YRC1000: Instructions

1 Safety
    1.1 For Your Safety
    1.2 Special Training
    1.3 MOTOMAN Manual List
    1.4 Personnel Safety
    1.5 MOTOMAN Safety
        1.5.1 Installation and Wiring Safety
        1.5.2 Work Area Safety
        1.5.3 Operation Safety
    1.6 Notes for Moving and Transferring the MOTOMAN
    1.7 Notes on MOTOMAN Disposal
2 Product Confirmation
    2.1 Contents Confirmation
    2.2 Order Number Confirmation
3 Installation
    3.1 Handling Procedure
        3.1.1 Using a Crane to Move the Controller
        3.1.2 Using a Forklift to Move the Controller
    3.2 Place of Installation
    3.3 Location
    3.4 Mounting the Controller
    3.5 Procedure of Stacking the Controllers
4 Connection
    4.1 Notes on Cable Junctions
    4.2 Power Supply
        4.2.1 Three-Phase Power Supply
        4.2.2 Noise Filter Installation
        4.2.3 Leakage Breaker Installation
        4.2.4 Primary Power Supply Breaker Installation
    4.3 Connection Methods
        4.3.1 Connecting the Primary Power Supply
        4.3.2 Connecting the Manipulator Cable
        4.3.3 Connecting the Programming Pendant
        4.3.4 User I/O Cable Connection
5 Turning ON and OFF the Power Supply
    5.1 Turning ON the Main Power Supply
        5.1.1 Initial Diagnosis
        5.1.2 When Initial Diagnosis Are Complete
    5.2 Turning ON the Servo Power
        5.2.1 During Play Mode
        5.2.2 Play Mode Enable Function
            5.2.2.1 Preparation of Switch
            5.2.2.2 Settings
            5.2.2.3 Procedures for Operation Mode Change
        5.2.3 During Teach Mode
    5.3 Turning OFF the Power Supply
        5.3.1 Turning OFF the Servo Power (Emergency Stop)
        5.3.2 Turning OFF the Main Power
        5.3.3 The Method of Stopping Manipulator Operation
6 Test of Program Operation
    6.1 Movement of the Axes
    6.2 Manual Brake Release Function
7 Security System
    7.1 Protection through Security Mode Settings
        7.1.1 Security Mode
            7.1.1.1 Changing the Security Mode
        7.1.2 User ID
            7.1.2.1 Changing User ID
        7.1.3 Main CPU SD Card ID
8 System Setup
    8.1 Home Position Calibration
        8.1.1 Home Position Calibration
        8.1.2 Calibrating Operation
            8.1.2.1 Registering All Axes at One Time
            8.1.2.2 Registering Individual Axes
            8.1.2.3 Changing the Absolute Data
            8.1.2.4 Clearing Absolute Data
        8.1.3 Home Position Posture of Manipulator
    8.2 Setting the Second Home Position
        8.2.1 Purpose of Position Check Operation
        8.2.2 Procedure for the Second Home Position Setting (Check Point)
        8.2.3 Procedure after the Alarm
    8.3 Tool Data Setting
        8.3.1 Registering Tool Files
            8.3.1.1 Number of Tool Files
            8.3.1.2 Registering Coordinate Data
            8.3.1.3 Registering Tool Posture Data
            8.3.1.4 Setting the Tool Load Information
        8.3.2 Tool Calibration
            8.3.2.1 Tool Calibration
            8.3.2.2 Setting of Tool Calibration Method
            8.3.2.3 Teaching of Calibration Point
            8.3.2.4 Clearing Calibration Data
            8.3.2.5 Checking the TCP
        8.3.3 Automatic Measurement of the Tool Load and the Center of Gravity
            8.3.3.1 What is the Automatic Measurement of the Tool Load and the Center of Gravity?
            8.3.3.2 Measurement of the Tool Load and the Center of Gravity
            8.3.3.3 Measurement of the Moment of Inertia at the Center of Gravity
    8.4 ARM Control
        8.4.1 ARM Control
        8.4.2 ARM CONTROL Window
            8.4.2.1 Robot Setup Condition
        8.4.3 Tool Load Information Setting
            8.4.3.1 Tool Load Information
            8.4.3.2 How to Calculate Tool Load Information
            8.4.3.3 Tool Load Information Registering
    8.5 Work Home Position
        8.5.1 What is the Work Home Position?
        8.5.2 Setting Work Home Position
            8.5.2.1 Work Home Position Window
            8.5.2.2 Registering/Changing the Work Home Position
            8.5.2.3 Returning to the Work Home Position
            8.5.2.4 Output of the Work Home Position Signal
    8.6 Interference Area
        8.6.1 Interference Area
