OM0105037E02 0109 YA-1NCseries Controller

Industrial Robot
Robot Controller
Operating Instructions
Model No. YA-1NA series
VR Series Contents
1.Specifications
2.Transportation
3.Installation
4.Connection
5.Safety Input/Output
6.Connection of External control signal
7.Parts List
8.Maintenance
9.Location of Warning labels
G controller
Before operating this product, please read the instructions carefully and save this
manual for future use.
OM0105037E02
(0105037)
0202
Systems of “Operating Instructions” of Panasonic Robot VR series
Name Description and remarks Usage

Safety manual Panasonic robots are designed and manufactured Use this document for training
on the premise that contents of this manual are programs at installation and also
conformed to by users. Personnel who use any periodic training on safe
other operating instructions listed in this table must operation of the robot, which
read and understand the contents of this manual must be taken by all personnel
first. who handle Panasonic robots.
This manual explains general rules and regulations
related to the industrial robots and also basic safety
instructions from installation, maintenance and
repair all the way down to disposal step by step.
Robot system The document explains configuration and installation Use this document to
Operating instructions of standard robot systems, such as CO2 welding understand robot system
robot system in general. configuration and connection
system at installation in general.
Robot manipulator The document explains transportation, installation, This document is for personnel
Operating instructions connection, initial settings and maintenance and who are in charge of installation
repair of the robot manipulator. and/or maintenance.
The contents of the document are limited to
hardware of the equipment.
Robot controller The document explains transportation, installation, This document is for personnel
Operating instructions connection, initial settings and maintenance and who are in charge of installation
repair of the robot controller. and/or maintenance.
The contents of the document are limited to
hardware of the equipment.
Note)
Initial settings of software at robot installation are
shown in “Operating instructions, Advanced
operation”.
Optional equipment The document explains installation, connection and The document is provided for
Operating instructions repair of the optional equipment applicable to G optional equipment.
series. The contents of the document are limited Each document is for personnel
to hardware of the equipment. who are in charge of installation
Note) and/or maintenance.
Initial settings of software at robot installation are
shown in “Operating instructions, Advanced
operation”.
Operating instructions The document is for operators who operate This is a guide for beginners of
Basic operation Panasonic robots G for the first time. The G series
document explains basic robot functions and basic
robot welding operation.
Operating instructions The document explains settings of robot, basic Refer to the document and try
Advanced operation parameters, I/O settings for AUTO play and initial operating the robot for better
settings of all optional equipment including welding understanding.
power source and external axis.
It explains robot commands in detail.
i
■ Introduction
Thank you for purchasing our Panasonic industrial robot VR2 series. This manual is the Operating
Instructions of the robot controller G2 controller series.
■ Safety
First of all, please read and understand separately provided “Safety Manual” thoroughly for proper and
safe operation of our robots.
Prior to operation, read this manual for proper operation. Keep this manual in an easily accessible
place and re-read as necessary.
The installation shall be made by qualified installation personnel and should conform to all national and
local codes.
The contents of manuals are subject to change without further notice.
ii
■ About Model No
Model No. Symbol Basic design policy

YA-1NA***T** T The robot is designed as standard specification for the use in T for the Japanese
market and Y for overseas markets in general.
YA-1NA***Y** Y
This product does not meet the requirements specified in the EC Directives which
are the EU safety ordinance. Please bear in mind that this product may not be
brought as is into the EU. The same restriction also applies to any country
which has singed the EEA accord.
Please be absolutely sure to consult with us before attempting to relocate or resell
this product to or in any EU member state or any other country which has signed
the EEA accord.
<Note>
If you are intended to use the robots in US, Canada or EU member states
(including countries signed the EEA accord), please purchase the robots designed
for those countries. (See the following models.)
YA-1NA***E** The robot is designed in accordance with the applicable European directive:
E
Machine Directive 98/37/EC, Low Voltage Directive 73/23/EEC (as last amended)
and EMC Directive 89/336/EEC (as last amended).
Before put into service the Robot manipulator in the European market the Robot
system shall be designed in accordance with the manufactures specification
described in this manual and Instruction manual.
Remodeling and/or modifying this product not in accordance with the

manufacturers specification then this declaration will loose its validity.
YA-1NA***U** The robot is basically designed in accordance with safety regulations and
U
standard applied in the US and Canadian markets.
This product does not meet the requirements specified in the EC Directives which
are the EU safety ordinance. Please bear in mind that this product may not be
brought as is into the EU. The same restriction also applies to any country
which has singed the EEA accord.
Please be absolutely sure to consult with us before attempting to relocate or resell
this product to or in any EU member state or any other country which has signed
the EEA accord.
The installation shall be made by qualified installation personnel and should
conform to all national and local codes.
Notice: Exporting the machine into Canada
Please bear in mind that exporting this product to Quebec, Canada requires all
name plates and manuals of the product shall be written in French.
■Registered trade mark

Microsoft Windows and WindowsCE are registered trade marks of Microsoft corporation in the United
States and/or other countries.
PS/2 is a registered trade mark of Internatinal Business Machines Corporation.
Other names of company and products are generally trade marks or registered trade marks of each
company.
iii
■ Warnings and Cautions
This manual is also structured on the premise that any personnel who handle industrial robots must complete the
appropriate training programs, which can be a requirement of related regulations and standards. Some safety
precautions are emphasized using the following symbols for extra caution.
Warnings, Cautions, Mandatory Actions and Prohibitions listed in this manual must be followed without fail. If directions
are not followed carefully, potentials for personal injury not only to the operator(s), but also other personnel and potential
for property damage to the equipment.
It is also important to ensure that equipment functions correctly at all times.
Panasonic robots are designed and manufactured on the premise that contents of this manual are conformed to by users.
Personnel who use any other manuals must read and understand the contents of this manual first.
●Improper operation of the machine may lead to various levels of hazardous conditions. This document classifies all of
these hazardous conditions into three levels, namely Danger, Warning or Caution, and indicates these levels by using
symbols.
The warning symbols and signal phrases are also used on the warning labels attached on the machine.
Warning
Signal phrase Description
symbol
When you see this symbol it means that a hazardous accident including death
Danger or serious personal injury is imminent, if directions are not followed carefully.
When you see this symbol it means that the potential for a hazardous accident
Warning including death or serious personal injury is high, if directions are not followed
carefully.
When you see this symbol it means that the potential for hazardous accident
Caution including medium-level or light personal injury and/or the potential for property
damage to the equipment are high if, directions are not followed carefully.
The above warning symbols are commonly used.
“Serious personal injury” refers to loss of eyesight, burns (high-temperature and low-temperature burn),
electrical shock, bone fractures and gas poisoning, as well as those that leave after-effects, which
require hospitalization or necessitate medical treatment for an extended period of time.
“Medium-level and light personal injury” refers to burns, electrical shock and injuries which do not
require hospitalization or necessitate medical treatment for an extended period of time. “Property
damage” refers to extensive damage to the surrounding items and equipment.
●Furthermore, the mandatory items or actions that must be performed and those that are prohibited are indicated as
follows.
Warning
Signal phrase Description
symbol
Mandatory Action which MUST be performed without fail, such as grounding.

Action
Prohibition Action which MUST NOT be performed.
The above warning symbols are commonly used.
iv
TABLE OF CONTENTS
CHAPTER 1. SPECIFICATIONS CHAPTER 6. CONNECTION OF EXTERNAL

CONTROL SIGNAL
1.1 Technical data...................................................1-1
1.1.1. Structure and control method..............................1-1 6.1 Terminal location of the Sequencer card ......... 6-1
1.1.2. Operational functions ..........................................1-2 6.2 Connecting and control method of external device
1.1.3. Inputs, outputs and communications...................1-3 ............................................................................. 6-4
1.1.4. Analogue welding specifications .........................1-4 6.2.1. I/O terminal equivalent circuit............................. 6-5
1.1.5. For welding applying digital communication
specifications..........................................................1-4 6.3 Auto start settings ............................................ 6-6
6.3.1. Master method ................................................... 6-6
1.2 Dimensional drawings and mass......................1-5 6.3.2. Program select................................................... 6-6
1.2.1. YA-1NCR type ....................................................1-5 6.3.3. Start method and I/O allocation.......................... 6-7
1.2.2. YA-1NC type .......................................................1-6 6.3.4. Program select method (common specifications)6-8
1.2.3. Teach Pendant....................................................1-7 6.3.5. Signal method .................................................... 6-8
1.2.4. Operation Box.....................................................1-8 6.3.6. Program select and Start Strobe ........................ 6-9
1.3 Accessories.......................................................1-9 6.3.7. Binary method...................................................6-10
1.3.1. Ground cable ......................................................1-9 6.3.8. BCD method .....................................................6-11
1.3.2. Accessories for the controller..............................1-9 6.4 Timing of program selection response........... 6-12
6.4.1. Program reservation in Signal method ..............6-12
CHAPTER 2. TRANSPORTATION 6.4.2. Program reservation in Binary and BCD methods6-12
6.5 Analogue welding control............................... 6-13
2.1 Transportation methods....................................2-1 6.5.1. Analogue output terminals.................................6-13
6.5.2. I/O terminal for the exclusive use of welding.....6-13
CHAPTER 3. INSTALLATION 6.6 Status IN/OUT................................................ 6-14
6.6.1. Status INPUT ....................................................6-14
3.1 An international protection code of the machine 6.6.2. Status OUTPUT ................................................6-15
..............................................................................3-1 6.7 Flowchart of Status Outputs........................... 6-16
3.2 Choosing an installation site.............................3-1 6.7.1. Operating and Holding output ...........................6-16
3.2.1. Installation site ....................................................3-1 6.7.2. Mode change (1I/O monitor) .............................6-16
6.7.3. Emergency stop 1 .............................................6-17
CHAPTER 4. CONNECTION 6.7.4. Emergency stop ................................................6-17
6.7.5. Error output .......................................................6-18
4.1 Connecting the controller to the manipulator....4-1 6.7.6. Connecting to sequencer card ..........................6-19
4.1.1. Encoder cable (round-shape connector).............4-1 6.8 External interface of Teach Pendant.............. 6-20
4.1.2. Motor cable (Square-shape connector) ..............4-1 6.8.1. PC Card slot......................................................6-20
4.2 Connection of primary power source and ground cable 6.8.2. PS/2 port ...........................................................6-20
..............................................................................4-2 6.9 End User License Agreement of software ..... 6-21
4.2.1. . Grounding .........................................................4-2
4.2.2. Connection of Grounding wire ............................4-2 CHAPTER 7. PARTS LAYOUT DRAWINGS
4.3 Connecting primary power cable......................4-3
4.3.1. Required power source capacity.........................4-3 7.1 Controller ......................................................... 7-1
4.3.2. Wiring of primary power source ..........................4-3 7.2 Teach pendant ................................................. 7-3
4.3.3. Connection of power cable .................................4-4 7.3 Operation Box .................................................. 7-5
4.3.4. T/Y Specifications only: Connection for 220VAC.4-4
4.3.5. Door handle ........................................................4-5
CHAPTER 8. MAINTENANCE AND INSPECTION
CHAPTER 5. SAFETY I/O SPECIFICATIONS 8.1 Daily check....................................................... 8-2
8.1.1. Inspections before turning on the power ............ 8-2
5.1 I/O for Safety circuit ..........................................5-1 8.1.2. Inspections after turning on the power ............... 8-2
5.1.1. External emergency stop input ...........................5-1 8.2 Periodical check............................................... 8-3
5.1.2. Door stop input ...................................................5-1 8.2.1. Battery replacement of Teach Pendant .............. 8-4
5.1.3. Spare emergency stop input ...............................5-2
5.1.4. External Dead Man’s input..................................5-2
5.1.5. Hand input ..........................................................5-2 CHAPTER 9. LOCATION OF WARNING LABELS
5.1.6. Input of the safety circuit .....................................5-3
5.1.7. Emergency stop output .......................................5-4 9.1 Location of labels ............................................. 9-1
5.2 Other safety input/output ..................................5-6
5.2.1. Safety holder input..............................................5-6
5.2.2. Installation input ..................................................5-6
v
Chapter 1. Specifications
1.1 Technical data
1.1.1. Structure and control method
Item Specifications
Structure Closed box type
Cooling method Indirect air cooling (Circulating internal air)
Ambient temperature/Humidity 0-45 , 20-90% (No dew condensation)
3-phase, 200 VAC ±20V,
Input power source

