Install and Wiring: User Manual

ROBOTICS
Install and Wiring

Robot controller
User manual
Created on: 2021-10
Revision: 02
Author: WOE
Document number: E1102000255GB02
Modifications made:
Rev. 01: Document created from the original RE-CTO-A222.4 (2018-10)
Rev. 02: Revised version (Chapter: 9.8 "Connection of GP I/O"
© Copyright 2021
This documentation (or parts of it) must not be reproduced or made available to third parties without
the express approval of YASKAWA Europe "Robotics Division GmbH”.
We have checked the content of this publication for compatibility 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.
Table of contents
Table of contents
1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 YASKAWA manual list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 MOTOMAN Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Safety during installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.1 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.2 Fixing the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3.3 Safety in the work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3.4 Operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2 Position type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Transporting method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1.1 Using a lifting truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.1 Protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2 Ambient conditions and installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1.1 3-phase power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.2 Noise filter installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1.3 Leakage breaker installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.4 Installation of primary power supply breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Connection methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.2.1 Connection to primary power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.2.2 Connection of the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.2.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.1 Regular inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Inspection of robot controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3 Cooling fan inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4 Emergency Stop Button Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.5 Inspection of the enabling switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3
Table of contents
7.6 Check battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.7 Check the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.8 Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8 Robot controller specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.1 Specification list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.2 Function list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.4 Device configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9 Description of Units and Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.1 Connection for connector on front panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.2 Connection of robot specific input signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.3 Installation of safety plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.4 Connection of external emergency stop signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.5 Connection for SERVO-ON enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.6 External axes overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.7 Emergency stop output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.8 Connection of GP I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.9 Assignment of universal I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4
General
1 General
1.1 Notes for safe operation
DANGER!
Indicates an immediate high-risk hazard situation, which can cause death or serious bodily
injuries if no precautions are taken.
WARNING!
Indicates a possible medium-risk hazard situation, which can cause death or serious bodily
injuries if no precautions are taken.
CAUTION!
Indicates a potentially dangerous situation with a low risk of minor or moderate bodily
injuries if no precautions are taken. This signal word can also be used for property damage
warnings.
NOTICE
These warnings mean that damage to property may occur, if no precautions are taken.
Note:
Indicates important background information and application advice.
1 -5
General
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:
Description Term
Control Robot control
Industrial robot Robot
Programming pendant/teach box Programming pendant or PP
Programming pendant safety signal short Programming pendant safety signal short
circuit connector circuit connector (optional)
Supplying cable between robot and robot Cable
control
Robot, robot control and cable Robot system
Yaskawa Electric Corporation YEC
YASKAWA Robotics Division YEU-R
Moving, calibrating and setting up of the ro- Teaching
bot
Movement sequences of the robot JOBs
Technical customer service TCS
Functional safety unit FSU
General purpose GP
Feedback FB
Time measuring TM
Personal computer PC
Switch SW
Control power supply CPS
1 -6
General
1.3 Target group

This manual is directed to users with the following knowledge:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• System knowledge of the robot control
• Specially trained staff
Note:
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 get in touch with your YASKAWA branch
office directly.
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
1 -7
General
1.5 Improper use
1 -8
General
1.6 About this manual

• 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 ("Instructions E1102000241XX01* and higher" and "Maintenance
E1102000242XX01* and higher").
• ARC Welding is only possible with the YRC1000 controller.
• 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.
The PP keys, buttons and displays are described as follows:
Programming pendant Manual designation

Character keys / Symbol keys The keys which have characters printed on them are
denoted with [ ], e. g. [ENTER].
Axis keys / Numeric keys [Axis Key] and [Numeric Key] are generic names for the
keys for axis operation and number input.
Keys pressed simultaneously A plus sign between the keys indicates that it is neces-
sary to press two keys simultaneously.
e.g. [SHIFT] + [COORD].
Mode switch Mode Switch can select three kinds of modes: RE-
MOTE, PLAY or TEACH.
(The modes are denoted as symbols.)
Button The PP has three buttons on the upper side: START
(green), HOLD (yellow) and EMERGENCY STOP.
Displays The menu displayed in the PP is denoted with { }, e.g.
{JOB}.
PC keyboard The name of the key is denoted. e.g. Ctrl key on the keyboard
Description of the operation procedure

In the explanation of the operation procedure, the expression "Select" means,
• that the cursor is moved to the object item and the [SELECT] key is pressed.
• that the item is directly selected by touching the screen.
Registered Trademark
1 -9
General
The names of companies and/or products used in this manual are trademarks. The
indications of ® and ™ are omitted.
1 - 10
General
1.7 Manufacturer
Address:
YASKAWA ELECTRIC CORPORATION
2-1 KUROSAKISHIROISHI
YAHATANISHI-KU
KITAKYUSHU
JAPAN
1.8 Authorized representative

Address:
YASKAWA Europe GmbH
Robotics Division
Yaskawastr. 1
85391 Allershausen
Germany
1 - 11
Safety
2 Safety
Programming pendant
1 Emergency stop button

1
M
P
E
ER O
G E N CY S T
WARNING!
Death or injury because of danger of crushing
If the emergency stop button does not function properly, the robot cannot be stopped in the
event of an emergency.
 The robot should not be used if the emergency stop button does not function.
 Before operating the robot check the function of the emergency stop button. The
SERVO power must be deactivated 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 off (see Fig. 2-1: "SERVO ON" LED").
Fig. 2-1: SERVO ON" LED

OP
EM
ER T
G ENCY S
Fig. 2-2: Emergency stop button
WARNING!
Before you release the emergency stop button note the following:
 Make sure that there is no one within the maximum working range of the robot.
 Clear the cell of all items which could collide with the robot.
 Now you can switch ON the SERVO power by pressing the enable switch on the
programming pendant.
2 - 12
Safety
WARNING!
if anyone enters the working area of the robot during operation or any problems occur,
always press the emergency stop button immediately. The emergency stop button is
located on the programming pendant (see figure "Programming pendant").
Observe the following precautions when performing teaching operations within the robot’s
working range:
 View the Robot from the front whenever possible.
 Always follow the prescribed operating procedure (see the instructions on robot control
as well as the operating instructions on "Handling" or "Universal Application").
 An area must be left clear so that the operator can retreat to it in case of emergency.
The following inspection procedures must be performed prior to teaching the robot. If
problems are found, correct them immediately, and be sure that all other necessary
measures have been performed.
• Check for problems in robot movement.
• Check the connectors for tight fit and all cables for damage.
• Hang the programming pendant back on the robot control after use.
• Make sure that the key for the key switch (Teach/Automatic) on the programming
pendant is kept by a competent person who has been specially trained.
• The key may be inserted in the key switch of the programming pendant only during
teach operation; after the teach operation it must be immediately removed and kept in
a safe place.
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. 2-3: CE mark
2 - 13
Safety
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.
Note:
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 program,
please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA branch
office.
2 - 14
Safety
2.1 YASKAWA manual list

Note:
It is important to have all the manuals of 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 (E1102000241XX01* and higher).
• Maintenance (E1102000242XX01* and higher
• Install and Wiring (E1102000255XX01* or higher).
• Alarm list (E1102000247XX01* or higher).
• SUPPLEMENTARY INSTRUCTIONS (Variable "Supplementary Instructions" not
defined.).
• GENERAL OPERATOR'S MANUAL (E1102000243XX01 or higher).
• Operating and maintenance instructions for the specific robot type.
* "XX" is the language of the document.
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.
2 - 15
Safety
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.
2 - 16
Safety
2.2 MOTOMAN Safety

The followings are safety functions of the robot controller.
• Emergency stop SW input (programming pendant)
• Enable SW input (programming pendant)
• Safeguarding interlock signal input (safety plug)
• External emergency stop SW input
• Protected stop signal input
• Overrun input (robot/external axis)
• GP safety input (Enabled when the option board (JANCD-ASF32-E) is connected
• 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 500 times/year

• Enable SW (programming pendant) 2000 times/year
2 - 17
Safety
2.3 Safety during installation and wiring

Caution!
Personal injury and damage from improper connections and unforeseen movements
Operators and other personnel may stumble on exposed wiring or piping. Damaged cables
may cause unexpected robot movements.
• Familiarize yourself with the wiring diagram and take notice thereof when establishing
the connections.
• Take precautions when wiring and piping between the robot controller, robot, and
peripheral equipment.
• Run the piping, wiring, or cables through a pit or use a protective cover, so that they are
not stepped on by personnel or run over by a forklift.
1 2 3
Fig. 2-4: Protective cover for forklift
1 Piping
2 Cable duct
3 Cables and tubes
For further details of the installation and the electrical connection please see Chapter 6.2.2
"Connection of the robot controller" on page 40.
DANGER due to electric current!

