ROBOTICS

Install and Wiring ANSI

Robot controller

User manual
Created on: 2023-02
Revision: 02
Author: DIE/WOE
Document number: E1102000315GB02

Modifications made:
Rev. 01: Document created from the original RE-CTO-A221.18 (2020-09)
Rev. 02: Revised the document

© Copyright 2023
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Personal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Safety during installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.3 Fixing the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.4 Safety in the work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.5 Operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Product confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Position type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Transporting method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1.2 Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1.3 Using a lifting truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 Protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Ambient conditions and installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Installation options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1.1 3-phase power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.2 Leakage breaker installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1.3 Installation of primary power supply breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.2 Connection methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2.1 Connection to primary power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2.2 Connection of the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2.4 I/O cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3
Table of contents

7 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7.1 Regular inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2 Inspection of robot controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2.1 Checking If the doors are firmly closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2.2 Check for gaps or damage to the sealed construction. . . . . . . . . . . . . . . . . . . . . 54
7.3 Cooling fan inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.4 Emergency Stop Button Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.5 Inspection of the enabling switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.6 Check battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.7 Check the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.8 Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.9 Check the phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

8 Robot controller specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.1 Specification list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2 Function list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.3 Programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.4 Device configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

9 Description of Units and Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

9.1 Power Supply Contactor Unit (JZRCR-APU0□-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.2 Control Power Supply Unit (CSRA-CPS01K□) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.3 Converter (CSRA-CV□□□0□A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.3.1 Converter (Small-capacity model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.3.2 Converter (Medium/Large-capacity model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.4 Inverter Unit (CSRA-SDA□□H01A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.4.1 Inverter unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.4.2 Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.4.3 SERVO control board (CSRA-SDCA01AA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.5 Safety circuit board (JANCD-ASF01-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.6 Safety Terminal Block Board (IM-YE250/5-80P). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.7 Board (machine safety). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.7.1 Connection tool shock sensor (SHOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.8 WAGO Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.9 Safety plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.10 Installation of safety plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.11 Connection of external emergency stop signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.12 SYSRUN signal output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.13 Connection for SERVO-ON enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.14 External axes overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.15 Emergency stop output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
9.16 General purpose safety input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.17 General purpose safety output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.18 Connection Direct-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.19 General purpose input (SERVO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
9.20 General purpose I/O board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.21 Assignment of universal I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4
Table of contents

9.21.1 ARC welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

9.21.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.21.3 GP application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.21.4 Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
9.21.5 List of device configuration depending on model . . . . . . . . . . . . . . . . . . . . . . . . 147

5
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 -6
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 the robot cable.
The terms are designated as follows in this manual:

Term Description
Control Robot control
Industrial robot Robot
Programming pendant / teach box Programming pendant or PP
Supplying cable between robot and robot 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

1 -7
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
Note:
According to the international 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 -8
General

1.5 Improper use

Any applications that deviate from the proper use are considered to impermissible misuse,
including:
• Transport of persons and animals
• Use as ascending aid
• Usage outside of the permissible operating limits
• Overload
• Use without protective equipment
Note:
Modifications to the robot, e.g. drilling holes or similar modifications, can damage parts.
This will be regarded as improper use (i.e. use that deviates from the intended use) and will
lead to loss of warranty and liability claims as well as loss of the declaration of incorporation.

CAUTION!
The robot system is a partly completed machine.
The robot system may be commissioned only if it has been determined that the partly
completed or complete machine into which the robot system is to be installed complies with
the following:
 It corresponds with all relevant standards.
 It corresponds with the state of the art.

1 -9
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 E1102000214XX01 and higher and maintenance
E1102000215XX01 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}.

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
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 and robot controller

1 Emergency stop button

1

Danger of death or injury from crushing

If the emergency stop button is not working properly, the robot cannot be stopped in the
event of an emergency.
• The robot should not be used if the emergency stop button is not working.
• Before operating the robot, check the function of the EMERGENCY STOP button. The
SERVO power must go off immediately when the EMERGENCY STOP button is
pressed on the programming pendant (see Fig. 2-2: "Emergency stop button").
• When the servo power is turned off, the "SERVO ON" LED on the PP goes out (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

2 - 12
Safety

Danger of death or injury from crushing

Before you release the emergency stop button, note the following.
• Make sure there is no one within the maximum operating range of the robot.
• Clear the cell of all items with which the robot could collide.
• Only then should you switch on the SERVO power by pressing the enabling switch on
the PP.
Danger of death or injury from crushing
If anyone enters the working area of the robot during operation or any problems occur,
always press the EMERGENCY STOP button immediately. It is located on the PP and on
the front panel of the robot controller (see Fig. "Programming Pendant and robot
controller").
Take the following precautions when performing teaching operations within the robot’s
operating range:
• Position yourself in front of the robot whenever possible.
• Always follow the prescribed operating procedure (see the YRC1000 instructions
manual (document no.: E1102000214XX01* or higher) on robot control as well as the
operating instructions on general operations manual (document no.:
E1102000220XX01 or higher)).
• There must be a free space into which the operator can retreat in the event of an
emergency.
The following test steps absolutely must be performed before you teach the robot. Deal with
any problems you find immediately and make sure that any other necessary steps have
been taken.
• Check for any problems in the movements of the robot.
• Check that the connectors are well secured and none of the cables are damaged.
• Hang the PP back on the robot controller after use.
• Make sure that the key for the mode selector (teach/automatic) on the PP is kept by a
competent person who has been specially trained by us.
• The key may only be inserted into the key switch of the PP during teaching. After
teaching, it must be immediately removed and kept in a safe place.

2 - 13
Safety

2.1 For your safety

In general, for robots apply different requirements than 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!
Observe international standard ISO 10218-1 for a safe operation of the robot or robot
equipment.
Other pertinent provisions are as follows:
– Occupational safety and health act in the U.S.
Increase the efficiency of your safety management system by determining authorised
employees and safety managers and performing regular training.

NOTICE
In reference to international standard ISO 10218-1, an operator of a robot system must be
trained before using the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For more detailed information on the training
programme, please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA
branch office.

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 (E1102000214XX01* or higher).
• Maintenance (E1102000215XX01* or higher
• Install and Wiring (E1102000216XX01* or higher).
• Alarm list (E1102000217XX01* or higher).
• SUPPLEMENTARY INSTRUCTIONS (E1102000275XX02* or higher).
• GENERAL OPERATOR'S MANUAL (E1102000220XX01 or higher).
• Operating and maintenance instructions for the specific robot type.
* "XX" is the language of the document.

2 - 14
Safety

2.2 Personal protection

The entire working area of the robot is potentially dangerous. The following staff must work
with appropriate preparation and subject to the maxim "Safety First" to ensure the safety
of all.
• Safety management
• Assembly staff
• Operating staff
• Maintenance staff

DANGER!
Death by electric shock; serious injury from fire hazard;
Avoid dangerous actions in the area where the robot is installed. Be sure to take safety
precautions
 Unauthorised persons should not have access to the robot.
 Unauthorised persons should not have access to the peripheral equipment.
 Put up signs in the respective working area, such as "Highly flammable","High
voltage","Stop" and "No unauthorized access" .

WARNING!
There is a risk of injury if there is contact with the robot or peripheral equipment.
Strictly observe the following items:
 Always wear approved work clothes (no loose-fitting clothes).
 Do not wear gloves when operating the robot.
 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.
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
• External enable SW input
• SERVO power enable input
• Overrun input (robot/external axis)
• GP safety input (including external enable SW input)
• Safety logic circuit
These safety functions conform to the following safety standards:
• EN ISO 13849-1:2015 Cat.3 / PL e
• EN 62061 (IEC 61508) SIL CL3
The use frequency of each switch for safety functions is assumed as below:

• Emergency stop SW 500 times/year

• Enable SW (programming pendant) 2000 times/year
• External enable SW 2000 times/year

2 - 16
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. 2-3: 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 47.

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.

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.

2 - 17
Safety

1 3
2

3 3

5
3
Fig. 2-4: Required installation planning

1 Safeguarding
2 Robot controller door
3 Safety distance with respect to the stopping time of the robot type (min.
1000 mm)
4 Maximum P-point range of the robot
5 Maximum working area of the robot including tool or workpiece

2.3.1 Using a crane

Using a crane

1 Wire cable
2 4 x M16 eye bolts
1
>= 45°
2

2.3.2 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 - 18
Safety

600

300
600

427

598 427 300

584
690

490
1

2 3
Fig. 2-5: Space for maintenance

1 Door 3 External dimensions YRC1000

2 Maintenance area All dimensions in mm

2.3.3 Fixing the robot controller

WARNING!
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 robots safety enclosure.
 Install the programing pendant outside the safety fence around the robot.

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.

2 - 19
Safety

40
1

60
6

40
2
30
50

3
Fig. 2-6: Fixing the robot controller

1 2 holes Ø 14 2 Tapped holes to M12 screws

3 Screws for the robot controller M12 x 20 (Maximum screw-in depth 14 mm, tightening
torque 45 Nm), recommended plate thickness 6 mm

2.3.4 Safety in the work area

WARNING!
Risk of injury from movements of the robot
• When the power supplies of the robot and the YRC1000 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.

2 - 20
Safety

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.

2.3.5 Operating safety

DANGER!
Death and fire hazard 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 of the robot
controller is turned off.
 Lock the switch, and display a warning sign.
 Never exceed the rated capacity of the robot (the robot capacity can be found in the
chapter "Technical Data" of the robot manual).

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.
Take the following precautions when performing teaching operations within the robot’s
operating range:
 Always view the robot from the front.
 Always follow the prescribed operating steps.
 Always have an escape plan in mind in case the robot comes toward you unexpectedly.
 There must be a free space to which the operator can retreat in the event of an
emergency.

Fig. 2-7: Secure the robot controller with a padlock

1 "OFF" position 2 Padlock

2 - 21
Safety

2.3.5.1 External safety

The robot and its auxiliary equipment must be surrounded by a safety guard. 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 first operating the robot, the machine must fulfil the “essential health and safety
requirements”.

2.3.5.2 Emergency stop function

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 - 22
Delivery

3 Delivery

3.1 Checking the scope of delivery

The standard delivery includes the following items:

1 2
3

䠮䡋䠾䡋䡐
䠮 䠾 䠩 READ 䡈
䠩䠽䡊䡑䠽䡈
ONLY MEMORY

5 'DWD 4
䠮䡋䠾䡋䡐
䠮 䠾 䠩䠽䡊䡑䠽䡈
䠩 䡈
READ ONLY MEMORY

Fig. 3-1: Scope of delivery

1 Programming pendant
2 Robot controller
3 Robot
4 Cable
5 The present assembly instructions

3 - 23
Delivery

3.2 Product confirmation

Main module options
• Socket with angled connector plate (height = 250 mm)

• Cabinet with or without angled connector plate, standard height (height = 499 mm).

• Cabinet with angled connector plate, double height (height = 989 mm).

3 - 24
Delivery

Additional options
• Drawer for socket

• Mounting plate for I/O unit in socket.

• Swing frame for standard cabinet (height = 499 mm).

Swing frame (high) for double height cabinet (height = 989 mm)

3 - 25
Delivery

• Hood for CEE-connector

• Covers

3 - 26
Delivery

3.3 Position type plate

Note:
Verify whether the serial number of the robot, the robot controller and the programming
pendant match with the delivery note. Otherwise, contact your YASKAWA representative.
The serial number can be found on the type plate as shown below.

No.

Fig. 3-2: Position type plate

3 - 27
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.

4.1 Transporting method

• Check that the eyebolts are securely fastened.
• The robot controller weighs approximately Small capacity model approx. 70 kg
Medium/Large capacity model approx. 85 kg. Use load-carrying devices strong enough
to withstand the weight.

4.1.1 Using a crane

Adequate load handling devices must be used to transport the robot controller. Make sure
that the robot controller is lifted as shown in the diagram "Transport by crane" below.

Using a crane

1 Wire cable
2 4 x M16 eye bolts
1
>= 45°
2

4 - 28
Transportation

4.1.2 Using a forklift

If the robot controller is to be transported by forklift, it must be secured with safety belts, as
shown in the figure "Transport by forklift" below. Make sure that the forklift and the
transportation route have sufficient bearing capacity.
Always take due care when transporting the robot controller.

Using a forklift

1 Protective padding
2 Safety rope
3 Palette
4 Forklift tines
1
2

3
4

4 - 29
Transportation

4.1.3 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.

Fig. 4-1: Using a lifting truck

4 - 30
Assembly and installation

5 Assembly and installation

CAUTION!
Personal and property damage
The following precautions must be taken:
 Check that the robot system is complete and not damaged.
 Do not put into operation a robot system that is damaged or incomplete.
 Check that all transport securing devices and transport screws have been removed.

5.1 Protection measures

DANGER!
Personal injury and damage to property
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
 Signs
 EMERGENCY STOP button
 Display elements

NOTICE
Operator's responsibility
The operator of a robot or robot system must ensure that all relevant specifications,
requirements and standards for safe operation are met.
These standards include the Occupational safety and health act in the U.S and the ISO
10218-1 and ISO 10218-2 standards.
The ISO 10218-1 and ISO 10218-2 standards 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 - 31
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.
• Install the controller in a location where you can easily see whether the door is open.
• It is recommended that there is clearance of at least 500 mm around the controller to
allow access for maintenance work. The minimum clearance at the rear of the controller
is 200 mm to ensure proper cooling.

Place of installation (above sea Maximum ambient temperature

level)
Up to 1000 m1 0 °C to 45 °C
2
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.

5.3 Installation options

WARNING!
Personal injury and damage to property
The following precautions must be taken.
 Keep the robot controller lifted by the crane until the robot controller is stacked and fixed
securely.

It is possible to stack the YRC1000 controllers.

Follow the procedures below when stacking the YRC1000 controllers.
1. Remove the four eyebolts (4 places) on the top of the YRC1000 to be stacked lower
level.

1 4 x 12 eyebolts 1

5 - 32
Assembly and installation

2. Lift the controller by using the crane, and stack the controllers. Refer to chapter 4.1.1
"Using a crane"”, when using the crane.

A A

3. After stacking the controllers, remove the grommets inside (A-A section “a” part) of the
upper controller. Install the M12 x 35 bolts, spring washers and washers for temporally.

1 2 x Grommet
1 5
2 "a" enlarged view
6
3 Robot controller (upper)
3 7
4 Robot controller (lower)
5 M12 x 35 4
2
6 Spring washer
7 Washer
8 A-A Section view
All dimensions in mm.
a a
8

5 - 33
Assembly and installation

4. Remove the back board and the plate on the back of the upper controller. When remove
the back board, remove the connector cover which fixed with the back board together.
A fixing screw for the back board is also on the inside of connector cover. Refer to the
following figure and remove the fixing screw.

NOTICE
Damage to the cables
 Removing the back board from the robot controller must be performed by two operators,
and make sure that one of operators keep holding the removed back board with due
care to prevent damage to the internal cables.

1 2

5
6

7
5 5 5
8

1 Backboard 5 Fixing screws for back board and connec-

2 Plate tor cover (4 screws)

3 Connector cover 6 Fixing screw for back board of inside con-

nector cover (1 screws)
4 Fixing screws for back board (8
screws) 7 Details of fixing screws on back board
8 Back view
5. After stacking the controllers, remove the grommets inside (A-A section “b” part) of the
upper controller. Install the M12 x 35 screws, spring washers and washers for
temporally.

1 2 x Grommet 1 5
2 "b" enlarged view 6
3 Robot controller (upper) 3 7
4 Robot controller (lower)
5 M12 x 35 4
6 Spring washer 2
b b
7 Washer
8 A-A Section view
All dimensions in mm
8
6. After confirming the stacking the controllers, tighten the temporally 4 x M12 bolts firmly
(a, b part, tightening torque: 35 Nm).

5 - 34
Assembly and installation

7. Reinstall the removed back board and plate at procedure No.4.

8. Remove the wire lifting.

5.4 Installation example

40
1
60
6

40

2
30
50

3
Fig. 5-1: Fixing the robot controller

1 2 holes Ø 14 2 Tapped holes to M12 screws

3 Screws for the robot controller M12 x 20 (Maximum screw-in depth 14 mm, tightening
torque 45 Nm), recommended plate thickness 6 mm

5 - 35
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.

6 - 36
Wiring

1 2 3

1 Piping
2 Cable duct
3 Cable

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 - 37
Wiring

6.1.1 3-phase power supply

The three-phase power supply consists of 3-phase 380-440VAC 50/60Hz (neutral

earthing).

YRC1000 type Power supply

For Japan ERAR-1000-xxxxxxx-A0x 3-phase 200 to 240 VAC (+10% to -15%)
at 50/60 Hz (±2%)
For Asia ERAR-1000-xxxxxxx-A1x 3-phase 380 to 440 VAC (+10% to -15%)
For Europe ERAR-1000-xxxxxxx-E1x at 50/60 Hz (±2%) (neutral earthing)

For North ERAR-1000-xxxxxxx-B1x 3-phase 380 to 480 VAC (+10% to -15%)

America 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 YRC1000.