Note)
See details to “Connection” chapter.
Protective Earth (PE) grounding is required.
Functional Earth (TE) is provided for high frequency generating applications.
Structure
(TIG welding, Plasma welding and cutting)

Grounding
Note)
See details to “Connection” chapter.
Body color Munsell color system 5Y8/1
An emergency stop switch and an Operating switch are available.
Separated from the controller.
Standard attached for U and E specifications.
Operation box Optional for T and Y specifications.
Note)
The Operation box requires optional software.
Teaching method Teaching playback
Control method
Path control PTP and CP (Linear and circular interpolation)

The number of control axes 6 axes simultaneously (Option: 12 external axes)
Position detection method Electronic type absolute pulse encoder
Position control method Software servo control
Speed control method Constant linear velocity control (during CP control)
Memory system IC memory (Battery back-up system)
Memory & Display
Memory capacity 40000 points

Motion mode 1.Teaching, 2. Play (Auto)
Edit protection function Provided (Write protection code)
User level registration (3 level)
Display method Teach pendant 7 inches TFT color LCD, graphic type
External memory Available by connecting to PC card (user procured part)
1. Mechanical stopper,
2. Overrun,
3. Software limit,
4. CPU abnormality monitoring,
5. Cable connection monitoring,
Protective function
6. Power abnormality,
(self-diagnosis)
7. Temperature abnormality inside the panel,
8. Servo abnormality
(Over-speed, Over-current, Overload)
9. Operation error
10. Low battery warning for memory backup.
1-1
1.1.2. Operational functions
Item Specifications
Linear interpolation,
Circular interpolation (3-D plane),
PTP
Weaving
Circular weaving
Interpolation
Weaving condition
Frequency: 5Hz or less by 6 axes motion.
10Hz or less of simple oscillation by wrist.
Hold time at center and
both ends: 0.1 to 9.9 seconds.
Coordinates selection 1. Cartesian, 2. Articulated, 3. Tool, 4. Cylinder, 5. User
Wrist compensation function Effective when Cartesian, tool, cylinder or User is selected.
Allowable setting range: 0.01 to 15 m/min.
in teaching
(Factory set to 15 m/min at delivery)
Speed setting
Allowable setting range: 0.01 to 120 m/min
in playback
(Direct numerical value input)
Teaching
Sequence It is possible to edit or input sequence from teach pendant.

Jog Adjustable to any distance.
Weld wire jog Forward and reverse feeding.
Input/Output, 2. Flow control, 3.Welding,
Commands 96 4. Arithmetic calculation, 5. Logical calculation,
6. Move, 7. Motion assist, 8. Shift, 9. Others
Function Cut, Copy, Paste, Add, Delete, Change and Others
Edit
Edit in operation Available (Effective from next cycle)

Program start method Master program, Signal, Binary and BCD
Drive conditions Limited speed, Robot lock, I/O lock and Arc lock
Reservation function Up to 16 programs which are not in operation or being reserved.
Robot operating time,
Operation
Control functions Overall operating time (can be reset)

Tact time per program
Re-start after the emergency Available (Home return procedure is not required.)
1-2
1.1.3. Inputs, outputs and communications
Item Specifications
Input Start Teaching mode
Hold Servo ON
Error release
Status I/O Operating mode
Output Running Teaching mode
External control I/O
Hold status Servo ON

Error Ready
Operating mode, Alarm
Input 40 points (Option: expandable to max. 504 points)
Common I/O Output 40 points (Option: expandable to max. 504 points)
Allocable I/O Program select input, other status I/O.
Other I/O Safety Holder input and Installation input
Input Photo-coupler (ON/OFF of 24 VDC, 12 mA)

I/O
T/Y U Spec. Open Collector
specifications Output
E spec. Open emitter
Dual circuit Emergency stop of Teach Pendant
input Spare emergency stop
External emergency stop
Door stop
Deadman switch
External deadman switch
Safety I/O
Safety circuit Hand input
Note)
The emergency stop of the Operation Box for the E and U specifications has
been connected to the “Spare emergency stop” at ex-factory.
Output Emergency stop output (system 4)
I/O Input Double contacts (Dual circuit)

specifications Output Double contacts (Dual circuit)
External IrDA (Infrared) communication port
Teach
Comm.
memory, 2 slots for PCMCIA card,

Pendant
Communication PS/2
Interface Controller Optional RS-232C and RS-422
1-3
1.1.4. Analogue welding specifications
Analogue Output unit (YA-1NPEA1) and Adapter Unit (AXU01192) are required to install.
Item Specifications
Welding current Note) Division: 256 Direct input of numerical values
Note) or Output:
Welding voltage Division: 256
Equi-partition 0 to 15 V
Speed output Division: 256 Exclusive for welding
Welding control
Current detect Torch contact

Input Arc cut Wire off/No gas
Welding I/O Stick check
(Exclusive connector) Arc start 4. Inching (Fwd/Back)
Output Gas valve control, (Incremental inching speed
Stick detection type)
Direct input of one of the five welding current/voltage set menus.
Welding condition setting <Correction>
In menu edit mode in teaching operation.
Protective function
Welding abnormality
(self-diagnosis)
1.1.5. For welding applying digital communication specifications

This section explains different specifications of controllers for the use of welding applying digital communication
(Panasonic “WELLINK”) from the one for analogue welding specification.
Item Specifications
Welding current Direct input of a numerical value.
Welding voltage Select either “Unification” or “Individual” for welding condition.
Speed output
Welding control
Input Gas check

Welding I/O 1. Amperage,
(Exclusive connector) Output 2. Voltage
3. Welding current detection
Direct and manual input and correction
Direct input of one of the five welding current/voltage set menus.
Welding condition setting
Manually correct values in menu edit mode in teaching operation
if necessary.
1-4
1.2 Dimensional drawings and mass
1.2.1. YA-1NCR type
This is a controller type for Robot controller models, YA-1NCR41*** (G -004),
YA-1NCR61*** (G -006) and YA-1NCR81*** (G -008).
Dimensions (W x D x H) 420 x 600 x 530 (mm)

Mass 48 kg (Including the Teach pendant and the Connection cable)
Connection Cable 4m (between the controller and the manipulator)
1-5
1.2.2. YA-1NC type
This is a controller type for Robot controller models, YA-1NC161*** (G -016) and YA-1NC321*** (G -032)
Dimensions (W x D x H) 420 x 630 x 530 (mm)

Mass 73 kg (Including the Teach pendant and the Connection cable)
Connection Cable 6m (between the controller and the manipulator)
1-6
1.2.3. Teach Pendant
mm
TP Cable 10 m (with a connector at the teach pendant side.)
1-7
1.2.4. Operation Box
mm
Connection cable 6m T/Y ×

“AUTO mode” switch The “AUTO” mode operation is functioned by (1) changing the E/U ○
Mode switch of the Teach Pendant to “AUTO” or (2) restarting after ○: Standard
door stop input in “AUTO” mode, and then the “AUTO mode” ×:Option
switch of the Operation Box to ON.
The connection wires are connected to the Status I/O and other
connection terminals.
Emergency Stop switch A switch connected to the “Spare emergency stop” input.
<Note> Optional software is required for using the Operation Box.
1-8
1.3 Accessories
1.3.1. Ground cable
Mode number of the controller Part number Q’ty
YA-1NCR41*** G 004
YA-1NCR61*** G 006 AWC40885LM (4m)
YA-1NCR81*** G 006L,G 008 2
YA-1NC161*** G 008L,G 016
AWC40885LP (6m)
YA-1NC321*** G 032
1.3.2. Accessories for the controller

Description Part number Q’ty
Teach Pendant AUR01047 1
TP Hook (*) AKC41013PA (for Teach Pendant) 1
Ball Chain (*) TM14-1L500 1
Mode selection switch 2
Fuse ST4-5AN1 (5A anti-rush type) 3
Fuse ST4-0.5A (0.5A anti-rush type) 2
Fuse See Note 1.
Fastener with key 6
Cord lock NSL18 1
Connector FCN361J040AU (for the Sequencer card) 2
Connector cover FCN360C040B (for the Sequencer card) 2
Harness AWC42038 (For external emergency stop and the Door Stop) 4
Label for Key switch ANS31017 1
(*) The part is attached as assembled unit.
(Note 1) The part number depends on the controller model.
Model number of the controller Part number Q’ty

YA-1NCR41*** G 004
YA-1NCR61*** G 006 FNW15 (15A)
3
YA-1NCR81*** G 006L,G 008
YA-1NC161*** G 008L,G 016
FNW30 (30A)
YA-1NC321*** G 032
1-9
Chapter 2. Transportation
2.1 Transportation methods
In principle, use a crane to transport a robot controller for installation or re-installation. When a crane is used, hang the
robot controller with double-wire through the attached two eyebolts as illustrated in the following figure.
Any transportation method that may apply any shock to the controller shall be avoided.
In case of using a crane, be sure not to stand under or near 5the lifted controller.
Caution
In case of using forklift, be sure no personnel shall hold the controller.
1. Double-wire hanging method.

