MRC K60 Service Manual

YASNAC MRC
Service manual, YASNAC MRC
MOTOMAN ROBOTICS AB
a subsidiary of YASKAWA Electric Corporation
MOTOMAN
ROBOTICS
Service manual MRC
AB Page: 1
1. About this manual .................................. 1

2. Configuration ......................................... 2
3. Installation ............................................. 2
Identification 2
General 3
Handling 3
Space required 5
Cable bundle 5
Connection 6
External cable bundle 9
Mounting; welding torch 10
Other safety 10
I/O-rack 10
4. Before first operation ........................... 12
Checkpoints 13
5. Description ........................................... 14
Technical specifications 14
Cabinet layout 15
Close units 15
Power supply 16
Safety equipment 16
MEU01-module 17
Speed control 18
Power supply 18
Teachbox 19
MRC panel 20
6. Service ................................................. 23
General 23
Board replacement 24
CPU-rack 25
Battery replacement 27
7. Spare parts .......................................... 29
Servopack 29
Servo motors 30
Recommended spare parts 31
Ordering spare parts 31
8. Trouble shooting .................................. 32
Alarm history 32
Alarmcodes - classing 34
Reset - robot overload 36
Reset - MRC overload 37
Reset MACHINE LOCK 37
Reset - software 38
Collision measure 39
Skapad: 98-09-02 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrcIH.fm

MOTOMAN
ROBOTICS
Service manual MRC
AB About this manual Page: 1
Service manual YASNAC MRC

Extract from; Installation and Maintenance Manuals.
Machine sign
Fig.1 YASNAC MRC
1. About this manual

Yaskawa’s electrical industrial robot system compromises an industrial
robot MOTOMAN SK- , SP- and SV-series, and a control unit YASNAC
MRC.
The workstation can be completed with external axes, grippers, fixtures,
and with other machines, safety guardings, etc.
This manual compromises:

-Technical specifications about YASNAC MRC.
-Installation information.
-Service information.
For robot instructions, see separate service manual for MOTOMAN

SK- , SP- and SV-series
Operator’s manual / Programming manual for robot, MRC, positioners
and welding equipment, etc., see separate document.
This english service manual is an extract from the Maintenance Manual,
see this manual for more close information and electrical drawings, etc.
Alarmlist, see separate document.
Skapad: 95-05-17 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrc.fm

Service manual MRC MOTOMAN
ROBOTICS
Page: 2 Configuration AB
This service manual may not be copied without our written permission
and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpuse.
Text written in BOLD letters means command or button.

Text written in ITALIC letters means text shown on display.
2. Configuration
-YASNAC MRC is based on modules. All repearments are made by
replacing the broken unit / module.
-CPU-software enclose different test- and maintenance programs.
-32-bits processor with the possibility to control two robots.
-Max. 21 controlled axes simultaneously.
-YASNAC MRC control system means high capacity, high reliability and
self diagnosting trouble shooting.
3. Installation
3.1 Identification
A label is placed on the lower part of theYASNAC MRC front door. This
label is a identification for the YASNAC MRC. Always specify the serial
number while ordering spare parts, etc.
MOTOMAN
ROBOTICS
YASNAC MRC
TYPE ERCS -
SYSTEM NO:
POWER SUPPLY PEAK KVA
AVERAGE KVA
SERIAL NO.
Fig.2 Machine sign
PART NO.
DATE /SIGNATURE
MADE IN SWEDEN

MOTOMAN
ROBOTICS
Service manual MRC
AB Installation Page: 3
3.2 General
a) Check that delivery correspond the components, written in the
order and the delivery note.
b) When installing more than one robot, check the serial numbers
and make sure that MRC and robot belong to each other!
c) Mount a safety guarding around the machine, according to safety
regulations.
d) Design jigs, fixtures and other equipments so that the robot don’t
get interfered.
e) Conect to earth the robot and the YASNAC MRC-cabinet (here
after MRC-cabinet), before operation.
f) Don’t let the robot or MRC be subjected to electrical noise or radio
frequency interference, from, for instance a TIG-welding applica-
tion or a radio transmitter. Contact MOTOMAN service.
g) If welding equipment will be mounted on the machine, it’s very
important that a separate earth connection will be connected to the
welding equipment.
h) Check carefully every safety function, before operation.
3.3 Handling
a) Before lifting robot or MRC-cabinet, check that there are enough
space for the equipment and personnel, so handling can be done
without danger. Warn personnel who works next to the location
where the equipment will be mounted.
b) Robot and MRC are accuracy euipment:
- Don’t use tools to pry or strike the equipment!
- Don’t sit or climb on the equipment!
c) When equipment is hoisted:
-Don’t affect the equipment, by hand!
-Don’t move the eqipment over another person!
-Don’t let any person walk under hanging load.
d) Follow lifting instructions. Check the weight of the eqipment and be
sure that the hoist stand the weight. Use eyebolts for lifting.
e) Check that the chipping bolts (yellow) are carefully mounted. For
lifting instructions, see separate service manuals.
f) Lifting the MRC-cabinet, check that the frontdoor is closed and that
the eyebolts are carefully mounted.
g) Robot weight without MRC-cabinet. (next page).

ROBOTICS
Page: 4 Installation AB
Model Robot weight Eye bolts
S604, S604-30 1100 kg M20 x 4
S604W, S604-30 1250 kg M20 x 4

K3 53 kg M8 x 2
K6 180 kg M16 x 2
K10 300 kg M16 x 2

K30 580 kg M20 x 2
K100, K100-120, K100-150, 1600 kg M24 x 4

K100C
K205 700 kg M30 x 4
K60 980 kg M20 x 4
NY serien 2700 - 2950 kg M30 x 4
SK6 145 kg M10 x 2
SK16 280 kg M12 x 2
SK16M 580 kg M20 x 2
SK120, SK120-150 1550 kg M24 x 2
SP100 1750 M24x4
SP160 1900 M24x4
SV3 30 M8x2
SV035 55 M8x2
SK45 600 M20x2
MRC K-, SK- och SP-Serie 190 kg M16 x 2

MRC NY-Serie 250 kg M16 x 2

MOTOMAN
ROBOTICS
Service manual MRC
3.4 Space required

a) Install the robot inside a safety guarding, according to safety regu-
lations. Mount the guarding, so that the robotarm can’t reach the
fencing walls, with the arm in full extended position, (incl. tools
mounted).
b) Install the MRC-cabinet outside the safety guarding!
c) Install the MRC, so that robot movement can be supervised from
the MRC operator’s panel.
d) Leave enough space around the MRC so that service can be car-
ried out without problem. (min. 500 mm to nearest wall).
e) If the robot are used for welding application, mount the MRC, so
that welding spatter, don’t reach the MRC.
f) The floor where the MRC is mounted must be rigid enough and be
levelled, so that the MRC don’t get exsposed to mechanical fen-
sions.
g) Mount the MRC to the floor by using the tapped holes, at the MRC
lower part. (attachments are made by customer).
h) The floor where the robot is mounted must be able to counteract
acceleration- and retardation forces. See separate instruction in
the robot service manual.
i) At ceilingmounted robot, more sequrity units need to be installed.
For instance support brackets. (if any bolt, etc. snaps).
3.5 Cable bundle

The cables between robot and MRC are included in low voltage cir-
cuits. Avoid to mount these cables next to high voltage cables. If this
is impossible, the cables should cross each other in face angles. If
this neither is possible the parallell length shall be as short as possi-
ble.
Don’t mount any cables under the welding equipment.
Length between signal cables and remaining cables.