Danger of death and serious injury from electrical shock and fire.
Carry out earthing in accordance with all applicable electrical regulations.
 Comply with the IEC 60204-1:2005 standard (EN 60204-1:2006) on the electrical
equipment of machines.
2 - 18
Safety
WARNING!
Danger of injury and damage due to unforeseen movements.
When planning installation, draw up simple guidelines to ensure work can be carried out in
safety. Take safety aspects into consideration when planning the installation. Observe the
following points when setting up the robot:
 Select an area such as that described below in which to set up the robot
 Make sure the area is large enough so that the fully extended arm including the tool
does not collide with the wall, the safety equipment or the robot controller.
 Note the figure entitled "Required installation planning" below when setting up the robot.
Required installation planning
1 Safeguarding
1 3
2 Robot controller 2
3 Safety distance with respect to
the stopping time of the robot
type (min. 1000 mm) 4
4 Maximum P-point range of the
robot 3 3
5 Maximum working area of the ro-
bot including tool or workpiece
5
3
2.3.1 Maintenance work
CAUTION!
Risk of injury during maintenance work
Make sure there is sufficient room for maintenance work on the robot, the robot controller
and the peripheral equipment (see the following illustration).
2 - 19
Safety
Space for maintenance
Installation space for YRC1000micro in horizontal position
Air
100 mm
1 Power supply cable
2 Top view
1
3 Left side view
PRM.DATA
65 mm
O/#
PARAMETER DATA PARAMETER DATA
4 Front view
120 mm
ロボット本体とコントローラーは、下記オーダの
同一No.と接続して御使用ください。
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER No.
NJ4014-1
120 mm
65 mm
All dimensions in mm 2
120 mm 100 mm
3 4
Installation space for YRC1000micro in vertical position
Air
100 mm
1 Power supply cable
2 Top view
3 Front view 60mm
4 Right side view
All dimensions in mm 1 120 mm
60mm
60mm
120 mm
100 mm
3 4
2 - 20
Safety
2.3.2 Fixing the robot controller
CAUTION!
Danger of injury and material damage in case of non-compliance with protective
measures
For safe operations, the following points must be observed.
 The equipment may be operated only by persons with sufficient training.
 Install the controller only in a safe location from which the robot is visible at any time.
 Fasten the robot with the specified bolts (listed in the operating and maintenance
manual for each robot model).
 Pay attention to the size and type of bolts (specified in the operation and maintenance
manual for each robot model).
 Install the robot controller outside the safeguarding of the manipulator’s safety
enclosure.
CAUTION!
Danger of injury and material damage from falling or movements
In case of improper installation of the robot controller it may move unexpectedly or fall down
(see the figure below: "Fixing the robot controller").
 Secure the position of the robot controller after setting up.
 Fasten the robot controller to the ground or slot.
 Use the screw holes on the underside of the robot controller.
Fixing the robot controller
1 8 threaded holes M5
2 Vertical installation
3 Horizontal installation
2 1
4 4 threaded holes M5 x 5
3
4 4
15.8
15.8
95
95
22.2
22.2
18.8 235 26.2 26.2 235 18.8
2.3.3 Safety in the work area
WARNING!
Risk of injury from movements of the robot
2 - 21
Safety
• When the power supplies of the robot and the YRC1000micro are turned ON at start-
up, be sure to confirm the following:
– Safety protection devices such as the emergency stop circuit, the safety plug, etc.
operate normally.
– Each axis operates normally in the TEACH mode.
– The robot operates normally at the speed limit or less in the TEACH mode (Speed
limit: 250 mm/s at the TCP or the flange).
– The teaching function and the playback function operate normally.
• The robot may stop its movement while waiting for a condition to be satisfied during
operation. In this case, the robot starts its movement again immediately after the
condition is satisfied. Thus it is dangerous to come close to the robot even if it is not
moving. Make sure to clearly indicate that the robot is in operation by using a pilot lamp
and/or an audible alert so that the operator does not come close to the robot. Or make
sure that the robot stops its operation if the operator comes close to it.
• Install safety fences around the robot to prevent any accidental contact with the robot
while the power is ON. Display a warning sign stating “Off-Limits During Operation” at
the entrance of the safety fence.
The gate of the safety fence must be equipped with a safety interlock (safety plug) to
turn the SERVO power OFF when the gate opens. Make sure that the interlock
operates properly before use.
For details of installation, refer to chapter 2 "Safety".
• For areas not enclosed by safety fences, use a photoelectric sensor, a safety light
curtain, etc. to make sure that the robot stops its operation if the operator enters its
operating range.
CAUTION!
Risk of injury from collisions of objects or equipment
Do not store items and equipment near the robot and robot control.
 Keep the tools at appropriate locations outside the barrier.
 Keep the equipment at appropriate locations outside the barrier.
 Tools and loose equipment must not be deposited on the floor around the robot, robot
controller and other components.
2.3.4 Operating safety
DANGER!
Death and fire caused by short circuiting
Switching on the power supply during tool installation may result in electric shock.
 Before fixing a tool (e.g. welding torch), make sure the power supply to the robot
controller is turned off.
 Lock the switch, and display a warning sign (refer to EN 60204-1).
 Never exceed the rated capacity of the robot (the robot capacity can be found in the
"Technical Data" section of this manual).
2 - 22
Safety
WARNING!
Danger of injury and material damage caused by unforeseen movements of the robot
If possible, teach jobs from outside the robot’s maximum work area.
Observe the following precautions when performing teaching operations within the
manipulator’s operating range:
 Always view the robot from the front.
 Always follow the predetermined operating procedure.
 Always have an escape plan in mind in case the robot comes toward you unexpectedly.
 Ensure that you have a place to retreat to in case of emergency.
2.3.4.1 External safety

The robot and its auxiliary equipment must be surronded by a safetyguard. Entrances
(doors, gates, etc.) must be protected by interlockings, electro-sensitive devices or similar.
Opening of the gates or entrance to the robot working area must stop all motions inside the
cell. Before taking the robot into operation, the complete machine must fulfill the “Essential
health and safety requirements relating to the design and construction of machinery”
according to the EU Machinery Directive.
2.3.4.2 Emergency stop function

The emergency stop circuits are designed according to category 1 (EN 418 item 4.1.5)
Using power to the servo motor to achieve the stop and then removal of power when stop
is achieved. If stop is not achieved after 0.8 seconds, mechanical brakes are engaged
automatically to support stopping.
2 - 23
Delivery
3 Delivery
3.1 Checking the scope of delivery

The standard delivery includes the following items (programming pendant (1) or Smart
Pendant (2):
1 2 3
4
7
X81
HB1370144-1
䠮䡋䠾䡋䡐
䠮䠾䡐䠩䠽
䠩䠽䡊䡑䠽䡈䡈
READ ONLY MEMORY
6 5
1 PP
2 or Smart Pendant
3 Robot controller
4 Robot
5 Cable
6 Complete set of documentations
7 PP dummy connector (optional)
3 - 24
Delivery
3.2 Position type plate

Note:
Please contact the local YASKAWA branch office if the serial numbers do not match the
information on the delivery note.
Verify whether the serial number of the robot, the robot controller and the programming
pendant match with the delivery note.
The serial number can be found on the type plate as shown below.
NJ4014-1
NJ4061
Fig. 3-1: Position type plate collaborative robot (example)
3 - 25
Transportation
4 Transportation
CAUTION!
Personal injury or material damage
The system consists of precision components. Failure to observe this caution may
adversely affect performance.
 Crane and forklift trucks must be performed only by authorised personnel. The same
applies to the application of loops.
 Avoid excessive vibration or shock during transportation.
 No external forces may be exercised on the robot control, the robot or other
components.
CAUTION!
Personal injury or material damage
Failure to observe this instruction may cause falling or overturning of the YRC1000micro
during transportation.
 Lift, move, or install the YRC1000micro by two or more persons Approx. mass of
YRC1000micro: Approx. 16 kg per unit).
 Use a platform truck to carry the YRC1000micro.
 Avoid jarring, dropping or hitting the YRC1000micro during handling.
The mass of the YRC1000micro is indicated on the nameplate. The location and content of
the nameplate is shown below.
Unpack and move the YRC1000micro by two or more persons.
Use a lifter to lift the YRC1000micro up to or put it down from the rack.
Also, use a platform truck to carry the YRC1000micro.
䠵䠮䠟䠍䠌䠌䠌䡉䡅䠿䡎䡋
䠰䠵䠬䠡
䠏䠬䠤䠝䠯䠡䚷䠝䠟䠎䠌䠌䠋䠎䠎䠌䠲
䠍䠬䠤䠝䠯䠡䚷䠝䠟䠎䠌䠌䠋䠎䠏䠌䠲
䠢䠮䠡䠭䠱䠡䠪䠟䠵䚷䠑䠌䠋䠒䠌䠤䡖
䠝䠲䠡䠮䠝䠣䠡
䠢䠱䠨䠨䚷䠨䠫䠝䠠䚷䠟䠱䠮䠮䠡䠪䠰
䠯䠤䠫䠮䠰䚷䠟䠥䠮䠟䠱䠥䠰䚷䠟䠱䠮䠮䠡䠪䠰
䠩䠝䠴䚷䠫䠟䠬䚷䠠䡎䡅䡒䡁䚷䠮䠽䡐䡅䡊䡃
䠝䠬䠬䠮䠫䠴䚷䠩䠝䠯䠯
䠠䠫䠟䠱䠩䠡䠪䠰䚷䠪䡋䠊䠬䠯䠦䠋䠡䠉䠵䠮䠟䠍䠌䠌䠌䡉䡅䠿䡎䡋䠉䠌䠌䠌䠌䠌
䠫䠋䠪
䠯䠋䠪
䠠䠝䠰䠡

䠎䠉䠍䚷䠧䡑䡎䡋䡏䠽䡇䡅䡏䡄䡅䡎䡋䡅䡏䡄䡅䠈䠵䠽䡄䠽䡐䠽䡊䡅䡏䡄䡅䠉䡇䡑䠈
䠧䡅䡐䠽䡇䡕䡑䡏䡕䡑䚷䠔䠌䠒䠉䠌䠌䠌䠐䚷䠦䠽䡌䠽䡊䠩䠝䠠䠡䚷䠥䠪䚷䠦䠝䠬䠝䠪
䠵䠮䠟䠍䠌䠌䠌䡉䡅䠿䡎䡋
䠰䠵䠬䠡
䠏䠬䠤䠝䠯䠡䚷䠝䠟䠎䠌䠌䠋䠎䠎䠌䠲
䠍䠬䠤䠝䠯䠡䚷䠝䠟䠎䠌䠌䠋䠎䠏䠌䠲
䠢䠮䠡䠭䠱䠡䠪䠟䠵䚷䠑䠌䠋䠒䠌䠤䡖
䠝䠲䠡䠮䠝䠣䠡
䠢䠱䠨䠨䚷䠨䠫䠝䠠䚷䠟䠱䠮䠮䠡䠪䠰
䠯䠤䠫䠮䠰䚷䠟䠥䠮䠟䠱䠥䠰䚷䠟䠱䠮䠮䠡䠪䠰
䠩䠝䠴䚷䠫䠟䠬䚷䠠䡎䡅䡒䡁䚷䠮䠽䡐䡅䡊䡃
䠝䠬䠬䠮䠫䠴䚷䠩䠝䠯䠯
䠠䠫䠟䠱䠩䠡䠪䠰䚷䠪䡋䠊䠬䠯䠦䠋䠡䠉䠵䠮䠟䠍䠌䠌䠌䡉䡅䠿䡎䡋䠉䠌䠌䠌䠌䠌
䠫䠋䠪
䠯䠋䠪
䠠䠝䠰䠡