Hook the wire to the provided eyebolts.
2. A method using forklift.

A controller shall be packed in a wooden case
2-1
Chapter 3. Installation
The installation shall be made by qualified installation personnel and should conform to all
Caution national and local codes.
3.1 An international protection code of the machine

The following table shows the environmental protection class of the machine.
Part of the machine Class

Controller (main body) IP32 or equivalents
Teach pendant IP42 or equivalents
IP54 or equivalents
T / Y ×
Operation box
/ ○
○: Standard, ×: Option
3.2 Choosing an installation site

1. A site where ambient temperature ranging 0-45°C and free from exposure directly to the sun.
2. Be sure to locate the controller close to but outside of the work envelope of a manipulator.
3. A site relatively free of dust or oil mist.
4. A site free of inflammable or corrosive gas.
5. A site where no obstructions present within the work envelope of the manipulator.
6. A site easily accessible in case of inspection or disassemble work.
7. A site relatively free of shock and vibration.
8. A site where no electrical noise source exists.
<Note>
If a significant noise source (plasma or high frequency etc.) exists at or around the installation site, please
consult us in advance.
3.2.1. Installation site

1. Be sure to locate the controller close to but outside
of the work envelope of a manipulator. Be sure to (Front)
maintain space shown in the following figure from
any wall or peripheral equipment for maintenance
and inspection work and to control temperature
600
inside of the controller.
2. Installing the controller on a base with approx.

50cm height raises the breaker handle to approx. 1
m, which makes operation easier.
300 500
(Left) (Right)
500
(Back)
[Unit: mm]
3-1
3. Teach pendant
2 -ƒÓ4 . 5
· Hook the teach pendant to the provided TP hook.
(Fixing hole)
· Be sure to place the teach pendant outside of
12
both the safety fence and the work envelope of
the manipulator so as to eliminate possible
t2.3
danger due to changing mode within the safety
24
12
fenced area. A mode switch key with ball chain
is provided with the TP hook.
5
12 25 [Unit: mm]
· The provided cable between the teach pendant
and the controller is 10 m in length.
4. Operation box
· In case of keeping the operation box fixed during
operation or to store it, the panel fixture is
provided with the operation box.
· Please supply a hook at customers’ end.

Make sure to place it where the customer can not
reach from inside of the system.
· The provided cable between the operation box

and the controller is 6 m in length.
T/Y × Unit mm
E/U ○
○: Standard
×: Option
3-2
Chapter 4. Connection
The installation shall be made by qualified installation personnel and should conform to all
Caution national and local codes.
4.1 Connecting the controller to the manipulator

The absolute origin of the robot manipulator (robot position control origin), which forms a pair with the controller, is stored
in the memory element of the controller. For that reason, a production number of the corresponding controller is
labeled on the robot controller.
Make sure to use the designated pair.
4.1.1. Encoder cable (round-shape connector)

1. Insert the male receptacle to the female plug. Be
sure to connect the correct side.
Gently rotate it by hand
2. Hold the cable with one hand and match the locator (clockwise)
pin, and then insert it.
3. Rotate the screw part to connect. Push the cable

some times and rotate it again to insert the cable to
the end.
Hold the cable and

insert it to the end.
<Note>
Make sure that locator pin fits in place and male and female sides are set correctly.
If not, rotating the screw part tight can damage the connector part such as the locator pin.
Insert the cable to the end completely without fail.
4.1.2. Motor cable (Square-shape connector)

1. Insert the cable connector at the controller side ( ) to
the connector of the manipulator ( ).
‡ @ ‡ A
2. Insert it by hand so that clearance between the
manipulator and the connector ( ) is 1 mm or less.
(The hook handle is positioned about perpendicular
to the cable.)
3. Turn the hook handle ( ) to the arrowed direction in

the above figure and then fix it
‡ B ‡ C
<Note>
Prior to turn down the hook handle, make sure that the cable connector is inserted as explained in the
above procedure (2) (1 mm or less apart from each other). Otherwise, the joint of the connection may
be removed which, as a result, can damage the pin.
Insert the cable to the end completely without fail.
4-1
4.2 Connection of primary power source and ground cable
Provide grounding to the protective earth terminal (PE) of the robot controller exclusively.
Caution Check the grounding work before operation.
4.2.1. Grounding
Factory ground cable
Provide grounding exclusively
(separate grounding work near the controller).
200 VAC 200 VAC
Protective conductor
It is recommended to provide
a cable to connect this
terminal to improve anti-noise
‚Q
property if necessary for
‚W
‡o or more system configuration.
(2 cables are provided)
Other
Manipulator
unit Controller
Cable
Operation
box
TE terminal
2
Two 8 mm (AWG8) Green/yellow wires are Grounding Additional protective
Countries
provided for grounding as accessory. resistance conductor
Japan 100Ω or less 8 mm2 or more.
USA 0.1Ω or less AWG8 or more
EU 100Ω or less 10 mm2 or more
Others Conform all national and local codes.
Size of the protective conductors for other devices shall be according to the corresponding instruction.
4.2.2. Connection of Grounding wire

For T/Y specifications For U specifications
Connect a grounding wire to PE terminal of the Connect a grounding wire to M6 screw on the
breaker. breaker fixing plate.
Breaker fixing plate
Grounding wire
Grounding wire
PE terminal
4-2
4.3 Connecting primary power cable
4.3.1. Required power source capacity
1. Power source : a 3-phase, 200 VAC ±20V, 50/60 Hz
2. Power capacity and size of the primary power cable of the controller
Model number of the controller Input power capacity Power cable

YA-1NCR41*** G 004
3.5 mm2 or more
YA-1NCR61*** G 006 6 kVA
AWG12 or more
YA-1NCR81*** G 006L,G 008
5.5 mm2 or more
YA-1NC161*** G 008L,G 016 10 kVA
AWG10 or more
8 mm2 or more
YA-1NC321*** G 032 15 kVA
AWG8 or more
4.3.2. Wiring of primary power source

1. Be sure to provide no-fuse breaker (earth
leakage breaker) or switch with fuse of 3-phase 3-phase
specified capacity for each controller 200 V 200 V
separately.
2. Choose no-fuse breakers or earth leakage

breakers, if applied, which are for inverter.
3. Choose earth leakage breakers, if applied, No-fuse breaker

(earth leakage breaker)
sensitivity of which is 100 mA.
4. Choose a stable primary power which is a

separate system from the one for welding or
Filter
drive.
5. To prevent noise from entering from the

power cable, if it is the case, install a filter
before the primary input. Welding
Other power
Controller device source
4-3
4.3.3. Connection of power cable
Cable lead-in port
1. Open the front door of the controller
2. Open the front door by unlocking the two fasteners

with keys (which fasten the front door to the controller
cover) located on the left side.
Be sure that the handle switch on the door is placed Switch
in the “OFF” position prior to opening.

Front door
fastenings with keys
Front door
(Left side)
Cord lock Primary power cable
1. Connect the primary power cable to the switch input
part of the controller.
Input terminal
2. Lead in the power cable from the cable lead-in port
Switch
on the front left of the controller. Protective
conductor
At that time avoid dust to be in from the lead-in port.
(There are two cable lead-in ports.)
Breaker PE
3. Fix the power cable with the provided cord lock and
Fastening
then connect to the switch input terminal. Be sure bolts Protective earth
terminal
to connect it completely with fastening bolts
Wire size applicable to the cord lock: φ13.5 to φ16 mm

Wire size applicable to switch input terminal:
- YA-1NCR41***, YA-1NCR61***, YA-1NCR81***:
1.5 to 6 mm2
- YA-1NC161***, YA-1NC321***: 2.5 to 16 mm2
4.3.4. T/Y Specifications only: Connection for 220VAC

Only for T/Y specifications.
For 220VAC power input, the cable reconnection in the Trasform er
‚t
‚s‚t‚T
‚Q‚U‚X
controller is required.
1. Open the rear side door by unlocking fasteners

with key (which fasten the rear side door to the
Power card
controller cover) provided two each at the back of ‚y
U‚d
‚o‚T‚V
‚O‚T
both (right and left) aides. Harness connecto
i
‚Q‚O
‚O‚ uj
2. Switch the connection of the primary harness
connector “200 V” of the transformer (UTU5269) Connector
Connector
from the connector “200V” to the connector “220 V” i
‚Q‚Q
‚O‚ uj
i
‚Q‚O
‚O‚ uj
on the power card (ZUEP5705).
3. Connect the primary power cable to the power

distribution box.
4-4
4.3.5. Door handle
The product is delivered in emergency stop state. (Open Installation input)
Caution Confirm total safety of robot system and short the external emergency stop input after the
completion of the installation and start-up of the system.
Normally the door handle is in the ON state during operation. The door handle is used to turn ON/OFF the switch.
ON
< Operation >
ß
90
1. Turn the handle clockwise to turn ON the
switch, and counter-clockwise to turn it off.
2. Turn OFF the switch before closing the door. OFF
Switch handle
· After turning on the input power, transferring the system

Transferring system data
data to the Teach Pendant is immediately started, and then
goes to operable state soon.
· To change the controller settings, it is necessary to input
USER ID. For details refer to the operating instructions
“Basic Operation” and “Advanced Operation.
<Note>
The “USER ID” and “PASSWORD” input box appears if
“Dialog display at power ON” of the “USER registration”
settings is set to effective.
Operable state
<Input screen for USER ID>
<Note>
Keep the breaker switch in the ON position at
all-times.
Open the front door to access the breaker at
Switch
bottom of the switch on the left side.
(Norm ally
ON)
Breaker
4-5
Chapter 5. Safety I/O specifications
5.1 I/O for Safety circuit
Dual circuit is applied to the safety circuit in order to ensure safety.
Use the safety I/O of the safety card on the sequencer card located on the right side panel of the controller.
Safety I/O requires following specification.