Cables with >600 VAC and >50A min. 1 m
Cables with <600 VAC och >10A min. 0,6 m
Other cables min. 0,2 m

ROBOTICS
3.6 Connection
Connect robot, welding equipment, safety units, etc. according to elctri-
cal drawings. Follow the drawings carefully. Incorrect connection can
damage electrical equipment.
For safety reasons, check that the cable bundles are safetly protected
while installing, this to avoid harm or injuries on personnel or equipment.
Protect cables from affection by tools, sharp edges, etc.
Connect large power consumers (rectifiers, transformers, etc.) on sepa-
rate fuse.
Power feeding to the MRC shall be connected in the upper part of the
cabinet.
Use cable discharge and gaiter to prevent dust in the MRC-cabinet.
Connect the transformer to power source so that incomming cur-

rent to the MRC is 200-220 VAC (3-phase)
The MRC is equipped with components to avoid interference, (fullfills the

EMC-directives), These components must not be removed.
Don’t connect components which not fullfills the Low voltage directive
(73/23/EEC).
On some MRC-systems, the interference filter are mounted under a
hood, outside the cabinet.
Note!
Incomming power are connected directly on the interference filter.
While switching OFF the power, the filter will still be connected!
Turn OFF the power sourch while working on main switch or inter-
ference filter!
Incomming cables
Fig.3 Main switch

MOTOMAN
ROBOTICS
Service manual MRC
3.6.A Earth connection

Make carefully earth installation, follow steps below:
MRC-cabinet, min 10 mm² earth cable shall be connected to the cab-
inet. The resistance shall not exceed 100 ohm.
Robot, min 6 mm² earth cable. Connect directly to the robot earth
screw, on the foot or base frame. The robot earth connection shall not
be used for welding equipments or options.
Positioner, connect the negative pole from the power source to the
positioner, as close as possible to the fixtures. This to avoid injuries
on bearings.
Option, Connect safety guardings, cable stages, etc. according to
current rules, to protective earth.
3.6.B Power consumption

Values below are only valid for singel robot. If servopack for external
axes, are feeded from the same transformer, the values will be differ-
ent.
Area
Type Effect Transformer 400V Fuse
Transformer
S604 21 kVA 30 kVA 6,0 mm² 43,3 A 50 A
S604-30 19 kVA 20 kVA 6,0 mm² 28,9 A 35 A

S604W
S604W-30
K3 2,5 kVA 5,7 kVA 2,5 mm² 8,2 A 16 A
K6 3,5 kVA 5,7 kVA 2,5 mm² 8,2 A 16 A
K10 8 kVA 10 kVA 2,5 mm² 14,5 A 16 A
K30 18 kVA 20 kVA 6,0 mm² 28,9 A 35 A
K60 23 kVA 30 kVA 10,0 mm² 43,4 A 50 A
K100 23 kVA 30 kVA 10,0 mm² 43,4 A 50 A
K205 23 kVA 30 kVA 6,0 mm² 28,9 A 35 A
NY-serien 32 kVA 40 kVA 16,0 mm² 55,7 A 63 A
SK6 3,5 kVA 5,7 kVA 2,5 mm² 8,2 A 16 A
SK16 6 kVA 7,5 kVA 2,5 mm² 10,8 A 16 A
SK16 M 6 kVA 7,5 kVA 2,5 mm² 10,8 A 16 A
SK120 23 kVA 30 kVA 10,0 mm² 43,4 A 50 A
SK45 18 kVA 20 kVA 6,0 mm² 28,9 A 35 A
SV035 3,5 kVA 5,7 kVA 2,5 mm² 8,2 A 16 A

SP100 11 kVA 15 kVA 6,0 mm² 22 A 25 A

ROBOTICS
3.6.C Connect equipment

a) Connect primary power supply, by releasing the cover over the poles
at the upper side of the filter. (Use a small screw driver). Pull the
cover straight out. Connect to the terminals L1, L2, L3 and PE (Pro-
tection Earth). Remount the cover.
b) Take the delivered robot cables and pull these through the cable-port
at the lower part of the cabinet. Tighten the cables using the cable fit-
ting
c) Connect the AC for servomotors by fixing the multi connector at the
lower part of the cabinet.
See electrical drawing no. 341958-xx (Valid for K3 up to SK16)
See electrical drawing no. 341976-xx (Valid for K30 and larger)
Servo connector (valid up to SK16)

Servo connector (valid for K30 and larger)
Fig.4 Servo connection in the MRC-cabinet
d) Mount connector 1SV (servopack; S-, L- and U-axes). Connect 2SV

(servopack; R-, B- and T-axes). The connectors are placed on the
servopack (board) in the upper part of the cabinet:
See electrical drawing no. 341957-xx (valid for up to SK16)
See electrical drawing no. 341975-xx (valid for K30 and bigger)
Robot cable
Fig.5 Servopack, fic-

ture shows MRC up to
robot SK16

MOTOMAN
ROBOTICS
Service manual MRC
e) After connection, check that all fittings are carefully tightened.

f) Connect internal signal cable MTU-CN6.
g) Connect signal cable BAT-1, at the right of the absolute encoder.
h) When equipment will be used for welding, connect cable bundle to
welding system board (JANCD-MEW02).
i) Connect cables to I/O-board. (JANCD-MIO04).
j) Connect cable to Programming Pendant, (here after called Teach-
box).
k) Connect cable to robot. Note location of the plug. Tighten the nuts
carefully.
l) Installation is complete.
BC1
Customer application
BC2
Air connection (customer)
Fig.6 Robot connector
3.7 External cable bundle

To maintain our EMC-guidlines, all cables, connected to the MRC,
shall be carried out as below. A shielded cable with 360° connection
against chassi, is valid.
Conductive seal Shield
Fig.7 Signal cable

connection

ROBOTICS
3.8 Mounting; welding torch

a) Insulate carefully between welding torch and torch holder. Do not expose
the robot to current from the power source plus pole.
b) The robot axes R, B and T shall be in home position, before mounting the
torch holder.
c) Mount the torch holder at the robot flange.
Don’t pull the screws to much, this can move the robot from home position.
Don’t use robot axes end position as a counter stop, the cables, gears, etc.
may be damaged.
d) The distance between B-axis center, and the TCP on the welding torch,
shall be as short as possible to keep highest accurancy. The distance
should not be over 435 mm.
3.9 Other safety