䠎䠉䠍䚷䠧䡑䡎䡋䡏䠽䡇䡅䡏䡄䡅䡎䡋䡅䡏䡄䡅䠈䠵䠽䡄䠽䡐䠽䡊䡅䡏䡄䡅䠉䡇䡑䠈
䠧䡅䡐䠽䡇䡕䡑䡏䡕䡑䚷䠔䠌䠒䠉䠌䠌䠌䠐䚷䠦䠽䡌䠽䡊䠩䠝䠠䠡䚷䠥䠪䚷䠦䠝䠬䠝䠪
4.1 Transporting method

• If transported manually, two people must hold the robot controller tightly on its
underside.
• The robot controller weighs approximately Approx. 16 kg. Use load-carrying devices
strong enough to withstand the weight.
4 - 26
Transportation
4.1.1 Using a lifting truck
CAUTION!
Personal injury and material damage during transport
 Avoid jarring, dropping, or hitting the controller during handling.
 Excessive vibration or impacting the robot controller may adversely affect the
performance of the robot controller.
 Lift, move, or install the robot controller by two or more persons.
 Use a lifting truck to carry the robot controller.
4 - 27
Assembly and installation
5 Assembly and installation

CAUTION!
Personal and property damage
The following precautions must be taken:
 Check that the robot controller is complete and not damaged.
 Do not put into operation a robot controller that is damaged or incomplete.
 Check that all transport securing devices and transport screws have been removed.
5.1 Protection measures
DANGER!
Personal and property damage
The robot system must not be operated without protective equipment. If the robot system
is put into operation without appropriate protective measures, it can result in death, serious
injury or damage to property.
Implement the following protection measures:
 Separating safety guards
 Non-contact protective equipment
 Enclosures
 Marked areas
 Warning signs
 EMERGENCY STOP button
 Display elements
NOTICE
Operator's responsibility
The operator of a robot or robot system must ensure that all specifications and
requirements of the EN ISO 10218-1 and EN ISO 10218-2 standards are met.
These primarily involve:
 Preparing a risk assessment
 Installing protective equipment
 Training employees on a regular basis
 Regularly inspecting all protective equipment
 Checking for compliance with intended use
5 - 28
Assembly and installation
5.2 Ambient conditions and installation location

A robot controller may only be installed in the following ambient conditions:
• Air humidity: 10% to 90% relative humidity (without condensation).
• Must be as dust-free, clean and dry as possible.
• Free of corrosive or explosive gases or liquids
• Protected against strong shocks (acceleration shock: max. 4.9 m/s² [0,5 G]).
• There must be no significant electromagnetic interference (plasma).
• Must be protected against collisions with moving equipment such as forklifts.
• Install the controller in a location where the robot is easily visible.
• Free from large electrical noise (an electrical noise source such as a TIG welding device
must not be placed close to the YRC1000micro).
• Free from excessive microwaves, ultraviolet rays, X-rays, or radiation.
• Must comply with the requirements of Directive 2004/108/EC on electromagnetic
compatibility.
Place of installation (above sea Maximum ambient temperature

level)
Up to 1000 m1 0° C to 45° C
23
maximum 2000 m 0° C to 40° C
1. During transport at -10 ° C to 60 ° C, the temperature change must not exceed 0.3 ° C / min.
2. At a height of more than 1000 m, the ambient temperature is 1% per 100 m.
3. When the altitude is 2000 m, the maximum ambient temperature during operation is 36°C.)
NOTICE
If the external electric noise applies, the alarm occurs and the robot may stop.
 When the alarm occurs and the robot stops, “YRC1000micro Maintenance manual
(E1102000242XX01* and higher)” and reset the alarm.
5 - 29
Wiring
6 Wiring
DANGER!
Death from electrical shock, risk of fire due to short circuit.
Wiring must be performed by authorized or certified personnel.
Failure to ground equipment may result in fire or electric shock.
Capacitors inside the robot controller store electricity after power is turned OFF. Exercise
caution whenever handling circuit boards.
Loose power circuit wires can cause fire and electric shock.
Incorrect wiring may cause fire and electric shock.
 Make sure that the earthing resistance does not exceed 0.1 Ω.
 Turn OFF the main power supply.
 Attach the required warning sign, e.g. "Do not energize!"
 Install a switch-on guard as prescribed.
 Do not touch any board inside the controller for five minutes after turning OFF the power
supply.
 Power cannot be turned ON unless the door is closed. Interlocks prevent power from
being turned ON.
 Any occurrence during wiring while the robot controller is in the emergency stop mode
is the user’s responsibility. Do an operation check once the wiring is completed.
 Wiring must be performed only by authorized personnel.
 Perform wiring in accordance with the rated capacity as specified in the Instructions.
 Be sure the power circuit screws are securely tightened.
 Do not handle the circuit board directly by hand.
• The cables that connect the controller to peripheral device are low voltage circuits. Do
not lay the signal cables of the robot controller together with the main power cable. High
voltage power lines should not be run in parallel to controller signal cables. Use metal
ducts for protection against electrical interference with the signals. If cables must be
crossed, run the power cables perpendicular across the signal cables.
• Confirm the connector and cable numbers to prevent misconnection. A wrong
connection can cause damage to electronic equipment.
• During wiring, only authorized persons may be present in this area.
• Lay all cables in the floor in a covered cable duct.
1 2 3
1 Piping
2 Cable duct
3 Cable
6 - 30
Wiring
6.1 Power supply
DANGER due to electric current!

Death from electrical shock and risk of fire due to short circuit
If the robot controller for European standards is used in Japan, an electric shock may result
from increase in leakage current due to differences in power supply condition.
 The robot controller must be grounded.
Note:
If the supply voltage differs, please contact the local YASKAWA branch office.
6 - 31
Wiring
6.1.1 3-phase power supply
For Europe
The three-phase 200 to 220 VAC (+10% to -15%) at 50/60 Hz (±2%) (neutral earthing)
The single-phase 200 to 230 VAC (+10% to -15%) at 50/60 Hz (±2%) (neutral earthing)
A specification of connectable power supply differs depending on the controller type.
Confirm the specification of power supply corresponding to the controller's model by the
rated label on the door of YRC1000micro.
2 3
ACIN
R
1 S 6
T
4 4
5 5
7
1 3-phase power supply

2 Filter module
3 Robot controller
4 Circuit protector
5 Noise filter
6 To CBB circuit (main circuit)
7 To CPS circuit (control circuit)
* The following models correspond to single-phase power supply:
• GP4, GP7, GP8, MotoMINI, HC10, HC10DT, HC10DTF, SG400 and SG650
6 - 32
Wiring
6.1.2 Noise filter installation
Insert the 3-phase/1-phase noise filter into the primary station of the non-fuse breaker filter
if noise coming from the power source is heard.
Seal up each cable opening so that dust does not enter.
5
3 6 7
ACIN(F)
R
1 S
T
8
4
R
2 T 9
1 3-phase 200V/220VAC 50/60Hz

2 1-phase1 200V/230VAC 50/60Hz
3 3-phase noise filter
4 1-phase noise filter
5 Robot controller
6 Circuit protector
7 Noise filter
8 To CBB circuit (main circuit)
9 To CPS circuit (control circuit)
1 Following models correspond single-phase GP7, GP8, MotoMINI HC10, HC10DT, HC10DTF, SG400, SG650.
6 - 33
Wiring
6.1.3 Leakage breaker installation
When connecting the leakage breaker to the controller power supply wiring, use a leakage
breaker which can handle high frequencies from the YRC1000micro inverter. Leakage
breakers which cannot handle high frequencies may malfunction.
Even with a leakage breaker installed, there is still a possibility of some high frequency
current leakage from the YRC1000micro. However, this current leakage presents no safety
risks.
Connection of the Leakage Breaker
1 3-phase 200/220 VAC at 50/60 Hz 2 3

2 Leakage Breaker R ACIN
3 Robot controller 1 S
5 6
T
4 Circuit protector
4
5 Noise filter
6 To CBB board (main circuit) 7
7 To CPS board (control circuit)
8 Single-phase1 200/230 VAC at 50/60 Hz
9 To CBB board 2 3
ACIN
10 Main circuit R
9
11 For single-phase 8 T 5
10
4
11
7
1. Following models correspond single-phase GP7, GP8 and MotoMIN, HC10, HC10DT, HC10DTF, SG400, SG650.
6 - 34
Wiring
6.1.4 Installation of primary power supply breaker
Install the primary power supply breaker as shown.
1 1
2 3
1 Breaker
2 Robot controller
3 Controller for positioner
Controller type Cable size1 Capacity of Robot Power ca-

circuit pro- pacity (kVA)
tector (A)
ERBR-100-06VX05-A0 2.5 16 MotoMini 0.5
ERBR-100-06VX8-A0 2.5 16 GP4, GP7, 1.0
GP8
ERBR-100-04SX650-A0 2.5 16 SG400, 1.0
SG650
ERBR-100-06VXH12-A 2.5 16 GP12 1.0
1. Size of terminal (In case of Capture cable (three cores) (mm²)
Tab. 6-1: YRC1000micro Power capacity, cable sizes, and breaker capacities
The maximum load value (payload, operation speed and frequency, etc.) is displayed.
However, the power capacity is different depending on work conditions.
Inquire at the nearest branch office listed on the back cover for information when selecting
the transformer.
NOTICE
The power capacity shown above is the continuous rating value.
When the robot is rapidly accelerated, the power capacity of several times the continuous
rating value may be needed instantly.
The power capacity is changed when using an external axis.
For details of the power capacity with an external axis, please contact to your YASKAWA
representative or check the rated value name plate on the controller.
6 - 35
Wiring
6.2 Connection methods
P
E
ER O
G E N C Y ST
Fig. 6-1: Connecting the robot system
6.2.1 Connection to primary power supply
Power cable connection

