14.2 Function list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
14.3 Programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
14.4 Device configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
14.5 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
14.5.1 Optional cabinets for controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
14.5.2 Options for socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
14.5.3 Swing frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
14.5.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
14.5.5 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
15 Description of Units and Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
15.1 Power Supply Contactor Unit (JZRCR-APU0-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
15.2 Control Power Supply Unit (CSRA-CPS01KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
15.3 CPU Unit (JZNC-ARK01-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
15.3.1 CPU unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
15.3.2 Unit and circuit board in the CPU unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
15.4 Converter (CSRA-CV05D01A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
15.5 Inverter Unit (CSRA-SDAH01A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

8
Table of contents
15.5.1 Inverter unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
15.5.2 Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
15.5.3 SERVO control board (CSRA-SDCA01AA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
15.6 Safety circuit board (JANCD-ASF01-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
15.7 Safety Terminal Block Board (IM-YE250/5-80P). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
15.8 Safety plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
15.9 Installation of safety plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
15.10 External emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
15.11 Connection for SERVO-ON enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
15.12 External axes overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
15.13 General purpose safety input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
15.14 General purpose safety output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
15.15 General purpose input (SERVO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
15.16 General purpose I/O board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
15.17 WAGO Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
15.18 Assignment of universal I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
15.18.1 ARC welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
15.18.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
15.18.3 General Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
15.18.4 List of device configuration depending on model. . . . . . . . . . . . . . . . . . . . . . . . 451

General
1- 9
1 General
1.1 Notes for safe operation
DANGER!
Indicating immediate danger at high risk, hazard that can cause death or serious bodily
injuries if no precautions are taken.
WARNING!
Indicating possible medium risk hazard situation which can cause death or serious bodily
injuries if it is not avoided.
CAUTION!
Indicating potentially dangerous situation with low risk of minor or moderate bodily injuries
result if it is not avoided. This signal word can also be used for property damage warnings.
NOTICE
Indicates important background information and application advice.
1.2 Frequently used terms
The YASKAWA robot is a product of YASKAWA Electric Corporation, and is provided by
default with the robot control, the programming pendant and robot cable.
The terms are designated as follows in this manual:
Term Description
Control Robot control
Industrial robot Robot
Programming pendant / teach box Programming pendant or PP
Supplying cable between robot and robot
control
Cable
Robot, robot control and cable Robot system
YASKAWA Electric Corporation YEC
YASKAWA Robotics Division YEU-R
Moving, calibrating and setting up of the ro-
bot
Teachen
Movement sequences of the robot JOBs
Technical customer service TCS
General purpose GP
FEEDBACK FB
Time Measuring TM
Personal computer PC

General
1- 10
1.3 Target group
This manual is directed at users with the following knowledge:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• System knowledge of the robot control
• Specially trained staff
NOTICE
According to the international DIN EN ISO 10218-1 standard, operators of a robot system
must receive training before they operate the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For more detailed information on the training
programs, please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA
branch office.
1.4 Intended use
Typical applications:
• Flange-mounting tools
• Installation of spot welding guns
• Installation of arc welding equipment
• Installation of grippers
• Machining and transporting workpieces or products

General
1- 11
1.5 Improper use
Any use that deviates from the intended use shall be regarded as impermissible misuse.
This includes:
• Transport of people and animals
• Use as ascending aid.
• Use outside the permissible operating limits.
• Use in environments with risk of explosion (except for ATEX-approved robots).
• Overload
• Use without protective equipment.
NOTICE
Modifications to the robot, e.g. drilling holes or similar modifications, can damage parts.
This will be regarded as improper use (i.e. use that deviates from the intended use) and will
lead to loss of warranty and liability claims as well as loss of the declaration of incorporation.
CAUTION!
The robot system is an incomplete machine.
The robot system may be put into operation only after it has been determined that the
incomplete or complete machine in which the robot system is being installed:
Corresponds to the provisions of the machinery directive.
Complies with all relevant (harmonized) standards.
Corresponds to the state of the art.