2
3 4
5
1 6

1 3-phase power supply

2 Robot controller
3 Breaker
4 Noise filter (only for Europe)
5 Contactor (1KM)
6 To converter
7 Fuse
8 To control power supply unit

6 - 38
Wiring

6.1.2 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 YRC1000 inverter. Leakage breakers
which cannot handle high frequencies may malfunction.

Maker Model
Mitsubishi Electric Co., Ltd. NV class (manufactured since 1988)
Fuji Electric Co., Ltd. ED, SG Series (manufactured since 1984), or EW Se-
ries

In order to avoid malfunction, select a leakage breaker with a sensitivity current of minimum
30 mA.
Even with a leakage breaker installed, there is still a possibility of some high frequency
current leakage from the YRC1000. However, this current leakage presents no safety risks.

1 3-phase power supply Connection of the Leakage Breaker

2 Leakage Breaker
2 3
3 Robot controller 5
4 Breaker 1 7
5 Contactor (1KM) 4 6
6 Fuse
8
7 To converter
8 To controller power supply unit

6 - 39
Wiring

6.1.3 Installation of primary power supply breaker

Install the primary power supply breaker as shown.

Install the breaker in range of 0.6 m to 1.9 m or less from the work surface for easy
operation.

1 1 1

2 3 4

1 Breaker (protector)
2 Robot controller
3 Controller for positioner
4 Power supply

6 - 40
Wiring

Robot Power ca- Cable size (terminal size) Breaker capacity in ro-
pacity (For cabtyre cable (three bot controller (A)
(kVA) cores))
GP7 1.0 AWG12 (M8) 15
AR900 1.0 AWG12 (M8) 15
GP8 1.0 AWG12 (M8) 15
AR700 1.0 AWG12 (M8) 15
GP12 1.5 AWG12 (M8) 15
AR1440 1.5 AWG12 (M8) 15
AR1440E 1.5 AWG12 (M8) 15
GP25 2.0 AWG12 (M8) 15
AR1730 2.0 AWG12 (M8) 15
GP25-12 2.0 AWG12 (M8) 15
AR2010 2.0 AWG12 (M8) 15
GP20HL 3.5 AWG10 (M8) 20
AR3120 3.5 AWG10 (M8) 20
GP50 4.5 AWG10 (M8) 20
GP35L 4.5 AWG10 (M8) 20
GP88 4.0 AWG10 (M8) 20
SP80 4.0 AWG10 (M8) 20
GP110 5.0 AWG10 (M8) 20
SP100 5.0 AWG10 (M8) 20
GP120 5.0 AWG10 (M8) 20
SP110 5.0 AWG10 (M8) 20
SP130 5.0 AWG10 (M8) 20
GP180 5.0 AWG10 (M8) 20
SP165 5.0 AWG10 (M8) 20
GP180-120 5.0 AWG10 (M8) 20
SP165-105 5.0 AWG10 (M8) 20
GP200S 5.0 AWG10 (M8) 20
GP215 5.0 AWG10 (M8) 20
GP225 5.5 AWG10 (M8) 20
SP210 5.5 AWG10 (M8) 20
GP250 5.0 AWG10 (M8) 20
SP235 5.0 AWG10 (M8) 20
GP280 5.0 AWG10 (M8) 20
GP165R 5.0 AWG10 (M8) 20
SP150R 5.0 AWG10 (M8) 20
GP200R 5.0 AWG10 (M8) 20
SP185R 5.0 AWG10 (M8) 20
SP110H 5.0 AWG10 (M8) 20
SP180H 5.0 AWG10 (M8) 20

6 - 41
Wiring

Robot Power ca- Cable size (terminal size) Breaker capacity in ro-
pacity (For cabtyre cable (three bot controller (A)
(kVA) cores))
GP180H-110 5.0 AWG10 (M8) 20
GP225H 5.0 AWG10 (M8) 20
SP225H 5.0 AWG10 (M8) 20
GP110B 5.0 AWG10 (M8) 20
SP100B 5.0 AWG10 (M8) 20
PH130RF 7.5 AWG10 (M8) 20
PH130F 7.5 AWG10 (M8) 20
GP400 7.0 AWG10 (M8) 20
GP600 7.0 AWG10 (M8) 20
GP400R 7.0 AWG10 (M8) 20
PL500 8.0 AWG10 (M8) 20

Tab. 6-1: YRC1000 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 - 42
Wiring

6.2 Connection methods

5
3

2 4
Fig. 6-1: Connecting the robot system

1 Primary power supply cable 4 Robot cable

2 Programming pendant cable 5 Robot
3 Robot controller

6.2.1 Connection to primary power supply

1. Turn the main switch to the OFF position.

Fig. 6-2: Main switch in OFF position

2. Open the front door of the YRC1000.

6 - 43
Wiring

3. Connect the primary power supply cable.

WARNING!
Danger of electric shock and/or mechanical failure
A lose cable connection may lead to ingress of dust, dirt or water.
 Always use a cable clamp to connect the primary power supply cable.
 Make sure to tightly fasten the cable clamp.

Run the primary power supply cable from the cable entrance on left side of the
YRC1000 and fix it firmly with the cable clamp so that it won’t shift or slip out of place.

Fig. 6-3: Fixing the primary power supply cable

4. Pull off the primary cover of the switch which is on the upper left side of the YRC1000.

Fig. 6-4: Pulling off the cover

6 - 44
Wiring

5. Connect a ground wire to reduce noise and prevent electric shock.

Connect the ground wire to the ground terminal (screw) which is on the upper left side
of YRC1000.

1 2

Fig. 6-5: Connecting the ground wire

1 Grounding terminal (M6 screws) 2 Grounding wire

Perform grounding in accordance with all relevant local and national electrical codes.
The size of ground wire must the same as listed on table 6.1 "Power supply"”.

NOTICE
Observe also local regulations.

NOTICE
 The grounding inside the robot controller is factory assembled (maximum grounding
resistance of 0.1 ).

1 Robot controller
2 Maximum earthing resistance of 0.1Ω
2
1

NOTICE
When performing D class grounding (with the ground resistance of 0,1 Ω or less) to operate
the YRC1000, be sure to use the leakage breaker (Refer to chapter 6.1.2 "Leakage breaker
installation").
Don’t connect the grounding wire with the wires for the electric power source, the welder,
etc.
Ground in accordance with all relevant governmental regulations when using metallic ducts,
metallic conduits and cable tray to construct the cable.

6 - 45
Wiring

6. Connect the primary power supply cable.

Fig. 6-6: Connecting the primary power supply cable

7. Install the cover.

Fig. 6-7: Installing the cover

8. Close the YRC1000 door.

6 - 46
Wiring

6.2.2 Connection of the robot controller

DANGER due to electric current!

Danger to life due to electric shock! or mechanical failure
Danger to life and serious injuries caused by high voltage.
 Before wiring the robot cable, make sure the primary power supply is turned OFF.
 Before remove the robot cable, make sure the primary power supply is turned OFF.

Note:
Before you connect the robot cable to the robot, ensure that the plug connection fits
together.

1. Connect the robot cable to the connector on the back side of the robot controller.

Fig. 6-8: Connection of the robot cable

1 Robot cable

6 - 47
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 - 48
Wiring

6.2.3 Connecting the programming pendant

Connect the PP cable to the connection (-X81).

Coding

6.2.4 I/O cable connection

User can choose one I/O cable connection method out of following three ways.

Connect user I/O signal to I/O ter- User connects general-purpose I/O signal through
minal blocks (Material-No. terminal blocks (Material-No. 105507), that are
105507) that are connected to mounted at the back side of the controller’s front
general-purpose I/O board door.
(JANCD-AIO0□-E).
Connect safety plug and system Connect safety plug and system external signal for
external signal for external emer- external emergency stop, etc. to safety terminal
gency stop, etc. to safety terminal block board which is mounted on the back side of the
block board (IM-YE250/5-80P). controller’s front door.
Directly connect user I/O signal to User connects user I/O signal to general-purpose I/O
general-purpose I/O board board (JANCD-AIO0□-E) directly.
(JANCD-AIO0□-E).

1. Remove covering plates from I/O cable openings on the back side panel or the right
side of the controller.

1 3 2

1 Robot controller right side view

2 Robot controller backside view
3 Covering plate for I/O cable opening

6 - 49
Wiring

2. Drill a hole in each cover and run the user I/O cables.
Use a cable gland, etc. to prevent any particles from getting inside the robot controller.
For the drawing length of the cable, refer to the table below since it varies depending
on the connecting part.
3. After running the cable through the I/O cable opening, set the covering plate back to the
original position.

1 3
4
5

1 To user device
2 Cover
3 I/O cable
4 I/O cable drawing length
5 Sealing plug

Connect user I/O signal to I/O Drawing length: Cable terminal process: Unshielded
terminal blocks (Material-No.: 1.5 m (Refer to "Connection Wire with Ro-
105507) connected to gener- bot General-Purpose I/O Connector
al-purpose I/O board (JANCD- (CN306, 307, 308, 309)” in chapter
AIO0□-E). 9.20 "General purpose I/O board").
Connect safety plug and sys- Drawing length: Cable terminal process: Unshielded
tem external signal for exter- 1.3 m (Cable Refer to “Wiring Procedure of the
nal emergency stop, etc. to length for termi- Terminal Block” in chapter: 9.6
safety terminal block board nal processing is "Safety Terminal Block Board (IM-
(IM-YE250/5-80P). included). YE250/5-80P)").
Directly connect user I/O sig- Drawing length: Cable terminal process: Connector
nal to general-purpose I/O 1.0 m (Cable (Refer to "Connection Wire with Ro-
board (JANCD-AIO0□-E). length for termi- bot General-Purpose I/O Connector
nal processing is (CN306, 307, 308, 309)” in chapter
included). 9.20 "General purpose I/O board").

6 - 50
Wiring

4. Draw the user system external signal cable and general-purpose I/O signal cable from
the cable openings to the front part of the controller along its right side.

1 Run the cable through the front side of the robot controller.
5. Run the general-purpose I/O signal cable through the I/O terminal block.
Note:
For the details of the connection, refer to “Connection Wire with Robot General-Purpose
I/O Connector (CN306, 307, 308, 309)” in chapter 9.20 "General purpose I/O board".
6. Run the system external signal cables such as the safety I/O signals through the safety
terminal block board (IM-YE250/5-80P) as shown by the red line in the figure below.
Note:
For the details of the connection, refer to “Wiring Procedure of the Terminal Block” in
chapter 9.6 "Safety Terminal Block Board (IM-YE250/5-80P)".

1
2

1 Fixing on the door side

2 Fixing on the right side

6 - 51
Wiring

7. Run the general-purpose I/O signal cables through the general-purpose I/O board
(JANCD-AIO0□-E) as shown by the red line in the figure below.
Note:
For the details of the connection, refer to “Wiring Procedure of the Terminal Block” in
chapter 9.20 "General purpose I/O board"”

Fix the cable on the door and right side by using the cable ties as shown in the figures.
Note of the following:
• Make sure that no cable tension occurs when the door is fully opened (required cable
length between the fixing part of the door side and the right side: approximately 150
mm).
• Make sure that the cables between the main body of the controller and the door do not
get stuck when the door is closed.

6 - 52
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 YRC1000
• shorten the life of YRC1000
• cause unexpected accidents.

Components Inspection Method Inspection

frequency
Check that the casing is com- Visual inspection Daily
pletely closed and not dam-
Robot controller aged.
Check for gaps or damage to Visual inspection Monthly
the sealed construction.
Backside duct fan Check operation (While power Visual inspection Monthly
ON)
Emergency stop Check operation (While SER- Visual inspection Yearly
button VO ON)
Enable switch Check operation (In TEACH Visual inspection When using
mode)
Battery Confirm battery alarm or mes- When an alarm
sage is displayed or not occurs
Power supply Check power supply voltage is Visual inspection Before using
normal
Circuit breaker Confirm that the lead cables are Visual inspection Before using
lead cables not falling out, loosing or break-
ing. Check the line voltage
YRC1000 cable Check for damage and deterio- Visual inspection Daily
ration of leads
Check the operation Visual inspection Monthly

Heat exchanger No filter clogging and no dust Visual inspection As required (at
least once a
month)

7 - 53
Maintenance and inspection

7.2 Inspection of robot controller

7.2.1 Checking If the doors are firmly closed

The robot controller is hermetically sealed to prevent external air containing oil mist from
getting in. Be sure to keep the robot controller doors fully closed at all times, even when the
controller is not operating.
Prior to this, the power supply must be turned off:
For opening or closing the maintenance doors, use the key provided.
To close, press the door shut and turn the key until you hear a click.
• The YRC1000 has a fully sealed construction, designed to keep external air containing
oil mist out of the YRC1000.
Be sure to keep the YRC1000 doors fully closed at all times, even when the controller
is not operating.
• When opening or closing the door for maintenance, etc., make sure to turn OFF the
main power first. Use a flat-blade screwdriver to properly turn the door lock (one door
lock per door).
When turning the door lock, keep pressing the door and turn the door lock clockwise to
open or counterclockwise to close the door by using the flat-blade screwdriver. When
closing the door, make sure to turn the door lock counterclockwise until the notch of the
door lock becomes horizontal.

1 Main power supply cable

4
2 Main power switch
1 5
3 Door lock 2 4
4 Emergency stop button
5 PP hook 3

7.2.2 Check for gaps or damage to the sealed construction.

• Open the door and check that the seal around the door is undamaged.
• Check that the inside of the controller is not stained badly. If it is, determine the cause,
take measures and immediately clean it.
• Firmly lock each door and check that no excessive gaps exist around the edge of the
door.

7 - 54
Maintenance and inspection

7.3 Cooling fan inspections

Before the Cooling Fan Inspections
In principle, the door must not be opened to prevent electric shock while power is on.
However, it is required to open the door if the cooling fan must be inspected. Exercise
extreme care in this case.

DANGER!
Death from electrical shock, risk of injury and fire due to short circuit
To perform this maintenance operation, the door of the YRC1000 must be opened while the
power is ON.
 Since a high voltage (200 to 480 VAC) is applied inside the YRC1000, do not touch any
unit in the YRC1000.
 Close the door of the YRC1000 immediately after completing a maintenance operation
such as an inspection of the cooling fan.

Inspect the cooling fans as required. A defective fan can cause the YRC1000 to malfunction
because of excessive high temperatures inside if the cooling fans and the heat exchanger
do not operate efficiently.
The heat exchangers normally operate 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.
Visually check the exterior fan of the heat exchanger for dust. If a lot of dust is found on the
fan, wipe off the dust.
<How to Open and Close the Door>
• Door lock mechanism
The reset-open mechanism is provided for the standard specification.The door of the
YRC1000 can be opened only when the OPEN (RESET) operation is performed. Note
that even at the ON or OFF position, the door of the YRC1000 can also be opened by
turning the release by using a screwdriver.

1 Release

1 Screwdriver max. width 5 mm or less

2 Screwdriver tip width 4 mm 1
2

7 - 55
Maintenance and inspection

• Safety device
The interlock lever is provided to prevent the breaker from turning ON while the door
ofthe YRC1000 is open. When the breaker must be turned ON while the dooris open for
maintenance etc., press and hold the interlock lever in the direction of the arrow and
turn the main power switch to ON.

1 Interlock lever

NOTICE
When the message “Cooling fan in CPS power supply stopped. Exchange fan.” is
displayed, it may be caused by the error occurrence at the cooling fan (CSRA-CPS01KA-
FN) inside the control power supply unit (CSRA-CPS01K□).
When the message “Cooling fan in CPS unit stopped, replace cooling fan.” is displayed,
carry out an inspection and the replacement of the cooling fan in the CPS unit as soon as
possible.

Cooling system

1 Backside duct
fan 6

2 Air inlet
3 Air outlet 1
4 Heat exchanger 2 2
5 Exterior fan for
heat exchanger 2
6 Interior fan for
5
heat exchanger
4

3
3

7.4 Emergency Stop Button Inspections

The emergency stop buttons are located on both the front door of the YRC1000 and the
programming pendant.
Before operating the robot, confirm that the SERVO power is OFF by pressing the
emergency stop button on the front door of the YRC1000 after the SERVO is ON.

7 - 56
Maintenance and inspection

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 front door of the YRC1000 is pressed.
 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 - 57
Maintenance and inspection

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.
The way to replace the battery is described in chapter 7.8 "Replacing the battery".

7 - 58
Maintenance and inspection

7.7 Check the power supply

Check the voltage of 1, 3, 5 terminal of the circuit breaker (-Q1M) with an electric tester.

