YRC1000

SETUP PROCEDURE MANUAL

STANDARD SYSTEM

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.

MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”.
The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.

178658-1CD
1

MANUAL NO.

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DANGER
• This manual explains the setup procedure (standard system) of the
YRC1000 system. Read this manual carefully and be sure to
understand its contents before handling the YRC1000. Any matter,
including operation, usage, measures, and an item to use, not
described in this manual must be regarded as “prohibited” or
“improper”.
• General information related to safety are described in “Chapter 1.
Safety” of the YRC1000 INSTRUCTIONS. To ensure correct and
safe operation, carefully read “Chapter 1. Safety” of the YRC1000
INSTRUCTIONS.

CAUTION
• In some drawings in this manual, protective covers or shields are
removed to show details. Make sure that all the covers or shields
are installed in place before operating this product.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids the
product warranty.

NOTICE
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
• If such modification is made, the manual number will also be
revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.

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NOTES FOR SAFE OPERATION

Read this manual carefully before installation, operation, maintenance, or
inspection of the YRC1000.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, or “NOTICE”.

Indicates an imminently hazardous

DANGER situation which, if not avoided, will
result in death or serious injury.
Safety Signs identified by the signal
word DANGER should be used
sparingly and only for those
situations presenting the most
serious hazards.

Indicates a potentially hazardous

WARNING situation which, if not avoided, will
result in death or serious injury.
Hazards identified by the signal
word WARNING present a lesser
degree of risk of injury or death than
those identified by the signal word
DANGER.

Indicates a hazardous situation,

CAUTION which if not avoided, could result in
minor or moderate injury. It may
also be used without the safety alert
symbol as an alternative to
“NOTICE”.

NOTICE is the preferred signal word

NOTICE to address practices not related to
personal injury. The safety alert
symbol should not be used with this
signal word. As an alternative to
“NOTICE”, the word “CAUTION”
without the safety alert symbol may
be used to indicate a message not
related to personal injury.

Even items described as “CAUTION” may result in a serious accident in

some situations.
At any rate, be sure to follow these important items.

To ensure safe and efficient operation at all times, be sure

NOTE to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION”.

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DANGER
• Before operating the manipulator, make sure the servo power is
turned OFF by performing the following operations. When the servo
power is turned OFF, the SERVO ON LED on the programming
pendant is turned OFF.
– Press the emergency stop buttons on the front door of the
YRC1000, on the programming pendant, on the external control
device, etc.
– Disconnect the safety plug of the safety fence.
(when in the play mode or in the remote mode)
If operation of the manipulator cannot be stopped in an emergency,
personal injury and/or equipment damage may result.
Fig. : Emergency Stop Button

• Before releasing the emergency stop, make sure to remove the

obstacle or error caused the emergency stop, if any, and then turn
the servo power ON.
Failure to observe this instruction may result in personal injury caused
by unintended manipulator movement.
Fig. : Release of Emergency Stop
TURN

• Observe the following precautions when performing a teaching

operation within the P-point maximum envelope of the manipulator:
– Be sure to perform lockout by putting a lockout device on the
safety fence when going into the area enclosed by the safety
fence. In addition, the operator of the teaching operation must
display the sign that the operation is being performed so that no
other person closes the safety fence.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Always keep in mind emergency response measures against the
manipulator’s unexpected movement toward a person.
– Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may result in personal injury caused
by improper or unintended manipulator movement.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that the operator is in a safe location before:
– Turning ON the YRC1000 power
– Moving the manipulator by using the programming pendant
– Running the system in the check mode
– Performing automatic operations
Injury may result if any person should enter the P-point maximum
envelope of the manipulator during operation. Immediately press an
emergency stop button whenever there is a problem. The emergency
stop buttons are located on the front panel of the YRC1000 and on the
right of the programming pendant.
• Read and understand the Explanation of the Warning Labels before
operating the manipulator.

