Replacing of Yaskawa YRC1000 control cabinet parts

Introduce:

This article will introduce the replacement process of three key components in the Yaskawa YRC1000 control cabinet. First, we will detail the steps for replacing the CPU unit, including removing the old CPU unit, inserting the new CPU unit, and the necessary configuration and calibration procedures. Secondly, we will discuss the replacement method of the robot I/F board (JANCD-AIF01), including disconnecting, removing the old board, installing a new board, and reconnecting the cables and connectors. Finally, we will introduce the battery replacement process to ensure stable power supply to the control cabinet.

For the layout of each unit and base board, please refer to "Unit and base board layout" to confirm.

The following maintenance tools are recommended:

• Cross-shaped screwdriver: large, medium, small (medium screwdriver length: 500mm)
• Slotted screwdriver: large, medium, small
• Tweezers, pliers, flat nose pliers 

Warning

Before opening the YRC1000 door, the power supply must be cut off, otherwise electric shock may occur.

When replacing the control power supply unit, the power must be cut off for at least 5 minutes before starting the operation. During this time, never touch the terminals. Also, please confirm that the orange LED lights of the rectifier and inverter units are off.

The residual voltage in the capacitor may cause electric shock or injury; 

If the charging indicator light does not go out for a long time, it may be due to abnormal power cut off (power cut off when servo is on, power outage, etc.). At this time, with the main power supply turned on, turn on the main power switch to discharge. After confirming that the charging indicator light is off, turn off the main power switch.

During maintenance, in order to prevent unrelated personnel from accidentally turning on the power supply, please hang "Prohibit power on" and "Prohibit power on" signs on the main power supply (knife switch, wiring breaker, etc.), YRC1000 and related control panels. Warning sign.

After replacing parts, you must confirm that there are no abnormalities in the robot and peripheral equipment, and that no one is in the action area before starting the robot.

After the robot is set up, if the robot system is changed due to replacement of parts, change of teaching pendants, replacement of tools and peripheral equipment, etc., the robot must be run at low speed and confirm that there are no abnormal sounds, vibrations, abnormal movements, etc. If an abnormality occurs, please turn off the power immediately and contact the safety manager.

When entering the safety fence, please confirm that there are no danger sources around. If there is a danger source, please fully understand the surrounding conditions before entering.

If it is necessary to perform work when the power is turned on or enter the action range, be sure to arrange for other workers to stand next to the control cabinet so that they can press the emergency stop button in time in case of abnormal conditions.

Notice

Do not touch the regenerative resistor when it is hot, otherwise it may cause personal burns.

After the repair is completed, please carefully confirm that no tools are forgotten in the YRC1000 and that the cabinet door is secure. Otherwise, an electric shock accident may occur, resulting in personal injury.

When replacing parts, be sure to use parts recommended by Yaskawa. If you use other than recommended parts, not only will performance not be guaranteed, it may cause equipment malfunction, and may even cause a fire.

When working in a dark environment, please use appropriate lighting.

Notice

For the layout of each unit and base board, please refer to "Unit and base board layout" in advance. During replacement work, screws and wires will be removed, so please be careful not to lose screws, etc. In addition, the access points have been marked on the wires, but in order to prevent forgetting to connect or not knowing the access points, please make relevant records before disassembly and assembly. 

Part 1. Parts replacement process of CPU unit

The CPU unit JZNC-ARK01-E is composed of the base board JANCD-ABB01-E, JANCD-ABB02-E robot I/F base board JANCD-AIF01-E, and the CPU base board JANCD-ACP01-E.

The robot I/F base board is a sub-base connected to the CPU base board.

Warning

When replacing the circuit board, be sure to cut off the power supply.

Wait 5 minutes after cutting off the power before replacing.

Also, please confirm that the charging light (orange LED) of the rectifier and inverter unit is off. Residual voltage in the capacitor may cause electric shock or injury.

Replacement steps

1. When the CPU board is connected to the robot I/F board, please remove the following wires:

①Control communication plug (CN111)

②Control power input plug (CN101)

③LAN1 plug (CN105) for teaching programmer

The following is the plug when adding optional functions. Please remove it when connecting.

④USB plug (CN102)

⑤RS232C/422 plug (CN103)

⑥LAN2 plug (CN106)

⑦LAN3 plug (CN107)

⑧I/0 I/F plug (CN112)

2. Remove the 2 screws fixing the CPU base board

3. Take out the substrate

4. Take out the SD card from the removed base board (CN104) and insert the new base board. The SD card plug has two methods: push-in and push-out. You can use your fingers to push in and remove the SD card. Follow the same steps to install a new base board.

5. Remove the 4 screws installed on the robot I/F base plate. Since the robot I/F board is connected by the connector (CNA) and the connector (CN12) of the CPU board, please carefully pull up the robot I/F board and take out the CPU board.

6. Connect and install the connector (CN12) of the new CPU base board and the connector (CNA) of the robot I/F base board. The connection of the base board plug is to align the fixing screw hole of the robot I/F base board with the hexagonal screw hole on the side of the CPU base board, and slowly press in the robot I/F base board. If the plug is pushed in while the position is misaligned, the plug may be damaged. So please confirm the location carefully before connecting.

6. Before installing it on the bracket, please confirm whether the battery wires are protruding. If installed while protruding, malfunctions such as being pressed by the base plate in the bracket or disconnection may occur.

7. Install the new base plate in the original position of the bracket

Important 

Insert the base board straight along the upper and lower lines on the left side of the bracket and connect it to the innermost base board plug.