1. Prepare the primary power supply cable by using the robot cable using the primary power
supply-side connector delivered with the YRC1000micro.
Refer to Fig. 6-3: "For 3-Phase power supply (ACIN(F)" and Fig. 6-4: "For 1-Phase power
supply (ACIN(F)" for the pin assignment of the YRC1000micro.
Model of YRC1000micro Power Supply Connector (ACIN)
• YRC1000micro-side connector: CE05-2A18-10PD-D
• Primary power supply-side connector: CE05-8A18-10SD-D-BAS Manufactured by
DDK (the supplied part of the YRC1000micro)
Fig. 6-2: Power Supply Connector (ACIN)
1 YRC1000micro side connector

2 Primary Power Supply side connector
Attention:
Connection voltage max. 3 x 200V/220VAC 50/60Hz or 1 x 200V/230VAC 50/60Hz (only for
GP4/GP7/GP8, MotoMini, HC10 and SG400/SG650)
Recommended when using a residual current operated circuit breaker (RCCB) then this
should be type B 30mA!
6 - 36
Wiring
3PH Connection point

+TB1 Attention 3X200V
L1
MAX 220V
L2 MAX 220V
-XG2 MAX 220V

L3
PE
-ACIN1 A B C D
PE
L1
L2
L3
Fig. 6-3: For 3-Phase power supply (ACIN(F)
6 - 37
Wiring
Attention:
Connection voltage max. 230 V
Connection for potential equalisation must be at least 10 mm² GNYE!
1PH Connection point
Customer 1X230V/50HZ
PE
PE
N
MAX 230V
L1
-ACIN1 A C D
Fig. 6-4: For 1-Phase power supply (ACIN(F)
1-Phase connection:
• Recommended use of a residual current operated circuit breaker type B.
• Only single robot systems
• Only GP4, GP7, GP8, MotoMINI, HC10, HC10DT, HC10DTF, SG400 and
SG650
2. Confirm that the circuit protector of the YRC1000micro filter module is turned OFF.
3. Confirm that the primary power supply is turned OFF.
4. Connect the primary power supply cable.
DANGER!
Failure to observe these cautions may result in electric shock orequipment failure.
 Make sure to use the supplied connector for the primary power supply connection.
 Tighten the cable clamp to prevent the cable from breaking.
Grounding method:
• Perform grounding as countermeasures against noise and electric shock.
• Follow the steps below:
– Connect the ground wire to the D terminal of the power connector (ACIN(F)).
– Perform grounding in accordance with all relevant local and national electrical
codes. The size of ground wire must the same as listed on “6.1.4 "Installation of
primary power supply breaker"”.
6 - 38
Wiring
Note:
The ground wire must be supplied by the user.
ACIN(F)
2
1
1 YRC1000micro
2 Maximum earthing resistance of 0.1Ω according to DIN EN ISO
60204-1
– Connect the ground wire with the YRC1000micro and the filter module respectively
as shown in the following figure. The size of the ground wire must be of the same
size or larger than the size of the power supply cable shown in table 6.1.4
"Installation of primary power supply breaker".
2 3
YRC1000micro PRAB
1 LAN
-X3
POWER
I 3
GPIO
ON
RSW -X1
OFF
USB O
-X81
AC IN
SAFETY
POWER SUPPLY
1 Ground wire
2 Filter module
3 Ground wire connecting screw M4
Note:
Do not connect the ground wire with the wires for the electric power source, the welder, etc.
If using metallic ducts, metallic conduits, or cable trays for cabling, perform grounding in
accordance with all relevant governmental regulations.
6 - 39
Wiring
6.2.2 Connection of the robot controller
1. Remove the package and take out the robot cable. Connect the cable to the connector
on the back side of .
a) Confirm that the connector lever of robot cable is at the initial position.
Then insert the robot cable straight into the connector on the front side of the
YRC1000micro (The connector is connected in the state that it is turned 90 degrees
to the left).
• Insert the robot cable to a fixed depth, then the lever rotate about 30 degrees forward
automatically.
b) Push the lever with the hand and turn it 30 degrees approx. to lock it. Then press
the positions as following figure to confirm the lever is locked.
When pull out the connector, push the unlock part of the lever to unlock and turn the
lever about 60 degrees to return to the initial position. Then pull out the connector
straight.
2. Connect the robot cable to the YRC1000micro ( See the chapter below).
Confirm the connector number of robot cable. Push the cable connector into the robot
side connector firmly and then tighten it securely.
CONTROLLER
-X81
2
1
1 PP cable
2 Encoder cable / power cable (1BC)
6 - 40
Wiring
1 6
7
(60
2 )
LO
UNLOCK
CK
UN
LO
CK
LOCK
3
(30 4 5
) 2
LO
CK
UN
UN
LO
LO
LO
CK
CK
CK
5 5
(60
)
LO
CK
UNLOCK
UN
LO
CK
LOCK
1 Inserting 5 Rotate manually

2 Initial position of lever 6 Removing
3 Insert 7 Push the unlock part
4 Rotate automatically 8 Pull out
6 - 41
Wiring
6.2.3 Connecting the programming pendant
NOTICE
If the PP is not used, connect the PP dummy connector to the connector connection (-X81).
Connect the PP cable to the connection (-X81) ( see the chapter 6.2.2 "Connection of
the robot controller").
The robot, YRC1000micro and PP connections are now complete.
DANGER!
Emergency button out of function on disconnected PP
Pressing the emergency button of a disconnected PP in case of an emergency will not stop
the robot. This may result in personal injury or damage to the equipment.
 Store the disconnected PP properly in a separate place from the robot and the
controller.
 Make sure that it is visually clear that the PP is disconnected from the controller.
6 - 42
Maintenance and inspection
7 Maintenance and inspection
7.1 Regular inspections

Carry out the following inspections.
Failure to perform the following inspections may,
• adversely affect the performance of YRC1000micro
• shorten the life of YRC1000micro
• cause unexpected accidents.
Components Inspection Inspection

frequency
Robot controller Check for damage, loss, or loose of screws Monthly
of the case.
Check for damage or gap in the body.
Power supply Check power supply voltage is normal. Before using
Power supply cable Check for damage and deterioration of Daily
leads.
YRC1000micro cable Confirm that the cables are not twisted or Daily
falling out.
Cooling fan Check the operation (while power ON) Monthly
1
Emergency stop button Check the operation (while power ON) Daily
(PP)
Enable switch (PP) Check the operation (In the TEACH mode) When using
Battery Confirm battery alarm or message is dis- When an alarm
played or not. occurs
1. Be sure to confirm that the SERVO can be turned OFF by pressing the external emergency button when the
programming pendant is not used. The external emergency button is prepared by the user.
7 - 43
7.2 Inspection of robot controller

Visually check for loss of screws of the cover. Check for loose screws by tightening each
screw by using the screwdriver.
Check for gap and/or damage in the body.
Fig. 7-1: YRC1000micro External View
7 - 44
7.3 Cooling fan inspections
NOTICE
Inspect the cooling fans as required. A defective fan can cause the YRC1000micro to
malfunction because of excessive high temperatures inside if the cooling fans and the heat
exchanger do not operate efficiently.
The heat exchanger normally operates while the power is tuned ON, and the backside duct
fan normally operates while the servo power is turned ON. Check if the fans are operating
correctly by visual inspection and by feeling air moving into the air intake and from the
outlet.
Clean the air outlet and air intake of plastic panel on the front door of YRC1000micro as
required.
Use a diluted neutral detergent to prevent damaging the plastic panel when cleaning.
The cooling fan located at the backside prevents the rise of temperature inside the
YRC1000micro since high temperature may affect the internal devices.
Thus, the cooling fan must be inspected once in a month to keep its normal performance.
1 Air outlet 1
2 Backside view (installing direction of cooling fan)
3 Air inlet
4 Top view (direction of cool wind) 2
7.4 Emergency Stop Button Inspections

The emergency stop button is located on the programming pendant. Before operating the
robot, make sure the SERVO voltage is switched off. For this, press the emergency stop
button after switching on the SERVO voltage.
7 - 45
7.5 Inspection of the enabling switch
NOTICE
If the [SERVO ON] lamp does not light in previous operation, check the following:
 The emergency stop button on the programming pendant is being pressed.
 The emergency stop signal was triggered by an external device.
 If a major alarm is occurring.
The programing pendant is equipped with a 3-position enable switch. Perform the following
operation to confirm the enable switch operates.
1. Set the mode switch with key on the programming pendant to "TEACH".
1 REMOTE
2 PLAY
3 TEACH
REMOTE TEACH
1 PLAY 3
2
2. Press [SERVO ON READY] on the programming pendant. The [SERVO ON] lamp
flashes.
1 SERVO ON READY
2 SERVO ON (flashing light) SERVO
1 ON
READY
2 SERVO ON
3. When the enable switch is pressed lightly, the SERVO power is turned ON.
When the enable switch is pressed firmly or released, the SERVO power is turned OFF.
7 - 46
7.6 Check battery unit

The robot controller has a battery unit that backs up the important program files for user
data in the CMOS memory.
A battery alarm indicates when a battery has expired and must be replaced. The
programming pendant display and the message "Memory battery weak" appears at the
bottom of the display.
Check that the message is NOT displayed on the programming pendant.
When the programming pendant is not used, confirm that the window for the 7-seg LED
lamp on the front panel is not lit up by the battery alarm LED (D4) as yellow.
The way to replace the battery is described in chapter 7.8 "Replacing the battery".
1
YRC1000micro
Power
ON
OFF
AC IN
Power Supply
3-Phase AC200-220V
1-Phase AC200-230V
Frequency 50-60HZ
Rated Current 13A
SCR(AIC),SCCR 5000A
1 Window for checking the 7-seg LED lamp
7 - 47
7.7 Check the power supply