General
1- 12
1.6 About this manual
NOTICE
• This manual explains the different components of the robot controller and the general
operating functions. Be sure to read and understand this manual thoroughly before
operating the robot controller..
• To ensure correct and safe operation, carefully read the operating instructions of the
robot controller ("Basic Information," "Setup," and "Connection and System Setup").
• In order to illustrate details clearly, some drawings are shown with the protective covers
or shields removed. All protective covers and shields must be mounted before the robot
is operated.
• The drawings and figures in this manual are representative illustrations. They may differ
from the product delivered.
• YEU-R reserves the right to make technical changes. These changes may include
product improvements, modifications or changes in specifications
• If your copy of the operating and maintenance instructions is damaged or lost, please
contact the local YASKAWA branch office to order a new copy. The official branch
offices are listed on the last page. Please mention the manual number in your order.
• YASKAWA Europe GmbH is not responsible for damage caused due to unauthorised
modification of the system. If any impermissible modifications are made to the system
and to the robot, all warranty and liability claims as well as the declaration of
incorporation will expire.
Descriptions of the programming pendant, buttons, and displays are shown as
follows:
Description of the operation procedure
In the explanation of the operation procedure, the expression "Select",
Programming pendant Manual designation
Character keys The keys which have characters printed on them are
denoted with [ ], e. g. [ENTER]
Symbol keys The keys which have a symbol printed on them are il-
lustrated with a small picture.
e. g. There is no picture for the cursor key.
Mode selection switch Three kinds of modes that can be selected by the mode
key are denoted as follows: REMOTE, PLAY and
TEACH
Keys There are three keys on the programming pendant,
which are referred to as follows: HOLD key; START
key; Emergency stop button
Axis keys Controlling the axes
Numeric keys Number input
Simultaneously pressed keys A plus sign between the keys indicates that it is neces-
sary to press two keys simultaneously.
e.g. [SHIFT] + [COORD] .
Display The menu displayed is denoted with { }.
e.g. {JOB}
SHIFT
TOOL SEL
COORD

General
1- 13
• means that the cursor is moved to the object item and the [SELECT] key is pressed.
• that the item is directly selected by touching the screen.
Registered Trademark
The names of companies and/or products used in this manual are trademarks. The
indications of ® and are omitted.

General
1- 14
1.7 Manufacturer
Address:
YASKAWA ELECTRIC CORPORATION
2-1 KUROSAKISHIROISHI
YAHATANISHI-KU
KITAKYUSHU
JAPAN
Address:
YASKAWA NORTIC AB
P.O. Box 504
Verkstadsgatan 2
385 25 Torsås
Sweden
1.8 Authorized representative
Address:
YASKAWA Europe GmbH
Robotics Division
Yaskawastr. 1
85391 Allershausen
Germany

Safety
2- 15
2 Safety
WARNING!
Danger of death or injury from crushing
If the emergency stop button is not working properly, the robot cannot be stopped in the
event of an emergency.
The robot should not be used if the emergency stop button is not working.
Before operating the robot, check the function of the EMERGENCY STOP button. The
servo power must go off immediately when the EMERGENCY STOP button is pressed
on the programming pendant (see Fig. 2-2: "Emergency stop button").
When the servo power is turned off, the "SERVO ON" LED on the programming
pendant goes out (see Fig. 2-1: ""SERVO ON" LED").
Fig. 2-1: "SERVO ON" LED
Fig. 2-2: Emergency stop button
Programming Pendant
Emergency stop button
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WARNING!
Danger of death or injury from crushing
Before you release the emergency stop button (see Fig. 2-3: "Releasing the emergency
stop button by rotating it"), note the following
Make sure there is no one within the maximum operating range of the robot.
Clear the cell of all items with which the robot could collide.
Only then should you switch on the servo power by pressing the enabling switch on the
programming pendant.
Fig. 2-3: Releasing the emergency stop button by rotating it
WARNING!
Danger of death or injury from crushing
If anyone enters the working area of the robot during operation or any problems occur,
always press the EMERGENCY STOP button immediately. It is located on the
programming pendant (see figure „Programming pendant“).
Take the following precautions when performing teaching operations within the robot’s
operating range:
Position yourself in front of the robot whenever possible.
Always follow the prescribed operating steps (see the instructions for the robot
controller, as well as the „Handling“ and „Universal Application“ manuals).
There must be a free space into which the operator can retreat in the event of an
emergency.
The following test steps absolutely must be performed before you teach the robot. Deal with
any problems you find immediately, and make sure that any other necessary steps have
been taken.
• Check for any problems in the movements of the robot.
• Check that the connectors are well secured and none of the cables are damaged.
• Hang the programming pendant back on the robot controller after use.
• Make sure that the key for the mode selector (teach/automatic) on the programming
pendant is kept by a competent person who has been specially trained by us.
• The key may only be inserted into the key switch of the programming pendant during
teaching. After teaching, it must be immediately removed and kept in a safe place.

