Wiring E1102000143GB03

Robot controller
User manual
Installation and Wiring

European
Created on: 11/2013
Revision: 3
Document number: E1102000143GB03 Author: WOE
Changes made in revision:

Rev. 01: Revision of TIM-RS
Rev. 02: Revision of the entire manual
Rev. 03: chapter: Recommended spare parts
© Copyright 2013
This documentation – also in part – may be reproduced or made available to third parties only with the
express approval of YASKAWA Europe "Robotics Division GmbH".
We have checked the content of this publication for compliance with the hardware described.
Nevertheless, discrepancies cannot be ruled out. Therefore, we cannot guarantee full compliance.
However, the information given in this publication is checked regularly and any necessary corrections
will be made in subsequent editions.
Subject to technical modifications.
Table of contents
Table of contents
1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
1.7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7.1 For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7.2 YASKAWA manual list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7.3 Personal protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7.4 Safety during installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.8 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.9 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Position type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Transporting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.2 Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.3 Using a lifting truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Installing protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Notes on cable junctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2 Power supply / feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.1 Installation of primary power supply breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.1 Connection to main power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.2 Connecting the robot control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Basic specifications robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Programming pendant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.1 Periodic inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Cooling fan inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Emergency Stop Button Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4 Inspection of the enabling switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3
Table of contents
7.5 Check battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.6 Check the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.7 Open Phase Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Description of Units and Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8.1 Power ON unit (JZRCR-YPU52 - ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.2 Axes control circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.2.1 Major axes control circuit board (SRDA-EAXA21A) . . . . . . . . . . . . . . . . . . . . . . 46
8.2.2 External axes control circuit board (SRDA-EAXB21A) . . . . . . . . . . . . . . . . . . . . 48
8.3 CPU unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.3.1 Unit and circuit board in the CPU unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.4 CPS (JZNC-YPS21-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.5 Machine safety I/O logic circuit board (JANCD-YSF22-E) . . . . . . . . . . . . . . . . . . . . . . . 51
8.5.1 Connection for tool shock sensor (SHOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.6 Machine safety terminal block circuit board (JANCD-YFC22-E). . . . . . . . . . . . . . . . . . . 54
8.7 External emergency stop signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.8 Safety plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.9 Installation of saftey plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.10 External enable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.11 Full speed test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.12 Slow speed mode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.13 External hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.14 External SERVO-ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.15 SYSRUN Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.16 External axes overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.17 SERVO-ON enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.18 Emergency stop button output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.19 Universal safety input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.20 Universal safety output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.21 Direct-in (SERVO) 1 to 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.22 Universal input (SERVO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.23 Universal output (SERVO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.24 Universal I/O circuit board (JANCD-YIO22-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.25 Brake control circuit board (JANCD-YBK21-3E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.26 Converter (SRDA-COA30A21B-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.27 Capacitor module (SRDA-CUA  AA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.28 Amplifier module (SDRA-SDA  A01A-E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.29 Assignment of general I/O signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.29.1 ARC welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.29.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.29.3 General application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.29.4 Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.29.5 JANCD-YEW01-E circuit board (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
8.29.6 The list of the Equipment configuration by model. . . . . . . . . . . . . . . . . . . . . . . 113
9 Recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4
General
1 General
1.1 Notes for safe operation
DANGER!
Indicating immediate danger at high risk, hazard that can cause death or serious bodily
injuries if no precautions are taken.
WARNING!
Indicating possible medium risk hazard situation which can cause death or serious bodily
injuries if it is not avoided.
CAUTION!
Indicating potentially dangerous situation with low risk of minor or moderate bodily injuries
result if it is not avoided. This signal word can also be used for property damage warnings.
1.2 Frequently used terms

The YASKAWA robot is a product of YASKAWA Electric Corporation, and is provided by
default with the robot controller, the handheld programming device and robot cable.
The terms are designated as follows in this manual:
Definitions Used
Control Robot controller
Industrial robot Robot
Programming pendant / teach box Programming pendant
Supplying cable between robot and robot Cable
controller
Robot, robot controller and cable Robot system
YASKAWA Electric Corporation YEC
YASKAWA Robotics Division YEU-R
Move, calibrate and setup of the robot Teaching
Movement sequences of the robot Jobs
Technical customer service TCS
1 -5
General
1.3 Target group

This manual is directed at users with the following knowledge:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• System knowledge of the robot controller
• Specially trained staff
NOTICE
According to the international DIN EN ISO 10218-1 standard, operators of a robot system
must receive training before they operate the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For information on the training programme, please visit
www.yaskawa.eu.com or contact our branch offices 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 -6
General
1.5 Improper use

Any use that deviates from the intended use shall be regarded as impermissible misuse.
This includes:
• Transport of people and animals
• Use as ascending aid.
• Use outside the permissible operating limits.
• Use in environments with risk of explosion (except for ATEX-approved robots).
• Overload
• Use without protective equipment.
NOTICE
Modifications to the robot, e.g. drilling holes or similar modifications, can damage parts.
This will be regarded as improper use (i.e. use that deviates from the intended use) and will
lead to loss of warranty and liability claims as well as loss of the declaration of incorporation.
CAUTION!
The robot system is an incomplete machine.
The robot system may be put into operation only after it has been determined that the
incomplete or complete machine in which the robot system is being installed:
 Corresponds to the provisions of the Machinery Directive.
 Complies with all relevant (harmonized) standards.
 Corresponds to the state of the art.
1 -7
General
1.6 About this manual

• This manual explains the various components of the robot controller and the general
operating functions. Be sure to read and understand this instruction manual thoroughly
before installing and operating the robot control.
• To ensure correct and safe operation, read the robot control operating instructions
(basic information, installation and wiring and system setup).
• In order to illustrate details clearly, some drawings are shown with the protective covers
or shields removed. All protective covers and shields must be mounted before the robot
is operated.
• The drawings and figures in this manual are representative illustrations. They may differ
from the product delivered.
• YEU-R reserves the right to make technical changes. These changes may include
product improvements, modifications or changes in specifications
• If your copy of the operating and maintenance instructions is damaged or lost, please
contact the local YASKAWA branch office to order a new copy. The official branch
offices are listed on the last page. Please mention the manual number in your order.
• YASKAWA Europe GmbH is not responsible for damage caused due to unauthorized
modification of the painting robot track. If any impermissible modifications are made to
the system and to the robot, all warranty and liability claims as well as the declaration
of incorporation will expire.
Descriptions of the programming pendant, buttons, and displays are shown as
follows:
Equipment Manual Designation

Character Keys The keys which have characters printed on them are de-
noted with [ ]. ex. [ENTER]
Symbol Keys The keys which have a symbol printed on them are not
denoted with [ ] but depicted with a small picture.
ex. page key The cursor key is an exception, and a
picture is not shown.
Mode Key Three kinds of modes that can be selected by the mode
key are denoted as follows: REMOTE, PLAY, or TEACH
Button Three buttons on the upper side of the programming
pendant are denoted as follows: HOLD button; START
button; EMERGENCY STOP button.
Axis Keys Keys for axis operation
Number Keys Keys for number input
Keys pressed simultaneously When two keys are to be pressed simultaneously, the
keys are shown with a “+” sign between them.
TOOL SEL
ex. [SHIFT] SHIFT

+ [COORD] COORD
.
Displays The menu displayed in the programming pendant is de-
noted with { }.ex. {JOB}
Description of the Operation Procedure
In the explanation of the operation procedure, the expression "Select • • • "
• the cursor is moved to the object item and the SELECT key is pressed.
• the that the item is directly selected by touching the screen.
Registered Trademark
1 -8
General
In this manual, names of companies, corporations, or products are trademarks, registered

trademarks, or brand names for each company or corporation. The indications of ® and 
are omitted.
1 -9
General
1.7 Safety
REMOTE TEACH
PLAY START HOLD
JOB EDIT DISPLAY UTILITY
JOB CONTENT
JOB NAME: TEST01
CONTROL GROUP: R1
0000
0001
0002
0003
NOP
SET B000 0
SET B001 1
MOVJ VJ=80.00
STEP NO: 0003
TOOL: 00
1
0004 MOVJ VJ=80.00
0005 DOUT OGH#(13) B002
0006 DOUT OT#(41) ON
0007 MOVL C00002 V=880.0 CV#(1) CTP=0.662
0008 DOUT OT#(44) ON
0009 TIMER T=3.0
0010 MOVL V=880.0
0011 MOVL V=880.0
0012 MOVL V=880.0
0013 MOVL V=880.0
Main Menu ShortCut !Turn on servo power
LAYOUT GO BACK
DIRECT
OPEN
COORD
Multi PAGE AREA
MAIN SHORT
SERVO SELECT
ON !? CANCEL
MENU CUT
READY ASSIST
SERVO ON
X- X+
S- S+ X- X+
HIGH R- R+
SPEED
Y-. Y+
L- L+ Y- Y+
.
B- B+
FAST
MANUAL SPEED
Z- Z+
U- U+ Z- Z+
SLOW T- T+
INTER 7 8 9 TEST
SHIFT LOCK START SHIFT
ROBOT INFORM 4 5. 6 BWD FWD

LIST
EX.AXIS 1 2 3 DELETE INSERT
BACK MOTION 0 . -
SPACE MODIFY ENTER
TYPE
MOTOMAN
Fig. 1-1: Programming pendant
1 Emergency stop button
WARNING!
Death or injury because of danger of crushing
If the emergency stop button does not function properly, the robot cannot be stopped in the
event of an emergency.
 The robot should not be used if the emergency stop button does not function.
 Before operating the manipulator check the emergency stop button. The servo voltage
must be deactivated immediately when the emergency stop button is pressed (see Fig.
1-3: "Emergency stop button") on the programming pendant.
 When the servo power is turned OFF, the "SERVO ON" LED (see Fig. 1-2: "LED
SERVO ON") on the programming pendant.
SERVO ON
Fig. 1-2: LED SERVO ON
Fig. 1-3: Emergency stop button
1 - 10
General
WARNING!
Before you release the emergency stop button (see Fig. 1-4: "Release of emergency stop
button by turning") note the following:
 Make sure that there is no one within the maximum working range of the robot.
 Clear the cell of all items which could collide with the robot.
 Now you can switch ON the servo voltage by pressing the hold-to-run button on the
programming pendant.
Fig. 1-4: Release of emergency stop button by turning
WARNING!
if anyone enters the working area of the robot during operation or any problems occur,
always press the emergency stop button immediately. This is located on the programming
pendant (see Fig. 1-1: "Programming pendant").
Observe the following precautions when performing teaching operations within the
manipulator’s operating range:
 View the Robot from the front whenever possible.
 Always follow the prescribed operating procedure (see the instructions on robot control
as well as the operating instructions on "Handling" or "Universal Application").
 An area must be left clear so that the operator can retreat to it in case of emergency.
The following inspection procedures must be performed prior to teaching the robot. If
problems are found, correct them immediately, and be sure that all other necessary
processing has been performed.
• Check for problems in robot movement.
• Check the connectors for tight fit and all cables for damage.
• Hang the programming pendant back on the robot controller after use.
• Make sure that the key for the operating mode selector switch (Teach/Automatic) of the
programming pendant is kept by a skilled person who has been specially trained by us.
• The key may be inserted in the key switch of the programming pendant only during
teach operation; after the teach operation it must be immediately removed and kept in
a safe place.
1.7.1 For your safety
In general, the requirements that apply to robots differ from those for other production
facilities. They include, for example, larger work areas, high speed operation, quick arm
movements etc., which may involve risks.
Please read the manuals as well as the related documentation carefully. Take all
precautions to avoid injuries to persons and damage to the system.
The operator is responsible for ensuring that all applicable standards, regulations, rules and
legal provisions on safety are observed and the operating conditions are safe.
1 - 11
General
CAUTION!
Teaching and maintenance of the robot qualify as "dangerous activities" under the
Occupational Health and Safety Act and must be performed in compliance with the
following rules and regulations:
– German Occupational Safety and Health Act.
– Enforcement Order of Occupational Safety and Health Law.
– Ordinance for the Occupational Safety and Health Law.
Other relevant provisions:
– Occupational Safety and Health Act in USA.
– EC Machinery Directive 2006/42/EC
Fig. 1-5: CE marking

Please comply with the international standard DIN EN ISO 10218-1 for safe operation of
the robot(s) or robotic device(s).
Increase the efficiency of your safety management system by defining authorized
employees and safety managers and conducting training on a regular basis.
NOTICE
According to the international DIN EN ISO 10218-1 standard, operators of a robot system
must receive training before they operate the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For information on the training programme, please visit
www.yaskawa.eu.com or contact our branch offices directly.
1 - 12
General
1.7.2 YASKAWA manual list
It is important to have all the manuals on the YASKAWA control or robot available and to
know their contents. Please make sure you have all these manuals. If you are missing any
manual, please contact the local YASKAWA branch office.
You must have the YASKAWA manuals listed below available.
• Basic information / Beginner's instructions (E1102000144XX01* and higher* and
higher).
• Setup and connection (E1102000143XX01* and higher*).
• Basic programming (E1102000147XX01* and higher*).
• System Setup (E1102000145XX01* or higher*).
• Alarm history (E1102000146XX01 or higher*).
• Operating and maintenance instructions for the specific robot type.
* "XX" is the language of the document.
1.7.3 Personal protection
The entire working area of the robot is potentially dangerous. The following staff must work
with appropriate preparation and subject to the maxim "Safety First" to ensure the safety
of all.
• Safety management
• Assembly staff
• Operating staff
• Maintenance staff
DANGER!
Death by electric shock; serious injury from fire hazard;
Avoid dangerous actions in the area where the robot is installed. Please be sure to take
safety precautions.
 Unauthorised persons should not have access to the robot.
 Unauthorised persons should not have access to the peripheral equipment.
 Put up signs in the respective working area, such as "Highly flammable", "High
voltage", "Stop" and "No unauthorized access".
WARNING!
There is a risk of injury if there is contact with the robot or peripheral equipment.
Strictly observe the following items:
 Always wear approved work clothes (no loose-fitting clothes).
 Do not wear gloves when operating the robot.
 Personal Protective Equipment (PPE) is subject to the provisions of the 89/656/EEC
guideline.
 Do not wear large jewellery, such as earrings, rings or pendants.
 Always wear protective safety equipment such as protective helmets, safety shoes
(with anti-slip soles), face shields, protective glasses and gloves as necessary.
CAUTION!
Injury and material damage due to unforeseen movements.
1 - 13
General
Observe the following note:

• Never forcibly move the robot axes.
• Never lean against the robot controller.

• Avoid inadvertent pressing of the keys.
• Do not allow unauthorised persons to touch the robot controller during operation.
Fig. 1-6: Do not lean on
1.7.4 Safety during installation and wiring
For further details of the installation and the electrical connection please see Chapter 5.3.2
"Connecting the robot control" on page 33.
DANGER due to electric current!