By using the electric tester, measure the voltage in the terminal parts of the breaker which
is located at the primary power source.
The specifications of power supply voltage are different depending on the specifications of
the YRC1000micro. Confirm the label on the side of the YRC1000micro.
Measured item Terminal Normal value

Line voltage Between 1 and 3, 3 and 5, 1 200 to 220V (+10%, -15%)
and 5
Voltage between earth (S- Between 1 and E, 5 and E 200 to 220V (+10%, -15%)
phase grounding Between 3 and E Approx. 0V
Tab. 7-1: Power supply voltage check (3-phase AC200-220V)
Measured item Terminal Normal value

Line voltage Between 1 and 3 200 to 230V (+10%, -15%)
Voltage between earth (S- Between 1 and E 200 to 230V (+10%, -15%)
phase grounding Between 3 and E Approx. 0V
Tab. 7-2: Power supply voltage check (1-phase AC200-230V)
7 - 48
7.8 Replacing the battery
NOTICE
 Although the CMOS memory is backed up by super capacitor, the battery must be
replaced as soon as the message “Memory battery weak” appears (within 30 days after
the message appears). Keep the breaker turned ON until just before starting the
replacement of the battery.
CPU Unit
1 CPU board JANCD-ACP01-E 1

2 CN105 LAN1 for programming pendant
3 SD card (CN104) CN107
2 (LAN3)
4 CPS input connector

5 Control communication connector (CN111) 3 CN106
(LAN2)
(Communication with SERVO control board/safety cir- 4 CN105

(LAN1)
cuit board) LED
1
2
3
DS1
10
4
6 Sensor board slot

BAT
CN104(SD)
5
LED
5
6
7
S1
11
7 Ground terminal
8
LED
9
10
11
12
13
8 2 PCIe Slots CN112
LINK
12
RS232C/422
CN113
9 Robot I/F board JANCD-AIF01-□E battery (back side) CN103
(COM)
CN111
10 I/O I/F (Communication with optional I/O) (CN112) CN102

(USB)
USB
11 Rotary switch (S1)
CN101
6 (PSU)
8
7
9
• Replacement Procedure
1. Disconnect the cables connected to the CPU board and robot I/F board below.
1 Control communication connector CN111

2 Control power supply input connector CN101
3 LAN1 for programming pendant connector CN105
Please disconnect the cable below if an optional function is added.
4 USB connector CN102
5 RS232C/422 connector CN103
6 LAN2 connector CN106
7 LAN3 connector CN107
8 I/O I/F connector CN112
7 - 49
2. Remove the screws fixing the CPU board from upper and lower side (2 places).
CN107
(LAN3)
CN106
(LAN2)
CN
(PSU)
3. Pull out the circuit board from the rack.

4. Check the position of battery and battery connectors.
Refer to figure "Robot /IF board and CPU board" and figure "Battery connecting 1".
This procedure is for the first replacement of battery.
From the second replacement, the connector (CN114) or the connector (CN115) is not
connected to the battery. Then connect the new battery to the disconnected connector.
Robot /IF board and CPU board
1 Position of mounting battery
Battery connecting 1
1 Battery connectors
Right: CN114 (Battery connect-
ed)
Left: CN114 (Battery not con-
nected)
7 - 50
5. Keep the old battery connecting and connect the new battery to the connector (CN115)
(left side).
Refer to figure „Battery connecting 2"
1 Connect the replacement battery

to the left connector (CN115)
6. Disconnect the connector which is connected to the old battery (CN114) (right side).
1 Disconnect the battery connector

(CN114 (right))
7 - 51
7. Remove the old battery from the battery holder.

1 Remove the old battery from

battery holder
8. Mount the new battery on the battery holder.

1 Mount the new battery on the

battery holder
9. Confirm not to run off the battery wires from the CPU board before mounting the CPU
board on the rack. If the CPU board is mounted with the battery wires running off, the
battery wires get caught in the backboard of rack and it may result in damage to
equipment such as a breaking of wire.
Refer to figure „Notes for battery wires (After replacement)"
Notes for battery wires (After replacement)
1 The battery wires do not run off

from the circuit board
7 - 52
10. Mount the CPU board on the original position.

Refer to figure „Mounting on rack“
NOTICE
Fit the side of the CPU board in the upper and lower rails which are on the left side in the
rack. Then insert the CPU board straight along the rails and connect to the backboard
connector.
If force the CPU board into the backboard connector while the CPU board deviates from the
rails, it may result in damage to the CPU board. If the CPU board stuck in the rails, pull out
the CPU board and confirm not to damage to it. Then insert the CPU board again.
Mounting on rack
1 Backboard connector for connecting CPU board

2 Insert the CPU board straight along the rails and connect to 1
the backboard connector
11. Tighten the screws fixing the CPU board from upper and lower side (2 places) and fix
to the rack.
12. Connect all cables are disconnected in step 1.
7 - 53
Robot controller specification
8 Robot controller specification

WARNING!
Make sure that there is no one within the P-point maximum envelope of the robot and that
you are in a safe place before turning ON the robot controller power.
Injury may result from collision with the robot to anyone entering the P-point maximum
envelope of the robot.
• Always set the teach lock before starting teaching.
• Observe the following precautions when performing teaching operations within the P-
point maximum envelope of the robot:
– View the robot from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always have an escape plan in mind in case the robot comes toward you
unexpectedly.
– Ensure that you have a place to retreat to in case of emergency.
Improper or unintentional robot operation can result in injury.
• Before operating the robot, check that the SERVO ON lamp goes out when the
emergency stop buttons on the programming pendant are pressed.
Injury or damage to machinery may result if the robot cannot be stopped in case of an
emergency.
The emergency stop buttons are located on the right of the programming pendant.
CAUTION!
• Perform the following inspection procedures prior to performing teaching operations. If
problems are found, correct them immediately and be sure that all other necessary
processing has been performed.
– Check for problems in robot movement.
– Check for damage to the insulation and sheathing of external wires.
• Always return the programming pendant to its specified position after use.
If the programming pendant is inadvertently left on the robot, fixture or on the floor, the robot
or a tool could collide with it during robot movement, possibly causing injuries or equipment
damage.
• Make sure that a system manager stores the key of the mode select switch of the
programming pendant. After operation, the key should be removed and stored by the
system manager.
Improper or unintended robot operation may result in injury.
Also, the key or the mode select switch may be damaged if the programming pendant is
dropped with the key inserted.
8 - 54
8.1 Specification list
Controller
Protection class IP20
Weight Approx. 16 kg
Dimension (W x H x D) in 425 x 125 x 280 (without protrusion parts)
mm
Cooling system Direct cooling
Power supply -3-phase 200/220 V AC (+10 % to -15 %) 50/60 Hz (+/-
2 %)
-1-phase 200/230 V AC (+10 % to -15 %)50/60 Hz (+/-2 %)
(Neutral point grounding must be performed.)
The specification of power supply differs depending on the
type of YRC1000micro.
Grounding Grounding resistance: 0,1 Ω
Noise level Less than 60 dB
Digital I/O Specific signal (hardware) 7 inputs and 1 outputs, General
signals (standard, max.) 8 inputs and 8 outputs (Transistor:
8 outputs, Relay: 0 outputs)
Positioning system By serial communication (absolute encoder)
Drive unit SERVOPACK for AC SERVO motors
Acceleration / Deceleration Software SERVO control
Memory capacity 200,000 steps, 10,000 instructions
Ambient conditions
Ambient temperature 0° C to + 40° C (During operation)
-10° C to + 60° C (During transit and storage)
Temperature change: 0.3°C/min or less
Relative humidity 10% to 90% RH (non-condensing)
Allowable altitude 2000 m or less (To use the YRC1000micro at the altitude
over 1000 m, calculate the maximum ambient temperature
by decreasing it by 1 % per 100 m. The maximum allow-
able altitude is 2000 m. When the altitude is 2000 m, the
maximum ambient temperature during operation is 36° C).
Vibration Acceleration 0.5G or less
Others Free from corrosive gas or liquid, or explosive gas.
Free from dirt, dust, cutting oil (including coolant), organic
solvent, oil fume, water, salt, chemicals or anti-rust oil.
Free from excessive electrical noise (plasma).
Free from strong microwave, UV light, X-ray or radiation.
8 - 55
8.2 Function list
Programming pendant operation

Coordinate • Joint
System • Rectangular/Cylindrical
• Tool
• User Coordinates
Modification of Teaching • Adding
Points • Deleting
• Correcting (Robot axes and external axes respectively can
be corrected)
Inching Operation Possible
Path Confirmation • Forward/Reverse step
• Continuous feeding
Speed Adjustment Fine adjustment possible during operating or pausing
Timer Setting Possible every 0.01 s
Short-cut Function Direct-open function, Multi-window
Interface • SD card slot
• USB port (USB2.0) (At Programming Pendant)
Application General
Essential Measures JIS (Japanese Industrial Standard)
Running Speed Limit User definable
Enable Switch 3 position type. SERVO power can be turned on at the middle
position only. (Located on programming pendant)
Collision proof Frames S-axis frame (doughnut-sector)
Cubic frame
Self-Diagnosis Classifies error and two types of alarms (major and minor) and
displays the data
User Alarm Display Possible to display alarm messages for peripheral device
Machine Lock Test-run of peripheral devices without robot motion
Door Interlock A door can be opened only when a circuit breaker is OFF.
Operation Time • Control power-on time
Display • SERVO power-on time
• PLAYBACK time
• Operation time
• Work time
Alarm Display • Alarm message
• Troubleshooting
• Previous alarm records
I/O Diagnosis Simulated enabled/disabled output possible
T.C.P. Calibration Automatically calibrates parameters for end effectors using a
master positioner
Programming Type Interactive programming
8 - 56
Programming pendant operation