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WARNING
• Perform the following inspection procedures prior to conducting
manipulator teaching. If there is any problem, immediately take
necessary steps to solve it, such as maintenance and repair.
– Check for a problem in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the
YRC1000 cabinet after use.
If the programming pendant is left unattended on the manipulator, on a
fixture, or on the floor, the Enable Switch may be activated due to
surface irregularities of where it is left, and the servo power may be
turned ON. In addition, in case the operation of the manipulator starts,
the manipulator or the tool may hit the programming pendant left
unattended, which may result in personal injury and/or equipment
damage.

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows.
Equipment Manual Designation
YRC1000 controller YRC1000
YRC1000 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller

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Descriptions of the programming pendant keys, buttons, and displays are

shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters or its
Pendant /Symbol Keys symbol printed on them are denoted with [ ].
ex. [ENTER]
Axis Keys [Axis Key] and [Numeric Key] are generic
/Numeric Keys names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a
“+” sign between them,
ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}

Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • • “
means that the cursor is moved to the object item and [SELECT] is
pressed, or that the item is directly selected by touching the screen.

Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.

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Contents

1 Overview of YRC1000 Setup Procedure ........................................................................................ 1-1

2 ACP01 Setup .................................................................................................................................. 2-1

2.1 Preparing the SD Card for ACP01..................................................................................... 2-1

2.2 Setting Up the ACP01 Board ............................................................................................. 2-6

3 Programming Pendant Setup.......................................................................................................... 3-1

3.1 Preparing the SD Card/USB for Upgrading ....................................................................... 3-2

3.2 Setting Up the Programming Pendant ............................................................................... 3-7

4 Initialization of System Configuration in Maintenance Mode .......................................................... 4-1

5 Troubleshooting .............................................................................................................................. 5-1

5.1 Possible Failures at Preparation of the SD card................................................................ 5-1

5.2 Possible Failure at Setup of the Programming Pendant.................................................... 5-3

5.3 Programming Pendant FlashRom Format Procedure ....................................................... 5-4

5.4 Redisplaying the Touch Calibration Display ...................................................................... 5-8

5.5 When the Message “Cannot find ‘YPP’ (or one of its components).” is Displayed .......... 5-10

5.6 Possible Failures at ACP01 Setup................................................................................... 5-11

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1 Overview of YRC1000 Setup Procedure

1 Overview of YRC1000 Setup Procedure

The following flowchart overviews how to set up the YRC1000.

YRC1000 setup
START

Required items:
SD preparation
Personal computer
ACP01 for ACP01
(Either Windows 7 which can use SD card)
Setup
SD card for shipping
ACP01 setup Operation Time: Approx. 5 minutes

SD/USB preparation Required items:

for programming pendant Personal computer
Programming
Pendant (Windows which can use following devices)
Setup SD card or USB memory for operation
Operation time: Approx. 5 minutes
Programming pendant
setup

System System configuration

Setup initialization
in maintenance mode

YRC1000 setup
END

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2 ACP01 Setup
2.1 Preparing the SD Card for ACP01

2 ACP01 Setup
Prepare the following items for the ACP01 setup operation.

• A personal computer: either Windows 7 which can use SD card

• SD card for shipping
*The SD card used for ACP01 requires no pretreatment because it is already
formatted by the SD card manufacturer.

2.1 Preparing the SD Card for ACP01

Followings are the data writing procedures into the shipping SD card
which is to be mounted on ACP01 (CPU) board.

1. Insert the SD card into the card reader.

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2 ACP01 Setup
2.1 Preparing the SD Card for ACP01

2. Start up (double-click) "mk_cf.exe" of the specified version.

3. Click “Main CPU Board,” and then click the appropriate language in
“Language” part.

Each abbreviation indicates the language as follows:

JP: Japanese EN: English DE: German IT: Italian
SUPPLE
-MENT
ES: Spanish FI: Finnish SE: Swedish FR: French
KR: Korean CN: Chinese TW: Taiwanese CZ: Czech

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2 ACP01 Setup
2.1 Preparing the SD Card for ACP01

4. Confirm that the version described in the Software Modification

Instructions and the version in the following window are the same.
Then click “Set boot loader” check box and “Delete all file” check box
under “Operation,” and click {START}.

Version

NOTICE
• Never execute the following operations while data is being written
into the SD card.
– Do not remove the card reader from the personal computer.
– Do not remove the SD card from the card reader.
– Do not turn OFF the card reader power supply.
• Failure to observe these instructions may cause SD card failure.