Measured item Terminal Normal value

Line voltage Between 1 and 3, 3 and 5, 1 200 to 240 V (+10%, -15%)
and 5
Voltage between earth (S- Between 1 and E, 5 and E 200 to 240 V (+10%, -15%)
phase grounding) Between 3 and E Approx. 0 V

Tab. 7-1: Power supply voltage check (AC 200-240 V)

Measured item Terminal Normal value

Line voltage Between 1 and 3, 3 and 5, 1 380 to 440 V (+10%, -15%)
and 5
Voltage between earth Between 1 and E, 3 and E, 220 to 245 V (+10%, -15%)
(neutral grounding) 5 and E

Tab. 7-2: Power supply voltage check (AC 380-440 V)

Measured item Terminal Normal value

Line voltage Between 1 and 3, 3 and 5, 1 380 to 480 V (+10%, -15%)
and 5
Voltage between earth Between 1 and E, 3 and E, 220 to 277 V (+10%, -15%)
(neutral grounding) 5 and E

Tab. 7-3: Power supply voltage check (AC 380-480 V)

Fig. 7-1: Circuit Breaker (-Q1M)

7 - 59
Maintenance and inspection

7.8 Replacing the battery

WARNING!
Failure to observe this instruction may result in electric shock and/or personal injury
due to residual voltage in the capacitor.
 Turn OFF the power before replacing a circuit board.
 After turning OFF the power supply, wait at least 5 minutes before the replacement
operation.
 In addition, confirm that the charge lamps (orange LED) on the converter and the
inverter unit are turned OFF.

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.

7 - 60
Maintenance and inspection

1
2 CN107
(LAN3)

10
3 CN106
(LAN2)

4
CN105
(LAN1)

LED DS1

1
2
3
4
BAT
CN104(SD)
LED
5
6
7
S1

11
5 8
LED
9
10 12
11
12

CN112
LINK 13
RS232C

CN113
CN103
(COM)
CN111
14
USB CN102
(USB)

CN101
(PSU)

7 8 9
Fig. 7-2: CPU Unit

1 Fixing screw for CPU board

2 LAN3 (CN107)
3 LAN2 (CN106)
4 LAN1 for PP (CN105)
5 SD card (CN104)
6 Control power supply input connector (CN101)
7 (Control communication connector (CN111)
Communication with SERVO control board/safety circuit board
8 Sensor board slot
9 Ground terminal
10 CPU board JANCD-ACP01-E
11 Rotary switch (S1)
12 I/O I/F (Communication with optional I/O) (CN112)
13 2 PCIe Slots
14 Robot I/F board JANCD-AIF01-□E battery (back side)

7 - 61
Maintenance and inspection

• 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 connector CN103
6 LAN2 connector CN106
7 LAN3 connector CN107
8 I/O I/F connector CN112
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.

7 - 62
Maintenance and inspection

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.

3 1

Fig. 7-3: Robot /IF board and CPU board

1 Position of mounting battery

2 Robot I/F board (back side)
3 CPU board
4 Maxell batteries will be replaced with the above Toshiba batteries due to
discontinuation of production. Toshiba batteries can also be used for
maintenance or replacement.

Fig. 7-4: Battery connecting 1

7 - 63
Maintenance and inspection

1 Battery connectors
Right: CN114 (Battery connected)
Left: CN114 (Battery not connected)
5. Keep the old battery connecting and connect the new battery to the connector (CN115)
(left side).
Refer to figure „Battery connecting 2"

Fig. 7-5: 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).
Refer to figure „Battery connecting 3"

Fig. 7-6: Battery connecting 3

1 Disconnect the battery connector (CN114 (right))

7 - 64
Maintenance and inspection

7. Remove the old battery from the battery holder.

Refer to figure „Battery connecting 4"

Fig. 7-7: Battery connecting 4

1 Remove the old battery from battery holder

8. Mount the new battery on the battery holder.
Refer to figure „Battery connecting 5"

Fig. 7-8: Battery connecting 5

1 Mount the new battery on the battery holder

7 - 65
Maintenance and inspection

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)"

Fig. 7-9: Notes for battery wires (After replacement)

1 The battery wires do not run off from the circuit board
10. Mount the CPU board on the original position.
Refer to figure „Mounting on rack“
Note:
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.

Fig. 7-10: Mounting on rack

1 Backboard connector for connecting CPU board

2 Insert the CPU board straight along the rails and connect to the back-
board connector
11. Tighten the screws fixing the CPU board from upper and lower side (2 places) and fix
to the rack.

7 - 66
Maintenance and inspection

12. Connect all cables are disconnected in step 1.

7.9 Check the phase

Check item Contents

Lead Cable Check Confirm if the lead cable for the power supply is wired as shown
in the following without any falling out, looseness or breaking from
the connecting part.
Input Power Supply Check the line voltage of the input power supply by using an elec-
Check tric tester.
The specification of power supply differs depending on the type of
YRC1000. Confirm the specification of power supply by referring
to the rating label on the door of YRC1000 (Normal value: 380 to
480 VAC (+10%, -15%), (neutral grounding)).

Circuit Breaker (- Turn ON the breaker and check the line voltage of “2, 4, 6” of the
Q1M) Check circuit breaker (-Q1M) by using an electric tester.
If abnormal, replace the circuit breaker (-Q1M).

Open phase diagram (Small-capacity model)

1 3-phase
1
2 Breaker RS T

3 Noise filter only for Eu- 1 3 5

rope) 2
(-Q1M)
4 Power supply unit 2 4 6

5 Contactor 3 4 6
CN601 CN602 CN551
6 Converter 1 1 2 1 1
2 3 4 2 2
3 5 6 3 3

5
(1KM)

Open phase diagram (Medium/Large-capacity model)

1 3-phase
1
2 Breaker RS T

3 Noise filter (only for Eu- 1 3 5

rope) 2
(-Q1M)
4 Power supply unit 2 4 6

5 Contactor 3 44 6 7
3 5 6
6 AC reactor CN601
1 1 2
CN602
1
CN551
1
2 3 4 2
7 Converter 3 5 6 3
2
3
7
5
(1KM)

7 - 67
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.

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Robot controller specification

8.1 Specification list

Controller
Construction Free-standing, enclose typed
Protection class IP54 (the back fan is IP2X)
Weight Small capacity model approx. 70 kg
Medium/Large capacity model approx. 85 kg
Dimension (W x H x D) in 598 x 490 x 427 (excluding protrusions)
mm
Cooling system Indirect cooling
Power supply 3-phase 380 - 480 (+10 % to -15 %) VAC 50/60 Hz (+/-
2 %) (Neutral earthing)
SCCR 5 kA1
Grounding Grounding resistance: 0,1 Ω
Noise level Less than 60 dB23
Digital I/O NPN
General signals (standard, max.), 40 inputs and 40 outputs
(Transistor: 32 outputs, relay: 8 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
CIO ladder Max. 20,000 steps
Safety category Safety category 3, PL e
1. SCCR (Short-Circuit current rating) represents the maximum short circuit current level which the controller can
withstand. An isolation transformer is necessary for SCCR over 5kA.

2. Measured at the Single system

3. From Machine Directive 2006/42/EC: Where the workstation(s) are undefined or cannot be defined, A-weighted
sound pressure levels must be measured at a distance of 1 metre from the surface of the machinery and at a height
of 1,6 metres from the floor or access platform. The position and value of the maximum sound pressure must be
indicated.

Ambient conditions
Ambient temperature 0 °C to + 45 °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 1000 m or less (To use the robot controller 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 40 °C).
Vibration Acceleration 0.5 G or less

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Robot controller specification

Ambient conditions
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.

8.2 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 • Arc welding
• Spot welding
• Handling
• Press tending
• Cutting
• Others
Essential Measures CE (Europe 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.

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Robot controller specification

Programming pendant operation

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
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)

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Robot controller specification

Safety feature
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
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

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Robot controller specification

Maintenance function
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

Programing function
Programming Type Interactive programming
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
structions • Calls
• 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

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Robot controller specification

8.3 Programming pendant

Type JZRCR-APP01-1
Material Reinforced plastic
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, Max: 36 m (optional)
Interface Provided with SD card slot (SD/SDHC/SDXC type)
1 x USB connector USB2.0
Key sheet Arc welding, Spot welding, Material handling, Jig-less, Spot-
and arc welding

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Robot controller specification

8.4 Device configuration

The robot controller is comprised of individual units and modules (circuit boards).
Malfunctioning components can generally be easily replaced.
This section explains the configuration of the robot controller equipment.

380V to 480V AC Specification small-capacity model 1

1 Inside Controller (Back view) 4

2 Inside Controller (Front view)
3 Door (Inside view)
4 Backside duct fan 09225VE-24P-CA-02
5 Regenerative resistor SMVK500W260J/
RO A6667 1
5

6 DC reactor 85R-15014A
6
7 Breaker
8 Power supply contactor unit JZRCR-
APU0□-1
9 Converter CSRA-CV05D01A 7 8 9 10 11
10 Inverter unit CSRA-SDA□□H01A
11 Safety circuit board JANCD-ASF01-E
GP I/O board JANCD-AIO0□-E
12 Control power supply unit CSRA-
2
CPS01K□
13 CPU unit JZNC-ARK5□-□E
14 Heat exchanger TCMSY-3□0DC
15 Safety terminal block board M-YE250/5-
80P 13 14 12

15

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Robot controller specification

Robot model YRC1000 controller

GP7
AR900
ERAR-1000-06VX8-B15
GP8
AR700
GP12
AR1440
GP25
ERAR-1000-06VXH25-B15
AR1730
GP25-12
AR2010

380V to 480V AC Specification small-capacity model 2

1 Inside Controller (Back view) 4

2 Inside Controller (Front view)
3 Door (Inside view)
4 Backside duct fan 09225VE-24P-CA-02
5 Regenerative resistor SMVK500W260J/
RO A6667 1
5

6 DC reactor 85R-15014A
6
7 Breaker
8 Power supply contactor unit JZRCR-
APU0□-1
9 Converter CSRA-CV05D01A 7 8 9 10 11 12
10 Inverter unit CSRA-SDA□□H01A
11 Safety circuit board JANCD-ASF01-E
GP I/O board JANCD-AIO0□-E
12 Single axis amplifier CSRA-SDB□□H01A
2
13 Control power supply unit CSRA-
CPS01K□
14 CPU unit JZNC-ARK5□-□E
15 Heat exchanger TCMSY-3□0DC
14 15 13
16 Safety terminal block board M-YE250/5-
80P

16

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Robot controller specification

Robot model YRC1000 controller

AR1440E ERAR-1000-07VXHE6-B15

380V to 480V AC Specification Medium/Large-Capacity Model 1

1 Inside Controller (Back view) 4

2 Inside Controller (Front view)
3 Door (Inside view)
4 Backside duct fan 09225VE-24P-CA-02
5 AC reactor SR-23A or UZBC-B 23A 5
6 DC reactor PI-EZ002-0213 1

7 Breaker 6
8 Power supply contactor unit JZRCR-
APU0□-1
9 Converter CSRA-CV10D03A
7 8 9 10 11
10 Inverter unit CSRA-SDA□□H01A
11 Safety circuit board JANCD-ASF01-E
GP I/O board JANCD-AIO0□-E
12 Control power supply unit CSRA-
CPS01K□
2
13 CPU unit JZNC-ARK5□-□E
14 Heat exchanger TCMSY-3□□DC
15 Safety terminal block board M-YE250/5-
80P-P
13 14 12

15

Robot model YRC1000 controller

GP20HL
ERAR-1000-06VXHL20-B15
AR3120

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Robot controller specification

Robot model YRC1000 controller

GP50
GP35L
GP88
SP80
GP110
SP100
SP130
GP180
SP165
GP180-120
SP165-105
GP200S
GP215
ERAR-1000-06VX280-B15
GP225
SP210
GP250
SP235
GP280
GP165R
SP150R
GP200R
SP185R
SP110H
SP180H
SP180H-110
SP225H
GP400
GP600 ERAR-1000-06VX600-B15
GP400R

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Robot controller specification

380V to 480V AC Specification Medium/Large-Capacity Model 2

1 Inside Controller (Back view) 4

2 Inside Controller (Front view)
3 Door (Inside view)
4 Backside duct fan 09225VE-24P-CA-02
5 AC reactor SR-23A or UZBC-B 23A 5
6 DC reactor PI-EZ002-0213 1

7 Breaker 6
8 Power supply contactor unit JZRCR-
APU0□-1
9 Converter CSRA-CV10D03A
7 8 9 10 11 12
10 Inverter unit CSRA-SDA□□H01A
11 Single axis amplifier CSRA-SDB71HA
12 Safety circuit board JANCD-ASF01-E
GP I/O board JANCD-AIO0□-E
13 Control power supply unit CSRA- 2
CPS01K□
14 CPU unit JZNC-ARK5□-□E
15 Heat exchanger TCMSY-3□□DC
16 Safety terminal block board M-YE250/5- 14 15 13
80P-P

16

Robot model YRC1000 controller

GP110B
ERAR-1000-07VXB110-B15
SP100B

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Robot controller specification

380V to 480V AC Specification Medium/Large-Capacity Model 3

1 Inside Controller (Back view) 4

2 Inside Controller (Front view)
3 Door (Inside view)
4 Backside duct fan 09225VE-24P-CA-02
5 AC reactor SR-23A or UZBC-B 23A 5
6 DC reactor PI-EZ002-0213 1

7 Breaker 6
8 Power supply contactor unit JZRCR-
APU0□-1
9 Converter CSRA-CV10D03A
7 8 9 10 11
10 Inverter unit CSRA-SDA□□H01A
11 Safety circuit board JANCD-ASF01-E
GP I/O board JANCD-AIO0□-E
12 Fan control relay LY2N-D2 DC24V
13 Power supply for robot fan S8VS-09024 2
14 Control power supply unit CSRA-
12
CPS01K□
15 CPU unit JZNC-ARK5□-□E
16 Heat exchanger TCMSY-3□□DC 15 16 14 13
17 Safety terminal block board M-YE250/5-
80P-P

17

Robot model YRC1000 controller

PH130RF
PH130F ERAR-1000-06VRF130-B15
PL500

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Robot controller specification

 Cooling System of the controller interior

The backside duct fan draws in air from the air intake and expels it from the air outlet to cool
the SERVOPACK. The fan mounted inside the door circulates the air to keep temperature
even throughout the interior of the robot controller. Make sure the door of the robot
controller is closed when it’s used to keep this cooling system effective.

Cooling system

1 Backside duct
fan 6

2 Air inlet
3 Air outlet 1
4 Heat exchanger 2 2
5 Exterior fan for
heat exchanger 2
6 Interior fan for
5
heat exchanger
4

3
3

8 - 81
Description of Units and Circuit Boards

9 Description of Units and Circuit Boards

• Cautions for connection of dual input signals.
Please follow the safety instructions in chapter 2 "Safety".

CAUTION!
Connect the switch (contact), which at the same time switches the 2-channel signals ON
and OFF.
If the timing that turns the two signals ON and OFF is not right, a disagreement alarm
occurs.
If one of the doubleted signals becomes abnormal, an alarm occurs.

1
6
2

3
5
4

Fig. 9-1: Connection of 2-channel inputs

1 Robot controller
2 Input for the robot system
3 Turn ON/OFF at the same time
4 Input signal 1
5 Input signal 2
6 Switch

9 - 82
Description of Units and Circuit Boards

CAUTION!
Damage to property caused by short-circuit
As power supply is reversed for each signal, a short-circuit and thus a possible a robot
control failure occurs.
Do not connect the two signals to the same contact (use two separate contacts).
An alarm occurs due to the judgment of the safety circuit

1
7 2

3
6
4

5
Fig. 9-2: Connecting 2-channel inputs to the same contact

1 Robot controller
2 Input for the robot system
3 Input signal 1
4 Input signal 2
5 Short circuit current
6 The same contact
7 Switch

9.1 Power Supply Contactor Unit (JZRCR-APU0□-1)

The power supply contactor unit consists of the main circuit contactor. It turns the main
circuit control contactor ON and OFF using the signal for the SERVO power control from
the safety circuit board and supplies power (3-phase) to the converter.

9 - 83
Description of Units and Circuit Boards

The power supply (1-phase) is supplied to the control power supply unit.

1 AC control power supply fuse 2

2 Fixing screw hole

2FU 10A 500V 1FU 10A 500V

NJ3869-N
3 Contactor control input connector
1

YASKAWA ELECTRIC CORPORATION

DATE
4 AC control power supply connector
1

MADE IN JAPAN
5 Front view
CN604
6 Power input connector

SER No.
TYPE
CN603
7 Power output connector 5
8 Right side view 3
4 2

CN601 CN602

6 7

9 - 84
Description of Units and Circuit Boards

9.2 Control Power Supply Unit (CSRA-CPS01K□)

This unit (CSRA-CPS01K□) supplies the DC power (DC12V, DC24V, DC26V) for control
(system, I/O, brake). It is also equipped with the input function for turning the control power
supply ON and OFF.

PE RIN_COM R-IN R_OUT_COM R_OUT

POWER ON
CN158

OHT
1 2 3 4 5 6

1 AC input connector 4 Remote control input/output connector

2 +26V3 power output connector 5 +24V1/+24V2 power output connector
3 Monitor/Alarm display 6 +12V/ALM output connector

Items Specification
Input Rating input voltage: 200 to 480VAC
Voltage Fluctuation Range: +10% to -15% (170 to 528VAC)
Frequency: 50/60Hz ± 2Hz (48 to 62Hz)
Output voltage DC + 12V
DC +24V (24V1: System, 24V2: I/O)
DC +26V
Indicator Display Color Status
POWER ON White Lights with +12V output (Power supply
status: being output)
+12V Red Lights with +12V low-voltage/over-cur-
rent (ON when abnormal)
FAN Red Lights when FAN error occurs.
OHT Red Lights when unit interior overheats
+24V Red Lights with +24V or +26V low-voltage/
over-current (ON when abnormal)
SOURCE White Lights with power supply input.
Lights out when internal live part com-
pletes discharge (Power supply status:
being input).