The MRC-cabinet is equiped with a safety module, to fullfill the European
safety demands (MEU01).
Connection of outher safety, like door switches, lightbeams, etc. are described
in a separate manual; Connection Guidelines, MEU01.
The safety module shall be tested continously, as described in separate man-

ual.
3.10 I/O-rack
The I/O-rack contain communication boards for robot;
-Communication for external control, MIO02-MIO03
-Communication for current sorch for welding, MEW02
-Communication with Fieldbus interface, MFB01
Fuse for external

power unit I/O-rack
JANCD-MBB02
Extra I/O-kort
MRY01
MIO03 MEW02
MIO02
Fig.8 I/O-rack

MOTOMAN
ROBOTICS
Service manual MRC
3.10.A External I/O connection

General there are two communication boards on the I/O-rack.
Connection to I/O-board is described in a separate manual.
Electrical drawings.
341000-90 (General application)
341000-91 (Welding applikation)
MIO02
32 inputs, 24 VDC max. 5 mA / 32 outputs, 24 VDC max. 50 mA.
(Power feed at some plugs; +24 VDC).
MIO03
16 inputs, 24 VDC max. 5mA / 16 outputs, 24 VDC max. 500 mA. The
board is connected to a connection terminal, mounted to the left,
inside the cabinet.
(Power feed at some plugs; +24 VDC).
3.10.B Fieldbus connection

As option, a fieldbus, can be installed in the I/O unit. To use for con-
trolling external fixtures, tracks and for PLC communication, etc.
On the fieldbus board different modules can be mounted, according to
different distributors. For instance:
-Profibus-DP
-Interbus-S
-DeviceNet
32-bits and 64-bits boards are also valible.
Connection to Fieldbus board is described in a separate manual.
3.10.C Welding interface

As option, a welding interface (MEW02) can be installed in the I/O-
unit.
At the welding interface board, two analogous outputs can be con-
nected to control wire feeding, etc.
The MEW02-board can be used for other applications, where analo-
gous signals are used.

ROBOTICS
Page: 12 Before first operation AB
4. Before first operation

Before first operation, the safety guarding, safety doors, lightbeams and
emergancy stops, has to be connected.
Personnel has to be instructed to keep out of safety guarding and out of
reach from moving units, while the machine is in operation.
Check the safety functions, emergancy stops, etc. Ignoring these tests
may lead to sever personnel injuries or death, together with exspensive
damage to the machine.
Radio Frequency Interference (RFI) and Electromagnetic Interference

(EMI) may cause unexpected movements, by robot or positioner.
At any suspicion to RFI or EMI, contact a test labratory or a consultant.
Avoid to have transmitters (mobile phones, etc.) near the MRC-cabinet.
At first operation, be observant for vibrations and unusual noise from the
equipment. If this appear, press EMERGANCY STOP and contact
MOTOMAN Service.

MOTOMAN
ROBOTICS
Service manual MRC
AB Before first operation Page: 13
4.1 Checkpoints
If operation seams defect, check electrical drawings or contact
MOTOMAN service.
Function Check that...
Press all the Emergancy Stops all movements stops immediately.
Reset all the Emergancy Stops playback operation do not continue automaticly.
Servo power supply has to be switched ON.
Open the service gate all movements, in the area, stops immediately.
Close the service gate the machine do not continue automatically.
Pass the light beam all movements, in the area, discontinue immediately.
Pass the light beam the positioner (option) is unloaded. (Servomotors do
not work). Power to the servomotors is cut OFF.
Pass the light beam the positioner (option) is locked. (Servomotors pre-
vent movement by own-weight, etc)
Reset the light beam the machine restarts by command.
Reset the light beam the machine do not continue automaticly.
Lift the teachbox (Programming all movements, in the area, stops immediately.
Pendant)
Dead-Man’s-Switch all movements stops if switch get released or pulled in

full position.
Dead-Man’s-Switch movement do not continue when switch get pulled in

right position.
Running from teachbox. robot speed has been decreased (safety speed)
External stop signals (wire feed affected components are stopped and that prospec-
error, lost of air supply, etc.) tive alarm is given.
Safety module Safety module trips while testing, according to the test
job. Function must be tested twice a year.

ROBOTICS
Page: 14 Description AB
5. Description
5.1 Technical specifications
Subject Values, data..
Control system Dimensions: 900(B) x 1600(H) x 650(D)

(MRC-cabinet)
Colour RAL 7032
Cooling Indirect cooling

Ambient 0°C up to +45°C (at operation)
temprature -10°C up to +60°C (storage)
Humidity of air 20% up to 80% non condensing (robot)

10% up to 90% non condensing (controller)
Air pollutions Minimize occurens of soot, dust, water.

Keep free from explosive and corrosive gases and liquids.
Outher influence Max. 0,5G (standard)

(vibrations)
Power, MRC 3x 400/415/440 VAC (-15 / +10%) 50 / 60 ±2 Hz
Earth connection Max 100 ohm
Positioning Absolute system (Absolute encoder)
Drive units Servopack for AC motors
Acc control Software (Servo controlled)
Programming 2200 steps and 1200 instructions

capacity
Panel Push buttons for MODE, CYCLE, START, HOLD, EMERGENCY

STOP and overload reset.
RS 232 connection, 100 VAC socket for floppy disk driver.
Teachbox Dimensions 211(B) x 382(H) x 71(D)

Display 40 signs x 12 rows, figures, symbols, latin alphabet and special signs.
Multi language Swedish, English, French, Italian, Spanish, Finnish and German.
Safety switch 3 level, “dead-man’s-switch”

(JOKAB SAFETY, JSHD2B)
Safety module Two channels system in the whole module

MOTOMAN
ROBOTICS
Service manual MRC
AB Description Page: 15
5.2 Cabinet layout

YASNAC MRC-cabinet exists in three different sizes:
-Low power cabinet (for robot up to -SK16)
-High power cabinet (for robot larger than -SK16)
-For robot serie -NY
Servopacks for
Power supply Servopack external axes
3 + 3 axes
Main Switch Doorpanel
Electrical noise filter
CPU
I/O-unit
MEU01-unit
(European
Safety guide lines) Fig.9 Cabinet layout up to robot SK16
5.3 Close units

5.3.A Board-panels
Door mounted
Operator’s panel JZNC-MPB02E
Inside
I/O rack JZNC-MRK09
Power supply relay board JANCD-MRY0B-3
I/O bord JANCD-MIO02
JANCD-MIO03
Welding board JANCD-MEW02
Fieldbus board JANCD-MFB01