The access lamp (LED) of the

card reader blinks while the data
is being written-in.
Do not remove the connection
with the personal computer and
with the SD card while the
access lamp is blinking.

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2 ACP01 Setup
2.1 Preparing the SD Card for ACP01

5. When the data has been written into the SD card successfully, “OK” is
displayed in the second column under “Target Drives”. To prepare
seven SD cards, it takes approx. five minutes.

B: Boot sector write-in completed

D: File deletion completed
F: File copy completed
V: File copy completed (for version-up)
/ : Processing failed
−: Processing passed

Even if “OK” is displayed on the above mentioned window,

NOTE the access lamp on the card reader may not stop blinking.
Please check that the lamp is OFF before removing the SD
card from the card reader.

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2 ACP01 Setup
2.1 Preparing the SD Card for ACP01

“NG” is displayed if the SD card is not inserted correctly.

SUPPLE
-MENT

6. Remove the SD card from the card reader.

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2 ACP01 Setup
2.2 Setting Up the ACP01 Board

2.2 Setting Up the ACP01 Board

1. Insert the SD card prepared in chapter 2.1 “Preparing the SD Card for
ACP01” into the ACP01 board.

<SD Card Slot on the ACP01 Board and Inserting Direction>

ACP01 Board
SD Card Slot

Insert the SD card with this surface facing right.

Inserting direction

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3 Programming Pendant Setup

3 Programming Pendant Setup

Prepare the following items.
Setting up operation requires either SD card or USB memory (hereinafter
referred to as “USB”).
• A personal computer: Windows which can use SD card
• SD card or USB for operations 1) 2)

1) The SD card and USB requires no pretreatment because it is already formatted

by the manufacturer.
If it should not read the data, format it with the following OS or file system before
using.
PC Windows Windows Windows
OS 7 8 10
File System FAT FAT32 FAT FAT32 FAT FAT32
SD card ○ ○ ○ ○ ○ ○
USB ○ ○ ○ ○ ○ ○
○: Available file system format

NOTE The device whose file system is formatted by exFAT is not

available for setting up of the programming pendant.

2) Followings are the recommended SD card and USB.

[Recommended SD card]

No. Manufacturer Model Remarks

1 Hagiwara Solutions Co., Ltd. NSD6-512MH(A01SDI-YE 512MB
2 Hagiwara Solutions Co., Ltd. NSD6-001GH(A01SDI 1GB
3 Hagiwara Solutions Co., Ltd. NSD6-002GH(A01SDI 2GB
4 Hagiwara Solutions Co., Ltd. NSD6-004GH(B20SEI 4GB
5 Hagiwara Solutions Co., Ltd. NSD6-008GH(B20SEI 8GB
6 Hagiwara Solutions Co., Ltd. NSD6-016GH(B20SEI 16GB
7 Hagiwara Solutions Co., Ltd. NSD4-032GH(B00MG) 32GB

[Recommended USB]

No. Manufacturer Model Remarks

1 Hagiwara Solutions Co., Ltd. UDG4-xGDRJS 1 GB, 2GB, and
4 GB are
available.

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3 Programming Pendant Setup

3.1 Preparing the SD Card/USB for Upgrading

3.1 Preparing the SD Card/USB for Upgrading

Write the data into the “SD card/USB for operations” which is to be
inserted into the programming pendant as follows:

1. For SD card, insert the SD card into the card reader, and insert the
USB of the card reader into the arbitrary USB connector of the
personal computer.
For USB, insert the USB into the arbitrary USB connector of the
personal computer.
(In case of SD card)

(In case of USB)

Insert

USB and USB Connector

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3 Programming Pendant Setup
3.1 Preparing the SD Card/USB for Upgrading

2. Download the software for the system from the network since it is
uploaded by the designer.
Following shows an example when the software for the system is
written on a CD-R.
Insert a CD into a personal computer, and start up Explorer. Then
select (double-click) “CD drive”.