9 - 85
Description of Units and Circuit Boards

Items Specification
Control power To turn ON the YRC1000 controller power, turn ON the non-fuse
ON/OFF breaker of the controller so that the control power supply is turned ON.
If the controller is not located at the workplace, the control power sup-
ply can be turned ON/OFF by an external device, etc. after the non-
fuse breaker of the controller is turned ON. It is operated by the exter-
nal switch connected with CN152 of the Control power supply unit as
shown in the following figure (CN152-3 and CN152-4 are short-circuit-
ed when shipment).
3

4
1 2 CN152

3
R-IN

4
R-INCOM

(1) Control Power Supply ON/OFF Switch

(2) Remove the short-circuit positioner
(3) YRC1000
(4) Control power supply unit (CSRA-CPS01K□)
See chapter 9.21 "Assignment of universal I/O signals" for wiring of
CN152 connector.

The robot I/F circuit board (JANCD-AIF01-□E) controls the entire robotic system. It is
connected to the CPU board (JANCD-ACP01-E) with a communication connector, and to
the servo control board (CSRA-SDCA01AA) with a communication cable.
Note:
Please do not change the factory setting of S1 (Factory setting is [0]).

9 - 86
Description of Units and Circuit Boards

9.3 Converter (CSRA-CV□□□0□A)

The converter (CSRA-CV□□□0□A) exchanges the power supply supplied by the power ON
unit for DC power supply and supplies the power to the inverter unit.

9.3.1 Converter (Small-capacity model)

Input voltage: 200 to 240 VAC

CSRA-CV05A00A

1 Main circuit power supply input (CN551)

2 Regenerative resistor connection (CN552)
3 Charge lamp 1
4 LED Monitor/alarm indicator
CN551

5 SERVO control board communication (CN561)

2
6 Main circuit power supply output (CN556)
CN552
4
7 +24V1 input (CN560) 3 CHARGE ALM
COM
RDY
PON
5
8 Grounding terminal
CN561

CN569
7 CN556
CN560
6

CN555

8 CN554

9 - 87
Description of Units and Circuit Boards

Input voltage:380 to 480 VAC

CSRA-CV05D01A

1 Main circuit power supply input (CN551)

2 Regenerative resistor connection (CN552)
3 Charge lamp 1
4 LED Monitor/alarm indicator
CN551

5 SERVO control board communication (CN561) 2

6 Main circuit power supply output (CN556)
CN552
4
7 +24V1 input (CN560) 3 CHARGE ALM
COM
RDY
PON

8 DC reactor connection 2 (CN555)

CN561

9 DC reactor connection 1 (CN554) 5

CN569

10 Grounding terminal CN556

7 CN560
6

CN555

10 CN554

9 - 88
Description of Units and Circuit Boards

9.3.2 Converter (Medium/Large-capacity model)

Input voltage: 200 to 240 VAC

CSRA-CV10A02A

1 Main circuit power supply input (CN551)

2 Discharge resistor connection (CN552)
1
3 Charge lamp
4 LED Monitor/alarm indicator
5 SERVO control board communication (CN561) 2
6 +24V1 input (CN560)
3 4
7 Main circuit power supply output (556)
8 Grounding terminal
5

Input voltage:380 to 480 VAC

CSRA-CV10D03A

1 Main circuit power supply input (CN551)

2 Discharge resistor connection (CN552)
3 Charge lamp 1
4 LED Monitor/alarm indicator
5 SERVO control board communication (CN561)
2
6 +24V1 input (CN560)
4
7 Main circuit power supply output (556) 3
8 DC reactor connection 2 (CN555)
5

9 DC reactor connection 1 (CN554) 6

10 Grounding terminal
7

10
9

9 - 89
Description of Units and Circuit Boards

9.4 Inverter Unit (CSRA-SDA□□H01A)

9.4.1 Inverter unit configuration

The inverter unit consists of following circuit boards.

1 Inverter
2 SERVO control board CSRA-SDCA01AA

9 - 90
Description of Units and Circuit Boards

9.4.2 Inverter

The inverter board and capacitor board exchange the DC power supply supplied by a
converter for a 3-phase motor power source and outputs to each SERVO motor.

Inverter (Small-capacity model)

1 SERVO control board connector

(CN571)
2 Charge lamp
3 Motor power output 1 (CN573)
4 External axes PN output 1 (CN580)
1
5 Motor power output 3 (CN575)
6 Motor power output 4 (CN576)
7 External axes PN output 2 (CN581)
8 External axes PN output 3 (CN582)
2
9 Power supply output for external
axes 3 (CN585)
10 Power supply output for external
17 3
axes 2 (CN584)
11 Power supply output for external 16 4
axes 1 (CN583)
15
12 Motor power output 5 (CN577) 5
14
13 Ground terminal
13
14 PN input (CN572) 6
15 Motor power output 6 (CN578) 12 7
11 10 9 8
16 Motor FG (CN579)
17 Motor power output 2 (CN574)

9 - 91
Description of Units and Circuit Boards

Inverter (Medium/Large-capacity model)

1 Motor power output 5 (CN577)

1
2 Motor power output 1 (CN573)
3 Control power supply 16V output
for external axes 1 (CN583)
4 Control power supply 16V output
for external axes 2 (CN584) 12
5 Control power supply 16V output
for external axes 3 (CN585)
6 Motor power output 2 (CN574)
7 Motor power output 3 (CN575)
8 Ground terminal
9 Motor FG (CN579)
10 PN input (CN572)
11 Charge lamp 2
12 Motor power output 4 (CN576) 11
10 3
4
9
8 5

7 6

9 - 92
Description of Units and Circuit Boards

9.4.3 SERVO control board (CSRA-SDCA01AA)

The SERVO control board controls the servomotors of the robots six axes and the
servomotors of the three external axes (up to nine axes).
It also controls the converter and the inverter.
The SERVO control board (CSRA-SDCA01AA) also has the following functions.
• Brake power supply control circuit
• Shock sensor (shock) input circuit
• Direct-in circuit

SERVO control board (CSRA-SDCA01AA)

1 Rotary switch (Setting length of commu- 1

16 17 18 2
nication cable)(S2)
2 External 3rd axis inverter I/F connector 15
(CN533)
3 Encoder signal connector 3 (CN535)
4 Encoder signal connector 4 (CN536) 14

5 Encoder signal connector 2 (CN534)

13
6 Encoder signal connector 1 (CN508)
3
7 Handbrake release unit I/F connector 12
(CN541)
4
8 Brake I/F connector (CN540) 11
9 External brake power supply input con- 10
nector (CN543)
9 8 7 6 5
10 Brake power supply input connector
(CN544)
11 Fan power supply connector (CN520)
12 Power supply input connector (CN509)
13 Converter I/F control connector (CN507)
14 Rotary switch (Setting number when op-
erating multiple robots) (S1)
15 Control communication connector
(CN516)
16 Control communication connector
(CN515)
17 External 1st axis inverter I/F connector
(CN531)
18 External 2nd axis inverter I/F connector
(CN532)

9 - 93
Description of Units and Circuit Boards

9.5 Safety circuit board (JANCD-ASF01-E)

This circuit board contains dual processing circuits for safety signal and the I/O circuit for
the non-safe signal.
It processes external safety signals with the dual processing circuits and control ON/OFF
of the main circuit control contactor of the power supply contactor unit (JZRCR-APU0□-1)
according to conditions.
Followings are the main functions of machine safety I/O logic unit.
• System safety input circuit (dual circuits)
• User safety input circuit (dual circuits)
• User safety output circuit (dual circuits)
• Emergency stop signal input circuit (dual circuits)
• SERVO power control signal output circuit (dual circuits)
• Non-safe I/O circuit for the robot system
• Safety terminal block board I/F

1 2 3

11

4
10

9
7 6 5
8

1 GP I/O board I/F connector (CNAX)

2 Expansion safety I/O board I/F connector (CN208)
3 Power supply input connector (CN207)
4 Terminal block board I/F connector (CN206)
5 Contactor control output connector (CN205)
6 Robot I/O connector (CN204)
7 I/F connector (Communication between safety circuit board when operating multiple
robots) (CN202)
8 I/F connector (Communication between safety circuit board when operating multiple
robots) (CN201)
9 Connection tap for the grounding
10 PP I/F connector (CN203)
11 Rotary switch (Setting number when operating multiple robots) (S1)

9 - 94
Description of Units and Circuit Boards

9.6 Safety Terminal Block Board (IM-YE250/5-80P)

The safety terminal block board (IM-YE250/5-80P) is the terminal block board to connect
the external signal such as the safety I/O signals. For connection, refer to the connection
diagrams for the respective unit.

NOTICE
If the length of cable between the safety terminal block board and the connected device is
longer than 30m, make sure to use the shielded cable so that the electromagnetic resistant
can be properly performed. Then the shield of shielded cable must come into contact with
the controller's body.

21 22 23 24 25 26 27 28 29 30

41 42 43 44 45 46 47 48 49 50

61 62 63 64 65 66 67 68 69 70
1
2
3
4
5

1
6
7
8
9
10

31 32 33 34 35 36 37 38 39 40

51 52 53 54 55 56 57 58 59 60

71 72 73 74 75 76 77 78 79 80
11
12
13
14
15
16
17
18
19
20

Fig. 9-3: Safety terminal block board

1 Safety circuit board I/F connector (CN220)

9 - 95
Description of Units and Circuit Boards

Signal name Connec- 2-channel Function Factory setting

tion no.:
SAFF_1+ 1 Possible Safety plug Bypass using a
SAFF_1- 2 Used to turn OFF the servo jumper cable

SAFF_2+ 3 power if the door on the

safeguarding is opened.
SAFF_2- 4 Connect to the interlock sig-
nal from the safety plug on
the safeguarding door.
If the interlock signal is in-
put, the servo voltage is
turned ON. As long as the
signal is ON.
The servo power cannot be
turned ON. Note that these
signals are disabled in teach
mode.
EXESP_1+ 5 Possible External Emergency Stop Bypass using a
EXESP_1- 6 Used to connect the emer- jumper cable

EXESP_2+ 7 gency stop switch of an ex-

ternal device.
EXESP_2- 8
If the contact is OPEN, the
servo power is turned OFF
and the JOB is stopped.
As long as the signal is pres-
ent, the servo voltage can-
not be switched on.
OT2_1+ 9 Possible External axes overrun Open
OT2_1- 10 Used to input the overrun in
OT2_2+ 11 the external axes other than
the main body of the robot.
OT2_2- 12
If the contact is OPEN, the
servo power is turned OFF
OT3_1+ 13 and the JOB is stopped.
OT3_1- 14
OT3_2+ 15
OT3_2- 16
OT4_1+ 17
OT4_1- 18
OT4_2+ 19
OT4_2- 20

9 - 96
Description of Units and Circuit Boards

Signal name Connec- 2-channel Function Factory setting

tion no.:
ONEN1_1+ 21 Possible Servo ON activated Bypass using a
ONEN1_1- 22 Connected to use a function jumper cable

ONEN1_2+ 23 which distributes the robot

system to the multiple servo
ONEN1_2- 24 systems, and turns the
ONEN2_1+ 25 SERVO power ON/OFF.
ONEN2_1- 26 If the contact is OPEN, the
ONEN2_2+ 27 SERVO power of corre-
ONEN2_2- sponding system is turned
28 OFF.
ONEN3_1+ 29
ONEN3_1- 30
ONEN3_2+ 31
ONEN3_2- 32
ONEN4_1+ 33
ONEN4_1- 34
ONEN4_2+ 35
ONEN4_2- 36
PPESP_3+ 37 - Contact output emergency Open
PPESP_3- 38 stop button

PPESP_4+ 39 Used to output a contact

point of the emergency stop
PPESP_4- 40 button on the programming
pendant.
GSIN1_1+ 41 Possible General purpose safety in- Open
GSIN1_1- 42 put

GSIN1-2+ 43 The general-purpose safety

output signal is used in the
GSIN1_2- 44 safety logical circuit func-
GSIN2_1+ 45 tion.
GSIN2_1- 46 Also, inputs and uses the
GSIN2_2+ 47 driven connection device
status as the monitoring sig-
GSIN2_2- 48 nal by the output signal.
GSOUT1_1+ 49 - Universal safety output Open
GSOUT1_1- 50 The universal safety output
GSOUT1_2+ 51 signal is used in the safety
logical circuit function.
GSOUT1_2- 52
Also, inputs and uses the
GSOUT2_1+ 53 driven connection device
GSOUT2_1- 54 status as the monitoring sig-
GSOUT2_2+ 55 nal by the output signal.

GSOUT2_2- 56

9 - 97
Description of Units and Circuit Boards

Signal name Connec- 2-channel Function Factory setting

tion no.:
SYSRUN+ 57 - SYSRUN signal Open
SYSRUN- 58 Use to determine the nor-
mal/abnormal condition of
the YRC1000 controller by
SYSRUN signal.
ALMIN2+ 59 Only for YASKAWA Open
ALMIN2- 60 This signal cannot be used
as it is only for YASKAWA.
24VAX 61 - DC +24V2 output terminal Open
24VAX 62 Rated current output:
150 mA or less
024V2 63 - DC024V2 output terminal Open
024V2 64 -
AXDIN_COM 65 - Direct input (SERVO) Open
AXDIN1 66 Used to input the quick re-
AXDIN2 67 sponding signals in the
search function etc.
AXDIN3 68
AXDIN4 69
24VAX 70 - DC+24V2 output terminal Open
24VAX 71 Rated current output:
150 mA or less
024V2 72 - DC 024V2 output terminal Open
024V2 73 -
AIN_COM 74 - General input (SERVO) Open
AXIN1 75 Used to input the general-
AXIN2 76 purpose signal from the ex-
ternal device.
This signal is optional.
This signal cannot be used
in case of standard specifi-
cation.
24VAX 77 - DC+24V2 output terminal Open
24VAX 78 Rated current output:
150 mA or less
AXOUT1 79 - Only for YASKAWA Open
AXOUT2 80 This signal cannot be used
as it is only for YASKAWA.

Tab. 9-1: M-YE250/5-80P Details for the Connection Terminal

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Description of Units and Circuit Boards

Wiring procedure of the terminal block

For your safety, appropriate work must be done by following the instructions below.
1.) Tool: screw driver
– For the connection, be sure to use a screwdriver of an applicable size and
configuration

WAGO standard screwdriver, WAGO 210-119, WAGO 210-119SB (short, delivered with the
product).
2.) Strip wires
• The length of the exposed conductor (L) should be as follows.
– The 9-10mm length of the exposed conductor for the terminal block WAGO series
250 (with 5.0 mm pitch).
– Maximum cable with an outer diameter of Ø 3.1 mm.

• A bent or wound up conductor should be adjusted as illustrated in the figure above

3.) Wire connections

1
250

250

250

209-188

1 Terminal block without screw WAGO series 250

1. Place the screwdriver on the lever upright as shown in the figure below and push
straight down.

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Description of Units and Circuit Boards

2. Insert the wire into the connection hole slowly until its leading end touches the end of
the hole.
For thin wires, never insert the wire with force, or the wire jacket may get caught
in.

3. Pull out the screwdriver to clamp the conductor with a spring.

4. Check if the wire is connected firmly by pulling the wire softly.

9 - 100
Description of Units and Circuit Boards

9.7 Board (machine safety)

9.7.1 Connection tool shock sensor (SHOCK)

Direct connection to tool shock sensor signal line

1. The minus SHOCK (-) pin is connected to the +24V2 pin on the inside of YRC1000 door.
Remove the minus SHOCK (-) pin from the +24V2 pin.
2. Connect the minus SHOCK (-) and +24V2 pin terminals to the signal lines of the tool
shock sensor. Use the following pin terminals for preparing the end of the signal line:

Terminal name Terminal model Signal line terminal model

SHOCK- TMEDN-630809-MA TMEDN-630809-FA (manufacturer:
NICHIFU Co., Ltd.)
+24V2 TMEDN-630809-MA TMEDN-630809-MA (manufacturer:
NICHIFU Co., Ltd.)

Direct connection to tool shock sensor signal line

1 Robot 3
2 Robot controller 1 2 (JANCD-ASF01-E)
CN204

3 Safety circuit board

TMEDN-630809-FA(NICHIFU)
+24V2
11
SHOCK+

4 Shock sensor signal cable 5

TMEDN-630809-MA(NICHIFU)
TMEDN-630809-FA(NICHIFU)

5 Shock sensor (option) 12

SHOCK-

TMEDN-630809-MA(NICHIFU)
SHOCK-

The pin terminal for the shock sensor is attached on the inside of the YRC1000’s door.

1. The minus SHOCK (-) pin is connected to the +24V2 pin on the inside of YRC1000's
door. Remove the minus SHOCK (-) pin from the +24V2 pin.
2. Connect the minus SHOCK (-) pin to the plus SHOCK (+) pin of robot.

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Description of Units and Circuit Boards

NOTICE
The shock sensor is optional. In case of the standard specification, the cables for shock
sensor of robot are not connected to the shock sensor. For wiring, refer to the internal
connection diagram of instruction manual corresponding to the robots model.

