Connecting to MRC I/O-boards

Installation and setup manual,

YASNAC MRC

MOTOMAN ROBOTICS AB
a subsidiary of YASKAWA Electric Corporation
 MOTOMAN
ROBOTICS
Connecting the YASNAC MRC
AB Page: 1

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

2. I/O-boards .............................................. 2
I/O-rack 2
Board replacement 3
3. Board connections ................................. 4
MRY01-board 4
MEW02-board 5
MIO02-board 6
MIO03-board 9
4. Initialising new boards ......................... 12

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 Connecting the YASNAC MRC MOTOMAN
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Revision
981005
First edition of this manual

Revision
990322
Corrections of layout for MIO03-board, IN-put logic switched.

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 MOTOMAN
ROBOTICS
Connecting the YASNAC MRC
AB About this manual Page: 1

Guidelines for connecting the MRC boards

Extract from; Installation and Maintenance Manuals.

Machine sign

Fig.1 YASNAC MRC

1. About this manual

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

This manual compromises:

-Technical guidelines about YASNAC MRC I/O-boards.

Reserved and free signals are described for a standard system!

Number of free I/O’s may differ due to options and special functions.

For general service and installation information, see separate service man-
ual for YASNAC MRC
Operator’s manual / Programming manual for robot, MRC, positioners
and welding equipment, etc., see separate document.
This english service manual is an extract from the Maintenance Manual,
see this manual for more close information and electrical drawings, etc.

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This service manual may not be copied without our written permission
and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpuse.

Text written in BOLD letters means command or button.

Text written in ITALIC letters means text shown on display.

2. I/O-boards
2.1 I/O-rack
The I/O-rack contain communication boards for robot;
-Communication for external control, MIO02-MIO03
-Communication for current sorch for welding, MEW02

Fuse for external

power unit I/O-rack
JANCD-MBB02

Extra I/O-board
MRY01

MIO03 MEW02

MIO02
Fig.2 I/O-rack

Slot 0 Slot 2 Slot 4

Slot 1 Slot 3

2.1.A External I/O connection

General there are two communication boards on the I/O-rack.
MRY01 and MIO03 are enclosed as standard. MIO02 is an option board.

Maximum 128 IN- and OUT-puts are available.

Electrical drawings.
341000-90 (General application)
341000-91 (Welding applikation)

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MRY01
Relay board for power ON. Four direct INPUT channels.

MIO02
32 inputs, 24 VDC max. 5 mA / 32 outputs, 24 VDC max. 50 mA.
(Power feed at some plugs; +24 VDC).

MIO03
16 inputs, 24 VDC max. 5mA / 16 outputs, 24 VDC max. 500 mA. The
board is connected to a connection terminal, mounted to the left, inside
the cabinet.
(Power feed at some plugs; +24 VDC).

2.1.B Welding interface

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

2.2 Board replacement

While replacing a current board, make sure the power is disconnected.

Use earth bracelet to carry off static electricity from your body,
before boards are removed from their safe position.

Untighten the board:

a) Pull out the upper and lower lever so that the board gets released
from the inner connectors.
b) Loose all outher cable connectors.
c) Take out the board.
d) Check that the new board is of same type.
e) Steer carefully the new board into the track. Use the levers to press
the board into the back board terminals
f) Remount if nessesary outher cable bundles on the board.

Don’t drop the board on the floor. Don’t try to repair damaged boards.
After service, check that all cables has been remounted and that all
boards are in thier position. Check that no tools are forgotten inside the
cabinet.

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3. Board connections
3.1 MRY01-board

YASNAC MRC CN1

JANCD-MRY01

+24V -1 +24V -1
-2 +24V -2
-3 +24V -3
Not Used (E. Stop) -4 -4
External HOLD Signal -5 -5
External Servo ON -6 -6
External Over Travel recovery -7 -7
External Over Travel Switch -8 -8

CN2

-1 IN -1
-2 DIN3 -2
IN
Each -3 IN -3
INPUT Point DIN2
24VDC -4 IN -4
max. 5 mA
-5 IN -5
-6 DIN1 -6
IN
-7 IN -7
-8 DIN0 -8
IN

INPUT number DIN#

CN3

+24VU -1 +24VU -1
-2 +24VU -2
024VU -3 024VU -3
-4 024VU -4
-5 -5
Control Power OFF -6 -6
Control Power Common -7 -7
Control Power ON -8 -8