ROBOTICS
CPU rack JZNC-MRK04 (K-serie)

JZNC-MRK11 (NY-serie)
System control board JANCD-MCP01, -MMM02-2
CIO board (concurrent I/O board) JANCD-MIF01
Motion control board JANCD-MCP02, -MMM04
Servo control board JANCD-MSV01, -MSV02, -MFC04
Ethernet board JANCD-MIF06
Servopack
Inside the cabinet there are room for 6 robot axes, and 3 further external
axes:
2 board slots, width 75 mm, effect up to 3,0 kW.
1 board slot, width 90 mm, effect up to 4,4 kW.
Further servopacks are mounted in an external cabinet.
NOTE!
The total effect consumption for these slots, shall not be over 4,5 kW.
5.3.B Cooler
Air is sucked in to the lower part of the cabinet. A fan in the upper part,
provide the servo control with cool air. Further a fan circulates the air
inside the cabinet.
5.4 Power supply

If power source frequence will fall with many Hz, even temporary, the
servo power will be shot down. Use therefor a power supply, free from
interfernece.
If electrical noise appear in the power supply, applicate a three face
interference filter.
We recommend that a earth fault circuit breaker is connected to the
power source.
5.5 Safety equipment

The power to the servopacks lead with 2 connectors, mounted in the
contactor unit. Each contactor, manouver voltage 24 VDC, are handled
undepending with different check circuits.

MOTOMAN
ROBOTICS
Service manual MRC
Factors which affect close the servo power supply:

1. Teachbox Emergancy Stop
2. MRC Panel Emergancy Stop
3. External Emergancy Stop
4. Robot axis movement overtravel
5. External axis movement overtravel
6. Break fuse blow
7. Fault in 24 V power supply
8. Chock sensor working
9. Safety speed over
10. System error
11. MEU Safety conditions not affected
These factors are supervised in the control unit and starts the process
which turn OFF the servo power supply.
-Factor 1 to 8. Turns OFF the servo power supply, by hardware logic,
at the MRY01-boards, in the I/O-rack.
Factor 1 to 5 and 9 are sent to the MEU01-module by the SIF.-mod-
ule, togheter with signals from the control unit.
Signals are render together with signals from dead-man’s-switch,
safety switches and other incomming signals. The result are sent to
factor 11.
-When safety demands, in MEU01, don’t get fullfilled, the contactors
for the servo power will be shot down (opened).
Electrical drawings for MEU01; MOTOMAN drawing no. 341902.
See separate drawing.
5.6 MEU01-module
The MEU01-module contain safety equipment. With signals from the
internal control unit and the outher incomming signals, the MEU01-
module manage the servo power, (on- and off-commands).
In the meantime the main contactors are manouvered.
By HSW and outher equipment, the MEU01 will send information to
the control unit, concerning which safety speed, that shall be used.
SP1 (=250mm/s), SP2 (=33mm/s) or 100%. The MEU01 also transmit
a checksignal to the speed module. If overspeed is detected, the
servo power will be shot OFF.
The MEU01-module are mounted at the left, in the lower part of the
MRC-cabinet.

ROBOTICS
5.7 Speed control

The speed for all robot axes, are watched by the MFC04-board, in the CPU-
rack. Control signals from MEU01. MFC04 checks the speed in three different
levels. If speed, at any axis, exceed the control signal, the servo power will be
turned OFF.
The three levels are..

Safety Speed 1 250 mm/s
Safety Speed 2 33 mm/s
Normal Speed 100%
Teachbox External SP1 External SP2 S.P. 1 S.P. 2 level
in position CLOSED CLOSED ON ON Normal (100%)
---- OPEN CLOSED OFF ON 250 mm/s
lifted ---- CLOSED OFF ON 250 mm/s
---- ---- OPEN ---- OFF 33 mm/s
5.8 Power supply

CPS (Control Power Supply Unit)
Side Type Value
Primary Power supply 200/220 VAC
Variation +10% / -15%
Frequence 50/60 Hz ±2 Hz
Secondary Power / current +5 V / 15 A

Power / current +24 V / 4,5 A
LED indication for power supply.
Position Indication LED-colour Cause
Normal Source power ON Green Position ON from AC source

Source power ON Green Position ON at min. 170 VAC
(input)
Abnormal +5V Red Power overload or current

overload in 5 V circuit
+24V Red Power overload or current

overload in 24 V circuit
OHT Red Abnormal high temprature,
inside MRC-cabinet. Thres-
hold value +65°C

MOTOMAN
ROBOTICS
Service manual MRC
LED indication,
according to table
Fig.10 LED indicator

for power supply
5.9 Teachbox
The teachbox is normally placed on the ERC-controller by means of a
safety switch. If the teachbox is lifted from this safety switch the speed of
the robot is lowered to safety speed (33 mm/sek).
The teachbox is equipped with a ”dead-mans-grip” i.e. a safety switch
mounted in the handle which has to be pressed during operation.
The safety switch has three positions:
Released Robot stopped
Easily pressed Robot ok
Hard pressed Robot stopped
If the handle is pressed into the bottom it has to be completely released
before it is possible to restart the robot again.
If the handle has been released and the easily pressed again, servo
power is automatically connected but a new command for motion must be
selected.
Fig.11 Teachbox

ROBOTICS
5.10 MRC panel
Fig.12 MRC panel
Explanation of keys and buttons, for the MRC

E.STOP panel, are described below.
EMERGANCY STOP - Turns OFF the servo power
SERVO POWER
SERVO POWER - Turns ON the servo power.
The key lit while the servo power is ON.
MODE
PLAY TEACH REMOTE MODE - Selects the operation mode
PLAY - Selects play mode, which allows playback

PLAY of a job after teaching.
The key lit while the play-mode is selected.
This key cannot select the play mode while the
teach-lock is applied.
TEACH TEACH - Selects teach mode, which allows axis

operation and editing operations from the teach-
box.
The key lit while the teach mode is selected.
Editing is prohibited while the optional EDIT LOCK
is ON.
REMOTE
REMOTE - Selects remote mode, which enables
operation by external signals inputs.
The key lit while the remote mode is selected.

MOTOMAN
ROBOTICS
Service manual MRC
CYCLE
AUTO 1CYCLE STEP
CYCLE - Selects the operation method of play-
back operation.
AUTO AUTO - The system contiuously and repeatedly

executes the job.
The key lit during operation.
1CYCLE 1CYCLE - The system executes the job once.

The key lit during one-cycle operation.
STEP
STEP - The system executes one instruction of
the job, at a time.
The key lit during step operation.
ALARM/ERROR ALARM/ERROR - This lamp lit to indicate that

an alarm or error has occured.
To reset, press CANCEL on the teachbox.
START
START - Starts the system playback operation.
The key lit during playback operation.
HOLD HOLD- Temporary stops the system playback

operation.
The key lit while playback operation is stopped.
Key operations for buttons placed under MRC panel cover.