3. Start up (double-click) "mk_cf.exe" of the specified version.

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3 Programming Pendant Setup

3.1 Preparing the SD Card/USB for Upgrading

4. Check “Main CPU Board,” and then click the appropriate language
under “Language”.

Each abbreviation indicates the language as follows:

JP: Japanese EN: English DE: German IT: Italian
SUPPLE
-MENT
ES: Spanish FI: Finnish SE: Swedish FR: French
KR: Korean CN: Chinese TW: Taiwanese CZ: Czech

5. Confirm that the version described in the Software Modification

Instructions and the version in the following window are the same.
Then click “START”.

Version

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3 Programming Pendant Setup
3.1 Preparing the SD Card/USB for Upgrading

NOTICE
• Never execute the following operations while data is being written
into the SD card.
– Do not remove the card reader from the personal computer.
– Do not remove the SD card from the card reader.
– Do not turn OFF the power supply to the card reader.
Failure to observe these instructions may cause SD card failure.

The access lamp (LED) of the card

reader blinks while the data is
being written-in.
Do not remove the connection with
the personal computer and with
the SD card while the access lamp
is blinking.

• Never execute the following operations while data is being written

into the USB.
– Do not remove the USB from the personal computer.

The access lamp (LED) of the

USB blinks while the data is being
written-in.
Do not remove the USB from the
personal computer while the
access lamp is blinking.

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3 Programming Pendant Setup

3.1 Preparing the SD Card/USB for Upgrading

6. When the data has been written into the SD card successfully, “OK” is
displayed in the second column under “Target Drives”. To prepare
seven SD cards, it takes approx. five minutes.

Even when “OK” is shown in the above window, the access

lamp of the device may keep blinking.
NOTE
Confirm that the access lamp is turned OFF, and then
remove the device from the PC.

“NG” is displayed if the SD card is not inserted correctly.

SUPPLE
-MENT

7. Remove the SD card from the card reader or the USB from the USB
connector.

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3 Programming Pendant Setup
3.2 Setting Up the Programming Pendant

3.2 Setting Up the Programming Pendant

The following two software need to be written into the programming
pendant.

(1) NK.BIN : Operating-system software for the programming

pendant (managing software)

(2) YPP.EXE, etc. : Application software for the programming pendant

For the normal setting up operation, the above two software need to be
installed. Also, upgrading of the application software (YPP.EXE, etc.) can
be solely executed to the already set-up programming pendant. In this
case, start from the step 9 of the following procedures.

Setting up procedures for the programming pendant are described as

follows.
1. Confirm that the main power supply of the YRC1000 is turned OFF.
2. Insert the SD card or USB to the programming pendant.
For the SD card, remove the rubber cap for the SD card slot of the
programming pendant, and then insert the SD card. The SD card
must be inserted with its front face upward.

<SD card Slot Position and Inserting Direction>

SD Card Inserting Direction

SD Card Slot

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3 Programming Pendant Setup

3.2 Setting Up the Programming Pendant

Before inserting an USB, remove the rubber cap of the USB connector at
the back side of the programming pendant.
<USB Connector Position and Inserting Direction>

USB Inserting Direction

86%&RQQHFWRU

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3 Programming Pendant Setup
3.2 Setting Up the Programming Pendant

3. While pressing [2] + [8] + [HIGH SPEED] simultaneously, turn ON the

YRC1000 main power supply. Release the keys when the
programming pendant buzzer sounds.

P
E
ER O
G EN C Y ST

Bit-map image appears

Press [2] + [8] + [HIGH SPEED]

4. NK.BIN (OS: Windows Embedded Compact 7) in the SD card is

written into the internal memory (FlashRom) of the programming
pendant from DRAM. At this time, the LED indicators blink as follows:

<While NK.BIN is being transferred <While NK.BIN is being written into

from SD card to DRAM> FlashRom from DRAM>

The four LED indicators blink clock- The three LED indicators blink clock-
wise. The blinking cycle is irregular. wise, every one to two seconds. It
(The indicators sometimes blink every takes approx. five minutes to write-in
one to two seconds, or sometimes the data.
four to five seconds.) It takes approx.
ten seconds to read the data.

Total time required for transfer and write-in is approx. five minutes.