        8.6.2 Cubic Interference Area
            8.6.2.1 Cubic Interference Area
            8.6.2.2 Cube Setting Method
            8.6.2.3 Setting Operation
        8.6.3 Axis Interference Area
            8.6.3.1 Axis Interference Area
            8.6.3.2 Setting Operation
        8.6.4 Clearing the Interference Area Data
    8.7 Shock Detection Function
        8.7.1 Shock Detection Function
        8.7.2 Shock Detection Function Setting
            8.7.2.1 Shock Detection Level Setting
            8.7.2.2 EACH AXIS LEVEL (CURRENT) Window
            8.7.2.3 Tool Load Information Setting
            8.7.2.4 U-Arm Payload Setting
            8.7.2.5 Instruction of Shock Detection Function
            8.7.2.6 Resetting the Shock Detected
        8.7.3 High-Sensitivity Shock Detection Function (for Arc Welding Application Only)
            8.7.3.1 Manipulator Type for High-Sensitivity Shock Detection Function
            8.7.3.2 Setting for High-Sensitivity Shock Detection Function
            8.7.3.3 Reading the Tool Load Information on the MAKER INITIAL VALUE Window
            8.7.3.4 Explanation of Maker Initial Value
            8.7.3.5 Reading the U-Arm Payload
            8.7.3.6 Explanation of Maker Initial Value
    8.8 User Coordinates Setting
        8.8.1 User Coordinates
            8.8.1.1 Methods for User Coordinates Setting
        8.8.2 User Coordinate Setting
        8.8.3 Clearing the User Coordinates
    8.9 Overrun/Tool Shock Sensor Releasing
    8.10 Soft Limit Release Function
    8.11 All Limit Release Function
    8.12 Instruction Level Setting
        8.12.1 Setting Contents
            8.12.1.1 Instruction Set
            8.12.1.2 Learning Function
        8.12.2 Setting the Instruction Set Level
        8.12.3 Setting the Learning Function
    8.13 Setting the Controller Clock
    8.14 Setting the Play Speed
    8.15 Numeric Key Customize Function
        8.15.1 About the Numeric Key Customize Function
        8.15.2 Allocatable Functions
            8.15.2.1 Key Allocation (EACH)
            8.15.2.2 Key Allocation (SIM)
        8.15.3 Allocating Operation
            8.15.3.1 Allocation Window
            8.15.3.2 Instruction Allocation
            8.15.3.3 Job Call Allocation
            8.15.3.4 Display Allocation
            8.15.3.5 Alternate Output Allocation
            8.15.3.6 Momentary Output Allocation
            8.15.3.7 Pulse Output Allocation
            8.15.3.8 Group (4-bit/8-bit) Output Allocation
            8.15.3.9 Analog Output Allocation
            8.15.3.10 Analog Incremental Output Allocation
        8.15.4 Allocation of I/O Control Instructions
        8.15.5 Execution of Allocation
            8.15.5.1 Executing the Instruction/Output Control Allocation
            8.15.5.2 Executing the Job Call Allocation
            8.15.5.3 Executing the Display Allocation
            8.15.5.4 Executing the I/O Control Allocation
    8.16 Changing the Output Status
    8.17 Changing the Parameter Setting
    8.18 File Initialization
        8.18.1 Initializing Job File
        8.18.2 Initializing Data File
        8.18.3 Initializing Parameter File
        8.18.4 Initializing I/O Data
        8.18.5 Initializing System Data
        8.18.6 Reset Safety Circuit Board FLASH Data
            8.18.6.1 Saving Dual Data
            8.18.6.2 FLASH Data Reset
    8.19 Display Setting Function
        8.19.1 Font Size Setting
            8.19.1.1 Applicable Range for the Font Size Change
            8.19.1.2 Settable Font Size
            8.19.1.3 Setting the Font Size
        8.19.2 Operation Button Size Setting
            8.19.2.1 Applicable Range for the Button Size Change
            8.19.2.2 Settable Button Size
            8.19.2.3 Setting the Button Size
        8.19.3 Initialization of Screen Layout
            8.19.3.1 Initializing the Screen Layout
        8.19.4 Layout Storage
    8.20 Encoder Back-Up Error Recovery Function
        8.20.1 About Encoder Back-Up Error Recovery Function
        8.20.2 Encoder Back-Up Error Recovery Function Operation
    8.21 Preventive Maintenance Function
        8.21.1 Preventive Maintenance Function
        8.21.2 Preventive Maintenance Function for the Speed Reducer
            8.21.2.1 Diagnose by the Lifetime Calculation