Language Robot language: INFORM II
Robot Motion Control • Joint coordinates
• Linear/Circular interpolations
• Tool coordinates
Speed Setting • Percentage for joint coordinates
• 0.1mm/s units for interpolations
• Angular velocity for T.C.P. fixed motion
Program Control In- • Jumps, Calls
structions • Timer
• Robot stop
• Execution of some instructions during robot motion
Operation Instructions Preparing the operation instructions for each application Arc
(ON), Arc (OFF), etc.
Variable • Global variable
• Local variable
Variable Type • Byte type
• Integer type
• Double precision type
• Real type
• Position type
• String type
I/O Instructions • Discrete I/O
• Pattern I/O processing
Safety feature
Essential Measures JIS (Japanese Industrial Standard)
Running Speed Limit User definable
Enable Switch 3 position type. SERVO power can be turned on at the middle
position only. (Located on programming pendant)
Collision proof Frames S-axis frame (doughnut-sector)
Cubic frame
Self-Diagnosis Classifies error and two types of alarms (major and minor) and
displays the data
User Alarm Display Possible to display alarm messages for peripheral device
Machine Lock Test-run of peripheral devices without robot motion
Door Interlock A door can be opened only when a circuit breaker is OFF.
• PLAYBACK time
• Operation time
• Work time
8 - 57
Safety feature
• Troubleshooting
I/O Diagnosis Simulated enabled/disabled output possible
master positioner
Language Robot language: INFORM II
Program Control In- • Jumps, Calls
structions • Timer
• Robot stop
Operation Instructions Preparing the operation instructions for each application Arc
(ON), Arc (OFF), etc.
• Local variable
• Integer type
• Real type
• Position type
• String type
Maintenance function
• PLAYBACK time
• Operation time
• Work time
• Troubleshooting
master positioner
8 - 58
Programming function
Language Robot language: INFORM
Program Control In- • Jumps
structions • Calls
• Timer
• Robot stop
Operation Instructions Preparing the operation instructions for each application.
• Local variable
• Integer type
• Real type
• Position type
• String type
8 - 59
8.3 Programming pendant
Typ JZRCR-APP01-1
Material Reinforced thermoplastic enclosure with a detachable sus-
pending strap
Dimensions 152 x 299 x 53 (excluding protrusions)
W x H x D in mm
Mass 0,730 kg
Protection class IP54
Displayed unit 640 x 480 pixels color LCD (Alphanumeric characters, Chi-
nese characters, Japanese letters, etc.)
Touch Panel
Operating modes Select keys
Axis keys
Numerical/application keys
Mode select switch with a key (mode: TEACH, PLAY, and RE-
MOTE)
Emergency stop button
Enable switch
SD card slot (1 port)
USB port (1 port)
IEC protection class IP54
Length of cable Standard: 8 m, maximum (optional): 20 m (Optional: can be
extended by 4, 8 or 12 m to the standard : 8 m cable)
Interface Provided with SD card slot (SD/SDHC/SDXC type)
USB connector 1 x USB2.0
Key sheet Arc, Spot, Material handling, Jig-less, Spot + arc
8 - 60
8.4 Device configuration

This section explains the configuration of the YRC1000micro equipment.
Configuration
Configuration ERBR-100-xxxxxxx-A00
Model YRC1000micro (I/O: NPN specification)
MotoMini ERBR-100-06VX05-A00 with JZRCR-BCS01-1
GP4
GP7 ERBR-100-06VX8-A00 with JZRCR-BCS01-1
GP8
GP12 ERBR-100-06VXH12-A00 with JZRCR-BCS01-1
SG400
ERBR-100-04SX650-A00 with JZRCR-BCS01-1
SG650
Configuration ERBR-100-xxxxxxx-A01) (Environmental resistance model)

Model YRC1000micro (I/O: NPN specification)
MotoMini ERBR-100-06VX05-A01
GP4
GP7 ERBR-100-06VX8-A01
GP8
GP12 ERBR-100-06VXH12-A01
SG400
ERBR-100-04SX650-A01
SG650
8 - 61
Description of Units and Circuit Boards
9 Description of Units and Circuit Boards

Cautions for connection of dual input signals
NOTICE
• To the dualized specific signal, connect the switch (contact) that turns the signal ON and
OFF simultaneously.
• If the timing of turning ON and OFF between the dualized signals, a disagreement
alarm occurs.
1 YRC1000micro 1 3
2 SIO board 2 4 5
3 Front panel
4
SAFF_1+
4 Safety
14
5 Switch (SW) SAFF_1-
6 Turn ON/OFF at the same time 5 6

SAFF_2+
15
SAFF_2-
• Do not connect two signals to the same contact point (Prepare two independent contact
points).
• Since the power supply for each signal is reversed, it will short-circuit and may cause
breakdown of YRC1000micro unit if the signals are connected to the same contact
point.
1 YRC1000micro 1 3
2 SIO board
2 4 5
3 Front panel
4
4 Safety SAFF_1+
14 6
5 Switch (SW) SAFF_1-
6 The same contact 5
SAFF_2+
7 Short-circuit current
15
SAFF_2-
9 - 62
9.1 Connection for connector on front panel

Connectors are arranged on the front panel of the YRC1000micro for the various signal
connections.
1 2 3 4 5 6
10
10 9 8 7
1 Connector for GP IO
2 LAN (RJ45)
3 7seg-LED
4 USB connector
5 Connector for power supply to the external axis (Covered when not used)
6 Switch for main power supply
7 Connector for AC power input
8 Connector for robot axis power supply
9 Connector for PP
10 Connector robot system input
11 Optional PCle slots
9 - 63
9.2 Connection of robot specific input signal

A connector to input the robot specific signal is arranged on the front panel of the
YRC1000micro.
For the connections, refer to figure below.
1 (SAFETY) Input connector for 1

specified signal for robot
Pin Assignment of the pin for the Robot Specific Signal Input Connector (SAFETY)
Connector types used when preparing the cable for connecting to the robot specific signal
are listed below.
Item Type Remarks

The YRC1000micro-side 10220-52A2PL Manufactured by Su-
connector mitomo 3M Limited
Cable-side connector 110120-3000PE (Connector body)
10320-52A0-008 (Shell jackscrew
type)
10320-52F0-008 (Shell single action
lock type)
Upon shipment of the YRC1000micro, a dummy connector which short-circuits each

specific signal is attached.
To input a specific signal, prepare the appropriate connector for the signal.
For unused signals, connect a jumper cable as when the YRC1000micro is shipped.
Pin Signal name Dual Details Setting when

No. input shipped
1 Not used
2 SAFF_1+ ○ Safety plug This signal is con-
12 SAFF_1- ○ This is the signal to turn OFF the nected by a jumper-
SERVO power when the gate of cable in the dummy
3 SAFF_2+ ○ connector.
the safety fence opens.
13 SAFF_2- ○
Connect the interlock signal such
as the safety plug, etc. which is
mounted on the gate of the safe-
ty fence.
When the interlock signal is
OPEN, the SERVO power turns
OFF and the SERVO power can-
not be turned ON.
This signal is disabled in the
TEACH mode.
9 - 64
Pin Signal name Dual Details Setting when

No. input shipped
4 EXESP_1+ ○ External emergency stop This signal is con-
14 EXESP_1- ○ This signal is used to connect the nected by a jumper-
emergency stop switch for the cable in the dummy
5 EXESP_2+ ○ connector.
external devices, etc.
15 EXESP_2- ○
When the contact is OPEN, the
SERVO power is turned OFF
and execution of the JOB is
stopped.
While the signal is being input,
the SERVO power cannot be
turned ON
6 ONEN1_1+ ○ Protection Stop Signal This signal is con-
16 ONEN1_1- ○ For safety, connect this signal nected by a jumper-
line when using the function to cable in the dummy
7 ONEN2_2+ ○ connector.
immediately turn OFF the SER-
17 ONEN2_2- ○ VO power to all of the control
groups that are connected to the
robot controller when the SER-
VO power is turned ON.
When the contact is OPEN, the
SERVO power for the target sys-
tem is turned OFF.
8 Not used
9 ESPOUT_1+ Emergency stop button contact Open
19 ESPOUT_1- output
10 ESPOUT_2+ While using the PP, this signal is

used to output the contact of the
20 ESPOUT_2- emergency stop button.
11 Not used
18 Not used
9 - 65
9.3 Installation of safety plug
CAUTION!
Personal injury and damage to property from electric shock
Upon shipment of the YRC1000micro, this signal is connected by a jumper cable in the
dummy connector.
If the signal is input with the jumper cable connected, it does not function.
 To use the signal, make sure to supply a new connector and then input it.
Connection of safety plug (safety fence) (SAFETY)
1 Robot controller 1 2
2 Front panel 3 4
2
3 Safety SAFF_1+
4 Safety plug (Safety fence) SAFF_1-

12
5 Turn ON/OFF simultaneously 3

5
SAFF_2+
13
SAFF_2-
This is the signal to turn OFF the servo power when the gate of the safety fence opens.
Connect the interlock signal such as the safety plug, etc. which is mounted on the gate of
the safety fence.
When the interlock signal is OPEN, the SERVO power turns OFF and the SERVO power
cannot be turned ON.
As this is disabled in the TEACH mode, make sure that nobody enters inside the safety
fence.
dummy connector.
When operating a robot, prepare a new connector and wire the safety fence signal.
For the unused robot specific input signal, connect a jumper cable as when the
YRC1000micro is shipped.
• Installation of safety plug
The robot must be surrounded by a safeguarding and a door protected by an interlock
function. The door must be opened by the technician to enter and the interlock function
stops the robot operation when the door is open. The safety plug input signal is connected
to the interlock signal from the gate.
9 - 66
9.4 Connection of external emergency stop signal

This signal is used to connect the emergency stop switch for the external devices, etc.
When the contact is OPEN, the SERVO power is turned OFF and execution of the JOB is
stopped.
While the signal is being input, the SERVO power cannot be turned ON
dummy connector.
When operating the robot, prepare a new connector and wire the safety fence signal.
For unused robot specific input signals, connect a jumper cable as when the
YRC1000micro is shipped
Connection for external emergency stop signal (EXESP)
2 Front panel 3 4
3 Safety EXESP_1+
4
4 External emergency stop 14