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3 Programming Pendant Setup

3.2 Setting Up the Programming Pendant

5. Approx. five minutes after the YRC1000 main power supply is turned
ON, the data will be written into FlashRom completely and the window
for touch panel calibration appears on the programming pendant. Use
a pen for touch panel or anything having a soft and sharp tip end (such
as ballpoint pen cap) to touch the center of the window for approx. two
seconds.

Use a pen for touch panel or

anything having a soft and
sharp tip end to touch the
center of the window for
approx. two seconds.

6. The cross cursor moves to the center, left top, left bottom, right bottom,
and then right top of the window in this order. Touch the center of the
cross for approx. two seconds for each.

The cross cursor moves in such

an order as shown on the left.

NOTE The cross cursor returns to the center if calibration fails. Try
calibration as described in step 6 again.

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3 Programming Pendant Setup
3.2 Setting Up the Programming Pendant

7. When touch calibration is successfully done, the following window

appears.

8. Pressing [ENTER] calls up the following window. Touch the OK button

at the right top of the dialog box to close the box.

OK button

Press [ENTER] to save the registry data in the FlashRom in

the programming pendant. It takes six to seven seconds to
NOTE save the data. Do not turn OFF the power of the YRC1000
while saving. To confirm that the saving is completed, touch
OK button at the right top of the dialog box and find if the
message is disappeared.

The following describes the procedure for installing application software

for the programming pendant.
In case that the operating-system software: NK.BIN has been already
installed, hold down [INTERLOCK], [9], and [SELECT] simultaneously,
and turn ON the YRC1000 main power supply to start up the system with
the display window as shown in procedure 8.
Then, touch “OK” on the window and perform the installation of application
software following the procedures from 9.

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3 Programming Pendant Setup

3.2 Setting Up the Programming Pendant

9. Use the pen to touch the left bottom, and the task bar appears. Then
touch “START” in the task bar.

Touch here to display

“START” indication.

10. When START menu appears, touch “Programs” and then “Windows
Explorer”.

Select “Windows Explorer”

11. Touch “Storage Card” folder to display the stored files in the SD card
and touch “USB Memory” to show the ones in the USB. .
<SD card> <USB>

Select “Storage Card” Select “USB Memory”

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3 Programming Pendant Setup
3.2 Setting Up the Programming Pendant

12. Touch “CESETUP.EXE” icon.

<SD card> <USB>

CESETUP.EXE

13. Touch the dialog box with “SD/USB→PP” on it. The file starts to be
copied from the SD card to the “DiskOnChip” folder. It takes 60
seconds to copy the data.
While it is copied from the USB, START lamp on the programming
pendant lights.
While it is copied from the SD card, HOLD lamp on the programming
pendant lights.

Touch here. After touching it, the data

starts to be written-in.
While the data is being written-in, the
HOLD lamp is ON for the SD card, the
START lamp is ON for the USB.

14. When the dialog box indicating the completion of copy appears, touch
“OK” at the right top of the dialog box to close the box.

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3 Programming Pendant Setup

3.2 Setting Up the Programming Pendant

When “END (Success)” appears, touch

“OK” to close the dialog box.

When the data have not been copied correctly, the following
dialog box appears. Execute the operation again.

Error display dialog box:

Click “OK” to close the
dialog box.

SUPPLE
-MENT

“END (Failure)” appears.

Click “OK” to close the
dialog box.

15. Turn OFF the YRC1000 main power supply. Then be sure to remove
the “SD card/USB for operations” from the programming pendant.
The setup of the programming pendant has been completed.

Refer to chapter 4 “Initialization of System Configuration in

NOTE Maintenance Mode” for details about putting the license
sticker.

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4 Initialization of System Configuration in Maintenance Mode

4 Initialization of System Configuration in Maintenance Mode

1. Turn ON the YRC1000 main power supply while pressing [MAIN
MENU].

P
E
ER O
G EN C Y ST

MAIN MENU

2. The initial window of the maintenance mode appears in approx. 50

seconds. The 7-segment LED indicators of the ACP01 indicate “F”.

“Maintenance mode” appears.