Connection with robot cable

1 Robot 3
2 Robot controller 1 2 (JANCD-ASF01-E)
CN204
11
3 Safety circuit board TMEDN-630809-FA(NICHIFU)
SHOCK+

+24V2
4 Supply cable (PG) 5
TMEDN-630809-FA(NICHIFU)

5 Shock sensor (option) SHOCK+ 12

SHOCK-

TMEDN-630809-MA(NICHIFU)
SHOCK-
4

NOTICE
When the tool shock sensor input signal is used, the stopping method of the robot can be
specified. The stopping methods are hold stop and SERVO power supply OFF. Selection
of the stopping method is set in the display of the PP.
For details refer to chapter "System setup" in the manual Instructions with the
document-no.: E1102000214XX01* and higher.

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Description of Units and Circuit Boards

9.8 WAGO Connector

The control power supply unit: CN152 on (CSRA-CPS01KA), and CN303 on the general-
purpose I/O board (JANCD-AIO0□-E) are equipped with a connector made by WAGO.
The “wiring tool for the WAGO connector” is necessary to wire the WAGO connector.
The tools (total 3, 2 types) are supplied with the robot controller.
Use them with the appropriate sizes of connectors.
The wiring procedure is described as follows:
1. Insert part A of the wiring tool into one of the holes designed for the tool.

Description Specification
Control power supply unit Max. cable outer diameter: Ø 4.1 mm
(CSRA-CPS01K□) CN152 Stripping length: 8-9 mm
General-purpose I/O board Max. cable outside diameter: Ø 3.41 mm
(JANCD-AIO0□-E) CN303 Stripping length: 7 mm

1 Wiring tool for WAGO connector

1
2 Holes for the wiring tool
3 WAGO connector (e.g. 4 pins type) 2

4 Wire

4
2. Insert or pull out the wire while pushing the wiring tool downward.

1 Wiring tool for WAGO connector

1

3. Remove the tool from the connector. Keep this tool for future use.

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Description of Units and Circuit Boards

9.9 Safety plug

This signal is used to turn OFF the SERVO power if the door on the safeguarding is opened.
Connect to the interlock signal from the safety plug on the safeguarding door. If the interlock
signal is input, the SERVO power turns OFF. While the signal is turned ON. The SERVO
power cannot be turned ON.
Note that these signals are disabled in TEACH mode. Make sure that no person goes inside
the safeguarding.

DANGER!
Injuries and machine damage as a result of short circuiting
Jumpers are installed at the factory. If the jumpers are not removed, the external emergency
stop will not work even when the signal is received.
 Always remove the jumpers before operation.

NOTICE
Because of the dual circuits signal to input, the alarm occurs if the signal does not match.
However, in the TEACH mode, even though the signal does not match, the alarm is not
detected. The alarm is detected only in the PLAY mode.

Connection for safety plug

1 Robot controller
1
2 Safety terminal block board
2 3
3 Safety circuit board CN206
1 SAFF_1+
4 Safety plug 4 2 SAFF_1-

5 Remove the jumper cable

6
6 Turn ON/OFF at the same time
3 SAFF_2+
4 SAFF_2-

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Description of Units and Circuit Boards

9.10 Installation of safety plug

• 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.

Installation of safety plug

1 Robot working area

2 Safety fence
3 Service door 2
1
4 Robot controller
5 Emergency stop button
6 Safety plug
7 Portable plug

5
3

7
6

If the SERVO power is ON when the interlock signal is input, the SERVO power turns OFF.
As long as the interlock signal is active, the SERVO power cannot be turned ON.
However, the SERVO power does not turn OFF when the door is opened only during the
TEACH mode.
In this case, the SERVO power can be turned ON while the interlock signal is input.

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Description of Units and Circuit Boards

9.11 Connection of external emergency stop signal

This signal is used to connect the emergency stop switch of an external device. If the signal
is input, the SERVO power is turned OFF and the JOB is stopped. While the signal is input,
the SERVO power cannot be turned ON.

DANGER due to electric current!

Injuries and machine damage as a result of short circuiting
Jumper cables are installed at the factory. If the jumper cables are not removed, the
external emergency stop will not work even when the signal is received.
 Always remove the jumper cables before operation.

2 3 CN206
5 EXESP_1+
4 6 EXESP_1-

7 EXESP_2+
8 EXESP_2-

5
Fig. 9-4: Connection of external emergency stop signal

1 Robot Controller 4 External emergency stop signal

2 Safety terminal block board 5 Remove jumper cables
3 Safety circuit board 6 Switch ON/OFF at the same time

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Description of Units and Circuit Boards

9.12 SYSRUN signal output

This signal is used to check whether the robot control status is normal or abnormal.
This signal is output on the following conditions.

22

3
Fig. 9-5: (1) Connection for SYSRUN signal output

1 Main power supply ON/OFF 3 SYSRUN ON/OFF

2 Robot control status normal/ab-
normal
The pulse signal is output every 100ms by the specific output signal (#50911) to the external
equipment. The pulse signal can be tested to see whether the robot control circuit board is
running normally or abnormally (see instructions: "Instructions for Concurrent I/O").

NOTICE
 Rated output value is DC24V and less than 50 mA. Avoid excessive load when connect.
 When connect the inductive load, such as the safety 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. It may cause the damage
on the output circuit.

Connection for SYSRUN signal output

1 YRC1000
1
2 Safety circuit board
(JANCD-ASF01-E) -X18
3 Safety terminal block board 2 CN206 3 CN220

SYSRUN+ 57
SYSRUN+
SYSRUN- 58
SYSRUN-

Because the pulse signal is outputted from the specific output signal (#50911) to the
external device for each 100 ms, it is also able to check whether the YRC1000 control circuit
board is normal or abnormal.
For details refer to chapter "Specific output signals" in the manual OPTIONS
INSTRUCTIONS FOR CONCURRENT I/O.

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Description of Units and Circuit Boards

9.13 Connection for SERVO-ON enable input

DANGER due to electric current!

Injuries and machine damage as a result of short circuiting
Jumper cables are installed at the factory. If the jumper cables are not removed, the
external emergency stop will not work even when the signal is received.
 Always remove the jumper cables before operation.

Connect the ONEN signal lines to enable the function to turn ON or OFF the SERVO power
supply of an individual SERVO when a robotic system is divided into SERVO systems.
Because these signals are not used for units of standard specifications, a jumper cable is
connected as shown in the following figure.
For safety reasons, dual circuits are used for the SERVO-ON Enable input signals. Connect
the signal so that both input signals are turned ON or OFF at the same time. If only one
signal is turned ON, an alarm occurs.

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Description of Units and Circuit Boards

For details on the usage of the Servo-ON Enable signals refer to chapter "SERVO power
supply individual control function” in the manual OPTIONS INSTRUCTIONS FOR
INDEPENDENT/COORDINATED CONTROL FUNCTION.

Connection for SERVO-ON enable input

1 YRC1000
1
2 Safety terminal block board
2 CN206 3
3 Safety circuit board 4 CN220
21 ONEN1_1+
22 ONEN1_1-
4 SERVO-ON enable input signal (Sys-
tem1) 5 6
5 Turn ON/OFF at the same time 23 ONEN1_2+
24 ONEN1_2-

6 Remove the jumper cable

7 SERVO-ON enable input signal (Sys-
tem2)
7
8 SERVO-ON enable input signal (Sys- 25
26
ONEN2_1+
ONEN2_1-
tem3)
9 SERVO-ON enable input signal (Sys- 5 6
tem4) 27 ONEN2_2+
28 ONEN2_2-

8 29 ONEN3_1+
30 ONEN3_1-

5 6
31 ONEN3_2+
32 ONEN3_2-

9 33 ONEN4_1+
34 ONEN4_1-

5 6
35 ONEN4_2+
36 ONEN4 _2-

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Description of Units and Circuit Boards

9.14 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" in the manual
Instructions with the document-no.: E1102000214XX01* and higher.

Connection for external axis overrun

1 YRC1000
1
2 Safety terminal block board -X18
2 3
3 Safety circuit board CN220 CN206
9 OT2_1+
4 External axis overrun 4 10 OT2_1-

5 Turn ON/OFF at the same

time 5
11 OT2_2+
12 OT2_2-

The figure below shows the factory standard wiring, where all external axes are connected
to the YRC1000.

9 - 110
Description of Units and Circuit Boards

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" in the manual Instructions with the document-
no.: E1102000214XX01* and higher).

Connection for external axis overrun (Multiple lines)

1 YRC1000
1
2 Safety terminal block board
-X18
2 3
3 Safety circuit board CN220 CN206
9 OT2_1+
4 External axis overrun 1st line 4 10 OT2_1-
5 Turn ON/OFF at the same time
6 External axis overrun 2nd line 5

7 External axis overrun 3rd line 11 OT2_2+

12 OT2_2-

13 OT3_1+
6 14 OT3_1-

5
15 OT3_2+
16 OT3_2-

17 OT4_1+
7 18 OT4_1-

5
19 OT4_2+
20 OT4_2-

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Description of Units and Circuit Boards

9.15 Emergency stop output

Outputs the contact output terminals for both emergency stop buttons on the programming
pendant and on the front door.
These contact outputs are always valid regardless of the YRC1000 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.

1 Front door of the robot control-

ler cabinet 5
1
2 Emergency stop button 2
3 CN206 4
3 Safety circuit board
4 Safety I/O terminal board 38
ESPOUT1-

5 Robot controller
40
6 PP ESPOUT2-

6
2

37
ESPOUT1+

39
ESPOUT2+

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Description of Units and Circuit Boards

9.16 General purpose safety input

The GP safety input signal will be used in the safety logical circuit function.

NOTICE
When using the external enable switch (EXDSW) or the full-speed test (FST), refer to
chapter "Axes detachment function" in the manual Instructions with the document-no.:
E1102000214XX01* and higher.

General purpose safety input

1 YRC1000
1
2 Safety terminal block board -X18
2 3
3 Safety circuit board 4 CN220
CN206
41 GSIN1_1+
4 General purpose safety input 42 GSIN1_1-

5 Turn ON/OFF at the same

5
43 GSIN1_2+
44 GSIN1_2-

4 45 GSIN2_1+
46 GSIN2_1-

5
47 GSIN2_2+
48 GSIN2_2-

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Description of Units and Circuit Boards

9.17 General purpose safety output

The GP safety output signal is used in the safety logic circuit function.
For example, composing the circuit to output the status signal, such as the SERVO ON
signal or the emergency stop button by the safety logic circuit function enables to output the
signals to the external device.
The signal is outputted as the dual signals.
For an example of the use of the GP safety output signal, refer to chapter "Safety logic
circuit" in the manual Instructions with the document-no.: E1102000214XX01* and higher.

NOTICE
 Rated output value is DC24V and less than 50 mA. Avoid excessive load when connect.
 When connect the inductive load, such as the safety relay, with the output circuit, use
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. It may cause the damage
on the output circuit.
 An error (e.g., relay contact sticking) of the device (e.g., safety relay, contactor)
controlled by the GP safety output signal (GSOUT) must be detected (signal
inconsistency) by the controlled device (e.g, by using a safety PLC).

Example of use of GP safety output signal

1 YRC1000
1
2 Safety circuit board
-X18
3 Safety terminal block board 2 CN206 3 CN220

4 GP safety output 1-1 GSOUT1_1+ 49

5 GP safety output 1-2 GSOUT1_1- 50

4
6 GP safety output 2-1
GSOUT1_2+ 51
7 GP safety output 2-2
GSOUT1_2- 52
5

GSOUT2_1+ 53

GSOUT2_1- 54
6

GSOUT2_2+ 55

GSOUT2 _2- 56
7

9 - 114
Description of Units and Circuit Boards

9.18 Connection Direct-in

This signal is used to input a response signal in search functions.

-X18
1 CN220
2 CN206
63,64
024V2
1 66 AXDIN1
2 67 AXDIN2
3 3 68 AXDIN3
4 69 AXDIN4

65 AXDIN_COM
61,62
+24VAX

-X18
1 CN220
2 CN206
63,64
024V2
66 AXDIN1
67 AXDIN2
68 AXDIN3
69 AXDIN4

4
65 AXDIN_COM
61,62
+24VAX

Fig. 9-6: Connection for Direct-in (SERVO) 1 to 4

1 Safety terminal block board 3 Direct-in (SERVO)

2 Safety circuit board 4 Connect the jumper cable

This part of the wiring is for the SLAVE, for control voltage supply and for the con-
trol card for the main axles of the slave robot, CSRA-SDCA01AA.

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Description of Units and Circuit Boards

9.19 General purpose input (SERVO)

Connect when use the general purpose signal.
This signal cannot be used for standard specification because this signal is optional.

General purpose input (SERVO)

1 YRC1000
1
2 Safety terminal block board
2 -X18
CN220
3
CN206
3 Safety circuit board 72,73
024V2
1 75 AXIN1
4 General purpose input 4
(SERVO) 2 76 AXIN2
74 AXIN_COM
5 Connect the jumper 70,71
+24VAX

9 - 116
Description of Units and Circuit Boards

9.20 General purpose I/O board

Four digital I/O connectors for the robot general purpose I/O are provided 40 inputs and 40
outputs.
The I/Os are divided into two types: general purpose I/O and specific I/O. The I/O
assignment differs depending on the application. Specific I/O is a signal in which the part is
decided in advance. Specific I/O is used when the external operation equipment such as
positioner controller and centralized controller control the robot and related equipment as a
system. General-purpose I/O are mainly used as timing signals for the manipulator and
peripheral devices in JOBs that require robot motion.
Refer to chapter “General purpose I/O signal assignment” for more details on signal
allocation.
For the connection of the robot’s general purpose I/O signal connectors, and the I/O signal
related to start and stop, refer to “Connection wire with robot general purpose I/O Connector
(CN306, 307, 308, 309)”and “Specific I/O signal related to start and stop”.
There are two types of general-purpose I/O boards.

Specification Type
NPN JANCD-AIO01-E
PNP (only for Europe) JANCD-AIO02-E

General purpose I/O board (JANCD-AIO01-E)

1 For switching external power

supply 1 2 3
2 Power Supply Protective Fuse
(F1) 3,15A / 250 V
CN304

CN303
3 Power Supply Output connector
4 Digital I/O connector (CN306,
CN307, CN308 and CN309)

CN307 CN309

CN306 CN308

• Connection wire with robot general purpose I/O connector (CN306, 307, 308, 309)
Please refer to the figure below when manufacturing the cable connection with robot
general purpose I/O connector (CN306, 307, 308, 309) of I/O unit. Unshielded twisted pair
cable must be used (the cable side connector and the I/O terminal block are the options).

9 - 117
Description of Units and Circuit Boards

B20 B1 B20 B1

A20 A1 A20 A1

1 2

1
5

3
CN307 CN309
CN306 CN308
2

CN306, 307, 308, 309 4

B1 B20

A1 A20

Fig. 9-7: Connection Wire with Robot GP I/O Connector

1 Connector A (cable side) 4 Connector B

2 Connector C (cable side) 5 I/O Cable (AIO ~ external)
3 GP I/O board (JANCD-AIO0□-E) 6 I/O Cable (AIO ~ Terminal Block)

Connector A
Connector model FCN-361J040-AU (FUJITSU) (Soldered Pin type)
Hood model FCN-360C040-B (FUJITSU)
Connector B
Connector model 1747053-1 (Tyco Electronics Amp)
Connector C
Connector model 1903404-1 Tyco Electronics Amp) (MT Type)

9 - 118
Description of Units and Circuit Boards

NPN 24VDC 0VDC

-X18 65 66 67 68 69
AXDIN_COM AXDIN1 AXDIN2 AXDIN3 AXDIN4

Fig. 9-8: NPN logic

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 chapter 9.21 "Assignment of universal I/O signals" about the maximum
current of the transistor and the relay output circuits.
• Specific I/O signal related to start and stop.
The following signals are specific I/O signals related to start and stop:
• SERVO ON (depending on application:
• External SERVO ON (common to all application)
• External start (depending on application)
• Operating (depending on application)

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Description of Units and Circuit Boards

• External hold (common to all application)

• External emergency stop (common to all application)

Timing chart

1 Robot
RUN
2 While SERVO-ON 1 STOP
ON
3 SERVO-ON 2 OFF

4 External start 3 ON
OFF
5 Operating T
ON
6 External hold 4 OFF T

7 External emergency stop 5 ON

OFF
ON
6 OFF
T
ON
7 OFF

Note:
Set T = 100 ms minimum
External Hold: At the factory default setting, the status turns to the hold status by turning
ON the external hold.

Timing Chart (87017 is turned ON)

1 Robot
RUN
1
2 Operating STOP
ON
3 External hold 2 OFF
T
ON
3 OFF

At the factory default setting, by setting the External Input signal (20011) ON, EX. HOLD
(SPECIFIC. IN TERMNL BLOCK) (40067) turns ON.
By turning ON the pseudo input signal (87017) (External hold contact), when the External
Input signal (20011) is turned OFF, switching of the external hold to ON is enabled.