If the circuit board is inserted out of alignment, the circuit board may be damaged. Therefore, if you feel something strange when inserting the circuit board, immediately take out the circuit board to check whether it is damaged, and then insert it again

8. Tighten the 2 fixing screws of the upper and lower CPU base plates

9. Install all the wires removed during operation 

Part 2. Replacement of robot I/F substrate (JANCD-AIF01)

Warning

When replacing the substrate, be sure to cut off the power supply

Wait 5 minutes after cutting off the power before replacing.

Also, confirm that the charging light (orange LED) of the rectifier and inverter unit is off.

Residual voltage in the capacitor may cause electric shock or injury.

important

Program data, parameters, etc. are stored on the robot I/F board. Therefore, data backup must be performed before replacement.

Robot I/F board, memory capacity: 2MB and 4MB

Before replacing the base board, you must confirm the used memory capacity and set memory capacity in maintenance mode.

Standard: JANCD-AIF01-1E (memory capacity: 2MB)

Optional: JANCD-AIF01-2E (memory capacity: 4MB)

JANCD-AIF01-3E (memory capacity: 4MB communication I/F allocation)

Before replacing the substrate, you need to perform the operation in factory mode.

Regarding operations in factory mode, please consult the Robot Division of Yaskawa Electric (China) Co., Ltd.

Replacement steps 

1. Carry out data backup before operation. Insert the SD card used to save data into the SD card slot of the teaching programmer, start it in maintenance mode, and select "External Storage - Save - CMOS"

For the backup method, please refer to the "YRC1000 User Manual" (R-CT0-A221-C)

2. Please cut off the power supply of the control cabinet after the backup is completed.

3. Disconnect all wires connected to the CPU board and robot I/F board

①Control communication plug (CN111)

②Control power input plug (CN101)

③LAN1 plug (CN105) for teaching programmer

Please remove the following plugs connected when adding optional functions

④USB plug (CN102)

⑤RS232C/422 plug (CN103)

⑥LAN2 plug (CN106)

⑦LAN3 plug (CN107)

⑧I/0 I/F plug (CN112)

4. Remove the 2 screws fixing the upper and lower parts of the CPU base plate and take out the base plate

5. Remove the 4 screws installed on the robot I/F base plate. The robot I/F board is connected by the connector (CNA) and the connector (CN12) of the CPU board, so please carefully pull up the robot I/F board and take out the CPU board

6. Confirm that the setting of the rotary switch (S1) of the new robot I/F board is consistent with the setting of the base board before replacement.

7. Connect and install the CPU board connector (CN12) and the new robot I/F board connector (CNA). The connection of the base board plug is to align the fixing screw hole of the robot I/F base board with the hexagonal screw hole on the side of the CPU base board, and slowly press the robot I/F base board in. If the plug is pushed in while misaligned, the plug may be damaged. So please confirm the location carefully before connecting.

8. Before installing it on the bracket, please confirm whether the battery wires are protruding. If installed in a protruding state, malfunctions such as being pressed by the base plate in the bracket and disconnection may occur.

9. Install the base plate in the original position of the bracket. Insert along the line on the left and connect to the baseboard plug inside

10. Tighten the 2 fixing screws on the upper and lower CPU base boards

Install all the wires removed during operation 1.

Part 3. Battery replacement

After the message "Memory battery is exhausted" is displayed on the teaching programmer screen, please replace the battery within 30 days.

When replacing batteries, turn on the circuit breaker to prevent data loss. 

Important

Important file data (CMOS memory) on the user program is backed up by a supercapacitor, but if "memory battery exhausted" is displayed, please replace the battery with a new one in time (within 30 days).

When replacing the battery, turn on the circuit breaker.

Replacement steps

1. Disconnect all the following wires connected to the CPU board and robot I/F board. (Refer to 5-15)

①Control communication plug (CN111)

②Control power input plug (CN101)

③LAN1 plug (CN105) for teaching programmer

Please remove the following plugs connected when adding optional functions

④USB plug (CN102)

⑤RS232C/422 plug (CN103)

⑥LAN2 plug (CN106)

⑦LAN3 plug (CN107)

⑧I/0 I/F plug (CN112)

2. Remove the 2 screws fixing the upper and lower parts of the CPU base plate

3.Take out the substrate

4. Confirm the position of the battery and battery plug. This section describes a typical example of the first replacement. When the second replacement is performed, one of the connectors (CN114) or (CN115) may not be connected. Please connect the replacement battery to the unconnected plug before proceeding.

5. When the existing battery is connected, connect the new replacement battery to the plug (left side of C115)

6. Remove the existing battery plug (right side of CN114)

7. Remove the existing battery from the battery compartment

8. Install the new battery into the battery box

9. Before installing it on the bracket, please confirm whether the battery wires are protruding. If installed in a protruding state, malfunctions such as being pressed by the base plate in the bracket and disconnection may occur.

10.Install the base plate to the original position of the bracket. Plug in along the wiring on the left and connect to the baseboard socket inside

11. Tighten the two fixing screws on the upper and lower sides of the CPU base plate

12. Install all the wires removed during operation 1 

Through the introduction of this article, we understand the replacement process of key components in the Yaskawa YRC1000 control cabinet. When replacing a CPU unit, correct fixing and configuration are critical steps to ensure proper operation of the control system. When replacing the robot I/F board, connecting cables and connectors correctly helps ensure stable communication between the robot and the control cabinet. In addition, timely replacement of batteries can ensure reliable power supply to the control cabinet to avoid data loss or system failure. Please note that before performing any repair and replacement operations, you should consult Yaskawa Robotics’ technical support team to ensure the correctness and safety of the operations. By following the correct procedures to replace these key components, the normal operation and long-term reliability of the Yaskawa YRC1000 control cabinet can be ensured.