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4 Initialization of System Configuration in Maintenance Mode

3. Touch {SYSTEM} and then {SECURITY}.

{SYSTEM}

{SECURITY}

4. Press [SELECT] on the programming pendant.

The initial status of the mode is the editing mode.

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4 Initialization of System Configuration in Maintenance Mode

5. Insert the USB for the manufacturer mode to the USB connector of the
programming pendant. The programming pendant recognizes the
USB, and then while pressing [INTERLOCK] of the programming
pendant, press [SELECT].

6. Press [SELECT] of the programming pendant to open the password

input window. In the password input window, enter the password for
the USB for the YASKAWA mode. After entering the password, press
[ENTER].

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4 Initialization of System Configuration in Maintenance Mode

7. The mode changes to YASKAWA mode.

8. Touch {SYSTEM} and then {INITIALIZE}.

{INITIALIZE}

{SYSTEM}

9. The LANGUAGE window to select a language appears. Perform

subsequent data settings for initialization in the same manner as the
YRC1000.

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4 Initialization of System Configuration in Maintenance Mode

10. When the data settings for initialization is completed, the following
window appears. Touch {YES} to execute initialization.

Touch {YES}”

11. During initialization, the message “Initializing system data. Don’t turn
the power OFF” is displayed. Initialization needs approx. 30 seconds.

The message “Initializing system

data. Don’t turn the power OFF”
appears.

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4 Initialization of System Configuration in Maintenance Mode

12. When initialization is completed, the buzzer sounds for a moment, and
at the same time, the message “Initializing system data. Don’t turn the
power OFF” disappears and “Maintenance mode” appears instead.

“Maintenance mode”
appears.

13. Turn OFF the YRC1000 main power supply.

14. If the SD card is inserted in the SD card slot of the programming
pendant, remove it. Then, put the license sticker as shown below.

Put the license sticker on the programming pendant.

Make sure to put the license sticker in the following manner:
• Place the sticker on the right of and immediately next to
the nameplate of the programming pendant.
• Align the tops of the sticker and the nameplate.

NOTE License sticker

Align the tops

Right next to
each other

NOTICE
If the system does not start up in the Maintenance mode due to
programming pendant hardware failure, never put the license sticker on
it.

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4 Initialization of System Configuration in Maintenance Mode

15. Turn ON the YRC1000 main power supply.

The main menu appears in approx. 50 seconds. At this time, both 7-
segment indicators of the ACP01 indicates “d”.

16. Select {SYSTEM INFO} and then {VERSION} to confirm that the
version described in the Software Modification Instructions and the
version in the following window are the same.

Confirm the version

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5 Troubleshooting
5.1 Possible Failures at Preparation of the SD card

5 Troubleshooting
This section describes the causes and remedies of the possible failures
that are assumed to occur during setup.

5.1 Possible Failures at Preparation of the SD card

These failures may occur during the following operations.

chapter 2.1 “Preparing the SD Card for ACP01”

chapter 3.1 “Preparing the SD Card/USB for
Upgrading”

Failure 1: For “mk_vx_cf” tool, the drive to which SD card is inserted is not
indicated.

The drive to which the SD card

is inserted is not displayed.

No. Cause Remedy

1 The card reader is not Connect the card reader to the arbitrary
connected to the personal USB port of the personal computer.
computer. (For SD card)

2 The SD card is not Connect the SD card to the card reader.

connected to the card
reader. (For SD card)

3 The USB connector is not Connect the USB connector to the arbitrary
connected to the personal USB connector of the personal computer.
computer. (For USB)

4 The power is not supplied Connect the AC adapter to the card reader,
to the card reader. and then supply the power. (Only for the
type of card reader to which the power is
not supplied from the USB port)

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5 Troubleshooting
5.1 Possible Failures at Preparation of the SD card

Failure 2: “NG” appears on the window when the data is written

into the SD card.

Displays the file where a file

copy error has occurred.