A separate B contact (normal closed contact) and separate wire shall be applied.
Capacity of these safeties input contacts are min. 5A load in order to reduce the risk of Relay contact weld.
5.1.1. External emergency stop input

A terminal to turn off the servo power of the manipulator from an external device.
Emergency stop switch
Prepare a switch with two normally closed contacts Emergency stop input
(contact B). Connect one of the contacts between the (Normally closed)
external emergency stop input 1+ and 1-, and the other
one between the external emergency stop input 2+ and
2-. Controller
5.1.2. Door stop input

A terminal to input door status (open/closed) of robot safety fence.
Prepare a switch with two normally closed contacts (contact B). Connect one of the contacts between the Door
stop 1+ and 1-, and the other one between the Door stop 2+ and 2-.
If the door stop is input as switch turns to open state, the robot goes in emergency stop state.
Please note that the door stop input does not function in “TEACH” mode.
Sequencer
Card
External Emg. stop input
Safety
Card
Door stop input
(Blue)
Holder input
(White)
<Note>
Safety holder inputs are factory connected to the user connector of
the manipulator.
Do not correct them (“SH1” and “SH2”) wrong way. Wrong
connection of those inputs keeps the safety holder active all the
time.
(SH+) (SH1) (SH+) (SH2)

(SH-) (SH2) (SH-) (SH1)
5-1
5.1.3. Spare emergency stop input
An emergency stop input terminal provided as the most significant level of safety circuit.
Apply it when an emergency stop input from an external device is so connected that the output of which takes first
priority over all other emergency stop push-button switches on the teach pendant.
It is one normally closed 2-contact (contact B) switch.
Connect one contact to the spare emergency stop inputs SP EMG1+ and SP EMG1-, and the other contact to the
spare emergency stop inputs SP EMG2+ and SP EMG2-.
If this input terminal is not to be used, short terminals between SPEMG1+ and SPEMG1-, and also SPEMG2+ and
SPEMG2- without fail. (They are factory shorted at shipment.)
<Note> T/Y ×
The Spare emergency stop input of the robot with the operation box has been
already connected to the wires from the operation box. E/U ○
○: Standard ×:Option
5.1.4. External Dead Man’s input

An input terminal used to make the Dead Man’s function effective from an external input.
Servo power is turned ON when both the Dead Man’s switch on the teach pendant and the external Dead Man’s
input are ON.
In case that the external Dead Man’s input is not used, set the terminals in the following state:
Short the external ENABLE input terminals (ENBL1+ and ENBL1-, ENBL2+ and ENBL2-) (They are factory
shorted at shipment.)
Sequencer
Card
Spare Emg. Stop input
Safety External Deadman input

Card
Installation input
5.1.5. Hand input

1. The Hand input is connected to the safety circuit and used Sequencer
Car d
for an input from the hand effecter.
2. A pair of normally closed contacts are used.
3. One contact is connected to “ ” and “ ” and
another contact is connected to “ ” and “ ”.
4. 4. When this input is not used, keep the circuits between” Safety
Card
” and “ ”, and between “ ” and “
2 shorted. (They are factory shorted at shipment.)
Hand input
5-2
5.1.6. Input of the safety circuit
Note)
Note)
The “Spare Emergency Stop” terminals are used for the
Operation box Emergency Stop if it is provided.
5-3
5.1.7. Emergency stop output
An output terminal to output the emergency stop state. (No-voltage relay contact output, Contact ratings: 3A,
DC30V) Open the terminals in an emergency state.
1. Emergency stop output To change output condition, change the connection of the
short-circuit connector to the connector (OUTMD0 to OUTMD4)
2. Reserve emergency stop output of the Safety card.
3. Application emergency stop output No difference in output condition is made by connecting the
short-circuit connector to any of the connectors (OUTMD0 to
4. Spare application emergency stop output OUTMD4) of the Safety card.
Sequencer card
Emergency
stop output
Emergency
Safety stop output for
card application
Spare
Emergency stop
output
Spare
Emergency stop
output for
application
4 kinds of emergency outputs are provided. Choose proper emergency stop output in accordance with the requirement
of robot system.
5-4
*The short-circuit connector is factory connected to the connector OUTMD1 at shipment.
Safety card
The following table shows the relationship between the connection of the short-circuit connector and the input type
and output state of the emergency stop.
“Application emergency stop

“Emergency stop output” and
output and “Spare application
“Reserve emergency stop output”
emergency stop output”
OUTMD OUTMD OUTMD OUTMD OUTMD

Not related
0 1 2 3 4
Spare emergency stop input

(E / : Emergency stop of C A A A A A
the operation box.)
Teach pendant
C A A A B A
Emergency stop input
Teach pendant
C A A B B A
Dead Man’s switch
External Dead Man’s input C A A B B A
Door stop C A A B B A
Hand input C A A B B A
Overrun input C A A B B A
External emergency stop
C A B B B A
input
: The emergency stop output is output when the emergency stop input is input..
The emergency stop output terminal is closed when the emergency stop input is released.
: Although the emergency stop input is input, the emergency stop output is not output.
: The emergency stop output is output when the emergency stop input is input..
The emergency stop output terminal is closed when the emergency stop input is released and the servo
power is turned on.
5-5
5.2 Other safety input/output
Ensure safe work environment by using the safety I/O equipped with the safety card.
5.2.1. Safety holder input

A terminal for safety holder cable, which is not included in the safety circuit. The input is always monitored by a
software.
The SHIN terminals are factory connected as shown in the following figure at shipment.
<Note>
As the SH1 and SH2 have polarity, make sure to connect the correct side.
Sequencer
Card
External Emg. stop switch
Safety
Card Door stop input
(Blue)
Safety Holder input
(White)
5.2.2. Installation input

Set the input open to indicate the following warning Sequencer
Card
message on the screen of the teach pendant every
time the controller is turned ON and mode change Spare Emg. Stop input
(operation mode/teaching mode) is executed so as to

warn the operator of the robot system that the safety
I/O setting of the robot system has not competed. Safety External Deadman input
Card
“Now installing. Check wire Installation input
connections. Short INST.”
Short this input after the completion of the installation

and start-up of the system or in normal operation
5-6
Chapter 6. Connection of external control signal
6.1 Terminal location of the Sequencer card
Open Collector type Sequencer card: ZUEP57113 or earlier revision.
1 User-IN001 1 Servo ON
2 User-IN002 2 Not in use *
STATUS IN
3 User-IN003 3 Operating mode
IN
4 User-IN004 4 Teaching mode
5 User-IN005 5 Not in use
6 User-IN006 6 Error release
7 User-IN007 7 Start
8 User-IN008 8 Hold
1 User-OUT008 1 Alarm
2 User-OUT007 2 Error
STATUS OUT
OUT8 1 3 User-OUT006 3 Operating mode *
4 User-OUT005 4 Teaching mode
5 User-OUT004 5 Ready
6 User-OUT003 6 Servo ON
7 User-OUT002 7 Running
8 User-OUT001 8 Hold status
EXOUT
EXIN
1 (Not in use) 1 (Not in use)
2
2
1 (Not in use) 1 COM
5 User-IN009 5 User-IN025
7 User-IN011 IN 7 User-IN027
IN
User-IN013 User-IN013
40 Line B
40 Line A
1 COM 1 (Not in use)
5 User-OUT009 5 User-OUT025
OUT
OUT
User-OUT013 User-OUT029
40 Line B
40 Line A
<Note>
1. When using the Operation Box, the terminal marked with (*) has been already connected a wire from the operation
Box.
6-1
2. The positional sequence of “OUT1 to 8” is reversed against ZUEP57114 or later board.
6-2
Open Collector type Sequencer card: ZUEP57114 or later revision.
Open Emitter type Sequencer card: ZUEP5725*
1 User-IN001 1 Servo ON
2 User-IN002 2 Not in use *
COM U24V
STATUS IN
3 User-IN003 3 Operating mode
IN
4 User-IN004 4 Teaching mode
5 User-IN005 5 Not in use
6 User-IN006 6 Error release
7 User-IN007 7 Start
STATUS IN 1 8̀
8 User-IN008 8 Hold
IN 1 8̀
1 User-OUT001 1 Alarm
2 User-OUT002 2 Error
STATUS OUT
3 User-OUT003 3 Operating mode *
OUT
4 User-OUT004 4 Teaching mode
5 User-OUT005 5 Ready
6 User-OUT006 6 Servo ON
STATUS OUT 1 8̀
7 User-OUT007 7 Running
OUT 1 8̀
8 User-OUT008 8 Hold status

EXOUT
EXIN
2
2
EXOUT1 2̀

EXIN1 2̀

1A
1B
IN
IN
User-IN013 40 Line B User-IN013
40 Line A
IN 9 4̀0
20A
20B

1A
1B

OUT 9 4̀0
OUT
OUT
User-OUT013 User-OUT029
40 Line B
40 Line A
20A
20B
<Note>
1. When using the Operation Box, the terminal marked with (*) has been already connected a wire from the operation
Box.
2. The positional sequence of “OUT1 to 8” is reversed against ZUEP57113 or earlier board.
6-3
Safety card
COM terminal for I/O
24V power supply for
maintenance
Safety card
Serial communication port for optional units

Upper: RS-232C
Lower: RS-422
Terminal or connector Sequencer card Application

COM All Sequencer cards #1 pin is used for the T/Y ×
Operation Box. E/U ○
○: Standard ×:Option
U24V ZUEP5711 Only for maintenance purpose.
ZUEP5725 DC24V input for I/O
RS-232C, RS-422 All Sequencer cards Only used for Panasonic optional units and digital
communication type of welding power source.
6.2 Connecting and control method of external device

It is applicable by teaching sequence commands editing User inputs/outputs. User inputs/outputs are provided on the
sequencer card.
In order to protect the controller from noises, be sure to apply a radio shield wire as I/O
connecting cable between an external device and robot I/O circuit.
Connect the shield wire to the TE terminal( ) on the right side of the controller.
The TE terminal is provided to prevent noise.