            8.21.2.2 Diagnose by the Torque Average Value
            8.21.2.3 After Replacement of the Speed Reducer
        8.21.3 Inspection Notice Function
            8.21.3.1 Setting Procedures
            8.21.3.2 The Inspection Notice Window
        8.21.4 Record of Inspection Date and Replacement Date
        8.21.5 Management of the Data
        8.21.6 Preventive Maintenance for the Hardware
            8.21.6.1 Target Components for Diagnosis
            8.21.6.2 Replacement Time Display
            8.21.6.3 Replacement of Component
        8.21.7 Setting of Preventive Maintenance for the Hardware
            8.21.7.1 Setting of Replacement Time Display
            8.21.7.2 Mask of Replacement Time Display (Signal Display)
        8.21.8 Display of the Numbers of Motor Revolution and Reverse Revolution
            8.21.8.1 Display of the Numbers of Revolution and Reverse Revolution
            8.21.8.2 Percent Display of the Number of Motor Revolution
            8.21.8.3 Resetting the Number of Revolution
            8.21.8.4 Changing the Numbers of Revolution and Reverse Revolution
    8.22 Operating Status Monitor Function
    8.23 Job Monitor Function
    8.24 Robot Monitor Function
    8.25 Brake Line Ground Judgment Function
        8.25.1 About the Brake Line Ground Judgment Function
        8.25.2 Operating Condition
        8.25.3 Operation
            8.25.3.1 Occurrence of a DC 24V Power Supply Failure (SERVO)
            8.25.3.2 Brake Line Ground Check
            8.25.3.3 Initializing the Related Information
    8.26 Safety Logic Circuit
        8.26.1 Outline
        8.26.2 Changing the Security Mode
        8.26.3 Available I/O Signals and Instructions in Safety Logic Circuit
            8.26.3.1 Full Speed Mode
            8.26.3.2 Switching Display of System and User Section
        8.26.4 Safety Logic Circuit
        8.26.5 Signal List Window
        8.26.6 Setting ON/OFF to the Input Signals
        8.26.7 Setting for the GP Safety I/O Signals
            8.26.7.1 Preliminary setting for the GP Safety I/O Signal
            8.26.7.2 Setting for the GP Safety Output Signals
        8.26.8 Safety Signal Board Allocation
        8.26.9 Timer Delay
        8.26.10 Timer
        8.26.11 Output Signal
        8.26.12 Display of the Message on the Programming Pendant
        8.26.13 Enable Switch Link Function
            8.26.13.1 Setting of the Enable Switch Link Function
            8.26.13.2 Example of Use of the Enable Switch Link Function
        8.26.14 Specific Input Signals Allocated to SPIN[xx]
        8.26.15 Output to the Control Status Signal
        8.26.16 Saving or Loading the File
            8.26.16.1 Saving the File
            8.26.16.2 Loading the File
        8.26.17 Initializing the Safety Logic Circuit File
            8.26.17.1 Initializing the Safety Logic Circuit File
            8.26.17.2 Safety Circuit Board FLASH ROM Data Erase and Reset
        8.26.18 Example of Safety Logic Circuit
        8.26.19 Alarm List of the Safety Logic Circuit
        8.26.20 General-Purpose Safety Output Monitoring Signal
    8.27 Robot Stop Factor Monitor Function
        8.27.1 Outline
            8.27.1.1 The Robot Stop Factor
            8.27.1.2 The Robot Stop Factor Record Number
        8.27.2 Operation
            8.27.2.1 Displaying the Robot Stop Factor Monitor
            8.27.2.2 Clear the Robot Stop Factor Information
    8.28 Robot Detachment Function
        8.28.1 Setting Maintenance Mode
        8.28.2 Setting Robot Detachment Function
    8.29 Axes Detachment Function
        8.29.1 Outline
        8.29.2 Connecting the Dummy Connector
        8.29.3 Setting Maintenance Mode
        8.29.4 Setting Axes Detachment Function
        8.29.5 Specific Output and Messages
        8.29.6 Restrictions
    8.30 User Group Input and Output
        8.30.1 Outline of the Function
        8.30.2 User Group Input
            8.30.2.1 User Group Input Setting
            8.30.2.2 Display of User Group Input
        8.30.3 User Group Output
            8.30.3.1 User Group Output Setting
            8.30.3.2 Display of User Group Output
    8.31 Variable Allocation
    8.32 Controller Information Display Function
    8.33 Power Supply Regeneration Monitor Function