No. Cause Remedy

1 The card reader is not Connect the card reader to the arbitrary
connected to the personal USB port of the personal computer.
computer. (For SD card)

2 The SD card is not Connect the SD card to the card reader.

connected to the card
reader. (For SD card)

3 The USB connector is not Connect the USB connector to the arbitrary
connected to the personal USB connector of the personal computer.
computer. (For USB)

4 The power is not supplied Connect the AC adapter to the card reader,
to the card reader. and then supply the power. (Only for the
type of card reader to which the power is
not supplied from the USB connector)

5 The capacity of the SD Click the drive of the relevant removable

card/USB is insufficient. disc on the personal computer, and delete
all the data and files in the SD card/USB.
Then, write-in the data to the SD card/USB
again.

6 The SD card Recommended SD card

recommended by Refer to chapter 3 “Programming Pendant
YASKAWA design division Setup”
is not used.

7 The SD card/USB is Replace the SD card/USB with a new one.

defective.

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 HW1483868

5 Troubleshooting
5.2 Possible Failure at Setup of the Programming Pendant

5.2 Possible Failure at Setup of the Programming Pendant

This failure may occur during the following operation.

chapter 3.2 “Setting Up the Programming Pendant”

Followings are the alarms occur when turning ON the YRC1000 main
power supply or OS write-in procedure is being done.
Failure: Alarms output by BootLoader during OS write-in procedures.

Alarm Details

All LED : Lighted OS is not written into the SD card or

Buzzer : Sound OS(NK.BIN) cannot be loaded due to
hardware failure.

Start lamp1) : Lighted Both the USB and the SD card are not
Hold lamp2) : Lighted inserted.
Other than above LEDs : Unlit

Start lamp : Lighted The USB is formatted by a file system that

Hold lamp : Unlit BootLoader cannot recognize.
Other than above LEDs : Lighted

Start lamp : Unlit The SD card is formatted by a file system

Hold lamp : Lighted that BootLoader cannot recognize.
Other than above LEDs : Lighted

Start lamp : Blink at 1 sec. cycle No referable text file for BootLoader exists
Hold lamp : Unli in the USB.
Other than above LEDs :
Blink at 1 sec. cycle

Start lamp : Unlit No referable text file for BootLoader exists

Hold lamp : Blink at 1 sec. cycle in the SD card.
Other than above LEDs :
Blink at 1 sec. cycle

Start lamp : Blink at 1 sec. cycle The OS(NK.BIN) mentioned in the text file
Hold lamp : Unlit inside the USB doesn’t exist.
Other than above LEDs : Unlit

Start lamp : Lighted The OS(NK.BIN) mentioned in the text file

Hold lamp : Blink at 1 sec. cycle inside the SD card doesn’t exist.
Other than above LEDs : Unlit

Buzzer : Sound OS(NK.BIN) which is on DRAM cannot be

(Either of Start lamp or Hold lamp written into FlashRom due to the following
is lighted.) reasons.
1, Capacity of FlashRom is insufficient
(writing area < OS size)
Refer to chapter 5.3 “Programming
Pendant FlashRom Format Procedure”

2, Hardware failure

1 Start lamp : allocated to the USB

2 Hold lamp : allocated to the SD card

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HW1483868
5 Troubleshooting
5.3 Programming Pendant FlashRom Format Procedure

5.3 Programming Pendant FlashRom Format Procedure

FlashRom of the programming pendant can be reformatted with the
following procedures. Note that the pendant application software and the
programming pendant OS written in the FlashRom of the programming
pendant will be deleted if FlashRom of the programming pendant is
reformatted.
(1) While pressing [INTERLOCK], [9], and [SELECT] simultaneously,
turn ON the YRC1000 main power supply.
(2) Following window appears. Touch “OK” at the right top of the dia-
log box to close the box.

(3) Use the pen to touch the left bottom, and the task bar appears.
Then touch {START} in the task bar. When START menu appears,
touch {Programs} and then {Windows Explorer}.

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 HW1483868

5 Troubleshooting
5.3 Programming Pendant FlashRom Format Procedure

(4) Select "Windows" folder.

(5) The contents of the "Windows" folder are displayed.

(6) Select {View} menu → {Details}.

Folders and details of them are displayed.

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HW1483868
5 Troubleshooting
5.3 Programming Pendant FlashRom Format Procedure

(7) Execute "DFORMAT_ALL_CLEAR.EXE" icon.

(8) Input TYPE KEY ID '777' and pressing [ENTER].