See, Maintenance manual

for further information

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3.2 MEW02-board

YASNAC MRC CN1 WELDER

JANCD-MEW02
-2
GASOF
-3
GAS SHORTAGE
GASOF
-4
WIRCUT
WIRE SHORTAGE
-5
WIRCUT
-6
ARCACT
ARC START
-7
ARCACT
-13
ARCOFF
ARC OFF DETECT
-14
ARCOFF
RY1 -26
STICK 1
STICK WELDING DETECT
DETECTOR -27
STICK 2
+5V -15
ARCON
RY2 ARC ON
-16
ARCON
-17
WIRINCH
RY3 WIRE INCHING
-18
WIRINCH
-19
WIRRTR
RY4 WIRE RETRACT
-20 INCHING
WIRRTR
-29
+24V
-30
0 24V
-31
CH0_A
D/A -32
CH0_G
ANALOG OUT
-33
CH1_A
D/A -34
CH1_G
-21
OUT 1
RY5 NOT USED
-22
OUT 1

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3.3 MIO02-board
3.3.A CN1-terminal

+24V RLY
1-1 OUT 1 1
1-2 OUT 2 RLY
2
1-3 OUT 3 RLY
3
1-4 OUT 4 RLY
4
1-5 OUT 5 RLY
5
1-6 OUT 6 RLY
Each 6
OUTPUT Point 1-7 OUT 7 RLY
24VDC 7
max. 50 mA 1-8 OUT 8 8 RLY

1-9 OUT 9 9 RLY

CN1
1-10 OUT 10 10 RLY

1-11 OUT 11 11 RLY

YASNAC MRC
12 RLY
JANCD-MIO02 1-12 OUT 12
1-13 OUT 13 13 RLY

1-14 OUT 14 14 RLY

1-15 OUT 15 15 RLY

1-16 OUT 16 16 RLY

1-17 024VU 17
1-18 PE 18

JANCD-MBB02 1-19 +24VU 19

OUTPUT Terminal X8
1-20 +24VU 20
Internal CN 7/8 number
1-21 +24VU 21
power OT#
+24V 1-22 +24VU 22
024V
1-23 +24VU 23
(24V1A)
1-24 +24VU 24
1-25 +24VU 25
1-26 +24VU 26

External 1-27 27
power INPUT
1-28 28
+24V number
024V 1-29 024VU 29
IN#
CN 7/8 1-30 024VU 30
1-31 024VU 31
1-32 024VU 32
1-33 IN 1 33
1-34 IN 2 34
1-35 IN 3 35
1-36 IN 4 36
1-37 IN 5 37
024VU 1-38 IN 6 38
1-39 IN 7 39
1-40 IN 8 40
Each
INPUT Point 1-41 IN 9 41
24VDC
max. 5 mA 1-42 IN 10 42
1-43 IN 11 43
1-44 IN 12 44
1-45 IN 13 45
1-46 IN 14 46
1-47 IN 15 47
1-48 IN 16 48
1-49 024VU 49
1-50 024VU 50

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3.3.B CN2-terminal

+24V RLY
2-1 OUT 17* 1
2-2 OUT 2 RLY
18*
2-3 OUT 3 RLY
19*
2-4 OUT 4 RLY
20*
2-5 OUT 5 RLY
21*
2-6 OUT 6 RLY
Each 22*
OUTPUT Point 2-7 OUT 7 RLY
24VDC 23*
max. 50 mA 2-8 OUT 24* 8 RLY

2-9 OUT 25* 9 RLY

CN2
2-10 OUT 26* 10 RLY

2-11 OUT 27* 11 RLY

YASNAC MRC
12 RLY
JANCD-MIO02 2-12 OUT 28*
2-13 OUT 29* 13 RLY

2-14 OUT 30* 14 RLY

2-15 OUT 31* 15 RLY

2-16 OUT 32* 16 RLY

2-17 024VU 17
2-18 PE 18

JANCD-MBB02 2-19 +24VU 19

OUTPUT
2-20 +24VU 20
Internal CN 7/8
number
2-21 +24VU 21
power OT#
+24V 2-22 +24VU 22
024V
2-23 +24VU 23
(24V1A)
2-24 +24VU 24
2-25 +24VU 25
2-26 +24VU 26

External 2-27 27
power
INPUT
2-28 28
+24V number
024V 2-29 024VU 29
IN#
CN 7/8 2-30 024VU 30
2-31 024VU 31
2-32 024VU 32
2-33 IN 17* 33
2-34 IN 18* 34
2-35 IN 19* 35
2-36 IN 20* 36
2-37 IN 21* 37
024VU 2-38 IN 22* 38
2-39 IN 23* 39
2-40 IN 24* 40
Each
INPUT Point 2-41 IN 25* 41
24VDC
max. 5 mA 2-42 IN 26* 42
2-43 IN 27* 43
2-44 IN 28* 44
2-45 IN 29* 45
2-46 IN 30* 46
2-47 IN 31* 47
2-48 IN 32* 48
2-49 024VU 49
2-50 024VU 50

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3.3.C Reserved I/O

The following channels are reserved at standard setup of MIO02-board.