Death and serious injury from electrical shock and fire hazard.
Carry out earthing in accordance with all applicable electrical regulations.
 Comply with the standard "Electrical Equipment of Machines" according to IEC 60204-
1:2005 (EN 60204-1:2006).
1 - 14
General
WARNING!
Injury and material damage due to unforeseen movements.
When planning installation, draw up easy-to-observe guidelines to ensure safety. Take
safety aspects into consideration when planning the installation. Observe the following
when installing the robot:
 Select an area such as that described below to install the robot
 Make sure the area is large enough so that the fully extended arm with tool does not
collide with the wall, the safeguards or the robot controller.
 During installation, pay attention to the following figure "Required installation planning".
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).
CAUTION!
Danger of injury and material damage in case of non-compliance with protective
measures
For safe operations, the following points must be observed.
 The equipment may be operated only by persons with sufficient training.
 Install the controller only in a safe location from which the robot is visible at any time.
 Fasten the robot with the specified bolts (listed in the operating and maintenance
manual for each robot model).
 Pay attention to the size and type of bolts (specified in the operation and maintenance
manual for each robot model).
 Install the robot controller outside the safeguarding of the manipulator’s safety
enclosure.
CAUTION!
Danger of injury and material damage from falling or movements
In case of improper installation of the robot controller it may move unexpectedly or fall down
(see the figure below: "Attaching the robot control").
 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.
1 - 15
General
CAUTION!
Personal injury and damage from improper connections and unforeseen movements
Operators and other personnel may sturnble 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. 1-7: Protective cover for forklift
1 Piping 3 Cables and tubes

2 Cable duct 4
1.7.4.1 Safety in the work area
WARNING!
Risk of injury from movements of the robot
To ensure safety, enforce the following precautions:
 Install a safeguarding.
 Post a warning sign stating "Off-limits During Operation" at the entrance of the
enclosure.
 The gate of the barrier must be equipped with a safety interlock.
 Make sure the interlock operates correctly before operation.
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.
1 - 16
General
1.7.4.2 Operating safety
DANGER!
Death and fire caused by short circuiting
Switching on the power supply during tool installation may result in electric shock.
 Before fixing a tool (e.g. welding torch), make sure the power supply to the robot
controller is turned off.
 Lock the switch, and display a warning sign (refer to EN 60204-1).
 Never exceed the rated capacity of the robot (the robot capacity can be found in the
"Technical Data" section of this manual).
WARNING!
Danger of injury and material damage caused by unforeseen movements of the robot
If possible, teach jobs from outside the robot’s maximum work area.
Observe the following precautions when performing teaching operations within the
manipulator’s operating range:
 Always view the robot from the front.
 Always follow the predetermined operating procedure.
 Always have an escape plan in mind in case the robot comes toward you unexpectedly.
 Ensure that you have a place to retreat to in case of emergency.
External safety
The robot and its auxiliary equipment must be surronded by a safetyguard. Entrances
(doors, gates, etc.) must be protected by interlockings, electro-sensitive devices or similar.
Opening of the gates or entrance to the robot working area must stop all motions inside the
cell. Before taking the robot into operation, the complete machine must fulfill the “Essential
health and safety requirements relating to the design and construction of machinery”
according to the EU Machinery Directive.
Emergency stop function

The emergency stop circuits are designed according to category 1 (EN 418 item 4.1.5)
Using power to the servo motor to achieve the stop and then removal of power when stop
is achieved. If stop is not achieved after 0.8 seconds, mechanical brakes are engaged
automatically to support stopping.
1 - 17
General
1.8 Manufacturer
Address:
YASKAWA ELECTRIC CORPORATION
2-1 SHIROISHI KUROSAKI
YAHATANISHILU KITAKYUSYU
JAPAN
1.9 Authorized representative

Address:
YASKAWA Europe GmbH
Robotics Division
Yaskawastr. 1
85391 Allershausen
Germany
1 - 18
Supply
2 Supply
2.1 Checking the scope of delivery
The standard delivery includes the following items:
1 2
DX200
MOTOMAN
MANU AL
4 5
Fig. 2-1: Scope of supply
1 Programming pendant 4 The present assembly instructions

2 Robot controller 5 Cable
3 Robot
2 - 19
Supply
2.2 Position type plate

Verify whether the serial number of the robot, the robot controller and the programming
pendant with the delivery. The serial number can be found on the type plate as shown
below.
S/N.
YASAKAW DX200
Part No.
Power Supply Peak kVA
AC 400/415/440 Average kVA
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN
YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen
DX200
Fig. 2-2: Position type plate
NOTICE
Please contact the local YASKAWA branch office if the serial numbers do not match the
information on the delivery note.
2 - 20
Transportation
3 Transportation
CAUTION!
Personal injury or damage to property
The system consists of precision components. Failure to observe this caution may
adversely affect performan
 Crane and forklift operations must be performed only by authorized personnel. The
same applies to the use of slings.
 Avoid excessive vibration or shock during transportation.
3.1 Transporting method

• Check that the eyebolts are securely fastened.
• The robot controller weights approximately 140 - 180 kg. Use load carrying devices
strong enough to withstand the weight.
• No external forces may be exerted on the robot controller. Failure to observe this
warning may result in personal injuries and material damage.
3 - 21
Transportation
3.1.1 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.
YASAKAW DX200
Part No.
YASAKAW DX200 Power Supply Peak kVA
Part No. AC 400/415/440 Average kVA
Power Supply Peak kVA Serial No.
AC 400/415/440 Average kVA Date/Signature
Serial No. Type ERDR-
Date/Signature Robot Type
Type ERDR- Robot Order No.
Robot Type Robot Serial No.
Robot Order No.
Robot Serial No.

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN YASKAWA Europe „Robotics Division“ GmbH
DX200
DX200
Fig. 3-1: Transport with crane
3.1.2 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.
Fig. 3-2: Using a forklift
1 Protective padding 3 Palette

2 Tiedown straps 4 Forklift tines
3.1.3 Using a lifting truck
By removing the lower front cover you will access to a tunnel under the cabinet. Normally
cables are led through this opening. However, it can also be used to lift the control cabinet.
1. Remove the lower front cover by grabbing it at left and right side.
3 - 22
Transportation
2. Pull it straight out.
Fig. 3-3: Using a lifting truck
3 - 23
Installation
4 Installation
WARNING!
Personal injury due to the risk of being crushed and material damage
The following warnings must be heeded.
 Install the safeguarding.
 Install the robot in a location where the fully extended arm and tool or workpiece will not
reach the wall, safeguarding, or controller. If this is not possible, additional measures
must be taken (e.g. S-axis locking screws).
 The robot must not be switched on.
 When mounting the robot on the wall, the base section must have sufficient strength
and rigidity to support the weight of the robot. Also, it is necessary to consider
countermeasures to prevent the robot from falling.
CAUTION!
Personal injury and damage to property
The following safety precautions must be taken.
 Check whether the robot is damaged or incomplete.
 Do not install or operate the robot that is damaged or lacks parts.
 Check whether all transport securing devices and shipping bolts have been removed.
4.1 Installing protective equipment

To ensure safe, be sure to install safeguarding.
The protective equipment includes:
• Separating protection devices
• Non-contact protection devices
• Enclosures
• Marked areas
• Signs
Operator's responsibility
The operator of a robot or a robot system/unit must ensure that all specifications and
requirements of the standards DIN EN ISO 10218-1 and DIN EN ISO 10218-2 are met.
This particularly includes:
• Preparing a risk assessment
• Implementing and installing safety measures / protection devices for the operator.
• Regular training of the employees
• Inspecting all safety measures
• Checking for compliance with intended use
4.2 Location
When installing a robot controller, it is necessary to satisfy the undermentioned
environmental conditions:
4 - 24
Installation
• Ambient temperature: 0° C to + 45° C.

• Air humidity: 20% to 80% relative humidity (non-condensing).
• Must be as dust-free, clean and dry as possible.
• Free from corrosive gas or liquid, or explosive gas or liquid
• Free from excessive vibration (Vibration acceleration: 4.9 m/s² [0.5 G] or less).
• Free from large electrical noise (plasma).
• Must be protected against collisions with moving equipment such as forklifts.
• Install the controller in a location from which the robot is easily visible.
• Install the controller in a location from which you can easily inspect it when the door is
open.
• It is recommended to have a free area around the controller of at least 500 mm to allow
maintenance acces. Minimum is 200 mm on the controllers backside for proper cooling.
• Must comply with the requirements of Directive 2004/108/EC on Electromagnetic
Compatibility.
4.3 Installation example
DX200
4 x M12 x 20
4 x M10 x35
YASAKAW DX200
Part No.
YASAKAW DX200 AC 400/415/440 Average kVA
Part No. Serial No.
Power Supply Peak kVA Date/Signature
Type ERDR-
Serial No.
Robot Type
Date/Signature
Robot Order No.
Type ERDR-
Robot Serial No.
Robot Type
Robot Order No.
Robot Serial No.
YASKAWA ELECTRIC CORPORATION YASKAWA Europe „Robotics Division“ GmbH

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN Yaskawastr. 1, D-85391 Allershausen

DX200
DX200
DX200
4x M12
Fig. 4-1: Connecting two cabinets
4 - 25
Installation
DX200
4 x M12 x 20
4 x M10 x35
YASAKAW DX200
Part No.
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.


DX200
DX200
4x M12
Fig. 4-2: Connecting three cabinets

Anchor the controller to the ground. To this purpose, use the bolts as shown below.
YASAKAW DX200
Part No.
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.


2
DX200
1 2 holes Ø 12 2 Holes for M10 screws
NOTICE
For more information about the installation of the robot please refer to the operating and
maintenance manual for each robot type.
4 - 26
Wiring
5 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.
5 - 27
Wiring
5.1 Notes on cable junctions

• The cables that connect the controller to peripheral device are low voltage circuits.
Keep robot controller signal cables away from the primary power circuit. 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 and equipment
damage. One connects the manipulator and robot controller. Another connects the
robot controller and peripheral device. A wrong connection can cause damage to
electronic equipment.
• Clear the area of all unauthorized personnel while making cable connections. Place all
cables in a covered cable channel in the floor.
1 2 3
1 Piping 3 Wire
2 Cable duct
5.2 Power supply / feed
DANGER!
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.
NOTICE
Connect the power supply to a stable power source that is not prone to power fluctuations.
5 - 28
Wiring
5.2.1 Installation of primary power supply breaker
Robot Power ca- Cable size (size Capacity of Capacity of

pacity (kVA) of terminal) (In breaker in robot breaker in robot
case of Cabtyre controller (with controller (with-
cable (three transformer) (A) out transformer)
cores))(AWG) (A)
MA1440 1.5 3.5 (M5) 10 15
MH12 1.5 3.5 (M5) 10 15
MS210 5.0 5.5 (M5) 20 30
5.3 Cable connections

A connection diagram for the robot, robot cable, primary power cable and programming
pendant is shown below.
1 (432BS6/ABB)
-X4 3
YASAKAW DX200
Part No.
Power Supply Peak
AC 400/415/440 Average
Serial No.
Date/Signature
kVA
kVA -X1
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.


PROGRAMMING PENDANT
X81
-X2
2
-X3
DX200
7 6 4
Fig. 5-1: Cable connection
1 Power supply connection 5 Primary power supply cable

2 Robot cable 6 Programming pendant cable
3 Robot 7 Front view
4 Back View
All dimensions in mm
5 - 29
Wiring
5.3.1 Connection to main power supply
1. Rotate the main power supply switch to the “OFF” position and open the door gently.
YASAKAW DX200
Part No.
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.


Fig. 5-2: Main switch in position OFF
1 Main switch
2. Confirm that the primary power supply is OFF.
3. Open the front door of the robot controller.
4. Insert the special key in the door lock on the front of robot controller, and rotate it 90
degrees clockwise.
Fig. 5-3: Rotating the Door Lock Clockwise
5 - 30
Wiring
5. Connect the primary power supply cable.

– Connect the primary power supply cable to the power supply connector on the back of
robot controller.
CAUTION!
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 system must be grounded.
 In the robot controller, the N-phase of the transformer wires to the ground. Therefore,
if the power supply whose S-phase wires to the ground is connected to the robot
controller, the earth leakage breaker of the equipment trips or the transformer oscillates.
 To connect the power supply whose S-phase does not wire to the ground to the, put an
isolation transformer between the equipment and the robot controller.
6. Connect a ground wire to reduce noise and prevent electric shock.

– Perform grounding in accordance with all relevant local and national electrical codes.
The size of ground wire must be 8.0 mm² or larger.
NOTICE
The customer must prepare the ground wire.
Fig. 5-4: Earth plinth
1 Robot controller 2 Maximum ground resistance of 0.1 Ω
NOTICE
Do not 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.
5 - 31
Wiring
7. Connect the primary power supply cable.
-X4
-X1
-X2 3
432BS6 (ABB)
-X3
Fig. 5-5: Connection to main power supply
1 Robot controller back view 3 Type of connector

2 Primary power supply cable 4
NOTICE
To connect the primary power supply to the robot controller, the user must prepare a CEE
connector (type: 432C6, manufacturer: ABB).
1
432C6 (ABB)
1 Connector type (cable side)
5 - 32
Wiring
5.3.2 Connecting the robot control
1. Connect the cable to the connectors on the back side of robot controller.
1
-X4
-X1
-X2
3
-X3
2
Fig. 5-6: Connecting the robot cable
1 Robot controller back view 3 Robot cable

2 Primary power supply cable
2. Connect the robot to the robot controller.
– Confirm the shape and size of the cable connector, the key fitting, and the position of
the pins of the robot. Push the cable connector into the robot side connector firmly, and
tighten securely.
3. Close the robot controller door.
4. Close the door slowly to avoid pinching the cable.
5. Rotate the door lock counterclockwise 90 degrees.
Fig. 5-7: Rotating the Door Lock Counterclockwise
NOTICE
Always close the door of the robot controller except for maintenance.
Make sure to rotate all the door locks counterclockwise.
If dust or water enter inside the controller, electric shock or breakdown of robot controller
may result.
5 - 33
Wiring
5.3.3 Connecting the programming pendant
Connect the programming pendant cable to the connector connection (X81) on the door of
the robot controller (see figure „Connection programming pendant“).
X81
YASAKAW DX200
Part No.
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.