OVERRUN RECOVERY
OVERRUN RECOVERY - The overrun status is
temporarily cancelled while this button is held
down.
Power outlet for floppy disk driver (FC1 / FC2)

100 VAC 0,5 A.

ROBOTICS
Serial connection for an external recorder, printer

or personal computer. RS-232 (D-SUB). Running
i.e. ROBCOM.
POWER
POWER - key lock switch - Turns ON / OFF the
ON main power remote from the controller.
This switch is an option.

OFF
EDIT LOCK
ON EDIT LOCK - Key-lock switch. In the ON-position
this switch disables editing from the teachbox or
operator’s panel.
OFF This switch is an option.

MOTOMAN
ROBOTICS
Service manual MRC
AB Service Page: 23
6. Service
6.1 General
At service, switch OFF the power supply on every machine; robot,
power source, positioner, etc.
Note!
Incomming power supply is connected directly to the interfer-
ence filter.
When power is turned off, the filter is still connected! At mainte-
nance on the power supply, main switch or filter, the incomming
power must be turned off.
Lock circuit switch while working on electrical units!
Inform surroundings that service operation is going on!
Fig.13 Main switch
Before service, decide if error can be measured by own staff or if

MOTOMAN service must be called.
Service shall be carried out by personnel, educated by Motoman
Robotics AB.
The key to the MRC-cabinet shall be kept by service personnel.
Check cable bundles continously, replace if nessesary.
Use only MOTOMAN spare parts.
6.1.A Service authority

Authority for different measures are devided in to different categories.
General:
No code is needed (normal teaching, running mode, etc.)
Local service:
Lowest safety level. The service code is as default [00000000] (eight
zeros).

ROBOTICS
Page: 24 Service AB
Maintenance mode (Customer mode)

At this mode you’re able to change some parameters and the system
setup.
MOTOMAN-service
By another maintenance code, you’re able to change system parame-
ters inside system mode.
6.1.B Open cabinet door

a) Put in the special key in to the locker, turn 135° clockwise.
b) Turn mainswitch to position OPEN RESET, open the door carefully,
NOTE! Sharp edges around the hole at the main switch.
6.1.C Close cabinet door

a) Put in the special key, check that the catches, inside the cabinet, are
pulled.
b) Close the door carefully, NOTE! Sharp edges around the hole at the
main switch.
c) Turn the key 135° counter clockwise. Take out the key.
6.2 Board replacement

While replacing a current board, make sure the power is disconnected.
Use earth bracelet to carry off static electricity from your body,
before boards are removed from their safe position.
Untighten the board:

a) Pull out the upper and lower lever so that the board gets released
from the inner connectors.
b) Loose all outher cable connectors.
c) Take out the board.
d) Check that the new board is of same type.
e) Steer carefully the new board into the track. Use the levers to press
the board into the back board terminals
f) Remount if nessesary outher cable bundles on the board.
Don’t drop the board on the floor. Don’t try to repair damaged boards.
After service, check that all cables has been remounted and that all
boards are in thier position. Check that no tools are forgotten inside the
cabinet. After replacing a MIF01-board, memory board, it is nessesary to
perform a home position calibration, see paragraph;
8.7 Collision measure.

MOTOMAN
ROBOTICS
Service manual MRC
AB Service Page: 25
6.3 CPU-rack
Display
200VAC Input
Standard port #1
(CN1) Alarm display
Serial
communication. Power supply
+5V / + 24V output

Battery connector
External encoder
MSV01-2
MCP02-1
Robot encoder Fig.14 CPU-rack for
Free slots MRC (not valid for -NY
MCP01-1 MIF01 serie)
6.3.A JANCD-MCP01-1
This board control; system data, text on teachbox display and func-
tions for manouver buttons.
In the upper part of the board, a digital display is mounted. It displays
a digit. At normal operation the “digital-figure” (SYSCON) is switched
off.
At damage on hardware resp. software, error codes (NMI) are shown
on this display, according to table on the next page.
Display views one digit or a serie containing four digits, which are
updated contiously.

ROBOTICS
Page: 26 Service AB
This board contains also the program memory (PROM) and interface to
RS-232C serial connection. One futher system board can be mounted in
the CPU-rack (-MIF02).
Display NMI-code
All segment, fully MCP01 / SROMS error
lit
All segment twink- Error in any or wrong mounted CPU-rack
les
1 to F Communicaton problems between MCP01 and PP
0000 Hardware error, NMI can not be shown.
0900 Watchdog timer error (A-bus) MCP02
0902 Watchdog timer error (A-bus) MSL#1
0903 Watchdog timer error (A-bus) MSL#2
0906 Watchdog timer error (A-bus) MCP01
0907 Watchdog timer error (A-bus) MIF01
0910 Watchdog timer error (D-bus) MSV#1
0920 Watchdog timer error (S-bus) MIF02
0930 Access error (A-bus) MCP02
0932 Access error (A-bus) MSL#1
0933 Access error (A-bus) MSL#2
0936 Access error (A-bus) MCP01
0937 Access error (A-bus) MIF01
0940 A-bus error MCP02
0942 A-bus error MSL#1
0943 A-bus error MSL#2
0946 A-bus error MCP01
0947 A-bus error MIF01

MOTOMAN
ROBOTICS
Service manual MRC
AB Service Page: 27
6.3.B JANCD-MIF01
CIO-board contains I/O-control, CMOS memory and I/O communica-
tion (LSI). On the board, parameters and adjusted data are stored.
The board also handles the communication between the I/O-unit and
MRC-panel.
Further the memory can be connected by an extra board (MMM01).
6.3.C JANCD-MCP02-1
Movement control. This board calculate interpolation and works like a
interface to the contol board. Program memory (PROM) are mounted
on this board.
6.3.D JANCD-MSV01-2
Servo control board. This board controls the 6 servo motors on the
robot arm.
6.3.E JANCD-MIF06
Ethernet board. This board is within for TCP/IP communication with
one, or more, personal computers (PC), over a data network.
PC-softwares are valid for, for instance, automatically backup.
6.4 Battery replacement

Replacement shall be made before 48 hours after “low battery power-
alarm” has occured. The alarm gets on the teachbox and via a LED
mounted on the CPU-rack JZNC-MRK04 (JZNC-MRK11 for NY-
serie).
The upper battery is valid for system backup.
The lower battery is valid for absolute encoder.
Pin
System battery
LED
Pin
Absolute encoder
battery
Cover
Fig.15 Battery replacement