IO No. Ladder (CIO)

MIO02 General application Arc Welding application
CN2-1 Running Running
CN2-2 SERVO ON SERVO ON
CN2-3 Master Job Head Master Job Head
CN2-4 Alarm/Error occurance Alarm/Error occurance
CN2-5 Battery Alarm Battery Alarm
CN2-6 REMOTE Mode Selected REMOTE Mode Selected
Output channel

CN2-7 PLAY Mode Selected PLAY Mode Selected

CN2-8 TEACH Mode Selected TEACH Mode Selected
CN2-9 Inside Cube 1 Inside Cube 1
CN2-10 Inside Cube 2 Inside Cube 2
CN2-11 Working Origin Working Origin
CN2-12 Driving possible on the way Driving possible on the way
CN2-13 Inside Cube 3 Gas Run-out
CN2-14 Inside Cube 4 Wire Disconnected
CN2-15 Working directive Wire Sticking
CN2-16 --- Wire Inching + Arc ON
CN2-33 External Start External Start
CN2-34 --- ---
CN2-35 Master Job Call Master Job Call
CN2-36 Alarm/Error reset Alarm/Error reset
CN2-37 REMOTE Mode Select REMOTE Mode Select
CN2-38 PLAY Mode Select PLAY Mode Select
Input channel

CN2-39 TEACH Mode Select TEACH Mode Select

CN2-40 --- ---
CN2-41 Interfer. 1 Inhibit Interfer. 1 Inhibit
CN2-42 Interfer. 2 Inhibit Interfer. 2 Inhibit
CN2-43 Working Inhibit Arc Start Inhibit
CN2-44 --- Arc ON Response
CN2-45 Interfer. 3 Inhibit Air Missing
CN2-46 Interfer. 4 Inhibit ---
CN2-47 --- Weaving Inhibit
CN2-48 --- Sensing Inhibit

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3.4 MIO03-board
3.4.A CN1-terminal

INPUT number IN#

YASNAC MRC CN1 Terminal X3

JANCD-MIO03

1-A1 +IN A1
121
2-B1 -IN B1
1-A2 +IN A2
122
1-B2 -IN B2
1-A3 +IN A3
123
1-B3 -IN B3
1-A4 +IN A4
124
Each 1-B4 -IN B4
INPUT Point
24VDC 1-A5 +IN A5
max. 5 mA 125
1-B5 -IN B5
1-A6 +IN A6
126
1-B6 -IN B6
1-A7 +IN A7
127
1-B7 -IN B7
1-A8 +IN A8
128
1-B8 -IN B8
1-A9 OUT A A9 RLY
121
1-B9 OUT B B9
1-A10 OUT A A10 RLY
122
1-B10 OUT B B10
1-A11 OUT A A11 RLY
123
Each 1-B11 OUT B B11
OUTPUT Point
24VDC 1-A12 OUT A A12 RLY
max. 0.5 A 124
1-B12 OUT B B12
1-A13 OUT A A13 RLY
125
1-B13 OUT B B13
1-A14 OUT A A14 RLY
126
1-B14 OUT B B14
1-A15 OUT A A15 RLY
127
1-B15 OUT B B15
1-A16 OUT A A16 RLY
128
1-B16 OUT B B16
JANCD-MBB02 1-A17 024VU A17

Internal 1-B17 024VU B17

CN 7/8
power 1-A18 024VU A18
+24V
024V 1-B18 024VU B18

(24V1A) 1-A19 +24VU A19

1-B19 +24VU B19
1-A20 +24VU A20
1-B20 B20
External
power
+24V
024V

CN 7/8 OUTPUT number OT#

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3.4.B CN2-terminal

INPUT number IN#

YASNAC MRC CN2 Terminal (Option)

JANCD-MIO03

2-A1 +IN A1
113 B1
2-B1 -IN
2-A2 +IN A2
114 B2
2-B2 -IN
2-A3 +IN A3
115 B3
2-B3 -IN
Each
INPUT Point 2-A4 +IN A4
24VDC 116
max. 5 mA 2-B4 -IN B4