Caution
If a system comprises a machine which generates high frequency (such as TIG, plasma),
the robot I/O circuit may be damaged by the high frequency noise. Be sure to design so
that any external input to the system should use a no-voltage contact signal and any
output to an external device should be converted into relay contact output.
6-4
6.2.1. I/O terminal equivalent circuit
For T/Y Specifications For Specifications
1. Input terminal equivalent circuit: 1. Power to activate input/output
To receive no-voltage ON/OFF contact signal from an It is necessary to apply 24 VDC of supply voltage between
external equipment. 24 V input and COM. Turn ON/OFF the power
External relay contact to be connected ... 1Ωor less, synchronous to the control power of the robot controller.
Chattering ..........10 ms or less The power to be provided by customer:
Pulse amplitude of an input signal should be 0.2s or Voltage : 24 VDC +10%/-0%
more. Capacity : 75 W or more
Make sure that noiseless power is applied. It is
recommended to use a capacitor to remove especially the
common-mode noise (see below figure). Recommended
capacitor: Film capacitor 0.1µF, 50 V
24 V +
To robot
-
0.2 s or more –
To the ground of the robot case
2. Input terminal equivalent circuit:

To receive no-voltage ON/OFF contact signal from an
external equipment.
External relay contact to be connected 1Ωor less
Chattering 10 ms or less
Pulse amplitude of an input signal should be 0.2 sec or
more.
3. Output terminal equivalent circuit 3. Output terminal equivalent circuit

Open collector output. Open emitter output.
Rated output is 24 VDC, 75 mA. Rated output is 24 VDC, 75 mA
Use a relay of 24 VDC, and coil current of 75 mA DC or Use a relay of 24 VDC and coil current of 75 mA DC or less,
less, and attach a noise adsorbing diode : D (100 V, 1 A). and attach a noise adsorption diode : D (100 V, 1 A).
Capacity of the emergency stop output contact: 3A, 30 Capacity of the emergency stop output contact: 3A, 30 VDC.
VDC.
+24V USER IN
+24V
+24V
2k
COM
IN
COM
INPUT
COM
No-voltage
contact
Outside
Inside of robot controller
COM
OUT +24V
D
Load
OUTPUT
CR
COM Inside of
24 VDC D
controller Outside
Outside
Inside of robot controller
6-5
6.3 Auto start settings
• To set the start method, the terminal to which the external signal to start robot operation is transferred to needs
to be allocated to the user I/O terminal.
• There are two types of start methods; ‘Manual’ and ‘Auto’. And in Auto-start method, there are two different
select methods; ‘Program select method’ and ‘Master method’.
• With Auto start method, it is not possible to start the robot by pressing the Start button on the teach pendant.
Start Select method

Description
method
Use the Start button on the teach pendant to operate a program.
Manual <Note>
Refer to section “AUTO mode” in the operating instructions (basic operation).
Use an external signal input to operate a program.
To start the specified program when the start signal is received from an
Master
Auto external device.
To start the program whose program number is equal to the total of the user
Program select
input terminal Nos. you specified.
6.3.1. Master method

It starts the program registered as a master program automatically.
Place the mode select switch in “Auto” position, then the master program you specified will be ready to start
automatically.
After the completion of the master program, it is ready to start the master program from the beginning automatically.
* This master method is good for complex start conditions (interlock etc.) as you can edit start
conditions within the master program using the teach pendant, such as interlocking method or
criteria of the start conditions.
6.3.2. Program select

There are three different number types to specify a program number.
Number type Description

It is possible to start programs whose program numbers are 1, 2, 4, 8, 16, 32,64, 128,256 and
Signal
512.
To start the program whose program number is equal to the sum of the numbers you specified.
Binary
It is possible to start programs of program numbers from 1 to 999.
A set of Four terminals is used to specify each digit of the program number you want to start.
BCD
It is possible to start programs of program numbers from 1 to 399.
<Program name>
Program name is indicated “ProgXXXX.prg” where XXXX is the program number. The result of the specified
calculation is applied.
Example: If the result is 16, then the program name is “Prog0016.prg”.
6-6
6.3.3. Start method and I/O allocation
1. On the Set menu, click Controller and Start condition to display the setting dialog box.
2. Specify the start method you want and then allocate user I/O terminals to be used to specify the program number
and to start a program.
INPUT Allocation box <OUTPUT allocation box>
6-7
6.3.4. Program select method (common specifications)
· If a program is reserved while running another program, the reserved program will be started automatically after the
completion of the current program.
· If the result exceeds the set range (from 1 to 999), then the program reservation is disregarded.
· It is possible to reserve up to 16 programs. (Programs on and after 17th program will be disregarded.)
· The programs already reserved and running program are not accetable to reserve.
· When the program select is disregarded, no select response will be output.
· Input ‘Cancel’ clears all selected programs except currently running program.
· To check program select status, click on Display change (View menu) and then click Operate state.
· It is possible to clear all selected programs during operation (except in override) by switching the mode select
switch to the ‘TEACH’ position.
6.3.5. Signal method

· When the start input is turned ON, the same numbered program is selected.
· Then the selected program will be executed.
· With this method, you can only program numbers 1, 2, 4, 8,16, 32, 64, 128, 256 and 512.
Timing chart
Running output
Start operation
Start input
0.2 s or more
Program reserve XXX
Prog0XXX.prg is selected.
Program reserve YYY
Prog0YYY.prg is selected.
Reserved output XXX
Reserved output YYY
Output strobe 0.1 s or more

About 0.2 s About 0.5 s About 0.2 s About 0.5 s
· “XXX” and “YYY” indicate ‘program reserve’ numbers you specified (001, 002, 004, 008, 016, 032, 064, 128, 256
or 512).
· The input signal must be kept ON for 0.2 seconds or more.
· ‘Start input’ may not be received if it is input in less than 0.2 seconds after the previous input is received.
· It requires at least 0.1 second after the ’output strobe’ signal is turned OFF to reserve the next program select
input.
· After the completion of the current program, the robot automatically starts the next reserved program if
any.
6-8
6.3.6. Program select and Start Strobe
Binary and BCD methods use Program select and start strobe signal.
Program select and start signals and program select and start strobe signal are required to meet following conditions.
0.2sec. or more
0.2sec. or more
Program select/start XXX

Prog0ZZZ.prg is reserved
Program select/start YYY
Program select/start strobe
0.2sec. or more
Program select and start signals should be retained for 0.2 seconds or more before accepting ON signaledge of
Program select and start strobe signal.
· Program select and start strobe signal should be retained for 0.2 seconds or more.
6-9
6.3.7. Binary method
It calculates the sum of ‘Program reserve input’ numbers having been in ON state when the ‘Input strobe’ is turned ON,
and then reserves the corresponding program.
Example:
Program reserve input
Sum Program name
512 256 128 64 32 16 8 4 2 1
○ ○ ○ ○ ○ ○ ○ ○ 999 Prog0999.prg
○ ○ ○ ○ 550 Prog0550.prg
○ ○ ○ 50 Prog0050.prg
○ ○ 17 Prog0017.prg
○ Prog0001.prg
○…Input is ON, (Blank)…Input is OFF
Timing chart
Running output
Start operation
Start input
Program reserve XXX

Prog0ZZZ.prg is selected.
Program reserve YYY
0.2 s or more
Input strobe
Reserved output XXX
Reserved output YYY
0.1 s or more
Output strobe
· “XXX” and “YYY” indicate ‘program reserve’ numbers you specified (001, 002, 004, 008, 016, 032, 064, 128, 256
or 512).
· “ZZZ” is the sum of “XXX” and “YYY”. The above example is of 2 ‘program reserve’ inputs which are turned ON,
however, ON/OFF status of all ‘program reserve’ inputs (001,002,004,008,016,032,064,128,256 and 512) are
checked for calculation.
· It requires at least 0.1 second after the ‘Output strobe’ signal is turned OFF to reserve the next ‘program reserve’
input.
· After the completion of the current program, the robot automatically starts the next reserved program if any.
6-10
6.3.8. BCD method
BCD is the abbreviation for binary-coded decimal code.
It specifies each digit of a number as a binary number using program reserve inputs 1, 2, 4 and 8 for the 1st digit, 16,
32, 64 and 128 for the 2nd digit and 256 and 512 for the 3rd digit.
It calculates the sum of ‘Program reserve input’ numbers having been in ON state when the ‘Input strobe’ is turned ON,
and then reserves the corresponding program.
* You can use the rotary switch of BCD specification sold at a store for easy operation.
Example:
Program reserve input
512 256 128 64 32 16 8 4 2 1
Sum Program name
3rd digit 2nd digit 1st digit
200 100 80 40 20 10 8 4 2 1
○ ○ ○ ○ ○ ○ 399 Prog0399.prg
○ ○ ○ ○ 226 Prog0226.prg
○ ○ ○ 32 Prog0032.prg
○ ○ 11 Prog0011.prg
○ 1 Prog0001.prg
○…Input is ON, (Blank)…Input is OFF
Timing chart
Running output
Start operation
Start input
Program reserve XXX
Prog0ZZZ.prg is selected.
Program reserve YYY
Input strobe 0.2 s or more
Reserved output XXX
Reserved output YYY
Output strobe 0.1 s or more
· “XXX” and “YYY” indicate ‘program reserve’ numbers you specified (001, 002, 004, 008, 016, 032, 064, 128, 256 or
512).
· “ZZZ” is the sum of “XXX” and “YYY”. The above example is of 2 ‘program reserve’ inputs which are turned ON,
however, ON/OFF status of all ‘program reserve’ inputs (001,002,004,008,016,032,064,128,256 and 512) are
checked for calculation.
· It requires at least 0.1 second after the ‘Output strobe’ signal is turned OFF to reserve the next ‘program reserve’
input.
· After the completion of the current program, the robot automatically starts the next reserved program if any.
6-11
6.4 Timing of program selection response
6.4.1. Program reservation in Signal method
· Reserved program in AUTO mode answers the program number to the outputs.
Status output
AUTO mode
AUTO m ode
AUTO mode selected finished
Program reserve XXX
‚O
.‚Q
s ec. or ‚O
. ‚Q
s ec. or more
more
Reserved output YYY

Valid Valid
Output strobe
Program reser vation
enabled 0.5 }
0.1sec. Program reservation
enabled
ª ª ª ª ª
ª
0.1sec. 0.2sec 0.1sec. or less 0.1sec. 0.2sec. 0.1sec. or less .
or less . or (PRG reservation is not or less or less (PRG reservation is not acceptable. j
less
acceptable.)
Robot ignores program
reservation signals.)
·
512).
· The ‘Reserved output YYY is retained until next ‘Reserved output’.( In case that Signal method is used.)
· The ‘Reserved output’ is effective only in AUTO mode. It is not available in manual start operation.
6.4.2. Program reservation in Binary and BCD methods

· Reserved program in AUTO mode answers the program number to the outputs.
Status output
AUTO m ode
AUTO m ode selected AUTO m ode
finished
Program reserve XXX
‚O
.‚Qsec. ‚O
.‚Q
sec.
or m ore or m ore
Reserved program YYY