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Description of Units and Circuit Boards

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
SERVO 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 AIO01.
PL: Pilot lamp
6 YRC1000
6
7 General purpose I/O board
(JANCD-AIO01-E)
8 External SERVO ON 7 CN308
9 SERVO-ON power ON 3
X1
10 Output while SERVO ON B3
8 (20014)
B7

9 +24VU
A18
X3
A8
10 (30011)

Note: This circuit is example in case of AIO01.

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Description of Units and Circuit Boards

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.

1 2 3 4 5
(30011) (30016) (30013) X5 6 7
X4
8 CN308 13
X3 X4
B1
9 (20010)
B7

X6 (30010) 5
X5 024VU
11 +24VU
12 B18
PL X6
B8
10 (30010)

Note:
Number in ( ) means output signal number assigned to AIO01.
PL: Pilot lamp
This circuit is example in case of AIO01
1 Run PB 8 External start command
2 While SERVO-ON 9 External start input
3 Selects PLAY mode 10 Ongoing output
4 Alarm/Error occurring 11 Running, etc.
5 Running confirmation 12 Execute X6
6 Start (Command) 13 GP I/O board (JANCD-AIO01-E)
7 Robot controller

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Description of Units and Circuit Boards

Connection of the external power supply for I/O

In the factory setting, the internal power supply for I/O is used. If the external power supply
for I/O will be used, connect as described below.
1. Remove the wire connected between CN303-1 to -3 and CN303-2 to -4 of the general
purpose I/O circuit board.
2. Connect +24 V of the external power supply to CN303-1 and 0V to CN303-2 of the
robot I/O unit.

(JANCD-AI2Ƒ-E)
(JANCD-AI2Ƒ-E) 2 1
1 CN303
CN303
+24VU +24VU
1(EX+24VIN) F1 +24V 1(EX+24VIN) F1

3.15A 3.15A
2(EX024VIN) 0V 2(EX024VIN)

024VU 024VU

+24V +24V
3(+24V) 3(+24V)

4(024V) 4(024V)

024V 024V

In case of using internal power supply In case of using external power supply
(The factory default settings)
1 General purpose I/O board
2 External power supply (Ready by customer)

NOTICE
 The internal power supply of 24 V of about 1.5 A of robot control can be used for I/O.
Use external 24 V power supply for higher currents and to isolate the circuit inside and
outside the robot controller.
 Power supply circuit for I/O (+24 VU, 024 VU) has 3.15 A fuses (F1).
 Install the external power supply outside the robot control to avoid electric noise
problems.
 If the internal power supply is selected and the external power supply is connected to
CN303-1 to -3 and CN303-2 to -4, do not connect the external power supply line to the
+24 VU and 0V U terminals. The unit may malfunction if the external power supply is
also connected.

9 - 123
Description of Units and Circuit Boards

9.21 Assignment of universal I/O signals

Logical Input name/Function

number
20010 EXTERNAL START
Functions the same as the [START] button of the PP. Only the rising edge
of the signal is valid. It starts robot operation (playback). This signal is in-
valid 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 de-
vice.
20015 SELECT PLAY MODE
The PLAY mode is selected when the key switch 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 key switch of the programming
pendant 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 se-
lection signal is ON, enabling the TEACH mode selection.
20020 INTERFERENCE 1 ENTRANCE PROHIBITED
If the robot attempts to enter the cube 12 area while this signal is ON, the
robot goes to wait status (with SERVO power ON). During wait status, the
robot operation restarts if this signal turns OFF.
20021 INTERFERENCE 2 ENTRANCE PROHIBITED
If the robot attempts to enter the cube 22 area while this signal is ON, the
robot goes to wait status (with SERVO power ON). During wait status, the
Robot operation restarts if this signal turns OFF.
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 main JOB, which manages the sub JOBs called up immediately after the power is
turned ON, is set as the master JOB.

2. See chapter "Interference area" in the manual Instructions with the document-no.: E1102000214XX01* and
higher

9 - 124
Description of Units and Circuit Boards

Logical Input name/Function

number
30010 RUNNING
This signal signifies that the JOB is running (Indicates that the JOB is run-
ning, system status is waiting reserved start or test run is running). This sig-
nal status is the same status as [START] in the PP.
30011 SERVO IS ON
This signal signifies that the SERVO power is turned ON, internal process-
ing such as current position creation is complete, and the system is able to
receive the START command. This signal turns OFF when the SERVO
power supply turns OFF. It can be used for YRC1000 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 to REMOTE/PLAY/TEACH MODE SELECTED
30017 This signal notifies the current mode setting. These signals are synchro-
nized with the key switch in the programming pendant. The signal corre-
sponding to the selected mode turns ON.
30020 IN CUBE 1
This signal turns ON when the current TCP lies inside a pre-defined space
(Cube 1). Use this signal to prevent interference with other robots and po-
sitioners.
30021 IN CUBE 2
This signal turns ON when the current TCP lies inside a predefined space
(Cube 2). Use this signal to prevent interference with other manipulators
and positioners.
30022 WORK HOME POSITION (IN CUBE 64)2
This signal turns ON when the current TCP lies inside the work home posi-
tion area. Use this signal to evaluate whether the manipulator is in the start
position.
30023 INTERMEDIATE START OK
This signal turns ON when the robot operates. It turns OFF when the cur-
rently executed line is moved with the cursor or when editing operation is
carried out after HOLD is applied during operation. Therefore, this signal
can be used as a restart interlock after a HOLD is applied. However, it also
turns ON in the TEACH mode and TEACH MODE SELECTED signal must
be referred together.
1. This signal is not output during operation.

9 - 125
Description of Units and Circuit Boards

2. The work home position cube and Cube 64 are the same.

9.21.1 ARC welding

• I/O Allocation and connection diagram for ARC welding

YRC1000
General-purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X51)
+24VU Model:TIFS553YS or TIFS5N53YS
CN306 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20040 B1 IN09 General-purpose IN
INPUT B1 B1
DC24V 20041 A1 IN10 IN A1 A1
6.8mA(TYP) 20042 B2 IN11 IN B2 B2
20043 A2 IN12 IN A2 A2
20044 B3 IN13 IN B3 B3
20045 A3 IN14 IN A3 A3
20046 B4 IN15 IN B4 B4
20047 A4 IN16 IN A4 A4
B5 B5 B5
A5 A5 A5

B6 B6 B6

A6 A6 A6
B7 024VU B7 024VU
A7
024VU A7 024VU
30040 B8 OUT09
OUTPUT
General-purpose OUT
B8 B8
30041 A8 OUT10 OUT A8 A8
30042 B9 OUT11 OUT B9 B9

30043 A9 OUT12 OUT A9 A9

30044 B10 OUT13 OUT B10 B10

30045 A10 OUT14 OUT A10 A10
30046 B11 OUT15 OUT B11 B11
30047 A11 OUT16 OUT A11 A11
B12 B12 B12
A12 A12 A12
Each Point B13 B13 B13
DC24V A13 A13
A13
50mA(MAX) B14 B14
B14
A14 A14
A14
B15 B15 B15

A15 A15 A15

B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 024VU
+24V B17 024VU B17
-4 024V A17 024VU
䠄24V䚸1.5A䠅 A17 024VU
B18 +24VU B18 +24VU䚷䚷䚷䚷
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24VE -2 024VU A19 +24VU
A19 +24VU
024VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU

* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU

when a external power supply is used. 024VU
+24VU䚷
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-9: JANCD-AIO01-E (CN306 Connector)

9 - 126
Description of Units and Circuit Boards

YRC1000
General-purpose I/O board䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X52)
+24VU
CN307 Connector Model:TIFS553YS or TIFS5N53YS
Logical Connector Name
Number Number Signal Terminal
Number
Each Point 20050 B1 IN17 IN B1 B1
DC24V 20051 A1 IN18 IN A1 A1
6.8mA(TYP) 20052 B2 IN19 IN B2 B2
20053 A2 IN20 IN A2 A2
20054 B3 IN21 IN B3 B3
20055 A3 IN22 IN A3 A3
20056 B4 IN23 IN B4 B4
20057 A4 IN24 IN A4 A4

B5 B5 B5
A5 A5 A5
B6 B6
B6
A6 A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30050 B8 OUT17- OUT B8 B8
A8 OUT17+ OUT A8 A8 RLY
30051 B9 OUT18- OUT B9 B9

A9 OUT18+ A9 A9 RLY
OUT
30052 B10 OUT19- OUT B10 B10

A10 OUT19+ OUT A10 A10 RLY

30053 B11 OUT20- OUT B11 B11
A11 OUT20+ OUT A11 A11 RLY
30054 B12 OUT21- OUT B12 B12

A12 OUT21+ OUT A12 A12 RLY

Each Point 30055 B13 OUT22- OUT B13 B13
DC24V A13 A13 RLY
A13 OUT22+ OUT
500mA(MAX) 30056 B14 OUT23- OUT B14 B14
A14 A14 RLY
A14 OUT23+ OUT
OUT B15 B15
30057 B15 OUT24-
A15 OUT24+ OUT A15 A15 RLY
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 +24V B17 024VU
B17 024VU
-4 024V A17 024VU
A17 024VU
䠄24V䚸1.5A䠅
B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24VE -2 024VU A19 +24VU
A19 +24VU * means internal relay
024VE B20 FG
B20 FG RLY means
A20 024VU
A20
024VU
024VU
024VU

* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU

when a external power supply is used. 024VU
+24VU䚷䚷䚷䚷
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-10: JANCD-AIO01-E (CN307 Connector)

9 - 127
Description of Units and Circuit Boards

YRC1000
General-purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X53)
+24VU Model:TIFS553YS or TIFS5N53YS
CN308 Connector
Logical Connector Terminal
Number Number Name Signal
Number
Each Point 20010 B1 External Start IN B1 B1
DC24V 20011 A1 External Hold IN A1 A1
6.8mA(TYP) 20012 B2 Call Master Job IN B2 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 External Servo ON IN B3 B3
20015 A3 Select Play Mode IN A3 A3
20016 B4 Select Teach Mode IN B4 B4
20017 A4 䠉 IN A4 A4
Interference1 Entrance B5
20020 B5 Prohibited IN B5
Interference2 Entrance
20021 A5 Prohibited IN A5 A5
20022 B6 Work Prohibited IN B6 B6
20023 A6 Work Response IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30010 B8 Running OUT B8 B8
30011 A8 Servo is ON OUT A8 A8
30012 B9 Top of Master Job OUT B9 B9
30013 A9 Alarm/Error Occurred OUT A9 A9
30014 B10 Battery Alarm OUT B10 B10
30015 A10 Remote Mode Selected OUT A10 A10
30016 B11 Play Mode Selected OUT B11 B11
30017 A11 Teach Mode Selected OUT A11 A11
30020 B12 In Cube 1 OUT B12 B12
30021 A12 In Cube 2 OUT A12 A12
30022 B13 Work Home Position OUT B13 B13
Each Point 30023 A13 Intermediate Start OK
A13 A13
(continuousing Sequence) OUT
24VDC B14
B14 B14
50mA (max.) A14
A14 A14
B15 B15 B15
A15 A15 A15
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 +24V B17 024VU B17 024VU
024V 024VU
-4 A17 024VU A17
䠄24V䚸1.5A䠅
B18 +24VU B18 +24VU
External A18 䚷䚷䚷䚷䚷䚷
+24VU
A18 +24VU
Power Supply -1 +24VU 䚷䚷䚷䚷䚷䚷
B19 +24VU B19 +24VU
+24VE -2 024VU A19 䚷䚷䚷䚷䚷䚷
+24VU
A19 +24VU
024VE 䚷䚷䚷䚷䚷䚷
B20 FG B20 FG
A20 A20 024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. 024VU
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷

Fig. 9-11: JANCD-AIO01-E (CN308 Connector)

9 - 128
Description of Units and Circuit Boards

YRC1000
Connector Terminal Converter
General-purppose I/O board 䠄JANCD-AIO01-E䠅 (Optional) (-X54)
+24VU Model:TIFS553YS or TIFS5N53YS
CN309 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20024 B1 䠉 IN B1 B1
DC24V 20025 A1 䠉 IN A1 A1
6.8mA(TYP) 20026 B2 Weaving Prohibited IN B2 B2
20027 A2 Sensing Prohibited IN A2 A2
IN01 General-purpose B3
20030 B3 INPUT IN B3
20031 A3 IN02 IN A3 A3
20032 B4 IN03 IN B4 B4
20033 A4 IN04 IN A4 A4
20034 B5 IN05 IN B5 B5
20035 A5 IN06 IN A5 A5

20036 B6 IN07 IN B6 B6

20037 A6 IN08 IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30024 B8 Gas Shortage (Monitor) OUT B8 B8
30025 A8 Wire Shortage (Monitor) OUT A8 A8
30026 B9 Wire Sticking (Monitor) OUT B9 B9
A9 A9
30027 A9 Arc Shortage (Monitor) OUT
30030 B10 OUT01
OUTPUT
General-purpose
OUT B10 B10
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03 OUT B11 B11
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12

30035 A12 OUT06 OUT A12 A12

30036 B13 OUT07 OUT B13 B13
30037 A13 OUT08 A13 A13
Each Point OUT
B14 B14
DC24V B14
A14 A14
50mA(MAX) A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 024VU
+24V B17 024VU B17
-4 024V A17 024VU
A17 024VU
䠄24V䚸1.5A䠅 +24VU
B18 +24VU B18
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24VE B19 +24VU
-2 024VU A19 +24VU
024VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used. +24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-12: JANCD-AIO01-E (CN309 Connector)

Logical Input name/Function

number
20022 WORK PROHIBITED (Arc Generation Prohibited)
Arc generation is prohibited while this signal is ON. Arc generation starts
when this signal turns OFF inside the arc-generation area. Use this signal
to confirm teaching.

9 - 129
Description of Units and Circuit Boards

Logical Input name/Function

number
20023 WORK RESPONSE (Pseudo Arc ON Response)
This signal is used as a pseudo signal in cases that “Arc Generation Con-
firmation” signal is not equipped on a welding power supply. Wire this signal
ON normally (short to OV).
20026 WEAVING PROHIBITED
Weaving is prohibited while this signal is ON. Use this signal to check
taught steps and movements without performing the weaving operation.
20027 SENSlNG PROHIBITED
Arc sensing is prohibited while this signal is ON. Use this signal to check
taught steps and movements if an arc sensor is mounted.

Logical Input name/Function

number
30024 GAS SHORTAGE (MONITOR)
This signal stays ON while the gas shortage signal from the welding power
supply is ON.
30023 INTERMEDIATE START OK
This signal turns ON when the robot operates. It turns OFF when the cursor
is moved or editing operation is carried out after HOLD is applied during op-
eration.
Therefore, this signal can be used as a restart interlock after a HOLD is ap-
plied.
However, it also turns ON in the TEACH MODE and TEACH MODE SE-
LECTED signal must be referred together.
30025 WIRE SHORTAGE (MONITOR)
This signal status ON while the wire shortage signal from the welding power
supply is ON.
30026 WIRE STICKING (MONITOR)
The wire sticking check is conducted automatically when the arc turns OFF.
If wire sticking is detected, this signal remains ON until the wire sticking is
released.
30027 ARC SHORTAGE (MONITOR)
This signal stays ON while the arc shortage signal from the welding power
supply is ON.