2-A5 +IN A5
117 B5
2-B5 -IN
2-A6 +IN A6
118 B6
2-B6 -IN
2-A7 +IN A7
119 B7
2-B7 -IN
2-A8 +IN A8
120 B8
2-B8 -IN
2-A9 OUT A A9 RLY
113 B9
2-B9 OUT B
2-A10 OUT A A10 RLY
114 B10
2-B10 OUT B
2-A11 OUT A A11 RLY
115 B11
Each 2-B11 OUT B
OUTPUT Point
24VDC 2-A12 OUT A A12 RLY
max. 0.5 A 116 B12
2-B12 OUT B
2-A13 OUT A A13 RLY
117 B13
2-B13 OUT B
2-A14 OUT A A14 RLY
118 B14
2-B14 OUT B
2-A15 OUT A A15 RLY
119 B15
2-B15 OUT B
2-A16 OUT A A16 RLY
120 B16
2-B16 OUT B
JANCD-MBB02 2-A17 024VU A17

Internal 2-B17 024VU B17

CN 7/8
power 2-A18 024VU A18
+24V
024V 2-B18 024VU B18

(24V1A) 2-A19 +24VU A19

2-B19 +24VU B19
2-A20 +24VU A20
2-B20 B20
External
power
+24V
024V

CN 7/8 OUTPUT number OT#

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3.4.C Reserved I/O

The following channels are reserved at standard setup of MIO03-board.

IO No. Ladder (CIO)

MIO03 General application Arc Welding application
CN1-AB1 --- ---
CN1-AB2 --- ---
Input channel

CN1-AB3 --- ---

CN1-AB4 --- ---
CN1-AB5 --- ---
CN1-AB6 --- ---
CN1-AB7 --- ---
CN1-AB8 --- ---
CN1-AB9 --- ---
CN1-AB10 --- ---
Output channel

CN1-AB11 --- ---

CN1-AB12 --- ---
CN1-AB13 --- ---
CN1-AB14 --- Manual Gas Output
CN1-AB15 Running Ready CANCEL (SCU) Manual Wire Output
CN1-AB16 Running Ready (SCU) Servo ON State

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4. Initialising new boards

To install an I/O-board, complete the following steps:

WARNING
To prevent electrical shock to personnel and to prevent equipment
damage, ensure power to MRC controller is turned OFF before
beginning the installation

CATION
Follow the proper anti-static procedures to ensure that static elec-
tricity does not damage the board.

a) Turn off the power to the MRC controller

b) Open the front door of the MRC cabinet and locate the I/O rack on
the MBB02 back board, which is situated to your left in the middle of
the cabinet.
c) Install the I/O-board in the first empty slot to the left in the I/O rack.
d) To place the MRC controller in maintenance mode, press CUSTO-
MER on the programming pendant and simultaneously turn on the
power to the MRC controller.
e) Enter your customer user ID number or 00000000 (eight zeros), and
press ENTER. The MAINTENENANCE MODE screen is displayed.
f) Ensure the SETUP SYSTEM is highlighted, and press ENTER. The
SETUP SYSTEM screen is displayed.
g) Ensure that SYSTEM CONFIGURATION is highlighted, and press
ENTER. The SYSTEM CONFIGURATON screen is displayed.
h) Ensure that IO MODULES is highlighted and press ENTER. The dis-
play lists the I/O modules installed in the MRC.
i) Press ENTER to display the YES/NO verification.
j) Ensure that YES is highlighted, and press ENTER again. You should
hear a beeping sound to confirm your input.
k) Turn off power to the MRC controller. The I/O-board installation is
complete.

CATION
Never change any of the settings on the I/O-board while controller
power is ON.

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Tel: +46-486-48800l Fax: +46-486-41410

Subsidiary:
MOTOMAN ROBOTICS UK LTD
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Tel: +34-36303478 l Fax: +34-36543459

Distributors:
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HN AUTOMATIC A/S
Hjulmagervej 4 l DK-7100 Vejle l Denmark
Tel: +45-79428000 l Fax: +45-79428001

LINCOLN-KD S.A.
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Tel: +34-36859600 l Fax: +34-36859633

MOTOMAN ROBOTIT OY
Kärsämäentie 8 l SF-20300 Turku l Finland
Tel: +358-22145600 l Fax: +358-22145660

ROBOT-TEKNIKK AS
Øvre Eikervei 177 l N-3048 Drammen l Norway
Tel: +47-32217830 l Fax: +47-32217840

SIAD S.p.a.
Via S. Bernardino, 92 l I-24126 Bergamo l Italy
Tel: +39-35-328111 l Fax: +39-35-320183

MOTOMAN ROBOTICS AB
a subsidiary of YASKAWA Electric Corporation