0.2sec.or m ore 0.2sec.or m ore
Input strobe
0.1sec.or less 0.1sec.or less
Valid Valid
Output strobe
Program reservation Program reservation
enabled
0.5 }
0.1sec. enabled
ª ª ª ª ª ª
0.1sec. 0.2sec. 0.1sec.or less 0.1sec/.or less0.2sec.or less 0.1sec.or less
orless or less (PRG reservation is not (PRG reservation is not acceptable.j
acceptable.)
Robot ignors the program
reservation signal
512).
· The ‘Reserved output YYY is retained until next ‘Reserved output’.( In case that Signal method is used.)
· The ‘Reserved output’ is effective only in AUTO mode. It is not available in manual start operation.
6-12
6.5 Analog welding control
The contents of this section are for analogue board unit (YA-1NPEA1) and adaptor unit (AXU01192).
6.5.1. Analogue output terminals

Analogue terminal equivalent circuit
Two analogue output terminal ports are provided
for welding current and voltage control. 18 VDC
Output impedance: 2.2 kΩ

Use the specified Panasonic welding power Output voltage: 0 to 15 VDC
source, then direct input of numerical values for
welding current and voltage is available. CNT
If welding power sources other than the specified
ones are used, input code values. In that case,
15 VDC is divided equally into 255 to output. GND
Robot controller side To welding machine

A port of user output is provided. It can be used
to output speed command or penetration control
command etc. to external device.
6.5.2. I/O terminal for the exclusive use of welding

There are 2 input contacts and 5 output contacts provided separately from user I/O terminal. Their I/O command
numbers are allocated as follows.
Connect them to the specified applicable power source or interface box.
Item Name Exclusive command number

Exclusive input Current detect WAITARC
WELDIN [Variable]=STICKCHK
Error input Stick Input: ON => Variable=1
Input: OFF => Variable=0
Torch switch TORCHSW [ON/OFF]
Gas valve GASVALVE [ON/OFF]
Exclusive output Stick check STICKCHK [ON/OFF]
Wire (Fwd) WIREFWD [ON/OFF]
Wire (Back) WIRERWD [ON/OFF]
6-13
6.6 Status IN/OUT
Dedicated input/output terminals to send signals when the robot is in specified state or to change robot status according
to the signal received.
6.6.1. Status INPUT

Status INPUT Description
z ON to enable servo power ON if the following conditions are all satisfied.
Condition 1: Status output signal ‘Ready’ output signal is ON.
Condition 2: Mode select switch is set to operation mode (‘AUTO’ position) and not
in Mode error state.
External servo Condition 3: Mode select is set to auto-operation (in operation mode)
ON INPUT Condition 4: Mode select switch is not switched to ‘TEACH’ position due to
override in operation.
Condition 5: The ‘Emergency stop’ input is not ON.
z The Input signal must satisfy the following conditions.
· The input signal must be ON in 0.2 seconds after the ‘Ready’ output signal goes ON.
When the robot is in an error state and the error dialog box is displayed, turn ON this
Error release input to close the dialog box. At that time, the error output goes off if it is in ON state.
INPUT Input signal is effective when the signal state is switched and kept it for 0.2 seconds or
Status INPUT dedicated terminals
more.
Turn ON this input signal to run a program. In hold state, turn on to restart.
The input signal is ignored under the following conditions.
· The servo power is OFF.
Start INPUT · Auto-operation is not set.
· In error condition.
· Stop input is ON.
· In override state.
· Turn ON this input signal to bring the operating robot in hold state.
· While the signal is ON, re-start, manual operation and trace operation are not operable.
Stop INPUT · The robot remains in hold state even if this signal is turned OFF.
· To restart operation, turn ON the start input signa.
· It is to switch the mode from teaching mode to operation mode.
· Use this input when the robot is in teaching mode.
· When the input signal is turned ON, a message to switch the mode select switch to
Operating mode operation mode appears.
INPUT · Switch the mode select switch to ‘AUTO’ or turn OFF the operating mode input to close
the message box.
Please be advised that while the message box is displayed, the robot is in the error
state.
· It is to switch the mode from operation mode to teaching mode.
· Use this input when the robot is in operation mode.
· When the input signal is turned ON, a message to switch the mode select switch to
Teaching mode teaching mode appears.
INPUT · Switch the mode select switch to ‘TEACH’ or turn OFF the teaching mode input to close
the message box.
Please be advised that while the message box is displayed, the robot is in the error
state.
This input signal is effective in operation mode. Turn it ON to bring the robot in arc lock
Arc OFF INPUT
state.
Note) Status input marked is to be allocated to user input terminal.
6-14
6.6.2. Status OUTPUT
Status OUTPUT Description
· The signal is output when the robot goes in an alarm condition. (At that time servo
Alarm OUTPUT power is turned OFF)
· Unless power is turned OFF, the output signal remains in OFF state.
· The signal is output while the robot is in an error condition.
Error OUTPUT · The signal is turned OFF when the error is released.
· The signal is output in operation mode (including override.)
Operating mode
· While the message box to switch to teaching mode is displayed (by turning on the
OUTPUT ‘Teaching mode’ input), if the operation mode is selected, this signal remains ON.
· The signal is output in teaching mode (excluding override.)
Teaching mode
· While the message box to switch to operation mode is displayed (by turning on the
OUTPUT ‘Operating mode’ input), if the teaching mode is selected, this signal remains ON.
· The signal is output when the robot is ready to receive a status input signal.
Status OUTPUT dedicated terminals
Ready OUTPUT · It goes OFF when the robot is in an alarm condition or when the ‘Emergency stop’ input is
ON.
The signal is output when the servo power is ON.
Example of installing a signal light (PATO light)
For Specifications For Specifications
Connection to the Open Collector circuit. Connection to the Open Emitter circuit.
Signal light
Signal light
Servo ON Servo ON
USER IN
M a x . DC 2 4 V
OUTPUT output
Con t r o
ller CR
CR
In operation output
COM
C o n tr o l l e r 1 0 0 V AC
· The signa is output while running a program (including override.)

Running
· It is turned OFF when the robot goes in hold or emergency stop state, and turned ON
OUTPUT again when the robot is re-started.
· The signal is output when the running program is stopped in operation mode.
· The signal is output while the robot is in hold state due to error or emergency stop input,
Hold status and is turned OFF when re-started.
OUTPUT · The signal is turned OFF when the mode select switch is placed in ‘TEACH’ position.
When the mode select switch is placed in operation mode and the robot is ready to
restart after turning on servo power, the signal is turned ON.
· The signal is output when the emergency stop is ON. It is turned OFF when the
emergency stop goes OFF.
· If the emergency stop select connector is set to OUTMD0, the signal is turned OFF after
the servo power is turned ON.
Emergency stop <Note>
Status INPUT to be allocated to user output terminals
OUTPUT ‘Emergency stop’ output of the safety card and this ‘Emergency stop’ output (of the status
output) do not correspond to each other. In teaching mode, when the Deadman switch is
OFF the ‘Emergency stop’ is OPEN while this ‘Emergency stop’ output (of the status
output). In either operation mode or teaching mode, those output signals correspond if
the both Deadman switches are in ON state.
The signal is output to indicate completion of preset procedure after the initial servo ON
Pre-set complete
when the main power (200 V) is turned ON.
OUTPUT
<Note>The setting is applied the next time you turn ON the power.
Weld off status This signal is effective in operation mode. The signal is output when the robot goes in arc
OUTPUT lock state.
Individual error It outputs the signal when the specified error occurs. It is turned OFF when the error
OUTPUT release input is input or when the error dialog box is closed.
Program reset It outputs the signal when the mode select switch is switched to AUTO mode in manual start
INPUT method. It is turned OFF when the robot goes in Teach mode. (The signal remains ON
during override operation.)
Operate mode It closes the running program file when the input is received.
OUTPUT Note:
It accepts the input while the operation is in hold or emergency stop state.
It accepts the input when the start method is set to “AUTO”.
6-15
6.7 Flowchart of Status Outputs
6.7.1. Operating and Holding output
AUTO Mode ON command is kept after completing PRG
if OFF command is not executed.
ON command
OFF command ON command
Restoration
Output (Setting- HOLD:OFF, EMG STOP:OFF)

ON command
OFF command ON command
Restoration
Output (Setting- H OLD:LOCK, EMG STOP:OFF)
ON command OFF command ON command
Output (Setting- HOLD:LOCK, EMG STOP:LOCK)
Running output
Hold status output
Servo ON
Program execution
(PRG1)
Opening file End of program (PRG2)
START (TP) HOLD EMG. STOP SERVO ON START i

Ext.reservation ji
Ext.start j
(TP) PRG1 reserved PRG2 reserved
(*) Above chart is drawn as positive logical setting.
6.7.2. Mode change (1I/O monitor)
AUTO Mode
No OFF command OFF command
ON command
Output (Setting- HOLD:OFF, EMG STOP:OFF

Output ‚ n
‚t‚ s ”1 No OFF command
OFF command
OFF command
Output (Setting- HOLFD: LOCK, EMG S TOP:OFF

Output ‚ n
‚t‚ s ”2
ON command OFF command
No restoration
Output (HOLD: LOCK, EMG STOP:LOCK

Output ‚ n
‚t‚ s ”3
Running output
Hold status output
Servo ON
‚o
rogram execution
Opening file End of program

#3 OFF #2 OFF
START (TP) HOLD by I/O monitor by I/O monitor Changin to Servo ON Restart
Changing to i
TP j
AUTO mode.
TEACH mode
Servo OFF
Servo OFF
TEACH mode
6-16
6.7.3. Emergency stop 1
The following chart shows output terminal status to the emergency stop operation when the safety PCB connector is set.
Power ON Power ‚ n
‚‚
ON com m and is kept after com pleting PRG
AUTO m ode O N com m and if OFF com m and is not executed.
O FF comm and O N com m and
Restoration
Output for assigned HO LD O FF,EM G.STO P O FF
O N com m and O FF comm and O N com m and

Restoration
Output for assinged HO LD LOCK,EM G.STOP OFF
O N com m and O FF comm an O N com m and
Output for assigned HO LD LOCK,EM G.STOP LOCK
Running output
Hold status output
Servo On
EM G.STOP
output Open
EM G.STOP Closed Open Closed Open
output(**)
‚o
rogram execution i
P RG1 j
End of program
O pening file End of program i
P RG2 j
START HO LD EM G. EM G.STOP Servo START PRG1 reserved Starti ng PRG1 PRG2 reserved
(TP)
STOP released O N (TP) i
Ext.reservation j i
Ext.START j i
Ext.reservation j

(**) The Safety PCB sets a connector to OUTMD0.
6.7.4. Emergency stop

Operation of the emergency stop output and Emergency stop status output vary with mode setting.
Power ‚ n
‚m ‚n
‚e‚e ‚n
‚m
Mode Auto TEACH AUTO