1
PROGRAMMING PENDANT
X81
DX200
Fig. 5-8: Connection programming pendant
1 Alignment marks
5 - 34
Technical data
6 Technical data
6.1 Basic specifications robot controller
Type: DX200
Cabinet:
Dimensions (H x L x W) 1000 x 800 x 650
Mass 140 - 180 kg
Cooling System Indirect cooling
Ambient temperature 0° C to + 45° C
Relative humidity Maximum 90% non-condensating
Main circuit power input 3-phase 400/415/440 VAC at 50/60
Hz
Digital I/O 25 inputs/ 5 outputs (specific signals
hardware) 40 inputs/40 outputs
(standard) (expandable to 2048 in-
puts/2048 outputs )
Analog I/O 40 channels (optional)
Positioning system Absolute encoder / serial interface
Programming capacity 200,000 steps, 10,000 instructions
and 20,000 PLC steps
Interface RS-232C, Ethernet
Protection class:
Cabinet IP54
Cooling fan not classified
Motor and signal cable IP67
Robot See the operation and maintenance
manual of the robot
Programming pendant IP65
Noise level: Emitted noise
Measured at 1.2 m distance from the cabinet, in- 53 dB
front of the door at 1.0 m over the floor.
Measured at 1.6 m distance from the cabinet, be- 54 dB
hind the cabinet, at 1.0 m over the floor.
* Measured using standard cooling fans
Maintenance function:
Functions System monitor, internal counter (e.
g. power ON time servo power).
Self-Diagnosis Classifies errors and major/minor
alarms and displays the data.
Operation Time Display Control power-on time, Servo power-
on time, Playback time, Operation
time, Work time
User Alarm Display Alarm messages for peripheral de-
vices.
6 - 35
Technical data
Alarmdisplay Alarm message, troubleshooting,

previous alarm records
I/O diagnosis Simulated enable/disable signals
possible.
T.C.P. Calibration Automatic calculation of tool center
point (TCP).
Security:
Specification 2-channel safety system (emergency
stop, safety interlock) 3-position
hold-to-run button, european safety
standard (EN ISO 10218-1).
Collision avoidance Freely definable interference areas.
Shock detection function Monitoring of the torque levels of the
robot axes.
Machine lock Test-run of the peripheral device is
possible without robot movement.
Programming functions:
Programming language INFORM III

Robot motion control Joint coordinates, linear/circular in-
terpolations, Tool coordinates.
Speed setting Percentage for joint coordinates,
0.1mm/s units for interpolations, An-
gular velocity for T.C.P. fixed motion
Program Control Instructions Jumps, Calls, Timer, Robot stop, ex-
ecution 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 pre-
cisiontype, Real type, Position type
I/O instruction Discrete I/O, pattern I/O processing
6 - 36
Technical data
6.2 Programming pendant specifications
Programming pendant:
material Reinforced thermoplastic enclosure with a detachable
suspending strap.
Dimensions (L x H x W) 1000 x 800 x 650
Mass 0.986 kg
Displayed units TFT Color liquid crystal display, VGA (640 × 480),
Touch panel.
Coordinate system Joint, Rectangular/Cylindrical, Tool, User Coordinates.
Speed setting Fine adjustment possible during operationor teach
mode.
Shortcuts Direct access keys and user selectable screen keys
possible.
Language Most important languages available (worldwide)
Interface Compact Flash card slot, USB port (USB1.1)
Operating system Windows CE
At the back of the programming pendant a three position enable device (Dead-mans-
switch (DSW) is placed.
Function:
Relased No function (circuit open).
Middle positon Operation (circuit closed).
Squeezed No function (circuit open)
6 - 37
Technical data
17 1 2 3 4
19
18
16
15
14
6
8
8 12
11 10 9 13
1 Start key 11 Keys for movement types

2 Hold key 12 3-position hold-to-run button
3 Emergency stop button 13 Optional position of the 3-position
hold-to-run button
4 Insertion slot for CF-Card 14 Cursor key
5 Page key 15 Color display with touch screen
6 "SELECT" selection key 16 Menu area
7 Speed keys 17 Key switch for selecting the operating
mode
8 Axis keys 18 USB connection
9 ENTER Key 19 Holder
10 Number keys / function keys
To get from sqeezed position to middle position the deadman switch be completely released
first.
When safety circuit is OK (all gates closed and reset), the DSW has no effect.
When safety circuit is down (gate open), servo power can be activated by DSW.
See table for combinations:
6 - 38
Technical data
Servo On
1 2 3
1 Released = OFF 3 Squeezed tightly = OFF

2 Squeezed = ON
6 - 39
Maintenance and inspection
7 Maintenance and inspection

7.1 Periodic inspection
DANGER!
Death from electrical shock, risk of injury and fire due to short circuit
 Do not touch the cooling fan or other equipment while the power is turned ON.
Carry out the following inspections.
Components Inspection Method Inspection fre-

quency
Robot controller Check that the casing is com- Visual inspec- Daily
pletely closed and not damaged. tion
Check for gaps or damage to the Visual inspec- Monthly
sealed construction. tion
Power cable Check for damage and deterio- Visual inspec- as required
ration of leads. tion
Interior circulation Check the function (while power Visual inspec- as required
fan and backside ON). tion
duct fan.
Emergency stop Check the function (while servo By pressing Before the robot is
button power ON). the keys put into operation.
Enabeling device Check the function (in teach as required

mode).
Battery Confirm battery alarm or mes- as required
sage is displayed or not.
Power supply Check power supply voltage is Visual inspec- as required
normal tion
7 - 40
7.2 Cooling fan inspections

Inspect the cooling fans as required. A defective fan can cause the robot controller to
malfunction because of excessive high temperatures inside.
The interior circulation fan and backside duct fan normally operate while the power is turned
ON. Check if the fans are operating correctly by visual inspection and by feeling air moving
into the air inlet and from the air outlet.
1 5
Option
4
-Q1M -TP1 -AE6.0
-TA9 -G3 -G4 -G5
-TA8
-TA7
-C1
-G1 -G2 FM FM FM
-FS1
-X9
-TA6
-Q1M
FM FM
-TA5
-TA4
2
2
-AE2 -TA3
-TA2 -R1-R6
-TA1
-AE3 -AE1.0 3 -V1

-AE4 -X181
-AE7
Option
-X18 -X81
-T1
-X12A -X12B -X13A -X13B Option

-X810 -EP2
Option
3
3
Fig. 7-1: Ventilation system
1 Front view 4 Door

2 Interior circulation fan 5 Back View
3 Air outlet
NOTICE
When the message of the "Cooling fan in YPS power supply stopped. Exchange fan" is
displayed, it may be caused by the error occurrence at the internal cooling fan (JZNC-
YZU01-E) inside CPU unit (JZNC-YPS21-E).
When the message of the "Cooling fan in YPS unit stopped, replace cooling fan" is
displayed, carry out an inspection and the replacement of the cooling fan in the CPS unit
(JZNC-YPS21-E)as soon as possible.
7.3 Emergency Stop Button Inspections

The emergency stop button is located on the programming pendant. Before operating the
robot, make sure the SERVO voltage is switched off. For this, press the emergency stop
button after switching on the SERVO voltage.
7.4 Inspection of the enabling switch

The programing pendant is equipped with a three-position enable switch. Perform the
following operation to confirm the enable switch operates.
7 - 41
1. Set the mode switch with key on the programming pendant to "TEACH".
1 3
Fig. 7-2: Enabeling device
1 REMOTE 3 TEACH
2 PLAY
2. Press [SERVO ON READY] on the programming pendant. The [SERVO ON] lamp will
flashes.
Fig. 7-3: Flashing light SERVO ON
1 SERVO ON reading 2 SERVO ON (flashing light)
3. When the enable switch is grasped lightly, the servo power is turned ON.
When the enable switch is grasped firmly or released, the servo power is turned OFF.
NOTICE
If the [SERVO ON] lamp does not light in previous operation, check the following:
 The emergency stop button on the programming pendant is being pressed.
 The emergency stop signal was triggered by an external device.
 If a major alarm is occurring
7.5 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 not displayed on the handheld programming device.
7 - 42
7.6 Check the power supply

Check the voltage of 1, 3, 5 terminal of the main power switch (Q1M) with an electric tester.
Measuring Items Terminals Correct Value

correlate voltage between 400/415/440V +/- 10%
1 and 3 (R-S),
3 and 5 (S-T),
1 and 5 (R-T)
Voltage between earth (phase between 230/240/255V +/- 10%
ground) 1 and E (R-E),
5 and E (R-E)
between About 0V
3 and E (S-G)
1 3 5
2 4 6
Fig. 7-4: Main switch
7.7 Open Phase Check
Check Item Operation

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 open phase voltage of input power supply with an elec-
Check tric tester. (Normal value: AC400/415/440V +10%, -15%)
Main switch (Q1M) Turn ON the main power switch and check the open phase volt-
control age of “2, 4, 6 of the main power switch (Q1M) with an electric tes-
ter. If abnormal, replace the main power switch (Q1M).
7 - 43
1(R) 3(S) 5(T)
(Q1M)
2(U) 4(V) 6(W)
X9
1 2 3
7 V1
4 5 6
3
T1 TP1
5
AC400-415-440V/200V
4
㸦FS1㸧
CN555
1KM AE2
6
2KM
Fig. 7-5: Open Phase Check
1 Power Supply X4 5 Converter

2 Main switch 6 Power Supply Contactor Unit
3 Transfer 7 Filters
4 Fuse
7 - 44
Description of Units and Circuit Boards
8 Description of Units and Circuit Boards

• Cautions for connecting 2-channel inputs.
Please follow the safety instructions in chapter 1.7 "Safety" on page 10.
CAUTION!
Thus, connect the switch (contact) that turns the dual signals ON and OFF simultaneously.
If the timing that turns the two signals ON and OFF is not right, a disagreement alarm
occurs.
6
2
-19
+24V2
-20
5
-21 3
4
-22
024V
Fig. 8-1: Connection of 2-channel inputs.
1 Robot controller 4 Input Signal 2

2 Switch 5 Input Signal 1
3 Turn ON/OFF at the same time 6 Input for the robot system
WARNING!
Damage to property caused by short-circuit
Do not connect the two signals to the same contact (use two separate contacts).
As power supply is reversed for each signal, a short-circuit and thus a possible a robot
control failure occurs.
7
2
-19
+24V2
-20 3
6
-21
5
-22
024V
Fig. 8-2: Connecting 2-channel inputs to the same contact
1 Robot controller 5 Input Signal 2

2 Switch 6 Input Signal 1
3 The same contact 7 Input for the robot system
4 Short circuit current
8 - 45
8.1 Power ON unit (JZRCR-YPU52 - )

The power ON unit consists of the power ON control circuit board (JARCR-YPC21-1) and
the main circuit contactor and the line filter. It turns the main circuit control contactor ON and
OFF using the signal for the servo power control from the machine safety I/O logic circuit
board, and supplies power(3-phase AC200/220V) to the converter.
The power supply (single phase AC200/220V) is supplied to the control power supply via
the line filter.
The power ON unit has the following two types according to its safety specification:
• Safety category 4: JZRCR-YPU52-
1 2
3
7
6
5 4
Fig. 8-3: Configuration power ON unit (JZRCR-YPU52 -)
1 Input connector contactor control 5 AC Cooling fan connector (CN606)

(607)
2 Brake interlock output connector 6 Main power supply input connector
(CN608) (601)
3 AC control power supply connector 7 Fuse for AC cooling fan GP25 (2.5A
(CN603, CN604, CN605) 250V)(3FU), (4FU)
4 Main power supply output connector 8 Fuse for AC Control Power Supply
(CN602) 0215010MXP (10A 250V) (1FU, 2FU)
8.2 Axes control circuit board
8.2.1 Major axes control circuit board (SRDA-EAXA21A)
The major axes control circuit board controls the servomotors of the robot’s six axes. It also
controls the converter and the PWM amplifiers. Mounting an external axes control circuit
board of an option (SRDA-EAXB21A) makes it possible to control the servomotor of nine
axes, including the robot axes.
The major axes control circuit board (SRDA-EAXA21A) also has the following functions:
• Brake power supply control circuit
• Shock sensor (shock) input circuit
• Direct-in circuit
8 - 46
18 1 2 3 4
5
17
6
16
15 7
14
8
13
9
12
11 10
Fig. 8-4: Major axes control circuit board (SRDA-EAXA21A)
1 Machine safety I/O I/F (CN511) 10 PWM amplifier 5 I/F (CN505)

2 Brake control signal (CN513 11 PWM amplifier 3 I/F (CN503)
3 STO control signal I/F (CN521) 12 PWM amplifier 1 I/F (CN501)
4 LED 13 Analog monitor I/F (CN519)
5 Control communication (CN515) 14 Rotary switch (S1)
6 Control communication (CN516) 15 Encoder signal (CN508)
7 PWM amplifier 2 I/F (CN502) 16 DC control power supply (CN510)
8 PWM amplifier 4 I/F(CN504) 17 Converter I/F (CN507)
9 PWM amplifier 6 I/F(CN506) 18 Control power supply input (CN509)
8 - 47
8.2.2 External axes control circuit board (SRDA-EAXB21A)
An external axes control circuit board (SRDA-EAXB21A) is an optional, and it can control
the additional three axes. It can be mounted on the external axes control circuit board.
12 5 4
11 10 9 8 7 6
Fig. 8-5: External axes control circuit board (SRDA-EAXB21A)
1 STO control signal I/F (CN524) 7 Encoder distribution for the machine
safety system (9th axis) (CN542)
4 PWM amplifier 9 I/F (CN533) 10 Encoder I/F(9th axis) (CN536)
5 PWM amplifier 7 I/F (Lower) (CN531) 11 Encoder I/F(8th axis) (CN535)
6 PWM amplifier 8 I/F (Upper) (CN532) 12 Encoder I/F(7th axis) (CN534)
8.3 CPU unit configuration

CPU unit consists of circuit board racks (flame, back circuit board, PCI riser circuit board),
CPU circuit board, robot I/F circuit board and the machine safety CPU circuit board. The
JZNC-YRK21-1E CPU unit contains only circuit board racks and CPU circuit boards.
Be sure that it does not contain robot I/F circuit board and the machine safety CPU circuit
board.
8 - 48
4
2 3 5
1 6
18
9
17
10
11
16 14 13 12
15
Fig. 8-6: CPU Unit Configuration (JZNC-YRK21-1E)
1 Rotary switch (S1) 10 For LAN (CN104)

2 PCI Slot for Sensor Board x 1 11 Serial port (RS232C) (CN103)
3 LED 12 I/O I/F (Communication with the func-
tional safety circuit board) (CN203)
4 Robot I/F circuit board 13 I/O I/F (Communication with the ma-
JANCD-YIF01-2E chine safety I/O logic circuit board: 2-
channel side) (CN202)
5 CPU board (machine safety) 14 I/O I/F (Communication with the ma-
JANCD-YSF21-E chine safety I/O logic circuit board: 1-
channel side) (CN201)
6 CPU board JANCD-YCP21-E 15 Terminal for the grounding connection
7 Compact Flash (CN107) 16 PCI Slot X2
8 USB (CN106) 17 Drive I/F (communication with basic
axis control circuit board) (CN113)
9 For Programming Pendant (CN105) 18 I/O I/F (Communication with the op-
tional I/O) (CN114)
8.3.1 Unit and circuit board in the CPU unit
8.3.1.1 CPU board (JANCD-YCP21-E)

The entire system is controlled with this circuit board (JANCD-YCP21-E). It controls the
display on the handheld programming device, the control keys and the movements, and it
calculates the interpolation. This control circuit board has the serial interface for RS-232C/
RS-422 and a LAN connection (100Base-TX/10Base-T), USB (USB2.0).
8.3.1.2 Robot I/O circuit board (JANCD-YIF01-2E)

The robot I/F circuit board controls the entire robot system. It is connected to the control
circuit board (JANCD-YCP01-E) with a PCI bus interface on the rear. Connection to the
basic axis control circuit board (SRDA-EAXA21A) for high speed transmission.
NOTICE
Please do not change the factory setting of S1 (Factory setting is [0]).
8 - 49
8.3.1.3 CPU board (machine safety)

This circuit board (JANCD-YSF21-E) performs I/O processing or diagnosis processing for
the safety sequence, and it is connected with the CPU circuit board (JANCD-YCP21-E) by
the PCI Express bus I/F in the back circuit board.
It is also connected with the machine safety I/O logic circuit board by the high speed serial
communications (two lines).
8.4 CPS (JZNC-YPS21-E)