9 - 130
Description of Units and Circuit Boards

9.21.2 Handling

• I/O Allocation and connection diagram for Handling

YRC1000
General- purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X51)
+24VU Model:TIFS553YS or TIFS5N53YS
CN306 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20040 B1 IN09 IN B1 B1
DC24V 20041 A1 IN10 IN A1 A1
6.8mA(TYP) 20042 B2 IN11 IN B2 B2
20043 A2 IN12 IN A2 A2
20044 B3 IN13 IN B3 B3
20045 A3 IN14 IN A3 A3
20046 B4 IN15 IN B4 B4

20047 A4 IN16 IN A4 A4

B5 B5 B5
A5 A5
A5
B6 B6
B6
A6 A6 A6

B7 024VU B7 024VU
A7 024VU A7 024VU

30040 B8 OUT09 OUT B8 B8

30041 A8 OUT10 OUT A8 A8
30042 B9 OUT11 OUT B9 B9

30043 A9 OUT12 A9 A9
OUT
30044 B10 OUT13 OUT B10 B10
30045 A10 OUT14 OUT A10 A10
30046 B11 OUT15 OUT B11 B11

30047 A11 OUT16 OUT A11 A11

B12 B12 B12

Each Point A12 A12 A12
DC24V B13 B13 B13
50mA(MAX) A13 A13
A13
B14 B14
B14
A14 A14
A14
B15 B15
B15
A15 A15 A15

B16 024VU B16 024VU

CN303 Internal A16 024VU
Power Supply A16 024VU
-3 B17 024VU
+24V B17 024VU
024V A17 024VU
-4 A17 024VU
䠄24V䚸1.5A䠅 +24VU
B18 +24VU B18
External A18 +24VU
Power Supply A18 +24VU
-1 +24VU B19 +24VU
+24VE B19 +24VU
024VU A19 +24VU
024VE -2 A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU

* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU

when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-13: JANCD-AIO01-E (CN306 Connector)

9 - 131
Description of Units and Circuit Boards

YRC1000
General- purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X52)
+24VU Model:TIFS553YS or TIFS5N53YS
CN307 Connector
Logical Connector Terminal
Number Number Name Signal
Number
Each Point 20050 B1 Sensor Input 1 IN B1 B1
DC24V 20051 A1 Sensor Input 2 IN A1 A1
6.8mA(TYP) 20052 B2 Sensor Input 3 IN B2 B2
20053 A2 Sensor Input 4 IN A2 A2
20054 B3 Sensor Input 5 B3 B3
IN
20055 A3 Sensor Input 6 IN A3 A3
B4 B4
20056 B4 Sensor Input 7 IN
A4 A4
20057 A4 Sensor Input 8 IN
B5 B5
B5
A5 A5
A5
B6 B6
B6
A6 A6
A6
B7 024VU B7 024VU
A7
024VU A7 024VU
B8 B8
30050 B8 Hand Value 1-1- OUT
A8 A8
A8 Hand Value 1-1+ OUT RLY
B9 B9
30051 B9 Hand Value 1-2- OUT
A9 A9 RLY
A9 Hand Value 1-2+ OUT
B10 B10
30052 B10 Hand Value 2-1- OUT
A10 A10 RLY
A10 Hand Value 2-1+ OUT
B11 B11
30053 B11 Hand Value 2-2- OUT
A11 A11 RLY
A11 Hand Value 2-2+ OUT
B12 B12
30054 B12 Hand Value 3-1- OUT
A12 A12 RLY
A12 Hand Value 3-1+ OUT
B13 B13
Each Point 30055 B13 Hand Value 3-2- OUT
A13 A13 RLY
DC24V A13 Hand Value 3-2+ OUT
B14 B14
500mA(MAX) 30056 B14 Hand Value 4-1- OUT
A14 A14 RLY
A14 Hand Value 4-1+ OUT
B15 B15
30057 B15 Hand Value 4-2- OUT
OUT A15 A15 RLY
A15 Hand Value 4-2+
B16 024VU
B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 B17 024VU
+24V B17 024VU
024V A17 024VU
-4 A17 024VU
䠄24V䚸1.5A䠅 B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24VE B19 +24VU
A19 +24VU * means internal relay
-2 024VU A19 +24VU
024VE B20 FG RLY means
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
024VU
when a external power supply is used.
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-14: JANCD-AIO01-E (CN307 Connector)

9 - 132
Description of Units and Circuit Boards

YRC1000
General- purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X53)
+24VU
CN308 Connector Model:TIFS553YS or TIFS5N53YS
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20010 B1 External Start IN B1 B1
DC24V 20011 A1 External Hold IN A1 A1
6.8mA(TYP) 20012 B2 Call Master Job IN B2 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 External Servo ON IN B3 B3
20015 A3 Select Play Mode IN A3 A3
20016 B4 Select Teach Mode IN B4 B4
20017 A4 䠉 IN A4 A4
Interference1 Entrance B5 B5
20020 B5 Prohibited IN
Interference2 Entrance A5 A5
20021 A5 Prohibited IN
20022 B6 䠉 IN B6 B6

20023 A6 䠉 IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30010 B8 Running OUT B8 B8
30011 A8 Servo is ON OUT A8 A8
30012 B9 Top of Master Job OUT B9 B9
A9 A9
30013 A9 Alarm/Error Occurred OUT
30014 B10 Battery Alarm OUT B10 B10
30015 A10 Remote Mode Selected OUT A10 A10
30016 B11 Play Mode Selected OUT B11 B11
30017 A11 Teach Mode Selected OUT A11 A11
30020 B12 In Cube 1 OUT B12 B12

30021 A12 In Cube 2 OUT A12 A12

30022 B13 Work Home Position OUT B13 B13
Intermediate Start OK A13 A13
Each Point 30023 A13 (continuousing Sequence) OUT
B14 B14
DC24V B14
50mA(MAX) A14 A14
A14
B15 B15 B15

A15 A15 A15

B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 +24V 024VU
B17 024VU B17
-4 024V A17 024VU
A17 024VU
䠄24V䚸1.5A䠅
B18 +24VU B18 +24VU
External A18 +24VU
Power Supply A18 +24VU
-1 +24VU B19 +24VU
B19 +24VU
+24VE -2 024VU A19 +24VU
A19 +24VU
024VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU

* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU

when a external power supply is used. 024VU
+24VU䚷
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-15: JANCD-AIO01-E (CN308 Connector)

9 - 133
Description of Units and Circuit Boards

YRC1000
General- purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X54)
+24VU Model:TIFS553YS or TIFS5N53YS
CN309 Connector
Logical Connector Name Signal
Number Number Terminal
Number
Each Point 20024 B1 䠉 IN B1 B1
DC24V 20025 A1 䠉 IN A1 A1
6.8mA(TYP) 20026 B2
Shock Sensor (NC)
- Hold IN B2 B2
20027 A2 Low Air Pressure IN A2 A2
20030 B3 IN01 General-purpose Input IN B3 B3
20031 A3 IN02 IN A3 A3
20032 B4 IN03 IN B4 B4
20033 A4 IN04 IN A4 A4
20034 B5 IN05 IN B5 B5
20035 A5 IN06 IN A5 A5

20036 B6 IN07 IN B6 B6

20037 A6 IN08 IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30024 B8 䠉 OUT B8 B8
30025 A8 䠉 OUT A8 A8
30026 B9 䠉 OUT B9 B9
䠉 A9 A9
30027 A9 OUT
30030 B10 OUT01 General-purpose Output OUT B10 B10
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03 OUT B11 B11
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12

30035 A12 OUT06 OUT A12 A12

30036 B13 OUT07 OUT B13 B13
Each Point 30037 A13 OUT08 A13 A13
OUT
DC24V B14 B14
B14
50mA(MAX) A14
A14 A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 024VU
+24V B17 024VU B17
-4 024V A17 024VU
A17 024VU
䠄24V䚸1.5A䠅
B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24VE -2 024VU A19 +24VU
A19 +24VU
024VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-16: JANCD-AIO01-E (CN309 Connector)

Logical Input name/Function

number
20026 TOOL SHOCK SENSOR
This is normally ON (NC) signal input. When it turns OFF, an YRC1000 dis-
plays a message “HAND TOOL SHOCK SENSOR OPERATING” and a
HOLD is applied. The releasing in TEACH mode is done on the handling
application diagnostic display. Set tool shock sensor function “NOT USE”
on the handling applications diagnostic display if this signal is not be used.

9 - 134
Description of Units and Circuit Boards

Logical Input name/Function

number
20027 LOW AIR PRESSURE
This signal is normally OFF (NO). When it turns ON, YRC1000 displays
user alarm in the PLAY mode or displays user message in the TEACH
mode.
20050 SENSOR INPUT 1 - 8
to20057 Inputs 1 to 8 are monitored with the HSEN handling specific instructions.
Sensor inputs 1 to 8 correspond to HSEN 1 to 8.

Logical Input name/Function

number
30023 INTERMEDIATE START OK
This signal turns ON when the robot operates. It turns OFF when the cursor
is moved or editing operation is carried out after HOLD is applied during op-
eration.
Therefore, this signal can be used as a restart interlock after a is applied.
However, it also turns ON in the teach mode and TEACH MODE SELECT-
ED signal must be referred together.
30050 HAND VALVE 1-4
to30057 These outputs are controlled by the HAND handling specific instructions.
Hand valves 1 to 4 correspond to HAND 1 to 4.

9 - 135
Description of Units and Circuit Boards

9.21.3 GP application

• I/O Allocation and connection diagram for GP-Application

YRC1000
General- purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X51)
+24VU Model:TIFS553YS or TIFS5N53YS
CN306 Connector
Logical Connector Terminal
Number Number Name Signal
Number
Each Point B1 B1
20040 B1 IN09 General-Purpose Input IN
DC24V A1
20041 A1 IN10 IN A1
6.8mA(TYP) B2
IN11 IN B2
20042 B2
20043 A2 A2 A2
IN12 IN
B3 B3
20044 B3 IN13 IN
A3 A3
20045 A3 IN14 IN
B4 B4
20046 B4 IN15 IN
A4 A4
20047 A4 IN16 IN
B5 B5
B5
A5 A5
A5
B6 B6
B6
A6 A6
A6
B7 024VU
B7 024VU
A7 024VU
A7 024VU
B8 B8
30040 B8 OUT09 General-purpose Output OUT
A8 A8
30041 A8 OUT10 OUT
B9 B9
30042 B9 OUT11 OUT
A9 A9
30043 A9 OUT12 OUT
B10 B10
30044 B10 OUT13 OUT
A10 A10
30045 A10 OUT14 OUT
B11 B11
30046 B11 OUT15 OUT
A11 A11
30047 A11 OUT16 OUT
B12 B12
B12
A12 A12
A12
B13 B13
B13 A13
Each Point A13
A13
DC24V B14 B14
B14
50mA(MAX) A14 A14
A14 B15
B15
B15
A15 A15
A15
B16 024VU
B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 B17 024VU
+24V B17 024VU
024V A17 024VU
-4 A17 024VU
䠄24V䚸1.5A䠅 B18 +24VU
B18 +24VU +24VU
A18
External A18 +24VU
-1 +24VU B19 +24VU
Power Supply
B19 +24VU A19 +24VU
+24VE -2 024VU A19 +24VU B20 FG
024VE
B20 FG 024VU
A20
A20 024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. +24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-17: JANCD-AIO01-E (CN306 Connector)

9 - 136
Description of Units and Circuit Boards

YRC1000
General- purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X52)
+24VU Model:TIFS553YS or TIFS5N53YS
CN307 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20050 B1 IN17 IN B1 B1
DC24V 20051 A1 IN A1
IN18 A1
6.8mA(TYP) B2
20052 B2 IN19 IN B2
20053 A2 IN20 IN A2 A2
20054 B3 IN21 IN B3 B3

20055 A3 IN22 IN A3 A3
IN23 IN B4 B4
20056 B4
IN24 IN A4 A4
20057 A4
B5 B5
B5
A5 A5
A5
B6 B6
B6
A6 A6 A6

B7 024VU B7 024VU
A7 024VU A7 024VU

30050 B8 OUT17- OUT B8 B8

OUT17+ A8 A8 RLY
A8 OUT
B9 B9
30051 B9 OUT18- OUT
A9 A9 RLY
A9 OUT18+ OUT
B10 B10
30052 B10 OUT19- OUT
A10 OUT19+ OUT A10 A10 RLY
B11 B11
30053 B11 OUT20- OUT
A11 OUT20+ OUT A11 A11 RLY
B12 B12
30054 B12 OUT21- OUT
A12 A12 RLY
A12 OUT21+ OUT
Each Point B13 B13
30055 B13 OUT22- OUT
A13 A13 RLY
DC24V A13 OUT22+ OUT
500mA(MAX) B14 B14
30056 B14 OUT23- OUT
A14 A14 RLY
A14 OUT23+ OUT
B15 B15
30057 B15 OUT24- OUT
A15 OUT24+ OUT A15 A15 RLY

B16 024VU B16 024VU

CN303 Internal A16 024VU
Power Supply A16 024VU
-3 B17 024VU
+24V B17 024VU
024V A17 024VU
-4 A17 024VU
䠄24V䚸1.5A䠅 B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24VE A19 +24VU * means internal relay
-2 024VU A19 +24VU
024VE B20 FG RLY means
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-18: JANCD-AIO01-E (CN307 Connector)

9 - 137
Description of Units and Circuit Boards

YRC1000
General- purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X53)
+24VU Model:TIFS553YS or TIFS5N53YS
CN308 Connector
Logical Connector Name Signal Terminal
Number Number Number
Each Point 20010 B1 External Start IN B1 B1
DC24V 20011 A1 External Hold IN A1 A1
6.8mA(TYP) 20012 B2 Call Master Job IN B2 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 External Servo ON IN B3 B3

20015 A3 Select Play Mode IN A3 A3

IN B4 B4
20016 B4 Select Teach Mode
A4 A4
20017 A4 䠉 IN
Interference1 Entrance B5 B5
20020 B5 Prohibited IN
Interference2 Entrance A5 A5
20021 A5 Prohibited IN
B6 B6
20022 B6 Work Prohibited IN
20023 A6 䠉 IN A6 A6

B7 024VU B7 024VU
A7 024VU A7 024VU

30010 B8 Running OUT B8 B8

30011 A8 Servo is ON OUT A8 A8

B9 B9
30012 B9 Top of Master Job OUT
A9 A9
30013 A9 Alarm/Error Occurred OUT
OUT B10 B10
30014 B10 Battery Alarm
30015 A10 Remote Mode Selected OUT A10 A10
B11 B11
30016 B11 Play Mode Selected OUT
OUT A11 A11
30017 A11 Teach Mode Selected
B12 B12
30020 B12 In Cube 1 OUT
A12 A12
30021 A12 In Cube 2 OUT
OUT B13 B13
30022 B13 Work Home Position
Intermediate Start OK A13 A13
Each Point 30023 A13 (continuousing Sequence) OUT
DC24V B14 B14
B14
50mA(MAX) A14 A14
A14
B15 B15
B15
A15 A15 A15

B16 024VU B16 024VU

CN303 Internal A16 024VU
Power Supply A16 024VU
-3 +24V B17 024VU
B17 024VU
024V A17 024VU
-4 A17 024VU
䠄24V䚸1.5A䠅 B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24VE B19 +24VU
024VU
A19 +24VU
024VE -2 A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. +24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-19: JANCD-AIO01-E (CN308 Connector)

9 - 138
Description of Units and Circuit Boards

YRC1000
General- purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X54)
+24VU Model:TIFS553YS or TIFS5N53YS
CN309 Connector
Logical Connector Name
Number Number Signal Terminal
Each Point Number
Interference3 Entrance
20024 B1 Prohibited IN B1 B1
DC24V Interference4 Entrance
20025 A1 Prohibited IN A1 A1
6.8mA(TYP)
20026 B2 䠉 IN B2 B2
20027 A2 䠉 IN A2 A2
20030 B3 IN01 General-purpose Input IN B3 B3
20031 A3 IN02 IN A3 A3
20032 B4 IN03 IN B4 B4
20033 A4 IN04 IN A4 A4
20034 B5 IN05 IN B5 B5
20035 A5 IN06 IN A5 A5

20036 B6 IN07 IN B6 B6

20037 A6 IN08 IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30024 B8 In Cube 3 OUT B8 B8
30025 A8 In Cube 4 OUT A8 A8
30026 B9 Work Instruction OUT B9 B9
A9 A9
30027 A9 䠉 OUT
30030 B10 OUT01 General-purpose Output OUT B10 B10
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03 OUT B11 B11
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12

30035 A12 OUT06 OUT A12 A12

30036 B13 OUT07 OUT B13 B13
30037 A13 OUT08 A13 A13
Each Point OUT
B14 B14
DC24V B14
A14 A14
50mA(MAX) A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 +24V B17 024VU
B17 024VU
-4 024V A17 024VU
A17 024VU
䠄24V䚸1.5A䠅
B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24VE B19 +24VU
-2 024VU A19 +24VU
024VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU

* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU

when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-20: JANCD-AIO021-E (CN309 Connector)

Logical Input name/Function

number
20022 WORK PROHIBITED (Tool ON Prohibited) R1 - R8
Even if TOOLON instruction is executed, YRC1000 doesn’t output to exter-
nal while this signal is ON.
20024 INTERFERENCE 3 ENTRANCE PROHIBITED
If the robot attempts to enter the cube 31 area while this signal is ON, the
robot goes to wait status (with SERVO power ON). During wait status, the
robot operation restarts if this signal turns OFF.

9 - 139
Description of Units and Circuit Boards

Logical Input name/Function

number
20025 INTERFERENCE 4 ENTRANCE PROHIBITED
If the robot attempts to enter the cube 42 area while this signal is ON, the
robot goes to wait status (with SERVO power ON). During wait status, the
robot operation restarts if this signal turns OFF.
1. See chapter "Interference area" in the manual Instructions with the document-no.: E1102000214XX01* and
higher

Logical Input name/Function

number
30024 IN CUBE 3
This signal turns ON when the current TCP lies inside a predefined space
(Cube 3). Use this signal to prevent interference with other robots and po-
sitioners.
30025 IN CUBE 4
This signal turns ON when the current TCP lies inside a predefined space
(Cube 4). Use this signal to prevent interference with other robots and po-
sitioners.
30026 WORK COMMAND
This signal provides the command for the general tool to operate. TOOL
ON instruction execution or the [TOOL ON] key in the programming pen-
dant turns this signal ON and TOOL OFF instruction execution or the
[TOOL OFF] key in the programming pendant turns it OFF. However, it re-
mains OFF while the WORK PROHIBITED signal (20022) is input or while
the robot is stopped.