EMG. STOP
Servo ‚ n
‚m Servo ON -‚ n
‚m Servo ON
(TP) (T‚o) ‚o
(‚s )
Servo Power ‚n
‚e‚e ‚n
‚m
Deadman switch
Ignore ‚n
‚e‚e ‚n
‚m Ignore
Door stop Closed Open Ignore
Emergency stop status output(*)

Emergency stop output
Open Closed
The output m arked with (*) is assigned

to the com m on output term inal.
6-17
6.7.5. Error output
AUTO Mode
ON command OFF command ON command OFF command
Restoration
Output for assigned
HOLD O FF,EM G.STOP OFF ON command
OFF command ON command OFF command
Restoration
Output for assigned
HOLD LOCK,EM G.STO P O FF. OFF command ON command OFF command
ON command
Output for assigned

HOLD LOCK,EM G.STO P LOCK
Running output
HOLD status output

Error output
‚o
rogram execution
End of program
Opening file
START (TP) Error Error j EM G.STOP

i Servo START
generated Cancel ON (TP)
6-18
6.7.6. Connecting to sequencer card
Since connector terminals are employed, they can be removed
from the board. Peel off lead wire cover from about 7 mm from
the end and wire it to the terminal with precision negative (-)
driver. Overall diameter of lead wire(s) to be connected to
terminals should be 1.5 mm2 or less.
Applicable connectors of INPUT, OUTPUT and STATUS IN/OUT

(Manufactured by FUJITSU)
Connection method INPUT, OUTPUT STATUS IN/OUT

FCN361J040AU (connector) FCN361J016AU (connector)
Soldering ÍProvided
FNC360C040B (cover) FCN360C016B (cover)
FCN363J040 (housing) FCN363J016 (housing)
Clamping FCN363J-AU (contact) FCN363J-AU (contact)
FCN360C040B (cover) FCN360C016B (cover)
Pressure welding FCN367J040-AU/F FCN367J016-AU/F
Soldering type connector is equipped.

If clamping or pressure welding type is applied, special tools need to be prepared.
6-19
6.8 External interface of Teach Pendant
6.8.1. PC Card slot
The Teach pendant provides 2 PC Card slot complied with type 2 of PCMCIA specifications. The slots are in the side
panel of the Teach Pendant and protected with a cover.
By connecting a memory card and a memory card adaptor (customer’s preparation), it is used as the interface for
external memory.
6.8.2. PS/2 port

One PS/2 port is provided to the left side of PC Card slots. It can connect mouse, keyboard or other equipment
complied with PS/2 specifications.
<Attention to use PS/2 port>

Connect PS/2 port before turning on the robot controller.
Disconnection of PS/2 port in operation kills the function of interface. After re-connection of PS/2 port,
reset the controller power.
‚h
‚’
‚c‚ `com m unication port
‚o
‚r/‚Qport PCM CIA port
6-20
6.9 End User License Agreement of software
The Teach Pendant is using “Windows CE” as operating software.
You have acquired a device (“DEVICE”) which includes software licensed by [Matsushita Welding Systems Co., Ltd.]
from one or more software licensors (“[Matsushita Welding Systems Co., Ltd.] Software Suppliers”). Such software
products, as well as associated media, printed materials, and “online” or electronic documentation (“SOFTWARE”) are
protected by international intellectual property laws and treaties. The SOFTWARE is licensed, not sold. All rights
reserved.
z IF YOU DO NOT AGREE TO THIS END USER LICENSE AGREEMENT (“EULA”), DO NOT USE THE DEVICE
OR COPY THE SOFTWARE. INSTEAD, PROMPTLY CONTACT [Matsushita Welding Systems Co., Ltd.] FOR
INSTRUCTIONS ON RETURN OF THE UNUSED DEVICE(S) FOR A REFUND. ANY USE OF THE SOFTWARE,
INCLUDING BUT NOT LIMITED TO USE ON THE DEVICE, WILL CONSTITUTE YOUR AGREEMENT TO THIS
EULA (OR RATIFICATION OF ANY PREVIOUS CONSENT).
z GRANT OF SOFTWARE LICENSE. This EULA grants you the following license:
¾ You may use the SOFTWARE only on the DEVICE.
¾ NOT FAULT TOLERANT. THE SOFTWARE IS NOT FAULT TOLERANT. [Matsushita Welding Systems Co., Ltd.]
HAS INDEPENDENTLY DETERMINED HOW TO USE THE SOFTWARE IN THE DEVICE, AND MS HAS RELIED
UPON [Matsushita Welding Systems Co., Ltd.] TO CONDUCT SUFFICIENT TESTINIG TO DETERMINE THAT THE
SOFTWARE IS SUITABLE FOR SUCH USE.
¾ NO WARRANTIES FOR THE SOFTWARE. THE SOFTWARE is provided “AS IS “ and with all faults. THE
ENTIRE RISK AS TO SATISFACTORY QUALITY, PERFORMANCE, ACCURACY, AND EFFORT (INCLUDIING
LACK OF NEGLIGENCE) IS WITH YOU. ALSO, THERE IS NO WARRANTY AGAINST INTERFERENCE WITH
YOUR ENJOYMENT OF THE SOFTWARE OR AGAINST INFRINGEMENT. IF YOU HAVE RECEIVED ANY
WARRANTIES REGARDING THE DEVICE OR THE SOFTWARE, THOSE WARRANTIES DO NOT ORIGINATE
FROM, AND ARE NOT BINDING ON, MS.
¾ Note on Java Support. The SOFTWARE may contain support for programs written in Java. Java technology is not
fault tolerant and is not designed, manufactured, or intended for use or resale as online control equipment in
hazardous environments requiring fail-safe performance, such as in the operation of nuclear facilities, aircraft
navigation or communication systems, air traffic control, direct life support machines, or weapons systems, in which
the failure of Java technology could lead directly to death, personal injury, or severe physical or environmental
damage. Sun Microsystems, Inc. has contractually obligated MS to make this disclaimer.
¾ No Liability for Certain Damages. EXCEPT AS PROHIBITED BY LAW, MS SHALL HAVE NO LIABILITY FOR
ANY INDIRECT, SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES ARISING FROM OR IN CONNECTION
WITH THE USE OR PERFORMANCE OF THE SOFTWARE. THIS LIMITATION SHALL APPLY EVEN IF ANY
REMEDY FAILS OF ITS ESSENTIAL PURPOSE. IN NO EVENT SHALL MS BE LIABLE FOR ANY AMOUNT IN
EXCESS OF U.S. TWO HUNDRED FIFTY DOLLARS (U.S.$250.00).
¾ Limitations on Reverse Engineering, De-compilation, and Disassembly. You may not reverse engineer,
de-compile, or disassemble the SOFTWARE, except and only to the extent that such activity is expressly permitted by
applicable law notwithstanding this limitation.
¾ SOFTWARE TRANSFER ALLOWED BUT WITH RESTRICTIONS. You may permanently transfer rights under this
EULA only as part of a permanent sale or transfer of the Device, and only if the recipient agrees to this EULA. If the
SOFTWARE is an upgrade, any transfer must also include all prior versions of the SOFTWARE.
EXPORT RESTRICTIONS. You acknowledge that SOFTWARE is of US-origin. You agree to comply with all applicable
international and national laws that apply to the SOFTWARE, including the U.S. Export Administration Regulations, as
well as end-user, end-use and country destination restrictions issued by U.S. and other governments. For additional
information on exporting the SOFTWARE, see http://www.microsoft.com/exporting/.
6-21
Chapter 7. Parts layout drawings
7.1 Controller
No. Description Part number Q’ty Note

1 Anti-surge parts AEB40054 1
4 Transformer UTU5269 1
5 DC Power Supply LWQ130-5225 1
6 Cooling Fan CN60B3 5
10 Power Source Card ZUEP5705 1
11 Main CPU Card ZUEP5585 1
12 Servo CPU Card ZUEP5587 1
No. 2 3 7 8
Model number of the controller Switch Breaker Servo Power Supply Amp 1 Amp 2
YA-1NCR41*** G 004 AED00132 AED00133
YA-1NCR61*** G 006 AED00138 AED00139
P132/V/SVBSW GV2M22 AED00130
G 006L
YA-1NCR81*** AED00128 AED00129
G 008
YA-1NC161*** G 008L
AED00155 AED00156
G 016 P363/V/SVBSW GV3M63 AED00137
YA-1NC321*** G 032 AED00152 AED00153
7-1
ZUEP5711 1 For Open collector outputs. T/Y, U
13 Sequencer Card
ZUEP5725 1 For Open emitter outputs. E
14 Safety Card ZUEP5702 1
17 TP Cable AWC32693LT 1 10m
No. 15 16
Note
Model number of the controller Connection Cable Motor Cable
YA-1NCR41*** G 004
YA-1NCR61*** G 006 AWC32690LM AWC32688LM 4m
G 006L
YA-1NCR81***
G 008
YA-1NC161*** G 016
AWC32690LP AWC32696LP 6m
YA-1NC321*** G 032
7-2
7.2 Teach pendant

1 Upper Case AKC21002 1
4 Dial AKC31006 1
9 LCD Cover AKK32004 1
10 Push button switch A165LTGYMMA1 1
11 Push button switch A165LTGYMMA2 1
12 Push button switch A165LTWMMA3 1
13 Key Switch A165KT2M2 1 With key
14 Emergency Stop Switch A165ES02 1
15 Encoder RE21BARE133 1
16 Key Sheet AKP32003 1 1 set (3 sheets)
17 TP CPU Card ZUEP5712 1
18 TP UP card ZUEP5716 1
19 TP Low Card ZUEP5717 1
20 TP Right Card ZUEP5718 1
21 TP Left Card ZUEP5719 1
23 LCD Display EDTCB23QAF 1
24 Inverter CXAL0612AVJL 1
27 TP Panel Cable AWC32694 1
29 Jog Cover AKC31007 1
7-3
2 Lower Case AKC21003 1
3 Battery Cover AKC31004 1
5 Lever 1 AKC31002 2
6 Lever 2 AKC31003 2
7 Trigger AKC31009 2
8 Cover AKC31005 1
22 DH Card SCE8700C02 1
25 Compact Flash SDCFB32-101 1
26 PCMCIA Connector 62236-22PR0 1
28 Flash Cable QCNM1493ACZZ 1
7-4
7.3 Operation Box
T/Y ×
E/U ○
○: Standard
×: Option