This unit (JZNC-YPS21-E) supplies the DC power (DC5V, DC24V) for control (system, I/O,
brake). It is also equipped with the input function for turning the control power supply ON
and OFF.
7
3
5
Fig. 8-7: Control power supply unit JZNC-YPS21-E
1 Connection with CPU 1 (CN158) 5 Remote Control (CN152)

Connection with CPU 2 (CN159)
2 +24V2 Power Supply Output (CN156/ 6 AC Power Supply Input (CN151)
CN157)
3 +24V1/+24V2 Power Supply Output 7 Monitor Alarm Display
(CN154/CN155)
4 +24V3 Power Supply Output (CN153)
• Input
Rating Input Voltage: 200/220VAC
Voltage Fluctuation Range: +10% to -15% (170 to 242VAC)
Frequency: 50/60Hz ± 2Hz (48 to 62Hz)
• Output Voltage
DC + 5V
DC +24V (24V1: System, 24V2: I/O, 24V3: Brake)
• Indicator
Display Color Status

SOURCE Green Lights with power supply input. Lights out when internal
live part completes discharge (Power supply status: be-
ing input).
POWER ON Green Lights when PWR_OK output signal is ON (Power sup-
ply status: being output).
8 - 50
Display Color Status

+5V Red Lights with +5V over-current (ON when abnormal).
+24V Red Lights with +24V over-current (ON when abnormal).
FAN Red Lights when FAN error occurs.
OHT Red Lights when unit interior overheats.
• Control Power ON/OFF

To turn ON the robot controller power, turn ON the non-fuse 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 supply 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 external
switch connected with CN152 of the Control power supply unit as shown in the following
figure (CN152-1 and CN152-2 is shortaged when shipment).
1
2
3
CN152
-1
R-IN 4
-2
R-INCOM
Fig. 8-8: Connection to control power supply unit
1 Robot controller 3 Remove the short-circuit positioner

2 Control power supply unit 4 Control power supply ON7OFF switch
8.5 Machine safety I/O logic circuit board (JANCD-YSF22-E)

Followings are the main functions of machine safety I/O logic unit.
It processes external safety signals with the dual processing circuits and control ON/OFF
of the main circuit control contactor of the power ON unit 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)
• Anti-safety I/O circuit for the robot system
• Machine safety terminal block circuit board I/F
8 - 51
1 2
13
5
12
6
11 10 9 8 7
1 Fuse for protecting the power supply 8 OT, SHOCK, LAMP (CN215)
1A/250V (F1)
2 Fuse for protecting the power supply 9 FANALM, FANCTL (CN216)
2A/250V (F2)
3 Power supply input connector 10 Output connector contactor control
(CN213) (CN217)
4 Rotary switch (S1/S2) 11 PP I/F connector (CN209)
5 (Communication with the CPU unit: 2- 12 Terminal for the grounding connection
channel side) I/O I/F (CN211)
6 (Communication with the CPU unit: 1- 13 Connection board machine safety I/F
channel side) I/O I/F (CN211) connector (CN219)
7 Major axes control circuit board I/F
connector (CN214)
NOTICE
If the F1 fuse becomes blown, it will cause a damage on the inner circuit of the board.
Replace the board instead of replacing the fuse (there is no attached spare of the fuse).
8.5.1 Connection for tool shock sensor (SHOCK)
8.5.1.4 To connect the tool shock sensor directly to the tool shock sensor signal
line
1. Disconnect the minus SHOCK (-) and +24V2 pin terminal from the DINAMIC connector,
the machine safety I/O logic circuit board (YSF22-CN214). The pin terminal for the
shock sensor is attached on the right side of the controller.
2. Connect the minus SHOCK (-) and +24V2 pin terminals to the signal line of the tool
shock sensor. Use the following plug-in terminals for the end of the signal line.
Pin terminal name Terminal model Signal line terminal model

SHOCK- TMEDN-630809-MA TMEDN-630809-FA (manufactured
by NICHIFU Co., Ltd.)
+24V2 TMEDN-630809-FA TMEDN-630809-MA (manufactured
by NICHIFU Co., Ltd.)
8 - 52
2
3
1 (JANCD-YSF22-E)
4 CN215
A3
SHOCK+
8 5
B3
SHOCK-
6
7
Fig. 8-9: Direct Connection to Tool Shock Sensor Signal Line
1 Robot 5 TMEDN-630809-MA (NICHIFU)

TMEDN-630809-FA (NICHIFU)
2 Robot controller 6 SHOCK- TMEDN-630809-MA
(NICHIFU)
3 Machine safety I/O logic circuit board 7 SHOCK sensor signal cable
4 TMEDN-630809-FA (NICHIFU) 8 Contact sensor (optional)
+24V2
8.5.1.5 To connect the tool shock sensor with the cable that is built into the robot
1. Disconnect the minus SHOCK (-) and +24V2 pin terminal from the DINAMIC connector,
the machine safety I/O logic circuit board (YSF22-CN214). The pin terminal for the
shock sensor is attached on the right side of the controller.
2. Connect the SHOCK (-) plug-in terminal to the SHOCK (+) plug-in terminal of the robot.
NOTICE
The cable installed on the robot is not connected to the shock sensor because the tool
shock sensor is an option. For connecting the tool shock sensor, refer to the wiring
diagrams in the INSTRUCTIONS for the robot.
2 3
1
(JANCD-YSF22-E)
CN215
A3
SHOCK+
4
8
5
B3
SHOCK-
6
7
Fig. 8-10: Connection with robot cable
1 Robot 5 TMEDN-630809-FA (NICHIFU)

2 Robot controller 6 SHOCK- TMEDN-630809-MA
(NICHIFU)
3 Machine safety I/O logic circuit board 7 Supply cables (PG)
4 TMEDN-630809-FA (NICHIFU) 8 Contact sensor (optional)
+24V2
8 - 53
NOTICE
If the tool shock sensor input signal is used, the method for stopping the robot can be
specified. The stop procedures stop and switch off the SERVO power supply. Selection of
the stopping method is set in the display of the programing pendant (Refer to explanations
in the "System Setup" manual).
8.6 Machine safety terminal block circuit board (JANCD-YFC22-

E)
The machine safety terminal block circuit board (JANCD-YFC22-E) is for the system
external signal to connect with the safety I/O signals. For connection, refer to the
connection diagrams of each item.
26-50 76-100
1-25 51-75 -AE4
51
76
26
1
-X18
CN219
-CN219
100
50
75
25
(348744-10)
Fig. 8-11: Machine safety terminal block
1 Machine safety I/O logic circuit board I/F connector (CN219)
8 - 54
Signal name Connec- Double Function Factory setting

tion no. (- channel
X18)
SAFF1+ -1 Possible Safety plug Short-circuit with
SAFF1- -2 Used to turn OFF the servo a jumper cable
power if the door on the
safeguarding is opened.
SAFF2+ -3 Connect to the interlock sig-
SAFF2- -4 nal from the safety plug on
the safeguarding door. If the
interlock signal is input, 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.
EXESP1+ -5 Possible External emergency stop Short-circuit with
EXESP1- -6 signal a jumper cable
Used to connect the emer-
gency stop switch of an ex-
EXESP2+ -7 ternal device.
EXESP2- -8 If the signal is input, the ser-
vo power is turned OFF and
the job is stopped.
As long as the signal input is
active, the servo power can-
not be turned ON.
EXDSW1+ -9 Possible External enable switch Short-circuit with
EXDSW1- -10 Used to connect a Enable a jumper cable
switch other than the one on
the programming pendant
EXDSW2+ -11 when two people are teach-
EXDSW2- -12 ing.
FST1+ -13 Possible Full-speed Test Open

FST1- -14 Used to reset the slow speed
limit for the test run in the
teach mode.
FST2+ -15
If this signal input circuit is
FST2- -16 short-circuited, the speed of
the test run becomes 100%
in the teach mode. If this sig-
nal’s circuit is open, the sta-
tus SSP input signal
determines the safety
speed: The first slow speed
(16%) or second slow speed
(2%).
8 - 55

tion no. (- channel
X18)
SSP+ -17 - Slow speed mode selection Short-circuit with
SSP- -18 Used to determine the speed a jumper cable
of the test run when the FST
(full-speed test) signal input
circuit is open.
Open: Second slow speed
(2%)
Short circuit: First slow
speed (16%)
EXHOLD+ -19 - External hold Short-circuit with
EXHOLD- -20 Used to connect the tempo- a jumper cable
rary stop switch of an exter-
nal device.
If the signal is input, the job
is stopped.
As long as the signal is ON,
starting and axis movements
cannot be enabled.
EXSVON+ -21 - External SERVO-ON Open
EXSVON- -22 Use to connect the servo ON
switch of an external opera-
tion device.
Upon entry of this signal, the
SERVO power supply is
turned ON.
SYSRUN+ -23 - SYSRUN signal Open
SYSRUN- -24 Use to determine the nor-
mal/abnormal condition of
the robot controller by SYS-
RUN signal.
24V2U3 -25
8 - 56

tion no. (- channel
X18)
ONEN11+ -26 Possible SERVO-ON enable Short-circuit with
ONEN11- -27 Connected to use a function a jumper cable
which distributes the robot
system to the multiple servo
ONEN12+ -28 areas, and turns the servo
ONEN12- -29 power ON/OFF.
ONEN21+ -30
ONEN21- -31
ONEN22+ -32
ONEN22- -33
ONEN31+ -34
ONEN31- -35
ONEN32+ -36
ONEN32- -37
ONEN41+ -38
ONEN41- -39
ONEN42+ -40
ONEN42- -41
OT21+ -42 External axis overun Open
OT21- -43 Used to input the overrun in
the external axes other than
the main body of the robot.
OT22+ -44
OT22- -45
OT31+ -46 -
OT31- -47
OT32+ -48
OT32- -49
024V2 -50
OT41+ -51 - External axis overun Open
OT41- -52 Used to input the overrun in
the external axes other than
the main body of the robot.
OT42+ -53
OT42- -54
8 - 57

tion no. (- channel
X18)
PBESP3+ -55 Contact output emergency Open
PBESP3- -56 - stop button
Used to output a contact

PBESP4+ -57 point of the emergency stop
button on the programing
PBESP4- -58 pendant.
PBESP3+ -59 - Used to output a contact
PBESP3- -60 point of the emergency stop
button on the front door of
the robot controller Control
PBESP4+ -61 panel.
PBESP4- -62
GSIN11+ -63 Possible Universal safety input Open
GSIN11- -64 The universal safety input
signal is used in the safety
logical circuit function.
GSIN12+ -65
GSIN12- -66
GSIN21+ -67 Possible
GSIN21- -68
GSIN22+ -69
GSIN22- -70
GSOUT11+ -71 - Universal safety output Open
GSOUT11- -72 The universal safety output
GSOUT12+ -73
GSOUT12- Also, inputs and uses the
-74 driven connection device
status as the monitoring sig-
nal by the output signal.
24V2U3 -75
GSOUT21+ -76 - Universal safety output Open
GSOUT21- -77 The universal safety output
GSOUT22+ -78
GSOUT22- Also, inputs and uses the
-79 driven connection device
8 - 58

tion no. (- channel
X18)
GSEDM1+ -80 - The universal safety output Open
GSEDM1- -81 signal is used in the safety
GSEDM2+ -82 -
Also, inputs and uses the
GSEDM2- -83 driven connection device
AXDIN_COM -84 - Direct-in (SERVO) Open

AXDIN1 -85 Used to input the quick re-
AXDIN2 -86 sponding signals in the
search function etc.
AXDIN3 -87
AXDIN4 -88
AXDIN5 -89
AXDIN6 -90
+24V2U3 -91 DC +24V2 output terminal Open
+24V2U3 -92 DC +24V2 output terminal Open
024V2 -93 DC +24V2 output terminal Open
AIN_COM -96 - Universal input (SERVO) Open
AXIN1 -96 Used to input the universal
AXIN2 -97 signal from the external de-
vice.
AXOUT1 -98 - Universal output (SERCO) Open

AXOUT2 -99 Used to output the universal
signal to the external device.

Tab. 8-1: JANCD-YFC22-E details for the connection terminal
8.7 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. As long as the signal input
is active, the servo power cannot be turned ON.
CAUTION!
Injuries and machine damages caused by short-circuit
Jumpers are installed at the factory. If the jumpers are not removed, the external emergency
stop will not work even with incoming signal.
 Be sure to remove the jumper before using.
8 - 59
2 3
-X18 (JANCD-YSF22-E)
1 CN219
5 EXESP_1+
4 6 EXESP_1-
7 EXESP_2+
8 EXESP_2-
Fig. 8-12: Connection external emergency stop signal
1 Robot controller 4 External emergency stop signal

2 I/O terminal (machine safety) 5 Remove the jumper cable
3 I/O board (machine safety) 6 Turn OFF/ON at the same time
8.8 Safety plug

This signal is used to turn OFF the servo power if the door of the protective device is
opened. Connect to the interlock signal from the safety plug on the safeguarding door. If the
interlock signal is input, 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.
CAUTION!
2 3
1 CN219
1 SAFF_1+
4 2 SAFF_1-
3 SAFF_2+
4 SAFF_2-
Fig. 8-13: Connection for safety plug
1 Robot controller 4 Safety plug

8 - 60
8.9 Installation of saftey plug
NOTICE
Observe DIN EN ISO 10218-2 with respect to the safety measures.
1
2
6
4
5
Fig. 8-14: Installation of Saftey Plug
1 Robot working area 4 Emergency shut-off

2 Safety casing 5 Plug
3 Service door 6 Safety plug
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.
8.10 External enable switch

This signal is used to connect Enable switch other than the one on the programming
pendant when two people are teaching.
CAUTION!
8 - 61
1 1
1 CN219
9 EXDSW1+
1 10 EXDSW1-
11 EXDSW2+
12 EXDSW2-
Fig. 8-15: Connection external emergency stop signal
1 Robot controller 4 External enable switch

8.11 Full speed test

This signal is used to reset the slow speed limit for the test run in the teach mode.
If this signal input circuit is short-circuited, the speed of the test run becomes 100% in the
play mode.
If this signal’s circuit is open, the status SSP input signal determines the slow speed: The
first slow speed (16%) or second slow speed (2%).
2 3
1 CN219
13 FST_1+
4 14 FST_1-
15 FST_2+
16 FST_2-
Fig. 8-16: Connection for Full-speed Test
1 Robot controller 4 External enable switch

2 I/O terminal (machine safety) 5 Full-speed Test
3 I/O board (machine safety)
8.12 Slow speed mode selection

This signal is used to determine the speed of the test run when the FST (full-speed test)
signal input circuit is open.
Open: Second slow speed (2%)
8 - 62
Short circuit: First slow speed (16%)
CAUTION!
1 2 3
4 CN219
5 17 SSP+
18 SSP-
Fig. 8-17: Connection for slow operation mode
1 Robot controller 4 Remove the jumper cable

2 I/O terminal (machine safety) 5 Slow mode selection
3 I/O board (machine safety)
8.13 External hold

This signal is used to connect a stop switch of an external device. If the signal is input, the
job is stopped. As long as the signal is ON, starting and axis movements cannot be enabled.
CAUTION!
1
2 3
4 CN219
19 EXHOLD+
5 20 EXHOLD-
Fig. 8-18: Connection for external hold
1 Robot controller 3 I/O board (machine safety)