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2.1 For your safety
Different requirements in general apply for robots than is the case for other production
facilities. Among those are for example larger workspaces, high speed operation, speedy
arm movements etc., which can pose risks.
Please read through the handbook and related documents carefully. Please observe all
precautionary measures to avoid personal injuries and damage to the plant.
The owner is responsible for ensuring that all applicable standards, ordinances,
regulations, and legal provisions for safety are observed and that the operating conditions
are safe.
CAUTION!
According to the German Occupational Safety and Health Protection Act, teaching and
maintaining the robot are considered to be "dangerous activities" and must be performed
under the observance of the following provisions and regulations:
– German Occupational Safety and Health Protection Act.
– Implementation Order for the German Occupational Safety and Health Protection Act.
– Ordinance Regarding the German Occupational Safety and Health Protection Act.
Other pertinent provisions are as follows
– U.S.-American laws governing occupational safety and health protection.
– EC Machinery Directive 2006/42/EC
Fig. 2-4: CE mark
Observe international standard EN ISO 10218-1 for a safe operation of the robot or robot
equipment.
Increase the efficiency of your safety management system by determining authorised
employees and safety managers and performing regular training.
NOTICE
In reference to international standard EN ISO 10218-1, an operator of a robot system must
be trained before using the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For more detailed information on the training
programme, please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA
branch office.

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2.2 YASKAWA manual list
It is important to have all the manuals on the YASKAWA control or robot available and to
know their contents. Please make sure you have all these manuals. If you are missing any
manual, please contact the local YASKAWA branch office.
You must have the YASKAWA manuals listed below available.
• Instructions (E1102000214XX01* and higher).
• Maintenance (E1102000215XX01* and higher
• Operator’s manual (for each purpose).
• Install and Wiring (E1102000216XX01* or higher).
• Alarm list (E1102000217XX01* or higher).
• Operating and maintenance instructions for the specific robot type.
* "XX" is the language of the document.

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2.3 Personal protection
The entire working area of the robot is potentially dangerous. The following staff must work
with appropriate preparation and subject to the maxim "Safety First" to ensure the safety
of all.
• Safety management
• Assembly staff
• Operating staff
• Maintenance staff
DANGER!
Death by electric shock; serious injury from fire hazard;
Avoid dangerous actions in the area where the robot is installed. Be sure to take safety
precautions
Unauthorised persons should not have access to the robot.
Unauthorised persons should not have access to the peripheral equipment.
Put up signs in the respective working area, such as "Highly flammable","High
voltage","Stop" and "No unauthorized access" .
WARNING!
There is a risk of injury if there is contact with the robot or peripheral equipment.
Strictly observe the following items:
Always wear approved work clothes (no loose-fitting clothes).
Do not wear gloves when operating the robot.
Personal Protective Equipment (PPE) is subject to the provisions of the 89/656/EEC
guideline.
Do not wear large jewellery, such as earrings, rings or pendants.
Always wear protective safety equipment such as protective helmets, safety shoes
(with anti-slip soles), face shields, safety goggles and gloves as necessary.
CAUTION!
Injury and material damage due to unforeseen movements.
Observe the following note:
• Never forcibly move the robot axes.
• Never sit against the robot control.
• Avoid inadvertent pressing of the keys.
• Do not allow unauthorized persons to touch the robot control during operation.

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2.4 MOTOMAN Safety
The followings are safety functions of robot controller.
• Emergency stop SW input (programming pendant)
• Enable SW input (programming pendant)
• Safeguarding interlock signal input (safety plug)
• External emergency stop SW input
• External enable SW input
• SERVO power enable input
• Overrun input (robot/external axis)
• GP safety input (including external enable SW input)
• Safety logic circuit
These safety functions conform to the following safety standards.
• EN ISO 13849-1:2015 Cat.3 / PL e
• EN 62061 (IEC 61508) SIL CL3
The use frequency of each switch for safety functions is assumed as below.
• Emergency stop SW
• Enable SW (programming pendant)
• External enable SW
500 times/year
2000 times/year
2000 times/year