⎯ Operation box AEU01293 E / AEU01282 U 1
1 Emergency Stop Switch A165ES02
2 Push Button Switch A165LJWM24D1
3 Cable AWC32723LP E / AWC32714LP U 6m
4 Fixing Metal AKC41016PA
<Note> Optional software is required to use the Operation Box.
7-5
Chapter 8. Maintenance and inspection
Caution
Maintenance and inspection work must be performed by qualified personnel who finished the appropriate
training programs and also well understand the contents.
The inspection work explained in this section is for the application of arc welding.
For the use of other applications, items for the inspection work must be reviewed for each application
Especially for handling application, inspection work twice as frequent as the one for welding operation is
recommended.
Maintenance and inspection works are inevitable to ensure full functions and performance of the robot and at the same
time to ensure safety during operation.
1. Daily inspections
2. Inspections every 500 hours (every third month)
3. Inspections every 2,000 hours (every year)
4. Inspections every 4,000 hours (every second year)
5. Inspections every 6,000 hours (every third year)
6. Inspections every 8,000 hours (every forth year)
7. Inspections every 10,000 hours (every fifth year)
• Refer to the table in the next page for the check items.
• Since the inspection intervals are set according to standard operation hours, apply either months or hours
whichever is shorter as the standard.
• In case of operation on two shifts, the every 500-hour inspection shall normally be performed every 1.5 months.
• Hours correspond to time while the controller is in ON state.
• It is recommended to have the overall inspection including overhauls specified by us at the time of every 2000-hour
inspection.
• If you enter into a periodical inspection contract with our company, our periodical inspections will start with a
2000-hour (yearly) inspection.
Caution
Never touch the rear side of the controller (shaded
part in the following figure), it may be heated to very
high temperature.
8-1
8.1 Daily check
8.1.1. Inspections before turning on the power
Parts Item Service Remarks
· Looseness
Ground cable · Re-tightening.
1 · Breaking or
Cables · Replacement
damage of wire
Do not blow them off with
compressed air. Or dust or
Attachment of spatter Removal of spatter
spatter may enter the clearance
or dust. or dust
2 Manipulator or inside of the cover, resulting
in damage to the robot.
Consult our service section if
Looseness Re-tightening
causes are not clear.
3 Safety fence Damage Repair
· Attachment of · Removal of
Welding torch Be sure to replace with genuine
4 spatter. spatter.
nozzle, tip parts.
· Wear at the tip hole · Replacement
5 Working area Tidiness
8.1.2. Inspections after turning on the power
Check to confirm that no personnel are present within the robot work envelope before
Caution
turning on the power.
Parts Item Service Remarks

· Repair Do not use the robot
Emergency Turn off the servo power
1 · Consult us if causes unless the switch is
stop switch immediately.
are not clear. repaired.
To approach the robot to
When the home return is
check the marks, press
completed, the origin Consult us if they do not
Origin marks the emergency stop
marks coincide with each match.
switch and turn off the
other.
2 servo power.
Each axis of the robot
makes steady and smooth
Do not use the robot
motions (no abnormal Consult us if causes are
Manipulator unless the manipulator is
vibration, noise or not clear.
repaired.
looseness) in manual and
3 operation mode.
· Cooling air inlet fan of
Be sure to turn off the
the controller rotates.
Fan Clean the fan. power to the controller
· Attachment of dust on
before cleaning the fan.
4 the fan.
8-2
8.2 Periodical check
Interval
Item Inspection and service
3 mth 1 yr. 2 yr. 3 yr. 4 yr. 5 yr.
Check for tightness and
○ Robot fixing bolts
re-tighten if necessary.
○ Screws at covers
○ Connecting cable connectors
○ Motor mount bolts
Check fastening torque.
○ Rotation / drive parts
Check for looseness.
Check fastening torque.
○ Reduction gears
Check visual appearance
Conductivity test
○ Manipulator inner wiring and connectors Check visual appearance
Apply grease
○ Batteries (Manipulator) Exchange with new one
○ Reduction gears Apply grease
Check tensile force and

○ Timing belts
adjust if necessary
Exchange with new one
○ Robot manipulator inner wiring
Apply grease
Exchange with new one
○ Timing belts
Adjust tensile force
○ Batteries (Teach pendant) Exchange with new one
• For details, please consult our service section.

• If you have a periodical inspection contract with our company, our periodical inspections will start with a 2000-hour
(yearly) inspection.
• Replacement of parts found to be replaced at the inspection will be charged.
8-3
8.2.1. Battery replacement of Teach Pendant
· The Teach Pendant has 2 pieces of back-up

batteries for teaching program memory.
· Replacement of the batteries is required every 4
years under normal usage, which is 8 hours a day Battery cover
and 5 working days a week. Any installation
environment worse than that may cause shorter life
time of the batteries.
· The message “Change back-up batteries” appears
when the batteries are in low level.
Once the message appeared, the batteries will be
exhausted in approximately 7 days in normal usage.
· Exhausted batteries may cause data crash when
power is disconnected by accidental power failure or
so.
Battery type: CR2450

Replacing procedure
1. Prepare 2 pieces of new batteries.

2. Turn off all input power of the robot system.
3. Remove the Battery Cover on rear side of the Teach Pendant.
4. Remove old batteries from the Battery Holder.
5. Place new batteries to the Battery Holder.
6. Reassemble the Battery Cover.
8-4
Chapter 9. Location of Warning labels
9.1 Location of labels
9-1
< Type label - ANM40196-□□ >
< Type label – ANM30270-□□ >
9-2
WARN I NG
Ca r e f u l l y r ead ope r a t i on manua l
be f o r e i n s t a l l a t i on .
Do no t open t he doo r .
E l e c t r i c s ho c k c an k i l l .
Do no t en t e r t he r obo t
wo r k en v e l ope wh i l e
r obo t i s ope r a t i ng .
CAUT ION
Encode r bac kup ba t t e r y
Rep l a c e ba t t e r y e v e r y 2 y ea r s .
Ope r a t i ng c ond i t i on s w i l l va r y
l i f e t i me o f ba t t e r y .
Re f e r t o ope r a t i on manua l .
ANT30022
< Warning and caution lable – ANT30022 >
9-3
CAUTION
GROUNDING
¡ Make reliable ground connection for the robot
independently from the protective earth terminal
of the robot controller.
2
¡ Use protective conductor more than AWG #8 (8mm ).

¡ As for thickness of protective conductor for
another machine,follow indication for each machine.
¡ Grounding work must be done by the qualified
personnel.
DAILY CHECK
¡ Check loseness and disconnection of protective conductor.
EARTH LINE OF FACTORY Make reliable ground connection

for the robot independently.
SWITCH BOX SWITCH BOX

Protective condutor
2
AWG#8(8mm ) or more
(Attached)
TE terminal
ANOTHER ROBOT ROBOT

MACHINE CONTROLLER MANIPULATOR
Cable
ANT30028
< Caution lable – ANT30028 >
CAUTION
¡ Do no t cover ven t i l a t i on f an . CAUT ION
I t may cause mach i ne damage . H i gh - Tempe r a t u r e Cau t i on
¡ Do no t p l ace any t h i ng on t op o f Do no t t ouch !
con t ro l l er . The t empera t ure may be
I t may cause mach i ne t o overhea t . ver y h i gh .
ANT40151
ANT40119
< Caution lable – ANT40119 > < Caution lable – ANT40151 >
9-4
CAUT I ON
I n case o f open i ng t he rear pane l comp l e t er y ƒLoca t i on „ ALM2 ALM1
( f or ma i n t enance wor k or so) , be sure t o d i sconnec t s i x
6 5 4 3 2 1 G2 G1
f l a t cab l es f or ser vo amp l i f i er s (or e i gh t cab l es i f t he
mach i ne i s bu i l t - i n ex t erna l ax i s t ype)and two wh i t e connec t or s
(ALM1 and ALM2) a t around t he cen t er o f ser vo amp l i f i er s prev i ous l y .
ANT30023
Only for E type
DNH0 0 1 0 9
< Cemark – DNH00109 >
9-5

OM0105037E02 0109 YA-1NCseries Controller

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

OM0105037E02 0109 YA-1NCseries Controller

Uploaded by

Copyright:

Available Formats

Industrial Robot

Model No. YA-1NA series

6.Connection of External control signal

9.Location of Warning labels

Name Description and remarks Usage

The contents of manuals are subject to change without further notice.

Model No. Symbol Basic design policy

Remodeling and/or modifying this product not in accordance with the

■Registered trade mark

Mandatory Action which MUST be performed without fail, such as grounding.

Prohibition Action which MUST NOT be performed.

The above warning symbols are commonly used.

CHAPTER 1. SPECIFICATIONS CHAPTER 6. CONNECTION OF EXTERNAL

Input power source

(TIG welding, Plasma welding and cutting)

Path control PTP and CP (Linear and circular interpolation)

Memory capacity 40000 points

Sequence It is possible to edit or input sequence from teach pendant.

Edit in operation Available (Effective from next cycle)

Control functions Overall operating time (can be reset)

Hold status Servo ON

Other I/O Safety Holder input and Installation input

Input Photo-coupler (ON/OFF of 24 VDC, 12 mA)

Safety circuit Hand input

I/O Input Double contacts (Dual circuit)

memory, 2 slots for PCMCIA card,

Current detect Torch contact

1.1.5. For welding applying digital communication specifications

Input Gas check

Dimensions (W x D x H) 420 x 600 x 530 (mm)

Dimensions (W x D x H) 420 x 630 x 530 (mm)

TP Cable 10 m (with a connector at the teach pendant side.)

Connection cable 6m T/Y ×

1.3.2. Accessories for the controller

Model number of the controller Part number Q’ty

1. Double-wire hanging method.

2. A method using forklift.

3.1 An international protection code of the machine

Part of the machine Class

3.2 Choosing an installation site

3.2.1. Installation site

inside of the controller.

2. Installing the controller on a base with approx.

· Be sure to place the teach pendant outside of

· Please supply a hook at customers’ end.

· The provided cable between the operation box

4.1 Connecting the controller to the manipulator

4.1.1. Encoder cable (round-shape connector)

3. Rotate the screw part to connect. Push the cable

Hold the cable and

Insert the cable to the end completely without fail.

4.1.2. Motor cable (Square-shape connector)

3. Turn the hook handle ( ) to the arrowed direction in

4.2.2. Connection of Grounding wire

Model number of the controller Input power capacity Power cable

4.3.2. Wiring of primary power source

2. Choose no-fuse breakers or earth leakage

3. Choose earth leakage breakers, if applied, No-fuse breaker

4. Choose a stable primary power which is a

5. To prevent noise from entering from the

2. Open the front door by unlocking the two fasteners

Be sure that the handle switch on the door is placed Switch

in the “OFF” position prior to opening.