9 - 140
Description of Units and Circuit Boards

9.21.4 Spot welding

• I/O Allocation and connection diagram for spot welding

YRC1000
General-purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X51)
+24VU Model:TIFS553YS or TIFS5N53YS
CN306 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20040 B1 IN17 IN B1 B1
DC24V 20041 A1 IN18 IN A1 A1
6.8mA(TYP) 20042 B2 IN19 IN B2 B2
20043 A2 IN20 IN A2 A2
20044 B3 IN21 IN B3 B3
20045 A3 IN22 IN A3 A3
20046 B4 IN23 IN B4 B4
20047 A4 IN24 IN A4 A4
B5 B5 B5
A5 A5 A5

B6 B6 B6

A6 A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30040 B8 OUT17 OUT B8 B8
30041 A8 OUT18 OUT A8 A8
30042 B9 OUT19 OUT B9 B9

30043 A9 OUT A9 A9
OUT20
30044 B10 OUT21 OUT B10 B10
30045 A10 OUT22 OUT A10 A10
30046 B11 OUT23 OUT B11 B11
30047 A11 OUT24 OUT A11 A11
B12 B12 B12
A12 A12 A12
Each Point B13 B13 B13
DC24V A13 A13
A13
50mA(MAX) B14 B14
B14
A14 A14
A14
B15 B15 B15

A15 A15 A15

B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 024VU
+24V B17 024VU B17
-4 024V A17 024VU
䠄24V䚸1.5A䠅 A17 024VU
B18 +24VU B18 +24VU䚷䚷䚷䚷
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24VE -2 024VU A19 +24VU
A19 +24VU
024VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU

* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU

when a external power supply is used. 024VU
+24VU䚷
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-21: JANCD-AIO01-E (CN306 Connector)

9 - 141
Description of Units and Circuit Boards

YRC1000
General-purpose I/O board䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X52)
+24VU
CN307 Connector Model:TIFS553YS or TIFS5N53YS
Logical Connector Name
Number Number Signal Terminal
Number
Each Point 20050 B1 Timer Cooling Water
Error (IN09) IN B1 B1
DC24V 20051 A1 Gun Cooling Water
Error (IN10) IN A1 A1
6.8mA(TYP) 20052 B2 Transthermo Error (IN11) IN B2 B2
20053 A2 Low Air Pressure (IN12) IN A2 A2
20054 B3 IN13 IN B3 B3
20055 A3 IN14 IN A3 A3
20056 B4 IN15 IN B4 B4
20057 A4 IN16 IN A4 A4

B5 B5 B5
A5 A5 A5
B6 B6
B6
A6 A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30050 B8 OUT B8 B8
A8 Weld ON/OFF (OUT09)*** OUT A8 A8 RLY
30051 B9 OUT B9 B9

A9 A9 A9 RLY
Weld Error Reset (OUT10)** OUT
30052 B10 OUT B10 B10

A10 Weld Condition 1 (OUT11)** OUT A10 A10 RLY

30053 B11 OUT B11 B11
A11 Weld Condition 2 (OUT12)** OUT A11 A11 RLY
30054 B12 OUT B12 B12

A12 Weld Condition 3 (OUT13)** OUT A12 A12 RLY

Each Point 30055 B13 OUT B13 B13
DC24V A13 A13 RLY
A13 Weld Condition 4 (OUT14)** OUT
500mA(MAX) 30056 B14 OUT B14 B14
A14 A14 RLY
A14 Weld Condition 5 (OUT15)** OUT
OUT B15 B15
30057 B15
A15 Tip Change Request (OUT16)** OUT A15 A15 RLY
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 +24V B17 024VU
B17 024VU
-4 024V A17 024VU
A17 024VU
䠄24V䚸1.5A䠅
B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
B19 +24VU
+24VE -2 024VU A19 +24VU
A19 +24VU * means internal relay
024VE B20 FG
B20 FG RLY means
A20 024VU
A20
024VU
024VU
024VU

* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU

when a external power supply is used. 024VU
+24VU䚷䚷䚷䚷
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-22: JANCD-AIO01-E (CN307 Connector)

9 - 142
Description of Units and Circuit Boards

YRC1000
General-purpose I/O board 䠄JANCD-AIO01-E䠅 Connector Terminal Converter
(Optional) (-X53)
+24VU Model:TIFS553YS or TIFS5N53YS
CN308 Connector
Logical Connector Terminal
Number Number Name Signal
Number
Each Point 20010 B1 External Start IN B1 B1
DC24V 20011 A1 External Hold IN A1 A1
6.8mA(TYP) 20012 B2 Call Master Job IN B2 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 External Servo ON IN B3 B3
20015 A3 Select Play Mode IN A3 A3
20016 B4 Select Teach Mode IN B4 B4
20017 A4 䠉 IN A4 A4
Interference1 Entrance B5
20020 B5 Prohibited IN B5
Interference2 Entrance
20021 A5 Prohibited IN A5 A5
20022 B6 Welding ON/OFF IN B6 B6
20023 A6 Welding Pause IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30010 B8 Running OUT B8 B8
30011 A8 Servo is ON OUT A8 A8
30012 B9 Top of Master Job OUT B9 B9
30013 A9 Alarm/Error Occurred OUT A9 A9
30014 B10 Battery Alarm OUT B10 B10
30015 A10 Remote Mode Selected OUT A10 A10
30016 B11 Play Mode Selected OUT B11 B11
30017 A11 Teach Mode Selected OUT A11 A11
30020 B12 In Cube 1 OUT B12 B12
30021 A12 In Cube 2 OUT A12 A12
30022 B13 Work Home Position OUT B13 B13
Each Point 30023 A13 Intermediate Start OK
A13 A13
(continuousing Sequence) OUT
24VDC B14
B14 B14
50mA (max.) A14
A14 A14
B15 B15 B15
A15 A15 A15
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 +24V B17 024VU B17 024VU
-4 024V 024VU
A17 024VU A17
䠄24V䚸1.5A䠅
B18 +24VU B18 +24VU
External A18 䚷䚷䚷䚷䚷䚷
+24VU
A18 +24VU
Power Supply -1 +24VU 䚷䚷䚷䚷䚷䚷
B19 +24VU B19 +24VU
+24VE -2 024VU A19 䚷䚷䚷䚷䚷䚷
+24VU
A19 +24VU
024VE 䚷䚷䚷䚷䚷䚷
B20 FG B20 FG
A20 A20 024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4 024VU
when a external power supply is used. 024VU
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷
+24VU
䚷䚷䚷䚷䚷䚷

Fig. 9-23: JANCD-AIO01-E (CN308 Connector)

9 - 143
Description of Units and Circuit Boards

YRC1000
Connector Terminal Converter
General-purppose I/O board 䠄JANCD-AIO01-E䠅 (Optional) (-X54)
+24VU Model:TIFS553YS or TIFS5N53YS
CN309 Connector
Logical Connector
Number Number Name Signal Terminal
Number
Each Point 20024 B1 Interference3 Entrance IN
Prohibited B1 B1
DC24V 20025 A1 Interference4 Entrance
Prohibited IN A1 A1
6.8mA(TYP) 20026 B2 - IN B2 B2
20027 A2 - IN A2 A2
20030 B3 IN1 USER INPUT IN B3 B3
20031 A3 IN2 IN A3 A3
20032 B4 IN B4 B4
IN3
20033 A4 IN4 IN A4 A4
20034 B5 IN5 IN B5 B5
20035 A5 IN6 IN A5 A5

20036 B6 IN B6 B6
IN7
20037 A6 IN8 IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30024 B8 In Cube 3 OUT B8 B8
30025 A8 In Cube 4 OUT A8 A8
30026 B9 OUT B9 B9
- A9 A9
30027 A9 OUT
-
30030 B10 OUT01 User Output OUT B10 B10
30031 A10 OUT02 OUT A10 A10
30032 B11 OUT03 OUT B11 B11
30033 A11 OUT04 OUT A11 A11
30034 B12 OUT05 OUT B12 B12

30035 A12 OUT06 OUT A12 A12

30036 B13 OUT07 OUT B13 B13
30037 A13 OUT08 A13 A13
Each Point OUT
B14 B14
DC24V B14
A14 A14
50mA(MAX) A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU
CN303 Internal A16 024VU
Power Supply A16 024VU
-3 024VU
+24V B17 024VU B17
-4 024V A17 024VU
A17 024VU
䠄24V䚸1.5A䠅 +24VU
B18 +24VU B18
External A18 +24VU
A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24VE B19 +24VU
-2 024VU A19 +24VU
024VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
* Remove Jumper-pin between CN303-1 and -3, CN303-2 and -4
when a external power supply is used. +24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU

Fig. 9-24: JANCD-AIO01-E (CN309 Connector)

Logical num- I/O designation/function

ber
20022 WELDING ON/OFF (from sequencer)
This signal inputs the welding ON/OFF selector switch status from the
sequencer in the interlock unit. The WELD ON/OFF signal is output to
the Power Source according to this signal and the robot status.

9 - 144
Description of Units and Circuit Boards

Logical num- I/O designation/function

ber
20023 WELDING PAUSE (from sequencer)
This signal is used to move the robot to the home position when an er-
ror occurs in the Power Source or the gun.
The robot ignores the spot welding instruction and operates playback
motion.
20025 INTERFERENCE 4 ENTRANCE PROHIBITED
If the robot attempts to enter cube 4 while this signal is ON, the robot is
put into wait status (with SERVO power ON). During wait status the ro-
bot movement is started as soon as the signal is switched to OFF.
200501 TIMER COOLING WATER ERROR
This signal monitors the status of timer cooling water. The robot dis-
plays alarm and stops when this signal is input. The SERVO power sup-
ply remains ON.
200511 GUN COOLING WATER ERROR
This signal monitors the status of gun cooling water. The robot displays
alarm and stops when this signal is input. The SERVO power supply re-
mains ON.
200521 TRANSTHERMO ERROR
Error signal is sent from the transformer in the welding gun to the robot.
The signal is normally an ON (NC) signal. An alarm occurs when the
signal is OFF. The SERVO power supply remains ON.
200531 LOW AIR PRESSURE
When air pressure is reduced and this input is turned ON, an alarm oc-
curs. The SERVO power supply remains ON.
2
WELD COMPLETION
This signal indicates that the Power Source completed welding without
error. This signal is used as a confirmation signal for welding instruction
execution and manual spot welding.
After this signal is input, the welding sequence is completed and the
next step is executed when confirmation limit switch is not provided.
2
WELDING ERROR
This signal indicates an abnormal welding result or Power Source’s er-
ror. Alarm occurs and the manipulator stops if this signal is input during
welding.
2
STICK DETECTION
This signal indicates an abnormal welding result or Power Source’s er-
ror. Alarm occurs and the manipulator stops if this signal is input during
welding.
2 GUN FULL OPEN DETECTION
This signal indicates that the stroke of the double stroke gun is full
open.
2
GUN SHORT OPEN DETECTION
This signal is connected with a single gun open verification limit switch
or a double stroke gun open verification limit switch to verify the gun
“open”.

9 - 145
Description of Units and Circuit Boards

Logical num- I/O designation/function

ber
2
GUN PRESSURE DETECTION
This signal indicates that a gun is in pressing status.
2 TIP REPLACE COMPLETION
When this signal is input after tip replacement, the TIP REPLACE RE-
QUEST signal turns OFF, and the stored number of welding is cleared.
1. This signal can be set to “USE” or “NOT USE” by pseudo input signal 8202x. If "NOT USE" is selected, this
signal can be used as the universal I/O signal described in parentheses.

2. This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.

Logical num- I/O designation/function

ber
30024 IN CUBE 3
This signal is turned ON when the current TCP lies within a pre-defined
area (CUBE 3). Use this signal to prevent faults due to other robots or
positioners.
30025 IN CUBE 4
This signal is turned ON when the current TCP lies within a pre-defined
area (CUBE 4). Use this signal to prevent faults due to other robots or
positioners.
300501 WELD ON/OFF
Outputs a signal input from the interlock panel, etc.considering the ro-
bot status.
300512 WELD ERROR RESET
This signal commands the reset error status of the power source. This
is operated with the programming pendant.
(30052 to WELD CONDITION (level signals)
300562 1(1), 2(2), 4(3), 8(4), 16(5), 32(6), 64(7), 128(8)
Sets the welding conditions for the power source.
The output format can be set as binary or discrete (bit number.) It can
handle up to 255 conditions. Most-significant bit is the parity bit (when
specified).
2
WELDING COMMAND
This signal outputs execution command signal to the Power Source.
This signal is not necessary for power sources which are executed us-
ing the WELDING CONDITION signal.
2
STROKE CHANGE1
SINGLE SOLENOID
DOUBLE SOLENOID
This is a signal, when a double stroke gun is used, to change the open
stroke of the welding gun.
2
GUN PRESS COMMAND
This outputs the command of gun press.

9 - 146
Description of Units and Circuit Boards

Logical num- I/O designation/function

ber
30057 TIP REPLACE REQUEST
This signal is output when the stored number of welding reaches the
number of welding set for the tip replacement.
1. This signal can be set to “USE” or “NOT USE” by pseudo input signal ”8202x”. If “NOT USE” is selected, this
signal can be used as the universal I/O signal described in parentheses.

2. This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.

9.21.5 List of device configuration depending on model

YRC1000 (ERAR-1000-xxxxxx-□□□) B15

Input voltage 380 to 480 VAC
Dimensions H x L x W (mm) 598 x 490 x 427 (excluding
protrusions)
Breaker NF125-HVU 3P 15A
Control power supply unit CSRA-CPS01KB1
CPU unit - JZNC-ARK01-E
CPU circuit board JANCD-ACP01-E
Back circuit board JANCD-ABB01-E
Riser board (PCIe/PCIe) JANCD-ABB02-E
Robot I/F board JANCD-AIF01-1E
Safety terminal block board IM-YE250/5-80P
General-purpose I/O board JANCD-AIO01-E
Power supply contactor unit JZRCR-APU03-1
Inverter unit Refer to Tab. 9-3: "Small-capacity model"
SERVO control board CSRA-SDCA01AA
Single axis amplifier Refer to Tab. 9-3: "Small-capacity model"
Safety circuit board JANCD-ASF01-E
Converter CSRA-CV05D01A
Regeneration resistor Type SMVK500W260J/RO A6667
Nominal value 500W
Resistance value 26 Ω
DC reactor 2 x 85R-15014A
Heat exchanger TCMSY-3□0DC
Cooling fan 4 x 09225VE-24P-CA-02
Noise filter -
1. Changed to CSRA-CPS01KB from CSRA-CPS01KA in controllers manufactured from October 28, 2019.

Tab. 9-2: Equipment configuration (Small-capacity model)

9 - 147
Description of Units and Circuit Boards

Model Inverter unit Single axis amplifier

GP7
AR900
CSRA-SDA01H01A No amplifier
GP8
AR700
GP12
AR1440
GP25
CSRA-SDA02H01A No amplifier
AR1700
GP25-12
AR2010
AR1440E CSRA-SDA02H01A CSRA-SDB21HA

Tab. 9-3: Small-capacity model

9 - 148
Description of Units and Circuit Boards

YRC1000 (ERAR-1000-xxxxxx-□□□) B15

Input voltage 380 to 480 VAC
Dimensions H x L x W (mm) 598 x 490 x 427 (excluding pro-
trusions)
Breaker NF125-HVU 3P20A
Control power supply unit CSRA-CPS01KB2
CPU unit - JZNC-ARK01-E
CPU circuit board JANCD-ACP01-E
Back circuit board JANCD-ABB01-E
Riser board (PCIe/PCIe) JANCD-ABB02-E
Robot I/F board JANCD-AIF01-1E
Safety terminal block board IM-YE250/5-80P
General-purpose I/O board JANCD-AIO01-E
Power supply contactor unit JZRCR-APU03-1
Inverter unit Refer to Tab. 9-5: "Medium/Large-capacity model"
SERVO control board CSRA-SDCA01AA
Single axis amplifier Refer to Tab. 9-5: "Medium/Large-capacity model"
Safety circuit board JANCD-ASF01-E
Converter CSRA-CV10D03A
DC reactor 2 x PI-EZ002-0213
AC reactor SR-23A or UZBC-B 23A
Heat exchanger TCMSY-3□□DC
Cooling fan 4 x 09225VE-24P-CA-02
Noise filter -
Power supply for ro- S8VK-T12024
bot fan1
Fan control relay1 LY2N-D2 DC24V
1. The power supply for the manipulator fan and fan control relay are installed only in the ERAR-1000-06VRF130-
□□□ type controllers.

2. Changed to CSRA-CPS01KB from CSRA-CPS01KA in controllers manufactured after October 28, 2019.

Tab. 9-4: Equipment configuration (Medium/Large-capacity model)

9 - 149
Description of Units and Circuit Boards

Model Inverter unit Single axis amplifier

GP20HL
CSRA-SDA12H01A No amplifier
AR3120
GP50
GP35L
GP88
SP80
GP110
SP100
GP120
SP110
SP130
GP180
SP165
GP180-120
SP165-105
GP200S
GP215
GP225
SP120
CSRA-SDA11H01A No amplifier
GP250
SP235
GP280
GP165R
SP150R
GP200R
SP185R
SP110H
SP180H
SP180H-110
SP225H
PH130RF
PH130F
GP400
GP600
GP400R
PL500
GP110B
CSRA-SDA11H01A CSRA-SDB71HA
SP100B

Tab. 9-5: Medium/Large-capacity model

9 - 150
Description of Units and Circuit Boards

9 - 151
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 [email protected].
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

[email protected]
www.yaskawa.eu.com