ROBOTICS
Page: 28 Service AB
6.4.A MRC for K- , SK-, SV- and SP-series

a) Pull the upper and lower pins toward you. Take away the cover.
b) Pull out the board.
c) Loosen the battery connector and take away the battery.
d) Mount the new battery and connect it.
e) Remount the cover and push in the pins.
Note!
The ICRAM and the absolute encoder are protected by a battery
backup. Mount the battery as soon as possible, after the alarm.
Waiting more than 48 hours, means risk for memory lost.
6.4.B MRC for NY-serie

Battery can be replaced in either ON or OFF position. A battery backup
keep the memory, a certain time, if the battery are replaced in OFF posi-
tion.
Battery has to be loaded 30 minutes before operation. Se separate
instruction.
a) Take off the covers for the JANCD-MFC05 and -06 boards. Dismount
the CNSUBAT-connector.
b) Take off the CNBAT-connector on the JANCD-MFC05 and -06
boards.
c) Dismount the battery (ER6V-36) from the holder and replace with a
new. (RE6V-3C)
d) Connect the CNBAT-connector on the JANCD-MFC05 and -06
boards.
e) Mount the covers over the JANCD-MFC05 and -06 boards.
6.4.C Battery backup

Loading battery backup is carried out by turning the MRC ON for at least
30 minutes.
It´s necessary to fullfill the replacement of battery (ER6V-3C) within 16
hours from the time when the battery was lost, according to backup cur-
rent capacity.
Replacement of JANCD-MFC06 shall be fullfilled within 48 hours,
according to backup current capacity.
Generally the replacement shall be made as soon as possible.

MOTOMAN
ROBOTICS
Service manual MRC
AB Spare parts Page: 29
7. Spare parts
7.1 Servopack
Robot Power unit S L U R B T
K3-C000 JZNC-MTU15-1 IR030303F IRA5A5A5F
K6-C000 JZNC-MTU15-1 IR050505F IR010101F
SV035-C000 JZNC-MTU15-1 IR050505F IR010101F
SK6-C000 JZNC-MTU15-1 IR050505F IR010101F
K10-C000 JZNC-MTU15-1 IR151515F IR020202F
SK16-serie JZNC-MTU15-1 IR101010F IR020202F
K30-C000 JZNC-MTU15-2 IR30SF IR30SF IR30SF IR101010F
SK16M-C000 JZNC-MTU15-2 IR30SF IR30SF IR30SF IR020202F
SK45-serie JZNC-MTU15-2 IR30SF IR30SF IR30SF IR101010F
SK120-C000 JZNC-MTU15-3 IR44SF IR44SF IR44SF IR151515F
- - IR44
SP100-serie JZNC-MTU15-2 IR44SF IR44SF IR44SF
SF
IR30 IR30 IR30
NY-Serie JZNC-MTU15-3 IR44SF IR44SF IR44SF
SF SF SF

ROBOTICS
Page: 30 Spare parts AB
7.2 Servo motors

Identification, for instance: USADED-40YRW11
Designation Category Variants
US AC Servo motor
AS = S-serie
AR = R-serie
AD Serie
AD = D-serie
AP = P-serie
E = Total capsulated, selfcooling.
E Capsuling K = Total capsulated, external coo-
ling fan.
D = Ferrite rotor
D Magnet type
M = Ferrite alloy rotor
40 Out effect
YR Adapt to robot
W = 12 bits
W Absolute encoder
S = 15 bits
11 Version number
Identification, for instance: SGMP-15AWA-YR11

Designation Category Variants
SGM AC Servo motor Sigma serie
G-serie (450 - 11.000 W)
P Serie D-serie (2200 - 4000 W)
P-serie (100 - 1500 W)
15 Out effect
A=200V
A Power
B=100V
W = 12 bits
W Absolut encoder
S = 15 bits
A Connection A=Flange, standard
YR Adapt to robot
11 Version number

MOTOMAN
ROBOTICS
Service manual MRC
AB Spare parts Page: 31
7.3 Recommended spare parts

Type Dim. quantity Model Place
Fuse 5A 6 x 30 6 st GDL-5A, 250V JANCD-MIU01
Fuse 1A 6 x 30 3 st GDL-1A, 250V Power on unit

MTU-XX
Fuse 3A 6 x 30 2 st GDL-3A, 250V MIU-XX

Fuse 3A 6 x 30 3 st SMI101-3A, 250V JANCD-MBB02
Alarm fuse3,2A 32x11x20 6 GP32 JANCD-MIU01

3,2A, 250V
Relay DC24A 36x28x21 1 LY2, DC24V JANCD-MIU01

Connector plug 1 FCN-367-J040-AU/F MIO04, 03
Connector plug 1 MR50F connector MIO02

(Honda) MR50L cover
7.4 Ordering spare parts
Address: MOTOMAN ROBOTICS AB

Box 504
385 25 TORSÅS
Sweden
Telephone: +46 486 - 488 00

Telefax: +46 486 - 414 10
...Or nearest distributor...(see last page..)

ROBOTICS
Page: 32 Trouble shooting AB
8. Trouble shooting
8.1 Alarm history
The list over occured alarms, can be seen on the screen ”I/O ALARM
SYSTEM UNIT”.
On the menu ”ALARM LIST”, more information about occured alarms,
are shown. For using this menu, follow instructions below:
Press DISP.
Press F5 [DIAG]
JOB POSN FILE VAR DIAG

▲ F1 F2 F3 F4 F5 MORE
Press MORE twice!
There after press F1 [ALM LST]
ALM LST ON/OFF DROP BLOCK SERVO

Last choosed alarmlist is shown automatically.

Latest occured alarm is shown at the top of the list.
To show minor alarm, press F2 [MIN ALM].
J:TEST S: 006 LOCK CYCLE STOP DISP
MAJOR ALARM
CODE DATE CLOCK
1 3011 1995/11/12 11:27
2 1330 1995/11/08 16:05
3
4
5
6
=> POSITION ERROR
MAJ ALM MIN ALM I/O SYS I/O USR OFFLINE


MOTOMAN
ROBOTICS
Service manual MRC
AB Trouble shooting Page: 33
The list for minor alarms are shown. To get more

information of a separate alarm and how it
occured, move the cursor up or down with the
ARROW BUTTONS and press F5 [DETAILS].
MINOR ALARM
CODE DATE CLOCK
1 5040 1995/12/11 10:57
2 4540 1995/11/08 11:17
=> UNDEFINED LABEL
DETAILS
Detail menu is shown for a specific alarm.

ALARM DETAILS
ALARM CODE : 4540
MESSAGE : UNDEFINED LABEL
JOB : TEST
LINE NO. : 0003
STEP NO. : 002
DATE : 1995/11/08
CLOCK : 11:48
MAJ ALM MIN ALM I/O SYS I/O USR OFFLINE

To return to job, press DISP and after that, press

F1 [JOB].
Error diagnosis. Devided into 2 classes:

-Error which can be measured by own service personnel.
-Error which has to be measured by MOTOMAN service.
Note!
-Errors are classified as, either ERROR CODE or ALARM CODE.
This are shown in connection to the code. Same figure combinations
are used for two alarm-types, but has different meanings, and need
different measures.