2 I/O terminal (machine safety) 4 External hold
8 - 63
8.14 External SERVO-ON

External SERVO-ON
This signal is used to connect the servo ON switch of an external operation device. If the
signal is input, the servo power is turned ON.
1
2 3
CN219
21 EXSVON+
4 22 EXSVON-
Fig. 8-19: Connection for external SERVO-ON
1 Robot controller 3 I/O board (machine safety)

2 I/O terminal (machine safety) 4 External SERVO-ON
8.15 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.
Fig. 8-20: (1) Connection for SYSRUN signal output
1 Main power supply ON/OFF 3 SYSRUN ON/OFF

2 Robot control status normal/abnormal
Because the pulse signal is outputted from the specific output signal (#50911) to the
external device for each 100ms, it is also able to check whether the robot controller control
circuit board is normal or abnormal (Refer to Instructions for Concurrent I/O for more
details).
8 - 64
1 2
-X18 (JANCD-YFC22-E)
CN219
SYSRUN+ 23
SYSRUN+
SYSRUN- 24
SYSRUN-
Fig. 8-21: (2) Connection for SYSRUN signal output
1 I/O board (machine safety) 2 I/O terminal (machine safety)
8.16 External axes overrun

With a unit of standard specifications without an external axis, the external axis overrun
input signal is not used. In this case, a jumper cable is connected as shown in the following
figure.
If an overrun input signal for an axis other than manipulator axes, for example the external
axis, is required, connect the signal input circuit in the following manner.
For safe reason, a dual circuits are used for the external axis overrun signal input. Connect
the external axis overrun signal so 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.
CAUTION!
If the cables are not removed, injury or damage to machinery may result and the external
emergency stop will not work even if the signal is input.
 Jumper cables are installed at the factory. Be sure to remove the jumper cables before
using.
2 3
1 -X18 (JANCD-YSF22-E)
CN219
42 OT2_1+
4 43 OT2_1-
44 OT2_2+
45 OT2_2-
Fig. 8-22: Connection for external axis overrun
1 Robot controller 4 External axis overun

8 - 65
The following figure shows the external axis overrun wiring of the factory default setting
when the external axes are connected to the robot controller.
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.
2 3
1 -X18 (JANCD-YSF22-E)
CN219
42 OT2_1+
4 43 OT2_1-
44 OT2_2+
45 OT2_2-
46 OT3_1+
6 47 OT3_1-
48 OT3_2+
49 OT3_2-
51 OT4_1+
7 52 OT4_1-
53 OT4_2+
54 OT4_2-
Fig. 8-23: Connection for external axis overrun (multiple lines)
1 Robot controller 5 Turn ON/OFF at the same time

2 I/O-Terminal (machine safety) 6 External axis overrun 2. line
3 I/O Platine (machine safety) 7 External axis overrun 3. line
4 External axis overrun 1. line
8 - 66
8.17 SERVO-ON enable input

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 areas.
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 switch so that both input signals are turned ON or OFF at the same time. If only
one signal is turned ON, an alarm occurs.
2 3
1 CN219
26 ONEN1_1+
4 27 ONEN1_1-
28 ONEN1_2+
29 ONEN1_2-
Fig. 8-24: Connection for SERVO-ON enable input
1 Robot controller 4 SERVO-ON enable input

8 - 67
8.18 Emergency stop button output

The extra contact output terminals of the emergency stop button on the programming
pendant are provided on the terminal block on the cabinet door.
These contacts are always valid no matter if the robot controller power supply is ON or OFF.
CAUTION!
Damage to property caused by short-circuit
 Do not use the emergency stop button with a voltage of 24 V AC, 0.5 A or more.
1 5
3 4
2
CN219
PBESP3+ 59
PBESP3+
PBESP3- 60
PBESP3-
PBESP4+ 61
PBESP4+
PBESP4- 62
PBESP4-
6
2
PPESP3+ 55
PPESP3+
PPESP3- 56
PPESP3-
PPESP4+ 57
PPESP4+
PPESP4- 58
PPESP4-
Fig. 8-25: Emergency stop button output
1 Control cabinet door of the robot con- 4 I/O terminal board (machine safety)
troller
2 Emergency stop button 5 Robot controller
3 I/O board (machine safety) 6 Programming pendant
8 - 68
8.19 Universal safety input
8.20 Universal safety output

The universal 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, and inputs the status of the driven devices by
the output signal as the monitoring signal.
1
2 3
CN219
GSOUT1_1+ 71
4
GSOUT1_1- 72
GSOUT1_2+ 73
GSOUT1_2- 74
5
GSEDM1+ 80
GSEDM1- 81
Fig. 8-26: Universal safety output
1 Robotcontroller 4 Universal safety output 1

2 Machine safety terminal block circuit 5 Universal safety output 2
board
3 Machine safety I/O logic ciruit board 6 Monitoring signal
NOTICE
 Rated output value is DC24V and less than 50mA. 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.
 The feedback signal must be inputted to the robot controller when use the universal
safety output signal.
8.21 Direct-in (SERVO) 1 to 6

This signal is used to input a response signal in search functions.
8 - 69
1 2 3
-X18 (JANCD-YSF22-E) (SRDA-EAXA21A)
CN219
93,94
024V2
85 AXDIN1
1
86 AXDIN2
2
87 AXDIN3
3
4 88 AXDIN4
4
89 AXDIN5
5
90 AXDIN6
6
84 AXDIN_COM
91,92
+24V2
1 2 3
(JANCD-YFC22-E) (JANCD-YSF22-E) (SRDA-EAXA21A)
CN219
93,94
024V2
85 AXDIN1
86 AXDIN2
87 AXDIN3
88 AXDIN4
89 AXDIN5
5 90 AXDIN6
84 AXDIN_COM
91,92
+24V2
Fig. 8-27: Connection for Direct-in (SERVO) 1 to 6
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, SRDA-EAXA01.
1 I/O terminal board (machine safety) 4 Direct-in (SERVO)

2 I/O board (machine safety) 5 Connect the jumper cable
3 Connect the jumper cable
8 - 70
8.22 Universal input (SERVO)

Connect when use the universal signal
1
2 3 4
-X18 (JANCD-YSF22-E) (SRDA-EAXA21A)
CN219
93,94
024V2
96 AXIN1
1
5
97 AXIN2
2
95 AXIN_COM
91,92
+24V2
Fig. 8-28: Universal input (SERVO)
1 Robotcontroller 4 Major axes control circuit board

2 Machine safety terminal block circuit 5 Universal input (SERVO)
board
3 Machine safety I/O logic ciruit board 6 Connect the jumper cable.
8.23 Universal output (SERVO)

Connect when use the universal signal
1
2 3 4
(SRDA-EAXA21A) (JANCD-YSF22-E) -X18
CN219
AXOUT1 98
5
AXOUT2 99
91,92
+24V2
Fig. 8-29: Universal input (SERVO)
1 Robotcontroller 4 Major axes control circuit board

2 Machine safety terminal block circuit 5 Universal output (SERVO)
board
3 Machine safety I/O logic ciruit board
8 - 71
8.24 Universal I/O circuit board (JANCD-YIO22-E)

Four digital I/O connectors for the robot universal I/O are provided:
40 inputs and 40 outputs. The I/Os are divided into two types: universal 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 position controller and central controller, controls the robot and the connected
devices as a system. Universal I/O are mainly used as timing signals for the robot and
peripheral devices in jobs that require robot motion.
Refer to chapter „Universal I/O signal assignment“ for more details on signal allocation.
For the connection of the robot’s universal I/O signal connectors, and the I/O signal related
to start and stop to refer to "Connetion wire with universal I/O Connector (CN306, 307, 308,
309)" and "Specific I/O Signal Related to Start and Stop".
1 2
4
4
4 4
Fig. 8-30: Universal I/O circuit board (JANCD-YIO21-E)
1 For switching external power supply 3 Power Supply Output (CN304)

(CN303)
2 Power Supply Protective Fuse (F1, 4 Digital I/O (CN307, CN306, CN308
F2) 3.15A/250 V and CN309)
• Connection wire with robot universal I/O connector (CN306, 307, 308, 309)
Please refer to the figure below when you manufacture the cable connecting with robot
universal I/O connector (CN306, 307, 308, 309) of robot I/O unit (JZNC-YIU01-E).
Unshielded twisted pair cable must be used (the cable side connector and the I/O terminal
block are the options).
AXDIN_COM
AXDIN 6
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
+24V2
+24V2
024V
024V
-X18 A1 A3 A5 A7 A9 A11 A13 A15 A17 A19 A31
Fig. 8-31: NPN logic
8 - 72
AXDIN_COM
AXDIN 6
AXDIN1
AXDIN2
AXDIN3
AXDIN4
AXDIN5
+24V2
+24V2
024V
024V
-X18 A1 A3 A5 A7 A9 A11 A13 A15 A17 A19 A31
Fig. 8-32: PNP logic
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 a fly-wheel diode
may damage the output circuit.
When connecting a load with a large inrush current such as a lamp, connect a current
limiting resistance 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
(JANCD-YIO22-E)
+24VU
5 4
024VU
1 Universal I/O circuit board 4 Lamp

2 Inductive load 5 Current limiting resistor
3 Flywheel diode
Refer to chapter 8.29 "Assignment of general I/O signal" from 82 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: JANCD-YIO22-E)
• External SERVO ON (common to all application: JANCD-YFC22-E) external start
(depending on application: JANCD-YIO22-E)
• Operating (depending on application: JANCD-YIO22-E)
• External Hold (common to all application: JANCD-YFC22-E)
• External Emergency Stop (common to all application: JANCD-YFC22-E)
8 - 73
RUN
1 STOP
2 ON
OFF
ON
3 OFF T
4 ON
OFF T
5 ON
OFF
T
6 ON
OFF
ON
7 OFF
Fig. 8-33: Timing chart
1 Robot 5 Execution
2 While SERVO-ON 6 Extern Stop
3 SERVO-ON 7 Emergency shut-off
4 external start Note: set T = 100 msec minimum
• Example of SERVO ON Sequence Circuit from 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 2 3 4
5 6
X1 (JANCD-YFC22-E) (JANCD-YSF22-E)
3 CN219
㼄㻝 X1
21 +24V2
22 EXSVON
10 (30011) 2
X2
7
PL JANCD-YIO21-E
8 CN308
+24VU
A18
X3
A8
9 (30011)
Fig. 8-34: Example of SERVO ON Sequence Circuit from External Device
1 SERVO ON PB 6 Machine safety I/O logic circuit board

2 SERVO ON confirmation 7 Universal I/O circuit board
3 SERVO_ON command 8 SERVO-ON power ON
4 Robot controller 9 SERVO-ON is output
5 Machine safety terminal block circuit 10 SERVO-ON power ON X3
board
NOTICE
Number in ( ) means output signal number assigned to YIU21.
PL: Pilot lamp
8 - 74
• Example of start sequence circuit from 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.
7
2 3 4 5
1 8 (JANCD-YIO21-E)
(30011) (30016) (30013) X5 6
㻯㻺㻟㻜㻤
㼄㻠㼄㻠
(20011)
㻮㻝
㼄㻟㻮㻣 9
㻜㻞㻠㼂㼁
5
12 X6 (30010) 11 㻗㻞㻠㼂㼁
㼄㻡㻮㻝㻤
㼄㻢
㻮㻤 (30010) 10
㻼㻸
Fig. 8-35: Example of start sequence circuit from external device
1 Run PB 7 Robot controller

2 While SERVO-ON 8 External Start Command
3 Selects PLAY mode 9 External start input
4 Alarm/Error Occuring 10 Ongoing output
5 Running confirmation 11 Running, etc.
6 Start (Command) 12 Running X6
NOTICE
Number in ( ) means output signal number assigned to YIU21.
PL: Pilot lamp
• 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 is used, connect it as described below.
1. Remove the wire connected between CN303-1 to -3 and CN303-2 to -4 of the universal
I/O circuit board.
2. Connect +24V of the external power supply to CN303-1 and 0V to CN303-2 of the robot
I/O unit.
8 - 75
(JANCD-YIO21-E) 1 (JANCD-YIO21-E) 1
CN303 2 CN303
+24VU +24VU
1(EX+24VIN) F1 +24V 1(EX+24VIN) F1
3.15A 3.15A
2(EX024VIN) F2 0V 2(EX024VIN) F2
3.15A 3.15A
3
024VU 024VU
+24V +24V
3(+24V) 3(+24V)
4(024V) 4(024V)
024V 024V
5 4
Fig. 8-36: Connection of the external power supply for I/O
1 Universal I/O circuit board 4 In case of using external power sup-

ply.
2 External supply 5 In case of using internal power supply
(factory settings).
3 Provided by the customer
NOTICE
 The internal power supply of 24V of about 1.5 A of robot control can be used for I/O.
Use external 24V power supply for higher currents and to isolate the circuit inside and
outside the robot control.
 Power supply circuit for I/O (+24 VU, 024 VU) has 3.15A fuses (F1, F2).
 Install the external power supply outside the DX200 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
+24VU and 0VU terminals. The unit may malfunction if the external power supply is also
connected.
8 - 76
8.25 Brake control circuit board (JANCD-YBK21-3E)

The brake control circuit board controls ON/OFF of the brakes of total nine axes (Robot +
external axes) according to the command signal from the major axes control circuit board
(SRDA-EAXA21A).
1
2
3
Fig. 8-37: Brake control circuit board (JANCD-YBK21-3E)
1 Axes control cicuit board I/F (CN405) 5 Brake interlock (CN402)

2 For external brake power supply 6 Handbrake release unit I/F (CN401)
(CN404)
3 Brake power supply input (CN403) 7 Brake I/F (CN400)
4 Brake power supply fuse (F1: For ex-
ternal axes) 3,15A/250V
8 - 77
8.26 Converter (SRDA-COA30A21B-E)

The converter (SRDA-COA30A21B-E) exchanges the power supply (3-phase: AC200/
220V) supplied by the power ON unit for DC power supply and supplies the power to the
amplifier module (PWM amplifiers).
1 2 3 4 5
6
14 13 12 11 9 8
Fig. 8-38: Converter (SDRA-COA30A21B-E)
1 Grounding detection input (CN554) 8 Charge lamp

2 Converter control signal (CN553) 9 External axes main circuit connection
(CN558)
3 Monitor/Alarm indication LED 10 Power supply regenerative unit con-
nection (CN559)
4 DC control power supply (CN551) 11 Main circuit power supply output
(CN556)
5 Control power supply output for six 12 Regenerative resistor (CN557)
axes amplifier (CN552A)
6 Control power supply output for exter- 13 Main circuit power supply input
nal axes amplifier (CN552B) (CN555)
7 Grounding terminal
8 - 78
8.27 Capacitor module (SRDA-CUA  AA)

The capacitor module smooth the DC voltage (PN voltage) created in the converter and
also save the electric energy.
There are two type of the capacitors shown below:
• Small capacity: SRDA-CUA662AA
• Medium / Large capacity: SRDA-CUA133AA
1 2
Fig. 8-39: Capacitor module (SDRA-CUA  AA)
1 Small capacity SRDA-CUA662AA 2 Large capacity SRDA-CUA133AA
8 - 79
8.28 Amplifier module (SDRA-SDA  A01A-E)