EXESP_1-
signal
5
5 Turn ON/OFF simultaneous- EXESP_2+
5
ly
15
EXESP_2-
9.5 Connection for SERVO-ON enable input

When dividing a robot system into multiple SERVO systems, it is connected when using a
function which can turn ON/OFF the SERVO power for each system.
When the contact is OPEN, the SERVO power for the target system is turned OFF.
dummy connector.
As this signal is not used as standard specifications, connect a jumper cable to a robot
specific input signal, as when the YRC1000micro is shipped. To use the signal, make sure
to replace the jumper cable by a connector. If the signal is input with the jumper cable
connected, it will not function, which may cause personal injury or equipment damage.
Since the input of SERVO-ON Enable is dualized for safety purposes, connect the SERVO-
ON Enable signal to a signal that turns the dual signals ON and OFF simultaneously.
9 - 67
In case one of the signals is turned ON, an alarm occurs.
Connection for SERVO-On enable signal (ONEN)
2 Front panel 3 4
3 Safety ONEN1_1+
6
4 ON enable 16
ONEN1_1-
5 Turn ON/OFF simultaneous- 5
ly ONEN2_2+
7
17
ONEN2_2-
9 - 68
9.6 External axes overrun
WARNING!
Danger of injury and damage to property if the signal is not working
The settings must be performed to activate the external axis overrun. If not, this function will
not be activated even if the signal is input, thus personal injury and/or equipment damage
may result.
 Before use, make sure to perform the settings of the external axis overrun. After that,
confirm that the overrun alarm occurs by turning OFF the external axis overrun signal.
In units with standard specifications without an external axis, the input signal for
overrunning of an external axis is not used. In this case, a jumper cable is installed (refer to
the following figure).
If an input signal overspeed is necessary for an external axis, connect the signal input
circuits as described below.
For safety reasons, redundant = two-channel switches have to be used for the overrun
signal input for external axes. Connect the signal input of the external axis this way that both
input signals are turned ON or OFF at the same time.
If only one signal is turned ON, the machine safety signal error occurs. For the setting of
the external axis overrun, refer to chapter "Addition of base and Station axes" to the manual
Instructions with the document-no.: E1102000214XX01* and higher.
The figure below shows the factory standard wiring, where all external axes are connected
to the YRC1000micro.
Please refer to the following figure to connect the external axes overrun signal to wire in the
another route. On that occasion, confirm the external axes overrun setting to connect (Refer
to chapter "Addition of base and Station axes" to the manual Instructions with the
document-no.: E1102000214XX01* and higher).
9 - 69
9.7 Emergency stop output
NOTICE
Failure to observe this instruction may result in damage to equipment.
When connect the inductive load, such as the relay, with the output circuit, use of the built-
in protective circuit for the surge suppressor or connect the flyback diode in parallel to the
inductive load to suppress the surge voltage.
 Do not use the emergency stop button with 24 V AC, 250 mA or more.
This signal is used to output the emergency button contact when the PP is used.
This emergency stop output is always enabled regardless of whether the YRC1000micro
power supply is ON/OFF (State output signal: Normal Close contact).
Outputs the contact output terminals for the emergency stop button on the programming
pendant.
These contact outputs are always valid regardless of the YRC1000micro main power
supply status ON or OFF (Status output signal: normally closed contact).
CAUTION!
Damage to property caused by short-circuit
 Do not use the emergency stop button with a voltage of 24 V AC, 0.1 A or more.
 When connect the inductive load, such as the relay, with the output circuit, use of the
built-in protective circuit for the surge suppressor or connect the flyback diode in parallel
to the inductive load to suppress the surge voltage.
Connection for SERVO-On enable signal (ONEN)
1 PP (optional) 1
2 Emergency stop button
2 3 4
3 Robot controller 5
9
6
ESPOUT_1+
4 Front panel 19
ESPOUT_1-
5 Safety 10
ESPOUT_2+
6 External emergency stop output 20

ESPOUT_2-
signal
9.8 Connection of GP I/O

The Direct-in signal is equipped on the front panel of the YRC1000micro as its standard
specification.
This signal is used when inputting a highly responsive signal for digital I/O (robot GP I/O)
for search function, etc.
• GP I/O point: 8 inputs and 8 outputs
• Direct-in point: 4 inputs
9 - 70
Position of GP I/O connector
1 GP IO connector (GPIO) 1
The GP I/O signal is used mainly in the motion JOB of the robot and used as a timing signal
between the robot and peripheral devices.
Connector types used when preparing a cable for connecting to the GP I/O and Direct-in
signal are listed below.
Item Type Remarks

The YRC1000micro- 10250-52A2PL Manufactured by Su-
side connector mitomo 3M Limited
Cable side connector 10150-3000PE (Connector body)
10350-52A0-008 (Shell jackscrew type)
10350-52F0-008 (Shell single-action
lock type)
For the details of the pin assignment, refer to figure “Position of GP I/O Connector”
above
NOTICE
When connecting an inductive load to the output circuit, connect a flyback (snubber) diode
in parallel to the inductive load to suppress the surge voltage. Not using the flyback
(snubber) diode may damage the output circuit.
When connecting the load with a large inrush current such as the lamp, connect the current
limiting resistor in series to the load, so that the output current does not exceed its maximum
value. Exceeding the maximum output current value may damage the output circuit.
1 General purpose I/O board 1

2 Inductive load
+24VU
3 Flyback diode
4 Lamp 2
5 Current limiting resistor
3
5 4
024VU
Refer to Fig. 9-1: "Connection diagram of GPIO connector (PNP)" and Fig. 9-2:
"Connection diagram of GPIO connector (NPN)"
9 - 71
Example of the SERVO ON sequence circuit from the external device
Only the rising edge of the SERVO ON signal is valid. This signal turns ON the robot SER-
VO power supply. The set and reset timings are shown in the following.
1 SERVO ON PB 1 2 3
2 SERVO ON confirmation X2 X1
3 SERVO ON command
X1
4 SERVO-ON power ON X3
5 SERVO ON confirmation
4 5
X2
(30011)
PL
Note:
Number in ( ) means output signal number assigned to ASF30.
PL: Pilot lamp
6 YRC1000micro 6
7 General purpose I/O board 7
GPIO
8 External SERVO ON
9 SERVO-ON power ON 3 X1
9 8
1 Output while SERVO ON 31 (20014)
0
9 +24VU
15
X3
37
10
(30011)
Note: This circuit is example in case of ASF30.
9 - 72
Example of start sequence circuit from the external device
Only the rising edge of the external start signal is valid. This signal starts the robot. Set
this signal with the interlock configuration which determines whether operation can be
started. The playback signal (RUNNING) confirms that the robot is actually moving.
2 3 4 5 7
1 (30016) (30013) X5 6 8 㻳㻼㻵㻻
(30011)
㼄㻠㼄㻠 9
㻮㻝
(20010)
㼄㻟㻮㻣
12 X6 (30010) 5 11
㻜㻞㻠㼂㼁
㻗㻞㻠㼂㼁
㼄㻡㻮㻝㻤
㼄㻢
㻮㻤 (30010)
㻼㻸
10
Note:
Number in ( ) means output signal number assigned to ASF30.
PL: Pilot lamp
This circuit is example in case of ASF30
1 Run PB 7 Robot controller
2 While SERVO-ON 8 External Start Command
3 Selects PLAY mode 9 External start input
4 Alarm/Error occurring 10 Ongoing output
5 Running confirmation 11 Running, etc.
6 Start (Command) 12 Running X6
9 - 73
YRC1000 micro
1
JANCD-ASF31-1E
2
DC24V
3 7mA MAX GPIO connector
Logical Connector Name Signal

number number
1 Direct-in common
2 Direct-in 1
27 Direct-in 2
GND
3 Direct-in 3
28 Direct-in 4
DC24V
3 6.9mA MAX
4
5
6 Input common
20010 7 External start IN
20011 32 External hold IN
GND
20012 8 Call master job IN
20013 33 Alarm/error reset IN
20014 9 External servo ON IN
20015 34 Select play mode IN
20016 10 Select teach mode IN
20017 35 OUT08 IN
+24VU 14
GND
18
11 +24VU
36 +24VU
DC24V 15 +24VU
3 100mA MAX 22 +24VU
25 +24VU
Buffer
40 +24VU
47 +24VU
30010 12 Running OUT
30011 37 Servo is ON OUT
30012 13 Top of master job OUT
30013 38 Alarm/error occurred OUT
30014 16 Battery alarm OUT
30015 41 Remote mode selected OUT
30016 17 Play mode/teach mode selected OUT
30017 42 OT08 OUT
024V 19
20
26 024VU
31 024VU
21
23
24
29
30
39
43
44
45
46
48
CN11 49
50
JANCD-APW30-E
4
CN5A
+24V
024V
5
Fig. 9-1: Connection diagram of GPIO connector (PNP)

* Cannot be connected to an external power supply.
1 Robot controller 4 Interface board (JANCD-APW30-E)

2 Safety Board (JANCD-ASF31-1E) 5 Internal power supply
3 For each point
9 - 74
YRC1000 micro
1
JANCD-ASF30-1E
2
DC24V
3 7mA MAX
GPIO
Logical Connector Name Signal