ROBOTICS
8.2 Alarmcodes - classing

Alarm- and Error-codes are indicated on the P-box display.
The alarm codes are classified below.
At alarm code level 0 - 3, the servo power supply is cut.
8.2.A Caution
Observe carefulness when alarm codes for the module Variable Data
(JANCD - MIF01) is handled. Then this presume that the system is
placed in maintenance mode.
The module MIF01 contains the basic information involved in the soft-
ware and are kept by the battery-backup. Carelessness can cause total
memory loss.
If the module MIF01 have to be replaced or need a more careful
examination, please contact your MOTOMAN representative before
further measures is taken.
Alarm codes Alarm level Remedial action
0 xxx Level 0
serious error
1 xxx Level 1 - 2 Reset of the alarm with the reset-button or an
2 xxx serious error external signal is not possible.
Turn OFF the servo power supply before error-
measure is taken.
3 xxx Level 3 Reset of the alarm with the reset-button is
serious error possible, but it´s impossible to reset with an
external signal. Reset the alarm and measure
the error. Turn the servo power supply ON.
4 xxx Level 4 - 8 Reset of the alarm with the reset-button or an
5 xxx minor error external signal is possible.
6 xxx
7 xxx
8 xxx
9 xxx Level 9
application
error
Start the trouble shooting with a replacement off the board which is
indicated by the MVS-figures.

MOTOMAN
ROBOTICS
Service manual MRC
MVS-number specification are made with the last figure in the alarm
code, a number between 0 - 6, for example 1180 to 1186.
xxx0 = MSV01
xxx1 = MSV02
xxx2 = MSV01
xxx3 = MSV02
xxx4 = MSV01
xxx5 = MSV02
xxx6 = MSV01
1: 3: 5:
0: 2: 4: 6:
MSV-board
8.2.B Servopack alarm indication

Red LED correspond servo power supply ON.
Green LED correspond to each axis on the servopack and lit at servo
power supply ON.
Green LED OFF, indicate an error has occurred in the servo motor
or in the cable bundle.
Red LED OFF, indicate an error has occurred in the servopack or in
the cable bundle. See alarm code.
Green LED
Red LED
Red LED

ROBOTICS
8.3 Reset - robot overload

If any of the robot axes gets overloaded, reset like follows:
a) If any robotaxes gets overloaded, the alarm codes 4670 or 4671 are
shown on the teachbox display and the servo power supply are turned
OFF. Every axis has an overload check.
4670 OVERRUN IN ROBOT AXIS See below
4671 OVERRUN IN EXTERNAL AXIS See below
a) Check which of the robot axes that are overloaded.

b) Search for the reason of overload.
c) Open the panel cover, press OVERRUN RECOVERY and keep it
affected.
Then press:
-The RESET-button on the teachbox
-Press SERVO POWER to activate the servo power.
-Set the MRC in TEACH-mode
-Press ENABLE to activate the teachbox
-Move the overloaded axis away from its position with keys on the teach-
box.
Upper arm U
U+ B+
R+
T+
T-
U- R-
B-
L-
Lower arm L
L+
S-axis
S+
Fig.16 Robot axes

S- name

MOTOMAN
ROBOTICS
Service manual MRC
8.4 Reset - MRC overload

No movement at the robot is possible in TEACH-mode, when MRC is
in any of the following positions:
-MACHINE LOCK-position
-Any of the axes has been overloaded (by software).
Following measures reset these problems.
8.5 Reset MACHINE LOCK

MACHINE LOCK is used to get possibility to run the job in the MRC,
without robot movements.
OBS! MACHINE LOCK is reset automatically if MRC power sup-

ply is turned OFF.
Restore manually by...

a) Activate the teachbox by pressing ENABLE.
b) Get the software screen by pressing SELECT.
c) Press F5 [SPECIAL] The screen for special functions is shown.
d) Move marker up by using the ARROW BUTTONS.
e) Press F5 [CANCEL] This will reset all settings for special func-
tions.

ROBOTICS
8.6 Reset - software

Be carefull while running the robot in this mode. It’s very easy to damage
the robot, when limit switch is inactivated. Be sure that the limit switch is
restored after operation.
Some of the following area limits has been exceeded by any axes:
-Max. allowed movement has been exceeded by any axis.
-Max. combinated movement has been exceeded by several axes.
-TCP enters restricted area set by software limits.
These software limits are watched continuously by the CPU. All move-
ments are stopped when the robot TCP has reach any of this limits.
Restore manually by...

a) Put MRC in TEACH mode.
b) Activate the teachbox by pressing ENABLE.
c) Press SELECT to get the software screen.
d) Call for more commands, by pressing MORE on the teachbox.
e) Move marker up by using the ARROW BUTTONS.
f) Press F2 [LIMIT] and the sofware are restored.
g) Press F1 [RELEASE].
h) Move the robotarm back inside the software limits. When restoring,
move the robot axes in opposite direction.
i) Return to normal operation, after measure. This can be done in three

differnet ways:
-Press F4 [CANCEL].
-Press PLAY or REMOTE on the MRC Operator’s panel.
-Turn OFF the power supply for the MRC, by using the main switch.
Note!
Programming can not be made when system is placed in RELEASE
mode.

MOTOMAN
ROBOTICS
Service manual MRC
8.7 Collision measure

After, for instance, MIF01 replacement, or if battery power has been to
low, it is nessecary to do a home position calibration.
8.7.A Problem
The robot may at a sever collision change position, the robot zero
point is moved, from normal position.
Measures as follows.
a) Drive robot to the reference points, to make sure which axes that is
wrong adjusted.
b) Check the pulse values for “real” position.
c) Check the pulse values for “should be” position.
d) Feed the diffenrece to ajust the absolute values.
e) Check the reference points, again.
8.7.B Measure
Put MRC in TEACH mode and press ENABLE on the teachbox.
Drive robot to the reference points. Check which axes that has moved
(usually the B-axis).
Check how many pulses the robot has moved, by driving the pro-
grammed point and check the axis pulse value.
Show position by pressing DISP, new software

keys are shown on the display.
Press F2 [POS.] and the screen with position

values are shown.
JOB POSN FILE VAR DIAG

Write down pulse values for each axis.
Press F3 [CMD POS]
PULSE XYZ CMD POS

Drive robot, in cordinate mode ”JOINT”, by

using the teachbox, to the reference points and
check the new pulse values.

ROBOTICS
Calculate the difference between these values, for each axis.