The amplifier module exchanges the DC power supply supplied by a converter for a 3-
phase motor power source and outputs to each servo motor.
4
AMP5
5
2
AMP4 AMP6
3
1 3
AMP1
2
5
AMP3
AMP2
4
Fig. 8-40: Amplifier configuration: Pattern 1
1 Terminal for the grounding connection 4 Motor power output (CN584)

2 Control power supply input (CN582) 5 PWM signal (CN581)
3 Main circuit power supply input
(CN583)
4
AMP5
5
2
AMP4 3
AMP6
1 3
AMP1
2
5
AMP3
AMP2
4

(CN583)
8 - 80
4
AMP5
5
2
AMP4 AMP6 3
3
1
AMP1
2
AMP3 5
AMP2
4

(CN583)
8 - 81
8.29 Assignment of general I/O signal
8.29.1 ARC welding
Universal I/O circuit board (JANCD-YIO22-E) Connector Terminal Converter

(Optional)
+24VU Model:TIFS553YS
CN308 Connector
Logical Connector Name Signal Terminal
Number Number Number
Each Point 20010 B1 External Start IN B1 B1

24VDC 20011 A1 - IN A1 A1
6.9 mA (TYP) 20012 B2 Call Master Job IN B2 B2
20013 A2 Alarm/Error Reset IN A2 A2
20014 B3 - IN B3 B3
20015 A3 Select Play Mode IN A3 A3
20016 B4 Select Teach Mode IN B4 B4
20017 A4 - IN A4 A4
Interference1 Entrance
20020 B5 Prohibited IN B5 B5
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
(continuousing Sequence) OUT A13 A13
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
+24 V B17 024VU B17 024VU
-4 024 V A17 024VU A17 024VU
(24V,1A)
B18 +24VU B18 +24VU
External A18 +24VU A18 +24VU
Power Supply -1 +24VU
B19 +24VU B19 +24VU
+24 VE
-2 024VU A19 +24VU A19 +24VU
024 VE
B20 FG B20 FG
A20 A20 024VU
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. 8-43: JANCD-YIO21-E (CN308 Connector) I/O allocation and connection diagram
8 - 82
Connector Terminal Converter

Universal I/O circuit board (JANCD-YIO22-E) (Optional)
CN309 Connector
Logical Connector
Number Number
Name Signal Terminal
Number
Each Point 20024 B1 - IN B1 B1
24VDC 20025 A1 - IN A1 A1
6.9mA (TYP)
20026 B2 Weaving Prohibited IN B2 B2
20027 A2 Sensing Prohibited IN A2 A2
20030 B3 IN01 User Output 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 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 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
Each Point 30037 A13 OUT08 OUT A13 A13
24VDC B14 B14
B14
50mA (max.) A14 A14
A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU
CN303 A16 024VU
Internal A16 024VU
-3 Power Supply
024VU
+24 V B17 024VU B17
024 V 024VU
-4 (24V,1A) A17 024VU A17
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
Power Supply -1 +24VU B19 +24VU
+24 VE B19 +24VU
024 VE -2 024VU A19 +24VU
A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 83

(Optional)
+24VU
Model: TIFS553YS
CN306 Connector
Logical Connector
Number Name Signal Terminal
Number
Number
Each Point 20040 B1 IN09 User Input IN B1 B1

24VDC 20041 A1 IN10 IN A1 A1
6.9mA (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 User Input 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

A13 A13
24VDC A13
B14 B14
50mA (max.) B14
A14 A14
A14
B15 B15 B15
A15 A15 A15

B16 024VU B16 024VU
CN303 A16 024VU
Internal A16 024VU
-3 Power Supply
+24 V B17 024VU B17 024VU
024 V
-4 (24V,1A) A17 024VU
A17 024VU
B18 +24VU B18 +24VU
A18 +24VU
External A18 +24VU
+24 VE B19 +24VU
024 VE -2 024VU A19 +24VU
A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
when a external power supply is used. 024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 84

(Optional)
+24VU Model: TIFS553YS
CN307 Connector
Logical Connector
Number Number Name Signal Terminal
Each Point Number
20050 B1 IN17 IN B1 B1
24VDC
20051 A1 IN18 IN A1 A1
6.9mA (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

30053 B11 OUT20- OUT B11 B11
30054 B12 OUT21- OUT B12 B12
30055 B13 OUT22- OUT B13 B13

Each Point A13 RLY
A13 OUT22+ OUT A13
24VDC
30056 B14 OUT23- OUT B14 B14
500mA (max.)
A14 A14 RLY
A14 OUT23+ OUT
OUT B15 B15
30057 B15 OUT24-
B16 024VU B16 024VU
Power Supply
A16 024VU
-3 +24 V B17 024VU
B17 024VU
024 V 024VU
-4 (24V,1A) A17 024VU A17
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
-1 +24VU B19 +24VU * means internal relay
Power Supply
+24 VE
B19 +24VU RLY means
-2 024VU A19 +24VU
024 VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
Logical number Input name / Function

20010 EXTERNAL STARTFunctions the same as the [START] button in
the programming pendant. Only the rising edge of the signal is val-
id. It starts robot operation (playback). This signal is invalid if exter-
nal start is prohibited from the playback condition display.
8 - 85

20012 CALL MASTER JOB
Only the rising edge of the signal is valid. It calls up the top of the
robot program, that is the top of the master job1. This signal is in-
valid during playback, during teach lock and when play master or
call is prohibited (set from the playback operation condition dis-
play).
20013 ALARM/ERROR RESET
After an alarm or error has occurred and the cause been corrected,
this signal resets the alarm or error.
20015 SELECT PLAY MODE
The play mode is selected when the mode key on the program-
ming pendant is set at "REMOTE". Only the rising edge of the sig-
nal is valid. When this selection signal assigned concurrently with
other mode selection signal, the teach mode is selected on a pri-
ority basis. The signal is invalid while EXTERNAL MODE SWITCH
is prohibited.
20016 SELECT TEACH MODE
The teach mode is selected when the mode key of the program-
ming pendant is set at "REMOTE". The other mode selection is un-
available when this signal is ON; the signal is selected by priority
even when the other selection 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.
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.
20023 WORK RESPONSE (Pseudo Arc ON Response)
This signal is used as a pseudo signal in cases that “Arc Genera-
tion Confirmation” signal is not equipped on a welding power sup-
ply. 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 weav-
ing 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.
1. A master job is a job (program) which can be called by CALL MASTER JOB.Other functions are the same as
for normal jobs. Normally, the parent job, which manages the child jobs called up immediately after the power is
turned ON, is set as the master job.
8 - 86
2. See you System Setup Manual chapter "Interference area".
Logical Number Output Name / Function

30010 RUNNING
This signal signifies that the job is running. (Signifies that the job is
running, system status is waiting reserved start, or test run is run-
ning.) This signal status is the same status as [START] in the pro-
gramming pendant.
30011 SERVO IS ON
This signal signifies that the SERVO power is turned ON, internal
processing such as current position creation is complete, and the
system is able to receive the START command. This signal turns
OFF when the SERVO power supply turns OFF. It can be used for
DX200 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 occurs, 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 warning signal.
30015 to30017 REMOTE/PLAY/TEACH MODE SELECTED
This signal notifies the current mode setting. These signals are
synchronized with the mode select switch in the programming pen-
dant. The signal corresponding to the selected mode turns ON.
30020 IN CUBE 1
This signal turns ON when the current TCP lies inside a pre-de-
fined space (Cube 1). Use this signal to prevent interference with
other robots and positioners.
30021 IN CUBE 2
30022 WORK HOME POSITION (IN CUBE 64)2
This signal turns ON when the current TCP lies inside the work
home position area. Use this signal to evaluate whether the robot
is in the start position.
8 - 87

30023 INTERMEDIATE START OK
This signal turns ON when the robot operates. It turns OFF when
the currently executed line is moved with the cursor or when edit-
ing 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.
30024 GAS SHORTAGE (MONITOR)
This signal stays ON while the gas shortage signal from the weld-
ing power supply is ON.
30025 WIRE SHORTAGE (MONITOR)
This signal status ON while the wire shortage signal from the weld-
ing 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.
1. This signal is not output during operation.
2. The work home position cube and Cube 64 are the same.
8 - 88
8.29.2 Handling

Universal I/O circuit board(JANCD-YIO22-E) (Optional)
Model: TIFS553YS
+24VU
CN308 Connector
Logical Connector
Number
24VDC -
20011 A1 IN A1 A1
6.9mA (TYP)
20012 B2 Call Master Job IN B2 B2
20014 B3 - IN B3 B3
20016 B4 Select Teach Mode IN B4 B4
20017 A4 - IN A4 A4
Interference1 Entrance B5 B5
20020 B5 Prohibited IN
Interference2 Entrance A5 A5
20021 A5 Prohibited IN
20022 B6 - IN B6 B6
20023 A6 - IN A6 A6
B7 024VU B7 024VU
A7 024VU A7 024VU
30012 B9 Top of Master Job OUT B9 B9
A9 A9
30013 A9 Alarm/Error Occurred OUT
30014 B10 Battery Alarm OUT B10 B10
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
30023 A13 (continuousing Sequence) OUT
Each Point B14 B14
B14
24VDC A14
A14
50mA (max.) A14
B15 B15 B15
A15 A15 A15

B16 024VU B16 024VU
A16 024VU
-3 Power Supply
+24 V B17 024VU B17 024VU
-4 024 V A17 024VU
(24V,1A) A17 024VU
B18 +24VU B18 +24VU
A18 +24VU
External A18 +24VU
B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 89
Universal I/O circuit board(JANCD-YIO22-E) Connector Terminal Converter

(Optional)
+24VU
Model: TIFS553YS
CN309 Connector
Logical Connector
Number
Each Point 20024 B1 - IN B1 B1
24VDC -
20025 A1 IN A1 A1
6.9mA (TYP) Shock Sensor (NC)
20026 B2 - Hold IN B2 B2
20027 A2 Low Air Pressure IN A2 A2
20030 B3 IN01 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 - OUT B8 B8
30025 A8 - OUT A8 A8
30026 B9 - OUT B9 B9
A9 A9
30027 A9 - OUT
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
OUT
Each Point B14 B14
B14
24VDC A14 A14
A14
50mA (max.) B15
B15 B15
A15 A15 A15

B16 024VU B16 024VU
A16 024VU
-3 Power Supply
+24 V B17 024VU B17 024VU
024 V A17 024VU
-4 (24V,1A) A17 024VU
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
+24 VE B19 +24VU
-2 024VU A19 +24VU
024 VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 90

(Optional)
CN306 Connector
Logical Connector
Number
Each Point 20040 B1 IN09 IN B1 B1
24VDC 20041 A1 IN10 IN A1 A1
6.9mA (TYP) IN11 IN B2
20042 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
A12 A12 A12

Each Point B13 B13
B13
24VDC A13 A13
A13
50mA (max.) B14 B14
B14
A14 A14
A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU

A16 024VU
-3 Power Supply 024VU
+24 V B17 024VU B17
-4 024 V A17 024VU
(24V,1A) A17 024VU
B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
+24 VE B19 +24VU
024VU A19 +24VU
024 VE -2 A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 91

(Optional)
CN306 Connector
Each Point B1 B1
20040 B1 IN09 General Input IN
24VDC A1 A1
6.9m A (TYP) 20041 A1 IN10 IN
B2 B2
20042 B2 IN11 IN
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 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
A13
A13
B14 B14
B14
Each Point A14 A14
24VDC A14 B15
B15
50mA (max.) B15
A15 A15
A15
B16 024VU
B16 024VU
-3 B17 024VU
+24V B17 024VU
024V A17 024VU
-4 (24V, 1A) A17 024VU
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
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 92

20010 EXTERNAL START
Functions the same as the [START] button in the programming
pendant. Only the rising edge of the signal is valid. It starts robot
operation (playback). This signal is invalid if external start is pro-
hibited from the playback condition display.
valid during playback, during teach lock and when play master or
play).
is prohibited.
mode selection.
20026 TOOL SHOCK SENSOR
This is normally ON (NC) signal input. When it turns OFF, an
DX200 displays a message "HAND TOOL SHOCK SENSOR OP-
ERATING" 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 diagnos-
tic display if this signal is not be used.
20027 LOW AIR PRESSURE
This signal is normally OFF (NO). When it turns ON, DX200 dis-
plays user alarm in the PLAY mode or displays user message in
the teach mode.
8 - 93

20050 to20057 SENSOR INPUT 1 - 8
Inputs 1 to 8 are monitored with the HSEN handling specific in-
structions. Sensor inputs 1 to 8 correspond to HSEN 1 to 8.
1. A master job is a job (program) which can be called by CALL MASTER JOB. Other functions are the same as

30010 RUNNING
gramming pendant.
30011 SERVO IS ON
has been called1.
OFF.
30014 BATTERY ALARM
30020 IN CUBE 1
8 - 94

30021 IN CUBE 2
30050 to30057 HAND VALVE 1-4
These outputs are controlled by the HAND handling specific in-
structions. Hand valves 1 to 4 correspond to HAND 1 to 4.
8 - 95
8.29.3 General application

Universal I/O circuit board (JANCD-YIO22-E) (Optional)
Model: TIFS553YS
+24VU
CN308 Connector
Logical Connector
Number
24VDC 20011 A1 - IN A1 A1
6.9mA (TYP) Call Master Job IN B2 B2
20012 B2
20014 B3 - IN B3 B3

Select Teach Mode IN B4 B4
20016 B4
- IN A4 A4
20017 A4
IN B5 B5
20020 B5 Prohibited
B6 B6
20022 B6 Work Prohibited IN
A6 A6
20023 A6 - IN
B7 024VU B7 024VU
A7 024VU A7 024VU

B9 B9
30012 B9 Top of Master Job OUT
A9 A9
OUT B10 B10
30014 B10 Battery Alarm
B11 B11
30016 B11 Play Mode Selected OUT
A11 A11
30017 A11 Teach Mode Selected OUT
B12 B12
30020 B12 In Cube 1 OUT
A12 A12
30021 A12 In Cube 2 OUT
B13 B13
30022 B13 Work Home Position OUT
A13 A13
30023 A13 Intermediate Start OK
(continuousing Sequence) OUT
Each Point B14 B14
B14
24VDC A14 A14
50mA (max.) A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU

A16 024VU
-3 Power Supply 024VU
+24 V B17 024VU B17
-4 024 V A17 024VU
(24V,1A) A17 024VU
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 96

(Optional)
CN309 Connector
Logical Connector
Number
Each Point 20024 B1 Interference3 Entrance
IN
Prohibited B1 B1
24VDC 20025 A1
IN
Prohibited A1 A1
6.9mA (TYP) - IN
20026 B2 B2 B2
20027 A2 - IN A2 A2
20030 B3 IN01 User 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 - OUT
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
24VDC B14
A14 A14
50mA (max.) A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU
A16 024VU
-3 Power Supply
+24 V B17 024VU B17 024VU
-4 024 V A17 024VU
(24V,1A) A17 024VU
B18 +24VU
B18 +24VU
External A18 +24VU
A18 +24VU
+24 VE B19 +24VU
-2 024VU A19 +24VU
024 VE A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 97