Number Pin No.
1 Direct in common
2 Direct in 1
27 Direct in 2
GND 3 Direct in 3
28 Direct in 4
3 DC24V
6.9 mA MAX
4
5
6 Input common 3_24V
20010 7 EXTERNAL START IN
20011 32 EXTERNAL HOLD IN
GND
20012 8 CALL MASTER JOB IN
20013 33 ALARM/ERROR RESET IN
20014 9 EXTERNAL SERVO ON IN
20015 34 SELECT PLAY MODE IN
20016 10 SELECT TEACH MODE IN
20017 35 PLAY MODE ENABLE SIGNAL SELECTION IN
+24VU 14
GND
18
11 +24VU
36 +24VU
15 +24VU
22 +24VU
25 +24VU
DC24V
3 100 mA MAX 40 +24VU
47 +24VU
Buffer 30010 12 RUNNING OUT
30011 37 SERVO IS ON OUT
30012 13 TOP OF MASTER JOB OUT
30013 38 ALARM/ERROR OCCURRED OUT
30014 16 BATTERY ALARM OUT
30015 41 REMOTE MODE SELECTED OUT
30016 17 PLAY/TEACH MODE LSELECTED OUT
30017 42 OT08 OUT
19
20
26 024VU
31 024VU
024V 024V 21
23
24
29
30
39
43
44
45
46
48
CN11 49
50
JANCD-APW30-E
CN5A
4
+24V
024V
5
Fig. 9-2: Connection diagram of GPIO connector (NPN)

* Cannot be connected to an external power supply.
1 Robot controller 4 Interface board (JANCD-APW30-E)

2 Safety Board (JANCD-ASF30-1E) 5 Internal power supply
3 For each point
9 - 75
9.9 Assignment of universal I/O signals
Logical Input name/Function

number
20010 EXTERNAL START
Functions the same as the [START] button in the programming pendant.
Only the rising edge of the signal is valid. It starts robot operation (play-
back). This signal is invalid if external start is prohibited from the playback
condition display.
20011 EXTERNAL HOLD
The hold lamp turns on and the signal “HOLDING (50071)” turns ON while
this signal is ON. Depending on the setting, the status of robot can be
“HOLDING” while this signal is OFF.
20012 CALL MASTER JOB
Only the rising edge of the signal is valid. It calls up the top of the robot pro-
gram, that is the top of the master JOB1. This signal is invalid during play-
back, during teach-lock and when play master or call is prohibited (set from
the playback operation condition display).
20013 ALARM/ERROR RESET
After an alarm or error has occurred and the cause been corrected, this sig-
nal resets the alarm or error.
20014 EXTERNAL SERVO ON
Only the rising edge of this signal is valid. This signal turns ON the SERVO
power.
Use this signal to turn ON the SERVO power from an external device.
20015 SELECT PLAY MODE
The PLAY mode is selected when the mode key on the programming pen-
dant is set to REMOTE. Only the rising edge of the signal is valid. When
this selection signal assigned concurrently with other mode selection sig-
nal, the TEACH mode is selected on a priority basis. The signal is invalid
while EXTERNAL MODE SWITCH is prohibited.
20016 SELECT TEACH MODE
The TEACH mode is selected when the mode key of the programming pen-
dant is set to REMOTE. The other mode selection is unavailable when this
signal is ON; the signal is selected by priority even when the other selection
signal is ON, enabling the TEACH mode selection.
20017 PLAY MODE ENABLE SIGNAL SELECTION
To change the operation mode from the TEACH mode to the PLAY mode,
change the mode switch of the programming pendant from TEACH to PLAY
or REMOTE and input the PLAY mode enable signal from an external de-
vice.
If the mode switch of the programming pendant is set to REMOTE and the
TEACH mode is selected, select the PLAY mode and input the PLAY mode
enable signal by using an external device to change the operation mode to
the PLAY mode.
For details refer to chapter
1. A master job is a JOB (program) which can be called by CALL MASTER JOB. Other functions are the same as
for normal JOBs. Normally, the parent JOB, which manages the child JOBs called up immediately after the power
is turned ON, is set as the master JOB.
9 - 76
Logical Input name/Function

number
30010 RUNNING
This signal signifies that the job is running. (Signifies that the JOB is run-
ning, system status is waiting reserved start, or test run is running.) This
signal status is the same status as [START] in the programming pendant.
30011 SERVO IS ON
This signal signifies that the servo power is turned ON, internal processing
such as current position creation is complete, and the system is able to re-
ceive the START command. This signal turns OFF when the SERVO power
supply turns OFF. It can be used for YRC1000micro status diagnosis for an
external start.
30012 TOP OF MASTER JOB
This signal signifies that the execution position is the top of the master JOB.
This signal can be used to confirm that the master job has been called1.
30013 ALARM/ERROR OCCURRED
This signal signifies that an alarm or an error occurred. If a major error oc-
curs, this signal remains ON until the main power is turned OFF.
30014 BATTERY ALARM
This signal turns ON to notify that the battery requires replacing when the
voltage drops from the battery for backup memory of the encoder. Major
problems may result if memory data is lost because of an expired battery.
It is recommended to avoid these problems by using this signal as a warn-
ing signal.
30015 REMOTE MODE SELECTED
This signal notifies the current mode setting. These signals are synchro-
nized with the mode select switch in the programming pendant. The signal
corresponding to the selected mode turns ON.
30016 PLAY/TEACH MODE SELECTED
This signal notifies the current mode setting. These signals are synchro-
nized with the mode select switch in the programming pendant. The signal
corresponding to the selected mode turns ON.
1. This signal is not output during operation.
9 - 77
YASKAWA GRUPPE DISTRIBUTORS
AT YASKAWA Austria BG ARAMET ROBOTICS Ltd.
Schwechat/Wien Yambol +359-885 317 294
+43(0)1-707-9324-15
Kammarton Bulgaria Ltd.
CZ YASKAWA Czech s.r.o. Sofia +359-02-926-6060
Rudná u Prahy +420-257-941-718
DK Robotcenter Danmark
ES YASKAWA Ibérica, S.L. Løsning +45 7022 2477
Gavà/Barcelona +34-93-6303478
EE RKR Seadmed OÜ
FR YASKAWA France SARL Tallinn/Estonia +372-68-35-235
Le Bignon +33-2-40131919
GR Gizelis Robotics
FI YASKAWA Finland Oy Schimatari Viotias +30-2262057199
Turku +358-(0)-403000600
HU Flexman Robotics Kft
GB YASKAWA UK Ltd. Budapest +36 1 259 0981
Banbury +44-1295-272755
LT Profibus UAB
IT YASKAWA Italia s.r.l. Panevezys +370-45-518575
Torino +39-011-9005833
NO Skala Robotech AS
IL YASKAWA Europe Technology Ltd. Lierstranda +47-32240600
Rosh Ha’ayin +972-3-9004114
PT ROBOPLAN Lda
NL YASKAWA Benelux B.V. Aveiro +351-234 943 900
Eindhoven +31-40-2895500
RO Sam Robotics srl
PL YASKAWA Polska Sp. z o.o. Timisoara +40 720 279 866
Wrocáaw +48-71-7928670
MPL Automation S.R.L.
RU YASKAWA Europe Holding AB Satu Mare +40 261 750 741
Moskva +46-480-417-800
NORMANDIA S.R.L.
SE YASKAWA Nordic AB Bra‫܈‬ov +40 268 549 236
Torsås +46-480-417-800
SI YASKAWA Slovenia
Ribnica +386-1-8372-410
TR YASKAWA Turkey Elektrik
Ticaret Ltd. Sti.
østanbul +90-216-5273450
ZA YASKAWA Southern Africa (PTY) Ltd
Johannesburg +27-11-6083182
YASKAWA Headquarter YASKAWA ACADEMY and All drawing dimension in mm.

Subject to technical changes and errors excepted.
sales office Frankfurt
YASKAWA Europe GmbH Dimensional data can be requested at robotics@yaskawa.eu.com.
Robotics Division YASKAWA Europe GmbH
Yaskawastraße 1 Robotics Division
85391 Allershausen Hauptstraße 185
Tel. +49 (0) 8166/90-0 65760 Eschborn
Fax +49 (0) 8166/90-103 Tel. +49 (0) 6196/77725-0
Fax +49 (0) 6196/77725-39
robotics@yaskawa.eu.com
www.yaskawa.eu.com

Install and Wiring: User Manual

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ROBOTICS

Install and Wiring

5 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.6 Check battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8 Robot controller specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

9 Description of Units and Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.1 Notes for safe operation

1.2 Frequently used terms

1.3 Target group

1.4 Intended use

1.5 Improper use

1.6 About this manual

Programming pendant Manual designation

Description of the operation procedure

1.8 Authorized representative

1 Emergency stop button

Fig. 2-1: SERVO ON" LED

Fig. 2-2: Emergency stop button

Fig. 2-3: CE mark

2.1 YASKAWA manual list

• Never sit against the robot control.

2.2 MOTOMAN Safety

• Emergency stop SW 500 times/year

2.3 Safety during installation and wiring

DANGER due to electric current!

Required installation planning

2.3.1 Maintenance work

Space for maintenance

Installation space for YRC1000micro in horizontal position

Installation space for YRC1000micro in vertical position

2.3.2 Fixing the robot controller

Fixing the robot controller

18.8 235 26.2 26.2 235 18.8

2.3.3 Safety in the work area

2.3.4 Operating safety

2.3.4.1 External safety

2.3.4.2 Emergency stop function

3.1 Checking the scope of delivery

3.2 Position type plate

Fig. 3-1: Position type plate collaborative robot (example)

YASKAWA ELECTRIC CORPORATION

YASKAWA ELECTRIC CORPORATION

4.1 Transporting method

4.1.1 Using a lifting truck

5 Assembly and installation

5.1 Protection measures

5.2 Ambient conditions and installation location

Place of installation (above sea Maximum ambient temperature

2. At a height of more than 1000 m, the ambient temperature is 1% per 100 m.

6.1 Power supply

DANGER due to electric current!

6.1.1 3-phase power supply

1 3-phase power supply

6.1.2 Noise filter installation

1 3-phase 200V/220VAC 50/60Hz

6.1.3 Leakage breaker installation

Connection of the Leakage Breaker

1 3-phase 200/220 VAC at 50/60 Hz 2 3

6.1.4 Installation of primary power supply breaker

Install the primary power supply breaker as shown.

Controller type Cable size1 Capacity of Robot Power ca-

6.2 Connection methods