(9) Select [1] on the programming pendant, and then formatting starts.

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 HW1483868

5 Troubleshooting
5.3 Programming Pendant FlashRom Format Procedure

(10) When the following message appears, turn OFF the YRC1000
main power supply. “D format finish.”

(11) For the setup operation of the programming pendant, refer to

chapter 3.2 “Setting Up the Programming Pendant” .

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HW1483868
5 Troubleshooting
5.4 Redisplaying the Touch Calibration Display

5.4 Redisplaying the Touch Calibration Display

The touch calibration display can be redisplayed with the following
procedures:
(1) While pressing [HIGH SPEED] and [SLOW] on the programming
pendant simultaneously, turn ON the YRC1000 main power sup-
ply.

(2) A crosshair cursor at the center of the display moves in the follow-
ing order: Center → Upper left → Lower left → Lower right →
Upper right.
– Press the center of the cursor for approx. 2 seconds at each point.
– If the touch calibration is failed, the cross cursor returns to the center
of the display. In this case, retry the calibration.

– When the touch calibration is successfully completed, the following

display appears.

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 HW1483868

5 Troubleshooting
5.4 Redisplaying the Touch Calibration Display

(3) The following display appears by pressing [ENTER] on the pro-

gramming pendant. Close the message box by touching the OK
button at the right top of the dialog box.

(4) Make sure the dialog box is closed, then turn OFF the YRC1000
main power supply.

Press [ENTER] to save the registry data in the Flash-Rom

in the programming pendant. It takes six to seven seconds
NOTE to save the data. Do not turn OFF the power of the
YRC1000 while saving. To confirm that the saving is com-
pleted, touch OK button at the right top of the dialog box
and find if the message is disappeared.

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HW1483868
5 Troubleshooting
5.5 When the Message “Cannot find ‘YPP’ (or one of its components).”
is Displayed
5.5 When the Message “Cannot find ‘YPP’ (or one of its
components).” is Displayed
If the following message is displayed while using the programming
pendant, perform the procedures described in chapter 3.2 “Setting Up the
Programming Pendant” .

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5 Troubleshooting
5.6 Possible Failures at ACP01 Setup

5.6 Possible Failures at ACP01 Setup

These failures may occur during the following operations.

chapter 4 “Initialization of System Configuration

in Maintenance Mode”

Failure 1: Even 30 seconds after the YRC1000 main power supply is

turned ON, the ACP01 7-segment LED indicator remains in “8”
and does not start to count up from “0”.

No. Cause Remedy

1 No SD card is inserted into Insert a SD card into the SD card slot of

the SD card slot of ACP01. ACP01.

2 Boot sector and software Prepare the SD card for ACP01 following
are not written in the SD the procedures in chapter 2.1 “Preparing
card for the ACP01. the SD Card for ACP01” and then insert
the SD card into the SD card slot of
ACP01.

3 The SD card Refer to chapter 3 “Programming Pendant

recommended by Setup”
YASKAWA design division
is not used.

4 The SD card is defective. Replace the SD card with a new one.

Failure 2: Although the ACP01 7-segment LED indicator counts up from

“0” to “d”, the message appears on the programming pendant
screen.

No. Cause Remedy

1 The Ethernet cable is not Connect the Ethernet cable to

connected to CN105 (LAN port) of CN105 (LAN port) of ACP01.
ACP01.

2 The connectors of the cable for Connect the cable for the
the programming pendant are not programming pendant.
connected to the connectors on
the YRC1000 or on the
programming pendant.

3 The programming pendant cable Replace the programming pendant

is defective due to disconnection, cable with a new one.
etc.

4 The programming pendant is out Replace the programming pendant

of order. with a new one.

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YRC1000
SETUP PROCEDURE MANUAL
STANDARD SYSTEM

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802

YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Europe GmbHRobotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800 Fax +46-486-414-10

YASKAWA Electric (China) Co., Ltd.

22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542

YASKAWA Electric Korea Corporation

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326
Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199

PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741

Specifications are subject to change without notice

for ongoing product modifications and improvements.

C Printed in Japan November 2017 16-09

MANUAL NO.

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