(Optional)
Model: TIFS553YS
+24VU
CN307 Connector
Each Point Logical
Number
Connector
Number Name Signal Terminal
Number
24VDC
20050 B1 IN17 IN B1 B1
6.9mA (TYP)
20051 A1 IN18 IN A1 A1
20052 B2 IN19 IN B2 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
B11 B11
30053 B11 OUT20- OUT
B12 B12
30054 B12 OUT21- OUT
A12 A12 RLY
A12 OUT21+ OUT
B13 B13
30055 B13 OUT22- OUT
A13 A13 RLY
A13 OUT22+ OUT
B14 B14
Each Point 30056 B14 OUT23- OUT
A14 A14 RLY
24VDC A14 OUT23+ OUT
500mA (max.) 30057 B15 OUT24- OUT B15 B15
B16 024VU B16 024VU

A16 024VU
-3 Power Supply B17 024VU
+24 V B17 024VU
A17 024VU
-4 024 V A17 024VU
(24V,1A) B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
+24 VE B19 +24VU
A19 +24VU
024 VE -2 024VU A19 +24VU
* means internal relay
B20 FG
B20 FG RLY means
A20 024VU
A20
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 98

(Optional)
CN306 Connector
Each Point B1 B1
20040 B1 IN09 General Input IN
24VDC A1 A1
6.9m A (TYP) 20041 A1 IN10 IN
B2 B2
20042 B2 IN11 IN
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 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
A13
A13
B14 B14
B14
Each Point A14 A14
24VDC A14 B15
B15
50mA (max.) B15
A15 A15
A15
B16 024VU
B16 024VU
-3 B17 024VU
+24V B17 024VU
024V A17 024VU
-4 (24V, 1A) A17 024VU
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
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 99

valid during playback, during teach-lock and when play master or
play).
is prohibited.
mode selection.
20022 WORK PROHIBITED (Tool ON Prohibited)
Even if TOOLON instruction is executed, DX200 doesn’t output to
external while this signal is ON.
8 - 100

30010 RUNNING
gramming pendant.
30011 SERVO IS ON
has been called1.
OFF.
30014 BATTERY ALARM
30020 IN CUBE 1
30021 IN CUBE 2
8 - 101

30024 IN CUBE 3
30025 IN CUBE 4
8 - 102
8.29.4 Spot welding
Universal I/O circuit board(JANCD-YIO22-E) Connector Terminal Converter

(Optional)
CN308 Connector
Logical Connector Signal Terminal
Number Number Name
Number
24VDC 20011 A1 - IN A1 A1
6.9mA (TYP) 20012 B2 Call Master Job IN B2 B2
20014 B3 - IN B3 B3

Select Teach Mode IN B4 B4
20016 B4
- A4 A4
20017 A4 IN
IN B5 B5
20020 B5 Prohibited
B6 B6
20022 B6 Welding ON/OFF IN
A6 A6
20023 A6 Welding Pause IN
B7 024VU B7 024VU
A7 024VU A7 024VU
Running OUT B8 B8
30010 B8
Servo is ON OUT A8 A8
30011 A8
B9 B9
30012 B9 Top of Master Job OUT
A9 A9
B10 B10
30014 B10 Battery Alarm OUT
A10 A10
30015 A10 Remote Mode Selected OUT
B11 B11
30016 B11 Play Mode Selected OUT
A11 A11
30017 A11 Teach Mode Selected OUT
B12 B12
30020 B12 In Cube 1 OUT
A12 A12
30021 A12 In Cube 2 OUT
B13 B13
30022 B13 Work Home Position OUT
Intermediate Start OK A13 A13
Each Point 30023 A13 (continuousing Sequence) OUT
B14 B14
24VDC B14
A14 A14
50mA (max.) A14
B15 B15
B15
A15 A15
A15
B16 024VU
B16 024VU
A16 024VU
+24 V B17 024VU
024 V A17 024VU
-4 A17 024VU
(24V,1A) +24VU
B18
B18 +24VU
A18 +24VU
xternal A18 +24VU
-1 +24VU B19 +24VU
ower Supply B19 +24VU
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 103

(Optional)
CN309 Connector
Logical Connector Terminal
Number Number Name Signal
Number
Each Point 20024 B1 Interference3 Entrance IN B1 B1
Prohibited
24VDC 20025 A1 Interference4 Entrance
IN A1 A1
Prohibited
6.9mA (TYP) IN B2 B2
20026 B2 -
20027 A2 - IN A2 A2
20030 B3 IN1 USER INPUT IN B3 B3
20031 A3 IN2 IN A3 A3
IN3 IN B4 B4
20032 B4
IN A4 A4
20033 A4 IN4
IN5 IN B5 B5
20034 B5
A5 A5
20035 A5 IN6 IN
B6 B6
20036 B6 IN7 IN
A6 A6
20037 A6 IN8 IN
B7 024VU B7 024VU
A7 024VU A7 024VU
30024 B8 In Cube 3 OUT B8 B8
30025 A8 In Cube 4 OUT A8 A8

B9 B9
30026 B9 OUT
A9 A9
30027 A9 - OUT
B10 B10
30030 B10 OUT01 User Output OUT
30031 A10 OUT02 OUT A10 A10
OUT B11 B11
30032 B11 OUT03
A11 A11
30033 A11 OUT04 OUT
B12 B12
30034 B12 OUT05 OUT
A12 A12
30035 A12 OUT06 OUT
B13 B13
30036 B13 OUT07 OUT
A13 A13
30037 A13 OUT08 OUT
Each Point B14 B14
24VDC B14
A14 A14
50mA (max.) A14
B15 B15
B15
A15 A15 A15
B16 024VU B16 024VU

A16 024VU
+24 V B17 024VU
024 V A17 024VU
-4 A17 024VU
(24V,1A)
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU
+24 VE B19 +24VU
A19 +24VU
024 VE -2 024VU A19 +24VU
B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 104

(Optional)
+24VU
Model: TIFS553YS
CN307 Connector
Logical Connector
Number
Each Point 20050 B1 Timer Cooling Water
IN B1 B1
Error (IN09)
24VDC 20051 A1 Gun Cooling Water
IN A1 A1
Error (IN10)
6.9mA (TYP) Transthermo Error (IN11) IN B2 B2
20052 B2
20053 A2 Low Air Pressure (IN12) IN A2 A2
20054 B3 IN13 IN B3 B3
20055 A3 IN14 IN A3 A3
IN15 IN B4 B4
20056 B4
IN16 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 OUT B8 B8
Weld ON/OFF (OUT09)*** OUT A8 A8 RLY
A8
B9 B9
30051 B9 OUT
A9 A9
A9 Weld Error Reset (OUT10)** OUT RLY
B10 B10
30052 B10 OUT
A10 Weld Condition 1 (OUT11)** OUT A10 A10 RLY
OUT B11 B11
30053 B11
A11 A11 RLY
A11 Weld Condition 2 (OUT12)** OUT
B12 B12
30054 B12 OUT
A12 A12 RLY
B13 B13
Each Point 30055 B13 OUT
A13 A13 RLY
24VDC A13 Weld Condition 4 (OUT14)** OUT
B14 B14
500mA (max.) 30056 B14 OUT
A14 A14 RLY
B15 B15
30057 B15 OUT
A15 Tip Change Request (OUT16)** OUT A15 A15 RLY
B16 024VU B16 024VU
CN303 A16 024VU
Internal A16 024VU
+24 V B17 024VU
024 V A17 024VU
-4 A17 024VU
(24V,1A)
B18 +24VU
B18 +24VU
A18 +24VU
External A18 +24VU * means internal relay
-1 +24VU B19 +24VU
Power Supply B19 +24VU RLY means
+24 VE A19 +24VU
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG
A20 024VU
A20
024VU
024VU
024VU
024VU
when a external power supply is used. +24VU
** This assignment can be changed at the I/O assignment display. +24VU
Refer to System Input List YIU01 and System Output List YIU01 for detail.
+24VU
*** This assignment can be changed at the PSEDU input display.
+24VU
Refer to System Input List YIU01 and System Output List YIU01 for detail.
+24VU
+24VU
+24VU
+24VU
8 - 105

(Optional)
CN306 Connector
Logical Connector Terminal
Number Number Name Signal
Number
Each Point 20040 B1 IN17 IN B1 B1

A1 A1
24VDC 20041 A1 IN18 IN
B2 B2
6.9mA (TYP) 20042 B2 IN19 IN
20043 A2 IN A2 A2
IN20
B3 B3
20044 B3 IN21 IN
IN22 A3 A3
20045 A3 IN
B4 B4
20046 B4 IN23 IN
A4 A4
20047 A4 IN24 IN
B5 B5
B5
A5 A5
A5
B6 B6
B6
A6 A6
A6
024VU B7 024VU
B7
A7 024VU
A7 024VU
B8 B8
30040 B8 OUT17 OUT
A8 A8
30041 A8 OUT18 OUT
B9 B9
30042 B9 OUT19 OUT
A9 A9
30043 A9 OUT20 OUT
B10 B10
30044 B10 OUT21 OUT
A10 A10
30045 A10 OUT22 OUT
B11 B11
30046 B11 OUT23 OUT
A11 A11
30047 A11 OUT24 OUT
B12 B12
B12
A12 A12
A12
B13 B13
B13
A13 A13
Each Point A13
B14 B14
24VDC B14
A14 A14
50mA (max.) A14
B15 B15
B15
A15 A15
A15
B16 024VU
B16 024VU
A16 024VU
+24 V B17 024VU
A17 024VU
-4 024 V A17 024VU
(24V,1A) B18 +24VU
B18 +24VU +24VU
A18
External A18 +24VU
-1 +24VU B19 +24VU
Power Supply
B19 +24VU A19 +24VU
+24 VE
-2 024VU A19 +24VU
024 VE B20 FG
B20 FG 024VU
A20
A20 024VU
024VU
024VU
024VU
024VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
+24VU
8 - 106
Logical num- Input name / Function

ber
Functions are identical to those of the [START] button of the program-
ming pendant. Only the rising edge of this signal is valid. It starts robot
movement (playback). This signal is invalid if external start is not al-
lowed according to the playback status display.
Only the rising edge of this signal is valid. The upper part of the robot
program is called, i.e. the upper part of the master job1, and it is invalid
during playback, during teach-lock and when play master or call is not
allowed (set in the playback status window).
If an alarm or error occurs and its cause has been corrected, this signal
resets the alarm/error.
The playback mode is selected when the selector switch on the pro-
gramming pendant is set to "REMOTE". Only the rising edge of this sig-
nal is valid. If this selection signal is assigned along with another mode
selection signal, priority is given to the selection of the teach mode. The
signal remains invalid as long as the external mode switch is not activat-
ed.
The teach mode is selected when the selector switch on the program-
ming pendant is set to "REMOTE". No other modes can be selected as
long as this signal is ON. The signal has priority even if the other selec-
tion signal is ON and enables teach mode selection.
If the robot attempts to enter cube 12 while this signal is ON, the robot
is put into wait status (with servo power ON). During wait status, robot
movement is started as soon as this signal turns OFF.
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.
20023 WELDING PAUSE (from sequencer)
This signal is used to move the robot to the home position when an error
occurs in the Power Source or the gun.
The robot ignores the spot welding instruction and operates playback
motion.
8 - 107

ber
200503 TIMER COOLING WATER ERROR
This signal monitors the status of timer cooling water. The robot displays
alarm and stops when this signal is input. The SERVO power supply re-
mains ON.
200513 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.
200523 TRANSTHERMO ERROR
Error signal is sent from the transformer in the gun to the robot. The sig-
nal is normally an ON (NC) signal. An alarm occurs when the signal is
OFF. The SERVO power supply remains ON.
200533 LOW AIR PRESSURE
When air pressure is reduced and this input is turned ON, an alarm oc-
curs. The SERVO power supply remains ON.
4
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.
4
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.
4 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.
4
GUN FULL OPEN DETECTION
This signal indicates that the stroke of the double stroke gun is full open.
4
GUN SHORT OPEN DETECTION
This signal is connected with a single gun open verification limit switch
or a double stroke gun short open verification limit switch to verify the
gun open.
4 GUN PRESSURE DETECTION
This signal indicates that a gun is in pressing status.
4
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.
8 - 108
for normal jobs. Normally, the main job, which manages the sub-jobs called immediately after the power is turned
ON, is set as the master job.
3. This signal can be set as “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.
4. This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.

ber
30010 RUNNING
This signal indicates that the job is running. (This means that the job is
running, the system status is "waiting for reserved start", or a test run is
being carried out). This signal status is identical to [START] on the pro-
gramming pendant.
30011 SERVO IS ON
This signal indicates that the servo power is turned ON, internal pro-
cessing, such as position definition, has been completed and that the
system is waiting for a start command. This signal is turned OFF when
the servo power supply is turned OFF. It can be used for DX100 status
diagnosis for an external start.
This signal indicates that the execution position is at the top of the mas-
ter job. This signal can be used to confirm that the master job has been
called1.
This signal indicates that an alarm or an error has occurred. If a major
alarm occurs, this signal remains ON until the power supply is turned
OFF.
30014 BATTERY ALARM
This signal indicates that the battery voltage for the backup memory of
the encoder is low and the battery must be replaced. Loss of data due
to exhausted batteries may have serious consequences. Therefore, it is
recommended to treat this signal as a warning.
30015 to 30017 REMOTE/PLAY/TEACH MODE SELECTED
This signal indicates the current mode setting. These signals are syn-
chronised with the mode selector switch on the programming pendant.
The signal corresponding to the mode selected is turned ON.
30020 IN CUBE 1
This signal is turned ON when the current TCP lies within a pre-defined
area (cube 1). Use this signal to prevent faults due to other robots or po-
sitioners.
30021 IN CUBE 2
sitioners.
8 - 109

ber
This signal turns ON when the current TCP lies within the work home
position area. Use this signal to check whether the robot is in the start
position.
30057 TIP REPLACE REQUEST
This signal is output when the stored number of welding reaches the
number of welding set for the tip replacement.
This signal is turned ON when the robot moves. It turns OFF when the
currently executed line is moved with the cursor or when editing is per-
formed after a HOLD operation during the movement. Therefore, this
signal can be used as a restart interlock after a HOLD operation. How-
ever, it is also triggered in teach mode and is to be referenced along with
the "Teach mode selected" signal.
30024 IN CUBE 3
sitioners.
30025 IN CUBE 4
sitioners.
300503 WELD ON/OFF
Outputs a signal input from the interlock panel, etc.considering the robot
status.
300514 WELD ERROR RESET
This signal commands the reset error status of the Power Source. This
is operated with the programing pendant operation.
(30052 to WELD CONDITION (level signals)
300564)4 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).
4 WELDING COMMAND
This signal outputs execution command signal to the Power Source.
This signal is not necessary for a power source which is executed using
the WELDING CONDITION signal.
4
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.
4 GUN PRESS COMMAND
This outputs gun press command.
8 - 110
3. This signal can be select “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.
4. This signal can be allocated to any universal I/O signal at the I/O allocation display in operation condition.
6
7 6 5 4 3 2 1 0
0 0 0 1 1 1 1 1
1
2
3
4
5
1 Timer cooling water error validating ( 4 Low air pressure validating (or IN12)
or IN09)
2 GUN Cooling Water Error Validating 5 Weld ON/OFF Validating (or OUT09)
(or IN10)
3 Transthermo error validating (or IN11) 6 Pseudo Input Signal 8202x
8.29.5 JANCD-YEW01-E circuit board (Standard)
JANCD-YEW01-E Circuit Board: Analog outputs ´ 2 ports, Analog inputs ´ 2 ports + Status
signal I/O of a Welder.
8 - 111
MR Connector MS Connector
Logical Connector Signal