        8.33.1 Outline
        8.33.2 Power Regeneration Window
        8.33.3 Regeneration Monitor Window
        8.33.4 Reset Time Setting
        8.33.5 Resetting the Amount of Regenerated Power for Today
    8.34 Step Diagnosis Function
9 System Backup
    9.1 System Backup with YRC1000
        9.1.1 Function Types of Data
            9.1.1.1 CMOS.BIN
            9.1.1.2 CMOSBK.BIN
        9.1.2 Device
    9.2 Backup by CMOS.BIN
        9.2.1 CMOS.BIN Save
        9.2.2 CMOS.BIN Load
    9.3 Automatic Backup Function
        9.3.1 Automatic Backup Function
            9.3.1.1 Objective
            9.3.1.2 Outline
        9.3.2 Settings for Automatic Backup
            9.3.2.1 The SD Card of the Programming Pendant
            9.3.2.2 The SD Card of the ACP01 Board
            9.3.2.3 RAMDISK on the ACP01 Board
            9.3.2.4 YRC1000 Status and Automatic Backup
            9.3.2.5 Setting Examples
            9.3.2.6 AUTO BACKUP FUNCTION SET Window
        9.3.3 Limiting the Automatic Backup File Creation
            9.3.3.1 Setting to Limit the Automatic Backup File Creation
    9.4 Loading the Backup Data from the SD Card
        9.4.1 Loading Procedure
    9.5 Error List
        9.5.1 Error Contents
10 Upgrade Function
    10.1 Functional Overview
    10.2 Upgrade Procedure
        10.2.1 Confirmation of Software Version
        10.2.2 Automatic Upgrade of the Programming Pendant
    10.3 Error Message
11 Programming Pendant
    11.1 Disconnection Function
    11.2 Reset Function
    11.3 Touch Panel Invalidate Function
    11.4 Reboot Robot System
12 Modification of System Configuration
    12.1 Addition of I/O Modules
    12.2 Allocating External I/O Signal
    12.3 Addition of Base and Station Axes
        12.3.1 Base Axis Setting
            12.3.1.1 Selection of Base Axis Type
            12.3.1.2 Connection Setting
            12.3.1.3 Axis Configuration Setting
            12.3.1.4 Mechanical Specification Setting
            12.3.1.5 Motor Specification Setting
        12.3.2 Station Axis Setting
            12.3.2.1 Selection of Station Axis Type
            12.3.2.2 Connection Setting
            12.3.2.3 Axis Configuration Setting
            12.3.2.4 Mechanical Specification Setting
            12.3.2.5 Motor Specification Setting
13 YRC1000 Specification
    13.1 Specification List
    13.2 Function List
    13.3 Programming Pendant
    13.4 Equipment Configuration
        13.4.1 Arrangement of Units and Circuit Boards
        13.4.2 Cooling System of the Controller Interior
14 Description of Units and Circuit Boards
    14.2 Control Power Supply Unit (CSRA-CPS01Ko)
    14.1 Power Supply Contactor Unit (JZRCR-APU0□-1)
        14.3.1 CPU Unit Configuration
    14.3 CPU Unit (JZNC-ARK5□-□E)
        14.3.2 Unit and Circuit Board in the CPU Unit
            14.3.2.1 CPU Board (JANCD-ACP01-E)
            14.3.2.2 Robot I/F Circuit Board (JANCD-AIF01-☐E)
        14.4.1 Converter (Small-Capacity Model)
    14.4 Converter (CSRA-CV□□□0□A)
        14.4.2 Converter (Medium/Large-Capacity Model)
        14.5.1 Inverter Unit Configuration
    14.5 Inverter Unit (CSRA-SDA□□H01A)
        14.5.2 Inverter
        14.5.3 Servo Control Board (CSRA-SDCA01AA)
    14.6 Safety Circuit Board (JANCD-ASF01-E)
        14.6.1 Safety Circuit Board (JANCD-ASF01-E)
        14.6.2 Connection for Tool Shock Sensor
            14.6.2.1 To Connect the Tool Shock Sensor with the Cable That is Built into the Manipulator
    14.7 Safety Terminal Block Board (IM-YE250/5-80P)
        14.7.1 Safety Plug
        14.7.2 External Emergency Stop
        14.7.3 SYSRUN Signal Output
        14.7.4 Connection for Servo-ON Enable Input
        14.7.5 External Axes Overrun
        14.7.6 Emergency Stop Output
        14.7.7 General-Purpose Safety Input
        14.7.8 General-Purpose Safety Output
        14.7.9 Connection for Direct-In
        14.7.10 General-Purpose Input (Servo)
    14.8 General-Purpose I/O Board (JANCD-AIO0□-E)
    14.9 WAGO Connector Wiring
    14.10 Robot General-Purpose I/O Signal Assignment
        14.10.1 Arc Welding
        14.10.2 Material Handling
        14.10.3 Press Tending, Cutting, and Other Applications
        14.10.4 Spot Welding
    14.11 The List of the Equipment Configuration