Ex. 1 = 13 500 pulses [POINT]
2 = 13 350 pulses [ACT.]
Difference 13 350 - 13 500 = -150 pulses.
Difference shall be used to change absolute values.
Press CUSTOMER and MORE to get right soft-

ware keys
TOOL USER SPEC PT RSV JOB Play SPD

Press F5 [ORG]
LANG INTRF OPE ORG ORG

Write your ID-number (8 signs).

Default [00000000] (eight zeros), this code can be
changed to customers desire.
Press ENTER.
Press F2 [ORG SET]
PRM TR. ORG SET RB CAL

New screen is shown.
HOME POSITIONING CUST

ABSOLUTE DATA SET SELECT
R1: S -583 l m
L 59598 l m
U -48941 l m
R -177 l m
B 7942 l m
T -9608 l m
EACH ALL QUIT


MOTOMAN
ROBOTICS
Service manual MRC
Press MORE and F1 [NUM KEY]
NUM KEY
New screen is shown.
← BACK SP →
Put in the new absolute values (the old + difference)
Ex. Existing value (B-axis) = 7942 pulses

Difference = +150
New value = 7942 + 150 = 8092 pulses
Finish with ENTER.
Drive robot to the refernece point and check that it’s right.

Headquarters:
MOTOMAN ROBOTICS AB
Box 504 l 385 25 Torsås l Sweden
Tel: +46-486-48800l Fax: +46-486-41410
Subsidiary:
MOTOMAN ROBOTICS UK LTD
1 Swan Industrial Estate l Banbury l OXON OX16 8DJ l England
Tel: +44-1295-272755 l Fax: +44-1295-267127
MOTOMAN ROBOTICS ITALIA SRL

Via Emilia 1420/16 l I-41100 Modena l ITALY
Tel: +39-59280496 l Fax: +39-59280602
MOTOMAN ROBOTICS FRANCE S.A.

Rue Nungesser et Coli l D2A Nantes-Atlantique l F-44860 Saint-Aignan-de-Grand-Lieu l France
Tel: +33-2-40131919 l Fax: +33-40754147
MOTOMAN ROBOTICS ESPAÑA S.L.

Avenida Marina 56 l Parcela 90 l ES-08830 ST. Boi de Llobregat l Spain
Tel: +34-36303478 l Fax: +34-36543459
Distributors:
ELECTRO-ARCO S.A.
Rua Vice Almirante Azevedo Coutinho, 4 l Venda Nova l PT-2700 Amadora l Portugal
Tel: +351-14968160 l Fax: +351-14990696
HN AUTOMATIC A/S
Hjulmagervej 4 l DK-7100 Vejle l Denmark
Tel: +45-79428000 l Fax: +45-79428001
LINCOLN-KD S.A.
Ctra, Laureà Miró 396-398 l E-08980 Sant Feliu de Llobregat l Spain
Tel: +34-36859600 l Fax: +34-36859633
MOTOMAN ROBOTIT OY
Kärsämäentie 8 l SF-20300 Turku l Finland
Tel: +358-22145600 l Fax: +358-22145660
ROBOT-TEKNIKK AS
Øvre Eikervei 177 l N-3048 Drammen l Norway
Tel: +47-32824890 l Fax: +47-32825155
SIAD S.p.a.
Via S. Bernardino, 92 l I-24126 Bergamo l Italy
Tel: +39-35-328111 l Fax: +39-35-320183
MOTOMAN ROBOTICS AB
a subsidiary of YASKAWA Electric Corporation

MRC K60 Service Manual

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YASNAC MRC

Service manual, YASNAC MRC

1. About this manual .................................. 1

Skapad: 98-09-02 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrcIH.fm

Service manual YASNAC MRC

Fig.1 YASNAC MRC

1. About this manual

This manual compromises:

For robot instructions, see separate service manual for MOTOMAN

Skapad: 95-05-17 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrc.fm

Text written in BOLD letters means command or button.

POWER SUPPLY PEAK KVA

Skapad: 95-05-17 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrc.fm

Skapad: 95-05-17 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrc.fm

Model Robot weight Eye bolts

S604, S604-30 1100 kg M20 x 4

S604W, S604-30 1250 kg M20 x 4

K10 300 kg M16 x 2

K100, K100-120, K100-150, 1600 kg M24 x 4

K205 700 kg M30 x 4

K60 980 kg M20 x 4

NY serien 2700 - 2950 kg M30 x 4

SK6 145 kg M10 x 2

SK16 280 kg M12 x 2

SK16M 580 kg M20 x 2

SK120, SK120-150 1550 kg M24 x 2

SP100 1750 M24x4

SP160 1900 M24x4

SK45 600 M20x2

MRC K-, SK- och SP-Serie 190 kg M16 x 2

Skapad: 95-05-17 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrc.fm

3.4 Space required

3.5 Cable bundle

Don’t mount any cables under the welding equipment.

Length between signal cables and remaining cables.

Skapad: 95-05-17 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrc.fm

Connect the transformer to power source so that incomming cur-

The MRC is equipped with components to avoid interference, (fullfills the

Fig.3 Main switch

Skapad: 95-05-17 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrc.fm

3.6.A Earth connection

3.6.B Power consumption

S604 21 kVA 30 kVA 6,0 mm² 43,3 A 50 A

S604-30 19 kVA 20 kVA 6,0 mm² 28,9 A 35 A

K3 2,5 kVA 5,7 kVA 2,5 mm² 8,2 A 16 A

K6 3,5 kVA 5,7 kVA 2,5 mm² 8,2 A 16 A

K10 8 kVA 10 kVA 2,5 mm² 14,5 A 16 A

K30 18 kVA 20 kVA 6,0 mm² 28,9 A 35 A

K60 23 kVA 30 kVA 10,0 mm² 43,4 A 50 A

K100 23 kVA 30 kVA 10,0 mm² 43,4 A 50 A

K205 23 kVA 30 kVA 6,0 mm² 28,9 A 35 A

NY-serien 32 kVA 40 kVA 16,0 mm² 55,7 A 63 A

SK6 3,5 kVA 5,7 kVA 2,5 mm² 8,2 A 16 A

SK16 6 kVA 7,5 kVA 2,5 mm² 10,8 A 16 A

SK16 M 6 kVA 7,5 kVA 2,5 mm² 10,8 A 16 A

SK120 23 kVA 30 kVA 10,0 mm² 43,4 A 50 A

SK45 18 kVA 20 kVA 6,0 mm² 28,9 A 35 A

SV035 3,5 kVA 5,7 kVA 2,5 mm² 8,2 A 16 A

Skapad: 95-05-17 Ändrad: 98-09-02 Filnamn: T:\M-ROBOT\ENGELSK\Uh-mrc.fm

3.6.C Connect equipment

Servo connector (valid up to SK16)

Fig.4 Servo connection in the MRC-cabinet

d) Mount connector 1SV (servopack; S-, L- and U-axes). Connect 2SV