Number Pin No.
Name
CN322-1 1
Each point
24 VDC 25110 CN322-2 +GASOF (Gas Shortage) IN 2
5mA MAX CN322-3 -GASOF (Gas Shortage) IN 3 S
25111 CN322-4 +WIRCUT (Wire Shortage) IN 4
CN322-5 -WIRCUT (Wire Shortage) IN 5 T
25113 CN322-6 +ARCACT (Arc Generation Confirm) IN 6
CN322-7 -ARCACT (Arc Generation Confirm) IN 7 P
CN322-8 CH2 (Current Input) IN 8
A/D +5V CN322-9 9
CN322-10 10
A/D +5V CN322-11 CH1 (Voltage Input) IN 11
CN322-12 CH1-G IN 12
DC24V 25112 CN322-13 +ARCOFF (Arc Shortage) IN 13
5mA MAX CN322-14 -ARCOFF (Arc Shortage) IN 14 R
DC24V 35111 CN322-15 ARCON (Arc ON) A OUT 15 K
0.5A MAX CN322-16 ARCON (Arc ON) B OUT 16 L
Power
35112 CN322-17 WIRINCH (Wire Inching) A OUT 17 F
Source
CN322-18 WIRINCH (Wire Inching) B OUT 18 G
35113 CN322-19 WIRINCH (Wire Retract) A OUT 19 H
CN322-20 WIRINCH (Wire Retract) B OUT 20 J
35127 CN322-21 GAS Checking OUT A OUT 21
CN322-22 GAS Checking OUT B OUT 22
CN322-23 23
CN322-24 24
CN322-25 25
25114 CN322-26 STICK (Wire Sticking) IN 26 M
Detector
CN322-27 *STICK (Wire Sticking) IN 27 N
CN322-28 CH2 -G IN 28
CN322-29 +24VU 29
CN322-30 024VU 30 E
CN322-31 CH1 (Voltage Command) OUT 31 A
D/A ±14V
CN322-32 CH1-G OUT 32 B
SW2 CN322-33 CH2 (Current Command) OUT 33 C

D/A ±14V
1 3 CN322-34 CH2 -G OUT 34 D
17BYTE 32BYTE
CN321-1 +24VU
DC24V 35115 CN321-2 Search Command A (Optional) OUT
0.5A MAX
CN321-4 Search Command B (Optional) OUT
CN321-5 024VU
MRP-34M01 Insulator
MRP-M112 Contactor MS3106 A, 20-29P
WAGO Connector(231-105/026-A0) RP-34 Casing MS3106 A, 20-29S
Fig. 8-59: JANCD-YEW01-E circuit board (Standard)
8 - 112
8.29.6 The list of the Equipment configuration by model
Model MA1440, MH12

Type ERER-MA01440-A00
Dimension W x H x D (mm) 600 × 730 × 520
Breaker NF32-SVF 3P 15A
Control power supply unit JZNC-YPS21-E
CPU unit - JZNC-YRK21-1E
CPU circuit board JANCD-YCP21-E
Back circuit board JANCD-YBB21-E
PCI raiser circuit board JANCD-YBB22-E
Robot I/F circuit board JANCD-YIF01-2E
Machine safety CPU circuit board JANCD-YSF21-E
Machine safety I/O logic circuit board JANCD-YSF22-E
Machine safety terminal block JANCD-YFC22-E
Universal I/O circuit board JANCD-YIO21-E
Power ON unit JZRCR-YPU51-1
Major axes control circuit board SRDA-EAXA21A
Brake control circuit board JANCD-YBK21-3E
Converter SRDA-COA30A21B-E
Capacitor module SRDA-CUA662AA
Amplifier module AMP1 (S-axis) SRDA-SDA14A01A-E
AMP2 (L-axis) SRDA-SDA21A01A-E
AMP3 (U-axis) SRDA-SDA14A01A-E
AMP4 (R-axis) SRDA-SDA06A01A-E
AMP5 (B-axis) SRDA-SDA06A01A-E
AMP6 (T-axis) SRDA-SDA06A01A-E
Regenerative resistor Type SMVK500W6R0J/R0 A6103
Rated value 500W
Register value 6Ω
Heat exchanger 4715MS-22T-B50-B00 x2
Colling fan 4715MS-22T-B50-B00 x3
Tab. 8-2: Small capacity model MA1440 and MH12
8 - 113
Model MS210
Type ERER-MS00210-A00
Dimension W x H x D (mm) 600 × 730 × 520
Breaker NF32-SVF 3P 30A
Control power supply unit JZNC-YPS21-E
CPU unit - JZNC-YRK21-1E
CPU circuit board JANCD-YCP21-E
Back circuit board JANCD-YBB21-E
PCI raiser circuit board JANCD-YBB22-E
Robot I/F circuit board JANCD-YIF01-2E
Machine safety CPU circuit board JANCD-YSF21-E
Machine safety I/O logic circuit board JANCD-YSF22-E
Machine safety terminal block JANCD-YFC22-E
Universal I/O circuit board JANCD-YIO21-E
Power ON unit JZRCR-YPU51-1
Major axes control circuit board SRDA-EAXA21A
Brake control circuit board JANCD-YBK21-3E
Converter SRDA-COA30A21B-E
Capacitor module SRDA-CUA133AA
Amplifier module AMP1 (S-axis) SRDA-SDA71A01A-E
AMP2 (L-axis) SRDA-SDA71A01A-E
AMP3 (U-axis) SRDA-SDA71A01A-E
AMP4 (R-axis) SRDA-SDA35A01A-E
AMP5 (B-axis) SRDA-SDA35A01A-E
AMP6 (T-axis) SRDA-SDA35A01A-E
Regenerative resistor Type SMVK500W2R0J A5978 x3
Rated value 1500W
Register value 6Ω
Heat exchanger TCSIP-16A4Y-0C
Cooling fan 4715MS-22T-B50-B00 x3
Tab. 8-3: Small capacity model MS210
8 - 114
Recommended spare parts list
9 Recommended spare parts list

It is recommended to keep in stock parts and components in the following table as spare
parts to use. Product performance cannot be guaranteed when using spare parts from any
company other than YASKAWA.
NOTICE
Please contact your YASKAWA branch office if you need spare or replacement parts.
3 1
2 13
4
7
14
8
15
9
16
10
17
11
18
12
19
20
1 Brake control board (-AE5), backside 11 CPU unit (-AE1)

of axis control board
2 Axis control board (-AE6.0) 12 I/O Terminal (-X12A-X13B) option
3 Ex. axis control board (-AE6.1) 13 Machine Safety I/O logic board (-AE4)
4 Safety functional board (-AE6.2 14 Functional safety (-X181) option
5 Main switch (-Q1M) 15 Machine safety terminal board (-X18)
6 Terminal (-X9) 16 General I/O board (-AE7)
7 Circuit breaker (-FS1) 17 Functional safety I/O board (-AE8) op-
tion
8 Converter unit (-TP1) 18 DSW 1-2 (-X810) option
9 Power on unit (-AE2) 19 Option board (-AE9, AE10,-AE11)
10 CPS unit (-AE3)
Tab. 9-1: Unit layout master
9 - 115
-TA7 -TA8 -TA9

(Option) (Option) (Option)
-TA4
-TA6
-TA5
-TA1
-TA3
-TA2
Fig. 9-1: SERVOPACK (-TA1 to -TA9)

The SERVOPACK types is different depending on robot model
9 - 116
3 2 1
4
6
11
7
8 12
9 13
14
10
15
1 Brake control board (-AE5), backside 9 CPS unit (-AE3)

of axis control board
2 Axis control board (-AE6.0) 10 I/O Terminal option
3 Ex. axis control board (-AE6.1) 11 Machine Safety I/O logic board (-AE4)
4 Safety functional board (-AE6.2 12 Functional safety (-X181) option
5 Terminal (-X9) 13 Machine safety terminal board (-X18)
6 Circuit breaker (-FS1) 14 Functional safety I/O board (-AE8) op-
tion
7 Converter unit (-TP1) 15 Option board (-AE9, AE10,-AE11)
8 Power on unit (-AE2)
Tab. 9-2: Unit layout slave
9 - 117
-TA7 -TA8 -TA9

(Option) (Option) (Option)
-TA4
-TA6
-TA5
-TA1
-TA3
-TA2
Fig. 9-2: SERVOPACK (-TA1 to -TA9)

The SERVOPACK types is different depending on robot model
Spare parts list robot controller for MA1440/MH12
Manufecturer
Material no.
Description
Type
Power supply JZNC-YPS21-E master 164754 YEC
additional power JZNC-YPS02-E Slave E147571 YEC

supply
Rack-circuit board JZNC-YRK21-1E master 164756 YEC
I/F board JANCD-YIF01-2E master E145855 YEC
Safety CPU board JANCD-YSF21-E master 164757 YEC
Safety I/O board JANCD-YSF22-E Master/Slave 164758 YEC
I/O board (PNP JANCD-YIO22-E master 164762 YEC

type)
Power supply unit JZRCR-YPU52-1 Master/Slave 164764 YEC
Converter SRDA-COA30A21B-E Master/Slave 164767 YEC
Capacity module SRDA-CUA662AA Master/Slave 164781 YEC

12A
SERVO package JZRCR-YSV24-111 Master/Slave 164772 YEC
9 - 118
Spare parts list robot controller for MA1440/MH12
Manufecturer
Material no.
Description
Type
Resistor SMVK500W6R0J A6103 Master/Slave 164775 YEC
Memory card MCF10P256MS(A00ACIYE) master 151281 YEC
Spare parts list robot controller for MS165/MH180
Manufecturer
Material no.
Description
Type

supply

type)

30A
Resistor SMVK500W2R0J A5978 Master/Slave E143574 YEC
9 - 119
Spare parts list robot controller for MS210/MH225
Manufecturer
Material no.
Description
Type

supply

type)

30A
Resistor SMVK500W2R0J A5978 Master/Slave E143574 YEC
NOTICE
Product performance cannot be guaranteed when using spare parts from any company
other than YASKAWA.
Please contact your YASKAWA branch office if you need spare or replacement parts.
9 - 120
9 - 121
YASKAWA Kontakte | YASKAWA contacts
YASKAWA YASKAWA Europe GmbH YASKAWA Academy und YASKAWA Europe GmbH
Zentrale Robotics Division Vertriebsniederlassung Robotics Division
Yaskawastraße 1 Frankfurt Hauptstraße 185
D-85391 Allershausen D-65760 Eschborn
Tel. +49 (0) 8166/90-0 Tel. +49 (0) 6196/77725-0
Fax +49 (0) 8166/90-103 Fax +49 (0) 6196/77725-39
YASKAWA Gruppe Distributors

A YASKAWA Austria BG Kammarton Bulgaria Ltd.
Schwechat/Wien +43(0)1-707-9324-15 Sofia +359-02-926-6060
CZ YASKAWA Czech s.r.o. CH Messer Eutectic Castolin Switzerland S.A.
Rudná u Prahy +420-257-941-718 Dällikon +41-44-847-17-17
E YASKAWA Ibérica, S.L. DK Robotcenter Danmark
Gavà/Barcelona +34-93-6303478 Løsning +45 7022 2477
F YASKAWA France SARL EE RKR Seadmed OÜ
Saint-Aignan-de-Grand-Lieu Tallinn/Estonia +372-68-35-235
+33-2-40131919 GR Gizelis Robotics
FIN YASKAWA Finland Oy Nea Kifissia +30-2106251455
Turku +358-(0)-403000600 H Flexman Robotics Kft
GB YASKAWA UK Ltd. Budapest +36-30-9510065
Banbury +44-1295-272755 LT Profibus UAB
I YASKAWA Italia s.r.l. Panevezys +370-45-518575
Torino +39-011-9005833 N Optimove as
IL YASKAWA Europe Technology Ltd. Lierstranda +47-32240600
Rosh Ha’ayin +972-3-9004114 PL Integrator RHC Sp. z o.o.
NL YASKAWA Benelux B.V. Torun +48-56-6519710
EB Son +31-40-2895500 RO Sam Robotics srl
RUS YASKAWA Nordic AB Timisoara +40-720-279-866
Moskva +46-480-417-800
RO MPL Automation srl
SE YASKAWA Nordic AB Satu Mare +40-261-750-741
Torsås +46-480-417-800
SI YASKAWA Slovenia
Ribnica +386-1-8372-410
TR YASKAWA Turkey Elektrik Ticaret Ltd. Stl.
İstanbul +90-216-5273450
ZA YASKAWA Southern Africa (PTY) Ltd
Johannesburg +27-11-6083182
www.yaskawa.eu.com
[email protected]
Änderung, welche dem technischen Fortschritt dienen, vorbehalten.

Alterations in the course of technical progress, are reserved, without separate information.

Wiring E1102000143GB03

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Robot controller

Installation and Wiring

Changes made in revision:

7 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.5 Check battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8 Description of Units and Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9 Recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1.2 Frequently used terms

1.3 Target group

1.4 Intended use

1.5 Improper use

1.6 About this manual

Equipment Manual Designation

ex. [SHIFT] SHIFT

In this manual, names of companies, corporations, or products are trademarks, registered

JOB EDIT DISPLAY UTILITY

Main Menu ShortCut !Turn on servo power

ROBOT INFORM 4 5. 6 BWD FWD

EX.AXIS 1 2 3 DELETE INSERT

Fig. 1-1: Programming pendant

1 Emergency stop button

Fig. 1-3: Emergency stop button

Fig. 1-4: Release of emergency stop button by turning

1.7.1 For your safety

Fig. 1-5: CE marking

1.7.2 YASKAWA manual list

1.7.3 Personal protection

Observe the following note:

• Never lean against the robot controller.

Fig. 1-6: Do not lean on

1.7.4 Safety during installation and wiring

DANGER due to electric current!

Fig. 1-7: Protective cover for forklift

1 Piping 3 Cables and tubes

1.7.4.1 Safety in the work area

1.7.4.2 Operating safety

Emergency stop function

1.9 Authorized representative

Fig. 2-1: Scope of supply

1 Programming pendant 4 The present assembly instructions

2.2 Position type plate

YASKAWA ELECTRIC CORPORATION

YASKAWA Europe „Robotics Division“ GmbH

Fig. 2-2: Position type plate

3.1 Transporting method

3.1.1 Using a crane

YASKAWA ELECTRIC CORPORATION

Fig. 3-1: Transport with crane

3.1.2 Using a forklift

Fig. 3-2: Using a forklift

1 Protective padding 3 Palette

3.1.3 Using a lifting truck

2. Pull it straight out.

Fig. 3-3: Using a lifting truck

4.1 Installing protective equipment

• Ambient temperature: 0° C to + 45° C.

4.3 Installation example

YASKAWA ELECTRIC CORPORATION YASKAWA Europe „Robotics Division“ GmbH

YASKAWA Europe „Robotics Division“ GmbH

Fig. 4-1: Connecting two cabinets